Aerco Modulex 303 Installation & Operation Manual
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Aerco Modulex 303 Installation & Operation Manual

Gas fired boiler systems modular, condensing, hot water boilers
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Instruction
GF-115H
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Installation, Operation
& Maintenance Instructions
Gas Fired
Boiler Systems
Modular, Condensing, Hot Water Boilers
Models: 303, 454, 606, 757, 909, 1060
7/17/08
Printed in U.S.A.

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  • Page 1: Maintenance Instructions

    Instruction GF-115H AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA Installation, Operation & Maintenance Instructions Gas Fired Boiler Systems Modular, Condensing, Hot Water Boilers Models: 303, 454, 606, 757, 909, 1060 7/17/08 Printed in U.S.A.
  • 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 AERCO International, Inc.

  • Page 3: Table Of Contents

    INSTALLATION, OPERATION & MAINTENANCE TABLE OF CONTENTS Chapter/Paragraph Page SAFETY SYMBOLS AND WARNINGS IMPORTANT FOR YOUR SAFETY GENERAL DESCRIPTION TECHNICAL FEATURES CODES AND STANDARDS APPROVALS INSTALLATION FLEXIBILITY DIMENSIONS TECHNICAL DATA MODULEX SIDE VIEW SHOWING MAIN COMPONENTS BOILER FREEZE PROTECTION INSTRUCTIONS FOR INSTALLERS INTRODUCTION INSTALLATION INSTRUCTIONS 2.2.1...
  • Page 4 INSTALLATION, OPERATION & MAINTENANCE TABLE OF CONTENTS - Continued Chapter/Paragraph Page GAS MAINS AND CONNECTION ELECTRICAL ELECTRICAL CONNECTIONS D.H.W. STORAGE TANK ENABLE/DISABLE INSTALLATION OF SENSORS BOILER OPERATION GENERAL DESCRIPTION AND OPERATION MODULATION THEORY IGNITION SEQUENCE MODES OF OPERATION 6.4.1 INDOOR/OUTDOOR RESET 6.4.2 0 TO 10 VOLT REMOTE SET-POINT 6.4.3...
  • Page 5 INSTALLATION, OPERATION & MAINTENANCE SAFETY SYMBOLS The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels. INDICATES AN IMMINENTLY HAZARDOUS SITUATION, WHICH IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.
  • Page 6 • CAUTION, THE IGNITER MAY BE HOT. USE CARE TO AVOID SERIOUS BURNS • Caution must be observed to prevent damage to the AERCO Modulex Boiler or associated equipment. Failure to observe precautions may also void the Boiler warranty. •...

  • Page 7: For Your Safety

    INSTALLATION, OPERATION & MAINTENANCE FOR YOUR SAFETY For boilers that use gaseous fuel, what to do if you smell gas. • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. •...
  • Page 8 INSTALLATION, OPERATION & MAINTENANCE Extracted Information From 248 CMR 5.08 (2) – Continued a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

  • Page 9: General Description

    1060 comprised of 7 heat modules has a total input of 1060 MBTU’s (See Table 1-1). For one Modulex 303 boiler consisting of two modules, the output modulates from 15% to 100%. For a Modulex 1060 boiler consisting of seven modules, the output modulates from 4.3% and 100%. If a system comprised of two boilers is installed, then the modulation range for each boiler increases to 7.5%...

  • Page 10: Codes And Standards Approvals

    INSTALLATION, OPERATION & MAINTENANCE 1.2 - CODE AND STANDARDS APPROVALS MODULEX has been reviewed for compliance with the applicable sections of the following North American Standards: Z21.13: GAS FIRED LOW PRESSURE STEAM AND HOT WATER BOILERS ASME SECTION IV: BOILER AND PRESSURE VESSEL CODE RULES FOR CONSTRUCTION OF HEATING BOILERS TESTING STANDARD METHOD TO DETERMINE EFFICIENCY OF BTS 2000:...
  • Page 11 INSTALLATION, OPERATION & MAINTENANCE 1.4 DIMENSIONS AND WEIGHTS The dimensions and weights for each Modulex Model are shown in sheets 1 and 2 of Figure 1-1. Figure 1-1. Modulex Dimensions and Weights (Sheet 1 of 2)
  • Page 12 INSTALLATION, OPERATION & MA INTENANCE Figure 1-1. Modulex Dimensions and Weights (Sheet 2 of 2)

  • Page 13: Dimensions

    INSTALLATION, OPERATION & MAINTENANCE 1.5 - TECHNICAL DATA (THE NAME PLATE IS PLACED UNDER THE FRONT JACKET NEXT TO THE CONTROL PANEL.) Model Number Min Input Max Input Max Output* Net IBR Rating MLX-303 45,500 303,000 260,000-279,000 237,000 MLX-454 45,500 454,000 390,000-418,000 355,000...

  • Page 14: Modulex Side View Showing Main Components

    INSTALLATION, OPERATION & MAINTENANCE SPECIFICATIONS: (continued) Model Number MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX-1060 Water Pressure Drop @ 5 psi 6 psi 9 psi 10 psi 13 psi 15 psi Max. Flow (34.5 kPa) (41.4 kPa) (62.1 kPa) (68.9 kPa) (89.6 kPa) (103.4 kPa) Water Volume: Gallons...

  • Page 15: Boiler Freeze Protection

    INSTALLATION, OPERATION & MAINTENANCE GAS VALVE AIR INTAKE CONNECTION GAS PIPE AUTOMATIC AIR VENT BURNER COVER IGNITION FLAME DETECTOR LOCAL NTC GLOBAL FLOW SENSOR NTC TEMPERATURE SENSOR H.L. THERMOSTAT HOT WATER BURNER OUTLET (SUPPLY) ALUMINUM/ 1/4" CONNECTION SILICON HEAT WITH PLUG EXCHANGER GLOBAL RETURN NTC TEMPERATURE...

  • Page 17: Instructions For Installers

    INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR INSTALLERS 2.1 INTRODUCTION The Modulex Boiler is intended to be installed as a Category IV vent installation and must be installed in compliance with all applicable laws and regulations including the ones below. See section 3.1 for Category descriptions.
  • Page 18 INSTALLATION, OPERATION & MAINTENANCE Packed inside the boiler packing you will find: • Painted steel panels: • The front one connected to the back panel by a shrink wrap film • The right hand side panel connected to the left hand panel by shrink wrap On the front of the boiler: •...

  • Page 19: Locating The Boiler

    The minimum clearance dimensions for service access, required by AERCO, are listed below (Figure 2-2) and on the boiler Data Plate shown in Figure 2-7. Local building codes may require more clearance and take precedence.

  • Page 20: Boiler Connections

    INSTALLATION, OPERATION & MAINTENANCE 2.2.4 Boiler Connections Upon delivery, Modulex Boiler connections R.H. side (Figure 2-3). Note that the R.H. orientation is the right hand side when viewed facing the front of the boiler. These connections include: water supply and return, gas, combustion air intake and flue collector outlet. The locations of the air intake and/or the flue collector outlet can be changed on site by removing knock-outs on the boiler right, left or back side panels.
  • Page 21 INSTALLATION, OPERATION & MAINTENANCE BCM TEMP SENSOR AUTOMATIC AIR VENT E8 TEMP SENSOR RETURN TEMP SENSOR BOILER DRAIN THERMOWELL SENSOR SENSOR BRACKET CONNECTOR THERMOWELL CLIP BRACKET SCREW E8 TEMP SENSOR TEMPERATURE SENSOR E8 SENSOR BCM & BOILER RETURN SENSORS Figure 2-4 Right Hand (R.H.) Connection...
  • Page 22 INSTALLATION, OPERATION & MAI NTENANCE 3. Disassemble the flow (supply) and return manifolds (Figure 2-5), leaving the rubber gaskets in place on the upper holes of the aluminum sections and the rubber gaskets/diaphragms in place on the lower holes. The diaphragms on the end sections have a hole diameter of .866 in. (22 mm). 4.
  • Page 23 INSTALLATION, OPERATION & MAINTENANCE AUTOMATIC AIR VENT BCM TEMP SENSOR E8 TEMP SENSOR RETURN TEMP SENSOR BOILER DRAIN THERMOWELL SENSOR SENSOR BRACKET CONNECTOR THERMOWELL CLIP BRACKET SCREW E8 TEMP SENSOR TEMPERATURE SENSOR E8 SENSOR BCM & BOILER RETURN SENSORS Figure 2-6 Left Hand (L.H.) Connection...

  • Page 24: Data Plate

    INSTALLATION, OPERATION & MAINTENANCE 6. For the gas connection, it is possible to keep the gas manifold inlet on the R.H. side, if desired, or it can be rotated 180° to have it on the L.H. side. In case of reversal from R.H. side to L.H. side of the gas manifold, only on the Modulex Model 303 will it be necessary to reverse plug C with the gas valve fitting A (see gas manifold connections in Figure 2-5).
  • Page 25 INSTALLATION, OPERATION & MAINTENANCE Figure 2-7 Sample Data Plate...
  • Page 26 INSTALLATION, OPERATION & MAINTENANCE Table 2-1. Modulex Data Plate Entries MODEL NUMBER MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX-1060 REVISION TYPE OF GAS NATURAL GAS NATURAL GAS NATURAL GAS NATURAL GAS NATURAL GAS NATURAL GAS (MLX-303H) (MLX-454H) (MLX-606H) (MLX-757H) (MLX-909H) (MLX-1060H OR PROPANE OR PROPANE OR PROPANE...

  • Page 27: Gas Vent Categories

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

  • Page 28: Removal Of Existing Boiler From Common Venting System

    INSTALLATION, OPERATION & MAINTENANCE Pipe lengths and fittings must be calculated as part of the equivalent length. The pressure drop of the vent and combustion air systems must not exceed 100 equivalent feet each. Note that this DOES NOT mean the allowed combined pressure drop between the vent and combustion air is 200 equivalent feet. That is, the vent cannot go above 100 equivalent feet, even if the combustion air is less than 100 equivalent feet, and vice versa.

  • Page 29: Piping

    PIPING NOTE: For in depth piping information for the boiler, see Piping Guide GF-115-P-H 4.1 MAKEUP WATER QUALITY Water at the installation should be checked, monitored, maintained and treated as described in GF-115-P-H. NOTE: Failure of the boiler due to water quality is not covered under warranty. 4.2 - MAXIMUM ALLOWABLE WORKING PRESSURE The Modulex boiler has a maximum allowable working pressure of 92 psi (634kPa, 6.34 bar), and a minimum of 15 psi (103 kPa, 1 bar).

  • Page 30: System Filling And Draining

    INSTALLATION, OPERATION & MAINTENANCE 4.6 SYSTEM FILLING & DRAINING • For filling-up the system a filling tap has to be inserted on the system return pipe. • The filling-up can also be made through the draining tap on the boiler return manifold. •...

  • Page 31: Electrical

    AERCO is not liable for any damage caused by connection to an improper grounding system. The gas and water feeding pipes and the central heating system pipes cannot be used as grounding means.

  • Page 32: Dhw Storage Tank

    INSTALLATION, OPERATION & MAINTENANCE It is necessary to install a double-pole switch on the supply line in an easily accessible position in order to quickly and safely disconnect service. Do Not affix switch to boiler sheet metal enclosure. Figure 5-1. Junction Box Wiring Connections After placing the boiler in operation, the ignition system safety shutoff device must be tested.
  • Page 33 INSTALLATION, OPERATION & MAINTENANCE Figure 5-2.

  • Page 35: Boiler Operation

    INSTALLATION, OPERATION & MAINTENANCE BOILER OPERATION 6.1 GENERAL DESCRIPTION AND OPERATION The Modulex is a cast aluminum body boiler consisting of mutually connected combustion chambers, each having its own burner, blower and air pressure switch, gas valve, ignitor and flame detection. Each group of these components is referred to as a module.

  • Page 36: Ignition Sequence

    INSTALLATION, OPERATION & MAINTENANCE 6.3 IGNITION SEQUENCE The ignition sequence is described below and shown in the following diagram (Figure 6-1). The Ignition Burner Management Module (BMM) is powered on and, after 5 seconds the fan starts at minimum speed. The fan remains running, actuating the air pressure switch and pre-purging the combustion chamber for 10 seconds.

  • Page 37: To 10 Volt Remote Set-Point

    INSTALLATION, OPERATION & MAINTENANCE The outside air sensor, supplied with the boiler, should be mounted on an outer North or Northeast, wall at a minimum height from floor of 8 feet, 2.5 inches (2.5 m) away from windows, doors and ventilation grates.
  • Page 38 INSTALLATION, OPERATION & MAINTENANCE 6.5.1 Tools and Instrumentation Required For Combustion Calibration The following tools and instrumentation are necessary to perform combustion calibration of the unit: • Digital Combustion Analyzer: Oxygen (O ) and Carbon Dioxide (CO ) accuracy to ±0.4%; Carbon Monoxide (CO) resolution to 1 ppm •...

  • Page 39: Preparing The Flue For Use With The Combustion

    INSTALLATION, OPERATION & MAINTENANCE 6.5.3 Preparing The Flue For Use With The Combustion Analyzer In order to provide an opening for the combustion analyzer, proceed as follows: 1. Drill a 3/8” hole in the PVC vent pipe, approximately 2 feet above the boiler exhaust manifold. 2.

  • Page 40: Combustion Calibration

    Combustion Calibration procedure in paragraph 6.5.5. 6.5.5 COMBUSTION CALIBRATION. The Modulex boiler is combustion calibrated prior to shipment from the factory. However, AERCO recommends that the following calibration and adjustments be performed due to possible differences in altitude, BTU content, installed gas supply piping and regulators used.
  • Page 41 INSTALLATION, OPERATION & MAINTENANCE CAP SCREW / OFFSET ADJUSTMENT OUTLET OUTLET PRESSURE TAP (NORMAL MANIFOLD PRESSURE) Figure 6-2. Gas Valve Adjustment 1. Refer to Figure 6-2 and locate the outlet pressure tap for the gas valve of the first Boiler Stage. 2.
  • Page 42 INSTALLATION, OPERATION & MAINTENANCE NOTE The CASCADE MANU (Cascade Manual) mode will time out after a period of 15 minutes. When this occurs, the boiler will revert the Auto mode and will function under program control. If this occurs prior to completing the combustion calibration for each Boiler stage, it will be necessary to repeat steps 7 through 15 and then sequence the Boiler stage to the one which was in-process when the time out occurred.

  • Page 43: Unit Reassembly

    INSTALLATION, OPERATION & MAINTENANCE 6.6 UNIT REASSEMBLY Once the combustion calibration procedures have been completed for each Boiler stage, the unit can be reassembled for service operation. 1. Set the ON/OFF switch on the front of the Modulex Boiler to the OFF position. 2.

  • Page 45: Maintenance

    INSTALLATION, OPERATION & MAINTENANCE MAINTENANCE 7.1 - MAIN FEATURES If the boiler is correctly adjusted, it needs very little maintenance. It only needs to be checked once a year and, if necessary, be cleaned. See the Annual Maintenance Schedule in Table 7-1 at the end of this section.
  • Page 46 INSTALLATION, OPERATION & MAINTENANCE 7. Remove the “E” screws on the two sides of the burner manifold. 8. Remove the sheet metal protections “F” on the two sides of the burner manifold. 9. Position the burner manifold, at the two sides, 3/8” (10 mm) higher than the standard position shown below.
  • Page 47 INSTALLATION, OPERATION & MAINTENANCE 10. Lift up the fan group “L” by rotating it on the gas manifold axis and keep it up by inserting the support rods “I”, attached to the frame, in the holes “M”. · 11. Access the condensate tray “N” and remove the cleaning plate “O” from the opposite side of the flue collector, or remove the complete tray terminal with the flue collector: This depends on which side the baffle “P”...
  • Page 48 INSTALLATION, OPERATION & MAINTENANCE 12. If you want to remove the baffle from the tray, rotate it within the tray before starting to remove it. Cleaning 1. Refer to the burner removal illustrations on the next page. Remove the burners and sealing gaskets from their seats.
  • Page 49 INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR BURNER REMOVAL WITH REAR GROUND TAB Warning. Remove the burners as shown in the illustration by first lifting up the side opposite to the ground tab indicated by the arrow. INSTRUCTIONS FOR BURNER REMOVAL WITH FRONT GROUND TAB Warning.
  • Page 50 INSTALLATION, OPERATION & MAINTENANCE Table 7-1. Annual Maintenance Schedule TASK RECOMMENDED REQUIRED Inspect air filters Inspect vent pipe Inspect condensate drain lines Inspect flue collector & condensate tray Wash heat exchanger Check and adjust air/fuel ratio Inspect and clean burner surface Check for gas leaks using a soapy solution Inspect igniter and flame sensor Inspect heat transfer surfaces...
  • Page 51 APPENDIX A APPENDIX Temperature Sensor Resistance Charts...

  • Page 52: Appendix A

    APPENDIX A TEMPERATURE SENSOR RESISTANCE CHART TEMPERATURE RESISTANCE °F (°C) (OHMS) -76 (-60) 698961 -58 (-50) 33908 -40 (-40) 167835 -22 (-30) 88340 -4 (-20) 48487 14 (-10) 27648 32 (0) 16325 50 (10) 9952 68 (20) 6247 77 (25) 5000 86 (30) 4028...

  • Page 53: Appendix B

    APPENDIX B APPENDIX B Modulex Parts List...
  • Page 54 APPENDIX B...
  • Page 55 APPENDIX B...
  • Page 56 APPENDIX B...
  • Page 57 APPENDIX B...
  • Page 59 NOTES: ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________...
  • Page 60 AERCO declines every responsibility for the possible inaccuracies if owed to errors of transcript or press. Also, AERCO reserves the right to bring those changes that will hold necessary to its own products or profits, without jeopardizing its essential characteristics.

This manual is also suitable for:

Modulex 757Modulex 454Modulex 606Modulex 909Modulex 1060Modulex mlx-303 ... Show all

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