Watts AERCO MLX EXT 1500 2S User Manual Download

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Heating and Hot Water Solutions

AERCO International, Inc. • 100 Oritani Drive • Blauvelt, NY 10913

USA: T: (845) 580-

8000 • Toll Free: (800) 526-0288 • AERCO.com

Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST

© 2022 AERCO

Installation, Operation & Maintenance Manual

Modulex EXT

–

Ufly Controller

Commercial Series

Modulating and Condensing Boilers

Applies To Modulex Models:

•

MLX EXT 1500 2S

•

MLX EXT 2300 2S

•

MLX EXT 2600 2S

•

MLX EXT 3000 2S

OMM-0160_A

• 6/28/2022

Disclaimer

The information contained in this manual is subject to change without 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, not for incidental or
consequential damages occurring in connection with the furnishing,
performance, or use of these materials.

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Summary of Contents for AERCO MLX EXT 1500 2S

Page 1: ... 1500 2S MLX EXT 2300 2S MLX EXT 2600 2S MLX EXT 3000 2S OMM 0160_A 6 28 2022 Disclaimer The information contained in this manual is subject to change without 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 liab...

Page 2: ...mits of The Boiler 15 CHAPTER 3 TECHNICAL FEATURES DIMENSIONS 16 3 1 MODULEX EXT Commercial Technical Features 16 3 1 1 Temperature Control Devices 16 3 1 2 Control Panel Ufly Includes 16 3 1 3 Other Features Include 16 3 2 General Boiler Operation 17 3 3 Boiler Freeze Protection 17 3 4 Dimensional Drawings 18 3 5 Performance Data 21 CHAPTER 4 INSTALLATION INSTRUCTIONS 22 4 1 Installation Warnings...

Page 3: ...Location 42 4 22 2 Minimum and Maximum Wall Thickness 43 4 23 Vent Pipe Sizing 43 4 24 Electrical Connections 45 4 24 1 Regulations in Force 45 4 24 2 Mains Electrical Supply Connection 120 V 60 Hz 45 4 24 3 Service Relay Requirement 46 4 24 4 Electrical Requirements 46 4 25 Functional Wiring Diagram page 1 48 4 26 Functional Wiring Diagram page 2 49 4 27 Module Ladder Diagram 50 4 28 General Ladd...

Page 4: ...y Controller Error Codes 91 7 1 1 BCM Boiler Communications Module Fault Codes 92 7 1 2 BMM Burner Management Module Fault Codes 94 CHAPTER 8 MAINTENANCE SCHEDULE 96 8 1 Instructions For Inspection and Maintenance 96 8 2 Periodic Examination Of Venting System 97 8 3 Proper Procedure For Cleaning Exhaust Flue 97 8 3 1 Cleaning the Condensate Drain Line 98 8 4 Checking CSD 1 Manifold Flow Switch 98 ...

Page 5: ...Modulex EXT Commercial Series CONTENTS OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 5 of 117 This Page Intentionally Blank ...

Page 6: ... 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 touch metal doorknobs or any grounded device or surface without using insulated gloves or other insulated material if you suspect static charge buildup Immediately call your gas supplier from a neighbor s phone ...

Page 7: ... of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that...

Page 8: ...e 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 special venti...

Page 9: ...Modulex EXT Commercial Series CHAPTER 1 SAFETY PRECAUTIONS OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 9 of 117 This page intentionally blank ...

Page 10: ...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 The User Go through the information in this manual with the owner operator and make sure that he or she is familiar with all necessary operating instructions in particular These instructions shall be...

Page 11: ...the flue pipe safety relief valve and its drainage pipe To the constructive components which influence the appliance s safe operation WARNING When adjusting the screw pipe connections use only properly sized wrenches The use of inadequate equipment can cause damage for example water or gas leakages to the equipment 2 6 For Appliances Operating with Propane Gas Before installing the appliance ensur...

Page 12: ...A sample Data Plate for a MODULEX EXT Commercial boiler is shown in the left figure below A sample of the Data Packaging label is shown in the right image below Figure 2 1 MODULEX EXT Commercial 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 13: ...approval for the vent system and condensate water connection to a public sewage system may be required 2 8 2 Regulatory Requirements You must also conform to any rules regulations or laws concerning the following Local building codes regarding the installation Local building codes concerning the air intake and outlet systems and the vent connection Regulations for the power supply connection Techn...

Page 14: ...ler using plate heat exchangers Close the valves of the boiler while flushing the system do not introduce any system cleaner into the boiler loop Flush system thoroughly to remove all system cleaner before filling boiler Approved antifreeze maximum concentration of 50 Sentinel X500 available from AERCO Rhomar RhoGard Mutli Metal AL safe Noble Noburst AL Approved system cleaners Sentinel X300 avail...

Page 15: ...ge to property The manufacturer shall not be held liable for any such injury and or damage Any repairs must be carried out by AERCO authorized technicians using original spare parts Non observance of the above requirement may jeopardize the appliance and void any warranties In the event of failure and or faulty functioning of the appliance switch off the boiler Do not attempt to make any repairs b...

Page 16: ...ing 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 3 1 1 Temperature Control Devices Local NTC sensor each heating element Limit thermostat each heating element Flow NTC sensor ...

Page 17: ...ally fires the maximum number of simultaneously operating heating elements in order to maximize heat production and overall efficiency Burner 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 among the components thus reducing maintenance and labor ...

Page 18: ...ercial Series CHAPTER 3 Technical Features Dimensions OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 18 of 117 3 4 Dimensional Drawings Figure 3 1 MODULEX EXT Commercial Dimensional Drawings ...

Page 19: ...ulex EXT Commercial Series CHAPTER 3 Technical Features Dimensions OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 19 of 117 TABLE 3 1 MODULEX EXT Commercial Dimensions and Sizes ...

Page 20: ...E RIL Detection electrode 2 Draining tap 15 TL Limit Thermostat Probe 3 SRR Global return temp sensor 16 Burner 4 PF Max air pressure switch 17 Aluminum silicon heat exchanger 5 SM Global flow temp sensor 18 SL Condensate sensor level 6 Automatic air vent 19 Exhaust manifold 7 VM Fan 20 Boiler frame 8 VG Gas Valve G Gas inlet 9 PF min Min air pressure switch M Heating system flow 10 Control panel ...

Page 21: ...9 82 89 82 89 82 89 82 Combustion efficiency at min load 90 52 Stand by losses 0 1 Flue gas temperature Flue gas temp room temp 113 F 45 C Air excess l 24 29 Condensate production max 11 57 Btu hr 25 51 kW 23 15 Btu hr 51 04 kW 28 97 Btu hr 63 87 kW 34 74 Btu hr 76 59 kW Boiler category II and IV Minimum water flow rate in CH circuit Δt 68 F 20 C 3 89 gal min 14 74 l min Min pressure in CH circuit...

Page 22: ...e only after this verification has been carried out 4 1 3 Installation Personnel Qualifications The appliance MUST be installed by a qualified engineer or technician who complies with the technical requirements who under his own responsibility guarantees the compliance of the standards according to the latest regulations The appliance must be positioned so that at least the minimum operational and...

Page 23: ...ater heaters and small boilers and process heaters CSD 1 Controls and safety devices for automatically gas fired boilers 4 3 Packaging The MODULEX EXT boiler is delivered assembled and protected by a plastic bag inside a strong cardboard box and affixed to a pallet This allows the boiler to be handled by a forklift The boiler minimum dimension without packaging is 37 2 By removing the sheet metal ...

Page 24: ... box straps plastic bags etc away from children to prevent suffocation and choking hazards AERCO is not liable for any injury to persons animals or damage to property derived from not following these directions Figure 4 2 Boiler Unpacking and Hoisting 1 Prior to opening the boiler may be moved by a hoist crane as shown Panel 1 or forklift 2 Remove packing straps Panel 2 and cardboard box Panel 3 m...

Page 25: ...hree 3 sensors o Remote temperature sensor o DHW Storage tank sensor o Outdoor temperature sensor Electrical resistor kit for emergency operation Combustion sampling port for the flue Metal plate and cable for power output CARDBOARD BOX 2 European to USA vent adaptor Two 2 gaskets for air intake and exhaust connections One 1 300 mm diameter gasket INSIDE CASING ON THE BACK OF THE BOILER Two 2 pipe...

Page 26: ...y horizontal and stable to reduce any possible vibrations or noises Figure 4 3 Boiler on Housekeeping Pad with Condensate Drain Pipe Front View 4 7 1 Boiler Room Safety Concerns When selecting the position for the installation of the boiler comply with the following requirements Ensure easy access to the components of the boiler to facilitate maintenance The room where the boiler will be placed mu...

Page 27: ...ntistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents Adhesives used to fasten building products Other damaging or flammable products 4 8 Recommended Clearances for Servicing Recommended clearances around the boiler are listed below see Figure 4 4 Figure 4 4 MODULEX EXT Boiler Clearances It is recommended to install the boiler with the clearances...

Page 28: ...bined with an on off solenoid valve on the gas supply line The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 PSI 3 5kPa The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas suppl...

Page 29: ...ropane Gas Piping Connections The boiler pipe is provided with external 3 ASME B16 5 flange onto which the tail piece of the gas shut off valve can be screwed Use appropriate sealing The connection to the boiler must include a suitable method of disconnection Use a gas shut off valve compatible with propane gases A sediment trap must be provided upstream of the gas controls Propane Gas Supply Pres...

Page 30: ...ressure Piping Code as applicable NOTE Lower system pressures require lower rated Pressure Relief Valves not supplied The Pressure Relief Valve is included separately in the shipping container It must be fitted on the CSD 1 manifold at the site per the instructions in the next section see Figure 4 5 IMPORTANT Discharge piping MUST be installed at the relief valve discharge and must run to a safe p...

Page 31: ...ith no flow turn adjustment screw on the switch counter clockwise until the switch trips b Then turn screw 1 2 turn clock wise and continue installation 3 Connect the following components to the tapped holes in the manifold assembly as shown above Flow Switch Pressure Temperature Gauge NOTE Ensure the flow switch is installed with the flow arrow pointing in the direction of the flow 4 Install the ...

Page 32: ...Location and Flow Switch Connection 4 13 Determination Of Primary Boiler Pump or Boiler System Pump The following table gives an indication of the pump s flow rate in function of the t of the primary circuit if the installation has a mixing header The size of the pumps must be determined by installers or technical engineers according to boiler data and system design ...

Page 33: ... MODULEX EXT Water Side Pressure Losses NOTE The use of a mixing header fitted between the boiler circuit and the system circuit is always advisable It becomes INDISPENSABLE if the system requires flow rates superior to the maximum permitted boiler flow rates which is to say lower than 27 F 15 K 4 14 Condensate Piping And Drain To avoid condensate collecting inside the combustion exhaust system th...

Page 34: ...r with limestone which normally has a base pH AERCO offers a condensate neutralizing kit and a neutralizing tank for preparing condensate waste for safe evacuation into a sewer system if other means of neutralizing the waste are not available Figure 4 8 MODULEX EXT Condensate Piping The outlet of the condensate drain pipe exits from the right side of the boiler just below the RIGHT SIDE flue outle...

Page 35: ...olds bacteria etc An appropriate treatment of the supply water will prevent the above stated problems and will maintain the correct operation and efficiency of the boiler over time In order to properly treat water for use in a hydronic boiler heating system the following physical chemical characteristics must be addressed Sediment If sediment is present in the system use a sediment filter or other...

Page 36: ...ing cycle 4 17 Optional Air Intake Connection Install air intake connector as shown in Figure 4 9 Use silicone to lubricate the internal surface of the seals before assembling For air intake connection piping use only 10 for MODULEX EXT 1500 2S 12 for MODULEX EXT 2300 2S 3000 2S The Air Intake Connector that ships with the unit is for spiral ducts only For other materials please contact AERCO dire...

Page 37: ...s necessary to assemble the Euro to USA adaptor to the flue manifold as shown in Figure 4 11 Figure 4 11 Assembly of European to American Flue Adaptor to Flue Manifold NOTE The gasket may seem large It is intentionally designed to produce a tight fit European To American Flue Adapter FLUE MANIFOLD Gasket For Attaching European To American Flue Adapter Flue Manifold Nuts 10 Washers 10 RECTANGULAR G...

Page 38: ...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 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 t...

Page 39: ...anufacturer PVC 58115 1 EXT 2300 2S 3000 2S 12 Stainless Contact vent manufacturer Polypropylene Contact vent manufacturer PVC 58115 2 In the case of PVC venting 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 plastic venting materials use schedule 40 or thicker single wall uninsulated pipes When using...

Page 40: ...ntilation air must be made in accordance with section 5 3 Air for Combustion and Ventilation of the National Flue Gas Code ANSI Z223 1 NFPA 54 or Sections 7 2 7 3 or 7 4 of CAN CSA B149 1 05 installation codes or applicable provisions of the local building codes 4 21 1 Insufficient Ventilation and Combustion Air CAUTION BOILER DAMAGE AND OPERATIONAL FAILURES may occur due to insufficient or improp...

Page 41: ...tion equipment in the confined space but no less than 100 square inches One opening shall commence within 12 inches 305 mm of the top and one opening shall commence within 12 inches 305 mm of the bottom of the enclosure The minimum dimension of air openings shall not be less than 4 inches 101 6 mm 4 21 3 Sealed Combustion The boiler room shall be provided with two permanent openings one commencing...

Page 42: ...kways adjacent buildings openable windows and building openings shall not be less than those values specified in the National Fuel Gas Code ANI Z223 1 NFPA 54 and or the Natural Gas and Propane Installation Code CAN CSA B149 1 Do not extend exposed vent pipe outside the building beyond recommended distance Condensate could freeze and block vent pipe Vent should terminate at least 3 ft 915 mm away ...

Page 43: ... the minimum and maximum wall thickness through which venting is allowed to penetrate horizontally However if venting is vertical then there is no minimum wall thickness 4 23 Vent Pipe Sizing The maximum length is the combined length of straight horizontal and vertical runs and the equivalent straight length of fittings The required lengths for each boiler are as follows NOTE The examples referenc...

Page 44: ...lex EXT Commercial Series CHAPTER 4 Installation Instructions OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 44 of 117 Figure 4 16 MODULEX EXT Allowable Venting Solution Examples ...

Page 45: ... 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 Use of any power supply equipment implies the observance of several fundamental rules such as Do not touch the applia...

Page 46: ...hich when the additional electrical safety devices if any 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 down 4 24 4 Electrical Requirements No changes may be made to the wiring of the boiler All connections should be designed in accordance with the a...

Page 47: ...x EXT Commercial Series CHAPTER 4 Installation Instructions OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 47 of 117 Figure 4 18 Main Power Junction Box Location and 120VAC Wiring ...

Page 48: ...Modulex EXT Commercial Series CHAPTER 4 Installation Instructions OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 48 of 117 4 25 Functional Wiring Diagram page 1 ...

Page 49: ...Modulex EXT Commercial Series CHAPTER 4 Installation Instructions OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 49 of 117 4 26 Functional Wiring Diagram page 2 ...

Page 50: ...ex EXT Commercial Series CHAPTER 4 Installation Instructions OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 50 of 117 4 27 Module Ladder Diagram Figure 4 19 Module Ladder Diagram ...

Page 51: ...x EXT Commercial Series CHAPTER 4 Installation Instructions OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 51 of 117 4 28 General Ladder Diagram Figure 4 20 General Ladder Diagram ...

Page 52: ...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 Modbus communication are also connected to the Input Output box See figure 4 21a for terminal block assignments Figure 4 21a E8 Controller Terminal Assignments ...

Page 53: ...r adjustments Never allow electrical or electronic components to come into contact with water 4 30 2 Supply Voltage Gas Pressure and Water pressure The unit must be able to function during maintenance procedures or when adjustments are performed For this reason the unit s supply voltage gas pressure and water pressure must be maintained and available during these activities WARNING Following maint...

Page 54: ...ty damage and or danger The central heating installation needs to be filled with clean water Use only clean water or approved glycol for filling the heating system When the water hardness of the filling water exceeds 9 grains per gallon gpg the water must be treated until below the maximum value of 9 gpg The pH value of the installation water must be between 6 5 and 8 0 Check the pH value using pr...

Page 55: ...ny 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 neighbor s phone or from outside with your cell phone and follow the gas supplier s instructions OPERATING INSTRUCTIONS 1 STOP Read the safety information ab...

Page 56: ...eating 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 ignition cycle and the display shows ERROR CODE 04 Ignition Failure 8 Connect the plug socket connection of the ionization cable 9 Press Reset Button and check that the boiler starts correctly WARNING Do no...

Page 57: ... to the mains supply system the gas valve must be re calibrated using Service Mode in the Burner Menu of the Ufly Controller see section 6 5 4 33 1 Installing Gas Analyzer Probe into Flue Outlet Before adjusting a gas analyzer sensor probe must be installed into the flue exhaust outlet 1 Remove the cap 2 from the gas outlet 1 2 Install the probe adapter 3 into the gas outlet 1 where cap was remove...

Page 58: ...pling point and connect a suitable gas analyzer 2 Operate the burner to a minimum power following the procedure described in Section 4 34 Service Mode function MANUAL BOILER FIRING RATE REQUEST 100 3 Check that the CO2 values are within the values indicated in Table 4 6 below 4 If necessary correct the value by turning the adjustment screw A in a CLOCKWISE direction to decrease the value or ANTICL...

Page 59: ... 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 in section 4 33 2 4 33 4 Final Check and Ignition Failure Adjustment Procedure After completing the Minimum and Maximum output adjustments check the CO2 minimum and ...

Page 60: ...3 25 3 50 87 FOR HIGH ALTITUDE Natural 7 0 1 74 9 1 9 2 4 6 4 8 31 100 0 35 9 80 2 26 1978 56 50 83 Propane 11 0 2 74 10 8 10 8 4 5 4 5 31 100 0 35 9 32 0 92 805 22 8 50 79 MODULEX EXT 2600 2S Type of Gas Supply Press in w c kPa CO2 levels O2 levels Fan speed Ø Mixer injectors Øin mm Gas Consumption Start output V max fan Min Output Max Output Min Output Max Output min max Minimum Maximum FL FH ft...

Page 61: ...EST Page 61 of 117 4 34 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 Modulex from 1 to 8 NOTE Note once selected the burner 3 the display page changes Burner 1 8 4 Activate manual control of selected burner ...

Page 62: ...ST Page 62 of 117 5 Burner operating 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 pressing Home icon NOTE The function defaults to the previous parameters after 15 minutes if there is no input ...

Page 63: ...altitudes at or above 5 000 feet Modify parameter 526 FU Fan maximum speed of the BMM 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 BMM Parameters Scroll to parameter 526 and change value Refer to appropriate model and fuel on table 4 6 Repeat the above procedure for the rest of the burners bmm 2 ...

Page 64: ... Conversion Label 4 37 Conversion 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 for the appropriate value 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 ...

Page 65: ...FLY User interface see instruction manual supplied with the boiler 4 39 Initial Boiler Ignition 4 39 1 Preliminary Checks CAUTION To ensure the continued safe operation of the boiler it is highly recommended that it is checked at regular intervals and serviced when necessary and that only original spare parts are used Regular attention will prolong the life of the boiler Before igniting the boiler...

Page 66: ...no water leaks The external mains electrical supply switch is on The boiler system s safety valve is not blocked and is connected to the waste water system The condensate drain line has been filled with water and that it is connected to the waste water system For more information see section 4 14 WARNING Before firing up the appliance be sure to fill up the condensate drain line see section 4 14 t...

Page 67: ...troller 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 overall operating efficiency of the boiler Provides access to all testing programming parameters of each individual heating module operation test operation time boiler freeze protection and pump s anti ...

Page 68: ...er 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 and troubleshooting settings This menu is password protected and is only for authorized AERCO technicians Setup Access general setup parameters including time and date display settings language and unit...

Page 69: ... 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 offered by the Modulex Boilers These additional control functions include the following A fault relay which energizes when any fault condition occurs BCM serves as a Back up Controller in the event that...

Page 70: ...mercial Series CHAPTER 5 UFLY CONTROLLER BCM MODULES OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 70 of 117 Figure 5 1 Boiler Communications Module BCM Figure 5 2 BCM Key and LEDs Legend ...

Page 71: ...Modulex EXT Commercial Series CHAPTER 5 UFLY CONTROLLER BCM MODULES OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 71 of 117 This page intentionally blank ...

Page 72: ......

Page 73: ... of 117 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 controller menus operating modes and functions refer to the Ufly Controller User Manual OMM 0159 Figure 6 1 Modulex Ufly Controller Main Menu ...

Page 74: ...Devices 6 1 1 Setting Time and Date 6 1 2 Setting Comfort and Eco Building Reference Temperatures The Comfort and Eco Building Reference Temperatures for the Outdoor Reset Mode are programmed in the Setup Menu For details on Outdoor Reset Mode and Building Reference Temperature see section 4 1 of the Control Manual OMM 0159 6 1 3 Setting Comfort and Eco Domestic Hot Water Setpoints The Comfort and...

Page 75: ...fter 20 seconds default of inactivity If the Always on is toggled on like in the image below the screen will remain on all the time NOTE Do not change the value of the Modbus address This is an internal function of the boiler For Modbus setup when communicating to AERCO ACS or BAS EMS see section 6 8 of the Controls Manual OMM 0159 6 1 4 Display Settings 6 1 5 Language and Unit Settings ...

Page 76: ... am 5 pm EST Page 76 of 117 6 1 6 Password For security and protection of the boiler the default password is only availalbe to Authorized AERCO Service 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 ...

Page 77: ...s including Outdoor Reset and Constant Setpoint Mode configurations For Space Heating programming details see sections 4 1 and 4 2 of the Control Manual OMM 0159 Outdoor Reset Parameter and Space Heating Setpoint can be accessed by clicking the settings button Building Reference Temperatures to use in Outdoor Reset Mode can be selected in the Heating Menu Menu Ch13 status Comfort Time program 21 1...

Page 78: ...c Hot Water Menu The Domestic Hot Water Menu provides access to parameters to provide domestic hot water DHW using a tank sensor For DHW programming details see sections 4 4 of the Controls Manual OMM 0159 The Comfort and Eco DHW Setpoints can be accessed by clicking the settings button The DHW Setpoint to use can be selected in the Domestic Hot Water Menu ...

Page 79: ...Module parameters BCM parameters for functions including 0 10V operation and domestic hot water operation and error history These parameters are for use by Authorized AERCO sercvice technicians only Password is required to access this Menu 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 buttons See Section 6 7 for li...

Page 80: ...Modulex EXT Commercial Series CHAPTER 8 Maintenance Schedule OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 80 of 117 Access and clear error history ...

Page 81: ...ctivate Button 4 Note that at this point the screen shown if for the whole boiler 5 Toggling the Activate button allows user to operate the boiler with a manual firing rate 6 Click on the Request buttons to set the boiler manual firing rate desired 7 If desired user can select which burner s to run during manual firing rate function a Select one of the available burners b Note that the next screen...

Page 82: ...n the Manual Setpoint button icon This will show an Activate Button 2 Toggling the Activate button allows user to operate the boiler with a manual setpoint Any setpoint in the Heating or DHW Mode are ignored while the Manual Setpoint Function is activated 3 Click on the Request buttons to set the manual setpoint desired 4 To disable the Manual Setpoint Function click on the Home button ...

Page 83: ...nance Schedule OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 83 of 117 6 5 3 Reset Burner Working Hours and Ignition Count Select one of the available burners Click the Reset button Password will be required to proceed ...

Page 84: ...ure Water ΔT protection 0 F 2 F 90 F 0 C 1 C 50 C 0 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 1 Minimum Setpoint 68 F to 221 F 20 C to 105 C 86 F 39 CH 1 Maximum Setpoint 68 F to 221 F 20 C to 105 C 185 F 799 Analogue input function 0 10 V 0...

Page 85: ...esent 0 No parallel Operation 0 100 0 650 DHW Minimum Setpoint DHW setpoint must be set higher than the value of Parameter 650 77 F to 113 F 25 C to 45 C 95 F 35 C 385 DHW Maximum Setpoint 122 F to 149 F 50 C to 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 tan...

Page 86: ... MLX EXT 450 2S 1100 2S 31 MLX EXT 1500 2S 3000 2S 28 800 Burners minimum inserted 1 8 1 616 Cascade insert lock time Burner insertion delay time 30 900 sec 120 sec 613 Cascade remove lock time Burner removal delay time 30 900 sec MLX EXT 450 2S 1100 2S 120 sec MLX EXT 1500 2S 3000 2S 60 sec 674 Generator automatic restart How often the boiler changes the operating burners to balance wear and tear...

Page 87: ...loses if a failure prevents the insertion of the requested number of burner s 1 Contact closes with each failure of the boiler See Description 1 771 Water Pressure 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 default value of 2 2 622 Minimum Flow Sen...

Page 88: ...odbus Communication Timeout 0 240 sec 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 Leave at default value of 0 0 322 Pump Off Delay NOT APPLICABLE Note Leave at default value of 3 min 3 min 341 Pump minimum control NOT APPLICABLE Note Leave at default ...

Page 89: ...T 1500 2S 3000 2S 91Hz 319 Maximum Modulation 1 100 100 346 Minimum modulation Burner Minimum modulation 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 2S 31 MLX EXT 1500 2S 3000 2S 33 617 Ignition minimum modulation 0 100 32 618 Ignition maximum mod...

Page 90: ...F 30 C 380 Programmable Sensor 1 function NOT APPLICABLE Note Leave 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 Temperature sensor type 0 10K 25 C B 3977 1 10K 25 C B 3435 2 PT1000 3 minimum water flow switch Note Leave at default value of 0 0 1 2 3 0 8...

Page 91: ...G 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 Boiler Control Module These fault codes are shown in Table 7 3 BMM Burner Management Module These fault codes are shown in Table 7 4 Figure 7 1 Ufly Error Code Location ERROR CODE ...

Page 92: ...Pump runs for 5 min at max speed Carefully defrost boiler AUTOMATIC when Flow sensor is greater than 41 F HCM 18 Global differential temperature Maximum Δ temperature protection Fault is detected if Global FlowSensor Return Sensor Param 483 50 F Note Referred parameter is BCM Param 483 All burners turned OFF and Pump ON at maximum speed Check circulation check installation AUTOMATIC Fault is clear...

Page 93: ...d OFF Check water flow or check switch AUTOMATIC 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 electrical connections BMM and e BUS AUTOMATIC HCM 58 Global temperature sensor BCM Sensor global flow detected Burners turned OFF Check the flow sensor...

Page 94: ...n 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 sen...

Page 95: ...ck 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 Ignition retry after 60 second delay and failure remains until we have a successful burner operation Check fan wiring AUTOMATIC MANUAL BMM 26 High fan speed Modulating fan speed failure failed to stop within ...

Page 96: ... damage to the equipment and or harm to persons TABLE 8 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 safety devices for water and gas Inspect and clean the combustion chamber 8 burners Inspect and clean flame rod and ignitor Inspect and c...

Page 97: ...lves 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 appliance to the electrical supply and switch on the mains electrical supply e Test for correct operation on the gas side and on the wa...

Page 98: ... water 3 Reassemble the drain in reverse order Figure 8 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 opening 8 4 Checking CSD 1 Manifold Flow...

Page 99: ...n port Figure 8 2 The flame pattern should resemble the flame in the illustration below 8 5 1 Flame Color YELLOW CO2 HIGH NOT SATISFACTORY BLUE CO2 LOW NOT SATISFACTORY ORANGE OK SATISFACTORY Figure 8 2 Boiler Flame Observation Port Location 8 6 Proper Reassembly And Resealing Of The Vent Air Intake System After removing inspecting and possibly cleaning the flue pipes and air intake replace the pi...

Page 100: ...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 of condensation problems within the hoses See Figure 8 3 Figure 8 3 Pressure Hose Lengths NOT ACCEPTABLE Original Length OK NOT ACCEPTABLE Original Length OK ...

Page 101: ...nput 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 33 8 9 Heat and Return Sensor Resistance Values Nominal resistance differences at a given temperature ratio between the primary and return heating sensors should be checked periodically by measuring the electrical resistance ohms betwee...

Page 102: ...r and ensure it is completely closed 2 Unlatch the top lid and raise the lid Figure 8 4 3 Remove screws from top of unit holding the front rear and side panels in place Figure 8 5 Remove the panels by tilting away from unit then lifting up and out Figure 8 6 Note the front and rear panels must be removed before the side panels can be removed Figure 8 4 Unlatch Top Lid Step 2 Figure 8 5 Remove Scre...

Page 103: ...n 10 screws from around exhaust outlet opening and remove flue assembly from unit Figures 8 7 8 8 Figure 8 8 Flue Removal Step 4 5 On each side of the air intake manifold unlatch spring clips holding it in place Figure 8 9 Figure 8 9 Unlatch Spring Clips from Left and Right Side of Manifold Step 5 Manifold Retention Spring Clip Left Right Air Intake Manifold ...

Page 104: ...ow a All Modules Use a 13mm wrench to remove all A and C nuts surrounded by horizontal dotted lines in Figure 8 11 below 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 8 ...

Page 105: ... Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 105 of 117 Figure 8 11 Removing the Burner Module Plate Covers Step 7 8 Use a 36 mm wrench to disassemble all pipes from the gas manifold See Figure 8 12 Figure 8 12 Removing the Gas Pipes from Gas Manifold Step 8 B C A ...

Page 106: ...o lift pins are aligned with the left and right side tab holes refer to Figure 8 13 Figure 8 13 Location of Burner Assembly Lifting Screw Step 9 10 Use a 4mm hex wrench to adjust the screw until it extends into the tab hole Figure 8 14 8 15 Figure 8 14 Unscrewing Lift Screw into Tab Hole Step 10 Figure 8 15 Left and Right Lift Screws Extended into Tab Holes Step 10 Elevate the burner assembly slig...

Page 107: ... am 5 pm EST Page 107 of 117 11 Refer to Figure 8 16 lift up the burner plates to expose the burner modules and latch it in place Figure 8 16 Lifting Burner Plates Left to Expose Burner Modules Right Figure 8 17 Exposing Burner Modules Left and Removing Right Figure 8 18 Exposed Combustion Chambers under Burner Modules ...

Page 108: ...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 entire 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...

Page 109: ... the by product buildup It will also loosen some of the buildup that remains which the boiler will then shed during normal operation 8 12 1 Mechanical Cleaning of the Heat Exchanger 1 Use a stiff plastic bristled brush to remove larger deposits from the heat exchanger rods Try to remove all large deposits The lower rods being closer together are harder to reach It won t be possible to reach all ro...

Page 110: ...f obstructions cleaning it if necessary 7 Blow compressed air into the combustion chamber to remove any dirt clogging the aluminum pins on the combustion chamber walls Remove any remaining buildup from the heat exchanger particularly on the lower heat exchanger pins with a stiff plastic brush 8 12 2 Cleaning the Heat Exchanger with Cleaning Solution If mechanical cleaning has not removed all of th...

Page 111: ...mount of buildup If large deposits still remain repeat the chemical cleaning process in section 8 12 2 After cleaning with AXI Therm deposits will be loosened The expansion and contraction of the heat exchanger during normal operation will continue to shed debris 8 13 Reassembly Of the Burner Modules Follow the instructions to reassemble the burner modules 1 After the cleaning of the combustion ch...

Page 112: ...ll the pressure test nipples previously opened have been closed 8 15 Maintenance Kit Part Number To order the MODULEX annual and 24 Month Fireside Inspection maintenance kits contact AERCO International and use P N 58086 TAB replacing the TAB with the appropriate suffix as determined in Table 8 3 and 8 4 Annual Maintenance Kits contain a flame detector and igniter while the 24 Month Fireside Inspe...

Page 113: ...Modulex EXT Commercial Series CHAPTER 8 Maintenance Schedule OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 113 of 117 CHAPTER 9 SPARE PARTS DRAWING AND LISTS ...

Page 114: ...XT 7 8M 13 95213408 Casing Top Panel MODULEX 4M 95213409 Casing Top Panel MODULEX 5 6M 95213410 Casing Top Panel MODULEX 7 8M 14 95004115 Centre Section 15 95004114 End Section front 16 95004113 End Section rear 17 95250624 Ignitor 18 95004112 Screw UNI 5931 M8X45 19 95250973 EPDM 56X38X5 gasket 20 95250992 Boiler Body Insulation MODULEX 4 Elements 95250991 Boiler Body Insulation MODULEX 5 Element...

Page 115: ...sor 45 46 95261535 Tank sensor 47 95611593 Ignitor Cable 48 49 50 95263708 Safety Thermostat 120 C 51 95262451 Mixer DUNGS SW16 RG148 nozzle D 9 52 95262565 Level sensor 53 95262767 D 300 EPDM Gasket 54 95262926 Gas spring 55 95262930 Hinge casing 56 95262931 Casing Top Panel lock 57 95262932 Inspection flue plug 58 95263546 Gas valve 59 95262961 Mesh Burner 60 95263553 Blower 61 95263579 Ignition...

Page 116: ...4096 Lower Rear Panel 5 6 elements 95004097 Lower Rear Panel 7 8 elements 80 95004098 Flow header Modulex 4 Elements 95004099 Flow header Modulex 5 Elements 95004100 Flow header Modulex 6 Elements 95004101 Flow header Modulex 7 Elements 95004102 Flow header Modulex 8 Elements 81 95004103 Return header 4 Elements 95004104 Return header 5 Elements 95004105 Return header 6 Elements 95004106 Return he...

Page 117: ...s CHAPTER 9 Spare Parts and Drawing Lists OMM 0160_A DRAFT Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 117 of 117 Change Log Date Description Changed by 6 28 2022 Initial Release DBarron AERCO International Inc 2022 ...

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