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Modulex EXT 321- 1123 User Manual (GF-143)

1. 35 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 3 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 8 3 3 Reversing Boiler Sensor Kf And Automatic Air 4 6 35 3 9 Gas Connection ese tenuto epis Fab tbe 36 2 9 Wi Natural Gas CONN OCTIONS ete mdr ahua aaa khaka sas 37 39 1 1 Natural Gas PIDIHE edu even RUP a 37 39 12 Natural Gas PIPINE 37 3 9 1 3 Natural Gas Supply Pressure Requirements 37 229 2 5 Wawas Sy 37 3 9 2 Propane Gas PIDIHg Sl ES uuu ro ence wap 37 39 2 2 Propane Sas PIPING oett E 37 3 9 2 3 Propane Gas Supply Pressure 38 IO Elow And Ret rn PIpe CONMC
2. SLM 46 3 21 Combustion Air and Ventilation 48 3 21 1 Insufficient Ventilations and Combustion 0000 0 48 3 21 2 ROOF AC COMDUSEI OM utt tp 49 321 3 sealed 49 3 22 Installation of the Exhaust and Air Intake System 0 000000 0 49 3 22 1 Important Factors for Terminal Orientation and LOCATION 50 3 22 2 Minimum and Maximum Wall nennen nennen nnn nnn nnns 51 2 29 u y yu aan Sia itu 51 3 24 225 53 3 24 ORCC uy 53 3 24 2 Mains Electrical Supply Connection 120 V 60 53 9 24 3 Service Relay Regultemeblb etii iH risa e i Ra ies E 54 3 24 4 Electrical RequiEG melts y u 54 5 25 FUNCEION Al Wiring Diagram Au unay 57 320 EUCLID i i 59 32r General 60 3 28 E8 Controller and BCM Terminal
3. aa ataqa 106 deitate to paie 110 5 10 1 Settipesf oriea mp Cir Cult 1 2 i edes sata 110 5 10 1 1 Heating Adjustment With Constant Flow 110 5 10 1 2 Temperature Settings For Heating Circuits 110 5 10 1 3 A Second DAW Storage 111 5 10 1 4 Temperature Setting For Second DHW Storage Tank 111 STOPS SWIMM POOL 111 5 10 1 6 Swimming Pool Temperature 111 5 10 1 7 Screed Dry Program For Floor Heating nn 111 5 10 1 8 Temperature Setting For Screed 111 SAO EI SC Ma Ecc 111 5 10 1 10 Slope And Temperature Setting with 0 10 V Signal 111 5 10 2 Setting OF DMW CFCU 256 Sue Dd due 112 5 0 2 L Operation or Parmps Tn Patrallelssskovaseoni
4. EXT321 481 641 4 Diameter S Contact vent manufacturer directly PVC JPN 49050 included EXT 802 962 1123 otainless Steel Contact vent manufacturer directly 6 Diameter HOSE CLAMP BOLT 4 2 WASHER 4 em amam NNNM Gee ADAPTOR GASKET INCLUDED European to American Standard Flue Access point for cleaning and inspection Adapter Figure 3 24 Flue Exhaust Diameter Reduction Adaptor Kit and Parts The flue venting pipe is affixed to the adapter using RTV liquid silicone and then clamped with a worm driven Hose Clamp When using non metallic plastic venting materials use Schedule 40 or thicker Single wall uninsulated pipes When using non metallic plastic vent systems for Canadian installations OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 47 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual per CSA B149 1 use vent systems that are certified to the standard for Type BH Gas Venting Systems ULC S636 The plastic components primers and glues of the certified vent system must be from a single system manufacturer and not mixed with other manufacturer s vent system parts The Inspection Port should be plugged with an appropriate plug not includ
5. Vas as AN us rui 112 5 10 2 2 Use of a DHW Storage Tank Thermostat On Off 112 SIOZ AMICE P 112 5 10 2 4 Setting Tor Solar Panel USS cisci irren Debates assays 112 SOISACCESS CODE SETTING tuin pete tene e a te yusa shyy 112 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 5 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual CHAPTER TROUBEESHOOTINQG 3 Ness p eaa o a REOS 113 GLES Controller o e OE 113 o I AVES Controller Fault COG CS secet a T t eaa o a t Ond 115 6 1 2 BCM Boiler Communications Module Fault 44 117 6 1 3 BMM Burner Management Module Fault 5 118 CHAPTER 7 MAINTENANCE SCHEDUIE 121 7 1 Instructions for Inspection and 4 122 7 2 Periodic Examination OPVentihg SVSEeIy a T as l 122 7 3 Proper Procedure For Cleaning Exha
6. 5 60 2 29 Installation 63 3 30 Starting Up Filling and Deaerating the 65 3 30 1 Necessary Preca ti nS TOL vn ada up spa 65 3 30 2 Supply Voltage Gas Pressure and Water 65 SEU 65 3 31 1 Necessary Precautions While Filling the System ns 65 3 31 2 Filling Locations and Preparation uu t IE 66 3 32 Testing The lenition Safety Shut Off DEVICE i uu 68 3 33 Burner CallbEalloF sess dae i xo emet washawan cease 69 3 394 Installing the Gas Analyzer PrODG ee 69 3 23 2 Maximum Output CallbratiOD Sei oen S 70 Mrd Odtput sas sas tp PS 71 3 33 4 Final Check and Ignition Failure Adjustment Procedure 71 Page 4 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone
7. 5 HORIZONTALLY VENTED indicates the minimum and maximum wall thickness direct vent Gellar will installed through which venting is allowed to penetrate CHAUDIERS AVEC EVACUATION HORIZONTAL DES hori Epaisseur de la paroi travers orizontally However if venting is vertical then there laquelle se fera l vacuation directe is no minimum wall thickness Minimum inch mm Maximum inch mm 4 101 6 36 914 4 00334526 3 23 Vent Pipe Sizing The maximum length is the combined length of straight horizontal and vertical runs and the equivalent straight length of fittings The required lengths for each boiler are as follows NOTE The examples referenced in the table below are on the next page Table 3 4 Modulex EXT Vent and Piping Diameter Chart aap a Max Vent Equiv Max Vent Equiv Modules Inches mm TE Jea xamples 1 amp 2 Examples 3 amp 4 z 5 152mm 6 152 mm 2 s e Table 3 5 Modulex EXT Vent and Piping Length Chart Vent Sharp 90 Sweep 90 Elbow 45 Elbow Maximum Elbow Length Pipe Equival Equivalent Equivalent Equival Diameter guiya eni Feet m Feet m FUSE Feet m Feet Meters EXT 321 4 10 Feet 5 Feet 5 Feet 100 Feet EXT 481 101 mm 3 m 1 5 m 1 5 m 30 m EXT 641 EXT 802 6 10 Feet 5 Feet 5 Feet 100 Feet EXT 962 152 mm 3 m 1 5 m 1 5 m 30 m EXT 1123 NOTE The maximum pressur
8. includes the 6 or 4 Dia Flue Piping cover for the right hand exhaust hole oee Figure 3 9 G a a aD ay cD a a gt ca E aD o gt aD a gt G as GN G E DD aa co aD a En GN G aay 7 9 200mm Dia a European Standard D Flue Outlet Rear flue manifold kit EnEn Adaptor for Connecting Figure 3 8 Rear Exhaust Kit P N 00364937 for Changing Exhaust Outlet from RIGHT HAND side to REAR on EXT 802 962 1123 only Page 32 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 00000000000000000000 00000000000000000000 00000000000000000000 Exhaust Opening Cover Figure 3 9 Rear Exhaust Kit P N 00364937 for Changing Exhaust Outlet from RIGHT HAND side to REAR 3 9 2 Reversing Gas Manifold Connections To move the gas connection from the RIGHT HAND side standard delivery position to the LEFT HAND side swap the end plate and the gas supply connector screwed onto the gas manifold ends as shown in Figure 3 10 Ensure that the gaskets for ALL connections are reversed along with the connectors themselves Gas Manifold Gas Manifold End Plate Gaske
9. senor testing Supports Modbus integration with AERCO BMS Il and AERCO Control System ACS or Building Automation Systems AERCO also offers a Communication Gateway to support BACnet Lonworks and N2 system integration OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 81 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual LCD Display Window Hinged Cover in closed position Rotary Knob Figure 4 1 MODULEX E8 Controller Front Panel Cover Closed 4 1 2 E8 Display Functions The E8 Controller operates in NORMAL Mode when the controller door is closed which allows for monitoring the boiler status through the display window and setting the HEATING Mode When the door is opened the unit enters MENU Mode and in this mode the boiler may be initialized configured and adjusted The controls and display for the E8 controller are described in the following sub sections MOOS e Figure 4 2 E8 NORMAL Mode Display Features Table 4 1 E8 NORMAL Mode Display Features and Functions Display of the active heating program for the first heating circuit here 6 00 to 08 00 a m and 4 00 to 10 00 p m Bus icon if this icon does not appear check data line to connected CAN controllers gt check eBUS via DISPLAY level Preparation Heating Mode display symbol The display symbo
10. aum 440 pue NO 195 19 043002 DW 2908d91H puz 104 puz 4 HI SOSd puz 10 15 9sIM20 2 uJn 19 043u05 351 404 NNS NOW NOS 1VS 5421 unt ST yn 45 043u02 CHNU re 15140 151 AVOSYNHL aswa Ay AVQS3NO3M AVOSNHL AVONON JOY 10 aq 195 kh 3NILT2HIS 24 104 Aejdsip ay uo UMOUS si 9u L 088 pesdgr3 SSIMYDOIS unl u do S E8 Quick Start Heating and Pump Program Settings Figure 5 4 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF Page 95 of 146 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 5 3 Menu And Sub Menu Descriptions There are six top level menus and five sub menus as listed below 5 3 1 9 9 2 Menus Top Level GENERAL Value selection summary Service gt for service engineers Date Time Holiday gt for users DISPLAY oystem value display e g senso
11. WARNING Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Do not use any phone in the building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot contact your gas supplier call the fire department WARNING The boiler must be 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 temperatures lower than 5 F 15 C or higher than 104 F 40 C The boiler must be protected against environmental variations with e The insulation of the hydraulic pipelines and the condensate drain The adoption of specific antifreeze products in the Cold Hot water installation OMM 0087_0F AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 9 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp 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 ims Made in Ital Unical wawa D YT Unical Boiler Model Catergory __ nica Serial N code CONDENSING BOILER Single
12. lt 85 4 1 6 Parameter Navigation Selection and 86 4 2 BEM Boiler Communication y ett iret u ene re eeu Pha Ue PR HEP au apana 87 4 2 T BCM Features and FUNCTIONS esee per aser venit uius CRUS A reda pO SS aa Sw Qux UP FUA NRI qu UR 87 A272 BEM t E 87 CHAPTER OPERATION auo d 91 5 1 Installation Menu Initializing the E8 92 5 2 AUCK Start eee hg amt ee ae 9 5 2 1 Setting Maximum and Minimum Flow Temperature 93 5 2 2 Setting Room Temperature and Outdoor Compensation 93 5 2 3 Setting Heating Programs and 94 5 2 Menu AndSub Menu Descrip ons eot da utut bout 96 53 TNBDUSTTODIEOVe Suec Dots teda usa d ee feu eod Do se 96 Helle ci uer C 96 5 Geheral IVIBills ue socie mau A duel uu teta tere piu 97 ECCE 99 5 5 DISMAY 101 DP WSC IMICII mee cT ECCL up ua 103 3S HME PROS dame cmm 105 LI EXPEC MEMU
13. 0 10V output to control variable speed primary pump Integral insulation with hypoallergenic synthetic wool Premix fiber mesh modulating burner premixes into the fan with automatic diaphragm backflow separation from the combustion chamber OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 15 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Less than 49 dBA of noise at maximum power e Heating operation instantaneous power microprocessor control with preset parameters for comparison between temperature or calculated from the external temperature regulation and global temperature flow Operation modes o Ability to control power to the individual heating elements for any calibration with or without confidential code access o Production of A C S Active Cooling System by NTC sensor of priorities for control by boiler feed pump or by three way diverter valve controller e electronic controller included BCM Boiler Communication Manager included e Ability to control power of the individual heating elements e Control of heat demand constant or remote setpoint Monitoring of operating status and temperature e Reporting of alarms e Setting of parameters e Emergency operation prevents the boiler from shutting down as a result of the interruption of communication with a cont
14. Gas Valve Connector remove from side of valve Remove Connector Retention Screw Figure 7 11 Removing Gas Valve Connector from All Gas Valves Step 7 7 On each gas valve unscrew the Gas Valve Connector with a Phillips head screwdriver Remove connector Figure 7 11 from the side of each gas valve OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 129 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Disassembling the Boiler for Maintenance Continued 8 On each fan remove each of two Fan Connectors Figure 4 10 ES s E Remove Two Connectors from Each Fan N w Figure 7 12 Removing Both Fan Connectors from Fans Step 8 9 Burner maintenance may be performed on all burner modules simultaneously or on each one separately as described in a and b below Modules Use a 13mm wrench to remove all A and C nuts surrounded by horizontal dotted lines in Figure 7 11 below Leave the B screws affixed so all burner plates may be lifted together Then complete the remainder of the instructions in this section b Separate Modules Use a 13mm wrench to remove only the and nuts on either side of the module in question vertical dotted lines in figure 7 12 then remove the B Phillips screw at the end of the burner modul
15. NOTE Ensure that the high gas pressure regulator is installed at least 6 to 10 feet upstream of the boiler 3 10 Flow And Return Pipe Connections cold and hot water flow and return circuits must be connected to the boiler via the respective 272 M and R connections as indicated in Table 2 1 When determining the size of the cold hot water circuit pipes it is essential to bear in mind the pressure losses induced by any of the system s components and by the configuration of the system When planning the routing of the cold hot water piping take the necessary precautions to avoid air traps and pockets and to facilitate the continuous purging of the system WARNING e Before installing the boiler we recommend that the system is flushed out with a suitable cleaning product in order to eliminate any metallic tooling or welding residues or oil and grime which could reach the boiler and affect the proper functioning of the boiler Ensure that the system piping is NOT used for earth grounding of electrical or telephone systems Such grounding of system piping is unsuitable and can cause serious damage to the piping boiler and radiators It is absolutely forbidden to fit on off valves in the piping before the required saftey devices 3 11 Pressure Relief Valve The included pressure relief valve Figure 3 15 must be fitted on the CSD 1 manifold which is installed on the flow pipe per instructions in the next section 3 12
16. opening 7 4 Checking CSD 1 Manifold Flow Switch Check the function of the flow switch in the CSD 1 manifoild at the boiler hot water outlet If it is not functioning check the wiring to the terminal of the BMM module labeled FL or replace with a new flow switch OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 123 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 7 5 Visual Inspection Of The Flame The burner must flame evenly over the entire surface when operating correctly The flame must burn with a clear ORANGE stable flame Check the flame through the flame observation port Figure 7 2 The flame pattern should resemble the flame in the illustration below FLAME COLOR SATISFACTORY YELLOW CO2HIGH NOT SATISFACTORY e BLUE CO2 LOW SATISFACTORY e ORANGE OK SATISFACTORY ORANGE FLAME Igniter Cable Flame Observation Port Flame Detector Figure 7 2 Boiler Flame Observation Port Location 7 6 Proper Reassembly and Resealing of the Vent Air Intake System After removing inspecting and possibly cleaning the flue pipes and air intake replace the piping correctly Refer to AERCO Venting Application Guide GF 136 V for information concerning Modulex venting requirements Page 124 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 1
17. 12 01 31 Adjust current year XXXX 01 12 01 31 XXXX 12 31 01 31 Set current holliday start year Set current holliday start month Set current holliday start day Set current holliday end year Set current holliday end year oet current holliday end day oet month for start of summer time Set earliest day for start of summer time oet month for start of winter time Set earliest day for start of winter time MONTH START DAY START MONTH STOP DAY STOP Page 98 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 5 5 Service Menu The SERVICE menu contains the TEST RELAY SENSOR TEST and OTHER PARAMETERS sub menus as shown below NOTE he SERVICE menu is accessed as shown below However SERVICE MODE fp is different and can only be accessed when the 8 cover is closed Open the door flap After 2 seconds DISPLAY gt GENERAL s DATE TIME Q SERVICE counterclokwise displayed counterclokwise Press to enter level TEST RELAY gt _ gt SENSOR TEST gt _ gt THER PARAMETERS Turn Tum clockwise clockwise Press to Press to C enter enter level CX level Turn clockwise SENSOR TEST SW NO XXXX Cx ACCESS e Insert the CODE 9 code CASCADE MANU 158 arise Tuin BURNER TIME
18. 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 34 Sweeper Mode Manual sicuri qs ts qux Es T Se ROV u u God t qu UU S Pax RU EO paa Cu 74 3 35 High Altitude Adjust melt cuisses Ox ed vens deos es e iu diede es b as dta unte kuyka 75 3 36 High Altitude Conversion 76 3 37 Conversion From Natural Gas Propane e yn iu a utei ese due aa EY vd P 77 3 296 Controls And Emersency FUNCTIONS u uyu u u Oe eel m DEN in I UM iE 78 9 39 BONEE Iac od eO n E 79 2 299 T Prelmitigb Chee u u umb e 79 CHAPTER 4 E8 CONTROLLER AND BCM MODULES 81 A MM Ee Ge arie 81 4 1 1 Controller Features and 81 4 1 2 ES Display FUNCTIONS 82 A SES HEATING MOGe SelectiIDI eni ers o enter e tut Rh ter e th t 83 4 1 4 MENU Mode Operation Door u uu 84 4 1 5 MENU Navigation and Parameter 5
19. BURNER START 1 8 LIMITER TEST 1 8 Burner time for all stages Burner start for all stages oafety temperature limiter test press and hold button Date Hour setting for service purposes Do not use Do not use Do not use Page 100 of 146 07 13 15 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 5 6 Display Menu DISPLAY menu contains the INSTALLATION HOT WATER HTG CIRCUIT 1 2 and SOLAR MF sub menus as shown below Open the door flap DISPLAY After 2 seconds the sub level is displayed SOLAR MF Press to enter level CN INSTALLATION A gt Turn l clockwise a Press to enter level Turn T OUTSIDE clockwise Turn T EXT DES clockwise T T COLLDES v aockwise T COLLECTOR T BOIL Turn clockwise T SOLID FUEL CM T RETURN 1 CN P T RETURN 2 Press to clockwise exit PLUS Turn T BUFFER clockwise Turn L clockwise TSTORAGE 3 CN clockwise MODGRAD C Turn clockwise Turn RETURN EN clockwise 2 HOTWATER gt 4 Turn Press to a enter level T DHW RATED KY aockwise Turn T DHW clockwise Turn T DHWL clockwise Turn CN clockwise Turn RETURN CN clockwise HTG CIRCUIT I
20. Continued HC FUNCTION 00 04 PUMP MODE 00 03 MIXER OPEN 5 25 MAX T FLOW 176 68 230 MIN T FLOW T FROST PROT 3 OUT TEMP DEL SLOPE OFFSET B HEAT SINK Circuit enable RETURN 2 RELAY FUNC 1104 00 26 T MF1 to 4 SETP 86 194 MF 1 to 4 HYST 4 18 FUNZ 15 00 02 RETURN 2 There is another sub menu under the EXPERT menu called EXPERT HS See section 3 35 High Altitude Adjustment for details 50 230 5 41 0 24 0 90 00 01 18 MIXER CLOSE Close mixer dynamic 12 5 25 10 2 NOTE Some menus are visible only if the relevant sensor is wired 5 10 Other Possible Settings 0 10 1 Settings for Heating Circuit 1 2 5 10 1 1 Heating Adjustment With Constant Flow Temp Without Outer Sensor Offers the possibility to have a constant flow temperature on the selected heating circuit INSTALLATION menu gt FUNC 01 5 10 1 2 Temperature Settings For Heating Circuits Only After Function Selection USER menu gt Heating circuit FLOW TEMP DAY USER menu Heating circuit ll FLOW TEMP NIGHT Page 110 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 5 10 1 3 A Second DHW Storage Tank Only After Function Selection Offers the possibility to use one of the
21. Figure 3 26 Minimum Distances of Exhaust Opening and Building Features 3 22 1 Important Factors for Terminal Orientation and Location Terminals should be positioned so as to avoid products of combustion from entering openings into the buildings or other vents The terminal should be located where dispersal of combustion products is not impeded and with due regard for the damage or discoloration that might occur to building surfaces in the vicinity In certain weather conditions condensation may also accumulate on the outside of the air inlet pipe Such conditions must be considered and where necessary insulation of the inlet pipe may be required In cold and or humid weather water vapor may condense when leaving the vent terminal The effect of such condensation must be considered The terminal must be located in a place not likely to cause a nuisance Maintain 12 of clearance above the highest anticipated snow level or grade or whichever is greater Please refer to your local codes for the snow level in your area The whole route of the vent system must be installed upwards and never completely nor partly downwards Page 50 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 22 2 Minimum and Maximum Wall Thickness The label at right which is placed on the unit
22. MF Temperature MF sensor 1 11 Temperature MF sensor 13 RETURN 8 Page1020f146 AERCO International Inc 100 Oritani Dr e Blauvelt 10013 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 5 User Menu The USER menu contains the INSTALLATION HOT WATER HTG CIRCUIT 1 2 and SOLAR MF sub menus as shown below Open the flap clockwise After 2 seconds sub level is displayed INSTALLATION 3 oT wareR Turn clockwise 9 Press to o Press to enter enter CQ FN HTG CIRCUIT IIl SOLAR PU Press to enter CX DISPLAY SEL Set the value Turn clockwise SELEC PROG gt Setthe value Turn clockwise RETURN z C Press to exit T ROOM DES 2 Set the value CM clockwise T ROOM DES 3 Set the value Turn clockwise T REDUCED Set the value Turn clockwise T ABSENCE Set the value Turn clockwise T LIMIT DAY gt setthe value C clockwise T DHW 2 Set the value Turn clockwise T DHW 3 Set the value Turn clockwise BOB VALUE gt value Turn C clockwise CIRCL P DHW Set the value Turn clockwise ANTILEGION Set the value Turn clockwise T
23. NOTE Only the basic features and functions of the BCM are described in the following sections Refer to the E8 Controller User Manual GF 115 C for detailed information and diagrams for wiring and using the BCM in its various capacities The BCM Boiler Communication Module is an electronic module in MODULEX boilers which supports full interoperability to BAS Building Automation Systems via Modbus protocol to make remote communications and control possible addition it provides customers with a remote alarm contact to notify customers of faults detected within any of the boiler s multiple thermal modules Finally in the event the boiler s master controller stops working the BCM also takes over operations of the boiler As a back up controller the BCM further increases the reliability of a product line already known for its uniquely redundant design Each MODULEX boiler combines between two and seven independent 160 500 BTU hr pre assembled thermal modules housed in a common enclosure Each module has its own dedicated controller with a combustion safeguard variable speed fan modulating gas valve electronic ignition modulating burner flow temperature sensor thermostat and heat exchanger The independent operation of these thermal modules increases each boiler s overall reliability If a single module requires maintenance or repair the other module s in the boiler can maintain the system load requirements thereby providing a
24. level of redundancy that was previously only realized in multi boiler installations A photo of the module is shown in Figure 4 6 Additional information for the BCM component can be found in Section 7 9 10 of the E8 Controller User Manual GF 115 C 4 2 1 BCM Features and Functions When installed and enabled the BCM enhances the range of control functions offered by the Modulex Boilers These additional control functions include the following e Providing a fault relay which energizes when any fault condition occurs the Modulex Boiler e Serving as Back up Controller in the event that the primary E8 Controller fails e Providing a 0 10 output to control a variable speed primary pump be selected as the Primary Controller instead of the E8 Functioning as a Slave to a Master Energy Management System EMS Building Automation System BAS or AERCO s Boiler Management System II BMS II AERCO Control System ACS on a Modbus Network 4 2 2 BCM Description The BCM shown in Figure 4 6 is housed in a compact enclosure measuring 4 13 105 mm x 3 50 89 mm The is installed on the front of the Modulex Boiler control panel Input Output connections to the BCM are made via four connectors mounted on the Printed Circuit Board PCB of the BCM Three Control Switches are mounted on the clear plastic cover on the front of the BCM Three LED Status Indicators are mounted directly on the BCM PCB an
25. 1 8 clockwise BURNER START 1 8 C ie aise C clockwise TEST RELAY 00 Turn M LIMITER TEST 1 8 CY aockuise A Turn SERVICE 18 clockwise a Turm ockwise clockwise Turn clockwise clockwise r Turn urn ad cose I TEST RELAY 02 im Turn Sus RESE T PRG 00 Wclockwise Turn TEST RELAY 03 clockwise Turn Turn RETURN clockwise Turn clockwise TEST RELAY 04 clockwise Win l Turn TEST RELAY 05 clockwise Tum F12 clockwise CN Press to Turn exit OTHER PARAMETRES seats Turn F14 clockwise Turn cotkwise d Press to exit SENSOR TEST Turn TEST RELAY 06 clockwise Turn TEST RELAY 07 docwiss Turn TEST RELAY 08 clockwise Turn TEST RELAY 09 clockwise TEST RELAY 10 cockwise I TEST RELAY 11 FRAU Press to exit RELAYS TEST Figure 5 6 SERVICE Menu 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 99 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 5 2 SERVICE Menu DESCRIPTION TEST RELAYS F14 Room temperature heating circuit 2 or measured value of the sensor or OTHER PARAMETERS SW NO XXX XX Software number with index CASCADE MANU Manual control of each module BURNER TIME 1 8
26. 115 C e It is obligatory to carry out comprehensive maintenance services annually with a combustion analysis every two years in compliance with national and local laws e 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 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 7 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp 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 e Children must be supervised so they do not play on around or with the appliance The installation adjustment and servicing of this appliance must be carried out by a competent person and installed in accordance with the current standards and regulations Failure to correctly install this appliance could cause injury to persons animals or damage to property The manufacturer shall not be held liable for any injury and or damage Servicing or repairs of the appliance must be carried out by AERCO authorized service tec
27. 3 33 7 9 Heat and Return Sensor Resistance Values Nominal resistance differences at a given temperature ratio between the primary and return heating sensors should be checked periodically by measuring the electrical resistance ohms between the two sensors with a voltmeter Use the chart below to determine the correct resistance values at the given temperature ratios Table 7 2 Table of Resistance Values for Primary and Return Heat Sensors Resistance 0 25 30 75 100 125 150 175 200 Temperature Example At 104 F 40 C the nominal resistance is 5 363 Ohm At 194 F 90 C the nominal resistance is 920 Ohm Page 126 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 7 10 Unit Disassembly To disassemble the unit for maintenance do the following Disassembling the EXT Boiler for Maintenance 1 Switch OFF external electrical power and CLOSE the gas supply valve upstream from the boiler and ensure it is completely closed Unlatch and raise the top lid Figure 7 4 Remove screws from top of unit holding the rear and side panels in place Figure 7 5 Remove panels by tilting away from unit then lifting up and out Figure 7 6 Note the front and rear panels must be removed before the sid
28. 7 1 3 Information to Be Made Available To The U Sere cio e e y u a E NN Loue Nn CEDE ra Eva 7 dius 8 1 5 Modifications Parts Connected To The 8 1 6 For Appliances Operating With Propane 9 Job P C aste d ue d tM Mea oie A 10 1 1 c awas edu UM Und aspe m 11 1 81 General seas edt rH Id 11 18 2 Regulatory Regue mente essi tei t admet ieu Rb nu 11 1 8 3 Water Quality 0020 nennen aE nn snnt 12 1 9 Tools Materials And Additional A 13 J 10 DispoOosalu uy cs cC EAE 13 l Il General uya utu dualis deni cete cu eto opt cce i cete cde T MO e 13 1 11 1 Using the Operation and Maintenance 13 1 11 2 Installation and Servicing 13 Installation tas eu end d quet m E ANE 13 1 11 4 Preparing Boiler Tor Servicing venia VOV Ox Qe RE VE pex EU BUD S
29. 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 3 6 Modulex EXT Pressure and O Level Calibration Tables EXT 802 Supply COzLevel O Level Fan Speed qn Gas Max Gas Pressure je Consumption Consumption Output Wc kPa 2 2 Co Ce Min ft hr mehr ft hr m hr Min Min Max NO Natural 70174 85 027 90 220 027 7074 3 0270 7902238 18 0 50 r BH Co CO CO Level Level Max Gas Pressure Consumption Consumption Output Vo 90 Max 3 3 3 3 Wc kPa Max Min Max FL ft hr m hr ft hr m hr DH CO B Supply CO Level Level Max Gas Pressure i je Consumption Consumption Output Vo 9o Min Max 3 3 3 3 Wc kPa Max Min Max FL FH ft hr m hr ft hr m hr NOMINAL ALTITUDE 7079 85 0212 5 8 100 027 7 45 129 1 106 31 34 11 2 74 108 10 8 43 3 1 0 27 7 18 0 50 384 10 91 Check the levels often especially at low flow rates For high altitude installations consult document number C302 6 MLX EXT Alt Derate Ww OMM 0087 OF AERCO International I
30. Check gas pressure and adjust if necessary Inspect and clean the flue exhaust assembly Check all water connections and valves Do combustion analysis and recalibrate if necessary Check electrical and electronic components Inspect condensate drain pipe and trap clean if necessary Check flow switch in the CSD 1 manifold for proper function OMM 0087_0F AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 121 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 7 1 Instructions for Inspection and Maintenance WARNING To ensure a long life of the boiler components and in order not to alter the conditions of an approved product ONLY original AERCO spare parts may be used Before servicing always carry out the following steps 1 Disconnect the mains electrical supply to the boiler 2 Separate the boiler from the electrical supply by means of a separating device with an open contact of at least 3 mm for example safety devices or power switches and ensure that it cannot be accidentally connected to power 3 Close the external ON OFF gas valve installed upstream of the boiler If necessary and in keeping with the type of work to be carried out close any ON OFF valves fitted on the C H flow and return pipes as well as the cold water inlet valve Remove the boiler front panel Perform the maintenance in k
31. Inspection Maintenance Kit 58086 TAB P N Suffix DESCRIPTION 16 EXT 962 24 MONTH FIRESIDE INSPECTION KIT 17 EXT 1123 24 MONTH FIRESIDE INSPECTION KIT 18 EXT 1530 24 MONTH FIRESIDE INSPECTION KIT 19 EXT 1912 24 MONTH FIRESIDE INSPECTION KIT 20 EXT 2295 24 MONTH FIRESIDE INSPECTION KIT 21 EXT 2677 24 MONTH FIRESIDE INSPECTION KIT 22 EXT 3060 24 MONTH FIRESIDE INSPECTION KIT OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 137 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 7 15 Accessory Kit Part Numbers The following Modulex EXT Accessory Kits are available 58081 for Modulex EXT models 321 481 641 58082 for Modulex EXT models 802 962 1123 The contents of each are listed in the table below Table 7 5 MLX Accessory Kits 58081 amp 58082 Included in Kit remy dy Panno Doscripion _ 4 1 tas675 2 GAUGE PRESSURETEMP 2 1 4 VEXHAUSTCONVPARTFORPNG 73 1 WEXWAUSTCONVPARTFORPNG 7 4 2 se ewomomvEHosEQwe v ex 142X144PVCREDCAP 94105 FLONSWTCH Y Page 138 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS
32. LIMIT N clockwise Set the value NOT AVAILABLE Set the value 2 ENGLISH 1X DHW Set the value Set the value Turn Turn Turn clockwise clockwise clockwise CONTRAST gt setthe value T DHW 1 y Set the value T ROOM DES 1 gt Set the value Turn Turn C Turn clockwise clockwise clockwise HEATSLOPE setthe value OQ Turn clockwise ADAPTION Set the value clockwise OPTIM HEAT setthe value clockwise ADAPT ROOM T 3 set the value Turn clockwise OPTIM HEAT Set the value clockwise MAX Set the value CM Turn clockwise ECONO OPTI 9 set the value Turn clockwise PC ENABLE Set the value Turn clockwise RETURN RETURN z Press to exit Figure 5 8 USER Menu OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 GF 143 Phone 800 526 0288 Page 103 of 146 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 5 4 USER Menu DESCRIPTION ENTRY INSTALLATION y J Defaut Range ENGLISH Setlmagage 11 1 1 1 1 11 ENG O CONTRAST Adjust intensity of display 00 20 20 DISPLAY SEL Selectadditional display in standard operation 01 02 RETU
33. The E8 does not control the boiler and the BCM will not take over the boiler if the Modbus signal fails The is the Gate way for Modbus and external control The E8 does not control the boiler and the BCM will take over the boiler if the Modbus signal fails If E8 is in Standby Position O Position Il see NOTE 2 See NOTE 3 The E8 is the primary controller and the BCM allows monitoring through Modbus but will not take over boiler if the E8 fails The E8 is the primary controller and the BCM allows monitoring and the BCM will take over the boiler if E8 fails If E8 is in Standby Mode E8 will cycle the pump Mode will cycle the pump with the boiler If E8 is in Day Mode the E8 will continuously run the pump must use Enable Disable If E8 is in Day Mode the E8 Will continuously run the pump I ON Enable DO NOT USE NOTES 1 DO NOT set the 3 Position Switch to Position I 2 Set the 3 Position Switch to Position O ONLY when controlling Boilers from an external Controller via Modbus Communication See Paragraph 3 1 2 of the E8 Controller User Manual GF 115 C for setting HEAT Modes 3 Position Il is the Default position for the 3 Position Switch Ensure it is set to this position when it arrives from the Factory See Paragraph 3 1 2 of the E8 Controller User Manual GF 115 C for setting HEAT Modes 0087 OF GF 143 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 1
34. Turn clockwise Turn clockwise Set the value Turn clockwise Turn clockwise Turn clockwise Set the value Turn clockwise EBUS SUPPLY Set the value Turn Turn CM clockwise clockwise TIME MASTER Set the value Turn clockwise MAX T COLL Set the value Turn clockwise Turn clockwise Turn clockwise Set the value Turn clockwise Set the value Turn CM clockwise Set the value Set the value Turn clockwise Set the value Set the value Turn clockwise EATSOURCE 2 gt s t the value Figure 5 10 EXPERT Menu 1 of 2 Page 106 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Open door the Turn EXPERT clockwise After 2 seconds the sub level is displayed gt HOT WATER CY HTG CIRCUITIII soLAR ME Turn Turn clockwise l clockwise e Press to e Press to T du level EN level Cy level Set the DHW RELIEF HC FUNCTION REALY FUNC 1to4 Set the Turn Turn Tum C clockwise CIDERWIRO clockwise Set th Set the PARALLEL gt vue PUMP MODE gt Fete 1104 Turn clockwise Ol a clockwise Set th Setthe MIXER O
35. VM 4 7 Modulating Fan 8 al SR 1 7 8 Local Flow NTC Temperature sensor p Yellow LED Blinking E ACC Let Ignition electrode General Limit Thermostat SRR Global Return NTC Temperature sensor communication between BMM and BCM OK E RIL 1 7 8 lonization electrode pres TL High limit thermostat DIZ Green LED ON Active Pump Pompe active FL Flow switch PF Fan minimum pressure switch ree sofeen LEL UN diet TL 1 7 8 Local High limit thermostat t IG Main switch SL Condensate level sensor TLG Global High limit thermostat 013 Red LED ON Failure code detected IS Request for emergency manual SMG Global Flow NTC Temperature sensor VG 1 7 8 Gas Valve SW Address selector TRA ACC 1 7 8 Ignition Transformer 8 Only for Modulex 900 OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 57 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual This page intentionally blank Page 58 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 26 Ladder Diagrams REFER TO INSTRUCTION MANUAL WIRING DIAGRAM CONSULTER LA NOTICE TECHNIQUE 7 D INSTALLATION SCHEMA DE RACCORDEMENT PRATIQUE LOW VOLTAG
36. a MODULEX boiler and also monitors supply and return water temperatures and domestic hot water zones The E8 Controller is housed in a compact enclosure measuring 5 7 145 mm x 3 9 100 mm The Controller is mounted on the front of the MODULEX Boiler and contains all of the controls indicators and displays necessary to adjust operate and troubleshoot the MODULEX Boiler The main components of the closed E8 Controller include the display door and data wheel see Figure 4 1 4 1 1 E8 Controller Features and Functions The E8 features the following functions for MODULEX boilers Shares the heating load among as many of the boiler s thermal heating modules as possible maximizing the overall operating efficiency of the boiler e Provides access to all testing programming parameters of each individual heating module operation test operation time boiler freeze protection and pump s anti seize program e Drives lead lag burner operation based on operating hours The boiler module with the least burner operating hours is the first to start and the burner with the most operating hours is the first to stop Supports DHW Domestic Hot Water production using a dedicated sensor to control a dedicated pump or 3 way diverting valve for storage tank temperature control Supports a manual operation service mode to control individual modules during troubleshooting or combustion calibration procedures e Drives diagnostics such as relay
37. amp Maintenance Manual 5 2 Quick Start Instructions Below are instructions for setting the most basic settings in the E8 controller including maximum and minimum flow temperature room temperature settings heat slope and initiation of heating programs IMPORTANT NOTE Before the boiler may be used the E8 controller MUST be first intitialized by entering language year month day and hour in the Installation Menu as described in section 5 1 above 5 2 1 Setting Maximum and Minimum Flow Temperature Open the Flap dria EXP E RT Elapsed 2 sec The sublevel is shown on the display EGTWiTER O WISGRGUTW gt Turn clockwise o Depress the push button HC FUNCTION Turn clockwise PUMP MODE Turn 22 clockwise MIXER OPEN clockwise MIXER CLOSE clockwise MAX T FLOW d Ve clockwise d d MINT FLOW RETURN d Depress the push button to exit clockwise clockwise Maximum Flow Temperature Minimum Flow Temperature Figure 5 2 E8 Quick Start Max amp Min Flow Temperature Settings 5 2 2 Setting Room Temperature and Outdoor Compensation 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 93 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Ma
38. boiler system Damage of seals and gaskets in boiler and system could occur resulting in substantial property damage danger The central heating installation needs to be filled with clean water Use only clean water or approved glycol for filling the heating system When the water hardness of the filling water exceeds 9 grains the water must be treated until below the maximum value of 9 grains The pH value of the installation water must be between 6 5 and 8 5 Check the pH value using proper equipment or by having the water analyzed by a water treatment company If pH differs from above contact AERCO engineering for further assistance WARNING Failure to adhere to the water quality requirements will result in a voidance of warranty 3 31 2 Filling Locations and Preparation For filling the system a filling tap must be inserted on the system return pipe e Filing can also be accomplished through the draining tap on the boiler return manifold e n both cases an approved hydraulic disconnection system must be fitted Before connecting the boiler carefully rinse out the whole system with running water Page 66 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual FOR YOUR SAFETY READ BEFORE OPERATING SS WARNING If you do n
39. burners by blowing into the side flame side of the burner mesh See Figure 7 24 e JR aa ms na am na ua p COMPRESSED AIR Figure 7 24 Burner Module Profile Compressed Air Orientation Step 17 3 Visually inspect burner mesh and the spot welds at the L profile where the mesh is welded to the frame for integrity If welds are compromised or the burner mesh is damaged the burner module should be replaced 4 Once all the burner modules are removed wash the combustion chamber underneath with water Avoid getting the electrical harnesses and components wet 5 During this operation inspect to the condensate drain pipe to determine if it is free of obstructions wash water should drain freely from the condensate drain pipe 6 Blow the combustion chamber with compressed air and attempt to remove any dirt clogging the aluminum pins of the combustion chamber wall If any buildup is found on the heat exchanger particularly on the lower heat exchanger pins remove it with a stiff plastic brush 7 Once the washing of the aluminum sections 15 finished make sure the condensate drain and trap are free of obstructions Clean them if necessary 8 Inspect the exhaust section including the exhaust piping 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 135 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILER
40. during transportation OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 27 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 5 Removal From Boiler Bed And Installation Of Boiler Feet Follow the directions below to prepare the boiler for installation 1 Remove the covers of the boiler Figure 3 4 2 Lift the boiler with a hoist or forklift bands Figure 3 4 3 Remove the 4 screws A Figure 3 4 Covers Remove Figure 3 4 EXT Unpacking Left With Covers Right Lifted Without Covers 4 Retrieve the four 4 support feet from one of the cardboard boxes packaged with the boiler 5 Attach the four 4 support feet to the chassis using the four A screws removed in Step 3 Figure 3 5 6 Place the boiler on concrete slab and re mount the cover s over the boiler Page 28 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Figure 3 5 MEXT Unpacking Left 2 Attach Feet Right Ready for Cover 3 6 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 boiler The installation shal
41. e 100 Oritani Dr e Blauvelt NY 10913 Page 105 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 5 9 Expert Menu The EXPERT menu contains the items shown below Open the door EXPERT For an explanation of the levels inside the dotted line please refear on the following page Turn clockwise After 2 seconds the sub level is displayed I I I I I INSTALLATION J Press to Press to Press to I enter enter enter J I level level level I 9 Oc ERO TOT A KWKI IW IKII lt XWIWQZIIIIOQISWTH II I IIIIII IIIIZII IIOIIAII IQT I A I T IIAIWII I IIAI4AIIIII II II I lt I II I IISTST T A IE EU EU 1 enter C4 level Turn clockwise STORAGE Hs2 the value Turn clockwise Turn clockwise RESET TIME Set the value CM Turn clockwise Turn clockwise ACCESS Insert the access CODE code CQ clockwise Set the value Set the value Turn Turn clockwise clockwise BUSIDHS gt a2 WARM UP T Set the value Set the value Turn Turn Turn Turn clockwise clockwise clockwise clockwise BUS ID 1 MIN DELIMI Set the value Set the value Turn Turn Turn clockwise clockwise clockwise HYSTERESIS Set the value
42. e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 7 3 1 Cleaning the Condensate Drain Line In order to inspect and clean the condensate drain do the following 1 Refer to Figure 7 1 disconnect the pipe at location A 2 Check that no deposits have accumulated inside the drain If there are any deposits flush them out with clean water 3 Reassemble the drain pipe in reverse order 1 1 if 1 T r k J n T amp 1 t illa Lll 1 LL Condensate Fill Hole Inspect for debris and deposits Refill with fresh water before operating boiler 10 gi ow x CONDENSATE DRAIN N L1 4 1 Ly ur i Rar LIU kaa ALI 1l L Sores xum ze r Au EET a a Te LESE mm Li Tr ITI n TIT i HH H E AT r nee us LINH TH l TTI L Hr m Li r wama m po Figure 7 1 Condensate Drain Location WARNING Before operating the boiler it is absolutely necessary to verify that the condensate P trap is filled with water If the boiler is operated without the P trap being properly filled there is a danger of toxic combustion gases escaping from the unfilled condensate drain
43. eo L u nn RE a daa e v tac teresa deu 23 3 1 4 Carbon Monoxide Detector lt 23 3 2 Code and Standards ADDI OVAIS sin posset stu ente dt aes Est isdt T 24 ur mau D ME UR M LM LM A tm 24 5 4 Transportine and Securing the BoilerS lely uuu uuu u ee m epe vae 27 3 5 Removal From Boiler Bed And Installation Of Boiler 28 3 6 Boiler Location Inside A Boiler 29 35 9 D Bolle Room CONCERNS e selbe qe Re manasya Wu tsi dis cunei neue 30 316 2 Products to Avoid IN tie Boiler ROOM e o Ei en p ei i en 30 3 7 Recommended Clearances Or Servicio 31 aaa 32 3 5 Changing Exhaust Outlet LOCION bra eee cuin 32 3 8 2 Reversing Gas Manifold Connections 00 0001000 r 33 3 8 3 Reversing Cold Hot Water Flow amp Return 5 2 00 101 0002282 34 3 8 3 1 Reversing Cold Hot Water Flow amp Return Piping Connectors I 34 3 8 3 2 Reversing Flow amp Return Temperature Sensors
44. for setting internal external boiler control 3 Position Switch Two position rocker switch enables the BCM to act as a Back Up FDE 1 0 Controller when placed the ON I position See Table 4 6 for 2 Position Switch ee description of settings related to Item B switch Momentary two position rocker switch resets clears fault relay and LED when activated Rotary switch labeled 0 9 Sets the corresponding address of Boiler on the input Modbus or EBUS Network Communication Status Indicator functions as follows Sttus Description No devices detected by either communication interface BLINKING Only one communication device detected at one communication interface input or output O Both communication interfaces input amp output are active Alarm Status LED lights when a fault is detected by the BCM DES Activating the Reset Switch will clear the faults DL3 LED GREEN Pump Status Indicator lights when Pump is running Page 88 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 4 6 BCM 3 Position and 2 Position Switch Functions 2 Pos Switch Enable Disable Position I NOTE 1 DO NOT USE OFF Disable 3 Pos Switch The is the Gate way for Modbus and external control
45. 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 indication on the packaging and on 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 The installation MUST conform to the requirements of the authority having jurisdiction or in the absence of such requirements to one of the following e United Sta
46. heating zones for the preparation of a second DHW storage tank EXPERT menu Heating circuit FUNC 03 5 10 1 4 Temperature Setting For Second DHW Storage Tank USER menu gt Heating circuit T HW 5 10 1 5 Swimming Pool Offers the possibility to use one of the heating zone for the heating of a swimming pool EXPERT menu gt Heating circuit 1 11 FUNC 02 5 10 1 6 Swimming Pool Temperature Setting Only After Function Selection USER menu Heating circuit ll POOL 1 2 3 5 10 1 7 Screed Dry Program For Floor Heating Installation A program setting for drying the screed EXPERT menu Installation SCREED 01 5 10 1 8 Temperature Setting For Screed Program USER menu gt Heating circuit Il 5 10 1 9 Signal 0 10 V Inlet of 0 10 V signal for slope control through an outer regulator connect 15 EXPERT menu gt Solar MF FUNC 15 01 5 10 1 10 Slope And Temperature Setting with 0 10 V Signal oee Table 5 7 for values EXPERT menu Installation TENS SLOPE 0 to 11 EXPERT menu Installation SLOPE 11 XX freely settable OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 111 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 5 7 0 10V Signal with Slope and Temperature Cuve Ut U2 T T2 UA 20V 10
47. kPa gal L Maximum operating temperature EC Minimum operating temperature F pressure in CH circuit Water content in primary circuit V Hz FLA Electrical supply Electrical req 120 V 15 AMP max Net weight Ib kg Gross weight Ib kg 46 000 13 48 321 000 94 08 288 900 84 67 281 000 82 36 40 300 11 81 87 58 87 54 290 000 84 98 44 200 12 95 13 48 481 000 140 98 432 900 126 88 422 000 123 68 40 300 11 81 87 76 87 54 437 000 128 08 44 200 12 85 90 82 95 96 88 1 88 6 0 1 113 45 20 57 46 000 13 48 641 500 188 02 577 350 169 22 564 000 165 30 40 300 11 81 87 94 87 54 579 000 169 70 44 200 12 95 90 28 95 96 BB 1 88 8 0 4 113 45 20 57 46 000 13 48 802 000 235 08 721 800 211 56 707 000 207 22 40 300 11 81 88 12 87 54 726 000 212 79 44 200 12 85 90 55 95 96 dynamic gas pressure A natural in we kPa l 10 5 2 61 Nominal dynamic gas pressure A natural in wc kPa 7 0 1 74 Min dynamic gas pressure A natural in Wc kPa 3 5 0 87 dynamic gas pressure E Propane HD in wc kPa 13 0 3 23 Nominal dynamic gas pressure E Propane HD in wc kPa 11 0 2 74 Min dynamic gas pressure E Propane HD in wc kPa 8 0 1 99 For adjustments refer to section 3 26 and 3 27 46 000 13 48 862 000 281 96 865 800 253 76 850 000 249 13 40 300 11 81
48. l Bg s F ie it 9 F E li ie 9 m a i Im i n Cardboard Box with Parts Cardboard Box with Parts Condensate Drain Pipe Figure 3 2 MODULEX EXT Unpacking Rear View Page 26 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 Installation Operation amp Maintenance Manual 1110 mm 43 7 1110 mm 43 7 1110 mm 43 7 1110 mm 54 1 1375 mm 54 1 1375 mm Figure 3 3 MODULEX EXT Shipping Package 49 2 1250 mm 49 2 1250 mm 49 2 1250 mm 49 2 1250 mm 49 2 1250 mm 49 2 1250 mm 3 4 Transporting and Securing the Boiler Safely MODULEX EXT 321 481 641 802 962 1123 BOILERS Table 3 1 MODULEX EXT Shipping Package Dimensions 448 Ib 203 kg 520 Ib 236 kg 650 Ib 295 kg 716 Ib 325 kg 851 Ib 386 kg 924 Ib 419 kg The boiler is susceptible to serious damage when not secured properly e Follow the transportation instructions on the packaging e Only transport the boiler using appropriate transportation equipment such as a hand truck with a fastening belt or special equipment for transporting heavy equipment e When moving the boiler it must be secured on the transportation equipment to prevent it from falling off e Protect all parts against impacts
49. o Z E2 Insufficient gas pressure o E4 j Noflamedetected duringtheigniionphase Lossofflame signal during boiler operation Z Over high water temperature detected by the heating sensor SR gt 203 Internal failure of the local control PCB BMM Flame signal detected before the ignition cycle Local flow sensor failure SR1 first module Failure of the heating return sensor SRR Difference between the global return heating temperature global sensor and the heating flow sensor greater than gt 86 F rp 10 Boiler body temperature very low Ice forming risk Flame signal detected after burner is OFF Modulating fan speed failure failed to reach the correct speed within 30 seconds from starting of burner ignition cycle Modulating fan speed failure failed to stop within 30 seconds from end of operation Common chimney obstruction Water inside chimney chamber Alteration of the operating parameters caused by EMC disturbances Mains supply voltage 108 VAC Low system flow rate Presence of air in the pump only with SensorLogic Pump blocked only with SensorLogic Pump wire failure only with SensorLogic System Manager Fault Sensor Defective break short circuit E8 F5 Flow temperature sensor heating circuit 2 E8 F11 Flow temperature sensor heating circuit 1 E8 F1 Lower storage temperature sensor Buffer E8 Higher storage temperature sensor Bu
50. or change menu item parameters Table 4 4 E8 Parameter Navigation Selection and Setting o mme Use Rotary Knob to navigate to the desired Menu Sub Example User Menu amp Hot Water Sub menu menu Menu and sub menu are indicated by two small black arrows at the bottom of the LCD display pointing down to menu sub menu names below the display see ULTRI Nd Displayed Figure 4 5 Press Program Key to access parameters in the selected displayed sub menu displayed parameters sub menu CQ accessed Turn Rotary Knob to sequence through the available Cycle thru parameters parameters To change a parameter value press the Program Key when the desired parameter is displayed The Change LED will light up indicating the displayed parameter may a now be changed To change the displayed parameter value turn the Rotary Knob clockwise to increase value and counter clockwise 5 thru Values to decrease the value To save the displayed parameter value to the controller memory press the Program Key The Change LED will Displayed turn off indicating the new value has been saved C9 Value Saved Page 86 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 4 2 BCM Boiler Communication Module
51. solvents Adhesives used to fasten building products other damaging or flammable products 3 Recommended Clearances for Servicing Recommended clearances around the boiler are listed below see Figure 3 7 TOP of the boiler 24 600 mm FRONT of the boiler 24 600 mm RIGHT side 24 600 mm LEFT side 24 600mm FLOOR GROUND 4 100mm BACK of the boiler 24 600 mm It is recommended to provide the boiler with the clearances as shown in the drawing in order to be able to perform normal service and cleaning operations Minimum required clearances depend on the piping and venting configuration For further details contact your loal manufacturer s 24 510 mm Figure 3 7 EXT Boiler Clearances representative OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 GF 143 Phone 800 526 0288 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 8 Boiler Connections At delivery the MODULEX EXT boiler is setup with all connections i e cold hot water flow amp return gas and exhaust outlet on its RIGHT HAND side 3 8 1 Changing Exhaust Outlet Location To move the flue exhaust outlet terminal from the RIGHT HAND side standard delivery position to the REAR position it is necessary to request the Rear Exhaust kit P N 00364937 which includes a cover for closing off the RIGHT HAND side panel exhaust opening see Figure 3 9
52. the heating mode C Heating Mode required The heating mode is indicated by a symbol at Selection the bottom of the display It takes effect when the setting is not changed for 5 seconds 1 Standby OFF Heat OFF and hot water HW preparation OFF only frost protection mode i Automatic Mode 1 Heat according to timer program 1 HW according to 1 HW program Heat according to timer program 2 HW according to Automatic Mode 2 HW program m Heating OFF HW according to HW program 24 Hour heating with comfort temperature 1 HW Day Mode according to HW program EB Night Mode 24 Hour heating with reduced temperature HW according to program LI Automatic reset after 15 minutes Boiler regulated at max boiler temperature 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 83 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 4 1 4 E8 MENU Mode Operation Door Open Opening the E8 controller hinged door reveals the E8 controls Figure 4 4 and initiates the MENU Mode which enables access to an extensive set of software menus 1 INSTALLATI gt Time Programs Hot water Heat circuit 1 Heat circuit ll Solar MF Figure 4 4 E8 MENU Mode Display Features Table 4 3 E8 MENU Mode Features and Functions ITEM FEATURE FUNCTION A LCD displa Se
53. the specific standards in force The gas supply system is correctly configured for the boiler s output The boiler s electrical supply is 120 V 60 Hz The system has been filled with water pressure registered on the gauge 0 8 1 bar with pump not running All of the system s on off valves are in the appropriate position open or closed as required The mains gas supply corresponds to the one which the boiler has been calibrated for Otherwise convert the boiler to use the available gas refer to section GAS CONVERSION This operation must be carried out by a qualified technician in compliance with the regulations in force The gas supply valve is open There are no gas leaks There are no water leaks The external mains electrical supply switch is on The boiler system s safety valve is not blocked and is connected to the waste water system The condensate drain line section 3 14 has been filled with water and that it is connected to the waste water system WARNING Before firing up the appliance be sure to fill up the condensate drain line see section 3 14 through the filling hole and check the correct drainage of the condensate Using the boiler with the condensate drain pipe empty could cause a dangerous condition due to poisonous emissions from the flue exhaust gasses All the necessary ventilation conditions and minimum clearance distances are in place for subsequent servicing in case the boiler is sit
54. values are within the values indicated in Table 3 6 If necessary correct the value by turning the adjustment screw A in a CLOCKWISE direction to decrease the value or ANTICLOCKWISE to increase the value Repeat the adjustment for all gas valves in the boiler Page 70 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 33 3 Minimum Output Calibration After setting the maximum gas output for each valve section 3 33 2 refer to Figure 3 37 above to locate the Minimum Gas Adjustment screw B on each valve Follow the instructions below to set the minimum gas output level for each valve Adjusting the Minimum B Gas Output Setting Operate the burner to a minimum power following the procedure described in section 3 34 Figure 3 39 Sweeper function CASCADE MAN 10 Check that the CO values are within the values indicated in Table 3 6 If necessary correct the value by turning the adjustment screw in CLOCKWISE direction to increase the value or ANTICLOCKWISE to decrease it the value Repeat the adjustment for all gas valves in the boiler NOTE If the percentage is too low check if the air and exhaust are obstructed If they are not obstructed check if the burner and or the exchanger aluminum sections are properly clean
55. wall of the flue exhaust system should not be below 32 F 0 C throughout its length For efficient venting of the combustion exhaust and to address condensation due to lower external temperatures ensure that combustion condensation is discharged into the boiler condensate tray or into another separate collection pan according to the installation A test nipple for measuring combustion gases should be installed onto the first three feet of the exhaust manifold flue To do this a hole with a diameter of 0 83 is drilled in a convenient location for testing and the test nipple hardware assembled to the flue pipe as shown in Figure 3 23 below Figure 3 23 Installation of Test Nipple into Flue Manifold Piping NOTE Damage caused by mistakes in installation failure to complete the instructions as written or the improper use of the flue system are not the responsibility of the supplier 3 20 Vent Starter Pieces Table 3 3 lists the vent starter pieces See Figure 3 25 for an illustration of a fully assembled kit PVC starter pieces are included with every unit Stainless steel starter pieces may by purchased from AERCO or directly from the vent manufacturer Page 46 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 3 3 Starter Pieces Boier Mods
56. 0913 Phone 800 526 0288 Page 89 of 146 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual This page intentionally blank Page 90 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual CHAPTER 5 OPERATION This chapter introduces the 8 controller basic menus sub menus needed to set up the MODULEX EXT boiler Refer to Chapter 4 for instructions for using the E8 controls to navigate and change settings For more detailed information concerning the E8 controller menus sub menus and functions refer to the E8 Controller User Manual GF 115 C Modulex E8 Controller Front Panel Cover Closed a 8 a v Date Time Ho lday Time Programs Installation Hot walter Heat circuit 1 Heat circuit I Solar MF Vi E Modulex E8 Controller Front Panel Cover Open 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 91 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 5 1 Installation Menu Initializing the E8 Controller Each time power is applied to the boiler and the E8 controller cover Figure 4 1 is opened the INSTALLATION Menu is displayed once only The
57. 0930 Burner Chamber End Section LH 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 143 of 146 GF 143 Phone 800 526 0288 07 13 15 0 1 12 13 1 15 16 17 18 19 20 21 NO NO NO NO MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 27 28 29 s Boiler Body Insulation EXT 321 Boiler Body Insulation EXT 481 Boiler Body Insulation EXT 641 Boiler Body Insulation EXT 802 Boiler Body Insulation EXT 962 Boiler Body Insulation EXT 1123 T T 3s 36 37 30 4o 2 43 T 45 4 a7 48 4o 50 Screw Washer Nut kit 12 pcs 5 sa 53 54 55 se 57 Page 144 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 O MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual s s s T s T s s n n 72 ra n 75 e 95372088 Gas Inlet Header Modulex 2 3 Elements EXT 321 amp EXT 481 79 95372089 Gas Inlet Header Modulex 4 5 Elements EXT 641 amp EXT 802 95372090 Gas Inlet Header Modulex 6 7 Elements EXT 962 amp EXT 1123 Flow Header 2 Elements EXT 321 Flow Header 3 Elements EXT 481 Flow Header 4 Elements EXT 641 Flow Header 5 Elements EXT 802 Flow Header 6 Elements EXT 962 Flow Header 7 Elements EXT 1123 Return Header 2 Elements EXT 321 Return Heade
58. 0v arr 1 F 20V 10 5 10 2 Setting of DHW Circuit 5 10 2 1 Operation of Pumps In Parallel Heating pump operation during DHW production EXPERT menu HotWater F PUMP PARAL 00 01 02 03 5 10 2 2 Use of a DHW Storage Tank Thermostat On Off To use an ON OFF thermostat instead of DHW sensor EXPERT menu HotWater gt THER IMPUT 01 5 10 2 3 Antilegion Activation of an antilegion program EXPERT menu gt HotWater 01 5 10 2 4 Setting for Solar Panel Use Use a PT 1000 sensor as a solar panel sensor EXPERT menu Solar MF FUNC RELAY 4 23 5 11 ACCESS CODE SETTING set the access code press the Programming button to enter the first parameter use the data knob to select a number and then press the Programming button to accept the value Repeat this procedure for each code number position 0 0 c ad 0 GA o 0 020 lt gt 2 000 oM A Figure 5 12 Setting the Access Code Page 112 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual CHAPTER 6 TROUBLESHOOTING 6 1 E8 Controller Error Codes Fault codes are displayed in the upper right hand section of the E8 Controller display see Figure 6 1 Use Table 6 1 next page to determine the fault message There are codes for
59. 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 2 3 Dimensional Drawings LEFT HAND SIDE VIEW FRONT VIEW 12 6 n TO imm 47 i120 mm 1150 mmi On Modulex EXT models 321 642 and 962 the flue terminal ends inside the casing 1323 mm 14 4 1359 mm 27 mmi 27 mimi i353 mmi 353 mmi RIGHT HAND SIDE VIEW mE Delivery condition for A REAR VIEW SS gt eS ES GE Km cS Q SSS ka dul x ES SS SS Gm QE qM ER qum gt g gt SS T a ii SS es gt An aS ami jm i827 mui 386 memi 13mm y mni Figure 2 1 MODULEX EXT Dimensional Drawings Side Views OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 17 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual TOP VIEW Figure 2 2 MODULEX EXT Dimensional Drawings Top View Table 2 1 MODULEX EXT Dimensions and Sizes Dime
60. 3 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 7 7 Pressure Switch Hoses And Connections If pressure switch hoses need to be replaced ensure that new hose lenghts are identical to the old hose lengths If too long there is an increased chance of condensation problems within the hoses See Ss ZI DRE SEIL Original Length OK Original Length OK ACCEPTABLE Figure 7 3 Pressure Hose Lengths Page 125 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 07 13 15 0087 OF P hone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 7 8 Burner Heat Exchanger Cleaning Procedure Dust and other particulate matter infiltrating into the combustion chamber over time will cause a decrease of heating efficiency and output due to the buildup of combusted by products onto the thermally conductive surfaces These surfaces must be cleaned from time to time in order to return the unit to its original specifications for thermal efficiency and heat output For detailed cleaning instructions see section 7 11 NOTE A reduction of the input can be caused by the obstruction of the vent or air intake Before cleaning the boiler body sections check the boiler input and the percentage see section
61. 4 79 2 88 96 8 105 6 WATER FLOW Gallons Minute Figure 3 18 MODULEX EXT Water Side Pressure Losses NOTE The use of a mixing header fitted between the boiler circuit and the system circuit is always advisable It becomes INDISPENSABLE if the system requires flow rates superior to the maximum permitted boiler flow rates which is to say lower than 27 F 15 K OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 41 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 14 Condensate Piping and Drain To avoid condensate collecting inside the combustion exhaust system the condenate piping must have an inclination toward the drain of at least 3 8 in ft 30 mm m The liquid column inside the condensate siphon see Condensate Siphon Plug in Figure 3 19 needs to be filled with water after installation The minimum height of the water in the column when all the fans are in operation must be at least 25 mm 1 in In order to avoid ice formation while the boiler is operating which can cause the boiler to stop functioning the entire condensate evacuation system must be well insulated Note that it is forbidden to evacuate the condensate through an open gutter to prevent the risk of ice forming and avoid exposure of the corrosive condensate to the external environment The condensate must be neutralized before being ev
62. 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 35 High Altitude Adjustment It is necessary to adjust the fan speed at altitudes at or above 5 000 feet Modify the parameter FAN MAX from the E8 Control Panel Note that it is modifiable only with an access code See Table 3 7 on the next page for a list of the FA Factory parameters 5 29 5 i 488 Be 8 This conversion to high altitude SSI 2 ex lt operation shall be made by qualified service agency in Ds EBs gt accordance with the manufacturer s 483 85 instructions and applicable codes and requirements of the authority QS E having jurisdiction The qualified Bi 5 service agency is responsible for the a t 25 proper installation of this conversion The installation is not proper and complete until the operation of the converted appliance is checked as specified the manufacturer s instructions supplied with the unit Turn clockwise 5 RETURN Press p toexit Turn clockwise QO 1 2 2 Sg Bp 5 m cu 28 55 4 s lt Loe 58 32 295 u SEB 262 552 552 See the value of parameter FH A Open the Flap EXPERT Turn clockwise Turn clockwise Turn clockwise FAN MAX in Table 3 7 and Modulex EXT Pressure and CO2 L evel Calibration in
63. 88 30 87 54 575 000 255 46 44 200 12 95 90 91 95 96 46 000 13 48 1 123 000 329 15 1 010 700 296 23 993 000 291 04 40 300 11 81 88 48 87 54 1 031 000 302 18 44 200 12 95 91 81 95 96 88 6 88 6 0 1 113 45 20 57 45 40 100 09 IV 2 94 8 47 7 25 50 82 630 8 08 The Technical data plate is placed under the casing 0087 OF GF 143 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Phone 800 526 0288 Page 21 of 146 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual This page intentionally blank Page 22 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual CHAPTER 3 INSTALLATION INSTRUCTIONS 3 1 General Warnings 3 1 1 Appropriate Use of the Boiler This boiler MUST be used for the use for which it has been expressively 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
64. 9 Page 6 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp 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 the 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 equipment appropriately and safely according to its design it is essential to carefully follow the instructions in this manual 1 2 Water Treatment e t is vital to maintain the pH of boiler water between 6 5 8 Failure to do so could result in severe damage to the boiler e The hardness of the main water supply influences the frequency with which the heat exchanger must be cleaned e n hard water areas where the main water can exceed 1571 total hardness a scale reducing device is recommended The choice of this device has to be made taking into consideration the characteristi
65. Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Power supply Power BA 31V 5 terminal block 1 2 4 EB 9 10 5 1 A2 A4 AS A6 A8 9 a10 A11 60Hz 120V us T2 T3 T4 2 7205 Sensor terminal block x Y Fog i Power terminal assignments Flow Outdoor Boiler Slorage Flow From Terminal Il sensor sensor sensor Tank sensor 1 Senso 2 z Neutral conductor mains Cr L1 Power supply unit re L2 Power supply to relay 8 Za heating circuit pump HK 1 B S tttt2 heating circuit pump HK 2 F a x Storage tank charging pump d 12 Mixer open heating circuit 2 s X 2 v Mixer closed heating circuit 2 2 U w t Terminal VI o cC gt 5 N Terminal IV 9 X14 Mixer open heating circuit 1 11 X1 Y Mixer closed heating circuit 1 2 amp 1 gt Ce Multifunction relay Recycle pump Multifunction relay v4 LLY OLV Q Figure 3 32 E8 Controller Terminal Assignments OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 61 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manua
66. CHIONS Au veio dte Qu 38 ValVeuuseseteatbdsveep us aede unius esu iay euin unas 38 3 12 CSD 1 Manifold Assembly Supplied 39 3 13 Determination of Primary Boiler Pump Or Boiler System Pump 40 9 14 PIPING e SI 42 digi 81 ml toes 43 3d61mportantinstallatlor MWaERIFIBS s tea usd 44 3 16 1 Oxygen Levels the System Water 44 3 16 2 Antitreeze Compatibililyy WINNE eiue eoe Ee SASS ka i waya dus 44 3 16 3 Lime Scale and Corrosive Water Damage Warning 44 3 16 4 Connection to Refrigeration System War i gBuuu l u nennen nennen nnns nnns nnns 44 3 17 Alt Intake Connecti soosiana e preda 44 3 18 FIGS Manifold Connect Opi a 45 2 ei 46 9 20 Vert starter Pleces adiens ias
67. E on PCB BASSE TENSION sur la PCB LOW VOLTAGE BASSE TENSION 120 VAC HIGH VOLTAGE AUTE TENSION Figure 3 30 Module Ladder Diagram 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 59 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 27 General Ladder Diagram l BCM G m m m sm ed i IG T wap 9295 1 modules LTLG 4 i Fi Oui 60 Hz e 1 2 only on 2 moduls soulement le 2 modules SR1 Only on BMM1 SR Only on Only on BMM1 SL Only on BMM 2 Figure 3 31 General Ladder Diagram 3 28 E8 Controller and BCM Terminal Assignments On the rear panel of the E8 controller there are two terminal blocks one of which is for the mains 120 V connections and the other for the low voltage connections The main controls necessary for the C H system management and for the boiler control as well some components which are part of the boiler housing must be connected to the terminal blocks See Figure 3 32 for a wiring diagram showing the E8 controller terminal wiring and see Figure 3 33 for a wiring diagram of sensor and BCM terminal wiring Page 60 of 146 AERCO International Inc e 100 Oritani Dr e
68. E05 Loss of Flame See Figure 3 34 20 35 T 2 e D EE AMNES Figure 3 34 Loss of Flame Error Code E 05 Press Reset Button on E8 Controller C The boiler will retry the ignition cycle and the display will show ERROR CODE E04 No Flame Detected During Ignition See Figure 3 35 Figure 3 35 No Flame Detected During Ignition Error Code E 04 Reconnect the ignition cable of BURNER 1 Press Reset Button z 10 Check that the boiler starts correctly WARNING Do not touch the inside of the ignition cable while it is disconnected during start up of the boiler Page 68 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 33 Burner Calibration WARNING All the instructions indicated below are for the exclusive use of qualified AERCO service technicians or installers All the boilers are supplied already calibrated and tested However if it is necessary to change the calibration due to gas conversion or adaptation to the mains supply system the gas valve must be re calibrated using Service Mode function in the E8 controller 3 33 1 Installing the Gas Analyzer Probe Before making adjustments a gas analyzer sensor probe must first be installed into the flue exhaust outlet as shown in Figure 3 36 Insta
69. Il Turn Press to a enter level T ROOM DES A KY Turn T ROOM clockwise HUMIDITY T POOL DES UCM a Turn fees clockwise RATED CN a T DHW clockwise C TUUM Turn TELON CN clockwise ON muU Turn RETURN C clockwise clockwise clockwise we O T DHW L 4 RETURN 42 Press to exit Turn T MF1 clockwise Turn ockwise Turn ockwise Turn ockwise T COLLECTOR T DHW clockwise Tum Turn ockwise Turn lockwise Press to exit Figure 5 7 DISPLAY Menu NOTE oome menus are visible only if the relevant sensor is wired e g HOT WATER is displayed only if the DHW storage sensor is wired OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 101 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 5 3 DISPLAY Menu DESCRIPTION INSTALLATION HS Header set value cascade HS Header temperature cascade Temperature and status of the HS HS1 58 L HOT WATER T DHW RATED T DHW T DHW L T CIRC RETURN HTG CIRCUITC 1 2 Hot water set temperature value Hot water temperature value Hot water temperature in infeed area Recirculating temperature RETURN SOLAR
70. Inc e 100 Oritani Dr e Blauvelt NY 10913 Phone 800 526 0288 Page 63 of 146 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual INSTALLATION OF A BOILERWITH CONNECTIONTO ONE MIXED AND ONE DIRECT HEATING ZONES D H W PROD VF VF 4 5 Flow sensor heating circuit 2 T 1 Flow sensor heating circuit 1 SPF 10 Ground outdoor sensor 6 7 Storage tank sensor C Ric F Heating Circuit 1 Heating Circuit 2 AF 9 10 outdoor sensor 4 Pump heating circuit 1 miz 5 Pump heating circuit 2 6 Cylinder charging pump w2 7 Mixer motor heating circuit 2 OPEN 8 Mixer motor heating circuit 2 CLOSE V Y 5 Re circulation pump storage tank 5 4 Primary pump Outside x Primar system pump INSTALLATION OF A BOILERWITH CONNECTION TOTWO MIXED ZONES D H W PRODUCTION VF eo 2 4 5 Flow sensor heating circuit 2 optional 1 Flow sensor heating circuit 1 SPF Qz 6 7 Storage tank sensor Q 10 Ground outdoor sensor AF 9 1 0 outdoor sensor Heating Circuit 1 Heating Circuit 2 4 tit 4 Pump heating circuit 1 5 Pump heating circuit 2 6 Cylinder charging pump 2 7 Mixer motor heating circuit 2 OPEN 8 Mixer motor heating circuit 2 CLOSE Y 1 i 1 Mixer motor heating circuit 1 OPEN 2 Mixer motor heating circuit 1CL
71. Installation Operation amp Maintenance Manual CHAPTER 8 SPARE PARTS DRAWING AND LISTS 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 139 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual This page intentionally blank Page 140 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual WM WM S WM 2 MN py SKE NENA N Z lt 7 55 4 X SS 17 N WD X Wow 4 556 4 Ke OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 141 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual This page intentionally Blank Page 142 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Modulex EXT Parts List Models EXT 321 481 641 802 962 amp 1123 Casing Front Panel EXT 321 amp EXT 481 95213325 Front Rear Panel EXT 962 amp EXT 1123 26 9500
72. Installation Operation amp Maintenance Manual Table 6 4 BMM Fault Codes Continued CODE DESCRIPTION EFFECT CORRECTION Maximum A temperature protection temperature Temperature gt Water A Temp Protection Boiler pipe is frozen Flow sensor temperature is 36 F or less Flame signal detected after burner is OFF No air flow at burner after fan started for 30 seconds pressure switch doesn t switch 0087 OF GF 143 burners turned OFF All burners turned OFF and Pump ON at maximum speed Ignition is inhibited Pump runs for 5 min at max speed Ignition is inhibited Ignition retry after 60 second delay and failure remains until a successful burner operation Ignition is inhibited AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Phone 800 526 0288 RESET Check return sensor or AUTOMATIC wiring Check the system AUTOMATIC installation when A temperature Water A Temp Protection AUTOMATIC when flow sensor is greater than 41 F Carefully defrost boiler Disconnect gas valve wire from BMM If failure goes away check wiring or change BMM If failure remains check or change gas valve MANUAL push reset switch or cycle power AUTOMATIC MAN UAL If fan is stopped check supply voltage and fan wiring If OK try another fan If still not working change the BMM If fan is not stopped check the exhaust g
73. LEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual WARNING e 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 Always check the safety of the gas pipe system by means of a soap bubble test using a leak search spray 3 9 1 Natural Gas Connections 3 9 1 1 Natural Gas Piping Sizes Contact your local gas supplier for natural gas pipe sizes and meter types 3 9 1 2 Natural Gas Piping Connections The boiler gas pipe is equipped with external 2 M NPT thread onto which the tail piece of the gas shut off valve can be connected Use appropriate sealing The connection to the boiler must include a suitable method of disconnection and a gas control valve must be installed adjacent to the boiler for isolation purposes 3 9 1 3 Natural Gas Supply Pressure Requirements The nominal inlet working gas pressure measured at the boiler should be 7 18 mbar for Natural Gas Gas A Maximum pressure with no flow
74. MODULEX EXT GF 143 User Manual OMM 0087 USER MANUAL RCO Installation Operation and Maintenance A Watts Water Technology Company MODULEX EXT Light Commercial Series Natural Gas Modulating amp Condensing Modular Hot I I Water Boiler Modular Condensing Boilers LIGHT COMMERCIAL SERIES Covering Models EXT 321 e EXT 481 641 802 962 1123 AERCO d Modulex L os GAS FIRED ASS CERTIFIED Latest Update 07 13 2015 Commercial Boers C US LISTED AERCO International Inc e 100 Oritani Dr e Blauvelt New York 10913 e Phone 800 526 0288 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp 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 merchantability 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 materials A Watts Water Technology Company 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 fo
75. OBAL RETURN A NTC TEMPERATURE X 4 ALUMINIUM SENSOR SILICON HEAT EXCHANGER C H RETURN CONDENSATE SENSOR LEVEL DRAINING TAP EXHAUST CONDENSATE ______ PONE DRAIN TRAP cI m SS ee ee Minimum Height 4 100 mm Figure 2 3a MODULEX EXT Main Components Left Side View OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 19 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual TA GAS VALVE PANEL 29 FAN GAS AUTOMATIC IGNITER AIR VENT FLAME SENSOR LOCAL NTC FLOW SENSOR SENSOR HIGH LIMIT GLOBAL FLOW THERMOSTAT NTC TEMP SENSOR GLOBAL FLOW ALUMINIUM NTC TEMP SILICON HEAT SENSOR EXCHANGER RETURN CONDENSATE SENSOR LEVEL i DRAINING TAP EXHAUST CONDENSATE MANIFOLD DRAIN TRAP Minimum Height 4 100 mm Figure 2 3b MODULEX EXT Main Components Right Side View e Exhaust and condensate evacuation connections are on the RIGHT HAND side supply condition but may be moved to the RIGHT HAND or REAR positions e Airintake connection located on the LEFT HAND side e Cold Hot flow connection on the RIGHT HAND side supply condition but may be moved to the LEFT HAND position e Cold Hot return connection on the RIGHT HAND side supply condition but may be moved to t
76. OSE Y Y 5 Re circulation pump storage tank 4 Outside S ERE Sensor Safer devices kit Min 1 Hs 4 O I3 Mixina Header fiter cu 2 gt quM Primary x system pump Page64of146 AERCOIntemational Inc e 100 Oritani Dr e Blauvelt NY 10132 0087 0 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 30 Starting Up Filling and Deaerating the Boiler Carry out the following tasks in connection with maintenance etc to an already installed unit Shut down all programs e Close the gas shutoff valve upstream from the boiler Shut off the power at the main power switch e Close the C H service valves supply and return 3 30 1 Necessary Precautions for Safety Observe the following rules of safety All work on the unit must take place in a dry environment AERCO units should never be in operation without their cover panels except in connection with maintenance or adjustments Never allow electrical or electronic components to come into contact with water 3 30 2 Supply Voltage Gas Pressure and Water pressure The unit must be able to function during maintenance procedures or when adjustments are performed For this reason the unit s supply voltage gas pressure and water pressure must be maintained and available during th
77. PEN gt 1to4 HYST Set the value T BOILER DHW value CM Turn Tum clockwise C clockwise Turn clockwise MIXER CLOSE Set the FUNZF 15 Setthe value value HYST DHW Setthe Turn C clockwise clockwise clockwise For an explanation of the levels inside the dotted line please refear on the previous page value Turn Set th RETURN clockwise MAX T FLOW dus Set the a value clockwise CN Press to exit Set the MIN T FLOW velis C Turn clockwise Set the T FROST PROT Turn clockwise OUT TEMP DEL Set the value Turn clockwise SLOPE OFFSET 5 the value Turn clockwise B HEAT SINK Set the value C Tum clockwise RETURN d FQ Press to exit Turn clockwise Set the THER INPUT value Turn clockwise WALL HUNG the Turn clockwise LOAD THROUGT M Tum ih clockwise RETURN A Press to exit Figure 5 11 EXPERT Menu 2 of 2 NOTE The shaded items in the following table indicate those parameters that change according to the boiler type and whether used singly or in a cascaded configuration OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 107 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installat
78. RN fe HOT WATER DW If the value is 1 the boiler switches on immediatly 00 _ 01 02 BOB VALUE Operation without burner solar or solid fuel integration 0 0 126 ome if the value is 01 the circulation pump runs when the m CIRCL P DHW hot water is enabled but the circulation program is 0 1 disabled nm If the value is 01 every 20th time that heating takes m ANTILEGION place or once a week on Saturday at 1 00 the storage 0 1 tank is heated up to 149 RETURN 14 HTG CIRCUIT 1 2 When setting an alternative oparating mode this only MODE i applies to the assigned heating circuit T ROOM DES 1 Room temperature setting in first enable time T ROOM DES 3 Room temperature setting in third enable time 41 105 41 105 41 105 41 105 41 105 3 104 23 104 NO x T LIMIT DAY Set the temperature value during heating time T LIMIT N Set the temperature value during reduction time 5 HEATSLOPE oet the Heatslope according to the installation 1 20 0 3 ADAPTION Only active if an FBR analogue room device is 0 1 connected and an outdoor sensor OPTIM HEAT Activates the function for automatically starting the unit 10 0 20 ADAP ROOM T Room sensor adaptation OPTIM HEAT Heating optimisation 00 02 MAX OPT TIME The start of heating is brought forward by no more than 2 00 03 this time ECONO OPTI Automatic reduction of burner disabling to the end of 00 02 set heat
79. S Installation Operation amp Maintenance Manual 7 12 Reassembly of the Burner Modules Follow the instructions to reassemble the burner modules Reassembling the Burner Modules After the cleaning of the boiler combustion chamber and or the burners reposition the burners in their proper positions Position the new graphite gaskets onto each burner module and ensure proper positioning Proceed with reassembly performing whichever disassembly operation was chosen all or The burner gaskets MUST be replaced at every cleaning individual method in reverse order For individual burner module reassembly only skip steps a d proceed directly to step e a Lower burner assembly Remove left and right lift pins at front and lift screws at rear Reinstall gas supply pipe to gas collector flange 4 bolts Reinstall gas collector tube ends onto boiler frame 2 screws per Reinstall bolts A B and C screws to secure burner assembly to boiler body NOTE Tighten the burner bolts with a torque of 13 Nm Reassemble red hoses to the air intake manifold place manifold onto the blowers then reattach tension spring clip to left and right ends of manifold g Proceed to section 7 13 for final procedures before returning boiler to service 7 13 Final Procedures After Maintenance Before returning the boiler to service the following procedures must be performed Final Procedures after Maintenance Before lighting t
80. T 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 4 1 5 E8 MENU Navigation and Parameter Settings The selected Menu and Sub menu are indicated by two black arrows at display bottom pointing to the Menu and Sub menu names silk screened below the display Figure 4 5 Following initial startup and one time entry of the required INSTALLATION menu items see section 5 1 to access view and or change menu items follow these instructions Sub MENU Name ee Points right to INSTALLATI Buss es Points left to Selected Buss es Points down to Points down to Selected Selected MENU Name 8 Sub MENU Name 5 E 5 5 Sub MENU Pines 5 3 Names a FL Figure 4 5 MODULEX E8 Controller Front Panel E8 Controller Menu Navigation Procedure When the ON OFF switch on the front of the boiler is turned ON and the swing down hinged panel is opened the controller will enter MENU Mode and INSTALLATION will be displayed Figure 4 5 in the LCD This is the initial INSTALLATION menu and it is assumed that all entries have already been made See sub section 4 8 of the E8 Controller User Manual GF 115 C for INSTALLATION menu initial entry information Turn the Rotary Knob clockwise until the display advances to the DISPLAY menu The dial on the clock face will rotate one revolution counterclockwise and then go off The display will then show INSTALLATION whic
81. Table 3 6 INSTALL 2 Hor WATER C HTG CIRCUIT Il SOLAR 2 EXPERT HS PARAM HS 04 Q PARAM HS 05 PARAM HS 06 E Os o a 88 88 45 lt lt lt 5 Tok e gu quo 2 2 9 ERL 5 gt g Yas 2 225 2258 BE 562 552 552 EZ 4 T e gt P 53 52 o 2 51 O O Figure 3 40 Adjusting Fan Speed to Set Input Range for High Altitude OMM 0087_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 75 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 3 7 MODULEX EXT FA Factory Parameters Set in PARAM HS xx Menu Parameters MODULEX EXT FANMODIGN Y 80 J NoChmge FANMODSTBY 6 1 2 FANMAX FH OA 120180 FL 3 X NoChmg MINFLOWPRO 00 1 Nohg 2 0 MNoChmmge 2 PUMPMNMOD 02 s4v 07 CAP FLOWRATE 000 00 0100 0000 08 12 NoCmng 2 FANSIPPOS 0 1 0 FANSIPNEG fe FANSTARTPW 0 2 1 0 RESTARTS 3 36 High Altitude Conversion Label After calibration of the unit from Normal Altitude 0 2 000 feet to High Altitude 2 000 4 500 feet operation the label bel
82. USA CANADA GROSS WEIGHT POIDS BRUT High OUTPUT Min Relief valve capacity WARNING ATTENTION Read technical instructions Lire la notice d installation Maximum water before installing the boiler avant d installer l appareil Read the user s Instructions Lire la notice pour l usager MAWP water before lighting the boiler avant de d marrer l apareil De purpose of input adjustment NATURAL Gas type Normal ESUBSEEBENFRERBERBE Min Electrical Power supply 120 V 60 Hz less than 12 Amp For either direct vent installation or for installation using indoor combustion air Pour installation avec vaquation directe ou avec air comburant A Cx Go 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 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp 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 ver
83. acuated to the sewer which can be achieved by mixing the condensate with lime or with drain water coming from washing machines dish washing machines etc which normally has a base pH The connection to the sewer will be through a closed but visible drain Given the high acidity pH 3 to 5 of the condensate only plastic material may be used for the condensate evacuation pipes Moreover it must be dimensioned and constructed so as to allow the correct out flow to the drain preventing any bottleneck and any leakage Consult local codes regarding condensate neutralization Neutralization may be obtained by mixing it with the buildings drain water or with limestone which normally has a base pH AERCO offers a condensate neutralizing kit and a neutalizing tank for preparing condensate waste for safe evacuation into a sewer system Front View F Upper part of drain lE pipe should not be t A 1 ra a 1 a E n t Condensate Siphon Plug MUST filled e bd with water before boiler operation condensate tray bottom Condensate Drain To 6 150 nn 4 101 mm EZ 7 Boiler House Floor Figure 3 19 MODULEX EXT Condensate Piping The outlet of the condensate drain pipe exits from the right side of the boiler just below the RIGHT SIDE flue outlet opening IMPORTANT NOTE If it is not possible to use 4 101mm base o
84. al age pum e ces Bjo m ga 537 FACTORY WIRED INSIDE THE BOLIER ue L1 M JUNCTION BOX L N 15 AMP semen J 15 ARIF z CIRCLIT BREAXER Uslu 120 V 60 Hz Figure 3 29 Power Junction Box Location and 120VAC Wiring Page 56 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 25 Functional Wiring Diagram MODULE 1 POSITION 0 ors a otc m D O 3 7 8 MODULES Eras Sa FERE XAR 7 PLEL AE N y us AHN Y MODULE 3 Rz br N POSITION 2 tn a MODULE 4 board of POSITION 3 2 module 2 97 74 zm p lt SIGNALALARM PUMP BOILER CIRCUIT D O 0 36 9 g 4 2 BL BL i ERERREE TERMINAL BLOCK saru 97577 8 L TR ACC 2 TR ACC 7 8 BL j Or zm a N 3 Dye BR BL 25 PC MODULES SELECTOR EACC2 EACC7 POSITION E RIL 2 E RIL 7 8 3 7 8 MODULES JB Junction Box SR Flow NTC Temperature sensor
85. al e Acardboard box containing O Four 4 frame support feet hole covers for switching flue exhaust location O 3insulation gaskets for installation outside e Acardboard box containing CSD 1 header O Relief valve ON THE BOILER RIGHT SIDE e One 39 3 inch 1 meter pipe for the condensate evacuation system Left and right side covers ON THE BACK OF THE BOILER e Socket front and rear ON THE BOILER TOP e aplastic bag containing o This installation manual for the installer O User manual for the user E8 controller instruction manual e Pins to hold the fan assembly in a raised position IN A SEPARATE BOX PVC venting starter piece and pipe clamps Temperature amp Pressure gauge e Flow Switch Pipe adaptor rubber OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 25 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Flue Assembly And Gasket EP S 7 M x Y lt 9 d D um MU zh gt q 1 aye Z 7 gt 2 D e DIE 6 LIA ts m S Tap I i I ip i t n f N 21 Ld gt 7 LW LL rZ Ex h Ss Hi 2 T N y EEN Spee sr Ies S ia ee K GE K re B EO f Ae 99 M rZ
86. an area where leakage of the boiler or connections will not result in damage to the area adjacent to the boiler or to lower floors of the structure When such locations cannot be avoided it is recommended that a suitable drain pan be installed under the boiler Do not restrict or seal any air intake or outlet openings If you find any defects you must inform the owner in writing of the system defect and the associated hazard OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 11 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp 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 information concerning water quality and treatment refer to AERCO technical documents Glycol Directive and AERCO Piping Application Guide GF 136 P Unsuitable heating system water can cause the formation of scale or sludge which affects system efficiency It can also cause corrosion and reduce life of the heat exchanger You must follow guidelines for boiler water quality Thoroughly flush the system prior to filling e Follow the cleaning instructions Never use water to fill the heating system that has be
87. anager Figure 3 33 Sensor and BCM Terminal Assignments Page 62 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 29 Installation Examples Functional Wiring and Connections Description INSTALLATION OF A BOILERWITH CONNECTIONTO A DIRECTHEATING ZONE Q AF 9 10 outdoor sensor Heating Circum 1 1 Flow sensor heating circuit 1 o 4 10 Ground outdoor sensor 4 Pump heating circuit 1 k 4 Primary pump ide Sensar Safety devices kit INSTALLATION OF A BOILERWITH CONNECTIONTOTWO DIRECT HEATING ZONES D H W PRODUCTION 1 Flow sensor heating circuit 1 VF 2 4 5 Flow sensor heating circuit 2 necessary for enabling 2 circuit SPF Qz 6 7 Storage tank sensor i D 10 Ground ouidoor sensor Heating Circuit 1 Heatina Circuir 2 AF 9 10 outdoor sensor Primary system pump iiti 4 Pump heating circuit 1 mz 5 Pump heating circuit 2 4 Cylinder charging pump 5 Re circulation pump storage tank ve ve Y 7 elec 4 Primary pump NM DN oc or o C s T x Safety devices kit L lii d Mixing Header Her 0087 OF GF 143 AERCO International
88. andled by a forklift Remove both straps and the cardboard box from above making sure the product is intact The packing elements cardboard box straps plastic bags etc should be kept away from children as these present suffocation and choking hazards AERCO refuses all liability for injury to persons animals or damage to property derived from not respecting the above mentioned recommendations In the packaging in addition to the boiler you will also find the following contents see Figures 3 1 and 3 2 ON THE BOILER FRONT e The flue exhaust terminal screwed to the front of the frame e The sealing gasket for flue outlet mounted in the flue assembly e Acardboard box containing The sealing gasket for connection between condensate tray and terminal O 4elbows 1 Tee piece 1 plastic plug 2 1 6 40 mm for condensate drain O the screws necessary for installing the flue exhaust terminal e External sensors Remote Temperature D H W storage tank amp Outdoor temperature e for flue exhaust gas sampling tests e Resistor kit for emergency operation e Cable glands for electrical supply e Pins for mounting sockets e Kit sheet for output cables 120 24 V Page 24 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manu
89. as outlet for blockage If OK check the air pressure switch wiring If still not working try another air pressure switch If still not working change the BMM Disconnect the air proving AUTOMATIC switch If problem goes away install a new switch If not check the wiring If wiring is OK change BMM Page 119 of 146 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 6 4 BMM Fault Codes Continued CODE DESCRIPTION EFFECT CORRECTION RESET Ignition retry Fan speed out of after 60 control It delay doesn t reach and failure U pre purge speed remains until Check fan wiring AUTOMATIC MANUAL within 30 we seconds successfu burner operation Fan speed out of control It doesn t stop Ignition is within 30 inhibited seconds after turned OFF Restart pre purge timer Air flow failure PEDE E cH ne dul toe Check air proving switch AUTOMATIC during ignition we have a and wiring successful burner operation Ignition is inhibited MANUAL cycle the Re program the settings Pump runs for power or send reset Contact factory o min at max message speed Wait for Line voltage too proper line Check input voltage Try low 96 VAC voltage gt 102 another BMM AUTOMATIC Low water flow Burners Check water flow or Low water flow AUTOMATIC turned OFF check switch switch activated C
90. ated Gas and Hydraulic Connection Openings 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 that all the supply piping be thoroughly cleaned in order to remove any residual grime which could compromise the boilers correct functioning As a safety measure against gas leaks AERCO recommends installing a surveillance and protective system made up of a gas leakage detector combined with an on off solenoid valve on the gas supply line The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 PSI 3 5 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 Page 36 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODU
91. below It complies with the ANSI ASME ANSI 221 13 CSA 4 9 Boiler and Pressure Vessel Code Section IV Heating Boilers and CSA B51 Boiler Pressure vessel and Pressure Piping Code as applicable 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 relief valves not supplied Page 38 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Figure 3 15 Pressure Relief Valve 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 Valve Figure 3 15 e Flow Switch e Pressure Temperature Gauge The pressure relief valve and other manifold components are shown in Figure 3 16 Flow Switch ad Valve Pressure Temperature Gauge Figure 3 16 Manifold Assembly and Components To install the pressure relief valve and the other components shown proceed as shown in instructions below NOTE Use Teflon tape or a s
92. boiler are shown in Figure 3 29 The power supply to the boiler 120 VAC 60 Hz single phase must be made in the JUNCTION BOX of the boiler with three core cable HO5VV F PHASE NEUTRAL EARTH according to the polarity of the phase and neutral power supply with phase and neutral terminals indicated on the plug It is necessary to fit a double pole switch on the electrical supply line having a contact separation in both poles in an easily accessible position in order to provide a means to remove power from the unit during servicing 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 53 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual WARNING Danger of fatal accident due to electric shock 120 VAC connections may be present on the external connection board when power is supplied to the boiler The electrical connections must be carried out only by a qualified engineer Before carrying out the connections or any other operation on the electrical parts always switch off and disconnect the electricity supply and ensure for yourself that it cannot be accidentally turned on 3 24 3 Service Relay Requirement Upstream of the electrical connection a service relay is required not supplied which when the additional electrical safety devices intervene shuts down the electrical supply to the on off fuel
93. cs of the water e n 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 e AERCO recommends inspecting the state of cleanliness of the domestic hot water heat exchanger at the end of the first year and subsequently on the basis of the lime scale found this period can be extended to two years after the initial inspection 1 3 Information to Be Made Available To The User Go through the information in this manual with the owner operator and make sure that he or she is familiar with all necessary operating instructions in particular These instructions shall be made available to the end user together with any other literature regarding this appliance It is highly recommended that the user keep these documents in a safe and convenient place in order to always have them at hand for future reference e tis imperative that a proper venting and exhaust system be implemented with this unit Refer to the AERCO Venting Application Guide GF 115 V e It is absolutely forbidden to make any alterations to the boiler not in keeping with the manufacturers recommendations and instructions e tis critical to check the system s water pressure and ensure it is at the correct pressure e For optimal operation of time and temperature controls thermostats heating controls radiators refer to separate E8 Controller User Manual GF
94. d can be viewed through the clear plastic cover In addition the PCB contains an on board screwdriver adjustable 10 position address switch which is used to set the corresponding address of the boiler on the input Modbus or EBUS Network Refer to Tables 4 5 and 4 6 for details on the features and functions of the BCM OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 87 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual DL1 YELLOW DL2 RED DL3 GREEN Input all Communications Connector Modbus Ebus acm Ur cer ad EMT mue hes arr poo gt H j p 4 N 2e 3 Pos Switch NIS q 299 3 Enable Disable 27 SSS na rM TDS 2 Pos Switch miw m X a i AAD Nee Reset Switch a gt 4 A E ir 22 y ru 4 4 7 4 DE z Output UN ME tt 7 T SW 7 pu LLL e C CC C SW1 Switch D d Communications 9 Connector Ebus D Figure 4 6 BCM Boiler Control Module Features Table 4 5 BCM Boiler Control Module Features and Functions Nange Over pe esraralel Three position rocker switch
95. e You can then skip the remaining steps in this section and continue with section 11 Cleaning the Burner Module and Combustion Chamber 10 To access individual burner modules refer to Figures 7 13 and 7 14 and using a standard Phillips head screwdriver remove the C screws of each burner module to be accessed These are the screws that are located at each end of each burner plate 2 per plate Figure 7 13 Removal of Burner Plate Hardware Steps 9 10 11 Page 130 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Disassembling the Boiler for Maintenance Continued Figure 7 14 Removal of Burner Plate Hardware Steps 9 10 11 11 Refer to Figure 7 15 and remove the two bolts white arrows at each end of the gas collection tube that mount it to the boiler chassis mm y 7 j 3 7 2 Figure 7 15 Uninstall Gas Collector Tube from Boiler Chassis Step 12 OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 131 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Disassembling the Boiler for Maintenance Continued 12 Refer to Figure 7 16 and using a 10mm socket wrench remove
96. e chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water boiler connected to heating coils located in air Handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 3 17 Air Intake Connection Install air intake as shown in Figure 3 20 For air intake connection piping use only e 24 PVC Pipes Schedule 40 80 for Modulex EXT 321 EXT 481 EXT 641 e 26 PVC Pipes Schedule 40 80 for Modulex EXT 802 EXT 962 EXT 1123 NOTE 6 Use silicone to NN lubricate the internal lt surface of the seals before assembling Figure 3 20 MODULEX EXT Air Intake Connection Page 44 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 18 Flue Manifold Connection To assemble the flue manifold to the boiler flue exhaust opening retrieve the six 6 nuts and washers from the plastic bag shipped with the boiler and affix to the boiler opening per Figure 3 21 The Manifold may be installed on the left front or rear If switching to left or rear positions the unused outlet should be c
97. e drop of the combustion air piping is also 100 equivalent feet 30 m NOTE The flue system must be installed in accordance with the local and national Standards OMM 0087_0F AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 51 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Example 1 40 foot 12 2 m length of vent pipe and 1 sharp 90 elbow add up to 40 ft 10 ft 50 equivalent ft 17 4 m Example 2 A 30 foot 10 4 m length of vent pipe and 2 sharp 90 elbows add up to 30 ft 2 x 10 ft 90 equivalent ft 17 4 m o 78 2 mm TB 2 mm Figure 3 27 Modulex EXT Allowable Venting Solutions Page 52 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 24 Electrical Connections 3 24 1 Regulations in Force The electrical connections to the boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Installations should also conform with CSA C22 1 Canadian Electrical Code Part 1 if installed in Canada WARNING The boiler must be electrically grounded in accordance with local codes or in absence of local codes with the National Elect
98. e note these restrictions and its dangers to the operator of the boiler When one expects contaminated combustion air near swimming pools chemical cleaning operations hair salons etc sealed combustion operation is recommended Page 48 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual WARNING Fire danger due to flammable materials or liquids Do not store flammable materials and liquids in the immediate vicinity of the boiler oee Section 3 6 2 for warnings and guidelines concerning materials and contaniments that should be avoided in the boiler room and near air inlets when operating the boiler 3 21 2 Room Air Combustion The boiler closet or room shall be provided with two permanent openings communicating directly with an additional room s The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of 1 square inch per 1 000 Btu per hour of total input rating of all gas utilization equipment in the confined space but no less than 100 square inches One opening shall commence within 12 inches 305 mm of the top and one opening shall commence within 12 inches 305 mm of the bottom of the enclosure The minimum dimension of air openings shal
99. e panels can be removed NOTE Commercial units have a special latch kit to hold up the top plate Unical part number 00362418 Figure 7 6 Remove Panels Step 3 Figure 7 7 Remove Flue Assembly Step 4 OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 127 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Disassembling the Boiler for Maintenance Continued 4 Remove screws from around exhaust outlet opening and remove flue assembly from unit Figures 7 7 amp 7 8 Figure 7 8 Flue Removal Step 4 o On each side of the air intake manifold unlatch spring clips holding it in place Figure 7 9 Air Intake Manifold Manifold Retention Spring Clip Left amp Right Figure 7 9 Unlatch Spring Clips from Left and Right Side of Manifold Step 5 Page 128 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Disassembling the Boiler for Maintenance Continued 6 Remove the red hoses quantity depends on model from bottom side of manifold Figure 7 10 then lift entire manifold from the unit Lift out manifold after removing red hoses Remove Red Hoses from under Manifold Air Intake Manifold
100. ed Test Nipple should be FLUE VENT PIPE INSTAL FLUE PIPING installed TO ADAPTER WITH Within first RTV LIQUID 3 feet of i SILICONE AND flue start WORM DRIVEN 22 Figure HOSE CLAMP ADAPTER ASSEMBLY EUROPEAN TO AMERICAN STANDARD FLUE ADAPTER Figure 3 25 Installed Flue Exhaust Diameter Reduction Adaptor Kit 3 21 Combustion Air and Ventilation Openings Provisions for combustion and ventiiation air must be made in accordance with section 5 3 Air for Combustion and Ventilation of the National Flue Gas Code ANSI Z223 1 NFPA 54 or Sections 7 2 7 3 or 7 4 of CAN CSA B149 1 05 installation codes or appilcable provisions of the local building codes 3 21 1 Insufficient Ventilations and Combustion Air BOILER DAMAGE AND OPERATIONAL FAILURES may occur due to insufficient or improper openings for combustion air and or ventilation of the boiler room Provisions for combustion air and ventilation are always required regardless of whether the combustion air is taken from the outside sealed combustion or inside room air used as combustion air Insufficient ventilation of the boiler room can lead to high air temperatures This can result in boiler damage Note the following Make sure that intake and exhaust openings are sufficiently sized and no reduction or closure of any openings takes place When a combustion air or ventilation problem is not resolved do not operate the boiler e Pleas
101. ed After confirmation check the maximum gas settings again as described in section 3 33 2 above 3 33 4 Final Check and lgnition Failure Adjustment Procedure After completing the Minimum and Maximum output adjustments check the minimum and maximum values at the flue outlet and if necessary make any required adjustments If the boiler fails to ignite perform the following procedure Ignition Failure Adjustment Procedure MAXIMUM OUTPUT ADJUSTMENT SCREW Figure 3 38 Maximum Output Adjustment Screw Tighten the maximum adjustment screw A in a clockwise direction until it is fully abutted into the gas valve body than slacken back out for nine 9 turns Verify boiler ignition If the boiler goes into lockout slacken the screw A again for one turn than retry ignition If the boiler goes into lockout again repeat step 3 and retry ignition Once ignition succeeds carry out the minimum and maximum gas output burner adjustments as previously described in sections 3 33 2 and 3 33 3 above OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 71 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 3 6 Modulex EXT Pressure CO and O Level Calibration Tables 321 pow Supply COzLevel Fan Speed Mixer Min Gas Max Gas Pressure je Consumption Consumpt
102. ed in a cupboard compartment There are no water leaks OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 79 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual This page intentionally blank Page 80 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual CHAPTER 4 E8 CONTROLLER AND BCM MODULES MODULEX boilers contain advanced and reliable electronic controls the E8 Controller and the BCM Boiler Communications Module which provide comprehensive programming and monitoring of the MODULEX boiler and its functions Features and functions of the E8 Controller and are described in this chapter CAUTION This chapter instructs how to operate and navigate the E8 Controller menus sub menus and parameters as well as describing the functions of the BCM Boiler Control Module However before the boiler may be used the E8 controller MUST be first intitialized by entering language year month day and hour in the Installation Menu described in section 5 1 4 1 E8 Controller A standard component included in MODULEX units the E8 Controller is responsible for the staging and modulation of individual thermal heating modules in
103. eeping with official instructions and accepted standards and regulations 7 After completing all the necessary maintenance work always follow these steps a Open the C H flow and return valves as well as the cold inlet valve if previously closed b Purge and if necessary proceed with restoring the heating system s pressure until a pressure of 0 8 1 0 bar is reached C Open the external ON OFF gas valve installed upstream of the boiler d Reconnect the appliance to the electrical supply and switch on the mains electrical supply e Test for correct operation on the gas side and on the water side 8 Replace the boiler front panel 7 2 Periodic Examination Of Venting System The inspection of the boiler and venting system should be performed every year and full maintenance should be done every two years Please contact AERCO for further guidance on the frequency of maintenance and service requirements Contact details can be found on the back page of this manual Verify that the air ventilation system air intake and air intake pipes are unobstructed 7 3 Proper Procedure For Cleaning Exhaust Flue The flue exhaust system including condensate evacuation should be checked annually Annual maintenance includes verifying that the flue manifold and exhaust vents are clean and unobstructed It is necessary to inspect and clean the condensate drain pipe in particular Page 122 of 146 AERCO International Inc e 100 Oritani Dr
104. en treated by reverse osmosis deionization or distilled water in order to soften the water Donotuse 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 5090 When using oxygen permeable pipes e g for under floor heating systems you must separate the system from the boiler using plate heat exchangers e 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 e Noble Noburst AL Approved system cleaners Noble Noburst Hydronic System Cleaner e Fernox 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 e Noble Noburst AL inhibitor AERCO Sentinel products See list in GF 136 P section 2 3 System Flushing Treatment and Cleansing Page 12 of 146 AERCO International Inc e 100 Oritan
105. eral Menu The GENERAL menu contains the sub menus DATE TIME HOLIDAY and CLOCK CHANGE Turn Open the flap counterclokwise bisPLAY GENERAL After a 2 second delay sub level is displayed DATETIME O rona CHANGE 3 RETURN Turn Turn Turn clockwise l clockwise clockwise o Press to Press to rece enter enter enter to return CN level CJ level CN level Set new Set new Set new value value value TIME HOURS Wm level CQ YEAR STAR l Ec a level MONTH START lt 5 us YEAR MONTH STAR DAY START dA se se a me CQ level level CJ level MONTH DAY START MONTH STOP to Press to d Press to enter enter enter level level EN level DAY YEAR STOP DAY STOP G eer du level G level MONTH STOP ca DAY STOP Figure 5 5 GENERAL Menu OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 97 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 5 1 GENERAL Menu DATE TIME TIME HOURS Current hours blink and can be adjusted YEAR MONTH Adjust current month DAY Adjust current day HOLIDAY YEAR START MONTH START DAY START YEAR STOP MONTH STOP DAY STOP ENTRY RANGE 00 00 24 00 XXXX 01
106. ese activities WARNING Following maintenance or other activities always check the integrity of all parts through which gas flows with a bubble test using soap spray to ensure there are no gas leaks 3 31 Filling the System 3 31 1 Necessary Precautions While Filling the System Do not mix the C H system s water with anti freeze or anti corrosion solutions using incorrect concentrations Doing so can cause damage to the gaskets and might cause noise during normal boiler operation WARNING AERCO refuses all liability for injury to persons animals or damage to property deriving from not having respected the above mentioned recommendations Before filling the heating system the complete system including all zones must be thoroughly cleaned and flushed to remove sediment Flush until clean water runs free of sediment AERCO suggests using an approved system cleaner to flush the system but not the boiler Always use AERCO approved antifreezes See the list in section 1 9 3 Water Quality Requirements Never use reverse osmosis deionized distilled water or mineral treated water for filling the heating system 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 65 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual WARNING Do not use petroleum based cleaning or sealing compounds in the
107. ffer E8 F9 Outer temperature sensor E8 F6 DHW storage temperature sensor 5 E8 F8 Boiler temperature sensor E8 F2 Room temperature sensor heating circuit 1 E8 F15 Room temperature sensor heating circuit 2 E8 F12 Lower DHW storage temperature sensor MF2 E8 F13 Boiler 2 Manifold 2 MF 3 E8 F14 Manifold 1 Multifunction 4 E8 F15 Room temperature Hc2 E 70 75 E 76 E 78 E 137 NJN N OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 115 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 6 2 E8 Controller Fault Codes Continued FAULT CODE FAULT DESCRIPTION Communication Fault the same time appliance E 207 Internal Fault EB E8 EEPROM fault The invalid value has been replaced by the standard value Page 116 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 6 1 2 BCM Boiler Communications Module Fault Codes The table below lists the fault codes and troubleshooting tips associated with the BCM Table 6 3 BCM Fault Codes CODE DESCRIPTION EFFECT CORRECTION RESET Boiler pipe is frozen Ignition is Carefully AUTOMATIC when Flow Flow se
108. for the installation of the boiler please comply with the following safety requirements e Ensure easy access to the components of the boiler to facilitate maintenance e The room where the boiler will be placed must always be frost free e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance e Never use or store any chlorinated detergents or halogenated hydrocarbons e g in spraycans solvents and detergents paints adhesives in proximity to the boiler e For outdoor installation see Warning for Outdoor installation on page 16 3 6 2 Products to Avoid in the Boiler Room Do NOT store the following products in the boiler room and or around combustion air intake vents e Spray cans containing chlorocarbons fluorocarbons Ammonium and or ammonium solutions e Permanent wave solutions e Chlorinated waxes and or cleaners e Chiorinated swimming pool chemicals e Calcium chloride used for thawing Sodium chloride used for water softening e Refrigerant leaks e Paint or varnish removers Page 30 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning
109. h is the first sub menu in the DISPLAY menu group Figure 4 5 The two small black arrows at the bottom of the display will point down to the menu and submenu names in this case DISPLAY and INSTALLATION respectively To view functions included in the INSTALLATION sub menu press the Program Key Item E Figure 4 4 If desired turn the Rotary Knob to scroll through the functions in the INSTALLATION sub menu As previously mentioned these display functions are read only and cannot be changed Once you reach the end of the sub menu RETURN will appear in the display To exit this sub menu and advance to the next sub menu in the DISPLAY menu press the Program Key while RETURN is displayed INSTALLATION will again be displayed Turn the Rotary Knob clockwise until the next sub menu is displayed Repeat steps 2 3 and 4 to view the remaining main menus and their associated sub menus The remaining main menus are USER TIME PROGRAM EXPERT EXPERT HS Not Applicable to MODULEX and GENERAL 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 85 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 4 1 6 E8 Parameter Navigation Selection and Setting When in the USER TIME PROGRAM EXPERT or GENERAL Main Menu virtually all sub menu items can be changed if desired Perform the following steps to access view and
110. he LEFT HAND position e Gas connection on the RIGHT HAND side supply condition but may be moved to the LEFT HAND position Page 20 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 2 4 Performance Data Table 2 2 MODULEX EXT Performance Data PARAMETER MODULEX EXT EXT 321 EXT 481 EXT 641 EXT 802 EXT 962 EXT 1125 46 000 Minimum heat input Btu hr kW Btu hr kW 7 Nominal heat input high reduction for Altitude Btu hr kW Nominal heat output HT Btu hr kW Btu hr kW Efficiency at full load 10095 96 Efficiency at min load 90 Nominal heat output condensing mode Btu hr kW Minimum heat output in condensing mode Btu hr Efficiency at nominal load in condensing mode 76 Efficiency at min load in condensing mode 50 Combustion efficiency at nominal load 7 Combustion efficiency at min load 95 Stand by losses 95 Flue gas temperature Flue gas temp room temp F FC Air excess 36 Condensate production max Ib hr Nominal heat input low Minimum heat output HT Boiler category Minimum water flow rate in CH circuit Xt 68 F 20 C gal min l min Min pressure in CH circuit psi kPa psi
111. he boiler make sure the condensate drain pipe has been filled with water Figure 7 1 Ensure the seal between the gas supply pipe and the gas collection tube flange are tight To do this open the external gas valve and bubble check for leaks using a soap solution When a single burner is ignited check immediately to ensure that the gas valve and the relevant premixing chamber are operating correctly Perform the combustion gas analysis and check all parameters section 3 33 Make sure that all the pressure test nipples previously opened have been closed Page 136 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 7 14 Maintenance Kit Part Number To order the MODULEX annual and 24 Month Fireside Inspection maintenance kits contact AERCO International and use P N 58086 TAB replacing the TAB with the appropriate suffix as determined in Tables 7 3 and 7 4 Annual Maintenance Kits contain a flame detector and igniter while the 24 Month Fireside Inspection Kits contain flame detector igniter and burner gaskets Table 7 3 MLX Annual Maintenance Kit 58086 TAB P N Suffix 01 EXT 321 ANNUAL MAINTENANCE KIT 02 EXT 481 ANNUAL MAINTENANCE KIT DESCRIPTION 06 41123 OREXFAETI ANNUAL MAINTENANCE KT Table 7 4 24 Month Fireside
112. heck fan wiring AUTOMATIC Settings corrupted Page 120 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE SCHEDULE The boiler must receive regular annual maintenance and cleaning in order to ensure reliable and efficient operation Regular maintenance will prolong the life of the boiler Refer to Table 7 1 for a suggested schedule of maintenance procedures Maintenance must be performed annually To ensure the continued safe and efficient operation of the boiler it is highly recommended that it be checked at regular intervals and serviced when necessary and that only original spare parts be used Regular maintenance will prolong the life of the boiler WARNING If the boiler is not checked and serviced regularly it could cause damage to the equipment and or harm to persons Table 7 1 Modulex EXT Maintenance Schedule 2 Check Once Check Eve Maintenance Operation gt a Year 2 Years Inspect for acceptable circulating and feed water quality and chemistry Inspect gas assembly components Inspect safety devices for water and gas Inspect and clean the combustion chamber amp burners Inspect and clean flame rod and ignitor Inspect and clean the fan blower Check the operation of the fan blower
113. hnicians 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 e The boiler e othe gas air water supply pipes and electrical power e pipe safety relief valve and its drainage pipe e othe constructive components which influence the appliance s safe operation WARNING When tightening or loosening the screw pipe connections use only properly sized wrenches The improper use of inadequate equipment can cause damage for example water or gas leakages to the equipment Page 8 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp 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 information If the tank has not been correctly purged problems may occur during ignition If this happens contact the liquid gas tank s supplier
114. i Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp 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 Manometer that is capable of reading both positive and negative pressures Combustion analyzer Digital multimeter pH digital meter Metric Allen wrenches Metric socket wrenches 1 10 Disposal e 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 provide important information regarding the safe installation use and servicing of this appliance Keep this manual in a safe place for future reference 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 i
115. ide location Low internal water volume Fast response to load variations Flue exhaust outlet positionable on three sides Manifold delivery and return reversible Made up of two or more heating elements 2 to 7 cast aluminum silicon magnesium Full range of modulation by variable speed blowers and premix burners Each heating element monitors its own water temperature and will individually shutdown if flow is interrupted without affecting the other burner sections One gas supply line reversible Individual modules capable of between 46 and 160 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 e Return NTC sensor General element e Safety thermostat approved manual Limit thermostat room each heating reset element Flow sensor BCM Flow NTC sensor General Control Panel E8 Includes ON OFF switch e Air pressure fans Temperature control Boiler operation e Condensate level sensor Fuses e Air pressure switch anti obstruction High limit sensors Other Features Include NTC heat sensors for global temperature control on the flow and return
116. ify whether the boiler is compliant with its intended location e g gas type power source and venting classification Only use the boiler with the accessories and spare parts listed Other combinations of accessories and products must only be used if they are specifically designed for the intended application and do not affect the system performance or the safety requirements Maintenance and repairs must only be performed by trained professionals Installation of a condensing gas boiler must be approved per all federal and local government codes regulations and laws Operation of a condensing gas boiler must use a vent system that has been specifically designed and approved for this type of boiler Note that local permission and approval for the vent system and condensate water connection to a public sewage system may be required 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 vent connection Regulations for the power supply connection Technical rules laid down by the gas utility company concerning the connection of the gas connection to the local gas mains Instructions and standards concerning the safety equipment for the water space heating system Installation instructions for building heating systems The boiler must be located in
117. ing time Code number for enabling access to heating circuit data from PC 0000 access is blocked SOLAR RETURN NOT USED NOTE Some menus are visible only if the relevant sensor is wired T ROOM DES 2 Room temperature setting in second enable time T REDUCED Required room temperature setting during night 5 reduction T ABSENCE Required room temperature setting during holidays 59 RON gt Page 104 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 5 8 Time Program Menu The TIME PROGRAM menu contains the items shown below Open the door Turn clockwise TIMER PROGRAM SET the Day After 2 ds th 2 seconds the TUESDAY i sub level is displayed Turn WEDNESDAY z hi clockwise THURSDAY FRIDAY 9 CIRCL TIME a EN SATURDAY NA lt gt T SUNDAY clockwise MON FRI SAT SUN HOTW PROG MON SUN RETURN Turn clockwise Tum C clockwise HTG PROG 2 ti Figure 5 9 TIME PROGRAM Menu Table 5 5 TIME PROGRAM Menu CIRCL TIME Program for circulation pump Active only with parameter 1 x HW 00 NOTE By leaving the hour blank _ the heating period is bypassed 0087 OF AERCO International Inc
118. intenance Manual Open the Flap Turn clockwise Elapsed 2 sec The sublevel is shown on the display Q pere re ROUT O Sous Tum Turn Tum clockwise clockwise l clockwise E Depress o Depress the push the push CQ button CJ button 1XACQUA C M clockwise clockwise clockwise clockwise clockwise clockwise clockwise C Turn Cha clockwise T AC 1 NOM cliche Shan T AC 2 NOM en L 2 3 cius d gt RETURN Depress the push button to exit Room Temperature Setting in First Enabled Time Room Temperature Setting in Second Enabled Time Room Temperature Setting in Third Enabled Time Flow Temperature Turn Shange the value clockwise HEAT SLOPE N d Compensation Slope Outer Temperature dp RETURN d Depress the push button lo exit 2016 2 8 4 O 4 8 12 6 Outer Temperature Figure 5 3 E8 Quick Start Room Temperature and Outdoor Compensation Settings with Outdoor Temperature Slope Chart 0 2 3 Setting Heating Programs and Pumps Page 94 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual
119. ion Operation amp Maintenance Manual Table 5 6 EXPERT Menu INSTALLATION RANGE Boiler Bus address only for cascade of E8 AF SUPPLY 01 15 BUS TERM Busteminatngresistor 01 00401 01 owitching eBUS supply on off in realtion to TIME MASTER 00 time master 01 controller is time master 00 01 01 MAX T COLL 176 86 230 eat requirement MAX T HS2 185 F 86 230 0 V 10 V HYSTERESIS Dyn Switching hysteresys stage1 9 Rar36Ra FOUND MODULS of burners automatically reported via 0 30 min CAP MODULE After restarting the controller searches the bus 0 1000 systems NEW CONFIG New bus configuration 00 01 MIN MOD CASC Min modulation cascade 0 00 100 HW BOILER Number of stages for HW operation 00 08 0 00 08 CONTRDEVIAT Header control variance 7 0 09 DESOUPUT Required system output in 0 100 Currently remaining value NENNEN NENNEN DYN DOWNWARD Dynamicheatgeneratordeactivaion 80 20 500 Resetting time for Controller Page 108 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 5 6 EXPERT Menu Continued LEVEL DESCRIPTION ENTRY INSTALLATION Cont DEFAULT RANGE If this modulat
120. ion Output Type Vo Max 3 3 3 3 Wc kPa Max Min Max FL FH ft hr m hr ft hr m hr 7074 35 108 108 13 34 DH Q CO B 481 Supply O Level Fan Speed Gas NO Pressure je Consumption Consumption Output Vo 90 Max 3 3 3 3 Wc kPa Max Min Max FL ft hr m hr ft hr m hr 7074 75 10 8 10 8 43 34 45 1 29 474 13 43 18 0 50 50 183 5 19 BE oO 100 0 27 7 45 129 474 13 43 0 27 7 18 0 50 164 4 67 641 Supply CO Level O Level Fan Speed Mixer Max Gas Pressure je Consumption Consumption Output Vo 9o Min Max 3 3 3 3 Wc kPa Max Min Max FL ft hr m hr ft hr m hr NO KUUSETCNEET TRES 18 0 50 243 6 88 50 Ww Gas BH 100 027 7 1787 0 5 8 5 1 29 11 2 74 108 108 43 3 1 0 27 7 18 0 50 219 6 23 NOTE Check the levels often especially at low flow rates For high altitude installations consult document number C302 6 MLX EXT Alt Derate Co CO Page 72 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802
121. ion degree is exceeded the next IMODULATMAX 35 10 60 MODULAT MIN If values drop this modulation degree the last heat 10 60 MIN MOD HS Connection of the next heat generator 0 60 MOD LEVEL HW Entry of the set modulation degree for the heat 40 100 generators 12345678 87654321 01 06 LOCK TIME geh delay time after switching on or with switching 00 30 HYST BURNER integration hysteresys for the charging 3 6 36 Ra HS COOL FCT 0 1 T HS COOL 122 203 00 05 STORAGE HS2 _ Heat accumulator for HS2 0 00 03 BUFFER Heater buffer storage tank 0 00 03 SCREED Activaionofscreeddryngproess 0 00 0 SCREED PROGR Program setting HOT WATER PARALLEL Pump parallel running 0 00 03 T BOILER DHW Boiler temperature setting with hot water 00 90 Ra preparation HYST DHW Hot water hysteresys 9 54 Ra DHW FOLLOWUP Pump run down time O 00 30 THER INPUT Storage tank with thermostat 0 00 01 WALL HUNG Boiler temperature setting with hot water 00 01 preparation LOAD THROUGH The charge through function can be activated by 00 01 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 109 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 5 6 EXPERT Menu
122. l 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 means of the appropriate 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 domestic hot water system allowing the water to flow an appropriate amount of time 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 e Max boiler temperature 180 F e Max Allowable Working Temperature ASME 200 F e Max Allowable Working Pressure ASME 92 psi Page 14 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual CHAPTER 2 TECHNICAL FEATURES AND DIMENSIONS 2 1 Modulex EXT Technical Features Compact gas fired Low NO condensing boiler Comprised of one sectional boiler body suitable as a single boiler or in a cascaded group May be installed in either an inside or outs
123. l Terminal VII Connection to BCM 326 Pin 1 eBUS or 0 10V output sH T HO Pin 2 Ground Terminal Buffer storage tank low sensor Buf stor tank middle sensor FBR heat circ 1 room sensor Buf stor tank top sensor FBR heat circ 1 set value Pin 4 Flow sensor heating circuit 2 ground Pin 5 Flow sensor heating circuit 2 Pin 6 Storage tank sensor Pin 7 Storage tank and boiler sensor ground Pin 8 Boiler sensor Pin 9 Outdoor sensor Pin 10 Outdoor sensor ground Terminal V Pin 1 Flow sensor heating circuit 1 sensor multifunction 1 SS Pin 2 Service water low sensor sensor multifunction 2 Terminal QD F13 Pin 1 Sensor 52 Solar 2 Multifunction relay 3 Pin 2 Sensor Solar 1 Sensor multifunction relay 4 Terminal II dks ie F15 Pin 1 FBR heating circuit 2 room sensor 0 10V IN Light m 12 Pin 2 FBR heating circuit 2 ground 2 HE lt Pin 3 FBR heating circuit 2 set value Pulse counter for For connection to remote control devices H CAN Bus Pin 1 H Data CAN Bus Pin 2 L Data CAN Bus Pin 3 ground Gnd CAN Bus Pin 4 12V supply Terminal assignments BCM SIGNAL ALARM PUMP BOILER CIRCUIT EMERGENCY SET POINT Choose set point value as indicatedin the table gt CONTROL VFD MODULATING PRIMARY PUMP EBUS remote ae Cascade m
124. l be in compliance with all the latest regulations and laws about boiler enclosures boiler rooms installations of heating and hot water systems ventilation vents capable of exhausting the flue gases of condensing boilers and any other applicable requirements The boiler can be put on a flat and sufficiently strong base with the same dimensions as the boiler and at least 3 93 100 mm high see Figure 3 6 in order to assemble the condensate trap An alternative to this base may be a 100mm deep well or trench next to the boiler to accommodate the condensate U drain pipe see Figure 3 6 After installation the boiler shall be perfectly horizontal and stable to reduce any possible vibrations or noises OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 29 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual E uu 2 CH m MODULEX EXT Boiler Front Condensate Boiler Housekeeping Drain Pipe Pad Support Base Well or Trench for Condensate At Least KIA I Figure 3 6 Boiler Front View Housekeeping Pad with Condensate Drain Pipe 3 6 1 Boiler Room Safety Concerns When selecting the position
125. l not be less than 4 inches 101 6 mm 3 21 3 Sealed Combustion The boiler closet or room shall be provided with two permanent openings one commencing within 12 inches 305 mm from the top of the enclosure and one commencing within 12 inches 305 mm from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors The minimum dimension of air openings shall be no less than 4 inches 101 6 mm 1 Where directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr of total input rating of all equipment in the enclosure 2 Where communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr of total input rating of all equipment in the enclosure 3 Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 Btu hr of total input rating of all equipment in the enclosure 4 Where ducts are used they shall be of the same cross sectional area as the free area of the opening to which they connect 3 22 Installation of the Exhaust and Air Intake System NOTE Consult local and state codes pertaining to special building code and fire department requirements Adhere to national code requirements NOTE Observe the listed maximum
126. lected Menu Sub menus parameter names values and selected busses are indicated in the LCD display when in MENU Mode Mounting Key Insert narrow screwdriver deep into holes and lift up controller to Access Holes remove When lit this LED indicates that the value shown in the display can HIDE ED be changed using the Rotary Knob A Optical Adaptor For PC connection Prouram Ke Used to select a sub menu level select a parameter value to 9 y change or save a new parameter value A 2 position 10 2 o clock screwdriver adjustable switch Normally this switch is set to the A 2 o clock position to allow program control of the boiler When set to the Manual 10 o clock position a flashing EMERG MODE message is displayed Manual Heating Circuit 1 HC1 pump and the first burner stage are switched on Pumps for Heating Circuit 2 HC2 and Domestic Hot Water DHW will also be switched on if sensors are installed and enabled The pump s will turn off when the flow temperature reaches the value set for MAX T FLOW in EXPERT HEAT CIRCUIT 1 menu The first burner stage will cut off when the boiler temperature reaches the value set for MAX T MODUL in EXPERT INSTALLATION menu Rotary Knob Used to navigate through menus and parameters or adjust parameters Page 84 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 Automatic Switch MODULEX EX
127. lengths of vent system which are dependent on boiler model The maximum permissible lengths are listed in section 3 23 below 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 49 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Minimum clearance of 4 ft 1 22m horizontally from and in no case above or below unless a 4 ft 1 22 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment The minimum distance from adjacent public walkways adjacent buildings openable windows and building openings shall not be less than those values specified in the National Fuel Gas Code ANI Z223 1 NFPA 54 and or the Natural Gas and Propabne Installation Code CAN CSA B149 1 Do not extend exposed vent pipe outside the building beyond recommended distance Condensate could freeze and block vent pipe Vent should terminate at least 3 ft 915 mm away from adjacent walls inside corners and 5 ft 1525 below roof overhang see Figure 3 26 It is not recommended to terminate vent above any door or window as condensate can freeze causing ice formations Do not use a chimney as a raceway if another boiler or fireplace is vented into or through the chimney 12 305 mm minimum 12 305 mm minimum 12 305 mm minimum 12 305 mm 12 305 mm minimum minimum
128. lling the Gas Analyzer Probe into Flue Outlet Remove the cap 2 from the gas outlet 1 Install the probe adapter 3 into the gas outlet 1 where cap was removed Insert the analysis probe 4 into hole of the probe adaptor After measurements are taken and adjustments made remove the probe probe adaptor then reinstall the cap 2 onto the gas outlet 1 Figure 3 36 Gas Analyzer Probe Location in Flue Outlet 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 69 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual MAXIMUM OUTPUT ADJUSTMENT SCREW E MINIMUM OUTPUT ADJUSTMENT SCREW Maximum Output Adjust Minimum Output Adjust T Figure 3 37 Location of Minimum and Maximum Adjustments Top View 3 33 2 Maximum Output Calibration After installing the gas analyzer probe Figure 3 36 refer to Figure 3 37 to locate the gas valves and the Maximum Gas Adjustment screw A on each valve Follow the instructions below to set the maximum gas output level for each valve Adiusting the Maximum A Gas Output Settin Remove the cap of the combustion gases sampling point Figure 3 36 and connect a suitable gas analyzer Operate the burner to a minimum power following the procedure described in Section 3 34 Figure 3 39 Sweeper function CASCADE MAN 100 Check that the CO
129. llowing examples Message Type Example and Description NOTE 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 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 Instructions are shown in a blue box with an underlined title 2 Alltext excepting in accompanying illustrations is colored blue 3 Allprocedures are listed in steps starting with 1 and using letters a b c etc indicating sub steps Steps that are continued on the next page have a Continued appended to the instruction title Page 2 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual TABLE OF CONTENTS CHAPTER 1 GENERAL 0 2 2 22 7 1 11 7 To Correct Use or the aku basta 7 AE d IM TEE Tc
130. lockup or with the boiler running is 10 5 inches W C Minimum pressure with the gas flowing verify during boiler startup is 4 0 inches W C 3 9 2 Propane Gas Connections 3 9 2 1 Propane Gas Piping Sizes Contact your local gas supplier for Propane gas pipe sizes tanks and 100 lockup gas pressure regulator 3 9 2 2 Propane Gas Piping Connections e Use a gas shut off valve compatible with propane gases e A sediment trap must be installed upstream of the gas controls The boiler pipe is provided with an external 2 MNPT thread onto which the tail piece of the gas shut off valve can be screwed Use appropriate sealing The connection to the boiler must include a suitable method of disconnection The nominal inlet working gas pressure measured at the boiler should be 11 W C 27 mbar for Propane gas Gas E OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 37 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual A gas control valve must be installed adjacent to the boiler for isolation purposes 3 9 2 3 Propane Gas Supply Pressure Requirements Pressures required at gas valve inlet pressure port e Nominal gas pressure 11 inches W C e Maximum gas pressure 13 inches W C with no flow lockup or with boiler running e Minimum gas pressure 8 inches W C with gas flowing verify during boiler startup
131. ls apply to all internal heating circuits for which a separate heating mode has been selected Note that each symbol occupies a different space across the display bottom See Figure 4 3 Display of current temperature of HS 1 or header temperature when cascading Display of number of active heat generators only applies when cascading Selectable display and Error Codes refer to DISPLAY SEL parameter in the USER menu EM Status display Shows symbols for Internal Burner 1 Relay ON Heating Mode Hot Water Page 82 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 4 1 3 E8 HEATING Mode Selection Heating modes may be selected using the Rotary Knob on the controller when the hinged door is in the closed position NORMAL Mode As the Rotary Knob is turned each appropriate heating mode symbol is displayed in turn along the lower edge of the display Mode changes take effect when the setting is not changed for 5 seconds The symbols and description for the available heating modes are shown in Figure 4 3 Heating Mode Symbols Only the one currently B D selected mode will be displayed Figure 4 3 E8 HEATING Mode Display Features NORMAL Mode Table 4 2 E8 HEATING Mode Features and Functions NORMAL Mode Turn the Rotary Knob to select
132. nc e 100 Oritani Dr e Blauvelt NY 10913 Page 73 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 34 Sweeper Mode Manual Control Before opening the controller door flap turn the encoder wheel clock wise Turn counterclock wise counterclock wise DISPLAY GENERAL DATA TIME SERVICE will be displayed ula FN the level Displayed O Turn clock wise SENSOR TEST Turn 55 clock wise VER SW XXXX to open the level 55 CASCADE MANU to open the level BOILER 01 00 eZ NUM CODE x 5 times to insert access VARY THE VALUE code 4 times 0 PERCENT 10 Displayed 0000 BOILER 01 00 gt BOILER 01 10 gt 55 Confirm Equivalent Q min PERCENT TO 10 BOILER 02 00 Qe BOILER 03 00 BOILER 01 100 a BOILER 04 00 Equivalent Q max Confirm BOILER 05 00 BOILER 06 00 BOILER 07 00 BOILER 08 00 Figure 3 39 Sweeper Mode Manual Control NOTE The function is active for 15 minutes after which if there is no input it defaults to the previous parameters Page 74 of 146 AERCO International Inc 100 Oritani Dr Blauvelt 10913 OMM 0087_0F 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481
133. nsions No of Modules 02 1 02 1 02 1 02 1 02 1 02 1 1323 1323 1323 1323 1323 1323 45 3 45 3 45 3 45 3 45 3 45 3 1150 1150 1150 1150 1150 1150 m 300 300 406 406 51 2 512 1032 1032 1300 1300 an op 278 278 384 384 489 489 303 303 303 303 303 30 3 Height Open inches mm Height Closed inches mm Depth E inches mm 27 74 27 74 27 74 27 74 27 74 27 74 704 704 704 704 704 704 Gas 2 24 2 2 2 2 60 3 60 3 60 3 60 3 60 3 60 3 M C H System Flow 2 272 272 275 215 275 inches mm 76 1 76 1 76 1 76 1 76 1 76 1 R C H System Return 2 2 272 272 25 2 2 76 1 76 1 76 1 76 1 76 1 76 1 Vent Connection 5 9 5 9 5 9 5 9 7 8 7 8 inches mm 150 150 150 150 200 200 Condensate drain diameter 1 57 1 57 1 57 1 57 1 57 1 87 inches mm 40 40 40 40 40 40 Page 18 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual MIN AIR PRESSURE SWITCH CONTROL GAS PANEL FAM AUTOMATIC AIR VENT GAS PIPE GLOBAL FLOW TUER FLAME SENSOR SENSOR 4 scree LOCAL NTC FLOW p SENSOR AIR HIGH LIMIT PRESSURE P THERMOSTAT SWITCH BURNER GL
134. nsor temp is inhibited Pump defrost boiler sensor is greater than 41 F 36 F or less runs for 5 min at max speed Maximum A All burners turned Check the AUTOMATIC when A temperature protection OFF and Pump system temperature Water A Flow temperature ON at maximum installation Temp Protection Return Temperature gt speed Water A Temp Protection 50 F High outlet All burners turned Check Flow AUTOMATIC when Flow temperature Flow OFF and pump oensor or sensor lt 176 F sensor temperature gt ON at maximum system pump 203 F speed Ignition is Re program inhibited Pump the settings MANUAL push reset runs for 5 min at Contact switch or cycle power max speed factory BCM No remote control detected BCM No BMM BCM Sensor global Ignition is Close request MANUAL push reset flow detected inhibited input for switch or cycle power manual operation Settings corrupted by electromagnetic interference OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 117 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 6 1 3 BMM Burner Management Module Fault Codes The table below lists the fault codes and troubleshooting tips associated with the BMM Table 6 4 BMM Fault Codes CODE DESCRIPTION EFFECT CORRECTION RESET High Limit STB All burner
135. or equivalent as close to the rating label as possible Boiler model LL LL W C kPa Inlet gas pressure Max 130 323 ofthe converted Normal 2 74 boiler Min 1 99 Normal altitude 0 2 0004 FH rpm 86 High altitude 2 000 4 500 ft rpm r3 Manifold pressure Factory Set not adjustable Input Rating This boiler was converted on DAY YEAR To gas E Propane By name tess Se Ul name and address of organization making this con version which accepts the responsibility that this conversion has been properly made 00334524 Figure 3 42 MODULEX EXT Label OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 77 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 38 Controls And Emergency Functions GLT General Limit Thermostat when enabled it cuts the power supply to the boiler and lights the warning lamp Item D To reset remove the cap and push the reset button Main Power Switch Fuses 1 6 3A 2 10 Warning lamp of the Thermostatic Lockout from General Limit Thermostat E8 Controller Module Hydrometer Optional Change over Series Parallel 0 Emergency is active or the control is managed by PLC or BMS Series connection the cascade is managed by the BCM I Pa
136. ot Water Flow and Return Connections and Sensors from RIGHT HAND to LEFT HAND Page 34 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 8 3 2 Reversing Flow amp Return Temperature Sensors One sensor is located on top of the lower Return pipe railing while the other one is located under the upper Flow pipe railing Move these two sensors to other end of Flow Return pipes C H Flow Sensor is installed same as Return Sensor except under Return pipe Sensor Cable Plugged Sensor cable unplugged into Sensor showing sensor sensor bracket and screw Figure 3 12 Reversing Flow and Return Temperature Sensors 3 8 3 3 Reversing Boiler Sensor Kf And Automatic Air Vent Reverse the positions of the Boiler Sensor KF and Automatic Air Vent located on the top Flow pipe Figure 3 13 Reversing Boiler Sensor KF with Automatic Air Vent NOTE When reversing hydraulic and gas pipe connections you must close up the chassis openings vacated after the change See Figure 3 14 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 35 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Figure 3 14 Caps and Plugs Used for Closing Up Vac
137. ot follow these instructions a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot light It is equipped with an ignition device which automatically lights the burner Do NOT try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor as some gas is heavier than air and will settle on the floor C Use only your hand to turn the gas ball valve knob Never use tools If the knob will not turn by hand do NOT try to repair it but rather call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been submerged under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control device that has been submerged under water WHAT TO DO IF YOU SMELL GAS Donottry to light any appliance Do not touch or operate any electric switch Do not use any phone in the building Immediately call your gas supplier from a neighbors phone or from outside with your cell phone and follow the gas supplier s instructions OPERATING INSTRUCTIONS DEN STOP Read the safety information above on this warning Turn off all electric power to the appliance Open the gas valve Check gas and water pressure Wait five 5 minutes to clear o
138. overed with the plate and gasket removed from outlet being used RECTANGULAR GASKET FLUE MANIFOLD Figure 3 21 Connection of Flue Manifold To Boiler Exhaust Opening For venting systems in the USA it is necessary to assemble the Euro to USA adaptor to the flue manifold as shown in Figure 3 22 GASKET NOTE The gasket may seem large It is intentionally designed to provide a tight fit EUROPEAN TO USA FLUE ADAPTER FLUE MANIFOLD Figure 3 22 Assembly of USA to European Flue Adaptor to Flue Manifold OMM 0087_0F AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 45 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 19 Flue Exhaust Piping to Vent In a condensing boiler the flue exhaust is evacuated at a very low temperature maximum of about 183 F 84 C Thus it is necessary that the chimney be impermeble to the condensate of the combustion products and is made of corrosion resistant materials The different joints must be well sealed and equipped with suitable gaskets in order to prevent the escape of condensate and prevent the ingress of air To determine the proper cross section and height dimensions of the flue exhaust piping it is necessary to make reference to national and local rules In order to prevent the formation of ice during the operation the temperature of the internal
139. ow must be filled out with the appropriate information and applied to the unit in close proximity to the rating label If the unit is calibrated again for normal altitude operation the label should be removed This appliance has been converted for use at Altitude of 2 000 4 500 Feet FH rpm 94 Change of parameter Input Date of conversion Type of Fuel Converted by 00334518 Figure 3 41 High Altitude Conversion Label Page 76 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 3 37 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Conversion From Natural Gas To Propane Gas To convert the unit to use propane gas instead of natural gas do the following 1 2 Converting From Natural Gas to Propane Gas oet nominal heat by adjusting the fan speed parameter FH FAN MAX from the E8 controller as shown in Table 3 7 and Modulex EXT Pressure and Level Calibration in Table 3 6 above This parameter requires a password to change Adjust CO 96 minimum and maximum levels according to the type of gas as shown in table below See section 3 33 Burner Calibration for more information Gas Type Level Minimum Level Maximum NawalGes 3 After gas conversion to propane and calibration the gas installer should complete and apply this label
140. r 3 Elements EXT 481 1 Return Header 4 Elements EXT 641 Return Header 5 Elements EXT 802 Return Header 6 Elements EXT 962 Return Header 7 Elements EXT 1123 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 145 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Change Log Rev E Applied final changes per A M Reformatted per current 12 01 2014 design standards Misc corrections and improvements Curtis Harvey Rev F DIR 195 Warranty pages removed Warranty information for all Modulex units is now included in a new stand alone 07 13 2015 document All Modulex Limited Warranty posted on the Chris Blair AERCO web site Clarified maintenance schedule added information on heat exchanger cleaning to Chapter 7 RERCO Qu TN Modulex E Unical AERCO A Watts Water Technology Company AERCO International Inc 2015 Page 146 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143
141. r e Blauvelt NY 10913 Page 133 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Disassembling the Boiler for Maintenance Continued NOTE The check valve 1 in Figure 7 21 should at this time be checked to ensure that it moves freely and closes properly Figure 7 21 Lifting Burner Assembly and Location of Check Valve Step 1 Figure 7 22 Lift Pins Inserted into Lift Holes Left and Right Sides Step 15 7 11 Cleaning the Burner Module and Combustion Chamber After lifting up the burner assembly the individual burner modules are now exposed and may be cleaned Follow the instructions to clean the burner modules Cleaning the Burner Modules Figure 7 23 Burner Modules Exposed for Cleaning Page 134 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Cleaning the Burner Modules Continued 1 Carefully lift each burner module from its position Remove both the module and the gasket Discard the used gasket as each one will be replaced at reassembly WARNING The burner gaskets MUS T be replaced at every cleaning Figure 7 23 Removing Individual Burner Module and Gasket Step 1 2 Use only compressed air to clean the
142. r housekeeping pad on which to place the boiler install the boiler on the floor and provide a well or trough minimum of 4 101 mm deep in which to lodge the U of the condensate piping See Figure 3 19 WARNING Before commissioning the boiler fill the condensate drain pipe with water at the dedicated filling up plug See Figure 3 19 Page 42 of 146 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual WARNING Do not install the condensate drain where freezing may occur Use materials approved by the authority having jurisdiction in your area In the absence of such authority PVC and CPVC pipe must comply with ASTM D1785 F441 or D2665 Cement and primer must comply with ASTM D2564 or F493 For Canada use ULC certified PVC or CPVC pipe fittings and cement Periodic cleaning of the condensate disposal system must be carried out 3 15 Water Treatment The chemical physical composition of the heating system s water is fundamental for the boiler s correct operation and safety Among the problems caused by poor quality of feed water the most frequent and the most serious is the buildup of deposits on boiler thermal exchange surfaces Less frequent but also serious are deposits on the water circulating piping surfaces Because of the low thermal conductivi
143. r values and setpoints No adjustments can be made Operating errors are therefore excluded in this area USER summary of settings that can be made by the operator TIME PROGRAMS Summary of time programs for heating circuits the hot water circuit and extra functions where applicable EXPERT Summary of values for which expert knowledge is required to make settings installation technician Values in the expert level are protected by a code number EXPERT FA Only for FA via BUS Summary of values transmitted by the automatic firing device Sub Menus INSTALLATION All display values and settings that relate to the unit or the entire system and cannot be assigned to a consumer circuit HOT WATER All display values and settings that affect central hot water preparation and circulation HEATING CIRCUIT I All indicator and set values that relate to the consumer circuit 1 also for example as decentralized hot water circuit HEATING CIRCUIT Il All indicator and set values that relate to the consumer circuit 2 also for example as decentralized hot water circuit SOLAR MF All indicator and set values that relate to solar energy recovery and settings for the multifunction relay Page 96 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 5 4 Gen
144. rallel connection condition of supply In position l the plant will operate when requested at CONSTANT SETPOINT 70 Max heat output 50 Enables burner reset in case of lock out YELLOW LED Blinking Communication between BMM and BCM is OK GREEN LED Active Pump RED LED ON Failure Code Detected See section 4 2 below for more information regarding the BCM Boiler Communication Module NOTE The emergency function enables the boiler s burners to fire only at 50 and at 50 in system return All the system s heating loads including the header pump must be controlled manually Page 78 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 39 Initial Boiler Ignition 3 39 1 Preliminary Checks WARNING To ensure the continued safe operation of the boiler it is highly recommended that it is checked at regular intervals and serviced when necessary and that only original spare parts are used Regular attention will prolong the life of the boiler Before igniting the boiler check that The boiler installation has been carried out in accordance with the specific standards as Instructed in this manual The combustion air inlet and the discharge of combustion exhaust occur in the correct manner in accordance to
145. rical Code ANSI INFPA 70 and or the CSA C22 1 Electrical Code The gas D H W Domestic Hot Water and C H system pipes must NEVER be used for electrical grounding Ensure that the above safety electrical requirements are instituted If in doubt ask a professionally qualified technician to check the appliance s electrical system AERCO does not accept responsibility for any damages arising from failure to correctly electrically ground the boiler It is necessary that a qualified technician verify that the electrical system is adequate to satisfy the appliance s maximum power requirements indicated on the data plate verifying in particular that the cables are suitable for the appliance s maximum power use For the appliance s general electrical supply the use of adaptors multiple sockets and or extension cords is strictly forbidden The use of any power supply equipment implies the observance of several fundamental rules such as Do not touch the appliance with any wet part of your body and or while barefooted Do not pull the supply cables Do not expose the boiler to sunlight rain etc unless it is explicitly prepared and installed for such use Do not permit children or inexpert people to use the appliance 3 24 2 Mains Electrical Supply Connection 120 V 60 Hz Mains electrical requirements call for a 120V 60 Hz power source The electric power connections to the junction box of the
146. rol system or any remote control unit e Alarm management e Alarm reset input e Warning alarm relay e Stainless steel condensate collector tank with siphon drain trap and smoke chamber Easily removable stainless steel panels painted for outdoor installation e Built in air vent 2 2 General Boiler Operation The boiler may be operated from the 8 controller or alternatively from BCM Boiler Cascade Manager The boiler management logic provides the maximum number of simultaneously operating heating elements in order to maximize heat production and overall efficiency Burner efficiency and a high heat exchange between surfaces contribute to the reliable and efficient output power The various components are designed to work together so that operating time is shared equally among the components thus reducing maintenance and labor costs The hot water moved by the pump is pushed to the return of the primary flow of the hydraulic separator From here a second pump will distribute the hot water to the various destinations The cooled return water is drawn by the pump through the hydraulic separator to resume the cycle via the boiler WARNING If installing to an outdoor location where freezing temperatures may occur it is necessary to install devices and or materials to prevent any freezing in the condensate drain and the Flow and Return manifolds Failure to do so may cause serious damage to the equipment Page 16 of
147. s Check flow sensor thermal MANUAL push Thermostat turned OFF and connection to boiler reset switch activated pump ON at when maximum speed temperature goes below limit Low gas All burners Check gas pressure or gas AUTOMATIC pressure turned OFF pressure switch when gas pressure switch closes No flame Burner control Check flame rod or MANUAL push detected at lockout combustion reset switch or burner start cycle power Flame loss during Ignition retry Check combustion and MANUAL push run wiring reset switch or cycle power High outlet All burners Check flow sensor or AUTOMATIC temperature turned OFF and system pump when Flow Flow sensor pump ON at sensor lt 176 temperature gt maximum speed 203 F Internal failure Ignition is Contact factory for new MANUAL cycle LIN NE EE d Flame signal Ignition is Disconnect flame rod wire MANUAL push detected before inhibited from BMM If problem reset switch or ignition goes away change flame cycle power rod and or wire If problem does not go away change BMM Flow sensor fault All burners Check flow sensor or AUTOMATIC turned OFF wiring The boiler will a Check aux sensor Aux sensor fault Flow sensor AUTOMATIC wiring without the Aux sensor Page 118 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS
148. s a person who has a specific technical qualification in the field of components for central heating systems for domestic use domestic hot water production and servicing This person must have the qualifications legitimized by the current laws and regulations in force Inappropriate incomplete or irregular servicing could compromise the safe operation of the appliance and could cause injury to persons animals or damage to property The manufacturer shall not be held liable for any such injury and or damage Any repairs must be carried out by AERCO authorized technicians and using only original spare parts Non observance of the above requirement may jeopardize the safety of the appliance and void any warranties In the event of failure and or faulty functioning of the appliance switch off the boiler Do not attempt to make any repairs but instead contact qualified technicians To guarantee the efficiency and correct functioning of the appliance it is required that the boiler be serviced annually by a qualified person 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 OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 13 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manua
149. se values MUST be entered in order to initialize the boiler for operation Once the values grouped here have been entered and accepted the controller is initiated and operatable and may be configured for your boiler installation To re enter the INSTALLATION menu cycle the boiler power and open the cover again To initialize the E8 Controller set the following values in the INSTALLATION Menu Set the parameters ENGLISH HOUR YEAR MONTH and DAY e Leave the BUS ID HS parameter blank Remaining parameters are already set and do not require any entry MODULEX MODULEX d Aerea EXT DV EXT DV CJ Level 1 E8 master slave Language gt ENGLISH Sei do Current Time gt TME 0 STORAGE Hs2 s ter Leva HC FUNCTION 2 Current Year gt YEAR 1 SCAN s Ji s Current Month MONTH 51 s Press to mim ini Current Day gt Day 1 41 TMF 3 SETP o Press to RELAY FUNC 4 WARNING do zs TMF 4 Menu selections shown MF4HYST the factory default settings Refer to GF 115 C for the complete menu selections a D Press to d cs Figure 5 1 INSTALLATION Menu Page 92 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation
150. t Gas Manifold Gasket Supply Gas to Gas Manifold Connector NOTE Torque all bolts to 8 85 ft lbs 12 N m Figure 3 10 Reversing Gas Connections from RIGHT HAND to LEFT HAND 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 33 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 8 3 Reversing Cold Hot Water Flow amp Return Connections Change of Water Flow and Return connections from RIGHT hand to LEFT hand requires reversing connectors moving the Flow and Return Temperture Sensors to other end and exchanging positions of the Boiler Sensor KF and Automatic Air Vent WARNING Ensure that the gaskets for ALL connections are reversed along with the connectors themselves 3 8 3 1 Reversing Cold Hot Water Flow amp Return Piping Connectors Refer to Figure 3 11 and reverse the connectors and end caps on Supply Flow and Return pipes Ensure that all gaskets are also reversed Reverse positions 2 of Boiler Sensor and Automatic Move Air Vent See lt end caps and Figure 3 13 gaskets to other M end of Do Flow Return pipes Move supply connectors and gaskets to other end of Flow Return pipes Move Flow and Return Sensors to other end of pipes See Figure 3 12 NOTE Torque all bolts to 8 85 ft Ibs 12 PN Figure 3 11 Reversing Cold H
151. ted without regard to position Remove this black jumper insert the two wires from the flow switch into terminal connector Figure 3 17 BMM Location and Flow Switch Connection 3 13 Determination of Primary Boiler Pump Or Boiler System Pump The following table gives an indication of the pump s flow rate in function of the At of the primary circuit if the installation has a mixing header The size of the pumps must be determined by installers or technical engineers according to boiler data and system design Page 40 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Table 3 2 MODULEX EXT Minimum Maximum Flow Rates Min flow rate demanded in gal min AT 27 F 15 Min flow rate demanded in gal min AT 36 F 20 C Max flow rate demanded in gal min AT 27 F 15 C Max flow rate demanded in gal min AT 36 F 20 C 55 6 651 1 The water side resistance curve of the boiler is shown in the diagram in Figure 3 18 The pump is not an integral part of the boiler It is recommended to choose a pump with the rate and delivery head at about 2 3 of its characteristic heating curve 45 118 rem EXT 1123 V 93 u EXT 321 2 6 6 7 5 2 ane 2 3 9 y 26 i i 0 8 8 17 6 26 4 35 2 44 52 8 61 6 70
152. tes Installation must conform to the requirements of the National Fuel Gas Code ANSI Z223 1 NFPA 54 e Canada Installation must conform to the requirements of CAN CSA B149 1 Natural Gas and Propane Installation Code e 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 OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 23 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 2 Code and Standards Approvals The MODULEX EXT boiler has been reviewed for compliance with the applicable sections of the following North American Standards ANSI Z21 13 CSA 4 9 Gas fired low pressure steam and hot water boilers ASME SECTION IV ASME Boiler and Pressure Vessel Code with addenda Section IV Rules for Construction of Heating Boilers e BTS 2000 Testing standard method to determine efficiency of commercial space heating boilers SCAQMD RULE 1146 2 Emissions of oxides of nitrogen from large water heaters and small boilers and process heaters CSD 1 Controls and safety devices for automatically gas fired boilers 3 3 Packaging The MODULEX EXT boiler is delivered assembled and protected by a plastic bag inside a strong cardboard box and fixed on a pallet This allows the boiler to be h
153. the following three different devices E8 Controller These are divided into four basic categories Element Faults oystem Manager Faults Communication Faults and Internal Faults These fault codes are shown in Table 6 2 BCM Boiler Control Module These fault codes are shown in Table 6 3 BMM Burner Management Module These fault codes are shown in Table 6 4 ERROR CODE Figure 6 1 E8 Error Code Location NOTE When interpreting fault codes in the E8 display that refer to the 8 controller itself the code number is directly referenced to a fault description in Table 6 2 Displayed fault codes not listed in Table 6 2 refer to devices other than the E8 controller such as the Boiler Management module BMM or Burner Controller Module BCM Use Table 6 1 and the formula described below the table to arrive at a fault number which can be looked up in Tables 6 3 and 6 4 for the fault description OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 113 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual In order to derive the error message from the code displayed in the E8 Controller display use Table 6 1 below to determine the working error code To use the table find the displayed number in the first column identify the affected module from the second column apply the formula from
154. the four bolts nuts white arrows to separate the Gas Collector Tube Flange from the gas supply piping f 4 Y A N Figure 7 16 Uninstall Gas Collector Flange from Gas Supply Piping Step 13 13 Refer to Figure 7 17 for location of burner assembly lifting screws There is one at each end Elevate the burner assembly slightly until screw is lined up with the tab hole then unscrew the lift screw until it extends into the hole Do this at both ends Tab Hole The burner assembly is elevated slightly to line up this screw with the tab hole Then using a 4mm open hex wrench the screw is extended into the hole See Figures 7 17 amp 7 18 Figure 7 17 Location of Burner Assembly Lifting Screw Step 14 Page 132 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Disassembling the Boiler for Maintenance Continued Figure 7 19 Lift Screws Extended into Tab Holes Left and Right Sides Step 14 14 Refer to Figure 7 20 then lift up the front of the burner assembly and raise up until the two lift pins can be inserted Figure 7 22 at the left and right sides in order to hold up the burner assembly X Figure 7 20 Lifting Barnet Assanibly Wan Front Step 15 0087 OF AERCO International Inc e 100 Oritani D
155. the third column and identify the Error Table to reference from the fourth column Table 6 1 Determining the Error Code Reading from the E8 Controller Display Observed Code nd Code to Look Up in Table Code between 256 and 511 BMM amp 1Fault Subtract256fromreading 64 Code between 512 and 767 6 4 Code between 768 and 1023 6 4 Code between 1024 and 1279 BMM 4 Fault Subtract 1024 from reading 64 Code between 1280 and 1535 BMM 5 Fault Subtract 1280 from reading Code between 1536 and 1791 BMM 6 Fault Subtract 1536 from reading 6 4 Code between 1792 and 2047 BMM 7 Fault Subtract 1792 from reading Code between 2048 and 65279 N A Invalid Codes NE Code above 65280 BCM Fault Subtract 65280 from reading 6 3 Example Based on the above a code reading of 261 means the fault occurred on BMM 44 The fault code is 261 256 2 5 An Error Code of 5 from the BMM Fault Codes table means Flame Loss During Page 114 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 6 1 1 E8 Controller Fault Codes The table below lists the fault codes and fault descriptions associated with the E8 Controller Table 6 2 E8 Controller Fault Codes FAULT CODE FAULT DESCRIPTION PCB Element Fault E4 intervention of the high limit thermostat TL X __
156. to be judged for water characteristics should be taken from the return pipe of the primary circuit downstream of the circulating pump 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 43 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 16 Important Installation Warnings 3 16 1 Oxygen Levels in the System Water Warning All necessary precautions must be taken for preventing the formation and localization of oxygen in the system s water For this reason ensure that the plastic piping used in under floor heating systems is impermeable to oxygen 3 16 2 Antifreeze Compatibility Warning If any anti freeze solutions are used ensure that they are compatible with aluminum and any other boiler components and materials 3 16 3 Lime Scale and Corrosive Water Damage Warning Any damage caused to the boiler due to the formation of lime scale or by corrosive water will not be covered by the warranty Appropriate steps must be taken to ensure the indirect tank water heater does not become plugged by scale caused by hard water or sediment If the indirect tank water heater becomes plugged by either scaling from hard water or sediment it is not the responsibility of AERCO International 3 16 4 Connection to Refrigeration System Warning The boiler when used in connection with a refrigeration system must be installed so th
157. ty of mineralization desposits caused by improperly treated water the thermal exchange efficiency may be seriously reduced and can result in very dangerous localized overheating AERCO suggests treating and conditioning feed water for the heating circuit in the following Cases When the hardness of the water is higher than 9 grains 15 f For cold hot water installations with large water content e Renewal of the water system due to uncontrolled leakages e Subsequent refilling of the system due to maintenance work on the installation e Presence of different metals the water circuit Properly treated system and feed water will eliminate or substantially reduce the following problems lime scale deposit corrosion sludge deposits microbiological growths molds bacteria etc An appropriate treatment of the supply water will prevent the above stated problems and will maintain the correct operation and efficiency of the boiler over time In order to properly treat water for use in a hydronic boiler heating system the following physical chemical characteristics must be addressed Water Hardness If water hardness is over 6 to 9 grains a water softener must be used Sediment If sediment is present in the system a sediment filter or other appropriate device must be used Water pH f water has pH above or below 5 then the water must be treated to provide medium pH of between 5 and 8 The system water
158. uitable pipe joint compound for component and piping connections described in the following steps Refer to Figure 5 for component identification 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 39 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Installing the Pressure Relief Valve and Other Components Attach manifold to the outlet supply connection on the boiler via the flanged connections Cut the flow switch for 2 1 2 pipe as directed in the flow switch paddle packaging For installations expecting less than a 10 gpm flow the switch must be adjusted as follows a With no flow turn adjustment screw on the switch counter clockwise until the switch trips b Then turn screw 1 2 turn clock wise and continue installation Connect the following components to the tapped holes in the manifold assembly see Figure 3 16 3 4 Pressure Relief Valve e Flow Switch e Pressure Temperature Gauge Check to ensure that all components are securely tightened and that the flow switch paddle moves freely without interference Locate the BMM module with the FL label at the unit front Figure 3 17 and remove the black jumper wire from the terminals of the connector shown in the detail of Figure 6 Connect the two flow switch wires to the two terminals Flow switch wires have no polarity so can be inser
159. ust 122 Z 321 Cleaning the Condensate Drai Elie opo MIR EIN Een EE ERO NE IRI E eas ER hori 123 7 4 Checking CSD 1 Manifold Flow Switch eese nennen nennen nnne nnn nnns sna annes naar nne 123 SNU Inspection The pe hue Era PI Ee RE 124 7 6 Proper Reassembly and Resealing of the Vent Air Intake System 124 7 7 Pressure Switch Hoses And 5 125 7 8 Burner Heat Exchanger Cleaning Procedure cccccccccccccccccccceccccccccccececccceeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 126 7 9 Heat and Return Sensor Resistance 126 FAO uy y CS 127 7 11 Cleaning the Burner Module and Combustion 134 7512 Reassembly or the Burber MOGOHIBS uuu deii em Rea e a Ue EYE eet iso cy I 136 7 13 Final Procedures After MaintenaliCe ooa a otro erue ne rev y etu YU Pe deg 136 JAA Maintenance Kit Part teer oo o RERBA IRAE Fox 137 TAS Accessory KIE Part NUIT GIGS I RR a vns 138 CHAPTER 8 SPARE PARTS DRAWING AND LISTS 13
160. ut any gas then smell for gas including near the floor If you smell gas STOP Follow the instructions WHAT DO IF YOU SMELL GAS that are printed above in these warnings If you do not smell gas go to the next step 7 Turn on all electric power to the appliance 8 Turn the start up switch next to the E8 controller to the ON position Replace the control access panel 9 Set Thermostat to the desired temperature 10 If the appliance will not operate follow instructions to turn off the gas see below and then call your service technician or gas supplier TURN OFF GAS TO APPLIANCE EN 1 Set the thermostat to its lowest setting gru E B9 2 Turn off all electric power to the appliance if service is to be performed 3 Close the gas valve OMM 0087 OF AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 67 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual 3 32 Testing The Ignition Safety Shut Off Device n Ignition Safety Shutoff Device Test Power on by switching on the ON OFF switch Create a request in C H Central Heating using the E8 controller Turn burners ON Disconnect the igniter cable WHITE of BURNER 1 See Figure 7 2 NOTE Ensure the cable end is not grounded to the enclosure frame or to any other grounded part The display will show ERROR CODE
161. v 14 1 11 5 Returning a Boller to Service 2 u L e nent tta 14 LII Chansa Ip tanus u aS a ia 14 1 12 Operational Limits OF the Bollef Sa Su LM 14 CHAPTER 2 TECHNICAL FEATURES AND 85 2 21 15 2 1 Niodulex EXT Techni6al Featuresuuu uu ar QE pedis Ure Os 15 271 Temperature Control DeviC657 EE 15 2 1 2 Control Panel ES Includes uat ie ptor EN u ON eei TAE 15 2 1 3 Other Features Include ei pic M MU CIN SM M 15 2 2 General Boller DDOrablor ss u I Sa Q sot xs ocn pu tuis 16 2 3 BHmne sionaliDE GOWINGS u us E 17 2 4 Pertormabee Dal u u 21 CHAPTER 3 INSTALLATION INSTRUCTIONS 23 SL Geheral ud Icd Sa OD EE iE 23 3 1 AD propriate Use the Boi oru suan mun ma 23 3 1 2 Prerequisite System osea a 23 3 1 3 Installation Personnel Qualifications ice
162. valve fitted on the gas supply circuit but not to the boiler so as to guarantee the running of the pump and permit the boiler to cool down 3 24 4 Electrical Requirements Nochanges may be made to the wiring of the boiler All connections should be designed in accordance with the applicable regulations e label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation e Verify proper operation after operation servicing NOTE Verify proper operation of the boiler after all servicing operations Page 54 of 146 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0087 OF 07 13 15 Phone 800 526 0288 GF 143 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manual Terminal block E8 back Terminal block BCM back pe CUNG PE T c abs ica ZU E Figure 3 28 120VAC Power Wiring for Main Electrical Junction Box and Signal Wiring for E8 Controller and Boiler Control Module BCM WARNING 120 VAC cables shall be separated from 24VAC and signal wires using the two plastic conduits supplied within the boiler casing LEFT HAND side panel OMM 0087_0F International Inc 100 Oritani Dr Blauvelt NY 10913 Page 55 of 146 GF 143 Phone 800 526 0288 07 13 15 MODULEX EXT 321 481 641 802 962 1123 BOILERS Installation Operation amp Maintenance Manu

Modulex EXT 321- 1123 User Manual (GF-143)

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