TriangleTube EXRKIT131 Manual

Exalt
Propane to Natural Gas Conversion
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.
NOTICE
Upon completion of the conversion from Natural to Pro-
pane, ax the new rating label included in the kit to the
unit adjacent to the existing rating label. DO NOT ax
the new label over the existing rating label. Add propane
conversion labeling to the gas valve.
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.
NOTICE
These instructions cover NG to LP conversion for Exalt
boilers only. Each kit is supplied with one venturi suitable
for use with that particular boiler model.
Kit Includes
• Propane Gas Venturi
• Venturi/blower O RIng
• Venturi Gasket
• Venturi/Blower Screws
• Gas Pipe Gaskets
• Aucoustic Dampening Foam (EXRKIT131 & EX-
RKIT132 Only)
• Rating Label
• Conversion Label
Recommended Tools
• Adjustable Wrench / 10 mm Socket & Ratchet
• Phillips Head Screwdriver
• Flat Head Screwdriver
• Calibrated Combustion Analyzer
Revision Date: 9/12/2022 2019-30 Exalt NG to LP Conversion
Kit Part Number Description Model
EXRKIT131 NG to LP Conversion Exalt 110 Solo
EXRKIT132 NG to LP Conversion Exalt 155 Solo & Combi
EXRKIT133 NG to LP Conversion Exalt 199 Solo & Combi

EXALT NATURAL TO PROPANE CONVERSION INSTRUCTIONS
2
1. Preliminary Instructions:
1. Verify that the venturi replacement kit is correct for
the model of boiler. See page 1.
2. Turn o electrical power supply to the boiler.
3. Close the manual gas shut o 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. Install the Acoustic Foam
NOTICE
The acoustic foam is only applicable to the 110 and 155
models. The Exalt 199 models do NOT use the additional
acoustic foam.
1. Cut a 7" length of 3" diameter air inlet piping.
2. Insert the 7" pipe into the air inlet adaptor.
The acoustic foam should be ush to the inside of the air inlet
adapter.
Fig. 4: Installing the Acoustic Foam (applicable to 110
and 155 models ONLY)

EXALT NATURAL TO PROPANE CONVERSION INSTRUCTIONS
3
NOTICE
The Exalt boiler has a length of acoustic foam already in-
stalled in the air inlet adaptor. DO NOT remove this
3. Insert the length of acoustic foam (supplied), into
the 7" pipe length.
4. Use either a straight coupling or elbow to continue
the air inlet installation. Refer to the Vent Supple-
ment for full details on the installation of air and
vent pipes.
3. Removal of Natural Gas 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.
3. Remove the gas valve to venturi pipe by loosening
the nuts at both ends of the pipe with an adjust-
able wrench.
NOTICE
There are gaskets at both ends of the gas valve to venturi
pipe. These gaskets must be replaced along with the pipe.
4. Using a 10 mm socket and ratchet, remove the
three (3) bolts securing the venturi to the fan as-
sembly and remove the natural gas venturi from
the unit, making sure not to damage the blower
O-ring gasket.
4. Install the Propane Venturi
1. Verify the following when aligning the propane
venturi:
1. The UP arrow on the plastic housing is pointing
upward.
2. The threaded connection for the gas piping is in
the correct orientation for re-tting the gas pipe.
WARNING
!
Failure to retain the O-ring gasket between the ventu-
ri and the blower will cause an improper seal resulting
in a potential risk of a gas leak. A gas leak can result in
substantial property damage, serious injury, or death.
2. Install the new venturi/blower gasket into the
blower.
WARNING
!
Ensure the proper venturi for the model is installed
per Table 1. Failure to comply will affect input rate
and combustion of the boiler which can result in sub-
stantial property 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
gaskets are seated properly before tightening the
nut.
5. Install the venturi interface on the venturi and ro-
tate 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 can 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.
8. Attach the Propane conversion label (Fig. 4) to the
side of the boiler and the rating label label (Fig. 5)

EXALT NATURAL TO PROPANE CONVERSION INSTRUCTIONS
4
over the applicable part of the existing rating label
Fig. 5: Propane Conversion Label
Fig. 6: Propane Rating Label
9. Enter the propane (LP) appliance code from the rat-
ing label:
1. Press and hold the UP and DOWN buttons to-
gether see Fig. 7.
Fig. 7: 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. With the CH/DHW Settings icon highlighted,
press the center button.
4. Press the DOWN button to highlight the Boiler
Settings icon then press the center button.
5. Scroll down to highlight Appliance Setting then
press the center button.
6. Enter the propane (LP) appliance code from the
rating label by using the LEFT and RIGHT buttons
to select a character and the UP and DOWN but-
tons to change the character. Press the center
button to enter the appliance code.
5. 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.
1. Touch simultaneously on the up and down soft
keys for 3 seconds to access the functions for the
installer. See Fig. 7.
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. 8: 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. 8

EXALT NATURAL TO PROPANE CONVERSION INSTRUCTIONS
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. 9)
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 re, manu-
ally place the boiler into low re mode by pressing
the LEFT button to adjust ring rate down to 1%
(low re).
8. If the combustion level (O2or CO2) during low re
is not are outside the recommended combustion
settings in Table 1 contact IdealUSA Technical Sup-
port.
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.
Table 1: Combustion Settings

EXALT NATURAL TO PROPANE CONVERSION INSTRUCTIONS
6
Fig. 9: Throttle Screw Location