Boiler
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.
- Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s
instructions.
- If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas
supplier.
Date 8/9/2011
2011-37 Challenger Solo User’s Manual
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 - Appliance Control Display
Page 8
Replacement Parts
Page 13
i
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.
WARNING
Indicates a potentially hazardous situation
which, if ignored, can result in death, serious injury or substantial property damage.
BEST PRACTICE
Indicates recommendations made by
Triangle Tube for the installers which will
help to ensure optimum operation and
longevity of the equipment.
CAUTION
Indicates a potentially hazardous situation
which, if ignored, may result in minor
injury or property damage.
NOTICE
Triangle Tube reserves the right to modify the technical specifications and components of
its products without prior notice.
ii
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. The CH (central heating) system piping
must be filled and pressurized to 12 psig [0.8 bar]
prior to startup. The appliance will shut down if the
pressure falls below 7 psig [0.5 bar].
•
Should overheating occur or the gas supply fail to
shut off, DO NOT turn OFF or disconnect the electrical supply to the pump. Instead, shut off the gas
supply at a location external to the appliance.
•
Do not use this appliance if any part has been under
water. Immediately call a qualified service technician to inspect the appliance and to replace any part
of the control system and any gas control, which has
been under water.
WARNING
HOMEOWNER: The CHALLENGER installation manual is for use only by a qualified heating installer /
service technician. Refer to this User’s Information
Manual for your reference. Failure to comply could
result in severe personal injury, death or substantial
property damage.
NOTICE
TECHNICIAN: When calling or writing about the
CHALLENGER, please have the appliance model
and serial number available.
STOP! READ BEFORE SERVICING
WARNING
Failure to adhere to the guidelines on this page can
result in severe personal injury, death or substantial
property damage.
Appliance & System Water
Service and Maintenance
•
Have the appliance and system water chemistry
checked at least annually by a qualified service technician.
•
Do not use petroleum-based cleaning or sealing
compounds in the appliance or system. Gaskets
and seals in the system may be damaged. This can
result in substantial property damage.
•
Do not use any product not specifically designed for
hydronic heating systems. Serious damage to the
appliance, piping system, personnel and / or property may result.
•
Continual fresh makeup water will reduce the life of
the CHALLENGER. Addition of oxygen can cause
internal corrosion in the system components. All
leaks in the piping system must be repaired at once
to prevent makeup water.
•
Do not add cold water to a hot appliance. Thermal
shock can cause premature failure to the appliance
heat exchanger.
•
To avoid electric shock, disconnect electrical supply
before performing service or maintenance.
•
Allow the appliance to cool down prior to servicing to
avoid severe burns.
•
The CHALLENGER must be maintained as outlined
in this manual and have at least annual service performed by a qualified service technician to ensure
appliance / system reliability.
1
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.
Contaminated combustion air will damage the appliance and its burner system, resulting in possible
severe personal injury, death or substantial property
damage.
WARNING
Do not operate a CHALLENGER if its combustion air
inlet or the appliance is located in or near a laundry
room or pool facility. These areas will always contain hazardous contaminates.
Pool and laundry products and common household
and hobby products often contain fluorine or chlorine compounds. When these chemicals pass
through the burner and vent system, they can form
strong acids. These acids can create corrosion of
the heat exchanger, burner components and vent
system, causing serious damage and presenting a
possible threat of flue gas spillage or water leakage
into the surrounding area.
-
Spray cans containing chloro/fluorocarbons
-
Permanent Wave Solutions
-
Chlorinated wax
-
Chlorine - based swimming pool chemicals and
spa cleaners
-
Calcium Chloride used for thawing ice
-
Sodium Chloride used for water softening
-
Refrigerant leaks
-
Paint or varnish removers
-
Hydrochloric acid / muriatic acid
-
Cements and glues
-
Antistatic fabric softeners used in clothes dryers
-
Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms
-
Adhesives used to fasten building products and
other similar products
Areas likely to find these products
Please read the following information. If contaminating chemicals will be present near the location of
the combustion air inlet, the installer should pipe the
combustion air inlet to another location per the
CHALLENGER installation manual.
2
-
Dry cleaning / laundry areas and establishments
-
Beauty salons
-
Metal fabrication shops
-
Swimming pools and health spas
-
Refrigeration Repair shops
-
Photo processing plants
-
Auto body shops
-
Plastic manufacturing plants
-
Furniture refinishing areas and establishments
-
New building construction
-
Remodeling areas
-
Garages with workshops
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.
-
Inspect the interior of the appliance jacket area;
clean and vacuum if necessary.
-
Clean the condensate drain assembly and fill with
fresh water.
-
Check vent piping.
-
Check combustion air inlet piping.
-
Check for leaks: water, gas, flue and condensate.
-
Check the pressure relief valve.
-
Verify flue vent piping and air inlet piping are in good
condition, sealed tight and properly supported.
-
Check the condensate drain assembly.
-
Check appliance water pressure, piping and expansion tank.
Every 6 months:
-
Check control settings.
-
Check ignition electrode (sand off any white oxide;
clean and reposition).
-
Check ignition wiring and ground wiring.
-
Check all control wiring and connections.
-
Check burner flame pattern (stable and uniform).
Monthly:
Clean heat exchanger and flue ways.
-
Remove burner assembly and clean burner head
using compressed air only.
Check appliance piping and gas supply piping for
corrosion or potential signs of leakage.
-
Operate the pressure relief valve.
WARNING
Follow the maintenance procedures given
throughout this manual. Failure to perform the
service and maintenance or follow the directions
in this manual could result in damage to the
CHALLENGER or in system components, resulting in severe personal injury, death or substantial property damage.
Additional items if combustion or performance is
poor:
-
-
Once the maintenance items are completed, review the
service with the owner.
3
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. Read the list of potential
materials listed on page 2 of this manual. If any
of these products are in the room from which the
appliance takes its combustion air, they must be
removed immediately or the combustion air
intake must be relocated to another area.
The CHALLENGER must be inspected and serviced
annually, preferably at the start of the heating season, by a qualified service technician. In addition,
the maintenance and care of the appliance as outlined on page 3 and further explained on pages 4
through 6 must be performed to assure maximum
efficiency and reliability of the appliance. Failure to
service and maintain the CHALLENGER and the system components could result in equipment failure,
causing possible severe personal injury, death or
substantial property damage.
Check Combustion Air Inlets
1. Verify that ventilation air openings to the
mechanical room are open and unobstructed.
NOTICE
The following information provides detailed instruction for completing the maintenance items outlined
in the maintenance schedule on page 3. In addition
to this maintenance, the CHALLENGER should be
serviced at the beginning of the heating season by a
qualified service technician.
2. Verify that the appliance’s vent termination and
combustion air intake are clean and free of
obstructions. Remove any debris on the air
intake or flue exhaust openings. If removing the
debris does not allow the appliance to operate
correctly, contact your qualified service technician to inspect the appliance and the vent / combustion air system.
Periodic Maintenance
Check Temperature Display and Pressure Gauge
Check the Surrounding Area
1. Ensure the pressure reading on the pressure
gauge does not exceed 25 psig [1.7 bar].
Higher pressure readings may indicate a problem with the expansion tank.
WARNING
To prevent potential of severe personal injury, death
or substantial property damage, eliminate all the
materials listed on page 2 from the area surrounding
the appliance and from the vicinity of the combustion air inlet. If contaminates are found:
2. Ensure the temperature on the display panel
does not exceed 194ºF [90ºC]. Higher temperature readings may indicate a problem with the
operating thermostat controls.
3. Contact a qualified service technician if problem persists.
Remove products immediately from the area. If they
have been there for an extended period, call a qualified service technician to inspect the appliance for
possible damage from acid corrosion.
If products cannot be removed, immediately call a
qualified service technician to re-pipe the combustion air inlet piping and locate the combustion air
intake away from the contaminated areas.
4
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. Ensure the condensate drain line is not blocked
by pouring water through the top open port on
the condensate drain assembly. The water
should flow out of the end of the drain line. If
water does not appear at the end of the drain
line, contact a qualified service technician to
inspect and clean the condensate line.
WARNING
Failure to inspect the venting system as noted and
have it repaired by a qualified service technician can
result in the vent system failure, causing severe personal injury or death.
4. To fill the condensate drain assembly, slowly
pour water into the top of the trap assembly until
water appears at the end of the drain line. Stop
filling.
Check Combustion Air Inlet Piping
1. Visually inspect the combustion air inlet piping for
any signs of blockage. Inspect the entire length
of the combustion air inlet piping to ensure piping
is intact and all joints are properly sealed.
Check Automatic Air Vents (If Used)
1. Remove the cap “A” from any automatic air vent
in the system and check operation by depressing
valve “B” slightly with the tip of a screwdriver. See
Fig. 1.
2. Notify a qualified service technician if any problems are found.
2. If the air vent valve appears to be working freely
and not leaking, replace cap “A”, screwing it on
fully.
Check Pressure Relief Valve
1. Visually inspect the primary pressure relief valve
and the relief valve discharge pipe for signs of
weeping or leakage.
3. Loosen cap “A” one full turn to allow vent to
operate properly.
4. Have the air vent replaced by a qualified service
technician if it does not operate correctly.
2. If the pressure relief valve often weeps, the
expansion tank may not be operating properly.
Immediately contact a qualified service technician to inspect the unit and system.
A
Check Vent Condensate Drain Assembly
B
1. While the appliance is operating, check the discharge end of the condensate drain tubing.
Ensure no flue gas is leaking from the condensate drain tubing by holding your fingers near
the termination.
2. If you notice flue gas leaking from the opening,
this indicates a dry condensate drain trap. Fill
the condensate trap assembly. Contact a qualified service technician to inspect the appliance
and condensate line and refill the condensate
trap if problem persists regularly.
Fig. 1: Automatic Air Vent
5
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. If the valve weeps, lift the lever again to
attempt to clean the valve seat. If the valve
does not properly seat and continues to weep
afterwards, contact a qualified service technician to inspect the valve and system.
1. Remove the appliance front jacket panel and perform a gas leak inspection per steps 1 through 6 of
the Operating Instructions on page 7. If gas odor
or leak is detected, immediately shut down the
appliance following procedures on page 7. Call a
qualified service technician.
2. Visually inspect for leaks around the internal appliance water connections and around the heat
exchanger. Visually inspect the external system piping, circulators, and system components and fittings.
Immediately call a qualified service technician to
repair any leaks.
4. If the water does not flow from the valve when
you lift the lever completely, the valve or discharge line may be blocked. Immediately shut
the appliance down per the instructions on page
7. Call a qualified service technician to inspect
the valve and system.
WARNING
Have leaks fixed at once by a qualified service technician. Failure to comply could result in severe personal injury, death or substantial property damage.
Operate Pressure Relief Valve
1. Before proceeding, verify that the relief valve
outlet has been piped to a safe place of discharge, avoiding any possibility of scalding from
hot water.
WARNING
To avoid water damage or scalding due to valve
operation, a discharge line must be connected to the
relief valve outlet and directed to a safe place of disposal. This discharge line must be installed by a
qualified service technician or heating / plumbing
installer in accordance with the CHALLENGER
installation manual. The discharge line must be terminated so as to eliminate possibility of severe
burns or property damage should the valve discharge.
6
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. Be sure to smell next to the floor
because some gas is heavier than air and will settle on
the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
phone in your building
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to turn the external manual gas
valve. Never use tools. If the valve will not turn by
hand, don’t try to repair it; call a qualified service technician. Force or attempted repair may result in a fire or
explosion.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
OPERATING INSTRUCTIONS
1.
STOP! Read the safety information above. This
appliance is equipped with an ignition device which
automatically lights the burner. DO NOT try to light
the burner by hand.
2.
Set room thermostat(s) to lowest setting. Turn the
external manual gas valve handle clockwise
“CLOSE” (valve handle shall be perpendicular to gas
piping).
3.
Turn “OFF” all electrical power to the appliance.
4.
Remove the front jacket panel on the appliance.
5.
Turn the external manual gas valve handle counter
clockwise
to “OPEN” gas supply (valve handle shall be parallel to gas piping).
6.
Wait five (5) minutes to clear out any gas. If you then
smell gas in the jacket enclosure or around the appliance, STOP! Follow “B” in the safety information
above. If you don’t smell gas, go to the next step.
7.
Turn “ON” all electric power to the appliance. Push
ON/OFF button on the CHALLENGER control panel
display until LED above button is lit.
8.
Set room thermostat(s) to desired setting(s).
9.
The CHALLENGER control panel display will show a
sequence of numbers (1,2,3,4) as the right digit.
Sequence digit 3 or 4 indicates the appliance is firing. A
blank display means there is no call for heat (all external thermostats are satisfied).
10. If the appliance will not operate with a call for heat and
the system piping is not hot, follow the instructions “To
Turn Off Gas to Appliance”, below and call your service
technician or gas supplier.
11. Replace the front jacket panel. Make sure the panel is seated firmly in place and all mounting screws are tightened.
TO TURN OFF GAS TO APPLIANCE
1.
Set the room thermostat to lowest setting.
2.
Turn“OFF” all electric power to the appliance if service is to be performed.
3.
7
Turn the external manual gas valve handle clockwise
to “CLOSE”, (valve handle shall be perpendicular to gas piping).
Appliance Control Display
SECTION V - Appliance Control Display
Operation
Read-Out
A. On/Off button
B. Parameter button
C. - button
D. + button
E. Units U.S. customary or metric
F. Not applicable
G. Service button
H. Reset/store button
1. On/Off (Lit when on)
2. CH operation or setting maximum CH temperature
3. DHW operation with optional Triangle Tube
SMART I.F.W.H
4. Main display with temperature water pressure
or fault code
5. Temperature ºF or pressure psi
6. Temperature ºC or pressure bar
7. Not applicable
8. Not applicable
9. Operating display
10. Flashes to indicate fault
Appliance ON/OFF
Units
1. The appliance operation is started using the
ON/OFF button.
Press Up or Down arrow button to change the displayed units from U.S. Customary (ºF or psi) to metric (ºC or bar). The ºF/psi LED will be lit for U.S.
Customary units or ºC/bar LED will be lit for metric
units.
2. When appliance is in operation, the green LED
above the
ON/OFF will be lit.
3. When the appliance is not in operation, the green
LED above the
ON/OFF will not be lit. The
main display will show “OFF” and the operating
display will show .
NOTICE
Units cannot be changed if the main display
(Parameter Mode) or operating display
(Error Mode) is flashing.
8
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)
with optional Triangle Tube SMART I.F.W.H.
XXX
6
Burner OFF due to reaching temperature
setpoint
7
Space Heating (CH) post pump cycle
9
Burner ON for freeze protection
Raise CH pressure above 7 psig [0.5 bar]
LOP*
The
The
LED will be lit for CH (central heating call)
LED will be lit for DHW (domestic hot water call) with optional Triangle Tube SMART I.F.W.H.
NOTICE
“X” represents temperature or pressure readings. When temperature is displayed it
will be followed by “ºF” or “ºC” in the main display and the appropriate LED will be
lit. When pressure is displayed it will be followed by a “P” in the main display. Pressure can only be read when the operating display is blank or shows a “A”.
* If factory installed CH Low Water Cut Off (LWCO) is below 7 psig [0.5 bar] the main display
will flash a soft lockout of LOP (burner and CH primary pump is blocked) followed by the
pressure reading. Once CH system pressure is increased above 7 psig [0.5 bar] normal boiler
operation will be restored. Check LWCO wiring if LOP flashes to 90 _P (PSI) or 6.0 _P (bar).
9
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. The operating display will show the parameter number and main
display will show the parameter setting.
3. To modify a parameter press the
or
NOTICE
If the
reset button is not pressed within 30
seconds, the settings menu is automatically
closed and the changes are stored.
buttons.
4. Press the “ ” button to scroll to the next parameter to be changed.
Main Display
If the
ON/OFF button is pressed prior to
the
resets button, the settings menu is
closed and the changes are NOT stored.
Operating
Display
Factory Settings Parameters
LED
(Flashing)
(Flashing)
186ºF [86Cº]
Description
Adjustments
120ºF [49Cº]
0
1
Boiler set point temperature
Not applicable
Installation type
Adjustment range 86ºF to 194ºF [30ºC to 90ºC]
Adjustment range 104ºF to 149ºF [40ºC to 65ºC]
0=Combi (Heat and DHW)
1=Heating + SMART I.F.W.H.
2=DHW only (no heating system required)
3=Heating only
0
2
CH pump continuous
86ºF [30Cº]
0ºF [-18Cº]
64 ºF [18Cº]
1
5
6
7
8
0
o
Min. supply temperature of the heat curve
Min. outside temperature of the heat curve
Max. outside temperature of the heat curve
CH pump post purge period
Not applicable
Adjustment range 60°F to 140°F [16ºC to 60ºC]
Adjustment range -22°F to 50°F [-30ºC to 10ºC]
Adjustment range 60°F to 78°F [16ºC to 26ºC]
Adjustment range 0 to 15 minutes
Adjustment range 0 to 15 minutes
0
P
Anti-cycling period during CH operation 1
Minimal switch-off time in CH operation
Adjustable from 0 to 15 minutes
0=Intermittent pump on for heat and post purge
1=Pump continously active except during DHW call or
if outside temperature is above parameter 7 with the
outdoor sensor installed - Warm Weather Shut Down.
1 The anti-cycling time starts when burner shuts down during a CH call due to boiler water reaching the boiler set point temperature plus a 6ºF [3ºC]
differential. The CH circulator will continue to operate while the burner is blocked.
10
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.
CAUTION
The appliance freeze protection feature is
disabled during a Hard Lockout, however
the CH circulator will operate.
CAUTION
During a hard lockout or low water condition
the appliance will not re-start without service. If the heating system is left unattended in
cold weather appropriate safeguards or
alarms should be installed to prevent property damage.
Table 6: 12 K Ohm NTC Sensor Resistance
11
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
return sensor S2
interchanged
• Check for proper flow direction
• Replace S1 or S2
10, 11, 12,
13, 14
• Check wiring for break
• Check for proper flow direction
• Replace S2
• E 20 Open sensor
• E 21 Shorted sensor
• E22 Decreased too quickly
• E23 Increased too quickly
• E24 Stuck
• Replace S1 and/or S2
• Air in installation
• Pump not running
• Insufficient flow in installation, shut off valves closed, pump setting too low
• CHeck for wiring
4
E
- No flame signal
• Manual gas shut off valve closed
• Remove air from gas pipe
• Gas supply pressure too low or failing
• Gas valve or ignition unit not powered
• Incorrect ignition gap
• Check adjustment of gas valve
5
E
- Poor flame signal
• Condensate drain blocked
• Check adjustment of gas valve
6
E
- Flame detection fault
• Replace ignition cable + spark plug cap
• Replace ignition unit at gas valve
• Replace boiler controller
8
E
- Incorrect fan speed
• Fan catching on casing
• Wiring between fan and casing
• Check wiring for poor wire contact
• Replace fan
29,30
E
- Gas valve relay fault
• Replace boiler controller
E
- Flue sensor
fault
• E18 open sensor
• E19 Shorted sensor
• Check/Replace sensor
- Improper frequency
• Verify ground
• Frequency should be between 45 and 65 Hz
18, 19
50F
* Red LED above
button will flash, correct condition, and press
button.
NOTICE
If outdoor sensosr is shorted the boiler will not enter into a hard lockout but will maintain the minimum supply temperature
of the heat curve.
12
Replacement Parts
S
T
Pressure relief and air vent assembly
Ignition electrode
Control/Display
CH supply sensor S1
CH Return sensor S2
Blower
High voltage terminal strip
Low voltage/terminal strip X4
Condensate pan
Condensate drain trap assembly
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.com for list of distributors nearest you.
WARNING
Replacement parts must be purchased
through a local Triangle Tube distributor.
When ordering part please provide the model
number and description and/or part number
of replacement part. Use only genuine
13
Replacement Parts
3
CHALLENGER Front Door
Item
Part Number Part Number Part Number
CC85s
CC105s
CC125s
1
CCRKIT04
Wall Bracket Assembly (Not Shown)
2
CCRKIT05
Pipe Connectors & Brackets Assembly
(Not Shown)
2A
CCFTG01
Connector Pipe CH (Not Shown) - 1/Kit
3
CCRKIT06
CCRKIT07
CCRKIT08
14
Description
Front Door Assembly
Replacement Part
1
2
2
3
3
2 3
4
3
CHALLENGER Vent Components
Item
Part Number
CC85s
Part Number
CC105s
Part Number
CC125s
CCRKIT09
80/125 Concentric Vent /Air Adapter Assembly
(option - shown)
CCRKIT35
3” Vent /Air Adapter 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
9
CHALLENGER Internal Components
Item
Part Number
CC85s
Part Number
CC105s
Part Number
CC125s
Description
1
CCRKIT15
Igniter Assembly
2
CCCLB01
Ignition Cable
3
CCRKIT16
Sight Glass Assembly
4
CCRKIT17
CH Sensor Assembly - 1 / Kit
7
CCRKIT19
LWCO/CH Pressure Sensor Assembly
8
9
CCRKIT20
CCRKIT21
CCRKIT22
CCRKIT23
CH Supply pipe Assembly
CH Return Pipe Assembly
16
Replacement Parts
4
1
2
3
CHALLENGER Blower & Gas Valve Components
Item
Part Number Part Number Part Number
CC85s
CC105s
CC125s
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
CC85s
CC105s
CC125s
1
CCRKIT33
Description
Burner Assembly
18
Replacement Parts
4
1
2
3
CHALLENGER Control Components
Item
Part Number Part Number Part Number
CC85s
CC105s
CC125s
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 99.9 % copper and brazed, ensuring
a high resistance to corrosion
-
Self cleaning and self descaling
-
Computerized sizing available from Triangle Tube/Phase III
-
Available in capacities from 25,000 BTU/hr to 5,000,000 BTU/hr
Phase III Indirect Fired Water Heaters
-
Exclusive “tank-in-tank” design
-
Stainless steel construction
-
Available in 8 sizes and 2 models
-
Limited LIFETIME residential warranty
-
15 year limited commercial warranty
-
Self cleaning/self descaling design
Maxi-flo Pool and Spa Heat Exchangers
-
Constructed of high quality corrosion resistant stainless steel (AISI 316)
-
Specially designed built-in flow restrictor to assure maximum heat exchange
-
Compact and light weight
-
Available in 5 sizes that can accommodate any size pool or spa
Freeway Center - 1 Triangle Lane
Blackwood, NJ 08012
Tel: (856) 228 8881 - Fax: (856) 228 3584
E-mail: sales@triangletube.com
Member of
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