MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS
Installation, Operation & Maintenance Manual
Page
4
of
146
AERCO International, Inc.
•
100 Oritani Dr.
•
Blauvelt, NY 10913
OMM-0087_0F
07/13/15
Phone: 800-526-0288
GF-143
3.8.3.3 Reversing Boiler Sensor Kf And Automatic Air Vent ............................................................................ 35
3.9 Gas Connection General Information ................................................................................................................ 36
Natural Gas Connections ........................................................................................................................ 37
3.9.1
3.9.1.1 Natural Gas Piping Sizes ....................................................................................................................... 37
3.9.1.2 Natural Gas Piping Connections .......................................................................................................... 37
3.9.1.3 Natural Gas Supply Pressure Requirements ........................................................................................ 37
Propane Gas Connections ....................................................................................................................... 37
3.9.2
3.9.2.1 Propane Gas Piping Sizes ..................................................................................................................... 37
3.9.2.2 Propane Gas Piping Connections ......................................................................................................... 37
3.9.2.3 Propane Gas Supply Pressure Requirements ....................................................................................... 38
3.10 Flow And Return Pipe Connections ................................................................................................................. 38
3.11 Pressure Relief Valve ....................................................................................................................................... 38
3.12 CSD-1 Manifold Assembly (Supplied) .............................................................................................................. 39
3.13 Determination of Primary Boiler Pump Or Boiler System Pump ..................................................................... 40
3.14 Condensate Piping and Drain .......................................................................................................................... 42
3.15 Water Treatment ............................................................................................................................................. 43
3.16 Important Installation Warnings ...................................................................................................................... 44
Oxygen Levels in the System Water Warning ....................................................................................... 44
3.16.1
Antifreeze Compatibility Warning ........................................................................................................ 44
3.16.2
Lime Scale and Corrosive Water Damage Warning .............................................................................. 44
3.16.3
Connection to Refrigeration System Warning ...................................................................................... 44
3.16.4
3.17 Air Intake Connection ...................................................................................................................................... 44
3.18 Flue Manifold Connection ............................................................................................................................... 45
3.19 Flue Exhaust Piping to Vent ............................................................................................................................. 46
3.20 Vent Starter Pieces .......................................................................................................................................... 46
3.21 Combustion Air and Ventilation Openings ...................................................................................................... 48
Insufficient Ventilations and Combustion Air ....................................................................................... 48
3.21.1
Room Air Combustion ........................................................................................................................... 49
3.21.2
Sealed Combustion ............................................................................................................................... 49
3.21.3
3.22 Installation of the Exhaust and Air Intake System ........................................................................................... 49
Important Factors for Terminal Orientation and Location ................................................................... 50
3.22.1
Minimum and Maximum Wall Thickness.............................................................................................. 51
3.22.2
3.23 Vent Pipe Sizing ............................................................................................................................................... 51
3.24 Electrical Connections ...................................................................................................................................... 53
Regulations in Force ............................................................................................................................. 53
3.24.1
Mains Electrical Supply Connection (120 V – 60 Hz) ............................................................................ 53
3.24.2
Service Relay Requirement ................................................................................................................... 54
3.24.3
Electrical Requirements ........................................................................................................................ 54
3.24.4
3.25 Functional Wiring Diagram .............................................................................................................................. 57
3.26 Ladder Diagrams .............................................................................................................................................. 59
3.27 General Ladder Diagram .................................................................................................................................. 60
3.28 E8 Controller and BCM Terminal Assignments ................................................................................................ 60
3.29 Installation Examples ....................................................................................................................................... 63
3.30 Starting Up: Filling and Deaerating the Boiler ................................................................................................. 65
Necessary Precautions for Safety ......................................................................................................... 65
3.30.1
Supply Voltage, Gas Pressure, and Water pressure.............................................................................. 65
3.30.2
3.31 Filling the System ............................................................................................................................................. 65
Necessary Precautions While Filling the System .................................................................................. 65
3.31.1
Filling Locations and Preparation.......................................................................................................... 66
3.31.2
3.32 Testing The Ignition Safety Shut Off Device ..................................................................................................... 68
3.33 Burner Calibration ........................................................................................................................................... 69
Installing the Gas Analyzer Probe ......................................................................................................... 69
3.33.1
Maximum Output Calibration ............................................................................................................... 70
3.33.2
Minimum Output Calibration ............................................................................................................... 71
3.33.3
Final Check and Ignition Failure Adjustment Procedure....................................................................... 71
3.33.4
