TriangleTube Challenger Manual

2011-60 Challenge Concent ic_Ai VentSup.
This document is intended to be used by a qualified heating contractor or service
technician. Read all instructions within this document and within the CHAL-
LENGER Installation and Maintenance Manual, before proceeding with the instal-
lation. It is recommended to follow the procedures in the steps given, skipping or
missing procedural steps could result in severe personal injury, death or sub-
stantial property damage.
The installation must conform to the requirements of the authority having juris-
diction or, in the absence of such requirements, to the National Fuel Gas Code,
AN I Z223.1/ NFPA 54, and/or Natural Gas and Propane Installation Code,
CAN/C A B149.1.
Concentric Vent/Air System Supplement
Dat : 4/22/13
NOTICE
WARNING

Table of Contents
i
RODUCT AND SAFETY INFORMATION
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SECTION I - RE-INSTALLATION ITEMS
General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Vent/Air System Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembled Vent/Air System Kit Dimensions. . . . . . . . . . . . . . . . . . . . . . . . 3
Optional Vent/Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION II - VENT/AIR SYSTEM INSTALLATION
Vent/Air System Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Determine Termination ocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Concentric Vent/Air Adapter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Vent/Air System Joint Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Termination Installation - Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Termination Installation - Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Cutting Termination Fitting or CCVPIP04 to ength . . . . . . . . . . . . . . . . . 9
Adjustable ength Vent/Air System Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fire Stop Support Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Multiple Vent/Air System Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION III - MAINTENANCE ROCEDURES
Inspect Vent/Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

P oduct & Safety Info mation
1
Indicates a potentially hazardous situation
which, if ignored, can result in death, seri-
ous injury or substantial property damage.
Indicates special instructions on installa-
tion, operation or maintenance, which are
important to appliance but not related to
personal injury hazards.
NOTICE
WARNING
The following terms are used throughout this manual to bring attention to the presence of potential
hazards or to important information concerning the appliance.
Triangle Tube reserves the right to modify the technical specifications and components of its prod-
ucts without prior notice.
NOTICE
Definitions
This Vent/Air System is listed to ULCS636 as Type BH Class IIC Vent System with a 110ºC (230ºF)
maximum flue temperature rating.
NOTICE

P e-Installation Items
2
SECTION I - re-Installation Items
General Requirements
The installation must conform to the requirements
of the authority having jurisdiction or, in the
absence of such requirements, to the National Fuel
Gas Code, ANSI Z223.1/ NF A 54, and/or Natural
Gas and ropane Installation Code, CAN/CSA
B149.1.
The vent/air system must be fully constructed using
ON Y the CHA ENGER Concentric Vent/Air
System components from Triangle Tube. Do not
mix other vent components or joining methods from
other manufacturers.
Do not mix vent components or joining meth-
ods from any other vent manufacturer with
Triangle Tube’s CHALLENGER Concentric
Vent/Air System. Failure to comply with this
requirement could cause vent failure result-
ing in leakage of flue products into the living
space of the building.
WARNING
Use of cellular core VC (ASTM F891) cellu-
lar core C VC, or Radel® (polyphenolsul-
fone) in venting system is prohibited.
Covering VC/C VC or olypropylene vent
pipe and fittings with thermal insulation is
prohibited.
Do not connect more than a single appliance into
the vent/air system.
All penetrations of the vent/air system through ceil-
ings, floors, walls or roofs must be properly fire
stopped. The installer must comply with all local
codes and requirements regarding fire stops and
vent/air penetrations.
The vent/air system must not penetrate or be routed
through any active vent system or chimney.
Vent/Air System Kit Components
Prior to installation of the vent/air system check to
ensure all parts required for the completion of the
system are present. See Figure 1 for complete
breakdown of horizontal concentric vent/air system
kit parts and Fig. 3, page 3 for optional components
including vertical venting.
NOTICE
NOTICE
Termination Assembly
Elbow
Clamp with
Locking Band
Support Plate
Fig. 1: Concentric Vent/Air ystem Kit Components Horizontal - CCVKIT01
Note: 1. Conc ntric V nt/Air Adapt r and mounting hardwar ar not shown
2. For v rtical v nting ord r parts s parat ly as list d in Fig. 3. Do not ord r - CCVKIT01

P e-Installation Items
3
33 1/4” [84.5 cm]
Face of Wall
Top of Boiler
6 3/4”
[17.1 cm]
7”
[17.8 cm]
Fig. 2: Assembled Horizontal Vent/Air ystem Kit Dimensions - CCVKIT01
Part # Description Qty
CCVADT011 Challenger Vent/Air Adapter 1
CCV I 01 Common Vent ipe – 39 Inches (990mm) Lgth 1
CCV I 02 Common Vent ipe – 79 inches (2007mm) Lgth 1
CCV I 03 Vent ipe adjustable length with clamp (10.8” to
15.5”) [ 27.3 mm to 39.4 mm] 1
CCV I 04 Vent ipe Cutable with Clamp 19.7” (50 cm)
CCELB01 90° Elbow with Clamp 1
CCELB01 45° Elbow with Clamp 1
CCVTERM01 Concentric Vertical Termination with Support Bracket 1
CCVCL 01 Fire Stop late 1
CCVCL 01 Clamp Hanging 1
CCVCL 02 Clamp (repair part only) 1
CCVFLA03 Exterior Roof Flashing – 0° / Flat 1
CCVFLA01 Exterior Roof Flashing – 0° - 25° itch 1
CCVFLA02 Exterior Roof Flashing – 25° - 45° itch 1
CCGSK01 Inner ipe gasket – 85 mm 1
Fig. 3: Concentric Vent ystem Components

4
h. ocate the vent and combustion air termina-
tions in a manner to protect from damage by
foreign objects, such as stones, balls, or
buildup of leaves or sediment.
3. Maintain the following clearances to the termi-
nation:
a. At least 3 feet [0.9 M] from adjacent walls
b. No closer than 3 feet [0.9 M] below roof
overhangs
c. At least 7 feet [2.1 M] above any public
walkways
d. At least 3 feet [0.9 M] above any forced air
intake within 10 feet [3 M] (does not apply
to the combustion air inlet of a direct vent
appliance).
e. Must be at least 4 feet [1.2 M] (6 feet [1.8 M]
Canada) from any electric meters, gas meters,
gas meter-regulators, relief valves or other
equipment. Never terminate above or below
any of these items within 4 feet [1.2 M] (6 feet
[1.8 M] Canada) horizontally.
f. No closer than 12” [ 30.5 cm] below or hor-
izontally from any door or window or grav-
ity air inlet.
g. Horizontal air intake must terminate at least
12 inches above grade (18” [45.7 cm]
Canada) or anticipated snow line as shown
in Fig. 5, page 5.
Vent/Ai System Installation
SECTION II - Vent/Air System
Installation
Vent/Air System Clearance Requirements
The vent/air system may maintain zero clearance to
combustible & non-combustible materials.
Determine Termination Location
1. The maximum equivalent length of the concen-
tric vent/air system should not exceed 85 Ft
[25.9 M] (excluding the termination). For each
90º elbow in the system, the equivalent length is
reduced by 10 feet [3 M] . For each 45º elbow
in the system, the equivalent length is reduced
by 5 feet [1.5 M] .
2. The installer must consider the following
when determining the location of the vent/air
system termination:
a. ocate the termination where flue vapors
will not damage surrounding shrubs, plants
or air conditioning equipment or be objec-
tionable to the homeowner.
b. The flue products will form a noticeable
plume as they condense in colder air. Avoid
terminating in areas where the plume could
obstruct window views.
c. Prevailing winds could cause freezing of
flue gas condensation and a buildup of
water/ice on surrounding plants, building
surfaces or combustion air inlet.
d. Avoid locations of possible accidental con-
tact of flue vapors with persons or pets.
e. Avoid locations where prevailing winds
could affect the performance of the appli-
ance or cause recirculation of the flue gases,
such as inside corners of buildings or near
adjacent buildings or vertical surfaces, win-
dow wells, stairwells, alcoves, courtyards,
or other recessed areas.
f. Do not terminate above any doors or win-
dows; flue condensate could freeze causing
ice formations.
g. ocate the termination to prevent possible
condensate damage to exterior finishes.
Fig. 4: Termination Clearances of Direct
Vent Systems
[30.5cm]
[2.1M]
[3M]
[0.9M]
[30.5cm]

5
Concentric Vent/Air Adapter Installation
Step 1: Removal of Existing Adapter 3” 2- ipe
Adapter
1. Remove the front cover of the Challenger.
2. While holding the flue tube in place, rotate the
existing 3” 2-pipe adapter counterclockwise less
that ¼ turn until it can be removed.
3. Remove the o-ring from the adapter. Save this o-
ring to be installed onto the bottom of the New
Adapter.
Step 2: Install the New Adapter
1. Install the O-ring onto the New Adapter. As
shown in Fig. 6.
2. Place the New Adapter onto the top of the
Challenger, positioning the flue tube inside the
adapter. The test port should face the front of
the Challenger and the O-ring should fit into the
top cover of the Challenger.
3. Rotate the New Adapter (Clockwise) until it
clicks into place (less than ¼ turn) and is square
with the front of the Challenger.
Vent/Ai System Installation
h. Horizontal termination must not extend
more than 6-3/4 inches [17.1 cm] beyond
the exterior wall as shown in Fig. 5, page 5.
4. Horizontal or vertical runs of the vent/air sys-
tem must be supported at every joint. The
installer should use an optional Hanging Clamp,
or perforated metal strap hangers or equivalent,
to support the piping.
5. The vent/air system must terminate using the
termination supplied in the horizontal kit -
CCVKIT01 or vertically with - CCVTERM01.
6. The vent/air system must be pitched back to the
appliance at minimum 5/8 inch per foot
[16mm/30cm] on any horizontal runs.
63/4”
[17.1cm]
[30.5cm]
Face of Wall
12”
Min.
Grade/Anticipated
Snow Line
Air Intake
Fig. 5: Installation Requirements - Horizontal
Fig. 6: Installation of O-Ring

Vent/Ai System Installation
6
Step 3: Inspect Condensate an and Reinstall
the Front Cover.
1. With the new Adapter in place inspect the Flue
and Condensate Pan to ensure proper fit.
2. Push up on the Condensate Pan underneath the
heat exchanger while pushing down on the
Condensate Pan where it engages with the
Condensate Trap. As shown in Fig. 8.
3. Inspect the connection with the Condensate Trap
to ensure the Condensate Pan fits snugly in the
gasketed connection to the Condensate Trap.
Improper installation may result in flue gas
leakage which may result in severe personal
injury or death.
4. This condition where the Condensate Pan does
not engage into the Condensate Trap as shown in
Fig. 10 is not acceptable and will result in flue
gas recirculation, harming the boiler. Adjust the
Condensate Pan to properly engage into the
Condensate Trap gasket. As shown in Fig. 9.
5. Reinstall the front cover of the Challenger.
Failure to properly support the vent and air
piping at the appliance may result in severe
personal injury or death.
WARNING
WARNING
Fig. 7: Inspecting Flue Tube/Adapter Connection
Fig. 8: Inspection of Condensate Pan
Fig. 9: Proper Engagement of Condensate Pan
Fig. 10: Improper Engagement of Condensate Pan

Vent/Ai System Installation
7
Vent/Air System Joint Assembly
1. When installing the vent system, the female end
of the pipe or fitting should face up or away
from the appliance.
2. Prior to assembly of any piping or fittings
inspect and ensure the inner pipe gasket seal is
present, undamaged and properly seated in the
groove of the pipe.
3. Insert and rotate the male end of the inner pipe
into the female end of the previous pipe section.
It is recommend to moisten the gasket seal with
clean water prior to assembly.
To aid in the assembly of the pipes and fit-
tings use only clean water to moisten the gas-
ket and the mating male end of the pipe. Use
a twisting motion as the pipe ends are pressed
together.
4. Push the sections together firmly until the outer
jacket bead of the new section has made contact
with the edge of the female end of the previous
section. When fully assembled, the outer female
end of the previous section will overlap the
male end by approximately 1”[25mm].
5. Use 2 self-drilling screws provided to secure the
outer sections together where they overlap.
Install screws 90º apart from one another. No
pre-drilling is required.
Do not over tig ten t e self-drilling screws
into t e sections. Use a low torque screw
drive to prevent stripping out t e oles. If a
ole becomes stripped due to over tig tening,
a larger diameter screw (lengt of screw
must not exceed 1/2” [13mm]) or a s ort pop
rivet may be used.
6. Seal the two components together by placing a
clamp over the connection and pressing down
on the clamp lever. The clamp should be cen-
tered over the connection and the edge of the
clamp should cover the beads on the end of each
component. If the clamp does not cover and
lock onto the component jacket beads, ensure
the components are fully pressed together and
interlocked.
WARNING
NOTICE
It is very important t at t e clamp be prop-
erly installed. Failure to properly connect
t e vent components could lead to vent fail-
ure and can result in deat , serious injury or
substantial property damage.
WARNING
Clamp
Female
End
Male End
Outer Jacket
Bead
Lever
Fig. 11: Vent Joint Assembly
Note: Secure outer sections together where they
overlap with 2 self-drilling screws provided, 90º
apart using low torque setting of driver.

8
Termination Installation - Horizontal
1. Determine the termination location using the
guidelines listed on page 4 and 5 and drill or cut
a 5 inch hole [12.7 cm].
2. Install the interior support plate on the inside
wall using the screws provided in the kit.
3. Mount the termination fitting through the interi-
or support plate from the exterior side of the
wall. Ensure the air inlet holes of the termina-
tion fitting are facing down and that the fitting
is mounted level.
To determine the appropriate length of the
termination fitting, mount the exterior sup-
port plate temporarily prior to the installation
of the interior support plate. Insert the termi-
nation fitting from the interior side of the wall
through the exterior support plate. The termi-
nation fitting has a formed bead that limits the
distance of penetration through the exterior
support plate. The termination fitting should
be measured and cut to length prior to mount-
ing the support plates. The termination may
be installed through a wall thickness of up to
20” [50.8 cm] maximum. For information on
measuring and cutting the termination fitting,
reference page 9.
4. Mount the exterior support plate around the ter-
mination on the outside wall. Ensure the support
plate is flush to the formed end of the termina-
tion fitting and the fitting is mounted level.
The termination fitting must be installed
level without pitch either to the appliance or
away from appliance.
5. The gaps between the outer pipe of the termina-
tion fitting and the support plates must be sealed
with a high quality silicone caulk. Also apply
the silicone caulk along the outer edge of the
support plates sealing the plates to the wall.
NOTICE
NOTICE
Termination Installation - Vertical
When venting vertically do not order the
Concentric Vent/Air Horizontal Kit - CCVK-
IT01 as shown in Fig. 1, order required parts
separately only from listed parts in Fig. 3.
When using an inoperative chimney as a
means of a chase for the vent/air piping the
surrounding space within the chimney can-
not be used to draw combustion air or vent
another appliance.
A gas vent extending through a roof should
not terminate near an adjacent wall or below
any building extensions such as roof eaves,
balconies or decks. Failure to comply with
the required clearances in this manual could
result in severe personal injury, death or sub-
stantial property damage.
1. Determine the termination location using the
guidelines listed on page 4 and 5 and drill or cut
a 5 inch [12.7 cm] hole.
2. Secure appropriately pitched flashing as listed
in Fig. 3.
3. Seal flashing to roof with appropriate sealant
(field supplied).
To determine the appropriate length of the
termination fitting, temporarily mount the
vertical termination - CCVTERM01 onto the
roof flashing. The termination fitting should
be measured and cut to length prior to secur-
ing termination to flashing. The termination
maybe installed through a wall thickness of
up to 20” [50.8 cm] maximum.
NOTICE
WARNING
NOTICE
NOTICE
Vent/Ai System Installation

9
Vent/Ai System Installation
4. Secure and support vertical termination to flash-
ing with included hardware.
5. Seal all exterior joints including pivot points
with silicone sealant.
Cutting Termination Fitting or CCVPIP04 to
Lengt
1. Only the termination fitting and CCV I 04 can
be cut to length if required.
Components that may be cut will have a label
on the male end of the part stating “CAN BE
CUT THIS END ONLY”
2. Add 3/4” [19 mm] to the required length and
mark the end of the outer pipe.
Make sure to add 3/4” [19 mm] to the overall
required length when cutting both inner and
outer pipes.
3. Cut the pipes using an abrasive cutoff saw or
hacksaw (minimum 32 teeth per inch). Make
sure that the inner pipe remains centered in the
outer pipe while cutting. It may be helpful to
temporarily connect the vent section to be cut
into another vent pipe to keep the center pipe
centered while cutting.
4. Mark the end of the outer pipe at the required
length. The length of the outer pipe should be
3/4” [19 mm] less than the inner pipe.
5. Cut through the outer pipe ONLY using a hack-
saw (minimum 32 teeth per inch), or snips.
6. File off any burrs or rough edges on both pipes.
Clean off any dust or dirt.
7. If the cutting process distorted the roundness of
the pipes, carefully use your thumbs to correct
the distortion.
NOTICE
NOTICE
53” (1354 mm)
38 1/2” (978 mm)
Fig. 12 : Vertical Concentric Termination
Optional Exterior
Flashing
O Degree Pitch-Flat
0-25 Degree Pitch
24-45 Degree Pitch
Vertical
Concentric
Termination
Interior Support
Bracket
Termination
Interior Pipe
Fig. 13: Vertical Concentric Termination

The Support late provided in the Concentric
Vent/Air System Kit does not contain tabs for
securing the pipe to the plate, where as the
Fire Stop Support late does.
4. Seal around the support plate where
attached to exterior of building and around
pipe penetration, through the support plates
with silicone sealant.
Multiple Vent/Air System Terminations
For multiple appliance vent/air system installations
maintain a minimum of 12 inches [30.5 cm] from
centerlines as illustrated in Fig. 14.
NOTICE
10
Vent/Ai System Installation
When cutting or correcting the shape of the
outer pipe, WEAR GLOVES. The ends of the
vent pipes can become very sharp when cut.
Adjustable Length Vent/Air System ipe
The component piping and fittings (exclud-
ing the termination fittings and CCV I 04)
are not design to be cut for custom lengths.
Cutting the piping or fittings to length may
compromise the vent seal causing potential
vent failure or leakage of flue gas resulting in
death, serious injury or substantial injury.
1. An adjustable straight vent/air system pipe
length is available for applications that require
custom lengths.
2. The adjustable length vent/air system pipe is
adjustable from a minimum of 12” [30.5 cm] up
to a maximum of 16.5” [41.9 cm].
3. To adjust the length, firmly grab each end of the
pipe and twist together to shorten or twist apart
to lengthen.
Fire Stop Support late
The Fire Stop Support Plate must be used when the
vent/air system piping passes through any floors, ceil-
ings, enclosed chase or exterior walls. This plate can
be used for vertical or horizontal penetrations.
1. Prepare a 5-inch [12.7 cm] round or square open-
ing. Remove any insulation from the opening.
2. Secure the plate at the corners using the
screws provided. For exterior wall penetra-
tions, 2 plates are required, one on each side
of exterior wall. For interior wall/floor pen-
etrations, 1 plate is required.
3. Install the concentric pipe through the plate.
Secure the pipe to the Fire Stop Support Plate
using only the self-drilling screws provided,
through the plate tabs and into the concentric
pipes outer jacket.
WARNING
WARNING
12"Min.
[30.5cm].
Fig. 14: Multiple Vent/Air System Terminations -
Horizontal or Vertical (not shown) Installations.

Maintenance P ocedu es
11
SECTION III - Maintenance rocedures
Inspect Vent/Air System
Visually inspect the vent/air system annually for
blockage, deterioration or leakage. Immediately
repair any joints that show signs of deterioration or
leakage with the appliance turned off.
Failure to inspect the vent/air system and
have any conditions repaired can result in
severe personal injury or death.
WARNING

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