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Aerco Modulex MLX-1060, User Manual

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MC2: 10/03/12                                                                                                                                        Page 

45

 of 

90

 

 

AERCO International, Inc. 

•

 100 Oritani Dr. 

•

  Blauvelt, NY 10913 

•

 Ph: 800-526-0288  

 

 

GF-115-H 

 

OMM-0083_0B 

Modulex MLX Series Gas Fired Boiler System 

 

Operation and Maintenance Manual 

Chap 8: Safety 
Device Testing 

 

8.6   FLAME FAULT TESTS 

Flame faults can occur during ignition or while the unit is already running.  It is necessary to perform the 
flame fault test using the GENERAL/SERVICE/CASCADE MANU menu, where the each burner may be 
selected and the valve position set open by a user specified percentage. To simulate each of these fault 
conditions for all two to seven burners (depending on model), proceed as follows: 

Flame Fault Tests 

1.  Set the 

ON/OFF

  switch to the 

ON

  position to start the  E8 controller, then  select  the 

GENERAL/SERVICE/CASCADE MANU menu, choose Burner 1, and set the valve position between 
25% and 30%.

 

2.  Disconnect the cable from the Burner 1 flame detector at front of unit (see Figure 8-4). 

3.  The unit should shut down after reaching the ignition cycle and display fault code 

E4

  in the E8 

controller display. The 

E4

 fault code indicates a failure to fire at startup.

 

4.  Plug the flame detector cable back onto the Burner 1 flame detector connector. 

5.  Reset the error displayed in the E8 controller (see paragraph 8.2 for instructions). 

6.  Use the E8 controller to select the GENERAL/SERVICE/CASCADE MANU menu, choose Burner 1, 

and set the valve position between 25% and 30%. 

7.  After the unit establishes a flame and runs for about a minute, unplug the Burner 1 flame detector 

cable at front of unit. The unit should shut down and display a fault code of “

E5

” on the E8 controller 

display. The 

E5

 fault code indicates a loss of flame while running. 

8.  Plug the flame detector cable back onto the flame detector. 

9.  Reset the error displayed in the E8 controller (see paragraph 8.2 for instructions). 

10.  Place the unit in the AUTO Mode and the unit should now restart and fire normally. 

 

11.  Repeat the above procedure for each of the unit’s burners.

 

 
 

 

 

 

Figure 8-4:  Flame Detector and Ignition Component Locations

 

Flame  

View Port 

Ground Wire 

Terminal 

Igniter  

Cable 

MLX Rear with Panel Removed 

Flame  

Detector 

Cable 

Summary of Contents for Modulex MLX-1060

Page 1: ...g Hot Water Boiler Models MLX 303 MLX 454 MLX 606 MLX 757 MLX 909 MLX 1060 Modulex MLX Series Boiler Other manuals for this product include GF 115 C MLX E8 Controller BCM Manual GF 115 E MLX Electrical Power Guide GF 115 P H MLX Piping Guide GF 115 V MLX Venting Guide GF 115 G MLX Gas Supply Guide Installation Operation and Maintenance Modulex MLX Series Gas Fired Boiler ...

Page 2: ...out notice from AERCO International Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual Nor for incidental or consequential damages occurring in connection with the furnishing performance or use of this m...

Page 3: ...nstallation 19 3 2 Installation Instructions 19 3 2 1 Unpacking the Boiler 19 3 2 2 Boiler Location 21 3 2 3 Pad Height for Boiler 21 3 2 4 Boiler Connections 22 3 3 Data Plate 23 CHAPTER 4 GENERAL INFORMATION FOR VENTING 25 4 1 Vent Pipe Connection 25 4 2 Gas Vent Categories 25 4 3 Installation And Sizing 25 4 4 Existing Boiler Removal From Common Venting System 26 CHAPTER 5 PIPING 27 5 1 Makeup ...

Page 4: ...n 35 7 5 2 Installing the Supply Gas Manometer 35 7 5 3 Preparing The Flue For Use With The Combustion Analyser 36 7 5 4 Supply Gas Pressure Check Adjustment 36 7 5 5 Combustion Calibration 38 7 6 Unit Reassembly 40 CHAPTER 8 SAFETY DEVICE TESTING 41 8 1 Testing of Safety Devices 41 8 2 Processing and Clearing Fault Codes 41 8 3 LOW GAS PRESSURE FAULT TEST 42 8 4 LOW WATER LEVEL FAULT TEST 43 8 5 ...

Page 5: ...he Condensate Tray Top Gasket 62 9 4 4 Re Assembly After Burner Section Replacement 64 9 5 Final Testing and Return To Service 64 CHAPTER 10 TROUBLE SHOOTING GUIDE 65 10 1 Introduction 65 CHAPTER 11 TEMPERATURE SENSOR RESISTANCE CHART 77 CHAPTER 12 MODULEX PARTS DRAWING AND LIST 78 CHAPTER 13 BOILER WATER QUALITY AND MAINTENANCE 83 13 1 Modulex Boiler Water Chemistry 84 13 1 1 Reaction of Metals t...

Page 6: ...age 6 of 90 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 This page left intentionally blank ...

Page 7: ... this manual to avoid injury death and damage to the equipment Failure to properly heed safety warnings and cautions may result in the voiding of applicable warranties NEVER USE FLAMES TO DETECT GAS LEAKS What to do if you smell gas Do NOT try to light or turn on any appliance Do NOT touch any electric switch or open switched doors Do NOT use any phone or intercom device in your building Do NOT to...

Page 8: ...serve that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In ...

Page 9: ...uctions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system D MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies...

Page 10: ...ge 10 of 90 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 This page left intentionally blank ...

Page 11: ...water temperatures as well as heating 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 progr...

Page 12: ... MLX 909 41 12 835 245 20 1 4 0 15 1 10 6 40 7 MLX 1060 41 12 975 286 23 1 4 6 17 6 12 4 47 1 MBH 1000 Btu hr 2 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 right hand side standard delivery condition or on the Left Hand left hand side This is accomplis...

Page 13: ...l Chap 2 General Description 2 4 Dimensions and Weights The dimensions and weights for each Modulex Model are shown in Diagram 1 and 2 of Figure 2 1 and Table 2 2 4 33 110 mm 12 40 315 mm 4 33 110 mm 16 73 425 mm 8 78 223 mm 13 39 340 mm L 8 78 223 mm 13 39 340 mm FRONT VIEW S 10 55 268 mm Ø 13 78 350 mm 13 58 345 mm B C TOP VIEW H D B A Figure 2 1 Modulex Dimensions and Weights Diagram 1 of 2 ...

Page 14: ...75 CONNECTION GAS 1 1 2 38 WATER OUTLET SUPPLY M 2 50 WATER INLET RETURN R 2 50 EXH VENT CONNECTION D 4 102 EXH VENT WIDTH H 9 45 240 CONDENSATE DRAIN DIA 1 57 40 27 36 695 30 32 770 27 36 695 32 28 820 30 71 780 408 185 463 210 1 1 2 38 2 50 2 50 4 102 9 45 240 1 57 40 32 83 834 38 11 968 35 7 908 41 0 1042 37 09 942 27 36 695 27 36 695 32 28 820 32 28 820 30 71 780 30 71 780 496 225 573 260 551 ...

Page 15: ...5 lbs 346 8 kg MLX 1060 42 1067 mm 49 1245 mm 27 686 mm 869 lbs 394 0 kg SPECIFICATIONS Model Number MLX 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 303B or Propane MLX 303BP Natural Gas MLX 454B or Propane MLX 454BP Natural Gas MLX 606B or Propane MLX 606BP Natural Gas MLX 757B or Propane MLX 757BP Natural Gas MLX 909B or Propane MLX ...

Page 16: ...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 Approvals All units have been certified by CSA and Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 2 6 Modulex Main Components Side View Figure 2 2 illustrates the Main Components included in each Modulex Boi...

Page 17: ...crease to less than 44 6 F 7 C the system pump will start 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 NOTE If glycol ...

Page 18: ...ERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual Chap 2 General Description This page left intentionally blank ...

Page 19: ...rs Also follow the maintenance recommendations in this manual For Massachusetts Installations The boiler must be installed by a plumber or gas fitter licensed within the Commonwealth of Massachusetts 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...

Page 20: ...or models 757 to 1060 A plastic bag containing 3 gaskets 1 rectangular for condensate tray and flue collector 1 square for exhaust 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 ...

Page 21: ... cable must be arranged so that they do not interfere with the removal of any cover or inhibit service or maintenance of the unit The boiler MUST NOT be installed on carpeting 3 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...

Page 22: ...turn 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 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 NO...

Page 23: ...ESSURE BOILER CSA 4 9 PERMISSIBLE INLET GAS PRESSURE BLUE STAR Minimum relief valve capacity MAWP Water 50psi Maximum Water 200 F BLUE FLAME BOILER CATEGORY MAX MIN NORMAL MANIFOLD PRESSURE NORMAL CERTIFIED BY UNICAL AG SPA 2 ALLOW 24 INCHES AT FRONT AND TOP FOR SERVICING AND CLEANING 3 FOR INSTALLATION ON COMBUSTIBLE FLOORS FRONT FLUE CONN SIDES 1 GREATER CLEARANCES FOR ACCESS SHOULD SUPERSEDE FI...

Page 24: ...0 909 000 1 060 000 MIN INPUT 45 000 45 000 45 000 45 000 45 000 45 000 OUTPUT 279 000 418 000 558 000 696 000 835 000 975 000 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...

Page 25: ...bove 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 than 140 degrees F 60 degrees C above its dew p...

Page 26: ...any unused openings in the common venting system 2 Visually inspect 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 commo...

Page 27: ...er output capacity are required These major components 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 5 5 Co...

Page 28: ...r installation Its minimum height when all the fans are in operation must be at least 1 in 25 mm See Figure 5 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 water...

Page 29: ...PORTANT 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 Boiler electric safety is guaranteed only when it is properly connected to an effective grounding system which is in compliance with the regulations in force The use of any electrically powered equipme...

Page 30: ... 4 The boiler s Junction Box contains a polarized terminal block Therefore the Red Line L1 and White Neutral L2 wires from the CSD 1 Manifold MUST BE connected to terminals L1 and L2 respectively on the terminal block in the Junction Box The output cable from the Junction Box is terminated with a 3 pole plug which connects to the boiler s electrical components If incorrectly wired the boiler goes ...

Page 31: ...o the OFF position then back to the ON position This is necessary to ensure that the Controller recognizes the added sensor A map of the connection points on the rear of the E8 Controller may be found in the E8 Controller manual Section 6 of GF 115 C 6 3 Enable Disable Enable Disable should be connected to terminals 3 F3 and 4 GND of E8 connector number I 6 4 Installation Of Sensors To avoid elect...

Page 32: ...90 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual Chap 6 Electrical This page left intentionally blank ...

Page 33: ...on Combustion gases pass thru the heat transfer surfaces Flue gases and condensate then exit the heat exchanger entering into the condensate tray 7 2 Modulation Theory One of the operating principles for this boiler is to have as many modules as possible operate simultaneously at minimum load to reach the maximum efficiency This is maintained by the System Manager E8 which determines a percent of ...

Page 34: ... 5 m away from windows doors and ventilation grates Never mount the outside air sensor in a sunny position The sensor connections are at connector 1 terminals 9 F9 and 10 GND of controller 7 4 2 0 To 10 Volt Remote Set Point The unit s setpoint can be controlled using a 0 to 10 volt signal The Modulex controls allow for full scaling capabilities of voltage and set point through use of the V Curve ...

Page 35: ...34 bar and a minimum of 15 psi 103 kPa 1 bar 7 5 1 Tools Instruments Required For Combustion Calibration The following tools and instrumentation are necessary to perform combustion calibration Digital Combustion Analyser Oxygen O2 and Carbon Dioxide CO2 accuracy to 0 4 Carbon Monoxide CO resolution to 1 ppm One 16 W C manometer or equivalent gauge Small and large flat tip screwdrivers T40 Torx too...

Page 36: ...lue gas flow DO NOT install the probe at this time 7 5 4 Supply Gas Pressure Check Adjustment The optimum gas pressure for the Modulex Boiler is 7 0 W C and is used as the desired pressure in the Combustion Calibration procedures in Paragraph 7 5 5 However it should be noted that the Modulex Boiler can be safely operated at gas pressures ranging from 4 0 W C minimum to 14 W C maximum as specified ...

Page 37: ...splay 8 With SERVICE displayed press the Program Key on the Controller NOTE The CASCADE MANU Cascade Manual Mode will time out after a period of 15 minutes When this occurs the boiler will revert to the Auto mode function under program control 9 Turn the Rotary Knob clockwise until CASCADE MANU is displayed 10 Press the Program Key BOILER 1 will be displayed 11 Press the Program Key again The disp...

Page 38: ...stage This is accomplished by connecting a 16 W C manometer or gauge to the Outlet Pressure Tap of each boiler stage gas valve to check pressure while making adjustments To calibrate the combustion of the Modulex boiler refer to Figure 7 3 below and follow the instructions on the next page NOTE The manometer installed in following steps 1 4 will be moved in turn to each boiler stage for calibratio...

Page 39: ...DE NIGHT MODE and finally SERVICE MODE The SERVICE MODE symbol appears as follows at far right of display 8 With the above symbol displayed open the swing down hinged panel of the controller INSTALLATION will then be displayed 9 Next turn the Rotary Knob counterclockwise until SERVICE appears in the display 10 With SERVICE displayed press the Program Key on the controller NOTE The CASCADE MANU Cas...

Page 40: ...at the outlet pressure tap The pressure should be approximately 0 50 W C at the 10 fire rate 22 Press the Program Key 23 Using the Rotary Knob set the displayed fire rate to zero 0 Press the Program key and wait until the boiler stage turns off 24 This completes the combustion calibration procedure for the first boiler stage 25 Disconnect the manometer connected in step 3 and close the Outlet Pres...

Page 41: ...VOLTAGES IN THIS SYSTEM MAY INCLUDE 120 AND 24 VOLTS AC POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK 8 2 Processing and Clearing Fault Codes When a fault occurs the appropriate fault code will be displayed along with a Flashing Triangle To process and clear the fault proceed as shown in the instructions below NOTE If the cause ...

Page 42: ...o the ON position to start the E8 controller then select the GENERAL SERVICE CASCADE MANU menu choose Burner 1 and set the valve position between 25 and 30 3 While the unit is firing slowly close the external manual gas shut off valve 4 The unit should shut down and display an E2 fault message at approximately 3 9 W C The fault indicator on the E8 controller should also start flashing 5 Fully open...

Page 43: ...aining the unit until the amber Low Water LED on the low water cut off switch illuminates see Figure 8 2 The unit should shut off completely the E8 controller will turn off 5 Close the drain and pressure relief valve used in draining the unit 6 Open the water shut off valve in the return piping to the unit 7 Open the water supply shut off valve to the unit to refill 8 After the unit is full press ...

Page 44: ...Test 1 Start the unit in the NORMAL operating mode Allow the unit to stabilize at its setpoint 2 Lower the adjustable over temperature switch setting to match the displayed OUTLET TEMPERATURE 3 Once the adjustable over temperature switch setting is approximately at or just below the actual outlet water temperature the unit should shut down completely It should not be possible to restart the unit 4...

Page 45: ...aching the ignition cycle and display fault code E4 in the E8 controller display The E4 fault code indicates a failure to fire at startup 4 Plug the flame detector cable back onto the Burner 1 flame detector connector 5 Reset the error displayed in the E8 controller see paragraph 8 2 for instructions 6 Use the E8 controller to select the GENERAL SERVICE CASCADE MANU menu choose Burner 1 and set th...

Page 46: ...nce Manual Chap 8 Safety Device Testing 8 7 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with the ASME Boiler and Pressure Vessel Code Section VI The ASME Boiler and Pressure Vessel Code BPVC is an American Society of Mechanical Engineers ASME standard that provides rules for the design fabrication and inspection of boilers and pressure vessels ...

Page 47: ...ate tray A detailed description of the Fireside Inspection tasks can be found in Sub section 9 3 NOTE The Fireside Inspection Kit already includes the components included in the Annual Maintenance Kit therefore when performing the Fireside Inspection you only need the Fireside Inspection Kit not both Figure 9 1 Typical Fireside Inspection Kit L and Annual Maintenance Kit R Table 9 1 Modulex Mainte...

Page 48: ...lace if needed AERCO P N 95261879 Inspect condensate drain lines clean if needed Check for gas leaks using a soapy solution Inspect igniter and flame sensor replace Igniter P N 95251245 Detector P N 95251246 Check pH of boiler system water refer to Appendix C Boiler Water Chemistry and Maintenance Check flame detection circuitry See paragraph 9 2 3 9 2 2 RECOMMENDED Tasks Inspect vent pipe clean i...

Page 49: ...onnecting these ground wire clips Note that all lugs have capture spring clips that are released by pressing a small nub under lug itself 3 Remove the top cover from the boiler A screwdriver may be needed to pry the cover from the two pins on either end 4 Carefully detach the ground wire clips from the underside of the cover see note above 5 Remove the front panel from the boiler to provide access...

Page 50: ...nd remove it from the boiler 3 Obtain a replacement flame detector from the maintenance kit 4 Install the replacement flame detector and secure it in place with the two 2 screws removed in step b 5 Reconnect the flame detector wire lead 6 Repeat steps 1 through 5 for each flame detector in the boiler 9 2 5 Testing the Flame Detection Circuitry The Modulex boiler is designed to automatically shut d...

Page 51: ... ground wires from the frame of the boiler are attached with clips to the underside of the top cover Use care when disconnecting these ground wire clips Note that all lugs have capture spring clips that are released by pressing a small nub under the lug body 4 Remove the front panel from the boiler to provide access to the fan assembly cover Figure 9 3 5 Remove the screws from the various location...

Page 52: ...800 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual Chap 9 Maintenance Figure 9 3 Remove Fan Assembly Cover Figure 9 4 Remove Fan Assembly Cover Figure 9 5 Remove Plastic Bolt Covers C Cover Screw Locations Fan Assembly Cover D3 D4 ...

Page 53: ...800 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual Chap 9 Maintenance Figure 9 6 Removing Intake Filters Figure 9 7 Removing End Plates Figure 9 8 Reposition Endplates to Offset Two Filters Located on Both Ends of Burner Manifold ...

Page 54: ...00 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual Chap 9 Maintenance Figure 9 9 Fan Assembly L Support Rod I and Holes M Figure 9 10 Accessing Condensate Tray Figure 9 11 Fan Assembly Lifted to Access Burner Modules Burner Modules ...

Page 55: ...iler body and discard These are no longer needed as the new replacement gaskets are self grounding Use only the newer style gaskets as replacements Ensure that the small plaited copper grounding used on OLD gaskets is completely removed along with old gaskets from the burner mounting surfaces 2 Remove each burner module from its seat by inserting a cutter between the gasket and the aluminum body o...

Page 56: ... use compressed air and blow the modules from the convex side to the dished side to blow away debris Inspect for deformations and damage to the mesh and the module body 2 Inspect the combustion chamber below the burners for scale and ash Using compressed air blow out the combustion chamber between the sections to remove all dirt and foreign particles from the aluminum protrusions Use a water jet t...

Page 57: ...he absence of a flame to prevent the buildup of unburned fuel in the combustion chamber Test the circuit by removing a flame detector lead from any of the burner sections Figure 9 2 while the unit is running If the unit shuts down after a few seconds the flame detection circuitry is functional 9 3 6 Disassembly Inspection and Maintenance for the Flue Collector Depending on the installation configu...

Page 58: ... Gas Fired Boiler System Operation and Maintenance Manual Chap 9 Maintenance Figure 9 14 Flue Collector Parts and Assembly Flue Starter Section Hose Clamp Exhaust Connect Flue Collector M4 Hex Nuts 3 M4 Bolts 3 Conden sate Tray M5 20 Bolt 4 5x15mm OD washers Exhaust Connector Hose Clamp Exhaust Connect Flue Collector Flue Collector Gasket ...

Page 59: ... only recommended action is the replacement of the entire section in question Prior to performing the following disassembly and inspection procedures ensure that all electrical power to the boiler has been turned off and the external gas shut off valve is fully closed Figure 9 15 Covers Removed Relevant to Burner Section Replacement WARNING Fan Assembly in lifted position Burner Modules 3 each in ...

Page 60: ...ds into cleaning position Figures 9 7 9 8 3 Lift up the Fan Burner assembly and insert support rods Figure 9 9 4 Remove burner modules and gaskets Paragraph 8 3 2 Figures 9 12 and 9 13 5 Remove the Flow Header upper and Return Header lower assembly Figure 9 17 below and keep all hardware and gaskets for re assembly 6 Remove the electrical connections igniter cable ground lead and flame detector ca...

Page 61: ...acement of Burner Sections After disassembly discard any sections to be replaced and follow steps in the instructions below Figure 9 19 Separating the Aluminum End and Middle Sections Metal Rods 4 ea 2 per side Remove Nut and Washer 4 places Middle Sections End Section Slide four rods out from the end End Section Combustion Chambers Flame Detector Lead Igniter Cable Ground Lead View Port Mounting ...

Page 62: ...mbly rests directly on top of the condensate tray gasket so it is necessary to hoist the entire burner assembly up at least a little to access the gasket Use a hoisting frame to avoid damage to components by the tensioned straps Follow instructions below to replace the gasket Replacement of Condensate Tray Top Gasket 1 Wrap hoisting straps around top left right metal rods holding sections together...

Page 63: ...3_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual Chap 9 Maintenance IMPORTANT NOTE Whenever burner sections are removed for any reason it is necessary to replace the condensate tray gasket beneath with a NEW one Figure 8 23 Figure 9 21 Condensate Tray with Top Gasket Four Piece Gasket ...

Page 64: ... the front panel on the boiler check to ensure that 10 All igniter cables and ground leads are firmly attached 11 All flame detector wire leads are firmly attached 12 All igniter and flame detector mounting screws are secure 13 Replace the side and top cover panels 14 Reconnect all ground wire clips to the underside of the top cover Re secure the top cover to the pins and spring clips on the frame...

Page 65: ...rresponds to Corrective Action No 1 etc When a fault occurs in the Modulex Boiler proceed as follows to isolate and correct the fault 1 Observe the fault code E1 E2 E3 etc displayed in the controller display Figure 9 1 2 Refer to the Fault Indication column in Troubleshooting Tables which follow and locate the fault that best describes the existing conditions 3 Proceed to the Probable Cause column...

Page 66: ... can respond 1 Check Temp HI Limit setting adjust Parameter to XXXXXX 2 Test the temperature sensor and replace if necessary 3 Test the temp switch to insure it trips at actual water temp setting 4 Check PID settings against Menu Default settings in the Appendix If the settings have been changed record the current readings then reset them to the default values 5 Use resistance charts in Appendix C...

Page 67: ...nal gas valve in the boiler Install and arc a spark igniter outside the unit 4 If there is no spark check for 120VAC at the primary side to the ignition transformer during the ignition cycle 5 If 120VAC is not present the IGST Board in the Control Box may be defective Refer fault to qualified service personnel 6 While externally arcing the spark ignitor observe open close indicator in Safety Shut ...

Page 68: ...etected by the heating sensor SR exceeds 203 F Immersed probe Water is not flowing properly It s detected when the local Flow Sensor temperature is 203 F 95 C and cleared when it s 80 C 176 F Verify that the water circulation is flowing properly Note By opening the flap of the E8 and pushing the pushbutton an indication of the number of degrees that the burner is in error is provided E10 Local PCB...

Page 69: ...tdoor Temperature sensor for loose or broken wiring 4 Check resistance of sensor to determine if it is within specification 5 Ensure that the correct sensor is installed E15 Difference between the global flow supply outlet temperature sensor and the return inlet temperature sensor exceeds 72 F This type of error code typically indicates that there is a water circulation problem Examples when such ...

Page 70: ...lace the valve and or actuator Close gas shut off valve downstream of SSOV Install a manometer or gauge in a gas test port between the SSOV and the gas shut off valve If a gas pressure reading is observed replace the SSOV valve and or actuator E22 Airflow fault during ignition AFDI 1 Inlet filter clogged 2 Burner clogged 3 Combustion chamber clogged 4 Check valve in gas manifold not opening 5 Blow...

Page 71: ...nd measure voltage at temperature transmitter and VFD analog input Verify that the voltage conforms to Table 8 3 for the inlet air temperature 12 Refer to CORRECTIVE ACTION 7 and verify that the resistance conforms to Table 8 3 13 See CORRECTIVE ACTION 7 14 See CORRECTIVE ACTION 8 15 Measure amperage at the I O box output and VFD analog input 4mA equates to 0 fire rate and 20 mA equates to 100 fir...

Page 72: ... from other blower known to function properly Replace blower if blower still does not function properly E27 Air pressure switch detects a fault during ignition time 1 Damaged hose 2 Faulty switch 3 Damaged wires 1 Check hoses and replace if necessary 2 Check switch and replace if damaged 3 Check wiring for damage and repair if necessary E30 Alteration of parameters settings due to EMC disturbances...

Page 73: ...hat the correct sensor is installed E75 E8 1 F9 Outdoor sensor 1 Loose or broken wiring 2 Defective Sensor 3 Incorrect Sensor 1 Inspect sensor for loose or broken wiring 2 Check resistance of sensor to determine if it is within specification 3 Ensure that the correct sensor is installed E76 E8 1 F6 Storage tank sensor 1 Loose or broken wiring 2 Defective Sensor 3 Incorrect Sensor 1 Inspect sensor ...

Page 74: ...within specification 3 Ensure that the correct sensor is installed E136 E8 8F13 PT1000 HS2 Collector 2 Multi Function relay sensor 3 1 Loose or broken wiring 2 Defective Sensor 3 Incorrect Sensor 1 Inspect sensor for loose or broken wiring 2 Check resistance of sensor to determine if it is within specification 3 Ensure that the correct sensor is installed E137 E8 8 F14 PT1000 Collector 1 Multi Fun...

Page 75: ...settings Select unused BUS ID address for device E99 E8 Internal failure E 8 failure Replace the E 8 E200 E8 Complete communication loss to from the E8 such as would occur when the three way switch is flipped to BCM control 1 bcm three way switch is in the wrong position zero position 2 Loose e buss connection pink and grey wires 1 E200 fault is normal when the BMC is control by an outside source ...

Page 76: ...Board harness failure Check with Desmond E205 E8 Communication Error Module 5 Same as E201 BMM Board failure BMM Board harness failure Check with Desmond E206 E8 Communication Error Module 6 Same as E201 BMM Board failure BMM Board harness failure Check with Desmond E207 E8 Communication Error Module 7 Same as E201 BMM Board failure BMM Board harness failure Check with Desmond Table 9 2 Boiler Tro...

Page 77: ...952 68 20 6247 77 25 5000 86 30 4028 104 40 2662 122 50 1801 140 60 1244 158 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 ...

Page 78: ...03 12 Page 78 of 90 GF 115 H TAG 0083_0B AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 CHAPTER 12 MODULEX PARTS DRAWING AND LIST Modulex MLX Series Exploded Parts Drawing Page 1 of 4 ...

Page 79: ...RCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual Chap 12 Part Drawings Modulex MLX Series Parts List Page 2 of 4 ...

Page 80: ...RCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual Chap 12 Part Drawings Modulex MLX Series Parts List Page 3 of 4 ...

Page 81: ...RCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual Chap 12 Part Drawings Modulex MLX Series Parts List Page 4 of 4 ...

Page 82: ...675 2 64013 1 1 3 4 PRESSURE RELIEF VALVE 50 PSIG 2 X 16 LG MANIFOLD ASS Y R H SIDE LOW WATER CUT OFF 64015 22033 1 1 PL A 152 CZ DWN BY APPD SCALE 091306 DATE DATE CSD 1 WATER MANIFOLD ASSEMBLY MODULEX GAS FIRED BOILER REV B INTERNATIONAL INC NORTHVALE NJ 07647 AERCO MLX 757 909 1060 MLX 303 454 606 92014 92013 ITEM 6 PART NO BOILER MODEL TABLE 1 4 3 6 7 2 1 5 LEFT HAND BOILER WATER CONNECTION TO...

Page 83: ...ing the Modulex boiler See Section C 4 for Flushing Treatment and Cleansing tips and guidelines Failure to clean a system will limit it from the full benefits offered by the high efficiency Modulex boiler Boiler drain valve and condensate drain trap should be arranged to permit the fluids to drain freely by gravity to a convenient floor drain Relief valve must be installed vertically in the top si...

Page 84: ...unds primarily CaCO3 are heated Rust and magnetite when combined with sludge can form a very hard scale which significantly reduces system efficiency and life expectancy of the heating system Scale reduces heat exchange due to its low heat conductivity and so may cause very dangerous localized overheating Waterside corrosion of all heating circuit surfaces is also a major concern 13 1 3 Make up or...

Page 85: ...g agents generally use salt which creates a chloride water chemistry a major contributor to the corrosion of the types of metals used in hydronic systems Elevated salt levels also contribute to higher conductivity levels another undesirable characteristic in hydronic systems Chloride Chlorides are salts resulting from the combination of the gas chlorine with a metal and are instrumental in acceler...

Page 86: ...ber 99155 1 Corrosion Scale Inhibitor Sentinel X100 Liquid Inhibitor 4 x 1 gallon case part number 99153 2 5 gallon jug part number 99153 1 Antifreeze Sentinel X500 Liquid Inhibited Antifreeze 5 gallon jug part number 99156 1 55 gallon jug part number 99156 2 275 gallon tote part number 99156 3 When cleaning treating and maintaining a heating system consult a qualified professional The following a...

Page 87: ...alve open until a steady flow of water is observed Close the valve and finish filling the system 13 4 Water Quality Maintenance and Boiler Warranty Heat exchanger failures due to improperly cleaned treated and poorly maintained water are not covered under warranty Scheduled system boiler water maintenance is required to maintain the heat exchanger warranty AERCO shall reserve the right to require ...

Page 88: ...hydronic systems including aluminum boilers Contact any of the individuals listed for more information Fernox Hydronic Agencies Ltd Sean Leonard Edmonton AB CANADA Phone 780 452 8661 Toll Free 877 FERNOX4U 877 337 6694 Fax 780 488 2304 Email sales hydronicagencies com www hydronicagencies com Fernox USA Cookson Electronics Brian Conrad Altoona PA Phone 814 946 1611 Toll Free 800 289 3797 Fax 814 9...

Page 89: ...MC2 10 03 12 Page 89 of 90 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual NOTES ...

Page 90: ... Page 90 of 90 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 GF 115 H OMM 0083_0B Modulex MLX Series Gas Fired Boiler System Operation and Maintenance Manual AERCO International Inc 2011 ...

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