Multiaqua MHRC2 Operation Manual
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Multiaqua MHRC2 Operation Manual

Chiller with mcs magnum controls
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MHRC 2 CHILLER
OPERATION MANUAL
MHRC2
with MCS MAGNUM Controls
Rev. 62016 NRC
Multiaqua, Inc.
306 Hagood Street, Easley, South Carolina 29640 • Phone: (864) 850-8990 Fax: (864) 850-8995

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  • Page 1 MHRC 2 CHILLER OPERATION MANUAL MHRC2 with MCS MAGNUM Controls Rev. 62016 NRC Multiaqua, Inc. 306 Hagood Street, Easley, South Carolina 29640 • Phone: (864) 850-8990 Fax: (864) 850-8995...
  • Page 2 All Multiaqua products are designed with the future in mind. That’s why all air conditioning chiller products are fl exible, which makes it easy to adapt to virtually all kinds of building applications.

  • Page 3: Table Of Contents

    Table of Contents 1. Table of Contents ..............................3 2. Introduction to Multiaqua and MCS-Magnum ....................5 2.1. About the Multiaqua Heat reclaim chiller (MHRC) ..................5 2.2. About the MCS-MAGNUM ..........................5 2.3. About PC Support Software for MCS-MAGNUM ..................5 2.4. Requirements for PC Software ........................5...
  • Page 4 23. APPENDIX B - MHRC Refrigerant Circuit Layout ....................42 24. APPENDIX C - Controls Layout..........................43 25. APPENDIX D - Wiring Diagram..........................45 26. APPENDIX E - MHRC2 Frequency Drive Drawings....................46 27. APPENDIX F - Configuration ..........................49 28. APPENDIX G - MCS Trouble Shooting Reference ....................64...

  • Page 5: Introduction To Multiaqua And Mcs-Magnum

    (SHC) or indepen- dently make hot or cold water. The Multiaqua MHRC is designed with great care to provide easy servicing by incorporating readily available components and diagnostics.

  • Page 6: Mcs- Magnum Keypad - Keys And Their Functions

    2.5. MCS- MAGNUM KEYPAD - Keys and their functions • LCD DISPLAY - displays current condition of controller. Pressing the Menu key, displays the 10 available Menu items. • FUNCTION KEYS - F1, F2, F3 are used to Page Up and Page Down as shown below, F2 - PG(page up), F3 - PG(page down).

  • Page 7: Mhrc Start Up Screens

    The following sequence occurs at Power Up: 3.1. MHRC OPERATIONAL MULTIAQUA LOGO SCREEN THIS DISPLAY APPEARS FOR A FEW SECONDS IT IS YOUR INDICATION THAT THE MAGNUM IS OPERATIONAL 3.2.

  • Page 8: Status Displays

    Status Displays The current status can be viewed on the LCD display by depressing the ‘Menu’ key and selecting STATUS, then depressing the  ‘ENTER KEY’. Or it can be accessed via the MCS-CONNECT program under status screen section (See MCS-CONNECT Manual for further details). 4.1.

  • Page 9: Compressor 1 Status- Running

    4.4. COMPRESSOR 1 STATUS- RUNNING HH:MM CMP 1 STATUS C TNK / H TNK COMPRESSOR IS RUNNING PROVIDES SATURATED SUCTION, SUCTION SUPERHEAT, SATURATED CONDENSING & DISCHARGE SUPERHEAT PRESS F3 PG TO CONTINUE REVIEWING STATUS 4.5. EXV VALVE OPENING HH:MM EXV 1 STATUS C TNK / H TNK OPENING EXV 1 TIME IN THIS MODE...

  • Page 10: Main Menu - Select Outputs Status

    Status Outputs 5.1. MAIN MENU - SELECT OUTPUTS STATUS HH:MM MENU, SELECT OUTPUTS THIS WILL ALLOW THE USER TO DISPLAY DETAILS OF THE OUTPUTS STATUS BOTH ANALOG & DIGITAL PRESS (ENTER KEY) TO SELECT 5.2. UNIT RELAYS STATUS HH:MM OUTPUTS (RELAY & ANALOG) THE 1ST FOUR RELAY OUTPUTS ARE PRESENTED ...

  • Page 11: Status Inputs

    Status Inputs 6.1. PRESS MENU - SELECT INPUTS HH:MM MENU KEY, SELECT INPUTS PRESS  ENTER THIS WILL ALLOW USER TO DISPLAY DETAILS OF THE INPUTS BOTH ANALOG & DIGITAL 6.2. INPUTS (SENSOR STATUS) HH:MM INPUTS (ANALOG & DIGITAL) THE FIRST FOUR INPUTS ARE PRESENTED ...

  • Page 12: Press Menu - Select Alarms

    Alarms 7.1. PRESS MENU - SELECT ALARMS HH:MM MENU KEY, SELECT ALARMS  ENTER THIS WILL ALLOW USER TO DISPLAY DETAILS OF THE ALARMS THERE ARE A MAXIMUM OF 100 ALARMS PRESENTED TWO TO A SCREEN WITH MOST CURRENT FIRST 7.2.

  • Page 13: Graphs

    Graphs 8.1. PRESS MENU - SELECT GRAPHS HH:MM MENU KEY, SELECT GRAPHS, PRESS ( ) ENTER THIS WILL ALLOW USER TO DISPLAY DETAILS OF A GRAPH ONE ITEM IS GRAPHED AT A TIME IT WILL BE PLOTTED IN REAL TIME 8.2.

  • Page 14: Press Menu - Select Set Points

    Set Points 9.1. PRESS MENU - SELECT SET POINTS HH:MM MENU KEY, SELECT SETPOINTS PRESS  ENTER KEY THIS WILL ALLOW THE USER TO DISPLAY DETAILS OF SETPOINTS SETPOINTS CAN BE DISPLAYED BASED ON AUTHORIZATION LEVEL 9.2. DISPLAY SET POINTS HH:MM THE 1ST FOUR SETPOINTS ARE DISPLAYED ...

  • Page 15: Service Tools

    10. Service Tools 10.1. PRESS MENU - SELECT SERV TOOLS HH:MM MENU KEY, SELECT SERV TOOLS, PRESS ( ) ENTER THIS WILL ALLOW USER TO DISPLAY DETAILS OF SERV TOOLS 10.2. SERV TOOLS OPTIONS HH:MM SERV TOOLS THE SERV TOOL OPTIONS ARE DISPLAYED ↑...

  • Page 16: System Info Screen 2

    10.5. SYSTEM INFO SCREEN 2 HH:MM SERV TOOLS SYSTEM INFO PRESS ENTER KEY TO SELECT 10.6. SYSTEM INFO SCREEN 3 HH:MM SYSTEM INFO SHOWS FIRMWARE VERSION & CONFIG NAME PG  CONTINUES TO NEXT SYSTEM INFO 10.7. SYSTEM INFO SCREEN 4 HH:MM SYSTEM INFO SHOWS COMPANY NAME...

  • Page 17: Press Menu - Select Lckout Rst

    11. Lockout Reset Alarms 11.1. PRESS MENU - SELECT LCKOUT RST HH:MM MENU KEY, SELECT LCKOUT RST  ENTER KEY THIS WILL ALLOW USED TO DISPLAY ANY LOCKOUTS 11.2. NO CURRENT LOCKOUTS HH:MM IF NO LOCKOUTS EXIST YOU WILL BE NOTIFIED IF THE UNIT IS IN LOCKOUT YOU WILL BE ALLOWED TO RESET.

  • Page 18: Press Menu - Select Lckout Alarm

    12. Lockout Alarms 12.1. PRESS MENU - SELECT LCKOUT ALARM HH:MM MENU KEY, SELECT LCKOUT ALARMS, PRESS ( ) ENTER THIS WILL ALLOW USER TO DISPLAY ANY LOCKOUTS ALARMS 12.2. 1ST LCKOUT ALARM DISPLAYED HH:MM SYSTEM INFO LOCKOUT ALARM NO LOCKOUT ALARMS...

  • Page 19: Press Menu - Select Passwords

    13. Passwords 13.1. PRESS MENU - SELECT PASSWORDS HH:MM MENU KEY, SELECT PASSWORD, PRESS ( ) ENTER THIS WILL ALLOW USER TO GET AUTHORIZED 13.2. ENTER PASSWORD HH:MM ENTER YOUR 4 DIGIT PASSWORD MUST BE NUMBERS BETWEEN 1 & 8 TO ENTER FROM KEYPAD CAN BE ANY COMBINATION FROM LAPTOP 13.3.

  • Page 20: Main Menu Functin Keys

    14. Main Menu Functin Keys 14.1. MAIN MENU HH:MM PRESS MENU KEY F1 KEY FOR HELP PRESS  ENTER 14.2. HELP DISPLAY HH:MM DESCRIPTION OF THE SYMBOLS USED TO MOVE CURSOR & KEYS USED TO ENTER PASSWORD 14.3. MHRC LARGE TYPE DISPLAY HH:MM PRESS F3 KEY AT MAIN MENU 14.4.

  • Page 21: Mhrc Modes

    15. MHRC MODES 15.1. UNIT IN POWER UP This state is entered when the Magnum is powered up or the system has been reset. The system will remain in this state for the time specifi ed in set point #23 “POWER DELAY” or for 60 seconds if not active. In this state all Relay Outputs are turned off.

  • Page 22: Unit Is Loading

    15.7. UNIT IS LOADING This state is entered when more capacity is required. Every second an adjustment is made to the step delay. When the delay reaches zero, the counter “steps wanted on” is increased by 1. 15.8. RUN/STOP SW OFF This state is entered when the run stop switch is off, in the stop position.

  • Page 23: Mhrc Sequence Of Operation

    16. MHRC Sequence of Operation 1. At power up, the Magnum does not start its algorithm until Set Point 23, POWERUP DELAY time has been satisfi ed. (This allows the power to stabilize) 2. At startup the MAGNUM verifi es the status of the ‘NO RUN CAPACITY CONTROL STATES’. If all stsates ed the hot and cold pumps are started.
  • Page 24 7. Once it has been determined that a compressor is wanted on, the MAGNUM reviews the ‘NO RUN CIRCUIT CONTROL STATES’ for an available compressor. 8. The condenser fan control logic runs once every second. Pumps and fans are cycled based on the compressor(s) discharge pressure and Set Point #45 to #55, depending on condenser type.

  • Page 25: Mcs-Magnum Exv Suction/Discharge Superheat Logic

    17. MCS-MAGNUM EXV Suctin/Discharge Superheat Logic...

  • Page 28: Exv Related Setpoints

    17.1.1. EXV Related Setpoints. (Refer Setpoints 9-20, 65-72, 109-110, 199-201, 205, 215, 217, and 230). These Setpoints were added to provide fi ne-tuning to the testing of the movement of the superheat temperature. Refer to EXV control logic chart in a previous section. 17.1.2.

  • Page 29: Magnum Condenser Control Strategy

    18. MAGNUM Condenser Control Strategy Modulating Step Common - This type of condenser has a common fan bank for the system. The control will be on the systems highest discharge pressure. The Relay Outputs are also supported along with an Analog Output When the system is in SHC (Simultaneous Heating and Cooling), the condenser fan is not used.

  • Page 30: Mcs-Connect Control Status Display

    19. "MCS-CONNECT" - CONTROL STATUS DISPLAY...

  • Page 31: Mhrc Magnum Setpoints

    20. MHRC MAGNUM Setpoints Name Description Cold Tank Targ Cold Tank Target. This value is used as the base to develop the Control Zone. The control target is used with the control zone and rate of change of the controlling sensor to determine required action for the Magnum.
  • Page 32 Name Description MAX ROC - If the negative Rate of Change exceeds this value we are approaching the target fast enough. The capacity control state is set to HOLDING. Used only with the Magnum Control Zone control method. MAX ROC + If the positive Rate of Change exceeds this value we are approaching the target fast enough.
  • Page 33 Name Description ACYC ON->ON This is the anti-cycle time delay (in seconds) from when the compressor was turned on. This value is used in a calculation to determine how long a compressor should be in the anti-cycle state. Defi nes the number of cycles per hour the compressor can have.
  • Page 34 If active, then this value will become the target temperature during heating mode. SwModeDelay Default delay when MHRC2 is switching modes, heat to cool, cool to heat, etc... FLA COMP#1 Full Load Amps for compressor #1. This is the amps at design suction and discharge pressures referenced in the MCS-Confi...

  • Page 35: Mhrc Magnum Alarms And Safeties

    21. MHRC MAGNUM Alarms and Safeties 21.1 Introduction There are three types of alarms that are generated by the MHRC MAGNUM control logic: ■  Information only alarms, ■  MHRC MAGNUM system alarms and ■  MHRC MAGNUM setpoint safety alarms. All of the alarms have the same format.

  • Page 36: Alarms Generated By The Control Algorithm

     SI TO (Selected Condition) – Generated when a user changes the condition of a Sensor Input (If a digital  input, then either AUTO, MANON, or MANOFF. If an analog input, then either AUTO or MANUAL. If MANUAL, then a dialog box will appear to input the number value). POINT INFO CLEAR –...

  • Page 37: Mhrc Unit Safeties

    21.4 MHRC Unit Safeties 21.4.1 Introduction The MHRC MAGNUM algorithm incorporates a number of safety checks to ensure MHRC unit operates in a safe matter. When a unit safety trip occurs the MHRC’s control state goes to “ NO RUN-LOCK OUT”. The unit will remain in this state until a lockout reset is perform via the LCD/Keypad or MCS-CONNECT.

  • Page 38: Mhrc Compressor Safeties

    PHASE LOSS If the digital input for the phase loss indicator is on and it remains on for two seconds, the MHRC will be locked out and a “PHASE LOSS” alarm generated. This fault requires a manual reset via the LCD/Keypad or MCS-CONNECT.

  • Page 39: Condenser Fan Safeties

    LOW DISCHARGE PRESSURE If the discharge pressure drops below the value of the setpoint #49 “LO DISCH PSI” and it remains there for the time specifi ed in the safety time of that setpoint, the compressor’s safety will trip and a “LO DISCH PSI #?”...

  • Page 40: Heating Stages Safeties

    21.7 Heating Stages Safeties For a safety to be interrogated, both the associated sensor input and the lockout setpoint must be active. If a safety trips, the alarm name will consist of the setpoint name plus a number indicating which condenser fan tripped.

  • Page 41: Appendix A - Magnum No Run Capacity Run States

    22. APPENDIX A - MAGNUM No Run Capacity Run States There are a number of functions that will not allow the MHRC to run, as follows: (These may be viewed by pressing selecting ‘Status” from the Menu key.) 1. UNIT IN POWER UP- The MAGNUM Chiller V8 software utilizes Set Point #23 “Power Up Delay”...

  • Page 42: Appendix B - Mhrc Refrigerant Circuit Layout

    APPENDIX C - Controls Layout Page 1 of 2...

  • Page 43: Appendix C - Controls Layout Page 2 Of 2

    APPENDIX C - Controls Layout Page 2 of 2...

  • Page 44: Appendix D - Wiring Diagram

    APPENDIX D - Wiring Diagram...
  • Page 45 APPENDIX E - MHRC Frequency Drive Drawings...

  • Page 46: Appendix E - Mhrc2 Frequency Drive Drawings

    APPENDIX E - MHRC Frequency Drive Drawings...
  • Page 47 APPENDIX E - MHRC Frequency Drive Drawings Common To Inverter...
  • Page 48 28. APPENDIX F - Confi guration Files - Frequency Drive System Information Company Name: MULTI AQUA Site and/or Unit Name: MHRC #1 Model Name: VFD SCROLL Serial Number: 2015-07-0000001 Config Version: Config Type: MHRC Mag Technician Initials: Revision Number: Firmware Version: Installation date: Date and Time of creation 4-18-16 at 11:35 PM...

  • Page 49: Appendix F - Configuration

    APPENDIX F - MHRC CONFIGURATION - FREQUENCY DRIVE MAGNUM Controller Information Display Units Deg F \ PSI Default Display Key UNIT STATUS Total Number of RO's Total Number of AO's Total Number of SI's Total Number of RO Boards Total Number of SI Boards Type of I/O Boards RO-10 &...
  • Page 50 APPENDIX F - MAGNUM CONTROLLER I/O Output and Input Information for Magnum Output Name Type Input Name Type AO Name Digital or OffSet M-1 COMP Step w\ EXV M-1 C TANK TMP MCST100 COMP % M-2 HotSV1A&B Standard M-2 C WTR OUT MCST100 EXV % M-3 Cnd SV2A...
  • Page 51 APPENDIX F - MAGNUM CONTROLLER INPUTS...
  • Page 52 REVISION 1 APPENDIX F MAG V17 CHL Information General Information Number of Circuits: Total Capacity Steps: Unit Type Cooling Only 1st MOD Motor Limit: Not Used Turbo Ice Machine: Lost BMS Comm.: Unit Control Run/Stop Switch: SI M16 RUN/STOP Network Run/Stop: Not Used Emergency Stop Switch: Not Used...
  • Page 53 APPENDIX F - MAGNUM MHRC CONFIGURATION Evaporator Information Capacity Control Control Method: Control Zone Control Temperature On: Leaving Temp Entering Temperature: SI M-3 H TANK TMP Leaving Temperature: SI M-1 C TANK TMP Target Reset: Normal AI 0-5 Volts Target (SP #1) Reset: Not Used Refrigerant Type: R410A...
  • Page 54 APPENDIX F - MHRC CONFIGURATION - FREQUENCY DRIVE Lockout Information Lockouts based on I/O boards not enabled Boiler Information Boiler Logic Not Enabled Circuit Information on Next Page ---->...
  • Page 55 APPENDIX F - MHRC CONFIGURATION - CIRCUIT INFORMATION...
  • Page 56 APPENDIX F - MHRC CONFIGURATION - CIRCUIT INFORMATION...
  • Page 57 APPENDIX F - MHRC CONFIGURATION - FACTORY SETPOINT PRESETS...
  • Page 58 APPENDIX F - MHRC CONFIGURATION - FACTORY SETPOINT PRESETS...
  • Page 59 APPENDIX F - MHRC CONFIGURATION - SCHEDULING Schedule Information Operating Schedule Day of the Week On Sched #1 Off Sched #1 On Sched #2 Off Sched #2 Sunday 00:00 24:00 00:00 24:00 Monday 00:00 24:00 00:00 24:00 Tuesday 00:00 24:00 00:00 24:00 Wednesday...
  • Page 60 APPENDIX F - MHRC CONFIGURATION - FREQUENCY DRIVE BMS Points Compressor State Chart State # State # BACnet State Text/Name MCS & Modbus LOST IO LOCKED CMP LOCKED OUT SWITCHED OFF UNLD & PMPDWN CMP ANTICYCLE CMP OFF/READY OIL PMP LUBING CMP IN STARTUP CMP UNLOADED CMP UNLD STEP1...
  • Page 61 APPENDIX F - MHRC CONFIGURATION - FREQUENCY DRIVE No Lookup Table SI Information S:\! Customer Jobs\Multiaqua\VFD unit\MHRC VFD 9-15-15-B.cfg CONFIG DATE = 9/15/15 at 04:09 PM PRINT DATE = 9/24/15 02:36 PM No Lookup Table AO Information S:\! Customer Jobs\Multiaqua\VFD unit\MHRC VFD 9-15-15-B.cfg...
  • Page 62 APPENDIX F - MHRC CONFIGURATION - FREQUENCY DRIVE Lookup Table Detail Information for Magnum Lookup Table Setup # Number Of Input Column Output Column Input Column Output Column Minimum Auth Rows Name Name Display Type Display Type Level Input #1 Output #1 Spare Spare...

  • Page 63: Appendix G - Mcs Trouble Shooting Reference

    REVISION 1 29. APPENDIX G - MCS Trouble Shooting Reference (A more detailed troubleshooting guide is available on our website: www.MCScontrols.com) PROBLEM POTENTIAL SOLUTION No Sensor + 5 vdc or sensor +5 vdc Indicates a possible shorted input sensor output is less than 4.90 vdc. Remove all sensor terminal blocks.
  • Page 64 PROBLEM POTENTIAL SOLUTION SI from AMPS board 10 A low. This indicates a problem with this SI only. Jumper setting on this SI in wrong position. Incorrect sensor type used. INVALID CONFIG VER Indicates layout of CFG wrong. CFG layout for different version than software INVALID CONFIG TYPE Indicates CFG incompatible with software.
  • Page 65 Multiaqua, Inc. 306 Hagood Street, Easley, South Carolina 29640 Phone: (864) 850-8990 Fax: (864) 850-8995...

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