TriangleTube Instinct SOLO 155 Instruction Manual

NOTICE
Installation &
Maintenance
Manual
SOLO 110-155-199 & COMBI 155-199
- Customer must register unit within thirty (30)
days of installation in order to gain warranty
coverage. See Warranty Card for details.
- Leave all documentation received with
appliance with the owner for future
reference.
• To maintain the safety & longevity of
your appliance, read and follow the
maintenance schedule information
throughout this manual.
• If the information in this manual
is not followed exactly, a fire or
explosion may result causing
substantial property damage,
serious injury, or death.
FOR YOUR SAFETY
• Do not store or use gasoline or
other flammable vapors and liquids
in the vicinity of this or any other
appliance.
• WHAT TO DO IF YOU SMELL GAS
- Do not try to light any appliance
- Do not touch any electrical switch;
do not use any phone in your
building.
- Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
- If you cannot reach your gas
supplier, call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
226389 A03 - Oct 2021
201 9 - 1 6 Instinct WHB
Installation &
Maintenance Manual
THE
O RI G I NA L
IN NO VAT ORS
WARNING

INTENTIONALLY LEFT BLANK

TABLE OF CONTENTS
iii
PRODUCT AND SAFETY INFORMATION .................................................................. XI
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS..................................................1
1.1. INSTINCT boilers - Code Compliance....................................................................................... 1
1.1.1 Code Restrictions ...................................................................................................1
1.1.2 Operating Restrictions............................................................................................1
1.2. Determining Product Location..............................................................................................2
1.3. Boiler Freeze Protection Feature .........................................................................................2
1.4. Boiler Replacement .............................................................................................................2
1.5. Recommended Clearances .................................................................................................3
1.6. Residential Garage Installations ..........................................................................................3
CHAPTER 2 - COMBUSTION AIR & VENTING ............................................................ 5
2.1. Combustion Air Contamination ............................................................................................5
2.2. Ventilation and Combustion Air Requirements - Direct Vent .................................................6
2.3. Ventilation and Combustion Air Requirements - Category IV ................................................6
2.4. Methods of Accessing Combustion Air Into A Space - Category IV............................................ 7
2.4.1. Indoor Combustion Air ................................................................................... 7
2.4.2. Outdoor Combustion Air ................................................................................. 7
2.4.3 Combination of Indoor and Outdoor Combustion Air ..................................................8
2.5. Combustion Air and Vent Piping...........................................................................................8
2.6. Removal of an Existing Boiler from a Common Vent System ..................................................... 9
2.7. Carbon Monoxide Detector Installation ..............................................................................10
2.8. Commonwealth of Massachusetts Installation Requirements.................................................. 10
2.8.1 Installation of Carbon Monoxide Detectors ..............................................................10
2.8.2 Approved Carbon Monoxide Detectors....................................................................10
2.8.3 Signage ...................................................................................................................11
2.8.4 Inspection ...............................................................................................................11
2.8.5 Manufacturer Requirements - Gas Equipment Venting System Provided.....................11
2.8.6 Manufacturer Requirements - Gas Equipment Venting System Not Provided...............11
CHAPTER 3 - UNIT PREPARATIONS ........................................................................ 13
3.1. Handling Instructions .............................................................................................................. 13
3.2. Wall Mounting Installation ..................................................................................................13
3.3. Accessories............................................................................................................................ 13
3.4. Wall Mounting Guidelines ....................................................................................................... 14
3.5. Stud Walls - Installation......................................................................................................14
3.6. Wall Bracket Installation - Solid Walls.................................................................................14
3.7. Boiler Mounting..................................................................................................................14
3.8. Front Panel Removal .............................................................................................................. 14

TABLE OF CONTENTS
iv
CHAPTER 4 - BOILER PIPING ................................................................................. 15
4.1. General Piping Requirements............................................................................................15
4.2. Pressure Relief Valve ........................................................................................................15
4.3. Boiler Air Vent....................................................................................................................16
4.4. Low Water Cutoff Device ...................................................................................................16
4.5. Additional Limit Control ......................................................................................................17
4.6. Backflow Preventer ................................................................................................................. 17
4.7. INSTINCT Solo Boiler System Piping ...................................................................................... 17
4.7.1 Expansion Tank and Makeup Water ........................................................................18
4.7.2 Diaphragm Expansion Tank...................................................................................18
4.7.3 Closed-Type Expansion Tank.................................................................................18
4.7.4 Circulator ............................................................................................................18
4.7.5 Sizing Primary Piping.....................................................................................19
4.7.6 Domestic Hot Water System Piping .................................................................19
4.7.7 System Piping – Zone Circulators ....................................................................19
4.7.8 System Piping – Zone Valves ..........................................................................19
4.7.9 System Piping – Through Boiler ......................................................................19
4.7.10 System Piping – Radiant Heating ....................................................................19
4.7.11 System Piping – Special Application.................................................................20
4.7.12 System Piping – Multiple Units Installation...............................................................20
4.8. INSTINCT Combi Boiler System Piping .............................................................................20
4.8.1 Expansion Tank and Makeup Water ........................................................................21
4.8.2 Diaphragm Expansion Tank...................................................................................21
4.8.3 Circulator ............................................................................................................21
4.8.4 Sizing Primary Piping.....................................................................................22
4.8.5 System Piping – Zone Circulators ....................................................................22
4.8.6 System Piping – Zone Valves ..........................................................................22
4.8.7 System Piping – Through Boiler ......................................................................22
4.8.8 System Piping – Radiant Heating ....................................................................22
4.8.9 System Piping – Special Application .................................................................22
4.9. Optional System Piping and Cascading .............................................................................22
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING ..................................23
5.1. Domestic Piping Pressure Relief Valve ............................................................................. 23
5.1.1 Standard Installation.................................................................................... 23
5.1.2 Pressure Relief Valve - Standard Installations ..........................................................23
5.1.3 Pressure Relief Valve Discharge Piping....................................................................23
5.2. Thermal Expansion........................................................................................................... 24
5.3. Water Hammer ................................................................................................................. 25
5.4. Vacuum Breaker ............................................................................................................... 25

TABLE OF CONTENTS
v
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........................................................................................29
7.1. Gas Supply Piping Connection.......................................................................................... 29
7.2. Natural Gas....................................................................................................................... 30
7.2.1 Pipe Sizing .................................................................................................. 30
7.2.2 Supply Pressure Requirements ...................................................................... 30
7.3. Propane Gas .......................................................................................................................... 31
7.3.1 Pipe Sizing...........................................................................................................31
7.3.2 Supply Pressure Requirements ...................................................................... 31
CHAPTER 8 - WIRING..............................................................................................35
8.1. Internal Wiring................................................................................................................... 35
8.1.1 General Requirements .................................................................................. 35
8.1.2 Fuse Locations............................................................................................. 35
8.2. External Wiring ................................................................................................................. 40
8.2.1 General Requirements .................................................................................. 40
8.2.2 Line Voltage Connections .............................................................................. 40
8.3. External Wiring - INSTINCT Solo Units ..............................................................................40
8.3.1 Circulator Wiring ..........................................................................................40
8.3.2 Low Voltage Connections ..............................................................................41
8.3.3 Thermostat Wiring ...............................................................................................41
8.3.4 Outdoor Sensor Wiring .........................................................................................41
8.3.5 Domestic Hot Water Wiring............................................................................41
8.3.6 Additional Boiler Limits..................................................................................41
8.3.7 External Modulation Control...........................................................................42
8.3.8 System Sensor Wiring ...................................................................................42
8.3.9 Cascade Wiring - Optional..............................................................................42
8.3.10 Modbus.......................................................................................................42
CHAPTER 9 - CTRLMAX OPERATION....................................................................... 43
9.1. CTRLMax Navigation ........................................................................................................43
9.2. CTRLMax Menu Structure.........................................................................................44
9.3. Home Screen ....................................................................................................................45
9.4. Status Line Messages .......................................................................................................46

TABLE OF CONTENTS
vi
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. Domestic Hot Water EZ Setup - INSTINCT Combi Units................................................ 51
9.10. Altitude Setup ....................................................................................................................51
9.11. EZ Setup Reset .................................................................................................................52
9.12. Display EZ Setup
.................................................................................................................. 52
9.13. C H / DHW O p e r a t i on ..............................................................................................................5 3
9.14. Boiler Information ..............................................................................................................53
9.14.1 Information Items................................................................................................54
9.14.2 Lockout Screen 55
9.14.3 Manual Reset Lockouts 56
9.14.4 Automatic Reset Blocking Lockouts .................................................................57
CHAPTER 10 - START-UP PREPARATION ................................................................59
10.1. Boiler System Fluid Requirements .................................................................................... 59
10.1.1 Boiler Fluid pH Level 6.0 to 8.0 ....................................................................... 59
10.1.2 Boiler Fluid Hardness Less Than 7 Grains ................................................................59
10.1.3 Chlorinated Water........................................................................................ 59
10.1.4 Flush Boiler to Remove Sediment ................................................................... 59
10.1.5 Cleaning of Old Boiler/System........................................................................ 59
10.1.6 Cleaning of New Boiler/System ...................................................................... 59
10.1.7 Check and Test Antifreeze............................................................................. 60
10.1.8 Use of Antifreeze in the Boiler System.....................................................................60
10.2. Filling the Boiler System.....................................................................................................61
10.3. INSTINCT Combi Water Heater - Water Requirements ........................................................... 61
10.3.1 Filling the Domestic Circuit ............................................................................ 61
10.4. Check Low Water Cut-Off Device.......................................................................................61
10.5. Check For Gas Leaks ............................................................................................................. 62
10.6. Check Thermostat Circuit..........................................................................................62
10.7. Inspect Condensate Drain Assembly .................................................................................62
CHAPTER 11 - START-UP PROCEDURES..................................................................63

TABLE OF CONTENTS
vii
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.....................................................................65
11.3.5 Measure Input - Natural Gas Only................................................................... 66
11.3.6 Test High Temperature Limit ......................................................................... 66
CHAPTER 12 - OUTDOOR RESET CONTROL.............................................................67
12.1. Mounting the Outdoor Sensor ............................................................................................67
12.2. Wiring the Sensor ..............................................................................................................67
CHAPTER 13 - EXTERNAL MODULATING CONTROL ................................................69
13.1. Wiring the Modulating Controller............................................................................... 69
13.2. CTRLMax Programming ................................................................................................... 69
13.3. Programming of External Modulating Control .................................................................... 69
CHAPTER 14 - CHECK-OUT PROCEDURES...............................................................71
CHAPTER 15 - INSTALLATION RECORD ..................................................................73
CHAPTER 16 - MAINTENANCE SCHEDULES ............................................................ 75
16.1. Service Technician ............................................................................................................75
16.2. Owner Maintenance ..........................................................................................................75
CHAPTER 17 - MAINTENANCE PROCEDURES ......................................................... 77
17.1. Service Technician Maintenance Procedures.......................................................................... 77
17.2. Reported Problems ...........................................................................................................77
17.3. Check Surrounding Area ...................................................................................................77
17.4. Inspect Burner Area...........................................................................................................77
17.5. Check System Piping ........................................................................................................77
17.6. Clean Condensate Drain Assembly ...................................................................................77
17.7. Check Ventilation Air Openings .........................................................................................78
17.8. Inspect Vent and Combustion Air Piping ............................................................................78
17.9. Check Boiler System .........................................................................................................78
17.10. Check Expansion Tank......................................................................................................78
17.11. Check Boiler Relief Valve ..................................................................................................78
17.12. Inspection of Ignitor.................................................................................................. 78
17.13. Check Ignition Cable and Ground Wiring ...........................................................................79
17.14. Check Control Wiring.........................................................................................................79

TABLE OF CONTENTS
viii
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. Clean Heat Exchanger.......................................................................................................80
17.22. Check Carbon Monoxide Detectors ...................................................................................80
17.23. Review With Owner ...........................................................................................................80
17.24. Torque Specifications Table ..............................................................................................80
CHAPTER 18 - REPLACEMENT PARTS ..................................................................... 81
CHAPTER 19 - PRODUCT SPECIFICATIONS ............................................................ 93

ix
INDEX OF ILLUSTRATIONS AND TABLES
Fig. 1 - All Combustion Air from Adjacent Indoor Spaces through Indoor Combustion Openings ....... 7
Fig. 2 -All Combustion Air from Outdoors Through One Permanent Air Opening................................ 7
Fig. 3 - All Combustion Air from Outdoors Through Ventilated Attic ................................................ 8
Fig. 4 - All Combustion Air from Outdoors Through Horizontal Ducts.............................................. 8
Fig. 5 - Accessories ............................................................................................................................13
Fig. 6 - INSTINCT Pressure Relief Valve, Drain Valve, T&P Gauge Installation....................................15
Fig. 7 - Piping Component Legend .....................................................................................................16
Fig. 8 - INSTINCT Solo Near Boiler Piping - Hydraulic Separator .......................................................17
Fig. 9 - INSTINCT Solo Near Boiler Piping - Closely Spaced Tees......................................................18
Fig. 10 - INSTINCT Combi Near Boiler Piping - Hydraulic Separator .................................................20
Fig. 11 - INSTINCT Combi Near Boiler Piping - Timesaver Manifold ...................................................21
Fig. 12 - Standard Installation of the domestic pressure relief valve ............ 23
Fig. 13 - INSTINCT Combi - Hydro-block Flow Diagram..................................................................... 24
Fig. 14 - Condensate Drain Assembly............................................................................................... 28
Fig. 15 - Recommended Gas Supply Piping.......................................................................................29
Fig. 16 - Gas Valve / Venturi Assembly - INSTINCT Solo 110............................................................. 32
F ig . 1 7 - G a s Va l v e / Ve nt uri As se mbly - IN S TIN C T S olo / C o mbi 1 55 ................................................ 32
F ig . 1 8 - G a s Va l v e / Ve nt uri As se mbly - IN S TIN C T S olo / C o mbi 1 99 ................................................ 33
Fig. 19 - CTRLMax Control Module Fuse Location............................................................................. 35
Fig. 20 - Multiple Zones - Panel Wiring with Circulators.................................................................... 36
Fig. 21 - INSTINCT Combi System Piping - Multiple Zones - Panel Wiring with Valves ..................... 37
Fig. 22 - INSTINCT Solo Boiler Factory Wiring ..................................................................................38
Fig. 23 - INSTINCT Combi Boiler Factory Wiring ............................................................................... 39
Fig. 24 - Terminal Strip Location ......................................................................................................40
Fig. 25 - Low Voltage Connections .....................................................................................................41
Fig. 26 - CTRLMax User Interface .....................................................................................................43
Fig. 27 - Throttle Screw Location .......................................................................................................65
Fig. 28 - INSTINCT Solo Jacket Components ....................................................................................81
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. 34 - INSTINCT Combi 199 Internal Components ....................................................................... 87
Fig. 35 - INSTINCT Solo 110 Burner Components ..........................................................................88
F ig . 36 - IN S TIN C T S olo / C o mbi 1 55 B ur n e r C o mp on e nt s ............................................................. 89
Fig. 37 - INSTINCT Combi 199 Burner Components ........................................................................90

x
INDEX OF ILLUSTRATIONS AND TABLES
Fig. 38 - INSTINCT Control & Display Enclosures........................................................................91
Fig. 39 - INSTINCT Combi Hydro-block ......................................................................................92
Fig. 40 - Front View INSTINCT Solo 110............................................................................................ 94
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. 45 - Right Side View INSTINCT Solo 199................................................................................... 99
Fig. 46 - Front View INSTINCT Combi 155...................................................................................... 100
Fig. 47 - Right Side View INSTINCT Combi 155.............................................................................. 101
Fig. 48 - Front View INSTINCT Combi 199...................................................................................... 102
Fig. 49 - Right Side View INSTINCT Combi 199.............................................................................. 103
Graph 1 - INSTINCT Solo - Pressure Loss Through Boiler................................................................ 104
Graph 2 - INSTINCT Combi - Pressure Loss Through Boiler............................................................. 104
Table 1 - Natural Gas Venturis ........................................................................................................... 30
Table 2 - Gas Piping Sizing - Natural Gas .....................................................................................30
Table 3 - Propane Conversion Venturis ........................................................................................31
Table 4 - Outdoor Reset Preset Selections ...................................................................................49
Table 5 - Throttle Screw Adjustment.............................................................................................65
Table 6 - Acceptable Combustion Levels .....................................................................................66