TriangleTube SOLO 110, SOLO 155, SOLO 199, COMBI 155, COMBI 199 User's Information Manual

User’s
Information
Manual

SOLO 110155199 & COMBI 155199

NOTICE

- Customer must register unit within thirty (30)
days of installation in order to gain warranty
coverage. See Warranty Card for details.

WARNING

• To maintain the safety & longevity of

your appliance, read and follow the
maintenance schedule information
throughout this manual.

• If the information in this manual

is not followed exactly, a fire or
explosion may result causing
substantial property damage,
serious injury, or death.

FOR YOUR SAFETY

• Do not store or use gasoline or

other flammable vapors and liquids
in the vicinity of this or any other
appliance.

- Leave all documentation received with
appliance with the owner for future
reference.

• 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.

222168 A01 - July 2019
2019-17

ORIGINAL

THE

INNOVATORS

INTENTIONALLY LEFT BLANK

TABLE OF CONTENTS

SAFETY INFORMATION .......................................................................................................V

PRODUCT AND SAFETY INFORMATION ...........................................................................VI

PRODUCT AND SAFETY INFORMATION ......................................................................... VII

CHAPTER 1 - COMBUSTION AIR CONTAMINATION ......................................................... 1

CHAPTER 2 - MAINTENANCE SCHEDULES ...................................................................... 3

2.1. Service Technician ..........................................................................................................................3

2.2. Owner Maintenance ........................................................................................................................3

CHAPTER 3 - MAINTENANCE PROCEDURES ................................................................... 5

3.1. Owner Maintenance Procedures ...................................................................................................5

3.2. Daily Maintenance ...........................................................................................................................5

3.2.1 Check Surrounding Area .....................................................................................................5

3.2.2 Check Ventilation Air Openings ............................................................................................ 5

3.2.3 Check Temperature Display and Pressure Gauge ..............................................................6

3.3. Monthly Maintenance .....................................................................................................................6

3.3.1 Check Vent and Combustion Air Piping ..............................................................................6

3.3.2 Check Pressure Relief Valve .................................................................................................6

3.3.3 Check Condensate Drain System ........................................................................................7

3.4. 6-Month Maintenance ....................................................................................................................8

3.4.1 Check Water and Gas Piping ................................................................................................8

3.4.2 Operate Pressure Relief Valve ..............................................................................................8

3.4.3 Check Carbon Monoxide Detectors ..................................................................................... 8

CHAPTER 4 - OPERATING INSTRUCTIONS ...................................................................... 9

CHAPTER 5 - CTRLMAX OPERATION ............................................................................... 11

5.1. CTRLMax Navigation .....................................................................................................................11

5.2. CTRLMax Menu Structure ............................................................................................................ 12

5.3. Home Screen ................................................................................................................................. 13

5.4. Status Line Messages ................................................................................................................... 14

5.5. Main Menu ..................................................................................................................................... 15

5.6. EZ Setup ........................................................................................................................................15

5.7. CH / DHW Operation ................................................................................................................... 16

5.8. Language Selection ...................................................................................................................... 17

5.9. Boiler Information ........................................................................................................................18

5.9.1 Information Items ................................................................................................................ 19

5.10. Lockout History ............................................................................................................................ 20

5.10.1 Lockout Screen .................................................................................................................... 21

5.10.2 Manual Reset Lockouts .......................................................................................................22

5.10.3 Automatic Reset Blocking Lockouts ..................................................................................23

iii

INDEX OF ILLUSTRATIONS

Fig. 1 - Condensate Drain Assembly ..........................................................................................................7

Fig. 2 - Condensate Retention Clip - (Solo Models only) .........................................................................7

Fig. 3 - CTRLMax User Interface ...............................................................................................................11

iv

SAFETY INFORMATION

TITLE

SAFETY

IMPORTANT EXTRACTS FROM THE CONSUMER
PRODUCT SAFETY COMMISSION WEBSITE

WWW.CPSC.GOV

Carbon monoxide is produced by burning fuel. There­fore, any fuel-burning appliance in your home is a po­tential CO source.

When cooking or heating appliances are kept in good
working order, they produce little CO. Improperly oper­ating appliances can produce fatal CO concentrations
in your home.

What should you do?

Proper installation, operation, and maintenance of fu­el-burning appliances in the home is the most import­ant factor in reducing the risk of CO poisoning.

Make sure appliances are installed according to the
manufacturer’s instructions and the local codes. Most
appliances should be installed by professionals.

Always follow the appliance manufacturer’s directions
for safe operation.

Have the heating system (including chimneys and
vents) inspected and serviced annually by a trained ser­vice technician.

Examine vents and chimneys regularly for improper
connections, visible cracks, rust or stains.

Look for problems that could indicate improper appli­ance operations:

• Decreased hot water supply

• Furnace unable to heat house or runs continuously

• Sooting, especially on appliances and vents

• Unfamiliar, or burning odor

• Increased moisture inside of windows
Operate portable generators outdoors and away from

open doors, windows, and vents that could allow CO to
come indoors.

In addition, install battery-operated CO alarms or plug­in CO alarms with battery back-up in your home. Ev­ery home should have a CO alarm in the hallway near
the bedrooms in each separate sleeping area. The CO
alarms should be certied to the requirements of the
most recent UL, IAS, or CSA standard for CO alarms. Test
your CO alarms frequently and replace dead batteries. A
CO alarm can provide added protection, but is no sub­stitute for proper installation, use and upkeep of appli­ances that are potential CO sources.

Symptoms of CO poisoning

The initial symptoms of CO poisoning are similar to the
u (but without the fever) They include:

• Headache

• Fatigue

• Shortness of breath

• Nausea

• Dizziness
If you suspect that you are experiencing CO poisoning,

get fresh air immediately. Leave the home and call for
assistance from a neighbor’s home. You could lose con­sciousness and die from CO poisoning if you stay in the
home.

Get medical attention immediately and inform medical
sta that CO poisoning is suspected. Call the Fire De­partment to determine when it is safe to reenter the
home.

v

SAFETY

PRODUCT AND SAFETY INFORMATION

IMPORTANT SAFETY INFORMATION FOR
THE HOMEOWNER AND THE TECHNICIAN

This manual contains important information with respect to
the operation and maintenance of the appliance.

This manual must be provided to the Homeowner, who will
keep it in a safe place for future reference.

Triangle Tube accepts no liability for any damage,
injury, or loss of life resulting from incorrect
installation, alteration of any factory supplied
parts, or the use of parts or ttings not specied by
Triangle Tube. If there is a conict or doubt about the
proper installation of the unit or any factory supplied

replacement parts please contact Triangle Tube
Technical Support.

DEFINITIONS

The following terms are used throughout this manual
to bring attention to the presence of potential hazards
or to important information concerning the product.

DANGER

Indicates the presence of a hazardous situa­tion which, if ignored, will result in substantial

property damage, serious injury, or death.

WARNING

Indicates a potentially hazardous situation
which, if ignored, can result in substantial

property damage, serious injury, or death.

CAUTION

Indicates a potentially hazardous situation
which, if ignored, can result in minor property

damage, or injury.

NOTICE

Indicates special instructions on installation,
operation or maintenance, which are import­ant to the equipment but not related to person-

al injury hazards.

BEST PRACTICE

Indicates recommendations made by Triangle
Tube for the installers, which will help to ensure
optimum operation and longevity of the equip-

ment.

STOP !

READ BEFORE SERVICING

Failure to adhere to the guidelines within this manual

can result in substantial property damage, serious

injury, or death.

TECHNICIAN: When calling or writing about the INSTINCT,
please have the boiler model and serial number available.

DANGER

• Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of
the control system which has been under water.

• Avoid electrical shock when servicing the
appliance, by disconnecting the electrical supply
prior to performing service or maintenance.

• Failure to comply with these instructions will
result in substantial property damage, serious

injury, or death.

WARNING

• The INSTINCT Installation manual is for use only
by a qualified heating installer/service technician.
The homeowner will use this User's Information
Manual for reference.

• What to do if you smell gas:

- Do not try to light any appliance

- Do not touch any electrical switch; do not use

any phone in your building.

- Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s
instructions.

- If you cannot reach your gas supplier, call the

fire department.

• Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.

• Prior to installing this product, the qualified
installer must read all instructions included in
this manual and all accompanying manuals/
documents with this appliance.

• All installation steps required in these manuals
must be performed in the proper order given.

• This product must be maintained / serviced and
inspected annually by a qualified service technician.

• Failure to comply with these instructions can
result in substantial property damage, serious
injury, or death.

vi

PRODUCT AND SAFETY INFORMATION

WARNING

• A byproduct of any gas fired appliance is carbon
monoxide. Triangle Tube requires the installation
of a minimum of two (2) hard-wired carbon
monoxide detectors with an alarm and battery
back-up; one in the mechanical room where
the boiler is located and another installed in
the living area outside the bedroom(s) for all
installations. Consult the local authority having
jurisdiction for any additional carbon monoxide

detector requirements in your area. See Chapter

2 of the INSTINCT Installation & Maintenance
Manual for additional carbon monoxide detector

requirements in Massachusetts.

• Failure to comply with these instructions can
result in substantial property damage, serious
injury, or death.

Service and Maintenance:

• Allow the unit to cool down prior to servicing to
avoid severe burns.

• The INSTINCT must be maintained as outlined
in this manual and have at least annual service
performed by a qualified service technician to
ensure unit / system reliability.

INSTINCT Operation

• Do not block flow of combustion air to the
INSTINCT. If the combustion air blockage is easily
accessible and removable, then remove it. If
blockage is not obvious or cannot be removed,
have the unit and system checked by a qualified
service technician. If in doubt turn off your
INSTINCT Boiler.

• Do not allow contaminated air to enter the unit’s
combustion air inlet. See page 3 for details.

SAFETY

Boiler and System Water

• Have the boiler and system water chemistry
checked at least annually by a qualified service
technician.

• Do not use petroleum-based cleaning or sealing
compounds in the boiler or system. Gaskets and
seals in the system may be damaged, which can
result in substantial property damage.

• Do not use any product not specifically designed
for boiler / hydronic heating systems. Serious
damage to the unit, piping system, personnel
and / or property may result.

• Continual fresh makeup water will reduce the life
of the INSTINCT. Addition of oxygen can cause
internal corrosion in the system components. All
leaks in the system must be repaired at once to
prevent excessive makeup water.

• Do not add cold makeup water when the
appliance is hot. Thermal shock can potentially
cause cracks in the heat exchanger.

• Failure to comply with these instructions can
result in substantial property damage, serious
injury, or death.

CAUTION

• It is prohibited to carry out any modifications to
the appliance without prior written consent from
Triangle Tube.

• Faulty parts must only be replaced by genuine
Triangle Tube factory parts.

• Failure to comply with these instructions can result
in minor property damage, or injury.

• The INSTINCT is equipped with a low water cutoff
device. The boiler and system piping must be filled
and pressurized to 12 psig prior to startup. The unit
will shut down if the pressure falls below 7.2 psig.

• Should overheating occur or if the gas supply fails
to shut off, DO NOT turn OFF or disconnect the
electrical supply to the pump. Instead, turn OFF the
manual gas control valve external to the appliance.

• Combustion Readings - For your safety and to
benefit from best warranty terms, ask your installer
to provide combustion readings that are to be
registered with Triangle Tube. See Warranty Card.
Combustion readings should be checked at least
annually for safe and reliable operation.

NOTICE

• The homeowner is only permitted to carry out the basic
set-up operations (EZ Setup) after he has received all
relevant instructions from the installer. Any other set­up must be carried out by a qualified installer.

• In case of any anomaly, please call your qualified
service technician.

• Make sure to reference the unit’s model number and
serial number from the rating label when inquiring
about service or troubleshooting.

• Triangle Tube reserves the right to change the
technical characteristics, components and features of
its products without prior notice. Check for an updated
version of this manual at www.triangletube.com.

vii

INTENTIONALLY LEFT BLANK

CHAPTER 1 - COMBUSTION AIR CONTAMINATION

WARNING

If the INSTINCT combustion air inlet is located
in an area likely to cause or contain contamina­tion, or if products which could contaminate
the air cannot be removed, the combustion air
must be repiped and terminated at another lo­cation. Contaminated combustion air will dam­age the unit and its burner system, and can
result in substantial property damage, serious

injury, or death.

DANGER

• Do not operate the INSTINCT if the com­bustion air inlet is located near a laundry
room or pool facility. These areas will al-

ways contain hazardous contaminants.

• Pool, laundry, common household, and
hobby products often contain fluorine or
chlorine compounds. When these chem­icals pass through the burner and vent
system, they can form strong acids. These
acids will corrode the heat exchanger,
burner components, and vent system,
causing serious damage and possible
flue gas spillage or water leakage into

the surrounding area.

• Please read the information listed below.
If contaminating chemicals are located
near the area of the combustion air inlet,
the installer must pipe the combustion
air inlet to an area free of these chemicals.

• Failure to comply with these instructions
will result in substantial property dam-

age, serious injury, or death.

• The INSTINCT boiler is classified as a
Category IV appliance. This utilizes un­contaminated indoor or outdoor air for
applicance combustion. A direct vent
installation uses the outdoor air. Air sup­ply, combusiton chamber, heat exchang­er and evacuation of POC (products of
combustion) for this type of appliance is
sealed with respect to the room in which

the appliance is installed.

• An in-direct installation uses uncontam­inated indoor air for appliance combus-

tion.

• When the air for combustion is taken
from the room an air grille must be in-

stalled by the contractor.

•

DANGER

•

• Ensure the vent grilles are free from ob­struction at all times. Do not be tempt­ed to restrict or cover the air grilles as it

could cause serious injury, or death.

Potential contaminating products

• Spray cans containing chloro/uorocarbons

• Permanent Wave Solutions

• Chlorinated wax

• Chlorine based swimming pool chemicals /
cleaners

• Calcium Chloride used for thawing ice

• Sodium Chloride used for water softening

• Refrigerant leaks

• Paint or varnish removers

• Hydrochloric acid / muriatic acid

• Cements and glues

• Antistatic fabric softeners used in clothes dryers

• Chlorine-type bleaches, detergents, and clean­ing solvents found in household laundry rooms

• Adhesives used to fasten building products and
other similar products

Areas likely to contain these products

• Dry cleaning / laundry areas and establishments

• Beauty salons

• Metal fabrication shops

• Swimming pools and health spas

• Refrigeration Repair shops

• Photo processing plants

• Auto body shops

• Plastic manufacturing plants

• Furniture renishing areas and establishments

• New building construction

• Remodeling areas

• Garages with workshops

CHAPTER 1

1

INTENTIONALLY LEFT BLANK

CHAPTER 2 - MAINTENANCE SCHEDULES

2.1. Service Technician

At least on an annual basis the following maintenance
should be performed by a qualied service technician:

General

• Attend to any reported problems.

• Inspect the interior of the boiler jacket area; clean
and vacuum if necessary.

• Clean the condensate drain assembly and ll with
fresh water.

• Check boiler uid pH on systems.

• Check for leaks, both inside and outside the unit:
water, gas, ue and condensate.

• Verify vent piping and air inlet piping are in good
condition, sealed tight and properly supported.

• Check boiler water pressure, piping and expansion
tank.

• Check control settings.

• Check ignition electrode (sand o any white oxide;
clean and reposition).

• Check ignition wiring and ground wiring.

• Check all control wiring and connections.

• Check burner ame pattern (stable and uniform).

• Check carbon monoxide detectors.

Additional items if combustion or performance is
poor:

• Clean heat exchanger and ue ways.

• Remove burner assembly and clean burner head
using compressed air only.

2.2. Owner Maintenance

Periodically:

• Check the area around the unit.

• Check and remove any blockage from the combus­tion air inlet and ventilation openings.

• Check the temperature and pressure gauges.

Monthly:

• Check vent piping.

• Check combustion air inlet piping or air grilles.

• Check the pressure relief valve.

• Check the condensate drain system.

Every 6 months:

• Check boiler piping and gas supply piping for cor­rosion or potential signs of leakage.

• Operate the pressure relief valve.

• Check carbon monoxide detectors.

WARNING

Follow the maintenance procedures given in
Chapter 3 on page 5 of this manual. Failure

to perform the service and maintenance or
follow the directions in this manual can result
in damage to the INSTINCT or system com­ponents, resulting in substantial property

damage, serious injury, or death.

CHAPTER 2

Service Technician maintenance procedures can be
found in Chapter 17 of the INSTINCT Installation and
Maintenance manual.

Once the maintenance items are completed, review
the service with the owner.

3

INTENTIONALLY LEFT BLANK

CHAPTER 3 - MAINTENANCE PROCEDURES

3.1. Owner Maintenance Procedures

WARNING

The INSTINCT must be inspected and ser­viced annually, preferably at the start of the
heating season, by a qualified service tech­nician. In addition, the owner maintenance

and care of the unit as outlined in Chapter
2 on page 3 and further explained in this

chapter should be performed to assure max­imum safety, efficiency and reliability of the
unit. Failure to service and maintain the
INSTINCT and the system components can
result in equipment failure, resulting in sub­stantial property damage, serious injury, or

death.

WARNING

In the case of In-direct vent installation the air
openings provided by the installer to supply
ventilation and combustion air are essential
for safe operation of the appliance. The user
must respect the importance of these air
openings and ensure that they are not partial
ly or fully blocked under any condition. Fail­ure to ensure free uncontaminated air flow
through the openings can result in substantial

property damage, serious injury, or death.

NOTICE

The following information provides detailed
instructions for completing the owner main­tenance items outlined in the maintenance

schedule in Chapter 2 on page 3.

3.2. Daily Maintenance

3.2.1 Check Surrounding Area

WARNING

If contaminates are found:

• Remove products immediately from the
area. If they have been there for an ex­tended period, call a qualified service
technician to inspect the unit for possible

damage from corrosion.

• If products cannot be removed, immedi­ately call a qualified service technician
to re-pipe the combustion air inlet pip­ing and locate the combustion air intake

away from the contaminated areas.

Failure to comply with these instructions can
result in substantial property damage, seri-

ous injury, or death

• Verify that the area surrounding the INSTINCT is
free of combustible / ammable materials or am­mable vapors or liquids. Remove immediately if
found.

• Verify that combustion air inlet area is free of any
contaminates. Refer to the materials listed in
Chapter 1 on page 1 of this manual. If any of
these products are in the area from which the unit

-

takes its combustion air, they must be removed
immediately or the combustion air intake must be
relocated to another area.

WARNING

CHAPTER 3

3.2.2 Check Ventilation Air Openings

Verify that all ventilation openings to the mechan­ical room or building are open and unobstructed.

Check and verify that the vent termination
and the combustion air intake are free of de­bris and obstructions. Remove any debris on
the air intake or flue exhaust openings. If re­moving the debris does not allow the unit to
operate correctly, contact a qualified service
technician to inspect the unit and the vent /

combustion air system.

Eliminate all the materials listed in Chapter 1
on page 1 from the area surrounding the

unit and from the vicinity of the combustion

air inlet.

5

CHAPTER 3 - MAINTENANCE PROCEDURES

CHAPTER 3

3.2.3 Check Temperature Display and Pressure Gauge

• Ensure the pressure reading on the pressure gauge
does not exceed 25 psig. Higher pressure readings
may indicate a problem with the expansion tank.

• Ensure the temperature on the display panel does
not exceed 194ºF. Higher temperature readings
may indicate a water ow problem.

• Contact a qualied service technician if problem
persists.

WARNING

The annual servie and inspection must ensure

the venting and air supply are maitained in a
correct and safe working condition. Damaged
vent and air supply can result in serious injury,

or death.

3.3. Monthly Maintenance

3.3.2 Check Pressure Relief Valve

1. Visually inspect the pressure relief valve and the
relief valve discharge pipe for signs of weeping or
leakage.

2. If the pressure relief valve weeps often, the expan­sion tank may not be operating properly. Immedi­ately contact a qualied service technician to in­spect the unit and system.

3.3.1 Check Vent and Combustion Air Piping

• Visually inspect the venting system and combus­tion air piping for blockage, deterioration of gas­kets or leakage. Contact a qualied service techni­cian immediately if any problems are found.

WARNING

In the case of In-direct vent installation the air
openings provided by the installer to supply
ventilation and combustion air are essential
for safe operation of the appliance. The user
must respect the importance of these air
openings and ensure that they are not partial
ly or fully blocked under any condition. Fail­ure to ensure free uncontaminated air flow
through the openings can result in substantial

property damage, serious injury, or death.

DANGER

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

or death.

-

6

CHAPTER 3 - MAINTENANCE PROCEDURES

3.3.3 Check Condensate Drain System

1. Ensure condensate drain assembly is rmly secured
to bottom of the unit. See Fig. 1 on the right. Ensure
the Retention clip is secure. See Fig. 2 (Solo Models
only).

WARNING

Do not operate the boiler without the fac­tory-supplied condensate drain assembly
installed. Operation of the boiler without
the condensate drain assembly installed can
result in property damage, serious injury, or

death.

2. While the unit is running, check the discharge end
of the condensate drain tubing. Ensure no ue gas
is leaking from the condensate drain tubing by
holding your ngers near the opening.

3. If you notice ue gas leaking, turn o the unit and
contact a qualied service technician to inspect the
unit and condensate drain assembly.

4. Ensure the condensate drain tubing is not blocked
by pouring water through the ll plug port on the
condensate drain assembly. The water should ow
out of the end of the drain tubing. If water does
not appear at the end of the drain tubing, contact
a qualied service technician to inspect and clean
the condensate drain assembly.

5. To ll the condensate drain assembly, remove the ll
plug from the condensate assembly. Slowly pour wa­ter into the assembly until water appears at the end
of the drain tubing. Stop lling and replace plug.

RETAINING NUT

RETENTION

CLIP

FOR SOLO

MODELS ONLY

REFER TO FIG. 2

PLASTIC BALL

NOT SHOWN

CONDENSATE

DRAIN ASSEMBLY

RETENTION

FOR SOLO

MODELS ONLY

SEALS

FILL PLUG WITH VACCUM
BREAK PORT

Fig. 1 - Condensate Drain Assembly

CLIP

COMPRESSION NUT
WITH RUBBER SEAL

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

RETAINING NUT

CHAPTER 3

Fig. 2 - Condensate Retention Clip - (Solo Models only)

7

CHAPTER 3 - MAINTENANCE PROCEDURES

TITLE

CHAPTER 3

3.4. 6-Month Maintenance

3.4.1 Check Water and Gas Piping

1. Remove the boiler front jacket panel and perform
a gas leak inspection per steps 1 through 6 of the
Operating Instructions on page 9. If gas odor or
a leak is detected, immediately shut down the unit
following procedures on page 9. Call a qualied
service technician.

2. Visually inspect for leaks around the internal boiler
water connections and around the heat exchanger.
Visually inspect the external system piping, circula
tors, and system components and ttings. Immedi­ately call a qualied service technician to repair any
leaks.

WARNING

Have leaks fixed at once by a qualified service
technician. Failure to comply can result in
substantial property damage, serious injury,

or death.

3.4.2 Operate Pressure Relief Valve

1. Before proceeding, verify that the relief valve outlet
has been piped to a safe place, avoiding any possi­bility of scalding from hot water.

3. If water ows freely, release the lever and allow
the valve to seat. Watch the end of the relief valve
discharge pipe to ensure that the valve does not
weep after the line has had time to drain. If the
valve weeps, lift the lever again to clean the valve
seat. If the valve does not properly seat and con­tinues to weep afterwards, contact a qualied ser­vice technician to inspect the valve.

f water does not ow from the valve when you lift

4. I
the lever completely, the valve or discharge line
may be blocked. Immediately shut the unit down
per the instructions on page 9. Call a qualied

-

service technician to inspect the valve and dis
charge line.

3.4.3 Check Carbon Monoxide Detectors

Verify that at least two (2) carbon monoxide detectors
are installed and operating properly. One must be in­stalled in the mechanical room where the INSTINCT is
located and another installed in the living area outside
the bedroom(s).

Contact a qualied service technician if carbon mon­oxide detectors are not installed or operating properly.

-

WARNING

To avoid water damage or scalding, a dis­charge line must be connected to the relief
valve outlet and directed to a safe place of
disposal. This discharge line must be installed
by a qualified service technician in accor
dance with the INSTINCT installation manu­al. The discharge line must be terminated so
as to eliminate possibility of severe burns or
property damage should the valve discharge.
Failure to comply can result in substantial

property damage, serious injury, or death.

2. Read the pressure gauge to ensure the system is
pressurized. Lift the relief valve top lever slightly,
allowing water to relieve through the valve and dis­charge piping.

-

8

CHAPTER 4 - OPERATING INSTRUCTIONS

FOR YOUR SAFETY, READ BEFORE LIGHTING

WARNING

If you do not follow these instructions exactly, a fire or explosion may result,

causing substantial property damage, serious injury, or death.

A. This appliance does not have a pilot. It is equipped

with an ignition device which automatically lights
the burner. DO NOT try to light the burner by hand.

B. BEFORE OPERATING, smell all around the appliance

area for gas. Be sure to smell next to the oor be­cause some gas is heavier than air and will settle on
the oor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not
use any phone in your building

• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas suppli­er’s instructions.

• If you cannot reach your gas supplier, call
the re department.

OPERATING INSTRUCTIONS

C. Use only your hand to turn the external manual

gas valve. Never use tools. If the valve will not turn
by hand, don’t try to repair it; call a qualied service
technician. Force or attempted repair may result in
a re or explosion.

D. Do not use this appliance if any part has been

under water. Immediately call a qualied service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.

CHAPTER 4

1. STOP! Read the safety information above. This ap­pliance is equipped with an ignition device which
automatically lights the burner. DO NOT try to
light the burner by hand.

2. Set room thermostat(s) to lowest setting. Turn the
external manual gas valve handle clockwise
to “CLOSE” (valve handle must be perpendicular to
gas piping).

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

4. Remove the front jacket panel on the unit.

5. Wait ve (5) minutes to clear out any gas. If you
then smell gas in the jacket enclosure or around
the unit, STOP! Follow “B” in the safety information
above. If you don’t smell gas, go to the next step.

6. Turn the external manual gas valve handle count­er clockwise
handle shall be parallel to gas piping).

to “OPEN” gas supply (valve

TO TURN OFF GAS TO APPLIANCE

1. Set the room thermostat to lowest setting.

2. Turn the service switch on the appliance control
panel to “OFF”

7. Turn the service switch on the appliance control
panel “ON”.

8. Set room thermostat(s) to desired setting(s).

9. The appliance control panel display will show the
current operating status on the Status Line at the
bottom of the screen. “Standby” means there is
no call for heat (all thermostats are satised). “CH
Demand” indicates a space heating call has been
received. “DHW Demand” indicates a domestic hot
water call has been received. A ame icon will be
displayed when the unit is red.

10. If the unit will not operate, follow the instructions
“To Turn O Gas to Appliance” and call your service
technician or gas supplier.

11. Replace the front jacket panel. Make sure the panel
is seated rmly in place and all mounting screws
are tightened.

3. Turn the external manual gas valve handle clock­wise

to “CLOSE”.

9

INTENTIONALLY LEFT BLANK

CHAPTER 5 - CTRLMAX OPERATION

The CTRLMax Boiler Management System is designed
to be exible yet easy to use. CTRLMax monitors and
controls the INSTINCT to provide heat as eciently as
possible.

All CTRLMax features are easy to use through a graphi­cal display where information is presented either graph­ically or in plain English, so code charts are not required.
Fig. 3 below shows an CTRLMax display example of the
INSTINCT Solo red for a domestic hot water demand.

5.1. CTRLMax Navigation

The CTRLMax navigation is performed through soft keys
that react to the touch and emit a short beep when tapped.

NOTICE

Exert a light and short touch (tap) on the soft
keys to activate their function. Holding the
touch too long will not generate any reaction
from the CTRLMax, unless it is a combination of
soft keys meant to be touched simultaneously
for a determined duration, as instructed in this
manual. The arrow keys can also be held longer

to increase or decrease values faster.

Navigation is performed through four arrow soft keys

by touching the center soft key .

To shut down the unit, touch the

DANGER

When touching the

shuts down but is not isolated from power
supply. Therefore, live current is still present
in the unit. For your safety, disconnect elec­trical power supply to the unit before servic­ing or making any electrical connections to
avoid possible electric shock hazard. Failure

to do so can cause serious injury, or death.

NOTICE

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

remain active.

• In addition, the arrow soft keys are no longer

illuminated, and the

,

dimmed.

soft key.

soft key, the unit

soft key,

soft key lighting is

, , with a center soft key (OK /Reset func-

tions) for making selections and entering information.
The Main Menu can be entered from the Home Screen

Instinct

DHW

DHW Demand

The menu system utilizes icons to represent each se­lection. The current selected menu is displayed as a re­versed image with a text description shown at the top
of the display. Menus can be entered by selecting the
the desired icon (highlights) using the arrow soft keys.

CHAPTER 5

Fig. 3 - CTRLMax User Interface

11

CHAPTER 5 - CTRLMAX OPERATION

5.2. CTRLMax Menu Structure

INSTINCT

186°F

DHW

156°F

Target = 186°F

DHW Demand

CHAPTER 5

EZ Setup

CH / DHW Operation

Heating Enabled

Select Language

Select Language

English

Français
Nederlands
Español
Italiano
Deutsch

Boiler Information

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Heating EZ Setup DHW EZ Setup

12

EZ Setup Reset Display EZ Setup

CHAPTER 5 - CTRLMAX OPERATION

5.3. Home Screen

The Home Screen presents status information in a very
user friendly way so that the current state of the boiler
can be quickly accessed.

• Screen backlight - it will illuminate when any soft
key is touched, and remain illuminated for ve min­utes.

• Screen brightness - it can be adjusted at the
Home screen by touching and holding simulta-

neously the
Touch the

crease the contrast. Touch

and soft keys for 2 seconds.

and soft key to increase or de-

to end the process.

Main Icons of CTRLMax display

• Central Heating - indicates information related
to central/space heating.

•

•

•

•

•

•

•

•

DHW - indicates information related to Domes-

tic Hot Water.

Home - to go back to the home screen.

Back - to go back to the previous screen.

Warm Weather Shutdown - displays on the
home screen when the outdoor temperature
reaches the Warm Weather Shutdown tempera­ture.

Reset - to reset the system to the factory set­tings.

Settings - to access controller settings (lan-

guage, units, etc.).

Easy Setup - to quickly adjust the most com-

mon settings.

CH/DHW operation - to enable/disable the
central/space heating or Domestic Hot Water func­tions

The model is indicated at the top of the screen.

The INSTINCT is represented in the center of the Home Screen. Basic operating infor-

mation such as supply and return temperatures are displayed as well as current burner

Radiator icon: indicates that a central heating
call has been received. A small number 1 or 2
indicates which CH calls are active

A ame symbol is displayed when the unit is red. The
ame size changes to indicate the current ring rate.

Basic information: The user can toggle

through items using the
keys to view Target, Supply, Return, Domestic,
Outdoor, System and Mix Zone temperatures,
DHW ow.

and soft

status.

INSTINCT Combi

186°F

156°F

Target = 186°F

DHW Demand

Information - to get information on the boiler.

•

Faucet icon: indicates that a DHW call has been
received.

Circulator icons: indicate which circulators are currently

DHW

powered.

Status line: displays the current operating state of
the boiler.

CHAPTER 5

13

CHAPTER 5 - CTRLMAX OPERATION

5.4. Status Line Messages

Standby - Indicates that the INSTINCT is ready to re-

spond when a demand is received.

CH Demand - A central heating call has been received.

DHW Demand - A domestic hot water call has been

received.

CH/DHW Demand - Central heating and domestic hot
water calls are being received simultaneously. Both calls
are being satised simultaneously because domestic
hot water priority has been disabled.

DHW Priority - Central heating and domestic hot wa­ter calls are being received simultaneously. Domestic
hot water call is being satised rst because it has prior­ity over central heating calls.

Priority Timeout - Central heating and domestic hot wa­ter calls are being received simultaneously. The domestic
hot water priority time limit has been exceeded. Priority
will now switch back and forth between central heating
and domestic hot water calls until one call is satised.

External Demand - An external modulation call has
been received.

DHW Post Pump - The domestic hot water circulator(s)
is/are running to remove heat from the INSTINCT at the
completion of a call.

Freeze Protection - The burner is red because the
freeze protection feature has been activated. Freeze
protection will end once the supply/system water tem­perature is raised to 60°F [16°C].

Boiler Protection - The burner ring rate is being re­duced because of an excessive dierence between the
boiler supply and return temperatures. The ring rate
will begin increasing once the temperature dierence
is less than 45°F [25°C].

Low Water Pressure - The system pressure has dropped
to 10.1 psi. The INSTINCT will still respond to calls until
the pressure drops below 7.2 psi. Increase system pres­sure to 14.5 psi to clear Low Water Pressure warning

Lockout Description - The lockout which currently
has the INSTINCT shut down is displayed.

CHAPTER 5

Slave Operation - The INSTINCT is a slave in a cascade
system.

Manual Operation - The burner or circulators have
manually been enabled in the Installer Menu.

CH Burner Delay - The burner will not re until the call
blocking time has elapsed.

DHW Burner Delay - The burner will not re until the
call blocking time has elapsed.

CH Setpoint Reached - The burner is not red because
the supply/system water temperature exceeds the set­point. The central heating circulator(s) continue(s) to
operate and the burner will re again once the supply/
system water temperature drops below the setpoint.

DHW Setpoint Reached - The burner is not red be­cause the supply/system water temperature exceeds the
setpoint. The domestic circulator(s) continue(s) to oper­ate and the burner will re again once the supply/system
water temperature drops below the setpoint.

CH Post Pump - The central heating circulator(s) is/are
running to remove heat from the INSTINCT at the com­pletion of a call.

14

CHAPTER 5 - CTRLMAX OPERATION

5.5. Main Menu

The Main Menu can be entered from the Home Screen

by touching the
The menu system utilizes icons to represent each se-

lection.
The currently selected menu is displayed as an inversed im-

age with a text description shown at the top of the display.
Menus can be entered by scrolling through the icons

using the arrow soft keys, highlighting the desired icon

and touching the

soft key.

soft key.

INSTINCT Combi

186°F

Target = 186°F

5.6. EZ Setup

The EZ Setup menus provide a simple way to quick­ly customize CTRLMax for each installation. EZ Setup
prompts the user to make selections which allows the
INSTINCT to be setup very quickly without searching
through long lists of settings and manually making ad­justments.

DHW

156°F

The EZ Setup menu can
be accessed by selecting
this icon.

The Boiler Information
Menu can be accessed
by selecting this icon.

DHW Demand

Touch center soft key

EZ Setup

CHAPTER 5

Currently selected menu

The CH / DHW Operation
Menu can be accessed by
selecting this icon.

The Home Screen icon at
the bottom of each screen
returns to the Home Screen
when selected.

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

15

CHAPTER 5 - CTRLMAX OPERATION

5.7. CH / DHW Operation

The CH / DHW Operation Menu can be entered from the Main Menu by selecting the CH / DHW Operation icon

CHAPTER 5

and touching the
heating or domestic hot water functions of the INSTINCT.

soft key. The CH / DHW Operation Menu provides a simple way to disable either the central

CH / DHW Operation

Heating Operation can be
enabled and disabled by se­lecting the radiator icon and

touching the
toggle operation between
enabled and disabled.

A radiator icon with an X
through it indicates that the
heating function is disabled.

This icon is also displayed on
the Home Screen when dis­abled.

soft key to

Heating Enabled

Domestic Hot Water Opera­tion can be enabled and dis­abled by selecting the faucet

icon and touching the
soft key to toggle operation
between enabled and dis­abled.

A faucet icon with an X
through it indicates that the
domestic hot water function
is disabled.

This icon is also displayed on
the Home Screen when dis­abled.

16

CHAPTER 5 - CTRLMAX OPERATION

5.8. Language Selection

The Select Language Menu can be entered from the Main Menu by selecting the Select Language icon and touch-

ing the
(nine dierent languages: English, French, Dutch, Spanish, Italian, German, Czech, Polish and Russian).

soft key. The Select Language Menu provides a simple way to select the language used on the display

Select Language

Touch the
to select the required lan-

guage then touch the
soft key to store the setting

and soft keys

Select Language

English

CHAPTER 5

Français
Nederlands
Español
Italiano
Deutsch

17

CHAPTER 5 - CTRLMAX OPERATION

5.9. Boiler Information

Boiler Information can be viewed by selecting the Boiler Information icon and pressing the OK button. Boiler
Information provides real time operating information of the INSTINCT.

Boiler Information

Boiler Information

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CHAPTER 5

Boiler Information displays six boil­er readings at a time. Each line con­tains an information item followed
by its current value. Touch the
and

soft key to scroll through

additional information items.

Some information items include a
logging function.

Select the information item then

touch the

soft key to view its

graph.
One sample is recorded every 12

minutes to produce a graph of the
last 24 hours.

Boiler Information

Boiler Status Standby

Heating Call No

DHW Call No

Boiler Firing Rate --

Ionization current 0μA

Boiler Setpoint --

The following items have a logging
function:

• Boiler Firing Rate

• Ionization Current

• Boiler Setpoint

Boiler Setpoint

194

• Boiler Supply Temperature

• Boiler Return Temperature

• Boiler Flue Temperature

• Outdoor Temperature

68

-16.00

-24.00

-8.00

0.00

• DHW Storage Temperature

• External Modulation Signal

• Pressure

18

CHAPTER 5 - CTRLMAX OPERATION

5.9.1 Information Items

Information Item Description

Boiler Status

Heating Call Displays if a central heating call is present.

DHW Call Displays if a domestic hot water call is present.

Boiler Firing Rate Displays the current ring rate of the INSTINCT.

Ionization Current Displays the current ame ionization current from the ignitor.

Boiler Setpoint Displays the current setpoint of the INSTINCT.

Supply Temp. Displays the current supply temperature of the INSTINCT.

Return Temp. Displays the current return temperature to the INSTINCT.

Boiler Flue Temp. Displays the current ue temperature of the INSTINCT.

Outdoor Temp. Displays the current outdoor temperature.

DHW Storage Temp.

External Modulation Signal

Displays the current operating state of the INSTINCT. This is the same as the sta­tus line on the home screen.

Displays the current DHW storage temperature when Indirect Water Heater Sen­sor PSRKIT22 is installed.

Displays the current external modulation signal being received from an external
controller.

CHAPTER 5

Pressure Displays the current system water pressure.

CH Ignitions

CH Runtime

DHW Ignitions

DHW Runtime

Mix Zone Temperature Displays the current low temperature mix zone temperature.

Displays the number of central heating ignitions since the unit was installed. This
counter increases in increments of twenty.

Displays the number of hours the INSTINCT has run for a central heating call since
the unit was installed.

Displays the number of domestic hot water ignitions since the unit was installed.
This counter increases in increments of twenty.

Displays the number of hours the INSTINCT has run for a domestic hot water call
since the unit was installed.

19

CHAPTER 5 - CTRLMAX OPERATION

5.10. Lockout History

Lockout History can be viewed by selecting the Lockout History icon and pressing the OK button. The Lockout
History Screen lists the last eight lockouts along with how long ago they occurred.

Boiler Information

Lockout History

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CHAPTER 5

Lockout History displays the last
eight lockouts. The newest lock­out is displayed at the top of the
screen.

The lockout message is followed
by how long ago the error oc­curred.

Touch the

and soft keys to

scroll through additional lockouts.

Lockout Details displays the lock­out at the top of the screen fol­lowed by a snapshot of the boiler
information recorded at the time
of the lockout.

Touch the

and soft keys to
scroll through additional informa­tion items.

Lockout History

1. Blower speed 5h ago

2. DHW Sensor Open 2h ago

3. Sensor Drift 25 h ago

4. No error 27 h ago

5. No error 27 h ago

6. No error 27 h ago

Lockout Details

Blower speed

Boiler Status --

Heating Call --

DHW Call --

Boiler Firing Rate 44%

Ionization current 44μA

20

CHAPTER 5 - CTRLMAX OPERATION

5.10.1 Lockout Screen

If a problem occurs, the Lockout Screen replaces the Home Screen. The backlight will remain on until the lockout
is reset.

Pressing any arrow button will return to the Home Screen so that additional troubleshooting can be performed. See
Sections 5.10.2 on page 22 and 5.10.3 on page 23 for a list of lockouts and descriptions.

The lockout message is displayed at the top of the screen

Low Water

The rst sentence gives a
description of the lockout.

The third sentence tells how
to reset the lockout

Water pressure has fallen below

an acceptable operating level.

Increase pressure to normal

range. Boiler will automatically

reset once water level returns to

normal.

The second sentence gives a
possible cure for the lockout.

Press any ARROW button to
return to the Home Screen
while locked out.

The Main Menu can then be
entered from the Home Screen
to help diagnose the problem.

Select the Home Screen icon
at the bottom of any menu
screen to return to the Lockout
Screen.

If problem persists,

call for service

Press any ARROW Button

INSTINCT Solo

186°F

156°F

Target = --

E37

The lower right corner displays
the lockout reference code

CHAPTER 5

Low Water

The status line now displays the lockout

21

CHAPTER 5 - CTRLMAX OPERATION

5.10.2 Manual Reset Lockouts

Code Lockout Message Description

E1 Failed Ignition The burner failed to light after 5 ignition attempts.

E2 False Flame Flame detected prior to ignition.

E3 High Boiler Temperature Boiler temperature has reached 210°F [99ºC] or 102°F [39°C].

E5 Blower Speed Blower is not at correct speed or speed signal is not being received by control module.

E8 Flame Circuit Error Flame circuit test failed.

E9 Gas Valve Circuit Error Gas valve circuit test failed.

E13 Reset Limit Reached Resets are limited to 5 every 15 minutes.

E15 Sensor Drift Supply or return sensor reading has drifted.

CHAPTER 5

E16 Supply Sensor Stuck Supply sensor reading is not changing.

E17 Return Sensor Stuck Return sensor reading is not changing.

E18 Sensor Failure Supply or return sensor reading changed very rapidly.

E19 Flame Failure During Startup Phase Flame lost after startup

E21 Internal Control Fault A / D conversion error.

E30 Supply Sensor Shorted A short circuit has been detected in the boiler supply temperature sensor circuit.

E31 Supply Sensor Open An open circuit has been detected in the boiler supply temperature sensor circuit.

E43 Return Sensor Shorted A short circuit has been detected in the boiler return temperature sensor circuit.

E44 Return Sensor Open An open circuit has been detected in the boiler return temperature sensor circuit.

E47 Water Pressure Sensor Error Water pressure sensor is disconnected or broken.

E80 Return > Supply Return temperature is higher than supply temperature.

E83 Delta T Protection Excessive difference between boiler supply and return temperatures has occured 5 times

E87 External Limit Open An external manual reset limit has opened

22

CHAPTER 5 - CTRLMAX OPERATION

5.10.3 Automatic Reset Blocking Lockouts

Code Lockout Message Description

E7 High Flue Temperature Flue temperature exceeds high limit.

E12 Internal Control Fault EEPROM misconguration.

E25 Internal Control Fault CRC check error.

E32 DHW Sensor Shorted A short circuit has been detected in the DHW temperature sensor circuit.

E33 DHW Sensor Open An open circuit has been detected in the DHW temperature sensor circuit.

E34 Low Voltage Line voltage has fallen below an acceptable operating level.

E37 Low Water Water pressure has fallen below 7.2 psi.

E45 Flue Sensor Shorted A short circuit has been detected in the boiler ue temperature sensor circuit.

E46 Flue Sensor Open An open circuit has been detected in the boiler ue temperature sensor circuit.

E76 External Limit Open An external automatic reset boiler limit has opened.

E77 High Mix Circuit Temperature Mix circuit temperature exceeds Mix zone high limit setting.

E78 Mix Circuit Sensor Shorted A short circuit has been detected in the mix circuit temperature sensor circuit.

E79 Mix Circuit Sensor Open An open circuit has been detected in the mix circuit temperature sensor circuit.

E81 Sensor Drift Supply and return temperatures are not equal.

E82 Delta T Protection Excessive dierence between the boiler supply and return temperatures.

E89 Incorrect Setting A parameter setting is in conict with another setting.

E90 Firmware Mismatch Control module and display rmware versions are incompatible.

E91 System Sensor Shorted A short circuit has been detected in the system temperature sensor circuit.

E92 System Sensor Open An open circuit has been detected in the system temperature sensor circuit.

E93 Outdoor Sensor Shorted A short circuit has been detected in the outdoor temperature sensor circuit.

E94 Internal Display Fault Display memory error.

E95 Supply Sensor Error Supply sensor reading is invalid.

E96 Outdoor Sensor Open An open circuit has been detected in the outdoor temperature sensor circuit.

CHAPTER 5

E97 Cascade Mismatch Cascade conguration has changed.

E98 Cascade Bus Error Communication with other boilers has been lost.

E99 Controller Bus Error Communication between boiler display and control module has been lost.

23

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24

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Tel: [phone] - Fax: [phone] - E-mail: [e-mail]