Modulex EXT

A breakthrough in high-efficiency design, AERCO’s condensing and fully modulating Modulex boilers support 321 to 3060 MBH hydronic heating systems while delivering a greater degree of operating reliability for customer peace of mind. To achieve the greatest possible fuel savings, each boiler combines independent, 161,500 or 382,000 BTU/hr thermal modules that operate to deliver superior turndown and a range of non-cycling operation not readily achieved by competitive equipment or controls.

Features and Benefits

  • Condensing Boiler
  • Natural Gas or Propane
  • Unmatched Turndown
  • 7:1 to 39:1 Depending Upon Unit
  • Whisper Quiet Operation <50 dBa
  • Low NOx Emission <20 ppm
  • Direct or Conventional Vent with PVC, CPVC,Polypropylene or AL29-4C Materials
  • Common Vent Capability
  • Outdoor Installation Capable with no additional accessories or changes
  • Small, Doorway-Size Footprint
  • Flexible Piping and Venting Connections
  • Equipped with Sealed Combustion
  • Superior Reliability
  • Minimal Maintenance
  • Easy Open Access for Serviceability
  • 0-10V output to control primary VFD pump
  • Supports Integration to BAS System

Model

Min. Input BTU/hr.

Max. Input BTU/hr.

Max Output* BTU/hr.

Efficiency Range

MLX EXT 321

46,000

321,000

281,000-305,000

87% to 99%

MLX EXT 481

46,000

481,500

422,000-457,000

87% to 99%

MLX EXT 641

46,000

642,000

564,000-609,000

87% to 99%

MLX EXT 802

46,000

802,500

707,000-762,000

87% to 99%

MLX EXT 962

46,000

963,000

850,000-914,000

87% to 99%

MLX EXT 1123

46,000

1,123,500

993,000-1,067,000 

87% to 99%

MLX EXT 1530

83,000

1,530,000

1,448,000-1,518,403

 

MLX EXT 1912

83,000

1,912,000

1,810,000-1,903,000

 

MLX EXT 2295

83,000

2,295,000

2,171,913-2,286,476

 

MLX EXT 2677

83,000

2,677,000

2,533,925-2,672,390

 

MLX EXT 3060  

83,000

3,060,000

2,897,080-3,071,951 

 

*Note: Max output varies depending on supply and return water temperatures, please contact for factory representative for greater details

Combustion view ports and easy access to all operating components further simplify minimal maintenance requirements. The Modulex EXT comes standard with a powder coated enclosure allowing for outdoor installations. In addition to controlling the boiler according to a constant set point, indoor/outdoor reset or 0-10V signal, one or more units can be integrated via Modbus communications protocol to a facility wide Energy Management or Building Automation System.In addition to minimizing redundant capacity needed for any project, these quiet and lightweight boilers can support low NOX and low gas pressure applications as well as a variety of venting materials. The unit offers multiple supply/return piping and venting locations for installation flexibility and allows for multiple units to be easily co-located for greater than 3 million BTU/hr applications.

Options and Accessories

AERCO Condensate Neutralizer Kit
Ideal for neutralizing condensate from condensing boilers and furnaces operating on natural gas or propane.

Communications Gateway
Optional accessory supports boiler or BMS integration with BACnet, LonWorks and N2 systems.

Constant Speed Pumps
These kits include a circuit setter which allows for setting flow rates that meet the minimum allowable boiler flow rate and do not exceed the maximum. Pump Kits 99127-1 to 99127-7 are in-line and permanently lubricated for ease of maintenance with a cast iron body and electrical requirement of 115V/1ph/60Hz. Pump Kits 99208-3 to 99208-7 incorporate back-pull-out design which allows service without disturbing the piping; cast iron body and electrical requirement of 115V/208-230V/1ph/60Hz.

Hydraulic Separator
These hydraulic separators establish primary-secondary piping for AM Series boiler applications. Primary-secondary piping de-couples the boiler loop from the system loop — making it independent from system loop pressure fluctuations associated with opening/closing of zone valves or 3-way valves.

Sentinel Products
Compatible with all materials found in a hydronic loop, these chemicals offer overall protection of a heating system from sludge, scale, corrosion, and freeze conditions.

Variable Speed Pumps
These kits include an Interface Module that accepts 0-10VDC control input for remote adjustment of differential pressure setpoint or pump speed. The pumps are in line, flanged wet rotor circulator for ease of maintenance with a cast iron body and electrical requirement of 230V/1ph/60Hz.

Technical Documents

Installation and Piping Drawings

Condensate Piping (SD-A-694)

pdf 33.05 KB | December 14, 2015

Condensate Piping (SD-A-694)

dwg 151.31 KB | December 14, 2015

MLX EXT 321-1123 Multi Unit Installation (SD-A-970)

pdf 169.84 KB | December 14, 2015

MLX EXT 321-1123 Multi Unit Installation (SD-A-970)

dwg 3.12 MB | December 14, 2015

MLX EXT 321-1123 Multi Unit with Hydraulic Separator Installation (SD-A-974)

pdf 177.6 KB | December 14, 2015

MLX EXT 321-1123 Multi Unit with Hydraulic Separator Installation (SD-A-974)

dwg 3.26 MB | December 14, 2015

MLX EXT 321-1123 Multi-Unit Installation Clearances (SD-A-968)

pdf 120.02 KB | December 14, 2015

MLX EXT 321-1123 Multi-Unit Installation Clearances (SD-A-968)

dwg 1.76 MB | December 14, 2015

MLX EXT 321-1123 Single Unit with Hydraulic Separator Installation (SD-A-973)

pdf 126.09 KB | December 14, 2015

MLX EXT 321-1123 Single Unit with Hydraulic Separator Installation (SD-A-973)

dwg 1.04 MB | December 14, 2015

MLX EXT 321-1123 Installation Clearances (SD-A-967)

pdf 61.15 KB | December 14, 2015

MLX EXT 321-1123 Installation Clearances (SD-A-967)

dwg 463.19 KB | December 14, 2015

MLX EXT 321-1123 Multi Unit Clearance (SD-A-977)

pdf 144.71 KB | December 14, 2015

MLX EXT 321-1123 Multi Unit Clearance (SD-A-977)

dwg 797.7 KB | July 14, 2016

MLX EXT 321-1123 Multi Unit with DWH Installation (SD-A-971)

pdf 182.99 KB | December 14, 2015

MLX EXT 321-1123 Multi Unit with DWH Installation (SD-A-971)

dwg 1.86 MB | July 14, 2016

MLX EXT 321-1123 Multi Unit with Hydraulic Separator and DWH Installation (SD-A-975)

pdf 196.68 KB | December 14, 2015

MLX EXT 321-1123 Multi Unit with Hydraulic Separator and DWH Installation (SD-A-975)

dwg 2.08 MB | July 14, 2016

MLX EXT 321-1123 Single Unit Installation (SD-A-969)

pdf 112.21 KB | December 14, 2015

MLX EXT 321-1123 Single Unit Installation (SD-A-969)

dwg 3.12 MB | December 14, 2015

MLX EXT 321-1123 Single Unit with DWH Installation (SD-A-972)

pdf 130.74 KB | December 14, 2015

MLX EXT 321-1123 Single Unit with DWH Installation (SD-A-972)

dwg 2.16 MB | July 14, 2016

MLX EXT 321-1123 Single Unit with Hydraulic Separator and DWH Installation (SD-A-976)

dwg 1.25 MB | July 14, 2016

MLX EXT 321-1123 Single Unit with Hydraulic Separator and DWH Installation (SD-A-976)

pdf 145.42 KB | July 14, 2016

Modulex EXT 1530-3060 Mult-Unit Installation (SD-A-985)

pdf 176.07 KB | December 14, 2015

Modulex EXT 1530-3060 Mult-Unit Installation (SD-A-985)

dwg 1.25 MB | December 14, 2015

Modulex EXT 1530-3060 Multi Unit With DHW Installation (SD-A-986)

pdf 173.48 KB | December 14, 2015

Modulex EXT 1530-3060 Multi Unit With DHW Installation (SD-A-986)

dwg 1.46 MB | July 14, 2016

Modulex EXT 1530-3060 Multi Unit With Hydraulic Separator (SD-A-987)

pdf 168.71 KB | December 14, 2015

Modulex EXT 1530-3060 Multi Unit With Hydraulic Separator (SD-A-987)

dwg 1.24 MB | December 14, 2015

Modulex EXT 1530-3060 Multi Unit with Hydraulic Separator and DWH Installation (SD-A-988)

dwg 1.5 MB | July 14, 2016

Modulex EXT 1530-3060 Multi Unit with Hydraulic Separator and DWH Installation (SD-A-988)

pdf 197.13 KB | July 14, 2016

Modulex EXT 1530-3060 Non-Sealed Install Clearances (SD-A-983)

pdf 76.35 KB | December 14, 2015

Modulex EXT 1530-3060 Non-Sealed Install Clearances (SD-A-983)

dwg 697.18 KB | December 14, 2015

Modulex EXT 1530-3060 Sealed Install Clearances (SD-A-984)

pdf 98.01 KB | December 14, 2015

Modulex EXT 1530-3060 Sealed Install Clearances (SD-A-984)

dwg 396.35 KB | December 14, 2015

Modulex EXT 1530-3060 Single Unit Installation (SD-A-978)

pdf 139.37 KB | December 14, 2015

Modulex EXT 1530-3060 Single Unit Installation (SD-A-978)

dwg 789.02 KB | December 14, 2015

Modulex EXT 1530-3060 Single Unit Installation Clearance (SD-A-982)

pdf 54.39 KB | December 14, 2015

Modulex EXT 1530-3060 Single Unit Installation Clearance (SD-A-982)

dwg 350.3 KB | December 14, 2015

Modulex EXT 1530-3060 Single Unit With DHW Installation (SD-A-979)

pdf 149.21 KB | July 14, 2016

Modulex EXT 1530-3060 Single Unit With DHW Installation (SD-A-979)

dwg 1.07 MB | July 14, 2016

Modulex EXT 1530-3060 Single Unit With Hydraulic Separator (SD-A-980)

pdf 139.63 KB | December 14, 2015

Modulex EXT 1530-3060 Single Unit With Hydraulic Separator (SD-A-980)

dwg 873.83 KB | December 14, 2015

Modulex EXT 1530-3060 Single Unit with Hydraulic Separator and DWH Installation (SD-A-981)

dwg 1.1 MB | July 14, 2016

Modulex EXT 1530-3060 Single Unit with Hydraulic Separator and DWH Installation (SD-A-981)

pdf 161.05 KB | July 14, 2016

Literature and Performance Data

Efficiency Curves (MLX EXT 1530-3060)

pdf 76.58 KB | December 14, 2015

Efficiency Curves (MLX EXT 321-1123)

pdf 176.29 KB | December 14, 2015

Modulex EXT 1530-3060 Tech Data Sheet

pdf 407.36 KB | January 24, 2017

Modulex EXT 321-1123 Technical Data Sheet

pdf 466.89 KB | January 24, 2017

Modulex Maintenance Kit Sell Sheet

pdf 149.04 KB | December 17, 2015

Natural Gas Altitude De-Rate Factor

pdf 56.88 KB | December 14, 2015

Water Quality in Hydronic Systems

pdf 194.03 KB | December 14, 2015

Operation and Maintenance Manuals (O&M)

E8 Controller (and BCM) For Modulex EXT Boilers (GF-136-C)

pdf 5.94 MB | December 14, 2015

Modulex EXT 1530- 3060 User Manual (GF-139) (OMM-0095)

pdf 12.66 MB | December 30, 2016

Modulex EXT 321-1123 User Manual (GF-143) (OMM-0087)

pdf 15.51 MB | December 30, 2016

Product and Component Drawings

MLX EXT 1530-3060 Dimensional Drawing (AP-A-935)

pdf 161.66 KB | August 8, 2016

MLX EXT 1530-3060 Dimensional Drawing (AP-A-935)

dwg 1.28 MB | August 8, 2016

MLX EXT 1530-3060 Revit Drawings

rfa 756 KB | September 27, 2016

MLX EXT 321-1123 Dimensional Drawing (AP-A-927)

pdf 159.14 KB | December 14, 2015

MLX EXT 321-1123 Dimensional Drawing (AP-A-927)

dwg 1.25 MB | December 14, 2015

MLX EXT 321-1123 Revit Drawings

rfa 796 KB | September 27, 2016

Sizing and Application Guidelines

FAQ: Code Classifications for Modulex EXT

pdf 49.87 KB | December 14, 2015

Gas Supply Application Guide (GF-136-G)

pdf 406.54 KB | December 14, 2015

MLX EXT Electrical Power Application Guide (GF-136-E)

pdf 309.63 KB | December 14, 2015

Modulex EXT Venting Application Guide (GF-136-V) (TAG-0054)

pdf 1.62 MB | January 26, 2017

Piping Application Guide (GF-136-P)

pdf 7.28 MB | December 14, 2015

Primary Loop Design Guidelines/Pump Selection Chart MLX EXT (C400.2)

pdf 350.4 KB | December 14, 2015

Specifications

Startup, Installation and Maintenance Forms

MLX EXT Maintenance Form

pdf 158.72 KB | December 17, 2015

MLX EXT Startup Form

pdf 120.54 KB | December 17, 2015

MLX Installation Form

pdf 253.93 KB | December 17, 2015

Warranty

Modulex Extended Warranty

pdf 45.68 KB | December 17, 2015

Wiring

0-10 VDC Remote Setpoint (SD-A-698)

pdf 92.87 KB | December 14, 2015

0-10 VDC Remote Setpoint (SD-A-698)

dwg 142.52 KB | December 14, 2015

BCM Wiring Diagram - BAS to BCM (SD-A-727)

pdf 37.57 KB | December 14, 2015

BCM Wiring Diagram - BAS to BCM (SD-A-727)

dwg 97.3 KB | December 14, 2015

Domestic Water Heating (SD-A-699)

pdf 98.69 KB | December 14, 2015

Domestic Water Heating (SD-A-699)

dwg 142.86 KB | December 14, 2015

Outdoor Reset (SD-A-697)

pdf 100.2 KB | December 14, 2015

Outdoor Reset (SD-A-697)

dwg 143.66 KB | December 14, 2015

Wiring Diagram (72103)

pdf 476.78 KB | December 14, 2015

Case Studies

Pages