ACV The Challenger Operating instructions

Combination
Boiler and/ or
Water Heater
* I N S TALLAT I O N AN D MAI N T E NAN C E *
M A N U A L
NOTICE
Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation in order to gain warranty coverage.
When receiving the CHALLENGER, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Leave all documentation received with appliance with owner for future reference.
WARNING If the information in this manual is not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
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.
Date: 11/25/13
Installation and service must be performed by a qualified installer, service agency or the
gas supplier.
2010-1Challenger Manual
Table of Contents
PRODUCT AND SAFETY INFORMATION
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
SECTION I - PRE-INSTALLATION ITEMS
Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Boiler or Water Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boiler Freeze Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION II - COMBUSTION AIR AND VENTING
Combustion Air Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ventilation Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Combustion Air and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal of an Existing Boiler and/or Water Heater
from a Common Vent System . . . . . . . . . . . . . . . . . . 9
Commonwealth of Massachusetts Installation . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION III - APPLIANCE PREPARATIONS
Shipping and Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wall Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wall Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Stud Walls - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wall Bracket Installation - Solid Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Appliance Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Piping Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION IV - BOILER PIPING
General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Low Water Cut Off/CH Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Additional Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Boiler System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Expansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Closed-Type Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
i
Table of Contents
Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Piping - Zone Circulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Near Boiler Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Piping - Radiant Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Piping - SMART Indirect Fired Water Heater (I.F.W.H). . . . . . . . . 19
System Piping - Special Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Central Heating (CH) System Piping Diagrams. . . . . . . . . . . . . . . . . . . . . . 20
SECTION V - DOMESTIC PIPING
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22
Pressure Relief Valve - Standard Installations . . . . . . . . . . . . . . . . . . . . . . . 22
Temperature & Pressure (T&P) Relief Valve
- Storage Tank or SMART Installations . . . . . . . . . . . . . . . . . . 23
Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Vacuum Breaker - Storage Tank or SMART Installations . . . . . . . . . . . . . . 24
General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Recirculation Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Storage Tank Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Setting The Thermostatic Mixing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Domestic Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27
SECTION VI - INSTALLING VENT / COMBUSTION AIR & CONDENSATE DRAIN
Installing Vent and Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installing Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29
SECTION VII - GAS PIPING
Gas Supply Piping Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Natural Gas
Pipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Natural Gas Supply Pressure Requirements. . . . . . . . . . . . . . . . . . . 31
Natural Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Propane Gas
Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 32
Propane Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 32
ii
Table of Contents
SECTION VIII - INTERNAL WIRING
General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CHALLENGER Factory Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION IX - EXTERNAL WIRING
Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Line Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control Module Circulator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Low Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CH Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DHW Circulator for Optional Smart IFWH. . . . . . . . . . . . . . . . . . . . . . . . . 37
System Circulator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 37
Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-39
SECTION X - START-UP PREPARATION
Check Boiler System Water Chemistry
Water pH Level 6.5 to 8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Water Total Hardness Less Than 7 Grains/Gallon . . . . . . . . . . . . . . 40
Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Flush Boiler and Domestic System to Remove Sediment . . . . . . . . . . . . . . 40
Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Check Low Water Cut-Off/CH Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 41
Check for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Check Thermostat Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspection of Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION XI - START-UP PROCEDURES
Final Checks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CHALLENGER Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
If CHALLENGER Does Not Start Correctly. . . . . . . . . . . . . . . . . . . . . . . . 43
Check the CHALLENGER and System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Set Boiler Maximum Central Heating (CH) Set Point Temperature . . . . . . 46
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Table of Contents
Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47
Set DHW Set Point Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Operation Verification - Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . 47-48
Control Display
Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Additional DHW Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Highfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Lowfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Flame Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Control Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Setting the Appliance Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fluctuating Water Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Error (Hard Lockout) Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION XII - OUTDOOR RESET CONTROL
Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Adjusting Outdoor Reset Curve
CH Maximum Boiler Operating Temperature. . . . . . . . . . . . . . . . . 56
CH Minimum Boiler Operating Temperature Setpoint (Parameter 5) . . . . . . . . 56
CH Reset Curve Coldest Day (Parameter 6) . . . . . . . . . . . . . . . . . . 56
CH Reset Curve Warmest Day (Parameter 7) . . . . . . . . . . . . . . . . . 56
Changing Outdoor Reset Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Outdoor Reset Curve Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTION XIII - CHECK-OUT PROCEDURES
Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SECTION XIV - INSTALLATION RECORD
Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
SECTIONS XV - MAINTENANCE SCHEDULE
Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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Table of Contents
SECTION XVI - MAINTENANCE PROCEDURES
Annual Maintenance Procedures
Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Check Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 62
Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 62
Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removing Internal Flue and Condensate Pan for Inspection. . . . . . 62-63
Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check Relief Valve (s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 64
Check Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Perform Start-Up and Checkout Procedure . . . . . . . . . . . . . . . . . . . 66
Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Clean Boiler Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Clean Domestic Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-68
Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Handling Previously Fired Combustion Chamber Insulation . . . . . 68
REPLACEMENT PARTS
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-75
PRODUCT SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Specifications Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-78
Specification Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-82
v
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
BEST PRACTICE
Indicates a potentially hazardous situation which, if ignored, can result in
death, serious injury or substantial
property damage.
Indicates recommendations made by
ACV-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
ACV-Triangle Tube reserves the right to modify the technical specifications and components of its products without prior notice.
1
Product & Safety Information
DANGER
WARNING
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 which has been
under water.
Qualified Installer:
Prior to installing this product read all instructions included in this manual and all accompanying manuals/documents with this appliance.
Perform all installation steps required in these
manuals in the proper order given. Failure to
adhere to the guidelines within these manuals
can result in severe personal injury, death or
substantial property damage.
WARNING
WHAT TO DO IF YOU SMELL GAS
- Do not try to light any appliance
Homeowner:
- This product should be maintained /
serviced and inspected annually by a
qualified service technician.
- This manual is intended for use by a
qualified Installer/Service Technician.
- 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.
NOTICE
Please reference the appliance model number and the serial number from the rating
label, on the right panel when inquiring
about service or troubleshooting.
Installation and service must be performed by a qualified installer, service
agency or the gas supplier.
WARNING
WARNING
ACV-Triangle Tube accepts no liability for
any damage, injury or loss of life resulting
from incorrect installation, from alteration of any factory supplied parts or from
the use of parts or fittings not specified by
ACV-Triangle Tube. If there is a conflict
or doubt about the proper installation of
the appliance or any factory supplied or
replacement parts please contact ACVTriangle Tube Technical Support.
Should overheating occur or the gas
supply fails to shut off, turn OFF the
manual gas control valve external to the
appliance.
WARNING
DO NOT add cold make up water when
the appliance is hot. Thermal shock can
cause potential cracks in the heat
exchanger.
WARNING
CAUTION
When servicing the appliance:
- Avoid electrical shock by disconnecting the electrical supply prior to
performing maintenance.
2
A byproduct of any gas fired appliance
(stove, fire place, clothes dryer, water
heater, furnace, boiler, etc.) is carbon
monoxide. In the absence of any state or
local codes requiring the installation of
carbon monoxide detector and alarms,
ACV-Triangle Tube’s recommendation
is to follow the requirements of the
Commonwealth of Massachusetts, see
page 10.
Product & Safety Information
DANGER
DANGER
Protection must be taken against
excessive pressure!
Bacteria can develop in the domestic
water system if certain minimum water
temperatures are not maintained.
TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE
DANGER
•
HOT WATER CAN SCALD!
Water temperature over 125ºF [52ºC] can
cause severe burns instantly or death from
scalds.
•
Children, disabled and elderly are at
highest risk of being scalded.
-
-
•
•
Never leave them unattended in or
near shower, bathtub or sink.
Never allow small children to use a
hot water faucet or draw their own
bath.
•
To avoid any potential scald hazard or if
codes require specific water temperatures
at the hot water faucet, the installer must:
-
and
-
Check if the 30 psi [2 bar] pressure
relief valve supplied is installed in
the recommended location. (CH side)
To avoid injury, install the relief
devices to comply with local code
requirements.
Install the factory supplied thermostatic mixing valve at this appliance
and ensure it is working properly
Set the thermostatic mixing valve to
the lowest temperature which satisfies your hot water needs.
Feel and adjust water temperature
before bathing or showering.
-
Water drained from the system drain
valves may be extremely hot.
-
Make sure all connections are tight.
BURN
TO AVOID INJURY:
-
Check if a 150 psi [10 bar] pressure
relief valve (field supplied) is installed
as recommended for standard installations or a temperature/pressure relief
valve for storage tank or ACV-Triangle
Tube SMART Indirect Fired Water
Heater (I.F.W.H.) installations. (DHW
side)
Direct water flow away from any person.
3
Pre-Installation Items
SECTION I - Pre-Installation Items
-
Code Compliance
NOTICE
The CHALLENGER is certified to both the
Boiler (ANSI Z21.13/CSA 4.9) and Water
Heater (ANSI Z21.10.3/CSA4.3) standards.
The CHALLENGER gas manifold and
gas controls meet the safe lighting and
other performance requirements as specified in ANSI Z21.13 standard.
Due to the CHALLENGER’s unique heat
exchanger design which incorporates two independent copper water tube coils; one for space
heating and the other for domestic hot water,
the CHALLENGER can be installed as a
Boiler or Water Heater or both. The unused
system does not have to be connected or filled.
Parameter 1 (Installation Type) will need to be
set accordingly (0= Heat and DHW, 2 = DHW
Only and 3 = Heat Only), see page 52 for
Setting Parameters.
Determining Product Location
Before locating the CHALLENGER check for
convenient locations to:
-
This appliance must be installed in accordance
to the following:
-
-
-
-
-
Standards for Controls and Safety
Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1, when required.
Heating system piping
Domestic water supply piping
Venting
Gas supply piping
Electrical service
Ensure the appliance location allows the combustion air and vent piping to be routed directly
through the building and terminate properly in
the same pressure zone outside with a minimum
amount of length and bends.
All applicable local, state, national and
provincial codes, ordinances, regulations and laws.
For installations in Massachusetts, code
requires the appliance to be installed by
a licensed plumber or gas fitter, and if
antifreeze is utilized, the installation of
a reduced pressure backflow preventer
device is required in the boiler’s cold
water fill or make up water supply line.
Ensure the area chosen for the installation of the
CHALLENGER is free of any combustible
materials, gasoline and other flammable liquids.
WARNING
Failure to remove or maintain the area
free of combustible materials, gasoline
and other flammable liquids or vapors
can result in severe personal injury,
death or substantial property damage.
For installation in Massachusetts all direct
vented appliances must comply with the
guidelines as outlined on page 10.
Massachusetts Plumbing Board Product
Approval Code # is CI-0111-219 for the
CHALLENGER.
Ensure the CHALLENGER and its controls
are protected from dripping or spraying water
during normal operation or service.
The National Fuel Gas Code NFPA54/
ANSI Z223.1 - Latest edition.
National Electric Code ANSI/NFPA 70.
For installations in Canada -“Installation
Code for Gas Burning Equipment”
CAN/CSA B149.1 Canadian Electrical
Code Part 1 CSA C22.1.
4
The CHALLENGER should be installed in a
location so that any water leaking from the
appliance, piping connections or relief valve
will not cause damage to the surrounding area
or any lower floors in the structure. When such
location cannot be avoided, it is recommended
that a suitable drain pan, adequately drained, be
installed under the appliance. The pan must not
restrict combustion air flow.
Pre-Installation Items
Boiler or Water Heater Replacement
NOTICE
If the CHALLENGER is replacing an existing
boiler and/or hot water heater system, the following items should be checked and corrected
prior to installation:
-
-
-
-
When maintaining the approved clearance or less than recommended service
clearances, some product labeling may
become hidden and unreadable.
Boiler and domestic piping leaks and
corrosion.
WARNING
Proper location and sizing of the expansion tank on the boiler heating loop.
Proper location and sizing of the thermal expansion tank (if used) on the
domestic supply line.
If the enclosure in which the appliance is
installed is less than 45 cubic feet [1.3
m3], the space must be ventilated. See
page 8 Ventilation Air Requirements for
guidelines and requirements.
If applicable, amount and quality of
propylene glycol.
WARNING
Vent condition
Clearances
When installing the CHALLENGER in a
confined space, sufficient air must be provided to allow, under normal operating conditions, proper air flow around the product
to maintain ambient temperatures within
safe limits to comply with the National Fuel
Gas Code NFPA 54 - Standard.
The CHALLENGER is approved for following clearance to combustibles:
-
Top panel - 12 inches [30.5 cm]
-
Bottom panel - 12 inches [30.5 cm]
-
Front - 0 inches
-
Rear - 0 inches
-
Left side - 1.5 inches [3.8 cm]
-
-
Residential Garage Installations
When installing the CHALLENGER in a residential garage, the following special precautions
per NFPA 54/ANSI Z223.1 must be taken:
Right side - 4 inches [10.2 cm]
-
Boiler and Domestic Piping - 0.25 inches [0.6 cm]
Reference the appropriate vent supplement for venting clearance requirements.
-
BEST PRACTICE
To provide serviceability to the appliance it is recommended that the following clearances be maintained:
Top panel - 24 inches [61 cm].
Front - 24 inches [61 cm].
Bottom panel - 24 inches [61 cm].
Rear - 0 inches
Sides - 6 inches [15.2 cm]
5
Mount the appliance a minimum 18
inches [458 mm] above the floor level
of the garage. Ensure the burner and
ignition devices / controls are no less
than 18 inches [458 mm] above the
floor level.
Locate or protect the appliance in a
manner so it cannot be damaged by a
moving vehicle.
Pre-Installation Items
Boiler Freeze Protection Feature
CAUTION
The boiler freeze protection feature is
designed to protect the boiler, installed
in a primary/secondary piping arrangement. See Section IV for primary/secondary piping examples. See Section X
for antifreeze guidelines.
The boiler control has a freeze protection feature. This feature monitors the boiler supply
water temperature and responds as follows when
no call for heat is present:
-
-
42ºF [6ºC] Boiler circulator and burner are
ON.
50ºF [10ºC] Boiler circulator and burner are
OFF.
CAUTION
The boiler freeze protection feature is
disabled during a hard lockout, (burner
does not operate) however the CH circulator will operate.
6
Combustion Air and Venting
SECTION II- Combustion Air and
Venting
Potential contaminating products
Combustion Air Contamination
-
Spray cans containing chloro/fluorocarbons
-
Chlorinated wax
-
WARNING
If the CHALLENGER combustion air
inlet is located in any area likely to cause
or contain contamination, or if products,
which could 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.
-
Chlorine - based swimming pool chemicals / cleaners
-
Sodium Chloride used for water softening
-
-
-
-
-
-
WARNING
Do not operate a CHALLENGER if the
combustion air inlet is located near a
laundry room or pool facility. These
areas will always contain hazardous contaminants.
Permanent Wave Solutions
-
-
Calcium Chloride used for thawing ice
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 contain these products
Pool, laundry products, 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.
-
Dry cleaning / laundry areas and establishments
-
Metal fabrication shops
-
Refrigeration Repair shops
-
-
Please read the information listed below.
If contaminating chemicals are located
near the area of the combustion air inlet,
the installer should pipe the combustion
air inlet to an area free of these chemicals per SECTION VI of this installation
manual.
Swimming pools and health spas
Photo processing plants
-
Auto body shops
-
Furniture refinishing areas and establishments
-
-
-
-
7
Beauty salons
Plastic manufacturing plants
New building construction
Remodeling areas
Garages with workshops
Combustion Air and Venting
Ventilation Air Requirements
Combustion Air and Vent Piping
The CHALLENGER requires a Category IV
venting system, which is designed for pressurized venting and condensate.
For installations, involving only the CHALLENGER, in which the minimum service
clearances are maintained as listed on page 5,
no ventilation openings are required.
The CHALLENGER is certified as Direct Vent
(sealed combustion) appliance. A Direct Vent
appliance utilizes uncontaminated outdoor air
(piped directly to the appliance) for combustion.
For installations with less than the minimum
service clearances involving only the CHALLENGER, the space / enclosure must provide
two openings for ventilation. The openings
must be sized to provide 1 square inch [6
square centimeters] of free area per 1,000
BTUH [0.3 Kw] of appliance input. The openings shall be placed 12 inches [30.5 cm] from
the top of the space and 12 inches [30.5 cm]
from the floor of the space.
NOTICE
Install combustion air and vent pipe as
detailed in the CHALLENGER PVC,
CPVC,PP and SS Vent Supplement 201338 included in the appliance installation
envelope. Refer to instructions for parts
list and method of installation.
For installations in which the CHALLENGER
shares the space with air movers (exhaust fan,
clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space must
be provided with adequate air openings to provide ventilation and combustion air to the
equipment. To properly size the ventilation /
combustion air openings, the installer must
comply with the National Fuel Gas Code
NFPA 54, ANSI Z223.1 for installations in the
U.S or CAN/CSA B149.1 for installations in
Canada/
NOTICE
Contact ACV-Triangle Tube for other
venting options including PVC Concentric Vent/Air Termination Supplement
2008-04 or CHALLENGER Concentric
Vent/Air System Supplement 2011-60.
Refer to these instructions for parts list
and method of installation.
DANGER
WARNING
Verify installed combustion air and vent
piping are sealed gas tight and meet all
provided instructions and applicable
codes, failure to comply will result in
severe personal injury of death.
The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements
(exhaust fans, clothes dryers, fireplaces,
etc.) and the total input of all appliances
located in the same space as the CHALLENGER. The input of a CHALLENGER which uses combustion air
directly from the outside, is excluded
thus additional free area for the openings is not required. Failure to provide
or properly size the openings could
result in severe personal injury, death or
substantial property damage.
8
Combustion Air and Venting
Removal of an Existing Boiler and or Water
Heater from a Common Vent System
5. Test for spillage at the draft hood relief
opening after 5 minutes of main burner
operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
BEST PRACTICE
When an existing boiler and/or water
heater is removed from a common venting system, the common venting system is
likely to be too large for proper venting of
the remaining appliances. At the time of
removal of an existing boiler and/or water
heater, the following steps shall be followed with each appliance remaining
connected to the common venting system
placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
6. After it has been determined that each
appliance remaining connected to the common venting system properly vents when
tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and
any other gas-burning appliance to their
previous condition of use.
7. Any improper operation of the common
venting system should be corrected so the
installation conforms with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54
and/or CAN/CSA B149.1, Installation
codes. When resizing any portion of the
common venting system, the common
venting system should be resized to
approach the minimum size as determined
using the appropriate tables in Part II of the
National Fuel Gas Code ANSI
Z223.1/NFPA 54 and/or CAN/CSA
B149.1, Installation codes.
1. Seal any unused openings in the common
venting system.
2. Visually inspect the venting system for
proper size and horizontal pitch and determine there is no blockage or restriction,
leakage, corrosion and other deficiencies
which could cause an unsafe condition.
3. Insofar as is practical, close all building
doors and windows and all doors between
the space in which the appliances remaining connected to the common venting system are located and other spaces of the
building. Turn on clothes dryers and any
appliance not connected to the common
venting system. Turn on any exhaust fans,
such as range hoods and bathroom
exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust
fan. Close fireplace dampers.
DANGER
Do not install the CHALLENGER into a
common vent with other gas or oil appliances. This may cause flue gas spillage or
appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.
4. Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
9
Combustion Air and Venting
Commonwealth of Massachusetts Installations Only
For direct-vent appliances, mechanicalvent heating appliances or domestic hot
water equipment, where the bottom of the
vent terminal and the air intake is installed
below four feet above grade the following
requirements must be satisfied:
4. A metal or plastic identification plate
shall be mounted at the exterior of the
building, four feet directly above the
location of vent terminal. The plate
shall be of sufficient size to be easily
read from a distance of eight feet away,
and read “Gas Vent Directly Below”.
1. If there is not one already present, on
each floor level where there are bedroom(s), a carbon monoxide detector
and alarm shall be placed in the living
area outside the bedroom(s). The carbon monoxide detector shall comply
with NFPA 720 (2005 Edition).
NOTICE
Installer must provide tag identification
plate and ensure the lettering meets code
requirements.
For direct-vent appliances, mechanicalvent heating appliances or domestic hot
water equipment, where the bottom of the
vent terminal and the air intake are installed
above four feet above grade the following
requirements must be satisfied:
2. A carbon monoxide detector shall also
be located in the room that houses the
appliance or equipment and shall:
a. Be powered by the same electrical
circuit as the appliance or equipment such that only one service
switch services both the appliance
and the carbon monoxide detector;
1. If there is not one already present, on
each floor level where there are bedroom(s), a carbon monoxide detector
and alarm shall be placed in the living
area outside the bedroom(s). The carbon monoxide detector shall comply
with NFPA 720 (2005 Edition).
b. Have battery back-up power;
c. Meet ANSI/UL 2034 Standards and
comply with NFPA 720 (2005
Edition); and
2. A carbon monoxide detector shall:
a. Be located in the room that houses
the appliances or equipment;
d. Have been approved and listed by
the Nationally Recognized Testing
Laboratory as recognized under 527
CMR.
b. Be either hard wired or battery
powered or both; and
c. Shall comply with NFPA 720 (2005
Edition)
3. A Product-approved vent terminal must
be used, and if applicable, a Productapproved air intake must be used.
Installation shall be in strict compliance
with the manufacturer’s instructions. A
copy of the installation instructions
shall remain with the appliance or
equipment at the completion of the
installation.
3. A Product-approved vent terminal must
be used, and if applicable, a Productapproved air intake must be used.
Installation shall be in strict compliance
with the manufacturer’s instructions. A
copy of the installation instructions
shall remain with the appliance or
equipment at the completion of the
installation.
10
Appliance Preparations
SECTION III - Appliance Preparations
Wall Mounting Installation
Shipping and Handling Instructions
NOTICE
Prior to mounting appliance install piping support bracket according to
instructions on page 13.
WARNING
To avoid damage to gas fitting and piping at
bottom of appliance, appliance must be
shipped with rear or back of appliance
(longest box length) laying down flat.
The CHALLENGER should be wall mounted
using the bracket provided with the appliance
and is not designed for floor installation. If
floor installation is required an optional floor
stand part number PSSTND04 is available
through ACV-Triangle Tube. Appliance is not
to be installed on carpeting.
The CHALLENGER is generally easier to
handle and maneuver once removed from the
shipping carton.
To remove the shipping carton:
CAUTION
Use care not to lift the appliance from
piping or damage can occur. Use care
not to drop or bump the appliance as
damage to the appliance may result.
1. Remove any shipping straps and the top
shipping carton.
2. Carefully lift the appliance out of the carton.
3. Discard all packing materials.
Fig. 1: Optional Floor Stand Assembly,
Part Number: PSSTND04
NOTICE
The wall used for mounting the CHALLENGER must be vertically plumb and
capable of supporting a minimum 110
pounds [50 kg]. Failure to comply with
these requirements could result in personal injury, death or substantial property damage.
11
Appliance Preparations
Wall Mounting Guidelines
stud centers and ensuring the upper edge of
the bracket is away from the wall.
1. The wall-mounting bracket is designed for
stud spacing of 12 inch [30.5 cm] or 16
inch [40.6 cm] on centers. For unconventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket.
3. Level the bracket, while maintaining it’s centering with the studs and use a pencil to mark
the location of the mounting slots/holes.
4. Remove the bracket from the wall and drill
1/4” [6 mm] diameter hole by 3” [76 mm]
deep positioned in the center of each mark.
For applications using metal studs and
3/16” [5 mm] toggle bolts, drill the
required clearance hole.
2. For applications using wood studs, install
the bracket using the lag screws provided
with the appliance. Ensure both lag screws
are installed securely in the studs.
3. For applications using metal studs, install the
bracket to the studs using 3/16” [5 mm] toggle bolts and washers (provided by others)
5. Reposition the bracket onto the wall and
align mounting slots/holes. Insert the two
lag screws provided (or toggle bolts for
metal studs) through the mounting
slots/holes and loosely tighten.
4. DO NOT mount or attempt to mount the
wall bracket to hollow sheet rock or lath
walls using anchors. Only install appliance
to studs or equivalent wood structure.
6. Level bracket and tighten screws (bolts for
metal studs) securely making sure not to overtighten to avoid damaging drywall or plaster.
5. For applications using solid walls (rock,
concrete, brick, cinder block, etc.), install
the wall bracket using anchors (double
expansion shields) bolts and washers provided with the appliance.
Wall Bracket Installation - Solid Walls
1. Locate the general area of the appliance
placement.
6. The appliance is too heavy and bulky for a
single person to lift and attempt to mount; a
minimum of 2 people is required for
mounting the appliance.
2. Place the wall-mounting bracket on the
wall ensuring the upper edge of the bracket
is away from the wall.
Use extreme care not to drop the appliance or cause bodily injury while lifting
or mounting the appliance onto the
bracket. Once mounted verify that the
appliance is securely attached to the
bracket and wall. Failure to comply with
the above guidelines could result in property damage, personal injury or death.
4. Remove the bracket from the wall and drill
a 5/8” [16 mm] diameter hole by 1-3/8” [35
mm] deep positioned in the center of each
mark.
3. Level the bracket and use a pencil to mark
the location of the mounting slots/holes on
the wall.
NOTICE
5. Install the anchors (provided) flush or
slightly recessed in the drilled holes with
threaded side facing down.
6. Reposition the bracket on the wall and
align mounting slots/holes. Insert the two
bolts with washers (provided) through the
mounting slots/holes and loosely tighten.
Stud Walls -Installation
1. Locate the studs in the general area of the
appliance placement.
7. Level bracket and tighten bolts securely.
2. Place the wall-mounting bracket on the
wall centering the mounting slots with the
12
Appliance Preparations
BEST PRACTICE
Wall Anchors
(Solid Wall Only)
Apply pipe joint compound suitable for
potable water systems to the compression ferrule and compression nut threads
of all brass fittings before installation.
Install appliance pipes into the fittings
until bottom of hex on gas pipe fitting
rests against the top of the piping support bracket before tightening any compression nuts. Do not over tighten compression nuts. If fitting leaks loosen compression nut first and then retighten.
Optional Concentric
Vent/Air Adapter
Lag Screw
(Stud Wall)
Bolts with
Washer
(Solid Wall)
2. Prior to mounting the appliance on the wall
and with the rear or back of appliance laying flat, slip the appliance piping into the
fittings until bottom of hex on gas pipe fitting rests against the top of the piping support bracket before tightening any compression nuts.
Fig. 2: Wall Mounting The CHALLENGER
3. Tighten all fittings to appliance piping
connections with two wrenches.
Appliance Mounting
1. Obtain assistance in lifting the appliance
onto the wall bracket.
WARNING
Use a two wrench method when tightening piping near the appliance and its piping connections. Use one wrench to prevent the appliance connections from
turning and the second to tighten adjacent piping. Failure to support the appliance piping connections could damage
piping.
2. Install the appliance making sure the appliance mounting lip located along the upper
edge of the rear jacket panel engages the
wall-mounting bracket. Ensure the appliance is seated properly and is secure.
Piping Support Bracket
CAUTION
4. Once appliance is mounted according to
Appliance Mounting instructions on this
page, secure piping support bracket to wall
with hardware supplied.
Appliance must be installed using the supplied copper fittings and piping support
bracket. DO NOT braze directly to copper appliance pipes or damage may result
to internal parts (gaskets and flow switch).
1. Pre-install the 4 brass compression fittings
into the piping support bracket as shown in
Fig. 4, page 15. Use retaining clips to hold
fittings in place.
13
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 components.
-
Use isolation valves to isolate system components.
-
Install unions for easy removal of the
CHALLENGER from the system piping.
WARNING
Should not contain any shut-off valves
or obstructions. No shut-off valve
should be piped between the appliance
and relief valve.
Low Water Cut Off / CH Pressure Sensor
NOTICE
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 connection as shown in Fig. 3 page 15.
-
-
2. To avoid potential water damage to the surrounding area or potential scalding hazard
due to the operation of the relief valve, the
discharge piping:
-
Should not be subject to conditions
where freezing could occur.
Failure to comply with the guidelines on
installing the pressure relief valve and discharge piping can result in personal injury,
death or substantial property damage.
Pressure Relief Valve (PRV)
-
Should terminate with a plain end, not
with a threaded end. The material of the
piping should have a serviceable temperature rating of 250ºF [121ºC] or greater.
WARNING
Use a two wrench method when tightening piping onto the appliance connections. 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.
-
above any drain connection to allow
clear visibility of the discharge.
-
Must be connected to the discharge outlet 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]
14
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 factory 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 domestic 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.
Boiler Piping
Pressure Relief Valve
(Supplied with Boiler)
3/4" Street Elbow
Manual Air Vent
(Supplied with Boiler)
Drain Piping Directed
to a Suitable
Place of Drainage
Boiler Supply
Connection
with Tee
Fitting and
Temperature/
Pressure Gauge
Boiler Return Connection
with Tee Fitting and
Boiler Drain Valve
Fig. 3: Boiler Pressure Relief Valve and Drain Valve Installation
Pressure Relief Valve
(supplied)
Manual
Air Vent
(supplied)
Note: Installer must provide
relief valve drain piping
directed to a suitable
place of drainage
3/4” Tee
(supplied)
3/4” Nipple
(supplied)
3/4” Street
Elbow (supplied)
Piping Bracket
(supplied)
1 inch
Compression
Assembly
(supplied)
1 inch
Compression
Assembly
(supplied)
1 inch
Tee
(supplied)
Fig. 4:
Drain Valve
(by Others)
1 inch Tee (by Others)
Compression
Nut
Compression
Ferrule
Retaining Clip
(supplied)
Temperature Pressure
Gauge (supplied)
Near Appliance Piping Assembly
Compression/NPT Adapater
15
Boiler Piping
Additional Limit Control
Boiler System Piping Applications
If a Low Water Cut Off (LWCO) is required by
certain local jurisdictions or when the boiler is
installed above the system piping, the following guidelines must be followed:
-
-
BEST PRACTICE
It is required on all piping applications
to utilize a primary/secondary piping
arrangement. Maintain the minimum
boiler flow rate, see Graphs 5-10 on
pages 79-81.
The LWCO must be designed for water
installations, electrode probe-type is
recommended.
Expansion Tank and Makeup Water
The LWCO must be installed in a tee
connection on the boiler supply piping
above the appliance.
Ensure the expansion tank is properly sized for
the boiler water volume (approximately 1 gallon [4 L]) and the system water volume and
temperature.
Wiring of the LWCO to the CHALLENGER should be done in series with
the 120 VAC service to the appliance .
CAUTION
Undersized expansion tanks will cause
system water to be lost through the pressure relief valve and cause additional
makeup water to be added to the system.
Eventual boiler heat exchanger failure
can result due to this excessive makeup
water addition.
If the installation is to comply with ASME
CSD-1 or Canadian requirements, an additional high temperature limit may be needed.
Consult local code requirements to determine
compliance. The limit should be installed as
follows:
-
-
-
Install the limit in the boiler supply piping between the boiler and any isolation
valve.
The expansion tank must be located as shown
in Fig. 5 and Fig. 6 on page 18 when using a
primary/secondary piping arrangement or as
per recognized design methods. Refer to the
expansion tank manufacturer instructions for
additional installation details.
Maximum set point for the limit is
200ºF [93ºC].
Wiring of the limit device to the CHALLENGER should be done in series with
the 120 VAC service to the appliance.
Connect the expansion tank to an air separator
only if the air separator is located on the suction side (inlet) of the system circulator.
Always locate and install the system fill connection at the same location as the expansion
tank connection to the system.
Backflow Preventer
-
Use a backflow preventer valve in the
make-up water supply to the appliance
as required by local codes.
Diaphragm Expansion Tank
Always install an automatic air vent on the top
of the air separator to remove residual air from
the system.
16
Boiler Piping
Closed-Type Expansion Tank
System Piping - Zone Circulators
It is recommended to pitch any horizontal piping upwards toward the expansion tank 1 inch
per 5 feet [2.5cm / 1.5 M] of piping. Use 3/4”
piping to the expansion tank to allow air within the system to rise.
Connect the CHALLENGER to the system
piping as shown in Fig. 7 page 20 when zoning
with zone circulators.
The installer must provide a separate circulator
for each zone of space heating.
CAUTION
DO NOT install automatic air vents on a
closed-type expansion tank system. Air
must remain in the system and be
returned to the expansion tank to provide an air cushion. An automatic air
vent would cause air to be vented from
the system resulting in a water-logged
expansion tank.
NOTICE
To ensure an adequate flow rate through
the CHALLENGER, the boiler supply
and return piping size must be a minimum of 1 inch.
System Piping - Zone Valves
Circulator
Connect the CHALLENGER to the system piping as shown in Fig. 8 page 20 when zoning with
zone valves. The primary / secondary piping
ensures that the boiler loop has sufficient flow.
The CHALLENGER must be supplied with a
Central Heating (CH) circulator with flow
check. The circulator when wired directly to the
CHALLENGER will allow for domestic hot
water priority and to provide circulation for the
freeze protection feature of the boiler control.
See Graph 5-10 on page 79-81 for pressure drop
and minimum flow rate through the boiler.
NOTICE
To ensure an adequate flow rate through
the CHALLENGER, the boiler supply
and return piping size must be a minimum of 1 inch.
Sizing Primary Piping
See Fig. 7 and 8, page 20, for recommended
piping arrangements based on various applications. Size the piping and system components
required in the space heating system, using recognized design methods.
17
Boiler Piping
System
Return
System
Supply
2
12" Max.
[30.5 cm]
6
1
3
Cold
Water Fill
6
4
6
7
10
11
5
Boiler
Supply
Fig. 5: Near Boiler Piping - Diaphragm Expansion Tank
Boiler
Return
9
System
Supply
8
4
6
Minimum
3/4" Piping
1
Cold
Water Fill
6
System
Return
12" Max.
[30.5 cm]
6
10
3
11
Boiler
Supply
Boiler
Return
Fig. 6 : Near Boiler Piping - Closed Type Expansion Tank
1.
2.
3.
4.
5.
6.
System circulator
Automatic air vent
Air separator
Automatic fill valve
Diaphragm expansion tank
Isolation valve
7. Drain/purge valve
8. Tank fitting
9. Closed type expansion tank
10. Primary/secondary connection
11. CH circulator with flow check
18
7
Boiler Piping
System Piping - Radiant Heating
NOTICE
The boiler system piping must be a
“closed” system to avoid any oxygen
contamination and potential failure of
the outer tank of the SMART.
The heat exchanger design of the CHALLENGER allows operation in a condensing
mode. This feature requires no regulation of
the return water temperature back to the boiler
in radiant heating applications.
The CHALLENGER’s domestic piping should
not be utilized. Refer to the installation manual
provided with the SMART for additional installation details.
The maximum boiler water supply temperature
can be maintained by the CHALLENGER,
potentially eliminating the need for a mixing
system to achieve the desired temperature if all
zones of heat are at the same temperature set
point.
See Parameter 1 and Note 3, page 52 for parameter, wiring and operational details using the
SMART I.F.W.H. with a CHALLENGER boiler.
Size the system piping and circulator to provide
the flow needed for the radiant system.
System Piping - Special Application
NOTICE
If the boiler is used in conjunction with a
chilled water/medium system, the boiler and
chiller must be piped in parallel. Install
flow/check valves to prevent the chilled medium from entering the boiler.
To ensure an adequate flow rate through
the CHALLENGER, the boiler supply
and return piping size must be a minimum of 1 inch.
System Piping - SMART Indirect Fired
Water Heater (I.F.W.H.)
If the boiler is used to supply hot water to the
heating coils of an air handler where they may
be exposed to chilled air circulation, install
flow/check valves or other automatic devices
to prevent gravity circulation of the boiler
water during cooling cycles.
See Figs. 7 and 8, page 20 for recommended piping for a ACV-Triangle Tube SMART I.F.W.H..
This application will provide higher domestic
hot water flow rates for a short period of time
(dump load) and will recover the SMART tank
faster than a domestic storage tank. The
SMART’s boiler piping should be piped off the
primary loop.
19
Boiler Piping
Fig. 7: Central Heating (CH)
System Piping - Zoning
with Zone Circulators
4
4
3
3
5
4
Additional
Zone Load
3
5
3
4
Zone Load
9
12" Max.
[30.5 cm]
4
4
6
7
8
4
4
11
1
10
2
12
Optional
SMART
I.F.W.H.
6
4
1.
2.
3.
4
5.
6.
CHALLENGER boiler
Boiler circulator with flow check
Flow/check valve
Isolation valve
Zone circulator
Drain/purge valve
Fig. 8: CH System
Piping - Zoning with
Zone Valves
6
7. Pressure relief valve
8. Air separator
9. Automatic air vent
10. Diaphragm expansion tank
11. Automatic fill valve
12. DHW circulator with flow check
4
5
4
5
4
Additional
Zone Load
4
Zone Load
9
4
12
12" Max.
[30.5 cm]
4
7
8
4
4
11
1
10
13
Optional
SMART
I.F.W.H.
4
1.
2.
4
5.
6.
7.
2
6
6
CHALLENGER boiler
Boiler circulator with flow check
Isolation valve
Zone valve
Drain/purge valve
Pressure relief valve
6
20
8. Air separator
9. Automatic air vent
10. Diaphragm expansion tank
11. Automatic fill valve
12. System circulator
13. DHW circulator with flow check
Domestic Piping
SECTION V - Domestic Piping
WARNING
HOT WATER CAN SCALD!
•
•
•
•
•
Water temperatures over 125ºF [52ºC]
can cause severe burns instantly, or
death from scalds.
Feel water before bathing or showering.
Consumer Product Safety Commission
and some states recommend temperatures settings of 130ºF [54ºC] or less.
Setting thermostat higher than 130ºF
[54ºC] will increase risk of scald injury
and cause severe personal injury or
death.
General Notes
•
Water heated to a temperature suitable
for clothes washing, dish washing and
other sanitizing needs will scald and
cause permanent injury.
Children and elderly, infirm, or physically handicapped persons are more
likely to be injured by hot water. Never
leave them unattended in or near a bathtub. If anyone using hot water in the
building fits this description, or if state
laws or local codes require certain
water temperatures at hot water faucets,
take special precautions.
•
Household water usage patterns will affect
water temperature at any faucet or shower.
Occasionally check temperature at each
point of use, then adjust thermostatic mixing valve accordingly. Always recheck
temperature after adjusting.
Lowering the thermostatic mixing valves as
indicated in these instructions will reduce water
temperature levels. Consult your installer or
service technician.
Operating Restrictions
•
Minimum DHW flow rate is 0.5 gpm [2
lpm] to initiate a domestic call for heat.
•
Minimum domestic working pressure is 40
psig [3 bar].
•
- Install the factory supplied thermostatic mixing valve at the water
heater. Installation must comply with
valve manufacturer’s recommendation and instructions.
Maximum DHW outlet temperature is
149ºF [65ºC].
NOTICE
- Use the lowest practical temperature
setting.
When the CHALLENGER is installed
in a domestic well application, the cut in
pressure of the domestic well pump’s
control must be set to 40 psig [3 bar] to
ensure more consistant domestic flow
and temperature performance.
- Check water temperature after any
adjustment. You must follow “Setting
the Thermostatic Mixing Valve” procedures.
21
Domestic Piping
•
•
Maximum domestic working pressure is
150 psig [10 bar].
relieve at or below 150 psi [ 10 bar] of domestic water pressure and a minimum relieving
capacity of 124,000 Btu/hr with 3/4” NPT
threads. For safe operation of the domestic
water heater, the relief valve must not be
removed from its designated location of installation or plugged.
Water quality limitations (based on E.P.A
National Secondary Drinking Water
Regulations):
-
Chloride, less than 150 ppm or mg/l
-
Total hardness 3 - 7 grains/gallon or 50120 ppm or mg/l.
-
-
-
-
-
-
-
1. The CHALLENGER is not supplied with a
150 psi [10 bar] pressure relief valve and
must be piped using a Pressure Relief Valve
connected as shown in Fig. 11 page 26.
pH value min. 6.5, max. 8.5
Total Dissolved Solids (TDS), less than
120 ppm or mg/l.
2. To avoid potential water damage to the surrounding area or potential scalding hazard
due to the operation of the relief valve, the
discharge piping:
Iron less than 0.3 ppm or mg/l.
Aluminum, less than 0.2 ppm or mg/l.
-
Copper, less than 1 ppm or mg/l.
Manganese, less than 0.05 ppm or mg/l.
-
Zinc, less than 5 ppm or mg/l.
BEST PRACTICE
-
In hard water areas (more than 7 grains
of hardness) soften the cold domestic
supply water to the appliance to prevent
scaling.
-
NOTICE
Any water conditioning system must be
installed and maintained in accordance
with manufacturer’s specifications.
Pressure Relief
Installations
Valve
-
-
Standard
-
The domestic water heater (if utilized) shall
have a field supplied pressure relief valve
installed within 6” [152 mm] of the DHW HOT
outlet connection with the relief valve spindle
installed in the vertical position.
Must be connected to the discharge outlet 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 [152 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 temperature 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.
WARNING
Failure to comply with the guidelines on
installing the pressure relief valve and discharge piping can result in personal injury,
death or substantial property damage.
The domestic water heater (if utilized) requires
a field supplied pressure relief valve identified
with the ASME V or HV symbol and set to
22
Domestic Piping
Temperature & Pressure (T&P) Relief ValveStorage Tank or SMART Installations
- plugged, reduced or restricted
- subject to freezing
CAUTION
•
•
WARNING
To reduce risk of excessive pressures and
temperatures in a storage tank or ACVTriangle Tube SMART I.F.W.H., install
temperature and pressure protective
equipment required by local codes, but no
less than a combination temperature and
pressure relief valve certified by a nationally recognized testing laboratory that
maintains periodic inspection of production of listed equipment or materials, as
meeting the requirements for Relief
Valves and Automatic Gas Shutoff
Devices for Hot Water Supply Systems,
ANSI Z21.22. This valve must be marked
with the maximum working pressure of
the domestic water heater (150 psi).
Do not install any valve between T&P
relief valve and the storage tank or
SMART connection or on T&P relief
valve discharge piping. Do not plug
T&P relief valve or discharge piping.
Improper placement and piping of T&P
relief valve can cause severe personal
injury, death or substantial property
damage.
WARNING
Isolation valves are only intended for
servicing the domestic coil. During any
domestic service the appliance should be
turned off and the domestic coil drained
to prevent over pressurization of the
appliance’s domestic coil.
The storage tank or SMART must be protected with a field supplied T&P relief valve.
Size the T&P relief valve by the following specifications, unless they conflict
with local codes: 3/4” NPT with an AGA
Rating of 124,000 BTU/hr.
Drain Valves
Drain valves and fittings are field supplied.
Thermal Expansion
T&P Relief Valve Discharge Piping
T&P relief valve discharge piping must be:
If a backflow preventer, check valve or pressure
reducing valve is installed on the cold water supply piping of the domestic water heater, install
an expansion tank on the cold water supply line
to prevent normal thermal expansion from
repeatedly forcing open the relief valve.
- made of material serviceable for temperatures of 250ºF [121ºC] or greater
- directed so that hot water flows away
from all persons
- directed to a suitable place for disposal
- installed so as to allow complete draining
of the T&P relief valve and discharge line
CAUTION
T&P relief valve discharge piping MUST
NOT be:
- excessively long, using more than 2
elbows or 15 feet [4.5 m] of piping can
reduce discharge capacity
- directly connected to a drain, terminate
discharge piping within 6” [152 mm]
from drain, refer to local codes
23
Relief valve is not intended for constant
duty, such as relief of pressure due to
repeated normal system water expansion.
Correct this condition by installing a
properly sized expansion tank in domestic water system. Refer to expansion tank
manufacturer’s installation instructions
for proper sizing.
Domestic Piping
The domestic water volume of the
CHALLENGER is approximately 0.26
gallons [ 1 l]. Remember to include this
volume when sizing the expansion tank.
•
Water Hammer
Installing a vacuum breaker on the inlet of the storage tank will prevent damage to the tank if a negative pressure is developed in the domestic supply
line. See manufacturer’s instructions for application and installation of the vacuum breaker.
•
Use dielectric unions or couplings to protect hot and cold water fittings from corrosion when connecting dissimilar materials
such as copper and galvanized iron pipe.
Use isolation valves to isolate the DHW
connections and system components.
If copper pipe is used for domestic water
connections, first solder pipe to a threaded
adapter and then screw adapter onto the
domestic cold water inlet of the appliance.
The domestic cold water inlet contains an
internal plastic flow switch which can be
damaged by heat from soldering.
NOTICE
Do not apply heat to the domestic cold
water inlet when making solder connections to water heater. Solder tubing to
adapter before fitting adapter to cold
water inlet of heater. It is imperative that
no heat be applied to the cold water inlet,
as it contains a non metallic flow switch.
General Piping Requirements
For domestic water piping diagrams, see
Figs 11 and 12, pages 26 and 27.
BEST PRACTICE
Thermostatic Mixing Valve
It is recommended to install flush valves
as outlined in Fig. 11 and 12, pages 26
and 27 for servicing the domestic coil.
The CHALLENGER is factory supplied with a
thermostatic mixing valve with built-in check
valves on the hot and cold inlets. The mixing valve
must be installed as shown in Figs. 9, 11 and 12.
BEST PRACTICE
•
Size all piping no smaller than the appliance’s DHW connections.
•
Vacuum Breaker - Storage Tank or SMART
Installations
•
•
•
Dishwashers, clothes washers and fast-closing
positive shut-off valves incorporated in the system all contribute to creating water shock. Install
a water hammer arrester to prevent damage to
pipes and appliances. See device manufacturer’s
instructions for application and installation.
Use pipe joint compound or tape suitable
for potable water systems.
The mixing water temperature range of the
thermostatic mixing valve is 85ºF [30ºC] to
140ºF [60ºC].
It is recommended to install a strainer on
the domestic cold water inlet to prevent
any nuisance issues with domestic flow
switch. An optional lead free, 60 mesh ystrainer is available through ACV-Triangle
Tube part number CCSTRA01.
The thermostatic mixing valve is preset to its minimum mixed water temperature, 85ºF [30ºC].
All plumbing must meet or exceed all local,
state and national plumbing codes.
24
Domestic Piping
Storage Tank Installations
For applications requiring high domestic hot
water flow rates for a short period of time (dump
load), the installer may install a storage type tank
(see Fig. 12 page 27) in the domestic piping.
The installer must:
BEST PRACTICE
Additional thermostatic/anti-scald valves
should be installed at each hot water
faucet, bath and shower outlet.
For applications with a domestic recirculation
loop, the recirculation pump should be controlled
by an aquastat. The maximum recommended setting of the aquastat is 10ºF [5ºC] lower than the
thermostatic mixing valve setting.
1. Relocate the thermostatic mixing valve from the
CHALLENGER to the outlet of the storage tank.
2. Remove domestic restrictor at the inlet of the
domestic flow switch.
DANGER
3. Provide recirculation from the storage tank
back to the CHALLENGER using a bronze
or stainless steel type circulator.
Setting the Thermostatic Mixing Valve
For proper operation of the thermostatic mixing valve and to prevent potential
scalding hazards, the recirculation loop
should be controlled by an aquastat. DO
NOT use continuous recirculation.
NOTICE
The thermostatic mixing valve controls
the outlet hot water temperature delivered to the faucets.
Check Valve
(cold & hot)
WARNING
t
Ho
Adapter
POTENTIAL SCALD HAZARD. The
mixing valve must be installed on the
CHALLENGER. Removal or adjustment
of the mixing valve will create a potential
scald hazard resulting in severe personal
injury or death.
ld
Co
Fig. 9: Mixing Valve Assembly
Mixed
If any adjustment needs to be made to the
valve’s temperature setpoint refer to the manufacturer’s instructions included with the valve.
Recirculation Piping
•
•
Recirculation return piping if applicable,
must be installed in the cold water inlet as
shown Figs 11 and 12, page 26 and 27.
A stainless steel or bronze circulator is recommended and must be controlled by a
aquastat.
25
Domestic Piping
1/2” compression x 3/4” NPT Adapter
Fittings for DHW
Fig. 10 : Installation of Domestic Compression Adapter Assemblies
1
5
8
6
2
9
M
H
7
c
10
DHW
Cold
Recirculating
Loop
(optional)
2
To Dish Washer
or High Temperature
Application
6
Fig. 11 : Domestic Piping - Standard Installations
1.
2.
3.
4.
5.
6.
CHALLENGER
Isolation valve
Backflow preventer or pressure reducing valve (*)
Thermal expansion tank (potable) (*)
Domestic pressure relief valve - 150 psi max.
Drain/flush valve
26
3
2
Water Inlet
4
7. Mixing valve with check valve
8. Strainer (*)
9. Flow check valve (*)
10. Circulator (potable , must be controlled by a aquastat ) (*)
(*) Optional device may be required by local codes
Domestic Piping
1
Recirculating
Loop (optional)
8
6
For service only
see warning on
page 23
9
2
10
6
2
M
C
H
Remove any
check valve
7
5
11
3
2
DHW
Cold
Water
Inlet
4
Storage
Tank
6
Note:
2
12
9
Domestic cold water inlet through a storage tank will yield a lower domestic pressure drop in addition to
greater domestic performance. Domestic set point temperature should be set to 149ºF [65ºC] see page 52. DHW
function button (
) should be set to ON (
) at the display panel, see page 49.
restrictor at inlet of the domestic flow switch.
Fig. 12 : Domestic Piping - Storage Tank Installations
1.
2.
3.
4.
5.
6.
7.
8.
9.
CHALLENGER
Isolation valve
Backflow preventer or pressure reducing valve (*)
Thermal expansion tank (potable) (*)
Temperature/Pressure relief valve
Drain/flush valve
Mixing valve with check valve
Circulator (potable, must be controlled by a aquastat) (*)
Flow check valve
Remove domestic
10. Strainer (*)
11. Vacuum breaker (*)
12. Domestic circulator (potable Grundfos UP26-99BF
or Taco 009-SF5 or equivalent sized for 2.5 gpm
[9.5 lpm] at 32 feet [9.7 m], must be controlled by
a aquastat mounted on the storage tank with a maximum set point of 130ºF [55ºC].
(*) Optional device maybe required by local codes
27
Installation Vent/Combustion Air & Condensate Drain
SECTION VI - Installing Vent /
Combustion Air & Condensate Drain
2. Remove front door and install trap. Ensure
the trap is completely seated and secure on
the appliance.
Installing Vent and Combustion Air
3. Connect 13/16” ID tubing to the drain
barbed fitting of the trap assembly.
DANGER
NOTICE
The CHALLENGER must be vented
and supplied with combustion air as
shown in the CHALLENGER PVC,
CPVC, PP and SS Vent Supplement
2013-38, included in the installation
envelope. Refer to instructions for parts
list and method of installation. Once
installation is completed, inspect the vent
and combustion air system thoroughly to
ensure systems are airtight and comply
with the instructions given in the venting
supplement and are within all requirements of applicable codes. Failure to
comply with the installation requirements on the venting and combustion air
piping will cause severe personal injury
or death.
The drain line materials must be an
approved material by the authority having jurisdiction. In absence of such
authority, PVC and CPVC piping must
comply with ASTM D1785 or D2845.
The cement and primer used on the piping must comply with ASME D2564 or
F493. For installations in Canada, use
ULC certified PVC or CPVC pipe, fittings and cement/primer.
4. Continue the tubing from the trap assembly
to a floor drain or condensate pump.
NOTICE
When selecting and installing a condensate pump, ensure the pump is approved
for use with condensing appliances. The
pump should be equipped with an overflow switch to prevent property damage
from potential condensate spillage.
NOTICE
Contact ACV-Triangle Tube for other
venting options including PVC Concentric Vent/Air Termination Supplement
2008-04 or CHALLENGER Concentric
Vent/Air System Supplement 2011-60.
Refer to these instructions for parts list
and method of installation.
5. The CHALLENGER will typically produce
a condensate that is considered slightly
acidic with a pH content below 4.0. Install
a neutralizing filter if required.
Installing Condensate Drain Assembly
1. Locate the condensate trap assembly and
cut top with hacksaw or knife and install as
shown in Fig. 13 page 29.
CAUTION
The condensate drain must remain
filled, unobstructed and allow unrestricted flow of condensate. The condensate should not be subject to conditions
where freezing could occur. If the condensate is subjected to freezing or
becomes obstructed , it can leak, resulting in potential water damage to the
appliance and surrounding area.
NOTICE
The installer must fill the condensate
trap with water prior to assembling on
the appliance. Do not operate appliance
without factory supplied condensate
trap installed on appliance.
28
Installation Vent/Combustion Air & Condensate Drain
*
* Carefully cut top of
condensate drain trap
assembly with hack saw
or knife at location shown.
Condensate Drain
Trap Assembly
Fig. 13: Condensate Drain Trap Assembly
29
Gas Piping
SECTION VII - Gas Piping
-
Gas Supply Piping Connection
NOTICE
WARNING
Do not check for gas leaks with an open
flame. Use a gas detection device or bubble test. Failure to check for gas leaks
can cause severe personal injury, death
or substantial property damage.
The gas supply piping must be installed
in accordance to all applicable local,
state and national codes and utility
requirements.
7. Use pipe joint compound compatible with
natural and propane gases. Apply sparingly only to the male threads of pipe joints so
that pipe dope does not block gas flow.
1. Install a 1/2” NPT pipe union at the factory
supplied gas piping nipple, for ease of service.
2. Install the factory supplied manual shutoff
valve in the gas supply piping as shown in
Fig. 14. For installations in Canada the
installer must tag and identify the main
shutoff valve.
WARNING
Failure to apply pipe joint compound as
detailed above can result in severe personal injury, death or substantial property damage.
3. Install a sediment trap (drip leg) on the gas
supply line prior to connecting to the CHALLENGER gas train as shown in Fig. 14.
4. Support the gas piping using hangers. Do
not support the piping by the appliance or
its components.
WARNING
Use a two-wrench method of tightening
gas piping near the appliance and its gas
piping connection. Use one wrench to
prevent the appliance gas line connection from turning and the second to
tighten adjacent piping. Failure to support the appliance gas piping connection
could damage the gas line components.
5. Purge all air from the gas supply piping.
6. Before placing the CHALLENGER into
operation, check and test all piping connections for leaks.
-
Close the manual shutoff valve during
any pressure test with less than 13”w.c.
[32 mbar].
NOTICE
Support gas piping
Disconnect the CHALLENGER and its
gas valve from the gas supply piping
during any pressure test greater than
13”w.c. [32 mbar].
Position Bracket so
Gas Pipe Hex Rests on Bracket
Union Fitting (by Others)
Tee Fitting (by Others)
Sediment Trap
Min. Length of 3” [7.6 cm]
Manual Gas
Valve
(Supplied)
Fig. 14: Recommended Gas Supply Piping
Cap Fitting
(by Others)
30
Gas Piping
NATURAL GAS
2. Install 100% lockup gas pressure regulator
in the gas supply line if inlet pressure can
exceed 13”w.c. [32 mbar] at any time.
Adjust the lockup pressure regulator for
13”w.c. [32 mbar] maximum.
Pipe Sizing - Natural Gas
Refer to Table 1 for schedule 40 metallic pipe
length and diameter requirements for natural
gas, based on rated CHALLENGER input
(divide by 1,000 to obtain cubic feet per hour).
-
-
WARNING
DO NOT adjust or attempt to measure
gas valve outlet pressure. The gas valve
is factory-set for the correct outlet pressure. This setting is suitable for natural
and propane gas and requires no field
adjustment. Attempts by the installer to
adjust or measure the gas valve outlet
pressure could result in damage to the
valve, causing potential severe personal
injury, death or substantial property
damage.
Table 1 is based on Natural Gas with a specific gravity of 0.60 and a pressure drop
through the gas piping of 0.30”w.c. [0.75
mbar].
For additional gas piping sizing information, refer to ANSI Z223.1. For Canadian
installations refer to B149.1.
Natural Gas Supply Pressure Requirements
1. Pressure required at the gas valve inlet
supply pressure port:
-
-
-
Table 2: Natural Gas Orifice Requirements
Maximum 13”w.c. [32 mbar] at flow or
no flow conditions to the burner.
CC85
Natural
Orifice Size
0.256” [6.50 mm]
Orifice
Marking
CC105
0.256” [6.50 mm]
650
CC125
0.285” [7.25 mm]
725
CHALLENGER
MODEL
Minimum 5”w.c. [13 mbar] during flow
conditions to the burner. Must be verified during start up and with all other
gas appliances operating within the gas
piping service.
Maximum gas inlet pressure must not
be exceeded and minimum gas inlet
pressure is for the purpose of input
adjustment.
650
Table 1: Gas Piping Sizing - Natural Gas
Length of Pipe in Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per
Feet
Hour (based on 0.60 specific gravity, 0.30" w.c. pressure drop)
SCH 40
1/2"
3/4"
30
73
152
10
20
40
50
75
100
150
132
92
63
56
45
38
31
1"
1-1/4"
1-1/2"
285
590
890
278
520
130
245
190
350
115
215
93
175
79
64
150
31
120
1050
730
500
440
360
305
250
1600
1100
760
670
545
460
380
Gas Piping
PROPANE GAS
WARNING
Pipe Sizing - Propane Gas
DO NOT adjust or attempt to measure gas
valve outlet pressure. The gas valve is factory-set for the correct outlet pressure.
This setting is suitable for natural gas and
propane and requires no field adjustment.
Attempts by the installer to adjust or measure the gas valve outlet pressure could
result in damage to the valve, causing
potential severe personal injury, death or
substantial property damage.
WARNING
The unit was shipped with a propane conversion kit which is located on the top of
the unit in the instructions packet. This kit
includes all the necessary parts and
instruction to perform the conversion
from natural to propane gas. If this conversion kit is missing, please contact ACVTriangle Tube Technical Support before
installing unit for missing kit.
Table 3: Propane Gas, Orifice Requirements:
CHALLENGER
Propane
MODEL
Orifice Size
CC85
0.199” [5.05 mm]
CC105
0.199” [5.05 mm]
CC125
0.220” [5.60 mm]
WARNING
Prior to start up, ensure the appliance is
set to fire propane. Check the rating label
for the type of fuel. Check the gas valve for
propane conversion label. If there is a conflict or doubt on the burner set up, remove
the gas valve and check for the propane
orifice, see Fig. 15, failure to ensure proper burner setup could result in severe personal injury, death or substantial property damage.
Orifice
Marking
505
505
- 580 -
Throttle Screw
Contact the local propane gas supplier for recommended sizing of piping, tanks and 100%
lockup gas regulator.
Gas Supply Inlet
Pressure Port
Propane Gas Supply Pressure Requirements
1. Adjust the propane supply regulator provided by the gas supplier for 13”w.c. [32
mbar] maximum pressure
Flow direction
2. Pressure required at the gas valve inlet supply pressure port:
-
-
Maximum 13”w.c. [32 mbar] at flow or
no flow conditions to the burner
Minimum 5”w.c. [13 mbar] during flow conditions to the burner. Must be verified during
start up and with all other gas appliances
operating within the gas piping service.
Maximum gas inlet pressure must not be
excceded and minimum gas inlet pressure
is for the purpose of input adjustment.
O-Ring Gasket
Gas Orifice
Fig. 15 : Gas Orifice Assembly
32
Internal Wiring
SECTION VIII - Internal Wiring
General Requirements
WARNING
-
Wiring must be N.E.C Class 1.
-
The CHALLENGER must be electrically
grounded as required by National
Electrical Code ANSI/NFPA 70 - latest edition and / or the Canadian Electrical Code
Part 1, CSA C22.1, Electrical Code.
-
ELECTRICAL SHOCK HAZARD. For
your safety, disconnect electrical power
supply to the appliance before servicing
or making any electrical connections to
avoid possible electric shock hazard.
Failure to do so can cause severe personal injury or death.
CAUTION
Prior to servicing, label all wires before
disconnecting. Wiring errors can cause
improper and dangerous operation.
Verify proper wiring and operation after
servicing.
33
If original wiring as supplied with the
appliance must be replaced, use only Type
T 194F [90ºC] wire or equivalent as a minimum.
Internal Wiring
Note -
Ladder Diagram
The wiring for 120V field connections to the appliance shall have a minimum size of 14 AWG and a temperature rating of at least 194ºF (90º).
If any of the original wire as supplied with the appliance must be replaced with T wire or it’s equivalent.
Schematic Diagram
Fig. 16: CHALLENGER Factory Wiring Diagrams
34
External Wiring
SECTION IX- External Wiring
WARNING
Installation Compliance
The ON/OFF switch of the CHALLENGER only disables the function of the
appliance. Electrical power remains at the
control module. To avoid a shock hazard,
disconnect power at the external service
switch when servicing the appliance.
All field wiring made during installation must
comply with:
-
-
National Electrical Code NFPA 70 and
any other national, state, provincial or
local codes or requirements.
Control Module Circulator AMP Ratings
In Canada, CSA C22.1 Canadian
Electrical Code Part 1, and any other
local codes.
-
WARNING
ELECTRICAL SHOCK HAZARD.
Before making any electrical connections to the CHALLENGER, disconnect
electrical power supply at the service
panel. Failure to comply can cause
severe personal injury or death.
Line Voltage Connections
1. Connect a 120 VAC/15A service to the
120V terminals L, N and G inside the
CHALLENGER as shown in Fig. 16,
page 34.
2. Route the incoming 120 VAC power wire
through the provided openings in the bottom right side jacket panel.
3. The appliance must be provided with an
external service switch, check local code
requirements for compliance.
NOTICE
The installer must provide and install a
fused disconnect or 15 amp (minimum)
service switch. Check local electrical
code requirements for compliance.
35
AMP draw of the CH circulator must not
exceed 2.3 amps.
External Wiring
Low Voltage Connections
Thermostat Wiring
NOTICE
1. Open the display cover and unscrew both
screws to remove the front cover
Isolate 120V wiring from low voltage
wiring to prevent any potential electrical
“noise”.
2. Pull the control/display forward until it tips
downward to provide access.
3. Ensure field installed low voltage wiring is
not run parallel or next to telephone or
power cable.
1. Connect room thermostat or the end switch
(isolated contact only) to the low voltage
terminal strip on the drop down control
panel, as shown in Fig. 16, page 34 and Fig.
17.
4. Consult Table 4 for making low voltage
connections.
Table 4: Low Voltage Electrical
Temperature control
Room thermostat
Outside temperature sensor
SMART I.F.W.H
Aquastat (Optional)
Connector X4
7–8
9 – 10
5–6
2. For proper operation install the room thermostat on an inside wall away from influences of heat and cold, i.e. water pipes,
areas of draft, lighting fixtures and fireplaces.
Notes
Voltage free
Voltage free
3. Set the thermostat anticipator (if applicable) as follows:
-
-
Set for 0.1 amps when wired directly to
the CHALLENGER.
Set to match the total electrical power
requirements of the connected devices
when wired to zone relays or other
devices. Refer to the relay manufacturers’ specifications and the thermostat
instructions for additional information
on the anticipator setting.
NOTICE
When making low voltage connections to
the CHALLENGER, ensure no external
voltage is present in the thermostat circuits. If external voltage is present, provide an isolated contact to prevent damage to the appliance control.
Fuse
Control/Display
Fig. 17: Accessing Low Voltage X4 Connections
36
External Wiring
CH Circulator
3. Maximum DHW circulator continuous current draw is 2.3 A.
1. Connect the CH primary circulator to the
CHALLENGER 120 V terminals 1,2 and 3
located inside the appliance as shown in
Fig. 16, page 34.
System Circulator - Zone Valve Application
To energize the system circulator shown as
item 12 in Fig. 8 page 20 reference Fig. 18.
Installer to provide a Transformer / Relay such
as Honeywell R8285 or equivalent and Zone
Valves with isolated end switch such as
Honeywell V8043 or equivalent.
2. Maximum CH circulator continuous current draw is 2.3 A.
DHW Circulator for Optional Smart IFWH
1. Connect the DHW circulator using the
CHALLENGER 120V, terminals 4, 5 and 6
located inside the appliance as shown in
Fig. 16, page 34.
Outdoor Reset Control
The CHALLENGER may operate with a variable appliance operating temperature using the
ACV-Triangle Tube outdoor sensor, see pages
55 through 57 for installation and set-up.
2. Remove one of the gray plastic strain
reliefs on the bottom of the boiler and
install a field supplied duplex connector
and two washers in its place. Place one
washer on the inside and the other outside
of the boiler before installing the duplex
connector. The duplex connector will allow
the wiring from the domestic circulator to
enter the boiler.
NOTICE
Fig. 18: Secondary System Circulator Wiring
If the installer opts for a fixed operating
temperature for the boiler system, the
outdoor sensor is not required and
should not be installed.
Room Thermostats
24 V
Transformer
by Others
Honeywell V8043
Zone Valves
or Equivalent
H
120V
N
R
C
G
1
3 4
6
Honeywell R8285B1038
Transformer / Relay
or Equivalent
7
8
System Circulator
37
24V Low Voltage Wiring
120V High Voltage Wiring
To Challenger
Low Voltage Terminal Strip
External Wiring
4 Wire Zone Valve
Transformer
(Power)
Zone 1
Zone 2
Additional zones
H 120 N
V.A.C. High Voltage
Room
Thermostat
24
V.A.C.
Zone Valve
Room
Thermostat
Zone
Valve
Additional zones may
be added as shown above
8
7
To Challenger
Low Voltage Terminal Strip
3 Wire Zone Valve
Transformer
(Power)
Zone 1
Zone 2
H 120 N
V.A.C. High Voltage
Room
Thermostat
24
V.A.C.
Zone Valve
NOTICE:
Room
Thermostat
*Use isolation relay on
3-wire zone valve with
non-isolated end switch.
Control can burn out if
isolation relay is not used.
Zone
Valve
Additional zones
Additional zones may
be added as shown above
* Isolation relay
7
Fig. 19: Multiple Zone Field Wiring Using Zone Valves
38
8
To Challenger
Low Voltage Terminal Strip
External Wiring
Fig. 20: Field Wiring with Zone Circulators
120 VAC
H N
Honeywell
R845A
Relay
T
T
T
T
2
1
Circulator
Zone 1
T
T
2
1
Thermostat
zone 1
4
3
5
6
Thermostat
zone 2
4
3
5
6
Circulator
Zone 2
Additional zones may be
added as shown above
7
Fig. 21: Typical Zone Relay Panel Wiring
R
L2 ZC L1 X1 X2
N
H
120 VAC
8
To Challenger
Low Voltage Terminal Strip
Thermostat
Zone 1
C
Thermostat
Zone 2
Thermostat
Zone 3
T1 T1
T2 T2
T3
PR PR C1 C1
C2 C2
C3 C3
8
7
To Challenger
Low Voltage Terminal Strip
Zone 1
Circulator
39
Zone 2
Circulator
T3
Zone 3
Circulator
Start-Up Preparation
SECTION X - Start-Up Preparation
Flush Boiler and Domestic System to
Remove Sediment
Check Boiler System Water Chemistry
The installer must flush the boiler system to
remove any sediment to allow proper operation
of the CHALLENGER .
WARNING
Do not use petroleum-base cleaning or
sealing compounds in the boiler system.
Damage to seals and gaskets in the system components could occur, resulting in
substantial property damage.
Flush the systems until the water runs clean
and is free of sediment.
For zoned systems, each zone should be flushed
through a purge valve. Purge valves and isolation valves should be installed on each zone to
allow proper flushing of the system.
NOTICE
Check and Test Antifreeze
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.
For boiler systems containing antifreeze solutions, follow the antifreeze manufacturer’s
instructions in verifying the inhibitor level and
to ensure the fluid characteristics are within
specification requirements.
Water pH Level 6.5 to 8.5
Maintain the boiler water pH between 6.5 and
8.5. Check using litmus paper or contact a water
treatment company for a chemical analysis.
Due to the degradation of inhibitors over time,
antifreeze fluids must be periodically replaced.
Refer to the manufacturer of the antifreeze for
additional instructions.
If the pH does not meet this requirement, do not
operate the CHALLENGER or leave the appliance filled, until the condition is corrected.
NOTICE
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.
Water Total Hardness Less Than 7
Grains/Gallon
For areas with unusually hard water (total
hardness above 7 grains/gallon or 120ppm or
mg/l) consult a water treatment company.
Chlorinated Water
Do not use the CHALLENGER to heat a
swimming pool or spa directly.
Maintain the chlorine level of the water at levels considered safe for drinking.
40
Start-Up Preparation
Use of Antifreeze in the Boiler System
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.
WARNING
NEVER use automotive or ethylene glycol antifreeze or undiluted antifreeze in
the boiler system as freeze protection.
This can cause severe personal injury,
death or substantial property damage if
ignored.
2. Open all system isolation valves.
3. Fill the boiler system to correct system
pressure. Correct pressure will vary with
each application.
NOTICE
Determine the antifreeze fluid quantity using
the system water content volume and following
the antifreeze manufacturer instructions.
Typical residential system fill pressure is
12 psi [0.8 bar]. System pressure will
increase when system temperature
increases. Operating pressure of the system should never exceed 25 psi [1.7 bar].
The boiler water volume of the CHALLENGER
CC 85 is 0.37 gallons [1.4 l], CC 105 is 0.42 gallons [1.6 l] and CC 125 is 0.50 gallons [1.9 l].
Remember to include this volume in sizing of the
expansion tank.
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.
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.
5. Once the system is completely filled and
purged of all air and sediment, check the
system pressure and check/repair any leaks.
WARNING
NOTICE
Unrepaired system leaks will cause continual makeup water to be added to the
appliance. Continual makeup water
could cause mineral buildup within the
heat exchanger, reducing the heat transfer, causing possible heat buildup and
eventual heat exchanger failure.
Massachusetts Code requires the installation of a backflow preventer if antifreeze
is used.
Ensure the concentration of antifreeze to water
does not exceed a 50/50 ratio.
Check Low Water Cut Off/CH Pressure
Sensor
NOTICE
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.
-
-
41
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 reading 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.
Start-Up Preparation
Check For Gas Leaks
NOTICE
In systems using 3-wire zone valves,
backfeed of voltage to the appliance is a
common problem. Use an isolation relay
to prevent voltage from the external circuit entering the CHALLENGER control panel.
WARNING
Prior to start-up and during initial operation, smell near the floor and around the
appliance for gas odorant or any unusual
odor. Do not proceed with the start-up if
there is any indication of a gas leak. Any
leaks found must be repaired immediately.
-
WARNING
Inspection of Condensate Drain Assembly
Propane installations only - The propane
supplier mixes an odorant with the
propane to make its presence detectable.
In some cases the odorant can fade and
the gas may no longer have an odor.
1. Inspect and ensure the Condensate Drain
Assembly is properly installed as described
on page 28 and shown in Fig. 13 on page
29.
Prior to start-up of the appliance and
periodically after start-up have the
propane supplier check and verify the
odorant level.
2. Remove the Condensate Drain Assembly
and fill with fresh water.
NOTICE
The condensate drain assembly must be
installed on the appliance and filled with
water when the CHALLENGER is in
operation. The condensate drain assembly prevents flue gas emissions from
entering the condensate line. Failure to
ensure trap is filled with water could
result in severe personal injury or death.
Check Thermostat Circuit
-
-
-
-
-
Reconnect the external thermostat
wires to the control terminal strip.
Disconnect the external thermostat wires
from the control terminal strip, located on
the drop down panel.
Connect a voltmeter across the wire ends
of the external thermostat wiring.
Energize each thermostat, zone valve and
relay in the external circuit, individually
and check the voltage reading across the
wire ends.
3. Re-Install the condensate drain assembly.
There should NEVER be voltage measured at the wire ends.
If voltage is measured at the panel under any
condition, check and correct the external
wiring.
42
Start-Up Procedures
SECTION XI - Start-Up Procedures
manual starting on page 52 for more information.
Final Checks Before Start-Up
c
c
c
c
c
c
2. Check for loose electrical connections,
blown fuse (external or internal at the
appliance control) or open service switch.
Read page 46 through 57 regarding the
operation of the CHALLENGER control.
Verify the CHALLENGER and the boiler
system are full of water and all system
components are correctly set for operation,
including the minimum flow rate through
the boiler, see pages 79-81.
3. Is the external limit control (if applicable)
open? Ensure the external limit is reset to
the closed position.
4. Is the gas supply valve(s) open at the appliance and meter?
Verify Start-up Preparation items outlined on
pages 40 thru 42 have been completed.
5. Is incoming gas supply pressure at the
appliance more than 5”w.c. [13 mbar] and
less than 13” w.c. [32 mbar] for natural or
propane with all gas appliances ON or
OFF.
Verify all electrical connections are correct
and securely fastened.
Inspect vent and combustion air piping for
signs of deterioration from corrosion, physical
damage or sagging. Verify combustion air
and vent piping are intact and correctly
installed and supported. Reference the proper
CHALLENGER vent supplement.
6. Are the heating thermostats set above room
temperature?
If none of these conditions correct the problem,
contact ACV-Triangle Tube Tech Service.
Verify burner configuration - gas orifice
size.
Check the CHALLENGER and System
- Check for proper labeling on the gas
valve (propane only) and the rating label
for proper gas configuration.
c
c
- If there is doubt on the burner configuration, remove the gas valve and check for
proper gas orifice size. See pages 31 and
32 for orifice sizes.
Ensure the vent Condensate
Assembly is filled with water.
CHALLENGER Start-Up
Drain
c
Check piping and components for
leaks. If found, shut down the appliance and repair immediately.
Purge any remaining air from the system
piping. Air in the system piping will
interfere with circulation creating heat
distribution problems and system noise.
Check Vent Piping and Combustion Air
Piping.
Check for gas-tight seal at every connection and seam of the venting and
combustion air piping.
1. Turn ON the electrical supply/service to the
appliance. Press the ON-OFF button “ ”
located on the front control panel to the OFF
position.
WARNING
Venting system must be sealed gas-tight
to prevent flue gas spillage and potential
carbon monoxide emissions, which will
result in severe personal injury or death.
2. Read and follow the Operating Instructions
outlined on page 45.
If CHALLENGER Does Not Start Correctly
1. Verify DHW and CH systems are turned
ON (parameter 1) is set to “0”. Read setting the appliance parameters section of the
Check Piping.
43
Start-Up Procedures
c
ACV-Triangle Tube Technical Support.
Failure to comply with this requirement
could result in severe personal injury,
death or substantial property damage.
Check Gas Piping
Check around the appliance for gas
odor following the procedure outlined
in this manual on Page 42.
Table 5: Recommended Combustion Levels
WARNING
c
Natural Gas
If any gas leaks are found or suspected,
shut the appliance down immediately.
Use a gas detection device or bubble test
to locate the source of the gas leak and
repair at once. Do not operate the appliance until the leak is corrected. Failure
to comply with this procedure could
result in severe personal injury, death or
substantial property damage.
High Fire
(h or H)
(
and +)
DOOR OFF*
Verify Flame Pattern and Combustion
Check the flame pattern through the
inspection port on the left side of the
heat exchanger. The flame should be
blue and stable and should be the length
of the burner.
(
WARNING
and -)
CO Max.
The combustion testing and adjustments
must be performed by a qualified
installer, service agency or the gas supplier. All combustion measurements must be
performed with calibrated equipment to
ensure proper reading and accuracy.
9% to 10.1% C02 10.5% to 11.1% C02
5% to 3.2% 02
5% to 4.1% 02
0 to 0.4 lower 0 to 0.4 lower C02
C02 than high fire
than high fire
9.0 % min. C02 10.5 % min. C02
0 to 0.6 higher
02 than high fire
5.0% max. 02
0 to 0.6 higher
02 than high fire
5.0% max. 02
100 ppm
100 ppm
* Door on can raise the maximum allowable C02 by
0.4 or lower the minimum allowable 02 by 0.6.
c
Measure Input - Natural Gas Only
1. Ensure the appliance is firing at maximum
firing rate. To manually place the appliance
into high fire mode, reference page 50.
Test for C02 or 02 and for CO during
high and low firing rate. To manually
place the appliance into high or low fire
mode, reference page 50. The combustion reading should be within the range
listed in Table 5. The CO level should
not exceed 100 ppm when combustion
is correct.
2. Operate the appliance for approximately
10 minutes.
3. Turn off all gas appliances on the gas service, except the CHALLENGER.
4. At the gas meter, record the time required
to use one cubic foot of gas.
WARNING
The combustion levels should be measured at high and low firing rate, refer to
page 50 of the CHALLENGER control
section on how to set the firing rate. If
the combustion levels are not within the
range given in Table 5 for the firing rate,
shut the appliance down and contact
Low Fire
(L)
Propane Gas
5. Calculate Natural gas input using the following equation:
3600 x 1000 / number of second recorded
for one cubic foot of gas = BTU/H.
6. The BTU/H calculated should approximate
the input rating listed on the appliance.
44
Start-Up Procedures
WARNING
FOR YOUR SAFETY READ BEFORE LIGHTING
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
• If you cannot reach your gas supplier, call the
fire department.
equipped with an ignition device which automatically lights the burner. DO NOT try to light the
burner by hand.
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.
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
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.
• 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.
1.
2.
3.
OPERATING INSTRUCTIONS
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.
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.
2.
9.
Turn “OFF” all electrical power to the appliance.
Remove the front jacket panel on the appliance.
1.
8.
Set room thermostat(s) to lowest setting. Turn the
external manual gas valve handle clockwise
“CLOSE” (valve handle shall be perpendicular to gas piping).
4.
5.
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.
Set room thermostat(s) to desired setting(s).
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.
Turn the external manual gas valve handle
counter clockwise
to “OPEN” gas supply (valve handle shall be parallel to gas piping).
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
Set the room thermostat to lowest setting.
Turn“OFF” all electric power to the appliance if
service is to be performed.
3.
45
Turn the external manual gas valve handle clockwise
to “CLOSE”, (valve handle shall be
perpendicular to gas piping).
Start-Up Procedures
Appliance ON/OFF
2. Turn off power to the appliance, wait a few
seconds and turn on power to the appliance.
1. The appliance operation is started using the
ON/OFF button.
3. The following operating displays should
occur:
2. When appliance is in operation, the green
LED above the
ON/OFF will be lit.
[A] Self check on power up
[ ] No call for heat
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 .
4. Initiate a call for heat by raising the set
point of the room thermostat to the highest
setting. The following operating display
should occur
Set Boiler Maximum Central Heating (CH)
Set Point Temperature
[1] This is the prepurge cycle. The burner
blower and the boiler circulator become
energized. The blower has a 5 second prepurge cycle.
1. Press the CH/DHW/Parameter button “ ”
at the display panel for approximately 2 to
3 seconds until the radiator symbol “ ”
(CH) LED, lights up and the main display
begins to flash.
[2] This is the ignition cycle. The control
module will energize and open the gas
valve and begin the spark for ignition.
2. Press the or buttons to set the desired
maximum temperature setting on the main
display.
3. Press the
reset button to close the setting menu and store the changes.
-
If the burner flame proves, the burner
will begin to modulate.
-
To verify flame failure safety lockout,
close the manual shut off valve on the
gas supply piping to the appliance and
repeat ignition sequence. When verification is completed, ensure the manual shut
off valve is returned to the open position.
-
NOTICE
If the
reset button is not pressed within 30 seconds, the settings menu is automatically closed and the changes are
stored.
If the
ON/OFF button is pressed prior
to the
reset button, the settings menu
is closed and the changes are NOT stored.
Operation Verification - Space Heating
If the burner flame is not established
the control module will repeat the ignition sequence after approximately 15
seconds . If the flame is not established
after four attempts the control will
lockout. The main display will
show [4] and the fault LED above the
reset button will flash and [E] will
flash in the operating display.
[3] This is the normal Central Heating
(CH) operation cycle. The control module
will begin to modulate the burner firing
rate based on actual appliance outlet temperature and the set point temperature.
The CH water temperature is displayed on
the main display.
NOTICE
Digits and characters shown in brackets
[0], in the following outline, represent
the control module operating display.
1. Set the room thermostat to the lowest setting.
46
5. Allow the appliance to operate and the boiler outlet temperature to reach the set point
temperature.
Start-Up Procedures
[1] The setpoint temperature has been
reached. Combustion will cease and the post
purge cycle of the blower begins. The control
module will de-energize the gas valve and
the blower will continue with the 10 second
post purge cycle, before shutting down. The
CH circulator will continue to run until the
room thermostat is satisfied.
3. Press the
reset button to close the setting menu and store the changes.
NOTICE
If the
reset button is not pressed within 30 seconds, the settings menu is automatically closed and the changes are
stored.
6. Lower the room thermostat set point below
the room temperature to end the call for
heat.
If the
ON/OFF button is pressed prior
to the
reset button, the settings menu
is closed and the changes are NOT stored.
[1] This begins a post purge cycle. When
the room thermostat is satisfied, the appliance will shutdown.
[7] The CH circulator will continue to run
for a 1 minute post pump cycle.
Operation Verification - Domestic Hot
Water (if applicable)
NOTICE
NOTICE
The CH circulator automatically runs
for 10 seconds once every 24 hours to
prevent seizing. Timing for this automatic switching starts after the last call for
heat.
[
Digits and characters shown in brackets
[0], in the following outline, represent
the control module operating display.
1. Set the room thermostat to the lowest setting.
] The appliance is in Standby MODE
waiting for a call for heat.
2. Turn off power to the appliance, wait a few
seconds and turn on power to the appliance.
7. Verify the operation of the appliance by
repeating the operational sequence several
times.
3. The following operating displays should
occur:
[A] Self check on power up
8. Return the room thermostat to a desired setting.
[ ] No call for heat
4. Turn on a domestic hot water faucet to initiate a domestic call. The display should show
Set DHW Set Point Temperature
[1] This is the prepurge cycle. The burner
blower become energized. The blower has
a 5 second prepurge cycle. The CH (central
heating) circulator will remain off, to provide DHW priority.
1. Press the CH/DHW/parameter button “ ”
at the display panel for approximately 2 to
3 seconds until the faucet “
” (DHW)
LED lights up and the main display begins
to flash.
[2] This is the ignition cycle. The control
module will energize and open the gas
valve and begin the spark for ignition.
2. Press the or buttons to set the desired
domestic water temperature on the main
display. Minimum setting is 104ºF [40ºC],
Maximum setting is 149ºF [65ºC], factory
default is 120ºF [49ºC].
-
47
If the burner flame proves, the burner
will begin to modulate.
Start-Up Procedures
-
-
If the burner flame is not established
the control module will repeat the ignition sequence after approximately 15
seconds . If the flame is not established
after four attempts the control will
lockout and the main display will
show [4]and the fault LED above the
reset button will flash and [E] will
flash in the operating display.
[4] This is the normal DHW operation
cycle. The control module will begin to
modulate the burner firing rate based on
actual DHW set point temperature. The
DHW water temperature is displayed in
the main display.
5. Turn off the domestic hot water faucet to
end the call for heat.
[1] This begins a post purge cycle. The
control module closes the gas valve and the
blower continues to operate for approximately 10 seconds.
To verify flame failure safety lockout,
close the manual shut off valve on the
gas supply piping to the appliance and
repeat ignition sequence. When verification is completed, ensure the manual
shut off valve is returned to the open
position.
6. Verify the DHW operation by repeating the
outlined operation sequence several times.
48
Start-Up Procedures
Control Display
Operation
Read-Out
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. Temperature ºC or pressure bar
7. DHW function eco (learned)
8. DHW function on (minimum block temp)
9. Operating display
10. Flashes to indicate fault
Appliance ON/OFF
1. The appliance operation is started using the
ON/OFF button.
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
Additional DHW Functions
Additonal DHW setting can be activated by
pressing the
DHW button.
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 .
-
Units
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.
-
NOTICE
Units cannot be changed if the main display (Parameter Mode) or operating display (Error Mode) is flashing.
ON (
LED lit above the
DHW
button) - The appliance DHW function
is activated continuously. The appliance
will maintain a minimum heat exchanger temperature to assure instant delivery
of hot water.
ECO ( LED lit above the
DHW
button) - The DHW function is self-learning. The appliance will maintain a minimum heat exchanger temperature during
times with typical domestic demands,
learned over the past 3 days of use.
OFF (no LED lit) - The appliance will not
maintain a minimum heat exchanger temperature. This will affect the delivery and performance of the initial DHW temperature.
BEST PRACTICE
49
In application in which the DHW is not
utilized or the DHW demand is minimal,
set the DHW function to OFF.
Start-Up Procedures
TO TEMPORARILY PLACE THE BURNER INTO LOW FIRE TEST MODE: press
” and “ ” button simuland hold both the “
taneously until operating display shows “L”.
Test Mode Function
TO TEMPORARILY PLACE THE BURNER INTO HIGH FIRE TEST MODE: press
” and “+” button simuland hold both the “
taneously once until operating display shows
“h” for CH high fire or twice until the operating display shows “H” for DHW high fire.
Flame Current
While in high fire or low fire test modes the
flame current (µA) can be checked at the control by pressing and holding the “
” DHW
button.
While in the test mode:
-
-
-
high limit will function
TO DEACTIVATE THE HIGH OR LOW
FIRE TEST MODE: press and hold both the
“+” and “-” button simultaneously.
appliance CH circulator will function
the test mode will time out in approximately 10 minutes
Control Software Version
To view the control sofware version cycle the
incoming power off then on to the CHALLENGER at the wall switch.
50
Start-Up Procedures
Function
Main Display
Operating Display
Press
button to turn appliance ON
LED lite above
button will be lit
when appliance is ON
No demand for heat
OFF
XXP
The
The
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
Burner ON for freeze protection
LOP*
Raise CH pressure above 7 psig [0.5 bar]
ODS**
Outdoor sensor not installed
POLE
Incoming line and neutral are reversed
LED will be lit for CH (central heating call)
LED will be lit for DHW (domestic call)
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).
** If the outdoor sensor is not installed the main display will display ODS when the boiler is in
standby without a CH or DHW call for heat or any errors. The lack of the outdoor sensor will
not prevent the unit from operating on a CH or DHW call for heat, but is recommended to
increase system efficiency
51
Start-Up Procedures
Setting the Appliance Parameters
5. After all parameters have been changed,
press the
reset 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 modifiy a parameter press the
buttons.
NOTICE
If the
reset button is not pressed within
30 seconds, the settings menu is automatically closed and the changes are stored.
or
If the
ON/OFF button is pressed prior
to the
reset button, the settings menu
is closed and the changes are NOT stored.
4. Press the “ ” button to scroll to the next
parameter to be changed.
Main Display
Operating
Display
LED
Factory Settings Parameters
(Flashing)
(Flashing)
186ºF [86ºC]
140ºF [60ºC]
Adjustments
Description
Boiler set point temperature
Adjustment range 86ºF to 194ºF [30ºC to 90ºC]
DHW (domestic) setpoint temperature
Adjustment range 104ºF to 149ºF [40ºC to 65ºC]
0
1
Installation type
0=Combi (Heat and DHW)
1=Heating + SMART I.F.W.H. 3
2=DHW only (no heating system required)
3=Heating only
0
2
CH pump continuous
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.
86ºF [30ºC]
0ºF [-18ºC]
5
6
Adjustment range 60°F to 140°F [16ºC to 60ºC]
Adjustment range -22°F to 50°F [-30ºC to 10ºC]
64 ºF [18ºC]
1
7
8
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
1
9
0
O
DHW post pump 4
Waiting time after a DHW demand before a
CH demand is answered 1
0
P
Anti-cycling period during CH operation 2
Adjustment range 60°F to 78°F [16ºC to 26ºC]
Adjustment range 0 to 15 minutes
Adjustment range 0 to 15 minutes
Adjustment range 0 to 15 minutes
Minimal switch-off time in CH operation
Adjustable from 0 to 15 minutes
Note:
1 The waiting time starts at the end of the DHW call (no DHW flow - DHW flow switch contacts are open) and blocks the burner and CH
circulator. if DHW function is turned ON ( LED is lit above the DHW button) or ECO is ON ( LED is lit above DHW button)
than the burner will continue to fire for DHW until a minimum heat exchanger temperature is achieved. Burner and CH circulator will
continue to be blocked until the remaining waiting time ends. This feature only applies if parameter 1 is set to 0.
2 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.
3 For installations with a ACV-Triangle Tube SMART Indirect Fired Water Heater (I.F.W.H.) piped off the primary loop, similar to figures
7 and 8 on page 20, parameter 1 should be set to 1. The SMART’s aquastat should be wired to CHALLENGER’S X4-5 and X4-6
electrical connectors, see Figure 16,page 34. The domestic I.F.W.H. circulator should be wired using the CHALLENGER’s 120 V
terminals 4 (line) 5 (neutral) and 6 (ground). During a domestic call for heat on terminals X4-5 and X4-6, only the domestic I.F.W.H.
circulator will operate and the boiler’s target supply water temperataure will shift to 186ºF [86ºC].
4 The DHW post pump function only applies when parameter 1 is set to a setting of 1 Heating & Smart I.F.W.H. and only occurs if no CH
call for heat is present
52
Start-Up Procedures
Fluctuating Water Temperature
CAUTION
Domestic water temperatures can fluctuate
with factory control settings when the domestic
hot water flow is less than 0.7 gpm. The fluctuation is due to the interaction between the
domestic water flow switch minimum setting
and the domestic hot water mixing valve. As
the domestic hot water leaving the appliance
approaches the domestic hot water mixing
valve setting, the mixing valve reduces the
amount of hot water through the appliance
below the domestic flow switch minimum setting. The appliance cycles off until the mixing
valve opens calling for more domestic water.
To improve the domestic hot water performance at low flows it is recommended to
reduce the domestic hot water temperature setpoint on the control down from 140°F (60°C)
to 125°F (52°C), see page 52 and or to turn the
domestic function on the control to ON or
ECO, see page 49. Additionally, ensure the
minimum domestic water pressure is 40 psi
(2.8 bar), see page 21. A lower domestic hot
water temperature setpoint will reduce the
domestic hot water temperature at higher
domestic flows.
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.
Error (Hard Lockout) Mode
Table 6: 12 K Ohm NTC Sensor Resistance
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.
53
Start-Up Procedures
Error (Hard Lockout) Codes*
Main Display
Operating
Display
(Flashing)
Possible Solution
Error Description
10, 11, 12,
13, 14
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
4
E
- No flame signal
5
E
- Poor flame signal
6
E
- Flame detection fault
8
E
- Incorrect fan speed
29,30
E
- Gas valve relay fault
18, 19
E
- Flue sensor
fault
7,16, 17
E
- DHW sensor
fault
50F
• Check wiring for break
• Check for proper flow direction
• Replace S1
• E10 Open sensor
• E11 Flow switch sticking of miss installed
• E 11 Shorted sensor
• E12 Decreased too quickly
• E13 Increased too quickly
• E14 Stuck
• 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
• Flow switch sticking or miss-installed
• CHeck for wiring
• Check for proper flow direction
• Replace S1 or S2
• 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
• Condensate drain blocked
• Check adjustment of gas valve
• Replace ignition cable + spark plug cap
• Replace ignition unit at gas valve
• Replace boiler controller
• Fan catching on casing
• Wiring between fan and casing
• Check wiring for poor wire contact
• Replace fan
• Replace boiler controller
• E18 open sensor
• E19 Shorted sensor
• Check/Replace sensor
• E16 Shorted sensor
• E17 Open sensor
• Check/replace sensor
• E7 Excessive temperature
• Check gas orifice
• Check combustion settings
• Verify ground
• Frequency should be between 45 and 65 Hz
- Improper frequency
* Red LED above
button will flash, correct condition, and press
button.
NOTICE If outdoor sensor is shorted the boiler will not enter into a hard lockout but
will maintain the minimum supply temperature of the heat curve.
54
Outdoor Reset Control
SECTION XII - Outdoor Reset Control
4. Mount the sensor enclosure at an elevation
on the exterior wall to prevent accidental
damage or tampering.
An outdoor reset function is included in the
CHALLENGER control. The use of the outdoor reset function is required to optimize boiler efficiency, see notice on page 56. If the outdoor sensor is not installed before turning on
the boiler, an Outdoor Sensor Open ODS will
be displayed. This display will not prevent the
appliance from operating. The ODS display
will automatically reset once the outdoor sensor is installed.
Plastic Anchors (2)
5. Avoid mounting the enclosure in areas subjected to excessive moisture.
6. Once an area on the exterior wall has been
determined, to affix the enclosure use the
enclosure as a template to mark the location
of the mounting screws.
7. Using a 3/16” [5 mm] drill bit, drill 2 pilot
holes on the marked locations.
8. Tap the enclosed plastic anchors into the
pilot holes. Use care not to damage the
anchors.
Sensor Enclosure
9. Mount the sensor enclosure using the
screws provided.
Wiring the Sensor
1. Route two 18 gauge wires through the seal
gasket. Connect the wires to the sensor terminals 1 and 2.
Seal Gasket
2. Route the sensor wire back to the CHALLENGER, ensuring the wires are not run
parallel to telephone or power cables.
Mounting
Screws
(2)
NOTICE
Fig. 22: Sensor Enclosure and Components
Front Cover
If the sensor wires are located in an area
with sources of potential electromagnetic
interference (close to 120 V wiring) the
sensor wires should be shielded or the
wires should be routed in a grounded
metal conduit. If using shielded cable,
the shielding should be connected to the
common ground of the appliance.
Mounting the Outdoor Sensor
1. Remove the front cover and mounting
screws / anchors from the sensor enclosure.
2. When mounting the enclosure, the exterior
wall selected should represent the coldest
outdoor temperature. Typically a northern
or northeastern wall will suit most buildings. A southern facing wall may suit buildings that have large glass walls or windows
on the southern face.
3. Connect the sensor wires to the outdoor sensor terminals 9 and 10 on the low voltage X4
connector terminal strip located at the control on the swing out panel (see appliance
wiring diagram, Fig. 16 page 34).
3. Ensure the sensor enclosure is shielded
from direct sunlight or the effects of heat or
cold from other sources (exhaust fans,
appliance vents...) to prevent false temperature sensing.
55
Outdoor Reset Control
Operating Temperature Setpoint becomes the
appliance setpoint on the CH Reset Curve
Coldest Day.
NOTICE
In accordance with Section 325 (f) (3) of the
Energy Policy and Conservation Act, this
boiler is equipped with a feature that saves
energy by reducing the boiler water temperature as the heating load decreases. This
feature is equipped with an override which
is provided primarily to permit the use of
an external energy management system
that serves the same function.
CH
Minimum
Boiler
Temperature Setpoint
(Parameter 5)
Factory Setting
64ºF
[18ºC]
THIS OVERRIDE MUST NOT BE USED
UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE.
•
•
•
•
CH Reset Curve Coldest Day
(Parameter 6)
This boiler is not used for any space
heating
This boiler is part of a modular or multiple boiler system having a total input
of 300,000 BTU/hr or greater.
Factory Setting
86ºF
[30ºC]
This boiler is equipped with a tankless
coil.
The appliance CH set point along with
Parameters 5, 6 & 7 define the settings of the
outdoor reset curve. See Graph 1 and Table 7,
page 57 for an example of modifying the outdoor reset curve.
86ºF
[30ºC]
Factory Setting
00ºF
[- 18ºC]
Maximum
Setting
194ºF
[90ºC]
If an outdoor temperature sensor is not connected to the appliance, the appliance setpoint
for a heating call will be set to the CH
Maximum Boiler Operating Temperature
Setpoint. If an outdoor temperature sensor is
connected, the CH Maximum Boiler
Minimum
Setting
59ºF
[16ºC]
CH Reset Curve Warmest Day
(Parameter 7)
CH Maximum Boiler Operating
Temperature
186ºF
[86ºC]
77ºF
[26ºC]
Maximum
Setting
140ºF
[60ºC]
This parameter is not applicable if an outdoor
sensor is not connected to the appliance. When
an outdoor temperature sensor is connected, the
CH Reset Curve Coldest Day is the coldest
design temperature of the heating system.
Adjusting Outdoor Reset Curve
Minimum
Setting
59ºF
[16ºC]
Maximum
Setting
This parameter is not applicable if an outdoor
sensor is not connected to the appliance. When
an outdoor temperature sensor is connected, the
CH Minimum Boiler Operating Temperature
Setpoint becomes the appliance setpoint on the
CH Reset Curve Warmest Day.
An external energy management system is installed that reduces the boiler
water temperature as the heating load
decreases.
Factory Setting
Minimum
Setting
Operating
Minimum
Setting
-22ºF
[-30ºC]
Maximum
Setting
50ºF
[10ºC]
This parameter is not applicable if an outdoor
sensor is not connected to the appliance. When
an outdoor temperature sensor is connected, the
CH Reset Curve Warmest Day is the warmest
design temperature of the heating system.
56
Outdoor Reset Control
Changing Outdoor Reset Parameters
4. Press the
button to close the setting
menu and store the changes.
1. Press the “ ” button at the display panel
for approximately 2 to 3 seconds until main
display begins to flash.
The appliance control module has now been
reprogrammed with the desired parameter values.
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 modifiy a parameter press the
buttons.
Pressing the
ON/OFF button will exit
the parameter setting mode without storing the parameter changes.
or
Boiler CH Set Point
140
100
77
Parameter 5
Set Point
Parameter 6 Setting
80
Parameter 7 Setting
Boiler Temperature ( F)
NOTICE
60
20
90
70
64
50
10
30
0
-10
Graph 1: Outdoor Air Temperature Reset Curve (Example)
Outdoor Air Temperature ( F)
Table 7: Outdoor Air Temperature Reset (Example)
Outdoor
Temperature
Appliance target Temp.
Based on Outdoor Temp.
30ºF
117ºF
10ºF or Lower
140ºF
50ºF
93ºF
64ºF or Higher
77ºF
Graph 1 illustrates Appliance CH Setpoint adjusted to 140ºF target temperature at 10ºF outdoor
air temperature
Note: Factory setting of CH set point is 186ºF
57
Check-Out Procedures
SECTION XIII- Check-Out Procedures
c
NOTICE
Perform the following check-out procedures as outlined and check off items as
completed. When procedures are completed, the installer should complete the
installation record on page 59.
c
c
Check-Out Procedures
c
c
c
c
c
c
c
c
c
c
c
c
Boiler system water chemistry checked and
verified as outlined on page 40.
c
Any automatic air vents caps placed within
the system are open one full turn.
c
Air is purged from the heating zones and
appliance system piping.
Confirm the appliance has proper gas orifice as noted on pages 31 and 32.
Thermostat circuit wiring checked and verified that no voltage is present to the low
voltage terminals as outlined on page 42.
Operating Instructions on page 45 were followed during start-up.
Combustion levels and flame pattern verified as outlined on page 44.
Measured the rate of input on Natural Gas
as outlined on page 44.
Checked the incoming gas pressure to the
CHALLENGER to ensure a minimum
pressure of 5”w.c [13 mbar] during flow
conditions to all gas appliances and a maximum pressure of 13”w.c [32 mbar] during
non-flow conditions for Natural and
Propane gas.
Adjusted balancing valves and system limit
controls to provide design temperatures to
the primary space heating system.
In multiple zone applications, adjusted for
correct flow of appliance water to each
zone.
58
Checked and verified room thermostat(s)
function properly and the thermostat(s)
heat anticipator (if used) was properly set.
Observed several operating cycles for
proper operation of the CHALLENGER
and the system.
Set the room thermostat(s) to the desired
room temperature.
Reviewed all instructions shipped with the
CHALLENGER with the homeowner or
maintenance personnel.
Completed the Installation Record on page
59.
Ensure all manuals and other documents
are returned to the Installation envelope
and given to the owner for safekeeping.
Installation Record
SECTION XIV - Installation Record
CHALLENGER Model Number:
Serial Number:
Date of Installation:
Fuel:
Natural Gas
Propane
Measured Rate of Input:
Btu/hr
Combustion Readings:
CO2
%
O2
%
CO
ppm
The following items were completed during installation:
Installation instructions have been followed and completed
Check-out procedures have been followed and completed
Information regarding the unit and installation received and left with owner /
maintenance personnel.
Installer Information
(Company) ____________________________________________________________________
(Address)
____________________________________________________________________
(Address)
____________________________________________________________________
(Phone Number) _________________________________________________________________
59
Maintenance Schedule
SECTION XV - Maintenance Schedule
Owner Maintenance
At least on an annual basis the following maintenance should be performed by a qualified service technician:
-
Check the area around the appliance.
-
Check the temperature and pressure
gauges.
Service Technician
Periodic:
-
General
-
-
-
-
-
-
-
-
-
-
Attend to any reported problems.
Inspect the interior of the appliance jacket
area; clean and vacuum if necessary.
Monthly:
Clean the condensate drain assembly and
fill with fresh water.
-
Check vent piping.
Verify flue vent piping and air inlet piping
are in good condition, sealed tight and
properly supported.
-
-
Check the pressure relief valve.
Check the condensate drain assembly.
-
Check control settings.
-
Check appliance piping and gas supply piping
for corrosion or potential signs of leakage.
-
Check for leaks: water, gas, flue and condensate.
-
Check combustion air inlet piping.
Every 6 months:
Check appliance water pressure, piping and
expansion tank.
Check ignition electrode (sand off any
white oxide; clean and reposition).
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.
Check ignition wiring and ground wiring.
Check all control wiring and connections.
Check burner flame pattern (stable and uniform).
Additional items if combustion or performance
is poor:
-
Check and remove any blockage from the
combustion air inlet and ventilation openings.
Clean heat exchanger and flue ways.
Remove burner assembly and clean inside
of burner head using compressed air only.
Once the maintenance items are completed,
review the service with the owner.
60
Maintenance Procedures
SECTION XVI - Maintenance
Procedures
Verify that combustion air inlet area is free of
any contaminates. Refer to the materials listed
on page 7 of this manual. If any of these products are in the area from which the appliance
takes its combustion air, they must be removed
immediately or the combustion air intake must
be relocated to another area.
Annual Maintenance Procedures
WARNING
The CHALLENGER should 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 60 and further
explained on pages 61 through 68 should
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.
Inspect Burner Area
Remove the appliance front jacket panel.
Vacuum any dirt or debris from the blower
component.
Re-install front jacket panel when completed.
WARNING
Do not use solvents to clean any of the
components. The components could be
damaged, resulting in unreliable or
unsafe operation.
NOTICE
Check System Piping
The following information provides
detailed instruction for completing the
maintenance items outlined in the maintenance schedule on page 60. In addition
to this maintenance, the CHALLENGER should be serviced at the
beginning of the heating season by a
qualified service technician.
Inspect all piping (water and gas) for leaks and
verify that the piping is leak free and properly
supported.
Inspect the fittings and components on the
appliance and verify they are leak free.
WARNING
Reported Problems
Eliminate all boiler leaks. Continual fresh
make-up water will reduce the heat
exchanger life causing appliance failure.
Leaking water may also cause severe
property damage to the surrounding area.
Inspect the gas supply piping using the
procedure outlined on Page 42.
Any problems reported by the owner should be
checked, verified and corrected before proceeding with any maintenance procedures.
Check Surrounding Area
Verify that the area surrounding the CHALLENGER is free of combustible / flammable
materials or flammable vapors or liquids.
Remove immediately if found.
61
Maintenance Procedures
Clean Condensate Drain Assembly
Check Boiler System
2. Empty any water from the trap and drain
assembly. Flush with fresh water as necessary to clean.
Check the cold fill pressure for the system, typical cold water fill pressure is 12 psig [0.8 bar].
1. Remove the condensate assembly from the
appliance.
Verify all system components are correctly
installed and operating properly.
3. Check the drain piping from the condensate
drain assembly to the drain. Flush to clean
as necessary.
Verify the system pressure, as the appliance
operates at high temperature, to ensure the pressure does not exceed 25 psig [1.7 bar].
Excessive pressure reading may indicate expansion tank sizing is incorrect or system performance problems.
4. Fill the condensate drain assembly with water.
5. Reassemble the condensate drain assembly
onto the appliance.
Inspect air vent and air separators in the system. Remove the caps on automatic air vents
and briefly depress the valve stem if present to
flush vent. Replace the cap when completed.
Ensure vents do not leak. Replace any leaking
vents.
WARNING
When re-assembling the condensate drain
assembly ensure all gaskets are in place and
correctly installed. Ensure all associated
internal joints are complete, tight and secure.
Failure to comply can result in flue gas leakage resulting in severe personal injury, death
or substantial property damage.
Check Ventilation Air Openings
Removing Internal Flue and Condensate
Pan For Inspection
1. Loosen the flue pipe retaining ring as
shown in Fig. 23, page 63.
Verify that all ventilation openings to the
mechanical room or building are open and
unobstructed. Check the operation and wiring
of any automatic ventilation dampers.
2. Pull up on the flue pipe to disengage from
the condensate pan as show in Fig. 24.
3. Pull the flue pipe down and out to disengage
from the vent adapter as shown in Fig. 24,
page 63.
Check and verify the vent discharge and the
combustion air intake are free of debris and
obstructions.
4. Lift up the condensate pan to disengage
from trap.
Inspect Vent and Combustion Air Piping
5. Once the condensate pan is clear of the bottom jacket, rotate it towards the front of the
appliance and push down on the rear to disengage from the heat exchanger as shown
in Fig. 25, page 63.
Visually inspect the venting system and combustion air piping for blockage, deterioration
or leakage. Repair any deficiencies.
Verify that the combustion air inlet piping is
connected, sealed and properly supported.
-
WARNING
Failure to inspect the vent system and
combustion air inlet piping and to have
any conditions repaired, can result in
severe personal injury or death.
62
Inspect the flue pipe and condensate
pan for cracks, damage or distortion.
Check all gaskets for tears, discoloration or other damage, replace as necessary.
Once inspection is completed re-assemble the condensate pan and flue pipe in
reverse order.
Maintenance Procedures
1
3
Fig. 23: Loosening of Flue Pipe
Retaining Ring
2
Fig. 24: Removal of Flue Pipe
3
2
1
Fig. 25: Removal of Condensate Pan
63
Maintenance Procedures
WARNING
WARNING
Before manually operating the relief
valve(s), ensure the discharge piping is
directed to a suitable place of disposal to
avoid a potential scald hazard. The discharge piping must be full size without
restriction and installed to permit complete drainage of both the valve and line.
When re-assembling the condensate pan
and flue pipe ensure all gaskets are in place
and correctly installed. Ensure all associated joints are complete, tight and secure.
Failure to comply can result in flue gas
leakage resulting in severe personal injury,
death or substantial property damage.
If after closing the valve, the valve fails to seat
properly or continually weeps, replace the
relief valve. Ensure the cause of the relief
valve to weep is the valve itself, not due to system over-pressurization caused by an expansion tank that is waterlogged or undersized.
Check Expansion Tank
Refer to Section IV - Boiler Piping for recommended location of the expansion tank
and air eliminators.
Inspection of Ignition Electrode
Closed -Type Tank:
-
-
-
Ensure tank is partially filled with
water leaving an air gap as a cushion.
Refer to the manufacturer’s instruction
for proper fill level.
Remove the ignition electrode using a 3 mm or
T-15 hex key inserted through the two top panel
holes located above the igniter. If necessary separate the top panel from the right side by inserting a straight screw driver in two slots on right
side of top panel and bending metal tab in slots
away from the side. Lift top panel .
Ensure the tank is fitted with a device that
reduces gravity circulation of air-saturated
tank water back into the system. This device
prevents air from bubbling up through the
water as it returns from the system.
Remove any white oxides accumulated on the
electrode using fine grit sandpaper or steel wool.
If the electrode does not clean to a satisfactory
condition. Replace the ignitor.
Ensure no automatic air vents are used
in the system. This will allow air to
escape from the system instead of
returning to the tank.
When replacing the ignition electrode, ensure
the gasket is in good condition and correctly
positioned replace gasket if necessary.
Diaphragm Tank:
-
-
Ensure the system contains a minimum of
one automatic air vent. Recommended
location of the air vent should be atop an
air eliminator.
Check igniter to Fig. 26, page 65.
Check Ignition Wiring and Ground Wiring
Remove the tank from the system and
check the charge pressure. For residential
applications the charge pressure is typically 12 psig [0.8 bar]. If tank does not hold
a charge pressure, then the membrane is
damaged and the tank should be replaced.
Inspect the ignition wiring from the burner control module to the ground at heat exchanger.
Ensure wiring is in good condition and securely connected.
Check ground continuity of the wiring to the
appliance heat exchanger or piping using a
continuity meter.
Check Relief Valve(s)
Inspect the relief valve(s) and lift the lever to
verify flow at least annually or as recommended on the warning tag of the valve.
64
Replace and correct ground wire if ground continuity is not completed and satisfactory.
Maintenance Procedures
º)
(45
0.43” [11 mm]
1.06” -1.12”
[27 mm - 29 mm]
0.12” [3 mm]
1.18” [30 mm]
1.75” [44 mm]
0.12” [ 3 mm]
Spark gap app. 0.18” [5 mm]
Fig. 26: Igniter Dimensions
65
Maintenance Procedures
Check Control Wiring
Disconnect the wiring harness connectors from
the blower.
Inspect all control wiring. Ensure wiring is in
good condition and properly connected.
Remove the mounting bolts and washers securing the front of the heat exchanger and set bolts
and washers aside.
Check Control Settings
1. Check the control CH/DHW/parameter settings by pressing the thermometer button “ ”
Carefully remove the front plate of the heat
exchanger. Ensure combustion chamber insulation is not damaged during removal. See
WARNING on page 68.
on control display. When the LED is lit for “
” this is the CH setting. When the LED is lit for
“ ” this is the DHW setting. Adjust settings
with “ ” or “ ” buttons as necessary.
Remove the burner head mounting screws and
remove the burner head. Inspect the burner head
for deterioration. Use compressed air or a vacuum to clean the burner head. Replace burner
head if necessary. Replace burner head gasket.
2. Press the
reset button to close the setting menu and store the changes.
3. Check any external limit control settings (if
used). Adjust settings as necessary.
Re-assemble the burner head and burner head
gasket. Ensure mounting screws are tight.
Perform Start-up and Checkout Procedures
Remove the blower.
Start the appliance and perform the start-up
procedure as listed in this manual.
Use a vacuum cleaner or compressed air to
clean the interior of the blower and venturi
assembly. Inspect the blower blades to ensure
they are clean and not damaged.
Verify the cold water fill pressure is correct and
the operating pressure of the boiler is within
normal operating range.
Re-assemble the blower and venturi onto front
plate of the heat exchanger . Ensure all gaskets are in good condition, and positioned correctly. Replace gaskets if necessary.
Complete the checkout procedures as referenced in this manual.
Check Burner Flame
Re-assemble the front plate of the heat
exchanger with bolts and washers onto the heat
exchanger. Ensure the gasket and combustion
chamber insulation is in place and not damaged, replace gasket and insulation if necessary. See WARNING on page 68. Ensure all
screws and bolts are tight.
Inspect the burner flame through the observation port on left side off the heat exchanger.
Verify flame pattern is blue and covers the entire
burner surface during high fire. Ensure combustion at both high and lowfire meet the requirements listed in Table 5, page 44. If combustion is
OK and flame pattern is not fully blue & covers
the entire burner surface during highfire, shut the
appliance down and allow it to cool thoroughly
before disassembly.
Close the external manual gas valve on the gas
supply line and disconnect the gas piping and
electrical connector to the gas valve inside the
appliance.
Reconnect the wiring harness connectors to the
blower.
66
Re-assemble the gas supply connections and
electrical connector to gas valve inside the
appliance. Open the external manual gas valve.
Check gas piping for any leaks as outlined on
page 42 and repair if necessary. Place the appliance back into service.
Maintenance Procedures
Check Combustion Levels
12. Attach a hose to the boiler drain valve and
flush the boiler thoroughly with fresh
water by using the purge valves to allow
water to enter through the make-up water
line to the boiler.
Refer to page 44 of this manual for measuring
combustion levels and burner adjustments.
Clean Boiler Heat Exchanger
13. Once the boiler has been completely
flushed, return the boiler and system piping back to operation.
1. Shut down the appliance:
- Follow the instructions on Page 45 "To
Turn Off Gas to Appliance"
14. Perform the required startup and checkout
procedures as outlined on pages 40 to 58.
- Do not drain the appliance unless it will
be subject to freezing conditions.
-
Clean Domestic Heat Exchanger
Do not drain the appliance if freeze
protection fluid is used in the system.
NOTICE
Before cleaning the domestic heat
exchanger it is recommended to remove
the domestic flow restrictor at the inlet
of the domestic flow switch and to reinstall the switch to hasten cleaning.
Reinstall the domestic flow restrictor
when cleaning is complete.
2. Allow the appliance to cool down to room
temperature before servicing.
3. Disconnect the gas piping and electrical
connector to the gas valve.
4. Disconnect the wiring harness connectors
from the blower.
1. Shut down the appliance:
5. Remove the mounting bolts and washers
securing the front of the heat exchanger
and set aside.
-
6. Carefully remove the front plate of the heat
exchanger. Ensure combustion chamber
insulation is not damaged during removal.
See WARNING on page 68.
2. Shut off all electrical power feed to the
appliance.
3. Allow the appliance to cool down to room
temperature before servicing.
7. Use a vacuum cleaner, compressed air or
water to remove any accumulation from
the heat exchanger flue ways. Do not use
any solvent.
4. Close the field installed isolation (shut off)
valves on both the domestic cold and hot
water lines to the appliance as shown in
figure 11 & 12 on pages 26 & 27.
8. Re-assemble the front plate of the heat
exchanger onto the heat exchanger. Ensure
the gasket and combustion chamber insulation is in place and not damaged, replace
gasket and insulation if necessary. See
WARNING on page 68.
5. Submerge one end of hose halfway into
cleaning fluid in a clean bucket with 4 gallons
of new undiluted, food grade, white vinegar.
6. Attach other end of hose to a potable
(bronze or stainless steel) circulating pump
with a 2.5 gallon per minute [9.5 liters per
minute] flow rate with 32 feet [9.7 meters]
of head equivalent to Grundfos UP 2699BF or Taco 009-SF5, use another hose to
connect from the pump to the field
installed domestic hot water outlet
drain/flush valve.
9. Re-assemble the blower the wiring harness.
10. Reconnect the gas piping and electrical
connector to gas valve. Check for leaks,
repair if necessary.
11. Close isolation valves at the appliance boiler piping to isolate the appliance from the
heating system.
Follow the instruction on Page 45 “To
Turn Off Gas to Appliance”
67
Maintenance Procedures
7. Attach separate hose to the field installed
domestic cold water inlet drain/flush valve.
14. Relocate the remaining hose still connected
to the domestic cold water inlet drain/flush
valve to the domestic hot water outlet
drain/flush valve and the other end of this
hose from the bucket to a suitable drain.
8. Submerge the other end of this hose
halfway in fluid in the same bucket.
9. Open both drain/flush valves on the domestic cold and hot water lines.
15. Rinse the domestic heat exchanger for 5 minutes by opening both the domestic hot water
outlet drain/flush valve and the isolation (shut)
off valve on the domestic cold water inlet.
WARNING
To avoid risk of electrocution ensure all
power is off to the appliance before servicing. Use G.F.C.I. protected power
supply to pump. Additionally before
powering up the circulating pump
ensure all hose connections and fittings
are leak free and no water is on the floor.
16. Close drain/flush valve on the domestic hot
water outlet.
17. Remove hose from the drain/flush valve on
the domestic hot water outlet.
18. Open the field installed isolation (shut off)
valve on the domestic hot water outlet.
10. Carefully power up the pump allowing the
vinegar to circulate through the domestic
heat exchanger for 1 hour.
19. Turn on all electric to the appliance.
20. Perform the required startup and checkout
procedures as outlined on pages 40 to 58.
11. Turn pump off and carefully remove all
power to the pump.
Review With Owner
12. Close both drain/flush valves on the
domestic cold and hot water lines.
Ensure the owner understands the importance to perform the maintenance schedule
specified in this manual.
13. Remove hose from bucket and pump connected to the drain/flush valve on the
domestic hot water outlet.
Remind the owner of the importance to call a
licensed contractor should the appliance or
system exhibit any unusual behavior.
Handling Previously Fired Combustion Chamber Insulation
2. Wear long sleeved, loose fitting clothing,
gloves and eyes protection.
WARNING
The combustion chamber insulation contains ceramic fibers, which are classified as
a possible human carcinogen. When
exposed to extremely high temperatures,
the ceramic fibers, which contain crystalline
silica, can be converted into cristobalite.
3. Assure adequate ventilation.
4. Wash with soap and water after contact.
5. Wash potentially contaminated clothes
separately from other laundry and rinse
washing machine thoroughly.
Avoid Breathing and Contact with Skin and Eyes
6. Discard used insulation in an air tight plastic
bag.
When removing or repairing the combustion chamber insulation follow these precaution measures:
1. Use a NIOSH approved respirator which meets
OSHA requirements for cristobalite dust, similar
to N95. Contact NIOSH at 1-800-356-4676 or
on the web at www.cdc.gov/niosh for latest recommendations.
NIOSH Stated First Aid:
Eye/Skin: Immediately irrigate
Breathing: Clean fresh air
68
Replacement Parts
S
T
U
DHW sensor S3
Pressure relief and air vent assembly
Condensate drain trap assembly
Control/Display
CH supply sensor S1
CH Return sensor S2
Blower
Low voltage/terminal strip X4
DHW flow switch & Restrictor
Condensate pan
Ignition electrode
High voltage terminal strip
U
Fig. 27: CHALLENGER Internal Components
WARNING
Replacement parts must be purchased
through a local ACV-Triangle Tube distributor. When ordering part please provide the model number and description
and/or part number of replacement part.
69
Flue Sensor
Use only genuine ACV-Triangle Tube
replacement parts to ensure warranty
coverage and to avoid damage to appliance and improper operation of appliance. Contact ACV-Triangle Tube at
856-228-8881 or www.triangletube.com
for list of distributors nearest you.
Replacement Parts
3
Fig. 28 : CHALLENGER Front Door
Item
Part Number Part Number Part Number
CC85
CC105
CC125
2
CCRKIT05
Pipe Connectors & Brackets Assembly
(Not Shown)
CCFTG02
Connector Pipe DHW (Not Shown) - 1/Kit
1
CCRKIT04
2A
2B
3
CCFTG01
CCRKIT06
CCRKIT07
Description
Wall Bracket Assembly (Not Shown)
Connector Pipe CH (Not Shown) - 1/Kit
CCRKIT08
70
Front Door Assembly
Replacement Parts
1
2
2
6
5
3
3
2 3
4
3
Fig. 29: CHALLENGER Vent Components
Item
Part Number
CC85
1
2
3
4
5
6
CCRKIT10
Part Number
CC105
CCRKIT09
CCRKIT35
CCRKIT11
CCRKIT13
Part Number
CC125
CCRKIT12
CCRKIT14
Description
80/125 Concentric Vent /Air Adapter
Assembly (optional - shown)
3” Vent/Air Adaptor Assembly ( standard -not shown)
Vent Assembly
Condensate Collector Assembly
Condensate Drain Trap Assembly
CCRKIT41
Condensate Collector/Trap Gasket
CCRKIT36
Flue Sensor
71
Replacement Parts
Fig. 30 : CHALLENGER Internal Components
2
1
13
3
4
8
4
7
6
14
9
11
Item
1
2
3
4
5
6
7
8
9
10
5
Part Number
CC85
Part Number
CC105
14
Part Number
CC125
CCRKIT15
CCCLB01
CCRKIT16
CCRKIT17
CCSENS02
CCRKIT18
CCRKIT19
CCRKIT21
CCRKIT23
CCRKIT26
CCRKIT20
11
12
13
10
CCRKIT22
CCRKIT27
CCRKIT49
N/A
CCRKIT42
CCRKIT40
N/A
CCRKIT50
Description
Igniter Assembly
Ignition Cable
Sight Glass Assembly
CH Sensor Assembly - 1/Kit
DHW Sensor
DHW Flow Switch Assembly
LWCO/CH Pressure Sensor Assembly
CH Supply pipe Assembly
CH Return Pipe Assembly
DHW Supply Pipe Assembly
DHW Return Pipe Assembly
N/A
N/A
CCRKIT51
72
LWCO Wiring Harness (not shown)
Ignitor Bushings -2/kit
DHW Flow Restrictor 2 gpm White
DHW Flow Restrictor 2.5 gpm Blue
DHW Flow Restrictor 3 gpm Red
Replacement Parts
6
4
1
2
5
3
Fig. 31 : CHALLENGER Blower & Gas Valve Components
Item
1
2
3
4
5
6
Part Number Part Number
CC85
CC105
CCRKIT28
CCRKIT29
CCRKIT30
N/A
N/A
CCRKIT31
CCRKIT32
CCRKIT45
CCRKIT47
Part Number
CC125
CCRKIT48
N/A
Description
Ignition Transformer Assembly
Gas Valve Assembly
Gas Pipe Assembly
N/A
CCRKIT46
N/A
Blower Assembly
Venturi 406
Venturi 362
Blower Outlet Orifice 1” (25 mm)
Blower Outlet Orifice 1-7/16” (37 mm)
Not Applicable
73
Replacement Parts
1
Fig. 32 : CHALLENGER Burner Components
Item
1
Part Number Part Number Part Number
CC85
CC105
CC125
CCRKIT33
74
Description
Burner Assembly
Replacement Parts
6
4
1
5
2
3
Fig. 33 : CHALLENGER Control Components
Item
Part Number Part Number Part Number
CC85
CC105
CC125
2
CCCS01
1
3
4
5
6
CCCON01
Control/Display
CCRKIT34
Flip Panel
Description
Housing Plastic Control
CCFUSE01
Fuse - 1/Kit
CCRKIT43
Connector - X4, 24V, 9 Pin (Not shown)
CCRKIT44
Connector - X2, 120V, 8 Pin (Not shown)
75
Specifications
9.45”
[24 cm]
6.10”
[15.5 cm]
17.72”
[45 cm]
4.63”
[11.8 cm] (3” Air)
Z
F A
CH Supply
CH Return
C
[8 cm] 3.15”
[6.5 cm] 2.56”
[6.5 cm] 2.56”
E
[6.5 cm] 2.56”
[5 cm] 1.97”
[6.5 cm] 2.56”
H
13.58”
[34.5 cm]
(80/125 Concentric Vent/Air or 3” Vent)
D
B
1” NPT
1” NPT
1/2” NPT
DHW Cold
3/4” NPT
DHW Hot
3/4” NPT
Condensate Drain Flexible
33.07” [84 cm]
Challenger CC 125
Challenger CC 105
30.71” [78 cm]
28.35” [72 cm]
Challenger CC 85
Vent/Air
80/125 Concentric Adapter
( optional - shown) or 3”
(standard -not shown)
Front View& Side CHALLENGER
76
Specifications - Water Heater
NOTICE
The following efficiency performance is achieved when the CHALLENGER is operated as
a Water Heater according to DOE 10CFR, Part 430, subpart B, Appendix E, test procedure.
Continuous
Domestic
Flow
77ºF Rise
Water
Heater
Energy
Factor
Shipping
Weight
Lbs [Kg]
Model
Fuel
Modulation
Input
BTUH [KW]
CC 85
Natural
or
Propane
23,000 [6.7]
to
84,000 [24.6]
1.8 gpm
[6.8 lpm]
110,000
.87
66 [30]
Natural
or
Propane
29,000 [8.5]
to
106,000 [31]
2.3 gpm
[8.7 lpm]
.86
73 [33]
Natural
or
Propane
33,000 [9.7]
to
124,000 [36.3]
2.7 gpm
[10.41 lpm]
.85
80 [36]
CC 105
CC 125
77
78
Domestic Flow Rate (GPM) @ 120F Domestic
Outlet Temperature
40
50
55
CC85
CC105
CC125
Domestic Inlet Temperature (F)
45
60
Graph 2 : Domestic Flow Rate at 120ºF Domestic Outlet and Varying Domestic Inlet Temperature
1.5
2.0
2.5
3.0
3.5
Challenger Domestic Performance
Specifications - Water Heater
Specifications - Boiler
CC85 Primary Loop Pumps - Grundfos
Graph 5 : Pressure Loss Through Boiler - Grundfos Circulators
CC85 Primary Loop Pumps - Taco
Graph 6 : Pressure Loss Through Boiler - Taco Circulators
NOTICE
Minimum allowable boiler flow rate at full input: 4 gpm [15 lpm] CHALLENGER CC85
Pump curves and system curves do NOT include any allowance for near boiler piping.
79
Specifications - Boiler
CC105 Primary Loop Circulators - Grundfos
Graph 7 : Pressure Loss Through Boiler - Grundfos Circulators
CC105 Primary Loop Circulators - Taco
Graph 8 : Pressure Loss Through Boiler - Taco Circulators
NOTICE
Minimum allowable boiler flow rate at full input: 5 gpm [19 lpm] CHALLENGER CC105
Pump curves and system curves do NOT include any allowance for near boiler piping.
80
Specifications - Boiler
CC125 Primary Loop Circulators - Grundfos
Graph 9 : Pressure Loss Through Boiler - Grundfos Circulators
CC125 Primary Loop Circulators - Taco
Graph 10 : Pressure Loss Through Boiler - Taco Circulators
NOTICE
Minimum allowable boiler flow rate at full input: 6 gpm [23 lpm] CHALLENGER CC125
Pump curves and system curves do NOT include any allowance for near boiler piping.
81
Specifications - Boiler
NOTICE
The following efficiency performance is achieved when the CHALLENGER is operated as
a Boiler according to ASHRAE 103 test procedure
Note 1:
Note 2:
Modulation
Input
BtTU/H (kW)
Note 4
DOE Heating Net Boiler
Capacity
IBR Rating
Btu/h (kW) BTUH (kW)
Note1 & 4
Note 2
DOE
Seasonal
Efficiency AFUE
Note 3
Shipping
Weight
Lbs (Kg)
Model
Fuel
CC 85
Natural
or
Propane
23 000 (6,7)
to
84 000 (24,6)
75 000
(22,3)
110,000
65 000
(19,3)
94%
66 (30)
CC 105
Natural
or
Propane
29 000 (8.5)
to
106 000 (31)
94 000
(27,8)
82 000
(24,3)
94%
73 (33)
CC 125
Natural
or
Propane
33 000 (9,7)
to
124 000 (36,3)
110 000
(32,8)
96 000
(28,4)
94%
80 (36)
Note 3:
The heating capacity of the CHALLENGER
CC 85/105/125 is based on the test requirements of the U.S. Department of Energy.
The IBR rating is based on a piping and pick
up allowance of 1.15. This allowance should
be sufficient for the standard radiation
requirements for a building load.
Note 4:
82
Based on the given AFUE the CHALLENGER CC 85/105/125 meets the energy
efficiency guidelines established by Energy
Star.
Input and output ratings are shown for sea
level applications. The CHALLENGER
automatically derates the input at approximately 2% for every 1,000 Ft. of altitude. No
alterations to the appliance or burner system
are required.
Notes
Notes
Notes
Additional quality water heating equipment available
from ACV-Triangle Tube
Maxi-Flo and Spa Heat Exchangers
-
-
-
Construction of high quality corrosion resistant
stainless steel (AISI 316) or titanium
Specially designed built-in flow restrictor to assure
maximum heat exchange
Compact and light weight
Available in 8 sizes that can accommodate any size
pool or spa
SMART Indirect Fired Water Heaters
-
Exclusive Tank-in-Tank design
Stainless steel construction
Available in 7 sizes
Limited LIFETIME residential warranty
6 year limited commercial warranty
Self cleaning/self descaling design
-
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 ACV-Triangle
Tube
Available in capacities from 25,000 BTU/hr to
5,000,000 BTU/hr
TTP Brazed Plate Heat Exchangers
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ACV-Triangle Tube - 1 Triangle Lane - Blackwood, NJ 08012 - Tel: (856) 228 8881 - Fax: (856) 228 3584
E-mail: sales@triangletube.com