TriangleTube CCRKIT36 Use and care manual

Challenger
Flue Sensor Replacement
1
WARNING
!
Indicates a potentially hazardous situation which,
if ignored, can result in serious injury or substan-
tial property damage.
NOTICE
Indicates special instructions on installation, operation
or maintenance, which are important to equipment
but not related to personal injury hazards.
WARNING
!
For your safety, turn off electrical power supply
at service panel and allow unit to cool before pro-
ceeding to avoid possible electrical shock and
scald hazard. Failure to do so can cause severe
personal injury or death.
WARNING
!
Failure to follow instructions below can result in
severe personal injury or damage if ignored.
• Instructions are for a qualified installer/ ser-
vice technician only.
• Read all instructions before proceeding.
• Follow instructions in proper order.
Each Kit Includes:
• Temperature Sensor
Recommended Tools:
• Phillips Head Screwdriver
• Pliers
Kit Part Number Description Model
CCRKIT36 Flue Sensor Replacement All Models
2020-35 - Challenger Flue Sensor Replacement
Revised 9/22/2022

Challenger
Flue Sensor Replacement
2
1. Preliminary Instructions:
1. Verify that the replacement kit is correct for the
model of boiler. See table on page 1.
2. Carefully open and unpack the PARTS BOX from its
shipping carton.
3. Carefully remove and check for any damage.
NOTICE
Do not proceed with installation and contact Triangle Tube
right away if the sensor is damaged in any way.
4. Turn o the electrical power supply to the boiler.
5. Close the manual gas shut o valve to the unit.
2. Accessing Temperature Sensor
1. Remove the front jacket panel by loosening the re-
taining screws on each side of the display (see Fig.
1).
Fig. 1: Loosing Retaining Screws
2. Dismount the front jacket panel by pulling the bot-
tom of the front panel out and the entire front jack-
et panel down.
3. Loosen the ue pipe retaining ring as shown 1 in
Fig. 2.
4. Pull up on the ue pipe to disengage from the con-
densate pan as show in Fig. 3.
5. Pull the ue pipe down and out to disengage from
the vent adapter as shown in Fig. 3.
6. Lift up the condensate pan to disengage from trap.
7. Once the condensate pan is clear of the bottom
jacket, rotate it towards the front of the appliance
and push down on the rear to disengage from the
heat exchanger as shown in Fig. 4.
WARNING
!
Inspect the flue pipe and condensate pan for cracks,
damage or distortion. Check all gaskets for tears, dis-
coloration or other damage. Installing damaged com-
ponents risks a gas leak causing severe personal inju-
ry, death or substantial property damage.
Fig. 2: Loosening of Flue Pipe Retaining Ring
Fig. 3: Removal of Flue Pipe

Challenger
Flue Sensor Replacement
3
Fig. 4: Removal of Condensate Pan
3. Replacing Old Style Sensor
NOTICE
Step 3 only applies to replacing the old style temperature
sensor. If replacing the new style temperature sensor (see Fig.
1) skip to step 4.
1. Unplug two black wires from the old temperature
sensor.
2. Pull pin straight down (see g Fig. 5).The old sensor
should come o.
Fig. 5: Old style sensor pin
3. Use a pair of plier to remove the old bracket (see
Fig. 6). The bracket will not be reused.
Fig. 6: Old style sensor bracket
4. Snap the new sensor in place as shown in Fig. 7.
Lightly tug the sensor to ensure it is secure.
Fig. 7: New style sensor installation
5. Plug the black wires as shown in Fig. 8.
Fig. 8: New style sensor wired

Challenger
Flue Sensor Replacement
4
4. Replacing new style sensor
NOTICE
Step 4 only applies to replacing the new style temperature
sensor (see Fig. 1). If replacing the old style temperature sen-
sor skip to step 5.
1. Unplug the two black wires from the new style
temperature sensor
2. Pull the sensor o of the heat exchanger.
3. Snap the new sensor in place as shown in Fig. 7.
Lightly tug the sensor to ensure it is secure.
4. Plug the black wires as shown in Fig. 8.
5. Return to service.
1. Reassembly the condensate pan and ue tube pre-
viously removed.
WARNING
!
When re-assembling the condensate pan and flue pipe
ensure all gaskets are in place and correctly installed.
Ensure all associated joints are complete, tight and se-
cure. Failure to comply can result in flue gas leakage
resulting in substantial property damage, serious in-
jury, or death.
2. Open the manual gas valve to the unit.
3. Turn on power to the unit.
4. Monitor the operation of the boiler to ensure the
new temperature sensor is operating correctly.
Contact Triangle tube right away if the boiler is not
operating as expected.
5. Replace the front jacket panel and secure with the
two retaining screws on the display panel and re-
turn to normal service.