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MODULEX EXT 321
Aerco MODULEX EXT 321 User Manual
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MODULEX EXT 321, 481, 641, 802,
962, 1123 BOILERS
Installation, Operation & Maintenance Manual
OMM
-
0087_0F
AERCO International, I
nc.
•
100 Oritani Dr.
•
Blauvel
t, NY 10913
Page
57
of
146
GF
-
143
Ph
one
: 800
-
526
-
0288
07/13/
1
5
3.25
Functional
Wiring Diagra
m
56
58
Table of Contents
Default Chapter
3
Table of Contents
3
Chapter 1: General Information
7
Correct Use of the Appliance
7
Water Treatment
7
Information to be Made Available to the User
7
Safety Warnings
8
Modifications to Parts Connected to the Appliance
8
For Appliances Operating with Propane Gas
9
Data Plate
10
Operational Requirements
11
General Requirements
11
Regulatory Requirements
11
Water Quality Requirements
12
Tools, Materials, and Additional Equipment
13
Disposal
13
General Warnings
13
Using the Operation and Maintenance Manual
13
Installation and Servicing Personnel
13
Installation Materials
13
Preparing Boiler for Servicing
14
Returning a Boiler to Service
14
Change in Ownership
14
Operational Limits of the Boiler
14
Chapter 2: Technical Features and Dimensions
15
Modulex EXT Technical Features
15
Temperature Control Devices
15
Control Panel (E8) Includes
15
Other Features Include
15
General Boiler Operation
16
Dimensional Drawings
17
Performance Data
21
Chapter 3: Installation Instructions
23
General Warnings
23
Appropriate Use of the Boiler
23
Prerequisite System Flushing
23
Installation Personnel Qualifications
23
Carbon Monoxide Detector Installation
23
Code and Standards Approvals
24
Packaging
24
Transporting and Securing the Boiler Safely
27
Removal from Boiler Bed and Installation of Boiler Feet
28
Boiler Location Inside a Boiler Room
29
Boiler Room Safety Concerns
30
Products to Avoid in the Boiler Room
30
Recommended Clearances for Servicing
31
Boiler Connections
32
Changing Exhaust Outlet Location
32
Reversing Gas Manifold Connections
33
Reversing Cold/Hot Water Flow & Return Connections
34
Reversing Cold/Hot Water Flow & Return Piping Connectors
34
Reversing Flow & Return Temperature Sensors
35
Reversing Boiler Sensor Kf and Automatic Air Vent
35
Gas Connection General Information
36
Natural Gas Connections
37
Natural Gas Piping Sizes
37
Natural Gas Piping Connections
37
Natural Gas Supply Pressure Requirements
37
Propane Gas Connections
37
Propane Gas Piping Sizes
37
Propane Gas Piping Connections
37
Propane Gas Supply Pressure Requirements
38
Flow and Return Pipe Connections
38
Pressure Relief Valve
38
Manifold Assembly (Supplied)
39
Determination of Primary Boiler Pump or Boiler System Pump
40
Boiler Model
41
Condensate Piping and Drain
42
Water Treatment
43
Important Installation Warnings
44
Oxygen Levels in the System Water Warning
44
Antifreeze Compatibility Warning
44
Lime Scale and Corrosive Water Damage Warning
44
Connection to Refrigeration System Warning
44
Air Intake Connection
44
Flue Manifold Connection
45
Flue Exhaust Piping to Vent
46
Vent Starter Pieces
46
Combustion Air and Ventilation Openings
48
Insufficient Ventilations and Combustion Air
48
Room Air Combustion
49
Sealed Combustion
49
Installation of the Exhaust and Air Intake System
49
Important Factors for Terminal Orientation and Location
50
Minimum and Maximum Wall Thickness
51
Vent Pipe Sizing
51
Electrical Connections
53
Regulations in Force
53
Mains Electrical Supply Connection (120 V - 60 Hz)
53
Service Relay Requirement
54
Electrical Requirements
54
Functional Wiring Diagram
57
Ladder Diagrams
59
General Ladder Diagram
60
E8 Controller and BCM Terminal Assignments
60
Installation Examples
63
Starting Up: Filling and Deaerating the Boiler
65
Necessary Precautions for Safety
65
Supply Voltage, Gas Pressure, and Water Pressure
65
Filling the System
65
Necessary Precautions While Filling the System
65
Filling Locations and Preparation
66
For Your Safety Read before Operating
67
Operating Instructions
67
To Turn off Gas to Appliance
67
Testing the Ignition Safety Shut off Device
68
Burner Calibration
69
Installing the Gas Analyzer Probe
69
Maximum Output Calibration
70
Minimum Output Calibration
71
Final Check and Ignition Failure Adjustment Procedure
71
Sweeper Mode (Manual Control)
74
High Altitude Adjustment
75
High Altitude Conversion Label
76
Conversion from Natural Gas to Propane Gas
77
Controls and Emergency Functions
78
Initial Boiler Ignition
79
Preliminary Checks
79
Chapter 4: E8 Controller and Bcm Modules
81
E8 Controller
81
E8 Controller Features and Functions
81
E8 Display Functions
82
E8 HEATING Mode Selection
83
E8 MENU Mode Operation (Door Open)
84
E8 MENU Navigation and Parameter Settings
85
E8 Parameter Navigation, Selection, and Setting
86
BCM (Boiler Communication Module)
87
BCM Features and Functions
87
BCM Description
87
Chapter 5: Operation
91
Installation Menu: Initializing the E8 Controller
92
Quick Start Instructions
93
Setting Maximum and Minimum Flow Temperature
93
Setting Room Temperature and Outdoor Compensation
93
Setting Heating Programs and Pumps
94
Menu and Sub-Menu Descriptions
96
Menus (Top Level)
96
Sub-Menus
96
General Menu
97
Service Menu
99
Display Menu
101
User Menu
103
Time Program Menu
105
Expert Menu
106
Other Possible Settings
110
Settings for Heating Circuit 1/2
110
Heating Adjustment with Constant Flow Temp
110
Temperature Settings for Heating Circuits
110
A Second DHW Storage Tank
111
Temperature Setting for Second DHW Storage Tank
111
Swimming Pool
111
Swimming Pool Temperature Setting
111
Screed Dry Program (for Floor Heating Installation)
111
Temperature Setting for Screed Program
111
Signal 0 - 10 V
111
Slope and Temperature Setting with 0 - 10 V Signal
111
Setting of DHW Circuit
112
Operation of Pumps in Parallel
112
Use of a DHW Storage Tank Thermostat (On/Off)
112
Antilegion
112
Setting for Solar Panel Use
112
Access Code Setting
112
Chapter 6: Troubleshooting
113
E8 Controller Error Codes
113
E8 Controller Fault Codes
115
BCM (Boiler Communications Module) Fault Codes
117
BMM (Burner Management Module) Fault Codes
118
Chapter 7: Maintenance Schedule
121
Instructions for Inspection and Maintenance
122
Periodic Examination of Venting System
122
Proper Procedure for Cleaning Exhaust Flue
122
Cleaning the Condensate Drain Line
123
Checking CSD-1 Manifold Flow Switch
123
Visual Inspection of the Flame
124
Proper Reassembly and Resealing of the Vent-Air Intake System
124
Pressure Switch Hoses and Connections
125
Burner / Heat Exchanger Cleaning Procedure
126
Heat and Return Sensor Resistance Values
126
Unit Disassembly
127
Cleaning the Burner Module and Combustion Chamber
134
Reassembly of the Burner Modules
136
Final Procedures after Maintenance
136
Maintenance Kit Part Number
137
Accessory Kit Part Numbers
138
Chapter 8: Spare Parts Drawing and Lists
139
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Aerco MODULEX EXT 321 Specifications
General
Brand
Aerco
Model
MODULEX EXT 321
Category
Boiler
Language
English
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