Star Cool SCU-20 Manuel de service

Operating and service manual

Star Cool refrigeration unit Model SCU-20/40 and SCI-20/40

Version 810900C April 2015

24-hour hotline support

Call us at +45 7364 3500 or send us an e-mail at [email protected].

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

Phone: +45 73 64 34 00

Fax.: +45 73 64 35 69

E-mail: [email protected]

www.starcool.com

Operating and service manual Version 810900C April 2015

1 of 194 pages

Operating and service manual

Preface

This version of the manual is dated April 2015, edited by Maersk Container Industry AS.

This user’s manual is valid for software version 0353 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.

While the information herein is assumed to be accurate, Maersk Container Industry AS assumes

no responsibility for any errors or omissions that may appear in this documentation.

This manual is valid for:

Model SCI - 20/40 and SCU - 20/40

Release Date 10.04.2015

Part number 810200B and 810300B.

Warnings

Do not operate or maintain this refrigeration unit until you have familiarized

yourself completely with the equipment and operating of this unit by reading the

instruction in this manual.

Do not perform any welding on the unit before disconnecting the power plug.

Furthermore, disconnect the power meas module and main controller (and

modem if present).

Disconnect main power supply to unit before inspecting the interior of the

controller box.

The unit is charged with R134a and ester oil BSE 55. Do not use any other

refrigerant or oil.

Do not use contaminated refrigerant or oil.

Do not release R134a into the atmosphere. Use recovery equipment according to

present legislation.

During maintenance please observe that R134a is operating with high and low

temperatures in combination with high pressures, which may cause personal

injuries if not handled properly.

During recovery and maintenance of R134a unit personal protection equipment

has to be worn.

Do not trap any liquid refrigerant inside pipes during soldering work. This may

lead to explosion of pipe.

Please note that some unit models do not have Schräder valve installed for PSUC

and PDIS transmitter.

Operating and service manual

2 of 194 pages

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....................................................................................................................................... 11

Economizer Valve ..................................................................................................................................... 12

Dehumidication ...................................................................................................................................... 12

Condenser Fan......................................................................................................................................... 13

Evaporator Fan ........................................................................................................................................ 13

Defrost Function ...................................................................................................................................... 13

QUEST (optional)...................................................................................................................................... 15

Bulb mode (Overall Description)................................................................................................................. 15

Product Perspective.................................................................................................................................. 15

Product Functions..................................................................................................................................... 15

User Interface.......................................................................................................................................... 15

Communication to Data Logger .................................................................................................................. 16

Bulb mode (System Feature) ..................................................................................................................... 16

Setting.................................................................................................................................................... 16

Conguration........................................................................................................................................... 16

Limitations .............................................................................................................................................. 16

Alarms .................................................................................................................................................... 16

Defaulting ............................................................................................................................................... 16

Tests ...................................................................................................................................................... 16

Function test ........................................................................................................................................... 17

Full PTI ................................................................................................................................................... 18

Short PTI ................................................................................................................................................ 18

Data Log ................................................................................................................................................. 18

Alarm Action System (AAS) ....................................................................................................................... 20

Temperature control ................................................................................................................................. 20

Expansion valve control ............................................................................................................................ 20

Condenser fan control............................................................................................................................... 21

Dehumidication control ........................................................................................................................... 21

Defrost control......................................................................................................................................... 21

Electrical control ...................................................................................................................................... 21

Refrigeration system data............................................................................................................................. 22

Refrigerant charge, R134a......................................................................................................................... 22

General specication ................................................................................................................................ 23

Compressor – motor assembly................................................................................................................... 23

Frequency converter (FC).......................................................................................................................... 23

High Pressure cut – out switch................................................................................................................... 23

Fusible plug, receiver................................................................................................................................ 23

Economizer.............................................................................................................................................. 23

Evaporator coil......................................................................................................................................... 23

Condenser coil ......................................................................................................................................... 24

Evaporator fan ......................................................................................................................................... 24

Condenser fan ......................................................................................................................................... 24

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Operating and service manual

Water cooled condenser (optional) ............................................................................................................. 24

Defrosting ............................................................................................................................................... 24

Fresh air exchange ................................................................................................................................... 25

Refrigeration controls ............................................................................................................................... 25

Electrical data.......................................................................................................................................... 25

Circuit Breaker......................................................................................................................................... 25

Contactors .............................................................................................................................................. 25

Fuses...................................................................................................................................................... 25

Power plug .............................................................................................................................................. 25

Power Cable ............................................................................................................................................ 25

USDA socket requirements ........................................................................................................................ 26

Evaporator fan motor................................................................................................................................ 26

Condenser fan motor ................................................................................................................................ 26

Evaporator coil heaters ............................................................................................................................. 27

Temperature sensors, including USDA ........................................................................................................ 27

Pressure transmitters ............................................................................................................................... 27

Miscellaneous .......................................................................................................................................... 27

User Interface............................................................................................................................................... 27

Indicator lights......................................................................................................................................... 27

Display.................................................................................................................................................... 28

Key pad .................................................................................................................................................. 29

Menu overview.............................................................................................................................................. 30

General Page layout.................................................................................................................................. 30

Using the cursor....................................................................................................................................... 31

Changing a parameter value ...................................................................................................................... 31

Activating a function................................................................................................................................. 31

Air exchange page.................................................................................................................................... 31

Operation...................................................................................................................................................... 32

Menu Structure ........................................................................................................................................ 32

General Operation.................................................................................................................................... 33

Temperature Setting................................................................................................................................. 33

Wake-up Mode ................................................................................................................................. 33

Contrast adjustment of the display ............................................................................................................. 33

PTI or Function Test execution ........................................................................................................... 34

Info Menu Viewing ................................................................................................................................... 37

Operation Parameter Setting ............................................................................................................. 40

Programs: ............................................................................................................................................... 40

Multiple Temperature Set points program, MTS............................................................................................ 41

Cold Treatment program, CT ..................................................................................................................... 42

Alarms ................................................................................................................................................... 43

Service Function Setting/Viewing ....................................................................................................... 44

Manual operations:................................................................................................................................... 45

Datalog view: .......................................................................................................................................... 46

Time adjust: ............................................................................................................................................ 47

Run time counters:................................................................................................................................... 47

Conguration:.......................................................................................................................................... 48

Serial Numbers ........................................................................................................................................ 49

°C and °F Temperature Scale Showing, Alternately ................................................................................ 50

Viewing graph of Supply and Return Temperature ................................................................................ 50

Manual Defrost Initiation ..................................................................................................................... 50

Water-cooling Activation/Deactivation ................................................................................................ 51

Emergency Operation ................................................................................................................................... 51

FC defective ............................................................................................................................................ 51

Controller defective .................................................................................................................................. 51

Operating and service manual

4 of 194 pages

External interfaces ....................................................................................................................................... 52

General requirements ............................................................................................................................... 52

List of terms used for external interfaces .................................................................................................... 52

Functions overview................................................................................................................................... 53

Location of valves ......................................................................................................................................... 54

Location of motors, temperature sensors, humidity sensor and air exchange potentiometer ...................... 55

Location of pressure transmitters, high pressure switch and oil outlet port ................................................ 56

General trouble shooting .............................................................................................................................. 56

Trouble shooting for Star Cool main controller ............................................................................................. 57

Detailed alarm description............................................................................................................................ 57

Alarm list ................................................................................................................................................ 58

Events ........................................................................................................................................................... 61

Temperature Sensor Alarms (AL 1XX)......................................................................................................... 63

Pressure transmitter Alarms (AL 2XX) ....................................................................................................... 73

Other Sensor Alarms (AL 3XX) ................................................................................................................... 76

Power Alarms (AL 4XX) ............................................................................................................................. 80

Frequency Converter (FC) Alarms (AL 5XX) ................................................................................................. 90

Operation Alarms (AL 6XX)...................................................................................................................... 105

Communication Alarms (AL 7XX).............................................................................................................. 119

Test Alarms (AL 8XX).............................................................................................................................. 123

Controller Alarms (AL 9XX)...................................................................................................................... 138

Calibration of air exchange sensor.............................................................................................................. 163

Sensor calibration using StarView .............................................................................................................. 163

Replacing of unit ......................................................................................................................................... 164

Replacement Evaporator motor and fan...................................................................................................... 165

Replacement Condenser motor and fan ...................................................................................................... 165

Replacement of evaporator......................................................................................................................... 166

Replacement of heating elements............................................................................................................... 167

Replacement of FC ...................................................................................................................................... 168

Replacement of compressor........................................................................................................................ 169

Replacement of compressor valve plate / cylinder head gasket ................................................................. 170

Service and maintenance ............................................................................................................................ 171

Evacuation of refrigerant......................................................................................................................... 171

Compressor pump down, operation .......................................................................................................... 172

Compressor pump down, replaced............................................................................................................ 172

Pump down of unit.................................................................................................................................. 173

Pressure Test......................................................................................................................................... 173

Charging of refrigerant ........................................................................................................................... 174

Charging of an empty unit....................................................................................................................... 174

Charging of unit low on charge................................................................................................................. 174

Leakage detection .................................................................................................................................. 175

Fan motors (in not using plug) ................................................................................................................. 175

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Operating and service manual

Drying lter........................................................................................................................................... 176

Replacing of drying lter ......................................................................................................................... 176

Compressor........................................................................................................................................... 176

Check of oil level .................................................................................................................................... 176

Charging of oil ....................................................................................................................................... 177

Draining of oil from compressor ............................................................................................................... 177

Soldering .............................................................................................................................................. 178

Welding................................................................................................................................................. 178

Tables ......................................................................................................................................................... 178

Datalog description ................................................................................................................................ 178

Temperature Sensor [°C] - Resistance Table.............................................................................................. 180

Temperature Sensor [°F] - Resistance Table .............................................................................................. 181

Air exchange Sensor table Voltage - m3/h for 35 CMH ................................................................................ 182

Voltage – Pressure Table, Low pressure transmitter (NSK) .......................................................................... 182

Air exchange Sensor table Voltage - m3/h for 75 CMH ................................................................................ 183

Voltage – Pressure Table, Low pressure transmitter (AKS) .......................................................................... 183

Voltage – Pressure Table, High pressure transmitter (NSK) ......................................................................... 184

Voltage – Pressure Table, High pressure transmitter (AKS) ......................................................................... 185

Temperature Sensor - Voltage Table ......................................................................................................... 186

Pressure/Temperature table for R134a ..................................................................................................... 187

Tightening torques ................................................................................................................................. 188

Controller Unit Illustration ......................................................................................................................... 189

Star Cool Unit, installation dimensions ....................................................................................................... 190

P & I diagram .............................................................................................................................................. 191

Overall Wiring Schematic............................................................................................................................ 192

Overall wiring schematics (optional) .......................................................................................................... 193

Operating and service manual

6 of 194 pages

Legend

Short name Name Short name Name

AirEx Air Exchange Pdis Discharge Pressure

AirEx mo Air exchange motor Pfc Power used by Frequency Converter

Alarm Alarm PhDir Phase Direction

AKS Danfoss pressure transmitter Psuc Suction Pressure

Bat Battery Ptot Power Total

CalAex Calibration value AirEx PTI Pre Trip Inspection

CalUs1 Calibration USDA sensor 1 PTI Short Pre Trip Inspection Short

CalUs2 Calibration USDA sensor 2 Pwr Power

CalUs3 Calibration USDA sensor 3 RH Relative Humidity

CalCar Calibration Cargo sensor RHset Relative Humidity Set point

CapAct Actual capacity RMM Remote Monitoring Modem

(power line communication)

CapReq Requested capacity

Com Communication SHTV Superheat Expansion Valve

ComQ Communication Quality FC Shp High pressure switch

Cpr Compressor SHReq Superheat Requested

CT Cold Treatment T0 Calculated Evaporator

Temperature

FC Frequency Converter

Fcpr Compressor Frequency Tact Actual Temperature

FcprAct Compressor Frequency actual Tamb Ambient Temperature

FcprReq Compressor Frequency requested TC Calculated condenser

Temperature

Flower Compressor Frequency min.

Fpower Power supply Frequency converter Tcargo Cargo Temperature

Fref Compressor Frequency requested Tevap Evaporator Temperature

Fupper Compressor Frequency max. Tfc Frequency converter Temperature

Gear Gear Tint Tinternal (controller board)

Gnd Ground Tret Return Air Temperature

Hevap Evaporator Heater Tset Temperature Setpoint

I1 Current Phase 1 Tsuc Suction Temperature

I2 Current Phase 2 Tsup Supply Air Temperature Average

I3 Current Phase 3 Tsup1 Supply Air Temperature 1

Idc Current in DC Frequency Converter Tsup2 Supply Air Temperature 2

Ifc Current in AC Compressor Motor Tusda1 USDA 1 Temperature

IceMas Theoretical Ice mass in Evaporator Tusda2 USDA 2 Temperature

LED Light Emitting Diode Tusda3 USDA 3 Temperature

MaxInt Max. internal temp. controller U12 Voltage Phase 1-2

Mcpr Compressor Motor U13 Voltage Phase 1-3

McOH Condenser Motor Over Heat U23 Voltage Phase 2-3

Mcond Condenser Motor U/f Voltage/frequency ratio

Mevap Evaporator Motor Ubat Battery voltage

Mevap1 Evaporator Motor 1 Udc DC voltage in Frequency Converter

Mevap2 Evaporator Motor 2 Umean Mean Voltage =

(U1-2+U1-3+U2-3)/3

Mevap1OH Evaporator Motor 1 overheat

Mevap2OH Evaporator Motor 2 overheat Umotor Mean Voltage Compressor Motor

MTS Multi Temperature Settings Veco Economizer Valve

NSK SAGInoMIYA pressure transmitter Vexp Expansion Valve

OprMod Operation Mode Vhg Hot gas Valve

PCB Printed Circuit Board Warn Warning

7 of 194 pages

Operating and service manual

Prex Description

FFrequency

HHeater

I Current

MMotor

PPressure

QPower

RH Relative humidity

S Switch / contact / key

SH Super heat

TTemperature

T0 Saturated suction temperature

UVoltage

VValve

Contraction Full name

Amb Ambient

Bat Battery

Cond Condenser

Cpr Compressor

Dis Discharge

Eco Economizer

Evap Evaporator

Fc Frequency converter

Motor Compressor motor

Pwr Power

Ret Return

Suc Suction

Sup Supply

Sufx Specication

Act Actual

In Input

OH Overheat

Out Output

Req Requested

Set Setpoint

Operating and service manual

8 of 194 pages

General description

The 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). The outer front frame is constructed of marine grade aluminium, 5000 and 6000 series,

designed to serve adequately as the container end wall.

The rear bulkhead is made of food-approved material. The unit is designed to operate with satis-

faction under sea going and environmental conditions as specied below:

• Salt – laden air, sea spray and high humidity.

• Rolling: Amplitude of 30° each side, period of 13 seconds.

• Pitching: Amplitude of 6° each side, period of 8 seconds.

• Permanent list: 15° on each side.

• Shock: 2g horizontal and 5g vertical.

• Vibrations: Of the types encountered on ships, trucks and rail.

The unit consists of the following modules.

• Frame module

• Condenser / compressor module

• Evaporator module

• Evaporator fan module

The cooling system of the unit is equipped with a two – stage compressor, electrically driven

through a FC.

The cooling system is also equipped with an economizer, which performs the task of sub-cooling

the liquid from receiver to evaporator, thereby increasing the cooling capacity of the cooling unit.

The evaporator and economizer are controlled by electronic expansion valves.

The equipment is designed to operate on a nominal 410/450 V AC, 3 phase, 50/60 Hz, primary

power source, according to ISO 1496-2.

An integrated dual winding transformer supplies the control circuit voltage. One winding for 24 V

AC (for RMM modem supply) and another for 26 V AC converted to DC-Voltage in the controller (for

controller and contactor supply). The output voltage is dependent on supply voltage. An automatic

system, power supply sensing and correction, is provided to ensure the correct direction of rota-

tion for the fan motors. This is done regardless of the incoming phase sequence from the primary

power supply, provided that all fan motors are wired correctly.

An optional water-cooled condenser is mounted in series with the air-cooled condenser. This

water-cooled condenser allows operation of unit below deck, where no air ventilation is possible,

provided that water connections are present.

The unit is controlled by an electronic controller manufactured by Lodam Electronics, controlling

the supply temperature probe in chilled mode (temperature setting above or equal to –5°C

(23°F)) and the return temperature in the frozen mode (temperature setting below –5°C (23°F)).

Controller accuracy is ±0.25°C (±0.45°F). The unit can operate the evaporator fans in low speed

and high speed. From the controller display, Normal or Economy mode can be selected under

operation menu. In economy mode the fans always run on low speed. In normal mode the fan

speed can run in high or low speed depending on running conditions.

The air from the unit is delivered to the bottom of the container, with return air through the top of

the evaporator coil section (bottom air delivery).

The unit is equipped with a de-humidication function controlled by the electronic controller of the

unit. The humidity setpoint can be set in the range from 95 – 65% (or 50 % with closed

ventilation) RH. The unit can control to the lowest level. The de-humidication function is active as

long as the temperature control is in set point range. The unit is equipped with heating elements,

mounted under the evaporator coil, for the de-humidication. The de-humidication system is also

active in economy mode.

9 of 194 pages

Operating and service manual

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. Furthermore the heating

elements, mounted under the evaporator coil, are energized during defrost. This dual system for

defrosting ensures a fast defrost sequence and thereby only a very small input of heat to the

container. This results in very small temperature variations for the transported cargo, after a

defrost sequence. The dual system for defrost also ensures an even distribution of heat to the

evaporator coil. The result of this is that there is no building up of ice in corners or other places of

the evaporator coil. The two defrost systems, hot gas and heating elements, are independent. This

ensures a defrost sequence to be carried out, any time. A demand defrost system is integrated in

the software ensuring that the evaporator coil will not ice up.

The unit is equipped with a datalogger incorporated in the controller.

The logging interval is in predened intervals, 15, 30, 60, 120 or 240 minutes. The logging of the

USDA–sensors (3 pieces) and Cargo-sensor is done with an interval of one hour according to USDA

requirements. With a logging interval of one hour, there is storage capacity for 365 days of tem-

perature loggings.

Datalogger accuracy is ±0.25°C (±0.45°F).

The data–log can be retrieved with a PC–system Starview and Psion Logman, via high-speed serial

communication port.

The controller has a battery back–up system for the datalogger, which after power down the unit

continues logging in battery mode for 120 times. For CIM6 the battery is rechargeable and for

CIM5 the battery is not rechargeable.

The controller is optimized for communication with Remote Monitoring Equipment, according to

ISO standard 10368. Events + Alarms and Data Log can be retrieved by various download tools

such as Refcon, Logman, StarView etc. and can be viewed by same.

Function description

Start-up procedure

The start-up procedure has 5 modes:

1. Initialize: Self check controller.

2. Stabilize: The evaporator fan operates at high speed to ensure that temperature sensors are at

current temperature.

3. Crank case heating: If Tamb is lower than 2°C (36°F) heat is applied until Tfc is above 12°C

(54°F).

4. Ramp up

5. Terminate: Switching to normal temperature and valve regulation.

Ce manuel convient aux modèles suivants

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