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Condensing Gas Water Heaters Indoor and Outdoor Domestic Hot Water Control Modulex EXT 95-864kw Tech Data Manual

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Page 1: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

Condensing Gas Water Heaters

Indoor and Outdoor

Domestic Hot Water Control

Modulex EXT95-864kw

Tech Data Manual

Page 2: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

A Flexible "machine"Modulex EXT

Low Emissionsfully modulatingvery high seasonal efficiencyguarantee of operationcompactnessquiet operationcan be directly used in outdoor installationmaximum accessibility to the components

The DNA of MODULEX EXT.

MODULEX EXT resolves any installation problem,

both, hydraulic and electronic.

MODULEX EXT boasts, the best ratio

.

Wide range formed by ten gas condensing models, with

outputs from 150 to 900 kW.

Very high modulation ratio, up to 1:40, in order to

supply the “correct power”.

Just one

• Pre-assembled thermal elements in

• Patented, electronic management system, to instantly

give the at any modulated

capacity: up to at the least modulated capacity.

Integration of the electronic controller within the

ideal for difficult installations.

thanks to the reduced weight, it allows easy

maneuverability within the boiler house; it can also be

supplied in loose parts and reassembled in the boiler

house.

even at it's maximum capacity, thanks to its

combustion characteristics and to the sophisticated

technology of the new fans, gas valves and multi-gas

burners

between:

output/overall dimensions and weight

always

technological boiler block:

aluminium,

silicon and magnesium casting

maximum efficiency

109%

disappearing panel board.

Compact

Light,

Silent:

Automatic Heating reserves the right to change specifications without notice.

Output(condensing

mode)(kW)

12 ÷ 150

12 ÷ 200

12 ÷ 250

12 ÷ 300

12 ÷ 350

22 ÷ 432

22 ÷ 540

22 ÷ 648

22 ÷ 756

22 ÷ 864

ModelEXT

MX150

MX200

MX250

MX300

MX350

MX

MX

MX

MX

MX

EXT

EXT

EXT

EXT

EXT

440EXT

550EXT

660EXT

770EXT

900EXT

ThermalmodulesN. OFF

3

4

5

6

7

4

5

6

7

8

Modulationratio

1:12

1:16

1:20

1:24

1:28

1:19,6

1:25

1:29

1:34

1:39

Productionof

condensate(kg/h)

23

30,6

38,3

45,9

53,6

73,4

91,7

110

128,4

146,7

Dimensions

(L x P x H)

764 x 770 x 1150

1032 x 770 x 1150

1032 x 770 x 1150

1300 x 770 x 1150

1300 x 770 x 1150

1087 x 946 x 1448

1355 x 946 x 1448

1355 x 946 x 1448

1623 x 946 x 1448

1623 x 946 x 1448

A “Heating Motor” that goes beyondthe simple concept of boiler.

Condensing Water Heaters > Modulex EXT Water Heaters

MODULEX EXT Tech Data Manual2

Page 3: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

MODULEX EXT Tech Data Manual 3

8 Points of Difference

Patented design technology

Gfirst generator with modular sections complete

with premix modulating burners

castings thermal elements in lightof the

alloy

cooling water ways in serpentine shape

original fin to increase its exchange surface

standardized flow and return manifolds without

interceptions between every section and hydraulically

balanced

burners, complete with safety devices

non return smoke valve

command and control electronic system with

of one/all the thermal elementsproportional regulation

MODULEX EXT, "OVER TEN YEARS OF PERFECTING,

THROUGH TECHNOLOGICAL ADVANCES HAS

RESULTED IN UNRIVALED SUCCESS"

Page 4: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

Condensing Water Heaters > Modulex EXT Water Heaters

The DetailsModulex EXT

Maximum saving and seasonal efficiency

Total safety

Flexibility of installation

Low environmental impact

Exclusive electronic technology

Wide range of dedicated accessories:

High efficiency thanks to:

• certified efficiency up to 109% at the minimum

modulated capacity

• seasonal efficiency: + 30% if compared with the

conventional boilers

• large modulation ratio: UP TO 1:40

• modulating pump directly managed by the boiler

to assure the maximum condensation at all times

• high reliability due to MULTI BURNER composition

and to the low number of parts in movement

• working and safety temperature sensors on every

casting section

• premixing within the fan with non return built-in valve

• auxiliary electronic circuits

• emergency operation in case the E8 controller is out

of service

• outdoor installation: protection degree IP55

• compact, light, of easy connection:

- reversible hydraulic and gas connections

(up to model 350 kW)

- smoke discharge: possible on 3 sides

(for all the models)

• low polluting emissions : <31 ppm Low NOx

(according to EN 15420)

• low acoustic impact <49 dBA

• low chimney flue losses

• premix burners providing constant C02 ratio

• electronic management and thermal regulation

completely automatic and pre-programmed (patented)

• possible cascade installation up to 8 boilers

• predisposition for telemanagement and telecontrol

- Primary ring with additional safety devices kit

- Plate heat exchanger with additional kit

- Acidic condensate neutralizers

- Regulation of additional zones

safety devices

MODULEX EXT Tech Data Manual4

Thanks to itsparticular structure,

synonymous with reliability ofit's time, the MODULEX EXT

boiler body is covered by a5 year guarantee.

Page 5: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

MODULEX EXT Tech Data Manual 5

Pre-assembledThermal Elements

MODULEX EXT is an assembly of thermal modules, together making a complete unit.

Every unit is constituted by pre-assembled thermal elements, in

Every element supplies, in continuous and progressive way, from 12 to 50 kW for the models

up to 350 kW, and from 22 up to 108 kW for larger models.

Al/Si/Mg.

More than 10 years experience assure:

resistance to the corrosion of the acidic condensate

very high thermal efficiency

Key:

1 -

2 -

3 -

4 -

5 -

6 -

7 -

8 -

9 -

10 -

11 -

12 -

13 -

14 -

15 -

16 -

17 -

18 -

19 -

20 -

Gas valve

Burner cover

Gas pipe

Ignition electrode

Ionization probe

Local NTC temperature sensor

Limit thermostat

Aluminium alloy heat exchanger

Condensate level sensor

Condensate & smoke

tray– chimney connection

Frame

Fan

Burner

Automatic air vent

Global NTC flow temperature

sensor

Central Heating flow

Global NTC return temperature

sensor

Central Heating return

Drain tap

Condensate evacuation

The basic element is formed by two aluminium alloy

castings that, on the smoke side, have dense fins,

with increasing height toward the smoke discharge,

placed in lower part of the casting, in order to increase

its exchange surface.

Inside the castings there are the water channels that,

always with more reduced section, zigzag cross the

casting, granting an exceptional heat transfer from

combustion gases to the water.

Every thermal element is equipped with:

The smoke and acidic condensate of the thermal elements

are collected in a stainless steel tray.

• premix modulating burner

• two stage modulating gas valve

• electronic ignition and ionization

• NTC working temperature sensor

• safety thermostats

• flame sight glass.

Page 6: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

Condensing Water Heaters > Modulex EXT Water Heaters

Radiation Combustion

Main protagonist for a perfect combustion and therefore the maximum

efficiency, is the modulating fan (1000-6000 rpm) of which every unit

is equipped.

The number of rpm of the fan, together with the opening of the valve gas

and the flame control, is directly programmed and controlled by the

electronics of every burner (BMM Burner Modular Module) and, in their

turn, they are managed by the E8 controller.

The output modulation depends on the speed of the fan and the difference

between the required temperature, and the maximum one.

Total Premix

The opening of the gas valve is produced by the

in the Cochlea of the fan and the air and gas mixture

happens inside before being introduced to the combustion

chamber (premix).

This perfect “mixing” combines the air and gas in parts

always in proportion through the multi-gas burner.

This system, characterized by the issue of electromagnetic

radiations, is most efficient for the transmission of thermal

energy.

The wide surface, on which the combustion happens,

guarantees:

long lasting burner structure

quiet operation

simple maintenance thanks to the use of few components

and easy accessibility

larger quantity of transmitted energy in comparison to a

traditional burner with the same flame temperature

absolute working safety for the absence of turbulences

very small production of pollutants due to the complete

oxidation of the gas molecules;

• excellent combustion efficiency: maximum CO2= 9,3%

• efficiency optimization thanks to the low

smoke temperature and the limited “air excess”

• very low pollutant emissions: NOX<53,8

mg/kWh (pondered value according to

• reduced turbulence

with the following advantages:

“Venturi

effect”

low combustion temperature

EN 15420).

The valve is directly mounted on the fan.

Inside its volute the air/gas mixing

calibration takes place.

NEW CONFIGURATION:

MODULEX EXT Tech Data Manual6

Page 7: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

MODULEX EXT Tech Data Manual 7

After the time “T1” from the starting, MODULEX EXT succeeds in satisfying the 30% of the load unlikea traditional boiler that, in the same time, is just at 15%.

After the time “T2” MODULEX EXT is at 50% of the load, while the traditional one is at 30%.After the time “T3” MODULEX EXT is at 100% of the load and the traditional one is only to 70%.

This clearly displays the speed of the Modulex EXT Boiler

Radiation Combustion

The MODULEX EXT exceeded all industry

requirements when it was first conceived over a

decade ago. These days the high standards and

benchmark qualities of this groundbreaking boiler are

a must in today's world.

This function enables you to drastically reduce the

number of switching ON and OFF of the boiler.

(Possible customization of the requested output).

• Higher efficiency and lower flue losses when burner

is OFF.

• Longer lasting of the parts in movement and of the

ignition systems.

On average a boiler operates at 50% of the thermal

need of the C.H. installation and can descend below

30%. MODULEX EXT adjusts in real time the output to

meet demand, because it is not influenced by the

thermal inertia, thanks to its low water content and,

being equipped with modulating pump, it further

reduces the electricity used.

This function promotes the production of condensate

and therefore the fast economic recovery of the

investment. All this in order to offer the user the

possibility to save with the maximum comfort both,

for C.H. and D.H.W. production, with a lower noise

level than the traditional boilers.

Setting option according to the thermal needs of

the C.H. system

Advantages:

Very low water content and high modulation

speed with maximum output ratio up to 1:40

Class A, variable speed, electronic pumps, for

the maximum condensate production

Page 8: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

Condensing Water Heaters > Modulex EXT Water Heaters

Concealed Panel Board

Modulation in cascadeThe applicable systems of communication: cascademanagement, leaving

eBUS, Mod-bus and canBUS allow the maximum elasticity in thefree choice to the consumer for the last interface of management.

E8 Thermo-controller BCM Boiler Cascade Manager

BCM

CASCADE MANAGED BY PLCCASCADE MANAGED BY E8 CASCADE MANAGED THROUGH BCM

BCM

BMM BMM BMM

BCM

BMM BMM BMM

Modbus

eBUS

eBUSBCM

BMM BMM BMM

BCM

BMM BMM BMMBMM BMM BMM

BCM

BMM BMM BMM

A perfect pneumatic system with gas dampers lifts the tamper proof

cover of MODULEX EXT.

Smart access to the panel board !

FEATURES:

E8

BCM

• external temperature sensor

• flow temperature sensor for mixed zone (zone 1)

• boiler temperature sensor

• D.H.W. storage tank temperature sensor

Thermo-controller

Boiler Cascade Manager

easy access to this controlling unit.

E8 is supplied complete with:

The E8 thermo-controller allows maximum

condensation and output modulation of the system

through complete program management.

MODULEX EXT Tech Data Manual8

Page 9: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

MODULEX EXT Tech Data Manual 9

A Clever Brain

E8, the thermo controllerCascade of 2 up to 8 MODULEX EXTWith simple connection.

KIT OF ZONE EXPANSION E8To control 2 direct/mixed zones and a D.H.W. storage tank up to a

maximum of 7 modules that can be connected with a two wire cable.

Remote management and remote control

Through dedicated sof

CO

tware and accessories, with electronic board

.CO.PC and GSM connection.

CommunicationWith the central automation systems (PLC).

For additional information, please contact our pre-sale department.

System optimization

0-10 volt signalthe great flexibility of the E8 alsopermits the MODULEX EXT set pointto be controlled by an external controlsignal. This will enable, having atdisposal an even more complexsystem, to exploit all the heatingcontrol’s functions..

Domestic hot water productionThere are many programmes which control thedomestic hot water production. You can choosefrom the maximum of comfort to the maximum fuelsaving. In order to permit the storage cylinder tosupply hot water rapidly, the heating controller bringsthe boiler’s temperature to the maximum set value.

Anti LegionellaEvery 20th heating start-up or once a weekon Saturday at 01:00 hrs, the storage tank isheated up to 60°C. This function will eliminateany eventual pathogens which have formedin the DHW.

DHW optimization (loading pump)The DHW loading pump is switched on only if the

boiler temperature exceeds the tank temperature

by 5°C. It is deactivated when the boiler temperature

drops below the storage tank temperature or if the

storage tank temperature is higher than the nominal

temperature.

DHW controlProgramme settingThe heating programmes can be setdaily or weekly, with more than oneOn-Off ring times or temperaturereductions during the day.

Multiple zone controlWith the same heating control deviceyou can control 2 independentcircuits with different characteristics,though having ensured allthe described functions, includingthe deep sliding temperaturefunction.

Management of up to 15mixed circuitscontrolled by the outdoor sensor

Setting

Integration withrenewable energy sourcesFor example: solar systemsand/or solid fuel fired boilers.

Energy sourcescontrol

Boiler heating OptimizationThe heating controllerthe timer/heating programme set by the useronce the system’s characteristics have beenevaluated, will activate the function forautomatically bringing forignition time so as to ensure that the settemperature is reached at the time requestedby the user

, on the basis of,

ward the heating

.

Fast set temperatureThis is obtained by calculating the optimumignition starbe carthe outdoor temperature or the roomtemperature.

t-up time. This calculation canried out taking into consideration

Overheating protectionThe boilervia the pump’s overrid of any ther

’s safety temperature is controlledrun time in order to get

mal inertia.

Self AdaptationThrough the elaboration of data transmittedby the room sensor, this function adjuststhe boiler’s output to the building’scharacteristics, ensuring a constantmonitoring of the indoor temperatureon the basis of the variation of the outdoortemperature, keeping in considerationthe building’s thermal inertia andthe contribution of “free” heat (solarradiation, internal heat sources etc).

Slope offset (heating slope distance)The boiler temperature that is requiredfor a mixed circuit is calculated by addingto the calculated temperature settingfor the heating circuit temperaturethe heating slope distance.The heating slope distance compensatesfor sensor tolerances and heat loss up tothe mixer.

Valve opening timeBased on the characteristics ofthe servomotor.

Number of burner ignitionsIt stabilizes the number of ignitionsof each burner.

Burner run hoursIt stabilizes the run hours of each burner.

Frost protection modeThe frost protection operation mode preventsthe CH system from freezing by automaticallyswitching heating operation on. In the frostprotection mode, the room temperaturefor all the heating circuits is set to 5°C andthe storage tank sensor frost protectionis activated when the temperature dropsbelow 10°C.

Swimming pool heating function

Page 10: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

Condensing Water Heaters > Modulex EXT Water Heaters

Boiler Cascade Manager BCM

BCM, powerful electronic module:

Managing the inside cascade of the boiler thermal elements

Supplying double certainty of operation (emergency operation

in case of breakdown to the thermo-controller E8, with activation

of the heat request at constant setpoint with maximum capacity

of 50%)

Managing the modulating pump of the primary rings (Analogical

outlet 0-10 V) with significant efficiency increase at part loads

Monitoring the state of working temperatures

Planning the parameters

Managing and resetting the alarms

Remoting alarm signals through relay.

Cascade Installations

With the cascade installation, the boiler output range can be

widened well over 900 kW, multiplying output and

modulation in order to satisfy any design demand. The space

saving (in particular it can be installed up to 40 cm from the

boiler house walls) features of the Modulex Boiler are tailored

specifically with service and easy access in mind.

Replacement of old obsolete boilers is also another benefit that a

small footprint allows.

Allowing the integration in the

boiler house automation systems,

realized with industrial PC / lonWorks

/ Modbus for Building Automation

Checking the heat demand: temperature setpoint and modulation level

MODULEX EXT Tech Data Manual10

Page 11: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

MODULEX EXT Tech Data Manual 11

Eco - Logic

MODULEX EXT has a certified efficiency

that, for all models above 350 kW, when

working in condensation, progressively

increase up to when the output

is reduced.

The genius of the thermo-controller E8

is that it keeps ON the

as possible, working at the

(as shown in

the examples beside).

The system will always work in the

conditions of maximum possible

efficiency, independently from the

supplied output.

When the requested output is less than

the capacity available the design of the

Modulex regulates evenly reducing the

output of each module to suit. Once the

minimum level for a module is reached

it is disabled in cascade sequence.

This modular system is such that as the

number of modules used decreases - the

efficiency increases. The flexibility of this

modular conception is ground breaking

and brings vast cost savings through

increased efficiency.

To avoid one element module being

over used more than others, the

thermo-controller automatically

alternates usage of all element

modules evenly.

109%

greatest number

of elements

smallest possible output

Output flexibilityand efficiency

Output sharing of MODULEX EXT of 4 modules of 50 kW

OFF OFF

Page 12: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

Condensing Water Heaters > Modulex EXT Water Heaters

The Right Solution....

The designers of heating systems have worked closely with

Modulex to give us this energy efficient unit which offers the following:

Comfort and low consumption

Small size installations (downsizing)

Control of the investment cost (cost of the life cycle)

Integration of the renewable sources

Instant response command function

Reduction of the maintenance costs

• Primary system for installation interface plant with mixing header

• Primary with plate heat exchanger

• Zone satellites system

Modulex EXT is fully integrable with various systems such as:

automated control benefits

system

The integrated design of the building-installations system:from the boiler to the integrated system

Floor Insulation Panels

Various system solutions available

allow maximum flexibility and

adaptability. Use of low temperature

heating fluid combined with heat

stratification results in significant

energy savings

MODULEX EXT Tech Data Manual12

Page 13: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

MODULEX EXT Tech Data Manual 13

Modulex EXT working within

a solar driven system supplies

up to 70% of your hot water !!

With the thermal solar panels

the whole heat of the sun

is captured: 20 years warranty

offered with accredited installer

PEXAL PIPING

The Pexal Pipe is perfect for

use with the Modulex EXT,

offering increased heat output

and reduced risk of oxygen

infiltration to the system

... for a Perfect Installation

" Please schedule an appointment with our team of experts

to find a solution that fits your needs - Today!! "

The range of storage tanks

with high efficiency coils

allow an elevated heat

exchange and optimize

the integration through

the thermal solar panels.

VERSATILITY

The brain of the Modulex EXT

is capable of splitting energy

to suit your particular

requirements. eg apartment

situations

THERMOMEX

Page 14: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

Condensing Water Heaters > Modulex EXT Water Heaters

Primary Rings withMixing Header

MODULEX EXT is a low water content boiler and therefore a

low thermal inertia boiler:

• high speed of output supply

• immediate answer to the load variations

• minimal heat losses.

The great variations of flow rate and temperature that follow

are, therefore, conveniently balanced by the so-called

hydraulic separator, before reaching these ultramodern

“heating engines”.

Modulex EXT introduces

Complete system, developed and tested in our laboratories

Rapidity of putting into service

Class A modulating pump

OGNITEMPO EXT, a special casing for coverage of the

primary rings in outdoor installations (class IPX5D).

Advantages:

the new range of 5 primaryrings with ultra-compact hydraulic separators.

Example of Primary Ring with mixing

header and adjustable height

The balance between supplied output

and the water flowrate is controlled via

the modulating pump. The BCM card

collates the data relating to flow return

and the low water level, and depending

on this it will either increase or decrease

the flowrate to suit the thermal jump

requirement.

The Modulex EXT will always operate

with the return temperature as low as

possible.

Class A modulating pump

Primary rings pre-assembledand with jacket

Modulex EXT Boilers

Ideal hydraulic balance

Crossing speed near to zero

1.

2.

3.

follow rigorous sizing criteria, in

terms of:

• (interference almost nothing

between primary and secondary ring)

• (minimal temperature

increase on the boiler return to safeguard the condensing

and the decanting effect)

To make independent the connected circuits

“Deslimer”, allowing the collection of the mud of the

circuits

“Deaerator”, to allow the automatic evacuation of the air.

developing three fundamental functions:

Mixing Headers

MODULEX EXT Tech Data Manual14

Page 15: AH ModulexEXT WaterH TechD · 2019-04-29 · boiler body is covered by a 5 year guarantee. MODULEX EXT Tech Data Manual 5 Pre-assembled ... quiet operation simple maintenance thanks

MODULEX EXT Tech Data Manual 15

Installation ComponentsPRIMARY RING composition

MIXING HEADER KitUpdated ADDITIONALSAFETIES Kit

“Y SHAPED” filter MODULATING PUMP

PRIMARY RINGSMIXING HEADER

combination with MODULEX EXT

Maximumcontrolled output

(kW)

Code

150 150 00361944

200 - 250 250 00361945

300 - 350 350 00361946

400 - 770 756 00361994

900* 864 00361995

* For higher capacities further sizings ar

Some additional safety devices ar

on the installation type.

e available on demand.

e not supplied because their sizing depends

MIXING HEADER KITcombination with MODULEX EXT

150 - 350 350 00361976

440 - 900 864 00361997

> 900 - 2700* 2700 00361501

ADDITION SAFETYDEVICES KIT

combination with MODULEX EXT

150 - 350 350 00361980

440 - 770 756 00361998

900 864 00361999

Coverage OGNITEMPO EXTfor MIXING HEADER

combination with MODULEX EXT

150 - 350 00362008

440 - 900 00362069

Maximumcontrolled output

(kW)

Code

Maximumcontrolled output

(kW)

Code

Code

* For information contact our pre-sale office.

UPDATED ADDITIONAL SAFETIES ASSEMBLY

All safety requirements are not only met, but exceeded.

UPDATED ADDITIONAL SAFETIES ASSEMBLY

CONTROL DEVICES

1 -

2 -

3 -4 -5 -6 -7 -

Pressure gauge with shock absorber and a cock for manometer: it shows the actual

pressure in the boiler, it must have the dial graduated in “bar”, the bottom of the dial

correlated to the maximum working pressure and be equipped with a three way cock

for the connection of a master pressure gauge.

Thermometer: it shows the real temperature of the water contained in the boiler; its

dial must be graduated in centigrades, with bottom of the dial not greater than 120°C.

Bulb holder: for master thermometer.

Stub pipes R 1 1/4’’: for the insertion safety valves.

Y shaped filter.

Modulating pump.

Mixing header.

• Certified expansion vessel: it allows to absorb the volume increase of the C.H. system

water following the temperature increase; the design pressure has not to be higher

than the setting pressure of the safety valve.

• Purging valve and drain cock.

Some parts need to be sized according to the characteristics of the installation:

8 -

9 -

10 -11 -

Safety thermostat: it has the function to stop the boiler in case the limit thermostats,

fitted in the boiler sections, are out of order. Its setting must NOT be changeable and

must be lower than 100°C.

Minimum water pressure switch: it has the function to stop the boiler in case the

minimal working pressure is below (0,5 - 1.7 bar). It has to be of manual reset type.

Additional stub pipe R 1’’.

Safety pressure switch: it has the function to stop the boiler in case of attainment of

the maximum working pressure (5 bar). Adjustable 1 to 6 bar.

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Condensing Water Heaters > Modulex EXT Water Heaters

Primary System with PlateHeat Exchanger

For the completion of the installation interfaces,

we propose a

physical separation: hydraulic circulation

is not present among the 2 circuits, the primary

of boiler and secondary of the installation

- possible different working pressure between

primary and secondary circuit (for example:

closed expansion vessel for the boiler and open

expansion vessel for the C.H. circuit)

boiler installation on old, obsolete C.H. circuits

with potential risks of sludge or water leaks,

with consequent frequent water reinstatements

external installation with primary circuit

protected against freezing and secondary circuit

with untreated water

variation of exchange parameters in case of C.H.

system modifications, by adding or removing

plates

new range of 6 primary ringswith plate heat exchanger.

Advantages: C.H. FLOW

C.H. RETURNRETURN INTOTHE BOILER

FLOW FROMTHE BOILER

fixed front plate

plates assembly

movable rear plate

MODULEX EXT Tech Data Manual16

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MOUDLEX EXT Tech Data Manual 17

PRIMARY RINGSPLATE HEATEXCHANGER

combination with MODULEX EXT

CODE Maximumcontrolled

output

(kW)

PRIMARYworking

temperatures

(°C)

SECONDARYworking

temperatures

(°C)

PRIMARYFLOW RATE

m 3F/R 80°/65°

SECONDARYFLOW RATE

m 3F/R 80°/65°

OGNITEMPO EXT for coverage

of PLATE HEAT EXCHANGER

combination with MODULEX EXT

CODE

Thanks to the modulating pump all the advantages

already seen for the models with mixing header are

maintained:

for all the outputs

OGNITEMPO EXT for coverage of primary rings,

suitable for external installations (class IPX5D).

• Efficacy in the condensating power• Energy recovery.

The supply, in parts to be assembled on site,foresees:

optional:

stainless steel AISI 316 L plate heat exchanger, withsealing gaskets in NBR, suitable for temperatures-15°C to 135 °C

additional safety devices kit

modulating pump

mechanical filtration system for the sludge

accessories, connections and basement

• t nearly constantΔ

150 ÷ 350 00362113

440 ÷ 900 00362120

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Condensing Water Heaters > Modulex EXT Water Heaters

Optional Accessories

To complete installation supports are available to help

sustain the weight of the smoke channel.

REAR SMOKE DISCHARGE KIT FOR MODULEX EXT 150 TO 350

Cod. 00362076

FLUE TERMINAL SUPPORT KIT

Cod. 00362075

Neutralizers optional KitThe condensate, produced during the combustion process, reacts with the

NOX forming acidic molecules (PH = 4,5). It could be demanded that the

condensate is neutralized before its immersion in the sewerage. In the respect

of the ecosystem, proposes the neutralizers of condensate NH.Modulex EXT

KIT NH 300 - for boilers up to 300 kW

Kit NH 1500-P - for boilers up to 1500 kW

RECHARGE:Neutralizing material 25 kgs: Refill NH

(cod. 00262827): the neutralization happens

according to the principle of the passage of the

acidic condensate through the granular

neutralization material. The passage happens

upward from the lower part.

(cod. 00262829): in the system NH 1500-P

the condensate flows through a patented run in a

zone filled with granular neutralizing material, in

which an integrated filtering layer is also found.

At the exit from such a zone the neutralized

condensate reaches a level controlled pump,

operating also as a lifting system, that push it

towards the evacuation duct.

This system is able to treat up to 550 l/h of

condensate, for boilers up to 1500 kW.

MAXIMUM FLOW RATE

MAXIMUM BOILER OUTPUT

MANOMETRIC HEAD

STAGNATION HEIGHT

NEUTRALIZING MATERIAL

DURATION OF NEUTRALIZING MATERIAL

DIMENSIONS (L x W x H)

INLET/OUTLET CONNECTIONS

INLET/OUTLET HEIGHT

OVERFLOW HEIGHT

ELECTRICAL CONNECTION

ABSORBED ELECTRICAL POWER

ABSORBED CURRENT

PROTECTION DEGREE

l/h

kW

m

mm

mm

mm

mm

mm

W

A

70

300

-

95

Calcium carbonate

12 months (1500 working hrs)

410x310x220

25

30/100

-

-

-

-

-

550

3

90

Calcium carbonate

12 months (1500 working hrs)

670X470X280

25 / 10

30

100

230V/50Hz

74

0,33

IP 54

MODULEX EXT Tech Data Manual18

KIT NH-300 KIT NH-1500P

1500

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MOUDLEX EXT Tech Data Manual 19

Modulex Ext 150 -350 Modulex Ext 440 - 900FRONT VIEW

RIGHT SIDEDelivery condition for right hand side connection

TOP VIEW

Gas inletDrain

GS

LEFT SIDE VIEW

PRE-CUT PARTFLOWLEFT SIDE

PRE-CUT PARTRETOURLEFT SIDE

PRE-CUT PARTGASLEFT SIDE

Water deliverySystem Return

MR

Gas inletDrain

GS

Water deliverySystem Return

MR

Dimensions

MODULEX EXT

NOMINAL INPUT on N.C.V. kW

NOMINAL OUTPUT in condensation 30° / 50°C kW

MINIMAL INPUT in condensation 30° / 50°C kW

NOMINAL OUTPUT in std. conditions 60° / 80°C kW

EFFICIENCY CLASS (directive EEC 92/42)

WATER EFFICIENCY at nom. load in condensation %

WATER EFFICIENCY at part load in condensation %

MAX. CONDENSATE PRODUCTION kg/h

NO x EMISSIONS (pondered value according to EN 15420) mg/kWh

WATER CONTENT l

Min.-Max WATER PRESSURE bar

WIDTH (L) mm

WIDTH (L1) mm

CHIMNEY CONNECTION mm

GAS CONNECTION G mm (inch)

C.H. FLOW / RETURN M / R mm (inch)

PROTECTION DEGREE IP

MAXIMUM ABSORBED POWER W

STAND-BY CONSUMPTION W

GROSS WEIGHT kg

150

150,1

12,5

146,1

100,8

106,8

23

53,8

14,2

0,5 - 6

764

706

150

50 (2)

64 (2½)

X5D

210

10

236

150

200

200,4

12,5

195,2

100,8

106,8

30,6

53,8

18,3

0,5 - 6

1032

974

150

50 (2)

64 (2½)

X5D

290

10

295

200

250

251,3

12,5

244,5

100,5

106,8

38,3

53,8

22,4

0,5 - 6

1032

974

200

50 (2)

64 (2½)

X5D

362

10

325

250

300

302,7

12,5

294

100,9

106,8

45,9

53,8

26,5

0,5 - 6

1300

1242

200

50 (2)

64 (2½)

X5D

435

10

386

300

348

354,6

12,5

342,2

101,9

106,8

53,6

53,8

30,6

0,5 - 6

1300

1242

200

50 (2)

64 (2½)

X5D

507

10

419

350

432

445

23,9

424,35

104

109

73,4

49

67

0,5 - 6

1087

1039

250 (2)

80 (3)

100 (4)

X5D

626

20

585

440

540

557,8

23,9

530,44

104

109

91,7

49

80

0,5 - 6

1355

1307

250

80 (3)

100 (4)

X5D

783

20

643

550

648

670,1

23,9

636,53

104

109

110

49

94

0,5 - 6

1355

1307

300

80 (3)

100 (4)

X5D

940

20

707

660

756

783,2

23,9

742,62

104

109

128,4

49

108

0,5 - 6

1623

1575

300

80 (3)

100 (4)

X5D

1096

20

806

770

864

900,3

23,9

849,05

104

109

146,7

49

122

0,5 - 6

1623

1575

300

80 (3)

100 (4)

X5D

1252

20

858

900

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Telephone FacsimileEmail

1800 337 959 +61 3 9310 [email protected]

P.O. Box 35 Epping VIC 3076 Australiawww.automaticheating.com.au

DISTRIBUTED BY

Autom

atic Heating P

ty LtdA

BN

90 446 545 923

Dimensional Data

Model Width Depth Height Connections Connections Gas Flue

L C Flow Return Connections Diametermm mm mm mm mm mm mm

MX150EXT 764 770 1150 50(2)64 (2 ½) 150*/20064 (2 ½)

50(2)64 (2 ½)64 (2 ½)MX200EXT 1032 770 1150 150*/200

MX250EXT 1032 770 1150 50(2)64 (2 ½) 20064 (2 ½)

MX300EXT 1300 770 1150 50(2)64 (2 ½) 20064 (2 ½)

MX350EXT 1300 770 1448 50(2)64 (2 ½) 20064 (2 ½)

(*) the flue connection adapter Ø200/250 is included in the boiler delivery

MX440EXT 1087 946 1448 80(3)100 (4) 300100 (4)

MX550EXT 1355 946 1448 80(3)100 (4) 300100 (4)

MX660EXT 1355 946 1448 80(3)100 (4) 300100 (4)

MX770EXT 1623 946 1448 80(3)100 (4) 300100 (4)

MX900EXT 1623 946 1448 80(3)100 (4) 300100 (4)