Installation & Maintenance Manual S O LO 110 -155-199 & CO MBI 155 -199 NOTICE - Customer must register unit within thirty (30) days of installation in order to gain warranty coverage. See Warranty Card for details. - Leave all documentation received with appliance with the owner for future reference.
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TABLE OF CONTENTS PRODUCT AND SAFETY INFORMATION........................................................................... XI CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS......................................................... 1 1.1. INSTINCT boilers - Code Compliance............................................................................................ 1 1.1.1 Code Restrictions................................................................................................................... 1 1.1.
TABLE OF CONTENTS CHAPTER 4 - BOILER PIPING............................................................................................ 15 4.1. General Piping Requirements....................................................................................................... 15 4.2. Pressure Relief Valve..................................................................................................................... 15 4.3. Boiler Air Vent..............................................................
TABLE OF CONTENTS 5.2. Thermal Expansion....................................................................................................................... 28 5.3. Water Hammer.............................................................................................................................. 29 5.4. Vacuum Breaker............................................................................................................................ 29 5.5. Hydro-Block................................
TABLE OF CONTENTS CHAPTER 9 - CTRLMAX OPERATION............................................................................... 51 9.1. CTRLMax Navigation..................................................................................................................... 51 9.2. CTRLMax Menu Structure............................................................................................................ 52 9.3. Home Screen..............................................................................
TABLE OF CONTENTS 10.4. Check Low Water Cut-Off Device................................................................................................. 69 10.5. Check For Gas Leaks.................................................................................................................... 70 10.6. Check Thermostat Circuit............................................................................................................ 70 10.7. Inspect Condensate Drain Assembly..............................
TABLE OF CONTENTS 17.9. Check Boiler System..................................................................................................................... 86 17.10. Check Expansion Tank.................................................................................................................. 86 17.11. Check Boiler Relief Valve.............................................................................................................. 86 17.12. Inspection of Ignitor...........................
INDEX OF ILLUSTRATIONS AND TABLES Fig. 1 - All Combustion Air from adjacent Indoor Spaces through Indoor Combustion Openings.......7 Fig. 2 - All Combustion Air from Outdoors Through One Permanent Air Opening................................7 Fig. 3 - All Combustion Air from Outdoors Through Ventilated Attic......................................................8 Fig. 4 - All Combustion Air from Outdoors Through Horizontal Ducts....................................................8 Fig. 5 - Accessories........
INDEX OF ILLUSTRATIONS AND TABLES Fig. 37 - INSTINCT Solo 110 Internal Components................................................................................ 91 Fig. 38 - INSTINCT Solo 155 Internal Components................................................................................ 92 Fig. 39 - INSTINCT Combi 155 Internal Components............................................................................ 93 Fig. 40 - INSTINCT Solo 199 Internal Components.........................................
SAFETY PRODUCT AND SAFETY INFORMATION IMPORTANT SAFETY INFORMATION FOR THE HOMEOWNER AND THE INSTALLER This manual contains important information with respect to the installation, starting up and maintenance of the appliance. This manual must be provided to the Homeowner, who will keep it in a safe place for future reference.
SAFETY PRODUCT AND SAFETY INFORMATION WARNING DANGER HOT WATER CAN SCALD! Water temperature over 125ºF can cause severe burns instantly or death from scalds. • • • Should overheating occur or if the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance. Do not add cold make up water when the appliance is hot. Thermal shock can potentially cause cracks in the heat exchanger.
Chapter 1 - PRE-INSTALLATION REQUIREMENTS INSTINCT boilers - Code Compliance The INSTINCT units must be installed by a qualified installer in accordance with the following: • All applicable local, state, national and provincial codes, ordinances, regulations and laws.
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.2. Determining Product Location CHAPTER 1 NOTICE The INSTINCT is certified for indoor, conditioned space installations ONLY. Before locating the INSTINCT check for convenient locations to: • Heating system piping • Venting • Gas supply piping • Electrical service Ensure the INSTINCT location allows the combustion air/ vent piping to be routed directly through the building and terminate properly outside with a minimum amount of length and bends.
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS Recommended Clearances The INSTINCT is approved for zero clearance to combustibles, excluding vent and boiler piping. • Boiler piping must be a minimum 1/4 inch from combustible materials. • Reference the INSTINCT Vent Supplement for vent pipe clearance requirements. BEST PRACTICE It is recommended that the following clearances be maintained for serviceability: • • • • • 1.6. Residential Garage Installations CHAPTER 1 1.5.
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2.1. Combustion Air Contamination WARNING If the INSTINCT combustion air inlet is located in an area likely to cause or contain contamination, or if products which could contaminate the air cannot be removed, the combustion air must be repiped and terminated at another location. Contaminated combustion air will damage the unit and its burner system, and can result in substantial property damage, serious injury, or death.
CHAPTER 2 - COMBUSTION AIR & VENTING 2.2. Ventilation and Combustion Air Requirements - Direct Vent A Direct Vent appliance utilizes uncontaminated outdoor air piped directly to the appliance for combustion. CHAPTER 2 For Direct Vent installations involving only the INSTINCT, in which the minimum service clearances are maintained as listed in Section 1.5 on page 3, no ventilation openings are required, but may be necessary to equalize the air pressure with the outside.
CHAPTER 2 - COMBUSTION AIR & VENTING Methods of Accessing Combustion Air Into A Space - Category IV 2.4.1. Indoor Combustion Air NOTICE • The methods listed in this chapter for accessing Indoor Combustion Air assume that the infiltration rate is adequate and not less than .40 ACH. • For infiltration rates less than .40 ACH, reference the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for additional guidance.
CHAPTER 2 - COMBUSTION AIR & VENTING • CHAPTER 2 Two Permanent Opening Method. Two permanent openings, one commencing within 12 in. of the top and one commencing within 12 in. of the bottom of the enclosure, shall be provided.
CHAPTER 2 - COMBUSTION AIR & VENTING In order to reduce the potential risks associated with indoor contaminates (see list in Section 2.1 on page 5), flammable vapors and tight housing construction with little or no infiltration air, it is recommended to pipe uncontaminated combustion air directly from the outdoors to the appliance. This practice also promotes higher system efficiency by reducing heated indoor air from being exhausted from the house and replaced by cold infiltration air into the house.
CHAPTER 2 - COMBUSTION AIR & VENTING 2.7. Carbon Monoxide Detector Installation CHAPTER 2 Triangle Tube requires the installation of a minimum of two (2) hard wired carbon monoxide detectors with an alarm and battery back-up in the mechanical room where the INSTINCT is located and another installed in the living area outside the bedroom(s) for all installations. Each carbon monoxide detector shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
2.8.5 Manufacturer Requirements - Gas Equipment Venting System Provided. 2.8.6 Manufacturer Requirements - Gas Equipment Venting System Not Provided.
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Chapter 3 - UNIT PREPARATIONS 3.1. Handling Instructions 3.2. The INSTINCT is generally easier to handle and maneuver once removed from the shipping carton. To remove the shipping carton: Wall Mounting Installation The INSTINCT should be wall mounted using the wall mounting template and bracket provided with the boiler. The INSTINCT is not designed for floor installation.
CHAPTER 3 - UNIT PREPARATIONS 3.4. Wall Mounting Guidelines 3.5. Stud Walls - Installation CHAPTER 3 The wall-mounting bracket is designed for stud spacing 1. Locate the studs in the general area of the boiler installation. of approximate 12 inch or 16 inch on centers. For un2. Place the wall-mounting bracket on the wall cenconventional stud spacing, a solid / secure mounting tering the mounting slots with the stud centers surface must be provided for installation of the bracket.
Chapter 4 - BOILER PIPING • • • • General Piping Requirements 4.2. All plumbing must meet or exceed all local, state and national plumbing codes. Support all piping using hangers. DO NOT support piping by the unit or its components. Use isolation valves to isolate system components. Install unions for easy removal of the INSTINCT from the system piping. WARNING Use a two-wrench method when tightening field piping onto the boiler piping connections.
CHAPTER 4 - BOILER PIPING 4.3. 4.4. Boiler Air Vent • NOTICE This boiler is supplied with a special automatic air vent that will provide reliable operation in purging air from the boiler. The hygroscopic cap supplied with the automatic air vent MUST remain tight at all times on the air vent body. The hygroscopic cap has a membrane which expands upon contact with water and seals the air vent until the membrane dries up due to new air forming in the air vent. CHAPTER 4 1.
CHAPTER 4 - BOILER PIPING 4.6. Additional Limit Control If a separate Low Water Cut Off (LWCO) is required by the local jurisdiction or when the boiler is installed above the system piping, the following guidelines must be followed: • The LWCO must be designed for water installations, electrode probe-type is recommended. • The LWCO must be installed in a tee connection on the boiler supply piping above the boiler. • Wiring of the LWCO to the INSTINCT is done directly onto the low voltage terminal strip.
CHAPTER 4 - BOILER PIPING 4.7.1 Expansion Tank and Makeup Water 4.7.2 Diaphragm Expansion Tank Ensure the expansion tank is properly sized for the boiler volume: • 2 gallons [8 L] for the INSTINCT Solo 110 • 3 gallons [12 L] for the INSTINCT Solo 155 • 4 gallons [15 L] for INSTINCT Solo 199 Always install an automatic air vent on top of the air separator to remove residual air from the system. the system water volume, and the system water temperature.
CHAPTER 4 - BOILER PIPING 4.7.5 Sizing Primary Piping 4.7.9 System Piping – Through Boiler See Fig. 12 on page 24 through Fig. 14 on page 26, for recommended piping arrangements based on various applications. Size the piping and system components required in the space heating system using recognized design methods. Primary / secondary piping is preferred, but is not required for smaller systems (1 to 3 zones) provided that at least the minimum flow rate through the boiler is maintained at all times.
OptionalExtra ExtraRequired: Required: Lead Leadfrom fromX15 X15 on on 11 boiler boiler to to X16 X16 on Optional on the the next next boiler boiler System System Sensor Sensor DHW DHW 3 6 X15 X16 4 X7 2 3 2 5 4 6 3 X15 X16 1 2 3 4 X7 4 X5 X5 3 4 6 5 System Sensor CH2 Thermostat 3 4 6 X5 System Sensor 5 4 3 X6 2 4 3 CH1 Thermostat 1 X4 DHW Sensor or aquastat 2 1 X6 2 Outdoor Sensor 1 2 4 3 CH1 Thermostat X6 2 Outdoor Sensor 1 DHW Sensor or aquastat 2 1
CHAPTER 4 - BOILER PIPING 4.8. 4.7.11 System Piping – Special Application If the boiler is used in conjunction with a chilled water/ medium system, the boiler and chiller must be piped in parallel. Install flow/check valves to prevent the chilled medium from entering the boiler.
CHAPTER 4 - BOILER PIPING 4.8.1 Expansion Tank and Makeup Water 4.8.3 Circulator Ensure the expansion tank is properly sized for the boiler volume: • 3 gallons [12 L] for the INSTINCT Combi 155 • 4 gallons [15 L] for the INSTINCT Combi 199 The INSTINCT Combi is supplied with a Boiler circulator that provides circulation for central/space heating(CH) and Domestic Hot Water (DHW) production. See the Graph 1 on page 113 . the system water volume, and the system water temperature. 4.8.
CHAPTER 4 - BOILER PIPING 4.8.7 System Piping – Through Boiler 4.8.8 System Piping – Radiant Heating The heat exchanger design of the INSTINCT Combi allows operation in a condensing mode. This feature requires no regulation of the return water temperature back to the boiler in radiant heating applications. The INSTINCT CANNOT be installed with non-oxygen barrier tubing.
CHAPTER 4 - BOILER PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Flame ON ON OFF CH Pump ON ON ON DHW Pump OFF OFF ON Note.
CHAPTER 4 - BOILER PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Flame ON ON OFF CH Pump ON ON ON DHW Pump OFF OFF ON External Limit LowVoltage Voltage Terminals Low Terminals CH2 Thermostat 5 4 3 Modulation Signal + 2 1 CH1 CH2 Thermostat Thermosta 4 t 3 X5 Outdoor Sensor 2 X6 1 DHW Sensor or Aquastat 2 1 X4 Manual Manual Modbus + 3 G 2 Line Voltage Terminals Line Voltage Terminals Auto Auto 1 X7 N G L FLAME N G L N G L POWER SUPPLY N G L CH PUMP DHW PUMP
CHAPTER 4 - BOILER PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Flame ON ON OFF CH Pump ON ON ON DHW Pump OFF OFF ON Note.
Chapter 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING Domestic Piping Pressure Relief Valve CAUTION To reduce risk of excessive pressures and temperatures in the water heater, install temperature and pressure protective equipment required by local codes, but no less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials, as meeting the requirements for Relief Valves and A
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.1.3 Pressure Relief Valve Discharge Piping 5.2. Pressure relief valve discharge piping must be: • Made of material serviceable for temperatures of 250ºF or greater. • Directed so that hot water flows away from all persons. • Directed to a suitable place for disposal. • Installed so as to allow complete draining of the pressure relief valve and discharge line.
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.4. Water Hammer Dishwashers, clothes washers and fast-closing positive shut-off valves incorporated in the system all contribute to creating water shock. Install a water hammer arrester to prevent damage to pipes and appliances. See device manufacturer’s instructions for application and installation. NOTICE Water hammering within the domestic piping system can cause premature failure of the domestic circuit of the boiler.
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.6. • • • • • • General Piping For domestic water piping diagrams, see Fig. 17 on page 31. All plumbing must meet or exceed all local, state and national plumbing codes. Use pipe dope or tape suitable for potable water systems. Use isolation valves to isolate system components. Use dielectric unions or couplings to protect hot and cold water fittings from corrosion when connecting dissimilar materials such as copper and galvanized iron pipe.
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Flame ON ON OFF CH Pump ON ON ON DHW Pump OFF OFF ON Note. Instinct Combi is pre-configured for this installation NOTICE Consult the INSTINCT CTRLMax Control Supplement for information on setting the required Preset Pump Configuration.
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Flame ON ON OFF CH Pump ON ON ON DHW Pump OFF OFF ON Note.
TITLE CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Flame ON ON OFF CH Pump ON ON ON DHW Pump OFF OFF ON Note.
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Flame ON ON OFF CH Pump ON ON ON DHW Pump OFF OFF ON Note.
CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING INSTINCT SOLO PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Flame ON ON OFF CH Pump ON ON OFF DHW Pump OFF OFF ON Note.
TITLE CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING INSTINCT SOLO PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Flame ON ON OFF CH Pump ON ON OFF DHW Pump OFF OFF ON Note.
CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING TITLE NOTICE CHAPTER 5 Cascading is only available on Solo Boilers. System Supply System Return 12" Max. P G Fig.
Chapter 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN 6.1. Installing Vent and Combustion Air DANGER The INSTINCT must be vented and supplied with combustion air as shown in the INSTINCT Vent Supplement, included in the installation envelope. Refer to instructions for parts list and method of installation.
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN 8. Route the tube from the condensate drain assembly to a floor drain or condensate pump. The condensate drain assembly must remain filled with water. Extended periods of non use or high temperature operation may allow the water to evaporate. Periodically check the water level in the condensate drain assembly and fill with water as necessary.
Chapter 7 - GAS PIPING 7.1. Gas Supply Piping Connection NOTICE The gas supply piping must be installed in accordance to all applicable local, state, national codes, and utility requirements. 1. Install a 3/4” NPT for INSTINCT pipe union at the gas nipple, for ease of service. 2. Install a manual shutoff valve in the gas supply piping as shown in Fig. 25 on the right. For installations in Canada, the installer must tag and identify the main shutoff valve. 3.
CHAPTER 7 - GAS PIPING 7.2. Natural Gas 2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c at any time. Adjust the lockup pressure regulator for 13”w.c maximum. 7.2.1 Pipe Sizing Refer to Table 2 below for schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated INSTINCT input (divide by 1,000 to obtain cubic feet per hour). • Table 1 is based on Natural Gas with a specific gravity of 0.
CHAPTER 7 - GAS PIPING 7.3. 7.3.2 Supply Pressure Requirements Propane Gas 1. Adjust the propane supply regulator provided by the gas supplier for 13”w.c. maximum pressure 2. Pressure required at the gas valve inlet supply pressure port: 7.3.1 Pipe Sizing WARNING • The unit was shipped with a propane conversion kit which is located on the top of the unit in the instructions packet. This kit includes all the necessary parts and instruction to perform the conversion from natural to propane gas.
CHAPTER 7 - GAS PIPING Venturi Venturi interface Pipe to Venturi Air Inlet Gas Valve Air reference Hose Fig. 26 - Gas Valve / Venturi Assembly - INSTINCT Solo110 CHAPTER 7 Air reference Hose Pipe to Venturi Gas Valve Air Inlet Venturi interface Venturi Fig.
CHAPTER 7 - GAS PIPING Air Inlet Venturi interface Venturi Air reference Hose Gas Valve Pipe to Venturi Fig.
Chapter 8 - WIRING 8.1. Internal Wiring WARNING ELECTRICAL SHOCK HAZARD. For your safety, disconnect electrical power supply to the unit before servicing or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause serious injury, or death. 8.1.2 Fuse Locations • • • • The CTRLMax control module contains 3 internal replaceable 5A fuses as shown in Fig. 29 below. The top two fuses protect the INSTINCT as well as the CH, DHW, and Flame outputs.
CHAPTER 8 - WIRING Key Instinct Solo Wiring Diagram Spark Generator Blower 1 Gas Valve G/Y R Electrode G 1 3 G W V BK 5 5 1 1 3 G W W G G W = White BK = Black R = Red G= Green O = Orange Y = Yellow BL = Blue G/Y = Green / Yellow GY = Grey BK W BK BK X10 1 3 1 P13 P14 6 1 X9 6 1 X12 4 1 1 X1 12 1 Y X3 R R 10 O R 1 X2 1 4 X15 X16 1 1 6 BL Auto Reset Limit Y Y Y Y Y GY GY GY 3 Water Pressure Sensor User Interface Cascade Slave Cascade Master Flame X7 3 1 Mod
CHAPTER 8 - WIRING Key Instinct Combi Wiring Diagram Spark Generator Pump Blower 1 Gas Valve G/Y R Electrode G 1 G BK 5 5 1 3 G W W G G W V 1 3 W = White BK = Black R = Red G= Green O = Orange Y = Yellow BL = Blue G/Y = Green / Yellow GY = Grey BK W BK BK X10 1 3 1 P13 P14 6 1 X9 6 1 X12 4 1 1 X1 BK R GY O Diverter Valve 12 1 Y X3 R Flue Temperature Sensor BL Supply Temperature Sensor Y R 10 O R 1 BR BR X2 R Return Temperature Sensor BL Manual Reset Limit Auto
CHAPTER 8 - WIRING 8.2. External Wiring 8.2.1 General Requirements All field wiring must comply with: • National Electrical Code (ANSI/NFPA 70) for installations in the U.S., and any other national, state, provincial or local codes or requirements. • Canadian Electrical Code Part 1 (CSA C22.1) for installations in Canada. WARNING ELECTRICAL SHOCK HAZARD.
CHAPTER 8 - WIRING 8.3.2 Low Voltage Connections 8.3.4 Outdoor Sensor Wiring Line and Low Voltage wiring should be separated to prevent possible electrical noise on the low voltage circuits. Line and Low Voltage wiring should use separate electrical knockouts on the INSTINCT cabinet and should remain separated inside the INSTINCT. The Outdoor Reset function and Warm Weather Shutdown (WWSD) features require the connection of the included outdoor temperature sensor.
CHAPTER 8 - WIRING 1. Remove the factory-installed brown jumper wire at the Manual Reset Limit terminals that will accept the additional boiler limit. 2. Remove the factory-installed orange jumper wire at the Auto Reset Limit terminals that will accept the additional boiler limit. 3. Connect the external limit wires to the Manual Reset Limit or Auto Reset Limit low voltage terminals located on the lower right corner of the CTRLMax control module housing as shown in Fig. 33 on page 49. 8.3.
Chapter 9 - CTRLMAX OPERATION The CTRLMax Boiler Management System is designed to be flexible yet easy to use. CTRLMax monitors and controls the INSTINCT to provide heat as efficiently as possible. CTRLMax includes many advanced features: • Two central/space heating (CH) call inputs with separate outdoor reset curves. • Domestic Hot Water (DHW) call input with optional priority in INSTINCT Solo units and DHW priority in INSTINCT Combi units.
CHAPTER 9 - CTRLMAX OPERATION The menu system utilizes icons to represent each selection. The current selected menu is displayed as a reversed image with a text description shown at the top of the display. Menus can be entered by selecting the the desired icon (highlights) using the arrow soft keys and touching the soft key. The Home Screen icon at the bottom of each screen returns to the Home Screen when selected.
CHAPTER 9 - CTRLMAX OPERATION 9.3. Main Icons of CTRLMax display Home Screen The Home Screen presents status information in a very user friendly way so that the current state of the boiler can be quickly accessed. • Screen backlight - it will illuminate when any soft key is touched, and remain illuminated for five minutes. • Screen brightness - it can be adjusted at the Home screen by touching and holding simultaneously the Touch the and soft keys for 2 seconds.
CHAPTER 9 - CTRLMAX OPERATION 9.4. Status Line Messages Standby - Indicates that the INSTINCT is ready to respond when a demand is received. CH Demand - A central heating call has been received. DHW Demand - A domestic hot water call has been received. CH/DHW Demand - Central heating and domestic hot water calls are being received simultaneously. Both calls are being satisfied simultaneously because domestic hot water priority has been disabled.
CHAPTER 9 - CTRLMAX OPERATION 9.6. Main Menu The EZ Setup menus provide a simple way to quickly customize CTRLMax for each installation. EZ Setup prompts the user to make selections which allows the INSTINCT to be setup very quickly without searching through long lists of settings and manually making adjustments. The Main Menu can be entered from the Home Screen soft key. by touching the The menu system utilizes icons to represent each selection.
CHAPTER 9 - CTRLMAX OPERATION 9.7. Heating EZ Setup Heating EZ Setup allows the installer to quickly customize the central heating settings for the application. 9.7.1 Select CH Demand (No outdoor sensor connected) EZ Setup Select CH Demand prompts the installer to select how a CH Demand is generated. Thermostat & Setpoint - A central heating call from a thermostat or zone panel will enable the INSTINCT and the setpoint will be fixed for central heating calls.
CHAPTER 9 - CTRLMAX OPERATION 9.7.2 Select CH Demand (Outdoor sensor connected) Select CH Demand prompts the installer to select how a CH Demand is generated. EZ Setup Heating EZ Setup Select CH Demand Thermostat & Outd. Curve – A central heating call from a thermostat or zone panel will enable the INSTINCT and the setpoint will vary with the outdoor temperature for central heating calls. After Thermostat & Outd. Curve is selected, the Select CH1 Reset Curve screen appears (see below).
CHAPTER 9 - CTRLMAX OPERATION 9.8. Domestic Hot Water EZ Setup - INSTINCT Solo Units Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application EZ Setup Select DHW Demand prompts the installer to select how a DHW Demand is generated. When Thermostat is selected in Select DHW Demand, a domestic hot water call from an aquastat or dry contact switch will enable the INSTINCT with a fixed setpoint for a domestic hot water call.
CHAPTER 9 - CTRLMAX OPERATION 9.9. Domestic Hot Water EZ Setup - INSTINCT Combi Units Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application DHW EZ Setup prompts the installer to select the DHW setpoint. EZ Setup DHW Setpoint prompts to enter the fixed setpoint temperature during a domestic hot water call. DHW EZ Setup or Touch the soft keys to adjust the temperature setpoint then touch to store the setting.
CHAPTER 9 - CTRLMAX OPERATION 9.11. EZ Setup Reset EZ Setup Reset allows reset of all EZ Setup settings back to the original factory defaults. See Chapter 13 on page 77 for the list of settings reset by this function. EZ Setup Follow the on-screen instructions to reset all EZ Setup settings. EZ Setup Reset EZ Setup Reset Press OK to restore factory settings, any other button to keep current settings. 9.12.
CHAPTER 9 - CTRLMAX OPERATION 9.13. CH/DHW Operation CH / DHW Operation CH/DHW Operation provides a simple way to enable/disable either the CH or the DHW function of the INSTINCT. Touch the or soft keys to select the CH or DHW icon, then touch to toggle between the enabled/disabled status. The status is displayed at the top of the screen. Heating Enabled Using the arrow keys, select the HOME or RETURN icon at the bottom of the screen to go back either to the home page or to the previous screen.
CHAPTER 9 - CTRLMAX OPERATION 9.14.1 Information Items CHAPTER 9 62 Information Item Description Boiler Status Displays the current operating state of the INSTINCT. This is the same as the status line on the home screen. Heating Call Displays if a central heating call is present. DHW Call Displays if a domestic hot water call is present. Boiler Firing Rate Displays the current firing rate of the INSTINCT. Ionization Current Displays the current flame ionization current from the ignitor.
CHAPTER 9 - CTRLMAX OPERATION Lockout History records the last eight lockouts. Six lines are displayed on the Lockout History screen at one time. Each line contains a lockout description followed by how long ago the lockout occurred. Boiler Information Lockout History abc de fb abc d bb b efb b abc d efb bb Touch the b bbb b de f abc e f bb b cd ab e f bbb cd ab Lockout History 1. Blower speed 5h ago 2. DHW Sensor Open 2h ago 3. Sensor Drift 25 h ago 4. No error 27 h ago 5.
CHAPTER 9 - CTRLMAX OPERATION 9.14.3 Manual Reset Lockouts CHAPTER 9 64 Code Lockout Message Description E1 Failed Ignition The burner failed to light after 5 ignition attempts. E2 False Flame Flame detected prior to ignition. E3 High Boiler Temperature Boiler temperature has reached 210°F [99ºC] or 102°F [39°C]. E5 Blower Speed Blower is not at correct speed or speed signal is not being received by control module. E8 Flame Circuit Error Flame circuit test failed.
CHAPTER 9 - CTRLMAX OPERATION 9.14.4 Automatic Reset Blocking Lockouts Lockout Message Description E7 High Flue Temperature Flue temperature exceeds high limit. E12 Internal Control Fault EEPROM misconfiguration. E25 Internal Control Fault CRC check error. E32 DHW Sensor Shorted A short circuit has been detected in the DHW temperature sensor circuit. E33 DHW Sensor Open An open circuit has been detected in the DHW temperature sensor circuit.
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Chapter 10 Chapter 10 - START-UP PREPARATION 10.1. Boiler System Fluid Requirements NOTICE Requirements below must be met for warranty coverage of INSTINCT heat exchangers. A thorough cleaning of any existing system, using approved heating system cleaning agents is required prior to installation of the INSTINCT boiler. System should be treated with an approved inhibitor after filling for long term protection. WARNING Do not use petroleum-based cleaning or sealing compounds in the boiler system.
Chapter 10 CHAPTER 10 - START-UP PREPARATION 10.1.7 Check and Test Antifreeze For boiler systems containing antifreeze solutions, follow the antifreeze manufacturer’s instructions in verifying the inhibitor level and to ensure the fluid characteristics are within specification requirements. Due to the degradation of inhibitors over time, antifreeze fluids must be periodically replaced. Refer to the manufacturer of the antifreeze for additional instructions.
Chapter 10 CHAPTER 10 - START-UP PREPARATION 10.2. Filling the Boiler System 1. Close the boiler drain valve located on the bottom of the unit and any manual or automatic air vents in the system. 2. Open all system isolation valves. 3. Fill the boiler system to correct system pressure. Correct pressure will vary with each application. NOTICE Typical residential system fill pressure is 12 psi. System pressure will increase as system temperature increases.
Chapter 10 CHAPTER 10 - START-UP PREPARATION 10.5. Check For Gas Leaks WARNING • • Prior to start-up and during initial operation, check for a gas leak using a combustable gas detector. Do not proceed with the start-up if there is any indication of a gas leak. Any leaks found must be repaired immediately. • Propane installations only - The propane supplier mixes an odorant with the propane to make its presence detectable. In some cases the odorant can fade and the gas may no longer have an odor.
Chapter 11 - START-UP PROCEDURES ØØ Read Chapter 9 on page 51 regarding the operation of the CTRLMax Boiler Management System. ØØ Verify the INSTINCT and the boiler system are full of water and all system components are correctly set for operation, including the minimum flow rate through the boiler, see specifications in Chapter 19 on page 102.. ØØ Verify Start-up Preparation items outlined in Chapter 10 on page 67 have been completed. ØØ Verify all electrical connections are correct and securely fastened.
FOR YOUR SAFETY, READ BEFORE OPERATING WARNING If you do not follow these instructions exactly, a fire or explosion may result, causing substantial property damage, serious injury, or death. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand. B. BEFORE OPERATING, smell all around the appliance area for gas.
CHAPTER 11 - START-UP PROCEDURES Check around the unit for gas odor following the procedure outlined in this manual on page 64. DANGER Manual Operation If any gas leaks are found or suspected, shut the unit down 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 unit until the leak is corrected. Failure to comply with this procedure will result in substantial property damage, serious injury, or death. 11.3.
CHAPTER 11 - START-UP PROCEDURES Table 5 - Throttle Screw Adjustment 3. Touch the CHAPTER 11 icon INSTINCT Solo/Combi Clockwise Decrease CO2 Increase O2 4. Touch the Counter-Clockwise Increase CO2 Decrease O2 tings icon 11.3.6 Measure Input - Natural Gas Only 1. Ensure the boiler is firing at maximum firing rate. To manually place the boiler into high fire, reference Section 11.3.5 on page 73. 2. Operate the unit for approximately 10 minutes. 3.
Chapter 12 - OUTDOOR RESET CONTROL 12.1. Mounting the Outdoor Sensor 1. The exterior wall selected for mounting the outdoor sensor should represent the heat load of the building. Typically a northern wall will suit most buildings. 2. Ensure the outdoor sensor is shielded from direct sunlight or the effects of heat or cold from other sources (exhaust fans, appliance vents...) to prevent false temperature readings. 3.
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Chapter 13 - EXTERNAL MODULATING CONTROL 13.1. Wiring the Modulating Controller Run two 18 gauge wires from the external modulating boiler controller’s 0-10 VDC boiler output to low voltage terminals X5-1&2 located at the bottom of the CTRLMax control module, as shown in Fig. 33 on page 49.. This signal will both enable and modulate the boiler. No wiring is required at the thermostat terminals.
CHAPTER 13 - EXTERNAL MODULATING CONTROL CTRLMax Factory Settings (cont’d) HEATING SETTING DHW Operation Enabled MAXIMUM SETTING EZ SETUP RESET INSTALLER RESET Enabled ✓ CHAPTER 13 Demand Type Thermostat N/A DHW Boiler Setpoint 168°F [75°C] 168°F [75°C] 96°F [35°C] 188°F [87°C] ✓ ✓ DHW Setpoint 140°F [60°C] 140°F [60°C] 68°F [20°C] 168°F [75°C] ✓ ✓ DHW Warmstart Setpoint N/A 125°F [52°C] 86°F [30°C] 140°F [60°C] ✓ ✓ DHW Warmstart Hysteresis N/A 30°F [17K] 9K 36K ✓ ✓ DH
Chapter 14 - CHECK-OUT PROCEDURES Perform the following check-out procedures as outlined and check off items as completed. When procedures are completed, the installer should complete the installation record in Chapter 15 on page 81. qq Boiler system fluid chemistry checked and verified as outlined in Section 10.1 on page 67.. qq Boiler system was completely flushed to remove any debris/sediment. qq Any automatic air vents placed within the system are open one full turn.
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Chapter 15 - INSTALLATION RECORD Ensure all manuals and other documents are returned to the Installation envelope and given to the owner for safekeeping.
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Chapter 16 - MAINTENANCE SCHEDULES 16.1. Service Technician 16.2. Owner Maintenance At least on an annual basis the following maintenance should be performed by a qualified service technician: Periodically: • Check the area around the unit. • Check and remove any blockage from the combustion air inlet and ventilation openings. • Check the temperature and pressure gauges. Monthly: • Check vent piping. • Check combustion air inlet piping. • Check the pressure relief valve.
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Chapter 17 - MAINTENANCE PROCEDURES • WARNING The INSTINCT must be inspected and serviced annually, preferably at the start of the heating season, by a qualified service technician. In addition, the owner maintenance and care of the unit as outlined in Chapter 16 on page 83 and further explained in the INSTINCT User’s Information manual should be performed to assure maximum efficiency and reliability of the unit.
CHAPTER 17 - MAINTENANCE PROCEDURES 17.7. Check Ventilation Air Openings • • Verify that all ventilation openings to the mechanical room or building are open and unobstructed. Check the operation and wiring of any automatic ventilation dampers. Check and verify the vent termination and the combustion air intake are free of debris and obstructions. 17.8.
CHAPTER 17 - MAINTENANCE PROCEDURES • • • • • Inspect the ignition cable from the spark generator to the ignitor. Inspect the ground wire from the spark generator to the ignitor. Ensure wiring is in good condition and securely connected. Check ground continuity using a continuity meter. Replace ground wire if ground continuity is not satisfactory. 17.14. Check Control Wiring Inspect all control wiring. Ensure wiring is in good condition and properly connected. 17.15.
CHAPTER 17 - MAINTENANCE PROCEDURES 17.19. Check Combustion Levels • Refer to Section 11.3.5 on page 73 for measuring combustion levels and burner adjustments. • 17.20. Check Flue Gas Temperature • • • Manually place the boiler into high fire. See Section 11.3.5 on page 73 for procedure. Navigate to the Boiler Information Menu to observe the flue gas temperature. See Section 9.14 on page 61 .
Chapter 18 - REPLACEMENT PARTS WARNING • Replacement parts must be purchased through a local Triangle Tube distributor. When ordering a 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 improper operation or damage to appliance. • Contact Triangle Tube at 856-228-8881 or www.triangletube.com for a list of distributors near you. Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS 1 Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig. 42 - INSTINCT Solo 110 Burner Components 12 It is essential to ensure during installation, maintenance or repair that items 12, 11 and 10 are correctly fitted between the blower and inlet adaptor. Failure to ensure correct fitting may result in serious injury, or death.
CHAPTER 18 - REPLACEMENT PARTS Fig. 43 - INSTINCT Solo/Combi 155 Burner Components 12 8 1 It is essential to ensure during installation, maintenance or repair that items 12, 11 and 10 are correctly fitted between the blower and inlet adaptor. Failure to ensure correct fitting may result in serious injury, or death.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
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Chapter 19 - PRODUCT SPECIFICATIONS Boiler Model Instinct 110 Solo Instinct 155 Solo Instinct 199 Solo Instinct 155 combi Instinct 199 combi Fuel Input (Btu/h) Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane 13,750 – 110,000 19,375 – 155,000 24,875 – 199,000 19,375 – 155,000 24,875 – 199,000 DOE Heating Net AHRI Rating Capacity (Btu/h) (Btu/h) AFUE Unpackaged Weight Lbs (Kg) Shipping Weight Lbs (Kg) 102,000 89,000 95% 84 (38) 99 (55) 142,000 123,000 95% 110
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 47 - Front View INSTINCT Solo 110 A B C D E F H K I G J B Item Boiler Width 3" Vent Outlet Dimension inches [mm] 21 5/8 [550] 17 1/2 [445.3] C D E F Vent\Com3" Com- 3/4" NSPC bustion Air Boiler bustion Air Relief Connection Height Valve Inlet Height 4 [101.6] 2 1/4 [57.2] 5 1/8 [130] 26 [659.5] G H 1" NPT Boiler Supply 1" NPT Boiler return 4 3/4 [119.5] 2 1/4 [57.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 48 - Right Side View INSTINCT Solo 110 L M P O N Q R L Items CHAPTER 19 Dimension inches [mm] 104 M 3" Combustion 3/4" NPSC Pressure Relief Air Inlet & 3" Vent Outlet Valve 7 3/4 [196.5] 3 ⁷/8 [97.8] N O P Q R 1" NPT Boiler Return Condensate Drain 1" NPT Boiler Supply 3/4" Gas Connection Boiler Depth 3 1/2 [90.1] 3 ⁷/8 [97.8] 3 1/8 [79.6] 11 1/2 [293.4] 16 3/4 [424.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 49 - Front View INSTINCT Solo 155 A B C D E F H G K I J B C Item Boiler Width 3" Combustion Air Inlet 3" Vent Outlet Dimension inches [mm] 21 5/8 [550] 16 [406.8] 5 [125.8] D E F G H I J K Vent\Com3/4" 3/4" NSPC Conden- Condenbustion Air Boiler 1" NPT Boil- 1" NPT BoilNPT Gas Relief sate Drain sate Height Connection Height er Supply er Return Connection Valve Height 1 5/8 [42.5] 5 1/8 [130] 26 [660] 2 3/4 [69.6] 1 7/8 [47] 4 1/4 [107.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 50 - Right Side View INSTINCT Solo 155 L M N O Q P R CHAPTER 19 106 L M N O P Q R Items 3/4" Pressure Relief Valve 3"Combustion Air Inlet & 3"Vent Outlet 1" NPT Boiler Return Condensate Drain 1" NPT Boiler Supply 3/4" NPT Gas Connection Boiler Depth Dimension inches [mm] 8 5/8 [218.5] 3 1/8 [80.3] 6 1/8 [156.0] 3 1/8 [80.3] 6 5/8 [169.0] 11 1/4 [287.2] 16 3/4 [424.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 51 - Front View INSTINCT Solo 199 A C B E D F G K H I J B Connection Boiler Width 3” Combustion Air Inlet Dimension inches [mm] 21 5/8 [550] 1 3/4 [44.5] C D E F G H I J K Vent/Combus- Con3/4" NPT CondenBoiler 1" NPT Boil-1" NPT Boil3” Vent 3/4” NPSC densate Gas Contion Air Adaptsate Drain Height er Supply er Return Outlet Relief Valve Height nection er Height 19 [481.4] 1 1/2 [39] 5 1/8 [130] 26 [659.5] 1 [25.4] 2 5/8 [66.2] 4 1/2 [113.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 52 - Right Side View INSTINCT Solo 199 M L R P Q N O CHAPTER 19 108 L M N O P Q R Items 3/4" Pressure Relief Valve 3"Combustion Air Inlet & 3"Vent Outlet 1" NPT Boiler Return Condensate Drain 1" NPT Boiler Supply 3/4" NPT Gas Connection Boiler Depth Dimension inches [mm] 8 [204.6] 4 1/8 [104.6] 8 5/8 [217.5] 3 1/2 [89.6] 6 1/8 [155.1] 10 1/2 [268.2] 16 3/4 [424.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 53 - Front View INSTINCT Combi 155 A B C D E F I L K J G A B Connection Boiler Width 3” Combustion Air Inlet Dimension inches [mm] 21 5/8 [550] 5 [125.8] C D E F G H I J K L 3/4" NPT CondenBoiler 1" NPT Boil-1" NPT Boil3” Vent 3/4” NPSC Gas Contion Air Adaptsate Drain Height er Supply er Return Outlet Relief Valve nection er Height DHW Inlet DHW Outlet 16 [406.8] 1 3/4 [44.7] 16 5/8 [422.7] Vent/Combus- 2 1/8 [54.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 54 - Right Side View INSTINCT Combi 155 M N P O,Q,T,U R S M CHAPTER 19 Items 3/4" Pressure Relief Valve Dimension inches [mm] 8 5/8 [218.5] 110 N O 3" Combustion 1" NPT Boiler Air Inlet & 3" Return Vent Outlet 3 1/8 [80.3] 8 3/8 [213.4] P Q R 3/4" NPT Condensate 1" NPT Boiler Gas ConDrain Supply nection 3 [73.7] 8 3/8 [213.4] 9 1/2 [240.8] S T U Boiler Depth DHW Inlet DHW Outlet 17 1/8 [436.5] 8 3/8 [213.4] 8 3/8 [213.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 55 - Front View INSTINCT Combi 199 B A C E D F H L A B Connection Boiler Width 3” Combustion Air Inlet Dimension inches [mm] 21 5/8 [550] 3 1/2 [89.5] C D K J E F G H I J Vent/Combus- 3/4" NPT CondenBoiler 1" NPT Boil-1" NPT Boil3” Vent 3/4” NPSC Gas Contion Air Adaptsate Drain Height er Supply er Return Outlet Relief Valve nection er Height 19 [481.4] 1 3/4 [44.5] 5 1/8 [130] 32 5/8 [828.3] 1 7/8 [48.2] 19 1/2 [494.2] 11 1/8 [283.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 56 - Right Side View INSTINCT Combi 199 N M P R O, Q, T, U S M CHAPTER 19 112 Items 3/4" Pressure Relief Valve Dimension inches [mm] 8 [204.6] N O 3" Combustion 1" NPT Boiler Air Inlet & 3" Return Vent Outlet 4 1/8 [104.7] 8 4/7 [217.5] P Q R 3/4" NPT Condensate 1" NPT Boiler Gas ConDrain Supply nection 4 1/8 [104.7] 8 4/7 [217.5] 9 [227.8] S T U Boiler Depth DHW Inlet DHW Outlet 16 2/3 [423.5] 8 4/7 [217.5] 8 4/7 [217.
CHAPTER 19 - PRODUCT SPECIFICATIONS PressureDrop DropIon-ic Instinct Solo Pressure Solo Pressure (Ft. W.C.) Pressure DropDrop (Ft. W.C.
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