Orion MODGAS-X User Manual

Factory Packaged Controls

MODGAS-X Controller

Field Technical Guide

Table of Contents

GENERAL INFORMATION ................................................................................................................................. 3

Overview ......................................................................................................................................................................................3

Features .......................................................................................................................................................................................3

INSTALLATION & WIRING ................................................................................................................................4

Important Wiring Considerations ..................................................................................................................................................4

Single Modulating Valve No Staging ............................................................................................................................................5

One Modulating Valve with Up To 14 Fixed Stages .....................................................................................................................7

Two Modulating Staged Valves with Up To 13 Fixed Stages .......................................................................................................9

Two Modulating Staged Valves ..................................................................................................................................................11

INPUTS/OUTPUTS .......................................................................................................................................... 13

OPERATION MODES ....................................................................................................................................... 14

Stand-Alone Mode......................................................................................................................................................................14

Communicating Mode ................................................................................................................................................................14

LCD DISPLAY SCREENS ................................................................................................................................. 15

TROUBLESHOOTING ...................................................................................................................................... 19

LED Diagnostics .........................................................................................................................................................................19

Troubleshooting Alarms .................................................................................................................................................................... 19

Temperature Sensor Testing ............................................................................................................................................................ 21

APPENDIX A - Supply Air Temperature Sensor Guide .................................................................................. 23

Supply Air Temperature Sensor Installation ...............................................................................................................................23

Supply Air Temperature Sensor Wiring Chart and Jumper Settings ...........................................................................................23

APPENDIX B - MODGAS-X Replacement of MODGAS II ................................................................................ 25

APPENDIX C - MAXITROL

Stepper Valve Types ........................................................................................... 26

PART NUMBER CROSS REFERENCE TABLE

PART DESCRIPTION

ORION

AAON

TULSA

MODGAS-X Controller OE377-26-00058 V12090 MHGRV-X Controller OE377-26-00059 V12100 MHGRV II Controller OE377-00-00042 R12190 MHGRV III Controller OE377-00-00054 R71830 Supply Air Temperature Sensor OE231 P87140 EBC E-BUS Cables - varying lengths EBC-XXXF N/A

WattMaster Controls Inc. 8500 NW River Park Drive · Parkville, MO 64152 Toll Free Phone: 866-918-1100 PH: (816) 505-1100 · FAX: (816) 505-1101 · E-mail: mail@wattmaster.com Visit our web site at www.orioncontrols.com WattMaster Form : AA-MODGASX-FIELD-TGD-01F

www.aaon.com

Manual Part No.: V16940

AAON Copyright September 2014 WattMaster Controls, Inc.

AAON

is a registered trademark of AAON, Inc., Tulsa, OK. MAXITROL® is a registered trademark of Maxitrol, Inc., South eld, MI Neither WattMaster Controls, Inc. nor AAON® assumes any responsibility for errors or omissions in this document. This document is subject to change without notice.

OVERVIEW

General Information

Overview

The OE377-26-00058 MODGAS-X Controller (AAON Part No. V12090) is designed to modulate up to (2) gas valves to maintain a desired Discharge Air Temperature. The MODGAS-X Controller also controls the speed of the induced draft fan to maintain proper combustion in the heat exchanger. See Figure 1 for dimensions.

The controller can be used as a stand-alone controller or communicating with an AAON Unit Controller. The MODGAS-X controller connects to an AAON unit controller or expansion module via a modular cable. Depending on the type of unit controller, this connection will utilize an I page 5 for wiring details.

The MODGAS-X Controller can be conﬁ gured at the factory for one (1) modulating valve, two (2) staged modulating valves, or one (1) or two (2) modulating with multiple ﬁ xed staged valves (stand- alone operation only).

The MODGAS-X Controller can be conﬁ gured at the factory for the

MAXITROL

0-20 volt valve(s) or the MAXITROL® EXA STAR

0-10 volt stepper valve(s).

C connection or an E-BUS connection. See

See Appendix C, page 26 for depiction.

5.73

5.24

When using the MODGAS-X Controller to replace an existing MODGAS II Controller, see Appendix B, page 25 for details.

Features

The MODGAS-X Controller provides the following:

• Monitors Supply Air Temperature and Supply Air Reset and modulates gas valve(s) to maintain Setpoint

• Provides proper control of the Induced Draft Fan

• Provides additional options for Stand-Alone control

• Contains a 2 x 8 LCD character display and 4 buttons that allow for status display, setpoint changes, and force modes

NOTE: The MODGAS-X Controller contains no user-

serviceable parts. Contact qualiﬁ ed technical personnel if your operating correctly.

MODGAS-X Controller is not

5.04

0.21

MADE IN USA

YS102378 REV 1

WATTMASTER

CONTROLS

TB2

TB4

STATUS

ALARM

COMM

POWER

C210

D210

C211

L210

.47uF

GND

RESET IN

SAT

GND

AUXAIN

GND

3.3uF

U210

AUX BIN

D12

HEATEN

D14

OPTIONS

R42

R210

1502

1020

1002

1 2

R39

SERIAL #

R2 C2

C212

.1uF

22uF

6042

1212

2803

1962

R R

0.57

2.62

2.04

4.09

R30

R19

R22

R26

2211

TB5

RLY1

RLY2

RLY3

RLY4

COMMON

1.20

TB1

VOUT

GAS

GND

VALVE

C18

.01uF

1.68

0.25

Note: Overall Depth is 1.49 inches.

5.63

Figure 1: OE377-26-00058 MODGAS-X Controller Dimensions (In Inches)

MODGAS-X Field Technical Guide

WIRING

Important Wiring Considerations

Please read carefully and apply the following information when wiring the

requires the following electrical connections:

3. Supply Air Temperature Sensor and Heat Enable must have

4. All 24 VAC wiring must be connected so that all ground

5. All wiring is to be in accordance with local and

6. Check all wiring leads at the terminal block for tightness.

MODGAS-X Controller. The MODGAS-X Controller

18 gauge minimum wire unless otherwise noted.

24 VAC power connection with an appropriate VA rating.

24 gauge minimum wire.

wires remain common. Failure to follow this procedure can result in damage to the module and connected devices.

national electrical codes and speciﬁ cations.

Be sure that wire strands do not stick out and touch adjacent terminals. Conﬁ rm that all transducers required for your system are mounted in the appropriate location and wired into the correct terminals.

WARNING: Do Not Connect Power To VOUT/Ground

Terminal Block!

WARNING: Observe polarity! All boards must be wired

GND-to-GND and 24 VAC-to-VAC. Failure to observe polarity could result in damage to the board.

MODGAS-X Field Technical Guide

WIRING

Single Modulating Valve No Staging - Stand-Alone Wiring

Single Modulating Valve No Staging Stand-Alone Wiring

This conﬁ guration operates as Stand-Alone (Figure 2, below) or communicating with an AAON Unit Controller (Figur e 3, page 6).

This conﬁ guration can use either the MAXITROL® 0-20 volt valve(s)

or the MAXITROL® EXA ST AR 0-10 volt stepper valve(s)—conﬁ g- ured at the factory.

Connect SAT and GND

Input to

Reheat

Board’s

SAT

Input If

Applicable.

Table 7,

See

Page 24

See Appendix C, page 26 for depiction.

MODGAS-X CONTROLLER

If using a MHGRV-X Controller along with the MODGAS-X Controller in Stand-Alone, the SAT Sensor always connects to the MODGAS-X Controller.

WARNING: Do Not Connect Power To VOUT/Ground

Terminal Block!

(OE377-26-00058)

Fan Enable And

Modulating Heat Enable

Low Speed Fan

See

For Settings.

Only One Supply Air Temperature Sensor

Table 8, Page 24

SAT OPTIONS Jumper

Can Be Used Per Application.

Figure 2: Single Modulating Valve No Staging Stand-Alone Wiring Diagram

MODGAS-X Field Technical Guide

24 VAC Power Input Terminals Max. Power Consumption 1 Gas Valve = 18 VA 2 Gas Valves = 33 VA

WIRING

Single Modulating Valve No Staging - Communicating Wiring

Single Modulating Valve No Staging Communicating Wiring

This conﬁ guration operates as Stand-Alone (Figure 2, page 5) or communicating with an AAON Unit Controller (Figure 3, below).

For connection to a VCB-X Controller or VCB-X Expansion Module, use an E-BUS Cable connecting to the appropriate E-BUS ports on those controllers. For all other controllers, including VAV/CAV, MUA, VCM, VCM-X, SA, and RNE Controllers, use an I connecting to the appropriate I2C ports on those controllers.

Connect

Supply Air Temperature

Sensor T

(This Does Not Apply To

See .)

o AI2 & GND

On Main Controller

Retrofit Applications.

Table 7, Page 24

Supply

Air Temperature

Sensor

Mount In Supply

Air Duct

C Cable

MODGAS-X CONTROLLER

This conﬁ guration can use either the MAXITROL® 0-20 volt valve(s)

or the MAXITROL

EXA ST AR 0-10 volt stepper valve(s)—conﬁ g-

ured at the factory. See Appendix C, page 26 for depiction.

WARNING: Do Not Connect Power To VOUT/Ground

Terminal Block!

NOTE: If additional ﬁ xed stages are required, these should be

conﬁ gured and wired to the AAON Unit Controller’s relays.

(OE377-26-00058)

Fan Enable And

Stage 1 Heat (Mod)

Low Speed Fan

The SAT OPTIONS Jumper Setting

Should Be Set to 1.

See For Settings.

Table 9, Page 24

Only One Supply Air Temperature Sensor

Can Be Used Per Application.

I C Cable

Connects To

I C Port On

Any Non VCB-X Controller

Or Expansion Module

Figure 3: Single Modulating Valve No Staging Communicating Wiring Diagram

MODGAS-X Field Technical Guide

EBC E-BUS Cable

Connects To

VCB-X Controller’s

Expansion

Port

24 VAC Power Input Terminals Max. Power Consumption 1 Gas Valve = 18 VA 2 Gas Valves = 33 VA

WIRING

Single Modulating Valve & Up To 14 Stages Fixed Heat Stand-Alone

One Modulating Valve With Up To 14 Additional Stages Of Fixed Heat Stand-Alone Wiring

This conﬁ guration only applies to a Stand-Alone operation (Figure 4, below) and is factory-conﬁ gured.

If using a MHGRV-X Controller along with the MODGAS-X Controller in Stand-Alone, the SAT Sensor always connects to the MODGAS-X Controller.

MODGAS-X CONTROLLER

Connect SAT and GND

Input to

Reheat

Board’s

SAT

Input If

Applicable.

Table 7,

See

Page 24

The ﬁ rst two ﬁ xed stages use AUX1 and AUX2 relays to enable them (Figure 4, below). Additional ﬁ xed stages can be added by using the 12-Relay E-BUS Expansion Module. (Figure 5, page 8).

This configuration

can use either the MAXITROL® 0-20 volt

valve(s) or the MAXITROL® EXA STAR 0-10 volt stepper valve(s) (conﬁ gured at the factory). See Appendix C, page 26 for depiction.

WARNING: Do Not Connect Power To VOUT/Ground

Terminal Block!

(OE377-26-00058)

Fan Enable And

Stage 1 Heat (Mod)

Low Speed Fan

Stage 2 Heat (Fixed)

Stage 3 Heat (Fixed)

See

For Settings.

Only One Supply Air Temperature Sensor

Can Be Used Per Application.

Table 8, Page 24

SAT OPTIONS Jumper

Figure 4: Single Modulating Valve - Stand-Alone

MODGAS-X Field Technical Guide

EBC-E-BUS Cable

Connects To

12 Relay E-BUS

Expansion

Port

24 VAC Power Input Terminals Max. Power Consumption 1 Gas Valve = 18 VA

WIRING

Single Modulating Valve & 14 Stages of Fixed Heat - Stand-Alone

One Modulating Valve With Up To 14 Additional Stages Of Fixed Heat

the MODGAS-X Controller will alarm and fall back to using only its onboard stages. If communications is restored, the MODGAS-X Controller will begin staging up if needed.

Stand-Alone Wiring, Continued

If communication is lost to the 12-Relay E-BUS Expansion Module, the 12-Relay E-BUS Expansion Module will turn off its relays and

WARNING!!

Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity will result in damage to one or more of the boards. Expansion Modules must be wired in such a way that the expansion modules and the controller are always powered together. Loss of power to the expansion module will cause the controller to become inoperative until power is restored to the expansion module.

Note:

All Relay Outputs Are Normally Open And Rated For 24 VAC Power Only. 1 Amp Maximum Load.

Heat Stage 4 (Fixed)

Heat Stage 5 (Fixed)

Heat Stage 6 (Fixed)

Heat Stage 7 (Fixed)

12-Relay E-BUS

Expansion Module

COM

RLY1 RLY2 RLY3 RLY4

RLY-COM

RLY1

RLY2

RLY3

RLY4

MADE IN USA

RLY-COM

RLY9

RLY10

RLY11

RLY12

COM

RLY9 RLY10 RLY11 RLY12

Heat Stage 12 (Fixed) Heat Stage 13 (Fixed) Heat Stage 14 (Fixed)

Heat Stage 15 (Fixed)

R9 R10 R11

R12

Heat Stage 8 (Fixed)

Heat Stage 9 (Fixed)

Heat Stage 10 (Fixed)

Heat Stage 11 (Fixed)

COM

RLY5 RLY6 RLY7 RLY8

EBC E-BUS Cable

Connect To MODGAS-X Controller

RLY-COM

RLY5

RLY6

RLY7

RLY8

RELAY

EXPANSION BOARD

YS102324 REV 2

GND

24VAC

GND

24 VAC

15 VA Minimum

Power Required

GND

24 VAC

Figure 5: Single Modulating Valve & 14 Stages of Fixed Heat - 12-Relay E-BUS Expansion Module

MODGAS-X Field Technical Guide

WIRING

Two Modulating Valves & Up To 13 Stages Fixed Heat Stand-Alone

Two Modulating Valves With Up To 13 Additional Stages Of Fixed Heat Stand-Alone Wiring

This conﬁ guration only applies to a Stand-Alone operation (Figure 6, below) and is factory-conﬁ gured.

In this conﬁ guration, the ﬁ rst Modulating Valve is enabled by the FAN RLY. The second Modulating Valve is enabled by the AUX1 relay. The ﬁ xed stage uses the AUX2 relay to enable it (Figure 6, below). Additional ﬁ xed stages can be added by using the 12-Relay E-BUS Expansion Module. (Figure 7, page 10).

MODGAS-X CONTROLLER

Connect SAT and GND

Input to

Reheat

Board’s

SAT

Input If

Applicable.

Table 7,

See

Page 24

If using a MHGRV-X Controller along with the MODGAS-X Controller in Stand-Alone, the SAT Sensor always connects to the MODGAS-X Controller.

This configuration

can use either the MAXITROL® 0-20 volt

valve(s) or the MAXITROL® EXA STAR 0-10 volt stepper valve(s) (conﬁ gured at the factory). See Appendix C, page 26 for depiction.

WARNING: Do Not Connect Power To VOUT/Ground

Terminal Block!

(OE377-26-00058)

Fan Enable And

Stage 1 Heat (Mod)

Low Speed Fan

Stage 2 Heat (Mod)

Stage 3 Heat (Fixed)

See

For Settings.

Only One Supply Air Temperature Sensor

Can Be Used Per Application.

Table 8, Page 24

SAT OPTIONS Jumper

Figure 6: Two Modulating Valves - Stand-Alone

MODGAS-X Field Technical Guide

EBC-E-BUS Cable

Connects To

12 Relay E-BUS

Expansion

Port

Revised 9/30/14

24 VAC Power Input Terminals Max. Power Consumption 1 Gas Valve = 18 VA 2 Gas Valves = 33 VA

+ 19 hidden pages