For specialists: installer, service engineer (11 pages)
Summary of Contents for ACV CC105
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Installation & Maintenance Manual CHALLENGER COMBI CC105, CC125, CC125H WARNING If the information in this manual is not followed exactly, a fire or explosion may re- sult 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.
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Table of Contents Section VI: Domestic Piping ..............................16 General Notes................................16 Operating Restrictions ...............................16 Pressure Relief Valve - Standard Installations ......................17 Temperature & Pressure (T&O) Relief Valve - Storage Tank or SMART/COMFORT Installations ......17 Drain Valves ................................18 Thermal Expansion..............................18 Water Hammer ................................18 Vacuum Breaker - Strage Tank or SMART/COMFORT Installations................18 General Piping Requirements ............................18 6.10 Thermostatic Mixing Valve............................18...
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Table of Contents 11.8 Inspect Condensate Drain Assembly.........................32 Section XII: Startup Procedures.............................33 12.1 Final Checks Before Startup ............................33 12.2 CHALLENGER Startup ...............................33 12.3 CHALLENGER Startup Troubleshooting........................33 12.4 Check the CHALLENGER and System ........................33 12.5 Appliance ON/OFF ..............................34 12.6 Set Boiler Maximum Central Heating (CH) Set Point Temperature .................34 12.7 Operation Verification - Space Heating ........................34 12.8 DHW Set Point Temperature ............................36 12.9 Operation Verification - Domestic Hot Water (If Applicable) ..................36...
BEST PRACTICE WARNING Indicates recommendations made by ACV-Triangle Tube for the installers which will help to ensure optimum op- 1.3 Qualified Installer eration and longevity of the equipment. Prior to installing this product, read all instructions included in this manual and all accompanying manuals/documents with this 1.2 Safety Information...
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1. Product & Safety Information NOTICE DANGER ACV-Triangle Tube reserves the right to modify the tech- HOT WATER CAN SCALD! nical specifications and components of its products without prior notice. Water temperature over 125°F [52°C] can cause severe burns instantly or death from scalds.
1. Product & Safety Information 1.5 Warranty NOTICE Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installa- tion in order to gain warranty coverage. NOTICE When receiving the CHALLENGER, any claims for dam- age or shortage in shipment must be filed immediately against the transportation company by the consignee.
2. Pre-Installation Items Section II: Pre-Installation Items 2.2 Determining Product Location Before locating the CHALLENGER, check for convenient locations to: 2.1 Code Compliance • Heating system piping The CHALLENGER is certified to the Boiler Standard (ANSI • Domestic water supply piping Z21.13/CSA 4.9) and the Water Heater Standard (ANSI Z21.10/CSA •...
2. Pre-Installation Items 2.4 Clearances 2.5 Residential Garage Installations The CHALLENGER is approved for the following clearance to When installing the CHALLENGER in a residential garage, the combustibles: following special precautions per NFPA 54/ANSI Z223.1 must be taken: • Top panel - 12 inches [30.5 cm] •...
3. Combustion Air & Venting Section III: Combustion Air & Venting • Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms 3.1 Combustion Air Contamination • Adhesives used to fasten building products and other similar products WARNING Areas likely to contain these products •...
Contact ACV-Triangle Tube for other venting options in- fireplace dampers, and any other gas-burning appliances to cluding PVC Concentric Vent/Air Termination Supple- their previous condition of use.
3. Combustion Air & Venting 3.5 Commonwealth of Massachusetts Installations Only For direct-vent, mechanical-vent, or domestic hot water equipment For direct-vent, mechanical-vent, or domestic hot water equipment and appliances where the bottom of the vent terminal and the air and appliances where the bottom of the vent terminal and the air intake is installed below four feet above grade, the following intake are installed above four feet above grade, the following requirements must be satisfied:...
WARNING installation. If floor installation is required, an option floor stand, P/N PSSTND04, is available through ACV-Triangle Tube, see Fig 1. This Use extreme care not to drop the appliance or cause appliance is not to be installed on carpeting.
4. Appliance Preparations 4.4 Stud Wall Installation 4.7 Piping Support Bracket Locate the studs in the general area of the appliance CAUTION installation. Place the wall-mounting bracket on the wall centering the Appliance must be installed using the supplied near mounting slots with the stud centers and ensuring the upper boiler piping assembly.
5. Boiler Piping Section V: Boiler Piping 5.3 Low Water Cut Off / CH Pressure Sensor 5.1 General Piping Requirements NOTICE All plumbing must meet or exceed all local, state and national The Low Water Cut Off (LWCO) only applies for space plumbing codes.
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5. 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 Boiler Return Connection Connection with Tee Fitting and with Tee Boiler Drain Valve Fitting and Temperature/ Pressure Gauge...
5.13 System Piping - Indirect Fired Water Heater with the CHALLENGER. The circulator when wired directly to the See Figs. 7 and 8, on page 15, for recommended piping of a ACV- CHALLENGER will provide circulation for the freeze protection feature Triangle Tube SMART/COMFORT I.F.W.H.
5. Boiler Piping The CHALLENGER’s domestic piping should not be utilized. Refer to 5.14 System Piping - Special Application the installation manual provided with the SMART/COMFORT for If the boiler is used in conjunction with a chilled water/medium additional installation details. system, the boiler and chiller must be piped in parallel.
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5. Boiler Piping Additional Zone Load Zone Load 12" Max. [30.5 cm] Optional SMART / COMFORT Fig. 7: System Piping - Zoning with Zone Circulators CHALLENGER Boiler Pressure Relief Valve Boiler Circulator with Flow Check Air Separator Flow/Check Valve Automatic Air Vent Isolation Valve Diaphragm Expansion Tank Zone Circulator...
6. Domestic Piping Section VI: Domestic Piping 6.1 General Notes • Household water usage patterns will affect water temperature at any faucet or shower. Occasionally check temperature at WARNING each point of use, then adjust thermostatic mixing valve HOT WATER CAN SCALD! accordingly.
To reduce risk of excessive pressures and temperatures The domestic water heater (if utilized) requires a field supplied in a storage tank or ACV-Triangle Tube SMART/COM- pressure relief valve identified with the ASME V or HV symbol and set FORT I.F.W.H., install a temperature and pressure relief...
An optional lead free, 60 mesh y- prevent over pressurization of the appliance’s domestic strainer is available through ACV-Triangle Tube, part coil. number CCSTRA01. 6.5 Drain valves •...
6. Domestic Piping DANGER For proper operation of the thermostatic mixing valve, Check Valve and to prevent potential scaling hazards, the recircula- (cold & hot) tion loop should be controlled by an aquastat. DO NOT use continuous recirculation. Adapter 6.11 Recirculation Piping •...
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6. Domestic Piping Figure 10: Installation of Domestic Compression Adapter Assemblies Cold To Dish Washer or High Temperature Water Inlet Application Figure 11 Domestic Piping - Standard Installations CHALLENGER Mixing valve with check valve Isolation valve Strainer (*) Backflow preventer or pressure reducing valve (*) Flow check valve (*) Thermal expansion tank (potable) (*) 10.
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6. Domestic Piping Recirculating Loop (optional) For service only see warning on page 23 Remove any check valve Cold Water Inlet Storage Tank Note: 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 149°F [65°C], see Section 12.8.
NOTICE the piping must comply with ASME D2564 or F493. For installations in Canada, use ULC certified PVC or CPVC Contact ACV - Triangle Tube for other venting options pipe, fittings, and cement/primer. including PVC Concentric Vent/Air Termination or CHALLENGER Concentric Vent/Air System. Refer to...
8. Gas Piping Section VIII: Gas Piping WARNING 8.1 Gas Supply Piping Connection Do not check for gas leaks with an open flame. Use a gas detection device or bubble test. Failure to check NOTICE for gas leaks can result in substantial property damage, serious injury, or death.
Model Orifice Size Marking - For additional gas sizing information, refer to ANSI Z223.1. For Canadian installations refer to CAN/CSA B149.1. CC105 0.256" [6.50 mm] 8.2.2 Supply Pressure Requirements Pressure required at the gas valve inlet supply pressure port: CC125 0.285"...
This kit includes all the necessary parts and instruction to perform the conversion from natural gas to propane gas. If this conversion kit is missing, please contact ACV - Triangle Tube Technical Support for missing kit before installing unit. WARNING Prior to start up, ensure the appliance is set to fire propane.
9. Internal Wiring Section IX: Internal Wiring 9.1 General Requirements WARNING 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 result in substantial property dam- age, serious injury, or death.
10. External Wiring Section X: External Wiring 10.6 System Circulator - Zone Valve Application To energize the system circulator shown as item 11 in Fig. 8 on page 10.1 Installation Compliance 15, reference Fig. 18 on page 28. Installer to provide a Transformer/Relay such as Honeywell R8285 or equivalent and Zone All field wiring made during installation must comply with: Valves with isolated end switch such as Honeywell V8043 or...
10. External Wiring 10.9 Outdoor Temperature Sensor Wiring NOTICE NOTICE Isolate line voltage wiring from low voltage wiring to prevent any potential for electical noise. When making low voltage connections to the CHAL- LENGER, ensure no external voltage is present in the 10.8 Thermostat Wiring thermostat circuits.
10. External Wiring V.A.C. High Voltage Transformer (Power) V.A.C. Room 4 Wire Thermostat Zone Valve Zone 1 Room Thermostat Zone 2 4 Wire Zone Valve Additional zones may Additional zones be added as shown above To Challenger Low Voltage Terminal Strip V.A.C.
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10. External Wiring Thermostat Honeywell zone 1 R845A Relay Circulator Zone 1 Thermostat zone 2 Circulator Zone 2 Additional zones may be added as shown above To Challenger Low Voltage Terminal Strip Fig. 20: Field Wiring with Zone Circulators Thermostat Thermostat Thermostat Zone 3...
Clinical Toxicology of Commerical Products. instructions. The boiler water volume of the CC105 is 0.42 gallons [1.6 l] and CC125 11.1.1 Water pH Level and CC125H is 0.50 gallons [1.9 l]. Remember to include this volume Maintain the boiler water pH between 6.5 and 8.5.
11. Startup Preparation Purge air and sediment from each zone of the hydronic system 11.7 Check Thermostat Circuit through the purge valves. Open air vents to allow air to be - Disconnect the external thermostat wires from the control vented from the zones. terminal strip, located on the drop down panel.
ON or OFF. Are the room thermostats set above room temperature? WARNING If none of these conditions correct the problem, contact ACV - Triangle Tube Technical Support. The combustion levels must be measured at high and 12.4 Check the CHALLENGER and System low firing rates.
12. Startup Procedures the changes. Table 5: Recommended Combustion Levels Combustion Levels Natural Gas Propane Gas NOTICE CO 2 Range 9% - 10.1% 10.5% - 11.1% If the reset button is not pressed within 30 sec- CO 2 Target 9.0% 10.8% onds, the parameter menu is automatically closed and O 2 Range...
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12. Startup Procedures FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion can result causing substatial prop- WARNING erty damage, serious injury or loss of life. A. This appliance does not have a pilot. It is equipped with an C.
12. Startup Procedures Allow the appliance to operate and the boiler outlet temperature 12.9 Operation Verification - Domestic Hot Water to reach the set point temperature. NOTICE [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 Digits and characters shown in brackets [0] represent the continue to run during the 10 second post purge cycle, before...
12. Startup Procedures 12.10 Control Display Read-Out Operation 1. On/Off (Lit when on) A. On/Off 2. CH operation or setting maximum CH temperature B. Parameter 3. DHW operation or setting DHW temperature C. Decrease 4. Main display with temperature or water pressure D.
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12. Startup Procedures 12.10.6 Test Mode Operation 12.10.7 Flame Current While in the test mode: While in high fire or low fire test modes, the flame current (µA) can be checked at the control by pressing and holding the “ ”...
6ºF [3ºC] di erential. The CH circulator will continue to operate while the burner is blocked. For installations with an optional ACV- Triangle Tube SMART Indirect Fired Water Heater (I.F.W.H.) piped o the primary loop, similar to Figures 7 and 8 on page 15, parameter 1 should be set to 1. The I.F.W.H. aquastat should be wired to CHALLENGER’s X4-5 and X4-6 electrical connector, see Figure 12, page 21.
12. Startup Procedures 12.12 Error Mode Table 6: 12 kOhm NTC Sensor Resistance If a boiler fault occurs, the CHALLENGER enters a hard lockout Temperature (°F) Temperature (°C) NTC (kOhm) condition which requires a manual reset by pressing the reset 171.70 button A hard lock is indicated by a flashing [E] on the operating...
12. Startup Procedures 12.14Error Codes 12.15 Warning Codes In situations where the boiler takes a preventative action without Red LED above the reset button will flash. Correct condition first, going into a hard lockout, a warning code flashes in the main display. then press the reset button.
13. Outdoor Reset Control Section XIII: Outdoor Reset Control Plastic Anchors (2) Sensor Enclosure 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 below. If the outdoor sensor is not installed, ODS will be displayed.
14. Checkout Procedures Section XIV: Checkout Procedures NOTICE Perform the following checkout procedures as outlined and checkoff items as completed. When procedures are completed, the installer should complete the installa- tion record on page 45. □ Boiler system water chemistry checked and verified as outlined in Section 11.1.
15. Installation Record Section XV: Installation Record CHALLENGER Model Number: Serial Number: Date of Installation: Fuel: Natural Gas Propane Measured Rate of Input: Btu/hr Combustion Readings: 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.
16. Maintenance Schedule Section XVI: Maintenance Schedule 16.2 Owner Maintenance 16.2.1 Periodic 16.1 Service Technician Check the area around the appliance. At least on an annual basis the following maintenance should be Check and remove any blockage from the combustion air inlet performed by a qualified service technician.
17. Maintenance Procedures Section XVII: Maintenance Procedures WARNING 17.1 Annual Maintenance Procedures Eliminate all boiler leaks. Continual fresh make-up water WARNING will reduce the heat exchanger life causing appliance fail- ure. Leaking water may also cause severe property dam- The CHALLENGER should be inspected and serviced age to the surrounding area.
16. Maintenance Procedures Verify the system pressure, as the appliance operates at high Diaphragm Tank: temperatures, to ensure the pressure does not exceed 25 psig [1.7 Ensure the system contains a minimum of one automatic air bar]. Excessive pressure reading may indicate expansion tank sizing is vent.
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17. Maintenance Procedures Fig. 23: Loosening of Flue Pipe Retaining Ring Fig. 24: Removal of Flue Pipe Fig. 25: Removal of Condensate Pan...
17. Maintenance Procedures 17.16 Check Control Settings Use a vacuum cleaner or compressed air to clean the interior of the blower and venturi assembly. Inspect the blower blades Check the control parameter settings by pressing the to ensure they are clean and not damaged. thermometer button “...
17. Maintenance Procedures Use a vacuum cleaner, compressed air or water to remove any Attach the other end of the hose to a potable (bronze or accumulation from the heat exchanger flue ways. Do not use stainless steel) circulating pump with a 2.5 gallon per minute any solvent.
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17. Maintenance Procedures Handling Previously Fired Combustion Chamber Insulation Wear long sleeved, loosing fitting clothing, gloves, WARNING and eyes protection. Assure adequate ventilation. The combustion chamber insulation contains ceramic Wash with soap and water after contact. fibers, which are classified as a possible human carcinogen. Wash potentially contaminated clothes separately When exposed to extremely high temperatures, the ceramic from other laundry and rinse washing machine...
Use only genuine ACV - Triangle Tube replacement parts to ensure warranty coverage and to avoid damage to appliance and im- proper operation of appliance. Contact ACV - Triangle Tube at 856-228-8881 or www.triangletube.com for a list of distributors nearest you.
18. Replacement Parts 18.2 Front Door Fig. 28: CHALLENGER Front Door Part Number Part Number Part Number Item Description CC105 CC125 CC125H CCRKIT04 Wall Bracket Assembly (Not Shown) Pipe Connectors & Brackets Assembly CCRKIT05 (Not Shown) CCFTG01 Connector Pipe CH (Not Shown) - 1/Kit...
18. Replacement Parts 18.3 Vent Components Fig. 29: CHALLENGER Vent Components Part Number Part Number Part Number Item Description CC105 CC125 CC125H 80/125 Concentric Vent/Air Adapter CCRKIT09 Assembly (Optional - Shown) 3" Vent/Air Adapter Assembly CCRKIT35 (Standard - Not shown)
18. Replacement Parts 18.5 Blower & Gas Valve Components Fig. 31: Blower & Gas Valve Components Part Number Part Number Part Number Item Description CC105 CC125 CC125H CCRKIT59 Ignition Transformer Assembly CCRKIT60 Gas Valve Assembly CCRKIT31 Lower Gas Pipe Assembly...
18. Replacement Parts 18.6 Burner Components Fig. 32: Burner Components Part Number Part Number Part Number Item Description CC105 CC125 CC125H CCRKIT33 Burner Assembly...
18. Replacement Parts 18.7 Control Components Fig. 33: Control Components Part Number Part Number Item Description CC105 & CC125 CC125H CCRKIT53 CCRKIT54 Control/Display CCCS01 Plastic Control Housing CCRKIT34 Flip Panel CCFUSE01 Fuse - 1/Kit Connector - X4, 24V, 9 Pin...
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Plates made of stainless steel, with 99.9% copper brazing ensuring a high resistance to corrosion. • Self Cleaning / Self Descaling • Computerized sizing available from ACV - Triangle Tube • Available in capacities from 25,000 BTUH to 5,000,000 BTUH 88349705...
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