Challenge Yachts Challenger 5L Portable User manual

Continuous Flow Hot Water Heaters
For Challenger LPG Water
Heaters:
Challenger 5L Portable
Challenger 5L
Challenger 6L
Challenger 6L Stainless Steel
Challenger 7L
Challenger 8L
Challenger 10L
Challenger 12L
Challenger 16L
Operating Manual

Challenger Water Heater Operating Instructions 1 |P a g e
Important
This appliance must be installed in accordance with:
Manufacturers installation instructions
Current AS/NZS 3500, AS/NZS 5601.1 and G12/AS1
For use with Natural Gas or Universal LPG as indicated on the
appliance.
Not suitable as a spa or swimming pool heater.
Not suitable for commercial or solar applications.
Appliance must be installed, commissioned and serviced by an
authorised person, being in New Zealand a licensed gasfitter, in
accordance with these instructions and all applicable local rules and
regulations.
Warning
Improper installation, adjustment, alteration, service and maintenance
can cause property damage, personal injury or loss of life
For more information about buying, using and servicing a Challenger
Appliance call: 09 8200 500
Challenge Yacht Limited
20 Saunders Place, Avondale, Auckland
PO BOX 68480, Wellesley Street, Auckland 1141

Challenger Water Heater Operating Instructions 2 |P a g e
Table of Contents
Limited Warranty...............................................................................................3
Installation Guide..............................................................................................5
Before Installation ...............................................................................................5
Appliance Location..............................................................................................5
General Safety Information.................................................................................6
Connections and Fittings.....................................................................................6
Commissioning ...................................................................................................7
Operation Guide................................................................................................8
About your Califont Water Heater.......................................................................8
Warning about Hot Water....................................................................................8
Safety and Important Messages .........................................................................9
General Information ............................................................................................10
Trouble Shooting ..............................................................................................11
Proof of Purchase.............................................................................................12
Installer Details .................................................................................................12
Diagram 1...........................................................................................................13
Diagram 2...........................................................................................................14
Diagram 3...........................................................................................................14
Diagram 4...........................................................................................................14
Water Heater Accessories................................................................................15

Challenger Water Heater Operating Instructions 3 |P a g e
Limited Warranty
Challenger Califont Water Heaters
Challenge Yachts Warranty Summary
This warranty is applicable to all Challenger Califont Water Heaters
manufactured from ____ onwards. All terms of the warranty, subject to
the conditions below, are effective from the date of purchase. Proof of
purchase will be required.
General Warranty Terms
Challenge Yachts reserves the right to make modifications and change
specifications and its parts without notice.
For the purposes of the Consumer Guarantees Act 1993, Challenge
Yachts only guarantees the availability of repair facilities and spare parts
for the express warranty periods recorded in the ‘Warranty Summary’.
Warranty Terms and Conditions
1. All terms of this warranty are effective from the date of purchase.
The attending service person reserves the right to verify this by
requesting a copy of the certificate of compliance prior to
commencement of any warranty work. Certificate of compliance
must be issued by the installer by law in New Zealand
2. All Challenger products must be installed, commissioned, serviced,
repaired and removed in accordance with the manufacturer’s
installation instructions, local regulations, and municipal building
codes by persons authorised by local regulations to do so
3. All appliances must be operated and maintained in accordance
with the manufacturers operating instructions
4. The warranty applies only to the components supplied by
Challenge Yachts. It does not apply to components supplied by
others, such as, isolating valves, pipe work, and where applicable
flue systems supplied by others, but not limited to these.
5. Where a failed component is replaced under warranty, the balance
of the original warranty will remain effective
6. Challenge Yachts reserve the right to transfer functional
components from defective appliances if they are suitable
7. Challenge Yachts reserve the right to have the installed product
returned to a designated service centre for repair

Challenger Water Heater Operating Instructions 4 |P a g e
Warranty Exclusions
The following exclusions may cause the warranty to become void and
will result in a service charge and costs of parts (if required).
1) Accidental damage and acts of God
2) Failure due to abuse or misuse, improper maintenance or improper
storage
3) Failure due to incorrect or unauthorised installations
4) Failure or damage caused by alterations, service or repair work
carried out by persons other than Challenge Yachts service persons
or service centres
5) Where it is found that there is no fault with the appliance and the
issue is related to the installation or is due to the failure of gas supply
6) Subject to any statutory provisions to the contrary, Challenge Yachts
does not accept: a. Liability for consequential damage or any
incidental expenses resulting from any breach of
warranty
b. Claims for damage to building or any other
consequential loss either directly or indirectly due
to leaks from the appliance or any other faults
Distributed by Challenge Yachts Ltd
PO Box 68 480 Wellesley Street • Auckland New
Zealand
Phone [phone] • Fax [phone]
Email [email protected]
www.challengeyachts.com

Challenger Water Heater Operating Instructions 5 |P a g e
Installation Guide
Before Installation
Check for damage: Unpack the appliance and check for damage.
DO NOT install any damaged items
Check components and gas type: Check all components have
been supplied and that you have the correct gas type
Reach these instructions: Get an overview of the steps required
before starting that installation. Failure to follow these instructions
could cause a malfunction of the appliance. This could result in
serious injury and property damage
Check your water flow: There are minimum and maximum water
flow requirements for each of the Challenger Water Heaters
models. Please refer to the specifications displayed on the side of
your appliance
Appliance Location
The appliance MUST BE mounted on a vertical structure with the water
and gas connections on the underside pointing downwards.
The appliance MUST BE placed as close as practicable to the most
frequently used hot water outlet or outlets to reduce the delay time for
hot water delivery. Alternatively multiple appliances can be strategically
placed to serve outlets with minimal delay time
All appliances MUST BE installed to ensure access can be gained
without hazard or undue difficulty for maintenance and servicing.
Sufficient clearances shall allow access and removal of all serviceable
components.
Appliances should not be mounted more than 2.5m above the ground or
floor level unless the customer can arrange permanent and safe access,
or can provide another means of safe access.

Challenger Water Heater Operating Instructions 6 |P a g e
General Safety Information
Securing the Challenger Califont Water Heater
The wall or structure on which the units are mounted MUST BE capable
of supporting the weight of the appliance and associated pipe work.
Ensure that suitable fixing screws or bolts are used to secure the unit to
the wall, in accordance with AS/NZS 5601 section 6. Wooden plugs
should not be used.
The appliance can be mounted directly against the wall or structure.
There is no need to use non-combustible sheeting between the
appliance back panel and the wall or structure for the purposes of
meeting the temperature hazard requirements of AS/NZS 5601.
Pipe Sizing
If the gas pipe sizing is insufficient the appliance won’t perform properly.
Gas pipe sizing must consider the gas input into this appliance as well
as other gas appliances in the premises.
Water pipe sizing and layout should be performed in accordance with
AS/NZS 3500.
All hot water pipe work should be insulated to optimise performance and
energy efficiency.
Connections and Fittings
A non-return valve is not required unless required by local regulations.
Purge gas and cold water supply lines to remove air and swarf before
final connection. Swarf in the gas or water supplies may cause damage,
a common problem, which is not covered by warranty.

Challenger Water Heater Operating Instructions 7 |P a g e
Commissioning
AS/NZS 5601.1, clauses 2.6.8 and 6.11.2 states that every part of a gas
installation shall be commissioned prior to initial use. It is the installer’s
responsibility to ensure all current AS/NZS 5601 requirements are met.
The appliance must be tested after installation. Ensure that the building
occupants do not have access to hot water outlets during this procedure.
If the appliance cannot be adjusted to perform correctly call Challenge
Yachts (09 8200 500) for assistance.
Steps to commissioning a Challenger Califont Water Heater
1) Purge water pipes and gas line
Before final connection of the water heater purge the gas, hot and
cold water supply lines. Swarf in the gar or water supplies may cause
damage, a common problem, which is not covered by warranty.
2) Connect gas line
3) Purge the gas line of air
4) Final connection test
5) Check supply pressure
Operate ALL other gas appliances at their maximum gas rate. With all
gas appliances on maximum the supply pressure must read between
1.13-3.0 kPa on Natural Gas. On LPG the pressure must be 2.75-3.0
kPa
If the pressure is lower, the gas supply is inadequate and the
appliance will not operate to specification. It is the installer’s
responsibility to check the gas meter, service regulator and pipe work
for correct operation and sizing and rectify as required
6) Operate and test for gas leaks
Operate and test for gas leaks using an electronic leak detector
7) Check cold water inlet filter
Inspect and clean the water inlet filter. This may need to be repeated
to ensure the filter remains clear, especially on new installations
If you feel the customer is capable of doing this check it would be
beneficial to show them how to inspect and clean the filter
8) Customer Handover
After testing is completed, explain to the customer the functions and
operation of the water heater

Challenger Water Heater Operating Instructions 8 |P a g e
Operation Guide
About Your Califont Water Heater
Before using or operating your water heater ensure your installer talks to
you about the use and care of this appliance, and that you understand
these instructions.
Principles of operation
The burner lights automatically when the hot water tap is opened, and
goes out when the tap is closed. Ignition is electronic, so there is no pilot
light. When the hot water tap is off, no gas is used.
Water Flow
There is a minimum flow rate required for your appliance to start, so if a
hot water tap is only opened a fraction, there may not be enough flow to
start the unit.
Warning about Hot Water
Excessively hot water is dangerous. Challenger Califont Water Heaters
allow you to control the temperature of hot water to safe levels.
Always
Test the water temperature with your elbow before placing your
child in the bath, and feel the water yourself before bathing or
showering
Supervise children whenever they are in the bathroom
Make sure the hot water tap is turned off when not in use
Consider
Installing child proof tap covers or child resistant taps, both will prevent a
child from being able to turn on a tap
Never
Leave a toddler in the care of another child. They may not understand
the need to have the water temperature at a safe level

Challenger Water Heater Operating Instructions 9 |P a g e
Safety and Important Messages
This appliance is not intended for use by persons (including children),
with reduced physical sensory or mental capabilities, or lack of
experience and knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for
their safety. Children should be supervised to ensure they do not play
with the appliance.
Do Not:
Touch the unit when it is in operation
Insert foreign objects into the unit
Spray aerosols in the vicinity of the appliance when it is in
operation
Use or store flammable materials near the appliance
Modify the appliance
Keep trees, shrubs etc. well clear of the appliance
Check the gas pipe and fittings regularly for corrosion or any signs of
wear, as this may cause a gas leakage
If the appliance is not used on a regular basis check and ensure that
foreign materials have not entered your appliance. This could create a
fire

Challenger Water Heater Operating Instructions 10 |P a g e
General Information
Frost protection
If the Califont Water Heater is not going to be used for a period of time,
turn off the water and gas supplies.
If the Califont Water Heater is subject to frost or freezing ensure that the
water is drained when not in use.
Draining your Califont Water Heater:
1. Turn off cold water supply to appliance
2. Open hot tap to drain water from system
3. Remove drain plug from inside the unit to drain remainder of water
inside of the unit.
Installation by a licensed tradesperson
Only a licensed tradesperson can install, maintain and service this water
heater. Any work carried out by a non-licensed tradesperson is illegal
and will void any warranty
Safety Devices
Your Challenger Califont Water Heater has the following safety devices
Flame Failure
Overheat protection
Battery Operated Automatic Ignition
20 minute built-in timer
Pressure release and drain valve
Discolouration of Appliance
The colour of the appliance may change over time due to New Zealand’s
harsh environment. This is normal. The discolouration will not damage
the unit and will not affect the performance of the water heater

Challenger Water Heater Operating Instructions 11 |P a g e
Trouble Shooting
Fault
Causes
Remedies
Unsuccessful
ignition
Lack of water flow, or
Lack of gas supply, or
Insufficient power
Open cold water tap
And/or turn on gas
supply And/or replace
batteries.
Flat batteries
Replace the batteries
Gas pipe is full of air
Turn tap off and on.
Lack of gas supply (less
than 0.3 bar)
Replace the LPG bottle
or regulator on bottle.
Heater does not
start
Water inlet filter is
clogged
Clean the filter
Flame goes out
during operation
Gas cock is half open.
Gas pressure is too low.
Turn the gas bottle on
fully.
Replace battery
Check your water
supply.
Batteries are flat.
Lack of water flow and
pressure.
If water heater
lights and is
immediately
extinguished
Lack of water pressure
and supply.
Check your water
supply. Check water
filter. Ensure your water
supply is to the
specifications displayed
on data label on water
heater or in the manual.
Abnormal flame
and smell
Blocked burners caused
by creepy crawlies.
Deliver it to the nearest
authorised service
center.
Lack of air supply.
Blocked exhaust outlet.
Check your flu system.
For any other issues please contact your water heater supplier.

Challenger Water Heater Operating Instructions 12 |P a g e
Proof of Purchase
Installer Details
Record your details of purchase below:
Retailer: ___________________________________________________
Retailer Address: ____________________________________________
Date of Purchase: ___________________________________________
Invoice Number: ____________________________________________
Record your details of installer below:
Company Name: ____________________________________________
Installer Name: _____________________________________________
Address: __________________________________________________
Phone: ____________________________________________________
Certificate of compliance number for installation: ___________________
Signed: ___________________________________________________
Dated: ____________________________________________________

Challenger Water Heater Operating Instructions 13 |P a g e
Diagram 1

Challenger Water Heater Operating Instructions 14 |P a g e
Diagram 2 Diagram 3
Diagram 4

Challenger Water Heater Operating Instructions 15 |P a g e
Califont Water Heater Accessories
Flue Kits | Gas Hose & Regulator Kits | Weather Covers | Pumps
Ignition Conversion Kits | Plumbing Fittings
Flue Kits
Plumbing Fittings
Pumps
Ignition Conversion Kits
Gas Hose & Regulator
Kits
Weather Covers

Challenger Water Heater Operating Instructions 16 |P a g e
20 Saunders Place, Avondale, Auckland 1026
Ph: 09 8200 500 | Fax: [phone]
[e-mail]
www.challengeyachts.com