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Dry Contact

Zone Valve

End Switches

Low Voltage Terminals

Outdoor Sensor

Line Voltage Terminals

DHW Sensor

CH2

Thermostat

6 5

System

Sensor

4 3

Modulation

Signal

2 1

CH2

Thermosta

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

Z.V.

L N G L N G L N G L N G

FLAME POWER SU PPLY

CH PUMP

DHW PUMP

CHAPTER 4

Fig. 12 - INSTINCT Combi System Piping - Zoning w Valves

• Consult the INSTINCT CTRLMax Control Supplement for information on setting the

required Preset Pump Configuration.

NOTICE

PRESET PUMP CONFIGURATION INSTINCT COMBI

Heat Call DHW Pump CH Pump Flame

CH1 OFF ON ON

CH2 OFF ON ON

DHW ON ON OFF

CHAPTER 4 - BOILER PIPING

Outdoor Sensor

Dry Contact

Zone Valve

End Switches

DHW Sensor

Manual Auto

Low Voltage Terminals

Line Voltage Terminals

External Limit

Terminals

Default Chapter3
- Table of Contents3
- Product and Safety Information11
Chapter 1 - Pre-Installation Requirements13
- INSTINCT Boilers - Code Compliance13
  - Code Restrictions13
  - Operating Restrictions13
- Determining Product Location14
- Boiler Freeze Protection Feature14
- Boiler Replacement14
- Recommended Clearances15
- Residential Garage Installations15
Chapter 2 - Combustion Air & Venting17
- Combustion Air Contamination17
- Ventilation and Combustion Air Requirements - Direct Vent18
- Ventilation and Combustion Air Requirements - Category IV18
- Methods of Accessing Combustion Air into a Space - Category IV19
  - Indoor Combustion Air19
  - Outdoor Combustion Air19
- Fig. 1 - All Combustion Air from Adjacent Indoor Spaces through Indoor Combustion Openings19
- Fig. 2 - All Combustion Air from Outdoors through One Permanent Air Opening19
  - Combination of Indoor and Outdoor Combustion Air20
- Combustion Air and Vent Piping20
- Fig. 3 - All Combustion Air from Outdoors through Ventilated Attic20
- Fig. 4 - All Combustion Air from Outdoors through Horizontal Ducts20
- Removal of an Existing Boiler from a Common Vent System21
- Carbon Monoxide Detector Installation22
- Commonwealth of Massachusetts Installation Requirements22
Chapter 3 - Unit Preparations25
- Handling Instructions25
- Wall Mounting Installation25
- Accessory Box25
- Fig. 5 - Accessory Box Contents25
- Wall Mounting Guidelines26
- Stud Walls - Installation26
- Wall Bracket Installation - Solid Walls26
- Boiler Mounting26
Chapter 4 - Boiler Piping27
- General Piping Requirements27
- Pressure Relief Valve27
- Fig. 6 - INSTINCT Pressure Relief Valve Installation27
- Boiler Air Vent28
- Low Water Cutoff Device28
- Fig. 7 - Piping Component Legend28
- Additional Limit Control29
- Backflow Preventer29
- INSTINCT solo Boiler System Piping29
- Fig. 8 - INSTINCT solo Near Boiler Piping - Diaphragm Expansion Tank29
- Fig. 9 - Near Boiler Piping - Closed Type Expansion Tank30
- Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump (Manual Pump Configuraiton)32
  - System Piping - Special Application33
  - System Piping - Multiple Units Installation33
- INSTINCT Combi Boiler System Piping33
- Fig. 11 - INSTINCT Combi Near Boiler Piping - Diaphragm Expansion Tank33
- Optional System Piping and Cascading35
- Fig. 12 - INSTINCT Combi System Piping - Zoning W Valves36
- Fig. 13 - INSTINCT Combi - System Piping - Multi Zone Valve - Single Circulator37
- Fig. 14 - INSTINCT Combi - System Piping - Single Zone with Single Circulator38
Chapter 5 - Instinct Combi Units - Domestic Piping39
- Domestic Piping Pressure Relief Valve39
  - Standard Installation39
  - Pressure Relief Valve - Standard Installations39
- Fig. 15 - Standard Installation of the Pressure Relief Valve39
  - Pressure Relief Valve Discharge Piping40
- Thermal Expansion40
- Water Hammer41
- Vacuum Breaker41
- Hydro-Block41
- Fig. 16 - INSTINCT Combi - Hydro-Block Flow Diagram41
- General Piping42
- Thermostatic Mixing Valve42
- Storage Tank Installation42
- Fig. 17 - INSTINCT Combi System Piping - Single Zone System with Single System/Boiler Circulator43
- Fig. 18 - INSTINCT Combi System Piping - Domestic Piping - Storage Tank Installation44
- Fig. 19 - Multiple Zones - Panel Wiring with Circulators45
- Fig. 20 - INSTINCT Combi System Piping - Multiple Zones - Panel Wiring with Valves46
- Fig. 21 - INSTINCT solo System Piping - Multi Zone System with Single System/Boiler Circulator47
- Fig. 22 - INSTINCT solo System Piping - Indirect Water Heater Installation48
- Fig. 23 - Instinct solo - Cascade Piping49
Chapter 6 - Installing Vent/Combustion Air & Condensate Drain50
- Installing Vent and Combustion Air50
- Installing Condensate Drain Assembly into INSTINCT solo Units50
- Fig. 24 - Condensate Drain Assembly51
Chapter 7 - Gas Piping52
- Gas Supply Piping Connection52
- Fig. 25 - Recommended Gas Supply Piping52
- Natural Gas53
  - Pipe Sizing53
  - Supply Pressure Requirements53
- Propane Gas54
  - Pipe Sizing54
  - Supply Pressure Requirements54
- Fig. 26 - Gas Valve / Venturi Assembly - INSTINCT Solo11055
- Fig. 27 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 15555
- Fig. 28 - Gas Valve / Venturi Assembly - INSTINCT Solo/Combi 19956
Chapter 8 - Wiring57
- Internal Wiring57
  - General Requirements57
  - Fuse Locations57
- Fig. 29 - Ctrlmax Control Module Fuse Location57
- Fig. 30 - INSTINCT solo Boiler Factory Wiring58
- Fig. 31 - INSTINCT Combi Boiler Factory Wiring59
- External Wiring60
  - General Requirements60
  - Line Voltage Connections60
- External Wiring - INSTINCT solo Units60
  - Circulator Wiring60
- Fig. 32 - Terminal Strip Location60
- Fig. 33 - Low Voltage Connections61
Chapter 9 - Ctrlmax Operation63
- Ctrlmax Navigation63
- Fig. 34 - Ctrlmax User Interface63
- Ctrlmax Menu Structure64
- Home Screen65
- Status Line Messages66
- Main Menu67
- EZ Setup67
- Heating EZ Setup68
  - Select CH Demand (no Outdoor Sensor Connected)68
  - Select CH Demand (Outdoor Sensor Connected)69
- Domestic Hot Water EZ Setup70
- Domestic Hot Water EZ Setup - INSTINCT Combi Units71
- Altitude Setup71
- EZ Setup Reset72
- Display EZ Setup72
- CH/DHW Operation73
- Boiler Information73
Chapter 10 - Start-Up Preparation79
- Boiler System Fluid Requirements79
- Filling the Boiler System81
- INSTINCT Combi Water Heater - Water Requirements81
  - Filling the Domestic Circuit81
- Check Low Water Cut-Off Device81
- Check for Gas Leaks82
- Check Thermostat Circuit82
- Inspect Condensate Drain Assembly82
Chapter 11 - Start-Up Procedures83
- Final Checks before Start-Up83
- INSTINCT Start-Up83
- Check the INSTINCT and System83
Chapter 12 - Outdoor Reset Control87
- Mounting the Outdoor Sensor87
- Wiring the Sensor87
Chapter 13 - External Modulating Control89
- Wiring the Modulating Controller89
- Ctrlmax Programming89
- Programming of External Modulating Control89
Chapter 14 - Check-Out Procedures91
Chapter 15 - Installation Record93
Chapter 16 - Maintenance Schedules95
- Service Technician95
- Owner Maintenance95
Chapter 17 - Maintenance Procedures97
- Service Technician Maintenance Procedures97
- Reported Problems97
- Check Surrounding Area97
- Inspect Burner Area97
- Check System Piping97
- Clean Condensate Drain Assembly97
- Check Ventilation Air Openings98
- Inspect Vent and Combustion Air Piping98
- Check Boiler System98
- Check Expansion Tank98
- Check Boiler Relief Valve98
- Inspection of Ignitor98
- Check Ignition Cable and Ground Wiring99
- Check Control Wiring99
- Check Control Settings99
- Perform Start-Up and Checkout Procedures99
- Check Burner Flame99
- Check Flame Signal99
- Check Combustion Levels100
- Check Flue Gas Temperature100
- Clean Heat Exchanger100
- Check Carbon Monoxide Detectors100
- Review with Owner100
- Torque Specifications Table100
Chapter 18 - Replacement Parts101
- Fig. 35 - INSTINCT solo Jacket Components101
- Fig. 36 - INSTINCT Combi Jacket Components102
- Fig. 37 - INSTINCT solo 110 Internal Components103
- Fig. 38 - INSTINCT solo 155 Internal Components104
- Fig. 39 - INSTINCT Combi 155 Internal Components105
- Fig. 40 - INSTINCT Combi 199 Internal Components106
- Fig. 41 - INSTINCT solo 110 Burner Components107
- Fig. 42 - INSTINCT Solo/Combi 155 Burner Components108
- Fig. 43 - INSTINCT Combi 199 Burner Components109
- Fig. 44 - INSTINCT Control & Display Enclosures110
- Fig. 45 - INSTINCT Combi Hydro-Block111
Chapter 19 - Product Specifications113
- Fig. 46 - Front View INSTINCT solo 110114
- Fig. 47 - Right Side View INSTINCT solo 110115
- Fig. 48 - Front View INSTINCT solo 155116
- Fig. 49 - Right Side View INSTINCT solo 155117
- Fig. 50 - Front View INSTINCT solo 199118
- Fig. 51 - Right Side View INSTINCT solo 199119
- Fig. 52 - Front View INSTINCT Combi 155120
- Fig. 53 - Right Side View INSTINCT Combi 155121
- Fig. 54 - Front View INSTINCT Combi 199122
- Fig. 55 - Right Side View INSTINCT Combi 199123
- Graph 1 - INSTINCT solo - Pressure Loss through Boiler124

Brand	TriangleTube
Model	Instinct Solo Series
Category	Boiler
Language	English

TriangleTube Instinct Solo Series Installation & Maintenance Manual

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