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CHALLENGER CC 125
TriangleTube CHALLENGER CC 125 User Manual
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34
Internal Wiring
Fig. 16:
CHALLENGER
Factory Wiring
Diagrams
Schematic
Diagram
Ladder Diagram
39
41
Table of Contents
Default Chapter
2
Table of Contents
2
Product and Safety Information
7
Definitions
7
Section I - Pre-Installation Items
10
Code Compliance
10
Determining Product Location
10
Boiler or Water Heater Replacement
11
Clearances
11
Residential Garage Installations
11
Boiler Freeze Protection Feature
12
Section II - Combustion Air and Venting
13
Combustion Air Contamination
13
Ventilation Air Requirements
14
Combustion Air and Vent Piping
14
Removal of an Existing Boiler And/Or Water Heater
15
From a Common Vent System
15
Commonwealth of Massachusetts Installation
16
Section III - Appliance Preparations
17
Handling Instructions
17
Wall Mounting Installation
17
Wall Mounting Guidelines
17
Stud Walls -Installation
18
Wall Bracket Installation - Solid Walls
18
Appliance Mounting
18
Piping Support Bracket
19
Section IV - Boiler Piping
20
General Piping Requirements
20
Pressure Relief Valve
20
Low Water Cutoff Device
20
Boiler Piping
21
Boiler Supply
21
Pressure Gauge
21
Additional Limit Control
22
Backflow Preventer
22
Boiler System Piping Applications
22
Expansion Tank and Makeup Water
22
Diaphragm Expansion Tank
22
Closed-Type Expansion Tank
23
Circulator
23
Sizing Primary Piping
23
System Piping - Zone Circulators
23
System Piping - Zone Valves
23
Near Boiler Piping Diagrams
24
System Piping - Radiant Heating
25
System Piping - Special Applications
25
Central Heating System Piping Diagrams
26
Section V - Domestic Piping
27
General Notes
27
Operating Restrictions
27
Pressure Relief Valve - Standard Installations
28
Temperature & Pressure (T&P) Relief Valve
29
Storage Tank Installations
29
Drain Valves
29
Thermal Expansion
29
Water Hammer
30
Vacuum Breaker - Storage Tank Installations
30
General Piping Requirements
30
Thermostatic Mixing Valve
30
Recirculation Piping
31
Storage Tank Installations
31
Setting the Thermostatic Mixing Valve
31
Domestic Piping Diagrams
32
Section VI - Installing Vent / Combustion Air & Condensate Drain
34
Installing Vent and Combustion Air
34
Installing Condensate Drain Assembly
34
Section VII - Gas Piping
36
Gas Supply Piping Connection
36
Natural Gas
37
Pipe Sizing -Natural Gas
37
Natural Gas Supply Pressure Requirements
37
Natural Gas Orifice Requirements
37
Propane Gas
38
Pipe Sizing - Propane Gas
38
Propane Gas Supply Pressure Requirements
38
Propane Gas Orifice Requirements
38
Section VIII - Internal Wiring
39
General Requirements
39
CHALLENGER Factory Wiring Diagrams
40
Section IX - External Wiring
41
Installation Compliance
41
Line Voltage Connections
41
Control Module Circulator AMP Ratings
41
Low Voltage Connections
42
Thermostat Wiring
42
CH Circulator
43
System Circulator - Zone Valve Application
43
Outdoor Reset Control
43
External Wiring Diagrams
44
Section X - Start-Up Preparation
46
Check Boiler System Water Chemistry
46
Water Ph Level 6.5 to 8.5
46
Water Total Hardness Less than 7 Grains/Gallon
46
Chlorinated Water
46
Flush Boiler and Domestic System to Remove Sediment
46
Check and Test Antifreeze
46
Use of Antifreeze in the Boiler System
47
Filling the Boiler System
47
Check Low Water Cut-Off Device
47
Check for Gas Leaks
48
Check Thermostat Circuit
48
Inspection of Condensate Drain Assembly
48
Section XI - Start-Up Procedures
49
Final Checks before Start-Up
49
CHALLENGER Start-Up
49
If CHALLENGER Does Not Start Correctly
49
Check the CHALLENGER and System
49
Operating Instructions
51
Appliance ON/OFF
52
Set Boiler CH Set Point Temperature
52
Operation Verification - Space Heating
52
Set DHW Set Point Temperature
53
Operation Verification - Domestic Hot Water
53
Control Display
55
Appliance ON/OFF
55
Units
55
Additional DHW Functions
55
Highfire
56
Lowfire
56
Display
58
Setting the Appliance Parameters
58
Error (Hard Lockout) Mode
59
Error (Hard Lockout) Codes
60
Section XII - Outdoor Reset Control
61
Mounting the Outdoor Sensor
61
Wiring the Sensor
61
Adjusting Outdoor Reset Curve
62
Appliance CH (Maximum Boiler Operating Temperature)
62
CH Minimum Boiler Operating Setpoint (Parameter 5)
62
CH Reset Curve Coldest Day (Parameter 6)
62
CH Reset Curve Warmest Day (Parameter 7)
62
Changing Outdoor Reset Parameters
62
Outdoor Reset Curve Example
63
Section XIII - Check-Out Procedures
64
Check-Out Procedures
64
Section XIV - Installation Record
65
Installation Record
65
Sections XV - Maintenance Schedule
66
Service Technician - General
66
Owner Maintenance
66
Section XVI - Maintenance Procedures
67
Maintenance Procedures
67
Reported Problems
67
Check Surrounding Area
67
Inspect Burner Area
67
Check System Piping
67
Clean Condensate Drain Assembly
68
Check Ventilation Air Openings
68
Inspect Vent and Combustion Air Piping
68
Check Boiler System
68
Removing Internal Flue and Condensate Pan for Inspection
68
Check Expansion Tank
70
Check Relief Valve(S)
70
Inspection of Ignition Electrode
70
Check Ignition Wiring and Ground Wiring
70
Check Control Wiring
72
Check Control Settings
72
Perform Start-Up and Checkout Procedure
72
Check Burner Flame
72
Check Combustion Levels
73
Clean Heat Exchanger
73
Review with Owner
73
Handling Previously Fired Combustion Chamber Insulation
74
Replacement Parts
75
Replacement Parts
81
Product Specifications
82
Specifications
82
Specifications
88
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TriangleTube CHALLENGER CC 125 Specifications
General
Brand
TriangleTube
Model
CHALLENGER CC 125
Category
Boiler
Language
English
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