IDEAL EXRKIT58 Use and care manual

Exalt
Flow Sensor 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
EXRKIT58 Flow Sensor Replacement Exalt 155 & 199 Combi
Each Kit Includes:
• Flow Sensor
Recommended Tools:
• Phillips Head Screwdriver
• Flat Head Screwdriver
2019765 Exalt Flow Sensor Replacement
Revised 10/20/2021

Exalt
Flow Sensor Replacement
2
1. Preliminary Instructions
1. Verify that the pressure sensor replacement kit is
correct for the model of boiler. See table on page 1.
2. Carefully open and unpack the PARTS BOX from its
shipping carton.
3. Carefully remove and check for any damage.
NOTICE
Installing a damaged sensor will cause malfunction of
the boiler. Contact IdealUSA right away if the pressure sen-
sor damaged in any way.
4. Turn o the electrical power supply to the boiler.
5. Close the manual gas shut o valve to the unit.
2. Drain the boiler
1. Turn power to the unit “OFF”
2. Close all isolation valves on the system piping to
the boiler. Close the ll valve line to the system.
3. Connect a garden hose to the boiler drain.
4. Direct the hose to a suitable place of drainage. En-
sure boiler drain connection is between the boiler
and the closed isolation valve.
5. Open the drain valve and begin draining the boiler.
WARNING
!
Water from the boiler drain connection may be ex-
tremely hot. To avoid personal injury, death or sub-
stantial property damage:
- Tighten all drain hose connections to avoid leakage.
- Direct hot water away from all persons.
3. Pressure Sensor Removal
1. Remove the screw from the bottom of the front
panel. Remove the front panel of the boiler. Pull
the panel up and forward to remove the front pan-
el from the unit. Do not discard the screws.
Hydroblock
3way Valve
Motor
3way Valve
Flow Sensor
DHW Sensor
Fig. 2: Flow Sensor Installation
2. Disconnect the wire harness from the ow sensor
by pulling back the locking clip and pulling the
harness out.
NOTICE
Take care to ensure the wiring and harness are not damaged.
3. Pull the lock pin below the Sensor out and pull the
pressure sensor out.
NOTICE
Do not pull the ow sensor out by the wire connection. This
can damage the plug.
NOTICE
If the ow sensor is stuck, gently pry the sensor out using a
screwdriver or the lock pin
4. Flow Sensor Installation
1. Ensure the wheel is installed on the new ow sen-
sor and spins freely.
2. Insert the new sensor with the wheel into the con-
nection. Insert the locking pin to secure in place.
3. Reconnect the wiring harness to the sensor.

Exalt
Flow Sensor Replacement
3
4. Give the sensor a light tug up to ensure the locking
clip is engaged properly.
5. Open all isolation valves and the ll system on the
boiler to rell the unit. Check for leaks around the
ow sensor and reseal the device if necessary.
WARNING
!
Water leaks from the boiler may be extremely hot and
may cause personal injury, death or substantial prop-
erty damage:
6. Re-installing the front jacket panel.
7. Reconnect power supply and return the boiler
back to service. Conrm proper operation by creat-
ing a domestic water demand and conrming the
Instinct boiler senses the ow.