Install Instructions

41
Start-Up Preparation
Use of Antifreeze in the Boiler System
NEVER use automotive or ethylene gly-
col antifreeze or undiluted antifreeze in
the boiler system as freeze protection.
This can cause severe personal injury,
death or substantial property damage if
ignored.
Determine the antifreeze fluid quantity using
the system water content volume and following
the antifreeze manufacturer instructions.
The boiler water volume of the CHALLENGER
CC 85 is 0.37 gallons [1.4 l], CC 105 is 0.42 gal-
lons [1.6 l] and CC 125 is 0.50 gallons [1.9 l].
Remember to include this volume in sizing of the
expansion tank.
Check with local codes requirements for the
installation of backflow preventers or actual
disconnection from the boiler’s cold water fill
or make up water supply line.
Massachusetts Code requires the installa-
tion of a backflow preventer if antifreeze
is used.
Ensure the concentration of antifreeze to water
does not exceed a 50/50 ratio.
System water, including additives, must
be practically non-toxic, having a toxicity
rating or Class of 1, as listed in Clinical
Toxicology of Commercial Products.
Filling the Boiler System
1. Close the boiler drain valve located on the
bottom of the appliance and any manual or
automatic air vent in the system.
2. Open all system isolation valves.
3. Fill the boiler system to correct system
pressure. Correct pressure will vary with
each application.
Typical residential system fill pressure is
12 psi [0.8 bar]. System pressure will
increase when system temperature
increases. Operating pressure of the sys-
tem should never exceed 25 psi [1.7 bar].
4. Purge air and sediment from each zone of
the hydronic system through the purge
valves. Open air vents to allow air to be
vented from the zones.
5. Once the system is completely filled and
purged of all air and sediment, check the
system pressure and check/repair any leaks.
Unrepaired system leaks will cause con-
tinual makeup water to be added to the
appliance. Continual makeup water
could cause mineral buildup within the
heat exchanger, reducing the heat trans-
fer, causing possible heat buildup and
eventual heat exchanger failure.
Check Low Water Cut Off/CH Pressure
Sensor
- The CHALLENGER is provided with a
factory installed LWCO that senses boiler
CH system pressure of more than 7 psig
[0.5 bar].
- Compare CH system pressure gauge read-
ing to CHALLENGER’s control pressure
display reading, which can only be viewed
when control is ON and no CH or DHW
call is present. Adjust pressure accordingly.
WARNING
NOTICE
NOTICE
NOTICE
WARNING