IDEAL Exalt User manual

Exalt
Venturi Replacement Kit
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
EXRKIT07 NG Venturi Replacement Exalt 110
EXRKIT08 LP Venturi Replacement Exalt 110
EXRKIT09 NG Venturi Replacement Exalt 155
EXRKIT10 LP Venturi Replacement Exalt 155
EXRKIT11 NG Venturi Replacement Exalt 199
EXRKIT12 LP Venturi Replacement Exalt 199
Each Kit Includes:
•(1) Venturi
• Venturi/blower O RIng
• Venturi Gasket
• Venturi/Blower Screws
• Gas Pipe Gaskets
Recommended Tools:
•Adjustable Wrenches
•10 mm Wrench
• Calibrated Combustion Analyzer
2019-64 Exalt Venturi
Replacement Revised11/26/2019

Exalt
Venturi Replacement Kit
2
1. Preliminary Instructions:
1. Verify that the venturi replacement kit is correct for
the model of boiler. See page 1.
2. Turn off electrical power supply to the boiler.
3. Close the manual gas shut off valve to the unit.
4. Remove the front panel of the Exalt by removing
the screw along the bottom edge of the unit. Pull
the bottom of the panel forward and then lift to re-
move the front panel from the unit.
5. Using a voltmeter ensure there is no electrical pow-
er to the boiler by checking for power on the boil-
er’s high voltage terminals L and N.
WARNING
!
ELECTRICAL SHOCK HAZARD
Ensure power to the boiler has been disconnected pri-
or to servicing the unit.
Fig. 1: Exalt 110 Gas Train
Fig. 2: Exalt 155 Gas Train
Fig. 3: Exalt 199 Gas Train
2. Removal of old Venturi
1. Remove the silicone tube from the air inlet elbow,
then remove the air inlet elbow.
2. Rotate the venturi interface approximately 60°
clockwise to release the clamping mechanism and
remove the venturi interface. Discard the gasket
between the venturi and venturi interface.
3. Remove the gas valve to venturi pipe by loosening
the nuts at both ends of the pipe with an adjust-
able wrench.
4. Remove and dispose of the gasket installed at both
ends of the gas valve to venturi pipe. These gaskets
must be removed and replaced with new gaskets.
5. Using a 10 mm wrench, remove the three (3) bolts
securing the venturi to the fan assembly and re-
move the venturi from the unit.

Exalt
Venturi Replacement Kit
3
6. Remove and dispose of Blower/Venturi O-ring
3. Installation venturi
1. Verify the threaded connection for the gas piping is
in the correct orientation for re-tting the gas pipe.
2. Install the new Blower/Venturi O-ring into the
blower.
WARNING
!
Failure to install the new O-ring gasket between the
venturi and the blower will cause an improper seal re-
sulting in a potential risk of a gas leak. A gas leak can
result in substantial property damage, serious injury,
or death.
WARNING
!
Ensure the proper venturi for the model is installed.
Failure to comply will affect input rate and combus-
tion of the boiler which can result in substantial prop-
erty damage, serious injury, or death.
NOTICE
Do not use adhesive on any gaskets or O-rings during the re-
assembly process.
3. Using a 10 mm socket and ratchet, reinstall the
three (3) bolts securing the venturi to the fan as-
sembly
4. Reassemble the gas valve to venturi pipe to the
gas valve and venturi taking care to ensure that the
new gaskets are seated properly before tightening
the nut.
WARNING
!
Failure to install the new gas pipe gasket between the
venturi and the gas valve will cause an improper seal
resulting in a potential risk of a gas leak. A gas leak
can result in substantial property damage, serious in-
jury, or death
5. Install the new gasket and install the venturi inter-
face on the venturi and rotate counterclockwise
until locked into place.
6. Install the air inlet elbow then attach the silicone
tube.
WARNING
!
Failure to properly install the air inlet elbow and at-
tach the silicone tube will affect combustion of the
boiler which can result in substantial property dam-
age, serious injury, or death.
7. Open the manual gas shut o valve to the unit.
Before placing the boiler back into operation, test
all gas connections for leaks and repair if leaks are
found.
WARNING
!
Do not check for gas leaks with an open flame. Use a
bubble test. Failure to test for gas leaks can result in
substantial property damage, serious injury, or death.
4. Combustion Test and Adjustments
NOTICE
The installer MUST perform a complete combustion check
to ensure the following combustion levels are met at high
and low input ring rates and the burner is operating at op-
timum conditions.
WARNING
!
The combustion testing and adjustments must be per-
formed by a qualified installer, service agency or the
gas supplier. All combustion measurements must be
performed with calibrated equipment to ensure prop-
er readings and accuracy.
WARNING
!
Failure to perform a complete combustion test at both
high and low input rates may result in incomplete
combustion and the production of carbon monoxide,
which can cause severe personal injury, death or sub-
stantial property damage.

Exalt
Venturi Replacement Kit
4
1. Touch simultaneously on the up and down soft
keys for 3 seconds to access the functions for the
installer. See Fig. 4.
Fig. 4: CTRLMax Navigation Control
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
CENTER button to enter the access code.
3. Press the RIGHT button to highlight the Manual
Operation icon then press the CENTER button.
Manual Operation
Released
O
O
O
CH1
FAN
DHW
CH2
Manual Operation
Released
O
O
O
CH1
FAN
DHW
CH2
Manual Operation
Released
O
O
O
CH2
FAN
DHW
CH1
Manual Operation
Released
O
O
O
DHW
FAN
CH1
CH2
Fig. 5: CTRLMax Manual Operation
4. Press the CENTER button while the FAN icon is
highlighted to manually re the burner and power
the CH circulator. See Fig. 5
NOTICE
An adequate CH load must be present to dissipate the heat
generated during the combustion test. If an adequate CH
load is not available, an indirect water heater can be used to
dissipate the heat by creating a DHW call which will enable
the DHW circulator.
5. Press the RIGHT button to adjust the ring rate to
100% (high re). Hold down the RIGHT button to
rapidly increase the ring rate.
6. If the combustion levels during high re are out-
side the recommended combustion settings (see
Table 1), adjust the THROTTLE SCREW (see Fig. 6)
using a at-blade screwdriver as follows:
Counter-clockwise adjustment of the THROTTLE
SCREW at High Fire (100% firing rate):
O2decreases and CO2 increases
Clockwise adjustment of the THROTTLE SCREW at
High Fire (100% firing rate):
O2increases and CO2decreases
7. Once the combustion level is set at high fire, manu-
ally place the boiler into low fire mode by pressing
the LEFT button to adjust firing rate down to 1%
(low fire).
8. If the combustion level (O2or CO2) during low fire
is not are outside the recommended combustion
settings in Table 1 contact Ideal USA Technical
Support.
9. Press the CENTER button while the fan icon is high-
lighted to shutdown the burner.
10. Press the LEFT or RIGHT button to highlight the
home screen icon to exit the service mode.
11. Replace the front panel and put the boiler back
into operation.

Exalt
Venturi Replacement Kit
5
Table 1: Combustion Settings
NG 110, 155 NG 199 Propane
High Fire
CO2Range 9.0 to 10.5% 8.5 to 10.5% 10.4 to 11.0%
O2Range 4.85 to 2.15 % 5.75 to 2.15 % 5.1 to 4.2 %
CO Max 150 ppm 200 ppm
Low Fire
CO2Range 9.0 to 10.0 % 8.5 to 10.0 % 10.4 to 11.0 %
Lower than or equal to High Fire CO2level
O2Range 4.85 to 3.0 % 5.75 to 3.0 % 5.1 to 4.2 %
Higher than or equal to High Fire CO2level
CO Max 10 ppm
Fig. 6: Throttle Screw Location