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Aerco MLX Series Application Manual

Gas fired boiler system
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PIPING APPLICATION GUIDE
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-H MLX series Boiler Manual
• GF-115-C MLX E8 Controller/ BCM Manual
• GF-115-G MLX Gas Supply Guide
• GF-115-V MLX Venting Guide
• GF-115-E MLX Electrical Power Guide
Revised: 05/05/2011
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288
High-Pressure Version
Modulex MLX Series
Gas Fired Boiler System
(90psi High Pressure)
GF-115-P-H
TAG-0030_0B

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  • Page 1 • GF-115-C MLX E8 Controller/ BCM Manual • GF-115-G MLX Gas Supply Guide • GF-115-V MLX Venting Guide • GF-115-E MLX Electrical Power Guide Revised: 05/05/2011 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288...
  • Page 2 The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for errors appearing in this manual.

  • Page 3: Table Of Contents

    NOTES ON CONDENSATE DRAIN ..............27 GAS MAINS AND CONNECTIONS ............... 29 8.1 Gas Main Connection Notes ................29 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 3 of 38...
  • Page 4 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 4 of 38...

  • Page 5: Important

    IMPORTANT! Local codes and authorities should be consulted prior to installation. • 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 6: Boiler Water Quality And Maintenance

    Consult your local AERCO representative for recommendations on glycol solutions. If a glycol solution is used as anti- freeze protection, a backflow preventer must be installed upstream of the fill/makeup valve.

  • Page 7: Testing And Maintenance Of Water Quality

    Water treatment is also advisable in the following cases: Very large heating systems High quantities of replenished water due to leakages or maintenance works AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 7 of 38...

  • Page 8: 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 9 Leave the relief valve open until a steady flow of water is observed. Close the valve and finish filling the system. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 9 of 38...

  • Page 10: Water Quality Maintenance And Boiler Warranty

    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, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 10 of 38...

  • Page 11: Maximum Allowable Working Pressure

    1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 2" Size Kit includes: Circuit 1-1/2” 1-1/2” 1-1/2” 2” 2” 2” Setter Size (NPT) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 11 of 38...
  • Page 12 1-1/2" 1-1/2" 1-1/2" 2" 2" Flange Size Kit includes: Circuit 1-1/2” 1-1/2” 2” 2” 2” 2” Setter Size (NPT) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 12 of 38...
  • Page 13 1-1/2" 2" 2" 2" 2" Flange Size Kit includes: Circuit 1-1/2” 2” 2” 2” 2-1/2” 2-1/2” Setter Size (NPT) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 13 of 38...
  • Page 14 2" 2" 2" 1-1/2" 1-1/2" Flange Size Kit includes: Circuit 2” 2” 2-1/2” 2-1/2” 2-1/2” 2-1/2” Setter Size (NPT) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 14 of 38...

  • Page 15: Primary Pump

    Select the pump flow rate so that the boiler water outlet temperature is 190°F (87.8°C) or below. Figure 2: Water Side Pressure Loss Chart AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 15 of 38...

  • Page 16: Strainers

    Figure 3: Electrical Connection of Primary Pump 3.2 Strainers AERCO requires the installation of a Y strainer to keep dirt out of the system and boiler. The valve should be installed in the return piping with isolation valves to allow for cleaning as necessary. The Y strainer shall have a 20 mesh or finer strainer.

  • Page 17: Csd-1 Manifold Assembly (Supplied)

    COLLECTION TRAY MANIFOLD FILLING-UP ELBOW 5.9" [150 mm]** 3.94" [100 mm] .98" [25 mm]* Figure 4: Modulex Main Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 17 of 38...
  • Page 18 Figure 5: CSD-1 Manifold Assembly and Components for Right-Hand Application Figure 6: CSD-1 Manifold Assembly and Components for Left-Hand Application AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 18 of 38...
  • Page 19 CONNECTION MANIFOLD WITH ALL COMPONENTS INSTALLED RETURN FLOW CONNECTION Figure 7: Manifold Assembly and Components Installed on Right-Hand Side AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 19 of 38...
  • Page 20 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B (This page left intentionally blank.) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 20 of 38...

  • Page 21: Connecting Supply And Return Piping

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 21 of 38...

  • Page 22: Changing Left-Hand Connections To Right-Hand

    To switch boiler connections from the standard right-hand side to the left-hand side, follow the steps in Instruction 5.5 on the next page. Figure 8: Boiler Connections AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 22 of 38...
  • Page 23 A (see gas manifold Figure 9: Right and Left Hand connections in Figure 9 at top). Connections AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 23 of 38...
  • Page 24 Sensor Thermowell Global Return Temperature Sensor Global Flow Temperature Sensor Figure 12: Sensor Assemblies Relocated When Switching Manifold Direction AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 24 of 38...
  • Page 25 Before operating the boiler, the complete gas train and all connections must be leak tested using a non- corrosive soap solution. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 25 of 38...
  • Page 26 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B (This page left intentionally blank.) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 26 of 38...

  • Page 27: System Filling And Draining

    Do not install the condensate drain where freezing may occur. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13...
  • Page 28 1-1/4" PVC PIPE 93090 1-1/4 PVC P-TRAP WITH UNION 93092 1-1/4 PVC STREET ELBOW Figure 14: Condensate Drain Assembly Components AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 28 of 38...

  • Page 29: Gas Mains And Connections

    • Prior to operation, the complete gas train ad all connections must be leak tested using a non- corrosive soap. Figure 15: Gas Piping AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 29 of 38...
  • Page 30 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B Figure 16: Single Modulex Boiler Piping System AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 30 of 38...
  • Page 31 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B Figure 17: Two Modulex Boiler Piping System AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 31 of 38...
  • Page 32 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B Figure 18: Modulex Boiler Piping System With Domestic Water Heating AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 32 of 38...
  • Page 33 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B Figure 19: Multiple Modulex Boiler Piping System with Domestic Water Heating AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 33 of 38...
  • Page 34 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B Figure 20: Modulex Gas Fired Boiler Single Unit Installation with Hydraulic Separator AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 34 of 38...
  • Page 35 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B Figure 21: Modulex Gas Fired Boiler Installation with Hydraulic Separator AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 35 of 38...
  • Page 36 GF-115-P-H Technical Application Guide TAG-0030_0B Figure 22: Modulex Gas Fired Boiler Installation with Hydraulic Separator and Domestic Water Heating AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 36 of 38...
  • Page 37 Technical Application Guide TAG-0030_0B Figure 23: Modulex Gas Fired Boiler Single Unit Installation with Hydraulic Separator and Domestic Water Heating AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 37 of 38...
  • Page 38 Modulex MLX Piping Guide GF-115-P-H Technical Application Guide TAG-0030_0B © AERCO International, Inc., 2008 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR2: 03/01/13 Page 38 of 38...

This manual is also suitable for:

Mlx-303Mlx-454Mlx-606Mlx-757Mlx-909Mlx-1060

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