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Instinct

Condensate Pan Replacement

1

WARNING

!

Indicates a potentially hazardous situation which, 
if ignored, can result in serious  injury or substan-
tial property damage.

NOTICE

Indicates special instructions on installation, operation 

or maintenance, which are important to equipment 

but not related to personal injury hazards.

WARNING

!

For your safety, turn off electrical power supply 
at service panel and allow unit to cool before pro-
ceeding to avoid possible electrical shock and 
scald hazard.  Failure to do so can cause severe 
personal injury or death.

WARNING

!

Failure to follow instructions below can result in 
severe personal injury or damage if ignored.

•  Instructions are for a qualified installer/ ser-

vice technician only.

•  Read all instructions before proceeding.
•  Follow instructions in proper order.

Kit Part Number

Description

Model

INSRKIT98

Condensate Pan Replacement

Instinct 110

INSRKIT99

Condensate Pan Replacement

Instinct 155 Models

INSRKIT100

Condensate Pan Replacement

Instinct 199 Models

Each Kit Includes:

•  Condensate Pan

•  Heat Exchanger Gasket

•  Flue Tube Gasket

Recommended Tools:

•  Adjustable Wrenches

•  Phillips Head Screwdriver

•  T-25 Torx Screwdriver  

•  8 mm Open Ended Wrench

•  10 mm Socket and/or 10 mm Open Ended Wrench

2020-54 Instinct Condensate Pan Replacement

Revised 04/27/20

Summary of Contents for INSRKIT100

Page 1: ...or death WARNING Failure to follow instructions below can result in severe personal injury or damage if ignored Instructions are for a qualified installer ser vice technician only Read all instruction...

Page 2: ...ining of the boiler remove the air vent at the top of the unit or manually lift open the pressure relief valve WARNING Water from the boiler drain connection may be ex tremely hot To avoid personal in...

Page 3: ...wer to the burner mounting plate Unscrew the other two bolts only as much as is needed to remove the blower venturi assembly 8 Slide the blower Venturi forward to disengage the rear bolts and remove t...

Page 4: ...Instinct Condensate Pan Replacement 4 Fig 5 Instinct 110 Fig 6 Instinct 155 Solo Fig 7 Instinct 199 Solo Fig 8 Instinct 155 Combi...

Page 5: ...card the seals as they will be reused 5 Removal of Flue Tube 1 Disconnect the molex plug connected to the flue temperature sensor in the flue tube 2 Remove the flue temperature sensor by pulling it st...

Page 6: ...9 Install New Condensate Pan 1 Seat the new flue tube gasket in the flue tube seat 2 Seat the new condensate pan gasket in the recess as shown in Fig 12 with the side with less ribs fac ing upward 3 I...

Page 7: ...ain nipple See Fig 10 2 Push the condensate trap onto the condensate nipple as far as it will go 3 Tighten the retaining nut to the condensate trap to secure the condensate trap 4 Pull the condensate...

Page 8: ...of the unit at the main manual shutoff valve to the unit Check and test all gas connections for leaks Repair leaks if found WARNING Do not check for gas leaks with an open flame Use a bubble test Fai...

Page 9: ...dequate 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 creatin...

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