Install Instructions

14
Boiler Piping
SECTION IV - Boiler Piping
General Piping Requirements
- All plumbing must meet or exceed all local,
state and national plumbing codes.
- Support all piping using hangers. DO NOT
support piping by the appliance or its com-
ponents.
- Use isolation valves to isolate system com-
ponents.
- Install unions for easy removal of the
CHALLENGER from the system piping.
Use a two wrench method when tighten-
ing piping onto the appliance connec-
tions. Use one wrench to prevent the
appliance piping from turning / twisting.
Failure to support the appliance piping
and connections in this manner could
cause damage to the appliance and its
components.
Pressure Relief Valve (PRV)
1. The CHALLENGER has a ASME
Maximum Allowable Working Pressure of
43.5 PSI [3 bar]. The appliance is supplied
with a 30 psi [2 bar] pressure relief valve
and must be piped using the PRV connec-
tion as shown in Fig. 3 page 15.
2. To avoid potential water damage to the sur-
rounding area or potential scalding hazard
due to the operation of the relief valve, the
discharge piping:
- Must be connected to the discharge out-
let of the relief valve and directed to a
safe place of disposal.
- Length should be as short and direct as
possible. The size of the discharge line
should not be reduced, maintain the
same size as the outlet of the relief valve.
- Should be directed downward towards
the floor at all times. The piping should
terminate at least 6 inches [153 mm]
above any drain connection to allow
clear visibility of the discharge.
- Should terminate with a plain end, not
with a threaded end. The material of the
piping should have a serviceable temper-
ature rating of 250ºF [121ºC] or greater.
- Should not be subject to conditions
where freezing could occur.
- Should not contain any shut-off valves
or obstructions. No shut-off valve
should be piped between the appliance
and relief valve.
Failure to comply with the guidelines on
installing the pressure relief valve and dis-
charge piping can result in personal injury,
death or substantial property damage.
Low Water Cut Off / CH Pressure Sensor
The Low Water Cut Off (LWCO) only
applies for space heating. Operation of
the LWCO does not prevent a domestic
hot water call for heat.
- The CHALLENGER is equipped with a fac-
tory installed pressure sensor type LWCO.
- The minimum operating Central Heating
(CH) system pressure is 7 psig [0.5 bar].
- If CH System pressure is below 7 psig [0.5
bar] the main display will flash a soft lockout
of “LOP” followed by the pressure reading.
Once CH system pressure is increased above
7 psi [0.5 bar] normal boiler operation will be
restored. If the appliance is installed as domes-
tic hot water heater only, set parameter 1
(installation type) to 2 (domestic only) to
eliminate the “LOP” error in the main display,
see page 52 for setting parameters.
- Check local codes if a LWCO is required. If
so, determine if this device meets their
requirements.
WARNING
WARNING
NOTICE