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Watts Aerco Modulex EXT Series, Technical Application Manual, Page: 1 / 28

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Modulex EXT Vent and Combustion Air Application Guide           

GF-136-V 

 

TAG-0054-0F  

  AERCO International, Inc. 

•

 100 Oritani Dr. 

•

  Blauvelt, NY 10913   

  Page 1 of 

28

  

GF-136-V  

 

 

Phone: 800-526-0288  

  09/25/2017 

 

 

 

Venting & Combustion Air Guide

 

  

Modulating Condensing Hot Water Boilers

 

 
 
 
 
 
 
 
 

 
 
 

 

 

 

 

 

 

Latest Update:  09/25/2017 

 

 

 TECHNICAL APPLICATION GUIDE  

APPLIES TO THE FOLLOWING 

LIGHT COMMERCIAL MODELS 

•

  MLX EXT 321 

•

  MLX EXT 450 / MLX EXT 481 

•

  MLX EXT 600 / MLX EXT 641 

•

  MLX EXT 800 / MLX EXT 802 

•

  MLX EXT 962 

•

  MLX EXT 1100 / MLX EXT 1123 

COMMERCIAL MODELS 

•

  MLX EXT 1500 / MLX EXT 1530  

•

  MLX EXT 1912 

•

  MLX EXT 2295 / MLX EXT 2300 

•

  MLX EXT 2600 / MLX EXT 2677 

•

  MLX EXT 3000 / MLX EXT 3060  

Summary of Contents for Aerco Modulex EXT Series

Page 1: ...r Guide Modulating Condensing Hot Water Boilers Latest Update 09 25 2017 TECHNICAL APPLICATION GUIDE APPLIES TO THE FOLLOWING LIGHT COMMERCIAL MODELS MLX EXT 321 MLX EXT 450 MLX EXT 481 MLX EXT 600 MLX EXT 641 MLX EXT 800 MLX EXT 802 MLX EXT 962 MLX EXT 1100 MLX EXT 1123 COMMERCIAL MODELS MLX EXT 1500 MLX EXT 1530 MLX EXT 1912 MLX EXT 2295 MLX EXT 2300 MLX EXT 2600 MLX EXT 2677 MLX EXT 3000 MLX EX...

Page 2: ...3 OPTION 3 Polypropylene 5 1 3 4 OPTION 4 PVC CPVC 5 1 4 FACTORY SUPPLIED INLET AND VENT COMPONENTS 6 1 4 1 Exhaust Manifold Assembly Supplied 6 1 4 2 European to American Flue Adaptor Supplied 6 1 4 3 Flue Exhaust Piping Starter Pieces 7 1 4 4 Air Intake Connector Supplied 8 CHAPTER 2 COMBUSTION AIR SYSTEM 9 2 1 COMBUSTION AIR REQUIREMENTS 9 2 2 COMBUSTION AIR PIPE SIZING 12 2 3 COMMON COMBUSTION...

Page 3: ...accordance with the manufacturer s recommendations Installing or venting a boiler or any other gas appliance with improper methods or materials may result in serious injury or death due to fire or to asphyxiation from poisonous gases carbon monoxide is odorless and invisible WARNING For correct installation of vent system read all of these instructions and refer to the vent pipe manufacturer s ins...

Page 4: ... temperature less than 140 F 60 C above 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 F 60 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 F 60 C above its de...

Page 5: ...ompany Inc Model CS Special Gas Vent 1 3 3 OPTION 3 Polypropylene DuraVent Polypro Commercial Available through AERCO Centrotherm ECO Systems InnoFlue Single Wall Commercial 1 3 4 OPTION 4 PVC CPVC Use Schedule 40 or thicker Single Wall Uninsulated Pipes When using Non Metallic Plastic vent systems for Canadian installations per CSA B149 1 use vent systems that are certified to the Standard for Ty...

Page 6: ...t opening covers with gaskets are used to cover the unused manifold openings Assembly of the exhaust manifold is described in detail in Chapter 3 See Figure 1 for image of the exhaust manifold parts Figure 1 Exhaust Manifold Components for Exhaust Outlet Supplied 1 4 2 European to American Flue Adaptor Supplied The exhaust manifold supplied with the unit requires the use of an adaptor to connect t...

Page 7: ... directly PVC P N 49051 included EXT 600 1123 6 Stainless Steel Contact vent manufacturer directly Polypropylene P N 39006 2 for Duravent PolyPro For other brands contact manufacturer directly PVC P N 49050 included EXT 1500 1530 1912 10 Stainless Contact vent manufacturer Polypropylene Contact vent manufacturer PVC 58115 1 EXT 2295 3060 12 Stainless Contact vent manufacturer Polypropylene Contact...

Page 8: ...g only For PVC ducting order either P N 58115 1 or 58115 2 as per Table 1 Figure 4 Air Intake Connection NOTE See Chapter 3 for instructions for assembling the flue piping including the exhaust manifold Euro to USA Adaptor and Diameter Reduction Kits When using sealed combustion observe the following requirements Sealed combustion is only available on the left of the unit only If using side by sid...

Page 9: ...0 in 2 516 cm 2 161 in 2 1039 cm 2 107 in 2 690 cm 2 EXT 481 450 120 in 2 774 cm 2 241 in 2 1555 cm 2 160 in 2 1032 cm 2 EXT 641 600 160 in 2 1032 cm 2 321 in 2 2071 cm 2 214 in 2 1381 cm 2 EXT 802 800 201 in 2 1297 cm 2 401 in 2 2587 cm 2 267 in 2 1723 cm 2 EXT 962 241 in 2 1655 cm 2 481 in 2 3103 cm 2 321 in 2 2071 cm 2 EXT 1123 1100 281 in 2 1813 cm 2 562 in 2 3626 cm 2 374 in 2 2413 cm 2 EXT 1...

Page 10: ... rating of all equipment in the room o When communicating with the outdoors by means of vertical ducts each opening shall have a minimum free area of 1 square inch per 4 000 BTU per total input rating of all appliances in the room o If horizontal ducts are used each opening and duct shall have a minimum free area of 1 square inch per 2 000 BTU per hour of total input rating of all appliances in th...

Page 11: ... Termination Locations 8 All inlet air ducts must be sealed air tight 9 When using sealed combustion the combustion air inlet and vent outlet must be located on the same surface same wall roof etc See Figures 7 This is required so that equal pressure zones are acting on both the air inlet and vent outlet This makes the installation a balanced vent system which helps maintain stable combustion char...

Page 12: ...IPE DIAM EQUIVALENT PIPE LENGTHS EXAMPLES MAXIMUM LENGTH EQUIVALENT FT M Sharp 90 Elbow Equiv Ft m Sweep 90 Elbow Equiv Ft m 45 Elbow Equiv Ft m EXT 321 EXT 481 450 EXT 641 600 4 102 mm 10 ft 3 05 m 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m EXT 802 800 EXT 962 EXT 1123 1100 6 152 mm 10 ft 3 05 m N A 5 ft 1 5 m 100 ft 30 5 m EXT 1530 1500 EXT 1912 10 254 mm 10 ft 3 05 m N A 5 ft 1 5 m 100 ft 30 5 m EXT 2...

Page 13: ...0 5 m 1 284 000 6 152 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 2 407 500 8 203 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 3 825 000 10 254 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 5 355 000 12 305 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 6 885 000 14 358 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 9 180 000 16 407 mm 10 ft 3 05 ...

Page 14: ... sharp 90 elbows The termination includes two 2 90 elbows Each individual combustion air connector consists of 10 ft straight run and one WYE Common Combustion air pipe 30 ft 3 x 10ft 2 x 10ft 80 equivalent ft 24 3 m Individual combustion air connector 10 ft 5 ft 15 equivalent ft 4 6 m Total Combustion air equivalent length 80 ft 15 ft 95 29 0 m 95 equivalent ft is LESS than 100 equivalent feet OK...

Page 15: ...mbustion Air Application Guide TAG 0054_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 15 of 28 GF 136 V Phone 800 526 0288 09 25 2017 Figure 10 Typical Common Combustion Air Inlet installation Through Wall ...

Page 16: ...section are design certified as Category IV for venting only when they are installed with manufacturer specified vent system components and installation practices Install supplied vent pipe starter piece at the boiler vent connector and work toward the vent or rain cap To attach the exhaust connector to the flue collector use the screws and the gasket supplied inside the plastic bag Use a 14mm soc...

Page 17: ...ction of Exhaust Manifold to Flue Exhaust Outlet EXT 321 1123 Figure 12 Connection of Exhaust Manifold to Flue Exhaust Outlet EXT 1500 3060 NOTE The gasket may seem large It is intentionally designed to produce a tight fit EUROPEAN FLUE EXHAUST MANIFOLD SUPPLIED FLUE ADAPTOR GASKET SUPPLIED NUTS 6 SUPPLIED EUROPEAN FLUE EXHAUST MANIFOLD SUPPLIED FLUE ADAPTOR GASKET SUPPLIED NUTS 10 SUPPLIED ...

Page 18: ... 136 V Figure 13 Assembly of USA Adaptor to European Flue Manifold EXT 321 1123 Figure 14 Assembly of USA Adaptor to European Flue Manifold EXT 1500 3060 EUROPEAN TO USA FLUE EXHAUST ADAPTER SUPPLIED EUROPEAN FLUE EXHAUST MANIFOLD INSPECTION PORT EUROPEAN FLUE EXHAUST MANIFOLD EUROPEAN TO USA FLUE EXHAUST ADAPTER SUPPLIED GASKET FOR FLUE ADAPTOR GASKET FOR FLUE ADAPTOR ...

Page 19: ... Dr Blauvelt NY 10913 Page 19 of 28 GF 136 V Phone 800 526 0288 09 25 2017 Figure 15 Flue Piping Starter Piece Assembly EXT 321 1123 OPTIONAL FLUE PIPING STARTER PIECE EUROPEAN TO USA FLUE ADAPTER EUROPEAN EXHAUST MANIFOLD WORM DRIVEN HOSE CLAMP BOLT 4 WASHER 4 GASKET ADAPTOR CONNECTOR 4 or 6 PVC or SS ...

Page 20: ...r Blauvelt NY 10913 TAG 0054 0F 09 25 2017 Phone 800 526 0288 GF 136 V Figure 16 Flue Piping Starter Piece Assembly EXT 1500 3060 GASKET EUROPEAN TO USA FLUE ADAPTER DIAMETER REDUCTION ADAPTOR CONNECTOR WORM DRIVEN HOSE CLAMP WASHERS 8 EACH SCREWS 8 EACH EUROPEAN EXHAUST MANIFOLD FLUE PIPING STARTER PIECE ...

Page 21: ...iece EXT 321 1123 Figure 18 Installed Flue Piping Starter Piece EXT 1500 3060 WARNING Do not insulate or otherwise wrap vent pipe or Fittings INSTALLED WITH RTV LIQUID SILICONE AND WORM DRIVEN HOSE CLAMP FLUE VENT PIPE FLUE STARTER PIECE EUROPEAN TO USA FLUE ADAPTER FLUE MANIFOLD INSTALLED WITH RTV LIQUID SILICONE AND WORM DRIVEN HOSE CLAMP FLUE VENT PIPE EUROPEAN TO USA FLUE ADAPTER FLUE MANIFOLD...

Page 22: ...ance of at least 4 feet 122 cm from any air openings into a building b In Massachusetts when side wall venting is used the vent termination must be located a minimum of 4 feet above grade For detailed information pertaining to side wall venting within the Commonwealth of Massachusetts refer to pages 8 and 9 in the MLX EXT manual GF 136 c At least 3 feet 92 cm above any forced air inlet located wit...

Page 23: ...T Vent and Combustion Air Application Guide TAG 0054_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 23 of 28 GF 136 V Phone 800 526 0288 09 25 2017 Figure 19 Determining Location of Vent Outlet ...

Page 24: ...within 10 ft See Figure 20 c Vertical terminations shall extend at least 3 ft 0 9 m above the highest point where it passes through a roof of a building and at least 2 ft 0 6 m higher than any portion of the building within a horizontal distance of 10 ft 3 m Terminations that extend more than 2 ft above the roof must be laterally supported d Combustion air inlet must also face away from the vent o...

Page 25: ...EXT 962 EXT 1123 1100 6 152 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m EXT 1530 1500 EXT 1912 10 254 mm 10 ft 3 05 m N A 5 ft 1 5 m TBD 100 ft 30 5 m EXT 2295 2300 EXT 2677 2600 EXT 3060 3000 12 305 mm 10 ft 3 05 m N A 5 ft 1 5 m TBD 100 ft 30 5 m The maximum pressure drop of the combustion air piping is also 100 equivalent feet 30 5 m See Section 2 2 Note that this does NOT mean the ...

Page 26: ... m 606 000 4 102 mm 10 ft 3 05 m 5 ft 1 5 m 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 1 284 000 6 152 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 2 407 500 8 203 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 3 825 000 10 254 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 5 355 000 12 305 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 100 ft 30 5 m 6 885 000 14 358 mm 10 ft 3 05...

Page 27: ...ve 100 equivalent feet 30 5 m even if the combustion air is less than 100 equivalent feet and vice versa Example The vent system of two MLX 802 800 2 x 802 000 BTU hr 1 604 000 BTU hr consists of 30 foot length of vent pipe and 2 sharp 90 elbows A termination vent or rain cap is also installed Each individual vent connector consists of 5 ft straight run and one WYE Common Vent pipe 30 ft 2 x 10ft ...

Page 28: ... 2017 Phone 800 526 0288 GF 136 V AERCO International Inc 2017 Change Log DATE DESCRIPTION CHANGED BY 02 22 2017 Rev E DIR 17 008 Added new model numbers for units with aluminum water connections Reformatted per new design standard Curtis Harvey 09 25 2017 Rev F DIR 17 066 Modify Table 1 Specify P N for PolyPro vents section 1 4 3 Chris Blair ...

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