Watts AERCO MLX EXT 1100 2S Page 95 Installation, Operation & Maintenance Manual Download

Page: 95 / 120

Modulex Light Commercial Series

SECTION 6: Gas Supply and Piping

OMM-0158_A

• 6/28/2022 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page

120

BMM (Burner Management Module) Fault Codes

The table below lists the fault codes and troubleshooting tips associated with the BMM.

CODE

DESCRIPTION

EFFECT

CORRECTION

RESET

BMM: 1

Overheat
thermostat

High Limit (STB)
Thermostat
activated.

All burners turned
OFF and pump ON at
maximum speed.

Check flow sensor thermal
connection to boiler.

MANUAL -
push reset
switch when
temperature
goes below
limit.

BMM: 4

Ignition failure

No flame detected at
burner start.

Burner control
lockout.

Check flame rod or combustion.

MANUAL -
push reset
switch or cycle
power.

BMM: 5

Flame lost

Flame loss during
run.

Ignition retry.

Check combustion and wiring.

MANUAL -
push reset
switch or cycle
power.

BMM: 6

Overheating

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.

BMM: 10

Internal
failure

Internal failure.

Ignition is inhibited.

Contact factory for new BMM.

MANUAL -
cycle the
power.

BMM: 11

Unexpected
flame

Flame signal
detected before
ignition.

Ignition is inhibited.

Disconnect flame rod wire from
BMM.  If problem goes away,
change flame rod and/or wire.
If problem does not go away,
change BMM.

MANUAL -
push reset
switch or cycle
power.

BMM: 12

CH flow
sensor

Flow sensor fault.

All burners turned
OFF.

Check flow sensor and its
resistance using the
resistance/Temp table); check
the sensor connections.

AUTOMATIC

BMM: 14

CH return
sensor

Return sensor fault.

NOT APPLICABLE

BMM: 15

Differential
temperature

Maximum Δ

temperature
protection.
Fault is detected if
Local FlowSensor

–

Return Sensor] >
[Param 483 + 50°F].

Note: Referred
parameter is BMM
Param. 483

All burners turned
OFF and Pump ON at
maximum speed.

Check the system installation.

AUTOMATIC -
Fault is cleared
when [Local
FlowSensor

–

Return Sensor]
< Param 483.

Note: Referred
parameter is
BMM Param.
483

BMM: 16

Frozen

Boiler pipe is frozen.
Flow sensor
temperature is 36°F
or less.

Ignition is inhibited.
Pump runs for 5 min
at max speed.

Carefully defrost boiler.

AUTOMATIC -
when flow
sensor is
greater than
41°F.

Summary of Contents for AERCO MLX EXT 1100 2S

Page 1: ...00 2S MLX EXT 800 2S MLX EXT 1100 2S Installation Operation Maintenance Manual Disclaimer The information contained in this manual is subject to change without notice from AERCO International Inc AERC...

Page 2: ..._________________________13 3 1 Modulex Ext Technical Features____________________________________________________________13 Temperature Control Devices _______________________________________________...

Page 3: ...tions in Force_________________________________________________________________49 Mains Electrical Supply Connection 120 V 60 Hz ________________________________________49 Service Relay Requirement __...

Page 4: ..._____________________________92 7 1 Ufly Controller Error Codes________________________________________________________________92 BCM Boiler Communications Module Fault Codes _________________________...

Page 5: ...ssachusetts Prior to unit operation the complete gas train and all connections must be leak tested using a non corrosive soap If a glycol solution is used as anti freeze protection a backflow prevente...

Page 6: ...entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a roo...

Page 7: ...changer 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 2 3 Information To Be Made Available To...

Page 8: ...flue pipe safety relief valve and its drainage pipe To the constructive components which influence the appliance s safe operation WARNING When tightening or loosening the screw pipe connections use o...

Page 9: ...9 of 120 2 7 Data Plate Each unit is fitted with a data plate indicating gas type power source and venting classification A sample Data Plate for a MODULEX EXT boiler is shown in the left figure belo...

Page 10: ...ty company concerning the connection of the gas connection to the local gas mains Instructions and standards concerning safety equipment for the water space heating system Installation instructions fo...

Page 11: ...tem cleaner Approved inhibitors Sentinel X100 available from AERCO Rhomar Pro tek 922 Noble Noburst AL inhibitor Intercool NFP AA Cryo tek 100 Al 2 9 Tools Materials And Additional Equipment For the i...

Page 12: ...y functioning of the appliance switch off the boiler Do not attempt to make any repairs but instead contact qualified technicians To guarantee the efficiency and correct functioning of the appliance i...

Page 13: ...ith 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 Temperature Contr...

Page 14: ...efficiency and a high heat exchange between surfaces contribute to the reliable and efficient output power The various components are designed to work together so that operating time is shared equally...

Page 15: ...DIMENSIONS OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 15 of 120 3 4 Dimensional Drawings Figure 3 1 MODULEX EXT Dimensional Drawings Side Views On Modulex EXT mode...

Page 16: ...52 1 1323 Height Closed inches mm 45 3 1150 45 3 1150 45 3 1150 45 3 1150 Width A inches mm 30 0 764 40 6 1032 40 6 1032 51 2 1300 Width B inches mm 27 8 707 38 4 975 38 4 975 48 9 1243 Depth D inche...

Page 17: ...Commercial Series CHAPTER 3 TECHNICAL FEATURES DIMENSIONS OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 17 of 120 Figure 3 3 MODULEX EXT Main Components Left Side View...

Page 18: ...tions are on the RIGHT HAND side supply condition but may be moved to the REAR position Air intake connection located on the LEFT HAND side Cold Hot flow connection on the RIGHT HAND side supply condi...

Page 19: ...FLA Water Connections NPT 2 1 2 2 1 2 2 1 2 2 1 2 Min Water Flow Min Fire GPM 7 9 11 16 Min Water Flow Full Fire GPM 18 24 30 42 Max Water Flow GPM 42 56 71 99 Water Pressure Drop Max Flow Ft of Hd 9...

Page 20: ...Modulex Light Commercial Series CHAPTER 3 TECHNICAL FEATURES DIMENSIONS OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 20 of 120 This page intentionally blank...

Page 21: ...ing 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 Qualificat...

Page 22: ...ION Remove straps and cardboard box from above making sure product is intact Keep cardboard box plastic bags etc away from children as these may be suffocation and choking hazards In addition to the b...

Page 23: ...The Boiler Front and rear skirt pieces On The Boiler Top A plastic bag containing o This installation manual for the installer o User manual for the user o Ufly controller instruction manual o Pins to...

Page 24: ...120 Figure 4 2 Unpacking TABLE 4 1 MODULEX EXT Shipping Package Dimensions Model A B C Gross Weight EXT 450 2S 43 7 1110 mm 35 0 890 mm 49 2 1250 mm 520 lb 236 kg EXT 600 2S 43 7 1110 mm 35 0 890 mm 4...

Page 25: ...ting heavy equipment Boiler must be secured to transportation equipment while moving to prevent it from falling Protect all parts against impacts during transportation 4 5 Removal From Boiler Bed And...

Page 26: ...Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 26 of 120 Figure 4 4 EXT Unpacking Left Attach Feet Right Ready for Cover 22 25 565 mm MLX 450 2S 26 14 in 664 mm MLX 600 800 2S 36 69 in 932 mm MLX 110...

Page 27: ...be a 100mm deep well or trench next to the boiler to accommodate the condensate U drain pipe see Figure 4 7 After installation the boiler shall be perfectly horizontal and stable to reduce any possib...

Page 28: ...tic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents Adhesives used to fasten building products Other damaging or flamm...

Page 29: ...on its RIGHT HAND side Changing Exhaust Outlet Location 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...

Page 30: ...om 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 4 11 Ensure that the gaske...

Page 31: ...th the connectors themselves 4 8 3 1 Reversing Cold Hot Water Flow Return Piping Connectors Refer to Figure 4 12 and reverse the connectors and end caps on Supply Flow and Return pipes Ensure that all...

Page 32: ...eversing Flow and Return Temperature Sensors 4 8 3 3 Moving Boiler Sensor KF Move the Boiler Sensor KF sensor only not the thermowell to the opposite side and install into thermowell under the air ven...

Page 33: ...as regulators are self contained with tapped diaphragm vent ports allowing the diaphragm to change its position These vents typically require piping to the outside For Canada the gas connection must c...

Page 34: ...10 1 2 Natural Gas Supply Pressure Requirements The nominal inlet working gas pressure at the boiler should be 7 W C 18 mbar for Natural Gas Gas A Maximum pressure with no flow lockup or with the boi...

Page 35: ...ge to the piping boiler and radiators It is absolutely forbidden to fit on off valves in the piping before the required safety devices 4 13 Pressure Relief Valve Supplied Each unit is delivered with a...

Page 36: ...st be adjusted as follows a With no flow turn adjustment screw on switch counter clockwise until switch trips b Then turn screw 1 2 turn clock wise and continue installation 3 Connect the Flow Switch...

Page 37: ...2S 800 2S 1100 2S Min flow rate demanded in gal min T 27 F 15 C 9 7 12 9 16 2 22 7 Min flow rate demanded in gal min T 36 F 20 C 7 3 9 7 12 1 17 0 Max flow rate demanded in gal min T 27 F 15 C 33 8 4...

Page 38: ...hich can be achieved by mixing the condensate 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 thro...

Page 39: ...eated water the thermal exchange efficiency may be seriously reduced and result in dangerous localized overheating AERCO suggests treating and conditioning feed water for the heating circuit in the fo...

Page 40: ...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 Connectio...

Page 41: ...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 4 20 Connection of Flue Manifold to B...

Page 42: ...t the formation of ice during the operation the temperature of the internal wall of the flue exhaust system should not be below 32 F 0 C throughout its length For efficient venting of the combustion e...

Page 43: ...eter Material Kit Part Number EXT 450 2S 4 Diameter Stainless Steel Contact vent supplier directly Polypropylene P N 39006 1 for Duravent PolyPro For other brands contact manufacturer directly PVC P N...

Page 44: ...ections 7 2 7 3 or 7 4 of CAN CSA B149 1 05 installation codes or appilcable provisions of the local building codes Insufficient Ventilations and Combustion Air BOILER DAMAGE AND OPERATIONAL FAILURES...

Page 45: ...inches 101 6 mm 1 Where directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr of total input rating of all equipment in the enclosure...

Page 46: ...uilding surfaces in the vicinity In certain weather conditions condensation may also accumulate on the outside of the air inlet pipe Such conditions must be considered and where necessary insulation o...

Page 47: ...6 1 8 1 8 EXT 800 2S 5 6 152 mm 100 ft 30 m 6 6 1 8 1 8 EXT 1100 2S 7 6 152 mm 100 ft 30 m 6 6 1 8 1 8 TABLE 4 5 Modulex EXT Vent and Piping Length Chart Model Vent Pipe Dia Sharp 90 Elbow Equivalent...

Page 48: ...lex Light Commercial Series CHAPTER 4 Installation Instructions OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 48 of 120 Figure 4 26 Modulex EXT Allowable Venting Solut...

Page 49: ...ckets and or extension cords is strictly forbidden The use of any power supply equipment implies the observance of fundamental rules such as Do not touch the appliance with any wet part of your body a...

Page 50: ...ler to cool down Electrical Requirements No changes may be made to the wiring of the boiler All connections should be designed in accordance with the applicable regulations Label all wires prior to di...

Page 51: ...28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 51 of 120 Figure 4 28 Main Power Junction Box Location and 120VAC Wiring NOTE Use the following disconnect switch and circuit breaker...

Page 52: ...Modulex Light Commercial Series CHAPTER 4 Installation Instructions OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 52 of 120 4 27 FUNCTIONAL WIRING DIAGRAM Page 1...

Page 53: ...Modulex Light Commercial Series CHAPTER 4 Installation Instructions OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 53 of 120 4 28 FUNCTIONAL WIRING DIAGRAM Page 2...

Page 54: ...x Light Commercial Series CHAPTER 4 Installation Instructions OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 54 of 120 4 29 Ladder Diagrams Figure 4 29 Module Ladder Di...

Page 55: ...ght Commercial Series CHAPTER 4 Installation Instructions OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 55 of 120 4 30 General Ladder Diagram Figure 4 30 General Ladde...

Page 56: ...1 Input Output Box Terminal Assignments Heating system components such as pump outside air sensor and flow switch must be connected to the Input Output box Alarm contact analog control input 0 10V and...

Page 57: ...serve the following rules of safety All work on the unit must take place in a dry environment AERCO units should never be in operation without their cover panels except in connection with maintenance...

Page 58: ...filling the heating system WARNING Do not use petroleum based cleaning or sealing compounds in the boiler system Damage of seals and gaskets in boiler and system could occur resulting in substantial p...

Page 59: ...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 buildi...

Page 60: ...Heating 3 Turn burners ON 4 Disconnect the plug and socket connection of the ionization cable WHITE of BURNER 1 5 The display will show ERROR CODE 05 6 Press Reset Button 7 The boiler will retry igni...

Page 61: ...alibrated using Service Mode in the Burner Menu of the Ufly Controller see section 6 5 Installing the Gas Analyzer Probe Before adjusting a gas analyzer sensor probe must first be installed into the f...

Page 62: ...utput level for each valve Adjusting the Maximum A Gas Output Setting 1 Remove the cap of the combustion gases sampling point Figure 4 33 and connect a suitable gas analyzer 2 Operate the burner to a...

Page 63: ...er NOTE If CO2 percentage is too low check air and exhaust flue for obstruction If not obstructed check if the burner and or the exchanger aluminum sections are properly cleaned After confirmation che...

Page 64: ...ural 7 0 1 74 8 9 9 0 5 0 5 1 34 100 0 27 7 46 1 29 569 16 11 50 77 Propane 11 0 2 74 10 8 10 8 4 5 4 5 35 100 0 27 7 18 0 5 220 6 23 50 73 EXT 800 2S Gas Type Supply Pressure Wc kPa CO2 Level O2 Leve...

Page 65: ...m EST Page 65 of 120 4 36 Sweeper Mode Manual Control 1 Insert psw and select sweeper again Vary mod request from 10 to 100 2 Activate Sweeper Mode 3 Chose burner among those available e g usually 1 M...

Page 66: ...rating to maximum power modulation 100 6 Vary of modulation request to the minimum 10 and select the burner 7 Boiler operating with modulation min modulation 0 8 Disable SWEEPER function Exit by press...

Page 67: ...an maximum speed of the BMM Burner Management Module in the Devices Menu NOTE This is modifiable only with an access code Access the BMM Menu by selecting the bmm buttons See Section 6 7 for a list of...

Page 68: ...on From Natural Gas To Propane Gas 1 Set nominal heat by changing parameter 526 FU Fan maximum speed of the BMM in the Devices Menu Refer to Modulex EXT Pressure and CO2 Level Calibration in Table 4 6...

Page 69: ...Modulex Light Commercial Series CHAPTER 4 Installation Instructions OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 69 of 120 4 40 Controls And Emergency Functions...

Page 70: ...ing All 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 us...

Page 71: ...ntroller Features and Functions The Ufly features the following functions for MODULEX boilers Shares the heating load among as many of the boiler s thermal heating modules as possible maximizing the o...

Page 72: ...ter Access domestic hot water parameters including setpoint timed programming and legionella protection function Solar This menu is currently not available Burner Access calibration manual operation a...

Page 73: ...e boiler s multiple thermal modules Finally in the event the boiler s master controller stops working the BCM also takes over operations of the boiler The BCM enhances the range of control functions o...

Page 74: ...ial Series CHAPTER 5 Ufly Controller and BMC Modules OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 74 of 120 Figure 5 1 Boiler Communications Module BCM Figure 5 2 BCM...

Page 75: ...75 of 120 CHAPTER 6 OPERATION MENU PARAMETERS This chapter introduces the Ufly controller basic menu contents needed to set up the MODULEX EXT boiler For more detailed information concerning the Ufly...

Page 76: ...Reference temperatures and domestic hot water setpoint change display and language settings and change the password for the Devices Setting Time and Date Setting Comfort and Eco Building Reference Te...

Page 77: ...on Domestic Hot Water Operation see section 4 4 of the Control Manual OMM 0159 The Ufly screen automatically turns off after 20 seconds default of inactivity If the Always on is toggled on like in th...

Page 78: ...technicians To Change the password 1 Enter the current password and click OK 2 Delete the current password using the backspace button 3 Enter new password and click OK 6 2 Heating Menu The Heating Men...

Page 79: ...licking the settings button Building Reference Temperatures to use in Outdoor Reset Mode can be selected in the Heating Menu 6 3 Domestic Hot Water Menu The Domestic Hot Water Menu provides access to...

Page 80: ...t to use can be selected in the Domestic Hot Water Menu 6 4 Devices Menu The Devices Menu allows access to BMM Burner Management Module parameters BCM parameters for functions including 0 10V operatio...

Page 81: ...22 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 81 of 120 Access the BCM Menu by clicking the hcm button See Section 6 6 for list of BCM Parameters Access the BMM Menu by clicking the bmm...

Page 82: ...is password protected and is only for authorized AERCO technicians Service Mode Manual Firing Rate Function 1 Click on the Service Mode icon 2 Enter the password 3 Click on the Service Mode Icon agai...

Page 83: ...ng rate d The Current Fire Rate of activated burners will equal the manual firing rate set in the Boiler Screen 8 To disable the Sweeper Manual Firing Rate Function press the Home button Manual Setpoi...

Page 84: ...upply and Piping OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 84 of 120 Reset Burner Working Hours and Ignition Count Select one of the available burners Click the Re...

Page 85: ...Disabled Units may be expressed in R or K MLX EXT 450 2S 1100 2S 45 F 25 C MLX EXT 1500 2S 3000 2S 54 F 30 C 34 Burner Hysteresis 9 F to 36 F 5 C to 20 C Units may be expressed in R or K 9 F 5 C 31 CH...

Page 86: ...65 C 149 F 65C 360 DHW tank adjustment tank temperature regulation gain Leave this Parameter set 0 for a constant boost temperature Param 660 when DHW is present 0 15 0 656 DHW request tank to target...

Page 87: ...start How often the boiler changes the operating burners to balance wear and tear 1 10 hr 2 H 647 Disable Burners Map NOT APPLICABLE Note Leave at default value of 0 0 648 First Burner Priority NOT AP...

Page 88: ...sure Sensor NOT APPLICABLE Note Leave at default value of 0 0 768 Min Gas Pressure Sensor NOT APPLICABLE Note Leave at default value of 0 0 793 Chimney Obstruction Sensor NOT APPLICABLE Note Leave at...

Page 89: ...ec 30 sec 896 Temperature unit 0 C 1 F See Description 0 799 Analogue input function 0 10 V NOT APPLICABLE Note Leave at default value of 0 0 376 Programmable Input 1 function NOT APPLICABLE Note Leav...

Page 90: ...n level 1 100 MLX EXT 450 2S 1100 2S 34 MLX EXT 1500 2S 3000 2S 31 314 Standby modulation 0 100 MLX EXT 450 2S 1100 2S 31 MLX EXT 1500 2S 3000 2S 33 620 Postpurge fan speed 0 100 MLX EXT 450 2S 1100 2...

Page 91: ...e at default value of 1 1 777 APS check NOT APPLICABLE Note Leave at default value of 0 0 623 Temperature sensors 0 10K 25 C B 3977 1 10K 25 C B 3435 Note Leave at default value of 0 0 1 0 626 Tempera...

Page 92: ...TING 7 1 Ufly Controller Error Codes Fault codes are displayed in the right hand section of the Ufly Controller display see Figure 7 1 There are codes for the following two different devices BCM Boile...

Page 93: ...t boiler AUTOMATIC when Flow sensor is greater than 41 F HCM 18 Global differential temperature Maximum temperature protection Fault is detected if Global FlowSensor Return Sensor Param 483 50 F Note...

Page 94: ...HCM 56 Heat control lack BCM No remote control detected It is possible to activate burner ignition from the BCM manual request button HCM 57 Burners lack BCM No BMM detected Burners turned OFF Check...

Page 95: ...en Flow sensor 176 F BMM 10 Internal failure Internal failure Ignition is inhibited Contact factory for new BMM MANUAL cycle the power BMM 11 Unexpected flame Flame signal detected before ignition Ign...

Page 96: ...heck the wiring If wiring is OK change BMM AUTOMATIC BMM 24 Low fan speed Modulating fan speed failure failed to reach the correct speed within 30 seconds from starting of burner ignition cycle Igniti...

Page 97: ...Inspect and clean flame rod and ignitor Inspect and clean the fan blower Check the operation of the fan blower Check gas pressure and adjust if necessary Inspect and clean the flue exhaust assembly Ch...

Page 98: ...cy of maintenance and service requirements Contact details can be found on the back page of this manual Verify that the air ventilation system air intake and air intake pipes are unobstructed 8 3 Prop...

Page 99: ...ntire surface when operating correctly The flame must burn with a clear ORANGE stable flame Check the flame through the flame observation port Figure 8 2 The flame pattern should resemble the flame in...

Page 100: ...120 8 7 Pressure Switch Hoses And Connections If pressure switch hoses need to be replaced ensure that new hose lengths are identical to the old hose lengths If too long there is an increased chance...

Page 101: ...f 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 4 35 8 9 Heat And Return Sensor...

Page 102: ...s supply valve upstream from the boiler and ensure it is completely closed 2 Unlatch and raise the top lid Figure 8 4 3 Remove screws from top of unit holding the rear and side panels in place Figure...

Page 103: ...move screws from around exhaust outlet opening and remove flue assembly from unit see Figure 8 7 and 8 8 Figure 8 8 Flue Removal Step 4 5 On each side of the air intake manifold unlatch spring clips h...

Page 104: ...ifold from the unit Figure 8 10 Removing Red Hoses and Manifold from Unit Step 6 Figure 8 11 Removing Gas Valve Connector from All Gas Valves Step 7 7 On each gas valve unscrew the Gas Valve Connector...

Page 105: ...her 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 in figure 8 14 then re...

Page 106: ...0 526 0288 Mon Fri 8 am 5 pm EST Page 106 of 120 Figure 8 14 Removal of Burner Plate Hardware Steps 9 10 11 11 Refer to Figure 8 15 and remove the two bolts white arrows at each end of the gas collect...

Page 107: ...Gas Collector Flange from Gas Supply Piping Step 13 13 Refer to Figure 8 17 for location of burner assembly lifting screws There is one at each end Elevate the burner assembly slightly until screw is...

Page 108: ...screwing Lift Screw into Tab Hole Step 14 Figure 8 19 Lift Screws Extended into Tab Holes Left and Right Sides Step 14 14 Refer to Figure 8 20 then lift up the front of the burner assembly and raise u...

Page 109: ...ION 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 Figure 8 23 Burner Modules Exposed...

Page 110: ...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 co...

Page 111: ...de of aluminum heat exchangers section 8 12 2 It may not be possible to completely restore the boiler to original factory condition However the instructions below should remove most of the by product...

Page 112: ...nks and using a pressure washer with angled nozzle to spray upwards Make sure to cover the top of the heat exchanger with a tarp to prevent water from spraying out of the top of the unit To clean this...

Page 113: ...react WARNING do not let this solution sit for more than 20 minutes as over exposure could damage the heat exchanger 3 Use a plastic bristle brush to clean the elements that can be reached and then ri...

Page 114: ...e sure condensate drain pipe is filled with water Figure 8 1 2 Ensure the seal between the gas supply pipe and the gas collection tube flange are tight To do this open the external gas valve and bubbl...

Page 115: ...ER 9 Spare Parts Drawings and Lists OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 115 of 120 CHAPTER 9 SPARE PARTS DRAWING AND LISTS MODULEX EXT Light Commercial Part...

Page 116: ...sembly MODULEX EXT 6M MLX EXT 960 2S 95213294 Boiler sump assembly MODULEX EXT 7M MLX EXT 1100 2S 17 95211301 Right Side Panel MODULEX EXT 18 95004084 Left Side Panel MODULEX EXT 19 95213304 RH latera...

Page 117: ...611 Flue terminal D 200 MODULEX EXT 42 95251841 Water manifold gasket 43 95261173 Burner gasket 44 95263570 Signal light 45 95261357 Boiler Drain Cock G 3 4 46 95263452 Suction hose 47 95261558 Main S...

Page 118: ...72090 Gas inlet header Modulex 6 7 Elements 80 95004067 Flow header Modulex 2 Elements 95004068 Flow header Modulex 3 Elements 95004069 Flow header Modulex 4 Elements 95004070 Flow header Modulex 5 El...

Page 119: ...Modulex EXT Light Commercial Series Boilers User Manual OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 119 of 120 NOTES...

Page 120: ...rcial Series Boilers User Manual OMM 0158_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 120 of 120 Change Log Date Description Changed by 5 5 2022 Initial Release DBarron AERCO...

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