IDEAL EXALT Solo 110 Instruction Manual

• To maintain the safety & longevity of
your appliance, read and follow the
maintenance schedule information
throughout this manual.
• If the information in this manual
is not followed exactly, a fire or
explosion may result causing
substantial property damage, serious
injury, or death.
FOR YOUR SAFETY
• Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
• WHAT TO DO IF YOU SMELL GAS
- Do not try to light any appliance
- Do not touch any electrical switch;
do not use any phone in your
building.
- Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
- If you cannot reach your gas supplier,
call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
WARNING
- Customer must register unit within thirty (30)
days of installation in order to gain warranty
coverage. See Warranty Card for details.
- Leave all documentation received with
appliance with the owner for future reference.
NOTICE
INSTALLATION &
MAINTENANCE MANUAL
EXALT Solo 110-155-199 & EXALT Combi 155-199
225296 A02 - August 2020
2019-28

INTENTIONALLY LEFT BLANK

iii
TABLE OF CONTENTS
PRODUCT AND SAFETY INFORMATION.......................................................................... XI
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS ........................................................ 1
1.1. EXALT Boilers - Code Compliance ................................................................................................ 1
1.1.1 Code Restrictions .................................................................................................................. 1
1.1.2 Operating Restrictions.......................................................................................................... 1
1.2. Determining Product Location.......................................................................................................2
1.3. Boiler Freeze Protection Feature ...................................................................................................2
1.4. Boiler Replacement.........................................................................................................................2
1.5. Recommended Clearances............................................................................................................3
1.6. Residential Garage Installations ....................................................................................................3
CHAPTER 2 - COMBUSTION AIR & VENTING ................................................................... 5
2.1. Combustion Air Contamination.....................................................................................................5
2.2. Ventilation and Combustion Air Requirements - Direct Vent......................................................6
2.3. Ventilation and Combustion Air Requirements - Category IV.....................................................6
2.4. Methods of Accessing Combustion Air Into A Space - Category IV ...........................................7
2.4.1. Indoor Combustion Air.......................................................................................................... 7
2.4.2. Outdoor Combustion Air.......................................................................................................7
2.4.3 Combination of Indoor and Outdoor Combustion Air ......................................................8
2.5. Combustion Air and Vent Piping....................................................................................................8
2.6. Removal of an Existing Boiler from a Common Vent System......................................................9
2.7. Carbon Monoxide Detector Installation ......................................................................................10
2.8. Commonwealth of Massachusetts Installation Requirements .................................................10
2.8.1 Installation of Carbon Monoxide Detectors. ......................................................................10
2.8.2 Approved Carbon Monoxide Detectors. ...........................................................................10
2.8.3 Signage .................................................................................................................................11
2.8.4 Inspection. ............................................................................................................................11
2.8.5 Manufacturer Requirements - Gas Equipment Venting System Provided. ....................11
2.8.6 Manufacturer Requirements - Gas Equipment Venting System Not Provided. .............11
CHAPTER 3 - UNIT PREPARATIONS ................................................................................ 13
3.1. Handling Instructions ...................................................................................................................13
3.2. Wall Mounting Installation ............................................................................................................ 13
3.3. Accessories ...................................................................................................................................13
3.4. Wall Mounting Guidelines ............................................................................................................. 14
3.5. Stud Walls - Installation ............................................................................................................... 14
3.6. Wall Bracket Installation - Solid Walls.......................................................................................... 14
3.7. Boiler Mounting............................................................................................................................. 14

iv
TABLE OF CONTENTS
CHAPTER 4 - BOILER PIPING ........................................................................................... 15
4.1. General Piping Requirements ...................................................................................................... 15
4.2. Pressure Relief Valve .................................................................................................................... 15
4.3. Boiler Air Vent................................................................................................................................ 16
4.4. Low Water Cutoff Device .............................................................................................................. 16
4.5. Additional Limit Control................................................................................................................ 17
4.6. Backflow Preventer....................................................................................................................... 17
4.7. EXALT Solo Boiler System Piping................................................................................................ 17
4.7.1 Expansion Tank and Makeup Water................................................................................... 18
4.7.2 Diaphragm Expansion Tank................................................................................................ 18
4.7.3 Closed-Type Expansion Tank .............................................................................................. 18
4.7.4 Circulator.............................................................................................................................. 19
4.7.5 Sizing Primary Piping .......................................................................................................... 19
4.7.6 Domestic Hot Water System Piping................................................................................... 19
4.7.7 System Piping – Zone Circulators...................................................................................... 19
4.7.8 System Piping – Zone Valves ............................................................................................. 19
4.7.9 System Piping – Through Boiler ........................................................................................ 19
4.7.10 System Piping – Radiant Heating ...................................................................................... 19
4.7.11 System Piping – Special Application ................................................................................. 21
4.7.12 System Piping – Multiple Units Installation ...................................................................... 21
4.8. EXALT Combi Boiler System Piping ............................................................................................ 21
4.8.1 Expansion Tank and Makeup Water...................................................................................22
4.8.2 Diaphragm Expansion Tank................................................................................................22
4.8.3 Circulator..............................................................................................................................22
4.8.4 Sizing Primary Piping..........................................................................................................23
4.8.5 System Piping – Zone Circulators......................................................................................23
4.8.6 System Piping – Zone Valves .............................................................................................23
4.8.7 System Piping – Through Boiler ........................................................................................23
4.8.8 System Piping – Radiant Heating ......................................................................................23
4.8.9 System Piping – Special Application .................................................................................23
4.9. Optional System Piping and Cascading ..................................................................................... 23

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TABLE OF CONTENTS
CHAPTER 5 - EXALT COMBI UNITS - DOMESTIC PIPING ............................................. 27
5.1. Domestic Piping Pressure Relief Valve........................................................................................27
5.1.1 Standard Installation...........................................................................................................27
5.1.2 Pressure Relief Valve - Standard Installations ..................................................................27
5.1.3 Pressure Relief Valve Discharge Piping .............................................................................27
5.2. Thermal Expansion ...................................................................................................................... 28
5.3. Water Hammer............................................................................................................................. 29
5.4. Vacuum Breaker........................................................................................................................... 29
5.5. Hydro-Block.................................................................................................................................. 29
5.6. General Piping .............................................................................................................................. 29
5.7. Thermostatic Mixing Valve.......................................................................................................... 29
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN .......... 37
6.1. Installing Vent and Combustion Air .............................................................................................37
6.2. Installing Condensate Drain Assembly into EXALT Solo Units .................................................37
CHAPTER 7 - GAS PIPING .................................................................................................39
7.1. Gas Supply Piping Connection.................................................................................................... 39
7.2. Natural Gas................................................................................................................................... 40
7.2.1 Pipe Sizing........................................................................................................................... 40
7.2.2 Supply Pressure Requirements ........................................................................................ 40
7.3. Propane Gas .................................................................................................................................. 41
7.3.1 Pipe Sizing............................................................................................................................ 41
7.3.2 Supply Pressure Requirements ......................................................................................... 41
CHAPTER 8 - WIRING ........................................................................................................45
8.1. Internal Wiring .............................................................................................................................. 45
8.1.1 General Requirements ....................................................................................................... 45
8.1.2 Fuse Locations.................................................................................................................... 45
8.2. External Wiring............................................................................................................................. 48
8.2.1 General Requirements ....................................................................................................... 48
8.2.2 Line Voltage Connections.................................................................................................. 48

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TABLE OF CONTENTS
8.3. External Wiring - EXALT Solo Units ............................................................................................ 48
8.3.1 Circulator Wiring................................................................................................................. 48
8.3.2 Low Voltage Connections .................................................................................................. 49
8.3.3 Thermostat Wiring ............................................................................................................. 49
8.3.4 Outdoor Sensor Wiring ...................................................................................................... 49
8.3.5 Domestic Hot Water Wiring ............................................................................................... 49
8.3.6 Additional Boiler Limits...................................................................................................... 49
8.3.7 External Modulation Control ............................................................................................. 50
8.3.8 System Sensor Wiring........................................................................................................ 50
8.3.9 Cascade Wiring - Optional ................................................................................................. 50
8.3.10 Modbus................................................................................................................................ 50
CHAPTER 9 - CTRLMAX OPERATION .............................................................................. 51
9.1. CTRLMax Navigation .................................................................................................................... 51
9.2. CTRLMax Menu Structure........................................................................................................... 52
9.3. Home Screen................................................................................................................................ 53
9.4. Status Line Messages.................................................................................................................. 54
9.5. Main Menu .................................................................................................................................... 55
9.6. EZ Setup ....................................................................................................................................... 55
9.7. Heating EZ Setup ................................................................................................................ 56
9.7.1 Select CH Demand (No outdoor sensor connected) ...................................................... 56
9.7.2 Select CH Demand (Outdoor sensor connected).............................................................57
9.8. Domestic Hot Water EZ Setup - EXALT Solo Units.......................................................... 58
9.9. Domestic Hot Water EZ Setup - EXALT Combi Units ...................................................... 59
9.10. Altitude Setup............................................................................................................................... 59
9.11. EZ Setup Reset ................................................................................................................... 60
9.12. Display EZ Setup .................................................................................................................. 60
9.13. CH/DHW Operation .............................................................................................................61
9.14. Boiler Information ................................................................................................................. 61
9.14.1 Information Items............................................................................................................... 62
9.14.2 Lockout Screen................................................................................................................... 63
9.14.3 Manual Reset Lockouts...................................................................................................... 64
9.14.4 Automatic Reset Blocking Lockouts................................................................................. 65

vii
TABLE OF CONTENTS
CHAPTER 10 - START-UP PREPARATION ........................................................................67
10.1. Boiler System Fluid Requirements ..............................................................................................67
10.1.1 Boiler Fluid pH Level 6.0 to 8.0 ..........................................................................................67
10.1.2 Boiler Fluid Hardness Less Than 7 Grains.........................................................................67
10.1.3 Chlorinated Water ...............................................................................................................67
10.1.4 Flush Boiler to Remove Sediment......................................................................................67
10.1.5 Cleaning of Old Boiler/System: .........................................................................................67
10.1.6 Cleaning of New Boiler/System: .......................................................................................67
10.1.7 Check and Test Antifreeze................................................................................................. 68
10.1.8 Use of Antifreeze in the Boiler System ............................................................................. 68
10.2. Filling the Boiler System .............................................................................................................. 69
10.3. EXALT Combi Water Heater - Water Requirements.................................................................. 69
10.3.1 Filling the Domestic Circuit................................................................................................ 69
10.4. Check Low Water Cut-Off Device................................................................................................ 69
10.5. Check For Gas Leaks ................................................................................................................... 70
10.6. Check Thermostat Circuit ........................................................................................................... 70
10.7. Inspect Condensate Drain Assembly ......................................................................................... 70
CHAPTER 11 - START-UP PROCEDURES ..........................................................................71
11.1. Final Checks Before Start-Up....................................................................................................... 71
11.2. EXALT Start-Up ............................................................................................................................. 71
11.3. Check the EXALT and System ..................................................................................................... 71
11.3.1 Check Boiler Piping. ............................................................................................................ 71
11.3.2 Check Vent and Combustion Air Piping............................................................................. 71
11.3.3 Check Gas Piping................................................................................................................. 71
11.3.4 Verify Flame Pattern and Combustion ..............................................................................73
11.3.5 Measure Input - Natural Gas Only......................................................................................74
11.3.6 Test High Temperature Limit..............................................................................................74
CHAPTER 12 - OUTDOOR RESET CONTROL................................................................... 75
12.1. Mounting the Outdoor Sensor .....................................................................................................75
12.2. Wiring the Sensor..........................................................................................................................75
CHAPTER 13 - EXTERNAL MODULATING CONTROL ..................................................... 77
13.1. Wiring the Modulating Controller.................................................................................................77
13.2. CTRLMax Programming...............................................................................................................77
13.3. Programming of External Modulating Control............................................................................77
CHAPTER 14 - CHECK-OUT PROCEDURES .....................................................................79
CHAPTER 15 - INSTALLATION RECORD .......................................................................... 81

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TABLE OF CONTENTS
CHAPTER 16 - MAINTENANCE SCHEDULES...................................................................83
16.1. Service Technician ....................................................................................................................... 83
16.2. Owner Maintenance..................................................................................................................... 83
CHAPTER 17 - MAINTENANCE PROCEDURES ............................................................... 84
17.1. Service Technician Maintenance Procedures ........................................................................... 84
17.2. Reported Problems...................................................................................................................... 84
17.3. Check Surrounding Area ........................................................................................................... 84
17.4. Inspect Burner Area..................................................................................................................... 84
17.5. Check System Piping ................................................................................................................... 84
17.6. Clean Condensate Drain Assembly ............................................................................................ 84
17.7. Check Ventilation Air Openings .................................................................................................. 85
17.8. Inspect Vent and Combustion Air Piping ................................................................................... 85
17.9. Check Boiler System.................................................................................................................... 85
17.10. Check Expansion Tank................................................................................................................. 85
17.11. Check Boiler Relief Valve ............................................................................................................. 85
17.12. Inspection of Ignitor..................................................................................................................... 85
17.13. Check Ignition Cable and Ground Wiring ................................................................................... 86
17.14. Check Control Wiring................................................................................................................... 86
17.15. Check Control Settings ............................................................................................................... 86
17.16. Perform Start-up and Checkout Procedures............................................................................. 86
17.17. Check Burner Flame .................................................................................................................... 86
17.18. Check Flame Signal...................................................................................................................... 86
17.19. Check Combustion Levels............................................................................................................87
17.20. Check Flue Gas Temperature.......................................................................................................87
17.21. Clean Heat Exchanger ..................................................................................................................87
17.22. Check Carbon Monoxide Detectors ............................................................................................87
17.23. Review With Owner .......................................................................................................................87
17.24. Torque Specifications Table .........................................................................................................87
CHAPTER 18 - REPLACEMENT PARTS.............................................................................88
CHAPTER 19 - PRODUCT SPECIFICATIONS.................................................................. 101

ix
INDEX OF ILLUSTRATIONS AND TABLES
Fig. 1 - All Combustion Air from Adjacent Indoor Spaces through Indoor Combustion Openings ......7
Fig. 2 - All Combustion Air from Outdoors Through One Permanent Air Opening ...............................7
Fig. 3 - All Combustion Air from Outdoors Through Ventilated Attic .....................................................8
Fig. 4 - All Combustion Air from Outdoors Through Horizontal Ducts...................................................8
Fig. 5 - Accessories................................................................................................................................... 13
Fig. 6 - EXALT Pressure Relief Valve, Drain Valve, T&P Gauge Installation.......................................... 15
Fig. 7 - Piping Component Legend .......................................................................................................... 16
Fig. 8 - EXALT Solo Near Boiler Piping - Hydraulic Separator............................................................... 17
Fig. 9 - Near Boiler Piping - Closely Spaced Tees...................................................................................18
Fig. 10 - 3 Boiler Cascade, 1 System Pump, 1 CH Pump and 1 DHW Pump......................................... 20
Fig. 11 - EXALT Combi Near Boiler Piping - Hydraulic Separator.......................................................... 21
Fig. 12 - EXALT Combi Near Boiler Piping -Timesaver Manifold .......................................................... 22
Fig. 13 - EXALT Combi System Piping - Zoning w Valves..................................................................... 24
Fig. 14 - EXALT Combi - System Piping - Multi Zone Valve - Single Circulator................................... 25
Fig. 15 - EXALT Combi - System Piping - Single Zone with Single Circulator ................................... 26
Fig. 16 - Standard Installation of the Domestic Pressure Relief Valve..................................................27
Fig. 17 - EXALT Combi - Hydro-block Flow Diagram ............................................................................. 28
Fig. 18 -
EXALT Combi Domestic Piping - Single Zone System with Single System/Boiler Circulator ... 30
Fig. 19 - Multiple Zones - Panel Wiring with Circulators........................................................................ 31
Fig. 20 - EXALT Combi System Piping - Multiple Zones - Panel Wiring with Valves.......................... 32
Fig. 21 - EXALT Solo System Piping - Multi Zone Valves - Single Circulator....................................... 33
Fig. 22 - EXALT Solo System Piping - Single Zone System - Single Circulator .................................. 34
Fig. 23 - EXALT Solo - Cascade Piping .................................................................................................. 35
Fig. 24 - Condensate Drain Assembly ................................................................................................... 38
Fig. 25 - Recommended Gas Supply Piping .......................................................................................... 39
Fig. 26 - Gas Valve / Venturi Assembly - EXALT Solo 110 ................................................................... 42
Fig. 27 - Gas Valve / Venturi Assembly - EXALT Solo/Combi 155 ....................................................... 42
Fig. 28 - Gas Valve / Venturi Assembly - EXALT Solo/Combi 199....................................................... 43
Fig. 29 - CTRLMax Control Module Fuse Location ............................................................................... 45
Fig. 30 - EXALT Solo Boiler Factory Wiring ........................................................................................... 46
Fig. 31 - EXALT Combi Boiler Factory Wiring..........................................................................................47
Fig. 32 - Terminal Strip Location............................................................................................................ 48
Fig. 33 - Low Voltage Connections ......................................................................................................... 49
Fig. 34 - CTRLMax User Interface ........................................................................................................... 51
Fig. 35 - Throttle Screw Location ............................................................................................................73
Fig. 36 - EXALT Solo Jacket Components ............................................................................................ 88
Fig. 37 - EXALT Combi Jacket Components.......................................................................................... 89
Fig. 38 - EXALT Solo 110 Internal Components.................................................................................... 90

x
INDEX OF ILLUSTRATIONS AND TABLES
Fig. 39 - EXALT Solo 155 Internal Components .....................................................................................91
Fig. 40 - EXALT Combi 155 Internal Components ................................................................................ 92
Fig. 41 - EXALT Solo 199 Internal Components.................................................................................... 93
Fig. 42 - EXALT Combi 199 Internal Components ............................................................................... 94
Fig. 43 - EXALT Solo 110 Burner Components ................................................................................... 95
Fig. 44 - EXALT Solo/Combi 155 Burner Components...................................................................... 96
Fig. 45 - EXALT Combi 199 Burner Components..................................................................................97
Fig. 46 - EXALT Control & Display Enclosures...................................................................................... 98
Fig. 47 - EXALT Combi Hydro-block ..................................................................................................... 99
Fig. 48 - Front View EXALT Solo 110 ....................................................................................................102
Fig. 49 - Right Side View EXALT Solo 110 ............................................................................................103
Fig. 50 - Front View EXALT Solo 155....................................................................................................104
Fig. 51 - Right Side View EXALT Solo 155 ............................................................................................105
Fig. 52 - Front View EXALT Solo 199....................................................................................................106
Fig. 53 - Right Side View EXALT Solo 199 ...........................................................................................107
Fig. 54 - Front View EXALT Combi 155 ................................................................................................108
Fig. 55 - Right Side View EXALT Combi 155........................................................................................109
Fig. 56 - Front View EXALT Combi 199................................................................................................ 110
Fig. 57 - Right Side View EXALT Combi 199.........................................................................................111
Graph 1 - EXALT Solo - Pressure Loss Through Boiler ........................................................................ 112
Graph 2 - EXALT Combi - Pressure Loss Through Boiler.................................................................... 112
Table 1 - Natural Gas Venturis................................................................................................................. 40
Table 2 - Gas Piping Sizing - Natural Gas............................................................................................... 40
Table 3 - Propane Conversion Venturis................................................................................................... 41
Table 4 - Outdoor Reset Preset Selections.............................................................................................57
Table 5 - Throttle Screw Adjustment ......................................................................................................73
Table 6 - Acceptable Combustion Levels................................................................................................74