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MODGAS-XWR2 Technical Guide

ASSEMBLED IN USA

U15

D13

R61

C28

SERIAL #

POWER

COMM

ALARM

STATUS

TB3

GND

AUX AIN

GND

1
2

SAT

OPTIONS

RESET IN

HEAT EN

AUX BIN

GND

J1 U1

TB2

YS102408 REV 3

TB1

RLY1

RLY2

RLY3

RLY4

RLY5

RLY6

COMMON

PO-IGN1

R33

PO-IGN2

D10

R36

C35

.01UF

R22

R18

R16

R12

R13

R42

R44

D14

SOFTWARE

C22

C27

GAS VALVE 2

GAS VALVE 1

ALARM

DOWN

ENTER

MODGAS-XWR2

AAON P/N: ASM01695

LABEL P/N:

G041530

E-BUS

DUAL

I2C

CONNECT

+24

GND

@ 24 VAC

1 AMP MAX

CONTACT

RATING IS

COMMON

RELAY

OUTPUTS

GAS VALVE

TERMINALS

GAS

LVE

GAS

LVE

INPUT TERMINALS (TYPE)

HEAT ENABLE (BI)

AUX. (BI)

GND

RESET IN (AI)
SAT IN (AI)
GND (AI)

GND

AUX. (AI)

www.aaon.com

LOW SPEED

HEAT 1

HEAT 2

HEAT 3
HEAT 4

PROOF OF IGNITION 1

PROOF OF IGNITION 2

FAN

STATUS LED

ALARM LED

COMM LED

POWER LED

NOT USED

HEAT ENABLE LED

FAN LED

LOW SPEED FAN LED

HEAT ENABLE 1 LED

HEAT ENABLE 2 LED

HEAT ENABLE 3 LED

HEAT ENABLE 4 LED

PROOF OF IGNITION 1 LED

GAS VALVE 1 LED

PROOF OF IGNITION 2 LED

GAS VALVE 2 LED

Figure 16: MODGAS-XWR2 LED Locations and Descriptions

TROUBLESHOOTING

LED Diagnostics

Summary of Contents for ASM01695

Page 1: ...MODGAS XWR2 Module Technical Guide ...

Page 2: ... trademark of Emerson Climate Technologies Inc St Louis MO AAON assumes no responsibility for errors or omissions in this document This document is subject to change without notice www aaon com MODGAS XWR2 PARTS REFERENCE PART DESCRIPTION PART NUMBER MODGAS XWR2 Module ASM01695 12 Relay E BUS Expansion Module ASM01873 VCCX2 Controller ASM01698 MHGRV X Module ASM01670 Supply Air Temperature Sensor ...

Page 3: ... Modulating Valves Two Ignitors Two Stages 2V2IGN2S 17 Two Modulating Valves One Ignitor One Stage 2V1IGN1S 19 INPUTS AND OUTPUTS 21 Inputs and Outputs 21 SEQUENCE OF OPERATION 23 Operating Modes and Min Mode 23 Heating Mode 24 Valve Failure Force Mode and Master vs Normal 25 LCD SCREENS 26 Navigation Keys 26 Main Screens Map 27 Main Screens 28 Alarms Menu and Slave Alarms 30 Setpoint Screens 31 F...

Page 4: ... Ignitors Two Stages 9 Figure 4 Stand Alone Wiring Secondary Board 2V2IGN2S 10 Figure 5 Stand Alone Wiring Two Modulating Valves One Ignitor One Stage 11 Figure 6 Stand Alone Wiring Secondary Board 2V1IGN1S 12 Figure 7 Stand Alone Wiring Two Modulating Valves Two Ignitors One Stage 13 Figure 8 Stand Alone Wiring 12 Relay E BUS Expansion Module 14 Figure 9 Communications Wiring One Modulating Valve...

Page 5: ...alves with two ignitors on each board The first valve on each board is stage one and the second valve on each board is stage two NOTE Primary Secondary configuration is not supported using I2 C communications VCM X E BUS The MODGAS XWR2 can also control or effect control of additional fixed valves for additional stages of heat by using the additional heat relays on the board itself When the MODGAS...

Page 6: ... PO IGN1 P3 D9 R33 R1 P1 PO IGN2 P4 D10 R36 R2 Q2 R5 P2 C35 01UF R8 R22 R18 R16 R12 R13 R42 R44 D14 SOFTWARE C22 C27 GAS VALVE 2 GAS VALVE 1 ALARM UP DOWN ENTER MENU MODGAS XWR2 AAON P N ASM01695 LABEL P N G041530 E BUS DUAL I2C CONNECT 24 VAC GND 24 VAC 1 AMP MAX CONTACT RATING IS COMMON RELAY OUTPUTS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET...

Page 7: ...rly 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 su...

Page 8: ...TS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT 2 HEAT 3 HEAT 4 PROOF OF IGNITION 1 PROOF OF IGNITION 2 FAN See SAT OPTIONS Tables for Jumper Settings Only one Supply Air Temperature Sensor can be used per application Notes 1 24 VAC must be connected so that all ground wires rem...

Page 9: ...lve 1 0 10VDC External Reset Signal Check your Fan Relay Wiring RLY1 Schematic for proper wiring Heat Valve 2 Fixed Heat Stage 3 Fixed Heat Stage 4 ALARM UP DOWN ENTER MENU MODGAS XWR2 AAON P N ASM01695 LABEL P N G041530 E BUS DUAL I2C CONNECT 24 VAC GND 24 VAC 1 AMP MAX CONTACT RATING IS COMMON RELAY OUTPUTS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GN...

Page 10: ...P N ASM01695 LABEL P N G041530 E BUS DUAL I2C CONNECT 24 VAC GND 24 VAC 1 AMP MAX CONTACT RATING IS COMMON RELAY OUTPUTS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT 2 HEAT 3 HEAT 4 PROOF OF IGNITION 1 PROOF OF IGNITION 2 FAN Notes 1 24 VAC must be connected so that all ground w...

Page 11: ... 1 AMP MAX CONTACT RATING IS COMMON RELAY OUTPUTS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT 2 HEAT 3 HEAT 4 PROOF OF IGNITION 1 PROOF OF IGNITION 2 FAN See SAT OPTIONS Tables for Jumper Settings Only one Supply Air Temperature Sensor can be used per application Notes 1 24 VAC...

Page 12: ...2 R18 R16 R12 R13 R42 R44 D14 SOFTWARE C22 C27 GAS VALVE 2 GAS VALVE 1 ALARM UP DOWN ENTER MENU MODGAS XWR2 AAON P N ASM01695 LABEL P N G041530 E BUS DUAL I2C CONNECT 24 VAC GND 24 VAC 1 AMP MAX CONTACT RATING IS COMMON RELAY OUTPUTS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT ...

Page 13: ...IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT 2 HEAT 3 HEAT 4 PROOF OF IGNITION 1 PROOF OF IGNITION 2 FAN See SAT OPTIONS Tables for Jumper Settings Only one Supply Air Temperature Sensor can be used per application Notes 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 E BUS ...

Page 14: ...to the expansion module will cause the controller to become inoperative until power is restored to the expansion module Note n Number of fixed heat stages configured on MODGAS XWR2 Fixed Heat Stage n 1 18 30 VAC GND 18 30 VAC GND 15 VA minimum power required E BUS cable connects to a MODGAS XWR2 or E BUS Adapter Hub Fixed Heat Stage n 2 Fixed Heat Stage n 3 Fixed Heat Stage n 4 Fixed Heat Stage n ...

Page 15: ...d Heat Stage 2 Fixed Heat Stage 3 Fixed Heat Stage 4 ALARM UP DOWN ENTER MENU MODGAS XWR2 AAON P N ASM01695 LABEL P N G041530 E BUS DUAL I2C CONNECT 24 VAC GND 24 VAC 1 AMP MAX CONTACT RATING IS COMMON RELAY OUTPUTS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT 2 HEAT 3 HEAT 4 PR...

Page 16: ...MODGAS XWR2 AAON P N ASM01695 LABEL P N G041530 E BUS DUAL I2C CONNECT 24 VAC GND 24 VAC 1 AMP MAX CONTACT RATING IS COMMON RELAY OUTPUTS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT 2 HEAT 3 HEAT 4 PROOF OF IGNITION 1 PROOF OF IGNITION 2 FAN Notes 1 24 VAC must be connected so ...

Page 17: ... VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT 2 HEAT 3 HEAT 4 PROOF OF IGNITION 1 PROOF OF IGNITION 2 FAN Notes 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 GV1 CR1 CR2 H1 Line 40 VA transf...

Page 18: ...1 HEAT 2 HEAT 3 HEAT 4 PROOF OF IGNITION 1 PROOF OF IGNITION 2 FAN Notes 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 E BUS cable connects to the primary MODGAS XWR2 GV3 CR3 CR4 H1 Line 40 VA transformer minimum GND 18 30 VAC H2 Proof of Ignition Signal 4 24 VAC GV4 Modulating Gas Valv...

Page 19: ...1 CR1 CR2 H1 Line 40 VA transformer minimum GND 18 30 VAC Modulating Gas Valve 2 GV2 Fixed Heat Stage 2 Fixed Heat Stage 3 Fixed Heat Stage 4 Supply Air Temperature Sensor Mount in unit supply air duct Connect Supply Air Temperature Sensor to AI2 VCM X and VCB X or AI3 VCCX2 and GND on main controller I2 C cable connects to the VCM X E BUS Controller s expansion port E BUS cable connects to the VC...

Page 20: ...EAT ENABLE BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT 2 HEAT 3 HEAT 4 PROOF OF IGNITION 1 PROOF OF IGNITION 2 FAN Notes 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 E BUS cable connects to the primary MODGAS XWR2 GV3 CR3 CR4 H1 Line 40 VA t...

Page 21: ...oof of Ignition 2 PO IGN2 The Proof of Ignition input is activated by a 24 VAC signal supplied from the ignition module to enable the modulating Gas Valve 2 If the flame does not ignite the ignition module will turn off this enable and the MODGAS XWR2 will turn on the No Proof of Flame Alarm Communicating Outputs Gas Valve Output 1 This communicating output will control the modulating gas valve It...

Page 22: ...nfiguration Heat 1 RLY3 and Heat 2 RLY4 are one stage 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 Once the MODGAS XWR2 brings on heat Heat 4 RLY6 is the third or fourth stage of heat if the MODGAS XWR2 is configured for four stages of heat and wi...

Page 23: ...AON unit controller for control The Supply Air Temperature Setpoint and Supply Air Temperature Reset values are set by the AAON unit controller If communication is interrupted between the MODGAS XWR2 and the AAON unit controller both boards will indicate an alarm The alarm condition will be cleared once communication is restored Min Mode Min Mode is used to help eliminate overshoot of the Supply A...

Page 24: ...ve the fan back into high speed 2V2IGN2S The PID loop runs every 10 seconds and determines the modulation percentage for the one variable valve Then the valve moves to the correct position Only after the stage up delay requirement has been met will the board stage up and open the second variable valve Then both valves will move to the same position During the modulation sequence if the valve posit...

Page 25: ...nt modulation for each valve NOTE Configuring one stage below the low speed cutoff and the other above it will cause low speed relay difficulties Forcing stages 2 4 on forces Heat 2 4 RLY4 RLY6 on 2V1IGN1S Forcing Stage 1 on forces Heat 1 RLY3 on and the next screen allows the option to select the modulation percentage since both valves are one stage they both modulate at the same percentage Forci...

Page 26: ...urations ENTER Use the ENTER key to navigate through the Main Menu Screen categories Editing Key Key Function UP or DOWN Use the UP or DOWN key to enter Edit Mode on a user adjustable screen Edit Mode is indicated 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 ...

Page 27: ... 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 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 rest of the screens ...

Page 28: ... the module moves into COMM_TIMEOUT the module is then put into this mode The module will not leave this mode until E BUS or I2 C communication returns Normal module operations do not continue when in this mode e g you cannot go into Heat mode If communication resumes the module moves into the previous communication state FORCED_STAND_ALONE In this mode the module acts as the master communicating ...

Page 29: ... through Modbus After 10 minutes of no keypad input the Force Mode will disengage VCMX_EOL If the module is being tested for the VCM X via I2 C communications then the module moves into this mode MOD HEAT STAGE After Ignition Mode the unit will enter the Heat Mode and will begin to modulate the gas valve s to maintain the Heating Supply Air Setpoint Once the call for heat goes away the unit will l...

Page 30: ...TOFF This indicates a Supply Air Temperature Cutoff Alarm condition which is activated if the SAT has risen above 200ºF The alarm will go away if after a fixed delay period the SAT has dropped below 200ºF SAT FAIL ERROR The Supply Air Temperature sensor has been disconnected for more than 60 seconds This will cause the Heat to be disabled This alarm will be disabled when the sensor is reconnected ...

Page 31: ...he AAON unit controller SET POINTS SAT SP 40 200 F HEATING SUPPLY AIR TEMPERATURE SETPOINT This is the target temperature while the heating is enabled If you are using the reset signal this is the setpoint it will calculate to at zero volts Will display only in Stand Alone Mode The SAT Setpoint is set by the LCD Display in Stand Alone Mode and is set by the AAON unit controller in Communications M...

Page 32: ...on to decrease the percentage NOTE When you turn the Force Mode back off or after 10 minutes of no keypad input the valve will reinitialize to zero and the relays will turn off STAGE 2 FORCE ON STAGE 2 FORCE ON OFF Press the UP 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 V2 POSITION X FORCE VALVE...

Page 33: ...any changes CONFIG ADDRESS 1 138 CURRENT BOARD ADDRESS The first number is the board address The number in parentheses is the E BUS address Use this screen to set the address for a Slave board Set the address to 2 for a slave board Default is 1 138 OPRATION NORMAL OPERATION MODE Normal or Master Default is Normal This screen is used to set a Primary MODGAS XWR2 board as a master board If only usin...

Page 34: ...ach header in which the first and second valves operate together for one modulating stage One valve is connected to Heat 1 Relay and the second valve is connected to Heat 2 Relay Additional stages may be added to Heat Relays 3 and 4 or off board if it is in a Communications Mode 2V2IGN2S Valve configuration used to control two modulating gas valves one on each header in which the first valve is mo...

Page 35: ... green LED will light up and stay lit as long as the Heat Enable 1 relay is active RLY4 This green LED will light up and stay lit as long as the Heat Enable 2 relay is active RLY5 This green LED will light up and stay lit as long as the Heat Enable 3 relay is active RLY6 This green LED will light up and stay lit as long as the Heat Enable 4 relay is active Binary Input LEDs AUX BIN Not Used HEAT E...

Page 36: ...N G041530 E BUS DUAL I2C CONNECT 24 VAC GND 24 VAC 1 AMP MAX CONTACT RATING IS COMMON RELAY OUTPUTS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET IN AI SAT IN AI GND AI GND AUX AI www aaon com LOW SPEED HEAT 1 HEAT 2 HEAT 3 HEAT 4 PROOF OF IGNITION 1 PROOF OF IGNITION 2 FAN STATUS LED ALARM LED COMM LED POWER LED NOT USED HEAT ENABLE LED FAN LED L...

Page 37: ...Stand Alone Mode or to AI2 VCM X or VCB X or to AI3 VCCX2 and GND on the main controller Communications Mode Remove SAT and GND wiring from MODGAS XWR2 and ohm sensor out this may indicate open or failed wiring Verify the SAT OPTIONS jumper settings on the MODGAS XWR2 for the Supply Air Temperature Sensor Fail Mode SAT Cutoff Remove SAT and GND wiring from the MODGAS XWR2 and ohm sensor out this m...

Page 38: ...om 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 7 0 3V Temperature Sensor Voltage and Resistance for Type III Sensors Temp F Temp C Resistance Ohms Voltage Input VDC 10 23 3 93333 2 98 5 ...

Page 39: ... 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 ...

Page 40: ...ule the SAT sensor is shared between the two modules and always attaches to the MODGAS XWR2 See Table 10 page 32 for SAT Options Jumper Settings and reference the appropriate figure for wiring See Table 9 page 41 for details about retrofit applications Communication Mode When communicating with AAON unit controllers the SAT Sensor will be connected to the AAON unit controller The exception would b...

Page 41: ...r in MODGAS XWR2 Connect to AAON unit controller using I2 C cable Install Supply Air Sensor in MHGRV X Connect to AAON unit controller using I2 C cable Install Supply Air Sensor in MODGAS XWR2 Connect to AAON unit controller using I2 C cable Table 9 SAT Wiring Conditions STAND ALONE MODE SAT OPTIONS JUMPER SETTINGS Condition Jumper Setting MODGAS XWR2 only 1 MODGAS XWR2 with MHGRV X 1 MODGAS XWR2 ...

Page 42: ...configuration you will be using Step 7 Connect power to the MODGAS XWR2 Step 8 Configure the MODGAS XWR2 using the LCD Display Screens Figure 18 MODGAS XWR2 Module APPENDIX B MODGAS XWR REPLACEMENT MODGAS XWR2 Replacement of MODGAS XWR STEP 2 STEP 4 STEP 5 STEP 6 ALARM UP DOWN ENTER MENU MODGAS XWR2 AAON P N ASM01695 LABEL P N G041530 E BUS DUAL I2C CONNECT 24 VAC GND 24 VAC 1 AMP MAX CONTACT RATI...

Page 43: ...served 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 PARTS For replacement parts please contact your local AAON Representativ...

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