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CHAPTER 5

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

Fig. 17 - INSTINCT Combi System Piping - Single Zone System with Single System/Boiler Circulator

Consult the INSTINCT CTRLMax Control Supplement for information on setting the re-

quired Preset Pump Configuration.

NOTICE

Low Voltage Terminals

Outdoor Sensor

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

DHW

Outlet

12" min

Heat Trap Loop

(Optional)

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

Loop (Optional)

Line Voltage 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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