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Aerco Modulex MLX-303 User Manual

Aerco Modulex MLX-303
90 pages
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MC2: 10/03/12 Page 1 of 90
GF-115-H
TAG-0083_0B
AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Ph: 800-526-0288
USER MANUAL
Revised: 10/03/2012
Modulating, Condensing,
Hot Water Boiler Models:
MLX-303
MLX-454
MLX-606
MLX-757
MLX-909
MLX-1060
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
Modulex MLX Series
Gas Fired Boiler

Table of Contents

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Aerco Modulex MLX-303 Specifications

General IconGeneral
BrandAerco
ModelModulex MLX-303
CategoryBoiler
LanguageEnglish

Summary

Safety Precautions

Understanding Safety Symbols and Warnings

Explains DANGER, WARNING, CAUTION symbols, and key safety instructions.

General Description

Introduction to Technical Features

Overview of the Modulex boiler's modular design, efficiency, and components.

Code Approvals and Installation Flexibility

Lists compliance standards and installation flexibility options.

Dimensions and Weights

Provides physical dimensions and weight specifications for models.

Technical Data and Specifications

Presents detailed technical specifications, input/output ratings, and electrical requirements.

Boiler Freeze Protection

Explains the boiler's built-in freeze protection mechanism and requirements.

Installation

Installation Introduction and Regulations

Outlines installation requirements, codes, and important notes for installers.

Unpacking the Boiler

Detailed steps for unpacking the boiler and checking its contents.

Boiler Location and Clearances

Specifies ideal boiler location, minimum clearances, and pad requirements.

Boiler Connections

Details the various connection points for water, gas, and venting.

Data Plate Information

Explains the information presented on the boiler's data plate.

General Information for Venting

Vent Pipe Connection and Categories

Discusses vent pipe connection types, categories, and installation codes.

Venting Installation and Sizing Guidelines

Provides guidance on venting installation, sizing, and Massachusetts requirements.

Common Venting System Removal

Outlines procedures for removing an existing boiler from a common venting system.

Piping

Makeup Water Quality Requirements

Stresses the importance of water quality and treatment per guidelines.

Maximum Allowable Working Pressure

States the maximum and minimum working pressure limits for the boiler.

CSD-1 Manifold Assembly and Piping

Describes the CSD-1 manifold assembly components and supply/return piping.

System Filling, Draining, and Condensate Drain

Covers procedures for filling, draining the system, and condensate drain installation.

Electrical

Electrical Connections and Wiring

Details electrical requirements, connections, grounding, and safety precautions.

DHW System and Sensor Wiring

Explains wiring for DHW storage tank connections and sensor installation.

Boiler Operation

Introduction to Boiler Operation

Introduces boiler operation principles, modules, and temperature monitoring.

Modulation Theory and Efficiency

Explains how the boiler achieves efficiency through modular operation and modulation.

Ignition Sequence

Describes the step-by-step process of the ignition sequence.

Boiler Control Modes

Details operation modes like Indoor/Outdoor Reset, Remote Set-Point, and Constant Set-Point.

Initial Startup Procedures

Covers essential steps for initial startup, including tool requirements and gas checks.

Combustion Calibration Procedure

Provides detailed steps for performing combustion calibration and adjustments.

Unit Reassembly

Instructions for reassembling the unit after calibration procedures.

Safety Device Testing

Overview of Safety Device Testing

Explains the importance and necessity of periodic safety device testing.

Processing and Clearing Fault Codes

Guides on how to display, correct, and clear fault codes from the controller.

Low Gas Pressure Fault Test

Procedure to test the low gas pressure fault detection system.

Low Water Level Fault Test

Details methods for testing the low water level safety switch.

Water Temperature Fault Test

Steps to simulate and test the high water temperature safety shutoff.

Flame Fault Tests

Procedures for testing flame detection during ignition and running modes.

Safety Pressure Relief Valve Test

Instructions for testing the safety pressure relief valve per ASME code.

Maintenance

Preventative Maintenance Kits

Introduces available maintenance kits for annual and fireside inspections.

Annual Maintenance Procedures

Lists required and recommended tasks for annual boiler maintenance.

Fireside Inspection Procedures

Guides for performing a fireside inspection, including disassembly and cleaning.

Burner Section Replacement

Instructions for disassembly and replacement of burner sections.

Final Testing and Return to Service

Procedures for final testing and returning the boiler to service after maintenance.

Troubleshooting Guide

Introduction to Troubleshooting

Explains the guide's purpose and how to use fault indication tables.

Fault Indications, Probable Causes, and Corrective Actions

Comprehensive table detailing error codes, potential causes, and solutions.

Temperature Sensor Resistance Chart

Modulex Parts Drawing and List

Boiler Water Quality and Maintenance

Boiler Water Chemistry Basics

Discusses metal reactions, scale, corrosion, and water chemistry principles.

Water Quality Testing and Maintenance

Details parameters for testing and maintaining water quality in the system.

System Flushing, Treatment, and Cleansing

Provides guidelines for flushing, cleaning, and treating the heating system water.

Water Quality Maintenance and Warranty

Links water quality maintenance to boiler warranty coverage.

Water Treatment Analysis and Resources

Covers analysis scheduling and resources for hydronic water treatment.

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