Aerco Modulex MLX-303 User Manual
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Aerco Modulex MLX-303 User Manual

Modulex mlx series
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See also: Operation & Installation Manual
Modulating, Condensing,
Hot Water Boiler Models:
• MLX-303
• MLX-454
• MLX-606
• MLX-757
• MLX-909
• MLX-1060
Other manuals for this product include:
• GF-115-C
MLX E8 Controller/BCM Manual
• GF-115-E
MLX Electrical Power Guide
• GF-115-P-H MLX Piping Guide
• GF-115-V
MLX Venting Guide
• GF-115-G
MLX Gas Supply Guide
Revised: 10/03/2012
MC2: 10/03/12
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
Modulex MLX Series
Gas Fired Boiler
USER MANUAL
Installation, Operation, and Maintenance
Modulex MLX Series Boiler
GF-115-H
TAG-0083_0B
Page 1 of 90

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Summary of Contents for Aerco Modulex MLX-303

  • Page 1 MLX Electrical Power Guide • GF-115-P-H MLX Piping Guide • GF-115-V MLX Venting Guide • GF-115-G MLX Gas Supply Guide Revised: 10/03/2012 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 1 of 90...
  • 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. AERCO International is not liable for errors appearing in this manual.

  • Page 3: Table Of Contents

    Notes On Condensate Drain ................... 28 Gas Mains and Connections ................... 28 CHAPTER 6: ELECTRICAL ....................29 Electrical Connections....................29 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 3 of 90...
  • Page 4 Replacing the Spark Igniters and Flame Detectors ..........50 9.2.5 Testing the Flame Detection Circuitry ..............50 Fireside Inspection Instructions ..................50 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 4 of 90...
  • Page 5 Water Treatment Certification ..................87 13.6 Water Treatment Analysis and Scheduling ..............87 13.7 Hydronic Water Testing and Treatment Resources ........... 88 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 5 of 90...
  • Page 6 GF-115-H Modulex MLX Series Gas Fired Boiler System OMM-0083_0B Operation and Maintenance Manual (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 6 of 90...

  • Page 7: Chapter 1: Safety Precautions

    NOTE Carefully read the warranty conditions and clauses on the warranty certificate attached to the boiler. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 7 of 90...

  • Page 8: Important - For Massachusetts Installations

    248 CMR 5.08(2)(a)1 through 4. (Continued on Next Page) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 8 of 90...
  • Page 9 [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 9 of 90...
  • Page 10 GF-115-H Modulex MLX Series Gas Fired Boiler System OMM-0083_0B Operation and Maintenance Manual (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 10 of 90...

  • Page 11: Chapter 2: General Description

    7.5% to 100% for the Modulex 303 and 2.2% to 100% for the Modulex 1060. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 12: Code And Standards Approvals

    Installation of the vent behind the unit will require accommodations for the easy removal of the venting in order to provide service that requires removal of the rear panel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 12 of 90...

  • Page 13: Dimensions And Weights

    10.55” (268 mm) Ø 13.78” (350 mm) 13.58 (345 mm) Figure 2-1: Modulex Dimensions and Weights (Diagram 1 of 2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 13 of 90...
  • Page 14 9.45 (240) 9.45 (240) CONDENSATE DRAIN DIA. 1.57 (40) 1.57 (40) 1.57 (40) 1.57 (40) 1.57 (40) 1.57 (40) IN (MM) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 14 of 90...

  • Page 15: Technical Data

    Min. Water Flow (GPM) Max. Water Flow (GPM) Water Pressure Drop @ Max. Flow (Ft. of 10.0 10.1 10.2 Head) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 15 of 90...

  • Page 16: Modulex Main Components - Side View

    DRAIN TRAP COLLECTION TRAY MANIFOLD FILLING-UP ELBOW 5.9" [150 mm] 4" [100 mm] 1" [25 mm] Figure 2-2: Modulex Main Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 16 of 90...

  • Page 17: Boiler Freeze Protection

    If glycol is used as antifreeze in the boiler, a back flow preventer must be installed in the make-up/fill line. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 17 of 90...
  • Page 18 Modulex MLX Series Gas Fired Boiler System Chap 2: General OMM-0083_0B Operation and Maintenance Manual Description (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 18 of 90...

  • Page 19: Chapter 3: Installation

    The packing elements (cardboard box, straps, plastic bags, etc…) should be kept away from small children as these pose a risk of suffocation and/or choking. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 19 of 90...
  • Page 20 See the packing list shipped in this manual package for a complete listing of accessories. See paragraph 5.4 for more information about the CSD-1 kits. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 21: Boiler Location

    The minimum clearance dimensions for service access, required by AERCO, are listed below (Figure 3-2) and on the boiler Data Plate (Figure 3-8). Local building codes may require more clearance and take precedence.

  • Page 22: Boiler Connections

    See Piping Application Guide GF-115-P-H for full instructions for changing from right-hand to left-hand sides. Figure 3-3: Boiler Connections AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 22 of 90...

  • Page 23: Data Plate

    3. FOR INSTALLATION ON COMBUSTIBLE FLOORS Minimum relief valve capacity BTU/HR "BLUE FLAME" "BLUE STAR" Figure 3-4: Sample Data Plate AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 23 of 90...
  • Page 24 (17.4 mbar) (17.4 mbar) (17.4 mbar) PRESSURE * NOTE: Normal manifold gas pressure measured at downstream port of gas valve. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 24 of 90...

  • Page 25: Chapter 4: General Information For Venting

    Installation And Sizing The AERCO Venting Guide, GF-115-V, must be consulted before any flue gas vent or air inlet piping is designed or installed. Certified venting materials specified in GF-115-V must be used for safety and code compliance.

  • Page 26: Existing Boiler Removal From Common Venting System

    Part 11 of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA B149, Installation Codes. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 27: Chapter 5: Piping

    • AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 27 of 90...

  • Page 28: System Filling And Draining

    Prior to operation, the complete gas train must be leak tested using a non- corrosive soap. For gas pipe sizing and additional details, see GF-115-P-H. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 29: Chapter 6: Electrical

    Prior to connecting external AC power to the Modulex boiler, the CSD-1 Supply Manifold must be installed using the procedures described in Piping Guide GF-115-P-H. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 29 of 90...
  • Page 30 National Electrical code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1, Electrical Code. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 30 of 90...

  • Page 31: Dhw (Domestic Hot Water) Storage Tank

    DHW NTC sensor or by a DHW thermostat. Figure 6-3: Electrical Pump Connection of a DHW Tank Loading Pump AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 31 of 90...
  • Page 32 Modulex MLX Series Gas Fired Boiler System Chap 6: OMM-0083_0B Operation and Maintenance Manual Electrical (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 32 of 90...

  • Page 33: Chapter 7: Boiler Operation

    10 seconds. Actuating the air pressure switch toggles it from normally open (NO) to normally closed (NC). This energizes the ignition AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 34: Modes Of Operation

    Ensure that all operating controls, menu settings, and limits have been properly set in accordance with Section 3 of the Modulex E8 Controller Operation & Wiring Guide GF-115-C (Controls). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 35: Tools & Instruments Required For Combustion Calibration

    5. Attach one end of the length of plastic tubing to the gas pressure tap. Attach the other end to the W.C. manometer (or gauge). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 36: Preparing The Flue For Use With The Combustion Analyser

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...
  • Page 37 This manometer will be used to measure gas valve outlet pressure for each stage during the Combustion Calibration procedure in Paragraph 7.5.5 on next page. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 38: Combustion Calibration

    Figure 7-2: Heat Mode Symbols 7.5.5 Combustion Calibration. The Modulex boiler is combustion calibrated prior to shipment from the factory. However, AERCO recommends that the following calibration and adjustments be performed due to possible differences in altitude, BTU content, installed gas supply piping and regulators used.
  • Page 39 18. Insert the combustion analyser probe into the 3/8” hole in the flue. Allow enough time for the combustion analyser to settle. (Continued) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 39 of 90...

  • Page 40: Unit Reassembly

    5. Cover the hole drilled in the PVC flue pipe with foil tape. Replace the top and side panels on the Modulex Boiler. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 40 of 90...

  • Page 41: Chapter 8: Safety Device Testing

    7. Monitor the display to ensure no other Fault Codes appear. 8. Resume normal operation after all faults have been cleared. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 41 of 90...

  • Page 42: Low Gas Pressure Fault Test

    Upon test completion, close the test port and remove the manometer. Valve Inlet Gas Supply CLOSE OPEN Figure 8-1: Gas Pressure Tap Location and Orientation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 42 of 90...

  • Page 43: Low Water Level Fault Test

    Lock Out LED (Red) Test Button Low Water LED (Amber) Reset Button Figure 8-2: Low Water Cut-Off Switch and Controls AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 43 of 90...

  • Page 44: Water Temperature Fault Test

    5. Press the red button on the over-temperature switch, and power will be restored to the unit. There will be no fault code displayed on the E8 controller. Set Temperature Reset Button Figure 8-3: Over-Temperature Switch and Controls AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 44 of 90...

  • Page 45: Flame Fault Tests

    View Port Detector Terminal Cable Igniter Cable MLX Rear with Panel Removed Figure 8-4: Flame Detector and Ignition Component Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 45 of 90...

  • Page 46: Safety Pressure Relief Valve Test

    The ASME Boiler and Pressure Vessel Code (BPVC) is an American Society of Mechanical Engineers (ASME) standard that provides rules design, fabrication, inspection of boilers and pressure vessels. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 46 of 90...

  • Page 47: Chapter 9: Maintenance

    TAG-0083_0B CHAPTER 9: MAINTENANCE Modulex Preventative Maintenance Kits To perform the necessary maintenance tasks described in this section, AERCO offers a line of maintenance kits for your Modulex boiler as described below. 9.1.1 Annual Maintenance Kit Each Annual Maintenance Kit contains a flame detector, spark igniter, and associated gaskets. A detailed description of the Annual Maintenance tasks can be found in Sub-section 9.2.

  • Page 48: Annual Maintenance Instructions

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 48 of 90...
  • Page 49 View Port Flame & Terminal Detector Igniter Cable MLX Rear with Panel Removed Flame Detector Figure 9-2: Electrical Connection Locations Screws AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 49 of 90...

  • Page 50: Replacing The Spark Igniters And Flame Detectors

    A Fireside Inspection Kit may be purchased from AERCO. A list of kit part numbers and models are in Table 9-1 in Sub-section 9.1. Before going through the Fireside Inspection, it is advised to check the CO percentage at the boiler input.

  • Page 51: Unit Disassembly For A Fireside Inspection

    (depends on which side it was originally installed). Remove the screw securing the baffle (P) and lower the baffle onto the tray bottom. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...
  • Page 52 Cover Figure 9-3: Remove Fan Assembly Cover Figure 9-4: Remove Fan Assembly Cover Figure 9-5: Remove Plastic Bolt Covers (C) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 52 of 90...
  • Page 53 Ends of Burner Manifold Figure 9-6: Removing Intake Filters Figure 9-7: Removing End Plates Figure 9-8: Reposition Endplates to Offset AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 53 of 90...
  • Page 54 Figure 9-9: Fan Assembly (L), Support Rod (I) and Holes (M) Figure 9-10: Accessing Condensate Tray Burner Modules Figure 9-11: Fan Assembly Lifted to Access Burner Modules AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 54 of 90...

  • Page 55: Removing The Burner Modules

    Figure 9-13). Take care to avoid deforming the burner module as it is removed. Figure 9-12: Remove Ground Tabs NOTE Old style gaskets are orange. Newer style gaskets are grey. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 55 of 90...

  • Page 56: Maintenance Of Burner Modules And Combustion Chamber

    Clean out the condensate tray of any scale or ash collected from cleaning the combustion chamber. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 57: Reassembly After Burner Mainentance

    6. Install the exhaust connector using a new exhaust connector gasket (P/N 95250632). 7. Connect the flue starter section to the flue connector and secure it using the clamp removed in Step AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...
  • Page 58 M5-20 Bolt (4) & 5x15mm OD washers Exhaust Connect Exhaust Connector Flue Collector Flue Collector Gasket Figure 9-14: Flue Collector Parts and Assembly AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 58 of 90...

  • Page 59: Burner Section Replacement Instructions

    Condensate Tray Burner Sections Metal Rods (Middle) Connecting Sections (4 each) Figure 9-15: Covers Removed Relevant to Burner Section Replacement AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 59 of 90...

  • Page 60: Disassembly For Burner Section Replacement

    9. Using a screwdriver, or appropriate hardened tool, leverage the affected sections apart while cutting the silicone seal between them. Flow Header (upper) Return Header (lower) Figure 9-17: Header Disassembly AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 60 of 90...

  • Page 61: Replacement Of Burner Sections

    (4 ea, 2 per side) Nut and Washer instruction). (4 places) Figure 9-19: Separating the Aluminum End and Middle Sections AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 61 of 90...

  • Page 62: Replacing The Condensate Tray Top Gasket

    4. Lower the aluminum Burner Assembly back onto condensate tray. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...
  • Page 63 NEW one (Figure 8-23). Four Piece Gasket Figure 9-21: Condensate Tray with Top Gasket AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 63 of 90...

  • Page 64: Re-Assembly After Burner Section Replacement

    Modulex boiler to service use, perform the Initial Startup Procedure specified in Sub-section 7.5 of this manual (GF-115-H). Perform the combustion analysis and check the combustion parameters per Sub- section 7.5.5). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 64 of 90...

  • Page 65: Chapter 10: Trouble Shooting Guide

    NOTE If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 65 of 90...

  • Page 66: Corrective Action

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 66 of 90...
  • Page 67 10. If there is no spark, check for 120VAC at the primary side Screw not installed to the ignition transformer during the ignition cycle. or loose. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 67 of 90...
  • Page 68 2. Check resistance of sensor to determine if it is within specification. Outlet wiring. temperature Ensure that the correct sensor is installed. 2. Defective Sensor. sensor failure (SR) 3. Incorrect Sensor. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 68 of 90...
  • Page 69 37.4ºF freezing 2. Check return sensor and replace if damaged. (3ºC) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 69 of 90...
  • Page 70 Remove the blocked-air inlet switch and inspect for signs of blockage, clean or replace as Defective Blower proof necessary. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 70 of 90...
  • Page 71 3. Try connecting blower to connector from other blower known to function properly. Replace blower if blower still does not function properly. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 71 of 90...
  • Page 72 1. Repair or replace power source. Electrical power damage. 2. Reseat connections. supply voltage < 2. Check for loose power 108 VAC wire connections AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 72 of 90...
  • Page 73 2. Defective Sensor. specification. sensor for Heating 3. Incorrect Sensor. 3. Ensure that the correct sensor is installed. Circuit 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 73 of 90...
  • Page 74 2. Check resistance of sensor to determine if it is within temperature sensor 2. Defective Sensor. specification. for HC2 3. Incorrect Sensor. 3. Ensure that the correct sensor is installed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 74 of 90...
  • Page 75 Check with Desmond E202: Same as E201 BMM Board failure. Communication BMM Board harness Error Module 2 failure Check with Desmond AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 75 of 90...
  • Page 76 CORRECTIVE ACTION INDICATION CAUSES E81: E8: EEPROM error. The invalid value has been replaced with the default value (Check parameter values) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 76 of 90...

  • Page 77: Chapter 11: Temperature Sensor Resistance Chart

    For Example: At 77°F (25°C), the resistance is 5000 Ohms At 194°F (90°C), the resistance is 458 Ohms AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 77 of 90...

  • Page 78: Chapter 12: Modulex Parts Drawing And List

    GF-115-H TAG-0083_0B CHAPTER 12: MODULEX PARTS DRAWING AND LIST Modulex MLX Series Exploded Parts Drawing (Page 1 of 4) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 78 of 90...
  • Page 79 Modulex MLX Series Gas Fired Boiler System Chap 12: OMM-0083_0B Operation and Maintenance Manual Part Drawings Modulex MLX Series Parts List (Page 2 of 4) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 79 of 90...
  • Page 80 Modulex MLX Series Gas Fired Boiler System Chap 12: OMM-0083_0B Operation and Maintenance Manual Part Drawings Modulex MLX Series Parts List (Page 3 of 4) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 80 of 90...
  • Page 81 Modulex MLX Series Gas Fired Boiler System Chap 12: OMM-0083_0B Operation and Maintenance Manual Part Drawings Modulex MLX Series Parts List (Page 4 of 4) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 81 of 90...
  • Page 82 GF-115-H Modulex MLX Series Gas Fired Boiler System Chap 12: OMM-0083_0B Operation and Maintenance Manual Part Drawings AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 82 of 90...

  • Page 83: Chapter 13: Boiler Water Quality And Maintenance

    MAINTENANCE IMPORTANT! • AERCO requires that the boiler loop to be de-coupled from the system loop. This can be achieved by one of the following: Employing primary-secondary piping. Installation of a hydraulic separator between the boiler and the system loop.

  • Page 84: Modulex Boiler Water Chemistry

    9.5, whereas the pH must be within 6.5 and 8.0 for use with aluminum. There are several AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 85: Water Treatment Certification

    • Total Solids - preferably less than 500 ppm, but a requirement of less than 1000 ppm AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 85 of 90...

  • Page 86: System Flushing, Treatment, And Cleansing

    275 gallon tote – part number 99156-3 When cleaning, treating, and maintaining, a heating system, consult a qualified professional. following are AERCO’s tips/guidelines for cleaning a heating system – these do NOT take precedence over detailed instructions from qualified professionals.

  • Page 87: Water Quality Maintenance And Boiler Warranty

    However, for boilers operating year round, this analysis should be made at least twice a year. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12...

  • Page 88: Hydronic Water Testing And Treatment Resources

    Toll Free: (800) 543-5975 Toll Free (800) 289-3797 Fax: (417) 862-6410 Fax: (814) 944-8094 Email: peggy@rhomarwater.com Email: www.rhomarwater.com fernox_americas@cooksonelectronics.com www.fernox.com AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 88 of 90...
  • Page 89 GF-115-H Modulex MLX Series Gas Fired Boiler System OMM-0083_0B Operation and Maintenance Manual NOTES: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 89 of 90...

  • Page 90: Mc2: 10/03/12 Aerco International, Inc. • 100 Oritani Dr. • Blauvelt, Ny 10913 • Ph: 800-526-0288

    GF-115-H Modulex MLX Series Gas Fired Boiler System OMM-0083_0B Operation and Maintenance Manual © AERCO International, Inc., 2011 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 MC2: 10/03/12 Page 90 of 90...

This manual is also suitable for:

Modulex mlx-454Modulex mlx-606Modulex mlx-757Modulex mlx-909Modulex mlx-1060

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