Orion MODGAS-XWR User Manual
Factory Packaged Controls
OE377-26-00060
(AAON Part No. V20780)
MODGAS-XWR Controller
Technical Guide
MADE IN USA
YS102530 REV 1
WATTMASTER
CONTROLS
RESET IN
SAT
GND
AUX AIN
GND
STATUS
ALARM
COMM
POWER
ANODE
AUX BIN
HEAT EN
OPTIONS
ALARM
www.aaon.com
OE377-26-00060
MODGAS-XWR
INPUT TERMINALS (TYPE)
GND
AUX. (BI)
HEAT ENABLE (BI)
RESET INPUT (AI)
SAT INPUT (AI)
GND(AI)
AUX. (AI)
GND
WattMaster No:
#SW000055
Rev.: 1A
GND
+24 VAC
I2C
CONNECT
M
MENU
DOWN
AAON No.: V20780
CONTACT RATING
IS 1 AMP MAX
@ 24 VAC
LOW SPEED
COMMON
PROOF OF IGNITION 1
PROOF OF IGNITION 2
GAS VALVE
TERMINALS
E-BUS
CONNECT
UP
RELAY OUTPUT
TERMINALS
FAN
HEAT 1
HEAT 2
GAS VALVE 1
GAS VALVE 2
ENTER
COMMON
PO-IGN1
ANODE
GAS VALVE 1
PO-IGN2
ANODE
GAS VALVE 2
RLY1
RLY2
RLY3
RLY4
TABLE OF CONTENTS
OVERVIEW & FEATURES ..................................................................................................3
INSTALLATION & WIRING .................................................................................................4
Important Wiring Considerations ..............................................................................................................................4
MODGAS-XWR Stand Alone Wiring ........................................................................................................................5
MODGAS-XWR Controller to Main Controller Wiring ..............................................................................................9
INPUTS/OUTPUTS ...........................................................................................................12
OPERATION MODES & STAGING CONFIGURATIONS .....................................................13
LCD DISPLAY SCREENS ..................................................................................................14
TROUBLESHOOTING .......................................................................................................20
LED Diagnostics ....................................................................................................................................................20
Troubleshooting Alarms ................................................................................................................................................22
Temperature Sensor Testing .................................................................................................... ....................................23
APPENDIX A - Supply Air Temperature Sensor Guide ...................................................25
Supply Air Temperature Sensor Installation ...........................................................................................................25
Supply Air Temperature Sensor Wiring Chart and Jumper Settings ......................................................................26
APPENDIX B - MODGAS-XWR Replacement of MODGAS II ............................................27
PART NUMBER CROSS REFERENCE TABLE
PART DESCRIPTION ORION AAON TULSA
MODGAS-XWR Controller OE377-26-00060 V20780
VCM-X Modular E-BUS Controller OE332-23E-VCMX-MOD-A V07150
VCB-X Controller OE335-26B-VCBX V28940
VCC-X Controller OE338-26B-VCCX V42430
12-Relay E-BUS Expansion Module OE358-23E-12R
Supply Air Temperature Sensor OE231 P87140
EBC E-BUS Cables - varying lengths EBC-XXXF N/A
TSDRSC Cables - varying lengths TSDRSC-XXXF N/A
www.aaon.com
R69180
2
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-MODGASXWR-TGD-01B
AAON® Manual Part No.: V22330
Copyright April 2015 WattMaster Controls, Inc.
AAON® is a registered trademark of AAON, Inc., Tulsa, OK.
Neither WattMaster Controls, Inc. nor AAON® assumes any
responsibility for errors or omissions in this document.
This document is subject to change without notice.
MODGAS-XWR Technical Guide
OVERVIEW
General Information
Overview
The OE377-26-00060 MODGAS-XWR Controller (AAON Part No.
V20780) is designed to modulate up to two (2) gas valves to maintain
a desired Discharge Air Temperature. The MODGAS-XWR Controller also controls the speed of the induced draft fan to maintain proper
combustion in the heat exchanger. See Figure 1.
The controller can be used as a stand-alone unit or be connected to
a VCM-X E-BUS Controller (OE332-23E-VCMX; AAON Part No.
V07150), VCB-X Controller (OE335-26B-VCBX; AAON Part No.
V28940), VCC-X Controller (OE338-26B-VCCX; AAON Part No.
V42430), or 12 Relay E-BUS Expansion Module (OE358-23E-12R;
AAON Part No. R69180) using a modular cable.
The MODGAS-XWR Controller can be confi gured at the factory for one
(1) modulating valve, two (2) staged modulating valves, or one (1) modulating with multiple fi xed staged valves (stand-alone operation only).
When using the MODGAS-XWR Controller to replace an existing
MODGAS II Controller, see Appendix B, page 27 for details.
MODGAS-XWR CONTROLLER
(OE377-26-00060)
Features
The MODGAS-XWR Controller provides the following:
• Can control two (2) Gas Valves using input from
Proof of Ignition Modules
• Up to four (4) MODGAS-XWR Modules can be daisychained together to control up to eight (8) Modulation Gas
Valves
• Monitors Supply Air Temperature and Supply Air Reset
and modulates gas valves to maintain Setpoint
• Provides active relays to control the Fan and
Heat Stages
• Contains a 2 x 8 LCD character display and 4 buttons
that allow for status display, setpoint changes, and
confi guration changes
NOTE: The MODGAS-XWR Controller contains no user-
serviceable parts. Contact qualifi ed technical personnel
if your MODGAS-XWR Controller is not operating
correctly.
MADE IN USA
YS102530 REV 1
WATTMASTER
CONTROLS
RESET IN
SAT
GND
AUX AIN
GND
STATUS
ALARM
COMM
POWER
ANODE
AUX BIN
HEAT EN
OPTIONS
ALARM
www.aaon.com
OE377-26-00060
MODGAS-XWR
INPUT TERMINALS (TYPE)
GND
AUX. (BI)
HEAT ENABLE (BI)
RESET INPUT (AI)
SAT INPUT (AI)
GND(AI)
AUX. (AI)
GND
WattMaster No:
#SW000055
Rev.: 1A
GND
+24 VAC
I2C
CONNECT
CONTACT RATING
Figure 1: OE377-26-00060 MODGAS-XWR Controller
M
MENU
DOWN
AAON No.: V20780
IS 1 AMP MAX
@ 24 VAC
LOW SPEED
HEAT 1
HEAT 2
COMMON
PROOF OF IGNITION 1
PROOF OF IGNITION 2
GAS VALVE
TERMINALS
E-BUS
CONNECT
UP
RELAY OUTPUT
TERMINALS
FAN
GAS VALVE 1
GAS VALVE 2
ENTER
COMMON
PO-IGN1
ANODE
PO-IGN2
ANODE
RLY1
RLY2
RLY3
RLY4
GAS VALVE 1
GAS VALVE 2
MODGAS-XWR Technical Guide
3
WIRING
Important Wiring Considerations
Important Wiring Considerations
Please read carefully and apply the following information when wiring the
MODGAS-XWR Controller. The MODGAS-XWR Controller
requires the following electrical connections:
1. 18 gauge minimum wire unless otherwise noted
24 VAC power connection with an appropriate VA rating
2.
3. Supply Air Temperature Sensor and Heat Enable must have
24 gauge minimum wire
4. All 24 VAC wiring must be connected so that all ground
wires remain common. Failure to follow this procedure can
result in damage to the module and connected devices
5. All wiring is to be in accordance with local and
national electrical codes and specifi cations
6. Check all wiring leads at the terminal block for tightness.
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.
4
MODGAS-XWR Technical Guide
WIRING
Single Modulating Valve No Staging - Stand-Alone Wiring
Single Modulating Valve No Staging Stand-Alone Wiring
This configuration operates as Stand-Alone (Figure 2, below) or
communicating with an AAON Unit Controller (Figure 6, page 9).
If using an MHGRV-X Controller along with the MODGAS-XWR
Controller in Stand-Alone, the SAT Sensor always attaches to the
MODGAS-XWR Controller.
MODGAS-XWR CONTROLLER
Connect SAT
Input to Reheat
Board’s SAT
Input if Applicable.
See Table 7,
Page 26.
0-10VDC
External
Reset Signal
Heat Enable
Signal
(24VAC)
W1
MADE IN USA
YS102530 REV 1
WATTMASTER
CONTROLS
RESET IN
SAT
GND
AUX AIN
GND
STATUS
ALARM
COMM
POWER
ANODE
AUX BIN
HEATEN
OPTIONS
ALARM
www.aaon.com
OE377-26-00060
MODGAS-XWR
INPUT TERMINALS (TYPE)
GND
AUX. (BI)
HEAT ENABLE (BI)
RESET INPUT (AI)
SAT INPUT (AI)
GND(AI)
AUX. (AI)
GND
WattMaster No:
#SW000055
Rev.: 1A
WARNING: Do Not Connect Power To VOUT/Ground
Terminal Block!
(OE377-26-00060)
UP
M
MENU
DOWN
AAON No.: V20780
CONTACT RATING
IS 1 AMP MAX
@ 24 VAC
FAN
LOW SPEED
HEAT 1
HEAT 2
COMMON
PROOF OF IGNITION 1
GAS VALVE 1
PROOF OF IGNITION 2
GAS VALVE
TERMINALS
GND
CONNECT
+24 VAC
I2C
E-BUS
CONNECT
GAS VALVE 2
ENTER
RELAY OUTPUT
TERMINALS
COMMON
PO-IGN1
ANODE
PO-IGN2
ANODE
RLY1
RLY2
RLY3
RLY4
GAS VALVE 1
GAS VALVE 2
Check Your Fan
Relay Wiring (RLY1)
Schematic For
Proper Wiring.
Proof of Ignition
Signal 1 (24 VAC)
Fan Enable
Low Speed Fan
Heat Valve 1
Modulating
Gas Valve 1
See
Table 8, Page 26
For SAT OPTIONS Jumper Settings
Only One Supply Air Temperature Sensor
Can Be Used Per Application.
Figure 2: Single Modulating Valve No Staging Stand-Alone Wiring Diagram
MODGAS-XWR Technical Guide
5
WIRING
Single Modulating Valve & 1 Fixed Heat Stage - Stand-Alone
One Modulating Valve & 1 Fixed Heat
Stage Stand-Alone Wiring
This configuration operates as Stand-Alone (Figure 3, below) or
communicating with an AAON Unit Controller (Figure 7, page 10).
If using an MHGRV-X Controller along with the MODGAS-XWR
Controller, the SAT Sensor always attaches to the MODGAS-XWR
Controller.
The fi xed stage uses the Heat Enable 1 relay to enable it (Figure 3,
below).
MODGAS-XWR CONTROLLER
Connect SAT
Input to Reheat
Board’s SAT
Input if Applicable.
See Table 7,
Page 26.
0-10VDC
External
Reset Signal
Heat Enable
Signal
(24VAC)
W1
-
MADE IN USA
YS102530 REV 1
WATTMASTER
CONTROLS
RESET IN
SAT
GND
AUX AIN
GND
STATUS
ALARM
COMM
POWER
ANODE
AUX BIN
HEATEN
OPTIONS
ALARM
www.aaon.com
OE377-26-00060
MODGAS-XWR
INPUT TERMINALS (TYPE)
GND
AUX. (BI)
HEAT ENABLE (BI)
RESET INPUT (AI)
SAT INPUT (AI)
GND(AI)
AUX. (AI)
GND
WattMaster No:
#SW000055
Rev.: 1A
NOTE: Up to 12 additional fi xed stages can be added by using the
12-Relay E-BUS Expansion Module. (Figure 5, page 8).
WARNING: Do Not Connect Power To VOUT/Ground
Terminal Block!
(OE377-26-00060)
UP
M
MENU
DOWN
AAON No.: V20780
GND
+24 VAC
I2C
CONNECT
CONTACT RATING
IS 1 AMP MAX
@ 24 VAC
GAS VALVE
TERMINALS
RELAY OUTPUT
FAN
LOW SPEED
HEAT 1
HEAT 2
COMMON
PROOF OF IGNITION 1
GAS VALVE 1
PROOF OF IGNITION 2
GAS VALVE 2
E-BUS
CONNECT
ENTER
TERMINALS
COMMON
PO-IGN1
ANODE
PO-IGN2
ANODE
RLY1
RLY2
RLY3
RLY4
GAS VALVE 1
GAS VALVE 2
Check Your Fan
Relay Wiring (RLY1)
Schematic For
Proper Wiring.
Fan Enable
Low Speed Fan
Heat Valve 1
Fixed Heat Stage
Proof of Ignition
Signal 1 (24 VAC)
Modulating
Gas Valve 1
See
Table 8, Page 26
For SAT OPTIONS Jumper Settings
Only One Supply Air Temperature Sensor
Can Be Used Per Application.
Figure 3: Single Modulating Valve & 1 Fixed Stage - Stand-Alone
6
EBC-E-BUS Cable
Can Connect To
12 Relay E-BUS
Expansion
Port
MODGAS-XWR Technical Guide
WIRING
Two Modulating Valves Staged - Stand-Alone Wiring
Two Modulating Valves Staged Stand-Alone Wiring
This configuration operates as Stand-Alone (Figure 4, below) or
communicating with an AAON Unit Controller (Figure 8, page 11).
If using an MHGRV-X Controller along with the MODGAS-XWR
Controller in Stand-Alone, the SAT Sensor always attaches to the
MODGAS-XWR Controller.
MODGAS-XWR CONTROLLER
Connect SAT
Input to Reheat
Board’s SAT
Input if Applicable.
See Table 7,
Page 26.
0-10VDC
External
Reset Signal
Heat Enable
Signal
(24VAC)
W1
MADE IN USA
YS102530 REV 1
WATTMASTER
CONTROLS
RESET IN
SAT
GND
AUX AIN
GND
STATUS
ALARM
COMM
POWER
ANODE
AUX BIN
HEATEN
OPTIONS
ALARM
www.aaon.com
OE377-26-00060
MODGAS-XWR
INPUT TERMINALS (TYPE)
GND
AUX. (BI)
HEAT ENABLE (BI)
RESET INPUT (AI)
SAT INPUT (AI)
GND(AI)
AUX. (AI)
GND
WattMaster No:
#SW000055
Rev.: 1A
NOTE: Up to 12 fi xed stages can be added by using the 12-Relay
E-BUS Expansion Module. (Figure 5, page 8).
WARNING: Do Not Connect Power To VOUT/Ground
Terminal Block!
(OE377-26-00060)
UP
M
MENU
DOWN
AAON No.: V20780
CONTACT RATING
IS 1 AMP MAX
@ 24 VAC
FAN
LOW SPEED
HEAT 1
HEAT 2
COMMON
PROOF OF IGNITION 1
GAS VALVE 1
PROOF OF IGNITION 2
GAS VALVE
TERMINALS
GND
CONNECT
+24 VAC
I2C
E-BUS
CONNECT
GAS VALVE 2
ENTER
RELAY OUTPUT
TERMINALS
COMMON
PO-IGN1
ANODE
PO-IGN2
ANODE
RLY1
RLY2
RLY3
RLY4
GAS VALVE 1
GAS VALVE 2
Check Your Fan
Relay Wiring (RLY1)
Schematic For
Proper Wiring.
Fan Enable
Low Speed Fan
Heat Valve 1
Heat Valve 2
Proof of Ignition
Signal 1 (24 VAC)
Modulating
Gas Valve 1
Proof of Ignition
Signal 2 (24 VAC)
Modulating
Gas Valve 2
See
Table 8, Page 26
For SAT OPTIONS Jumper Settings
Only One Supply Air Temperature Sensor
Can Be Used Per Application.
Figure 4: Two Modulating Valves Staged Stand-Alone Wiring Diagram
MODGAS-XWR Technical Guide
EBC-E-BUS Cable
Can Connect To
12 Relay E-BUS
Expansion
Port
7
WIRING
12-Relay E-BUS Expansion Module - Stand Alone
One Modulating Valve with 1 Fixed
Stage or Two Modulating Valves 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 the
MODGAS-XWR Controller will alarm and fall back to using only its
onboard stages. If communications is restored, the MODGAS-XWR
Controller will begin staging up if needed.
The 12-Relay E-BUS Expansion Module is only used with Single
Modulating Valve One Fixed Stage Stand-Alone (Figure 3, page 6) or
Two Modulating V alves Stand-Alone (Figur e 4, page 7) confi gurations.
See Figure 5, below.
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.
12-Relay E-BUS
Note:
All Relay Outputs Are Normally Open
And Rated For 24 VAC Power Only.
1 Amp Maximum Load.
R1
Fixed Heat Stage 3
R2
Fixed Heat Stage 4
R3
Fixed Heat Stage 5
R4
Fixed Heat Stage 6
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
Fixed Heat Stage 11
Fixed Heat Stage 12
Fixed Heat Stage 13
Fixed Heat Stage 14
R9
R10
R11
R12
R5
Fixed Heat Stage 7
R6
Fixed Heat Stage 8
R7
Fixed Heat Stage 9
R8
Fixed Heat Stage 10
COM
RLY5
RLY6
RLY7
RLY8
EBC E-BUS Cable
Connect To MODGAS-XWR 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: Stand-Alone Up to 12 Additional Stages of Fixed Heat - 12-Relay E-BUS Expansion Module
8
MODGAS-XWR Technical Guide
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 6, 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.
Connect
Only One Supply Air Temperature Sensor
Supply Air Temperature
to AI2 & GND
Sensor
On Main Controller
Mount In Supply
Air Duct
Supply
Air Temperature
Sensor
The SAT OPTIONS Jumper Setting
Should Be Set to 1.
See For Settings.
Table 9, Page 26
Can Be Used Per Application.
MADE IN USA
YS102530 REV 1
WATTMASTER
CONTROLS
RESET IN
SAT
GND
AUX AIN
GND
STATUS
ALARM
COMM
POWER
ANODE
MODGAS-XWR CONTROLLER
ALARM
AUX BIN
HEATEN
OPTIONS
www.aaon.com
OE377-26-00060
MODGAS-XWR
INPUT TERMINALS (TYPE)
GND
AUX. (BI)
HEAT ENABLE (BI)
RESET INPUT (AI)
SAT INPUT (AI)
GND(AI)
AUX. (AI)
GND
WattMaster No:
#SW000055
Rev.: 1A
For all other controllers, including VCM-X or Expansion Modules, use
an I2C Cable connecting to the appropriate I2C ports on those controllers.
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.
(OE377-26-00060)
UP
M
MENU
DOWN
AAON No.: V20780
GND
+24 VAC
I2C
CONNECT
CONTACT RATING
IS 1 AMP MAX
@ 24 VAC
GAS VALVE
TERMINALS
RELAY OUTPUT
FAN
LOW SPEED
HEAT 1
HEAT 2
COMMON
PROOF OF IGNITION 1
GAS VALVE 1
PROOF OF IGNITION 2
GAS VALVE 2
E-BUS
CONNECT
ENTER
TERMINALS
COMMON
PO-IGN1
ANODE
PO-IGN2
ANODE
RLY1
RLY2
RLY3
RLY4
GAS VALVE 1
GAS VALVE 2
Check Your Fan
Relay Wiring (RLY1)
Schematic For
Proper Wiring.
Fan Enable
Low Speed Fan
Heat Valve 1
Proof of Ignition
Signal 1 (24 VAC)
Modulating
Gas Valve 1
Modular Cable Connects To
VCM-X E-BUS Controller’s
Expansion Port
Figure 6: Single Modulating Valve No Staging Communicating Wiring Diagram
MODGAS-XWR Technical Guide
EBC E-BUS Cable
Connects To
VCB-X Controller’s
Expansion
Port
9
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