AERCO Modulex 303, Modulex 454, Modulex 606, Modulex 757, Modulex 909 General Manual
...
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Instruction
GF-115
Installation, Operation
& Maintenance Instructions
Gas Fired
Boiler Systems
Modular, Condensing, Hot Water Boilers
Models: 303, 454, 606, 757, 909, 1060
Printed in U.S.A.
REVISED 2/27/08
Telephone Support
Direct to AERCO Technical
Support
(8 to 5 pm EST, Mon. – Fri.)
1-800- 526-0288
AERCO International, Inc.
159 Paris Avenue
Northvale, NJ 07647-0128
www.aerco.com
© AERCO International, Inc., 2008
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, inc luding but not limited
to implied warranties of merchantability and
fitness for a particular application. AERCO
International is not liabl e for errors appearing in
this manual. Nor for inc idental or consequenti al
damages occurring in connection with the
furnishing, performance, or use of this material.
INSTALLATION, OPERATION & MAINTENANCE
TABLE OF CONTENTS
Chapter/Paragraph Page
SAFETY SYMBO LS AND WARNING S iii
IMPORTANT iii
FOR YOUR SAFETY v
1
GENERAL DESCRIPTION
1.1
1.4 DIMENSIONS 1-3
1.5 TECHNICAL DATA 1-5
1.6 MODULEX SIDE VIEW SHOWING MAIN COMPONENTS 1-6
1.7 BOILER FREEZE PROTECTION 1-7
1.2 CODES AND STANDARDS APPROVALS 1-2
1.3 INSTALLATION FLEXIBILITY 1-2
TECHNICAL FEATURES 1-1
1-1
2 INSTRUCTIONS FOR INSTALLERS 2-1
2.1 INTRODUCTION 2-1
2.2 INSTALLATION INSTRUCTIONS 2-1
2.2.1 UNPACKING THE BOILER 2-1
2.2.2 LOCATING THE BOILER 2-3
2.2.3 PAD HEIGHT FOR BOILER 2-3
2.2.4 BOILER CONNECTIONS 2-4
3
3.1 GAS VENT CATEGORIES 3-1
3.2 VENT PIPE CONNECTIONS 3-1
3.3 INSTALLATION & SIZING 3-1
3.4 REMOVAL OF EXISTING BOILER FROM COMMON VENTING
2.3
GENERAL INFORMATION FOR THE VENTING SYSTEM
BOILER DATA PLATE 2-8
SYSTEM
3-1
3-2
4 PIPING 4-1
4.1 MAKEUP WATER QUALITY 4-1
4.2 MAXIMUM ALLOWABLE WORKING PRESSURE 4-1
4.3 BOILER LOOP DESIGN GUIDELINES 4-1
4.4 CSD-1 MANIFOLD ASSEMBLY 4-1
4.5 CONNECTING SUPPLY AND RETURN PIPING 4-1
4.6 SYSTEM FILLING AND DRAINING 4-2
4.7 NOTES ON CONDENSATE DRAIN 4-2
i
INSTALLATION, OPERATION & MAINTENANCE
TABLE OF CONTENTS
- Continued
Chapter/Paragraph Page
4.8 GAS MAINS AND CONNECTION 4-3
5 ELECTRICAL 5-1
5.1 ELECTRICAL CONNECTIONS 5-1
5.2 D.H.W. STORAGE TANK 5-2
5.3 ENABLE/DISABLE 5-2
5.4 INSTALLATION OF SENSORS 5-2
6 BOILER OPERATION 6-1
6.1 GENERAL DESCRIPTION AND OPERATION 6-1
6.2 MODULATION THEORY 6-1
6.3 IGNITION SEQUENCE 6-2
6.4 MODES OF OPERATION 6-2
6.4.1 INDOOR/OUTDOOR RESET 6-2
6.4.2 0 TO 10 VOLT REMOTE SET-POINT 6-3
6.4.3 CONSTANT SET-POINT 6-3
6.4.4 BOILER OPERATION IN CASE OF TROUBLESHOOTING
(MANUAL MODE)
6.5 MODULEX BOILER INITIAL STARTUP 6-3
6.5.1 TOOLS & INSTRUMENTION REQUIRED FOR COMBUSTION
CALIBRATION
6.5.2 INSTALLATION OF SUPPLY GAS MANOMETER 6-4
6.5.3 PREPARING THE FLUE FOR USE WITH THE COMBUSTION
ANALYZER
6.5.4 COMBUSTION CALIBRATION 6-6
6.6 UNIT REASSEMBLY 6-8
6-3
6-4
6-5
7 MAINTENANCE 7-1
7.1 MAIN FEATURES 7-1
APPENDIX A
APPENDIX B
TEMPERATURE SENSOR RESISTANCE CHART A-1
MODULEX PARTS LIST B-1
ii
INSTALLATION, OPERATION & MAINTENANCE
SAFETY SYMBOLS
The following defined symbols are used throughout this manual to notify the reader
of potential hazards of varying risk levels.
INDICATES AN IMMINENTLY HAZARDOUS SITU ATION, WHICH IF NOT AVOIDED,
WILL RESULT IN DEATH OR SERIOUS INJURY.
INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH IF NOT
AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.
INDICATES A POTENTIAL HAZARDOUS SITUATION, WHICH IF NOT AVOIDED,
MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO
ALERT AGAINST UNSAFE PRACTICES.
READ ALL INSTRUCTIONS BEFORE INSTALLING.
The following WARNINGS appear here and in one or more Chapters of
this manual.
• KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND
FLAMMABLE VAPORS OR LIQ UID S.
• NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK
FOR GAS LEAKS.
• DO NOT ATTEMPT TO DRY FIRE THE BOILER. STARTING THE UNIT WITHOUT A FULL
WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN INJURY TO
PERSONNEL OR PROPER T Y DAMAGE. T H IS SIT U AT IO N W ILL VOID ANY WARRANTY.
• ELECTRICAL VOLT AGES IN THIS SYSTEM MAY INCLUDE 120 AND 24 VOLTS AC. IT MUST
BE SERVICED BY TECHNICALLY COMPETENT SERVICE TECHNICIANS.
• ELECTRICAL POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR
OTHER TEST PROC EDUR ES T H AT C AN RESU LT IN ELECTRICAL SHOCK.
• TO AVOID PERSONAL INJU RY, OBSER V E T HE F OLLOWING WARNINGS:
• DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY
CIRCUIT BREAKER
• SHUT OFF THE GAS SUPPLY AT THE MANUAL SHUT-OFF VALVE
• PROVIDED WITH THE UNIT
• ALLOW THE UNIT TO COOL TO A SAFE TEMPERATURE TO PREVENT
• SEVERE BURNS.
iii
INSTALLATION, OPERATION & MAINTENANCE
WARNINGS CONTINUED
• This INSTRUCTION MANUAL is a n integral and indispensable part of the product. It must be
given to the user by the installers and m ust be kept in a safe place for future referenc e. In the
event that the boiler is transferr ed or sold, the manual must accompan y the equipment.
• This boiler mus t be used only for the purposes for which it has bee n designed. Any other use
shall be considered incorrec t and danger ous , thereb y void ing the warranty
• The boiler must be installe d in com plianc e with app licable laws and standar ds and ac cor ding to
the manufacturer’s instructions given in this manual. Incorrect installation may cause injury to
personnel and/ or d am age to pro per t y. The m anufac turer sha ll not b e he ld li abl e for an y suc h i n j u ry
and/or damage.
• Damage and/or injury caused by incorrect installation or use, or failure to observe the
manufacturer’s instructions shall relieve AERCO from any and all contractual and extra
contractual liability.
• DO NOT obstruct the air suction to th e boiler room and/or heat dissipation de vices in an y other
room.
• Keep the packaging out of the reac h of children as it may represent a choking and suffocation
hazard.
• Non-obser vance of the above requirem ent may jeopardize the safety of the boilers and ex pose
people, animals and propert y to danger.
CAUTIONS appear here and in one or more Chapters of this
manual.
• CAUTION, THE IGNITER MAY BE HOT. USE CARE TO AVOID SER IOU S BU RN S
• Caution must be observed to prevent damage to the AERCO Modulex Boiler or associated
equipment. Failure to observe prec autions may also void the Boiler warranty.
• Prior to installing the boiler, check to ensure that the technical data corresponds to
requirements for its intended use in the system.
• Check that the boiler is int act and that it has no t been damage d during transpor t and handl ing. Do
not install equipment, which is evidently damaged and/or faulty.
• Only original accessories must be used for all boilers supplied with options or kits (including
electrical ones).
• Dispose of the packaging with car e, as all the materials can be recycled. The packaging must
therefore be sent to specific waste managem ent s ites.
• In the event of f ailure and/or faulty functioning, switch off the boiler. Do not attempt to m ake
repairs: contact qualified technic ians. O riginal par ts m ust be us ed f or all repair s to the boiler.
• In t he ev ent of long p eriods of inact ivit y of the b oiler, dis connect it fr om the p ower mains and clos e
the gas valve. (In this case, the boiler’s electronic anti-freeze function will not be operative.)
Should there be a risk of freezing, add anti-freeze: it is not advisable to empty the system as
this may result in damage; use specific “aluminum-friendly”, neutral pH anti-freeze products
suitable for multi-m etal heating systems.
•
To guarantee efficiency and correct functioning of the equipment it is legally binding to
service the boilers once a year according to the schedule indicated in the relative
section of this manual.
iv
INSTALLATION, OPERATION & MAINTENANCE
FOR YOUR SAFETY
For boilers that use gaseous fuel, what to do if you smell gas.
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the
gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
NEVER USE FLAMES TO DETECT GAS LEAKS.
This boiler h as been built for installat ion in the country indic ated on the technical
data plate. Installation in any other country may be a source of danger for
people, animals and property.
Carefully read the warranty conditions and clauses on the warranty certificate
attached to the boiler.
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 non-corrosive 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
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
. At the time of installation of the
- v -
INSTALLATION, OPERATION & MAINTENANCE
Extracted Information From 248 CMR 5.08 (2) – Continued
a. In the event that the side wall horizontall y vented g as 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 instal led on the next adj ac ent floor le ve l.
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.
required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
3. SIGNAGE
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
equipment shall not approve the installation unless, upon inspection, the inspector observes
carbon monoxide detectors and signage ins ta l led in acc or dance with the pr ovis i on s of 248 CMR
5.08(2)(a)1 through 4.
(b) EXEMPTIONS
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.
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.
. A metal or plastic identification plate shall be permanently mounted to the exterior
. The state or local gas inspector of the side wall horizontally vented gas fueled
: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
Each carbon monoxide detector as
When
(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)]
vi
INSTALLATION, OPERATION & MAINTENANCE
1
GENERAL DESCRIPTION
IMPORTANT
Each AERCO Modulex Boiler is shipped as eit her a Natural Gas Only
a Propane Gas Only
Boiler. It Is Not a Dual-Fuel Boiler. Ensure that the correct
Boiler OR
fuel and fuel pressure are used when operating the equipment.
1.1 – TECHNICAL FEATURES
Modulex is a compact, modular, gas f ired, Low NOx, condensing boiler. The boiler bod y, is comprised
of sections of cast aluminum/m agnesium/silicon alloy. The boiler is designed to recover the sensible
and the latent heat of the combustion gases, thereby allowing it to attain a thermal eff iciency of 92% as
tested by the Hydronics Institute, a Division of GAMA. T hes e c as t alum inum s ections make up modules
referred to as the heat modules. Each module can deliver an output between a maximum of 152 MBH
and a minimum of 45 MBH and are compos ed of a pre mix c ombustion cham ber, m etallic m es h radiant
burner, modulating fan with control pr essure switch, gas valve, ignition device, flame detection, NT C
sensor for local temperature control and a s af et y thermos tat.
The heat modules are ho used in a single enclosure and are connected to a single exhaust manifold.
These modules are independent of each and are sequentially staged, known as cascading, to take
advantage of higher efficiencies. Eac h heat module has its own printed circuit (PC) boar d that controls
and monitors combustion as well as the tem perature of each heat module pr oviding operational safet y.
The entire boiler is control led by a single micr oprocessor. This microproces sor is responsible for the
staging and modulation of the heat modules, m onitoring supply and return water temperatures as well
as heating and domestic hot water (D HW) zones. Other features include:
• The heating load is shared with as many boiler modules as possible running at a minimum
output to ensure the maximum efficienc y at partial lo ad operation.
• Ac cess to all testing/programming parameters of each module: operation test, operation tim e,
boiler freeze protection from 45°F ( 7°C), pump’s anti seize program.
• Lead-lag burner operation based on burner operatin g hours. The boiler module with the leas t
burner operating hours is the first to star t and the burner with the most operating hours is the
first to stop.
• D.H.W. production by a priority sensor, with control capabil ity of a dedicated pump or a 3-way
diverting valve for stor age tank temperature control.
• A service mode for manual operation of individual he at modules capability for tr oubleshooting
or combustion calibration
• Diagnostics including relay and s ens or testing.
Reliability is improved b y the m odular design of the Modulex sinc e each heat module is ind ependent of
the other, having its own ignition and c ombus tion safeguard s ystem. If one of the boiler’s heat modules
stops functioning, the remaining m odule(s ) c ontinue to oper ate.
The Modulex boiler can b e comprised of from 2 to 7 modules and 3 to 8 cast aluminum sec tions. The
input to each heat module is 151.5 MBTU/Hr. The smallest Modulex 303, comprised of two heat
modules, has a combined total input of 303,000 BTU/Hr (2 x 151.5 = 303 MBT U) while the larges t, the
1060 comprised of 7 heat modules has a total input o f 1060 MBTU’s (See Table 1-1).
For one Modulex 303 boiler consisting of two modules, the output modulates from 15% to 100%. For a
Modulex 1060 boiler consisting of seven modules, the output modulates from 4.3% and 100%. If a
system comprised of two boilers is installed, then the modulation range for each boiler increases to 7.5%
to 100% for the Modulex 303 and 2.2% to 100% for the Modulex 1060.
1-1
INSTALLATION, OPERATION & MAINTENANCE
1.2 - CODE AND STANDARDS APPROVALS
MODULEX has been reviewed for compliance with the applicable sections of the following North
American Standards:
Z21.13:
ASME SECTION IV:
BTS 2000:
SCAQMD Rule
1146.2:
CSD-1-2004:
Table 1-1. – Modulex Boiler Output Range, Turn-Down Ratio & Condensate Production
GAS FIRED LOW PRESS U RE STEAM AND HOT WAT ER BO ILERS
BOILER AND PRESSURE VESSEL CODE RULES FOR CONSTRUCTION
OF HEATING BOILERS
TESTING STANDARD METHOD TO DETERMINE EFFICIENCY OF
COMMERCIAL SPACE HEATING BOILERS
NOx EMISSIONS FROM WATER HEATERS AND SMALL BOILERS
CONTROLS AND SAFET Y DEVICES FOR AUTOMATICALLY FIRED
BOILERS
Heat
Modules Model
2 303 41(12) 279 (82) 6:1
3 454 41(12) 418 (122) 10:1 1.9 (7.3) 5.3 (20)
4 606 41(12) 558 (163) 13:1 2.7 (10.1) 7.1 (27)
5 757 41(12) 696 (204) 16:1
6 909 41(12) 835 (245) 20:1
7 1060 41(12) 975 (286) 23:1
1
MBH = 1000 Btu/hr
Output Range MBH1(KW) Condensate Production [gph (l/h)]
Min. Max.
Turn Down
Ratio
Min. Max.
1.3 (5) 3.4 (13)
3.3 (12.6) 9.0 (34)
4.0 (15.1) 10.6 (40)
4.6 (17.6) 12.4 (47)
1.3 INSTALLATION FLEXIBILITY
The Modulex boiler allows for installation flexibility, i.e. it is suitable to be connected with the water
supply and return and the gas connections on the Ri ght Hand (R.H.) side (standard delivery condition)
or on the Left Hand (L.H.) side. This is accom plished by reversing the gas and water m anifolds utilizing
the instructions supplied wit h the boiler. The same is true for the vent pipe connection, which at the
installation, can be moved from the R.H. side (standard delivery condition) to the L.H. side or to the r ear
of the boiler. The installation f lex ibilit y featur es inc lude the f ollowing:
• Modulex can be installed in a multiple boiler system by the combination of two or more boilers .
• Gas connec ting pipes, supply
the left or right hand side of the unit, the u nit is shipped with all connec tions on the right hand
side as viewed from the front of the unit).
• Vent pipe, adjustable on the right, the left and beh ind the heatin g s ystem .
/
return water pipes can be arranged for any connection (b y either
1-2
INSTALLATION, OPERATION & MAINTENANCE
1.4 DIMENSIONS AND WEIGHTS
The dimensions and weights for eac h Modulex Model ar e s hown in sheets 1 and 2 of Figur e 1-1.
Figure 1-1. Modulex Dimensions and Weights (Sheet 1 of 2)
1-3
INSTALLATION, OPERATION & MAINTENANCE
Figure 1-1. Modulex Dimensions and Weights (Sheet 2 of 2)
1-4
INSTALLATION, OPERATION & MAINTENANCE
1.5 - TECHNICAL DATA
CONTROL PANEL.)
(THE NAME PLATE IS PLACED UNDER THE FRONT JACKET NEXT TO THE
Model Number Min Input Max Input Max Output* Net IBR Rating
MLX-303
MLX-454
MLX-606
MLX-757
MLX-909
MLX-1060
45,500 303,000 260,000-279,000 237,000
45,500 454,000 390,000-418,000 355,000
45,500 606,000 521,000-558,000 474,000
45,500 757,000 651,000-696,000 592,000
45,500 909,000 781,000-835,000 710,000
45,500 1,060,000 912,000-975,000 829,000
DIMENSIONS:
Model Number Height Width Depth Weight
MLX-303
MLX-454
MLX-606
MLX-757
MLX-909
MLX-1060
42” (1067 mm) 28” (711 mm) 27” (686 mm) 331 lbs. (150.1 kg)
42” (1067 mm) 28” (711 mm 27” (686 mm) 408 lbs. (185.1 kg)
42” (1067 mm) 33” (838 mm) 27” (686 mm) 496 lbs. (225.0 kg)
42” (1067 mm) 38” (965 mm) 27” (686 mm) 573 lbs. (259.9 kg)
42” (1067 mm) 44” (112 mm) 27” (686 mm) 672 lbs. (304.8 kg)
42” (1067 mm) 49” (1245 mm) 27” (686 mm) 761 lbs. (345.2 kg)
SPECIFICATIONS:
Model Number MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX-1060
Boiler Category IV IV IV IV IV IV
Type of Gas
Gas Connections (NPT) 1.5” 1.5” 1.5” 1.5” 1.5” 1.5”
Max. Gas Pressure 14” W.C.
Optimal Gas Pressure 7” W.C.
Min. Gas Pressure 4”
Max. Allowed Working
Pressure
Electrical Req:
120V 15 Amp. Max.
Water Connections
(NPT)
Min. Water Flow (GPM) 11 17 22 28 38 39
Max. Water Flow (GPM) 28 42 55 70 84 98
Water Pressure Drop
@ Max. Flow (Ft. of
Head)
Natural Gas
(MLX-303B)
or Propane
(MLX-303BP)
(34.8 mbar)
(17.4 mbar)
(10 mbar)
50 psi
(344.7 kPa)
1.2 FLA 1.8 FLA 2.4 FLA 3.0 FLA 3.6 FLA 4.2 FLA
2” 2” 2” 2” 2” 2”
10.5 10.6 11.6 12.6 13.7 16.1
Natural Gas
(MLX-454B)
or Propane
(MLX-454BP)
14” W.C.
(34.8 mbar)
7” W.C.
(17.4 mbar)
4”
(10 mbar)
50 psi
(344.7 kPa)
Natural Gas
(MLX-606B)
or Propane
(MLX-606BP)
14” W.C.
(34.8 mbar)
7” W.C.
(17.4 mbar)
4”
(10 mbar)
50 psi
(344.7 kPa)
Natural Gas
(MLX-757B)
or Propane
(MLX-757BP)
14” W.C.
(34.8 mbar)
7” W.C.
(17.4 mbar)
4”
(10 mbar)
50 psi
(344.7 kPa)
Natural Gas
(MLX-909B)
or Propane
(MLX-909BP)
14” W.C.
(34.8 mbar)
7” W.C.
(17.4 mbar)
4”
(10 mbar)
50 psi
(344.7 kPa)
Natural Gas
(MLX-1060B)
or Propane
(MLX-1060BP)
14” W.C.
(34.8 mbar)
7” W.C.
(17.4 mbar)
4”
(10 mbar)
50 psi
(344.7 kPa)
1-5
INSTALLATION, OPERATION & MAINTENANCE
SPECIFICATIONS: (continued)
Model Number MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX-1060
Water Pressure Drop @
Max. Flow
Water Volume: Gallons 2.7 3.8 4.9 6.0 7.1 8.2
Water Volume: Liters 10.2 14.4 18.5 22.7 26.9 31.0
Thermal Modules 2 3 4 5 6 7
Turn-Down Ratio 6:1 10:1 13:1 16:1 20:1 23:1
Vent Size 4” (102 mm) 4” (102 mm) 4” (102 mm) 6” (152mm) 6” (152mm) 6” (152mm)
Vent Materials (per local
code)
Temperature Control
Range
Maximum Noise Level All units deliver <50 dBA when operating at or below full fire.
NOx Emissions
Certification
Standard Listings &
Approvals
5 psi
(34.5 kPa)
Can support PVC, ABS, CPVC, or AL29-4C venting materials.
All units can be applied to deliver 50°F to 185°F (10°C to 85°C) supply water.
All units have been certified by SCAQMD and TCEQ for <30 ppm NOx.
6 psi
(41.4 kPa)
All units have been certified by CSA.
9 psi
(62.1 kPa)
(68.9 kPa)
10 psi
13 psi
(89.6 kPa)
15 psi
(103.4 kPa)
1.6 MODULEX SIDE VIEW SHOWING MAIN COMPONENTS
Figure 1-2 on the following page illustrates the Main Components included in each Modulex Boiler
Model. In addition, an exploded view parts lis t drawin g is inc luded in App endix B .
1-6
FAN
INSTALLATION, OPERATION & MAINTENANCE
GAS VALVE
GAS PIPE
BURNER
COVER
IGNITION
FLAME
DETECTOR
LOCAL NTC
SENSOR
H.L.
THERMOSTAT
BURNER
ALUMINUM/
SILICON HEAT
EXCHANGER
BOILER
FRAME
CONDENSATE
COLLECTION
TRAY MANIFOLD
AIR INTAKE
CONNECTION
AUTOMATIC
AIR VENT
GLOBAL FLOW
NTC TEMPERATURE
SENSOR
HOT WATER
OUTLET (SUPPLY)
1/4" CONNECTION
WITH PLUG
GLOBAL RETURN
NTC TEMPERATURE
SENSOR
COLD WATER INLET
(RETURN)
WATER DRAIN
VALVE
CONDENSATE
DRAIN TRAP
FILLING-UP
ELBOW
[100 mm]
4"
1" [25 mm]
5.9" [150 mm]
Figure 1-2.
Modulex Main Components
1.7 BOILER FREEZE PROTECTION
Should the boiler wat er ou tl et temperature decrease t o les s tha n 4 4.6 °F ( 7°C), the system pump will star t.
Should temperature dec rea se to less than 37.4°F ( 3°C), all heat modules will start at minimum output until
the return temperature reac hes 50°F ( 10°C). Suc h a protecti on devic e is exc lusivel y for the boiler. For the
protection of the whole system, a second freeze protection thermostat is necessary to switch on the
heating system pump.
NOTE
If glycol is used as antif reeze in the boi ler, a back flow preventer m ust be installed in t he
make-up/fill line.
1-7
INSTALLATION, OPERATION & MAINTENANCE
INSTRUCTIONS FOR INSTALLERS
2
2.1 INTRODUCTION
The Modulex Boiler is intended to be installed as a Category IV vent installation and m ust be installed
in compliance with all applicable laws and regulations including the ones below. See section 3.1 for
Category descriptions.
Before boiler installation, complete all of the following
instructions:
The installation mus t conform to the requir ements of the authorit y having juris diction or, in t he absenc e
of such requirements, to one of the following:
• United St ates - Installation must conform to the requirem ents of the National Fuel Gas Code,
ANSI Z223.1 Installation Codes.
• Canada - Installation must conform to the r equirem ents of CAN/CG A B149 Install ation Codes .
Where required by the authority having jurisdiction, the installation must conform to the Standard for
Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
NOTES:
• Installers must follow local regulations with respect to installation of Carbon
Monoxide (CO) Detectors. Also, follow the maintenance recommendations in this
manual.
• FOR MASSACHUSETTS INSTALLATIONS: The boiler must be installed by a
plumber or gas fitter licensed within the Commonwealth of Massachusetts.
Also, for installations in buildings used for residential purposes, if a side-wall vent
termination is less than 7 feet above grade, an NFPA 720 compliant, ANSI/UL 2034
listed and IAS certified carbon monoxide detector must be installed on the floor level
where the boiler is installed and on each level of the building served by the boiler.
2.2 INSTALLATION INSTRUCTIONS
The following paragraphs in this Section provide the instructions to unpack and install the Modulex Boiler.
2.2.1 Unpacking the Boiler
The Modulex Boiler is delivered ass embled and protected by a plastic bag inside a rugged cardboard
box, which is fixed on a pallet ( see Figure 2- 1). T he pallet allo ws the boi ler to be handle d by a f ork lift or
pallet jack. The boiler, with the p ac kaging, can fit through a door wa y of 32 in. (8 1 cm), whereas, without
packaging, it can fit through a doorway of 28 in. (71 cm). To unpack the Modulex , remove both straps
and then the cardboard box from above. Chec k to ens ure that the pr oduc t is intac t.
The packing elements (cardboard box, straps, plastic bags, etc…)
must not be left in children’s hands since they may be dangerous.
2-1
INSTALLATION, OPERATION & MAINTENANCE
Packed inside the boiler packing you w ill f ind:
• Painted steel panels:
• The front one connected to the back panel by a shrink wrap f ilm
• The right hand side panel connected to the left hand panel b y shrink wrap
On the front of the boiler:
• Flue collector, with exhaust connector screwed to the pallet: 6 inc h for models 303 to 606 and 8
inch for models 757 to 106 0. Use these it ems only when the specif ied flue pipe s ize is incr eased
to 6” (for models 303 to 606) and 8” (for models 757 to 1060). Otherwise, use the exhaust
connector “shipped in the separate carton” described below (4” for models 303 to 606, 6” for
models 757 to 1060).
• A plastic bag c ontaining 3 gaskets (1 rectangular for condensate tra y and flue collector , 1 square
for exhaust connector.
• T hr ee (3) s urface-mount s trap-on s ensor s.
• Screws necessary for accessory installation.
• Pipin g f or 1 ½” c ondens ate drain, inc lud ing one t ee a nd two 90 degree elbo ws.
On the back of the boiler:
• Plas tic c ondens ate drainp i pe, 38.5 inc hes ( 1meter) long, placed under the casing rear panel.
• O utside air sens or with 49 f eet, 2.5 inches ( 15 m) c able.
• Manual G as Shutoff Valve.
Shipped in a separate carton are the following:
• Accessory kit that includes a CSD- 1 installation kit, P/N 29031 for Models 303 through 606 and
P/N 29032 for Models 754 through 1060. See the pac k ing list shipped in t his m anual pack age f or
a complete listing of access ories and paragr aph 4.4 f or m ore info rm ation about the CSD 1- k its .
Figure 2-1.
Packaged Modulex Boiler
2-2
INSTALLATION, OPERATION & MAINTENANCE
2.2.2 Locating the Boiler
The boiler should be located on a level, solid area or base as near to the outside wall as possible and
centrally located to the space heating d istribution syst em. Special attention must be given to local regulations
and codes about b oiler rooms and par ticu lar ly t o th e m ain tai ning of mi nim um c lear anc es and empty space
around the boiler. The installation must be in compliance with all recent regulations and laws about boiler
rooms, installations of heating and hot water systems, ventilation, boiler venting systems capable of
evacuating the flue gases of condensing boilers and any other applic able req u ire m ent.
The minimum clearanc e dimensions for service acc ess, required by AERCO, are lis ted below (Figure 2-2)
and on the boiler Data Plate shown in Figure 2-7. Local building codes may require more clearance and
take precedence.
Minimum clearances required:
Sides 24" (510 mm)
Front 24" (510 mm)
Rear 24" (510 mm)
Top 24" (510 mm)
Figure 2-2
Boiler Clearances (Top View)
NOTE: All gas piping, water piping and electrical conduit or cable must be arranged so that
they do not interfere with the removal of any cover, or inhibit service or maintenance of the
unit.
The boiler MUST NOT be installed on carpeting
2.2.3 Pad Height for Boiler
To properly drain and service the boiler’s condensate system, attention must be given to installation
requirements regarding the mounting heig ht of the boiler as well as installatio n clearances for the removal
of the condensate collector baffle.
The boiler should be mounted on a flat and sufficiently strong base with the same dimensions as the boiler
(see Figure 1-1) and at least 4 inches (100mm) high (see Figure 4-1 in paragraph 4.7), to allow for
assembly of the condensate drain trap. An alter native to this base m ay be a 4 inc h (100mm ) deep well nex t
to the boiler to house the condensate siphon.
The condensate collector baffle (see Section 7) can be fixed, from the Right Hand (R.H) or Left Hand (L.H.)
side of the condensate tray. If no modification has been made, the boiler must have its R.H. side
accessible, with the vent connection f itted on the R.H or L.H. side. However, if the flue collector term inal,
with the exhaust connector, is left to of the R.H. side and if, from this same side, the baffle has to be
removed, and then the exhaust connector must have the possibility to be also removed. If it is preferred,
the baffle can be moved in order to have its mounting s crew on the oppos ite side , regardles s the positi on of
the flue collector chamber term inal.
2-3
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