MCC EM-1 User manual

OPERATION AND SERVICE
for
SPLIT SYSTEMS
Generation 4 & 5
REV. 08/2012
T-299 Manual
T-299 Manual
©2012 Mobile Climate Control

©2012 Mobile Climate Control T-299 Rev. 08/2012
Safety --1
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, service,
and maintenance of the equipment covered herein. The general safety notices are presented in the following
three sections labeled: First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific
warnings and cautions appearing elsewhere in the manual follows the general safety notices.
FIRST AID
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention
immediately.
OPERATING PRECAUTIONS
Always wear protective eye wear (safety glasses or goggles).
Keep hands, clothing and tools clear of the evaporator and condenser fans.
No work should be performed on the system unless battery power is disconnected.
Always work in pairs. Never work on the equipment alone.
In case of severe vibration or unusual noise, stop the system and investigate.
MAINTENANCE PRECAUTIONS
Familiarize yourself with the proper operation of any service equipment you will be using (voltmeter, amp
probe, manifold gauges, etc.). Always read the owner's manual that is enclosed with the equipment
Always follow the manufacturers instructions for your recovery/recycling equipment. Failure to do so could
cause personal injury or damage to your equipment. Never perform any maintenance or service on your
equipment before consulting with authorized service personnel. Always unplug unit before attempting any
maintenance. Removing internal fittings and filters can release pressurized refrigerant. Slowly release pressure
and always wear appropriate safety wear.
Avoid breathing any refrigerant vapor, lubricant vapor, or mist. Exposure to these, particularly PAG oil mist,
may irritate your eyes, nose, or throat.
Always use a DOT (Department of Transportation) approved cylinder for storing used and recycled
refrigerant. Approved cylinders will be stamped DOT 4BW or DOT 4BA. MCC recommends a MACS(Mobile
Air Conditioning Society) certification in Recovery/Recycling to gain more information on handling and using
refrigerants.
Never attempt to apply heat or open flame to a refrigerant cylinder. High temperatures can raise the cylinder
pressure to dangerous levels. MCC recommends using a heat blanket to increase the internal temperature of the
refrigerant cylinder, greatly increasing the transfer of refrigerant to the bus air conditioning system.
Never use compressed air (shop-air) to leak-test or pressure test a R134a system. Under certain conditions,
pressurized mixtures of R134a and air can be combustible. In addition, shop air will inject moisture into the
system.
Always use mineral oil to lubricate “O” Rings, hoses, and fittings on R134a systems.PAG oils will absorb
moisture and become very acidic and corrosive. Mineral oil will not absorb moisture and thus prevent
corrosion. Always wear gloves when working with PAG and Ester lubricants to prevent irritation to your skin.
R134a lubricants can also damage vehicles paint, plastic parts, engine drive belts and coolant hoses.
Beware of unannounced starting of the evaporator and condenser fans.Do not remove the evaporator cover or
condenser fan guards without disconnecting the vehicle battery cable.
Be sure power is turned off before working on motors, controllers, and electrical control switches. Tag system
controls and vehicle battery to prevent accidental energizing of the system.

Safety - 2
©2012 Mobile Climate Control T-299 Rev. 08/2012
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires.
Problems with the system should be diagnosed, and any necessary repairs performed, by qualified service
personnel.
When performing any arc welding on the vehicle, disconnect the vehicle battery.
In case of electrical fire, extinguish with CO2(never use water). Disconnect vehicle battery power if possible.
SPECIFIC WARNINGS
WARNING
Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the
fans and compressor unexpectedly as control requirements dictate.
WARNING
Be sure to observe warnings listed in the safety summary in the front of this manual before per
forming maintenance on the air conditioning system
WARNING
Never use air for leak testing. It has been determined that pressurized, air-rich mixtures of re
frigerants and air can undergo combustion when exposed to an ignition source.
WARNING
Do not use a nitrogen cylinder without a pressure regulator. Do not use oxygen in or near a
refrigeration system or as an explosion may occur.
WARNING
To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suc
tion pressure before disconnecting.
WARNING
There may be liquid refrigerant trapped behind the block valve. Slowly loosen the fitting and avoid
contact with exposed skin or eyes.
WARNING
The filter-drier may contain liquid refrigerant. Slowly open the fitting nuts and avoid contact with
exposed skin or eyes.
CAUTION
Unless there was a catastrophic failure, such as a blown or ruptured refrigerant hose, additional
oil may not be needed.

©2012 Mobile Climate Control T-299 Rev. 08/2012
Safety --3
CAUTION
Use only the exact oil specified by the compressor manufacturer. Use of oil other than that spe
cified will void the compressor warranty.

1
©2012 Mobile Climate Control T-299 Rev. 08/2012
Table of Contents
SAFETY SUMMARY Safety -1...............................................................
SPECIFIC WARNINGS Safety -2......................................................
SECTION 1 1-1............................................................................
DESCRIPTION 1-1....................................................................
1.1 INTRODUCTION 1-1.......................................................
1.2 WHAT IS AIR CONDITIONING 1-1...........................................
1.3 MODEL AND SERIAL NUMBER TAGS 1-1.....................................
1.4 SYSTEM REQUIREMENTS LABEL 1-5........................................
1.5 SYSTEM DESIGNATIONS 1-5................................................
1.6 SYSTEM COMPONENTS 1-5.................................................
1.7 REFRIGERATION SYSTEM COMPONENT SPECIFICATIONS 1-6.................
a. EXPANSION/BLOCK VALVE: 1-6......................................................
b. PRESSURE SWITCHES: 1-6.............................................................
c. FREEZE-UP THERMOSTAT: 1-7........................................................
d. RETURN AIR THERMOSTAT/SENSOR 1-7...............................................
e. EVAPORATOR MOTORS 1-7...........................................................
f. CONDENSER MOTORS 1-7............................................................
g. COMPRESSORS 1-7...................................................................
1.8 COOLING CYCLE 1-7.......................................................
1.9 HEATING CYCLE (If Applicable) 1-10...........................................
SECTION 2 2-1............................................................................
OPERATION 2-1......................................................................
2.1 OPERATING INSTRUCTIONS 2-1............................................
2.2 MANUAL CONTROLS 2-1...................................................
2.2.1 Driver's Control Panel 2-1...............................................................
2.2.2 Fan Speed Switch (three speed or variable) 2-1................................................
2.2.3 Thermostat Control 2-1.................................................................
2.2.4 Electrical Control Panel 2-1..............................................................
2.3 FLORIDA CONTROL (TEMPCON) 2-2........................................
2.3.1 ON/OFF Function 2-2.................................................................
2.3.2 Fan Speed Switch - 3 Speed 2-2...........................................................
2.3.3 Adjusting Set Point (Interior Temperature Adjustment) 2-2......................................
2.4 IN-LINE FUSE (FLORIDA CONTROL) 2-2.....................................
2.5 TOTAL CONTROL 2-3......................................................
2.5.1 Total Control Operation 2-3...................................................
2.6 GEN 4 - WITH TOTAL CONTROL, UNIT OPERATING INSTRUCTIONS 2-5........
2.7 PRE-TRIP INSPECTION 2-5..................................................
2.8 SEQUENCE OF OPERATION 2-5.............................................
2.8.1 Three Position Switch Operation 2-5.......................................................

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©2012 Mobile Climate Control T-299 Rev. 08/2012
Table of Contents
2.8.2 Variable Speed Control Operation 2-6......................................................
2.8.3 Total Control - Gen 5 Operation 2-6.......................................................
2.8.4 Total Control - Gen 4 Operation 2-6.......................................................
2.8.5 Heat Option 2-7.......................................................................
2.9 EnviroMATE Controller (Single Zone) 2-8........................................
2.9.1 Controller Operation 2-8................................................................
2.9.2 Evaporator Fan Operation 2-8............................................................
2.9.3 Cooling Mode 2-9......................................................................
2.9.4 Heating Mode (If equipped) 2-9...........................................................
2.9.5 Sensors 2-9...........................................................................
2.9.6 Voltage 2-9...........................................................................
2.9.7 Schematics 2-9........................................................................
2.9.8 Alarm Descriptions 2-10..................................................................
2.10 EnviroMATE Controller (Dual Zone) 2-11.........................................
2.10.1 Controller Operation 2-11................................................................
2.10.2 Evaporator Fan Operation (Automatic) 2-12..................................................
2.10.3 Evaporator Fan Operation (Manual) 2-12.....................................................
2.10.4 Cooling Mode 2-12......................................................................
2.10.5 Heating Mode (If equipped) 2-13...........................................................
2.10.6 Sensors 2-13...........................................................................
2.10.7 Voltage 2-13...........................................................................
2.10.8 Schematics 2-13........................................................................
2.10.9 Alarm Description (Dual Zone) 2-14........................................................
SECTION 3 3-1............................................................................
TROUBLESHOOTING 3-1..................................................................
3.1 INSUFFICIENT OR NO COOLING 3-1. ..........................................
3.1.1 Preliminary Checks 3-1.. .....................................................................
3.1.2 Checking System Air Output 3-1.. .............................................................
3.1.3 Check The Sight Glass For Bubbles 3-1.. ........................................................
3.1.4 Compressor Amp Draw 3-1.. .................................................................
3.2 SYSTEM WILL NOT COOL 3-4. .................................................
3.3 SYSTEM RUNS BUT HAS INSUFFICIENT COOLING 3-4. ...........................
SECTION 4 4-1............................................................................
SERVICE 4-1........................................................................
4.1 PREVENTATIVE MAINTENANCE SCHEDULE 4-1.............................
4.2 MAINTENANCE PROCEDURES 4-2..........................................
4.3 INSTALLING MANIFOLD GAUGES 4-2.......................................
4.4 REFRIGERANT RECOVERY 4-5..............................................
4.5 REFRIGERANT LEAK CHECKING 4-5........................................
4.6 EVACUATION AND DEHYDRATION 4-5.....................................
4.6.1 General 4-5...........................................................................

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©2012 Mobile Climate Control T-299 Rev. 08/2012
Table of Contents
4.6.2 Preparation 4-5........................................................................
4.6.3 Procedure For Evacuation and Dehydrating System (Triple Evacuation) 4-6.........................
4.7 PROCEDURE FOR EVACUATION AND DEHYDRATING SYSTEM 4-6............
4.8 ADDING REFRIGERANT TO A SYSTEM 4-6...................................
4.8.1 Checking Refrigerant Charge 4-6..........................................................
4.8.2 Adding Full Charge 4-6.................................................................
4.8.3 Adding Partial Charge 4-6................................................................
4.9 COMPRESSOR(S) 4-7........................................................
4.9.1 Evaporator Tie-In 4-9.. ...................................................................
4.10 TORQUE SPECIFICATIONS - REFRIGERANT FITTINGS 4-11.....................
4.11 TORQUE SPECIFICATIONS - BOLTS 4-11......................................
4.11.1 Electrical Control Panel - Torque Values 4-11.................................................
4.12 DRIVE BELT INSTALLATION 4-12............................................
4.12.1 Introduction 4-12.......................................................................
4.12.2 Belt Clearance 4-12......................................................................
4.12.3 Pulley Alignment 4-12...................................................................
4.12.4 Drive Belt Tension Guidelines 4-13.........................................................
4.12.5 Measuring Methods for Belt Tension 4-14....................................................
4.13 RETURN AIR FILTER 4-14....................................................
4.13.1 GEN 4 (EXCEL) Series 4-14..............................................................
4.13.2 GEN 5 Series 4-14......................................................................
4.14 EVAPORATOR BLOWER AND/OR MOTOR ASSEMBLY 4-15.....................
4.14.1 GEN 4 Series 4-15......................................................................
4.14.2 GEN 5 Series 4-15......................................................................
4.15 RESISTORS 4-15.............................................................
4.15.1 GEN 4 Series (Excel) 4-15................................................................
4.15.2 GEN 5 Series 4-15......................................................................
4.16 CONDENSER FAN ASSEMBLY 4-16...........................................
4.17 REPLACING THERMOSTATIC BLOCK VALVE 4-16.............................
4.18 CHECKING AND REPLACING HIGH PRESSURE SWITCH 4-16...................
4.18.1 Replacing High or Low Pressure Switch 4-16.................................................
4.18.2 Checking High Pressure Switch 4-16........................................................
4.19 MOISTURE INDICATOR (SYSTEM) 4-17........................................
4.20 FILTER-DRIER OR RECEIVER-DRIER 4-17.....................................
SECTION 5 5-1........................................
ELECTRICAL SCHEMATIC DIAGRAMS 5-1.....................................................
5.1 INTRODUCTION 5-1.......................................................

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©2012 Mobile Climate Control T-299 Rev. 08/2012
List of Tables
Table 1-1 Additional Support Manuals 1-1................................................
Table 3-1 Evaporator Current Draw (GEN 4) 3-2..........................................
Table 3-2 Evaporator Current Draw (GEN 5) 3-3..........................................
Table 3-3 Condenser Current Draw (GEN 5) 3-3...........................................
Table 3-4 GENERAL SYSTEM TROUBLESHOOTING PROCEDURES 3-4...................
Table 3-4 GENERAL SYSTEM TROUBLESHOOTING PROCEDURES - Continued 3-5.........
Table 4-1 Split System Refrigerant And Oil Charging Table - Thru GEN 4 4-8....................
Table 4-2 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (GEN-5) 4-8.......
Table 4-3 SPLIT-SYSTEM GEN-5 WITH MICRO-CHANNEL CONDENSER 4-8..............
Table 4-4 Compressor Oil Type & Part Numbers 4-9.......................................
Table 4-5 Mobile Climate Control SYSTEM PERFORMANCE CHART 4-10.....................
Table 4-6 STANDARD TORQUE REQUIREMENTS 4-11..................................
Table 4-7 Metric Torque Specs 4-11......................................................
Table 4-8 U.S. Torque Specs 4-11........................................................
Table 4-9 Belt Tension Guide 4-14.......................................................
Table 4-10 R-134a Temperature - Pressure Chart 4-19........................................
List of Figures
Figure 1-1 Condenser Model CM2/3 - Serial Number Location 1-2............................
Figure 1-2 GEN 4 Evaporator Model - Serial Number Location 1-2...........................
Figure 1-3 GEN 5 Evaporator Model (All) - Serial Number Location 1-2.......................
Figure 1-4 GEN 4, IW-2 & IW-7 - Serial Number Location 1-3...............................
Figure 1-5 GEN 4, IW-1 - Serial Number Location 1-3.....................................
Figure 1-6 CM-7/11 Rooftop Condensers (No Longer Offered) - Serial Number Location 1-4.......
Figure 1-7 KR-2/KR-3 Rooftop Condensers - Serial Number/PID Location 1-4.................
Figure 1-8 System Requirements Label 1-4...............................................
Figure 1-9 Component Location Diagram 1-6............................................
Figure 1-10 Air Conditioning Refrigerant Flow Diagram - Small Split System 1-9..................
Figure 1-11 Heating System Flow Diagram (Typical) 1-10....................................
Figure 2-1 Drivers Control Panel 2-1...................................................
Figure 2-2 Electrical Panel (Typical) 2-1.................................................
Figure 2-3 Switch Assembly (TEMPCON) 2-2............................................
Figure 2-4 In-Line Fuse & Holder (3 Amp) 2-2...........................................
Figure 2-5 Total Control Key Pad/Display 2-3............................................
Figure 2-6 Null Band 2-4............................................................
Figure 2-7 Total Control Electrical Control Panel (Typical) 2-4...............................
Figure 2-8 EnviroMATE Control Panel 2-8..............................................
List of Figures

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©2012 Mobile Climate Control T-299 Rev. 08/2012
Figure 2-9 EnviroMATE Alarms (Single Zone) 2-10........................................
Figure 2-10 EnviroMATE Control Panel 2-11.............................................
Figure 2-11 EnviroMATE Alarms (Dual Zone) 2-14........................................
Figure 4-1 Manifold Gauge Set 4-2.....................................................
Figure 4-2 Refrigerant Service Connections (Split Systems) 4-4...............................
Figure 4-1 Micro-Channel Style Condenser Assembly 4-9...................................
Figure 4-3 Metric Bolt Markings 4-11....................................................
Figure 4-4 U.S. Bolt Markings 4-11......................................................
Figure 4-5 Belt Clearance Requirements 4-12..............................................
Figure 4-6 Belt Misalignment 4-13......................................................
Figure 4-7 Straight-Edge Application 4-13................................................
Figure 4-8 GEN 4 Series Resistor Assembly 4-15...........................................
Figure 4-9. Checking High Pressure Switch 4-17............................................
Figure 4-10 Filter Drier 4-18...........................................................
Figure 4-11 Receiver-Drier 4-18........................................................
Figure 5-1 Electrical Schematic Diagram - Symbols 5-1.....................................
Figure 5-2 Legend - Electrical Schematic Diagrams 5-2.....................................
Figure 5-3 GEN 4 System Schematic - EM-1 With CM-2/3 5-3...............................
Figure 5-4 GEN 4 System Schematic - EM-1 With CM-2/3 - Tie-In 5-4........................
Figure 5-5 GEN 4 System Schematic - EM-3 With (2) CM-3 Condensers & (2) Compressors 5-6.....
Figure 5-6 GEN 5 Evaporator (With Variable Speed Control) Schematic 5-6....................
Figure 5-7 GEN 5 System Schematic With Total Control 5-7.................................
Figure 5-8 GEN 4 EM-3 With (2) CM-3 With Total Control - System Schematic 5-8..............
Figure 5-9 GEN 4 Series With Total Control 5-9..........................................
Figure 5-10 Gen V with EnviroMATE Controller (Single Zone) 5-10...........................
Figure 5-11 Gen V with EnviroMATE Controller (Dual Zone, 2 Evaps., 2 condensers, 2 Comps.) 5-11.
Figure 5-12 Gen V with EnviroMATE Controller (Dual Zone, 3 Evaps., 2 condensers, 2 Comps.) 5-12.

1--1
©2012 Mobile Climate Control T-299 Rev. 08/2012
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
This manual contains Operating, Service, and
Maintenance Instructions for Gen 4 and Gen 5 Split
System Air Conditioning and Heating equipment
furnished by Mobile Climate Control. Additional
support manuals are listed in Table 1-1.
A Split System normally includes an Evaporator(s), a
Condenser(s) a Compressor(s) and interconnecting
refrigerant hoses, fittings, and electrical harnesses
and controls. A listing of the evaporator and
condenser models, along with specific data for each,
is provided in the component data that follows.
Specific systems may vary, this manual does not
cover all combinations, variations, and applications,
it does set up standards from which processes can be
measured. Contact Mobile Climate Control
Technical Service Hot-Line for additional assistance
(800-450-2211).
1.2 WHAT IS AIR CONDITIONING
Air Conditioning is the cooling, heating,
dehumidification, and filtration of the air located
within the passenger compartment of a vehicle.
1.3 MODEL AND SERIAL NUMBER TAGS
In order to identify the air conditioning components
you have, you will need to know the model number
and serial number. All Mobile Climate Control
evaporators, condensers and compressors have a
model/serial number tag or PID decal located on the
assembly. See Figure 1-1 for all skirt mounted
condenser data tag locations, Figure 1-2 for GEN 4
evaporator data tag location, Figure 1-3 for GEN 5
evaporator data tag locations, Figure 1-4 &
Figure 1-5 for In-Wall data tag locations, Figure 1-7
for KR-2 & KR-3 PID locations and Figure 1-6 for
the CM-7 & CM-11 rooftop condensers data tag
location. The CM-7 and CM-11 rooftop condensers
are no longer available from MCC.
NOTE
The EM-9 evaporator data tag is located on
the side of the evaporator assembly, not
between the blower assemblies (See
Figure 1-2).
Knowing these locations and the information on the
data tags will aid you in identifying the correct service
procedures.
1.3.1 PID Data Tag (Decal)
All KR2, KR3 & KR4 Rooftop Condensers have
PID Decals instead of the standard Model/Serail tag.
These tags will list the following:
a. System Model No. (Example - 68KR4-101-2)
b. Serial No.
c. P.I.D. (Example - KR4C00032)
d. Refrigerant (Example - R134a)
e. Voltage (Example - 13.5 VDC)
f. Amps (Example - 25A)
g. Unit Weight (Example - 186 lbs.)
Table 1-1 Additional Support Manuals
MANUAL NUMBER EQUIPMENT COVERED TYPE OF MANUAL
T-299PL Split Systems Parts List
T-311 Split Systems Installation Procedures