Watts AERCO MLX EXT 1500 2S, Installation, Operation & Maintenance Manual

Page: 3 / 117

Modulex EXT Commercial Series
CONTENTS
OMM-0160_A
• DRAFT Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page
3 of 117
Propane Gas Piping Sizes ............................................................................................................... 29
Propane Gas Piping Connections .................................................................................................... 29
Propane Gas Supply Pressure Requirements .................................................................................. 29
4.10 Flow And Return Pipe Connections ............................................................................................................ 29
4.11 Pressure Relief Valve ................................................................................................................................. 30
4.12 CSD-1 Manifold Assembly (Supplied) ......................................................................................................... 30
4.13 Determination Of Primary Boiler Pump or Boiler System Pump.................................................................. 32
4.14 Condensate Piping And Drain .................................................................................................................... 33
4.15 Water Treatment ...................................................................................................................................... 35
4.16 Important Installation Warnings ................................................................................................................ 35
4.16.1 Oxygen Levels in the System Water Warning .................................................................................. 35
4.16.2 Antifreeze Compatibility Warning ................................................................................................... 35
4.16.3 Lime Scale and Corrosive Water Damage Warning .......................................................................... 35
4.16.4 Connection to Refrigeration System Warning .................................................................................. 36
4.17 Optional Air Intake Connection ................................................................................................................. 36
4.18 Flue Manifold Installation.......................................................................................................................... 36
4.19 Flue Exhaust Piping To Vent ...................................................................................................................... 38
4.20 Vent Starter Pieces.................................................................................................................................... 39
4.21 Combustion Air and Ventilation Openings ................................................................................................. 40
4.21.1 Insufficient Ventilation and Combustion Air .................................................................................... 40
4.21.2 Room Air Combustion ..................................................................................................................... 41
4.21.3 Sealed Combustion ......................................................................................................................... 41
4.22 Installing the Exhaust and Air Intake System .............................................................................................. 42
4.22.1 Important Factors for Terminal Orientation and 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 Ladder Diagram ........................................................................................................................... 51
4.29 Input/Output Box Terminal Assignments ................................................................................................... 52
4.30 Starting Up: Filling and De-Aerating The Boiler .......................................................................................... 53
4.30.1 Necessary Precautions for Safety .................................................................................................... 53
4.30.2 Supply Voltage, Gas Pressure, and Water pressure.......................................................................... 53
4.31 Filling The System ..................................................................................................................................... 53
4.31.1 Necessary Precautions While Filling the System .............................................................................. 53
4.31.2 Filling Locations and Preparation .................................................................................................... 54
4.32 Testing The Ignition Safety Shut-Off Device ............................................................................................... 56
4.33 Burner Calibration ..................................................................................................................................... 57
4.33.1 Installing Gas Analyzer Probe into Flue Outlet ................................................................................. 57
4.33.2 Maximum Output Calibration ......................................................................................................... 58
4.33.3 Minimum Output Calibration .......................................................................................................... 59
4.33.4 Final Check and Ignition Failure Adjustment Procedure ................................................................... 59
4.34 Sweeper Mode (Manual Control) .............................................................................................................. 61
4.35 High Altitude Adjustment .......................................................................................................................... 63
4.36 High Altitude Conversion Label.................................................................................................................. 64
4.37 Conversion From Natural Gas to Propane Gas ........................................................................................... 64
4.38 Controls And Emergency Functions ........................................................................................................... 65
4.39 Initial Boiler Ignition .................................................................................................................................. 65
4.39.1 Preliminary Checks ......................................................................................................................... 65
CHAPTER 5: UFLY CONTROLLER & BCM MODULES ...................................................................... 67