Installation & Maintenance Manual - Triangle Tube

NOTICE. THE. ORIGINAL. INNOVATORS. SOLO 110-155-199 & COMBI 155-199 . Installation &. Maintenance. Manual. 223703 A01 - August 2019. 2019-16 ...

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Installation & Maintenance Manual

SOLO 110-155-199 & COMBI 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.

WARNING

· To maintain the safety & longevity of your appliance, read and follow the maintenance schedule information throughout this manual.
· If the information in this manual is not followed exactly, a fire or explosion may result causing substantial property damage, serious 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.

223703 A01 - August 2019 2019-16

THE ORIGINAL INNOVATORS

INTENTIONALLY LEFT BLANK

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 1.1.2 Operating Restrictions........................................................................................................... 1 1.2. Determining Product Location........................................................................................................2 1.3. Boiler Freeze Protection Feature....................................................................................................2 1.4. Boiler Replacement.........................................................................................................................2 1.5. Recommended Clearances.............................................................................................................3 1.6. Residential Garage Installations.....................................................................................................3 CHAPTER 2 - COMBUSTION AIR & VENTING.................................................................... 5 2.1. Combustion Air Contamination......................................................................................................5 2.2. Ventilation and Combustion Air Requirements - Direct Vent.......................................................6 2.3. Ventilation and Combustion Air Requirements - Category IV......................................................6 2.4. Methods of Accessing Combustion Air Into A Space - Category IV............................................7 2.4.1. Indoor Combustion Air........................................................................................................... 7 2.4.2. Outdoor Combustion Air....................................................................................................... 7 2.4.3 Combination of Indoor and Outdoor Combustion Air .......................................................8 2.5. Combustion Air and Vent Piping.....................................................................................................8 2.6. Removal of an Existing Boiler from a Common Vent System......................................................9 2.7. Carbon Monoxide Detector Installation.......................................................................................10 2.8. Commonwealth of Massachusetts Installation Requirements..................................................10 2.8.1 Installation of Carbon Monoxide Detectors. ....................................................................... 10 2.8.2 Approved Carbon Monoxide Detectors. ............................................................................ 10 2.8.3 Signage ................................................................................................................................. 10 2.8.4 Inspection. ............................................................................................................................ 10 2.8.5 Manufacturer Requirements - Gas Equipment Venting System Provided. .....................11 2.8.6 Manufacturer Requirements - Gas Equipment Venting System Not Provided. ..............11 CHAPTER 3 - UNIT PREPARATIONS................................................................................. 13 3.1. Handling Instructions.................................................................................................................... 13 3.2. Wall Mounting Installation............................................................................................................. 13 3.3. Accessories.................................................................................................................................... 13 3.4. Wall Mounting Guidelines.............................................................................................................. 14 3.5. Stud Walls - Installation ................................................................................................................ 14 3.6. Wall Bracket Installation - Solid Walls........................................................................................... 14 3.7. Boiler Mounting.............................................................................................................................. 14
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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................................................................................................................................. 16 4.4. Low Water Cutoff Device............................................................................................................... 16 4.5. Additional Limit Control................................................................................................................. 17 4.6. Backflow Preventer........................................................................................................................ 17 4.7. INSTINCT Solo Boiler System Piping........................................................................................... 17
4.7.1 Expansion Tank and Makeup Water.................................................................................... 18 4.7.2 Diaphragm Expansion Tank................................................................................................. 18 4.7.3 Closed-Type Expansion Tank............................................................................................... 18 4.7.4 Circulator............................................................................................................................... 18 4.7.5 Sizing Primary Piping........................................................................................................... 19 4.7.6 Domestic Hot Water System Piping.................................................................................... 19 4.7.7 System Piping ­ Zone Circulators....................................................................................... 19 4.7.8 System Piping ­ Zone Valves.............................................................................................. 19 4.7.9 System Piping ­ Through Boiler......................................................................................... 19 4.7.10 System Piping ­ Radiant Heating....................................................................................... 19 4.7.11 System Piping ­ Special Application.................................................................................. 21 4.7.12 System Piping ­ Multiple Units Installation....................................................................... 21 4.8. INSTINCT Combi Boiler System Piping........................................................................................ 21 4.8.1 Expansion Tank and Makeup Water....................................................................................22 4.8.2 Diaphragm Expansion Tank.................................................................................................22 4.8.3 Circulator...............................................................................................................................22 4.8.4 Sizing Primary Piping...........................................................................................................22 4.8.5 System Piping ­ Zone Circulators.......................................................................................22 4.8.6 System Piping ­ Zone Valves..............................................................................................22 4.8.7 System Piping ­ Through Boiler.........................................................................................23 4.8.8 System Piping ­ Radiant Heating.......................................................................................23 4.8.9 System Piping ­ Special Application..................................................................................23 4.9. Optional System Piping and Cascading...................................................................................... 23 CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING........................................ 27 5.1. Domestic Piping Pressure Relief Valve.........................................................................................27 5.1.1 Standard Installation............................................................................................................27 5.1.2 Pressure Relief Valve - Standard Installations...................................................................27 5.1.3 Pressure Relief Valve Discharge Piping............................................................................. 28
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TABLE OF CONTENTS
5.2. Thermal Expansion....................................................................................................................... 28 5.3. Water Hammer.............................................................................................................................. 29 5.4. Vacuum Breaker............................................................................................................................ 29 5.5. Hydro-Block................................................................................................................................... 29 5.6. General Piping............................................................................................................................... 30 5.7. Thermostatic Mixing Valve........................................................................................................... 30 5.8. Storage Tank Installation.............................................................................................................. 30 CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN...........38 6.1. Installing Vent and Combustion Air............................................................................................. 38 6.2. Installing Condensate Drain Assembly into INSTINCT Solo Units............................................ 38 CHAPTER 7 - GAS PIPING................................................................................................. 40 7.1. Gas Supply Piping Connection..................................................................................................... 40 7.2. Natural Gas..................................................................................................................................... 41
7.2.1 Pipe Sizing............................................................................................................................. 41 7.2.2 Supply Pressure Requirements.......................................................................................... 41 7.3. Propane Gas.................................................................................................................................. 42 7.3.1 Pipe Sizing............................................................................................................................ 42 7.3.2 Supply Pressure Requirements......................................................................................... 42 CHAPTER 8 - WIRING.........................................................................................................45 8.1. Internal Wiring............................................................................................................................... 45 8.1.1 General Requirements........................................................................................................ 45 8.1.2 Fuse Locations..................................................................................................................... 45 8.2. External Wiring.............................................................................................................................. 48 8.2.1 General Requirements........................................................................................................ 48 8.2.2 Line Voltage Connections................................................................................................... 48 8.3. External Wiring - INSTINCT Solo Units........................................................................................ 48 8.3.1 Circulator Wiring.................................................................................................................. 48 8.3.2 Low Voltage Connections................................................................................................... 49 8.3.3 Thermostat Wiring.............................................................................................................. 49 8.3.4 Outdoor Sensor Wiring....................................................................................................... 49 8.3.5 Domestic Hot Water Wiring................................................................................................ 49 8.3.6 Additional Boiler Limits....................................................................................................... 49 8.3.7 External Modulation Control.............................................................................................. 50 8.3.8 System Sensor Wiring......................................................................................................... 50 8.3.9 Cascade Wiring - Optional.................................................................................................. 50 8.3.10 Modbus................................................................................................................................. 50
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TABLE OF CONTENTS

CHAPTER 9 - CTRLMAX OPERATION............................................................................... 51
9.1. CTRLMax Navigation..................................................................................................................... 51 9.2. CTRLMax Menu Structure............................................................................................................ 52 9.3. Home Screen................................................................................................................................. 53 9.4. Status Line Messages................................................................................................................... 54 9.5. Main Menu..................................................................................................................................... 55 9.6. EZ Setup........................................................................................................................................ 55

9.7. Heating EZ Setup ................................................................................................................. 56 9.7.1 Select CH Demand (No outdoor sensor connected)....................................................... 56 9.7.2 Select CH Demand (Outdoor sensor connected)..............................................................57

9.8. Domestic Hot Water EZ Setup

- INSTINCT Solo Units..................................................... 58

9.9. Domestic Hot Water EZ Setup

- INSTINCT Combi Units................................................. 59

9.10. Altitude Setup................................................................................................................................ 59

9.11. EZSetup Reset

.................................................................................................................... 60

9.12. Display EZ Setup ................................................................................................................... 60

9.13. CH/DHW Operation .............................................................................................................. 61
9.14. Boiler Information .................................................................................................................. 61 9.14.1 Information Items................................................................................................................ 62 9.14.2 Lockout Screen.................................................................................................................... 63 9.14.3 Manual Reset Lockouts....................................................................................................... 64 9.14.4 Automatic Reset Blocking Lockouts.................................................................................. 65
CHAPTER 10 - START-UP PREPARATION......................................................................... 67
10.1. Boiler System Fluid Requirements...............................................................................................67 10.1.1 Boiler Fluid pH Level 6.0 to 8.0...........................................................................................67 10.1.2 Boiler Fluid Hardness Less Than 7 Grains..........................................................................67 10.1.3 Chlorinated Water................................................................................................................67 10.1.4 Flush Boiler to Remove Sediment.......................................................................................67 10.1.5 Cleaning of Old Boiler/System: ..........................................................................................67 10.1.6 Cleaning of New Boiler/System: ........................................................................................67 10.1.7 Check and Test Antifreeze.................................................................................................. 68 10.1.8 Use of Antifreeze in the Boiler System.............................................................................. 68
10.2. Filling the Boiler System............................................................................................................... 69 10.3. INSTINCT Combi Water Heater - Water Requirements............................................................. 69
10.3.1 Filling the Domestic Circuit................................................................................................. 69

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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.......................................................................................... 70 CHAPTER 11 - START-UP PROCEDURES...........................................................................71

11.1. Final Checks Before Start-Up........................................................................................................ 71 11.2. INSTINCT Start-Up........................................................................................................................ 71 11.3. Check the INSTINCT and System................................................................................................. 71
11.3.1 Check Boiler Piping.............................................................................................................. 71 11.3.2 Check Vent and Combustion Air Piping............................................................................. 71 11.3.3 Verify Carbon Monoxide Detector...................................................................................... 71 11.3.4 Check Gas Piping..................................................................................................................73 11.3.5 Verify Flame Pattern and Combustion...............................................................................73 11.3.6 Measure Input - Natural Gas Only.......................................................................................74 11.3.7 Test High Temperature Limit...............................................................................................74 CHAPTER 12 - OUTDOOR RESET CONTROL.................................................................... 75

12.1. Mounting the Outdoor Sensor......................................................................................................75 12.2. Wiring the Sensor...........................................................................................................................75 CHAPTER 13 - EXTERNAL MODULATING CONTROL...................................................... 77

13.1. Wiring the Modulating Controller..................................................................................................77 13.2. CTRLMax Programming................................................................................................................77 13.3. Programming of External Modulating Control............................................................................77 CHAPTER 14 - CHECK-OUT PROCEDURES......................................................................79

CHAPTER 15 - INSTALLATION RECORD........................................................................... 81

CHAPTER 16 - MAINTENANCE SCHEDULES....................................................................83

16.1. Service Technician........................................................................................................................ 83 16.2. Owner Maintenance...................................................................................................................... 83 CHAPTER 17 - MAINTENANCE PROCEDURES.................................................................85

17.1. 17.2. 17.3. 17.4. 17.5. 17.6. 17.7. 17.8.

Service Technician Maintenance Procedures............................................................................ 85 Reported Problems....................................................................................................................... 85 Check Surrounding Area ............................................................................................................ 85 Inspect Burner Area...................................................................................................................... 85 Check System Piping.................................................................................................................... 85 Clean Condensate Drain Assembly............................................................................................. 85 Check Ventilation Air Openings................................................................................................... 86 Inspect Vent and Combustion Air Piping.................................................................................... 86

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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...................................................................................................................... 86 17.13. Check Ignition Cable and Ground Wiring.....................................................................................87 17.14. Check Control Wiring.....................................................................................................................87 17.15. Check Control Settings.................................................................................................................87 17.16. Perform Start-up and Checkout Procedures...............................................................................87 17.17. Check Burner Flame......................................................................................................................87 17.18. Check Flame Signal........................................................................................................................87 17.19. Check Combustion Levels............................................................................................................ 88 17.20. Check Flue Gas Temperature....................................................................................................... 88 17.21. Clean Heat Exchanger.................................................................................................................. 88 17.22. Check Carbon Monoxide Detectors............................................................................................ 88 17.23. Review With Owner....................................................................................................................... 88 17.24. Torque Specifications Table......................................................................................................... 88 CHAPTER 18 - REPLACEMENT PARTS.............................................................................89 CHAPTER 19 - PRODUCT SPECIFICATIONS................................................................... 102
viii

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.................................................................................................................................... 13 Fig. 6 - INSTINCT Pressure Relief Valve Installation............................................................................... 15 Fig. 7 - Piping Component Legend........................................................................................................... 16 Fig. 8 - INSTINCT Solo Near Boiler Piping - Diaphragm Expansion Tank.............................................. 17 Fig. 9 - Near Boiler Piping - Closed Type Expansion Tank......................................................................18 Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump.......................................... 20 Fig. 11 - INSTINCT Combi Near Boiler Piping - Diaphragm Expansion Tank......................................... 21 Fig. 12 - INSTINCT Combi System Piping - Zoning w Valves................................................................ 24 Fig. 13 - INSTINCT Combi - System Piping - Multi Zone Valve - Single Circulator.............................. 25 Fig. 14 - INSTINCT Combi - System Piping - Single Zone with Single Circulator............................... 26 Fig. 15 - Standard Installation of the Pressure Relief Valve....................................................................27 Fig. 16 - INSTINCT Combi - Hydro-block Flow Diagram........................................................................ 29 Fig. 17 - INSTINCT Combi Domestic Piping - Single Zone System with Single System/Boiler Circulator.................................................................................................................................................... 31 Fig. 18 - INSTINCT Combi Domestic Piping - Storage tank installation.............................................. 32 Fig. 19 - Multiple Zones - Panel Wiring with Circulators........................................................................ 33 Fig. 20 - INSTINCT Combi System Piping - Multiple Zones - Panel Wiring with Valves..................... 34 Fig. 21 - INSTINCT Solo System Piping - Multi Zone System with Single System/Boiler Circulator.35 Fig. 22 - INSTINCT Solo System Piping - Indirect Water Heater installation...................................... 36 Fig. 23 - Instinct Solo - Cascade Piping...................................................................................................37 Fig. 24 - Condensate Drain Assembly.................................................................................................... 39 Fig. 25 - Recommended Gas Supply Piping........................................................................................... 40 Fig. 26 - Gas Valve / Venturi Assembly - INSTINCT Solo110 ................................................................ 43 Fig. 27 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 155.................................................. 43 Fig. 28 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 199.................................................. 44 Fig. 29 - CTRLMax Control Module Fuse Location ................................................................................ 45 Fig. 30 - INSTINCT Solo Boiler Factory Wiring....................................................................................... 46 Fig. 31 - INSTINCT Combi Boiler Factory Wiring.....................................................................................47 Fig. 32 - Terminal Strip Location............................................................................................................. 48 Fig. 33 - Low Voltage Connections.......................................................................................................... 49 Fig. 34 - CTRLMax User Interface............................................................................................................ 51 Fig. 35 - INSTINCT Solo Jacket Components........................................................................................ 89 Fig. 36 - INSTINCT Combi Jacket Components..................................................................................... 90
ix

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.............................................................................. 94 Fig. 41 - INSTINCT Combi 199 Internal Components............................................................................ 95 Fig. 42 - INSTINCT Solo 110 Burner Components............................................................................... 96 Fig. 43 - INSTINCT Solo/Combi 155 Burner Components..................................................................97 Fig. 44 - INSTINCT Combi 199 Burner Components............................................................................ 98 Fig. 45 - INSTINCT Control & Display Enclosures................................................................................. 99 Fig. 46 - INSTINCT Combi Hydro-block.............................................................................................. 100 Fig. 47 - Front View INSTINCT Solo 110 ................................................................................................103 Fig. 48 - Right Side View INSTINCT Solo 110 .......................................................................................104 Fig. 49 - Front View INSTINCT Solo 155...............................................................................................105 Fig. 50 - Right Side View INSTINCT Solo 155.......................................................................................106 Fig. 51 - Front View INSTINCT Solo 199................................................................................................107 Fig. 52 - Right Side View INSTINCT Solo 199.......................................................................................108 Fig. 53 - Front View INSTINCT Combi 155...........................................................................................109 Fig. 54 - Right Side View INSTINCT Combi 155................................................................................... 110 Fig. 55 - Front View INSTINCT Combi 199............................................................................................111 Fig. 56 - Right Side View INSTINCT Combi 199................................................................................... 112
Graph 1 - INSTINCT Solo - Pressure Loss Through Boiler.................................................................... 113
Table 1 - Natural Gas Venturis................................................................................................................... 41 Table 2 - Gas Piping Sizing - Natural Gas................................................................................................. 41 Table 3 - Propane Conversion Venturis................................................................................................... 42 Table 4 - Outdoor Reset Preset Selections..............................................................................................57 Table 5 - Throttle Screw Adjustment.......................................................................................................74 Table 6 - Acceptable Combustion Levels................................................................................................74
x

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.
Triangle Tube accepts no liability for any damage, injury, or loss of life resulting from incorrect installation, alteration of any factory supplied parts, or the use of parts or fittings not specified by Triangle Tube. If there is a conflict or doubt about the proper installation of the unit or any factory supplied replacement parts please contact Triangle Tube Technical Support.
DEFINITIONS
The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product.
DANGER
Indicates the presence of a hazardous situation which, if ignored, will result in substantial
property damage, serious injury, or death.
WARNING
Indicates a potentially hazardous situation which, if ignored, can result in substantial
property damage, serious injury, or death.
CAUTION
Indicates a potentially hazardous situation which, if ignored, can result in minor property
damage, or injury.
NOTICE
Indicates special instructions on installation, operation or maintenance, which are important to the equipment but not related to person-
al injury hazards.
BEST PRACTICE
Indicates recommendations made by Triangle Tube for the installers, which will help to ensure optimum operation and longevity of the equip-
ment.

DANGER
· Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water.
· Avoid electrical shock when servicing the appliance, by disconnecting the electrical supply prior to performing maintenance.
· Failure to comply with these instructions will result in substantial property damage, serious injury, or death.
WARNING
· 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.
· Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
· Prior to installing this product, the qualified installer must read all instructions included in this manual and all accompanying manuals/ documents with this appliance.
· All installation steps required in these manuals must be performed in the proper order given.
· This product must be maintained / serviced and inspected annually by a qualified service technician.
· A byproduct of any gas fired appliance is carbon monoxide. Triangle Tube requires the installation of a minimum of two (2) hard-wired carbon monoxide detectors with an alarm and battery back-up; one in the mechanical room where the boiler is located and another installed in the living area outside the bedroom(s) for all installations. Consult the local authority having jurisdiction for any additional carbon monoxide detector requirements in your area. See Section 2.8 on page 10 for additional carbon monoxide detector requirements in Massachusetts.
· Failure to comply with these instructions can result in substantial property damage, serious injury, or death.

xi

SAFETY

PRODUCT AND SAFETY INFORMATION
DANGER
HOT WATER CAN SCALD! Water temperature over 125ºF can cause se-
vere burns instantly or death from scalds.
· Children, disabled and elderly are at highest risk of being scalded.
 Never leave them unattended in or near shower, bathtub or sink.
 Never allow small children to use a hot water faucet or draw their own bath.
· To avoid any potential scald hazard or if codes require specific water temperatures at the hot water faucet, the installer must:  Install a thermostatic mixing valve at this appliance and ensure it is working property AND  Set the domestic hot water temperature to the lowest temperature which satisfies your hot water needs.  Feel and adjust water temperature before bathing or showering.  Water drained from the system drain valves may be extremely hot. TO AVOID INJURY:
· Make sure all connections are tight. · Direct water flow away from any person. · Failure to comply with these instructions
will result in substantial property damage, serious injury, or death.
WARNING
Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained. Failure to maintain at least 140°F [60°C] domestic hot water temperature or use the Antilegionella function can result in bacteria development, which can result in serious injury, or death.
xii

WARNING
· 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.
· Failure to comply with these instructions can result in substantial property damage, serious injury, or death.
WARNING
Protection must be taken against excessive pressure!
TO PROTECT AGAINST EXCESSIVE PRESSURE:
· Verify that a field supplied 150 psi pressure relief valve is installed in the recommended location for Combi models using the domestic hot water function (DHW Side).
· Verify the 30 psi relief valve supplied is installed in the location provided (CHSide). In installations where the CH pressure exceeds 30 psi, a 50 psi relief valve (not included) can be installed in lieu of the 30 psi relief valve.
· To avoid injury, install the relief valves in compliance with local code requirements.
Failure to comply with these instructions can result in substantial property damage, seri-
ous injury, or death.
CAUTION
· It is prohibited to carry out any modifications to the appliance without prior written consent from Triangle Tube.
· Faulty parts must only be replaced by genuine Triangle Tube factory parts.
· Failure to comply with these instructions can result in minor property damage, or injury.
· The Instinct appliance is supplied with an acoustic dampening foam rubber insert located in the appliance air inlet. DO NOT remove this on installation.
NOTICE
· The homeowner is only permitted to carry out the basic set-up operations (EZ Setup) after he has received all relevant instructions from the installer. Any other setup must be carried out by a qualified installer.
· In case of any anomaly, please call your qualified service technician.
· Make sure to reference the unit's model number and serial number from the rating label when inquiring about service or troubleshooting.
· Triangle Tube reserves the right to change the technical characteristics, components and features of its products without prior notice. Check for an updated version of this manual at www.triangletube.com.

CHAPTER 1

Chapter 1 - PRE-INSTALLATION REQUIREMENTS

1.1. 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.
· For installations in Massachusetts, code requires the INSTINCT to be installed by a licensed plumber or gas fitter, and if antifreeze is utilized, the installation of a reduced pressure back-flow preventer device is required in the boiler's cold water fill or make up water supply line.
· For installation in Massachusetts, all direct vented appliances must comply with the guidelines as outlined in Section 2.8 on page 10.
· The National Fuel Gas Code (NFPA54/ ANSI Z 223.1).
· National Electric Code (ANSI/NFPA 70).
· For installations in Canada - Installation Code for Gas Burning Equipment (CAN/CSA B149.1), Canadian Electrical Code Part 1 (CSA C22.1).
· Standards for Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1), when required.
NOTICE
The Instinct gas manifold and gas controls meet the safe lighting and other performance
requirements as specified in ANSI Z21.13.
Where recommendations in this manual differ from local or national codes, the local or national codes take precedence.
1.1.1 Code Restrictions
The single wall heat exchanger in the INSTINCT Combi water heater complies with National Standard Plumbing Code, provided that:
· Boiler water (including additives) is practically non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products, and
· Boiler water pressure is limited to maximum 30 psig by approved relief valve.
Single wall heat exchangers are permitted under the Uniform Plumbing Code - Paragraph L3.2. and L3.3 if they satisfy all of the following requirements.
· The heat transfer medium is potable water or contains only substances which are recognized as safe by the U.S. Food and Drug Administration.
· The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system

· The equipment is permanently labeled to indicate that only additives recognized as safe by the FDA shall be used in the heat transfer medium.
Other heat exchanger designs may be permitted where approved by the Administrative Authority.
1.1.2 Operating Restrictions
· Maximum INSTINCT Combi DHW outlet temperature is 149ºF, when mixing valve is installed.
· Maximum boiler water temperature rating is 210ºF. · Maximum DWH working pressure is 150 psig. · Maximum boiler (CH) working pressure is
50 psig. · Water quality limitations (based on E.P.A Nation-
al Secondary Drinking Water Regulations):  Chloride, less than 150 ppm or mg/l  pH value min. 6, max. 8  Total hardness 3 - 7 grains/gallon or 50-120
ppm or mg/l.  Total Dissolved Solids (TDS), less than 120
ppm or mg/l.  Iron less than 0.3 ppm or mg/l.  Aluminum, less than 0.2 ppm or mg/l.  Copper, less than 1 ppm or mg/l.  Manganese, less than 0.05 ppm or mg/l.  Zinc, less than 5 ppm or mg/l.
BEST PRACTICE
In hard water areas (more than 7 grains of hardness) soften the cold domestic supply wa-
ter to the appliance to prevent scaling.
NOTICE
· Any water conditioning system must be installed and maintained in accordance with manufacturer's specifications.
· Do not install the INSTINCT Combi in any application if the boiler piping contains non-oxygen barrier tubing or if the boiler piping is considered an "open system". Exposing the internal circulator to oxygen contamination will lead to premature failure and denial of the warranty.

1

CHAPTER 1

CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS

1.2. Determining Product Location
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. Ensure the area chosen for the installation of the INSTINCT is free of any combustible materials, gasoline, or other flammable liquids.
WARNING
Failure to remove or maintain the area free of combustible materials, gasoline, or other flammable liquids or vapors can result in substantial property damage, serious injury,
or death.
Ensure the INSTINCT and its controls are protected from dripping or spraying water during normal operation or service. The INSTINCT should be installed in a location so that any water leaking from the boiler, piping connections, or relief valve will not cause damage to the surrounding area or any lower floors in the structure.

1.3. Boiler Freeze Protection Feature
The CTRLMax boiler management system has a freeze protection feature built in. This feature monitors the boiler water temperature and responds as follows when no call for heat is present: · 46ºF [8ºC] Pump outputs configured to respond to
a CH1 Call are enabled. · 42ºF [6ºC] Pump outputs configured to respond to
a CH1 or CH2 Call are enabled, Burner operates at low fire. · 60ºF [15ºC] Freeze protection ends. Burner & all pumps turn off after completing CH Post Pump Time.
CAUTION
· The boiler freeze protection feature is disabled during a hard lockout. The burner will not fire, but the circulators will operate.
· The boiler freeze protection feature is designed to protect the boiler, not the heating system. The boiler should be installed in a primary/secondary piping arrangement if it is installed in an unheated space or exposed to water temperatures of 46ºF or less. Refer to Chapter 4 for primary/secondary piping and Chapter 10 for antifreeze guides.
· Failure to comply can result in minor property damage, or injury.
1.4. Boiler Replacement
If the INSTINCT is replacing an existing boiler, the following items should be checked and corrected prior to installation:
· Boiler piping leaks and corrosion. · Proper location and sizing of the expansion
tank on the boiler heating loop. · The existing vent system is appropriate for the
INSTINCT and it is correctly installed. Refer to the INSTINCT Vent Supplement for the vent system requirements. · Amount and quality of propylene glycol within the system, if applicable.

2

CHAPTER 1

CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS

1.5. 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:
· Top boiler jacket - 24 inches [610 mm]. · Front - 24 inches [610 mm]. · Bottom boiler piping - 24 inches [610 mm]. · Rear - 0 inches · Sides - 6 inches [153 mm]

1.6. Residential Garage Installations
When installing the INSTINCT in a residential garage, the following special precautions perNFPA 54/ANSI Z223.1 must be taken:
· Mount the unit a minimum 18 inches [458 mm] above the floor level of the garage. Ensure the burner and ignition devices / controls are no less than 18 inches [458 mm] above the floor level.
· Locate or protect the unit in a manner so it cannot be damaged by a moving vehicle.

NOTICE
When maintaining less than recommended service clearances, some product labeling, including the rating label, may become hidden
and unreadable.
WARNING
· If the recommended clearances listed above cannot be maintained or the enclosure in which the boiler is installed is less than 70 cubic feet, the space must be ventilated. See Section 2.2 on page 6.
· When installing the INSTINCT in a confined space, sufficient air must be provided to allow, under normal operating conditions, proper air flow around the product to maintain ambient temperatures within safe limits to comply with the National Fuel Gas Code (NFPA 54 / ANSI Z223.1)
· Failure to comply with these instructions can result in substantial property damage, serious injury, or death.

3

INTENTIONALLY LEFT BLANK

CHAPTER 2

Chapter 2 - COMBUSTION AIR & VENTING

2.1. Combustion Air Contamination

· An in-direct installation uses uncontaminated indoor air for appliance combustion.

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.
DANGER
· Do not operate the INSTINCT if the combustion air inlet is located near a laundry room or pool facility. These areas will always contain hazardous contaminants.
· Pool, laundry, common household, and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the burner and vent system, they can form strong acids. These acids will corrode the heat exchanger, burner components, and vent system, causing serious damage and possible flue gas spillage or water leakage into the surrounding area.
· Please read the information listed below. If contaminating chemicals are located near the area of the combustion air inlet, the installer must pipe the combustion air inlet to an area free of these chemicals, as indicated in Chapter 6 on page 38.
· Failure to comply with these instructions will result in substantial property damage, serious injury, or death.
· The INSTINCT boiler is classified as a Category IV appliance. This utilizes uncontaminated indoor or outdoor air for applicance combustion. A direct vent installation uses the outdoor air. Air supply, combusiton chamber, heat exchanger and evacuation of POC (products of combustion) for this type of appliance is sealed with respect to the room in which the appliance is installed.

· When the air for combustion is taken from the room air grilles must be installed by the contractor. The air grilles should be sized in accordance with ANSI Z223.1/ NFPA54 and/or Natural Gas and Propane Installation Code CAN/CSA B149.1.
· The grille providing air when taking air directly from the room should be clearly labelled; "AIR SUPPLY, DO NOT COVER OR RESTRICT. FAILURE TO PROVIDE ADEQUATE AIR FOR COMBUSTION COULD RESULT IN SERIOUS INJURY, OR DEATH."
Potential contaminating products · Spray cans containing chloro/fluorocarbons · Permanent Wave Solutions · Chlorinated wax · Chlorine based swimming pool chemicals / cleaners · Calcium Chloride used for thawing ice · Sodium Chloride used for water softening · Refrigerant leaks · Paint or varnish removers · Hydrochloric acid / muriatic acid · Cements and glues · Antistatic fabric softeners used in clothes dryers · Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms · Adhesives used to fasten building 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 workshops

5

CHAPTER 2

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.
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.
For Direct Vent installations involving only the INSTINCT, in which the minimum service clearances are not maintained as listed in Section 1.5 on page 3, the space / enclosure must provide two openings for ventilation. The openings must be sized to provide 1 square inch of free area per 1,000 BTUH of boiler input. The openings shall be placed 12 inches from the top of the space and 12 inches from the floor of the space.
For installations in which the INSTINCT shares the space with air movers (exhaust fan, clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space must be provided with adequate air openings to provide ventilation and combustion air to the equipment. To properly size the ventilation / combustion air openings, the installer must comply with the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/CSA B149.1 for installations in Canada.
WARNING
The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements (exhaust fans, clothes dryers, fireplaces, etc.) and the total input of all appliances located in the same space as the INSTINCT, excluding the input of a Direct Vent INSTINCT which uses combustion air directly from the outside, thus additional free area for the openings is not required. Failure to provide or properly size the openings can result in substantial prop-
erty damage, serious injury, or death.

2.3. Ventilation and Combustion Air Requirements - Category IV
A Category IV appliance utilizes uncontaminated indoor or outdoor air surrounding the appliance for combustion.
BEST PRACTICE
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.
For installations in which the INSTINCT shares the space with air movers (exhaust fan, clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space must be provided with adequate air openings to provide ventilation and combustion air to the equipment. To properly size the ventilation / combustion air openings, the installer must comply with the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/ CSA B149.1 for installations in Canada.
WARNING
The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements (exhaust fans, clothes dryers, fireplaces, etc.) and the total input of all appliances, including the INSTINCT when located in the same space. Failure to provide or properly size the openings can result in substantial property damage,
serious injury, or death.

6

CHAPTER 2

CHAPTER 2 - COMBUSTION AIR & VENTING

2.4. 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.
· Indoor combustion air vent supply must be installed with a minimum equivalent vent length of 10 feet. Refer to Vent Supplement for further guidance.
Opening Size and Location
Openings used to connect indoor spaces shall be sized and located in accordance with the following, see Fig. 1 below : · Combining spaces on the same story. Each opening
shall have a minimum free area of 1 sq. in./1000 Btu/hr of the total input rating of all gas utilization equipment in the space, but not less than 100 sq. inches. One opening shall commence within 12 inches of the top, and one opening shall commence within 12 inches of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 inches.
Gas Vent

2.4.2. Outdoor Combustion Air
BEST PRACTICE
Isolating the combustion appliance room from the rest of the building and bringing in uncontaminated outside air for combustion and ven-
tilation is always preferred.
Opening Size and Location
The minimum dimension of air openings shall be not less than 3 inches
Openings used to supply combustion and ventilation air shall be sized and located in accordance with the following:
· One Permanent Opening Method . One permanent opening, commencing within 12 in. of the top of the enclosure, shall be provided as shown in Fig. 2 below. The equipment shall have clearances of at least 1 inch from the sides and 6 in. from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following: · 1sq. in./3000 Btu/hr of the total input rating of all equipment located in the enclosures, and
· Not less than the sum of the areas of all vent connectors in the space.

Gas Vent

Ion-ic 186°F
DHW 156°F
Target = 186°F DHW Demand

Openings

Fig. 1 - All Combustion Air from adjacent Indoor Spaces through Indoor Combustion Openings
· Combining spaces in different stories. The volumes of spaces in different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 sq. in./1000 Btu/hr of total input rating of all gas utilization equipment.

Alternate opening location

Opening

Ion-ic 186°F
DHW 156°F
Target = 186°F DHW Demand

Fig. 2 - All Combustion Air from Outdoors Through One Permanent Air Opening
7

CHAPTER 2

CHAPTER 2 - COMBUSTION AIR & VENTING

· 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. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows: · Where directly communicating with the outdoors or where communication to the outdoors is through vertical ducts, each opening shall have a minimum free area of 1 sq. in./4000 Btu/ hr of total input rating of all equipment in the enclosure. See Fig. 3 below.

Gas Vent

Ventilation louvers (each end of the attic)

Outlet air
Inlet air duct (ends 1ft (30 cm)
above floor)
Ion-ic 186°F
DHW 156°F Target = 186°F DHW Demand

· Where communicating with the outdoors is through horizontal ducts, each opening shall have a minimum free area of not less than 1 sq.in./2000 Btu/hr of total input rating of all equipment in the enclosure. See Fig. 4 below.
2.4.3 Combination of Indoor and Outdoor Combustion Air
Indoor Openings. Where used, openings connecting the interior spaces shall comply with Section 2.4.1 on page 7.
Outdoor Opening(s) Location. Outdoor opening(s) shall be located in accordance with Section 2.4.2 on page 7.
Outdoor Opening(s) Size. Outdoor opening(s) shall be calculated in accordance with the following: · The ratio of the interior spaces shall be the avail-
able volume of all communicating spaces divided by the required volume. · The outdoor size reduction factor shall be 1 minus the ratio of interior spaces. · The minimum size of outdoor opening(s) calculated in accordance with the above outdoor air chapter multiplied by the reduction factor. The minimum dimension of air openings shall not be less than 3 in.

Fig. 3 - All Combustion Air from Outdoors Through Ventilated Attic
Gas Vent
Outlet air duct
Ion-ic 186°F
DHW 156°F Target = 186°F DHW Demand
Inlet air duct
Fig. 4 - All Combustion Air from Outdoors Through Horizontal Ducts

2.5. Combustion Air and Vent Piping
The INSTINCT requires a Category IV venting system, which is designed for pressurized venting and condensate. The INSTINCT is certified as a Category IV or Direct Vent (sealed combustion) appliance. A Category IV appliance utilizes uncontaminated indoor or outdoor air surrounding the appliance for combustion. A Direct Vent appliance utilizes uncontaminated outdoor air piped directly to the appliance for combustion.
DANGER
Do not install the INSTINCT into a common vent with any other gas or oil appliances. This will cause flue gas spillage or appliance malfunction, which will result in substantial
property damage, serious injury, or death.
DANGER
It is essential that the supply of air for combustion is not blocked or restricted - this
could result in serious injury, or death.

8

CHAPTER 2

CHAPTER 2 - COMBUSTION AIR & VENTING

BEST PRACTICE
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 re-
placed by cold infiltration air into the house.
DANGER
Verify installed combustion air and vent piping are sealed gas tight and meet all provided instructions and applicable codes, failure to comply will result in serious injury, or death.
WARNING
Failure to properly support the vent system can cause the venting system to fail, resulting in substantial property damage, serious
injury, or death.
NOTICE
Install combustion air and vent pipe as detailed in the INSTINCT Vent Supplement included in the boiler installation envelope. Refer to optional vent kit instructions for additional vent
installation instructions.
2.6. Removal of an Existing Boiler from a Common Vent System
BEST PRACTICE
When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the
common venting system are not in operation.

1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3. Insofar as is practical:
· Close all exterior building doors and 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 dryers and any appliance not connected to the common venting system.
· Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed.
· Do not operate a summer exhaust fan.
· Close fireplace dampers. 4. Place in operation the appliance being inspected.
· Follow the lighting instructions.
· Adjust thermostat so appliance will operate continuously.
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous condition of use.
7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/CSA B149.1 for installations in Canada. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/CSA B149.1 for installations in Canada.
DANGER
Do not install the INSTINCT into a common vent with any other gas or oil appliances. This will cause flue gas spillage or appliance malfunction, resulting in substantial property
damage, serious injury, or death.

9

CHAPTER 2

CHAPTER 2 - COMBUSTION AIR & VENTING

2.7. Carbon Monoxide Detector Installation
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.
Consult the local authority having jurisdiction for any additional carbon monoxide detector requirements in your area. See Section 2.8 on page 10 for additional carbon monoxide detector requirements in Massachusetts.
WARNING
A byproduct of any gas fired appliance is carbon monoxide. Failure to install carbon monoxide detectors with alarms can result in seri-
ous injury, or death.
2.8. Commonwealth of Massachusetts Installation Requirements
For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
2.8.1 Installation of Carbon Monoxide Detectors.
1. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed.
2. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment.
3. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2.8.2 Approved Carbon Monoxide Detectors.
Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
2.8.3 Signage
A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
The sign shall read, in print size no less than one half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
2.8.4 Inspection.
The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
Exemptions
The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

10

CHAPTER 2

CHAPTER 2 - COMBUSTION AIR & VENTING

2.8.5 Manufacturer Requirements - Gas Equipment Venting System Provided.
When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.

2.8.6 Manufacturer Requirements - Gas Equipment Venting System Not Provided.
When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

11

INTENTIONALLY LEFT BLANK

CHAPTER 3

Chapter 3 - UNIT PREPARATIONS

3.1. Handling Instructions
The INSTINCT is generally easier to handle and maneuver once removed from the shipping carton. To remove the shipping carton:
NOTICE
Use care not to drop, bump or rotate the boiler upside down, as damage to the boiler will result.
1. Remove any shipping straps. 2. Slide the cardboard sleeve from the unit. 3. Remove the wall mounting template. 4. Remove the accessory boxes. 5. Remove upper and lower cardboard end pieces. 6. Remove the boiler from the cardboard tray. 7. Discard all packing materials and recycle where
possible.

3.2. 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. The INSTINCT is not to be installed on carpeting
WARNING
The wall used for mounting the INSTINCT must be vertically plumb and capable of sup-
porting at minimum: · 101 pounds [46 kg] for the INSTINCT Solo 110 · 137 pounds [62 kg] for the INSTINCT Solo 155 · TBC pounds [TBC kg] for INSTINCT Solo 199 · 154 pounds [70 kg] for INSTINCT Combi 155 · TBC pounds [TBC kg] for INSTINCT Combi 199 Note. All weights above include INSTINCT
water volumes.
Failure to comply with these requirements can result in substantial property damage,
serious injury, or death.

3.3. Accessories
Unpack and check the the list of all accessories as shown in Fig. 5 below.

Venturi

Auto Air Vent

Pressure Gauge

Bird Screens (x2)

Pressure Relief Valve Sensor DHW

3/4" Elbow

Reduced Tee

Union

Screws (x4) / Anchors (x4)

Gas Valve to Venturi Gaskets (x2)

LP Foam

Fig. 5 - Accessories

13

CHAPTER 3

CHAPTER 3 - UNIT PREPARATIONS

3.4. Wall Mounting Guidelines

3.5. Stud Walls - Installation

The wall-mounting bracket is designed for stud spacing of approximate 12 inch or 16 inch on centers. For unconventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket.
1. For applications using wood studs, install the bracket using the lag screws provided with the boiler. Ensure both lag screws are installed securely in the studs.
2. For applications using metal studs, install the bracket to the studs using 3/16" toggle bolts and washers.
3. DO NOT mount or attempt to mount the wall bracket to hollow sheet rock or lath walls using anchors. Only install boiler to studs or equivalent wood structure.
4. For applications using solid walls (rock, concrete, brick, cinder block, etc.), install the wall bracket using anchors (double expansion shields) and bolts with washers provided with the boiler.
5. The boiler is too heavy and bulky for a single person to lift and attempt to mount; a minimum of 2 people are required for mounting the boiler.

1. Locate the studs in the general area of the boiler installation.
2. Place the wall-mounting bracket on the wall centering the mounting slots with the stud centers and ensuring the upper edge of the bracket is away from the wall.
3. Level the bracket, while maintaining it's centering with the studs and use a pencil to mark the location of the mounting slots.
4. Remove the bracket from the wall and drill a 1/4" diameter by 3" deep hole in the center of each mark. For applications using metal studs and 3/16" toggle bolts, drill the required clearance hole.
5. Reposition the bracket on the wall and align with the mounting slots/holes. Insert the two lag screws provided (or toggle bolts for metal studs) through the mounting slots/holes and loosely tighten.
6. Level bracket and tighten screws (bolts for metal studs) securely making sure not to over-tighten to avoid damaging drywall or plaster.
3.6. Wall Bracket Installation - Solid Walls

WARNING
Use extreme care not to drop the boiler or cause bodily injury while lifting or mounting the boiler onto the wall bracket. Once mounted, verify that the boiler is securely attached to the bracket and wall. Failure to comply with the above guidelines can result in substantial property damage, serious inju-
ry, or death.

1. Locate the general area of the boiler installation. 2. Place the wall-mounting bracket on the wall ensuring
the upper edge of the bracket is away from the wall. 3. Level the bracket and use a pencil to mark the loca-
tion of the mounting slots on the wall. 4. Remove the bracket from the wall and drill a 5/8"
diameter by 1-3/8" deep hole in the center of each mark. 5. Install the provided anchors flush or slightly recessed in the drilled holes with threaded side facing down. 6. Reposition the bracket on the wall and align with the mounting slots/holes. Insert the two bolts with washers through the mounting slots/holes and loosely tighten. 7. Level bracket and tighten bolts securely.
3.7. Boiler Mounting
1. Obtain assistance in lifting the boiler onto the wall bracket.
2. Install the boiler making sure the boiler mounting lip located along the upper edge of the rear jacket panel engages the wall-mounting bracket. Ensure the boiler is seated properly and is secure.

14

CHAPTER 4

Chapter 4 - BOILER PIPING

4.1. General Piping Requirements
· All plumbing must meet or exceed all local, state and national plumbing codes.
· Support all piping using hangers. DONOT 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. Use one wrench to prevent the boiler connections from turning and the second to tighten field piping. Failure to support the boiler piping connections could damage piping, causing a leak, resulting in substantial property dam-
age, serious injury, or death.

3/4" Street Elbow Air Vent

Pressure relief valve (supplied with boiler)

4.2. Pressure Relief Valve
1. The INSTINCT is supplied with a 30 psi pressure relief valve and must be piped using the PRV connection as shown in Fig. 5 below.
NOTICE
In installations where the CH pressure exceeds 30 psi, a 50 psi relief valve (not included) can be
installed in lieu of the 30 psi relief valve.
2. To avoid potential water damage to the surrounding area or potential scalding hazard due to the operation of the relief valve, the discharge piping: · Must be connected to the discharge outlet of the relief valve and directed to a safe place of disposal. · Length should be as short and direct as possible. The size of the discharge line must not be reduced, maintain the same size as the outlet of the relief valve. · Must be directed downward towards the floor at all times. The piping should terminate at least 6 inches [153 mm] above any drain connection to allow clear visibility of the discharge. · Must terminate with a plain end, not with a threaded end. The material of the piping must have a serviceable temperature rating of 250ºF or greater. · Must not be subject to conditions where freezing could occur. · Must not contain any shut-off valves or obstructions. No shut-off valve should be piped between the boiler and relief valve.
WARNING
Failure to comply with the guidelines on installing the pressure relief valve and discharge piping can result in substantial prop-
erty damage, serious injury, or death.

Drain piping directed to a suitable place of drainage

Fig. 6 - INSTINCT Pressure Relief Valve Installation 15

CHAPTER 4

CHAPTER 4 - BOILER PIPING
4.3. 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.
1. Make sure to fully tighten the cap on the air vent during initial installation.
2. Never loosen the hygroscopic cap to allow air to escape the air vent. Air will exit with the cap fully tightened in place.
3. If the hygroscopic cap is not fully tightened, water may leak from the cap. Simply tighten the cap securely.

4.4. Low Water Cutoff Device
· The INSTINCT is equipped with a factory installed pressure sensor type Low Water Cut Off (LWCO).
· The minimum operating system pressure is 10 psi. In the event that the pressure falls below 10 psi the burner will deactivate until proper pressure has been restored.
· Check local codes if a Low Water Cutoff is required. If so, determine if this device meets their requirements.
NOTICE
The INSTINCT control system also senses the water temperatures entering and exiting the heat exchanger to provide protection against low water conditions. Where local codes and jurisdiction do not accept a pressure device for low water protection, the jurisdiction may accept this INSTINCT integral control function as
a means of providing low water protection.

Circulator Circulator w/Isolation Flgs Air Separator Auto Air Vent 24 vac Motorized Zone Valve Backflow Preventer

Pressure Relief Valve Union Spring Check Valve Ball Valve Style Boiler Drain Full Port Ball Valve Pressure Reducing Valve
Valve & Drain Assembly

Pressure Differential Bypass Valve Diaphragm Style Expansion Tank

Closed style Expansion Tank

Heat Emitters (Baseboard, Radiant Manifolds, Radiant Panels) Fig. 7 - Piping Component Legend
16

CHAPTER 4 - BOILER PIPING
4.5. 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. Reference Fig. 30 on page 46 for available external limit (manual or auto reset) terminals.
If the installation is to comply with ASME or Canadian requirements, an additional high temperature limit may be required. Consult local code requirements to determine compliance. The limit should be installed as follows:
· Install the limit in the boiler supply piping between the boiler and any isolation valve.
· Consult heat exchanger for maximum temperature set point.
· For wiring of the limit, reference Fig. 30 on page 46. Wire the limit to the manual reset terminals on the low voltage terminal strip. An open manual reset limit will require a manual reset of the control.

4.6. Backflow Preventer
· Use a backflow preventer valve in the make-up water supply to the unit as required by local codes.
4.7. INSTINCT Solo Boiler System Piping
BEST PRACTICE
· It is recommended on all piping applications to utilize a primary/secondary piping arrangement as a means to provide freeze protection of the boiler, which is an integral function of the boiler control. Maintain at least the minimum boiler flow rate shown in the Graphs of Chapter 19 on page 102. For other piping arrangements, contact Triangle Tube Technical Support or consult other approved/recognized design arrangements.
· On piping applications utilizing a single zone or other recognized piping design arrangements, it is recommended that the installer uses flow/check valves with weighted seats at or near the INSTINCT Solo to prevent gravity circulation.

SSyysstteemm SSuupppplyly

BBooiilleerr BBooiilleerr SSuuppppllyy RReettuurrnn

SSyystsetemm RReetuturnrn

CHAPTER 4

CCooldld WWataetrer
FiFllill

1122"" MMaaxx.

Fig. 8 - INSTINCT Solo Near Boiler Piping - Diaphragm Expansion Tank 17

CHAPTER 4 - BOILER PIPING

4.7.1 Expansion Tank and Makeup Water
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
the system water volume, and the system water temperature.
CAUTION
Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler heat exchanger failure can result due to this excessive
makeup water addition.
The expansion tank must be located as shown in Fig. 8 on page 17 and Fig. 9 below, when using a primary/secondary piping arrangement or as per recognized design methods. Refer to the expansion tank manufacturer for additional installation details.
Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator. Always locate and install the system fill connection at the same location as the expansion tank connection to the system.

4.7.2 Diaphragm Expansion Tank
Always install an automatic air vent on top of the air separator to remove residual air from the system.
4.7.3 Closed-Type Expansion Tank
It is recommended to pitch any horizontal piping upwards toward the expansion tank 1 inch per 5 feet of piping. Use 3/4" piping to the expansion tank to allow air within the system to rise.
NOTICE
DO NOT install automatic air vents on a closedtype expansion tank system. Air must remain in the system and be returned to the expansion tank to provide an air cushion. An automatic air vent would cause air to be vented from the system resulting in a water-logged expansion tank.
4.7.4 Circulator
A circulator with flow check must be utilized with the INSTINCT Solo. The circulator, when wired directly to the INSTINCT, will allow for domestic hot water priority and provide circulation for the freeze protection feature of the boiler control. See the Graphs in Chapter 19 on page 102 for pressure drop and minimum flow rate through the boiler.

CHAPTER 4

SSyysstteemm SSuuppppllyy

BBooilielerr BBooiilleerr SSuupppplyly RReettuurrnn

SSyystsetemm RReetuturnrn CCooldld WWFaFiatliletller r

12"1M2"ax Max.
Fig. 9 - Near Boiler Piping - Closed Type Expansion Tank 18

CHAPTER 4 - BOILER PIPING

CHAPTER 4

4.7.5 Sizing Primary Piping
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.
4.7.6 Domestic Hot Water System Piping
See Fig. 12 on page 24 through Fig. 14 on page 26 for recommended piping to a DHW system. This recommended piping configuration ensures priority is given to the production and recovery of DHW. The piping for DHW is separate from the boiler system piping and does not require a primary / secondary piping configuration. To wire the DHW circulator to the boiler control module, reference Chapter 8 on page 45.
4.7.7 System Piping ­ Zone Circulators
Connect the INSTINCT Solo to the system piping as shown in Fig. 13 on page 25 when zoning with zone circulators. The installer must provide a separate circulator for each zone of space heating.
NOTICE
To ensure an adequate flow rate through the INSTINCT Solo, the boiler supply and return piping size must be a minimum of 1 inch for the INSTINCT Solo 110, 1-1/4 inch for the INSTINCT
Solo 155/199.
4.7.8 System Piping ­ Zone Valves
Connect the INSTINCT Solo to the system piping when zoning with zone valves. 
NOTICE
To ensure an adequate flow rate through the INSTINCT Solo, the boiler supply and return piping size must be a minimum of 1 inch for the INSTINCT Solo 110, 1-1/4 inch for the INSTINCT
Solo 155/199.

4.7.9 System Piping ­ Through Boiler
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. The circulator must be sized to overcome the pressure drop through the system as well as the INSTINCT Solo. See the Graphs in Chapter 19 on page 102 for pressure drop and minimum flow rate through the boiler.
Fig. 13 on page 25 illustrates a multiple zone valve system with a single system/boiler circulator. A by-pass loop with a pressure differential valve must be installed on the system piping.
Fig. 14 on page 26 illustrates a single zone system utilizing the boiler circulator as the system circulator.
4.7.10 System Piping ­ Radiant Heating
The heat exchanger design of the INSTINCT Solo 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 design and construction of the INSTINCT Solo heat exchanger allows the installation of the boiler on systems with non - oxygen barrier tubing.
NOTICE
DO NOT install a SMART indirect water heater along with the INSTINCT Solo in systems with non-oxygen barrier tubing. Failure to comply will result in prema-
ture failure of the SMART indirect water heater.
The boiler water supply temperature can be maintained by the INSTINCT Solo, potentially eliminating the need for a mixing system to achieve the desired temperature if all zones of heat require the same temperature setpoint. It is recommended to install a high temperature limit to ensure that the primary supply temperature does not exceed the maximum allowable temperature for the radiant tubing.
NOTICE
The addition of a high temperature limit is important if the INSTINCT Solo is connected to a domestic hot water system, which requires a
high primary supply water temperature.
Size the system piping and circulator to provide the flow needed for the radiant system.

NOTICE
To ensure an adequate flow rate through the INSTINCT Solo, the boiler supply and return piping size must be a minimum of 1 inch for the INSTINCT Solo 110, 1-1/4 inch for the INSTINCT Solo 155/199.

19

Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump 20

OOpptitoionnalaEl ExtxrtaraRReeqquuirieredd: :LLeeaaddffrroommXX1155oonn11bbooiilleerr ttoo XX1166 oonn tthhee nneexxtt bbooiilleerr

CHAPTER 4

ZV1 ZV2
ZV3 ZV4

CCHH

DDHHWW

SSyysstetemm SSeennssoorr

PP33

BBooiilleerr11 ((MMaasstteerr))

CH2 Thermostat

6

5

System Sensor

4

3

X5

Modulation Signal

-

+

2

1

CH1

Outdoor

Thermostat Sensor

4

3

2

1

X6

DHW Sensor or
aquastat

2

1

X4

Modbus

-

G

+

32

1

X7

NG L FLAME

NG L SUPPLY

NG L CH PUMP

NG L DHW PUMP

L GN

Heating Call From Zone Panel OutOdutodoororSSeennssoorr
DHDHWWSSeennssoor

321
SSyysstteemmSSeennssoorr

MMaaininCCoonnttrrool lBBooaarrdd

123 456

X15

X16

X7

12 34

CCaassccaaddee MMaasstteerr

BBooilielerr22((SSllaavvee))

CH2 Thermostat

6

5

System Sensor

4

3

X5

Modulation Signal

-

+

2

1

CH1

Outdoor

Thermostat Sensor

4

3

2

1

X6

DHW Sensor or
aquastat

2

1

X4

Modbus

-

G

+

3

2

1

X7

PP33

CCHH DDHHWW

NG L FLAME

NG L SUPPLY

NG L CH PUMP

NG L DHW PUMP

MMaaininCCoonnttrrool lBBooaarrdd

123 456

X15

X16

12 34

CCascade MMaastterr

Back of Display PPaanneell

X7

CCaassccaaddee SSllaavvee

321

BBooilielerr33((SSlave)

CH2 Thermostat

6

5

System Sensor

4

3

X5

Modulation Signal

-

+

2

1

CH1

Outdoor

Thermostat Sensor

4

3

2

1

X6

DHW Sensor or
aquastat

2

1

X4

Modbus

-

G

+

32

1

X7

BBack of Display PPaanneell

CCaassccaaddee SSllaavvee

NG L FLAME

NG L SUPPLY

NG L CH PUMP

NG L DHW PUMP

Note. Instinct Solo is pre-configured for this installation

ON

OFF

OFF

DHW

OFF

ON

ON

CH2

OFF

ON

ON

CH1

DHW Pump

CH Pump

Flame

Heat Call

INSTINCT SOLO PRESET PUMP CONFIGURATION

CHAPTER 4 - BOILER PIPING

CHAPTER 4 - BOILER PIPING

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. If the boiler is used to supply hot water to the heating coils of an air handler where they may be exposed to chilled air circulation, install flow/check valves or other automatic devices to prevent gravity circulation of the boiler water during cooling cycles.
4.7.12 System Piping ­ Multiple Units Installation
Use a balanced manifold system as the primary / secondary connection to the space heating piping. For the space heating piping, refer to the applications mentioned in this manual or use recognized design methods.

4.8. INSTINCT Combi Boiler System Piping
BEST PRACTICE
It is recommended on all piping applications to utilize a primary/secondary piping arrangement as a means to provide freeze protection of the boiler, which is an integral function of the boiler control. Maintain at least the minimum boiler flow rate shown in the Graphs of Chapter 19 on page 102. For other piping arrangements, contact Triangle Tube Technical Support or consult other approved/recognized design
arrangements.
On piping applications utilizing a single zone or other recognized piping design arrangements, it is recommended that the installer uses flow/ check valves with weighted seats at or near the INSTINCT Combi to prevent gravity circulation.

CHAPTER 4

SSyysstteemm SSuuppppllyy

BBooiilleerr BBooiilleerr SSuuppppllyy RReettuurrnn

SSyysstteemm RReettuurrnn

CCooldld waWteartfeilrl
Fill
12"12M"ax. Max.
Fig. 11 - INSTINCT Combi Near Boiler Piping - Diaphragm Expansion Tank

21

CHAPTER 4

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 system water volume, and the system water temperature.
CAUTION
Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler heat exchanger failure can result due to this exces-
sive makeup water addition.
The expansion tank must be located as shown in Fig. 11 on page 21 when using a primary/secondary piping arrangement. Refer to the expansion tank manufacturer for additional installation details.
Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator. Always locate and install the system fill connection at the same location as the expansion tank connection to the system.

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 .
4.8.4 Sizing Primary Piping
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.
4.8.5 System Piping ­ Zone Circulators
Connect the INSTINCT Combi to the system piping as shown in when zoning with zone circulators. The installer must provide a separate circulator for each zone of space heating.
NOTICE
To ensure an adequate flow rate through the INSTINCT Combi, the boiler supply and return piping size must be a minimum of 1-1/4 inch
for the INSTINCT Combi 155/199.

CAUTION
The expansion tank must be located directly on the INSTINCT Combi return pipe, before the return check valve. Incorrect expansion tank location will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler heat exchanger failure can result due
to this excessive makeup water addition.
4.8.2 Diaphragm Expansion Tank
Always install an automatic air vent on top of the air separator to remove residual air from the system.

4.8.6 System Piping ­ Zone Valves
Connect the INSTINCT Combi to the system piping as shown in Fig. 12 on page 24 when zoning with zone valves.
NOTICE
To ensure an adequate flow rate through the INSTINCT Combi, the boiler supply and return piping size must be a minimum of 1-1/4 inch
for the INSTINCT Combi 155/199.

22

CHAPTER 4

CHAPTER 4 - BOILER PIPING

4.8.7 System Piping ­ Through Boiler
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. The internal circulator must be able to overcome the pressure drop through the system as well as the INSTINCT Combi. See the Graphs on page 113 for pressure drop and minimum flow rate through the boiler.
Fig. 13 on page 25 illustrates a multiple zone valve system with a single system/boiler circulator. A by-pass loop with a pressure differential valve must be installed on the system piping.
Fig. 14 on page 26 illustrates a single zone system utilizing the boiler circulator as the system circulator.
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.
The boiler water supply temperature can be maintained by the INSTINCT Combi, potentially eliminating the need for a mixing system to achieve the desired temperature if all zones of heat require the same temperature setpoint.
It is recommended to install a high temperature limit to ensure that the primary supply temperature does not exceed the maximum allowable temperature for the radiant tubing.

NOTICE
To ensure an adequate flow rate through the INSTINCT Combi, the boiler supply and return piping size must be a minimum of 1-1/4 inch
for the INSTINCT Combi 155/199.
4.8.9 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. If the boiler is used to supply hot water to the heating coils of an air handler where they may be exposed to chilled air circulation, install flow/check valves or other automatic devices to prevent gravity circulation of the boiler water during cooling cycles.
4.9. Optional System Piping and Cascading
Several additional configurations (mixing device, cascading, etc.) are possible with INSTINCT Solo and Combi Units, provided an optional wiring kit is used. Please refer to Fig. 10 on page 20 for more information.

NOTICE
The addition of a high temperature limit is important if the INSTINCT Combi is connected to a domestic hot water system, which requires a
high primary supply water temperature.
Size the system piping and circulator to provide the flow needed for the radiant system.

23

CHAPTER 4 - BOILER PIPING

INSTINCT COMBI PRESET PUMP CONFIGURATION

Heat Call

Flame

CH Pump

DHW Pump

CH1

ON

ON

OFF

CH2

ON

ON

OFF

DHW

OFF

ON

ON

Note. Instinct Combi is pre-configured for this installation

LLoowwVVooltltaaggeeTeTremrminianlas ls

CH2 Thermostat
6 5

System Sensor 4 3
X5

Modulation Signal -+ 2 1

TThheeCCrrmmHHo12osstatat 4t3

Outdoor Sensor 2 1

X6

DHW Sensor or Aquastat 2 1
X4

Modbus + G 3 2 1
X7

EExxTTtteeeerrrrmnnmaaiinllnLaLaililmsms iitt MMaannuuaal AAuutoto

EEDZDnZnrodrodyynnSSCeCewwooVViinnttaaccttllaavhhvcceeeettss

LineLinVeoVltoalgtaegTeeTremrminianlasls

N GL NGL NGL NGL

FLAME

POWER SUPPLY CH PUMP DHW PUMP

OutOdutodoororSSeennssorr DDHHWWSSeennssorr
internal to boiler

Z.V. Z.V.
CHAPTER 4

Fig. 12 - INSTINCT Combi System Piping - Zoning w Valves 24

CHAPTER 4 - BOILER PIPING

INSTINCT COMBI PRESET PUMP CONFIGURATION

Heat Call

Flame

CH Pump

DHW Pump

CH1

ON

ON

OFF

CH2

ON

ON

OFF

DHW

OFF

ON

ON

Note. Instinct Combi is pre-configured for this installation

LoLowwVVoollttaaggeeTTeremrminainlsals

CH2 Thermostat
6 5

System Sensor 4 3
X5

Modulation Signal -+ 2 1

TThheeCCrrmmHHo12osstatat 4t3

Outdoor Sensor 2 1

X6

DHW Sensor or Aquastat 2 1
X4

Modbus + G 3 2 1
X7

EExxTTtteeeerrrrmnnmaaiinlnl LLaaiillmmss iitt MMananuuaall AAuutto

DDrryyCCoonnttaacctt ZZoonne eVaVlvaelvEned EndSwSiwtchitceshes

LinLeinVeoVlotaltgageeTTeerrmmiinnaalsls

N G L N G L N G L N GL

FLAME

POWER SUPPLY CH PUMP DHW PUMP

OuOtutddoooorr SSeennssoorr DDHHWWSSeennssoor
internal to boiler
CHAPTER 4

Z.V. Z.V.

Fig. 13 - INSTINCT Combi - System Piping - Multi Zone Valve - Single Circulator 25

CHAPTER 4 - BOILER PIPING

INSTINCT COMBI PRESET PUMP CONFIGURATION

Heat Call

Flame

CH Pump

DHW Pump

CH1

ON

ON

OFF

CH2

ON

ON

OFF

DHW

OFF

ON

ON

Note. Instinct Combi is pre-configured for this installation

LLoowwVVoollttaaggee TTeerrmmiinnaallss

CH2 Thermostat
6 5

System Sensor 4 3
X5

Modulation Signal -+ 2 1

TThheeCCrrmmHHo12osstatat 4t3

Outdoor Sensor 2 1

X6

DHW Sensor or Aquastat 2 1
X4

Modbus + G 3 2 1
X7

EExxteterrnnaall Limmiitt TTeerrmminallss

LineLVinoeltVaogletaTgeerTmerinmailnsals

MMaannuualal AuAtouto

NGL NGL NGL NGL

FLAME

POWER SUPPLY CH PUMP DHW PUMP

OutOdutodoororSeSennssoorr DHDHWWSSeennssorr
internal to boiler

68

CHAPTER 4

Fig. 14 - INSTINCT Combi - System Piping - Single Zone with Single Circulator 26

CHAPTER 5

Chapter 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING

5.1. 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 Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22. This valve must be marked with a maximum working pressure
of the water heater.
Failure to comply with this instruction can result in minor property damage, or injury.
The INSTINCT Combi domestic circuit must be protected with a pressure relief valve (150 psi).
5.1.1 Standard Installation
Install pressure relief valve as shown in Fig. 15.

Pressure relief valve (field supplied

Domestic connection with Tee fitting

Domestic Hot Water
Supply

5.1.2 Pressure Relief Valve - Standard Installations
The domestic water heater (if utilized) shall have a field supplied pressure relief valve installed within 6" [152mm] of the DHW hot outlet connection with the relief valve spindle installed in the vertical position.
The domestic water heater (if utilized) requires a field supplied pressure relief valve identified with the ASME V or HV symbol and set to relieve at or below 150 psi [10 bar] of domestic water pressure and a minimum relieving capacity of 199,000 Btu/hr with 3/4" NPT threads. For safe operation of the domestic water heater, the relief valve must not be removed from its designated location of installation or plugged. 1. The INSTINCT is not supplied with a 150 psi [10bar]
pressure relief valve and must be piped using a pressure relief valve connected as shown in Fig. 15 on page 27
2. To avoid potential water damage to the surrounding area or potential scalding hazard due to the operation of the relief valve, the discharge piping:
· Must be connected to the discharge outlet of the relief valve and directed to a safe place of disposal.
· Length should be as short and direct as possible. The size of the discharge line should not be reduced, maintain the same size as the outlet of the relief valve.
· Should be directed downward towards the floor at all times. The piping should terminate at least 6 inches [152mm] above any drain connection to allow clear visibility of the discharge.
· Should terminate with a plain end, not with a threaded end. The material of the piping should have a serviceable temperature rating 250°F [121°C] or greater.
· Should not be subject to conditions here freezing could occur.
· Should not contain any shut-off valves or obstructions. No shutoff valves should be piped between the appliance and relief valve.
WARNING

Fig. 15 - Standard Installation of the Pressure Relief Valve

Failure to comply with the guidelines on installing the pressure relief valve and discharge piping can result in substantial prop-
erty damage, serious injury or death.

27

CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING

5.1.3 Pressure Relief Valve Discharge Piping
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.
Pressure relief valve discharge piping must not be: · Excessively long. Using more than 2 elbows or 15 feet of piping can reduce discharge capacity. · Directly connected to a drain. Terminate discharge piping within 6" from drain. Refer to local codes. · Plugged, reduced or restricted. · Subject to freezing.

5.2. Thermal Expansion
If a backflow preventer, check valve or pressure reducing valve is piped on cold water supply piping of water heater, install an expansion tank on cold water supply line to prevent thermal expansion from repeatedly forcing open pressure relief valve.
NOTICE
The pressure relief valve is not intended for constant duty, such as relief of pressure due to repeated normal thermal expansion. Correct this condition by installing a properly sized expansion tank in the domestic water system. Refer to expansion tank manufacturer's installation
instructions for proper sizing.

WARNING
Do not install any valve between pressure relief valve and tank connection or on pressure relief valve discharge piping. Do not plug pressure relief valve or discharge piping. Improper placement and piping of T&P relief valve can cause severe personal injury, death or substantial property damage.

CHAPTER 5

28

CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING

5.3. 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. This type of failure is
NOT covered under warranty.

5.4. Vacuum Breaker
Installing a vacuum breaker on the domestic cold water inlet will prevent damage to the domestic circuit if a negative pressure is developed in the domestic supply line. See manufacturer's instructions for application and installation of the vacuum breaker.
5.5. Hydro-Block
The domestic circuit provides domestic hot water through a hydro-block. It is made of a plate-to-plate heat exchanger and connections to the primary and domestic piping. Water heated in the primary circuit (central heating) flows into the plate-to-plate heat exchanger, which in turn heats the domestic water flowing through it in its own circuit. Refer to Fig. 16 below for flow diagram.

CH SUPPLY
1"

Stepper motor + cartridge Plate-to-plate heat exchanger

CH RETURN
to PUMP
1"

1"
CH SUPPLY

3/4"

3/4"

DHW Temperature Sesnor Flow Sensor

DHW SUPPLY

DHW INLET

1"
CH RETURN

Fig. 16 - INSTINCT Combi - Hydro-block Flow Diagram

CHAPTER 5

29

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.
· When the water supply pressure is higher than 70 psig, it is recommended to install a pressure reducing valve on cold water supply line to prevent water loss through T&P relief valve.

5.8. Storage Tank Installation
For applications requiring high domestic hot water flow rates for a short period of time (dump load), the installer may install a storage type tank (see Fig. 18 on page 32) in the domestic piping.
The installer must : 1. Relocate the thermostatic mixing valve from the IN-
STINCT 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 INSTINCT using a bronze or stainless steel circulator.

5.7. Thermostatic Mixing Valve
A thermostatic mixing valve must be installed in the DHW circuit. The operating range of the thermostatic mixing is 85ºF [30ºC] to 150ºF [65ºC]. For applications with a domestic recirculation loop, the recirculation pump should be controlled by an aquastat. The maximum recommended setting of the aquastat is 10ºF lower than the thermostatic mixing valve setting. If any adjustment needs to be made to the valve's temperature setpoint, refer to the manufacturer's instructions included with the valve.
DANGER
For proper operation of the thermostatic mixing valve and to prevent potential scalding hazards, the recirculation loop should be controlled by an aquastat. DO NOT use con-
tinuous recirculation.
Failure to comply with this instruction will result in serious injury, or death.

CHAPTER 5

30

CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING

INSTINCT COMBI PRESET PUMP CONFIGURATION

Heat Call

Flame

CH Pump

DHW Pump

CH1

ON

ON

OFF

CH2

ON

ON

OFF

DHW

OFF

ON

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.

LoLwowVVooltlataggee TTeerrmmininaalsls

CH2 Thermostat
6 5

System Sensor 4 3
X5

Modulation Signal -+ 2 1

TThheeCCrrmmHHo12osstatat 4t3

Outdoor Sensor 2 1

X6

DHW Sensor or Aquastat 2 1
X4

Modbus + G 3 2 1
X7

EExxtteernaall LLiimmiitt Teerminnaallss
Manual Auto

LinLeinVeolVtaogletaTgeermTeinramlsinals

NGL NGL NGL NGL

FLAME

POWER SUPPLY CH PUMP DHW PUMP

OutOudtdoooorrSSeennsorr DDHHWW SSeensoorr
internal to boiler
CHAPTER 5

DHDWHW OuOtleutlet

12" m12in" Hmeiant Trap HLeoaotpT(rOapptiLonoaolp)
(Optional)

Fig. 17 - INSTINCT Combi Domestic Piping - Single Zone System with Single System/Boiler Circulator 31

CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING

INSTINCT COMBI PRESET PUMP CONFIGURATION

Heat Call

Flame

CH Pump

DHW Pump

CH1

ON

ON

OFF

CH2

ON

ON

OFF

DHW

OFF

ON

ON

Note. Instinct Combi is pre-configured for this installation

LLooww VVooltltaaggeeTeTrmerinmalisnals

CH2 Thermostat
6 5

System Sensor 4 3
X5

Modulation Signal -+ 2 1

TThheeCCrrmmHHo12osstatat 4t3

Outdoor Sensor 2 1

X6

DHW Sensor or Aquastat 2 1
X4

Modbus + G 3 2 1
X7

EExxtteerrnnaall LLiimmiitt TTeerrmmiinnaallss
MMaannuuaall AAuutoto

LinLeinVeoVlotaltgageeTTeerrmmininaalsls

NGL NGL NGL NGL

FLAME

POWER SUPPLY CH PUMP DHW PUMP

OOututddoooorr SSeennssoorr DDHHWW SSeennssoorr
internal to boiler

CHAPTER 5

DDHHWW OOuuttlleett

SSttoorraaggee TTaannkk

12" m1i2n"hmeaint trap loHoepat(oTprtaiopnLaol)op
(Optional)

Fig. 18 - INSTINCT Combi Domestic Piping - Storage tank installation 32

TCIHTALEPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING

INSTINCT COMBI PRESET PUMP CONFIGURATION

Heat Call

Flame

CH Pump

DHW Pump

CH1

ON

ON

OFF

CH2

ON

ON

OFF

DHW

OFF

ON

ON

Note. Instinct Combi is pre-configured for this installation

LoLwowVVooltltaaggee TTeermrminianlsals

CH2 Thermostat
6 5

System Sensor 4 3
X5

Modulation Signal -+ 2 1

TThheeCCrrmmHHo12osstatat 4t3

Outdoor Sensor 2 1

X6

DHW Sensor or Aquastat 2 1
X4

Modbus + G 3 2 1
X7

EExxtteerrnnaall LLimimitit TTeerrmmiinnaallss
Maannuuaall AAuutoo

LiLnineeVVoollttaaggeeTeTremrimnailns als

N GL NGL N GL N GL

FLAME

POWER SUPPLY CH PUMP DHW PUMP

OOututddoooor SSeensor DDHW SSeensorr
internal to boiler
CHAPTER 5

120V/15A CH DHW Service

Zone 1

Zone 2

Zone 3

Thermostat Thermostat Thermostat

68

68

68

SLAVE MASTER

1234 EXPANSION

PLUG IN CARDS

MODE RESET

NORMAL

ZONE1

ZONE2

ZONE3

ZONE4

FOUR ZONE SWITCHING RELAY WITH OPTIONAL PRIORITY

ZONE 4 PRIORITY
ON
OFF

FUSE 1 AMP

X X END
SWITCH

ZC ZR

ZONE1

ZONE2

ZONE3

120 VOLT CIRCULATORS

ZONE4

POWER INPUT

Zone 1 Thermostat

Zone 2 Thermostat

120 VAC Zone 3 INPUT Thermostat (H & N)

Fig. 19 - Multiple Zones - Panel Wiring with Circulators

33

CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING

INSTINCT COMBI PRESET PUMP CONFIGURATION

Heat Call

Flame

CH Pump

DHW Pump

CH1

ON

ON

OFF

CH2

ON

ON

OFF

DHW

OFF

ON

ON

Note. Instinct Combi is pre-configured for this installation

Motor End Switch Motor End Switch Motor End Switch
CHAPTER 5

LoLwowVoVltoalgtaegTeerTmeirnmalisnals

CH2 Thermostat
6 5

System Sensor 4 3
X5

Modulation Signal -+ 2 1

TThheeCCrrmmHHo12osstatat 4t3

Outdoor Sensor 2 1

X6

DHW Sensor or Aquastat 2 1
X4

Modbus + G 3 2 1
X7

EExxtteerrnnaall LLiimmitit TTeerrmmiinnaalsls

LineLiVneolVtaoglteagTeeTremrminianlasls

MMannuuaal l AAuutoto

N GL N G L N G L N G L FLAME POWER SUPPLY CH PUMP DHW PUMP

OutOdutodoororSSeennssorr DDHHWWSSeennssorr
internal to boiler

120V/15A Internal Service Circulator

Zone 1 Thermostat
68

Zone 2 Thermostat
68

Zone 3 Thermostat
68

Factory Installed Transformer

34

Factor y Installed Transformer

POWER IN

POWER CONTROLS

SLAVE

12 34
EXPANSION

RESET

MODE

NORMAL

MASTER

PLUG-IN CARDS

TT ZONE 1

TT ZONE 2

TT ZONE 3

FOUR ZONE ZONE VALVE CONTROL WITH OPTIONAL PRIORITY

TT ZONE 4

ZONE 4 PRIORITY
ON
OFF

FUSE 7 AMP MAX

ENDSW B
PUMP

N/O

COM

N/C

ZONE 4 RELAY

ENDSW A
BOILER

ZONE 1 12 34

ZONE 2 12 34

ZONE 3 12 34

System Circulator

1 2 3 4
Zone 1 Zone Valve

1 2 3 4
Zone 2 Zone Valve

1 2 3 4
Zone 3 Zone Valve

ZONE 4 12 34

Fig. 20 - INSTINCT Combi System Piping - Multiple Zones - Panel Wiring with Valves

CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING

INSTINCT SOLO PRESET PUMP CONFIGURATION

Heat Call

Flame

CH Pump

DHW Pump

CH1

ON

ON

OFF

CH2

ON

ON

OFF

DHW

OFF

OFF

ON

Note. Instinct Solo is pre-configured for this installation

Low VLoowltaVgoeltaTegremTienramlsinals

CH2 Thermostat
6 5

System Sensor 4 3
X5

Modulation Signal -+ 2 1

TThheeCCrrmmHHo12osstatat 4t3

Outdoor Sensor 2 1

X6

DHW Sensor or Aquastat 2 1
X4

Modbus + G 3 2 1
X7

EExxtteerrnnaal lLiLmimit it Terrmminianlas ls
MMaannuuaall AAuuttoo

DDrryyCCoonnttact

LinLeinVeolVtaoglteaTgeermTeinrmalsinals

NGL N GL N GL NGL

FLAME

POWER SUPPLY CH PUMP DHW PUMP

DDHHWW DDHHWW HHoot CCoolldd
smart

OutdOoutodroorSeSennssoorr DHDWHWSeSennssoorr
CHAPTER 5

Z.V. Z.V.

Fig. 21 - INSTINCT Solo System Piping - Multi Zone System with Single System/Boiler Circulator 35

CTIHTALPETER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING

INSTINCT SOLO PRESET PUMP CONFIGURATION

Heat Call

Flame

CH Pump

DHW Pump

CH1

ON

ON

OFF

CH2

ON

ON

OFF

DHW

OFF

OFF

ON

Note. Instinct Solo is pre-configured for this installation

LoLowwVVoolttaaggeeTTeermrminainlsals

CH2 Thermostat
6 5

System Sensor 4 3
X5

Modulation Signal -+ 2 1

TThheeCCrrmmHHo12osstatat 4t3

Outdoor Sensor 2 1

X6

DHW Sensor or Aquastat 2 1
X4

Modbus + G 3 2 1
X7

External Limit TEexTtreemrrmnaiinlnLaalimslsit
MMaannuuaal l AAutouto

LiLneinVeoVltaogletaTgeermTinearlms inals

NGL NGL NGL NGL

FLAME

POWER SUPPLY CH PUMP DHW PUMP

OutdooOrutdSooernSesnosror DHWDSHeWnSesnsoorr

DDHHWW DDHHWW HHoott CCoolldd

68

smart

CHAPTER 5

Fig. 22 - INSTINCT Solo System Piping - Indirect Water Heater installation 36

TCIHTALEPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING
NOTICE
Cascading is only available on Solo Boilers.

CHAPTER 5

System Return

12" Max.

System Supply
P G

Fig. 23 - Instinct Solo - Cascade Piping 37

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.
Once installation is completed, inspect the vent and combustion air system thoroughly to ensure systems are airtight, properly supported, and comply with the instructions given in the venting supplement and are within all requirements of applicable codes. Failure to comply with the venting and combustion air piping installation requirements will result in substantial property damage, serious
injury, or death.
NOTICE
Contact Triangle Tube for other venting options. Refer to the instructions included with these kits
for method of installation.

assembly up until it stops.
3. Tighten the condensate drain assembly retaining nut.
WARNING
· Ensure installation of the condensate drain assembly included the seals. Failure to comply could result in the assembly dislocating from the boiler. Dislocation of the condensate drain assembly can result in property damage, serious injury, or death.
· Ensure the condensate drain assembly contains the plastic ball. Do not install the condensate drain assembly if the ball is lost or missing, replace the entire assembly. Installing the condensate drain assembly without the plastic ball can result in substantial property damage, serious injury, or death.
4. Remove the compression nut and rubber seal from the condensate drain assembly drain outlet.
5. Slide the compression nut and rubber seal over the 3/4" x 2' flexible tube provided.

6.2. Installing Condensate Drain Assembly into INSTINCT Solo Units
NOTICE
The condensate drain assembly is factory-installed in the INSTINCT Combi units.
1. Locate the condensate drain assembly and ensure the seals are installed as shown in Fig. 24 on page 39.
NOTICE
The installer may want to fill the condensate drain assembly with water prior to assembling
on the unit.
WARNING
Do not operate the boiler without the factory-supplied condensate drain assembly installed. Operation of the boiler without the condensate drain assembly installed can result in property damage, serious injury, or
death. 2. Install the condensate drain assembly on the boiler
condensate drain by pushing the condensate drain

NOTICE
The use of 3/4" PVC or CPVC pipe is also acceptable. If 3/4" pipe is used, deburr and chamfer pipe to allow mating onto the drain assembly.
6. Thread the rubber seal into the compression nut to ease installation of the tube to the condensate drain assembly.
7. Seat the tube onto the condensate drain assembly and tighten the compression nut. Hand tight only!
NOTICE
· The installer may opt to use 13/16" ID tubing in lieu of provided tube.
· The drain line materials must be an approved material by the authority having jurisdiction. In absence of such authority, PVC and CPVC piping must comply with ASTM D1785 or D2845. The cement and primer used on the piping must comply with ASME D2564 or F493. For installations in Canada, use ULC certified PVC or CPVC pipe, fittings and cement/primer.

CHAPTER 6

38

CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN

8. Route the tube from the condensate drain assembly to a floor drain or condensate pump.
NOTICE
When selecting and installing a condensate pump, ensure the pump is approved for use with condensing appliances. The pump should be equipped with an overflow switch to prevent property damage from potential condensate
spillage.
9. The INSTINCT will typically produce a condensate that is considered slightly acidic with a pH content below 4.0. Install a neutralizing filter if required by authority having jurisdiction.

WARNING
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. Failure to keep the condensate drain assembly full of water can result in substantial proper-
ty damage, serious injury, or death.
CAUTION
The drain assembly must remain unobstructed and allow unrestricted flow of condensate. The condensate should not be subject to conditions where freezing could occur. If the condensate is subjected to freezing or becomes obstructed , it can leak, resulting in potential water damage
to the boiler and surrounding area.

CHAPTER 6

RETAINING NUT
RETENTION CLIP
(FOR SOLO MODELS ONLY
PLASTIC BALL (NOT SHOWN) CONDENSATE DRAIN ASSEMBLY

SEALS

FILL PLUG WITH VACCUM BREAK PORT

RETENTION CLIP
(FOR SOLO MODELS ONLY

COMPRESSION NUT WITH RUBBER SEAL

Flexible tubing (or 3/4 PVC/ CPVC Piping to Drain)

Fig. 24 - Condensate Drain Assembly 39

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. Install a sediment trap (drip leg) on the gas supply line prior to connecting to the INSTINCT gas train as shown in Fig. 25 on the right.
4. Support the gas piping using hangers. Do not support the piping by the unit or its components.
5. Purge all air from the gas supply piping. 6. Before placing the INSTINCT into operation, check
and test all connections for leaks. · Close the manual shutoff valve during any pres-
sure test with less than 13"w.c.. · Disconnect the INSTINCT and its gas valve from
the gas supply piping during any pressure test greater than 13"w.c..

Gas Flow

External Manual

Gas Shut Off

Valve (Must Be

Ion-ic 186°F
DHW 156°F
Target = 186°F DHW Demand

Within 6" of the Boiler )

Union Fitting

Tee Fitting
Sediment Trap Min. Length of 3" Cap

Fig. 25 - Recommended Gas Supply Piping

CHAPTER 7

WARNING
Do not check for gas leaks with an open flame. Use a gas detection device or bubble test. Failure to check for gas leaks can cause substantial property damage, serious injury, or death.
7. Use pipe dope compatible with natural and propane gases. Apply sparingly only to the male threads of pipe joints so that pipe dope does not block gas flow.
WARNING
· Failure to apply pipe dope as detailed above can result in substantial property damage, serious injury, or death.
· Use a two-wrench method when tightening field piping onto the boiler piping connections. Use one wrench to prevent the boiler connections from turning and the second to tighten field piping. Failure to support the boiler piping connections could damage piping, causing a leak, resulting in substantial property damage, serious injury, or death.

40

CHAPTER 7 - GAS PIPING

7.2. Natural Gas
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 grav-
ity of 0.60 and a pressure drop through the gas piping of 0.30"w.c.. · For additional gas pipe sizing information, refer to National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/CSA B149.1 for installations in Canada.

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.
WARNING
DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure can result in damage to the valve, causing substantial property dam-
age, serious injury, or death.

7.2.2 Supply Pressure Requirements
1. Pressure required at the gas valve inlet supply pressure port:
· Maximum 13"w.c. at flow or no flow conditions to the burner.
· Minimum 5"w.c. during flow conditions to the burner. Must be verified during start up and with all other gas appliances operating within the building.

WA· RNING
The INSTINCT is factory equipped with the required natural gas venturi. The natural gas venturi must never be modified or replaced with a different size venturi. Failure to use the required natural gas venturi can result in substantial property damage, serious injury, or
death.

CHAPTER 7

Model
110 Solo 155 Solo 199 Solo 155 Combi 199 Combi

Venturi Diameter
22mm 24mm TBC 24mm TBC

Table 1 - Natural Gas Venturis

Top injector
3.60mm 4.00mm
TBC 4.00mm
TBC

Bottom Injector
3.40mm 3.90mm
TBC 3.90mm
TBC

Label Colour
White White TBC White TBC

Part No.
INSRKIT07 INSRKIT09 INSRKIT11 INSRKIT09 INSRKIT11

Length of Pipe in Feet
SCH 40 10 20 30 40 50 75 100 150

Table 2 - Gas Piping Sizing - Natural Gas

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on 0.60 specific gravity, 0.30" w.c. pressure drop)

1/2"

3/4"

1"

1-1/4"

1-1/2"

132

278

520

1050

1600

92

190

350

730

1100

73

152

285

590

890

63

130

245

500

760

56

115

215

440

670

45

93

175

360

545

38

79

150

305

460

31

64

120

250

380

41

CHAPTER 7 - GAS PIPING

7.3. Propane Gas

7.3.2 Supply Pressure Requirements

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. If this conversion kit is missing, please contact Triangle Tube Technical Support for missing kit before installing unit.
· Prior to start up, ensure the unit is set to fire propane. Check the rating label for the type of fuel. Check the gas valve for propane conversion label. If there is a conflict or doubt on the burner set up, remove the gas valve and check for the propane orifice, see Fig. 17 on page 31 and Fig. 27 on page 43 and Fig. 28 on page 44.
· Failure to ensure proper burner setup can result in substantial property damage, serious injury, or death.
· Operating a natural gas INSTINCT boiler on propane will create excessive and dangerious carbon monoxide levels which could cause serious injury, or death.
Contact the local propane gas supplier for recommended sizing of piping, tanks and 100% lockup gas regulator.

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:
· Maximum 13"w.c. at flow or no flow conditions to the burner
· Minimum 8"w.c. during flow conditions to the burner. Must be verified during start up and with all other gas appliances operating within the building.
WARNING
DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure can result in damage to the valve, causing substantial property dam-
age, serious injury, or death.
WA· RNING
The propane gas venturi assembly must never be modified or replaced with a different assembly. See the below chart for the full specification. Failure to use the required propane gas venturi assembly can result in substantial prop-
erty damage, serious injury or death.

Table 3 - Propane Conversion Venturis

Model Venturi Diameter

110 Solo 155 Solo 199 Solo 155 Combi 199 Combi

22mm 24mm TBC 24mm TBC

Top injector
2.90mm 3.15mm
TBC 3.15mm
TBC

Bottom Injector
2.65mm 2.95mm
TBC 2.95mm
TBC

Label Colour
Black Black TBC Black TBC

Part No.
INSRKIT08 INSRKIT10 INSRKIT12 INSRKIT10 INSRKIT12

Note: Propane conversion venturis have an additional yellow label to identify use for propane

CHAPTER 7

42

CHAPTER 7 - GAS PIPING

Pipe to Venturi

Venturi Venturi interface

Gas Valve

Air Inlet

CHAPTER 7

Air reference Hose
Fig. 26 - Gas Valve / Venturi Assembly - INSTINCT Solo110
Air reference Hose

Air Inlet

Pipe to Venturi

Gas Valve

Venturi interface

Venturi

Fig. 27 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 155

43

CHAPTER 7 - GAS PIPING

Venturi

Venturi interface

Air Inlet Air reference Hose

Pipe to Venturi

Gas Valve

Fig. 28 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 199

CHAPTER 7

44

Chapter 8 - WIRING 8.1. Internal Wiring

8.1.2 Fuse Locations

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 in-
jury, or death.

· 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.
· Spare fuses are located on the back of the control module enclosure.
· A 2.5A fuse is also located on the terminal strip, to protect the output. Refer to Fig. 32 on page 48.

CAUTION
Prior to servicing, label all wires before disconnecting. Wiring errors can cause improper and dangerous operation. Verify proper wiring and
operation after servicing.
8.1.1 General Requirements
· Wiring must be N.E.C Class 1. · If original wiring as supplied with the unit must
be replaced, use only Type T 194ºF [90ºC] wire or equivalent as a minimum. · The INSTINCT Solo must be electrically grounded as required by National Electrical Code (ANSI/NFPA 70) for installations in the U.S., or the Canadian Electrical Code Part 1(CSA C22.1) for installations in Canada.

Location of fuses

Fig. 29 - CTRLMax Control Module Fuse Location

CHAPTER 8

45

CHAPTER 8 - WIRING

Instinct Solo Wiring Diagram

G/Y Electrode

Spark Generator

Gas Valve

Blower

1 R

G

V

W

G 3

1 1

5 1

5 BK 3
G

Key
W = White BK = Black R = Red G= Green O = Orange Y = Yellow BL = Blue G/Y = Green / Yellow GY = Grey

W

G

G

BK

W

W

BK BK

X10
1 3 1 P14 6 1 X9 6 1 X12 4 1 P13

1 X1

12

1 Y

Flue Temperature

Return Temperature

X3

Y

Sensor

Sensor

R

BL

R

Supply

10 R

Temperature

BL

Sensor

O

BR 1

BR O
X2 W

BK

Manual Reset Limit Auto Reset Limit
Water Pressure

14

R 3

Sensor

Cascade Master ModBus DHW Sensor Outdoor Sensor CH1 Thermostat Modulation Signal Cascade Sensor CH2 Thermostat
CHAPTER 8

BK
W BK
BK W
W
BK GND G
W

1

Y

X11

Y

Y

Y

L Output 110V

G N

~2.5A

Y

10

1

X15

GY

L G

DHW

N Pump

6

X4 X5 1 4 X6 1 1

X7 3 1

X16

4

1 6

GY GY

L G N

CH Pump

L G

Power

N Supply

L G

Flame

N

User Interface
Cascade Slave

Fig. 30 - INSTINCT Solo Boiler Factory Wiring

222497 A04

46

CHAPTER 8 - WIRING

Instinct Combi Wiring Diagram

Pump

G/Y Electrode

Spark Generator

Gas Valve

Blower

1 R

G

V W

G 3

1 1

5 1

5 BK 3
G

Key
W = White BK = Black R = Red G= Green O = Orange Y = Yellow BL = Blue G/Y = Green / Yellow GY = Grey

BK
W BK
BK W
W
BK GND G
W

W

W

W

G

G

BK

BK BK

X10
1 3 1 P14 6 1 X9 6 1 X12 4 1 P13

O 1 BK
R
GY X1

Diverter Valve

12

1 Y

Flue Temperature

Return Temperature

X3

Y

Sensor

Sensor

R

BL

R

Supply

10 R

Temperature

BL

Sensor

O

BR 1

Manual Reset Limit

BR O

Auto Reset Limit

X2 W

Water

R

BK Y

Pressure Sensor

14

R 3

BK 3

DHW Turbine

1

Y

X11

Y

Y

Y

L Output 110V

G N

~2.5A

Y 10
1

X15

GY

L G

DHW

N Pump

6

X4 X5 1 4 X6 1 1

X7 3 1

X16

4

1 6

GY GY

L G N

PCuHmpGBWK

ModBus
Outdoor Sensor CH1 Thermostat 0-10V Input CH2 Thermostat

L G

Power

N Supply

L G

Flame

N

DHW Sensor

User Interface

Fig. 31 - INSTINCT Combi Boiler Factory Wiring

222496 A04

47

CHAPTER 8

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 installa-
tions 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. 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.
NOTICE
The low voltage terminals are located at the bottom of the CTRLMax control module. The line voltage terminals are located in the lower
left corner as shown in Fig. 21 below. 8.2.2 Line Voltage Connections 1. Connect a dedicated 120 VAC/15A service to the
line voltage terminals located internally in the lower left corner, as shown in Fig. 32 below. 2. Route the incoming 120 VAC power wires through one of the provided openings in the bottom jacket panel. 3. The unit is provided with a service switch located on the front panel, check local code requirements for compliance.
2.5A Fuse

NOTICE
If local electrical codes require an additional service switch, the installer must provide and install a fused
disconnect or minimum 15 amp service switch.
8.3. External Wiring - INSTINCT Solo Units
8.3.1 Circulator Wiring
1. The circulator connections used will depend on the systems piping layout. See Fig. 17 on page 31 and Fig. 18 on page 32 for common system piping applications and associated circulator wiring. Consult the Fig. 10 on page 20 and the INSTINCT CTRLMax Control Supplement for additional options.
NOTICE
The circulator output is protected by fuses on the CTRLMax control module. The total combined amp draw of the CH, DHW, and Flame outputs must not exceed 4 amps at any time for the INSTINCT 110 and 155 units, or 3 amps at any time for the INSTINCT 199 units. Use an isolation relay to lower the total combined amp
draw if exceeding this limits.
2. Connect the CH circulator wiring to the line voltage terminals located internally in the lower left corner, as shown in Fig. 32 on the left. This circulator is typically used to supply heat to the central/space heating loop.
3. Connect the DHW circulator wiring to the line voltage terminals located internally in the lower left corner, as shown in Fig. 32 on the left. This circulator is typically used to supply heat to an indirect hot water heater.
4. Connect the system pump wiring to the line voltage terminals located internally in the lower left corner, as shown in Fig. 32 on the left.

CHAPTER 8

Fig. 32 - Terminal Strip Location 48

CHAPTER 8 - WIRING

8.3.2 Low Voltage Connections
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.
NOTICE
CH and DHW call connections to the INSTINCT require a dry contact with no external voltage present. Ensure no external voltage is present on each set of wires before connecting to the INSTINCT. If external voltage is present, the use of an isolation relay is required to pre-
vent damage to the CTRLMax controller.
8.3.3 Thermostat Wiring
The CTRLMax control has two thermostat call inputs for multiple zone / temperature systems. This allows each call to have its own outdoor reset curve and maximizes the efficiency of the system.
NOTICE
Simultaneous CH1 and CH2 calls will result in the INSTINCT operating at the highest target
temperature.

8.3.4 Outdoor Sensor Wiring
The Outdoor Reset function and Warm Weather Shutdown (WWSD) features require the connection of the included outdoor temperature sensor. See Chapter 12 on page 75 for outdoor sensor installation and setup.
8.3.5 Domestic Hot Water Wiring
The Domestic Hot Water terminals can accept either a call from an aquastat (thermostat) or temperature sensor. Use of the included indirect water heater sensor is recommended.
1. Connect the DHW aquastat or temperature sensor wires to low voltage terminals X4-1&2 located at the bottom of the CTRLMax control module as shown in Fig. 33 on page 49.
8.3.6 Additional Boiler Limits
Additional boiler limits (High Temperature Limit, LWCO, etc.) can be wired into either the Manual Reset Limit or Auto Reset Limit terminals of the INSTINCT. These limit connections will provide a "hard" lockout requiring a manual reset of the INSTINCT or a"soft"lockout in which the INSTINCT will automatically reset when the limit resets. A Manual Reset External Limit Open (E87) lockout will occur anytime the manual reset terminals are open. An Auto Reset External Limit Open (76) lockout will not occur until just before ignition when the auto reset terminals are open. The Auto Reset terminals should be used for any type of burner interlock such as a combustion air louver or water flow proving switch.

Low voltage connections

External limit Terminals
Fig. 33 - Low Voltage Connections

NOTICE
· The Manual Reset Limit and Auto Reset Limit terminals are located on the lower right corner of the CTRLMax control module housing.
· Manual Reset Limit and Auto Reset Limit connections to the INSTINCT require a dry contact with no external voltage present. Ensure no external voltage is present on each set of wires before connecting to the INSTINCT. If external voltage is present, the use of an isolation relay is required to prevent damage to the CTRLMax controller.

CHAPTER 8

49

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.
8.3.7 External Modulation Control
The INSTINCT firing rate can be controlled by an external modulating boiler controller. See Chapter 13 on page 77 for external modulation signal wiring and setup.
8.3.8 System Sensor Wiring
An optional system temperature sensor can be placed on the central heating loop to control the temperature in the central heating loop instead of the boiler loop. When connected, the INSTINCT will automatically modulate to maintain the target temperature in the central heating loop. The boiler supply temperature sensor will continue to be used as a high temperature limit.

8.3.9 Cascade Wiring - Optional
The CTRLMax control includes the ability to operate up to six Solo boilers together as one without the need for external controllers. Consult the Fig. 10 on page 20 for more information.
8.3.10 Modbus
The CTRLMax control includes the ability to communicate with building management systems (BMS) through a Modbus interface. Consult the INSTINCT CTRLMax Control Supplement for more information.
Modbus communication will only occur if the external device is properly wired to the INSTINCT as follows: X7-1 = RS-485 ­ X7-2 = RS-485 Ground X7-3 = RS-485 +

CAUTION
Locate the system temperature sensor where it can accurately measure the supply temperature to the heating system. Inaccurate system temperature readings could lead to overheating or
under heating resulting in property damage.
1. Connect the system temperature sensor wires to low voltage terminals X5-3&4 located at the bottom of the CTRLMax control module as shown in Fig. 33 on page 49.

CHAPTER 8

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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.
· EZ Setup feature allows the installer to quickly customize CTRLMax for each installation.
· Optional cascade function (Solo models only), using an optional wiring kit, allows up to six INSTINCT boilers to operate together in a single heating system. Refer to Fig. 10 on page 20 for more information.
· Modbus interface for integrating with building management systems.
All CTRLMax features are easy to use through a graphical display where information is presented either graphically or in plain English, so code charts are not required. Fig. 34 below shows an CTRLMax display example of the INSTINCT fired for a domestic hot water demand.

9.1. CTRLMax Navigation
The CTRLMax navigation is performed through soft keys that react to the touch and emit a short beep when tapped.
NOTICE
Exert a light and short touch (tap) on the soft keys to activate their function. Holding the touch too long will not generate any reaction from the CTRLMax, unless it is a combination of soft keys meant to be touched simultaneously for a determined duration, as instructed in this manual. The arrow keys can also be held longer
to increase or decrease values faster.
Navigation is performed through four arrow soft keys ,
, , with a center soft key (OK /Reset functions) for making selections and entering information. The installing contractor is provided with full access to all available features after simultaneously touching
the and soft keys for 3 seconds and entering a code. Reference the INSTINCT CTRLMax Control Supplement for Installer level functions The Main Menu can be entered from the Home Screen
by touching the center soft key .
To shut down the unit, touch the soft key.
DANGER

Instinct DHW
DHW Demand
Fig. 34 - CTRLMax User Interface

When touching the

soft key, the unit

shuts down but is not isolated from power

supply. Therefore, live current is still present

in the unit. For your safety, disconnect elec-

trical power supply to the unit before servic-

ing or making any electrical connections to

avoid possible electric shock hazard. Failure

to do so can cause serious injury, or death.

NOTICE

· When shutting down using the soft key, the appliance will not react to any heat demand. However, the basic appliance protection functions (such as frost protection, etc.) remain active.

· In addition, the arrow soft keys are no longer
illuminated, and the soft key lighting is dimmed.

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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. The Previous Screen icon at the bottom of each screen returns to the previous screen when selected.
9.2. CTRLMax Menu Structure

Home Screen

INSTINCT
186°F
DHW
156°F
Target = 186°F
DHW Demand

EZ Setup

CH / DHW Operation

Select Language

Boiler Information

Heating Enabled

Select Language
English Français Nederlands Español Italiano Deutsch

Boiler Information

aababbcccddedeeffbfbbbbbbb b

aaabbbcccdddeeefffbbbbbbbbbb

Lockout History

aaabbbcccdddeeeffbfbbbbbbb b

aaabbbcccdddeeefffbbbbbbbb

b b

b b
CHAPTER 9

Heating EZ Setup

DHW EZ Setup

EZ Setup Reset

Display EZ Setup

52

CHAPTER 9 - CTRLMAX OPERATION
9.3. 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 simulta-
neously the and soft keys for 2 seconds. Touch the and soft key to increase or de-
crease the contrast. Touch to end the process.

Main Icons of CTRLMax display

·

Central Heating - indicates information related

to central/space heating.

·

DHW - indicates information related to Domes-

tic Hot Water.

·

Home - to go back to the home screen.

·

Back - to go back to the previous screen.

·

Warm Weather Shutdown - displays on the

home screen when the outdoor temperature

reaches the Warm Weather Shutdown tempera-

ture.

·

Reset - to reset the system to the factory set-

tings.

·

Settings - to access controller settings (lan-

guage, units, etc.).

·

Easy Setup - to quickly adjust the most com-

mon settings.

·

CH/DHW operation - to enable/disable the

central/space heating or Domestic Hot Water func-

tions

·

Information - to get information on the boiler.

The model is indicated at the top of the screen.
The INSTINCT is represented in the center of the Home Screen. Basic operating information such as supply and return temperatures are displayed as well as current burner
status.

Radiator icon: indicates that a central heating call has been received. A small number 1 or 2 indicates which CH calls are active
A flame symbol is displayed when the unit is fired. The flame size changes to indicate the current firing rate.
Basic information: The user can toggle
through items using the and soft keys to view Target, Supply, Return, Domestic, Outdoor, System and Mix Zone temperatures, DHW flow.

INSTINCT Combi
186°F
DHW
156°F

Faucet icon: indicates that a DHW call has been received.
Circulator icons: indicate which circulators are currently powered.

Target = 186°F
DHW Demand

Status line: displays the current operating state of the boiler. See Section 9.4 on page 54.

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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.
DHW Priority - Central heating and domestic hot water calls are being received simultaneously. Domestic hot water call is being satisfied first because it has priority over central heating calls.
Priority Timeout - Central heating and domestic hot water calls are being received simultaneously. The domestic hot water priority time limit has been exceeded. Priority will now switch back and forth between central heating and domestic hot water calls until one call is satisfied.
External Demand - An external modulation call has been received.
Slave Operation - The INSTINCT is a slave in a cascade system.
Manual Operation - The burner or circulators have manually been enabled in the Installer Menu.
CH Burner Delay - The burner will not fire until the call blocking time has elapsed.
DHW Burner Delay - The burner will not fire until the call blocking time has elapsed.
CH Setpoint Reached - The burner is not fired because the supply/system water temperature exceeds the setpoint. The central heating circulator(s) continue(s) to operate and the burner will fire again once the supply/ system water temperature drops below the setpoint.

DHW Setpoint Reached - The burner is not fired because the supply/system water temperature exceeds the setpoint. The domestic circulator(s) continue(s) to operate and the burner will fire again once the supply/system water temperature drops below the setpoint.
CH Post Pump - The central heating circulator(s) is/are running to remove heat from the INSTINCT at the completion of a call.
DHW Post Pump - The domestic hot water circulator(s) is/are running to remove heat from the INSTINCT at the completion of a call.
Freeze Protection - The burner is fired because the freeze protection feature has been activated. Freeze protection will end once the supply/system water temperature is raised to 60°F [16°C].
Boiler Protection - The burner firing rate is being reduced because of an excessive difference between the boiler supply and return temperatures. The firing rate will begin increasing once the temperature difference is less than 45°F [25°C].
Low Water Pressure - The system pressure has dropped to 10.1 psi. The INSTINCT will still respond to calls until the pressure drops below 7.2 psi. Increase system pressure to 14.5 psi to clear Low Water Pressure warning
Lockout Description - The lockout which currently has the INSTINCT shut down is displayed

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9.5. Main Menu
The Main Menu can be entered from the Home Screen
by touching the soft key. The menu system utilizes icons to represent each selection. The currently selected menu is displayed as an inversed image with a text description shown at the top of the display. Menus can be entered by scrolling through the icons using the arrow soft keys, highlighting the desired icon
and touching the soft key.

9.6. EZ Setup
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.

INSTINCT Combi
186°F
DHW
156°F
Target = 186°F
DHW Demand

Touch center soft key

The EZ Setup menu can be accessed by selecting this icon.
The Boiler Information Menu can be accessed by selecting this icon.
The Home Screen icon at the bottom of each screen returns to the Home Screen when selected.

EZ Setup

Currently selected menu The CH / DHW Operation Menu can be accessed by selecting this icon.
The Previous Screen icon at the bottom of each screen returns to the previous screen when selected.
55

CHAPTER 9

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
Heating EZ Setup
Select CH Demand
Thermostat & Setpoint Constant & Setpoint 0 - 10 V Modulation Signal

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. After Thermostat & Setpoint is selected, the CH1 Setpoint screen appears. (see below).

Select CH Demand

Thermostat & Setpoint Constant & Setpoint 0 - 10 V Modulation Signal
CH1 Setpoint
140°F

68°F

188°F

CH2 Setpoint

140°F

68°F

188°F

EZ Setup Complete

Heating EZ setup is complete. Additional changes can be made in
the Installer Menu if required.
Press OK to return to EZ Setup Menu

Constant & Setpoint - The INSTINCT will maintain setpoint without an external CH call from a thermostat or zone panel. The setpoint will be fixed for CH calls. After Constant & Setpoint is selected, the CH1 Setpoint screen appears.
CH1 Setpoint prompts to enter the fixed setpoint for a CH1 heating call when a Setpoint option is chosen in Select CH Demand.

Touch the or soft keys to adjust the temperature setpoint
then touch to store the setting. The CH2 Setpoint screen then appears. CH2 Setpoint prompts to enter the fixed setpoint for a CH2 heating call when a Setpoint option is chosen in Select CH Demand.

Touch the or soft keys to adjust the temperature setpoint

then touch Setup.

to store the setting and complete the Heating EZ

CH1 Default: 140°F [60°C] CH2 Default: 140°F [60°C]

Select CH Demand
Thermostat & Setpoint Constant & Setpoint 0 - 10 V Modulation Signal
EZ Setup Complete
Heating EZ setup is complete. Additional changes can be made in
the Installer Menu if required.
Press OK to return to EZ Setup Menu

0 - 10V Modulation Signal - This option allows the INSTINCT firing rate to be controlled by an external control system.
Refer to Chapter 13 on page 77 for more information.

CHAPTER 9

56

CHAPTER 9 - CTRLMAX OPERATION 9.7.2 Select CH Demand (Outdoor sensor connected)

EZ Setup
Heating EZ Setup
Select CH Demand
Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0 - 10 V Modulation Signal

Select CH Demand prompts the installer to select how a CH Demand is generated.
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).

Select CH Demand

Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0 - 10 V MoSdeulleatcitonCSHig1nRaleset Curve
140°F
MAX

Select CH2 Reset Curve
80°F

140°F 18°C

-12°C

Current Settings

Warm Weather Shutdown
80°F

18°C

-O12°C

Current Settings

O

EZ Setup25C°Complete

Heating EZ setup is complete. Additional changes can be made in
the Installer Menu if required.
Press OK to return to EZ Setup Menu

Constant & Outdoor Curve - The INSTINCT will maintain setpoint without an external CH call from a thermostat or zone panel. The setpoint will vary with the outdoor temperature for central heating calls. After Constant & Outdoor Curve is selected, the Select CH1 Reset Curve screen appears
Select CH1 Reset Curve prompts to select an outdoor reset curve for a CH1 heating call when an Outdoor Curve option is chosen in Select CH Demand. Outdoor reset curve presets are available to cover most applications. The outdoor reset curve can also be adjusted to any desired settings in the Installer Menu.
Touch the or soft keys to select the outdoor reset curve appropriate for the type of heating
system, then touch to store the setting. The Select CH2 Reset Curve screen then appears.
Default: Radiators 2
Select CH2 Reset Curve prompts to select an outdoor reset curve for a CH2 heating call when an Outdoor Curve option is chosen in Select CH Demand. Outdoor reset curve presets are available to cover most applications. The outdoor reset curve can also be adjusted to any desired settings in the Installer Menu.

Table 4 - Outdoor Reset Preset Selections

Preset

Minimum Setpoint Maximum Setpoint

Floor Heat Low Temp. Floor Heat High Temp. Radiators 1

76°F [24°C] 76°F [24°C] 80°F [27°C]

96°F [35°C] 104°F [40°C] 120°F [49°C]

Radiators 2 Radiators 3 Radiators 4 Radiators 5 Cast iron baseboard Finned tube baseboard

80°F [27°C] 80°F [27°C] 80°F [27°C] 80°F [27°C] 100°F [38°C] 120°F [49°C]

140°F [60°C] 158°F [70°C] 176°F [80°C] 185°F [85°C] 170°F [77°C] 180°F [82°C]

Radiators 6 Fancoil

120°F [49°C] 140°F [60°C]

170°F [77°C] 180°F [82°C]

Touch the or soft keys to select the outdoor reset curve appropriate for the type of heating
system, then touch to store the setting. The Warm Weather Shutdown screen then appears. Default: Radiators 2 Warm Weather Shutdown prompts to enter an optional outdoor temperature at which to disable the central heating function and any circulator placed into constant circulation with the Pump Permanent Circulation setting. The INSTINCT will continue to respond to a domestic hot water call or a 0- 10V Modulation Signal when the outdoor temperature exceeds the Warm Weather Shutdown Temperature setting.
Touch the or soft keys to adjust the Warm Weather Shutdown Temperature then
touch the soft key to store the setting and complete Heating EZ Setup.
The Warm Weather Shutdown icon ( ) is displayed on the home screen when the outdoor temperature reaches the Warm Weather Shutdown temperature. Default: OFF.

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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

DHW EZ Setup

Select DHW Demand

Thermostat Sensor

DHW Boiler Setpoint
168°F

96°F

188°F

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. After Thermostat is selected, the DHW Boiler Setpoint screen appears.
Default: Thermostat
DHW Boiler Setpoint prompts to enter the fixed boiler setpoint temperature during a domestic hot water call. Touch the or soft keys to adjust the temperature setpoint then touch to store the setting. The DHW Priority Timeout screen then appears (see below).
Default: 168°F [75°C].

EZ Setup

DHW EZ Setup

Select DHW Demand

Thermostat Sensor
DHW Storage Setpoint
140°F

68°F

168°F

DHW Priority Timeout O

O

120 min.

EZ Setup Complete

DHW EZ setup is complete. Additional changes can be made in
the Installer Menu if required.

Press OK to return to EZ Setup Menu

When Sensor is selected in Select DHW Demand, use of an (optional) Indirect Water Heater Sensor is required. The INSTINCT monitors the DHW storage temperature and generates a DHW call whenever the temperature drops below the DHW storage setpoint by 6°F [3°C]. DHW Storage Setpoint prompts to enter the DHW Storage Setpoint temperature.
Touch the or soft keys to adjust the temperature setpoint then touch to store the setting. The DHW Priority Timeout screen then appears.
Default: 140°F [60°C].
NOTICE
The DHW Boiler Setpoint will automatically be set 28°F [15°C] higher than the DHW Storage Setpoint setting
DHW Priority Timeout prompts to enter an optional time limit that a domestic hot water call has priority over central heating call.
Touch the or soft keys to adjust the timeout value, if required, then touch to store the setting and complete the DHW EZ Setup.
Default: Off

58

CHAPTER 9

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

EZ Setup

DHW EZ Setup

DHW Setpoint 140°F

68°F

168°F

DHW Warmstart Temperature
125°F

86°F

140°F

O

DHW Warmstart Hysteresis
30°F

9

36°F

EZ Setup Complete

DHW EZ setup is complete. Additional changes can be made in
the Installer Menu if required.

Press OK to return to EZ Setup Menu

DHW EZ Setup prompts the installer to select the DHW setpoint.
DHW Setpoint prompts to enter the fixed setpoint temperature during a domestic hot water call. Touch the or soft keys to adjust the temperature setpoint then touch to store the setting. The DHW Warmstart Temperature screen then appears .
Default: 140°F [60°C].
DHW Warmstart Temperature prompts to enter the DHW temperature in case you want to speed up the delivery of DHW in summer conditions. Touch the or soft keys to adjust the temperature then touch
to store the setting. At the minimum temperature (86°F), this function is OFF. The DHW Warmstart Hysteresis screen then appears .
Default: 125°F [52°C].
DHW Warmstart Hysteresis prompts to enter the DHW hysteresis value, comprised between 9°F (5K) and 36°F (20K). Touch the or soft keys to adjust the hysteresis value, then touch to store the setting.
Default: 30°F (17k).

9.10. Altitude Setup
INSTINCT Combi
88°F
ENTER ACCESS CODE
84°F

Altitude must be correctly set to allow reliable operation of the boiler.
From the home screen touch the or soft keys simultaneously for 5 seconds and "Enter Access Code" screen will be shown.

Target = - -

CH & DHW Settings

Standby 0 5 [4]

CH Settings

Boiler Settings

Boiler Settings

Model

Instinct Combi

Lockout Temp. Modbus Address

B2o10ilºeF r[9S9eºCt1]tings

Pump Settings Ignition levelPump Setti3n0g0srpm

Mix zone highIglnimitiot n level114ºF Mix zone high limit

3A0l0ti01t1urp4dºmFe

WP di trigger

0cpsi

Appliance setting

Altitude

49200fftt

Touch the or soft keys to set the access code to 054. Touch and the CH & DHW Settings creen will be shown.
Touch and the CH Setting screen will be shown. Touch the soft key and the "Boiler Settings" (list) screen will be shown. Touch the soft key until the "Altitude" option is highlighted. Touch and the Altitude screen will be shown.
Touch the soft key until the correct altitude is shown, then touch the soft key to highlight the home icon. Touch to confirm.
Note. The altitude moves in steps of 984 ft (300m).

0ft

19680ft

CHAPTER 9

59

CHAPTER 9 - CTRLMAX OPERATION 9.11. EZSetup Reset
EZ Setup
EZ Setup Reset
EZ Setup Reset
Press OK to restore factory settings, any other button to keep current
settings.

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. Follow the on-screen instructions to reset all EZ Setup settings.

9.12. Display EZ Setup

EZ Setup Display EZ Setup

Select Language

English
Français Nederlands Español Italiano Deutsch

Select Unit

Fahrenheit Celsius

Display EZ Setup allows language (English, French, Dutch, Spanish, Italian, German, Czech) and temperature units selection.
Touch the or soft keys to select the required language then touch to store the setting. The Select Unit screen then appears.
Touch the or soft keys to select the required temperature units then touch to store the setting.

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CHAPTER 9 - CTRLMAX OPERATION 9.13. CH/DHW Operation
CH / DHW Operation
Heating Enabled

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. 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 screHeeanti.ng Enabled
Default :

9.14. Boiler Information

Boiler Information

Boiler Information

aababbcccddedeeffbfbbbbbbb b

b

aaabbbcccdddeeefffbbbbbbbbbb

Boiler Information

Boiler Status Heating Call DHW Call Boiler Firing Rate Ionization current Boiler Setpoint

Standby No No -0A --

Boiler Information provides real time operating information of the INSTINCT. Each line contains an information item followed by its current value. Six lines are displayed on the screen at one time.

Some information items include a logging function which records one sample every 12 minutes to produce a graph of the last 24 hours. Select the information item in Boiler Information then touch the soft key to view its graph. The following items have a logging function:

·

Boiler Firing Rate

·

Ionization Current

·

Boiler Setpoint

·

Boiler Supply Temperature

·

Boiler Return Temperature

·

Boiler Flue Temperature

·

Outdoor Temperature

·

DHW Storage Temperature

·

External Modulation Signal

·

Pressure

Touch the or soft keys to scroll through the items.

CHAPTER 9

61

CHAPTER 9 - CTRLMAX OPERATION 9.14.1 Information Items

Information Item
Boiler Status Heating Call DHW Call Boiler Firing Rate Ionization Current Boiler Setpoint Supply Temp. Return Temp. Boiler Flue Temp. Outdoor Temp. DHW Storage Temp.
External Modulation Signal Pressure CH Ignitions
CH Runtime
DHW Ignitions
DHW Runtime Mix Zone Temperature

Description
Displays the current operating state of the INSTINCT. This is the same as the status line on the home screen.
Displays if a central heating call is present. Displays if a domestic hot water call is present. Displays the current firing rate of the INSTINCT. Displays the current flame ionization current from the ignitor. Displays the current setpoint of the INSTINCT. Displays the current supply temperature of the INSTINCT. Displays the current return temperature to the INSTINCT. Displays the current flue temperature of the INSTINCT. Displays the current outdoor temperature.
Displays the current DHW storage temperature when Indirect Water Heater Sensor PSRKIT22 is installed.
Displays the current external modulation signal being received from an external controller.
Displays the current system water pressure.
Displays the number of central heating ignitions since the unit was installed. This counter increases in increments of twenty.
Displays the number of hours the INSTINCT has run for a central heating call since the unit was installed.
Displays the number of domestic hot water ignitions since the unit was installed. This counter increases in increments of twenty.
Displays the number of hours the INSTINCT has run for a domestic hot water call since the unit was installed.
Displays the current low temperature mix zone temperature.

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CHAPTER 9 - CTRLMAX OPERATION

Boiler Information

Lockout History

aaabbbcccdddeeeffbfbbbbbbb b

b

aaabbbcccdddeeefffbbbbbbbb

b b

Lockout History

1. Blower speed

5h ago

2. DHW Sensor Open 2h ago

3. Sensor Drift 4. No error

25 h ago 27 h ago

5. No error 6. No error

27 h agoLockout Details
27 h ago Blower speed

Boiler Status Heating Call DHW Call Boiler Firing Rate Ionization current

---44% 44A

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.
Touch the or soft keys to scroll through the items then touch to select and get more details through the Lockout Details screen.
The following information items are recorded at the time of a lockout: · Boiler Status · Heating Call · Domestic Call · Boiler Firing Rate · Flame Ionization Current · Boiler Setpoint · Boiler Supply Temperature · Boiler Return Temperature · Boiler Flue Temperature · Outdoor Temperature · System Temperature

9.14.2 Lockout Screen
If a problem occurs, the Lockout Screen replaces the Home Screen. The backlight will remain on until the lockout is reset. Touching any arrow soft key will return to the Home Screen so that additional troubleshooting can be performed. See Sections 9.14.3 on page 64 and 9.14.4 on page 65 for a list of lockouts and descriptions. Select the Home Screen icon at the bottom of any screen to return to the lockout screen.
Lockout message.

Low Water
Water pressure has fallen below 7.2 psi. Increase pressure to normal range.
If problem persists, call for service

Lockout text. The first sentence describes the lockout, the second sentence gives a possible cure, and the third tells how to reset the lockout.

E37

Lockout reference code. Refer to Sections 9.14.3

on page 64 and 9.14.4 on page 65 for more

information.

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63

CHAPTER 9 - CTRLMAX OPERATION 9.14.3 Manual Reset Lockouts

Code Lockout Message

E1

Failed Ignition

Description 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.

E9

Gas Valve Circuit Error

Gas valve circuit test failed.

E13 Reset Limit Reached

Resets are limited to 5 every 15 minutes.

E15 Sensor Drift

Supply or return sensor reading has drifted.

E16 Supply Sensor Stuck

Supply sensor reading is not changing.

E17 Return Sensor Stuck

Return sensor reading is not changing.

E18 Sensor Failure

Supply or return sensor reading changed very rapidly.

E19 Flame Failure During Startup Phase Flame lost after startup

E21 Internal Control Fault

A / D conversion error.

E30 Supply Sensor Shorted

A short circuit has been detected in the boiler supply temperature sensor circuit.

E31 Supply Sensor Open

An open circuit has been detected in the boiler supply temperature sensor circuit.

E43 Return Sensor Shorted

A short circuit has been detected in the boiler return temperature sensor circuit.

E44 Return Sensor Open

An open circuit has been detected in the boiler return temperature sensor circuit.

E47 Water Pressure Sensor Error

Water pressure sensor is disconnected or broken.

E80 Return > Supply

Return temperature is higher than supply temperature.

E83 Delta T Protection

Excessive difference between boiler supply and return temperatures has occured 5 times

E84 High Flue Temperature

Flue temperature has exceeded high limit 5 times

E87 External Limit Open

An external manual reset limit has opened

CHAPTER 9

64

CHAPTER 9 - CTRLMAX OPERATION 9.14.4 Automatic Reset Blocking Lockouts

Code Lockout Message

E7

High Flue Temperature

E12 Internal Control Fault

E25 Internal Control Fault

E32 DHW Sensor Shorted

E33 DHW Sensor Open

E34 Low Voltage

E37 Low Water

E45 Flue Sensor Shorted

E46 Flue Sensor Open

E76 External Limit Open

E77 High Mix Circuit Temperature

E78 Mix Circuit Sensor Shorted

E79 Mix Circuit Sensor Open

E81 Sensor Drift

E82 Delta T Protection

E89 Incorrect Setting

E90 Firmware Mismatch

E91 System Sensor Shorted

E92 System Sensor Open

E93 Outdoor Sensor Shorted

E94 Internal Display Fault

E95 Supply Sensor Error

E96 Outdoor Sensor Open

E97 Cascade Mismatch

E98 Cascade Bus Error

E99 Controller Bus Error

Description Flue temperature exceeds high limit. EEPROM misconfiguration. CRC check error. A short circuit has been detected in the DHW temperature sensor circuit. An open circuit has been detected in the DHW temperature sensor circuit. Line voltage has fallen below an acceptable operating level. Water pressure has fallen below 7.2 psi. A short circuit has been detected in the boiler flue temperature sensor circuit. An open circuit has been detected in the boiler flue temperature sensor circuit. An external automatic reset boiler limit has opened. Mix circuit temperature exceeds Mix zone high limit setting. A short circuit has been detected in the mix circuit temperature sensor circuit. An open circuit has been detected in the mix circuit temperature sensor circuit. Supply and return temperatures are not equal. Excessive difference between the boiler supply and return temperatures. A parameter setting is in conflict with another setting. Control module and display firmware versions are incompatible. A short circuit has been detected in the system temperature sensor circuit. An open circuit has been detected in the system temperature sensor circuit. An open circuit has been detected in the outdoor temperature sensor circuit. Display memory error. Supply sensor reading is invalid. An open circuit has been detected in the outdoor temperature sensor circuit. Cascade configuration has changed. Communication with other boilers has been lost. Communication between boiler display and control module has been lost.

CHAPTER 9

65

INTENTIONALLY LEFT BLANK

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. Damage to seals and gaskets in the system components can occur, resulting in substantial
property damage, serious injury, or death.

10.1.3 Chlorinated Water
Do not use the INSTINCT to heat a swimming pool or spa directly.
Maintain the chlorine level of the water at levels considered safe for drinking.
10.1.4 Flush Boiler to Remove Sediment
The installer must flush the boiler system to remove any sediment to allow proper operation of the INSTINCT . Flush the system until the water runs clean and is free of sediment. For zoned systems, each zone should be flushed through a purge valve. Purge valves and isolation valves should be installed on each zone to allow proper flushing of the system.

NOTICE
System fluid including additives, must be practically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of
Commercial Products.
10.1.1 Boiler Fluid pH Level 6.0 to 8.0
Maintain the boiler fluid pH between 6.0 and 8.0. Check using litmus paper or contact a water treatment company for a chemical analysis.

10.1.5 Cleaning of Old Boiler/System:
· Drain the existing system. · Fill system with fresh water and cleaner, place exist-
ing boiler in operation and run all zones. · Follow manufacturer's instructions for proper clean-
er concentration and proper cleaning time. · Thoroughly drain and flush system with fresh water
after cleaning. · Install new boiler and fill system with fresh water
and proper amount of inhibitor. · Verify pH and inhibitor level per inhibitor manufac-
turer's specs; add inhibitor if necessary.

If the pH does not meet this requirement, do not operate the INSTINCT or leave the unit filled until the condition is corrected.
10.1.2 Boiler Fluid Hardness Less Than 7 Grains
For areas with unusually hard water (hardness above 7 grains) consult a water treatment company.

10.1.6 Cleaning of New Boiler/System:
· Install new boiler and flush system with clean water to remove any debris.
· Fill system with fresh water and proper amount of inhibitor.
· Verify pH and inhibitor level per inhibitor manufacturer's specs; add inhibitor if necessary.

67

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.
10.1.8 Use of Antifreeze in the Boiler System
WARNING
NEVER use automotive or ethylene glycol antifreeze or undiluted antifreeze in the system as freeze protection. This can result in substantial property damage, serious injury, or
death. Determine the antifreeze fluid quantity using the system water volume and following the antifreeze manufacturer instructions.
The water volume of the INSTINCT is approximately: -- 2 gallons [8 L] for INSTINCT Solo 110 -- 3 gallons [12 L] for INSTINCT Solo/Combi 155 and
INSTINCT Solo 199 -- 4 gallons [15 L] for INSTINCT Combi 199. Remember to include the volume of the expansion tank.
Check with local code requirements for the installation of backflow preventers or actual disconnection of the boiler's cold water fill or make up water supply line.
NOTICE
Massachusetts Code requires the installation of a backflow preventer if antifreeze is used.
Ensure the concentration of antifreeze to water does not exceed a 50/50 ratio.
NOTICE
System fluid including additives, must be practically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of
Commercial Products.

DANGER
HOT WATER CAN SCALD!
· Water temperatures over 125ºF can cause severe burns instantly, or death from scalds.
· Feel water before bathing or showering.
· Consumer Product Safety Commission and some states recommend temperatures settings of 130ºF or less. Setting thermostat higher than 130ºF will increase risk of scald injury and cause severe personal injury or death.
· Water heated to a temperature suitable for clothes washing, dish washing and other sanitizing needs will scald and cause permanent injury.
· Children and elderly, infirm, or physically handicapped persons are more likely to be injured by hot water. Never leave them unattended in or near a bathtub. If anyone using hot water in the building fits this description, or if state laws or local codes require certain water temperatures at hot water faucets, take special precautions.
 Install the factory supplied automatic mixing valve at water heater and/ or install a point of use mixing valve at each hot water faucet, bath and shower outlet. Selection and installation of point of use mixing valves must comply with valve manufacturer's recommendation and instructions.
 Use the lowest practical temperature setting.
 Check water temperature after any adjustment of the mixing valve.
· Failure to comply with these instructions will result in serious injury, or death.

68

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. Operating pressure of the
system should never exceed 30 psi.
4. Purge air and sediment in each zone of the boiler system through the purge valve. Open air vents to allow air to be purged from the zones.
5. Once the system is completely filled and purged of all air and sediment, check the system pressure and check/repair any leaks.

General Notes · Household water usage patterns will affect water
temperature at any faucet or shower. Occasionally check temperature at each point of use, then adjust the mixing valve setting accordingly. Always recheck temperature after adjusting the mixing valve. · Lowering the automatic mixing valve as indicated in these instructions will reduce water temperature levels. Consult your installer or service technician.
10.3.1 Filling the Domestic Circuit
CAUTION
· Never use the INSTINCT Combi unless the circuits of the water heater are completely filled with water.
· Failure to comply with these instructions can result in minor property damage, or injury.
1. Close domestic water drain valve. 2. Open domestic water isolation valves slowly on the
water heater piping.

WARNING
Unrepaired system leaks will cause continual makeup water to be added to the boiler. Continual makeup water will cause mineral buildup within the heat exchanger, reducing the heat transfer, causing heat buildup and eventual heat exchanger failure. This can result in substantial property damage, serious
injury, or death.

CAUTION
Make sure to open the domestic isolation valve slowly to prevent any damage to the domestic
circuit flow sensor.
3. Vent air from domestic circuit by opening nearest hot water faucet, until there is a constant flow of water.
4. Close hot water faucet.

10.3. INSTINCT Combi Water Heater - Water Requirements
NOTICE
The thermostatic mixing valve controls the hot water temperature delivered to the faucets.
WARNING
POTENTIAL SCALD HAZARD. A mixing valve must be installed on the INSTINCT Combi. Removal or adjustment of the mixing valve will create a potential scald hazard, which can result in serious injury, or death.
If any adjustment needs to be made to the valve's temperature setpoint refer to the manufacturer's instructions included with the valve.

10.4. Check Low Water Cut-Off Device
· The INSTINCT is provided with a factory installed LWCO device that monitors system pressure.
· Access the Boiler Information Menu by following instructions in Section 9.14 on page 61. Scroll down to see the current system pressure and verify it is within the range given in Section 10.2 above.

69

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.
· Prior to start-up of the unit and periodically after start-up have the propane supplier check and verify the odorant level.
· Failure to comply with these instructions can result in substantial property damage, serious injury, or death.

· There should NEVER be voltage measured at the wire ends.
· If voltage is measured under any condition, check and correct the external wiring.
NOTICE
In systems using 3-wire zone valves, voltage backfeed to the unit is a common problem. Use an isolation relay to prevent voltage from the ex-
ternal circuit from entering the INSTINCT.
· Reconnect the external thermostat wires to the low voltage terminal strip.
10.7. Inspect Condensate Drain Assembly 1. Inspect and ensure the Condensate Drain Assembly
is properly installed as described in Section 6.2 on page 38. 2. Remove the plug from the Condensate Drain Assembly and fill with fresh water.

10.6. Check Thermostat Circuit
· Disconnect the external thermostat wires from the low voltage terminals.
· Connect a voltmeter across the wire ends of the external thermostat wiring.
· Close each thermostat, zone valve and relay in the external circuit one zone at a time and check the voltage reading across the wire ends.

WARNING
The condensate drain assembly must be filled with water when the INSTINCT is in operation. The condensate drain assembly prevents flue gas emissions from entering the condensate line. Failure to ensure trap is filled with water
can result in serious injury, or death.
3. Re-Install plug in condensate drain assembly.

70

CHAPTER 11

Chapter 11 - START-UP PROCEDURES

11.1. Final Checks Before Start-Up
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.
ØØ Inspect vent and combustion air piping for signs of deterioration from corrosion, physical damage or sagging. Verify combustion air and vent piping are intact and correctly installed and supported. Reference the INSTINCT Vent Supplement.
ØØ Verify burner configuration - Propane only. · Check for proper labeling on the venturi and the rating label for propane configuration. · If there is doubt on the burner configuration, remove the venturi and check for proper propane gas orifice sizing on venturi labeling. Refer to Section 7.3.2 on page 42 for orifice sizes. Refer to Fig 16, Fig 17 or Fig. 28 on page 44 for location of the propane gas orifice.
ØØ Ensure the Condensate Drain Assembly is filled with water.
11.2. INSTINCT Start-Up
1. Turn ON the electrical supply/service to the unit. Touch the ON-OFF button located on the front control panel to the OFF position.
2. Read and follow the Operating Instructions outlined on following page.
If INSTINCT Does Not Start Correctly 1. Check for loose electrical connections, blown fuses
on control module, or an open service switch. 2. Verify CH and DHW operation is enabled. A radiator
or faucet icon with an X through it indicates that function is disabled. 3. Check the system pressure in the Boiler Information Menu by following the instructions in Section 9.14 on page 61.

4. Is an external limit (if applicable) open? Ensure the external limit is reset to the closed position.
5. Are the gas supply valves open at the unit and meter?
6. Is incoming gas supply pressure at the unit more than 5"w.c. and less than 13" w.c. with all gas appliances ON and OFF.
7. Are the heating thermostats set above room temperature?
If none of these conditions correct the problem, contact Triangle Tube Technical Support.
11.3. Check the INSTINCT and System
11.3.1 Check Boiler Piping.
· Check Boiler system piping and components for leaks. If found, shut down the unit and repair immediately.
· Purge any remaining air from the system. Air in the system will interfere with circulation, creating heat distribution problems and noise.
11.3.2 Check Vent and Combustion Air Piping.
· Check for a gas-tight seal at every connection and seam of the vent and combustion air piping.
DANGER
Venting system must be sealed gas-tight to prevent flue gas spillage and carbon monoxide emissions, which will result in serious
injury, or death.
11.3.3 Verify Carbon Monoxide Detector
Verify that at least two (2) carbon monoxide detectors are installed and operating properly. One must be installed in the mechanical room where the INSTINCT is located and another installed in the living area outside the bedroom(s).

71

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. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
· Do not try to light any appliance. · Do not touch any electric 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.

C. Use only your hand to turn the external manual gas valve. Never use tools. If the valve will not turn by hand, don't try to repair it; call a qualified service technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above. This ap-

pliance is equipped with an ignition device which

automatically lights the burner. DONOT try to light the burner by hand.

2. Set room thermostat(s) to lowest setting. Turn the

external manual gas valve handle clockwise

to "CLOSE" (valve handle must be perpendicular to gas piping).

3. Turn the service switch on the appliance control panel OFF.

4. Remove the front jacket panel on the unit.

5. Wait five (5) minutes to clear out any gas. If you then smell gas in the jacket enclosure or around the unit,

STOP! Follow "B" in the safety information above. If

you don't smell gas, go to the next step.

6. Turn the external manual gas valve handle counter

clockwise

to "OPEN" gas supply (valve handle

shall be parallel to gas piping).

7. Turn the service switch on the appliance control panel "ON".
8. Set room thermostat(s) to desired setting(s).
9. The appliance control panel display will show the current operating status on the Status Line at the bottom of the screen. "Standby" means there is no call for heat (all thermostats are satisfied)."CH Demand" indicates a space heating call has been received. "DHW Demand" indicates a domestic hot water call has been received. A flame icon will be displayed when the unit is fired.
10. If the unit will not operate, follow the instructions "To Turn Off Gas to Appliance" and call your service technician or gas supplier.
11. Replace the front jacket panel. Make sure the panel is seated firmly in place and all mounting screws are tightened.

TO TURN OFF GAS TO APPLIANCE

1. Set the room thermostat to lowest setting.
2. Turn the service switch on the appliance control panel to "OFF"

3. Turn the external manual gas valve handle clock-

wise

to "CLOSE".

72

CHAPTER 11

CHAPTER 11 - START-UP PROCEDURES

11.3.4 Check Gas Piping
Check around the unit for gas odor following the procedure outlined in this manual on page 64.

d. Touch the soft key while the FAN icon is highlighted to manually fire the burner and power the CH circulator(s).

DANGER
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, seri-
ous injury, or death.

Manual Operation

FAN
CH1 DHW CH2

Released O O O

11.3.5 Verify Flame Pattern and Combustion
1. Check the flame pattern through the observation port of the heat exchanger. The flame should be blue and stable. The flame should be over the length of the burner head. It is not possible to determine correct combustion by inpecting eh colour and pattern of the flame. It is important to measure combustion with a calibrated flue gas analyser.
NOTICE
Combustion testing and adjustments must be performed by a qualified installer, service agency or the gas supplier. All combustion measurements must be performed with recently calibrated equipment (1 year max.) to ensure
proper reading and accuracy.
2. Test for CO2 or O2 and for CO during high firing rate. The combustion readings must be within the range listed in Table 6 on page 74. The CO level must not exceed 150 ppm for natural gas and 200 ppm for propane gas when combustion is correct. Perform the following procedure to manually place the burner into high fire.

a. Touch simultaneously on the and soft keys for 3 seconds to access the functions for the installer. Reference Section 9.1 on page 51.

b. Enter the installer access code "054" by using

the and soft keys to select a digit location

and the and soft keys to change the digit.

Touch the soft key to enter the access code.

c. Touch the

abcafdbecbfgdbeabfbbcbbdb abcadbecfdabebbfcbbdbeb

aaabbbccc

dddeee

f f

bbbbb

b

soft key to highlight the Manual aaabbbcccdddeeffbbbbbb

Operation icon then touch the soft key.

NOTICE
An adequate CH load must be present to dissipate the heat generated during the combustion test. If an adequate CH load is not available, an indirect water heater can be used to dissipate the heat by creating a DHW call which will en-
able the DHW circulator.
e. Touch the soft key to adjust the firing rate from 1% to 100%. Hold down the soft key to rapidly increase the firing rate.
f. Touch the soft key while the FAN icon is highlighted to shutdown the burner.
3. If the combustion levels during highfire (100%) are outside the acceptable levels, adjust the THROTTLE SCREW (see Fig. 13 on page 25 and Fig. 27 on page 43, and Fig. 28 on page 44) according to Table 5 on page 74.
4. Once the combustion level is set at high fire (100%), manually place the boiler into low fire (1%) mode by touching the soft key to adjust firing rate down.
5. Verify the combustion levels during low fire (1%) are within the acceptable combustion levels in Table 6 on page 74.
WARNING
If the combustion levels at low fire (1%) are not within the range given in Table 6 on page 74, shut the boiler down and contact Triangle Tube Technical Support. Failure to comply with this requirement can result in substantial property damage, serious injury, or
death.

73

CHAPTER 11

CHAPTER 11 - START-UP PROCEDURES

Table 5 - Throttle Screw Adjustment

3. Touch the soft key while CH & DHW Settings

Direction Clockwise Counter-Clockwise

INSTINCT Solo/Combi
Decrease CO2 Increase O2 Increase CO2 Decrease O2

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. Turn off all gas appliances within the building, ex-
cept the INSTINCT. 4. At the gas meter, record the time required to use
one cubic foot of gas. 5. Calculate Natural gas input using the following
equation: 3600 x 1000 / number of seconds recorded for one cubic foot of gas = BTU/H. 6. The BTU/H calculated should approximate the input rating listed on the unit.

icon is highlighted.

4. Touch the

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soft key to highlight the Boiler Set- aaabbbccc

dddeee

f f

bbbbb

b

aaabbbcccdddeeffbbbbb b

tings icon then touch the soft key.

5. Touch the soft key to highlight Lockout Tem-

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perature then touch the aaabbbccc

dddeee

f f

bbbbb

b

aaabbbcccdddeeffbbbbb b

soft key.

6. Touch the soft key to highlight 102ºF [39ºC] then

touch the soft key.

7. Touch the soft key to highlight the Home Screen icon then touch the soft key.

8. Initiate a CH or DHW call and confirm that a High Boiler Temperature lockout occurs once the supply temperature reaches 102ºF [39ºC].

9. Touch any ARROW soft key to return to the Home Screen. 10. Touch simultaneously on the and soft keys for
3 seconds to access the functions for the installer. 11. Touch the soft key while the CH & DHW Settings

icon

abcafdbecbfgdbeabfbbcbbdb abcadbecfdabebbfcbbdbeb

is highlighted.

aaabbbccc

dddeee

f f

bbbbb

b

aaabbbcccdddeeffbbbbb b

12. Touch the

abcafdbecbfgdbeabfbbcbbdb abcadbecfdabebbfcbbdbeb

soft key to highlight the Boiler Set- aaabbbccc

dddeee

f f

bbbbb

b

aaabbbcccdddeeffbbbbb b

11.3.7 Test High Temperature Limit

tings icon then touch the soft key.

The high temperature limit can be temporarily lowered 13. Touch the soft key to highlight Lockout Tem-

from 210ºF [99ºC] to 102º F [39ºC] for testing. 1. Touch simultaneously on the and soft keys

abcafdbecbfgdbeabfbbcbbdb abcadbecfdabebbfcbbdbeb

perature, then touch the aaabbbccc

dddeee

f f

bbbbb

b

aaabbbcccdddeeffbbbbb b

soft key.

14. Touch the soft key to highlight 210ºF [99ºC] then

for 3 seconds to access the functions for the install-

touch the soft key.

er. Reference Fig. 34 on page 51.

15. Touch the soft key to highlight the Home Screen

2. Enter the installer access code "054", using the

icon then touch the soft key.

and soft keys to select a digit and the and soft keys to change the digit. Touch the soft key to enter the access code.

16. Touch the soft key to reset the lockout and return the unit to service.

Table 6 - Acceptable Combustion Levels

High Fire

CO2 Range CO2 Target O2 Range O2 Target CO Max CO2 Range
O2 Range
CO Max

Natural Gas (All Models) 9.0 to 10.5%

Propane (All Models) 10.4 to 11.0%

9.50%

10.80%

4.85 to 2.15 % 3.95%

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5.1 to 4.2 % aaabbbccc

dddeee

f f

bbbbb

b

aaabbbcccdddeeffbbbbb b

4.50%

150 ppm

200 ppm

Low Fire CO2 range 9.0 to 10.0 %
Target values are equivalent to High Fire values, ensure CO2 values measured are less than or equal to High Fire
CO2 measurements

Low Fire CO2 range 10.4 to 11.0 %
Target values are equivalent to High Fire values, ensure CO2 values measured are less than or equal to High Fire
CO2 measurements

Low Fire O2 range 4.85 to 3.0 %
Target values are equivalent to High Fire values, ensure O2 values measured are higher than or equal to High
Fire O2 measurements

Low Fire O2 range 5.1 to 4.2 %
Target values are equivalent to High Fire values, ensure O2 values measured are higher than or equal to High
Fire O2 measurements

10 ppm

10 ppm

Low Fire

74

CHAPTER 12

Chapter 12 - OUTDOOR RESET CONTROL

The use of the outdoor reset function is required to optimize boiler efficiency, see notice below. If the outdoor sensor is not installed before turning on the INSTINCT, an Outdoor Sensor Open error (E96) will be displayed. The error will not prevent the boiler from operating. The error will automatically reset once the outdoor sensor is installed or if the outdoor reset function is disabled. Reference Section 9.7 on page 56 for information on disabling the outdoor reset function. The outdoor reset function can only be disabled if the installation meets one of the exceptions listed in the IMPORTANT notice below.
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. Mount the outdoor sensor at an elevation on the exterior wall to prevent accidental damage or tampering.
4. Avoid mounting the outdoor sensor in areas subjected to excessive moisture.
5. Once an area on the exterior wall has been determined, follow the mounting instructions included with the outdoor sensor.

12.2. Wiring the Sensor
1. Connect 18 AWG 2-wire cable or similar to the outdoor sensor.
2. Route the cable back to the INSTINCT boiler, ensuring the wires are not run parallel to telephone or power wiring.
NOTICE
If the sensor wires are located in an area with sources of electromagnetic interference (EMI), the sensor wires should be shielded or the wires should be run in a grounded metal conduit. If using shielded cable, the shielding should be connected to the common ground of
the unit.
3. Connect the outdoor sensor wires to low voltage terminals X6-1&2 located at the bottom of the CTRLMax control module as shown in Fig. 33 on page 49.

IMPORTANT
In accordance with Chapter 325 (f ) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE.
· An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.
· This boiler is not used for any space heating · This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/
hr or greater. · This boiler is equipped with a tankless coil.
75

INTENTIONALLY LEFT BLANK

CHAPTER 13

Chapter 13 - EXTERNAL MODULATING CONTROL

The INSTINCT can directly accept an analog 0-10 VDC signal from an external modulating boiler controller to control the firing rate.
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.
External modulating control will only function if the external modulating controller is properly wired to the INSTINCT as follows:
· X5-1 = + · X5-2 = -

13.2. CTRLMax Programming
The CTRLMax control module must be programmed to accept the 0-10 VDC signal from the external modulating boiler control.
1. Use the Heating EZSetup function to set CHDemand to 0-10V Modulation Signal. Reference Section 9.7 on page 56.
13.3. Programming of External Modulating Control
The external modulating control must be programmed to send 2 VDC to enable the boiler and run it at low fire, and 10 VDC to run the boiler at high fire. Once the control enables the boiler, it must wait 30 seconds to allow the burner to stabilize before modulating the boiler.

NOTICE
Ensure that the polarity of the connections from the external modulating boiler controller to the boiler are correct. Reversed polarity will
lead to no response from the boiler.
CTRLMax Factory Settings

HEATING SETTING
Heating Operation Demand Type Absolute Max CH Setpoint CH1 Maximum Setpoint CH1 Minimum Setpoint Outdoor Curve Coldest Day Outdoor Curve Warmest Day CH2 Circuit CH2 Maximum Setpoint CH2 Minimum Setpoint Warm Weather Shutdown Circulation Pump Permanent CH Post Pump Time Freeze Protection Frost Protection Setpoint Parallel Shift Value CH Call Blocking

FACTORY DEFAULT

INSTINCT Solo

INSTINCT Combi

Enabled
Thermostat & Outd. Curve
185°F [85°C]

Enabled
Thermostat & Outd. Curve
185°F [85°C]

180°F [82°C]

180°F [82°C]

80°F [27°C]

80°F [27°C]

10°F [-12°C]

10°F [-12°C]

64°F [18°C]

64°F [18°C]

Enabled

Enabled

140°F [60°C]

140°F [60°C]

80°F [27°C]

80°F [27°C]

Off

Off

Disabled

Disabled

5 Minutes

5 Minutes

Enabled

Enabled

-22°F [-30°C]

-22°F [-30°C]

0°F [0°C]

0°F [0°C]

2 Minutes

2 Minutes

MINIMUM SETTING
68°F [20°C] 68°F [20°C] 60°F [15°C] -30°F [-34°C] 60°F [15°C]
68°F [20°C] 60°F [15°C]
Off
Off
-22°F [-30°C] 0°F [0°C] 0 Minute

MAXIMUM EZ SETUP RESET INSTALLER RESET
SETTING







188°F [87°C]



188°F [87°C]





188°F [87°C]





50°F [10°C]



78°F [25°C]





194°F [90°C]





190°F [88°C]





78°F [25°C]







20 Minutes





50°F [10°C]



144°F [80°C]



30 Minutes



77

CHAPTER 13 - EXTERNAL MODULATING CONTROL

HEATING SETTING
DHW Operation Demand Type DHW Boiler Setpoint DHW Setpoint DHW Warmstart Setpoint DHW Warmstart Hysteresis DHW On Differential DHW Storage Adder DHW Post Pump Time DHW Priority Timeout DHW Priority DHW Call Blocking DHW to CH Call Blocking Antilegionella Function

CTRLMax Factory Settings (cont'd)

FACTORY DEFAULT

MINIMUM

INSTINCT Solo INSTINCT Combi SETTING

MAXIMUM SETTING

Enabled

Enabled

Thermostat 168°F [75°C] 140°F [60°C]
N/A N/A 6°F [3K] 27°F [15°K] 2 Minutes Off Enabled 1 Minute 1 Minute Disabled

N/A 168°F [75°C] 140°F [60°C] 125°F [52°C] 30°F [17K] 18°F [10K]
N/A 2 Minutes
Off Enabled 1 Minute 1 Minute Enabled

96°F [35°C] 68°F [20°C] 86°F [30°C]
9K 4°F [2°C] 10°F [5°C]
Off Off
0 Minute 0 Minute

188°F [87°C] 168°F [75°C] 140°F [60°C]
36K 18°F [10°C] 54°F [30°C] 30 Minutes 120 Minutes
30 Minutes 30 Minutes

EZ SETUP RESET INSTALLER RESET

   

Enabled

 Thermostat
    6°F [3K] 27°F [15°K]      

CHAPTER 13

BOILER SETTING
Lockout Temp. Modbus Address Flex. Relay 1(CH) Flex. Relay 2(DHW) Flex. Relay 3(P3) Flex. Relay 4(ERR) Flex. Relay 5(Flame) Flex. Relay 6(P4) Error Relay Pump PWM Minimum Ignition Level Mix Zone High Limit Appliance Setting Altitude Setting

FACTORY DEFAULT INSTINCT Solo INSTINCT Combi 210°F [99°C] 0=BCST
CH1
DHW
CH1/CH2/DHW
ERROR
FLAME
CH2 On Lockout, Blocking
and Warning 30%
Varies by model
114°F [45°C]
Varies by model
0 ft

MINIMUM SETTING 0=BCST
1% 68°F [20°C]
0 ft

MAXIMUM SETTING

EZ SETUP RESET INSTALLER RESET



247





100% 176°F [80°C]
20,000 ft

78

Chapter 14 - CHECK-OUT PROCEDURES

NOTICE
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.
qq Air is purged from the heating zones and boiler system piping.
qq If applicable, confirm that the burner has been properly configured for Propane as outlined in Section 7.3 on page 42.
qq Thermostat circuit wiring checked and verified that no voltage is present as outlined in Section 10.6 on page 70.
qq Operating Instructions were followed during startup.
qq Combustion levels and flame pattern verified as outlined in Section 11.3.5 on page 73.

qq Measured the rate of input on Natural Gas as outlined in Section 11.3.6 on page 74.
qq Test high temperature limit as outlined in Section 11.3.7 on page 74.
qq Checked the incoming gas pressure to the INSTINCT to ensure a minimum pressure of 5"w.c during flow conditions to all gas appliances and a maximum pressure of 13"w.c during non-flow conditions for Natural and Propane.
qq Adjusted balancing valves and system limit controls to provide design temperatures to the primary space heating system.
qq In multiple zone applications, adjusted for correct flow of boiler water to each zone.
qq Checked and verified room thermostat(s) function properly and the thermostat(s) heat anticipator (if used) was properly set.
qq Observed several operating cycles for proper operation of the INSTINCT and the system.
qq Set the room thermostat(s) to the desired room temperature.
qq Reviewed all instructions shipped with the INSTINCT with the homeowner or maintenance personnel.
qq Completed the Installation Record of Chapter 15 on page 81.
qq Ensure all manuals and other documents are returned to the Installation envelope and given to the owner for safekeeping.

CHAPTER 14

79

INTENTIONALLY LEFT BLANK

Chapter 15 - INSTALLATION RECORD
Ensure all manuals and other documents are returned to the Installation envelope and given to the owner for safekeeping.

INSTINCT Model Number:

Serial Number:

Date of Installation:

Fuel:

Natural Gas

Propane

Measured Rate of Input:

Btu/hr =

3600 seconds per 1ft3 gas

x 1000

Combustion Readings: As Operating:

As Installation Manual Table 6:

OK

CO2

%

CO2

O 2

%

O 2

CO

ppm

CO

The following items were completed during installation:

% % ppm

NOT OK

Installation instructions have been followed and completed

Check-out procedures have been followed and completed

Information regarding the unit and installation received and left with owner / maintenance personnel.

If air for combustion is taken from inside the property the customer has been made aware of their obligation to ensure air grilles remain free from obstruction at all times.

Installer Information

(Company)

(Address)

(Address)

(Phone Number)

(Contractor / Installer Name)

Signature

Date

(Customer Name)

Signature

Date

CHAPTER 15

81

INTENTIONALLY LEFT BLANK

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:
General · Attend to any reported problems. · Inspect the interior of the boiler jacket area; clean
and vacuum if necessary. · Clean the condensate drain assembly and fill with
fresh water. · Check boiler fluid pH on systems. · Check for leaks, both inside and outside the unit:
water, gas, flue and condensate. · Verify vent piping and air inlet piping are in good
condition, sealed tight and properly supported. · Check boiler water pressure, piping and expansion
tank. · Check control settings. · Check ignition electrode (sand off any white oxide;
clean and reposition). · Check ignition wiring and ground wiring. · Check all control wiring and connections. · Check burner flame pattern (stable and uniform). · Check carbon monoxide detectors.
Additional items if combustion or performance is poor: · Clean heat exchanger and flue ways. · Remove burner assembly and clean burner head
using compressed air only.
Once the maintenance items are completed, review the service with the owner.

Periodically: · Check the area around the unit. · Check and remove any blockage from the combus-
tion 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. · Check that the condensate drain system goes to
the flloor drain. Every 6 months: · Check boiler piping and gas supply piping for cor-
rosion or potential signs of leakage. · Operate the pressure relief valve.
WARNING
Follow the maintenance procedures given throughout this manual. Failure to perform the service and maintenance or follow the directions in this manual can result in damage to the INSTINCT or system components, resulting in substantial property damage, se-
rious injury, or death.
DANGER
· Where air for combustion is taken directly from inside the property. It is essential this air supply is free from obstruciton. Failure to supply adequate air for combustion may result in serious injury or death.

CHAPTER 16

83

INTENTIONALLY LEFT BLANK

Chapter 17 - MAINTENANCE PROCEDURES

17.1. Service Technician 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. Failure to service and maintain the INSTINCT and the system components can result in equipment failure, resulting in substantial property
damage, serious injury, or death.
NOTICE
The following information provides detailed instructions for completing the service technician maintenance items outlined in the main-
tenance schedule of Chapter 16 on page 83.
17.2. Reported Problems
Any problems reported by the owner should be checked, verified and corrected before proceeding with any maintenance procedures.
17.3. Check Surrounding Area
· Verify that the area surrounding the INSTINCT is free of combustible / flammable materials or flammable vapors or liquids. Remove immediately if found.
· Verify that combustion air inlet area is free of any contaminates. Refer to the materials listed in Section 2.1 on page 5 of this manual. If any of these products are in the area from which the unit takes its combustion air, they must be removed immediately or the combustion air intake must be relocated to another area.
17.4. Inspect Burner Area
· Remove the boiler front jacket panel and venturi inlet elbow.
· Vacuum any dirt or debris from the burner/blower components.
· Check the burner plate mounting nuts for tightness, see Section 17.24 on page 88 for torque specification.
· Check burner plate gasket for discoloration or damage. · Check for flue gas leakage where the condensate
pan connects to the heat exchanger and at the top and bottom of the internal vent pipe.

· Re-install venturi inlet elbow and front jacket panel when completed.
WARNING
Do not use solvents to clean any of the burner components. The components could be damaged, resulting in unreliable or unsafe operation. Failure to comply with this instruction can result in substantial property
damage, serious injury, or death.
17.5. Check System Piping
· Inspect all water and gas piping for leaks and verify that the piping is properly supported.
· Inspect the fittings and components on the unit and verify they are leak free.
WARNING
Eliminate all system water leaks. Continual fresh make-up water will reduce the heat exchanger life causing boiler failure. Leaking water may also cause severe property damage to the surrounding area. Inspect the gas supply piping using the procedure outlined in Section 11.3.4 on page 73. Failure to comply with this instruction can result in substantial
property damage, serious injury, or death.
17.6. Clean Condensate Drain Assembly
NOTICE
For the INSTINCT Combi unit, the front panel needs to be removed to gain access to the con-
densate drain assembly.
· Loosen the retaining nut from the condensate drain assembly and disconnect the assembly from the boiler.
· Empty any water from the trap and flush with fresh water as necessary to clean.
· Remove plastic ball and clean with fresh water. · Check the drain piping from the condensate drain
assembly to the drain. Refer to Section 6.2 on page 38. Flush to clean as necessary. · Install the plastic ball into the condensate drain assembly and reassemble onto the boiler by tightening the retaining nut with rubber seal onto the boiler. Hand tight only. · Remove the fill plug on the condensate drain assembly and fill with water. See Fig. 24 on page 39. · Replace the fill plug on drain assembly.

CHAPTER 17

85

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. Inspect Vent and Combustion Air Piping
· Visually inspect the venting system and combustion air piping for blockage, deterioration of gaskets or leakage. Repair any deficiencies.
· Verify that the combustion air inlet and vent piping is connected, sealed and properly supported.

into the system. This device prevents air from bubbling up through the water as it returns from the system.
· Ensure no automatic air vents are used in the system. This will allow air to escape from the system instead of returning to the tank.
Diaphragm Tank:
· Ensure the system contains a minimum of one automatic air vent. Recommended location of the air vent should be atop an air eliminator.
· Remove the tank from the system and check the charge pressure. For residential applications, the charge pressure is typically 12 psig. If tank does not hold pressure, then the membrane is damaged and the tank should be replaced.

DANGER
Failure to inspect the vent system and combustion air inlet piping and to have any conditions repaired, will result in serious injury, or death.

17.11. Check Boiler Relief Valve
Inspect the relief valve and lift the lever to verify flow at least annually or as recommended on the warning tag of the valve.

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.
· Verify the system pressure, as the unit operates at high temperature, does not exceed 30 psig. Excessive pressure indicates expansion tank sizing is incorrect or system performance problems.
· Inspect air vent and air separators in the system. Ensure vents do not leak, replace any leaking vents.
· Verify boiler fluid pH level is between 6.0 and 8.0. · Check and verify inhibitor /antifreeze concentration
within the boiler water meets inhibitor/antifreeze manufacturer's specifications. · If necessary contact a boiler water treatment company for a chemical analysis.
17.10. Check Expansion Tank
Refer to Chapter 4 on page 15 for recommended location of the expansion tank and air eliminators.
Closed -Type Tank:
· Ensure tank is partially filled with water leaving an air gap as a cushion. Refer to the manufacturer's instruction for proper fill level.
· Ensure the tank is fitted with a device that reduces gravity circulation of air-saturated tank water back

WARNING
Before manually operating the pressure relief valve, ensure the discharge piping is directed to a suitable place of disposal to avoid a potential scald hazard. The discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line. Failure to comply with this instruction can result in substantial property
damage, serious injury, or death.
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.
17.12. Inspection of Ignitor
· Remove the ignitor from the burner mounting plate.
· Remove any white oxides accumulated on the ignitor using fine grit sandpaper or steel wool. If the ignitor does not clean to a satisfactory condition, replace the ignitor.
· When installing the ignitor, ensure the gasket is in good condition and correctly positioned. Replace the gasket if necessary. Tighten ignitor screws in multiple steps, alternating between the screws to ensure proper alignment. See Section 17.24 on page 88 for torque specifications.

CHAPTER 17

86

CHAPTER 17 - MAINTENANCE PROCEDURES

17.13. Check Ignition Cable and Ground Wiring
· 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. Check Control Settings
· Review all boiler settings in the Heating &DHW EZ Setup menus. Adjust settings as necessary, see Section 9.7 on page 56 and Section 9.8 on page 58
· Check any external limit control settings (if used). Adjust settings as necessary.
17.16. Perform Start-up and Checkout Procedures
· Start the unit and perform the start-up procedures as listed in Chapter 11 on page 71.
· Verify the cold water fill pressure is correct and the operating pressure of the boiler is within normal operating range.
· Complete the checkout procedures as outlined in Chapter 14 on page 79.
17.17. Check Burner Flame
· Inspect the flame pattern through the observation port of the heat exchanger.
· If flame pattern is not fully blue and covers the entire burner surface during high fire, shut the unit down and allow it to cool thoroughly before disassembly.
· Close the external manual gas valve on the gas supply line and disconnect the gas piping and gas valve wire harness connector.
· Disconnect the wiring harness connectors from the blower and remove the blower. Remove the blower from the unit.
· Remove the mounting nuts securing the burner plate to the heat exchanger and set aside. Also remove the two screws* securing the burner plate to the back panel at the rear and discard. * These two screws are for transportation purposes only and can be discarded.

· Carefully remove the burner plate assembly from the heat exchanger by lifting the front of the burner plate initially then disengage the plate from rear studs. Ensure that the combustion chamber 2-in-1 insulation is not damaged during removal of burner mounting plate assembly.
· Remove the burner head mounting screws and remove the burner head. Inspect the burner head for deterioration. Use compressed air or a vacuum to clean the burner head.
· Remove the venturi and gas valve assembly from the blower.
· Use a vacuum cleaner or compressed air to clean the interior of the blower assembly. Inspect the blower blades to ensure they are clean and not damaged.
· Re-assemble the venturi and gas valve onto the blower. Ensure the venturi gasket or o-ring is in good condition and positioned correctly. Replace gasket or o-ring if necessary.
· Re-assemble the burner head onto the burner mounting plate. Ensure the burner head gasket is in good condition and positioned correctly. Replace gasket if necessary.
· Re-assemble the burner plate assembly onto the heat exchanger. Ensure the combustion chamber 2-in-1 insulation is in place and positioned correctly. Replace if necessary.
· Remove the blower gasket from the burner plate assembly and clean with fresh water. Reinstall blower gasket onto burner plate assembly with the check valve hinge at the top.
· Re-assemble the blower onto the burner plate and reconnect the wiring harness connectors.
· Re-assemble the gas supply connection and wire harness to the gas valve. Open the external manual gas valve. Check gas piping for any leaks as outlined in Section 10.5 on page 70 and repair if necessary.
· Torque all screws, bolts, and nuts in accordance with specifications in Section 17.24 on page 88.
· Place the unit back into service.
17.18. Check Flame Signal
· The flame signal can be read from the Boiler Information screen. It should be a min. 2-3  at low fire.
· Check the ignitor condition if flame signal is low. · Check ground wire for continuity if flame signal is
low. Replace ignitor if conditions are satisfactory.
87

CHAPTER 17

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 .
· If the flue gas temperature is more than 54°F [30°C] above the supply water temperature, shut the boiler down and follow the heat exchanger cleaning procedure below.
17.21. Clean Heat Exchanger
Shut down the boiler: · Follow the instructions on page 72 "To Turn Off Gas to Appliance" · Do not drain the boiler unless the boiler will be subject to freezing conditions. · Do not drain the boiler if antifreeze is used in the system.
· Allow the boiler to cool down to room temperature before servicing.
· Close the external manual gas valve on the gas supply line and disconnect the gas piping and gas valve wire harness connector.
· Disconnect the wiring harness connectors from the blower and remove the blower clamp. Remove the blower from the unit.
· Remove the mounting nuts securing the burner plate to the heat exchanger and set aside.
· Carefully remove the burner plate assembly from the heat exchanger. Ensure that the combustion chamber 2-in-1 insulation is not damaged during removal of burner mounting plate assembly.
· Use compressed air or water to remove any accumulation from the heat exchanger flue ways.
· Re-assemble the burner plate assembly onto the heat exchanger. Ensure the combustion chamber 2-in-1 insulation is in place and positioned correctly. Replace if necessary.
· Remove the blower gasket from the burner plate assembly and clean with fresh water. Reinstall blower gasket onto burner plate assembly with the check valve hinge at the top.

· Re-assemble the blower onto the burner plate and reconnect the wiring harness connectors.
· Reconnect the gas piping and wire harness to the gas valve. Open the external manual gas valve. Check gas piping for any leaks as outlined in Section 10.5 on page 70 and repair if necessary.
· Torque all screws, bolts, and nuts in accordance with specifications in Section 17.24 on page 88.
· Close isolation valves on the boiler water piping to isolate the boiler from the heating system.
· Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh water by using the purge valves to allow water to enter through the make-up water line to the boiler.
· Once the boiler has been completely flushed, return the boiler back into operation.
· Perform the required startup and checkout procedures as outlined in Chapter 10 on page 67 and Chapter 14 on page 79.
17.22. Check Carbon Monoxide Detectors
Verify that at least two (2) carbon monoxide detectors are installed and operating properly. One must be installed in the mechanical room where the INSTINCT is located and another installed in the living area outside the bedroom(s).
17.23. Review With Owner
Ensure the owner understands the importance of performing the maintenance schedule specified in this manual.

17.24. Torque Specifications Table

Item Burner Plate Nuts Burner Head Bolts Fan Clamp Screw Gas Valve Screws Venturi Screws Ignitor Screws

Torque Req'd (in-lbs)

Min.

Max.

44

53

26.5

31

62

71

31

35

31

35

26.5

31

CHAPTER 17

88

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.

3 2

Fig. 35 - INSTINCT Solo Jacket Components

1

4 5

CHAPTER 18

6

Item
1 2 3 4 5 6

Part #
INSJKT01 INSRKIT92 INSJKT02 INSRKIT90 INSJKT03 INSRKIT91

Description
Front Jacket Panel Control Box Mounting Box Left Side Jacket Panel Wall Mounting Bracket with Hardware Right Side Jacket Panel User Interface Mounting Bracket

89

CHAPTER 18 - REPLACEMENT PARTS
Fig. 36 - INSTINCT Combi Jacket Components
3 4
2 5
1
6

CHAPTER 18

Item 1 2 3 4 5 6
90

Part # INSJKT04 INSRKIT92 INSKT05 INSRKIT90 INSKT06 INSRKIT91

Description Front Jacket Panel Control Box Mounting Bracket Left Side Jacket Panel Wall Mounting Bracket with Hardware Right Side Jacket Panel User Interface Mounting Bracket

CHAPTER 18 - REPLACEMENT PARTS
Fig. 37 - INSTINCT Solo 110 Internal Components
1
7 8
2 3
4 5
6

Item

Part #

1

INSRKIT40

2

INSRKIT01

2

INSRKIT03

3

PTRKIT122

4

PARKIT04

5

PTRKIT122

6

PSRKIT05

7

INSRKIT41

8

PARKIT01

Description
Vent Outlet/Combustion Air Inlet Adapter Heat Exchanger Body (110) Heat Exchanger Body (199) CH Supply Temperature Sensor Low Water Cut Off CH Return Temperature Sensor Condensate Drain Assembly Flue Tube Flue Temperature Sensor

3 4 5 6
91

CHAPTER 18

CHAPTER 18 - REPLACEMENT PARTS
Fig. 38 - INSTINCT Solo 155 Internal Components
1 7
2 8 3 4 5
6 6

CHAPTER 18

Item 1 2 3 4 5 6 7 8

Part # INSRKIT40 INSRKIT02 PTRKIT122 PARKIT04 PTRKIT122 PSRKIT05 INSRKIT41 PARKIT01

92

Description Vent Outlet/Combustion Air Inlet Adapter Heat Exchanger Body CH Supply Temperature Sensor Low Water Cut Off CH Return Temperature Sensor Condensate Drain Assembly Flue Tube Flue Temperature Sensor

CHAPTER 18 - REPLACEMENT PARTS
Fig. 39 - INSTINCT Combi 155 Internal Components
1
7 7
2 9 3
4 5 8

CHAPTER 18

Item
1 2 3 4 5 6 7 8 9

Part #
INSRKIT40 INSRKIT02 PTRKIT122 PARKIT04 PTRKIT122 PSRKIT05 INSRKIT41 PARKIT24 PARKIT01

Description
Vent Outlet/Combustion Air Inlet Adapter Heat Exchanger Body CH Supply Temperature Sensor Low Water Cut Off CH Return Temperature Sensor Condensate Drain Assembly Flue Tube Circulator Flue Temperature Sensor

6
93

CHAPTER 18 - REPLACEMENT PARTS

1

Fig. 40 - INSTINCT Solo 199 Internal Components

7 2

8

3

4 5

CHAPTER 18

6 6

Item
1 2 3 4 5 6 7 8

Part #
INSRKIT40 INSRKIT03 PTRKIT122 PARKIT04 PTRKIT122 PSRKIT05 INSRKIT41 PARKIT01

Description
Vent Outlet/Combustion Air Inlet Adapter Heat Exchanger Body CH Supply Temperature Sensor Low Water Cut Off CH Return Temperature Sensor Condensate Drain Assembly Flue Tube Flue Temperature Sensor

94

CHAPTER 18 - REPLACEMENT PARTS
Fig. 41 - INSTINCT Combi 199 Internal Components
1
7
2 3
9
4 5 8

CHAPTER 18

Item

Part #

1

INSRKIT40

2

INSRKIT03

3

PTRKIT122

4

PARKIT04

5

PTRKIT122

6

PSRKIT05

7

INSRKIT41

8

PARKIT24

9

PARKIT01

6
Description Vent Outlet/Combustion Air Inlet Adapter Heat Exchanger Body CH Supply Temperature Sensor Low Water Cut Off CH Return Temperature Sensor Condensate Drain Assembly Flue Tube Circulator Flue Temperature Sensor

95

CHAPTER 18 - REPLACEMENT PARTS

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.
1

Fig. 42 - INSTINCT Solo 110 Burner Components
12
11 10 3
13

7

9 8

2 4 5 6

Item 1 2 3 3 4 5 6 7 8 9 10 11 12 13
96

Part # INSRKIT04 INSRKIT06 INSRKIT07 INSRKIT08 INSRKIT14 INSRKIT18 INSRKIT24 INSRKIT27 PSRKIT16 INSRKIT30 INSRKIT13 INSRKIT74 INSRKIT75 INSRKIT76

Description Blower Assembly Gas Valve NG - Venturi LP - Venturi Burner Plate Combustion Chamber 2-in-1 Insulation Burner Head Assembly Igniter Assembly Sight Glass Assembly Burner Plate Insulation Venturi Air Inlet Air Inlet Elbow Air Inlet Adapter Venturi Gas Inlet Pipe

CHAPTER 18

CHAPTER 18 - REPLACEMENT PARTS

12 11
10 3

Fig. 43 - INSTINCT Solo/Combi 155 Burner Components

1

13

8

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.

2 5

4
6 6
7

Item

Part #

1

INSRKIT04

2

INSRKIT27

3

INSRKIT31

4

PSRKIT16

5

INSRKIT15

6

INSRKIT19

7

INSRKIT25

8

INSRKIT09

8

INSRKIT10

9

INSRKIT06

10

INSRKIT13

11

INSRKIT74

12

INSRKIT75

13

INSRKIT77

Description Blower Assembly Igniter Assembly Burner Plate Insulation Sight Glass Assembly Burner Plate Combustion Chamber 2-in-1 Insulation Burner Head Assembly NG Venturi LP Venturi Gas Valve Venturi Air Inlet Air Inlet Elbow Air Inlet Adapter Venturi Gas Inlet Pipe

9
97

CHAPTER 18

CHAPTER 18 - REPLACEMENT PARTS
Fig. 44 - INSTINCT Combi 199 Burner Components

1

10 8

12 11

4 6
7

13 9
2
3 5

CHAPTER 18

Item 1 2 3 4 5 6 7 8 8 9 10 11 12 13
98

Part # INSRKIT05 INSRKIT27 INSRKIT32 PSRKIT16 INSRKIT16 INSRKIT20 INSRKIT25 INSRKIT11 INSRKIT12 INSRKIT16 INSRKIT13 INSRKIT74 INSKRIT75 INSRKIT78

Description Blower Assembly Ignitor Assembly Burner Plate Insulation Sight Glass Assembly Burner Plate Combustion two in one Insulation Burner Head Assembly Venturi (NG) Venturi (LP) Gas Valve Venturi Air Inlet Air Inlet Elbow Air Inlet Adaptor Venturi Gas Valve Inlet Pipe

CHAPTER 18 - REPLACEMENT PARTS
Fig. 45 - INSTINCT Control & Display Enclosures
2 1 5
4 3

CHAPTER 18

Item

Part #

1

INSRKIT52

2

PARKIT188

3

INSRKIT53

4

INSRKIT54

5

INSRKIT55

Description Control Module Control Box Hinges Display Module Display Enclosure Control Enclosure

99

CHAPTER 18 - REPLACEMENT PARTS
Fig. 46 - INSTINCT Combi Hydro-block
2

3 5
9
6 4

1 8
7

Item 1 2 3 4 5 5 6 7 8 9
100

Part # INSRKIT60 INSRKIT61 INSRKIT62 INSRKIT58 INSRKIT64 INSRKIT69 INSRKIT65 INSRKIT66 INSRKIT67 PTRKIT122

Description Hydroblock Valve Motor 3 Way Valve Flow Sensor CH Supply Fitting (155) CH Supply Fitting (199) DHW Supply Fitting DHW Inlet Fitting CH Return Fitting Domestic Water Temperature Sensor

CHAPTER 18

INTENTIONALLY LEFT BLANK

Chapter 19 - PRODUCT SPECIFICATIONS

Boiler Model
Instinct 110 Solo Instinct 155 Solo Instinct 199 Solo Instinct 155 combi Instinct 199 combi

Fuel
Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane

DOE Heating Net AHRI Rating

Input (Btu/h)

Capacity (Btu/h)

(Btu/h)

13,750 ­ 110,000 19,375 ­ 155,000 24,875 ­ 199,000 19,375 ­ 155,000 24,875 ­ 199,000

102,000 142,000 184,000 142,000 184,000

89,000 123,000 159,000 123,000 159,000

AFUE
95% 95% 95% 95% 95%

Unpackaged Weight Lbs (Kg)

Shipping Weight Lbs
(Kg)

84 (38)

99 (55)

110 (50)

128 (58)

TBC

TBC

128 (58)

145 (66)

TBC

TBC

NOTICE
· The heating capacity of the INSTINCT Solo 110/155/199 and INSTINCT Combi 155/199 is based on the test requirements of the U.S. Department of Energy.
· The AHRI rating is based on a piping and pick up allowance of 1.15. This allowance should be sufficient for standard radiation requirements.
· Based on the given AFUE the INSTINCT Solo 110/155/199 and INSTINCT Combi 155/199 meet the energy efficiency guidelines established by Energy Star.
· Input and output ratings are shown for sea level applications. The INSTINCT features altitude compensation, altitude of the boiler installation must be inputted via the INSTINCT menu. Failure in selecting the correct altitude may compromise boiler ignition performance and will derate the boiler by 1.7% per 1000ft above sea level.
102

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS
Fig. 47 - Front View INSTINCT Solo 110
A B C

D

E

F

K

H

I

G J

A Boiler Item Width

Dimension inches [mm]

21 5/8 [550]

B

C

D

E

F

3" Vent Outlet

Vent\Com-

3" Com- 3/4" NSPC

bustion Air

bustion Air Relief

Connection

Inlet

Valve

Height

Boiler Height

17 1/2

4

[445.3] [101.6]

2 1/4 [57.2]

5 1/8 [130]

26 [659.5]

G
1" NPT Boiler Supply
4 3/4 [119.5]

H

I

J

K

1" NPT 3/4" Gas Conden- Conden-
Boiler Connection sate Drain sate Height
return

2 1/4 [57.3]

4 3/8

17 1/4

6 3/4

[112.4] [439.5] [171.0]

103

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS
Fig. 48 - Right Side View INSTINCT Solo 110
L M

P

O

N Q R

Items
Dimension inches [mm]

L

M

N

3/4" NPSC 3" Combustion

Pressure Relief Air Inlet & 3" Vent

Valve

Outlet

1" NPT Boiler Return

7 3/4 [196.5]

3 /8 [97.8]

3 1/2 [90.1]

O
Condensate Drain
3 /8 [97.8]

P
1" NPT Boiler Supply
3 1/8 [79.6]

Q
3/4" Gas Connection
11 1/2 [293.4]

R Boiler Depth
16 3/4 [424.9]

104

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS
Fig. 49 - Front View INSTINCT Solo 155
A B C

D

E

F

K

H

G

I

J

Item
Dimension inches [mm]

A
Boiler Width
21 5/8 [550]

B

C

3" Com3" Vent
bustion Air Outlet
Inlet

16

5

[406.8] [125.8]

D

E

F

G

H

I

J

K

Vent\Com3/4" NSPC
bustion Air Relief
Connection Valve
Height

Boiler Height

3/4"

1" NPT Boil-1" NPT Boil-

Conden- Conden-

NPT Gas

er Supply er Return

sate Drain sate Height

Connection

1 5/8 [42.5]

5 1/8 [130]

26 [660]

2 3/4 [69.6]

1 7/8

4 1/4

4 3/4

6 3/4

[47] [107.3] [119.3] [171]

105

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS
Fig. 50 - Right Side View INSTINCT Solo 155
L M

N

O
P Q R

Items
Dimension inches [mm]

L
3/4" Pressure Relief Valve

M
3"Combustion Air Inlet & 3"Vent
Outlet

N
1" NPT Boiler Return

8 5/8 [218.5]

3 1/8 [80.3]

6 1/8 [156.0]

O
Condensate Drain
3 1/8 [80.3]

P

Q

R

1" NPT Boiler

3/4" NPT

Boiler Depth

Supply Gas Connection

6 5/8 [169.0]

11 1/4 [287.2]

16 3/4 [424.9]

106

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS

Fig. 51 - Front View INSTINCT Solo 199
A

C

B

E D

F

G

K

H

I

J

Connection
Dimension inches [mm]

A
Boiler Width
21 5/8 [550]

B

C

D

E

F

G

H

I

J

K

3" Combustion Air
Inlet

3" Vent Outlet

Vent/Combus3/4" NPSC
tion Air AdaptRelief Valve
er Height

Boiler Height

3/4" NPT

Con-

1" NPT Boil-1" NPT Boil-

Conden-

Gas Con-

densate

er Supply er Return nection sate Drain Height

1 3/4

19

1 1/2

[44.5] [481.4] [39]

5 1/8 [130]

26 [659.5]

1 [25.4]

2 5/8 [66.2]

4 1/2

18 3/4 6 3/4

[113.1] [475.5] [171.6]

107

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS
Fig. 52 - Right Side View INSTINCT Solo 199
M L

R P
Q N
O

Items
Dimension inches [mm]

L
3/4" Pressure Relief Valve

M
3"Combustion Air Inlet & 3"Vent
Outlet

N
1" NPT Boiler Return

8 [204.6]

4 1/8 [104.6]

8 5/8 [217.5]

O
Condensate Drain
3 1/2 [89.6]

P

Q

R

1" NPT Boiler

3/4" NPT

Boiler Depth

Supply Gas Connection

6 1/8 [155.1]

10 1/2 [268.2]

16 3/4 [424.9]

108

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS

Fig. 53 - Front View INSTINCT Combi 155
A B C

D

E

F

JG IK L H

Connection
Dimension inches [mm]

A
Boiler Width
21 5/8 [550]

B

C

D

E

F

G

H

I

J

3" Combustion Air
Inlet

3" Vent Outlet

Vent/Combus3/4" NPSC
tion Air AdaptRelief Valve
er Height

Boiler Height

3/4" NPT

1" NPT Boil-1" NPT Boil-

Conden-

Gas Con-

er Supply er Return nection sate Drain

5

16

[125.8] [406.8]

2 1/8 [54.2]

5 1/8 [130]

32 5/8 [828.3]

2 3/4 [69.7]

19 /8 [497.7]

11 [278]

8 3/8 [211.8]

K
DHW Inlet
1 3/4 [44.7]

L
DHW Outlet
16 5/8 [422.7]

109

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS
Fig. 54 - Right Side View INSTINCT Combi 155
M N

P O,Q,T,U
R S

Items

M

N

O

P

Q

R

3" Combustion

3/4" NPT

3/4" Pressure

1" NPT Boiler Condensate 1" NPT Boiler

Air Inlet & 3"

Gas Con-

Relief Valve

Return

Drain

Supply

Vent Outlet

nection

Dimension inches [mm]

8 5/8 [218.5]

3 1/8 [80.3]

8 3/8 [213.4]

3 [73.7]

8 3/8 [213.4]

9 1/2 [240.8]

S

T

U

Boiler

DHW

DHW Inlet

Depth

Outlet

17 1/8 [436.5]

8 3/8 [213.4]

8 3/8 [213.4]

110

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS

Fig. 55 - Front View INSTINCT Combi 199
B A C

D

E

F

I

K

G

J

H L

Connection
Dimension inches [mm]

A
Boiler Width
21 5/8 [550]

B

C

D

E

F

G

H

I

J

3" Combustion Air
Inlet

3" Vent Outlet

Vent/Combus3/4" NPSC
tion Air AdaptRelief Valve
er Height

Boiler Height

3/4" NPT

1" NPT Boil-1" NPT Boil-

Conden-

Gas Con-

er Supply er Return nection sate Drain

3 1/2 [89.5]

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

11 1/8

15

[494.2] [283.7] [383.2]

K
DHW Inlet
5 1/2 [141.2]

L
DHW Outlet
16 5/8 [419.2]

111

CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS
Fig. 56 - Right Side View INSTINCT Combi 199
N
M

P

R

S

O, Q, T, U

Items
Dimension inches [mm]

M

N

O

P

Q

R

3" Combustion

3/4" NPT

3/4" Pressure

1" NPT Boiler Condensate 1" NPT Boiler

Air Inlet & 3"

Gas Con-

Relief Valve

Return

Drain

Supply

Vent Outlet

nection

8 [204.6]

4 1/8 [104.7]

8 4/7 [217.5]

4 1/8 [104.7]

8 4/7 [217.5]

9 [227.8]

S

T

U

Boiler

DHW

DHW Inlet

Depth

Outlet

16 2/3 [423.5]

8 4/7 [217.5]

8 4/7 [217.5]

112

CHAPTER 19

PressPurreessDurroepD(rFot.p (WF.t.C.)W.C.)
CHAPTER 19

CHAPTER 19 - PRODUCT SPECIFICATIONS

PPreressssuurreeDDrrooppIIonns-tiicnSctoSloolo
16 14 12 10
8 6 4 2 0
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
FFlolowwRRaatete(G(GPMM)P)
INonS-TiIcNSCoTloSo1l1o01/1505/1/15959
Graph 1 - INSTINCT Solo - Pressure Loss Through Boiler

Note:

Minimum allowable flow rate at full input: - 5 gpm SOLO 110 - 7gpm SOLO 155 - TBC SOLO 199

113

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