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AERCO MLX EXT 450 2S
Watts AERCO MLX EXT 450 2S Manuals
Manuals and User Guides for Watts AERCO MLX EXT 450 2S. We have
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Watts AERCO MLX EXT 450 2S manuals available for free PDF download: Installation, Operation & Maintenance Manual, Technical Application Manual
Watts AERCO MLX EXT 450 2S Installation, Operation & Maintenance Manual (120 pages)
Brand:
Watts
| Category:
Controller
| Size: 4 MB
Table of Contents
Table of Contents
2
Chapter 1: Safety Precautions
5
Chapter 2: General Information
7
Correct Use of the Appliance
7
Water Treatment
7
Information to be Made Available to the User
7
Safety Warnings
8
Modifications to Parts Connected to the Appliance
8
For Appliances Operating with Propane Gas
8
Data Plate
9
Operational Requirements
10
General Requirements
10
Regulatory Requirements
10
Water Quality Requirements
10
Tools, Materials, and Additional Equipment
11
Disposal
11
General Warnings
11
Using the Operation and Maintenance Manual
11
Installation and Servicing Personnel
12
Installation Materials
12
Preparing Boiler for Servicing
12
Returning a Boiler to Service
12
Change in Ownership
12
Operational Limits of the Boiler
12
Chapter 3: Technical Features & Dimensions
13
Modulex Ext Technical Features
13
Temperature Control Devices
13
Control Panel (Ufly) Includes
13
Other Features Include
13
General Boiler Operation
14
Boiler Freeze Protection
14
Dimensional Drawings
15
Performance Data
19
Chapter 4: Installation Instructions
21
General Warnings
21
Appropriate Use of the Boiler
21
Prerequisite System Flushing
21
Installation Personnel Qualifications
21
Carbon Monoxide Detector Installation
21
Code and Standards Approvals
22
Packaging
22
Transporting and Securing the Boiler Safely
25
Removal from Boiler Bed and Installation of Boiler Feet
25
Boiler Location Inside a Boiler Room
27
Boiler Room Safety Concerns
27
Products to Avoid in the Boiler Room
28
Recommended Clearances for Servicing
28
Boiler Connections
29
Changing Exhaust Outlet Location
29
Reversing Gas Manifold Connections
30
Reversing Cold/Hot Water Flow & Return Connections
31
Gas Connection General Information
33
Natural Gas Connections
34
Propane Gas Connections
34
Flow and Return Pipe Connections
35
Pressure Relief Valve (Supplied)
35
Csd-1 Manifold Assembly (Supplied)
35
Installing the Flow Switch and CSD-1 Components
36
Determination of Primary Boiler Pump or Boiler System Pump
37
Condensate Piping and Drain
38
Water Treatment
39
Important Installation Warnings
40
Oxygen Levels in the System Water Warning
40
Antifreeze Compatibility Warning
40
Lime Scale and Corrosive Water Damage Warning
40
Connection to Refrigeration System Warning
40
Air Intake Connection
40
Flue Manifold Connection
41
Flue Exhaust Piping to Vent
42
Vent Starter Pieces
43
Combustion Air and Ventilation Openings
44
Insufficient Ventilations and Combustion Air
44
Room Air Combustion
45
Sealed Combustion
45
Installation of the Exhaust and Air Intake System
45
Important Factors for Terminal Orientation and Location
46
Minimum and Maximum Wall Thickness
46
Vent Pipe Sizing
47
Electrical Connections
49
Regulations in Force
49
Mains Electrical Supply Connection (120 V - 60 Hz)
49
Service Relay Requirement
50
Electrical Requirements
50
FUNCTIONAL WIRING DIAGRAM Page 1
52
FUNCTIONAL WIRING DIAGRAM Page 2
53
Ladder Diagrams
54
General Ladder Diagram
55
Input/Output Box Terminal Assignments
56
Starting Up: Filling and De-Aerating the Boiler
57
Necessary Precautions for Safety
57
Supply Voltage, Gas Pressure, and Water Pressure
57
Filling the System
58
Necessary Precautions While Filling the System
58
Filling Locations and Preparation
58
Testing the Ignition Safety Shut off Device
60
Burner Calibration
61
Installing the Gas Analyzer Probe
61
Maximum Output Calibration
62
Minimum Output Calibration
63
Final Check and Ignition Failure Adjustment Procedure
63
Sweeper Mode (Manual Control)
65
High Altitude Adjustment
67
High Altitude Conversion Label
68
Conversion from Natural Gas to Propane Gas
68
Controls and Emergency Functions
69
Initial Boiler Ignition
70
Preliminary Checks
70
Chapter 5: Ufly Controller & Bcm Modules
71
Ufly Controller
71
Ufly Controller Features and Functions
71
Reading the Icons on Home Page
72
Display Modes
73
Bcm (Boiler Communication Module)
73
Chapter 6: Operation, Menu & Parameters
75
Setup Menu
76
Setting Time and Date
76
Setting Comfort and Eco Building Reference Temperatures
76
Setting Comfort and Eco Domestic Hot Water Setpoints
77
Display Settings
77
Language and Unit Settings
77
Password
78
Heating Menu
78
Domestic Hot Water Menu
79
Devices Menu
80
Burner Menu
82
Service Mode/Manual Firing Rate Function
82
Manual Setpoint Function
83
Reset Burner Working Hours and Ignition Count
84
Bcm Parameters
85
Bmm Parameters
89
Chapter 7: Troubleshooting
92
Ufly Controller Error Codes
92
BCM (Boiler Communications Module) Fault Codes
93
BMM (Burner Management Module) Fault Codes
95
Chapter 8: Maintenance Schedule
97
Instructions for Inspection and Maintenance
97
Periodic Examination of Venting System
98
Proper Procedure for Cleaning Exhaust Flue
98
Cleaning the Condensate Drain Line
98
Checking Csd-1 Manifold Flow Switch
99
Visual Inspection of the Flame
99
Reassembly and Resealing of Vent-Air Intake System
99
Pressure Switch Hoses and Connections
100
Burner / Heat Exchanger Cleaning Procedure
101
Heat and Return Sensor Resistance Values
101
Unit Disassembly
102
Cleaning the BURNER MODULE and COMBUSTION CHAMBER
109
Cleaning the Heat Exchanger
111
Mechanical Cleaning of the Heat Exchanger
111
Cleaning the Heat Exchanger with Cleaning Solution
113
Repeat Cleaning
113
Reassembly of the Burner Modules
114
Final Procedures after Maintenance
114
Maintenance Kit Part Numbers
114
Chapter 9: Spare Parts Drawing and Lists
115
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Watts AERCO MLX EXT 450 2S Installation, Operation & Maintenance Manual (83 pages)
Modulex Ufly Controller & BCM
Brand:
Watts
| Category:
Controller
| Size: 2 MB
Table of Contents
Table of Contents
2
Chapter 1: Introduction
5
Chapter 2: Ufly Controller & Bcm Modules
7
Ufly Controller
7
Ufly Controller Features and Functions
7
Reading the Icons on Home Page
8
Display Modes
9
Boiler Communication Module (Bcm)
10
Chapter 3: Operation, Menu & Parameters
11
Setup Menu
12
Setting Time and Date
12
Setting Comfort and Eco Building Reference Temperatures
12
Setting Comfort and Eco Domestic Hot Water Setpoints
13
Display Settings
13
Language and Unit Settings
13
Password
14
Heating Menu
14
Domestic Hot Water Menu
16
Devices Menu
17
Burner Menu
18
Service Mode/Manual Firing Rate Function
18
Manual Setpoint Function
19
Reset Burner Working Hours and Ignition Count
20
Chapter 4: Ufly Setup and Programming
21
Indoor/Outdoor Reset Mode
21
Wiring Connections
21
Indoor/Outdoor Reset Operation Configuration
22
Viewing the Boiler Setpoint
28
Constant Set Point Mode
28
0-To-10-Volt Remote Set Point Mode
29
Wiring Connections
29
0-To-10-Volt Remote Setpoint Mode Operation Configuration
30
Domestic Hot Water Operation Using a Tank Sensor
32
Sensor Wiring Connections
32
Configuring the Controller for DHW with a Tank Sensor
32
Boiler & Pump Enable/Disable
36
Chapter 5: Input/Output Box, Bcm Terminal Assignments
39
Terminal Assignments
40
Chapter 6: Boiler Communications Module (Bcm)
41
Bcm Description
41
Bcm Fault Relay
43
BCM Fault Relay Wiring
43
Clearing Faults
43
Bcm: Backup Controller Function
44
Backup Controller Setpoint
44
Operating the BCM as a Backup Controller
45
Bcm Control of Variable Speed Primary Pump
48
Pump Control Wiring
48
Pump Control Operation
48
Control Via Modbus (through Bcm)
50
Operating Scenario
50
Physical Modbus RS485 Wiring
50
AERCO BMS II/ACS Master to BCM Slave Wiring Connections
51
EMS or BAS Master to BCM Slave Wiring Connections
51
Rs485 Loop Termination Resistors and Bias
51
Master BMS II/ACS or EMS/BAS Terminating Resistor and Bias
52
BCM Controller Terminating Resistor
52
Modbus Network Wiring Diagram
53
Modbus Software Set-Up
54
BCM Set-Up for Modbus Operation
54
AERCO ACS Modbus Control and Monitoring
56
Modbus Remote Setpoint Control and Monitoring
56
EMS or BAS Set-Up as Master to BCM Controller Slaves
56
Multiple Modulex Boiler Heating Mode - Using Acs
56
Sequence of Operation (Example: Four-Modulex Boiler Installation)
57
Chapter 7: Bcm Modbus and Address Assignments
59
Bcm Modbus Comm. & Support Requirements
59
Function Codes
59
Modbus Support Requirements
59
Bcm Controller Standard Holding Register Assignments
60
BCM Controller Standard Input Register Assignments
60
Chapter 8: Troubleshooting
71
Ufly Controller Error Codes
71
BCM (Boiler Communications Module) Fault Codes
72
BMM (Burner Management Module) Fault Codes
74
Appendix A: Bcm Parameters
76
Appendix B: Bmm Parameters
80
Watts AERCO MLX EXT 450 2S Technical Application Manual (37 pages)
Modulating and Condensing Boilers
Brand:
Watts
| Category:
Boiler
| Size: 3 MB
Table of Contents
Table of Contents
2
Mandatory Requirements
3
Boiler Quality and Maintenance
5
Boiler Water Chemistry
5
Reaction of Metals to Water Chemistry
5
Scale and Corrosion
5
Make-Up or Feed Water Quality
5
Treating Water to Prevent Freezing
5
Water Treatment Certification
5
Testing and Maintenance of Water Quality
6
System Flushing, Treatment, and Cleansing
7
System Flushing Recommendations
7
Water Quality Maintenance and Boiler Warranty
8
Water Treatment Certification
8
Water Treatment Analysis and Scheduling
8
Hydronic System Water Testing and Treatment Resources
8
Boiler Loop Design Guidelines
10
Flow Rate & Pressure Drops: Models EXT 450 2S, 600 2S, 800 2S & 1100 2S
10
Flow Rate & Pressure Drops: Models EXT 1500 2S, 2300 2S, 2600 2S & 3000 2S
12
Primary Pump
15
Strainers
16
Isolation Valves
16
Air Venting of the Heating System
17
Csd-1 Manifold Assembly (Supplied)
19
Installing the Pressure Relief Valve and Other Components
20
Connecting Supply & Return Piping
22
Boiler Connections
22
Primary-Secondary Piping
22
Additional Supply and Return Piping
22
Changing Right-Hand Connections to Left-Hand
22
Modulex Light Commercial Models EXT 450 2S, 600 2S, 800 2S & 1100 2S
22
Modulex Commercial Models EXT 1500 2S, 2300 2S, 2600 2S & 3000 2S
23
Reversing Gas Manifold Connections (EXT 450 2S - 1100 2S)
24
Reversing Cold/Hot Water Flow & Return Connections (EXT 450 2S - 1100 2S)
24
Reversing Flow & Return Temperature Sensors
26
Reversing the Boiler Sensor KF and Automatic Air Vent
26
System Filling and Draining
27
Condensate Drain
28
Piping Diagrams
30
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