Modulex EXT Commercial Series Boilers User Manual
GF-139
USER MANUAL
INSTALLATION, OPERATION & MAINTENANCE
Modulating and Condensing Boilers
APPLIES TO MODELS:
• MLX EXT 1530 / MLX EXT 1500
• MLX EXT 1912
• MLX EXT 2295 / MLX EXT 2300
• MLX EXT 2677 / MLX EXT 2600
• MLX EXT 3060 / MLX EXT 3000
Latest Update: 09/15/2017
OMM-0095_0H
GF-139
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
Page 1 of 144
09/15/2017
Modulex EXT Commercial Series Boilers User Manual
Table of Contents:
CHAPTER 1: SAFETY PRECAUTIONS ..................................................................................................... 7
CHAPTER 2: GENERAL INFORMATION ................................................................................................ 11
2.1 CORRECT USE OF THE APPLIANCE .....................................................................................................................11
2.2 WATER TREATMENT ..........................................................................................................................................11
2.3 INFORMATION TO BE MADE AVAILABLE TO THE USER .....................................................................................11
2.4 SAFETY WARNINGS ............................................................................................................................................12
2.5 MODIFICATIONS TO PARTS CONNECTED TO THE APPLIANCE ...........................................................................12
2.6 FOR APPLIANCES OPERATING WITH PROPANE GAS ..........................................................................................13
2.7 DATA PLATE .......................................................................................................................................................14
2.8 OPERATIONAL REQUIREMENTS .........................................................................................................................15
2.8.1 General Requirements ............................................................................................................................15
2.8.2 Regulatory Requirements .......................................................................................................................15
2.8.3 Water Quality Requirements ..................................................................................................................16
2.9 TOOLS, MATERIALS, AND ADDITIONAL EQUIPMENT .........................................................................................17
2.10 DISPOSAL OF PACKAGING AND PARTS ............................................................................................................17
2.11 GENERAL WARNINGS .......................................................................................................................................17
2.11.1 Using the Operation and Maintenance Manual ...................................................................................17
2.11.2 Installation and Servicing Personnel .....................................................................................................17
2.11.3 Installation Materials ............................................................................................................................17
2.11.4 Preparing Boiler for Servicing ...............................................................................................................18
2.11.5 Returning a Boiler to Service ................................................................................................................18
2.11.6 Change in Ownership ............................................................................................................................18
2.12 OPERATIONAL LIMITS OF THE BOILER .............................................................................................................18
CHAPTER 3: TECHNICAL FEATURES & DIMENSIONS ........................................................................ 19
3.1 MODULEX EXT COMMERCIAL TECHNICAL FEATURES ........................................................................................19
3.1.1 Temperature Control Devices: ................................................................................................................19
3.1.2 Control Panel (E8) Includes: ....................................................................................................................19
3.1.3 Other Features Include: ..........................................................................................................................19
3.2 GENERAL BOILER OPERATION ...........................................................................................................................20
3.3 DIMENSIONAL DRAWINGS.................................................................................................................................21
3.4 PERFORMANCE DATA ........................................................................................................................................24
CHAPTER 4: INSTALLATION INSTRUCTIONS ...................................................................................... 25
4.1 INSTALLATION WARNINGS AND REQUIREMENTS .............................................................................................25
4.1.1 Appropriate Use of the Boiler .................................................................................................................25
4.1.2 Prerequisite System Flushing ..................................................................................................................25
4.1.3 Installation Personnel Qualifications ......................................................................................................25
4.1.4 Carbon Monoxide Detector Installation .................................................................................................25
4.1.5 Installation Conformity Requirements ...................................................................................................25
4.2 CODE AND STANDARDS APPROVALS .................................................................................................................26
4.3 PACKAGING ........................................................................................................................................................26
4.4 TRANSPORTING AND SECURING THE BOILER SAFELY ........................................................................................27
4.5 UNPACKING THE BOILER ....................................................................................................................................27
4.6 BOILER PACKAGE CONTENTS .............................................................................................................................28
4.7 BOILER LOCATION IN A BOILER ROOM ..............................................................................................................29
4.7.1 Boiler Room Safety Concerns .................................................................................................................29
4.7.2 Products to Avoid in the Boiler Room.....................................................................................................30
4.8 RECOMMENDED CLEARANCES FOR SERVICING.................................................................................................30
4.9 GAS CONNECTION GENERAL INFORMATION .....................................................................................................31
4.9.1 Natural Gas Connections ........................................................................................................................32
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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
OMM-0095_0H
GF-139
Modulex EXT Commercial Series Boilers User Manual
4.9.1.1 Natural Gas Piping Sizes .......................................................................................................................32
4.9.1.2 Natural Gas Piping Connections ..........................................................................................................32
4.9.1.3 Natural Gas Supply Pressure Requirements ........................................................................................32
4.9.2 Propane Gas Connections .......................................................................................................................32
4.9.2.1 Propane Gas Piping Sizes .....................................................................................................................32
4.9.2.2 Propane Gas Piping Connections .........................................................................................................32
4.9.2.3 Propane Gas Supply Pressure Requirements.......................................................................................32
4.10 FLOW AND RETURN PIPE CONNECTIONS ........................................................................................................33
4.11 PRESSURE RELIEF VALVE ..................................................................................................................................33
4.12 CSD-1 MANIFOLD ASSEMBLY (SUPPLIED) ........................................................................................................34
4.13 DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP ......................................................35
4.14 CONDENSATE PIPING AND DRAIN ...................................................................................................................36
4.15 WATER TREATMENT ........................................................................................................................................38
4.16 IMPORTANT INSTALLATION WARNINGS..........................................................................................................38
4.16.1 Oxygen Levels in the System Water Warning .......................................................................................38
4.16.2 Antifreeze Compatibility Warning ........................................................................................................38
4.16.3 Lime Scale and Corrosive Water Damage Warning ..............................................................................39
4.16.4 Connection to Refrigeration System Warning ......................................................................................39
4.17 OPTIONAL AIR INTAKE CONNECTION ..............................................................................................................39
4.18 FLUE MANIFOLD INSTALLATION ......................................................................................................................39
4.19 FLUE EXHAUST PIPING TO VENT ......................................................................................................................41
4.20 VENT STARTER PIECES .....................................................................................................................................42
4.21 COMBUSTION AIR AND VENTILATION OPENINGS ...........................................................................................43
4.21.1 Insufficient Ventilation and Combustion Air.........................................................................................43
4.21.2 Room Air Combustion ...........................................................................................................................44
4.21.3 Sealed Combustion ...............................................................................................................................44
4.22 INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM ............................................................................45
4.22.1 Important Factors for Terminal Orientation and Location ...................................................................45
4.22.2 Minimum and Maximum Wall Thickness..............................................................................................46
4.23 VENT PIPE SIZING .............................................................................................................................................46
4.24 ELECTRICAL CONNECTIONS .............................................................................................................................48
4.24.1 Regulations in Force .............................................................................................................................48
4.24.2 Mains Electrical Supply Connection (120 V – 60 Hz) ............................................................................48
4.24.3 Service Relay Requirement ...................................................................................................................49
4.24.4 Electrical Requirements ........................................................................................................................49
4.25 FUNCTIONAL WIRING DIAGRAM .....................................................................................................................53
4.26 LADDER DIAGRAMS .........................................................................................................................................55
4.27 GENERAL LADDER DIAGRAM ...........................................................................................................................56
4.28 E8 CONTROLLER AND BCM TERMINAL ASSIGNMENTS....................................................................................56
4.29 INSTALLATION EXAMPLES ................................................................................................................................59
4.30 STARTING UP: FILLING AND DE-AERATING THE BOILER ..................................................................................61
4.30.1 Necessary Precautions for Safety .........................................................................................................61
4.30.2 Supply Voltage, Gas Pressure, and Water pressure..............................................................................61
4.31 FILLING THE SYSTEM ........................................................................................................................................61
4.31.1 Necessary Precautions While Filling the System ..................................................................................61
4.31.2 Filling Locations and Preparation..........................................................................................................62
4.32 TESTING THE IGNITION SAFETY SHUT-OFF DEVICE ..........................................................................................64
4.33 BURNER CALIBRATION .....................................................................................................................................65
4.33.1 Installing the Gas Analyzer Probe .........................................................................................................65
4.33.2 Maximum Output Calibration ...............................................................................................................66
4.33.3 Minimum Output Calibration ...............................................................................................................67
4.33.4 Final Check and Ignition Failure Adjustment Procedure.......................................................................67
4.34 SWEEPER MODE (MANUAL CONTROL) ............................................................................................................70
4.35 HIGH ALTITUDE ADJUSTMENT .........................................................................................................................71
4.36 HIGH ALTITUDE CONVERSION LABEL ...............................................................................................................72
4.37 CONVERSION FROM NATURAL GAS TO PROPANE GAS ...................................................................................73
OMM-0095_0H
GF-139
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
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4.38 CONTROLS AND EMERGENCY FUNCTIONS ......................................................................................................74
4.39 INITIAL BOILER IGNITION .................................................................................................................................75
4.39.1 Preliminary Checks................................................................................................................................75
CHAPTER 5: E8 CONTROLLER AND BCM MODULES ......................................................................... 77
5.1 E8 CONTROLLER .................................................................................................................................................77
5.1.1 E8 Controller Features and Functions.....................................................................................................77
5.1.2 E8 Display Functions ...............................................................................................................................78
5.1.3 E8 HEATING Mode Selection ..................................................................................................................79
5.1.4 E8 MENU Mode Operation (Door Open) ................................................................................................80
5.1.5 E8 MENU Navigation and Parameter Settings ........................................................................................81
5.1.6 E8 Parameter Navigation, Selection, and Setting ...................................................................................82
5.2 BCM (BOILER COMMUNICATION MODULE) ......................................................................................................83
5.2.1 BCM Features and Functions ..................................................................................................................83
5.2.2 BCM Description .....................................................................................................................................83
CHAPTER 6: OPERATION OF THE E8 CONTROLLER ......................................................................... 87
6.1 INSTALLATION MENU: INITIALIZING THE E8 CONTROLLER................................................................................88
6.2 QUICK START INSTRUCTIONS .............................................................................................................................89
6.2.1 Setting Maximum and Minimum Flow Temperature .............................................................................89
6.2.2 Setting Room Temperature and Outdoor Compensation ......................................................................90
6.2.3 Setting Heating Programs and Pumps ....................................................................................................91
6.3 MENU AND SUB-MENU DESCRIPTIONS .............................................................................................................92
6.3.1 Menus (Top Level): .................................................................................................................................92
6.3.2 Sub-Menus: .............................................................................................................................................92
6.4 GENERAL MENU .................................................................................................................................................93
6.5 SERVICE MENU...................................................................................................................................................95
6.6 DISPLAY MENU...................................................................................................................................................97
6.7 USER MENU .......................................................................................................................................................99
6.8 TIME PROGRAM MENU ...................................................................................................................................101
6.9 EXPERT MENU ..................................................................................................................................................102
6.10 OTHER POSSIBLE SETTINGS............................................................................................................................106
6.10.1 Settings for Heating Circuit 1/2 ..........................................................................................................106
6.10.1.1 Heating Adjustment With Constant Flow Temp ...............................................................................106
6.10.1.2 Temperature Settings For Heating Circuits......................................................................................106
6.10.1.3 A Second DHW Storage Tank ...........................................................................................................107
6.10.1.4 Temperature Setting For Second DHW Storage Tank......................................................................107
6.10.1.5 Swimming Pool ................................................................................................................................107
6.10.1.6 Swimming Pool Temperature Setting ..............................................................................................107
6.10.1.7 Screed Dry Program (For Floor Heating Installation) .......................................................................107
6.10.1.8 Temperature Setting For Screed Program .......................................................................................107
6.10.1.9 Signal 0 – 10 V .................................................................................................................................107
6.10.1.10 Slope And Temperature Setting with 0 – 10 V Signal ...................................................................107
6.10.2 Setting of DHW Circuit ........................................................................................................................108
6.10.2.1 Operation of Pumps In Parallel ........................................................................................................108
6.10.2.2 Use of a DHW Storage Tank Thermostat (On/Off)...........................................................................108
6.10.2.3 Antilegion .........................................................................................................................................108
6.10.2.4 Setting for Solar Panel Use ..............................................................................................................108
6.11 ACCESS CODE SETTING ..................................................................................................................................108
CHAPTER 7: TROUBLESHOOTING ...................................................................................................... 109
7.1 E8 CONTROLLER FAULT CODES ........................................................................................................................109
7.1.1 E8 Controller Fault Codes .....................................................................................................................111
7.1.2 BCM (Boiler Communications Module) Fault Codes.............................................................................115
7.1.3 BMM (Burner Management Module) Fault Codes ...............................................................................116
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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
OMM-0095_0H
GF-139
Modulex EXT Commercial Series Boilers User Manual
CHAPTER 8: MAINTENANCE SCHEDULE ........................................................................................... 119
8.1 INSTRUCTIONS FOR INSPECTION AND MAINTENANCE ...................................................................................120
8.2 PERIODIC EXAMINATION OF VENTING SYSTEM ..............................................................................................120
8.3 PROPER PROCEDURE FOR CLEANING EXHAUST FLUE .....................................................................................120
8.3.1 Cleaning the Condensate Drain Line .....................................................................................................121
8.4 CHECKING CSD-1 MANIFOLD FLOW SWITCH ...................................................................................................121
8.5 VISUAL INSPECTION OF THE FLAME ................................................................................................................122
8.5.1 FLAME COLOR: ......................................................................................................................................122
8.6 PROPER REASSEMBLY AND RESEALING OF THE VENT-AIR INTAKE SYSTEM ....................................................122
8.7 PRESSURE SWITCH HOSES AND CONNECTIONS ..............................................................................................123
8.8 BURNER / HEAT EXCHANGER CLEANING PROCEDURE ....................................................................................124
8.9 HEAT AND RETURN SENSOR RESISTANCE VALUES ..........................................................................................124
8.10 UNIT DISASSEMBLY ........................................................................................................................................125
8.11 CLEANING THE BURNER MODULE .................................................................................................................131
8.12 CLEANING THE HEAT EXCHANGER .................................................................................................................131
8.12.1 Mechanical Cleaning of the Heat Exchanger ......................................................................................132
8.12.2 Cleaning the Heat Exchanger with Cleaning Solution .........................................................................133
8.12.3 Repeat Cleaning ..................................................................................................................................134
8.13 REASSEMBLY OF THE BURNER MODULES ......................................................................................................134
8.14 FINAL PROCEDURES AFTER MAINTENANCE...................................................................................................135
8.15 MAINTENANCE KIT PART NUMBER................................................................................................................136
8.16 ACCESSORY KIT PART NUMBER .....................................................................................................................137
CHAPTER 9: SPARE PARTS DRAWING AND LISTS .......................................................................... 139
OMM-0095_0H
GF-139
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
OMM-0095_0H
GF-139
Modulex EXT Light Commercial Series Boilers User Manual
CHAPTER 1: Safety Precautions
CHAPTER 1: SAFETY PRECAUTIONS
The following defined symbols are used throughout this manual to notify the reader of potential
hazards of varying risk levels.
DANGER!
Indicates an imminently hazardous situation, which if not avoided, WILL result in death or
serious injury.
WARNING!
Indicates a potentially hazardous situation, which if not avoided, MAY result in death or
serious injury.
CAUTION!
Indicates a potential hazardous situation, which if not avoided, COULD result in minor or
moderate injury. Also may caution against unsafe practices.
Note that all hazard notifications and notes are presented enclosed in a rectangle with filleted
(round) corners, as shown below, in order to differentiate them from the main text.
It is of utmost importance to observe all CAUTIONS and WARNINGS presented in this manual to avoid
injury, death, and damage to the equipment. Failure to properly heed safety warnings and cautions may
result in the voiding of applicable warranties.
WARNING!
Never use flames to detect gas leaks!
What 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 or, if you are outside, your cell
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
WARNING!
This boiler has been built for installation in the country indicated on the technical data plate.
Installation in any other country may be a source of danger for people, animals and
property.
NOTE:
Carefully read the warranty conditions and clauses on the warranty certificate attached to the
boiler.
OMM-0095_0H
GF-139
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
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Modulex EXT Light Commercial Series Boilers User Manual
CHAPTER 1: Safety Precautions
Important – For Massachusetts Installations
Boiler Installations within the Commonwealth of Massachusetts must conform to the following
requirements:
•
Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of
Massachusetts.
•
Prior to unit operation, the complete gas train and all connections must be leak tested using a noncorrosive soap.
•
If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed
upstream of the Fill/Makeup Valve.
•
The vent termination must be located a minimum of 4 feet above grade level.
•
If side-wall venting is used, the installation must conform to the following requirements extracted
from 248 CMR 5.08 (2):
A. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or
structure used in whole or in part for residential purposes, including those owned or operated by
the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet
above finished grade in the area of the venting, including but not limited to decks and porches,
the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the
side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional level of the dwelling, building
or structure served by the side wall horizontal vented gas fueled equipment. It shall be the
responsibility 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 the requirements of this subdivision can not be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as
required in accordance with the above provisions shall comply with NFPA 720 and be
ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior
of the building at a minimum height of eight (8) feet above grade directly in line with the
exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled
equipment shall not approve the installation unless, upon inspection, the inspector observes
carbon monoxide detectors and signage installed in accordance with the provisions of 248
CMR 5.08(2)(a)1 through 4.
(Continued on Next Page)
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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
OMM-0095_0H
GF-139
Modulex EXT Light Commercial Series Boilers User Manual
CHAPTER 1: Safety Precautions
Important - For Massachusetts Installations
(Continued from Previous Page)
B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 to 4:
1. The equipment listed in Chapter 10 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 room or
structure separate from the dwelling, building or structure used in whole or in part for
residential purposes.
C. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED:
When the manufacturer of Product Approved side wall horizontally vented gas equipment
provides a venting system design or venting system components with the equipment, the
instructions provided by the manufacturer for installation of the equipment and the venting system
shall include:
1. Detailed instructions for the 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
venting systems", the following requirements shall be satisfied by the manufacturer:
1. The identification of each "special venting system" shall include the listing of either the
website, phone number or manufacturer’s address where the venting system installation
instructions can be obtained; and
2. The "special venting systems" shall be Product Approved by the Board, and the
instructions provided with the system shall include a parts list and detailed installation
instructions.
E. A copy of all installation instructions for the Product Approved side wall horizontally vented gas
fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting
design instructions shall remain with the appliance or equipment at the completion of the
installation.
[End of Extracted Information From 248 CMR 5.08 (2)]
OMM-0095_0H
GF-139
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
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CHAPTER 1: Safety Precautions
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Phone: 800-526-0288
OMM-0095_0H
GF-139
Modulex EXT Commercial Series Boilers User Manual
CHAPTER 2: General Information
CHAPTER 2: GENERAL INFORMATION
2.1 CORRECT USE OF THE APPLIANCE
The MODULEX EXT Commercial boiler has been designed utilizing the latest heating
technologies and in compliance with current safety regulations. However, if not used or
operated properly, the unit may cause injury or death to persons, or serious damage to the
equipment or surrounding objects.
The MODULEX EXT Commercial boiler is designed to be used in pumped hot water central
heating systems. Any other use of this appliance shall be considered improper, and AERCO
declines any responsibility for damages or injuries caused by the improper use of this
equipment. In order to use the equipment appropriately and safely according to its design, it is
essential to carefully follow the instructions in this manual.
2.2 WATER TREATMENT
•
•
•
•
•
It is vital to maintain the pH of boiler water between 6.5 and 8. Failure to do so could result in
severe damage to the boiler.
The hardness of the main water supply influences the frequency with which the heat
exchanger must be cleaned.
In hard water areas where the main water can exceed 15°F total hardness, a scale reducing
device is recommended.
In order to improve the resistance to lime scale it is recommended that the domestic hot water
temperature be as near as possible to the temperature required for end use.
AERCO recommends inspecting the state of cleanliness of the domestic hot water heat
exchanger 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 made available to the end user, together with any other literature
regarding this appliance. It is highly recommended that the user keep these documents in a
safe and convenient place in order to always have them at hand for future reference.
It is imperative that a proper venting and exhaust system be implemented with this unit. Refer
to the AERCO Venting Application Guide (GF-136-V).
It is absolutely forbidden to make any alterations to the boiler not in keeping with the
manufacturers recommendations and instructions.
It is critical to check the system’s water pressure and ensure it is at the correct pressure.
For optimal operation of time and temperature controls, thermostats, heating controls, and
radiators, refer to separate E8 Controller User Manual (GF-136-C).
It is obligatory to carry out comprehensive maintenance services annually with a combustion
analysis every two years (in compliance with national and local laws).
If the appliance is sold or transferred to another owner, or if the present user moves from the
installation site and leaves the appliance installed, ensure that the manual stays with the boiler
so that it can be consulted by the new owner and/or installer.
OMM-0095_0H
GF-139
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 2: General Information
Failure to follow the instructions indicated in this manual, which is supplied with the boiler,
could cause injury to persons, animals or damage to property. The manufacturer shall not
be held liable for any such injury and/or damage.
2.4 SAFETY WARNINGS
WARNING!
Children must be supervised so they do not play on, around, or with the appliance.
The installation, adjustment, and servicing of this appliance must be carried out by a
competent person and installed in accordance with the current standards and regulations.
Failure to correctly install this appliance could cause injury to persons, animals or
damage to property. The manufacturer shall not be held liable for any injury and/or
damage.
Servicing or repairs of the appliance must be carried out by AERCO authorized service
technicians; AERCO recommends drawing up a service contract.
Incomplete,
inappropriate, or irregular servicing could compromise the safe operation of the
appliance, and could cause injury to persons, animals or damage to property for which
AERCO shall not be held liable.
2.5 MODIFICATIONS TO PARTS CONNECTED TO THE APPLIANCE
Do NOT carry out any modifications to the following parts:
•
The boiler
•
To the gas, air, water supply pipes and electrical power
•
To the 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 only properly sized
wrenches. The improper use of inadequate equipment can cause damage (for example,
water or gas leakages) to the equipment.
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Phone: 800-526-0288
OMM-0095_0H
GF-139
Modulex EXT Commercial Series Boilers User Manual
CHAPTER 2: General Information
2.6 FOR APPLIANCES OPERATING WITH PROPANE GAS
Before installing the appliance, ensure that the gas tank has been purged. For correct
instructions on purging the tank, contact the liquid gas supplier or a competent person who is
legally authorized to provide such information. If the tank has not been correctly purged,
problems may occur during ignition. If this happens contact the liquid gas tank’s supplier.
WARNING!
Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or
any other appliance..
WHAT TO DO IF YOU SMELL GAS:
•
•
•
•
•
Do not try to light any appliance.
Do not touch any electrical switch.
Do not use any phone in the building.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
If you cannot contact your gas supplier, call the fire department.
WARNING!
The boiler must be protected against environmental variations with:
The insulation of the hydraulic pipelines and the condensate drain.
The adoption of specific antifreeze products in the Cold/Hot water installation.
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CHAPTER 2: General Information
2.7 DATA PLATE
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.
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 2: General Information
2.8 OPERATIONAL REQUIREMENTS
2.8.1 General Requirements
The following instructions MUST be followed:
•
The boiler must only be used for its designated purpose as described in these installation
instructions.
•
Each unit is fitted with a data plate. Consult the details on this plate to verify whether the
boiler is compliant with its intended location, e.g.: gas type, power source, and venting
classification.
•
Only use the boiler with the accessories and spare parts listed.
•
Other combinations of accessories and products must only be used if they are specifically
designed for the intended application and do not affect the system performance or the
safety requirements.
•
Maintenance and repairs must only be performed by trained professionals.
•
Installation of a condensing gas boiler must be approved per all federal and local
government codes, regulations, and laws.
•
Operation of a condensing gas boiler must use a vent system that has been specifically
designed and approved for this type of boiler.
•
Note that local permission and 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.
•
Technical rules laid down by the gas utility company concerning the connection of the gas
connection to the local gas mains.
•
Instructions and standards concerning the safety equipment for the water/space heating
system.
•
Installation instructions for building heating systems.
•
The boiler must be located in an area where leakage of the boiler or connections will not
result in damage to the area adjacent to the boiler or to lower floors of the structure. When
such locations cannot be avoided, it is recommended that a suitable drain pan be installed
under the boiler.
•
Do not restrict or seal any air intake or outlet openings.
•
If you find any defects, you must inform the owner, in writing, of the system defect and the
associated hazard.
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CHAPTER 2: General Information
WARNING!
Should overheating occur, or the gas supply fail to shut off, do not turn off or disconnect
the electrical supply to the pump. Instead, shut off the gas supply at a location external to
the boiler.
2.8.3 Water Quality Requirements
NOTE:
For additional information concerning water quality and treatment, refer to AERCO technical
documents Glycol Directive and AERCO Piping Application Guide (GF-136-P).
Unsuitable heating system water can cause the formation of scale or sludge, which affects
system efficiency. It can also cause corrosion and reduce life of the heat exchanger.
•
•
•
•
You must follow guidelines for boiler water quality.
Thoroughly flush the system prior to filling.
Follow the cleaning instructions.
Never use water to fill the heating system that has been treated by reverse osmosis,
deionization, or distilled water in order to soften the water.
• Do not use inhibitors or other additives unless approved by AERCO for that purpose.
• When frost protection of the heating system is desired, only use AERCO-approved
antifreezes. The allowed maximum concentration is 50%.
• When using oxygen-permeable pipes, e. g. for under floor heating systems, you must
separate the system from the boiler 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 (available from AERCO)
• Noble Noburst Hydronic System Cleaner
• Fernox F3 Cleaner
• Rhomar Hydro-Solv 9100
The system cleaners from NoBurst, Rhomar, and Fernox are NOT to be used in the boiler itself.
The boiler must be closed off (valves closed) from the rest of the system or not connected while
the cleaners are in the system. The system should then be drained and then thoroughly flushed
with clean water to remove all the system cleaner.
Approved inhibitors:
•
•
•
•
•
Sentinel X100 (available from AERCO)
Rhomar Pro-tek 922
Noble Noburst AL inhibitor
Intercool NFP-AA
Cryo-tek 100/Al
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 2: General Information
2.9 TOOLS, MATERIALS, AND ADDITIONAL EQUIPMENT
For the installation and maintenance of the boiler you will need:
•
•
•
•
•
•
•
Standard tools for space heating, gas, and water fitting
Manometer that is capable of reading both positive and negative pressures
Combustion analyzer
Digital multimeter
pH digital meter
Metric Allen wrenches
Metric socket wrenches
2.10 DISPOSAL OF PACKAGING AND PARTS
•
•
Dispose of the boiler packaging in an environmentally sound manner.
Dispose of components of the heating system (e.g. boiler or control device), that must be
replaced in an environmentally responsible manner.
2.11 GENERAL WARNINGS
2.11.1 Using the Operation and Maintenance Manual
This instruction manual is an integral and indispensable part of the product and must be
retained by the person in charge of the appliance. Please read the instructions contained in this
manual carefully as they provide important information regarding the safe installation, use and
servicing of this appliance. Keep this manual in a safe place for future reference.
2.11.2 Installation and Servicing Personnel
Installation and servicing must be carried out in accordance with the regulations in force
according to the manufacturer’s instructions and by legally competent authorized persons. By
definition, a competent person is a person who has a specific technical qualification in the field
of components for central heating systems for domestic use, domestic hot water production, and
servicing. This person must have the qualifications legitimized by the current laws and
regulations in force.
Inappropriate, incomplete, or irregular servicing could compromise the safe operation of the
appliance, and could cause injury to persons, animals or damage 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 and using only original spare
parts. Non-observance of the above requirement may jeopardize the safety of 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, but instead contact qualified technicians.
To guarantee the efficiency and correct functioning of the appliance it is required that the boiler be
serviced annually by a qualified person.
2.11.3 Installation Materials
The installations for the domestic hot water production MUST be built, in their entirety, with
materials (taps, pipes, fittings, etc.) approved for drinkable water.
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CHAPTER 2: General Information
2.11.4 Preparing Boiler for Servicing
Before carrying out any cleaning or servicing turn off the electrical supply to the boiler by means
of the ON/OFF switch and/or by means of the appropriate shutdown devices.
2.11.5 Returning a Boiler to Service
Before putting a boiler, which has been unused for a length of time, back into service, rinse the
entire domestic hot water system, allowing the water to flow an appropriate amount of time in
order to circulate throughout the entire system.
2.11.6 Change in Ownership
If the appliance is sold or transferred to another owner, or if the present user moves from the
installation site and leaves the appliance installed, ensure that the manual stays with the
appliance so that it can be consulted by the new owner and/or installer.
2.12 OPERATIONAL LIMITS OF THE BOILER
•
Max. boiler temperature: 180° F (80° C)
•
Max Allowable Working Temperature ASME: 200 °F
•
Max. Allowable Working Pressure ASME: 92 psi
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 3: Technical Features & Dimensions
CHAPTER 3: TECHNICAL FEATURES & DIMENSIONS
3.1 MODULEX EXT COMMERCIAL TECHNICAL FEATURES
•
•
•
•
•
•
•
•
•
•
Compact, gas fired, Low NOx, condensing boiler.
•
•
One gas supply line.
Comprised of one sectional boiler body, suitable as a single boiler or in a cascaded group.
May be installed in either an inside or outside location.
Low internal water volume.
Fast response to load variations.
Flue exhaust outlet positionable on three sides.
Manifold delivery and return.
Made up of four or more heating elements (4 to 8), cast aluminum / silicon / magnesium.
Full range of modulation by variable speed blowers and premix burners.
Each heating element monitors its own water temperature, and will individually shutdown
if flow is interrupted, without affecting the other burner sections.
Individual modules capable of between 83 and 382.5 kBTU/hr.
These boilers are designed for use with category IV venting.
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 (General)
• Return NTC sensor (General)
3.1.2 Control Panel (E8) Includes:
• ON-OFF switch
• Temperature control / Boiler operation
• Fuses
• High limit sensors
•
•
Safety thermostat approved (manual
reset)
Flow sensor BCM
•
•
•
Air pressure fans
Condensate level sensor
Air pressure switch (anti-obstruction)
3.1.3 Other Features Include:
• NTC heat sensors for global temperature control on the flow and return.
• 0-10 V output to control variable speed primary pump
• Integral insulation with hypoallergenic synthetic wool.
•
•
Premix fiber mesh modulating burner (premixes into the fan with automatic diaphragm
backflow separation from the combustion chamber).
Less than 49 dBA of noise at maximum power.
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CHAPTER 3: Technical Features & Dimensions
•
•
Heating operation: instantaneous power microprocessor control, with preset parameters for
comparison between temperature (or calculated from the external temperature regulation) and
global temperature flow.
Operation modes:
o Ability to control power to the individual heating elements for any calibration with or
without confidential code access.
o
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Production of A.C.S. (Active Cooling System) by NTC sensor of priorities for control by
boiler feed pump or by three-way diverter valve controller.
E8 electronic controller included.
BCM (Boiler Communication Module) included.
Ability to control power of the individual heating elements.
Control of heat demand: constant or remote setpoint.
Monitoring of operating status and temperature.
Reporting of alarms.
Setting of parameters.
Emergency operation prevents the boiler from shutting down as a result of the interruption of
communication with a control system or any remote control unit.
Alarm management.
Alarm reset input.
Warning alarm relay.
Stainless steel condensate collector tank with siphon, drain trap, and smoke chamber.
Easily removable stainless steel panels painted for outdoor installation.
Built-in air vent
3.2 GENERAL BOILER OPERATION
The boiler may be operated from the E8 controller or alternatively from a BCM (Boiler Cascade
Manager). The boiler management logic automatically 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 costs.
The hot water moved by the pump is pushed to the return of the primary flow of the hydraulic
separator. From here a second pump will distribute the hot water to the various destinations.
The cooled return water is drawn by the pump through the hydraulic separator to resume the
cycle via the boiler.
WARNING!
If installing to an outdoor location where freezing temperatures may occur, it is necessary
to install devices and/or materials to prevent any freezing in the condensate drain and the
Flow and Return manifolds. Failure to do so may cause serious damage to the
equipment.
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 3: Technical Features & Dimensions
3.3 DIMENSIONAL DRAWINGS
Figure 3-1: MODULEX EXT Commercial Dimensional Drawings
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CHAPTER 3: Technical Features & Dimensions
TABLE 3-1: MODULEX EXT Commercial Dimensions and Sizes
EXT
1530
1500
EXT
1912
EXT
2295
2300
EXT
2677
2600
EXT
3060
3000
(*) DN 80 – 3” ASME B16.5 Flange 150 lbs./sq. inch
(*) DN 100 – 4” ASME B16.5 Flange 150 lbs./sq. inch
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 3: Technical Features & Dimensions
Figure 3-2: MODULEX EXT Commercial Main Components (Left Side View)
•
•
•
•
•
•
Flue Exhaust connection is located on the RIGHT HAND side (supply condition),
but may be moved to LEFT or REAR positions.
Air Intake connection is located on the LEFT HAND side.
Condensate Evacuation connection is located on the RIGHT HAND side.
Cold/Hot Flow connection is located on the LEFT HAND side.
Cold/Hot Return connection is located on the LEFT HAND side.
Gas Connection is located on the LEFT HAND side.
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CHAPTER 3: Technical Features & Dimensions
3.4 PERFORMANCE DATA
TABLE 3-2: MODULEX EXT Commercial Performance Data
EXT
1530
1500
MODULEX EXT MODEL
EXT
1912
EXT
2295
2300
EXT
2677
2600
EXT
3060
3000
NOTE:
The Technical data plate is placed under the casing. See section 2.7 for more information.
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 4: Installation Instructions
CHAPTER 4: INSTALLATION INSTRUCTIONS
4.1 INSTALLATION WARNINGS AND REQUIREMENTS
4.1.1 Appropriate Use of the Boiler
This boiler MUST be used in the application for which it has been expressly designed. Any other
use shall be considered improper and therefore dangerous. This boiler is designed to heat water
at a temperature below the boiling point at atmospheric pressure.
4.1.2 Prerequisite System Flushing
Before installing the boiler the following actions MUST be carried out by a competent engineer
or technician:
a) The whole system should be thoroughly flushed in order to remove any residual dirt or
grime which could compromise correct boiler operation.
b) Check that the boiler has been preset for operating with the gas type available. This is
verifiable via the data badge.
c) Check that the flue pipe has an adequate draft, does not have any constrictions or
obstructions, and that no other appliance’s flue outlets have been fitted, unless the flue
pipe is serving more than one heating appliance, according 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.
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 servicing
clearances are provided. The boiler must be connected to a heating system which is compatible
to its performance and output.
FOR MASSACHUSETTS INSTALLATIONS: The boiler MUST be installed by a plumber or gas
fitter licensed within the Commonwealth of Massachusetts.
4.1.4 Carbon Monoxide Detector Installation
Installers MUST follow local regulations with respect to installation of Carbon Monoxide (CO)
Detectors. Also, they must follow the maintenance recommendations in this manual.
4.1.5 Installation Conformity Requirements
The installation MUST conform to the requirements of the authority having jurisdiction or, in the
absence of such requirements, to one of the following:
•
•
•
United States: Installation must conform to the requirements of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54.
Canada: Installation must conform to the requirements of CAN/CSA-B149.1 - Natural Gas
and Propane Installation Code
Where required by the authority having jurisdiction, the installation must conform to the
Standard ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers.
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CHAPTER 4: Installation Instructions
4.2 CODE AND STANDARDS APPROVALS
The MODULEX EXT boiler has been reviewed for compliance with the applicable sections of
the following North American Standards:
•
•
•
•
•
ANSI Z21.13/CSA 4.9: Gas-fired low pressure steam and hot water boilers
ASME SECTION IV: ASME Boiler and Pressure Vessel Code with addenda, Section IV:
Rules for Construction of Heating Boilers
BTS – 2000: Testing standard method to determine efficiency of commercial space
heating boilers.
SCAQMD RULE 1146.2: Emissions of oxides of nitrogen from large water 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, the unit
can be moved through a standard 36” doorway.
Figure 4-1: MODULEX EXT Shipping Package and Included Parts Location
TABLE 4-1: MODULEX EXT Shipping Package Dimensions
MODEL
A
B
C
GROSS WEIGHT
EXT 1530 / 1500
49.3‘‘
(1252 mm)
44.8‘‘
(1140 mm)
82.4‘‘
(2095 mm)
1289 lb.
(585 kg)
EXT 1912
59.8”
(1531 mm)
44.8‘‘
(1140 mm)
82.4‘‘
(2095 mm)
1417 lb.
(643 kg)
EXT 2295 / 2300
59.8”
(1531 mm)
44.8‘‘
(1140 mm)
82.4‘‘
(2095 mm)
1558 lb.
(707 kg)
EXT 2677 / 2600
71.6‘‘
(1819 mm)
44.8‘‘
(1140 mm)
82.4‘‘
(2095 mm)
1776 lb.
806 kg
EXT 3060 / 3000
71.6‘‘
(1819 mm)
44.8‘‘
(1140 mm)
82.4‘‘
(2095 mm)
1891 lb.
(858 kg)
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 4: Installation Instructions
4.4 TRANSPORTING AND SECURING THE BOILER SAFELY
The boiler is susceptible to serious damage when not secured properly.
•
Follow the transportation instructions on the packaging.
•
Only transport the boiler using appropriate transportation equipment, such as a hand-truck
with a fastening belt or special equipment for transporting heavy equipment.
•
When moving the boiler, it must be secured on the transportation equipment to prevent it
from falling off.
•
Protect all parts against impacts during transportation.
4.5 UNPACKING THE BOILER
CAUTION!
The packing elements (cardboard box, straps, plastic bags, etc.) should be kept away from
children to prevent suffocation and choking hazards. AERCO refuses all liability for injury to
persons, animals or damage to property derived from not respecting the above mentioned
recommendations.
Refer to panels 1-6 of Figure 4-2 while unpacking per these instructions:
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 both packing straps (Panel 2) and, finally, the cardboard box from above (Panel 3),
making sure the product is intact.
3. For the removal of the boiler from the pallet it is necessary to have a jib crane (Panel 5), to
avoid damage to the boiler during the removal.
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CHAPTER 4: Installation Instructions
4. To prepare the boiler for lifting by the hoist, remove panel covers from front, rear, right, left
and top (Panel 6).
5. Use the four hoist straps (Panel 5) as slings and place one under each of four boiler legs
ensuring that strap is located UNDER the cross bars of the frame as shown in Panel 6.
6. Ensure belts are placed correctly on all four boiler legs before attempting to lift it.
4.6 BOILER PACKAGE CONTENTS
In the packaging, in addition to the boiler, you will also find the following contents:
ON THE LEFT HAND SIDE OF BOILER (UNDER PANEL)
•
CSD-1 manifold.
CARDBOARD BOX #1
• Gasket between exhaust manifold and adaptor
• Four (4) piping elbows, a piping tee, and plastic plug
for condensate draining system
• Hardware for assembling exhaust manifold
• Three (3) sensors:
o Remote temperature sensor
o DHW Storage tank sensor
o Outdoor temerature 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
connections
• One (1) 300 mm diameter gasket
and
Box #2
Flue Parts
CSD-1
Manifold
exhaust
INSIDE CASING ON THE BACK OF THE BOILER
• Two (2) pipes, each 39.3 feet (1 m) long for the
condensate draining system
ABOVE THE TOP COVER OF THE BOILER
•
A plastic bag containing:
o This installation and user manual for the installer.
o E8 controller instruction manual.
IN A SEPARATE BOX
•
•
•
•
Air intake adaptor for spiral ducting only
Temperature & Pressure gauge
Flow Switch
Pipe adaptor (rubber)
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 4: Installation Instructions
4.7 BOILER LOCATION IN A BOILER ROOM
Special attention shall be paid to local regulations and laws about boiler enclosures and boiler
rooms, particularly to the minimum clearances around the boiler. The installation shall be in
compliance with all the latest regulations and laws about boiler enclosures, boiler rooms,
installations of heating and hot-water systems, ventilation, vents capable of exhausting the flue
gases of condensing boilers, and any other applicable requirements.
The boiler can be put on a flat and sufficiently strong base with the same dimensions as the
boiler and at least 3.93’’ (100 mm) high (see Figure 4-3), in order to assemble the condensate
trap. An alternative to this base may be a 100 mm deep well or trench next to the boiler to
accommodate the condensate “U” drain pipe (see Figure 4-3). After installation the boiler shall
be perfectly horizontal and stable, to reduce any possible vibrations or noises.
Flue Manifold
European-to-USA
Flue Adapter
Well or Trench for Condensate Drain Pipe
Boiler Housekeeping
Pad (Support Base)
Condensate Drain Pipe
At Least
4” (100mm)
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 please comply with the following
safety requirements:
• Ensure easy access to the components of the boiler to facilitate maintenance.
• The room where the boiler will be placed must always be frost free.
• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or
any other appliance.
• Never use or store any chlorinated detergents or halogenated hydrocarbons (e.g. in
spraycans, solvents and detergents, paints, adhesives) in proximity to the boiler.
• For outdoor installation see Warning for Outdoor installation on page 10.
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CHAPTER 4: Installation Instructions
4.7.2 Products to Avoid in the Boiler Room
Do NOT store the following products in the boiler room and/or around combustion air intake
vents.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Spray cans containing chlorocarbons/fluorocarbons
Ammonium and/or ammonium solutions
Permanent wave solutions
Chlorinated waxes and/or cleaners
Chlorinated swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic 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 flammable products
4.8 RECOMMENDED CLEARANCES FOR SERVICING
Recommended clearances around the boiler are listed below (see Figure 4-4):
TOP of the boiler:
24‘‘ (600 mm)
FRONT of the boiler:
24’’ (600 mm)
UNVENTED side:
24’’ (600 mm)
VENTED side:
32’’ (600 mm)
FLOOR/GROUND:
4’’
REAR of the boiler:
24’’ (600 mm)
FLOOR/GROUND:
4’’
(100 mm)
(100 mm)
Figure 4-4: MODULEX EXT Boiler Clearances
It is recommended to provide the boiler with the clearances as shown in the drawing in order to
be able to perform normal service and cleaning operations. Minimum required clearances
depend on the piping and venting configuration. For further details, contact your loal
manufacturer’s representative.
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Phone: 800-526-0288
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 4: Installation Instructions
4.9 GAS CONNECTION GENERAL INFORMATION
For natural gas connections, refer to Section 4.9.1. For propane gas connections, refer to
Section 4.9.2.
The gas supply connection must comply with local regulations or, if such regulations do not
exist, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
An external gas pressure regulator is mandatory for the State of Massachusetts, regardless of
supply pressure; for all other jurisdictions, a lock-up style regulator is required when supply
pressure is greater than 10.5” W.C. (see Fig. 1). The regulator must be installed with at least 2
feet of pipe between the regulator and the unit gas inlet. The regulator discharge range must
able to maintain 3.5” W.C. Gas 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 comply with local regulations or, if such regulations do not
exist, with the CAN/CSA-B149.1 - Natural Gas and Propane Installation Code.
Before installing the boiler it is recommended that all the supply piping be thoroughly cleaned in
order to remove any residual grime which could compromise the boilers correct functioning.
As a safety measure against gas leaks, AERCO recommends installing a surveillance and
protective system made up of a gas leakage detector combined 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 supply piping system at test pressures
equal to or less than 1/2 PSI (3.5 kPa).
Clause 1.34.1b.12: Provisions for combustion and ventilation air in accordance with the section
“Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or
Sections 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or
applicable provisions of the local building codes.
Clause 1.34.1b.21: A sediment trap must be provided upstream of the gas controls.
WARNING!
THE GAS CONNECTION MUST BE INSTALLED BY A REGISTERED INSTALLER
WHO MUST COMPLY WITH THE REGULATIONS IN FORCE AND TO THE
REQUIREMENTS INDICATED BY THE LOCAL GAS SUPPLIER. AN INCORRECT
INSTALLATION CAN CAUSE INJURY OR DEATH TO PERSONS, ANIMALS OR
DAMAGE TO PROPERTY. THE MANUFACTURER SHALL NOT BE HELD LIABLE FOR
ANY INJURY AND/OR DAMAGE DUE TO INAPPROPRIATE INSTALLATION.
Do not use the boiler for another type of gas than indicated on the identification plate of
the boiler. This will cause improper functioning and can damage the boiler. The suitable
gas type for the boiler is indicated on the packaging label and on the data plate boiler.
First check the identification plate on the boiler for the suitable gas type.
Always check the safety of the gas pipe system by means of a soap bubble test using a
leak-search spray.
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CHAPTER 4: Installation Instructions
4.9.1 Natural Gas Connections
4.9.1.1 Natural Gas Piping Sizes
Contact your local gas supplier for natural gas pipe sizes and meter types.
4.9.1.2 Natural Gas Piping Connections
The boiler gas pipe is equipped with external 3’’ ASME B16.5 flange, onto which the tail
piece of the gas shut off valve can be connected. Use appropriate sealing.
The connection to the boiler must include a suitable method of disconnection and a gas
control valve must be installed adjacent to the boiler for isolation purposes.
4.9.1.3 Natural Gas Supply Pressure Requirements
The nominal inlet working gas pressure measured at the boiler should be 7” W.C. (18 mbar)
for natural gas. Maximum pressure with no flow (lockup) or with the boiler running is 10.5
inches W.C. Minimum pressure with gas flowing (verify during boiler startup) is 4.0 inches
W.C.
4.9.2 Propane Gas Connections
4.9.2.1 Propane Gas Piping Sizes
Contact your local gas supplier for Propane gas pipe sizes, tanks, and 100% lockup gas
pressure regulator.
4.9.2.2 Propane 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 provide upstream of the
gas controls.
4.9.2.3 Propane Gas Supply Pressure Requirements
Pressures required at gas valve inlet pressure port:
•
•
•
Nominal gas pressure is 11 inches W.C.
Maximum gas pressure is 13 inches W.C. with no flow (lockup) or with boiler
running.
Minimum gas pressure is 8 inches W.C. with gas flowing (verify during boiler
startup).
NOTE:
Ensure that the high gas pressure regulator is installed at least 6 to 10 feet upstream of the boiler.
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 4: Installation Instructions
4.10 FLOW AND RETURN PIPE CONNECTIONS
The cold and hot water flow and return circuits must be connected to the boiler via the
respective 4” M and R connections as indicated in Table 2-1.
When determining the size of the cold/hot water circuit pipes it is essential to bear in mind the
pressure losses induced by any of the system’s components and by the configuration of the
system.
When planning the routing of the cold/hot water piping, take the necessary precautions to avoid
air traps and pockets and to facilitate the continuous purging of the system.
WARNING!
Before installing the boiler we recommend that the system is flushed out with a suitable
cleaning product in order to eliminate any metallic tooling or welding residues, or oil and
grime, which could reach the boiler and affect the proper functioning of the boiler.
Ensure that the system piping is NOT used for earth grounding of electrical or telephone
systems. Such grounding of system piping is unsuitable and can cause serious damage
to the piping, boiler, and radiators.
IT IS ABSOLUTELY FORBIDDEN TO FIT ON-OFF VALVES IN THE PIPING BEFORE
THE REQUIRED SAFETY DEVICES.
4.11 PRESSURE RELIEF VALVE
Each unit is delivered with a 1-1/2 inch, 80 psi Pressure Relief Valve that complies with the
ANSI/ASME ANSI Z21.13 / CSA 4.9 Boiler and Pressure Vessel Code, Section IV (‘’Heating
Boilers’’), and CSA B51, Boiler, Pressure vessel, and Pressure Piping Code, as applicable.
NOTE:
Lower system pressures require lower rated Pressure Relief Valves (not supplied).
On newer EXT models (with aluminum headers) the Pressure Relief Valve is factory installed
inside the chassis.
IMPORTANT!
Discharge piping MUST be installed at the relief valve discharge. The discharge piping must
be installed in accordance with localcodes.
On older models, the Pressure Relief Valve is not factory installed, but instead 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, 4.12 (see Figure 4-6).
(Image removed)
Figure 4-5: Pressure Relief Valve
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CHAPTER 4: Installation Instructions
4.12 CSD-1 MANIFOLD ASSEMBLY (SUPPLIED)
The installation of a flow switch and pressure/temperature gauge are required. A 1-1/2”
Pressure Relief Valve designed for the boiler output capacity must also be installed:
• On newer models (with aluminum headers), the 1-1/2” Pressure Relief Valve is preinstalled inside the boiler chassis at the factory.
•
On older units, the 1-1/2” Pressure Relief Valve must be installed on-site (see Step 4).
These components are supplied with the boiler and must be assembled and wired when the
boiler is installed at the site. The manifold components are shown installed into the CSD-1
manifold in Figure 4-6. The manifold assembly components supplied are:
•
•
•
1-1/2” Pressure Relief Valve – must be installed on older models only
Flow Switch
Pressure/Temperature Gauge
The pressure relief valve and all other manifold components are shown in Figure 4-6.
1-1/2” Pressure Relief Valve
Flow Switch
Pressure/
Temperature
Gauge
OLDER MODELS
NEWER MODELS
Figure 4-6: CSD-1 Manifold Assembly and Components
Complete the instructions below to install the pressure relief valve and the other components.
NOTE:
Use Teflon tape or a suitable pipe joint compound for component and piping connections
described in the following steps. Refer to Figure 4- 6 for component identification.
Installing the Pressure Relief Valve and Flow Switch
1. Attach manifold to the outlet supply connection on the boiler via the flanged connections.
2. Cut the flow switch paddle for 4” pipe, as directed in the flow switch paddle packaging. For
installations expecting less than a 10 gpm flow, the switch must be adjusted as follows:
a)
With 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.
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CHAPTER 4: Installation Instructions
Installing the Pressure Relief Valve and Other Components – Continued
3. Connect the following components to the tapped holes in the manifold assembly, as shown
in Figure 4-6, above:
•
Flow Switch
•
Pressure/Temperature Gauge
NOTE:
It is important to ensure that the flow switch be installed with the “flow” arrow pointing in the
direction of the flow.
4. On older models only, also install the 1-1/2” Pressure Relief Valve to the third tapped hole
in the CSD-1 manifold assembly, as shown in Figure 4-6, above.
5. Check to ensure that all components are securely tightened and that the flow switch
paddle moves freely without interference.
6. Locate the BMM module with the “FL” label (Figure 4-7), and remove the black jumper
wire from the terminals of the connector shown in the detail of Figure 4-7. Connect the two
flow switch wires to the two terminals. Flow switch wires have no polarity, so can be
inserted without regard to position.
DETAIL
Terminal Connector
Remove this black jumper and
insert the two wires from the flow
switch into terminal connector.
Figure 4-7: BMM 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.
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CHAPTER 4: Installation Instructions
TABLE 4-2: MODULEX EXT Minimum/Maximum Flow Rates
BOILER MODEL
EXT
1530/1500
EXT
1912
EXT
2295/2300
EXT
2677/2600
EXT
3060/3000
Min. flow rate demanded
in gpm ∆T 27°F (15°C)
5
5
5
5
5
Min. flow rate demanded
in gpm ∆T 36°F (20°C)
4
4
4
4
4
Max flow rate demanded
in gpm ∆T 27°F (15°C)
102
128
153
179
205
Max flow rate demanded
in gpm ∆T 36°F (20°C)
77
96
115
134
153
The water side resistance curve of the boiler is shown in the diagram in Figure 4-8.
The pump is not an integral part of the boiler. It is recommended to choose a pump with the rate
and delivery head at about 2/3 of its characteristic heating curve.
EXT
1530
1500
EXT
1912
EXT
2295
2300
EXT
2677
2600
EXT
3060
3000
Figure 4-8: 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, the condensate piping
must slope toward the drain at least 3/8 inch per foot (30 mm/m).
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CHAPTER 4: Installation Instructions
The liquid column, inside the condensate siphon, (see Condensate Siphon Filling Plug in Figure
4-9) needs to be filled with water after installation. The minimum height of the water in the
column, when all the fans are in operation, must be at least 25 mm (1 in.).
In order to avoid ice formation while the boiler is operating, which can cause the boiler to stop
functioning, the entire condensate evacuation system must be well insulated. Note that it is
forbidden to evacuate the condensate through an open gutter to prevent the risk of ice forming
and avoid exposure of the corrosive condensate to the external environment.
The condensate must be neutralized before being evacuated to the sewer, which 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 through a closed, but visible drain. Given the high acidity
(pH 3 to 5) of the condensate, only plastic material may be used for the condensate evacuation
pipes. Moreover it must be dimensioned and constructed so as to allow the correct out-flow to
the drain, preventing any bottleneck and any leakage.
Consult local codes regarding condensate neutralization. Neutralization may be obtained by
mixing it with the buildings drain water or with limestone, which normally has a base pH.
AERCO International 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 4-9: 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 outlet opening.
IMPORTANT!
If it is not possible to use a 4’’ (101mm) base or housekeeping pad on which to place the
boiler, install the boiler on the floor and provide a well or trough (minimum of 4’’ - 101 mm
deep) in which to lodge the U of the condensate piping. See Figure 4-9.
WARNING!
•
•
Before commissioning the boiler, fill the condensate siphon with water, at the
dedicated filling-up plug. See Figure 4-9.
Do not install the condensate drain where freezing may occur.
Use materials approved by the authority having jurisdiction in your area. In the absence of such
authority, PVC and CPVC pipe must comply with ASTM D1785, F441 or D2665. Cement and
primer must comply with ASTM D2564 or F493. For Canada, use ULC certified PVC or CPVC
pipe, fittings and cement. Periodic cleaning of the condensate disposal system must be
carried out.
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CHAPTER 4: Installation Instructions
4.15 WATER TREATMENT
The chemical/physical composition of the heating system’s water is fundamental for the boiler’s
correct operation and safety.
Among the problems caused by poor quality of feed water, the most frequent and the most
serious is the buildup of deposits on boiler thermal exchange surfaces.
Less frequent, but also serious, are deposits on the water circulating piping surfaces. Because
of the low thermal conductivity of mineralization desposits caused by improperly treated water,
the thermal exchange efficiency may be seriously reduced, and can result in very dangerous
localized overheating.
AERCO suggests treating and conditioning feed water for the heating circuit in the following
cases:
•
•
•
•
•
When the hardness of the water is higher than 9 grains (15°f).
For cold/hot water installations with large water content.
Renewal of the water system due to uncontrolled leakages.
Subsequent refilling of the system due to maintenance work on the installation.
Presence of different metals in the water circuit.
Properly treated system and feed water will eliminate or substantially reduce the following
problems:
•
•
•
•
lime scale deposit
corrosion sludge
deposits
microbiological growths (molds, 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.
Water Hardness: If water hardness is over 6 to 9 grains, a water softener must be used.
Sediment: If sediment is present in the system, a sediment filter or other appropriate device,
must be used.
Water pH: If water has a pH above 8, or below 5, then the water must be treated to provide a
medium pH of between 5 and 8.
The system water to be judged for water characteristics should be taken from the return pipe of
the primary circuit downstream of the circulating pump.
4.16 IMPORTANT INSTALLATION WARNINGS
4.16.1 Oxygen Levels in the System Water Warning
All necessary precautions must be taken for preventing the formation and localization of oxygen
in the system’s water. For this reason, ensure that the plastic piping used in under-floor heating
systems is impermeable to oxygen.
4.16.2 Antifreeze Compatibility Warning
If any anti-freeze solutions are used ensure that they are compatible with aluminum and any
other boiler components and materials.
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4.16.3 Lime Scale and Corrosive Water Damage Warning
Any damage caused to the boiler due to the formation of lime scale or by corrosive water will not
be covered by the warranty. Appropriate steps must be taken to ensure the indirect tank water
heater does not become plugged 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.
4.16.4 Connection to Refrigeration System Warning
The boiler, when used in connection with a refrigeration system, must be installed so the chilled
medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium
from entering the boiler.
The boiler piping system of a hot water boiler connected to heating coils located in air Handling
units where they may be exposed to refrigerated air circulation must be equipped with flow
control valves or other automatic means to prevent gravity circulation of the boiler water during
the cooling cycle.
4.17 OPTIONAL AIR INTAKE CONNECTION
Install air intake connector as shown in Figure 4-10. Use silicone to lubricate the internal surface
of the seals before assembling. For air intake connection piping use only:
•
10” for MODULEX EXT 1530 / 1500, 1912
•
12” for MODULEX EXT 2295 / 2300, 2677 / 2600, 3060 / 3000
The Air Intake Connector that ships with the unit is for spiral ducts only. For other materials,
please contact AERCO directly.
AIR INTAKE PIPING
(NOT SUPPLIED)
AIR INTAKE
CONNECTOR
(SUPPLIED)
Figure 4-10: MODULEX EXT Air Intake Connection
4.18 FLUE MANIFOLD INSTALLATION
To assemble the flue manifold to the boiler flue exhaust opening, retrieve the ten (10) nuts and
washers from the plastic bag, shipped with the boiler, and affix to the boiler opening per Figure
4-11. The Manifold may be installed on left, front, or rear. If switching to left or rear positions,
unused outlet should be covered with the plate and gasket removed from outlet being used.
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CHAPTER 4: Installation Instructions
RECTANGULAR GASKET
WASHERS (10)
NUTS (10)
FLUE MANIFOLD
GASKET FOR ATTACHING
EUROPEAN-TO-USA
FLUE ADAPTER
Figure 4-11: Connection of Exhaust Manifold To Boiler Flue Exhaust Outlet
For venting systems in the USA, it is necessary to assemble the Euro-to-USA adaptor to the flue
manifold as shown in Figure 4-12.
GASKET FOR ATTACHING
EUROPEAN-TO-USA FLUE
ADAPTER
EUROPEAN-TO-USA
FLUE ADAPTER
FLUE MANIFOLD
Figure 4-12: Assembly of USA-to-European Flue Adaptor to Flue Manifold
NOTE:
The gasket may seem large. It is intentionally designed to produce a tight fit.
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CHAPTER 4: Installation Instructions
4.19 FLUE EXHAUST PIPING TO VENT
In a condensing boiler the flue exhaust is evacuated at a very low temperature (maximum of
about 183°F / 84°C). Thus, it is necessary that the chimney be impermeable to the condensate
of the combustion products and be made of corrosion resistant materials.
The different joints must be well sealed and equipped with suitable gaskets in order to prevent
the escape of condensate and prevent the ingress of air.
To determine the proper cross section and height dimensions of the flue exhaust piping, refer to
national and local codes.
In order to prevent 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 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 the installation.
A test nipple, for measuring combustion gases, should be installed onto the first three feet of the
exhaust manifold flue. To do this, a hole with a diameter of 0.83‘‘ is drilled in a convenient
location for testing and the test nipple hardware assembled to the Flue pipe as shown in Figure
4-13.
Figure 4-13: Installation of Test Nipple into Flue Manifold Piping
NOTE:
Damage caused by mistakes in installation, failure to complete the instructions as written, or the
improper use of the flue system are not the responsibility of the supplier.
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CHAPTER 4: Installation Instructions
4.20 VENT STARTER PIECES
All vent starter pieces for the MODULEX EXT 1500 through 3060 can be purchased directly
from the vent manufacturer.
Example Vent Starter Piece
WORM-DRIVEN HOSE CLAMP
SCREWS (8 EACH)
WASHERS (8 EACH)
DIAMETER REDUCTION
ADAPTOR CONNECTOR
GASKET
EUROPEAN-TO-USA
STANDARD FLUE ADAPTER
FLUE MANIFOLD
ACCESS POINT FOR
CLEANING (underneath)
Figure 4-14: Flue Exhaust Diameter Reduction Adaptor Kit
TABLE 4-3: Vent Part Numbers
MODEL
DIA.
EXT 1530 / 1500
EXT 1912
EXT 2295 / 2300
EXT 2677 / 2600
EXT 3060 / 3000
10”
12”
MATERIAL
PART NUMBER
Stainless
Polypropylene
PVC
Stainless
Polypropylene
PVC
Contact vent manufacturer
Contact vent manufacturer
58115-1
Contact vent manufacturer
Contact vent manufacturer
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 non-metallic (plastic) vent systems for Canadian installations,
per CSA B149.1, use vent systems that are certified to the standard for Type BH Gas Venting
Systems, ULC-S636.
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Please note that 10” and 12” PVC can be heavy and expensive. Alternative vent materials, such
as AL29-4C or polypropylene should be considered prior to installation.
The plastic components, primers and glues of the certified vent system must be from a single
system manufacturer and not mixed with other manufacturer’s vent system parts.
The Inspection Port should be plugged with an appropriate plug (not included).
FLUE VENT PIPE
3 feet
(914.4 mm)
INSTALL FLUE
PIPING TO ADAPTER
WITH RTV LIQUID
SILICONE AND
WORM-DRIVEN
HOSE CLAMP
Test Nipple
should be
installed
within first
3 feet of
flue start.
ADAPTER ASSEMBLY
EUROPEAN TO AMERICAN
STANDARD FLUE ADAPTER
Figure 4-15: Installed Flue Exhaust Diameter Reduction Adaptor Kit
4.21 COMBUSTION AIR AND VENTILATION OPENINGS
Provisions for combustion and ventilation 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
BOILER DAMAGE AND OPERATIONAL FAILURES may occur due to insufficient or improper
openings for combustion air and/or ventilation of the boiler room.
Provisions for combustion air and ventilation are always required, regardless of whether the
combustion air is taken from the outside (sealed combustion) or inside (room air used as
combustion air).
Insufficient ventilation of the boiler room can lead to high air temperatures. This can result in
boiler damage. Note the following:
•
•
Make sure that intake and exhaust openings are sufficiently sized and no reduction or closure
of any openings takes place.
When a combustion air or ventilation problem is not resolved, do not operate the boiler.
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CHAPTER 4: Installation Instructions
When one expects contaminated combustion air (near swimming pools, chemical cleaning
operations, hair salons, etc.), sealed combustion operation is recommended.
WARNING!
Fire danger due to flammable materials or liquids. Do not store flammable materials and
liquids in the immediate vicinity of the boiler.
CAUTION!
See Section 4.7.2 for warnings and guidelines concerning materials and contaminants that
should be avoided in the boiler room and near air inlets when operating the boiler.
4.21.2 Room Air Combustion
The boiler room shall be provided with two permanent openings communicating directly with an
additional room(s). The total input of all gas utilization equipment installed in the combined
space shall be considered in making this determination. Each opening shall have a minimum
free area of 1 square inch per 1,000 Btu per hour of total input rating of all gas utilization
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 within 12
inches (305 mm) from the top of the enclosure, and one commencing within 12 inches (305 mm)
from the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the
outdoors or spaces (crawl or attic) that freely communicate with the outdoors. The minimum
dimension of air openings shall be no less than 4 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.
2. Where communicating with the outdoors through vertical ducts, 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.
3. Where communicating with the outdoors through horizontal ducts, each opening shall have a
minimum free area of 1 square inch per 2,000 Btu/hr of total input rating of all equipment in the
enclosure.
4. Where ducts are used, they shall be of the same cross-sectional area as the free area of the
opening to which they connect.
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4.22 INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM
NOTES:
Consult local and state codes pertaining to special building code and fire department
requirements. Adhere to national code requirements.
Observe the listed maximum lengths of vent system which are boiler model dependent. The
maximum permissible lengths are listed in Section 4.23.
Minimum clearance of 4 ft. (1.22m) horizontally from, and in no case above or below, unless a 4
ft (1.22 m) horizontal distance is maintained, from electric meters, gas meters, regulators and
relief equipment.
The minimum distance from adjacent public walkways, 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 Propabne 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 from adjacent walls, inside corners and 5 ft.
(1525 mm) below roof overhang (see Figure 4-16).
It is not recommended to terminate vent above any door or window, as condensate can freeze
causing ice formations.
Do not use a chimney as a raceway if another boiler or fireplace is vented into or through the
chimney.
Figure 4-16: Minimum Distances of Exhaust Opening and Building Features
4.22.1 Important Factors for Terminal Orientation and Location
Terminals should be positioned so as to avoid products of combustion from entering openings
into the buildings or other vents.
The terminal should be located where dispersal of combustion products is not impeded and with
due regard for the damage or discoloration that might occur to building surfaces in the vicinity.
In certain weather conditions condensation may also accumulate on the outside of the air inlet
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CHAPTER 4: Installation Instructions
pipe. Such conditions must be considered and where necessary insulation of the inlet pipe may
be required. In cold and/or humid weather water vapor may condense when leaving the vent
terminal. The effect of such condensation must be considered. The terminal must be located in
a place not likely to cause a nuisance.
Maintain 12” of clearance above the highest anticipated snow level or grade, whichever is
greater. Please refer to your local codes for the snow level in your area.
The whole route of the vent system must be installed upwards and NEVER completely nor
partly downwards.
4.22.2 Minimum and Maximum Wall Thickness
The label at right, which is placed on the unit,
indicates 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 referenced in the table below are on the next page.
TABLE 4-4: MODULEX EXT Vent and Piping DIAMETER Chart
NO. OF
MODULES
VENT
DIAMETER
INCHES (MM)
MAX. VENT EQUIV.
FEET (M)
EXAMPLES 1 & 2
MAX. VENT EQUIV.
FEET (M)
EXAMPLES 3 & 4
EXT 1530 / 1500
4
10” (254 mm)
100 ft. (30 m)
6 + 6 (1.8 + 1.8)
EXT 1912
5
10” (254 mm)
100 ft. (30 m)
6 + 6 (1.8 + 1.8)
EXT 2295 / 2300
6
12” (304 mm)
100 ft. (30 m)
6 + 6 (1.8 + 1.8)
EXT 2677 / 2600
7
12” (304 mm)
100 ft. (30 m)
6 + 6 (1.8 + 1.8)
EXT 3060 /3000
8
12” (304 mm)
100 ft. (30 m)
6 + 6 (1.8 + 1.8)
MODEL
TABLE 4-5: MODULEX EXT Vent and Piping LENGTH Chart
MODEL
EXT 1530 / 1500
EXT 1912
VENT PIPE
DIAMETER
SHARP 90°
ELBOW
EQUIVALENT
FEET (M)
SWEEP 90°
ELBOW
EQUIVALENT
FEET (M)
45° ELBOW
EQUIVALENT
FEET (M)
MAXIMUM
LENGTH
EQUIVALENT
FEET
(METERS)
10”
(254 mm)
13 Feet
(4 m)
7 Feet
(2 m)
5 Feet
(1.5 m)
100 Feet
(30 m)
12”
(304 mm)
13 Feet
(4 m)
7 Feet
(2 m)
5 Feet
(1.5 m)
100 Feet
(30 m)
EXT 2295 / 2300
EXT 2677 / 2600
EXT 3060 / 3000
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NOTE:
The flue system must be installed in accordance with the local and national Standards.
Figure 4-17: MODULEX EXT Allowable Venting Solution Examples
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4.24 ELECTRICAL CONNECTIONS
4.24.1 Regulations in Force
The electrical connections to the boiler must be made in accordance with all applicable local
codes and the latest revision of the National Electrical Code, ANSI/NFPA-70.
Installations should also conform with CSA C22.1 Canadian Electrical Code Part 1, if installed in
Canada.
CAUTION!
The boiler must be electrically grounded in accordance with local codes, or in absence of
local codes, with the National Electrical Code, ANSI/NFPA 70 and/or the CSA C22.1,
Electrical Code.
The gas, D.H.W. (Domestic Hot Water), and C/H system pipes must NEVER be used for
electrical grounding.
Ensure that the above safety electrical requirements are instituted. If in doubt, ask a
professionally qualified technician to check the appliance’s electrical system.
AERCO does not accept responsibility for any damages arising from failure to correctly
electrically ground the boiler.
It is necessary that a qualified technician verify that the electrical system is adequate to satisfy
the appliance’s 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.
The use of any power supply equipment implies the observance of several fundamental
rules, such as:
• Do not touch the appliance with any wet part of your body and/or while barefooted.
• Do not pull the supply cables.
• Do not expose the boiler to sunlight, rain, etc., unless it is explicitly prepared and
installed for such use.
• Do not permit children or inexpert people to use the appliance.
4.24.2 Mains Electrical Supply Connection (120 V – 60 Hz)
Mains electrical requirements call for a 120V, 60 Hz power source. The electric power
connections to the junction box of the boiler are shown in Figure 4-18.
The power supply to the boiler, 120 VAC - 60 Hz single phase, must be made in the JUNCTION
BOX of the boiler, with three core cable H05VV-F (PHASE - NEUTRAL - EARTH) according to
the polarity of the phase and neutral power supply, with phase and neutral terminals indicated
on the plug.
It is required to fit a double pole switch on the electrical supply line, having a contact separation
in both poles, in an easily accessible position in order to provide a means to remove power from
the unit during servicing.
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WARNING!
DANGER OF FATAL ACCIDENT DUE TO ELECTRIC SHOCK! 120 VAC connections
may be present on the external connection board when power is supplied to the boiler.
The electrical connections must be carried out only by a qualified person. Before carrying
out the connections or any other operation on the electrical parts, always switch off and
disconnect the electricity supply and ensure for yourself that it cannot be accidentally
turned on.
4.24.3 Service Relay Requirement
Upstream of the electrical connection, a service relay is required (not supplied) which, when the
additional electrical safety devices (if any) intervene, shuts down the electrical supply to the onoff 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 applicable regulations.
•
Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation.
NOTE:
Verify proper operation of the boiler after all servicing operations.
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AUX
Figure 4-18: 120VAC Power Wiring for Main Electrical Junction Box and Signal
Wiring for E8 Controller and Boiler Control Module (BCM)
WARNING!
120 VAC cables shall be separated from 24VAC and signal wires, using the two plastic
conduits supplied within the boiler casing LEFT-HAND side panel.
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(GROUND)
CHAPTER 4: Installation Instructions
Figure 4-19: Main Power Junction Box Location and 120VAC Wiring
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4.25 FUNCTIONAL WIRING DIAGRAM
Figure 4-20: MODULEX EXT 1500 through 3060 Wiring Diagram
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4.26 LADDER DIAGRAMS
Figure 4-21: Module Ladder Diagram
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4.27 GENERAL LADDER DIAGRAM
Figure 4-22: General Ladder Diagram
4.28 E8 CONTROLLER AND BCM TERMINAL ASSIGNMENTS
On the rear panel of the E8 controller, there are two terminal blocks, one of which is for the
mains (120 V) connections, and the other for the low voltage connections.
The main controls, necessary for the C/H system management and for the boiler control, as well
some components which are part of the boiler housing, must be connected to the terminal
blocks. See Figure 4-23 for a wiring diagram showing the E8 controller terminal wiring, and see
Figure 4-24 for a wiring diagram of sensor and BCM terminal wiring.
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Figure 4-23: E8 Controller Terminal Assignments
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Figure 4-24: Sensor and BCM Terminal Assignments
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4.29 INSTALLATION EXAMPLES
(Functional Wiring and Connections Description)
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4.30 STARTING UP: FILLING AND DE-AERATING THE BOILER
Carry out the following tasks in connection with maintenance, etc. to an already installed unit:
•
Shut down all programs
•
Close the gas shutoff valve upstream from the boiler
•
Shut off the power at the main power switch
•
Close the C/H service valves (supply and return)
4.30.1 Necessary Precautions for Safety
The following safety rules MUST be observed:
•
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 or 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 maintenance or other activities, always check the integrity of all parts through
which gas flows with a bubble test using soap spray to ensure there are no gas leaks.
4.31 FILLING THE SYSTEM
4.31.1 Necessary Precautions While Filling the System
Do not mix the C/H system’s water with anti-freeze or anti-corrosion solutions using incorrect
concentrations! Doing so can cause damage to the gaskets and might cause noise during
normal boiler operation.
WARNING!
AERCO refuses all liability for injury to persons, animals or damage to property deriving
from not having respected the above mentioned recommendations.
Before filling the heating system, the complete system, including all zones, must be thoroughly
cleaned and flushed to remove sediment.
Flush until clean water runs free of sediment. AERCO suggests using an approved system
cleaner to flush the system, but not the boiler. Always use AERCO approved antifreezes. See
the list in Section 2.8.3, Water Quality Requirements.
Never use reverse osmosis, deionized, distilled water or mineral treated water for filling the
heating system.
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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
property 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, the water must be treated until
below the maximum value of 9 grains.
The pH value of the installation water must be between 6.5 and 8. Check the pH value using
proper equipment or by having the water analyzed by a water treatment company.
If pH differs from above, contact AERCO engineering for further assistance.
WARNING!
Failure to adhere to the water quality requirements will result in a voidance of
warranty.
of
4.31.2 Filling Locations and Preparation
•
For filling the system, a filling tap must be inserted on the system return pipe.
•
Filling can also be accomplished through the draining tap on the boiler return manifold.
•
In both cases, an approved hydraulic disconnection system must be fitted.
•
Before connecting the boiler, carefully rinse out the whole system with running water.
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FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions, a fire or explosion may result
causing property damage, personal injury, or loss of life.
A. This appliance does not have a pilot light. It is equipped with an ignition device, which
automatically lights the burner. Do NOT try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next
to the floor, as some gas is heavier than air and will settle on the floor.
C. Use only your hand to turn the gas ball-valve knob. Never use tools. If the knob will not
turn by hand, do NOT try to repair it, but rather call a qualified service technician. Force
or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been submerged under water. Immediately call
a qualified service technician to inspect the appliance and to replace any part of the
control system and 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 building
Immediately call your gas supplier from a neighbors phone or
from outside with your cell phone and follow the gas supplier’s
instructions.
OPERATING INSTRUCTIONS
1.
2.
3.
4.
5.
6.
STOP! Read the safety information above on this warning.
Turn off all electric power to the appliance.
Open the gas valve.
Check gas and water pressure.
Wait five (5) minutes to clear out any gas, then smell for gas, including near the floor.
If you smell gas, STOP! Follow the instructions “WHAT TO DO IF YOU SMELL GAS” that are
printed above in these warnings. If you do not smell gas, go to the next step.
7. Turn on all electric power to the appliance.
8. Turn the start-up switch (next to the E8 controller) to the ON position. Replace the control
access panel.
9. Set Thermostat to the desired temperature.
10. If the appliance will not operate, follow instructions to turn off the gas (see below), and then call
your service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to its lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Close the gas valve.
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4.32 TESTING THE IGNITION SAFETY SHUT-OFF DEVICE
Ignition Safety Shut-off Device Test
1. Power on by switching on the ON-OFF switch.
2. Create a request in C/H Central Heating using the E8 controller.
3. Turn burners ON.
4. Disconnect the igniter cable (WHITE) of BURNER 1 (See Figure 8-2).
NOTE
Ensure the cable end is not grounded to the enclosure frame, or to
any other grounded part.
5. The display will show Fault Code E05 (Loss of Flame).
Figure 4-25: “Loss of Flame” FaultCode (E 05)
6. Press Reset Button on E8 Controller.
7. The boiler will retry the ignition cycle and the display will show Fault Code E04 (No Flame
Detected During Ignition).
Figure 4-26: “No Flame Detected During Ignition” Fault Code (E 04)
8. Reconnect the ignition cable of BURNER 1.
9. Press Reset Button
10. Check that the boiler starts correctly.
WARNING!
Do not touch the inside of the ignition cable while it is disconnected during start-up of the
boiler.
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4.33 BURNER CALIBRATION
WARNING!
All the instructions indicated below are for the exclusive use of qualified AERCO service
technicians or installers.
All the boilers are supplied already calibrated and tested. However, if it is necessary to change
the calibration due to gas conversion or adaptation to the mains supply system, the gas valve
must be re-calibrated (using Service Mode function in the E8 controller).
4.33.1 Installing the Gas Analyzer Probe
Before making adjustments, a gas analyzer sensor probe must first be installed into the flue
exhaust outlet, as shown in Figure 4-27.
Installing the Gas Analyzer Probe into Flue 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 removed.
3. Insert the analysis probe (#4) into hole of the probe adaptor.
4. After measurements are taken and adjustments made, remove the probe, probe adaptor,
then reinstall the cap (#2) onto the gas outlet (#1).
Figure 4-27: Gas Analyzer Probe Location in Flue Outlet
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REAR
BOILER
TOP VIEW
FRONT
B
B
Minimum
Output Adjust
Maximum
Output Adjust
A
A
Figure 4-28: Location of Minimum and Maximum Adjustments (Top View)
4.33.2 Maximum Output Calibration
After installing the gas analyzer probe (Figure 4-27), refer to Figure 4-28 to locate the gas
valves and the Maximum Gas Adjustment screw (A) on each valve. Follow the instructions
below to set the maximum gas output level for each valve.
Adjusting the Maximum (A) Gas Output Setting
1. Remove the cap of the combustion gases sampling point (Figure 4-27) and connect a
suitable gas analyzer.
2. Operate the burner to a minimum power following the procedure described in Section 4.34
(Figure 4-30) ‘’Sweeper’’ function (CASCADE MAN 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 ANTICLOCKWISE to increase the value.
5. Repeat the adjustment for all gas valves in the boiler.
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4.33.3 Minimum Output Calibration
After setting the maximum gas output for each valve (section 4.33.2), refer to Figure 4-28,
above, to locate the Minimum Gas Adjustment screw (B) on each valve. Follow the instructions
below to set the minimum gas output level for each valve.
Adjusting the Minimum (B) Gas Output Setting
1. Operate the burner to a minimum power following the procedure described in section 4.34
(Figure 4-30) ‘’Sweeper’’ function (CASCADE MAN 10%).
2. Check that the CO2 values are within the values indicated in Table 4-6, below.
3. If necessary, correct the value by turning the adjustment screw “B” in a CLOCKWISE
direction to increase the value or ANTICLOCKWISE to decrease it the value.
4. Repeat the adjustment for all gas valves in the boiler.
NOTE
If the CO2 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
maximum values at the flue outlet and, if necessary, make any required adjustments.
If the boiler fails to ignite, perform the following procedure:
Ignition Failure Adjustment Procedure
Figure 4-29: Maximum Output Adjustment Screw
1. Tighten the maximum adjustment screw “A” (see Figure 4-29) in a clockwise direction until it is
fully abutted into the gas valve body, than slacken back out for nine (9) turns.
2. Verify boiler ignition.
3. If the boiler goes into lockout, slacken the screw “A” again for one turn, than retry ignition.
4. If the boiler goes into lockout again, repeat step 3 and retry ignition.
5. Once ignition succeeds, carry out the minimum and maximum gas output burner adjustments,
described in section 4.33.2 and 4.33.3, above.
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CHAPTER 4: Installation Instructions
TABLE 4-6: EXT Pressure, CO2 and O2 Level Calibration Tables
EXT 1530 /1500
Gas
Type
Supply
Pressure
Wc (kPa)
CO2 Level
(%)
Min.
O2 Level
(%)
(%)
Max. Min.
(%)
Max.
Ǿ Mixer
Min. Gas
Max. Gas
Start
Injectors
Consumption Consumption Output
Ǿ in.
Min. Max.
3
3
3
3
ft /hr (m /hr)
ft /hr (m /hr)
% IG
(mm)
(FL) (FH)
Fan Speed
NOMINAL ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
26
84
0.35 (9)
79.8 (2.26)
1466 (41.5)
50
Propane
11 (2.74)
10
11
1.3
3.1
26
82
0.35 (9)
32.4 (0.92)
595 (16.8)
50
HIGH ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
28
100
0.35 (9)
79.8 (2.26)
1411 (39.9)
50
Propane
11 (2.74)
10.8
10.8
1.3
3.1
26
76
0.35 (9)
32.4 (0.92)
536 (19.2)
50
EXT 1912
Gas
Type
Supply
Pressure
Wc (kPa)
CO2 Level
(%)
Min.
O2 Level
(%)
(%)
Max. Min.
(%)
Max.
Ǿ Mixer
Min. Gas
Max. Gas
Start
Injectors
Consumption Consumption Output
Ǿ in.
Min. Max.
3
3
3
3
ft /hr (m /hr)
ft /hr (m /hr)
% IG
(mm)
(FL) (FH)
Fan Speed
NOMINAL ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
26
84
0.35 (9)
79.8 (2.26)
1832 (51.8)
50
Propane
11 (2.74)
10
11
1.3
3.1
26
82
0.35 (9)
32.4 (0.92)
744 (21.1)
50
HIGH ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
28
100
0.35 (9)
79.8 (2.26)
1832(51.8)
50
Propane
11 (2.74)
10.2
10.6
1.3
3.1
26
76
0.35 (9)
32.4 (0.92)
670 (19.0)
50
EXT 2295 / 2300
Gas
Type
Supply
Pressure
Wc (kPa)
CO2 Level
(%)
Min.
O2 Level
(%)
(%)
Max. Min.
(%)
Max.
Ǿ Mixer
Min. Gas
Max. Gas
Start
Injectors
Consumption Consumption Output
Ǿ in.
Min. Max.
3
3
3
3
ft /hr (m /hr)
ft /hr (m /hr)
% IG
(mm)
(FL) (FH)
Fan Speed
NOMINAL ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
26
84
0.35 (9)
79.8 (2.26)
2199 (62.2)
50
Propane
11 (2.74)
10
11
1.3
3.1
26
82
0.35 (9)
32.4 (0.92)
893 (25.3)
50
HIGH ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
28
100
0.35 (9)
79.8 (2.26)
2199 (62.2)
50
Propane
11 (2.74)
10.2
10.6
1.3
3.1
26
76
0.35 (9)
32.4 (0.92)
804 (22.8)
50
NOTE:
Check the O2 levels often, especially at low flow rates.
For high altitude installations, consult document number C302.6 (MLX EXT Alt Derate).
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CHAPTER 4: Installation Instructions
TABLE 4-6: EXT Pressure, CO2 and O2 Level Calibration Tables
EXT 2677 / 2600
Gas
Type
Supply
Pressure
Wc (kPa)
CO2 Level
(%)
Min.
O2 Level
(%)
(%)
Max. Min.
(%)
Max.
Ǿ Mixer
Min. Gas
Max. Gas
Start
Injectors
Consumption Consumption Output
Ǿ in.
Min. Max.
3
3
3
3
ft /hr (m /hr)
ft /hr (m /hr)
% IG
(mm)
(FL) (FH)
Fan Speed
NOMINAL ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
26
84
0.35 (9)
79.8 (2.26)
2565 (72.6)
50
Propane
11 (2.74)
10
11
1.3
3.1
26
82
0.35 (9)
32.4 (0.92)
1042 (29.5)
50
HIGH ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
28
100
0.35 (9)
79.8 (2.26)
2565 (72.5)
50
Propane
11 (2.74)
10.2
10.6
1.3
3.1
26
76
0.35 (9)
32.4 (0.92)
938 (26.6)
50
EXT 3060 / 3000
Gas
Type
Supply
Pressure
Wc (kPa)
CO2 Level
(%)
Min.
O2 Level
(%)
(%)
Max. Min.
(%)
Max.
Ǿ Mixer
Min. Gas
Max. Gas
Start
Injectors
Consumption Consumption Output
Ǿ in.
Min. Max.
3
3
3
3
ft /hr (m /hr)
ft /hr (m /hr)
% IG
(mm)
(FL) (FH)
Fan Speed
NOMINAL ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
26
84
0.35 (9)
79.8 (2.26)
2932 (83.0)
50
Propane
11 (2.74)
10
11
1.3
3.1
26
82
0.35 (9)
32.4 (0.92)
1191 (33.7)
50
HIGH ALTITUDE
Natural
7 (1.74)
8.5
10
3.1
5.8
28
100
0.35 (9)
79.8 (2.26)
2639 (82.9)
50
Propane
11 (2.74)
10.2
10.6
1.3
3.1
26
76
0.35 (9)
32.4 (0.92)
1072 (30.3)
50
NOTE:
Check the O2 levels often, especially at low flow rates.
For high altitude installations, consult document number C302.6 (MLX EXT Alt Derate).
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CHAPTER 4: Installation Instructions
4.34 SWEEPER MODE (MANUAL CONTROL)
Figure 4-30: Sweeper Mode (Manual Control)
NOTE:
The function is active for 15 minutes, after which it defaults to the previous parameters.
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CHAPTER 4: Installation Instructions
4.35 HIGH ALTITUDE ADJUSTMENT
It is necessary to adjust the fan speed at altitudes at or above 5,000 feet. Modify the parameter
FAN MAX from the E8 Control Panel. Note that it is modifiable only with an access code. See
Table 4-7 on the next page for a list of the FA (Factory) parameters.
NOTE
This conversion to high altitude
operation shall be made by a
qualified
service
agency
in
accordance with the manufacturer’s
instructions and all applicable codes
and requirements of the authority
having jurisdiction. The qualified
service agency is responsible for
the proper installation of this
conversion. The installation is not
proper and complete until the
operation
of
the
converted
appliance is checked as specified in
the
manufacturer’s
instructions
supplied with the unit.
See the value of parameter FH
(FAN MAX) in Table 4-7,
MODULEX EXT Pressure and CO2
Level Calibration Tables.
WARNING!
Figure 4-31: Adjusting Fan Speed to Set Input Range for High Altitude
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CHAPTER 4: Installation Instructions
TABLE 4-7: MODULEX EXT FA (Factory) Parameters Set in PARAM HS
xx Menu
PARAMETERS
FAN MOD IGN
FAN MOD STBY
FAN MAX (FH)
FAN MIN (FL)
MAX DIFF PRO
MIN FLOW PRO
MIN FLOW RAT
BOIL HYS
BOIL SLP LIM
BOIL P VAL
BOIL I VAL
BOIL D VAL
PUMP OVERRUN
PUMP MIN MOD
CAP FLOW RATE
FAN P VAL
FAN I VAL
FAN SLP
FAN SLP POS
FAN SLP NEG
FAN START PW
FAN ADAPT
RESTARTS
SW NO
SW RWV
MODULEX EXT
FOR LOW ALTITUDE
FOR HIGH ALTITUDE
80
26
84
31
30
00
200
5
10
25
12
00
05
------04
08
No Change
No Change
100
28
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
------No Change
No Change
---------------Software N°
Software Revision
---------------Software N°
Software Revision
4.36 HIGH ALTITUDE CONVERSION LABEL
After calibration of the unit from Normal Altitude (0 - 2,000 feet) to High Altitude (2,000 – 4,500
feet) operation, the label below must be filled out with the appropriate information and applied to
the unit in close proximity to the rating label. If the unit is calibrated again for normal altitude
operation, the label should be removed.
Figure 4-32: High Altitude Conversion Label
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CHAPTER 4: Installation Instructions
4.37 CONVERSION FROM NATURAL GAS TO PROPANE GAS
To convert the unit to use propane gas, instead of natural gas, do the following:
Converting From Natural Gas to Propane Gas
1. Set nominal heat by adjusting the fan speed parameter FH (FAN MAX) from the E8
controller as shown in Table 4-6, MODULEX EXT Pressure and CO2 Level Calibration
Tables in Section 4.33.4. This parameter requires a password to change.
2. Adjust CO2 (%) minimum and maximum levels according to the type of gas as shown in the
table below. See section 4.33 - Burner Calibration, above, for more information.
GAS TYPE
CO2 LEVEL (%) MINIMUM
CO2 LEVEL (%) MAXIMUM
Natural Gas
8.5
10
Propane Gas
10
11
3. After gas conversion to propane and calibration, the gas installer should complete and apply
this label, or equivalent, as close to the rating label as possible:
Figure 4-33: MODULEX EXT Label
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CHAPTER 4: Installation Instructions
4.38 CONTROLS AND EMERGENCY FUNCTIONS
Figure 4-34: MODULEX EXT Panel Controls and Indicators
TABLE 4-8: Panel Controls and Indicators
ITEM
COMPONANT/FUNCTION
A
GLT (General Limit Thermostat): when enabled, it cuts the power supply to the
boiler and lights the warning lamp (Item D). To reset, remove the cap and push
the reset button.
B
C
D
E
Main Power Switch
Fuses: 1 = 6.3 A
2 = 10 A
Warning lamp of the Thermostatic Lockout from GTL (General Limit Thermostat).
Main Switch
F*
Change-over Series/Parallel:
0 = Emergency is active or the control is managed by PLC or BMS.
I = Series connection (the cascade is managed by the BCM)
II = Parallel connection (condition of supply).
G*
In position “I” the plant will operate when requested at “CONSTANT SETPOINT”:
70°C – Max heat output 50%.
H*
Enables burner reset in case of lock-out.
I*
YELLOW LED = Blinking = Communication between BMM and BCM is OK.
GREEN LED = ON = Active Pump
RED LED
= ON = Failure Code Detected
*See Chapter 5, section 5.2 for more information regarding the BCM (Boiler Communication
Module).
NOTE:
The emergency function enables the boiler’s burners to fire only at 50% and at 50°C in system
return. All the system’s heating loads, including the header pump, must be controlled manually.
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CHAPTER 4: Installation Instructions
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, check that:
•
The boiler installation has been carried out in accordance with the specific standards as
instructed in this manual.
•
The combustion air inlet and the discharge of combustion exhaust occur in the correct
manner in accordance to the specific standards in force.
•
The gas supply system is correctly configured for the boiler’s output.
•
The boiler’s electrical supply is 120 V - 60 Hz.
•
The system has been filled with water (pressure registered on the gauge 0.8/1 bar with
pump not running).
•
All of the system’s 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 use the available gas (refer to section: “GAS
CONVERSION”). This operation must be carried out by a qualified technician in compliance
with the regulations in force.
•
The gas supply valve is open.
•
There are no gas leaks.
•
There are 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) through the filling hole and check the correct drainage of the condensate.
Using the boiler with the condensate drain siphon empty could cause a dangerous
condition due to poisonous emissions from the flue exhaust gasses.
•
All the necessary ventilation conditions and minimum clearance distances are in place for
subsequent servicing in case the boiler is sited in a cupboard compartment.
•
There are no water leaks.
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CHAPTER 4: Installation Instructions
(This Page Intentionally Blank)
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CHAPTER 5: E8 Controller and BCM Modules
CHAPTER 5: E8 CONTROLLER AND BCM MODULES
MODULEX boilers contain advanced and reliable electronic controls, the E8 Controller and the
BCM (Boiler Communications Module), which provide comprehensive programming and
monitoring of the MODULEX boiler and its functions. Features and functions of the E8 Controller
and BCM are described in this chapter.
CAUTION!
This chapter instructs how to operate and navigate the E8 Controller menus, sub-menus, and
parameters, as well as describing the functions of the BCM (Boiler Control Module).
However, before the boiler may be used, the E8 controller MUST be first initialized by
entering language, year, month, day, and hour in the Installation Menu, as described in
Chapter 6, section 6.1.
5.1 E8 CONTROLLER
A standard component included in MODULEX units, the E8 Controller is responsible for the
staging and modulation of individual thermal heating modules in a MODULEX boiler and also
monitors supply and return water temperatures and domestic hot water zones.
The E8 Controller is housed in a compact enclosure measuring 5.7” (145 mm) x 3.9” (100 mm).
The Controller is mounted on the front of the MODULEX Boiler and contains all of the controls,
indicators and displays necessary to adjust, operate and troubleshoot the MODULEX Boiler.
The main components of the closed E8 Controller include the display, door, and data wheel
(see Figure 5-1).
5.1.1 E8 Controller Features and Functions
The E8 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 seize program.
•
Drives lead-lag burner operation based on operating hours. The boiler module with the least
burner operating hours is the first to start and the burner with the most operating hours is the
first to stop.
•
Supports DHW (Domestic Hot Water) production using a dedicated sensor to control a
dedicated pump or 3-way diverting valve for storage tank temperature control.
•
Supports a manual operation service mode to control individual modules during
troubleshooting or combustion calibration procedures.
•
Drives diagnostics such as relay and senor testing.
•
Supports Modbus integration with AERCO BMS II and AERCO Control System (ACS) or
Building Automation Systems. AERCO also offers a Communication Gateway to support
BACnet, Lonworks and N2 system integration.
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CHAPTER 5: E8 Controller and BCM Modules
LCD Display
Window
Hinged Cover
(in closed position)
Rotary Knob
Figure 5-1: MODULEX E8 Controller Front Panel (Cover Closed)
5.1.2 E8 Display Functions
The E8 Controller operates in NORMAL Mode when the controller door is closed, which allows
for monitoring the boiler status through the display window and setting the HEATING Mode.
When the door is opened, the unit enters MENU Mode, and in this mode the boiler may be
initialized, configured, and adjusted. The controls and display for the E8 controller are described
in the following sub-sections.
A
I
B
H
C
G
D
F
E
Figure 5-2: E8 (NORMAL Mode) Display Features
TABLE 5-1: E8 Display Features and Functions (NORMAL Mode)
ITEM
FUNCTION
A
Current time (24 hour format)
B
DCF reception OK (only if receiver is connected via eBUS)
C
Display of the active heating program for the first heating circuit (here: 6:00 to 08:00 a.m. and
4:00 to 10:00 p.m.)
D
Bus icon (if this icon does not appear, check data line to connected CAN controllers => check
eBUS via DISPLAY level)
E
Status display: Shows symbols for Internal Burner 1 Relay ON; Heating Mode; Hot Water
Preparation.
F
Heating Mode display symbol. The display symbols apply to all internal heating circuits for which
a separate heating mode has been selected. Note that each symbol occupies a different space
across the display bottom. See Figure 5-3.
G
Display of current temperature of HS 1 or header temperature when cascading.
H
Display of number of active heat generators (only applies when cascading).
I
Selectable display and Fault Codes (refer to "DISPLAY SEL" parameter in the USER menu).
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CHAPTER 5: E8 Controller and BCM Modules
5.1.3 E8 HEATING Mode Selection
Heating modes may be selected using the Rotary Knob on the controller when the hinged door
is in the closed position (NORMAL Mode). As the Rotary Knob is turned, each appropriate
heating mode symbol is displayed, in turn, along the lower edge of the display.
Mode changes take effect when the setting is not changed for 5 seconds. The symbols and
description for the available heating modes are shown in Figure 5-3.
Heating Mode
Symbols: Only the
one currently
selected mode will
be displayed.
Figure 5-3: E8 HEATING Mode Display Features (NORMAL Mode)
TABLE 5-2: E8 HEATING Mode Features & Functions (NORMAL Mode)
SYMBOL
MODE NAME
DESCRIPTION
Heating Mode
Selection
Turn the Rotary Knob to select the heating mode
required. The heating mode is indicated by a symbol at
the bottom of the display. It takes effect when the
setting is not changed for 5 seconds.
Standby / OFF
Heat OFF and hot water (HW) preparation OFF, only
frost protection mode.
Automatic Mode 1
Heat according to timer program 1; HW according to
HW program.
Automatic Mode 2
Heat according to timer program 2; HW according to
HW program.
Summer Mode
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Day Mode
24 Hour heating with comfort temperature 1; HW
according to HW program.
Night Mode
24 Hour heating with reduced temperature; HW
according to program.
Service Mode
Automatic reset after 15 minutes. Boiler regulated at
max boiler temperature.
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CHAPTER 5: E8 Controller and BCM Modules
5.1.4 E8 MENU Mode Operation (Door Open)
Opening the E8 controller hinged door reveals the E8 controls (Figure 5-4) and initiates the
MENU Mode, which enables access to an extensive set of software menus.
INSTALLATION
A
B
B
C
G
D
E
F
Figure 5-4: E8 MENU Mode Display Features
TABLE 5-3: E8 MENU Mode Features and Functions
ITEM
FEATURE
A
LCD display
B
Mounting Key
Access Holes
C
Change LED
D
Optical
Adaptor
E
Program Key
F
Manual/
Automatic
Switch
G
Rotary Knob
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FUNCTION
Selected Menu/Sub-menus, parameter names/values, and selected
busses are indicated in the LCD display when in MENU Mode.
Insert narrow screwdriver deep into holes and lift up controller to
remove.
When lit, this LED indicates that the value shown in the display can
be changed using the Rotary Knob (A).
For PC connection
Used to select a sub-menu level, select a parameter value to
change, or save a new parameter value.
A 2-position (10/2 o’clock) screwdriver adjustable switch. Normally,
this switch is set to the Automatic (2 o’clock) position to allow
program control of the boiler. When set to the Manual (10 o’clock)
position, a flashing “EMERG – MODE” message is displayed.
Heating Circuit 1 (HC1) pump and the first burner stage are switched
on. Pumps for Heating Circuit 2 (HC2) and Domestic Hot Water
(DHW) will also be switched on if sensors are installed and enabled.
The pump(s) will turn off when the flow temperature reaches the
value set for MAX T-FLOW (in EXPERT/HEAT CIRCUIT 1 menu).
The first burner stage will cut off when the boiler temperature
reaches the value set for MAX T-MODUL (in
EXPERT/INSTALLATION menu).
Used to navigate through menus and parameters or adjust
parameters.
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CHAPTER 5: E8 Controller and BCM Modules
5.1.5 E8 MENU Navigation and Parameter Settings
The selected Menu and Sub-menu are indicated by two black arrows at display bottom pointing
to the Menu and Sub-menu names silk-screened below the display (Figure 5-5).
Following initial startup and one-time entry of the required INSTALLATION menu items (see
Chapter 6, section 6.1), to access, view and/or change menu items follow these instructions:
Sub-MENU Name
INSTALLATION
Points right to
Selected
Buss(es)
Points left to
Selected Buss(es)
Points down to
Selected
Sub-MENU Name
Points down to
Selected
MENU Name
MENU
Names
Sub-MENU
Names
Figure 5-5: MODULEX E8 Controller Front Panel
E8 Controller Menu Navigation Procedure
1.
When the ON/OFF switch on the front of the boiler is turned ON and the swing-down hinged
panel is opened, the controller will enter MENU Mode and INSTALLATION will be displayed
(Figure 5-5) in the LCD. This is the initial INSTALLATION menu and it is assumed that all
entries have already been made. See sub-section 4.8 of the E8 Controller User Manual
(GF-115-C) for INSTALLATION menu initial entry information.
2.
Turn the Rotary Knob clockwise until the display advances to the DISPLAY menu. The dial
on the clock face will rotate one revolution counterclockwise and then go off. The display
will then show INSTALLATION, which is the first sub-menu in the DISPLAY menu group
(Figure 5-5). The two small black arrows at the bottom of the display will point down to the
menu and submenu names, in this case DISPLAY and INSTALLATION, respectively.
3.
To view functions included in the INSTALLATION sub-menu, press the Program Key (Item
E, Figure 5-4). If desired, turn the Rotary Knob to scroll through the functions in the
INSTALLATION sub-menu. As previously mentioned, these display functions are read-only
and cannot be changed. Once you reach the end of the sub-menu, RETURN will appear in
the display.
4.
To exit this sub-menu and advance to the next sub-menu in the DISPLAY menu, press the
Program Key while RETURN is displayed. INSTALLATION will again be displayed. Turn the
Rotary Knob clockwise until the next sub-menu is displayed.
5.
Repeat steps 2, 3 and 4 to view the remaining main menus and their associated submenus. The remaining main menus are: USER, TIME PROGRAM, EXPERT, EXPERT HS
(Not Applicable to MODULEX), and GENERAL.
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CHAPTER 5: E8 Controller and BCM Modules
5.1.6 E8 Parameter Navigation, Selection, and Setting
When in the USER, TIME PROGRAM, EXPERT, or GENERAL Main Menu, virtually all submenu items can be changed, if desired. Perform the following steps to access, view, and/or
change menu item parameters:
TABLE 5-4: E8 Parameter Navigation, Selection, and Setting
DESCRIPTION
EXAMPLES
Use Rotary Knob to navigate to the desired Menu/Submenu. Menu and sub-menu are indicated by two small
black arrows at the bottom of the LCD display pointing
down to menu/sub-menu names below the display (see
Figure 5-5).
Example: User Menu & Hot Water Sub-menu
HOT-WATER
Displayed
Sub-menu
Display Detail
push
Press Program Key to access parameters in the selected
(displayed) sub-menu.
Turn Rotary Knob to sequence through the available
parameters.
To change a parameter value, press the Program Key
when the desired parameter is displayed. The Change
LED will light up indicating the displayed parameter may
now be changed.
To change the displayed parameter value, turn the
Rotary Knob; clockwise to increase value and counterclockwise to decrease the value.
HOT-WATER
T-DHW
displayed
sub-menu
parameters
accessed
Cycle thru
parameters
T-DHW
push
T-DHW
140.0
displayed
parameter
values
accessed
cycle thru
values
141.0
push
To save the displayed parameter value to the controller
memory, press the Program Key. The Change LED will
turn off indicating the new value has been saved.
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142.0
142.0
displayed
value
Displayed
Value Saved!
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CHAPTER 5: E8 Controller and BCM Modules
5.2 BCM (BOILER COMMUNICATION MODULE)
NOTE
Only the basic features and functions of the BCM are described in the following sections. Refer to
the E8 Controller User Manual (GF-115-C) for detailed information and diagrams for wiring and
using the BCM in its various capacities.
The BCM (Boiler Communication Module) is an electronic module in MODULEX boilers, which
supports full interoperability to BAS (Building Automation Systems) via Modbus protocol to
make remote communications and control possible. In addition, it provides customers with a
remote alarm contact to notify customers of faults detected within any of the 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.
As a back-up controller, the BCM further increases the reliability of a product line already known
for its uniquely redundant design. Each MODULEX boiler combines between four and eight
independent, 382,000 BTU/hr., pre-assembled thermal modules housed in a common
enclosure. Each module has its own dedicated controller with a combustion safeguard, variablespeed fan, modulating gas valve, electronic ignition, modulating burner, flow temperature
sensor, thermostat and heat exchanger. The independent operation of these thermal modules
increases each boiler's overall reliability. If a single module requires maintenance or repair, the
other module(s) in the boiler can maintain the system load requirements -- thereby providing a
level of redundancy that was previously only realized in multi-boiler installations.
A photo of the module is shown in Figure 5-6. Additional information for the BCM component
can be found in Section 7, 9, and 10 of the E8 Controller User Manual (GF-115-C).
5.2.1 BCM Features and Functions
When installed and enabled, the BCM enhances the range of control functions offered by the
MODULEX Boilers. These additional control functions include the following:
•
Providing a fault relay which energizes when any fault condition occurs in the MODULEX
Boiler.
•
Serving as a Back-up Controller in the event that the primary E8 Controller fails.
•
Providing a 0-10V output to control a variable speed primary pump
•
May be selected as the Primary Controller instead of the E8.
•
Functioning as a “Slave” to a “Master” Energy Management System (EMS), Building
Automation System (BAS) or AERCO’s Boiler Management System II (BMS II/AERCO
Control System [ACS]) on a Modbus Network.
5.2.2 BCM Description
The BCM shown in Figure 5-6 is housed in a compact enclosure measuring 4.13” (105 mm) x
3.50” (89 mm). The BCM is installed on the front of the MODULEX Boiler control panel.
Input/Output (I/O) connections to the BCM are made via four connectors mounted on the
Printed Circuit Board (PCB) of the BCM. Three Control Switches are mounted on the clear
plastic cover on the front of the BCM. Three LED Status Indicators are mounted directly on the
BCM PCB and can be viewed through the clear plastic cover. In addition, the PCB contains an
on-board, screwdriver-adjustable 10-position address switch, which is used to set the
corresponding address of the boiler on the input Modbus or EBUS Network.
Refer to Tables 5-5 and 5-6 for details on the features and functions of the BCM.
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CHAPTER 5: E8 Controller and BCM Modules
DL1 (YELLOW)
DL2 (RED)
DL3 (GREEN)
E
F
G
Input
Communications
Connector
(Modbus/Ebus)
A
Change-Over
3-Pos. Switch
B
Enable/Disable
2-Pos. Switch
C
Reset Switch
D
Output
Communications
Connector (Ebus)
SW1 Switch
Figure 5-6: BCM (Boiler Control Module) Features
TABLE 5-5: BCM (Boiler Control Module) Features and Functions
ITEM
FEATURE
FUNCTION
A
Change-Over Series/Parallel,
3-Position Switch
Three-position rocker switch for setting internal/external boiler control.
B
Enable/Disable (I/0),
2-Position Switch
C
Reset Switch
D
SW1,
10-Position Rotary Switch
Two-position rocker switch enables the BCM to act as a Back-Up
Controller when placed in the ON (I) position. See Table 5-6 for
description of settings related to Item B switch.
Momentary two-position rocker switch resets (clears) fault relay and
LED when activated.
Rotary switch labeled 0 – 9. Sets the corresponding address of Boiler
on the input Modbus or EBUS Network.
Communication Status Indicator functions as follows:
Status
E
OFF
DL1 LED: (YELLOW)
BLINKING
ON
F
DL2 LED: (RED)
G
DL3 LED: (GREEN)
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Description
No devices detected by either communication
interface.
Only one communication device detected at
one communication interface (input or output).
Both communication interfaces
(input & output) are active.
Alarm Status LED lights when a fault is detected by the BCM.
Activating the Reset Switch will clear the faults.
Pump Status Indicator lights when Pump is running.
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CHAPTER 5: E8 Controller and BCM Modules
TABLE 5-6: BCM 3-Position and 2-Position Switch Functions
2-POS SWITCH
(ENABLE/DISABLE)
O = OFF (Disable)
I = ON (Enable)
3-POS SWITCH
(I/O/II)
Position I
(NOTE 1)
Position O
(see NOTE 2)
Position II
(See NOTE 3)
DO NOT USE
The BCM is the Gate-way for
Modbus and external control.
The E8 does not control the
boiler and the BCM will not
take over the boiler if the
Modbus signal fails.
The E8 is the primary
controller and the BCM
allows monitoring through
Modbus, but will not take
over boiler if the E8 fails.
DO NOT USE
The BCM is the Gate-way for
Modbus and external control.
The E8 does not control the
boiler and the BCM will take
over the boiler if the Modbus
signal fails. If E8 is in Standby
Mode, BCM will cycle the
pump with the boiler. If E8 is
in Day Mode, the E8 will
continuously run the pump.
The E8 is the primary
controller and the BCM
allows monitoring, and the
BCM will take over the
boiler if E8 fails. If E8 is in
Standby Mode, E8 will cycle
the pump (must use
Enable/Disable). If E8 is in
Day Mode, the E8 will
continuously run the pump.
NOTES:
1) DO NOT set the 3-Position Switch to Position I.
2) Set the 3-Position Switch to Position O ONLY when controlling Boilers from an external
Controller via Modbus Communication. See Paragraph 3.1.2 of the E8 Controller User
Manual (GF-115-C) for setting HEAT Modes.
3) Position II is the Default position for the 3-Position Switch. Ensure it is set to this position
when it arrives from the Factory. See Paragraph 3.1.2 of the E8 Controller User Manual
(GF-115-C) for setting HEAT Modes.
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CHAPTER 5: E8 Controller and BCM Modules
(This Page Intentionally Blank)
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CHAPTER 6: Operation of the E8 Controller
CHAPTER 6: OPERATION OF THE E8 CONTROLLER
This chapter introduces the E8 controller basic menus/sub-menus needed to set up the
MODULEX EXT boiler. Refer to Chapter 4 for instructions for using the E8 controls to navigate
and change settings. For more detailed information concerning the E8 controller menus, submenus, and functions, refer to the E8 Controller User Manual (GF-115-C).
MODULEX E8 Controller Front Panel (Cover Closed)
MODULEX E8 Controller Front Panel (Cover Open)
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CHAPTER 6: Operation of the E8 Controller
6.1 INSTALLATION MENU: INITIALIZING THE E8 CONTROLLER
Each time power is applied to the boiler and the E8 controller cover (Figure 7-1) is opened, the
INSTALLATION Menu is displayed once (only). These values MUST be entered in order to
initialize the boiler for operation. Once the values grouped here have been entered and
accepted, the controller is initiated and operatable and may be configured for your boiler
installation. To re-enter the INSTALLATION menu, cycle the boiler power and open the cover
again.
To initialize the E8 Controller, set the following values in the INSTALLATION Menu:
•
•
•
Set the parameters: ENGLISH, HOUR, YEAR, MONTH, and DAY.
Leave the BUS – ID HS parameter blank.
Remaining parameters are already set and do not require any entry.
WARNING
Menu selections shown are
the factory default settings.
Refer to GF-115-C for the
complete menu selections.
Figure 6-1: INSTALLATION Menu
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CHAPTER 6: Operation of the E8 Controller
6.2 QUICK START INSTRUCTIONS
Below are instructions for setting the most basic settings in the E8 controller, including
maximum and minimum flow temperature, room temperature settings, heat slope, and initiation
of heating programs.
IMPORTANT!
Before the boiler may be used, the E8 controller MUST be first initialized by entering
language, year, month, day, and hour in the Installation Menu, as described in section 6.1,
above.
6.2.1 Setting Maximum and Minimum Flow Temperature
INSTALLATION
Figure 6-2: E8 Quick Start, Max. & Min. Flow Temperature Settings
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CHAPTER 6: Operation of the E8 Controller
6.2.2 Setting Room Temperature and Outdoor Compensation
INSTALLATION
Figure 6-3: E8 Quick Start, Room Temperature and Outdoor Compensation
Settings with Outdoor Temperature (Slope) Chart
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CHAPTER 6: Operation of the E8 Controller
6.2.3 Setting Heating Programs and Pumps
Figure 6-4: E8 Quick Start, Heating and Pump Program Settings
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CHAPTER 6: Operation of the E8 Controller
6.3 MENU AND SUB-MENU DESCRIPTIONS
There are six top level menus and five sub-menus as listed below.
6.3.1 Menus (Top Level):
•
GENERAL
Value selection summary. Service => for service engineers. Date/Time/Holiday => for
users.
•
DISPLAY
System value display (e.g. sensor values and setpoints). No adjustments can be made.
Operating errors are therefore excluded in this area.
•
USER
Summary of settings that can be made by the operator.
•
TIME PROGRAMS
Summary of time programs for heating circuits, the hot water circuit and extra functions
where applicable
•
EXPERT
Summary of values for which expert knowledge is required to make settings (installation
technician). Values in the expert level are protected by a code number.
•
EXPERT FA (Only for FA via BUS)
Summary of values transmitted by the automatic firing device.
6.3.2 Sub-Menus:
•
INSTALLATION
All display values and settings that relate to the unit or the entire system and cannot be
assigned to a consumer circuit.
•
HOT WATER
All display values and settings that affect central hot water preparation and circulation.
•
HEATING CIRCUIT I
All indicator and set values that relate to the consumer circuit 1 (also, for example, as
decentralized hot-water circuit).
•
HEATING CIRCUIT II
All indicator and set values that relate to the consumer circuit 2 (also, for example, as
decentralized hot-water circuit).
•
SOLAR/MF
All indicator and set values that relate to solar energy recovery and settings for the
multifunction relay.
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CHAPTER 6: Operation of the E8 Controller
6.4 GENERAL MENU
The GENERAL menu contains the sub-menus DATE/TIME, HOLIDAY, and CLOCK CHANGE.
Figure 6-5: GENERAL Menu
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CHAPTER 6: Operation of the E8 Controller
TABLE 6-1: GENERAL Menu
LEVEL
DESCRIPTION
ENTRY RANGE
DATE/TIME
TIME (HOURS)
Current hours blink and can be adjusted
00:00 - 24:00
YEAR
Adjust current year
XXXX
MONTH
Adjust current month
01 - 12
DAY
Adjust current day
01 - 31
YEAR START
Set current holiday start year
XXXX
MONTH START
Set current holiday start month
01 - 12
DAY START
Set current holiday start day
01 - 31
YEAR STOP
Set current holiday end year
XXXX
MONTH STOP
Set current v end year
12 - 31
DAY STOP
Set current holiday end day
01 - 31
MONTH START
Set month for start of summer time
01 - 12
DAY START
Set earliest day for start of summer time
01 - 31
MONTH STOP
Set month for start of winter time
12 - 31
DAY STOP
Set earliest day for start of winter time
01 - 31
HOLIDAY
CLOCK CHANGE
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CHAPTER 6: Operation of the E8 Controller
6.5 SERVICE MENU
The SERVICE menu contains the TEST RELAY, SENSOR TEST, and OTHER PARAMETERS
sub-menus as shown below:
NOTE
The SERVICE menu is accessed as shown below. However, SERVICE MODE (
and can only be accessed when the E8 cover is closed.
) is different
Figure 6-6: SERVICE Menu
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CHAPTER 6: Operation of the E8 Controller
TABLE 6-2: SERVICE Menu
LEVEL
DESCRIPTION
TEST RELAYS
RELAY TEST 00
RELAY TEST 01
RELAY TEST 02
RELAY TEST 03
RELAY TEST 04
RELAY TEST 05
RELAY TEST 06
RELAY TEST 07
RELAY TEST 08
RELAY TEST 09
RELAY TEST 10
RELAY TEST 11
No relay
A1: Pump heating circuit 1
A2: Pump heating circuit 2
A3: Hot water charging pump
A4: Mixer OPEN heating circuit 2
A5: Mixer CLOSED heating circuit 2
A6: Heat Source 1 ON
A7: Heat Source 2 ON [2 stage: HS 1+2 (after 10s) ON]
A8: Mixer OPEN heating circuit 1 / Multifunction 1
A9: Mixer CLOSED heating circuit 1 / Multifunction 2
A10: Multifunction 3
A11: Collector pump / Multifunction 4
SENSOR TEST
F1
F2
F3
F5
F6
F8
F9
F11
F12
Lower buffer storage temperature
Middle buffer storage temperature or room temperature heating circuit 1
Upper buffer storage temperature
Flow temperature heating circuit 2
Upper hot water temperature
Boiler/Header temperature
Outside temperature
Flow temperature heating circuit 1 or temperature multifunction 1
Hot water temperature lower or temperature multifunction 2
F13
Solid fuel boiler temperature or collector 2 or temperature multifunction 3
F14
Collector 1 temperature or temperature multifunction 4
Room temperature heating circuit 2 or measured value of the sensor or
voltage value 0-10V input
F15
OTHER PARAMETERS
SW NO XXX-XX
CASCADE MANU
BURNER TIME (1÷8)
BURNER START (1÷8)
LIMITER TEST (1÷8)
SERVICE
RESET USER 00
RESET EXPERT 00
RESET T-PRG 00
RETURN
Software number with index
Manual control of each module
Burner time for all stages
Burner start for all stages
Safety temperature limiter test: press and hold button
Date/Hour setting for service purposes
Do not use
Do not use
Do not use
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CHAPTER 6: Operation of the E8 Controller
6.6 DISPLAY MENU
The DISPLAY menu contains the INSTALLATION, HOT-WATER, HTG CIRCUIT 1/2, and
SOLAR / MF sub-menus as shown below:
Figure 6-7: DISPLAY Menu
NOTE:
Some menus are visible only if the relevant sensor is wired (e.g. HOT WATER is displayed only if
the DHW storage sensor is wired).
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CHAPTER 6: Operation of the E8 Controller
TABLE 6-3: DISPLAY Menu
LEVEL
INSTALLATION
T-OUTSIDE
T-EXT DES
T-COLL DES
T-COLLECTOR
T-BOIL
T-SOLID FUEL
T-RETURN 1
T-RETURN 2
T-BUFFER T
T-BUFFER M
T-BUFFER L
T-STORAGE 3
MODGRAD
DESCRIPTION
Outside temperature
External set value specification (0-10 V)
HS / Header set value (cascade)
HS / Header temperature (cascade)
Temperature and status of the HS (HS1 - HS8)
For HS2 = Solid fuel boiler
Return flow temperature of HS 1
Return flow temperature of HS 2
Buffer storage tank temperature: top position
Buffer storage tank temperature: midle position
Buffer storage tank temperature: lower position
Temperature of storage tank 3 (e.g. solar pool-heating)
Modulation level for each module
RETURN
HOT-WATER
T-DHW RATED
T-DHW
T-DHW L
T-CIRC
RETURN
Hot water set temperature value
Hot water temperature value
Hot water temperature in infeed area
Recirculating temperature
HTG CIRCUITC 1/2
T-ROOM DES A
T-ROOM
HUMIDITY
T-POOL DES
T-POOL
T-DHW RATED
T-DHW
T-FLOW RATED
T-FLOW
N-OPT-TIME
RETURN
Current value for set room temperature
Room temperature
Displays room humidity (if value is available)
Pool set temperature
Pool temperature
Hot water set temperature value
Hot water temperature value
Current flow temperature setting
Current flow temperature
Display of the time last required for heating-up
SOLAR / MF
T-MF1
T-MF2
T-MF3
T-MF4
T-COLLECTOR
T-DHW
T-DHW L
RETURN
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Temperature MF sensor 1 (=F11)
Temperature MF sensor 2 (=F12)
Temperature MF sensor 3 (=F13)
Temperature MF sensor 4 (=F14)
Temperature collector 1
Upper hot water temperature
Hot water temperature infeed
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CHAPTER 6: Operation of the E8 Controller
6.7 USER MENU
The USER menu contains the INSTALLATION, HOT-WATER, HTG CIRCUIT 1/2, and SOLAR /
MF sub-menus as shown below:
Figure 6-8: USER Menu
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CHAPTER 6: Operation of the E8 Controller
TABLE 6-4: USER Menu
LEVEL
INSTALLATION
ENGLISH
CONTRAST
DISPLAY SEL
SELEC-PROG
RETURN
HOT WATER
1-DHW
T-DHW 1
T-DHW 2
T-DHW 3
BOB VALUE
CIRCL-P-DHW
ANTILEGION
DESCRIPTION
ENTRY
Default
Range
Set language
Adjust intensity of display
Select additional display in standard operation
Heating circuit 1 or Heating circuit 2
ENG
00
---01
If the value is 1, the boiler switches on immediatly
Hot water temperature setting in first enable time
Hot water temperature setting in second enable time
Hot water temperature setting in third enable time
Operation without burner (solar or solid fuel integration)
if the value is 01, the circulation pump runs when the
hot water is enabled, but the circulation program is
disabled.
If the value is 01, every 20th time that heating takes
place or once a week on Saturday at 1:00, the storage
tank is heated up to 149° F
00
140
140
140
0
(01 ÷ 02)
(50 ÷ 158)
(50 ÷ 158)
(50 ÷ 158)
(0 ÷ 126)
0
(0 ÷ 1)
0
(0 ÷ 1)
(-20) / (20)
(01 ÷ 02)
RETURN
HTG CIRCUIT 1/2
T-ROOM DES 1
T-ROOM DES 2
When setting an alternative oparating mode this only
applies to the assigned heating circuit
Room temperature setting in first enable time
Room temperature setting in second enable time
T-ROOM DES 3
Room temperature setting in third enable time
MODE
T REDUCED
T-ABSENCE
T-LIMIT DAY
T-LIMIT N
HEATSLOPE
ADAPTION
OPTIM HEAT
ADAP ROOM-T
OPTIM HEAT
MAX OPT-TIME
ECONO OPTI
PC-ENABLE
SOLAR / MF
RETURN
Required room temperature setting during night
reduction
Required room temperature setting during holidays
Set the temperature value during heating time
Set the temperature value during reduction time
Set the Heatslope according to the installation
Only active if an FBR analogue room device is
connected and an outdoor sensor
Activates the function for automatically starting the unit
Room sensor adaptation
Heating optimisation
The start of heating is brought forward by no more than
this time
Automatic reduction of burner disabling to the end of
set heating time
Code number for enabling access to heating circuit
data from a PC (0000= access is blocked)
----68
68
(41÷105)
(41÷105)
68
(41÷105)
50
(41÷105)
59
66
50
1,20
(41÷105)
(23 ÷104)
(23 ÷ 104)
(0 ÷ 3)
0
(0 ÷ 1)
10
0
0
(0 ÷ 20)
(-9 ÷ 9)
(00 ÷ 02)
2
(00 ÷ 03)
0
(00 ÷ 02)
0000
(0000÷9999)
NOT USED
NOTE:
Some menus are visible only if the relevant sensor is wired.
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CHAPTER 6: Operation of the E8 Controller
6.8 TIME PROGRAM MENU
The TIME PROGRAM menu contains the items shown below:
Figure 6-9: TIME PROGRAM Menu
TABLE 6-5: TIME PROGRAM Menu
LEVEL
DESCRIPTION
CIRCL TIME
Program for circulation pump
*
Program for hot water charging pump
HOTW-PROG ( )
HTG-PROG 1
1
1st Heating program for first controller heating circuit
HTG-PROG 2
1
2nd Heating program for first controller heating circuit
HTG-PROG 1
2
1st Heating program for second controller heating circuit
HTG-PROG 2
2
2nd Heating program for second controller heating circuit
*
( ) = Active only with parameter 1 x HW = 00
NOTE:
By leaving the hour blank_ _ : _ _ the heating period is bypassed.
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CHAPTER 6: Operation of the E8 Controller
6.9 EXPERT MENU
The EXPERT menu contains the items shown below:
Figure 6-10: EXPERT Menu – 1 of 2
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Figure 6-10: EXPERT Menu – 2 of 2
NOTE:
The shaded items in the following table indicate those parameters that change according to the
boiler type and whether used singly or in a cascaded configuration.
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CHAPTER 6: Operation of the E8 Controller
TABLE 6-6: EXPERT Menu
LEVEL
DESCRIPTION
INSTALLATION
BUS-ID HS
BUS ID 1
BUS ID 2
AF SUPPLY
BUS TERM
EBUS SUPPLY
TIME MASTER
MAX T-COLL
MIN T-COLL
MAX T-HS2
MIN T-HS2
V-CURVE
CURVE 11 - U1
CURVE 11 - U2
CURVE 11 - T1
CURVE 11 - T2
CURVE 11 - UA
HYSTERESIS
FOUND MODULS
CAP/MODULE
NEW CONFIG
MIN MOD CASC
HW-BOILER
CONTR DEVIAT
DES OUPUT
BLOCK TIME
MAX T-MODUL
DYN UPWARD
DYN DOWNWARD
RESET TIME
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ENTRY
DEFAULT
RANGE
----
(01 ÷ 08)
01
(01 ÷ 15)
--
(01 ÷ 15)
01
01
(01 ÷ 15)
(00 ÷ 01)
01
(00 ÷ 01)
00
176°F
(01 ÷ 01)
(86 ÷ 230)
50°F
(50 ÷ 176)
185°F
(86 ÷ 230)
104°F
(50 ÷ 176)
11
0V
10 V
68°F
185°F
2V
9
(00 ÷ 11)
(0 V÷10 V)
(0 V÷10 V)
(32 ÷ 248)
(32 ÷ 248)
(0 V÷10 V)
(4Ra÷36Ra)
0
(0÷30 min)
----
(0÷1000)
Boiler Bus address only for cascade of E8
controllers
The heating circuits are sequentially
numbered.....
The heating circuits are sequentially
numbered.....
Outdoor sensor power supply
Bus terminating resistor
Switching eBUS supply on/off in realtion to
connected
00 no time master; 01 controller is time master
Protects the HS from overheating
Decreased condensation build-up in HS with low
heat requirement
Protects the HS from overheating
Decreased condensation build-up in HS with low
heat requirement
Only for 0-10V input/output
Low voltage set
Higth voltage set
Low temperature level
High temperature level
Starting with this voltage level
Dyn. Switching hysteresys stage 1
Display of burners automatically reported via
BUS
After restarting the controller searches the bus
systems
New bus configuration
Min. modulation cascade
Number of stages for HW operation
Header control variance
Required system output [in %]
Currently remaining value
Maximum temperature of the heat generator
Dynamic heat generator connection
Dynamic heat generator deactivation
Resetting time for I-Controller
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0
0
185°F
100
80
180
(00 ÷ 01)
(00 ÷ 100)
(00 ÷ 08)
(00 ÷ 08)
(0 ÷ 100)
(122 ÷ 230)
(20 ÷ 500)
(20 ÷ 500)
(5 ÷ 500)
OMM-0095_0H
GF-139
Modulex EXT Commercial Series Boilers User Manual
CHAPTER 6: Operation of the E8 Controller
TABLE 6-6: EXPERT Menu - Continued
LEVEL
DESCRIPTION
INSTALLATION (Cont.)
IMODULAT MAX
MODULAT MIN
MIN MOD HS
MOD LEVEL HW
SEQUENCE 1
SEQUENCE 2
SEQU CHANGE
SEQ SW TIME
LOCK TIME
HYST BURNER2
HS COOL-FCT
T-HS COOL
HEATSOURCE 1
HS 1 BUS
HEATSOURCE 2
STORAGE HS 2
BUFFER
SCREED
SCREED PROGR
If this modulation degree is exceeded, the next
heat .....
If values drop this modulation degree, the last heat
Connection of the next heat generator
Entry of the set modulation degree for the heat
generators
Boiler sequence 1
Boiler sequence 2
Sequence change mode
Time to sequence change
Min. delay time after switching on or with switching
HS
Solid fuel integration: hysteresys for the charging
pump
Not used
Not used
Primary heat generator type
Connections for HS
Secondary heat generator type
Heat accumulator for HS2
Heater buffer storage tank
Activation of screed drying process
Program setting
ENTRY
DEFAULT
RANGE
35
(10 - 60)
35
35
(10 - 60)
(0 - 60)
80
(40 - 100)
06
200
12345678
87654321
(01 - 06)
(10 - 800)
01
(00 - 30)
4
(3.6 – 36)Ra
0
176
06
02
0
0
0
0
(0 - 1)
(122 - 203)
(00 - 06)
(00 - 04)
(00 - 05)
(00 - 03)
(00 - 03)
(00 - 01)
0
0
(00 - 01)
(00 - 03)
36
(00 - 90) Ra
5
0
0
(9 - 54) Ra
(00 - 30)
(00 - 01)
0
(00 - 01)
0
(00 - 01)
RETURN
HOT-WATER
DHW RELIEF
PARALLEL
T-BOILER DHW
HYST DHW
DHW FOLLOWUP
THER INPUT
WALL HUNG
LOAD THROUGH
The charging pump is not switched until.....
Pump parallel running
Boiler temperature setting with hot water
preparation
Hot water hysteresys
Pump run-down time
Storage tank with thermostat
Boiler temperature setting with hot water
preparation
The charge through function can be activated by...
RETURN
OMM-0095_0H
GF-139
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Page 105 of 144
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 6: Operation of the E8 Controller
TABLE 6-6: EXPERT Menu - Continued
LEVEL
DESCRIPTION
ENTRY
HTG CIRCUIT 1/2
HC FUNCTION
PUMP MODE
MIXER OPEN
MIXER CLOSE
MAX T-FLOW
MIN T-FLOW
T-FROST PROT
OUT-TEMP-DEL
SLOPE OFFSET
B-HEAT SINK
RETURN
Heating circuit function selection
Pump operating mode
Open mixer dynamic
Close mixer dynamic
Max flow temperature setting
Min flow temperature setting
Frost protection temperature
Ouside temperature delay
Heating slope distance
Circuit enable
0
00
18
12
176
10
32
0
9
0
(00 ÷ 04)
(00 ÷ 03)
(5 ÷ 25)
(5 ÷ 25)
(68 ÷ 230)
(50 ÷ 230)
(5 ÷ 41)
(0 ÷ 24)
(0 ÷ 90)
(00 ÷ 01)
SOLAR / MF
RELAY FUNC 1 to 4
T-MF1 to 4 SETP
MF 1 to 4 HYST
FUNZ. F15
RETURN
Function selection relay 1 to 4
Switching temperature relay MF1 to 4
Hysteresys relay MF1 to 4
Sersor function F15
0
86
9
0
(00 ÷ 26)
(86 ÷ 194)
(4 ÷ 18)
(00 ÷ 02)
NOTES:
•
There is another sub-menu under the EXPERT menu called EXPERT HS. See section 4.35
– High Altitude Adjustment for details.
•
Some menus are visible only if the relevant sensor is wired.
6.10 OTHER POSSIBLE SETTINGS
6.10.1 Settings for Heating Circuit 1/2
6.10.1.1 Heating Adjustment With Constant Flow Temp
(Without Outer Sensor)
Offers the possibility to have a constant flow temperature on the selected heating circuit.
•
INSTALLATION menu >
HC FUNC “01”
6.10.1.2 Temperature Settings For Heating Circuits
(Only After Function Selection)
•
USER menu
⇒
Heating circuit I / II
⇒
FLOW TEMP DAY
•
USER menu
⇒
Heating circuit I / II
⇒
FLOW TEMP NIGHT
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 6: Operation of the E8 Controller
6.10.1.3 A Second DHW Storage Tank
(Only After Function Selection)
Offers the possibility to use one of the heating zones for the preparation of a second DHW
storage tank.
EXPERT menu ⇒ Heating circuit I/II ⇒ HC FUNC. “03”
6.10.1.4 Temperature Setting For Second DHW Storage Tank
USER menu ⇒
⇒
Heating circuit / II
T- HW
6.10.1.5 Swimming Pool
Offers the possibility to use one of the heating zones for the heating of a swimming pool.
EXPERT menu ⇒ Heating circuit I/II ⇒ HC FUNC “02”
6.10.1.6 Swimming Pool Temperature Setting
(Only After Function Selection)
USER menu ⇒ Heating circuit I / II
⇒
T- POOL 1 / 2 / 3
6.10.1.7 Screed Dry Program (For Floor Heating Installation)
A program setting for drying the screed.
EXPERT menu ⇒ Installation ⇒ SCREED “01”
6.10.1.8 Temperature Setting For Screed Program
USER menu
⇒
Heating circuit I / II
6.10.1.9 Signal 0 – 10 V
Uses a 0-10 V input to control fire rate via an external control..
EXPERT menu ⇒ Solar/MF ⇒ FUNC. F15 “01”
6.10.1.10 Slope And Temperature Setting with 0 – 10 V Signal
See Table 6-7 for values.
EXPERT menu ⇒ Installation
EXPERT menu ⇒ Installation
OMM-0095_0H
GF-139
⇒ TENS SLOPE (0 to 11)
⇒ SLOPE 11 – XX (freely settable)
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 6: Operation of the E8 Controller
TABLE 6-7: 0-10V Signal with Slope and Temperature
Curve
U1
U2
T1
T2
UA
0
1
2
3
4
5
6
7
8
9
10
11
2.0 V
2.5 V
2.5 V
2.5 V
4.0 V
4.0 V
4.0 V
4.0 V
4.0 V
4.0 V
4.0 V
4.0 V
10.0 V
0.3 V
0.3 V
0.3 V
0.1 V
0.1 V
0.1 V
0.1 V
0.1 V
0.1 V
0.1 V
0.1 V
32° F
100° F
100° F
100° F
68° F
68° F
68° F
68° F
68° F
68° F
68° F
68° F
194° F
176° F
167° F
113° F
185° F
167° F
131° F
189° F
189° F
163° F
127° F
194° F
2.0 V
5.0 V
5.0 V
5.0 V
5.0 V
5.0 V
5.0 V
5.0 V
5.0 V
5.0 V
5.0 V
5.0 V
6.10.2 Setting of DHW Circuit
6.10.2.1 Operation of Pumps In Parallel
Heating pump operation during DHW production.
EXPERT menu ⇒ Hot Water ⇒ F-PUMP PARAL “00,01,02,03”
6.10.2.2 Use of a DHW Storage Tank Thermostat (On/Off)
To use an ON - OFF thermostat instead of DHW sensor.
EXPERT menu ⇒ Hot Water ⇒ THER IMPUT “01”
6.10.2.3 Antilegion
Activation of an antilegion program.
EXPERT menu ⇒ Hot Water ⇒
ANTILEGION “01”
6.10.2.4 Setting for Solar Panel Use
Use a PT 1000 sensor as a solar panel sensor.
EXPERT menu ⇒ Solar/ MF ⇒ FUNC RELAY 4 “23”
6.11 ACCESS CODE SETTING
To set the access code, press the Programming button to enter the first parameter, use the data
knob to select a number, and then press the Programming button to accept the value. Repeat
this procedure for each code number position.
Figure 6-11: Setting the Access Code
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 7: Troubleshooting
CHAPTER 7: TROUBLESHOOTING
7.1 E8 CONTROLLER FAULT CODES
Fault codes are displayed in the upper right hand section of the E8 Controller display (see
Figure 7-1). Use Table 7-1 (next page) to determine the fault message. There are codes for the
following three different devices:
•
E8 Controller: These are divided into four basic categories: PCB element faults, system
manager faults, communication faults, and internal faults. These fault codes are shown in
Table 7-2.
•
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.
FAULT CODE
Figure 7-1: E8 Fault Code Location
NOTE:
When interpreting fault codes in the E8 display that refer to the E8 controller itself, the code
number is directly referenced to a fault description in Table 7-2.
Displayed fault codes not listed in Table 7-2 refer to devices other than the E8 controller, such
as the Boiler Management module (BMM) or Burner Controller Module (BCM). Use Table 7-1
(and the formula described below the table) to arrive at a fault number, which can be looked up
in Tables 7-3 and 7-4 for the fault description.
OMM-0095_0H
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 7: Troubleshooting
In order to derive the fault message from the code displayed in the E8 Controller display, use
Table 7-1 below to determine the working fault code. To use the table, find the displayed
number in the first column, identify the affected module from the second column, apply the
formula from the third column, and identify the fault table to reference from the fourth column.
TABLE 7-1: Determining the “Error Code” Reading from the E8 Display
OBSERVED CODE
OBSERVED
CODE
CODE TO LOOK UP IN
TABLE
Code = 0
N/A
No Fault
-
Code between 1 and 255
BMM #0 Fault
Look up code
6-4
Code between 256 and 511
BMM #1 Fault
Subtract 256 from reading
6-4
Code between 512 and 767
BMM #2 Fault
Subtract 512 from reading
6-4
Code between 768 and 1023
BMM #3 Fault
Subtract 768 from reading
6-4
Code between 1024 and 1279
BMM #4 Fault
Subtract 1024 from reading
6-4
Code between 1280 and 1535
BMM #5 Fault
Subtract 1280 from reading
6-4
Code between 1536 and 1791
BMM #6 Fault
Subtract 1536 from reading
6-4
Code between 1792 and 2047
BMM #7 Fault
Subtract 1792 from reading
6-4
Code between 2048 and 65279
N/A
Invalid Codes
Code above 65280
BCM Fault
Subtract 65280 from reading
6-3
EXAMPLE:
Based on the above, a code reading of “261” means the fault occurred on BMM #1.
The fault code is (261 – 256 = ) 5. An Error Code of 5 from the BMM Fault Codes table
means “Flame Loss During Run”.
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 7: Troubleshooting
7.1.1 E8 Controller Fault Codes
The table below lists the fault codes and fault descriptions associated with the E8 Controller.
TABLE 7-2: E8 Controller Fault Codes
CODE
DESCRIPTION
EFFECT
CORRECTION
RESET
PCB Element Fault
E1
Intervention of the
high limit thermostat
(TL).
Insufficient gas
pressure.
Boiler shuts off.
E4
No flame detected
during the ignition
phase.
Boiler will not remain
lit after 3 attempts.
E5
Loss of flame signal
during boiler
operation.
Boiler fails after
establishing flame
E6
Over high water
temperature detected
by the heating sensor
(SR) (>203°F).
Internal failure of the
local control PCB
(BMM).
Boiler shuts off.
Flame signal detected
before the ignition
cycle.
Local flow sensor
failure SR1 first
module.
Failure of the heating
return sensor (SRR).
Difference between
the global return
heating temperature
global sensor and the
heating flow sensor
greater than (>) 86 °F
(rp +10).
Boiler will not
attempt ignition.
E2
E 10
E 11
E 12
E 14
E 15
OMM-0095_0H
GF-139
Check for any obstructions
in the piping. Ensure
sufficient flow.
Check gas supply to the
unit and ensure minimum
3.5" w.c. at high fire
Watch ignition through
viewport. Ensure correct
120V wiring to the unit.
Clean or replace flame rod.
Ensure sufficient gas
pressure and flow during
high fire operation and
with any other connected
gas equpiment running.
Check and clean flame rod.
Check for any obstructions
in the piping. Ensure
sufficient flow.
MANUAL - Pushbutton
under cap, located to the
left of the E8 controller.
AUTOMATIC
Shut off power to the
boiler. Check fuse on
BMM. Replace BMM if
necessary.
Allow flame rod to cool.
Possibly replace flame rod.
AUTOMATIC - After turning
power on to the unit.
Check with multimeter and
replace if necessary.
AUTOMATIC
Check with multimeter and
replace if necessary.
Boiler shuts off and
Check for any obstructions
pump turns on at max in the piping. Ensure
speed.
sufficient flow.
AUTOMATIC
Boiler will not run.
Module shuts off.
Module will not run.
Module will not run.
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MANUAL - Clear fault and
retry ignition.
AUTOMATIC - Clear fault
and retry ignition.
AUTOMATIC - After
temperature falls.
MANUAL - Clear fault and
retry ignition.
AUTOMATIC - When ΔT <
protection temperature
Page 111 of 144
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CHAPTER 7: Troubleshooting
TABLE 7-2: E8 Controller Fault Codes (Continued)
CODE
E 16
DESCRIPTION
EFFECT
Boiler body
temperature very low:
Ice forming risk
Flame signal detected
after burner is OFF.
Modulating fan speed
failure: failed to reach
the correct speed
within 30 seconds
from starting of
burner ignition cycle.
Modulating fan speed
failure: failed to stop
within 30 seconds
from end of operation
Common chimney
obstruction.
Boiler will not run.
Pump runs for 5
minutes.
Boiler will not run.
E29
Water inside exhaust
chamber.
Boiler shuts off.
E 30
Alteration of the
operating parameters
caused by EMC
disturbances.
Mains supply voltage
< 108 VAC.
Low water flow.
Boiler will not run.
Pump runs for 5
minutes.
E 20
E 24
E 26
E 28
E 32
E 40
E 41
E 42
E 43
Presence of air in the
pump (only with
SensorLogic)
Pump blocked (only
with SensorLogic)
Pump wire failure
(only with
SensorLogic)
Page 112 of 144
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CORRECTION
RESET
Carefully defrost boiler.
AUTOMATIC - when
sensor is >41°F
Allow flame rod to cool.
Possibly replace flame rod.
Check Expert HS fan speed
settings. May require a new
blower.
MANUAL - Push reset
switch or cycle power.
AUTOMATIC
Boiler will not
ignite.
Check Expert HS fan speed
settings. Check fan wiring. May
require a new blower.
AUTOMATIC
Boiler will not run.
Check pressure in chimney
during operation. Ensure hoses
to pressure switches are clear.
Check for backed up
condensate in exhaust
manifold. Clean p-trap and
condensate drain line. Check
float sensor in exhaust
manifold for proper operation.
Re-program settings. Contact
factory.
MANUAL
Boiler shuts off/will
not run.
Boiler shuts off/will
not run.
n/a
Check supply voltage.
AUTOMATIC
Check water flow, flow switch
(or LWCO) operation.
n/a
AUTOMATIC
n/a
n/a
n/a
n/a
n/a
n/a
Boiler will not
ignite.
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AUTOMATIC
MANUAL - Push reset
switch or cycle power.
n/a
OMM-0095_0H
GF-139
Modulex EXT Commercial Series Boilers User Manual
CHAPTER 7: Troubleshooting
TABLE 7-2: E8 Controller Fault Codes (Continued)
CODE
DESCRIPTION
EFFECT
CORRECTION
RESET
System Manager Fault – Sensor Defective (Break/Short Circuit)
E 69
E 70
E 71
E 72
E 75
E 76
E 78
E 80
E 83
E 135
E 136
E 137
E 138
E8: F5 – Flow temperature
sensor heating circuit 2.
E8: F11 – Flow
temperature sensor
heating circuit 1.
E8: F1 – Lower storage
temperature sensor
(Buffer).
E8: F3 – Higher storage
temperature sensor
(Buffer).
E8: F9 – Outer
temperature sensor (AF).
E8: F6 – DHW storage
temperature sensor (SPF).
E8: F8 – Boiler
temperature sensor (KF).
E8: F2 – Room
temperature sensor
heating circuit 1.
E8: F15 – Room
temperature sensor
heating circuit 2.
E8: F12 – Lower DHW
storage temperature
sensor MF2.
E8: F13 – Boiler 2,
Manifold 2 MF 3.
E8: F14 – Manifold 1,
Multifunction 4.
E8: F15 – Room
temperature Hc2.
Check continuity. Use
multimeter to measure sensor.
Check continuity. Use
multimeter to measure sensor.
AUTOMATIC
Check continuity. Use
multimeter to measure sensor.
AUTOMATIC
Check continuity. Use
multimeter to measure sensor.
AUTOMATIC
Check continuity. Use
multimeter to measure sensor.
Check continuity. Use
multimeter to measure sensor.
Check continuity. Use
multimeter to measure sensor.
Check continuity. Use
multimeter to measure sensor.
AUTOMATIC
Check continuity. Use
multimeter to measure sensor.
AUTOMATIC
Check continuity. Use
multimeter to measure sensor.
AUTOMATIC
Check continuity. Use
multimeter to measure sensor.
Check continuity. Use
multimeter to measure sensor.
Check continuity. Use
multimeter to measure sensor.
AUTOMATIC
AUTOMATIC
AUTOMATIC
AUTOMATIC
AUTOMATIC
AUTOMATIC
AUTOMATIC
Communication Fault
E 90
E 91
E 99
E8: BUS addresses 0 and 1.
The BUS codes 0 and 1
cannot be used at the
same time.
E8: BUS code occupied.
The set BUS code is
already used by another
appliance.
E8: Internal failure.
OMM-0095_0H
GF-139
Check addresses
Check addresses
Check E8 settings. Possibly
replace E8.
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AUTOMATIC
Page 113 of 144
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CHAPTER 7: Troubleshooting
TABLE 7-2: E8 Controller Fault Codes (Continued)
CODE
DESCRIPTION
EFFECT
CORRECTION
E 200
Communication Error HS1
Communications issue with BMM
0. Check all eBUS addresses
E 201
Communication Error HS1
Communications issue with BMM
1. Check all eBUS addresses
E 202
Communication Error HS1
Communications issue with BMM
2. Check all eBUS addresses
E 203
Communication Error HS1
Communications issue with BMM
3. Check all eBUS addresses
E 204
Communication Error HS1
Communications issue with BMM
4. Check all eBUS addresses
E 205
Communication Error HS1
Communications issue with BMM
5. Check all eBUS addresses
E 206
Communication Error HS1
Communications issue with BMM
6. Check all eBUS addresses
E 207
Communication Error HS1
Communications issue with BMM
7. Check all eBUS addresses
RESET
Internal Fault
E 81
E8: EEPROM fault. The
invalid value has been
replaced by the standard
value.
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 7: Troubleshooting
7.1.2 BCM (Boiler Communications Module) Fault Codes
The table below lists the fault codes and troubleshooting tips associated with the BCM.
TABLE 7-3: BCM Fault Codes
CODE
DESCRIPTION
EFFECT
CORRECTION
RESET
Boiler pipe is frozen.
Flow sensor temp. 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.
E 18
Maximum Δtemperature protection.
Flow temperature Return Temperature >
Water Δ-Temp
Protection + 50°F
All burners turned
OFF and Pump
ON at maximum
speed.
Check the
system
installation.
AUTOMATIC - when Δtemperature < Water ΔTemp Protection.
E 19
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.
E 37
BCM: Internal fault
E 38
Settings corrupted by
electromagnetic
interference.
Ignition is
inhibited. Pump
runs for 5 min at
max speed.
Re-program
the settings.
Contact
factory.
E 56
BCM: No remote
control detected
E 57
BCM: No BMM
detected
Ignition is
inhibited.
Close request
input for
manual
operation.
E 17
E 58
BCM: Sensor global
flow detected.
OMM-0095_0H
GF-139
MANUAL - push reset
switch or cycle power.
MANUAL - push reset
switch or cycle power.
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 7: Troubleshooting
7.1.3 BMM (Burner Management Module) Fault Codes
The table below lists the fault codes and troubleshooting tips associated with the BMM.
TABLE 7-4: BMM Fault Codes
CODE
E1
E2
E4
E5
E6
E 10
E 11
E 12
E 13
DESCRIPTION
EFFECT
CORRECTION
RESET
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.
Low gas
pressure.
All burners
turned OFF.
Check gas pressure or gas
pressure switch.
AUTOMATIC when gas
pressure switch
closes.
No flame
detected at
burner start.
Burner control
lockout.
Check flame rod or
combustion.
MANUAL - push
reset switch or
cycle power.
Flame loss during
run.
Ignition retry.
Check combustion and
wiring.
MANUAL - push
reset switch or
cycle power.
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.
Internal failure.
Ignition is
inhibited.
Contact factory for new
BMM.
MANUAL - cycle
the power.
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.
Flow sensor fault.
All burners
turned OFF.
Check flow sensor or
wiring.
AUTOMATIC
The boiler will
operate from the
Flow sensor
without the Aux
sensor.
Check aux sensor or
wiring.
Aux sensor fault.
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 7: Troubleshooting
TABLE 7-4: BMM Fault Codes
CODE
DESCRIPTION
EFFECT
CORRECTION
RESET
E 14
Return sensor
fault.
All burners
turned OFF.
Check return sensor or
wiring.
AUTOMATIC
All burners
turned OFF
and Pump
ON at
maximum
speed.
Check the system
installation.
AUTOMATIC - when
Δ-temperature < Water
Δ-Temp Protection.
E 15
Maximum Δtemperature
protection.
Flow
temperature Return
Temperature >
Water Δ-Temp
Protection +
50°F.
Ignition is
inhibited.
Pump runs for
5 min at max
speed.
Carefully defrost boiler.
E 16
Boiler pipe is
frozen. Flow
sensor
temperature is
36°F or less.
AUTOMATIC - when
flow sensor is greater
than 41°F.
Flame signal
detected after
burner is OFF.
Ignition is
inhibited.
Disconnect gas valve wire
from BMM. If failure goes
away, check wiring or
change BMM. If failure
remains, check or change
gas valve.
MANUAL - push reset
switch or cycle power.
No air flow at
burner after fan
started for 30
seconds.
Ignition retry
after 60
second delay
and failure
remains until
a successful
burner
operation.
If fan is stopped, check
supply voltage and fan
wiring. If OK, try another
fan. If still not working,
change the BMM.
If fan is not stopped, check
the exhaust gas outlet for
blockage. If OK, check the
air pressure switch wiring.
If still not working, try
another air pressure
switch. If still not working,
change the BMM.
AUTOMATIC/MANUAL
The air
pressure
switch doesn't
switch off.
Ignition is
inhibited.
Disconnect the air proving
switch. If problem goes
away, install a new switch.
If not, check the wiring. If
wiring is OK, change BMM.
AUTOMATIC
E 20
E 22
E 23
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CHAPTER 7: Troubleshooting
TABLE 7-4: BMM Fault Codes
CODE
DESCRIPTION
EFFECT
CORRECTION
RESET
E 24
Fan speed out
of control: It
doesn't reach
pre-purge
speed within 30
seconds.
Ignition retry
after 60
second delay
and failure
remains until
we have a
successful
burner
operation.
Check fan wiring.
AUTOMATIC/MANUAL
E 26
Fan speed out
of control: It
doesn't stop
within 30
seconds after
turned OFF.
Ignition is
inhibited.
Check fan wiring.
AUTOMATIC
Air flow failure
during ignition.
Restart prepurge timer.
The failure
remains until
we have a
successful
burner
operation.
Check fan and wiring.
Check air proving switch
and wiring.
AUTOMATIC
E 30
Settings
corrupted.
Ignition is
inhibited.
Pump runs for
5 min at max
speed.
Re-program the
settings. Contact
factory.
MANUAL - cycle the
power or send reset
message.
E 32
Line voltage too
low (<96 VAC).
Wait for proper
line voltage
(>102 VAC).
Check input voltage. Try
another BMM.
AUTOMATIC
E 40
Low water flow.
Low water flow
switch
activated.
Burners turned
OFF.
Check water flow or
check switch.
AUTOMATIC
E 27
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CHAPTER 8: Maintenance Schedule
CHAPTER 8: MAINTENANCE SCHEDULE
The boiler must receive regular, annual maintenance and cleaning in order to ensure reliable
and efficient operation. Regular maintenance will prolong the life of the boiler. Refer to Table 81 for a suggested schedule of maintenance procedures.
Maintenance must be performed annually.
CAUTION!
To ensure the continued safe and efficient operation of the boiler it is highly recommended
that it be checked at regular intervals and serviced when necessary, and that only original
spare parts be used. Regular maintenance will prolong the life of the boiler.
WARNING!
If the boiler is not checked and serviced regularly it could cause damage to the
equipment and/or harm to persons.
TABLE 8-1: MODULEX EXT Maintenance Schedule
MAINTENANCE OPERATION
CHECK ONCE
A YEAR
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 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.
●
●
Check all water connections and valves.
Do combustion analysis and recalibrate if necessary.
●
●
Check electrical and electronic components
Inspect condensate drain and P-trap, clean if necessary.
●
Check flow switch in CSD-1 manifold for proper function
●
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CHAPTER 8: Maintenance Schedule
8.1 INSTRUCTIONS FOR INSPECTION AND MAINTENANCE
WARNING!
To ensure a long life of the boiler components and in order not to alter the conditions of
an approved product, ONLY original AERCO spare parts may be used.
Before servicing, always carry out the following steps:
1. Disconnect the mains electrical supply to the boiler.
2. Separate the boiler from the electrical supply by means of a separating device with an open
contact of at least 3 mm (for example, safety devices or power switches) and ensure that it
cannot be accidentally connected to power.
3. Close the external ON-OFF gas valve installed upstream of the boiler.
4. If necessary, and in keeping with the type of work to be carried out, close any ON-OFF
valves fitted on the C/H flow and return pipes, as well as the cold water inlet valve.
5. Remove the boiler front panel.
6. Perform the maintenance in keeping with official instructions and accepted standards and
regulations.
7. After completing all the necessary maintenance work, always follow these steps:
a) Open the C/H flow and return valves 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 water side.
8. Replace the boiler front panel.
8.2 PERIODIC EXAMINATION OF VENTING SYSTEM
The inspection of the boiler and venting system should be performed every year and full
maintenance should be done every two years. Please contact AERCO for further guidance on
the frequency 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 PROPER PROCEDURE FOR CLEANING EXHAUST FLUE
The flue exhaust system, including condensate evacuation, should be checked annually. Annual
maintenance includes verifying that the flue manifold and exhaust vents are clean and
unobstructed. It is necessary to inspect and clean the condensate siphon in particular.
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8.3.1 Cleaning the Condensate Drain Line
In order to inspect and clean the condensate line, do the following:
1. Refer to Figure 8-1, disconnect the pipe at location “A“.
2. Check that no deposits have accumulated inside the drain. If there are any deposits flush
them out with clean 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 SWITCH
Check the function of the flow switch in the CSD-1 manifoild at the boiler hot water outlet. If it is
not functioning, check the wiring to the terminal of the BMM module labeled “FL“ or replace with
a new flow switch.
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CHAPTER 8: Maintenance Schedule
8.5 VISUAL INSPECTION OF THE FLAME
(2 and 4 year maintenance)
The burner must flame evenly over the entire 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 the illustration below.
8.5.1 FLAME COLOR:
•
YELLOW
= CO2 HIGH
NOT SATISFACTORY
•
BLUE
= CO2 LOW
NOT SATISFACTORY
•
ORANGE
=
SATISFACTORY
OK
IGNITER CABLE
FLAME OBSERVATION
PORT
FLAME DETECTOR
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
piping correctly. Refer to AERCO’s MODULEX Venting Application Guide (GF-136-V) for
information concerning MODULEX venting requirements.
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CHAPTER 8: Maintenance Schedule
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 of condensation problems within the
hoses. See
Original
Length OK
NOT
ACCEPTABLE
Original
Length OK
NOT
ACCEPTABLE
Figure 8-3: Pressure Hose Lengths
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CHAPTER 8: Maintenance Schedule
8.8 BURNER / HEAT EXCHANGER CLEANING PROCEDURE
Dust and other particulate matter infiltrating into the combustion chamber over time will cause a
decrease of heating efficiency and output due to the buildup of combustion by-products onto the
thermally conductive surfaces. These surfaces must be cleaned from time to time in order to
return the unit to its original specifications for thermal efficiency and heat output.
For detailed cleaning instructions, see section 8.11.
NOTE:
A reduction of 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 4.33).
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)
between the two sensors with a voltmeter. Use the chart below to determine the correct
resistance values at the given temperature ratios.
TABLE 8-2: Resistance Values for Primary and Return Heat Sensors
Resistance (Ω)
°F
°C
32°
0°
32,755
50°
10°
20,003
68°
20°
12,571
86°
30°
8,112
104°
40°
5,363
122°
50°
3,627
140°
60°
2,504
152°
70°
1,762
176°
80°
1,263
194°
90°
920
Example: At 104 °F (40°C), the nominal resistance is 5,363 Ohm. At 194 °F (90°C), the nominal
resistance is 920 Ohm
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CHAPTER 8: Maintenance Schedule
8.10 UNIT DISASSEMBLY
To disassemble the unit for maintenance, do the following:
Disassembling the EXT Boiler for Maintenance
1. Switch OFF external electrical power and CLOSE the gas supply valve upstream from the
boiler, 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 85). 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.
NOTE
Commercial units have a special
latch kit to hold up the top plate,
Unical part number 00362418.
Figure 8- 4: Unlatch Top Lid (Step 2)
Figure 8-5: Remove Screws at Edges and Remove Side and Rear Panels (Step 3)
Figure 8-6: Remove Panels (Step 3) Figure 8-7: Remove Flue Assembly (Step 4)
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CHAPTER 8: Maintenance Schedule
Disassembling the Boiler for Maintenance – Continued
4. Remove ten (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).
Air Intake
Manifold
Manifold
Retention
Spring Clip
(Left & Right)
Figure 8-9: Unlatch Spring Clips from Left and Right Side of Manifold (Step 5)
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Disassembling the Boiler for Maintenance – Continued
6. Remove the rubber hoses (quantity depends on model) from bottom side of manifold
(highlighted in Figure 8-10), then lift entire manifold from the unit.
Lift out manifold after removing hoses.
Remove
Hoses from under
Manifold
(one per module)
Air Intake
Manifold
Figure 8-10: Removing Red Hoses and Manifold from Unit (Step 6)
7. Burner maintenance may be performed on all burner modules simultaneously or on each
one separately, as described in a) and b) below:
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 8-11), then remove the “B”
Phillips screw at the end of the burner module. You can then skip the remaining steps in
this section and continue with section 8-11 - Cleaning the Burner Module.
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CHAPTER 8: Maintenance Schedule
Disassembling the Boiler for Maintenance – Continued
C
B
A
Figure 8-11: Removing the Burner Module Plate Covers (Step 7)
8. Use a 36 mm wrench to disassemble all the gas pipes from the gas manifold. See Figure
8-12.
Figure 8-12: Removing the Gas Pipes from Gas Manifold (Step 8)
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Disassembling the Boiler for Maintenance – Continued
9. In order to hold up the burner assembly in place, lift up the front of the burner assembly
until the two lift pins are aligned with the left and right side tab holes (refer to Figure 8-13).
Tab
Hole
Elevate the burner assembly slightly to line
up this screw with the tab hole.
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)
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CHAPTER 8: Maintenance Schedule
Disassembling the Boiler for Maintenance – Continued
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
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CHAPTER 8: Maintenance Schedule
Disassembling the Boiler for Maintenance – Continued
NOTE
The check valve (1 in Fig. 719) should be checked at this
time to ensure that it moves
freely and closes properly.
Figure 8-19 Lifting Burner Assembly and Location of the Check Valve
8.11 CLEANING THE BURNER MODULE
After completing the previous section, the individual burner modules are exposed and available
to be cleaned. Follow the instructions to clean the burner modules.
Cleaning the Burner Modules
1. Carefully lift each burner module from its position. Remove both the module and the
gasket. Discard the used gasket, as each one will be replaced at reassembly.
WARNING!
The burner gaskets MUST be replaced at every cleaning.
2. Use only compressed air to clean the burners by blowing into the “flame” side of the
burner mesh, as shown in Figure 8-20.
COMPRESSED AIR
Figure 8-20: Burner Module Profile Compressed Air Orientation (Step 2)
3. Visually inspect burner mesh and the spot welds 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. Inspect the flue exhaust section, including the exhaust piping.
8.12 CLEANING THE HEAT EXCHANGER
Over time, hard combustion by-product deposits can form on the combustion chambers’ heat
exchanger elements. Routine annual maintenance may be sufficient to keep these elements
clean. However, if the by-product build-up is too great, the efficiency of the heat exchanger will
degrade and the unit’s overall efficiency will decline.
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CHAPTER 8: Maintenance Schedule
If an inspection of the heat exchanger reveals a build-up of combustion by-product deposits,
complete the instructions below to clean the heat exchangers mechanically (section 8.12.1) and,
if necessary, with a chemical cleaning solution specifically designed for removing combustion
by-products from the fire side 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 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
Complete the instructions below to mechanically remove as much combustion by-product as
possible from each burner’s combustion chamber.
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 rows of pins, however a combination of different
sized brushes may be useful.
Figure 8-21: Modulex Heat Exchangers – Cut-Away View
CAUTION!
Use only plastic-bristled brushes, not wire brushes, during cleaning. Wire brushes could
damage the surface of the aluminum heat exchanger rods.
2. Wash the combustion chamber underneath with water. Avoid getting the electrical
harnesses and components wet. During this operation, inspect the condensate drain pipe
to determine if it is free of obstructions; wash water should drain freely from the
condensate drain pipe.
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Mechanical Cleaning of the Heat Exchanger – Continued
Figure 8-22: Angle of Cleaning Instrument – Heat Exchanger Cut-Away View
3. The most crucial area to clean is the bottom of the heat exchanger, where the heat
exchanger pins are the closest. This can be done by removing one of the exhaust
manifold “blanks” 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 area manually, insert your cleaning
instrument at an angle between the pins, as shown in Figure 8-22, below. Be sure to clean
the space between each pin.
4. Repeat the previous step on each burner module in the unit.
5. After mechanical cleaning, rinse each heat exchanger with water until no further debris
comes out.
6. After washing the aluminum components, make sure the condensate siphon is free of
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 the build-up, complete the instructions below to
clean the heat exchangers with a cleaning solution specifically designed for removing
combustion by-products from aluminum heat exchangers. The product approved by AERCO is
AXI-Therm Boiler Combustion Side Cleaner, Part A and Part B. The instructions below
require 4 to 12 oz. (120 mL to 360 mL) EACH of Part A and Part B per 100,000 BTU/hr. of unit
capacity.
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CHAPTER 8: Maintenance Schedule
CAUTION!
Use of neoprene gloves and protective goggles is recommended. Consult the Axiom
Industries web site (axiomind.com) for additional health and safety information.
Chemical Cleaning of the Heat Exchanger
1. Spray undiluted AXI-Therm Boiler Combustion Side Cleaner, Part A directly onto all
the heat exchanger’s internal surfaces, continuing till they are completely wet. A heavy
application of the solution should reach most of the surfaces that cannot be seen.
2. Let stand for 10 to 20 minutes to allow the product to 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 rinse all
surfaces with clean water.
4. Next, spray undiluted AXI-Therm Boiler Combustion Side Cleaner, Part B directly onto
all heat exchanger surfaces, allow to stand for 10 to 20 minutes, and then rinse with plenty
of clean water. This step creates a thin oxide layer on the aluminum pins, which protects
them during operation. WARNING: do not let this solution sit for more than 20
minutes, as over-exposure could damage the heat exchanger.
5. Collect and dispose of the used solution and rinse water according to local regulations –
DO NOT dispose of rinse water into the environment or local sewer system.
8.12.3 Repeat Cleaning
The procedure in the previous section will remove smaller deposits and loosen larger deposits.
If there are still large deposits, repeat the manual cleaning process in section 8.12.1. At this
point a stiff plastic bristle brush should remove a significant amount 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:
Reassembling the Burner Modules
1. After the cleaning of the combustion chamber and/or the burners, inspect the condensate
drain pipe to determine if it is free of obstructions; wash water should drain freely from the
condensate drain pipe. Also make sure the condensate siphon is free of obstructions,
cleaning it if necessary.
2. Reposition the burners into their proper positions.
3. Position the new gaskets onto each burner module and ensure proper positioning. Make sure
all surfaces are smooth and free of debris.
WARNING!
The burner gaskets MUST be replaced at every cleaning.
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Reassembling the Burner Modules – Continued
4. Proceed with reassembly, performing whichever disassembly operation was chosen (all or
individual method) in reverse order.
a) Lower burner assembly
b) Reinstall gas collector tubes to the gas manifold tube.
c) Reinstall nuts “A,” “C” and “B” screws to secure burner assembly to boiler body.
NOTE:
Tighten the burner bolts with a torque of 9.5 ft-lbs (13 Nm).
d) Reassemble rubber hoses to the air intake manifold, place manifold onto the blowers,
then reattach tension spring clip to left and right ends of manifold.
e) Proceed to section 8.14 for final procedures before returning boiler to service.
8.14 FINAL PROCEDURES AFTER MAINTENANCE
Before returning the boiler to service, the following procedures must be performed:
Final Procedures after Maintenance
1. Before lighting the boiler ensure the condensate line has been 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 bubble check for leaks using a soap solution.
3. When a single burner is ignited, check immediately to ensure that the gas valve and the
relevant premixing chamber are operating correctly.
4. Perform the combustion gas analysis and check all parameters (see section 4.33).
5. Make sure that all the pressure test nipples, previously opened, have been closed.
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CHAPTER 8: Maintenance Schedule
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
Inspection Kits contain flame detector, igniter, and burner gaskets.
TABLE 8-3: MLX 12-Month Maintenance Kit
P/N
DESCRIPTION
58086-01
EXT-321, ANNUAL MAINTENANCE KIT
58086-02
EXT-481/450, ANNUAL MAINTENANCE KIT
58086-03
EXT -641/600 OR EXT-1530/1500, ANNUAL MAINTENANCE KIT
58086-04
EXT -802/800 OR EXT-1912, ANNUAL MAINTENANCE KIT
58086-05
EXT -962 OR EXT-2295/2300, ANNUAL MAINTENANCE KIT
58086-06
EXT -1123/1100 OR EXT-2677/2600, ANNUAL MAINTENANCE KIT
58086-11
EXT -3060/3000, ANNUAL MAINTENANCE KIT
TABLE 8-4: MLX 24-Month Maintenance Kit (Fireside Inspection)
P/N
DESCRIPTION
58086-12
EXT -321, 24 MONTH FIRESIDE INSPECTION KIT
58086-13
EXT -481/450, 24 MONTH FIRESIDE INSPECTION KIT
58086-14
EXT -641/600, 24 MONTH FIRESIDE INSPECTION KIT
58086-15
EXT -802/800, 24 MONTH FIRESIDE INSPECTION KIT
58086-16
EXT -962, 24 MONTH FIRESIDE INSPECTION KIT
58086-17
EXT -1123/1100, 24 MONTH FIRESIDE INSPECTION KIT
58086-18
EXT -1530/1500, 24 MONTH FIRESIDE INSPECTION KIT
58086-19
EXT -1912, 24 MONTH FIRESIDE INSPECTION KIT
58086-20
EXT -2295/2300, 24 MONTH FIRESIDE INSPECTION KIT
58086-21
EXT -2677/2600, 24 MONTH FIRESIDE INSPECTION KIT
58086-22
EXT -3060/3000, 24 MONTH FIRESIDE INSPECTION KIT
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 8: Maintenance Schedule
8.16 ACCESSORY KIT PART NUMBER
The following MODULEX EXT Accessory Kits are available:
• 58096, for MODULEX EXT models: 1530 / 1500, 1912
• 58097, for MODULEX EXT models: 2295 / 2300, 2677 / 2600, 3060 / 3000
The contents of each are listed in the table below:
TABLE 8-5: MLX Accessory Kit (P/N 58096 & 58097)
ITEM #
QTY.
P/N
1
1
123675-2
2
1
3
DESCRIPTION
Included in Kit
58096
58097
GAUGE, PRESSURE/TEMP


39003-1
10” AIR INLET ADAPTER

1
39003-2
12” AIR INLET ADAPTER
4
1
93087
1-1/2 X 1-1/4 PVC RED.CLAMP


5
1
64105
FLOW SWITCH


OMM-0095_0H
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
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CHAPTER 8: Maintenance Schedule
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 9: Spare Parts and Drawing Lists
CHAPTER 9: SPARE PARTS DRAWING AND LISTS
OMM-0095_0H
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CHAPTER 9: Spare Parts and Drawing Lists
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Modulex EXT Commercial Series Boilers User Manual
CHAPTER 9: Spare Parts and Drawing Lists
Modulex EXT Commercial Spare Parts List
Item Part No.
Description
Quantity
1
95000021
Heating Sensor 3/4” T7335D1016 10K
1
2
95000467
Sight glass Kit - Comb Chamber
1
3
95000657
Silicone tube 4 X 8
1
95000970
COMPLETE CASTING SECTIONS ASSEMBLY MLX 1500 & 1530
1
95000971
COMPLETE CASTING SECTIONS ASSEMBLY MLX 1912
1
95000972
COMPLETE CASTING SECTIONS ASSEMBLY MLX 2295 & 3000
1
95000973
COMPLETE CASTING SECTIONS ASSEMBLY MLX 2600 & 2677
1
95000974
COMPLETE CASTING SECTIONS ASSEMBLY MLX 3000 & 3060
1
5
95000975
BMM ELECTRONIC BOARD MLX 1500 – 3060
1
6
95000962
BCM control unit
1
95213360
CONDENSATE TRAY ASSEMBLY MLX EXT 1500 & 1530
1
4
95213365
CONDENSATE TRAY ASSEMBLY MLX EXT 1912
1
95213366
CONDENSATE TRAY ASSEMBLY MLX EXT 2295 & 3000
1
95213367
CONDENSATE TRAY ASSEMBLY MLX EXT 2600 & 2677
1
95213368
CONDENSATE TRAY ASSEMBLY MLX EXT 3000 & 3060
1
95213960
Left Side Panel MLX EXT 1500 – 3060
1
9
95213399
Right Side Panel MLX EXT 1500 – 3060
1
10
95213400
Plate side closing MLX EXT 1500 – 3060
1
95213402
Casing Front Panel MLX EXT 1500 & 1530
1
7
8
11
95213403
Casing Front Panel MLX EXT 1912 – 2300
1
95213404
Casing Front Panel MLX EXT 2600 - 3060
1
95213405
Casing Rear Panel MLX EXT 1500 & 1530
1
95213406
Casing Rear Panel MLX EXT 1912 – 2300
1
95213407
Casing Rear Panel MLX EXT 2600 – 3060
1
95213408
Casing Top Panel MLX EXT 1500 & 1530
1
95213409
Casing Top Panel MLX EXT 1912 – 2300
1
95213410
Casing Top Panel MLX EXT 2600 – 3060
1
14
95240136
Centre Section MLX EXT 1500 – 3060
1
15
95240137
End Section front MLX EXT 1500 – 3060
1
16
95240138
End Section rear MLX EXT 1500 – 3060
1
17
95250624
Ignitor
1
18
95250669
Screw UNI 5931 M8X80
12
19
95250973
EPDM 56X38X5 gasket
7
95250992
Boiler Body Insulation MLX EXT 1500 & 1530
1
95250991
Boiler Body Insulation MLX EXT 1912
1
95250990
Boiler Body Insulation MLX EXT 2295 & 2300
1
95250989
Boiler Body Insulation MLX EXT 2600 & 2677
1
95251330
Boiler Body Insulation MLX EXT 3000 & 3060
1
21
95251921
Diaphragm to external modules
2
22
95251035
Diaphragms flow manifold
10
23
95251052
Diaphragms + gasket flow manifold
7
12
13
20
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CHAPTER 9: Spare Parts and Drawing Lists
Modulex EXT Commercial Spare Parts List
Item Part No.
24
Description
Quantity
95251096
Gasket - H/E-Flue Box MLX EXT 1500 & 1530
1
95251095
Gasket - H/E-Flue Box MLX EXT 1912
1
95000852
Gasket - H/E-Flue Box MLX EXT 2295 & 3000
1
95251067
Gasket - H/E-Flue Box MLX EXT 2600 & 2677
1
95251652
Gasket - H/E-Flue Box MLX EXT 3000 & 3060
1
95251210
Ignitor gasket 10
10
26
95251274
Flame Detector
1
27
95251592
Silicone gasket
3
28
95251632
Burner gasket MLX EXT 1500 – 3060
8
29
95251633
Flue outlet terminal MLX EXT 1500 – 3060
1
30
95251644
Fan NRG137 gasket
3
31
95251645
Airbox gasket MLX EXT 1500 – 3060
3
32
95251650
Sealing Gskt-Flue box Outlet MLX EXT 1500 – 3060
1
33
95251654
Gasket 33X21X2
10
34
95263767
Air Pressure Switch (Max)
1
35
95260588
Automatic Air Vent G3/4”
1
36
95611641
Junction box MLX EXT 1530-3060
1
37
95261357
Boiler Drain Cock G 3/4”
1
38
95263795
Thermal breaker
1
39
95263802
Air Pressure Switch MLX EXT 1500 – 3060
1
40
95263570
Signal light
1
95282743
Gas inlet header MLX EXT 1500 & 1530
1
95282744
Gas inlet header MLX EXT 1912 – 2300
1
95282745
Gas inlet header MLX EXT 2600 – 3060
1
42
95262137
Thermostat 90-110° (104°) L=3000
1
43
95262207
E8 - System Manager
1
44
95262208
External sensorE8 - System Manager
1
45
95262209
Mixed flow sensor E8 - System Manager
1
46
95262211
Tank sensor E8 - System Manager
1
47
95611593
Ignitor Cable
1
48
95262220
10A Fuse
10
49
95262221
6,3A Fuse
10
50
95263708
Safety Thermostat MLX EXT 1500 – 3060
1
51
95262451
Mixer DUNGS SW16 - RG148 - nozzle D.9
1
52
95262565
Level sensor
1
53
95262767
D.300 EPDM Gasket
1
54
95262926
Gas spring
1
55
95262930
Hinge casing
2
56
95262931
Casing Top Panel lock
1
57
95262932
Inspection flue plug
1
58
95263546
Gas valve MLX EXT 1500 – 3060
1
59
95262961
Mesh Burner MLX EXT 1500 – 3060
1
60
95263553
Blower MLX EXT 1500 – 3060
1
61
95263579
Ignition Transformer
1
25
41
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Phone: 800-526-0288
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GF-139
Modulex EXT Commercial Series Boilers User Manual
CHAPTER 9: Spare Parts and Drawing Lists
Modulex EXT Commercial Spare Parts List
Item Part No.
Description
Quantity
62
95310512
Drain Elbow HTB DN40
2
63
95310513
Drain TEE HTEA DN 40/40
1
64
95310515
Drain Pipe 1M LG. DN 40
1
65
95362314
AERCO plate
1
66
95371895
Sheath probe holder (FOR CASTING TEMPERATURE SENSOR)
1
67
95611133
CASTING TEMPERATURE SENSOR MLX EXT 1500 – 3060
1
68
95611410
Flame Detector Cable MLX EXT 1500 – 3060
1
69
95900234
Sheat probe holder (FOR OUTLET TEMPERATURE SENSOR)
1
70
95251906
Flanged flue outlet terminal MLX EXT 1500 – 3060
1
71
95251937
Flue terminal gasket MLX EXT 1500 – 3060
1
Modulex EXT Commercial Spare Parts List
Ite
m
Part No.
Description
72
95282672
Flow header MLX EXT 1500& 1530
95282673
Flow header MLX EXT 1912
1
95282674
Flow header MLX EXT 2295 & 2300
1
95282675
Flow header MLX EXT 2600 & 2677
1
95282676
Flow header MLX EXT 3000 & 3060
1
95282677
Return header MLX EXT 1500 & 1530
1
95282678
Return header MLX EXT 1912
1
95282679
Return header MLX EXT 2295 & 2300
1
95282680
Return header MLX EXT 2600 & 2677
1
95282681
Return header MLX EXT 3000 & 3060
1
95211352
Heating Sensor bracket
3
73
74
OMM-0095_0H
GF-139
Quantity
1
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
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Modulex EXT Commercial Series Boilers User Manual
Change Log:
Date
Description
Changed by
07/07/2016
Rev-G:
Reformatted, new logo, applied misc. changes per AM.
DIR 340: Added combustion chamber cleaning instructions.
DIR 368: Changed Spare Parts item 50 P/N from 95363708
to 95263708 on page 137.
Curtis Harvey
09/15/2017
Rev H:
DIR 17-008: Added new model numbers for units with
aluminum water connections, reformatted per new design
standard.
DIR 17-011: Revised Section 9: Spare Parts Lists,
DIR 17-046: Modified Relief Valve location & mounting
instructions (sections 4.11 & 4.12).
DIR 17-063: Added new Chapter 1 Safety Precautions, with
Massachusetts-specific requirements, renumbered all
chapters, sections, figures and tables.
Chris Blair
© AERCO International, Inc., 2017
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Phone: 800-526-0288
OMM-0095_0H
GF-139
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