Modulex EXT brochure_3.0

EDITION 3.0
automaticheating.com.au
Modulex EXT
Condensing Water Heaters

Modulex EXT Condensing Water Heaters
Modulex EXT
Condensing Water Heaters 150 – 1200kW
Modulex EXT is a new range of floor-standing
condensing water heaters that provides
an infinitely flexible solution for buildings
requiring a high output heating system.
There are thirteen floor-standing water heaters to
choose from, with outputs ranging from 150kW to
1200kW. Each one is made up of a number of selfcontained
heat generating modules forming what is,
in essence, a series of water heaters linked together
within a single casing. This modular design enables
Modulex EXT water heaters to optimise energy
efficiency and comfort levels for building occupiers
like no other water heaters available today.
Each linked module shares a single set of ancillary
components including flow and return pipes,
electronic controls and flue. This greatly eases the
installation process and, along with the internal
easy access layout of each water heater, simplifies
servicing. Compact overall dimensions and ultralow
operating noise levels gives the system designer
greater flexibility when it comes to positioning
the water heater within the building. With a host
of benefits for the consultant, contractor, client
and building occupier, Modulex EXT water heaters
provide the perfect heating solution for a wide range
of projects from hotels to office buildings, schools to
sports centres.
Each heat generating module within our Modulex
EXT water heaters is self-contained, with its own
downfiring pre-mix gas burner, fan, ignition and
safety controls. As system load decreases, a built-in
Water Heater Cascade Manager modulates the water
heater down to the combined minimum. As loads
continue to reduce, individual modules are switched
off as necessary down to a minimum output of a
single module – 12kW for 150-350kW models and
22kW for 440-1200kW models.
Product Quick Check
Type
Range
Efficiency
Outdoor Option
Fuel Type
Gas Approval Type
Condensing Premixed
150-1200kW
109% (Net) 98% (Gross)
Yes
Natural Gas, LPG
Type B (approved to AS3814)
Modulation 1:54
Cascadeable Yes
Max Pressure 600kPa
Low Nox
Yes
Building J Code Yes
2019 compliant
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Automatic Heating

Modulex EXT Condensing Water Heaters
This ensures optimum load matching and minimises wasteful water heater cycling, maximising energy
efficiency in the process. The combination of a high modulation ratio up to 1:54 and a high output plus very
low water content ensures rapid warm-up and turn-down times for Modulex EXT water heaters. They are
subsequently also able to respond quickly to changing demands throughout the day. Thanks to their modular
design, Modulex EXT water heaters will continue to operate even in the unlikely event that a single module
malfunctions.
Features
• Exceptional energy efficiency
(up to 109% at the minimum modulated capacity)
• Low noise
• Ultra low emissions
• Full BMS capability.
Allows monitoring of performance and faults
• Variable Water Flow rate - Allows the water heater
to operate at a constant 20°ΔT – maintaining the
water heater at the most efficient duty point.
• Able to be supplied as dismantled - When needing
to achieve installation in tight plant rooms or
inaccessible areas, this feature can enable much
better access and often saves significant costs
involved in placing equipment via a crane from
outside the building.
Advantages
• High turndown ratio of up to 1:54 - This provides
significant energy savings, particularly for part load
or low load requirements. It also stops water heater
cycling and contributes to its very quiet operation.
• Multi burner construction - If one burner requires
maintenance, the other burners can continue to
operate, providing built-in redundancy.
• Small space saving footprint - This makes it easy
to install in plant rooms where floor space is at a
premium.
Full BMS capability
Allows monitoring of
performance and faults
Low Noise

Modulex EXT Condensing Water Heaters
Technical Features
Maximum Saving & Seasonal Efficiency
• High efficiency thanks to:
• Certified efficiency up to 109% at the minimum
modulated capacity
• Seasonal efficiency: + 30% if compared with the
conventional heaters
• Large modulation ratio: up to 1:54
• Modulating pump directly managed by the heater
to assure the maximum condensation at all times
Total Safety
• 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
Flexibility Of Installation
• 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 Environmental Impact
• Low polluting emissions :

Modulex EXT Condensing Water Heaters
Pre-assembled Thermal Elements
MODULEX EXT is an assembly of thermal modules,
together making a complete unit. Every unit is
constituted by pre-assembled thermal elements, in
Al/Si/Mg. 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.
More than 10 years experience assure:
• Resistance to the corrosion of the acidic
condensate
• Very high thermal efficiency
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
zigzag cross the casting, granting an exceptional
heat transfer from combustion gases to the water.
Every thermal element is equipped with:
• Premix modulating burner
• Two stage modulating gas valve
• Electronic ignition and ionization
• NTC working temperature sensor
• Safety thermostats
• Flame sight glass
The smoke and acidic condensate of the thermal
elements are collected in a stainless steel tray.
Air/Gas
Mixture
Burner
Combustion
Chamber
Condensate
Finned
Casting
Water
Gas Valve
Burner Cover
Gas Pipe
Ignition Electrode
Ignition Probe
Local NTC Temp. Sensor
Fan
Burner
Automatic Air Vent
Global NTC Flow
Temp. Sensor
Limit Thermostat
Aluminium Alloy
Heat Exchanger
Condensate
Level Sensor
Condensate & Smoke Tray
Chimney Connection
Frame
Central Heating Flow
Global NTC Return
Temp. Sensor
Central Heating Return
Drain Tap
Condensate
Evactuation
Automatic Heating 5

Modulex EXT Condensing Water Heaters
Output Flexibility and Efficiency
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 heater are a
must in today’s world.
Temperature (ºC)
80
70
60
50
40
30
20
Comparison of the steady state condition reaching time between a modulex
and a high intertia/water content heater
Setting option according to the
thermal needs of the central
heating system
This function enables you to
drastically reduce the number
of switching ON and OFF of the
heater (Possible customization of
the requested output)
Advantages:
• Higher efficiency and lower flue
losses when burner is OFF
• Longer lasting of the parts in
movement and of the ignition
systems
Very low water content and high
modulation speed with maximum
output ratio up to 1:54
On average a heater operates
at 50% of the thermal need of
the central heating 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.
Class A, variable speed,
electronic pumps, for the
maximum condensate production
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 central
heating and D.H.W. production,
with a lower noise level than the
traditional water heaters
Nominal Load 100 (%)
Effciency (%)
10
100
90
80
70
60
50
40
30
20
10
110
108
106
104
102
100
98
96
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Time (min)
T1 T2 T3 T4
Time
MODULEX Ext Low Water Content Heater
Modulating flow rate pump
High Water Content Heater
After the time “T1” from the starting, MODULEX EXT succeeds in satisfying the
30% of the load unlike a traditional heater 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 at 70%. This clearly displays the speed of the Modulex EXT
Heater
190 170 150 100 70 48
Output (kW)
+3%
Constant flow rate pump
Efficiency comparison between pump with modulating flow rate versus a
heater with constant flow rate
12
6
Automatic Heating

Modulex EXT Condensing Water Heaters
Modulex EXT Efficiency
Efficiency (%)
109
108
107
106
104
102
Output sharing of MODULEX EXT of 4 modules of 50 kW
50kW
12kW
50kW
12kW
12 22 50 110
Output (kW)
Modulex EXT 150 | 350
Max Output
50kW
Total Efficiency η = 102
25% Output
12kW
50kW
12kW
Modulex EXT 440 | 900
25kW
12kW
50% Output
25kW
Off
25kW
Total Efficiency η = 104
Min Output
Off
25kW
Off
MODULEX EXT has a certified
efficiency that, for all models
above 350 kW, when working
in condensation, progressively
increase up to 109% when the
output is reduced.
The genius of the thermocontroller
E8 is that it keeps
ON the greatest number of
elements as possible, working at
the smallest possible output (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.
Total Efficiency η = 106.5
Total Efficiency η = 107
Automatic Heating 7

Modulex EXT Condensing Water Heaters
Installation Examples
With the cascade installation, the
water heater output range can
be widened to well in excess of
1200kW, multiplying output and
modulation in order to satisfy any
design demand. The space saving
(in particular the water heaters
can be installed up to 40cm from
the water heater house walls)
features of the Modulex Water
Heater are tailored specifically
with service and easy access
in mind. Replacement of old
obsolete water heaters is also
another benefit that a small foot
print allows.
Modulex EXT cascade installation
using a single hydraulic separator
Modulex EXT installation using a
hydraulic separator
Modulex EXT installation using
a plate heat exchanger
8
Automatic Heating

Modulex EXT Condensing Water Heaters
Performance Data
Product
Code
Output
(50/30ºc)
kW
Net
Efficiency
(50/30ºc)
%
Output
(80/60ºc)
kW
Net
Efficiency
(80/60ºc)
%
Nominal
Input
MJ/hr
Burner
Quantity
Minimum
Heat
Output
kW
Modulation
Ratio
Minimum
flow rate
in l/sec*
Design
flow rate
in l/sec
(Δt=20K)
Waterside
Pressure
Drop kPa
Total
Water
Volume
litres
Dry
Weight
Kg
Power Supply
V/A/Hz
MX150EXT 150 107 146 97 540 3 x 50kW 12 1:12 0.43 1.75 16 14 236 240/0.875/50
MX200EXT 200 107 195 98 720 4 x 50kW 12 1:16 0.57 2.33 16 18 295 240/1.208/50
MX250EXT 251 107 245 99 900 5 x 50kW 12 1:20 0.72 2.92 16 22 325 240/1.508/50
MX300EXT 303 107 294 98 1080 6 x 50kW 12 1:24 0.86 3.51 16 26 386 240/1.771/50
MX350EXT 355 107 342 98 1260 7 x 50kW 12 1:28 1 4.11 16 31 419 240/2.112/50
MX440EXT 445 109 424 98 1600 4 x 110kW 22 1:19 1.05 5.07 15 67 501 240/2.608/50
MX550EXT 558 109 530 98 2000 5 x 110kW 22 1:25 1.31 6.33 18 80 595 240/3.262/50
MX660EXT 670 109 637 98 2400 6 x 110kW 22 1:29 1.58 7.6 20 94 657 240/3.916/50
MX770EXT 783 109 743 98 2800 7 x 110kW 22 1:34 1.84 8.87 22 108 754 240/4.566/50
MX900EXT 900 109 849 98 3200 8 x 110kW 22 1:39 2.1 10.14 20 122 906 240/5.216/50
MX1000EXT 1015 109 947 97 3500 9 x 110kW 22 1:44 2.37 11.31 26 140 981 240/5.868/50
MX1100EXT 1223 109 1052 97 3888 10 x 110kW 22 1:49 2.63 12.57 26 154 1090 240/6.520/50
MX1200EXT 1237 109 1157 98 4277 11 x 110kW 22 1:54 2.89 13.82 26 168 1200 240/7.172/50
*Primary Pump must be controlled by Modulex Water Heater
Automatic Heating 9

Menu
Menu
Modulex EXT Condensing Water Heaters
Dimensional Data
MX150EXT - MX350EXT FRONT VIEW
FRONT VIEW
FRONT
L
L
RIGHT SIDE
RIGHT SIDE
Delivery condition for right
hand side Delivery connection condition for right
hand side RIGHT connection
770
770
387 384
387 384
318
TOP VIEW
TOP VI
318
70
70
1150
1150
106
833
106
275
833
275
390
750
390
750
Delivery
condition
for right
hand side
connection
IDE
n for right
SIDE nection
ion for right
nnection
384
384
318
62.5
318
L1
120
TOP VIEW L1
into the casing
TOP VIEW
62.5
TOP
into the casing
120
255 276
352 353
255 276
705
LEFT SIDE
352 353
705
LEFT SIDE
LEFT
Pre-cut
Flow
Left Side
Pre-cut
Gas Left
Side
390
750
750
Pre-cut
Return
Left Side
76
390
353
276
353
62
62
2025
2025
G Gas Inlet M Water Delivery S Drain R System Return
Model
Width L
mm
Width L1
mm
Connections Flow
mm
S
MX250EXT 1032 974 64 (2 ½) 64 (2 ½) 50(2) 200
S
MX300EXT 1300 1242 64 (2 ½) 64 (2 ½) 50(2) 200
MX350EXT 309 1300 1977 1242 64 (2 ½) 64 (2 ½) 50(2) 200
309 1977
*the flue connection adapter 150/200 is included in the water heater delivery
1 61 7
448
1
Connections Return
mm
1 61 7
448
1
Gas Connections
mm
MX150EXT 764 706 64 (2 ½) 64 (2 ½) 50(2) 150*
MX200EXT 1032 974 64 (2 ½) 64 (2 ½) 50(2) 150*
Ø 350
Ø 350
Flue Diameter
mm
2310
S
231
10
G
Automatic Heating
5
G

Menu
Menu
E
for right
ection
IDE
Dimensional Data
L1
for right MX440EXT - MX900EXT
318
nection
4
TOP VIEW
L1
TOP VIEW
into
into
the
the
casing
casing
120
120
106 106
833 833
Modulex EXT Condensing Water Heaters
275
255 276
255 276
352
352
353
353
LEFT SIDE
705
705
390 390
750 750
LEFT SIDE
384
318
62.5 62.5
RIGHT
390
750
390
750
FRONT
53
62
62
2025
2025
LEFT
1 61 7
1 61 7
1
448
1
448
TOPS
S
Smoke outlet: Left side (standard condition), Right side, Back side
Ø 350
Ø 350
309 1977
309 1977
G Gas Inlet M Water Delivery S Drain R System Return
G
Model
MX440EXT 1087 1039 100 (4) 100 (4) R 80(3) 300
MX550EXT 1355 1307 100 (4) 100 (4) 80(3) M 300
S
MX660EXT 1355 1307 100 (4) 100 (4) 80(3) 300
Ø 350
MX770EXT 1623 1575 100 (4) 100 (4) 80(3) R 300
MX900EXT 1623 1575 100 (4) 100 (4) 80(3)
53
300
S
151
2310
111 363 349
Ø 350
Width L
mm
Width L1
S
mm
Connections Flow
mm
974 53
S
151
2310
111 363 349
Automatic Heating 948
11
002
1
002
1
3 96 1 4 5 3 0 7 41 5
Connections Return
mm
M Gas Connections G
mm
3 96 1 4 5 3 0 7 41 5
948
Flue Diameter
mm
974

75
Menu
Menu
390
390
750
Modulex EXT Condensing Water Heaters
53 6
353
Dimensional Data
MX1000EXT - MX1200EXT
62
62
FRONT
2025
2025
RIGHT
1 61 7
448
1
1 61 7
1
448
S
S
Ø 350
Ø 350
309 1977
309 1977
LEFT
TOP
G
G
Ø 350
Ø 350
S
002
002
1
1
3 96 1 4 5 3 0 7 41 5
3 96 1 4 5 3 0 7 41 5
M
M
R
R
2310
53
53
S S
151 151
111 111 363 363 349 349
948 948
974 974
G Gas Inlet M Water Delivery S Drain R System Return
Model Connections Flow mm Connections Return mm Gas Connections mm Flue Diameter mm
MX1000EXT 125 (5) 125 (5) 80(3) 350
MX1100EXT 125 (5) 125 (5) 80(3) 350
MX1200EXT 125 (5) 125 (5) 80(3) 350
12
Automatic Heating

Modulex EXT Condensing Water Heaters
Case Studies
Aquamoves Lakeside Shepparton, Shepparton VIC
2 x 440kW Modulex EXT
Aquanation Aquatic Centre, Ringwood VIC
4 x 900kW Modulex EXT
Automatic Heating 13

Modulex EXT Condensing Water Heaters
Botanicca 3 Building, Burnley VIC
2 x 550kW Modulex EXT 2 x 770kW Modulex EXT
National Archive Preservation Facility, Mitchell ACT
3 x 440kW Modulex EXT
14
Automatic Heating

Modulex EXT Condensing Water Heaters
Wunggurrwil Dhurrung Centre, Wyndham Vale VIC
1 x 250kW Modulex EXT
Wodonga Hospital, Wodonga VIC
2 x 660kW Modulex EXT
Automatic Heating 15

Automatic Heating Global Pty Ltd
T. +613 8352 7000
E. sales@automaticheating.com.au
67 Gateway Boulevard, Epping VIC 3076
P.O. Box 35a Epping VIC 3076 Australia
W. automaticheating.com.au 18785 210615