Watts Aerco Modulex EXT Series, User Manual

Page 1: ...NY 10913 Page 1 of 144 GF 139 Phone 800 526 0288 09 15 2017 GF 139 INSTALLATION OPERATION MAINTENANCE Modulating and Condensing Boilers Latest Update 09 15 2017 APPLIES TO MODELS MLX EXT 1530 MLX EXT...

Page 2: ...r Servicing 18 2 11 5 Returning a Boiler to Service 18 2 11 6 Change in Ownership 18 2 12 OPERATIONAL LIMITS OF THE BOILER 18 CHAPTER 3 TECHNICAL FEATURES DIMENSIONS 19 3 1 MODULEX EXT COMMERCIAL TECH...

Page 3: ...t Ventilation and Combustion Air 43 4 21 2 Room Air Combustion 44 4 21 3 Sealed Combustion 44 4 22 INSTALLATION OF THE EXHAUST AND AIR INTAKE SYSTEM 45 4 22 1 Important Factors for Terminal Orientatio...

Page 4: ...D SUB MENU DESCRIPTIONS 92 6 3 1 Menus Top Level 92 6 3 2 Sub Menus 92 6 4 GENERAL MENU 93 6 5 SERVICE MENU 95 6 6 DISPLAY MENU 97 6 7 USER MENU 99 6 8 TIME PROGRAM MENU 101 6 9 EXPERT MENU 102 6 10 O...

Page 5: ...2 8 5 1 FLAME COLOR 122 8 6 PROPER REASSEMBLY AND RESEALING OF THE VENT AIR INTAKE SYSTEM 122 8 7 PRESSURE SWITCH HOSES AND CONNECTIONS 123 8 8 BURNER HEAT EXCHANGER CLEANING PROCEDURE 124 8 9 HEAT AN...

Page 6: ...Modulex EXT Commercial Series Boilers User Manual Page 6 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 This Page Intentionally Blank...

Page 7: ...ost importance to observe all CAUTIONS and WARNINGS presented in this manual to avoid injury death and damage to the equipment Failure to properly heed safety warnings and cautions may result in the v...

Page 8: ...asfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall...

Page 9: ...1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system D MANUFACTURER RE...

Page 10: ...Commercial Series Boilers User Manual CHAPTER 1 Safety Precautions Page 10 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 This page in...

Page 11: ...required for end use AERCO recommends inspecting the state of cleanliness of the domestic hot water heat exchanger at the end of the first year and subsequently on the basis of the lime scale found th...

Page 12: ...ersons 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 techni...

Page 13: ...s may occur during ignition If this happens contact the liquid gas tank s supplier WARNING Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other applia...

Page 14: ...0288 GF 139 2 7 DATA PLATE A sample Data Plate for a MODULEX EXT Commercial boiler is shown in the left figure below A sample of the Data Packaging label is shown in the right image below Figure 2 1 M...

Page 15: ...densing 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 conn...

Page 16: ...itors or other additives unless approved by AERCO for that purpose When frost protection of the heating system is desired only use AERCO approved antifreezes The allowed maximum concentration is 50 Wh...

Page 17: ...rvicing 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...

Page 18: ...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 throughou...

Page 19: ...dules capable of between 83 and 382 5 kBTU hr These boilers are designed for use with category IV venting The boiler is supplied complete with all the safety and control devices in accordance with all...

Page 20: ...reset input Warning alarm relay Stainless steel condensate collector tank with siphon drain trap and smoke chamber Easily removable stainless steel panels painted for outdoor installation Built in ai...

Page 21: ...nual CHAPTER 3 Technical Features Dimensions OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 21 of 144 GF 139 Phone 800 526 0288 09 15 2017 3 3 DIMENSIONAL DRAWINGS Figure 3...

Page 22: ...RCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 TABLE 3 1 MODULEX EXT Commercial Dimensions and Sizes DN 80 3 ASME B16 5 Flange 150 lbs sq inch...

Page 23: ...ial Main Components Left Side View Flue Exhaust connection is located on the RIGHT HAND side supply condition but may be moved to LEFT or REAR positions Air Intake connection is located on the LEFT HA...

Page 24: ...100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 3 4 PERFORMANCE DATA TABLE 3 2 MODULEX EXT Commercial Performance Data MODULEX EXT MODEL EXT 1530 1500 EXT 1912 EXT 22...

Page 25: ...and flue outlet can be made only after this verification has been carried out 4 1 3 Installation Personnel Qualifications The appliance MUST be installed by a qualified engineer or technician who com...

Page 26: ...ters and small boilers and process heaters CSD 1 Controls and safety devices for automatically gas fired boilers 4 3 PACKAGING The MODULEX EXT boiler is delivered assembled and protected by a plastic...

Page 27: ...lling off Protect all parts against impacts during transportation 4 5 UNPACKING THE BOILER CAUTION The packing elements cardboard box straps plastic bags etc should be kept away from children to preve...

Page 28: ...ifold CARDBOARD BOX 1 Gasket between exhaust manifold and adaptor Four 4 piping elbows a piping tee and plastic plug for condensate draining system Hardware for assembling exhaust manifold Three 3 sen...

Page 29: ...be a 100 mm deep well or trench next to the boiler to accommodate the condensate U drain pipe see Figure 4 3 After installation the boiler shall be perfectly horizontal and stable to reduce any possi...

Page 30: ...ic acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents Adhesives used to fasten building products Other dama...

Page 31: ...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 p...

Page 32: ...kup or with the boiler running is 10 5 inches W C Minimum pressure with gas flowing verify during boiler startup is 4 0 inches W C 4 9 2 Propane Gas Connections Propane Gas Piping Sizes 4 9 2 1 Contac...

Page 33: ...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 boi...

Page 34: ...2 Pressure Relief Valve must be installed on older models only Flow Switch Pressure Temperature Gauge The pressure relief valve and all other manifold components are shown in Figure 4 6 OLDER MODELS...

Page 35: ...nsure that all components are securely tightened and that the flow switch paddle moves freely without interference 6 Locate the BMM module with the FL label Figure 4 7 and remove the black jumper wire...

Page 36: ...nce curve of the boiler is shown in the diagram in Figure 4 8 The pump is not an integral part of the boiler It is recommended to choose a pump with the rate and delivery head at about 2 3 of its char...

Page 37: ...sioned 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...

Page 38: ...eated 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 treatme...

Page 39: ...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...

Page 40: ...t For venting systems in the USA it is necessary to assemble the Euro to USA adaptor to the flue manifold as shown in Figure 4 12 Figure 4 12 Assembly of USA to European Flue Adaptor to Flue Manifold...

Page 41: ...der to prevent the formation of ice during the operation the temperature of the internal wall of the flue exhaust system should not be below 32 F 0 C throughout its length For efficient venting of the...

Page 42: ...T 2295 2300 EXT 2677 2600 EXT 3060 3000 12 Stainless Contact vent manufacturer Polypropylene Contact vent manufacturer PVC 58115 2 In the case of PVC venting the flue venting pipe is affixed to the ad...

Page 43: ...A 54 or Sections 7 2 7 3 or 7 4 of CAN CSA B149 1 05 installation codes or applicable provisions of the local building codes 4 21 1 Insufficient Ventilation and Combustion Air BOILER DAMAGE AND OPERAT...

Page 44: ...ll commence within 12 inches 305 mm of the top and one opening shall commence within 12 inches 305 mm of the bottom of the enclosure The minimum dimension of air openings shall not be less than 4 inch...

Page 45: ...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 free...

Page 46: ...te horizontally However if venting is vertical then there is no minimum wall thickness 4 23 VENT PIPE SIZING The maximum length is the combined length of straight horizontal and vertical runs and the...

Page 47: ...ctions OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 47 of 144 GF 139 Phone 800 526 0288 09 15 2017 NOTE The flue system must be installed in accordance with the local and...

Page 48: ...te to satisfy the appliance s maximum power requirements indicated on the data plate verifying in particular that the cables are suitable for the appliance s maximum power use CAUTION For the applianc...

Page 49: ...ure for yourself that it cannot be accidentally turned on 4 24 3 Service Relay Requirement Upstream of the electrical connection a service relay is required not supplied which when the additional elec...

Page 50: ...NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 Figure 4 18 120VAC Power Wiring for Main Electrical Junction Box and Signal Wiring for E8 Controller and Boiler Control Module BCM WARNING 120...

Page 51: ...User Manual CHAPTER 4 Installation Instructions OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 51 of 144 GF 139 Phone 800 526 0288 09 15 2017 Figure 4 19 Main Power Junction...

Page 52: ...cial Series Boilers User Manual CHAPTER 4 Installation Instructions Page 52 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 This Page I...

Page 53: ...al CHAPTER 4 Installation Instructions OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 53 of 144 GF 139 Phone 800 526 0288 09 15 2017 4 25 FUNCTIONAL WIRING DIAGRAM Figure 4...

Page 54: ...cial Series Boilers User Manual CHAPTER 4 Installation Instructions Page 54 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 This Page I...

Page 55: ...oilers User Manual CHAPTER 4 Installation Instructions OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 55 of 144 GF 139 Phone 800 526 0288 09 15 2017 4 26 LADDER DIAGRAMS Fig...

Page 56: ...NMENTS 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 fo...

Page 57: ...es Boilers User Manual CHAPTER 4 Installation Instructions OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 57 of 144 GF 139 Phone 800 526 0288 09 15 2017 Figure 4 23 E8 Contr...

Page 58: ...es Boilers User Manual CHAPTER 4 Installation Instructions Page 58 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 Figure 4 24 Sensor a...

Page 59: ...er Manual CHAPTER 4 Installation Instructions OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 59 of 144 GF 139 Phone 800 526 0288 09 15 2017 4 29 INSTALLATION EXAMPLES Functi...

Page 60: ...ulex EXT Commercial Series Boilers User Manual CHAPTER 4 Installation Instructions Page 60 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF...

Page 61: ...this reason the unit s supply voltage gas pressure and water pressure must be maintained and available during these activities WARNING Following maintenance or other activities always check the integr...

Page 62: ...exceeds 9 grains the water must be treated until below the maximum value of 9 grains The pH value of the installation water must be between 6 5 and 8 Check the pH value using proper equipment or by ha...

Page 63: ...of the control system and any gas control device that has been submerged under water WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch or operate any electric switch Do not u...

Page 64: ...HITE of BURNER 1 See Figure 8 2 NOTE Ensure the cable end is not grounded to the enclosure frame or to any other grounded part 5 The display will show Fault Code E05 Loss of Flame Figure 4 25 Loss of...

Page 65: ...ion to the mains supply system the gas valve must be re calibrated using Service Mode function in the E8 controller 4 33 1 Installing the Gas Analyzer Probe Before making adjustments a gas analyzer se...

Page 66: ...the maximum gas output level for each valve Adjusting the Maximum A Gas Output Setting 1 Remove the cap of the combustion gases sampling point Figure 4 27 and connect a suitable gas analyzer 2 Operate...

Page 67: ...ler NOTE If the CO2 percentage is too low check if the air and exhaust flue are obstructed If they are not obstructed check if the burner and or the exchanger aluminum sections are properly cleaned Af...

Page 68: ...Min Gas Consumption ft 3 hr m 3 hr Max Gas Consumption ft 3 hr m 3 hr Start Output IG Min Max Min Max Min FL Max FH NOMINAL ALTITUDE Natural 7 1 74 8 5 10 3 1 5 8 26 84 0 35 9 79 8 2 26 1832 51 8 50...

Page 69: ...042 29 5 50 HIGH ALTITUDE Natural 7 1 74 8 5 10 3 1 5 8 28 100 0 35 9 79 8 2 26 2565 72 5 50 Propane 11 2 74 10 2 10 6 1 3 3 1 26 76 0 35 9 32 4 0 92 938 26 6 50 EXT 3060 3000 Gas Type Supply Pressure...

Page 70: ...age 70 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 4 34 SWEEPER MODE MANUAL CONTROL Figure 4 30 Sweeper Mode Manual Control NOTE Th...

Page 71: ...parameters Figure 4 31 Adjusting Fan Speed to Set Input Range for High Altitude NOTE See the value of parameter FH FAN MAX in Table 4 7 MODULEX EXT Pressure and CO 2 Level Calibration Tables WARNING T...

Page 72: ...IM 10 No Change BOIL P VAL 25 No Change BOIL I VAL 12 No Change BOIL D VAL 00 No Change PUMP OVERRUN 05 No Change PUMP MIN MOD CAP FLOW RATE FAN P VAL 04 No Change FAN I VAL 08 No Change FAN SLP FAN S...

Page 73: ...eed parameter FH FAN MAX from the E8 controller as shown in Table 4 6 MODULEX EXT Pressure and CO2 Level Calibration Tables in Section 4 33 4 This parameter requires a password to change 2 Adjust CO2...

Page 74: ...rmostatic Lockout from GTL General Limit Thermostat E Main Switch F Change over Series Parallel 0 Emergency is active or the control is managed by PLC or BMS I Series connection the cascade is managed...

Page 75: ...f 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 boile...

Page 76: ...cial Series Boilers User Manual CHAPTER 4 Installation Instructions Page 76 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 This Page I...

Page 77: ...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 ma...

Page 78: ...Mode ITEM FUNCTION A Current time 24 hour format B DCF reception OK only if receiver is connected via eBUS C Display of the active heating program for the first heating circuit here 6 00 to 08 00 a m...

Page 79: ...TABLE 5 2 E8 HEATING Mode Features Functions NORMAL Mode SYMBOL MODE NAME DESCRIPTION Heating Mode Selection Turn the Rotary Knob to select the heating mode required The heating mode is indicated by a...

Page 80: ...the display can be changed using the Rotary Knob A D Optical Adaptor For PC connection E Program Key Used to select a sub menu level select a parameter value to change or save a new parameter value F...

Page 81: ...splay advances to the DISPLAY menu The dial on the clock face will rotate one revolution counterclockwise and then go off The display will then show INSTALLATION which is the first sub menu in the DIS...

Page 82: ...he display see Figure 5 5 Press Program Key to access parameters in the selected displayed sub menu Turn Rotary Knob to sequence through the available parameters To change a parameter value press the...

Page 83: ...r module s in the boiler can maintain the system load requirements thereby providing a level of redundancy that was previously only realized in multi boiler installations A photo of the module is show...

Page 84: ...two position rocker switch resets clears fault relay and LED when activated D SW1 10 Position Rotary Switch Rotary switch labeled 0 9 Sets the corresponding address of Boiler on the input Modbus or EB...

Page 85: ...control The E8 does not control the boiler and the BCM will take over the boiler if the Modbus signal fails If E8 is in Standby Mode BCM will cycle the pump with the boiler If E8 is in Day Mode the E...

Page 86: ...al Series Boilers User Manual CHAPTER 5 E8 Controller and BCM Modules Page 86 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 This Page...

Page 87: ...8 CONTROLLER This chapter introduces the E8 controller basic menus sub menus needed to set up the MODULEX EXT boiler Refer to Chapter 4 for instructions for using the E8 controls to navigate and chang...

Page 88: ...ialize 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 th...

Page 89: ...the most basic settings in the E8 controller including maximum and minimum flow temperature room temperature settings heat slope and initiation of heating programs IMPORTANT Before the boiler may be u...

Page 90: ...0 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 6 2 2 Setting Room Temperature and Outdoor Compensation Figure 6 3 E8 Quick Start Roo...

Page 91: ...R 6 Operation of the E8 Controller OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 91 of 144 GF 139 Phone 800 526 0288 09 15 2017 6 2 3 Setting Heating Programs and Pumps Fig...

Page 92: ...tions 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...

Page 93: ...ation of the E8 Controller OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 93 of 144 GF 139 Phone 800 526 0288 09 15 2017 6 4 GENERAL MENU The GENERAL menu contains the sub m...

Page 94: ...NTH Adjust current month 01 12 DAY Adjust current day 01 31 HOLIDAY YEAR START Set current holiday start year XXXX MONTH START Set current holiday start month 01 12 DAY START Set current holiday start...

Page 95: ...auvelt NY 10913 Page 95 of 144 GF 139 Phone 800 526 0288 09 15 2017 6 5 SERVICE MENU The SERVICE menu contains the TEST RELAY SENSOR TEST and OTHER PARAMETERS sub menus as shown below NOTE The SERVICE...

Page 96: ...wer buffer storage temperature F2 Middle buffer storage temperature or room temperature heating circuit 1 F3 Upper buffer storage temperature F5 Flow temperature heating circuit 2 F6 Upper hot water t...

Page 97: ...velt NY 10913 Page 97 of 144 GF 139 Phone 800 526 0288 09 15 2017 6 6 DISPLAY MENU The DISPLAY menu contains the INSTALLATION HOT WATER HTG CIRCUIT 1 2 and SOLAR MF sub menus as shown below Figure 6 7...

Page 98: ...T STORAGE 3 Temperature of storage tank 3 e g solar pool heating MODGRAD Modulation level for each module RETURN HOT WATER T DHW RATED Hot water set temperature value T DHW Hot water temperature valu...

Page 99: ...e E8 Controller OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 99 of 144 GF 139 Phone 800 526 0288 09 15 2017 6 7 USER MENU The USER menu contains the INSTALLATION HOT WATER...

Page 100: ...F 0 0 1 RETURN HTG CIRCUIT 1 2 MODE When setting an alternative oparating mode this only applies to the assigned heating circuit T ROOM DES 1 Room temperature setting in first enable time 68 41 105 T...

Page 101: ...ABLE 6 5 TIME PROGRAM Menu LEVEL DESCRIPTION CIRCL TIME Program for circulation pump HOTW PROG Program for hot water charging pump HTG PROG 1 1 1st Heating program for first controller heating circuit...

Page 102: ...PTER 6 Operation of the E8 Controller Page 102 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 6 9 EXPERT MENU The EXPERT menu contains...

Page 103: ...RCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 103 of 144 GF 139 Phone 800 526 0288 09 15 2017 Figure 6 10 EXPERT Menu 2 of 2 NOTE The shaded items in the following table indicate those p...

Page 104: ...overheating 185 F 86 230 MIN T HS2 Decreased condensation build up in HS with low heat requirement 104 F 50 176 V CURVE Only for 0 10V input output 11 00 11 CURVE 11 U1 Low voltage set 0 V 0 V 10 V CU...

Page 105: ...y time after switching on or with switching HS 01 00 30 HYST BURNER2 Solid fuel integration hysteresys for the charging pump 4 3 6 36 Ra HS COOL FCT Not used 0 0 1 T HS COOL Not used 176 122 203 HEATS...

Page 106: ...0 90 B HEAT SINK Circuit enable 0 00 01 RETURN SOLAR MF RELAY FUNC 1 to 4 Function selection relay 1 to 4 0 00 26 T MF1 to 4 SETP Switching temperature relay MF1 to 4 86 86 194 MF 1 to 4 HYST Hystere...

Page 107: ...ssibility to use one of the heating zones for the heating of a swimming pool EXPERT menu Heating circuit I II HC FUNC 02 Swimming Pool Temperature Setting 6 10 1 6 Only After Function Selection USER m...

Page 108: ...1 4 0 V 0 1 V 68 F 194 F 5 0 V 6 10 2 Setting of DHW Circuit Operation of Pumps In Parallel 6 10 2 1 Heating pump operation during DHW production EXPERT menu Hot Water F PUMP PARAL 00 01 02 03 Use of...

Page 109: ...r faults communication faults and internal faults These fault codes are shown in Table 7 2 BCM Boiler Control Module These fault codes are shown in Table 7 3 BMM Burner Management Module These fault c...

Page 110: ...LOOK UP IN TABLE Code 0 N A No Fault Code between 1 and 255 BMM 0 Fault Look up code 6 4 Code between 256 and 511 BMM 1 Fault Subtract 256 from reading 6 4 Code between 512 and 767 BMM 2 Fault Subtrac...

Page 111: ...e Ensure sufficient gas pressure and flow during high fire operation and with any other connected gas equpiment running Check and clean flame rod AUTOMATIC Clear fault and retry ignition E 6 Over high...

Page 112: ...n 30 seconds from end of operation Boiler will not ignite Check Expert HS fan speed settings Check fan wiring May require a new blower AUTOMATIC E 28 Common chimney obstruction Boiler will not run Che...

Page 113: ...rage temperature sensor SPF Check continuity Use multimeter to measure sensor AUTOMATIC E 78 E8 F8 Boiler temperature sensor KF Check continuity Use multimeter to measure sensor AUTOMATIC E 80 E8 F2 R...

Page 114: ...ck all eBUS addresses E 202 Communication Error HS1 Communications issue with BMM 2 Check all eBUS addresses E 203 Communication Error HS1 Communications issue with BMM 3 Check all eBUS addresses E 20...

Page 115: ...perature protection Flow temperature Return Temperature Water Temp Protection 50 F All burners turned OFF and Pump ON at maximum speed Check the system installation AUTOMATIC when temperature Water Te...

Page 116: ...detected at burner start Burner control lockout Check flame rod or combustion MANUAL push reset switch or cycle power E 5 Flame loss during run Ignition retry Check combustion and wiring MANUAL push r...

Page 117: ...sensor is greater than 41 F E 20 Flame signal detected after burner is OFF Ignition is inhibited Disconnect gas valve wire from BMM If failure goes away check wiring or change BMM If failure remains c...

Page 118: ...of control It doesn t stop within 30 seconds after turned OFF Ignition is inhibited Check fan wiring AUTOMATIC E 27 Air flow failure during ignition Restart pre purge timer The failure remains until...

Page 119: ...ed Regular maintenance will prolong the life of the boiler WARNING If the boiler is not checked and serviced regularly it could cause damage to the equipment and or harm to persons TABLE 8 1 MODULEX E...

Page 120: ...rds 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 a...

Page 121: ...ts flush them out with clean water 3 Reassemble the drain in reverse order Figure 8 1 Condensate Drain Location WARNING Before operating the boiler it is absolutely necessary to verify that the conden...

Page 122: ...through the flame observation port Figure 8 2 The flame pattern should resemble the flame in the illustration below 8 5 1 FLAME COLOR YELLOW CO2 HIGH NOT SATISFACTORY BLUE CO2 LOW NOT SATISFACTORY ORA...

Page 123: ...Phone 800 526 0288 09 15 2017 8 7 PRESSURE SWITCH HOSES AND CONNECTIONS If pressure switch hoses need to be replaced ensure that new hose lengths are identical to the old hose lengths If too long the...

Page 124: ...11 NOTE A reduction of the input can be caused by the obstruction of the vent or air intake Before cleaning the boiler body sections check the boiler input and the O2 percentage see section 4 33 8 9 H...

Page 125: ...and ensure it is completely closed 2 Unlatch the top lid and raise the lid Figure 8 4 3 Remove screws from top of unit holding the front rear and side panels in place Figure 8 5 Remove the panels by...

Page 126: ...ing the Boiler for Maintenance Continued 4 Remove ten 10 screws from around exhaust outlet opening and remove flue assembly from unit Figures 8 7 8 8 Figure 8 8 Flue Removal Step 4 5 On each side of t...

Page 127: ...r on each one separately as described in a and b below a All Modules Use a 13mm wrench to remove all A and C nuts surrounded by horizontal dotted lines in Figure 8 11 below Leave the B screws affixed...

Page 128: ...Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 Disassembling the Boiler for Maintenance Continued Figure 8 11 Removing the Burner Module Plate Covers Step 7 8 Use a 36 mm wrench t...

Page 129: ...ift up the front of the burner assembly until the two lift pins are aligned with the left and right side tab holes refer to Figure 8 13 Figure 8 13 Location of Burner Assembly Lifting Screw Step 9 10...

Page 130: ...017 Phone 800 526 0288 GF 139 Disassembling the Boiler for Maintenance Continued 11 Refer to Figure 8 16 lift up the burner plates to expose the burner modules and latch it in place Figure 8 16 Liftin...

Page 131: ...2 Use only compressed air to clean the burners by blowing into the flame side of the burner mesh as shown in Figure 8 20 Figure 8 20 Burner Module Profile Compressed Air Orientation Step 2 3 Visually...

Page 132: ...g normal operation 8 12 1 Mechanical Cleaning of the Heat Exchanger Complete the instructions below to mechanically remove as much combustion by product as possible from each burner s combustion chamb...

Page 133: ...h pin 4 Repeat the previous step on each burner module in the unit 5 After mechanical cleaning rinse each heat exchanger with water until no further debris comes out 6 After washing the aluminum compo...

Page 134: ...s solution sit for more than 20 minutes as over exposure could damage the heat exchanger 5 Collect and dispose of the used solution and rinse water according to local regulations DO NOT dispose of rin...

Page 135: ...reattach tension spring clip to left and right ends of manifold e Proceed to section 8 14 for final procedures before returning boiler to service 8 14 FINAL PROCEDURES AFTER MAINTENANCE Before returni...

Page 136: ...03 EXT 641 600 OR EXT 1530 1500 ANNUAL MAINTENANCE KIT 58086 04 EXT 802 800 OR EXT 1912 ANNUAL MAINTENANCE KIT 58086 05 EXT 962 OR EXT 2295 2300 ANNUAL MAINTENANCE KIT 58086 06 EXT 1123 1100 OR EXT 26...

Page 137: ...ODULEX EXT Accessory Kits are available 58096 for MODULEX EXT models 1530 1500 1912 58097 for MODULEX EXT models 2295 2300 2677 2600 3060 3000 The contents of each are listed in the table below TABLE...

Page 138: ...ercial Series Boilers User Manual CHAPTER 8 Maintenance Schedule Page 138 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 This Page Int...

Page 139: ...ies Boilers User Manual CHAPTER 9 Spare Parts and Drawing Lists OMM 0095_0H AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 139 of 144 GF 139 Phone 800 526 0288 09 15 2017 CHAPTER 9 SPAR...

Page 140: ...l Series Boilers User Manual CHAPTER 9 Spare Parts and Drawing Lists Page 140 of 144 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0095_0H 09 15 2017 Phone 800 526 0288 GF 139 This Page...

Page 141: ...LY MLX EXT 3000 3060 1 8 95213960 Left Side Panel MLX EXT 1500 3060 1 9 95213399 Right Side Panel MLX EXT 1500 3060 1 10 95213400 Plate side closing MLX EXT 1500 3060 1 11 95213402 Casing Front Panel...

Page 142: ...witch Max 1 35 95260588 Automatic Air Vent G3 4 1 36 95611641 Junction box MLX EXT 1530 3060 1 37 95261357 Boiler Drain Cock G 3 4 1 38 95263795 Thermal breaker 1 39 95263802 Air Pressure Switch MLX E...

Page 143: ...11410 Flame Detector Cable MLX EXT 1500 3060 1 69 95900234 Sheat probe holder FOR OUTLET TEMPERATURE SENSOR 1 70 95251906 Flanged flue outlet terminal MLX EXT 1500 3060 1 71 95251937 Flue terminal gas...

Page 144: ...mber cleaning instructions DIR 368 Changed Spare Parts item 50 P N from 95363708 to 95263708 on page 137 Curtis Harvey 09 15 2017 Rev H DIR 17 008 Added new model numbers for units with aluminum water...