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Aerco MODULEX EXT 1123, User Manual

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Aerco MODULEX EXT 1123 User Manual Download Page 145

MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS

 

Installation, Operation & Maintenance Manual

 

 

OMM-0087_0F 

  AERCO International, Inc. 

•

 100 Oritani Dr. 

•

  Blauvelt, NY 10913   

 Page 

145

 of 

146

 

GF-143 

 Phone: 800-526-0288  

07/13/15   

No. 

Part No. 

Description 

58 

95262220 

10A Fuse  

59 

95262221 

6,3A Fuse 

60 

95263074 

Gas Valve 

61 

95262565 

Level Sensor 

62 

95262579 

Automatic Air Vent G3/4"  

63 

95262765 

D.200 EPDM Gasket 

64 

95263419 

Mesh Burner 

65 

95262925 

Screw UNI 5931 M8X110 

66 

95262926 

Gas Spring 

67 

95262932 

Gas Cap Inspection 

68 

95310512 

Drain Elbow HTB DN40 

69 

95310513 

Drain TEE HTEA DN 40/40 

70 

95310515 

Drain Pipe 1M LG. DN 40 

71 

95611085 

Flame Detector Cable 

72 

95611593 

Igniter Cable 

73 

95000963 

Electronic Board 

74 

95262930 

Hinge Casing 

75 

95262931 

Casing Top Panel lock 

76 

95000721 

Junction Box 

77 

95261720 

Terminal Strip 

78 

95251877 

Flanged Flue Outlet Terminal 

79 

 

95372088 

Gas Inlet Header Modulex 2/3 Elements, EXT 321 & EXT 481 

95372089 

Gas Inlet Header Modulex 4/5 Elements, EXT 641 & EXT 802  

95372090 

Gas Inlet Header Modulex 6/7 Elements, EXT 962 & EXT 1123 

80 

95372093 

Flow Header, 2 Elements, EXT 321 

95372094 

Flow Header, 3 Elements, EXT 481 

95372095 

Flow Header, 4 Elements, EXT 641 

95372096 

Flow Header, 5 Elements, EXT 802 

80 

95372097 

Flow Header, 6 Elements, EXT 962 

95372098 

Flow Header, 7 Elements, EXT 1123 

81 

 

95372099 

Return Header, 2 Elements, EXT 321 

95372100 

Return Header, 3 Elements, EXT 481 

95372101 

Return Header, 4 Elements, EXT 641 

95372102 

Return Header, 5 Elements, EXT 802 

95372103 

Return Header, 6 Elements, EXT 962 

95372104 

Return Header, 7 Elements, EXT 1123 

 

 

 

Summary of Contents for MODULEX EXT 1123

Page 1: ... Phone 800 526 0288 USER MANUAL Installation Operation and Maintenance MODULEX EXT Light Commercial Series Modular Condensing Boilers Natural Gas Modulating Condensing Modular Hot Water Boiler LIGHT COMMERCIAL SERIES Covering Models EXT 321 EXT 481 EXT 641 EXT 802 EXT 962 EXT 1123 Latest Update 07 13 2015 ...

Page 2: ...cument some types of information are presented as shown in the following examples Message Type Example and Description Notes NOTE NOTE messages indicate specific information related to the surrounding contextual information and highlighted for special attention Cautions CAUTION CAUTION messages inform of potential problems relating to the functioning of equipment safety to persons harm to the envi...

Page 3: ...1 12 Operational Limits of the Boiler 14 CHAPTER 2 TECHNICAL FEATURES AND DIMENSIONS 15 2 1 Modulex EXT Technical Features 15 Temperature Control Devices 15 2 1 1 Control Panel E8 Includes 15 2 1 2 Other Features Include 15 2 1 3 2 2 General Boiler Operation 16 2 3 Dimensional Drawings 17 2 4 Performance Data 21 CHAPTER 3 INSTALLATION INSTRUCTIONS 23 3 1 General Warnings 23 Appropriate Use of the ...

Page 4: ...18 Flue Manifold Connection 45 3 19 Flue Exhaust Piping to Vent 46 3 20 Vent Starter Pieces 46 3 21 Combustion Air and Ventilation Openings 48 Insufficient Ventilations and Combustion Air 48 3 21 1 Room Air Combustion 49 3 21 2 Sealed Combustion 49 3 21 3 3 22 Installation of the Exhaust and Air Intake System 49 Important Factors for Terminal Orientation and Location 50 3 22 1 Minimum and Maximum ...

Page 5: ...tart Instructions 93 Setting Maximum and Minimum Flow Temperature 93 5 2 1 Setting Room Temperature and Outdoor Compensation 93 5 2 2 Setting Heating Programs and Pumps 94 5 2 3 5 3 Menu And Sub Menu Descriptions 96 Menus Top Level 96 5 3 1 Sub Menus 96 5 3 2 5 4 General Menu 97 5 5 Service Menu 99 5 6 Display Menu 101 5 7 User Menu 103 5 8 Time Program Menu 105 5 9 Expert Menu 106 5 10 Other Poss...

Page 6: ...xamination Of Venting System 122 7 3 Proper Procedure For Cleaning Exhaust Flue 122 Cleaning the Condensate Drain Line 123 7 3 1 7 4 Checking CSD 1 Manifold Flow Switch 123 7 5 Visual Inspection Of The Flame 124 7 6 Proper Reassembly and Resealing of the Vent Air Intake System 124 7 7 Pressure Switch Hoses And Connections 125 7 8 Burner Heat Exchanger Cleaning Procedure 126 7 9 Heat and Return Sen...

Page 7: ...e be as near as possible to the temperature required for end use AERCO recommends inspecting the state of cleanliness of the domestic hot water heat exchanger at the end of the first year and subsequently on the basis of the lime scale found this period can be extended to two years after the initial inspection 1 3 Information to Be Made Available To The User Go through the information in this manu...

Page 8: ...o persons animals or damage to property The manufacturer shall not be held liable for any injury and or damage Servicing or repairs of the appliance must be carried out by AERCO authorized service technicians AERCO recommends drawing up a service contract Incomplete inappropriate or irregular servicing could compromise the safe operation of the appliance and could cause injury to persons animals o...

Page 9: ...line or other flammable vapors or liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Do not use any phone in the building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot contact your gas supplier call the fire department WARNING The bo...

Page 10: ... Phone 800 526 0288 GF 143 1 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 1 1 MODULEX EXT Data Plate L and Data Packing Label R Each unit is fitted with a data plate which may be consulted for the details on gas type power source and venting classification ...

Page 11: ... condensing gas boiler must use a vent system that has been specifically designed and approved for this type of boiler Note that local permission and approval for the vent system and condensate water connection to a public sewage system may be required Regulatory Requirements 1 8 2 You must also conform to any rules regulations or laws concerning the following Local building codes regarding the in...

Page 12: ...e water Do not use inhibitors or other additives unless approved by AERCO for that purpose When frost protection of the heating system is desired only use AERCO approved antifreezes The allowed maximum concentration is 50 When using oxygen permeable pipes e g for under floor heating systems you must separate the system from the boiler using plate heat exchangers Close the valves of the boiler whil...

Page 13: ...el 1 11 2 Installation and servicing must be carried out in accordance with the regulations in force according to the manufacturer s instructions and by legally competent authorized persons By definition a competent person is a person who has a specific technical qualification in the field of components for central heating systems for domestic use domestic hot water production and servicing This p...

Page 14: ...ting 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 order to circulate throughout the entire system Change in Ownership 1 11 6 If the appliance is sold or transferred to another owner or if the present user moves from the installation site and leaves the appliance installed...

Page 15: ... reversible Individual modules capable of between 46 and 160 5 kBTU hr These boilers are designed for use with category IV venting The boiler is supplied complete with all the safety and control devices in accordance with all current regulations and its technical and functional features comply with the regulations prescribed by ANSI Z21 13 CSA 4 9 Gas fired low pressure steam and hot water boilers...

Page 16: ...nit Alarm management Alarm reset input Warning alarm relay Stainless steel condensate collector tank with siphon drain trap and smoke chamber Easily removable stainless steel panels painted for outdoor installation Built in air vent 2 2 General Boiler Operation The boiler may be operated from the E8 controller or alternatively from a BCM Boiler Cascade Manager The boiler management logic provides ...

Page 17: ...anual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 17 of 146 GF 143 Phone 800 526 0288 07 13 15 2 3 Dimensional Drawings Figure 2 1 MODULEX EXT Dimensional Drawings Side Views On Modulex EXT models 321 642 and 962 the flue terminal ends inside the casing ...

Page 18: ...3 1150 45 3 1150 45 3 1150 45 3 1150 Width A inches mm 30 0 764 30 0 764 40 6 1032 40 6 1032 51 2 1300 51 2 1300 Width B inches mm 27 8 707 27 8 707 38 4 975 38 4 975 48 9 1243 48 9 1243 Depth D inches mm 30 3 770 30 3 770 30 3 770 30 3 770 30 3 770 30 3 770 Depth E inches mm 27 7 704 27 7 704 27 7 704 27 7 704 27 7 704 27 7 704 Connections Gas inches mm 2 60 3 2 60 3 2 60 3 2 60 3 2 60 3 2 60 3 M...

Page 19: ...62 1123 BOILERS Installation Operation Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 19 of 146 GF 143 Phone 800 526 0288 07 13 15 Figure 2 3a MODULEX EXT Main Components Left Side View ...

Page 20: ...evacuation connections are on the RIGHT HAND side supply condition but may be moved to the RIGHT HAND or REAR positions Air intake connection located on the LEFT HAND side Cold Hot flow connection on the RIGHT HAND side supply condition but may be moved to the LEFT HAND position Cold Hot return connection on the RIGHT HAND side supply condition but may be moved to the LEFT HAND position Gas connec...

Page 21: ...eration Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 21 of 146 GF 143 Phone 800 526 0288 07 13 15 2 4 Performance Data Table 2 2 MODULEX EXT Performance Data NOTE The Technical data plate is placed under the casing ...

Page 22: ...81 641 802 962 1123 BOILERS Installation Operation Maintenance Manual Page 22 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 This page intentionally blank ...

Page 23: ...e heating appliance according to the specific standards and regulations in force The connection between the boiler and flue outlet can be made only after this verification has been carried out Installation Personnel Qualifications 3 1 3 The appliance must be installed by a qualified engineer or technician who complies with the technical requirements who under his own responsibility guarantees the ...

Page 24: ... This allows the boiler to be handled by a forklift CAUTION Remove both straps and the cardboard box from above making sure the product is intact The packing elements cardboard box straps plastic bags etc should be kept away from children as these present suffocation and choking hazards AERCO refuses all liability for injury to persons animals or damage to property derived from not respecting the ...

Page 25: ...on outside A cardboard box containing o CSD 1 header o Relief valve ON THE BOILER RIGHT SIDE One 39 3 inch 1 meter pipe for the condensate evacuation system Left and right side covers ON THE BACK OF THE BOILER Socket front and rear ON THE BOILER TOP a plastic bag containing o This installation manual for the installer o User manual for the user o E8 controller instruction manual Pins to hold the f...

Page 26: ... of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 Figure 3 1 MODULEX EXT Unpacking Front View Figure 3 2 MODULEX EXT Unpacking Rear View Cardboard Box with Parts Cardboard Box with Parts Flue Assembly And Gasket Condensate Drain Pipe ...

Page 27: ... lb 295 kg 802 43 7 1110 mm 35 0 890 mm 49 2 1250 mm 716 lb 325 kg 962 54 1 1375 mm 35 0 890 mm 49 2 1250 mm 851 lb 386 kg 1123 54 1 1375 mm 35 0 890 mm 49 2 1250 mm 924 lb 419 kg 3 4 Transporting and Securing the Boiler Safely The boiler is susceptible to serious damage when not secured properly Follow the transportation instructions on the packaging Only transport the boiler using appropriate tr...

Page 28: ...ler for installation 1 Remove the covers of the boiler Figure 3 4 2 Lift the boiler with a hoist or forklift bands Figure 3 4 3 Remove the 4 screws A Figure 3 4 Figure 3 4 EXT Unpacking Left With Covers Right Lifted Without Covers 4 Retrieve the four 4 support feet from one of the cardboard boxes packaged with the boiler 5 Attach the four 4 support feet to the chassis using the four A screws remov...

Page 29: ...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 The boiler can be put on a flat and sufficiently strong base with the same dimensions as the boiler and at least 3 93 100 mm high see Figure 3 ...

Page 30: ...cinity of this or any other appliance Never use or store any chlorinated detergents or halogenated hydrocarbons e g in spraycans solvents and detergents paints adhesives in proximity to the boiler For outdoor installation see Warning for Outdoor installation on page 16 Products to Avoid in the Boiler Room 3 6 2 Do NOT store the following products in the boiler room and or around combustion air int...

Page 31: ...ing or flammable products 3 7 Recommended Clearances for Servicing Recommended clearances around the boiler are listed below see Figure 3 7 TOP of the boiler 24 600 mm FRONT of the boiler 24 600 mm RIGHT side 24 600 mm LEFT side 24 600 mm FLOOR GROUND 4 100 mm BACK of the boiler 24 600 mm Figure 3 7 EXT Boiler Clearances It is recommended to provide the boiler with the clearances as shown in the d...

Page 32: ...et on its RIGHT HAND side Changing Exhaust Outlet Location 3 8 1 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 P N 00364937 which includes a cover for closing off the RIGHT HAND side panel exhaust opening see Figure 3 9 Figure 3 8 Rear Exhaust Kit P N 00364937 for Changing Exhaust Ou...

Page 33: ...3 8 2 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 3 10 Ensure that the gaskets for ALL connections are reversed along with the connectors themselves Figure 3 10 Reversing Gas Connections from RIGHT HAND to LEFT HAND Exhaust Opening Cover Sup...

Page 34: ...e that the gaskets for ALL connections are reversed along with the connectors themselves 3 8 3 1 Reversing Cold Hot Water Flow Return Piping Connectors Refer to Figure 3 11 and reverse the connectors and end caps on Supply Flow and Return pipes Ensure that all gaskets are also reversed Figure 3 11 Reversing Cold Hot Water Flow and Return Connections and Sensors from RIGHT HAND to LEFT HAND Move en...

Page 35: ...her end of Flow Return pipes Figure 3 12 Reversing Flow and Return Temperature Sensors 3 8 3 3 Reversing Boiler Sensor Kf And Automatic Air Vent Reverse the positions of the Boiler Sensor KF and Automatic Air Vent located on the top Flow pipe Figure 3 13 Reversing Boiler Sensor KF with Automatic Air Vent NOTE When reversing hydraulic and gas pipe connections you must close up the chassis openings ...

Page 36: ...do not exist with the CAN CSA B149 1 Natural Gas and Propane Installation Code Before installing the boiler it is recommended that all the supply piping be thoroughly cleaned in order to remove any residual grime which could compromise the boilers correct functioning As a safety measure against gas leaks AERCO recommends installing a surveillance and protective system made up of a gas leakage dete...

Page 37: ...external 2 M NPT thread onto which the tail piece of the gas shut off valve can be connected Use appropriate sealing The connection to the boiler must include a suitable method of disconnection and a gas control valve must be installed adjacent to the boiler for isolation purposes 3 9 1 3 Natural Gas Supply Pressure Requirements The nominal inlet working gas pressure measured at the boiler should ...

Page 38: ...outing of the cold hot water piping take the necessary precautions to avoid air traps and pockets and to facilitate the continuous purging of the system WARNING Before installing the boiler we recommend that the system is flushed out with a suitable cleaning product in order to eliminate any metallic tooling or welding residues or oil and grime which could reach the boiler and affect the proper fu...

Page 39: ... 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 Figure 3 15 Flow Switch Pressure Temperature Gauge The pressure relief valve and other manifold components are shown in Figure 3 16 Figure 3 16 Manifold Assembly and Components To install the pressure relief valve and the other components s...

Page 40: ...16 3 4 Pressure Relief Valve Flow Switch Pressure Temperature Gauge 4 Check to ensure that all components are securely tightened and that the flow switch paddle moves freely without interference 5 Locate the BMM module with the FL label at the unit front Figure 3 17 and remove the black jumper wire from the terminals of the connector shown in the detail of Figure 6 Connect the two flow switch wire...

Page 41: ...27 F 15 C 24 5 36 8 49 2 61 7 74 2 86 8 Max flow rate demanded in gal min T 36 F 20 C 18 4 27 6 36 9 46 3 55 6 65 1 The water side resistance curve of the boiler is shown in the diagram in Figure 3 18 The pump is not an integral part of the boiler It is recommended to choose a pump with the rate and delivery head at about 2 3 of its characteristic heating curve Figure 3 18 MODULEX EXT Water Side P...

Page 42: ...ate with lime or with drain water coming from washing machines dish washing machines etc which normally has a base pH The connection to the sewer will be through a closed but visible drain Given the high acidity pH 3 to 5 of the condensate only plastic material may be used for the condensate evacuation pipes Moreover it must be dimensioned and constructed so as to allow the correct out flow to the...

Page 43: ... in very dangerous localized overheating AERCO suggests treating and conditioning feed water for the heating circuit in the following cases When the hardness of the water is higher than 9 grains 15 f For cold hot water installations with large water content Renewal of the water system due to uncontrolled leakages Subsequent refilling of the system due to maintenance work on the installation Presen...

Page 44: ...become plugged by scale caused by hard water or sediment If the indirect tank water heater becomes plugged by either scaling from hard water or sediment it is not the responsibility of AERCO International Connection to Refrigeration System Warning 3 16 4 The boiler when used in connection with a refrigeration system must be installed so the chilled medium is piped in parallel with the boiler with ...

Page 45: ...The Manifold may be installed on the left front or rear If switching to left or rear positions the unused outlet should be covered with the plate and gasket removed from outlet being used Figure 3 21 Connection of Flue Manifold To Boiler Exhaust Opening For venting systems in the USA it is necessary to assemble the Euro to USA adaptor to the flue manifold as shown in Figure 3 22 Figure 3 22 Assemb...

Page 46: ...ld not be below 32 F 0 C throughout its length For efficient venting of the combustion exhaust and to address condensation due to lower external temperatures ensure that combustion condensation is discharged into the boiler condensate tray or into another separate collection pan according to the installation A test nipple for measuring combustion gases should be installed onto the first three feet...

Page 47: ...er directly PVC P N 49051 included EXT 802 962 1123 6 Diameter Stainless Steel Contact vent manufacturer directly Polypropylene Contact vent manufacturer directly PVC P N 49050 included Figure 3 24 Flue Exhaust Diameter Reduction Adaptor Kit and Parts The flue venting pipe is affixed to the adapter using RTV liquid silicone and then clamped with a worm driven Hose Clamp When using non metallic pla...

Page 48: ...tilations and Combustion Air 3 21 1 BOILER DAMAGE AND OPERATIONAL FAILURES may occur due to insufficient or improper openings for combustion air and or ventilation of the boiler room Provisions for combustion air and ventilation are always required regardless of whether the combustion air is taken from the outside sealed combustion or inside room air used as combustion air Insufficient ventilation...

Page 49: ...r room shall be provided with two permanent openings one commencing within 12 inches 305 mm from the top of the enclosure and one commencing within 12 inches 305 mm from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors The minimum dimension of air openings shall be no less than 4 inc...

Page 50: ...e formations Do not use a chimney as a raceway if another boiler or fireplace is vented into or through the chimney Figure 3 26 Minimum Distances of Exhaust Opening and Building Features Important Factors for Terminal Orientation and Location 3 22 1 Terminals should be positioned so as to avoid products of combustion from entering openings into the buildings or other vents The terminal should be l...

Page 51: ...XT Vent and Piping Diameter Chart Model No of Modules Vent Diameter Inches mm Max Vent Equiv Feet M Examples 1 2 Max Vent Equiv Feet M Examples 3 4 EXT 321 2 4 101 mm 100 ft 30 m 6 6 1 8 1 8 EXT 481 3 4 101 mm 100 ft 30 m 6 6 1 8 1 8 EXT 641 4 4 101 mm 100 ft 30 m 6 6 1 8 1 8 EXT 802 5 6 152 mm 100 ft 30 m 6 6 1 8 1 8 EXT 962 6 6 152 mm 100 ft 30 m 6 6 1 8 1 8 EXT 1123 7 6 152 mm 100 ft 30 m 6 6 1...

Page 52: ...uvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 Example 1 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 17 4 m Figure 3 27 Modulex EXT Allowable Venting Solutions ...

Page 53: ...ate to satisfy the appliance s maximum power requirements indicated on the data plate verifying in particular that the cables are suitable for the appliance s maximum power use CAUTION For the appliance s general electrical supply the use of adaptors multiple sockets and or extension cords is strictly forbidden The use of any power supply equipment implies the observance of several fundamental rul...

Page 54: ...t it cannot be accidentally turned on Service Relay Requirement 3 24 3 Upstream of the electrical connection a service relay is required not supplied which when the additional electrical safety devices intervene shuts down the electrical supply to the on off fuel valve fitted on the gas supply circuit but not to the boiler so as to guarantee the running of the pump and permit the boiler to cool do...

Page 55: ... 10913 Page 55 of 146 GF 143 Phone 800 526 0288 07 13 15 Figure 3 28 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 AUX AUX ...

Page 56: ...BOILERS Installation Operation Maintenance Manual Page 56 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 Figure 3 29 Main Power Junction Box Location and 120VAC Wiring GROUND ...

Page 57: ...81 641 802 962 1123 BOILERS Installation Operation Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 57 of 146 GF 143 Phone 800 526 0288 07 13 15 3 25 Functional Wiring Diagram ...

Page 58: ...81 641 802 962 1123 BOILERS Installation Operation Maintenance Manual Page 58 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 This page intentionally blank ...

Page 59: ...62 1123 BOILERS Installation Operation Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 59 of 146 GF 143 Phone 800 526 0288 07 13 15 3 26 Ladder Diagrams Figure 3 30 Module Ladder Diagram ...

Page 60: ...gnments 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 The main controls necessary for the C H system management and for the boiler control as well some components which are part of the boiler housing must be connected to the terminal blocks See Figure 3 32 for a wiring diagram showi...

Page 61: ...02 962 1123 BOILERS Installation Operation Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 61 of 146 GF 143 Phone 800 526 0288 07 13 15 Figure 3 32 E8 Controller Terminal Assignments ...

Page 62: ...2 962 1123 BOILERS Installation Operation Maintenance Manual Page 62 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 Figure 3 33 Sensor and BCM Terminal Assignments ...

Page 63: ...OILERS Installation Operation Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 63 of 146 GF 143 Phone 800 526 0288 07 13 15 3 29 Installation Examples Functional Wiring and Connections Description ...

Page 64: ...DULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation Maintenance Manual Page 64 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 ...

Page 65: ...s reason the unit s supply voltage gas pressure and water pressure must be maintained and available during these activities WARNING Following maintenance or other activities always check the integrity of all parts through which gas flows with a bubble test using soap spray to ensure there are no gas leaks 3 31 Filling the System Necessary Precautions While Filling the System 3 31 1 Do not mix the ...

Page 66: ... exceeds 9 grains the water must be treated until below the maximum value of 9 grains The pH value of the installation water must be between 6 5 and 8 5 Check the pH value using proper equipment or by having the water analyzed by a water treatment company If pH differs from above contact AERCO engineering for further assistance WARNING Failure to adhere to the water quality requirements will resul...

Page 67: ...t of the control system and any gas control device that has been submerged under water WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch or operate any electric switch Do not use any phone in the building Immediately call your gas supplier from a neighbors phone or from outside with your cell phone and follow the gas supplier s instructions OPERATING INSTRUCTIONS 1 STOP Re...

Page 68: ... See Figure 7 2 NOTE Ensure the cable end is not grounded to the enclosure frame or to any other grounded part 5 The display will show ERROR CODE E05 Loss of Flame See Figure 3 34 Figure 3 34 Loss of Flame Error Code E 05 6 Press Reset Button on E8 Controller 7 The boiler will retry the ignition cycle and the display will show ERROR CODE E04 No Flame Detected During Ignition See Figure 3 35 Figure...

Page 69: ...ion to the mains supply system the gas valve must be re calibrated using Service Mode function in the E8 controller Installing the Gas Analyzer Probe 3 33 1 Before making adjustments a gas analyzer sensor probe must first be installed into the flue exhaust outlet as shown in Figure 3 36 Installing the Gas Analyzer Probe into Flue Outlet 1 Remove the cap 2 from the gas outlet 1 2 Install the probe ...

Page 70: ...tions below to set the maximum gas output level for each valve Adjusting the Maximum A Gas Output Setting 1 Remove the cap of the combustion gases sampling point Figure 3 36 and connect a suitable gas analyzer 2 Operate the burner to a minimum power following the procedure described in Section 3 34 Figure 3 39 Sweeper function CASCADE MAN 100 3 Check that the CO2 values are within the values indic...

Page 71: ... the CO2 percentage is too low check if the air and exhaust flue are obstructed If they are not obstructed check if the burner and or the exchanger aluminum sections are properly cleaned After confirmation check the maximum gas settings again as described in section 3 33 2 above Final Check and Ignition Failure Adjustment Procedure 3 33 4 After completing the Minimum and Maximum output adjustments...

Page 72: ...s Ǿ in mm Min Gas Consumption ft 3 hr m 3 hr Max Gas Consumption ft 3 hr m 3 hr Start Output IG Min Max Min Max Min FL Max FH NOMINAL ALTITUDE Natural 7 1 74 7 5 10 3 1 5 8 31 91 0 27 7 45 1 29 474 13 43 50 Propane 11 2 74 10 11 1 3 3 1 30 84 0 27 7 18 0 50 183 5 19 50 HIGH ALTITUDE Natural 7 1 74 8 5 10 3 1 5 8 35 100 0 27 7 45 1 29 474 13 43 50 Propane 11 2 74 10 8 10 8 1 3 3 1 30 73 0 27 7 18 0...

Page 73: ... in mm Min Gas Consumption ft 3 hr m 3 hr Max Gas Consumption ft 3 hr m 3 hr Start Output IG Min Max Min Max Min FL Max FH NOMINAL ALTITUDE Natural 7 1 74 8 5 10 3 1 5 8 31 91 0 27 7 45 1 29 948 26 87 50 Propane 11 2 74 10 11 1 3 3 1 30 84 0 27 7 18 0 50 367 10 39 50 HIGH ALTITUDE Natural 7 1 74 8 5 10 3 1 5 8 35 100 0 27 7 45 1 29 948 26 87 50 Propane 11 2 74 10 8 10 8 1 3 3 1 30 73 0 27 7 18 0 5...

Page 74: ...f 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 3 34 Sweeper Mode Manual Control Figure 3 39 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 ...

Page 75: ...meters Figure 3 40 Adjusting Fan Speed to Set Input Range for High Altitude NOTE See the value of parameter FH FAN MAX in Table 3 7 and Modulex EXT Pressure and CO 2 Level Calibration in Table 3 6 WARNING This conversion to high altitude operation shall be made by a qualified service agency in accordance with the manufacturer s instructions and all applicable codes and requirements of the authorit...

Page 76: ...P LIM 10 No Change BOIL P VAL 25 No Change BOIL I VAL 12 No Change BOIL D VAL 00 No Change PUMP OVERRUN 05 No Change PUMP MIN MOD CAP FLOW RATE FAN P VAL 04 No Change FAN I VAL 08 No Change FAN SLP FAN SLP POS FAN SLP NEG FAN START PW FAN ADAPT RESTARTS SW NO Software N Software N SW RWV Software Revision Software Revision 3 36 High Altitude Conversion Label After calibration of the unit from Norm...

Page 77: ... fan speed parameter FH FAN MAX from the E8 controller as shown in Table 3 7 and Modulex EXT Pressure and CO2 Level Calibration in Table 3 6 above This parameter requires a password to change 2 Adjust CO2 minimum and maximum levels according to the type of gas as shown in table below See section 3 33 Burner Calibration for more information Gas Type CO2 Level Minimum CO2 Level Maximum Natural Gas 8...

Page 78: ...l Limit Thermostat E E8 Controller Module F Hydrometer Optional G Change over Series Parallel 0 Emergency is active or the control is managed by PLC or BMS I Series connection the cascade is managed by the BCM II Parallel connection condition of supply H In position I the plant will operate when requested at CONSTANT SETPOINT 70 C Max heat output 50 I Enables burner reset in case of lock out J YEL...

Page 79: ... running All of the system s on off valves are in the appropriate position open or closed as required The mains gas supply corresponds to the one which the boiler has been calibrated for Otherwise convert the boiler to use the available gas refer to section GAS CONVERSION This operation must be carried out by a qualified technician in compliance with the regulations in force The gas supply valve i...

Page 80: ...81 641 802 962 1123 BOILERS Installation Operation Maintenance Manual Page 80 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 This page intentionally blank ...

Page 81: ...0 mm The Controller is mounted on the front of the MODULEX Boiler and contains all of the controls indicators and displays necessary to adjust operate and troubleshoot the MODULEX Boiler The main components of the closed E8 Controller include the display door and data wheel see Figure 4 1 E8 Controller Features and Functions 4 1 1 The E8 features the following functions for MODULEX boilers Shares ...

Page 82: ...ns Item Function A Current time 24 hour format B DCF reception OK only if receiver is connected via eBUS C Display of the active heating program for the first heating circuit here 6 00 to 08 00 a m and 4 00 to 10 00 p m D Bus icon if this icon does not appear check data line to connected CAN controllers check eBUS via DISPLAY level E Status display Shows symbols for Internal Burner 1 Relay ON Heat...

Page 83: ...e 4 2 E8 HEATING Mode Features and Functions NORMAL Mode SYMBOL MODE NAME DESCRIPTION Heating Mode Selection Turn the Rotary Knob to select the heating mode required The heating mode is indicated by a symbol at the bottom of the display It takes effect when the setting is not changed for 5 seconds Standby OFF Heat OFF and hot water HW preparation OFF only frost protection mode Automatic Mode 1 Hea...

Page 84: ...he display can be changed using the Rotary Knob A D Optical Adaptor For PC connection E Program Key Used to select a sub menu level select a parameter value to change or save a new parameter value F Manual Automatic Switch A 2 position 10 2 o clock screwdriver adjustable switch Normally this switch is set to the Automatic 2 o clock position to allow program control of the boiler When set to the Ma...

Page 85: ...advances to the DISPLAY menu The dial on the clock face will rotate one revolution counterclockwise and then go off The display will then show INSTALLATION which is the first sub menu in the DISPLAY menu group Figure 4 5 The two small black arrows at the bottom of the display will point down to the menu and submenu names in this case DISPLAY and INSTALLATION respectively 3 To view functions includ...

Page 86: ...e display see Figure 4 5 Press Program Key to access parameters in the selected displayed sub menu Turn Rotary Knob to sequence through the available parameters To change a parameter value press the Program Key when the desired parameter is displayed The Change LED will light up indicating the displayed parameter may now be changed To change the displayed parameter value turn the Rotary Knob clock...

Page 87: ...module s in the boiler can maintain the system load requirements thereby providing a level of redundancy that was previously only realized in multi boiler installations A photo of the module is shown in Figure 4 6 Additional information for the BCM component can be found in Section 7 9 and 10 of the E8 Controller User Manual GF 115 C BCM Features and Functions 4 2 1 When installed and enabled the ...

Page 88: ...o position rocker switch resets clears fault relay and LED when activated D SW1 10 Position Rotary Switch Rotary switch labeled 0 9 Sets the corresponding address of Boiler on the input Modbus or EBUS Network E DL1 LED YELLOW Communication Status Indicator functions as follows Status Description OFF No devices detected by either communication interface BLINKING Only one communication device detect...

Page 89: ...control The E8 does not control the boiler and the BCM will take over the boiler if the Modbus signal fails If E8 is in Standby Mode BCM will cycle the pump with the boiler If E8 is in Day Mode the E8 will continuously run the pump The E8 is the primary controller and the BCM allows monitoring and the BCM will take over the boiler if E8 fails If E8 is in Standby Mode E8 will cycle the pump must us...

Page 90: ...81 641 802 962 1123 BOILERS Installation Operation Maintenance Manual Page 90 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 This page intentionally blank ...

Page 91: ... 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 Modulex E8 Controller Front Panel Cover Closed Modulex E8 Contro...

Page 92: ...lize the boiler for operation Once the values grouped here have been entered and accepted the controller is initiated and operatable and may be configured for your boiler installation To re enter the INSTALLATION menu cycle the boiler power and open the cover again To initialize the E8 Controller set the following values in the INSTALLATION Menu Set the parameters ENGLISH HOUR YEAR MONTH and DAY L...

Page 93: ... 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 5 1 above Setting Maximum and Minimum Flow Temperature 5 2 1 Figure 5 2 E8 Qui...

Page 94: ... Manual Page 94 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 Figure 5 3 E8 Quick Start Room Temperature and Outdoor Compensation Settings with Outdoor Temperature Slope Chart Setting Heating Programs and Pumps 5 2 3 ...

Page 95: ...1123 BOILERS Installation Operation Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 95 of 146 GF 143 Phone 800 526 0288 07 13 15 Figure 5 4 E8 Quick Start Heating and Pump Program Settings ...

Page 96: ...ons where applicable EXPERT Summary of values for which expert knowledge is required to make settings installation technician Values in the expert level are protected by a code number EXPERT FA Only for FA via BUS Summary of values transmitted by the automatic firing device Sub Menus 5 3 2 INSTALLATION All display values and settings that relate to the unit or the entire system and cannot be assig...

Page 97: ...eration Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 97 of 146 GF 143 Phone 800 526 0288 07 13 15 5 4 General Menu The GENERAL menu contains the sub menus DATE TIME HOLIDAY and CLOCK CHANGE Figure 5 5 GENERAL Menu ...

Page 98: ...st current month 01 12 DAY Adjust current day 01 31 HOLIDAY YEAR START Set current holliday start year XXXX MONTH START Set current holliday start month 01 12 DAY START Set current holliday start day 01 31 YEAR STOP Set current holliday end year XXXX MONTH STOP Set current holliday end year 12 31 DAY STOP Set current holliday end day 01 31 CLOCK CHANGE MONTH START Set month for start of summer tim...

Page 99: ...auvelt NY 10913 Page 99 of 146 GF 143 Phone 800 526 0288 07 13 15 5 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 Figure 5 6 SERVICE Menu ...

Page 100: ...r buffer storage temperature F2 Middle buffer storage temperature or room temperature heating circuit 1 F3 Upper buffer storage temperature F5 Flow temperature heating circuit 2 F6 Upper hot water temperature F8 Boiler Header temperature F9 Outside temperature F11 Flow temperature heating circuit 1 or temperature multifunction 1 F12 Hot water temperature lower or temperature multifunction 2 F13 So...

Page 101: ...velt NY 10913 Page 101 of 146 GF 143 Phone 800 526 0288 07 13 15 5 6 Display Menu The DISPLAY menu contains the INSTALLATION HOT WATER HTG CIRCUIT 1 2 and SOLAR MF sub menus as shown below Figure 5 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 102: ... STORAGE 3 Temperature of storage tank 3 e g solar pool heating MODGRAD Modulation level for each module RETURN HOT WATER T DHW RATED Hot water set temperature value T DHW Hot water temperature value T DHW L Hot water temperature in infeed area T CIRC Recirculating temperature RETURN HTG CIRCUITC 1 2 T ROOM DES A Current value for set room temperature T ROOM Room temperature HUMIDITY Displays room...

Page 103: ...tenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 103 of 146 GF 143 Phone 800 526 0288 07 13 15 5 7 User Menu The USER menu contains the INSTALLATION HOT WATER HTG CIRCUIT 1 2 and SOLAR MF sub menus as shown below Figure 5 8 USER Menu ...

Page 104: ...0 0 1 RETURN HTG CIRCUIT 1 2 MODE When setting an alternative oparating mode this only applies to the assigned heating circuit T ROOM DES 1 Room temperature setting in first enable time 68 41 105 T ROOM DES 2 Room temperature setting in second enable time 68 41 105 T ROOM DES 3 Room temperature setting in third enable time 68 41 105 T REDUCED Required room temperature setting during night reductio...

Page 105: ...le 5 5 TIME PROGRAM Menu LEVEL DESCRIPTION CIRCL TIME Program for circulation pump HOTW PROG Program for hot water charging pump HTG PROG 1 1 1st Heating program for first controller heating circuit HTG PROG 2 1 2nd Heating program for first controller heating circuit HTG PROG 1 2 1st Heating program for second controller heating circuit HTG PROG 2 2 2nd Heating program for second controller heati...

Page 106: ...allation Operation Maintenance Manual Page 106 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 5 9 Expert Menu The EXPERT menu contains the items shown below Figure 5 10 EXPERT Menu 1 of 2 ...

Page 107: ...RCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 107 of 146 GF 143 Phone 800 526 0288 07 13 15 Figure 5 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 ...

Page 108: ...erheating 185 F 86 230 MIN T HS2 Decreased condensation build up in HS with low heat requirement 104 F 50 176 V CURVE Only for 0 10V input output 11 00 11 CURVE 11 U1 Low voltage set 0 V 0 V 10 V CURVE 11 U2 Higth voltage set 10 V 0 V 10 V CURVE 11 T1 Low temperature level 68 F 32 248 CURVE 11 T2 High temperature level 185 F 32 248 CURVE 11 UA Starting with this voltage level 2 V 0 V 10 V HYSTERES...

Page 109: ...time after switching on or with switching HS 01 00 30 HYST BURNER2 Solid fuel integration hysteresys for the charging pump 4 3 6 36 Ra HS COOL FCT Not used 0 0 1 T HS COOL Not used 176 122 203 HEATSOURCE 1 Primary heat generator type 06 00 06 HS 1 BUS Connections for HS 02 00 04 HEATSOURCE 2 Secondary heat generator type 0 00 05 STORAGE HS 2 Heat accumulator for HS2 0 00 03 BUFFER Heater buffer st...

Page 110: ...0 B HEAT SINK Circuit enable 0 00 01 RETURN SOLAR MF RELAY FUNC 1 to 4 Function selection relay 1 to 4 0 00 26 T MF1 to 4 SETP Switching temperature relay MF1 to 4 86 86 194 MF 1 to 4 HYST Hysteresys relay MF1 to 4 9 4 18 FUNZ F15 Sersor function F15 0 00 02 RETURN NOTE There is another sub menu under the EXPERT menu called EXPERT HS See section 3 35 High Altitude Adjustment for details NOTE Some ...

Page 111: ... to use one of the heating zone for the heating of a swimming pool EXPERT menu Heating circuit I II HC FUNC 02 5 10 1 6 Swimming Pool Temperature Setting Only After Function Selection USER menu Heating circuit I II T POOL 1 2 3 5 10 1 7 Screed Dry Program For Floor Heating Installation A program setting for drying the screed EXPERT menu Installation SCREED 01 5 10 1 8 Temperature Setting For Scree...

Page 112: ...4 0 V 0 1 V 68 F 194 F 5 0 V Setting of DHW Circuit 5 10 2 5 10 2 1 Operation of Pumps In Parallel Heating pump operation during DHW production EXPERT menu Hot Water F PUMP PARAL 00 01 02 03 5 10 2 2 Use of a DHW Storage Tank Thermostat On Off To use an ON OFF thermostat instead of DHW sensor EXPERT menu Hot Water THER IMPUT 01 5 10 2 3 Antilegion Activation of an antilegion program EXPERT menu Ho...

Page 113: ...Manager Faults Communication Faults and Internal Faults These fault codes are shown in Table 6 2 BCM Boiler Control Module These fault codes are shown in Table 6 3 BMM Burner Management Module These fault codes are shown in Table 6 4 Figure 6 1 E8 Error Code Location NOTE When interpreting fault codes in the E8 display that refer to the E8 controller itself the code number is directly referenced t...

Page 114: ...de Code to Look Up in Table Code 0 N A No Fault Code between 1 and 255 BMM 0 Fault Look up code 6 4 Code between 256 and 511 BMM 1 Fault Subtract 256 from reading 6 4 Code between 512 and 767 BMM 2 Fault Subtract 512 from reading 6 4 Code between 768 and 1023 BMM 3 Fault Subtract 768 from reading 6 4 Code between 1024 and 1279 BMM 4 Fault Subtract 1024 from reading 6 4 Code between 1280 and 1535 B...

Page 115: ...me signal detected after burner is OFF E 24 Modulating fan speed failure failed to reach the correct speed within 30 seconds from starting of burner ignition cycle E 26 Modulating fan speed failure failed to stop within 30 seconds from end of operation E 28 Common chimney obstruction E29 Water inside chimney chamber E 30 Alteration of the operating parameters caused by EMC disturbances E 32 Mains ...

Page 116: ...US addresses 0 and 1 The BUS codes 0 and 1 cannot be used at the same time E 91 E8 BUS code occupied The set BUS code is already used by another appliance E 99 E8 Internal failure E 200 Communication Error HS1 E 201 Communication Error HS1 E 202 Communication Error HS1 E 203 Communication Error HS1 E 204 Communication Error HS1 E 205 Communication Error HS1 E 206 Communication Error HS1 E 207 Comm...

Page 117: ... temperature protection Flow temperature Return Temperature Water Δ Temp Protection 50 F All burners turned OFF and Pump ON at maximum speed Check the system installation AUTOMATIC when Δ temperature Water Δ Temp Protection E 19 High outlet temperature Flow sensor temperature 203 F All burners turned OFF and pump ON at maximum speed Check Flow Sensor or system pump AUTOMATIC when Flow sensor 176 F...

Page 118: ...flame detected at burner start Burner control lockout Check flame rod or combustion MANUAL push reset switch or cycle power E 5 Flame loss during run Ignition retry Check combustion and wiring MANUAL push reset switch or cycle power E 6 High outlet temperature Flow sensor temperature 203 F All burners turned OFF and pump ON at maximum speed Check flow sensor or system pump AUTOMATIC when Flow sens...

Page 119: ...TIC when flow sensor is greater than 41 F E 20 Flame signal detected after burner is OFF Ignition is inhibited Disconnect gas valve wire from BMM If failure goes away check wiring or change BMM If failure remains check or change gas valve MANUAL push reset switch or cycle power E 22 No air flow at burner after fan started for 30 seconds Ignition retry after 60 second delay and failure remains unti...

Page 120: ...n speed out of control It doesn t stop within 30 seconds after turned OFF Ignition is inhibited Check fan wiring AUTOMATIC E 27 Air flow failure during ignition Restart pre purge timer The failure remains until we have a successful burner operation Check fan and wiring Check air proving switch and wiring AUTOMATIC E 30 Settings corrupted Ignition is inhibited Pump runs for 5 min at max speed Re pr...

Page 121: ...sed Regular maintenance will prolong the life of the boiler WARNING If the boiler is not checked and serviced regularly it could cause damage to the equipment and or harm to persons Table 7 1 Modulex EXT Maintenance Schedule Maintenance Operation Check Once a Year Check Every 2 Years Inspect for acceptable circulating and feed water quality and chemistry Inspect gas assembly components Inspect saf...

Page 122: ...ards and regulations 7 After completing all the necessary maintenance work always follow these steps a Open the C H flow and return valves as well as the cold inlet valve if previously closed b Purge and if necessary proceed with restoring the heating system s pressure until a pressure of 0 8 1 0 bar is reached c Open the external ON OFF gas valve installed upstream of the boiler d Reconnect the a...

Page 123: ...its flush them out with clean water 3 Reassemble the drain pipe in reverse order Figure 7 1 Condensate Drain Location WARNING Before operating the boiler it is absolutely necessary to verify that the condensate P trap is filled with water If the boiler is operated without the P trap being properly filled there is a danger of toxic combustion gases escaping from the unfilled condensate drain openin...

Page 124: ...rough the flame observation port Figure 7 2 The flame pattern should resemble the flame in the illustration below FLAME COLOR YELLOW CO2 HIGH NOT SATISFACTORY BLUE CO2 LOW NOT SATISFACTORY ORANGE OK SATISFACTORY Figure 7 2 Boiler Flame Observation Port Location 7 6 Proper Reassembly and Resealing of the Vent Air Intake System After removing inspecting and possibly cleaning the flue pipes and air i...

Page 125: ...F 143 Phone 800 526 0288 07 13 15 7 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 See Figure 7 3 Pressure Hose Lengths NOT ACCEPTABLE Original Length OK NOT ACCEPTABLE Original Length OK ...

Page 126: ...OTE A reduction of the input can be caused by the obstruction of the vent or air intake Before cleaning the boiler body sections check the boiler input and the O2 percentage see section 3 33 7 9 Heat and Return Sensor Resistance Values Nominal resistance differences at a given temperature ratio C between the primary and return heating sensors should be checked periodically by measuring the electri...

Page 127: ...m the boiler and ensure it is completely closed 2 Unlatch and raise the top lid Figure 7 4 3 Remove screws from top of unit holding the rear and side panels in place Figure 7 5 Remove panels by tilting away from unit then lifting up and out Figure 7 6 Note the front and rear panels must be removed before the side panels can be removed Figure 7 4 Unlatch Top Lid Step 2 Figure 7 5 Remove Screws at E...

Page 128: ...assembling the Boiler for Maintenance Continued 4 Remove screws from around exhaust outlet opening and remove flue assembly from unit Figures 7 7 7 8 Figure 7 8 Flue Removal Step 4 5 On each side of the air intake manifold unlatch spring clips holding it in place Figure 7 9 Figure 7 9 Unlatch Spring Clips from Left and Right Side of Manifold Step 5 Manifold Retention Spring Clip Left Right Air Int...

Page 129: ...ide of manifold Figure 7 10 then lift entire manifold from the unit Figure 7 10 Removing Red Hoses and Manifold from Unit Step 6 Figure 7 11 Removing Gas Valve Connector from All Gas Valves Step 7 7 On each gas valve unscrew the Gas Valve Connector with a Phillips head screwdriver Remove connector Figure 7 11 from the side of each gas valve Air Intake Manifold Remove Red Hoses from under Manifold ...

Page 130: ...Leave the B screws affixed so all burner plates may be lifted together Then complete the remainder of the instructions in this section b Separate Modules Use a 13mm wrench to remove only the A and C nuts on either side of the module in question vertical dotted lines in figure 7 12 then remove the B Phillips screw at the end of the burner module You can then skip the remaining steps in this section...

Page 131: ...1 of 146 GF 143 Phone 800 526 0288 07 13 15 Disassembling the Boiler for Maintenance Continued Figure 7 14 Removal of Burner Plate Hardware Steps 9 10 11 11 Refer to Figure 7 15 and remove the two bolts white arrows at each end of the gas collection tube that mount it to the boiler chassis Figure 7 15 Uninstall Gas Collector Tube from Boiler Chassis Step 12 A B C ...

Page 132: ...rom the gas supply piping Figure 7 16 Uninstall Gas Collector Flange from Gas Supply Piping Step 13 13 Refer to Figure 7 17 for location of burner assembly lifting screws There is one at each end Elevate the burner assembly slightly until screw is lined up with the tab hole then unscrew the lift screw until it extends into the hole Do this at both ends Figure 7 17 Location of Burner Assembly Lifti...

Page 133: ...e Boiler for Maintenance Continued Figure 7 18 Unscrewing Lift Screw into Tab Hole Step 14 Figure 7 19 Lift Screws Extended into Tab Holes Left and Right Sides Step 14 14 Refer to Figure 7 20 then lift up the front of the burner assembly and raise up until the two lift pins can be inserted Figure 7 22 at the left and right sides in order to hold up the burner assembly Figure 7 20 Lifting Burner As...

Page 134: ...on of Check Valve Step 1 Figure 7 22 Lift Pins Inserted into Lift Holes Left and Right Sides Step 15 7 11 Cleaning the Burner Module and Combustion Chamber After lifting up the burner assembly the individual burner modules are now exposed and may be cleaned Follow the instructions to clean the burner modules Cleaning the Burner Modules Figure 7 23 Burner Modules Exposed for Cleaning NOTE The check...

Page 135: ...at the L profile where the mesh is welded to the frame for integrity If welds are compromised or the burner mesh is damaged the burner module should be replaced 4 Once all the burner modules are removed wash the combustion chamber underneath with water Avoid getting the electrical harnesses and components wet 5 During this operation inspect to the condensate drain pipe to determine if it is free o...

Page 136: ...d Reinstall gas collector tube ends onto boiler frame 2 screws per end e Reinstall bolts A B and C screws to secure burner assembly to boiler body NOTE Tighten the burner bolts with a torque of 13 Nm f Reassemble red hoses to the air intake manifold place manifold onto the blowers then reattach tension spring clip to left and right ends of manifold g Proceed to section 7 13 for final procedures be...

Page 137: ...ION 01 EXT 321 ANNUAL MAINTENANCE KIT 02 EXT 481 ANNUAL MAINTENANCE KIT 03 EXT 641 OR EXT 1530 ANNUAL MAINTENANCE KIT 04 EXT 802 OR EXT 1912 ANNUAL MAINTENANCE KIT 05 EXT 962 OR EXT 2295 ANNUAL MAINTENANCE KIT 06 EXT 1123 OR EXT 2677 ANNUAL MAINTENANCE KIT 11 EXT 3060 ANNUAL MAINTENANCE KIT Table 7 4 MLX 24 Month Fireside Inspection Maintenance Kit 58086 TAB P N Suffix DESCRIPTION 12 EXT 321 24 MO...

Page 138: ...T Accessory Kits are available 58081 for Modulex EXT models 321 481 641 58082 for Modulex EXT models 802 962 1123 The contents of each are listed in the table below Table 7 5 MLX Accessory Kits 58081 58082 Included in Kit Item Qty Part No Description 58081 58082 1 1 123675 2 GAUGE PRESSURE TEMP 2 1 49051 4 EXHAUST CONN PART FOR PVC 3 1 49050 6 EXHAUST CONN PART FOR PVC 4 2 59039 6 WORK DRIVE HOSE ...

Page 139: ...1 802 962 1123 BOILERS Installation Operation Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 139 of 146 GF 143 Phone 800 526 0288 07 13 15 CHAPTER 8 SPARE PARTS DRAWING AND LISTS ...

Page 140: ...81 641 802 962 1123 BOILERS Installation Operation Maintenance Manual Page 140 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 This page intentionally blank ...

Page 141: ...DULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation Maintenance Manual OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 141 of 146 GF 143 Phone 800 526 0288 07 13 15 ...

Page 142: ...81 641 802 962 1123 BOILERS Installation Operation Maintenance Manual Page 142 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 This page intentionally Blank ...

Page 143: ...Sensor Bracket 16 95213277 Boiler Sump Assembly EXT 321 95213280 Boiler Sump Assembly EXT 481 95213284 Boiler Sump Assembly EXT 641 95213287 Boiler Sump Assembly EXT 802 95213291 Boiler Sump Assembly EXT 962 95213294 Boiler Sump Assembly EXT 1123 17 95213301 Right Side Panel 18 95213953 Left Side Panel 19 95213303 RH lateral Panel 20 95213304 LH lateral Panel 21 95213305 Locking plate flue MODULEX...

Page 144: ...lation EXT 802 32 95250851 Boiler Body Insulation EXT 962 95250852 Boiler Body Insulation EXT 1123 33 95251210 Graphite Electrode Gasket 34 95251274 Flame Detector 35 95251529 Return Manifold Gasket 36 95251587 Fan Blower Manifold Gasket 37 95251588 Fan NRG118 Gasket 38 95251592 Silicone Gasket 39 95251851 Sheath Bulbs 40 95251607 Gas Manifold Gasket 41 95251611 Flue Terminal D 200 42 95251841 Wat...

Page 145: ...0963 Electronic Board 74 95262930 Hinge Casing 75 95262931 Casing Top Panel lock 76 95000721 Junction Box 77 95261720 Terminal Strip 78 95251877 Flanged Flue Outlet Terminal 79 95372088 Gas Inlet Header Modulex 2 3 Elements EXT 321 EXT 481 95372089 Gas Inlet Header Modulex 4 5 Elements EXT 641 EXT 802 95372090 Gas Inlet Header Modulex 6 7 Elements EXT 962 EXT 1123 80 95372093 Flow Header 2 Element...

Page 146: ...Description Changed By 12 01 2014 Rev E Applied final changes per A M Reformatted per current design standards Misc corrections and improvements Curtis Harvey 07 13 2015 Rev F DIR 195 Warranty pages removed Warranty information for all Modulex units is now included in a new stand alone document All Modulex Limited Warranty posted on the AERCO web site Clarified maintenance schedule added informati...

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