ACV The Challenger Installation And Maintenance Manual
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ACV The Challenger 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 *
NOTI E
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.
When receiving the CHALLENGER, any claims for damage or shortage in shipment must be filed immedi-
ately 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: 11/25/13
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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  • Page 1 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. When receiving the CHALLENGER, any claims for damage or shortage in shipment must be filed immedi- ately against the transportation company by the consignee.

  • Page 2: Table Of Contents

    Table of Contents PRODUCT AND SAFETY INFORMATION Definitions........... 1 Product and Safety Information .
  • Page 3 Table of Contents Circulator ........... 17 Sizing Primary Piping.
  • Page 4 If CHALLENGER Does Not Start Correctly......43 Check the CHALLENGER and System......43-44 Operating Instructions.
  • Page 5 Table of Contents Operation Verification - Space Heating ......46-47 Set DHW Set Point Temperature ....... . . 47 Operation Verification - Domestic Hot Water .
  • Page 6 Table of Contents SECTION XVI - MAINTENANCE PROCEDURES Annual Maintenance Procedures Reported Problems ........61 Check Surrounding Area.

  • Page 7: Definitions

    CAUTION Indicates a potentially hazardous situ- ation which, if ignored, may result in minor injury or property damage. NOTI E ACV-Triangle Tube reserves the right to modify the technical specifications and compo- nents of its products without prior notice.
  • Page 8 ACV-Triangle Tube. If there is a conflict or doubt about the proper installation of WARNING the appliance or any factory supplied or...
  • Page 9 Water temperature over 125ºF [52ºC] can tions or a temperature/pressure relief cause severe burns instantly or death from valve for storage tank or ACV-Triangle scalds. Tube SMART Indirect Fired Water Heater (I.F.W.H.) installations. (DHW •...

  • Page 10: Section I - Pre-Installation Items

    Devices for Automatically Fired Boilers, Code Compliance ANSI/ASME CSD-1, when required. NOTI E The CHALLENGER is certified to both the The CHALLENGER gas manifold and Boiler (ANSI Z21.13/CSA 4.9) and Water gas controls meet the safe lighting and Heater (ANSI Z21.10.3/CSA4.3) standards.

  • Page 11: Boiler Or Water Heater Replacement

    Pre-Installation Items Boiler or Water Heater Replacement NOTI E If the CHALLENGER is replacing an existing When maintaining the approved clear- boiler and/or hot water heater system, the fol- ance or less than recommended service lowing items should be checked and corrected...

  • Page 12: Boiler Freeze Protection Feature

    Pre-Installation Items Boiler Freeze Protection Feature CAUTION The boiler freeze protection feature is The boiler control has a freeze protection fea- designed to protect the boiler, installed ture. This feature monitors the boiler supply in a primary/secondary piping arrange- water temperature and responds as follows when ment.

  • Page 13: Section Ii - Combustion Air And Venting

    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 or contain contamination, or if products, Calcium Chloride used for thawing ice...

  • Page 14: Ventilation Air Requirements

    5, no ventilation openings are required. The CHALLENGER is certified as Direct Vent (sealed combustion) appliance. A Direct Vent For installations with less than the minimum appliance utilizes uncontaminated outdoor air service clearances involving only the CHAL- (piped directly to the appliance) for combustion.

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

    3. Insofar as is practical, close all building DANGER doors and windows and all doors between Do not install the CHALLENGER into a the space in which the appliances remain- common vent with other gas or oil appli- ing connected to the common venting sys- ances.

  • 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

    To avoid damage to gas fitting and piping at bottom of appliance, appliance must be shipped with rear or back of appliance The CHALLENGER should be wall mounted (longest box length) laying down flat. using the bracket provided with the appliance and is not designed for floor installation.

  • Page 18: Wall Mounting Guidelines

    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 3. Level the bracket, while maintaining it’s cen- inch [40.6 cm] on centers.

  • Page 19: Appliance Mounting

    Fig. 2: Wall Mounting The CHALLENGER pression nuts. 3. Tighten all fittings to appliance piping Appliance Mounting connections with two wrenches.

  • Page 20: Section Iv - Boiler Piping

    Maximum Allowable Working Pressure of 43.5 PSI [3 bar]. The appliance is supplied with a 30 psi [2 bar] pressure relief valve The CHALLENGER is equipped with a fac- and must be piped using the PRV connec- tory installed pressure sensor type LWCO.

  • Page 21: Boiler Piping

    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 22: Additional Limit Control

    Boiler Piping Additional Limit Control Boiler System Piping Applications If a Low Water Cut Off (LWCO) is required by BEST PRACTICE certain local jurisdictions or when the boiler is It is required on all piping applications installed above the system piping, the follow- to utilize a primary/secondary piping ing guidelines must be followed: arrangement.

  • Page 23: Closed-Type Expansion Tank

    System Piping - Zone Valves expansion tank. Circulator Connect the CHALLENGER to the system pip- ing as shown in Fig. 8 page 20 when zoning with The CHALLENGER must be supplied with a zone valves. The primary / secondary piping Central Heating (CH) circulator with flow ensures that the boiler loop has sufficient flow.

  • 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 Max. 12" Minimum [30.5 cm] 3/4" Piping Boiler Boiler Supply...

  • Page 25: System Piping - Radiant Heating

    The CHALLENGER’s domestic piping should The maximum boiler water supply temperature not be utilized. Refer to the installation manual can be maintained by the CHALLENGER, provided with the SMART for additional instal- potentially eliminating the need for a mixing lation details.

  • Page 26: Central Heating (Ch) System Piping Diagrams

    Boiler Piping Fig. 7: Central Heating (CH) System Piping - Zoning Additional with Zone Circulators Zone Load Zone Load 12" Max. [30.5 cm] Optional SMART I.F.W.H. 1. CHALLENGER boiler 7. Pressure relief valve 2. Boiler circulator with flow check 8. Air separator 3.

  • Page 27: Section V - Domestic Piping

    NOTI E - Use the lowest practical temperature setting. When the CHALLENGER is installed in a domestic well application, the cut in - Check water temperature after any pressure of the domestic well pump’s adjustment. You must follow “Setting control must be set to 40 psig [3 bar] to the Thermostatic Mixing Valve”...

  • Page 28: Pressure Relief Valve - Standard Installations

    Chloride, less than 150 ppm or mg/l 1. The CHALLENGER is not supplied with a pH value min. 6.5, max. 8.5 150 psi [10 bar] pressure relief valve and Total hardness 3 - 7 grains/gallon or 50- must be piped using a Pressure Relief Valve 120 ppm or mg/l.

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

    CAUTION WARNING To reduce risk of excessive pressures and Do not install any valve between T&P temperatures in a storage tank or ACV- relief valve and the storage tank or Triangle Tube SMART I.F.W.H., install temperature and pressure protective SMART connection or on T&P relief equipment required by local codes, but no valve discharge piping.

  • Page 30: Water Hammer

    Thermostatic Mixing Valve It is recommended to install flush valves as outlined in Fig. 11 and 12, pages 26 The CHALLENGER is factory supplied with a and 27 for servicing the domestic coil. thermostatic mixing valve with built-in check valves on the hot and cold inlets. The mixing valve must be installed as shown in Figs.

  • Page 31: Recirculation Piping

    DANGER 3. Provide recirculation from the storage tank back to the CHALLENGER using a bronze For proper operation of the thermostat- or stainless steel type circulator. ic mixing valve and to prevent potential...

  • 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 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.

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

    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 Installing Condensate Drain Assembly acidic with a pH content below 4.0. Install a neutralizing filter if required.
  • Page 35 Installation Vent/Combustion Air & Condensate Drain * Carefully cut top of condensate drain trap Condensate Drain assembly with hack saw Trap Assembly or knife at location shown. Fig. 13: Condensate Drain Trap Assembly...

  • Page 36: Section Vii - Gas Piping

    5. Purge all air from the gas supply piping. gas piping near the appliance and its gas piping connection. Use one wrench to 6. Before placing the CHALLENGER into prevent the appliance gas line connec- operation, check and test all piping connec- tion from turning and the second to tions for leaks.

  • 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

    If this con- substantial property damage. version kit is missing, please contact ACV- Table 3: Propane Gas, Orifice Requirements: Triangle Tube Technical Support before installing unit for missing kit.

  • Page 39: Section Viii - Internal Wiring

    T 194F [90ºC] wire or equivalent as a min- supply to the appliance before servicing imum. or making any electrical connections to avoid possible electric shock hazard. The CHALLENGER must be electrically Failure to do so can cause severe person- grounded required National al injury or death.

  • Page 40: Challenger Factory Wiring Diagrams

    Internal Wiring Ladder Diagram The wiring for 120V field connections to the appliance shall have a minimum size of 14 AWG and a tem- Note perature 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.

  • Page 41: Section Ix - External Wiring

    2.3 amps. WARNING ELECTRICAL SHOCK HAZARD. Before making any electrical connec- tions 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.

  • Page 42: Low Voltage Connections

    NOTI E When making low voltage connections to the CHALLENGER, ensure no external voltage is present in the thermostat cir- cuits. If external voltage is present, pro- vide an isolated contact to prevent dam- age to the appliance control.

  • Page 43: Ch Circulator

    Outdoor Reset Control CHALLENGER 120V, terminals 4, 5 and 6 located inside the appliance as shown in The CHALLENGER may operate with a vari- Fig. 16, page 34. able appliance operating temperature using the 2. Remove one of the gray plastic strain...

  • 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 Low Voltage Terminal Strip 3 Wire Zone Valve V.A.C.
  • Page 45 External Wiring Fig. 20: Field Wiring with Zone Circulators 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. 21: Typical Zone Relay Panel Wiring Thermostat Thermostat Thermostat...

  • Page 46: Section X - Start-Up Preparation

    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 lev- els considered safe for drinking.

  • Page 47: Use Of Antifreeze In The Boiler System

    Operating pressure of the sys- The boiler water volume of the CHALLENGER tem should never exceed 25 psi [1.7 bar]. CC 85 is 0.37 gallons [1.4 l], CC 105 is 0.42 gal- lons [1.6 l] and CC 125 is 0.50 gallons [1.9 l].

  • Page 48: Check For Gas Leaks

    NOTI E The condensate drain assembly must be Check Thermostat Circuit installed on the appliance and filled with water when the CHALLENGER is in Disconnect the external thermostat wires operation. The condensate drain assem- from the control terminal strip, located on bly prevents flue gas emissions from the drop down panel.

  • Page 49: Section Xi - Start-Up Procedures

    (external or internal at the operation of the CHALLENGER control. appliance control) or open service switch. Verify the CHALLENGER and the boiler 3. Is the external limit control (if applicable) system are full of water and all system open? Ensure the external limit is reset to components are correctly set for operation, the closed position.
  • Page 50 5. Calculate Natural gas input using the fol- sured at high and low firing rate, refer to lowing equation: page 50 of the CHALLENGER control 3600 x 1000 / number of second recorded section on how to set the firing rate. If for one cubic foot of gas = BTU/H.

  • Page 51: Operating Instructions

    Set room thermostat(s) to desired setting(s). 2. Set room thermostat(s) to lowest setting. Turn the 9. The CHALLENGER control panel display will external manual gas valve handle clockwise show a sequence of numbers (1,2,3,4) as the right “CLOSE”...

  • Page 52: Appliance On/Off

    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.

  • Page 53: Set Dhw Set Point Temperature

    Start-Up Procedures ] The setpoint temperature has been 3. Press the reset button to close the set- reached. Combustion will cease and the post ting menu and store the changes. purge cycle of the blower begins. The control module will de-energize the gas valve and NOTI E the blower will continue with the 10 second post purge cycle, before shutting down.
  • Page 54 Start-Up Procedures If the burner flame is not established ] This is the normal DHW operation the control module will repeat the igni- cycle. The control module will begin to tion sequence after approximately 15 modulate the burner firing rate based on seconds .

  • Page 55: Control Display

    Start-Up Procedures Control Display 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 Test Mode Function TO TEMPORARILY PLACE THE BURN- ER INTO LOW FIRE TEST MODE: press TO TEMPORARILY PLACE THE BURN- and hold both the “ and “ button simul- ” ” ER INTO HIGH FIRE TEST MODE: press taneously until operating display shows “L”.
  • 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

    6ºF [3ºC] differential. The CH circulator will continue to operate while the burner is blocked. 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.

  • Page 59: Fluctuating Water Temperature

    Start-Up Procedures Fluctuating Water Temperature CAUTION Domestic water temperatures can fluctuate During a hard lockout or low water con- with factory control settings when the domestic dition the appliance will not re-start hot water flow is less than 0.7 gpm. The fluc- without service.

  • Page 60: Error (Hard Lockout) Codes

    Start-Up Procedures Error (Hard Lockout) Codes* Operating Display Main Display Error Description Possible Solution (Flashing) • Check wiring for break • Check for proper flow direction • Replace S1 • E10 Open sensor - CH supply 10, 11, 12, • E11 Flow switch sticking of miss installed 13, 14 sensor fault S1 •...

  • Page 61: Section Xii - Outdoor Reset Control

    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 out- 5.

  • Page 62: Adjusting Outdoor Reset Curve

    Outdoor Reset Control Operating Temperature Setpoint becomes the NOTI E appliance setpoint on the CH Reset Curve In accordance with Section 325 (f) (3) of the Coldest Day. Energy Policy and Conservation Act, this Minimum Boiler Operating boiler is equipped with a feature that saves Temperature Setpoint energy by reducing the boiler water tem- (Parameter 5)

  • Page 63: Outdoor Reset Curve Example

    Outdoor Reset Control Changing Outdoor Reset Parameters 4. Press the button to close the setting 1. Press the “ ” button at the display panel menu and store the changes. for approximately 2 to 3 seconds until main The appliance control module has now been display begins to flash.

  • Page 64: Section Xiii - Check-Out Procedures

    (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. completed. When procedures are com-...

  • 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 Periodic: 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

    WARNING be relocated to another area. The CHALLENGER should be inspect- Inspect Burner Area ed and serviced annually, preferably at the start of the heating season, by a qual- ified service technician.

  • 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 Fig. 24: Removal of Flue Pipe Retaining Ring Fig. 25: Removal of Condensate Pan...

  • Page 70: Check Expansion Tank

    Maintenance Procedures WARNING WARNING Before manually operating the relief When re-assembling the condensate pan valve(s), ensure the discharge piping is and flue pipe ensure all gaskets are in place directed to a suitable place of disposal to and correctly installed. Ensure all associat- avoid a potential scald hazard.

  • Page 71: Maintenance Procedures

    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 Disconnect the wiring harness connectors from Inspect all control wiring. Ensure wiring is in the blower. good condition and properly connected. Remove the mounting bolts and washers secur- Check Control Settings ing the front of the heat exchanger and set bolts and washers aside.

  • Page 73: Check Combustion Levels

    Maintenance Procedures Check Combustion Levels 12. Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh Refer to page 44 of this manual for measuring water by using the purge valves to allow combustion levels and burner adjustments. water to enter through the make-up water line to the boiler.

  • Page 74: Review With Owner

    Maintenance Procedures 7. Attach separate hose to the field installed 14. Relocate the remaining hose still connected domestic cold water inlet drain/flush valve. to the domestic cold water inlet drain/flush valve to the domestic hot water outlet 8. Submerge the other end of this hose drain/flush valve and the other end of this halfway in fluid in the same bucket.

  • Page 75: Replacement Parts

    WARNING coverage and to avoid damage to appli- Replacement parts must be purchased ance and improper operation of appli- through a local ACV-Triangle Tube dis- ance. Contact ACV-Triangle Tube at tributor. When ordering part please pro- 856-228-8881 or www.triangletube.com vide the model number and description for list of distributors nearest you.
  • 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) - 1/Kit CCFTG02 Connector Pipe DHW (Not Shown) - 1/Kit CCRKIT06...
  • Page 77 Replacement Parts Fig. 29: CHALLENGER Vent Components Part Number Part Number Part Number Item Description CC85 CC105 CC125 80/125 Concentric Vent /Air Adapter CCRKIT09 Assembly (optional - shown) 3” Vent/Air Adaptor Assembly ( stan- CCRKIT35 dard -not shown) CCRKIT10 CCRKIT11 CCRKIT12 Vent Assembly CCRKIT13...
  • 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 - 1/Kit CCSENS02 DHW Sensor CCRKIT18 DHW Flow Switch Assembly CCRKIT19 LWCO/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 CCRKIT45 Venturi 406 CCRKIT46 Venturi 362 CCRKIT47...
  • 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 - 1/Kit CCRKIT43 Connector - X4, 24V, 9 Pin (Not shown) CCRKIT44 Connector - X2, 120V, 8 Pin (Not shown)

  • Page 82: Specifications

    Specifications 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 3/4” NPT DHW Cold 3/4” NPT DHW Hot Condensate Drain Flexible Challenger CC 125 33.07”...

  • Page 83: Specifications Water Heater

    Specifications - Water Heater NOTI E 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 Water Modulation Shipping Domestic Heater Input...

  • Page 84: Specifications Water Heater

    Specifications - Water Heater...

  • Page 85: Specification Boiler

    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 NOTI E 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.
  • Page 86 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 NOTI E 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.
  • Page 87 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 NOTI E 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.
  • Page 88 Specifications - Boiler NOTI E The following efficiency performance is achieved when the CHALLENGER is operated as a Boiler according to ASHRAE 103 test procedure Modulation DOE Heating Net Boiler Input Seasonal Capacity IBR Rating Shipping BtTU/H (kW) Btu/h (kW)
  • Page 89 Notes...
  • Page 90 Notes...
  • Page 91 Notes...
  • Page 92 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 ACV-Triangle Tube - 1 Triangle Lane - Blackwood, NJ 08012 - Tel: (856) 228 8881 - Fax: (856) 228 3584 E-mail: sales@triangletube.com...

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