DRAKE MCS-Magnum User manual

www.drakechillers.com
2900 Samuel Drive | Bensalem, PA 19020
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MCS – Magnum
Error / Alarm
Manual

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MCS – Magnum Error / Alarm Manual
Version: 1.0
Table of Contents
General Troubleshooting..............................................................................................1
Microprocessor Features .............................................................................................2
Display Features............................................................................................................3
Unit States .....................................................................................................................4
Unit in Power Up..........................................................................................................4
Scheduled Off..............................................................................................................4
Run / Stop Switch Off...................................................................................................5
Off - No Flow................................................................................................................5
No Run - I/O Lost.........................................................................................................6
Unit is Holding..............................................................................................................6
Unit Unloading .............................................................................................................7
Unit is Loading............................................................................................................. 7
Unit is Unloaded........................................................................................................... 8
Unit is Loaded..............................................................................................................8
Unit in Lockout............................................................................................................. 9
Alarms..........................................................................................................................10
Freeze........................................................................................................................10
Low Suction Superheat.............................................................................................. 11
High Discharge Pressure...........................................................................................12
Low Discharge Pressure............................................................................................13
Low / Unsafe Suction Pressure..................................................................................14
No Flow......................................................................................................................15
Phase Loss................................................................................................................ 16
Emergency Stop ........................................................................................................17
Low Discharge Superheat.......................................................................................... 18
High Discharge Temperature.....................................................................................19
High Motor Temperature / Motor Fault....................................................................... 20
High Motor Amperage................................................................................................ 21
Low Motor Amperage................................................................................................. 22
No Compressor Proof ................................................................................................23
Dirty Filter and Low / Unsafe Oil Differential ..............................................................24

MCS – Magnum Error / Alarm Manual
Version: 1.0
Oil Float...................................................................................................................... 25
Sensor Fault............................................................................................................... 26
Appendices..................................................................................................................26
Appendix A: Magnum Board Troubleshooting............................................................26
Appendix B: Diagnosing Sensor Errors...................................................................... 30
Appendix C: Phase Monitor Faults............................................................................. 36
Appendix D: Enter Password.....................................................................................38
Appendix E: Enable Run / Stop and Reset Emergency Stop.....................................39
Appendix F: Change Date / Time...............................................................................41
Appendix G: Setting Schedules and Holidays............................................................ 42

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MCS – Magnum Error / Alarm Manual
Version: 1.0
1. Before calling Drake, make sure you:
a. Have ready:
i. Chiller’s serial number (located on
the exterior of the chiller, inside the
electrical panel door, and, on the
sticker shown to the right)
ii. Multimeter
iii. Ambient readings, temperature
probes, and pressure transducers
iv. Small flathead screwdriver
v. Laptop, for in-depth diagnostics
using MCS-Connect
vi. An RS-485 to USB cable (shipped
in the manilla folder with the chiller)
b. Check all fuses
c. Check fluids
i. Verify freeze point
ii. Check tank level
d. Make sure unit is correctly wired (no loose
wires) and receiving power matching that
found on the data tag
2. For component locations, refer to the included
wiring and piping diagrams
WARNING!
Make sure to shut down AND disconnect chiller, waiting for ALL
displays or indicator lights to turn off, BEFORE making wiring
changes or replacing fuses
Failure to follow could result in serious injury or death
General Troubleshooting

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MCS – Magnum Error / Alarm Manual
Version: 1.0
Microprocessor Features
Standard Features
•Operates within +/- 0.1°F accuracy
•Powered from chiller 24 VAC (or 12 VDC) control circuit, eliminating high voltage interference
•Can support up to 20 compressors
•Can be set up to use either °F or °C and PSI or Bar
•Can control chiller using inlet or outlet temperature
•Compressor short-cycling reduction to increase compressor lifespan
•Compressor pump-down capability
•Alarm lockouts for chiller protection
•Automatic compressor lead-lag on dual circuit chillers
•Basic chiller functionality for easy setup and operation
•Custom factory configurations
oProgrammable for VFDs
oProgrammable for EC fans
•Two RS-485 serial communication ports and one ethernet port
•Can communicate with Modbus RTU or BACnet/IP
•Wet contact supply for field-installed Run / Stop switch
•Dry contact for alarm output
•Scheduled shutdown capabilities
•Integrates with MCS-Connect, a simple, free to use chiller monitoring computer software
•Custom programmable control logic (call Drake for more information)
•Remote control capabilities
•Expansion boards for additional inputs and outputs
•Can add Gateway Card for BACnet MSTP, LonTalk, and Johnson N2
12 Sensor Inputs
(INPUTS – SI)
RS485 Serial
Communication
24 VAC Input
(optional 12VDC)
10 Relay Outputs
(OUTPUTS - RO)
12 VDC Output
4 Analog Outputs
(OUTPUTS – AO)
4 Digital Inputs
(INPUTS – SI)
Ethernet Port
MCS IO
Magnum Keypad

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MCS – Magnum Error / Alarm Manual
Version: 1.0
Standard Features
•LED-backlit display with a 9-button navigation menu
oDisplays current unit status and lockout alarms
oDisplays full range of sensor inputs, relay outputs, and setpoints
oSuction / discharge pressure and superheat monitoring
oMonitors compressor runtime and cycles per day
•Data logging capabilities, setpoint changes, and sensor calibration
•Alarm history of previous 99 alarms and events
•Capable of extracting data from the last 90 minutes of runtime
•Password authorization for setpoint changes
•NEMA4 gasket seal for extreme weather protection
•Saves operational data of last five alarms
Note
All changes, modifications, and alarm resets
require a supervisor password (2112) to be
entered first
Display Features
LCD Backlit
Display
9 Button
Menu Keypad
ENTER
Button

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MCS – Magnum Error / Alarm Manual
Version: 1.0
A 60-second delay (configurable) during chiller
startup in which all Relay Outputs are shut off and
ensures the board is receiving stable power.
When the unit is shut off due to a user set
schedule, the unit displays this status. In this state,
all relays are disabled, and their statuses will read
“OFF.” The schedule can be viewed or modified in
the Service Tools menu.
Unit in Power Up
1.
Scheduled Off
Magnum Unit States
2.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This status is displayed when the Run/Stop Switch
has been turned off. In this state, all relays are
disabled, and their statuses will read “OFF.”
To enable the Run/Stop, refer to Appendix E.
This status is displayed when the Flow Switch does
not detect any flow through the evaporator. In this
state, all relays are disabled
until flow is
reestablished, and their statuses will read “OFF.”
Magnum Unit States
Run/Stop Switch
Off
Off – No Flow
3.
4.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
Magnum Unit States
This state is displayed when the connection with
an expansion board (whether a relay or sensor
expansion board) has been lost. The board will
keep trying to reconnect and will display a LOST
I/O RESTART if it reconnects to board. In this
state, all relay outputs except the alarm relay will
be turned off.
This state is displayed when:
- The unit is at the target temperature, and is
maintaining the temperature
- The unit temperature is above the target,
but no additional cooling levels are needed
because Setpoint #27 is satisfied
- The unit temperature is below the target,
but the current level of cooling is adequate
because Setpoint #28 is satisfied
No Run – I/O Lost
Unit is Holding
5.
6.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This state is displayed when the unit needs fewer
cooling levels. The system will then start to
decrease in capacity by turning off compressors or,
if applicable, turning on compressor unloader
valves.
This state is displayed when the unit needs more
cooling levels. The unit will then start to increase in
capacity by turning on compressors or, if
applicable, turning off compressor unloader
valves.
Magnum Unit States
Unit Unloading
Unit is Loading
7.
8.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This state is displayed when all possible levels of
cooling have been disabled, and thus the unit is no
longer running. All compressors will be shut off in
this state. No cooling is currently required but the
unit is ready to react to any cooling requirements
This state is displayed when all possible levels of
cooling are active, and thus the unit is running at
full capacity. All compressors will be running in this
state.
Magnum Unit States
Unit is Unloaded
Unit is Loaded
9.
10.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This state is entered whenever a critical situation
is encountered that could cause harm tothe chiller.
In this state, all Relay Outputs except the alarm
and pumps
are turned off and will read
“LOCKOUT.”
Lockouts can be reset from the keypad or with the
MCS-Connect program; however, if the lockout
condition has not been corrected, the system will
again be forced into this state.
Note - If the Lockout Reset is used more than 6
times in one day, the unit cannot be reset except
with Factory authorization. Call Drake for support.
Magnum Unit States
Note: Supervisor password (2112) is
required to reset lockouts
Unit in Lockout
11.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This alarm will trip if the fluid out temperature drops
below the value of Setpoint #111. The chiller will
lockout and all Relay Outputs will be disabled to
avoid damage to the chiller.
Note: Supervisor password (2112) is
required to reset lockouts
Possible Causes
Solutions
Sensor Fault /
Calibration on fluid out
See Appendix B to troubleshoot
Setpoint #111 is
incorrect for operating
conditions
Change setpoint to a lower value
IMPORTANT! If supply fluid is water, do NOT change setpoint to a
value lower than 40°F (4.5°C) as the liquid may freeze and cause
severe damage to the chiller!
Ambient temperature is
cold enough to affect
fluid temperatures
Verify insulation thickness is suitable for the lowest ambient
operating temperature
Add more glycol to lower freezing point, and then adjust Setpoint
#111 accordingly
Lack of flow through the
evaporator
Check that all valves are opened and that
there are no blockages or restrictions in the y-
strainer (shown to the right) or process
plumbing
Freeze
Magnum Alarms
1.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This alarm will trip if the suction superheat falls
below the value of Setpoint #17 for a
configurable
time. When suction superheat
drops too low, liquid refrigerant could enter the
compressor, causing damage. If the
compressor has low suction superheat, a LO
SUPERHEAT alarm will display. The unit will
attempt to run again after a few minutes, but
another trip within the next hour will result in a
lockout.
Note: Supervisor password (2112) is
required to reset lockouts
Magnum Alarms
Possible Causes
Solutions
Sensor Fault /
Calibration on suction
pressure or temperature
See Appendix B to troubleshoot
Lack of a load Verify the chiller has a heat load
Lack of fluid flow
Confirm active flow to the chiller
Ensure y-strainer (shown to the right) and
process plumbing are free of blockages or
restrictions, and that all ball valves are
opened
TXV
Verify superheat reading with physical gauges
Adjust the TXV (shown to the right)
Replace if not responding to adjustments
Refrigerant Overcharge Contact Drake
Low Suction
Superheat
2.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This alarm will trip if the discharge pressure rises
above the value of Setpoint #81. If the compressor
has high discharge pressure, it locks out the
compressor and the HI DISC
PSI alarm will
display.
Note: Supervisor password (2112) is
required to reset lockouts
Magnum Alarms
Possible Causes
Solutions
Sensor Fault /
Calibration on
discharge pressure
See Appendix B to troubleshoot
Condenser panels
removed
Replace the panels on the chiller
Condenser dirty or
damaged
(Air-cooled)
Clean or replace condenser coils
(shown to the right)
Condenser blocked
(Air-cooled)
Poor installation location (overhang, other equipment installed too
close, wall, fence or other object is within 3’ of the chiller blocking
airflow
Fans not running
(Air-cooled)
Verify fuses are not blown (left
picture)
Carefully, with ONLY an insulated
screwdriver, bump the condenser
contactor at the circled spot to see
if fans turn on (right picture)
Restriction in cooling
water
(Water-cooled)
Confirm that all valves are opened
Adjust regulator (shown to the right)
Refrigerant Overcharge
Contact Drake
High Discharge
Pressure
3.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This alarm will trip if the discharge pressure
drops below the value of Setpoint #85. If the
compressor has low discharge pressure, it will
lockout and display the LO DISC PSI alarm.
Note: Supervisor password (2112) is
required to reset lockouts
Magnum Alarms
Possible Causes Solutions
Sensor Fault /
Calibration on
discharge pressure
See Appendix B to troubleshoot
Condenser fans not
cycling properly
Check Setpoint #85 to ensure enough head pressure is being built
Flooded head pressure
controls (Receivers
only)
Adjust the ORI valve (shown to the right) for a
higher receiver pressure setting
Refrigerant charge is
low
Check for refrigerant leak
Contact Drake to determine the charge
Low Discharge
Pressure
4.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
The low suction pressure alarm will trip if the suction
pressure drops below the value of Setpoint #77 for a
configurable time. If the compressor has low suction
pressure, it will lockout and display the LOW
SUCTION alarm.
The unsafe suction pressure alarm will trip if the
suction pressure drops below the value of Setpoint
#80. This alarm warns
of critically low suction
pressure and will lockout the compressor on that
circuit.
Note: Supervisor password (2112) is
required to reset lockouts
Magnum Alarms
Possible Causes
Solutions
Sensor Fault /
Calibration on suction
pressure
See Appendix B to troubleshoot
Liquid line
blocked/restricted
Check that all valves are open between the
condenser and TXV, and that filter dryer (shown
to the right) is not blocked
Ensure TXV is opening and is set properly
Lack of load/flow
Ensure y-strainer (shown to the right) and process
plumbing are free of blockages or restrictions, and
that all ball valves are opened
Ensure heat load is present
Setpoint #77 is incorrect
for operating conditions
Check with Drake, then change setpoint to a lower value
Defective TXV valve
Shut down system, fully backseat TXV (shown to
the right), then front-seat TXV. Set TXV back to
the operating position. If operating problems
persist, call Drake
Refrigerant charge is low Check for refrigerant leak
Contact Drake to determine the charge
Low / Unsafe
Suction Pressure
5.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This alarm will trip if the Flow Switch on the
evaporator detects no flow. With this alarm tripped,
the compressors will shut down and stay off until
flow is reestablished.
All outputs are disabled
except for the pumps.
Note: Supervisor password (2112) is
required to reset lockouts
Magnum Alarms
Possible Causes
Solutions
Flow switch is not
reading
The flow switch (top photo) is out of
adjustment. Isolate, then remove from
the pipe and clean sensor
Air is present in the chilled fluid lines.
Purge air from the system
No fluid in the tank or low fluid levels
Ensure y-strainer (bottom photo) and
process plumbing are free of blockages
or restrictions, and that all ball valves are
opened
Check for a loose wire on flow sensor
terminal block, and check that Magnum
is outputting 5VDC
Pump not operating
correctly
Verify pump is running
Check for any blown fuses (left photo)
Verify that the overload relay has not
been tripped (right photo, reset button
circled)
Check pump phasing to ensure it is
rotating in the proper direction
No Flow
6.

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MCS – Magnum Error / Alarm Manual
Version: 1.0
This alarm will trip if the chiller has lost phase,
forcing the chiller to temporarily shut down until any
faults are cleared on the phase monitor. All relay
outputs will shut off except the alarm.
Note: Supervisor password (2112) is
required to reset lockouts
Magnum Alarms
Possible Causes Solutions
Problem with 24VAC
Check transformer output to make sure it is
outputting 24VAC to the phase monitor. If
not, make sure the transformer inputs are
set up for the correct line voltage
Verify that all wires are connected securely
to the transformer and the phase monitor
Check for any blown fuses (left photo)
Problem with 5VDC
Magnum output
Ensure Magnum is outputting 5VDC from the sensor terminal
If Magnum is not outputting 5VDC, call Drake for assistance
Fault on Phase Monitor See Appendix C to troubleshoot
(Phase monitor is shown to the right)
Phase Loss
7.