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ACV Triangle Tube CHALLENGER SOLO Installation & Maintenance Manual

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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.
•
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
•
WHAT TO DO IF YOU SMELL GAS
•
Do not try to light any appliance
•
Do not touch any electrical switch; do not use any phone in your building.
•
Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
•
If you cannot reach your gas supplier, call the fire department.
•
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
Date: 5/15/2017
Installation & Maintenance Manual
CHALLENGER
FOR YOUR SAFETY
SOLO
CC50s, CC85s, CC105s, CC125s, CC125Hs, CC150s
2016-21 Challenger Solo Manual

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Summary of Contents for ACV Triangle Tube CHALLENGER SOLO

  • Page 1 Installation & Maintenance Manual CHALLENGER SOLO CC50s, CC85s, CC105s, CC125s, CC125Hs, CC150s 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 •...

  • Page 2: Table Of Contents

    Table of Contents Section I: Product & Safety Information ..........................1 Definitions ..................................1 Safety Information ..............................1 Qualified Installer ...............................1 Homeowner ................................1 Warranty ..................................2 Section II: Pre-Installation Items ............................3 Code Compliance ...............................3 Determining Product Location...........................3 Boiler Replacement..............................3 Clearances..................................3 Residential Garage Installations ..........................4 Boiler Freeze Protection Feature..........................4 Section III: Combustion Air &...
  • Page 3 Table of Contents Section VI: Installing Vent / Combustion Air & Condensation Drain .................15 Installing Vent & Combustion Air ..........................15 Installing Condensate Drain Assembly ........................15 Section VII: Gas Piping................................16 Gas Supply Piping Connection ..........................16 Natural Gas.................................17 Propane Gas ................................18 Section VIII: Internal Wiring..............................19 General Requirements ...............................19 Section IX: External Wiring ..............................20 Installation Compliance .............................20...
  • Page 4 Table of Contents Section XII: Outdoor Reset Control............................34 12.1 Mounting the Sensor..............................34 12.2 Wiring the Sensor...............................34 12.3 Adjusting Outdoor Reset Curve ..........................34 12.4 Changing Outdoor Reset Parameters........................35 Section XIII: Checkout Procedures ............................36 Section XIV: Installation Record.............................37 Section XV: Maintenance Schedule ............................38 15.1 Service Technician..............................38 15.2 Owner Maintenance ..............................38...
  • Page 5 Table of Contents Section XVIII: Product Specifications ..........................52 18.1 Dimensions & Connections ............................52 18.2 CC50s & CC85s Pressure Loss Curves ........................53 18.3 CC105s Pressure Loss Curves ...........................54 18.4 CC125s, CC125Hs, & CC150s Pressure Loss Curves....................55 18.5 Performance Ratings ..............................56 Section XIX: Notes ................................57...

  • Page 6: Section I: Product & Safety Information

    BEST PRACTICE WARNING Indicates recommendations made by ACV-Triangle Tube for the installers which will help to ensure optimum oper- ation and longevity of the equipment. 1.3 Qualified Installer Prior to installing this product, read all instructions included in this 1.2 Safety Information...

  • Page 7: Warranty

    (30) days of installation in order to gain warranty coverage. NOTICE NOTICE ACV-Triangle Tube reserves the right to modify the techni- cal specifications and components of its products with- When receiving the CHALLENGER, any claims for damage out prior notice.

  • Page 8: Section Ii: Pre-Installation Items

    2. Pre-Installation Items Section II: Pre-Installation Items WARNING 2.1 Code Compliance Failure to remove or maintain the area free of com- The CHALLENGER is certified to the Boiler Standard (ANSI bustible materials, gasoline, or other flammable liquids or Z21.13/CSA 4.9) Standard. vapors can result in substantial property damage, serious This appliance must be installed in accordance with the lates edition injury, or death.

  • Page 9: Residential Garage Installations

    2. Pre-Installation Items 2.6 Boiler Freeze Protection Feature NOTICE The boiler control has a freeze protection feature. This feature monitors the boiler supply water temperature and responds as When maintaining the approved clearance but less than follows when no call for heat is present: recommended service clearances, some product labeling •...

  • Page 10: Section Iii: Combustion Air & Venting

    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 •...

  • Page 11: Combustion Air And Vent Piping

    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.

  • Page 12: Commonwealth Of Massachusetts Installations Only

    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:...

  • Page 13: Section Iv: Appliance Preparations

    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 bod- appliance is not to be installed on carpeting.

  • Page 14: Stud Wall Installation

    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.

  • Page 15: Section V: Boiler Piping

    5. Boiler Piping Section V: Boiler Piping 5.3 Low Water Cut Off / CH Pressure Sensor The CHALLENGER is equipped with a factory installed pressure 5.1 General Piping Requirements sensor type Low Water Cut Off (LWCO). All plumbing must meet or exceed all local, state and national The minimum operating Central Heating (CH) system pressure plumbing codes.
  • Page 16 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...

  • Page 17: Expansion Tank And Makeup Water

    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 14, for recommended piping of a ACV- CHALLENGER will provide circulation for the freeze protection feature Triangle Tube SMART/COMFORT I.F.W.H.

  • Page 18: System Piping - Special Application

    5. Boiler Piping Refer to the installation manual provided with the SMART/COMFORT 5.14 System Piping - Special Application for additional installation details. If the boiler is used in conjunction with a chilled water/medium See Setting the Appliance Parameters, Section 11.9, for parameter, system, the boiler and chiller must be piped in parallel.
  • Page 19 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...

  • Page 20: Section Vi: Installing Vent / Combustion Air & Condensation Drain

    ASME D2564 or F493. For installa- tions in Canada, use ULC certified PVC or CPVC pipe, Contact ACV - Triangle Tube for other venting options in- fittings, and cement/primer. cluding PVC Concentric Vent/Air Termination or CHAL- LENGER Concentric Vent/Air System.

  • Page 21: Section Vii: Gas Piping

    7. Gas Piping Section VII: Gas Piping WARNING 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.

  • Page 22: Natural Gas

    7. Gas Piping Natural Gas 7.2.3 Orifice Requirements 7.2.1 Pipe Sizing Refer to Table 2 for orifice required for appliance operation using natural gas. All units come set up for natural gas installation with the Refer to Table 1 for schedule 40 metallic pipe length and diameter appropriate orifice pre-installed.

  • Page 23: Propane Gas

    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.

  • Page 24: Section Viii: Internal Wiring

    8. Internal Wiring Section VIII: Internal Wiring 8.1 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.

  • Page 25: Section Ix: External Wiring

    9. External Wiring Section IX: External Wiring 9.6 System Circulator - Zone Valve Application To energize the system circulator shown as item 11 in Fig. 8 on page 9.1 Installation Compliance 14, reference Fig. 14 on page 21. 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...

  • Page 26: Thermostat (Dry Contact) Wiring

    9. External Wiring 9.9 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 9.8 Thermostat Wiring thermostat circuits.
  • Page 27 9. 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.
  • Page 28 9. 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. 16: Field Wiring with Zone Circulators Thermostat Thermostat Thermostat Zone 3...

  • Page 29: Section X: Startup Preparation

    10. Startup Preparation Section X: Startup Preparation 10.2 Flush Boiler System to Remove Sediment The installer must flush the boiler system to remove any sediment to 10.1 Check Boiler System Water Chemistry allow proper operation of the CHALLENGER. Flush the system until the water runs clean and is free of sediment. WARNING For zoned systems, each zone should be flushed through a purge valve.

  • Page 30: Check Low Water Cut Off

    10. Startup Preparation Purge air and sediment from each zone of the hydronic system 10.7 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.

  • Page 31: Section Xi: Startup Procedures

    Are the room thermostats set above room temperature? procedure to manually place unit into high or low fire. If none of these conditions correct the problem, contact ACV - Triangle The combustion readings should be within the range Tube Technical Support.

  • Page 32: Appliance On/Off

    If the combustion levels are not within the range given in Table 5, shut down the appliance and NOTICE contact ACV - Triangle Tube Technical Support. Failure to comply with this requirement can result in substan- Digits and characters shown below in brackets repre- tial property damage, serious injury, or death.
  • Page 33 11. Startup Procedures FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property dam- WARNING age, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an C.

  • Page 34: Control Display

    11. Startup Procedures To verify flame failure safety lockout, close the manual Lower the room thermostat set point below the room shut off valve on the gas supply piping to the appliance temperature to end the call for heat. and repeat the ignition sequence. When verification is [ 1 ] This begins a post purge cycle.
  • Page 35 11. Startup Procedures 11.8.3 High Fire Test Mode 11.8.6 Flame Current While in high fire or low fire test modes, the flame current (µA) can be Press both the “ ” and “+” buttons simultaneously once until the checked at the control by pressing and holding the “ ”...

  • Page 36: Setting The Appliance Parameters

    6ºF [3ºC] differential. The CH circulator will continue to operate while the burner is blocked. For installations with an optional ACV- Triangle Tube SMART/COMFORT Indirect Fired Water Heater (I.F.W.H.) piped off the CHALLENGER, similar to Figures 7 and 8 on page 14, parameter 1 should be set to 1. The I.F.W.H. aquastat should be wired to CHALLENGER’s X4-5 and X4-6 terminals, see Figure 12, page 19.

  • Page 37: Error Mode

    11. Startup Procedures 11.10 Error Mode Table 6: 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 lockout is indicated by a flashing [E] on the operating 98.82 display as well as a flashing LED above the reset button.

  • Page 38: Error Codes

    11. Startup Procedures 11.11 Error Codes 11.12 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.

  • Page 39: Section Xii: Outdoor Reset Control

    12. Outdoor Reset Control Section XII: 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.

  • Page 40: Changing Outdoor Reset Parameters

    12. Outdoor Reset Control 12.3.2 CH Minimum Boiler Temperature (Parameter 5) 12.3.4 CH Reset Curve Warmest Day (Parameter 7) Minimum Maximum Minimum Maximum Factory Setting Factory Setting Setting Setting Setting Setting 64°F 59°F 77°F 86°F 59°F 140°F [18°C] [16°C] [26°C] [30°C] [16°C] [60°C]...

  • Page 41: Section Xiii: Checkout Procedures

    13. Checkout Procedures Section XIII: 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 37. Boiler system water chemistry checked and verified as outlined in Section 10.1.

  • Page 42: Section Xiv: Installation Record

    14. 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: 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.

  • Page 43: Section Xv: Maintenance Schedule

    15. Maintenance Schedule Section XV: Maintenance Schedule 15.2 Owner Maintenance 15.2.1 Periodic 15.1 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.

  • Page 44: Section Xvi: Maintenance Procedures

    16. Maintenance Procedures Section XVI: Maintenance Procedures 16.5 Check System Piping Inspect all piping (water and gas) for leaks and verify that the piping is 16.1 Annual Maintenance Procedures leak free and properly supported. Inspect the fittings and components on the appliance and verify they are leak free. WARNING WARNING The CHALLENGER should be inspected and serviced...

  • Page 45: Check Boiler System

    16. Maintenance Procedures 16.9 Check Boiler System Ensure no automatic air vents are used in the system. This will allow air to escape from the system instead of returning to the Verify all system components are correctly installed and operating tank.
  • Page 46 16. Maintenance Procedures Fig. 19: Loosening of Flue Pipe Retaining Ring Fig. 20: Removal of Flue Pipe Fig. 21: Removal of Condensate Pan...
  • Page 47 16. Maintenance Procedures 0.43” [11 mm] 0.12” [ 3 mm] Spark gap app. 0.18” [5 mm] Fig. 22: Igniter Dimensions...

  • Page 48: Check Control Wiring

    16. Maintenance Procedures 16.15 Check Control Wiring Re-assemble the burner head and burner head gasket. Ensure mounting screws are tight. Inspect all control wiring. Ensure wiring is in good condition and properly connected. Remove the blower. Use a vacuum cleaner or compressed air to clean the interior 16.16 Check Control Settings of the blower and venturi assembly.

  • Page 49: Review With Owner

    16. Maintenance Procedures Carefully remove the front plate of the heat exchanger. Close isolation valves at the boiler piping to isolate the Ensure combustion chamber insulation is not damaged appliance from the heating system. during removal. See WARNING on page 44. Attach a hose to the boiler drain valve and flush the boiler Use a vacuum cleaner, compressed air or water to remove thoroughly with fresh water by using the purge valves to...

  • Page 50: Section Xvii: Replacement Parts

    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.

  • Page 51: Front Door

    17. Replacement Parts 17.2 Front Door Fig. 24: CHALLENGER Front Door Part Number Part Number Part Number Part Number Item Description CC50s & CC85s CC105s CC125Hs CC125s & CC150s CCRKIT04 Wall Bracket Assembly (Not Shown) Pipe Connectors & Brackets Assembly CCRKIT05 (Not Shown) CCFTG01...

  • Page 52: Vent Components

    17. Replacement Parts 17.3 Vent Components Fig. 25: CHALLENGER Vent Components Part Number Part Number Part Number Part Number Part Number Item Description CC50s & CC85s CC105s CC125s CC125Hs CC150s 80/125 Concentric Vent/Air Adapter CCRKIT09 Assembly (Optional - Shown) 3" Vent/Air Adapter Assembly CCRKIT35 (Standard - Not shown) CCRKIT10...

  • Page 53: Heat Exchanger Components

    17. Replacement Parts 17.4 Heat Exchanger Components Fig. 26: CHALLENGER Heat Exchanger Components Part Number Part Number Part Number Part Number Item Description CC50s & CC85s CC105s CC125Hs CC125s & CC150s CCRKIT15 Igniter Assembly CCCLB01 Ignition Cable CCRKIT16 Sight Glass Assembly CCRKIT17 CH Sensor Assembly - 1/Kit CCRKIT19...

  • Page 54: Blower & Gas Valve Components

    17. Replacement Parts 17.5 Blower & Gas Valve Components Fig. 27: Blower & Gas Valve Components Part Number Part Number Part Number Part Number Part Number Item Description CC50s CC85s CC105s CC125Hs CC125s & CC150s CCRKIT59 Ignition Transformer Assembly CCRKIT60 Gas Valve Assembly CCRKIT30 CCRKIT31...

  • Page 55: Burner Components

    17. Replacement Parts 17.6 Burner Components Fig. 28: Burner Components Part Number Part Number Part Number Part Number Item Description CC50s & CC85s CC105s CC125Hs CC125s & CC150s CCRKIT33 Burner Assembly...

  • Page 56: Control Components

    17. Replacement Parts 17.7 Control Components Fig. 29: Control Components Part Number Part Number Part Number Part Number Item Description CC50s CC85s, CC105s, & CC125s CC125Hs CC150s CCRKIT52 CCRKIT53 CCRKIT54 CCRKIT55 Control/Display CCCS01 Plastic Control Housing CCRKIT34 Flip Panel CCFUSE01 Fuse - 1/Kit Connector - X4, 24V, 9 Pin CCRKIT43...

  • Page 57: Section Xviii: Product Specifications

    18. Product Specifications Section XVIII: Product Specifications 18.1 Dimensions & Connections 17.72” [45 cm] 4.63” [11.8 cm] (3” Air) 13.58” [34.5 cm] (80/125 Concentric Vent/Air or 3” Vent) CH Supply 1” NPT CH Return 1” NPT 1/2” NPT Condensate Drain Flexible 37.40”...

  • Page 58: Cc50S & Cc85S Pressure Loss Curves

    18. Product Specifications 18.2 CC50s & CC85s Pressure Loss Curves CC50s & CC85s Primary Loop Circulators - Grundfos Graph 2: Pressure Loss Through Boiler - Grundfos Circulators CC50s & CC85s Primary Loop Circulators - Taco Graph 3: Pressure Loss Through Boiler - Taco Circulators NOTICE Minimum boiler flow rate required at full input: CC50s - 3 gpm [11 lpm]...

  • Page 59: Cc105S Pressure Loss Curves

    18. Product Specifications 18.3 CC105s Pressure Loss Curves CC105s Primary Loop Circulators - Grundfos Graph 4: Pressure Loss Through Boiler - Grundfos Circulators CC105s Primary Loop Circulators - Taco Graph 5: Pressure Loss Through Boiler - Taco Circulators NOTICE Minimum boiler flow rate required at full input: CC105s - 5 gpm [19 lpm] Pump curves and system curves DO NOT include any allowance for near boiler piping...

  • Page 60: Cc125S, Cc125Hs, & Cc150S Pressure Loss Curves

    18. Product Specifications 18.4 CC125s, CC125Hs, & CC150s Pressure Loss Curves CC125s, CC125Hs, CC150s Primary Loop Circulators - Grundfos Graph 6: Pressure Loss Through Boiler - Grundfos Circulators CC125s, CC125Hs, CC150s Primary Loop Circulators - Taco Graph 7: Pressure Loss Through Boiler - Taco Circulators NOTICE Minimum boiler flow rate required at full input: CC125s &...

  • Page 61: Performance Ratings

    18. Product Specifications 18.5 Performance Ratings NOTICE The following efficiency performance is achieved when the CHALLENGER is operated as a boiler according to the ASHRAE 103 test procedure. Input Net AHRI CHALLENGER Weight Modulation Heating Capacity Rating AFUE Fuel Model Lbs [kg] BTUH [kW] BTUH [kW]...

  • Page 62: Notes

    19. Notes Section XIX: Notes...
  • Page 63 19. Notes...
  • Page 64 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 88392705...

This manual is also suitable for:

Cc50sCc85sCc105sCc125sCc125hsCc150s

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