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EDITION <strong>3.0</strong><br />

automaticheating.com.au<br />

<strong>Modulex</strong> <strong>EXT</strong><br />

Condensing Water Heaters


<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

<strong>Modulex</strong> <strong>EXT</strong><br />

Condensing Water Heaters 150 – 1200kW<br />

<strong>Modulex</strong> <strong>EXT</strong> is a new range of floor-standing<br />

condensing water heaters that provides<br />

an infinitely flexible solution for buildings<br />

requiring a high output heating system.<br />

There are thirteen floor-standing water heaters to<br />

choose from, with outputs ranging from 150kW to<br />

1200kW. Each one is made up of a number of selfcontained<br />

heat generating modules forming what is,<br />

in essence, a series of water heaters linked together<br />

within a single casing. This modular design enables<br />

<strong>Modulex</strong> <strong>EXT</strong> water heaters to optimise energy<br />

efficiency and comfort levels for building occupiers<br />

like no other water heaters available today.<br />

Each linked module shares a single set of ancillary<br />

components including flow and return pipes,<br />

electronic controls and flue. This greatly eases the<br />

installation process and, along with the internal<br />

easy access layout of each water heater, simplifies<br />

servicing. Compact overall dimensions and ultralow<br />

operating noise levels gives the system designer<br />

greater flexibility when it comes to positioning<br />

the water heater within the building. With a host<br />

of benefits for the consultant, contractor, client<br />

and building occupier, <strong>Modulex</strong> <strong>EXT</strong> water heaters<br />

provide the perfect heating solution for a wide range<br />

of projects from hotels to office buildings, schools to<br />

sports centres.<br />

Each heat generating module within our <strong>Modulex</strong><br />

<strong>EXT</strong> water heaters is self-contained, with its own<br />

downfiring pre-mix gas burner, fan, ignition and<br />

safety controls. As system load decreases, a built-in<br />

Water Heater Cascade Manager modulates the water<br />

heater down to the combined minimum. As loads<br />

continue to reduce, individual modules are switched<br />

off as necessary down to a minimum output of a<br />

single module – 12kW for 150-350kW models and<br />

22kW for 440-1200kW models.<br />

Product Quick Check<br />

Type<br />

Range<br />

Efficiency<br />

Outdoor Option<br />

Fuel Type<br />

Gas Approval Type<br />

Condensing Premixed<br />

150-1200kW<br />

109% (Net) 98% (Gross)<br />

Yes<br />

Natural Gas, LPG<br />

Type B (approved to AS3814)<br />

Modulation 1:54<br />

Cascadeable Yes<br />

Max Pressure 600kPa<br />

Low Nox<br />

Yes<br />

Building J Code Yes<br />

2019 compliant<br />

2<br />

Automatic Heating


<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

This ensures optimum load matching and minimises wasteful water heater cycling, maximising energy<br />

efficiency in the process. The combination of a high modulation ratio up to 1:54 and a high output plus very<br />

low water content ensures rapid warm-up and turn-down times for <strong>Modulex</strong> <strong>EXT</strong> water heaters. They are<br />

subsequently also able to respond quickly to changing demands throughout the day. Thanks to their modular<br />

design, <strong>Modulex</strong> <strong>EXT</strong> water heaters will continue to operate even in the unlikely event that a single module<br />

malfunctions.<br />

Features<br />

• Exceptional energy efficiency<br />

(up to 109% at the minimum modulated capacity)<br />

• Low noise<br />

• Ultra low emissions<br />

• Full BMS capability.<br />

Allows monitoring of performance and faults<br />

• Variable Water Flow rate - Allows the water heater<br />

to operate at a constant 20°ΔT – maintaining the<br />

water heater at the most efficient duty point.<br />

• Able to be supplied as dismantled - When needing<br />

to achieve installation in tight plant rooms or<br />

inaccessible areas, this feature can enable much<br />

better access and often saves significant costs<br />

involved in placing equipment via a crane from<br />

outside the building.<br />

Advantages<br />

• High turndown ratio of up to 1:54 - This provides<br />

significant energy savings, particularly for part load<br />

or low load requirements. It also stops water heater<br />

cycling and contributes to its very quiet operation.<br />

• Multi burner construction - If one burner requires<br />

maintenance, the other burners can continue to<br />

operate, providing built-in redundancy.<br />

• Small space saving footprint - This makes it easy<br />

to install in plant rooms where floor space is at a<br />

premium.<br />

Full BMS capability<br />

Allows monitoring of<br />

performance and faults<br />

Low Noise


<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

Technical Features<br />

Maximum Saving & Seasonal Efficiency<br />

• High efficiency thanks to:<br />

• Certified efficiency up to 109% at the minimum<br />

modulated capacity<br />

• Seasonal efficiency: + 30% if compared with the<br />

conventional heaters<br />

• Large modulation ratio: up to 1:54<br />

• Modulating pump directly managed by the heater<br />

to assure the maximum condensation at all times<br />

Total Safety<br />

• High reliability due to MULTI BURNER composition<br />

and to the low number of parts in movement<br />

• Working and safety temperature sensors on every<br />

casting section<br />

• Premixing within the fan with non return built-in<br />

valve<br />

• Auxiliary electronic circuits<br />

• Emergency operation in case the E8 controller is<br />

out of service<br />

Flexibility Of Installation<br />

• Outdoor installation: protection degree IP55<br />

• Compact, light, of easy connection:<br />

- Reversible hydraulic and gas connections<br />

(up to model 350 kW)<br />

- Smoke discharge: possible on 3 sides<br />

(for all the models)<br />

Low Environmental Impact<br />

• Low polluting emissions :


<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

Pre-assembled Thermal Elements<br />

MODULEX <strong>EXT</strong> is an assembly of thermal modules,<br />

together making a complete unit. Every unit is<br />

constituted by pre-assembled thermal elements, in<br />

Al/Si/Mg. Every element supplies, in continuous and<br />

progressive way, from 12 to 50 kW for the models<br />

up to 350 kW, and from 22 up to 108 kW for larger<br />

models.<br />

More than 10 years experience assure:<br />

• Resistance to the corrosion of the acidic<br />

condensate<br />

• Very high thermal efficiency<br />

The basic element is formed by two aluminium alloy<br />

castings that, on the smoke side, have dense fins,<br />

with increasing height toward the smoke discharge,<br />

placed in lower part of the casting, in order to<br />

increase its exchange surface.<br />

Inside the castings there are the water channels that<br />

zigzag cross the casting, granting an exceptional<br />

heat transfer from combustion gases to the water.<br />

Every thermal element is equipped with:<br />

• Premix modulating burner<br />

• Two stage modulating gas valve<br />

• Electronic ignition and ionization<br />

• NTC working temperature sensor<br />

• Safety thermostats<br />

• Flame sight glass<br />

The smoke and acidic condensate of the thermal<br />

elements are collected in a stainless steel tray.<br />

Air/Gas<br />

Mixture<br />

Burner<br />

Combustion<br />

Chamber<br />

Condensate<br />

Finned<br />

Casting<br />

Water<br />

Gas Valve<br />

Burner Cover<br />

Gas Pipe<br />

Ignition Electrode<br />

Ignition Probe<br />

Local NTC Temp. Sensor<br />

Fan<br />

Burner<br />

Automatic Air Vent<br />

Global NTC Flow<br />

Temp. Sensor<br />

Limit Thermostat<br />

Aluminium Alloy<br />

Heat Exchanger<br />

Condensate<br />

Level Sensor<br />

Condensate & Smoke Tray<br />

Chimney Connection<br />

Frame<br />

Central Heating Flow<br />

Global NTC Return<br />

Temp. Sensor<br />

Central Heating Return<br />

Drain Tap<br />

Condensate<br />

Evactuation<br />

Automatic Heating 5


<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

Output Flexibility and Efficiency<br />

The MODULEX <strong>EXT</strong><br />

exceeded all industry<br />

requirements when it was<br />

first conceived over a<br />

decade ago. These days<br />

the high standards and<br />

benchmark qualities of this<br />

groundbreaking heater are a<br />

must in today’s world.<br />

Temperature (ºC)<br />

80<br />

70<br />

60<br />

50<br />

40<br />

30<br />

20<br />

Comparison of the steady state condition reaching time between a modulex<br />

and a high intertia/water content heater<br />

Setting option according to the<br />

thermal needs of the central<br />

heating system<br />

This function enables you to<br />

drastically reduce the number<br />

of switching ON and OFF of the<br />

heater (Possible customization of<br />

the requested output)<br />

Advantages:<br />

• Higher efficiency and lower flue<br />

losses when burner is OFF<br />

• Longer lasting of the parts in<br />

movement and of the ignition<br />

systems<br />

Very low water content and high<br />

modulation speed with maximum<br />

output ratio up to 1:54<br />

On average a heater operates<br />

at 50% of the thermal need of<br />

the central heating installation<br />

and can descend below 30%.<br />

MODULEX <strong>EXT</strong> adjusts in real<br />

time the output to meet demand,<br />

because it is not influenced by<br />

the thermal inertia, thanks to its<br />

low water content and, being<br />

equipped with modulating pump,<br />

it further reduces the electricity<br />

used.<br />

Class A, variable speed,<br />

electronic pumps, for the<br />

maximum condensate production<br />

This function promotes the<br />

production of condensate and<br />

therefore the fast economic<br />

recovery of the investment. All<br />

this in order to offer the user<br />

the possibility to save with the<br />

maximum comfort both, for central<br />

heating and D.H.W. production,<br />

with a lower noise level than the<br />

traditional water heaters<br />

Nominal Load 100 (%)<br />

Effciency (%)<br />

10<br />

100<br />

90<br />

80<br />

70<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

110<br />

108<br />

106<br />

104<br />

102<br />

100<br />

98<br />

96<br />

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30<br />

Time (min)<br />

T1 T2 T3 T4<br />

Time<br />

MODULEX Ext Low Water Content Heater<br />

Modulating flow rate pump<br />

High Water Content Heater<br />

After the time “T1” from the starting, MODULEX <strong>EXT</strong> succeeds in satisfying the<br />

30% of the load unlike a traditional heater that, in the same time, is just at 15%.<br />

After the time “T2” MODULEX <strong>EXT</strong> is at 50% of the load, while the traditional<br />

one is at 30%. After the time “T3” MODULEX <strong>EXT</strong> is at 100% of the load and the<br />

traditional one is only at 70%. This clearly displays the speed of the <strong>Modulex</strong> <strong>EXT</strong><br />

Heater<br />

190 170 150 100 70 48<br />

Output (kW)<br />

+3%<br />

Constant flow rate pump<br />

Efficiency comparison between pump with modulating flow rate versus a<br />

heater with constant flow rate<br />

12<br />

6<br />

Automatic Heating


<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

<strong>Modulex</strong> <strong>EXT</strong> Efficiency<br />

Efficiency (%)<br />

109<br />

108<br />

107<br />

106<br />

104<br />

102<br />

Output sharing of MODULEX <strong>EXT</strong> of 4 modules of 50 kW<br />

50kW<br />

12kW<br />

50kW<br />

12kW<br />

12 22 50 110<br />

Output (kW)<br />

<strong>Modulex</strong> <strong>EXT</strong> 150 | 350<br />

Max Output<br />

50kW<br />

Total Efficiency η = 102<br />

25% Output<br />

12kW<br />

50kW<br />

12kW<br />

<strong>Modulex</strong> <strong>EXT</strong> 440 | 900<br />

25kW<br />

12kW<br />

50% Output<br />

25kW<br />

Off<br />

25kW<br />

Total Efficiency η = 104<br />

Min Output<br />

Off<br />

25kW<br />

Off<br />

MODULEX <strong>EXT</strong> has a certified<br />

efficiency that, for all models<br />

above 350 kW, when working<br />

in condensation, progressively<br />

increase up to 109% when the<br />

output is reduced.<br />

The genius of the thermocontroller<br />

E8 is that it keeps<br />

ON the greatest number of<br />

elements as possible, working at<br />

the smallest possible output (as<br />

shown in the examples beside).<br />

The system will always work in the<br />

conditions of maximum possible<br />

efficiency, independently from the<br />

supplied output.<br />

When the requested output is less<br />

than the capacity available the<br />

design of the <strong>Modulex</strong> regulates<br />

evenly reducing the output of<br />

each module to suit. Once the<br />

minimum level for a module is<br />

reached it is disabled in cascade<br />

sequence.<br />

This modular system is such<br />

that as the number of modules<br />

used decreases - the efficiency<br />

increases. The flexibility of this<br />

modular conception is ground<br />

breaking and brings vast cost<br />

savings through increased<br />

efficiency.<br />

To avoid one element module<br />

being over used more than<br />

others, the thermo-controller<br />

automatically alternates usage of<br />

all element modules evenly.<br />

Total Efficiency η = 106.5<br />

Total Efficiency η = 107<br />

Automatic Heating 7


<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

Installation Examples<br />

With the cascade installation, the<br />

water heater output range can<br />

be widened to well in excess of<br />

1200kW, multiplying output and<br />

modulation in order to satisfy any<br />

design demand. The space saving<br />

(in particular the water heaters<br />

can be installed up to 40cm from<br />

the water heater house walls)<br />

features of the <strong>Modulex</strong> Water<br />

Heater are tailored specifically<br />

with service and easy access<br />

in mind. Replacement of old<br />

obsolete water heaters is also<br />

another benefit that a small foot<br />

print allows.<br />

<strong>Modulex</strong> <strong>EXT</strong> cascade installation<br />

using a single hydraulic separator<br />

<strong>Modulex</strong> <strong>EXT</strong> installation using a<br />

hydraulic separator<br />

<strong>Modulex</strong> <strong>EXT</strong> installation using<br />

a plate heat exchanger<br />

8<br />

Automatic Heating


<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

Performance Data<br />

Product<br />

Code<br />

Output<br />

(50/30ºc)<br />

kW<br />

Net<br />

Efficiency<br />

(50/30ºc)<br />

%<br />

Output<br />

(80/60ºc)<br />

kW<br />

Net<br />

Efficiency<br />

(80/60ºc)<br />

%<br />

Nominal<br />

Input<br />

MJ/hr<br />

Burner<br />

Quantity<br />

Minimum<br />

Heat<br />

Output<br />

kW<br />

Modulation<br />

Ratio<br />

Minimum<br />

flow rate<br />

in l/sec*<br />

Design<br />

flow rate<br />

in l/sec<br />

(Δt=20K)<br />

Waterside<br />

Pressure<br />

Drop kPa<br />

Total<br />

Water<br />

Volume<br />

litres<br />

Dry<br />

Weight<br />

Kg<br />

Power Supply<br />

V/A/Hz<br />

MX150<strong>EXT</strong> 150 107 146 97 540 3 x 50kW 12 1:12 0.43 1.75 16 14 236 240/0.875/50<br />

MX200<strong>EXT</strong> 200 107 195 98 720 4 x 50kW 12 1:16 0.57 2.33 16 18 295 240/1.208/50<br />

MX250<strong>EXT</strong> 251 107 245 99 900 5 x 50kW 12 1:20 0.72 2.92 16 22 325 240/1.508/50<br />

MX300<strong>EXT</strong> 303 107 294 98 1080 6 x 50kW 12 1:24 0.86 3.51 16 26 386 240/1.771/50<br />

MX350<strong>EXT</strong> 355 107 342 98 1260 7 x 50kW 12 1:28 1 4.11 16 31 419 240/2.112/50<br />

MX440<strong>EXT</strong> 445 109 424 98 1600 4 x 110kW 22 1:19 1.05 5.07 15 67 501 240/2.608/50<br />

MX550<strong>EXT</strong> 558 109 530 98 2000 5 x 110kW 22 1:25 1.31 6.33 18 80 595 240/3.262/50<br />

MX660<strong>EXT</strong> 670 109 637 98 2400 6 x 110kW 22 1:29 1.58 7.6 20 94 657 240/3.916/50<br />

MX770<strong>EXT</strong> 783 109 743 98 2800 7 x 110kW 22 1:34 1.84 8.87 22 108 754 240/4.566/50<br />

MX900<strong>EXT</strong> 900 109 849 98 3200 8 x 110kW 22 1:39 2.1 10.14 20 122 906 240/5.216/50<br />

MX1000<strong>EXT</strong> 1015 109 947 97 3500 9 x 110kW 22 1:44 2.37 11.31 26 140 981 240/5.868/50<br />

MX1100<strong>EXT</strong> 1223 109 1052 97 3888 10 x 110kW 22 1:49 2.63 12.57 26 154 1090 240/6.520/50<br />

MX1200<strong>EXT</strong> 1237 109 1157 98 4277 11 x 110kW 22 1:54 2.89 13.82 26 168 1200 240/7.172/50<br />

*Primary Pump must be controlled by <strong>Modulex</strong> Water Heater<br />

Automatic Heating 9


Menu<br />

Menu<br />

<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

Dimensional Data<br />

MX150<strong>EXT</strong> - MX350<strong>EXT</strong> FRONT VIEW<br />

FRONT VIEW<br />

FRONT<br />

L<br />

L<br />

RIGHT SIDE<br />

RIGHT SIDE<br />

Delivery condition for right<br />

hand side Delivery connection condition for right<br />

hand side RIGHT connection<br />

770<br />

770<br />

387 384<br />

387 384<br />

318<br />

TOP VIEW<br />

TOP VI<br />

318<br />

70<br />

70<br />

1150<br />

1150<br />

106<br />

833<br />

106<br />

275<br />

833<br />

275<br />

390<br />

750<br />

390<br />

750<br />

Delivery<br />

condition<br />

for right<br />

hand side<br />

connection<br />

IDE<br />

n for right<br />

SIDE nection<br />

ion for right<br />

nnection<br />

384<br />

384<br />

318<br />

62.5<br />

318<br />

L1<br />

120<br />

TOP VIEW L1<br />

into the casing<br />

TOP VIEW<br />

62.5<br />

TOP<br />

into the casing<br />

120<br />

255 276<br />

352 353<br />

255 276<br />

705<br />

LEFT SIDE<br />

352 353<br />

705<br />

LEFT SIDE<br />

LEFT<br />

Pre-cut<br />

Flow<br />

Left Side<br />

Pre-cut<br />

Gas Left<br />

Side<br />

390<br />

750<br />

750<br />

Pre-cut<br />

Return<br />

Left Side<br />

76<br />

390<br />

353<br />

276<br />

353<br />

62<br />

62<br />

2025<br />

2025<br />

G Gas Inlet M Water Delivery S Drain R System Return<br />

Model<br />

Width L<br />

mm<br />

Width L1<br />

mm<br />

Connections Flow<br />

mm<br />

S<br />

MX250<strong>EXT</strong> 1032 974 64 (2 ½) 64 (2 ½) 50(2) 200<br />

S<br />

MX300<strong>EXT</strong> 1300 1242 64 (2 ½) 64 (2 ½) 50(2) 200<br />

MX350<strong>EXT</strong> 309 1300 1977 1242 64 (2 ½) 64 (2 ½) 50(2) 200<br />

309 1977<br />

*the flue connection adapter 150/200 is included in the water heater delivery<br />

1 61 7<br />

448<br />

1<br />

Connections Return<br />

mm<br />

1 61 7<br />

448<br />

1<br />

Gas Connections<br />

mm<br />

MX150<strong>EXT</strong> 764 706 64 (2 ½) 64 (2 ½) 50(2) 150*<br />

MX200<strong>EXT</strong> 1032 974 64 (2 ½) 64 (2 ½) 50(2) 150*<br />

Ø 350<br />

Ø 350<br />

Flue Diameter<br />

mm<br />

2310<br />

S<br />

231<br />

10<br />

G<br />

Automatic Heating<br />

5<br />

G


Menu<br />

Menu<br />

E<br />

for right<br />

ection<br />

IDE<br />

Dimensional Data<br />

L1<br />

for right MX440<strong>EXT</strong> - MX900<strong>EXT</strong><br />

318<br />

nection<br />

4<br />

TOP VIEW<br />

L1<br />

TOP VIEW<br />

into<br />

into<br />

the<br />

the<br />

casing<br />

casing<br />

120<br />

120<br />

106 106<br />

833 833<br />

<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

275<br />

255 276<br />

255 276<br />

352<br />

352<br />

353<br />

353<br />

LEFT SIDE<br />

705<br />

705<br />

390 390<br />

750 750<br />

LEFT SIDE<br />

384<br />

318<br />

62.5 62.5<br />

RIGHT<br />

390<br />

750<br />

390<br />

750<br />

FRONT<br />

53<br />

62<br />

62<br />

2025<br />

2025<br />

LEFT<br />

1 61 7<br />

1 61 7<br />

1<br />

448<br />

1<br />

448<br />

TOPS<br />

S<br />

Smoke outlet: Left side (standard condition), Right side, Back side<br />

Ø 350<br />

Ø 350<br />

309 1977<br />

309 1977<br />

G Gas Inlet M Water Delivery S Drain R System Return<br />

G<br />

Model<br />

MX440<strong>EXT</strong> 1087 1039 100 (4) 100 (4) R 80(3) 300<br />

MX550<strong>EXT</strong> 1355 1307 100 (4) 100 (4) 80(3) M 300<br />

S<br />

MX660<strong>EXT</strong> 1355 1307 100 (4) 100 (4) 80(3) 300<br />

Ø 350<br />

MX770<strong>EXT</strong> 1623 1575 100 (4) 100 (4) 80(3) R 300<br />

MX900<strong>EXT</strong> 1623 1575 100 (4) 100 (4) 80(3)<br />

53<br />

300<br />

S<br />

151<br />

2310<br />

111 363 349<br />

Ø 350<br />

Width L<br />

mm<br />

Width L1<br />

S<br />

mm<br />

Connections Flow<br />

mm<br />

974 53<br />

S<br />

151<br />

2310<br />

111 363 349<br />

Automatic Heating 948<br />

11<br />

002<br />

1<br />

002<br />

1<br />

3 96 1 4 5 3 0 7 41 5<br />

Connections Return<br />

mm<br />

M Gas Connections G<br />

mm<br />

3 96 1 4 5 3 0 7 41 5<br />

948<br />

Flue Diameter<br />

mm<br />

974


75<br />

Menu<br />

Menu<br />

390<br />

390<br />

750<br />

<strong>Modulex</strong> <strong>EXT</strong> Condensing Water Heaters<br />

53 6<br />

353<br />

Dimensional Data<br />

MX1000<strong>EXT</strong> - MX1200<strong>EXT</strong><br />

62<br />

62<br />

FRONT<br />

2025<br />

2025<br />

RIGHT<br />

1 61 7<br />

448<br />

1<br />

1 61 7<br />

1<br />

448<br />

S<br />

S<br />

Ø 350<br />

Ø 350<br />

309 1977<br />

309 1977<br />

LEFT<br />

TOP<br />

G<br />

G<br />

Ø 350<br />

Ø 350<br />

S<br />

002<br />

002<br />

1<br />

1<br />

3 96 1 4 5 3 0 7 41 5<br />

3 96 1 4 5 3 0 7 41 5<br />

M<br />

M<br />

R<br />

R<br />

2310<br />

53<br />

53<br />

S S<br />

151 151<br />

111 111 363 363 349 349<br />

948 948<br />

974 974<br />

G Gas Inlet M Water Delivery S Drain R System Return<br />

Model Connections Flow mm Connections Return mm Gas Connections mm Flue Diameter mm<br />

MX1000<strong>EXT</strong> 125 (5) 125 (5) 80(3) 350<br />

MX1100<strong>EXT</strong> 125 (5) 125 (5) 80(3) 350<br />

MX1200<strong>EXT</strong> 125 (5) 125 (5) 80(3) 350<br />

12<br />

Automatic Heating


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Automatic Heating 13


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14<br />

Automatic Heating


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Automatic Heating 15


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T. +613 8352 7000<br />

E. sales@automaticheating.com.au<br />

67 Gateway Boulevard, Epping VIC 3076<br />

P.O. Box 35a Epping VIC 3076 Australia<br />

W. automaticheating.com.au 18785 210615

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