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Table of Contents

Section VI: Installing Vent / Combustion Air & Condensation Drain .................................................................................15

6.1

Installing Vent & Combustion Air...............................................................................................................................15

6.2

Installing Condensate Drain Assembly ......................................................................................................................15

Section VII: Gas Piping............................................................................................................................................................16

7.1

Gas Supply Piping Connection ..................................................................................................................................16

7.2

Natural Gas.................................................................................................................................................................17

7.3

Propane Gas ...............................................................................................................................................................18

Section VIII: Internal Wiring....................................................................................................................................................19

8.1

General Requirements ...............................................................................................................................................19

Section IX: External Wiring .....................................................................................................................................................20

9.1

Installation Compliance .............................................................................................................................................20

9.2

Line Voltage Connections...........................................................................................................................................20

9.3

Circulator Maximum Current Rating .........................................................................................................................20

9.4

Central Heating (CH) Circulator ................................................................................................................................20

9.5

DHV Circulator for Optional SMART/COMFORT I.F.W.H............................................................................................20

9.6

System Circulator - Zone Valve Application...............................................................................................................20

9.7

Low Voltage Connections ...........................................................................................................................................20

9.8

Thermostat (Dry Contact) Wiring..............................................................................................................................21

9.9

Outdoor Temperature Sensor Wiring.........................................................................................................................21

9.10 SMART/COMFORT Aquastat Wiring ..........................................................................................................................21

Section X: Startup Preparation ..............................................................................................................................................24

10.1 Check Boiler System Water Chemistry......................................................................................................................24
10.2 Flush Boiler System to Remove Sediment ................................................................................................................24
10.3 Use of Antifreeze in the Boiler System.......................................................................................................................24
10.4 Filling the Boiler System ............................................................................................................................................24
10.5 Check Low Water Cut Off ...........................................................................................................................................25
10.6 Check for Gas Leaks...................................................................................................................................................25
10.7 Check Thermostat Circuit..........................................................................................................................................25
10.8 Inspect Condensate Drain Assembly.........................................................................................................................25

Section XI: Startup Procedures..............................................................................................................................................26

11.1

Final Checks Before Startup ......................................................................................................................................26

11.2 CHALLENGER Startup ...............................................................................................................................................26
11.3 CHALLENGER Startup Troubleshooting....................................................................................................................26
11.4 Check the CHALLENGER and System .......................................................................................................................26
11.5 Appliance ON/OFF .....................................................................................................................................................27
11.6 Set Boiler Maximum Central Heating (CH) Set Point Temperature .........................................................................27
11.7 Operation Verification - Space Heating .....................................................................................................................27
11.8 Control Display ...........................................................................................................................................................29
11.9 Setting the Appliance Parameters.............................................................................................................................31
11.10 Error Mode..................................................................................................................................................................32
11.11 Error Codes.................................................................................................................................................................33
11.12 Warning Codes ...........................................................................................................................................................33