user manual

Transcription

user manual

GF-115-H
TAG-0083_0B
Modulating, Condensing,
Hot Water Boiler Models:
•
•
•
•
•
•
Modulex MLX Series
Gas Fired Boiler
MLX-303
MLX-454
MLX-606
MLX-757
MLX-909
MLX-1060
USER MANUAL
Installation, Operation, and Maintenance
Modulex MLX Series Boiler
Other manuals for this product include:
• GF-115-C
• GF-115-E
• GF-115-P-H
• GF-115-V
• GF-115-G
MLX E8 Controller/BCM Manual
MLX Electrical Power Guide
MLX Piping Guide
MLX Venting Guide
MLX Gas Supply Guide
Revised: 10/03/2012
MC2: 10/03/12
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
Page 1 of 90
Modulex MLX Series Gas Fired Boiler System
GF-115-H
Operation and Maintenance Manual
OMM-0083_0B
Technical Support:
(Mon–Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
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 this material.
MC2: 10/03/12
Page 2 of 90
GF-115-H
TAG-0083_0B
TABLE OF CONTENTS
TABLE OF CONTENTS .................................................................................................................... 3
CHAPTER 1: SAFETY PRECAUTIONS .................................................................................. 7
Important – For Massachusetts Installations .............................................................................. 8
CHAPTER 2: GENERAL DESCRIPTION ............................................................................. 11
2.1 Introduction To Technical Features ............................................................................... 11
2.2 Code and Standards Approvals ...................................................................................... 12
2.3 Installation Flexibility .................................................................................................... 12
2.4 Dimensions and Weights ................................................................................................ 13
2.5 Technical Data................................................................................................................ 15
2.6 Modulex Main Components – Side View ...................................................................... 16
2.7 Boiler Freeze Protection ................................................................................................. 17
CHAPTER 3: INSTALLATION ............................................................................................... 19
3.1 Introduction to Installation ............................................................................................. 19
3.2 Installation Instructions .................................................................................................. 19
3.2.1 Unpacking the Boiler .......................................................................................... 19
3.2.2 Boiler Location.................................................................................................... 21
3.2.3 Pad Height for Boiler .......................................................................................... 21
3.2.4 Boiler Connections .............................................................................................. 22
3.3 Data Plate ....................................................................................................................... 23
CHAPTER 4: GENERAL INFORMATION FOR VENTING .............................................. 25
4.1 Vent Pipe Connection..................................................................................................... 25
4.2 Gas Vent Categories ....................................................................................................... 25
4.3 Installation And Sizing ................................................................................................... 25
4.4 Existing Boiler Removal From Common Venting System ............................................ 26
CHAPTER 5: PIPING ................................................................................................................ 27
5.1 Makeup Water Quality ................................................................................................... 27
5.2 Maximum Allowable Working Pressure ...................................................................... 27
5.3 Boiler Loop Design Guidelines ...................................................................................... 27
5.4 CSD-1 Manifold Assembly (Supplied) .......................................................................... 27
5.5 Connecting Supply And Return Piping (Per ANSI Z21.13a) ........................................ 27
5.6 System Filling and Draining .......................................................................................... 28
5.7 Notes On Condensate Drain ........................................................................................... 28
5.8 Gas Mains and Connections ........................................................................................... 28
CHAPTER 6: ELECTRICAL ................................................................................................... 29
6.1 Electrical Connections.................................................................................................... 29
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6.2 DHW (Domestic Hot Water) Storage Tank ................................................................... 31
6.3 Enable / Disable ............................................................................................................. 31
6.4 Installation Of Sensors ................................................................................................... 31
CHAPTER 7: BOILER OPERATION ..................................................................................... 33
7.1 Introduction to Boiler Operation .................................................................................... 33
7.2 Modulation Theory......................................................................................................... 33
7.3 Ignition Sequence ........................................................................................................... 33
7.4 Modes of Operation........................................................................................................ 34
7.4.1 Indoor/Outdoor Reset .......................................................................................... 34
7.4.2 0 To 10 Volt Remote Set-Point ........................................................................... 34
7.4.3 Constant Set-Point ............................................................................................... 34
7.4.4 Boiler Operation for Troubleshooting (Manual Mode)....................................... 34
7.5 Modulex Boiler Initial Startup ....................................................................................... 34
7.5.1 Tools & Instruments Required For Combustion Calibration .............................. 35
7.5.2 Installing the Supply Gas Manometer ................................................................. 35
7.5.3 Preparing The Flue For Use With The Combustion Analyser ............................ 36
7.5.4 Supply Gas Pressure Check & Adjustment ......................................................... 36
7.5.5 Combustion Calibration. ..................................................................................... 38
7.6 Unit Reassembly ............................................................................................................ 40
CHAPTER 8: SAFETY DEVICE TESTING .......................................................................... 41
8.1 Testing of Safety Devices .............................................................................................. 41
8.2 Processing and Clearing Fault Codes ............................................................................. 41
8.3 LOW GAS PRESSURE FAULT TEST......................................................................... 42
8.4 LOW WATER LEVEL FAULT TEST ......................................................................... 43
8.5 WATER TEMPERATURE FAULT TEST ................................................................... 44
8.6 FLAME FAULT TESTS ................................................................................................ 45
8.7 SAFETY PRESSURE RELIEF VALVE TEST ............................................................ 46
CHAPTER 9: MAINTENANCE ............................................................................................... 47
9.1 Modulex Preventative Maintenance Kits ....................................................................... 47
9.1.1 Annual Maintenance Kit ..................................................................................... 47
9.1.2 Fireside Inspection Kit ........................................................................................ 47
9.2 Annual Maintenance Instructions................................................................................... 48
9.2.1 REQUIRED Tasks: ............................................................................................. 48
9.2.2 RECOMMENDED Tasks: .................................................................................. 48
9.2.3 Tools Required .................................................................................................... 48
9.2.4 Replacing the Spark Igniters and Flame Detectors ............................................. 50
9.2.5 Testing the Flame Detection Circuitry ................................................................ 50
9.3 Fireside Inspection Instructions ..................................................................................... 50
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9.3.1 Unit Disassembly for a Fireside Inspection ........................................................ 51
9.3.2 Removing The Burner Modules .......................................................................... 55
9.3.3 Maintenance of Burner Modules and Combustion Chamber .............................. 56
9.3.4 Reassembly After Burner Mainentance .............................................................. 57
9.3.5 Testing the Flame Detection Circuitry ................................................................ 57
9.3.6 Disassembly, Inspection, and Maintenance for the Flue Collector ..................... 57
9.4 Burner Section Replacement Instructions ...................................................................... 59
9.4.1 Disassembly For Burner Section Replacement ................................................... 60
9.4.2 Replacement of Burner Sections ......................................................................... 61
9.4.3 Replacing the Condensate Tray Top Gasket ....................................................... 62
9.4.4 Re-Assembly After Burner Section Replacement ............................................... 64
9.5 Final Testing and Return To Service.............................................................................. 64
CHAPTER 10: TROUBLE SHOOTING GUIDE ................................................................... 65
10.1
Introduction ................................................................................................................ 65
CHAPTER 11: TEMPERATURE SENSOR RESISTANCE CHART.................................. 77
CHAPTER 12: MODULEX PARTS DRAWING AND LIST ................................................ 78
CHAPTER 13: BOILER WATER QUALITY AND MAINTENANCE ............................... 83
13.1
Modulex Boiler Water Chemistry .............................................................................. 84
13.1.1
Reaction of Metals to Water Chemistry .......................................................... 84
13.1.2
Scale and Corrosion ......................................................................................... 84
13.1.3
Make-up or Feed Water Quality ...................................................................... 84
13.1.4
Treating Water to Prevent Freezing................................................................. 84
13.1.5
Water Treatment Certification ......................................................................... 85
13.2
Testing and Maintenance of Water Quality................................................................ 85
13.3
System Flushing, Treatment, and Cleansing .............................................................. 86
13.4
Water Quality Maintenance and Boiler Warranty ...................................................... 87
13.5
Water Treatment Certification .................................................................................... 87
13.6
Water Treatment Analysis and Scheduling ................................................................ 87
13.7
Hydronic Water Testing and Treatment Resources ................................................... 88
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GF-115-H
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CHAPTER 1: SAFETY PRECAUTIONS
The following defined symbols are used throughout this manual to notify the reader of potential hazards of
varying risk levels.
!
Indicates an imminently hazardous situation, which if not avoided, WILL
result in death or serious injury.
! WARNING !
Indicates a potentially hazardous situation, which if not avoided, MAY
result in death or serious injury.
!
DANGER
Indicates a potential hazardous situation, which if not avoided, COULD
result in minor or moderate injury. Also may caution against unsafe
practices.
Note that all hazard notifications and notes are presented enclosed in a rectangle with filleted (round)
corners, as shown below, in order to differentiate them from the main text.
! CAUTION !
It is of utmost importance to observe all CAUTIONS and WARNINGS presented in this manual to avoid
injury, death, and damage to the equipment. Failure to properly heed safety warnings and cautions may
result in the voiding of applicable warranties.
!
WARNING
!
NEVER USE FLAMES TO DETECT GAS LEAKS!
What to do if you smell gas:
• Do NOT try to light or turn on any appliance.
• Do NOT touch any electric switch or open switched doors.
• Do NOT use any phone or intercom device in your building.
• Do NOT touch metal doorknobs or any grounded device or surface without using insulated
gloves or other insulated material if you suspect static charge buildup.
• Immediately call your gas supplier from a neighbor’s phone or, if you are outside, your cell
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
! WARNING !
This boiler has been built for installation in the country indicated on the
technical data plate. Installation in any other country may be a source
of danger for people, animals and property.
NOTE
Carefully read the warranty conditions and clauses on the warranty
certificate attached to the boiler.
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Page 7 of 90
Chap 1: Safety
Precautions
GF-115-H
OMM-0083_0B
Important – For Massachusetts Installations
Boiler Installations within the Commonwealth of Massachusetts must conform to the following
requirements:
•
Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of
Massachusetts.
•
Prior to unit operation, the complete gas train and all connections must be leak tested using a noncorrosive soap.
•
If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed
upstream of the Fill/Makeup Valve.
•
The vent termination must be located a minimum of 4 feet above grade level.
•
If side-wall venting is used, the installation must conform to the following requirements extracted
from 248 CMR 5.08 (2):
A. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or
structure used in whole or in part for residential purposes, including those owned or operated by
the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet
above finished grade in the area of the venting, including but not limited to decks and porches,
the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the
side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional level of the dwelling, building
or structure served by the side wall horizontal vented gas fueled equipment. It shall be the
responsibility of the property owner to secure the services of qualified licensed professionals
for the installation of hard wired carbon monoxide detectors
a) In the event that the side wall horizontally vented gas fueled equipment is installed in a
crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery
back-up may be installed on the next adjacent floor level.
b) In the event that the requirements of this subdivision can not be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as
required in accordance with the above provisions shall comply with NFPA 720 and be
ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior
of the building at a minimum height of eight (8) feet above grade directly in line with the
exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled
equipment shall not approve the installation unless, upon inspection, the inspector observes
carbon monoxide detectors and signage installed in accordance with the provisions of 248
CMR 5.08(2)(a)1 through 4.
(Continued on Next Page)
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Chap 1: Safety
Precautions
GF-115-H
OMM-0083_0B
Important - For Massachusetts Installations
(Continued from Previous Page)
B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 to 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the
most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or
structure separate from the dwelling, building or structure used in whole or in part for
residential purposes.
C. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED:
When the manufacturer of Product Approved side wall horizontally vented gas equipment
provides a venting system design or venting system components with the equipment, the
instructions provided by the manufacturer for installation of the equipment and the venting system
shall include:
1. Detailed instructions for the installation of the venting system design or the venting system
components; and
2. A complete parts list for the venting system design or venting system.
D. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT
PROVIDED: When the manufacturer of a Product Approved side wall horizontally vented gas
fueled equipment does not provide the parts for venting the flue gases, but identifies "special
venting systems", the following requirements shall be satisfied by the manufacturer:
1. The identification of each "special venting system" shall include the listing of either the
website, phone number or manufacturer’s address where the venting system installation
instructions can be obtained; and
2. The "special venting systems" shall be Product Approved by the Board, and the
instructions provided with the system shall include a parts list and detailed installation
instructions.
E. A copy of all installation instructions for the Product Approved side wall horizontally vented gas
fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting
design instructions shall remain with the appliance or equipment at the completion of the
installation.
[End of Extracted Information From 248 CMR 5.08 (2)]
MC2: 10/03/12
Page 9 of 90
GF-115-H
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Page 10 of 90
GF-115-H
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CHAPTER 2: GENERAL DESCRIPTION
!
CAUTION
!
Each AERCO Modulex Boiler is shipped as either a Natural Gas Only
Boiler OR a Propane Gas Only Boiler. It is NOT a Dual-Fuel Boiler.
Ensure that the correct fuel and f
\
2.1
Introduction To Technical Features
Modulex is a compact, modular, gas fired, Low NOx, condensing boiler. The boiler body is comprised of
sections of cast aluminum/magnesium/silicon alloy. The boiler is designed to recover the latent heat of
the combustion gases, thereby allowing it to attain a thermal efficiency of 92% as tested by the
Hydronics Institute, a Division of GAMA. These cast aluminum sections make up modules referred to
as the heat modules. Each module can deliver an output between a maximum of 152 MBH and a
minimum of 45 MBH and are composed of a pre mix combustion chamber, metallic mesh radiant
burner, modulating fan with control pressure switch, gas valve, ignition device, flame detection, NTC
sensor for local temperature control and a safety thermostat.
The heat modules are housed in a single enclosure and are connected to a single exhaust manifold.
These modules are independent of each other and are sequentially staged, a technique known as
cascading, which produces reliable and stable heat at high efficiencies. Each heat module has its own
printed circuit (PC) board that controls and monitors combustion as well as the temperature of each
heat module, providing operational reliability and safety. The entire boiler is controlled by a single
microprocessor. This microprocessor is responsible for the staging and modulation of the heat
modules, monitoring supply and return water temperatures as well as heating and domestic hot water
(DHW) zones. Other features include:
•
The heating load is shared with as many boiler modules as possible running at a minimum output to
ensure the maximum efficiency at partial load operation.
•
Access to all testing/programming parameters of each module: operation test, operation time, boiler
freeze protection from 45°F (7°C), pump’s anti seize program.
•
Lead-lag burner operation based on burner 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.
•
D.H.W. production by a priority sensor, with control capability of a dedicated pump or a 3-way
diverting valve for storage tank temperature control.
•
A service mode for manual operation of individual heat modules capability for troubleshooting or
combustion calibration
•
Diagnostics including relay and sensor testing.
Reliability is improved by the modular design of the Modulex since each heat module is independent of
the other, having its own ignition and combustion safeguard system. If one of the boiler’s heat modules
stops functioning, the remaining module(s) continue to operate.
The Modulex boiler can be comprised of from 2 to 7 modules and 3 to 8 cast aluminum sections. The
input to each heat module is 151.5 MBTU/Hr. The smallest Modulex 303, comprised of two heat
modules, has a combined total input of 303,000 BTU/Hr (2 x 151.5 = 303 MBTU) while the largest, the
1060 comprised of 7 heat modules has a total input of 1060 MBTU’s (See Table 2-1).
For one Modulex 303 boiler consisting of two modules, the output modulates from 15% to 100%. For a
Modulex 1060 boiler consisting of seven modules, the output modulates from 4.3% and 100%. If a
system comprised of two boilers is installed, then the modulation range for each boiler increases to 7.5%
to 100% for the Modulex 303 and 2.2% to 100% for the Modulex 1060.
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Chap 2: General
Description
2.2
GF-115-H
OMM-0083_0B
Code and Standards Approvals
MODULEX has been reviewed for compliance with the applicable sections of the following North
American Standards:
•
Z21.13: Gas fired low pressure steam and hot water boilers.
•
ASME SECTION IV: Boiler and pressure vessel code rules for construction of heating
boilers.
•
BTS 2000: Testing standard method to determine efficiency of commercial space heating
boilers.
•
SCAQMD Rule 1146.2: NOx emissions from water heaters and small boilers.
•
CSD-1-2004: Controls and safety devices for automatically fired boilers.
Table 2-1: Modulex Boiler Output Range, Turn-Down Ratio & Condensate Production
Heat
Modules
Model
Output Range MBH
(KW)
1
Min.
Max.
Turn
Down
Ratio
Condensate Production [gph (l/h)]
Min.
Max.
2
MLX-303
41(12)
279 (82)
6:1
1.3 (5)
3.4 (13)
3
MLX-454
41(12)
418 (122)
10:1
1.9 (7.3)
5.3 (20)
4
MLX-606
41(12)
558 (163)
13:1
2.7 (10.1)
7.1 (27)
5
MLX-757
41(12)
696 (204)
16:1
3.3 (12.6)
9.0 (34)
6
MLX-909
41(12)
835 (245)
20:1
4.0 (15.1)
10.6 (40)
7
MLX-1060
41(12)
975 (286)
23:1
4.6 (17.6)
12.4 (47)
1
MBH = 1000 Btu/hr
2.3
Installation Flexibility
The Modulex boiler allows for installation flexibility, i.e. it is suitable to be connected with the water
supply and return and the gas connections on the Right Hand (right-hand) side (standard delivery
condition) or on the Left Hand (left-hand) side. This is accomplished by reversing the gas and water
manifolds utilizing the instructions supplied with the boiler. The same is true for the vent pipe
connection, which at the installation, can be moved from the right-hand side (standard delivery condition)
to the left-hand side or to the rear of the boiler. The installation flexibility features include the following:
•
Two or more Modulex boilers may be installed in a multiple boiler system with gas connecting pipes,
supply/return water pipes arranged for connection to either the left or right-hand side of each unit.
The unit is shipped with all connections on the right hand side as viewed from the front of the unit.
•
The vent pipe may be installed on the right, the left, or behind the heating system.
NOTE
Installation of the vent behind the unit will require accommodations for
the easy removal of the venting in order to provide service that requires
removal of the rear panel.
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Chap 2: General
Description
2.4
GF-115-H
OMM-0083_0B
Dimensions and Weights
The dimensions and weights for each Modulex Model are shown in Diagram 1 and 2 of Figure 2-1 and
Table 2-2.
FRONT VIEW
13.39”
(340 mm)
L
8.78”
(223 mm)
13.39”
(340 mm)
8.78”
(223 mm)
4.33” (110 mm)
12.40”
(315 mm)
S
16.73”
(425 mm)
4.33” (110 mm)
TOP VIEW
10.55” (268 mm)
13.78”
(350 mm)
ØD
C
B
H
A
13.58
(345 mm)
B
Figure 2-1: Modulex Dimensions and Weights (Diagram 1 of 2)
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Chap 2: General
Description
GF-115-H
OMM-0083_0B
RIGHT HAND SIDE VIEW
LEFT HAND SIDE VIEW
8.35”
(212 mm)
4.96”
(126 mm)
8.35”
(212 mm)
6.90”
(175 mm)
11.86”
(301 mm)
G
G
M
10.43”
(265 mm)
M
8.66”
(220 mm)
R
41.46”
(1053 mm)
8.66”
(220 mm)
R
36.50”
(927 mm)
20.94”
(532 mm)
15.47”
(393 mm)
4.17”
(106 mm)
5.39
17.80” (452 mm)
17.92” (455 mm)
27.36” (695 mm)
Figure 2-1: Modulex Dimensions and Weights (Diagram 2 of 2)
Table 2-2: Modulex Models Dimensions and Weights
MODULEX MODELS
MLX-303
DIMENSIONS
MLX-454
MLX-606
MLX-757
MLX-909
MLX-1060
(2 MODULES) (3 MODULES) (4 MODULES) (5 MODULES) (6 MODULES) (7 MODULES)
HEIGHT
IN (MM)
41.46 (1053)
41.46 (1053)
41.46 (1053)
41.46 (1053)
41.46 (1053)
41.46 (1053)
WIDTH "L" NET
IN (MM)
27.36 (695)
27.36 (695)
32.83 (834)
38.11 (968)
43.39 (1102)
48.66 (1236)
WIDTH W/PACKAGING
IN (MM)
30.32 (770)
30.32 (770)
35.7 (908)
41.0 (1042)
46.3 (1176
51.6/1310
DEPTH "C"
IN (MM)
37.09 (942)
37.09 (942)
37.09 (942)
37.09 (942)
37.09 (942)
37.09 (942)
DEPTH "A"
IN (MM)
27.36 (695)
27.36 (695)
27.36 (695)
27.36 (695)
27.36 (695)
27.36 (695)
DEPTH "B"
IN (MM)
32.28 (820)
32.28 (820)
32.28 (820)
32.28 (820)
32.28 (820)
32.28 (820)
DEPTH W/PACKAGING
IN (MM)
30.71 (780)
30.71 (780)
30.71 (780)
30.71 (780)
30.71 (780)
30.71 (780)
NET WEIGHT
LB (KG)
331 (150)
408 (185)
496 (225)
573 (260)
672 (305)
761 (345)
GROSS WEIGHT
LB (KG)
386 (175)
463 (210)
551 (250)
639 (290)
739 (335)
827 (375)
GAS
IN (MM)
1-1/2 (38)
1-1/2 (38)
1-1/2 (38)
1-1/2 (38)
1-1/2 (38)
1-1/2 (38)
WATER OUTLET (SUPPLY) M
IN (MM)
2 (50)
2 (50)
2 (50)
2 (50)
2 (50)
2 (50)
WATER INLET (RETURN) R
IN (MM)
2 (50)
2 (50)
2 (50)
2 (50)
2 (50)
2 (50)
4 (102)
4 (102)
4 (102)
6 (152)
6 (152)
6 (152)
CONNECTION
EXH. VENT CONNECTION "D" IN (MM)
EXH. VENT WIDTH "H"
IN (MM)
9.45 (240)
9.45 (240)
9.45 (240)
9.45 (240)
9.45 (240)
9.45 (240)
CONDENSATE DRAIN DIA.
IN (MM)
1.57 (40)
1.57 (40)
1.57 (40)
1.57 (40)
1.57 (40)
1.57 (40)
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Chap 2: General
Description
2.5
GF-115-H
OMM-0083_0B
Technical Data
(The Name Plate is placed under the front jacket next to the control panel.)
MIN/MAX INPUT AND OUTPUT:
Model Number
Min Input
Max Input
Max Output*
Net IBR Rating
MLX-303
MLX-454
45,500
45,500
303,000
454,000
260,000-279,000
390,000-418,000
237,000
355,000
MLX-606
45,500
606,000
521,000-558,000
474,000
MLX-757
45,500
757,000
651,000-696,000
592,000
MLX-909
45,500
909,000
835,000-836,000
710,000
MLX-1060
45,500
1,060,000
912,000-975,000
829,000
DIMENSIONS:
Model Number
MLX-303
MLX-454
MLX-606
MLX-757
MLX-909
MLX-1060
Height
42” (1067 mm)
42” (1067 mm)
42” (1067 mm)
42” (1067 mm)
42” (1067 mm)
42” (1067 mm)
Width
28” (711 mm)
28” (711 mm
33” (838 mm)
38” (965 mm)
44” (112 mm)
49” (1245 mm)
Depth
27” (686 mm)
27” (686 mm)
27” (686 mm)
27” (686 mm)
27” (686 mm)
27” (686 mm)
Weight
405 lbs. (183.7 kg)
484 lbs. (219.6 kg)
575 lbs. (260.8 kg)
673 lbs. (305.2 kg)
765 lbs. (346.8 kg)
869 lbs. (394.0 kg)
SPECIFICATIONS:
Model Number
Boiler Category
MLX-454
IV
MLX-606
IV
MLX-757
IV
MLX-909
IV
MLX-1060
IV
Natural Gas
Natural Gas Natural Gas Natural Gas Natural Gas Natural Gas
(MLX-1060B)
(MLX-303B) (MLX-454B) (MLX-606B) (MLX-757B) (MLX-909B)
or Propane
or Propane
or Propane
or Propane
or Propane
or Propane
(MLX(MLX-303BP) (MLX-454BP) (MLX-606BP) (MLX-757BP) (MLX-909BP)
1060BP)
Type of Gas
Gas Connections (NPT)
Max. Gas Pressure
Optimal Gas Pressure
Min. Gas Pressure
Max. Allowed Working
Pressure
Electrical Req:
120V 15 Amp. Max.
Water Connections
(NPT)
Min. Water Flow (GPM)
Max. Water Flow (GPM)
Water Pressure Drop
@ Max. Flow (Ft. of
Head)
MC2: 10/03/12
MLX-303
IV
1.5”
1.5”
1.5”
1.5”
1.5”
1.5”
14” W.C.
14” W.C.
14” W.C.
14” W.C.
14” W.C.
14” W.C.
(34.8 mbar) (34.8 mbar) (34.8 mbar) (34.8 mbar) (34.8 mbar) (34.8 mbar)
7” W.C.
7” W.C.
7” W.C.
7” W.C.
7” W.C.
7” W.C.
(17.4 mbar) (17.4 mbar) (17.4 mbar) (17.4 mbar) (17.4 mbar) (17.4 mbar)
4”
4”
4”
4”
4”
4”
(10 mbar)
(10 mbar)
(10 mbar)
(10 mbar)
(10 mbar)
(10 mbar)
92 psi
92 psi
92 psi
92 psi
92 psi
92 psi
(634 kPa)
(634 kPa)
(634 kPa)
(634 kPa)
(634 kPa)
(634 kPa)
1.2 FLA
1.8 FLA
2.4 FLA
3.0 FLA
3.6 FLA
4.2 FLA
2-1/2”
2-1/2”
2-1/2”
2-1/2”
2-1/2”
2-1/2”
11
28
17
42
22
55
28
70
38
84
39
98
7.8
9.3
9.4
10.0
10.1
10.2
Page 15 of 90
Chap 2: General
Description
GF-115-H
OMM-0083_0B
SPECIFICATIONS (Continued):
Model Number
MLX-303
MLX-454
MLX-606
MLX-757
MLX-909
MLX-1060
Water Volume: Gallons
2.8
3.8
4.9
5.9
6.9
8.0
Water Volume: Liters
10.4
14.4
18.4
22.3
26.9
30.2
Thermal Modules
2
3
4
5
6
7
Turn-Down Ratio
6:1
10:1
13:1
16:1
20:1
23:1
Vent Size
4” (102 mm) 4” (102 mm) 4” (102 mm) 6” (152mm) 6” (152mm) 6” (152mm)
Vent Materials (per
local code)
Can support PVC, ABS, CPVC, or AL29-4C venting materials.
Temperature Control
Range
All units can be applied to deliver 50°F to 185°F (10°C to 85°C) supply
water.
Maximum Noise Level
All units deliver <50 dBA when operating at or below full fire.
NOx Emissions
Certification
All units have been certified by SCAQMD and TCEQ for <30 ppm NOx.
Standard Listings &
Approvals
All units have been certified by CSA and Standard for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
2.6
Modulex Main Components – Side View
Figure 2-2 illustrates the Main Components included in each Modulex Boiler model. In addition, an
exploded view parts list drawing is included in Appendix B.
FAN
GAS VALVE
AIR INTAKE
CONNECTION
GAS PIPE
AUTOMATIC
AIR VENT
BURNER
COVER
IGNITION
FLAME
DETECTOR
LOCAL NTC
SENSOR
GLOBAL FLOW
NTC TEMPERATURE
SENSOR
H.L.
THERMOSTAT
BURNER
HOT WATER
OUTLET (SUPPLY)
ALUMINUM/
SILICON HEAT
EXCHANGER
1/4" CONNECTION
WITH PLUG
GLOBAL RETURN
NTC TEMPERATURE
SENSOR
BOILER
FRAME
COLD WATER INLET
(RETURN)
WATER DRAIN
VALVE
CONDENSATE
DRAIN TRAP
CONDENSATE
COLLECTION
TRAY MANIFOLD
FILLING-UP
ELBOW
5.9" [150 mm]
4"
[100 mm]
1" [25 mm]
Figure 2-2: Modulex Main Components
MC2: 10/03/12
Page 16 of 90
Chap 2: General
Description
2.7
GF-115-H
OMM-0083_0B
Boiler Freeze Protection
Should the boiler water outlet temperature decrease to less than 44.6°F (7°C), the system pump will start.
Should temperature decrease to less than 37.4°F (3°C), all heat modules will start at minimum output until
the return temperature reaches 50°F (10°C). Such a protection device is exclusively for the boiler. For the
protection of the whole system, a second freeze protection thermostat is necessary to switch on the
heating system pump.
NOTE
If glycol is used as antifreeze in the boiler, a back flow preventer must be
installed in the make-up/fill line.
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Chap 2: General
Description
GF-115-H
OMM-0083_0B
MC2: 10/03/12
Page 18 of 90
GF-115-H
TAG-0083_0B
CHAPTER 3: INSTALLATION
3.1
Introduction to Installation
The Modulex Boiler is intended to be installed as a Category IV vent installation and must be installed
in compliance with all applicable laws and regulations including the ones below. See Sub-section 4.2
for category descriptions.
WARNING !
To ensure proper boiler installation, complete ALL instructions in
Section 3.2.
!
The installation must conform to the requirements of the authority having jurisdiction or, in the absence
of such requirements, to one of the following:
UNITED STATES: Installation must conform to the requirements of the National Fuel Gas Code, ANSI
Z223.1 installation Codes.
CANADA: Installation must conform to the requirements of CAN/CGA CSA B149.1 installation codes.
Where required by the authority having jurisdiction, the installation must conform to the Standard for
Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
IMPORTANT NOTE!
Installers must follow local regulations with respect to installation of
Carbon Monoxide (CO) Detectors. Also, follow the maintenance
recommendations in this manual.
For Massachusetts Installations:
The boiler must be installed by a plumber or gas fitter licensed within the
Commonwealth of Massachusetts. For installations in buildings used for
residential purposes, if a side-wall vent termination is less than 7 feet
above grade, an NFPA 720 compliant, ANSI/UL 2034 listed and IAS
certified carbon monoxide detector must be installed on the floor level
where the boiler is installed and on each level of the building served by
the boiler.
3.2
Installation Instructions
The following information in this section provides the instructions to unpack and install the Modulex Boiler.
3.2.1 Unpacking the Boiler
The Modulex Boiler is delivered assembled and protected by a plastic bag inside a rugged
cardboard box, which is fixed on a pallet (see Figure 3-1). The pallet allows the boiler to be handled
by a forklift or pallet jack. The boiler, with the packaging, can fit through a doorway of 32 in. (81 cm),
whereas, without packaging, it can fit through a doorway of 28 in. (71 cm). To unpack the Modulex,
remove both straps and then the cardboard box from above. Check to ensure that the product is
intact.
! WARNING !
The packing elements (cardboard box, straps, plastic bags, etc…)
should be kept away from small children as these pose a risk of
suffocation and/or choking.
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Page 19 of 90
Chap 3:
Installation
GF-115-H
OMM-0083_0B
Figure 3-1: Packaged Modulex Boiler
Packed inside the boiler packing you will find:
Painted steel panels:
•
The front one connected to the back panel by a shrink wrap film
•
The right hand side panel connected to the left hand panel by shrink wrap
On the front of the boiler:
•
Flue collector, with exhaust connector screwed to the pallet:
1. 4 inch for models 303 to 606.
2. 6 inch for models 757 to 1060.
Use these items only when the specified flue pipe size is increased to 4” (for models
303 to 606) and 6” (for models 757 to 1060). Otherwise, use the exhaust connector
“shipped in the separate carton” described below (4” for models 303 to 606, 6” for
models 757 to 1060).
•
A plastic bag containing 3 gaskets (1 rectangular for condensate tray and flue collector, 1
square for exhaust connector.
•
Three (3) surface-mount strap-on sensors.
•
Screws necessary for accessory installation.
•
Piping for 1 ½” condensate drain, including one tee and two 90 degree elbows.
On the back of the boiler:
•
Plastic condensate drainpipe, 38.5 inches (1meter) long, placed under the casing rear
panel.
•
Outside air sensor with 49 feet, 2.5 inches (15 m) cable.
•
Manual Gas Shutoff Valve.
Shipped in a separate carton are the following:
Accessory kit that includes a CSD-1 installation kit for Models 303 through 606 and Models 754
through 1060 as follows:
• Kit P/N 29073: For Models 303-606 with 50 psig Relief Valve
See the packing list shipped in this manual package for a complete listing of accessories. See
paragraph 5.4 for more information about the CSD-1 kits.
MC2: 10/03/12
Page 20 of 90
Chap 3:
Installation
GF-115-H
OMM-0083_0B
3.2.2 Boiler Location
The boiler should be located on a level, solid area or base as near to the outside wall as possible and
centrally located to the space heating distribution system. Special attention must be given to local
regulations and codes about boiler rooms and particularly to the maintaining of minimum clearances and
empty space around the boiler. The installation must be in compliance with all recent regulations and
laws about boiler rooms, installations of heating and hot water systems, ventilation, boiler venting
systems capable of evacuating the flue gases of condensing boilers and any other applicable
requirement.
The minimum clearance dimensions for service access, required by AERCO, are listed below (Figure
3-2) and on the boiler Data Plate (Figure 3-8). Local building codes may require more clearance and
take precedence.
Minimum clearances required:
Sides
24" (510 mm)
Front
24" (510 mm)
Rear
24" (510 mm)
Top
24" (510 mm)
Figure 3-2: Boiler Clearances (Top View)
NOTE
All gas piping, water piping and electrical conduit or cable must be
arranged so that they do not interfere with the removal of any cover, or
inhibit service or maintenance of the unit.
!
WARNING
!
The boiler MUST NOT be installed on carpeting.
3.2.3 Pad Height for Boiler
To properly drain and service the boiler’s condensate system, attention must be given to installation
requirements regarding the mounting height of the boiler as well as installation clearances for the
removal of the condensate collector baffle.
The boiler should be mounted on a flat and sufficiently strong base with the same dimensions as the
boiler (see Table 2-2) and at least 4 inches (100mm) high, to allow for assembly of the condensate
drain trap (Figure 5-1). An alternative to this base may be a 4 inch (100mm) deep well next to the
boiler to house the condensate siphon.
The condensate collector baffle (Figure 8-12) can be fixed to the right-hand or left-hand side of the
condensate tray. If no modification is made, the boiler must have its right-hand side accessible,
whether the vent connection is fitted on the right-hand or left-hand side. However, if the flue collector
terminal, with the exhaust connector, is left of the right-hand side, and if, from this same side, the baffle
has to be removed, then the exhaust connector must have the possibility to also be removed. If it is
preferred, the baffle can be moved in order to have its mounting screw on the opposite side, regardless
of the position of the flue collector chamber terminal.
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Page 21 of 90
Chap 3:
Installation
GF-115-H
OMM-0083_0B
3.2.4 Boiler Connections
Upon delivery, the Modulex Boiler has all the connections fitted on its right-hand side (Figure 3-3).
Note that the right-hand orientation is the right hand side when viewed facing the front of the boiler.
These connections include: water supply and return, gas, combustion air intake and flue collector
outlet. The locations of the air intake and/or the flue collector outlet can be changed on site by
removing knock-outs on the boiler right, left or back side panels. To attach the exhaust connector to the
flue collector, use the screws and the gaskets supplied inside the plastic bag and use a cross-tip
(Phillips) screwdriver at least 12 in. (300 mm) long.
NOTE
Water supply and return and gas connections can be moved to the
boiler’s left-hand side by inverting the flow and return manifolds to the
left side. See Piping Application Guide GF-115-P-H for full instructions
for changing from right-hand to left-hand sides.
Figure 3-3: Boiler Connections
MC2: 10/03/12
Page 22 of 90
Chap 3:
Installation
3.3
GF-115-H
OMM-0083_0B
Data Plate
A sample Data Plate for a Modulex Boiler is shown in Figure 3-4. The data in Table 3-1 following this
Figure indicates the required entries for each Modulex Model.
CAUTION
I=
B=
R
BEFORE LIGHTING MAKE CERTAIN HOT WATER
SYSTEM IS FULL OF WATER
159 Paris Avenue, Northvale NJ 07647
FOR YOUR SAFETY
REV.
MODEL NO.
TYPE OF
GAS
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE
VICINITY OF THIS OR ANY OTHER APPLIANCE.
SERIAL NO.
IMPORTANT
RATINGS-BTUH
MAX INPUT
BTU/HR
MIN. INPUT
BTU/HR
OUTPUT
BTU/HR
NET I=B=R RATING
BTU/HR
BOILER CATEGORY
PERMISSIBLE INLET GAS PRESSURE
MAX.
IN. W.C.
NORMAL
IN. W.C.
MIN.
IN. W.C.
NORMAL MANIFOLD
PRESSURE
IN. W.C.
ELECTRICAL INPUT 115V__LESS THAN 12AMPS
LOW PRESSURE BOILER
FOR INSTALLATION ON COMBUSTIBLE FLOORS,
MINIMUM CLEARANCES TO COMBUSTIBLE
CONSTRUCTION ARE:
INPUTS 400,000
BTU/HR. OR
LESS
TOP
FRONT
FLUE
CONN.
REAR
SIDES
INPUTS OVER
400,000 BTU/HR
0
CLOSET
24
24
0
24
0
0
24
24
1. GREATER CLEARANCES FOR ACCESS SHOULD
SUPERSEDE FIRE PROTECTION CLEARANCES.
2. ALLOW 24 INCHES AT FRONT AND TOP FOR
SERVICING AND CLEANING.
CERTIFIED BY:
UNICAL AG SPA
MAWP, Water 50psi
Maximum Water 200°F
3. FOR INSTALLATION ON COMBUSTIBLE FLOORS
Minimum relief valve capacity
"BLUE FLAME"
IN ORDER TO START UP THE BOILER:
1) OPEN THE GAS VALVE
2) CHECK GAS AND WATER PRESSURE
3) TURN THE START UP SWITCH ON.
IN CASE THE BOILER DID NOT START
WAIT 5 MINUTES AND REPEAT THIS
PROCEDURE.
FOR PURPOSE OF
INPUT ADJUSTMENT
ANSI Z21.13
CSA 4.9
1. TURN POWER TO THE BOILER ON AND
FOLLOW OPERATING INSTRUCTIONS FOR
THIS BOILER WHICH ARE LOCATED NEAR
THIS RATING.
BTU/HR
"BLUE STAR"
Figure 3-4: Sample Data Plate
MC2: 10/03/12
Page 23 of 90
Chap 3:
Installation
GF-115-H
OMM-0083_0B
Table 3-1: Modulex Data Plate Entries
MODEL NUMBER
REVISION
TYPE OF GAS
*SERIAL NO.
MLX-303
MLX-454
MLX-606
MLX-757
MLX-909
MLX-1060
A
A
A
A
A
A
NATURAL GAS NATURAL GAS NATURAL GAS NATURAL GAS NATURAL GAS NATURAL GAS
(MLX-1060H
(MLX-909H)
(MLX-757H)
(MLX-454H)
(MLX-606H)
(MLX-303H)
OR PROPANE OR PROPANE OR PROPANE OR PROPANE OR PROPANE OR PROPANE
(MLX-1060HP)
(MLX-909HP)
(MLX-757HP)
(MLX-606HP)
(MLX-303HP)
(MLX-454HP)
303-XX-XXXX
454-XX-XXX
606-XX-XXXX
757-XX-XXXX
909-XX-XXXX
1060-XXXXXX
MAX INPUT
303,000
454,000
606,000
757,000
909,000
1,060,000
MIN INPUT
45,000
45,000
45,000
45,000
45,000
45,000
OUTPUT
279,000
418,000
558,000
696,000
835,000
975,000
NET IBR RATING
237,000
355,000
474,000
592,000
710,000
829,000
IV
IV
IV
IV
IV
IV
14” W.C
(34.8 mbar).
14” W.C
(34.8 mbar).
14” W.C
(34.8 mbar).
14” W.C
(34.8 mbar).
14” W.C
(34.8 mbar).
14” W.C
(34.8 mbar).
4”
(10 mbar)
4”
(10 mbar)
4”
(10 mbar)
4”
(10 mbar)
4”
(10 mbar)
4”
(10 mbar)
3.2” Nat. Gas
(MLX-303H)
2.5” Propane
(MLX-303HP)
3.2” Nat. Gas
(MLX-454H)
2.5” Propane
(MLX-454HP)
3.2” Nat. Gas
(MLX-606H)
2.5” Propane
(MLX-606HP)
3.2” Nat. Gas
(MLX-757H)
2.5” Propane
(MLX-757HP)
3.2” Nat. Gas
(MLX-909H)
2.5” Propane
(MLX-909HP)
3.2” Nat. Gas
(MLX-1060H)
2.5” Propane
(MLX-1060HP)
7.0”
(17.4 mbar)
7.0”
(17.4 mbar)
7.0”
(17.4 mbar)
7.0”
(17.4 mbar)
7.0”
(17.4 mbar)
7.0”
(17.4 mbar)
BOILER CATEGORY
MAX INLET (SUPPLY)
GAS PRESSURE
MIN INLET (SUPPLY)
GAS PRESSURE
*NORMAL MANIFOLD
GAS PRESSURE
OPTIMAL INLET
(SUPPLY) GAS
PRESSURE
* NOTE: Normal manifold gas pressure measured at downstream port of gas valve.
MC2: 10/03/12
Page 24 of 90
GF-115-H
TAG-0083_0B
CHAPTER 4: GENERAL INFORMATION FOR VENTING
See Venting Guide GF-115-V for venting specifications and materials.
4.1
Vent Pipe Connection
!
CAUTION
!
The Modulex boiler is approved for a Category IV vent configuration as
well as for sealed combustion installations. Provisions for combustion
and ventilation air in accordance with Section 5.3, Air for Combustion
and Ventilation, of the National Fuel Gas code, ANSI Z223.1, or
Sections 7.2, 7.3, or 7.4 of CAN/CGA CSA B149.1, Installation codes,
or applicable provisions of the local building codes.
Maintain clearances from combustible construction for boiler, vent
connector, and steam and hot-water pipes.
4.2
Gas Vent Categories
Federal Codes have categorized gas appliances by the vented flue gas pressure and temperature.
These categories are defined as follows:
Category I, being a gas appliance that operates with a non-positive vent (or natural drafted vent)
conne ctor with a flue gas pressure and temperature at least 140°F (60°C) above its dew point.
Category II, being a gas appliance that operates with a non-positive vent (or natural drafted vent)
connector with a flue gas pressure and temperature less than 140 degrees F (60 degrees C)
above its dew point.
Category III, being a gas appliance that operates with a positive vent (fan forced vent) connector
with a flue gas pressure and temperature at least 140 degrees F (60 degrees C) above its dew
point.
Category IV, being a gas appliance that operates with a positive vent (fan forced vent) connector
with a flue gas pressure and temperature less than 140 degrees F (60 degrees C) above its dew
point.
Direct Vent, a gas appliance is constructed and installed so that all air for combustion is derived
directly from the outdoors and all flue gases are discharged to the outdoors.
4.3
Installation And Sizing
The AERCO Venting Guide, GF-115-V, must be consulted before any flue gas vent or air inlet piping is
designed or installed. Certified venting materials specified in GF-115-V must be used for safety and
code compliance. Because the Modulex boiler is capable of discharging low temperature exhaust
gases, the flue must be pitched back to the unit a minimum of ¼” per foot to avoid any condensate
pooling and to allow for proper drainage.
For Side Wall Venting In Massachusetts:
The vent termination must be located at a minimum of 4 feet above grade level. See Section
1 of this manual for detailed information pertaining to side wall venting within the
Commonwealth of Massachusetts.
Pipe lengths and fittings must be calculated as part of the equivalent length. The pressure drop of the
vent and combustion air systems must not exceed 100 equivalent feet each. This DOES NOT mean the
MC2: 10/03/12
Page 25 of 90
Chap 4: General
Venting Information
GF-115-H
OMM-0083_0B
allowed combined pressure drop between the vent and combustion air is 200 equivalent feet. That is,
the vent cannot go above 100 equivalent feet, even if the combustion air is less than 100 equivalent
feet, and vice versa. (See GF-115-V for detailed sizing guidelines.)
The combustion air must be free of chlorine, halogenated hydrocarbons, or other chemicals that can
become hazardous when used in gas-fired equipment. Common sources of these compounds are
swimming pools, degreasing compounds, plastic processing compounds and refrigerants. Whenever
the environment contains these types of chemicals, combustion air must be supplied from a clean area
outdoors for protection and longevity of the equipment.
The Modulex is CSA listed for 100% sealed combustion or can be installed using room air as long as
there is an adequate supply. (See GF-115-V for detailed sizing guidelines.)
4.4
Existing Boiler Removal From Common Venting System
At the time of removal of an existing boiler, the steps as shown in the instructions below, shall be
followed with each appliance remaining connected to the common venting system placed in operation,
while the other appliances remaining connected to the common venting system are not in operation.
Existing Boiler Removal from Common Venting System
1. Seal any unused openings in the common venting system.
2. Visually inspect venting system for proper size and horizontal pitch and determine there are no
blockages or restrictions, leakage, corrosion and other deficiencies that could cause an unsafe
condition.
3. When practical, close all building doors and windows as well as all doors between the space in
which the appliances remaining connected to the common venting system are located and other
spaces of the building. Turn on any appliances not connected to the common venting system, such
as clothes dryers. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they
will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4. Turn on the appliance being inspected. Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use a
match or candle flame, or smoke from a cigarette, cigar or pipe.
6. After determining that each appliance remaining connected to the common venting system properly
vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and
other gas-burning appliance to their previous state of use.
7. Any improper operation of the common venting system should be corrected so the installation
conforms to the National Fuel Gas code, ANSI Z223.1 and/or CAN/CGA B149, Installation Codes.
When resizing any portion of the common venting system, the common venting system should be
resized to approach the minimum size as determined using the appropriate tables in Part 11 of the
National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA B149, Installation Codes.
MC2: 10/03/12
Page 26 of 90
GF-115-H
TAG-0083_0B
CHAPTER 5: PIPING
See Piping Guide GF-115-P-H for in-depth piping information.
5.1 Makeup Water Quality
Installation water must be checked, monitored, maintained and treated per GF-115-P-H.
NOTE
Failure of the boiler due to water quality is not covered under warranty.
See Appendix C, Boiler Water Chemistry and Maintenance for more
information about water quality.
5.2
Maximum Allowable Working Pressure
!
CAUTION
!
The Modulex boiler has a maximum allowable working pressure of 92
psi (634kPa, 6.34 bar), and a minimum of 15 psi (103 kPa, 1 bar).
5.3
Boiler Loop Design Guidelines
For proper and safe operation of the water tube Modulex boiler, the primary (boiler) loop piping and the
associated fittings and accessories must be designed/selected as discussed in the following sections.
5.4
CSD-1 Manifold Assembly (Supplied)
The installation of a low water cutoff, manual reset high limit aquastat and an ASME compliant safety
pressure relief valve designed for the boiler output capacity are required. These major components
along with a manifold and several others are supplied with the boiler and must be assembled and wired
when installing the boiler at the site. The manifold assembly components supplied are:
•
•
•
•
•
•
5.5
3/4” Pressure Relief Valve
Manifold Assembly [2-1/2” x 16” long (64 mm x 406 mm)]
2-1/2” NPT Union
Low Water Cut-Off Switch
Aquastat
Pressure/Temperature Gauge
Connecting Supply And Return Piping (Per ANSI Z21.13a)
Reference the following points when designing supply and return piping:
•
The boiler, when used in connection with a refrigeration system, must be installed so the chilled
medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium
from entering the boiler.
•
The boiler piping system of a hot water boiler connected to heating coils located in air handling
units where they may be exposed to refrigerated air circulation must be equipped with flow
control valves or other automatic means to prevent gravity circulation of boiler water during the
cooling cycle.
•
A hot water boiler installed above radiation level or as required by Authority having jurisdiction,
must be provided with a low water cutoff device either as a part of the boiler or at the time of the
installation.
•
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Chap 5:
Piping
5.6
GF-115-H
OMM-0083_0B
System Filling and Draining
Reference the following points when filling and draining the system:
•
For filling-up the system, a filling tap has to be inserted on the system return pipe.
•
The filling-up can also be made through the draining tap on the boiler return manifold.
•
In both cases, an approved hydraulic disconnection system has to be fitted.
•
Before connecting the boiler, carefully rinse out the whole system with running water.
5.7
Notes On Condensate Drain
To maintain proper flow of condensate the drain pipe must slope toward the drain of at least 3/8 in./ft.
(30 mm/m). The liquid column inside the condensate siphon needs to be filled with water after
installation. Its minimum height when all the fans are in operation must be at least 1 in. (25 mm). See
Figure 5-1. In order to help avoid ice from forming, the condensate piping system must be well
insulated.
WARNING !
Do not install the condensate drain where freezing may occur.
!
Consult local codes with regard to condensate neutralization. Neutralization can be obtained by mixing
it with the buildings drain water or with limestone, which normally have a base pH.
THE UPPER PART OF THE DRAIN
PIPE SHALL NOT BE HIGHER
THAN THE TRAY BOTTOM
INITIAL TRAP
FILLING-UP PLUG
BOILER
ROOM
FLOOR
TO CONDENSATE
DRAIN WITH MIN.
INCLINATION OF
3/8 IN/FT [30 mm/M]
TOWARD DRAIN
5.9"
[150 mm]**
5.9" [150 mm]**
BASE (MIN. H = 4" [100 mm ]
0.98" [25mm]*
Figure 5-1: Typical Condensate Drain Installation
5.8
Gas Mains and Connections
Connect gas service meter to control assembly in accordance with the current version of the ANSI Z223.1
and the local codes or utility. Prior to operation, the complete gas train must be leak tested using a noncorrosive soap. For gas pipe sizing and additional details, see GF-115-P-H.
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GF-115-H
TAG-0083_0B
CHAPTER 6: ELECTRICAL
See Electrical Guide GF-115-E for in-depth electrical information.
6.1
Electrical Connections
A complete electrical wiring diagram for the Modulex is provided under separate cover in the manual
package. For electrical ratings, refer to the technical data in Sub-section 2.5. The boiler installation
requires a 120 VAC, 60 Hz – single-phase power input. The electrical connections must conform to
local and NEC or CEC requirements. Utilization of adapters, multiple sockets or extensions cords are
not permitted. It is imperative that these safety requirements be adhered to. If in doubt, request an
accurate assessment of your electric system by highly qualified personnel.
IMPORTANT!
AERCO is not liable for any damage caused by connection to an
improper grounding system. The gas and water feeding pipes and the
central heating system pipes cannot be used as grounding means.
Boiler electric safety is guaranteed only when it is properly connected
to an effective grounding system, which is in compliance with the
regulations in force.
The use of any electrically powered equipment implies the observance of some fundamental rules, such
as:
•
Do not touch the boiler with any wet part of your body and/or barefooted; do not pull the supply
cable.
•
Do not expose the boiler to sunlight, rain, etc.
•
Keep untrained people away from the boiler.
! WARNING !
The boiler’s electrical supplying cable must not be replaced by the user.
In case of any damage to the cable, stop the boiler and contact qualified
personnel for its replacement.
IMPORTANT!
Prior to connecting external AC power to the Modulex boiler, the CSD-1
Supply Manifold must be installed using the procedures described in
Piping Guide GF-115-P-H.
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OMM-0083_0B
The Modulex boiler should be wired for power per the instructions and Figure 6-1 below.
Wiring the MLX Boiler for Power
1. External power at 120 VAC, 60 Hz, single phase is first connected to the Low Water Cutoff and
Aquastat provided on the CSD-1 Supply Manifold. Refer to Wiring Diagram 68004 provided in the
manual package for connections to the CSD-1 Manifold.
2. Following connection of 120 VAC power to the CSD-1 Manifold, the power leads are routed to the
Junction Box shown in Figure 6-1. The Junction Box is accessed by removing the front panel from
the boiler.
3. Route the wires from the CSD-1 Manifold through the cutout labeled 120V on the Left side of the
boiler. If necessary, the cutout labeled 24V is used for low voltage signals such as external
sensors.
4. The boiler’s Junction Box contains a polarized terminal block. Therefore, the Red (Line - L1) and White
(Neutral - L2) wires from the CSD-1 Manifold MUST BE connected to terminals L1 and L2
respectively on the terminal block in the Junction Box. The output cable from the Junction Box is
terminated with a 3-pole plug, which connects to the boiler’s electrical components. If incorrectly
wired, the boiler goes into a “lockout” condition.
It is necessary to install a double-pole switch on the supply line in an easily accessible position in order to
quickly and safely disconnect service. DO NOT affix switch to boiler sheet metal enclosure.
Terminal Block
Cable to
3-Pole
Plug
3-Pole Plug
Cover
Terminal Block
L2
Ground
L1
Figure 6-1: Junction Box Wiring
After placing boiler in operation, the ignition system safety shutoff device must be tested. If an external
electrical source is utilized, the boiler, when installed, must be electrically bonded to ground in
accordance with the requirements of the authority having jurisdiction or, in the absence of such
requirements, with the National Electrical code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical
Code (CEC) Part I, CSA C22.1, Electrical Code.
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Chap 6:
Electrical
6.2
GF-115-H
OMM-0083_0B
DHW (Domestic Hot Water) Storage Tank
Domestic hot water (DHW) production by an external storage tank connected to the boiler can be
implemented by an electric diverting valve or a separated storage tank loading pump. See Figure 6-2
and 6-3. Contact AERCO for information on AERCO tanks designed for this purpose.
To monitor the DHW temperature, connect the aquastat wire leads to Connector KF/SPF, Terminals 6
(F6) and 7 (GND). After the sensor is connected, turn the ON/OFF switch to the OFF position, then back
to the ON position. This is necessary to ensure that the Controller recognizes the added sensor.
A map of the connection points on the rear of the E8 Controller may be found in the E8 Controller
manual, Section 6 of GF-115-C.
6.3
Enable / Disable
Enable/Disable should be connected to terminals 3 (F3) and 4 (GND) of E8 connector number I.
6.4
Installation Of Sensors
To avoid electromagnetic interference, it is necessary to separate any external sensor wiring (between
sensor and terminal strip) from any 120 VAC power wiring.
WARNING!
There is a 120 VAC between terminals A10 and N whenever the E8
boiler controller is on.
Figure 6-2: Electrical Pump Connection for Primary Boiler
WARNING!
There is a 120 VAC between terminals A3 and N when there is a heating
demand by the DHW NTC sensor or by a DHW thermostat.
Figure 6-3: Electrical Pump Connection of a DHW Tank Loading Pump
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Chap 6:
Electrical
GF-115-H
OMM-0083_0B
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GF-115-H
TAG-0083_0B
CHAPTER 7: BOILER OPERATION
7.1
Introduction to Boiler Operation
The Modulex is a cast aluminum body boiler consisting of mutually connected combustion chambers,
each having its own burner, blower and air pressure switch, gas valve, igniter and flame detection.
Each group of these components is referred to as a module.
The boiler has supply and return temperature sensors that the System (E8) Manager uses to monitor
total outlet temperature from each module and the system return water temperatures before being
redistributed to each module. These sensors are negative temperature coefficient (NTC) sensors and
are designated the Global Flow Sensor for the supply sensor and the Global Return for the return
sensor. Each module has its own temperature sensor called the Local Flow NTC, which monitors the
water temperature of each module. The water temperature measured by the Local NTC sensor is
compared to the return supply water temperature. If for any reason the temperature difference between
the Local Flow and the Global Return temperatures becomes greater than 54°F (30°C), the module or
modules will begin to modulate as follows:
• 0°F to 54°F (0°C to 30°C)
Normal Operation
• 54°F to 63°F (30°C to 35°C)
Burner will begin Modulating down
o
o
Burner will stay at 45,500 BTU’s
• 63 F to 72 F (35°C to 40°C)
• Above 72°F (40°C)
Burner will shut off
The variable speed fan's pressure drives the gas valve to allow gas to enter into the pre-combustion
chamber where it mixes with the combustion air. The mixed air and gas pass thru the check valve on to
the burner surface for ignition. Combustion gases pass thru the heat transfer surfaces. Flue gases and
condensate then exit the heat exchanger entering into the condensate tray.
7.2
Modulation Theory
One of the operating principles for this boiler is to have as many modules as possible operate
simultaneously at minimum load to reach the maximum efficiency. This is maintained by the System
Manager (E8) which determines a percent of modulation based on the difference between the set point
temperature and the actual supply water (global flow) temperature. This operating principle provides
efficiencies much higher than those obtained in traditional groups of small boilers installed in cascade.
Each of the boiler’s modules represents a maximum output of 151.5 MBH (44.4 kW). The number of
modules x 100% determines the maximum output expressed in percent. For example, if a four module
boiler is requested to operate at its max output, this shall be 400%, i.e. 151.5 MBH (44.4 kW) x 4
modules = 606 MBH (177.6 kW) = 400%.
If the required percentage is 200%, each module will operate at 50% output. This equals a total of 303
MBH (88.8 kW) out of a possible 606MBH (177.6 kW), and each module will be operating at 75.75
MBH (22.2 kW) out of a possible 151.5 MBH (44.4 kW).
When the output shared on each module is less than approximately 30%, one module after the other is
automatically turned off and the remaining output is shared on modules having the smallest number of
operation hours (by the automatic operation-time calculating system).
7.3
Ignition Sequence
The ignition sequence may be described as follows: The Ignition Burner Management Module (BMM) is
powered on and, after 5 seconds, the fan starts at minimum speed. The fan remains running, actuating
the air pressure switch and pre-purging the combustion chamber for 10 seconds. Actuating the air
pressure switch toggles it from normally open (NO) to normally closed (NC). This energizes the ignition
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transformer and permits the gas valve to be opened after 5 to 8 seconds allowing the AIR/GAS mixture
into combustion chamber through the check valve. If the burner does not light within the ignition time
frame, the burner is put in lockout position for 5 sec, after which it repeats the ignition sequence once
again. If no positive result is obtained, then a lockout condition occurs and the display on the System
Manager will show an error message.
NOTE
When power is applied, fans are already on to prevent back flow through
the air system.
7.4
Modes of Operation
The Modulex boiler is capable of operating in several control modes including, Indoor/Outdoor Reset, 0
to 10 Volt Remote Setpoint, and Constant Setpoint. The following subordinate paragraphs briefly
describe each of these modes.
NOTE
Refer to the Modulex E8 Controller Manual GF-115C for additional
information on operating modes, set-up, and programming of the E8
Controller.
7.4.1 Indoor/Outdoor Reset
In indoor/outdoor reset mode the Modulex boiler will adjust its set-point based on the outside air
temperature and the programmed heating curve. The heating curve can be customized by changing the
Slope parameter found in the User/ Heating Circuit 1 menu in the boilers controller.
The outside air sensor, supplied with the boiler, should be mounted on an outer North or Northeast wall
at a minimum height from floor of 8 feet, 2.5 inches (2.5 m) away from windows, doors and ventilation
grates. Never mount the outside air sensor in a sunny position. The sensor connections are at
connector #1, terminals 9 (F9) and 10 (GND) of controller.
7.4.2 0 To 10 Volt Remote Set-Point
The unit’s setpoint can be controlled using a 0 to 10 volt signal. The Modulex controls allow for full
scaling capabilities of voltage and set-point through use of the V-Curve in the Expert Menu of the
Controller. Input wiring for this mode will be to terminals 1 (F15) and 2 (GND) of the E8 Controller
connector number 3 (III). See Sub-section 5.3 in E8 Controller Manual, GF-115-C.
7.4.3 Constant Set-Point
The constant set-point mode is used when a fixed header temperature is desired. Common uses for
this mode of operation include water source heat pump loops and indirect heat exchangers for potable
ho water systems or processes. No external connections are required for this mode of operation.
7.4.4 Boiler Operation for Troubleshooting (Manual Mode)
For service and test purposes, any single module, or all simultaneously, can be kept operating at full or
reduced load. In this way the CO2 level can be checked and, if necessary, adjusted at full or reduced
load (for any single module or for all simultaneously). With this option, troubleshooting failures on each
module is simplified.
7.5
Modulex Boiler Initial Startup
Prior to initial start-up of the complete Modulex Boiler, check the following items:
•
Ensure that all Installation procedures have been completed as presented in Section 3 of this
document (GF-115-H), including references to documents GF-115-G (Gas), GF-115-P-H (Piping),
GF-115-V (Venting), and GF-115-E (Electrical).
•
Ensure that all operating controls, menu settings, and limits have been properly set in accordance
with Section 3 of the Modulex E8 Controller Operation & Wiring Guide GF-115-C (Controls).
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OMM-0083_0B
• Ensure that the mode of operation settings have been made per document GF-115-C (Controls).
Upon completion of the above items, perform the initial startup and combustion calibration procedures as
described in the following paragraphs.
!
CAUTION
!
All installation procedures specified in this document (GF-115H, Section
3) must be completed before attempting to start the unit. DO NOT
attempt to fire the boiler without a full water level. Failure to observe this
precaution can seriously damage the unit and may result in personal
injury or property damage, and is not covered by warranty.
!
CAUTION
!
The Modulex boiler has a maximum allowable working pressure of 92
psi (634kPa, 6.34 bar), and a minimum of 15 psi (103 kPa, 1 bar).
7.5.1 Tools & Instruments Required For Combustion Calibration
The following tools and instrumentation are necessary to perform combustion calibration:
•
Digital Combustion Analyser: Oxygen (O2) and Carbon Dioxide (CO2) accuracy to ±0.4%; Carbon
Monoxide (CO) resolution to 1 ppm
•
One 16” W.C. manometer or equivalent gauge
•
Small and large flat-tip screwdrivers
•
T40 Torx tool
•
Length of plastic tubing (3/8” I.D.)
7.5.2 Installing the Supply Gas Manometer
Install the W.C. manometer (or gauge) per instructions below.
Installing the Supply Gas Manometer on the Gas Pressure Tap
1. Turn off the external main gas supply valve to the unit.
2. Remove top panel from boiler to access the gas supply manifold (Figure 7-1, top).
3. Locate the gas pressure tap on the gas supply manifold. (Figure 7-1, lower)
4. Using a flat-tip screwdriver, rotate the pressure tap screw counter-clockwise three full revolutions to
the open position.
5. Attach one end of the length of plastic tubing to the gas pressure tap. Attach the other end to the
W.C. manometer (or gauge).
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OMM-0083_0B
Gas
Valve
Inlet Gas
Supply
OPEN
CLOSE
Figure 7-1: Gas Pressure Tap Location and Orientation
7.5.3 Preparing The Flue For Use With The Combustion Analyser
In order to provide an opening for the combustion analyser, proceed as follows:
•
If there is no combustion analyser port available, you will have to drill a 3/8” hole in vent pipe,
approximately 2 feet above boiler exhaust manifold.
•
If necessary, adjust the stop on the combustion analyser probe so that it will extend mid-way into
the flue gas flow. DO NOT install the probe at this time.
7.5.4 Supply Gas Pressure Check & Adjustment
The optimum gas pressure for the Modulex Boiler is 7.0” W.C. and is used as the desired pressure in
the Combustion Calibration procedures in Paragraph 7.5.5. However, it should be noted that the
Modulex Boiler can be safely operated at gas pressures ranging from 4.0” W.C. (minimum) to 14” W.C.
(maximum) as specified in the Gas Supply Design Guide, GF-115-G.
An external gas pressure regulator is mandatory for the state of Massachusetts. For all applications, a
lock-up style regulator is required when supply gas pressure is greater than 14” W.C. In order to ensure
that the supply gas pressure is adequate for installation, the pressure must be checked under full-fire
conditions using procedures as outlined in the instructions on the following page.
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Supply Gas Pressure Check and Adjustment
1. Open the water supply and return valves to the unit and ensure that the system pumps are running.
2. Open external gas supply valve to the boiler.
3. Measure the gas pressure using the W.C. manometer connected to the inlet gas manifold. If an
external regulator is installed, adjust the pressure to 7.0” W.C. If an external regulator is not installed,
ensure the supply gas pressure is at least 4.0” W.C.
NOTE
When performing the remaining steps in this procedure, refer to Sections 1 and
2 in Modulex E8 Controller Operation & Wiring Guide GF-115C for locations and
descriptions of the controls and display on the Controller.
4. Set the ON/OFF switch on the front of the boiler to the ON position.
5. With the controller hinged panel closed, turn the Rotary Knob clockwise and monitor the displayed
symbols on the lower portion of the display. The symbols will increment from left to right and show the
appropriate symbols (Figure 7-2, below): Standby/OFF, AUTO MODE 1, AUTO MODE 2, SUMMER
MODE, DAY MODE, NIGHT MODE and finally, SERVICE MODE. The SERVICE MODE symbol
appears at the far right (
).
6. With the SERVICE Mode symbol displayed, open the swing-down hinged panel of the controller.
INSTALLATION will then be displayed.
7. Next, turn the Rotary Knob counterclockwise until SERVICE appears in the display.
8. With SERVICE displayed, press the Program Key on the Controller.
NOTE
The CASCADE MANU (Cascade Manual) Mode will time out after a period of 15
minutes. When this occurs, the boiler will revert to the Auto mode function under
program control.
9.
10.
11.
12.
Turn the Rotary Knob clockwise until CASCADE MANU is displayed.
Press the Program Key. BOILER 1 will be displayed.
Press the Program Key again. The display will show CODE NO., requesting valid code to be entered.
Enter code 0000 (4 zeros) by pressing Program Key four times. Red LED remains lit while the four
code digits are entered. LED turns off after last digit entered.
13. With BOILER 1 displayed, press the Program Key. The red LED will light.
14. Turn the Rotary Knob clockwise and select a fire rate of 100%. Press the Program Key to store the
100% fire rate.
15. Wait until Boiler stage fires at 100% fire rate.
16. Next, turn the Rotary Knob clockwise until BOILER 2 is displayed.
17. Repeat steps 13 to 16 for each Boiler stage.
18. With all Boiler stages firing at 100%, check inlet manifold gas pressure. Verify pressure is at least 4.0” W.C.
19. If the gas pressure is less than 4.0” W.C., contact your gas supplier. DO NOT proceed until the
supply gas pressure is corrected.
20. If the gas pressure is adequate at full-fire, close the hinged panel of the controller.
21. Set the ON/OFF switch on the front of the boiler to the OFF position.
22. Turn off the gas supply to the boiler by closing the external shut-off valve.
Remove the manometer from the gas manifold pressure tap. Close the tap by rotating the adjustment
screw fully clockwise to its stop. This manometer will be used to measure gas valve outlet pressure for
each stage during the Combustion Calibration procedure in Paragraph 7.5.5 on next page.
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Standby/
OFF
AUTO
MODE 1
AUTO
MODE 2
SUMMER
MODE
DAY
MODE
NIGHT SERVICE
MODE MODE
Figure 7-2: Heat Mode Symbols
7.5.5 Combustion Calibration.
The Modulex boiler is combustion calibrated prior to shipment from the factory. However, AERCO
recommends that the following calibration and adjustments be performed due to possible differences in
altitude, BTU content, installed gas supply piping and regulators used.
In addition to checking the oxygen (O2), carbon dioxide (CO2) and carbon monoxide (CO) combustion
readings, this procedure also checks the gas valve outlet pressure for each boiler stage. This is
accomplished by connecting a 16” W.C. manometer (or gauge) to the Outlet Pressure Tap of each
boiler stage gas valve to check pressure while making adjustments.
To calibrate the combustion of the Modulex boiler, refer to Figure 7-3 below, and follow the instructions
on the next page.
NOTE
The manometer installed in following steps 1-4 will be moved, in turn, to
each boiler stage for calibration. Ensure that each outlet pressure tap for
each gas valve is fully closed (rotated fully clockwise) BEFORE
connecting the manometer to the next valve for calibration.
Top View: Unit
Top View: Gas Valve
OPEN
Gas Valves
(Detail at Right)
Exposed Offset
Adjustment Screw
Oblique View: Gas Valve
CLOSE
Pressure Tap Outlet Cap Screw
And Adjustment Screw Removed
Outlet
Pressure
Tap
Figure 7-3: Gas Valve Offset Adjustment Screw and Outlet Pressure Tap
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Chap 7: Boiler
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OMM-0083_0B
Combustion Calibration Procedure
1. Refer to Figure 7-3 (previous page) and locate the Outlet Pressure Tap for the gas valve of the first
boiler stage. This outlet features a screw operated needle valve in the tap to open and close it.
2. Turn the screw of the Outlet Pressure Tap1/2 turn counterclockwise to open the tap.
3. Attach the plastic tubing between the Outlet Pressure Tap and the manometer.
4. Open the water supply and return valves of the boiler and ensure that the system pumps are running.
5. Ensure that the external gas supply valve to the boiler is open.
6. Set the ON/OFF switch on the front of the boiler to the ON position.
NOTE
When performing the remaining steps in the combustion calibration
procedure, refer to Sections 1 and 2 in Modulex E8 Controller Operation
& Wiring Guide GF-115C for locations and descriptions of the controls
and display on the controller.
7. With the controller hinged panel closed, turn the Rotary Knob clockwise and monitor the displayed
symbols on the lower portion of the display. The symbols will increment from left to right and show the
appropriate symbols (see Figure 7-2): Standby/OFF, AUTO MODE 1, AUTO MODE 2, SUMMER
MODE, DAY MODE, NIGHT MODE and finally, SERVICE MODE. The SERVICE MODE symbol
appears as follows at far right of display:
8. With the above symbol displayed, open the swing-down hinged panel of the controller.
INSTALLATION will then be displayed.
9. Next, turn the Rotary Knob counterclockwise until SERVICE appears in the display.
10. With SERVICE displayed, press the Program Key on the controller.
NOTE
The CASCADE MANU (Cascade Manual) mode will time out after a
period of 15 minutes. When this occurs, the boiler will revert the Auto
mode and will function under program control. If this occurs prior to
completing the combustion calibration for each boiler stage, it will be
necessary to repeat steps 7 through 15 and then sequence the boiler
stage to the one which was in-process when the time out occurred.
11. Turn the Rotary Knob clockwise until CASCADE MANU is displayed.
12. Press the Program Key. BOILER 1 will be displayed.
13. Press the Program Key again. The display will show CODE NO., requesting the valid code to be
entered.
14. Enter code 0000 (4 zeros) by pressing the Program Key four times. The red LED will remain lit while
the four code digits are entered. The LED will turn off after the last code digit is entered.
15. With BOILER 1 displayed, press the Program Key. The red LED will light.
16. Turn the Rotary Knob clockwise and select a fire rate of 10%. Press the Program Key to store the
setting.
17. Wait until the first boiler stage fires and stabilizes at the 10% fire rate.
18. Insert the combustion analyser probe into the 3/8” hole in the flue. Allow enough time for the
combustion analyser to settle.
(Continued)
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Table 7-1: Acceptable Combustion Gas Ratios at Boiler Input
GAS SUPPLY
OXYGEN (O2)
CARBON
DIOXIDE (CO2)
CARBON
MONOXIDE (CO)
NATURAL GAS
4.7% to 5.3%
9.1% to 8.8%
<100 ppm
PROPANE
4.4% to 5.0%
10.7% to 10.4%
<100 ppm
Combustion Calibration Procedure (Continued)
19. Verify that the oxygen (O2) level is within the range shown in Table 7-1 above. Also, ensure that the
carbon dioxide (CO2) and carbon monoxide (CO) are within the ranges shown.
20. If the oxygen level is not within the required tolerance, the gas valve for the boiler stage must be
adjusted. Remove the cap screw with a T40 Torx tool to access the Offset Adjustment Screw (Figure
7-3). Slowly rotate the Offset Adjustment Screw (in approximately 1/4 turn increments) in the desired
direction. Clockwise rotation reduces the oxygen level, while counterclockwise rotation increases the
oxygen level. Allow time for the combustion analyser to stabilize following each gas valve adjustment.
21. Once the oxygen level is within the required range for the first boiler stage, measure the gas pressure
at the outlet pressure tap. The pressure should be approximately 0.50” W.C. at the 10% fire rate.
22. Press the Program Key.
23. Using the Rotary Knob, set the displayed fire rate to zero (0). Press the Program key and wait until
the boiler stage turns off.
24. This completes the combustion calibration procedure for the first boiler stage.
25. Disconnect the manometer connected in step 3 and close the Outlet Pressure Tap by turning the
screw fully clockwise to its stop in preparation for the next boiler stage test.
On the controller, turn the Rotary Knob clockwise to the next Boiler stage. Repeat steps 16 through 25
for each remaining boiler stage (up to seven stages, depending on boiler size).
7.6
Unit Reassembly
Once the combustion calibration procedures have been completed for each boiler stage, the unit can
be reassembled for service operation per the instructions below.
Unit Reassembly
1. If it is still attached, remove the manometer from the gas valve outlet pressure tap. Close the tap by
rotating the screw fully clockwise to its stop.
2. Set the ON/OFF switch on the front of the Modulex boiler to the OFF position.
3. Turn off the gas supply to the boiler by closing the external shut-off valve.
4. Disconnect AC power.
5. Cover the hole drilled in the PVC flue pipe with foil tape.
Replace the top and side panels on the Modulex Boiler.
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GF-115-H
TAG-0083_0B
CHAPTER 8: SAFETY DEVICE TESTING
8.1
Testing of Safety Devices
Periodic safety device testing is required to ensure that the control system and safety devices are
operating properly. The boiler control system comprehensively monitors all combustion-related safety
devices before, during and after the start sequence. The following tests check to ensure that the system
is operating as designed.
Operating controls and safety devices should be tested on a regular basis or following service or
replacement. All testing must conform to local codes such as ASME CSD-1.
NOTE:
SERVICE modes of operation are required to perform the following tests.
For a complete explanation of these modes, see Chapter 3.
NOTE:
It will be necessary to remove the front/top panel from the unit to perform
the following tests.
WARNING
ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 120
AND 24 VOLTS AC. POWER MUST BE REMOVED PRIOR TO
PERFORMING
WIRE
REMOVAL
OR
OTHER
TEST
PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK.
8.2
Processing and Clearing Fault Codes
When a fault occurs, the appropriate fault code will be displayed along with a “Flashing Triangle”. To
process and clear the fault, proceed as shown in the instructions below:
NOTE
If the cause of the fault has not been corrected, the displayed Fault Code
will reappear after performing the following steps.
Processing and Clearing a Fault Code
1. Open the hinged cover on the E8 controller.
2. Press the Program Key. The red LED will light. Also, the display will show the fault code and the
number of the suspect module.
3. Correct the cause of the fault.
4. Press the Program Key again. The red LED will go off and the Fault Code will clear.
5. If more than one fault (or more than 1 failed module) exists, repeat the above steps until all fault
codes are cleared.
6. Close the hinged cover on the Controller.
7. Monitor the display to ensure no other Fault Codes appear.
8. Resume normal operation after all faults have been cleared.
MC2: 10/03/12
Page 41 of 90
Chap 8: Safety
Device Testing
8.3
GF-115-H
OMM-0083_0B
LOW GAS PRESSURE FAULT TEST
Refer to Figure 8-1 and ensure that the test port located on the manifold is closed. To perform the low gas
pressure fault test, follow the instructions below.
Low Gas Pressure Fault Test
1. Open the pressure port in the gas manifold and install the manometer. See Figure 8-1.
2. Set the ON/OFF switch to the ON position to start the E8 controller, then select the
GENERAL/SERVICE/CASCADE MANU menu, choose Burner 1, and set the valve position between
25% and 30%.
3. While the unit is firing, slowly close the external manual gas shut-off valve.
4. The unit should shut down and display an “E2” fault message at approximately 3.9” W.C. The fault
indicator on the E8 controller should also start flashing.
5. Fully open the external manual gas shut-off valve and reset the fault on the E8 controller (see
paragraph 8.2)..
6. The fault message should clear and the indicator displaying the E2 fault message should turn off.
7. Upon test completion, close the test port and remove the manometer.
Gas
Valve
Inlet Gas
Supply
OPEN
CLOSE
Figure 8-1: Gas Pressure Tap Location and Orientation
MC2: 10/03/12
Page 42 of 90
Chap 8: Safety
Device Testing
8.4
GF-115-H
OMM-0083_0B
LOW WATER LEVEL FAULT TEST
There are two ways in which to test the low water level fault. Method 1 requires draining the unit, while
the other involves pressing a “test” button while the unit is operating to check the sensor operation. To
simulate a low water level fault, proceed as follows:
NOTE
This sensor is located on the CSD-1 header
Low Water Level Fault Test (Method 1)
1. Set the ON/OFF switch to the ON position to start the E8 controller, and then select the
GENERAL/SERVICE/CASCADE MANU menu, which will prevent the boiler from firing.
2. Close the water shut-off valves in the supply and return piping to the unit.
3. Slowly open the drain valve on the rear of the unit. If necessary the unit’s relief valve may be opened
to aid in draining.
4. Continue draining the unit until the amber “Low Water” LED on the low-water cut-off switch illuminates
(see Figure 8-2). The unit should shut off completely (the E8 controller will turn off).
5. Close the drain and pressure relief valve used in draining the unit.
6. Open the water shut-off valve in the return piping to the unit.
7. Open the water supply shut-off valve to the unit to refill.
8. After the unit is full, press the Reset button on the water level sensor to reset the cutoff switch.
9. Power is now restored to the unit. There will be no fault code displayed on the E8 controller.
Low Water Level Fault Test (Method 2)
1. Set the ON/OFF switch to the ON position to start the E8 controller, and then select the
GENERAL/SERVICE/CASCADE MANU menu, which will prevent the boiler from firing.
2. Press and hold the “TEST” button on the low water cut-off switch (Figure 8-2). The unit should shut
off completely (the E8 controller will turn off).
3. Release the “test” button, then press and release the “reset” button.
4. Power is now restored to the unit. There will be no fault code displayed on the E8 controller.
Lock Out LED (Red)
Low Water LED (Amber)
Test Button
Reset Button
Figure 8-2: Low Water Cut-Off Switch and Controls
MC2: 10/03/12
Page 43 of 90
Chap 8: Safety
Device Testing
8.5
GF-115-H
OMM-0083_0B
WATER TEMPERATURE FAULT TEST
A high water temperature fault is simulated by adjusting the automatic over-temperature switch. This
switch is accessible on the CSD-1 header, as shown in Figure 8-3. Follow the instructions below to
perform the test.
Water Temperature Fault Test
1. Start the unit in the NORMAL operating mode. Allow the unit to stabilize at its setpoint.
2. Lower the adjustable over-temperature switch setting to match the displayed OUTLET
TEMPERATURE.
3. Once the adjustable over-temperature switch setting is approximately at, or just below, the actual
outlet water temperature, the unit should shut down completely. It should not be possible to restart
the unit.
4. Reset the adjustable over-temperature switch to its original setting.
5. Press the red button on the over-temperature switch, and power will be restored to the unit. There will
be no fault code displayed on the E8 controller.
Set Temperature
Reset Button
Figure 8-3: Over-Temperature Switch and Controls
MC2: 10/03/12
Page 44 of 90
Chap 8: Safety
Device Testing
8.6
GF-115-H
OMM-0083_0B
FLAME FAULT TESTS
Flame faults can occur during ignition or while the unit is already running. It is necessary to perform the
flame fault test using the GENERAL/SERVICE/CASCADE MANU menu, where the each burner may be
selected and the valve position set open by a user specified percentage. To simulate each of these fault
conditions for all two to seven burners (depending on model), proceed as follows:
Flame Fault Tests
1. Set the ON/OFF switch to the ON position to start the E8 controller, then select the
GENERAL/SERVICE/CASCADE MANU menu, choose Burner 1, and set the valve position between
25% and 30%.
2. Disconnect the cable from the Burner 1 flame detector at front of unit (see Figure 8-4).
3. The unit should shut down after reaching the ignition cycle and display fault code E4 in the E8
controller display. The E4 fault code indicates a failure to fire at startup.
4. Plug the flame detector cable back onto the Burner 1 flame detector connector.
5. Reset the error displayed in the E8 controller (see paragraph 8.2 for instructions).
6. Use the E8 controller to select the GENERAL/SERVICE/CASCADE MANU menu, choose Burner 1,
and set the valve position between 25% and 30%.
7. After the unit establishes a flame and runs for about a minute, unplug the Burner 1 flame detector
cable at front of unit. The unit should shut down and display a fault code of “E5” on the E8 controller
display. The E5 fault code indicates a loss of flame while running.
8. Plug the flame detector cable back onto the flame detector.
9. Reset the error displayed in the E8 controller (see paragraph 8.2 for instructions).
10. Place the unit in the AUTO Mode and the unit should now restart and fire normally.
11. Repeat the above procedure for each of the unit’s burners.
Flame
Ground Wire
View Port
Terminal
Flame
Detector
Cable
Igniter
Cable
MLX Rear with Panel Removed
Figure 8-4: Flame Detector and Ignition Component Locations
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Page 45 of 90
Chap 8: Safety
Device Testing
8.7
GF-115-H
OMM-0083_0B
SAFETY PRESSURE RELIEF VALVE TEST
Test the safety Pressure Relief Valve in accordance with the ASME Boiler and Pressure Vessel Code,
Section VI.
The ASME Boiler and Pressure Vessel Code (BPVC) is an American Society of Mechanical
Engineers (ASME) standard that provides rules for the design, fabrication, and inspection
of boilers and pressure vessels.
MC2: 10/03/12
Page 46 of 90
GF-115-H
TAG-0083_0B
CHAPTER 9: MAINTENANCE
9.1
Modulex Preventative Maintenance Kits
To perform the necessary maintenance tasks described in this section, AERCO offers a line of
maintenance kits for your Modulex boiler as described below.
9.1.1 Annual Maintenance Kit
Each Annual Maintenance Kit contains a flame detector, spark igniter, and associated gaskets. A
detailed description of the Annual Maintenance tasks can be found in Sub-section 9.2.
9.1.2 Fireside Inspection Kit
Each Fireside Inspection kit contains a flame detector, spark igniter, and gaskets for the flue collector,
burner modules and condensate tray. A detailed description of the Fireside Inspection tasks can be
found in Sub-section 9.3.
NOTE
The Fireside Inspection Kit already includes the components included in
the Annual Maintenance Kit, therefore, when performing the Fireside
Inspection, you only need the Fireside Inspection Kit, not both.
Figure 9-1: Typical Fireside Inspection Kit (L) and Annual Maintenance Kit (R)
Table 9-1: Modulex Maintenance Kit Part Numbers
Model & Kit Type
MLX-303 Maintenance
MLX-454 Maintenance
MLX-606 Maintenance
MLX-757 Maintenance
MLX-909 Maintenance
MLX-1060 Maintenance
MC2: 10/03/12
P/N
Kit 58019-01
Kit 58019-02
Kit 58019-03
Kit 58019-04
Kit 58019-05
Kit 58019-06
Model & Kit Type
MLX-303 Fireside Inspection
P/N
Kit 58019-07
Kit 58019-08
Kit 58019-09
Kit 58019-10
Kit 58019-11
Kit 58019-12
Page 47 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
Contact your local AERCO representative to order your kit.
9.2
Annual Maintenance Instructions
Following are the procedures necessary to perform the annual maintenance on all Modulex MLX boiler
models and sizes.
A correctly adjusted Modulex boiler needs very little care other than yearly maintenance. The frequency
of cleaning needed depends on the cleanliness of the air used for combustion. Note that dust present in
the air at the combustion intake will result in reduced burn efficiency and, consequently, reduced heat
output.
Annual maintenance consists of a number of recommended and required tasks as listed below. This
section provides instructions for the yearly requirement of inspection, and if necessary, replacement of
the igniter and flame detector for each burner section.
9.2.1 REQUIRED Tasks:
•
Inspect air filters (replace if needed, AERCO P/N 95261879)
•
Inspect condensate drain lines (clean if needed)
•
Check for gas leaks using a soapy solution
•
Inspect igniter and flame sensor (replace, Igniter: P/N 95251245, Detector: P/N 95251246)
•
Check pH of boiler system water (refer to Appendix C, Boiler Water Chemistry and Maintenance)
•
Check flame detection circuitry (See paragraph 9.2.3)
9.2.2 RECOMMENDED Tasks:
•
Inspect vent pipe (clean if needed)
•
Inspect flue collector & condensate tray (clean if needed) (see paragraph 9.3.6)
•
Wash heat exchanger (clean if needed) (see paragraph 9.3.3)
•
Check and adjust air/fuel ratio (see paragraph 7.5.5)
•
Inspect and clean burner surface (see paragraph 9.3.3)
•
Inspect heat transfer surfaces (clean if needed)
•
Clean strainer mesh (Monthly)
•
Check inlet gas pressure. Changes in gas pressure require combustion recalibration (see
paragraph 7.5.5)
•
Check vent and inlet air terminations
•
Check electrical supply voltages
9.2.3 Tools Required
Common hand tools, plus a spark gap feeler gauge are required to perform the annual maintenance tasks
described in this bulletin.
WARNING !
Prior to performing the following disassembly and inspection procedures,
ensure that all electrical power to the boiler has been turned off and the
external gas shut-off valve is fully closed.
!
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Page 48 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
Unit Disassembly for Annual Maintenance
1. Disconnect electrical power to the unit by turning off the external circuit breaker.
2. Turn off the external gas supply shutoff valve.
NOTE
The cover is secured with spring clips and pins to front, back and side
panels of the unit. In addition, two (2) groups of ground wires from the
frame of the boiler are attached with clips to the underside of the top
cover. Use care when disconnecting these ground wire clips. Note that
all lugs have capture spring clips that are released by pressing a small
nub under lug itself
3. Remove the top cover from the boiler. A screwdriver may be needed to pry the cover from the two
pins on either end.
4. Carefully detach the ground wire clips from the underside of the cover (see note above).
5. Remove the front panel from the boiler to provide access to the spark igniter and flame detector for
each heat module of the boiler (see Figure 9-2).
6. Refer to Figure 9-2 and locate the installed locations of the igniter and flame detector cables.
NOTE
The number of burner sections, and thus the electrical components,
varies by model.
Flame
Ground Wire
View Port
& Terminal
Igniter
Cable
MLX Rear with Panel Removed
Figure 9-2: Electrical Connection Locations
MC2: 10/03/12
Flame
Detector
Flame
Detector
Screws
Page 49 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
9.2.4 Replacing the Spark Igniters and Flame Detectors
The Spark Igniter and Flame Detector are replaced per the instructions below.
Replacing the Spark Igniter
The spark igniter for each heat module is installed to the left of the view port as shown in Figure 9-2.
Remove and replace as follows:
1. Disconnect the spark igniter ground wire and unplug the igniter cable.
2. Using a Phillips head screwdriver, remove the two (2) screws securing the igniter and remove it from
the boiler.
3. Obtain a replacement igniter from the maintenance kit. Using a spark gap feeler gauge, ensure that
the igniter spark gap is 4mm to 5 mm.
4. Install the replacement igniter and secure it in place with the two (2) screws removed in step (b).
5. Reconnect the igniter cable and ground wire
6. Repeat steps (1) through (5) for each igniter in the Modulex boiler.
Replacing the Flame Detector
The flame detector for each heat module is installed beneath the view port as shown in Figure 9-2.
Remove and replace as follows:
1. Disconnect the flame detector wire lead.
2. Using a Phillips head screwdriver, remove the two (2) screws securing the flame detector and remove
it from the boiler.
3. Obtain a replacement flame detector from the maintenance kit.
4. Install the replacement flame detector and secure it in place with the two (2) screws removed in step
(b).
5. Reconnect the flame detector wire lead.
6. Repeat steps (1) through (5) for each flame detector in the boiler.
9.2.5 Testing the Flame Detection Circuitry
The Modulex boiler is designed to automatically shut down in the absence of a flame to prevent the
buildup of unburned fuel in the combustion chamber. Test the circuit by removing a flame detector lead
from any of the burner sections (Figure 9-2) while the unit is running. If the unit shuts down after a few
seconds, the flame detection circuitry is functional. If boiler does not automatically shut down, there is a
problem with the circuit. In this case, manually shut down the boiler and contact appropriate technical
help to resolve the problem.
9.3
Fireside Inspection Instructions
This section provides instructions for a Fireside Inspection, including maintenance to the burner
modules, flue collector, spark igniter, and flame detector. A Fireside Inspection Kit may be purchased
from AERCO. A list of kit part numbers and models are in Table 9-1 in Sub-section 9.1.
Before going through the Fireside Inspection, it is advised to check the CO2 percentage at the boiler
input. If the CO2 percentage is within 5% of the value shown in Table 9-2, then the burner modules do
not need to be inspected and cleaned. The operation then can be limited to the inspection and cleaning
of the flue collector.
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Page 50 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
Table 9-2: Acceptable Combustion Gas Ratios at Boiler Input
GAS SUPPLY
OXYGEN (O2)
CARBON
DIOXIDE (CO2)
CARBON
MONOXIDE (CO)
NATURAL GAS
4.7% to 5.3%
9.1% to 8.8%
<100 ppm
PROPANE
4.4% to 5.0%
10.7% to 10.4%
<100 ppm
Note that a reduction of airflow at the input may indicate the burners need cleaning, but first check the
flue outlet and the air intake for any physical obstruction. If there is no obstruction, then proceed with
the maintenance procedures starting with unit disassembly per the instructions below.
9.3.1 Unit Disassembly for a Fireside Inspection
Tools required: Phillips head screwdriver, 13mm socket wrench (with extender), and an Exacto blade (or
small sharp knife). Access to a steel brush and water jet are also recommended.
WARNING !
ensure that all electrical power to the boiler has been turned OFF and
the external gas shut-off valve is fully CLOSED.
!
Unit Disassembly for Fireside Inspection
1. Disconnect electrical power to the unit by turning off the external circuit breaker.
2. Turn off the external gas supply shutoff valve.
3. Remove the top cover from the boiler. A screwdriver may be needed to pry the cover from the two
pins on either end. The cover is secured with spring clips and pins to the front, back and side panels
of the unit. In addition, two (2) groups of ground wires from the frame of the boiler are attached with
clips to the underside of the top cover. Use care when disconnecting these ground wire clips. Note
that all lugs have capture spring clips that are released by pressing a small nub under the lug body.
4. Remove the front panel from the boiler to provide access to the fan assembly cover (Figure 9-3).
5. Remove the screws from the various locations on the fan assembly cover. A sampling of screw
locations is shown in Figure 9-3.
6. Remove the plastic cap bolt covers (C) from the bottom of the fan chamber to access the bolts
holding the fan assembly in place (Figure 9-4).
7. Using a 13 mm socket wrench, remove the bolts D1, D2, D3, and D4 that secure the fan chamber
cover onto the burner assembly (Figure 9-5).
8. Unscrew the two air filters from each end of the burner manifold (Figure 9-6).
9. Remove the two screws and the sheet metal cover from each of two ends of the burner manifold
(Figure 9-7).
10. Position burner manifolds, at each end, 3/8” (10mm) higher than the standard position (Figure 9-8,
left). Line up the “E” hole of the gas pipe flange with the “G” hole of the side support panel and affix
with one of the two screws previously removed.
11. Lift up the fan group (L) by rotating it on the gas manifold axis and keep it up by inserting the
support rods (I), attached to the frame, in the holes (M) (Figure 9-9).
NOTE
There are six boiler models with two, three, four, five, six, or seven
burner modules. Figure 9-11 shows a Modulex MLX-606 with four
modules.
12. Access the condensate tray (N, Figure 9-10) and remove the cleaning plate (O) from the side
opposite from the flue collector (depends on which side it was originally installed). Remove the
screw securing the baffle (P) and lower the baffle onto the tray bottom.
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Page 51 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
Fan Assembly
Cover
Cover Screw Locations
Figure 9-3: Remove Fan Assembly Cover
Figure 9-4: Remove Fan Assembly Cover
D4
D3
Figure 9-5: Remove Plastic Bolt Covers (C)
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Page 52 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
Two Filters Located on Both
Ends of Burner Manifold
Figure 9-6: Removing Intake Filters
Figure 9-7: Removing End Plates
Figure 9-8: Reposition Endplates to Offset
MC2: 10/03/12
Page 53 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
Figure 9-9: Fan Assembly (L), Support Rod (I) and Holes (M)
Figure 9-10: Accessing Condensate Tray
Burner Modules
Figure 9-11: Fan Assembly Lifted to Access Burner Modules
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Page 54 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
9.3.2 Removing The Burner Modules
To remove the burner modules and gaskets, refer to the instructions, below.
NOTE
Before removing the burners and gaskets, verify if the gaskets have
been glued to the aluminum surface. If they have, apply an appropriate
solvent and let set for the recommended time before attempting to
remove the gaskets.
Removing Burner Module(s)
1. If present, remove all the grounding tabs (Figure 9-12) at the rear of the burner modules (one per
burner and screwed onto the boiler body) and discard. These are no longer needed as the new
replacement gaskets are self-grounding. Use only the newer style gaskets as replacements.
!
CAUTION
!
Ensure that the small plaited copper grounding used on OLD gaskets is
completely removed along with old gaskets from the burner mounting
surfaces.
2. Remove each burner module from its seat by inserting a cutter between the gasket and the aluminum
body on which it rests, and then carefully running the cutter down three sides of the burner. The
photos in Figure 9-13 show the (1) cutter being run along the shorter front edge, (2) along right long
edge, and (3) along left long edge.
3. Next, remove the burner by carefully rotating it upward ONLY along the left or right long edge axis (#4
in Figure 9-13). Take care to avoid deforming the burner module as it is removed.
Figure 9-12: Remove Ground Tabs
NOTE
Old style gaskets are orange. Newer style gaskets are grey.
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Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
1
2
3
4
Figure 9-13: Cutting the Gasket (1-3) and Removing a Burner Module (4)
9.3.3 Maintenance of Burner Modules and Combustion Chamber
After disassembly of the boiler, do the procedures as described below.
Maintenance of Burner Modules and Combustion Chamber
1. After removing the burner modules and sealing gaskets from the recesses, use compressed air and
blow the modules from the convex side to the dished side to blow away debris. Inspect for
deformations and damage to the mesh and the module body.
2. Inspect the combustion chamber below the burners for scale and ash. Using compressed air, blow
out the combustion chamber between the sections to remove all dirt and foreign particles from the
aluminum protrusions. Use a water jet to wash the chamber out. Use care to avoid wetting the
electrical wiring.
Inspect the flue duct and flue collector. During this operation, ensure that the condensate drain pipe is
free of blockage so water does not accumulate in the tray. Clean out the condensate tray of any scale
or ash collected from cleaning the combustion chamber.
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Page 56 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
9.3.4 Reassembly After Burner Mainentance
After maintenance, reassemble the unit as described below.
Unit Reassembly after Maintenance
1. THE BURNER SEALING GASKETS MUST ALWAYS BE REPLACED AFTER EACH BURNER
CLEANING. When positioning the replacement gaskets (P/N 95261173), place them on top of the
burner modules and not between the burner modules and aluminum boiler body.
2. Reassemble all other components previously removed by reversing the order of the disassembly
steps.
3. Before starting the boiler, verify that the condensate siphon and boiler are filled with water
and pump is running.
4. Before opening the gas cock on the burner manifold, make sure that the coupling is securely
tightened. To do this, open the gas cock and check the union for leaks using a soap solution.
5. As soon as a burner is put into operation, check immediately for leakage between the gas valve
and the relevant premixing chamber.
6. Perform the combustion analysis and check the combustion parameters per paragraph 7.5.5.
NOTE
Make sure that all gas pressure test nipples previously open, are closed
and tight.
9.3.5 Testing the Flame Detection Circuitry
The Modulex boiler is designed to automatically shut down in the absence of a flame to prevent the
buildup of unburned fuel in the combustion chamber. Test the circuit by removing a flame detector lead
from any of the burner sections (Figure 9-2) while the unit is running. If the unit shuts down after a few
seconds, the flame detection circuitry is functional.
9.3.6 Disassembly, Inspection, and Maintenance for the Flue Collector
Depending on the installation configuration, the flue collector may be installed on the left side, right side
or rear of the Modulex boiler. Inspect the flue collector per the instructions below.
Disassembly, Inspection, and Maintenance of the Flue Collector
1. Disconnect flue starter section from the flue collector by loosening the hose clamp (Figure 8-17).
2. Remove the flue collector and flue collector gasket from the condensate tray (Figure 8-17). The
collector is secured to the tray with three (3) M4 bolts (bottom flange) and three M4 hex nuts (top
flange). You will need to use a 7mm socket wrench with universal joint and extender to reach and
remove the nuts and bolts.
3. Disconnect exhaust connector and exhaust connector gasket from the flue collector by removing the
four (4) M5-20 bolts and washers shown in Figure 9-14.
4. Inspect and then clean the flue collector using a water jet or wet cloth.
5. Following inspection and cleaning refer to Figure 9-14, then reconnect the flue collector to the
condensate tray using a new flue collector gasket (P/N 95250612).
6. Install the exhaust connector using a new exhaust connector gasket (P/N 95250632).
7. Connect the flue starter section to the flue connector and secure it using the clamp removed in Step
1.
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Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
Flue Starter
Section
Hose Clamp
M4 Hex
Nuts (3)
Exhaust
Connect
M4 Bolts
(3)
Condensate Tray
Flue
Collector
Hose Clamp
M5-20 Bolt (4) &
5x15mm OD washers
Exhaust
Connect
Exhaust
Connector
Flue Collector
Flue Collector
Gasket
Figure 9-14: Flue Collector Parts and Assembly
MC2: 10/03/12
Page 58 of 90
Chap 9:
Maintenance
9.4
GF-115-H
OMM-0083_0B
Burner Section Replacement Instructions
The aluminum burner sections are typically only replaced in the unlikely event of a leak. For any kind of
leak in these parts the only recommended action is the replacement of the entire section in question.
WARNING !
ensure that all electrical power to the boiler has been turned off and the
external gas shut-off valve is fully closed.
!
Fan
Assembly
(in lifted
position)
Burner Modules
(3 each in this
model)
Burner
Gaskets
Burner
Section
(End)
Flow
Header
Burner
Section
(End)
Condensate
Tray Gasket
Return Header
Condensate
Tray
Metal Rods
Connecting
Sections (4 each)
Burner
Sections
(Middle)
Figure 9-15: Covers Removed Relevant to Burner Section Replacement
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Chap 9:
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GF-115-H
OMM-0083_0B
9.4.1 Disassembly For Burner Section Replacement
Follow instructions, below, to replace the aluminum burner sections in an MLX boiler.
IMPORTANT NOTE!
Refer to Paragraph 9.2.2 and 9.2.3 for detailed disassembly instructions
per steps 1-3. The burner gaskets, condensate tray gasket, and flue
collector gasket must always be replaced with new gaskets during this
maintenance task.
Unit Disassembly for Burner Section Replacement
1. Remove the top cover, side covers, and fan assembly cover (Paragraph 9.3.1.).
2. Unbolt fan assembly (Figures 9-5), remove filters (Figure 9-6), affix burner manifold ends into
cleaning position (Figures 9-7, 9-8).
3. Lift up the Fan/Burner assembly and insert support rods. (Figure 9-9).
4. Remove burner modules and gaskets. (Paragraph 8.3.2, Figures 9-12 and 9-13).
5. Remove the Flow Header (upper) and Return Header (lower) assembly (Figure 9-17, below), and
keep all hardware and gaskets for re-assembly.
6. Remove the electrical connections (igniter cable, ground lead, and flame detector cable) from each
aluminum section (Figure 9-18).
7. Disassemble flue collector from the condensate tray by removing the three (3) M4 screws along the
top flange and three (3) M4 bolts from along the bottom flange of tray (Figure 9-14).
8. Remove the nut and washer from the end of each of the four threaded metal rods that hold the
aluminum sections together. Slide the rods out from the other end (Figure 9-19).
9. Using a screwdriver, or appropriate hardened tool, leverage the affected sections apart while cutting
the silicone seal between them.
Flow
Header
(upper)
Return
Header
(lower)
Figure 9-17: Header Disassembly
MC2: 10/03/12
Page 60 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
Ground Lead
Mounting
Screws (2)
View
Port
Igniter
Cable
Flame
Detector
Lead
Figure 9-18: Electrical Connections on Rear of Burner Sections
9.4.2 Replacement of Burner Sections
After disassembly, discard any sections to be replaced and follow steps in the instructions below.
Combustion
Chambers
End Section
Middle Sections
End Section
Slide four
rods out
from
the end.
NOTE
In USA, use G.E.
Silicones as
source for
Grey Acetyl
Silicone (see
instruction).
Metal Rods
(4 ea, 2 per side)
Remove
Nut and Washer
(4 places)
Figure 9-19: Separating the Aluminum End and Middle Sections
MC2: 10/03/12
Page 61 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
Replacement of Aluminum Burner Sections
1. Remove any residual silicone from the exposed surfaces of sections being kept in service with a
sharp blade and/or appropriate solvent.
2. Apply two (2) new beads of grey silicone acetyl on each section side that will mate with another
section as indicated by the white lines in Figure 8-22; two (2) places on each side for middle sections
or two (2) places on one side for end sections. Use enough silicone to ensure a water-tight seal.
3. Place the new replacement section(s) together and reassemble with the four (4) metal rods, washers,
and nuts. Tighten hardware and wipe away any oozing excess silicone.
Silicon
Bead
Figure 9-20: Applying Silicone Beads on Replacement Section
9.4.3 Replacing the Condensate Tray Top Gasket
The aluminum burner assembly rests directly on top of the condensate tray gasket so it is necessary to
hoist the entire burner assembly up at least a little to access the gasket. Use a hoisting frame to avoid
damage to components by the tensioned straps. Follow instructions below to replace the gasket.
Replacement of Condensate Tray Top Gasket
1. Wrap hoisting straps around top left & right metal rods (holding sections together) at four points
where the rod enters a section, to avoid bending the rod. If boiler frame is used to anchor the hoisting
straps, make sure straps are securely fastened and not twisted before working under the burner
assembly.
2. This gasket is in four pieces which fit together into the appropriate shape. Remove each of four
gasket sections and any residual adhesive from the condensate tray top flange.
3. Install each of the four separate replacement gasket sections to the top flange of the condensate tray
from each side of the tray. Apply a long bead of silicone to affix the gasket to the tray and a long bead
of silicone to the top of the gasket to create a watertight seal between tray and burner assembly.
4. Lower the aluminum Burner Assembly back onto condensate tray.
MC2: 10/03/12
Page 62 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
IMPORTANT NOTE!
Whenever burner sections are removed for any reason, it is necessary to
replace the condensate tray gasket beneath with a NEW one (Figure 8-23).
Four Piece
Gasket
Figure 9-21: Condensate Tray with Top Gasket
MC2: 10/03/12
Page 63 of 90
Chap 9:
Maintenance
GF-115-H
OMM-0083_0B
9.4.4 Re-Assembly After Burner Section Replacement
Reverse the disassembly procedures to assemble. Follow instructions below.
Unit Reassembly After Burner Section Replacement
1. Reattach the flue collector back onto the condensate tray end (Figure 8-17).
2. Reattach the electrical connections (igniter cable, ground lead, and flame detector lead) back onto the
appropriate components on each aluminum section (Figure 8-20).
3. Reattach the flow and return header assemblies with hardware and gaskets (Figure 8-19).
4. Replace the burner modules and NEW replacement burner gaskets onto the burner assembly top.
See Paragraph 8.3.4 for instructions.
5. Disengage support rods from burner lid and lower into the down position (Figure 8-11).
6. Reposition manifold ends (Figures 8-9, 8-10) and reinstall filters to both ends (Figure 8-8).
7. Reinstall bolts D1, D2, D3, and D4 (Figure 8-7) and re-install the plastic protectors onto bolt recesses
(Figure 8-6).
8. Reassemble cover back onto fan assembly (Figure 8-5).
9. Prior to replacing the front panel on the boiler, check to ensure that:
10. All igniter cables and ground leads are firmly attached.
11. All flame detector wire leads are firmly attached.
12. All igniter and flame detector mounting screws are secure.
13. Replace the side and top cover panels.
14. Reconnect all ground wire clips to the underside of the top cover. Re-secure the top cover to the pins
and spring clips on the frame and sheet metal panels.
15. Apply external AC power to the unit by setting the external circuit breaker to the ON position.
16. Open the external gas shutoff valve to the boiler.
17. Before starting the boiler, verify that the condensate siphon is filled with water.
18. Before opening the gas cock on the burner manifold, make sure that the coupling is securely
tightened. To do this, open the gas cock and check the union for leaks using a non-corrosive soap
solution.
19. As soon as a burner is put into operation, check immediately for leakage between the gas valve
and the relevant premixing chamber.
20. Perform the combustion analysis and check the combustion parameters.
9.5
Final Testing and Return To Service
Upon completion of all inspections, maintenance tasks, and reassembly and prior to returning the
Modulex boiler to service use, perform the Initial Startup Procedure specified in Sub-section 7.5 of this
manual (GF-115-H). Perform the combustion analysis and check the combustion parameters per Subsection 7.5.5).
MC2: 10/03/12
Page 64 of 90
GF-115-H
TAG-0083_0B
CHAPTER 10: TROUBLE SHOOTING GUIDE
10.1 Introduction
This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a
fault in a Modulex Boiler. In the event of an operational failure, the controller used with Modulex boilers
will display a code to indicate the failure type. Troubleshooting procedures are presented in tabular form
on the following pages. The tables are comprised of three columns labeled: Fault Indication, Probable
Cause and Corrective Action. The numbered items in the Probable Cause and Corrective Action
columns correspond to each other. For example, Probable Cause No. 1 corresponds to Corrective
Action No. 1, etc.
When a fault occurs in the Modulex Boiler, proceed as follows to isolate and correct the fault:
1. Observe the fault code (E1, E2, E3, etc.) displayed in the controller display (Figure 9-1).
2. Refer to the Fault Indication column in Troubleshooting Tables, which follow, and locate the fault
that best describes the existing conditions.
3. Proceed to the Probable Cause column and start with the first item (1) listed for the Fault Indication.
4. Perform the checks and procedures listed in the Corrective Action column for the first Probable
Cause candidate.
5. Continue checking each additional Probable Cause for the existing fault until corrected.
6. Table 9-2, found at the end of this section, contains additional troubleshooting information which may
apply when no fault code is displayed.
NOTE
If the fault cannot be corrected using the information provided in the
Troubleshooting Tables, contact your local AERCO Representative.
MC2: 10/03/12
Page 65 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
Error Codes are
Displayed Here
Figure 10-1: E8 Controller Front Panel Showing Error Code in Display
Table 10-1: Boiler Troubleshooting – PCB Terminal
FAULT
INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
1. Temp HI Limit setting is too
low.
1. Check Temp HI Limit setting adjust Parameter to
2. Faulty temperature sensor.
2. Test the temperature sensor and replace if necessary.
3. Faulty Water temperature
switch.
3. Test the temp switch to insure it trips at actual water
4. Incorrect PID settings.
4. Check PID settings against Menu Default settings in
5. Faulty shell temp. sensor.
XXXXXX.
temp setting.
the Appendix. If the settings have been changed,
record the current readings then reset them to the
default values.
5. Use resistance charts in Appendix C. Measure the
E1:
Thermostat
indicates high
temperature limit
exceeded
6. Unit in Manual mode
7. Unit setpoint is greater than
Over Temp Switch setpoint.
8. Boiler Management System
PID or other settings not
correctly setup.
9. No interlock to boiler or BMS
to disable boiler(s) in event
that system pumps have
failed.
10. System flow rate changes
are occurring faster than
boilers can respond.
MC2: 10/03/12
resistance of Shell sensor and BTU sensor at a known
water temperature.
6. If unit is in Manual Mode switch to Auto Mode.
7. Check setpoint of unit and Temperature Switch;
Ensure that the temperature switch is set higher than
the unit’s setpoint.
8. Check the BMS for changes to PID default values and
correct.
9. If system pump is controlled by Energy Management
System other than BMS or pumps are individually
controlled by boiler, check to see if flow switches are
interlocked to the BMS or boiler.
10. If the system is a variable flow system, monitor
system flow changes to ensure that the rate of
flow change is not faster than what the boilers can
respond to.
Page 66 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
Table 10-1: Boiler Troubleshooting – PCB Terminal (Continued)
FAULT
INDICATION
E2:
Low gas
supply
pressure
PROBABLE CAUSES
1. Incorrect supply gas
pressure.
2. Defective Low
Pressure Gas Switch
CORRECTIVE ACTION
1. The optimum gas pressure for the Modulex Boiler is 7.0”
W.C., also used as desired pressure in the Combustion
Calibration procedures in Paragraph 6.5.5. The boiler can
be safel y operated at gas pressures ranging from 4.0” W.C.
(min) to 14” W.C. (max) per Gas Supply Design Guide GF115-G.
2. Measure gas pressure at the low gas pressure switch. If it is
greater than 2.6” W.C., measure continuity across the
switch and replace if necessary.
E4:
Flame lost
during
ignition
(FLDI)
1. Burner Ground
Screw not installed or
loose.
2. Worn flame detector
3. No spark from Spark
Plug
4. Defective Ignition
Transformer
5. Defective
Ignition/Stepper
(IGST) Board
6. Defective SSOV
7. Contaminated gas
supply (propane)
1. Inspect and install/retighten Burner Ground Screw.
2. Remove and inspect the flame detector for signs of wear.
Replace if necessary.
3. Close the internal gas valve in the boiler. Install and arc a
spark igniter outside the unit.
4. If there is no spark, check for 120VAC at the primary side to
the ignition transformer during the ignition cycle.
5. If 120VAC is not present, the IGST Board in the Control Box
may be defective. Refer fault to qualified service personnel.
6. While externally arcing the spark ignitor, observe open/close
indicator in Safety Shut-Off Valve to ensure it is opening. If
the valve does not open, check for 120VAC at the valves
input terminals. If 120VAC not present, the IGST board in
the Control Box may be defective. Refer fault to qualified
service personnel.
7. Investigate propane quality and switch supply if necessary.
E5:
Flame lost
during run
(FLDR)
1.
Annual maintenance
not done
2.
Air filter (Clogged)
3.
Burner clogged
4.
Heat exchanger
plugged
5.
Combustion
calibration not
correct
6.
7.
MC2: 10/03/12
Interrupted gas
supply and air
supply
Burner Ground
Screw not installed
or loose.
1.
Perform maintenance
2.
Clean or replace clogged filter
3.
Clean burner
4.
Clean and unclog heat exchanger
5.
Recalibrate combustion
6.
Check and clear obstructions to gas or air supply.
7.
Inspect and install/retighten Burner Ground Screw.
8.
Remove and inspect the flame detector for signs of wear.
Replace if necessary.
9.
Close the internal gas valve in the boiler. Install and arc a
spark igniter outside the unit.
10. If there is no spark, check for 120VAC at the primary side
to the ignition transformer during the ignition cycle.
Page 67 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
FAULT
INDICATION
PROBABLE CAUSES
8.
Worn flame detector
9.
No spark from Spark
Plug
10. Defective Ignition
Transformer
11. Defective
Ignition/Stepper
(IGST) Board
12. Defective SSOV
13. Defective Differential
Pressure Regulator
14. Carbon or other
debris on Burner
CORRECTIVE ACTION
11. If 120VAC is not present, the IGST Board in the Control
Box may be defective. Refer fault to qualified service
personnel.
12. While externally arcing the spark ignitor, observe the
open/close indicator in the Safety Shut-Off Valve to ensure
it is opening. If the valve does not open, check for 120VAC
at the valves input terminals. If 120VAC is not present, the
IGST board in the Control Box may be defective. Refer
fault to qualified service personnel.
13. Check gas pressure readings using gauge or manometer
into and out of the Air/Fuel Valve to ensure gas is getting to
the burner.
14. Remove the burner and inspect for any carbon or debris.
Clean and reinstall
E6:
Outlet water
temperature
as detected
by the
heating
sensor (SR)
exceeds
203°F.
Immersed
probe
Water is not flowing
properly. It’s detected
when the local Flow
Sensor temperature is >
203°F (95°C) and cleared
when it’s < 80°C (176°F).
Verify that the water circulation is flowing properly.
E10:
Local PCB
failure – BMM
Board
Boiler not seeing
information from Boiler
Management Module
PCB.
Check connections. If fault persists, contact qualified Service
Personnel.
E11:
Residual
flame at start
1. shorted flame rod
1. Annual Maintenance: Clean the flame rod
2. SSOV not fully
closed.
2. Check open/close indicator window of Safety Shut-Off Valve
(SSOV) and ensure that the SSOV is fully closed. If not fully
closed, replace the valve and or actuator.
Close gas shut-off valve downstream of SSOV. Install a
manometer or gauge in a gas test port between the SSOV
and the gas shut off valve. If a gas pressure reading is
observed replace the SSOV valve and or actuator.
1. Loose or broken
wiring.
1. Inspect Outlet Temperature sensor for loose or broken wiring.
2. Check resistance of sensor to determine if it is within specification.
E12:
Outlet
temperature
sensor failure
(SR)
MC2: 10/03/12
2. Defective Sensor.
Note: By opening the flap of the E8 and pushing the pushbutton,
an indication of the number of degrees that the burner is in error
is provided.
3. Ensure that the correct sensor is installed.
3. Incorrect Sensor.
Page 68 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
FAULT
INDICATION
PROBABLE
CAUSES
E13:
Auxiliary sensor
failure (DHW)
1. Open sensor circuit
1. Check circuit continuity and replace if defective.
2. Temperature out of
range
2. ??
3. Loose or broken
wiring.
E14:
Return
temperature
sensor failure
(SRR)
CORRECTIVE ACTION
3. Inspect Outdoor Temperature sensor for loose or
broken wiring.
4. Check resistance of sensor to determine if it is within
specification.
1. Open sensor circuit
1. Check circuit continuity and replace if defective.
2. Temperature out of
range
2. ??
3. Loose or broken
wiring.
3. Inspect Outdoor Temperature sensor for loose or broken
wiring.
Surface mount
sensor
specification.
E15:
Difference
between the
global flow
(supply/outlet)
temperature
sensor and the
return/inlet
temperature
sensor exceeds
72°F
This type of error code
typically indicates that
there is a water
circulation problem.
Examples when such a
situation might occur
includes situations
where the filter is dirty
or the pump is too small
(or damaged) with
respect to the power of
the boiler.
Check all possible causes of failed water circulation.
Included here would be a dirty filter, a malfunctioning water
pump, etc.
This error code is
presented when the Δtemperature = flow
temperature –
RetSensor
temperature is > 40°C
(104°F). It is cleared
when Δ-temperature <
30 °C (86 °F).
E16:
Low temperature
condition may
cause risk of
freezing
MC2: 10/03/12
1. Faulty controller
circuit not starting
boiler when
ambient temp is
less than 37.4ºF
(3ºC)
1. Replace controller circuit
2. Check return sensor and replace if damaged.
Page 69 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
FAULT
INDICATION
PROBABLE
CAUSES
2. Defective return
sensor not reading cold temps.
(Continued)
Low temperature
condition may
cause risk of
freezing
3.
Return temp is not
reaching 50°F
(10°C)
4. System has no
external
temperature
sensor switch to
turn on boiler
5. System pipes are
not sufficiently
insulated from cold
6. Water not properly
treated with antifreeze.
CORRECTIVE ACTION
3. Incorporate a hydronic separator (mixing bottle) to
isolate the boiler from the piping system.
4. Install external temperature sensor to piping system
5. Insulate piping system.
6. Treat water with anti-freeze (install backflow preventer).
E20:
Residual flame
is present after
burner is
switched off
1. Shorted flame rod
1. Annual Maintenance: Clean the flame rod
2. SSOV not fully closed.
2. Check open/close indicator window of Safety
Shut-Off Valve (SSOV) and ensure that the SSOV
is fully closed. If not fully closed, replace the valve
and or actuator. Close gas shut-off valve
downstream of SSOV. Install a manometer or
gauge in a gas test port between the SSOV and
the gas shut off valve. If a gas pressure reading is
observed replace the SSOV valve and or actuator.
E22:
Airflow fault
during ignition
(AFDI)
1.
Inlet filter clogged
1.
Replace filters with new ones
2.
Burner clogged
2.
Clean burners (see Sub-section 8.1)
3.
Combustion chamber
clogged
3.
Clear the chamber by brushing and flushing (see
Sub-section 8.1)
4.
Check valve in gas
manifold not opening
4.
Remove check valve from the manifold and
check operation, clean if necessary.
5.
Blower stopped running
due to thermal or
current overload
5.
Check combustion blower for signs of excessive
heat or high current drain that may trip thermal or
current overload devices.
6.
Blocked Blower inlet or
inlet ductwork
6.
7.
Blocked Blower proof
switch
Inspect the inlet to the combustion blower
including any ductwork leading up to the
combustion blower for signs of blockage.
7.
Blocked blocked-air
inlet switch
Remove the Blower proof switch and inspect for
signs of blockage, clean or replace as necessary.
8.
Remove the blocked-air inlet switch and inspect
for signs of blockage, clean or replace as
necessary.
8.
9.
MC2: 10/03/12
Defective Blower proof
Page 70 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
switch
10. Defective blocked-air
inlet switch
11. Loose temperature
transmitter to VFD’s
analog input wire
connection
(Continued)
Airflow fault
during ignition
(AFDI)
12. Loose temperature
sensor to temperature
transmitter wire
connection.
13. Defective temperature
transmitter
14. Defective temperature
sensor
15. Loose wire connection
between the 4-20 mA
signal from I/O box to
VFD analog input
16. Defective I/O box
17. Wrong 4-20 mA output
selection on the control
box
18. Defective air-fuel valve
potentiometer
9.
Measure the Blower proof switch for continuity
with the combustion blower running. If there is an
erratic resistance reading or the resistance
reading is greater than zero ohms, replace the
switch.
10. Measure the blocked-air inlet switch for continuity
with the combustion blower running. If there is an
erratic resistance reading or the resistance
reading is greater than zero ohms, replace the
switch.
11. Check the actual inlet air temperature and
measure voltage at temperature transmitter and
VFD analog input. Verify that the voltage
conforms to Table 8-3 for the inlet air
temperature.
12. Refer to CORRECTIVE ACTION 7 and verify that
the resistance conforms to Table 8-3.
13. See CORRECTIVE ACTION 7.
15. Measure amperage at the I/O box output and
VFD analog input, 4mA equates to 0% fire rate
and 20 mA equates to 100% fire rate
17. Check C-More configuration menu, mA OUT –
Fire Rate should be selected
19. Defective or missing
VFD’s logic stick
18. Check air fuel valve position at 0%, 50% and
100% fire rates, the position on the c-more
barograph should match the valve
20. 16. Defective program
on the logic stick or
Defective VFD.
19. Confirm that the logic stick is securely mounted
on the VFD
20. 16. Check the following VFD parameters: Max Hz
= 67, Min Hz = 0, parameter 59 & 60 should be
set to 2.
E23:
Air pressure
switch is always
active
1. Defective Switch or
Actuator
1. Check switch continuity, and either adjust or
replace the switch.
2. Incorrectly wired switch.
2. Ensure that the switch is correctly wired.
E24:
Blower speed is
incorrect for
ignition
1. Blower power connector
not properly attached to
blower.
1. Check blower connector to ensure it is properly
seated.
2. Bad wire connection.
3. Blower is faulty
MC2: 10/03/12
2. Check electrical continuity of blower wires. Repair
or replace wires if necessary.
3. Try connecting blower to connector from other
blower known to function properly. Replace
blower if blower still does not function properly.
Page 71 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
FAULT
INDICATION
E26:
Blower fails to
stop within 30
seconds of
termination of
ignition
PROBABLE CAUSES
1. Blower power connector
not properly attached to
blower.
2. Bad wire connection.
CORRECTIVE ACTION
1. Check blower connector to ensure it is properly
seated.
2. Check electrical continuity of blower wires. Repair
or replace wires if necessary.
3. Blower is faulty
3. Try connecting blower to connector from other
blower known to function properly. Replace
blower if blower still does not function properly.
1. Damaged hose.
1. Check hoses and replace if necessary.
2. Faulty switch.
2. Check switch and replace if damaged.
3. Damaged wires.
3. Check wiring for damage and repair if necessary.
E30:
Alteration of
parameters
settings due to
EMC
disturbances
1. Ground cabling loose or
damaged.
1. Check ground cabling and replace if necessary.
E32:
Electrical power
supply voltage <
108 VAC
1. Test power supply for
damage.
E27:
Air pressure
switch detects a
fault during
ignition time
MC2: 10/03/12
2. Interference with
external devices emitting
EMC.
2. Investigate for nearby devices emitting EMC
interference.
1. Repair or replace power source.
2. Reseat connections.
2. Check for loose power
wire connections
Page 72 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
Table 10-1: Boiler Troubleshooting – System Manager – Defective Sensor
FAULT
INDICATION
PROBABLE
CAUSES
CORRECTIVE ACTION
E69:
E8/1/F5 – Flow
sensor Heating
Circuit 2
Defective or
damaged PCB
Replace PCB
E70:
E8/5/F11 – Flow
sensor Heating
Circuit 1
Defective or
damaged PCB
Replace PCB
E71:
E8/1/F1 – Buffer
storage tank low
sensor
1. Loose or broken
wiring.
2. Defective
Sensor.
1. Inspect sensor for loose or broken wiring.
specification.
E72:
E8/1/F3 – Buffer
storage tank top
sensor
1. Loose or broken
wiring.
2. Defective
Sensor.
specification.
E75:
E8/1/F9 – Outdoor
sensor
1. Loose or broken
wiring.
specification.
E76:
E8/1/F6 – Storage
tank sensor
1. Loose or broken
wiring.
specification.
E78:
E8/1/F8 – Boiler
sensor
1. Loose or broken
wiring.
specification.
E80:
E8/1/F2 – Room
sensor for Heating
Circuit 1
1. Loose or broken
wiring.
specification.
MC2: 10/03/12
Page 73 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
Table 10-1: Boiler Troubleshooting – System Manager – Defective Sensor (Cont.)
FAULT
INDICATION
PROBABLE
CAUSES
E83:
E8/3/F15 – Room
sensor for Heating
Circuit 2
1. Loose or broken
wiring.
CORRECTIVE ACTION
specification.
E135:
E8/5/F12 – HW
storage tank low
sensor, MultiFunction relay
sensor 2
1. Loose or broken
wiring.
specification.
E136:
E8/8F13 –
(PT1000): HS2,
Collector 2, MultiFunction relay
sensor 3
1. Loose or broken
wiring.
E137:
E8/8/F14 –
(PT1000): Collector
1, Multi-Function 4
E138:
E8/3/F15 – Room
temperature sensor
for HC2
MC2: 10/03/12
specification.
1. Loose or broken
wiring.
specification.
1. Loose or broken
wiring.
specification.
Page 74 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
FAULT
INDICATION
PROBABLE
CAUSES
E90:
E8: BUS
addresses 0 and 1
both used. BUS
address 0 and 1
may not be used
simultaneously.
Bus setting incorrect.
Change setting to use only one bus.
E91:
E8: BUS ID
already used. The
set BUS ID is
already in use by
another device.
BMM rotary switches
improperly set –
duplicate address
settings.
Select unused BUS ID address for device.
E99:
E8: Internal failure
E-8 failure
Replace the E-8
E200:
E8: Complete
communication
loss to/from the
E8 such as would
occur when the
three way switch is
flipped to BCM
control
1. bcm three-way
switch is in the
wrong position
(zero position)
1. E200 fault is normal when the BMC is control by an
outside source using Modbus. (BMS II or EMS/BAS)
2. Check connection or replace harness.
2. Loose e-buss
connection (pink
and grey wires)
E201:
E8:
Communication
Error Module 1
BMM Board failure.
BMM Board harness
failure
Check with Desmond
E202:
E8:
Communication
Error Module 2
Same as E201
BMM Board failure.
BMM Board harness
failure
Check with Desmond
MC2: 10/03/12
CORRECTIVE ACTION
Page 75 of 90
Chap 10:
Troubleshooting
GF-115-H
OMM-0083_0B
FAULT
INDICATION
PROBABLE
CAUSES
E203:
E8:
Communication
Error Module 3
Same as E201
BMM Board failure.
BMM Board harness
failure
Check with Desmond
E204:
E8:
Communication
Error Module 4
Same as E201
BMM Board failure.
BMM Board harness
failure
Check with Desmond
E205:
E8:
Communication
Error Module 5
Same as E201
BMM Board failure.
BMM Board harness
failure
Check with Desmond
E206:
E8:
Communication
Error Module 6
Same as E201
BMM Board failure.
BMM Board harness
failure
Check with Desmond
E207:
E8:
Communication
Error Module 7
Same as E201
BMM Board failure.
BMM Board harness
failure
Check with Desmond
CORRECTIVE ACTION
Table 9-2: Boiler Troubleshooting – Internal Error
FAULT
INDICATION
E81:
E8: EEPROM
error. The invalid
value has been
replaced with the
default value
(Check parameter
values)
MC2: 10/03/12
PROBABLE
CAUSES
TBD
CORRECTIVE ACTION
TBD
Page 76 of 90
GF-115-H
TAG-0083_0B
CHAPTER 11: TEMPERATURE SENSOR RESISTANCE
CHART
Temperature Sensor Resistance Chart
TEMPERATURE
°F (°C)
-76 (-60)
-58 (-50)
-40 (-40)
-22 (-30)
-4 (-20)
14 (-10)
32 (0)
50 (10)
68 (20)
77 (25)
86 (30)
104 (40)
122 (50)
140 (60)
158 (70)
176 (80)
194 (90)
212 (100)
230 (110)
248 (120)
RESISTANCE
(OHMS)
698961
33908
167835
88340
48487
27648
16325
9952
6247
5000
4028
2662
1801
1244
876
628
458
339
255
194
The temperature sensors used in the Modulex boiler are 5k Ohm Negative Temperature Coefficient
(NTC). The relationship between temperature (°F or °C) and the nominal resistance (Ohms) of the
sensor are inversely proportional. That is; when temperature increases, sensor resistance decreases
and vice versa.
For Example:
At 77°F (25°C), the resistance is 5000 Ohms
At 194°F (90°C), the resistance is 458 Ohms
MC2: 10/03/12
Page 77 of 90
GF-115-H
TAG-0083_0B
CHAPTER 12: MODULEX PARTS DRAWING AND LIST
Modulex MLX Series Exploded Parts Drawing (Page 1 of 4)
MC2: 10/03/12
Page 78 of 90
Chap 12:
Part Drawings
GF-115-H
OMM-0083_0B
Modulex MLX Series Parts List (Page 2 of 4)
MC2: 10/03/12
Page 79 of 90
Chap 12:
Part Drawings
GF-115-H
OMM-0083_0B
MC2: 10/03/12
Page 80 of 90
Chap 12:
Part Drawings
GF-115-H
OMM-0083_0B
MC2: 10/03/12
Page 81 of 90
MC2: 10/03/12
1
1
64013
123675-2
3
4
1
1
9-320
99023
8
3/4" THERMOWELL
3/4" STREET ELL 90 B/I
3/4 PRESSURE RELIEF VALVE, 50 PSIG
1
SEE TABLE 1
6
7
2" NPT UNION
1
9-294
5
GAGE, PRESS/TEMP
AQUASTAT, 100°F TO 200°F
1
2" X 16"LG MANIFOLD ASS'Y, R.H. SIDE
LOW WATER CUT-OFF
1
DESCRIPTION
64015
QTY
22033
PART NO.
1
2
2
FRONT VIEW
1
ITEM
8
4
* - APPLIES ONLY TO UNITS WITH BOILER WATER CONNECTED TO THE LEFT HAND SIDE
*
3
TOP VIEW
7
LEFT HAND BOILER WATER CONNECTION
6
92014
ITEM #6 PART NO.
MLX-757, 909, 1060
TABLE 1
92013
BOILER MODEL
MLX-303, 454, 606
5
INTERNATIONAL, INC.
NORTHVALE, NJ 07647
DWN.BY CZ
SCALE
APPD.
DATE
DATE 091306
PL-A-152
B
REV.
CSD-1 WATER MANIFOLD ASSEMBLY
MODULEX GAS FIRED BOILER
AERCO
FRONT VIEW
TOP VIEW
RIGHT HAND BOILER WATER CONNECTION
Chap 12:
Part Drawings
GF-115-H
OMM-0083_0B
Page 82 of 90
GF-115-H
TAG-0083_0B
CHAPTER 13: BOILER WATER QUALITY AND
MAINTENANCE
IMPORTANT!
•
AERCO requires that the boiler loop to be de-coupled from the system loop. This can be achieved by
one of the following:
o Employing primary-secondary piping.
o Installation of a hydraulic separator between the boiler and the system loop.
o Installation of a heat exchanger (for example, plate heat exchanger) between the boiler and the
system loop. If water treatment used in the system is not Aluminum compatible, the use of
a heat exchanger between the system and the boiler piping is MANDATORY.
•
AERCO requires cleaning of the whole system and to fit a mandatory Y-strainer on the return pipe to
the boiler, equipped with isolation valves (See Figures 16 to 23 at the end of Piping Design
Application Guide GF115-P-H. See Section C.4 in this manual for Flushing, Treatment, and
Cleansing tips and guidelines).
•
For boiler replacement installations, cleaning of the whole system is required before connecting the
Modulex boiler (See Section C.4 for Flushing, Treatment, and Cleansing tips and guidelines).
•
Failure to clean a system will limit it from the full benefits offered by the high efficiency Modulex boiler.
•
Boiler drain valve and condensate drain trap should be arranged to permit the fluids to drain freely, by
gravity, to a convenient floor drain.
•
Relief valve must be installed vertically in the top, side, or to a valveless header connected to the
water supply outlet.
•
Locate water supply and return fittings (i.e. unions, elbows, etc.) a minimum of 6 inches (from the
boiler fittings to prevent interference with the removal of the boiler panels and covers.
•
All piping and electrical connections (i.e. service switches, conduit boxes, etc.) should be located at a
minimum of 6 inches from the boiler panels and covers.
• See Table 1 for sizing guidelines for the mandatory primary pump and boiler strainer.
A discharge pipe must be used and must not have an internal cross-sectional area less than the outlet of
the relief valve. The discharge pipe must be installed so that there will be no danger of scalding to the
boiler attendants. See Figure 1, next page, for discharge pipe example on the Modulex boiler. The relief
valve point of discharge piping must have provisions for proper drainage.
]
MC2: 10/03/12
Page 83 of 90
Chap 13: Boiler
Water Quality
GF-115-H
OMM-0083_0B
Figure 1: Relief
Valve Point of
Discharge Example
13.1 Modulex Boiler Water Chemistry
13.1.1 Reaction of Metals to Water Chemistry
Acidic condensates with a pH of 3.0 to 5.0 are commonly produced by the burning of natural gasses
within hydronic heating systems. It is very important to maintain a neutral chemistry of the water because
although the aluminum alloys used in the construction of Modulex boilers resist acidic conditions, they are
still vulnerable to highly alkaline environments (pH of 9.0 and above).
Metals, including aluminum, steel, iron, and copper used in hydronic heating systems are highly reactive
to acidic and alkaline chemical environments, so the water must be treated with protectants and buffers to
prevent corrosion of these metals. Because of this, most chemical water treatments have been developed
to protect an array of metals.
13.1.2 Scale and Corrosion
Free oxygen can cause the formation of rust (iron oxides), which degrades metallic materials. Magnetite
is formed in un-inhibited water if there is electrolytic action in the presence of oxygen. Sludge is formed
when calcium compounds, primarily CaCO3, are heated. Rust and magnetite, when combined with
sludge, can form a very hard scale, which significantly reduces system efficiency and life expectancy of
the heating system. Scale reduces heat exchange due to its low heat conductivity and so may cause very
dangerous localized overheating. Waterside corrosion of all heating circuit surfaces is also a major
concern.
13.1.3 Make-up or Feed Water Quality
Make-up or feed water is water added to a closed hydronic system to replenish water lost through
evaporation, maintenance, or leakage. The quality of make-up or feed water, which may contain
dissolved oxygen, minerals and other dissolved contaminants, is extremely important. Such introduced
water must be chemically treated or strictly limited when ensuring neutral chemical conditions in boiler
system water. Generally, any closed hydronic heating system should be restricted from receiving
untreated makeup water of no more than 5% of the total volume of system water per year.
13.1.4 Treating Water to Prevent Freezing
When using anti-freeze solutions, their compatibility with the AERCO Modulex aluminum heat exchanger
and other components of the heating system must be determined prior to use. Traditional HVAC
propylene glycol is not suitable for aluminum heat exchangers: the pH of the glycol at various dilutions is
in excess of 9.5, whereas the pH must be within 6.5 and 8.0 for use with aluminum. There are several
MC2: 10/03/12
Page 84 of 90
Chap 13: Boiler
Water Quality
GF-115-H
OMM-0083_0B
suitable aluminum safe propylene glycols available that can provide the same levels of burst, freeze and
corrosion inhibiting protection as traditional propylene glycols. Consult your local AERCO representative
for recommendations on glycol solutions. If a glycol solution is used as anti-freeze protection, a backflow
preventer must be installed upstream of the fill/makeup valve.
Only virgin glycol should be used for systems requiring freeze protection, and it must be treated with an
inhibitor compatible with the particular chemical treatment being used in the system. Note that glycol must
be changed from time to time due to its limited useful life.
13.1.5 Water Treatment Certification
When using chemical treatments in hydronic systems, it is necessary to ensure that the chosen treatment
is appropriate and certified by the manufacturer for such environments. The manufacturer should also
guarantee that the treatment, when applied according to the manufacturer’s recommendations, will not
cause harm to the boiler, pumps, piping, and other components of the hydronic boiler system.
13.2 Testing and Maintenance of Water Quality
Water in the installation should be checked, monitored, and treated for the following conditions and
characteristics:
•
Hardness - High hardness of the available water is measured in grains of hardness and indicates the
quantity of minerals (mostly calcium and magnesium) which are dissolved in the water. Hardness
substantially contributes to the formation of scaling, which is highly undesirable. The total hardness
must be less than 200 ppm (11.7 grains/gallon)
•
Artificial Softness – Do NOT use artificially softened water. Artificial softening agents generally use
salt, which creates a chloride water chemistry, a major contributor to the corrosion of the types of
metals used in hydronic systems. Elevated salt levels also contribute to higher conductivity levels,
another undesirable characteristic in hydronic systems.
•
Chloride - Chlorides are salts resulting from the combination of the gas chlorine with a metal and are
instrumental in accelerating corrosion in the types of metals used in hydronic systems. Chlorides may
be introduced into the water naturally. Concentrations of chlorides in system water should be less
than 150 ppm.
•
Conductivity – Dissolved metals and minerals increase the conductivity of water and indicate not
only the presence of undesired corrosive agents, but also contribute to the transfer and migration of
ions and charged particles in the water that contribute to fouling of sensors, valves, and other devices
used in the system. Additionally, high conductivity contributes to galvanic corrosion, in which one
metal will preferentially corrode when in contact with another type of metal, when both are in contact
with an electrolyte. Conductivity should be less than 3000 μS.
•
pH - The pH, a measure of the acidic, neutrality, and alkalinity of the water, MUST always be within
6.5 and 8.0 for boilers using aluminum alloys, such as the Modulex boiler system.
•
Oxygen - All precautions should be taken to avoid the formation and localization of oxygen in the
water of a heating system. Water that is low in minerals (soft water) absorbs oxygen much more
readily than mineralized (hard) water. For this reason it is necessary that in heating systems using
floor radiant heating, the plastic pipes used are impermeable to oxygen.
•
Scale and Corrosion - The use of an inhibitor is advisable to treat feed and make-up water and to
protect heating systems against scale, corrosion and microbiologic growth. To prevent freezing, the
use of an anti-freezing agent together with the inhibitor is advisable. Qualified companies can also
provide boiler de-scaling.
•
Total Solids - preferably less than 500 ppm, but a requirement of less than 1000 ppm
MC2: 10/03/12
Page 85 of 90
Chap 13: Boiler
Water Quality
•
GF-115-H
OMM-0083_0B
Water treatment is also advisable in the following cases:
o
Very large heating systems
o
High quantities of replenished water due to leakages or maintenance works
13.3 System Flushing, Treatment, and Cleansing
Note that prior to cleaning the heating system, the boiler MUST be isolated from the piping to prevent
infusion of containments, including sludge, into the boiler. Instruction 1.3, below, shows
recommendations for flushing, cleaning, and treating the water used in the Modulex boiler system.
IMPORTANT!
Cleaning solution and inhibitors used must be compatible with heat
exchanger material. Corrosion/scale inhibitor will be ineffective if
added to a dirty system; therefore, it is very important to clean the
system first.
Water treatments used must be compatible with EPDM gaskets used in
the Modulex Boiler. (EPDM = Ethylene Propylene Diene Manomer).
AERCO recommends the following cleaning solution, inhibitor, and antifreeze products.
www.aerco.com for Product Fact sheet and Material Safety Data Sheets:
Visit
Cleaning solution — Sentinel X400 Liquid System Restorer
4 x 1 gallon case – part number 99155-2
5 gallon jug – part number 99155-1
Corrosion/Scale Inhibitor — Sentinel X100 Liquid Inhibitor
4 x 1 gallon case – part number 99153-2
Antifreeze — Sentinel X500 Liquid Inhibited Antifreeze
275 gallon tote – part number 99156-3
When cleaning, treating, and maintaining, a heating system, consult a qualified professional. The
following are AERCO’s tips/guidelines for cleaning a heating system – these do NOT take precedence
over detailed instructions from qualified professionals.
•
Make sure to use appropriate amount of cleaning solution, carefully following the manufacturer’s
instructions. Follow the chemical manufacturer’s recommendations when introducing cleaning agents
into the system.
•
Ensure that the cleaning solution is circulated thoroughly in the system.
•
Flush the system thoroughly to remove the maximum amount of contaminants. When emptying the
system, make sure it is done as quickly as possible using all drain off points and ensuring all low lying
pipework is fully drained. Opening all bleed valves ensures the system will be completely emptied.
•
A reliable test to determine if a system is clean is if the Total Dissolved Solids (TDS) of the water
being drained is within 10% of the make-up water TDS. This indicates that sufficient contamination
has been flushed from the system. If the difference in TDS is more than 10%, it is recommended to
repeat the cleaning process until that is achieved. Turbidity test can be used as an alternate way to
determine if a system is clean.
MC2: 10/03/12
Page 86 of 90
Chap 13: Boiler
Water Quality
GF-115-H
OMM-0083_0B
•
For boiler retrofit/replacement installation, it will be necessary to repeat the cleaning process until the
draining water appears to be clear. Once clear, the above TDS comparison (or a turbidity test)
should be performed.
•
If a flushing machine is used in the cleaning process, carefully follow the manufacturer’s instructions.
If the flushing machine is designed to flush individual zones, the TDS comparison must be made
between each zone and the make-up water, or the turbidity test performed for each zone.
•
Add corrosion and scale inhibitor after the system has been declared clean, using the appropriate
amount recommended by the manufacturer. Introduce the Multi-Metal protector/scale inhibitor to the
system following the chemical treatment manufacturer’s instructions. Adding inhibitor to a dirty
system reduces its effectiveness. It is better to add more inhibitor than less – that is, it is better to
exceed the recommended amount than less.
•
When refilling the system, ensure the boiler is not air-bound by opening the pressure-relief valve
located at the rear of the boiler. Leave the relief valve open until a steady flow of water is observed.
Close the valve and finish filling the system.
13.4 Water Quality Maintenance and Boiler Warranty
Heat exchanger failures due to improperly cleaned/treated and poorly maintained water are not covered
under warranty. Scheduled system/boiler water maintenance is required to maintain the heat exchanger
warranty. AERCO shall reserve the right to require maintenance records when evaluating warranty
claims.
13.5 Water Treatment Certification
When using chemical treatments in hydronic systems, it is necessary to ensure that the chosen treatment
is appropriate and certified by the manufacturer for such environments. The manufacturer should also
guarantee that the treatment, when applied according to the manufacturer’s recommendations, will not
cause harm to the boiler, pumps, piping, and other components of the hydronic boiler system.
13.6 Water Treatment Analysis and Scheduling
The proper mixture of water, chemical treatment and glycol (if used) should be ascertained based on a
sample of the system water and the make-up water. Your local water treatment company, or one of the
manufacturers listed below, may analyze your sample. Adjust the chemical composition of your system
water based on the analysis. After this initial analysis, the chemical composition of your system water
should be tested at the beginning of the heating season for boilers operated to provide comfort heat.
However, for boilers operating year round, this analysis should be made at least twice a year.
MC2: 10/03/12
Page 87 of 90
Chap 13: Boiler
Water Quality
GF-115-H
OMM-0083_0B
13.7 Hydronic Water Testing and Treatment Resources
On the internet at www.awt.org, you may find a listing of water treatment firms and manufacturers of
chemical treatments developed for use in multi-metal hydronic systems. Click on the “Find a Water
Treater” button to access this list.
Below is a list of companies providing water treatment systems certified as safe for use in multi-metal
hydronic systems, including aluminum boilers. Contact any of the individuals listed for more information.
Fernox
Hydronic Agencies Ltd.
Sean Leonard
Edmonton, AB, CANADA
Phone: (780) 452-8661
Toll Free: (877) FERNOX4U
(877-337-6694)
Fax: (780) 488-2304
Email: [email protected]
www.hydronicagencies.com
Fernox USA
Cookson Electronics
Brian Conrad
Altoona PA
Phone: (814) 946-1611
Toll Free (800) 289-3797
Fax: (814) 944-8094
Email:
[email protected]
www.fernox.com
MC2: 10/03/12
H-O-H Water Technology, Inc.
Steve Sadowski
Greendale, WI
Phone: (414) 421-2070,
Toll Free: (800) 944-9746
Fax: (414) 421-2077
Email:
[email protected]
www.hohwatertechnology.com
Rhomar Water Management, Inc.
Dwight Hedgepeth
Springfield, MO
Phone: (417) 862-2600,
Toll Free: (800) 543-5975
Fax: (417) 862-6410
Email: [email protected]
www.rhomarwater.com
Page 88 of 90
GF-115-H
OMM-0083_0B
NOTES:
MC2: 10/03/12
Page 89 of 90
GF-115-H
OMM-0083_0B
© AERCO International, Inc., 2011
MC2: 10/03/12
Page 90 of 90

user manual

Transcription

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