ACV CC105 Installation & Maintenance Manual Download

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Installation & Maintenance Manual

CHALLENGER

COMBI

CC105, CC125, CC125H

If the information in this manual is not followed exactly, a fire or explosion may re-
sult 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 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.

WARNING

Date: 10/6/2016

2016-23 CHALLENGER Combi Manual

Summary of Contents for CC105

Page 1: ...the vicinity of this or any other appliance WHATTO DO IFYOU 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 inst...

Page 2: ...Massachusetts Installations Only 8 Section IV Appliance Preparations 9 4 1 Shipping Handling Instructions 9 4 2 Wall Mounting Installation 9 4 3 Wall Mounting Guidelines 9 4 4 Stud Wall Installation 10 4 5 Solid Wall Installation 10 4 6 Appliance Mounting 10 4 7 Piping Support Bracket 10 Section V Boiler Piping 11 5 1 General Piping Requirements 11 5 2 Pressure Relief Valve PRV 11 5 3 Low Water Cu...

Page 3: ...y 22 Section VIII Gas Piping 23 8 1 Gas Supply Piping Connection 23 8 2 Natural Gas 24 8 3 Propane Gas 25 Section IX Internal Wiring 26 9 1 General Requirements 26 Section X External Wiring 27 10 1 Installation Compliance 27 10 2 Line Voltage Connections 27 10 3 Circulator Maximum Current Rating 27 10 4 Central Heating CH Circulator 27 10 5 DHW Circulator for Optional SMART COMFORT I F W H 27 10 6...

Page 4: ...41 12 15 Warning Codes 41 Section XIII Outdoor Reset Control 42 13 1 Mounting the Sensor 42 13 2 Wiring the Sensor 42 13 3 Adjusting Outdoor Reset Curve 42 13 4 Changing Outdoor Reset Parameters 43 Section XIV Checkout Procedures 44 Section XV Installation Record 45 Section XVI Maintenance Schedule 46 16 1 Service Technician 46 16 2 Owner Maintenance 46 Section XVII Maintenance Procedures 47 17 1 ...

Page 5: ...52 17 22 Review With Owner 52 Section XVIII Replacement Parts 54 18 1 Internal Components 54 18 2 Front Door 55 18 3 Vent Components 56 18 4 Heat Exchanger Components 57 18 5 Blower Gas Valve Components 58 18 6 Burner Components 59 18 7 Control Components 60 Section XIX Dimensions Connections 61 Section XX Domestic Specifications 62 20 1 Performance Ratings 62 20 2 Domestic Flow 63 Section XXI Boi...

Page 6: ...o not touch any electrical 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 Installation and service must be performed by a quali fied installer service agency or the gas supplier Should overheating occur or the gas supply fails to shut off t...

Page 7: ... pressure relief valve field supplied is installed as recommended for standard domestic hot water installations or a tem perature pressure relief valve for storage tank or ACV Triangle Tube SMART COMFORT Indirect Fired Water Heater I F W H installations Check if the 30 psi 2 bar pressure relief valve supplied is installed in the recommended location for heating applications To avoid injury install...

Page 8: ...irty 30 days of installa tion in order to gain warranty coverage When receiving the CHALLENGER any claims for dam age or shortage in shipment must be filed immediately against the transportation company by the consignee Leave all documentation received with the appliance with the owner for future reference NOTICE NOTICE NOTICE ...

Page 9: ...s manifold and gas controls meet the safe lighting and other performance requirements as specified in ANSI Z21 13 NOTICE 2 2 Determining Product Location Before locating the CHALLENGER check for convenient locations to Heating system piping Domestic water supply piping Venting Gas supply piping Electrical service Ensure the appliance location allows the combustion air and vent piping to be routed ...

Page 10: ...o maintain ambient temperatures within safe lim its to comply with the National Fuel Gas Code NFPA 54 ANSI Z223 1 WARNING WARNING NOTICE BEST PRACTICE 2 5 Residential Garage Installations When installing the CHALLENGER in a residential garage the following special precautions per NFPA54 ANSI Z223 1 must be taken Mount the appliance a minimum 18 inches 458 mm above the floor level of the garage Ens...

Page 11: ...ing products and other similar products Areas likely to contain 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 worksho...

Page 12: ...determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition NOTICE NOTICE DANGER BEST PRACTICE Insofar as is practical close all exterior building doors and 3 windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dry...

Page 13: ... the completion of the installation Ametal or plastic identification plate shall be mounted on the 4 exterior of the building four feet directly above the location of the 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 en sure the lettering meets code requir...

Page 14: ...ry or death 4 3 Wall Mounting Guidelines The wall mounting bracket is designed for stud spacing of 12 1 inch 30 5 cm or 16 inch 40 6 cm on centers For unconventional stud spacing a solid secure mounting surface must be provided for installation of the bracket For applications using wood studs install the bracket using the 2 lag screws provided with the appliance see Fig 2 Ensure both lag screws ar...

Page 15: ...Level bracket and tighten bolts securely 7 4 6 Appliance Mounting Obtain assistance in lifting the appliance onto the wall bracket 1 Install the appliance making sure the appliance mounting lip 2 located along the upper edge of the rear jacket panel engages the wall mounting bracket Ensure the appliance is seated properly and is secure 4 7 Piping Support Bracket Appliance must be installed using t...

Page 16: ...WARNING WARNING 5 3 Low Water Cut Off CH Pressure Sensor The Low Water Cut Off LWCO only applies for space heating Operation of the LWCO does not prevent a Do mestic hot water call for heat The CHALLENGER is equipped with a factory installed pressure 1 sensor type LowWater Cut Off LWCO The minimum operating Central Heating CH system pressure 2 is 7 psig 0 5 bar If CH System pressure is below 7 psi...

Page 17: ...ain Valve Installation Drain Valve by Others 1 inch Compression Assembly supplied 1 inch Compression Assembly supplied 1 inch Tee by Others 1 inch Tee supplied Temperature Pressure Gauge supplied Piping Bracket supplied Retaining Clip supplied Compression Ferrule Compression Nut Compression NPT Adapter Manual Air Vent supplied 3 4 Tee supplied 3 4 Nipple supplied 3 4 Street Elbow supplied Installe...

Page 18: ... 66 for pressure drop and minimum flow rate required through the boiler 5 9 Sizing Primary Piping See Fig 7 and 8 on page 15 for recommended piping arrangements based on various applications Size the piping and system components required in the space heating system using recognized design methods CAUTION CAUTION 5 10 System Piping Zone Circulators Connect the CHALLENGER to the system piping as sho...

Page 19: ...k 11 The CHALLENGER s domestic piping should not be utilized Refer to the installation manual provided with the SMART COMFORT for additional installation details See Setting theAppliance Parameters Section 12 11 for parameter wiring and operational details using the SMART COMFORTwith a CHALLENGER boiler 5 14 System Piping Special Application If the boiler is used in conjunction with a chilled wate...

Page 20: ...Valves CHALLENGER Boiler 1 Boiler Circulator with Flow Check 2 Flow Check Valve 3 IsolationValve 4 Zone Circulator 5 Drain PurgeValve 6 Pressure ReliefValve 7 Air Separator 8 AutomaticAirVent 9 Diaphragm ExpansionTank 10 Automatic Fill Valve 11 DHW Circulator with Flow Check 12 CHALLENGER Boiler 1 Boiler Circulator with Flow Check 2 IsolationValve 3 ZoneValve 4 Drain PurgeValve 5 Pressure ReliefVa...

Page 21: ...ct water temperature at any faucet or shower Occasionally check temperature at each point of use then adjust thermostatic mixing valve accordingly Always recheck temperature after adjusting Lowering the thermostatic mixing valves as indicated in these instructions will reduce water temperature levels Consult your installer or service technician 6 2 Operating Restrictions Minimum DHW flow rate is 0...

Page 22: ...nce and relief valve Failure to comply with the guidelines on installing the pressure relief valve and discharge piping can result in substantial property damage serious injury or death WARNING 6 4 Temperature Pressure T P Relief Valve Storage Tank or SMART COMFORT Installations To reduce risk of excessive pressures and temperatures in a storage tank or ACV Triangle Tube SMART COM FORT I F W H ins...

Page 23: ...estic coil WARNING CAUTION BEST PRACTICE It is recommended to install a strainer on the domestic cold water inlet to prevent any nuisance issues with the domestic flow sensor An optional lead free 60 mesh y strainer is available through ACV Triangle Tube part number CCSTRA01 All plumbing must meet or exceed all local state and national plumbing codes Use pipe joint compound or tape suitable for po...

Page 24: ...ping The installer must 1 Relocate the thermostatic mixing valve from the CHALLENGER to the outlet of the storage tank 2 Remove domestic restrictor at the inlet of the domestic flow sensor 3 Provide recirculation from the storage tank back to the CHALLENGER using a bronze or stainless steel circulator 6 13 Setting the Thermostatic Mixing Valve The thermostatic mixing valve controls the outlet hot ...

Page 25: ...ure 10 Installation of Domestic Compression Adapter Assemblies 1 CHALLENGER 2 Isolation valve 3 Backflow preventer or pressure reducing valve 4 Thermal expansion tank potable 5 Domestic pressure relief valve 150 psi max 6 Drain flush valve 7 Mixing valve with check valve 8 Strainer 9 Flow check valve 10 Circulator potable must be controlled by an aquastat Optional device may be required by local c...

Page 26: ... display panel see Section 12 5 Figure 12 Domestic Piping Storage Tank Installations 1 CHALLENGER 2 Isolation valve 3 Backflow preventer or pressure reducing valve 4 Thermal expansion tank potable 5 Temperature Pressure relief valve 6 Drain flush valve 7 Mixing valve with check valve 8 Circulator potable must be controlled by an aquastat 9 Flow check valve 10 Strainer 11 Vacuum breaker 12 Domestic...

Page 27: ...propriate part numbers Using the standard condensate trap 4 75 120 mm long on these mod els is prohibited and can result in substantial property damage serious injury or death Remove front door and install trap Ensure the trap is 2 completely seated and secure on the appliance Connect 13 16 ID tubing to the drain barbed fitting on the trap 3 assembly The drain line materials must be an approved ma...

Page 28: ...se pipe joint compound compatible with natural and propane 9 gases Apply sparingly only to the male threads of pipe joints so that pipe dope does not block gas flow The gas supply piping must be installed in accordance to all applicable local state and national codes in addi tion to all utility requirements NOTICE Do not check for gas leaks with an open flame Use a gas detection device or bubble t...

Page 29: ...any time Adjust the lockup pressure regulator for 13 w c 32 mbar 8 2 3Orifice Requirements Refer toTable 2 for orifice required for appliance operation using natural gas All units come set up for natural gas installation with the appropriate orifice pre installed DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting ...

Page 30: ...ed on the top of the unit in the instruc tions packet This kit includes all the necessary parts and instruction to perform the conversion from natural gas to propane gas If this conversion kit is missing please contact ACV Triangle Tube Technical Support for missing kit before installing unit WARNING Prior to start up ensure the appliance is set to fire propane Check the rating label for the type ...

Page 31: ... Canadian Electrical Code Part 1 CSAC22 1 ELECTRICAL SHOCK HAZARD For your safety disconnect electrical power supply to the appliance before servicing or making any electrical connections to avoid possible electric shock hazard Failure to do so can result in substantial property dam age serious injury or death WARNING Prior to servicing label all wires before disconnecting Wiring errors can cause ...

Page 32: ... on page 15 reference Fig 18 on page 28 Installer to provide a Transformer Relay such as Honeywell R8285 or equivalent and Zone Valves with isolated end switch such as HoneywellV8043 or equivalent 10 7 Low Voltage Connections Open the display cover and unscrew both screws to remove the 1 front cover see Fig 17 Pull the control display forward until it tips downwards to 2 provide access to the low ...

Page 33: ...oor reset function requires the connection of the included outdoor temperature sensor See SectionXIII for outdoor temperature sensor installation and wiring instructions 10 10SMART COMFORTAquastat Wiring Wire SMART COMFORTaquastat to the control module low voltage terminal strip as shown in Fig 16 on page 26 24 V Transformer by Others Honeywell V8043 Zone Valves or Equivalent Honeywell R8285B1038 ...

Page 34: ...one Valve 7 8 Fig 19 Multiple Zone Field Wiring Using Zone Valves To Challenger Low Voltage Terminal Strip H N High Voltage 120 V A C 24 V A C Room Thermostat Room Thermostat Zone 1 Zone 2 Additional zones Additional zones may be added as shown above Transformer Power 3 Wire Zone Valve 3 Wire Zone Valve Isolation relay 7 8 Use isolation relay on 3 wire zone valve with non isolated end switch Contr...

Page 35: ...onal zones may be added as shown above 7 8 6 2 1 4 3 5 6 2 1 4 3 5 T T T T Fig 20 Field Wiring with Zone Circulators Thermostat Zone 1 Zone 1 Circulator 120 VAC N To Challenger Low Voltage Terminal Strip Zone 2 Circulator Zone 3 Circulator Thermostat Zone 2 Thermostat Zone 3 R C T1 T1 T2 T2 T3 T3 C3 C3 C2 C2 C1 C1 PR PR X2 X1 L1 L2 ZC H 7 8 Fig 21 Typical Zone Relay Panel Wiring ...

Page 36: ...ifreeze manufacturer instructions The boiler water volume of the CC105 is 0 42 gallons 1 6 l and CC125 and CC125H is 0 50 gallons 1 9 l Remember to include this volume in sizing of the expansion tank Check with local code requirements for the installation of backflow preventers or actual disconnection from the boiler s cold water make up water supply line Ensure the concentration of antifreeze to ...

Page 37: ...mbly Inspect and ensure the Condensate DrainAssembly is properly 1 installed as described in Section 7 2 and shown in Fig 13 on page 22 Remove the Condensate DrainAssembly and fill with fresh 2 water Reinstall the Condensate DrainAssembly 3 Prior to startup and during initial operation smell near the floor and around the appliance for gas odorant or any unusual odor Do not proceed with the startup...

Page 38: ...ntactACV Triangle TubeTechnical Support 12 4 Check the CHALLENGER and System Check Piping 1 a Check heating system for leaks If found shut down the appliance and repair immediately b Purge any remaining air from the system Air in the system will interfere with circulation causing heat distribution problems and system noise CheckVent Piping and CombustionAir Piping 2 a Check for gas tight seal at e...

Page 39: ...ing The following operating display should occur 1 This is the prepurge cycle The burner blower and the CH circulator become energized The blower has a 5 second prepurge cycle 2 This is the ignition cycle The control module will open the gas valve and begin the spark for ignition a If the burner lights and the flame is proven the burner will begin to modulate b If the burner fails to light or the ...

Page 40: ... to light the burner by hand Set room thermostat s to lowest setting Turn the external 2 manual gas valve handle clockwise CLOSE valve handle shall be perpendicular to gas piping Turn OFF all electrical power to the appliance 3 Remove the front jacket panel on the appliance 4 Turn the external manual gas valve handle counter clockwise 5 to OPEN gas supply valve handle shall be parallel to gas pipi...

Page 41: ...le The control module closes the gas valve and the blower continues to operate for approximately 10 seconds Verify the DHW operation by repeating the outlined operation 6 sequence several times NOTICE Allow the appliance to operate and the boiler outlet temperature 5 to reach the set point temperature 1 The setpoint temperature has been reached Combustion will cease and the post purge cycle of the...

Page 42: ...g times with typical domestic demands learned over the past 3 days of use OFF no LED lit The appliance will not maintain a minimum 3 heat exchanger termperature This will delay the delivery of hot water In applications in which the DHW is not utilized or the DHW demand is minimal set the DHW function to OFF 12 10 4 High Fire Test Mode Press both the and buttons simultaneously once until the operat...

Page 43: ...ed 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 If the outdoor sensor is not installed the main display will displa...

Page 44: ...o 15 minutes DHW to CH anti cycle time 0 Adjustment range 0 to 15 minutes Anti cycling period during CH operation The anti cycle 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 0 Minimal switch off time in CH operation Adjustable from ...

Page 45: ...nce dips below 0 5 gpm To improve the domestic hot water performance at low flows it is recommended to reduce the domestic hot water temperature setpoint on the control down from 140 F 60 C to 125 F 52 C see Section 12 8 or to turn domestic function on the control to ON or ECO see Section 12 10 3 Additionally ensure the minimum domestic water pressure is 40 psi 3 8 bar A lower domestic hot water s...

Page 46: ...k for wiring error Supply sensor and return sensor swapped Check for proper flow direction Replace supply and or return sensors No flame signal Manual gas shut off valve closed Remove air from gas pipe Gas supply pressure too low 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...

Page 47: ... sensor terminals 9 and 3 10 of the low voltageX4 connector located on the control see appliance wiring diagram Fig 16 on page 26 13 3 Adjusting Outdoor Reset Curve The appliance CH set point along with Parameters 5 6 and 7 define the settings of the outdoor reset curve See Graph 1 andTable 7 on page 43 for an example of modifying the outdoor reset curve 13 3 1 CH Maximum Boiler Temperature If an ...

Page 48: ...n display begins to flash Press the button repeatedly to scroll through the list of 2 parameters The operating display will show the parameter number and the main display will show the parameter setting To modify a parameter press the or buttons 3 Press the reset button to close the parameter menu and 4 store the changes The appliance control module has now been reprogrammed 5 with the desired out...

Page 49: ...liances and a maximum pressure of 13 w c 32 mbar during non flow conditions for Natural and Propane gas Adjusted balancing valves and system limit controls to provide design temperatures to the space heating system In multiple zone applications adjusted for correct flow of water to each zone Checked and verified room thermostat s function properly and the thermostat s heat anticipator if used was ...

Page 50: ...pleted Check out procedures have been followed and completed Information regarding the unit and installation received and left with owner maintenance personnel Installer Information Company Address Address Phone Number Btu hr ____________________________________________________________________ ____________________________________________________________________ ____________________________________...

Page 51: ...m 11 16 1 2 Poor Combustion or Performance Clean heat exchanger and flue ways 1 Remove burner assembly and clean inside of burner head using 2 compressed air only Once the maintenance items are completed review the service with the owner 16 2 Owner Maintenance 16 2 1 Periodic Check the area around the appliance 1 Check and remove any blockage from the combustion air inlet 2 and ventilation opening...

Page 52: ...tem and combustion air piping for blockage deterioration or leakage Repair any deficiencies Verify that the combustion air inlet piping is connected sealed and properly supported 17 9 Check Boiler System Verify all system components are correctly installed and operating properly Check the cold fill pressure for the system typical cold water fill pressure is 12 psig 0 8 bar The CHALLENGER should be...

Page 53: ... or as recommended on the warning tag of the valve If after closing the valve the valve fails to seat properly or continually weeps replace the relief valve Ensure the cause of the relief valve to weep is the valve itself not due to system over pressurization caused by an expansion tank that is waterlogged or undersized 17 13 Inspection of Igniter Remove the igniter using a 3 mm orT 15 hex key ins...

Page 54: ...49 17 Maintenance Procedures 1 2 3 1 2 3 Fig 23 Loosening of Flue Pipe Retaining Ring Fig 24 Removal of Flue Pipe Fig 25 Removal of Condensate Pan ...

Page 55: ...50 17 Maintenance Procedures 0 12 3 mm 0 12 3 mm 0 43 11 mm Spark gap app 0 18 1 06 1 12 27 mm 29 mm 5 mm 1 75 44 mm 1 18 30 mm 45º Fig 26 Igniter Dimensions ...

Page 56: ...e burner head Replace burner head if necessary Replace burner head gasket Re assemble the burner head and burner head gasket Ensure 8 mounting screws are tight Remove the blower 9 Use a vacuum cleaner or compressed air to clean the interior 10 of the blower and venturi assembly Inspect the blower blades to ensure they are clean and not damaged Re assemble the blower and venturi onto the front plat...

Page 57: ... and fittings are leak free and no water is on the floor Carefully power up the pump allowing the vinegar to 10 circulate through the domestic heat exchanger for 1 hour Turn pump off and carefully remove power to the pump 11 Close both drain flush valves on the domestic cold and hot 12 water lines Remove the hose from the bucket and pump connected to 13 the drain flush valve on the domestic hot wa...

Page 58: ...amber insulation follow these precaution measures Use a NIOSH approved respirator which meets OSHA 1 requirements for cristobalite dust similar to N95 Contact NIOSH at 1 800 356 4676 or on the web at www cdc gov niosh for latest recommendations Wear long sleeved loosing fitting clothing gloves 2 and eyes protection Assure adequate ventilation 3 Wash with soap and water after contact 4 Wash potenti...

Page 59: ...age and to avoid damage to appliance and im proper operation of appliance Contact ACV Triangle Tube at 856 228 8881 or www triangletube com for a list of distributors nearest you WARNING B Gas Valve J Pressure Relief Air Vent Connection Q Condensate Drain Trap Assembly C Control Display K Sight Glass R Heat Exchanger D CH Supply Sensor M Vent Air Adapter 80 125 Concentric Option shown 3 Standard n...

Page 60: ...er CC105 Part Number CC125 Part Number CC125H 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 2B CCFTG02 Connector Pipe DHW Not Shown 1 Kit 3 CCRKIT07 CCRKIT08 Front Door Assembly ...

Page 61: ...rt Number CC125H Description 1 CCRKIT09 80 125 Concentric Vent Air Adapter Assembly Optional Shown CCRKIT35 3 Vent Air Adapter Assembly Standard Not shown 2 CCRKIT11 CCRKIT12 Vent Assembly 3 CCRKIT13 Condensate Collector Assembly 4 CCRKIT14 CCRKIT14A Condensate Trap Assembly 5 CCRKIT41 Condensate Collector Trap Gasket 6 CCRKIT36 Flue Sensor ...

Page 62: ...Igniter Assembly 2 CCCLB01 Ignition Cable 3 CCRKIT16 Sight Glass Assembly 4 CCRKIT17 CH Sensor Assembly 1 Kit 5 CCSENS02 DHW Temperature Sensor 6 CCRKIT56 DHW Flow Sensor Assembly 7 CCRKIT19 LWCO CH Pressure Sensor Assembly 8 CCRKIT21 CCRKIT22 CH Supply Pipe Assembly 9 CCRKIT23 CH Return Pipe Assembly 10 CCRKIT26 DHW Hot Water Outlet Pipe 11 CCRKIT57 DHW Cold Water Inlet Pipe 12 CCRKIT40 Igniter B...

Page 63: ...59 Ignition Transformer Assembly 2 CCRKIT60 Gas Valve Assembly 3 CCRKIT31 Lower Gas Pipe Assembly 4 CCRKIT61 CCRKIT62 Upper Gas Pipe Assembly 5 CCRKIT32 Blower Assembly 6 CCRKIT45 N A Venturi 406 N A N A CCRKIT63 Venturi 471 N A CCRKIT46 N A Venturi 362 7 CCRKIT48 N A Blower Outlet Orifice 1 7 16 37 mm N A Not Applicable 18 5 Blower Gas Valve Components ...

Page 64: ...59 18 Replacement Parts 1 Fig 32 Burner Components 18 6 Burner Components Item Part Number CC105 Part Number CC125 Part Number CC125H Description 1 CCRKIT33 Burner Assembly ...

Page 65: ...l Components Item Part Number CC105 CC125 Part Number CC125H Description 1 CCRKIT53 CCRKIT54 Control Display 2 CCCS01 Plastic Control Housing 3 CCRKIT34 Flip Panel 4 CCFUSE01 Fuse 1 Kit 5 CCRKIT43 Connector X4 24V 9 Pin Not Shown 6 CCRKIT44 Connector X2 120V 8 Pin Not Shown ...

Page 66: ...m E Z 33 07 84 cm 30 71 78 cm CH Supply DHW Cold DHW Hot Vent Air CH Return Flexible 1 NPT 1 NPT 1 2 NPT C D 80 125 Concentric Adapter Condensate Drain Challenger CC 105 Challenger CC125 CC125H 3 4 NPT 3 4 NPT B 13 58 34 5 cm 80 125 Concentric Vent Air or 3 Vent 4 63 11 8 cm 3 Air 17 72 45 cm optional shown or 3 standard not shown Fig 34 Dimensions Connections ...

Page 67: ...ng to DOE 10CFR Part 430 subpart B Appendix E test procedure NOTICE Model Fuel Input Modulation BTUH kW Continuous Domestic Flow 77 F Rise Water Heater Energy Factor Weight Lbs kg CC105 Natural or Propane 29 000 106 000 8 5 31 2 3 gpm 8 7 lpm 86 73 33 CC125 Natural or Propane 33 000 124 000 9 7 36 3 2 7 gpm 10 41 lpm 85 80 36 CC125H Natural or Propane 20 000 125 000 5 9 36 6 2 7 gpm 10 41 lpm 85 8...

Page 68: ...63 20 Domestic Specifications CC125H Graph 2 Domestic Flow Rate at 120 F Domestic Outlet and Varing Domestic Inlet Temperature 20 2 Domestic Flow ...

Page 69: ... derates the input at approximately 2 for every 1 000 ft of altitude No alterations to the appliance or burner system are required The following efficiency performance is achieved when the CHALLENGER is operated as a boiler according to the ASHRAE 103 test procedure NOTICE 21 1 Performance Ratings CHALLENGER Model Fuel Input Modulation BTUH kW Note 4 DOE Heating Capacity BTUH kW Note 1 4 Net AHRI ...

Page 70: ...dfos Circulators Graph 4 Pressure Loss Through Boiler Taco Circulators Minimum boiler flow rate required at full input CC105 5 gpm 19 lpm Pump curves and system curves DO NOT include any allowance for near boiler piping NOTICE CC105 Primary Loop Circulators Grundfos CC105 Primary Loop Circulators Taco ...

Page 71: ...rculators Graph 6 Pressure Loss Through Boiler Taco Circulators Minimum boiler flow rate required at full input CC125 CC125H 6 gpm 23 lpm Pump curves and system curves DO NOT include any allowance for near boiler piping NOTICE CC125 CC125H Primary Loop Circulators Grundfos CC125 CC125H Primary Loop Circulators Taco ...

Page 72: ...67 22 Notes Section XXII Notes ...

Page 73: ...68 22 Notes ...

Page 74: ...69 22 Notes ...

Page 75: ...70 22 Notes ...

Page 76: ...siveTank in Tank design Stainless steel construction Self cleaning Self descaling heat exchanger SMARTavailable in 7 sizes COMFORT available in 2 sizes SMART Limited LIFETIME residential warranty Limited 6 year commercial warranty COMFORT Limited 10 year warranty TTP Brazed Plate Heat Exchangers For domestic water snow melting radiant floor and more Plates made of stainless steel with 99 9 copper ...

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