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Installation &
Maintenance
Manual
SO LO 110-155-1 9 9 & CO MB I 1 55 -19 9
- 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.
226979 A01 - February 2021
2021-01
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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Summary of Contents for TriangleTube Instinct FSB SOLO 110
- Page 1 Installation & Maintenance Manual SO LO 110-155-1 9 9 & CO MB I 1 55 -19 9 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 CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING........29 5.1. Domestic Piping Pressure Relief Valve ..................29 5.1.1 Standard Installation ......................29 5.1.2 Pressure Relief Valve - Standard Installations ..............29 5.1.3 Pressure Relief Valve Discharge Piping ................30 5.2.
- Page 6 TABLE OF CONTENTS 8.3. External Wiring - INSTINCT Solo Units ..................46 8.3.1 Circulator Wiring ......................... 46 8.3.2 Electrical Socket Connection .................... 46 8.3.3 Low Voltage Connections ....................47 8.3.4 Thermostat Wiring ......................47 8.3.5 Outdoor Sensor Wiring .......................47 8.3.6 Domestic Hot Water Wiring ....................47 8.3.7 Additional Boiler Limits .......................47 8.3.8 External Modulation Control .....................
- Page 7 TABLE OF CONTENTS CHAPTER 10 - START-UP PREPARATION ................65 10.1. Boiler System Fluid Requirements ..................... 65 10.1.1 Boiler Fluid pH Level 6.0 to 8.0 ..................65 10.1.2 Boiler Fluid Hardness Less Than 7 Grains ................ 65 10.1.3 Chlorinated Water ......................65 10.1.4 Flush Boiler to Remove Sediment ..................
- Page 8 TABLE OF CONTENTS CHAPTER 16 - MAINTENANCE SCHEDULES ..............81 16.1. Service Technician ........................81 16.2. Owner Maintenance ........................81 CHAPTER 17 - MAINTENANCE PROCEDURES ..............83 17.1. Service Technician Maintenance Procedures ................83 17.2. Reported Problems ........................83 17.3. Check Surrounding Area ......................83 17.4.
- Page 9 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.
- Page 10 INDEX OF ILLUSTRATIONS AND TABLES Fig. 38 - INSTINCT Solo 199 Internal Components ................92 Fig. 39 - INSTINCT Combi 199 Internal Components ................93 Fig. 40 - INSTINCT Solo 110 Burner Components ................94 Fig. 41 - INSTINCT Solo/Combi 155 Burner Components ..............95 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 water. This manual contains important information with respect to the Immediately call a qualified service technician to inspect installation, starting up and maintenance of the appliance. - Page 12 PRODUCT AND SAFETY INFORMATION Bacteria can develop in the domestic water DANGER system if certain minimum water temperatures are not maintained. Failure to maintain at least 140°F [60°C] domestic hot water temperature HOT WATER CAN SCALD! or use the Antilegionella function can result in Water temperature over 125ºF can cause severe bacteria development, which can result in serious burns instantly or death from scalds.
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Page 13: Chapter 1 - Pre-Installation Requirements
Check for an updated • The pressure of the heat transfer medium is version of this manual at www.triangletube.com. 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 1.1. -
Page 14: Determining Product Location
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS Ensure the INSTINCT and its controls are protected from BEST PRACTICE BEST PRACTICE dripping or spraying water during normal operation or In hard water areas (more than 7 grains of service. hardness) soften the cold domestic supply The INSTINCT should be installed in a location so that water to the appliance to prevent scaling. -
Page 15: Boiler Replacement
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.4. Boiler Replacement WARNING If the INSTINCT is replacing an existing boiler, the If the recommended clearances listed above following items should be checked and corrected prior cannot be maintained or the enclosure in to installation: which the boiler is installed is less than 70 cubic feet, the space must be ventilated. - Page 16 INTENTIONALLY LEFT BLANK...
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Page 17: Chapter 2 - Combustion Air & Venting
CHAPTER 2 - COMBUSTION AIR & VENTING 2.1. Combustion Air Contamination • An in-direct installation uses uncontaminat- ed indoor air for appliance combustion. WARNING • When the air for combustion is taken from the room air grilles must be installed by the contractor. -
Page 18: Ventilation And Combustion Air Requirements - Direct Vent
CHAPTER 2 - COMBUSTION AIR & VENTING 2.2. Ventilation Combustion 2.3. Ventilation Combustion Requirements - Direct Vent Requirements - Category IV A Direct Vent appliance utilizes uncontaminated A Category IV appliance utilizes uncontaminated outdoor air piped directly to the appliance for indoor or outdoor air surrounding 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 BEST PRACTICE 2.4.1. Indoor Combustion Air Isolating the combustion appliance room from the rest of the building and bringing in NOTICE uncontaminated outside air for combustion •... -
Page 20: Combination Of Indoor And Outdoor Combustion Air
CHAPTER 2 - COMBUSTION AIR & VENTING • Two Permanent Opening Method. Two permanent • Where communicating with the outdoors is openings, one commencing within 12 in. of the top through horizontal ducts, each opening shall have and one commencing within 12 in. of the bottom a minimum free area of not less than 1 sq.in./2000 of the enclosure, shall be provided. -
Page 21: Removal Of An Existing Boiler From A Common Vent System
CHAPTER 2 - COMBUSTION AIR & VENTING 2.6. Removal of an Existing Boiler from a DANGER Common Vent System It is essential that the supply of air for combustion BEST PRACTICE BEST PRACTICE is not blocked or restricted - this could result in serious injury, or death. -
Page 22: Carbon Monoxide Detector Installation
CHAPTER 2 - COMBUSTION AIR & VENTING 2.8. Commonwealth of Massachusetts 7. Any improper operation of the common venting sys- tem should be corrected so the installation conforms Installation Requirements with the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. -
Page 23: Approved Carbon Monoxide Detectors
CHAPTER 2 - COMBUSTION AIR & VENTING 2.8.5 Manufacturer Requirements - 2.8.2 Approved Carbon Monoxide Detectors. Gas Equipment Venting System Provided. Each carbon monoxide detector as required in When the manufacturer of Product Approved side accordance with the above provisions shall comply with wall horizontally vented gas equipment provides a NFPA 720 and be ANSI/UL 2034 listed and IAS certified. - Page 24 INTENTIONALLY LEFT BLANK...
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Page 25: Chapter 3 - Unit Preparations
CHAPTER 3 - UNIT PREPARATIONS 3.1. Handling Instructions 3.2. Floor Mounting Installation The Instinct must be transferred to the installation The boiler must stand on a non-combustible floor location whilst fully packed to prevent any transit (i.e. concrete or brick) which must be flat, level and of damage. -
Page 26: Floor Mounting Guidelines
CHAPTER 3 - UNIT PREPARATIONS 3.4. Floor Mounting Guidelines 3.6. Front Panel Removal For convenience the hydraulic separator may be fitted Remove the two securing screws on top of the control to the left or right side of the Instinct to assist with pod. -
Page 27: Chapter 4 - Boiler Piping
CHAPTER 4 - BOILER PIPING 4.1. General Piping Requirements • Must not be subject to conditions where freezing could occur. • All plumbing must meet or exceed all local, state • Must not contain any shut-off valves or and national plumbing codes. obstructions. -
Page 28: Boiler Air Vent
CHAPTER 4 - BOILER PIPING 4.4. Low Water Cutoff Device 4.3. Boiler Air Vent NOTICE • The INSTINCT is equipped with a factory installed pressure sensor type Low Water Cut Off (LWCO). This boiler is supplied with a special automatic air •... -
Page 29: Additional Limit Control
CHAPTER 4 - BOILER PIPING 4.5. Additional Limit Control If the installation is to comply with ASME or Canadian requirements, an additional high temperature limit may If a separate Low Water Cut Off (LWCO) is required by be required. Consult local code requirements to deter- the local jurisdiction or when the boiler is installed mine compliance. -
Page 30: Fig. 10 - Instinct Air Vent - Exploded View
CHAPTER 4 - BOILER PIPING The manual air vents must be DHW hot outlet installed on the side of the appliance which is not connected to the system. DHW cold inlet CH PRV System Piping can be attached on either side of the Instinct Floor Standing Boiler Gas inlet CH supply... -
Page 31: Hydraulic Separator
CHAPTER 4 - BOILER PIPING 4.7. Hydraulic Separator 110 and 155 Models BEST PRACTICE BEST PRACTICE CAUTION • It is recommended on all piping app- Ensure the washers are properly seated before tightening lications to utilize the hydraulic separator the fittings. arrangement as a means to provide The hydraulic separator is supplied is supplied with freeze protection of the boiler, which is... -
Page 32: Instinct Solo Boiler System Piping
CHAPTER 4 - BOILER PIPING 4.8. INSTINCT Solo Boiler System Piping Connect the hydraulic separator using the sealing washers provided. 4.8.1 Expansion Tank and Makeup Water Fit the manual air vents to the unused connections on the side opposite the hydraulic separator. Ensure the expansion tank is properly sized for the boiler volume: 199 Models... -
Page 33: Circulator
CHAPTER 4 - BOILER PIPING 4.8.4 Circulator 4.8.9 Instinct Connections The Instinct is supplied with system connections on both A circulator with flow check must be utilized with the sides. The appliance must be installed with the hydraulic INSTINCT Solo. The circulator, when wired directly to the separator supplied, to provide isolation from the heating INSTINCT, will allow for domestic hot water priority and system. -
Page 34: Fig. 13 - 3 Boiler Cascade, 1 System Pump, 1 Ch Pump And 1 Dhw Pump
CHAPTER 4 - BOILER PIPING INSTINCT SOLO PRESET PUMP CONFIGURATION Heat Call Boiler Pump CH1 Pump CH2 Pump DHW Pump Note. Instinct Solo is pre-configured for this installation Fig. 13 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump... -
Page 35: System Piping - Special Application
CHAPTER 4 - BOILER PIPING Size the system piping and circulator to provide the NOTICE flow needed for the radiant system. DO NOT install a SMART indirect water heater along with 4.8.12 System Piping – Special Application the INSTINCT Solo in systems with non-oxygen barrier tubing. -
Page 36: System Piping - Multiple Units Installation
CHAPTER 4 - BOILER PIPING 4.8.13 System Piping – Multiple Units Installation The expansion tank must be located as shown in Fig. 14 on page 23, when using a hydraulic separator Use a balanced manifold system as the primary / arrangement. -
Page 37: System Piping - Through Boiler
CHAPTER 4 - BOILER PIPING 4.10. Optional System Piping and Cascading 4.9.6 System Piping – Through Boiler Several additional configurations (cascading, etc.) are Fig. 15 on page 26 and Fig. 16 on page 27 illustrates possible with INSTINCT Solo Units, provided an optional a multiple zone valve system with a single system/boiler wiring kit is used. -
Page 38: Fig. 15 - Instinct Combi System Piping - Zoning W Valves
CHAPTER 4 - BOILER PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call Boiler Pump CH1 Pump CH2 Pump DHW Pump OFF -> ON Note. Need to change Flex relay 3 to be on for CH1 & CH2 External Limit Low Voltage Terminals Line Voltage Terminals Terminals Manual... -
Page 39: Fig. 16 - Instinct Combi - System Piping - Multi Zone Valve - Single Circulator
CHAPTER 4 - BOILER PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call Boiler Pump CH1 Pump CH2 Pump DHW Pump Note. Instinct Combi is pre-configured for this installation External Limit Low Voltage Terminals Line Voltage Terminals Terminals Manual Auto CH 2 CH 2 CH 2 System... -
Page 40: Fig. 17 - Instinct Combi - System Piping - Single Zone With Single Circulator
CHAPTER 4 - BOILER PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call Boiler Pump CH1 Pump CH2 Pump DHW Pump Note. Instinct Combi is pre-configured for this installation External Limit Low Voltage Terminals Line Voltage Terminals Terminals Manual Auto CH 2 CH 2 CH 2 System... -
Page 41: 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 Installations 5.1.1 Standard Installation The domestic water heater (if utilized) shall have a field supplied pressure relief valve installed within 6” Install pressure relief valve onto the domestic piping [152mm] of the DHW hot outlet connection with the as shown in Fig 18 below. -
Page 42: Pressure Relief Valve Discharge Piping
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.1.3 Pressure Relief Valve Discharge Piping WARNING Pressure relief valve discharge piping must be: Do not install any valve between pressure relief valve and tank connection or on • Made of material serviceable for temperatures pressure relief valve discharge piping. -
Page 43: Thermal Expansion
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.6. General Piping 5.2. Thermal Expansion If a backflow preventer, check valve or pressure reducing • All plumbing must meet or exceed all local, state valve is piped on cold water supply piping of water and national plumbing codes. -
Page 44: Fig. 20 - Multiple Zones - Panel Wiring With Circulators
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call Boiler Pump CH1 Pump CH2 Pump DHW Pump Note. Instinct Combi is pre-configured for this installation External Limit Low Voltage Terminals Line Voltage Terminals Terminals Manual Auto... -
Page 45: Fig. 21 - Instinct Combi System Piping - Multiple Zones - Panel Wiring With Valves
TITLE CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call Boiler Pump CH1 Pump CH2 Pump DHW Pump Note. Instinct Combi is pre-configured for this installation External Limit Low Voltage Terminals Line Voltage Terminals Terminals Manual Auto... - Page 46 INTENTIONALLY LEFT BLANK...
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Page 47: Chapter 6 - Installing Vent/Combustion Air & Condensate Drain
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN 6.1. Installing Vent and Combustion Air WARNING DANGER • Ensure installation of the condensate drain assembly included the seals. Failure to comply The INSTINCT must be vented and supplied could result in the assembly dislocating from with combustion air as shown in the INSTINCT the boiler. -
Page 48: Fig. 22 - Condensate Drain Assembly
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN WARNING NOTICE The condensate drain assembly must remain When selecting and installing a condensate pump, filled with water. Extended periods of non use or ensure the pump is approved for use with condens- high temperature operation may allow the water ing appliances. -
Page 49: Chapter 7 - Gas Piping
CHAPTER 7 - GAS PIPING Gas Flow External Manual Gas Shut Off Valve (Must Be Within 6” of the Ion-ic 186°F Boiler ) 156°F Target = 186°F DHW Demand Tee Fitting Sediment Trap Min. Length of 3" Fig. 23 - Recommended Gas Supply Piping 7.1. -
Page 50: 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 51: Propane Gas
CHAPTER 7 - GAS PIPING 7.3. Propane Gas 7.3.2 Supply Pressure Requirements 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 WARNING pressure port: •... -
Page 52: Fig. 24 - Gas Valve / Venturi Assembly - Instinct Solo 110
CHAPTER 7 - GAS PIPING Venturi Venturi Interface Pipe to Venturi Air Inlet Gas Valve Air Reference Hose Fig. 24 - Gas Valve / Venturi Assembly - INSTINCT Solo 110 Air Reference Hose Gas Valve Pipe to Venturi Air Inlet Venturi Interface Venturi Fig. -
Page 53: Fig. 26 - Gas Valve / Venturi Assembly - Instinct Solo/Combi 199
CHAPTER 7 - GAS PIPING Air Inlet Venturi Interface Venturi Air Reference Hose Pipe to Venturi Gas Valve Fig. 26 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 199... - Page 54 INTENTIONALLY LEFT BLANK...
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Page 55: Chapter 8 - Wiring
CHAPTER 8 - WIRING 8.1. Internal Wiring 8.1.2 Fuse Locations WARNING • The CTRLMax control module contains 3 internal replaceable 5A fuses as shown in Fig. 27 below. ELECTRICAL SHOCK HAZARD. For your safety, • The top two fuses protect the INSTINCT as well as disconnect electrical power supply to the the CH, DHW, and Flame outputs. -
Page 56: Fig. 28 - Instinct Solo Boiler Factory Wiring
Ins�nct Solo FSB Wiring Diagram CHAPTER 8 - WIRING Gas Valve On/Off Spark Generator Blower Switch Electrode Electrical Socket Pump Pump Boiler Pump Power Supply Pump Flue Temperature Sensor Return Temperature Sensor Supply Temperature Sensor Manual Reset Limit Auto Reset Limit Water Pressure Sensor... -
Page 57: Fig. 29 - Instinct Combi Boiler Factory Wiring
Ins�nct Combi FSB Wiring Diagram CHAPTER 8 - WIRING Gas Valve On/Off Spark Generator Blower Switch Electrode Electrical Socket Pump Boiler Pump Pump Power Supply Pump Diverter Valve Flue Temperature Sensor Return Temperature Sensor Supply Temperature Sensor Manual Reset Limit Auto Reset Limit Water Pressure... -
Page 58: External Wiring
CHAPTER 8 - WIRING 8.2. External Wiring NOTICE 8.2.1 General Requirements If local electrical codes require an additional service switch, the installer must provide and install a fused All field wiring must comply with: disconnect or minimum 15 amp service switch. •... -
Page 59: Low Voltage Connections
CHAPTER 8 - WIRING 8.3.3 Low Voltage Connections 8.3.5 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 60: External Modulation Control
CHAPTER 8 - WIRING 1. Remove the factory-installed brown jumper wire at 8.3.10 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 61: 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 62: Ctrlmax Menu Structure
CHAPTER 9 - CTRLMAX OPERATION The menu system utilizes icons to represent each The Home Screen icon at the bottom of each screen returns to the Home Screen when selected. The selection. The current selected menu is displayed as Previous Screen icon at the bottom of each screen a reversed image with a text description shown at the returns to the previous screen when selected. -
Page 63: 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 64: Status Line Messages
CHAPTER 9 - CTRLMAX OPERATION 9.4. Status Line Messages CH Setpoint Reached - The burner is not fired because the supply/system water temperature exceeds the Standby - Indicates that the INSTINCT is ready to setpoint. The central heating circulator(s) continue(s) to respond when a demand is received. -
Page 65: Main Menu
CHAPTER 9 - CTRLMAX OPERATION 9.6. EZ Setup 9.5. Main Menu The EZ Setup menus provide a simple way to quickly The Main Menu can be entered from the Home Screen customize CTRLMax for each installation. EZ Setup by touching the soft key. -
Page 66: 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 67: 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 enable the INSTINCT and the setpoint will vary with the outdoor temperature for central Heating EZ Setup heating calls. -
Page 68: Domestic Hot Water Ez Setup - Instinct Solo Units
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 69: 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 70: 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 EZ Setup original factory defaults. See Chapter 13 on page 75 for the list of settings reset by this function. Follow the on-screen instructions to reset all EZ Setup settings. -
Page 71: 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 72: 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 73: 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 74: 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 75: 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 76 INTENTIONALLY LEFT BLANK...
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Page 77: 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 coverage of INSTINCT heat exchangers. -
Page 78: Check And Test Antifreeze
CHAPTER 10 - START-UP PREPARATION 10.1.7 Check and Test Antifreeze DANGER For boiler systems containing antifreeze solutions, follow the antifreeze manufacturer’s instructions in HOT WATER CAN SCALD! verifying the inhibitor level and to ensure the fluid • Water temperatures over 125ºF can cause characteristics are within specification requirements. -
Page 79: Filling The Boiler System
CHAPTER 10 - START-UP PREPARATION 10.2. Filling the Boiler System If any adjustment needs to be made to the valve’s temperature setpoint refer to the manufacturer’s 1. Close the boiler drain valve located on the bottom instructions included with the valve. of the unit and any manual or automatic air vents in the system. -
Page 80: Check For Gas Leaks
CHAPTER 10 - START-UP PREPARATION 10.5. Check For Gas Leaks NOTICE WARNING In systems using 3-wire zone valves, voltage backfeed to the unit is a common problem. Use • Prior to start-up and during initial operation, an isolation relay to prevent voltage from the check for a gas leak using a combustable gas external circuit from entering the INSTINCT. -
Page 81: Chapter 11 - Start-Up Procedures
CHAPTER 11 - START-UP PROCEDURES 11.1. Final Checks Before Start-Up 5. Are the gas supply valves open at the unit and meter? Ø Read Chapter 9 on page 49 regarding the oper- 6. Is incoming gas supply pressure at the unit more ation of the CTRLMax Boiler Management System. - Page 82 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 83: Verify Flame Pattern And Combustion
CHAPTER 11 - START-UP PROCEDURES 11.3.4 Verify Flame Pattern and Combustion NOTICE 1. Check the flame pattern through the observa- An adequate CH load must be present to dissipate tion port of the heat exchanger. The flame should the heat generated during the combustion test. If an be blue and stable. -
Page 84: Measure Input - Natural Gas Only
CHAPTER 11 - START-UP PROCEDURES 11.3.5 Measure Input - Natural Gas Only 4. Touch the soft key to highlight the Boiler Settings 1. Ensure the boiler is firing at maximum firing rate. To icon then touch the soft key. manually place the boiler into high fire, reference 5. -
Page 85: 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 86 INTENTIONALLY LEFT BLANK...
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Page 87: 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 88 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 89: Chapter 14 - Check-Out Procedures
CHAPTER 14 - CHECK-OUT PROCEDURES q Test high temperature limit as outlined in Section NOTICE 11.3.6 on page 72. q Checked the incoming gas pressure at the unit Perform the following check-out procedures as more than 5”w.c. and less than 13”w.c. for Natural outlined and check off items as completed. - Page 90 INTENTIONALLY LEFT BLANK...
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Page 91: 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 92 INTENTIONALLY LEFT BLANK...
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Page 93: 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 combustion air inlet and ventilation openings. - Page 94 INTENTIONALLY LEFT BLANK...
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Page 95: Chapter 17 - Maintenance Procedures
CHAPTER 17 - MAINTENANCE PROCEDURES 17.1. Service Technician Maintenance Procedures 17.4. Inspect Burner Area • Remove the boiler front jacket panel and venturi WARNING inlet elbow. • Vacuum any dirt or debris from the burner/blower The INSTINCT must be inspected and serviced components. -
Page 96: Clean Condensate Drain Assembly
CHAPTER 17 - MAINTENANCE PROCEDURES 17.6. Clean Condensate Drain Assembly 17.9. Check Boiler System • Verify all system components are correctly installed NOTICE and operating properly. For the INSTINCT Combi unit, the front panel • Check the cold fill pressure for the system. Typical needs to be removed to gain access to the cold water fill pressure is 12 psig. -
Page 97: Check Boiler Relief Valve
CHAPTER 17 - MAINTENANCE PROCEDURES 17.11. Check Boiler Relief Valve 17.15. Check Control Settings Inspect the relief valve and lift the lever to verify flow at • Review all boiler settings in the Heating & DHW least annually or as recommended on the warning tag EZ Setup menus. -
Page 98: Check Flame Signal
CHAPTER 17 - MAINTENANCE PROCEDURES • Use a vacuum cleaner or compressed air to clean above the supply water temperature, shut the boil- the interior of the blower assembly. Inspect the er down and follow the heat exchanger cleaning blower blades to ensure they are clean and not procedure below. -
Page 99: Check Carbon Monoxide Detectors
• Contact Triangle Tube at 856-228-8881 are installed and operating properly. One must be in- or www.triangletube.com for a list of stalled in the mechanical room where the INSTINCT is distributors near you. located and another installed in the living area outside the bedroom(s). -
Page 100: Chapter 18 - Replacement Parts
CHAPTER 18 - REPLACEMENT PARTS Fig. 34 - INSTINCT Jacket Components Item Part # Description INSJKT17 Front Jacket Panel INSRKIT92 Control Box Mounting Bracket INSJKT18 Left Side Jacket Panel INSJKT19 Right Side Jacket Panel... -
Page 101: Fig. 35 - Instinct Solo 110 Internal Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 35 - INSTINCT Solo 110 Internal Components Item Part # Description INSRKIT40 Vent Outlet/Combustion Air Inlet Adapter INSRKIT01 Heat Exchanger Body PTRKIT122 CH Supply Temperature Sensor PARKIT04 Low Water Cut Off PTRKIT122 CH Return Temperature Sensor PSRKIT05 Condensate Drain Assembly INSRKIT41... -
Page 102: Fig. 36 - Instinct Solo 155 Internal Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 36 - 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 PSRKIT05 Condensate Drain Assembly INSRKIT41... -
Page 103: Fig. 37 - Instinct Combi 155 Internal Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 37 - 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 PSRKIT05 Condensate Drain Assembly INSRKIT41... -
Page 104: Fig. 38 - Instinct Solo 199 Internal Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 38 - INSTINCT Solo 199 Internal Components Item Part # Description INSRKIT40 Vent Outlet/Combustion Air Inlet Adapter INSRKIT03 Heat Exchanger Body PTRKIT122 CH Supply Temperature Sensor PARKIT04 Low Water Cut Off PTRKIT122 CH Return Temperature Sensor PSRKIT05 Condensate Drain Assembly INSRKIT41... -
Page 105: Fig. 39 - Instinct Combi 199 Internal Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 39 - INSTINCT Combi 199 Internal Components Item Part # Description INSRKIT40 Vent Outlet/Combustion Air Inlet Adapter INSRKIT03 Heat Exchanger Body PTRKIT122 CH Supply Temperature Sensor PARKIT04 Low Water Cut Off PTRKIT122 CH Return Temperature Sensor PSRKIT05 Condensate Drain Assembly INSRKIT41... -
Page 106: Fig. 40 - Instinct Solo 110 Burner Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 40 - INSTINCT Solo 110 Burner Components 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. -
Page 107: Fig. 41 - Instinct Solo/Combi 155 Burner Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 41 - INSTINCT Solo/Combi 155 Burner Components 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. -
Page 108: Fig. 42 - Instinct Combi 199 Burner Components
CHAPTER 18 - REPLACEMENT PARTS Fig. 42 - INSTINCT Combi 199 Burner Components 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. -
Page 109: Fig. 43 - Instinct Control & Display Enclosures
CHAPTER 18 - REPLACEMENT PARTS Fig. 43 - INSTINCT Control & Display Enclosures Item Part # Description INSRKIT52 Control Module INSRKIT53 Display Module INSRKIT121 Power Switch INSRKIT123 IOT Diagnostic Device... -
Page 110: Fig. 44 - Instinct Combi Hydro-Block
CHAPTER 18 - REPLACEMENT PARTS Fig. 44 - INSTINCT Combi Hydro-block Item Part # Description INSRKIT60 Hydroblock INSRKIT61 Valve Motor INSRKIT62 3 Way Valve INSRKIT58 Flow Sensor INSRKIT69 Combi supply fittings (CH & DHW) INSRKIT71 Combi DHW inlet fitting INSRKIT72 Combi CH return PTRKIT122 Domestic Water Temperature Sensor... -
Page 111: Chapter 19 - Product Specifications
CHAPTER 19 - PRODUCT SPECIFICATIONS Shipping DOE Heating Net AHRI Rating Unpackaged Boiler Model Fuel Input (Btu/h) AFUE Weight Lbs Capacity (Btu/h) (Btu/h) Weight Lbs (Kg) (Kg) Natural 13,750 – Instinct 110 Solo 102,000 89,000 145 (65.7) 196 (89) Propane 110,000 Natural 19,375 –... -
Page 112: Fig. 45 - Front View Instinct Solo 110
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 45 - Front View INSTINCT Solo 110 THIS IS THE 110 SOLO Vent\Com- 3" Com- NSPC 1" NPT 1" NPT Conden- Conden- 3/4" Boiler 3" Vent bustion Air Boiler 3/4" Item bustion Air Relief Boiler Boiler sate Drain... -
Page 113: Fig. 46 - Right Side View Instinct Solo 110
CHAPTER 19 - PRODUCT SPECIFICATIONS THIS IS THE 110 SOLO Fig. 46 - Right Side View INSTINCT Solo 110 P&Q 3" Combustion NPSC Relief 1" NPT Boiler 1" NPT Boiler 1" NPT Boiler 3/4" 3/4" Items Air Inlet & 3" Vent Boiler Depth Valve Return... -
Page 114: Fig. 47 - Front View Instinct Solo 155
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 47 - Front View INSTINCT Solo 155 THIS IS THE 155 SOLO THIS IS THE 155 SOLO Vent\Com- 3" Com- NSPC 1" NPT 1" NPT Conden- Conden- 3/4" Boiler 3" Vent bustion Air Boiler 3/4"... -
Page 115: Fig. 48 - Right Side View Instinct Solo 155
THIS IS THE 155 SOLO CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 48 - Right Side View INSTINCT Solo 155 P&Q 3"Combustion NPSC 1" NPT Boiler 1" NPT Boiler 1" NPT Boiler 3/4" 3/4" Items Air Inlet & 3"Vent Boiler Depth Relief Valve Return Supply... -
Page 116: Fig. 49 - Front View Instinct Solo 199
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 49 - Front View INSTINCT Solo 199 this is for the 199 solo this is for the 199 solo Vent\Com- Con- 3" Com- NSPC 1" NPT 1" NPT 3/4" 3/4" Conden- Boiler 3" Vent Boiler bustion Air densate... -
Page 117: Fig. 50 - Right Side View Instinct Solo 199
CHAPTER 19 - PRODUCT SPECIFICATIONS this is for the 199 solo Fig. 50 - Right Side View INSTINCT Solo 199 P&Q 3"Combustion NPSC 1" NPT Boiler 1" NPT Boiler 1" NPT Boiler 3/4" 3/4" Items Air Inlet & 3"Vent Boiler Depth Relief Valve Return Supply... -
Page 118: Fig. 51 - Front View Instinct Combi 155
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 51 - Front View INSTINCT Combi 155 U&V THIS IS THE 155 COMBI THIS IS THE 155 COMBI Con- Conden- NPSC 3/4" 3” Com- Vent/Combus- 1" NPT 1" NPT 3/4" NPT densate Boiler 3” Vent 3/4”... -
Page 119: Fig. 52 - Right Side View Instinct Combi 155
CHAPTER 19 - PRODUCT SPECIFICATIONS THIS IS THE 155 COMBI Fig. 52 - Right Side View INSTINCT Combi 155 P&Q 3" Combustion 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 1" NPT Boiler 1" NPT Boiler 1" NPT Boiler NPT Gas Boiler 3/4"... -
Page 120: Fig. 53 - Front View Instinct Combi 199
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 53 - Front View INSTINCT Combi 199 U&V this is for the 199 combi this is for the 199 combi Con- NPSC Vent/Combus- 3/4" Conden- 3” Com- 1" NPT 1" NPT 3/4" NPT densate Boiler 3”... -
Page 121: Fig. 54 - Right Side View Instinct Combi 199
CHAPTER 19 - PRODUCT SPECIFICATIONS this is for the 199 combi Fig. 54 - Right Side View INSTINCT Combi 199 P&Q 3" Combustion 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 1" NPT Boiler 1" NPT Boiler 1" NPT Boiler NPT Gas Boiler 3/4"... - 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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Questions and answers
Controler bus error communication between boiler display and control module has been lost - message appears on screen - no heat.
The "Controller Bus Error Communication between boiler display and control module has been lost" message (E99) on the TriangleTube Instinct FSB SOLO 110 boiler means that the display panel is no longer able to communicate with the main control module. This indicates a communication failure, which could be caused by a wiring issue, a loose connection, or a faulty component.
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