AAON MODGAS-XWR2 Technical Manual
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AAON MODGAS-XWR2 Technical Manual

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MODGAS-XWR2 Module
Technical Guide

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Summary of Contents for AAON MODGAS-XWR2

  • Page 1 MODGAS-XWR2 Module Technical Guide...
  • Page 2 Technologies, Inc., St. Louis, MO AAON Controls Support: 866-918-1100 AAON assumes no responsibility for errors or omissions in It is the intent of AAON to provide accurate and current product this document. information. However, in the interest of product improvement, This document is subject to change without notice.

  • Page 3: Table Of Contents

    SAT Sensor Testing ............................... 38 APPENDIX A: SAT SENSOR ..................40 Installation ................................40 SAT Sensor Wiring Guide and Jumper Settings ....................41 APPENDIX B: MODGAS - XWR REPLACEMENT ............42 MODGAS-XWR2 Replacement of MODGAS-XWR ....................42 MODGAS-XWR2 Technical Guide...
  • Page 4 Figure 13: ..........19 Stand-Alone Wiring - Secondary Board 2V1IGN1S Figure 14: ...................20 LCD Display and Navigation Keys Figure 15: ........................26 MODGAS-XWR2 LED Locations and Descriptions Figure 16: ...................36 Supply Air Temperature Sensor Installation Figure 17: ......................40 MODGAS-XWR2 Module Figure 18: ............................42...

  • Page 5: Overview

    When the MODGAS- XWR2 is attached to one of the listed AAON unit controllers, these additional stages are affected through the AAON unit controller.

  • Page 6: Dimensions

    GAS VALVE TERMINALS PROOF OF IGNITION 2 LABEL P/N: DUAL G041530 CONNECT E-BUS ASSEMBLED IN USA .01UF 2.04 0.25 Note: Depth is 1.49 inches. 0.58 Note: All dimensions are in inches. 4.10 Figure 1: MODGAS-XWR2 Module Dimensions MODGAS-XWR2 Technical Guide...

  • Page 7: Wiring

    Important Wiring Considerations Wiring Please carefully read and apply the following information when wiring the AAON unit controller, MODGAS-XWR2 and any The modules must be connected to an 18-30 VAC power source associated module. of the proper size for the calculated VA load requirements. All 1.

  • Page 8: Stand-Alone Wiring

    Gas Valve 1 (attached to Heat 1 (RLY3)). configured by using Heat 2 (RLY4), Heat 3 If using an MHGRV-X along with the MODGAS-XWR2 in (RLY5) and Heat 4 (RLY6). Up to 12 additional Stand-Alone Mode, the SAT Sensor always attaches to the fixed stages can be added by using the 12 Relay MODGAS-XWR2.

  • Page 9: Two Modulating Valves, Two Ignitors, Two Stages (2V2Ign2S)

    12 Relay E-BUS Expansion to Heat 2 (RLY4). Module. (Figure 8, page 14). If using an MHGRV-X along with the MODGAS-XWR2 in Stand-Alone Mode, the SAT Sensor always attaches to the MODGAS-XWR2. Check your Fan Relay Wiring (RLY1) Schematic for proper wiring.

  • Page 10: Figure 4: Stand-Alone Wiring - Secondary Board 2V2Ign2S

    (RLY6). Up to 12 additional fixed stages can be If using an MHGRV-X Module along with the secondary added by using the 12 Relay E-BUS Expansion MODGAS-XWR2 in Stand-Alone Mode, the SAT Sensor always Module. (Figure 8, page 14). attaches to the Primary MODGAS-XWR2.

  • Page 11: Two Modulating Valves, One Ignitor, One Stage (2V1Ign1S)

    12 Relay If using an MHGRV-X Module along with the secondary E-BUS Expansion Module. (Figure 8, page 14). MODGAS-XWR2 in Stand-Alone Mode, the SAT Sensor always attaches to the primary MODGAS-XWR2. Check your Fan Relay Wiring (RLY1) Schematic for proper wiring.

  • Page 12: Figure 6: Stand-Alone Wiring - Secondary Board 2V1Ign1S

    (RLY5) and Heat 4 (RLY6). Up to 12 additional If using an MHGRV-X Module along with the secondary fixed stages can be added by using the 12 Relay MODGAS-XWR2 in Stand-Alone Mode, the SAT Sensor always E-BUS Expansion Module. (Figure 8, page 14). attaches to the Primary MODGAS-XWR2.

  • Page 13: Two Modulating Valves, Two Ignitors, One Stage (2V2Ign1S)

    Heat 2 (RLY4). Module. (Figure 8, page 14). If using an MHGRV-X Module along with the secondary MODGAS-XWR2 in Stand-Alone Mode, the SAT Sensor always attaches to the Primary MODGAS-XWR2. Check your Fan Relay Wiring (RLY1) Schematic for proper wiring.

  • Page 14: 12 Relay E-Bus Expansion Module

    Note: n = Number of fixed heat stages Note: All relay outputs are normally open configured on MODGAS-XWR2. and rated for 24 VAC power only. 1 amp maximum load. Fixed Heat Stage n + 1...

  • Page 15: Communications Wiring

    I C port on the controller. stages are required, these should be configured and wired to the AAON unit controller’s relays. For all other controllers, use an E-BUS cable connecting to an E-BUS port on the controller. Check your Fan Relay Wiring (RLY1) Schematic for proper wiring.

  • Page 16: Two Modulating Valves, Two Ignitors, One Stage (2V2Ign1S)

    Heat 1 (RLY3) and the second valve is connected these should be configured and wired to the to Heat 2 Relay. AAON unit controller’s relays. For VCM-X Controllers, use an I C cable connecting to the appropriate I C port on the controller.

  • Page 17: Two Modulating Valves, Two Ignitors, Two Stages (2V2Ign2S)

    2 (Gas Valve 2).The first valve is attached to these should be configured and wired to the Heat 1 (RLY3) and the second valve is attached to Heat 2 (RLY4). AAON unit controller’s relays. For VCM-X Controllers, use an I C cable connecting to the appropriate I C port on the controller.

  • Page 18: Figure 12: Communications Wiring - Secondary Board 2V2Ign2S

    (RLY6). If additional fixed stages are required, these should be configured and wired to the This configuration is not supported when using NOTE: AAON unit controller’s relays. C communications. Check your Fan Relay Wiring (RLY1) Schematic for proper wiring. Fan Enable...

  • Page 19: Two Modulating Valves, One Ignitor, One Stage (2V1Ign1S)

    For VCM-X Controllers, use an I C cable connecting to the and wired to the AAON unit controller’s relays. appropriate I C port. For all other controllers, use an E-BUS cable connecting to an E-BUS port on the controller.

  • Page 20: Figure 14: Stand-Alone Wiring - Secondary Board 2V1Ign1S

    (RLY6), and Heat 4 (RLY6). If additional fixed stages are required, these should be configured The Four Modulating Valves Primary/Secondary NOTE: and wired to the AAON unit controller’s relays. configuration is not supported when using I communications. Check your Fan Relay Wiring (RLY1) Schematic for proper wiring.

  • Page 21: Inputs And Outputs

    Gas Valve 1 (and the modulating Gas Valve 2 in the 2V1IGN1S configuration). If the flame does not ignite, the ignition module Analog Inputs will turn off this enable and the MODGAS-XWR2 will turn on (RST IN) Reset Signal the “No Proof of Flame” Alarm.
  • Page 22 RLY5 - Heat 3 Once the MODGAS-XWR2 brings on heat, Heat 3 (RLY5) is the second or third stage of heat if the MODGAS-XWR2 is configured for three stages of heat and will be a fixed heat stage. RLY6 - Heat 4...

  • Page 23: Sequence Of Operation

    The MODGAS-XWR2 can be used in Stand-Alone Mode or Min Mode is used to help eliminate overshoot of the Supply Air connected to a AAON unit controller using an E-BUS or modular Temperature Setpoint as additional stages of heat are activated.

  • Page 24: Heating Mode

    Despite the Supply Air Temperature relation is below 55%, the low speed fan relay will energize. Once it to the Supply Air Temperature Setpoint, the MODGAS-XWR2 goes above 55%, the relay will de-energize and move the fan will continue heating as long as Heat is enabled (through either back into high speed.

  • Page 25: Valve Failure, Force Mode And Master Vs. Normal

    In order to help clarify operating modes, master and normal continues normal operation and moves to the next fixed stages. are used to denote two MODGAS-XWR2 boards that are Every ignition retry period (set in the hidden configurations communicating with one another. With one MODGAS-XWR2,...

  • Page 26: Lcd Screens

    The MENU key cancels editing when in Edit Mode. The screen you were editing will return to its original value and the underscore will disappear. A second press of the MENU key will return you to the Main Menu. Table 4: Editing Key Functions MODGAS-XWR2 Technical Guide...

  • Page 27: Main Screens Map

    ALARMS Screens. Press to go to SLAVE ALARMS Screens. SLAVE ALARMS Press to scroll through SLAVE ALARMS Screens. Note: This screen only displays if a secondary MODGAS-XWR2 is present. Press to go to SETPOINT MENU Screens. SETPOINT MENU Press to scroll through FORCE VALVES Screens.

  • Page 28: Main Screens

    SLAVE_MODE: If the module is acting as a secondary module to another MODGAS-XWR2 Module, then it operates in this control state. This mode limits many Module operations (e.g. the PID Loop does not run in this mode). In this mode, the board essentially mimics the operation of the MASTER MODGAS-XWR2 board.
  • Page 29 PID Loop control. A secondary module in this mode simply mimics the FAN SPEED STATUS operation of the MASTER XWR2 board. Low, High, Off TEST_MODE: If the module is being tested through Prism, the module will move into this mode to operate (e.g. turn relays on/off). MODGAS-XWR2 Technical Guide...

  • Page 30: Alarms Menu And Slave Alarms

    12 RELAY BOARD COMM LOSS: Communications have been lost with the 12 Relay Expansion Board. This alarm will disable when communications resume. STAGE 1 FAILURE: Indicates a failure to ignite Stage 1 Heat. STAGE 2 FAILURE: Indicates a failure to ignite Stage 2 Heat. MODGAS-XWR2 Technical Guide...

  • Page 31: Setpoint Screens

    It will only display in Stand-Alone Mode. The Reset Setpoint is set by the LCD Display in Stand-Alone Mode key must be pressed after and is set by the AAON unit controller in Communications Mode. WARNING: <ENTER>...

  • Page 32: Force Valves Screens

    FORCE ON STAGE 2 FORCE ON/OFF <UP> Press the button to turn the Force Mode on. Press the <DOWN> button to turn the Force Mode off. If the screen says DISABLED, the ON/OFF selection is not possible. MODGAS-XWR2 Technical Guide...

  • Page 33: Protected And Configuration Screens

    OPERATION MODE CONFIG Normal or Master. Default is Normal. This screen is used to set a Primary MODGAS-XWR2 board as a master board. If only using one MODGAS-XWR2 board, this should be set to normal. ENTER TO...

  • Page 34: Configuration Screens

    NOTE: If it is set to 0, Min Mode will not initialize and the sequence will continue to Heating Mode. STG UP DLY 1 STAGE UP DELAY MinPosTP Range is 1 to 10 minutes. Default is 3. XXXs MIN MODE RUN TIME Range: 0-500 seconds. MODGAS-XWR2 Technical Guide...

  • Page 35: Troubleshooting

    Communication LED This yellow LED will light up and blink when COMM: The MODGAS-XWR2 is equipped with LEDs that can be used communications are detected. to verify operation and perform troubleshooting. There are LEDs for communication, operation modes, and diagnostic codes. The Relay LEDs module has 14 LEDs—12 used for operation and status, and two...

  • Page 36: Figure 16: Modgas-Xwr2 Led Locations And Descriptions

    PROOF OF IGNITION 2 LED SERIAL # AUX. (AI) GAS VALVE TERMINALS GAS VALVE 2 LED PROOF OF IGNITION 2 LABEL P/N: DUAL G041530 CONNECT E-BUS ASSEMBLED IN USA .01UF Figure 16: MODGAS-XWR2 LED Locations and Descriptions MODGAS-XWR2 Technical Guide...

  • Page 37: Alarms

    Troubleshooting Alarms Communications Loss • Check COMM LED on MODGAS-XWR2. Mechanical Failure • Verify 18-30 VAC power to all interconnected AAON • Check relay outputs on the MODGAS-XWR2 for unit controllers. 18-30 VAC output. • Verify E-BUS connection between the MODGAS- •...

  • Page 38: Sat Sensor Testing

    Note: If the voltage is above 3.3 VDC the sensor or wiring is “open.” If the voltage is less than 0.05 VDC, the sensor or wiring is shorted. Table 7: 0-3V Temperature Sensor - Voltage and Resistance for Type III Sensors MODGAS-XWR2 Technical Guide...

  • Page 39: Table 8: 0-5V Temperature Sensor - Voltage And Resistance For Type Iii Sensors

    Note: If the voltage is above 5.08 VDC the sensor or wiring is “open.” If the voltage is less than 0.05 VDC, the sensor or wiring is shorted. Table 8: 0-5V Temperature Sensor - Voltage and Resistance for Type III Sensors MODGAS-XWR2 Technical Guide...

  • Page 40: Appendix A: Sat Sensor

    When communicating with AAON unit controllers, the SAT Sensor will be connected to the AAON unit controller. For best accuracy, apply insulation on the outside of the duct, The exception would be in retrofit applications with older over the sensor.

  • Page 41: Sat Sensor Wiring Guide And Jumper Settings

    Table 8, page 39 for jumper setting 2. ** For SAT Sensor testing, use Table 8, page 39 for jumper setting ** Set MHGRV-X SAT Option to MODGAS-XWR2. See the 1. SAT should be connected to the MODGAS-XWR2. MHGRV-X Technical Guide for more information.

  • Page 42: Appendix B: Modgas-Xwr Replacement

    MODGAS-XWR and replug them into the MODGAS- MODGAS-XWR2 XWR2 board. The retrofit replacement involves a few easy steps. Refer to Wire the MODGAS-XWR2 relays according to the Step 6: Figure 18, this page. valve configuration you will be using. Disconnect power from the MODGAS-XWR module.
  • Page 43 MODGAS-XWR2 Technical Guide V22330 · Rev. D · 211101 AAON Factory Technical Support: 918-382-6450 techsupport@aaon.com AAON Controls Support: 866-918-1100 Monday through Friday, 7:00 AM to 5:00 PM Central Standard Time Controls Support website: www.aaon.com/controlstechsupport NOTE: Before calling Technical Support, please have the model and serial number of the unit available.

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