IDEAL EXALT Combi 199 Installation & Maintenance Manual

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Ideal - 1240 Forest Parkway, Suite 100, West Deptford NJ 08066

Tel: (800) 411 9999 - Fax: (856) 228 3584 - E-mail: info@idealusa.com

Table of Contents

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

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IDEAL EXALT Combi 199 Specifications

General

Brand	IDEAL
Model	EXALT Combi 199
Category	Boiler
Language	English

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