GETTING STARTED MANUAL REVISION 2.0
10
Preparing to Upgrade an Existing Chiller
Step 1- Open MCS Supplied Upgrade Kit
(Usually fits in a 16” x 16” x 16” box)
Verify Packing list of all MCS parts
Obtain Spiral Binder (Divided in up to 4 sections):
Getting Started Manual
MCS-Config printout (Inputs, outputs, setpoints, etc.)
Drawings of each MCS printed circuit board with wiring connections
Specification sheet for each MCS part
Step 2- Plan to Mount New Microprocessor
Keypad / Display
Chiller Installed Outside- You should use a Panel mount which you install inside the existing rain
proof enclosure.
Chiller Installed Inside- You should use a Door mount with a Template for mounting
Mount electronics in dry location.
Do not mount in enclosure with Frequency Drive or High Voltage.
Avoid mounting in front of or close to High Voltage Contactors.
High Voltage wiring should be run separate from Low Voltage wiring.
All wiring to Analog Sensors must be with shielded cable.
When running shielded cable in areas with high voltage avoid running parallel. (Run perpendicular)
Allow adequate space on all sides of MCS boards to run cables and plug in communication cables.
If at all possible, avoid splicing shielded cable. If a splice is required please do the following:
Splice in an area where no high voltage is within three (3) feet.
Splice in a dry area.
Splice all wires including Drain wire with butt connectors or solder. (Foil shield need not be
connected. Tape connections.) Stagger where butt connectors are made to avoid bulky
connections.
GROUND CONNECTIONS
It is important to provide a good earth ground to the 120 VAC power input to the printed circuit
boards.
Do not jumper the ground connections to MCS boards. Each printed MCS board should have its
ground wired directly to ground with a wire made as short as possible (12AWG).
Step 3- Prepare to Start the Unit
Relay Output Check - Once the microprocessor has been completely wired a dry test of the wiring should
be done. To accomplish this use the following procedure:
Keep main power to compressors off. Keep high voltage breakers off or pull fuses to compressors.
Turn on 120 VAC control power.
Get authorized on the MCS-Magnum controller. (via the keypad or MCS-Connect.)
Put each Relay Output in ‘MANUAL ON’ and verify the appropriate contactor or solenoid turns on.
When testing the wiring to a Liquid Line Solenoid be careful not to leave it on too long if the system
uses an expansion valve.)
Place each digital Sensor Input in ‘MANUAL ON’ to verify the correct value.
Verify all Analog Sensors are within reasonable tolerances.
Remove the Packard connector from each pressure transducer. Verify the computer reads -99.9P
on the correct sensor.
Calibrate pressure transducer offsets.
If you have any Analog Outputs verify they are correct. Manually set analog values to 0%, 50%,
and 100%.
After testing all Outputs and Inputs, make sure all RO’s, SI’s and AO’s are in ‘AUTO’ mode.
Through the keypad, clear alarms and point information under ‘Service Diagnostics’ with factory
authorization.
If any compressor is in Lockout, perform a Lockout Reset to clear.
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