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MODULEX EXT
1530, 1912, 2295, 2677, 3060 Boilers
Installation, Operation & Maintenance Manual
3.9.2 Propane Gas Connections ....................................................................................................................... 28
3.9.2.1 Propane Gas Piping Sizes ..................................................................................................................... 28
3.9.2.2 Propane Gas Piping Connections ......................................................................................................... 28
3.9.2.3 Propane Gas Supply Pressure Requirements ....................................................................................... 28
3.10 Flow and Return Pipe Connections .................................................................................................................. 29
3.11 Pressure Relief Valve ....................................................................................................................................... 29
3.12 CSD-1 MANIFOLD ASSEMBLY (SUPPLIED) ........................................................................................................ 30
3.13 Determination of Primary Boiler Pump or Boiler System Pump ...................................................................... 31
3.14 Condensate Piping and Drain .......................................................................................................................... 32
3.15 Water Treatment ............................................................................................................................................. 34
3.16 Important Installation Warnings...................................................................................................................... 34
3.16.1 Oxygen Levels in the System Water Warning ....................................................................................... 34
3.16.2 Antifreeze Compatibility Warning ........................................................................................................ 34
3.16.3 Lime Scale and Corrosive Water Damage Warning .............................................................................. 35
3.16.4 Connection to Refrigeration System Warning ...................................................................................... 35
3.17 Optional Air Intake Connection ....................................................................................................................... 35
3.18 Flue Manifold Installation ................................................................................................................................ 35
3.19 Flue Exhaust Piping to Vent ............................................................................................................................. 37
3.20 Vent Starter Pieces .......................................................................................................................................... 37
3.21 Combustion Air and Ventilation Openings ...................................................................................................... 39
3.21.1 Insufficient Ventilation and Combustion Air......................................................................................... 39
3.21.2 Room Air Combustion ........................................................................................................................... 40
3.21.3 Sealed Combustion ............................................................................................................................... 40
3.22 Installation of the Exhaust and Air Intake System ........................................................................................... 41
3.22.1 Important Factors for Terminal Orientation and Location ................................................................... 42
3.22.2 Minimum and Maximum Wall Thickness .............................................................................................. 42
3.23 Vent Pipe Sizing ............................................................................................................................................... 42
3.24 Electrical Connections...................................................................................................................................... 44
3.24.1 Regulations in Force.............................................................................................................................. 44
3.24.2 Mains Electrical Supply Connection (120 V – 60 Hz)............................................................................. 44
3.24.3 Service Relay Requirement ................................................................................................................... 45
3.24.4 Electrical Requirements ........................................................................................................................ 45
3.25 Functional Wiring Diagram .............................................................................................................................. 49
3.26 Ladder Diagrams .............................................................................................................................................. 51
3.27 General Ladder Diagram .................................................................................................................................. 52
3.28 E8 Controller and BCM Terminal Assignments ................................................................................................ 52
3.29 Installation Examples ....................................................................................................................................... 55
3.30 Starting Up: Filling and De-Aerating the Boiler ................................................................................................ 57
3.30.1 Necessary Precautions for Safety ......................................................................................................... 57
3.30.2 Supply Voltage, Gas Pressure, and Water pressure .............................................................................. 57
3.31 Filling the System ............................................................................................................................................. 57
3.31.1 Necessary Precautions While Filling the System .................................................................................. 57
3.31.2 Filling Locations and Preparation.......................................................................................................... 58
3.32 Testing the Ignition Safety Shut-off Device ..................................................................................................... 60
3.33 Burner Calibration ........................................................................................................................................... 61
3.33.1 Installing the Gas Analyzer Probe ......................................................................................................... 61
3.33.2 Maximum Output Calibration ............................................................................................................... 62
3.33.3 Minimum Output Calibration................................................................................................................ 63
3.33.4 Final Check and Ignition Failure Adjustment Procedure....................................................................... 63
3.34 Sweeper Mode (Manual Control) .................................................................................................................... 66
3.35 High Altitude Adjustment ................................................................................................................................ 67
3.36 High Altitude Conversion Label........................................................................................................................ 68
3.37 Conversion from Natural Gas to Propane Gas ................................................................................................. 69
3.38 Controls and Emergency Functions ................................................................................................................. 70
3.39 Initial Boiler Ignition......................................................................................................................................... 71
3.39.1 Preliminary Checks................................................................................................................................ 71
Page 4 of 138
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
OMM-0095_0E
12/01/14
Phone: 800-526-0288
GF-139
