MC2: 10/03/12 Page 57 of 90
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
Modulex MLX Series Gas Fired Boiler System
Operation and Maintenance Manual
9.3.4 Reassembly After Burner Mainentance
After maintenance, reassemble the unit as described below.
Unit Reassembly after Maintenance
1. THE BURNER SEALING GASKETS MUST ALWAYS BE REPLACED AFTER EACH BURNER
CLEANING. When positioning the replacement gaskets (P/N 95261173), place them on top of the
burner modules and not between the burner modules and aluminum boiler body.
2. Reassemble all other components previously removed by reversing the order of the disassembly
steps.
3. Before starting the boiler, verify that the condensate siphon and boiler are filled with water
and pump is running.
4. Before opening the gas cock on the burner manifold, make sure that the coupling is securely
tightened. To do this, open the gas cock and check the union for leaks using a soap solution.
5. As soon as a burner is put into operation, check immediately for leakage between the gas valve
and the relevant premixing chamber.
6. Perform the combustion analysis and check the combustion parameters per paragraph 7.5.5.
NOTE
Make sure that all gas pressure test nipples previously open, are closed
and tight.
9.3.5 Testing the Flame Detection Circuitry
The Modulex boiler is designed to automatically shut down in the absence of a flame to prevent the
buildup of unburned fuel in the combustion chamber. Test the circuit by removing a flame detector lead
from any of the burner sections (Figure 9-2) while the unit is running. If the unit shuts down after a few
seconds, the flame detection circuitry is functional.
9.3.6 Disassembly, Inspection, and Maintenance for the Flue Collector
Depending on the installation configuration, the flue collector may be installed on the left side, right side
or rear of the Modulex boiler. Inspect the flue collector per the instructions below.
Disassembly, Inspection, and Maintenance of the Flue Collector
1. Disconnect flue starter section from the flue collector by loosening the hose clamp (Figure 8-17).
2. Remove the flue collector and flue collector gasket from the condensate tray (Figure 8-17). The
collector is secured to the tray with three (3) M4 bolts (bottom flange) and three M4 hex nuts (top
flange). You will need to use a 7mm socket wrench with universal joint and extender to reach and
remove the nuts and bolts.
3. Disconnect exhaust connector and exhaust connector gasket from the flue collector by removing the
four (4) M5-20 bolts and washers shown in Figure 9-14.
4. Inspect and then clean the flue collector using a water jet or wet cloth.
5. Following inspection and cleaning refer to Figure 9-14, then reconnect the flue collector to the
condensate tray using a new flue collector gasket (P/N 95250612).
6. Install the exhaust connector using a new exhaust connector gasket (P/N 95250632).
7. Connect the flue starter section to the flue connector and secure it using the clamp removed in Step
1.
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