Aerco MODULEX EXT 321 User Manual
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Aerco MODULEX EXT 321 User Manual

Natural gas modulating & condensing modular hot water boiler
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Natural Gas Modulating &
Condensing Modular Hot
Water Boiler
LIGHT COMMERCIAL SERIES
Covering Models:
• EXT 321
• EXT 481
• EXT 641
• EXT 802
• EXT 962
• EXT 1123
Latest Update: 07/13/2015
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288
MODULEX EXT
User Manual
USER MANUAL
Installation, Operation and Maintenance
Modular Condensing Boilers
MODULEX EXT
Light Commercial Series
GF-143
OMM-0087_0F

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Summary of Contents for Aerco MODULEX EXT 321

  • Page 1 LIGHT COMMERCIAL SERIES Covering Models: • EXT 321 • EXT 481 • EXT 641 • EXT 802 • EXT 962 • EXT 1123 Latest Update: 07/13/2015 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288...
  • Page 2 The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application.

  • Page 3: Table Of Contents

    Reversing Cold/Hot Water Flow & Return Connections ................. 34 3.8.3.1 Reversing Cold/Hot Water Flow & Return Piping Connectors ............. 34 3.8.3.2 Reversing Flow & Return Temperature Sensors .................. 35 OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 3 of 146 GF-143 Phone: 800-526-0288...
  • Page 4 Maximum Output Calibration ....................... 70 3.33.3 Minimum Output Calibration ....................... 71 3.33.4 Final Check and Ignition Failure Adjustment Procedure............... 71 Page 4 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 5 5.10.2.2 Use of a DHW Storage Tank Thermostat (On/Off)................112 5.10.2.3 Antilegion ............................112 5.10.2.4 Setting for Solar Panel Use ......................112 5.11 ACCESS CODE SETTING ..........................112 OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 5 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 6 7.14 Maintenance Kit Part Number ........................137 7.15 Accessory Kit Part Numbers ........................... 138 CHAPTER 8: SPARE PARTS DRAWING AND LISTS ............... 139 Page 6 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 7: Chapter 1: General Information

    The MODULEX EXT boiler is designed to be used in pumped hot water central heating systems. Any other use of this appliance shall be considered improper, and AERCO declines any responsibility for damages or injuries caused by the improper use of this equipment. In order to use the equipment appropriately and safely according to its design, it is essential to carefully follow the instructions in this manual.

  • Page 8: Safety Warnings

    AERCO shall not be held liable. 1.5 Modifications To Parts Connected To The Appliance Do not carry out any modifications to the following parts: •...

  • Page 9: For Appliances Operating With Propane Gas

    The insulation of the hydraulic pipelines and the condensate drain. The adoption of specific antifreeze products in the Cold/Hot • water installation. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 9 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 10: Data Plate

    Each unit is fitted with a data plate, which may be consulted for the details on gas type, power source and venting classification. Page 10 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15...

  • Page 11: Operational Requirements

    • If you find any defects, you must inform the owner, in writing, of the system defect and the associated hazard. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 11 of 146 GF-143 Phone: 800-526-0288...

  • Page 12: Water Quality Requirements

    Never use water to fill the heating system that has been treated by reverse osmosis, deionization, or distilled water in order to soften the water. • Do not use inhibitors or other additives unless approved by AERCO for that purpose. • When frost protection of the heating system is desired, only use AERCO-approved antifreezes.

  • Page 13: Tools, Materials, And Additional Equipment

    Any repairs must be carried out by AERCO authorized technicians and using only original spare parts. Non-observance of the above requirement may jeopardize the safety of the appliance and void any warranties.

  • Page 14: Preparing Boiler For Servicing

    Max. boiler temperature: 180° F • Max Allowable Working Temperature ASME: 200 °F • Max. Allowable Working Pressure ASME: 92 psi Page 14 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 15: Chapter 2: Technical Features And Dimensions

    Integral insulation with hypoallergenic synthetic wool. • Premix fiber mesh modulating burner (premixes into the fan with automatic diaphragm backflow separation from the combustion chamber). OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 15 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 16: General Boiler Operation

    Flow and Return manifolds. Failure to do so may cause serious damage to the equipment. Page 16 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 17: Dimensional Drawings

    On Modulex EXT models 321, 642 and 962 the flue terminal ends inside the casing Figure 2-1: MODULEX EXT Dimensional Drawings (Side Views) OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 17 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 18 5.9‘‘ 5.9‘‘ 7.8‘‘ 7.8‘‘ Vent Connection ‘’C’’ - inches/mm 1.57‘‘ 1.57‘‘ 1.57‘‘ 1.57‘‘ 1.57‘‘ 1.57‘‘ Condensate drain diameter - inches/mm Page 18 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 19 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual Figure 2-3a: MODULEX EXT Main Components (Left Side View) OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 19 of 146 GF-143 Phone: 800-526-0288...
  • Page 20 • Gas connection: on the RIGHT HAND side (supply condition) , but may be moved to the LEFT HAND position. Page 20 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 21: Performance Data

    Installation, Operation & Maintenance Manual 2.4 Performance Data Table 2-2: MODULEX EXT Performance Data NOTE The Technical data plate is placed under the casing. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 21 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 22 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual (This page intentionally blank) Page 22 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 23: Chapter 3: Installation Instructions

    Where required by the authority having jurisdiction, the installation must conform to the Standard ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 23 of 146 GF-143 Phone: 800-526-0288...

  • Page 24: Code And Standards Approvals

    The packing elements (cardboard box, straps, plastic bags, etc…) should be kept away from children, as these present suffocation and choking hazards. AERCO refuses all liability for injury to persons, animals or damage to property derived from not respecting the above mentioned recommendations.
  • Page 25 • PVC venting starter piece and pipe clamps • Temperature & Pressure gauge • Flow Switch • Pipe adaptor (rubber) OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 25 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 26 Parts with Parts Figure 3-1: MODULEX EXT Unpacking (Front View) Condensate Drain Pipe Figure 3-2: MODULEX EXT Unpacking (Rear View) Page 26 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 27: Transporting And Securing The Boiler Safely

    When moving the boiler, it must be secured on the transportation equipment to prevent it from falling off. • Protect all parts against impacts, during transportation. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 27 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 28: Removal From Boiler Bed And Installation Of Boiler Feet

    5) Attach the four (4) support feet to the chassis using the four ’’A’’ screws removed in Step 3 (Figure 3-5). 6) Place the boiler on concrete slab and re-mount the cover(s) over the boiler. Page 28 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 29: Boiler Location Inside A Boiler Room

    “U” drain pipe (see Figure 3-6). After installation the boiler shall be perfectly horizontal and stable, to reduce any possible vibrations or noises. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 29 of 146 GF-143...

  • Page 30: Boiler Room Safety Concerns

    Calcium chloride used for thawing • Sodium chloride used for water softening • Refrigerant leaks • Paint or varnish removers Page 30 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 31: Recommended Clearances For Servicing

    Minimum required clearances depend on the piping and venting configuration. For further details, contact your loal manufacturer’s representative. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 31 of 146 GF-143 Phone: 800-526-0288...

  • Page 32: Boiler Connections

    Changing Exhaust Outlet from RIGHT Figure 3-8: Rear Exhaust Kit (P/N HAND side to REAR on EXT 802, 962, 1123 (only) Page 32 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 33: Reversing Gas Manifold Connections

    NOTE Torque all bolts to 8.85 ft-lbs (12 N/m) Figure 3-10: Reversing Gas Connections from RIGHT HAND to LEFT HAND OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 33 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 34: Reversing Cold/Hot Water Flow & Return Connections

    Torque all bolts to 8.85 ft-lbs (12 N/m) Figure 3-11: Reversing Cold/Hot Water Flow and Return Connections and Sensors from RIGHT HAND to LEFT HAND Page 34 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 35: Reversing Flow & Return Temperature Sensors

    When reversing hydraulic and gas pipe connections, you must close up the chassis openings vacated after the change. See Figure 3-14. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 35 of 146 GF-143 Phone: 800-526-0288...

  • Page 36: Gas Connection General Information

    As a safety measure against gas leaks, AERCO recommends installing a surveillance and protective system made up of a gas leakage detector combined with an on-off solenoid valve on the gas supply line.

  • Page 37: Natural Gas Connections

    The nominal inlet working gas pressure measured at the boiler should be 11” W.C. (27 mbar) for Propane gas (Gas E). OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 37 of 146 GF-143 Phone: 800-526-0288...

  • Page 38: Propane Gas Supply Pressure Requirements

    The boiler ships with an 80 psi pressure relief valve for installation into the CSD-1 manifold header. Lower system pressures will require lower rated pressure relief valves (not supplied). Page 38 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15...

  • Page 39: Manifold Assembly (Supplied)

    Use Teflon tape or a suitable pipe joint compound for component and piping connections described in the following steps. Refer to Figure 5 for component identification. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 39 of 146 GF-143 Phone: 800-526-0288...

  • Page 40: Determination Of Primary Boiler Pump Or Boiler System Pump

    The size of the pumps must be determined by installers or technical engineers according to boiler data and system design. Page 40 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 41: Boiler Model

    27° F (15 K). OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 41 of 146 GF-143...

  • Page 42: Condensate Piping And Drain

    Consult local codes regarding condensate neutralization. Neutralization may be obtained by mixing it with the buildings drain water or with limestone, which normally has a base pH. AERCO offers a condensate neutralizing kit and a neutalizing tank for preparing condensate waste for safe evacuation into a sewer system.

  • Page 43: Water Treatment

    AERCO suggests treating and conditioning feed water for the heating circuit in the following cases: •...

  • Page 44: Important Installation Warnings

    Install air intake as shown in Figure 3-20. For air intake connection piping use only: • Ø 4’’ PVC Pipes Schedule 40/80 for Modulex EXT 321, EXT 481, EXT 641 Ø 6’’ PVC Pipes Schedule 40/80 for Modulex EXT 802, EXT 962, EXT 1123 •...

  • Page 45: Flue Manifold Connection

    It is intentionally designed to provide a tight fit. EUROPEAN-TO-USA FLUE ADAPTER FLUE MANIFOLD Figure 3-22: Assembly of USA-to-European Flue Adaptor to Flue Manifold OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 45 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 46: Flue Exhaust Piping To Vent

    PVC starter pieces are included with every unit. Stainless steel starter pieces may by purchased from AERCO or directly from the vent manufacturer. Page 46 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15...
  • Page 47 When using non-metallic (plastic) venting materials, use Schedule 40 or thicker, Single-wall, uninsulated pipes. When using non-metallic (plastic) vent systems for Canadian installations, OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 47 of 146 GF-143...

  • Page 48: Combustion Air And Ventilation Openings

    • Please note these restrictions and its dangers to the operator of the boiler. When one expects contaminated combustion air (near swimming pools, chemical cleaning operations, hair salons, etc.), sealed combustion operation is recommended. Page 48 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 49: Room Air Combustion

    Observe the listed maximum lengths of vent system, which are dependent on boiler model. The maximum permissible lengths are listed in section 3.23, below. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 49 of 146 GF-143 Phone: 800-526-0288...

  • Page 50: Important Factors For Terminal Orientation And Location

    Please refer to your local codes for the snow level in your area. The whole route of the vent system must be installed upwards and never completely nor partly downwards. Page 50 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 51: Minimum And Maximum Wall Thickness

    The maximum pressure drop of the combustion air piping is also 100 equivalent feet (30 m). NOTE: NOTE The flue system must be installed in accordance with the local and national Standards. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 51 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 52 A 30 foot (10.4 m) length of vent pipe and 2 sharp 90° elbows add up to 30 ft. + (2 x 10 ft.) = 50 equivalent ft. (17.4 m). Figure 3-27: Modulex EXT Allowable Venting Solutions Page 52 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 53: Electrical Connections

    Ensure that the above safety electrical requirements are instituted. If in doubt, ask a professionally qualified technician to check the appliance’s electrical system. AERCO does not accept responsibility for any damages arising from failure to correctly electrically ground the boiler.

  • Page 54: Service Relay Requirement

    • Verify proper operation after operation servicing. NOTE Verify proper operation of the boiler after all servicing operations. Page 54 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 55 120 VAC cables shall be separated from 24VAC and signal wires, using the two plastic conduits supplied within the boiler casing LEFT-HAND side panel. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 55 of 146 GF-143 Phone: 800-526-0288...
  • Page 56 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual Figure 3-29: Main Power Junction Box Location and 120VAC Wiring Page 56 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 57: Functional Wiring Diagram

    MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual 3.25 Functional Wiring Diagram OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 57 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 58 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual (This page intentionally blank) Page 58 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 59: Ladder Diagrams

    MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual 3.26 Ladder Diagrams Figure 3-30: Module Ladder Diagram OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 59 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 60: General Ladder Diagram

    See Figure 3-32 for a wiring diagram showing the E8 controller terminal wiring, and see Figure 3-33 for a wiring diagram of sensor and BCM terminal wiring. Page 60 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15...
  • Page 61 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual Figure 3-32: E8 Controller Terminal Assignments OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 61 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 62 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual Figure 3-33: Sensor and BCM Terminal Assignments Page 62 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 63: Installation Examples

    MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual 3.29 Installation Examples (Functional Wiring and Connections Description) OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 63 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 64 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual Page 64 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 65: Starting Up: Filling And Deaerating The Boiler

    Observe the following rules of safety: • All work on the unit must take place in a dry environment. • AERCO units should never be in operation without their cover panels, except in connection with maintenance or adjustments. • Never allow electrical or electronic components to come into contact with water.

  • Page 66: Filling Locations And Preparation

    The pH value of the installation water must be between 6.5 and 8.5. Check the pH value using proper equipment or by having the water analyzed by a water treatment company. If pH differs from above, contact AERCO engineering for further assistance. WARNING! Failure to adhere to the water quality requirements will result in a voidance of warranty.

  • Page 67: For Your Safety Read Before Operating

    1. Set the thermostat to its lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. Close the gas valve. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 67 of 146 GF-143 Phone: 800-526-0288...

  • Page 68: Testing The Ignition Safety Shut Off Device

    10. Check that the boiler starts correctly. WARNING! Do not touch the inside of the ignition cable while it is disconnected during start-up of the boiler. Page 68 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 69: Burner Calibration

    4. After measurements are taken and adjustments made, remove the probe, probe adaptor, then reinstall the cap (#2) onto the gas outlet (#1). Figure 3-36: Gas Analyzer Probe Location in Flue Outlet OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 69 of 146 GF-143 Phone: 800-526-0288...

  • Page 70: Maximum Output Calibration

    ANTICLOCKWISE to increase the value. 5. Repeat the adjustment for all gas valves in the boiler. Page 70 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 71: Minimum Output Calibration

    5. Once ignition succeeds, carry out the minimum and maximum gas output burner adjustments as previously described in sections 3.33.2 and 3.33.3, above. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 71 of 146 GF-143...
  • Page 72 Check the O levels often, especially at low flow rates. For high altitude installations, consult document number C302.6 (MLX EXT Alt Derate). Page 72 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...
  • Page 73 Check the O levels often, especially at low flow rates. For high altitude installations, consult document number C302.6 (MLX EXT Alt Derate). OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 73 of 146 GF-143 Phone: 800-526-0288...

  • Page 74: Sweeper Mode (Manual Control)

    NOTE The function is active for 15 minutes, after which, if there is no input, it defaults to the previous parameters. Page 74 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 75: High Altitude Adjustment

    Figure 3-40: Adjusting Fan Speed to Set Input Range for High Altitude OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 75 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 76: High Altitude Conversion Label

    If the unit is calibrated again for normal altitude operation, the label should be removed. Figure 3-41: High Altitude Conversion Label Page 76 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 77: Conversion From Natural Gas To Propane Gas

    After gas conversion to propane and calibration, the gas installer should complete and apply this label, or equivalent, as close to the rating label as possible: Figure 3-42: MODULEX EXT Label OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 77 of 146 GF-143 Phone: 800-526-0288...

  • Page 78: Controls And Emergency Functions

    The emergency function enables the boiler’s burners to fire only at 50% and at 50°C in system return. All the system’s heating loads, including the header pump, must be controlled manually. Page 78 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 79: Initial Boiler Ignition

    All the necessary ventilation conditions and minimum clearance distances are in place for subsequent servicing in case the boiler is sited in a cupboard compartment. • There are no water leaks. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 79 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 80 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual (This page intentionally blank) Page 80 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 81: Chapter 4: E8 Controller And Bcm Modules

    • Drives diagnostics such as relay and senor testing. • Supports Modbus integration with AERCO BMS II and AERCO Control System (ACS) or Building Automation Systems. AERCO also offers a Communication Gateway to support BACnet, Lonworks and N2 system integration.

  • Page 82: E8 Display Functions

    Display of number of active heat generators (only applies when cascading). Selectable display and Error Codes (refer to "DISPLAY SEL" parameter in the USER menu). Page 82 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15...

  • Page 83: E8 Heating Mode Selection

    24 Hour heating with reduced temperature; HW Night Mode according to program. Automatic reset after 15 minutes. Boiler regulated at Service Mode max boiler temperature. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 83 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 84: E8 Menu Mode Operation (Door Open)

    MAX T-MODUL (in EXPERT/INSTALLATION menu). Used to navigate through menus and parameters or adjust Rotary Knob parameters. Page 84 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 85: E8 Menu Navigation And Parameter Settings

    Repeat steps 2, 3 and 4 to view the remaining main menus and their associated sub- menus. The remaining main menus are: USER, TIME PROGRAM, EXPERT, EXPERT HS (Not Applicable to MODULEX), and GENERAL. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 85 of 146 GF-143 Phone: 800-526-0288...

  • Page 86: E8 Parameter Navigation, Selection, And Setting

    Program Key. The Change LED will displayed Displayed turn off indicating the new value has been saved. value Value Saved! Page 86 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 87: Bcm (Boiler Communication Module)

    May be selected as the Primary Controller instead of the E8. • Functioning as a “Slave” to a “Master” Energy Management System (EMS), Building Automation System (BAS) or AERCO’s Boiler Management System II (BMS II/AERCO Control System [ACS]) on a Modbus Network. 4.2.2 BCM Description The BCM shown in Figure 4-6 is housed in a compact enclosure measuring 4.13”...
  • Page 88 DL2 LED: (RED) Activating the Reset Switch will clear the faults. DL3 LED: (GREEN) Pump Status Indicator lights when Pump is running. Page 88 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 89 3) Position II is the Default position for the 3-Position Switch. Ensure it is set to this position when it arrives from the Factory. See Paragraph 3.1.2 of the E8 Controller User Manual (GF-115-C) for setting HEAT Modes. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 89 of 146 GF-143 Phone: 800-526-0288...
  • Page 90 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual (This page intentionally blank) Page 90 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 91: Chapter 5: Operation

    E8 Controller User Manual (GF-115-C). Modulex E8 Controller Front Panel (Cover Closed) Modulex E8 Controller Front Panel (Cover Open) OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 91 of 146 GF-143 Phone: 800-526-0288...

  • Page 92: Installation Menu: Initializing The E8 Controller

    Menu selections shown are the factory default settings. Refer to GF-115-C for the complete menu selections. Figure 5-1: INSTALLATION Menu Page 92 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 93: Quick Start Instructions

    Setting Maximum and Minimum Flow Temperature Figure 5-2: E8 Quick Start, Max. & Min. Flow Temperature Settings 5.2.2 Setting Room Temperature and Outdoor Compensation OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 93 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 94: Setting Heating Programs And Pumps

    Figure 5-3: E8 Quick Start, Room Temperature and Outdoor Compensation Settings with Outdoor Temperature (Slope) Chart 5.2.3 Setting Heating Programs and Pumps Page 94 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 95 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual Figure 5-4: E8 Quick Start, Heating and Pump Program Settings OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 95 of 146 GF-143 Phone: 800-526-0288...

  • Page 96: Menu And Sub-Menu Descriptions

    • SOLAR/MF All indicator and set values that relate to solar energy recovery and settings for the multifunction relay. Page 96 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 97: General Menu

    Installation, Operation & Maintenance Manual 5.4 General Menu The GENERAL menu contains the sub-menus DATE/TIME, HOLIDAY, and CLOCK CHANGE. Figure 5-5: GENERAL Menu OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 97 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 98 Set month for start of winter time 12 - 31 DAY STOP Set earliest day for start of winter time 01 - 31 Page 98 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 99: Service Menu

    SERVICE MODE ( ) is different and can only be accessed when the E8 cover is closed. Figure 5-6: SERVICE Menu OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 99 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 100 Date/Hour setting for service purposes RESET USER 00 Do not use RESET EXPERT 00 Do not use RESET T-PRG 00 Do not use RETURN Page 100 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 101: Display Menu

    Some menus are visible only if the relevant sensor is wired (e.g. HOT WATER is displayed only if the DHW storage sensor is wired). OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 101 of 146 GF-143...
  • Page 102 Temperature MF sensor 4 (=F14) T-COLLECTOR Temperature collector 1 T-DHW Upper hot water temperature T-DHW L Hot water temperature infeed RETURN Page 102 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 103: User Menu

    The USER menu contains the INSTALLATION, HOT-WATER, HTG CIRCUIT 1/2, and SOLAR / MF sub-menus as shown below: Figure 5-8: USER Menu OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 103 of 146 GF-143 Phone: 800-526-0288...
  • Page 104 PC (0000= access is blocked) SOLAR / MF RETURN NOT USED NOTE: Some menus are visible only if the relevant sensor is wired. Page 104 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 105: Time Program Menu

    ) = Active only with parameter 1 x HW = 00 NOTE By leaving the hour blank_ _ : _ _ the heating period is bypassed. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 105 of 146 GF-143 Phone: 800-526-0288...

  • Page 106: Expert Menu

    Installation, Operation & Maintenance Manual 5.9 Expert Menu The EXPERT menu contains the items shown below: Figure 5-10: EXPERT Menu – 1 of 2 Page 106 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 107 The shaded items in the following table indicate those parameters that change according to the boiler type and whether used singly or in a cascaded configuration. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 107 of 146 GF-143 Phone: 800-526-0288...
  • Page 108 (20 ÷ 500) DYN DOWNWARD Dynamic heat generator deactivation (20 ÷ 500) RESET TIME Resetting time for I-Controller (5 ÷ 500) Page 108 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 109 WALL HUNG (00 - 01) preparation LOAD THROUGH The charge through function can be activated by... (00 - 01) RETURN OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 109 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 110: Other Possible Settings

    Heating circuit I / II ⇒ FLOW TEMP DAY • USER menu ⇒ Heating circuit I / II ⇒ FLOW TEMP NIGHT Page 110 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 111: A Second Dhw Storage Tank

    EXPERT menu ⇒ Installation ⇒ TENS SLOPE (0 to 11) EXPERT menu ⇒ Installation ⇒ SLOPE 11 – XX (freely settable) OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 111 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 112: Setting Of Dhw Circuit

    Programming button to accept the value. Repeat this procedure for each code number position. Figure 5-12: Setting the Access Code Page 112 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 113: Chapter 6: Troubleshooting

    Table 6-1 (and the formula described below the table) to arrive at a fault number, which can be looked up in Tables 6- 3 and 6-4 for the fault description. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 113 of 146 GF-143 Phone: 800-526-0288...
  • Page 114 BMM #1. The fault code is (261 – 256 = ) 5. An Error Code of 5 from the BMM Fault Codes table means “Flame Loss During Run”. Page 114 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15...

  • Page 115: E8 Controller Fault Codes

    E8: F13 – Boiler 2, Manifold 2 MF 3. E 137 E8: F14 – Manifold 1, Multifunction 4. E 138 E8: F15 – Room temperature Hc2. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 115 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 116 Communication Error HS1 Internal Fault E8: EEPROM fault. The invalid value has been replaced by the standard E 81 value. Page 116 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 117: Bcm (Boiler Communications Module) Fault Codes

    Ignition is Close request MANUAL - push reset flow detected. inhibited. input for switch or cycle power. E 58 manual operation. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 117 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 118: Bmm (Burner Management Module) Fault Codes

    Check aux sensor or E 13 Aux sensor fault. Flow sensor AUTOMATIC wiring. without the Aux sensor. Page 118 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 119 E 23 doesn't switch away, install a new switch. off. If not, check the wiring. If wiring is OK, change BMM. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 119 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 120 Low water flow. Burners Check water flow or E 40 Low water flow AUTOMATIC turned OFF. check switch. switch activated. Page 120 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 121: Chapter 7: Maintenance Schedule

    Inspect condensate drain pipe and trap, clean if necessary. ● Check flow switch in the CSD-1 manifold for proper function. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 121 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 122: Instructions For Inspection And Maintenance

    The inspection of the boiler and venting system should be performed every year and full maintenance should be done every two years. Please contact AERCO for further guidance on the frequency of maintenance and service requirements. Contact details can be found on the back page of this manual.

  • Page 123: Cleaning The Condensate Drain Line

    BMM module labeled “FL“ or replace with a new flow switch. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 123 of 146 GF-143 Phone: 800-526-0288...

  • Page 124: Visual Inspection Of The Flame

    7.6 Proper Reassembly and Resealing of the Vent-Air Intake System After removing, inspecting, and possibly cleaning the flue pipes and air intake, replace the piping correctly. Refer to AERCO Venting Application Guide (GF-136-V) for information concerning Modulex venting requirements. Page 124 of 146 AERCO International, Inc.

  • Page 125: Pressure Switch Hoses And Connections

    If too long, there is an increased chance of condensation problems within the hoses. See Original Length ACCEPTABLE Original Length ACCEPTABLE Figure 7-3: Pressure Hose Lengths OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 125 of 146 GF-143 Phone: 800-526-0288 07/13/15...

  • Page 126: Burner / Heat Exchanger Cleaning Procedure

    Example: At 104 °F (40°C), the nominal resistance is 5,363 Ohm. At 194 °F (90°C), the nominal resistance is 920 Ohm Page 126 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288...

  • Page 127: Unit Disassembly

    Figure 7-5: Remove Screws at Edges and Remove Side and Rear Panels (Step 3) Figure 7-6: Remove Panels (Step 3) Figure 7-7: Remove Flue Assembly (Step 4) OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 127 of 146 GF-143 Phone: 800-526-0288...
  • Page 128 Retention Spring Clip (Left & Right) Figure 7-9: Unlatch Spring Clips from Left and Right Side of Manifold (Step 5) Page 128 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 129 7. On each gas valve, unscrew the Gas Valve Connector with a Phillips head screwdriver. Remove connector (Figure 7-11) from the side of each gas valve. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 129 of 146 GF-143...
  • Page 130 These are the screws that are located at each end of each burner plate (2 per plate). Figure 7-13: Removal of Burner Plate Hardware (Steps 9, 10, 11) Page 130 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15...
  • Page 131 11. Refer to Figure 7-15 and remove the two bolts (white arrows) at each end of the gas collection tube that mount it to the boiler chassis. Figure 7-15: Uninstall Gas Collector Tube from Boiler Chassis (Step 12) OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 131 of 146 GF-143 Phone: 800-526-0288...
  • Page 132 4mm open hex wrench, the screw is extended into the hole. (See Figures 7-17 & 7-18). Figure 7-17: Location of Burner Assembly Lifting Screw (Step 14) Page 132 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 133 (Figure 7-22) at the left and right sides in order to hold up the burner assembly. Figure 7-20: Lifting Burner Assembly from Front (Step 15) OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 133 of 146 GF-143 Phone: 800-526-0288...

  • Page 134: Cleaning The Burner Module And Combustion Chamber

    Follow the instructions to clean the burner modules. Cleaning the Burner Modules Figure 7-23: Burner Modules Exposed for Cleaning Page 134 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 135 7. Once the washing of the aluminum sections is finished, make sure the condensate drain and trap are free of obstructions. Clean them if necessary. 8. Inspect the flue exhaust section, including the exhaust piping. OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 135 of 146 GF-143 Phone: 800-526-0288...

  • Page 136: Reassembly Of The Burner Modules

    4. Perform the combustion gas analysis and check all parameters (section 3.33). 5. Make sure that all the pressure test nipples, previously opened, have been closed. Page 136 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15...

  • Page 137: Maintenance Kit Part Number

    7.14 Maintenance Kit Part Number To order the MODULEX annual and 24-Month Fireside Inspection maintenance kits, contact AERCO International and use P/N 58086-TAB, replacing the “TAB” with the appropriate suffix as determined in Tables 7-3 and 7-4. Annual Maintenance Kits contain a flame detector and igniter, while the 24-Month Fireside Inspection Kits contain flame detector, igniter, and burner gaskets.

  • Page 138: Accessory Kit Part Numbers

    6” WORK DRIVE HOSE CLAMP   93087 1-1/2 X 1-1/4 PVC RED.CLAMP   64105 FLOW SWITCH   Page 138 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

  • Page 139: Chapter 8: Spare Parts Drawing And Lists

    MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual CHAPTER 8: SPARE PARTS DRAWING AND LISTS OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 139 of 146 GF-143 Phone: 800-526-0288...
  • Page 140 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual (This page intentionally blank) Page 140 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 141 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 141 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 142 MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS Installation, Operation & Maintenance Manual (This page intentionally Blank) Page 142 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 143 Front/Rear Panel, EXT 641 & EXT 802 95213325 Front/Rear Panel, EXT 962 & EXT 1123 95000930 Burner Chamber, End Section LH OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 143 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 144 External Sensor E8 - System Manager 95262209 Mixed Flow Sensor E8 - System Manager 95262211 Tank Sensor E8 - System Manager Page 144 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...
  • Page 145 Return Header, 5 Elements, EXT 802 95372103 Return Header, 6 Elements, EXT 962 95372104 Return Header, 7 Elements, EXT 1123 OMM-0087_0F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 145 of 146 GF-143 Phone: 800-526-0288 07/13/15...
  • Page 146 AERCO web site. Clarified maintenance schedule, added information on heat exchanger cleaning to Chapter 7. © AERCO International, Inc., 2015 Page 146 of 146 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0087_0F 07/13/15 Phone: 800-526-0288 GF-143...

This manual is also suitable for:

Modulex ext 481Modulex ext 802Modulex ext 1123Modulex ext 641Modulex ext 962

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