Watts AERCO MLX EXT 321 Installation, Operation & Maintenance Manual
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Watts AERCO MLX EXT 321 Installation, Operation & Maintenance Manual

Watts AERCO MLX EXT 321 Installation, Operation & Maintenance Manual

Modulating and condensing boilers
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Installation, Operation & Maintenance Manual
Modulex EXT Light
Commercial Series
Modulating and Condensing Boilers
APPLIES TO MODELS:
• MLX EXT 321
• MLX EXT 481 / MLX EXT 450
• MLX EXT 641 / MLX EXT 600
• MLX EXT 802 / MLX EXT 800
• MLX EXT 962
• MLX EXT 1123 / MLX EXT 1100
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, not for incidental or
consequential damages occurring in connection with the furnishing,
performance, or use of these materials.
• GF-143 • 11/17/2020
OMM-0087_J
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
© 2020 AERCO

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  • Page 1 Installation, Operation & Maintenance Manual Modulex EXT Light Commercial Series Modulating and Condensing Boilers APPLIES TO MODELS: • MLX EXT 321 • MLX EXT 481 / MLX EXT 450 • MLX EXT 641 / MLX EXT 600 • MLX EXT 802 / MLX EXT 800 •...

  • Page 2: Table Of Contents

    Modulex Light Commericial Series 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 Light Commericial Series User Manual 4.8.3.3 Reversing Boiler Sensor Kf And Automatic Air Vent ................39 4.9 GAS CONNECTION GENERAL INFORMATION ..................... 40 4.10 NATURAL GAS CONNECTIONS ......................... 41 4.10.1.1 Natural Gas Piping Connections ......................41 4.10.1.2 Natural Gas Supply Pressure Requirements ..................41 4.11 PROPANE GAS CONNECTIONS .........................
  • Page 4 Modulex Light Commericial Series User Manual 4.37 HIGH ALTITUDE ADJUSTMENT ......................... 79 4.38 HIGH ALTITUDE CONVERSION LABEL ....................... 80 4.39 CONVERSION FROM NATURAL GAS TO PROPANE GAS ................... 81 4.40 CONTROLS AND EMERGENCY FUNCTIONS ...................... 82 4.41 INITIAL BOILER IGNITION ..........................83 Preliminary Checks..........................
  • Page 5 Modulex Light Commericial Series User Manual BMM (Burner Management Module) Fault Codes ................122 CHAPTER 8: MAINTENANCE SCHEDULE ................... 125 8.1 Instructions for Inspection and Maintenance....................126 8.2 PERIODIC EXAMINATION OF VENTING SYSTEM ....................126 8.3 PROPER PROCEDURE FOR CLEANING EXHAUST FLUE ..................126 Cleaning the Condensate Drain Line .....................
  • Page 6 Modulex Light Commericial Series User Manual (This page intentionally blank) OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 6 of 150...

  • Page 7: Chapter 1: Safety Precautions

    Modulex Light Commericial Series 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 Light Commericial Series 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 Light Commericial Series 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 Light Commericial Series CHAPTER 1: Safety Precautions (This page intentionally blank) OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 10 of 150...

  • Page 11: Chapter 2: General Information

    Modulex Light Commericial Series CHAPTER 2: General Information CHAPTER 2: GENERAL INFORMATION 2.1 CORRECT USE OF THE APPLIANCE The MODULEX EXT boiler has been designed utilizing the latest heating technologies and in compliance with the 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 Light Commericial Series 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. 2.4 SAFETY WARNINGS WARNING! •...

  • Page 13: For Appliances Operating With Propane Gas

    Modulex Light Commericial Series 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 Light Commericial Series CHAPTER 2: General Information 2.7 DATA PLATE A sample Data Plate for a MODULEX EXT 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 Data Plate (Left) and Data Packing Label (Right) 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 Light Commericial Series CHAPTER 2: General Information 2.8 OPERATIONAL REQUIREMENTS General Requirements The following instructions MUST be followed: • The boiler must only be used for its designated purpose as described in these Installation Instructions. • Each unit is fitted with a data plate. Consult the details on this plate to verify whether the boiler is compliant with its intended location, e.g.: gas type, power source and venting classification.

  • Page 16: Water Quality Requirements

    Modulex Light Commericial Series CHAPTER 2: General Information Water Quality Requirements NOTE: For additional information concerning water quality and treatment, refer to AERCO technical documents Glycol Directive and AERCO Piping Application Guide (GF-136-P). Unsuitable heating system water can cause the formation of scale or sludge, which affects system efficiency.

  • Page 17: Tools, Materials, And Additional Equipment

    Modulex Light Commericial Series 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 Light Commericial Series CHAPTER 2: General Information 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. 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 Light Commericial Series CHAPTER 3: Technical Features & Dimensions CHAPTER 3: TECHNICAL FEATURES & DIMENSIONS 3.1 MODULEX EXT 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 Light Commericial Series 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 Modulex Light Commericial Series CHAPTER 3: Technical Features & Dimensions On Modulex EXT models 321, 642 and 962 the flue terminal ends inside the casing Figure 3-1: MODULEX EXT Dimensional Drawings (Side Views) OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 21 of 150...
  • Page 22 Modulex Light Commericial Series CHAPTER 3: Technical Features & Dimensions Figure 3-2: MODULEX EXT and Vent Adaptor Dimensional Drawings (Top View) TABLE 3-1: MODULEX EXT Dimensions and Sizes Model 481 / 450 641 / 600 802 / 800 1123 / 1100 Dimensions No.
  • Page 23 Modulex Light Commericial Series CHAPTER 3: Technical Features & Dimensions NOTE: ON MODELS WITH CONTROL PANEL ALUMINUM HEADERS, THE RELIEF VALVE IS FACTORY INSTALLED AS SHOWN IN INSET BELOW. SEE SEC. 3.11. RELIEF VALVE Figure 3-3a: MODULEX EXT Main Components (Left Side View) OMM-0087_J •...
  • Page 24 Modulex Light Commericial Series CHAPTER 3: Technical Features & Dimensions Figure 3-3b: MODULEX EXT Main Components (Right Side View) • Exhaust and condensate evacuation connections: are on the RIGHT HAND side (supply condition), but may be moved to the RIGHT HAND or REAR positions.

  • Page 25: Performance Data

    Modulex Light Commericial Series CHAPTER 3: Technical Features & Dimensions 3.4 PERFORMANCE DATA TABLE 3-2: MODULEX EXT Performance Data EXT 321 Modulex 1912 1123 Parameter 1100 NOTE: The Technical data plate is placed under the casing. OMM-0087_J • GF-143 • 11/17/2020 Technical Support •...
  • Page 26 Modulex Light Commericial Series CHAPTER 3: Technical Features & Dimensions (This page intentionally blank) OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 26 of 150...

  • Page 27: Chapter 4: Installation Instructions

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions CHAPTER 4: INSTALLATION INSTRUCTIONS 4.1 GENERAL WARNINGS Appropriate Use of the Boiler This boiler MUST be used for the use for which it has been expressively designed. Any other use shall be considered improper and therefore dangerous. This boiler is designed to heat water at a temperature below the boiling point at atmospheric pressure.

  • Page 28: Code And Standards Approvals

    Modulex Light Commericial Series 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 29 Modulex Light Commericial Series CHAPTER 4: Installation Instructions ON THE BOILER FRONT: • The European to USA flue adaptor screwed to the front of the frame. • The sealing gasket for flue outlet and the flue assembly. • A cardboard box containing: o The sealing gasket for connection between exhaust manifold and vent.
  • Page 30 Modulex Light Commericial Series CHAPTER 4: Installation Instructions Cardboard Boxes with Parts Flue Assembly European to American And Gasket CSD-1 Header Standard Flue Adapter Figure 4-1: MODULEX EXT Unpacking (Front View) Condensate Drain Pipe Figure 4-2: MODULEX EXT Unpacking (Rear View) OMM-0087_J •...

  • Page 31: Transporting And Securing The Boiler Safely

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions Figure 4-3: MODULEX EXT Shipping Package TABLE 4-1: MODULEX EXT Shipping Package Dimensions Model Gross Weight 43.7‘‘ 35.0‘‘ 49.2‘‘ 448 lb. EXT 321 1110 mm 890 mm 1250 mm 203 kg 43.7‘‘ 35.0‘‘...

  • Page 32: Removal From Boiler Bed And Installation Of Boiler Feet

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.5 REMOVAL FROM BOILER BED AND INSTALLATION OF BOILER FEET See Figure 4-4 and follow the directions below to prepare the boiler for installation: 1) Remove the covers of the boiler. 2) Lift the boiler with a hoist or forklift bands. 3) Remove the 4 screws ’’A’’.
  • Page 33 Modulex Light Commericial Series CHAPTER 4: Installation Instructions Figure 4-5: EXT Unpacking (Left = Attach Feet, Right = Ready for Cover) 23.82 (605 mm) MLX 321 - 481 = 26.14 in. (664 mm) MLX 600 - 802 = 36.69 in. (932 mm) MLX 962 - 1123 = 47.24 in.

  • Page 34: Boiler Location Inside A Boiler Room

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.6 BOILER LOCATION INSIDE 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 35: Products To Avoid In The Boiler Room

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 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 • Ammonium and/or ammonium solutions •...

  • Page 36: Boiler Connections

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.8 BOILER CONNECTIONS At delivery, the MODULEX EXT boiler is setup with all connections, (i.e. cold/hot water flow & return, gas, and exhaust outlet) on its RIGHT HAND side. Changing Exhaust Outlet Location To move the flue exhaust outlet terminal from the RIGHT HAND side (standard delivery position) to the REAR position, it is necessary to request the Rear Exhaust kit, which includes a cover for closing off the RIGHT HAND side panel exhaust opening (see Figure 4-10).

  • Page 37: Reversing Gas Manifold Connections

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions Exhaust Opening Cover Figure 4-10: Rear Exhaust Kit for Changing Exhaust Outlet from RIGHT HAND Side to REAR Reversing Gas Manifold Connections To move the gas connection from the RIGHT HAND side (standard delivery position) to the LEFT HAND side, swap the end plate and the gas supply connector screwed onto the gas manifold ends, as shown in Figure 4-11.

  • Page 38: Reversing Cold/Hot Water Flow & Return Connections

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions Reversing Cold/Hot Water Flow & Return Connections Change of Water Flow and Return connections from RIGHT hand to LEFT hand requires reversing connectors, moving the Flow and Return Temperture Sensors to other end, and exchanging positions of the Boiler Sensor KF and Automatic Air Vent.

  • Page 39: Reversing Flow & Return Temperature Sensors

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.8.3.2 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 Flow/Return pipes.

  • Page 40: Gas Connection General Information

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions Figure 4-15: Caps and Plugs Used for Closing Up Vacated Gas and Hydraulic Connection Openings 4.9 GAS CONNECTION GENERAL INFORMATION For natural gas connections, refer to section 4.10.1. For propane gas connections, refer to section 4.10.2.

  • Page 41: Natural Gas Connections

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 PSI (3.5kPa). The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSI (3.5 kPa).

  • Page 42: Propane Gas Supply Pressure Requirements

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions The nominal inlet working gas pressure measured at the boiler should be 11” W.C. (27 mbar) for Propane gas (Gas E). A gas control valve must be installed adjacent to the boiler for isolation purposes. 4.11.1.3 Propane Gas Supply Pressure Requirements Pressures required at gas valve inlet pressure port: •...

  • Page 43: Manifold Assembly (Supplied)

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions On older models (MLX EXT 321, 481, 641, 802, 962,1123), the Pressure Relief Valve is not factory installed, but instead included separately in the shipping container. It must be fitted on the CSD-1 manifold at the site, per the instructions in the next section, 4.14 (see Figure 4-17). 3/4"...
  • Page 44 Modulex Light Commericial Series CHAPTER 4: Installation Instructions To install the required CSD-1 components, proceed as instructed below. NOTE: Use Teflon tape or a suitable pipe joint compound for component and piping connections described in the following steps. Installing the Flow Switch and CSD-1 Components 1.

  • Page 45: Determination Of Primary Boiler Pump Or Boiler System Pump

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.15 DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP ∆t The following table gives an indication of the pump’s flow rate in function of the of the primary circuit if the installation has a mixing header. The size of the pumps must be determined by installers or technical engineers according to boiler data and system design.

  • Page 46: Condensate Piping And Drain

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.16 CONDENSATE PIPING AND DRAIN To avoid condensate collecting inside the combustion exhaust system, the condenate piping must have an inclination toward the drain of at least 3/8 in./ft (30 mm/m). The liquid column, inside the condensate siphon, (see Condensate Siphon Plug in Figure 4-20) needs to be filled with water after installation.

  • Page 47: Water Treatment

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions WARNING! • Before commissioning the boiler, fill the condensate drain pipe with water, at the dedicated filling-up plug. See Figure 4-20. • Do not install the condensate drain where freezing may occur. •...

  • Page 48: Oxygen Levels In The System Water Warning

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions Oxygen Levels in the System Water Warning All necessary precautions must be taken for preventing the formation and localization of oxygen in the system’s water. For this reason, ensure that the plastic piping used in under-floor heating systems is impermeable to oxygen.

  • Page 49: Flue Manifold Connection

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.20 FLUE MANIFOLD CONNECTION To assemble the flue manifold to the boiler flue exhaust opening, retrieve the six (6) nuts and washers from the plastic bag, shipped with the boiler, and affix to the boiler opening per Figure 4-22.

  • Page 50: Flue Exhaust Piping To Vent

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.21 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 impermeble to the condensate of the combustion products and is made of corrosion resistant materials.

  • Page 51: Vent Starter Pieces

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.22 VENT STARTER PIECES Table 4-3 lists the vent starter pieces. See Figure 4-26 for an illustration of a fully assembled kit. PVC starter pieces are included with every unit. Stainless steel and polypropylene vent starter pieces are available from AERCO if the venting is purchased through aerco.ventquote.com.

  • Page 52: Combustion Air And Ventilation Openings

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions The flue venting pipe is affixed to the adapter using high temperature RTV and then clamped with a worm-driven Hose Clamp. When using non-metallic (plastic) venting materials, use Schedule 40 or thicker Single-wall, uninsulated pipes.

  • Page 53: Room Air Combustion

    Modulex Light Commericial Series 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 54: Important Factors For Terminal Orientation And Location

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions The minimum distance from adjacent public walkways, adjacent buildings, openable windows and building openings shall not be less than those values specified in the National Fuel Gas Code, ANI Z223.1 / NFPA 54 and/or the Natural Gas and Propabne Installation Code CAN/CSA B149.1.

  • Page 55: Minimum And Maximum Wall Thickness

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions Minimum and Maximum Wall Thickness The label at right, which is placed on the unit, indicates the minimum and maximum wall thickness through which venting is allowed to penetrate horizontally. However, if venting is vertical, then there is no minimum wall thickness.
  • Page 56 Modulex Light Commericial Series CHAPTER 4: Installation Instructions A 40 foot (12.2 m) length of vent pipe and 1 sharp 90° elbow add up to 40 ft. + 10 ft. = 50 equivalent ft. (17.4 m). EXAMPLE 2: A 30 foot (10.4 m) length of vent pipe and 2 sharp 90° elbows add up to 30 ft. + (2 x 10 ft.) = 50 equivalent ft.

  • Page 57: Electrical Connections

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.26 ELECTRICAL CONNECTIONS 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 58: Service Relay Requirement

    Modulex Light Commericial Series 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 engineer. 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 Service Relay Requirement...
  • Page 59 Modulex Light Commericial Series CHAPTER 4: Installation Instructions Figure 4-29: 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 60 Modulex Light Commericial Series CHAPTER 4: Installation Instructions Figure 4-30: Main Power Junction Box Location and 120VAC Wiring OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 60 of 150...

  • Page 61: Functional Wiring Diagram

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.27 FUNCTIONAL WIRING DIAGRAM OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 61 of 150...
  • Page 62 Modulex Light Commericial Series CHAPTER 4: Installation Instructions (This page intentionally blank) OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 62 of 150...

  • Page 63: Ladder Diagrams

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.28 LADDER DIAGRAMS Figure 4-31: Module Ladder Diagram OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 63 of 150...

  • Page 64: General Ladder Diagram

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.29 GENERAL LADDER DIAGRAM Figure 4-32: General Ladder Diagram 4.30 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 65 Modulex Light Commericial Series CHAPTER 4: Installation Instructions Figure 4-33: E8 Controller Terminal Assignments OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 65 of 150...
  • Page 66 Modulex Light Commericial Series CHAPTER 4: Installation Instructions Figure 4-34: Sensor and BCM Terminal Assignments OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 66 of 150...

  • Page 67: Installation Examples

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.31 INSTALLATION EXAMPLES (Functional Wiring and Connections Description) OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 67 of 150...
  • Page 68 Modulex Light Commericial Series CHAPTER 4: Installation Instructions OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 68 of 150...

  • Page 69: Starting Up: Filling And De-Aerating The Boiler

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.32 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 70: Filling Locations And Preparation

    Modulex Light Commericial Series 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. Use only clean water or approved glycol for filling the heating system.
  • Page 71 Modulex Light Commericial Series 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. This appliance does not have a pilot light. It is equipped with an ignition device, which automatically lights the burner.

  • Page 72: Testing The Ignition Safety Shut Off Device

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.34 TESTING THE IGNITION SAFETY SHUT OFF DEVICE Ignition Safety Shutoff 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 73: Burner Calibration

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.35 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 74: Maximum Output Calibration

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions Maximum Output Adjust Minimum Output Adjust Figure 4-38: Location of Minimum and Maximum Adjustments (Top View) Maximum Output Calibration After installing the gas analyzer probe (Figure 4-37), refer to Figure 4-38 to locate the gas valves and the Maximum Gas Adjustment screw (A) on each valve.

  • Page 75: Minimum Output Calibration

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions Minimum Output Calibration After setting the maximum gas output for each valve (section 4.35.2), refer to Figure 4-38, 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 76 Modulex Light Commericial Series CHAPTER 4: Installation Instructions TABLE 4-6: Modulex EXT Pressure, CO and O Level Calibration Tables EXT 321 Ǿ Mixer Level Level Fan Speed Supply Min. Gas Max. Gas Start Injectors Pressure Consumption Consumption Output Ǿ in. Type Min.
  • Page 77 Modulex Light Commericial Series CHAPTER 4: Installation Instructions TABLE 4-6: Modulex EXT Pressure, CO and O Level Calibration Tables EXT 802/800 Ǿ Mixer Level Level Fan Speed Supply Min. Gas Max. Gas Start Injectors Pressure Consumption Consumption Output Ǿ in. Type Min.

  • Page 78: Sweeper Mode (Manual Control)

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.36 SWEEPER MODE (MANUAL CONTROL) Figure 4-40: Sweeper Mode (Manual Control) NOTE: The function is active for 15 minutes, after which, if there is no input, it defaults to the previous parameters. OMM-0087_J •...

  • Page 79: High Altitude Adjustment

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.37 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 80: High Altitude Conversion Label

    Modulex Light Commericial Series 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 FAN MOD IGN No Change FAN MOD STBY No Change FAN MAX (FH) FAN MIN (FL) No Change...

  • Page 81: Conversion From Natural Gas To Propane Gas

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.39 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. Set nominal heat by adjusting the fan speed parameter FH (FAN MAX) from the E8 controller as shown in Table 4-7, above, and Modulex EXT Pressure and CO Level Calibration in Table 4-6, above.

  • Page 82: Controls And Emergency Functions

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.40 CONTROLS AND EMERGENCY FUNCTIONS Figure 4-44: MODULEX EXT Panel Controls and Indicators Legend to Figure 4-44 ITEM COMPONENT / FUNCTION Manual Reset High-Limit switch: When enabled, it cuts the power supply to the boiler and lights the warning lamp (Item D).

  • Page 83: Initial Boiler Ignition

    Modulex Light Commericial Series CHAPTER 4: Installation Instructions 4.41 INITIAL BOILER IGNITION Preliminary Checks WARNING! 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 84 Modulex Light Commericial Series CHAPTER 4: Installation Instructions (This page intentionally blank) OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 84 of 150...

  • Page 85: Chapter 5: E8 Controller And Bcm Modules

    Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC 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 86: E8 Display Functions

    Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC Modules LCD Display Window Hinged Cover Rotary Knob (in closed position) Figure 5-1: MODULEX E8 Controller Front Panel (Cover Closed) 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 87: E8 Heating Mode Selection

    Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC Modules 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 88: E8 Menu Mode Operation (Door Open)

    Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC Modules 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 89: E8 Menu Navigation And Parameter Settings

    Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC Modules 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 section 6.1), to access, view and/or change menu items follow these instructions: Sub-MENU Name...

  • Page 90: E8 Parameter Navigation, Selection, And Setting

    Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC Modules 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 91: Bcm (Boiler Communication Module)

    Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC 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 92 Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC Modules Refer to Table 5-5 and 5-6 for details on the features and functions of the BCM. DL2 (RED) DL3 (GREEN) DL1 (YELLOW) Input Communications Connector (Modbus/Ebus) Change-Over 3-Pos. Switch Enable/Disable 2-Pos.
  • Page 93 Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC 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 The E8 is the primary for Modbus and external controller and the BCM...
  • Page 94 Modulex Light Commericial Series CHAPTER 5: E8 Controller and BMC Modules (This page intentionally blank) OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 94 of 150...

  • Page 95: Chapter 6: Operation

    Modulex Light Commericial Series CHAPTER 6: Operation CHAPTER 6: OPERATION 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. For more detailed information concerning the E8 controller menus, sub- menus, and functions, refer to the E8 Controller User Manual (GF-115-C).

  • Page 96: Installation Menu: Initializing The E8 Controller

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

  • Page 97: Quick Start Instructions

    Modulex Light Commericial Series CHAPTER 6: Operation 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. IMPORTANT NOTE! Before the boiler may be used, the E8 controller MUST be first intitialized by entering language, year, month, day, and hour in the Installation Menu, as described in section 6.1, above.

  • Page 98: Setting Room Temperature And Outdoor Compensation

    Modulex Light Commericial Series CHAPTER 6: Operation Setting Room Temperature and Outdoor Compensation Figure 6-3: E8 Quick Start, Room Temperature and Outdoor Compensation Settings with Outdoor Temperature (Slope) Chart OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 98 of 150...

  • Page 99: Setting Heating Programs And Pumps

    Modulex Light Commericial Series CHAPTER 6: Operation Setting Heating Programs and Pumps Figure 6-4: E8 Quick Start, Heating and Pump Program Settings OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 99 of 150...

  • Page 100: Menu And Sub-Menu Descriptions

    Modulex Light Commericial Series CHAPTER 6: Operation 6.3 MENU AND SUB-MENU DESCRIPTIONS There are six top level menus and five sub-menus as listed below. Menus (Top Level): • GENERAL Value selection summary. Service => for service engineers. Date/Time/Holiday => for users.

  • Page 101: General Menu

    Modulex Light Commericial Series CHAPTER 6: Operation 6.4 GENERAL MENU The GENERAL menu contains the sub-menus DATE/TIME, HOLIDAY, and CLOCK CHANGE. Figure 6-5: GENERAL Menu TABLE 6-1: GENERAL Menu OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 101 of 150...
  • Page 102 Modulex Light Commericial Series CHAPTER 6: Operation 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 Adjust current day 01 - 31 HOLIDAY YEAR START Set current holliday start year...

  • Page 103: Service Menu

    Modulex Light Commericial Series CHAPTER 6: Operation 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 104 Modulex Light Commericial Series CHAPTER 6: Operation 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 A4: Mixer OPEN heating circuit 2 RELAY TEST 05...

  • Page 105: Display Menu

    Modulex Light Commericial Series CHAPTER 6: Operation 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. HOT WATER is displayed only if the DHW storage sensor is wired).

  • Page 106: User Menu

    Modulex Light Commericial Series CHAPTER 6: Operation 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 Temperature and status of the HS (HS1 - HS8) T-SOLID FUEL For HS2 = Solid fuel boiler...
  • Page 107 Modulex Light Commericial Series CHAPTER 6: Operation 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 TABLE 6-4: USER Menu LEVEL DESCRIPTION ENTRY OMM-0087_J • GF-143 • 11/17/2020 Technical Support •...
  • Page 108 Modulex Light Commericial Series CHAPTER 6: Operation 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 (01 ÷ 02) RETURN HOT WATER 1-DHW...

  • Page 109: Time Program Menu

    Modulex Light Commericial Series CHAPTER 6: Operation 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 Program for hot water charging pump HOTW-PROG ( 1st Heating program for first controller heating circuit HTG-PROG 1...

  • Page 110: Expert Menu

    Modulex Light Commericial Series CHAPTER 6: Operation 6.9 EXPERT MENU The EXPERT menu contains the items shown below: Figure 6-10: EXPERT Menu – 1 of 2 OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 110 of 150...
  • Page 111 Modulex Light Commericial Series CHAPTER 6: Operation Figure 6-11: 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-0087_J •...
  • Page 112 Modulex Light Commericial Series CHAPTER 6: Operation 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 BUS ID 1 The heating circuits are sequentially numbered..(01 ÷...
  • Page 113 Modulex Light Commericial Series CHAPTER 6: Operation TABLE 6-6: EXPERT Menu - Continued LEVEL DESCRIPTION ENTRY INSTALLATION (Cont.) DEFAULT RANGE If this modulation degree is exceeded, the next IMODULAT MAX (10 - 60) heat ..MODULAT MIN If values drop this modulation degree, the last heat (10 - 60) MIN MOD HS Connection of the next heat generator...

  • Page 114: Other Possible Settings

    Modulex Light Commericial Series CHAPTER 6: Operation 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 ÷ 03) MIXER OPEN Open mixer dynamic (5 ÷...

  • Page 115: A Second Dhw Storage Tank

    Modulex Light Commericial Series CHAPTER 6: Operation 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.  Heating circuit I/II ...

  • Page 116: Setting Of Dhw Circuit

    Modulex Light Commericial Series CHAPTER 6: Operation 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 100°...

  • Page 117: Chapter 7: Troubleshooting

    Modulex Light Commericial Series CHAPTER 7: Troubleshooting CHAPTER 7: TROUBLESHOOTING 7.1 E8 CONTROLLER ERROR 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 118 Modulex Light Commericial Series CHAPTER 7: Troubleshooting In order to derive the error message from the code displayed in the E8 Controller display, use Table 7-1 below to determine the working error 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 Error Table to reference from the fourth column.

  • Page 119: E8 Controller Fault Codes

    Modulex Light Commericial Series CHAPTER 7: Troubleshooting 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 FAULT CODE FAULT DESCRIPTION PCB Element Fault Intervention of the high limit thermostat (TL). Insufficient gas pressure.
  • Page 120 Modulex Light Commericial Series CHAPTER 7: Troubleshooting TABLE 7-2: E8 Controller Fault Codes (Continued) FAULT FAULT DESCRIPTION CODE Communication Fault E8: BUS addresses 0 and 1. The BUS codes 0 and 1 cannot be used at the E 90 same time. E8: BUS code occupied.

  • Page 121: Bcm (Boiler Communications Module) Fault Codes

    Modulex Light Commericial Series CHAPTER 7: Troubleshooting 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 Ignition is Boiler pipe is frozen. inhibited.

  • Page 122: Bmm (Burner Management Module) Fault Codes

    Modulex Light Commericial Series CHAPTER 7: Troubleshooting 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 Check flow sensor thermal MANUAL - push...
  • Page 123 Modulex Light Commericial Series CHAPTER 7: Troubleshooting TABLE 7-4: BMM Fault Codes (Continued) 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 124 Modulex Light Commericial Series CHAPTER 7: Troubleshooting TABLE 7-4: BMM Fault Codes (Continued) CODE DESCRIPTION EFFECT CORRECTION RESET Ignition retry after 60 Fan speed out of second delay control: It and failure doesn't reach E 24 remains until Check fan wiring. AUTOMATIC/MANUAL pre-purge speed we have a...

  • Page 125: Chapter 8: Maintenance Schedule

    Modulex Light Commericial Series 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 126: Instructions For Inspection And Maintenance

    Modulex Light Commericial Series 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 127: Cleaning The Condensate Drain Line

    Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Cleaning the Condensate Drain Line In order to inspect and clean the condensate drain, do the following: 1. Refer to Figure 8-1, disconnect the pipe at location (A). 2. Check that no deposits have accumulated inside the drain. If there are any deposits, flush them out with clean water.

  • Page 128: Visual Inspection Of The Flame

    Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule 8.5 VISUAL INSPECTION OF THE FLAME 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 129: Pressure Switch Hoses And Connections

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

  • Page 130: Burner / Heat Exchanger Cleaning Procedure

    Modulex Light Commericial Series 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 combusted by-products onto the thermally conductive surfaces.

  • Page 131: Unit Disassembly

    Modulex Light Commericial Series 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 132 Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued 4. Remove screws from around exhaust outlet opening and remove flue assembly from unit (see Figure 8-7 and 8-8). Figure 8-8: Flue Removal (Step 4) 5.
  • Page 133 Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued 6. Remove the red hoses (quantity depends on model) from bottom side of manifold (Figure 8- 10), then lift entire manifold from the unit. Lift out manifold after removing red hoses.
  • Page 134 Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued 8. On each fan, remove each (of two) Fan Connectors. Remove Two Connectors from Each Fan Figure 8-12: Removing Both Fan Connectors from All Fans 9.
  • Page 135 Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued Figure 8-14: Removal of Burner Plate Hardware (Steps 9, 10, 11) 11. Refer to Figure 8-15 and remove the two bolts (white arrows) at each end of the gas collection tube that mount it to the boiler chassis.
  • Page 136 Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued 12. Refer to Figure 8-16 and, using a 10mm socket wrench, remove the four bolts/nuts (white arrows) to separate the Gas Collector Tube Flange from the gas supply piping. Figure 8-16: Uninstall Gas Collector Flange from Gas Supply Piping (Step 13) 13.
  • Page 137 Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued Figure 8-18: Unscrewing Lift Screw into Tab Hole (Step 14) Figure 8-19: Lift Screws Extended into Tab Holes, Left and Right Sides (Step 14) 14. Refer to Figure 8-20, then lift up the front of the burner assembly and raise up until the two lift pins can be inserted (Figure 8-22) at the left and right sides in order to hold up the burner assembly.

  • Page 138: Cleaning The Burner Module And Combustion Chamber

    Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Disassembling the Boiler for Maintenance – Continued NOTE The check valve (1 in Figure 8-21) should at this time be checked to ensure that it moves freely and closes properly. Figure 8-21 Lifting Burner Assembly and Location of Check Valve (Step 1) Figure 8-22: Lift Pins Inserted into Lift Holes, Left and Right Sides (Step 15) 8.11 CLEANING THE BURNER MODULE AND COMBUSTION CHAMBER...
  • Page 139 Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Cleaning the Burner Modules – Continued 1. Carefully lift each burner module from its position. Remove both the module and the gasket. Discard the used gasket, as each one will be replaced at reassembly. WARNING! The burner gaskets MUST be replaced at every cleaning.

  • Page 140: Cleaning The Heat Exchanger

    Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule 8.12 CLEANING THE HEAT EXCHANGER Over time, hard combustion by-product deposits can form on the combustion chambers’ heat exchanger elements. Routine annual maintenance may be sufficient to keep these elements clean. However, if the by-product build-up is too great, the efficiency of the heat exchanger will degrade and the unit’s overall efficiency will decline.
  • Page 141 Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Mechanical Cleaning of the Heat Exchanger – Continued Figure 8-27: Angle of Cleaning Instrument – Heat Exchanger Cut-Away View Wash the combustion chamber underneath with water. Avoid getting the electrical harnesses and components wet. During this operation, inspect the condensate drain pipe to determine if it is free of obstructions;...

  • Page 142: Cleaning The Heat Exchanger With Cleaning Solution

    Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule Cleaning the Heat Exchanger with Cleaning Solution If mechanical cleaning has not removed all of the build-up, complete the instructions below to clean the heat exchangers with a cleaning solution specifically designed for removing combustion by-products from aluminum heat exchangers.

  • Page 143: Reassembly Of The Burner Modules

    Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule 8.13 REASSEMBLY OF THE BURNER MODULES Follow the instructions to reassemble the burner modules: Reassembling the Burner Modules 1. After the cleaning of the boiler combustion chamber and/or the burners, reposition the burners in their proper positions.

  • Page 144: Maintenance Kit Part Number

    Modulex Light Commericial Series CHAPTER 8: Maintenance Schedule 8.15 MAINTENANCE KIT PART NUMBER To order the MODULEX 12-Month 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. Annual Maintenance Kits contain a flame detector and igniter, while the 24-Month Fireside Inspection Kits contain flame detector, igniter, and burner gaskets.

  • Page 145: Chapter 9: Spare Parts Drawing And Lists

    Modulex Light Commericial Series CHAPTER 9: Spare Parts Drawings and Lists CHAPTER 9: SPARE PARTS DRAWING AND LISTS MODULEX EXT Light Commercial Part List (EXT 321, 481, 641, 802, 962, 1123) OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 145 of 150...
  • Page 146 Modulex Light Commericial Series CHAPTER 9: Spare Parts Drawings and Lists MODULEX EXT Light Commercial Part List PART NO. DESCRIPTION 95000020 Outlet pressure G1/8" 95000021 Heating Sensor 3/4" T7335D1016 10K 95000467 Sightglass Kit - Comb Chamber 95362314 AERCO plate 95000657 Silicone tube 4 X 8 95262953 High Water Temp Switch...
  • Page 147 Modulex Light Commericial Series CHAPTER 9: Spare Parts Drawings and Lists MODULEX EXT Light Commercial Part List PART NO. DESCRIPTION 95250618 Gasket - H/E-Flue Box MODULEX 7M 95250619 Gasket - H/E-Flue Box MODULEX 6M 95250620 Gasket - H/E-Flue Box MODULEX 5M 95250621 Gasket - H/E-Flue Box MODULEX 4M 95250622...
  • Page 148 Modulex Light Commericial Series CHAPTER 9: Spare Parts Drawings and Lists MODULEX EXT Light Commercial Part List PART NO. DESCRIPTION 95263419 Mesh Burner 95262925 Screw UNI 5931 M8X110 95262926 Gas spring 95262932 Gas cap inspection 95310512 Drain Elbow HTB DN40 95310513 Drain TEE HTEA DN 40/40 95310515...
  • Page 149 Modulex EXT Light Commercial Series Boilers User Manual NOTES: OMM-0087_J • GF-143 • 11/17/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 149 of 150...
  • Page 150 Modulex EXT Light Commercial Series Boilers User Manual Change Log: Date Description Changed by Rev I: DIR 17-008: Added new model numbers for units with aluminum water connections, reformatted per new design standard DIR 17-011: Removed P/N 00364937 from all places, replaced spare parts drawing and list.

This manual is also suitable for:

Aerco mlx ext 481Aerco mlx ext 450Aerco mlx ext 641Aerco mlx ext 600Aerco mlx ext 802Aerco mlx ext 800 ... Show all

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