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TriangleTube CHALLENGER CC 105 User Manual

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Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of
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.
* 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
2010-1Challenger Manual
If the information in this manual is not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
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 neighbors phone. Follow the gas
suppliers 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.
Combination
Boiler
Water Heater
/
and
or
Date: 12/9/2010
WARNING
NOTICE

Table of Contents

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TriangleTube CHALLENGER CC 105 Specifications

General IconGeneral
CategoryBoiler
BrandTriangleTube
ModelCHALLENGER CC 105
Fuel TypeNatural Gas or Propane
Input BTU/hr105, 000
Efficiency95% AFUE
IgnitionElectronic
Vent Diameter3 inches

Summary

Installation and Maintenance Manual

Product and Safety Information

Definitions

Explains terms used throughout the manual for hazard awareness.

Product and Safety Information

Provides essential safety warnings and guidelines for product use.

Pre-Installation Items

Code Compliance

Outlines adherence to all applicable local, state, and national codes.

Determining Product Location

Guides selection of an appropriate location for the appliance.

Boiler or Water Heater Replacement

Lists checks for replacing existing heating systems.

Clearances

Specifies minimum distances required around the appliance.

Residential Garage Installations

Details special precautions for garage installations.

Boiler Freeze Protection Feature

Explains the built-in feature to prevent freezing.

Combustion Air and Venting

Combustion Air Contamination

Warns about contaminants affecting combustion air and appliance damage.

Ventilation Air Requirements

Details air requirements for safe operation and ventilation.

Combustion Air and Vent Piping

Covers requirements for sealed combustion air and vent piping.

Removal of an Existing Boiler and/or Water Heater from a Common Vent System

Provides steps for safely removing old appliances from common vent systems.

Commonwealth of Massachusetts Installation

Outlines specific regulations for Massachusetts installations.

Appliance Preparations

Handling Instructions

Provides guidance on safely handling and unpacking the appliance.

Wall Mounting Installation

Details the process for mounting the appliance on a wall.

Wall Mounting Guidelines

Provides specific instructions and requirements for wall mounting.

Stud Walls - Installation

Explains how to mount the bracket on stud walls.

Wall Bracket Installation - Solid Walls

Explains how to mount the bracket on solid walls.

Appliance Mounting

Describes how to securely attach the appliance to the wall bracket.

Piping Support Bracket

Details the installation of the piping support bracket.

Boiler Piping

General Piping Requirements

Outlines general requirements for all plumbing installations.

Pressure Relief Valve

Details the installation and requirements for the pressure relief valve.

Low Water Cut Off Device

Explains the function and installation of the low water cutoff device.

Additional Limit Control

Discusses requirements for additional limit controls.

Backflow Preventer

Advises on installing a backflow preventer as required.

Boiler System Piping Applications

Discusses common piping arrangements for boiler systems.

Expansion Tank and Makeup Water

Covers the proper sizing and installation of expansion tanks.

Diaphragm Expansion Tank

Provides details on diaphragm expansion tank installation.

Closed-Type Expansion Tank

Details installation requirements for closed-type expansion tanks.

Circulator

Explains the role and requirements for the circulator.

Sizing Primary Piping

Guides on sizing primary piping for the heating system.

System Piping - Zone Circulators

Details piping for systems using zone circulators.

System Piping - Zone Valves

Details piping for systems using zone valves.

Domestic Piping

General Notes

Provides general notes for domestic water piping.

Operating Restrictions

Lists operating limits for domestic water systems.

Pressure Relief Valve - Standard Installations

Details requirements for standard domestic pressure relief valve installations.

Temperature & Pressure (T&P) Relief Valve- Storage Tank Installations

Covers T&P relief valve requirements for storage tank installations.

Drain Valves

Mentions drain valves and fittings.

Thermal Expansion

Explains thermal expansion and the need for an expansion tank.

Water Hammer

Discusses water hammer and its prevention.

Installing Vent / Combustion Air & Condensate Drain

Installing Vent and Combustion Air

Details the installation of the vent and combustion air system.

Installing Condensate Drain Assembly

Explains how to install the condensate drain assembly.

Gas Piping

Gas Supply Piping Connection

Covers the connection of the gas supply piping.

Pipe Sizing - Natural Gas

Provides guidance on sizing natural gas piping.

Natural Gas Supply Pressure Requirements

Details required supply pressure for natural gas.

Pipe Sizing - Propane Gas

Provides guidance on sizing propane gas piping.

Propane Gas Supply Pressure Requirements

Details required supply pressure for propane gas.

Internal Wiring

General Requirements

Outlines general wiring requirements and codes.

CHALLENGER Factory Wiring Diagrams

Provides factory wiring diagrams for reference.

External Wiring

Installation Compliance

States that all field wiring must comply with codes.

Line Voltage Connections

Details how to connect the 120 VAC power supply.

Control Module Circulator AMP Ratings

Specifies the maximum AMP draw for the CH circulator.

Low Voltage Connections

Covers connections for low voltage wiring.

Thermostat Wiring

Explains how to wire the room thermostat.

CH Circulator

Details connecting the CH primary circulator.

System Circulator - Zone Valve Application

Explains wiring for system circulators in zone valve applications.

Outdoor Reset Control

Discusses the function and setup of the outdoor reset control.

External Wiring Diagrams

Provides diagrams for external wiring configurations.

Start-Up Preparation

Check Boiler System Water Chemistry

Details checks for boiler water chemistry.

Water pH Level 6.5 to 8.5

Specifies the required pH range for boiler water.

Water Total Hardness Less Than 7 Grains/Gallon

Advises on water hardness limits and consultation.

Chlorinated Water

Prohibits heating pools/spas and specifies chlorine limits.

Flush Boiler and Domestic System to Remove Sediment

Instructs on flushing the system to remove sediment.

Check and Test Antifreeze

Guides on checking and testing antifreeze in the system.

Use of Antifreeze in the Boiler System

Provides warnings and guidelines for using antifreeze.

Filling the Boiler System

Details the procedure for filling the boiler system.

Check Low Water-Cut-Off Device

Instructs on checking the low water cutoff device.

Check For Gas Leaks

Outlines procedures for checking and addressing gas leaks.

Check Thermostat Circuit

Details how to check the thermostat wiring circuit.

Inspection of Condensate Drain Assembly

Guides on inspecting the condensate drain assembly.

Start-Up Procedures

Final Checks Before Start-Up

Lists final checks before initiating appliance operation.

CHALLENGER Start-Up

Provides the steps to start the CHALLENGER appliance.

If CHALLENGER Does Not Start Correctly

Offers steps to take if the appliance fails to start.

Check the CHALLENGER and System

Guides on checking the appliance and the overall system.

Check Gas Piping

Details checking the gas piping for leaks and odor.

Verify Flame Pattern and Combustion

Guides on checking flame pattern and combustion.

Measure Input - Natural Gas Only

Explains how to measure the natural gas input rate.

Appliance ON/OFF

Describes how to turn the appliance on and off.

Set Boiler CH Set Point Temperature

Details how to set the central heating set point temperature.

Operation Verification - Space Heating

Guides on verifying space heating operation.

Operation Verification - Domestic Hot Water

Guides on verifying domestic hot water operation.

Set DHW Set Point Temperature

Details how to set the domestic hot water temperature.

Setting the Appliance Parameters

Explains how to adjust appliance parameters.

Control Display and Operation

Explains the control display, buttons, and functions.

Control Display Codes and Functions

Provides a summary of control display codes and their meanings.

Error (Hard Lockout) Mode

Error (Hard Lockout) Codes

Outdoor Reset Control

Mounting the Outdoor Sensor

Details the process for mounting the outdoor temperature sensor.

Wiring the Sensor

Explains how to wire the outdoor temperature sensor.

Adjusting Outdoor Reset Curve

Guides on adjusting the outdoor reset curve parameters.

Boiler CH (Maximum Boiler Operating Temperature)

Explains setting the maximum boiler operating temperature.

CH Minimum Boiler Operating Setpoint (Parameter 5)

Details setting the minimum boiler operating setpoint.

CH Reset Curve Coldest Day (Parameter 6)

Explains setting the reset curve for the coldest day.

CH Reset Curve Warmest Day (Parameter 7)

Explains setting the reset curve for the warmest day.

Changing Outdoor Reset Parameters

Guides on how to change outdoor reset parameters.

Outdoor Reset Curve Graph

Illustrates the outdoor air temperature reset curve.

Check-Out Procedures

Installation Record

Maintenance Schedule

Service Technician

Outlines annual maintenance tasks for qualified technicians.

Owner Maintenance

Lists periodic and monthly maintenance tasks for owners.

Maintenance Procedures

Reported Problems

Advises on checking and correcting reported issues.

Check Surrounding Area

Guides on ensuring the area around the appliance is clear.

Inspect Burner Area

Details how to inspect and clean the burner area.

Check System Piping

Guides on inspecting piping for leaks and support.

Clean Condensate Drain Assembly

Provides steps for cleaning the condensate drain assembly.

Check Ventilation Air Openings

Guides on checking ventilation openings for obstructions.

Inspect Vent and Combustion Air Piping

Details inspection of vent and combustion air piping.

Check Boiler System

Covers checks for the boiler system components and pressure.

Removing Internal Flue and Condensate Pan For Inspection

Details removing internal parts for inspection.

Check Relief Valve(s)

Guides on inspecting and testing relief valves.

Check Expansion Tank

Details how to check the expansion tank.

Inspection of Ignition Electrode

Explains how to inspect and clean the ignition electrode.

Check Ignition Wiring and Ground Wiring

Guides on checking ignition wiring and ground connections.

Check Control Wiring

Details checking control wiring for condition and connection.

Check Control Settings

Guides on verifying control settings.

Perform Start-up and Checkout Procedures

Instructs to perform start-up and checkout after maintenance.

Check Burner Flame

Guides on inspecting the burner flame pattern and combustion.

Check Combustion Levels

Details checking combustion levels and burner adjustments.

Clean Heat Exchanger

Provides steps for cleaning the heat exchanger.

Review With Owner

Emphasizes reviewing maintenance and appliance behavior with the owner.

Handling Previously Fired Combustion Chamber Insulation

Replacement Parts

Internal Components Overview

Identifies the main internal components of the CHALLENGER.

Front Door Components

Lists replacement parts for the CHALLENGER front door.

Vent Components

Lists replacement parts for the CHALLENGER vent system.

Internal Components (Detailed)

Provides a detailed breakdown of internal components and their parts.

Blower and Gas Valve Components

Lists replacement parts for the blower and gas valve.

Burner Components

Lists replacement parts for the CHALLENGER burner assembly.

Control Components

Lists replacement parts for the CHALLENGER control components.

Specifications

Dimensions and Connections

Shows the physical dimensions and connection types of the CHALLENGER.

Model Specifications

Provides technical specifications for different CHALLENGER models.

Domestic Performance Graph

Illustrates domestic hot water flow rate versus temperature.

Domestic Pressure Drop Graph

Shows pressure loss through domestic piping for different models.

Optional Strainer Pressure Drop Graph

Illustrates pressure loss through the optional domestic strainer.

Pressure Loss - Grundfos Circulators

Compares pressure loss through the boiler with Grundfos circulators.

Pressure Loss - Taco Circulators

Compares pressure loss through the boiler with Taco circulators.

Pressure Loss - Grundfos Circulators (Continued)

Further comparison of pressure loss with Grundfos circulators.

Pressure Loss - Taco Circulators (Continued)

Further comparison of pressure loss with Taco circulators.

Pressure Loss - Grundfos Circulators (Further)

Additional comparison of pressure loss with Grundfos circulators.

Pressure Loss - Taco Circulators (Further)

Additional comparison of pressure loss with Taco circulators.

Additional Water Heating Equipment

Maxi-Flo and Spa Heat Exchangers

Describes construction and features of Maxi-Flo and Spa Heat Exchangers.

SMART Indirect Fired Water Heaters

Details features of SMART Indirect Fired Water Heaters.

TTP Brazed Plate Heat Exchangers

Describes TTP Brazed Plate Heat Exchangers for various applications.

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