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Maersk Container Industry Star Cool SCI-20 Operating And Service Manual

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Operating and Service Manual
Star Cool Refrigeration Unit
Model SCI-20/40/CA and SCU-20/40
Version 810900E June 2019

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Summary of Contents for Maersk Container Industry Star Cool SCI-20

  • Page 1 Operating and Service Manual Star Cool Refrigeration Unit Model SCI-20/40/CA and SCU-20/40 Version 810900E June 2019...

  • Page 2: Preface

    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 accu- rate, Maersk Container Industry AS assumes no responsibility for any errors or omissions that may appear in this documentation.

  • Page 3: Table Of Contents

    2 of 112 pages 3. Contents 1. Preface ................................. 1 2. Warnings ..............................1 3. Contents............................... 2 4. Legend ................................. 6 5. General description ............................8 6. Function description ............................ 9 6.1 Start-up procedure ..........................9 6.2 Temperature control..........................9 6.3 Capacity control and limiter ........................10 6.4 Electrical control ...........................12 6.5 Expansion valve ............................12...
  • Page 4 3 of 112 pages 8.26 USDA socket requirements ........................24 8.27 O sensor ............................24 8.28 CO sensor ............................24 8.29 Temperature sensors, including USDA ....................24 8.30 CA pressure transmitter ........................24 8.31 Pressure transmitters ..........................25 8.32 Miscellaneous .............................25 9. User interface .............................25 9.1 Indicator lights .............................25 9.2 Display ..............................26 9.3 Key pad ...............................27 10.
  • Page 5 4 of 112 pages 15. Location of valves .............................66 16. Location of motors, temperature sensors, humidity sensor and air exchange potentiometer ....67 17. Location of pressure transmitters, high pressure switch and oil outlet port ..........68 18. Location of AV and CA components ......................69 19.
  • Page 6 5 of 112 pages 23.6 Voltage – pressure table, LP transmitter (NSK) + DST ................98 23.7 Voltage – pressure table, LP transmitter (AKS) ..................99 23.8 Voltage – pressure table, HP transmitter (NSK) + DST ................100 23.9 Voltage – pressure table, HP transmitter (AKS) ..................101 23.10 Pressure - temperature table for R134a .....................102 23.11 Pressure - temperature table for R513A .....................102 23.12 Tightening torques ..........................103...

  • Page 7: Legend

    6 of 112 pages 4. Legend Short name Name Short name Name Alarm Action System Mevap Evaporator motor Actual Mevap1 Evaporator motor 1 Automatic Cold Treatment Mevap2 Evaporator motor 2 AirEx Air exchange Maximum operating pressure Danfoss pressure transmitter Mpump Vacuum pump motor Alarm Multi Temperature Setpoints program...
  • Page 8 7 of 112 pages Short name Name Tusda2 USDA 2 temperature Tusda3 USDA 3 temperature Ubat Battery voltage DC voltage in frequency converter Voltage/frequency ratio Valve Veco Economizer valve Vexp Expansion valve Hot gas valve Operating and service manual...

  • Page 9: General Description

    8 of 112 pages 5. General description units, models SCU-40 and SCI-40 are electric powered picture frames, cooling STAR COOL and heating units operating on refrigerant R134a or R513A. 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

    9 of 112 pages From the controller display, Normal or Economy mode can be selected under the 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 unit is equipped with a datalogger incorporated into the controller.

  • Page 11: Capacity Control And Limiter

    10 of 112 pages Chill mode Defect sensor(s) Substitution sensor/Action Alarm Tsup1 (2) Tact = Tsup2 (1) Tsup1 and Tsup2 Tact = Tret + constant 611, Too many sensor err Tsup1, Tsup2, and Tret Tact = Tevap + constant Tsup1, Tsup2, Tret, and Tevap 600, No control sensor Frozen mode Defective sensor(s)
  • Page 12 11 of 112 pages The below figure indicates the ranges for the capacity and compressor speed (frequency). System Capacity Heating % -100 Capacity % Cool eco Cool PWM Heat -20% +10% -100% 100% cooling heating Cooling % If there is a limiter active on the unit then the compressor speed will be slower and the unit will op- erate with reduced capacity.

  • Page 13: Electrical Control

    12 of 112 pages 6.4 Electrical control The following graphical illustration shows the accepted volt/Hz range and the set off values for the alarms AL 415, AL 418, AL 424, and AL 425. Supply frequency [Hz] Alarm 425 Unit stop (Power frequency) Fans low speed Alarm 418...

  • Page 14: Dehumidification

    13 of 112 pages 6.7 Dehumidification The dehumidification function dehumidifies air in the container by means of a heater. This function can only be activated if the temperature control function is active. Dehumidification is achieved by decreasing evaporator surface temperature. This is done through activation of the heater and letting the temperature control increase cooling capacity resulting in an evaporator temperature descending.

  • Page 15: Evaporator Fan

    14 of 112 pages 6.9 Evaporator fan The evaporator fan function ensures correct fan speed (high or low). The function is active in the automatic mode. This function has 2 modes: 1. Normal Low speed in Frozen mode or if the following three conditions are set: - Tset is more than or equal to 0°C (32°F) - No fresh air exchange - Dehumidification is turned off or humidity setpoint below 65%...

  • Page 16: Alarm Action System

    15 of 112 pages General information If the Tevap sensor is not OK, adaptive defrosting uses a reduced defrost interval compared to normal calculated defrost intervals. Setpoint alteration leads to a new calculated defrost interval, and defrost starts when the defrost criteria is reached. With manual defrost initiation the current defrost interval is set to default defrost interval.
  • Page 17 16 of 112 pages Event ID Param. 1 Param. 2 Param. 3 Param. 4 Param. 5 Tsup Supply air temperature [°C] Tret Return air temperature [°C] Tusda1 USDA 1 temperature [°C] Tusda2 USDA 2 temperature [°C] Tusda3 USDA 3 temperature [°C] Tcargo Cargo temperature [°C] Tset...

  • Page 18: Tests

    17 of 112 pages Extended Log Type 3 Extended Log Type 4 Header can be retrieved by Refcon, Logman, StarView and can be viewed in Refcon, LogView and StarView. Extended Log Type 1 can only be retrieved by Logman and StarView and shown in LogView and StarView.

  • Page 19: Function Test

    18 of 112 pages 7.1 Function test Function test is a unit component test (non destructive). The test is based on a GO/NO GO proce- dure. All tests must be executed without failure one by one for the function test result to be PASS. The tests can also be performed individually.

  • Page 20: Full Pti

    19 of 112 pages NOTE: At ambient temperature above +40°C (+104°F) and below -20°C (-4°F), the unit has to be running in normal operating mode at setpoint of 0°C (32°F) for of 10 minutes with com- pressor running before executing a function test or PTI test. The reason for this is to en- sure correct function of unit during PTI test or function test.

  • Page 21: Compressor - Motor Assembly

    20 of 112 pages 8.3 Compressor – motor assembly 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 3.8 kW Compressor oil type Reniso Triton SEZ 55 or equivalent Compressor oil quantity 1.5 L and 0.4 L in system Compressor housing...

  • Page 22: Evaporator Fan Motor

    21 of 112 pages 8.8 Evaporator fan motor Manufacturer Grundfos dahlander motor ABB dahlander motor Type Enclosed, non-vented Frame size 071B14 Shaft material Stainless steel, X20CrNi172 No. of motors Voltage 3–phases, 400/460 V AC, 50/60 Hz Nominal power 0.45/0.07 kW @ 460V/60 Hz 0.45/0.07 kW @ 460V/60 Hz Protection, Thermistors...

  • Page 23: Condenser Fan Motor

    22 of 112 pages 8.11 Condenser fan motor Manufacturer Grundfos dahlander motor Zhongda dahlander motor ABB dahlander motor Type Enclosed, non-vented Frame size 071B3 Shaft material Stainless steel, X20CrNi172 No. of motors Voltage 3–phases, 400/460 V AC, 50/60 Hz Nominal power 0,25/0,07 kW 0,30/0,08 kW 0,30/0,08 kW at 460 V/60 Hz...

  • Page 24: Economizer

    23 of 112 pages 8.15 Economizer Type Brazed plate heat exchanger Material Stainless steel, AISI 316 L 8.16 Refrigeration controls Expansion valves 2 solenoid valves, electronically controlled by the controller Filter drier Danfoss DML 164 with O-ring or equivalent Hot gas valve Solenoid valve electronically controlled by the controller Moisture indicator...

  • Page 25: Power Plug

    24 of 112 pages 8.24 Power plug Type CEE 3P+E (4 pole) 32 A 400/460 V, 50/60 Hz 8.25 Power cable Type 4 x 2.5 mm , 450/750 V, PU – sheath Length/colour 18 m/Yellow Temperature range -37°C to +90°C (-34.6°F to +194°F) 8.26 USDA socket requirements Location Rear left side...

  • Page 26: Pressure Transmitters

    25 of 112 pages 8.31 Pressure transmitters Manufacturer High pressure side 0 to 32 BarE 0 to 30 BarE 0 to 40 BarE Low pressure side -1.0 to 12.0 BarE -0.69 to 9.8 BarE -0.69 to 13.0 BarE Type Ratio metric pressure transmitter, with sealed gauge measuring principle. ¼”...

  • Page 27: Display

    26 of 112 pages 9.2 Display Setpoint temperature Setpoint control Control sensor temperature Secondary information Icons ______ ______ Suction pressure Discharge pressure Status text °C/°F unit and bar graph and bar graph Intelligent Trip Inspection passed Temperature and pressure unit selection C / F Celsius and Bar or Fahrenheit and Psi Pre Trip Inspection or Function Test is running...

  • Page 28: Key Pad

    27 of 112 pages 9.3 Key pad Use these keys to move menu display up/down and to change Navigation keys parameter values Leave active sub menu Cancel Cancel active parameter adjustment Move menu one line up Increment parameter value in menu Increment setpoint on main display page Zoom out (graphical view) Move menu one line down...

  • Page 29: Menu Overview

    28 of 112 pages Function keys Direct activation and deactivation of commonly used functions As long as the button is pressed, °F is shown instead of °C and Psi is Unit shown instead of Bar in the display. Otherwise °C and Bar is shown when pressed if software is set to °F/Psi default Shortcut to graphical view of logged temperatures.

  • Page 30: Using The Cursor

    29 of 112 pages 10.2 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: Operation

    30 of 112 pages 11. Operation 11.1 Menu structure MAIN PAGE INFORMATION PROGRAMS MULTI. TEMP. SETP. Relative humidity > Active program Hour Multi. Temp setp. > > Auto Cold Treatment > > Bulb mode > Last defr interval AIR EXCHANGE USDA 1 temp >...

  • Page 32: General Operation

    31 of 112 pages 11.2 General operation The following text is a general description of operating menus and editing parameters. By pressing a menu key the menu is selected and its icon is illuminated. The lower part of the display shows parameter number, parameter value and a short information text in English.

  • Page 33: Viewing Graph Of Supply And Return Temperature

    32 of 112 pages 11.7 Viewing graph of supply and return temperature Press to enter graphical view (this function is a shortcut to L03 ( “11.20 Datalog view” p. 51)). To return to main page press two times. Press to toggle between stored set of temperatures: Setpoint temperature + supply air temperature, return air temperature and the other set of temperatures: USDA 1 + 2 + 3 temperatures and cargo temperature.
  • Page 34 33 of 112 pages 1. One alarm for PTI or function test failure. Status are also listed in the menu items T04 – T12(FT)/T18(PTI). 2. One or more alarms for a specific error during the test. Only listed in alarm list. Failures found during the tests are listed in the alarm list and the results of the separate PTI test steps are in menu items T04 to T18.
  • Page 35 34 of 112 pages X06 ITI Off cycle Function: Display remaining off time of current test interval. Value: Shown as hours. X07 ITI Pass date Function: Date of last ITI pass –> checkmark set. Value: YYYY-MM-DD or N/A. T03 Function test start Function: Start function test runs to verify full functionality of the unit without performance tests.
  • Page 36 35 of 112 pages 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 AL 815 - 817. T11 Test result: 60 Evaporator heater Function: Shows the status of the test of the evaporator heater.

  • Page 37: Info Menu

    36 of 112 pages 11.10 Info menu By pressing the Information menu is selected. The icon is displayed. The info menu includes the following parameters: I01 Relative humidity Function: Shows current relative humidity in the container. Value: Shown as a percent value. I03 O2 level Function: Shows the O...
  • Page 38 37 of 112 pages I12 Supply air 1 temperature Function: Shows current temperature for supply 1 sensor. Value: Shown in temperature scale °C or °F. Switch by pressing I13 Supply air 2 temperature Function: Shows current temperature for supply 2 sensor. Value: Shown in temperature scale °C or °F.
  • Page 39 38 of 112 pages I22 Compressor frequency Function: Shows current compressor frequency. Value: Shown in units of Hz. I23 Power frequency Function: Shows current power (net) frequency. Value: Shown in units of Hz. I24 Current consumption phase 1 Function: Shows actual current consumption on phase 1 for the unit excluding the compressor. Value: Shown in units of ampere.

  • Page 40: Raw Sensors

    39 of 112 pages Value: Shown in temperature scale °C or °F. Switch by pressing I33 Condenser fan speed Function: Shows current speed for condenser fan. Value: Shown as OFF, LO, HI or OH (overheat). I34 Evaporator fan speed Function: Shows current speed for evaporator fan.
  • Page 41 40 of 112 pages E03 CO2 Function: Shows the CO level [%]. Value: An actual value of the CO level inside the container. E04 USDA 1 temp Function: Shows current temperature for USDA 1 sensor. Value: Shown in temperature scale °C or °F. Switch by pressing E05 USDA 2 temp Function: Shows current temperature for USDA 2 sensor.

  • Page 42: Operation Parameter Settings

    41 of 112 pages Value: Shown in temperature scale °C or °F. Switch by pressing E14 Suction press Function: Shows current suction pressure for compressor. 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).

  • Page 43: Programs

    42 of 112 pages 11.13 Programs O06 Programs Function: Leads to the programs sub-menu. Value: Go to the programs sub menu. P01-P04 Show/select active program Function: Shows active program or activates selected program. Attention: Program setpoints have to be set before activating the program is activated. Value: Shown as None, ACT, MTS or Bulb mode.

  • Page 44: Multiple Temperature Setpoints Program, Mts

    43 of 112 pages B02 Treatment limit Function: Setting of the maximum allowed temperature of the mounted USDA sensors. Value: -4.7°C to +30.0°C. Shall be locked after ACT activation. B03 Treatment setpoint Function: Setting of the setpoint during the treatment. Value: -4.9°C to [Treatment limit - 0.2K].

  • Page 45: Bulb Mode

    44 of 112 pages 11.13.3 Bulb mode The major functionality in Bulb mode is: 1. 1. Bulb mode selection: a. MevapL b. MevapH c. MevapL for 1 hour then MevapH for 1 hour etc. 2. This in connection with the possibility to control dehumidification and termination temperature of defrosts.

  • Page 46: Av/Av+/Ca Settings

    45 of 112 pages Bulb mode off after: 1. PTI pass or fail 2. Manual deactivation of program 11.14 AV/AV+/CA settings The Star Cool AV+ is a system designed to automatically regulate the internal atmosphere of the container using greatly reduced energy consumption compared to manual or other automated fresh air systems.
  • Page 47 46 of 112 pages The basic principle is that the fruit will generate CO from O via respiration. This will increase the CO level and decrease the O level inside the container. When the CO level reaches above the CO set- point the vacuum pump will activate and evacuate CO with the selective membrane.

  • Page 48: Manual Defrost

    47 of 112 pages O07 O2 setpoint Function: setpoint. Value: Range 3 - 21%. O08 CO2 setpoint Function: setpoint. Value: Range 4 - 12%. O09 Active application Function: Actual application. Value: - Std (standard) - AV (automatic ventilation) - AV+ (automatic ventilation +) - CA (controlled atmosphere) O13 Flush mode Function:...

  • Page 49: Intelligent Trip Inspection

    48 of 112 pages 11.16 Intelligent Trip Inspection (ITI) O11 Intelligent Trip Inspection Function: Turning Intelligent Trip Inspection on or off. Value: OFF, ON. O12 User request of Intelligent trip inspection result log Function: Activating command generates result of ITI, if test sequence is completed. Value: NONE, LOG.

  • Page 50: Service Function Settings

    49 of 112 pages The AAS (Active Alarm System) will substitute a missing or malfunctioning sensor with one of the other sensors and thereby try to keep the cargo safe and well as long as absolutely possible. The substitution may lead to a deteriorated control precision, especially in Frozen mode, but the unit is not stopped fully until there are no further sensors to substitute with.
  • Page 51 50 of 112 pages M03 Turn the evaporator fan on/off Function: Manual evaporator fan on/off. Note that value is only accepted if control is in the manual mode (menu item M01 is MANUAL). Value: Set to OFF, LO (low speed) or HI (high speed). M04 Turn the condenser fan on/off Function: Manual condenser fan on/off .

  • Page 52: Datalog View

    51 of 112 pages 11.20 Datalog view  The number under the text Ref shows the temperature at the mark, ex. 5°C. Press to toggle between stored set of temperatures: Setpoint temperature + supply air tem- perature, return air temperature and the other set of temperatures: USDA 1 + 2 + 3 temperatures and cargo temperature.

  • Page 53: Run Time Counters

    52 of 112 pages C05 Setting of min. (GMT-Minute) Function: Setting of min. Note: when min. are set, sec. are set to 00. Value: Set from 0 to 59. 11.22 Run time counters R01 Viewing of operation hours for the Star Cool unit Function: Viewing of Star Cool unit operation hours.
  • Page 54 53 of 112 pages F02 Software version viewing Function: Viewing of software version and revision. Value: F03 Compressor FC type setting Function: Setting of actual FC type. Value:  Setting as DANFOSS for Danfoss VLT and NONE for no FC mounted (see “22. Emergency opera- tion”...

  • Page 55: Starconomy

    54 of 112 pages F10 Model code Function: Configure the reefer unit model Value: See table below. Value: Function Water-cooled condenser AV/AV+ Limit off/on off/on off/on SCU-40 SCU-40-W SCU-40-AV+ SCU-40-W-AV+ SCU-40-AV+02 SCI-20 SCI-20-W SCI-20-AV+ SCI-20-W-AV+ SCI-40 SCI-40-W SCI-40-AV+ SCI-40-W-AV+ SCI-40-CA SCI-40-W-CA SC-MCI140 SC-MCI140-WC...

  • Page 56: Serial Numbers

    55 of 112 pages 11.24 Serial numbers N01 SMC Function: Main controller. Value: Main controller serial no. N02 SUP Function: User panel. Value: User panel serial no. N03 SPM Function: Power meas. Value: Power meas serial no. N04 RH Function: Humidity sensor.

  • Page 57: Usb Menu

    56 of 112 pages 11.25 USB menu SERVICE USB PROGRESS MANUAL OPERATION DATALOG VIEW Updating firmware ... TIME ADJUST RUNTIME COUNTERS S03xxxx.bin CONFIGURATION SERIAL NUMBERS FIRMWARE FILES USB MENU V01 S035c_1.bin V02 S035c_2.bin USB MENU USB PROGRESS Firmware update > Datalog Fastlog Copying log to USB Stick...

  • Page 58: External Interfaces

    57 of 112 pages 12. External interfaces The Star Cool controller can be accessed externally in the following ways: StarCool Unit RefCon / Slave Master GRASP RS 232 Powerline RS 485 modem modem RCCU-6 Binary Retriever LogMan LogView Controller RS 232 RS 232 logfile socket...

  • Page 59: Events

    58 of 112 pages Calibrate USDA and cargo sensors Acknowledge alarms Initiate manual defrost Initiate Trip Start Initiate Function test and PTI Terminate Function test and PTI Display Function test and PTI results Retrieve datalog from unit Save datalog file (binary) Save datalog file (RefCon) Save datalog file (CSV text) Display datalog file (binary)
  • Page 60 59 of 112 pages Trip Start 1: Auto trip-start SW ver. low SW ver. high SW rev. 0: User trip-start USDA Sensor Calibrated 1: USDA 1 Sensor offset Compatibility flag 2: USDA 2 (reading of 0x8000 = version 3: USDA 3 uncalibrated probe 1 format 4: CARGO...
  • Page 61 60 of 112 pages ACT restarted Treatment Treatment Probes Used Duration: X New setpoint: limit: XX.XX setpoint: XX.XX 1: USDA 1 (in days) XX.XX ACT redefined 2: USDA 2 4: USDA 3 ACT terminated 8: CARGO defaulting Power Spike Robustness Udc value Udc limit Model code changed...

  • Page 62: Detailed Alarm Description

    61 of 112 pages Debug (intern. use) 1:Alarm system Task number 0 = Recovered, 1 Tick count Tick count info (obsolete) Started (1) / = Warning 2:Watchdog timer Stopped (0) Errorcode Errorcode Alarm count Sensor Status after value after value sensor clean- ppm diff be- before value...

  • Page 63: Alarm List

    62 of 112 pages 14.1 Alarm list The following list includes a view of all alarms as listed on the display and a longer text. This list is subject to constant updates. Be sure to visit alarm.starcool.com for latest update. Display text Description Alarm type...
  • Page 64 63 of 112 pages Invalid power sup FC overvoltage fault Alarm FC supply error Power supply error indication Alarm FC over temp FC over temperature fault Alarm FC inrush FC inrush fault Alarm FC internal error Frequency converter high voltage fault warning Alarm FC temp counter P3000 only...
  • Page 65 64 of 112 pages Hevap current OFF Evaporator heater off current fault Warning Hevap current error Hevap current failure Warning Hpump current ON Heat vacuum pump too high or too low Warning Hpump current OFF Measured current is too high when heater is turned off Warning Mpump current error Mpump current failure...
  • Page 66 65 of 112 pages Pdis sens sup HI Controller internal voltage reference fault Psuc sens sup LO Controller internal voltage reference fault Psuc sens sup HI Controller internal voltage reference fault Controller sup LO Controller internal voltage reference fault Controller sup HI Controller internal voltage reference fault AirExMot sup LO Controller internal voltage reference fault...

  • Page 67: Location Of Valves

    66 of 112 pages 15. Location of valves Position Description Discharge service valve Economizer service valve Hot gas valve Manual stop valve Expansion valve, evaporator Expansion valve, economizer Suction service valve Liquid charging valve Evacuation valve Evacuation valve Operating and service manual...

  • Page 68: Location Of Motors, Temperature Sensors, Humidity Sensor And Air Exchange Potentiometer

    67 of 112 pages 16. Location of motors, temperature sensors, humidity sensor and air exchange potentiometer Pos Description Short Quantity 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 Supply temperature sensor...

  • Page 69: Location Of Pressure Transmitters, High Pressure Switch And Oil Outlet Port

    68 of 112 pages 17. Location of pressure transmitters, high pressure switch and oil outlet port Pos Description Short name Quantity Location Discharge pressure transmitter Pdis Outside High pressure switch Outside Suction pressure transmitter Psuc Outside Oil outlet port Outside Operating and service manual...

  • Page 70: Location Of Av And Ca Components

    69 of 112 pages 18. Locations of AV and CA components Position Description Vacuum pump Air exchange module Vacuum pump hose CA membrane module Sensor location (O and CO Pressure release valve Injection ports Air exchange module Operating and service manual...
  • Page 71 70 of 112 pages CA membrane module Oil filter Note: O-ring has to be in place Pressure transmitter sensor sensor Displayed sensors may vary from currently used models Operating and service manual...
  • Page 72 71 of 112 pages Vacuum pump Plug Terminal box Pump inlet integrated connection Pressure transmitter connection Oil inlet (charge) Pump discharge Oil filter (inside) Sight glass Temp. sensor pocket Heating element Oil outlet (drain) Tightening torques for M6 screws on vacuum pump cover shield: 6 Nm Tightening torques for plugs and heating element: 15 Nm Operating and service manual...

  • Page 73: Replacements

    72 of 112 pages 19. Replacements 19.1 Replacement of 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 earth wire placed directly on the motor.

  • Page 74: Replacement Of Evaporator

    73 of 112 pages 19.3 Replacement of evaporator Position Description Back plate, evaporator Evaporator The replacing of evaporator is done in the following steps: 1. Evacuate refrigerant as described in this manual (see “20.1 Evacuation of refrigerant” p. 79). 2. Remove the evaporator back plate (pos. 1). 3.

  • Page 75: Replacement Of Heating Elements

    74 of 112 pages 19.4 Replacement of heating elements Dismount the upper back plate of the unit and replace the defective heating element. After replacing the heating element, reinstall the back plate of the unit. Please note that the illustrated model may be different from the actual model.

  • Page 76: Replacement Of Fc

    75 of 112 pages 19.5 Replacement of FC Good Full flush Air gap " " Thermal paste Position Description Black cover, FC 2.0 Frequency converter 2.0 Cable, FC 2.0 to compressor Threaded bushing, FC mounting The procedure for replacing the FC is as follows (Please ensure correct tightening torque is used throughout replacement): 1.

  • Page 77: Replacement Of Compressor

    76 of 112 pages Be aware that cables might tilt 19.6 Replacement of compressor Torque according to data sheet Position Description Compressor Bracket, compressor Black cover, FC 2.0 Frequency converter 2.0 Cable, FC 2.0 to compressor The procedure for replacing the compressor is as follows. Please ensure correct tightening torque is used throughout replacement.

  • Page 78: Replacement Of Compressor Valve Plate/Cylinder Head Gasket

    77 of 112 pages a. Close Veco and Vsuc. b. Go to the Service menu and select Manual operation and set the compressor freq to 20 Hz. c. Let the pressure drop to vacuum. d. Stop the compressor by pressing Off on the controller and closing discharge stop valve. e.

  • Page 79: Replacement Of Filter Dryer

    78 of 112 pages 19.8 Replacement of filter dryer 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 indicators indicate too much moisture in the refrigerant circuit.

  • Page 80: Service And Maintenance

    79 of 112 pages 20. Service and maintenance 20.1 Evacuation of refrigerant Evacuation of refrigerant from the unit is done by the following procedure: 1. Connect a service gauge manifold to the evacuation point, pos. 6 and 27 (P & I diagram) on the compressor.

  • Page 81: Compressor Pump Down And Operation

    80 of 112 pages 20.2 Compressor pump down and operation Pump down of the compressor is done by the following procedure: 1. Connect a service gauge manifold to the two evacuation points, pos. 6 and 27 (P & I diagram) on the compressor.

  • Page 82: Pump Down Of Unit

    81 of 112 pages 20.4 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 service gauge manifold to the evacuation points, pos. 6 and 27 (P & I diagram) on the compressor.

  • Page 83: Charging Of Refrigerant

    82 of 112 pages 11. Disconnect the pressurized gas bottle. 12. Open the discharge stop valve on the service gauge manifold to release the pressure from the unit. 13. Do a pump down of unit (see “20.4 Pump down of unit” p. 81). 14.

  • Page 84: Leakage Detection

    83 of 112 pages 1. Install a service gauge manifold to the unit, and connect the HP hose to the Liquid charging line, pos. 11 (P & I diagram) and the LP to the closed suction service valve - pos 27 (P & I diagram). 2.

  • Page 85: Compressor

    84 of 112 pages 20.9 Compressor 20.9.1 Check of oil level Oil level dipstick Compressor with sight glass: The oil level can be checked on the sight glass of the compressor. During normal operation the oil level should be between 1/3 and 2/3 sight glass full. Run the unit on full Cool mode for as long as possible (minimum 1 hr) before the oil level is checked.

  • Page 86: Draining Of Oil From Compressor

    85 of 112 pages Oil charge 20.9.3 Draining of oil from compressor If the compressor has been overcharged with oil, the procedure for drainage is as follows: 1. The two oil outlets are placed on a tee-piece located on the compressor end opposite of the FC end.

  • Page 87: Soldering

    86 of 112 pages 20.10 Soldering When soldering and desoldering components on the unit, please observe the following: 1. 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 88: Container Leak Test

    87 of 112 pages 20.12 Container leak test When using the CA system, the box must conform to leak rates in order to maintain control of the and CO setpoints. The minimum box requirement is a pressure of 500Pa/2” to 250 Pa/1” for 8 minutes or more.

  • Page 89: Container Venting Procedure

    88 of 112 pages 7. Check that the gas injection tanks/bottle have proper operation handles and pressure gauges in order to control the gas flow correctly. 8. Connect both the N and CO gas tanks/bottles to the damper or injection ports. 9.

  • Page 90: Sensor Calibration Using Starview

    89 of 112 pages 20.16 Sensor calibration using StarView When placing the USDA and cargo probes in ice water, they should display 0°C. If any reading deviates from this value the probe requires calibration. Calibration is simply done by looking at the reading for the USDA sensor and then double clicks in e.g.

  • Page 91: Trouble Shooting For The Star Cool The Main Controller

    90 of 112 pages 4. Liquid refrigerant is entering the compressor through the evaporator. The temperature sensor, Tsuc is not working properly. Check that the sensor is mounted close to the pipe and is placed beneath the isolation. The pressure transmitter, Psuc is not working properly. The evaporator sensor, Tevap is not working properly.

  • Page 92: Trouble Shooting The Vacuum Hose

    91 of 112 pages CA membrane Vacuum pump Problem area if reading below 30 mBar Problem area if reading above 30 mBar 21.3 Trouble shooting the vacuum hose In case the vacuum hose is defective: 1. Check the hose for leaks. Repair or replace the hose. 2.

  • Page 93: Emergency Operation

    92 of 112 pages 22. Emergency operation Warning: High voltage. Unit must be disconnected from power. Only to be done by trained personnel. 22.1 FC defective If the FC is defective and no replacement part is available, the compressor may be run in On/off mode.

  • Page 94: Tables

    93 of 112 pages 23. Tables 23.1 Datalog description Explanations of datalog loggings: Values are stored in °C/BarE and are converted to °F/Psi on retrieval or listing on the display. The logged data in the datalog can be seen: • On the display menu L01, the viewable temperatures are listed.
  • Page 95 94 of 112 pages Extended data 2 (only retrievable by StarView): Name Value Unit Tsup1 Supply air temperature °C Tsup2 Supply air temperature °C Tevap Evaporator temperature °C Tsuc Suction temperature °C Hot gas valve opening Vexp Expansion valve opening Veco Economizer valve opening SHref...

  • Page 96: Temperature Sensor - Resistance Table

    95 of 112 pages 23.2 Temperature sensor - resistance table Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp [Ω] [Ω] [Ω] [Ω] [Ω] [°C] [°F] [°C] [°F] [°C] [°F] [°C] [°F] [°C] [°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...

  • Page 97: Temperature Sensor - Voltage Table

    96 of 112 pages 23.3 Temperature sensor - voltage table Temperature sensors except for reference temperature sensor. Vcc = 3 V Voltage Temp Temp Voltage Temp Temp Voltage Temp Temp [°C] [°F] [°C] [°F] [°C] [°F] 3.00 -40.0 2.03 15.8 0.85 71.6 2.98...

  • Page 98: Air Exchange Sensor Voltage Table - M /H For 35 Cmh

    97 of 112 pages 23.4 Air exchange sensor table voltage - m /h for 35 CMH 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...

  • Page 99: Voltage - Pressure Table, Lp Transmitter (Nsk) + Dst

    98 of 112 pages 23.6 Voltage – pressure table, LP transmitter (NSK) + DST Vcc = 5 V. Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure Voltage Pressure Pressure [BarE] [Psi] [BarE] [Psi] [BarE] [Psi] -0,69 -10,01 3,92 56,87 3,15 8,66 125,59...

  • Page 100: Voltage - Pressure Table, Lp Transmitter (Aks)

    99 of 112 pages 23.7 Voltage – pressure table, LP transmitter (AKS) Vcc = 5 V. Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure Voltage Pressure Pressure [BarE] [Psi] [BarE] [Psi] [BarE] [Psi] 0.50 -1.000 -14.50 1.85 3.388 49.14 3.20 7.775 112.77...

  • Page 101: Voltage - Pressure Table, Hp Transmitter (Nsk) + Dst

    100 of 112 pages 23.8 Voltage – pressure table, HP transmitter (NSK) + DST Vcc = 5 V. Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure Voltage Pressure Pressure [BarE] [Psi] [BarE] [Psi] [BarE] [Psi] 0,00 1,85 13,50 195,858 27,00 391,716 0,55...

  • Page 102: Voltage - Pressure Table, Hp Transmitter (Aks)

    101 of 112 pages 23.9 Voltage – pressure table, HP transmitter (AKS) Vcc = 5 V. Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure Voltage Pressure Pressure [BarE] [Psi] [BarE] [Psi] [BarE] [Psi] 0.50 0.00 0.00 1.85 10.80 156.64 3.20 21.60 313.28...

  • Page 103: Pressure - Temperature Table For R134A

    102 of 112 pages 23.10 Pressure - temperature table for R134a °C °F °C °F °C °F -0,5 -7.3 2,13 30.9 10,29 149.2 -0,45 -6.5 2,36 34.3 10,89 157.9 -0,38 -5.6 2,61 37.8 11,52 -0,32 -4.6 2,86 41.5 12,17 176.5 -0,25 -3.6 3,13...

  • Page 104: Tightening Torques

    103 of 112 pages 23.12 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 105: Controller Unit Illustration

    104 of 112 pages 24. Controller unit illustration Pos. Description Controller hatch User panel (SUP6) Battery pack Controller module (SMC6) Modem Contactor Duo terminal Transformer, 105VA Power measurement module (SPM6) Auxiliary contact Main circuit breaker, 16A Fuseholder for 0.4A fuse On/Off switch Fuse, 400mA High pressure switch...

  • Page 106: Star Cool Unit Installation Dimensions

    105 of 112 pages 25. Star Cool unit installation dimensions 2025 Type: SCU 1974,7 117,15 298,45 5x298,45 (1492,25) Type: SCI Operating and service manual...

  • Page 107: Diagrams

    106 of 112 pages 26. Diagrams 26.1 P & I diagram Operating and service manual...

  • Page 108: Ca Diagram

    107 of 112 pages 26.2 CA function overview - two versions Inside container CA membrane Air ex valve RS 485 Pressure sensor Output Controller Vacuum pump module SMC6 RS 485 Thermal circuit switch (Only available for some models) RS 485 Controller Signals module SSC6-...
  • Page 109 108 of 112 pages Operating and service manual...

  • Page 110: Overall Wiring Schematic

    109 of 112 pages 27. Overall wiring schematic Operating and service manual...

  • Page 111: Overall Wiring Schematics (Optional)

    110 of 112 pages 28. Overall wiring schematics (optional) Operating and service manual...
  • Page 112 111 of 112 pages Operating and service manual...
  • Page 113 112 of 112 pages Operating and service manual...
  • Page 114 Star Cool Service The app For troube shooting help, manuals, alarm codes and more, download our free Star Cool Service app by simply scanning the QR code with your smart device. See more at apps.starcool.com Training Our expert service team offer a variety of comprehensive seminars and hands- on instruction all around the world.

This manual is also suitable for:

Star cool sci-40Star cool scu-40Star cool sci-20-caStar cool sci-40-caStar cool scu-20

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