TriangleTube CCRKIT32 Bedienungsanleitung

Challenger Blower

Replacement Kit

WARNING

Indicates a potentially hazardous situation which,

if ignored, can result in

substantial property dam-

age, serious injury, or death

NOTICE

Indicates special instructions on installation, operation

or maintenance, which are important to equipment

but not related to personal injury hazards.

WARNING

For your safety, turn oﬀ electrical power supply at

service panel before proceeding to avoid possible

electrical shock hazard. Failure to do so can cause

severe personal injury or death.

WARNING

For your safety, the boiler may be extremely hot.

Ensure the boiler has properly cooled prior to ser-

vicing. Failure to do so can cause severe personal

injury.

WARNING

Failure to follow instructions below can result in

severe personal injury or damage if ignored.

• Instructions are for a qualiﬁed installer/ ser-

vice technician only.

• Read all instructions before proceeding.

• Follow instructions in proper order.

Kit Part Numbers:

• CCRKIT32: Challenger Blower Kit

Kit Includes:

1. Blower

2. Blower Outlet Gasket

3. (2) M5 Flange Nuts

4. Gas Pipe O-ring

5. Venturi Clip

Recommended Tools:

• Phillips screwdriver

• 8 mm socket and/or 8 mm wrench

• Adjustable wrench

• Pliers

• Flat putty knife

• Combustion Analyzer

Challenger Blower

Replacement Kit

1. Removal of Blower

1. Turn o power to the unit at the main service

switch.

2. Close the external gas shut o valve to the appli-

ance.

3. Remove the front panel by ipping down the dis-

play cover and loosening the (2) Phillips head

screws at the control panel as per Fig. 1. Pull bot-

tom of front panel forward to remove.

Fig. 1: Control Panel Screws

4. Disconnect the two wire harness plugs from the

blower motor.

BEST PRACTICE

For ease of service, remove the vent pipe between the

vent adapter and the condensate drain pan before re-

moving the blower. To remove the vent pipe, loosen the

vent pipe retaining ring attaching it to the condensate

pan then slide the pipe up and out of the condensate

pan. Pull the vent pipe out and down to remove.

5. Loosen the gas pipe brass nut at the gas valve. Set

aside the orice and o-ring for reinstallation. See

Fig. 2

Fig. 2: Gas Orice location

NOTICE

Do not discard the gas orice and gasket as they will be re-

used.

6. Remove the (2) M5 ange nuts attaching the blow-

er to the burner assembly with an 8 mm socket or

wrench.

7. Remove the blower assembly from the Challenger

by pulling downward and out.

NOTICE

If the blower gasket sticks to the burner assembly, use a at

blade putty knife to remove any gasket material. Make sure

not to scratch the mating surface on the burner assembly.

8. For Challenger models 85 and 105 only, remove the

blower orice and save to be reinstalled. See Fig. 3.

Challenger Blower

Replacement Kit

NOTICE

Do not discard the blower orice as it will be reused.

9. Once the blower is taken out, remove the venturi

clip on the back of the blower using pliers.

10. Remove the gas pipe & venturi assembly from the

blower inlet, See Fig. 3.

NOTICE

Note the orientation of the gas pipe and venturi before re-

moval for reassembly.

Fig. 3: Blower Assembly

* Blower orice installed in 85 and 105 only

2. Installation of Blower

1. Prior to reassembling the gas pipe and venturi into

the new blower, replace the gas pipe o-ring at the

end of the gas pipe.

2. Insert the venturi and gas pipe into the blower

housing in the proper orientation, see Fig. 4. Ensure

the venturi and gas pipe are properly seated.

3. Insert the venturi clip into the blower housing. En-

sure the venturi clip is holding the venturi and gas

pipe in place by lightly pulling on the gas pipe.

NOTICE

Do NOT force the clip into a ush t with the blower surface.

Fig. 4: Venturi assembly installation

4. Seat the blower orice (if required) and blower

outlet gasket onto the blower ange. Position the

gasket so it will allow alignment with the mounting

studs of the burner assembly.

NOTICE

Do not use any adhesive on the gasket surface during as-

sembly.

5. Install the new blower on the burner assembly us-

ing (2) M5 ange nuts.

WARNING

Failure to insert the gas oriﬁce before reassembling

the gas pipe to the gas valve can result in the produc-

tion of carbon monoxide due to incomplete combus-

tion and may result in substantial property damage,

serious injury, or death.

Challenger Blower

Replacement Kit

6. With the gas orice in place, reconnect the gas pipe

brass nut to the gas valve. See Fig. 2.

7. If previously removed, reinstall the vent pipe.

WARNING

When reassembling the vent pipe, ensure all gaskets

are in place and correctly installed. Ensure all associat-

ed internal joints are complete, tight and secure. Fail-

ure to comply can result in ﬂue gas leakage resulting

in severe personal injury.

8. Reattach the wire harness plugs to the blower mo-

tor.

9. Replace the front jacket panel and secure with the

two Phillips head mounting screws at the control

panel.

10. Open the main shuto valve to the gas supply pip-

ing. Before placing the Challenger back into service

check and test all gas piping connections for leaks.

Repair leaks if found.

WARNING

If any gas leaks are found or suspected, shut down the

appliance immediately. Use a gas detection device or

bubble test to locate the source of the gas leak and

repair at once. Do not operate the appliance until the

leak is corrected. Failure to comply with this proce-

dure can result in substantial property damage, seri-

ous injury, or death.

11. Turn on power at the main service switch and re-

turn to service.

12. Perform a combustion analysis by measuring CO2

or O2 and CO during both low and high ring rates.

The combustion readings must be within the range

listed in Table 1. The CO level must not exceed 100

ppm for natural gas and 150 ppm for propane gas

when combustion is correct.

Perform the following procedure to manually place

the burner into high re. Press both the “ ” and

“+”buttons simultaneously once until the operating

display shows “h” or twice until the operating dis-

play shows“H” for high re.

Perform the following procedure to manually place

the burner into low re. Press both the “ ” and

“-” buttons simultaneously until operating display

shows “L”.

Table 1: Acceptable Combustion levels

Combustion Levels Natural Gas Propane Gas

High Fire

DOOR OFF*

CO2 Range 9% - 10.1% 10.5% - 11.1%

CO2 Target 9.0% 10.8%

O2 Range 3.0% - 5% 4.1% - 5.0%

O2 Target 5.0% 4.5%

Low Fire

CO2 Range 0% - 0.4% <H.F.

0% - 0.4% <H.F.

10.5% min.

O2 Range 0% - 0.6% > H.F.

5.0% max.

0% - 0.6% > H.F.

5.0% max.

CO Max. 100 ppm 150 ppm

* Door On can raise the maximum allowable CO2 by 0.4

or lower the minimum O2 by 0.6

WARNING

If the combustion levels are not within the range giv-

en in Table 1, shut the appliance down and contact Tri-

angle Tube Technical Support. Failure to comply with

this requirement can result in substantial property

damage, serious injury, or death.

2019-05 Challenger Blower Replacement Instructions

Revised 02/27/2019

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