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CHAPTER 4

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

CH1 ON ON OFF

CH2 ON ON OFF

DHW OFF ON ON

Note. EXALT Combi is pre-congured for this installation

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

Line Voltage Terminals

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

FLAME

POWER SUPPLY

CH PUMP

DHW PUMP

Outdoor Sensor

Low Voltage Terminals

Line Voltage Terminals

External Limit

Terminals

Manual Auto

DHW Sensor

internal to boiler

Default Chapter3
- Table of Contents3
- Product and Safety Information11
Chapter 1 - Pre-Installation Requirements13
- EXALT 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
- Accessories25
- Fig. 5 - Accessories25
- 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 - EXALT Pressure Relief Valve, Drain Valve, T&P Gauge Installation27
- Boiler Air Vent28
- Low Water Cutoff Device28
- Fig. 7 - Piping Component Legend28
- Additional Limit Control29
- Backflow Preventer29
- EXALT solo Boiler System Piping29
- Fig. 8 - EXALT solo Near Boiler Piping - Hydraulic Separator29
- Fig. 9 - Near Boiler Piping - Closely Spaced Tees30
- Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump32
  - System Piping - Special Application33
  - System Piping - Multiple Units Installation33
- EXALT Combi Boiler System Piping33
- Fig. 11 - EXALT Combi Near Boiler Piping - Hydraulic Separator33
- Fig. 12 - EXALT Combi Near Boiler Piping -Timesaver Manifold34
- Optional System Piping and Cascading35
- Fig. 13 - EXALT Combi System Piping - Zoning W Valves36
- Fig. 14 - EXALT Combi - System Piping - Multi Zone Valve - Single Circulator37
- Fig. 15 - EXALT Combi - System Piping - Single Zone with Single Circulator38
Chapter 5 - Exalt Combi Units - Domestic Piping39
- Domestic Piping Pressure Relief Valve39
- Fig. 16 - Standard Installation of the Domestic Pressure Relief Valve39
- Thermal Expansion40
- Fig. 17 - EXALT Combi - Hydro-Block Flow Diagram40
- Water Hammer41
- Vacuum Breaker41
- Hydro-Block41
- General Piping41
- Thermostatic Mixing Valve41
- Fig. 18 - EXALT Combi Domestic Piping - Single Zone System with Single System/Boiler Circulator42
- Fig. 19 - Multiple Zones - Panel Wiring with Circulators43
- Fig. 20 - EXALT Combi System Piping - Multiple Zones - Panel Wiring with Valves44
- Fig. 21 - EXALT solo System Piping - Multi Zone Valves - Single Circulator45
- Fig. 22 - EXALT solo System Piping - Single Zone System - Single Circulator46
- Fig. 23 - EXALT solo - Cascade Piping47
Chapter 6 - Installing Vent/Combustion Air & Condensate Drain49
- Installing Vent and Combustion Air49
- Installing Condensate Drain Assembly into EXALT solo Units49
- Fig. 24 - Condensate Drain Assembly50
Chapter 7 - Gas Piping51
- Gas Supply Piping Connection51
- Fig. 25 - Recommended Gas Supply Piping51
- Natural Gas52
  - Pipe Sizing52
  - Supply Pressure Requirements52
- Propane Gas53
  - Pipe Sizing53
  - Supply Pressure Requirements53
- Fig. 26 - Gas Valve / Venturi Assembly - EXALT solo 11054
- Fig. 27 - Gas Valve / Venturi Assembly - EXALT Solo/Combi 15554
- Fig. 28 - Gas Valve / Venturi Assembly - EXALT Solo/Combi 19955
Chapter 8 - Wiring57
- Internal Wiring57
  - General Requirements57
  - Fuse Locations57
- Fig. 29 - Ctrlmax Control Module Fuse Location57
- Fig. 30 - EXALT solo Boiler Factory Wiring58
- Fig. 31 - EXALT Combi Boiler Factory Wiring59
- External Wiring60
  - General Requirements60
  - Line Voltage Connections60
- External Wiring - EXALT 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 Setup - EXALT solo Units70
- Domestic Hot Water EZ Setup - EXALT Combi Units71
- Altitude Setup71
- EZ Setup Reset72
- Display EZ Setup72
- DHW Operation73
- Boiler Information73
Chapter 10 - Start-Up Preparation79
- Boiler System Fluid Requirements79
- Filling the Boiler System81
- EXALT 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
- EXALT Start-Up83
- Check the EXALT and System83
- Fig. 35 - Throttle Screw Location85
  - Measure Input - Natural Gas Only86
  - Test High Temperature Limit86
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 Procedures96
- Service Technician Maintenance Procedures96
- Reported Problems96
- Check Surrounding Area96
- Inspect Burner Area96
- Check System Piping96
- Clean Condensate Drain Assembly96
- Check Ventilation Air Openings97
- Inspect Vent and Combustion Air Piping97
- Check Boiler System97
- Check Expansion Tank97
- Check Boiler Relief Valve97
- Inspection of Ignitor97
- Check Ignition Cable and Ground Wiring98
- Check Control Wiring98
- Check Control Settings98
- Perform Start-Up and Checkout Procedures98
- Check Burner Flame98
- Check Flame Signal98
- Check Combustion Levels99
- Check Flue Gas Temperature99
- Clean Heat Exchanger99
- Check Carbon Monoxide Detectors99
- Review with Owner99
- Torque Specifications Table99
Chapter 18 - Replacement Parts100
- Fig. 36 - EXALT solo Jacket Components100
- Fig. 37 - EXALT Combi Jacket Components101
- Fig. 38 - EXALT solo 110 Internal Components102
- Fig. 39 - EXALT solo 155 Internal Components103
- Fig. 40 - EXALT Combi 155 Internal Components104
- Fig. 41 - EXALT solo 199 Internal Components105
- Fig. 42 - EXALT Combi 199 Internal Components106
- Fig. 43 - EXALT solo 110 Burner Components107
- Fig. 44 - EXALT Solo/Combi 155 Burner Components108
- Fig. 45 - EXALT Combi 199 Burner Components109
- Fig. 46 - EXALT Control & Display Enclosures110
- Fig. 47 - EXALT Combi Hydro-Block111
Chapter 19 - Product Specifications113
- Fig. 48 - Front View EXALT solo 110114
- Fig. 49 - Right Side View EXALT solo 110115
- Fig. 50 - Front View EXALT solo 155116
- Fig. 51 - Right Side View EXALT solo 155117
- Fig. 52 - Front View EXALT solo 199118
- Fig. 53 - Right Side View EXALT solo 199119
- Fig. 54 - Front View EXALT Combi 155120
- Fig. 55 - Right Side View EXALT Combi 155121
- Fig. 56 - Front View EXALT Combi 199122
- Fig. 57 - Right Side View EXALT Combi 199123
- Graph 1 - EXALT solo - Pressure Loss through Boiler124
- Graph 2 -EXALT Combi - Pressure Loss through Boiler124

Brand	IDEAL
Model	EXALT Combi 199
Category	Boiler
Language	English

IDEAL EXALT Combi 199 Installation & Maintenance Manual

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