AER 89030 Owner's manual

Heating and Hot Water Solutions
AERCO International, Inc. • 100 Oritani Drive • Blauvelt, NY 10913
USA: T: [phone] • Toll Free: [phone] • AERCO.com
Technical Support • [phone] • Mon-Fri, 8 am - 5 pm EST
© 2022 AERCO
Condensate Neutralizer Tank Kit
Part Description
P/N:
Condensate Neutralization
Tank, 18 Liter (4.8 gal), with
x2 Unions and x2 Nipples
89030
Replacement Neutralization
Media (40 lbs.) for BMK,
INN, Recon, MFC (nat. gas
only), Modulex, and KC
89031
Replacement Neutralization
Media (25 lbs.) for AM
Series Boilers/Heaters
62801022
Condensate Neutralization Tank
For Neutralizing Condensate Waste from Gas
Burning Boilers & Water Heaters
Technical Instruction Document
Applies to the following AERCO models:
Benchmark Series
Innovation Series
Recon Series
MFC Series (natural gas only)
Modulex Series
AM Series (Maintenance only. For tank installation see O&M manual GF-146)
KC1000 Models
TID-0074_0H •8/22/2022
Disclaimer
The information contained in this manual is subject to change without notice
from AERCO International, Inc. AERCO makes no warranty of any kind with
respect to this material, including, but not limited to, implied warranties of
merchantability and fitness for a particular application. AERCO International is
not liable for errors appearing in this manual, not for incidental or
consequential damages occurring in connection with the furnishing,
performance, or use of these materials.

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 2of 14
INTRODUCTION
The Condensate Neutralization Tank is used for neutralizing condensate from condensing boilers
that use natural gas or propane as fuel. Waste condensate, produced by the burning of these
fuels, is potentially harmful to the environment and can corrode unprotected piping systems. The
kit is used to neutralize the acidic PH of the condensate to ensure the harmful effects are
minimized.
Features and Benefits:
•Prevents acidic condensate from corroding pipes and sewer systems.
•Environmentally friendly.
•Fast and easy installation.
•Kit materials are made from corrosion resistant materials.
•For use on all types of Natural Gas and Propane appliances.
•Initial charge of neutralizer agent is included.
•Includes: baffles designed to channel flow thoroughly for complete neutralization, integral
bypass to prevent condensate backflow into appliance, NPT connections with unions for fast
and versatile installation.
INSTALLATION INSTRUCTIONS
NOTE: Check with your local water authority for regulations regarding discharge of treated
condensate into a drain or sewer system.
W A R N I N G !
RISK OF DAMAGE TO APPLIANCE!
Follow these instructions carefully to avoid damage to equipment and appliances.
The Condensate Neutralization Tank can be installed using either of the following methods:
•Neutralization tank is installed such that the inlet and discharge of the tank are at a lower
elevation than the AERCO condensate trap outlet. This can be achieved by:
a) Installing the Neutralization Tank in a pit (see Figure 2).
b) Elevating the AERCO boiler/water heater(s) and the AERCO condensate trap(s) (see
Figure 3).
•A condensate pump is used to lift the condensate from the appliance to the Neutralization
Tank (Figure 4).
Do not allow exhaust flue gases to vent through the Neutralization Tank. Flue gas leakage can
cause injury or death from carbon monoxide. Ensure the AERCO condensate trap is properly
installed with the boiler/water heater, upstream of the Neutralization Tank. See the boiler/water
heater installation manual for condensate trap installation instructions.
Connection to the appliance and Neutralization Tank must be installed to ensure that no
condensate backflow into the appliance can occur.

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 3of 14
TABLE 1: Condensate Neutralizer Tank Contents (P/N 89030)
Qty.
Description
1
18 liter (4.8 U.S. gallon) tank (1” FNPT inlet/outlet connections) and lid made from
polypropylene construction; comes filled with neutralization media (P/N 89031).
2
1” NPT PVC unions
2
1” NPT PVC close nipples
Each Neutralization Tank will neutralize condensate from appliances up to 6,400,000 BTU/hr
input. Table 1 lists the parts included in the Condensate Neutralization Kit (P/N 89030).
The neutralizer tank can be used for multiple appliance installation with a combined BTU/hr. input
not exceeding 6,400,000. See Tables 2 and 3 for selection guideline for all AERCO gas fired
products.
TABLE 2: Neutralizer Tank Application Chart (BMK, INN, MLX EXT)
AERCO Equipment
BTU/Hr. Input
Kit Qty Required
Eight (8) BMK750
6,000,000
1
Six (6) BMK1000
6,000,000
1
Four (4) BMK1500
6,000,000
1
Three (3) BMK2000
6,000,000
1
Two (2) BMK2500
5,000,000
1
Four (4) BMK2500
10,000,000
2*
Two (2) BMK3000
6,000,000
1
Four (4) BMK3000
12,000,000
2*
One (1) BMK6000
6,000,000
1
Eight (8) INN800
6,400,000
1
Six (6) INN1060
6,360,000
1
Four (4) INN1350
5,400,000
1
Eight (8) MLX EXT 802
6,416,000
1
Six (6) MLX EXT 962
5,772,000
1
Five (5) MLX EXT 1123
5,615,000
1
Four (4) MLX EXT 1530
6,120,000
1
Three (3) MLX EXT 1912
5,736,000
1
Two (2) MLX EXT 2295
4,590,000
1
Two (2) MLX EXT 2677
5,354,000
1
Four (4) MLX EXT 2677
10,708,000
2*
Two (2) MLX EXT 3060
6,120,000
1
Four (4) MLX EXT 3060
12,240,000
2*
* Use one (1) neutralizer tank for each pair of BMK 3.0/BMK 3000. Do not install
multiple neutralizer tanks in series.

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 4of 14
TABLE 3: Neutralizer Tank Application Chart (MFC Series)
AERCO Equipment
BTU/Hr. Input
Kit Qty Required
Two (2) MFC 3000
6,000,000
1
One (1) MFC 4000
4,000,000
1
One (1) MFC 5000
5,000,000
1
One (1) MFC 6000
6,000,000
1
One (1) MFC 8000
8,000,000
2**
One (1) MFC 10000
10,000,000
2**
** Neutralizertanks are tobe installed inparallel. Do not installmultiple neutralizer tanks in series.
Figure 1: Condensate Neutralization Tank (P/N 89030) Dimensions
The inlet connection (6.5") is higher than the outlet connection (6.3"). Set the neutralization tank
on a secure and level base. Connections to the appliance and neutralization kit must be installed
to ensure that no condensate backflow can occur. Connect appliance condensate drain to the
inlet using corrosion resistant piping. Do not route the condensate line through any area that is
exposed to freezing temperatures. If traffic poses a risk, install some protection to prevent
movement and/or damage. Mount as per installation diagram. Ensure that no air pockets will
remainor form in the pipingand that the condensate willflow freelyfrom theappliance condensate
drain into the tank and then to the drain. Access to the discharge is necessary for proper
maintenance in order to check the effectiveness of the neutralizing media, using pH test strips.
If there is no gravity drain available or if the boiler/water heater cannot be elevated to be higher
than the Neutralization Tank, install a condensate removal pump designed for use on condensing
boilers and furnaces (Figure 4).

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 5of 14
The condensate pump must be equipped with an over flow switch to prevent the appliance from
running should a failure occur. The over flow switch must be wired to the Remote Interlock of the
AERCO boiler/water heater I/O Box for KC1000, Innovation, and Benchmark units (see Figure 8);
or, for Modulex units, on Pins 3 and 4 of Connector I on Modulex E8 controller (see Figure 9).
NOTE:
For Modulex boilers, an over flow switch may only be utilized in Indoor/Outdoor Reset and
Constant Set Point modes of operation.
It cannot be utilized in 0 to 10 Volt Remote Set Point mode and when a BMS II is used.
To utilize an overflow switch, set the Modulex boiler to Standby mode ( ). To set the boiler
to Standby mode, close the swing-down front panel door of the E8 and turn the wheel counter-
clockwise until the Standby symbol ( ) is displayed. With pins 3 and 4 closed, the Standby
symbol, and others in the display, will be blinking. This indicates that the boiler is enabled.
When the connection is broken between pins 3 and 4, the Standby symbol, and others in the
display, will stop blinking indicating that the boiler is disabled. Closing/breaking pins 3 and 4
not only start/stops the boiler but also start/stops other pumps (boiler water pumps) wired to
the Modulex boiler.

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 6of 14
Figure 2: Multiple Boiler Units with Tank (P/N 89030) Placed in a Pit
Minimum Pit Depth
BOILER MODEL
DIM. A (MIN. PIT DEPTH)
BMK1500/2000
1-1/4"
BMK2500/3000
1"
BMK 4000/5000N
2"
Use Figure 2 and the above table for installations where a boiler pad no thicker than 4" is desired.
For models not shown in this table: the condensate neutralizer can be installed on the floor while
the boiler is installed on a 4 inch pad.

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 7of 14
Figure 3: Elevated Multiple Boiler Units with Tank (P/N 89030)
NOTE: The condensate neutralizer tank inlet and outlet ports must be lower than the boiler
condensate outlet.
Minimum Boiler Pad Height
BOILER MODEL
DIM. A (MIN. BOILER PAD HEIGHT)
BMK1500/2000
5-1/4”
BMK2500/3000
5”
BMK 4000/5000N
6”
Use Figure 3 and the above table for installations where a pit cannot be constructed for the
condensate neutralizer tank. For models not shown in this table: the condensate neutralizer can
be installed on the floor using a 4 inch pad.

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 8of 14
Figure 4: Multiple Boiler Units with Tank and Condensate Pump (P/N 89030)

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 9of 14
Figure 5: MFC 3000: Dual Boiler Units with Condensate Neutralizer Tank (P/N 89030)

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 10 of 14
Figure 6: MFC-4000 –6000: Single Boiler Unit with Condensate Tank (P/N 89030)

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 11 of 14
Figure 7: MFC8000 –10000: Single Boiler Unit with Two Condensate Tanks (P/N 89030)

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 12 of 14
mA OUT
RS-485
COMM. +
-
+
-
ANALOG IN
SENSOR COMMON
OUTDOOR SENSOR IN REMOTE INTL'K IN
B.M.S. (PWM) IN
SHIELD
+
-
+
-
(AIR) AUX SENSOR IN
NOT USED
EXHAUST SWITCH IN
DELAYED INTL'K IN
FAULT RELAY
120 VAC, 5A, RES
AUX RELAY
120 VAC, 5A, RES
G
RELAY CONTACTS:
120 VAC, 30 VDC
5 AMPS RESISTIVE
DANGER
120 VAC USED
IN THIS BOX
NOT USED NOT USED
NC
COM
NO
NC
COM
NO
NOT USED
0 –10V
AGND
Figure 8: BMK, KC, and INN I/O Box Wiring for Overflow Switch Relay Connection
(REMOTE INTL’K IN)
Figure 9: Modulex E8 Controller Wiring for Overflow Switch Relay Connection
(Pins 3 & 4 of Connector I)
Pins
4 - 3
Overflow Switch
Relay Connections
Modulex Connector I
NOTE:
Remove the jumper between
the two “REMOTE INTL”K IN”
terminals before connecting
the Overflow Switch Relay.
Overflow Switch
Relay Connections
REMOTE INTL’K IN

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 13 of 14
OPERATION
The appliance condensate will flow through the neutralizing media, raising the condensate pH to
a level that will help prevent corrosion of the domestic drain and the public sewer system.
MAINTENANCE
Monitor the level of the neutralization media in the tank periodically. The pH can be checked after
the condensate has exited the tank or by removing the lid and taking a sample from the last
chamber before the outlet. Check the pH level every three months forthe first year. Use a suitable
pH test strip paper or an electronic pH meter for precise measurement. The frequency of checking
the pH levelcanbe reduced toevery sixmonthsorevery yeardependingon thereadingsobtained
compared to local water authority requirements. The neutralizing media should be replaced when
the pH level drops below the minimum level of the local water authority. For replacement media
contact your local AERCO sales representative.
•Replacement neutralization media for KC, BMK, INN, Recon, MFC, and Modulex series
models is P/N 89031.
•Replacement neutralization media for AM Series models is P/N 62801022.
At delivery, the replacement media comes in two clear plastic bags; a smaller one inside the
bigger (Figure 10). The larger bag consists of larger pieces of neutralization material, while the
smaller bag consists ofsmaller pelletsof neutralization material. Replenish thetank with the larger
material, then sprinkle the smaller pellets on top.
Figure 10: Condensate Neutralization Tank Replacement Media (In Bags)
LIMITED WARRANTY
The unit is warranted against defects in materials and workmanship for one year.
Bag Inside
Containing
Smaller Pieces
of Media
Inside
Bag Containing
Larger Pieces
of Media

Condensate Neutralization Tank User Instructions
TID-0074_0H •8/22/2022 Technical Support •[phone] •Mon-Fri, 8 am - 5 pm EST Page 14 of 14
Change Log:
Date
Description
Changed By
11/13/2019
Rev F:
DIR 19-71 –Updated overall format; Updated Figure 3.
Linley Thobourne
8/22/2022
Rev G:
Added BMK 4000 & 5000N to tables.
Lisa Weiss
© AERCO International, Inc., 2022