AER Modulex MLX Series Owner's manual

AERCO International, Inc.
•
100 Oritani Dr.
•
Blauvelt, New York 10913
•
Phone: [phone]
TID-0026_0A
TECHNICAL INSTRUCTIONS
Modulex Model: Maintenance Kit P/N:
MLX-303 Annual Maintenance Kit
58019-01
MLX-454 Annual Maintenance Kit
58019-02
MLX-606 Annual Maintenance Kit
58019-03
MLX-757 Annual Maintenance Kit
58019-04
MLX-909 Annual Maintenance Kit
58019-05
MLX-1060 Annual Maintenance Kit
58019-06
Revised: 05/19/2011
NOTE
For Modulex 24-Month maintenance
instructions (Fireside Inspection), see
Document TID-0027.
Procedure:
Modulex
Annual (12-Month)
Maintenance
Applies to Modulex Boiler Models:
•MLX-303
•MLX-454
•MLX-606
•MLX-757
•MLX-909
•MLX-1060
Description of Document:
Annual maintenance consists of a
number of recommended and required
tasks. This document provides
instructions for the yearly requirement of
inspection, and if necessary,
replacement of the igniter and flame
detector for each burner section.
Modulex MLX Series Boiler
Modulex Annual (12-Month) Maintenance Kit
Modulex Models and Associated Annual Maintenance Kit P/Ns

PR2: 04/01/11 Page 2 of 5
AERCO International, Inc.
•
100 Oritani Dr.
•
Blauvelt, New York 10913
•
Phone: [phone]
Modulex Annual (12 Month) Maintenance
Technical instruction Document
TID-0026_0A
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. Nor for incidental or consequential damages occurring in
connection with the furnishing, performance, or use of this material.
Technical Support:
(Mon–Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com

PR2: 04/01/11 Page 3 of 5
AERCO International, Inc.
•
100 Oritani Dr.
•
Blauvelt, New York 10913
•
Phone: [phone]
Modulex Annual (12 Month) Maintenance
Technical instruction Document
TID-0026_0A
1. Annual (12-Month) Maintenance Instructions
Following are the procedures necessary to perform the annual (12 month) maintenance on all Modulex
MLX boiler models and sizes. Each Annual Maintenance Kit contains a flame detector, spark igniter,
and associated gaskets.
A correctly adjusted Modulex boiler needs very little care other than yearly maintenance. The frequency
of cleaning needed depends on the cleanliness of the air used for combustion. Note that dust present in
the air at the combustion intake will result in reduced burn efficiency and, consequently, reduced heat
output.
Annual maintenance consists of a number of recommended and required tasks as listed below. This
section provides instructions for the yearly requirement of inspection, and if necessary, replacement of
the igniter and flame detector for each burner section. Some of the more involved inspection and
cleaning (such as cleaning the burner modules or condensate tray) are described in both the main
Modulex boiler manual (GF-115-H) and the Instructions for the MLX 24-month Fireside Maintenance
instructions (P/N TID-0027). For each of the different Modulex boiler models, there is an associated
maintenance kit P/N, as shown in the table on the cover and at the end of these instructions.
REQUIRED Tasks:
•Inspect air filters (replace if needed, AERCO P/N 95261879)
•Inspect condensate drain lines (clean if needed)
•Check for gas leaks using a soapy solution
•Inspect igniter and flame sensor (replace, Igniter: P/N 95251245, Detector: P/N 95251246)
•Check pH of boiler system water (refer to Appendix C, Boiler Water Chemistry and Maintenance)
in MLX boiler manual GF-115-H.
•Check flame detection circuitry (See paragraph 1.3)
RECOMMENDED Tasks:
•Inspect vent pipe (clean if needed)
•Inspect flue collector (clean if needed)
•condensate tray (clean if needed)
•Wash heat exchanger (clean if needed) (see MLX boiler manual GF-115-H, paragraph 8.3.3)
•Check and adjust air/fuel ratio (see MLX boiler manual GF-115-H, paragraph 7.5.5)
•Inspect and clean burner surface (see MLX boiler manual GF-115-H, section 8.3)
•Inspect heat transfer surfaces (clean if needed)
•Clean strainer mesh (Monthly)
•Check inlet gas pressure. Changes in gas pressure require combustion recalibration (see MLX
boiler manual GF-115-H, paragraph 7.5.5)
•Check vent and inlet air terminations
•Check electrical supply voltages
Tools Required
Common hand tools, plus a spark gap feeler gauge are required to perform the annual maintenance tasks
described in this bulletin.
Prior to performing the following disassembly and inspection procedures, ensure
that all electrical power to the boiler has been turned off and the external gas shut-
off valve is fully closed.
WARNING
!
!

PR2: 04/01/11 Page 4 of 5
AERCO International, Inc.
•
100 Oritani Dr.
•
Blauvelt, New York 10913
•
Phone: [phone]
Modulex Annual (12 Month) Maintenance
Technical instruction Document
TID-0026_0A
1.1 - Disassembly for Annual Maintenance
Disassemble the unit per Instruction 1.1, below, and locate the electrical components to be replaced.
Unit Disassembly for Annual
Maintenance
1. Disconnect electrical power to the unit
by turning off the external circuit
breaker.
2. Turn off the external gas supply shutoff
valve.
3. Remove the top cover from the boiler. A
screwdriver may be needed to pry the
cover from the two pins on either end.
4. Carefully detach the ground wire clips
from the underside of the cover (see
note above).
5. Remove the front panel from the boiler
to provide access to the spark igniter
and flame detector for each heat
module of the boiler (see Figure 1).
6. Refer to Figure 2and Figure 3and
locate the installed locations of the
igniters and flame detectors. These
Figures show a Modulex MLX-757
containing five (5) igniters and five (5)
flame detectors.
NOTE
The cover is secured with spring clips
and pins to front, back and side panels
of the unit. In addition, two (2) groups of
ground wires from the frame of the
boiler are attached with clips to the
underside of the top cover. Use care
when disconnecting these ground wire
clips. Note that all lugs have capture
spring clips that are released by
pressing a small nub under lug itself.
INSTRUCTION 1.1
Figure 1: Cover Removed (Rear)
Figure 2: Electrical Connections
Figure 3: Electrical Components
See Figure 3
See Figure 2
Flame
Detector
Lead
Igniter
Cable
Ground Lead
View
Port
Mounting
Screws (2)
NOTE
The number of burner sections, and thus the
electrical components, varies by model.
END

PR2: 04/01/11 Page 5 of 5
AERCO International, Inc.
•
100 Oritani Dr.
•
Blauvelt, New York 10913
•
Phone: [phone]
Modulex Annual (12 Month) Maintenance
Technical instruction Document
TID-0026_0A
1.2 Replacing the Spark Igniters and Flame Detectors
The Spark Igniter and Flame Detector are replaced per Instructions 1.2 A and 1.2Bbelow.
1.3 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 3) while the unit is running. If the unit shuts down after a few
seconds, the flame detection circuitry is functional. If boiler does not automatically shut down, there is a
problem with the circuit. In this case, manually shut down the boiler and contact appropriate technical
help to resolve the problem.
Modulex Model: Maintenance Kit P/N:
MLX-303 Annual Maintenance Kit
58019-01
MLX-454 Annual Maintenance Kit
58019-02
MLX-606 Annual Maintenance Kit
58019-03
MLX-757 Annual Maintenance Kit
58019-04
MLX-909 Annual Maintenance Kit
58019-05
MLX-1060 Annual Maintenance Kit
58019-06
© AERCO International, Inc., 2011
Replacing the Spark Igniter
The spark igniter for each heat module is installed to
the left of the view port as shown in Figure 3.
Remove and replace as follows:
1. Disconnect the spark igniter ground wire and
unplug the igniter cable.
2. Using a Phillips head screwdriver, remove the two
(2) screws securing the igniter and remove it from
the boiler.
3. Obtain a replacement igniter
from the
maintenance kit. Using a spark gap feeler gauge,
ensure that the igniter spark gap is 4mm to 5 mm.
4. Install the replacement igniter and secure it in
place with the two (2) screws removed in step (b).
5. Reconnect the igniter cable and ground wire
6. Repeat steps (1) through (5) for each igniter in the
Modulex boiler.
Replacing the Flame Detector
The flame detector for each heat module is
installed beneath the view port as shown in
Figure 3. Remove and replace as follows:
1. Disconnect the flame detector wire lead.
2. Using a Phillips head screwdriver,
remove the two (2) screws securing the
flame detector and remove it from the
boiler.
3. Obtain a replacement flame detector
from the maintenance kit.
4. Install the replacement flame detector
and secure it in place with the two (2)
screws removed in step (b).
5. Reconnect the flame detector wire lead.
6. Repeat steps (1) through (5) for each
flame detector in the boiler.
INSTRUCTION 1.2 A
INSTRUCTION 1.2 B
END
END
Modulex Models and Associated Annual Maintenance Kit P/Ns