IDEAL EXRKIT52 Manuale per l'uso e la cura

Exalt

Control & Display Module Replacement

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

EXRKIT52 Control Module Replacement

Display Module Replacement All Exalt Models

Each Kit Includes:

• Control Module

• Display Module with cover

Recommended Tools:

• Phillips Head Screwdriver

2019-66 Exalt Control Module Replacement

Revised 7/29/2021

1. Preliminary Instructions

1. Verify that the 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 equipment will cause malfunction

of the boiler. Contact IdeaUSA right away if the control

module is damaged in any way.

4. Close the manual gas shut off valve to the unit.

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

transferred 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.

Fig. 2: Installer Access Code

3. Press the OK button while the CH & DHW Settings

icon is highlighted.

Fig. 3: CH & DHW Settings

4. Press the OK button while the CH Settings icon is

highlighted.

Fig. 4: CH Settings

5. Press the UP and DOWN buttons to scroll thru the

various settings.

Fig. 5: Heating Settings

Exalt

Control & Display Module Replacement

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 Set-

tings icon then press the OK button.

Fig. 6: DHW Settings

8. Press the UP and DOWN buttons to scroll thru the

various settings and record all DHW Settings in Ta-

ble 1. Once completed, press the RIGHT button to

highlight the Previous Screen icon, then press the

OK button.

Fig. 7: DHW Settings

9. Press the DOWN button to highlight the Boiler Set-

tings 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 but-

ton 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 or the System Temperature Sensor is being used on

a single Exalt.

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 thru the

various settings, and record all Cascade Settings in

Table 1.

3. Remove Control Module

1. Turn the electrical power“OFF”.

2. Remove the front jacket panel by removing the

screws on panel. Pull the panel out and up to re-

move the panel. Do not discard these screws as

they will be reused.

3. Remove the screw holding the metal shipping

bracket in place as shown in Fig. 8

Shipping

Bracket

Screw

Shipping

Bracket

Control

Module

Cover

Control

Module

Retaining Tab

Fig. 8: Control Module

4. The shipping bracket and screw can be discarded.

5. Pull the retaining tab on top of the control module

case to remove the cover.

6. Record the current location of all plugs.

7. Remove all Molex wiring connectors from the

Control Module. Some plugs are equipped with a

locking clip. Squeeze the clip to unlock the plug.

Support Control Module with one hand while re-

moving individual Molex connectors. Press tabs on

Molex plugs for quick release.

8. Unclip the 1 clip on the side of the control module

Exalt

Control & Display Module Replacement

and pull the module out.

4. Installation of Control Module

1. Mount the control module into the case by secure-

ing it behind the mounting clips on both sides of

the case.

2. Reconnect the Molex connectors to proper posi-

tion. Each connector is designed to fit only in its re-

spective mating connector. If the plug is equipped

with a locking clip, ensure the clip is engaged.

3. Place the cover in place and lock in the top retain-

ing tab.

4. Remount the front jacket panel to the boiler.

5. Turn power to the unit “ON” and return the boiler

to service.

5. Replace Display Module

1. Pull the retaining clip on top of the enclosure and

pull the front cover off.

2. Disconnect the yellow cables by squeezing the clip

on the back of the plug in and pulling firmly out

from the back of the display module. Use care not

to damage the plug.

3. Remove the rubber grommet holdind the yellow

cables from the old display ensloure.

4. Install the rubber grommet with the yellow cables

onto one of the tabs in the bottom of the new dis-

play ensloure.

5. Reconnect the yellow cables by pushing the plug

into the terminal. The clip on the back of the plug

will lock the plug into place. Use care not to dam-

age the cable or display module.

6. Close the front cover onto the back cover by

insert-ing the two tabs on the bottom of the front

cover into the appriopriate holes in the back cover

and close, engaging the tab in the top. Give the

cover a light tug to make sure the top retaining

clip is tight.

Exalt

Control & Display Module Replacement

Fig. 9: Display Module

The display module comes preinstalled in the front red dis-

play enclosure as shown in Fig. 8.

NOTICE

4. Programming new Control and DIsplau 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. 10 and Fig. 11.

Fig. 10: Installer Menu

Fig. 11: Appliance setting

3. The required code is written on the data plate lo-

cated 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 po-

sition 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 record-

ed 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 Ta-

ble 1 back into the controls.

Exalt

Control & Display Module Replacement

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

Exalt

Control & Display Module Replacement

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

Exalt

Control & Display Module Replacement

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