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

AAON MODGAS-XWR2-B Technical Manual

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MODGAS-XWR2-B Module
Technical Guide

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Summary of Contents for AAON MODGAS-XWR2-B

  • Page 1 MODGAS-XWR2-B 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

    Main Screens Map ..............................28 Main Screens ................................ 29 Status Screens ..............................30 Alarms Menu and Slave Alarms ..........................31 Setpoint Screens ..............................32 Force Valves Screens ............................33 Protected and Configuration Screens ........................34 Configuration Screens ............................35 MODGAS-XWR2-B Technical Guide...
  • Page 4 Alarms ................................... 38 SAT Sensor Testing ............................... 39 APPENDIX A: SAT SENSOR .......................... 41 Installation ................................41 SAT Sensor Wiring Guide and Jumper Settings ....................42 APPENDIX B: MODGAS-XWR REPLACEMENT ..................43 MODGAS-XWR2-B Replacement of MODGAS-XWR ..................43 MODGAS-XWR2-B Technical Guide...
  • Page 5 ..........20 Communications Wiring - Secondary Board 2V1IGN1S Figure 14: .................. 21 LCD Display and Navigation Keys Figure 15: ........................27 MODGAS-XWR2-B LED Locations and Descriptions Figure 16: ..................37 Supply Air Temperature Sensor Installation Figure 17: ....................... 41 MODGAS-XWR2-B Module Figure 18: ..........................

  • Page 6: Overview

    The MODGAS-XWR2-B can also control additional fixed valves for additional stages of heat by using the additional heat relays on the board itself. When the MODGAS-XWR2-B is attached to one of the listed AAON unit controllers, these additional stages are controlled through the AAON unit controller.

  • Page 7: Dimensions

    AUX. (AI) GAS VALVE TERMINALS PROOF OF IGNITION 2 LABEL P/N: DUAL G112180 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-B Module Dimensions MODGAS-XWR2-B Technical Guide...

  • Page 8: Wiring

    The 24 VAC power must be connected so that all ground wires remain common. If after making all these checks, the POWER LED does not light up, please contact AAON Controls Support for assistance. MODGAS-XWR2-B Technical Guide...

  • Page 9: Stand-Alone Wiring

    2. All wiring to be in accordance with local and national minimum 12 Relay E-BUS Expansion electrical codes and specifications. Module or secondary Line MODGAS-XWR-2 series module. Figure 2: Stand-Alone Wiring - One Modulating Valve, One Ignitor, One Stage MODGAS-XWR2-B Technical Guide...

  • Page 10: Two Modulating Valves, Two Ignitors, Two Stages (2V2Ign2S)

    12 Relay E-BUS Expansion Module. (Figure 8, page 15). If using an MHGRV-X series module along with the MODGAS- XWR2-B in Stand-Alone Mode, the SAT Sensor always attaches to the MODGAS-XWR2-B. Check your Fan Relay Wiring (Both RLY1 and RLY2) Schematic for proper wiring.

  • Page 11: Secondary Board - Four Modulating Valves, Two Ignitors, Two Stages (2V2Ign2S)

    12 Relay E-BUS Expansion Module. If using an MHGRV-X series module along with the secondary (Figure 8, page 15). MODGAS-XWR2-B in Stand-Alone Mode, the SAT Sensor always attaches to the Primary MODGAS-XWR2-B. Check your Fan Relay Wiring (Both RLY1 and RLY2) Schematic for proper wiring.

  • Page 12: Two Modulating Valves, One Ignitor, One Stage (2V1Ign1S)

    12 Relay E-BUS Expansion Module. (Figure 8, page 15). If using an MHGRV-X series module along with the secondary MODGAS-XWR2-B in Stand-Alone Mode, the SAT Sensor always attaches to the primary MODGAS-XWR2-B. Check your Fan Relay Wiring (Both RLY1 and RLY2) Schematic for proper wiring.

  • Page 13: Secondary Board - Four Modulating Valves, One Ignitor, One Stage (2V1Ign1S)

    12 Relay E-BUS Expansion If using an MHGRV-X series module along with the secondary Module. (Figure 8, page 15). MODGAS-XWR2-B in Stand-Alone Mode, the SAT Sensor always attaches to the Primary MODGAS-XWR2-B. Check your Fan Relay Wiring (Both RLY1 and RLY2) Schematic for proper wiring.

  • Page 14: Two Modulating Valves, Two Ignitors, One Stage (2V2Ign1S)

    12 Relay E-BUS Expansion Module. (Figure 8, page 15). If using an MHGRV-X series module along with the secondary MODGAS-XWR2-B in Stand-Alone Mode, the SAT Sensor always attaches to the Primary MODGAS-XWR2-B. Check your Fan Relay Wiring (Both RLY1 and RLY2) Schematic for proper wiring.

  • Page 15: 12 Relay E-Bus Expansion Module

    Fixed Heat Stage n + 6 Fixed Heat Stage n + 7 Fixed Heat Stage n + 8 18-30 E-BUS cable connects to a MODGAS-XWR2 series module or E-BUS Adapter Hub Figure 8: Stand-Alone Wiring - 12 Relay E-BUS Expansion Module MODGAS-XWR2-B Technical Guide...

  • Page 16: Communications Wiring

    Heat 4 (RLY6). If additional fixed stages are Use an E-BUS cable connecting to an E-BUS port on the controller. required, these should be configured and wired to the AAON unit controller’s relays. Check your Fan Relay Wiring (Both RLY1 and RLY2) Schematic for proper wiring.

  • Page 17: Two Modulating Valves, Two Ignitors, One Stage (2V2Ign1S)

    (RLY6). If additional fixed stages are required, these to Heat 1 (RLY3) and the second valve is connected to Heat 2 Relay. should be configured and wired to the AAON unit controller’s relays. Use an E-BUS cable connecting to an E-BUS port on the controller..

  • Page 18: Two Modulating Valves, Two Ignitors, Two Stages (2V2Ign2S)

    (RLY6). If additional fixed stages are required, these (Gas Valve 2).The first valve is attached to Heat 1 (RLY3) and the should be configured and wired to the AAON unit second valve is attached to Heat 2 (RLY4). controller’s relays.

  • Page 19: Secondary Board - Four Modulating Valves, Two Ignitors, Two Stages (2V2Ign2S)

    Heat 3 (RLY5) and Heat 4 creating four modulating valves as two stages. (RLY6). If additional fixed stages are required, these should be configured and wired to the AAON unit controller’s relays. Check your Fan Relay Wiring (Both RLY1 and RLY2) Schematic for proper wiring.

  • Page 20: Two Modulating Valves, One Ignitor, One Stage (2V1Ign1S)

    Heat 4 (RLY6). If additional fixed stages are connected to Heat 1 (RLY3). 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.

  • Page 21: Secondary Board - Four Modulating Valves, One Ignitor, One Stage (2V1Ign1S)

    Heat 4 (RLY6). If additional fixed stages are required, these should be configured and wired to the AAON unit controller’s relays. Check your Fan Relay Wiring (Both RLY1 and RLY2) Schematic for proper wiring.

  • Page 22: Inputs And Outputs

    Mode; it is not required when used as an expansion board to other Analog Inputs AAON unit controllers. The Heat Enable input is activated by a 24 (RST IN) Reset Signal VAC signal. The module will not operate without 24 VAC being applied to this input terminal when used in a Stand-Alone Mode.

  • Page 23: Relay Outputs

    RLY6 - Heat 4 Once the MODGAS-XWR2-B heating mode is enabled, Heat 4 (RLY6) is the third or fourth stage of heat if the MODGAS-XWR2-B is configured for four stages of heat and will be a fixed heat stage. MODGAS-XWR2-B Technical Guide...

  • Page 24: Sequence Of Operation

    The MODGAS-XWR2-B 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 25: Heating Mode

    Despite the Supply Air Temperature relation to sequence, if the valve position is below 55%, the combustion fan the Supply Air Temperature Setpoint, the MODGAS-XWR2-B will low speed relay (RLY2 - LOW SPEED) will energize. Once it goes...

  • Page 26: Valve Failure, Force Mode And Master Vs. Normal

    In order to help clarify operating modes, master and normal are process. used to denote two MODGAS-XWR2 series boards that are communicating with one another. With one MODGAS-XWR2-B, Force Mode the maximum number of modulating valves is two, but with two boards the maximum is four (two for each board).

  • Page 27: Lcd Screens

    The MENU key cancels editing when in Edit Mode. The screen you were editing will return to its original MENU 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-B Technical Guide...

  • Page 28: Main Screens Map

    MENU Press to scroll through ALARMS Screens. Press to go to SLAVE ALARMS Screens. SLAVE ALARMS Press to scroll through SLAVE ALARMS Screens. This screen only displays if a secondary MODGAS- Note: XWR2 series module is present. MODGAS-XWR2-B Technical Guide...

  • Page 29: Main Screens

    FORCED_STAND_ALONE: In this mode, the module acts as the master MODULATION CONFIGURATION communicating to either another MODGAS-XWR2-B Module or a 12 Values are in the format xVyIGNzS, where x is the number of valves Relay Module for additional fixed stages. The only way to leave this (V), y is the number of ignitors (IGN) and z is the number of stages (S).

  • Page 30: Status Screens

    MASTER XWR2 series board. 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). VALVE 1 100% VALVE 1 POSITION 0% to 100% or Closed MODGAS-XWR2-B Technical Guide...

  • Page 31: 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-B Technical Guide...

  • Page 32: Setpoint Screens

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

  • Page 33: 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-B Technical Guide...

  • Page 34: Protected And Configuration Screens

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

  • Page 35: 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-B Technical Guide...

  • Page 36: Troubleshooting

    Communication LED This yellow LED will light up and blink when COMM: The MODGAS-XWR2-B 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 37: Figure 16: Modgas-Xwr2-B 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 G112180 E-BUS ASSEMBLED IN USA . 01UF Figure 16: MODGAS-XWR2-B LED Locations and Descriptions MODGAS-XWR2-B Technical Guide...

  • Page 38: Alarms

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

  • Page 39: 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-B Technical Guide...

  • Page 40: 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-B Technical Guide...

  • Page 41: Appendix A: Sat Sensor

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

  • Page 42: Sat Sensor Wiring Guide And Jumper Settings

    MODGAS-XWR2 AND MHGRV-X ONLY Stand- Install Supply Air Sensor in Install Supply Air Sensor in MHGRV-X Install sensor in MODGAS-XWR2-B and daisy-chain it to Alone MODGAS-XWR2-B. series module. Set “SAT Options” the MHGRV-X. Set “SAT Options” Jumpers to “MODGAS Jumpers to Normal”.

  • Page 43: Appendix B: Modgas-Xwr Replacement

    MODGAS-XWR2-B Replacement of MODGAS-XWR Replacing the MODGAS-XWR with the Unplug the TB2 input terminal block from the MODGAS- Step 4: XWR and replug it into the MODGAS-XWR2-B board. MODGAS-XWR2-B Unplug the Ignition blocks and Valve headers from the Step 5: The retrofit replacement involves a few easy steps.
  • Page 44 PARTS: For replacement parts, please contact your local AAON Representative. 2425 South Yukon Ave • Tulsa, OK • 74107-2728 Ph: (918) 583-2266 • Fax: (918) 583-6094 AAON P/N: G112860, Rev. A Printed in the USA • Copyright July 2022 • All Rights Reserved...

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