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Star Cool SC-MCI40 Operating And Service Manual

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Operating and service manual
Star Cool refrigeration unit Model SC – MCI40 and SC – MCI40 – WC
Version 810900B

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Summary of Contents for Star Cool SC-MCI40

  • Page 1 Operating and service manual Star Cool refrigeration unit Model SC – MCI40 and SC – MCI40 – WC Version 810900B...

  • Page 2: Preface

    Operating and service manual Preface This version of the manual is edited by Maersk Container Industry AS. All rights reserved. This user’s manual is valid for software version 0240 or newer versions. The information herein is subject to change without notice and does not represent a commitment on any part of Maersk Container Industry AS.

  • Page 3: Table Of Contents

    Operating and service manual Contents Preface ................................1 Warnings ................................. 1 Legend ................................6 General description ............................8 Function description ............................9 Start-up procedure ............................. 9 Climate Control Function ........................... 10 Temperature Control ..........................10 Capacity Control and Limiter ........................10 Expansion Valve ............................
  • Page 4 Location of motors, temperature sensors, humidity sensor and air exchange potentiometer ...... 54 Location of pressure transmitters, high pressure switch and oil outlet port ..........55 General trouble shooting ..........................55 Trouble shooting for Star Cool main controller ..................... 56 3 of 222 pages...
  • Page 5 Operating and service manual Detailed alarm description ..........................56 Alarm list ..............................57 Temperature Sensor Alarms (AL 1XX) ......................61 Pressure transmitter Alarms (AL 2XX) ....................... 90 Other Sensor Alarms (AL 3XX) ........................97 Power Alarms (AL 4XX) ........................... 104 Frequency Converter (FC) Alarms (AL 5XX) ....................
  • Page 6 Voltage – Pressure Table, High pressure transmitter (NSK) ................. 215 Temperature Sensor - Voltage Table ......................216 Tightening torques ..........................217 P & I diagram .............................. 218 Controller Unit Illustration ......................... 219 Star Cool Unit, installation dimensions ....................... 220 Overall Wiring Schematic ..........................222 5 of 222 pages...

  • Page 7: Legend

    Operating and service manual Legend Short name Name Short name Name AirEx Air Exchange Power used by Frequency Converter Alarm Alarm PhDir Phase Direction Danfoss pressure transmitter Psuc Suction Pressure Battery Ptot Power Total CalAex Calibration value AirEx Pre Trip Inspection CalUs1 Calibration USDA sensor 1 PTI Short...
  • Page 8 Operating and service manual Prefix Description Frequency Heater Current Motor Pressure Power Relative humidity Switch / contact / key Super heat Temperature Saturated suction tem- perature Voltage Valve Contraction Full name Ambient Battery Cond Condenser Compressor Discharge Economizer Evap Evaporator Frequency converter Motor Compressor motor...

  • Page 9: General Description

    Operating and service manual General description units, models SCU-40 and SCI-40 are electric powered picture frames, cooling and heating units operating on refrigerant R134a. The unit is designed to maintain cargo temperatures in a range from –30°C (-22°F) to +30°C (86°F). The unit is designed to operate in ambient temperatures from –30°C (-22°F) to +50°C (122°F).

  • Page 10: Function Description

    Operating and service manual temperature control is in set point range. The unit is equipped with heating elements, mounted under the evaporator coil, for the de-humidification. The de-humidification system is also active in economy mode. The unit is equipped with a dual system for defrosting. There is installed a hot gas valve, in the refrigeration system, for hot gas defrosting of the evaporator coil.

  • Page 11: Climate Control Function

    Operating and service manual Climate Control Function Temperature Control This function incorporates the container temperature controller. The function has 2 modes: Chill and Frozen. • Chill If Tset more than (>) -5°C (23°F) the chill mode is activated and Tact = Tsup. •...

  • Page 12: Expansion Valve

    Operating and service manual Below figure indicates the ranges for the capacity and compressor speed (frequency). Compressor frequency, Hz 110 Hz (3300 rpm) Set point Set point line 1 line 3 20 Hz (600 rpm) line 2 -100% -20% +10% 100% Capacity cooling...

  • Page 13: Economizer Valve

    Operating and service manual At start-up the opening rate is 0%. The electronic expansion valve is an on/off valve controlled on the basis of opening rate with a constant cycle time. MOP function The MOP function prevents the suction pressure from getting too high. Economizer Valve This function ensures optimum sub cooling of liquid to the evaporator and cooling of the FC.

  • Page 14: Condenser Fan

    Operating and service manual Condenser Fan Condenser fan control will reduce condenser pressure through condenser ventilation. The condenser pressure control also monitors the compressor outlet pressure in case of water- cooling. This function is activated when control is being in the automatic mode. Condenser pressure control has two primary modes: Air-cooled Water-cooled...
  • Page 15 Operating and service manual Wait mode termination can be due to: • Calculated ice amount in the evaporator is above critical level (Demand defrost) • Defrosting action initiated manually (Manual defrost initiation) Initialize Wait until condenser temperature is above 50°C (122°F), however no more than 300 sec. Execute In this mode the actual evaporator defrosting takes place: A Defrost start event is made in the trip log.

  • Page 16: Quest (Optional)

    If O03 is empty, QUEST is not installed. Star Cool is responsible for that the QUEST function is operating within the parameters and the running pattern defined by the protocol. Star Cool is however not liable for any consequent dam- ages caused by the QUEST functionality.

  • Page 17: Function Test

    Operating and service manual Function test Function test is a unit component test. (Non destructive) Test is based on a GO/NO GO procedure. All tests must be executed without failure one by one for the function test result to be PASS. Note: The tests can also be performed individually.
  • Page 18 Operating and service manual When an alarm is activated it triggers a complete log, however max. one per 15 min. The datalogger can hold approximately 10.000 logs or more than 1 year of loggings with default logging interval of one log per hour. The following tables show retrievables with Starview and Psion Logman software: File Download Info Signature...

  • Page 19: Alarm Action System (Aas)

    Extended Log Type 1 can only be retrieved by Logman and StarView and shown in LogView and StarView. Extended Log Type 2 can only be retrieved by StarView and viewed in StarView. StarView is the unique program designed for communication with a Star cool unit through a serial connection to a PC. Alarm Action System (AAS) This function defines what to do if a sensor is defect.

  • Page 20: Dehumidification Control

    Operating and service manual Pdis Start up: Condenser fan speed = slow Chill/Freeze mode: Condenser fan speed depends on ambient temperature. Tamb Tamb = Tinternal Tret, Tevap and Tsup1 Tact = Tsup2 + constant Tamb and Tinternal Tcmin Dehumidification control If dehumidification is active: Defective sensor(s) Substitution sensor / Action...

  • Page 21: Refrigeration System Data

    Operating and service manual Frequency AL417, AL418, AL429 AL427 AL428 AL429 AL414, (f) [Hz] AL419 at voltage at voltage at voltage at voltage AL415, Min. voltage (U) [V] (U) [V] (U) [V] (U) [V] AL416 (U) [V] Fatal Alarm Fatal Alarm Max.

  • Page 22: Compressor - Motor Assembly

    Operating and service manual Compressor – motor assembly Manufacturer Bitzer Type Semi – hermetic two-stage reciprocating Number of cylinders 2 Low stage cylinders 2 High stage cylinders Speed Variable, FC controlled Model S4BCF – 5.2Y. Nominal power 5.5 kW Compressor oil type Reniso Triton SEZ 55 or equivalent Compressor oil quantity 1.5 L...

  • Page 23: Evaporator Fan

    Operating and service manual Fin spacing 2.0 mm Coating, tube/fin Cataphoresis treatment, with additional acrylic resin Evaporator fan Material Polypropylene, glass fibre reinforced Type Axial Number of fans / blades 2 pcs / 7 pcs Pitch 25° Diameter ø315 mm Drive Direct on motor shaft Condenser fan...

  • Page 24: Fresh Air Exchange

    Operating and service manual Fresh air exchange Fresh air exchange Adjustable 0 – 220 m3/h (0 – 129 CFM) at 60 Hz. adjustable by steps of 5 m3/h. Equivalent to 0 - 170 m3/h (0 –100 CFM) at 50 Refrigeration controls Expansion valves 2 solenoid valves, electronically controlled by the controller...

  • Page 25: Power Cable

    Operating and service manual Power Cable Type 4 x (2.5-4) mm , 450 / 750 V, PU – sheath Length 18 m Colour Yellow Temperature Range -37°C to +90°C (-34.6°F to 194°F) USDA socket requirements Location Rear left side Number 3 pieces + 1 cargo sensor Type Deutsch HD 10, female socket.

  • Page 26: Evaporator Coil Heaters

    Operating and service manual Bearing size Drive end Non - drive end 6204 2Z C3 6201 2Z C3 Bearing lubricant Lubricant Klüberquiet BQH 72 – 102 or equivalent. Temp. range: -40°C to +140°C (-40°F to 284°F) Evaporator coil heaters Type ø8,5 mm in stainless steel AISI 304 Number Rating...

  • Page 27: User Interface

    Operating and service manual User Interface Indicator lights Alarm indicator light In-range indicator light Alarm In range SLOW FLASH if there are active NORMAL FLASH when controlling alarms. temperature probe is inside the QUICK FLASH if there are fatal acceptable range alarms.

  • Page 28: Key Pad

    Operating and service manual It is possible to obtain a datalog graph display ( “Datalog view:” p. 46) Key pad Navigation keys Use these keys to move menu display up / down and to change parameter values Cancel Leave active sub menu Cancel active parameter adjustment Move menu one line up Increment parameter value in menu...

  • Page 29: Menu Overview

    Operating and service manual Menu keys Press key to select menu display Press again to move menu one full page down Wake-up Turn on and off battery powered display operation No display backlight will be active Show PRE TRIP INSPECTION menu (start/stop test and view re- sults) Info Show INFORMATION menu (actual data read out)

  • Page 30: General Page Layout

    Operating and service manual General Page layout Control mode Using the cursor The parameter ID is only used for identifying each displayed line of the menu system. Pressing the arrow keys will move the highlighted cursor one menu line up or down. In the upper right corner of the display is shown the actual line number of the cursor together with the total number of lines in the current menu.

  • Page 31: Air Exchange Page

    Operating and service manual Air exchange page Air exchange 1/ 1 Press (X) to leave This page is automatically displayed when the user starts changing the air exchange valve posi- tion. The display returns to the main page after 10 min. or when the Cancel key is pressed. To view actual airflow at a different time use information menu I02 30 of 222 pages...

  • Page 32: Operation

    Operating and service manual Operation Menu Structure INFORMATION PROGRAMS Relative humidity Active program Air exchange Multi. Temp setp. > Last defr interval Cold treatment > USDA 1 temp USDA 2 temp USDA 3 temp Cargo temp Time to defrost COLD TREATMENT Ambient temp Supply air 1 temp Duration...

  • Page 33: General Operation

    Wake-up Mode When no main power is present the controller is switched off. The controller includes a battery for “Star Cool” operation when no external voltage supply is present. For battery saving in this situation, controller will turn itself off upon disappearance of external voltage supply.

  • Page 34: Pti Or Function Test Execution

    Operating and service manual PTI or Function Test execution The test menu is opened by pressing . In the test menu, press keys to scroll the menu. For a complete PTI test START must be highlighted by pressing at menu item T01. Pressing once more initiates the test.
  • Page 35 Operating and service manual T03 Abort the running test (Abort the test) Function: Stop the running PTI or function- test. Value: To stop the running test, STOP must be highlighted by pressing . Pressing once more stops the test. T04 Test status (Test status) Function: Shows the status of the last/running test: Value:...
  • Page 36 Operating and service manual Value: “-“ if not done yet. “RUN” if still running test. “PASS” if test finished successfully. “FAIL” if the test failed. “ABORT” if the test was aborted by the user. See specific description for alarm 820 - 821 in Test alarms p.154 T11 Test result: 80 Compressor (80 Compressor) Function:...

  • Page 37: Info Menu Viewing

    Operating and service manual Value: “-“ if not done yet. “RUN” if still running test. “PASS” if test finished successfully. “FAIL” if the test failed. “ABORT” if the test was aborted by the user. See specific description for alarm 870 in Test alarms p.161 T18 Test result: 140 PTI status (140 PTI status) Function:...
  • Page 38 Operating and service manual I08 Time to next defrost (Time to defrost) Function: Shows current time to the next defrosting. Value: Shown in hours and minutes. I09 Ambient temperature (Ambient temp) Function: Shows current ambient temperature. Value: Shown in temperature scale °C or °F. Switch by pressing I10 Supply air 1 temperature (Supply air 1 temp) Function: Shows current temperature for supply 1 sensor.
  • Page 39 Operating and service manual Value: Shown in units of Bar or Psi relative to atmosphere pressure. Switch by pressing (at °C pres- sure is shown in BarE, at °F in Psi). I19 Expansion valve opening (Expansion valve) Function: Shows current percentage of expansion valve opening. Pulse Wide Modulation Value: Shown as a percent value.
  • Page 40 Operating and service manual Value: Shown in units of volt. I29 Phase direction (Phase direction) Function: Shows current phase sequence. Value: Shown as CW or CCW or None. Value is not user-changeable. If AL 423 “No phase direction” go to configuration F05 for settings.

  • Page 41: Operation Parameter Setting

    Operating and service manual Operation Parameter Setting By pressing the operation menu is selected. The icon is displayed. Use the arrow keys to navigate and the Enter key to select. Operation menu includes the following parameters: O01 Setpoint (Setpoint) Function: The function is used for changing the setpoint.

  • Page 42: Multiple Temperature Set Points Program, Mts

    Operating and service manual P01 Show/select active program (Active program) Function: Shows active program or activates selected program. Attention: Program set points have to be set before activating the program is activated. Value: Shown as None, CT or MTS. Press for 3 seconds to activate selected program or stop an active program by selecting None.

  • Page 43: Cold Treatment Program, Ct

    Operating and service manual Cold Treatment program, CT B01 Duration of the treatment B05 (CT Status) Loading cargo Cold Treatment Pull down to Ramp up temp. passed treatment = 0.1 C°/hour temperature O01 = set-point B01 = Cold Treatment periode B03 = Cold Treatment temperatur Cold Treatment...

  • Page 44: Alarms

    Operating and service manual B04 Final temperature (Final temperature) Function: Setting of final setpoint Value: Value: -10.0°C to +30.0°C. After the treatment period the cargo might need to be warmed up to a higher temperature. The setpoint is increased by 0.1°C per hour until the final temperature is reached. When the final tem- perature is reached, the Cold Treatment program is finished and stops automatically and the “CT”...

  • Page 45: Service Function Setting/Viewing

    Operating and service manual Alarm type Datalog Alarm list Red LED Cargo risk No risk for the cargo Warning No risk for the cargo Alarm SLOW FLASH Risk for the cargo 2% ON, 98 % OFF Duty time of 3 sec Fatal Alarm QUICK FLASH Serious risk for the...

  • Page 46: Manual Operations

    In menu item M05 compressor frequency is set. In case of no keyboard activities for 5 min., manual mode is automatically deactivated and unit starts automatically up. Note that the “Star Cool” should only be set in the manual mode by trained service personnel! Value: Set to MANUAL or AUTOMATIC.

  • Page 47: Datalog View

    Operating and service manual M08 Setting of economizer valve % opening (Economizer valve) Function: Manual setting of economizer valve % opening. Note that value is only accepted if control is in the manual mode (menu item M01 is MANUAL). Value: Set from 0 to 100%.

  • Page 48: Run Time Counters

    Setting of min. Note: when min. are set, sec. are set to 00. Value: Set from 0 to 59. Run time counters: R01 Viewing of operation hours for the Star Cool unit (Unit) Function: Viewing of Star Cool unit operation hours. Value: Shown as hours.

  • Page 49: Configuration

    Operating and service manual Configuration: F01 Container ID viewing (Container) Function: Viewing of container ID. Value: Shown in the lower display line. E.g. MCID 000 001 2 F02 Software version viewing (Software version) Function: Viewing of software version and revision Value: F03 Compressor FC type setting (FC type) Function:...

  • Page 50: Serial Numbers

    A automatically or manually initiated defrosting may be terminated by pressing and holding it for 3 sec. The display will cancel the icon. Water-cooling Activation/Deactivation The following only applies for Model SC-MCI40-WC Water-cooling connecting is executed as follows: • The container must be connected to the water-cooling system. •...

  • Page 51: Emergency Operation

    Operating and service manual Emergency Operation Warning: High Voltage. Unit must be disconnected from power. Only to be done by trained personnel. FC dismounted If FC is defective and no replacement part is available, compressor may be run in the on / off mode.

  • Page 52: External Interfaces

    Operating and service manual External interfaces The Star Cool controller can be accessed externally in the following ways: StarCool Unit RefCon RefCon logfile RS 232 Powerline modem RCCU-5 Controller & Datalogger Binary Retriever LogMan LogView logfile RS 232 RS 232...

  • Page 53: Functions Overview

    Operating and service manual Functions overview It is defined in the table below, which Star Cool functions each device and system will support. Function LogMan LogView RefCon StarView Controller Display basic data Display alarm list Display controller information Change container ID...

  • Page 54: Location Of Valves

    Operating and service manual Location of valves Position Description Discharge pressure stop valve Intermediate pressure stop valve Hot gas valve Service valve, economizer Electronical expansion valve, evaporator Electronical expansion valve, economizer Suction pressure stop valve 53 of 222 pages...

  • Page 55: Location Of Motors, Temperature Sensors, Humidity Sensor And Air Exchange Potentiometer

    Operating and service manual Location of temperature sensors, humidity sensor and air exchange potentiometer 100mm Insert depth: 60mm 100mm Description Short Number Location Accessibility name Suction temperature sensor Tsuc Inside Through inspection hatch Relative humidity sensor Inside Through inspection hatch Evaporator temperature sensor Tevap Inside Through inspection hatch...

  • Page 56: Location Of Pressure Transmitters, High Pressure Switch And Oil Outlet Port

    Operating and service manual Location of pressure transmitters, high pressure switch and oil outlet port Description Short name Number Location Discharge Pressure transmitter Pdis Outside Economizer Pressure transmitter Peco Outside (optional) High pressure switch Outside Suction Pressure transmitter Psuc Outside Oil outlet port Outside General trouble shooting...

  • Page 57: Trouble Shooting For Star Cool Main Controller

    5. Display is blank. Adjust contrast (see “Contrast adjustment of the display” p. 32) Trouble shooting for Star Cool main controller A method to check if the controller is performing correct readings. If there is a problem with a sensor or a transmitter, the X1 cable on the controller door must be disconnected to see if the defect is with the sensor/transmitter or the controller door.

  • Page 58: Alarm List

    Operating and service manual Alarm list The following list includes a view of all alarms as listed on the display and a longer text. Display text Description Alarm type 1. Temperature sensor alarms Tret open Return Air Temperature Sensor Open Circuit Warning Tret short Return Air Temperature Sensor Short Circuit...
  • Page 59 Operating and service manual AirEx short Air Exchange Sensor Short Circuit Warning Not implemented yet AirEx invalid Air Exchange Sensor Invalid. Not implemented yet Warning High press switch High pressure switch is active Warning 4. Power alarms Mevap 1 over heat Evaporator Motor 1 overheat Warning Mevap 2 over heat...
  • Page 60 Operating and service manual 6. Operation alarms No control sensors Supply Air Sensor 1, Supply Air Sensor 2, Return Air Fatal Alarm Sensor All Malfunctioning No watercooling Water-cooling fault Warning Tset unreachable Tset Unreachable. Not implemented yet Alarm In range fault In-range Fault Fatal Alarm Fatal Alarm...
  • Page 61 Operating and service manual Battery malfunction Battery Malfunctioning Alarm Remote mon missing Remote Monitor Modem Missing Alarm Datalog error SCCU6 Data log Fault Alarm Database corrupt SCCU6 Database Fault Realtime error Real-time Clock Unreliable Alarm Realtime invalid Real-time Clock Unavailable Display error Display Unavailable Warning...

  • Page 62: Temperature Sensor Alarms (Al 1Xx)

    If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 63 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 64 Tables starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check Trouble shooting for Star Cool Controller p.56 before replacing controller door. Criteria Sensor is defect and the missing sensor reading has been substituted by a value from AAS system.
  • Page 65 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 66 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 67 Tables starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check Trouble shooting for Star Cool Controller p.56 before replacing controller door. Criteria Value is below alarm limit -60°C (-76°F) or above +140°C (284°F) or difference (>)
  • Page 68 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 69 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 70 Tables starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check Trouble shooting for Star Cool Controller p.56 before replacing controller door. Criteria Value is below alarm limit -60°C (-76°F) or above +140°C (284°F) or difference between (>)
  • Page 71 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 72 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 73 Tables starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check Trouble shooting for Star Cool Controller p.56 before replacing controller door. Criteria Activated by UWS or AL 901...
  • Page 74 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 75 Tables starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check Trouble shooting for Star Cool Controller p.56 before replacing controller door. Criteria Activated by UWS or AL 901...
  • Page 76 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 77 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 78 Tables starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check Trouble shooting for Star Cool Controller p.56 before replacing controller door. Criteria Activated by UWS or AL 901...
  • Page 79 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 80 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 81 Tables starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check Trouble shooting for Star Cool Controller p.56 before replacing controller door. Criteria Activated by UWS or AL 901...
  • Page 82 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 83 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 84 Tables starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check (Trouble shooting for Star Cool Controller p.56) before replacing controller door. Criteria Value below alarm limit -60°C (-76°F) or above +140°C (+284°F). Value must be invalid for 30 sec.
  • Page 85 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 86 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 87 Tables starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check, see Trouble shooting for Star Cool Controller p.56 before replacing controller door. Criteria Value below alarm limit -60°C (-76°F) or above +140°C (+284°F). Value must be invalid for 30 sec.
  • Page 88 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 89 If the voltage is outside the above range, the controller PCB is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 90 Table starting p.204, the temperature sensor and cable are defect and should be replaced. b) If the resistance is within range, perform controller door check Trouble shooting for Star Cool Controller p.56 before replacing controller door. Criteria Value below alarm limit -60°C (-76°F) or above +140°C (284°F). Value must be invalid for 30 sec.

  • Page 91: Pressure Transmitter Alarms (Al 2Xx)

    NSK: If the voltage is between 0.37V DC and 4.0V DC and this alarm is still active, replace controller door. Before replacing controller door see Trouble shooting for Star Cool Controller p.56 Criteria Value below low alarm limit 0.1 BarE (2 Psi)
  • Page 92 NSK: If the voltage is between 0.37V DC and 4.0V DC and this alarm is still active, replace controller door. Before replacing controller door see Trouble shooting for Star Cool Controller p.56 Criteria Value below low alarm limit 0.1 BarE (2 Psi)
  • Page 93 NSK: If the voltage is between 0.37V DC and 4.0V DC and this alarm is still active, replace controller door. Before replacing controller door see Trouble shooting for Star Cool Controller p.56 Criteria Value below alarm limit 0.1 BarE (2 Psi) or above 31.9 BarE (462 Psi). Value invalid for 30 sec.
  • Page 94 NSK: If the voltage is between 0.37V DC and 4.0V DC and this alarm is still active, replace controller door. Before replacing controller door see Trouble shooting for Star Cool Controller p.56 Criteria Value above high alarm limit 11.9 BarE (172 Psi)
  • Page 95 NSK: If the voltage is between 0.37V DC and 4.0V DC and this alarm is still active, replace controller door. Before replacing controller door see Trouble shooting for Star Cool Controller p.56 Criteria Value above low alarm limit -0.9 BarE (-13 Psi)
  • Page 96 NSK: If the voltage is between 0.37V DC and 4.0V DC and this alarm is still active, replace controller door. Before replacing controller door see Trouble shooting for Star Cool Controller p.56 Criteria Value below alarm limit -0.9 BarE (-13 Psi) or above 11.8 BarE (171 Psi). Value invalid for 30 sec.
  • Page 97 Operating and service manual Press sensor type Alarm Description Saved FC ID does not match the current FC ID Cause Replaced Frequency Converter or controller door Trouble Possible causes: shooting Accompanied alarms: • AL 207 and AL 611 Trouble shooting: 1.

  • Page 98: Other Sensor Alarms (Al 3Xx)

    4) Mount signal wire. Measure voltage between SIGNAL and GND. If voltage is between 0.5V DC and 10V DC and this alarm is still active, replace controller door. Before replacing controller door see Trouble shooting for Star Cool Controller p.56 Criteria...
  • Page 99 4) Mount signal wire. Measure voltage between SIGNAL and GND. If voltage is between 0.5V DC and 10V DC and this alarm is still active, replace controller door. Before replacing controller door see Trouble shooting for Star Cool Controller p.56 Criteria...
  • Page 100 Mount signal wire. Measure voltage between SIGNAL and GND. If voltage is between 0.5V DC and 10V DC and this alarm is still active, replace controller door. Before replacing controller door see Trouble shooting for Star Cool Controller p.56 Criteria Value below alarm limit 10% RH or above 110% RH.
  • Page 101 4) Mount signal wire. Measure voltage between SIGNAL and GND. If the voltage is between 0.2V DC and 4.0V DC and this alarm is still active continue to 5). 5) Check controller, see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 102 4) Mount signal wire. Measure voltage between SIGNAL and GND. If the voltage is between 0.2V DC and 4.0V DC and this alarm is still active, continue to 5) 5) Check controller, see Trouble shooting for Star Cool Controller before replacing controller door.
  • Page 103 4) Mount signal wire. Measure voltage between SIGNAL and GND. If the voltage is between 0.2V DC and 4.0V DC and this alarm is still active, continue to 5) 5) Check controller, see Trouble shooting for Star Cool Controller p.56 before replacing controller door.
  • Page 104 Operating and service manual High press switch Warning Description High pressure switch is active Cause Discharge pressure is too high and the high pressure switch off Trouble Possible causes: shooting High pressure due to • Ambient temperature is over spec. limit +50°C (+122°F) −...

  • Page 105: Power Alarms (Al 4Xx)

    Operating and service manual Power Alarms (AL 4XX) Mevap 1 overheat Warning Description Evaporator Motor 1 Overheat Cause Indication of an overheated motor or a loose thermistor cable connection Trouble Possible causes: shooting • Evaporator motor 1 defect. Defect resistances on the interface/terminal block PCB. •...
  • Page 106 Operating and service manual Mevap 2 overheat Warning Description Evaporator Motor 2 Overheat Cause Indication of an overheated motor or a loose thermistor cable connection Trouble Possible causes: shooting Evaporator motor 1 defect. • Defect resistances on the interface/terminal block PCB. •...
  • Page 107 Operating and service manual Mcond overheat Warning Description Condenser Motor Overheat Cause Indication of an overheated motor or a loose thermistor cable connection Trouble Possible causes: shooting • Condenser motor defect. • Defect resistances on the interface/terminal block PCB. • Cable for measuring condenser motor overheat defect.
  • Page 108 Operating and service manual Unit over current Description Unit Over current Cause Indication of short circuit Trouble Possible causes: shooting • The unit is using too much power. Accompanied alarms: N/A. • Trouble shooting: 1) The voltage may have been too low for too long. 2) Check for loose connections.
  • Page 109 Operating and service manual U1-2 over voltage Fatal Alarm Description U1-2 over voltage Cause Indication of error in container supply voltage between phases 1 and 2 Trouble Possible causes: shooting The unit is supplied with a voltage above specified level. •...
  • Page 110 Operating and service manual U1-3 over voltage Fatal Alarm Description U1-3 over voltage Cause Indication of error in container supply voltage between phases 1 and 3 Trouble See AL 414 shooting Criteria Value above top alarm limit 525 Volt Controller breaks supply after 60 sec. After 30 sec. the unit restarts with a normal Controller startup procedure.
  • Page 111 Operating and service manual U2-3 under voltage Warning Description U2-3 under voltage Cause Indication of error in container supply voltage between phases 2 and 3 Trouble See trouble shooting for AL 417 shooting Criteria Value below low alarm limit 335 Volt Controller breaks supply after 60 sec.
  • Page 112 Operating and service manual I1 over current Description I1 over current Cause Indication of short circuit in electric installations of Star Cool unit Trouble Possible causes: shooting • The unit is using too much power on one phase. Defect Power Meas PCB •...
  • Page 113 Operating and service manual I3 over current Description I3 Over current Cause Indication of short circuit in electric installations of Star Cool unit Trouble See trouble shooting for AL 420 shooting Criteria Value above upper alarm limit 20 Amp None...
  • Page 114 Operating and service manual Frequency too high Warning Description Power Frequency Too High Warning Cause Power generator adjusted to too high frequency Trouble Possible causes: shooting • The power frequency is out of specified range. Accompanied alarms: AL 423 may also be active. •...
  • Page 115 Operating and service manual (Voltage/freq.) U/f ratio low Alarm Description Bad power supply - over loaded / under supplied Cause Power generator adjusted to too high frequency compared to supply voltage Trouble Possible causes: shooting • Overload of power supply Bad connection in plug •...
  • Page 116 Operating and service manual (Voltage/freq.) U/f ratio Fatal alarm Description Bad power supply Cause See AL 427 and AL 428 Trouble Possible causes: shooting • See AL 427 and AL 428 Accompanied alarms: • AL 427 and AL 428 Trouble shooting: 1) See AL 427 and AL 428 Criteria Lower limit: Umean is less than (<) 90 + 5.0 * frequence...

  • Page 117: Frequency Converter (Fc) Alarms (Al 5Xx)

    Operating and service manual Frequency Converter (FC) Alarms (AL 5XX) For some of the alarms in this section, the FC may be faulty and must be replaced. For continuing operation until replacement is possible, the unit can be rewired and started for emergency opera- tion: See “Emergency Operation”...
  • Page 118 Operating and service manual FC local control Alarm Description FC setting in Local Mode Cause Indication of FC set in the local control mode Trouble Possible causes: shooting • Cable FC-com periodically defective. Internal fault in the FC. • Defect FC. •...
  • Page 119 Operating and service manual FC 24 V fault Alarm Description FC Internal 24 V Supply Fault Alarm Cause Indication of problems with FC Trouble Possible causes: shooting • Internal fault in the FC. (A15) Accompanied alarms: One or more AL 5XX may also be active. •...
  • Page 120 Operating and service manual FC over cur Alarm Description FC Overcurrent Alarm Cause Indication of problems with compressor Trouble Possible causes: shooting The compressor motor draws too much current. • (A13) Defect FC. • • Condenser blocked due to dirt and residue. Accompanied alarms: One or more AL 5XX may also be active.
  • Page 121 Operating and service manual FC overload Alarm Description FC Overload Alarm Cause Indication of problems with compressor Trouble Possible causes: shooting • The FC cannot deliver enough power to the compressor. (A9) Insufficient cooling for the FC. • Defect FC. •...
  • Page 122 Operating and service manual FC under volt Alarm Description FC Undervoltage Fault Alarm Cause Indication of problems with supply voltage Trouble Possible causes: shooting The FC is supplied with too low voltage for continuous operation. • (A9) Defect FC. • Accompanied alarms: AL 417, AL 418 or AL 419 may be active.
  • Page 123 Operating and service manual FC phase loss Alarm Description FC Phase Loss Fault Alarm Cause Indication of lack of phase or defective FC Trouble Possible causes: shooting • One or more phases are not applied to the FC. (A4) Unstable power supply (generator). •...
  • Page 124 Operating and service manual FC over temp Alarm Description FC Overtemperature Fault Alarm Cause Indication of problems with compressor or FC Trouble Possible causes: shooting • FC operates at operating limits. (A36) Insufficient cooling for the FC. • Defect FC. •...
  • Page 125 Operating and service manual FC inrush Alarm Description FC Inrush Fault Alarm Cause Indication of problems with supply voltage Trouble Possible causes: shooting • The FC has had too many restarts within short time. (A36) • CIM5: Manual activation of contactor (K8) on/off too many times. •...
  • Page 126 Operating and service manual FC high volt Warning Description FC High Voltage Fault Warning Cause Indication of problems with supply voltage Trouble Possible causes: shooting The unit is supplied with voltage above specification. • (W7) Defective FC. • Accompanied alarms: AL 515.
  • Page 127 Operating and service manual FC high temp Description FC Overtemperature Warning Cause Indication of problems with compressor or FC Trouble Possible causes: shooting • FC operates at operating limits. (W36) Insufficient cooling for the FC. • Defect FC. • Accompanied alarms: •...
  • Page 128 Operating and service manual FC phase loss Warning Description FC Phase Loss Fault Warning Cause Indication of defective FC or missing phase Trouble Possible causes: shooting • One or more phases are not applied to the FC. (W36) Unstable power supply (generator). •...
  • Page 129 Operating and service manual FC current limit Warning Description FC Current Limit Fault Warning Cause Indication of problems with compressor. Error may be seen during pull-down Trouble Possible causes: shooting • The compressor motor draws too much current. (A12) Defect FC. •...
  • Page 130 Operating and service manual FC overload Warning Description FC Overload Warning Cause Indication of problems with compressor Trouble Possible causes: shooting The FC cannot supply enough power to the compressor. • (W9) Insufficient cooling for the FC. • • Defect FC. Accompanied alarms: AL 522 or AL 525 may also be active and should be checked first.
  • Page 131 Operating and service manual FC setup error Warning Description FC Setup Warning Cause The setup of the FC is rejected by the FC. Either communication problems or phase fault Trouble Possible causes: shooting Defect FC. • (A37) Accompanied alarms: There may be other AL 5XX alarms. •...
  • Page 132 Operating and service manual FC Trip Lock Description The FC has tripped and stopped Cause Alarm indicates problem with compressor or frequency controller Trouble Possible causes: shooting • Other alarms have tripped (stopped) the FC. Defect FC. • Accompanied alarms: There is another alarm(s), especially AL 5XX alarms.

  • Page 133: Operation Alarms (Al 6Xx)

    Operating and service manual Operation Alarms (AL 6XX) No control sensors Fatal Alarm Description Supply Air Sensor 1, Supply Air Sensor 2, Return Air Sensor and Evaporator Sensor are all malfunctioning. Cause Alarm indicates that all control-relevant sensors are defective or unreliable. See also Temperature control and Expansion valve control p.18 Trouble Possible causes:...
  • Page 134 Operating and service manual No water cooling Warning Description Water-cooling fault Cause Lack of water-cooling Trouble Possible causes: shooting Water cooling selected and no water cooling active. • Insufficient water cooling capacity. • • If program is chosen, warning can occur in units without water cooling. Accompanied alarms: AL 100 and AL 108.
  • Page 135 Operating and service manual Tset unreachable Alarm Description Tset Unreachable. (Not implemented yet) Cause Indication of insufficient yield Trouble Possible causes: shooting • Container doors are open or gasket defect. Not enough refrigerant for the compressor. • Insufficient airflow though evaporator. •...
  • Page 136 Operating and service manual In range fault Fatal Alarm Description In-range fault Cause Indication of insufficient yield or defective controller Trouble Possible causes: shooting Container doors are open or gasket defect. • • Not enough refrigerant for the compressor. Insufficient airflow though evaporator. •...
  • Page 137 Operating and service manual High press trouble Fatal Alarm Description High Pressure Switch is active Cause Hot gas valve, expansion valve and economizer valves are all closed and compressor is running Trouble Possible causes: shooting Repeated high pressure alarms. • Accompanied alarms: AL 306.
  • Page 138 Operating and service manual Defrost Trouble Warning Description Defrost is running Cause Defrost terminated on Tsuc Trouble Possible causes: shooting • Hot gas valve not working probably. Defective Psuc. • Defective Tevap. • Accompanied alarms: • Maybe AL 207 Maybe AL 123 •...
  • Page 139 Operating and service manual Defrost time exceed Warning Description Max. defrost time exceeded Cause Defrost terminated on time > 45 minutes Trouble Possible causes: shooting • There has been too much ice in the evaporator. • The heaters are not working/defect. •...
  • Page 140 Operating and service manual Too many sensor errors Alarm Description Too many (controlling) sensors have errors Cause If too many (controlling) sensors have errors, the controller cannot maintain correct temperature. See also “Temperature control” p. 18 and “Expansion valve control” p. 18 Trouble Possible causes: shooting...
  • Page 141 Operating and service manual Motor trouble Alarm Description Evaporator fan motor 1 or 2 or condenser fan motor overheated several times Cause One or both evaporator fan motors or the condenser fan motor are overheating either permanently or repeatedly generated overheat alarm within the last 30 min.
  • Page 142 Operating and service manual Cpr start failed Fatal Alarm Description Not implemented yet Cause Trouble shooting Criteria None Controller action Alarm Alarm light Quick flash Consequence No cooling of the cargo Elimination Parm 1 Parm 2 Parm 3 Parm 4 Parm 5 Log data Active/Inactive...
  • Page 143 Operating and service manual CT outrange Alarm Description Cold Treatment out of range Cause Indication of insufficient yield or defective controller Trouble Possible causes: shooting • Difference between treatment setpoint and maximum USDA temperature too small. Container doors are open. •...
  • Page 144 Operating and service manual Manual phase dir Warning Description Manually Selected Phase Direction Cause Indication of insufficient yield or defective controller Trouble Possible causes: shooting • The user has selected a manual phase direction. Accompanied alarms: AL 423 should have been active before using manual phase direction has •...

  • Page 145: Alarms Not Used

    Operating and service manual Fuse blown Warning Description Blown Fuse for fan motors and heaters Cause Indication of blown fuse Trouble Possible causes: shooting A 10 A fuse is blown. • • Unit has used too much power. There is a short-circuit in the power cables used in the unit. •...

  • Page 146: Test Alarms (Al 8Xx)

    Operating and service manual Test Alarms (AL 8XX) Func test failed Alarm Description Function Test Fault Cause Trouble Possible causes: shooting One or more of the individual test steps have failed. • Accompanied alarms: AL 8XX. • Trouble shooting: 1) See individual AL 8XX alarms for cause Criteria One or more of the individual test steps have failed FC will soon trip with error 516 and stop compressor...
  • Page 147 Operating and service manual Controller Alarm Description Controller Internal Voltage Reference Fault Cause Trouble Possible causes: shooting • Power supply for controller PCB defect. • Controller PCB defect. Accompanied alarms: • Check for AL 951 up to AL 996 • There may be other accompanied alarms.
  • Page 148 Operating and service manual Idle current Alarm Description Unit idle overcurrent fault Cause Trouble Possible causes: shooting • There is a short-circuit in the controller PCB. • The power meas PCB is defect. Accompanied alarms: • N/A. Trouble shooting: 1) Check cables for sensors for damages. 2) The controller PCB is defect.
  • Page 149 Operating and service manual Mevap cur HI speed Alarm Description Evaporator motor high speed current fault Cause Indication of defective motor or defective supply cables to motor Trouble Possible causes: shooting • Evaporator motor jammed or defect. Evaporator motor cables defect. •...
  • Page 150 Operating and service manual Mevap direction Alarm Description Not implemented yet Mcond cur LO speed Alarm Description Condenser Motor Low Speed Current Fault Cause Indication of defective motor or defective supply cables to motor Trouble Possible causes: shooting Condenser motor jammed or defect. •...
  • Page 151 Operating and service manual Mcond cur HI speed Alarm Description Condenser Motor High Speed Current Fault Cause Indication of defective motor or defective supply cable to motor Trouble Possible causes: shooting Condenser motor jammed or defect. • Condenser motor cable defect. •...
  • Page 152 Operating and service manual Hevap current ON Alarm Description Evaporator Heater On Current Fault Cause Indication of defective heater or defective supply cables to heater Trouble Possible causes: shooting • Heaters defect. Heater power cable defect. • Accompanied alarms: N/A. •...
  • Page 153 Operating and service manual Valve leaks Alarm Description Valve Leak Fault Cause Indication of leakage of one or more of the valves or problems with the compressor Trouble Possible causes: shooting One or more valves have leaks (defect) • Accompanied alarms: See other AL 84X alarms for valve failures.
  • Page 154 Operating and service manual Expansion valve Alarm Description Expansion Valve Fault Cause Indication of non-operating electronic expansion valve Trouble Possible causes: shooting • Cable for expansion valve mounted on wrong valve. Cable for expansion valve defect. • Expansion valve defect. •...
  • Page 155 Operating and service manual Economizer valve Alarm Description Economizer Valve Fault Cause Indication of non-operating economizer valve Trouble Possible causes: shooting Cable for economizer valve mounted on wrong valve. • Cable for economizer valve defect. • • Economizer valve defect. Driver circuit for economizer valve defect.
  • Page 156 Operating and service manual Hot gas valve Alarm Description Hot gas Valve Fault Cause Indication of non-operating hot gas valve Trouble Possible causes: shooting • Cable for hot gas valve mounted on wrong valve. Cable for hot gas valve defect. •...
  • Page 157 Operating and service manual Cpr pump down Alarm Description Compressor pump down fault Cause Indication of insufficient performance in the compressor Trouble Possible causes: shooting Sensor defect (high pressure transmitter and or high pressure switch) • • One or more valves defect. Compressor needs repair.
  • Page 158 Operating and service manual PTI test failed Alarm Description PTI Test Fault Cause Normal function will be affected Trouble Possible causes: shooting • There is one or more alarms. Accompanied alarms: AL 8XX and maybe other alarms. • Trouble shooting: 1) There are other AL 8XX alarms.
  • Page 159 Operating and service manual PTI Tset 0 Alarm Description PTI 0°C Set Fault Cause Indication of insufficient performance Trouble Possible causes: shooting • Doors are open. The heaters do not operate normally. • The cooling capacity is too limited. • There may not be enough refrigerant in the unit.
  • Page 160 Operating and service manual PTI defrost Alarm Description PTI Defrost Fault Cause Trouble Possible causes: shooting Defect Tevap temperature sensor. • Defect Psuc pressure sensor. • • Defect heaters. Defect hot gas valve. • Evaporator was filled with too much ice. •...

  • Page 161: Controller Alarms (Al 9Xx)

    Operating and service manual PTI Tset -18 Alarm Description PTI –18°C Set Fault Cause Indication of insufficient performance Trouble Possible causes: shooting Doors are open. • The cooling capacity is too limited. • • There may not be enough refrigerant in the unit. Accompanied alarms: N/A.
  • Page 162 Operating and service manual Measurement error Warning Description Error in measurement of condensator on circuit board Cause The temperature measurement of the channel is faulty Trouble Possible causes: shooting • Measurement system of the controller is (partly) defective Accompanied alarms: •...
  • Page 163 Operating and service manual Remote mon missing Alarm Description Remote Monitor Modem Missing. (Only valid for units with rem. monitor) Cause Indication of missing or defective modem Trouble Possible causes: shooting • The communication cable, RMM-com is defect or unplugged. •...
  • Page 164 Operating and service manual Database corrupt Description SCCU6 Database Faulty Cause Failed validation of EEPROM backup Trouble Possible causes: shooting • Controller PCB defect. Accompanied alarms: AL 801 will be activated during FT- or PTI test. • Trouble shooting: 1) Controller PCB defect. Replace controller door. Criteria Controller database corrupted Default value preset...
  • Page 165 Operating and service manual Realtime invalid Description Real-time Clock Unavailable Cause Real-time clock battery defect Trouble Possible causes: shooting • Real-time clock battery defect. Accompanied alarms: AL 801 will be activated during FT- or PTI test. • Trouble shooting: 1) Real-time clock battery defective. Replace controller door.
  • Page 166 Operating and service manual Main power failure Description Main Power Fault Cause Indication of insufficient supply voltage Trouble Possible causes: shooting • Unstable or insufficient power supply. Accompanied alarms: N/A. • Trouble shooting: 1) Supply unit with power according to specification. Criteria Supply voltage below warning limit Controller tries safe close-down.
  • Page 167 Operating and service manual Battery voltage HI Description High Battery Voltage Cause Trouble Possible causes: shooting • Battery defect. Battery cables defect. • Accompanied alarms: AL 801 will be activated during FT- or PTI test. • Trouble shooting: 1) Check that cables for the battery are not damaged and in contact with other voltages.
  • Page 168 Operating and service manual Power ref HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting Defect power supply for controller PCB. • Defect controller PCB. • Accompanied alarms: There may be sensor alarms. •...
  • Page 169 Operating and service manual Temp ref 1 LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for main controller. Defect sensor pulling power supply down. •...
  • Page 170 Operating and service manual Temp ref 1 HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defective power supply for controller PCB. Defective controller PCB. • Accompanied alarms: There may be sensor alarms.
  • Page 171 Operating and service manual Temp ref 2 LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. Defect sensor pulling power supply down. •...
  • Page 172 Operating and service manual Temp ref 2 HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. Defect controller PCB. • Accompanied alarms: There may be sensor alarms.
  • Page 173 Operating and service manual Gnd ref HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. Defect controller PCB. • Accompanied alarms: There may be sensor alarms. •...
  • Page 174 Operating and service manual RH sens sup LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. • Defect relative humidity sensor. • Defect controller PCB.
  • Page 175 Operating and service manual RH sens sup HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. • Too high voltage for the unit. •...
  • Page 176 Operating and service manual Pdis sens sup LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. Defect Pdis pressure transmitter. • Defect controller PCB. •...
  • Page 177 Operating and service manual Pdis sens sup HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting Defect power supply for controller PCB. • Defect controller PCB. • Accompanied alarms: There may be sensor alarms, especially AL 203 •...
  • Page 178 Operating and service manual Psuc sens sup LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting Defect power supply for controller PCB. • Defect Psuc pressure transmitter. • • Defect controller PCB.
  • Page 179 Operating and service manual Psuc sens sup HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting Defect power supply for controller PCB. • Defect controller PCB. • Accompanied alarms: There may be sensor alarms.
  • Page 180 Operating and service manual Controller sup HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. Defect controller PCB. • Accompanied alarms: There may be sensor alarms. •...
  • Page 181 Operating and service manual AirEx sens sup LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. Defect sensor pulling power supply down. •...
  • Page 182 Operating and service manual AirEx sens sup HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. Defect controller PCB. • Accompanied alarms: There may be sensor alarms, AL 3XX.
  • Page 183 Operating and service manual Sensor bus sup LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting Defect power supply for controller PCB. • Defect controller PCB. • Accompanied alarms: There may be sensor alarms •...
  • Page 184 Operating and service manual Pspare sens sup HI Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. Defect controller PCB. • Accompanied alarms: •...
  • Page 185 Operating and service manual Tinternal LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes: shooting • Defect power supply for controller PCB. Defect controller PCB. • Accompanied alarms: AL 801 will be activated during FT- or PTI test. •...
  • Page 186 Operating and service manual Software test ver Warning Description Software test version Cause Indication of Software test version loading into controller Trouble Possible causes: shooting Test sw in the controller PCB. • Accompanied alarms: • AL 801 will be activated during FT- or PTI test. Trouble shooting: 1) There is a wrong sw version in the controller PCB.

  • Page 187: Calibration Of Air Exchange Sensor

    Operating and service manual Eeprom error Alarm Description EEPROM fault Cause Trouble Possible causes: shooting • Check of validity of program storage failed. Accompanied alarms: • AL 801 will be activated during FT- or PTI test. Trouble shooting: 1) There is a fault on the controller PCB. Replace the controller door. Criteria None Controller...

  • Page 188: Replacing Of Unit

    Operating and service manual Replacing of unit Handling of SCU unit during replacement is done by means of a special yoke, see below sketch. Depending on the model, use either position 1, 2 or 3 for the yoke. Pos. 1 Pos.

  • Page 189: Replacement Evaporator Motor And Fan

    Operating and service manual Replacement Evaporator motor and fan Note: Turn off main power supply for unit before replacing evaporator motor and fan. Note: Due to high aerodynamic requirements (decreased energy consumption) beware of sharp edges is located in this area! Disconnect the power supply to the motor by removing the motor cover and unscrew the earthwire placed directly on the motor.

  • Page 190: Replacement Condenser Motor And Fan

    Operating and service manual Replacement Condenser motor and fan Note: Turn off main power supply for unit before replacing condenser motor and fan. Remove the condenser grill and disconnect the power supply to the motor by removing the motor cover and unscrew the earth wire, which is placed directly on the motor. Do not disconnect the other cable connection which is connected directly in the motor cover.

  • Page 191: Replacement Of Evaporator

    Operating and service manual Replacement of evaporator Old model In order to replace the evaporator the unit has to be dismounted from the container, as described in this manual. After dismounting the unit there is free access to all parts on the backside of the unit. Position Description Back plate, unit...

  • Page 192: New Model

    Operating and service manual 10. Disconnect evaporator fans and return air sensor. 11. Remove pos. 2. 12. Remove pos. 3. 13. Desolder the suction and liquid pipe for pos. 6. 14. Remove / drill out rivets heads and remove pos. 6. 15.

  • Page 193: Replacement Of Heating Elements

    Operating and service manual Replacement of heating elements Dismount the back plate for the unit and replace the defect heating element. After replacing heating elements reinstall back plate for unit. Please note that the illustrated model may be different from the actual model. 192 of 222 pages...

  • Page 194: Replacement Of Fc

    Operating and service manual Replacement of FC Position Description Cover for FC Motor cable Cable room cover The procedure for replacing the FC is as follows: 1. Dismount the cable room cover, pos. 4. 2. Remove the cover for FC, pos. 1. 3.

  • Page 195: Replacement Of Compressor

    Operating and service manual Replacement of compressor Position Description Compressor Bracket for compressor Cover for FC Motor cable Cable room cover The procedure for replacing the compressor is as follows: 1. Dismount the cable room cover, pos. 6. 2. Remove the cover for FC, pos. 3. 3.

  • Page 196: Replacement Of Compressor Valve Plate / Cylinder Head Gasket

    Operating and service manual Replacement of compressor valve plate / cylinder head gasket 1. Depressurize the compressor. 2. Dismount cylinder head and valve plate (using a rubber mallet, if necessary). Carefully clean all sealing surfaces. 3. Check valve plate; Exchange entire valve plate if damaged. Determine the cause and eliminate it. 4.

  • Page 197: Service And Maintenance

    Operating and service manual Service and maintenance Evacuation of refrigerant Evacuation of refrigerant for the unit is done by the following procedure: 1. Install a service gauge manifold on the unit to the two evacuation points, pos. 6 and 27 (P & I – diagram) 2.

  • Page 198: Compressor Pump Down, Operation

    Operating and service manual Compressor pump down, operation Pump down of the compressor is done by the following procedure: 1. Connect the vacuum pump to the two evacuation points, pos. 6 & 27 (P & I – diagram). 2. Ensure that the valves on the vacuum pump are closed. 3.

  • Page 199: Pump Down Of Unit

    Operating and service manual Pump down of unit Main power supply to unit shall be switched off during pump down of unit. Pump down of unit is done by the following procedure: 1. Connect a vacuum pump with a service gauge manifold to the two evacuation points, pos. 6 & 27 (P &...

  • Page 200: Charging Of Refrigerant

    Operating and service manual Charging of refrigerant Charging of an empty unit The power to the unit must be off. The charging of an empty unit is done by weight, by the following procedure: 1. Pump down unit as described in this manual. 2.

  • Page 201: Leakage Detection

    Operating and service manual Caution: Do not overcharge the unit. Leakage detection Leakage detection is done under pressure test, as described in this manual. While the unit is pressurized it is possible to check all soldered and screwed joints of the piping system.

  • Page 202: Drying Filter

    Operating and service manual Drying filter Replacing of drying filter Before replacing the drying filter, the power plug to the unit has to be disconnected. The drying filter has to be changed every time the compressor is changed or if the moisture indi- cators indicate too much moisture is in the refrigerant circuit.

  • Page 203: Charging Of Oil

    Operating and service manual Charging of oil If during normal operation is has been observed that there is too little oil charge on the compres- sor, additional oil may be charged. The compressor is filled with 1,5 L Reniso Triton SEZ 55 or equivalent oil from the factory. The procedure for adding oil is as follows: 1.

  • Page 204: Soldering

    Operating and service manual Soldering When soldering and desoldering components on the unit, please observe the following: Use the following material for soldering: For Copper - Copper (all pipes): Soldering rod: L - Ag15P according to DIN 8513 or B - CuP5 according to AWS A 5.8.
  • Page 205 Operating and service manual Data: Name Value Unit Tsupply temperature Temperature from supply sensor °C Treturn temperature Temperature from return sensor °C Tusda 1 temperature Temperature from USDA sensor 1 °C Tusda 2 temperature Temperature from USDA sensor 2 °C Tusda 3 temperature Temperature from USDA sensor 3 °C...
  • Page 206 Operating and service manual Events: Name Parameter explanation No. 1 No. 2 No. 3 No. 4 No. 5 Temperature set-point Old set-point New set-point SW revision altered Humidity set-point Old set-point New set-point altered Water-cooling Off Water-cooling On Function test Start Version Alarms count Function test Pass...
  • Page 207 Operating and service manual CT ramp up Actual temp. USDA1 temp USDA2 temp USDA3 temp Final setpoint temp. Multiple Temperature Step number Step duration Step setpoint Step temp. Step humidity Set points (MTS) start chg. /hour setpoint MTS step stop Step number 0: Normal Step setpoint...

  • Page 208: Temperature Sensor [°C] - Resistance Table

    Operating and service manual Temperature Sensor [°C] - Resistance Table Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp [Ω] [°C] [Ω] [°C] [Ω] [°C] [Ω] [°C] [Ω] [°C] 3,095,611.00 138,322.00 13,682.60 2,315.20 570.82 2,851,363.00 130,243.00 13,052.80 2,234.70 554.86 2,627,981.00 122,687.00 12,493.70...

  • Page 209: Temperature Sensor [°F] - Resistance Table

    Operating and service manual Temperature Sensor [°F] - Resistance Table Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp [Ω] [°F] [Ω] [°F] [Ω] [°F] [Ω] [°F] [Ω] [°F] 3,095,611.00 138,322.00 13,682.60 2,315.20 570.82 2,851,363.00 130,243.00 13,052.80 2,234.70 554.86 2,627,981.00 122,687.00 12,493.70...

  • Page 210: Temperature [°C] - Pressure [Bare] Table - R134A

    Operating and service manual Temperature [°C] – Pressure [BarE] Table – R134a Pres. Temp Pres. Temp Pres. Temp Pres. Temp Pres. Temp Pres. Temp Pres. Temp [BarE] [°C] [BarE] [°C] [BarE] [°C] [BarE] [°C] [BarE] [°C] [BarE] [°C] [BarE] [°C] -0.9 -67.34 7.42...

  • Page 211: Temperature [°F] - Pressure [Psi] Table - R134A

    Operating and service manual Temperature [°F] – Pressure [Psi] Table – R134a Pres. Temp Pres. Temp Pres. Temp Pres. Temp Pres. Temp Pres. Temp Pres. Temp [Psi] [°F] [Psi] [°F] [Psi] [°F] [Psi] [°F] [Psi] [°F] [Psi] [°F] [Psi] [°F] -13.05 -89.21 40.61...

  • Page 212: Air Exchange Sensor Table Voltage - M3/H

    Operating and service manual Air exchange Sensor table Voltage - m3/h There is an offset of 0.2 V due to mechanical design. The air exchange must be properly calibrated before measuring. Voltage Air exchange Voltage Air exchange Voltage Air exchange Voltage Air exchange [m3/h]...

  • Page 213: Voltage - Pressure Table, Low Pressure Transmitter (Aks)

    Operating and service manual Voltage – Pressure Table, Low pressure transmitter (AKS) Vcc = 5 V. Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure [BarE] [Psi] [BarE] [Psi] 0.50 -1.000 -14.50 2.55 5.663 82.13 0.55 -0.838 -12.15 2.60 5.825 84.48 0.60 -0.675...

  • Page 214: Voltage - Pressure Table, Low Pressure Transmitter (Nsk)

    Operating and service manual Voltage – Pressure Table, Low pressure transmitter (NSK) Vcc = 5 V. Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure [BarE] [Psi] [BarE] [Psi] -0,69 -10,01 4,57 66,34 -0,65 -9,49 1,95 4,74 68,71 0,35 -0,49 -7,12 4,90 71,08...

  • Page 215: Voltage - Pressure Table, High Pressure Transmitter (Aks)

    Operating and service manual Voltage – Pressure Table, High pressure transmitter (AKS) Vcc = 5 V. Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure [BarE] [Psi] [BarE] [Psi] 0.50 0.00 0.00 2.55 16.40 237.86 0.55 0.40 5.80 2.60 16.80 243.66 0.60 0.80...

  • Page 216: Voltage - Pressure Table, High Pressure Transmitter (Nsk)

    Operating and service manual Voltage – Pressure Table, High pressure transmitter (NSK) Vcc = 5 V. Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure [BarE] [Psi] [BarE] [Psi] 0,00 2,05 15,50 224,874 0,55 0,50 7,254 16,00 232,128 1,00 14,508 2,15 16,50 239,382...

  • Page 217: Temperature Sensor - Voltage Table

    Operating and service manual Temperature Sensor - Voltage Table Temperature sensors except for reference temperature sensor. Vcc = 5V Voltage Temp Temp Voltage Temp Temp Voltage Temp Temp [°C] [°F] [°C] [°F] [°C] [°F] 4.55 -40.0 3.07 15.8 1.29 71.6 4.52 -38.2 3.00...

  • Page 218: Tightening Torques

    Operating and service manual Tightening torques Description Type Torque [Nm] ± 5% General Hex Head Bolt + Nut, M5 Hex Head Bolt + Nut, M6 Hex Head Bolt + Nut, M8 Hex Head Bolt + Nut, M10 Hex Socket Counters. Head Bolt, M6 Hex Socket Counters.

  • Page 219: P & I Diagram

    Operating and service manual P & I diagram 218 of 222 pages...

  • Page 220: Controller Unit Illustration

    Operating and service manual Controller Unit Illustration 219 of 222 pages...

  • Page 221: Star Cool Unit, Installation Dimensions

    Operating and service manual Star Cool Unit, installation dimensions 220 of 222 pages...
  • Page 222 Operating and service manual 221 of 222 pages...

  • Page 223: Overall Wiring Schematic

    Operating and service manual Overall Wiring Schematics Brown [Black] Mcpr POWER IN AWG 14 Blue or Grey Main 4 x 4mm2 [Black] FC-pwr switch (4 x 2.5mm2 / Black [Black] 4 x AWG 13) Outside Box PWR5 PWRMEAS PCB Y/Gr Y/Gr Inside Box [Black]...
  • Page 224 24-hour hotline support Call us at +45 7364 3500 or send us an e-mail at service@starcool.com. Our service department is available 24 hours a day, 7 days a week - providing easy access to the answers you need. For further troubleshooting help, go to our website URL: m.starcool.com or simply scan the QR code with Your smartphone Bjerndrupvej 47, 6360 Tinglev, Denmark...

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