TriangleTube CHALLENGER CC 85 Manual

Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of
installation in order to gain warranty coverage.
When receiving the CHALL NG R, any claims for damage or shortage in shipment must be filed imme-
diately 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
2010-1Challenger 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 SM LL 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: 12/9/2010
WARNING
NOTICE

PRODUCT AND SAFETY INFORMATION
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
SECTION I - PRE-INSTA ATION ITEMS
Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Boiler or Water Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boiler Freeze Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION II - COMBUSTION AIR AND VENTING
Combustion Air Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ventilation Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Combustion Air and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal of an xisting Boiler and/or Water Heater
from a Common Vent System . . . . . . . . . . . . . . . . . . 9
Commonwealth of Massachusetts Installation . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION III - APP IANCE PREPARATIONS
Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wall Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wall Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stud Walls - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wall Bracket Installation - Solid Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Appliance Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Piping Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION IV - BOI ER PIPING
General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Low Water Cut Off Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Additional Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Boiler System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
xpansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Diaphragm xpansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table of Contents
i

Closed-Type xpansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Piping - Zone Circulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Near Boiler Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Piping - Radiant Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Piping - Special Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Central Heating 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 Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Thermal xpansion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Vacuum Breaker - Storage Tank 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 Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installing Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29
SECTION VII - GAS PIPING
Gas Supply Piping Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
CHALL NG R Factory Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION IX - EXTERNA WIRING
Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Line Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control Module Circulator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Low Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CH Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
System Circulator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 37
Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
xternal Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-39
SECTION X - START-UP PREPARATION
Check Boiler System Water Chemistry
Water pH Level 6.5 to 8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Water Total Hardness Less Than 7 Grains/Gallon . . . . . . . . . . . . . . 40
Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Flush Boiler and Domestic System to Remove Sediment . . . . . . . . . . . . . . 40
Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Check Low Water Cut-Off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Check for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Check Thermostat Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspection of Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION XI - START-UP PROCEDURES
Final Checks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CHALL NG R Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
If CHALL NG R Does Not Start Correctly. . . . . . . . . . . . . . . . . . . . . . . . 43
Check the CHALL NG R and System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Set Boiler CH Set Point Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47
Set DHW Set Point Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table of Contents
iii

Operation Verification - Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . 47-48
Control Display
Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Additional DHW Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Highfire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Lowfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Setting the Appliance Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
rror (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
rror (Hard Lockout) Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION XII - OUTDOOR RESET CONTRO
Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Adjusting Outdoor Reset Curve
Appliance CH (Maximum Boiler Operating Temperature). . . . . . . 56
CH Minimum Boiler Operating Setpoint (Parameter 5) . . . . . . . . . 56
CH Reset Curve Coldest Day (Parameter 6) . . . . . . . . . . . . . . . . . . 56
CH Reset Curve Warmest Day (Parameter 7) . . . . . . . . . . . . . . . . . 56
Changing Outdoor Reset Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Outdoor Reset Curve xample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTION XIII - CHECK-OUT PROCEDURES
Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SECTION XIV - INSTA ATION RECORD
Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
SECTIONS XV - MAINTENANCE SCHEDU E
Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SECTION XVI - MAINTENANCE PROCEDURES
Maintenance Procedures
Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Check Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table of Contents
iv

Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 62
Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 62
Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removing Internal Flue and Condensate Pan for Inspection. . . . . . 62-63
Check xpansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check Relief Valve (s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspection of Ignition lectrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 64
Check Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Perform Start-Up and Checkout Procedure . . . . . . . . . . . . . . . . . . . 66
Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Clean Heat xchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Handling Previously Fired Combustion Chamber Insulation . . . . . 68
REP ACEMENT PARTS
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-75
PRODUCT SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-82
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
Triangle Tube for the installers which
will help to ensure optimum operation
and longevity of the equipment.
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.
Triangle Tube reserves the right to modify the technical specifications and components 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.
WARNING
WARNING
WARNING
CAUTION
DANGER
Qualified Installer:
Prior to installing this product read all
instructions included in this manual and all
accompanying manuals/documents with this
appliance. Perform all installation steps
required in these manuals in the proper
order given. Failure to adhere to the guide-
lines 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.
Triangle Tube accepts no liability for any
damage resulting from incorrect instal-
lation or from the use of components or
fittings not specified by Triangle Tube.
NOTICE
NOTICE
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.
• Children, 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.
- Feed 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 per-
son.
Protection must be taken against
excessive pressure!
TO PROTECT AGAINST EXCES-
SIVE TEMPERATURE AND PRES-
SURE
• Check 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 installations.
(DHW side)
• Check if the 30 psi [2 bar] pressure
relief valve supplied is installed in
the recommended location. (CH 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 CHALL NG R is certified to both the
Boiler (ANSI Z21.13/CSA 4.9) and Water
Heater (ANSI Z21.10.3/CSA4.3) standards.
Due to the CHALL NG R’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 CHALL NG R 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.
- The National Fuel Gas Code NFPA54/
ANSI Z223.1 - Latest edition.
- National lectric Code ANSI/NFPA 70.
- For installations in Canada -“Installation
Code for Gas Burning quipment”
CAN/CSA B149.1 Canadian lectrical
Code Part 1 CSA C22.1.
- Standards for Controls and Safety
Devices for Automatically Fired Boilers,
ANSI/ASM CSD-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 CHALL NG R check for
convenient locations to:
- Heating system piping
- Domestic water supply piping
- Venting
- Gas supply piping
- lectrical service
nsure the appliance location allows the com-
bustion air and vent piping to be routed directly
through the building and terminate properly out-
side with a minimum amount of length and
bends.
nsure the area chosen for the installation of the
CHALL NG R 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.
nsure the CHALL NG R and its controls
are protected from dripping or spraying water
during normal operation or service.
The CHALL NG R should be installed in a
location so that any water leaking from the
appliance or 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 CHALL NG R is replacing an existing
boiler or hot water heater system, the following
items should be checked and corrected prior to
installation:
- Boiler and domestic piping leaks and
corrosion.
- Improper location and sizing of the
expansion tank on the boiler heating
loop. Improper location and sizing of
the thermal expansion tank (if used) on
the domestic supply line.
- If applicable, level and quality of freeze
protection within the boiler system.
- Vent condition
Clearances
The CHALL NG R 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 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]
If the recommended service clearances
listed above cannot be maintained or 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 for ventilation requirements.
When maintaining the approved clear-
ance or less than recommended service
clearances, some product labeling may
become hidden and unreadable.
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 CHALL NG R 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. nsure 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
WARNING
NOTICE
WARNING
5

6
Pre-Installation Items
Boiler Freeze Protection Feature
The boiler control has a freeze protection feature
built in. This feature monitors the boiler supply
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. The boil-
er must be installed in a primary/sec-
ondary piping arrangement. See Section
IV for primary/secondary piping exam-
ples. See Section X for antifreeze guide-
lines.
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 would 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 its
combustion air inlet is located near a
laundry room or pool facility. These
areas will always contain hazardous con-
taminants.
Pool and laundry products and common
household 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 cor-
rosion of the heat exchanger, burner
components and vent system, causing
serious damage and presenting a possi-
ble 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
- Chlorinated wax
- Chlorine - based swimming pool chem-
icals / cleaners
- Calcium Chloride used for thawing ice
- Sodium Chloride used for water soft-
ening
- Refrigerant leaks
- Paint or varnish removers
- Hydrochloric acid / muriatic acid
- Cements and glues
- Antistatic fabric softeners used in
clothes dryers
- Chlorine-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 CHAL-
L NG R, 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 CHAL-
L NG R, 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 CHALL NG R
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 Code
NFPA 54, ANSI Z223.1 for installations in the
U.S or CAN/CSA B149.1 for installations in
Canada/
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 CHALL NG R requires a Category IV
venting system, which is designed for pressur-
ized venting and condensate.
The CHALL NG R 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
Concentric Vent/Air System
Supplement 2010-23 included in the
appliance installation envelope. Refer to
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

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. Close 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 Code, ANSI Z223.1/NFPA 54
and/or CAN/CSA 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 Code ANSI
Z223.1/NFPA 54 and/or CAN/CSA
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 dition).
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
dition); and
d. Have been approved and listed by
the Nationally Recognized Testing
Laboratory as recognized under 527
CMR.
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 dition).
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
dition)
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
Handling Instructions
The CHALL NG R 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 will result.
1. Remove any shipping straps and the top
shipping carton.
2. Carefully lift the appliance out of the carton.
3. Discard all packing materials.
Wall Mounting Installation
The CHALL NG R should be wall mounted
using the bracket provided with the appliance.
The CHALL NG R is not designed for floor
installation. If floor installation is required an
optional floor stand part number PSSTND04 is
available through 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.
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. nsure 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.
NOTICE
CAUTION
Fig. 1: Optional Floor Stand Assembly,
Part Number: PSSTND04

12
Appliance Preparations
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
property 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.
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. nsure the appli-
ance is seated properly and is secure.
NOTICE
Lag Screw
(Stud Wall)
Bolts with
Washer
(Solid Wall)
Wall Anchors
(Solid Wall Only)
Fig. 2: Wall Mounting The CHA ENGER

13
Appliance Preparations
Piping Support Bracket
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. Once the appliance is mounted onto the
wall, slip the appliance piping into the fit-
tings until bottom of hex on gas pipe fitting
rests against the top of the piping support
bracket before tightening any compression
nuts.
3. Secure piping support bracket to wall with
hardware supplied.
4. 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.
BEST PRACTICE
WARNING

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
CHALL NG R 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
1. The CHALL NG R has a ASM
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 [121ºC] 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 Cutoff Device
The ow Water Cutoff Device only
applies for space heating. Operation of
the ow Water Cutoff Device does not
prevent a domestic hot water call for heat.
- The CHALL NG R is equipped with a fac-
tory installed pressure switch type Low Water
Cut Off device.
- The minimum operating space heating (CH)
system pressure allowable with this device is
7 psig [0.5 bar].
- If CH System pressure is below 7 psig [0.5
bar] the main display will show an error of
“LOP”. If the appliance is installed as domes-
tic hot water heater only, set parameter 2
(installation type) to 2 (domestic only) to
eliminate the “LOP” error in the main display,
see page 52 for setting parameters.
- Check local codes if a Low Water Cutoff
Device is required. If so, determine if this
device meets the requirements of the local
codes.
WARNING
WARNING
NOTICE