Modulex. Gas Fired Boiler Systems PIPING GUIDE GF-115-P. Modular, Condensing, Hot Water Boilers Models: 303, 454, 606, 757, 909, Instruction No.

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1 Instruction No. AERCO INTERNATIONAL, Inc., Northvale, New Jersey, USA PIPING GUIDE GF-115-P Modulex Gas Fired Boiler Systems Modular, Condensing, Hot Water Boilers Models: 303, 454, 606, 757, 909, 1060 Printed in U.S.A. DECEMBER 19, 2006

2 Telephone Support Direct to AERCO Technical Support (8 to 5 pm EST, Mon. Fri.) AERCO International, Inc. 159 Paris Avenue Northvale, NJ The information contained in this piping guide 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 guide. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material AERCO International, Inc., 2006

3 TABLE OF CONTENTS Paragraph Page IMPORTANT 1 1. FEEDING WATER QUALITY AND GLYCOL SOLUTION GLYCOL SOLUTION 2 2. MAXIMUM ALLOWABLE WORKING PRESSURE 2 3. BOILER LOOP DESIGN GUIDELINES RECIRCULATION PUMP STRAINERS ISOLATION VALVES AIR VENTING OF THE HEATING SYSTEM 7 4. CSD-1 MANIFOLD ASSEMBLY (supplied) 7 5. CONNECTING SUPPLY AND RETURN PIPING (Per ANSI Z21.13a) SYSTEM FILLING & DRAINING NOTES ON CONDENSATE DRAIN GAS MAINS AND CONNECTIONS 13 i

4

5 IMPORTANT PIPING GUIDE Local codes and authorities should be consulted prior to installation. AERCO recommends the installation of a primary/secondary piping system with a common pipe and a simple water purge and rinse of the whole system and to fit a mandatory Y- strainer on the return pipe to the boiler, equipped with isolation valves (See Figures 11, 12, 13 and 14 at the end of this document). For existing boiler replacement installations, we recommend to purge and to rinse properly the whole system before connecting the 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. Relief valve must be installed vertically in the top, side or to a valveless header connected to the water supply outlet. All components marked with an asterisk (*) in Figures 11, 12, 13 AND 14 are included separately in shipment from the factory. The manifold for these components is also included separately in the factory shipment. 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 locate at a minimum of 6 inches from the boiler panels and covers. See Table 1 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 discharge pipe example on the Modulex boiler. The relief valve point of discharge piping must have provisions for proper drainage. Figure 1 Relief Valve Point of Discharge Example 1

6 1. MAKEUP WATER QUALITY AND GLYCOL SOLUTION The system and make-up water chemical properties are important for correct and safe operation of the boiler. One of the most frequent and serious problems caused by low quality feed water, is the scale deposits on heat exchanger surfaces. It is known that scale, reduces heat exchange due to their low heat conductivity. Scale may cause very dangerous localized overheating. Less frequent, but not less serious, is the waterside corrosion of all heating circuit surfaces. Water at the installation should be checked, monitored, maintained and treated for the following: Hardness ph High hardness of the available water measured in grains of hardness The ph, for boilers with aluminum alloy bodies, MUST ALWAYS BE WITHIN 6.5 AND 8.0. Oxygen All precautions will be taken to avoid the formation and localization of oxygen in the water of a heating system. For this reason it will be necessary that in the heating systems using floor radiant heating, the plastic pipes used is impermeable to the oxygen. Anti-Freeze Solutions When using anti-freeze solutions, their compatibility with aluminum alloys and other components of the heating system must be determined prior to use. If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed upstream of the fill/makeup valve. Water treatment is also advisable in the following cases: 1. Very large heating systems 2. High quantities of replenished water due to leakages or maintenance works The use of an inhibitor is advisable to treat feeding waters and to protect heating systems against scale, corrosion and microbiologic growth. In case of freezing as well, the use of an anti-frost together with the inhibitor is advisable. Qualified companies can provide boiler de-scaling. NOTE: Failure of the boiler due to water quality is not covered under warranty. 1.1 GLYCOL SOLUTION Antifreeze HVAC glycol, where required, must be suitable for aluminum heat exchangers when used with the high efficiency AERCO Modulex boiler. Traditional propylene glycol is not suitable for aluminum heat exchangers: the ph of the glycol at various dilutions is in excess of 9.5, whereas the ph must be lower than 8.0 for use with aluminum (tap water is ph). 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 your local AERCO representative for recommendations on glycol solutions. 2

7 2. MAXIMUM ALLOWABLE WORKING PRESSURE The Modulex boiler has a maximum allowable working pressure of 50 psi (345kPa, 3.5 bar), and a minimum of 15 psi (103 kpa, 1 bar) 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 for strainer requirement details). Table 1. Flow Rate and Pressure Drops Min. Water Flow in GPM Max. T of 50 F Water Pressure Drop (Ft. (m) of Min. Flow Strainer P (Ft. (m) of Hd.) (2 NPT Y Strainer, 20 Mesh) P [Ft. (m)] (20 SCH. 40-2, 4 x 90, 2 x Ball Valve) Total Min. Flow (Ft. (m) of Hd.) Water Flow GPM 40 F T Water Pressure Drop (Ft.(m) of 40 F T Flow Strainer P (Ft. (m) of Hd.) (2 NPT Y Strainer, 20 Mesh) P [Ft. (m)] (20 SCH. 40-2, 4 x 90, 2 x Ball Valve) Total Min. Flow (Ft. (m) of Hd.) MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX GPM (41.6 LPM) 2 Ft. (.610 m).04 Ft. (.012 m).16 Ft. (.049 m) 2.2 Ft. (.671 m) 14 GPM (53.0 LPM) 3 Ft. (.914 m).07 Ft. (.021 m).25 Ft. (.076 m) 3.32 Ft. (1.012 m) 17 GPM (64.3 LPM) 2 Ft. (.610 m).10 Ft. (.030 m).36 Ft. (.120 m) 2.46 Ft. (.750 m) 21 GPM (79.5 LPM) 3 Ft. (.914 m).15 Ft. (.046 m).54 Ft. (.165 m) 3.69 Ft. (1.125 m) 22 GPM (83.3 LPM) 3 Ft. (.914 m).17 Ft. (.052 m).59 Ft. (.180 m) 3.76 Ft. (1.146m) 28 GPM (106.0 LPM) 4 Ft. (1.219 m).27 Ft. (.082 m).9 Ft. (.287 m) Ft. (1.588 m) 28 GPM (106.0 LPM) 4 Ft. (1.219 m).27 Ft. (.082 m).94 Ft. (.287 m) 5.21 Ft. (1.588m) 35 GPM (132.5 LPM) 5 Ft. (1.524 m).42 Ft. (.128 m) 1.46 Ft. (.445 m) 6.88 Ft. (2.097 m) 34 GPM (128.7 LPM) 4 Ft. (1.219 m).40 Ft. (.122 m) 1.38 Ft. (.421 m) 5.78 Ft. (1.762m) 42 GPM (159.0 LPM) 6 Ft. (1.829 m).60 Ft. (.183 m) 2.09 Ft. (.637 m) 8.69 Ft. (2.649 m) 39 GPM (147.6 LPM) 4 Ft. (1.219 m).52 Ft. (.158 m) 1.80 Ft. (.549 m) 6.32 Ft. (1.926m) 49 GPM (185.5 LPM) 7 Ft. (2.134 m).82 Ft. (.250 m) 2.81 Ft. (.856 m) Ft. (3.340 m) 3

8 Table 1. Flow Rate and Pressure Drops - Continued Water Flow GPM 30 F T Water Pressure Drop (Ft. (m) of 30 F T Flow Strainer P (Ft. (m) of Hd.) (2 NPT Y Strainer, 20 Mesh) P [Ft. (m)] (20 SCH. 40-2, 4 x 90, 2 x Ball Valve) Total Min. Flow (Ft. (m) of Hd.) Max. Water Flow [GPM Min. T of 20 F Water Pressure Drop (Ft. (m) of Max. Flow Strainer P (Ft. (m) of Hd.) (2 NPT Y Strainer, 20 Mesh) P [Ft. (m)] (20 SCH. 40-2, 4 x 90, 2 x Ball Valve) Total Min. Flow (Ft. (m) of Hd.) MLX-303 MLX-454 MLX-606 MLX-757 MLX-909 MLX GPM (71.9 LPM) 4 Ft. (1.219 m).12 Ft. (.037 m).45 Ft. (.137 m) 4.57 Ft. (1.393 m) 28 GPM (106.0 LPM) 10 Ft. (3.048 m).27 Ft. (.082 m).94 Ft. (.287 m) Ft. (3.417 m) 28 GPM (106.0 LPM) 7 Ft. (2.134 m).27 Ft. (.082 m).94 Ft. (.287 m) 8.21 Ft. (2.502 m) 42 GPM (159.0 LPM) 12 Ft. (3.658 m).60 Ft. (.183 m) 2.09 Ft. (.637 m) Ft. (4.478 m) 37 GPM (140.0 LPM) 7 Ft. (2.134 m).47 Ft. (.143 m) 1.63 Ft. (.497 m) 9.10 Ft. (2.774 m) 55 GPM (208.2 LPM) 13 Ft. (3.962 m) 1.04 Ft. (.317 m) 3.53 Ft. (1.076 m) Ft. (5.355 m) 46 GPM (174.1 LPM) 8 Ft. (2.438 m).73 Ft. (.223 m) 2.49 Ft. (.759 m) Ft. (3.420 m) 70 GPM (265.0 LPM) 18 Ft. (5.486 m) 1.68 Ft. (.512 m) 5.67 Ft. (1.728 m) Ft. (7.727 m) 56 GPM (212.0 LPM) 10 Ft. (3.048 m) 1.08 Ft. (.329 m) 3.66 Ft. (1.116 m) Ft. (4.493 m) 84 GPM (317.9 LPM) 23 Ft. (7.010 m) 2.42 Ft. (.738 m) 8.14 Ft. (2.481 m) Ft. ( m) 65 GPM (246.0 LPM) 13 Ft. (3.962 m) 1.45 Ft. (.442 m) 4.90 Ft. (1.494 m) 19.3 Ft. (5.898 m) 98 GPM (370.9 LPM) 30 Ft. (9.144 m) 3.29 Ft. (1.00 m) Ft. (3.350 m) Ft. ( m) 3.1 RECIRCULATION PUMP The recirculation pump shall have a discharge pressure able to assure the water flow rate as per the diagram in Figure 2. When selecting a pump, take into account the pressure drop across the boiler, fittings, accessories and piping. See Table 1. Electrical connection shall be made at terminals A1 and N, and A2 and N as shown in Figure 3 Pumps shall be calculated by installers or engineers according to boiler and system parameters. The waterside resistance curve of the boiler is shown in Figure 2. The pump is not an integral part of the boiler. Maximum Water Flow Rate Demanded, gpm (L/hr) Temp. Heat Output, 1000 BTU/Hr (KW) Rise 287 (80) 409 (120) 573 (160) 717 (200) 860 (240) 1003 (280) 18 F (10 C) (7,000) (10,800) (13,800) (17,200) (20,800) (24,200) 4

9 Water Side Pressure Losses Model 757 Model 909 Model 1060 FEET OF HEAD FT> HD Model 303 Model 454 Model Water Flowrate (gpm) Figure 2. 5

10 THERE IS 120V BETWEEN TERMINALS A8, N AND A9 AND BETWEEN A4, N AND A5 WHEN THERE IS A HEATING DEMAND BY THE DHW NTC SENSOR OR BY A DHW THERMOSTAT. THERE IS 120V BETWEEN TERMINALS A3 AND N WHEN THERE IS A HEATING DEMAND BY THE DHW NTC SENSOR OR BY A DHW THERMOSTAT. THERE IS 120V BETWEEN TERMINALS A1 AND N AND BETWEEN A2 AND N WHEN THERE IS A HEATING DEMAND. Figure 3. 6

11 3.2 STRAINERS AERCO requires the installation of a Y strainer to keep dirt out of the system and boiler. The valve should be installed in the return piping with isolation valves to allow for cleaning as necessary. The Y strainer shall have a 20 mesh or finer strainer. Such filter shall protect the boiler from the heating system dirt. Its regular cleaning has to be foreseen. 3.3 ISOLATION VALVES It is MANDATORY that ball or other type of valves be installed in the system supply and return piping to isolate the boiler if necessary. In this case the boiler can be disconnected or drained without having to drain the whole system. Never bypass safety devices, such as safety valve and expansion vessel. 3.4 AIR VENTING OF THE HEATING SYSTEM The Modulex boiler comes standard with an air vent inside the boiler (see Figure 4). This vent is for the boiler only and not the entire heating system. An effective air vent for air removal for the entire heating system must be installed in the highest point of the system piping. 4. CSD-1 MANIFOLD ASSEMBLY (supplied) The installation of a low water cutoff, manual reset high limit aquastat and an ASME compliant safety pressure relief valve designed for the boiler output capacity are required. These major components along with a manifold and several others are supplied with the boiler and must be assembled and wired when installing the boiler at the site. The manifold assembly components supplied are: 3/4 Pressure Relief Valve Manifold Assembly [2 x 16 long (51 mm x 406 mm)] 2 NPT Union Low Water Cut-Off Switch Aquastat Pressure/Temperature Gauge The pressure relief valve and all other manifold components are shown in Figures 5 and 6 for R.H. and L.H. applications respectively. 7

12 FAN GAS VALVE GAS PIPE BURNER COVER AIR INTAKE CONNECTION AUTOMATIC AIR VENT IGNITION IONIZATION LOCAL NTC SENSOR H.L. THERMOSTAT BURNER ALUMINUM/ SILICON HEAT EXCHANGER GLOBAL FLOW NTC TEMPERATURE SENSOR HOT WATER OUTLET (SUPPLY) 1/4" CONNECTION WITH PLUG GLOBAL RETURN NTC TEMPERATURE SENSOR BOILER FRAME COLD WATER INLET (RETURN) DRAINING TAP CONDENSATE COLLECTION TRAY MANIFOLD CONDENSATE DRAIN SIPHON FILLING-UP ELBOW 5.9" [150 mm]** 3.94" [100 mm].98" [25 mm]* Figure 4. Modulex Main Components 8

13 Figure 5 CSD-1 Manifold Assembly and Component for R.H. Application Figure 6 CSD-1 Manifold Assembly and Component for L.H. Application 9

14 To install the pressure relief valve and the other components shown, proceed as follows: NOTE: USE TEFLON TAPE OR A SUITABLE PIPE JOINT COMPOUND FOR COMPONENT AND PIPING CONNECTIONS DESCRIBED IN THE FOLLOWING STEPS. REFER TO FIGURE 9 AND 10 FOR COMPONENT IDENTIFICATION. 1. Attach the 2 NPT union and manifold assembly to the outlet supply connection on the boiler (Figure 7). 2. Connect the following components to the tapped holes in the manifold assembly (Figure 5 or 6): Pressure Relief Valve Low Water Cut-Off Switch Aquastat Pressure/Temperature Gauge Check to ensure that all components are securely tightened. 3. For electrical connections and wiring the CSD-1 manifold assembly in Figures 5 and 6, see the separate CSD-1 wiring diagram included with the manual package. Figure 7 Manifold Assembly and Components Shown Installed on R.H. Side 10

15 5. CONNECTING SUPPLY AND RETURN PIPING (Per ANSI Z21.13a) The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during the cooling cycle. A hot water boiler installed above radiation level or as required by Authority having jurisdiction, must be provided with a low water cutoff device either as a part of the boiler or at the time of the installation. 6. SYSTEM FILLING & DRAINING For filling-up the system, a filling tap has to be inserted on the system return pipe. The filling-up can also be made through the draining tap on the boiler return manifold (see Figure 4). In both cases, an approved hydraulic disconnection system has to be fitted. Before connecting the boiler, carefully rinse out the whole system with running water. The boiler is equipped with its own drain (see Figure 4 for the drain position). NEVER USE IT TO DRAIN THE SYSTEM, since the system dirt could gather in the boiler and compromise its operation. The system itself shall be equipped with its own drain, whose size will depend on the system capacity. The application of a strainer on the return pipe to the boiler is required. 7. NOTES ON CONDENSATE DRAIN To maintain proper flow of condensate the drain pipe must slope toward the drain of at least 3/8 in./ft. (30 mm/m). The liquid column inside the condensate siphon needs to be filled with water after installation. Its minimum height when all the fans are in operation must be at least 1 in. (25 mm). In order to prevent ice from forming, the condensate piping must be well insulated. A typical condensate drain installation is shown in Figure 8. The parts required to fabricate the condensate drain system are shipped with the boiler and are illustrated in Figure 9. Items 7 and 8 are included in the Accessory Kit which is packed separately. The remaining parts shown in Figure 9 are packed inside the boiler shipping carton on the front or back of the boiler. A 38.5 (1 meter) PVC pipe is packed on the back of the Modulex boiler. It is important to note that this pipe must be cut to the appropriate lengths to obtain items 3 and 5 shown in Figure 9. The actual lengths required will depend on the Modulex model and prevailing conditions at the installation site. 11

16 DO NOT INSTALL THE CONDENSATE DRAIN WHERE FREEZING MAY OCCUR. Consult local codes with regard to condensate neutralization. Neutralization can be obtained by mixing it with the buildings drain water or with limestone, which normally have a base ph. Figure 8 Typical Condensate Drain Installation Figure 9 Condensate Drain Assembly Components 12

17 8. GAS MAINS AND CONNECTIONS Connect gas service meter to control assembly in accordance with the current version of the ANSI Z223.1 and the local codes or utility. For easy removal of gas control for servicing, a ground union can be installed. A drip leg (or trap) must be installed at the inlet of the boiler (see Figure 10) Check with local utility for required location of manual shutoff valve. Use pipe compound resistant to the action of liquid petroleum gases on all pipe thread connection. Prior to operation, the complete gas train ad all connections must be leak tested using a noncorrosive soap. Figure 10 Gas Piping 13

18 Figure 11 - Single Modulex Boiler Piping System 14

19 Figure 12 - Two Modulex Boiler Piping System 15

20 Figure 13 Modulex Boiler Piping System With Domestic Water Heating 16

21 Figure 14 Multiple Modulex Boiler Piping System With Domestic Water Heating 17

22

23 NOTES: 19

24 AERCO INTERNATIONAL INC. 159 PARIS AVENUE NORTHVALE, N.J PHONE FAX AERCO declines every responsibility for the possible inaccuracies if owed to errors of transcript or press. Also, AERCO reserves the right to bring those changes that will hold necessary to its own products or profits, without jeopardizing its essential characteristics.

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