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INSTALLATION, OPERATION & MAINTENANCE

1-7

FAN

GAS VALVE

BURNER

COVER

IGNITION

FLAME

DETECTOR

LOCAL NTC

SENSOR

H.L.

THERMOSTAT

BURNER

FILLING-UP

ELBOW

GAS PIPE

AIR INTAKE

CONNECTION

GLOBAL FLOW

NTC TEMPERATURE

SENSOR

HOT WATER

OUTLET (SUPPLY)

1/4" CONNECTION

WITH PLUG

GLOBAL RETURN

NTC TEMPERATURE

SENSOR

COLD WATER INLET

(RETURN)

WATER DRAIN

VALVE
CONDENSATE

DRAIN TRAP

1" [25 mm]

BOILER

FRAME

ALUMINUM/

SILICON HEAT

EXCHANGER

AUTOMATIC

AIR VENT

CONDENSATE

COLLECTION

TRAY MANIFOLD

5.9" [150 mm]

4"

[100 mm]

Figure 1-2.

Modulex

1.7 BOILER FREEZE PROTECTION

e to less than 44.6°F (7°C), the system pump will start.

NOTE

If glycol is used as antifreeze in the boile

flow preventer must be installed in the

Main Components

Should the boiler water outlet temperature decreas
Should temperature decrease to less than 37.4°F (3°C), all heat modules will start at minimum output until
the return temperature reaches 50°F (10°C). Such a protection device is exclusively for the boiler. For the
protection of the whole system, a second freeze protection thermostat is necessary to switch on the
heating system pump.

r, a back

make-up/fill line.

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Summary of Contents for Modulex 1060

Page 1: ...H 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 Printed in U S A 7 17 08 ...

Page 2: ...h 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 Nor for incidental or consequential damages occurring in connection with the furnishing performance or use of this material AERCO International Inc 159 Paris Avenue Northvale NJ 07647 0128 www ae...

Page 3: ...2 2 INSTALLATION INSTRUCTIONS 2 1 2 2 1 UNPACKING THE BOILER 2 1 2 2 2 LOCATING THE BOILER 2 3 2 2 3 PAD HEIGHT FOR BOILER 2 3 2 2 4 BOILER CONNECTIONS 2 4 2 3 BOILER DATA PLATE 2 8 3 GENERAL INFORMATION FOR THE VENTING SYSTEM 3 1 3 1 GAS VENT CATEGORIES 3 1 3 2 VENT PIPE CONNECTIONS 3 1 3 3 INSTALLATION SIZING 3 1 3 4 REMOVAL OF EXISTING BOILER FROM COMMON VENTING SYSTEM 3 2 4 PIPING 4 1 4 1 MAKE...

Page 4: ...F OPERATION 6 2 6 4 1 INDOOR OUTDOOR RESET 6 2 6 4 2 0 TO 10 VOLT REMOTE SET POINT 6 3 6 4 3 CONSTANT SET POINT 6 3 6 4 4 BOILER OPERATION IN CASE OF TROUBLESHOOTING MANUAL MODE 6 3 6 5 MODULEX BOILER INITIAL STARTUP 6 3 6 5 1 TOOLS INSTRUMENTION REQUIRED FOR COMBUSTION CALIBRATION 6 4 6 5 2 INSTALLATION OF SUPPLY GAS MANOMETER 6 4 6 5 3 PREPARING THE FLUE FOR USE WITH THE COMBUSTION ANALYZER 6 5 ...

Page 5: ...OM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS NEVER USE MATCHES CANDLES FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS DO NOT ATTEMPT TO DRY FIRE THE BOILER STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE...

Page 6: ...ual 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 Prior to installing the boiler check to ensure that the technical data corresponds to requirements for its intended use in the system Check that the boiler is intact and tha...

Page 7: ...ve The vent termination must be located a minimum of 4 feet above grade level If side wall venting is used the installation must conform to the following requirements extracted from 248 CMR 5 08 2 a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the C...

Page 8: ...Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizo...

Page 9: ...and domestic hot water DHW zones Other features include The heating load is shared with as many boiler modules as possible running at a minimum output to ensure the maximum efficiency at partial load operation Access to all testing programming parameters of each module operation test operation time boiler freeze protection from 45 F 7 C pump s anti seize program Lead lag burner operation based on ...

Page 10: ...9 41 12 835 245 20 1 4 0 15 1 10 6 40 7 1060 41 12 975 286 23 1 4 6 17 6 12 4 47 1 MBH 1000 Btu hr 1 3 INSTALLATION FLEXIBILITY The Modulex boiler allows for installation flexibility i e it is suitable to be connected with the water supply and return and the gas connections on the Right Hand R H side standard delivery condition or on the Left Hand L H side This is accomplished by reversing the gas...

Page 11: ...LLATION OPERATION MAINTENANCE 1 3 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 1 4 INTENANCE Figure 1 1 Modulex Dimensions and Weights Sheet 2 of 2 ...

Page 13: ...303 MLX 454 MLX 606 MLX 757 MLX 909 MLX 1060 Boiler Category IV IV IV IV IV IV Type of Gas Natural Gas MLX 303H or Propane MLX 303HP Natural Gas MLX 454H or Propane MLX 454HP Natural Gas MLX 606H or Propane MLX 606HP Natural Gas MLX 757HB or Propane MLX 757HP Natural Gas MLX 909H or Propane MLX 909HP Natural Gas MLX 1060H or Propane MLX 1060HP Gas Connections NPT 1 5 1 5 1 5 1 5 1 5 1 5 Max Gas Pr...

Page 14: ...6 152mm 6 152mm Vent Materials per local code Can support PVC ABS CPVC or AL29 4C venting materials Temperature Control Range All units can be applied to deliver 50 F to 185 F 10 C to 85 C supply water Maximum Noise Level All units deliver 50 dBA when operating at or below full fire NOx Emissions Certification All units have been certified by SCAQMD and TCEQ for 30 ppm NOx Standard Listings Approv...

Page 15: ...CTION TRAY MANIFOLD 5 9 150 mm 4 100 mm Figure 1 2 Modulex 1 7 BOILER FREEZE PROTECTION e to less than 44 6 F 7 C the system pump will start NOTE If glycol is used as antifreeze in the boile flow preventer must be installed in the Main Components Should the boiler water outlet temperature decreas Should temperature decrease to less than 37 4 F 3 C all heat modules will start at minimum output unti...

Page 16: ......

Page 17: ...tions in this manual FOR MASSACHUSETTS INSTALLATIONS The boiler must be installed by a plumber or gas fitter licensed within the Commonwealth of Massachusetts Also for installations in buildings used for residential purposes if a side wall vent termination is less than 7 feet above grade an NFPA 720 compliant ANSI UL 2034 listed and IAS certified carbon monoxide detector must be installed on the f...

Page 18: ...xhaust connector Three 3 surface mount strap on sensors Screws necessary for accessory installation Piping for 1 condensate drain including one tee and two 90 degree elbows On the back of the boiler Plastic condensate drainpipe 38 5 inches 1meter long placed under the casing rear panel Outside air sensor with 49 feet 2 5 inches 15 m cable Manual Gas Shutoff Valve Shipped in a separate carton are t...

Page 19: ...or inhibit service or maintenance of the unit The boiler MUST NOT be installed on carpeting 2 2 3 Pad Height for Boiler To properly drain and service the boiler s condensate system attention must be given to installation requirements regarding the mounting height of the boiler as well as installation clearances for the removal of the condensate collector baffle The boiler should be mounted on a fl...

Page 20: ...r right left or back side panels To attach the exhaust connector to the flue collector use the screws and the gaskets supplied inside the plastic bag and use a cross tip Phillips screwdriver at least 12 in 300 mm long Figure 2 3 Boiler Connections Water supply and return and gas connections can also be moved to the boiler s L H side by inverting the flow supply return manifold on the left side usi...

Page 21: ...AIR VENT BCM TEMP SENSOR E8 TEMP SENSOR RETURN TEMP SENSOR BOILER DRAIN BRACKET SCREW SENSOR BRACKET SENSOR CONNECTOR THERMOWELL CLIP THERMOWELL E8 TEMP SENSOR TEMPERATURE SENSOR E8 SENSOR BCM BOILER RETURN SENSORS Figure 2 4 Right Hand R H Connection ...

Page 22: ...tion of the drain cock and the automatic air vent Figure 2 6 5 Reposition the temperature sensor white and red leads onto the new flow supply manifold and the temperature sensor white and green leads onto the new return manifold GAS CONNECTIONS ON L H SIDE AFTER MODIFICATION CONDITION FRONT VIEW L H A C B GAS CONNECTIONS ON R H SIDE STD DELIVERY CONDITION A C B REAR VIEW REAR VIEW C H FLOW AND RET...

Page 23: ...AIR VENT BCM TEMP SENSOR E8 TEMP SENSOR RETURN TEMP SENSOR BOILER DRAIN BRACKET SCREW SENSOR BRACKET SENSOR CONNECTOR TEMPERATURE SENSOR THERMOWELL CLIP E8 TEMP SENSOR THERMOWELL E8 SENSOR BCM BOILER RETURN SENSORS Figure 2 6 Left Hand L H Connection ...

Page 24: ...si 14 W C 3 5 kPa 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 0 5 psi 3 5 kPa The boiler shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and...

Page 25: ...INSTALLATION OPERATION MAINTENANCE 2 9 Figure 2 7 Sample Data Plate ...

Page 26: ... 558 000 696 000 835 000 975 000 NET IBR RATING 237 000 355 000 474 000 592 000 710 000 829 000 BOILER CATEGORY IV IV IV IV IV IV MAX INLET SUPPLY GAS PRESSURE 14 W C 34 8 mbar 14 W C 34 8 mbar 14 W C 34 8 mbar 14 W C 34 8 mbar 14 W C 34 8 mbar 14 W C 34 8 mbar MIN INLET SUPPLY GAS PRESSURE 4 10 mbar 4 10 mbar 4 10 mbar 4 10 mbar 4 10 mbar 4 10 mbar NORMAL MANIFOLD GAS PRESSURE 3 2 Nat Gas MLX 303...

Page 27: ...ature less than 140 degrees F 60 degrees C above its dew point Category III being a gas appliance that operates with a positive vent fan forced vent connector with a flue gas pressure and temperature at least 140 degrees F 60 degrees C above its dew point Category IV being a gas appliance that operates with a positive vent fan forced vent connector with a flue gas pressure and temperature less tha...

Page 28: ...ng system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there are no blockages or restrictions leakage corrosion and other deficiencies that could cause an unsafe condition 3 When practical close all building doors and windows as well as all doors between the space in which the appliances remaining connected to the common venting system are located and ot...

Page 29: ...ents along with a manifold and several others are supplied with the boiler and must be assembled and wired when installing the boiler at the site The manifold assembly components supplied are 3 4 Pressure Relief Valve Manifold Assembly 2 1 2 x 16 long 64 mm x 406 mm 2 1 2 NPT Union Low Water Cut Off Switch Aquastat Pressure Temperature Gauge 4 5 CONNECTING SUPPLY AND RETURN PIPING PER ANSI Z21 13A...

Page 30: ...r after installation Its minimum height when all the fans are in operation must be at least 1 in 25 mm See Figure 4 1 In order to help avoid ice from forming the condensate piping system must be well insulated DO NOT INSTALL THE CONDENSATE DRAIN WHERE FREEZING MAY OCCUR Consult local codes with regard to condensate neutralization Neutralization can be obtained by mixing it with the buildings drain...

Page 31: ...the boiler to sunlight rain etc Keep the boiler away from untrained people WARNING The boiler s electrical supplying cable must not be replaced by the user In case of any damage to the cable stop the boiler and contact qualified personnel for its replacement IMPORTANT Prior to connecting external AC power to the Modulex boiler the CSD 1 Supply Manifold must be installed using the procedures descri...

Page 32: ...f such requirements with the National Electrical code NEC ANSI NFPA 70 and or the Canadian Electrical Code CEC Part I CSA C22 1 Electrical Code 5 2 DHW STORAGE TANK Domestic hot water DHW production by an external storage tank connected to the boiler can be implemented by an electric diverting valve or a separated storage tank loading pump See Figure 5 2 The DHW tank temperature sensor will be con...

Page 33: ...INSTALLATION OPERATION MAINTENANCE 5 3 Figure 5 2 ...

Page 34: ......

Page 35: ...llow gas to enter into the pre combustion chamber where it mixes with the combustion air The mixed air and gas pass thru the check valve on to the burner surface for ignition Combustion gases pass thru the heat transfer surfaces Flue gases and condensate then exit the heat exchanger entering into the condensate tray 6 2 MODULATION THEORY One of the operating principles for this boiler is to have a...

Page 36: ...put in lockout position for 5 sec after which it repeats the ignition sequence once again If no positive result is obtained then a lockout conditions occurs and the display on the System Manager will show an error message Figure 6 1 6 4 MODES OF OPERATION The Modulex boiler is capable of operating in several control modes including Indoor Outdoor Reset 0 to 10 Volt Remote Setpoint and Constant Set...

Page 37: ...ode For service and test purposes any single module or all simultaneously can be kept operating at full or reduced load In this way the CO2 level can be checked and if necessary adjusted at full or reduced load for any single module or for all simultaneously With this option troubleshooting failures on each module is simplified 6 5 MODULEX BOILER INITIAL STARTUP Prior to initial start up of the co...

Page 38: ...tic tubing 3 8 I D 6 5 2 INSTALLING THE SUPPLY GAS MANOMETER Install the W C manometer or gauge as follows 1 Turn off the external main gas supply valve to the unit 2 Remove the top panel from the Modulex boiler to provide access to gas supply manifold 3 Refer to Figure 6 1 and locate the gas pressure tap on the gas supply manifold 4 Using a flat tip screwdriver rotate the pressure tap screw count...

Page 39: ...dure 1 Open the water supply and return valves to the unit and ensure that the system pumps are running 2 Open the external gas supply valve to the boiler 3 Measure the gas pressure using the W C manometer connected to the inlet gas manifold If an external regulator is installed adjust the pressure to obtain 7 0 W C If an external regulator is not installed ensure that the supply gas pressure is a...

Page 40: ...0 If the gas pressure is adequate at full fire close the hinged panel of the Controller 21 Set the ON OFF switch on the front of the boiler to the OFF position 22 Turn off the gas supply to the boiler by closing the external shut off valve 23 Remove the manometer from the gas manifold pressure tap Close the tap by rotating the adjustment screw fully clockwise to its stop This manometer will be use...

Page 41: ...the combustion calibration procedure refer to Figures 1 and 2 in Modulex E8 Controller Operation Wiring Guide GF 115 C for locations and descriptions of the controls and displays on the Controller 7 With the Controller hinged panel closed turn the Rotary Knob clockwise and monitor the displayed symbols on the lower right portion of the display The symbols will increment from left to right and show...

Page 42: ...t the oxygen O2 level is within the range shown below Also ensure that the carbon dioxide CO2 and carbon monoxide CO are within the ranges shown GAS SUPPLY OXYGEN O2 CARBON DIOXIDE CO2 CARBON MONOXIDE CO NATURAL GAS 4 7 to 5 3 9 1 to 8 8 100 ppm PROPANE 4 4 to 5 0 10 7 to 10 4 100 ppm 20 If the oxygen level is not within the required tolerance the gas valve Figure 6 2 for the Boiler stage must be ...

Page 43: ...FF switch on the front of the Modulex Boiler to the OFF position 2 Turn off the gas supply to the boiler by closing the external shut off valve 3 Disconnect AC power 4 Remove the manometer from the gas valve outlet pressure tap Close the tap by rotating the screw fully clockwise to its stop 5 Cover the hole drilled in the PVC flue pipe with foil tape 6 Replace the top and front panels on the Modul...

Page 44: ......

Page 45: ...O2 percentage If the actual input with the correct CO2 is within 5 of the value shown in paragraph 1 5 the boiler does not need to be cleaned The operation then can be limited to the cleaning of the condensate drain NOTE A reduction of the input can be caused by the obstruction of the flue outlet or of the air intake Check first of all that this is not the reason Disassembly 1 Switch off power and...

Page 46: ...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 It is possible to achieve this by positioning the tapped hole of the gas pipe flange relative to the G hole of the side support and inserting one of the two screws E previously removed see following pictures and drawing ...

Page 47: ...ached 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 is attached R H side or L H side Remove the screw securing the baffle P and lower the baffle onto the tray bottom ...

Page 48: ... accumulate in the tray 4 Using compressed air blow out the combustion chamber between the sections to remove all dirt and foreign particles from the aluminum protrusions Inspect the flue duct and flue collector Reassembly 1 Replace the burner sealing gaskets Reassemble all the components previously removed by reversing the order of the disassembly steps 2 Before starting the boiler verify that th...

Page 49: ...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 Remove the burners as shown in the illustration by first lifting up the side opposite to the ground tab indicated by the arrow ...

Page 50: ...te tray X Wash heat exchanger X Check and adjust air fuel ratio X Inspect and clean burner surface X Check for gas leaks using a soapy solution X Inspect igniter and flame sensor X Inspect heat transfer surfaces X Clean strainer mesh Monthly X Check inlet gas pressure X Check pH of boiler system water X Check vent and inlet air terminations X Check electrical supply voltages X Check flame safeguar...

Page 51: ...APPENDIX A A 1 APPENDIX A Temperature Sensor Resistance Charts ...

Page 52: ...70 876 176 80 628 194 90 458 212 100 339 230 110 255 248 120 194 The temperature sensors used in the Modulex boiler are 5k Ohm Negative Temperature Coefficient NTC The relationship between temperature F or C and the nominal resistance Ohms of the sensor are inversely proportional That is when temperature increases sensor resistance decreases and vice versa For Example At 77 F 25 C the resistance i...

Page 53: ...APPENDIX B B 1 APPENDIX B Modulex Parts List ...

Page 54: ...APPENDIX B B 2 ...

Page 55: ...APPENDIX B B 3 ...

Page 56: ...APPENDIX B B 4 ...

Page 57: ... 6 7 2 1 5 LEFT HAND BOILER WATER CONNECTION TOP VIEW FRONT VIEW RIGHT HAND BOILER WATER CONNECTION TOP VIEW FRONT VIEW 8 3 4 THERMOWELL 8 99023 1 APPLIES ONLY TO UNITS WITH BOILER WATER CONNECTED TO THE LEFT HAND SIDE PART NO 92013 ITEM 6 ITEM 4 RELIEF VLV SETTING PSIG MLX 303H 454H 606H MLX 757H 909H 1060H MLX 757B 909B 1060B 123675 2 92014 MLX 757H 909H 1060H MLX 303H 454H 606H 123675 3 92029 9...

Page 58: ......

Page 59: ...___________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________...

Page 60: ...AX 201 784 8073 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 ...

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