MCC 50-2104 Operation And Service Manual
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MCC 50-2104 Operation And Service Manual

Eco xcel series inline roof mount hvac system
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T-367 Manual
OPERATION/SERVICE MANUAL
for
MCC Eco Xcel SERIES
T-367
REV. 05/2015
© 2015 Mobile Climate Control

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Summary of Contents for MCC 50-2104

  • Page 1 T-367 Manual OPERATION/SERVICE MANUAL MCC Eco Xcel SERIES T-367 REV. 05/2015 © 2015 Mobile Climate Control...
  • Page 2 1--5 OPERATION of MCC XCEL DRIVER DISPLAY ...........
  • Page 3 OPENING TOP COVER (EVAPORATORS) ..........REMOVING TOP COVERS (CONDENSER) .
  • Page 4 2--10 Figure 2-10 MCC Eco NG Coolview Inputs and Mode (VIEW Tab) ........
  • Page 5 LIST OF FIGURES (Continued) Figure 4-15. Removing Bypass Piston Plug ............4-17 Figure 4-16.

  • Page 6: Safety Summary

    SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. A listing of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices.
  • Page 7 The Filter-drier May Contain Liquid Refrigerant. Slowly Loosen The Connecting Nuts And Avoid Con­ tact With Exposed Skin Or Eyes. CAUTION The 50-2104 Rooftop Systems have R134a service port couplings installed on the compressor and on the unit piping. CAUTION To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pres­...
  • Page 8 Table 1-1 Models Model Voltage Controller With Heat Single Loop W/Covers MCC EcoTemp NG 50-2104 24 VDC Microprocessor MCC EcoTemp NG T50-2112 24 VDC Microprocessor Table 1-2 Additional Support Manuals...
  • Page 9 1.2 GENERAL DESCRIPTION 1.2.1 Rooftop Unit The rooftop unit includes the condenser section and the evaporator sections (See Figure 1-1). Condenser Section Evaporator Section EVAPORATOR SECTION Interior Location Model/Serial Number Plate Figure 1-1 Rooftop Unit (Eco Xcel) 1.2.2 Condensing Section equipped with a pressure relief valve (fusible plug) which protects the system from unsafe high pressure The condensing section includes 2 micro-channel...
  • Page 10 1.4 ELECTRICAL SPECIFICATIONS - MOTORS 1.2.4 MCC Microprocessor a. Evaporator Blower/Motor The MCC controller maintains desired temperature Brushless set point by controlling compressor capacity, fan Evaporator Motor 24 VDC speeds and heat valve operation.
  • Page 11 1.5 SAFETY DEVICES Defrost Mode Opens Compressor Output at: 28° F (-2.2°C) System components are protected from damage Closes Compressor Output at: 32° F (0°C) caused by unsafe operating conditions with safety devices. Safety devices with Mobile Climate Control The ambient temperature sensor measures the supplied equipment include high pressure switch condenser inlet air temperature.
  • Page 12 1.6 AIR CONDITIONING REFRIGERATION CYCLE evaporator fans. Heat transfer is established from the evaporator air (flowing over the tubes) to the When air conditioning (cooling) is selected by the refrigerant (flowing inside the tubes). The controller, the unit operates as a vapor compression evaporator tubes have aluminum fins to increase system using R-134a as a refrigerant (See Figure 1-2 heat transfer from the air to the refrigerant;...
  • Page 13 CONDENSER SECTION EVAPORATOR SECTION HT HP SHV HT HP SCL LT LP SM LT LP SHV High Pressure Switch Thermal Expansion Valve (TXV) Low Pressure Switch Liquid Line Sight Glass Discharge Service Valve Pressure Transducer (DPT) Suction Service Valve Filter Drier Service Valve Discharge Check Valve Filter Drier Service Port, (High Side)
  • Page 14 MAIN ENGINE CONDENSER SECTION RADIATOR Boost Pump INLET OUTLET EVAPORATOR SECTION Heat Valve (N.C.) Figure 1-3 Heat Flow Diagram 1--7 T-367Rev. 05/2015 © 2015 Mobile Climate Control...

  • Page 15: Description 1

    OPERATION of MCC EcoXcel DRIVER DISPLAY 2.1 General Description 2.2.1 Starting Operation of the MCC Eco Xcel unit is controlled a. If the engine is not running, start the engine. through the MCC Driver's display. b. When the 24VDC power is applied, the driver dis­...

  • Page 16: Sequence Of Operation 2

    Operation Mode Temperature Set Point Fan Speed Indicator Interior/Exterior Temperatures 5.. Alarm Indicator Symbol Figure 2-2 Driver Display Module- Display Layout 2.3 SEQUENCE OF OPERATION d. Information/Display Settings Key - Allows ac­ cess to display settings and system diagnostics. 2.3.1 Function of Keys when “Engine On” and controller active: a.

  • Page 17: Basic Operating Instructions 2

    BASIC OPERATING INSTRUCTIONS The reheat mode will be disabled if the outside am­ bient air temperature is below 43° F (6.1° C). When the engine is running, press the On/Off b. Cooling - In the cooling mode, the Compressor, button on display. condenser fans and evaporator fans will be ener­...

  • Page 18: Figure 2-3 Capacity Control Ladder Diagrams 2

    COOL 3°F 3°F 4 CYLINDER 2°F 2°F COOL 2CYLINDERS 1°F 1°F VENT SETPOINT SETPOINT - -1°F - -1°F REHEAT DUTY CYCLE 0- -100% HEAT 2 CYLINDERS FLOOR BLOWERS - -2°F - -2°F - -3°F - -3°F HEAT - -4°F - -4°F WITH HEAT FLOOR BLOWERS...

  • Page 19: Display Settings 2

    2.4.6 Display Settings c. To adjust settings, press the up or down cursor keys to scroll to desired parameter (Item 3 in To adjust display settings, from the main menu: Figure 2-1). d. To adjust settings, press the up or down temperat­ a.

  • Page 20: Hvac Information Screens 2

    2.4.7 HVAC Information Screens c. To reset individual error and timer hours, use tem­ perature buttons (Item 2 in Figure 2-1). to select The information screens will allow user to view the parameter and press On/Off button (Item 1 in system parameters temperature...

  • Page 21: Hvac Diagnostics Screens 2

    2.4.8 HVAC Diagnostics Screens a. Press the “Information” button (Item 4 in Figure 2-1). The Diagnostics screens will allow user to view the b Scroll through the screens by pressing the “Curs­ real time status of system components. These or” buttons (Item 3 in Figure 2-1), until diagnost­ screens will aide in troubleshooting system problems ic screens are shown.

  • Page 22: Hvac Alarm Description 2

    2) For low pressure condition, the condenser and evaporator fan circuits remain energized. After The MCC Eco Temp NG Controller will notify user the one minute compressor “Off” cycle, if pressures in the event there is a problem or interruption in return to operational limits, the compressor circuit system control.

  • Page 23: Mcc Eco Ng Coolview 2

    MCC Eco NG Coolview MCC Coolview is designed to assist in monitoring, diagnosing and troubleshooting of the vehicle HVAC system via a communication cable between the controller and laptop/remote computer. Output Section Section Tabs Communication Section Input Section Switch Input Section...

  • Page 24: Starting The Mcc Coolview Application 2

    Connect USB end of USB to RS-485 converter Coolview. In normal operation, the “Rx” commu­ (MCC P/N 35-0735) to USB port of computer. nication light on Eco NG coolview screen and b. Connect RS-485 end of USB to RS-485 converter USB to RS-485 converter will flash to indicate to controller's RS-485 communication cable.

  • Page 25: Coolview Screen Layout 2

    HVAC Mode/ Blower Status HVAC Set Point Temperature Sensors (Real Time) Pressure Transducers (Real Time) Heat Valve Status System Status Figure 2-10 MCC Eco NG Coolview Inputs and Mode (VIEW Tab) 2--11 T-367Re v. 05/2015 © 2015 Mobile Climate Control...

  • Page 26: Figure 2-11 Mcc Eco Ng Coolview Outputs (View Tab) 2

    Only errors that have occurred are displayed. See Figure 2-12. Hours since Component reset Component Error reset Reset all Error Count Errors Figure 2-12 MCC Eco NG Coolview Error List (ERROR Tab) 2--12 T-367Rev05/2015 © 2015 Mobile Climate Control...

  • Page 27: Figure 2-13 Mcc Eco Ng Coolview Statistics (Hours Tab) 2

    Statistics- Coolview displays the run hours of the following items shown in Figure 2-13. Component Error reset Reset all Errors Hours since Run hours Component reset Figure 2-13 MCC Eco NG Coolview Statistics (HOURS Tab) 2--13 T-367Re v. 05/2015 © 2015 Mobile Climate Control...

  • Page 28: Figure 2-14 Mcc Eco Ng Coolview Simulation Mode 2

    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 Stand By Simulation Mode Button Button Mode Indicator Figure 2-14 MCC Eco NG Coolview Simulation Mode 2--14 T-367Rev05/2015 © 2015 Mobile Climate Control...

  • Page 29: Figure 2-15 Mcc Eco Ng Coolview Data Logger 2

    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 2--15 T-367Re v. 05/2015 © 2015 Mobile Climate Control...

  • Page 30: Eco Ng Display Pin Out Description 2

    2.5.3 Eco NG Display Pin out Description Pin 1 Pin 10 Pin out Function Function Power J1939H Dimmer J1939 L 5V Output J1939 Shield Ground Ground RS‐485(Pos) RS‐485(Neg ) Figure 2-16 MCC Eco NG Display Pin out 2--16 T-367Rev05/2015 © 2015 Mobile Climate Control...

  • Page 31: Eco Ng Controller Pin Out Description 2

    PWM 4 Analog Ground Digital Output 6 Valve 2 CW Valve 1 CW Ground Digital Output 7 Boost Pump (High Current) Ground Valve CCW Figure 2-17 MCC Eco NG Controller Pin out 2--17 T-367Re v. 05/2015 © 2015 Mobile Climate Control...

  • Page 32: Safety Devices 1

    SECTION 3 TROUBLESHOOTING Table 3-1 General System Troubleshooting Procedures INDICATION - POSSIBLE CAUSES TROUBLE System Will Not Cool Compressor will not run Drive-Belt loose or defective Clutch coil defective Clutch malfunction Compressor malfunction Electrical malfunction Coach power source defective Circuit Breaker/safety device open System Runs But Has Insufficient Cooling Compressor Drive-Belt loose or defective...

  • Page 33: No Evaporator Air Flow Or Restricted Air Flow 3

    Table 3-1 General System Troubleshooting Procedures - Continued INDICATION - POSSIBLE CAUSES TROUBLE Abnormal Noise Or Vibrations - Continued Condenser or evaporator fans Loose mounting hardware Defective bearings Blade interference Blade missing or broken No Evaporator Air Flow Or Restricted Air Flow Air flow through coil blocked Coil frosted over Dirty coil...
  • Page 34 SECTION 4 SERVICE WARNING Be sure to observe warnings listed in the safety summary in the front of this manual before performing maintenance on the hvac system. WARNING Read the entire procedure before beginning work. Park the coach on a level surface, with parking brake applied.

  • Page 35: Opening Top Cover (Evaporators)

    4.2 OPENING TOP COVER (EVAPORATORS) To open the evaporator assembly cover do the following: (See Figure 4-1.) a. Remove all 4 of the (5/16” x 18 x 1”) retaining bolts at front end of cover. b. Grasp the front cover section under the bottom edge and lift up. Cover will pivot on the 2 hinges at rear of cover.

  • Page 36: Suction And Discharge Service Valves

    4.4 SUCTION AND DISCHARGE SERVICE VALVES discharge gauge port is open to both the compressor and the line. The suction and discharge service valves (Figure 4-3) are provided with a double seat and a gauge port, TO DISCHARGE OR VALVE STEM CAP FROM SUCTION LINE which allows servicing of the compressor and refrigerant lines.

  • Page 37: Installing R--134A Manifold Guage Set

    4.4.1 Installing R-134a Manifold Guage Set CAUTION A R-134a manifold gauge/hose set with self-sealing hoses is required for service of models covered To prevent trapping liquid refrigerant in within this manual. To perform service using the the manifold gauge set be sure set is manifold gauge/hose set, do the following: brought to suction pressure before dis­...
  • Page 38 CONDENSER SECTION EVAPORATOR SECTION High Pressure Switch Receiver Tank Low Pressure Switch Filter Drier Service Valve (Inlet) Discharge Service Valve Filter Drier Service Valve (Outlet) Suction Service Valve Filter Drier Pressure Transducer (SPT) Liquid Line Solenoid Valve Thermal Expansion Valve (TXV) Fusible Plug Pressure Transducer (DPT) Discharge Check Valve...

  • Page 39: System Pump Down For Low Side Repair

    4.4.2 SYSTEM PUMP DOWN FOR LOW SIDE REPAIR f. Replace filter-drier (11). Leak check connections on the low side of system by adding nitrogen To service or replace the thermostatic expansion through the suction service port. Refer to para­ valves, filter drier, suction line or liquid line solenoid graph 4.5.

  • Page 40: Removing Entire System Charge

    4.4.3. Removing Entire System Charge NOTE It is emphasized that only the correct refrig­ NOTES erant should be used to pressurize the sys­ tem. Use of any other refrigerant will con­ It is recommended that the Filter/Drier be taminate the system. replaced after opening the refrigeration sys­...

  • Page 41: Procedure For Evacuation And Dehydrating System (One Time Evacuation)

    b. Essential tools to properly evacuate and dehydrate f. Break the vacuum with nitrogen. Raise system any system include a good two stage vacuum pressure to approximately 2 psig. pump with a minimum of 6 cfm (10.2 m /hr) vol­ g.

  • Page 42: Checking Refrigerant Charge By Receiver Sight Glasses

    4.7.3 Adding Full Charge a. Install manifold gauge set at the compressor suc­ 4.7.2 Checking Refrigerant Charge By Receiver Sight tion service valve and discharge service port. See Glasses figure Figure 4-5. For the purpose of checking refrigerant sight glasses b.
  • Page 43 CONDENSER SECTION Refrigerant Bottle Scale EVAPORATOR SECTION High Pressure Switch Receiver Tank Low Pressure Switch Filter Drier Service Valve (Inlet) Discharge Service Valve Filter Drier Service Valve (Outlet) Suction Service Valve Filter Drier Pressure Transducer (SPT) Liquid Line Solenoid Valve Thermal Expansion Valve (TXV) Fusible Plug Pressure Transducer (DPT)

  • Page 44: Adding Partial Charge

    4.7.4 Adding Partial Charge 4.9 CHECKING AND REPLACING HIGH OR LOW PRES- SURE SWITCH a. Check charge level in accordance with the proce­ dures of paragraph 4.7.2. WARNING b. Install manifold gauge set at the compressor suc­ tion service valve and discharge service port. See Do not use a nitrogen cylinder without a figure Figure 4-5.

  • Page 45: Filter--Drier

    switch should close, (continuity) within required c. Lock out/Tag out the bus electrical system to pre­ cut in tolerance. vent unit operation. d. Using wrenches to back up the service valves, f. For a low pressure switch, close cylinder valve and slowly loosen hex nuts retaining the filter drier.

  • Page 46: Coil Replacement

    3 Incomplete magnet circuit due to the omission of the coil housing or plunger. 4 Mechanical interface with movement of plunger which may be caused by a deformed enclosing tube. Failure to open may be caused by the following: 1 Coil burned out or an open circuit to coil connec­ tions.

  • Page 47: Thermostatic Expansion Valve

    4.12 THERMOSTATIC EXPANSION VALVE The thermostatic expansion valve (Figure 4-10) is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure. The valve functions are: (a) automatic control of refrigerant flow to match the evaporator load and (b) prevention of liquid refrigerant entering the compressor.

  • Page 48: Replacing Evaporator Return Air Filters

    i. If superheat is not within tolerance, replace the The filters should be checked for cleanliness valve. periodically depending on operating conditions. A dirty filter will restrict air flow over the evaporator 4.13 REPLACING EVAPORATOR RETURN AIR FILTERS coil which may cause insufficient cooling or heating The evaporator return air filters are located in the and possible frost buildup on the coil.

  • Page 49: Compressor Maintenance

    4.14 COMPRESSOR MAINTENANCE 4.14.1 Shaft Seal Reservoir Compressor is fitted with a shaft seal reservoir equipped with a clear tube for checking level as well as for draining oil from reservoir, it is recommended that the reservoir is checked and serviced regularly. 1.

  • Page 50: Removing The Compressor

    g. Once vacuum is maintained, re-connect low pres­ g. Remove the three socket head capscrews from the sure switch. Backseat compressor service valves cylinder head(s) that have unloader valves instal­ and disconnect manifold gauge set. led. See Figure 4-15. Remove the unloader valve and bypass piston assembly, keeping the same h.

  • Page 51: Transferring Compressor Clutch

    30 ft-lbs discharge service valves). rotation. k. Leak check connections and replace filter-drier. e. Install a 7/8-14 x 4” (MCC P/N 07-00381-00) capscrew into the center hole of the armature as­ l. Using refrigerant hoses designed for vacuum ser­ sembly and use it as a jacking bolt to remove the vice, connect a vacuum pump (see Figure 4-13) armature.

  • Page 52: Compressor Oil Level

    g. With the clearance set, hold each set screw while WARNING tightening the lock nuts to 7 ft/lbs. h. Reconnect wiring and test clutch operation. Extreme care must be taken to ensure 4.14.6 Compressor Oil Level that all the refrigerant has been removed from the compressor crankcase or the re­...
  • Page 53 f. If pressures do not react as described, check un­ gauge set. loader coil or repair unloader mechanism as re­ h. Disconnection of the suction pressure transducer quired. will cause an alarm. Once the transducer is recon­ g. When testing is complete, reconnect transducer nected, the alarm will go to inactive and can then and unloader connectors and remove manifold be cleared.

  • Page 54: Table 4-1 Temperature Sensor Resistance

    4.15 TEMPERATURE SENSOR CHECKOUT b. Determine with the gauges whether one or both pressure readouts are correct. If one is correct, ex­ a. An accurate ohmmeter must be used to check re­ change the pressure transducer locations. If the sistance values shown in Table 4-1. problem moves with the transducer, replace the faulty transducer.
  • Page 55 Table 4-2 Pressure Transducer Voltage “/hg Voltage Psig Voltage Psig Voltage Psig Voltage Psig Voltage Psig Voltage 20” 0.369 0.858 1.397 1.936 2.475 3.014 10” 0.417 0.907 1.446 1.985 2.524 3.063 Psig Voltage 0.956 1.495 2.034 2.573 3.112 0.466 1.007 1.544 2.083 2.622...
  • Page 56 Table 4-3 R-134a Temperature - Pressure Chart Temperature Vacuum Temperature Pressure ° ° “/hg Kg/cm@ ° ° Psig Kg/cm@ 14.6 37.08 0.49 24.5 1.72 1.69 26.1 1.84 1.80 12.3 31.25 0.42 27.8 1.95 1.92 24.64 0.33 29.6 2.08 2.04 17.00 0.23 31.3 2.20...
  • Page 57 Additional technical data regarding wiring, electrical Eco Xcel model rooftop air conditioning units which are fitted connectors and relay assignment are listed below . UNIT CONTROLLER FIGURE NUMBERS 50-2104 Figure 5-1 T50-2112 Figure 5-2 5--1 © 2015 Mobile Climate Control...
  • Page 58 © 2015 Mobile Climate Control 5--2 T-367 Rev. 05/2015...
  • Page 59 © 2015 Mobile Climate Control 5--3 T-367 Rev. 05/2015...
  • Page 60 INDEX Low Pressure Switch 1--3, 1--4, 4-11 Air Filter 4-15 Maintenance Schedule 4-1 Circuit Breaker 1--4 Clutch 4-18 Oil Level 4-19 Compressor 1--3, 4-16, 4-17 Operating Instructions 2--1 Condenser Fan 1--3 OPERATION 2--1 Condensing Section 1--2 Pressure Transducer 4-21 DESCRIPTION 1--1 Pump Down 4-6, 4-16...
  • Page 61 INDEX Top Cover TROUBLESHOOTING 3--1 Water Temperature Switch 1--3 T-367Rev05/2015 © 2015 Mobile Climate Control...
  • Page 62 MCC provides exceptional performance in mobile climate comfort. 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. 3189 Farmtrail Road York PA 17406 USA Tel: 1--800--673--2431 Fax: 1--717--764--0401 T-367 Rev.

This manual is also suitable for:

T50-2112

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