Watts AERCO Modulex EXT Series Technical Application Manual
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Watts AERCO Modulex EXT Series Technical Application Manual

Modulating and condensing boilers
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Technical Application Guide
Modulex EXT Series
Piping Application Guide
Modulating and Condensing Boilers
Applies to the following
Modulex EXT Series models:
• MLX EXT 450 2S
• MLX EXT 600 2S
• MLX EXT 800 2S
• MLX EXT 1100 2S
• MLX EXT 1500 2S
• MLX EXT 2300 2S
• MLX EXT 2600 2S
• MLX EXT 3000 2S
Disclaimer
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 or for incidental or consequential
damages occurring in connection with the furnishing, performance, or use of
these materials.
• 10/7/2021
TAG-0099
Heating and Hot Water Solutions
AERCO International, Inc. • 100 Oritani Drive • Blauvelt, NY 10913
USA: T: (845) 580-8000 • Toll Free: (800) 526-0288 • AERCO.com
Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST
© 2021 AERCO

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Summary of Contents for Watts AERCO Modulex EXT Series

  • Page 1 Technical Application Guide Modulex EXT Series Piping Application Guide Modulating and Condensing Boilers Applies to the following Modulex EXT Series models: • MLX EXT 450 2S • MLX EXT 600 2S • MLX EXT 800 2S • MLX EXT 1100 2S •...

  • Page 2: Table Of Contents

    Modulex EXT Series Piping Application Guide MANDATORY REQUIREMENTS Contents SECTION 1: MANDATORY REQUIREMENTS 3 SECTION 2: BOILER QUALITY AND MAINTENANCE 2.1. BOILER WATER CHEMISTRY ....................5 2.1.1. Reaction of Metals to Water Chemistry ................. 5 2.1.2. Scale and Corrosion ...................... 5 2.1.3.

  • Page 3: Mandatory Requirements

    Modulex EXT Series Piping Application Guide MANDATORY REQUIREMENTS SECTION 1: MANDATORY REQUIREMENTS The following actions are mandatory to ensure proper piping and drainage of the Modulex EXT system. CAUTION! Local codes and authorities must be consulted prior to installation. • AERCO requires that the boiler loop to be de-coupled from the system loop.
  • Page 4 Modulex EXT Series Piping Application Guide MANDATORY REQUIREMENTS RELIEF VALVE DISCHARGE PIPING RELIEF VALVE PIPED TO POINT OF DISCHARGE Figure 1: Relief Valve Point of Discharge Example AERCO International, Inc. • 100 Oritani Dr. Page 4 of 37 Blauvelt, NY 10913 TAG-0099 Phone: 800-526-0288 10.07.2010...

  • Page 5: Boiler Quality And Maintenance

    Modulex EXT Series Piping Application Guide BOILER QUALITY AND MAINTENANCE SECTION 2: BOILER QUALITY AND MAINTENANCE 2.1. BOILER WATER CHEMISTRY 2.1.1. Reaction of Metals to Water Chemistry A neutral water pH must be maintained because, although the aluminum alloys used in the construction of Modulex EXT boilers resist acidic conditions, they are still vulnerable to highly alkaline environments (pH of 9.0 and above).

  • Page 6: Testing And Maintenance Of Water Quality

    Modulex EXT Series Piping Application Guide BOILER QUALITY AND MAINTENANCE cause harm to the boiler, pumps, piping, and other components of the hydronic boiler system. 2.2. TESTING AND MAINTENANCE OF WATER QUALITY Water in the installation should be checked, monitored, and treated for the following: •...

  • Page 7: System Flushing, Treatment, And Cleansing

    Modulex EXT Series Piping Application Guide BOILER QUALITY AND MAINTENANCE 2.3. SYSTEM FLUSHING, TREATMENT, AND CLEANSING Note that prior to cleaning the heating system, the boiler MUST be isolated from the piping to prevent infusion of containments, including sludge, into the boiler. Section 2.3 provides recommendations for flushing, cleaning, and treating the water used in the Modulex EXT boiler system.

  • Page 8: Water Quality Maintenance And Boiler Warranty

    Modulex EXT Series Piping Application Guide BOILER QUALITY AND MAINTENANCE • A reliable test to determine if a system is clean is if the Total Dissolved Solids (TDS) of the water being drained is within 10% of the make-up water TDS. This indicates that sufficient contamination has been flushed from the system.
  • Page 9 Modulex EXT Series Piping Application Guide BOILER QUALITY AND MAINTENANCE Fernox H-O-H Water Technology, Inc. Hydronic Agencies Ltd. Steve Sadowski Sean Leonard Greendale, WI Edmonton, AB, CANADA Phone: (414) 421-2070, Phone: (780) 452-8661 Toll Free: (800) 944-9746 Toll Free: (877) FERNOX4U Fax: (414) 421-2077 (877-337-6694) ssadowski@hohwatertechnology.com...

  • Page 10: Boiler Loop Design Guidelines

    Modulex EXT Series Piping Application Guide BOILER LOOP DESIGN GUIDELINES SECTION 3: BOILER LOOP DESIGN GUIDELINES For proper and safe operation of the water tube Modulex boiler, the primary (boiler) loop piping and the associated fittings and accessories must be designed/selected as discussed in the following sections. Table 1 shows the required minimum flow rates at various system designed temperature rises.
  • Page 11 Modulex EXT Series Piping Application Guide BOILER LOOP DESIGN GUIDELINES ∆ TABLE 1.2: Light Commercial: 40 F T Water Flow 40°F ΔT Water Flow EXT 450 2S EXT 600 2S EXT 800 2S EXT 1100 2S Water Flow @ 40°F ΔT G = Gallons per Min Water Pressure Drop (Ft.

  • Page 12: Flow Rate & Pressure Drops: Models Ext 1500 2S, 2300 2S, 2600 2S & 3000 2S

    Modulex EXT Series Piping Application Guide BOILER LOOP DESIGN GUIDELINES ∆ TABLE 1.4: Light Commercial: 20 F T Water Flow 20°F ΔT Water Flow EXT 450 2S EXT 600 2S EXT 800 2S EXT 1100 2S Water Flow (GPM) @ Min. ΔT of 20°F Water Pressure Drop (Ft.
  • Page 13 Modulex EXT Series Piping Application Guide BOILER LOOP DESIGN GUIDELINES ∆ TABLE 2.2: Commercial: 40 F T Water Flow 40°F ΔT Water Flow EXT 1500 2S EXT 2300 2S EXT 2600 2S EXT 3000 2S Water Flow (GPM) @ Max. ΔT of 40°F Water Pressure Drop (Ft.
  • Page 14 Modulex EXT Series Piping Application Guide BOILER LOOP DESIGN GUIDELINES ∆ TABLE 2.4: Commercial: 25 F T Water Flow 25°F ΔT Water Flow EXT 1500 2S EXT 2300 2S EXT 2600 2S EXT 3000 2S Water Flow (GPM) @ Max. ΔT of 25°F Water Pressure Drop (Ft.

  • Page 15: Primary Pump

    Modulex EXT Series Piping Application Guide BOILER LOOP DESIGN GUIDELINES 3.3. PRIMARY PUMP The primary pump shall have a discharge pressure able to assure the designed water flow rate, taking into account pressure drop losses as shown in Figure 2. When selecting a pump, take into account the pressure drop across the boiler, fittings, accessories and piping.

  • Page 16: Strainers

    Modulex EXT Series Piping Application Guide BOILER LOOP DESIGN GUIDELINES Figure 3: Electrical Connection of Primary Pump WARNING! There is 120 VAC between terminals Y4-1 and Y4-2 whenever the boiler is ON. 3.4. STRAINERS AERCO requires the installation of a Y strainer to keep dirt out of the system and boiler. The strainer should be installed in the return piping with isolation valves to allow for cleaning as necessary.

  • Page 17: Air Venting Of The Heating System

    Modulex EXT Series Piping Application Guide BOILER LOOP DESIGN GUIDELINES 3.6. AIR VENTING OF THE HEATING SYSTEM The Modulex boiler comes standard with an automatic air vent inside the boiler (see Figure 4a and 4b). This vent is for the boiler only and not the entire heating system. An effective air vent for air removal for the entire heating system must be installed in the highest point of the system piping.
  • Page 18 Modulex EXT Series Piping Application Guide BOILER LOOP DESIGN GUIDELINES Figure 4b: MODULEX EXT Main Components (Left Side View) (EXT 1500 2S - 3000 2S) AERCO International, Inc. • 100 Oritani Dr. Page 18 of 37 Blauvelt, NY 10913 TAG-0099 Phone: 800-526-0288 10.07.2010...

  • Page 19: Csd-1 Manifold Assembly (Supplied)

    Modulex EXT Series Piping Application Guide CSD-1 MANIFOLD ASSEMBLY (SUPPLIED) SECTION 4: CSD-1 MANIFOLD ASSEMBLY (SUPPLIED) The installation of a flow switch, pressure/temperature gauge, and an ASME compliant safety pressure relief valve designed for the boiler output capacity is required. These major components are supplied with the boiler and must be assembled and wired when installing the boiler at the site.

  • Page 20: Installing The Pressure Relief Valve And Other Components

    Modulex EXT Series Piping Application Guide CSD-1 MANIFOLD ASSEMBLY (SUPPLIED) The pressure relief valve and all other manifold components are shown in Figures 5 and 6. 3/4” Pressure Flow Switch Relief Valve Pressure/Temperature Gauge Figure 6: Manifold Assembly and Components for EXT 450 2S, 600 2S, 800 2S & 1100 2S Flow Switch 1-1/2”...
  • Page 21 Modulex EXT Series Piping Application Guide CSD-1 MANIFOLD ASSEMBLY (SUPPLIED) 3. Connect the following components to the tapped holes in the manifold assembly (Fig. 6 & 7): • 3/4” Pressure Relief Valve • Flow Switch • Pressure/Temperature Gauge NOTE: Ensure that the flow switch is installed with the “flow” arrow pointing in the direction of the flow. 4.

  • Page 22: Connecting Supply & Return Piping

    Modulex EXT Series Piping Application Guide CONNECTING SUPPLY & RETURN PIPING SECTION 5: CONNECTING SUPPLY & RETURN PIPING 5.1. BOILER CONNECTIONS Upon delivery, the various models of Modulex EXT boilers are configured with connections for water, gas, air intake, and flue exhaust. Note that references to right-hand or left-hand orientation refer to the right- hand or left-hand side when viewed facing the front of the boiler.

  • Page 23: Modulex Commercial Models Ext 1500 2S, 2300 2S, 2600 2S & 3000 2S

    Modulex EXT Series Piping Application Guide CONNECTING SUPPLY & RETURN PIPING FRONT VIEW LEFT-SIDE CONNECTIONS RIGHT-HAND CONNECTIONS AIR INLET WATER FLOW WATER FLOW GAS SUPPLY GAS SUPPLY WATER RETURN WATER RETURN EXHAUST OUTLET EXHAUST (DELIVERY OUTLET POSITION) RIGHT-SIDE VIEW LEFT-SIDE VIEW FOR EXT MODELS: EXHAUST •...

  • Page 24: Reversing Gas Manifold Connections (Ext 450 2S - 1100 2S)

    Modulex EXT Series Piping Application Guide CONNECTING SUPPLY & RETURN PIPING 5.4.3. Reversing Gas Manifold Connections (EXT 450 2S - 1100 2S) To move the gas connection from the RIGHT-HAND (standard) side to the LEFT-HAND side, swap the end plate and the gas supply connector screwed onto the gas manifold ends as shown. Ensure that the gaskets for ALL connections are reversed along with the connectors themselves.
  • Page 25 Modulex EXT Series Piping Application Guide CONNECTING SUPPLY & RETURN PIPING Refer to Figure 10 and reverse the connectors and end caps on Supply, Flow, and Return pipes. Ensure that all gaskets are also reversed. Reverse positions of Boiler Sensor KF and Automatic Move end caps (and Air Vent.

  • Page 26: Reversing Flow & Return Temperature Sensors

    Modulex EXT Series Piping Application Guide CONNECTING SUPPLY & RETURN PIPING 5.4.5. Reversing Flow & Return Temperature Sensors One sensor is located on top of the lower Return pipe railing, while the other one is located under the upper Flow pipe railing. Move these two sensors to other end of the Flow/Return pipes. C.H.

  • Page 27: System Filling And Draining

    Modulex EXT Series Piping Application Guide SYSTEM FILLING AND DRAINING NOTE: When reversing hydraulic and gas pipe connections, you must close up the chassis openings vacated after the change. See Figure 13. Figure 13: Caps and Plugs Used for Closing Up Vacated Gas and Hydraulic Connection Openings SECTION 6: SYSTEM FILLING AND DRAINING The boiler is equipped with its own drain (see Figures 4a and 4b for the drain position).

  • Page 28: Condensate Drain

    Modulex EXT Series Piping Application Guide CONDENSATE DRAIN SECTION 7: CONDENSATE DRAIN To maintain proper flow of condensate, the drain pipe must have a slope toward the drain of at least 3/8 in./ft. (30 mm/m). The liquid column inside the condensate siphon needs to be filled with water after installation.
  • Page 29 Modulex EXT Series Piping Application Guide CONDENSATE DRAIN ITEM # QTY. DESCRIPTION DN 40 PP Cap 95310512 DN 40 PP Elbow 95310513 DN 40 PP Tee 1 or 2 * 95310515 DN 40 PP Straight Pipe 1 ¼” PVC Joining Clamp 93087 (Optional, only if connecting to PVC instead of PP, not shown)

  • Page 30: Piping Diagrams

    Modulex EXT Series Piping Application Guide PIPING DIAGRAMS SECTION 8: PIPING DIAGRAMS Figure 16: Modulex EXT Single Boiler Installation AERCO International, Inc. • 100 Oritani Dr. Page 30 of 37 Blauvelt, NY 10913 TAG-0099 Phone: 800-526-0288 10.07.2010...
  • Page 31 Modulex EXT Series Piping Application Guide PIPING DIAGRAMS Figure 17: Modulex EXT Single Boiler Installation with DHW Installed AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 TAG-0099 Page 31 of 37 Phone: 800-526-0288 10.07.2021...
  • Page 32 Modulex EXT Series Piping Application Guide PIPING DIAGRAMS Figure 18: Modulex EXT Single Boiler Installation with Hydraulic Separator Installed AERCO International, Inc. • 100 Oritani Dr. Page 32 of 37 Blauvelt, NY 10913 TAG-0099 Phone: 800-526-0288 10.07.2010...
  • Page 33 Modulex EXT Series Piping Application Guide PIPING DIAGRAMS Figure 19: Modulex EXT Single Boiler Installation with Hydraulic Separator and DWH Installed AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 TAG-0099 Page 33 of 37 Phone: 800-526-0288 10.07.2021...
  • Page 34 Modulex EXT Series Piping Application Guide PIPING DIAGRAMS Figure 20: Modulex EXT Multiple Boiler Installation AERCO International, Inc. • 100 Oritani Dr. Page 34 of 37 Blauvelt, NY 10913 TAG-0099 Phone: 800-526-0288 10.07.2010...
  • Page 35 Modulex EXT Series Piping Application Guide PIPING DIAGRAMS Figure 21: Modulex EXT Multiple Boiler Installation with DHW Installed AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 TAG-0099 Page 35 of 37 Phone: 800-526-0288 10.07.2021...
  • Page 36 Modulex EXT Series Piping Application Guide PIPING DIAGRAMS Figure 22: Modulex EXT Multiple Boiler Installation with Hydraulic Separator Installed AERCO International, Inc. • 100 Oritani Dr. Page 36 of 37 Blauvelt, NY 10913 TAG-0099 Phone: 800-526-0288 10.07.2010...
  • Page 37 Modulex EXT Series Piping Application Guide PIPING DIAGRAMS Figure 23: Modulex EXT Multiple Boiler Installation with Hydraulic Separator and DHW Installed AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 TAG-0099 Page 37 of 37 Phone: 800-526-0288 10.07.2021...

This manual is also suitable for:

Aerco mlx ext 450 2sAerco mlx ext 600 2sAerco mlx ext 800 2sAerco mlx ext 1100 2sAerco mlx ext 1500 2sAerco mlx ext 2300 2s ... Show all

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