Modulex EXT

A breakthrough in high-efficiency design, AERCO’s condensing and fully modulating Modulex boilers support 481 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
  • 10.5:1 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 450

46,000

481,500

422,000-457,000

87% to 99%

MLX EXT 600

46,000

642,000

564,000-609,000

87% to 99%

MLX EXT 800

46,000

802,500

707,000-762,000

87% to 99%

MLX EXT 1100

46,000

1,123,500

993,000-1,067,000 

87% to 99%

MLX EXT 1500

83,000

1,530,000

1,448,000-1,518,403

87% to 99%

MLX EXT 2300

83,000

2,295,000

2,171,913-2,286,476

87% to 99%

MLX EXT 2600

83,000

2,677,000

2,533,925-2,672,390

87% to 99%

MLX EXT 3000  

83,000

3,060,000

2,897,080-3,071,951 

87% to 99%

*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 450-1100 Multi Unit Installation (SD-A-970)

dwg 1.15 MB | April 12, 2017

MLX EXT 450-1100 Multi Unit Installation (SD-A-970)

pdf 172.55 KB | April 12, 2017

MLX EXT 450-1100 Multi Unit with Hydraulic Separator Installation (SD-A-974)

dwg 1.25 MB | April 12, 2017

MLX EXT 450-1100 Multi Unit with Hydraulic Separator Installation (SD-A-974)

pdf 180.76 KB | April 12, 2017

MLX EXT 450-1100 Multi-Unit Installation Clearances (SD-A-968)

dwg 1.28 MB | April 12, 2017

MLX EXT 450-1100 Multi-Unit Installation Clearances (SD-A-968)

pdf 116.79 KB | April 12, 2017

MLX EXT 450-1100 Installation Clearances (SD-A-967)

dwg 456.5 KB | April 12, 2017

MLX EXT 450-1100 Installation Clearances (SD-A-967)

pdf 59.97 KB | April 12, 2017

MLX EXT 450-1100 Multi Unit Clearance (SD-A-977)

dwg 502.63 KB | April 12, 2017

MLX EXT 450-1100 Multi Unit Clearance (SD-A-977)

pdf 77.67 KB | April 12, 2017

MLX EXT 450-1100 Multi Unit with DWH Installation (SD-A-971)

dwg 1.25 MB | April 12, 2017

MLX EXT 450-1100 Multi Unit with DWH Installation (SD-A-971)

pdf 190.44 KB | April 12, 2017

MLX EXT 450-1100 Multi Unit with Hydraulic Separator and DWH Installation (SD-A-975)

dwg 1.42 MB | April 12, 2017

MLX EXT 450-1100 Multi Unit with Hydraulic Separator and DWH Installation (SD-A-975)

pdf 200.75 KB | April 12, 2017

Modulex EXT 1500-3000 Mult-Unit Installation (SD-A-985)

dwg 912.45 KB | April 12, 2017

Modulex EXT 1500-3000 Mult-Unit Installation (SD-A-985)

pdf 163.88 KB | April 12, 2017

Modulex EXT 1500-3000 Multi Unit With DHW Installation (SD-A-986)

dwg 1.01 MB | April 12, 2017

Modulex EXT 1500-3000 Multi Unit With DHW Installation (SD-A-986)

pdf 178.98 KB | April 12, 2017

Modulex EXT 1500-3000 Multi Unit With Hydraulic Separator (SD-A-987)

dwg 869.5 KB | April 12, 2017

Modulex EXT 1500-3000 Multi Unit With Hydraulic Separator (SD-A-987)

pdf 124.19 KB | April 12, 2017

Modulex EXT 1500-3000 Multi Unit with Hydraulic Separator and DWH Installation (SD-A-988)

dwg 1.01 MB | April 12, 2017

Modulex EXT 1500-3000 Multi Unit with Hydraulic Separator and DWH Installation (SD-A-988)

pdf 140.91 KB | April 12, 2017

Modulex EXT 1500-3000 Non-Sealed Install Clearances (SD-A-983)

dwg 437.69 KB | April 12, 2017

Modulex EXT 1500-3000 Non-Sealed Install Clearances (SD-A-983)

pdf 82.97 KB | April 12, 2017

Modulex EXT 1500-3000 Sealed Install Clearances (SD-A-984)

dwg 270.75 KB | April 12, 2017

Modulex EXT 1500-3000 Sealed Install Clearances (SD-A-984)

pdf 103.97 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit Installation (SD-A-978)

dwg 564.28 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit Installation (SD-A-978)

pdf 129.82 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit Installation Clearance (SD-A-982)

dwg 233.63 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit Installation Clearance (SD-A-982)

pdf 61.23 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit With DHW Installation (SD-A-979)

dwg 758.83 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit With DHW Installation (SD-A-979)

pdf 146.94 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit With Hydraulic Separator (SD-A-980)

dwg 608.01 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit With Hydraulic Separator (SD-A-980)

pdf 133.61 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit with Hydraulic Separator and DWH Installation (SD-A-981)

dwg 770.41 KB | April 12, 2017

Modulex EXT 1500-3000 Single Unit with Hydraulic Separator and DWH Installation (SD-A-981)

pdf 157.05 KB | April 12, 2017

Modulex EXT 450-1100 Single Unit Installation (SD-A-969)

dwg 643.12 KB | April 12, 2017

Modulex EXT 450-1100 Single Unit Installation (SD-A-969)

pdf 116.04 KB | April 12, 2017

Modulex EXT 450-1100 Single Unit with DWH Installation (SD-A-972)

dwg 1.43 MB | April 12, 2017

Modulex EXT 450-1100 Single Unit with DWH Installation (SD-A-972)

pdf 204.34 KB | April 12, 2017

Modulex EXT 450-1100 Single Unit with Hydraulic Separator and DWH Installation (SD-A-976)

dwg 905.28 KB | April 12, 2017

Modulex EXT 450-1100 Single Unit with Hydraulic Separator and DWH Installation (SD-A-976)

pdf 149.68 KB | April 12, 2017

Modulex EXT 450-1100 Single Unit with Hydraulic Separator Installation (SD-A-973)

dwg 748.08 KB | April 12, 2017

Modulex EXT 450-1100 Single Unit with Hydraulic Separator Installation (SD-A-973)

pdf 130.33 KB | April 12, 2017

Literature and Performance Data

AERCO Modulex Brochure

pdf 8.21 MB | April 12, 2017

AERCO Modulex EXT 1500-3000 Technical Data Sheet

pdf 405.71 KB | April 12, 2017

AERCO Modulex EXT 450-1100 Technical Data Sheet

pdf 460.67 KB | April 12, 2017

Efficiency Curves (MLX EXT 1500-3000)

pdf 76.98 KB | April 12, 2017

Efficiency Curves (MLX EXT 450-1100)

pdf 87.96 KB | April 12, 2017

Modulex Maintenance Kit Sell Sheet

pdf 358.37 KB | April 13, 2017

Modulex Natural Gas Altitude De-Rate Factor

pdf 27.1 KB | April 13, 2017

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) (OMM-0093)

pdf 4.43 MB | August 14, 2017

Modulex EXT 1500- 3000 User Manual (GF-139) (OMM-0095)

pdf 9.3 MB | April 13, 2017

Modulex EXT 450-1100 User Manual (GF-143) (OMM-0087)

pdf 12.47 MB | April 13, 2017

Product and Component Drawings

MLX EXT 1500-3000 Dimensional Drawing (AP-A-935)

dwg 742.2 KB | April 13, 2017

MLX EXT 1500-3000 Dimensional Drawing (AP-A-935)

pdf 129.85 KB | April 13, 2017

MLX EXT 1500-3000 Revit Drawings

rfa 756 KB | September 27, 2016

MLX EXT 450-1100 Dimensional Drawing (AP-A-927)

dwg 1.24 MB | April 13, 2017

MLX EXT 450-1100 Dimensional Drawing (AP-A-927)

pdf 162.04 KB | April 13, 2017

MLX EXT 450-1100 Revit Drawings

rfa 796 KB | September 27, 2016

Sizing and Application Guidelines

FAQ: Code Classifications for Modulex EXT (TAG-0057)

pdf 258.45 KB | April 13, 2017

Gas Supply Application Guide (GF-136-G) (TAG-0052)

pdf 520.32 KB | April 13, 2017

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

pdf 432.3 KB | April 13, 2017

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

pdf 1.31 MB | April 13, 2017

Piping Application Guide (GF-136-P)

pdf 2.88 MB | April 13, 2017

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

pdf 154.94 KB | April 13, 2017

Specifications

Startup, Installation and Maintenance Forms

MLX EXT Maintenance Form

pdf 69.49 KB | April 13, 2017

MLX EXT Startup Form

pdf 57.94 KB | April 13, 2017

MLX Installation Form

pdf 89.63 KB | April 13, 2017

Warranty

AERCO Modulex Extended Warranty

pdf 52.19 KB | July 13, 2017

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