Watts Aerco Modulex EXT Series User guide

Technical Application Guide

Modulex EXT Series

Piping Application Guide

Modulating and Condensing Boilers

Applies to the following

Modulex EXT Series models:

•MLX EXT 450 2S

•MLX EXT 600 2S

•MLX EXT 800 2S

•MLX EXT 1100 2S

•MLX EXT 1500 2S

•MLX EXT 2300 2S

•MLX EXT 2600 2S

•MLX EXT 3000 2S

TAG-0099 • 10/7/2021

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 or for incidental or consequential

damages occurring in connection with the furnishing, performance, or use of

these materials.

Heating and Hot Water Solutions

AERCO International, Inc. • 100 Oritani Drive • Blauvelt, NY 10913

USA: T: (845) 580-8000 • Toll Free: (800) 526-0288 • AERCO.com

Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST

AERCO International, Inc. •100 Oritani Dr. Blauvelt, NY 10913
Phone: 800-526-0288 
Page 2of 37 
10.07.2010 
TAG-0099 
Modulex EXT Series Piping Application Guide 
MANDATORY REQUIREMENTS 
 
 
Contents 
SECTION 1: MANDATORY REQUIREMENTS 3 
SECTION 2: BOILER QUALITY AND MAINTENANCE 5 
2.1. BOILER WATER CHEMISTRY................................................................................................5 
2.1.1. Reaction of Metals to Water Chemistry.........................................................................5 
2.1.2. Scale and Corrosion......................................................................................................5 
2.1.3. Make-up or Feed Water Quality ....................................................................................5 
2.1.4. Treating Water to Prevent Freezing ..............................................................................5 
2.1.5. Water Treatment Certification .......................................................................................5 
2.2. TESTING AND MAINTENANCE OF WATER QUALITY..........................................................6 
2.3. SYSTEM FLUSHING, TREATMENT, AND CLEANSING ........................................................7 
2.3.1. System Flushing Recommendations.............................................................................7 
2.3.2. Water Quality Maintenance and Boiler Warranty...........................................................8 
2.3.3. Water Treatment Certification .......................................................................................8 
2.3.4. Water Treatment Analysis and Scheduling....................................................................8 
2.3.5. Hydronic System Water Testing and Treatment Resources..........................................8 
SECTION 3: BOILER LOOP DESIGN GUIDELINES 10 
3.1. Flow Rate & Pressure Drops: Models EXT 450 2S, 600 2S, 800 2S & 1100 2S .................10 
3.2. Flow Rate & Pressure Drops: Models EXT 1500 2S, 2300 2S, 2600 2S & 3000 2S............12 
3.3. PRIMARY PUMP....................................................................................................................15 
3.4. STRAINERS...........................................................................................................................16 
3.5. ISOLATION VALVES.............................................................................................................16 
3.6. AIR VENTING OF THE HEATING SYSTEM..........................................................................17 
SECTION 4: CSD-1 MANIFOLD ASSEMBLY (SUPPLIED) 19 
4.1. Installing the Pressure Relief Valve and Other Components ............................................20 
SECTION 5: CONNECTING SUPPLY & RETURN PIPING 22 
5.1. BOILER CONNECTIONS.......................................................................................................22 
5.2. PRIMARY-SECONDARY PIPING..........................................................................................22 
5.3. ADDITIONAL SUPPLY AND RETURN PIPING.....................................................................22 
5.4. CHANGING RIGHT-HAND CONNECTIONS TO LEFT-HAND ..............................................22 
5.4.1. Modulex Light Commercial Models EXT 450 2S, 600 2S, 800 2S & 1100 2S..............22 
5.4.2. Modulex Commercial Models EXT 1500 2S, 2300 2S, 2600 2S & 3000 2S ................23 
5.4.3. Reversing Gas Manifold Connections (EXT 450 2S - 1100 2S)...................................24 
5.4.4. Reversing Cold/Hot Water Flow & Return Connections (EXT 450 2S - 1100 2S)........24 
5.4.5. Reversing Flow & Return Temperature Sensors.........................................................26 
5.4.6. Reversing the Boiler Sensor KF and Automatic Air Vent.............................................26 
SECTION 6: SYSTEM FILLING AND DRAINING 27 
SECTION 7: CONDENSATE DRAIN 28 
SECTION 8: PIPING DIAGRAMS 30 
 

Modulex EXT Series Piping Application Guide

MANDATORY REQUIREMENTS

TAG-0099 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 3of 37

Phone: 800-526-0288 10.07.2021

SECTION 1: MANDATORY REQUIREMENTS

The following actions are mandatory to ensure proper piping and drainage of the Modulex EXT system.

CAUTION!

Local codes and authorities must be consulted prior to installation.

•AERCO requires that the boiler loop to be de-coupled from the system loop. This can be achieved by

one of the following:

oEmploying primary-secondary piping.

oInstalling a hydraulic separator between the boiler and the system loop.

oInstalling a heat exchanger (e.g. plate heat exchanger) between the boiler and the system loop. If

water treatment used in the system is not Aluminum compatible, the use of a heat exchanger

between the system and the boiler piping is MANDATORY.

•AERCO requires cleaning of the whole system and to fit a mandatory Y-strainer on the return pipe to

the boiler, equipped with isolation valves (See Figure 13 through 20 at the end of this document).

•For boiler replacement installations, cleaning of the whole system is required before connecting the

Modulex boiler (See Section 2.3 for Flushing, Treatment, and Cleansing tips and guidelines). Failure to

clean a system will limit it from the full benefits offered by the high efficiency Modulex boiler.

•Boiler drain valve and condensate drain trap should be arranged to permit the fluids to drain freely, by

gravity, to a convenient floor drain.

•For units installed in environments likely to experience freezing temperatures, it is necessary to ensure

that the condensate line and exhaust manifold are equipped with suitable freeze protection, such as a

heat trace line.

•Relief valve must be installed vertically in the top, side, or to a valveless header connected to the water

supply outlet.

•Locate water supply and return fittings (i.e. unions, elbows, etc.) a minimum of 6 inches from the boiler

fittings to prevent interference with the removal of the boiler panels and covers.

•All piping and electrical connections (i.e. service switches, conduit boxes, etc.) should be located at a

minimum of 6 inches from the boiler panels and covers.

•For all outdoor applications, electrical connections must either be NEMA4 rated or protected by a

suitable outdoor enclosure.

•See Table 1 (Section 3) for sizing guidelines for the mandatory primary pump and boiler strainer.

•A discharge pipe must be used and must not have an internal cross-sectional area less than the outlet

of the relief valve.

•The discharge pipe must be installed so that there will be no danger of scalding to the boiler attendants.

See Figure 1, below, for a discharge pipe example on the Modulex boiler.

•The relief valve point of discharge piping must have provisions for proper drainage.

AERCO International, Inc. •100 Oritani Dr. Blauvelt, NY 10913

Phone: 800-526-0288

Page 4of 37

10.07.2010

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Modulex EXT Series Piping Application Guide

MANDATORY REQUIREMENTS

Figure 1: Relief Valve Point of Discharge Example

RELIEF VALVE

PIPED TO POINT OF

DISCHARGE

RELIEF VALVE DISCHARGE PIPING

Modulex EXT Series Piping Application Guide

BOILER QUALITY AND MAINTENANCE

TAG-0099 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 5of 37

Phone: 800-526-0288 10.07.2021

SECTION 2: BOILER QUALITY AND MAINTENANCE

2.1. BOILER WATER CHEMISTRY

2.1.1. Reaction of Metals to Water Chemistry

A neutral water pH must be maintained because, although the aluminum alloys used in the construction of

Modulex EXT boilers resist acidic conditions, they are still vulnerable to highly alkaline environments (pH of

9.0 and above). THE WATERSIDE pH MUST BE MAINTAINED BETWEEN 6.5 and 8.0.

Metals such as aluminum, steel, iron, and copper used in hydronic heating systems are highly reactive to

acidic and alkaline environments; the water must be treated with protectants and buffers to prevent

corrosion. Most chemical water treatments have been developed to protect an array of metals.

2.1.2. Scale and Corrosion

Free oxygen can cause the formation of rust (iron oxides), which degrade metallic materials. Magnetite is

formed in un-inhibited water if there is electrolytic action in the presence of oxygen. Sludge is formed when

calcium compounds, primarily CaCO3, are heated. Rust and magnetite, when combined with sludge, can

form a very hard scale, which significantly reduces system efficiency and life expectancy of the heating

system. Scale reduces heat exchange due to its low heat conductivity and so may cause very dangerous

localized overheating. Waterside corrosion of all heating circuit surfaces is also a major concern.

2.1.3. Make-up or Feed Water Quality

Make-up or feed water is water added to a closed hydronic system to replenish water lost through

evaporation, maintenance, or leakage. The quality of make-up or feed water, which may contain dissolved

oxygen, minerals and other dissolved contaminants, is extremely important. Such introduced water must

be chemically treated or strictly limited when ensuring neutral chemical conditions in boiler system water.

Generally, any closed hydronic heating system should be restricted from receiving untreated makeup water

of no more than 5% of the total volume of system water per year. Reverse osmosis, deionized, distilled or

mineral treated water should not be used.

2.1.4. Treating Water to Prevent Freezing

When using anti-freeze solutions, their compatibility with the AERCO Modulex aluminum heat exchanger

and other components of the heating system must be determined prior to use. TRADITIONAL HVAC

PROPYLENE GLYCOL IS NOT SUITABLE FOR ALUMINUM HEAT EXCHANGERS: the pH of glycol at

various dilutions is in excess of 9.5, whereas the pH must be within 6.5 and 8.0 for use with

aluminum. There are several suitable aluminum safe propylene glycols available that can provide the

same levels of burst, freeze and corrosion inhibiting protection as traditional propylene glycols. Consult

Section 2.3 for recommendations on glycol solutions. If a glycol solution is used as anti-freeze protection, a

backflow preventer must be installed upstream of the fill/makeup valve.

Only virgin glycol should be used for systems requiring freeze protection, and it must be treated with an

inhibitor compatible with the particular chemical treatment being used in the system. Note that glycol must

be changed from time to time due to its limited useful life.

2.1.5. Water Treatment Certification

When using chemical treatments in hydronic systems, it is necessary to ensure that the chosen treatment

is appropriate and certified by the manufacturer for such environments. The manufacturer should also

guarantee that the treatment, when applied according to the manufacturer’s recommendations, will not

AERCO International, Inc. •100 Oritani Dr. Blauvelt, NY 10913

Phone: 800-526-0288

Page 6of 37

10.07.2010

TAG-0099

Modulex EXT Series Piping Application Guide

BOILER QUALITY AND MAINTENANCE

cause harm to the boiler, pumps, piping, and other components of the hydronic boiler system.

2.2. TESTING AND MAINTENANCE OF WATER QUALITY

Water in the installation should be checked, monitored, and treated for the following:

•Hardness –High hardness of the available water is measured in grains of hardness and indicates the

quantity of minerals (mostly calcium and magnesium) which are dissolved in the water. Hardness

substantially contributes to the formation of scaling, which is highly undesirable. The total hardness

must be less than 200 ppm (11.7 grains/gallon).

•Artificial Softness –Do NOT use artificially softened water. Artificial softening agents generally use

salt, which creates a chloride water chemistry, a major contributor to the corrosion of the types of

metals used in hydronic systems. Elevated salt levels also contribute to higher conductivity levels,

another undesirable characteristic in hydronic systems.

•Chloride –Chloride salts result from the combination of chlorine gas with a metal and are

instrumental in accelerating corrosion in the types of metals used in hydronic systems. Chlorides may

be introduced into the water naturally. Concentrations of chlorides in system water should be less than

150 ppm.

•Conductivity –Dissolved metals and minerals increase the conductivity of water and indicate not only

the presence of undesired corrosive agents, but also contribute to the transfer and migration of ions

and charged particles in the water that contribute to fouling of sensors, valves, and other devices used

in the system. Additionally, high conductivity contributes to galvanic corrosion, in which one metal will

preferentially corrode when in contact with another type of metal, when both are in contact with an

electrolyte. Conductivity should be less than 3000 μS.

•pH –The pH, a measure of the acidic, neutrality, and alkalinity of the water, MUST ALWAYS BE

WITHIN 6.5 AND 8.0 FOR BOILERS USING ALUMINUM ALLOYS, such as the Modulex boiler

system.

•Oxygen –All precautions should be taken to avoid the formation and localization of oxygen in the

water of a heating system. Water that is low in minerals (soft water) absorbs oxygen much more

readily than mineralized (hard) water. For this reason it is necessary that in heating systems using

floor radiant heating, the plastic pipes used be impermeable to oxygen.

•Scale and Corrosion –The use of an inhibitor is advisable to treat feed and make-up water and to

protect heating systems against scale, corrosion and microbiologic growth. To prevent freezing, an

anti-freezing agent is advisable. Qualified companies can also provide boiler de-scaling.

•Total Solids –preferably less than 500 ppm, but a requirement of less than 1000 ppm.

•Water treatment is also advisable in the following cases:

oVery large heating systems

oHigh quantities of replenished water due to leakages or maintenance work

Modulex EXT Series Piping Application Guide

BOILER QUALITY AND MAINTENANCE

TAG-0099 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 7of 37

Phone: 800-526-0288 10.07.2021

2.3. SYSTEM FLUSHING, TREATMENT, AND CLEANSING

Note that prior to cleaning the heating system, the boiler MUST be isolated from the piping to prevent

infusion of containments, including sludge, into the boiler. Section 2.3 provides recommendations for

flushing, cleaning, and treating the water used in the Modulex EXT boiler system.

IMPORTANT!

Cleaning solution and inhibitors used must be compatible with heat exchanger material. Corrosion/scale

inhibitor will be ineffective if added to a dirty system; therefore, it is very important to clean the system first.

Water treatments used must be compatible with EPDM gaskets used in the Modulex Boiler. (EPDM =

Ethylene Propylene Diene Manomer).

AERCO recommends the following cleaning solution, inhibitor, and antifreeze products. Visit

www.aerco.com for Product Fact sheet and Material Safety Data Sheets:

•Water Quality Testing —X100 Quick Test Kit

Part number 99152-1

•Corrosion/Scale Inhibitor —Sentinel X100 Liquid Inhibitor

4 x 1 gallon case –part number 99153-2

5 gallon jug –part number 99153-1

•Boiler Noise Reducer —Sentinel X200 Liquid Noise Inhibitor

4 x 1 gallon case –part number 99154-2

5 gallon jug –part number 99154-1

•System Cleaner —Sentinel X300 Liquid System Cleaner

4 x 1 gallon case –part number 99199-2

5 gallon jug –part number 99199-1

•Cleaning solution —Sentinel X400 Liquid System Restorer

4 x 1 gallon case –part number 99155-2

5 gallon jug –part number 99155-1

•Antifreeze —Sentinel X500 Liquid Inhibited Antifreeze

5 gallon jug –part number 99156-1

55 gallon jug –part number 99156-2

275 gallon tote –part number 99156-3

When cleaning, treating, and maintaining, a heating system, consult a qualified professional. The following

are AERCO’s tips/guidelines for cleaning a heating system – these do NOT take precedence over detailed

instructions from qualified professionals.

2.3.1. System Flushing Recommendations

•Use an appropriate amount of cleaning solution, carefully following the manufacturer’s instructions.

Follow the manufacturer’s recommendations when introducing cleaning agents into the system.

•Ensure that the cleaning solution is circulated thoroughly in the system.

•Flush the system thoroughly to remove the maximum amount of contaminants. When emptying the

system, make sure it is done as quickly as possible using all drain off points and ensuring all low lying

pipework is fully drained. Opening all bleed valves ensures the system will be completely emptied.

AERCO International, Inc. •100 Oritani Dr. Blauvelt, NY 10913

Phone: 800-526-0288

Page 8of 37

10.07.2010

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Modulex EXT Series Piping Application Guide

BOILER QUALITY AND MAINTENANCE

•A reliable test to determine if a system is clean is if the Total Dissolved Solids (TDS) of the water being

drained is within 10% of the make-up water TDS. This indicates that sufficient contamination has been

flushed from the system. If the difference in TDS is more than 10%, repeat the cleaning process until

that is achieved. A turbidity test can be used as an alternate way to determine if a system is clean.

•For boiler retrofit/replacement installation, repeat the cleaning process until the draining water is clear.

Once clear, the above TDS comparison (or a turbidity test) should be performed.

•If a flushing machine is used in the cleaning process, carefully follow the manufacturer’s instructions. If

the flushing machine is designed to flush individual zones, the TDS comparison must be made

between each zone and the make-up water, or the turbidity test performed for each zone.

•Add corrosion and scale inhibitor after the system has been declared clean, using the appropriate

amount recommended by the manufacturer. Introduce the Multi-Metal protector/scale inhibitor to the

system following the manufacturer’s instructions. Adding inhibitor to a dirty system reduces its

effectiveness. It is better to add more inhibitor (exceed the recommended amount) than less.

When refilling the system, ensure the boiler is not air-bound by opening the pressure-relief valve on the rear

of the boiler. Leave the relief valve open until a steady flow of water is observed. Close the valve and finish

filling the system.

2.3.2. Water Quality Maintenance and Boiler Warranty

Heat exchanger failures due to improperly cleaned/treated and poorly maintained water are not covered

under warranty. Scheduled system/boiler water maintenance is required to maintain the heat exchanger

warranty. AERCO shall reserve the right to require maintenance records when evaluating warranty claims.

2.3.3. Water Treatment Certification

When using chemical treatments in hydronic systems, it is necessary to ensure that the chosen treatment

is appropriate and certified by the manufacturer for such environments. The manufacturer should also

guarantee that the treatment, when applied according to the manufacturer’s recommendations, will not

cause harm to the boiler, pumps, piping, and other components of the hydronic boiler system.

2.3.4. Water Treatment Analysis and Scheduling

The proper mixture of water, chemical treatment, and glycol (if used) should be ascertained based on a

sample of the system water and the make-up water. Your local water treatment company, or one of the

manufacturers listed below, may analyze your sample. Adjust the chemical composition of your system

water based on the analysis. After this initial analysis, the chemical composition of your system water should

be tested at the beginning of each heating season. For boilers operating year round, this analysis should

be made at least twice a year.

2.3.5. Hydronic System Water Testing and Treatment Resources

On the internet at www.awt.org, you may find a listing of water treatment firms and manufacturers of

chemical treatments developed for use in multi-metal hydronic systems. Click on the “Find a Water Treater”

button to access this list.

Below is a list of companies providing water treatment systems certified as safe for use in multi-metal

hydronic systems, including aluminum boilers. Contact any of the individuals listed for more information.

Modulex EXT Series Piping Application Guide

BOILER QUALITY AND MAINTENANCE

TAG-0099 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 9of 37

Phone: 800-526-0288 10.07.2021

Fernox

Hydronic Agencies Ltd.

Sean Leonard

Edmonton, AB, CANADA

Phone: (780) 452-8661

Toll Free: (877) FERNOX4U

(877-337-6694)

Fax: (780) 488-2304

sales@hydronicagencies.com

www.hydronicagencies.com

H-O-H Water Technology, Inc.

Steve Sadowski

Greendale, WI

Phone: (414) 421-2070,

Toll Free: (800) 944-9746

Fax: (414) 421-2077

ssadowski@hohwatertechnology.com

www.hohwatertechnology.com

Fernox USA

Cookson Electronics

Brian Conrad

Altoona PA

Phone: (814) 946-1611

Toll Free (800) 289-3797

Fax: (814) 944-8094

fernox_americas@cooksonelectronics.com

www.fernox.com

Rhomar Water Management, Inc.

Dwight Hedgepeth

Springfield, MO

Phone: (417) 862-2600,

Toll Free: (800) 543-5975

Fax: (417) 862-6410

peggy@rhomarwater.com

www.rhomarwater.com

AERCO International, Inc. •100 Oritani Dr. Blauvelt, NY 10913

Phone: 800-526-0288

Page 10 of 37

10.07.2010

TAG-0099

Modulex EXT Series Piping Application Guide

BOILER LOOP DESIGN GUIDELINES

SECTION 3: BOILER LOOP DESIGN GUIDELINES

For proper and safe operation of the water tube Modulex boiler, the primary (boiler) loop piping and the

associated fittings and accessories must be designed/selected as discussed in the following sections.

Table 1 shows the required minimum flow rates at various system designed temperature rises. Also

shown are pressure drops through strainers typically needed in the boiler loop (see paragraph 4.2 for

strainer requirement details).

The following primary/secondary piping design guidelines should be used for AERCO Modulex Boiler

installations. The data was calculated based upon systems with Return Water Temperatures above 80F.

A 20 mesh strainer (or finer) is required at each boiler inlet. Water flow rates and pressure drops shown

below are for the boiler loop. Boiler water flow rates vary with system design parameters. The boiler

loop fittings and strainer pressure drops shown below are examples only –actual pressure drops

will vary depending on actual piping layout and strainer size/type used.

3.1. Flow Rate & Pressure Drops: Models EXT 450 2S, 600 2S, 800 2S & 1100 2S

TABLE 1.1: Light Commercial: 50F∆T Water Flow

50°F ΔT Water Flow

EXT 450 2S

EXT 600 2S

EXT 800 2S

EXT 1100 2S

WaterFlow(GPM)@Max. ∆T of 50F

WaterPressureDrop(Ft.ofHd.)acrossBoiler@50F

∆T Flow

2.1

1.7

1.6

1.8

Strainer ∆P (Ft. of Hd.) – (‘Y’ Strainer, 20 mesh)

0.50

0.89

0.41

0.80

∆P (Ft. of Hd.) – (20’ SCH.40, 4 x 90°, 2 x reducing

couplings,2xBallValve)

0.81

1.47

0.65

1.23

Total Primary Loop ∆P (Ft. of Hd.) @ ∆T of 50F

3.44

4.09

2.67

3.82

Strainer, Pipes, Valves and Fittings Sizes used to

estimate ∆P for above piping configurations

1-1/2"

RecommendedAERCO Pump+CircuitSetterKitfor

pipingconfigurationsnotexceedingtheaboveexample

99127-1

99127-2

99127-3

Kitincludes:PumpFlangeSize

1-1/2"

Kit includes:Circuit SetterSize (NPT)

1-1/2”

2”

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