MCC 50-2104 Operation And Service Manual Download Page 62

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3189 Farmtrail Road

York PA 17406 USA

Tel: 1--800--673--2431

Fax: 1--717--764--0401

MCC provides exceptional performance in mobile climate comfort.

Every driver deserves the best possible

vehicle climate with MCC products

www.mcc-hvac.com

Member of MCC Group

Certified ISO 9001 and ISO 1 4001.

Specifications subject to change without notice. MCC is a registered trademark.

2015 Mobile Climate Control

T-367 Rev. 05/2015

Summary of Contents for 50-2104

Page 1: ...OPERATION SERVICE MANUAL for MCC Eco Xcel SERIES T 367 Manual REV 05 2015 T 367 2015 Mobile Climate Control ...

Page 2: ...ve 2 2 2 4 BASIC OPERATING INSTRUCTIONS 2 3 2 4 1 Display 2 3 2 4 2 Interior Set Point Temperature Control 2 3 2 4 3 Blower Speed Setting 2 3 2 4 4 Mode Selection Descriptions 2 3 2 4 5 Capacity Control Ladder Diagrams 2 3 2 4 6 Display Settings 2 5 2 4 7 HVAC Information Screens 2 6 2 4 8 HVAC Diagnostics Screens 2 7 2 4 9 HVAC Alarm Description 2 8 2 5 MCC Eco NG Coolview 2 9 2 5 1 Starting the ...

Page 3: ...CHECKING SYSTEM FOR NON CONDENSIBLES 4 11 4 9 CHECKING AND REPLACING HIGH OR LOW PRESSURE SWITCH 4 11 4 10 FILTER DRIER 4 12 4 10 1 To Check Filter Drier 4 12 4 10 2 To Replace Filter Drier 4 12 4 11 SERVICING THE LIQUID LINE SERVICE VALVE 4 12 4 11 1 Coil Replacement 4 13 4 11 2 Internal Part Replacement 4 13 4 11 3 Replace Entire LLS Valve 4 13 4 12 THERMOSTATIC EXPANSION VALVE 4 14 4 12 1 Valve...

Page 4: ...w VIEW Tab 2 10 Figure 2 10 MCC Eco NG Coolview Inputs and Mode VIEW Tab 2 11 Figure 2 11 MCC Eco NG Coolview Outputs VIEW Tab 2 12 Figure 2 12 MCC Eco NG Coolview Error List ERROR Tab 2 12 Figure 2 13 MCC Eco NG Coolview Statistics HOURS Tab 2 13 Figure 2 14 MCC Eco NG Coolview Simulation Mode 2 14 Figure 2 15 MCC Eco NG Coolview Data Logger 2 15 Figure 2 16 MCC Eco NG Display Pinout 2 16 Figure ...

Page 5: ...67Rev 05 2015 LIST OF FIGURES Continued Figure 4 15 Removing Bypass Piston Plug 4 17 Figure 4 16 Compressor Clutch 4 18 Figure 4 17 Transducer Terminal Location 4 21 Figure 5 1 Schematic 50 2104S 5 2 Figure 5 2 Schematic T50 2112S 5 3 ...

Page 6: ...upply is disconnected Always work in pairs Never work on the equipment alone In case of severe vibration or unusual noise stop the unit and investigate MAINTENANCE PRECAUTIONS Beware of unannounced starting of the evaporator and condenser fans Do not open the unit cover before turning power off Be sure power is turned off before working on motors controllers solenoid valves and electrical controls...

Page 7: ... level surface with parking brake applied Turn main electrical disconnect switch to the off position WARNING Do Not Use A Nitrogen Cylinder Without A Pressure Regulator WARNING Do Not Use Oxygen In Or Near A Refrigeration System As An Explosion May Occur WARNING The Filter drier May Contain Liquid Refrigerant Slowly Loosen The Connecting Nuts And Avoid Con tact With Exposed Skin Or Eyes CAUTION Th...

Page 8: ...mplete the system the air conditioning and heating equipment interfaces electrical cabling refrigerant piping engine coolant piping for heating duct work and other components furnished by Mobile Climate Control and or the bus manufacturer Additional support manuals are shown in Table 1 2 Operation of the unit is controlled automatically by a Mobile Climate Control Microprocessor based controller T...

Page 9: ...rigerant gas at a high temperature and pressure into a liquid at high temperature and pressure The condenser fans circulate ambient air across the outside of the condenser tubes at a temperature lower than refrigerant circulating inside the tubes this results in condensation of the refrigerant into a liquid The receiver tank is also equipped with a pressure relief valve fusible plug which protects...

Page 10: ...apacity fan speeds and heat valve operation Refer to Section 2 for operational sequences 1 3 REFRIGERATION SYSTEM COMPONENT SPECIFI CATIONS a System Capacity Cooling 120 000 Btu Hr 35 kW Heating 126 000 Btu Hr 37 kW b Refrigerant Charge R 134a Approximate NOTE Refrigerant charge will depend on hose lengths and diameters or if there is an In Dash unit front evaporator The following should only be u...

Page 11: ...0 Amp for 24 VDC systems is recommended Independent fuses and circuit breakers protect electrical circuits from high current conditions During a high current condition the circuit protection may open c Ambient Lockout Auto Mode Opens Compressor Output at 43 F 6 1 C Closes Compressor Output at 47 F 8 3 C Defrost Mode Opens Compressor Output at 28 F 2 2 C Closes Compressor Output at 32 F 0 C The amb...

Page 12: ...um use of the evaporator heat transfer surface The low pressure low temperature liquid that flows into the evaporator tubes is colder than the air that is circulated over the evaporator tubes by the evaporator fans Heattransfer isestablished fromthe evaporator air flowing over the tubes to the refrigerant flowing inside the tubes The evaporator tubes have aluminum fins to increase heat transfer fr...

Page 13: ...w Pressure Switch 3 Discharge Service Valve 4 Suction Service Valve 5 Discharge Check Valve 6 Service Port High Side 7 Service Port Low Side 8 Pressure Transducer SPT 9 Thermal Expansion Valve TXV 10 Liquid Line Sight Glass 11 Pressure Transducer DPT 12 Filter Drier Service Valve 13 Filter Drier 14 Liquid Line Solenoid Valve 15 Receiver Tank 16 Fusible Plug Figure 1 2 Refrigerant Flow Diagram ...

Page 14: ...1 7 2015 Mobile Climate Control T 367Rev 05 2015 MAIN ENGINE RADIATOR CONDENSER SECTION EVAPORATOR SECTION Boost Pump Heat Valve N C INLET OUTLET Figure 1 3 Heat Flow Diagram ...

Page 15: ...rting electrical power must be available from the bus power supply A circuit breaker fuse in the battery compartment passes power for the clutch evaporator and condenser assemblies 2 2 1 Starting a If the engine is not running start the engine b When the 24VDC power is applied the driver dis play will be ready to except request for system op eration Press the On Off key Item 1 Figure 2 1 onthe dis...

Page 16: ...emperature Set Point Control Keys These buttons increase or decrease the temperature set point for the passenger area HVAC unit c Cursor Mode Selection Key Used to toggle through parameter settings in diagnostic mode or set the operating mode to Auto Heat Vent Cool and Defrost in normal display mode NOTE Depending on Customer specification the modes of operation may be controlled strictly through ...

Page 17: ...itionalde humidification of interior space The reheat mode will be disabled if the outsideam bient air temperature is below 43 F 6 1 C b Cooling In the cooling mode the Compressor condenser fans and evaporator fans will be ener gized The heater solenoid valve will be energized closed to provide full cooling The compressor and condenser fans will be de en ergized 2 degrees F below set point The eva...

Page 18: ...CYLINDERS REHEAT DUTY CYCLE 2 CYLINDERS SETPOINT 2 F 3 F 1 F 2 F 4 F 3 F 1 F 5 F HEAT 0 100 VENT HEAT SETPOINT 2 F 3 F 1 F 2 F 4 F 3 F 1 F 5 F HEAT AUTO COOL HEAT WITH FLOOR BLOWERS FLOOR BLOWERS OFF 4 CYLINDER Reheat Figure 2 3 Capacity Control Ladder Diagrams ...

Page 19: ... 3 in Figure 2 4 to access the display set up screen c To adjust settings press the up or down cursor keys to scroll to desired parameter Item 3 in Figure 2 1 d To adjust settings press the up or down temperat ure control keys to scroll to adjust parameter e After adjustment press Information button Item 4 in Figure 2 1 to exit set up screen Info Button Main Menu Screen View Screen Display Set Up ...

Page 20: ...can be seen in Figure 2 5 c To reset individual error and timer hours use tem perature buttons Item 2 in Figure 2 1 to select parameter and press On Off button Item 1 in Figure 2 1 to reset the parameter d To reset all error and timer hours shown on a screen press up or down temperature button Item 2 in Figure 2 1 until all 0 flashes on screen To reset all parameters shown press On Off button Item...

Page 21: ...sor unloaders condenser fan and LLS status heat valve boost pump floor blower and engine coolant switch status To enter the diagnostic screens a Press the Information button Item 4 in Figure 2 1 b Scroll through the screens by pressing the Curs or buttons Item 3 in Figure 2 1 until diagnost ic screens are shown c To exit the diagnostics screens press the Inform ation button Item 4 in Figure 2 1 Ex...

Page 22: ...pressor Off cycle if pressures return to operational limits the compressor circuit will re energize If the low pressure condition occurs more than four 4 times within a 20 minute period the compressor LLS and condenser circuit will be locked out and an alarm will be broadcast to the Driver display and A C Fail light b High or Low Transducer Failure In the event a high pressure or low pressure tran...

Page 23: ...ned to assist in monitoring diagnosing and troubleshooting of the vehicle HVAC system via a communication cable between the controller and laptop remote computer Communication Section Input Section Switch Input Section Output Section Section Tabs Figure 2 8 MCC Eco NG Coolview Example Screen shot ...

Page 24: ...lable Port section in Coolview screen See Figure 2 9 f Click Start button See Figure 2 9 to begin communication between controller and Eco NG Coolview In normal operation the Rx commu nication light on Eco NG coolview screen and USB to RS 485 converter will flash to indicate Communication has been established If transmit ting a command such as sim on or re setting er rors the Tx will flash to indi...

Page 25: ...Inputs and Mode Indicator Coolview displays real time status of the items shown in Figure 2 10 HVAC Mode Blower Status Temperature Sensors Real Time Pressure Transducers Real Time Heat Valve Status System Status HVAC Set Point Figure 2 10 MCC Eco NG Coolview Inputs and Mode VIEW Tab ...

Page 26: ...ched off Component Output Component Indicator Figure 2 11 MCC Eco NG Coolview Outputs VIEW Tab c Error List Coolview displays input output communication and compressor errors that are stored in con troller s memory Only errors that have occurred are displayed See Figure 2 12 Component Error Count Hours since reset Component Error reset Reset all Errors Figure 2 12 MCC Eco NG Coolview Error List ER...

Page 27: ... 367Re v 05 2015 d Statistics Coolview displays the run hours of the following items shown in Figure 2 13 Hours since reset Run hours Component Component Error reset Reset all Errors Figure 2 13 MCC Eco NG Coolview Statistics HOURS Tab ...

Page 28: ... start simulation mode 1 Click the Simulation Button on the Eco Ng Coolview screen to toggle the simulation mode on or off 2 Once simulation mode has been toggled On click the stand by button to the right of component 3 Click the button to the right of component to engage or adjust Simulation Mode Button Simulation Mode Indicator Stand By Button Figure 2 14 MCC Eco NG Coolview Simulation Mode ...

Page 29: ...imate Control T 367Re v 05 2015 f Logger Tab The Logger retrieves data that is saved in the Data Logger on board memory The data can be used for diagnostics and troubleshooting Figure 2 15 MCC Eco NG Coolview Data Logger ...

Page 30: ...05 2015 2 5 3 Eco NG Display Pin out Description Pin 1 Pin 10 Pin out Pin Function Pin Function 1 Power 6 J1939H 2 Dimmer 7 J1939 L 3 5V Output 8 J1939 Shield 4 Ground 9 Ground 5 RS 485 Pos 10 RS 485 Neg Figure 2 16 MCC Eco NG Display Pin out ...

Page 31: ...3 14 Power 2 4 Clutch High Current 15 5 Digital Output 2 16 Not Used 6 Power 1 17 7 18 8 19 Valve 2 CCW 9 20 Boost Pump 10 Digital Output 3 21 Valve 2 CW 11 22 Boost Pump High Current Connector 2 Digital Input 10 Digital Input 12 Digital Input 13 RS 485 Neg Ground Ground Ground Ground Ground 49 PWM 3 Analog Out 61 Not Used 50 PWM 3 62 Ground 51 63 52 64 53 65 5V Out 54 66 55 67 56 68 57 69 58 J193...

Page 32: ...n Restricted air flow No evaporator air flow or restriction Heating system Heat valve stuck open 3 3 Abnormal Pressures High discharge pressure Refrigerant overcharge Noncondensable in system Condenser motor failure Condenser coil dirty Low discharge pressure Compressor valve s worn or broken Low refrigerant charge High suction pressure Compressor valve s worn or broken Low suction pressure Suctio...

Page 33: ...h super heat Low refrigerant charge Wax oil or dirt plugging valve orifice Ice formation at valve seat Power assembly failure Loss of bulb charge Broken capillary tube Low superheat and liquid slugging in the compressor Bulb is loose or not installed Superheat setting too low Ice or other foreign material holding valve open Side to side temperature difference Warm Coil Wax oil or dirt plugging val...

Page 34: ...s you must comply with all local government environmental laws 4 1 MAINTENANCE SCHEDULE SYSTEM SYSTEM ON OFF a Daily Maintenance X X Pre trip Inspection after starting Check tension and condition of V belt b Weekly Inspection X X X X Perform daily inspection Check condenser evaporator coils and air filters for cleanliness Check refrigerant hoses and compressor shaft seal for leaks Feel filter drie...

Page 35: ... at rear of cover Hinges Retaining Bolts Figure 4 1 Opening Top Cover Evaporator 4 3 REMOVING TOP COVERS CONDENSER The condenser cover consist of the condenser fan deck and 2 side covers a To remove the side covers remove the 14 5 16 x 18 x 1 from each cover and carefully lift covers off Item 1 2 in Figure 4 2 b To remove the fan deck remove the 3 5 16 x 18 x 1 from each end of fan deck assembly a...

Page 36: ...ays be backseated before removing the gauge port cap Turning the valve stem clockwise all the way forward will frontseat the valve to isolate the compressor line and open the gauge port To measure suction or discharge pressure midseat the valve by opening the valve clockwise 1 4 to 1 2 turn With the valve stem midway between frontseated and backseated positions the suction or discharge gauge port ...

Page 37: ...ccess valve 3 Turn the field service coupling knob clockwise which will open the system to the gauge set 4 Read system pressures 5 Repeat the procedure to connect the other side of the gauge set c Removing the Manifold Gauge Set 1 While the compressor is still ON backseat the high side service valve 2 Midseat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge s...

Page 38: ... Pressure Switch 3 Discharge Service Valve 4 Suction Service Valve 5 Pressure Transducer SPT 6 Thermal Expansion Valve TXV 7 Pressure Transducer DPT 8 Receiver Tank 9 Filter Drier Service Valve Inlet 10 Filter Drier Service Valve Outlet 11 Filter Drier 12 Liquid Line Solenoid Valve 13 Fusible Plug 14 Discharge Check Valve Figure 4 5 Service Connections ...

Page 39: ... discharge service valve re connect the com pressor clutch wiring and repeat steps c and d until the system remains at 0 psig 0 Bar e Service or replace necessary components f Replace filter drier 11 Leak check connections on the low side of system by adding nitrogen through the suction service port Refer to para graph 4 5 g Energize the Liquid Line Solenoid Valve LSV 12 using an external power so...

Page 40: ...con taminate the system a Ensure the service valves are open b Energize the Liquid Line Solenoid Valve LSV Item 12 in Figure 4 5 using an external power source 24 VDC c If system is without refrigerant charge system with refrigerant vapor to build up pressure to approximately 30 PSIG R 134a d Add sufficient nitrogen to raise system pressure to 150 to 200 psig 10 21 to 13 61 bar e Check for leaks T...

Page 41: ...ternal power source 24 VDC d Start vacuum pump Slowly open valves halfway and then open vacuum gauge valve e Evacuate unit until vacuum gauge indicates 2000 microns Hg vacuum Close gauge valve vacuum pump valve and stop vacuum pump f Break the vacuum with nitrogen Raise system pressure to approximately 2 psig g Purge the nitrogen from the system h Repeat steps d thru g one time i Start vacuum pump...

Page 42: ... Adding Full Charge a Install manifold gauge set at the compressor suc tion service valve and discharge service port See figure Figure 4 5 b Leak check the system Refer to paragraph 4 5 c Evacuate and dehydrate system Refer to para graph 4 6 d Add manifold gauge set at filter drier outlet valve item 10 in Figure 4 7 Connect center hose of gauge set to appropriate refrigerant cylinder and high side...

Page 43: ...re Switch 2 Low Pressure Switch 3 Discharge Service Valve 4 Suction Service Valve 5 Pressure Transducer SPT 6 Thermal Expansion Valve TXV 7 Pressure Transducer DPT 8 Receiver Tank 9 Filter Drier Service Valve Inlet 10 Filter Drier Service Valve Outlet 11 Filter Drier 12 Liquid Line Solenoid Valve 13 Fusible Plug 14 Discharge Check Valve Figure 4 7 Service Connections ...

Page 44: ... at the condenser and receiver c Check pressure at the filter drier inlet service valve d Check saturation pressure as it corresponds to the condenser receiver temperature using the Tem perature Pressure Chart Table 4 3 e If gauge reading is 3 psig 0 20 bar or more than the saturation pressure in step d noncondensibles are present f Remove refrigerant using a refrigerant recovery system g Evacuate...

Page 45: ...m to pre vent unit operation d Using wrenches to back up the service valves slowly loosen hex nuts retaining the filter drier WARNING The filter drier may contain liquid refrig erant Slowly loosen the ORS hex nuts to avoid refrigerant contact with exposed skin or eyes e Place a new filter drier near the unit for immediate installation f Loosen or remove clamps securing the filter drier g Remove th...

Page 46: ...y and en sure no pressure remains within the valve Disas semble valve and replace defective parts c Assemble valve and leak check Refer to paragraph 4 5 d Evacuate Dehydrate low side of system Refer to paragraph e Open valves and test operation 1 Coil retaining screw 2 Coil Assembly 3 Enclosing Tube Assembly 4 Gasket 5 Body 1 2 3 4 5 Figure 4 10 Liquid Line Solenoid Valve 4 11 3 Replace Entire LLS...

Page 47: ...uperheat Refer to paragraph 4 12 2 4 12 2 Superheat Measurement NOTE All readings must be taken from the TXV bulb location and out of the direct air stream 1 Suction Line section view 2 TXV Bulb Clamp 3 Nut Bolt clamp 4 Thermocouple 5 TXV Bulb Shown in the 4 clock position 1 2 3 4 5 Figure 4 11 Thermostatic Expansion Valve Bulb and Thermocouple a Remove Presstite insulation from expansion valve bu...

Page 48: ...ocated in the return air section in ceiling Access to the filters is accomplished by opening the return air cover The filters should be checked for cleanliness periodically depending on operating conditions A dirty filter will restrict air flow over the evaporator coil which may cause insufficient cooling or heating and possible frost buildup on the coil To removethe filters do the following ...

Page 49: ...valves and disconnect manifold gauge set f Check refrigerant level Refer to paragraph 4 7 It may be necessary to clear any alarms that have been generated D S 7 1 2 3 4 5 6 1 Discharge Service Valve and Port 2 Suction Service Valve and Port 3 Manifold Gauge Set 4 Vacuum Pump 5 Reclaimer 6 Refrigerant Cylinder 7 Thermistor Vacuum Gauge Figure 4 13 Compressor Service Connections 4 14 3 Pump Down An ...

Page 50: ...lacement compressor head must be installed in the failed compressor if returning for warranty or core credit 3 Do not interchange allen head capscrews that mount the piston plug and unloader they are not interchangeable 4 Check oil level in service replacement compressor Refer to paragraphs 1 3 and 4 14 6 g Remove the three socket head capscrews from the cylinder head s that have unloader valves i...

Page 51: ... it as a jacking bolt to remove the armature Use spanner wrench as in step d to pre vent crankshaft rotation f Using special tool MCC P N 07 00242 01 re move the rotor nut and rotor Retain original key g Noting the position of the wire remove the three bolts holding the coil to the compressor h Removeeveryotherbolt fromthe sealcover ofthe new compressor in the same manner as the origi nal compress...

Page 52: ...elow atmospheric WARNING Extreme care must be taken to ensure that all the refrigerant has been removed from the compressor crankcase or the re sultant pressure will forcibly discharge compressor oil 2 Drain or pump out compressor oil until the lev el is brought between the Min Max markings 3 Evacuate the compressor to 500 microns Back seat the compressor service valves and repeat the oil level ch...

Page 53: ...coil or repair unloader mechanism as re quired g When testing is complete reconnect transducer and unloader connectors and remove manifold gauge set h Disconnection of the suction pressure transducer will cause an alarm Once the transducer is recon nected the alarm will go to inactive and can then be cleared ...

Page 54: ...lay and manifold gauges to check suction and or dis charge pressure s simultaneously b Determine with the gauges whether one or both pressure readouts are correct If one is correct ex change the pressure transducer locations If the problem moves with the transducer replace the faulty transducer c If the driver display read out disagrees with both values shown on the manifold gauges proceed to step...

Page 55: ... 105 1 495 160 2 034 215 2 573 270 3 112 0 0 466 55 1 007 110 1 544 165 2 083 220 2 622 275 3 161 5 0 515 60 1 054 115 1 593 170 2 132 225 2 671 280 3 210 10 0 564 65 1 103 120 1 642 175 2 181 230 2 720 285 3 259 15 0 614 70 1 152 125 1 691 180 2 230 235 2 769 290 3 308 20 0 663 75 1 204 130 1 740 185 2 279 240 2 818 295 3 357 25 0 712 80 1 250 135 1 789 190 2 328 245 2 867 300 2 406 30 0 761 85 1...

Page 56: ... 8 1 11 1 09 18 8 17 1 1 20 1 18 20 7 18 5 1 30 1 28 22 6 19 9 1 40 1 37 24 4 21 4 1 50 1 48 26 3 22 9 1 61 1 58 Temperature Pressure F C Psig Kg cm Bar 28 2 24 5 1 72 1 69 30 1 26 1 1 84 1 80 32 0 27 8 1 95 1 92 34 1 29 6 2 08 2 04 36 2 31 3 2 20 2 16 38 3 33 2 2 33 2 29 40 4 35 1 2 47 2 42 45 7 40 1 2 82 2 76 50 10 45 5 3 20 3 14 55 13 51 2 3 60 3 53 60 16 57 4 4 04 3 96 65 18 64 1 4 51 4 42 70 ...

Page 57: ...ides information for the Eco Xcel model rooftop air conditioning units which are fitted with two evaporator blower motor assemblies in each evaporator section and four 4 condenser fan motor assemblies Additional technical data regarding wiring electrical connectors and relay assignment are listed below UNIT CONTROLLER FIGURE NUMBERS 50 2104 MCC Figure 5 1 T50 2112 MCC Figure 5 2 ...

Page 58: ...5 2 2015 Mobile Climate Control T 367 Rev 05 2015 Model 50 2104 Figure 5 1 SCHEMATIC 50 2104S ...

Page 59: ...5 3 2015 Mobile Climate Control T 367 Rev 05 2015 Model T50 2112 Figure 5 2 SCHEMATIC T50 2112S ...

Page 60: ...1 5 High Pressure Switch 1 2 1 3 1 4 4 11 L LEAK CHECK 4 7 Low Pressure Switch 1 3 1 4 4 11 M Maintenance Schedule 4 1 O Oil Level 4 19 Operating Instructions 2 1 OPERATION 2 1 P Pressure Transducer 4 21 Pump Down 4 6 4 16 R Refrigerant Charge 1 3 4 8 4 9 4 11 Refrigerant Removal 4 7 4 16 Refrigeration Cycle 1 5 Rooftop Unit 1 2 S SAFETY Safety 1 SERVICE 4 1 Service Valves 4 3 Shaft Seal Reservoir...

Page 61: ...INDEX 2 2015 Mobile Climate Control T 367Rev05 2015 Top Cover 4 2 TROUBLESHOOTING 3 1 W Water Temperature Switch 1 3 ...

Page 62: ...formance in mobile climate comfort Every driver deserves the best possible vehicle climate with MCC products www mcc hvac com Member of MCC Group S Certified ISO 9001 and ISO 1 4001 Specifications subject to change without notice MCC is a registered trademark 2015 Mobile Climate Control T 367 Rev 05 2015 ...

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