IDEAL EXALT Solo 110 Installation & Maintenance Manual
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IDEAL EXALT Solo 110 Installation & Maintenance Manual

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INSTALLATION &
MAINTENANCE MANUAL
- Customer must register unit within thirty (30)
days of installation in order to gain warranty
coverage. See Warranty Card for details.
• 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.
225296 A02 - August 2020
2019-28
EXALT Solo 110-155-199 & EXALT Combi 155-199
NOTICE
- Leave all documentation received with
WARNING
• WHAT TO DO IF YOU SMELL GAS
- Do not try to light any appliance
- Do not touch any electrical switch;
- Immediately call your gas supplier
- If you cannot reach your gas supplier,
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
appliance with the owner for future reference.
do not use any phone in your
building.
from a neighbor's phone. Follow the
gas supplier's instructions.
call the fire department.

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  • Page 1 INSTALLATION & MAINTENANCE MANUAL EXALT Solo 110-155-199 & EXALT Combi 155-199 NOTICE - Customer must register unit within thirty (30) - Leave all documentation received with days of installation in order to gain warranty appliance with the owner for future reference.
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  • Page 3: Table Of Contents

    TABLE OF CONTENTS PRODUCT AND SAFETY INFORMATION ................XI CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS ............1 1.1. EXALT 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.
  • Page 4 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.
  • Page 5 TABLE OF CONTENTS CHAPTER 5 - EXALT 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 ................27 5.2.
  • Page 6 TABLE OF CONTENTS 8.3. External Wiring - EXALT 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 ......................
  • Page 7 TABLE OF CONTENTS 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 ....................
  • Page 8 TABLE OF CONTENTS CHAPTER 16 - MAINTENANCE SCHEDULES ..............83 16.1. Service Technician ........................83 16.2. Owner Maintenance ........................83 CHAPTER 17 - MAINTENANCE PROCEDURES ............... 84 17.1. Service Technician Maintenance Procedures ................84 17.2. Reported Problems ........................84 17.3. Check Surrounding Area ......................84 17.4.
  • Page 9 Fig. 24 - Condensate Drain Assembly ....................38 Fig. 25 - Recommended Gas Supply Piping ..................39 Fig. 26 - Gas Valve / Venturi Assembly - EXALT Solo 110 ..............42 Fig. 27 - Gas Valve / Venturi Assembly - EXALT Solo/Combi 155 ............42 Fig.
  • Page 10 Fig. 41 - EXALT Solo 199 Internal Components ..................93 Fig. 42 - EXALT Combi 199 Internal Components ................94 Fig. 43 - EXALT Solo 110 Burner Components ................... 95 Fig. 44 - EXALT Solo/Combi 155 Burner Components ..............96 Fig.

  • Page 11: Product And Safety Information

    • Failure to comply with these instructions will fittings not specified by Ideal. If there is a conflict or result in substantial property damage, serious doubt about the proper installation of the unit or any injury, or death.
  • Page 12 It is prohibited to carry out any modifications to the appliance to the lowest temperature which satisfies without prior written consent from Ideal. your hot water needs. • Faulty parts must only be replaced by genuine Ideal factory Ū Feel and adjust water temperature before parts. bathing or showering. •...

  • Page 13: Chapter 1 - Pre-Installation Requirements

    CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.1. EXALT Boilers - Code Compliance • The equipment is permanently labeled to indicate that only additives recognized as safe The EXALT units must be installed by a qualified installer by the FDA shall be used in the heat transfer in accordance with the following: medium.

  • Page 14: Determining Product Location

    CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.2. Determining Product Location 1.3. Boiler Freeze Protection Feature The CTRLMax boiler management system has a freeze NOTICE protection feature built in. This feature monitors the boiler water temperature and responds as follows when The EXALT is certified for indoor, no call for heat is present: conditioned space installations ONLY.

  • Page 15: Recommended Clearances

    CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.5. Recommended Clearances 1.6. Residential Garage Installations The EXALT is approved for zero clearance to combusti- When installing the EXALT in a residential garage, the bles, excluding vent and boiler piping. following special precautions per NFPA 54/ANSI Z223.1 must be taken: •...
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  • Page 17: Chapter 2 - Combustion Air & Venting

    CHAPTER 2 - COMBUSTION AIR & VENTING • An in-direct installation uses uncontaminated 2.1. Combustion Air Contamination indoor air for appliance combustion. WARNING • When the air for combustion is taken from the room air grilles must be installed by the contractor.

  • Page 18: Ventilation And Combustion Air Requirements - Direct Vent

    CHAPTER 2 - COMBUSTION AIR & VENTING 2.2. Ventilation Combustion 2.3. Ventilation Combustion Requirements - Direct Vent Requirements - Category IV A Direct Vent appliance utilizes uncontaminated A Category IV appliance utilizes uncontaminated outdoor air piped directly to the appliance for indoor or outdoor air surrounding the appliance for combustion.

  • Page 19: Methods Of Accessing Combustion Air Into A Space - Category Iv

    CHAPTER 2 - COMBUSTION AIR & VENTING 2.4. Methods of Accessing Combustion Air 2.4.2. Outdoor Combustion Air Into A Space - Category IV BEST PRACTICE BEST PRACTICE 2.4.1. Indoor Combustion Air Isolating the combustion appliance room from the rest of the building and bringing in NOTICE uncontaminated outside air for combustion •...

  • Page 20: Combination Of Indoor And Outdoor Combustion Air

    CHAPTER 2 - COMBUSTION AIR & VENTING • Two Permanent Opening Method. Two permanent • Where communicating with the outdoors is through horizontal ducts, each opening shall have openings, one commencing within 12 in. of the top a minimum free area of not less than 1 sq.in./2000 and one commencing within 12 in.

  • Page 21: Removal Of An Existing Boiler From A Common Vent System

    CHAPTER 2 - COMBUSTION AIR & VENTING 1. Seal any unused openings in the common venting BEST PRACTICE BEST PRACTICE system. 2. Visually inspect the venting system for proper size In order to reduce the potential risks associated and horizontal pitch and determine there is no with indoor contaminates (see list in Section blockage or restriction, leakage, corrosion and other 2.1 on page 5), flammable vapors and tight...

  • Page 22: Carbon Monoxide Detector Installation

    2.8.1 Installation of Carbon Monoxide Detectors. 1. At the time of installation of the side wall horizontal Ideal follows the recommended advice of CPSC and vented gas fueled equipment, the installing plumber requires the installation of a minimum of two (2) carbon...

  • Page 23: Signage

    CHAPTER 2 - COMBUSTION AIR & VENTING 2.8.5 Manufacturer Requirements 2.8.3 Signage Equipment Venting System Provided. A metal or plastic identification plate shall be When the manufacturer of Product Approved side permanently mounted to the exterior of the building at wall horizontally vented gas equipment provides a a minimum height of eight (8) feet above grade directly venting system design or venting system components...
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  • Page 25: Chapter 3 - Unit Preparations

    2. Slide the cardboard sleeve from the unit. minimum: 3. Remove the wall mounting template. • 119.5 pounds [54 kg] for the EXALT Solo 110 4. Remove the accessory boxes. • 141 pounds [64 kg] for the EXALT Solo 155 5.

  • Page 26: Wall Mounting Guidelines

    CHAPTER 3 - UNIT PREPARATIONS 3.4. Wall Mounting Guidelines 3.5. Stud Walls - Installation 1. Locate the studs in the general area of the boiler The wall-mounting bracket is designed for stud spacing installation. of approximate 12 inch or 16 inch on centers. For unconventional stud spacing, a solid / secure mounting 2.

  • Page 27: Chapter 4 - Boiler Piping

    CHAPTER 4 - BOILER PIPING 4.1. General Piping Requirements 2. To avoid potential water damage to the surrounding area or potential scalding hazard due to the • All plumbing must meet or exceed all local, state operation of the relief valve, the discharge piping: and national plumbing codes.

  • Page 28: Boiler Air Vent

    CHAPTER 4 - BOILER PIPING 4.3. Boiler Air Vent 4.4. Low Water Cutoff Device NOTICE • The EXALT is equipped with a factory installed pressure sensor type Low Water Cut Off (LWCO). This boiler is supplied with a special automatic air •...

  • Page 29: Additional Limit Control

    101. For other piping be required. Consult local code requirements to determine arrangements, contact Ideal Technical compliance. The limit should be installed as follows: Support or consult other approved/ recognized design arrangements.

  • Page 30: Expansion Tank And Makeup Water

    Always locate and install the boiler volume: system fill connection at the same location as the • 2 gallons [8 L] for the EXALT Solo 110 expansion tank connection to the system. • 3 gallons [12 L] for the EXALT Solo 155 4.7.2 Diaphragm Expansion Tank...

  • Page 31: Circulator

    Solo, the boiler supply and return piping size must Solo. The circulator, when wired directly to the EXALT, will be a minimum of 1 inch for the EXALT Solo 110, 1-1/4 allow for domestic hot water priority and provide circulation inch for the EXALT Solo 155/199.

  • Page 32: Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 Ch Pump And 1 Dhw Pump

    CHAPTER 4 - BOILER PIPING EXALT SOLO PRESET PUMP CONFIGURATION Heat Call Flame CH Pump DHW Pump Note. EXALT Solo is pre-configured for this installation Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump...

  • Page 33: System Piping - Special Application

    Solo, the boiler supply and return piping size must be a BEST PRACTICE BEST PRACTICE minimum of 1 inch for the EXALT Solo 110, 1-1/4 inch for the EXALT Solo 155/199. It is recommended on all piping applications to utilize a primary/secondary piping arrangement as 4.7.11 System Piping –...

  • Page 34: Expansion Tank And Makeup Water

    CHAPTER 4 - BOILER PIPING System System Supply Return Optional Instinct Optional Exalt Combi Timesaver Combi Timesaver EXRKIT84 EXRKIT84 Cold Water Fill Fig. 12 - EXALT Combi Near Boiler Piping - Timesaver Manifold 4.8.1 Expansion Tank and Makeup Water CAUTION Ensure the expansion tank is properly sized for the The expansion tank must be located directly on the boiler volume:...

  • Page 35: Sizing Primary Piping

    CHAPTER 4 - BOILER PIPING 4.8.4 Sizing Primary Piping 4.8.8 System Piping – Radiant Heating See Fig. 11 on page 21 through Fig. 15 on page 26, for The heat exchanger design of the EXALT Combi allows recommended piping arrangements based on various operation in a condensing mode.

  • Page 36: Fig. 13 - Exalt Combi System Piping - Zoning W Valves

    CHAPTER 4 - BOILER PIPING EXALT COMBI PRESET PUMP CONFIGURATION Heat Call Flame CH Pump DHW Pump Note. EXALT Combi is pre-configured for this installation External Limit Line Voltage Terminals Low Voltage Terminals External Limit Terminals Low Voltage Terminals Line Voltage Terminals Terminals Manual Auto...

  • Page 37: Fig. 14 - Exalt Combi - System Piping - Multi Zone Valve - Single Circulator

    CHAPTER 4 - BOILER PIPING EXALT COMBI PRESET PUMP CONFIGURATION Heat Call Flame CH Pump DHW Pump Note. EXALT Combi is pre-configured for this installation External Limit Line Voltage Terminals Low Voltage Terminals External Limit Low Voltage Terminals Terminals Line Voltage Terminals Terminals Manual Auto...

  • Page 38: Fig. 15 - Exalt Combi - System Piping - Single Zone With Single Circulator

    CHAPTER 4 - BOILER PIPING EXALT COMBI PRESET PUMP CONFIGURATION Heat Call Flame CH Pump DHW Pump Note. EXALT Combi is pre-configured for this installation Line Voltage Terminals External Limit Line Voltage Terminals Low Voltage Terminals External Limit Low Voltage Terminals Terminals Terminals Manual...

  • Page 39: Chapter 5 - Exalt Combi Units - Domestic Piping

    CHAPTER 5 - EXALT COMBI UNITS - DOMESTIC PIPING 5.1. Domestic Piping Pressure 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: 5.1.1 Standard Installation •...

  • Page 40: Thermal Expansion

    CHAPTER 5 - EXALT COMBI UNITS - DOMESTIC PIPING Pressure relief valve discharge piping must not be: 5.2. Thermal Expansion • Excessively long. Using more than 2 elbows or If a backflow preventer, check valve or pressure reducing valve is piped on cold water supply piping of water 15 feet of piping can reduce discharge capacity.

  • Page 41: Water Hammer

    CHAPTER 5 - EXALT COMBI UNITS - DOMESTIC PIPING 5.3. Water Hammer • Use dielectric unions or couplings to protect hot and cold water fittings from corrosion when Dishwashers, clothes washers and fast-closing positive connecting dissimilar materials such as copper and shut-off valves incorporated in the system all contribute galvanized iron pipe.

  • Page 42: Fig. 18 - Exalt Combi Domestic Piping - Single Zone System With Single System/Boiler Circulator

    CHAPTER 5 - EXALT COMBI UNITS - DOMESTIC PIPING EXALT COMBI PRESET PUMP CONFIGURATION Heat Call Flame CH Pump DHW Pump Note. EXALT Combi is pre-configured for this installation Line Voltage Terminals Low Voltage Terminals Line Voltage Terminals External Limit External Limit Low Voltage Terminals Terminals...

  • Page 43: Fig. 19 - Multiple Zones - Panel Wiring With Circulators

    TITLE CHAPTER 5 - EXALT COMBI UNITS - DOMESTIC PIPING EXALT COMBI PRESET PUMP CONFIGURATION Heat Call Flame CH Pump DHW Pump Note. EXALT Combi is pre-configured for this installation External Limit Line Voltage Terminals Low Voltage Terminals External Limit Low Voltage Terminals Line Voltage Terminals Terminals...

  • Page 44: Fig. 20 - Exalt Combi System Piping - Multiple Zones - Panel Wiring With Valves

    CHAPTER 5 - EXALT COMBI UNITS - DOMESTIC PIPING EXALT COMBI PRESET PUMP CONFIGURATION Heat Call Flame CH Pump DHW Pump Note. EXALT Combi is pre-configured for this installation External Limit Low Voltage Terminals External Limit Line Voltage Terminals Low Voltage Terminals Line Voltage Terminals Terminals Terminals...

  • Page 45: Fig. 21 - Exalt Solo System Piping - Multi Zone Valves - Single Circulator

    CHAPTER 5 - EXALT SOLO UNITS - DOMESTIC PIPING EXALT SOLO PRESET PUMP CONFIGURATION Heat Call Flame CH Pump DHW Pump Note. EXALT Solo is pre-configured for this installation Low Voltage Terminals External Limit External Limit Line Voltage Terminals Low Voltage Terminals Line Voltage Terminals Terminals Terminals...

  • Page 46: Fig. 22 - Exalt Solo System Piping - Single Zone System - Single Circulator

    CHAPTER 5 - EXALT SOLO UNITS - DOMESTIC PIPING TITLE EXALT SOLO PRESET PUMP CONFIGURATION Heat Call Flame CH Pump DHW Pump Note. EXALT Solo is pre-configured for this installation External Limit Low Voltage Terminals Line Voltage Terminals External Limit Terminals Low Voltage Terminals Line Voltage Terminals...

  • Page 47: Fig. 23 - Exalt Solo - Cascade Piping

    TITLE CHAPTER 5 - EXALT SOLO UNITS - DOMESTIC PIPING NOTICE Cascading is only available on Solo Boilers. System Supply System Return 12" Max. Fig. 23 - EXALT Solo - Cascade Piping...
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  • Page 49: Chapter 6 - Installing Vent/Combustion Air & Condensate Drain

    4. Remove the compression nut and rubber seal from NOTICE the condensate drain assembly drain outlet. Contact Ideal for other venting options. Refer to the 5. Slide the compression nut and rubber seal over the instructions included with these kits for method of 3/4”...

  • Page 50: Fig. 24 - Condensate Drain Assembly

    CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN 8. Route the tube from the condensate drain assem- WARNING bly to a floor drain or condensate pump. The condensate drain assembly must remain filled with water. Extended periods of non use or NOTICE high temperature operation may allow the water to evaporate.

  • Page 51: Chapter 7 - Gas Piping

    CHAPTER 7 - GAS PIPING Gas Flow External Manual Gas Shut Off Valve (Must Be Within 6” of the 186°F 156°F Boiler ) Target = 186°F DHW Demand Tee Fitting Union Fitting Sediment Trap Min. Length of 3" Fig. 25 - Recommended Gas Supply Piping 7.1.

  • Page 52: Natural Gas

    CHAPTER 7 - GAS PIPING 7.2. Natural Gas 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 7.2.1 Pipe Sizing for 13”w.c maximum. Refer to Table 2 below for schedule 40 metallic pipe length and diameter requirements for natural gas, WARNING...

  • Page 53: Propane Gas

    If this conversion the building. kit is missing, please contact Ideal Technical Support for missing kit before installing unit. WARNING • Prior to start up, ensure the unit is set to fire propane.

  • Page 54: Fig. 26 - Gas Valve / Venturi Assembly - Exalt Solo 110

    CHAPTER 7 - GAS PIPING Venturi Venturi interface Pipe to Venturi Air Inlet Gas Valve Air reference Hose Fig. 26 - Gas Valve / Venturi Assembly - EXALT Solo 110 Air reference Hose Pipe to Venturi Gas Valve Air Inlet Venturi interface Venturi...

  • Page 55: Fig. 28 - Gas Valve / Venturi Assembly - Exalt Solo/Combi 199

    CHAPTER 7 - GAS PIPING Air Inlet Venturi interface Venturi Air reference Hose Gas Valve Pipe to Venturi Fig. 28 - Gas Valve / Venturi Assembly - EXALT Solo/Combi 199...
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  • Page 57: Chapter 8 - Wiring

    CHAPTER 8 - WIRING 8.1. Internal Wiring 8.1.2 Fuse Locations WARNING • The CTRLMax control module contains 3 internal replaceable 5A fuses as shown in Fig. 29 below. ELECTRICAL SHOCK HAZARD. For your safety, • The top two fuses protect the EXALT as well as the disconnect electrical power supply to the CH, DHW, and Flame outputs.

  • Page 58: Fig. 30 - Exalt Solo Boiler Factory Wiring

    CHAPTER 8 - WIRING Instinct Solo Wiring Diagram W = White BK = Black R = Red G= Green Spark Generator Blower O = Orange Gas Valve Y = Yellow Electrode BL = Blue G/Y = Green / Yellow GY = Grey V = Violet Flue Return...

  • Page 59: Fig. 31 - Exalt Combi Boiler Factory Wiring

    CHAPTER 8 - WIRING Combi Wiring Diagram W = White BK = Black R = Red G= Green Spark Generator Pump Blower O = Orange Gas Valve Y = Yellow Electrode BL = Blue G/Y = Green / Yellow GY = Grey V = Violet Diverter Valve...

  • Page 60: External Wiring

    CHAPTER 8 - WIRING 8.2. External Wiring NOTICE 8.2.1 General Requirements If local electrical codes require an additional service All field wiring must comply with: switch, the installer must provide and install a fused disconnect or minimum 15 amp service switch. •...

  • Page 61: Low Voltage Connections

    CHAPTER 8 - WIRING 8.3.2 Low Voltage Connections 8.3.4 Outdoor Sensor Wiring Line and Low Voltage wiring should be separated to The Outdoor Reset function and Warm Weather prevent possible electrical noise on the low voltage Shutdown (WWSD) features require the connection of circuits.

  • Page 62: External Modulation Control

    CHAPTER 8 - WIRING 1. Remove the factory-installed brown jumper wire at 8.3.9 Cascade Wiring - Optional the Manual Reset Limit terminals that will accept The CTRLMax control includes the ability to operate up the additional boiler limit. to six Solo boilers together as one without the need for 2.

  • Page 63: Chapter 9 - Ctrlmax Operation

    CHAPTER 9 - CTRLMAX OPERATION 9.1. CTRLMax Navigation The CTRLMax Boiler Management System is designed to be flexible yet easy to use. CTRLMax monitors and The CTRLMax navigation is performed through soft keys controls the EXALT to provide heat as efficiently as that react to the touch and emit a short beep when tapped.

  • Page 64: Ctrlmax Menu Structure

    CHAPTER 9 - CTRLMAX OPERATION The menu system utilizes icons to represent each The Home Screen icon at the bottom of each screen returns to the Home Screen when selected. The selection. The current selected menu is displayed as a Previous Screen icon at the bottom of each screen reversed image with a text description shown at the top...

  • Page 65: Home Screen

    CHAPTER 9 - CTRLMAX OPERATION 9.3. Home Screen Main Icons of CTRLMax display • Central Heating - indicates information related The Home Screen presents status information in a very to central/space heating. user friendly way so that the current state of the boiler can be quickly accessed.

  • Page 66: Status Line Messages

    CHAPTER 9 - CTRLMAX OPERATION 9.4. Status Line Messages DHW Setpoint Reached - The burner is not fired be- cause the supply/system water temperature exceeds the Standby - Indicates that the EXALT is ready to respond setpoint. The domestic circulator(s) continue(s) to oper- when a demand is received.

  • Page 67: Main Menu

    CHAPTER 9 - CTRLMAX OPERATION 9.6. EZ Setup 9.5. Main Menu The EZ Setup menus provide a simple way to quick- The Main Menu can be entered from the Home Screen ly customize CTRLMax for each installation. EZ Setup by touching the soft key.

  • Page 68: Heating Ez Setup

    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 Select CH Demand prompts the installer to select how a CH De- Heating EZ Setup mand is generated.

  • Page 69: Select Ch Demand (Outdoor Sensor Connected)

    CHAPTER 9 - CTRLMAX OPERATION 9.7.2 Select CH Demand (Outdoor sensor connected) Select CH Demand prompts the installer to select how a CH Demand is generated. EZ Setup Thermostat & Outd. Curve – A central heating call from a thermostat or zone panel will Heating EZ Setup enable the EXALT and the setpoint will vary with the outdoor temperature for central heating calls.

  • Page 70: Domestic Hot Water Ez Setup - Exalt Solo Units

    CHAPTER 9 - CTRLMAX OPERATION 9.8. Domestic Hot Water EZ Setup - EXALT Solo Units Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application EZ Setup Select DHW Demand prompts the installer to select how a DHW Demand is generated.

  • Page 71: Domestic Hot Water Ez Setup - Exalt Combi Units

    CHAPTER 9 - CTRLMAX OPERATION 9.9. Domestic Hot Water EZ Setup - EXALT Combi Units Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application DHW EZ Setup prompts the installer to select the DHW setpoint. EZ Setup DHW Setpoint prompts to enter the fixed setpoint temperature during a domestic hot water call.

  • Page 72: Ez Setup Reset

    CHAPTER 9 - CTRLMAX OPERATION 9.11. EZ Setup Reset EZ Setup Reset allows reset of all EZ Setup settings back to the orig- EZ Setup inal factory defaults. See Chapter 13 on page 77 for the list of set- tings reset by this function. Follow the on-screen instructions to reset all EZ Setup settings.

  • Page 73: Dhw Operation

    CHAPTER 9 - CTRLMAX OPERATION 9.13. CH/DHW Operation CH / DHW Operation CH/DHW Operation provides a simple way to enable/disable either the CH or the DHW function of the EXALT. Touch the soft keys to select the CH or DHW icon, then touch to toggle between the enabled/disabled status.

  • Page 74: Information Items

    CHAPTER 9 - CTRLMAX OPERATION 9.14.1 Information Items Information Item Description Displays the current operating state of the EXALT. This is the same as the status Boiler Status line on the home screen. Heating Call Displays if a central heating call is present. DHW Call Displays if a domestic hot water call is present.

  • Page 75: Lockout Screen

    CHAPTER 9 - CTRLMAX OPERATION Lockout History records the last eight lockouts. Six lines are dis- Boiler Information played on the Lockout History screen at one time. Each line contains a lockout description followed by how long ago the lockout occurred. Lockout History Touch the soft keys to scroll through the items then touch...

  • Page 76: Manual Reset Lockouts

    CHAPTER 9 - CTRLMAX OPERATION 9.14.3 Manual Reset Lockouts Code Lockout Message Description Failed Ignition The burner failed to light after 5 ignition attempts. False Flame Flame detected prior to ignition. High Boiler Temperature Boiler temperature has reached 210°F [99ºC] or 102°F [39°C]. Blower Speed Blower is not at correct speed or speed signal is not being received by control module.

  • Page 77: Automatic Reset Blocking Lockouts

    CHAPTER 9 - CTRLMAX OPERATION 9.14.4 Automatic Reset Blocking Lockouts Code Lockout Message Description High Flue Temperature Flue temperature exceeds high limit. Internal Control Fault EEPROM misconfiguration. Internal Control Fault CRC check error. DHW Sensor Shorted A short circuit has been detected in the DHW temperature sensor circuit. DHW Sensor Open An open circuit has been detected in the DHW temperature sensor circuit.
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  • Page 79: Chapter 10 - Start-Up Preparation

    CHAPTER 10 - START-UP PREPARATION 10.1. Boiler System Fluid Requirements 10.1.3 Chlorinated Water Do not use the EXALT to heat a swimming pool or spa directly. NOTICE Requirements below must be met for warranty Maintain the chlorine level of the water at levels consid- coverage of EXALT heat exchangers.

  • Page 80: Check And Test Antifreeze

    The water volume of the EXALT is approximately: fits this description, or if state laws 2 gallons [8 L] for EXALT Solo 110 or local codes require certain water 3 gallons [12 L] for EXALT Solo/Combi 155 temperatures at hot water faucets, take special precautions.

  • Page 81: Filling The Boiler System

    CHAPTER 10 - START-UP PREPARATION 10.2. Filling the Boiler System If any adjustment needs to be made to the valve’s temperature setpoint refer to the manufacturer’s 1. Close the boiler drain valve located on the bottom instructions included with the valve. of the unit and any manual or automatic air vents in the system.

  • Page 82: Check For Gas Leaks

    CHAPTER 10 - START-UP PREPARATION 10.5. Check For Gas Leaks NOTICE WARNING In systems using 3-wire zone valves, voltage backfeed to the unit is a common problem. Use • Prior to start-up and during initial an isolation relay to prevent voltage from the operation, check for a gas leak using external circuit from entering the EXALT.

  • Page 83: Chapter 11 - Start-Up Procedures

    101.. If none of these conditions correct the problem, contact Ø Verify Start-up Preparation items outlined in Ideal Technical Support. Chapter 10 on page 67 have been completed. Ø Verify all electrical connections are correct and 11.3. Check the EXALT and System securely fastened.
  • Page 84 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 C.

  • Page 85: Verify Flame Pattern And Combustion

    Enter the installer access code “054” by using not within the range given in Table 6 on page soft keys to select a digit location 74, shut the boiler down and contact Ideal and the soft keys to change the digit.

  • Page 86: Measure Input - Natural Gas Only

    CHAPTER 11 - START-UP PROCEDURES 11.3.5 Measure Input - Natural Gas Only 4. Touch the soft key to highlight the Boiler Set- 1. Ensure the boiler is firing at maximum firing rate. To tings icon then touch the soft key. manually place the boiler into high fire, reference 5.

  • Page 87: Chapter 12 - Outdoor Reset Control

    CHAPTER 12 - OUTDOOR RESET CONTROL 12.2. Wiring the Sensor The use of the outdoor reset function is required to op- timize boiler efficiency, see notice below. If the outdoor 1. Connect 18 AWG 2-wire cable or similar to the out- sensor is not installed before turning on the EXALT, an door sensor.
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  • Page 89: Chapter 13 - External Modulating Control

    CHAPTER 13 - EXTERNAL MODULATING CONTROL 13.2. CTRLMax Programming EXALT directly accept analog 0-10 VDC signal from an external modulating boiler The CTRLMax control module must be programmed controller to control the firing rate. to accept the 0-10 VDC signal from the external modulating boiler control.
  • Page 90 CHAPTER 13 - EXTERNAL MODULATING CONTROL CTRLMax Factory Settings (cont’d) FACTORY MINIMUM MAXIMUM DEFAULT HEATING SETTING EZ SETUP RESET INSTALLER RESET SETTING SETTING EXALT Solo EXALT Combi DHW Operation Enabled Enabled ✓ Demand Type Thermostat Thermostat DHW Boiler Setpoint 168°F [75°C] 168°F [75°C] 96°F [35°C] 188°F [87°C]...

  • Page 91: Chapter 14 - Check-Out Procedures

    CHAPTER 14 - CHECK-OUT PROCEDURES q Measured the rate of input on Natural Gas as outlined in Section 11.3.5 on page 74. NOTICE q Test high temperature limit as outlined in Section Perform the following check-out procedures 11.3.6 on page 74. outlined check items...
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  • Page 93: Chapter 15 - Installation Record

    CHAPTER 15 - INSTALLATION RECORD Ensure all manuals and other documents are returned to the Installation envelope and given to the owner for safekeeping. EXALT Model Number: Serial Number: Date of Installation: Fuel: Natural Gas Propane Measured Rate of Input: 3600 Btu/hr = x 1000...
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  • Page 95: Chapter 16 - Maintenance Schedules

    CHAPTER 16 - MAINTENANCE SCHEDULES 16.1. Service Technician 16.2. Owner Maintenance At least on an annual basis the following maintenance Periodically: should be performed by a qualified service technician: • Check the area around the unit. General • Check and remove any blockage from the combustion air inlet and ventilation openings.

  • Page 96: Chapter 17 - Maintenance Procedures

    CHAPTER 17 - MAINTENANCE PROCEDURES 17.1. Service Technician Maintenance Procedures • Re-install venturi inlet elbow and front jacket panel when completed. WARNING WARNING The EXALT must be inspected and serviced annually, Do not use solvents to clean any of the burner preferably at the start of the heating season, by a components.

  • Page 97: Check Ventilation Air Openings

    CHAPTER 17 - MAINTENANCE PROCEDURES 17.7. Check Ventilation Air Openings into the system. This device prevents air from bubbling up through the water as it returns from • Verify that all ventilation openings to the mechan- the system. ical room or building are open and unobstructed. •...

  • Page 98: Check Ignition Cable And Ground Wiring

    CHAPTER 17 - MAINTENANCE PROCEDURES 17.13. Check Ignition Cable and Ground Wiring * These two screws are for transportation purposes only and can be discarded. • Inspect the ignition cable from the spark generator • Carefully remove the burner plate assembly from to the ignitor.

  • Page 99: Check Combustion Levels

    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 11.3.4 on page 73 for measuring • Reconnect the gas piping and wire harness to the combustion levels and burner adjustments.

  • Page 100: Chapter 18 - Replacement Parts

    CHAPTER 18 - REPLACEMENT PARTS WARNING • Replacement parts must be purchased through a local Ideal distributor. When ordering a part, please provide the model number and description and/or part number of replacement part. • Use only genuine Ideal replacement parts to ensure warranty coverage and to avoid improper operation or damage to appliance.

  • Page 101: Fig. 37 - Exalt Combi Jacket Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 37 - EXALT Combi Jacket Components Item Part # Description EXJKT04 Front Jacket Panel EXRKIT92 Control Box Mounting Bracket EXJKT05 Left Side Jacket Panel EXRKIT90 Wall Mounting Bracket with Hardware EXJKT06 Right Side Jacket Panel EXRKIT91 User Interface Mounting Bracket...

  • Page 102: Fig. 38 - Exalt Solo 110 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 38 - EXALT Solo 110 Internal Components Item Part # Description EXRKIT40 Vent Outlet/Combustion Air Inlet Adapter EXRKIT01 Heat Exchanger Body (110) EXRKIT03 Heat Exchanger Body (199) EXRKIT56 CH Supply Temperature Sensor EXRKIT59 Low Water Cut Off...

  • Page 103: Fig. 39 - Exalt Solo 155 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 39 - EXALT Solo 155 Internal Components Item Part # Description EXRKIT40 Vent Outlet/Combustion Air Inlet Adapter EXRKIT02 Heat Exchanger Body EXRKIT56 CH Supply Temperature Sensor EXRKIT59 Low Water Cut Off EXRKIT56 CH Return Temperature Sensor EXRKIT85 Condensate Drain Assembly EXRKIT41...

  • Page 104: Fig. 40 - Exalt Combi 155 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 40 - EXALT Combi 155 Internal Components Item Part # Description EXRKIT40 Vent Outlet/Combustion Air Inlet Adapter EXRKIT02 Heat Exchanger Body EXRKIT56 CH Supply Temperature Sensor EXRKIT59 Low Water Cut Off EXRKIT56 CH Return Temperature Sensor EXRKIT85 Condensate Drain Assembly EXRKIT41...

  • Page 105: Fig. 41 - Exalt Solo 199 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 41 - EXALT Solo 199 Internal Components Item Part # Description EXRKIT40 Vent Outlet/Combustion Air Inlet Adapter EXRKIT03 Heat Exchanger Body EXRKIT56 CH Supply Temperature Sensor EXRKIT59 Low Water Cut Off EXRKIT56 CH Return Temperature Sensor EXRKIT85 Condensate Drain Assembly EXRKIT41...

  • Page 106: Fig. 42 - Exalt Combi 199 Internal Components

    CHAPTER 18 - REPLACEMENT PARTS TITLE Fig. 42 - EXALT Combi 199 Internal Components Item Part # Description EXRKIT40 Vent Outlet/Combustion Air Inlet Adapter EXRKIT03 Heat Exchanger Body EXRKIT56 CH Supply Temperature Sensor EXRKIT59 Low Water Cut Off EXRKIT56 CH Return Temperature Sensor EXRKIT85 Condensate Drain Assembly EXRKIT41...

  • Page 107: Fig. 43 - Exalt Solo 110 Burner Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 43 - EXALT Solo 110 Burner Components It is essential to ensure during installation, main- tenance or repair that items 12, 11 and 10 are correctly fitted between the blower and inlet adaptor. Failure to ensure correct fitting may result in serious injury, or death.

  • Page 108: Fig. 44 - Exalt Solo/Combi 155 Burner Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 44 - EXALT Solo/Combi 155 Burner Components It is essential to ensure during installation, main- tenance or repair that items 12, 11 and 10 are correctly fitted between the blower and inlet adaptor. Failure to ensure correct fitting may result in serious injury, or death.

  • Page 109: Fig. 45 - Exalt Combi 199 Burner Components

    CHAPTER 18 - REPLACEMENT PARTS Fig. 45 - EXALT Combi 199 Burner Components It is essential to ensure during installation, main- tenance or repair that items 12, 11 and 10 are correctly fitted between the blower and inlet adaptor. Failure to ensure correct fitting may result in serious injury, or death.

  • Page 110: Fig. 46 - Exalt Control & Display Enclosures

    CHAPTER 18 - REPLACEMENT PARTS Fig. 46 - EXALT Control & Display Enclosures Item Part # Description EXRKIT52 Control Module EXRKIT86 Control Box Hinges EXRKIT53 Display Module EXRKIT55 Control Enclosure...

  • Page 111: Fig. 47 - Exalt Combi Hydro-Block

    CHAPTER 18 - REPLACEMENT PARTS Fig. 47 - EXALT Combi Hydro-block Item Part # Description EXRKIT60 Hydroblock EXRKIT61 Valve Motor EXRKIT62 3 Way Valve EXRKIT58 Flow Sensor EXRKIT69 Combi supply fittings (CH & DHW) EXRKIT71 Combi DWH inlet fitting EXRKIT72 Combi CH return EXRKIT56 Domestic Water Temperature Sensor...
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  • Page 113: Chapter 19 - Product Specifications

    The AHRI rating is based on a piping and pick up allowance of 1.15. This allowance should be sufficient for standard radiation requirements. • Based on the given AFUE the EXALT Solo 110/155/199 and EXALT Combi 155/199 meet the energy efficiency guidelines established by Energy Star. •...

  • Page 114: Fig. 48 - Front View Exalt Solo 110

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 48 - Front View EXALT Solo 110 Vent\Com- 3" Com- NSPC 1" NPT 1" NPT 3/4" Boiler 3" Vent bustion Air Boiler Conden- Conden- 3/4" Item bustion Air Relief Boiler Boiler Width Outlet Connection...

  • Page 115: Fig. 49 - Right Side View Exalt Solo 110

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 49 - Right Side View EXALT Solo 110 3" Combustion NPSC Relief 1" NPT Boiler Condensate 1" NPT Boiler 3/4" 3/4" Items Air Inlet & 3" Vent Boiler Depth Valve Return Drain Supply Connection...

  • Page 116: Fig. 50 - Front View Exalt Solo 155

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 50 - Front View EXALT Solo 155 Vent\Com- 3" Com- NSPC 1" NPT 1" NPT 3/4" Boiler 3" Vent bustion Air Boiler Conden- Conden- 3/4" Item bustion Air Relief Boiler Boiler Width Outlet Connection Height Connection sate Drain...

  • Page 117: Fig. 51 - Right Side View Exalt Solo 155

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 51 - Right Side View EXALT Solo 155 3"Combustion NPSC 1" NPT Boiler Condensate 1" NPT Boiler 3/4" 3/4" Items Air Inlet & 3"Vent Boiler Depth Relief Valve Return Drain Supply Gas Connection Outlet Dimension 8 5/8 3 1/8...

  • Page 118: Fig. 52 - Front View Exalt Solo 199

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 52 - Front View EXALT Solo 199 Vent/Combus- 3” Combus- 3” Vent 3/4" NPSC Boiler 1" NPT Boiler 1" NPT Boiler 3/4" NPT Gas Condensate Conden- Connection Boiler Width tion Air Adapter tion Air Inlet Outlet Relief Valve Height...

  • Page 119: Fig. 53 - Right Side View Exalt Solo 199

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 53 - Right Side View EXALT Solo 199 3" Combustion NPSC 1" NPT Boiler Condensate 1" NPT Boiler 3/4" 3/4" Items Air Inlet & 3"Vent Boiler Depth Relief Valve Return Drain Supply Gas Connection Outlet Dimension 8 5/8...

  • Page 120: Fig. 54 - Front View Exalt Combi 155

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 54 - Front View EXALT Combi 155 Vent/Combus- 3” Com- 3/4" NPT 3/4" NPT 3/4" NPT Boiler 3” Vent 3/4” NPSC Boiler 1" NPT Boil- 1" NPT Boil- Conden- Connection bustion Air tion Air Adapt- Gas Con- Width Outlet...

  • Page 121: Fig. 55 - Right Side View Exalt Combi 155

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 55 - Right Side View EXALT Combi 155 O,Q,T,U 3" Combustion 3/4" NPT NPSC 1" NPT Boiler Condensate 1" NPT Boiler NPT Gas Boiler 3/4" 3/4" 3/4" NPT DHW Items Air Inlet & 3" Outlet Relief Valve Return...

  • Page 122: Fig. 56 - Front View Exalt Combi 199

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 56 - Front View EXALT Combi 199 Vent/Combus- 3” Com- 3/4" NPT 3/4" NPT 3/4" NPT Boiler 3” Vent 3/4” NPSC Boiler 1" NPT Boil- 1" NPT Boil- Conden- Connection bustion Air tion Air Adapt- Gas Con- Width Outlet...

  • Page 123: Fig. 57 - Right Side View Exalt Combi 199

    CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 57 - Right Side View EXALT Combi 199 O, Q, T, U 3" Combustion 3/4" NPT NPSC 1" NPT Boiler Condensate 1" NPT Boiler NPT Gas Boiler 3/4" 3/4" 3/4" NPT DHW Items Air Inlet & 3" Outlet Relief Valve Return...

  • Page 124: Graph 1 - Exalt Solo - Pressure Loss Through Boiler

    CHAPTER 19 - PRODUCT SPECIFICATIONS EXALT Solo Pressure Drop Exalt Solo Pump Curve 25.0 Exalt 110S Exalt 155S 20.0 Exalt 199S 15.0 10.0 Flow Rate (GPM) Graph 1 - EXALT Solo - Pressure Loss Through Boiler Note: Minimum allowable flow rate at full input: - 5 gpm SOLO 110 - 7 gpm SOLO 155 - 9 gpm SOLO 199...
  • Page 128 Ideal - 1240 Forest Parkway, Suite 100, West Deptford NJ 08066 Tel: (800) 411 9999 - Fax: (856) 228 3584 - E-mail: info@idealusa.com...

This manual is also suitable for:

Exalt solo 155Exalt solo 199Exalt combi 155Exalt combi 199

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