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EXALT COMBI
IDEAL EXALT COMBI Installation & Maintenance Manual
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Fig
. 47 - EXAL
T Combi Hydro-blo
ck
2
1
3
8
7
6
4
5
99
CHAPTER 1
8
CHAPTER
18
- REPL
A
CEMENT P
AR
TS
Item
Part #
Description
1
EXRKIT60
Hydroblock
2
EXRKIT61
Valv
e Motor
3
EXRKIT62
3 Wa
y Valv
e
4
EXRKIT58
Flow Sensor
5
EXRKIT69
Combi supply fittings (
CH
& DHW)
6
EXRKIT71
Combi
DWH
inlet fitting
7
EXRKIT72
Combi
CH
return
8
EXRKIT56
Domestic Water Temperature Sensor
110
112
Table of Contents
Default Chapter
3
Table of Contents
3
Product and Safety Information
11
Chapter 1 - Pre-Installation Requirements
13
EXALT Boilers - Code Compliance
13
Code Restrictions
13
Operating Restrictions
13
Determining Product Location
14
Boiler Freeze Protection Feature
14
Boiler Replacement
14
Recommended Clearances
15
Residential Garage Installations
15
Chapter 2 - Combustion Air & Venting
17
Combustion Air Contamination
17
Ventilation and Combustion Air Requirements - Direct Vent
18
Ventilation and Combustion Air Requirements - Category IV
18
Methods of Accessing Combustion Air into a Space - Category IV
19
Indoor Combustion Air
19
Outdoor Combustion Air
19
Fig. 1 - All Combustion Air from Adjacent Indoor Spaces through Indoor Combustion Openings
19
Fig. 2 - All Combustion Air from Outdoors through One Permanent Air Opening
19
Combination of Indoor and Outdoor Combustion Air
20
Combustion Air and Vent Piping
20
Fig. 3 - All Combustion Air from Outdoors through Ventilated Attic
20
Fig. 4 - All Combustion Air from Outdoors through Horizontal Ducts
20
Removal of an Existing Boiler from a Common Vent System
21
Carbon Monoxide Detector Installation
22
Commonwealth of Massachusetts Installation Requirements
22
Installation of Carbon Monoxide Detectors
22
Approved Carbon Monoxide Detectors
22
Signage
23
Inspection
23
Manufacturer Requirements - Gas Equipment Venting System Provided
23
Manufacturer Requirements - Gas Equipment Venting System Not Provided
23
Chapter 3 - Unit Preparations
25
Handling Instructions
25
Wall Mounting Installation
25
Accessories
25
Fig. 5 - Accessories
25
Wall Mounting Guidelines
26
Stud Walls - Installation
26
Wall Bracket Installation - Solid Walls
26
Boiler Mounting
26
Chapter 4 - Boiler Piping
27
General Piping Requirements
27
Pressure Relief Valve
27
Fig. 6 - EXALT Pressure Relief Valve, Drain Valve, T&P Gauge Installation
27
Boiler Air Vent
28
Low Water Cutoff Device
28
Fig. 7 - Piping Component Legend
28
Additional Limit Control
29
Backflow Preventer
29
EXALT solo Boiler System Piping
29
Fig. 8 - EXALT solo Near Boiler Piping - Hydraulic Separator
29
Expansion Tank and Makeup Water
30
Diaphragm Expansion Tank
30
Closed-Type Expansion Tank
30
Fig. 9 - Near Boiler Piping - Closely Spaced Tees
30
Circulator
31
Sizing Primary Piping
31
Domestic Hot Water System Piping
31
System Piping - Zone Circulators
31
System Piping - Zone Valves
31
System Piping - through Boiler
31
System Piping - Radiant Heating
31
Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump
32
System Piping - Special Application
33
System Piping - Multiple Units Installation
33
EXALT Combi Boiler System Piping
33
Fig. 11 - EXALT Combi Near Boiler Piping - Hydraulic Separator
33
Expansion Tank and Makeup Water
34
Diaphragm Expansion Tank
34
Circulator
34
Fig. 12 - EXALT Combi Near Boiler Piping -Timesaver Manifold
34
Sizing Primary Piping
35
System Piping - Zone Circulators
35
System Piping - Zone Valves
35
System Piping - through Boiler
35
System Piping - Radiant Heating
35
System Piping - Special Application
35
Optional System Piping and Cascading
35
Fig. 13 - EXALT Combi System Piping - Zoning W Valves
36
Fig. 14 - EXALT Combi - System Piping - Multi Zone Valve - Single Circulator
37
Fig. 15 - EXALT Combi - System Piping - Single Zone with Single Circulator
38
Chapter 5 - Exalt Combi Units - Domestic Piping
39
Domestic Piping Pressure Relief Valve
39
Standard Installation
39
Pressure Relief Valve - Standard Installations
39
Pressure Relief Valve Discharge Piping
39
Fig. 16 - Standard Installation of the Domestic Pressure Relief Valve
39
Thermal Expansion
40
Fig. 17 - EXALT Combi - Hydro-Block Flow Diagram
40
Water Hammer
41
Vacuum Breaker
41
Hydro-Block
41
General Piping
41
Thermostatic Mixing Valve
41
Fig. 18 - EXALT Combi Domestic Piping - Single Zone System with Single System/Boiler Circulator
42
Fig. 19 - Multiple Zones - Panel Wiring with Circulators
43
Fig. 20 - EXALT Combi System Piping - Multiple Zones - Panel Wiring with Valves
44
Fig. 21 - EXALT solo System Piping - Multi Zone Valves - Single Circulator
45
Fig. 22 - EXALT solo System Piping - Single Zone System - Single Circulator
46
Fig. 23 - EXALT solo - Cascade Piping
47
Chapter 6 - Installing Vent/Combustion Air & Condensate Drain
49
Installing Vent and Combustion Air
49
Installing Condensate Drain Assembly into EXALT solo Units
49
Fig. 24 - Condensate Drain Assembly
50
Chapter 7 - Gas Piping
51
Gas Supply Piping Connection
51
Fig. 25 - Recommended Gas Supply Piping
51
Natural Gas
52
Pipe Sizing
52
Supply Pressure Requirements
52
Propane Gas
53
Pipe Sizing
53
Supply Pressure Requirements
53
Fig. 26 - Gas Valve / Venturi Assembly - EXALT solo 110
54
Fig. 27 - Gas Valve / Venturi Assembly - EXALT Solo/Combi 155
54
Fig. 28 - Gas Valve / Venturi Assembly - EXALT Solo/Combi 199
55
Chapter 8 - Wiring
57
Internal Wiring
57
General Requirements
57
Fuse Locations
57
Fig. 29 - Ctrlmax Control Module Fuse Location
57
Fig. 30 - EXALT solo Boiler Factory Wiring
58
Fig. 31 - EXALT Combi Boiler Factory Wiring
59
External Wiring
60
General Requirements
60
Line Voltage Connections
60
External Wiring - EXALT solo Units
60
Circulator Wiring
60
Fig. 32 - Terminal Strip Location
60
Low Voltage Connections
61
Thermostat Wiring
61
Outdoor Sensor Wiring
61
Domestic Hot Water Wiring
61
Additional Boiler Limits
61
Fig. 33 - Low Voltage Connections
61
External Modulation Control
62
System Sensor Wiring
62
Cascade Wiring - Optional
62
Modbus
62
Chapter 9 - Ctrlmax Operation
63
Ctrlmax Navigation
63
Fig. 34 - Ctrlmax User Interface
63
Ctrlmax Menu Structure
64
Home Screen
65
Status Line Messages
66
Main Menu
67
EZ Setup
67
Heating EZ Setup
68
Select CH Demand (no Outdoor Sensor Connected)
68
Select CH Demand (Outdoor Sensor Connected)
69
Domestic Hot Water EZ Setup - EXALT solo Units
70
Domestic Hot Water EZ Setup - EXALT Combi Units
71
Altitude Setup
71
EZ Setup Reset
72
Display EZ Setup
72
DHW Operation
73
Boiler Information
73
Information Items
74
Lockout Screen
75
Manual Reset Lockouts
76
Automatic Reset Blocking Lockouts
77
Chapter 10 - Start-Up Preparation
79
Boiler System Fluid Requirements
79
Boiler Fluid Ph Level 6.0 to 8.0
79
Boiler Fluid Hardness Less than 7 Grains
79
Chlorinated Water
79
Flush Boiler to Remove Sediment
79
Cleaning of Old Boiler/System
79
Cleaning of New Boiler/System
79
Check and Test Antifreeze
80
Use of Antifreeze in the Boiler System
80
Filling the Boiler System
81
EXALT Combi Water Heater - Water Requirements
81
Filling the Domestic Circuit
81
Check Low Water Cut-Off Device
81
Check for Gas Leaks
82
Check Thermostat Circuit
82
Inspect Condensate Drain Assembly
82
Chapter 11 - Start-Up Procedures
83
Final Checks before Start-Up
83
EXALT Start-Up
83
Check the EXALT and System
83
Check Boiler Piping
83
Check Vent and Combustion Air Piping
83
Check Gas Piping
83
Verify Flame Pattern and Combustion
85
Fig. 35 - Throttle Screw Location
85
Measure Input - Natural Gas Only
86
Test High Temperature Limit
86
Chapter 12 - Outdoor Reset Control
87
Mounting the Outdoor Sensor
87
Wiring the Sensor
87
Chapter 13 - External Modulating Control
89
Wiring the Modulating Controller
89
Ctrlmax Programming
89
Programming of External Modulating Control
89
Chapter 14 - Check-Out Procedures
91
Chapter 15 - Installation Record
93
Chapter 16 - Maintenance Schedules
95
Service Technician
95
Owner Maintenance
95
Chapter 17 - Maintenance Procedures
96
Service Technician Maintenance Procedures
96
Reported Problems
96
Check Surrounding Area
96
Inspect Burner Area
96
Check System Piping
96
Clean Condensate Drain Assembly
96
Check Ventilation Air Openings
97
Inspect Vent and Combustion Air Piping
97
Check Boiler System
97
Check Expansion Tank
97
Check Boiler Relief Valve
97
Inspection of Ignitor
97
Check Ignition Cable and Ground Wiring
98
Check Control Wiring
98
Check Control Settings
98
Perform Start-Up and Checkout Procedures
98
Check Burner Flame
98
Check Flame Signal
98
Check Combustion Levels
99
Check Flue Gas Temperature
99
Clean Heat Exchanger
99
Check Carbon Monoxide Detectors
99
Review with Owner
99
Torque Specifications Table
99
Chapter 18 - Replacement Parts
100
Fig. 36 - EXALT solo Jacket Components
100
Fig. 37 - EXALT Combi Jacket Components
101
Fig. 38 - EXALT solo 110 Internal Components
102
Fig. 39 - EXALT solo 155 Internal Components
103
Fig. 40 - EXALT Combi 155 Internal Components
104
Fig. 41 - EXALT solo 199 Internal Components
105
Fig. 42 - EXALT Combi 199 Internal Components
106
Fig. 43 - EXALT solo 110 Burner Components
107
Fig. 44 - EXALT Solo/Combi 155 Burner Components
108
Fig. 45 - EXALT Combi 199 Burner Components
109
Fig. 46 - EXALT Control & Display Enclosures
110
Fig. 47 - EXALT Combi Hydro-Block
111
Chapter 19 - Product Specifications
113
Fig. 48 - Front View EXALT solo 110
114
Fig. 49 - Right Side View EXALT solo 110
115
Fig. 50 - Front View EXALT solo 155
116
Fig. 51 - Right Side View EXALT solo 155
117
Fig. 52 - Front View EXALT solo 199
118
Fig. 53 - Right Side View EXALT solo 199
119
Fig. 54 - Front View EXALT Combi 155
120
Fig. 55 - Right Side View EXALT Combi 155
121
Fig. 56 - Front View EXALT Combi 199
122
Fig. 57 - Right Side View EXALT Combi 199
123
Graph 1 - EXALT solo - Pressure Loss through Boiler
124
Graph 2 -EXALT Combi - Pressure Loss through Boiler
124
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4
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IDEAL EXALT COMBI Specifications
General
Brand
IDEAL
Model
EXALT COMBI
Category
Boiler
Language
English
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