Modulex Boilers
OVERVIEW

Modulex Boilers

A breakthrough in high-efficiency design, this line of condensing and fully modulating boilers supports 300,000 to 1 million Btu/hr. hydronic heating systems while delivering a greater degree or operating reliability for customer peace-of-mind.
 
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Note: AERCO Modulex Boilers are only available in North America.

  • Condensing Boiler
  • Unmatched Turndown Up to 23:1 for MLX-1060
  • Whisper Quiet Operation Less than 50 dBa
  • Low NOx Emission <14ppm
  • Direct or Conventional Vent With PVC, CPVC or AL29-4C
  • Small, Doorway-Size Footprint From 42”H x 28”W x 27”D Up to 42”H x 49”W x 27”D
  • Flexible Piping & Venting
  • Optional Sealed Combustion
  • Superior Reliability


Cutaway view of two cast aluminum heat exchangers in a five module MLX-757.
Cutaway view of two cast aluminum heat exchangers

Each thermal module has a burner viewport, igniter, flame detector and safety components.
Each thermal module has a burner viewport, ignitor, flame detector and safety components.
Unique AERCO Controls
AERCO’s unique controls approach employs load sharing to maximize operating efficiency. After all thermal modules in a boiler come online, with each operating at its lowest firing rate (45,500 BTU/hr.), they continue to share the increasing load equally. All modules smoothly increase or decrease output in 1% increments to meet load changes.

Firing rates
A breakthrough in high-efficiency design, this line of condensing and fully modulating boilers supports 300,000 to 1 million Btu/hr. hydronic heating systems while delivering a greater degree or operating reliability for customer peace-of-mind.

To achieve the greatest possible fuel savings, each boiler combines independent, 151,500 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. Six units are available:

  Min. Input
BTU/hr.
Max. Input
BTU/hr.
Max Output*
BTU/hr.
MLX - 303 45,500 303,000 260,000-279,000
MLX - 454 45,500 454,000 390,000-418,000
MLX - 606 45,500 606,000 521,000-558,000
MLX - 757 45,500 757,000 651,000-696,000
MLX - 909 45,500 909,000 781,000-835,000
MLX-1060 45,500 1,060,000 912,000-975,000
* Depending on Return Water Temperature


In addition to minimizing the redundant capacity needed for any project, these quiet and lightweight boilers can support low NOX and low gas pressure applications as well as PVC venting materials. Each unit enclosure offers multiple supply/return piping and venting locations for installation flexibility and allows for multiple units to be easily co-located for greater than 1 million Btu/hr. applications. Combustion view ports and easy access to all operating components further simplify minimal maintenance requirements.
Unmatched Operating Efficiency
Operating efficiency is influenced by the firing rate and return water temperature delivered to each Modulex boiler. The following chart outlines efficiency at 100% fire under BTS-2000 test conditions.

  Thermal
Modules
Total
Turndown
Full-Fire
Efficiency
MLX - 303 2 6:1 92%
MLX - 454 3 10:1 92%
MLX - 606 4 13:1 92%
MLX - 757 5 16:1 92%
MLX - 909 6 20:1 92%
MLX-1060 7 23:1 92%
Revolutionary Design
Depending on unit size, each AERCO Modulex boiler contains between two and seven, pre-assembled thermal modules housed within a common enclosure. Each standalone, 151,500 BTU/hr. thermal module features:
  • a controller with built-in combustion safeguard;
  • a variable speed fan;
  • a modulating gas valve;
  • an electronic iginition with flame detector;
  • radiating, pre-mix, >3:1 modulating burner;
  • flow temperature sensor;
  • overtemperature limiting thermostat;
  • cast aluminum heat exchanger.
The operation of each 151,500 BTU/hr. thermal module is regulated by its own dedicated controller located internally along the front panel of the unit. Equipped with a combustion safeguard, each of these controllers drives the fan speed, gas delivery, burner turndown, etc. for its corresponding thermal module. All the individual thermal controllers are linked in a slave-to-master relationship with the boiler’s master controller. It is the master controller which drives or bypasses one or more thermal modules based on the total system load and in response to operating feedback received from each thermal module controller.

Enhanced Efficiency & Reliabilty
The independent operation of two or more thermal modules increases each boiler's turndown range while also increasing its overall reliability. And since thermal efficiency increases as firing rates drop, the simultaneous low-fire operation of multiple modules also ensures that Modulex boilers continuously maximize operating efficiency.

For example, the MLX-1060 combines the power of seven thermal modules — each operating with greater than 3:1 turndown to deliver a 23:1 range of operations. From the low fire input of a single module (45,500 BTU/hr.) to the unit’s full fire capacity (1,060,000 BTU/hr.), the boiler precisely matches load without cycling or temperature overshoot. Importantly, it does so by always employing as many modules as possible – each firing at its lowest possible firing rate. Less energy is required for the group of thermal modules, each firing at part load, to heat a building than if only some modules, each operating at full fire, carried the entire load. Consequently, this controls approach results in greater fuel savings than if each thermal module reached its full 151,500 BTU/hr. capacity before the next module came on line.

In the event that one module is not working correctly, the remaining modules – hence the boiler unit – will continue to operate. Independently operating thermal modules deliver built-in redundancy to the boiler through the availability of multiple combustion safeguards, burners, gas valves, blowers, etc. Such a design approach is unique in the industry and can significantly reduce the need for redundant system capacity.
Accessories
Modulex Pump Kits: Specifically selected for hydronic heating, these pumps are ideal for the boiler loop pump of Modulex installations.

Hydraulic Separator: These hydraulic separators establish primary-secondary piping for Modulex 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.

Sentinal Products - Compatible with all materials found in a heating system, these chemicals offer overall protection of a heating system from sludge, scale, corrosion, and freeze conditions.
 
AERCO Condensate Neutralizer Kit- is ideal for neutralizing condensate from condensing boilers and furnaces operating on natural gas or propane.


Literature & Performance Data
File Type View Save File Type View Save
Pressure Drop Curves .pdf
Altitude De-Rating Factor .pdf
Modulex Family Brochure .pdf
Modulex Technical Data Sheet .pdf
Modulex Efficiency Curves .doc
Sizing & Application Guidelines
File Type View Save File Type View Save
Primary Loop Design Data .pdf
Glycol Directive C401.0 .doc
Gas Supply Design Guide (GF-115-G) .pdf
Electrical Power Guide (GF-115-E) .pdf
Piping Guide (GF-115-PH) .pdf
Venting Guide (GF-115-V) .pdf
Controls Guide (GF-115-C) .pdf
Product & Component Drawings
File Type View Save File Type View Save
CSD-1 Manifold Assembly .pdf .dwg
Bill of Materials / Parts List (PL-A-153) .pdf .dwg
Dimensional Drawings            
MLX-303H & MLX-454H .pdf .dwg
3D Models            
Modulex Revit Drawings .rfa
Installation & Piping Drawings
File Type View Save File Type View Save
Anchor Bolt Location .pdf .dwg
Clearance Drawing - Standalone .pdf .dwg
Clearance Drawing - Zero Side .pdf .dwg
Single Unit Installation .pdf .dwg
Single Unit Installation with DHW .pdf .dwg
Multi-Unit Installation - 2 Unit Side by Side .pdf .dwg
Multi-Unit Installation with DHW .pdf .dwg
Condensate Piping (SD-A-694) .pdf .dwg
Modulex Snowmelt System Installation with Injection Pump .pdf .dwg
Modulex Snowmelt System Installation with 4-Way Valve .pdf .dwg
Single Unit Installation with Hydraulic Separator .pdf .dwg
Multi-Unit Installation with Hydraulic Separator .pdf .dwg
Multi-Unit Installation with Hydraulic Separator & DHW .pdf .dwg
Single Unit Installation with Hydraulic Separator & DHW .pdf .dwg
Controls
File Type View Save File Type View Save
Controls Guide (GF-115-C) .pdf
Wiring
File Type View Save File Type View Save
Internal Wiring            
Internal Wiring Diagram .pdf
Field Wiring            
BCM Wiring Diagram - BAS to BCM (SD-A-727) .pdf .dwg
Outdoor Reset (SD-A-697) .pdf .dwg
0-10 VDC Remote Setpoint (SD-A-698) .pdf .dwg
Domestic Water Heating (SD-A-699) .pdf .dwg
Specifications
File Type View Save File Type View Save
MLX-303H .doc
MLX-454H .doc
MLX-606H .doc
MLX-757H .doc
MLX-909H .doc
MLX-1060H .doc
Certifications/Approvals
File Type View Save File Type View Save
CSA Approval Letter .pdf
SCAQMD Letter .pdf
TCEQ Letter .pdf
FAQ: Code Classifications for Modulex .pdf
Warranty
File Type View Save File Type View Save
Modulex Boiler Warranty .pdf

Operation & Maintenance
File Type View Save File Type View Save
Modulex High Pressure Manual (GF-115H) .pdf
Modulex General Manual (GF-115) .pdf
Controls            
E8 Controls Guide (GF-115-C) .pdf
Instructions
File Type View Save File Type View Save
Modulex Users Guide (MUIM) .pdf
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