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MODGAS-XWR2-B Technical Guide

G112860 · Rev. A · 220725

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

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

AAON P/N:

G112860

, Rev. A

AAON Controls Support:

866-918-1100

Monday through Friday, 7:00 AM to 5:00 PM Central Time

Controls Support website:

www.aaon.com/aaon-controls-technical-support

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 MODGAS-XWR2-B

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

Page 2: ...registered 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 MODGAS XWR2 PARTS REFERENCE PART DESCRIPTION PART NUMBER MODGAS XWR2 Module ASM01695 MODGAS XWR2 B Module ASM06909 12 Relay E BUS Expansion Module ASM01873 VCCX2 Controller ASM01698 MHGRV X Module ASM01670 MHG...

Page 3: ...g Valve One Ignitor One Stage 1V1IGN1S 16 Two Modulating Valves Two Ignitors One Stage 2V2IGN1S 17 Two Modulating Valves Two Ignitors Two Stages 2V2IGN2S 18 Secondary Board Four Modulating Valves Two Ignitors Two Stages 2V2IGN2S 19 Two Modulating Valves One Ignitor One Stage 2V1IGN1S 20 Secondary Board Four Modulating Valves One Ignitor One Stage 2V1IGN1S 21 INPUTS AND OUTPUTS 22 Inputs and Output...

Page 4: ...NTENTS TROUBLESHOOTING 36 LED Diagnostics 36 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 ...

Page 5: ...Ignitors Two Stages 10 Figure 4 Stand Alone Wiring Secondary Board 2V2IGN2S 11 Figure 5 Stand Alone Wiring Two Modulating Valves One Ignitor One Stage 12 Figure 6 Stand Alone Wiring Secondary Board 2V1IGN1S 13 Figure 7 Stand Alone Wiring Two Modulating Valves Two Ignitors One Stage 14 Figure 8 Stand Alone Wiring 12 Relay E BUS Expansion Module 15 Figure 9 Communications Wiring One Modulating Valve...

Page 6: ...es may be configured to control four modulating valves 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 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 listedAAON unit controllers ...

Page 7: ...OMMON 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 AAON P N ASM06909 MODGAS XWR2 B LABEL P N G112180 DUAL E BUS 24 VAC GND CONTACT RATING IS 1 AMP MAX 24 VAC COMMON RELAY OUTPUTS GAS VALVE TERMINALS GAS VALVE 1 GAS VALVE 2 INPUT TERMINALS TYPE HEAT ENABLE BI AUX BI GND RESET IN A...

Page 8: ...perly 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 ...

Page 9: ...S 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 in Appendix A 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 ...

Page 10: ...ge 3 Fixed Heat Stage 4 ALARM UP DOWN ENTER MENU AAON P N ASM06909 MODGAS XWR2 B LABEL P N G112180 DUAL E BUS 24 VAC GND CONTACT RATING IS 1 AMP MAX 24 VAC 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 F...

Page 11: ...G IS 1 AMP MAX 24 VAC 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 wires remain common 2 All wiring to be in accordance with local and national el...

Page 12: ...D 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 CR2 H1 Line 40 VA transformer minimum Supply Air Temperature Sensor Mount in unit supply air d...

Page 13: ... ASM06909 MODGAS XWR2 B LABEL P N G112180 DUAL E BUS 24 VAC GND CONTACT RATING IS 1 AMP MAX 24 VAC 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 wi...

Page 14: ...d so that all ground wires remain common 2 All wiring to be in accordance with local and national electrical codes and specifications GV1 CR2 H1 Line 40 VA transformer minimum Supply Air Temperature Sensor Mount in unit supply air duct Heat Enable Signal 24 VAC W1 GND 18 30 VAC H2 Proof of Ignition Signal 2 24 VAC GV2 Modulating Gas Valve 2 Modulates with Valve 1 as 1 Stage 0 10VDC External SAT Re...

Page 15: ...r 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 series module Fixed Heat Stage n 1 18 30 VAC GND 18 30 VAC GND E BUS cable connects to a MODGAS XWR2 series module 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 16: ...0 DUAL E BUS 24 VAC GND CONTACT RATING IS 1 AMP MAX 24 VAC 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 wires remain common 2 All wiring to be in ...

Page 17: ...UAL E BUS 24 VAC GND CONTACT RATING IS 1 AMP MAX 24 VAC 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 wires remain common 2 All wiring to be in acc...

Page 18: ...ED 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 CR2 H1 Line 40 VA transformer minimum GND 18 30 VAC H2 Modulating Gas Valve 2 Proof of Ignition Signal 2 24 VAC GV2 Supply Air Temperature Sensor Mount in u...

Page 19: ...F 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 series module GV3 H1 Line 40 VA transformer minimum GND 18 30 VAC H2 Proof of Ignition Signal 2 24 VAC GV4 Modulating Gas Valve 4 Slave to Mod Gas Valve 2 CR2 Combusti...

Page 20: ...Temperature Sensor to AI2 VCB X or AI3 VCCX2 and GND on main controller E BUS cable connects to the VCCX2 or VCB X Controller s E BUS port See SAT OPTIONS Tables in Appendix A for Jumper Settings Only one Supply Air Temperature Sensor can be used per application Modulating Gas Valve 1 Modulates with Valve 2 as 1 Stage Modulating Gas Valve 2 Modulates with Valve 1 as 1 Stage Combustion Fan Enable C...

Page 21: ...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 series module GV3 H1 Line 40 VA transformer minimum GND 18 30 VAC GV4 Fixed Heat Stage 5 ...

Page 22: ...minal when used in a Stand Alone Mode Proof of Ignition 1 PO IGN1 The Proof of Ignition input is activated by a 24 VAC signal supplied from the ignition module to enable the modulating Gas Valve 1 and the modulating Gas Valve 2 in the 2V1IGN1S configuration If the flame does not ignite the ignition module will turn off this enable and the MODGAS XWR2 B will turn on the No Proof of Flame Alarm Proo...

Page 23: ...l to air ratios RLY3 Heat 1 Once the MODGAS XWR2 B heating mode is enabled Heat 1 RLY3 is the first stage of heat RLY4 Heat 2 Once the MODGAS XWR2 B heating mode is enabled Heat 2 RLY4 is the second stage of heat if the MODGAS XWR2 B is configured for two stages of heat This can either be a modulating heat stage or fixed heat stage NOTE In the 2V2IGN1S configuration Heat 1 RLY3 and Heat 2 RLY4 are...

Page 24: ...he MODGAS XWR2 B uses the Supply Air Temperature from theAAON unit controller for control The Supply Air Temperature Setpoint and SupplyAir Temperature Reset values are set by the AAON unit controller If communication is interrupted between the MODGAS XWR2 B and the AAON unit controller both boards will indicate an alarm The alarm condition will be cleared once communication is restored Min Mode M...

Page 25: ...speed 2V2IGN2S The PID loop runs every 10 seconds and determines the modulation percentage and commands the valve accordingly The valve will not close more than the minimum position while the heating is enabled Only after the stage up delay requirement has been met will the board stage up and open the second valve Then both valves will move to the same position During the modulation sequence if th...

Page 26: ...e low speed cutoff and the other above it will cause combustion fan low speed relay RLY2 LOW SPEED 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 Forcing Stages 2 4 on forces Heat 2 4 R...

Page 27: ...gurations 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 28: ... ALARMS Press to scroll through SLAVE ALARMS Screens Note This screen only displays if a secondary MODGAS XWR2 series module is present 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 press the MENU button Press to go to SETPOINT MENU Screens SETPOINT MENU Press to scroll...

Page 29: ... 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 to either another MODGAS XWR2 B Module or a 12 Relay Module for additional fixed stages The only way to leave this control state is to change the S A MODE configuration from FORCED to AUTO in the configuration screens ...

Page 30: ... position set from either the Force Menu or through Modbus After 10 minutes of no keypad input the Force Mode will disengage 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 leave the Heat Mode SLAVE_HEATING If the module is secondary to another ...

Page 31: ...UTOFF 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 32: ... the 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...

Page 33: ...ton 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 VALV...

Page 34: ...elections Press ENTER to save 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 B boar...

Page 35: ... each 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 ...

Page 36: ...w Speed Fan relay is active RLY3 This 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 Bina...

Page 37: ...AON P N ASM06909 MODGAS XWR2 B LABEL P N G112180 DUAL E BUS 24 VAC GND CONTACT RATING IS 1 AMP MAX 24 VAC 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 USE...

Page 38: ...on the MODGAS XWR2 B Stand Alone Mode or to AI2 VCB X or to AI3 VCCX2 and GND on the main controller Communications Mode Remove SAT and GND wiring from MODGAS XWR2 B and ohm sensor out this may indicate open or failed wiring Verify the SAT OPTIONS jumper settings on the MODGAS XWR2 B for the Supply Air Temperature Sensor Fail Mode SAT Cutoff Remove SAT and GND wiring from the MODGAS XWR2 B and ohm...

Page 39: ...rmistor sensor while disconnected 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 7 0 3V Temperature Sensor Voltage and Resistance for Type III Sensors Temp F Temp C Resistance Ohms Vol...

Page 40: ...60552 4 390 10 12 2 52500 4 297 15 9 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...

Page 41: ...one Mode the MODGAS XWR2 B is used in conjunction with a Stand Alone MHGRV X series module the SAT sensor is shared between the two modules and always attaches to the MODGAS XWR2 B See Table 10 page 42 for SAT Options Jumper Settings and reference the appropriate figure for wiring See Table 9 page 42 for details about retrofit applications Communication Mode When communicating with AAON unit contr...

Page 42: ...sing E BUS cable Install Supply Air Sensor in VCCX2 or VCB X Connect to VCCX2 or VCB X using E BUS cable Install Supply Air Sensor in VCCX2 or VCB X Connect to VCCX2 or VCB X using E BUS cable Table 9 SAT Wiring Conditions STAND ALONE MODE SAT OPTIONS JUMPER SETTINGS Condition Jumper Setting MODGAS XWR2 B only 1 MODGAS XWR2 B with MHGRV X series module 1 Set MHGRV X SAT Option to MODGAS XWR2 See t...

Page 43: ...B relays according to the valve configuration you will be using Step 7 Connect power to the MODGAS XWR2 B Step 8 Configure the MODGAS XWR2 B using the LCD Display Screens Figure 18 MODGAS XWR2 B Module STEP 2 STEP 4 STEP 5 STEP 6 ALARM UP DOWN ENTER MENU AAON P N ASM06909 MODGAS XWR2 B LABEL P N G112180 DUAL E BUS 24 VAC GND CONTACT RATING IS 1 AMP MAX 24 VAC COMMON RELAY OUTPUTS GAS VALVE TERMINA...

Page 44: ...erved AAON Controls Support 866 918 1100 Monday through Friday 7 00 AM to 5 00 PM Central Time Controls Support website www aaon com aaon controls technical support 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 Representat...

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