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Modulex ext – AERCO Modulex EXT 1530 - 3060 User Manual

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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

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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913

OMM-0095_0E

12/01/14

Phone: 800-526-0288

GF-139