Document Outline

• CHAPTER 1: General Information
  • 1.1 Correct Use of the Appliance
  • 1.2 Water Treatment
  • 1.3 Information to Be Made Available To The User
  • 1.4 Safety Warnings
  • 1.5 Modifications To Parts Connected To The Appliance
  • 1.6 For Appliances Operating With Propane Gas
  • 1.7 Data Plate
  • 1.8 Operational Requirements
    • 1.8.1 General Requirements
    • 1.8.2 Regulatory Requirements
    • 1.8.3 Water Quality Requirements
  • 1.9 Tools, Materials, And Additional Equipment
  • 1.10 Disposal
  • 1.11 General Warnings
    • 1.11.1 Using the Operation and Maintenance Manual
    • 1.11.2 Installation and Servicing Personnel
    • 1.11.3 Installation Materials
    • 1.11.4 Preparing Boiler for Servicing
    • 1.11.5 Returning a Boiler to Service
    • 1.11.6 Change in Ownership
  • 1.12 Operational Limits of the Boiler
• CHAPTER 2: Technical features and dimensions
  • 2.1 Modulex EXT Technical Features
    • 2.1.1 Temperature Control Devices:
    • 2.1.2 Control Panel (E8) Includes:
    • 2.1.3 Other Features Include:
  • 2.2 General Boiler Operation
  • 2.3 Dimensional Drawings
  • 2.4 Performance Data
• CHAPTER 3: Installation Instructions
  • 3.1 General Warnings
    • 3.1.1 Appropriate Use of the Boiler
    • 3.1.2 Prerequisite System Flushing
    • 3.1.3 Installation Personnel Qualifications
    • 3.1.4 Carbon Monoxide Detector Installation
  • 3.2 Code and Standards Approvals
  • 3.3 Packaging
  • 3.4 Transporting and Securing the Boiler Safely
  • 3.5 Removal From Boiler Bed And Installation Of Boiler Feet
  • 3.6 Boiler Location Inside A Boiler Room
    • 3.6.1 Boiler Room Safety Concerns
    • 3.6.2 Products to Avoid in the Boiler Room
  • 3.7 Recommended Clearances for Servicing
  • 3.8 Boiler Connections
    • 3.8.1 Changing Exhaust Outlet Location
    • 3.8.2 Reversing Gas Manifold Connections
    • 3.8.3 Reversing Cold/Hot Water Flow & Return Connections
      • 3.8.3.1 Reversing Cold/Hot Water Flow & Return Piping Connectors
      • 3.8.3.2 Reversing Flow & Return Temperature Sensors
      • 3.8.3.3 Reversing Boiler Sensor Kf And Automatic Air Vent
  • 3.9 Gas Connection General Information
    • 3.9.1 Natural Gas Connections
      • 3.9.1.1 Natural Gas Piping Sizes
      • 3.9.1.2 Natural Gas Piping Connections
      • 3.9.1.3 Natural Gas Supply Pressure Requirements
    • 3.9.2 Propane Gas Connections
      • 3.9.2.1 Propane Gas Piping Sizes
      • 3.9.2.2 Propane Gas Piping Connections
      • 3.9.2.3 Propane Gas Supply Pressure Requirements
  • 3.10 Flow And Return Pipe Connections
  • 3.11 Pressure Relief Valve
  • 3.12 CSD-1 Manifold Assembly (Supplied)
  • 3.13 Determination of Primary Boiler Pump Or Boiler System Pump
  • 3.14 Condensate Piping and Drain
  • 3.15 Water Treatment
  • 3.16 Important Installation Warnings
    • 3.16.1 Oxygen Levels in the System Water Warning
    • 3.16.2 Antifreeze Compatibility Warning
    • 3.16.3 Lime Scale and Corrosive Water Damage Warning
    • 3.16.4 Connection to Refrigeration System Warning
  • 3.17 Air Intake Connection
  • 3.18 Flue Manifold Connection
  • 3.19 Flue Exhaust Piping to Vent
  • 3.20 Vent Starter Pieces
  • 3.21 Combustion Air and Ventilation Openings
    • 3.21.1 Insufficient Ventilations and Combustion Air
    • 3.21.2 Room Air Combustion
    • 3.21.3 Sealed Combustion
  • 3.22 Installation of the Exhaust and Air Intake System
    • 3.22.1 Important Factors for Terminal Orientation and Location
    • 3.22.2 Minimum and Maximum Wall Thickness
  • 3.23 Vent Pipe Sizing
  • 3.24 Electrical Connections
    • 3.24.1 Regulations in Force
    • 3.24.2 Mains Electrical Supply Connection (120 V – 60 Hz)
    • 3.24.3 Service Relay Requirement
    • 3.24.4 Electrical Requirements
  • 3.25 Functional Wiring Diagram
  • 3.26 Ladder Diagrams
  • 3.27 General Ladder Diagram
  • 3.28 E8 Controller and BCM Terminal Assignments
  • 3.29 Installation Examples
  • 3.30 Starting Up: Filling and Deaerating the Boiler
    • 3.30.1 Necessary Precautions for Safety
    • 3.30.2 Supply Voltage, Gas Pressure, and Water pressure
  • 3.31 Filling the System
    • 3.31.1 Necessary Precautions While Filling the System
    • 3.31.2 Filling Locations and Preparation
  • 3.32 Testing The Ignition Safety Shut Off Device
  • 3.33 Burner Calibration
    • 3.33.1 Installing the Gas Analyzer Probe
    • 3.33.2 Maximum Output Calibration
    • 3.33.3 Minimum Output Calibration
    • 3.33.4 Final Check and Ignition Failure Adjustment Procedure
  • 3.34 Sweeper Mode (Manual Control)
  • 3.35 High Altitude Adjustment
  • 3.36 High Altitude Conversion Label
  • 3.37 Conversion From Natural Gas To Propane Gas
  • 3.38 Controls And Emergency Functions
  • 3.39 Initial Boiler Ignition
    • 3.39.1 Preliminary Checks
• CHAPTER 4: E8 Controller and BCM Modules
  • 4.1 E8 Controller
    • 4.1.1 E8 Controller Features and Functions
    • 4.1.2 E8 Display Functions
    • 4.1.3 E8 HEATING Mode Selection
    • 4.1.4 E8 MENU Mode Operation (Door Open)
    • 4.1.5 E8 MENU Navigation and Parameter Settings
    • 4.1.6 E8 Parameter Navigation, Selection, and Setting
  • 4.2 BCM (Boiler Communication Module)
    • 4.2.1 BCM Features and Functions
    • 4.2.2 BCM Description
• CHAPTER 5: OPERATION
  • 5.1 Installation Menu: Initializing the E8 Controller
  • 5.2 Quick Start Instructions
    • 5.2.1 Setting Maximum and Minimum Flow Temperature
    • 5.2.2 Setting Room Temperature and Outdoor Compensation
    • 5.2.3 Setting Heating Programs and Pumps
  • 5.3 Menu And Sub-Menu Descriptions
    • 5.3.1 Menus (Top Level):
    • 5.3.2 Sub-Menus:
  • 5.4 General Menu
  • 5.5 Service Menu
  • 5.6 Display Menu
  • 5.7 User Menu
  • 5.8 Time Program Menu
  • 5.9 Expert Menu
  • 5.10 Other Possible Settings
    • 5.10.1 Settings for Heating Circuit 1/2
      • 5.10.1.1 Heating Adjustment With Constant Flow Temp
      • 5.10.1.2 Temperature Settings For Heating Circuits
      • 5.10.1.3 A Second DHW Storage Tank
      • 5.10.1.4 Temperature Setting For Second DHW Storage Tank
      • 5.10.1.5 Swimming Pool
      • 5.10.1.6 Swimming Pool Temperature Setting
      • 5.10.1.7 Screed Dry Program (For Floor Heating Installation)
      • 5.10.1.8 Temperature Setting For Screed Program
      • 5.10.1.9 Signal 0 – 10 V
      • 5.10.1.10 Slope And Temperature Setting with 0 – 10 V Signal
    • 5.10.2 Setting of DHW Circuit
      • 5.10.2.1 Operation of Pumps In Parallel
      • 5.10.2.2 Use of a DHW Storage Tank Thermostat (On/Off)
      • 5.10.2.3 Antilegion
      • 5.10.2.4 Setting for Solar Panel Use
  • 5.11 ACCESS CODE SETTING
• CHAPTER 6: TROUBLESHOOTING
  • 6.1 E8 Controller Error Codes
    • 6.1.1 E8 Controller Fault Codes
    • 6.1.2 BCM (Boiler Communications Module) Fault Codes
    • 6.1.3 BMM (Burner Management Module) Fault Codes
• CHAPTER 7: MAINTENANCE SCHEDULE
  • 7.1 Instructions for Inspection And Maintenance
  • 7.2 Periodic Examination Of Venting System
  • 7.3 Proper Procedure For Cleaning Exhaust Flue
    • 7.3.1 Cleaning the Condensate Drain Line
  • 7.4 Checking CSD-1 Manifold Flow Switch
  • 7.5 Visual Inspection Of The Flame
  • 7.6 Proper Reassembly and Resealing of the Vent-Air Intake System
  • 7.7 Pressure Switch Hoses And Connections
  • 7.8 Burner / Heat Exchanger Cleaning Procedure
  • 7.9 Heat and Return Sensor Resistance Values
  • 7.10 Unit Disassembly
  • 7.11 Cleaning the Burner Module and Combustion Chamber
  • 7.12 Reassembly of the Burner Modules
  • 7.13 Final Procedures After Maintenance
  • 7.14 Maintenance Kit Part Number
  • 7.15 Accessory Kit Part Numbers
• CHAPTER 8: Spare Parts Drawing and Lists
• AERCO/MODULEX STANDARD WARRANTY