TriangleTube Challenger Guide

2011-37 Challenger Solo User’s Manual
If the information in this manual is not followed exactly, a fire or explosion
may result causing property damage, personal injury or loss of life.
F R Y UR 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.
Boiler
User s Information Manual
Date 8/9/2011
WARNING

Table of Contents
i
RODUCT & SAFETY INFORMATION Page 1
Service and Maintenance
CHA ENGER Operation
Appliance & System Water
SECTION I - Combustion Air - revention of Contamination Page 2
Potential Contaminating Products
Areas likely to find these Products
SECTION II - Maintenance Schedule Page 3
Service Technician
Owner Maintenance
SECTION III - Maintenance rocedures Page 4
Periodic Maintenance
Monthly Maintenance
6-Month Maintenance
SECTION IV - Operations Instructions Page 7
SECTION V - Appliance Control Display Page 8
Replacement arts Page 13

ii
Prod ct & Safety Information
Indicates the presence of a hazardous situa-
tion which, if ignored, will result in death, seri-
ous injury or substantial property damage.
Indicates a potentially hazardous situation
which, if ignored, can result in death, seri-
ous injury or substantial property damage.
Indicates a potentially hazardous situation
which, if ignored, may result in minor
injury or property damage.
Indicates special instructions on installa-
tion, 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.
Definitions
Triangle Tube reserves the right to modify the technical specifications and components of
its products without prior notice.
NOTICE

Prod ct & Safety Information
1
RODUCT & SAFETY INFORMATION
HOMEOWNER: The CHALLENGER installation man-
ual is for use only by a qualified heating installer /
service technician. Refer to this User’s Information
Manual for your reference. Failure to comply could
result in severe personal injury, death or substantial
property damage.
TECHNICIAN: When calling or writing about the
CHALLENGER, please have the appliance model
and serial number available.
STO ! READ BEFORE SERVICING
Failure to adhere to the guidelines on this page can
result in severe personal injury, death or substantial
property damage.
Service and Maintenance
• To avoid electric shock, disconnect electrical supply
before performing service or maintenance.
• Allow the appliance to cool down prior to servicing to
avoid severe burns.
• The CHA ENGER must be maintained as outlined
in this manual and have at least annual service per-
formed by a qualified service technician to ensure
appliance / system reliability.
WARNING
WARNING
NOTICE
CHALLENGER Operation
• Do not block flow of combustion air to the CHA -
ENGER. If the combustion air blockage is easily
accessible and removable, then remove it. If block-
age is not obvious or cannot be removed, have the
appliance and system checked by a qualified service
technician.
• Do not allow contaminated air to enter the appli-
ance’s combustion air inlet. See page 2 for details.
• The CHA ENGER is equipped with a low water cut
off device. The CH (central heating) system piping
must be filled and pressurized to 12 psig [0.8 bar]
prior to startup. The appliance will shut down if the
pressure falls below 7 psig [0.5 bar].
• Should overheating occur or the gas supply fail to
shut off, DO NOT turn OFF or disconnect the elec-
trical supply to the pump. Instead, shut off the gas
supply at a location external to the appliance.
• Do not use this appliance if any part has been under
water. Immediately call a qualified service techni-
cian to inspect the appliance and to replace any part
of the control system and any gas control, which has
been under water.
Appliance & System Water
• Have the appliance and system water chemistry
checked at least annually by a qualified service tech-
nician.
• Do not use petroleum-based cleaning or sealing
compounds in the appliance or system. Gaskets
and seals in the system may be damaged. This can
result in substantial property damage.
• Do not use any product not specifically designed for
hydronic heating systems. Serious damage to the
appliance, piping system, personnel and / or proper-
ty may result.
• Continual fresh makeup water will reduce the life of
the CHA ENGER. Addition of oxygen can cause
internal corrosion in the system components. All
leaks in the piping system must be repaired at once
to prevent makeup water.
• Do not add cold water to a hot appliance. Thermal
shock can cause premature failure to the appliance
heat exchanger.

Comb stion Air - Prevention of Contamination
2
SECTION I - COMBUSTION AIR - REVENTION OF
CONTAMINATION
If the CHALLENGER combustion air inlet is located
in any area likely to cause or contain contamination,
or if products, which would contaminate the air can-
not be removed, the combustion air must be re-
piped and terminated to another location.
Contaminated combustion air will damage the appli-
ance and its burner system, resulting in possible
severe personal injury, death or substantial property
damage.
Do not operate a CHALLENGER if its combustion air
inlet or the appliance is located in or near a laundry
room or pool facility. These areas will always con-
tain hazardous contaminates.
ool and laundry products and common household
and hobby products often contain fluorine or chlo-
rine 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 components and vent
system, causing serious damage and presenting a
possible threat of flue gas spillage or water leakage
into the surrounding area.
lease read the following information. If contami-
nating chemicals will be present near the location of
the combustion air inlet, the installer should pipe the
combustion air inlet to another location per the
CHALLENGER installation manual.
WARNING
WARNING
otential Contaminating roducts
-Spray cans containing chloro/fluorocarbons
- Permanent Wave Solutions
- Chlorinated wax
- Chlorine - based swimming pool chemicals and
spa cleaners
- Calcium Chloride used for thawing ice
- Sodium Chloride used for water softening
- 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 clean-
ing solvents found in household laundry rooms
- Adhesives used to fasten building products and
other similar products
Areas likely to find these products
- Dry cleaning / laundry areas and establishments
- 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 establishments
- New building construction
- Remodeling areas
- Garages with workshops

Maintenance Sched le
3
SECTION II - Maintenance Schedule
Service Technician
At least on an annual basis the following maintenance
should be performed by a qualified service technician:
General
- Attend to any reported problems.
- Inspect the interior of the appliance jacket area;
clean and vacuum if necessary.
- Clean the condensate drain assembly and fill with
fresh water.
- Check for leaks: water, gas, flue and condensate.
- Verify flue vent piping and air inlet piping are in good
condition, sealed tight and properly supported.
- Check appliance water pressure, piping and expan-
sion tank.
- Check control settings.
- Check ignition electrode (sand off any white oxide;
clean and reposition).
- Check ignition wiring and ground wiring.
- Check all control wiring and connections.
- Check burner flame pattern (stable and uniform).
Additional items if combustion or performance is
poor:
- Clean heat exchanger and flue ways.
- Remove burner assembly and clean burner head
using compressed air only.
Once the maintenance items are completed, review the
service with the owner.
Owner Maintenance
Periodic
- Check the area around the appliance.
- Check and remove any blockage from the combus-
tion air inlet and ventilation openings.
- Check the temperature/pressure gauge.
Monthly:
- Check vent piping.
- Check combustion air inlet piping.
- Check the pressure relief valve.
- Check the condensate drain assembly.
Every 6 months:
- Check appliance piping and gas supply piping for
corrosion or potential signs of leakage.
- Operate the pressure relief valve.
Follow the maintenance procedures given
throughout this manual. Failure to perform the
service and maintenance or follow the directions
in this manual could result in damage to the
CHALLENGER or in system components, result-
ing in severe personal injury, death or substan-
tial property damage.
WARNING

Maintenance Proced res
4
SECTION III - MAINTENANCE ROCEDURES
The CHALLENGER must be inspected and serviced
annually, preferably at the start of the heating sea-
son, by a qualified service technician. In addition,
the maintenance and care of the appliance as out-
lined on page 3 and further explained on pages 4
through 6 must be performed to assure maximum
efficiency and reliability of the appliance. Failure to
service and maintain the CHALLENGER and the sys-
tem components could result in equipment failure,
causing possible severe personal injury, death or
substantial property damage.
The following information provides detailed instruc-
tion for completing the maintenance items outlined
in the maintenance schedule on page 3. In addition
to this maintenance, the CHALLENGER should be
serviced at the beginning of the heating season by a
qualified service technician.
eriodic Maintenance
Check the Surrounding Area
To prevent potential of severe personal injury, death
or substantial property damage, eliminate all the
materials listed on page 2 from the area surrounding
the appliance and from the vicinity of the combus-
tion air inlet. If contaminates are found:
Remove products immediately from the area. If they
have been there for an extended period, call a quali-
fied service technician to inspect the appliance for
possible damage from acid corrosion.
If products cannot be removed, immediately call a
qualified service technician to re-pipe the combus-
tion air inlet piping and locate the combustion air
intake away from the contaminated areas.
WARNING
WARNING
NOTICE
1. Combustible / flammable materials - Do not
store combustible materials, gasoline or other
flammable vapors or liquids near the appliance.
Remove immediately if found.
2. Air contaminates - Products containing chlorine
or fluorine, if allowed to contaminate the com-
bustion air, will cause acidic condensate within
the appliance. This will cause significant dam-
age to the appliance. Read the list of potential
materials listed on page 2 of this manual. If any
of these products are in the room from which the
appliance takes its combustion air, they must be
removed immediately or the combustion air
intake must be relocated to another area.
Check Combustion Air Inlets
1. Verify that ventilation air openings to the
mechanical room are open and unobstructed.
2. Verify that the appliance’s vent termination and
combustion air intake are clean and free of
obstructions. Remove any debris on the air
intake or flue exhaust openings. If removing the
debris does not allow the appliance to operate
correctly, contact your qualified service techni-
cian to inspect the appliance and the vent / com-
bustion air system.
Check Temperature Display and ressure Gauge
1. Ensure the pressure reading on the pressure
gauge does not exceed 25 psig [1.7 bar].
Higher pressure readings may indicate a prob-
lem with the expansion tank.
2. Ensure the temperature on the display panel
does not exceed 194ºF [90ºC]. Higher tempera-
ture readings may indicate a problem with the
operating thermostat controls.
3. Contact a qualified service technician if prob-
lem persists.

Maintenance Proced res
Monthly Maintenance
Check Vent iping
1. Visually inspect the flue gas vent piping for any
signs of blockage, leakage or deterioration of
the piping. Notify a qualified service technician
immediately if any problems are found.
Failure to inspect the venting system as noted and
have it repaired by a qualified service technician can
result in the vent system failure, causing severe per-
sonal injury or death.
Check Combustion Air Inlet iping
1. Visually inspect the combustion air inlet piping for
any signs of blockage. Inspect the entire length
of the combustion air inlet piping to ensure piping
is intact and all joints are properly sealed.
2. Notify a qualified service technician if any prob-
lems are found.
Check ressure Relief Valve
1. Visually inspect the primary pressure relief valve
and the relief valve discharge pipe for signs of
weeping or leakage.
2. If the pressure relief valve often weeps, the
expansion tank may not be operating properly.
Immediately contact a qualified service techni-
cian to inspect the unit and system.
Check Vent Condensate Drain Assembly
1. While the appliance is operating, check the dis-
charge end of the condensate drain tubing.
Ensure no flue gas is leaking from the conden-
sate drain tubing by holding your fingers near
the termination.
2. If you notice flue gas leaking from the opening,
this indicates a dry condensate drain trap. Fill
the condensate trap assembly. Contact a quali-
fied service technician to inspect the appliance
and condensate line and refill the condensate
trap if problem persists regularly.
WARNING
Under some circumstances the CHALLENGER may
not produce enough condensate to keep the con-
densate trap full of liquid. If the trap is not full, small
amounts of flue gases can be emitted into the sur-
rounding area through the condensate drain line.
3. Ensure the condensate drain line is not blocked
by pouring water through the top open port on
the condensate drain assembly. The water
should flow out of the end of the drain line. If
water does not appear at the end of the drain
line, contact a qualified service technician to
inspect and clean the condensate line.
4. To fill the condensate drain assembly, slowly
pour water into the top of the trap assembly until
water appears at the end of the drain line. Stop
filling.
Check Automatic Air Vents (If Used)
1. Remove the cap “A” from any automatic air vent
in the system and check operation by depressing
valve “B” slightly with the tip of a screwdriver. See
Fig. 1.
2. If the air vent valve appears to be working freely
and not leaking, replace cap “A”, screwing it on
fully.
3. oosen cap “A” one full turn to allow vent to
operate properly.
4. Have the air vent replaced by a qualified service
technician if it does not operate correctly.
WARNING
5
A
B
Fig. 1: Automatic Air Vent

Maintenance Proced res
6-Month Maintenance
Check Water and Gas iping
1. Remove the appliance front jacket panel and per-
form a gas leak inspection per steps 1 through 6 of
the Operating Instructions on page 7. If gas odor
or leak is detected, immediately shut down the
appliance following procedures on page 7. Call a
qualified service technician.
2. Visually inspect for leaks around the internal appli-
ance water connections and around the heat
exchanger. Visually inspect the external system pip-
ing, circulators, and system components and fittings.
Immediately call a qualified service technician to
repair any leaks.
Have leaks fixed at once by a qualified service tech-
nician. Failure to comply could result in severe per-
sonal injury, death or substantial property damage.
Operate ressure Relief Valve
1. Before proceeding, verify that the relief valve
outlet has been piped to a safe place of dis-
charge, avoiding any possibility of scalding from
hot water.
To avoid water damage or scalding due to valve
operation, a discharge line must be connected to the
relief valve outlet and directed to a safe place of dis-
posal. This discharge line must be installed by a
qualified service technician or heating / plumbing
installer in accordance with the CHALLENGER
installation manual. The discharge line must be ter-
minated so as to eliminate possibility of severe
burns or property damage should the valve dis-
charge.
WARNING
WARNING
2. Read the temperature and pressure gauge to
ensure the system is pressurized. ift the relief
valve top lever slightly, allowing water to relieve
through the valve and discharge piping.
3. If water flows freely, release the lever and allow
the valve to seat. Watch the end of the relief
valve discharge pipe to ensure that the valve
does not weep after the line has had time to
drain. If the valve weeps, lift the lever again to
attempt to clean the valve seat. If the valve
does not properly seat and continues to weep
afterwards, contact a qualified service techni-
cian to inspect the valve and system.
4. If the water does not flow from the valve when
you lift the lever completely, the valve or dis-
charge line may be blocked. Immediately shut
the appliance down per the instructions on page
7. Call a qualified service technician to inspect
the valve and system.
6

Operating Instr ctions
7
SECTION IV - O ERATING INSTRUCTIONS
WARNING
F R Y UR SAFETY READ BEF RE LIGHTING
PERATING INSTRUCTI NS
T TURN FF GAS T APPLIANCE
1. ST P! Read the safety information above. This
appliance is equipped with an ignition device which
automatically lights the burner. DO OT try to light
the burner by hand.
2. Set room thermostat(s) to lowest setting. Turn the
external manual gas valve handle clockwise
“CLOSE” (valve handle shall be perpendicular to gas
piping).
3. Turn “OFF” all electrical power to the appliance.
4. Remove the front jacket panel on the appliance.
5. Turn the external manual gas valve handle counter
clockwise to “OPE ” gas supply (valve han-
dle shall be parallel to gas piping).
6. Wait five (5) minutes to clear out any gas. If you then
smell gas in the jacket enclosure or around the appli-
ance, STOP! Follow “B” in the safety information
above. If you don’t smell gas, go to the next step.
7. Turn “O ” all electric power to the appliance. Push
O /OFF button on the CHALLE GER control panel
display until LED above button is lit.
8. Set room thermostat(s) to desired setting(s).
9. The CHALLE GER control panel display will show a
sequence of numbers (1,2,3,4) as the right digit.
Sequence digit 3 or 4 indicates the appliance is firing. A
blank display means there is no call for heat (all exter-
nal thermostats are satisfied).
10. If the appliance will not operate with a call for heat and
the system piping is not hot, follow the instructions “To
Turn Off Gas to Appliance”, below and call your service
technician or gas supplier.
11. Replace the front jacket panel. Make sure the panel is seat-
ed firmly in place and all mounting screws are tightened.
If you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
1. Set the room thermostat to lowest setting.
2. Turn“OFF” all electric power to the appliance if serv-
ice is to be performed.
3. Turn the external manual gas valve handle clockwise
to “CLOSE”, (valve handle shall be perpendi-
cular to gas piping).
A. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights the
burner. D N T try to light the burner by hand.
B. BEFORE OPERATI G, smell all around the appli-
ance area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle on
the floor.
WHAT T D IF Y U SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
phone in your building
•Immediately call your gas supplier from a neigh-
bor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to turn the external manual gas
valve. ever use tools. If the valve will not turn by
hand, don’t try to repair it; call a qualified service tech-
nician. Force or attempted repair may result in a fire or
explosion.
D. 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 and any gas control which has been
under water.

Appliance Control Display
8
SECTI N V - Appliance Control Display
1. On/Off (Lit when on)
2. CH operation or setting maximum CH temperature
3. DHW operation with optional Triangle Tube
SMART I.F.W.H
4. Main display with temperature water pressure
or fault code
5. Temperature ºF or pressure psi
6. Temperature ºC or pressure bar
7. Not applicable
8. Not applicable
9. Operating display
10. Flashes to indicate fault
A. On/Off button
B. Parameter button
C. - button
D. + button
E. Units U.S. customary or metric
F. Not applicable
G. Service button
H. Reset/store button
Read-Out Operation
Appliance N/ FF
1. The appliance operation is started using the
O /OFF button.
2. When appliance is in operation, the green LED
above the O /OFF will be lit.
3. When the appliance is not in operation, the green
LED above the O /OFF will not be lit. The
main display will show “OFF” and the operating
display will show .
Units
Press Up or Down arrow button to change the dis-
played units from U.S. Customary (ºF or psi) to met-
ric (ºC or bar). The ºF/psi LED will be lit for U.S.
Customary units or ºC/bar LED will be lit for metric
units.
Units cannot be changed if the main display
(Parameter Mode) or operating display
(Error Mode) is flashing.
NOTICE

9
Appliance Control Display
Function
Main Display Operating Display
OFF
XXP
XXP
XXX
7
Press
No demand for heat
Control self-test
Fan pre purge or post purge cycle
Space Heating (CH) post pump cycle
XXX
XXX
6
A
1
Ignition sequence
XXX
2
Burner ON for space heating (CH)
XXX
LOP*
3
Burner ON for domestic hot water (DHW)
with optional Triangle Tube SMART I.F.W.H.
4
Raise CH pressure above 7 psig [0.5 bar]
Burner ON for freeze protection
The LED will be lit for CH (central heating call)
9
Burner OFF due to reaching temperature
setpoint
button to turn appliance ON
LED lite above button will be lit
The LED will be lit for DHW (domestic hot water call) with optional Triangle Tube SMART I.F.W.H.
NOTICE
when appliance is ON
“X” represents temperature or pressure readings. When temperature is displayed it
will be followed by “ºF” or “ºC” in the main display and the appropriate LED will be
lit. When pressure is displayed it will be followed by a “P” in the main display. Pres-
sure can only be read when the operating display is blank or shows a “A”.
* If factory installed CH Low Water Cut Off (LWCO) is below 7 psig [0.5 bar] the main display
will flash a soft lockout of LOP (burner and CH primary pump is blocked) followed by the
pressure reading. Once CH system pressure is increased above 7 psig [0.5 bar] normal boiler
operation will be restored. Check LWCO wiring if LOP flashes to 90 _P (PSI) or 6.0 _P (bar).

10
Appliance Control Display
Setting the Appliance Parameters
1. Press the “”button at the display panel for
approximately 2 to 3 seconds until main display
begins to flash.
2. Press the “”button repeatedly to scroll
through the list of parameters. The operating dis-
play will show the parameter number and main
display will show the parameter setting.
3. To modify a parameter press the or buttons.
4. Press the “”button to scroll to the next param-
eter to be changed.
5. After all parameters have been changed, press
the button to close the setting menu and store
the changes. The main display will go blank and
a P will be displayed in the operating display to
let you know the control was programmed.
If the reset button is not pressed within 30
seconds, the settings menu is automatically
closed and the changes are stored.
If the N/ FF button is pressed prior to
the resets button, the settings menu is
closed and the changes are N T stored.
NOTICE
Adjustments
Description
Parameters
(Flashing)
Factory Settings
LED
(Flashing)
Installation type
0
186ºF [86Cº]
120ºF [49Cº]
0=Combi (Heat and DHW)
2=DHW only (no heating system required)
3=Heating only
CH pump continuous
00=Intermittent pump on for heat and post purge
1=Pump continously active except during DHW call or
if outside temperature is above parameter 7 with the
outdoor sensor installed - Warm Weather Shut Down.
1=Heating + SMART I.F.W.H.
Min. supply temperature of the heat curve
86ºF [30Cº] Adjustment range 60°F to 140°F [16ºC to 60ºC]
Min. outside temperature of the heat curve
0ºF [-18Cº] Adjustment range -22°F to 50°F [-30ºC to 10ºC]
Max. outside temperature of the heat curve
64 ºF [18Cº] Adjustment range 60°F to 78°F [16ºC to 26ºC]
CH pump post purge period
1Adjustment range 0 to 15 minutes
Not applicable
0Adjustment range 0 to 15 minutes
Anti-cycling period during CH operation
The anti-cycling time starts when burner shuts down during a CH call due to boiler water reaching the boiler set point temperature plus a 6ºF [3ºC]
differential. The CH circulator will continue to operate while the burner is blocked.
0Minimal switch-off time in CH operation
Adjustable from 0 to 15 minutes
1
2
5
6
7
8
o
P
Main Display Operating
Display
Boiler set point temperature
Not applicable
Adjustment range 86ºF to 194ºF [30ºC to 90ºC]
Adjustment range 104ºF to 149ºF [40ºC to 65ºC]
1
1

Appliance Control Display
11
Error (Hard Lockout) Mode
If a system fault occurs, the system enters a hard
lockout condition which requires a manual reset by
pressing the RESET button . A hard lock is indi-
cated by a flashing [E] on the operating display as
well as a flashing LED light above the reset but-
ton. The error code is located on the main display.
The error must be corrected before the control will
reset.
The appliance freeze protection feature is
disabled during a Hard Lockout, however
the CH circulator will operate.
During a hard lockout or low water condition
the appliance will not re-start without serv-
ice. If the heating system is left unattended in
cold weather appropriate safeguards or
alarms should be installed to prevent proper-
ty damage.
CAUTION
CAUTION
Table 6: 12 K hm NTC Sensor Resistance

Appliance Control Display
12
10, 11, 12,
1, 28
4
0
2
29,30
5
6
8
13, 14 sensor fault S1
- CH supply
• Check wiring for break
• Check for proper flow direction
• Replace S1
•E10 Open sensor
• E 11 Shorted sensor
• E12 Decreased too quickly
• E13 Increased too quickly
• E14 Stuck
• Replace S2
• E 20 Open sensor
• E 21 Shorted sensor
• E22 Decreased too quickly
• E23 Increased too quickly
• E24 Stuck
20, 21, 22,
23, 24
- CH return
sensor fault S2
• Check wiring for break
• Check for proper flow direction
- Sensor fault after self check • Replace S1 and/or S2
- Temperature too high
• Air in installation
• Pump not running
• Insufficient flow in installation, shut off valves closed, pump setting too low
• CHeck for wiring
- CH supply sensor S1 and CH
return sensor S2
interchanged
• Check for proper flow direction
• Replace S1 or S2
- No flame signal
• Manual gas shut off valve closed
• Remove air from gas pipe
• Gas supply pressure too low or failing
• Gas valve or ignition unit not powered
• Incorrect ignition gap
• Check adjustment of gas valve
- Poor flame signal • Condensate drain blocked
• Check adjustment of gas valve
- Flame detection fault
• Replace ignition cable + spark plug cap
• Replace ignition unit at gas valve
• Replace boiler controller
- Incorrect fan speed
• Fan catching on casing
• Wiring between fan and casing
• Check wiring for poor wire contact
• Replace fan
- Gas valve relay fault • Replace boiler controller
* Red LED above button will flash, correct condition, and press button.
Operating
Display
(Flashing)
Main Display Possible Solution
Error Description
E
18, 19 fault
- Flue sensor • E18 open sensor
• E19 Shorted sensor
• Check/Replace sensor
E
50F - Improper frequency • Verify ground
• Frequency should be between 45 and 65 Hz
E
E
E
E
E
E
E
E
E
If outdoor sensosr is shorted the boiler will not enter into a hard lockout but will maintain the minimum supply temperature
of the heat curve.
NOTICE
Error (Hard Lockout) Codes*

13
Replacement Parts
Pressure relief and air vent assembly
T
S
Low voltage/terminal strip X4
Blower
Ignition electrode
High voltage terminal strip
Condensate drain trap assembly
Condensate pan
Control/Display
CH Return sensor S2
CH supply sensor S1
CHALLENGER Internal Components
Replacement parts must be purchased
through a local Triangle Tube distributor.
When ordering part please provide the model
number and description and/or part number
of replacement part. Use only genuine
Triangle Tube replacement parts to ensure
warranty coverage and to avoid damage to
appliance and improper operation of appli-
ance. Contact Triangle Tube at 856-228-8881
or www.triangletube.com for list of distribu-
tors nearest you.
WARNING

14
Replacement Parts
3
CHALLENGER Front Door
Item art Number
CC85s
art Number
CC105s
art Number
CC125s Description
1 CCRKIT04 Wall Bracket Assembly (Not Shown)
2 CCRKIT05 Pipe Connectors & Brackets Assembly
(Not Shown)
2A CCFTG01 Connector Pipe CH (Not Shown) - 1/Kit
3 CCRKIT06 CCRKIT07 CCRKIT08 Front Door Assembly

15
Replacement Part
2
2
3
1
23
3
4
3
CHALLENGER Vent Components
Item art Number
CC85s
art Number
CC105s
art Number
CC125s Description
1
CCRKIT09 80/125 Concentric Vent /Air Adapter Assembly
(option - shown)
CCRKIT35 3” Vent /Air Adapter Assembly (standard - not
shown)
2 CCRKIT10 CCRKIT11 CCRKIT12 Vent Assembly
3 CCRKIT13 Condensate Collector Assembly
4 CCRKIT14 Condensate Drain Trap Assembly

16
Replacement Parts
9
1
3
2
8
4
7
4
CHALLENGER Internal Components
Item art Number
CC85s
art Number
CC105s
art Number
CC125s Description
1 CCRKIT15 Igniter Assembly
2 CCC B01 Ignition Cable
3 CCRKIT16 Sight Glass Assembly
4 CCRKIT17 CH Sensor Assembly - 1 / Kit
7 CCRKIT19 WCO/CH Pressure Sensor Assembly
8 CCRKIT20 CCRKIT21 CCRKIT22 CH Supply pipe Assembly
9 CCRKIT23 CH Return Pipe Assembly

17
Replacement Parts
4
1
2
3
CHALLENGER Blower & Gas Valve Components
Item art Number
CC85s
art Number
CC105s
art Number
CC125s Description
1 CCRKIT28 Ignition Transformer Assembly
2 CCRKIT29 Gas Valve Assembly
3 CCRKIT30 CCRKIT31 Gas Pipe Assembly
4 CCRKIT32 Blower Assembly