Watts AERCO Modulex EXT Commercial Series User Manual
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Watts AERCO Modulex EXT Commercial Series User Manual

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Modulex EXT Commercial Series Boilers User Manual
INSTALLATION, OPERATION & MAINTENANCE
Modulating and Condensing Boilers
Latest Update: 09/15/2017
OMM-0095_0H
GF-139
USER MANUAL
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
APPLIES TO MODELS:
• MLX EXT 1530 / MLX EXT 1500
• MLX EXT 1912
• MLX EXT 2295 / MLX EXT 2300
• MLX EXT 2677 / MLX EXT 2600
• MLX EXT 3060 / MLX EXT 3000
GF-139
Page 1 of 144
09/15/2017

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  • Page 1 GF-139 Modulex EXT Commercial Series Boilers User Manual USER MANUAL INSTALLATION, OPERATION & MAINTENANCE Modulating and Condensing Boilers APPLIES TO MODELS: • MLX EXT 1530 / MLX EXT 1500 • MLX EXT 1912 • MLX EXT 2295 / MLX EXT 2300 •...

  • Page 2: Table Of Contents

    Modulex EXT Commercial Series Boilers User Manual Table of Contents: CHAPTER 1: SAFETY PRECAUTIONS ..................... 7 CHAPTER 2: GENERAL INFORMATION ....................11 2.1 CORRECT USE OF THE APPLIANCE ........................11 2.2 WATER TREATMENT ............................11 2.3 INFORMATION TO BE MADE AVAILABLE TO THE USER ..................11 2.4 SAFETY WARNINGS ............................
  • Page 3 Modulex EXT Commercial Series Boilers User Manual 4.9.1.1 Natural Gas Piping Sizes ........................32 4.9.1.2 Natural Gas Piping Connections ......................32 4.9.1.3 Natural Gas Supply Pressure Requirements ..................32 4.9.2 Propane Gas Connections ........................32 4.9.2.1 Propane Gas Piping Sizes ........................32 4.9.2.2 Propane Gas Piping Connections ......................
  • Page 4 Modulex EXT Commercial Series Boilers User Manual 4.38 CONTROLS AND EMERGENCY FUNCTIONS ...................... 74 4.39 INITIAL BOILER IGNITION ..........................75 4.39.1 Preliminary Checks..........................75 CHAPTER 5: E8 CONTROLLER AND BCM MODULES ................. 77 5.1 E8 CONTROLLER ..............................77 5.1.1 E8 Controller Features and Functions ..................... 77 5.1.2 E8 Display Functions ..........................
  • Page 5 Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: MAINTENANCE SCHEDULE ................... 119 8.1 INSTRUCTIONS FOR INSPECTION AND MAINTENANCE ................... 120 8.2 PERIODIC EXAMINATION OF VENTING SYSTEM ....................120 8.3 PROPER PROCEDURE FOR CLEANING EXHAUST FLUE ..................120 8.3.1 Cleaning the Condensate Drain Line ..................... 121 8.4 CHECKING CSD-1 MANIFOLD FLOW SWITCH ....................
  • Page 6 Modulex EXT Commercial Series Boilers User Manual (This Page Intentionally Blank) Page 6 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...

  • Page 7: Chapter 1: Safety Precautions

    Modulex EXT Light Commercial Series Boilers User Manual CHAPTER 1: Safety Precautions CHAPTER 1: SAFETY PRECAUTIONS The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels. DANGER! Indicates an imminently hazardous situation, which if not avoided, WILL result in death or serious injury.
  • Page 8 Modulex EXT Light Commercial Series Boilers User Manual CHAPTER 1: Safety Precautions Important – For Massachusetts Installations Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements: • Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
  • Page 9 Modulex EXT Light Commercial Series Boilers User Manual CHAPTER 1: Safety Precautions Important - For Massachusetts Installations (Continued from Previous Page) B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 to 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board;...
  • Page 10 Modulex EXT Light Commercial Series Boilers User Manual CHAPTER 1: Safety Precautions (This page intentionally blank) Page 10 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...

  • Page 11: Chapter 2: General Information

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 2: General Information CHAPTER 2: GENERAL INFORMATION 2.1 CORRECT USE OF THE APPLIANCE The MODULEX EXT Commercial boiler has been designed utilizing the latest heating technologies and in compliance with current safety regulations. However, if not used or operated properly, the unit may cause injury or death to persons, or serious damage to the equipment or surrounding objects.

  • Page 12: Safety Warnings

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 2: General Information Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to persons, animals or damage to property. The manufacturer shall not be held liable for any such injury and/or damage.

  • Page 13: For Appliances Operating With Propane Gas

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 2: General Information 2.6 FOR APPLIANCES OPERATING WITH PROPANE GAS Before installing the appliance, ensure that the gas tank has been purged. For correct instructions on purging the tank, contact the liquid gas supplier or a competent person who is legally authorized to provide such information.

  • Page 14: Data Plate

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 2: General Information 2.7 DATA PLATE A sample Data Plate for a MODULEX EXT Commercial boiler is shown in the left figure below. A sample of the Data Packaging label is shown in the right image below. Figure 2-1: MODULEX EXT Commercial Data Plate (L) and Data Packing Label (R) Each unit is fitted with a data plate, which may be consulted for the details on gas type, power source, and venting classification.

  • Page 15: Operational Requirements

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 2: General Information 2.8 OPERATIONAL REQUIREMENTS 2.8.1 General Requirements The following instructions MUST be followed: • The boiler must only be used for its designated purpose as described in these installation instructions. •...

  • Page 16: Water Quality Requirements

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 2: General Information WARNING! Should overheating occur, or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the boiler.

  • Page 17: Tools, Materials, And Additional Equipment

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 2: General Information 2.9 TOOLS, MATERIALS, AND ADDITIONAL EQUIPMENT For the installation and maintenance of the boiler you will need: • Standard tools for space heating, gas, and water fitting • Manometer that is capable of reading both positive and negative pressures •...

  • Page 18: Preparing Boiler For Servicing

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 2: General Information 2.11.4 Preparing Boiler for Servicing Before carrying out any cleaning or servicing turn off the electrical supply to the boiler by means of the ON/OFF switch and/or by means of the appropriate shutdown devices. 2.11.5 Returning a Boiler to Service Before putting a boiler, which has been unused for a length of time, back into service, rinse the entire domestic hot water system, allowing the water to flow an appropriate amount of time in...

  • Page 19: Chapter 3: Technical Features & Dimensions

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 3: Technical Features & Dimensions CHAPTER 3: TECHNICAL FEATURES & DIMENSIONS 3.1 MODULEX EXT COMMERCIAL TECHNICAL FEATURES • Compact, gas fired, Low NO , condensing boiler. • Comprised of one sectional boiler body, suitable as a single boiler or in a cascaded group. •...

  • Page 20: General Boiler Operation

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 3: Technical Features & Dimensions • Heating operation: instantaneous power microprocessor control, with preset parameters for comparison between temperature (or calculated from the external temperature regulation) and global temperature flow. • Operation modes: o Ability to control power to the individual heating elements for any calibration with or without confidential code access.

  • Page 21: Dimensional Drawings

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 3: Technical Features & Dimensions 3.3 DIMENSIONAL DRAWINGS Figure 3-1: MODULEX EXT Commercial Dimensional Drawings OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 21 of 144 GF-139 Phone: 800-526-0288 09/15/2017...
  • Page 22 Modulex EXT Commercial Series Boilers User Manual CHAPTER 3: Technical Features & Dimensions TABLE 3-1: MODULEX EXT Commercial Dimensions and Sizes 1530 2295 2677 3060 1912 1500 2300 2600 3000 (*) DN 80 – 3” ASME B16.5 Flange 150 lbs./sq. inch (*) DN 100 –...
  • Page 23 Modulex EXT Commercial Series Boilers User Manual CHAPTER 3: Technical Features & Dimensions Figure 3-2: MODULEX EXT Commercial Main Components (Left Side View) • Flue Exhaust connection is located on the RIGHT HAND side (supply condition), but may be moved to LEFT or REAR positions. •...

  • Page 24: Performance Data

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 3: Technical Features & Dimensions 3.4 PERFORMANCE DATA TABLE 3-2: MODULEX EXT Commercial Performance Data 1530 1912 2295 2677 3060 MODULEX EXT MODEL 1500 2300 2600 3000 NOTE: The Technical data plate is placed under the casing. See section 2.7 for more information. Page 24 of 144 AERCO International, Inc.

  • Page 25: Chapter 4: Installation Instructions

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions CHAPTER 4: INSTALLATION INSTRUCTIONS 4.1 INSTALLATION WARNINGS AND REQUIREMENTS 4.1.1 Appropriate Use of the Boiler This boiler MUST be used in the application for which it has been expressly designed. Any other use shall be considered improper and therefore dangerous.

  • Page 26: Code And Standards Approvals

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.2 CODE AND STANDARDS APPROVALS The MODULEX EXT boiler has been reviewed for compliance with the applicable sections of the following North American Standards: • ANSI Z21.13/CSA 4.9: Gas-fired low pressure steam and hot water boilers •...

  • Page 27: Transporting And Securing The Boiler Safely

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.4 TRANSPORTING AND SECURING THE BOILER SAFELY The boiler is susceptible to serious damage when not secured properly. • Follow the transportation instructions on the packaging. • Only transport the boiler using appropriate transportation equipment, such as a hand-truck with a fastening belt or special equipment for transporting heavy equipment.

  • Page 28: Boiler Package Contents

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4. To prepare the boiler for lifting by the hoist, remove panel covers from front, rear, right, left and top (Panel 6). 5. Use the four hoist straps (Panel 5) as slings and place one under each of four boiler legs ensuring that strap is located UNDER the cross bars of the frame as shown in Panel 6.

  • Page 29: Boiler Location In A Boiler Room

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.7 BOILER LOCATION IN A BOILER ROOM Special attention shall be paid to local regulations and laws about boiler enclosures and boiler rooms, particularly to the minimum clearances around the boiler. The installation shall be in compliance with all the latest regulations and laws about boiler enclosures, boiler rooms, installations of heating and hot-water systems, ventilation, vents capable of exhausting the flue gases of condensing boilers, and any other applicable requirements.

  • Page 30: Products To Avoid In The Boiler Room

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.7.2 Products to Avoid in the Boiler Room Do NOT store the following products in the boiler room and/or around combustion air intake vents. • Spray cans containing chlorocarbons/fluorocarbons •...

  • Page 31: Gas Connection General Information

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.9 GAS CONNECTION GENERAL INFORMATION For natural gas connections, refer to Section 4.9.1. For propane gas connections, refer to Section 4.9.2. The gas supply connection must comply with local regulations or, if such regulations do not exist, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

  • Page 32: Natural Gas Connections

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.9.1 Natural Gas Connections 4.9.1.1 Natural Gas Piping Sizes Contact your local gas supplier for natural gas pipe sizes and meter types. 4.9.1.2 Natural Gas Piping Connections The boiler gas pipe is equipped with external 3’’ ASME B16.5 flange, onto which the tail piece of the gas shut off valve can be connected.

  • Page 33: Flow And Return Pipe Connections

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.10 FLOW AND RETURN PIPE CONNECTIONS The cold and hot water flow and return circuits must be connected to the boiler via the respective 4” M and R connections as indicated in Table 2-1. When determining the size of the cold/hot water circuit pipes it is essential to bear in mind the pressure losses induced by any of the system’s components and by the configuration of the system.

  • Page 34: Manifold Assembly (Supplied)

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.12 CSD-1 MANIFOLD ASSEMBLY (SUPPLIED) The installation of a flow switch and pressure/temperature gauge are required. A 1-1/2” Pressure Relief Valve designed for the boiler output capacity must also be installed: •...

  • Page 35: Determination Of Primary Boiler Pump Or Boiler System Pump

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions Installing the Pressure Relief Valve and Other Components – Continued 3. Connect the following components to the tapped holes in the manifold assembly, as shown in Figure 4-6, above: •...

  • Page 36: Condensate Piping And Drain

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions TABLE 4-2: MODULEX EXT Minimum/Maximum Flow Rates BOILER MODEL 1530/1500 1912 2295/2300 2677/2600 3060/3000 Min. flow rate demanded in gpm ∆T 27°F (15°C) Min. flow rate demanded in gpm ∆T 36°F (20°C) Max flow rate demanded in gpm ∆T 27°F (15°C) Max flow rate demanded...
  • Page 37 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions The liquid column, inside the condensate siphon, (see Condensate Siphon Filling Plug in Figure 4-9) needs to be filled with water after installation. The minimum height of the water in the column, when all the fans are in operation, must be at least 25 mm (1 in.).

  • Page 38: Water Treatment

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.15 WATER TREATMENT The chemical/physical composition of the heating system’s water is fundamental for the boiler’s correct operation and safety. Among the problems caused by poor quality of feed water, the most frequent and the most serious is the buildup of deposits on boiler thermal exchange surfaces.

  • Page 39: Lime Scale And Corrosive Water Damage Warning

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.16.3 Lime Scale and Corrosive Water Damage Warning Any damage caused to the boiler due to the formation of lime scale or by corrosive water will not be covered by the warranty. Appropriate steps must be taken to ensure the indirect tank water heater does not become plugged by scale caused by hard water or sediment.
  • Page 40 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions RECTANGULAR GASKET WASHERS (10) NUTS (10) FLUE MANIFOLD GASKET FOR ATTACHING EUROPEAN-TO-USA FLUE ADAPTER Figure 4-11: Connection of Exhaust Manifold To Boiler Flue Exhaust Outlet For venting systems in the USA, it is necessary to assemble the Euro-to-USA adaptor to the flue manifold as shown in Figure 4-12.

  • Page 41: Flue Exhaust Piping To Vent

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.19 FLUE EXHAUST PIPING TO VENT In a condensing boiler the flue exhaust is evacuated at a very low temperature (maximum of about 183°F / 84°C). Thus, it is necessary that the chimney be impermeable to the condensate of the combustion products and be made of corrosion resistant materials.

  • Page 42: Vent Starter Pieces

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.20 VENT STARTER PIECES All vent starter pieces for the MODULEX EXT 1500 through 3060 can be purchased directly from the vent manufacturer. Example Vent Starter Piece WORM-DRIVEN HOSE CLAMP SCREWS (8 EACH) WASHERS (8 EACH) DIAMETER REDUCTION...

  • Page 43: Combustion Air And Ventilation Openings

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions Please note that 10” and 12” PVC can be heavy and expensive. Alternative vent materials, such as AL29-4C or polypropylene should be considered prior to installation. The plastic components, primers and glues of the certified vent system must be from a single system manufacturer and not mixed with other manufacturer’s vent system parts.

  • Page 44: Room Air Combustion

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions When one expects contaminated combustion air (near swimming pools, chemical cleaning operations, hair salons, etc.), sealed combustion operation is recommended. WARNING! Fire danger due to flammable materials or liquids. Do not store flammable materials and liquids in the immediate vicinity of the boiler.

  • Page 45: Installation Of The Exhaust And Air Intake System

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.22 INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM NOTES: Consult local and state codes pertaining to special building code and fire department requirements. Adhere to national code requirements. Observe the listed maximum lengths of vent system which are boiler model dependent.

  • Page 46: Minimum And Maximum Wall Thickness

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions pipe. Such conditions must be considered and where necessary insulation of the inlet pipe may be required. In cold and/or humid weather water vapor may condense when leaving the vent terminal.
  • Page 47 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions NOTE: The flue system must be installed in accordance with the local and national Standards. Figure 4-17: MODULEX EXT Allowable Venting Solution Examples OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 47 of 144 GF-139 Phone: 800-526-0288...

  • Page 48: Electrical Connections

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.24 ELECTRICAL CONNECTIONS 4.24.1 Regulations in Force The electrical connections to the boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code, ANSI/NFPA-70. Installations should also conform with CSA C22.1 Canadian Electrical Code Part 1, if installed in Canada.

  • Page 49: Service Relay Requirement

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions WARNING! DANGER OF FATAL ACCIDENT DUE TO ELECTRIC SHOCK! 120 VAC connections may be present on the external connection board when power is supplied to the boiler. The electrical connections must be carried out only by a qualified person. Before carrying out the connections or any other operation on the electrical parts, always switch off and disconnect the electricity supply and ensure for yourself that it cannot be accidentally turned on.
  • Page 50 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions Figure 4-18: 120VAC Power Wiring for Main Electrical Junction Box and Signal Wiring for E8 Controller and Boiler Control Module (BCM) WARNING! 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.
  • Page 51 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions Figure 4-19: Main Power Junction Box Location and 120VAC Wiring OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 51 of 144 GF-139 Phone: 800-526-0288 09/15/2017...
  • Page 52 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions (This Page Intentionally Blank) Page 52 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...

  • Page 53: Functional Wiring Diagram

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.25 FUNCTIONAL WIRING DIAGRAM Figure 4-20: MODULEX EXT 1500 through 3060 Wiring Diagram OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 53 of 144 GF-139 Phone: 800-526-0288 09/15/2017...
  • Page 54 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions (This Page Intentionally Blank) Page 54 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...

  • Page 55: Ladder Diagrams

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.26 LADDER DIAGRAMS Figure 4-21: Module Ladder Diagram OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 55 of 144 GF-139 Phone: 800-526-0288 09/15/2017...

  • Page 56: General Ladder Diagram

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.27 GENERAL LADDER DIAGRAM Figure 4-22: General Ladder Diagram 4.28 E8 CONTROLLER AND BCM TERMINAL ASSIGNMENTS On the rear panel of the E8 controller, there are two terminal blocks, one of which is for the mains (120 V) connections, and the other for the low voltage connections.
  • Page 57 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions Figure 4-23: E8 Controller Terminal Assignments OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 57 of 144 GF-139 Phone: 800-526-0288 09/15/2017...
  • Page 58 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions Figure 4-24: Sensor and BCM Terminal Assignments Page 58 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...

  • Page 59: Installation Examples

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.29 INSTALLATION EXAMPLES (Functional Wiring and Connections Description) OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 59 of 144 GF-139 Phone: 800-526-0288 09/15/2017...
  • Page 60 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions Page 60 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...

  • Page 61: Starting Up: Filling And De-Aerating The Boiler

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.30 STARTING UP: FILLING AND DE-AERATING THE BOILER Carry out the following tasks in connection with maintenance, etc. to an already installed unit: • Shut down all programs • Close the gas shutoff valve upstream from the boiler •...

  • Page 62: Filling Locations And Preparation

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions WARNING! Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage of seals and gaskets in boiler and system could occur, resulting in substantial property damage and/or danger. The central heating installation needs to be filled with clean water.
  • Page 63 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions, a fire or explosion may result causing property damage, personal injury, or loss of life. A.

  • Page 64: Testing The Ignition Safety Shut-Off Device

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.32 TESTING THE IGNITION SAFETY SHUT-OFF DEVICE Ignition Safety Shut-off Device Test 1. Power on by switching on the ON-OFF switch. 2. Create a request in C/H Central Heating using the E8 controller. 3.

  • Page 65: Burner Calibration

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.33 BURNER CALIBRATION WARNING! All the instructions indicated below are for the exclusive use of qualified AERCO service technicians or installers. All the boilers are supplied already calibrated and tested. However, if it is necessary to change the calibration due to gas conversion or adaptation to the mains supply system, the gas valve must be re-calibrated (using Service Mode function in the E8 controller).

  • Page 66: Maximum Output Calibration

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions REAR BOILER TOP VIEW FRONT Minimum Output Adjust Maximum Output Adjust Figure 4-28: Location of Minimum and Maximum Adjustments (Top View) 4.33.2 Maximum Output Calibration After installing the gas analyzer probe (Figure 4-27), refer to Figure 4-28 to locate the gas valves and the Maximum Gas Adjustment screw (A) on each valve.

  • Page 67: Minimum Output Calibration

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.33.3 Minimum Output Calibration After setting the maximum gas output for each valve (section 4.33.2), refer to Figure 4-28, above, to locate the Minimum Gas Adjustment screw (B) on each valve. Follow the instructions below to set the minimum gas output level for each valve.
  • Page 68 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions TABLE 4-6: EXT Pressure, CO and O Level Calibration Tables EXT 1530 /1500 Ǿ Mixer Level Level Fan Speed Supply Min. Gas Max. Gas Start Injectors Pressure Consumption Consumption Output Ǿ...
  • Page 69 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions TABLE 4-6: EXT Pressure, CO and O Level Calibration Tables EXT 2677 / 2600 Ǿ Mixer Level Level Fan Speed Supply Min. Gas Max. Gas Start Injectors Pressure Consumption Consumption Output Ǿ...

  • Page 70: Sweeper Mode (Manual Control)

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.34 SWEEPER MODE (MANUAL CONTROL) Figure 4-30: Sweeper Mode (Manual Control) NOTE: The function is active for 15 minutes, after which it defaults to the previous parameters. Page 70 of 144 AERCO International, Inc.

  • Page 71: High Altitude Adjustment

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.35 HIGH ALTITUDE ADJUSTMENT It is necessary to adjust the fan speed at altitudes at or above 5,000 feet. Modify the parameter FAN MAX from the E8 Control Panel. Note that it is modifiable only with an access code. See Table 4-7 on the next page for a list of the FA (Factory) parameters.

  • Page 72: High Altitude Conversion Label

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions TABLE 4-7: MODULEX EXT FA (Factory) Parameters Set in PARAM HS xx Menu MODULEX EXT PARAMETERS FOR LOW ALTITUDE FOR HIGH ALTITUDE No Change FAN MOD IGN FAN MOD STBY No Change FAN MAX (FH) FAN MIN (FL)

  • Page 73: Conversion From Natural Gas To Propane Gas

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.37 CONVERSION FROM NATURAL GAS TO PROPANE GAS To convert the unit to use propane gas, instead of natural gas, do the following: Converting From Natural Gas to Propane Gas 1.

  • Page 74: Controls And Emergency Functions

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.38 CONTROLS AND EMERGENCY FUNCTIONS Figure 4-34: MODULEX EXT Panel Controls and Indicators TABLE 4-8: Panel Controls and Indicators ITEM COMPONANT/FUNCTION GLT (General Limit Thermostat): when enabled, it cuts the power supply to the boiler and lights the warning lamp (Item D).

  • Page 75: Initial Boiler Ignition

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions 4.39 INITIAL BOILER IGNITION 4.39.1 Preliminary Checks CAUTION! To ensure the continued safe operation of the boiler it is highly recommended that it is checked at regular intervals and serviced when necessary, and that only original spare parts are used.
  • Page 76 Modulex EXT Commercial Series Boilers User Manual CHAPTER 4: Installation Instructions (This Page Intentionally Blank) Page 76 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...

  • Page 77: Chapter 5: E8 Controller And Bcm Modules

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules CHAPTER 5: E8 CONTROLLER AND BCM MODULES MODULEX boilers contain advanced and reliable electronic controls, the E8 Controller and the BCM (Boiler Communications Module), which provide comprehensive programming and monitoring of the MODULEX boiler and its functions.

  • Page 78: E8 Display Functions

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules LCD Display Window Hinged Cover Rotary Knob (in closed position) Figure 5-1: MODULEX E8 Controller Front Panel (Cover Closed) 5.1.2 E8 Display Functions The E8 Controller operates in NORMAL Mode when the controller door is closed, which allows for monitoring the boiler status through the display window and setting the HEATING Mode.

  • Page 79: E8 Heating Mode Selection

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules 5.1.3 E8 HEATING Mode Selection Heating modes may be selected using the Rotary Knob on the controller when the hinged door is in the closed position (NORMAL Mode). As the Rotary Knob is turned, each appropriate heating mode symbol is displayed, in turn, along the lower edge of the display.

  • Page 80: E8 Menu Mode Operation (Door Open)

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules 5.1.4 E8 MENU Mode Operation (Door Open) Opening the E8 controller hinged door reveals the E8 controls (Figure 5-4) and initiates the MENU Mode, which enables access to an extensive set of software menus. INSTALLATION Figure 5-4: E8 MENU Mode Display Features TABLE 5-3: E8 MENU Mode Features and Functions...

  • Page 81: E8 Menu Navigation And Parameter Settings

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules 5.1.5 E8 MENU Navigation and Parameter Settings The selected Menu and Sub-menu are indicated by two black arrows at display bottom pointing to the Menu and Sub-menu names silk-screened below the display (Figure 5-5). Following initial startup and one-time entry of the required INSTALLATION menu items (see Chapter 6, section 6.1), to access, view and/or change menu items follow these instructions: Sub-MENU Name...

  • Page 82: E8 Parameter Navigation, Selection, And Setting

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules 5.1.6 E8 Parameter Navigation, Selection, and Setting When in the USER, TIME PROGRAM, EXPERT, or GENERAL Main Menu, virtually all sub- menu items can be changed, if desired. Perform the following steps to access, view, and/or change menu item parameters: TABLE 5-4: E8 Parameter Navigation, Selection, and Setting DESCRIPTION...

  • Page 83: Bcm (Boiler Communication Module)

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules 5.2 BCM (BOILER COMMUNICATION MODULE) NOTE Only the basic features and functions of the BCM are described in the following sections. Refer to the E8 Controller User Manual (GF-115-C) for detailed information and diagrams for wiring and using the BCM in its various capacities.
  • Page 84 Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules DL2 (RED) DL3 (GREEN) DL1 (YELLOW) Input Communications Connector (Modbus/Ebus) Change-Over 3-Pos. Switch Enable/Disable 2-Pos. Switch Reset Switch Output Communications SW1 Switch Connector (Ebus) Figure 5-6: BCM (Boiler Control Module) Features TABLE 5-5: BCM (Boiler Control Module) Features and Functions ITEM FEATURE...
  • Page 85 Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules TABLE 5-6: BCM 3-Position and 2-Position Switch Functions 2-POS SWITCH 3-POS SWITCH (ENABLE/DISABLE) (I/O/II) Position I Position O Position II (NOTE 1) (see NOTE 2) (See NOTE 3) The BCM is the Gate-way for The E8 is the primary Modbus and external control.
  • Page 86 Modulex EXT Commercial Series Boilers User Manual CHAPTER 5: E8 Controller and BCM Modules (This Page Intentionally Blank) Page 86 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...

  • Page 87: Chapter 6: Operation Of The E8 Controller

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller CHAPTER 6: OPERATION OF THE E8 CONTROLLER This chapter introduces the E8 controller basic menus/sub-menus needed to set up the MODULEX EXT boiler. Refer to Chapter 4 for instructions for using the E8 controls to navigate and change settings.

  • Page 88: Installation Menu: Initializing The E8 Controller

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.1 INSTALLATION MENU: INITIALIZING THE E8 CONTROLLER Each time power is applied to the boiler and the E8 controller cover (Figure 7-1) is opened, the INSTALLATION Menu is displayed once (only). These values MUST be entered in order to initialize the boiler for operation.

  • Page 89: Quick Start Instructions

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.2 QUICK START INSTRUCTIONS Below are instructions for setting the most basic settings in the E8 controller, including maximum and minimum flow temperature, room temperature settings, heat slope, and initiation of heating programs.

  • Page 90: Setting Room Temperature And Outdoor Compensation

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.2.2 Setting Room Temperature and Outdoor Compensation INSTALLATION Figure 6-3: E8 Quick Start, Room Temperature and Outdoor Compensation Settings with Outdoor Temperature (Slope) Chart Page 90 of 144 AERCO International, Inc.

  • Page 91: Setting Heating Programs And Pumps

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.2.3 Setting Heating Programs and Pumps Figure 6-4: E8 Quick Start, Heating and Pump Program Settings OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 91 of 144 GF-139 Phone: 800-526-0288...

  • Page 92: Menu And Sub-Menu Descriptions

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.3 MENU AND SUB-MENU DESCRIPTIONS There are six top level menus and five sub-menus as listed below. 6.3.1 Menus (Top Level): • GENERAL Value selection summary. Service => for service engineers. Date/Time/Holiday => for users.

  • Page 93: General Menu

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.4 GENERAL MENU The GENERAL menu contains the sub-menus DATE/TIME, HOLIDAY, and CLOCK CHANGE. Figure 6-5: GENERAL Menu OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 93 of 144 GF-139 Phone: 800-526-0288...
  • Page 94 Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller TABLE 6-1: GENERAL Menu LEVEL DESCRIPTION ENTRY RANGE DATE/TIME TIME (HOURS) Current hours blink and can be adjusted 00:00 - 24:00 YEAR Adjust current year XXXX MONTH Adjust current month 01 - 12...

  • Page 95: Service Menu

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.5 SERVICE MENU The SERVICE menu contains the TEST RELAY, SENSOR TEST, and OTHER PARAMETERS sub-menus as shown below: NOTE The SERVICE menu is accessed as shown below. However, SERVICE MODE ( ) is different and can only be accessed when the E8 cover is closed.
  • Page 96 Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller TABLE 6-2: SERVICE Menu LEVEL DESCRIPTION TEST RELAYS RELAY TEST 00 No relay RELAY TEST 01 A1: Pump heating circuit 1 RELAY TEST 02 A2: Pump heating circuit 2 RELAY TEST 03 A3: Hot water charging pump RELAY TEST 04...

  • Page 97: Display Menu

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.6 DISPLAY MENU The DISPLAY menu contains the INSTALLATION, HOT-WATER, HTG CIRCUIT 1/2, and SOLAR / MF sub-menus as shown below: Figure 6-7: DISPLAY Menu NOTE: Some menus are visible only if the relevant sensor is wired (e.g.
  • Page 98 Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller TABLE 6-3: DISPLAY Menu LEVEL DESCRIPTION INSTALLATION T-OUTSIDE Outside temperature T-EXT DES External set value specification (0-10 V) T-COLL DES HS / Header set value (cascade) T-COLLECTOR HS / Header temperature (cascade) T-BOIL...

  • Page 99: User Menu

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.7 USER MENU The USER menu contains the INSTALLATION, HOT-WATER, HTG CIRCUIT 1/2, and SOLAR / MF sub-menus as shown below: Figure 6-8: USER Menu OMM-0095_0H AERCO International, Inc.
  • Page 100 Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller TABLE 6-4: USER Menu LEVEL DESCRIPTION ENTRY INSTALLATION Range Default ENGLISH Set language CONTRAST Adjust intensity of display (-20) / (20) DISPLAY SEL Select additional display in standard operation ---- SELEC-PROG Heating circuit 1 or Heating circuit 2...

  • Page 101: Time Program Menu

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.8 TIME PROGRAM MENU The TIME PROGRAM menu contains the items shown below: Figure 6-9: TIME PROGRAM Menu TABLE 6-5: TIME PROGRAM Menu LEVEL DESCRIPTION CIRCL TIME Program for circulation pump HOTW-PROG ( Program for hot water charging pump...

  • Page 102: Expert Menu

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.9 EXPERT MENU The EXPERT menu contains the items shown below: Figure 6-10: EXPERT Menu – 1 of 2 Page 102 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288...
  • Page 103 Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller Figure 6-10: EXPERT Menu – 2 of 2 NOTE: 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-0095_0H AERCO International, Inc.
  • Page 104 Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller TABLE 6-6: EXPERT Menu LEVEL DESCRIPTION ENTRY INSTALLATION DEFAULT RANGE Boiler Bus address only for cascade of E8 BUS-ID HS ---- (01 ÷ 08) controllers The heating circuits are sequentially BUS ID 1 (01 ÷...
  • Page 105 Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller TABLE 6-6: EXPERT Menu - Continued LEVEL DESCRIPTION ENTRY INSTALLATION (Cont.) DEFAULT RANGE If this modulation degree is exceeded, the next (10 - 60) IMODULAT MAX heat ..

  • Page 106: Other Possible Settings

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller TABLE 6-6: EXPERT Menu - Continued LEVEL DESCRIPTION ENTRY HTG CIRCUIT 1/2 HC FUNCTION Heating circuit function selection (00 ÷ 04) PUMP MODE Pump operating mode (00 ÷...

  • Page 107: A Second Dhw Storage Tank

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller 6.10.1.3 A Second DHW Storage Tank (Only After Function Selection) Offers the possibility to use one of the heating zones for the preparation of a second DHW storage tank.

  • Page 108: Setting Of Dhw Circuit

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 6: Operation of the E8 Controller TABLE 6-7: 0-10V Signal with Slope and Temperature Curve 2.0 V 10.0 V 32° F 194° F 2.0 V 2.5 V 0.3 V 100° F 176° F 5.0 V 2.5 V 0.3 V...

  • Page 109: Chapter 7: Troubleshooting

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting CHAPTER 7: TROUBLESHOOTING 7.1 E8 CONTROLLER FAULT CODES Fault codes are displayed in the upper right hand section of the E8 Controller display (see Figure 7-1). Use Table 7-1 (next page) to determine the fault message. There are codes for the following three different devices: •...
  • Page 110 Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting In order to derive the fault message from the code displayed in the E8 Controller display, use Table 7-1 below to determine the working fault code. To use the table, find the displayed number in the first column, identify the affected module from the second column, apply the formula from the third column, and identify the fault table to reference from the fourth column.

  • Page 111: E8 Controller Fault Codes

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting 7.1.1 E8 Controller Fault Codes The table below lists the fault codes and fault descriptions associated with the E8 Controller. TABLE 7-2: E8 Controller Fault Codes CODE DESCRIPTION EFFECT CORRECTION RESET PCB Element Fault Intervention of the...
  • Page 112 Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting TABLE 7-2: E8 Controller Fault Codes (Continued) CODE DESCRIPTION EFFECT CORRECTION RESET E 16 Boiler body Boiler will not run. Carefully defrost boiler. AUTOMATIC - when temperature very low: Pump runs for 5 sensor is >41°F Ice forming risk minutes.
  • Page 113 Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting TABLE 7-2: E8 Controller Fault Codes (Continued) CODE DESCRIPTION EFFECT CORRECTION RESET System Manager Fault – Sensor Defective (Break/Short Circuit) E 69 E8: F5 – Flow temperature Check continuity. Use AUTOMATIC sensor heating circuit 2.
  • Page 114 Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting TABLE 7-2: E8 Controller Fault Codes (Continued) CODE DESCRIPTION EFFECT CORRECTION RESET E 200 Communication Error HS1 Communications issue with BMM 0. Check all eBUS addresses E 201 Communication Error HS1 Communications issue with BMM 1.

  • Page 115: Bcm (Boiler Communications Module) Fault Codes

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting 7.1.2 BCM (Boiler Communications Module) Fault Codes The table below lists the fault codes and troubleshooting tips associated with the BCM. TABLE 7-3: BCM Fault Codes CODE DESCRIPTION EFFECT CORRECTION RESET Boiler pipe is frozen.

  • Page 116: Bmm (Burner Management Module) Fault Codes

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting 7.1.3 BMM (Burner Management Module) Fault Codes The table below lists the fault codes and troubleshooting tips associated with the BMM. TABLE 7-4: BMM Fault Codes CODE DESCRIPTION EFFECT CORRECTION RESET High Limit (STB) All burners...
  • Page 117 Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting TABLE 7-4: BMM Fault Codes CODE DESCRIPTION EFFECT CORRECTION RESET Return sensor All burners Check return sensor or AUTOMATIC E 14 fault. turned OFF. wiring. Maximum Δ- All burners Check the system AUTOMATIC - when Δ-temperature <...
  • Page 118 Modulex EXT Commercial Series Boilers User Manual CHAPTER 7: Troubleshooting TABLE 7-4: BMM Fault Codes CODE DESCRIPTION EFFECT CORRECTION RESET Ignition retry after 60 Fan speed out second delay of control: It and failure doesn't reach E 24 remains until Check fan wiring.

  • Page 119: Chapter 8: Maintenance Schedule

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule CHAPTER 8: MAINTENANCE SCHEDULE The boiler must receive regular, annual maintenance and cleaning in order to ensure reliable and efficient operation. Regular maintenance will prolong the life of the boiler. Refer to Table 8- 1 for a suggested schedule of maintenance procedures.

  • Page 120: Instructions For Inspection And Maintenance

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule 8.1 INSTRUCTIONS FOR INSPECTION AND MAINTENANCE WARNING! To ensure a long life of the boiler components and in order not to alter the conditions of an approved product, ONLY original AERCO spare parts may be used. Before servicing, always carry out the following steps: 1.

  • Page 121: Cleaning The Condensate Drain Line

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule 8.3.1 Cleaning the Condensate Drain Line In order to inspect and clean the condensate line, do the following: 1. Refer to Figure 8-1, disconnect the pipe at location “A“. 2.

  • Page 122: Visual Inspection Of The Flame

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule 8.5 VISUAL INSPECTION OF THE FLAME (2 and 4 year maintenance) The burner must flame evenly over the entire surface when operating correctly. The flame must burn with a clear, ORANGE, stable flame. Check the flame through the flame observation port (Figure 8-2).

  • Page 123: Pressure Switch Hoses And Connections

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule 8.7 PRESSURE SWITCH HOSES AND CONNECTIONS If pressure switch hoses need to be replaced, ensure that new hose lengths are identical to the old hose lengths. If too long, there is an increased chance of condensation problems within the hoses.

  • Page 124: Burner / Heat Exchanger Cleaning Procedure

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule 8.8 BURNER / HEAT EXCHANGER CLEANING PROCEDURE Dust and other particulate matter infiltrating into the combustion chamber over time will cause a decrease of heating efficiency and output due to the buildup of combustion by-products onto the thermally conductive surfaces.

  • Page 125: Unit Disassembly

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule 8.10 UNIT DISASSEMBLY To disassemble the unit for maintenance, do the following: Disassembling the EXT Boiler for Maintenance 1. Switch OFF external electrical power and CLOSE the gas supply valve upstream from the boiler, and ensure it is completely closed.
  • Page 126 Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued 4. Remove ten (10) screws from around exhaust outlet opening and remove flue assembly from unit (Figures 8-7 & 8-8). Figure 8-8: Flue Removal (Step 4) 5.
  • Page 127 Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued 6. Remove the rubber hoses (quantity depends on model) from bottom side of manifold (highlighted in Figure 8-10), then lift entire manifold from the unit. Lift out manifold after removing hoses.
  • Page 128 Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued Figure 8-11: Removing the Burner Module Plate Covers (Step 7) 8. Use a 36 mm wrench to disassemble all the gas pipes from the gas manifold. See Figure 8-12.
  • Page 129 Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued 9. In order to hold up the burner assembly in place, lift up the front of the burner assembly until the two lift pins are aligned with the left and right side tab holes (refer to Figure 8-13). Hole Elevate the burner assembly slightly to line up this screw with the tab hole.
  • Page 130 Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued 11. Refer to Figure 8-16, lift up the burner plates to expose the burner modules, and latch it in place. Figure 8-16: Lifting Burner Plates (Left) to Expose Burner Modules (Right) Figure 8-17: Exposing Burner Modules (Left) and Removing (Right) Figure 8-18: Exposed Combustion Chambers under Burner Modules Page 130 of 144...

  • Page 131: Cleaning The Burner Module

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued NOTE The check valve (1 in Fig. 7- 19) should be checked at this time to ensure that it moves freely and closes properly. Figure 8-19 Lifting Burner Assembly and Location of the Check Valve 8.11 CLEANING THE BURNER MODULE After completing the previous section, the individual burner modules are exposed and available...

  • Page 132: Mechanical Cleaning Of The Heat Exchanger

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule If an inspection of the heat exchanger reveals a build-up of combustion by-product deposits, complete the instructions below to clean the heat exchangers mechanically (section 8.12.1) and, if necessary, with a chemical cleaning solution specifically designed for removing combustion by-products from the fire side of aluminum heat exchangers (section 8.12.2).

  • Page 133: Cleaning The Heat Exchanger With Cleaning Solution

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule Mechanical Cleaning of the Heat Exchanger – Continued Figure 8-22: Angle of Cleaning Instrument – Heat Exchanger Cut-Away View 3. The most crucial area to clean is the bottom of the heat exchanger, where the heat exchanger pins are the closest.

  • Page 134: Repeat Cleaning

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule CAUTION! Use of neoprene gloves and protective goggles is recommended. Consult the Axiom Industries web site (axiomind.com) for additional health and safety information. Chemical Cleaning of the Heat Exchanger 1.

  • Page 135: Final Procedures After Maintenance

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule Reassembling the Burner Modules – Continued 4. Proceed with reassembly, performing whichever disassembly operation was chosen (all or individual method) in reverse order. a) Lower burner assembly b) Reinstall gas collector tubes to the gas manifold tube. c) Reinstall nuts “A,”...

  • Page 136: Maintenance Kit Part Number

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule 8.15 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 Table 8-3 and 8-4.

  • Page 137: Accessory Kit Part Number

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule 8.16 ACCESSORY KIT PART NUMBER The following MODULEX EXT Accessory Kits are available: • 58096, for MODULEX EXT models: 1530 / 1500, 1912 • 58097, for MODULEX EXT models: 2295 / 2300, 2677 / 2600, 3060 / 3000 The contents of each are listed in the table below: TABLE 8-5: MLX Accessory Kit (P/N 58096 &...
  • Page 138 Modulex EXT Commercial Series Boilers User Manual CHAPTER 8: Maintenance Schedule (This Page Intentionally Blank) Page 138 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...

  • Page 139: Chapter 9: Spare Parts Drawing And Lists

    Modulex EXT Commercial Series Boilers User Manual CHAPTER 9: Spare Parts and Drawing Lists CHAPTER 9: SPARE PARTS DRAWING AND LISTS OMM-0095_0H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 139 of 144 GF-139 Phone: 800-526-0288 09/15/2017...
  • Page 140 Modulex EXT Commercial Series Boilers User Manual CHAPTER 9: Spare Parts and Drawing Lists (This Page Intentionally Blank) Page 140 of 144 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0095_0H 09/15/2017 Phone: 800-526-0288 GF-139...
  • Page 141 Modulex EXT Commercial Series Boilers User Manual CHAPTER 9: Spare Parts and Drawing Lists Modulex EXT Commercial Spare Parts List Item Part No. Description Quantity 95000021 Heating Sensor 3/4” T7335D1016 10K 95000467 Sight glass Kit - Comb Chamber 95000657 Silicone tube 4 X 8 95000970 COMPLETE CASTING SECTIONS ASSEMBLY MLX 1500 &...
  • Page 142 Modulex EXT Commercial Series Boilers User Manual CHAPTER 9: Spare Parts and Drawing Lists Modulex EXT Commercial Spare Parts List Item Part No. Description Quantity 95251096 Gasket - H/E-Flue Box MLX EXT 1500 & 1530 95251095 Gasket - H/E-Flue Box MLX EXT 1912 95000852 Gasket - H/E-Flue Box MLX EXT 2295 &...
  • Page 143 Modulex EXT Commercial Series Boilers User Manual CHAPTER 9: Spare Parts and Drawing Lists Modulex EXT Commercial Spare Parts List Item Part No. Description Quantity 95310512 Drain Elbow HTB DN40 95310513 Drain TEE HTEA DN 40/40 95310515 Drain Pipe 1M LG. DN 40 95362314 AERCO plate 95371895...
  • Page 144 Modulex EXT Commercial Series Boilers User Manual Change Log: Date Description Changed by Rev-G: Reformatted, new logo, applied misc. changes per AM. 07/07/2016 Curtis Harvey DIR 340: Added combustion chamber cleaning instructions. DIR 368: Changed Spare Parts item 50 P/N from 95363708 to 95263708 on page 137.

This manual is also suitable for:

Aerco modulex mlx ext 1530Aerco modulex mlx ext 1500Aerco modulex mlx ext 1912Aerco modulex mlx ext 2295Aerco modulex mlx ext 2300Aerco modulex mlx ext 2677 ... Show all

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