TriangleTube Challenger Manual

Warranty Registration ard 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 HALLENGER, 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.

* 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

2011-38 hallenger Boiler 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 neighbor’s phone. Follow the gas

supplier’s 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

Date: 9/17/2014

ARNING

NOTICE

PRODUCT AND SAFETY INFORMATION

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

SECTION I - PRE-INSTALLATION ITEMS

ode ompliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Boiler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

learances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Boiler Freeze Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION II - COMBUSTION AIR AND VENTING

ombustion Air ontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ventilation Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

ombustion Air and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Removal of an Existing Boiler from a ommon Vent System . . . . . . . . . . 9

ommonwealth of Massachusetts Installation . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION III - APPLIANCE PREPARATIONS

Shipping and Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Wall Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Wall Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Stud Walls - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wall Bracket Installation - Solid Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Appliance Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Piping Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION IV - BOILER PIPING

General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Low Water ut Off/ H Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Additional Limit ontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Boiler System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Expansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

losed-Type Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

irculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table of Contents

Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

System Piping - Zone irculators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Near Boiler Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

System Piping - Radiant Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - SMART Indirect Fired Water Heater (I.F.W.H). . . . . . . . . 19

System Piping - Special Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

entral Heating ( H) System Piping Diagrams. . . . . . . . . . . . . . . . . . . . . . 20

SECTION V - INSTALLING VENT / COMBUSTION AIR & CONDENSATE DRAIN

Installing Vent and ombustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Installing ondensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22

SECTION VI - GAS PIPING

Gas Supply Piping onnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Natural Gas

Pipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Natural Gas Supply Pressure Requirements. . . . . . . . . . . . . . . . . . . 24

Natural Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Propane Gas

Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 25

Propane Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION VII - INTERNAL WIRING

General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

HALLENGER Factory Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION VIII - EXTERNAL WIRING

Installation ompliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Line Voltage onnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

ontrol Module irculator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Low Voltage onnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

H irculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

DHW irculator for Optional Smart IFWH. . . . . . . . . . . . . . . . . . . . . . . . . 30

System irculator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 30

Outdoor Reset ontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-32

Table of Contents

SECTION IX - START-UP PREPARATION

heck Boiler System Water hemistry

Water pH Level 6.5 to 8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Water Total Hardness Less Than 7 Grains/Gallon . . . . . . . . . . . . . . 33

hlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Flush Boiler System to Remove Sediment. . . . . . . . . . . . . . . . . . . . . . . . . . 33

heck and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

heck Low Water ut-Off/ H Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 34

heck for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

heck Thermostat ircuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Inspection of ondensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 35

SECTION X - START-UP PROCEDURES

Final hecks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

HALLENGER Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

If HALLENGER Does Not Start orrectly. . . . . . . . . . . . . . . . . . . . . . . . 36

heck the HALLENGER and System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-37

Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Set Boiler Maximum entral Heating ( H) Set Point Temperature . . . . . . 39

Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-40

ontrol Display

Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Highfire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Lowfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Flame urrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

ontrol Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Setting the Appliance Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Error (Hard Lockout) odes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SECTION XI - OUTDOOR RESET CONTROL

Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Table of Contents

iii

Adjusting Outdoor Reset urve

H Maximum Boiler Operating Temperature. . . . . . . . . . . . . . . . . 48

H Minimum Boiler Operating Temperature Setpoint (Parameter 5) . . . . . . . . 48

H Reset urve oldest Day (Parameter 6) . . . . . . . . . . . . . . . . . . 48

H Reset urve Warmest Day (Parameter 7) . . . . . . . . . . . . . . . . . 48

hanging Outdoor Reset Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Outdoor Reset urve Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

SECTION XII - CHEC -OUT PROCEDURES

heck-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

SECTION XIII - INSTALLATION RECORD

Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTIONS XIV - MAINTENANCE SCHEDULE

Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SECTION XV - MAINTENANCE PROCEDURES

Annual Maintenance Procedures

Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

heck Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

heck System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

lean ondensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 54

heck Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Inspect Vent and ombustion Air Piping . . . . . . . . . . . . . . . . . . . . . 54

heck Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Removing Internal Flue and ondensate Pan for Inspection. . . . . . 54-55

heck Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

heck Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

heck Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 56-57

heck ontrol Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

heck ontrol Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Perform Start-Up and heckout Procedure . . . . . . . . . . . . . . . . . . . 58

heck Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

heck ombustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Table of Contents

lean Boiler Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Handling Previously Fired ombustion hamber Insulation . . . . . 60

REPLACEMENT PARTS

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-67

PRODUCT SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Specification Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-72

Table of Contents

Indicates the presence of a hazardous

situation which, if ignored, will result

in death, serious injury or substantial

property damage.

Indicates a potentially hazardous situ-

ation which, if ignored, can result in

death, serious injury or substantial

property damage.

Indicates a potentially hazardous situ-

ation which, if ignored, may result in

minor injury or property damage.

Indicates special instructions on instal-

lation, operation or maintenance,

which are important to equipment but

not related to personal injury hazards.

Indicates recommendations made by

ACV-Triangle Tube for the installers

which will help to ensure optimum

operation and longevity of the equip-

ment.

NOTICE

ARNING

CAUTION

BEST PRACTICE

DANGER

The following terms are used throughout this manual to bring attention to the presence of

potential hazards or important information concerning the product.

ACV-Triangle Tube reserves the right to modify the technical specifications and compo-

nents of its products without prior notice.

NOTICE

Definitions

Product & Safety Information

Do not use this appliance if any part has

been under water. Immediately call a

qualified service technician to inspect

the appliance and to replace any part of

the control system which has been

under water.

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 supplier’s instructions.

- If you cannot reach your gas suppli-

er, call the fire department.

Installation and service must be per-

formed by a qualified installer, service

agency or the gas supplier.

Should overheating occur or the gas

supply fails to shut off, turn OFF the

manual gas control valve external to the

appliance.

DO NOT add cold make up water when

the appliance is hot. Thermal shock can

cause potential cracks in the heat

exchanger.

When servicing the appliance:

- Avoid electrical shock by discon-

necting the electrical supply prior to

performing maintenance.

Qualified Installer:

Prior to installing this product read all instruc-

tions included in this manual and all accompa-

nying manuals/documents with this appliance.

Perform all installation steps required in these

manuals in the proper order given. Failure to

adhere to the guidelines within these manuals

can result in severe personal injury, death or

substantial property damage.

Homeowner:

- This product should be maintained /

serviced and inspected annually by a

qualified service technician.

- This manual is intended for use by a

qualified Installer/Service Technician.

Please reference the appliance model num-

ber and the serial number from the rating

label, on the right panel when inquiring

about service or troubleshooting.

ACV-Triangle Tube accepts no liability

for any damage, injury or loss of life

resulting from incorrect installation, from

alteration of any factory supplied parts or

from the use of parts or fittings not speci-

fied by ACV-Triangle Tube. If there is a

conflict or doubt about the proper instal-

lation of the appliance or any factory sup-

plied or replacement parts please contact

ACV-Triangle Tube Technical Support.

A byproduct of any gas fired appliance

(stove, fire place, clothes dryer, water

heater, furnace, boiler, etc.) is carbon

monoxide. In the absence of any state or

local codes requiring the installation of

carbon monoxide detector and alarms,

ACV-Triangle Tube’s recommendation

is to follow the requirements of the

Commonwealth of Massachusetts, see

page 10.

ARNING

CAUTION

DANGER ARNING

NOTICE

ARNING

Product & Safety Information

Protection must be taken against

excessive pressure!

TO P OTECT AGAINST EXCES-

SIVE TEMPE ATU E AND P ES-

SU E

• Check if the 30 psi 2 bar] pressure

relief valve supplied is installed in

the recommended location.

• To avoid injury, install the relief

devices to comply with local code

requirements.

Parameter 1 (Installation Type) must

be set to 3 (Heating Only) or 1

(Heating + SMA T I.F.W.H.) for all

CHALLENGE Solo Boilers (Heat

Only, CC50s, CC85s, CC105s, CC125s

and CC150s), see page 44 for setting

Parameters.

DANGER

NOTICE

Pre-Installation Items

SECTION I - Pre-Installation Items

Code Compliance

The HALLENGER is certified to the Boiler

(ANSI Z21.13/ SA 4.9) standard.

This appliance must be installed in accordance

to the following:

- All applicable local, state, national and

provincial codes, ordinances, regula-

tions and laws.

- For installations in Massachusetts, code

requires the appliance to be installed by

a licensed plumber or gas fitter, and if

antifreeze is utilized, the installation of

a reduced pressure backflow preventer

device is required in the boiler’s cold

water fill or make up water supply line.

- For installation in Massachusetts all direct

vented appliances must comply with the

guidelines as outlined on page 10.

- Massachusetts Plumbing Board Product

Approval ode # is I-0111-219 for the

HALLENGER.

- The National Fuel Gas ode NFPA54/

ANSI Z223.1 - Latest edition.

- National Electric ode ANSI/NFPA 70.

- For installations in anada -“Installation

ode for Gas Burning Equipment”

AN/ SA B149.1 anadian Electrical

ode Part 1 SA 22.1.

- Standards for ontrols and Safety

Devices for Automatically Fired Boilers,

ANSI/ASME SD-1, when required.

The CHALLENGER gas manifold and

gas controls meet the safe lighting and

other performance requirements as speci-

fied in ANSI Z21.13 standard.

Determining Product Location

Before locating the HALLENGER check for

convenient locations to:

- Heating system piping

- Venting

- Gas supply piping

- Electrical service

Ensure the appliance location allows the com-

bustion air and vent piping to be routed directly

through the building and terminate properly in

the same pressure zone outside with a minimum

amount of length and bends.

Ensure the area chosen for the installation of the

HALLENGER is free of any combustible

materials, gasoline and other flammable liquids.

Failure to remove or maintain the area

free of combustible materials, gasoline

and other flammable liquids or vapors

can result in severe personal injury,

death or substantial property damage.

Ensure the HALLENGER and its controls

are protected from dripping or spraying water

during normal operation or service.

The HALLENGER should be installed in a

location so that any water leaking from the

appliance, piping connections or relief valve

will not cause damage to the surrounding area

or any lower floors in the structure. When such

location cannot be avoided, it is recommended

that a suitable drain pan, adequately drained, be

installed under the appliance. The pan must not

restrict combustion air flow.

NOTICE

ARNING

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