IDEAL EXALT FSB User manual

1
EXALT FSB (Floor Standing Boiler)
HMI (Human Machine Interface) Removal
WARNING
!
Indicates a potentially hazardous situation
which, if ignored, can result in serious injury or
substantial 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 o 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 qualied installer/
service technician only.
• Read all instructions before proceeding.
• Follow instructions in proper order.
UIN 233226 A01
2021-52 Exalt FSB HMI Replacement
Revision Date: 02/2022
Kit Part Number Description Model
EXRKIT128 HMI Replacement EXALT Floor Standing
Models
Each Kit Includes:
• Display Module with cover
Recommended Tools:
• Pozidriv Screwdriver
• Flat Head Screwdriver

2
EXALT FSB (Floor Standing Boiler)
HMI (Human Machine Interface) Removal
1. Preliminary Instructions
1. Verify that the replacement kit is correct for the
model of boiler.
2. Carefully open and unpack the PARTS BOX from its
shipping carton.
3. Carefully remove and check for any damage.
NOTICE
Installing damaged equipment will cause malfunction of the
boiler. Contact Ideal USA right away if the display module is
damaged in any way.
4. Close the manual gas shut o valve to the unit.
5. Turn the power to the boiler o.
2. Save Settings
NOTICE
Prior to replacing the control module and/or display module, it
is important to access and document the boiler’s settings. This
will ensure any settings revised from factory defaults are trans-
ferred to the new module(s). Use Table 1 to record the existing
settings. Do not revise any settings when recording settings.
1. To access the Installer screen, touching simultane-
ously the up and down soft keys for 3 seconds as
shown in Fig. 1.
Fig. 1: Installer Button
2. Enter the installer access code “054” by using the
LEFT and RIGHT buttons to select a digit and the
UP and DOWN buttons to change the digit. Press
the OK button to enter the access code.
ENTER INSTALLER
ACCESS CODE
[0]XX
Fig. 2: Installer Access Code
3. Press the OK button while the CH & DHW Settings
icon is highlighted.
CH & DHW Settings
Fig. 3: CH & DHW Settings
4. Press the OK button while the CH Settings icon is
highlighted.
CH Settings
Fig. 4: CH Settings
5. Press the UP and DOWN buttons to scroll through
the various settings.
Heating Settings
Heating Operation
Demand
Absolute Max CH Setpoint
CH1 Maximum Setpoint
CH1 Minimum Setpoint
Reset Curve Coldest Day
Enabled
Switch & Setpoint
188ºF
180ºF
120ºF
0ºF
Fig. 5: Heating Settings

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EXALT FSB (Floor Standing Boiler)
HMI (Human Machine Interface) Removal
6. Record all CH Settings in Table 1. Once completed,
press the RIGHT button to highlight the Previous
Screen icon, then press the OK button.
7. Press the RIGHT button to highlight the DHW
Settings icon then press the OK button.
DHW Settings
Fig. 6: DHW Settings
8. Press the UP and DOWN buttons to scroll through
the various settings and record all DHW Settings in
Table 1. Once completed, press the RIGHT button
to highlight the Previous Screen icon, then press
the OK button.
DHW Settings
DHW Operation
Demand
Boiler DHW Setpoint
DHW Storage Setpoint
DHW On Dierential
DHW Storage Adder
Enabled
Switch
186ºF
140ºF
6ºF
46ºF
Fig. 7: DHW Settings
9. Press the DOWN button to highlight the Boiler
Settings icon if present icon, then press the OK
button.
10. Press the UP and DOWN buttons to scroll through
the various settings and record all Boiler Settings in
Table 1. Once completed, press the RIGHT button
to highlight the Previous Screen icon, then press
the OK button.
NOTICE
Perform the following steps if the EXALT is part of a Cascade
System.
11. Press the RIGHT then DOWN buttons to highlight
the Previous Screen icon, then press the OK button.
12. Press the RIGHT then DOWN buttons to highlight
the Cascade icon, then press the OK button.
13. Press the RIGHT button to highlight the Cascade
Settings icon, then press the OK button.
14. Press the UP and DOWN buttons to scroll through
the various settings, and record all Cascade Settings
in Table 1.

4
EXALT FSB (Floor Standing Boiler)
HMI (Human Machine Interface) Removal
3. Locate and undo the 2 M6 access screws.
1. Locate and undo the 2 M6 access screws
Fig. 8: Access Screws
2. Raise the HMI Pod.
3. Disconnect the high and low voltage connectors.
Fig. 9: High and Low Voltage Connectors
4. Rotate the HMI Pod down.
5. Remove the 4 M5 Pozidriv screws from the hinges.
Fig. 10: Hinges
6. Remove the HMI.
Fig. 11: HMI Removal
2
3
3

5
EXALT FSB (Floor Standing Boiler)
HMI (Human Machine Interface) Removal
WARNING
!
Be careful when using the at blade screwdriver. Do not
cause damage to the surface of the Wi-Fi Module 21.
4. Remove the Wi-Fi Module 21
1. Locate the Wi-Fi Module 21. Using a at head
screwdriver, carefully ease-out the Wi-Fi Module 21
from either the top or bottom of the module.
Reset
Power
Reset
Fig. 12: Wi-Fi Module 21 Removal
2. Remove the Wi-Fi Module 21 and remove the 8
way harness from the aperture. Keep the harness
plugged into the Wi-Fi Module 21.
Reset
Power
Fig. 13: 8-way harness
5. Fitting Wi-Fi Module on replacement HMI.
1. Connect to wire harness to the new HMI as shown
in Figure 13.
2. Push the Wi-Fi Module in place, paying attention to
the orientation. See Figure 12.
6. Fitting replacement HMI.
1. Replace HMI. See Figure 11.
2. Replace the M5 pozidriv screw through the hinge.
See Figure 10.
3. Connect the high and low voltage connectors. See
Figure 9.
4. Locate and fasten the 2 M6 access screws. See
Figure 8.
5. Return power to the boiler.

6
EXALT FSB (Floor Standing Boiler)
HMI (Human Machine Interface) Removal
7. Programming new Display Board
1. Follow the instructions in step 2 to gain access to
the installer menu.
2. Go to boiler settings and click appliance setting, as
seen in Fig. 14 and Fig. 15.
CH & DHW Settings
Boiler Settings
Fig. 14: Installer Menu
Boiler Settings
Modbus Address
Pump settings
Ignition Level
Mix zone high limit
WP di trigger
Appliance setting
0=BCST
3500rpm
114ºF
0pcsi
Fig. 15: Appliance Setting
3. The required code is written on the data plate
located at the side of the boiler. Use the code for
the gas type, either Natural Gas or Propane.
4. Increase/decrease the value (from 0 to 9, then A
to Z) using the UP or DOWN keys to, then change
position with the LEFT or RIGHT keys.
5. Follow the instructions on the screen to enter the
appliance code for your boiler.
6. The boiler will now be factory set for that particular
model. Return to step 2 and enter settings recorded
in Table 1 back into the controls to return the boiler
to the customized settings of the old control.
7. Return to step 2 and enter settings recorded in
Table 1 back into the controls.

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EXALT FSB (Floor Standing Boiler)
HMI (Human Machine Interface) Removal
Table 1: Controls Settings
HEATINGSETTING FACTORYDEFAULT MINIMUMSETTING MAXIMUMSETTING EXISTINGSETTING
Heating Operation Enabled
Demand Type Thermostat & Outd.
Curve
Absolute Max CH Setpoint 185°F [85°C] 68°F [20°C] 188°F [87°C]
CH1 Maximum Setpoint 180°F [82°C] 68°F [20°C] 188°F [87°C]
CH1 Minimum Setpoint 80°F [27°C] 60°F [15°C] 188°F [87°C]
Outdoor Curve Coldest Day 10°F [-12°C] -30°F [-34°C] 50°F [10°C]
Outdoor Curve Warmest Day 64°F [18°C] 60°F [15°C] 78°F [25°C]
CH2 Circuit Enabled
CH2 Maximum Setpoint 140°F [60°C] 68°F [20°C] 194°F [90°C]
CH2 Minimum Setpoint 80°F [27°C] 60°F [15°C] 190°F [88°C]
Warm Weather Shutdown O O 78°F [25°C]
Circulation Pump
Permanent
Disabled
CH Post Pump Time 5 Minutes O 20 Minutes
Freeze Protection Enabled
Frost Protection Setpoint -22°F [-30°C] -22°F [-30°C] 50°F [10°C]
Parallel Shift Value 0°F [0°C] 0°F [0°C] 144°F [80°C]
CH Call Blocking 2 Minutes 0 Minutes 30 Minutes
DOMESTICSETTING SOLO
FACTORY
DEFAULT
COMBI
FACTORY
DEFAULT
MINIMUM
SETTING
MAXIMUM
SETTING
EXISTING
SETTING
DHW Operation Enabled Enabled
Demand Type Thermostat N/A
DHW Boiler Setpoint 168°F [76°C] 168°F [76°C] 96°F [35°C] 188°F [87°C]
DHW Setpoint 140°F [60°C] 140°F [60°C] 68°F [20°C] 168F [75°C]
DHW Warmstart Setpoint N/A 125°F [52°C] 86°F [30°C] 140°F [60°C]
DHW Warmstart Hysteresis N/A 30°F [17K] 9K 36K
DHW On Dierential 6°F [3°C] N/A 4°F [2°C] 18°F [10°C]
DHW Storage Adder 27°F [15°C] 18°F [10°C] 10°F [5°C] 54°F [30°C]
DHW Post Pump Time 2 Minutes 2 Minutes O 30 Minutes
DHW Priority Timeout O O O 120 Minutes
DHW Priority Enabled Enabled
DHW Call Blocking 1 Minute 1 Minute 0 Minute 30 Minutes
DHW to CH Call Blocking 1 Minute 1 Minute 0 Minute 30 Minutes
Antilegionella Function Disabled Enabled

8
EXALT FSB (Floor Standing Boiler)
HMI (Human Machine Interface) Removal
Table 1 Cont:
BOILERSETTING FACTORYDEFAULT MINIMUMSETTING MAXIMUMSETTING EXISTINGSETTING
Lockout Temp. 210°F [99°C]
Modbus Address 0=BCST 0=BCST 247
Flex. Relay 1(CH) CH1
Flex. Relay 2(DHW) DHW
Flex. Relay 3(P3) CH1/CH2/DHW
Flex. Relay 4(ERR) ERROR
Flex. Relay 5(Flame) FLAME
Flex. Relay 6(P4) CH2
Error Relay On Lockout, Blocking
andWarning
Pump PWM Minimum 30% 1% 100%
Ignition Level Varies by model
Mix Zone High Limit 114°F [45°C] 68°F [20°C] 176°F [80°C]
Appliance Setting Varies by model
Altitude Setting 0 ft 0 ft 20,000 ft