TriangleTube Challenger Installation And Maintenance Manual

TriangleTube Challenger Installation And Maintenance Manual

Combination boiler and/or water heater
Table of Contents

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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 installa-
NOTI E
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: 8/4/2011
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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Summary of Contents for TriangleTube Challenger

  • Page 1 NOTI E 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.
  • 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 CHALLENGER Start-Up ........
  • 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

    Product & Safety Information Definitions The following terms are used throughout this manual to bring attention to the presence of potential hazards or important information concerning the product. DANGER NOTI E Indicates the presence of a hazardous Indicates special instructions on instal- situation which, if ignored, will result lation, operation or maintenance, in death, serious injury or substantial...
  • Page 8 Product & Safety Information DANGER WARNING Do not use this appliance if any part Should overheating occur or the gas has been under water. Immediately call supply fails to shut off, turn OFF the a qualified service technician to inspect manual gas control valve external to the appliance and to replace any part of the appliance.
  • 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

    Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required. Code Compliance NOTI E The CHALLENGER is certified to both the Boiler (ANSI Z21.13/CSA 4.9) and Water The CHALLENGER gas manifold and Heater (ANSI Z21.10.3/CSA4.3) standards. gas controls meet the safe lighting and other performance requirements as speci- Due to the CHALLENGER’s unique heat...
  • 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- lowing items should be checked and corrected ance or less than recommended service...
  • Page 12: Boiler Freeze Protection Feature

    Pre-Installation Items Boiler Freeze Protection Feature CAUTION The boiler control has a freeze protection fea- The boiler freeze protection feature is ture. This feature monitors the boiler supply designed to protect the boiler, installed water temperature and responds as follows in a primary/secondary piping arrange- when no call for heat is present: ment.
  • Page 13: Section Ii - Combustion Air And Venting

    Cements and glues Antistatic fabric softeners used in WARNING clothes dryers Do not operate a CHALLENGER if the Chlorine-type bleaches, detergents, and combustion air inlet is located near a cleaning solvents found in household laundry room or pool facility.
  • 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

    DANGER doors and windows and all doors between the space in which the appliances remain- Do not install the CHALLENGER into a ing connected to the common venting sys- common vent with other gas or oil appli- tem are located and other spaces of the 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

    13. To avoid damage to gas fitting and piping at bottom of appliance, appliance must be The CHALLENGER should be wall mounted shipped with rear or back of appliance using the bracket provided with the appliance (longest box length) laying down flat.
  • 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 3. Tighten all fittings to appliance piping connections with two wrenches.
  • Page 20: Section Iv - Boiler Piping

    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- ing guidelines must be followed: to utilize a primary/secondary piping arrangement.
  • Page 23: Closed-Type Expansion Tank

    System Piping - Zone Valves expansion tank. Connect the CHALLENGER to the system pip- Circulator ing as shown in Fig. 8 page 20 when zoning with The CHALLENGER must be supplied with a zone valves.
  • 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

    SMART I.F.W.H. 12" Max. [30.5 cm] Fig. 7: Central Heating (CH) System Piping - Zoning with Zone Circulators 1. CHALLENGER boiler 7. Pressure relief valve 2. Boiler circulator with flow check 8. Air separator 3. Flow/check valve 9. Automatic air vent 4 Isolation valve 10.
  • Page 27: Section V - Domestic Piping

    - Use the lowest practical temperature NOTI E 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

    Domestic Piping Temperature & Pressure (T&P) Relief Valve- - plugged, reduced or restricted Storage Tank or SMART 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 or Triangle Tube SMART I.F.W.H., install tempera- relief valve and the storage tank or ture and pressure protective equipment...
  • Page 30: Water Hammer

    BEST PRACTICE Thermostatic Mixing Valve It is recommended to install flush valves The CHALLENGER is factory supplied with a as outlined in Fig. 11 and 12, pages 26 and 27 for servicing the domestic coil. thermostatic mixing valve with built-in check valves on the hot and cold inlets.
  • Page 31: Recirculation Piping

    1. Relocate the thermostatic mixing valve from the by an aquastat. The maximum recommended set- CHALLENGER to the outlet of the storage tank. ting of the aquastat is 10ºF [5ºC] lower than the 2. Provide recirculation from the storage tank thermostatic mixing valve setting.
  • Page 32: Domestic Piping Diagrams

    To Dish Washer or High Temperature Water Inlet Application Fig. 11 : Domestic Piping - Standard Installations 1. CHALLENGER 7. Mixing valve with check valve 2. Isolation valve 8. Strainer (*) 3. Backflow preventer or pressure reducing valve (*) 9. Flow check valve (*) 4.
  • Page 33 ( ) should be set to ON ( ) at the display panel, see page 49 Fig. 12 : Domestic Piping - Storage Tank Installations 1. CHALLENGER 10. Strainer (*) 2. Isolation valve 11. Vacuum breaker (*) 3. Backflow preventer or pressure reducing valve (*) 12.
  • Page 34: Section Vi - Installing Vent / Combustion Air & Condensate Drain

    Vent/Air System Supplement 2010-23. 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 Condensate Drain Trap Assembly trap assembly at location shown. Fig. 13: Condensate Drain Trap Assembly...
  • Page 36: Section Vii - Gas Piping

    Use a two-wrench method of tightening 5. Purge all air from the gas supply piping. gas piping near the appliance and its gas 6. Before placing the CHALLENGER into piping connection. Use one wrench to operation, check and test all piping connec- prevent the appliance gas line connec- tions for leaks.
  • Page 37: Natural Gas

    Adjust the lockup pressure regulator for Refer to Table 1 for schedule 40 metallic pipe 13”w.c. [32 mbar] maximum. length and diameter requirements for natural gas, based on rated CHALLENGER input (divide by 1,000 to obtain cubic feet per hour). WARNING...
  • Page 38: Propane Gas Orifice Requirements

    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.
  • 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 The CHALLENGER must be electrically avoid possible electric shock hazard. grounded required National...
  • Page 40: Challenger Factory Wiring Diagrams

    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 Boiler Circulator Aquastat Fig. 16: CHALLENGER Factory Wiring Diagrams...
  • Page 41: Section Ix - External Wiring

    Line Voltage Connections 1. Connect a 120 VAC/15A service to the 120V terminals L, N and G inside the CHALLENGER as shown in Fig. 16, page 34. 2. Route the incoming 120 VAC power wire through the provided openings in the bot- tom right side jacket panel.
  • 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

    CH Circulator Outdoor Reset Control 1. Connect the CH primary circulator to the The CHALLENGER may operate with a vari- 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.
  • Page 44: External Wiring Diagrams

    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. High Voltage Transformer (Power) V.A.C. Room Zone Valve Thermostat...
  • Page 45 Relay Circulator Zone 1 Thermostat zone 2 Circulator Zone 2 Additional zones may be added as shown above To Challenger Low Voltage Terminal Strip Thermostat Thermostat Thermostat Zone 3 Zone 2 Zone 1 Fig. 21: Typical Zone Relay Panel Wiring...
  • 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

    The condensate drain assembly must be Check Thermostat Circuit installed on the appliance and filled with Disconnect the external thermostat wires water when the CHALLENGER is in from the control terminal strip, located on operation. The condensate drain assem- 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 The combustion levels should be mea- lowing equation: sured at high and low firing rate, refer to 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

    Pole Double Throw (D.P.D.T) coil relay, similar to Honeywell’s R4222D1013 relay. One of the normally open contacts should switch line voltage to the domestic I.F.W.H. pump, the other normally open contacts should be wired to the CHALLENGER’s Low voltage X4-5 and X4-6 electrical connectors, see Figure 17, page 36.
  • 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 • Replace S1 - CH supply 10, 11, 12, • E10 Open sensor 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. 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 Reset Control Adjusting Outdoor Reset Curve an outdoor temperature sensor is connected, the CH Reset Curve Coldest Day is the coldest The appliance CH set point along with design temperature of the heating system. Parameters 5, 6 & 7 define the settings of the outdoor reset curve.
  • Page 63: Outdoor Reset Curve Example

    Outdoor Reset 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

    (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...
  • 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 Retaining Ring Fig. 24: Removal of Flue Pipe 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 electrical connector to the gas valve inside the appliance. Inspect all control wiring. Ensure wiring is in good condition and properly connected. Disconnect the wiring harness connectors from the blower. Check Control Settings Remove the mounting bolts and washers secur- ing the front of the heat exchanger and set bolts 1.
  • Page 73: Check Combustion Levels

    Maintenance Procedures page 42 and repair if necessary. Place the 11. Close isolation valves at the appliance boil- appliance back into service. er piping to isolate the appliance from the heating system. 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...
  • Page 74: Review With Owner

    Maintenance Procedures 15. Rinse the domestic heat exchanger for 5 WARNING minutes by opening both the domestic hot water outlet drain/flush valve and the isola- tion (shut) off valve on the domestic cold To avoid risk of electrocution ensure all water inlet.
  • Page 75: Replacement Parts

    Ignition electrode Blower Low voltage/terminal strip X4 DHW flow switch High voltage terminal strip 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) - 1/Kit CCFTG02 Connector Pipe DHW (Not Shown) - 1/Kit...
  • 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 ( standard - CCRKIT35 not shown) CCRKIT10 CCRKIT11...
  • 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...
  • 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 - 1/Kit...
  • Page 82: Specifications

    DHW Hot Condensate Drain Flexible Challenger CC 125 33.07” [84 cm] Challenger CC 105 30.71” [78 cm] Challenger CC 85 28.35” [72 cm] 80/125 Concentric Adapter Vent/Air ( optional - shown) or 3” (standard -not shown) Front View& Side CHALLENGER...
  • 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...
  • Page 85: Specifications Water Heater

    Specifications - Water Heater 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: Specification Boiler

    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 87 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 88 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 89 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 Net Boiler Input Heating Capacity Shipping IBR Rating DOE Seasonal Fuel BTUH [KW] BTUH [KW]...
  • 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...

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