Challenge Yachts Challenger LPG Series User manual

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

Challenger Water Heater Operating Instructions 1 |Page
Table of Contents
Limited Warranty...............................................................................................2
Proof of Purchase.............................................................................................2
Important ...........................................................................................................3
Installation Safety................................................................................................3
Improper Installations..........................................................................................3
Hot Water Temperature Warning........................................................................3
Frost Protection...................................................................................................3
How the Challenger Water Heater Works........................................................4
Information about your Challenger LPG Water Heater..................................4
Safety Features .................................................................................................5
Commissioning your Water Heater .................................................................6
Important.............................................................................................................6
Location ..............................................................................................................6
Precaution...........................................................................................................6
Installation...........................................................................................................7
Operating Instructions......................................................................................8
Safety Measures................................................................................................9
Maintenance......................................................................................................10
Trouble Shooting ..............................................................................................11
Diagram 1...........................................................................................................12
Diagram 2...........................................................................................................13
Diagram 3...........................................................................................................13
Diagram 4...........................................................................................................13

Challenger Water Heater Operating Instructions 2 |Page
Limited Warranty
Challenge Yachts Ltd offers a 12-month warranty on parts and labour.
This warranty applies to all Challenger LPG continuous flow hot water
heaters. If you are claiming a warranty then you must return the water
heater to the place of purchase, or, to Challenge Yachts Ltd Auckland.
This warranty does not include return shipping costs. Warranty work
must only be carried out at Challenge Yachts Ltd Service Centre. The
warranty is effective from the date of purchase. Proof of purchase (copy
of invoice) is required for warranty. From time to time Challenge Yachts
Ltd may appoint an authorised agent to carry out the warranty work.
Proof of Purchase
Please complete your purchase details and attach your proof of
purchase below.
Congratulations on purchasing a
Challenger LPG continuous flow hot water heater!
Please keep this manual in a safe place
together with your proof of purchase.
Date of Purchase
Date
Month
Year
Purchased from
Inv No.
Name
Address
Phone
Distributed by Challenge Yachts Ltd
PO Box 68 480 Wellesley Street • Auckland New
Zealand
Phone [phone] • Fax [phone]
Email [e-mail]
www.challengeyachts.com

Challenger Water Heater Operating Instructions 3 |Page
Important
Improper Installations
Improper installation, repairs, servicing, or interfering with designed
components internally or electronically to gas appliances and fittings
may cause personal injury, loss of life, or damage to property. Use a
qualified gas fitter for installation and repair.
Hot Water Temperature Warning
Use the control knobs provided on the front of the water heater to make
the correct adjustments for water flow and gas supply so you arrive to a
safe water temperature. Some water heaters have three adjustment
knobs; the middle control knob is designated for summer and winter
adjustment
If the appliance is not fitted to the appropriate specifications this could
increase the water temperature dramatically and make the appliance
unsafe. So please ensure the appliance is fitted to the current New
Zealand Gas Safety Authority Standards and Regulations.
Frost Protection
If your water heater installation is subject to frost or freezing please
ensure that the water is drained when not in use. This will prevent
internal mechanical damage to your water heater. Each water heater is
provided with a frost drain plug which is situated on the left side of the
water inlet at the bottom of the appliance. See page 12, diagram1.
Installation Safety:
To comply with New Zealand Gas Safety Standards you are required to
have a licensed gas worker or a gas Fitter to install or certify your
installation. A licensed gas worker will ensure that your gas appliance
or installation is connected correctly, has adequate ventilation, is
appropriately flued and is in good working order.

Challenger Water Heater Operating Instructions 4 |Page
How the Challenger Water Heater Works
By turning on the hot tap the water will flow through the water heater
turning the water heater on. As the water circulates through the water
heater the water is heated.
By turning off the hot tap the water stops circulating through the water
heater, and the water heater turns off automatically.
The built in automatic safety features within the water heater ensure that
the gas is turned off immediately the flame is extinguished.
Information about your Challenger LPG
Water Heater
•The Challenger LPG continuous flow water heater provides an
energy efficient method of heating water.
•For Challenger LPG Water Heater installations, please refer to the
New Zealand Gas Safety Regulations or consult with your
registered gas worker or installer.
•Challenger Water Heaters operate on low pressure LPG. They
require a low pressure gas regulator and can be used with a
portable LPG gas cylinder.
•The Challenger 5,6,7,8,10,12 & 16 litre models do not require a
power point (240 volt) and can be installed internally with a flue
system to vent the emissions to the outside. Internal installation
must comply with current New Zealand Gas Safety Installation
Standards & Regulations. The 5,6,7,8,10,12 & 16 litre models can
be installed externally provided the unit has adequate shelter to
prevent water from entering the unit and damaging the electronics
within the water heater.

Challenger Water Heater Operating Instructions 5 |Page
•There are minimum and maximum water flow requirements for
each of the Challenger water heater models. If there is not enough
water flow to the water heater the gas will not ignite and the water
will not heat up. If the water supply is more than is specified for the
water heater the water will not be heated to the water heaters
specified temperature range. Please ensure that your water supply
complements the particular water heater model that you are
installing. Please refer to the specifications displayed on the side
of your water heater.
Safety Features
•Flame failure safety device
•Battery operated automatic IC ignition
•Incomplete combustion safety device
•Over water temperature protection device.
•Water-gas safety device mechanism
•20 minute built-in timer.
•Pressure release and drain valve.
•Draught protection
•Gas volume regulator knob
•Water volume regulator knob
•Manufactured by ISO 9001 certified company

Challenger Water Heater Operating Instructions 6 |Page
Commissioning your Water Heater
Important
•Before using the water heater please read the instructions
thoroughly.
•Always retain the user manual for future use.
•It is not only the quality of the water heater but also correct
installation that will ensure that your heater works to your
satisfaction
•The heater must be installed and checked only by a qualified and
authorized gas worker.
Location
•It is always advisable to install a gas water heater externally.
•In the rare case the water heater is to be installed internally
ensure that there is sufficient ventilation and the heater is
exhausted to the outside (do not install in confined
areas).Consult an authorised gas worker for such installations.
•The heater requires air supply for efficient operation. Fixed vents
or air inlets near the heater should never be obstructed or
blocked.
•There should be adequate ventilation in the room with an
external air supply (either open door or window)
•There must be a minimum of 300mm clearance above the water
heater to allow for appropriate exhausting as well as the fitting of
ventilation or exhaust kits.
Precaution
Before installation please check the following:
•Check that the gas supply meets the specified requirement
displayed on the specification plate on the water heater and that
the gas supply complies with New Zealand LPG Gas Safety
Standards.
•Ensure the water supply meets the specified requirement
displayed on the specification plate on the water heater
•Do not install the gas water heater near inflammable,
combustible, explosive or acidic environments.
*For all of the instructions above please consult with your licensed
installer.

Challenger Water Heater Operating Instructions 7 |Page
Installation
See page 13 diagrams 2 & 3
•The water heater must be a permanent fixture.
•The water heater must be mounted on a true vertical surface
(cannot be mounted on angled or leaning walls).
•Drill two holes on the wall and fix the screws into the wall. Mount
the gas water heater onto the screws.
•Ensure that the gas and water connection pipes are free of dirt or
waste material and clean thoroughly. (Please ensure that you use
thread seal or Locktite, materials for the gas and water
connections).
•Connect the gas pipe inlet connection.
•Connect the water inlet and outlet connections.
•Before starting please check for gas leaks.
•Check all connections.
•Battery recommendations: Insert two dry batteries of 1.5V in the
battery box with correct polarities. We recommend using alkaline
LR20 D Batteries or IECR20 Batteries.
•Close battery box
Your heater is now ready to be tested and operated.

Challenger Water Heater Operating Instructions 8 |Page
Operating Instructions
•Adjust control knobs located on the front of the heater.
Gas Knob (left) Water Knob (Right) set to mid position. See page
13, diagram 4.
•Turn on LPG gas bottle.
•Open hot water tap. As soon as the water starts flowing the
electronic ignition will start your heater.
•If the burners do not ignite then close the tap and repeat the
operation. This may happen due to air in the gas line.
•Gas Regulator and Control Knob on your water heater:
oTurn the gas (left) knob clockwise to increase the flame and
anti-clockwise to decrease the flame.
•Water Regulator Control Knob:
oTo get hotter water; reduce the water flow rate by turning the
right knob clockwise. If you turn the right knob anti-clockwise
water flow rate will increase and the temperature of the water
will decrease.
oThe temperature of the hot water can be controlled by
turning the gas control knob and/or the water flow control
knob accordingly.
oTo turn off the gas water heater turn off the tap.
If you are not using your water heater regularly it is recommended that
you turn off the gas supply.
Temperature limit 45 degrees Celsius (Please note califont-type water
heaters will not produce boiling or near boiling water).

Challenger Water Heater Operating Instructions 9 |Page
Safety Measures
•To prevent gas leakage always close the gas supply to the heater.
•Do not have any flammable materials on or near the water heater.
•If you find any gas leakage immediately close the gas supply and
ventilate the area. DO NOT switch electrical appliances on/off.
Immediately. Call a qualified service technician.
•Freezing Prevention
oIn winter if water temperature goes below 4°C drain out the
water completely from the gas water heater through the drain
valve to avoid any damage to the heater due to freezing.
Drain valve provided on the heater situated left of water inlet
pipe. See page 12 diagram 1
•If the water heater is not required to be used for a long time do the
following:
oTurn off the gas.
oRemove batteries from the battery box.
oDrain water from the heater.
•Please avoid touching the burner viewing window while the heater
is on.
•Check the gas pipe and fittings regularly for corrosion, cracks,
damage etc. as this may cause gas leakage
•If the heater is not used on a regular basis please check and
ensure that foreign materials, creepy crawlies, birds and rodents
have not chosen to nest in your water heater. These obstacles
could create a fire.

Challenger Water Heater Operating Instructions 10 |Page
Maintenance
•If the heater has been shut down for any length of time please
ensure that no residue or debris deposits have accumulated inside
the heater from bugs, birds, spiders etc.
•The heater must be checked for safe operation annually
regardless of frequency of use. This refers principally to the correct
combustion of the main burners. Service and maintenance should
be carried out by a qualified and authorised technician only.
•If the heater is installed in a hard water area in time the following
may occur:
oFall in hot water temperature
oA reduction of the water flow
This happens due to scale formation.
Since scale formation is proportionate to the outlet water temperature to
reduce scaling it is recommended to use the water and gas control knob
to obtain the desired water temperature instead of mixing cold water with
hot water.
The scaling should be removed by authorized technicians only.

Challenger Water Heater Operating Instructions 11 |Page
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 |Page
Diagram 1

Challenger Water Heater Operating Instructions 13 |Page
Diagram 2 Diagram 3
Diagram 4

Challenger Water Heater Operating Instructions 14 |Page