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TriangleTube Challenger User Manual

TriangleTube Challenger
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2011-37 Challenger Solo User’s Manual
If the information in this manual is not followed exactly, a fire or explosion
may result causing property damage, personal injury or loss of life.
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 neighbor’s 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.
Boiler
User s Information Manual
Date 8/9/2011
WARNING

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TriangleTube Challenger Specifications

General IconGeneral
ModelChallenger
CategoryBoiler
BrandTriangle Tube
Heat Exchanger MaterialStainless Steel
Installation TypeWall-mounted
Boiler TypeCondensing
Fuel TypeNatural Gas, Propane
Efficiency95%
Warranty10 years heat exchanger
Vent Diameter2" - 3"

Summary

Introduction and Safety Precautions

General Safety Warning

General safety warning regarding fire or explosion due to improper manual information.

Safety Information for Gas Handling

Guidance on actions to take if gas is smelled, emphasizing immediate notification of authorities.

Understanding Safety Symbols and Notices

Hazard Level Definitions

Defines hazard levels: Danger, Warning, and Caution, with associated risks of injury or damage.

Instructional Notices and Best Practices

Explains the meaning of Notice and Best Practice advisories for operation and maintenance.

Installation and Service Guidelines

Homeowner and Technician Responsibilities

Clarifies installation manual usage and technician information requirements.

Pre-Servicing Safety Checks

Mandates reading safety information before servicing and highlights risks of non-compliance.

Service and Maintenance Procedures

Outlines essential safety steps before service and requirements for annual maintenance by qualified technicians.

Challenger Operation Safety

Details safe operation practices, including combustion air, water pressure, and handling of overheating or gas failure.

Appliance and System Water Quality

Advises on water chemistry checks and proper usage of cleaning compounds for system longevity.

Combustion Air Contamination Prevention

Contaminated Air Warning and Repiping

Warns of damage and injury from contaminated combustion air and advises on repiping the intake.

Laundry and Pool Area Hazards

Highlights risks associated with laundry and pool chemicals creating corrosive acids in the system.

List of Potential Contaminating Products

Provides a list of common household and industrial products that can contaminate combustion air.

Locations Prone to Contamination

Identifies areas and establishments where contaminating products are commonly found.

Maintenance Schedule Overview

Service Technician Maintenance Tasks

Details annual maintenance tasks for qualified service technicians, including general checks and specific procedures.

Owner Periodic Maintenance Checks

Lists routine checks for owners: area inspection, blockage removal, and gauge checking.

Owner Monthly Maintenance Checks

Outlines monthly checks for owners: vent piping, air inlet piping, and pressure relief valve.

Owner Bi-Annual Maintenance Checks

Specifies 6-month checks for owners: piping for leaks and operation of the pressure relief valve.

Detailed Maintenance Procedures

Annual Inspection and Servicing Reminder

Reiterates the need for annual inspection and service by a qualified technician for optimal performance.

Periodic Maintenance: Area and Air Inlet Checks

Details periodic checks for surrounding area hazards and combustion air inlet obstructions.

Periodic Maintenance: Gauge and Display Checks

Explains how to check temperature and pressure gauges, and what readings indicate potential issues.

Monthly Maintenance Tasks

Vent Piping Inspection

Instructions for inspecting vent piping for blockages, leaks, or deterioration, with safety warnings.

Combustion Air Inlet Piping Inspection

Guidance on inspecting combustion air inlet piping for blockages, integrity, and proper sealing.

Pressure Relief Valve Check

Procedure for checking the pressure relief valve for leaks and identifying potential expansion tank issues.

Condensate Drain Assembly Check

Steps to check the condensate drain for leaks and proper function, including filling the trap.

Automatic Air Vent Check (If Used)

Instructions for checking the operation of automatic air vents and ensuring proper cap adjustment.

Six-Month Maintenance Procedures

Water and Gas Piping Leak Inspection

Procedure for inspecting water and gas piping for leaks, including immediate shutdown protocols.

Pressure Relief Valve Operation Test

Detailed steps for operating the pressure relief valve, checking for flow, weeping, and blockages.

Appliance Operation and Safety

Pre-Lighting Safety and Gas Leak Procedures

Crucial safety warnings before lighting, including ignition device use and gas smell procedures.

Step-by-Step Appliance Startup

Detailed instructions for safely starting the Challenger appliance, including thermostat and gas valve settings.

Procedure to Turn Off Gas Supply

Instructions for safely shutting off the gas supply to the appliance for service or emergencies.

Control Panel Display Overview

Control Panel Read-Out Functions

Explains the meaning of various read-out indicators on the appliance control panel, including operating and fault codes.

Appliance ON/OFF Control

Details how to start and stop the appliance using the ON/OFF button and its associated LED indicator.

Unit Display and Selection

Describes how to switch between U.S. Customary (°F/psi) and metric (°C/bar) units on the display.

Appliance Operating Modes and Displays

Main and Operating Display Functions

Details the functions and meanings of the main display and operating display for various appliance states.

Understanding Operating Status Codes

Explains codes displayed for different operational states like OFF, no demand, fan purge, ignition, and burner status.

Configuring Appliance Parameters

Parameter Adjustment Procedure

Step-by-step guide on how to access and modify appliance parameters using the control panel buttons.

Key Appliance Parameter Settings

Details specific parameters like boiler set point, installation type, pump control, and temperature settings.

Error Handling and Lockout Modes

Understanding Hard Lockout Conditions

Explains how a hard lockout occurs, requiring manual reset via the RESET button, and indicates error codes.

Freeze Protection During Lockout

Notes that freeze protection is disabled during a hard lockout, but the circulator remains operational.

NTC Sensor Resistance Table

Provides a table correlating NTC sensor resistance values with specific temperatures in Celsius and Fahrenheit.

Error Code Troubleshooting Guide

CH Supply and Return Sensor Faults

Details error codes related to CH supply/return sensor faults (S1, S2) and their possible solutions.

Flame Signal and Detection Errors

Covers errors related to no flame signal, poor flame signal, and flame detection faults, including solutions.

Gas Valve and Flue Sensor Errors

Addresses error codes for gas valve relay faults, flue sensor faults, and improper frequency, with troubleshooting steps.

Internal Component Identification

Diagram of Internal Components

Illustrates the Challenger's internal components with labels corresponding to a parts list.

List of Internal Component Part Numbers

Provides a detailed list of internal components with their part numbers for ordering.

Genuine Replacement Parts Warning

Emphasizes using only genuine Triangle Tube replacement parts for warranty and proper operation.

Front Door Replacement Parts

Front Door Assembly Diagram

Diagram illustrating the Challenger front door components and their assembly.

Front Door Part Number List

Table detailing part numbers for the front door assembly and related hardware.

Vent Components Replacement Parts

Vent Components Diagram

Illustration of Challenger vent components, including adapters and assemblies.

Vent Assembly Part Numbers

List of part numbers for various vent assemblies and the condensate drain trap assembly.

Additional Internal Component Parts

Internal Components Diagram 2

Second diagram showing more internal components like igniter, sensors, and piping.

Internal Part Number Listings

Part numbers for igniter, ignition cable, sensors, and supply/return pipes.

Blower and Gas Valve Parts

Blower and Gas Valve Diagram

Illustration of the Challenger blower and gas valve components.

Blower and Gas Valve Part Numbers

Part numbers for ignition transformer, gas valve, gas pipe, and blower assemblies.

Burner Assembly Replacement Parts

Burner Components Diagram

Diagram showing the Challenger burner assembly components.

Burner Assembly Part Number

Part number for the Challenger burner assembly.

Control Components Replacement Parts

Control Components Diagram

Illustration of Challenger control and display components.

Control Part Numbers

Part numbers for the control/display, housing, flip panel, and fuse.

Triangle Tube Additional Products

Brazed Plate Heat Exchangers

Description of Triangle Tube's Brazed Plate Heat Exchangers for various applications.

Phase III Indirect Fired Water Heaters

Details on Phase III Indirect Fired Water Heaters, including features and warranty.

Maxi-flo Pool and Spa Heat Exchangers

Information on Maxi-flo Pool and Spa Heat Exchangers, highlighting construction and sizes.

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