AERCO EXT 1530, EXT 3060 User Manual
OMM-0095_0E
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288
MODULEX EXT
USER MANUAL
Natural Gas Modulating &
Condensing Modular Hot
Water Boiler
COMMERCIAL CAPACITY
Covering Models:
• EXT 1530
• EXT 1912
• EXT 2295
• EXT 2677
• EXT 3060
GF-139
Installation, Operation and Maintenance
Modular Condensing Boilers
.0
Commercial Series
Latest Update: 12/01/2014
MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
Installation, Operation & Maintenance Manual
DISCLAIMER
The information contained in this manual is subject to change without notice from AERCO
International, Inc. AERCO makes no warranty of any kind with respect to this material, including,
but not limited to, implied warranties of m erchantability and fitness for a particular application.
AERCO International is not liable for errors appearing in this manual, nor for incidental or
consequential damages occurring in connection with the furnishing, performance, or use of
these m aterials.
AERCO Technical Support:
(Mon–Fri, 8am-5pm EST)
1 (800) 526-0288
AERCO Document Conventions
In this document, some types of information are presented as shown in the following examples:
Message Type Example and Description
NOTE
Notes
NOTE messages indicate specific information related to the
surrounding contextual information, and highlighted for special
attention.
CAUTION!
Cautions
CAUTION messages inform of potential problems relating to the
functioning of equipment, safety to persons, harm to the
environment, and/or damage to property or equipment.
WARNING!
Warnings
WARNING messages warn of potential dangerous situations that
may result in serious injury and/or death to persons or animals.
Text is red within a red box.
How Instructions are Presented
1. Instructions are shown in a blue box with an underlined title.
2. All text, excepting in accompanying illustrations, is colored blue.
Instructions
3. All procedures are listed in steps starting with “1.” and using
letters [a), b), c), etc.], indicating sub=steps.
4. Steps that are continued on the next page have a “- Continued”
appended to the instruction title.
Page 2 of 138 AERCO Int ernational, Inc. • 100 Orita ni D r. • Blau v elt, NY 10913 OMM-0095_0E
12/01/14 Phone: 800-526-0288 GF-139
MODULEX EXT 1530, 1912, 2295, 2677, 3060 BOILERS
Installation, Operation & Maintenance Manual
TABLE OF CONTENTS
CHAPTER 1: GENERAL INFORMATION .............................................................................................. 7
1.1 Correct Use of the Appliance ............................................................................................................................... 7
1.2 Water Treatment ................................................................................................................................................. 7
1.3 Information to Be Made Available to the User .................................................................................................... 7
1.4 Safety Warnings ................................................................................................................................................... 8
1.5 Modifications to Parts Connected To the Appliance ........................................................................................... 8
1.6 For Appliances Operating with Propane Gas ....................................................................................................... 9
1.7 Data Plate .......................................................................................................................................................... 10
1.8 Operational Requirements ................................................................................................................................ 11
1.8.1 General Requirements ............................................................................................................................ 11
1.8.2 Regulatory Requirements ....................................................................................................................... 11
1.8.3 Water Quality Requirements .................................................................................................................. 12
1.9 Tools, Materials, and Additional Equipment ..................................................................................................... 13
1.10 Disposal of Packaging and Parts ...................................................................................................................... 13
1.11 General Warnings ............................................................................................................................................ 13
1.11.1 Using the Operation and Maintenance Manual ................................................................................... 13
1.11.2 Installation and Servicing Personnel ..................................................................................................... 13
1.11.3 Installation Materials ............................................................................................................................ 13
1.11.4 Preparing Boiler for Servicing ............................................................................................................... 14
1.11.5 Returning a Boiler to Service ................................................................................................................ 14
1.11.6 Change in Ownership ............................................................................................................................ 14
1.12 Operational Limits of the Boiler....................................................................................................................... 14
CHAPTER 2: TECHNICAL FEATURES AND DIMENSIONS ................................................................ 15
2.1 Modulex EXT Technical Features ....................................................................................................................... 15
2.1.1 Temperature Control Devices: ................................................................................................................ 15
2.1.2 Control Panel (E8) Includes: .................................................................................................................... 15
2.1.3 Other Features Include: .......................................................................................................................... 15
2.2 General Boiler Operation ................................................................................................................................... 16
2.3 Dimensional Drawings ....................................................................................................................................... 17
2.4 Performance Data .............................................................................................................................................. 20
CHAPTER 3: INSTALLATION INSTRUCTIONS .................................................................................. 21
3.1 Installation Warnings and Requirements .......................................................................................................... 21
3.1.1 Appropriate Use of the Boiler ................................................................................................................. 21
3.1.2 Prerequisite System Flushing .................................................................................................................. 21
3.1.3 Installation Personnel Qualifications ...................................................................................................... 21
3.1.4 Carbon Monoxide Detector Installation ................................................................................................. 21
3.1.5 Installation Conformity Requirements.................................................................................................... 21
3.2 Code and Standards Approvals .......................................................................................................................... 22
3.3 Packaging ........................................................................................................................................................... 22
3.4 Transporting and Securing the Boiler Safely ...................................................................................................... 23
3.5 Unpacking the Boiler.......................................................................................................................................... 23
3.6 Boiler Package Contents .................................................................................................................................... 24
3.7 Boiler Location Inside a Boiler Room ................................................................................................................. 25
3.7.1 Boiler Room Safety Concerns.................................................................................................................. 25
3.7.2 Products to Avoid in the Boiler Room ..................................................................................................... 26
3.8 Recommended Clearances for Servicing ........................................................................................................... 26
3.9 Gas Connection General Information ................................................................................................................ 27
3.9.1 Natural Gas Connections ........................................................................................................................ 28
3.9.1.1 Natural Gas Piping Sizes ....................................................................................................................... 28
3.9.1.2 Natural Gas Piping Connections........................................................................................................... 28
3.9.1.3 Natural Gas Supply Pressure Requirements ........................................................................................ 28
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GF-139 Phone: 800-526-0288 12/01/14
MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
Installation, Operation & Maintenance Manual
3.9.2 Propane Gas Connections ....................................................................................................................... 28
3.9.2.1 Propane Gas Piping Sizes ..................................................................................................................... 28
3.9.2.2 Propane Gas Piping Connections ......................................................................................................... 28
3.9.2.3 Propane Gas Supply Pressure Requirements ....................................................................................... 28
3.10 Flow and Return Pipe Connections .................................................................................................................. 29
3.11 Pressure Relief Valve ....................................................................................................................................... 29
3.12 CSD-1 MANIFOLD ASSEMBLY (SUPPLIED) ........................................................................................................ 30
3.13 Determination of Primary Boiler Pump or Boiler System Pump ...................................................................... 31
3.14 Condensate Piping and Drain .......................................................................................................................... 32
3.15 Water Treatment ............................................................................................................................................. 34
3.16 Important Installation Warnings...................................................................................................................... 34
3.16.1 Oxygen Levels in the System Water Warning ....................................................................................... 34
3.16.2 Antifreeze Compatibility Warning ........................................................................................................ 34
3.16.3 Lime Scale and Corrosive Water Damage Warning .............................................................................. 35
3.16.4 Connection to Refrigeration System Warning ...................................................................................... 35
3.17 Optional Air Intake Connection ....................................................................................................................... 35
3.18 Flue Manifold Installation ................................................................................................................................ 35
3.19 Flue Exhaust Piping to Vent ............................................................................................................................. 37
3.20 Vent Starter Pieces .......................................................................................................................................... 37
3.21 Combustion Air and Ventilation Openings ...................................................................................................... 39
3.21.1 Insufficient Ventilation and Combustion Air......................................................................................... 39
3.21.2 Room Air Combustion ........................................................................................................................... 40
3.21.3 Sealed Combustion ............................................................................................................................... 40
3.22 Installation of the Exhaust and Air Intake System ........................................................................................... 41
3.22.1 Important Factors for Terminal Orientation and Location ................................................................... 42
3.22.2 Minimum and Maximum Wall Thickness .............................................................................................. 42
3.23 Vent Pipe Sizing ............................................................................................................................................... 42
3.24 Electrical Connections...................................................................................................................................... 44
3.24.1 Regulations in Force.............................................................................................................................. 44
3.24.2 Mains Electrical Supply Connection (120 V – 60 Hz)............................................................................. 44
3.24.3 Service Relay Requirement ................................................................................................................... 45
3.24.4 Electrical Requirements ........................................................................................................................ 45
3.25 Functional Wiring Diagram .............................................................................................................................. 49
3.26 Ladder Diagrams .............................................................................................................................................. 51
3.27 General Ladder Diagram .................................................................................................................................. 52
3.28 E8 Controller and BCM Terminal Assignments ................................................................................................ 52
3.29 Installation Examples ....................................................................................................................................... 55
3.30 Starting Up: Filling and De-Aerating the Boiler ................................................................................................ 57
3.30.1 Necessary Precautions for Safety ......................................................................................................... 57
3.30.2 Supply Voltage, Gas Pressure, and Water pressure .............................................................................. 57
3.31 Filling the System ............................................................................................................................................. 57
3.31.1 Necessary Precautions While Filling the System .................................................................................. 57
3.31.2 Filling Locations and Preparation.......................................................................................................... 58
3.32 Testing the Ignition Safety Shut-off Device ..................................................................................................... 60
3.33 Burner Calibration ........................................................................................................................................... 61
3.33.1 Installing the Gas Analyzer Probe ......................................................................................................... 61
3.33.2 Maximum Output Calibration ............................................................................................................... 62
3.33.3 Minimum Output Calibration................................................................................................................ 63
3.33.4 Final Check and Ignition Failure Adjustment Procedure....................................................................... 63
3.34 Sweeper Mode (Manual Control) .................................................................................................................... 66
3.35 High Altitude Adjustment ................................................................................................................................ 67
3.36 High Altitude Conversion Label........................................................................................................................ 68
3.37 Conversion from Natural Gas to Propane Gas ................................................................................................. 69
3.38 Controls and Emergency Functions ................................................................................................................. 70
3.39 Initial Boiler Ignition......................................................................................................................................... 71
3.39.1 Preliminary Checks................................................................................................................................ 71
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 BOILERS
Installation, Operation & Maintenance Manual
CHAPTER 4: E8 CONTROLLER AND BCM MODULES ...................................................................... 72
4.1 E8 Controller ...................................................................................................................................................... 72
4.1.1 E8 Controller Features and Functions ..................................................................................................... 72
4.1.2 E8 Display Functions ............................................................................................................................... 73
4.1.3 E8 HEATING Mode Selection................................................................................................................... 74
4.1.4 E8 MENU Mode Operation (Door Open) ................................................................................................ 75
4.1.5 E8 MENU Navigation and Parameter Settings ........................................................................................ 76
4.1.6 E8 Parameter Navigation, Selection, and Setting ................................................................................... 77
4.2 BCM (Boiler Communication Module) ............................................................................................................... 78
4.2.1 BCM Features and Functions .................................................................................................................. 78
4.2.2 BCM Description ..................................................................................................................................... 78
CHAPTER 5: OPERATION OF THE E8 CONTROLLER ...................................................................... 81
5.1 Installation Menu: Initializing the E8 Controller ................................................................................................ 82
5.2 Quick Start Instructions ..................................................................................................................................... 83
5.2.1 Setting Maximum and Minimum Flow Temperature ............................................................................. 83
5.2.2 Setting Room Temperature and Outdoor Compensation....................................................................... 84
5.2.3 Setting Heating Programs and Pumps .................................................................................................... 85
5.3 Menu and Sub-Menu Descriptions .................................................................................................................... 86
5.3.1 Menus (Top Level): ................................................................................................................................. 86
5.3.2 Sub-Menus: ............................................................................................................................................. 86
5.4 General Menu .................................................................................................................................................... 87
5.5 Service Menu ..................................................................................................................................................... 89
5.6 Display Menu ..................................................................................................................................................... 91
5.7 User Menu ......................................................................................................................................................... 93
5.8 Time Program Menu .......................................................................................................................................... 95
5.9 Expert Menu ...................................................................................................................................................... 96
5.10 Other Possible Settings .................................................................................................................................. 100
5.10.1 Settings for Heating Circuit 1/2........................................................................................................... 100
5.10.1.1 Heating Adjustment With Constant Flow Temp .............................................................................. 100
5.10.1.2 Temperature Settings For Heating Circuits ...................................................................................... 100
5.10.1.3 A Second DHW Storage Tank ........................................................................................................... 101
5.10.1.4 Temperature Setting For Second DHW Storage Tank ...................................................................... 101
5.10.1.5 Swimming Pool ................................................................................................................................ 101
5.10.1.6 Swimming Pool Temperature Setting .............................................................................................. 101
5.10.1.7 Screed Dry Program (For Floor Heating Installation) ....................................................................... 101
5.10.1.8 Temperature Setting For Screed Program ....................................................................................... 101
5.10.1.9 Signal 0 – 10 V ................................................................................................................................. 101
5.10.1.10 Slope And Temperature Setting with 0 – 10 V Signal ................................................................... 101
5.10.2 Setting of DHW Circuit ........................................................................................................................ 102
5.10.2.1 Operation of Pumps In Parallel ........................................................................................................ 102
5.10.2.2 Use of a DHW Storage Tank Thermostat (On/Off) ........................................................................... 102
5.10.2.3 Antilegion ......................................................................................................................................... 102
5.10.2.4 Setting for Solar Panel Use .............................................................................................................. 102
5.11 Access Code Setting ....................................................................................................................................... 102
CHAPTER 6: TROUBLESHOOTING.................................................................................................. 103
6.1 E8 Controller Fault Codes ................................................................................................................................ 103
6.1.1 Using the Fault Code Tables.................................................................................................................. 103
6.1.2 E8 Controller Fault Codes ..................................................................................................................... 105
6.1.3 BCM (Boiler Communications Module) Fault Codes ............................................................................. 109
6.1.4 BMM (Burner Management Module) Fault Codes ............................................................................... 110
CHAPTER 7: INSPECTION AND MAINTENANCE SCHEDULE ........................................................ 113
7.1 Instructions for Inspection and Maintenance.................................................................................................. 114
7.2 Periodic Examination of Venting System ......................................................................................................... 114
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
Installation, Operation & Maintenance Manual
7.3 Proper Procedure for Cleaning Exhaust Flue ................................................................................................... 114
7.3.1 Cleaning the Condensate Drain Line ..................................................................................................... 115
7.4 Checking CSD-1 Manifold Flow Switch ............................................................................................................ 115
7.5 Visual Inspection of the Flame......................................................................................................................... 116
7.5.1 FLAME COLOR: ...................................................................................................................................... 116
7.6 Proper Reassembly and Resealing of the Vent-Air Intake System................................................................... 116
7.7 Pressure Switch Hoses And Connections ......................................................................................................... 117
7.8 Burner / Heat Exchanger Cleaning Procedure ................................................................................................. 118
7.9 Heat and Return Sensor Resistance Values ..................................................................................................... 118
7.10 Unit Disassembly ........................................................................................................................................... 119
7.11 Cleaning the Burner Module and Combustion Chamber............................................................................... 125
7.12 Reassembly of the Burner Modules............................................................................................................... 126
7.13 Final Procedures after Maintenance ............................................................................................................. 126
7.14 Maintenance Kit Part Number ....................................................................................................................... 126
7.15 Accessory Kit Part Number ............................................................................................................................ 128
CHAPTER 8: SPARE PARTS DRAWING AND LISTS ....................................................................... 129
AERCO/MODULEX STANDARD WARRANTY ................................................................................... 137
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 BOILERS
Installation, Operation & Maintenance Manual
CHAPTER 1: GENERAL INFORMATION
1.1 Correct Use of the Appliance
The MODULEX EXT 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 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 equipm ent appropriately and safely according to its design, it is essential to carefully
follow the instructions in this manual.
1.2 Water Treatment
It is vital to maintain the pH of boiler water betw een 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 recomm ended.
• 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 rec omm ends 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.
1.3 Information to Be Made Available to the User
Go through the information in this manual with the owner/operator and m ake sure that he or she is
familiar with all necessary operating instructions, in particular:
• These instructions shall be m ade 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-115-V).
• It is absolutely forbidden to make any alterations to the boiler not in keeping with the
manufacturers recomm endations 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 Controll er User Manual (GF-115-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_0E AERCO International, Inc. • 100 Or itani Dr. • Blau v elt, NY 10913 Page 7 of 138
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
Installation, Operation & Maintenance Manual
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.
1.4 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,
anim als or dam age 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.
1.5 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 pow er
• 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
equipm ent can cause damage (for example, water or gas leakages)
to the equipm ent.
Page 8 of 138 AERCO Int ernational, Inc. • 100 Orita ni D r. • Blau v elt, NY 10913 OMM-0095_0E
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 BOILERS
WARNING!
WHAT TO DO IF YOU SMELL GAS:
Installation, Operation & Maintenance Manual
1.6 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 inform ation. If the tank has not been correctly purged, problems may
occur during ignition. If this happens contact the liquid gas tank’s supplier.
Do not store or use gasoline or other flammable vapors
or liquids in the vicinity of this or any other appliance.
• 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 installed in such way as to avoid, under the
foreseen operation conditions, the freezing of the water and to
prevent the control devices from being exposed to tem peratures
lower than 5°F (15°C) or higher than 104°F (40°C). The boiler must
be protected against environm ental 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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MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
Installation, Operation & Maintenance Manual
1.7 Data Plate
A sample Data Plate for a MODULEX EXT boiler is shown in the left figure below. A sample of the
Data Packaging label is shown in the right image below.
Figure 1-1: MODULEX EXT Data Plate (L) and Data Packing Label (R)
Each unit is fitted with a data plate, which may be consulted for the details on gas type, power
source, and venting classification.
Page 10 of 138 AERCO Int ernational, Inc. • 100 Orita ni D r. • Blau v elt, NY 10913 OMM-0095_0E
12/01/14 Phone: 800-526-0288 GF-139
MODULEX EXT 1530, 1912, 2295, 2677, 3060 BOILERS
Installation, Operation & Maintenance Manual
1.8 Operational Requirements
1.8.1 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 perform ed by trained professionals.
• Installation of a condensing gas boiler must be approved per all federal and local
governm ent 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.
1.8.2 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 ven t 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 equipm ent for the w ater/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 l ower 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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MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
Installation, Operation & Maintenance Manual
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.
1.8.3 Water Quality Requirements
NOTE
For additional inform ation concerning water quality and treatm ent,
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
separ ate 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%):
• Rhomar RhoGard Mutli-Metal (AL safe)
• Noble Noburst AL
Approved system cleaners:
• 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:
• Rhomar Pro-tek 922
• Noble Noburst AL inhibitor
• AERCO/Sentinel products. See list in GF-136-P, section 2.3 - System Flushing, Treatment,
and Cleansing.
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 BOILERS
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Installation, Operation & Maintenance Manual
1.9 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
Manom eter that is capable of reading both positive and negative pressures
Combustion analyzer
Digital multimeter
pH digital m eter
Metric Allen wrenches
Metric socket wrenches
1.10 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.
1.11 General Warnings
1.11.1 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 pr ovid e important information regarding the safe
installation, use and servicing of this appliance. Keep this manual in a safe place for
future referenc e.
1.11.2 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 com ponents for central heating system s 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, incom plete, or irr egul ar servicing could compromise the safe op eration of
the appliance, and could cause injury to persons, animals or damage t o 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.
1.11.3 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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Installation, Operation & Maintenance Manual
1.11.4 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 m eans of the approp riate shutdown devices.
1.11.5 Returning a Boiler to Service
Before putting a boiler, which has been unused for a length of time, back into service,
rinse the entire dom estic hot water system, allowing the water to flow an appropriate
amount of tim e in order to circulate throughout the entire system.
1.11.6 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.
1.12 Operational Limits of the Boiler
Max. boiler temperature: 180° F (80° C)
•
Max Allowable Working Temperature ASME: 200 °F
•
• Max. Allowable W orking Pressur e ASME: 92 psi
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Installation, Operation & Maintenance Manual
CHAPTER 2: TECHNICAL FEATURES AND DIMENSIONS
2.1 Modulex EXT Technical Features
Compact, gas fired, Low NOx, condensing boiler.
•
Comprised of one sectional boiler body, suitable as a single boil er or in a cascaded group.
•
May be installed in either an inside or outside l ocation.
•
Low internal water volume.
•
Fast response to load variations.
•
Flue exhaust outlet positionabl e on three sides.
•
Mani fold delivery and return.
•
Made up of four or more heating elements (4 to 8), cast alum inum / silicon / m agnesium.
•
Full range of modulation by variable speed blowers and premix burners.
•
Each heating element monitors its ow n water tem perature, and will individually shutdown
•
if flow is interrupted, without affecting the other burner sections.
One gas supply line.
•
• 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.
2.1.1 Temperature Control Devices:
• Local NTC sensor (each heating
element)
• Limit thermostat (each heating
element)
• Return NTC sensor (General)
• Safety therm ostat approved (manual
reset)
• Flow sensor BCM
• Flow NTC sensor (Gen eral)
2.1.2 Control Panel (E8) Includes:
• ON-OFF switch
• Temperature control / Boiler operation
• Fuses
• Air pressure fans
• Condensate level sensor
• Air pressure switch (anti-obstruction)
• High limit sensors
2.1.3 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 m esh m odulating burner (premixes into the fan with autom at ic diaphragm
backflow separation from the combustion chamber).
Less than 49 dBA of noise at m aximum power.
Heating operation: instantaneous power microprocessor control, with preset param eters for
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Installation, Operation & Maintenance Manual
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 managem ent.
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
2.2 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 maxim ize 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 tim e 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
separ ator. 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 dam age to the
equipm ent.
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 BOILERS
Installation, Operation & Maintenance Manual
2.3 Dimensional Drawings
Figure 2-1: MODULEX EXT Dimensional Drawings
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
(*) DN 80 – 3” ASME B16.5 Flange 150 lbs./sq. inch
Installation, Operation & Maintenance Manual
Table 2-1: MODULEX EX T Dim ens ion s and Size s
(*) DN 100 – 4” ASME B16.5 Flange 150 lbs./sq. inch
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 BOILERS
Installation, Operation & Maintenance Manual
Figure 2-2: MODULEX EXT 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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MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
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2.4 Performance Data
Table 2-2: MODULEX EXT Performance Data
NOTE
The Technical data plate is placed under the casing.
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Installation, Operation & Maintenance Manual
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.1 Installation Warnings and Requirements
3.1.1 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.
3.1.2 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.
3.1.3 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.
3.1.4 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.
3.1.5 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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MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
Model
A B C
Gross Weight
(1252 mm)
(1140 mm)
(2095 mm)
(585 kg)
59.8”
(1531 mm)
44.8‘‘
(1140 mm)
82.4‘‘
(2095 mm)
1417 lb.
(643 kg)
(1531 mm)
(1140 mm)
(2095 mm)
(707 kg)
(1819 mm)
(1140 mm)
(2095 mm)
806 kg
71.6‘‘
44.8‘‘
82.4‘‘
1891 lb.
Installation, Operation & Maintenance Manual
3.2 Code and Standards Approvals
The MODULEX EXT boiler has been reviewed for com pliance with the applicable sections of
the following North American Standards:
• ANSI Z21.13/CSA 4.9: Gas-fired low pressure steam and hot water boil ers
• ASME SECTION IV: ASME Boiler and Pressure Vessel Code with addenda, Section IV:
Rules for Construction of Heating Boilers
• BTS – 2000: Testing standard m ethod to determ ine efficiency of commercial space
heating boilers.
• SCAQMD RULE 1146.2: Emissions of oxides of nitrogen from large water heaters and
small boilers and process heat ers.
• CSD-1: Controls and safety devices for aut omatically gas-fir ed boilers.
3.3 Packaging
The MODULEX EXT boiler is delivered assembled and protected by a plastic bag inside a
strong cardboard box and affi xed 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 3-1: MODULEX EXT Shipping Package and Included Parts Location
Table 3-1: MODULEX EXT Shipping Package Dimensions
EXT 1530
EXT 1912
EXT 2295
EXT 2677
EXT 3060
49.3‘‘
59.8”
71.6‘‘
(1819 mm)
44.8‘‘
44.8‘‘
44.8‘‘
(1140 mm)
82.4‘‘
82.4‘‘
82.4‘‘
(2095 mm)
1289 lb.
1558 lb.
1776 lb.
(858 kg)
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Installation, Operation & Maintenance Manual
3.4 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 equipm ent.
• When m oving the boiler, it must be secured on the transportation equipment to prevent it
from falling off.
• Protect all parts against impacts during transportation.
3.5 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,
anim als or dam age to property derived from not respecting the
above mentioned recommendations.
Refer to panels 1-6 of Figure 3-2 while unpacking per these instructions:
Figure 3-2: 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 r em oval of the boiler from the pallet it is necessary to have a jib crane (P anel 5), to
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CSD-1
Manifold
Installation, Operation & Maintenance Manual
avoid damage to the boiler during the removal.
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.
3.6 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
condenstate draining system
• Hardware for assembling exhaust manifold
Box #2
Flue Parts
• 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 and exhaust connections
• One (1) 300mm diameter gasket
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
• Temperature & Pressure gauge
• Flow Switch
• Pipe adaptor (rubber)
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 BOILERS
Boiler Housekeeping
Pad (Support Base)
European-to-USA
Flue Adapter
Flue Manifold
Installation, Operation & Maintenance Manual
3.7 Boiler Location Inside 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 boil er. The installation shall be in
com pliance with all the latest regulations and laws ab out boiler enclosures, boiler rooms,
installations of heating and hot-water system s, ventilation, vents capable of exhausting the flue
gases of cond ensing boilers, and any other applicable requirements.
The boil er 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 3-3), in order to assemble the condensate
trap. An alternative to this base m ay be a 100mm deep well or trench next to the boiler to
accommodate the condensate “U” dr ain pipe (see Figure 3-3). After installation the boiler shall
be perfectly horizontal and stable, to reduc e any possible vibrations or noises.
Well or Trench for Condensate Drain Pipe
At Least
4” (100mm )
Condensate Drain Pipe
Figure 3-3: Boiler on Housekeeping Pad with Condensate Drain Pipe (Front View)
3.7.1 Boiler Room Safety Concerns
When selecting the position for the inst allation of the boiler please comply with the following
safety requir em ents:
• Ensure easy access to the com ponents of the boiler to facilitate maintenance.
• The room where the b oiler 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
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any other appliance.
Never use or st ore any chlorinated d et ergents or halog enat ed hydroc arbons (e.g. in
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spraycans, solvents and detergents, paints, adhesives) in proximity to the boiler.
•
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For outdoor installation see Warning for Outdoor installation on page 10.
MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
TOP of the boiler: 24‘‘ (600 mm)
Installation, Operation & Maintenance Manual
3.7.2 Products to Avoid in the Boiler Room
Do NOT store the foll owing products in the boiler room and/or around combustion air intake
vents.
• Spray cans containing chlorocarb ons/fluorocarbons
• Ammonium and/or amm onium solutions
• Permanent wave solutions
• Chlorinated waxes and/or cleaners
• Chlorinated swimming pool chemicals
• Calcium chloride used for thawing
• Sodium chloride used for water soft ening
• Refrigerant leaks
• Paint or varnish rem overs
• Hydrochloric acid/muriatic acid
• Cements and glues
• Antistatic fabric soft en ers used in clothes dryers
• Chlorine-type bleaches, deterg ents, and cleaning solvents
• Adhesives used to fasten building products
• other damaging or flammable products
3.8 Recommended Clearances for Servicing
Recommended clearances around the boiler are listed below (see Figure 3-4):
FRONT of the boiler: 24’’ (600 mm)
UNVENTED side: 24’’ (600 mm)
VENTED side: 32’’ (600 mm)
FLOOR/GROUND: 4’’ (100 mm)
REAR of the boiler: 24’’ (600 mm)
Figure 3-4: MODULEX EXT Boiler Clearances
It is recomm ended 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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Installation, Operation & Maintenance Manual
3.9 Gas Connection General Information
For natural gas connections, refer to section 3.9.1. For propane gas connections, refer to
Section 3.9.2.
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.
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 t hat all the supply piping be thoroughly cleaned in
order to remove any residual grim e 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 d etector 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 ENGINEER 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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Installation, Operation & Maintenance Manual
3.9.1 Natural Gas Connections
Natural Gas Piping Sizes 3.9.1.1
Contact your local gas supplier for natural gas pipe sizes and meter types.
Natural Gas Piping Connections 3.9.1.2
The boiler g as 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 adjac ent to the boiler for isolation purp oses.
Natural Gas Supply Pressure Requirements 3.9.1.3
The nominal inlet working gas pressure measured at the boiler should be 7” W.C. (18 mbar)
for natural gas. Maxim um 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.
3.9.2 Propane Gas Connections
Propane Ga s Pi pin g Si zes 3.9.2.1
Contact your local gas supplier for Propane gas pipe sizes, tanks, and 100% lockup gas
pressure regulator.
Propane Ga s Pi pin g C onnec tions 3.9.2.2
The boil er pipe is provided with external 3’’ ASME B16.5 flange, onto which the t ail piec e of
the gas shut off valve can be screwed. Use appropriat e 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.
Propane Gas Supply Pressure Requirements 3.9.2.3
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 1530, 1912, 2295, 2677, 3060 BOILERS
Installation, Operation & Maintenance Manual
3.10 Flow and Return Pipe Connections
The cold and hot water flow and return circuits must be connected to the boiler via the
resp ective 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/h ot 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 recomm end that the system is
flushed out with a suitable cleaning product in order to eliminate
any m etallic 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 SAFTEY DEVICES.
3.11 Pressure Relief Valve
A pressure relief valve (Figure 3-5) must be fitted on the CSD-1 manifold. It must be
dim ensioned for the capacity of the boiler and must comply with the ANSI/ASME
CSA 4.9
Pressure vessel, and Pressure Piping Code, as applicable.
The boiler ships with an 80 psi pressure relief valve for installation into the CSD-1 manifold
header. Lower system pressures will require lower rated pressure reli ef valves (not supplied).
Boiler and Pressure Vessel Code, Section IV (‘’Heating Boilers’’), or CSA B51, Boiler,
ANSI Z21.13 /
Figure 3-5: Pressure Relief Val ve
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MODULEX EXT 1530, 1912, 2295, 2677, 3060 Boilers
Flow S witch
3/4” Pressure Relief
Installation, Operation & Maintenance Manual
3.12 CSD-1 MANIFOLD ASSEMBLY (SUPPLIED)
The installation of a flow switch, pressure/temperature gauge, and an ASME compliant safety
pressure relief valve designed for the boiler output capacity are required. These major
components are supplied with the boiler and must be assembled and wired when installing the
boiler at the site. The manifold assembly components supplied are:
• 3/4” Pressure Relief Val ve
• Flow Switch
• Pressure/Temperature Gauge
The pressure relief valve and all other manifold components are shown in Figure 3-6.
Valve
Pressure/Temperature
Gauge
Figure 3-6: Manifold Assembly and Components
To install the pressure reli ef valve and the other components shown, proceed as shown in
Instruction 4.0, below.
NOTE
Use T eflon tape or a suit able pipe joint compound for com ponent
and piping connections described in the following steps. Refer to
Figure 3- 6 for component identification.
Installing the Pressure Relief Valve and Other Components
1. Attach manifold to the outlet supply connection on the boiler via the flanged connections.
2. Cut the flow switch paddle. For EXT models 1530 to 3060, cut for 4” pipe as directed in
the flow switch paddle packaging. For installations expecting less than a 10 gpm flow,
the switch m ust be adjusted as follows:
a) With no flow, turn adjustm ent screw on the switch counter-clockwise until the switch
trips.
b) Then turn screw 1/2 turn clock-wise and continue installation.
Page 30 of 138 AERCO Int ernational, Inc. • 100 Orita ni D r. • Blau v elt, NY 10913 OMM-0095_0E
12/01/14 Phone: 800-526-0288 GF-139
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