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 

2 

Automatic Heating


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


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 :


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


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 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 


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 


Automatic Heating 7


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


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 




MX350EXT 355 107 342 98 1260 7 x 50kW 12 1:28 1 4.11 16 31 419 240/2.112/50 









*Primary Pump must be controlled by Modulex Water Heater 

Automatic Heating 9

Menu 

Menu 


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 


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 


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 

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 


53 6 

353 


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 


Model Connections Flow mm Connections Return mm Gas Connections mm Flue Diameter mm 

MX1000EXT 125 (5) 125 (5) 80(3) 350 



12 

Automatic Heating


Case Studies 

Aquamoves Lakeside Shepparton, Shepparton VIC 

2 x 440kW Modulex EXT 

Aquanation Aquatic Centre, Ringwood VIC 


Automatic Heating 13


Botanicca 3 Building, Burnley VIC 

2 x 550kW Modulex EXT 2 x 770kW Modulex EXT 

National Archive Preservation Facility, Mitchell ACT 


14 

Automatic Heating


Wunggurrwil Dhurrung Centre, Wyndham Vale VIC 


Wodonga Hospital, Wodonga VIC 


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

Modulex EXT brochure_3.0

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