ACV The 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 A T I O N A N D M A I N T E N A N C E *
* I N S T A A T I O N A N D M A I N T E N A N C E *
M A N U A
M A N U A
2010-1 hallenger 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.
Combination
Boiler
Water Heater
/
and or
Date: 11/25/13
WARNING
NOTICE

PRODUCT AND SAFETY INFORMATION
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
SECTION I - PRE-INSTA ATION ITEMS
ode ompliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Boiler or Water Heater 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 and/or Water Heater
from a ommon Vent System . . . . . . . . . . . . . . . . . . 9
ommonwealth of Massachusetts Installation . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION III - APP IANCE 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 - BOI ER 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
Table of Contents
i

irculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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 - DOMESTIC PIPING
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22
Pressure Relief Valve - Standard Installations . . . . . . . . . . . . . . . . . . . . . . . 22
Temperature & Pressure (T&P) Relief Valve
- Storage Tank or SMART Installations . . . . . . . . . . . . . . . . . . 23
Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Thermal Expansion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Vacuum Breaker - Storage Tank or SMART Installations . . . . . . . . . . . . . . 24
General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Recirculation Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Storage Tank Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Setting The Thermostatic Mixing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Domestic Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27
SECTION VI - INSTA ING VENT / COMBUSTION AIR & CONDENSATE DRAIN
Installing Vent and ombustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installing ondensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29
SECTION VII - GAS PIPING
Gas Supply Piping onnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Natural Gas
Pipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Natural Gas Supply Pressure Requirements. . . . . . . . . . . . . . . . . . . 31
Natural Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Propane Gas
Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 32
Propane Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table of Contents
ii

SECTION VIII - INTERNA WIRING
General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HALLENGER Factory Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION IX - EXTERNA WIRING
Installation ompliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Line Voltage onnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ontrol Module irculator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Low Voltage onnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
H irculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DHW irculator for Optional Smart IFWH. . . . . . . . . . . . . . . . . . . . . . . . . 37
System irculator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 37
Outdoor Reset ontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-39
SECTION X - START-UP PREPARATION
heck Boiler System Water hemistry
Water pH Level 6.5 to 8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Water Total Hardness Less Than 7 Grains/Gallon . . . . . . . . . . . . . . 40
hlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Flush Boiler and Domestic System to Remove Sediment . . . . . . . . . . . . . . 40
heck and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
heck Low Water ut-Off/ H Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 41
heck for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
heck Thermostat ircuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspection of ondensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION XI - START-UP PROCEDURES
Final hecks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
HALLENGER Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
If HALLENGER Does Not Start orrectly. . . . . . . . . . . . . . . . . . . . . . . . 43
heck the HALLENGER and System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Set Boiler Maximum entral Heating ( H) Set Point Temperature . . . . . . 46
Table of Contents
iii

Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47
Set DHW Set Point Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Operation Verification - Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . 47-48
ontrol Display
Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Additional DHW Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Highfire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Lowfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Flame urrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ontrol Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Setting the Appliance Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fluctuating Water Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Error (Hard Lockout) odes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION XII - OUTDOOR RESET CONTRO
Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Adjusting Outdoor Reset urve
H Maximum Boiler Operating Temperature. . . . . . . . . . . . . . . . . 56
H Minimum Boiler Operating Temperature Setpoint (Parameter 5) . . . . . . . . 56
H Reset urve oldest Day (Parameter 6) . . . . . . . . . . . . . . . . . . 56
H Reset urve Warmest Day (Parameter 7) . . . . . . . . . . . . . . . . . 56
hanging Outdoor Reset Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Outdoor Reset urve Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTION XIII - CHECK-OUT PROCEDURES
heck-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SECTION XIV - INSTA ATION RECORD
Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
SECTIONS XV - MAINTENANCE SCHEDU E
Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Table of Contents
iv

SECTION XVI - MAINTENANCE PROCEDURES
Annual Maintenance Procedures
Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
heck Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
heck System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
lean ondensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 62
heck Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Inspect Vent and ombustion Air Piping . . . . . . . . . . . . . . . . . . . . . 62
heck Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removing Internal Flue and ondensate Pan for Inspection. . . . . . 62-63
heck Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
heck Relief Valve (s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
heck Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 64
heck ontrol Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
heck ontrol Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Perform Start-Up and heckout Procedure . . . . . . . . . . . . . . . . . . . 66
heck Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
heck ombustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
lean Boiler Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
lean Domestic Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-68
Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Handling Previously Fired ombustion hamber Insulation . . . . . 68
REP ACEMENT PARTS
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-75
PRODUCT SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Specifications Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-78
Specification Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-82
Table of Contents
v

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
WARNING
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
1

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 SME 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 alter-
ation of any factory supplied parts or from
the use of parts or fittings not specified by
ACV-Triangle Tube. If there is a conflict
or doubt about the proper installation of
the appliance or any factory supplied 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.
WARNING
WARNING
WARNING
CAUTION
DANGER WARNING
NOTICE
WARNING
WARNING
2

3
Product & Safety Information
Bacteria can develop in the domestic
water system if certain minimum water
temperatures are not maintained.
HOT WATER CAN SCA D!
Water temperature over 125ºF [52ºC] can
cause severe burns instantly or death from
scalds.
• hildren, disabled and elderly are at
highest risk of being scalded.
- Never leave them unattended in or
near shower, bathtub or sink.
- Never allow small children to use a
hot water faucet or draw their own
bath.
• To avoid any potential scald hazard or if
codes require specific water temperatures
at the hot water faucet, the installer must:
- Install the factory supplied thermo-
static mixing valve at this appliance
and ensure it is working properly
and
- Set the thermostatic mixing valve to
the lowest temperature which satis-
fies your hot water needs.
- Feel and adjust water temperature
before bathing or showering.
- Water drained from the system drain
valves may be extremely hot.
TO AVOID INJURY:
- Make sure all connections are tight.
- Direct water flow away from any person.
Protection must be taken against
excessive pressure!
TO PROTECT AGAINST EXCES-
SIVE TEMPERATURE AND PRES-
SURE
• heck if a 150 psi [10 bar] pressure
relief valve (field supplied) is installed
as recommended for standard installa-
tions or a temperature/pressure relief
valve for storage tank or A V-Triangle
Tube SMART Indirect Fired Water
Heater (I.F.W.H.) installations. (DHW
side)
• heck if the 30 psi [2 bar] pressure
relief valve supplied is installed in
the recommended location. ( H side)
• To avoid injury, install the relief
devices to comply with local code
requirements.
DANGER
DANGER
DANGER
BURN

Pre-Installation Items
4
SECTION I - Pre-Installation Items
Code Compliance
The HALLENGER is certified to both the
Boiler (ANSI Z21.13/ SA 4.9) and Water
Heater (ANSI Z21.10.3/ SA4.3) standards.
Due to the HALLENGER’s unique heat
exchanger design which incorporates two inde-
pendent copper water tube coils; one for space
heating and the other for domestic hot water,
the HALLENGER can be installed as a
Boiler or Water Heater or both. The unused
system does not have to be connected or filled.
Parameter 1 (Installation Type) will need to be
set accordingly (0= Heat and DHW, 2 = DHW
Only and 3 = Heat Only), see page 52 for
Setting Parameters.
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 CHA ENGER gas manifold and
gas controls meet the safe lighting and
other performance requirements as speci-
fied in ANSI Z21.13 standard.
Determining Product ocation
Before locating the HALLENGER check for
convenient locations to:
- Heating system piping
- Domestic water supply 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
WARNING

Pre-Installation Items
Boiler or Water Heater Replacement
If the HALLENGER is replacing an existing
boiler and/or hot water heater system, the fol-
lowing items should be checked and corrected
prior to installation:
- Boiler and domestic piping leaks and
corrosion.
- Proper location and sizing of the expan-
sion tank on the boiler heating loop.
Proper location and sizing of the ther-
mal expansion tank (if used) on the
domestic supply line.
- If applicable, amount and quality of
propylene glycol.
- Vent condition
Clearances
The HALLENGER is approved for follow-
ing clearance to combustibles:
- Top panel - 12 inches [30.5 cm]
- Front - 0 inches
- Bottom panel - 12 inches [30.5 cm]
- Rear - 0 inches
- Right side - 4 inches [10.2 cm]
- Left side - 1.5 inches [3.8 cm]
- Boiler and Domestic Piping - 0.25 inch-
es [0.6 cm]
- Reference the appropriate vent supple-
ment for venting clearance requirements.
To provide serviceability to the appli-
ance it is recommended that the follow-
ing clearances be maintained:
Top panel - 24 inches [61 cm].
Front - 24 inches [61 cm].
Bottom panel - 24 inches [61 cm].
Rear - 0 inches
Sides - 6 inches [15.2 cm]
When maintaining the approved clear-
ance or less than recommended service
clearances, some product labeling may
become hidden and unreadable.
If the enclosure in which the appliance is
installed is less than 45 cubic feet [1.3
m3], the space must be ventilated. See
page 8 Ventilation Air Requirements for
guidelines and requirements.
When installing the CHA ENGER in a
confined space, sufficient air must be pro-
vided to allow, under normal operating con-
ditions, proper air flow around the product
to maintain ambient temperatures within
safe limits to comply with the National Fuel
Gas Code NFPA 54 - Standard.
Residential Garage Installations
When installing the HALLENGER in a resi-
dential garage, the following special precautions
per NFPA 54/ANSI Z223.1 must be taken:
- Mount the appliance a minimum 18
inches [458 mm] above the floor level
of the garage. Ensure the burner and
ignition devices / controls are no less
than 18 inches [458 mm] above the
floor level.
- Locate or protect the appliance in a
manner so it cannot be damaged by a
moving vehicle.
BEST PRACTICE
NOTICE
WARNING
WARNING
5

6
Pre-Installation Items
Boiler Freeze Protection Feature
The boiler control has a freeze protection fea-
ture. This feature monitors the boiler supply
water temperature and responds as follows when
no call for heat is present:
- 42ºF [6ºC] Boiler circulator and burner are
ON.
- 50ºF [10ºC] Boiler circulator and burner are
OFF.
The boiler freeze protection feature is
disabled during a hard lockout, (burner
does not operate) however the CH circu-
lator will operate.
The boiler freeze protection feature is
designed to protect the boiler, installed
in a primary/secondary piping arrange-
ment. See Section IV for primary/sec-
ondary piping examples. See Section X
for antifreeze guidelines.
CAUTION
CAUTION

Combustion Air and Venting
7
SECTION II- Combustion Air and
Venting
Combustion Air Contamination
If the CHA ENGER combustion air
inlet is located in any area likely to cause
or contain contamination, or if products,
which could contaminate the air cannot
be removed, the combustion air must be
repiped and terminated to another loca-
tion. Contaminated combustion air will
damage the appliance and its burner sys-
tem, resulting in possible severe personal
injury, death or substantial property
damage.
Do not operate a CHA ENGER if the
combustion air inlet is located near a
laundry room or pool facility. These
areas will always contain hazardous con-
taminants.
Pool, laundry products, common house-
hold and hobby products often contain
fluorine or chlorine compounds. When
these chemicals pass through the burner
and vent system, they can form strong
acids. These acids can create corrosion
of the heat exchanger, burner compo-
nents and vent system, causing serious
damage and presenting a possible threat
of flue gas spillage or water leakage into
the surrounding area.
Please read the information listed below.
If contaminating chemicals are located
near the area of the combustion air inlet,
the installer should pipe the combustion
air inlet to an area free of these chemi-
cals per SECTION VI of this installation
manual.
Potential contaminating products
- Spray cans containing chloro/fluorocar-
bons
- Permanent Wave Solutions
- hlorinated wax
- hlorine - based swimming pool chem-
icals / cleaners
- alcium hloride used for thawing ice
- Sodium hloride used for water soft-
ening
- Refrigerant leaks
- Paint or varnish removers
- Hydrochloric acid / muriatic acid
- ements and glues
- Antistatic fabric softeners used in
clothes dryers
- hlorine-type bleaches, detergents, and
cleaning solvents found in household
laundry rooms
- Adhesives used to fasten building prod-
ucts and other similar products
Areas likely to contain these products
- Dry cleaning / laundry areas and estab-
lishments
- Beauty salons
- Metal fabrication shops
- Swimming pools and health spas
- Refrigeration Repair shops
- Photo processing plants
- Auto body shops
- Plastic manufacturing plants
- Furniture refinishing areas and estab-
lishments
- New building construction
- Remodeling areas
- Garages with workshops
WARNING
WARNING

8
Combustion Air and Venting
Ventilation Air Requirements
For installations, involving only the HAL-
LENGER, in which the minimum service
clearances are maintained as listed on page 5,
no ventilation openings are required.
For installations with less than the minimum
service clearances involving only the HAL-
LENGER, the space / enclosure must provide
two openings for ventilation. The openings
must be sized to provide 1 square inch [6
square centimeters] of free area per 1,000
BTUH [0.3 Kw] of appliance input. The open-
ings shall be placed 12 inches [30.5 cm] from
the top of the space and 12 inches [30.5 cm]
from the floor of the space.
For installations in which the HALLENGER
shares the space with air movers (exhaust fan,
clothes dryers, fireplaces, etc.) and other com-
bustion equipment (gas or oil) the space must
be provided with adequate air openings to pro-
vide ventilation and combustion air to the
equipment. To properly size the ventilation /
combustion air openings, the installer must
comply with the National Fuel Gas ode
NFPA 54, ANSI Z223.1 for installations in the
U.S or AN/ SA B149.1 for installations in
anada/
The space must be provided with venti-
lation / combustion air openings proper-
ly sized for all make-up air requirements
(exhaust fans, clothes dryers, fireplaces,
etc.) and the total input of all appliances
located in the same space as the CHA -
ENGER. The input of a CHA -
ENGER which uses combustion air
directly from the outside, is excluded
thus additional free area for the open-
ings is not required. Failure to provide
or properly size the openings could
result in severe personal injury, death or
substantial property damage.
Combustion Air and Vent Piping
The HALLENGER requires a ategory IV
venting system, which is designed for pressur-
ized venting and condensate.
The HALLENGER is certified as Direct Vent
(sealed combustion) appliance. A Direct Vent
appliance utilizes uncontaminated outdoor air
(piped directly to the appliance) for combustion.
Install combustion air and vent pipe as
detailed in the CHA ENGER PVC,
CPVC,PP and SS Vent Supplement 2013-
38 included in the appliance installation
envelope. Refer to instructions for parts
list and method of installation.
Contact ACV-Triangle Tube for other
venting options including PVC Concen-
tric Vent/Air Termination Supplement
2008-04 or CHA ENGER Concentric
Vent/Air System Supplement 2011-60.
Refer to these instructions for parts list
and method of installation.
Verify installed combustion air and vent
piping are sealed gas tight and meet all
provided instructions and applicable
codes, failure to comply will result in
severe personal injury of death.
WARNING
NOTICE
DANGER
NOTICE

9
Combustion Air and Venting
Removal of an Existing Boiler and or Water
Heater from a Common Vent System
When an existing boiler and/or water
heater is removed from a common vent-
ing system, the common venting system is
likely to be too large for proper venting of
the remaining appliances. At the time of
removal of an existing boiler and/or water
heater, the following steps shall be fol-
lowed with each appliance remaining
connected to the common venting system
placed in operation, while the other appli-
ances remaining connected to the com-
mon venting system are not in operation.
1. Seal any unused openings in the common
venting system.
2. Visually inspect the venting system for
proper size and horizontal pitch and deter-
mine there is no blockage or restriction,
leakage, corrosion and other deficiencies
which could cause an unsafe condition.
3. Insofar as is practical, close all building
doors and windows and all doors between
the space in which the appliances remain-
ing connected to the common venting sys-
tem are located and other spaces of the
building. Turn on clothes dryers and any
appliance not connected to the common
venting system. Turn on any exhaust fans,
such as range hoods and bathroom
exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust
fan. lose fireplace dampers.
4. Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the draft hood relief
opening after 5 minutes of main burner
operation. Use the flame of a match or can-
dle, or smoke from a cigarette, cigar or pipe.
6. After it has been determined that each
appliance remaining connected to the com-
mon venting system properly vents when
tested as outlined above, return doors, win-
dows, exhaust fans, fireplace dampers, and
any other gas-burning appliance to their
previous condition of use.
7. Any improper operation of the common
venting system should be corrected so the
installation conforms with the National
Fuel Gas ode, ANSI Z223.1/NFPA 54
and/or AN/ SA B149.1, Installation
codes. When resizing any portion of the
common venting system, the common
venting system should be resized to
approach the minimum size as determined
using the appropriate tables in Part II of the
National Fuel Gas ode ANSI
Z223.1/NFPA 54 and/or AN/ SA
B149.1, Installation codes.
Do not install the CHA ENGER into a
common vent with other gas or oil appli-
ances. This may cause flue gas spillage or
appliance malfunction, resulting in possi-
ble severe personal injury, death or sub-
stantial property damage.
DANGER
BEST PRACTICE

10
Combustion Air and Venting
For direct-vent appliances, mechanical-
vent heating appliances or domestic hot
water equipment, where the bottom of the
vent terminal and the air intake is installed
below four feet above grade the following
requirements must be satisfied:
1. If there is not one already present, on
each floor level where there are bed-
room(s), a carbon monoxide detector
and alarm shall be placed in the living
area outside the bedroom(s). The car-
bon monoxide detector shall comply
with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall also
be located in the room that houses the
appliance or equipment and shall:
a. Be powered by the same electrical
circuit as the appliance or equip-
ment such that only one service
switch services both the appliance
and the carbon monoxide detector;
b. Have battery back-up power;
c. Meet ANSI/UL 2034 Standards and
comply with NFPA 720 (2005
Edition); and
d. Have been approved and listed by
the Nationally Recognized Testing
Laboratory as recognized under 527
MR.
3. A Product-approved vent terminal must
be used, and if applicable, a Product-
approved air intake must be used.
Installation shall be in strict compliance
with the manufacturer’s instructions. A
copy of the installation instructions
shall remain with the appliance or
equipment at the completion of the
installation.
4. A metal or plastic identification plate
shall be mounted at the exterior of the
building, four feet directly above the
location of vent terminal. The plate
shall be of sufficient size to be easily
read from a distance of eight feet away,
and read “Gas Vent Directly Below”.
Installer must provide tag identification
plate and ensure the lettering meets code
requirements.
For direct-vent appliances, mechanical-
vent heating appliances or domestic hot
water equipment, where the bottom of the
vent terminal and the air intake are installed
above four feet above grade the following
requirements must be satisfied:
1. If there is not one already present, on
each floor level where there are bed-
room(s), a carbon monoxide detector
and alarm shall be placed in the living
area outside the bedroom(s). The car-
bon monoxide detector shall comply
with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall:
a. Be located in the room that houses
the appliances or equipment;
b. Be either hard wired or battery
powered or both; and
c. Shall comply with NFPA 720 (2005
Edition)
3. A Product-approved vent terminal must
be used, and if applicable, a Product-
approved air intake must be used.
Installation shall be in strict compliance
with the manufacturer’s instructions. A
copy of the installation instructions
shall remain with the appliance or
equipment at the completion of the
installation.
NOTICE
Commonwealth of Massachusetts Installations Only

11
Appliance Preparations
SECTION III - Appliance Preparations
Shipping and Handling Instructions
To avoid damage to gas fitting and piping at
bottom of appliance, appliance must be
shipped with rear or back of appliance
(longest box length) laying down flat.
The HALLENGER is generally easier to
handle and maneuver once removed from the
shipping carton.
To remove the shipping carton:
Use care not to lift the appliance from
piping or damage can occur. Use care
not to drop or bump the appliance as
damage to the appliance may result.
1. Remove any shipping straps and the top
shipping carton.
2. arefully lift the appliance out of the carton.
3. Discard all packing materials.
Wall Mounting Installation
Prior to mounting appliance install pip-
ing support bracket according to
instructions on page 13.
The HALLENGER should be wall mounted
using the bracket provided with the appliance
and is not designed for floor installation. If
floor installation is required an optional floor
stand part number PSSTND04 is available
through A V-Triangle Tube. Appliance is not
to be installed on carpeting.
The wall used for mounting the CHA -
ENGER must be vertically plumb and
capable of supporting a minimum 110
pounds [50 kg]. Failure to comply with
these requirements could result in per-
sonal injury, death or substantial prop-
erty damage.
NOTICE
CAUTION
NOTICE
WARNING
Fig. 1: Optional Floor Stand Assembly,
Part Number: PSSTND04

12
Appliance Preparations
Wall Mounting Guidelines
1. The wall-mounting bracket is designed for
stud spacing of 12 inch [30.5 cm] or 16
inch [40.6 cm] on centers. For unconven-
tional stud spacing, a solid / secure mount-
ing surface must be provided for installa-
tion of the bracket.
2. For applications using wood studs, install
the bracket using the lag screws provided
with the appliance. Ensure both lag screws
are installed securely in the studs.
3. For applications using metal studs, install the
bracket to the studs using 3/16” [5 mm] tog-
gle bolts and washers (provided by others)
4. DO NOT mount or attempt to mount the
wall bracket to hollow sheet rock or lath
walls using anchors. Only install appliance
to studs or equivalent wood structure.
5. For applications using solid walls (rock,
concrete, brick, cinder block, etc.), install
the wall bracket using anchors (double
expansion shields) bolts and washers pro-
vided with the appliance.
6. The appliance is too heavy and bulky for a
single person to lift and attempt to mount; a
minimum of 2 people is required for
mounting the appliance.
Use extreme care not to drop the appli-
ance or cause bodily injury while lifting
or mounting the appliance onto the
bracket. Once mounted verify that the
appliance is securely attached to the
bracket and wall. Failure to comply with
the above guidelines could result in prop-
erty damage, personal injury or death.
Stud Walls -Installation
1. Locate the studs in the general area of the
appliance placement.
2. Place the wall-mounting bracket on the
wall centering the mounting slots with the
stud centers and ensuring the upper edge of
the bracket is away from the wall.
3. Level the bracket, while maintaining it’s cen-
tering with the studs and use a pencil to mark
the location of the mounting slots/holes.
4. Remove the bracket from the wall and drill
1/4” [6 mm] diameter hole by 3” [76 mm]
deep positioned in the center of each mark.
For applications using metal studs and
3/16” [5 mm] toggle bolts, drill the
required clearance hole.
5. Reposition the bracket onto the wall and
align mounting slots/holes. Insert the two
lag screws provided (or toggle bolts for
metal studs) through the mounting
slots/holes and loosely tighten.
6. Level bracket and tighten screws (bolts for
metal studs) securely making sure not to over-
tighten to avoid damaging drywall or plaster.
Wall Bracket Installation - Solid Walls
1. Locate the general area of the appliance
placement.
2. Place the wall-mounting bracket on the
wall ensuring the upper edge of the bracket
is away from the wall.
3. Level the bracket and use a pencil to mark
the location of the mounting slots/holes on
the wall.
4. Remove the bracket from the wall and drill
a 5/8” [16 mm] diameter hole by 1-3/8” [35
mm] deep positioned in the center of each
mark.
5. Install the anchors (provided) flush or
slightly recessed in the drilled holes with
threaded side facing down.
6. Reposition the bracket on the wall and
align mounting slots/holes. Insert the two
bolts with washers (provided) through the
mounting slots/holes and loosely tighten.
7. Level bracket and tighten bolts securely.
NOTICE

13
Appliance Preparations
Appliance Mounting
1. Obtain assistance in lifting the appliance
onto the wall bracket.
2. Install the appliance making sure the appli-
ance mounting lip located along the upper
edge of the rear jacket panel engages the
wall-mounting bracket. Ensure the appli-
ance is seated properly and is secure.
Piping Support Bracket
Appliance must be installed using the sup-
plied copper fittings and piping support
bracket. DO NOT braze directly to cop-
per appliance pipes or damage may result
to internal parts (gaskets and flow switch).
1. Pre-install the 4 brass compression fittings
into the piping support bracket as shown in
Fig. 4, page 15. Use retaining clips to hold
fittings in place.
Apply pipe joint compound suitable for
potable water systems to the compres-
sion ferrule and compression nut threads
of all brass fittings before installation.
Install appliance pipes into the fittings
until bottom of hex on gas pipe fitting
rests against the top of the piping sup-
port bracket before tightening any com-
pression nuts. Do not over tighten com-
pression nuts. If fitting leaks loosen com-
pression nut first and then retighten.
2. Prior to mounting the appliance on the wall
and with the rear or back of appliance lay-
ing flat, slip the appliance piping into the
fittings until bottom of hex on gas pipe fit-
ting rests against the top of the piping sup-
port bracket before tightening any com-
pression nuts.
3. Tighten all fittings to appliance piping
connections with two wrenches.
Use a two wrench method when tighten-
ing piping near the appliance and its pip-
ing connections. Use one wrench to pre-
vent the appliance connections from
turning and the second to tighten adja-
cent piping. Failure to support the appli-
ance piping connections could damage
piping.
4. Once appliance is mounted according to
Appliance Mounting instructions on this
page, secure piping support bracket to wall
with hardware supplied.
BEST PRACTICE
CAUTION
WARNING
Lag Screw
(Stud Wall)
Bolts with
Washer
(Solid Wall)
Wall Anchors
(Solid Wall Only)
Optional Concentric
Vent/Air Adapter
Fig. 2: Wall Mounting The CHA ENGER

14
Boiler Piping
SECTION IV - Boiler Piping
General Piping Requirements
- All plumbing must meet or exceed all local,
state and national plumbing codes.
- Support all piping using hangers. DO NOT
support piping by the appliance or its com-
ponents.
- Use isolation valves to isolate system com-
ponents.
- Install unions for easy removal of the
HALLENGER from the system piping.
Use a two wrench method when tighten-
ing piping onto the appliance connec-
tions. Use one wrench to prevent the
appliance piping from turning / twisting.
Failure to support the appliance piping
and connections in this manner could
cause damage to the appliance and its
components.
Pressure Relief Valve (PRV)
1. The HALLENGER has a ASME
Maximum Allowable Working Pressure of
43.5 PSI [3 bar]. The appliance is supplied
with a 30 psi [2 bar] pressure relief valve
and must be piped using the PRV connec-
tion as shown in Fig. 3 page 15.
2. To avoid potential water damage to the sur-
rounding area or potential scalding hazard
due to the operation of the relief valve, the
discharge piping:
- Must be connected to the discharge out-
let of the relief valve and directed to a
safe place of disposal.
- Length should be as short and direct as
possible. The size of the discharge line
should not be reduced, maintain the
same size as the outlet of the relief valve.
- Should be directed downward towards
the floor at all times. The piping should
terminate at least 6 inches [153 mm]
above any drain connection to allow
clear visibility of the discharge.
- Should terminate with a plain end, not
with a threaded end. The material of the
piping should have a serviceable temper-
ature rating of 250ºF [121º ] or greater.
- Should not be subject to conditions
where freezing could occur.
- Should not contain any shut-off valves
or obstructions. No shut-off valve
should be piped between the appliance
and relief valve.
Failure to comply with the guidelines on
installing the pressure relief valve and dis-
charge piping can result in personal injury,
death or substantial property damage.
ow Water Cut Off / CH Pressure Sensor
The ow Water Cut Off ( WCO) only
applies for space heating. Operation of
the WCO does not prevent a domestic
hot water call for heat.
- The HALLENGER is equipped with a fac-
tory installed pressure sensor type LW O.
- The minimum operating entral Heating
( H) system pressure is 7 psig [0.5 bar].
- If H System pressure is below 7 psig [0.5
bar] the main display will flash a soft lockout
of “LOP” followed by the pressure reading.
Once H system pressure is increased above
7 psi [0.5 bar] normal boiler operation will be
restored. If the appliance is installed as domes-
tic hot water heater only, set parameter 1
(installation type) to 2 (domestic only) to
eliminate the “LOP” error in the main display,
see page 52 for setting parameters.
- heck local codes if a LW O is required. If
so, determine if this device meets their
requirements.
WARNING
WARNING
NOTICE