TriangleTube Instinct SOLO 110 Installation & Maintenance Manual
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Installation &
Maintenance
Manual
S O LO 1 10 -155 -199 & COMBI 155 -199
- Customer must register unit within thirty (30)
days of installation in order to gain warranty
coverage. See Warranty Card for details.
• 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.
222169 A01 - July 2019
2019-16
NOTICE
- Leave all documentation received with
appliance with the owner for future
reference.
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.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
T H E
O R I G I N A L
I N N O V A T O R S
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Table of Contents
Related Manuals for TriangleTube Instinct SOLO 110
Summary of Contents for TriangleTube Instinct SOLO 110
- Page 1 Installation & Maintenance Manual S O LO 1 10 -155 -199 & COMBI 155 -199 NOTICE - Customer must register unit within thirty (30) - Leave all documentation received with days of installation in order to gain warranty appliance with the owner for future coverage.
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Page 3: Table Of Contents
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. - Page 4 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.
- Page 5 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.
- Page 6 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.
- Page 7 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.
- Page 8 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.
- Page 9 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 Fig. 37 - INSTINCT Solo 110 Internal Components ................91...
- Page 10 Fig. 39 - INSTINCT Combi 155 Internal Components ................93 Fig. 40 - INSTINCT Combi 199 Internal Components ................94 Fig. 41 - INSTINCT Solo 110 Burner Components ................95 Fig. 42 - INSTINCT Solo/Combi 155 Burner Components ..............96 Fig.
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Page 11: Product And Safety Information
PRODUCT AND SAFETY INFORMATION IMPORTANT SAFETY INFORMATION FOR DANGER THE HOMEOWNER AND THE INSTALLER • Do not use this appliance if any part has been under This manual contains important information with respect to the water. Immediately call a qualified service technician installation, starting up and maintenance of the appliance. - Page 12 • 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.
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Page 13: Chapter 1 - Pre-Installation Requirements
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.1. INSTINCT boilers - Code Compliance • The equipment is permanently labeled to indi- cate that only additives recognized as safe by The INSTINCT units must be installed by a qualified in- the FDA shall be used in the heat transfer me- staller in accordance with the following: dium. -
Page 14: Determining Product Location
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.2. Determining Product Location 1.3. Boiler Freeze Protection Feature The CTRLMax boiler management system has a freeze NOTICE protection feature built in. This feature monitors the boiler water temperature and responds as follows when The INSTINCT is certified for indoor, condi- no call for heat is present: tioned space installations ONLY. -
Page 15: Recommended Clearances
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.5. Recommended Clearances 1.6. Residential Garage Installations The INSTINCT is approved for zero clearance to com- When installing the INSTINCT in a residential garage, bustibles, excluding vent and boiler piping. the following special precautions per NFPA 54/ANSI •... - Page 16 INTENTIONALLY LEFT BLANK...
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Page 17: Chapter 2 - Combustion Air & Venting
CHAPTER 2 - COMBUSTION AIR & VENTING • An in-direct installation uses uncontami- 2.1. Combustion Air Contamination nated indoor air for appliance combustion. • When the air for combustion is taken from the room air grilles must be installed WARNING by the contractor. -
Page 18: Ventilation And Combustion Air Requirements - Direct Vent
CHAPTER 2 - COMBUSTION AIR & VENTING 2.2. Ventilation and Combustion Air Require- 2.3. Ventilation and Combustion Air Require- ments - Direct Vent ments - Category IV A Direct Vent appliance utilizes uncontaminated out- A Category IV appliance utilizes uncontaminated indoor door air piped directly to the appliance for combustion. -
Page 19: Methods Of Accessing Combustion Air Into A Space - Category Iv
CHAPTER 2 - COMBUSTION AIR & VENTING 2.4. Methods of Accessing Combustion Air 2.4.2. Outdoor Combustion Air Into A Space - Category IV BEST PRACTICE 2.4.1. Indoor Combustion Air Isolating the combustion appliance room from the rest of the building and bringing in uncon- NOTICE taminated outside air for combustion and ven- •... -
Page 20: Combination Of Indoor And Outdoor Combustion Air
CHAPTER 2 - COMBUSTION AIR & VENTING • Where communicating with the outdoors is • Two Permanent Opening Method. Two permanent through horizontal ducts, each opening shall have openings, one commencing within 12 in. of the top a minimum free area of not less than 1 sq.in./2000 and one commencing within 12 in. -
Page 21: Removal Of An Existing Boiler From A Common Vent System
CHAPTER 2 - COMBUSTION AIR & VENTING BEST PRACTICE 1. Seal any unused openings in the common venting system. In order to reduce the potential risks associat- 2. Visually inspect the venting system for proper size ed with indoor contaminates (see list in Section and horizontal pitch and determine there is no 2.1 on page 5), flammable vapors and tight blockage or restriction, leakage, corrosion and other... -
Page 22: Carbon Monoxide Detector Installation
CHAPTER 2 - COMBUSTION AIR & VENTING 2.7. Carbon Monoxide Detector Installation a. In the event that the side wall horizontally vent- ed gas fueled equipment is installed in a crawl Triangle Tube requires the installation of a minimum space or an attic, the hard wired carbon mon- of two (2) hard wired carbon monoxide detectors with oxide detector with alarm and battery back-up may be installed on the next adjacent floor lev-... -
Page 23: Manufacturer Requirements - Gas Equipment Venting System Provided
CHAPTER 2 - COMBUSTION AIR & VENTING 2.8.6 Manufacturer Requirements - Gas Equip- 2.8.5 Manufacturer Requirements - Gas Equip- ment Venting System Not Provided. ment Venting System Provided. When the manufacturer of Product Approved side wall When the manufacturer of a Product Approved side horizontally vented gas equipment provides a venting wall horizontally vented gas fueled equipment does system design or venting system components with the... - Page 24 INTENTIONALLY LEFT BLANK...
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Page 25: Chapter 3 - Unit Preparations
2. Slide the cardboard sleeve from the unit. porting at minimum: 3. Remove the wall mounting template. • 101 pounds [46 kg] for the INSTINCT Solo 110 4. Remove the accessory boxes. • 137 pounds [62 kg] for the INSTINCT Solo 155 5. -
Page 26: Wall Mounting Guidelines
CHAPTER 3 - UNIT PREPARATIONS 3.4. Wall Mounting Guidelines 3.5. Stud Walls - Installation 1. Locate the studs in the general area of the boiler The wall-mounting bracket is designed for stud spacing installation. of approximate 12 inch or 16 inch on centers. For un- 2. -
Page 27: Chapter 4 - Boiler Piping
CHAPTER 4 - BOILER PIPING 4.1. General Piping Requirements 4.2. Pressure Relief Valve 1. The INSTINCT is supplied with a 30 psi pressure re- • All plumbing must meet or exceed all local, state lief valve and must be piped using the PRV connec- and national plumbing codes. -
Page 28: Boiler Air Vent
CHAPTER 4 - BOILER PIPING 4.4. Low Water Cutoff Device 4.3. Boiler Air Vent • The INSTINCT is equipped with a factory installed NOTICE pressure sensor type Low Water Cut Off (LWCO). This boiler is supplied with a special automat- •... -
Page 29: Additional Limit Control
CHAPTER 4 - BOILER PIPING 4.6. Backflow Preventer 4.5. Additional Limit Control • Use a backflow preventer valve in the make-up wa- If a separate Low Water Cut Off (LWCO) is required by ter supply to the unit as required by local codes. the local jurisdiction or when the boiler is installed above the system piping, the following guidelines 4.7. -
Page 30: Expansion Tank And Makeup Water
Always install an automatic air vent on top of the air er volume: separator to remove residual air from the system. • 2 gallons [8 L] for the INSTINCT Solo 110 4.7.3 Closed-Type Expansion Tank • 3 gallons [12 L] for the INSTINCT Solo 155 •... -
Page 31: Sizing Primary Piping
INSTINCT Solo, the boiler supply and return pip- ing size must be a minimum of 1 inch for the The boiler water supply temperature can be maintained INSTINCT Solo 110, 1-1/4 inch for the INSTINCT by the INSTINCT Solo, potentially eliminating the need for Solo 155/199. -
Page 32: Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 Ch Pump And 1 Dhw Pump (Manual Pump Configuraiton)
CHAPTER 4 - BOILER PIPING Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump (Manual Pump Configuraiton) -
Page 33: System Piping - Special Application
CHAPTER 4 - BOILER PIPING 4.7.11 System Piping – Special Application 4.8. INSTINCT Combi Boiler System Piping If the boiler is used in conjunction with a chilled water/ BEST PRACTICE medium system, the boiler and chiller must be piped in parallel. -
Page 34: Expansion Tank And Makeup Water
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 boil- The INSTINCT Combi is supplied with a Boiler circulator er volume: that provides circulation for central/space heating(CH) •... -
Page 35: System Piping - Through Boiler
CHAPTER 4 - BOILER PIPING 4.8.7 System Piping – Through Boiler NOTICE Primary / secondary piping is preferred, but is not re- To ensure an adequate flow rate through the quired for smaller systems (1 to 3 zones) provided that INSTINCT Combi, the boiler supply and return at least the minimum flow rate through the boiler is piping size must be a minimum of 1-1/4 inch... -
Page 36: Fig. 12 - Instinct Combi System Piping - Zoning W Valves
CHAPTER 4 - BOILER PIPING PRESET PUMP CONFIGURATION INSTINCT COMBI Heat Call DHW Pump CH Pump Flame NOTICE • Consult the INSTINCT CTRLMax Control Supplement for information on setting the required Preset Pump Configuration. External Limit Low Voltage Terminals Line Voltage Terminals External Limit Terminals Low Voltage Terminals... -
Page 37: Fig. 13 - Instinct Combi - System Piping - Multi Zone Valve - Single Circulator
CHAPTER 4 - BOILER PIPING PRESET PUMP CONFIGURATION INSTINCT COMBI Heat Call DHW Pump CH Pump Flame NOTICE Consult the INSTINCT CTRLMax Control Supplement for information on setting the re- quired Preset Pump Configuration. External Limit Low Voltage Terminals Line Voltage Terminals External Limit Low Voltage Terminals Terminals... -
Page 38: Fig. 14 - Instinct Combi - System Piping - Single Zone With Single Circulator
CHAPTER 4 - BOILER PIPING PRESET PUMP CONFIGURATION INSTINCT COMBI Heat Call DHW Pump CH Pump Flame NOTICE Consult the INSTINCT CTRLMax Control Supplement for information on setting the re- quired Preset Pump Configuration. External Limit Line Voltage Terminals Line Voltage Terminals Low Voltage Terminals External Limit Low Voltage Terminals... -
Page 39: Chapter 5 - Instinct Combi Units - Domestic Piping
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.1. Domestic Piping Pressure Relief Valve 5.1.2 Pressure Relief Valve - Standard Installa- tions CAUTION The domestic water heater (if utilized) shall have a To reduce risk of excessive pressures and field supplied pressure relief valve installed within 6”... -
Page 40: Pressure Relief Valve Discharge Piping
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.1.3 Pressure Relief Valve Discharge Piping 5.2. Thermal Expansion If a backflow preventer, check valve or pressure reduc- Pressure relief valve discharge piping must be: ing valve is piped on cold water supply piping of water •... -
Page 41: Water Hammer
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.3. Water Hammer 5.4. Vacuum Breaker Dishwashers, clothes washers and fast-closing positive Installing a vacuum breaker on the domestic cold wa- shut-off valves incorporated in the system all contrib- ter inlet will prevent damage to the domestic circuit if a negative pressure is developed in the domestic sup- ute to creating water shock. -
Page 42: General Piping
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.6. General Piping 5.8. Storage Tank Installation • For domestic water piping diagrams, see Fig. 17 on For applications requiring high domestic hot water flow rates for a short period of time (dump load), the install- page 31. -
Page 43: Fig. 17 - Instinct Combi System Piping - Single Zone System With Single System/Boiler Circulator
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING PRESET PUMP CONFIGURATION 5 - INSTINCT COMBI UNITS Heat Call Flame CH Pump DHW Pump NOTICE Consult the INSTINCT CTRLMax Control Supplement for information on setting the re- quired Preset Pump Configuration. Line Voltage Terminals Line Voltage Terminals External Limit... -
Page 44: Fig. 18 - Instinct Combi System Piping - Domestic Piping - Storage Tank Installation
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING PRESET PUMP CONFIGURATION 5 - INSTINCT COMBI UNITS Heat Call Flame CH Pump DHW Pump NOTICE Consult the INSTINCT CTRLMax Control Supplement for information on setting the re- quired Preset Pump Configuration. External Limit External Limit Low Voltage Terminals... -
Page 45: Fig. 19 - Multiple Zones - Panel Wiring With Circulators
TITLE CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING External Limit External Limit Line Voltage Terminals Low Voltage Terminals Low Voltage Terminals Line Voltage Terminals Terminals Terminals Manual Auto Manual Auto System Modulation Outdoor Modbus Thermostat Sensor Signal Thermostat Sensor Sensor or Thermosta... -
Page 46: Fig. 20 - Instinct Combi System Piping - Multiple Zones - Panel Wiring With Valves
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING External Limit Low Voltage Terminals External Limit Line Voltage Terminals Low Voltage Terminals Line Voltage Terminals Terminals Terminals Manual Auto Manual Auto System Modulation Outdoor Modbus Thermostat Sensor Signal Thermostat Sensor Sensor or Thermosta Aquastat... -
Page 47: Fig. 21 - Instinct Solo System Piping - Multi Zone System With Single System/Boiler Circulator
CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING Low Voltage Terminals External Limit External Limit Line Voltage Terminals Low Voltage Terminals Line Voltage Terminals Terminals Terminals Manual Auto Manual Auto System Modulation Outdoor Modbus Thermostat Sensor Signal Thermostat Sensor Sensor or Thermosta Aquastat... -
Page 48: Fig. 22 - Instinct Solo System Piping - Indirect Water Heater Installation
TITLE CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING External Limit Low Voltage Terminals Line Voltage Terminals External Limit Terminals Low Voltage Terminals Line Voltage Terminals Terminals Manual Auto Manual Auto System Modulation Outdoor Modbus Thermostat Sensor Signal Thermostat Sensor Sensor or Thermosta... -
Page 49: Fig. 23 - Instinct Solo - Cascade Piping
CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING TITLE NOTICE Cascading is only available on Solo Boilers. System Supply System Return 12" Max. Fig. 23 - Instinct Solo - Cascade Piping... -
Page 50: Chapter 6 - Installing Vent/Combustion Air & Condensate Drain
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN 6.1. Installing Vent and Combustion Air 2. Install the condensate drain assembly on the boiler condensate drain by pushing the condensate drain assembly up until it stops. DANGER 3. Tighten the condensate drain assembly retaining nut. The INSTINCT must be vented and supplied with combustion air as shown in the INSTINCT WARNING... -
Page 51: Fig. 24 - Condensate Drain Assembly
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN 8. Route the tube from the condensate drain assem- WARNING bly to a floor drain or condensate pump. The condensate drain assembly must remain filled with water. Extended periods of non NOTICE use or high temperature operation may allow the water to evaporate. -
Page 52: Chapter 7 - Gas Piping
CHAPTER 7 - GAS PIPING 7.1. Gas Supply Piping Connection NOTICE The gas supply piping must be installed in ac- cordance to all applicable local, state, national codes, and utility requirements. Gas Flow 1. Install a 3/4” NPT for INSTINCT pipe union at the gas nipple, for ease of service. -
Page 53: Natural Gas
CHAPTER 7 - GAS PIPING 7.2. Natural Gas 2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c at any time. Adjust the lockup pressure regulator 7.2.1 Pipe Sizing for 13”w.c maximum. Refer to Table 2 below for schedule 40 metallic pipe length and diameter requirements for natural gas, WARNING... -
Page 54: Propane Gas
CHAPTER 7 - GAS PIPING 7.3.2 Supply Pressure Requirements 7.3. Propane Gas 1. Adjust the propane supply regulator provided by 7.3.1 Pipe Sizing the gas supplier for 13”w.c. maximum pressure 2. Pressure required at the gas valve inlet supply pres- sure port: WARNING •... -
Page 55: Fig. 26 - Gas Valve / Venturi Assembly - Instinct Solo110
CHAPTER 7 - GAS PIPING Venturi Venturi interface Pipe to Venturi Air Inlet Gas Valve Air reference Hose Fig. 26 - Gas Valve / Venturi Assembly - INSTINCT Solo110 Air reference Hose Pipe to Venturi Gas Valve Air Inlet Venturi interface Venturi Fig. -
Page 56: Fig. 28 - Gas Valve / Venturi Assembly - Instinct Solo/Combi 199
CHAPTER 7 - GAS PIPING Fig. 28 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 199... -
Page 57: Chapter 8 - Wiring
CHAPTER 8 - WIRING 8.1.2 Fuse Locations 8.1. Internal Wiring • The CTRLMax control module contains 3 internal WARNING replaceable 5A fuses as shown in Fig. 29 below. ELECTRICAL SHOCK HAZARD. For your safe- • The top two fuses protect the INSTINCT as well as ty, disconnect electrical power supply to the the CH, DHW, and Flame outputs. -
Page 58: Fig. 30 - Instinct Solo Boiler Factory Wiring
CHAPTER 8 - WIRING Instinct Solo Wiring Diagram Spark Generator Spark Generator Blower Blower Gas Valve Ignitor Gas Valve Ignitor W = White BK = Black R = Red G= Green O = Orange Y = Yellow BL = Blue Flue Flue Return... -
Page 59: Fig. 31 - Instinct Combi Boiler Factory Wiring
CHAPTER 8 - WIRING Instinct Combi Wiring Diagram Spark Generator Spark Generator Blower Blower W = White BK = Black Ignitor Gas Valve Gas Valve Ignitor R = Red G= Green O = Orange Y = Yellow BL = Blue Diverter Diverter Valve... -
Page 60: External Wiring
CHAPTER 8 - WIRING 8.2. External Wiring NOTICE 8.2.1 General Requirements If local electrical codes require an additional service All field wiring must comply with: switch, the installer must provide and install a fused • National Electrical Code (ANSI/NFPA 70) for installa- disconnect or minimum 15 amp service switch. -
Page 61: Low Voltage Connections
CHAPTER 8 - WIRING 8.3.2 Low Voltage Connections 8.3.4 Outdoor Sensor Wiring Line and Low Voltage wiring should be separated to The Outdoor Reset function and Warm Weather Shut- prevent possible electrical noise on the low voltage down (WWSD) features require the connection of the circuits. -
Page 62: External Modulation Control
CHAPTER 8 - WIRING 1. Remove the factory-installed brown jumper wire at 8.3.9 Cascade Wiring - Optional the Manual Reset Limit terminals that will accept The CTRLMax control includes the ability to operate up the additional boiler limit. to six Solo boilers together as one without the need for 2. -
Page 63: Chapter 9 - Ctrlmax Operation
CHAPTER 9 - CTRLMAX OPERATION 9.1. CTRLMax Navigation The CTRLMax Boiler Management System is designed to be flexible yet easy to use. CTRLMax monitors and The CTRLMax navigation is performed through soft keys controls the INSTINCT to provide heat as efficiently as that react to the touch and emit a short beep when tapped. -
Page 64: Ctrlmax Menu Structure
CHAPTER 9 - CTRLMAX OPERATION The menu system utilizes icons to represent each se- The Home Screen icon at the bottom of each screen returns to the Home Screen when selected. The Previ- lection. The current selected menu is displayed as a re- ous Screen icon at the bottom of each screen re- versed image with a text description shown at the top... -
Page 65: Home Screen
CHAPTER 9 - CTRLMAX OPERATION Main Icons of CTRLMax display 9.3. Home Screen • Central Heating - indicates information related The Home Screen presents status information in a very to central/space heating. user friendly way so that the current state of the boiler •... -
Page 66: Status Line Messages
CHAPTER 9 - CTRLMAX OPERATION 9.4. Status Line Messages DHW Setpoint Reached - The burner is not fired be- cause the supply/system water temperature exceeds the Standby - Indicates that the INSTINCT is ready to re- setpoint. The domestic circulator(s) continue(s) to oper- spond when a demand is received. -
Page 67: Main Menu
CHAPTER 9 - CTRLMAX OPERATION 9.6. EZ Setup 9.5. Main Menu The EZ Setup menus provide a simple way to quick- The Main Menu can be entered from the Home Screen ly customize CTRLMax for each installation. EZ Setup by touching the soft key. -
Page 68: Heating Ez Setup
CHAPTER 9 - CTRLMAX OPERATION 9.7. Heating EZ Setup Heating EZ Setup allows the installer to quickly customize the central heating settings for the application. 9.7.1 Select CH Demand (No outdoor sensor connected) EZ Setup Select CH Demand prompts the installer to select how a CH De- Heating EZ Setup mand is generated. -
Page 69: Select Ch Demand (Outdoor Sensor Connected)
CHAPTER 9 - CTRLMAX OPERATION 9.7.2 Select CH Demand (Outdoor sensor connected) Select CH Demand prompts the installer to select how a CH Demand is generated. EZ Setup Thermostat & Outd. Curve – A central heating call from a thermostat or zone panel will Heating EZ Setup enable the INSTINCT and the setpoint will vary with the outdoor temperature for central heating calls. -
Page 70: Domestic Hot Water Ez Setup
CHAPTER 9 - CTRLMAX OPERATION 9.8. Domestic Hot Water EZ Setup - INSTINCT Solo Units Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application EZ Setup Select DHW Demand prompts the installer to select how a DHW Demand is generated. -
Page 71: Domestic Hot Water Ez Setup - Instinct Combi Units
CHAPTER 9 - CTRLMAX OPERATION 9.9. Domestic Hot Water EZ Setup - INSTINCT Combi Units Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application DHW EZ Setup prompts the installer to select the DHW setpoint. EZ Setup DHW Setpoint prompts to enter the fixed setpoint temperature during a domestic hot water call. -
Page 72: Ez Setup Reset
CHAPTER 9 - CTRLMAX OPERATION 9.11. EZ Setup Reset EZ Setup Reset allows reset of all EZ Setup settings back to the orig- EZ Setup inal factory defaults. See Chapter 13 on page 77 for the list of set- tings reset by this function. Follow the on-screen instructions to reset all EZ Setup settings. -
Page 73: Ch/Dhw Operation
CHAPTER 9 - CTRLMAX OPERATION 9.13. CH/DHW Operation CH / DHW Operation CH/DHW Operation provides a simple way to enable/disable either the CH or the DHW function of the INSTINCT. Touch the soft keys to select the CH or DHW icon, then touch to toggle between the enabled/disabled status. -
Page 74: Information Items
CHAPTER 9 - CTRLMAX OPERATION 9.14.1 Information Items Information Item Description Displays the current operating state of the INSTINCT. This is the same as the sta- Boiler Status tus line on the home screen. Heating Call Displays if a central heating call is present. DHW Call Displays if a domestic hot water call is present. -
Page 75: Lockout Screen
CHAPTER 9 - CTRLMAX OPERATION Lockout History records the last eight lockouts. Six lines are dis- Boiler Information played on the Lockout History screen at one time. Each line contains a lockout description followed by how long ago the lockout occurred. Lockout History Touch the soft keys to scroll through the items then touch... -
Page 76: Manual Reset Lockouts
CHAPTER 9 - CTRLMAX OPERATION 9.14.3 Manual Reset Lockouts Code Lockout Message Description Failed Ignition The burner failed to light after 5 ignition attempts. False Flame Flame detected prior to ignition. High Boiler Temperature Boiler temperature has reached 210°F [99ºC] or 102°F [39°C]. Blower Speed Blower is not at correct speed or speed signal is not being received by control module. -
Page 77: Automatic Reset Blocking Lockouts
CHAPTER 9 - CTRLMAX OPERATION 9.14.4 Automatic Reset Blocking Lockouts Code Lockout Message Description High Flue Temperature Flue temperature exceeds high limit. Internal Control Fault EEPROM misconfiguration. Internal Control Fault CRC check error. DHW Sensor Shorted A short circuit has been detected in the DHW temperature sensor circuit. DHW Sensor Open An open circuit has been detected in the DHW temperature sensor circuit. - Page 78 INTENTIONALLY LEFT BLANK...
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Page 79: Chapter 10 - Start-Up Preparation
CHAPTER 10 - START-UP PREPARATION 10.1. Boiler System Fluid Requirements 10.1.3 Chlorinated Water Do not use the INSTINCT to heat a swimming pool or spa directly. NOTICE Requirements below must be met for warranty Maintain the chlorine level of the water at levels consid- coverage of INSTINCT heat exchangers. -
Page 80: Check And Test Antifreeze
The water volume of the INSTINCT is approximately: cal codes require certain water tempera- tures at hot water faucets, take special 2 gallons [8 L] for INSTINCT Solo 110 precautions. 3 gallons [12 L] for INSTINCT Solo/Combi 155 and INSTINCT Solo 199 Ū... -
Page 81: Filling The Boiler System
CHAPTER 10 - START-UP PREPARATION 10.2. Filling the Boiler System General Notes • Household water usage patterns will affect water 1. Close the boiler drain valve located on the bottom temperature at any faucet or shower. Occasionally of the unit and any manual or automatic air vents check temperature at each point of use, then adjust in the system. -
Page 82: Check For Gas Leaks
CHAPTER 10 - START-UP PREPARATION 10.5. Check For Gas Leaks • There should NEVER be voltage measured at the wire ends. • If voltage is measured under any condition, check WARNING and correct the external wiring. • Prior to start-up and during initial oper- NOTICE ation, check for a gas leak using a com- bustable gas detector. -
Page 83: Chapter 11 - Start-Up Procedures
CHAPTER 11 - START-UP PROCEDURES 11.1. Final Checks Before Start-Up 4. Is an external limit (if applicable) open? Ensure the external limit is reset to the closed position. Ø Read Chapter 9 on page 51 regarding the oper- 5. Are the gas supply valves open at the unit and me- ation of the CTRLMax Boiler Management System. - Page 84 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 C.
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Page 85: Check Gas Piping
CHAPTER 11 - START-UP PROCEDURES 11.3.4 Check Gas Piping d. Touch the soft key while the FAN icon is Check around the unit for gas odor following the proce- highlighted to manually fire the burner and dure outlined in this manual on page 64. power the CH circulator(s). -
Page 86: Measure Input - Natural Gas Only
CHAPTER 11 - START-UP PROCEDURES Table 5 - Throttle Screw Adjustment 3. Touch the soft key while CH & DHW Settings Direction INSTINCT Solo/Combi icon is highlighted. Decrease CO 2 Clockwise 4. Touch the soft key to highlight the Boiler Set- Increase O 2 Increase CO 2 tings icon... -
Page 87: Chapter 12 - Outdoor Reset Control
CHAPTER 12 - OUTDOOR RESET CONTROL 12.2. Wiring the Sensor The use of the outdoor reset function is required to op- timize boiler efficiency, see notice below. If the outdoor 1. Connect 18 AWG 2-wire cable or similar to the out- sensor is not installed before turning on the INSTINCT, door sensor. - Page 88 INTENTIONALLY LEFT BLANK...
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Page 89: Chapter 13 - External Modulating Control
CHAPTER 13 - EXTERNAL MODULATING CONTROL 13.2. CTRLMax Programming The INSTINCT can directly accept an analog 0-10 VDC signal from an external modulating boiler The CTRLMax control module must be programmed to controller to control the firing rate. accept the 0-10 VDC signal from the external modulat- ing boiler control. - Page 90 CHAPTER 13 - EXTERNAL MODULATING CONTROL CTRLMax Factory Settings (cont’d) FACTORY MINIMUM MAXIMUM DEFAULT HEATING SETTING EZ SETUP RESET INSTALLER RESET SETTING SETTING INSTINCT Solo INSTINCT Combi DHW Operation Enabled Enabled ✓ Demand Type Thermostat Thermostat DHW Boiler Setpoint 168°F [75°C] 168°F [75°C] 96°F [35°C] 188°F [87°C]...
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Page 91: Chapter 14 - Check-Out Procedures
CHAPTER 14 - CHECK-OUT PROCEDURES q Measured the rate of input on Natural Gas as out- lined in Section 11.3.6 on page 74. NOTICE q Test high temperature limit as outlined in Section Perform the following check-out procedures 11.3.7 on page 74. as outlined and check off items as complet- q Checked the incoming gas pressure to the IN- ed. - Page 92 INTENTIONALLY LEFT BLANK...
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Page 93: Chapter 15 - Installation Record
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: 3600 Btu/hr = x 1000... - Page 94 INTENTIONALLY LEFT BLANK...
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Page 95: Chapter 16 - Maintenance Schedules
CHAPTER 16 - MAINTENANCE SCHEDULES 16.1. Service Technician 16.2. Owner Maintenance At least on an annual basis the following maintenance Periodically: should be performed by a qualified service technician: • Check the area around the unit. General • Check and remove any blockage from the combus- tion air inlet and ventilation openings. - Page 96 INTENTIONALLY LEFT BLANK...
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Page 97: Chapter 17 - Maintenance Procedures
CHAPTER 17 - MAINTENANCE PROCEDURES 17.1. Service Technician Maintenance Procedures • Re-install venturi inlet elbow and front jacket panel when completed. WARNING WARNING The INSTINCT must be inspected and serviced Do not use solvents to clean any of the burn- annually, preferably at the start of the heating er components. -
Page 98: Check Ventilation Air Openings
CHAPTER 17 - MAINTENANCE PROCEDURES 17.7. Check Ventilation Air Openings into the system. This device prevents air from bub- bling up through the water as it returns from the • Verify that all ventilation openings to the mechan- system. ical room or building are open and unobstructed. •... -
Page 99: Check Ignition Cable And Ground Wiring
CHAPTER 17 - MAINTENANCE PROCEDURES 17.13. Check Ignition Cable and Ground Wiring • Carefully remove the burner plate assembly from the heat exchanger. Ensure that the combustion • Inspect the ignition cable from the spark generator chamber 2-in-1 insulation is not damaged during to the ignitor. -
Page 100: Check Combustion Levels
CHAPTER 17 - MAINTENANCE PROCEDURES 17.19. Check Combustion Levels • Re-assemble the blower onto the burner plate and reconnect the wiring harness connectors. Refer to Section 11.3.5 on page 73 for measuring • Reconnect the gas piping and wire harness to the combustion levels and burner adjustments. -
Page 101: Chapter 18 - Replacement Parts
Use only genuine Triangle Tube replacement parts to ensure warranty coverage and to avoid improper operation or damage to appliance. • Contact Triangle Tube at 856-228-8881 or www.triangletube.com for a list of distributors near you. Fig. 35 - INSTINCT Solo Jacket Components... -
Page 102: Fig. 36 - Instinct Combi Jacket Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 36 - INSTINCT Combi Jacket Components Item Part # Description INSJKT04 Front Jacket Panel INSRKIT92 Control Box Mounting Bracket INSKT05 Left Side Jacket Panel INSRKIT90 Wall Mounting Bracket with Hardware INSKT06 Right Side Jacket Panel INSRKIT91 User Interface Mounting Bracket... -
Page 103: Fig. 37 - Instinct Solo 110 Internal Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 37 - INSTINCT Solo 110 Internal Components Item Part # Description INSRKIT40 Vent Outlet/Combustion Air Inlet Adapter INSRKIT01 Heat Exchanger Body (110) INSRKIT03 Heat Exchanger Body (199) PTRKIT122 CH Supply Temperature Sensor PARKIT04 Low Water Cut Off... -
Page 104: Fig. 38 - Instinct Solo 155 Internal Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 38 - INSTINCT Solo 155 Internal Components Item Part # Description INSRKIT40 Vent Outlet/Combustion Air Inlet Adapter INSRKIT02 Heat Exchanger Body PTRKIT122 CH Supply Temperature Sensor PARKIT04 Low Water Cut Off PTRKIT122 CH Return Temperature Sensor PARKIT05 Condensate Drain Assembly INSRKIT41... -
Page 105: Fig. 39 - Instinct Combi 155 Internal Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 39 - INSTINCT Combi 155 Internal Components Item Part # Description INSRKIT40 Vent Outlet/Combustion Air Inlet Adapter INSRKIT02 Heat Exchanger Body PTRKIT122 CH Supply Temperature Sensor PARKIT04 Low Water Cut Off PTRKIT122 CH Return Temperature Sensor PARKIT05 Condensate Drain Assembly INSRKIT41... -
Page 106: Fig. 40 - Instinct Combi 199 Internal Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 40 - INSTINCT Combi 199 Internal Components Item Part # Description... -
Page 107: Fig. 41 - Instinct Solo 110 Burner Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 41 - INSTINCT Solo 110 Burner Components It is essential to ensure during installation, main- tenance 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. -
Page 108: Fig. 42 - Instinct Solo/Combi 155 Burner Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 42 - INSTINCT Solo/Combi 155 Burner Components It is essential to ensure during installation, main- tenance 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. -
Page 109: Fig. 43 - Instinct Combi 199 Burner Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 43 - INSTINCT Combi 199 Burner Components Item Part # Description... -
Page 110: Fig. 44 - Instinct Control & Display Enclosures
CHAPTER 18 - REPLACEMENT PARTS Fig. 44 - INSTINCT Control & Display Enclosures Item Part # Description PARKIT102 Control Module PARKIT188 Control Box Hinges PARKIT101 Display Module INSRKIT50 Display Enclosure INSRKIT51 Control Enclosure... -
Page 111: Fig. 45 - Instinct Combi Hydro-Block
CHAPTER 18 - REPLACEMENT PARTS Fig. 45 - INSTINCT Combi Hydro-block Item Part # Description INSRKIT60 Hydroblock INSRKIT61 Valve Motor INSRKIT62 3 Way Valve PTRKIT122 Flow Sensor INSRKIT64 CH Supply Fitting DHW Supply Fitting INSRKIT65 DHW Inlet Fitting INSRKIT66 CH Return Fitting INSRKIT67 Domestic Water Temperature Sensor PTRKIT122... - Page 112 INTENTIONALLY LEFT BLANK...
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Page 113: Chapter 19 - Product Specifications
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. •... -
Page 114: Fig. 46 - Front View Instinct Solo 110
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 46 - Front View INSTINCT Solo 110 Vent\Com- 3" Com- 3/4" NSPC 1" NPT 1" NPT Boiler 3" Vent bustion Air Boiler 3/4" Gas Conden- Conden- Item bustion Air Relief Boiler Boiler Width Outlet... -
Page 115: Fig. 47 - Right Side View Instinct Solo 110
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 47 - Right Side View INSTINCT Solo 110 3/4" NPSC 3" Combustion 1" NPT Boiler Condensate 1" NPT Boiler 3/4" Gas Items Pressure Relief Air Inlet & 3" Vent Boiler Depth Return Drain Supply... -
Page 116: Fig. 48 - Front View Instinct Solo 155
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 48 - Front View INSTINCT Solo 155 Vent\Com- 3" Com- 3/4" NSPC 3/4" Boiler 3" Vent bustion Air Boiler 1" NPT Boil- 1" NPT Boil- Conden- Conden- Item bustion Air Relief NPT Gas Width Outlet Connection Height... -
Page 117: Fig. 49 - Right Side View Instinct Solo 155
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 49 - Right Side View INSTINCT Solo 155 3"Combustion 3/4" Pressure 1" NPT Boiler Condensate 1" NPT Boiler 3/4" NPT Items Air Inlet & 3"Vent Boiler Depth Relief Valve Return Drain Supply Gas Connection Outlet Dimension 8 5/8... -
Page 118: Fig. 50 - Front View Instinct Solo 199
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 50 - Front View INSTINCT Solo 199... -
Page 119: Fig. 51 - Right Side View Instinct Solo 199
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 51 - Right Side View INSTINCT Solo 199... -
Page 120: Fig. 52 - Front View Instinct Combi 155
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 52 - Front View INSTINCT Combi 155 Vent/Combus- 3” Com- 3/4" NPT Boiler 3” Vent 3/4” NPSC Boiler 1" NPT Boil- 1" NPT Boil- Conden- Connection bustion Air tion Air Adapt- Gas Con- Width Outlet Relief Valve Height... -
Page 121: Fig. 53 - Right Side View Instinct Combi 155
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 53 - Right Side View INSTINCT Combi 155 O,Q,T,U 3" Combustion 3/4" NPT 3/4" Pressure 1" NPT Boiler Condensate 1" NPT Boiler Boiler Items Air Inlet & 3" Gas Con- DHW Inlet Relief Valve Return Drain Supply... -
Page 122: Fig. 54 - Front View Instinct Combi 199
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 54 - Front View INSTINCT Combi 199... -
Page 123: Fig. 55 - Right Side View Instinct Combi 199
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 55 - Right Side View INSTINCT Combi 199... -
Page 124: Graph 1 - Instinct Solo - Pressure Loss Through Boiler
Pressure Drop Ion-ic Solo Flow Rate (GMP) Flow Rate (GPM) Ion-ic Solo 110/155/199 INSTINCT Solo 110/155 Graph 1 - INSTINCT Solo - Pressure Loss Through Boiler Note: Minimum allowable flow rate at full input: - 5 gpm SOLO 110 - 7gpm SOLO 155... - Page 128 Computerized sizing available from Triangle Tube • Available in capacities from 25,000 BTU/hr to 5,000,000 BTU/hr Triangle Tube - 1240 Forest Parkway, Suite 100, West Deptford NJ 08066 Tel: (856) 228 8881 - Fax: (856) 228 3584 - E-mail: info@triangletube.com...
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