USER MANUAL Installation, Operation, and Maintenance

Transcription

1 TAG-0083_0B Modulating, Condensing, Hot Water Boiler Models: MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX-1060 Modulex MLX Series Gas Fired Boiler USER MANUAL Installation, Operation, and Maintenance Modulex MLX Series Boiler Other manuals for this product include: GF-115-C MLX E8 Controller/BCM Manual GF-115-E MLX Electrical Power Guide GF-115-P-H MLX Piping Guide GF-115-V MLX Venting Guide GF-115-G MLX Gas Supply Guide Revised: 10/03/2012 MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 1 of 90

2 Technical Support: (Mon Fri, 8am-5pm EST) 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 2 of 90

3 TAG-0083_0B TABLE OF CONTENTS TABLE OF CONTENTS... 3 CHAPTER 1: SAFETY PRECAUTIONS... 7 Important For Massachusetts Installations... 8 CHAPTER 2: GENERAL DESCRIPTION Introduction To Technical Features Code and Standards Approvals Installation Flexibility Dimensions and Weights Technical Data Modulex Main Components Side View Boiler Freeze Protection CHAPTER 3: INSTALLATION Introduction to Installation Installation Instructions Unpacking the Boiler Boiler Location Pad Height for Boiler Boiler Connections Data Plate CHAPTER 4: GENERAL INFORMATION FOR VENTING Vent Pipe Connection Gas Vent Categories Installation And Sizing Existing Boiler Removal From Common Venting System CHAPTER 5: PIPING Makeup Water Quality Maximum Allowable Working Pressure Boiler Loop Design Guidelines CSD-1 Manifold Assembly (Supplied) Connecting Supply And Return Piping (Per ANSI Z21.13a) System Filling and Draining Notes On Condensate Drain Gas Mains and Connections CHAPTER 6: ELECTRICAL Electrical Connections MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 3 of 90

4 6.2 DHW (Domestic Hot Water) Storage Tank Enable / Disable Installation Of Sensors CHAPTER 7: BOILER OPERATION Introduction to Boiler Operation Modulation Theory Ignition Sequence Modes of Operation Indoor/Outdoor Reset To 10 Volt Remote Set-Point Constant Set-Point Boiler Operation for Troubleshooting (Manual Mode) Modulex Boiler Initial Startup Tools & Instruments Required For Combustion Calibration Installing the Supply Gas Manometer Preparing The Flue For Use With The Combustion Analyser Supply Gas Pressure Check & Adjustment Combustion Calibration Unit Reassembly CHAPTER 8: SAFETY DEVICE TESTING Testing of Safety Devices Processing and Clearing Fault Codes LOW GAS PRESSURE FAULT TEST LOW WATER LEVEL FAULT TEST WATER TEMPERATURE FAULT TEST FLAME FAULT TESTS SAFETY PRESSURE RELIEF VALVE TEST CHAPTER 9: MAINTENANCE Modulex Preventative Maintenance Kits Annual Maintenance Kit Fireside Inspection Kit Annual Maintenance Instructions REQUIRED Tasks: RECOMMENDED Tasks: Tools Required Replacing the Spark Igniters and Flame Detectors Testing the Flame Detection Circuitry Fireside Inspection Instructions MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 4 of 90

5 9.3.1 Unit Disassembly for a Fireside Inspection Removing The Burner Modules Maintenance of Burner Modules and Combustion Chamber Reassembly After Burner Mainentance Testing the Flame Detection Circuitry Disassembly, Inspection, and Maintenance for the Flue Collector Burner Section Replacement Instructions Disassembly For Burner Section Replacement Replacement of Burner Sections Replacing the Condensate Tray Top Gasket Re-Assembly After Burner Section Replacement Final Testing and Return To Service CHAPTER 10: TROUBLE SHOOTING GUIDE Introduction CHAPTER 11: TEMPERATURE SENSOR RESISTANCE CHART CHAPTER 12: MODULEX PARTS DRAWING AND LIST CHAPTER 13: BOILER WATER QUALITY AND MAINTENANCE Modulex Boiler Water Chemistry Reaction of Metals to Water Chemistry Scale and Corrosion Make-up or Feed Water Quality Treating Water to Prevent Freezing Water Treatment Certification Testing and Maintenance of Water Quality System Flushing, Treatment, and Cleansing Water Quality Maintenance and Boiler Warranty Water Treatment Certification Water Treatment Analysis and Scheduling Hydronic Water Testing and Treatment Resources MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 5 of 90

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7 TAG-0083_0B CHAPTER 1: SAFETY PRECAUTIONS The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.! DANGER! 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.! CAUTION! 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. 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 7 of 90

8 Chap 1: Safety Precautions 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) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 8 of 90

9 Chap 1: Safety Precautions 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 9 of 90

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11 TAG-0083_0B \ 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 MBTU/Hr. The smallest Modulex 303, comprised of two heat modules, has a combined total input of 303,000 BTU/Hr (2 x = 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 MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 11 of 90

12 Chap 2: General Description 2.2 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 : NOx emissions from water heaters and small boilers. CSD : Controls and safety devices for automatically fired boilers. Table 2-1: Modulex Boiler Output Range, Turn-Down Ratio & Condensate Production Output Range MBH 1 Turn Heat Condensate Production [gph (l/h)] Model (KW) Down Modules Min. Max. Ratio Min. Max. 2 MLX (12) 279 (82) 6:1 1.3 (5) 3.4 (13) 3 MLX (12) 418 (122) 10:1 1.9 (7.3) 5.3 (20) 4 MLX (12) 558 (163) 13:1 2.7 (10.1) 7.1 (27) 5 MLX (12) 696 (204) 16:1 3.3 (12.6) 9.0 (34) 6 MLX (12) 835 (245) 20:1 4.0 (15.1) 10.6 (40) 7 MLX (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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 12 of 90

13 Chap 2: General Description 2.4 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 (340 mm) L (340 mm) 8.78 (223 mm) 8.78 (223 mm) 4.33 (110 mm) (315 mm) (425 mm) S 4.33 (110 mm) TOP VIEW (268 mm) (350 mm) Ø D B C H A (345 mm) B Figure 2-1: Modulex Dimensions and Weights (Diagram 1 of 2) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 13 of 90

14 Chap 2: General Description LEFT HAND SIDE VIEW 8.35 (212 mm) RIGHT HAND SIDE VIEW 4.96 (126 mm) 8.35 (212 mm) (301 mm) 6.90 (175 mm) 8.66 (220 mm) M R G (1053 mm) (927 mm) G M R (265 mm) 8.66 (220 mm) (532 mm) (393 mm) 4.17 (106 mm) (452 mm) (455 mm) (695 mm) DIMENSIONS Figure 2-1: Modulex Dimensions and Weights (Diagram 2 of 2) Table 2-2: Modulex Models Dimensions and Weights MLX-303 MODULEX MODELS 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) (1053) (1053) (1053) (1053) (1053) (1053) WIDTH "L" NET IN (MM) (695) (695) (834) (968) (1102) (1236) WIDTH W/PACKAGING IN (MM) (770) (770) 35.7 (908) 41.0 (1042) 46.3 ( /1310 DEPTH "C" IN (MM) (942) DEPTH "A" IN (MM) (695) (942) (942) (942) (942) (942) (695) (695) (695) (695) (695) DEPTH "B" IN (MM) (820) (820) (820) (820) (820) (820) DEPTH W/PACKAGING IN (MM) (780) (780) (780) (780) (780) (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) CONNECTION 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) EXH. VENT CONNECTION "D" IN (MM) 4 (102) 4 (102) 4 (102) 6 (152) 6 (152) 6 (152) 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) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 14 of 90

15 Chap 2: General Description 2.5 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 , , , , ,000 MLX , , , , ,000 MLX , , , , ,000 MLX , , , , ,000 MLX , , , , ,000 MLX ,500 1,060, , , ,000 DIMENSIONS: Model Number Height Width Depth Weight MLX (1067 mm) 28 (711 mm) 27 (686 mm) 405 lbs. (183.7 kg) MLX (1067 mm) 28 (711 mm 27 (686 mm) 484 lbs. (219.6 kg) MLX (1067 mm) 33 (838 mm) 27 (686 mm) 575 lbs. (260.8 kg) MLX (1067 mm) 38 (965 mm) 27 (686 mm) 673 lbs. (305.2 kg) MLX (1067 mm) 44 (112 mm) 27 (686 mm) 765 lbs. (346.8 kg) MLX (1067 mm) 49 (1245 mm) 27 (686 mm) 869 lbs. (394.0 kg) SPECIFICATIONS: Model Number MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX-1060 Boiler Category IV IV IV IV IV IV Type of Gas Natural Gas (MLX-303B) or Propane (MLX-303BP) Natural Gas (MLX-454B) or Propane (MLX-454BP) Natural Gas (MLX-606B) or Propane (MLX-606BP) Natural Gas (MLX-757B) or Propane (MLX-757BP) Natural Gas (MLX-909B) or Propane (MLX-909BP) Natural Gas (MLX-1060B) or Propane (MLX- 1060BP) Gas Connections (NPT) Max. Gas Pressure 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) Optimal Gas Pressure 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) Min. Gas Pressure (10 mbar) (10 mbar) (10 mbar) (10 mbar) (10 mbar) (10 mbar) Max. Allowed Working Pressure 92 psi (634 kpa) 92 psi (634 kpa) 92 psi (634 kpa) 92 psi (634 kpa) 92 psi (634 kpa) 92 psi (634 kpa) Electrical Req: 120V 15 Amp. Max. 1.2 FLA 1.8 FLA 2.4 FLA 3.0 FLA 3.6 FLA 4.2 FLA Water Connections (NPT) 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 Min. Water Flow (GPM) Max. Water Flow (GPM) Water Pressure Max. Flow (Ft. of Head) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 15 of 90

16 Chap 2: General Description SPECIFICATIONS (Continued): Model Number MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX-1060 Water Volume: Gallons Water Volume: Liters Thermal Modules 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 Maximum Noise Level NOx Emissions Certification Standard Listings & Approvals All units can be applied to deliver 50 F to 185 F (10 C to 85 C) supply water. All units deliver <50 dba when operating at or below full fire. All units have been certified by SCAQMD and TCEQ for <30 ppm NOx. All units have been certified by CSA and Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD 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 GAS PIPE BURNER COVER IGNITION FLAME DETECTOR LOCAL NTC SENSOR H.L. THERMOSTAT BURNER ALUMINUM/ SILICON HEAT EXCHANGER AIR INTAKE CONNECTION AUTOMATIC AIR VENT GLOBAL FLOW NTC TEMPERATURE SENSOR HOT WATER OUTLET (SUPPLY) 1/4" CONNECTION WITH PLUG GLOBAL RETURN NTC TEMPERATURE SENSOR BOILER FRAME CONDENSATE COLLECTION TRAY MANIFOLD COLD WATER INLET (RETURN) WATER DRAIN VALVE CONDENSATE DRAIN TRAP FILLING-UP ELBOW 5.9" [150 mm] 4" [100 mm] 1" [25 mm] Figure 2-2: Modulex Main Components MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 16 of 90

17 Chap 2: General Description 2.7 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 17 of 90

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19 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 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 19 of 90

20 Chap 3: Installation 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 inch for models 757 to 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 with 50 psig Relief Valve Kit P/N 29074: For Models with 50 psig Relief Valve Kit P/N 29075: For Models with 90 psig Relief Valve Kit P/N 29076: For Models with 90 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 20 of 90

21 Chap 3: Installation 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 Pad Height for Boiler! WARNING! The boiler MUST NOT be installed on carpeting. 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 21 of 90

22 Chap 3: Installation 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 22 of 90

23 Chap 3: Installation 3.3 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. MODEL NO. TYPE OF GAS MAX INPUT MIN. INPUT OUTPUT NET I=B=R RATING BOILER CATEGORY MAX. MIN. FOR PURPOSE OF INPUT ADJUSTMENT ELECTRICAL INPUT 115V LESS THAN 12AMPS ANSI Z21.13 CSA 4.9 PERMISSIBLE INLET GAS PRESSURE NORMAL NORMAL MANIFOLD PRESSURE CERTIFIED BY: UNICAL AG SPA MAWP, Water 50psi Maximum Water 200 F Minimum relief valve capacity 159 Paris Avenue, Northvale NJ SERIAL NO. RATINGS-BTUH REV. I= B= BTU/HR BTU/HR BTU/HR BTU/HR IN. W.C. IN. W.C. IN. W.C. IN. W.C. LOW PRESSURE BOILER R BTU/HR 1. TURN POWER TO THE BOILER ON AND FOLLOW OPERATING INSTRUCTIONS FOR THIS BOILER WHICH ARE LOCATED NEAR THIS RATING. 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 INSTALLATION ON COMBUSTIBLE FLOORS, MINIMUM CLEARANCES TO COMBUSTIBLE CONSTRUCTION ARE: TOP FRONT FLUE CONN. REAR SIDES CAUTION BEFORE LIGHTING MAKE CERTAIN HOT WATER SYSTEM IS FULL OF WATER FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. IMPORTANT INPUTS 400,000 BTU/HR. OR LESS 0 24 CLOSET INPUTS OVER 400,000 BTU/HR GREATER CLEARANCES FOR ACCESS SHOULD SUPERSEDE FIRE PROTECTION CLEARANCES. 2. ALLOW 24 INCHES AT FRONT AND TOP FOR SERVICING AND CLEANING. 3. FOR INSTALLATION ON COMBUSTIBLE FLOORS "BLUE FLAME" "BLUE STAR" Figure 3-4: Sample Data Plate MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 23 of 90

24 Chap 3: Installation Table 3-1: Modulex Data Plate Entries MODEL NUMBER MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX-1060 REVISION A A A A A A TYPE OF GAS NATURAL GAS (MLX-303H) OR PROPANE (MLX-303HP) NATURAL GAS (MLX-454H) OR PROPANE (MLX-454HP) NATURAL GAS (MLX-606H) OR PROPANE (MLX-606HP) NATURAL GAS (MLX-757H) OR PROPANE (MLX-757HP) NATURAL GAS (MLX-909H) OR PROPANE (MLX-909HP) NATURAL GAS (MLX-1060H OR PROPANE (MLX-1060HP) *SERIAL NO. 303-XX-XXXX 454-XX-XXX 606-XX-XXXX 757-XX-XXXX 909-XX-XXXX 1060-XX- XXXX MAX INPUT 303, , , , ,000 1,060,000 MIN INPUT 45,000 45,000 45,000 45,000 45,000 45,000 OUTPUT 279, , , , , ,000 NET IBR RATING 237, , , , , ,000 BOILER CATEGORY IV IV IV IV IV IV MAX INLET (SUPPLY) GAS PRESSURE 14 W.C (34.8 mbar). MIN INLET (SUPPLY) GAS PRESSURE 4 (10 mbar) *NORMAL MANIFOLD GAS PRESSURE OPTIMAL INLET (SUPPLY) GAS PRESSURE 3.2 Nat. Gas (MLX-303H) 2.5 Propane (MLX-303HP) 7.0 (17.4 mbar) 14 W.C (34.8 mbar). 4 (10 mbar) 3.2 Nat. Gas (MLX-454H) 2.5 Propane (MLX-454HP) 7.0 (17.4 mbar) 14 W.C (34.8 mbar). 4 (10 mbar) 3.2 Nat. Gas (MLX-606H) 2.5 Propane (MLX-606HP) 7.0 (17.4 mbar) 14 W.C (34.8 mbar). 4 (10 mbar) 3.2 Nat. Gas (MLX-757H) 2.5 Propane (MLX-757HP) 7.0 (17.4 mbar) 14 W.C (34.8 mbar). 4 (10 mbar) 3.2 Nat. Gas (MLX-909H) 2.5 Propane (MLX-909HP) 7.0 (17.4 mbar) * NOTE: Normal manifold gas pressure measured at downstream port of gas valve. 14 W.C (34.8 mbar). 4 (10 mbar) 3.2 Nat. Gas (MLX-1060H) 2.5 Propane (MLX-1060HP) 7.0 (17.4 mbar) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 24 of 90

25 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 25 of 90

26 Chap 4: General Venting Information 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 26 of 90

27 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: 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 5.5 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 27 of 90

28 Chap 5: Piping 5.6 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. INITIAL TRAP FILLING-UP PLUG THE UPPER PART OF THE DRAIN PIPE SHALL NOT BE HIGHER THAN THE TRAY BOTTOM BOILER ROOM FLOOR 5.9" [150 mm]** 5.9" [150 mm]** TO CONDENSATE DRAIN WITH MIN. INCLINATION OF 3/8 IN/FT [30 mm/m] TOWARD DRAIN 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 28 of 90

29 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 29 of 90

30 Chap 6: Electrical 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 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. Cable to 3-Pole Plug Terminal Block 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 30 of 90

31 Chap 6: Electrical 6.2 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 MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 31 of 90

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33 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 63 o F to 72 o F (35 C to 40 C) Burner will stay at 45,500 BTU s 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 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 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 MBH (22.2 kw) out of a possible 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 MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 33 of 90

34 Chap 7: Boiler Operation 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 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 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 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 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 CO 2 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 (), 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). MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 34 of 90

35 Chap 7: Boiler Operation 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) Tools & Instruments Required For Combustion Calibration The following tools and instrumentation are necessary to perform combustion calibration: Digital Combustion Analyser: Oxygen (O 2 ) and Carbon Dioxide (CO 2 ) 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.) 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). MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 35 of 90

36 Chap 7: Boiler Operation Gas Valve Inlet Gas Supply OPEN CLOSE Figure 7-1: Gas Pressure Tap Location and Orientation 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 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 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 36 of 90

37 Chap 7: Boiler Operation 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. Turn the Rotary Knob clockwise until CASCADE MANU is displayed. 10. Press the Program Key. BOILER 1 will be displayed. 11. Press the Program Key again. The display will show CODE NO., requesting valid code to be entered. 12. 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 on next page. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 37 of 90

38 Chap 7: Boiler Operation Standby/ OFF AUTO MODE Combustion Calibration. AUTO MODE 2 SUMMER MODE DAY MODE NIGHT MODE Figure 7-2: Heat Mode Symbols SERVICE MODE 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 (O 2 ), carbon dioxide (CO 2 ) 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 Oblique View: Gas Valve Gas Valves (Detail at Right) Exposed Offset Adjustment Screw OPEN CLOSE Pressure Tap Outlet And Adjustment Screw Cap Screw Removed Outlet Pressure Tap Figure 7-3: Gas Valve Offset Adjustment Screw and Outlet Pressure Tap MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 38 of 90

39 Chap 7: Boiler Operation 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) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 39 of 90

40 Chap 7: Boiler Operation Table 7-1: Acceptable Combustion Gas Ratios at Boiler Input GAS SUPPLY OXYGEN (O 2 ) CARBON DIOXIDE (CO 2 ) 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 (O 2 ) level is within the range shown in Table 7-1 above. Also, ensure that the carbon dioxide (CO 2 ) 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 40 of 90

41 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 41 of 90

42 Chap 8: Safety Device Testing 8.3 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 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 42 of 90

43 Chap 8: Safety Device Testing 8.4 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 43 of 90

44 Chap 8: Safety Device Testing 8.5 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 44 of 90

45 Chap 8: Safety Device Testing 8.6 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. Igniter Cable Ground Wire Terminal Flame View Port Flame Detector Cable MLX Rear with Panel Removed Figure 8-4: Flame Detector and Ignition Component Locations MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 45 of 90

46 Chap 8: Safety Device Testing 8.7 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 46 of 90

47 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 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 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 P/N MLX-303 Maintenance Kit MLX-454 Maintenance Kit MLX-606 Maintenance Kit MLX-757 Maintenance Kit MLX-909 Maintenance Kit MLX-1060 Maintenance Kit Model & Kit Type P/N MLX-303 Fireside Inspection Kit MLX-454 Fireside Inspection Kit MLX-606 Fireside Inspection Kit MLX-757 Fireside Inspection Kit MLX-909 Fireside Inspection Kit MLX-1060 Fireside Inspection Kit MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 47 of 90

48 Chap 9: Maintenance 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 REQUIRED Tasks: Inspect air filters (replace if needed, AERCO P/N ) Inspect condensate drain lines (clean if needed) Check for gas leaks using a soapy solution Inspect igniter and flame sensor (replace, Igniter: P/N , Detector: P/N ) Check ph of boiler system water (refer to Appendix C, Boiler Water Chemistry and Maintenance) Check flame detection circuitry (See paragraph 9.2.3) 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 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 48 of 90

49 Chap 9: Maintenance 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. Igniter Cable Ground Wire & Terminal Flame View Port Flame Detector MLX Rear with Panel Removed Figure 9-2: Electrical Connection Locations Flame Detector Screws MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 49 of 90

50 Chap 9: Maintenance 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 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 CO 2 percentage at the boiler input. If the CO 2 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 50 of 90

51 Chap 9: Maintenance Table 9-2: Acceptable Combustion Gas Ratios at Boiler Input GAS SUPPLY OXYGEN (O 2) CARBON DIOXIDE (CO 2) 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 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! 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. 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 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 51 of 90

52 Chap 9: Maintenance 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) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 52 of 90

53 Chap 9: Maintenance 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 53 of 90

54 Chap 9: Maintenance 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 MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 54 of 90

55 Chap 9: Maintenance 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 55 of 90

56 Chap 9: Maintenance Figure 9-13: Cutting the Gasket (1-3) and Removing a Burner Module (4) 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 56 of 90

57 Chap 9: Maintenance 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 ), 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 NOTE Make sure that all gas pressure test nipples previously open, are closed and tight 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 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 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 ). 6. Install the exhaust connector using a new exhaust connector gasket (P/N ). 7. Connect the flue starter section to the flue connector and secure it using the clamp removed in Step 1. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 57 of 90

58 Chap 9: Maintenance Flue Starter Section Hose Clamp Exhaust Connect Flue Collector M4 Hex Nuts (3) M4 Bolts (3) Condensate Tray 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 58 of 90

59 Chap 9: Maintenance 9.4 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! 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. Fan Assembly (in lifted position) Burner Modules (3 each in this model) Burner Gaskets Burner Section (End) Condensate Tray Gasket Flow Header Burner Section (End) Condensate Tray Metal Rods Connecting Sections (4 each) Return Header Burner Sections (Middle) Figure 9-15: Covers Removed Relevant to Burner Section Replacement MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 59 of 90

60 Chap 9: Maintenance Disassembly For Burner Section Replacement Follow instructions, below, to replace the aluminum burner sections in an MLX boiler. IMPORTANT NOTE! Refer to Paragraph and 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 ). 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 60 of 90

61 Chap 9: Maintenance Ground Lead Mounting Screws (2) View Port Igniter Cable Flame Detector Lead Figure 9-18: Electrical Connections on Rear of Burner Sections 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) Figure 9-19: Separating the Aluminum End and Middle Sections Remove Nut and Washer (4 places) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 61 of 90

62 Chap 9: Maintenance 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 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 62 of 90

63 Chap 9: Maintenance 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 63 of 90

64 Chap 9: Maintenance 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 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 (). Perform the combustion analysis and check the combustion parameters per Subsection 7.5.5). MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 64 of 90

65 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 65 of 90

66 Chap 10: Troubleshooting 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 E1: Thermostat indicates high temperature limit exceeded PROBABLE CAUSES 1. Temp HI Limit setting is too low. 2. Faulty temperature sensor. 3. Faulty Water temperature switch. 4. Incorrect PID settings. 5. Faulty shell temp. sensor. 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. CORRECTIVE ACTION 1. Check Temp HI Limit setting adjust Parameter to XXXXXX. 2. Test the temperature sensor and replace if necessary. 3. Test the temp switch to insure it trips at actual water temp setting. 4. Check PID settings against Menu Default settings in 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 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 66 of 90

67 Chap 10: Troubleshooting Table 10-1: Boiler Troubleshooting PCB Terminal (Continued) FAULT INDICATION E2: Low gas supply pressure E4: Flame lost during ignition (FLDI) PROBABLE CAUSES 1. Incorrect supply gas pressure. 2. Defective Low Pressure Gas Switch 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) 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 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 GF- 115-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. 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. Interrupted gas supply and air supply 7. 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 67 of 90

68 Chap 10: Troubleshooting Table 10-1: Boiler Troubleshooting PCB Terminal (Continued) 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 E10: Local PCB failure BMM Board E11: Residual flame at start E12: Outlet temperature sensor failure (SR) 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). Boiler not seeing information from Boiler Management Module PCB. 1. shorted flame rod 2. SSOV not fully closed. 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. Verify that the water circulation is flowing properly. 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. Check connections. If fault persists, contact qualified Service Personnel. 1. Annual Maintenance: Clean the flame rod 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. Inspect Outlet Temperature sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 68 of 90

69 Chap 10: Troubleshooting Table 10-1: Boiler Troubleshooting PCB Terminal (Continued) FAULT INDICATION E13: Auxiliary sensor failure (DHW) E14: Return temperature sensor failure (SRR) Surface mount sensor PROBABLE CAUSES 1. Open sensor circuit 2. Temperature out of range 3. Loose or broken wiring. 4. Defective Sensor. 5. Incorrect Sensor. 1. Open sensor circuit 2. Temperature out of range 3. Loose or broken wiring. 4. Defective Sensor. 5. Incorrect Sensor. CORRECTIVE ACTION 1. Check circuit continuity and replace if defective. 2.?? 3. Inspect Outdoor Temperature sensor for loose or broken wiring. 4. Check resistance of sensor to determine if it is within specification. 5. Ensure that the correct sensor is installed. 1. Check circuit continuity and replace if defective. 2.?? 3. Inspect Outdoor Temperature sensor for loose or broken wiring. 4. Check resistance of sensor to determine if it is within specification. 5. Ensure that the correct sensor is installed. 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. This error code is presented when the Δ- temperature = flow temperature RetSensor temperature is > 40 C (104 F). It is cleared when Δ-temperature < 30 C (86 F). Check all possible causes of failed water circulation. Included here would be a dirty filter, a malfunctioning water pump, etc. E16: Low temperature condition may cause risk of freezing 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 69 of 90

70 Chap 10: Troubleshooting FAULT INDICATION (Continued) Low temperature condition may cause risk of freezing Table 10-1: Boiler Troubleshooting PCB Terminal (Continued) PROBABLE CAUSES 2. Defective return sensor not reading cold temps. 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 E22: Airflow fault during ignition (AFDI) 1. Shorted flame rod 2. SSOV not fully closed. 1. Inlet filter clogged 2. Burner clogged 3. Combustion chamber clogged 4. Check valve in gas manifold not opening 5. Blower stopped running due to thermal or current overload 6. Blocked Blower inlet or inlet ductwork 7. Blocked Blower proof switch 8. Blocked blocked-air inlet switch 9. Defective Blower proof 1. Annual Maintenance: Clean the flame rod 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. Replace filters with new ones 2. Clean burners (see Sub-section 8.1) 3. Clear the chamber by brushing and flushing (see Sub-section 8.1) 4. Remove check valve from the manifold and check operation, clean if necessary. 5. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices. 6. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage. 7. 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 70 of 90

71 Chap 10: Troubleshooting Table 10-1: Boiler Troubleshooting PCB Terminal (Continued) (Continued) Airflow fault during ignition (AFDI) E23: Air pressure switch is always active switch 10. Defective blocked-air inlet switch 11. Loose temperature transmitter to VFD s analog input wire connection 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 19. Defective or missing VFD s logic stick Defective program on the logic stick or Defective VFD. 1. Defective Switch or Actuator 2. Incorrectly wired switch. 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 See CORRECTIVE ACTION See CORRECTIVE ACTION 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 16. See CORRECTIVE ACTION Check C-More configuration menu, ma OUT Fire Rate should be selected 18. Check air fuel valve position at 0%, 50% and 100% fire rates, the position on the c-more barograph should match the valve 19. Confirm that the logic stick is securely mounted on the VFD Check the following VFD parameters: Max Hz = 67, Min Hz = 0, parameter 59 & 60 should be set to Check switch continuity, and either adjust or replace the 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. 2. Bad wire connection. 3. Blower is faulty 1. Check blower connector to ensure it is properly seated. 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. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 71 of 90

72 Chap 10: Troubleshooting Table 10-1: Boiler Troubleshooting PCB Terminal (Continued) 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. 3. Blower is faulty 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. Try connecting blower to connector from other blower known to function properly. Replace blower if blower still does not function properly. E27: Air pressure switch detects a fault during ignition time E30: Alteration of parameters settings due to EMC disturbances E32: Electrical power supply voltage < 108 VAC 1. Damaged hose. 2. Faulty switch. 3. Damaged wires. 1. Ground cabling loose or damaged. 2. Interference with external devices emitting EMC. 1. Test power supply for damage. 2. Check for loose power wire connections 1. Check hoses and replace if necessary. 2. Check switch and replace if damaged. 3. Check wiring for damage and repair if necessary. 1. Check ground cabling and replace if necessary. 2. Investigate for nearby devices emitting EMC interference. 1. Repair or replace power source. 2. Reseat connections. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 72 of 90

73 Chap 10: Troubleshooting Table 10-1: Boiler Troubleshooting System Manager Defective Sensor FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION E69: E8/1/F5 Flow sensor Heating Circuit 2 E70: E8/5/F11 Flow sensor Heating Circuit 1 Defective or damaged PCB Defective or damaged PCB Replace PCB Replace PCB E71: E8/1/F1 Buffer storage tank low sensor 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. E72: E8/1/F3 Buffer storage tank top sensor 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. E75: E8/1/F9 Outdoor sensor 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. E76: E8/1/F6 Storage tank sensor 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. E78: E8/1/F8 Boiler sensor 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. E80: E8/1/F2 Room sensor for Heating Circuit 1 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 73 of 90

74 Chap 10: Troubleshooting Table 10-1: Boiler Troubleshooting System Manager Defective Sensor (Cont.) FAULT INDICATION E83: E8/3/F15 Room sensor for Heating Circuit 2 PROBABLE CAUSES 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. CORRECTIVE ACTION 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. E135: E8/5/F12 HW storage tank low sensor, Multi- Function relay sensor 2 E136: E8/8F13 (PT1000): HS2, Collector 2, Multi- Function relay sensor 3 E137: E8/8/F14 (PT1000): Collector 1, Multi-Function 4 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. E138: E8/3/F15 Room temperature sensor for HC2 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. 1. Inspect sensor for loose or broken wiring. 2. Check resistance of sensor to determine if it is within specification. 3. Ensure that the correct sensor is installed. MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 74 of 90

75 Chap 10: Troubleshooting Table 10-1: Boiler Troubleshooting System Manager Defective Sensor (Cont.) FAULT INDICATION E90: E8: BUS addresses 0 and 1 both used. BUS address 0 and 1 may not be used simultaneously. E91: E8: BUS ID already used. The set BUS ID is already in use by another device. E99: E8: Internal failure PROBABLE CAUSES Bus setting incorrect. BMM rotary switches improperly set duplicate address settings. E-8 failure Replace the E-8 CORRECTIVE ACTION Change setting to use only one bus. Select unused BUS ID address for device. 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) 2. Loose e-buss connection (pink and grey wires) 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. 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 75 of 90

76 Chap 10: Troubleshooting Table 10-1: Boiler Troubleshooting System Manager Defective Sensor (Cont.) FAULT INDICATION E203: E8: Communication Error Module 3 PROBABLE CAUSES Same as E201 BMM Board failure. BMM Board harness failure Check with Desmond CORRECTIVE ACTION 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 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) PROBABLE CAUSES TBD TBD CORRECTIVE ACTION MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 76 of 90

77 TAG-0083_0B CHAPTER 11: TEMPERATURE SENSOR RESISTANCE CHART Temperature Sensor Resistance Chart TEMPERATURE F ( C) RESISTANCE (OHMS) -76 (-60) (-50) (-40) (-30) (-20) (-10) (0) (10) (20) (25) (30) (40) (50) (60) (70) (80) (90) (100) (110) (120) 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 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 77 of 90

78 TAG-0083_0B CHAPTER 12: MODULEX PARTS DRAWING AND LIST Modulex MLX Series Exploded Parts Drawing (Page 1 of 4) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 78 of 90

79 Chap 12: Part Drawings Modulex MLX Series Parts List (Page 2 of 4) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 79 of 90

80 Chap 12: Part Drawings Modulex MLX Series Parts List (Page 3 of 4) MC2: 10/03/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY Ph: Page 80 of 90