TriangleTube SOLO 155 Installation & Maintenance Manual
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TriangleTube SOLO 155 Installation & Maintenance Manual

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Installation &
Maintenance
Manual
SOLO 11 0 -15 5 -199 & COMBI 155 -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.
226389 A03 - Oct 2021
2019-16 Instinct WHB
Installation &
Maintenance Manual
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.
THE
O RI G I NA L
IN NO VAT ORS

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  • Page 1 Installation & Maintenance Manual SOLO 11 0 -15 5 -199 & COMBI 155 -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 5.5. Hydro-Block ........................25 5.6. General Piping ........................25 5.7. Thermostatic Mixing Valve ....................25 CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN ..27 6.1. Installing Vent and Combustion Air ..................27 6.2. Installing Condensate Drain Assembly into INSTINCT Solo Units ..........27 CHAPTER 7 - GAS PIPING ..................
  • Page 6 TABLE OF CONTENTS 9.5. Main Menu......................... 47 9.6. EZ Setup ........................... 47 9.7. Heating EZ Setup ......................48 9.7.1 Select CH Demand (No outdoor sensor connected) ..........48 9.7.2 Select CH Demand (Outdoor sensor connected) ............49 9.8. Domestic Hot Water EZ Setup - INSTINCT Solo Units ........... 50 9.9.
  • Page 7 TABLE OF CONTENTS 11.1. Final Checks Before Start-Up ..................63 11.2. INSTINCT Start-Up ....................63 11.3. Check the INSTINCT and System ..................63 11.3.1 Check Boiler Piping..................63 11.3.2 Check Vent and Combustion Air Piping ..............63 11.3.3 Check Gas Piping ..................63 11.3.4 Verify Flame Pattern and Combustion ..............
  • Page 8 TABLE OF CONTENTS 17.15. Check Control Settings ...................... 79 17.16. Perform Start-up and Checkout Procedures ..............79 17.17. Check Burner Flame ......................79 17.18. Check Flame Signal ......................79 17.19. Check Combustion Levels ....................80 17.20. Check Flue Gas Temperature .................... 80 17.21.
  • Page 9 Fig. 29 - INSTINCT Combi Jacket Components ................82 Fig. 30 - INSTINCT Solo 110 Internal Components ................83 Fig. 31 - INSTINCT Solo 155 Internal Components ................84 Fig. 32 - INSTINCT Combi 155 Internal Components ................ 85 Fig. 33 - INSTINCT Solo 199 Internal Components................86 Fig.
  • Page 10 Fig. 41 - Right Side View INSTINCT Solo 110 ..................95 Fig. 42 - Front View INSTINCT Solo 155 ................... 96 Fig. 43 - Right Side View INSTINCT Solo 155 ................... 97 Fig. 44 - Front View INSTINCT Solo 199 ..................98 Fig.

  • Page 11: Product And Safety Information

    Section BEST PRACTICE 2.8 on page 10 for additional carbon monoxide detector requirements in Massachusetts. Indicatesrecommendationsmade by TriangleTube • Failure to comply with these instructions can fortheinstallers, which willhelp toensure optimum result in substantial property damage, serious operation and longevity of theequipment.
  • Page 12 Triangle Tube reserves the right to change the or use the Antilegionella function can result in technical characteristics, components and features of bacteria development, which can result in serious its products without prior notice. Check for an updated injury, or death. version of this manual at www.triangletube.com.

  • Page 13: Chapter 1 - Pre-Installation Requirements

    CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.1. INSTINCT boilers - Code Compliance The equipment is permanently labeled to indicate that only additives recognized as safe The INSTINCT units must be installed by a qualified by the FDA shall be used in the heat transfer installer in accordance with the following: medium.

  • 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, no call for heat is present: conditioned 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 Z223.1 must be taken: •...
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  • Page 17: Chapter 2 - Combustion Air & Venting

    CHAPTER 2 - COMBUSTION AIR & VENTING • Anin-directinstallationusesuncontaminated 2.1. Combustion Air Contamination indoor air for appliance combustion. WARNING • When the air for combustion is taken from the room air grilles must be installed by the contractor. The air grilles should be If the INSTINCT combustion air inlet is located in sized in accordance with ANSI Z223.1/ anarealikely tocause or contain contamination,...

  • 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 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 • 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 1. Seal any unused openings in the common venting BEST PRACTICE system. 2. Visually inspect the venting system for proper size In order to reduce the potential risks associated and horizontal pitch and determine there is no with indoor contaminates (see list in Section blockage or restriction, leakage, corrosion and other 2.1 on page 5), flammable vapors and tight...

  • Page 22: Carbon Monoxide Detector Installation

    CHAPTER 2 - COMBUSTION AIR & VENTING 2.7. Carbon Monoxide Detector Installation 2.8.1 Installation of Carbon Monoxide Detectors. 1. At the time of installation of the side wall horizontal Triangle Tube follows the recommended advice of CPSC vented gas fueled equipment, the installing plumber and requires the installation of a minimum of two (2) or gasfitter shall observe that a hard wired carbon carbon monoxide detectors with an alarm and battery...

  • Page 23: Signage

    CHAPTER 2 - COMBUSTION AIR & VENTING 2.8.5 Manufacturer Requirements - Gas Equip- 2.8.3 Signage ment Venting System Provided. A metal or plastic identification plate shall be When the manufacturer of Product Approved side wall permanently mounted to the exterior of the building at horizontally vented gas equipment provides a venting a minimum height of eight (8) feet above grade directly system design or venting system components with the...
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  • Page 25: Chapter 3 - Unit Preparations

    • 116.6 pounds [52.9 kg] for the INSTINCT Solo 110 3. Remove the wall mounting template. • 137.9 pounds [62.5 kg] for the INSTINCT Solo 155 4. Remove the accessory boxes. • 153.2 pounds [69.6 kg] for INSTINCT Solo 199 5.

  • Page 26: Wall Mounting Guidelines

    CHAPTER 3 - UNIT PREPARATIONS 3.4. Wall Mounting Guidelines 4. Remove the bracket from the wall and drill a 1/4” di- ameter by 3” deep hole in the center of each mark. The wall-mounting bracket is designed for stud spacing For applications using metal studs and 3/ ”...

  • Page 27: General Piping Requirements

    CHAPTER 4 - BOILER PIPING 4.1. General Piping Requirements 2. To avoid potential water damage to the surrounding area or potential scalding hazard due to the • All plumbing must meet or exceed all local, state operation of the relief valve, the discharge piping: and national plumbing codes.

  • 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 4.6. Backflow Preventer • Use a backflow preventer valve in the make-up If a separate Low Water Cut Off (LWCO) is required by the local jurisdiction or when the boiler is installed water supply to the unit as required by local codes.

  • Page 30: Expansion Tank And Makeup Water

    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 • 4 gallons [15 L] for INSTINCT Solo 199 It is recommended to pitch any horizontal piping up- wards toward the expansion tank 1 inch per 5 feet of the system water volume, and the system water temperature.

  • Page 31: Sizing Primary Piping

    1 inch for the INSTINCT the maximum allowable temperature for the radiant tubing. Solo 110, 1-1/4 inch for the INSTINCT Solo 155/19 4.7.8 System Piping – Zone Valves NOTICE...

  • Page 32: 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 33: Expansion Tank And Makeup Water

    CHAPTER 4 - BOILER PIPING System System Supply Return Optional Instinct Combi Timesaver INSRKIT84 Cold Water Fill Fig. 11 - INSTINCT Combi Near Boiler Piping - Timesaver Manifold 4.8.1 Expansion Tank and Makeup Water CAUTION Ensure the expansion tank is properly sized for the boiler volume: The expansion tank must be located directly on the •...

  • Page 34: Sizing Primary Piping

    CHAPTER 4 - BOILER PIPING 4.8.4 Sizing Primary Piping 4.8.8 System Piping – Radiant Heating The heat exchanger design of the INSTINCT Combi See Fig. 15 on page 29 Fig. 11 on page 21 through Fig. allows operation in a condensing mode. This feature 15 on page 26, for recommended piping arrangements requires no regulation of the return water temperature based on various applications.

  • Page 35: Chapter 5 - Instinct Combi Units - Domestic Piping

    CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.1. Domestic Piping Pressure Relief Valve 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. 12 5.1.1 Standard Installation on page 23 2.

  • Page 36: Thermal Expansion

    CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING Pressure relief valve discharge piping must not be: 5.2. Thermal Expansion • Excessively long. Using more than 2 elbows or If a backflow preventer, check valve or pressure reducing 15 feet of piping can reduce discharge capacity. valve is piped on cold water supply piping of water heater, install an expansion tank on cold water supply •...

  • Page 37: Water Hammer

    CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.3. Water Hammer • Use dielectric unions or couplings to protect hot and cold water fittings from corrosion when Dishwashers, clothes washers and fast-closing positive connecting dissimilar materials such as copper and shut-off valves incorporated in the system all contribute galvanized iron pipe.
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  • Page 39: Chapter 6 - Installing Vent/Combustion Air & Condensate Drain

    CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN 6.1. Installing Vent and Combustion Air 3. Tighten the condensate drain assembly retaining nut. WARNING DANGER • Ensure installation of the condensate drain The INSTINCT must be vented and supplied assembly included the seals. Failure to comply with combustion air as shown in the INSTINCT could result in the assembly dislocating from Vent Supplement, included in the installation...

  • Page 40: Fig. 14 - 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 use or NOTICE high temperature operation may allow the water to evaporate.

  • Page 41: 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 156° Boiler ) T ar g et = 18 6° F Tee Fitting Union Fitting Sediment Trap Min. Length of 3" Fig.

  • Page 42: 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 43: 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 44: Fig. 16 - 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. 16 - Gas Valve / Venturi Assembly - INSTINCT Solo 110 Air reference Hose Pipe to Venturi Gas Valve Air Inlet Venturi interface Venturi Fig.

  • Page 45: Fig. 18 - Gas Valve / Venturi Assembly - Instinct Solo/Combi 199

    CHAPTER 7 - GAS PIPING Air Inlet Venturi interface Venturi Air reference Hose Gas Valve Pipe to Venturi Fig. 18 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 199...
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  • Page 47: 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. 19 below. ELECTRICAL SHOCK HAZARD. For your safety, • The top two fuses protect the INSTINCT as well as disconnect electrical power supply the CH1, CH2, DHW boiler outputs.

  • Page 48: Fig. 20 - Multiple Zones - Panel Wiring With Circulators

    CHAPTER 8- WIRING 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 Line Voltage Terminals Low Voltage Terminals External Limit Low Voltage Line Voltage Terminal Terminals Manual...

  • Page 49: Fig. 21 - Instinct Combi System Piping - Multiple Zones - Panel Wiring With Valves

    CHAPTER 8 - WIRING 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 External Limit Low Voltage Line Voltage Terminal Terminals System...

  • Page 50: Fig. 22 - Instinct Solo Boiler Factory Wiring

    CHAPTER 8- WIRING lo Wiring Diagram Blower W = White BK = Black W = White Gas Valve R = Red G= Green BK = Black Electrode R = Red OrangeY = Yellow BL G= Green = Blue O = Orange G/Y = Green / Yellow GY = Grey Y = Yellow...

  • Page 51: Fig. 23 - Instinct Combi Boiler Factory Wiring

    CHAPTER 8 - WIRING Combi Wiring Diagram Spark Generator Blower W = White W = White BK = Black BK = Black Gas Valve R = Red G= Green R = Red Electrode G= Green OrangeY = Yellow BL O = Orange = Blue G/Y = Green / Yellow Y = Yellow...

  • Page 52: 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 disconnect or minimum 15 amp serviceswitch. •...

  • Page 53: 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 54: 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 55: 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 56: 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 57: 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 58: 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 59: 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 60: 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 61: Select Ch Demand(Outdoorsensorconnected)

    CHAPTER 9 - CTRLMAX OPERATION 9.7.2 Select CH Demand(Outdoorsensorconnected) 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 62: 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 63: 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 64: 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 69 for the list of settings reset by this function. Follow the on-screen instructions to reset all EZ Setup settings.

  • Page 65: 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 66: 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 67: 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 or soft keys to scroll through the items then touch...

  • Page 68: 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 69: 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.
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  • Page 71: 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 NOTICE spa directly. Requirements below must be met for warranty Maintain the chlorine level of the water at levels coverage of INSTINCT heat exchangers.

  • Page 72: 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 characteristics are within specification requirements. Water temperatures over 125ºF can cause •...

  • Page 73: 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 74: 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 75: 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? ► Read Chapter 9 on page 43 regarding the oper- 6. Is incoming gas supply pressure at the unit more ation of the CTRLMax Boiler Management System.
  • Page 76 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. Use only your hand to turn the external manual gas with an ignition device which automatically lights valve.

  • Page 77: Verify Flame Pattern And Combustion

    CHAPTER 11 - START-UP PROCEDURES NOTICE 11.3.4 Verify Flame Pattern and Combustion 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 adequate CH load is not available, an indirect water be blue and stable.

  • Page 78: 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 79: 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.
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  • Page 81: 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 82 CHAPTER 13 - EXTERNAL MODULATING CONTROL CTRLMax Factory Settings (cont’d) FACTORY MAXIMUM MINIMUM 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]...

  • Page 83: Chapter 14 - Check-Out Procedures

    CHAPTER 14 - CHECK-OUT PROCEDURES D Measured the rate of input on Natural Gas as outlined in Section 11.3.5 on page 66. NOTICE D Test high temperature limit as outlined in Section 11.3.6 on page 66. Perform the following check-out procedures as outlined and check off items as completed.
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  • Page 85: 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...
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  • Page 87: Chapter 16 - Maintenance Schedules

    CHAPTER 16 - MAINTENANCE SCHEDULES 16.1. Service Technician 16.2. Owner Maintenance Periodically: At least on an annual basis the following maintenance 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.
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  • Page 89: Chapter 17 - Maintenance Procedures

    CHAPTER 17 - MAINTENANCE PROCEDURES 17.1. ServiceTechnician 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 burner annually, preferably at thestartoftheheating season, components.

  • Page 90: Check Ventilation Air Openings

    CHAPTER 17 - MAINTENANCE PROCEDURES 17.7. Check Ventilation Air Openings into the system. This device prevents air from bubbling up through the water as it returns from • Verify that all ventilation openings to the mechanical the system. room or building are open and unobstructed. •...

  • Page 91: Check Ignition Cable And Ground Wiring

    CHAPTER 17 - MAINTENANCE PROCEDURES 17.13. Check Ignition Cable and Ground Wiring * These two screws are for transportation purposes only and can be discarded. • Inspect the ignition cable from the spark generator • Carefully remove the burner plate assembly from to the ignitor.

  • Page 92: 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 11.3.4 on page 65 for measuring • Reconnect the gas piping and wire harness to the combustion levels and burner adjustments.

  • Page 93: 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. 28 - INSTINCT Solo Jacket Components...

  • Page 94: Fig. 29 - Instinct Combi Jacket Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 29 - INSTINCT Combi Jacket Components Item Part # Description INSJKT04 Front Jacket Panel INSRKIT92 Control Box Mounting Bracket INSJKT05 Left Side Jacket Panel INSRKIT90 Wall Mounting Bracket with Hardware INSJKT06 Right Side Jacket Panel INSRKIT91 User Interface Mounting Bracket...

  • Page 95: Fig. 30 - Instinct Solo 110 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 30 - 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 PTRKIT122 CH Return Temperature Sensor PSRKIT05...

  • Page 96: Fig. 31 - Instinct Solo 155 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 31 - 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...

  • Page 97: Fig. 32 - Instinct Combi 155 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 32 - 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 98: Fig. 33 - Instinct Solo 199 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 33 - 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 99: Fig. 34 - Instinct Combi 199 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 34 - 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 100: Fig. 35 - Instinct Solo 110 Burner Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 35 - 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 101: Fig. 36 - Instinct Solo/Combi 155 Burner Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 36 - 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 102: Fig. 37 - Instinct Combi 199 Burner Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 37 - INSTINCT Combi 199 Burner Components Item Part # Description INSRKIT05 Blower Assembly INSRKIT27 Ignitor Assembly INSRKIT32 Burner Plate Insulation PSRKIT16 Sight Glass Assembly INSRKIT16 Burner Plate INSRKIT20 Combustion two in one Insulation INSRKIT25 Burner Head Assembly INSRKIT11...

  • Page 103: Fig. 38 - Instinct Control & Display Enclosures

    CHAPTER 18 - REPLACEMENT PARTS Fig. 38 - INSTINCT Control & Display Enclosures Item Part # Description INSRKIT52 Control Module PARKIT188 Control Box Hinges INSRKIT53 Display Module INSRKIT55 Control Enclosure...

  • Page 104: Fig. 39 - Instinct Combi Hydro-Block

    CHAPTER 18 - REPLACEMENT PARTS Fig. 39 - 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 105: Chapter 19 - Product Specifications

    CHAPTER 19 - PRODUCT SPECIFICATIONS Shipping DOE Heating Net AHRI Rating Unpackaged AFUE Weight Lbs Boiler Model Fuel Input (Btu/h) (Btu/h) Capacity (Btu/h) Weight Lbs (Kg) (Kg) 102,000 89,000 83.5 (37.9) 99 (44.9) Propane 110,000 Instinct 155 Solo 19,375 – 143,000 124,000 93.7 (42.5)

  • Page 106: Fig. 40 - Front View Instinct Solo 110

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 40 - Front View INSTINCT Solo 110 Vent\Com- 3" Com- NSPC 1" NPT 1" NPT 3/4" Boiler 3" Vent bustion Air Boiler Conden- Conden- 3/4" Item bustion Air Relief Boiler Boiler Width Outlet Connection Height Connection sate Drain...

  • Page 107: Fig. 41 - Right Side View Instinct Solo 110

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 41 - Right Side View INSTINCT Solo 110 3" Combustion NPSC Relief 1" NPT Boiler Condensate 1" NPT Boiler 3/4" 3/4" Items Air Inlet & 3" Vent Boiler Depth Valve Return Drain Supply Connection Outlet Dimension 7 3/4...

  • Page 108: Fig. 42 - Front View Instinct Solo 155

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 42 - Front View INSTINCT Solo 155 Vent\Com- 3" Com- NSPC 1" NPT 1" NPT 3/4" Boiler 3" Vent bustion Air Boiler Conden- Conden- 3/4" Item bustion Air Relief Boiler Boiler Width Outlet Connection...

  • Page 109: Fig. 43 - Right Side View Instinct Solo 155

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 43 - Right Side View INSTINCT Solo 155 3"Combustion NPSC 1" NPT Boiler Condensate 1" NPT Boiler 3/4" 3/4" Items Air Inlet & 3"Vent Boiler Depth Relief Valve Return Drain Supply Gas Connection Outlet...

  • Page 110: Fig. 44 - Front View Instinct Solo 199

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 44 - Front View INSTINCT Solo 199 Vent/Combus- 3” Combus- 3” Vent 3/4" NPSC Boiler 1" NPT Boiler 1" NPT Boiler 3/4" NPT Gas Condensate Conden- Connection Boiler Width tion Air Adapter tion Air Inlet Outlet Relief Valve Height...

  • Page 111: Fig. 45 - Right Side View Instinct Solo 199

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 45 - Right Side View INSTINCT Solo 199 3" Combustion NPSC 1" NPT Boiler Condensate 1" NPT Boiler 3/4" 3/4" Items Air Inlet & 3"Vent Boiler Depth Relief Valve Return Drain Supply Gas Connection Outlet Dimension 8 5/8...

  • Page 112: Fig. 46 - Front View Instinct Combi 155

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 46 - Front View INSTINCT Combi 155 Vent/Combus- 3” Com- 3/4" NPT 3/4" NPT 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...

  • Page 113: Fig. 47 - Right Side View Instinct Combi 155

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 47 - Right Side View INSTINCT Combi 155 O,Q,T,U 3" Combustion 3/4" NPT NPSC 1" NPT Boiler Condensate 1" NPT Boiler NPT Gas Boiler 3/4" 3/4" 3/4" NPT DHW Items Air Inlet & 3" Outlet Relief Valve Return...

  • Page 114: Fig. 48 - Front View Instinct Combi 199

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 48 - Front View INSTINCT Combi 199 Vent/Combus- 3” Com- 3/4" NPT 3/4" NPT 3/4" NPT 3/4” NPSC Boiler 3” Vent Boiler 1" NPT Boil- 1" NPT Boil- Conden- Connection bustion Air tion Air Adapt- Gas Con- Relief Valve Width...

  • Page 115: Fig. 49 - Right Side View Instinct Combi 199

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 49 - Right Side View INSTINCT Combi 199 O, Q, T, U 3" Combustion 3/4" NPT NPSC 1" NPT Boiler Condensate 1" NPT Boiler NPT Gas Boiler 3/4" 3/4" 3/4" NPT DHW Items Air Inlet & 3" Relief Valve Return Drain...

  • Page 116: Graph 1 - Instinct Solo - Pressure Loss Through Boiler

    Flow Rate (GPM) Graph 1 - INSTINCT Solo - Pressure Loss Through Boiler Note: Minimum allowable flow rate at full input: - 5 gpm SOLO 110 - 7 gpm SOLO 155 - 9 gpm SOLO 199 Instinct Combi Pressure Drop 40.0...
  • Page 120 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...

This manual is also suitable for:

Solo 110Solo 199Combi 155Combi 199Ins155s

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