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AAON ASM01668, Technical Manual

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MODGAS-X Technical Guide

V16940 · Rev. J · 210617

2425 South Yukon Ave • Tulsa, OK • 74107-2728

Ph: (918) 583-2266 • Fax: (918) 583-6094

AAON P/N: 

V16940

, Rev. J

Printed in the USA • Copyright June 2021 • All Rights Reserved 

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

AAON Factory Technical Support: 918-382-6450 

[email protected]

NOTE:

 Before calling Technical Support, please have the 

model and serial number of the unit available.

PARTS:

 For replacement parts, please contact your local 

AAON Representative.

Summary of Contents for ASM01668

Page 1: ...MODGAS X Module Technical Guide ...

Page 2: ...ghts reserved AAON is a registered trademark of AAON Inc Tulsa OK AAON assumes no responsibility for errors or omissions in this document This document is subject to change without notice www aaon com MODGAS X PARTS REFERENCE PART DESCRIPTION PART NUMBER MODGAS X Module ASM01668 MODGAS X Low Turn Down Module ASM01669 MHGRV X Module ASM01670 MHGRV II Module replaced by ASM01670 MHGRV III Module rep...

Page 3: ...ating Staged Valves Communicating Wiring 15 INPUTS AND OUTPUTS 16 Inputs and Outputs 16 SEQUENCE OF OPERATION 18 Operating Modes 18 LCD SCREENS 20 Navigation Keys 20 Main Screens Map 21 MODGAS X Screens 22 Status and Alarms Screens 23 Setpoint and Force Screens 24 Protected and Diagnostic Screens 25 Configuration Screens 26 TROUBLESHOOTING 28 LED Diagnostics 28 Alarms 30 SAT Sensor Testing 31 APPE...

Page 4: ... Valve No Staging Stand Alone Wiring Diagram 8 Figure 3 Single Modulating Valve No Staging Communicating Wiring Diagram 9 Figure 4 Single Modulating Valve Stand Alone Wiring Diagram 10 Figure 5 Single Modulating Valve and 14 Stages of Fixed Heat 12 Relay E BUS Expansion Module 11 Figure 6 Two Modulating Valves Stand Alone 12 Figure 7 Two Modulating Valves and 13 Stages of Fixed Heat 12 Relay E BUS...

Page 5: ...configurations One modulating valve Two staged modulating valves One or two modulating with multiple fixed staged valves Stand Alone Mode only The MODGAS X can be configured at the factory for the MAXITROL 0 20 volt valve s or the MAXITROL EXA STAR 0 10 volt stepper valve s See Appendix C page 36 for depiction When using the MODGAS X to replace an existing MODGAS II see Appendix B page 35 for deta...

Page 6: ...L210 R 1uF 01uF 1962 2803 1212 6042 1502 1020 1002 2211 47uF 22uF 3 3uF 2211 2211 2211 5 73 2 62 2 04 4 09 0 57 0 21 5 04 5 63 5 24 1 68 1 20 0 25 MODGAS X AAON P N ASM01668 LABEL P N G041210 E BUS CONNECT I2C CONNECT 24 VAC GND CONTACT RATING 24 VAC IS 1 AMP MAX VOUT GND GAS VALVE TERMINALS COMM RELAY OUTPUT TERMINALS INPUT TERMINALS TYPE HEAT EN BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX...

Page 7: ... inserted and tightened into the terminal blocks Do not allow wire strands to stick out and touch adjoining terminals which could potentially cause a short circuit 7 When communication wiring is to be used to interconnect AAON unit controllers together or to connect to other communication devices all wiring must be plenum rated minimum 18 gauge two conductor twisted pair with shield AAON can suppl...

Page 8: ...put terminals maximum power consumption One Gas Valve 18 VA Two Gas Valves 33 VA Note 1 24 VAC must be connected so that all ground wires remain common 2 All wiring to be in accordance with local and national electrical codes and specifications 40 VA transformer minimum 18 30 VAC GND Line Connect SAT and GND Input to Reheat board s SAT Input if applicable 0 10 VDC External Reset Signal Heat Enable...

Page 9: ...so that all ground wires remain common 2 All wiring to be in accordance with local and national electrical codes and specifications 40 VA transformer minimum 18 30 VAC GND Line Supply Air Temperature Sensor Mount in unit supply air duct GV2 GV1 CR1 H1 CR2 Two gas valves can be connected as shown MODGAS X AAON P N ASM01668 LABEL P N G041210 E BUS CONNECT I2C CONNECT 24 VAC GND CONTACT RATING 24 VAC...

Page 10: ...fall back to using only its onboard stages If communications is restored the MODGAS X will begin staging up if needed Fan Enable And Stage 1 Heat Mod Low Speed Fan See for jumper settings Only one Supply Air Temperature Sensor can be used per application SAT OPTIONS Table 24 VAC power input terminals maximum power consumption One Gas Valve 18 VA Note 1 24 VAC must be connected so that all ground w...

Page 11: ...Stage 15 Fixed 18 30 VAC GND 18 30 VAC GND power required 15 VA minimum E BUS cable connects to MODGAS X Figure 5 Single Modulating Valve and 14 Stages of Fixed Heat 12 Relay E BUS Expansion Module WARNING Observe Polarity All boards must be wired with GND to GND and 24 VAC to 24 VAC Failure to observe polarity will result in damage to one or more of the boards Expansion modules must be wired in s...

Page 12: ...t GV2 24 VAC power input terminals maximum power consumption One Gas Valve 18 VA Two Gas Valves 33 VA YS102378 REV 1 Two Modulating Valves with up to 13 Additional Stages of Fixed Heat Stand Alone Wiring This configuration only applies to Stand Alone Mode Figure 6 this page and is factory configured In this configuration the first Modulating Valve is enabled by the FAN Relay RLY1 The second Modula...

Page 13: ...Stage 15 Fixed 18 30 VAC GND 18 30 VAC GND power required 15 VA minimum E BUS cable connects to MODGAS X Figure 7 Two Modulating Valves and 13 Stages of Fixed Heat 12 Relay E BUS Expansion Module WARNING Observe Polarity All boards must be wired with GND to GND and 24 VAC to 24 VAC Failure to observe polarity will result in damage to one or more of the boards Expansion modules must be wired in suc...

Page 14: ...t GV2 GV1 CR1 H1 CR2 MODGAS X AAON P N ASM01668 LABEL P N G041210 E BUS CONNECT I2C CONNECT 24 VAC GND CONTACT RATING 24 VAC IS 1 AMP MAX VOUT GND GAS VALVE TERMINALS COMM RELAY OUTPUT TERMINALS INPUT TERMINALS TYPE HEAT EN BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI AUX 1 LOW SPEED FAN AUX 2 Stage 2 Heat Mod H2 YS102378 REV 1 Two Modulating Staged Valves Wiring In this configuration the...

Page 15: ...AUX 1 LOW SPEED FAN AUX 2 Connect Supply Air Temperature Sensor to AI2 and GND or AI3 and GND on main controller This does not apply to retrofit applications See SAT Wiring Conditions Table I C cable connects to I C Port on any non VCCX2 or VCB X Controller or expansion module 2 2 E BUS cable connects to VCCX2 or VCB X Controller s expansion port Stage 2 Heat Mod H2 YS102378 REV 1 Two Modulating S...

Page 16: ...put will supply a 0 20 VDC or 0 10 VDC output signal for control of the modulating gas valve With a 0 20 VDC valve the operation is reverse acting so high voltage means closed and low voltage means open With a 0 10 VDC valve the operation is direct acting WARNING For 0 20VDC valves the maximum number that can be connected configured is two For 0 10 VDC valves the maximum number that be can connect...

Page 17: ...tpoint The Stage Up Delay default is three minutes The Stage Down Delay default is one minute 12 Relay E BUS Expansion Module Stages 4 15 Fixed Heat These relays should only be used in Stand Alone Mode when more than three stages of heat are configured These relays will successively stage up based on the Stage Up Delay to maintain the configured Supply Air Temperature Setpoint This stage and any a...

Page 18: ...ght gas valves for 0 10 volt valves to maintain a desired Discharge Air Temperature It also controls the speed of the induced draft fan to maintain proper combustion in the heat exchanger Off Mode 1 If the Heating is disabled the unit will be in the Off Mode 2 In this mode the unit will be completely shut off 3 The Heat Valve Output will be set to 100 4 Once the unit enters the Off Mode it will st...

Page 19: ...ated if the valve modulates above 34 3 4 VDC for five seconds Additional Stages of Heat If the MODGAS X is controlling more than one Stage of Heat it will use the following staging sequence 1 If the ModGas Valve Signal is at 100 for three minutes adjustable the Aux Relays will stage up If the Supply Air Temperature is 32 F or less the stage up delay will reset to one minute 2 If the ModGas Valve S...

Page 20: ...o navigate through the Main Menu Screen categories Editing Key Key Function UP or DOWN Use the UP or DOWN key to enter editing mode on a user adjustable screen Edit Mode is indicat ed by the underscore appearing on the screen NOTE Entering Edit Mode will also adjust the value up one UP key or down one DOWN key so you may have to readjust the value ENTER Use the ENTER key to move through the digits...

Page 21: ... ALARMS Press to scroll through the ALARMS Screens Press to go to the SETPOINT Screens SETPOINT Press to scroll through the SETPOINT Screens Press to go to the FORCE VALVES Screens FORCE VALVES Press to scroll through the FORCE VALVES Screens Main Screens Map Refer to the following map when navigating through the LCD Main Screens The first screen is an initialization screen To scroll through the r...

Page 22: ...et length errors This will stop at 9999 until power is cycled Example P XXXX 4 Number of initialization errors if communication is I2 C Example I XXXX SOFTWARE 1044 V XXX CURRENT SOFTWARE VERSION ADDRESS 1 138 CURRENT BOARD ADDRESS Number in parenthesis is E BUS address VALV CONFG 0 20 VLT VALVE CONFIGURATION 0 20 Volt standard MODGAS X Module 0 10 Volt 10 to 1 ratio MODGAS X Screens From the MODG...

Page 23: ...mperature Sensor has been disconnected for more than 60 seconds This alarm will be disabled when the sensor is reconnected VLV POS 100 VALVE POSITION 0 to 100 SA TEMP XX X SUPPLY AIR TEMPERATURE 40ºF to 200ºF 5ºC to 93ºC If no sensor is detected screen will display NO SENSR ACTIV SP XX X ACTIVE SUPPLY AIR SETPOINT Calculated from SAT Setpoint and Reset Signal in Stand Alone Mode In Communications ...

Page 24: ... F RESET HEATING SUPPLY AIR SETPOINT This is the maximum temperature at which the Supply Air Temperature 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 Minimum Default Maximum 40ºF 120ºF 200ºF 5ºC 49ºC 93ºC Force Screens Refer to the following map when navigating t...

Page 25: ...of the screens press the MENU button Diagnostic Screens Refer to the following map when navigating through the Diagnostic Screens From the DIAGNSTC Screen press ENTER to scroll through the screens DIAGNSTC VLV VOLT X XX GAS VALVE VOLTAGE 0 20 Volts WDOG CNT WATCHDOG TIMER Displays the number of times the board has been reset due to watchdog timer overflow PWER CNT POWER LOSS COUNT Displays the num...

Page 26: ... You must press the ENTER key in order to save the configuration so that when any power cycles the unit will run with the saved settings MOD STG 1 NUMBER OF MODULATING STAGES 0 20 Volt Range is 1 or 2 Default is 1 0 10 Volt Range is 1 to 8 Default is 1 ADDRESS 1 TO 4 CURRENT ADDRESS OF THE BOARD The address is only used in Communications Mode Default 1 STG UP DLY 1 STAGE UP DELAY Range is 1 to 10 ...

Page 27: ...nd and subsequent stages of heat Range 1 120 seconds St MinDb XXº MIN MODE DEADBAND Range 0 30 degrees NOTE If it is set to 0 Min Mode will not initialize and the sequence will continue to Heating Mode MinPosTP XXXs MIN MODE RUN TIME Range 0 500 seconds LCD SCREENS Configuration Screens ...

Page 28: ...ll blink an alarm code when an alarm s occurs The highest priority failure code will be indicated first You must correct the highest priority alarm before other problems will be indicated See Table 7 this page Communication LED COMM This yellow LED will light up and blink when communications are detected Relay LEDs RLY1 This green LED will light up and stay lit as long as the Fan Relay is active R...

Page 29: ...GAS X AAON P N ASM01668 LABEL P N G041210 E BUS CONNECT I2C CONNECT 24 VAC GND CONTACT RATING 24 VAC IS 1 AMP MAX VOUT GND GAS VALVE TERMINALS COMM RELAY OUTPUT TERMINALS INPUT TERMINALS TYPE HEAT EN BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI AUX 1 LOW SPEED FAN AUX 2 YS102378 REV 1 Figure 11 MODGAS X LED Locations and Descriptions TROUBLESHOOTING LED Diagnostics ...

Page 30: ...and GND on specificAAON unit controllers Communications Mode Remove SAT and GND wiring from MODGAS X and ohm the sensor out this may indicate open or failed wiring Refer to Table 8 page 31 and Table 9 page 32 Verify the SAT OPTIONS jumper settings on the MODGAS X for the Supply Air Temperature Sensor See Table 11 page 34 Sat Cutoff Mode Remove SAT and GND wiring from the MODGAS X and ohm the senso...

Page 31: ...nected from the controllers not powered 2 Use the voltage column to check sensors while connected to powered controllers Read voltage with meter set on DC volts Place the minus lead on GND terminal and the plus lead on the sensor input terminal being investigated Table 8 0 3V Temperature Sensor Voltage and Resistance for Type III Sensors Temp F Temp C Resistance Ohms Voltage Input VDC 10 23 3 9333...

Page 32: ...4 45902 4 200 20 6 6 40147 4 095 25 3 9 35165 3 982 30 1 1 30805 3 862 35 1 7 27140 3 737 40 4 4 23874 3 605 45 7 2 21094 3 470 50 10 18655 3 330 52 11 1 17799 3 275 54 12 2 16956 3 217 56 13 3 16164 3 160 58 14 4 15385 3 100 60 15 6 14681 3 042 62 16 7 14014 2 985 64 17 8 13382 2 927 66 18 9 12758 2 867 68 20 12191 2 810 69 20 6 11906 2 780 70 21 1 11652 2 752 71 21 7 11379 2 722 Temperature to R...

Page 33: ...he SAT sensor is shared between the two modules and always attaches to the MODGAS X See Table 11 page 34 for SAT Options Jumper Settings and see Figures 2 4 5 6 7 and 8 for wiring See Table 10 page 34 for details about retrofit applications Communications Mode When communicating with AAON unit controllers the SAT Sensor will be connected to the AAON unit controller The exception would be in retrof...

Page 34: ...nnect to AAON unit controller using I2 C cable Install Supply Air Sensor on MHGRV X Connect to AAON unit controller using I2 C cable Install Supply Air Sensor on MODGAS X Connect to AAON unit controller using I2 C cable Table 10 SAT Wiring Conditions STAND ALONE MODE SAT OPTIONS JUMPER SETTINGS Condition Jumper Setting MODGAS X only 1 MODGAS X with MHGRV X 1 MODGAS X with MHGRV II 2 MODGAS X with ...

Page 35: ...er or module it is currently on If it is currently installed on the MODGAS II module then reinstall it on the MODGAS X Step 3 Set the SAT Options Jumper per Table 12 page 34 Step 4 Connect power to the MODGAS X I C cable connects to AAON unit controller s expansion port 2 See for Jumper Settings Only one Supply Air Temperature Sensor can be used per application SAT OPTIONS Table 18 30 VAC GND Supp...

Page 36: ...cal Guide Figure 14 Two Wire 0 20 Volt Reverse Acting MAXITROL Selectra Stepper Valve Figure 15 Four Wire 0 10 Volt Directing Acting MAXITROL EXA STAR Stepper Valve APPENDIX C MAXITROL VALVES MAXITROL Stepper Valve Types ...

Page 37: ...37 MODGAS X Technical Guide NOTES ...

Page 38: ...ved 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 AAON Factory Technical Support 918 382 6450 techsupport aaon com NOTE Before calling Technical Support please have the model and serial number of the unit available PARTS For replacement parts please contact your local AAON Representative ...

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