Combination Boiler and/ or Water Heater User s Information Manual WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. FOR YOUR SAFETY • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. • WHAT TO DO IF YOU SMELL GAS - Do not try to light any appliance - Do not touch any electrical switch; do not use any phone in your building.
Table of Contents PRODUCT & SAFETY INFORMATION Page 1 Service and Maintenance CHALLENGER Operation Appliance & System Water SECTION I - Combustion Air - Prevention of Contamination Page 2 Potential Contaminating Products Areas likely to find these Products SECTION II - Maintenance Schedule Page 3 Service Technician Owner Maintenance SECTION III - Maintenance Procedures Page 4 Periodic Maintenance Monthly Maintenance 6-Month Maintenance SECTION IV - Operations Instructions Page 7 SECTION V - Appli
Product & Safety Information Definitions The following terms are used throughout this manual to bring attention to the presence of potential hazards or important information concerning the product. DANGER NOTICE Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage. Indicates special instructions on installation, operation or maintenance, which are important to equipment but not related to personal injury hazards.
Product & Safety Information PRODUCT & SAFETY INFORMATION CHALLENGER Operation • Do not block flow of combustion air to the CHALLENGER. If the combustion air blockage is easily accessible and removable, then remove it. If blockage is not obvious or cannot be removed, have the appliance and system checked by a qualified service technician. • Do not allow contaminated air to enter the appliance’s combustion air inlet. See page 2 for details. • The CHALLENGER is equipped with a low water cut off device.
Combustion Air - Prevention of Contamination SECTION I - COMBUSTION AIR - PREVENTION OF CONTAMINATION Potential Contaminating Products WARNING If the CHALLENGER combustion air inlet is located in any area likely to cause or contain contamination, or if products, which would contaminate the air cannot be removed, the combustion air must be repiped and terminated to another location.
Maintenance Schedule SECTION II - Maintenance Schedule Owner Maintenance Service Technician Periodic At least on an annual basis the following maintenance should be performed by a qualified service technician: - Check the area around the appliance. - Check and remove any blockage from the combustion air inlet and ventilation openings. - Check the temperature/pressure gauge. General - Attend to any reported problems.
Maintenance Procedures SECTION III - MAINTENANCE PROCEDURES 1. Combustible / flammable materials - Do not store combustible materials, gasoline or other flammable vapors or liquids near the appliance. Remove immediately if found. WARNING 2. Air contaminates - Products containing chlorine or fluorine, if allowed to contaminate the combustion air, will cause acidic condensate within the appliance. This will cause significant damage to the appliance.
Maintenance Procedures Monthly Maintenance WARNING Check Vent Piping Under some circumstances the CHALLENGER may not produce enough condensate to keep the condensate trap full of liquid. If the trap is not full, small amounts of flue gases can be emitted into the surrounding area through the condensate drain line. 1. Visually inspect the flue gas vent piping for any signs of blockage, leakage or deterioration of the piping. Notify a qualified service technician immediately if any problems are found. 3.
Maintenance Procedures 6-Month Maintenance 2. Read the temperature and pressure gauge to ensure the system is pressurized. Lift the relief valve top lever slightly, allowing water to relieve through the valve and discharge piping. Check Water and Gas Piping 3. If water flows freely, release the lever and allow the valve to seat. Watch the end of the relief valve discharge pipe to ensure that the valve does not weep after the line has had time to drain.
Operating Instructions SECTION IV - OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand. B. BEFORE OPERATING, smell all around the appliance area for gas.
Appliance Control Display SECTION V - Appliance Control Display Operation Read-Out A. On/Off button B. CH /DHW/parameter button C. - button D. + button E. Units U.S. customary or metric F. DHW function off/eco/on G. Service button H. Reset/store button 1. On/Off (Lit when on) 2. CH operation or setting maximum CH temperature 3. DHW operation or setting DHW temperature 4. Main display with temperature of CH or DHW or CH water pressure or fault code 5. Temperature ºF or pressure psi 6.
Appliance Control Display Function Main Display Operating Display Press button to turn appliance ON LED lite above button will be lit when appliance is ON OFF XXP No demand for heat XXP A Control self-test XXX 1 Fan pre purge or post purge cycle XXX 2 Ignition sequence XXX 3 Burner ON for space heating (CH) XXX 4 Burner ON for domestic hot water (DHW) XXX 6 Burner OFF due to reaching temperature setpoint 7 Space Heating (CH) post pump cycle 8 Burner ON for DHW pre-heating 9 Burne
Appliance Control Display Setting the Appliance Parameters 5. After all parameters have been changed, press the button to close the setting menu and store the changes. The main display will go blank and a P will be displayed in the operating display to let you know the control was programmed. 1. Press the “ ” button at the display panel for approximately 2 to 3 seconds until main display begins to flash. 2. Press the “ ” button repeatedly to scroll through the list of parameters.
Appliance Control Display Error (Hard Lockout) Mode If a system fault occurs, the system enters a hard lockout condition which requires a manual reset by pressing the RESET button . A hard lock is indicated by a flashing [E] on the operating display as well as a flashing LED light above the reset button. The error code is located on the main display. The error must be corrected before the control will reset.
Appliance Control Display Error (Hard Lockout) Codes* Main Display Operating Display (Flashing) Possible Solution Error Description • Check wiring for break • Check for proper flow direction • Replace S1 • E10 Open sensor • E 11 Shorted sensor • E12 Decreased too quickly • E13 Increased too quickly • E14 Stuck E - CH supply sensor fault S1 20, 21, 22, 23, 24 E - CH return sensor fault S2 0 E - Sensor fault after self check 1, 28 E - Temperature too high 2 E - CH supply sensor S1 and CH re
Replacement Parts S T Condensate pan Control/Display Pressure relief and air vent assembly Condensate drain trap assembly CH supply sensor S1 CH Return sensor S2 Blower DHW flow switch DHW sensor S3 Low voltage/terminal strip X4 Ignition electrode High voltage terminal strip CHALLENGER Internal Components Triangle Tube replacement parts to ensure warranty coverage and to avoid damage to appliance and improper operation of appliance. Contact Triangle Tube at 856-228-8881 or www.triangletube.
Replacement Parts 3 CHALLENGER Front Door Item Part Number Part Number Part Number CC85 CC105 CC125 1 CCRKIT04 Wall Bracket Assembly (Not Shown) 2 CCRKIT05 Pipe Connectors & Brackets Assembly (Not Shown) 2A CCFTG01 Connector Pipe CH (Not Shown) - 1/Kit 2B CCFTG02 Connector Pipe DHW (Not Shown) - 1/Kit 3 CCRKIT06 CCRKIT07 CCRKIT08 14 Description Front Door Assembly
Replacement Parts 1 2 2 3 3 2 3 4 3 CHALLENGER Vent Components Item Part Number Part Number Part Number CC85 CC105 CC125 CCRKIT09 80/125 Concentric Vent /Air Adapter Assembly (optional - shown) CCRKIT35 3” Vent/Air Adaptor Assembly ( standard not shown) 1 2 CCRKIT10 Description CCRKIT11 CCRKIT12 Vent Assembly 3 CCRKIT13 Condensate Collector Assembly 4 CCRKIT14 Condensate Drain Trap Assembly 15
Replacement Parts 2 1 3 4 8 4 7 6 9 11 5 10 CHALLENGER Internal Components Item Part Number CC85 Part Number CC105 Part Number CC125 Description 1 CCRKIT15 Igniter Assembly 2 CCCLB01 Ignition Cable 3 CCRKIT16 Sight Glass Assembly 4 CCRKIT17 CH Sensor Assembly - 1/Kit 5 CCSENS02 DHW Sensor 6 CCRKIT18 DHW Flow Switch Assembly 7 CCRKIT19 LWCO/CH Pressure Sensor Assembly 8 CCRKIT20 CCRKIT21 CCRKIT22 CH Supply pipe Assembly 9 CCRKIT23 CH Return Pipe Assembly 10 CCRKIT
Replacement Parts 4 1 2 3 CHALLENGER Blower & Gas Valve Components Item Part Number Part Number Part Number CC85 CC105 CC125 1 CCRKIT28 Ignition Transformer Assembly 2 CCRKIT29 Gas Valve Assembly 3 4 CCRKIT30 CCRKIT31 Description Gas Pipe Assembly CCRKIT32 Blower Assembly 17
Replacement Parts 1 CHALLENGER Burner Components Item Part Number Part Number Part Number CC85 CC105 CC125 1 CCRKIT33 Description Burner Assembly 18
Replacement Parts 4 1 2 3 CHALLENGER Control Components Item Part Number Part Number Part Number CC85 CC105 CC125 1 CCCON01 2 CCCS01 3 CCRKIT34 Flip Panel 4 CCFUSE01 Fuse - 1/Kit Description Control/Display Housing Plastic Control 19
Notes
Additional quality water heating equipment available from Triangle Tube Brazed Plate Heat Exchangers - For domestic water, snow melting, radiant floor, refrigeration - Plates made of stainless steel, with a 99.
