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Instinct COMBI 199

TriangleTube Instinct SOLO 110, Instinct SOLO 155, Instinct SOLO 199, Instinct COMBI 155, Instinct COMBI 199 Installation & Maintenance Manual

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Page 1
Installation & Maintenance 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.
222169 A01 - July 2019 2019-16
ORIGINAL
THE
INNOVATORS
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INTENTIONALLY LEFT BLANK
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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. 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 ................................................................................................................................ 10
2.8.4 Inspection. ...........................................................................................................................10
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. Accessory Box ...............................................................................................................................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
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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. 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 ................................................................................. 21
4.7.12 System Piping – Multiple Units Installation ...................................................................... 21
4.8. INSTINCT Combi Boiler System Piping ....................................................................................... 21
4.8.1 Expansion Tank and Makeup Water ...................................................................................22
4.8.2 Diaphragm Expansion Tank ................................................................................................22
4.8.3 Circulator ..............................................................................................................................22
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 ........................................................................................23
4.8.8 System Piping – Radiant Heating ......................................................................................23
4.8.9 System Piping – Special Application .................................................................................23
4.9. Optional System Piping and Cascading ..................................................................................... 23
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING........................................ 27
5.1. Domestic Piping Pressure Relief Valve ........................................................................................27
5.1.1 Standard Installation ...........................................................................................................27
5.1.2 Pressure Relief Valve - Standard Installations ..................................................................27
5.1.3 Pressure Relief Valve Discharge Piping ............................................................................ 28
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TABLE OF CONTENTS
5.2. Thermal Expansion ...................................................................................................................... 28
5.3. Water Hammer ............................................................................................................................. 29
5.4. Vacuum Breaker ........................................................................................................................... 29
5.5. Hydro-Block .................................................................................................................................. 29
5.6. General Piping .............................................................................................................................. 30
5.7. Thermostatic Mixing Valve .......................................................................................................... 30
5.8. Storage Tank Installation ............................................................................................................. 30
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN ..........38
6.1. Installing Vent and Combustion Air ............................................................................................ 38
6.2. Installing Condensate Drain Assembly into INSTINCT Solo Units ........................................... 38
CHAPTER 7 - GAS PIPING ................................................................................................ 40
7.1. Gas Supply Piping Connection ....................................................................................................40
7.2. Natural Gas .................................................................................................................................... 41
7.2.1 Pipe Sizing ............................................................................................................................ 41
7.2.2 Supply Pressure Requirements ......................................................................................... 41
7.3. Propane Gas ................................................................................................................................. 42
7.3.1 Pipe Sizing ........................................................................................................................... 42
7.3.2 Supply Pressure Requirements ........................................................................................ 42
CHAPTER 8 - WIRING ........................................................................................................45
8.1. Internal Wiring .............................................................................................................................. 45
8.1.1 General Requirements ....................................................................................................... 45
8.1.2 Fuse Locations .................................................................................................................... 45
8.2. External Wiring ............................................................................................................................. 48
8.2.1 General Requirements ....................................................................................................... 48
8.2.2 Line Voltage Connections .................................................................................................. 48
8.3. External Wiring - INSTINCT Solo Units ....................................................................................... 48
8.3.1 Circulator Wiring ................................................................................................................. 48
8.3.2 Low Voltage Connections .................................................................................................. 49
8.3.3 Thermostat Wiring ............................................................................................................. 49
8.3.4 Outdoor Sensor Wiring ...................................................................................................... 49
8.3.5 Domestic Hot Water Wiring ............................................................................................... 49
8.3.6 Additional Boiler Limits ...................................................................................................... 49
8.3.7 External Modulation Control ............................................................................................. 50
8.3.8 System Sensor Wiring ........................................................................................................ 50
8.3.9 Cascade Wiring - Optional ................................................................................................. 50
8.3.10 Modbus ................................................................................................................................ 50
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TABLE OF CONTENTS
CHAPTER 9 - CTRLMAX OPERATION .............................................................................. 51
9.1. CTRLMax Navigation .................................................................................................................... 51
9.2. CTRLMax Menu Structure ........................................................................................................... 52
9.3. Home Screen ................................................................................................................................ 53
9.4. Status Line Messages .................................................................................................................. 54
9.5. Main Menu .................................................................................................................................... 55
9.6. EZ Setup ....................................................................................................................................... 55
9.7. Heating EZ Setup
9.7.1 Select CH Demand (No outdoor sensor connected) ...................................................... 56
9.7.2 Select CH Demand (Outdoor sensor connected) .............................................................57
9.8. Domestic Hot Water EZ Setup
9.9. Domestic Hot Water EZ Setup
9.10. Altitude Setup ............................................................................................................................... 59
9.11. EZ Setup Reset
9.12. Display EZ Setup
9.13. CH/DHW Operation
9.14. Boiler Information
9.14.1 Information Items ............................................................................................................... 62
9.14.2 Lockout Screen ................................................................................................................... 63
9.14.3 Manual Reset Lockouts ...................................................................................................... 64
9.14.4 Automatic Reset Blocking Lockouts ................................................................................. 65
................................................................................................................ 56
- INSTINCT Solo Units .................................................... 58
- INSTINCT Combi Units ................................................ 59
................................................................................................................... 60
.................................................................................................................. 60
.............................................................................................................61
................................................................................................................. 61
CHAPTER 10 - START-UP PREPARATION ........................................................................ 67
10.1. Boiler System Fluid Requirements ..............................................................................................67
10.1.1 Boiler Fluid pH Level 6.0 to 8.0 ..........................................................................................67
10.1.2 Boiler Fluid Hardness Less Than 7 Grains ......................................................................... 67
10.1.3 Chlorinated Water ...............................................................................................................67
10.1.4 Flush Boiler to Remove Sediment ......................................................................................67
10.1.5 Cleaning of Old Boiler/System: .........................................................................................67
10.1.6 Cleaning of New Boiler/System: .......................................................................................67
10.1.7 Check and Test Antifreeze ................................................................................................. 68
10.1.8 Use of Antifreeze in the Boiler System ............................................................................. 68
10.2. Filling the Boiler System .............................................................................................................. 69
10.3. INSTINCT Combi Water Heater - Water Requirements ............................................................ 69
10.3.1 Filling the Domestic Circuit ................................................................................................ 69
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TABLE OF CONTENTS
10.4. Check Low Water Cut-Off Device ................................................................................................ 69
10.5. Check For Gas Leaks ................................................................................................................... 70
10.6. Check Thermostat Circuit ........................................................................................................... 70
10.7. Inspect Condensate Drain Assembly ......................................................................................... 70
CHAPTER 11 - START-UP PROCEDURES ..........................................................................71
11.1. Final Checks Before Start-Up ....................................................................................................... 71
11.2. INSTINCT Start-Up ....................................................................................................................... 71
11.3. Check the INSTINCT and System ................................................................................................ 71
11.3.1 Check Boiler Piping. ............................................................................................................ 71
11.3.2 Check Vent and Combustion Air Piping............................................................................. 71
11.3.3 Verify Carbon Monoxide Detector ..................................................................................... 71
11.3.4 Check Gas Piping .................................................................................................................73
11.3.5 Verify Flame Pattern and Combustion ..............................................................................73
11.3.6 Measure Input - Natural Gas Only ...................................................................................... 74
11.3.7 Test High Temperature Limit .............................................................................................. 74
CHAPTER 12 - OUTDOOR RESET CONTROL ................................................................... 75
12.1. Mounting the Outdoor Sensor .....................................................................................................75
12.2. Wiring the Sensor ..........................................................................................................................75
CHAPTER 13 - EXTERNAL MODULATING CONTROL ..................................................... 77
13.1. Wiring the Modulating Controller .................................................................................................77
13.2. CTRLMax Programming ...............................................................................................................77
13.3. Programming of External Modulating Control............................................................................77
CHAPTER 14 - CHECK-OUT PROCEDURES .....................................................................79
CHAPTER 15 - INSTALLATION RECORD .......................................................................... 81
CHAPTER 16 - MAINTENANCE SCHEDULES ...................................................................83
16.1. Service Technician ....................................................................................................................... 83
16.2. Owner Maintenance ..................................................................................................................... 83
CHAPTER 17 - MAINTENANCE PROCEDURES ................................................................85
17.1. Service Technician Maintenance Procedures ........................................................................... 85
17.2. Reported Problems ...................................................................................................................... 85
17.3. Check Surrounding Area ........................................................................................................... 85
17.4. Inspect Burner Area ..................................................................................................................... 85
17.5. Check System Piping ................................................................................................................... 85
17.6. Clean Condensate Drain Assembly ............................................................................................ 85
17.7. Check Ventilation Air Openings .................................................................................................. 86
17.8. Inspect Vent and Combustion Air Piping ................................................................................... 86
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TABLE OF CONTENTS
17.9. Check Boiler System .................................................................................................................... 86
17.10. Check Expansion Tank ................................................................................................................. 86
17.11. Check Boiler Relief Valve ............................................................................................................. 86
17.12. Inspection of Ignitor ..................................................................................................................... 86
17.13. Check Ignition Cable and Ground Wiring ....................................................................................87
17.14. Check Control Wiring ....................................................................................................................87
17.15. Check Control Settings ................................................................................................................87
17.16. Perform Start-up and Checkout Procedures ..............................................................................87
17.17. Check Burner Flame .....................................................................................................................87
17.18. Check Flame Signal .......................................................................................................................87
17.19. Check Combustion Levels ........................................................................................................... 88
17.20. Check Flue Gas Temperature ...................................................................................................... 88
17.21. Clean Heat Exchanger ................................................................................................................. 88
17.22. Check Carbon Monoxide Detectors ........................................................................................... 88
17.23. Review With Owner ...................................................................................................................... 88
17.24. Torque Specifications Table ........................................................................................................ 88
CHAPTER 18 - REPLACEMENT PARTS.............................................................................89
CHAPTER 19 - PRODUCT SPECIFICATIONS .................................................................. 101
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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 - Accessory Box Contents .............................................................................................................13
Fig. 6 - INSTINCT Pressure Relief Valve Installation ..............................................................................15
Fig. 7 - Piping Component Legend ..........................................................................................................16
Fig. 8 - INSTINCT Solo Near Boiler Piping - Diaphragm Expansion Tank ............................................. 17
Fig. 9 - Near Boiler Piping - Closed Type Expansion Tank .....................................................................18
Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump (Manual Pump Configuraiton) ....20
Fig. 11 - INSTINCT Combi Near Boiler Piping - Diaphragm Expansion Tank ........................................ 21
Fig. 12 - INSTINCT Combi System Piping - Zoning w Valves ............................................................... 24
Fig. 13 - INSTINCT Combi - System Piping - Multi Zone Valve - Single Circulator ............................. 25
Fig. 14 - INSTINCT Combi - System Piping - Single Zone with Single Circulator .............................. 26
Fig. 15 - Standard Installation of the Pressure Relief Valve ...................................................................27
Fig. 16 - INSTINCT Combi - Hydro-block Flow Diagram ....................................................................... 29
Fig. 17 - INSTINCT Combi System Piping - Single Zone System with Single System/Boiler Circulator .....31
Fig. 18 - INSTINCT Combi System Piping - Domestic piping - Storage tank installation .................. 32
Fig. 19 - Multiple Zones - Panel Wiring with Circulators ....................................................................... 33
Fig. 20 - INSTINCT Combi System Piping - Multiple Zones - Panel Wiring with Valves .................... 34
Fig. 21 - INSTINCT Solo System Piping - Multi Zone System with Single System/Boiler Circulator .....35
Fig. 22 - INSTINCT Solo System Piping - Indirect Water Heater installation ..................................... 36
Fig. 23 - Instinct Solo - Cascade Piping ..................................................................................................37
Fig. 24 - Condensate Drain Assembly ................................................................................................... 39
Fig. 25 - Recommended Gas Supply Piping ..........................................................................................40
Fig. 26 - Gas Valve / Venturi Assembly - INSTINCT Solo110 ............................................................... 43
Fig. 27 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 155 ................................................. 43
Fig. 28 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 199 ................................................. 44
Fig. 29 - CTRLMax Control Module Fuse Location ............................................................................... 45
Fig. 30 - INSTINCT Solo Boiler Factory Wiring ...................................................................................... 46
Fig. 31 - INSTINCT Combi Boiler Factory Wiring ....................................................................................47
Fig. 32 - Terminal Strip Location ............................................................................................................48
Fig. 33 - Low Voltage Connections ......................................................................................................... 49
Fig. 34 - CTRLMax User Interface ........................................................................................................... 51
Fig. 35 - INSTINCT Solo Jacket Components ....................................................................................... 89
Fig. 36 - INSTINCT Combi Jacket Components .................................................................................... 90
Fig. 37 - INSTINCT Solo 110 Internal Components ............................................................................... 91
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INDEX OF ILLUSTRATIONS AND TABLES
Fig. 38 - INSTINCT Solo 155 Internal Components ............................................................................... 92
Fig. 39 - INSTINCT Combi 155 Internal Components ........................................................................... 93
Fig. 40 - INSTINCT Combi 199 Internal Components .......................................................................... 94
Fig. 41 - INSTINCT Solo 110 Burner Components .............................................................................. 95
Fig. 42 - INSTINCT Solo/Combi 155 Burner Components ................................................................ 96
Fig. 43 - INSTINCT Combi 199 Burner Components ............................................................................97
Fig. 44 - INSTINCT Control & Display Enclosures ................................................................................ 98
Fig. 45 - INSTINCT Combi Hydro-block ............................................................................................... 99
Fig. 46 - Front View INSTINCT Solo 110 ..............................................................................................102
Fig. 47 - Right Side View INSTINCT Solo 110 .......................................................................................103
Fig. 48 - Front View INSTINCT Solo 155 ..............................................................................................104
Fig. 49 - Right Side View INSTINCT Solo 155 ......................................................................................105
Fig. 50 - Front View INSTINCT Solo 199 ..............................................................................................106
Fig. 51 - Right Side View INSTINCT Solo 199 ......................................................................................107
Fig. 52 - Front View INSTINCT Combi 155 ...........................................................................................108
Fig. 53 - Right Side View INSTINCT Combi 155 ..................................................................................109
Fig. 54 - Front View INSTINCT Combi 199 .......................................................................................... 110
Fig. 55 - Right Side View INSTINCT Combi 199 ................................................................................... 111
Graph 1 - INSTINCT Solo - Pressure Loss Through Boiler ................................................................... 112
Table 1 - Natural Gas Venturis .................................................................................................................. 41
Table 2 - Gas Piping Sizing - Natural Gas ................................................................................................ 41
Table 3 - Propane Conversion Venturis .................................................................................................. 42
Table 4 - Outdoor Reset Preset Selections .............................................................................................57
Table 5 - Throttle Screw Adjustment ......................................................................................................74
Table 6 - Acceptable Combustion Levels ...............................................................................................74
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PRODUCT AND SAFETY INFORMATION
IMPORTANT SAFETY INFORMATION FOR THE HOMEOWNER AND THE INSTALLER
DANGER
SAFETY
This manual contains important information with respect to the installation, starting up 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.
• 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 maintenance.
• Failure to comply with these instructions will result in substantial property damage, serious
injury, or death.
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.
• 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.
• 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
Section
2.8 on page 10 for additional carbon monoxide
detector requirements in Massachusetts.
• Failure to comply with these instructions can result in substantial property damage, serious injury, or death.
xi
Page 12
SAFETY
PRODUCT AND SAFETY INFORMATION
WARNING
DANGER
HOT WATER CAN SCALD!
Water temperature over 125ºF can cause se-
vere burns instantly or death from scalds.
• Children, disabled and elderly are at highest risk of being scalded.
Ū Never leave them unattended in or
near shower, bathtub or sink.
Ū Never allow small children to use a hot
water faucet or draw their own bath.
• To avoid any potential scald hazard or if codes require specific water temperatures at the hot water faucet, the installer must:
Ū Install a thermostatic mixing valve at
this appliance and ensure it is working property AND
Ū Set the domestic hot water tempera-
ture to the lowest temperature which satisfies your hot water needs.
Ū Feel and adjust water temperature be-
fore bathing or showering.
Ū Water drained from the system drain
valves may be extremely hot.
TO AVOID INJURY:
• Make sure all connections are tight.
• Direct water flow away from any person.
• Failure to comply with these instructions will result in substantial property damage, serious injury, or death.
• Should overheating occur or if the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance.
• Do not add cold make up 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.
Protection must be taken against excessive pressure!
TO PROTECT AGAINST EXCESSIVE PRESSURE:
• Verify that a field supplied 150 psi pressure
relief valve is installed in the recommended location for Combi models using the domes­tic hot water function (DHW Side).
• Verify the 30 psi relief valve supplied is in-
stalled in the location provided (CH Side). In installations where the CH pressure exceeds 30 psi, a 50 psi relief valve (not included) can be installed in lieu of the 30 psi relief valve.
• To avoid injury, install the relief valves in com-
pliance with local code requirements.
Failure to comply with these instructions can result in substantial property damage, seri-
• 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 appliance is supplied with an acoustic dampening foam rubber insert located in the appliance air inlet. DO NOT remove this on installation.
WARNING
ous injury, or death.
CAUTION
NOTICE
WARNING
Bacteria can develop in the domestic water system if certain minimum water tempera­tures are not maintained. Failure to maintain at least 140°F [60°C] domestic hot water tem­perature or use the Antilegionella function can result in bacteria development, which can result in serious injury, or death.
xii
• 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.
Page 13
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS
1.1. INSTINCT boilers - Code Compliance
The INSTINCT units must be installed by a qualied in­staller in accordance with the following:
• All applicable local, state, national and provin­cial codes, ordinances, regulations and laws.
• For installations in Massachusetts, code re­quires the INSTINCT to be installed by a licensed plumber or gas tter, and if antifreeze is utilized, the installation of a reduced pressure back-ow preventer device is required in the boiler’s cold water ll or make up water supply line.
• For installation in Massachusetts, all direct vented appliances must comply with the guidelines as outlined in Section 2.8 on page 10.
• The National Fuel Gas Code (NFPA54/ ANSI Z 223.1).
• National Electric Code (ANSI/NFPA 70).
• For installations in Canada - Installation Code for Gas Burning Equipment (CAN/CSA B149.1), Ca­nadian Electrical Code Part 1 (CSA C22.1).
• Standards for Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1), when required.
NOTICE
The Instinct gas manifold and gas controls meet the safe lighting and other performance
requirements as specified in ANSI Z21.13.
Where recommendations in this manual dier from lo­cal or national codes, the local or national codes take precedence.
1.1.1 Code Restrictions
The single wall heat exchanger in the INSTINCT Combi water heater complies with National Standard Plumb­ing Code, provided that:
• Boiler water (including additives) is practically non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products, and
• Boiler water pressure is limited to maximum 30 psig by approved relief valve.
Single wall heat exchangers are permitted under the Uniform Plumbing Code - Paragraph L3.2. and L3.3 if they satisfy all of the following requirements.
• The heat transfer medium is potable water or contains only substances which are recognized as safe by the U.S. Food and Drug Administration.
• The pressure of the heat transfer medium is maintained less than the normal minimum op­erating pressure of the potable water system
• The equipment is permanently labeled to indi­cate that only additives recognized as safe by the FDA shall be used in the heat transfer me­dium.
Other heat exchanger designs may be permitted where approved by the Administrative Authority.
1.1.2 Operating Restrictions
• Maximum INSTINCT Combi DHW outlet tem­perature is 149ºF, when mixing valve is installed.
• Maximum boiler water temperature rating is 210ºF.
• Maximum DWH working pressure is 150 psig.
• Maximum boiler (CH) working pressure is 50 psig.
• Water quality limitations (based on E.P.A Nation­al Secondary Drinking Water Regulations):
Ū Chloride, less than 150 ppm or mg/l Ū pH value min. 6, max. 8 Ū Total hardness 3 - 7 grains/gallon or 50-120
ppm or mg/l.
Ū Total Dissolved Solids (TDS), less than 120
ppm or mg/l. Ū Iron less than 0.3 ppm or mg/l. Ū Aluminum, less than 0.2 ppm or mg/l. Ū Copper, less than 1 ppm or mg/l. Ū Manganese, less than 0.05 ppm or mg/l.
Ū Zinc, less than 5 ppm or mg/l.
BEST PRACTICE
In hard water areas (more than 7 grains of hardness) soften the cold domestic supply wa-
ter to the appliance to prevent scaling.
NOTICE
• Any water conditioning system must be in­stalled and maintained in accordance with
manufacturer’s specifications.
• Do not install the INSTINCT Combi in any application if the boiler piping contains non-oxygen barrier tubing or if the boiler piping is considered an “open system”. Ex­posing the internal circulator to oxygen contamination will lead to premature fail-
ure and denial of the warranty.
CHAPTER 1
1
Page 14
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS
CHAPTER 1
1.2. Determining Product Location
NOTICE
The INSTINCT is certified for indoor, condi-
tioned space installations ONLY.
Before locating the INSTINCT check for convenient lo­cations to:
• Heating system piping
• Venting
• Gas supply piping
• Electrical service
Ensure the INSTINCT location allows the combustion air/ vent piping to be routed directly through the building and terminate properly outside with a minimum amount of length and bends.
Ensure the area chosen for the installation of the INSTINCT is free of any combustible materials, gasoline, or other ammable liquids.
WARNING
Failure to remove or maintain the area free of combustible materials, gasoline, or oth­er flammable liquids or vapors can result in substantial property damage, serious injury,
or death.
Ensure the INSTINCT and its controls are protected from dripping or spraying water during normal operation or service.
The INSTINCT should be installed in a location so that any water leaking from the boiler, piping connections, or relief valve will not cause damage to the surrounding area or any lower oors in the structure.
1.3. Boiler Freeze Protection Feature
The CTRLMax boiler management system has a freeze protection feature built in. This feature monitors the boiler water temperature and responds as follows when no call for heat is present:
• 46ºF [8ºC] Pump outputs congured to respond to a CH1 Call are enabled.
• 42ºF [6ºC] Pump outputs congured to respond to a CH1 or CH2 Call are enabled, Burner operates at low re.
• 60ºF [15ºC] Freeze protection ends. Burner & all pumps turn o after completing CH Post Pump Time.
CAUTION
• The boiler freeze protection feature is dis­abled during a hard lockout. The burner will not fire, but the circulators will operate.
• The boiler freeze protection feature is de­signed to protect the boiler, not the heating system. The boiler should be installed in a primary/secondary piping arrangement if it is installed in an unheated space or exposed to water temperatures of 46ºF or less. Refer
to Chapter 4 for primary/secondary piping
and Chapter 10 for antifreeze guides.
• Failure to comply can result in minor prop-
erty damage, or injury.
1.4. Boiler Replacement
If the INSTINCT is replacing an existing boiler, the fol­lowing items should be checked and corrected prior to installation:
• Boiler piping leaks and corrosion.
• Proper location and sizing of the expansion tank on the boiler heating loop.
• The existing vent system is appropriate for the INSTINCT and it is correctly installed. Refer to the INSTINCT Vent Supplement for the vent sys­tem requirements.
• Amount and quality of propylene glycol within the system, if applicable.
2
Page 15
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS
1.5. Recommended Clearances
The INSTINCT is approved for zero clearance to com­bustibles, excluding vent and boiler piping.
• Boiler piping must be a minimum 1/4 inch from combustible materials.
• Reference the INSTINCT Vent Supplement for vent pipe clearance requirements.
BEST PRACTICE
It is recommended that the following clearances
be maintained for serviceability:
• Top boiler jacket - 24 inches [610 mm].
• Front - 24 inches [610 mm].
• Bottom boiler piping - 24 inches [610 mm].
• Rear - 0 inches
• Sides - 6 inches [153 mm]
NOTICE
When maintaining less than recommended service clearances, some product labeling, in­cluding the rating label, may become hidden
and unreadable.
1.6. Residential Garage Installations
When installing the INSTINCT in a residential garage, the following special precautions per NFPA 54/ANSI Z223.1 must be taken:
• Mount the unit a minimum 18 inches [458 mm] above the oor level of the garage. Ensure the burner and ignition devices / controls are no less than 18 inches [458 mm] above the oor level.
• Locate or protect the unit in a manner so it can­not be damaged by a moving vehicle.
CHAPTER 1
WARNING
• If the recommended clearances list­ed above cannot be maintained or the enclosure in which the boil­er is installed is less than 70 cubic feet, the space must be ventilated.
See Section 2.2 on page 6.
• When installing the INSTINCT in a con­fined space, sufficient air must be provided to allow, under normal operating condi­tions, proper air flow around the product to maintain ambient temperatures within safe limits to comply with the National Fuel
Gas Code (NFPA 54 / ANSI Z223.1)
• Failure to comply with these instructions can result in substantial property dam-
age, serious injury, or death.
3
Page 16
INTENTIONALLY LEFT BLANK
Page 17
CHAPTER 2 - COMBUSTION AIR & VENTING
2.1. 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,
as indicated in Chapter 6 on page 38.
• 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 combustion.
• When the air for combustion is taken from the room air grilles must be installed by the contractor. The air grilles should be sized in accordance with ANSI Z223.1/ NFPA54 and/or Natural Gas and Propane
Installation Code CAN/CSA B149.1.
• The grille providing air when taking air directly from the room should be clear­ly labelled; "AIR SUPPLY, DO NOT COVER OR RESTRICT. FAILURE TO PROVIDE AD­EQUATE AIR FOR COMBUSTION COULD
RESULT IN 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 2
5
Page 18
CHAPTER 2 - COMBUSTION AIR & VENTING
CHAPTER 2
2.2. Ventilation and Combustion Air Require­ments - Direct Vent
A Direct Vent appliance utilizes uncontaminated out­door air piped directly to the appliance for combustion.
For Direct Vent installations involving only the IN­STINCT, in which the minimum service clearances are maintained as listed in Section 1.5 on page 3, no ventilation openings are required, but may be neces­sary to equalize the air pressure with the outside.
For Direct Vent installations involving only the INSTINCT, in which the minimum service clearances are not main­tained as listed in Section 1.5 on page 3, the space / enclosure must provide two openings for ventilation. The openings must be sized to provide 1 square inch of free area per 1,000 BTUH of boiler input. The openings shall be placed 12 inches from the top of the space and 12 inches from the oor of the space.
For installations in which the INSTINCT shares the space with air movers (exhaust fan, clothes dryers, replaces, etc.) and other combustion equipment (gas or oil) the space must be provided with adequate air openings to provide ventilation and combustion air to the equipment. To properly size the ventilation / combustion air openings, the installer must comply with the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/CSA B149.1 for installations in Canada.
WARNING
The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements (exhaust fans, clothes dryers, fireplaces, etc.) and the total input of all appliances located in the same space as the INSTINCT, excluding the input of a Direct Vent INSTINCT which uses com­bustion air directly from the outside, thus additional free area for the openings is not required. Failure to provide or properly size the openings can result in substantial prop-
erty damage, serious injury, or death.
2.3. Ventilation and Combustion Air Require­ments - Category IV
A Category IV appliance utilizes uncontaminated indoor or outdoor air surrounding the appliance for combus­tion.
BEST PRACTICE
In order to reduce the potential risks associated with indoor contaminates (see list in Section
2.1 on page 5), flammable vapors and tight housing construction with little or no infiltration air, it is recommended to pipe uncontaminated combustion air directly from the outdoors to the appliance. This practice also promotes high­er system efficiency by reducing heated indoor air from being exhausted from the house and
replaced by cold infiltration air into the house.
For installations in which the INSTINCT shares the space with air movers (exhaust fan, clothes dryers, replaces, etc.) and other combustion equipment (gas or oil) the space must be provided with adequate air openings to provide ventilation and combustion air to the equipment. To properly size the ventilation / combustion air openings, the installer must comply with the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/ CSA B149.1 for installations in Canada.
WARNING
The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements (exhaust fans, clothes dryers, fireplaces, etc.) and the to­tal input of all appliances, including the IN­STINCT when located in the same space. Fail­ure to provide or properly size the openings can result in substantial property damage,
serious injury, or death.
6
Page 19
CHAPTER 2 - COMBUSTION AIR & VENTING
DHW Demand
DHW
186°F
156°F
Target = 186°F
Ion-ic
2.4. Methods of Accessing Combustion Air Into A Space - Category IV
2.4.1. Indoor Combustion Air
NOTICE
• The methods listed in this chapter for accessing Indoor Combustion Air assume that the infiltra tion rate is adequate and not less than .40 ACH.
• For infiltration rates less than .40 ACH, refer­ence the National Fuel Gas Code (NFPA 54 /
ANSI Z223.1) for additional guidance.
• Indoor combustion air vent supply must be installed with a minimum equivalent vent length of 10 feet. Refer to Vent Supplement
for further guidance.
Opening Size and Location
Openings used to connect indoor spaces shall be sized and located in accordance with the following, see Fig. 1 below :
• Combining spaces on the same story. Each opening
shall have a minimum free area of 1 sq. in./1000 Btu/hr of the total input rating of all gas utilization equipment in the space, but not less than 100 sq. inches. One opening shall commence within 12 inches of the top, and one opening shall commence within 12 inches of the bottom of the enclosure. The minimum dimen­sion of air openings shall be not less than 3 inches.
Gas Vent
-
2.4.2. Outdoor Combustion Air
BEST PRACTICE
Isolating the combustion appliance room from the rest of the building and bringing in uncon­taminated outside air for combustion and ven-
tilation is always preferred.
Opening Size and Location
The minimum dimension of air openings shall be not less than 3 inches
Openings used to supply combustion and ventilation air shall be sized and located in accordance with the following:
• One Permanent Opening Method . One permanent
opening, commencing within 12 in. of the top of the enclosure, shall be provided as shown in Fig. 2 below. The equipment shall have clearances of at least 1 inch from the sides and 6 in. from the front of the appliance. The opening shall directly communicate with the outdoors or shall commu­nicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following:
• 1sq. in./3000 Btu/hr of the total input rating of all equipment located in the enclosures, and
• Not less than the sum of the areas of all vent connectors in the space.
CHAPTER 2
Openings
Fig. 1 - All Combustion Air from adjacent Indoor Spaces
through Indoor Combustion Openings
• Combining spaces in dierent stories. The volumes of
spaces in dierent stories shall be considered as com­municating spaces where such spaces are connected by one or more openings in doors or oors having a total minimum free area of 2 sq. in./1000 Btu/hr of to­tal input rating of all gas utilization equipment.
Gas Vent
Alternate opening location
Ion-ic
186°F
DHW
156°F
Target = 186°F
DHW Demand
Fig. 2 - All Combustion Air from Outdoors
Through One Permanent Air Opening
Opening
7
Page 20
CHAPTER 2 - COMBUSTION AIR & VENTING
CHAPTER 2
• Two Permanent Opening Method. Two permanent
openings, one commencing within 12 in. of the top and one commencing within 12 in. of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:
• Where directly communicating with the out­doors or where communication to the outdoors is through vertical ducts, each opening shall have a minimum free area of 1 sq. in./4000 Btu/ hr of total input rating of all equipment in the enclosure. See Fig. 3 below.
Ventilation louvers
Outlet air
Inlet air duct
(ends 1ft (30 cm)
above oor)
(each end of the attic)
Gas Vent
Ion-ic
186°F
DHW
156°F
Target = 186°F
DHW Demand
• Where communicating with the outdoors is through horizontal ducts, each opening shall have a minimum free area of not less than 1 sq.in./2000 Btu/hr of total input rating of all equipment in the enclosure. See Fig. 4 below.
2.4.3 Combination of Indoor and Outdoor Combustion Air
Indoor Openings. Where used, openings connecting the in­terior spaces shall comply with Section 2.4.1 on page 7.
Outdoor Opening(s) Location. Outdoor opening(s) shall be located in accordance with Section 2.4.2 on page 7.
Outdoor Opening(s) Size. Outdoor opening(s) shall be calculated in accordance with the following:
• The ratio of the interior spaces shall be the avail-
able volume of all communicating spaces divided by the required volume.
• The outdoor size reduction factor shall be 1 minus
the ratio of interior spaces.
• The minimum size of outdoor opening(s) calculat-
ed in accordance with the above outdoor air chap­ter multiplied by the reduction factor. The mini­mum dimension of air openings shall not be less than 3 in.
Fig. 3 - All Combustion Air from Outdoors Through
Ventilated Attic
Gas Vent
Outlet air duct
Ion-ic
186°F
DHW
156°F
Target = 186°F
DHW Demand
Inlet air duct
Fig. 4 - All Combustion Air from Outdoors Through
Horizontal Ducts
2.5. Combustion Air and Vent Piping
The INSTINCT requires a Category IV venting system, which is designed for pressurized venting and conden­sate.
The INSTINCT is certied as a Category IV or Direct Vent (sealed combustion) appliance. A Category IV appliance utilizes uncontaminated indoor or outdoor air surround­ing the appliance for combustion. A Direct Vent appli­ance utilizes uncontaminated outdoor air piped directly to the appliance for combustion.
DANGER
Do not install the INSTINCT into a common vent with any other gas or oil appliances. This will cause flue gas spillage or appliance malfunction, which will result in substantial
property damage, serious injury, or death.
DANGER
It is essential that the supply of air for com­bustion is not blocked or restricted - this
could result in serious injury, or death.
8
Page 21
CHAPTER 2 - COMBUSTION AIR & VENTING
BEST PRACTICE
In order to reduce the potential risks associat­ed with indoor contaminates (see list in Section
2.1 on page 5), flammable vapors and tight housing construction with little or no infiltration air, it is recommended to pipe uncontaminated combustion air directly from the outdoors to the appliance. This practice also promotes higher system efficiency by reducing heated indoor air from being exhausted from the house and re-
placed by cold infiltration air into the house.
DANGER
Verify installed combustion air and vent pip­ing are sealed gas tight and meet all provided instructions and applicable codes, failure to
comply will result in serious injury, or death.
WARNING
Failure to properly support the vent system can cause the venting system to fail, result­ing in substantial property damage, serious
injury, or death.
NOTICE
Install combustion air and vent pipe as detailed in the INSTINCT Vent Supplement included in the boiler installation envelope. Refer to op­tional vent kit instructions for additional vent
installation instructions.
2.6. Removal of an Existing Boiler from a Common Vent System
BEST PRACTICE
When an existing boiler is removed from a com­mon venting system, the common venting system is likely to be too large for proper venting of the re­maining appliances. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the
common venting system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deciencies which could cause an unsafe condition.
3. Insofar as is practical:
• Close all exterior building doors and windows
and all doors between the space in which the appliances remaining connected to the com­mon venting system are located and other spaces of the building.
• Turn on clothes dryers and any appliance not
connected to the common venting system.
• Turn on any exhaust fans, such as range hoods
and bathroom exhausts, so they will operate at maximum speed.
• Do not operate a summer exhaust fan.
• Close replace dampers.
4. Place in operation the appliance being inspected.
• Follow the lighting instructions.
• Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the ame of a match or candle, or smoke from a ciga­rette, cigar or pipe.
6. After it has been determined that each appliance remaining connected to the common venting sys­tem properly vents when tested as outlined above, return doors, windows, exhaust fans, replace dampers, and any other gas-burning appliance to their previous condition of use.
7. Any improper operation of the common venting sys­tem should be corrected so the installation conforms with the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/CSA B149.1 for installations in Canada. When resizing any por­tion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/CSA B149.1 for installations in Canada.
DANGER
Do not install the INSTINCT into a common vent with any other gas or oil appliances. This will cause flue gas spillage or appliance mal­function, resulting in substantial property
damage, serious injury, or death.
CHAPTER 2
9
Page 22
CHAPTER 2 - COMBUSTION AIR & VENTING
CHAPTER 2
2.7. Carbon Monoxide Detector Installation
Triangle Tube requires the installation of a minimum of two (2) hard wired carbon monoxide detectors with an alarm and battery back-up in the mechanical room where the INSTINCT is located and another installed in the living area outside the bedroom(s) for all installa­tions.
Each carbon monoxide detector shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certied.
Consult the local authority having jurisdiction for any ad­ditional carbon monoxide detector requirements in your area. See Section 2.8 on page 10 for additional carbon monoxide detector requirements in Massachusetts.
WARNING
A byproduct of any gas fired appliance is car­bon monoxide. Failure to install carbon mon­oxide detectors with alarms can result in seri-
ous injury, or death.
2.8. Commonwealth of Massachusetts In­stallation Requirements
For all side wall horizontally vented gas fueled equip­ment installed in every dwelling, building or structure used in whole or in part for residential purposes, includ­ing those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above nished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satised:
2.8.1 Installation of Carbon Monoxide Detectors.
1. At the time of installation of the side wall horizontal
vented gas fueled equipment, the installing plumber or gastter shall observe that a hard wired carbon mon­oxide detector with an alarm and battery back-up is installed on the oor level where the gas equipment is to be installed.
2. In addition, the installing plumber or gastter shall
observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment.
3. It shall be the responsibility of the property owner to
secure the services of qualied licensed professionals for the installation of hard wired carbon monoxide de­tectors.
a. In the event that the side wall horizontally vent-
ed gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon mon­oxide detector with alarm and battery back-up may be installed on the next adjacent oor lev­el.
b. In the event that the requirements of this sub-
division can not be met at the time of comple­tion of installation, the owner shall have a peri­od of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2.8.2 Approved Carbon Monoxide Detectors.
Each carbon monoxide detector as required in accor­dance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certied.
2.8.3 Signage
A metal or plastic identication plate shall be perma­nently mounted to the exterior of the building at a min­imum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
The sign shall read, in print size no less than one half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
2.8.4 Inspection.
The state or local gas inspector of the side wall horizon­tally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage in­stalled in accordance with the provisions of 248 CMR
5.08(2)(a) 1 through 4.
Exemptions
The following equipment is exempt from 248 CMR
5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equip­ment Not Required To Be Vented” in the most cur­rent edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.
10
Page 23
CHAPTER 2 - COMBUSTION AIR & VENTING
2.8.5 Manufacturer Requirements - Gas Equip­ment Venting System Provided.
When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufac­turer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting
system design or the venting system components; and
2. A complete parts list for the venting system design
or venting system.
2.8.6 Manufacturer Requirements - Gas Equip­ment Venting System Not Provided.
When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ue gases, but identies “special venting systems”, the following re­quirements shall be satised by the manufacturer:
1. The referenced “special venting system” instructions
shall be included with the appliance or equipment installation instructions; and
2. The “special venting systems” shall be Product Ap-
proved by the Board, and the instructions for that sys­tem shall include a parts list and detailed installation instructions.
A copy of all installation instructions for all Product Ap­proved side wall horizontally vented gas fueled equip­ment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the com­pletion of the installation.
CHAPTER 2
11
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Page 25
CHAPTER 3 - UNIT PREPARATIONS
3.1. Handling Instructions
The INSTINCT is generally easier to handle and maneu­ver once removed from the shipping carton.
To remove the shipping carton:
NOTICE
Use care not to drop, bump or rotate the boiler upside down, as damage to the boiler will result.
1. Remove any shipping straps.
2. Slide the cardboard sleeve from the unit.
3. Remove the wall mounting template.
4. Remove the accessory boxes.
5. Remove upper and lower cardboard end pieces.
6. Remove the boiler from the cardboard tray.
7. Discard all packing materials and recycle where possible.
3.2. Wall Mounting Installation
The INSTINCT should be wall mounted using the wall mounting template and bracket provided with the boil­er. The INSTINCT is not designed for oor installation. The INSTINCT is not to be installed on carpeting
WARNING
The wall used for mounting the INSTINCT must be vertically plumb and capable of sup-
porting at minimum:
• 101 pounds [46 kg] for the INSTINCT Solo 110
• 137 pounds [62 kg] for the INSTINCT Solo 155
• TBC pounds [TBC kg] for INSTINCT Solo 199
• 154 pounds [70 kg] for INSTINCT Combi 155
• TBC pounds [TBC kg] for INSTINCT Combi 199
Note. All weights above include INSTINCT
water volumes.
Failure to comply with these requirements can result in substantial property damage,
serious injury, or death.
CHAPTER 3
Venturi
3/4" Elbow
Auto Air Vent
Reduced Tee
Pressure Gauge
Union
3.3. Accessory Box
Unpack and check the the list of all accessories as shown in Fig. 5 below.
Bird Screens (x2)
Screws (x4) / Anchors (x4)
Pressure Relief Valve Sensor DHW
Gas Valve to Venturi Gaskets (x2)
Fig. 5 - Accessory Box Contents
13
Page 26
CHAPTER 3 - UNIT PREPARATIONS
CHAPTER 3
3.4. Wall Mounting Guidelines
The wall-mounting bracket is designed for stud spacing of approximate 12 inch or 16 inch on centers. For un­conventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket.
1. For applications using wood studs, install the brack­et using the lag screws provided with the boiler. Ensure both lag screws are installed securely in the studs.
2. For applications using metal studs, install the brack­et to the studs using 3/16” toggle bolts and wash­ers.
3. DO NOT mount or attempt to mount the wall bracket to hollow sheet rock or lath walls using anchors. Only install boiler to studs or equivalent wood structure.
4. For applications using solid walls (rock, concrete, brick, cinder block, etc.), install the wall bracket us­ing anchors (double expansion shields) and bolts with washers provided with the boiler.
5. The boiler is too heavy and bulky for a single person to lift and attempt to mount; a minimum of 2 peo­ple are required for mounting the boiler.
3.5. Stud Walls - Installation
1. Locate the studs in the general area of the boiler installation.
2. Place the wall-mounting bracket on the wall cen­tering the mounting slots with the stud centers and ensuring the upper edge of the bracket is away from the wall.
3. Level the bracket, while maintaining it’s centering with the studs and use a pencil to mark the location of the mounting slots.
4. Remove the bracket from the wall and drill a 1/4” di­ameter by 3” deep hole in the center of each mark. For applications using metal studs and 3/16” toggle bolts, drill the required clearance hole.
5. Reposition the bracket on the wall and align with the mounting slots/holes. Insert the two lag screws provided (or toggle bolts for metal studs) through the mounting slots/holes and loosely tighten.
6. Level bracket and tighten screws (bolts for metal studs) securely making sure not to over-tighten to avoid damaging drywall or plaster.
3.6. Wall Bracket Installation - Solid Walls
WARNING
Use extreme care not to drop the boiler or cause bodily injury while lifting or mount­ing the boiler onto the wall bracket. Once mounted, verify that the boiler is securely attached to the bracket and wall. Failure to comply with the above guidelines can result in substantial property damage, serious inju-
ry, or death.
1. Locate the general area of the boiler installation.
2. Place the wall-mounting bracket on the wall ensuring the upper edge of the bracket is away from the wall.
3. Level the bracket and use a pencil to mark the loca­tion of the mounting slots on the wall.
4. Remove the bracket from the wall and drill a 5/8” diameter by 1-3/8” deep hole in the center of each mark.
5. Install the provided anchors ush or slightly recessed in the drilled holes with threaded side facing down.
6. Reposition the bracket on the wall and align with the mounting slots/holes. Insert the two bolts with washers through the mounting slots/holes and loosely tighten.
7. Level bracket and tighten bolts securely.
3.7. Boiler Mounting
1. Obtain assistance in lifting the boiler onto the wall bracket.
2. Install the boiler making sure the boiler mounting lip located along the upper edge of the rear jacket panel engages the wall-mounting bracket. Ensure the boiler is seated properly and is secure.
14
Page 27
CHAPTER 4 - BOILER PIPING
4.1. General Piping Requirements
• All plumbing must meet or exceed all local, state and national plumbing codes.
• Support all piping using hangers. DO NOT support piping by the unit or its components.
• Use isolation valves to isolate system components.
• Install unions for easy removal of the INSTINCT from the system piping.
WARNING
Use a two-wrench method when tightening field piping onto the boiler piping connections. Use one wrench to prevent the boiler connec­tions from turning and the second to tighten field piping. Failure to support the boiler pip­ing connections could damage piping, causing a leak, resulting in substantial property dam-
age, serious injury, or death.
3/4" Street Elbow
Air Vent
Pressure relief valve (supplied with boiler)
4.2. Pressure Relief Valve
1. The INSTINCT is supplied with a 30 psi pressure re­lief valve and must be piped using the PRV connec-
tion as shown in Fig. 5 below.
NOTICE
In installations where the CH pressure exceeds 30 psi, a 50 psi relief valve (not included) can be
installed in lieu of the 30 psi relief valve.
2. To avoid potential water damage to the surround­ing area or potential scalding hazard due to the op­eration of the relief valve, the discharge piping:
• Must be connected to the discharge outlet of the
relief valve and directed to a safe place of disposal.
• Length should be as short and direct as possible.
The size of the discharge line must not be reduced, maintain the same size as the outlet of the relief valve.
• Must be directed downward towards the oor
at all times. The piping should terminate at least 6 inches [153 mm] above any drain con­nection to allow clear visibility of the discharge.
• Must terminate with a plain end, not with a threaded
end. The material of the piping must have a service­able temperature rating of 250ºF or greater.
• Must not be subject to conditions where freez-
ing could occur.
• Must not contain any shut-o valves or ob-
structions. No shut-o valve should be piped between the boiler and relief valve.
WARNING
Failure to comply with the guidelines on installing the pressure relief valve and dis­charge piping can result in substantial prop-
erty damage, serious injury, or death.
CHAPTER 4
Drain piping directed to a suitable place of drainage
Fig. 6 - INSTINCT Pressure Relief Valve Installation
15
Page 28
CHAPTER 4 - BOILER PIPING
CHAPTER 4
4.3. Boiler Air Vent
NOTICE
This boiler is supplied with a special automat­ic air vent that will provide reliable operation in purging air from the boiler. The hygroscopic cap supplied with the automatic air vent MUST remain tight at all times on the air vent body. The hygroscopic cap has a membrane which expands upon contact with water and seals the air vent until the membrane dries up due to
new air forming in the air vent.
1. Make sure to fully tighten the cap on the air vent during initial installation.
2. Never loosen the hygroscopic cap to allow air to escape the air vent. Air will exit with the cap fully tightened in place.
3. If the hygroscopic cap is not fully tightened, water may leak from the cap. Simply tighten the cap se­curely.
4.4. Low Water Cutoff Device
• The INSTINCT is equipped with a factory installed pressure sensor type Low Water Cut O (LWCO).
• The minimum operating system pressure is 10 psi. In the event that the pressure falls below 10 psi the burner will deactivate until proper pressure has been restored.
• Check local codes if a Low Water Cuto is required. If so, determine if this device meets their require­ments.
NOTICE
The INSTINCT control system also senses the water temperatures entering and exiting the heat exchanger to provide protection against low water conditions. Where local codes and jurisdiction do not accept a pressure device for low water protection, the jurisdiction may ac­cept this INSTINCT integral control function as
a means of providing low water protection.
Circulator
Circulator w/Isolation Flgs
Air Separator
Auto Air Vent
24 vac Motorized Zone Valve
Backflow Preventer
Pressure Differential Bypass Valve
Diaphragm Style Expansion Tank
Pressure Relief Valve
Union
Spring Check Valve
Ball Valve Style Boiler Drain
Full Port Ball Valve
Pressure Reducing Valve
Valve & Drain Assembly
Closed style Expansion Tank
16
Heat Emitters (Baseboard, Radiant Manifolds, Radiant Panels)
Fig. 7 - Piping Component Legend
Page 29
Boiler
Supply
Boiler
Return
System
Supply
Cold
Water
Fill
System
Return
12"
Max.
CHAPTER 4 - BOILER PIPING
4.5. Additional Limit Control
If a separate Low Water Cut O (LWCO) is required by the local jurisdiction or when the boiler is installed above the system piping, the following guidelines must be followed:
• The LWCO must be designed for water installations, electrode probe-type is recommended.
• The LWCO must be installed in a tee connection on the boiler supply piping above the boiler.
• Wiring of the LWCO to the INSTINCT is done directly onto the low voltage terminal strip. Reference Fig. 30 on page 46 for available external limit (manual or auto reset) terminals.
If the installation is to comply with ASME or Canadian requirements, an additional high temperature limit may be required. Consult local code requirements to determine compliance. The limit should be installed as follows:
• Install the limit in the boiler supply piping between the boiler and any isolation valve.
• Consult heat exchanger for maximum temperature set point.
• For wiring of the limit, reference Fig. 30 on page
46. Wire the limit to the manual reset terminals on the low voltage terminal strip. An open manual reset limit will require a manual reset of the control.
4.6. Backflow Preventer
• Use a backow preventer valve in the make-up wa­ter supply to the unit as required by local codes.
4.7. INSTINCT Solo Boiler System Piping
BEST PRACTICE
• It is recommended on all piping applica-
tions to utilize a primary/secondary piping arrangement as a means to provide freeze protection of the boiler, which is an integral function of the boiler control. Maintain at least the minimum boiler flow rate shown in the Graphs of Chapter 19 on page 101. For other piping arrangements, contact Triangle Tube Technical Support or con­sult other approved/recognized design ar-
rangements.
• On piping applications utilizing a single zone
or other recognized piping design arrange­ments, it is recommended that the installer uses flow/check valves with weighted seats at or near the INSTINCT Solo to prevent gravity
circulation.
CHAPTER 4
Cold
Water
Fill
System Supply
Boiler
Supply
Fig. 8 - INSTINCT Solo Near Boiler Piping - Diaphragm Expansion Tank
Boiler
Return
12"
Max
System
Return
17
Page 30
CHAPTER 4 - BOILER PIPING
Boiler
Supply
Boiler
Return
System
Supply
Cold
Water
Fill
System
Return
12"
Max.
CHAPTER 4
4.7.1 Expansion Tank and Makeup Water
Ensure the expansion tank is properly sized for the boil­er volume:
• 2 gallons [8 L] for the INSTINCT Solo 110
• 3 gallons [12 L] for the INSTINCT Solo 155
• 4 gallons [15 L] for INSTINCT Solo 199
the system water volume, and the system water tem­perature.
CAUTION
Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler heat ex­changer failure can result due to this excessive
makeup water addition.
The expansion tank must be located as shown in Fig. 8 on page 17 and Fig. 9 below, when using a prima-
ry/secondary piping arrangement or as per recognized design methods. Refer to the expansion tank manufac­turer for additional installation details.
Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator. Always locate and install the system ll connection at the same location as the ex­pansion tank connection to the system.
4.7.2 Diaphragm Expansion Tank
Always install an automatic air vent on top of the air separator to remove residual air from the system.
4.7.3 Closed-Type Expansion Tank
It is recommended to pitch any horizontal piping up­wards toward the expansion tank 1 inch per 5 feet of piping. Use 3/4” piping to the expansion tank to allow air within the system to rise.
NOTICE
DO NOT install automatic air vents on a closed­type expansion tank system. Air must remain in the system and be returned to the expansion tank to provide an air cushion. An automatic air vent would cause air to be vented from the sys­tem resulting in a water-logged expansion tank.
4.7.4 Circulator
A circulator with ow check must be utilized with the INSTINCT Solo. The circulator, when wired directly to the INSTINCT, will allow for domestic hot water priority and provide circulation for the freeze protection feature of the boiler control. See the Graphs in Chapter 19 on page 101 for pressure drop and minimum ow rate through the boiler.
18
System
Supply
Boiler
Supply
Fig. 9 - Near Boiler Piping - Closed Type Expansion Tank
Boiler
Return
12" Max
System
Return
Cold
Water
Fill
Page 31
CHAPTER 4 - BOILER PIPING
4.7.5 Sizing Primary Piping
See Fig. 12 on page 24 through Fig. 14 on page 26, for recommended piping arrangements based on vari­ous applications. Size the piping and system compo­nents required in the space heating system using recog­nized design methods.
4.7.6 Domestic Hot Water System Piping
See Fig. 12 on page 24 through Fig. 14 on page 26 for recommended piping to a DHW system. This recom­mended piping conguration ensures priority is given to the production and recovery of DHW.
The piping for DHW is separate from the boiler system piping and does not require a primary / secondary pip­ing conguration.
To wire the DHW circulator to the boiler control mod­ule, reference Chapter 8 on page 45.
4.7.7 System Piping – Zone Circulators
Connect the INSTINCT Solo to the system piping as shown in Fig. 13 on page 25 when zoning with zone
circulators. The installer must provide a separate circulator for each
zone of space heating.
4.7.9 System Piping – Through Boiler
Primary / secondary piping is preferred, but is not required for smaller systems (1 to 3 zones) provided that at least the minimum ow rate through the boiler is maintained at all times. The circulator must be sized to overcome the pres­sure drop through the system as well as the INSTINCT Solo. See the Graphs in Chapter 19 on page 101 for pressure drop and minimum ow rate through the boiler.
Fig. 13 on page 25 illustrates a multiple zone valve system with a single system/boiler circulator. A by-pass loop with a pressure dierential valve must be installed on the system piping.
Fig. 14 on page 26 illustrates a single zone system utilizing the boiler circulator as the system circulator.
4.7.10 System Piping – Radiant Heating
The heat exchanger design of the INSTINCT Solo allows operation in a condensing mode. This feature requires no regulation of the return water temperature back to the boiler in radiant heating applications. The design and construction of the INSTINCT Solo heat exchanger allows the installation of the boiler on systems with non - oxygen barrier tubing.
NOTICE
CHAPTER 4
NOTICE
To ensure an adequate flow rate through the INSTINCT Solo, the boiler supply and return pip­ing size must be a minimum of 1 inch for the INSTINCT Solo 110, 1-1/4 inch for the INSTINCT
Solo 155/199.
4.7.8 System Piping – Zone Valves
Connect the INSTINCT Solo to the system piping when zoning with zone valves.
NOTICE
To ensure an adequate flow rate through the INSTINCT Solo, the boiler supply and return pip­ing size must be a minimum of 1 inch for the INSTINCT Solo 110, 1-1/4 inch for the INSTINCT
Solo 155/199.
DO NOT install a SMART indirect water heater along with the INSTINCT Solo in systems with non-oxygen barrier tubing. Failure to comply will result in prema-
ture failure of the SMART indirect water heater.
The boiler water supply temperature can be maintained by the INSTINCT Solo, potentially eliminating the need for a mixing system to achieve the desired temperature if all zones of heat require the same temperature setpoint.
It is recommended to install a high temperature limit to en­sure that the primary supply temperature does not exceed the maximum allowable temperature for the radiant tubing.
NOTICE
The addition of a high temperature limit is im­portant if the INSTINCT Solo is connected to a domestic hot water system, which requires a
high primary supply water temperature.
Size the system piping and circulator to provide the ow needed for the radiant system.
NOTICE
To ensure an adequate flow rate through the IN­STINCT Solo, the boiler supply and return piping size must be a minimum of 1 inch for the INSTINCT Solo 110, 1-1/4 inch for the INSTINCT Solo 155/199.
19
Page 32
CHAPTER 4 - BOILER PIPING
N G L
CHAPTER 4
L N G L N G L N G L N G
+
Boiler 1 (Master)
Boiler 1 (Master)
ModbusDHW Sensor
- G 3 2
or
aquastat
Sensor
CH1CH2
1 4 3 2 1 2 1 1
+
Signal
-
Modulation
X5 X6 X4 X7
System Outdoor
6 5 4 3 2
Thermostat ThermostatSensor
ZV1
DHW PUMP
SUPPLY CH PUMP
FLAME
DHW PUMP
DHW PUMP
CH
SUPPLY CH PUMP
FLAME
+
ModbusDHW Sensor
- G 3 2
Boiler 2 (Slave)
Boiler 2 (Slave)
or
aquastat
Sensor
Outdoor
CH1CH2
1 3 2 1 2 1 1
+
Signal
-
Modulation
X5 X6 X4 X7
Sensor
System
6 5 4 3 2 4
Thermostat Thermostat
L N G L N G L N G L N G
Slave
Slave
Cascade
Cascade
Boiler 3 (Slave)
Boiler 3 (Slave)
Back of Display Panel
Back of Display Panel
Master
Master
Cascade
Cascade
1
23
1 2
X16
3 4
X7
X15
1 2 3
4 5 6
Main Control Board
Main Control Board
P3 DHW
P3 CH DHW
DHW S
ensor
HW Sen
sor
D
Out
door S
ensor
Outd
oor Se
nsor
From Zone Panel
Heating Call
Master
Master
Cascade
Cascade
ystemem S
ensor
S
Syst
Sens
or
Main Control Board
Main Control Board
ZV2
ZV3
123
1 2
X16
3 4
X7
X15
1 2 3
4 5 6
ZV4
SUPPLY CH PUMP
FLAME
L N G L N G L N G L N G
Slave
Slave
Cascade
+
Modbus
- G 3 2
or
aquastat
DHW Sensor
Sensor
Outdoor
CH1CH2
1 4 3 2 1 2 1 1
+
Signal
-
Modulation
X5 X6 X4 X7
Sensor
System
5 4 3 2
6
Thermostat Thermostat
Cascade
Back of Display Panel
Back of Display Panel
CH
CH
DHW
DHW
P3
P3
Sensor
System
Sensor
System
Optional Extra Required: Lead from X15 on 1 boiler to X16 on the next boiler
Optional Extra Required: Lead from X15 on 1 boiler to X16 on the next boiler
20
Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump (Manual Pump Conguraiton)
Page 33
Boiler
Supply
Boiler
Return
System
Supply
Cold
Water
Fill
System
Return
12"
Max.
CHAPTER 4 - BOILER PIPING
4.7.11 System Piping – Special Application
If the boiler is used in conjunction with a chilled water/ medium system, the boiler and chiller must be piped in parallel. Install ow/check valves to prevent the chilled medium from entering the boiler.
If the boiler is used to supply hot water to the heating coils of an air handler where they may be exposed to chilled air circulation, install ow/check valves or other automatic devices to prevent gravity circulation of the boiler water during cooling cycles.
4.7.12 System Piping – Multiple Units Installation
Use a balanced manifold system as the primary / sec­ondary connection to the space heating piping.
For the space heating piping, refer to the applications mentioned in this manual or use recognized design methods.
4.8. INSTINCT Combi Boiler System Piping
BEST PRACTICE
It is recommended on all piping applications to utilize a primary/secondary piping arrange­ment as a means to provide freeze protection of the boiler, which is an integral function of the boiler control. Maintain at least the minimum boiler flow rate shown in the Graphs of Chap­ter 19 on page 101. For other piping arrange­ments, contact Triangle Tube Technical Support or consult other approved/recognized design
arrangements.
On piping applications utilizing a single zone or other recognized piping design arrangements, it is recommended that the installer uses flow/ check valves with weighted seats at or near the
INSTINCT Combi to prevent gravity circulation.
CHAPTER 4
System
Supply
Boiler
Supply
Fig. 11 - INSTINCT Combi Near Boiler Piping - Diaphragm Expansion Tank
Boiler
Return
12" Max.
System
Return
Cold
water ll
21
Page 34
CHAPTER 4 - BOILER PIPING
CHAPTER 4
4.8.1 Expansion Tank and Makeup Water
Ensure the expansion tank is properly sized for the boil­er volume:
• 3 gallons [12 L] for the INSTINCT Combi 155
• 4 gallons [15 L] for the INSTINCT Combi 199
the system water volume, and the system water tem­perature.
CAUTION
Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler heat exchanger failure can result due to this exces-
sive makeup water addition.
The expansion tank must be located as shown in Fig. 11 on page 21 when using a primary/secondary piping
arrangement. Refer to the expansion tank manufactur­er for additional installation details.
Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator. Always locate and install the system ll connection at the same location as the ex­pansion tank connection to the system.
4.8.3 Circulator
The INSTINCT Combi is supplied with a Boiler circulator that provides circulation for central/space heating(CH) and Domestic Hot Water (DHW) production. See the Graph 1 on page 112 .
4.8.4 Sizing Primary Piping
See Fig. 12 on page 24 through Fig. 14 on page 26, for recommended piping arrangements based on var­ious applications. Size the piping and system compo­nents required in the space heating system using rec­ognized design methods.
4.8.5 System Piping – Zone Circulators
Connect the INSTINCT Combi to the system piping as shown in when zoning with zone circulators.
The installer must provide a separate circulator for each zone of space heating.
NOTICE
To ensure an adequate flow rate through the INSTINCT Combi, the boiler supply and return piping size must be a minimum of 1-1/4 inch
for the INSTINCT Combi 155/199.
CAUTION
The expansion tank must be located directly on
the INSTINCT Combi return pipe, before the re­turn check valve. Incorrect expansion tank loca­tion will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Even­tual boiler heat exchanger failure can result due
to this excessive makeup water addition.
4.8.2 Diaphragm Expansion Tank
Always install an automatic air vent on top of the air separator to remove residual air from the system.
4.8.6 System Piping – Zone Valves
Connect the INSTINCT Combi to the system piping as shown in Fig. 12 on page 24 when zoning with zone valves.
NOTICE
To ensure an adequate flow rate through the INSTINCT Combi, the boiler supply and return piping size must be a minimum of 1-1/4 inch
for the INSTINCT Combi 155/199.
22
Page 35
CHAPTER 4 - BOILER PIPING
4.8.7 System Piping – Through Boiler
Primary / secondary piping is preferred, but is not re­quired for smaller systems (1 to 3 zones) provided that at least the minimum ow rate through the boiler is maintained at all times. The internal circulator must be able to overcome the pressure drop through the sys­tem as well as the INSTINCT Combi. See the Graphs on page 112 for pressure drop and minimum ow rate through the boiler.
Fig. 13 on page 25 illustrates a multiple zone valve system with a single system/boiler circulator. A by-pass loop with a pressure dierential valve must be installed on the system piping.
Fig. 14 on page 26 illustrates a single zone system utilizing the boiler circulator as the system circulator.
4.8.8 System Piping – Radiant Heating
The heat exchanger design of the INSTINCT Combi al­lows operation in a condensing mode. This feature re­quires no regulation of the return water temperature back to the boiler in radiant heating applications. The INSTINCT CANNOT be installed with non-oxygen bar­rier tubing.
The boiler water supply temperature can be main­tained by the INSTINCT Combi, potentially eliminating the need for a mixing system to achieve the desired temperature if all zones of heat require the same tem­perature setpoint.
It is recommended to install a high temperature limit to ensure that the primary supply temperature does not exceed the maximum allowable temperature for the radiant tubing.
NOTICE
To ensure an adequate flow rate through the INSTINCT Combi, the boiler supply and return piping size must be a minimum of 1-1/4 inch
for the INSTINCT Combi 155/199.
4.8.9 System Piping – Special Application
If the boiler is used in conjunction with a chilled water/ medium system, the boiler and chiller must be piped in parallel. Install ow/check valves to prevent the chilled medium from entering the boiler.
If the boiler is used to supply hot water to the heating coils of an air handler where they may be exposed to chilled air circulation, install ow/check valves or other automatic devices to prevent gravity circulation of the boiler water during cooling cycles.
4.9. Optional System Piping and Cascading
CHAPTER 4
Several additional congurations (mixing device, cas­cading, etc.) are possible with INSTINCT Solo and Com­bi Units, provided an optional wiring kit is used. Please refer to Fig. 10 on page 20 for more information.
NOTICE
The addition of a high temperature limit is im­portant if the INSTINCT Combi is connected to a domestic hot water system, which requires a
high primary supply water temperature.
Size the system piping and circulator to provide the ow needed for the radiant system.
23
Page 36
CHAPTER 4
CHAPTER 4 - BOILER PIPING
PRESET PUMP CONFIGURATION INSTINCT COMBI
Heat Call DHW Pump CH Pump Flame
CH1 OFF ON ON
CH2 OFF ON ON
DHW ON ON OFF
NOTICE
• Consult the INSTINCT CTRLMax Control Supplement for information on setting the required Preset Pump Configuration.
Low Voltage Terminals
Low Voltage Terminals
CH2
System
Thermostat
6 5
Modulation
Sensor
Signal
-+
4 3
2 1
Dry Contact
Dry Contact
Zone Valve
Zone Valve
End Switches
End Switches
CH1
CH2
Thermostat
Thermosta
t
4 3
Z.V.
External Limit
External Limit
Terminals
Terminals
Manual Auto
Outdoor
DHW Sensor or Aquastat
2 1
DHW Sensor
DHW Sensor
Modbus
+ G ­3 2 1
Sensor
2 1
X6X5
Outdoor Sensor
Outdoor Sensor
Manual Auto
X7X4
Z.V.
Line Voltage Terminals
Line Voltage Terminals
L N G L N G L N G L N G
FLAME POWER SUPPLY
CH PUMP
DHW PUMP
24
Fig. 12 - INSTINCT Combi System Piping - Zoning w Valves
Page 37
CHAPTER 4 - BOILER PIPING
PRESET PUMP CONFIGURATION INSTINCT COMBI
Heat Call DHW Pump CH Pump Flame
CH1 OFF ON ON
CH2 OFF ON ON
DHW ON ON OFF
Consult the INSTINCT CTRLMax Control Supplement for information on setting the re-
Low Voltage Terminals
Low Voltage Terminals
CH2
System
Modulation
CH1
Outdoor
Thermostat
Sensor
6 5
4 3
Dry Contact
Dry Contact
Zone Valve End
Zone Valve
Switches
End Switches
Signal
-+
2 1
CH2
Thermostat
Thermosta
t
4 3
Sensor
2 1
X6X5
NOTICE
quired Preset Pump Configuration.
External Limit
External Limit
DHW
Sensor or
Aquastat
2 1
Modbus
+ G ­3 2 1
X7X4
Terminals
Terminals
Manual Auto
Manual Auto
Line Voltage Terminals
Line Voltage Terminals
L N G L N G L N G L N G
FLAME POWER SUPPLY
CH PUMP
DHW PUMP
CHAPTER 4
DHW Sensor
DHW Sensor
Outdoor Sensor
Outdoor Sensor
Z.V.
Z.V.
Fig. 13 - INSTINCT Combi - System Piping - Multi Zone Valve - Single Circulator
25
Page 38
Low Voltage Terminals
Outdoor Sensor
DHW Sensor
CH2
Thermostat
6 5
System Sensor
4 3
Modulation
Signal
-+ 2 1
CH2
Thermosta
t
CH1
Thermostat
4 3
Outdoor
Sensor
2 1
DHW Sensor or Aquastat
2 1
Modbus
+ G ­3 2 1
X7X4
X6X5
External Limit
Terminals
Manual Auto
68
Line Voltage Terminals
L N G L N G L N G L N G
FLAME POWER SUPPLY
CH PUMP
DHW PUMP
CHAPTER 4 - BOILER PIPING
PRESET PUMP CONFIGURATION INSTINCT COMBI
Heat Call DHW Pump CH Pump Flame
CH1 OFF ON ON
CH2 OFF ON ON
DHW ON ON OFF
Consult the INSTINCT CTRLMax Control Supplement for information on setting the re-
NOTICE
quired Preset Pump Configuration.
CHAPTER 4
Low Voltage Terminals
External Limit
Terminals
Line Voltage Terminals
Manual Auto
DHW Sensor
Outdoor Sensor
26
Fig. 14 - INSTINCT Combi - System Piping - Single Zone with Single Circulator
Page 39
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING
5.1. Domestic Piping Pressure Relief Valve
CAUTION
To reduce risk of excessive pressures and temperatures in the water heater, install tem­perature and pressure protective equipment required by local codes, but no less than a com­bination temperature and pressure relief valve certified by a nationally recognized testing lab­oratory that maintains periodic inspection of production of listed equipment or materials, as meeting the requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22. This valve must be marked with a maximum working pressure
of the water heater.
Failure to comply with this instruction can re-
sult in minor property damage, or injury.
The INSTINCT Combi domestic circuit must be protect­ed with a pressure relief valve (150 psi).
5.1.1 Standard Installation
Install pressure relief valve as shown in Fig. 15.
Pressure relief valve
(eld supplied
5.1.2 Pressure Relief Valve - Standard Installa­tions
The domestic water heater (if utilized) shall have a eld supplied pressure relief valve installed within 6” [152mm] of the DHW hot outlet connection with the relief valve spindle installed in the vertical position.
The domestic water heater (if utilized) requires a eld supplied pressure relief valve identied with the ASME V or HV symbol and set to relieve at or below 150 psi [10 bar] of domestic water pressure and a minimum re­lieving capacity of 199,000 Btu/hr with 3/4” NPT threads. For safe operation of the domestic water heater, the re­lief valve must not be removed from its designated lo­cation of installation or plugged.
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. 15
on page 27
2. To avoid potential water damage to the surround-
ing area or potential scalding hazard due to the op­eration of the relief valve, the discharge piping:
• Must be connected to the discharge outlet of the relief valve and directed to a safe place of disposal.
• Length should be as short and direct as possi­ble. The size of the discharge line should not be reduced, maintain the same size as the outlet of the relief valve.
• Should be directed downward towards the oor at all times. The piping should terminate at least 6 inches [152mm] above any drain con­nection to allow clear visibility of the discharge.
• Should terminate with a plain end, not with a threaded end. The material of the piping should have a serviceable temperature rating 250°F [121°C] or greater.
• Should not be subject to conditions here freez­ing could occur.
• Should not contain any shut-o valves or ob­structions. No shuto valves should be piped between the appliance and relief valve.
CHAPTER 5
Domestic connection
with Tee tting
Fig. 15 - Standard Installation of the Pressure Relief Valve
Domestic Hot Water
Supply
WARNING
Failure to comply with the guidelines on installing the pressure relief valve and dis­charge piping can result in substantial prop-
erty damage, serious injury or death.
27
Page 40
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING
CHAPTER 5
5.1.3 Pressure Relief Valve Discharge Piping
Pressure relief valve discharge piping must be:
• Made of material serviceable for temperatures of 250ºF or greater.
• Directed so that hot water ows away from all persons.
• Directed to a suitable place for disposal.
• Installed so as to allow complete draining of the pressure relief valve and discharge line.
Pressure relief valve discharge piping must not be:
• Excessively long. Using more than 2 elbows or 15 feet of piping can reduce discharge capacity.
• Directly connected to a drain. Terminate dis­charge piping within 6” from drain. Refer to lo­cal codes.
• Plugged, reduced or restricted.
• Subject to freezing.
WARNING
Do not install any valve between pres­sure relief valve and tank connection or on pressure relief valve discharge piping. Do not plug pressure relief valve or discharge piping. Improper placement and piping of T&P relief valve can cause severe personal in-
jury, death or substantial property damage.
5.2. Thermal Expansion
If a backow preventer, check valve or pressure reduc­ing valve is piped on cold water supply piping of water heater, install an expansion tank on cold water supply line to prevent thermal expansion from repeatedly forc­ing open pressure relief valve.
NOTICE
The pressure relief valve is not intended for con­stant duty, such as relief of pressure due to re­peated normal thermal expansion. Correct this condition by installing a properly sized expan­sion tank in the domestic water system. Refer to expansion tank manufacturer’s installation
instructions for proper sizing.
28
Page 41
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING
5.3. Water Hammer
Dishwashers, clothes washers and fast-closing positive shut-o valves incorporated in the system all contrib­ute to creating water shock. Install a water hammer ar­rester to prevent damage to pipes and appliances. See device manufacturer’s instructions for application and installation.
NOTICE
Water hammering within the domestic piping system can cause premature failure of the do­mestic circuit of the boiler. This type of failure is
NOT covered under warranty.
5.4. Vacuum Breaker
Installing a vacuum breaker on the domestic cold wa­ter inlet will prevent damage to the domestic circuit if a negative pressure is developed in the domestic sup­ply line. See manufacturer’s instructions for application and installation of the vacuum breaker.
5.5. Hydro-Block
The domestic circuit provides domestic hot water through a hydro-block. It is made of a plate-to-plate heat exchanger and connections to the primary and domestic piping. Water heated in the primary circuit (central heating) ows into the plate-to-plate heat ex­changer, which in turn heats the domestic water ow­ing through it in its own circuit. Refer to Fig. 16 below for ow diagram.
CH SUPPLY
1” 3/4”
CH SUPPLY
Stepper motor + cartridge
Plate-to-plate heat exchanger
1”
CH RETURN
to PUMP
1”
CHAPTER 5
DHW Temperature Sesnor
DHW SUPPLY
Fig. 16 - INSTINCT Combi - Hydro-block Flow Diagram
Flow Sensor
DHW INLET
3/4”
1”
CH RETURN
29
Page 42
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING
CHAPTER 5
5.6. General Piping
• For domestic water piping diagrams, see Fig. 17 on page 31.
• All plumbing must meet or exceed all local, state and national plumbing codes.
• Use pipe dope or tape suitable for potable water systems.
• Use isolation valves to isolate system components.
• Use dielectric unions or couplings to protect hot and cold water ttings from corrosion when con­necting dissimilar materials such as copper and gal­vanized iron pipe.
• When the water supply pressure is higher than 70 psig, it is recommended to install a pressure reduc­ing valve on cold water supply line to prevent wa­ter loss through T&P relief valve.
5.7. Thermostatic Mixing Valve
A thermostatic mixing valve must be installed in the DHW circuit.
The operating range of the thermostatic mixing is 85ºF [30ºC] to 150ºF [65ºC].
For applications with a domestic recirculation loop, the recirculation pump should be controlled by an aquastat. The maximum recommended setting of the aquastat is 10ºF lower than the thermostatic mixing valve setting.
If any adjustment needs to be made to the valve’s tem­perature setpoint, refer to the manufacturer’s instruc­tions included with the valve.
5.8. Storage Tank Installation
For applications requiring high domestic hot water ow rates for a short period of time (dump load), the install­er may install a storage type tank (see Fig. 18 on page
32) in the domestic piping. The installer must :
1. Relocate the thermostatic mixing valve from the IN­STINCT to the outlet of the storage tank.
2. Remove domestic restrictor at the inlet of the do­mestic ow sensor.
3. Provide recirculation from the storage tank back to the INSTINCT using a bronze or stainless steel cir­culator.
DANGER
For proper operation of the thermostatic mixing valve and to prevent potential scald­ing hazards, the recirculation loop should be controlled by an aquastat. DO NOT use con-
tinuous recirculation.
Failure to comply with this instruction will re-
sult in serious injury, or death.
30
Page 43
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING
PRESET PUMP CONFIGURATION 5 - INSTINCT COMBI UNITS
Heat Call Flame CH Pump DHW Pump
CH1 ON ON OFF
CH2 ON ON OFF
DHW OFF ON ON
NOTICE
Consult the INSTINCT CTRLMax Control Supplement for information on setting the re-
quired Preset Pump Configuration.
Low Voltage Terminals
CH2
System Sensor
4 3
Modulation
Signal
-+ 2 1
Thermostat
6 5
CH1
CH2
Thermostat
Thermosta
t
4 3
External Limit
Terminals
Outdoor
DHW
Sensor or
Aquastat
2 1
Modbus
+ G ­3 2 1
DHW Sensor
Sensor
2 1
X6X5
Outdoor Sensor
Manual Auto
X7X4
DHW
Line Voltage Terminals
Line Voltage Terminals
L N G L N G L N G L N G
FLAME POWER SUPPLY
CH PUMP
DHW PUMP
12" min Heat Trap
12" min
Heat Trap Loop
Loop (Optional)
(Optional)
CHAPTER 5
Outlet
Fig. 17 - INSTINCT Combi System Piping - Single Zone System with Single System/Boiler Circulator
31
Page 44
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING
PRESET PUMP CONFIGURATION 5 - INSTINCT COMBI UNITS
Heat Call Flame CH Pump DHW Pump
CH1 ON ON OFF
CH2 ON ON OFF
DHW OFF ON ON
NOTICE
Consult the INSTINCT CTRLMax Control Supplement for information on setting the re-
quired Preset Pump Configuration.
External Limit
X7X4
External Limit
Terminals
Terminals
Manual Auto
Manual Auto
Line Voltage Terminals
L N G L N G L N G L N G
FLAME POWER SUPPLY
Low Voltage Terminals Line Voltage Terminals
Low Voltage Terminals
CH2
System Sensor
4 3
Modulation
Signal
-+
2 1
Thermostat
6 5
CH1
CH2
Thermostat
Thermosta
t
4 3
X6X5
Outdoor
Sensor
2 1
DHW Sensor or Aquastat
2 1
Modbus
+ G ­3 2 1
CH PUMP
DHW PUMP
CHAPTER 5
DHW
DHW
Outlet
Outlet
Outdoor Sensor
Outdoor Sensor
DHW Sensor
DHW Sensor
Storage
Storage
Tank
Tank
12" min heat trap
12" min
loop (optional)
Heat Trap Loop
(Optional)
32
Fig. 18 - INSTINCT Combi System Piping - Domestic piping - Storage tank installation
Page 45
TITLE
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING
External Limit
CH2
Thermostat
6 5
Low Voltage Terminals
Low Voltage Terminals
System Sensor
4 3
Modulation
Signal
-+
2 1
CH1
CH2
Thermostat
Thermosta
t
4 3
X6X5
Outdoor
Sensor
2 1
Sensor or
Aquastat
2 1
DHW
Modbus
+ G ­3 2 1
X7X4
External Limit
Terminals
Terminals
Manual Auto
AutoManual
Line Voltage Terminals
Line Voltage Terminals
Outdoor Sensor
Outdoor Sensor
DHW Sensor
DHW Sensor
SLAVE
MASTER
1 2 3 4
EXPANSION
RESET NORMAL
PLUG IN CARDS
MODE
L N G L N G L N G L N G
FLAME POW ER SUPPLY
CH PUMP
120V/15A
Service
Zone 1
Thermostat
Zone 2
Thermostat
Thermostat
6868
FOUR ZONE SWITCHING RELAY
WITH OPTIONAL PRIORITY
Zone 3
68
ZONE4ZONE3ZONE2ZONE1
DHW PUMP
DHWCH
ZONE 4
PRIORITY
ON
OFF
CHAPTER 5
X X
END
ZRZC
SWITCH
FUSE 1 AMP
Zone 1
Thermostat
Fig. 19 - Multiple Zones - Panel Wiring with Circulators
ZONE2ZONE1
120 VOLT CIRCULATORS
Zone 2
Thermostat
ZONE3
Zone 3
Thermostat
ZONE4
120 VAC
POWER
INPUT
INPUT
(H & N)
33
Page 46
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING
External Limit
Low Voltage Terminals
Low Voltage Terminals
CH2
System Sensor
4 3
Modulation
Signal
-+ 2 1
Thermostat
6 5
CH1
CH2
Thermostat
Thermosta
t
4 3
X6X5
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G ­3 2 1
X7X4
External Limit
Terminals
Terminals
Manual Auto
AutoManual
Line Voltage Terminals
Line Voltage Terminals
CHAPTER 5
L N G L N G L N G L N G
FLAME POWER SUPPLY
120V/15A
DHW Sensor
DHW Sensor
Outdoor Sensor
Outdoor Sensor
Zone 1
Thermostat
68
PLUG-IN
Factory
Installed
Transformer
Factory
Installed
Transformer
POWER
CONTROLS
POWER IN
MODE
RESET NORMAL
ENDSW
B
PUMP
N/O N/ CCOM
ZONE 4 RELAY
1 2 3 4
SLAVE
MASTER
EXPANSION
ENDSW
A
BOILER
CARDS
FUSE 7 AMP MAX
ZONE 1
1 2 3 4
T T
ZONE 1
Service
Zone 2
Thermostat
68
T T
ZONE 2
FOUR ZONE ZONE VALVE CONTROL WITH OPTIONAL PRIORITY
ZONE 2
1 2 3 4
CH PUMP
Internal
Circulator
Thermostat
ZONE 3
1 2 3 4
DHW PUMP
Zone 3
68
T T
ZONE 3
T T
ZONE 4
ZONE 4
1 2 3 4
ZONE 4
PRIORITY
ON
OFF
34
System
Motor
1 2
End Switch
3 4
Zone 1
Zone Valve
Motor
1 2
End Switch
3 4
Zone 2
Zone Valve
Motor
1
2
End Switch
3 4
Zone 3
Zone Valve
Circulator
Fig. 20 - INSTINCT Combi System Piping - Multiple Zones - Panel Wiring with Valves
Page 47
CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING
External Limit
X7X4
External Limit
Terminals
Terminals
AutoManual
Manual Auto
Line Voltage Terminals
Line Voltage Terminals
L N G L N G L N G L N G
FLAME POWER SUPPLY
CH PUMP
DHW PUMP
Low Voltage Terminals
Low Voltage Terminals
CH2
System
Modulation
CH1
Thermostat
Sensor
6 5
4 3
Dry Contact
Dry Contact
Signal
-+ 2 1
CH2
Thermostat
Thermosta
t
4 3
X6X5
Outdoor
Sensor
2 1
Outdoor Sensor
Outdoor Sensor
DHW
Sensor or
Aquastat
2 1
DHW Sensor
Modbus
+ G ­3 2 1
DHW Sensor
DHW
Z.V.
Z.V.
DHW
Hot
Hot
DHW
smart
DHW
Cold
Cold
CHAPTER 5
Fig. 21 - INSTINCT Solo System Piping - Multi Zone System with Single System/Boiler Circulator
35
Page 48
TITLE
CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING
External Limit
Modbus
X7X4
External Limit
Terminals
Terminals
AutoManual
Manual Auto
Line Voltage Terminals
Line Voltage Terminals
L N G L N G L N G L N G
FLAME POWER SUPPLY
CH PUMP
DHW PUMP
Low Voltage Terminals
Low Voltage Terminals
CH2
System
Modulation
CH1
Outdoor
Thermostat
6 5
Sensor
4 3
Signal
-+ 2 1
CH2
Thermostat
Thermosta
4 3
t
X6X5
Sensor
2 1
Outdoor Sensor
DHW Sensor or Aquastat
2 1
+ G ­3 2 1
DHW Sensor
DHW Sensor
Outdoor Sensor
CHAPTER 5
DHW
68
DHW
Hot
Hot
DHW
DHW
Cold
Cold
smart
36
Fig. 22 - INSTINCT Solo System Piping - Indirect Water Heater installation
Page 49
CHAPTER 5 - INSTINCT SOLO UNITS - DOMESTIC PIPING
TITLE
NOTICE
Cascading is only available on Solo Boilers.
System
Return
12"
Max.
P G
System
Supply
CHAPTER 5
Fig. 23 - Instinct Solo - Cascade Piping
37
Page 50
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN
6.1. Installing Vent and Combustion Air
DANGER
The INSTINCT must be vented and supplied with combustion air as shown in the IN Vent Supplement, included in the installa­tion envelope. Refer to instructions for parts
list and method of installation.
Once installation is completed, inspect the vent and combustion air system thoroughly to ensure systems are airtight, properly sup­ported, and comply with the instructions giv­en in the venting supplement and are within all requirements of applicable codes. Failure to comply with the venting and combustion air piping installation requirements will re­sult in substantial property damage, serious
injury, or death.
STINCT
NOTICE
Contact Triangle Tube for other venting options including PVC Concentric Vent/Air Termination and Stainless Steel or PVC Flush Mount Horizon­tal Terminations. Refer to the instructions includ-
ed with these kits for method of installation.
2. Install the condensate drain assembly on the boiler condensate drain by pushing the condensate drain assembly up until it stops.
3. Tighten the condensate drain assembly retaining nut.
WARNING
• Ensure installation of the condensate drain assembly included the seals. Failure to comply could result in the assembly dislocating from the boiler. Dislocation of the condensate drain assembly can result in property damage, serious injury, or
• Ensure the condensate drain assembly contains the plastic ball. Do not install the condensate drain assembly if the ball is lost or missing, replace the entire as­sembly. Installing the condensate drain assembly without the plastic ball can re­sult in substantial property damage, seri-
4. Remove the compression nut and rubber seal from the condensate drain assembly drain outlet.
5. Slide the compression nut and rubber seal over the 3/4” x 2’ exible tube provided.
death.
ous injury, or death.
CHAPTER 6
6.2. Installing Condensate Drain Assembly into INSTINCT Solo Units
NOTICE
The condensate drain assembly is factory-in-
stalled in the INSTINCT Combi units.
1. Locate the condensate drain assembly and ensure
the seals are installed as shown in Fig. 24 on page
39.
NOTICE
The installer may want to fill the condensate drain assembly with water prior to assembling
on the unit.
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.
NOTICE
The use of 3/4” PVC or CPVC pipe is also accept­able. If 3/4” pipe is used, deburr and chamfer
pipe to allow mating onto the drain assembly.
6. Thread the rubber seal into the compression nut to ease installation of the tube to the condensate drain assembly.
7. Seat the tube onto the condensate drain assembly and tighten the compression nut. Hand tight only!
NOTICE
• The installer may opt to use 13/16” ID tub­ing in lieu of provided tube.
• The drain line materials must be an ap-
proved material by the authority having jurisdiction. In absence of such authority, PVC and CPVC piping must comply with ASTM D1785 or D2845. The cement and primer used on the piping must comply with ASME D2564 or F493. For installations in Canada, use ULC certified PVC or CPVC
pipe, fittings and cement/primer.
38
Page 51
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN
8. Route the tube from the condensate drain assem­bly to a oor drain or condensate pump.
NOTICE
When selecting and installing a condensate pump, ensure the pump is approved for use with condensing appliances. The pump should be equipped with an overflow switch to prevent property damage from potential condensate
spillage.
9. The INSTINCT will typically produce a condensate that is considered slightly acidic with a pH content below 4.0. Install a neutralizing lter if required by authority having jurisdiction.
WARNING
The condensate drain assembly must remain
filled with water. Extended periods of non use or high temperature operation may allow the water to evaporate. Periodically check the water level in the condensate drain as­sembly and fill with water as necessary. Fail­ure to keep the condensate drain assembly full of water can result in substantial proper-
ty damage, serious injury, or death.
CAUTION
The drain assembly must remain unobstructed and allow unrestricted flow of condensate. The condensate should not be subject to conditions where freezing could occur. If the condensate is subjected to freezing or becomes obstructed , it can leak, resulting in potential water damage
to the boiler and surrounding area.
RETAINING NUT
RETENTION
CLIP
FOR SOLO
MODELS ONLY
PLASTIC BALL
NOT SHOWN
CONDENSATE
DRAIN ASSEMBLY
SEALS
FILL PLUG WITH VACCUM BREAK PORT
COMPRESSION NUT WITH RUBBER SEAL
Flexible tubing (or 3/4 PVC/ CPVC Piping to Drain)
Fig. 24 - Condensate Drain Assembly
RETENTION
CLIP
FOR SOLO
MODELS ONLY
CHAPTER 6
39
Page 52
CHAPTER 7 - GAS PIPING
7.1. Gas Supply Piping Connection
NOTICE
The gas supply piping must be installed in ac­cordance to all applicable local, state, national
codes, and utility requirements.
1. Install a 3/4” NPT for INSTINCT pipe union at the gas nipple, for ease of service.
nstall a manual shuto valve in the gas supply piping as
2. I shown in Fig. 25 on the right. For installations in Canada, the installer must tag and identify the main shuto valve.
3. Install a sediment trap (drip leg) on the gas supply line prior to connecting to the INSTINCT gas train as shown in Fig. 25 on the right.
4. Support the gas piping using hangers. Do not sup­port the piping by the unit or its components.
5. Purge all air from the gas supply piping.
6. Before placing the INSTINCT into operation, check and test all connections for leaks.
• Close the manual shuto valve during any pres-
sure test with less than 13”w.c..
• Disconnect the INSTINCT and its gas valve from
the gas supply piping during any pressure test greater than 13”w.c..
Union Fitting
Gas Flow
External Manual Gas Shut O
Ion-ic
186°F
DHW
156°F
Target = 186°F
DHW Demand
Cap
Fig. 25 - Recommended Gas Supply Piping
Valve (Must Be Within 6” of the Boiler )
Tee Fitting
Sediment Trap Min. Length of 3"
CHAPTER 7
WARNING
Do not check for gas leaks with an open flame. Use a gas detection device or bubble test. Fail
-
ure to check for gas leaks can cause substan-
tial property damage, serious injury, or death.
7. Use pipe dope compatible with natural and pro­pane gases. Apply sparingly only to the male threads of pipe joints so that pipe dope does not block gas ow.
WARNING
• Failure to apply pipe dope as detailed above can result in substantial property
damage, serious injury, or death.
• Use a two-wrench method when tight­ening field piping onto the boiler piping connections. Use one wrench to prevent the boiler connections from turning and the second to tighten field piping. Failure to support the boiler piping connections could damage piping, causing a leak, re­sulting in substantial property damage,
serious injury, or death.
40
Page 53
CHAPTER 7 - GAS PIPING
7.2. Natural Gas
7.2.1 Pipe Sizing
Refer to Table 2 below for schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated INSTINCT input (divide by 1,000 to ob­tain cubic feet per hour).
• Table 1 is based on Natural Gas with a specic grav­ity of 0.60 and a pressure drop through the gas pip­ing of 0.30”w.c..
• For additional gas pipe sizing information, refer to National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for installations in the U.S. or CAN/CSA B149.1 for installations in Canada.
7.2.2 Supply Pressure Requirements
1. Pressure required at the gas valve inlet supply pres-
sure port:
• Maximum 13”w.c. at ow or no ow conditions to the burner.
• Minimum 5”w.c. during ow conditions to the burner. Must be veried during start up and with all other gas appliances operating within the building.
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 for 13”w.c maximum.
WARNING
DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is facto­ry-set for the correct outlet pressure. This set­ting is suitable for natural gas and propane and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure can result in damage to the valve, causing substantial property dam-
age, serious injury, or death.
•
WARNING
The INSTINCT is factory equipped with the re­quired natural gas venturi. The natural gas venturi must never be modified or replaced with a different size venturi. Failure to use the required natural gas venturi can result in sub­stantial property damage, serious injury, or
death.
Table 1 - Natural Gas Venturis
Model Venturi Diameter Top injector Bottom Injector Label Colour Part No.
110 Solo 22mm 3.60mm 3.40mm White INSRKIT07 155 Solo 24mm 4.00mm 3.90mm White INSRKIT09
199 Solo TBC TBC TBC TBC INSRKIT11 155 Combi 24mm 4.00mm 3.90mm White INSRKIT09 199 Combi TBC TBC TBC TBC INSRKIT11
Table 2 - Gas Piping Sizing - Natural Gas
Length of Pipe in Feet
SCH 40 1/2” 3/4” 1” 1-1/4” 1-1/2”
10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 890 40 63 130 245 500 760 50 56 115 215 440 670
75 45 93 175 360 545 100 38 79 150 305 460 150 31 64 120 250 380
Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based
on 0.60 specific gravity, 0.30” w.c. pressure drop)
CHAPTER 7
41
Page 54
CHAPTER 7 - GAS PIPING
7.3. Propane Gas
7.3.1 Pipe Sizing
WARNING
• The unit was shipped with a propane con­version kit which is located on the top of the unit in the instructions packet. This kit includes all the necessary parts and instruction to perform the conversion from natural to propane gas. If this con­version kit is missing, please contact Tri­angle Tube Technical Support for missing
kit before installing unit.
• Prior to start up, ensure the unit is set to fire propane. Check the rating label for the type of fuel. Check the gas valve for propane conversion label. If there is a conflict or doubt on the burner set up, re move the gas valve and check for the pro-
pane orifice, see Fig. 17 on page 31
Fig. 27 on page 43 and Fig. 28 on page 44.
• Failure to ensure proper burner setup can result in substantial property damage,
serious injury, or death.
-
and
7.3.2 Supply Pressure Requirements
1. Adjust the propane supply regulator provided by the gas supplier for 13”w.c. maximum pressure
2. Pressure required at the gas valve inlet supply pres­sure port:
• Maximum 13”w.c. at ow or no ow conditions
to the burner
• Minimum 8”w.c. during ow conditions to the
burner. Must be veried during start up and with all other gas appliances operating within the building.
WARNING
DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is facto­ry-set for the correct outlet pressure. This set­ting is suitable for natural gas and propane and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure can result in damage to the valve, causing substantial property dam-
age, serious injury, or death.
CHAPTER 7
• Operating a natural gas INSTINCT boiler on propane will create excessive and dan­gerious carbon monoxide levels which
could cause serious injury, or death.
Contact the local propane gas supplier for recommend­ed sizing of piping, tanks and 100% lockup gas regulator.
Table 3 - Propane Conversion Venturis
Model Venturi Diameter Top injector Bottom Injector Label Colour Part No.
110 Solo 22mm 2.90mm 2.65mm Black INSRKIT08
155 Solo 24mm 3.15mm 2.95mm Black INSRKIT10
199 Solo TBC TBC TBC TBC INSRKIT12
155 Combi 24mm 3.15mm 2.95mm Black INSRKIT10
199 Combi TBC TBC TBC TBC INSRKIT12
Note: Propane conversion venturis have an additional yellow label to identify use for propane
The propane gas venturi assembly must never be modified or replaced with a different assem­bly. See the below chart for the full specifica­tion. Failure to use the required propane gas venturi assembly can result in substantial prop-
erty damage, serious injury or death.
•
WARNING
42
Page 55
CHAPTER 7 - GAS PIPING
Pipe to Venturi
Gas Valve
Venturi
Venturi interface
Air Inlet
Air reference Hose
Air Inlet
Fig. 26 - Gas Valve / Venturi Assembly - INSTINCT Solo110
Venturi interface
Air reference Hose
Pipe to Venturi
Gas Valve
CHAPTER 7
Venturi
Fig. 27 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 155
43
Page 56
CHAPTER 7 - GAS PIPING
TBC
CHAPTER 7
Fig. 28 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 199
44
Page 57
CHAPTER 8 - WIRING
8.1. Internal Wiring
WARNING
ELECTRICAL SHOCK HAZARD. 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 in-
jury, or death.
CAUTION
Prior to servicing, label all wires before discon­necting. Wiring errors can cause improper and dangerous operation. Verify proper wiring and
operation after servicing.
8.1.1 General Requirements
• Wiring must be N.E.C Class 1.
• If original wiring as supplied with the unit must be replaced, use only Type T 194ºF [90ºC] wire or equivalent as a minimum.
• The INSTINCT Solo must be electrically grounded as required by National Electrical Code (ANSI/NFPA
70) for installations in the U.S., or the Canadian Elec­trical Code Part 1(CSA C22.1) for installations in Can­ada.
8.1.2 Fuse Locations
• The CTRLMax control module contains 3 internal
replaceable 5A fuses as shown in Fig. 29 below.
• The top two fuses protect the INSTINCT as well as the CH, DHW, and Flame outputs.
• Spare fuses are located on the back of the control module enclosure.
• A 2.5A fuse is also located on the terminal strip, to protect the output. Refer to Fig. 32 on page 48.
Location of fuses
Fig. 29 - CTRLMax Control Module Fuse Location
CHAPTER 8
45
Page 58
Insnct Solo Wiring Diagram
CHAPTER 8 - WIRING
Spark Generator
Spark Generator
Gas Valve
Ignitor
Ignitor
GND
GND
Gas Valve
3
1
1
5
1
Blower
Blower
3
1
R
W
V
BK
5
Key
W = White BK = Black R = Red G= Green O = Orange Y = Yellow BL = Blue
GND
GND
G
W
BK
1 6 3
1
P13
W
BK W BK
P14 1 6 X9 1 4
X12
X10
1
O
1
X1
X3
12
10
Flue
Y
1
Y
R
R
Temperature
Sensor
Supply
Temperature
Sensor
Flue
Temperature
Temperature
Sensor
BL
Supply
Temperature
Sensor
BL
Return
Sensor
Return
Temperature
Sensor
BK
BR
O
1
BR
X2
R
14
O
Y
W BK
R
3
Manual Reset Limit
Manual Reset Limit
Auto Reset Limit
Auto Reset Limit
Pressure
Water
Sensor
Water Pressure Sensor
CHAPTER 8
BK
GND
BK
W
W
BK
W
GND
G W
BK
46
G N L G N L G N L
G N L
DHW Pump
CH Pump
Power Supply
Flame
DHW
Pump
CH
Pump
Power
Supply
Flame
X11
X5 1 6 X6 1 4
CH2 Thermostat
System Sensor
X4
1
Outdoor Sensor
CH1 Thermostat
Modulation Signal
System Sensor
CH2 Thermostat
Modulaon Signal
CH1 Thermostat
Outdoor Sensor
DHW Aquastat/Sensor
X7
1 3
DHW Aquastat/Sensor
ModBus
X16
4
Cascade Master
Modbus
Fig. 30 - INSTINCT Solo Boiler Factory Wiring
X15
1
10
6
1
Y Y
Y Y
Y
1
Cascade Slave
Cascade Master
Cascade Slave
User
Interface
User Interface
Page 59
Insnct Combi Wiring Diagram
CHAPTER 8 - WIRING
Ignitor
Ignitor
Spark Generator
GND
Spark Generator
GND
3
Gas Valve
1
1
Gas Valve
Blower
5
Blower
1
Key
1
R
W
V
BK
5
3
W = White BK = Black R = Red G= Green O = Orange Y = Yellow BL = Blue
W
BK
BK
W
BK
GND G
BK
W
BK W BK
P14 1 6 X9 1 4
X12
X3
R
X1
12
O
X2
14
10
X10
1
1
1
1
BR
O
BK
R
W
Flue
Y
Y
R
R
BR
Y
Temperature
Temperature
Sensor
Supply
Temperature
Temperature
Sensor
Manual Reset Limit
Auto Reset Limit
O
W BK
3
R
BK
3
Diverter Valve
Flue
Sensor
Supply
Sensor
Manual Reset Limit
Auto Reset Limit
Return
Temperature
Sensor
BL
Water Pressure Sensor
DHW Flow Sensor
Diverter
Pressure
Valve
Return
Temperature
Sensor
BL
Water
Sensor
DHW
Flow
Sensor
BK
GND
W
G
BK
1 6 3
1
P13
1
X11
10
G
DHW
DHW
N
Pump
Pump
L G
CH
CH
CH2 Thermostat
N
Pump
Pump
Power
Supply
Flame
L G N L
G N L
Power Supply
Flame
W
W
Modulation Signal
CH2 Thermostat
X5 1 6 X6 1 4
Outdoor Sensor
CH1 Thermostat
Modulaon Signal
X4
X7
1
Modbus
CH1 Thermostat
Outdoor Sensor
DHW Sensor
ModBus
DHW
Sensor
X15
X16
4
1 3
6
1
Y Y
Y Y
Y
1
User Interface
User
Interface
CHAPTER 8
Fig. 31 - INSTINCT Combi Boiler Factory Wiring
47
Page 60
CHAPTER 8 - WIRING
8.2. External Wiring
8.2.1 General Requirements
All eld wiring must comply with:
• National Electrical Code (ANSI/NFPA 70) for installa­tions in the U.S., and any other national, state, pro­vincial or local codes or requirements.
• Canadian Electrical Code Part 1 (CSA C22.1) for in­stallations in Canada.
NOTICE
If local electrical codes require an additional service switch, the installer must provide and install a fused
disconnect or minimum 15 amp service switch.
8.3. External Wiring - INSTINCT Solo Units
8.3.1 Circulator Wiring
CHAPTER 8
WARNING
ELECTRICAL SHOCK HAZARD. 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
The low voltage terminals are located at the bottom of the CTRLMax control module. The line voltage terminals are located in the lower
left corner as shown in Fig. 21 below.
8.2.2 Line Voltage Connections
1. Connect a dedicated 120 VAC/15A service to the
line voltage terminals located internally in the low­er left corner, as shown in Fig. 32 below.
2. Route the incoming 120 VAC power wires through one
of the provided openings in the bottom jacket panel.
3. The unit is provided with a service switch located
on the front panel, check local code requirements for compliance.
2.5A Fuse
1. The circulator connections used will depend on the
systems piping layout. See Fig. 17 on page 31 and Fig. 18 on page 32 for common system pip-
ing applications and associated circulator wiring. Consult the Fig. 10 on page 20 and the INSTINCT
CTRLMax Control Supplement for additional op­tions.
NOTICE
The circulator output is protected by fuses on the CTRLMax control module. The total com­bined amp draw of the CH, DHW, and Flame outputs must not exceed 4 amps at any time for the INSTINCT 110 and 155 units, or 3 amps at any time for the INSTINCT 199 units. Use an isolation relay to lower the total combined amp
draw if exceeding this limits.
2. Connect the CH circulator wiring to the line voltage terminals located internally in the lower left corner, as
shown in Fig. 32 on the left. This circulator is typically used to supply heat to the central/space heating loop.
3. Connect the DHW circulator wiring to the line volt­age terminals located internally in the lower left
corner, as shown in Fig. 32 on the left. This circulator is typically used to supply heat to an indirect hot water heater.
4. Connect the system pump wiring to the line volt­age terminals located internally in the lower left
corner, as shown in Fig. 32 on the left.
48
Fig. 32 - Terminal Strip Location
Page 61
CHAPTER 8 - WIRING
8.3.2 Low Voltage Connections
Line and Low Voltage wiring should be separated to prevent possible electrical noise on the low voltage circuits. Line and Low Voltage wiring should use sepa­rate electrical knockouts on the INSTINCT cabinet and should remain separated inside the INSTINCT.
NOTICE
CH and DHW call connections to the IN­STINCT require a dry contact with no external voltage present. Ensure no external voltage is present on each set of wires before connecting to the INSTINCT. If external voltage is present, the use of an isolation relay is required to pre-
vent damage to the CTRLMax controller.
8.3.3 Thermostat Wiring
The CTRLMax control has two thermostat call inputs for multiple zone / temperature systems. This allows each call to have its own outdoor reset curve and maximizes the eciency of the system.
NOTICE
Simultaneous CH1 and CH2 calls will result in the INSTINCT operating at the highest target
temperature.
8.3.4 Outdoor Sensor Wiring
The Outdoor Reset function and Warm Weather Shut­down (WWSD) features require the connection of the included outdoor temperature sensor. See Chapter 12 on page 75 for outdoor sensor installation and setup.
8.3.5 Domestic Hot Water Wiring
The Domestic Hot Water terminals can accept either a call from an aquastat (thermostat) or temperature sen­sor. Use of the included indirect water heater sensor is recommended.
1. Connect the DHW aquastat or temperature sensor wires to low voltage terminals X4-1&2 located at the bottom of the CTRLMax control module as shown in Fig. 33 on page 49.
8.3.6 Additional Boiler Limits
Additional boiler limits (High Temperature Limit, LWCO, etc.) can be wired into either the Manual Reset Limit or Auto Reset Limit terminals of the INSTINCT. These lim­it connections will provide a “hard” lockout requiring a manual reset of the INSTINCT or a “soft” lockout in which the INSTINCT will automatically reset when the limit re­sets.
A Manual Reset External Limit Open (E87) lockout will occur anytime the manual reset terminals are open. An Auto Reset External Limit Open (76) lockout will not oc­cur until just before ignition when the auto reset termi­nals are open. The Auto Reset terminals should be used for any type of burner interlock such as a combustion air louver or water ow proving switch.
Low voltage connections
Fig. 33 - Low Voltage Connections
External limit Terminals
NOTICE
• The Manual Reset Limit and Auto Reset Limit terminals are located on the lower right corner of the CTRLMax control mod­ule housing.
• Manual Reset Limit and Auto Reset Limit connections to the INSTINCT require a dry contact with no external voltage present. Ensure no external voltage is present on each set of wires before connecting to the INSTINCT. If external voltage is present, the use of an isolation relay is required to pre-
vent damage to the CTRLMax controller.
CHAPTER 8
49
Page 62
CHAPTER 8 - WIRING
1. Remove the factory-installed brown jumper wire at the Manual Reset Limit terminals that will accept the additional boiler limit.
2. Remove the factory-installed orange jumper wire at the Auto Reset Limit terminals that will accept the additional boiler limit.
3. Connect the external limit wires to the Manual Reset Limit or Auto Reset Limit low voltage terminals locat­ed on the lower right corner of the CTRLMax control
module housing as shown in Fig. 33 on page 49.
8.3.7 External Modulation Control
The INSTINCT ring rate can be controlled by an exter­nal modulating boiler controller. See Chapter 13 on page 77 for external modulation signal wiring and setup.
8.3.8 System Sensor Wiring
An optional system temperature sensor can be placed on the central heating loop to control the temperature in the central heating loop instead of the boiler loop. When connected, the INSTINCT will automatically mod­ulate to maintain the target temperature in the central heating loop. The boiler supply temperature sensor will continue to be used as a high temperature limit.
8.3.9 Cascade Wiring - Optional
The CTRLMax control includes the ability to operate up to six Solo boilers together as one without the need for external controllers. Consult the Fig. 10 on page 20 for more information.
8.3.10 Modbus
The CTRLMax control includes the ability to communi­cate with building management systems (BMS) through a Modbus interface. Consult the INSTINCT CTRLMax Control Supplement for more information.
Modbus communication will only occur if the external device is properly wired to the INSTINCT as follows:
X7-1 = RS-485 – X7-2 = RS-485 Ground X7-3 = RS-485 +
CHAPTER 8
CAUTION
Locate the system temperature sensor where it can accurately measure the supply temperature to the heating system. Inaccurate system tem­perature readings could lead to overheating or
under heating resulting in property damage.
1. Connect the system temperature sensor wires to low voltage terminals X5-3&4 located at the bottom of the CTRLMax control module as shown in Fig. 33
on page 49.
50
Page 63
CHAPTER 9 - 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. CTRLMax includes many advanced features:
• Two central/space heating (CH) call inputs with separate outdoor reset curves.
• Domestic Hot Water (DHW) call input with optional priority in INSTINCT Solo units and DHW priority in INSTINCT Combi units.
• EZ Setup feature allows the installer to quickly cus­tomize CTRLMax for each installation.
• Optional cascade function (Solo models only), using an optional wiring kit, allows up to six INSTINCT boil­ers to operate together in a single heating system. Refer to Fig. 10 on page 20 for more information.
• Modbus interface for integrating with building management systems.
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. 34 below shows an CTRLMax display example of the INSTINCT red for a domestic hot water demand.
9.1. 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
, , with a center soft key (OK /Reset func-
tions) for making selections and entering information. The installing contractor is provided with full access
to all available features after simultaneously touching
the code. Reference the INSTINCT CTRLMax Control Sup­plement for Installer level functions
The Main Menu can be entered from the Home Screen
and soft keys for 3 seconds and entering a
,
Instinct
DHW
DHW Demand
Fig. 34 - CTRLMax User Interface
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.
.
soft key.
soft key, the unit
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
soft key,
illuminated, and the
dimmed.
soft key lighting is
CHAPTER 9
51
Page 64
CHAPTER 9 - CTRLMAX OPERATION
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
and touching the
soft key.
Home Screen
INSTINCT
186°F
DHW
156°F
Target = 186°F
DHW Demand
EZ Setup
CH / DHW Operation
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 re-
turns to the previous screen when selected.
9.2. CTRLMax Menu Structure
Select Language
Boiler Information
CHAPTER 9
Heating Enabled
Heating EZ Setup DHW EZ Setup
Select Language
English
Français Nederlands Español Italiano Deutsch
Boiler Information
EZ Setup Reset Display EZ Setup
Lockout History
a
b
b
c
b
d
b
e
b
a
b
b
c
b
d
b
e
b
f
f
b
e
b
d
b
a
b
c
c
b
b
d
b
b
e
a
f
f
e
b
d
b
a
b
b
c
b
c
b
d
b
b
e
a
f
f
b
e
b
d
b
c
b
b
a
f
f
b
e
b
d
b
a
b
c
c
b
b
b
d
b
e
a
f
f
e
b
d
b
a
b
b
c
b
c
b
d
b
b
e
a
f
f
b
e
b
d
b
c
b
b
a
52
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CHAPTER 9 - CTRLMAX OPERATION
9.3. 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. See Section 9.4 on page 54.
53
CHAPTER 9
Page 66
CHAPTER 9 - CTRLMAX OPERATION
9.4. 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.
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.
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.
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 9
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.
54
Page 67
CHAPTER 9 - CTRLMAX OPERATION
9.5. 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
9.6. 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
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.
CHAPTER 9
55
Page 68
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
Heating EZ Setup
Select CH Demand
Thermostat & Setpoint
Constant & Setpoint 0 - 10 V Modulation Signal
Select CH Demand
Thermostat & Setpoint
Constant & Setpoint
0 - 10 V Modulation Signal
CH1 Setpoint
140°F
68°F 188°F
CH2 Setpoint
68°F 188°F
140°F
EZ Setup Complete
Heating EZ setup is complete.
Additional changes can be made in
the Installer Menu if required.
Select CH Demand prompts the installer to select how a CH De­mand is generated. Thermostat & Setpoint - A central heating call from a thermostat or zone panel will enable the INSTINCT and the setpoint will be xed for central heating calls. After Thermostat & Setpoint is selected, the
CH1 Setpoint screen appears. (see below).
Constant & Setpoint - The INSTINCT will maintain setpoint without
an external CH call from a thermostat or zone panel. The setpoint will be xed for CH calls. After Constant & Setpoint is selected, the CH1 Setpoint screen appears.
CH1 Setpoint prompts to enter the xed setpoint for a CH1 heating call when a Setpoint option is chosen in Select CH Demand.
Touch the
then touch
or soft keys to adjust the temperature setpoint
to store the setting. The CH2 Setpoint screen then
appears. CH2 Setpoint prompts to enter the xed setpoint for a CH2 heating
call when a Setpoint option is chosen in Select CH Demand.
Touch the
then touch
or soft keys to adjust the temperature setpoint
to store the setting and complete the Heating EZ
Setup.
CHAPTER 9
56
Select CH Demand
Thermostat & Setpoint Constant & Setpoint
0 - 10 V Modulation Signal
Press OK to return to EZ Setup Menu
Press OK to return to EZ Setup Menu
EZ Setup Complete
Heating EZ setup is complete.
Additional changes can be made in
the Installer Menu if required.
CH1 Default: 140°F [60°C]
CH2 Default: 140°F [60°C]
0 - 10V Modulation Signal - This option allows the INSTINCT ring
rate to be controlled by an external control system.
Refer to Chapter 13 on page 77 for more information.
Page 69
CHAPTER 9 - CTRLMAX OPERATION
9.7.2 Select CH Demand (Outdoor sensor connected)
EZ Setup
Heating EZ Setup
Select CH Demand
Thermostat & Outd. Curve
Constant & Outdoor Curve
Constant & Setpoint
0 - 10 V Modulation Signal
Select CH1 Reset Curve
140°F
MAX
Select CH2 Reset Curve
80°F
140°F
18°C
Current Settings
80°F
Select CH Demand
Thermostat & Outd. Curve
Constant & Outdoor Curve
Constant & Setpoint
0 - 10 V Modulation Signal
-12°C
Warm Weather Shutdown
O
18°C
-12°C
Current Settings
O 25°C
EZ Setup Complete
Heating EZ setup is complete.
Additional changes can be made in
the Installer Menu if required.
Press OK to return to EZ Setup Menu
Select CH Demand prompts the installer to select how a CH Demand is generated.
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 calls. After Thermostat & Outd. Curve is selected, the Select CH1 Reset Curve screen appears (see below).
Constant & Outdoor Curve - The INSTINCT will maintain setpoint without an external CH call from a thermostat or zone panel. The setpoint will vary with the outdoor temperature for central heating calls. After Constant & Outdoor Curve is selected, the Select CH1 Reset Curve screen appears
Select CH1 Reset Curve prompts to select an outdoor reset curve for a CH1 heating call when an Outdoor Curve option is chosen in Select CH Demand. Outdoor reset curve presets are available to cover most applications. The outdoor reset curve can also be adjusted to any desired settings in the Installer Menu.
Touch the
system, then touch
or soft keys to select the outdoor reset curve appropriate for the type of heating
to store the setting. The Select CH2 Reset Curve screen then appears.
Default: Radiators 2
Select CH2 Reset Curve prompts to select an outdoor reset curve for a CH2 heating call
when an Outdoor Curve option is chosen in Select CH Demand. Outdoor reset curve pre­sets are available to cover most applications. The outdoor reset curve can also be adjusted to any desired settings in the Installer Menu.
Table 4 - Outdoor Reset Preset Selections
Preset Minimum Setpoint Maximum Setpoint
Floor Heat Low Temp. 76°F [24°C] 96°F [35°C] Floor Heat High Temp. 76°F [24°C] 104°F [40°C] Radiators 1 80°F [27°C] 120°F [49°C] Radiators 2 80°F [27°C] 140°F [60°C] Radiators 3 80°F [27°C] 158°F [70°C] Radiators 4 80°F [27°C] 176°F [80°C] Radiators 5 80°F [27°C] 185°F [85°C] Cast iron baseboard 100°F [38°C] 170°F [77°C] Finned tube baseboard 120°F [49°C] 180°F [82°C] Radiators 6 120°F [49°C] 170°F [77°C] Fancoil 140°F [60°C] 180°F [82°C]
Touch the
system, then touch
or soft keys to select the outdoor reset curve appropriate for the type of heating
to store the setting. The Warm Weather Shutdown screen then appears.
Default: Radiators 2 Warm Weather Shutdown prompts to enter an optional outdoor temperature at which to
disable the central heating function and any circulator placed into constant circulation with the Pump Permanent Circulation setting. The INSTINCT will continue to respond to a domes­tic hot water call or a 0- 10V Modulation Signal when the outdoor temperature exceeds the Warm Weather Shutdown Temperature setting.
Touch the
touch the
The Warm Weather Shutdown icon (
or soft keys to adjust the Warm Weather Shutdown Temperature then
soft key to store the setting and complete Heating EZ Setup.
) is displayed on the home screen when the out-
door temperature reaches the Warm Weather Shutdown temperature. Default: OFF.
CHAPTER 9
57
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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
DHW EZ Setup
Select DHW Demand
Thermostat
Sensor
DHW
Boiler Setpoint
168°F
96°F 188°F
Select DHW Demand prompts the installer to select how a DHW Demand is generated.
When Thermostat is selected in Select DHW Demand, a domestic hot water call from an aquastat or dry contact switch will enable the INSTINCT with a xed setpoint for a domestic hot water call. After Thermostat is selected, the DHW Boiler Setpoint screen appears.
Default: Thermostat
DHW Boiler Setpoint prompts to enter the xed boiler setpoint
temperature during a domestic hot water call.
Touch the
then touch
or soft keys to adjust the temperature setpoint
to store the setting. The DHW Priority Timeout
screen then appears (see below).
Default: 168°F [75°C].
CHAPTER 9
EZ Setup
DHW EZ Setup
Select DHW Demand
Thermostat
Sensor
DHW Storage Setpoint
140°F
68°F 168°F
DHW Priority Timeout
O 120 min.
O
EZ Setup Complete
DHW EZ setup is complete.
Additional changes can be made in
the Installer Menu if required.
Press OK to return to EZ Setup Menu
When Sensor is selected in Select DHW Demand, use of an (optional) Indirect Water Heater Sensor is required. The INSTINCT monitors the DHW storage temperature and generates a DHW call whenever the temperature drops below the DHW storage setpoint by 6°F [3°C].
DHW Storage Setpoint prompts to enter the DHW Storage Set­point temperature.
Touch the
touch
or soft keys to adjust the temperature setpoint then
to store the setting. The DHW Priority Timeout screen
then appears.
Default: 140°F [60°C].
NOTICE
The DHW Boiler Setpoint will automatically be set 28°F
[15°C] higher than the DHW Storage Setpoint setting
DHW Priority Timeout prompts to enter an optional time limit that a domestic hot water call has priority over central heating call.
Touch the
then touch
Defau
or soft keys to adjust the timeout value, if required,
to store the setting and complete the DHW EZ Setup.
lt: O
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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
EZ Setup
DHW EZ Setup
DHW Setpoint
68°F 168°F
140°F
DHW
Warmstart Temperature
125°F
86°F O
Warmstart Hysteresis
9 36°F
140°F
DHW
30°F
EZ Setup Complete
DHW EZ setup is complete.
Additional changes can be made in
the Installer Menu if required.
Press OK to return to EZ Setup Menu
DHW EZ Setup prompts the installer to select the DHW setpoint.
DHW Setpoint prompts to enter the xed setpoint temperature
during a domestic hot water call.
Touch the
then touch
or soft keys to adjust the temperature setpoint
to store the setting. The DHW Warmstart Tempera-
ture screen then appears .
Default: 140°F [60°C].
DHW Warmstart Temperature prompts to enter the DHW tem-
perature in case you want to speed up the delivery of DHW in sum­mer conditions.
Touch the
or soft keys to adjust the temperature then touch
to store the setting. At the minimum temperature (86°F), this function is OFF. The DHW Warmstart Hysteresis screen then ap­pears .
Default: 125°F [52°C].
DHW Warmstart Hysteresis prompts to enter the DHW hysteresis
value, comprised between 9°F (5K) and 36°F (20K).
Touch the
touch
or soft keys to adjust the hysteresis value, then
to store the setting.
Default: 30°F (17k).
9.10. Altitude Setup
INSTINCT Combi
88°F
ENTER ACCESS CODE
84°F
Target = - -
Standby
CH & DHW Settings
0 5 [4]
CH Settings
Boiler Settings
Boiler Settings
Model Instinct Combi
Lockout Temp. Modbus Address Pump Settings Ignition level Mix zone high limit
210ºF [99ºC]
Boiler Settings
1
Pump Settings
300rpm
Ignition level Mix zone high limit WP di trigger Appliance setting
Altitude 0ft
3000 rpm
114ºF
Altitude
114ºF
0cpsi
4920ft
0ft 19680ft
Altitude must be correctly set to allow reliable operation of the boiler.
From the home screen touch the
or soft keys simultaneously for 5
seconds and “Enter Access Code” screen will be shown.
Touch the
or soft keys to set the access code to 054. Touch
and the CH & DHW Settings creen will be shown.
Touch
and the CH Setting screen will be shown. Touch the
soft key and the “Boiler Settings” (list) screen will be shown.
Touch the
Touch
Touch the
the
soft key until the “Altitude” option is highlighted.
and the Altitude screen will be shown.
soft key until the correct altitude is shown, then touch
soft key to highlight the home icon. Touch to conrm.
Note. The altitude moves in steps of 984 ft (300m).
CHAPTER 9
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CHAPTER 9 - CTRLMAX OPERATION
9.11. EZ Setup Reset
EZ Setup
EZ Setup Reset
EZ Setup Reset
Press OK to restore factory settings,
any other button to keep current
settings.
9.12. Display EZ Setup
EZ Setup
EZ Setup Reset allows reset of all EZ Setup settings back to the orig­inal factory defaults. See Chapter 13 on page 77 for the list of set­tings reset by this function.
Follow the on-screen instructions to reset all EZ Setup settings.
Display EZ Setup allows language (English, French, Dutch, Spanish, Italian, German, Czech) and temperature units selection.
CHAPTER 9
Display EZ Setup
Select Language
English
Français Nederlands Español Italiano Deutsch
Fahrenheit
Celsius
Select Unit
Touch the
touch
Touch the
then touch
or soft keys to select the required language then
to store the setting. The Select Unit screen then appears.
or soft keys to select the required temperature units
to store the setting.
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CHAPTER 9 - CTRLMAX OPERATION
Heating Enabled
9.13. CH/DHW Operation
CH / DHW Operation
Heating Enabled
9.14. Boiler Information
Boiler Information
Boiler Information
a
b
b
c
b
d
b
e
b
f
f
b
e
b
d
b
a
b
c
c
b
b
d
b
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e
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f
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f
f
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e
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d
b
c
b
b
a
Boiler Information
Boiler Status Standby
Heating Call No
DHW Call No
Boiler Firing Rate --
Ionization current 0μA
Boiler Setpoint --
CH/DHW Operation provides a simple way to enable/disable either the CH or the DHW function of the INSTINCT.
Touch the
touch
or soft keys to select the CH or DHW icon, then
to toggle between the enabled/disabled status. The sta-
tus is displayed at the top of the screen.
Using the arrow keys, select the HOME or RETURN icon at the bot­tom of the screen to go back either to the home page or to the previous screen.
Default :
Boiler Information provides real time operating information of the
INSTINCT. Each line contains an information item followed by its cur­rent value. Six lines are displayed on the screen at one time.
Some information items include a logging function which records one sample every 12 minutes to produce a graph of the last 24 hours. Se­lect the information item in Boiler Information then touch the
soft
key to view its graph. The following items have a logging function:
• Boiler Firing Rate
• Ionization Current
• Boiler Setpoint
• Boiler Supply Temperature
• Boiler Return Temperature
• Boiler Flue Temperature
• Outdoor Temperature
• DHW Storage Temperature
• External Modulation Signal
• Pressure
Touch the
or soft keys to scroll through the items.
CHAPTER 9
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CHAPTER 9 - CTRLMAX OPERATION
9.14.1 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 9
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.
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CHAPTER 9 - CTRLMAX OPERATION
Boiler Information
Lockout History
a
b
b
c
b
d
b
e
b
f
f
b
e
b
d
b
a
b
c
c
b
b
b
d
b
e
a
f
f
e
b
d
b
a
b
b
c
b
c
b
d
b
b
e
a
f
f
b
e
b
d
b
c
b
b
a
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
9.14.2 Lockout Screen
If a problem occurs, the Lockout Screen replaces the Home Screen. The backlight will remain on until the lockout is reset.
Touching any arrow soft key will return to the Home Screen so that additional troubleshooting can be per­formed. See Sections 9.14.3 on page 64 and 9.14.4 on page 65 for a list of lockouts and descriptions.
Select the Home Screen icon at the bottom of any screen to return to the lockout screen.
Lockout History records the last eight lockouts. Six lines are dis­played on the Lockout History screen at one time. Each line contains a lockout description followed by how long ago the lockout occurred.
Touch the
or soft keys to scroll through the items then touch
to select and get more details through the Lockout Details screen.
The following information items are recorded at the time of a lockout:
• Boiler Status
• Heating Call
• Domestic Call
• Boiler Firing Rate
• Flame Ionization Current
• Boiler Setpoint
• Boiler Supply Temperature
• Boiler Return Temperature
• Boiler Flue Temperature
• Outdoor Temperature
• System Temperature
Low Water
Water pressure has fallen below
7.2 psi. Increase pressure to normal range.
If problem persists,
call for service
E37
Lockout message.
Lockout text. The rst sentence describes the lockout,
the second sentence gives a possible cure, and the third tells how to reset the lockout.
Lockout reference code. Refer to Sections 9.14.3
on page 64 and 9.14.4 on page 65 for more
information.
CHAPTER 9
63
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CHAPTER 9 - CTRLMAX OPERATION
9.14.3 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.
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
CHAPTER 9
E84 High Flue Temperature Flue temperature has exceeded high limit 5 times
E87 External Limit Open An external manual reset limit has opened
64
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CHAPTER 9 - CTRLMAX OPERATION
9.14.4 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 An open 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.
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.
CHAPTER 9
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INTENTIONALLY LEFT BLANK
Page 79
CHAPTER 10 - START-UP PREPARATION
10.1. Boiler System Fluid Requirements
NOTICE
Chapter 10
10.1.3 Chlorinated Water
Do not use the INSTINCT to heat a swimming pool or spa directly.
Requirements below must be met for warranty coverage of INSTINCT heat exchangers. A thor­ough cleaning of any existing system, using approved heating system cleaning agents is re­quired prior to installation of the INSTINCT boil­er. System should be treated with an approved
inhibitor after filling for long term protection.
WARNING
Do not use petroleum-based cleaning or seal­ing compounds in the boiler system. Dam­age to seals and gaskets in the system com­ponents can occur, resulting in substantial
property damage, serious injury, or death.
NOTICE
System fluid including additives, must be prac­tically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of
Commercial Products.
10.1.1 Boiler Fluid pH Level 6.0 to 8.0
Maintain the boiler uid pH between 6.0 and 8.0. Check using litmus paper or contact a water treatment com­pany for a chemical analysis.
Maintain the chlorine level of the water at levels consid­ered safe for drinking.
10.1.4 Flush Boiler to Remove Sediment
The installer must ush the boiler system to remove any sediment to allow proper operation of the INSTINCT .
Flush the system until the water runs clean and is free of sediment.
For zoned systems, each zone should be ushed through a purge valve. Purge valves and isolation valves should be installed on each zone to allow proper ushing of the system.
10.1.5 Cleaning of Old Boiler/System:
• Drain the existing system.
• Fill system with fresh water and cleaner, place exist­ing boiler in operation and run all zones.
• Follow manufacturer’s instructions for proper clean­er concentration and proper cleaning time.
• Thoroughly drain and ush system with fresh water after cleaning.
• Install new boiler and ll system with fresh water and proper amount of inhibitor.
• Verify pH and inhibitor level per inhibitor manufac­turer’s specs; add inhibitor if necessary.
If the pH does not meet this requirement, do not oper­ate the INSTINCT or leave the unit lled until the condi­tion is corrected.
10.1.2 Boiler Fluid Hardness Less Than 7 Grains
For areas with unusually hard water (hardness above 7 grains) consult a water treatment company.
10.1.6 Cleaning of New Boiler/System:
• Install new boiler and ush system with clean water to remove any debris.
• Fill system with fresh water and proper amount of inhibitor.
• Verify pH and inhibitor level per inhibitor manufac­turer’s specs; add inhibitor if necessary.
67
Page 80
Chapter 10
CHAPTER 10 - START-UP PREPARATION
10.1.7 Check and Test Antifreeze
For boiler systems containing antifreeze solutions, fol­low the antifreeze manufacturer’s instructions in verify­ing the inhibitor level and to ensure the uid character­istics are within specication requirements.
Due to the degradation of inhibitors over time, antifreeze uids must be periodically replaced. Refer to the manu­facturer of the antifreeze for additional instructions.
10.1.8 Use of Antifreeze in the Boiler System
WARNING
NEVER use automotive or ethylene glycol an­tifreeze or undiluted antifreeze in the system as freeze protection. This can result in sub­stantial property damage, serious injury, or
death.
Determine the antifreeze uid quantity using the sys­tem water volume and following the antifreeze manu­facturer instructions.
The water volume of the INSTINCT is approximately:
- 2 gallons [8 L] for INSTINCT Solo 110
- 3 gallons [12 L] for INSTINCT Solo/Combi 155 and
INSTINCT Solo 199
- 4 gallons [15 L] for INSTINCT Combi 199.
Remember to include the volume of the expansion tank.
Check with local code requirements for the installation of backow preventers or actual disconnection of the boiler’s cold water ll or make up water supply line.
DANGER
HOT WATER CAN SCALD!
• Water temperatures over 125ºF can cause severe burns instantly, or death from scalds.
• Feel water before bathing or showering.
• Consumer Product Safety Commission and some states recommend tempera­tures settings of 130ºF or less. Setting thermostat higher than 130ºF will in­crease risk of scald injury and cause se-
vere personal injury or death.
• Water heated to a temperature suitable for clothes washing, dish washing and other sanitizing needs will scald and
cause permanent injury.
• Children and elderly, infirm, or physical­ly handicapped persons are more likely to be injured by hot water. Never leave them unattended in or near a bathtub. If anyone using hot water in the building fits this description, or if state laws or lo­cal codes require certain water tempera­tures at hot water faucets, take special
precautions.
Ū Install the factory supplied automat-
ic mixing valve at water heater and/ or install a point of use mixing valve at each hot water faucet, bath and shower outlet. Selection and instal­lation of point of use mixing valves must comply with valve manufac­turer’s recommendation and instruc-
tions.
NOTICE
Massachusetts Code requires the installation of
a backflow preventer if antifreeze is used.
Ensure the concentration of antifreeze to water does not exceed a 50/50 ratio.
NOTICE
System fluid including additives, must be prac­tically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of
Commercial Products.
68
Ū Use the lowest practical temperature
setting.
Ū Check water temperature after any
adjustment of the mixing valve.
• Failure to comply with these instructions
will result in serious injury, or death.
Page 81
CHAPTER 10 - START-UP PREPARATION
10.2. Filling the Boiler System
1. Close the boiler drain valve located on the bottom of the unit and any manual or automatic air vents in the system.
2. Open all system isolation valves.
3. Fill the boiler system to correct system pressure. Correct pressure will vary with each application.
NOTICE
Typical residential system fill pressure is 12 psi. System pressure will increase as system tem­perature increases. Operating pressure of the
system should never exceed 30 psi.
4. Purge air and sediment in each zone of the boiler system through the purge valve. Open air vents to allow air to be purged from the zones.
5. Once the system is completely lled and purged of all air and sediment, check the system pressure and check/repair any leaks.
Chapter 10
General Notes
• Household water usage patterns will aect water temperature at any faucet or shower. Occasionally check temperature at each point of use, then adjust the mixing valve setting accordingly. Always re­check temperature after adjusting the mixing valve.
• Lowering the automatic mixing valve as indicated in these instructions will reduce water temperature levels. Consult your installer or service technician.
10.3.1 Filling the Domestic Circuit
CAUTION
• Never use the INSTINCT Combi unless the circuits of the water heater are completely
filled with water.
• Failure to comply with these instructions can
result in minor property damage, or injury.
1. Close domestic water drain valve.
2. Open domestic water isolation valves slowly on the water heater piping.
WARNING
Unrepaired system leaks will cause continu­al makeup water to be added to the boiler. Continual makeup water will cause mineral buildup within the heat exchanger, reducing the heat transfer, causing heat buildup and eventual heat exchanger failure. This can re­sult in substantial property damage, serious
injury, or death.
10.3. INSTINCT Combi Water Heater - Water Requirements
NOTICE
The thermostatic mixing valve controls the hot water temperature delivered to the faucets.
WARNING
POTENTIAL SCALD HAZARD. A mixing valve must be installed on the INSTINCT Combi. Removal or adjustment of the mix­ing valve will create a potential scald hazard,
which can result in serious injury, or death.
CAUTION
Make sure to open the domestic isolation valve slowly to prevent any damage to the domestic
circuit flow sensor.
3. Vent air from domestic circuit by opening nearest hot water faucet, until there is a constant ow of water.
4. Close hot water faucet.
10.4. Check Low Water Cut-Off Device
• The INSTINCT is provided with a factory installed
LWCO device that monitors system pressure.
• Access the Boiler Information Menu by following
instructions in Section 9.14 on page 61. Scroll down to see the current system pressure and verify it is within the range given in Section 10.2 above.
If any adjustment needs to be made to the valve’s tem­perature setpoint refer to the manufacturer’s instruc­tions included with the valve.
69
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Chapter 10
CHAPTER 10 - START-UP PREPARATION
10.5. Check For Gas Leaks
WARNING
• Prior to start-up and during initial oper­ation, check for a gas leak using a com­bustable gas detector. Do not proceed with the start-up if there is any indication of a gas leak. Any leaks found must be re-
paired immediately.
• Propane installations only - The propane supplier mixes an odorant with the pro­pane to make its presence detectable. In some cases the odorant can fade and the
gas may no longer have an odor.
• Prior to start-up of the unit and periodi­cally after start-up have the propane sup-
plier check and verify the odorant level.
• Failure to comply with these instructions can result in substantial property dam-
age, serious injury, or death.
• There should NEVER be voltage measured at the wire ends.
• If voltage is measured under any condition, check and correct the external wiring.
NOTICE
In systems using 3-wire zone valves, voltage backfeed to the unit is a common problem. Use an isolation relay to prevent voltage from the ex-
ternal circuit from entering the INSTINCT.
• Reconnect the external thermostat wires to the low voltage terminal strip.
10.7. Inspect Condensate Drain Assembly
1. Inspect and ensure the Condensate Drain Assembly
is properly installed as described in Section 6.2 on
page 38.
2. Remove the plug from the Condensate Drain As-
sembly and ll with fresh water.
10.6. Check Thermostat Circuit
• Disconnect the external thermostat wires from the low voltage terminals.
• Connect a voltmeter across the wire ends of the ex­ternal thermostat wiring.
• Close each thermostat, zone valve and relay in the external circuit one zone at a time and check the voltage reading across the wire ends.
WARNING
The condensate drain assembly must be filled with water when the INSTINCT is in operation. The condensate drain assembly prevents flue gas emissions from entering the condensate line. Failure to ensure trap is filled with water
can result in serious injury, or death.
3. Re-Install plug in condensate drain assembly.
70
Page 83
CHAPTER 11 - START-UP PROCEDURES
11.1. Final Checks Before Start-Up
Ø Read Chapter 9 on page 51 regarding the oper-
ation of the CTRLMax Boiler Management System.
Ø Verify the INSTINCT and the boiler system are full
of water and all system components are correctly set for operation, including the minimum ow rate through the boiler, see specications in Chapter
19 on page 101..
Ø Verify Start-up Preparation items outlined in Chap-
ter 10 on page 67 have been completed.
Ø Verify all electrical connections are correct and se-
curely fastened.
Ø Inspect vent and combustion air piping for signs
of deterioration from corrosion, physical damage or sagging. Verify combustion air and vent piping are intact and correctly installed and supported. Refer­ence the INSTINCT Vent Supplement.
Ø Verify burner conguration - Propane only.
• Check for proper labeling on the venturi and the rating label for propane conguration.
• If there is doubt on the burner conguration, remove the venturi and check for proper pro­pane gas orice sizing on venturi labeling. Refer to Section 7.3.2 on page 42 for orice sizes. Refer to Fig 16, Fig 17 or Fig. 28 on page 44 for location of the propane gas orice.
Ø Ensure the Condensate Drain Assembly is lled
with water.
4. Is an external limit (if applicable) open? Ensure the external limit is reset to the closed position.
5. Are the gas supply valves open at the unit and me­ter?
6. Is incoming gas supply pressure at the unit more than 5”w.c. and less than 13” w.c. with all gas appli­ances ON and OFF.
7. Are the heating thermostats set above room tem­perature?
If none of these conditions correct the problem, con­tact Triangle Tube Technical Support.
11.3. Check the INSTINCT and System
11.3.1 Check Boiler Piping.
• Check Boiler system piping and components for
leaks. If found, shut down the unit and repair im­mediately.
• Purge any remaining air from the system. Air in the
system will interfere with circulation, creating heat distribution problems and noise.
11.3.2 Check Vent and Combustion Air Piping.
• Check for a gas-tight seal at every connection and
seam of the vent and combustion air piping.
DANGER
CHAPTER 11
11.2. INSTINCT Start-Up
1. Turn ON the electrical supply/service to the unit. Touch the ON-OFF button located on the front con­trol panel to the OFF position.
2. Read and follow the Operating Instructions out­lined on following page.
If INSTINCT Does Not Start Correctly
1. Check for loose electrical connections, blown fuses on control module, or an open service switch.
2. Verify CH and DHW operation is enabled. A radiator or faucet icon with an X through it indicates that function is disabled.
3. Check the system pressure in the Boiler Information Menu by following the instructions in Section 9.14
on page 61.
Venting system must be sealed gas-tight to prevent flue gas spillage and carbon mon­oxide emissions, which will result in serious
injury, or death.
11.3.3 Verify Carbon Monoxide Detector
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).
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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
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
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 shall be parallel to gas piping).
to “OPEN” gas supply (valve handle
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.
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.
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”
72
3. Turn the external manual gas valve handle clock­wise
to “CLOSE”.
Page 85
CHAPTER 11 - START-UP PROCEDURES
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11.3.4 Check Gas Piping
Check around the unit for gas odor following the proce­dure outlined in this manual on page 64.
DANGER
If any gas leaks are found or suspected, shut the unit down immediately. Use a gas de­tection device or bubble test to locate the source of the gas leak and repair at once. Do not operate the unit until the leak is correct­ed. Failure to comply with this procedure will result in substantial property damage, seri-
ous injury, or death.
11.3.5 Verify Flame Pattern and Combustion
1. Check the ame pattern through the observation port of the heat exchanger. The ame should be blue and stable. The ame should be over the length of the burner head. It is not possible to de­termine correct combustion by inpecting eh colour and pattern of the ame. It is important to measure combustion with a calibrated ue gas analyser.
d. Touch the soft key while the FAN icon is
highlighted to manually re the burner and power the CH circulator(s).
Manual Operation
FAN
CH1
DHW
Released
O
O
O
CH2
NOTICE
An adequate CH load must be present to dissi­pate the heat generated during the combustion test. If an adequate CH load is not available, an indirect water heater can be used to dissipate the heat by creating a DHW call which will en-
able the DHW circulator.
CHAPTER 11
NOTICE
Combustion testing and adjustments must be performed by a qualified installer, service agen­cy or the gas supplier. All combustion mea­surements must be performed with recently calibrated equipment (1 year max.) to ensure
proper reading and accuracy.
2. Test for CO2 or O2 and for CO during high ring rate. The combustion readings must be within the range listed in Table 6 on page 74. The CO level
must not exceed 150 ppm for natural gas and 200 ppm for propane gas when combustion is correct. Perform the following procedure to manu-
ally place the burner into high re.
a. Touch simultaneously on the and soft
keys for 3 seconds to access the functions for the installer. Reference Section 9.1 on page 51.
b. Enter the installer access code “054” by using
and soft keys to select a digit location
the and the Touch the
c. Touch the
Operation icon
and soft keys to change the digit.
soft key to enter the access code.
soft key to highlight the Manual
then touch the soft key.
e. Touch the
from 1% to 100%. Hold down the
soft key to adjust the ring rate
soft key to
rapidly increase the ring rate.
f. Touch the
soft key while the FAN icon is
highlighted to shutdown the burner.
3. If the combustion levels during high re (100%) are outside the acceptable levels, adjust the THROTTLE SCREW (see Fig. 13 on page 25 and Fig. 27 on
page 43, and Fig. 28 on page 44) according to Table 5 on page 74.
4. Once the combustion level is set at high re (100%), manually place the boiler into low re (1%) mode by touching the
soft key to adjust ring rate down.
5. Verify the combustion levels during low re (1%) are within the acceptable combustion levels in Table 6
on page 74.
WARNING
If the combustion levels at low fire (1%) are not within the range given in Table 6 on page 74, shut the boiler down and contact Trian-
gle Tube Technical Support. Failure to com­ply with this requirement can result in sub­stantial property damage, serious injury, or
death.
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CHAPTER 11 - START-UP PROCEDURES
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CHAPTER 11
Table 5 - Throttle Screw Adjustment
Direction INSTINCT Solo/Combi
Clockwise
Counter-Clockwise
Decrease CO2
Increase O
2
Increase CO2
Decrease O
2
11.3.6 Measure Input - Natural Gas Only
1. Ensure the boiler is ring at maximum ring rate. To
manually place the boiler into high re, reference Section 11.3.5 on page 73.
2. Operate the unit for approximately 10 minutes.
3. Turn o all gas appliances within the building, ex­cept the INSTINCT.
4. At the gas meter, record the time required to use one cubic foot of gas.
5. Calculate Natural gas input using the following equation:
3600 x 1000 / number of seconds recorded for one
cubic foot of gas = BTU/H.
6. The BTU/H calculated should approximate the in-
3. Touch the
icon
4. Touch the
tings icon
5. Touch the perature then touch the
6. Touch the touch the
7. Touch the icon
soft key while CH & DHW Settings
is highlighted.
soft key to highlight the Boiler Set-
then touch the soft key.
soft key to highlight Lockout Tem-
soft key.
soft key to highlight 102ºF [39ºC] then soft key.
soft key to highlight the Home Screen
then touch the soft key.
8. Initiate a CH or DHW call and conrm that a High Boiler Temperature lockout occurs once the supply temperature reaches 102ºF [39ºC].
9. Touch any ARROW soft key to return to the Home Screen.
10. Touch simultaneously on the
and soft keys for
3 seconds to access the functions for the installer.
11. Touch the
icon
soft key while the CH & DHW Settings
is highlighted.
put rating listed on the unit.
12. Touch the
soft key to highlight the Boiler Set-
11.3.7 Test High Temperature Limit
The high temperature limit can be temporarily lowered from 210ºF [99ºC] to 102º F [39ºC] for testing.
1. Touch simultaneously on the for 3 seconds to access the functions for the install-
er. Reference Fig. 34 on page 51.
2. Enter the installer access code “054”, using the and
soft keys to select a digit and the and
soft keys to change the digit. Touch the to enter the access code.
CO2 Range 9.0 to 10.5% 10.4 to 11.0%
CO2 Target 9.50% 10.80%
O2 Range 4.85 to 2.15 % 5.1 to 4.2 %
High Fire
O2 Target 3.95% 4.50%
CO Max 150 ppm 200 ppm
CO2 Range Low Fire CO2 range 9.0 to 10.0 %
Target values are equivalent to High Fire values, ensure
CO2 values measured are less than or equal to High Fire
O2 Range Low Fire O2 range 4.85 to 3.0 %
Low Fire
Target values are equivalent to High Fire values, ensure
O2 values measured are higher than or equal to High
CO Max 10 ppm 10 ppm
and soft keys
soft key
Table 6 - Acceptable Combustion Levels
Natural Gas (All Models) Propane (All Models)
CO2 measurements
Fire O2 measurements
tings icon
13. Touch the perature, then touch the
14. Touch the touch the
15. Touch the icon
16. Touch the turn the unit to service.
then touch the soft key.
soft key to highlight Lockout Tem-
soft key.
soft key to highlight 210ºF [99ºC] then soft key.
soft key to highlight the Home Screen
then touch the soft key.
soft key to reset the lockout and re-
Low Fire CO2 range 10.4 to 11.0 %
Target values are equivalent to High Fire values, ensure
CO2 values measured are less than or equal to High Fire
CO2 measurements
Low Fire O2 range 5.1 to 4.2 %
Target values are equivalent to High Fire values, ensure
O2 values measured are higher than or equal to High
Fire O2 measurements
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Page 87
CHAPTER 12 - OUTDOOR RESET CONTROL
The use of the outdoor reset function is required to op­timize boiler eciency, see notice below. If the outdoor sensor is not installed before turning on the INSTINCT, an Outdoor Sensor Open error (E96) will be displayed. The error will not prevent the boiler from operating. The error will automatically reset once the outdoor sensor is installed or if the outdoor reset function is disabled. Reference Section 9.7 on page 56 for information on disabling the outdoor reset function. The outdoor reset function can only be disabled if the installation meets one of the exceptions listed in the IMPORTANT notice below.
12.1. Mounting the Outdoor Sensor
1. The exterior wall selected for mounting the out­door sensor should represent the heat load of the building. Typically a northern wall will suit most buildings.
2. Ensure the outdoor sensor is shielded from direct sunlight or the eects of heat or cold from other sources (exhaust fans, appliance vents...) to prevent false temperature readings.
3. Mount the outdoor sensor at an elevation on the exterior wall to prevent accidental damage or tam­pering.
4. Avoid mounting the outdoor sensor in areas sub­jected to excessive moisture.
5. Once an area on the exterior wall has been deter­mined, follow the mounting instructions included with the outdoor sensor.
12.2. Wiring the Sensor
1. Connect 18 AWG 2-wire cable or similar to the out­door sensor.
2. Route the cable back to the INSTINCT boiler, ensur­ing the wires are not run parallel to telephone or power wiring.
NOTICE
If the sensor wires are located in an area with sources of electromagnetic interference (EMI), the sensor wires should be shielded or the wires should be run in a grounded metal conduit. If using shielded cable, the shielding should be connected to the common ground of
the unit.
3. Connect the outdoor sensor wires to low voltage ter­minals X6-1&2 located at the bottom of the CTRLMax control module as shown in Fig. 33 on page 49.
CHAPTER 12
IMPORTANT
In accordance with Chapter 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS
IS TRUE.
• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.
• This boiler is not used for any space heating
• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/ hr or greater.
• This boiler is equipped with a tankless coil.
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Page 89
CHAPTER 13 - EXTERNAL MODULATING CONTROL
The INSTINCT can directly accept an analog 0-10 VDC signal from an external modulating boiler controller to control the ring rate.
13.1. Wiring the Modulating Controller
Run two 18 gauge wires from the external modulating boiler controller’s 0-10 VDC boiler output to low voltage terminals X5-1&2 located at the bottom of the CTRLMax control module, as shown in Fig. 33 on page 49.. This signal will both enable and modulate the boiler. No wir­ing is required at the thermostat terminals.
External modulating control will only function if the external modulating controller is properly wired to the INSTINCT as follows:
• X5-1 = +
• X5-2 = -
NOTICE
13.2. CTRLMax Programming
The CTRLMax control module must be programmed to accept the 0-10 VDC signal from the external modulat­ing boiler control.
1. Use the Heating EZ Setup function to set CH De-
mand to 0-10V Modulation Signal. Reference Sec-
tion 9.7 on page 56.
13.3. Programming of External Modulating Control
The external modulating control must be programmed to send 2 VDC to enable the boiler and run it at low re, and 10 VDC to run the boiler at high re. Once the con­trol enables the boiler, it must wait 30 seconds to allow the burner to stabilize before modulating the boiler.
CHAPTER 13
Ensure that the polarity of the connections from the external modulating boiler controller to the boiler are correct. Reversed polarity will
lead to no response from the boiler.
CTRLMax Factory Settings
FACTORY DEFAULT
HEATING SETTING
Heating Operation Enabled Enabled
Demand Type
Absolute Max CH Setpoint 185°F [85°C] 185°F [85°C] 68°F [20°C] 188°F [87°C]
CH1 Maximum Setpoint 180°F [82°C] 180°F [82°C] 68°F [20°C] 188°F [87°C]
CH1 Minimum Setpoint 80°F [27°C] 80°F [27°C] 60°F [15°C] 188°F [87°C]
Outdoor Curve Coldest Day 10°F [-12°C] 10°F [-12°C] -30°F [-34°C] 50°F [10°C]
Outdoor Curve Warmest Day 64°F [18°C] 64°F [18°C] 60°F [15°C] 78°F [25°C]
CH2 Circuit Enabled Enabled
CH2 Maximum Setpoint 140°F [60°C] 140°F [60°C] 68°F [20°C] 194°F [90°C]
CH2 Minimum Setpoint 80°F [27°C] 80°F [27°C] 60°F [15°C] 190°F [88°C]
Warm Weather Shutdown O O O 78°F [25°C]
Circulation Pump Permanent Disabled Disabled
CH Post Pump Time 5 Minutes 5 Minutes O 20 Minutes
Freeze Protection Enabled Enabled
Frost Protection Setpoint -22°F [-30°C] -22°F [-30°C] -22°F [-30°C] 50°F [10°C]
Parallel Shift Value 0°F [0°C] 0°F [0°C] 0°F [0°C] 144°F [80°C]
CH Call Blocking 2 Minutes 2 Minutes 0 Minute 30 Minutes
INSTINCT
Solo
Thermostat &
Outd. Curve
INSTINCT
Combi
Thermostat &
Outd. Curve
MINIMUM
SETTING
MAXIMUM
SETTING
EZ SETUP RESET INSTALLER RESET
✓
✓ ✓
✓
✓ ✓
✓ ✓
✓
✓
✓
✓ ✓
✓ ✓
✓ ✓
✓
✓
✓
✓
✓
✓
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Page 90
CHAPTER 13 - EXTERNAL MODULATING CONTROL
CTRLMax Factory Settings (cont’d)
FACTORY
HEATING SETTING
DEFAULT
INSTINCT Solo INSTINCT Combi
DHW Operation Enabled Enabled
Demand Type Thermostat N/A Thermostat
DHW Boiler Setpoint 168°F [75°C] 168°F [75°C] 96°F [35°C] 188°F [87°C]
DHW Setpoint 140°F [60°C] 140°F [60°C] 68°F [20°C] 168°F [75°C]
DHW Warmstart Setpoint N/A 125°F [52°C] 86°F [30°C] 140°F [60°C]
DHW Warmstart Hysteresis N/A 30°F [17K] 9K 36K
DHW On Dierential 6°F [3K] 18°F [10K] 4°F [2°C] 18°F [10°C] 6°F [3K]
CHAPTER 13
DHW Storage Adder 27°F [15°K] N/A 10°F [5°C] 54°F [30°C] 27°F [15°K]
DHW Post Pump Time 2 Minutes 2 Minutes Off 30 Minutes
DHW Priority Timeout O O Off 120 Minutes
DHW Priority Enabled Enabled
DHW Call Blocking 1 Minute 1 Minute 0 Minute 30 Minutes
DHW to CH Call Blocking 1 Minute 1 Minute 0 Minute 30 Minutes
Antilegionella Function Disabled
Enabled
MINIMUM
SETTING
MAXIMUM
SETTING
EZ SETUP RESET INSTALLER RESET
✓
✓ ✓
✓ ✓
✓ ✓
✓ ✓
✓
✓ ✓
✓
✓
✓
Enabled
✓
BOILER SETTING
FACTORY DEFAULT
MINIMUM
SETTING
MAXIMUM
SETTING
INSTINCT Solo
INSTINCT Combi
Lockout Temp. 210°F [99°C]
Modbus Address 0=BCST 0=BCST 247
Flex. Relay 1(CH) CH1
Flex. Relay 2(DHW) DHW
Flex. Relay 3(P3) CH1/CH2/DHW
Flex. Relay 4(ERR) ERROR
Flex. Relay 5(Flame) FLAME
Flex. Relay 6(P4) CH2
Error Relay
On Lockout, Blocking
and Warning
Pump PWM Minimum 30% 1% 100%
Ignition Level Varies by model
Mix Zone High Limit 114°F [45°C] 68°F [20°C] 176°F [80°C]
Appliance Setting Varies by model
Altitude Setting 0 ft 0 ft 20,000 ft
EZ SETUP RESET INSTALLER RESET
✓
✓
✓
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Page 91
CHAPTER 14 - CHECK-OUT PROCEDURES
NOTICE
Perform the following check-out procedures as outlined and check off items as complet­ed. When procedures are completed, the in­staller should complete the installation record
in Chapter 15 on page 81.
q Boiler system uid chemistry checked and veried
as outlined in Section 10.1 on page 67..
q Boiler system was completely ushed to remove
any debris/sediment.
q Any automatic air vents placed within the system
are open one full turn.
q Air is purged from the heating zones and boiler sys-
tem piping.
q If applicable, conrm that the burner has been
properly congured for Propane as outlined in Sec-
tion 7.3 on page 42.
q Thermostat circuit wiring checked and veried that
no voltage is present as outlined in Section 10.6 on
page 70.
q Operating Instructions were followed during start-
up.
q Combustion levels and ame pattern veried as
outlined in Section 11.3.5 on page 73.
q Measured the rate of input on Natural Gas as out-
lined in Section 11.3.6 on page 74.
q Test high temperature limit as outlined in Section
11.3.7 on page 74.
q Checked the incoming gas pressure to the IN-
STINCT to ensure a minimum pressure of 5”w.c during ow conditions to all gas appliances and a maximum pressure of 13”w.c during non-ow con­ditions for Natural and Propane.
q Adjusted balancing valves and system limit con-
trols to provide design temperatures to the primary space heating system.
q In multiple zone applications, adjusted for correct
ow of boiler water to each zone.
q Checked and veried room thermostat(s) function
properly and the thermostat(s) heat anticipator (if used) was properly set.
q Observed several operating cycles for proper oper-
ation of the INSTINCT and the system.
q Set the room thermostat(s) to the desired room
temperature.
q Reviewed all instructions shipped with the IN-
STINCT with the homeowner or maintenance per­sonnel.
q Completed the Installation Record of Chapter 15
on page 81.
q Ensure all manuals and other documents are re-
turned to the Installation envelope and given to the owner for safekeeping.
CHAPTER 14
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Page 93
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:
Combustion Readings: As Operating:
CO
2
%
Btu/hr =
As Installation Manual Table 6:
CO
2
3600
seconds per 1ft
%
3
gas
x 1000
OK
NOT OK
O
2
CO
%
ppm
O
2
CO
%
ppm
The following items were completed during installation:
Installation instructions have been followed and completed
Check-out procedures have been followed and completed
Information regarding the unit and installation received and left with owner / maintenance personnel.
If air for combustion is taken from inside the property the customer has been made aware of their obligation to ensure air grilles remain free from obstruction at all times.
CHAPTER 15
Installer Information
(Company)
(Address)
(Address)
(Phone Number)
(Contractor / Installer Name)
(Customer Name)
Signature Date
Signature Date
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CHAPTER 16 - MAINTENANCE SCHEDULES
16.1. 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.
16.2. 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.
• Check the pressure relief valve.
• Check that the condensate drain system goes to the loor drain.
Every 6 months:
• Check boiler piping and gas supply piping for cor­rosion or potential signs of leakage.
• Operate the pressure relief valve.
WARNING
Follow the maintenance procedures given throughout 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, se-
rious injury, or death.
Once the maintenance items are completed, review the service with the owner.
DANGER
• Where air for combustion is taken direct­ly from inside the property. It is essential this air supply is free from obstruciton. Failure to supply adequate air for combus-
tion may result in serious injury or death.
CHAPTER 16
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CHAPTER 17 - MAINTENANCE PROCEDURES
17.1. Service Technician 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 16 on page 83 and further explained in the INSTINCT User’s Infor­mation manual should be performed to assure maximum 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.
NOTICE
The following information provides detailed instructions for completing the service techni­cian maintenance items outlined in the main-
tenance schedule of Chapter 16 on page 83.
17.2. Reported Problems
Any problems reported by the owner should be checked, veried and corrected before proceeding with any maintenance procedures.
17.3. Check Surrounding Area
• Re-install venturi inlet elbow and front jacket panel when completed.
WARNING
Do not use solvents to clean any of the burn­er components. The components could be damaged, resulting in unreliable or unsafe operation. Failure to comply with this in­struction can result in substantial property
damage, serious injury, or death.
17.5. Check System Piping
• Inspect all water and gas piping for leaks and verify that the piping is properly supported.
• Inspect the ttings and components on the unit and verify they are leak free.
WARNING
Eliminate all system water leaks. Continual fresh make-up water will reduce the heat ex­changer life causing boiler failure. Leaking water may also cause severe property dam­age to the surrounding area. Inspect the gas supply piping using the procedure outlined in
Section 11.3.4 on page 73. Failure to comply with this instruction can result in substantial
property damage, serious 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 Sec- tion 2.1 on page 5 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.
17.4. Inspect Burner Area
• Remove the boiler front jacket panel and venturi inlet elbow.
• Vacuum any dirt or debris from the burner/blower components.
• Check the burner plate mounting nuts for tight­ness, see Section 17.24 on page 88 for torque specication.
• Check burner plate gasket for discoloration or damage.
• Check for ue gas leakage where the condensate pan connects to the heat exchanger and at the top and bottom of the internal vent pipe.
17.6. Clean Condensate Drain Assembly
NOTICE
For the INSTINCT Combi unit, the front panel needs to be removed to gain access to the con-
densate drain assembly.
• Loosen the retaining nut from the condensate drain assembly and disconnect the assembly from the boiler.
• Empty any water from the trap and ush with fresh water as necessary to clean.
• Remove plastic ball and clean with fresh water.
• Check the drain piping from the condensate drain assembly to the drain. Refer to Section 6.2 on page
38. Flush to clean as necessary.
• Install the plastic ball into the condensate drain assembly and reassemble onto the boiler by tight­ening the retaining nut with rubber seal onto the boiler. Hand tight only.
• Remove the ll plug on the condensate drain as­sembly and ll with water. See Fig. 24 on page 39.
• Replace the ll plug on drain assembly.
CHAPTER 17
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CHAPTER 17 - MAINTENANCE PROCEDURES
17.7. Check Ventilation Air Openings
• Verify that all ventilation openings to the mechan­ical room or building are open and unobstructed. Check the operation and wiring of any automatic ventilation dampers.
• Check and verify the vent termination and the com­bustion air intake are free of debris and obstructions.
17.8. Inspect Vent and Combustion Air Piping
• Visually inspect the venting system and combus­tion air piping for blockage, deterioration of gas­kets or leakage. Repair any deciencies.
• Verify that the combustion air inlet and vent piping is connected, sealed and properly supported.
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.
17.9. Check Boiler System
• Verify all system components are correctly installed and operating properly.
• Check the cold ll pressure for the system. Typical cold water ll pressure is 12 psig.
• Verify the system pressure, as the unit operates at high temperature, does not exceed 30 psig. Exces­sive pressure indicates expansion tank sizing is in­correct or system performance problems.
• Inspect air vent and air separators in the system. Ensure vents do not leak, replace any leaking vents.
CHAPTER 17
• Verify boiler uid pH level is between 6.0 and 8.0.
• Check and verify inhibitor /antifreeze concentration within the boiler water meets inhibitor/antifreeze manufacturer’s specications.
• If necessary contact a boiler water treatment com­pany for a chemical analysis.
17.10. Check Expansion Tank
Refer to Chapter 4 on page 15 for recommended lo­cation of the expansion tank and air eliminators.
Closed -Type Tank:
• Ensure tank is partially lled with water leaving an air gap as a cushion. Refer to the manufacturer’s instruction for proper ll level.
• Ensure the tank is tted with a device that reduces gravity circulation of air-saturated tank water back
into the system. This device prevents air from bub­bling up through the water as it returns from the system.
• Ensure no automatic air vents are used in the sys­tem. This will allow air to escape from the system instead of returning to the tank.
Diaphragm Tank:
• Ensure the system contains a minimum of one au­tomatic air vent. Recommended location of the air vent should be atop an air eliminator.
• Remove the tank from the system and check the charge pressure. For residential applications, the charge pressure is typically 12 psig. If tank does not hold pressure, then the membrane is damaged and the tank should be replaced.
17.11. Check Boiler Relief Valve
Inspect the relief valve and lift the lever to verify ow at least annually or as recommended on the warning tag of the valve.
WARNING
Before manually operating the pressure relief valve, ensure the discharge piping is direct­ed to a suitable place of disposal to avoid a potential scald hazard. The discharge piping must be full size without restriction and in­stalled to permit complete drainage of both the valve and line. Failure to comply with this instruction can result in substantial property
damage, serious injury, or death.
If after closing the valve, the valve fails to seat properly or continually weeps, replace the relief valve. Ensure the cause of the relief valve to weep is the valve itself, not due to system over-pressurization caused by an ex­pansion tank that is waterlogged or undersized.
17.12. Inspection of Ignitor
• Remove the ignitor from the burner mounting plate.
• Remove any white oxides accumulated on the ig­nitor using ne grit sandpaper or steel wool. If the ignitor does not clean to a satisfactory condition, replace the ignitor .
• When installing the ignitor, ensure the gasket is in good condition and correctly positioned. Replace the gasket if necessary. Tighten ignitor screws in multiple steps, alternating between the screws to ensure proper alignment. See Section 17.24 on page 88 for torque specications.
86
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CHAPTER 17 - MAINTENANCE PROCEDURES
17.13. Check Ignition Cable and Ground Wiring
• Inspect the ignition cable from the spark generator to the ignitor.
• Inspect the ground wire from the spark generator to the ignitor.
• Ensure wiring is in good condition and securely connected.
• Check ground continuity using a continuity meter.
• Replace ground wire if ground continuity is not satisfactory.
17.14. Check Control Wiring
Inspect all control wiring. Ensure wiring is in good con­dition and properly connected.
17.15. Check Control Settings
• Review all boiler settings in the Heating & DHW EZ Setup menus. Adjust settings as necessary, see Section 9.7 on page 56 and Section 9.8 on page 58
• Check any external limit control settings (if used). Adjust settings as necessary.
17.16. Perform Start-up and Checkout Proce-
dures
• Start the unit and perform the start-up procedures as listed in Chapter 11 on page 71.
• Verify the cold water ll pressure is correct and the operating pressure of the boiler is within normal operating range.
• Complete the checkout procedures as outlined in
Chapter 14 on page 79.
17.17. Check Burner Flame
• Inspect the ame pattern through the observation port of the heat exchanger.
• If ame pattern is not fully blue and covers the en­tire burner surface during high re, shut the unit down and allow it to cool thoroughly before dis­assembly.
• Close the external manual gas valve on the gas supply line and disconnect the gas piping and gas valve wire harness connector.
• Disconnect the wiring harness connectors from the blower and remove the blower clamp. Remove the blower from the unit.
• Remove the mounting nuts securing the burner plate to the heat exchanger and set aside.
• Carefully remove the burner plate assembly from the heat exchanger. Ensure that the combustion chamber 2-in-1 insulation is not damaged during removal of burner mounting plate assembly.
• Remove the burner head mounting screws and re­move the burner head. Inspect the burner head for deterioration. Use compressed air or a vacuum to clean the burner head.
• Remove the venturi and gas valve assembly from the blower.
• Use a vacuum cleaner or compressed air to clean the interior of the blower assembly. Inspect the blower blades to ensure they are clean and not damaged.
• Re-assemble the venturi and gas valve onto the blower. Ensure the venturi gasket or o-ring is in good condition and positioned correctly. Replace gasket or o-ring if necessary.
• Re-assemble the burner head onto the burner mounting plate. Ensure the burner head gasket is in good condition and positioned correctly. Re­place gasket if necessary.
• Re-assemble the burner plate assembly onto the heat exchanger. Ensure the combustion chamber 2-in-1 insulation is in place and positioned correct­ly. Replace if necessary.
• Remove the blower gasket from the burner plate assembly and clean with fresh water. Reinstall blower gasket onto burner plate assembly with the check valve hinge at the top.
• Re-assemble the blower onto the burner plate and reconnect the wiring harness connectors.
• Re-assemble the gas supply connection and wire harness to the gas valve. Open the external manual gas valve. Check gas piping for any leaks as outlined
in Section 10.5 on page 70 and repair if necessary.
• Torque all screws, bolts, and nuts in accordance with specications in Section 17.24 on page 88.
• Place the unit back into service.
17.18. Check Flame Signal
• The ame signal can be read from the Boiler Infor­mation screen. It should be a min. 2-3 Α at low re.
• Check the ignitor condition if ame signal is low.
• Check ground wire for continuity if ame signal is low. Replace ignitor if conditions are satisfactory.
CHAPTER 17
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CHAPTER 17 - MAINTENANCE PROCEDURES
17.19. Check Combustion Levels
• Re-assemble the blower onto the burner plate and reconnect the wiring harness connectors.
Refer to Section 11.3.5 on page 73 for measuring combustion levels and burner adjustments.
17.20. Check Flue Gas Temperature
• Manually place the boiler into high re. See Section
11.3.5 on page 73 for procedure.
• Navigate to the Boiler Information Menu to observe the
ue gas temperature. See Section 9.14 on page 61 .
• If the ue gas temperature is more than 54°F [30°C] above the supply water temperature, shut the boil­er down and follow the heat exchanger cleaning procedure below.
• Reconnect the gas piping and wire harness to the gas valve. Open the external manual gas valve. Check gas piping for any leaks as outlined in Sec- tion 10.5 on page 70 and repair if necessary.
• Torque all screws, bolts, and nuts in accordance with specications in Section 17.24 on page 88.
• Close isolation valves on the boiler water piping to isolate the boiler from the heating system.
• Attach a hose to the boiler drain valve and ush the boiler thoroughly with fresh water by using the purge valves to allow water to enter through the make-up water line to the boiler.
• Once the boiler has been completely ushed, re-
17.21. Clean Heat Exchanger
Shut down the boiler:
• Follow the instructions on page 72 “To Turn O Gas to Appliance”
• Do not drain the boiler unless the boiler will be subject to freezing conditions.
• Do not drain the boiler if antifreeze is used in the system.
• Allow the boiler to cool down to room temperature before servicing.
turn the boiler back into operation.
• Perform the required startup and checkout proce-
dures as outlined in Chapter 10 on page 67 and Chapter 14 on page 79.
17.22. 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).
• Close the external manual gas valve on the gas supply line and disconnect the gas piping and gas valve wire harness connector.
• Disconnect the wiring harness connectors from the blower and remove the blower clamp. Remove the blower from the unit.
CHAPTER 17
• Remove the mounting nuts securing the burner
17.23. Review With Owner
Ensure the owner understands the importance of per­forming the maintenance schedule specied in this manual.
plate to the heat exchanger and set aside.
• Carefully remove the burner plate assembly from
17.24. Torque Specifications Table
the heat exchanger. Ensure that the combustion chamber 2-in-1 insulation is not damaged during removal of burner mounting plate assembly.
• Use compressed air or water to remove any accu­mulation from the heat exchanger ue ways.
• Re-assemble the burner plate assembly onto the heat exchanger. Ensure the combustion chamber 2-in-1 insulation is in place and positioned correct­ly. Replace if necessary.
Item Min. Max.
Burner Plate Nuts 44 53 Burner Head Bolts 26.5 31 Fan Clamp Screw 62 71 Gas Valve Screws 31 35 Venturi Screws 31 35 Ignitor Screws 26.5 31
Torque Req’d (in-lbs)
• Remove the blower gasket from the burner plate assembly and clean with fresh water. Reinstall blower gasket onto burner plate assembly with the check valve hinge at the top.
88
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