TriangleTube CHALLENGER CC 85 Installation And Maintenance Manual
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TriangleTube CHALLENGER CC 85 Installation And Maintenance Manual

Combination boiler and/or water heater
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Combination
Boiler
Water Heater
* I N S T A L L A T I O N A N D M A I N T E N A N C E *
* I N S T A L L A T I O N A N D M A I N T E N A N C E *
Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of
NOTI E
installation in order to gain warranty coverage.
When receiving the CHALLENGER, any claims for damage or shortage in shipment must be filed imme-
diately against the transportation company by the consignee.
Leave all documentation received with appliance with owner for future reference.
If the information in this manual is not followed exactly, a fire or explosion may
WARNING
result causing property damage, personal injury or death.
• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
• WHAT TO DO IF YOU SMELL GAS
Installation and service must be performed by a qualified installer, service agency or the
gas supplier.
Date: 12/9/2010
and or
/
M A N U A L
M A N U A L
this or any other appliance.
- 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.
FOR YOUR SAFETY
2010-1Challenger Manual

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Do you have a question about the CHALLENGER CC 85 and is the answer not in the manual?

Questions and answers

RON ST. JEAN
April 25, 2025

How to remove ignitor

0
1 comments:
Mr. Anderson
May 12, 2025

To remove the ignitor from a TriangleTube Challenger CC 85:

1. Turn off all electrical power to the appliance to avoid electrical shock.
2. Use a T-15 Torx wrench to remove the ignition electrode.
3. Carefully remove the ignition electrode from its position.

If necessary, clean the electrode or replace it if it does not clean to a satisfactory condition.

This answer is automatically generated

0

Related Manuals for TriangleTube CHALLENGER CC 85

Summary of Contents for TriangleTube CHALLENGER CC 85

  • Page 1 Combination Boiler and or Water Heater * I N S T A L L A T I O N A N D M A I N T E N A N C E * * I N S T A L L A T I O N A N D M A I N T E N A N C E * M A N U A L M A N U A L Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of...

  • Page 2: Table Of Contents

    Table of Contents PRODUCT AND SAFETY INFORMATION Definitions........... 1 Product and Safety Information .
  • Page 3 Table of Contents Closed-Type Expansion Tank ......17 Circulator ........... 17 Sizing Primary Piping.
  • Page 4 Table of Contents SECTION VIII - INTERNAL WIRING General Requirements......... . 33 CHALLENGER Factory Wiring Diagrams.
  • Page 5 Table of Contents Operation Verification - Domestic Hot Water ..... . . 47-48 Control Display Appliance ON/OFF........49 Units .
  • Page 6 Table of Contents Check System Piping ........61 Clean Condensate Drain Assembly .

  • Page 7: Definitions

    CAUTION Indicates a potentially hazardous situ- ation which, if ignored, may result in minor injury or property damage. NOTI E Triangle Tube reserves the right to modify the technical specifications and components of its products without prior notice.
  • Page 8 NOTI E order given. Failure to adhere to the guide- lines within these manuals can result in Triangle Tube accepts no liability for any severe personal injury, death or substantial damage resulting from incorrect instal- property damage.
  • Page 9 Product & Safety Information DANGER DANGER Bacteria can develop in the domestic Protection must be taken against water system if certain minimum water excessive pressure! temperatures are not maintained. TO PROTECT AGAINST EXCES- SIVE TEMPERATURE AND PRES- SURE DANGER • Check if a 150 psi [10 bar] pressure HOT WATER CAN SCALD! relief valve (field supplied) is installed...

  • Page 10: Section I - Pre-Installation Items

    Pre-Installation Items SECTION I - Pre-Installation Items NOTI E Code Compliance The CHALLENGER gas manifold and gas controls meet the safe lighting and The CHALLENGER is certified to both the other performance requirements as speci- Boiler (ANSI Z21.13/CSA 4.9) and Water fied in ANSI Z21.13 standard.

  • Page 11: Boiler Or Water Heater Replacement

    Pre-Installation Items Boiler or Water Heater Replacement WARNING If the CHALLENGER is replacing an existing boiler or hot water heater system, the following If the recommended service clearances items should be checked and corrected prior to listed above cannot be maintained or the installation: enclosure in which the appliance is installed is less than 45 cubic feet [1.3...

  • Page 12: Boiler Freeze Protection Feature

    Pre-Installation Items Boiler Freeze Protection Feature CAUTION The boiler control has a freeze protection feature The boiler freeze protection feature is built in. This feature monitors the boiler supply designed to protect the boiler. The boil- temperature and responds as follows when no er must be installed in a primary/sec- call for heat is present: ondary piping arrangement.

  • Page 13: Section Ii - Combustion Air And Venting

    Combustion Air and Venting SECTION II- Combustion Air and Potential contaminating products Venting Spray cans containing chloro/fluorocar- bons Combustion Air Contamination Permanent Wave Solutions Chlorinated wax WARNING Chlorine - based swimming pool chem- If the CHALLENGER combustion air icals / cleaners inlet is located in any area likely to cause Calcium Chloride used for thawing ice or contain contamination, or if products,...

  • Page 14: Ventilation Air Requirements

    Combustion Air and Venting Ventilation Air Requirements Combustion Air and Vent Piping For installations, involving only the CHAL- The CHALLENGER requires a Category IV LENGER, in which the minimum service venting system, which is designed for pressur- clearances are maintained as listed on page 5, ized venting and condensate.

  • Page 15: Removal Of An Existing Boiler And/Or Water Heater

    Combustion Air and Venting Removal of an Existing Boiler and or Water 5. Test for spillage at the draft hood relief Heater from a Common Vent System opening after 5 minutes of main burner operation. Use the flame of a match or can- dle, or smoke from a cigarette, cigar or pipe.

  • Page 16: Commonwealth Of Massachusetts Installation

    Combustion Air and Venting Commonwealth of Massachusetts Installations Only For direct-vent appliances, mechanical- 4. A metal or plastic identification plate vent heating appliances or domestic hot shall be mounted at the exterior of the water equipment, where the bottom of the building, four feet directly above the vent terminal and the air intake is installed location of vent terminal.

  • Page 17: Section Iii - Appliance Preparations

    Ensure both lag screws optional floor stand part number PSSTND04 is are installed securely in the studs. available through Triangle Tube. Appliance is not to be installed on carpeting. 3. For applications using metal studs, install the bracket to the studs using 3/16”...

  • Page 18: Stud Walls -Installation

    Appliance Preparations 3. Level the bracket and use a pencil to mark NOTI E the location of the mounting slots/holes on the wall. Use extreme care not to drop the appli- ance or cause bodily injury while lifting 4. Remove the bracket from the wall and drill or mounting the appliance onto the a 5/8”...

  • Page 19: Piping Support Bracket

    Appliance Preparations Piping Support Bracket 2. Once the appliance is mounted onto the wall, slip the appliance piping into the fit- tings until bottom of hex on gas pipe fitting 1. Pre-install the 4 brass compression fittings rests against the top of the piping support into the piping support bracket as shown in bracket before tightening any compression Fig.

  • Page 20: Section Iv - Boiler Piping

    Boiler Piping SECTION IV - Boiler Piping above any drain connection to allow clear visibility of the discharge. General Piping Requirements Should terminate with a plain end, not All plumbing must meet or exceed all local, with a threaded end. The material of the state and national plumbing codes.

  • Page 21: Boiler Piping

    Boiler Piping Pressure Relief Valve (Supplied with Boiler) 3/4" Street Elbow 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 22: Additional Limit Control

    Boiler Piping Additional Limit Control Boiler System Piping Applications If a LWCO device is required by certain local BEST PRACTICE jurisdictions or when the boiler is installed above the system piping, the following guide- It is required on all piping applications to lines must be followed: utilize a primary/secondary piping arrangement.

  • Page 23: Closed-Type Expansion Tank

    Boiler Piping Closed-Type Expansion Tank System Piping - Zone Circulators It is recommended to pitch any horizontal pip- Connect the CHALLENGER to the system ing upwards toward the expansion tank 1 inch piping as shown in Fig. 7 page 20 when zoning per 5 feet [2.5cm / 1.5 M] of piping.

  • Page 24: Near Boiler Piping Diagrams

    Boiler Piping System System Supply Return Max. 12" [30.5 cm] Cold Water Fill Boiler Boiler Supply Return Fig. 5: Near Boiler Piping - Diaphragm Expansion Tank System System Supply Return Cold Water Fill 12" Max. Minimum [30.5 cm] 3/4" Piping Boiler Boiler Supply...

  • Page 25: System Piping - Radiant Heating

    Boiler Piping System Piping - Radiant Heating System Piping - Special Application The heat exchanger design of the CHAL- If the boiler is used in conjunction with a LENGER allows operation in a condensing chilled water/medium system, the boiler and mode.

  • Page 26: Central Heating System Piping Diagrams

    Boiler Piping Additional Zone Load Zone Load 12" Max. [30.5 cm] Fig. 7: CH System Piping - Zoning with Zone Circulators 1. CHALLENGER boiler 7. Pressure relief valve 2. CH circulator 8. Air separator 3. Flow/check valve 9. Automatic air vent 4 Isolation valve 10.

  • Page 27: Section V - Domestic Piping

    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 tempera- tures settings of 130ºF [54ºC] or less.

  • Page 28: Pressure Relief Valve - Standard Installations

    Domestic Piping Iron less than 0.3 ppm or mg/l. 2. To avoid potential water damage to the sur- rounding area or potential scalding hazard Aluminum, less than 0.2 ppm or mg/l. due to the operation of the relief valve, the discharge piping: Copper, less than 1 ppm or mg/l.

  • Page 29: Temperature & Pressure (T&P) Relief Valve

    Domestic Piping Temperature & Pressure (T&P) Relief - plugged, reduced or restricted. Valve- Storage Tank Installations - subject to freezing. CAUTION WARNING To reduce risk of excessive pressures and Do not install any valve between T&P temperatures in a storage tank, install relief valve and storage tank connection temperature and pressure protective equipment required by local codes, but...

  • Page 30: Water Hammer

    An optional lead free, 60 mesh y- The operating range of the thermostatic mixing strainer is available through Triangle Tube is 90ºF [32ºC] to 120ºF [49ºC]. part number CCSTRA01, see Graph 4, page 79 for strainer pressure loss curve.

  • Page 31: Recirculation Piping

    Domestic Piping by an aquastat. The maximum recommended set- 2. Provide recirculation from the storage tank back to the CHALLENGER using a ting of the aquastat is 10ºF [5ºC] lower than the bronze type circulator. Maximum recom- thermostatic mixing valve setting. mended recirculation flow rate is 1 gpm.

  • Page 32: Domestic Piping Diagrams

    Domestic Piping 1/2” compression x 3/4” NPT Adapter Fittings for DHW Fig. 10 : Installation of Domestic Compression Adapter Assemblies Cold To Dish Washer or High Temperature Water Inlet Application Fig. 11 : Domestic Piping - Standard Installations 1. CHALLENGER 7.
  • Page 33 Domestic Piping Cold Recirculating Water Loop Inlet Storage Tank Fig. 12 : Domestic Piping - Storage Tank Installations 1. CHALLENGER 7. Mixing valve with check valve 2. Isolation valve 8. Circulator (potable, must be controlled by a aquastat) 3. Backflow preventer or pressure reducing valve (*) 9.

  • Page 34: Section Vi - Installing Vent / Combustion Air & Condensate Drain

    Installation Vent/Combustion Air & Condensate Drain SECTION VI - Installing Vent / NOTI E Combustion Air & Condensate Drain The drain line materials must be an Installing Vent and Combustion Air approved material by the authority hav- ing jurisdiction. In absence of such DANGER authority, PVC and CPVC piping must comply with ASTM D1785 or D2845.
  • Page 35 Installation Vent/Combustion Air & Condensate Drain * Carefully cut top of condensate drain Condensate Drain Assembly assembly with hack saw or knife at location shown. Fig. 13: Condensate Drain Assembly...

  • Page 36: Section Vii - Gas Piping

    Gas Piping SECTION VII - Gas Piping Disconnect the CHALLENGER and its gas valve from the gas supply piping during any pressure test greater than Gas Supply Piping Connection 13”w.c. [32 mbar]. WARNING NOTI E Do not check for gas leaks with an open The gas supply piping must be installed flame.

  • Page 37: Natural Gas

    Gas Piping NATURAL GAS 2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can Pipe Sizing - Natural Gas exceed 13”w.c. [32 mbar] at any time. Adjust the lockup pressure regulator for Refer to Table 1 for schedule 40 metallic pipe 13”w.c.

  • Page 38: Propane Gas

    Gas Piping PROPANE GAS Table 3: Propane Gas, Orifice Requirements: Pipe Sizing - Propane Gas Propane Orifice CHALLENGER MODEL Orifice Size Marking Contact the local propane gas supplier for rec- ommended sizing of piping, tanks and 100% lockup gas regulator. CC85 0.199”...

  • Page 39: Section Viii - Internal Wiring

    Internal Wiring SECTION VIII - Internal Wiring General Requirements Wiring must be N.E.C Class 1. WARNING If original wiring as supplied with the ELECTRICAL SHOCK HAZARD. For appliance must be replaced, use only Type your safety, disconnect electrical power T 194F [90ºC] wire or equivalent as a min- supply to the appliance before servicing imum.

  • Page 40: Challenger Factory Wiring Diagrams

    Internal Wiring Ladder Diagram Schematic Diagram Fig. 16: CHALLENGER Factory Wiring Diagrams...

  • Page 41: Section Ix - External Wiring

    External Wiring SECTION IX- External Wiring Control Module Circulator AMP Ratings Installation Compliance AMP draw of the CH circulator must not exceed 2.3 amps. All field wiring made during installation must comply with: WARNING National Electrical Code NFPA 70 and any other national, state, provincial or The ON/OFF switch of the CHAL- local codes or requirements.

  • Page 42: Low Voltage Connections

    External Wiring Low Voltage Connections Thermostat Wiring 1. Open the display cover and unscrew both NOTI E screw to remove the front cover Isolate 120V wiring from 24V wiring to 2. Pull the control/display forward until it tips prevent any potential electrical “noise”. downward to provide access.

  • Page 43: Ch Circulator

    CHALLENGER 120 V terminals 1,2 and 3 able appliance operating temperature using the located inside the appliance as shown in Triangle Tube outdoor sensor, see pages 55 Fig. 16, page 34. through 57 for installation and set-up. 2. Maximum CH circulator continuous cur- rent draw is 2.3 A.

  • Page 44: External Wiring Diagrams

    External Wiring 4 Wire Zone Valve V.A.C. High Voltage Transformer (Power) V.A.C. Room Zone Valve Thermostat Zone 1 Room Thermostat Zone 2 Zone Valve Additional zones may Additional zones be added as shown above To Challenger 24V Terminal Strip 3 Wire Zone Valve V.A.C.
  • Page 45 External Wiring Thermostat Honeywell Fig. 20: Field Wiring with Zone Circulators zone 1 R845A Relay Circulator Zone 1 Thermostat zone 2 Circulator Zone 2 Additional zones may be added as shown above To Challenger 24V Terminal Strip Thermostat Thermostat Thermostat Zone 3 Zone 2 Zone 1...

  • Page 46: Section X - Start-Up Preparation

    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 Flush the systems until the water runs clean Do not use petroleum-base cleaning or and is free of sediment.

  • Page 47: Use Of Antifreeze In The Boiler System

    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 WARNING automatic air vent in the system. NEVER use automotive or ethylene gly- 2.

  • Page 48: Check For Gas Leaks

    Start-Up Preparation Check For Gas Leaks NOTI E WARNING In systems using 3-wire zone valves, backfeed of voltage to the appliance is a Prior to start-up and during initial oper- common problem. Use an isolation relay ation, smell near the floor and around the to prevent voltage from the external cir- appliance for gas odorant or any unusual cuit entering the CHALLENGER con-...

  • Page 49: Section Xi - Start-Up Procedures

    If none of these conditions correct the problem, installed and supported. Reference the contact Triangle Tube Tech Service. CHALLENGER vent supplement. Verify burner configuration - gas orifice Check the CHALLENGER and System size.
  • Page 50 Table 5 for the firing rate, Check around the appliance for gas shut the appliance down and contact odor following the procedure outlined Triangle Tube Engineering Department. in this manual on Page 42. Failure to comply with this requirement could result in severe personal injury, WARNING death or substantial property damage.

  • Page 51: Operating Instructions

    Start-Up Procedures FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may WARNING result causing property damage, personal injury or loss of life. • If you cannot reach your gas supplier, call the .

  • Page 52: Appliance On/Off

    Start-Up Procedures Appliance ON/OFF 3. The following displays should occur: 1. The appliance operation is started using the ] Self check on power up ON/OFF button. [ ] No call for heat 2. When appliance is in operation, the green 4.

  • Page 53: Set Dhw Set Point Temperature

    Start-Up Procedures trol module will close the gas valve and the NOTI E blower will continue for 30 seconds for a post purge cycle before shutting down. The CH circulator will continue to run until the If the reset button is not pressed with- room thermostat is satisfied.
  • Page 54 Start-Up Procedures If the burner flame is not proven the ] This is the normal DHW operation control module will repeat the ignition cycle. The control module will begin to sequence after approximately 15 sec- modulate the burner firing rate based on onds .

  • Page 55: Control Display

    Start-Up Procedures Control Dispaly Read-Out Operation A. On/Off button 1. On/Off (Lit when on) B. CH /DHW/parameter button 2. CH operation or setting maximum CH temperature C. - button 3. DHW operation or setting DHW temperature D. + button 4. Main display with temperature of CH or DHW or E.

  • Page 56: Highfire

    Start-Up Procedures TO TEMPORARILY PLACE THE BURN- TO TEMPORARILY PLACE THE BURN- ER INTO HIGH FIRE TEST MODE: press ER INTO LOW FIRE TEST MODE: press and hold both the “ ” and “+” button simul- and hold both the “ ”...
  • Page 57 Start-Up Procedures Function Operating Display Main Display Press button to turn appliance ON LED lite above button will be lit when appliance is ON No demand for heat Control self-test Fan pre purge or post purge cycle Ignition sequence Burner ON for space heating (CH) Burner ON for domestic hot water (DHW) Burner OFF due to reaching temperature setpoint...

  • Page 58: Display

    Start-Up Procedures Setting the Appliance Parameters NOTI E 1. Press the “ ” button at the display panel for approximately 2 to 3 seconds until main If the reset button is not pressed with- display begins to flash. in 30 seconds, the settings menu is auto- matically closed and the changes are 2.

  • Page 59: Error (Hard Lockout) Mode

    Start-Up Procedures Error (Hard Lockout) Mode If a system fault occurs, the system enters a hard lockout condition which requires a manu- al reset by pressing the RESET button hard lock is indicated by a flashing [E] on the operating display as well as a flashing LED light above the reset button.

  • Page 60: Error (Hard Lockout) Codes

    Start-Up Procedures Error (Hard Lockout) Codes Operating Display Main Display Possible Solution Error Description (Flashing) • Check wiring for break • Check for proper flow direction 10, 11, 12, - CH Supply • Replace S1 13, 14 Sensor fault S1 •...

  • Page 61: Section Xii - Outdoor Reset Control

    Outdoor Resest Control SECTION XII - Outdoor Reset Control 4. Mount the sensor enclosure at an elevation on the exterior wall to prevent accidental damage or tampering. The appliance setpoint for a heating call can be fixed or vary with the outdoor temperature. If 5.

  • Page 62: Adjusting Outdoor Reset Curve

    Outdoor Resest Control Adjusting Outdoor Reset Curve the CH Reset Curve Coldest Day is the coldest design temperature of the heating system. The appliance CH set point along with Parameters 5, 6 & 7 define the settings of the CH Reset Curve Warmest Day outdoor reset curve.

  • Page 63: Outdoor Reset Curve Example

    Outdoor Resest Control Boiler CH Set Point Parameter 5 Set Point Outdoor Air Temperature ( F) Graph 1: Outdoor Air Temperature Reset Curve (Example) Table 7: Outdoor Air Temperature Reset (Example) Outdoor Appliance target Temp. Temperature Based on Outdoor Temp. 10ºF or Lower 140ºF 30ºF...

  • Page 64: Section Xiii - Check-Out Procedures

    Check-Out Procedures SECTION XIII- Check-Out Procedures Checked and verified room thermostat(s) function properly and the thermostat(s) heat anticipator (if used) was properly set. NOTI E Observed several operating cycles for Perform the following check-out proce- proper operation of the CHALLENGER dures as outlined and check off items as and the system.

  • Page 65: Section Xiv - Installation Record

    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 66: Sections Xv - Maintenance Schedule

    Maintenance Schedule SECTION XV - Maintenance Schedule Owner Maintenance Service Technician Periodically: At least on an annual basis the following main- Check the area around the appliance. tenance should be performed by a qualified ser- Check and remove any blockage from the vice technician: combustion air inlet and ventilation open- General...

  • Page 67: Section Xvi - Maintenance Procedures

    Maintenance Procedures SECTION XVI - Maintenance Verify that combustion air inlet area is free of Procedures any contaminates. Refer to the materials listed on page 7 of this manual. If any of these prod- ucts are in the area from which the appliance Maintenance Procedures takes its combustion air, they must be removed immediately or the combustion air intake must...

  • Page 68: Clean Condensate Drain Assembly

    Maintenance Procedures Clean Condensate Drain Assembly Check Boiler System 1. Remove the condensate assembly from the Verify all system components are correctly appliance. installed and operating properly. 2. Empty any water from the trap and drain Check the cold fill pressure for the system, typ- assembly.
  • Page 69 Maintenance Procedures Fig. 23: Loosening of Flue Pipe Retaining Ring Fig. 24: Removal of Flue Pipe Fig. 25: Removal of Condensate Pan...

  • Page 70: Check Expansion Tank

    Maintenance Procedures Check Relief Valve(s) WARNING Inspect the relief valve(s) and lift the lever to When re-assembling the condensate pan verify flow at least annually or as recommend- and flue pipe ensure all gaskets are in ed on the warning tag of the valve. place and correctly installed.
  • Page 71 Maintenance Procedures 0.43 [11 mm] 0.12 [ 3 mm] Spark gap app. 0.18” [5 mm] Fig. 26: Igniter Dimensions...

  • Page 72: Check Control Wiring

    Maintenance Procedures Check Control Wiring Close the external manual gas valve on the gas supply line and disconnect the gas piping and Inspect all control wiring. Ensure wiring is in plug inside the appliance. good condition and properly connected. Disconnect the wiring harness connectors from the blower.

  • Page 73: Check Combustion Levels

    Maintenance Procedures Re-assemble the gas supply connections and 9. Re-assemble the blower the wiring har- plug to gas valve inside the appliance. Open ness. the external manual gas valve. Check gas pip- 10. Reconnect the gas piping and plug to gas ing for any leaks as outlined on page 42 and valve.

  • Page 74: Handling Previously Fired Combustion Chamber Insulation

    Maintenance Procedures Handling Previously Fired Combustion Chamber Insulation 2. Wear long sleeved, loose fitting clothing, WARNING gloves and eyes protection. The combustion chamber insulation 3. Assure adequate ventilation. contains ceramic fibers, which are clas- 4. Wash with soap and water after contact. sified as a possible human carcinogen.

  • Page 75: Replacement Parts

    High voltage terminal strip Low voltage/terminal strip X4 DHW flow switch Condensate pan Fig. 27: CHALLENGER Internal Components Use only genuine Triangle Tube replace- WARNING ment parts to ensure warranty coverage and to avoid damage to appliance and Replacement parts must be purchased improper operation of appliance.
  • Page 76 Replacement Parts Fig. 28 : CHALLENGER Front Door Part Number Part Number Part Number Item Description CC85 CC105 CC125 CCRKIT04 Wall Bracket Assembly (Not Shown) Pipe Connectors & Brackets Assembly CCRKIT05 (Not Shown) CCFTG01 Connector Pipe CH (Not Shown) CCFTG02 Connector Pipe DHW (Not Shown) CCRKIT06 CCRKIT07 CCRKIT08...
  • Page 77 Replacement Parts Fig. 29: CHALLENGER Vent Components Part Number Part Number Part Number Item Description CC85 CC105 CC125 CCRKIT09 80/125 Vent /Air Adapter Assembly CCRKIT10 CCRKIT11 CCRKIT12 Vent Assembly CCRKIT13 Condensate Collector Assembly CCRKIT14 Condensate Drain Assembly...
  • Page 78 Replacement Parts Fig. 30 : CHALLENGER Internal Components Part Number Part Number Part Number Item Description CC85 CC105 CC125 CCRKIT15 Igniter Assembly CCCLB01 Ignition Cable CCRKIT16 Sight Glass Assembly CCRKIT17 CH Sensor Assembly CCSENS02 DHW Sensor CCRKIT18 DHW Flow Switch Assembly CCRKIT19 CH Pressure Sensor Assembly CCRKIT20...
  • Page 79 Replacement Parts Fig. 31 : CHALLENGER Blower & Gas Valve Components Part Number Part Number Part Number Item Description CC85 CC105 CC125 CCRKIT28 Ignition Transformer Assembly CCRKIT29 Gas Valve Assembly CCRKIT30 CCRKIT31 Gas Pipe Assembly CCRKIT32 Blower Assembly...
  • Page 80 Replacement Parts Fig. 32 : CHALLENGER Burner Components Part Number Part Number Part Number Item Description CC85 CC105 CC125 CCRKIT33 Burner Assembly...

  • Page 81: Replacement Parts

    Replacement Parts Fig. 33 : CHALLENGER Control Components Part Number Part Number Part Number Item Description CC85 CC105 CC125 CCCON01 Control/Display CCCS01 Housing Plastic Control CCRKIT34 Flip Panel CCFUSE01 Fuse...

  • Page 82: Specifications

    CH Return 1” NPT 1/2” NPT 3/4” NPT DHW Cold 3/4” NPT DHW Hot flexible Challenger CC 125 33.07 [84 cm] Challenger CC 105 30.71 [85.6 cm] Challenger CC 85 28.35 [72 cm] 80/125 (concentric) Vent/Air Front View& Side CHALLENGER...
  • Page 83 Specifications Modulation Net Boiler Input Heating Capacity Shipping IBR Rating DOE Seasonal Fuel BTUH [KW] Model BTUH [KW] BTUH [KW] Efficiency AFUE Weight Note 4 Note 1 & 4 Note 2 Lbs [Kg] Note 3 Natural 23,000 [6.7] CHALLENGER 75,000 65,000 66 [30] CC 85...
  • Page 84 Specifications...
  • Page 85 Specifications Domestic Pressure Drop Graph 3 : Pressure Loss Through Domestic CCSTRA01 Optional Strainer Pressure Drop Curve Graph 4 : Pressure Loss Through Optional Domestic Strainer...
  • Page 86 Specifications Pressure Drop Comparison - Grundfos Graph 5 : Pressure Loss Through Boiler - Grundfos Circulators Pressure Drop Comparison - Taco Graph 6 : Pressure Loss Through Boiler - Taco Circulators NOTI E Minimum allowable boiler flow rate at full input: - 4 gpm CHALLENGER CC85...
  • Page 87 Specifications Pressure Drop Comparison - Grundfos Graph 7 : Pressure Loss Through Boiler - Grundfos Circulators Pressure Drop Comparison - Taco Graph 8 : Pressure Loss Through Boiler - Taco Circulators NOTI E Minimum allowable boiler flow rate at full input: - 5 gpm CHALLENGER CC105...

  • Page 88: Specifications

    Specifications Pressure Drop Comparison - Grundfos Graph 9 : Pressure Loss Through Boiler - Grundfos Circulators Pressure Drop Comparison - Taco Graph 10 : Pressure Loss Through Boiler - Taco Circulators NOTI E Minimum allowable boiler flow rate at full input: - 6 gpm CHALLENGER CC125...
  • Page 89 Notes...
  • Page 90 Notes...
  • Page 91 Notes...
  • Page 92 Self cleaning and self descaling Computerized sizing available from Triangle Tube/Phase III Available in capacities from 25,000 BTU/hr to 5,000,000 BTU/hr Member of 1 Triangle Lane - Blackwood, NJ 08012 Tel: (856) 228 8881 - Fax: (856) 228 3584 http://www.triangletube.com E-mail: Info@triangletube.com Group...

This manual is also suitable for:

Challenger cc 105Challenger cc 125

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