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2. STARS COOL Cool Thinking Version 810900C STAR OO Operating and service manual 1 Preface This version of the manual is dated December 2013 edited by Maersk Container Industry AS All rights reserved This user s manual is valid for software version 0351 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 40 and SCU 40 Release Date 01 12 2013 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 mo dem if present Disconnect main power supply to unit before inspecting the interior of the con troller box The unit is charged with R134a and ester oil BSE 55 Do not use any other refrig erant or oil Do not use contaminated refrigerant or oil Do not r
3. Y 198 Pressure EE 198 Charging of refrigerant EE 199 Charging of an empty unit einen nan enti Ee saca ku kesudusa ka e YR B RR AR a gi Ig KY SE REENERT IR KR ER IR EES 199 Charging Of Uo ToS lol ON Wolar ge PL M 199 Leakage detection ege qum exe lurousME RR E NNNM I eEEE 200 Fan motors in not using e WEE 200 Drying filter E 201 Replacing of drying filEGr iius cotone ttes ena EEEE EENS ER ani anani ERr EA aid dci Ra ema d PRU nEaN NiE inadai 201 Rang 201 Check of oil lOVEl mE 201 Charging OF Ol sicisistesosenstverstans ege ee ees eE ue ARA NIESEN aA E U EE E ENEE EE EE EE EE NES EE AEN RER EE 202 Draining ot oil from COmbpF6eSSOF initi sain ausus hRE RE Ie cRR Q4 ERR ROG Y EXCXR E RINFNEDEDRRAELURIRRNAPRIR ain ETES SEN 202 Elle mU 203 VO e Hi e BEE 203 ICD 203 Datalog AeSCHIDUOM EPUM 203 Temperature Sensor 9G Resistance Tables reso oir EE Ra oe aee dea pa ge EE BRENNEN E AER ante 205 Temperature Sensor PF Resistance Table iier esten SEENEN EEN s ARRIERE REES dE Nd Ee ee 206 4 of 231 pages STAR COOL Operating and service manual Air exchange Sensor table Voltage m3 h for 35 CMH essssseesesesesesenhnnene nenne nura k ase se suse sa uana s ases se sana 207 Air exchange Sensor table Voltage m3 h for 75 CMH eiascsessse sexe suonare tu nna Resa na kc kr rai R4 4 SEE EE EE ENKEN 207 Voltage Pressure Table Low p
4. Parameter name Value Unit 29 of 231 pages STAR OO Operating and service manual 1 Using the cursor The parameter ID is only used for identifying each displayed line of the menu system Pressing the 4 and ei 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 Changing a parameter value 1 First move the cursor up press O or down press to the line of the parameter to be changed 2 Then press the Enter key The cursor will now highlight the parameter value instead of the ID 3 Use the Up or Down arrow keys to increase or decrease the displayed value Accept the new parameter value by pressing the Enter key once more 5 If not pressing any key for 5 sec or if pressing the Cancel key GI the value will not be changed 6 The cursor returns to the ID column and can now be moved to other lines Activating a function 1 First move cursor Up press 4 or Down press y to the line of the function to be activated Then press the Enter key SC The cursor will now highlight the function value instead of the ID 3 Do the activation by pressing the Enter key once more If not pressing any key for 5 sec or if pressing the Cancel key GI no function will be activated 5 The cursor returns to the ID column and can now be mo
5. TWNDIS IVNOSIS aN9 aN9 uMd uMd aNd ONG uMd uMd ONG xD 7 9 xog Ja JOUOD episu lajqeebeyooy ES e droe C 8 5Nr1009 C GLLSOEH3G 3ONVHN NOW Jejonuoo 1e Bnjd YOLINOW Nid t xog 4ej o4u02 episino xog 4eJ 04 u02 episu VOWOO l1Ssoudadd GND NOW 3ONVUNI yous IX 07 pucoyy 07 desay 94 xog Ja O4JUOD IS TQ c2 SH LO COIN co S Tt aNd nton Nonton Njo n tooa e Tine N lt an9 zo Z Zu o 3 Nov o Zi xxu J n9 o E bh Sa 3 naa dad QNO axy axy ax ax QNO QNO axy v ax 8 QNO QNO nz Act v v a DI QNO QNO NO NO 0 YMd uMd QNO QNO c IVNDIS IVNOIS TWNOIS ON X v uMd uMd ONG ONG uMd uMd ONG ONG uMd uMd ONG ONG LN 9 uMd uMd ONG ONG uMd uMd ONG ONG uMd ONG 8 ONG uMd ONG uMd X AS AS IVNOIS IVNOIS ONG ONG AS AS IVNDIS IVNOSIS ONG ONG o Se N gt x lt ar N Se lt j A Slt oan ceo e Sei d OAH Selm AH ka 22 DER oeg WI E x D JL Auo WI a zZ o Ul09 24 a a z g Kg xog 48J 04 uoz episu xog J8jj04ju02 PISINO Y NOD
6. Ai ES H evasn Ma D gt evasn Hs ER gt H Joie w09 NWH x E euiioMod 40A NWH x D VirEdEASH ge pdensH V9 SUEASH xog 48 o4uoz episino xog JO ONUOD 8pisuj ft zsx er 1 9L DMV reuondo xog 4eJ o4ju02 episino xog Ja 04JUOD episu YOIeH 4eJJo4uo QVdA33 QVdA33 Al OV Ave 9 g eura OV AZZ v euruue OV AOvY c L Jeuruue p seDeyoA xouddy LL OAVEL OVAvZ DX ano OVAO HUM 4 Teu SUL z Loro tHL 9 U9HMS beu Or r3 HO UO zuo 1 1 oO H LMS ozz D zi cm n E 3 n n mz m L 5 vvo zur ed eal g 5 eza d ei 28 z z LI D D VEH HL _ a e UI ld xog 48J O 1UO7 apisu T T DN xog 4e 041u02 KI 9pisini z PISINO o z guusz jid Beer c MESS SEA 1 EE z o umo NI H3MOd LSO 222 of 231 pages ae Operating and service manual STAR LOOL O 2 9H L1819SLS2S N d S S9IUOJ O9 9 wepo oneuieuos BuulM e1910 cOEO9SIS88 lNHdt 900S 1002 KAKLS 39NVHNI xog 48J o4uo2 episu xog J8 041U07 6 I es Q o em OTAN OFN
7. Indication of short circuited supply air temperature sensor Trouble Possible causes shooting e Temperature sensor Tsup2 or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 108 Trouble shooting 1 Same trouble shooting is to be used for Tsup2 as used for Tret in AL 101 Criteria Value above high alarm limit 140 C 284 F Replacement by new value from AAS system Controller P y y action Alarm light Deteriorated control precision in the chill mode When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data me Active Inactive High limit Present i 70 of 231 pages STAR OO Operating and service manual 108 Tsup 2 invalid Alarm Supply Air Temperature Sensor 2 Invalid Indication of defective supply air temperature sensor or its measuring circuitry or sensor not mounted correctly in unit Trouble Possible causes shooting Active alarms AL 106 AL 107 or AL 901 if CIM5 software Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F Difference between Tsup1 and Tsup2 is larger than 1 C 1 C difference for more than 30 min or up to 10 C difference in more than 3 min Accompanied alarms e AL 106 or AL 107 may also be active Trouble shooting 1 If alarms AL 106 or AL 107 are active check their trouble shooting section first
8. Auxiliary Contact Contactor ain Circuit Breaker 16A Power Meas Module SPM6 Controller Hatch Mech Part ser Panel SUP 6 8 7 6 5 D 3 2 1 0 9 Fuseholder for 0 4A Fuse 8 7 6 5 D 3 2 1 Setup may vary depending on model Controller Module SMC6 Pos ltem Description 215 of 231 pages STAR LOOL Operating and service manual 216 of 231 pages STAR OO Operating and service manual Star Cool Unit installation dimensions Type SCU pessaJduo un Buppeg 9447 1937 Packing uncompressed PEP T CES SEZZ EK IIe S re zxo 2125 1974 7 6x298 45 11791 71 117 15 217 of 231 pages STAR OO Operating and service manual Type SCI moy i 218 of 231 pages STAR OO Operating and service manual P amp I diagram 19 34 37 32 11 8 12 A pear Refrigerant R134a Legend Low Pressure Stage Suction Gas Line Liquid Line Hot Gas Line Electrical Line High Pressure Stage 3 4 bi 12 Water Inlet Water Outlet 13 c 4 eo b i 3230 oa Qo CO CO CO td CO hO hO hO hO hO hQ bh N N2 z 3 ch ch 7 OC Ek OQ m O c Ae O E Q m zem c oo KR WH Compressor Frequenc
9. Check hot gas valve for leaking Let the compressor run in manual for some time Stop compressor and see if the suction pressure rises more than normal If valve is defective replace valve Temperature no longer in range Has been in range for minimum 30 min and after that in out range for more than 4 consecutive hours None Controller action Alarm Tight Quick fash If error is detected during PTI test PTI test will fail Alarm will be marked as inactive in alarm list when in range is reached and alarm may then be deleted Log data 129 of 231 pages STAR LOO Operating and service manual High press trouble Fatal Alarm Description High Pressure Switch is active Hot gas valve expansion valve and economizer valves are all closed and compressor is running Trouble Possible causes shooting e Repeated high pressure alarms Accompanied alarms e AL 306 Trouble shooting 1 See and clear error for alarm AL 306 Criteria AL 306 has been active 3 times within 30 min Control not possible Controller P action GE ee e Alarm light Consequence Unit Unit stop E Alarm 604 will be marked as inactive in alarm list when alarm 306 disappears After 30 min restart delay unit starts again and alarm may then be deleted Log data ActivefInactive IT TI AirEx open Fatal Alarm Description Description Air exchange valve open in conflict with settings Cause Indication of
10. I19 Discharge pressure Discharge press Function Shows current discharge pressure for compressor Value Shown in units of Bar or Psi relative to atmosphere pressure Switch by pressing ur at C pres sure is shown in BarE at F in Psi I20 Expansion valve o Function Shows current percentage of expansion valve opening Pulse Wide Modulation Value Shown as a percent value I21 Evaporator superheat Evap superheat Function Shows current superheat of expansion valve Tsuc TO SH Value Shown in temperature scale C or F Switch by pressing E Value is only user changeable with system in the service mode I22 Compressor frequency Compressor freq Function Shows current compressor frequency Value Shown in units of Hz I23 Power frequency Power frequenc Function Shows current power net frequency Value Shown in units of Hz I24 Current consumption phase 1 Current phase 1 Function Shows actual current consumption on phase 1 for the unit excluding the compressor Value Shown in units of ampere I25 Current consumption phase 2 Current phase 2 Function Shows actual current consumption on phase 2 for the unit excluding the compressor Value Shown in units of ampere I26 Current consumption phase 3 Current phase 3 Function Shows actual current consumption on phase 3 for the unit excluding the compressor 38 of 231 pages STAKSkZO0L Operating and service m
11. Setting of interval between loggings in the data log Setting the datalog interval to 60 min default value allows logging of data for over a year Value Interval set to 15 30 60 120 or 240 min Default 60 min Programs O06 Programs selection menu PROGRAMS Function Leads to the programs sub menu Value 40 of 231 pages STARK LOOL Operating and service manual 1 Go to the programs sub menu O09 Active application Active application Function Actual application Value PO1 PO3 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 Values NONE CT and MTS Multiple Temperature Set points program MTS D01 D06 Settings Hours Set RH Function Settings for step 1 to 6 of the Multiple Temperature Set points program Value D01 D06 Step number 1 6 Hours Defines how many hours the temperature set point is used from 1 to 999 hours When set point from Set is in range the time starts Setting Hours to Off clears all settings in this step and the succeeding steps Set The set point temperature to use for this step Temperature change per hour ramp is fixed for cooling and change is done with maxi mum cooling
12. e AL 305 Trouble shooting 1 If the cable by inspection is defective replace cable 2 Calibrate AirEx see Calibration of air exchange sensor p 188 If the value shown in controller is wrong or alarm still active then disconnect the cable for AirEx on the main controller according to the wiring schematics inside the control cabinet and from the AirEx sensor Mount the cable for AirEx in controller cabinet and on the sensor Disconnect signal wire on main controller Measure voltage between wire and GND on the main controller If the voltage is over 4 0 V DC sensor or connection between sensor and cable is defective If the voltage is between 0 2 V DC and 4 0 V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND If the voltage is between 0 2 V DC and 4 0 V DC and this alarm is still active continue to 5 Check controller see Trouble shooting for Star Cool main controller p 57 before replacing main controller Criteria Value above alarm limit 225 m3 hour Controller action Consequence Log data When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted 92 of 231 pages STAR OO Operating and service manual Description Air Exchange Sensor Short Circuit Not implemented yet Cause Indication of short circuited air exchange sensor Trouble shooting Controller action Possible causes AirEx is out of calibr
13. Accompanied alarms e AL 710 Trouble shooting 1 If any accompanied alarms are active handle these first 2 Exchange the keyboard 3 Exchange the user panel Criteria A key has been pressed for minimum 20 times during 1 hour None Controller action Aiarmight Menus can change automatically Elimination Solve issue with trouble shooting guidelines Log data a 187 of 231 pages STAR ZOQL Operating and service manual Calibration of air exchange sensor Air exchange sensor calibration 1 Close the fresh air cover plate 2 Inthe Service menu line F06 Air exchange calibration select START and press the Enter button 3 Calibration is done Sensor calibration using StarView USDA and Cargo temperature probe offset adjustment um EJ x ZE Sensor calibration iew USDA 1 probe t Tools Setup Device Help gF gt Offset eC Correction C Calibrated WE Container ID USDA 2 probe Sensor calibration Airl po Unit configuration Offset EE E Correction C Calibrated E UR m Software upload USDA 3 probe li Offset C Correction Cc Calibrated C CARGO probe Offset Ed KR Correction C Calibrated C Calibrate 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 US
14. Extended data Value Suction pressure effective Discharge pressure effective Power frequency Upower voltage Highest power voltage of U1 U2 Value Current 12 I3 current Current I3 Current FC Compressor frequency Heater on time 7 10 11 12 13 Evaporator motor OFF LO HI ERR 14 Condenser motor OFF LO HI ERR Value 15 16 Tfc temperature Temperature of frequency control ler Tambient temperature Ambient temperature 30 96 Extended data 2 only retrievable by StarView 7 SHref Alarms Alarms which may occur and a detailed explanation and trouble shooting is described previously in this manual 204 of 231 pages STARK LOOL Operating and service manual Temperature Sensor C Resistance Table Resistance Temp Resistance Temp Resistance Temp 70 130 322 00 _ Fe 130 243 00 Fes izzeszoo Fe 1561300 Ls 10855100 Le 1278700 ea ss57 0 Les 01 525 00 ES ES EN EN ES ES ES Resistance Temp 0 C 3 095 611 00 2 851 363 00 2 627 981 00 2 423 519 00 2 236 398 00 2 064 919 00 1 907 728 00 1 763 539 00 1 631 173 00 1 509 639 00 1 397 935 00 1 295 239 00 1 200 732 00 1 113 744 00 1 033 619 00 359 789 00 ss 58 39700 xao fsa sem 770 880 00 717 310 00 667 828 00 622 055 00 579 718 00 540 530 00 504 230 00 470 609 00 Resistance Temp Q 61 693 00 38 108 50 36 182 80 34 366 10 5 115 60 4 915 50
15. Firmware update Failed to activate firmware fail 991 Select model code Model code missing 995 Replace ctrl Controller module must be replaced Fatal Alarm module Software CRC Prom CRC Fault Alarm error Keyboard failure Indication of defective keyboard XO X O XO H jojo Ko 7 Sensor bus sup HI Controller Internal Voltage Reference Fault EE Events Name Parameter explanation el D irme nd Ls mam o Temperature setpoint Old set point Newsetpom S revision i Humidity set point Ol setpom Newseteom o weecodeeet ERR ERR ERR ERR ER s watroaseet Sid LE E s rmsa iverson E Were count pee ERI PTI start PTI Version 1 Full PTI Alarms count 2 Short PTI 3 CA PTI 62 of 231 pages STARK LOOL Operating and service manual PTI test ID 1 Manual start 2 Ice counter 3 Demand defrost start PTI abort N Manual mode select m Manual mode deselect Defrost Start Current de frost interval sec 1 Auto trip start 0 User trip start 1 USDA 1 2 USDA 2 3 USDA 3 4 CARGO Unit run time hours Defrost Stop Trip Start Hm m Sensor Calibrated 1 User Wake up Power Down SW ver low Current sw ver low Old date Software update 5 26 7 28 29 Real time clock FC type Datalog interval N Defrost interval FC ID Container ID change Old min Old ID 1st Old
16. Freq FC 116 of 231 pages STAR OO Operating and service manual 517 FC over temp Alarm FC Overtemperature Fault Alarm Cause Indication of problems with compressor or FC Trouble Possible causes shooting A36 e FC operates at operating limits e Insufficient cooling for the FC e Defective FC Accompanied alarms e AL 522 Trouble shooting 1 Verify that supply voltage is not too high 2 Check that the FC is mounted and tightened correctly to the compressor If the FC is mounted correctly it should not be possible to insert an air gap gauge between FC and compressor 3 Motor cable between FC and compressor may be jammed between FC and compressor Cooling of FC is insufficient If this alarm appears more than once Dismount FC and check motor cable before mounting the FC again Fasten bolts properly for better cooling If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 FC temperature exceeds 85 C 185 F or above 78 C 172 F for more than 15 min FC shut Controller onde done action Alarm light Slow flash Unit stops and restarts when FC has cooled down Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Active Inactive Freq FC 117 of 231 pages STAR LOO Operating and service manual FC Inrush Fault Alarm Cause Indication of problems with s
17. Old LP Source HR Press sensor type Parameter change o Cold Treatment CT start 0 Normal 41 42 CT period start CT Passed Actual temp Ww Tact Step number CT ramp up A Multiple Temperature Set points MTS start MTS step stop Step number CT Done Number of valid USDA sensors CT Failed 0 Sensor error 1 Aborted QUEST mode QUEST2 start i ES E Ge Em ial ES 61 Last event reason time sec Alarms count Ice counter 2 Abnormal 3 Tsuc 4 Tret o Old Cal New Cal Value Value Compr run Mevap run time time hours hours SW ver high ver high Br Telegram id min min temp 0 Normal Step setpoint 1 Aborted CT Duration min Mcond run time hours Hevap run time hours Vbatt New sw ver low New sw ver high Power up count Reset count New date New time New ID New ID hibyte Old HP Old value New HP New value n a CT setpoint emp Tusda2 CT setpoint CT high limit Final setpoint temp Tusda3 CT high limit Tcargo Final setpoint temp Tusda3 Step temp chg hour Tcargo Step humid ity setpoint Step temp chg hour CT high temp limit Step humid ity setpoint CT setpoint temp Final setpoint temp CT high Tusdai Tusda2 Tusda3 temp limit 63 of 231 pages E STAR LOO Operating and service manual 62 QUEST2 stop Last event n a n a n a n a reason ECH 72 Atm
18. When currents are normal it is marked as inactive in alarm list and may then be deleted Value must be valid for 30 sec to set alarm inactive Log data Phase missing Fatal alarm Description Description Phase missing Cause Indication of lack of supply from one fase Trouble Possible causes shooting e Bad connection between controller and supply e Bad connection or defective supply cable and or plug e Defect power meas module Accompanied alarms e AL 423 Trouble shooting 1 Check the connection from power meas module to power supply 2 If supply is OK check power meas module Replace power meas module if defective If no replacement is available disconnect communication cable manually Set phase direction manually in configuration Criteria Difference between highest and lowest measured phase voltage is more than 50 V AC Controller action Alarm light Deteriorated control precision and capacity When currents are normal it is marked as inactive in alarm list and may then be deleted Value must be valid for 30 sec to set alarm inactive 142 of 231 pages STAKSkZO0L Operating and service manual Les Log data Communication Alarms AL 7XX GENE NM FC Missing Cause Indication of defective FC lack of or improper connection Trouble Possible causes shooting Communication with FC broken Power voltage to the FC not applied wired for emergency operation Defective
19. gt 2n o o z o oO o t o 42 x lu 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 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 The strategy is to substitute the missing sensors reading with the value from another sensor a constant so that the unit can maintain its functionality with reduced precision Temperature control Chill mode Defect sensor s Substitution sensor Action Alarm Hug Siac Tou Hsupl Tsup2 and Tet Tact Tevap constat Freeze mode Defective sensor s Substitution sensor Action Alarm me mezTeaprcnsam E Tret Tevap and Tsupl Tact Tsup2 constant lt No more available sensors for substitution Expansion valve control Defective sensor s Substitution sensor Action Alarm ssi Emergency injection 611 Too many sensor err Emergency injection 611 Too many sensor err 19 of 231 pages STAR OO Operating and service manual Condenser fan control Defective sensor s Substitution sensor Action Alarms Start up Conden
20. mem e mm Active Inactive High timit Present CS 128 Tamb short Warning Ambient Temperature Sensor Short Circuit Cause Indication of short circuited ambient temperature sensor Possible causes shooting e Temperature sensor Tamb or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 129 Trouble shooting 1 Same trouble shooting is to be used for Tamb as used for Tret in AL 101 Criteria Value above high alarm limit 140 C 284 F Replacement by new value from AAS system action Alarm light No consequence as to control When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data Seas Active Inactive High limit Present 85 of 231 pages STAR LOA Operating and service manual m 1129 Tamb invalid Warning Ambient Temperature Sensor Invalid Cause Indication of defective supply ambient sensor or its measuring circuitry Trouble Possible causes shooting e Active alarms AL 127 AL 128 or AL 901 if CIM5 software e Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F Accompanied alarms e AL 127 AL 128 or AL 901 may also be active Trouble shooting 1 If alarms AL 127 or AL 128 are active check their trouble shooting section first 2 Disconnect the sensor cable for sensor Tamb from
21. tion See Emergency Operation p 51 501 FClocal control Alarm FC setting in Local Mode Cause Indication of FC set in the local control mode Trouble Possible causes shooting e Cable FC com periodically defective e Internal fault in the FC e Defective FC Accompanied alarms e One or more AL 5XX may also be active Trouble shooting 1 Check that the cable FC com is connected and not damaged 2 If the alarm is then still active the FC is defective and must be replaced If there is no FC replacement available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria FC in the local mode 110 of 231 pages STAR OO Operating and service manual 1 Mcond Mevap1 and Mevap2 fan motors forced to low speed Controller p R Alarm will be marked as inactive in alarm list when local mode is reset on frequency converter Alarm may then be deleted Parm 5 Log data i Active Inactive FC Short Circuit Alarm Cause Indication of defective cable compressor motor or FC Trouble Possible causes shooting A16 e Short circuit on the FC power output e Damaged cable and or plugs Accompanied alarms e One or more AL 5XX may also be active Trouble shooting 1 There is a short circuit on the compressor motor Mcpr terminals or in the motor Check the cable and replace if it is defective 2 The FC is defective and must be
22. 4 724 30 439 445 00 410 532 00 383 712 00 358 806 00 335 671 00 314 179 00 294 193 00 Ee 275 605 00 37 23 016 00 258 307 00 21 921 70 242 195 00 20 885 20 34 227 196 00 213 219 00 200 184 00 188 026 00 176 683 00 166 091 00 156 199 00 146 959 00 EN 33 E ES 328 E27 205 of 231 pages 26 s f gt 62 25 UG 2 es s 24 20 EC 23 JI 65 22 22 2 66 EN 23 JI IS 20 fi CE ER GG JI 9 38 GG JI zo E fi z 36 28 JI z2 EE 29 JI Es ES 30 JI Ee 33 JI Es EE 2 fi zs u 33 fi E 30 fi KS NN 5 JI z9 s Ge JI 80 7 i fi s E i s2 E peor Ta asi e pee D E Se ae ET 94 a JI 85 JI 86 a3 JI 87 Ess ES EN EE 89 6 90 CE CE 8 92 a9 93 IS 50 E z ENE EE s 52 96 ES E 97 fio 54 98 ERN 55 99 m2 56 100 o 57 ET ES ES 102 s 59 103 He 60 104 s Eu i05 149 STAR LOO Operating and service manual Temperature Sensor F Resistance Table Resistance Temp Resistance Temp Resistance Temp Resistance Temp Resistance Temp S 9 F I9 F 22 F I9 Fl 3 095 611 00 d 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 2 156 70 147 Lal il 2 423 519 00 115 613 00 11 943 30 2 082 30 149 524 51 228 2 010 80 151 510 06 230 1 942
23. AKS bes m 1 Supply GROUND BEOHSJ 3 dutout 4r D 2 Ground BS SUPPLY VOLTAGE if V f II IL 00 95 VW De 3 SY 024 0 TYP my i N QUTPUT Figure for AKS Figure for AKS Figure for NSK Figure for NSK Check the cable measure the resistance in the cable If the cable is defective replace cable Mount the cable for Psuc in controller cabinet and on the transmitter Disconnect signal wire on main controller Measure voltage between wire and GND on main controller AKS If voltage is below 0 5 V DC transmitter or connection between transmitter and cable is defective If voltage is between 0 5 V DC and 4 5 V DC continue to 4 NSK If voltage is below 0 37 V DC transmitter or connection between transmitter and cable is defective If voltage is between 0 37 V DC and 4 0 V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND AKS If voltage is between 0 5 V DC and 4 5 V DC and this alarm is still active replace main controller NSK If the voltage is between 0 37 V DC and 4 0 V DC and this alarm is still active replace main controller Before replacing main controller see Trouble shooting for Star Cool main controller p 57 Value below low limit 1 1 BarE 16 Psi for AKS Value below low limit 0 9 BarE 13 Psi for NSK Value above high alarm limit 11 9 BarE 172 Psi for AKS Value above high alarm limit 9 8 BarE 142 Psi for NSK Replacement b
24. Acive Imctive o LI TI 78 of 231 pages STAR OO Operating and service manual 1118 Tcargo open Warning Cargo Temperature Sensor Open Circuit Cause Indication of loose connection defective or lack of cargo temperature sensor Trouble Possible causes shooting e Temperature sensor Tcargo or its cable defective e X24 and X25 cable is defective e Defective plug inside or cable on the unit backside e Main controller defective Accompanied alarms e N A Trouble shooting 1 Same trouble shooting is to be used for Tcargo as used for Tusdal AL 109 Value below low alarm limit 609C 76 F and the sensor reading has been in the valid area since power up None ti iit Alarm light May be incomplete cargo data logging When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data cm Active Inactive Highimit Present 119 Tcargo short Warning Cargo Temperature Sensor Short Circuit Cause Indication of short circuited cargo temperature sensor Trouble Possible causes shooting Temperature sensor Tcargo or its cable defective X24 and X25 cable is defective Defective plug inside or cable on the unit backside Main controller defective Accompanied alarms e N A Trouble shooting 1 Same trouble shooting is to be used for Tcargo as for Tusdal in AL 110 Value above high alarm limit 140 C 284 F and the sensor read
25. C Max duration 2 min Pfc lt Pfc stabile 10 Max duration 6 min If error AL843 16 of 231 pages STAR OO Operating and service manual 1 Vexp Max duration 5 min When Pdis 5 Bar Testing capacity Max change in Pdis 0 75 When Pdis 5 Bar Max change in Pdis 0 3 When Tret 15 C Min change in TO 20 K When Tret 15 C Min change in TO 10 K If error AL842 Vhg hot gas valve Max duration 5 min When Pdis 5 Bar Testing capacity Max change in Pdis 0 75 When Pdis 5 Bar Max change in Pdis 0 3 When Tret 15 C Min change in TO 20 K When Tret 15 C Min change in TO 10 K If error AL844 9 Test completion status 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 compressor running before executing a function test or PTI test The reason for this is to ensure correct function of unit during PTI test or function test PTI Test The purpose of the PTI test is to verify the presence of cooling performance The test is based on a GO NO GO procedure All tests must be executed without failure one by one for the PTI test results to be PASS PTI test includes the following test items Full PTI Function test see Function test 5 C 41 F test 0 C 32 F run test 0 C 32 F hold test 18 C 0 4 F run te
26. Connect a service gauge manifold to the two evacuation points pos 6 and 27 P amp I dia 196 of 231 pages STARK LOOL Operating and service manual gram on the compressor Connect a recovery unit to the gauge manifold a Connect a recycling bottle to the recovery unit b Use a scale underneath the bottle for measuring the amount of recycled refrigerant Close the suction service valve and economizer suction service valve pos 26 and 30 P amp I diagram Close the discharge service valve pos 5 P amp I diagram approx 4 turns Run the compressor in manual operation on 50 Hz as described in Manual operation sec tion Observe the LP indication Until a vacuum of 0 5 Bar E 7 3 Psi has been reached Suction pressure indicator Turn of the compressor Close the discharge service valve pos 5 P amp I diagram a The evacuation points pos 6 and 27 P amp I diagram are open when the service valves pos 5 and 26 P amp I diagram are closed Open the HP valve on the service gauge manifold Check that the Recovery unit are set for Vapor recovery Start and operate the recovery unit as long as necessary to evacuate the remaining pressure Check the service gauge manifold should be in a slight vacuum After disconnecting evacuation unit the compressor is now ready to be replaced Compressor pump down replaced Pump down of a new replaced compressor is done by the following proced
27. H TO Saturated suction tem perature Dis Discharge Power Battery r Actual 7 of 231 pages STAR OO Operating and service manual General description The 7440 coot 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 229F 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 satisfaction under sea going and environmental conditions as specified 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 t
28. KE oz z 9 a XY HEEL AB YORUOD 5 lt ele xog 48jJo4u02 episu g o9 GIS T T T PI OV AVZ 9 G euruuo L OW MZ RUS L GE GEI GE OV At z jeutuue 8S 9dE SH r esx er Ride Kee Rz 5 t E LLOJVHL 8r rdenoH Si ydeno gt 9t OWAve JOVA NNE Vi Cdensn Vir denoH tra EE S HOA 8I5MV vast OVAO WINH Su MI NNYgeydeeH MN ee LC SevdeneH pou ee sr osx Teel SUL veces aer EBON 2 EN Z Sg PEL Szeen L7 HOD Neze o uonMs peu ut V2 LdeA eH Ve Lde oH A a HO UO Ra 7 WS SSS Seen SI Zde SH bos PP 9 2 2 LMS SN VrFTdensH VI TdEASH sok ya ia emo SS 89 9densH 89 9deneH ng m ei LX NW V9 SdenoH V9 GdexSH peor t ox TS dena ZS CH gt va SS n 1 3901 o zs 0 cul 9 5 H3INI P i amp gos SIP S ei Em m hg T g woe cr P al a D VER THI 3 Le El ie a u09 53 i Hog i M F uL H4 xog Ja jONUOD E 8y z episino M 5 X E S ec H ye CM pec se Cae a pun 1 k 8 Y i v a CIE UIW pue 9 i5 o ong n i HMH 2 Pl DN Les A 4 H amp ij1ueJino4eAQ z amp UMON NI H3MOd ado FE a LA LSO STAR OO 224 of 231 pages weg 1689948 ou ped sedg d xog 48JJo1ju07 apIsul Operating and service manual STAR OO
29. Mevap cur HI speed Alarm Evaporator motor high speed current fault Cause Indication of defective motor or defective supply cables to motor Trouble Possible causes shooting e Evaporator motor jammed or defective e Evaporator motor cables defective e Bad connection in plug e Evaporator motor cables wired wrong in controller cabinet Accompanied alarms e N A Trouble shooting 1 Check the evaporator motor fans can rotate freely Turn off power first Replace motor s or make it turn freely again 2 Check evaporator motor cables for damages 3 Check that the evaporator motor cables are mounted correct Evaporator fan motors have exceeded current limit at high speed 50 Hz 1 8 1 9 Amp 60 Hz 2 1 2 6 Amp None action Alarm light Slow fash Test failed Elimination Alarm may then be deleted after test completed Log data 812 Mevap current OFF Alarm Description Evaporator Motor Off Current Fault Cause Indication of defective motor contactor or contactor driver circuitry Trouble Possible causes shooting e Defective evaporator motor contactor e Defective contactor driver circuit Accompanied alarms e N A Trouble shooting 1 Check the evaporator motor contactor for defects Replace the contactor 2 Check that the evaporator motor cables are mounted correctly Criteria Evaporator fan motors have exceeded off current limit Controller None action Alarm light
30. e Test sw in the main controller Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 There is a wrong sw version test software in the main controller Update the software in the controller to the latest version 2 If updated software is not accepted by the PCB replace PCB None Controller Sep Consequence Elimination Replace ste O Log data 990 Firmware update fail Alarm Failed to activate firmware Cause Hardware or operation miss match Trouble Possible causes shooting e Operating software is not compatible with hardware SUP6 SMC6 SPM6 Accompanied alarms e AL 996 and AL 997 will be activated during FT or PTI test Trouble shooting 1 Check if the software is to be used with unit 2 Test the software with unit of the same type as the failing one If software is running then see 3 3 There is still a fault on either SUP6 SMC6 SPM6 None Controller action DECHE Consequence Log data SMC6 SUP6 SPM6 SCC 185 of 231 pages STAR LOA Operating and service manual es 991 Select model code Warning Model code missing Cause Installed software without model code Trouble Possible causes shooting e New software e New controller Accompanied alarms e None Trouble shooting 1 Go to service menu Select configuration S05 and F10 Select model code according to Data Decal placed on the
31. or y and press which initiates the test The PTI test is automatically terminated in case of no errors Finally temperature set point will be set to the same value as before test initiation TO2 Last Function Type and date of latest past PTI Value 33 of 231 pages STARK LOOL Operating and service manual 1 YYYY MM DD FULL SHORT or if failed TO3 Function test start Function test Function Start function test runs to verify full functionality of the unit without performance tests Value For starting function test START must be highlighted by pressing Pressing once more initi ates the test TO4 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 TO5 Test status Test status Function Shows the status of the last running test Value The value depends on the function running For PTI the values can be RUN for running PASS for test passed successfully ABORT for test aborted by a user FAIL for a failing PTI test see the alarm list for specific reason TO6 Test result 10 Init 10 Init Function Shows the status of the test initialization This test is always done Value if not done yet RUN if still running test PASS if test finished successfully FAIL if the test failed ABORT if the te
32. refrigerant in the compressor 1 Check that all bolts fixing the FC to the compressor are properly fastened and nothing is jammed between the FC and the compressor 2 Check the motor cable and replace it if it is defective Fasten bolts properly for better cooling 3 The compressor is wearing down and drawing increasingly power from the FC Check other alarms if there have been more alarms from the FC a If the ambient temperature is not high the compressor must be replaced If the ambient temperature is high the compressor and FC should be OK but close to operating limit Monitor unit and see if problem continues 4 The FC is defective and must be replaced If there is no FC replacement available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria FC overloaded Current has been above 24 Amp for 20 sec FC shut Controller SEHR SE GE BR Slow flash Consequence Unit unt stop The FC will be restarted after 10 min Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Active Inactive Freq FC 114 of 231 pages STAKSkZO0L Operating and service manual Description FC Undervoltage Fault Alarm Cause Indication of problems with supply voltage Trouble Possible causes shooting A9 e The FC is supplied with too low voltage for continuous operation e Defective FC Accompanied alarms e AL 417
33. 17 Alarm Action System RE EE 19 TEMPS lature COMER e E EDIDI LLL IL LITT 19 Expansion REI elle de EEUU 19 Condenser fan control aie scsusinicu sue ote ex ar aba RRRRERRRRRRR XE SYRR EECH A RE user anenanad Meus ined SRERArYNK X SVIRINMRERR EES EES RE 20 DehumMidification CONFON PP M 20 Defrost control uera E SNE ENEE EES sae Reo R RR ERR SR Ga RXXI 2R3GSdgu XR RG RRERRR FREI cada KR EEN EELER EES SES 20 Electrical COMtrOl EEUU 20 Refrigeration system data ee es raise reri Vo ANEREN bi OR E mra de ER xi SEENEN See Eege 21 RefrigerantiGharge OECD I Er 21 General See E DE T 22 Compressor motor assembly ane eg sed n s ER Rer Rm RR e S REES EES SES EE EES Seege AE 22 Frequency converter EC T 22 High Pressure cut out SWIER a E A An a EAE Ehi 22 giLils Soi t emyg Ie i ee DV 22 Seille VEER 22 Evaporatot Goik mec m 22 Sors iml RAM Ln 23 Evaporator Fe mem e IPS 23 en E ET E 23 Water cooled condenser optional er ttp Age EENS ka Eeer d et 23 RI EE 23 Fresh alriexchan cer rm 24 R frigeration GONMEOlS PLI 24 Electrical Gata sic m 24 CINGUIE BREAK c pp HM 24 KEES RR EE 24 FUSES ii RRE ee AE ttAdeR AER RE REA RATEN CERE BEER AR ES KREE FED Pri RRERULRLEE PEE EAR PR eEERE KE LER ER UE DE KE RE EER RAF E PFERDE ANDERE 24 oj I imHellu e Rn 24 doy Tuer rr seeend geegent eege ees deg Eege Ee EES 24 2 of 231 pages STA
34. 2 Check that both sensors Tsupi and Tsup2 are mounted correct in the supply air pockets 3 If AL 901 is active see trouble shooting for AL 901 4 Disconnect the sensor cable for sensor Tsup2 from the connector on the main controller according to the wiring schematics inside in the control cabinet 5 Measure the resistance between the two wires a If the resistance is out of range of the resistance and temperature table Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check Trouble shooting for Star Cool main controller p 57 before replacing main controller Value is below alarm limit 60 C F or above 140 C 284 F or difference between Tsup1 and Tsup2 is more than gt 1 C for 30 min or up to 10 C difference Value invalid for 30 sec for alarm activation Repl t EIE eplacement by new value from AAS system action Alarm light Consequence Deteriorated control precision in the chill mode When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data i 71 of 231 pages STAR OO Operating and service manual A 109 Tusda 1 open Warning USDA 1 Temperature Sensor Open Circuit Cause Indication of loose connection defective or lack of USDA 1 temperature sensor Possible causes Trouble
35. 30 31 9 BarE 435 462 Psi Value invalid for 30 sec for alarm activation Replacement by new value from AAS system Controller P y y action Alarm lig Consequence OOO OOO When transmitter value becomes valid it is marked as inactive in alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data Aciv Iacive o 204 Psuc open see AL 206 205 Psuc short see AL 206 88 of 231 pages STAR OO Operating and service manual Compressor Suction Pressure Transmitter Open or Short Circuit Indication of loose connection short circuited defective or complete lack of compressor suction pressure transmitter Trouble shooting Controller action Possible causes Connector for suction pressure transmitter Psuc disconnected or not correctly mounted Suction pressure transmitter Psuc defective Cable for suction pressure transmitter Psuc defective X22 and cable is defective Shortage between Ground and Output Main controller defective Accompanied alarms e AL 204 or AL 205 or AL 207 may also be active Trouble shooting Disconnect the cable for Psuc on the main controller according to the wiring schematics inside the control cabinet and from the suction pressure transmitter 1 Check that the connector is mounted correctly according to the drawing for pressure transmitter AKS or NSK respectively The earth stud must be on the opposite side of the cable
36. 30 sec the unit restarts with a normal Controller startup procedure action Alarm light Alarm will be marked as inactive if another phase voltage measuring is above limit It may then be deleted Log data mem Active Inactive Highimit_ vottage OC 103 of 231 pages STAR OO Operating and service manual U2 3 under voltage Fatal Alarm U2 3 under voltage 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 After 30 sec the unit restarts with a normal Controller startup procedure action Alarm light Alarm will be marked as inactive if another phase voltage measuring is above limit It may then be deleted Log data qm um Active Inactive High limit Voltage o O o U1 3 under voltage Fatal Alarm U1 3 under voltage Indication of error in container supply voltage between phases 1 and 3 Trouble See trouble shooting for AL 417 shooting Criteria Value below low alarm limit 335 Volt Controller breaks supply after 60 sec After 30 sec the unit restarts with a normal Controller startup procedure action Alarm light Unit stops Alarm will be marked as inactive if another phase voltage measuring is above limit It may then be deleted Log data nu Active Inactive Low ett Highlimit Volage 0 o 104 of 23
37. 38 d 36 3 35 5 33 6 31 8 29 50 27 52 26 54 24 55 22 57 20 59 18 61 17 63 9 1 3 5 7 8 00 206 of 231 pages es E STAR OO Air exchange Sensor table Voltage m3 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 Voltage Air exchange V m3 h V m3 h V m3 h V m3 h fo 30 s 1 45 2 25 s s ss o 3 35 oss fi jo So mo o80 20 joes 25 30 o 95 CE ES 0 he D 0 5 oss se 5 0 5 0 5 e mw e ES mooo Ras hz fo zs o es o hzs Js ss 15 hes s ez 1e Tos fos zs 15s o foo zse fo os ms so fs 13 fo zi ue 2 o has fs daa s da s 2 2 3 3 4 4 120 125 130 135 140 145 150 155 160 165 170 175 Air exchange Sensor table Voltage m3 h for 75 CMH V m3 h m3 h V m3 h V m3 h 9 V nes ss 1 60 90 155 95 160 oo 280 piss 5 180 Jm Le Io 0 190 fuo 295 Io us 180 20 185 0 130 195 5 135 200 mo i 2o JD 2 po ps fe ERN joes In Ia 50 60 65 US 90 A 3 3 4 3 a mo ss zs as ws ss no as s ess ue s las 10 155 20 160 0 100 165 105 170 110 175 5 115 180 50 120 185 130 195 6 1
38. By pressing 4 or y the set point is adjusted 0 1 C 0 1 F and the set point digits are highlight ed in inverse writing If the key is held the set point will automatically be incremented by 0 1 C 0 1 F until the key is no longer held After approximately 3 sec the set point will be incremented by 1 C 1 F Upon reaching desired temperature press and hold for 3 seconds The set point will be accepted and shown in normal writing again During inverse writing the new temperature set point is erasable by pressing GI and the previous set point is shown again If the keys 4 Z y or are not pressed for 5 sec current setting will be cancelled and previous set point shown again 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 By pressing controller is enabled and controller operation will be possible In case of no key board activities for 30 sec controller will be turned off again Controller may be manually turned off in this mode by pressing again Contrast adjustment of the display Press and hold while pressing or y to adjust contrast and or p to adjust background lightning of the display This can be done both in battery mode and when main power is
39. Close the stop valve pos 14 P amp I diagram 3 Start the unit in Manual operation 4 Select compressor frequency to 40 Hz 5 Observe the Suction Pressure Psuc When Psuc 0 BarE power off the unit 6 Carefully loosen the two union nuts for the drying filter Beware of pressurized escaping refrigerant Always wear protective goggles and gloves 7 Replace the drying filter with a Danfoss DML 164 O ring or equivalent Before mounting of the filter put some drops of compressor ester oil on the flare in order to ensure correct tightness 8 Tighten the two union nuts for the drying filter See torque values in tables 9 Remove the electrical coils and mount permanent magnet on the two electronically expansion valves pos 16 amp 18 P amp I diagram 10 Carefully loosen the upper union nut for the drying filter allowing a little amount of refriger ant gas to escape 11 Tighten the union nut 12 Remove the permanent magnets and reinstall the electrical coils on the two electronically expansionvalves pos 16 amp 18 P amp I diagram 13 Open the stop valve pos 14 P amp I diagram 14 Power up the unit Compressor Check of oil level 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 Normal operation is when the unit has been running on setpoint in a steady condition for minimum 6 hours If the o
40. If voltage is between 0 5 V DC and 4 5 V DC and this alarm is still active replace main controller NSK If the voltage is between 0 37 V DC and 4 0 V DC and this alarm is still active replace main controller Before replacing main controller see Trouble shooting for Star Cool main controller p 57 Value above high alarm limit 32 BarE 464 Psi for AKS Value above high alarm limit 30 BarE 435 Psi for NSK Value below low alarm limit 0 1 BarE 1 5 Psi AKS Value below low alarm limit 0 15 BarE 2 Psi NSK Replacement by new value from AAS system When transmitter value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 120 sec to set alarm inactive Parm 2 Active Inactive Low limit High limit Present 6 sec 87 of 231 pages STAR LOO Operating and service manual A ii 203 Pdis invalid Warning Compressor Discharge Pressure Transmitter Invalid Indication of defective compressor discharge pressure transmitter or its measuring circuitry Trouble Possible causes shooting Connector for high pressure transmitter Pdis not correctly mounted High pressure transmitter Pdis defective Cable for high pressure transmitter Pdis defective X22 and cable is defective Main controller defective Accompanied alarms e AL 200 AL 201 or AL 202 may also be active Trouble shooting See Trouble shooting for AL 202 Value below alarm limit 0 1 BarE 2 Psi or above
41. Ifthere is no voltage the main controller is defective Replace the main controller Pdis more than gt 5 BarE Max change on Pdis 0 75 Bar Pdis is less than 5 BarE Max change on Pdis 0 30 Bar Tret is more than or equal to 15 C Min change on TO 20 K Tret is less than lt 15 C Min change on TO 10 K Test failed Elimination Alarm may then be deleted after test completed Log data 84 0x TO diff Pais diff See Function test p 16 157 of 231 pages STAR LOA Operating and service manual 845 Cpr pump down Alarm Compressor pump down fault Cause X Indication of insufficient performance in the compressor Trouble Possible causes shooting e Sensor defective high pressure transmitter and or high pressure switch e One or more valves defective e Compressor needs repair Accompanied alarms e AL 250 Trouble shooting 1 If alarm 250 is displayed check the high pressure transmitter settings and the high pressure switch 2 If only alarm 845 is displayed check that there is sufficient refrigerant on the unit 3 If only alarm 845 is displayed replace compressor valve plates Criteria Tc TO more than gt 20 C None Controller action Alarm light Slow fash Test failed Elimination Alarm may then be deleted after test completed Log data See Function test p 16 846 FCCheck Alarm Internal fault in FC Cause Indication of
42. JON ang p PR io S Bu Aktie E S g WA na Joe 9 r deo gt 6LX 8LX reuondo 9 i Jano umd rh 9 t SR z oe dMd z H gt 3 Ej vd Lex D EN Jojowiry I erf WE elt be s Pa xay av z WNOIS WNOIS z os td Jore T jeuondo ana NS any M 4 I s e HA AS v sg 2 ueud d sug Kos uge gel t d Sid sagt ee ig do 8 JON QN9 9 z de ew 8 3 5 EZX cex frees P 225 of 231 pages Bjerndrupvej 47 6360 Tinglev Denmark Phone 45 73 64 34 00 Fax 45 73 64 35 69 E mail starcool starcool com www starcool com Version 810900C 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 STAR le Cool Thinking Copyright 2013 Maersk Container Industry AS
43. Please read Pressure Test Pressure Test After performing a major repair to the unit piping system it is recommended to perform a pres sure test Pressure test has the purpose of checking the piping system for leakages The pressure test is done by means of a high pressurized gas ex N which is let into the piping system through the two evacuation points pos 6 and 27 P amp I diagram The procedure for this is as follows NOTE DO NOT USE OXYGEN 0 FOR A PRESSURE TEST BUT ONLY NITROGEN N 1 Install a service gauge manifold on the unit to the two evacuation points pos 6 and 27 P amp I diagram 2 Close the compressor discharge stopvalve and compressor suction stopvalve pos 5 and 26 P amp I diagram 4 turns 3 Connect the pressurized gas bottle ex N to the discharge stopvalve of the service gauge manifold 4 Remove the electrical coils and mount permanent magnet on the two electronically expansion valves pos 16 and 18 P amp I diagram 5 Open the discharge stopvalve of the service gauge manifold 6 Carefully open the hand valve of the pressurized gas bottle until the two gauges of the ser vice gauge manifold show a pressure of 12 BarE Close the discharge stopvalve of the service gauge manifold Do a leakage detection as described in this manual Leave the unit pressurized for minimum 2 hours If the pressure gauges still show 12 BarE after 2 hours the unit is without any leakages
44. QNS IN ena tY av CH engl iv av EN enal Iv ON ev NoN 4X tenal tY av 84 eng tY ev Um SOd1010IA AS fois Joes xog HO episui Bnd Jo eujeH c csud Jeurejuoo ui Bnd Joie ec csu d jonsa d sid 223 of 231 pages Les Operating and service manual Jeuuuu uid v last n l v UIN A AS N ueud d S INS VNOIS S d sipa DE al moud pud 9 aND an 9 ELE kal zs EZX Zex rvdEv SUE dni mweris owois tc z 183 Eq t rvasn gig dns 2 JaN9 GND z jg pen yJ Cv 1 B8B og IVNDIS WNOIS EI d ESL 24 A evasn gis ems E zasi Je Jano QN9 E Spent zi8dc8 Sio S eweg Neel S vv wig we T JES e SS Be que C 9 ONG AND 9 LI gps EES evdsn i L eweg WNOIS A ons fos L ons A 8 QN5 ONS 8 D on Eu LO J osteo 6 IVNDIS WNOIS 6 dena lt gt L deno 0L ON5 an9 0L Dm Sex vex AWNDIS wes Z puoow L LOeA9IN 8 puoow 2 CHE QN9 2 s densi 9 Myns TWNDIS 7 zaenegi duind y QN5 ONS Faso Lex 9cx jeuondo
45. Trouble shooting for Star Cool main controller p 57 before replacing main controller Value below alarm limit 60 C 76 F or above 140 C 284 F Value must be invalid for 30 sec for alarm activation Replacement by new value from AAS system Controller ti dl Alarm light Consequence When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data Active Inactive CT y 82 of 231 pages STAR OO Operating and service manual 124 Tsucopen Warning Suction Temperature Sensor Open Circuit ET Indication of loose connection defective or complete lack of suction temperature sensor Trouble Possible causes shooting e Temperature sensor Tsuc or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 126 Trouble shooting 1 Same trouble shooting is to be used for Tsuc as used for Tret in AL 100 Criteria Value below low alarm limit 60 C 76 F Replacement by new value from AAS system action Alarm light Superheat control deactivation When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data me Active Inactive High limit_ Present i 125 Tsuc short Warning Suction Temperature Sensor Short Circuit Cause Indication of short circuited suction
46. U1 2 overvoltage U2 3 overvoltage 16 U1 3 overvoltage 1 U1 2 undervoltage U2 3 undervoltage U1 3 undervoltage 20 I1 overcurrent 2 I2 overcurrent 2 I3 overcurrent 25 Phase Direction Not Detectable 24 Phase Frequency Error 2 Power Frequency too high Power Frequency too high 27 Bad power supply over loaded under supplied Bad power supply voltage regulation out of order Bad power supply 30 Power Cable From FC to Compressor Faulty 5 FC alarms FC local control FC short circ FC 24 V fault FC earth fault FC over cur Warning Warning Alarm Alarm Warning Replace O2 sensor Replace CO2 sensor Replace O2 sensor Warning EN TU EN Warning Warning Warning Fatal Alarm AIBIR Oljmn n D Oo a Fatal Alarm Fatal Alarm Fatal Alarm Fatal Alarm Fatal Alarm Fatal Alarm E ze aje IS S aS S me e W OIN rir OJo oO ja AA Nie D Fatal alarm D Oo a Warning Alarm Alarm Alarm Fatal alarm Alarm Ha N Olm D ZP N Co N Ko 4 D Ul e KA FC Local Mode Fault FC Short Circuit Fault Alarm FC Internal 24 V Supply Fault Alarm FC Earth Fault Alarm FC Overcurrent Fault Alarm Alarm Alarm Alarm Alarm Alarm ul e Co ui U1 SIE BE 3overcurent to Ui m m 59 of 231 pages STAR OO Operating and service manual FC motor therm 13 FC overload 1 FC under volt il FC over volt 516 FC phase loss 1 FC over temp
47. Viewing of ID for FC for compressor Value FO5 Setting of phase direction Phase direction Function Setting of phase direction Value Is only possible when AL423 is active Default setting is Auto for automatic phase detection automatically selected when the unit has been switched off for more than 30 min before switching it on again Can be used for manual phase setting Setting as CW for clockwise rotation or CCW for counter clockwise rotation If manual phase direction is set heat is reduced to 60 of max Function Zero adjust of AirExchange sensor when the air inlet is closed Value Actual value of sensor is set to zero when enter key is pressed 48 of 231 pages STARK LOO Operating and service manual FO7 Type of low pressure transmitter Low pres type Function Set the pressure transmitter that is physically mounted for low pressure measurement Press En ter for 3 sec to make the selection Value AKS for Danfoss pressure transmitter NSK for SAGInoMIYA pressure transmitter Function Set the pressure transmitter that is physically mounted for high pressure measurement Press Enter for 3 sec to make the selection Value AKS for Danfoss pressure transmitter NSK for SAGInoMIYA pressure transmitter FO9 Serial number of controller board Main PCB Function Shows the serial number of the controller board Value F10 Model code Function Model Value Fil Freshair type Functio
48. and 3 Trouble For trouble shooting 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 action Alarm light Quick flash Unit stops Alarm will be marked as inactive if another phase voltage measuring is below limit It may then be deleted Parm 1 Parm 5 Log data m e Active Inactive High limit Voltage 417 U1 2 under voltage Fatal Alarm U1 2 under voltage Cause Indication of error in container supply voltage between phases 1 and 2 Trouble Possible causes shooting e The unitis supplied with a voltage below specified level e Defective Power module PCB Accompanied alarms e N A Trouble shooting 1 Measure the voltage applied to the unit 2 Apply correct voltage to the unit The FC will not be able to maintain stable speed of the compressor motor due to a too low voltage and therefore the unit will make a restart 3 Measure the actual voltage and compare with the value in the display If the measurement differs the power module PCB may be defective Replace or bypass power module PCB by pressing Veda configuration then phase direction and then cw If condenser fan rotates in the wrong direction choose ccw This action is to be performed at every unit start up Criteria Value below low alarm limit 335 Volt Controller breaks supply after 60 sec After
49. capacity available RH De humidification humidity set point Values Off 50 95 Off means the controller maintains as high humidity as possible at all other values the controller will use the humidity set point to maintain de humidification De humidification is active immediately when the step starts including under temperature ramps If the duration hours is set to OFF or it is the last step the program is terminated After this the unit continues with the temperature set as last step in the MTS The Multiple Temperature Set points program stops automatically if the unit has been powered off for more than 48 hours or if the user stops the program or if PTI or Cold Treatment is initiated 41 of 231 pages STAR ZOQL Operating and service manual Cold Treatment program CT H L Loading cargo I Pull down to Cold Treatment i treatment Ramp up temp passed A 0 1 C hour O01 set point B01 Cold Treatment gt B03 Cold Treatment Cold Treatment done or failed Start cold treatment at 1 or 2 Cold Treatment can only be started when all Tusda sensors are in function If one or more Tusda sensors fail under the Cold Treatment period the treatment temperature is kept as set point for the whole trip When Cold Treatment is done without any sensor failure CT pass is written in the display status text When Cold Treatment is done with 1 or 2 sensor failures CT done is
50. controller Criteria Activated by UWS or AL 901 Replacement by new value from AAS system Controller P y y action Alarm light If activated Cold Treatment CT it will be affected When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data Acive Imctive o LI TI 80 of 231 pages STAR OO Operating and service manual 121 Tevap open Warning Evaporator Temperature Sensor Open Circuit geen Indication of loose connection defective or lack of evaporator temperature sensor Trouble Possible causes shooting e Temperature sensor Tevap or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 123 Trouble shooting 1 Same trouble shooting is to be used for Tevap as used for Tret in AL 100 Criteria Value below low alarm limit 60 C 76 F Replacement by new value from AAS system n When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data 122 Tevap short Warning Evaporator Temperature Sensor Short Circuit Cause Indication of short circuited evaporator temperature sensor Possible causes shooting e Temperature sensor Tevap or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 123 Trouble shooting 1 Same tro
51. controller defective Accompanied alarms e N A Trouble shooting 1 Same trouble shooting is to be used for Tusda3 as used for Tusdal in AL 109 Value below low alarm limit 609C 76 F and the sensor reading has been in the valid area since power up None ti Seid Alarm light Consequence May be incomplete USDA data logging If activated Cold Treatment CT it will be affected When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data 116 Tusda 3 short Warning USDA 3 Temperature Sensor Short Circuit Cause Indication of short circuited USDA 3 temperature sensor Possible causes shooting Temperature sensor Tusda3 or its cable defective X24 and X25 cable is defective Defective plug inside or cable on the unit backside Main controller defective Accompanied alarms e N A Trouble shooting 1 Same trouble shooting is to be used for Tusda3 as for Tusdal in AL 110 Value above high alarm limit 140 C 284 F and the sensor reading has been in the valid area since power up None dd Alarm light Consequence May be incomplete USDA data logging If activated Cold Treatment CT it will be affected When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data m Active Inactive High timit_ Present 77 of 231 pages STAR LOO Operating and service manual Tusda 3 inval
52. copper tubes according to EN 12735 1 Pipe coating Primer Epoxy resin zf a120 Top coat Polyurethane resin Hipon 50 Electrical data Input power operational 3 x 360 V 460 V 50Hz 3 x 400 V 500 V 60 Hz Control circuit voltage 12 VDC AUX voltage AC 19 30 V AC 24 V AC Nominal Circuit Breaker Main power ampere AGA Contactors Nominal 9 amp at 40 C 104 F amp 400 volt a 7 amp at 70 C 158 F amp 520 volt Fuses Control circuit supply 0 4 A tube fuse Power plug Type CEE 17 4 pole with earth 32 amp 400 460 V 50 60 Hz Power Cable 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 24 of 231 pages STAR OO Operating and service manual USDA socket requirements Rear left side 3 pieces 1 cargo sensor Deutsch HD 10 female socket Tin Plated Evaporator fan motor Manufacturer Grundfos ABB Enclosed non vented dahlander motor Frame size 071B14 Shaft material Stainless steel X20CrNi172 No of motors Voltage 3 phases 400 460 Vac 50 60 Hz Nominal power 0 45 0 07 kW at 460V 60 Hz 0 45 0 07 kW at 460V 60 Hz Protection electrical Thermistors Speed Dual speed Dual speed 3460 2850 rpm 60 50 Hz 3430 2890 rpm 60 50 Hz 1760 1425 rpm 60 50 Hz 1750 1440 rpm 60 50 Hz Counter clockwise when viewed from shaft end Permanently lubricated sealed Bearing size D
53. e AJo EN EM MM D Ns E NE S ai ul N Bile Ble N q s asa A EN o EES 2 EN EN ENG co 213 of 231 pages STAR LOL Operating and service manual Tightening torques 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 Head Bolt M8 Flare Nut 1 2 Brass Schrader Valve 1 8 Cable Gland M12 e Ui AJN NW N Ww AJo Lock Nut Cap Nut Gland Cap Nut Cable Gland M20 Gland Lock Nut Cap Nut Lock Nut Cap Nut Cable Gland M16 Cable Gland M25 Air Exchange Potentiometer Slotted Cheese Head Screw M3 1 FC Mounting Hexckobular Socket Seen M6 C Hex Head M10 Hex Socket Counters Head Bolt M10 Hex Head Bolt M8 Hex Head Hex Socket Counters Head Bolt M6 Hex Head Hex Head Hex Head N o Cylinder Head Bearing Cover o Oil Pump Cover Sight Glass Terminal Block oo Pressure Transmitter AKS Pressure Transmitter NSK High Pressure Switch M o Water Inlet Coupling Female brass Water Outlet Coupling Male brass Hex Head Ul eo Water Inlet Coupling Female Alu Water Outlet Coupling Male Alu Sight Glass Melt Fuse Hex Head Hex Head Hex Head Ul eo 65 u A Suction Gas Valve Hex Head Bolt M10 Hex Socket Counters Head Bolt M10 Hex Head Bolt M8 Hex Head Suction Gas Valve Flange LA o Discharge and Interm
54. failure See if there should be other FC alarms AL 5XX and if they can be deleted first 2 Turn of the unit off for 10 min and then start again If this alarm becomes active again the FC has a permanent internal fault and must be replaced If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria Internal error in FC Controller FC shut down Alarm reset requires that supply voltage is disconnected from frequency converter Alarm will be marked as inactive in alarm list when reset by FC The alarm may then be deleted Parm 5 Log data Active Inactive Freq FC FC High Voltage Fault Warning Cause Indication of problems with supply voltage Trouble Possible causes shooting e The unit is supplied with voltage above specification W7 e Defective FC Accompanied alarms e AL 515 Trouble shooting 1 Measure if the power voltage to the unit is within specification Apply correct voltage 2 Turn the unit off for 10 min and then start it again If this alarm becomes active again the FC has an internal fault and must be replaced If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria Supply voltage of FC has exceeded 535 V AC 760 V DC Controller None action Alarm light If not solved this problem can cause FC to stop due to alarm 515 Warning will be mar
55. have been several FC errors within the last 30 min or a constant FC error Controller action eneen Wem ENERO Alarm light Slow fash Consequence Restart time Restart time for the FC is extended to 15 min the FC is extended to 15 min When the FC has been without errors for more than 1 hours this alarm is marked inactive and can be deleted Log data Acive Iacive III y 134 of 231 pages STARK LOOL Operating and service manual 613 Motor trouble Alarm Evaporator fan motor 1 or 2 or condenser fan motor overheated several times 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 Trouble Possible causes shooting e Repeated evaporator fan motor trouble e Repeated condenser fan motor trouble Accompanied alarms e Alarms AL 400 AL 401 or AL 402 are have been active Trouble shooting 1 Check and clear AL 400 AL 401 or AL 402 first 2 Check that the condenser fan can rotate freely 3 Check that the evaporator fans can rotate freely 4 Check contactors interlock and aux contactors 5 Change the defective motor There have been several overheating signals or a permanent overheating signal from evaporator fan motor 1 or 2 or condenser fan motor within 30 min Restart delay increased to 10 12 min Controller action Alarm light Siow flash Consequence Evaporator fan motor There is no or limi
56. internal failure in the FC Trouble Possible causes shooting e Internal failure in the FC Accompanied alarms e N A Trouble shooting 1 Check and clear other alarms first 2 Check that FC cover is mounted correctly with all screws 3 Check motor cable Connection cable between FC and compressor 4 The FC needs repair and should be replaced Criteria FC temperature not increased by 15 C within 5 min during step 8 of Function test None Controller action Alarm light slow Rash Test failed Elimination Alarm may then be deleted after test completed Log data n 158 of 231 pages STAR OO Operating and service manual 850 IP test failed Alarm Description PTI Test Fault Cause Normal function will be affected Trouble Possible causes shooting e There is one or more alarms Accompanied alarms e AL 8XX and maybe other alarms Trouble shooting 1 There are other AL 8XX alarms Check and clear the other alarms first Then a new PTI test can be run Criteria One or more of the individual PTI test steps have failed None action Alarm light Slow Rash Test failed Elimination Alarm may then be deleted after test completed Parm 4 Log data Active Inactive Test time sec 855 PTI Tset 5 LTE PTI 5 C Set Fault Cause Indication of insufficient performance Trouble Possible causes shooting Doors are open The heaters do no
57. limit Umean is less than 23 6 2 frequency Upper limit Umean is more than gt 155 6 2 frequency Umean U1 2 U2 3 U1 3 3 Controller action Alarm light Quick Aash All fans forced into Low Speed Alarm will be marked as inactive in alarm list when proper supply is established Alarm may then be deleted Log data m us urs _ NetFreq 109 of 231 pages STAR LOO Operating and service manual 430 _ Cpr connection Alam lial compressor is not using any power Trouble Possible causes shooting e The power cable between the FC and the compressor motor is defective e The current measuring circuit in the FC is faulty e The compressor motor is damaged Accompanied alarms e N A Trouble shooting 1 Check if voltage on all 3 phases is within specified range 2 Check that the power cable between the FC and the compressor motor is not damaged 3 Measure that the compressor motor is not damaged 4 The FC may be defective Criteria FC is running but the current from the FC is below alarm limit Mcond Mevapi and Mevap2 fan motors forced to low speed Controller action Alarm liont slow fash Controller will retry after 1 min Log data 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
58. or other sensors may be defective and pulling the voltage down Check other alarms and Trouble shooting for Star Cool main controller p 57 before replacing main controller Value is above high alarm limit 140 C 284 F and the sensor reading has been in the valid area since power up None May be incomplete USDA data logging If activated Cold Treatment CT it will be affected When sensor value becomes valid it is marked inactive in the alarm list and may then be deleted Controller action Log data 73 of 231 pages STAR LOO Operating and service manual 1111 Tusda 1 invalid USDA 1 Temperature Sensor Invalid Indication of defective supply air temperature sensor or its measuring circuitry or sensor not mounted correctly in unit Trouble Possible causes shooting e Active alarms AL 110 AL 109 or AL 901 if CIM5 software e Temperature sensor reading is out of valid range 60 C 76 F or above 70 C 284 F Accompanied alarms e AL 110 AL 109 or AL 901 may also be active Trouble shooting 1 If alarms AL 110 or AL 109 are active check their trouble shooting section first 2 If AL 901 is active see trouble shooting for AL 901 3 Disconnect the sensor cable for sensor Tusdal from the connector on the main controller according to the wiring schematics inside in the control cabinet 4 Measure the resistance between the two wires a If the resistance is out of range of the resistance and t
59. plugs Accompanied alarms e One or more AL 5XX may also be active Trouble shooting 1 The power cable for the compressor motor Mcpr may have defective isolation Check the cable and replace if it is defective 2 Measure resistance fase to ground must be above 2 MQ 3 The FC is defective and must be replaced If there is no FC replacement available the unit can be rewired for emergency operation See Emergency Operation p 51 Leakage current from outlets to ground of FC Current 3 A for more than 10 usec 0 00001 sec FC shut Controller fo SUE GOD n Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data A Active Inactive Freq FC 112 of 231 pages STAKSkZO0L Operating and service manual FC Overcurrent Alarm Cause Indication of problems with compressor Trouble Possible causes shooting A13 e The compressor motor draws too much current e Defective FC e Condenser blocked due to dirt and residue Accompanied alarms e One or more AL 5XX may also be active Check also these alarms before replacing anything Trouble shooting 1 The compressor motor draws too much current from the FC The motor may be jammed or defective 2 Turn off unit and wait 10 min before turning on the unit again 3 If the compressor cannot run or runs very short time before this alarm comes again the compressor is defective and must be re
60. press type F09 F10 Model code F11 Freshair type SERIAL NUMBERS N01 SMC N02 SUP N03 SPM N04 RH N05 02 N06 co2 NO7 ssc N08 FCCP Only for some models 31 of 231 pages STAR OO Operating and service manual 1 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 After 30 sec with no keyboard activities the display returns to the main display menu By press ing GI the display returns to the previous menu level in the menu structure If one of the other menu keys is pressed menu selection changes By pressing the 4 and y keys the individual parameters are scroll able For parameter change press and the parameter is highlighted in inverse writing By pressing and keys parameter values are changeable When desired value is set press to accept value and parameter is shown in normal writing again As long as the parameter value is shown in inverse writing setting is erasable by pressing GI and the previous parameter value is shown again If the keys 4 P y or are not pressed for 5 sec setting is cancelled and the previous param eter value is shown again Temperature Setting Temperature set point adjustment is made from the operating menu
61. replaced If there is no FC replacement available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria Short circuit in compressor or its terminals Motor current has been above 40 Amp FC shut Controller SES EEN SE Alarm light Slow flash Unit stop Alarm will be marked as inactive in alarm list when reset by FC and can then be deleted Log data R Active Inactive Freq FC 509 FC 24 V fault Alarm FC Internal 24 V Supply Fault Alarm Cause Indication of problems with FC Trouble Possible causes shooting e Internal fault in the FC A15 Accompanied alarms e One or more AL 5XX may also be active Trouble shooting 1 Switch off the unit and wait 10 min before switching on the unit again 2 If the alarm is then still active the FC is defective and must be replaced If there is no FC replacement available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria Internal 24 V supply error 111 of 231 pages STAR OO Operating and service manual 1 FC shut Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data 3 Active Inactive Freq FC FC Earth Fault Alarm Cause Indication of problems with cable compressor or FC Trouble Possible causes shooting A14 e Isolation damaged on the FC power output to the compressor e Defective FC e Damaged cable and or
62. sec the unit restarts with a normal startup action Alarm light Unit stops Elimination Solve the issue according to Trouble Shooting guidelines Log data 411 Unit over current Cause Indication of short creue oS Trouble Possible causes shooting e The unit is using too much power Accompanied alarms e N A Trouble shooting 1 The voltage may have been too low for too long 2 Check for loose connections When cargo is unloaded run a PTI test and see if one of the motors or heater is using too much power Check power cables for short circuits and damages Check cables for heaters and motors for short circuits and damages Criteria Maximum current consumption has been exceeded Controller Controller breaks supply action Hs p m Wem Unit stops Log data m This alarm is used for service purposes the fuses are protecting the unit 101 of 231 pages STAR OO Operating and service manual U1 2 over voltage Fatal Alarm Description U1 2 over voltage Cause X Indication of error in container supply voltage between phases 1 and 2 Trouble Possible causes shooting e The unit is supplied with a voltage above specified level Accompanied alarms e N A Trouble shooting 1 Measure the voltage applied to the unit 2 Apply correct voltage to the unit The FC will be destroyed if it is running at a too high voltage 3 Measure the actual voltage and compare with the valu
63. shooting Temperature sensor Tusda1 or its cable defective X24 and X25 cable is defective Defective plug inside or cable on the unit backside Main controller defective Accompanied alarms e N A Trouble shooting 1 2 Disconnect the sensor cable for sensor Tusdal from the connector on the main controller according to the wiring schematics inside in the control cabinet Measure the resistance between the two wires a If the resistance is more than 1 5 MQ the cable or the plug on the backside of the unit or the sensor is defective Check plug before replacing the sensor and cable b If the resistance matches the resistance and temperature in Tables p 203 the temperature sensor and cable are OK Measure the voltage over the connector for Tusdai1 It should be between 3 2 and 3 4 V DC a If the voltage is inside the above range connect sensor again Measure the voltage over the sensor and check voltage temperature according to Tables p 203 b If the voltage is outside the above range the main controller is defective or other sensors may be defective and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool main controller p 57 before replacing main controller Value below low alarm limit 609C 76 F and the sensor reading has been in the valid area since power up None Controller action Log data May be incomplete USDA data logging If activated C
64. temperature exceeds limit for water cooling 60 C 140 F in more than 1 hour Water cooling is deactivated Controller action Alarm light Ew M bk O Alarm will be marked as inactive in alarm list next time water cooling is activated Alarm may then be deleted Log data 127 of 231 pages STAR LOO Operating and service manual 602 Tsetunreachable Alarm Tset Unreachable Not implemented yet Cause Indication of insufficient yield Trouble Possible causes shooting Container doors are open or gasket defective Not enough refrigerant for the compressor Insufficient airflow though evaporator Insufficient airflow though condenser Defective hot gas valve leaking Commodities are producing more heat than the cooling system can remove Accompanied alarms e Other alarms may be active Trouble shooting The unit will continue the cooling but the next steps could be checked anyway 1 If other alarms follow troubleshooting for these alarms 2 Check container doors and gaskets Check if there is enough refrigerant in the unit Check if the evaporator is filled with ice or dirt blocking air circulation Check if evaporator motors can rotate Watch fingers turn unit off first Check if the condenser is filled with dirt and blocking air circulation Check if condenser motor can rotate Watch fingers turn unit off first Check hot gas valve for leaking Let the compressor run in
65. the connector on the main controller according to the wiring schematics inside in the control cabinet 3 If AL 901 is active see trouble shooting for AL 901 4 Measure the resistance between the two wires a Ifthe resistance is out of range of the resistance and temperature table Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check Trouble shooting for Star Cool main controller p 57 before replacing main controller Value below alarm limit 60 C 58 F or above 140 C 284 F Value must be invalid for 30 sec for alarm activation Replacement by new value from AAS system Controller action Alarm light No consequence as to control When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 120 sec to set alarm inactive Log data Acive Iacive IT Pressure transmitter Alarms AL 2XX 200 Pdis open see AL 202 Warning 201 Pdis short see AL 202 Warning 86 of 231 pages STAR OO Operating and service manual Description Compressor Discharge Pressure Transmitter Open or Short Circuit Indication of loose connection defective short circuited or lack of compressor discharge pressure transmitter Trouble shooting Controller action Log data Possible causes Connector for high HP transmitter Pdis dis
66. the heater and letting the temperature control increase cooling capacity resulting in an evaporator temperature descending This function has 3 modes Off Active Override Dehumidification Off The dehumidification function is in the OFF position Dehumidification Active The heater Hevap is activated when RH is more than gt RHSet and deactivated when RH is less than lt RHSet 3 9 6 The humidity set point can be set in the range 50 to 95 relative humidity The range 50 to 64 is only possible with no fresh air evap ventilation in low speed The range 65 95 is possible to run with fresh air evap ventilation in high speed Dehumidification Override Accessing override mode if Cooling demand exceeds 80 capacity Large demand for heating PTI A fatal alarm is active When operating without FC Manual operation is active Defrosting Other comments 12 of 231 pages STAR OO Operating and service manual 1 The dehumidification icon 8 is shown in the display even if override is active The heat icon amp follows the current state of the heater 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
67. user having left air exchange open Trouble Possible causes shooting e Air exchange valve open in freeze mode or AV mode e Air exchange open in 50 60 RH e Cable or air exchange sensor defective or not calibrated correctly Accompanied alarms e Possibly AL 305 Trouble shooting Calibrate the air exchange sensor see Controller System Menu decal for air exchange sensor calibration 1 See and clear error for alarm AL 305 2 Close air exchange If air exchange is closed cable for air exchange sensor or sensor is defective see AL 305 for trouble shooting Air exchange is open while unit being in the frozen mode dehumidification with set point below 60 and or with CA or AV running None Controller action Alarm lign Quick flash Deteriorated control precision Alarm will be marked as inactive in alarm list when air exchange is closed and may then be deleted Log data ActivefInactive 1 y 130 of 231 pages STAR OO Operating and service manual Select AirEx type Warning Cause Ju cnecneg OOOO Trouble Possible causes shooting e AirEx type is set to NONE in Settings Accompanied alarms e None Trouble shooting Go to Settings and Configuration and choose either 35m3 h or 75m3 h depending on valve type 35 m3 h 75 m3 h m uw Alarm light None Consequence o Alarm will be marked as inactive in alarm list when air exchange is set and may the
68. written in the display Display p 27 When Cold Treatment is done with 3 sensor fail ures CT fail is written in the display Display p 27 The CT status will be displayed until Program status set to none Initiated PTI Power off more than 48 hours Termination of an active CT can only be done by manually setting active program P01 to none or if the unit has been powered off for more than 48 hours Datalog interval during CT is default 60 min cannot be changed Changes in Treatment set point during active Cold Treatment has been limited to a decrement of 2 5 C 4 5 F to an increment of up to max allowable set point from original Treatment set point BO1 Duration of the treatment Duration Function Setting of duration in days of the Cold Treatment Value Values 1 99 days The number of days to use depends on the cargo and the treatment tempera ture The treatment time is counted from the validity of at least 3 USDA sensors all showing a tempera ture below the maximum USDA temperature If one or more USDA sensors is outrange and re turns to inrange again the timer for the Cold Treatment will reset CT passed shows that all USDA sensors have been under maximum allowed temperature in the duration time in one period BO2 Maximum allowed temperature for the USDA sensors Maximum USDA temp Function Setting of the maximum allowed temperature of the USDA sensors Value Value 10 0 C to 30 0 C BO3 Treatment s
69. 1 pages STAR OO Operating and service manual 420 Iiovercurent jLog Description I1 over current Cause X Indication of short circuit in electric installations of Star Cool unit Trouble Possible causes shooting e The unit is using too much power on one phase e Defective Power module PCB Accompanied alarms e N A Trouble shooting 1 The voltage may have been too low for too long 2 Check power cables for short circuits and damages 3 Check cables for heaters and motors for short circuits and damages 4 Measure the actual current and compare with the value in the display If the measurement differs the power module PCB may be defective Replace or bypass power module PCB by pressing Veia configuration then phase direction and then cw If condenser fan rotates in the wrong direction choose ccw This action is to be performed at every unit start up Criteria Value above upper alarm limit 20 Amp None action Hog x Wem Aemhem or Unit stops Log data Active Inactive Mionimit Presem o o This alarm is used for service purposes The fuses are protecting the unit 421 I2 over current Log 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 action up Wem Wem or Log data Active inactive ho
70. 10 Ifthe pressure gauges are below 12 BarE perform a leakage detection as described in this manual ON 198 of 231 pages STARK LOOL Operating and service manual 11 Disconnect the pressurized gas bottle 12 Open the discharge stopvalve on the service gauge manifold to release the pressure from the unit 13 Do a pump down of unit as described in this manual 14 Charge the unit as described in this 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 Open Discharge service valve complete pos 5 P amp I diagram 3 Close HP valve on the service gauge manifold 4 Connect HP service gauge manifold to the Liquid charging valve pos 11 P amp I diagram 5 Close Service valve economizer pos 14 P amp I diagram 6 With installed service gauge manifold to the evacuation points LP on pos 27 and HP on Liquid charging valve pos 11 P amp I diagram 7 Place a refrigerant bottle on a scale for weighing Record the weight of the refrigerant bottle 8 Connect manifold service hose to refrigerant bottle and purge as needed 9 Setrefrigerant bottle for liquid charging and open refrigerant bottle hand valve 10 Check that service valve pos 26 are fully open and 1 turn closed for service manifold gauge reading keep the manifold gauge LP valve cl
71. 10 153 496 08 232 1 876 00 154 482 55 234 1 812 60 156 469 45 235 1 751 60 158 456 76 237 1 693 00 160 444 48 239 1 636 63 162 432 58 241 1 582 41 163 421 06 243 1 530 28 165 409 90 244 E 68 86 es 1480 12 167 102 1 140 71 181 104 1 104 99 183 1 070 58 185 30753 264 2 236 398 00 2 064 919 00 E 1 907 728 00 E 1 763 539 00 1 631 173 00 1 509 639 00 1 397 935 00 E 1 295 239 00 E 1 200 732 00 d 1 113 744 00 S 1 033 619 00 959 789 00 891 689 00 828 865 00 770 880 00 717 310 00 667 828 00 622 055 00 579 718 00 540 530 00 504 230 00 470 609 00 439 445 00 410 532 00 383 712 00 358 806 00 335 671 00 314 179 00 294 193 00 275 605 00 258 307 00 242 195 00 227 196 00 213 219 00 200 184 00 188 026 00 176 683 00 166 091 00 156 199 00 146 959 00 72 895 00 68 927 00 i 8 056 00 65 198 00 5 773 70 42 314 60 g 1 037 40 187 299 82 266 1 005 40 189 292 34 268 32 650 80 31 030 40 4 366 90 4 199 90 944 81 192 278 03 271 916 11 194 271 19 273 888 41 196 264 54 275 861 70 198 258 09 277 835 93 199 egen 4 541 60 974 56 190 285 08 270 29 500 10 1 28 054 20 26 687 60 25 395 50 3 887 20 3 601 00 40 149 50 2 399 40 4 4 4 4 4 28 29 29 29 29 29 94 15 92 13 11 87 85 83 4 81 2 78 76 74 72 71 10 67 12 65 14 63 16 62 18 19 58 21 56 23 54 25 53 27 51 28 49 30 47 32 45 34 44 36 42 37 40 39
72. 2 Check voltage level of 24 V DC and 5 V signals to see if power supply has an open circuit or other damages If the correct voltage is measured at X22 and at X23 then circuit is defective Replace main controller Criteria Reference voltage AirEx above 5 50 V DC None action Hs p oem mi Less accurate readings from measurement Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data ES ES 177 of 231 pages STAR OO Operating and service manual L ii Sensor bus sup LO Warning Supply voltage sensor bus low Cause X Indication of controller voltage reference fault Trouble Possible causes shooting e Defective 12 V power supply on main controller e Defective main controller e Short circuit on sensor Accompanied alarms e There may be sensor alarms AL 730 and or 740 e AL 801 will be activated during FT or PTI test Trouble shooting 1 2 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting Access the special menu by pressing qj for more than 3 sec Scroll down until you see the label U sensor bus in the display The value of U sensor bus should be in the range between 11 and 14 V DC While displaying U sensor bus remove the connector on the RH cable at the first bus sensor RH and or CO2 sensor If U sensor bus is now inside the correct above r
73. 2 or AL 113 are active check their trouble shooting section first 2 If AL 901 is active see trouble shooting for AL 901 3 Disconnect the sensor cable for sensor Tusdal from the connector on the main controller according to the wiring schematics inside in the control cabinet 4 Measure the resistance between the two wires a If the resistance is out of range of the resistance and temperature table in Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check Trouble shooting for Star Cool main controller p 57 before replacing main controller Criteria Activated by UWS or AL 901 Replacement by new value from AAS system Controller P y y action Alarm light If activated Cold Treatment CT it will be affected When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data Acive Imctive o LI TI 76 of 231 pages STAR OO Operating and service manual 115 Tusda3 open Warning USDA 3 Temperature Sensor Open Circuit Cause Indication of loose connection defective or lack of USDA 3 temperature sensor Trouble Possible causes shooting e Temperature sensor Tusda3 or its cable defective e X22 X23 X24 and X25 cable is defective e Defective plug inside or cable on the unit backside e Main
74. 3 5 30 00 435 24 2 15 00 217 62 211 of 231 pages STAR LOO Operating and service manual Temperature Sensor Voltage Table Temperature sensors except for reference temperature sensor Vec 5V Voltage Temp Temp Voltage Temp Temp Voltage Temp 3 00 2 98 2 97 2 95 2 92 2 90 2 88 2 86 2 83 2 81 2 78 2 75 2 73 2 69 2 67 LN 34 Ww co N Lr io eo Ww N o co Ui ERR ER L LA o co 7 L N VD N N N RER EC 2 ps e L N N A r M w L N Ui Oo r a co LN 2 s Er LAE po CE aa e pe ee E s a pn ET ESL pesi e pee pa Jos 2 EN EC pre oem em 7 LONE NEN NEN E CNN NN EL NIC CNN NN per imam ms LONE NN ECEEN LECCE NT LIBENTI MEN MEN mec pur mec e c EON CI EN RENI pee Jus e LIMEN INN NN pe po Hu pen qos cu een Juss qe 2 60 2 57 2 53 2 49 2 46 2 42 2 39 2 35 2 31 2 27 2 23 2 19 2 15 2 11 2 07 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 44 45 47 50 7 7 10 11 12 13 14 15 16 17 18 19 20 21 o co N A 212 of 231 pages Temp Pel 71 6 73 4 75 2 77 0 78 8 80 6 82 4 84 2 86 0 87 8 89 6 91 4 93 2 95 0 96 8 98 6 100 4 102 2 104 0 105 8 107 6 109 4 111 2 113 0 114 8 116 6 118 4 120 2 122 0 es STAR OO Operating and service manual Pressure Temperature table for R134a 73 ejeje
75. 35 200 75 140 205 145 210 150 215 207 of 231 pages STAR LOO Operating and service manual es Voltage Pressure Table Low pressure transmitter AKS Vcc 5 V Pressure is relative Voltage Pressure Pressure Pressure Voltage V BarE Psi V BarE Pressure Psi 82 13 84 48 86 85 89 20 91 56 93 91 96 28 98 63 100 99 103 34 105 70 108 05 110 42 112 77 115 13 117 48 119 84 122 19 124 56 126 91 129 27 131 62 133 99 136 34 138 70 141 05 143 41 145 76 148 13 150 48 152 84 155 19 157 55 159 90 162 27 164 62 166 98 169 33 171 70 174 05 208 of 231 pages Es STAR OO Operating and service manual Voltage Pressure Table Low pressure transmitter NSK Vcc 5 V Pressure is relative Voltage Voltage Pressure Pressure V BarE Psi V BarE Psi 0 69 10 01 1 9 4 57 66 34 0 3 0 65 9 49 1 95 4 74 68 71 0 35 0 49 7 12 2 4 90 71 08 0 4 0 33 4 75 2 05 5 06 73 45 0 45 0 16 2 38 2 1 5 23 75 82 0 5 0 00 0 01 2 15 5 39 78 19 0 55 0 16 2 36 2 2 5 55 80 56 0 6 0 33 4 73 2 25 5 72 82 93 0 65 0 49 7 10 2 3 5 88 85 30 0 7 0 65 9 47 2 35 6 04 87 67 0 75 0 82 11 84 2 4 6 21 90 04 0 8 0 98 14 21 2 45 6 37 92 41 0 85 1 14 16 58 2 5 6 53 94 78 0 9 1 31 18 95 2 99 6 70 97 15 0 95 1 47 21 32 2 6 6 86 99 52 1 1 63 23 69 2 65 7 02 101 89 1 05 1 80 26 06 2 7 7 19 104 26 1 1 1
76. 416 U V Fatal Alarm Fatal Alarm Max voltage U V Fatal Alarm Please note that values may vary from values in previous software versions Refrigeration system data Refrigerant charge R134a 4 5 kg with water cooled and non water cooled condenser 21 of 231 pages STAR OO Operating and service manual General specification Total unit weight Range from 400 to 460 kg depending on model Dimensions Height Width 2235 mm 2025 mm Noise level Less than 75 dB A in 250 Hz band Measured 1 5 m in front of unit and 1 2 m above the ground with the unit operating at 50 Hz Compressor motor assembly 2 High stage cylinders Compressor housing Sea water resistant aluminium unpainted Weight 58 Kg Frequency converter FC High Pressure cut out switch 22 5 BarE 326 3 psi 0 7 Bar 10 2 Psi 15 9 Bart 230 6 psi 0 7 Bar 10 2 Psi Fusible plug receiver Economizer Type Brazed plate heat exchanger Material Stainless steel AISI 316 L Evaporator coil Tube material Copper inner grooved Fin Material Aluminium Hydrophilic treated Attitude 45 from horizontal 22 of 231 pages STAR OO Operating and service manual Condenser coil Tube material Copper inner grooved Fin Material Coating tube fin Cataphoresis treatment with additional acrylic resin Evaporator fan Condenser fan Water cooled condenser optional Operating water pressure max 8 BarE 115 Ps
77. 52 2 40 31 60 458 32 2 45 32 00 464 12 210 of 231 pages Es STAR OO Operating and service manual Voltage Pressure Table High pressure transmitter NSK Vcc 5 V Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure gt BarE V BarE Psi 0 00 2 05 15 50 224 874 T 0 50 7 254 2 1 16 00 232 128 0 6 1 00 14 508 2 15 16 50 239 382 0 65 1 50 21 762 2 2 17 00 246 636 0 7 2 00 29 016 2 25 17 50 253 89 0 75 2 50 36 27 2 3 18 00 261 144 0 8 3 00 43 524 2 35 18 50 268 398 0 85 3 50 50 778 2 4 19 00 275 652 0 9 4 00 58 032 2 45 19 50 282 906 0 95 4 50 65286 2 5 20 00 290 16 1 5 00 72 54 2 55 20 50 297 414 1 05 5 50 79 794 2 6 21 00 304 668 1 1 6 00 87 048 2 65 21 50 311 922 1 15 6 50 94 302 2 7 22 00 319 176 1 2 7 00 101 556 2 75 22 50 326 43 1 25 7 50 108 81 2 8 23 00 333 684 1 3 8 00 116 064 2 85 23 50 340 938 1 35 8 50 123 318 2 9 24 00 348 192 1 4 9 00 130 572 2 95 24 50 355 446 1 45 9 50 137 826 3 25 00 362 7 1 5 10 00 145 08 3 05 25 50 369 954 1 55 10 50 152 334 3 1 26 00 377 208 1 6 11 00 159 588 3 15 26 50 384 462 1 65 11 50 166 842 3 2 27 00 391 716 CS 12 00 174 096 3 25 27 50 398 97 1 75 12 50 181 35 13 3 28 00 406 224 1 8 13 00 188 604 3 35 28 50 413 478 1 85 13 50 195 858 3 4 29 00 420 732 1 9 14 00 203 112 3 45 29 50 427 986 1 95 14 50 210 366 4
78. 622 Loss of cooling Warning The refrigeration systems tries to cool down but Tsup is above Tret Cause X No cooling capacity Trouble Possible causes shooting e System leak loss of refrigerant e Defective compressor valve plate s e Defective compressor e Defective valves Accompanied alarms e AL 623 Trouble shooting 1 If more alarms are active see troubleshooting for these alarms first 2 Check refrigerant level If low find leak point repair and recharge unit 3 Check the function of these valves Vexp Veco and Vhg Perform a function test and troubleshoot according to the test alarms 4 If the compressor has low performance isolate the compressor Recover the refrigerant from the compressor and check LP and HP valve plates for damage Defective valve plates can be replaced if the bore of the cylinder is not damaged Replace the defective compressor if replacement of valve plates is not possible or if another part of the compresor is defective Compressor is running AND evaporator heaters are off AND Tret is 0 5 C below Tsup AND inrange LED is off AND requested capacity is 100 All above criterieas must be true for 30 min before alarm is activated None Controller action Alarm light Log data FCType__ FreaAct_ Hevap pct 138 of 231 pages STAR OO Operating and service manual Loss of cooling Fatal Alarm The refrigeration systems tries to cool down but Tsup is above Tret Cause
79. 96 28 43 2 75 7 35 106 63 1 15 2 12 30 80 2 8 7 51 109 00 1 2 2 29 33 17 2 85 7 68 111 37 1 25 2 45 35 54 2 9 7 84 113 74 1 3 2 61 37 91 2 95 8 00 116 11 1 35 2 78 40 28 3 8 17 118 48 1 4 2 94 42 65 3 05 8 33 120 85 1 45 3 10 45 02 341 8 49 123 22 1 5 3 27 47 39 3 15 8 66 125 59 1 55 3 43 49 76 3 2 8 82 127 96 1 6 3 59 52 13 3 25 8 98 130 33 1 65 3 76 54 50 3 2 9 15 132 70 1 7 3 92 56 87 3 35 9 31 135 07 1 75 4 08 59 24 3 4 9 47 137 44 1 8 4 25 61 61 3 45 9 64 139 81 1 85 4 41 63 97 3 5 9 80 142 18 209 of 231 pages STAR LOO Operating and service manual es Voltage Pressure Table High pressure transmitter AKS Vcc 5 V Pressure is relative Voltage Pressure Pressure Voltage V BarE Psi V Pressure Psi 237 86 243 66 249 46 255 27 261 07 266 87 272 67 278 47 284 27 290 08 295 88 301 68 Pressure BarE 1 10 21 20 307 48 1 15 21 60 313 28 as 6 00 ezo so 4o ass 1 40 104 43 3 45 23 60 342 29 1 45 110 23 3 50 24 00 348 09 1 50 116 03 3 55 24 40 353 89 1 55 121 83 3 60 24 80 359 69 1 60 12763 3 65 25 20 365 50 1 65 13343 3 70 25 60 371 30 1 70 139 24 3 75 26 00 377 10 1 75 145 04 3 80 26 40 382 90 1 80 150 84 3 85 26 80 388 70 1 85 156 64 3 90 27 20 394 50 1 90 16244 3 95 27 60 400 30 1 95 168 24 28 00 406 11 2 00 174 05 4 05 28 40 411 91 2 05 179 85 4 10 28 80 417 71 2 10 185 65 4 15 2 30 30 80 446 72 2 35 114 80 214 66 Joan 3120 452
80. A 1 2 3 temperatures and cargo temperature Press up or down to show newer or older stored set of values from the data log Manual Defrost Initiation A manual defrost is only accepted if Tevap less than lt 15 C 59 F Defrosting is manually initiated by pressing the key and holding it for 3 sec The display shows the zu icon as an acceptance of defrost initiation A automatically or manually initiated defrosting may be terminated by pressing and holding it for 3 sec The display will cancel the icon 50 of 231 pages STAR OO Operating and service manual 1 Water cooling Activation Deactivation amp The following only applies for with water cooling WC Water cooling connecting is executed as follows The container must be connected to the water cooling system Press and hold it for 3 sec The display shows the icon as an acceptance of water cooling operation The condenser fan is deactivated Water cooling turn off is executed as follows Press amp and hold it for 3 sec The display turns off the E icon as an acceptance of non op erating water cooling The condenser fan turns on automatically The container can be disconnected from the water cooling system If the water supply is insufficient the water hose is jammed the water is not running or the water temperature is too high the temperature in the condenser will rise and cooling capacity is de creasing and thereby threatening the cargo If
81. AL 418 or AL 419 may be active Trouble shooting 1 Supply unit with correct power voltage according to specification 2 If voltage is within specification and not unstable the FC may be defective and must be replaced If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 Supply voltage to FC is less than 330 V AC with full load The minimum voltage depends on the load of the FC Controller FC shut down action O Siow Fash Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Active Inactive Freq FC FC Overvoltage Fault Alarm Cause Indication of problems with supply voltage Trouble Possible causes shooting A7 e The FC is supplied with too high voltage for continuous operation e Defective FC Accompanied alarms e AL 414 AL 415 AL 416 or AL 521 may be active Trouble shooting 1 Supply unit with correct power voltage according to specification The FC will be destroyed at too high voltages and is therefore being shut down 2 If voltage is within specification and not unstable the FC may be defective and must be replaced If there is no FC replacement available the unit can be rewired for emergency operation See Emergency Operation p 51 SEEN Supy votage of FC more then Co S50 AC GN VE Controller FC shut down iden Unit stop Alarm will be marked as
82. CU6 DatabaseFaut Log Invalid date time Date and time notvaid Log Realtime error Reak time Clock Unreliable Alarm Realtime invalid og og og Co LA D Ww N o co A 4 g D oa co co A Wu Oo gg e Func test failed Controller Idle current Mevap current OFF Mevap direction 817 Mcond current OFF Hevap current ON _ Deep current OFF Valve leaks Expansion valve Economizer valve _ Hot gas valve Cpr pump down FE check PTI test failed PTI Tset5 0 PTI TsetO 0 PTIdefrost PTITset 18 VI VI E N Ul Ko o Co L 10 Vin power failure Battery voltage LO Warning 912 Battery voltage Hi 5 Controller Internal Voltage Reference Faut warning 954 Controller Internal Voltage Reference Fault Warning Ko Ko m mA VO LA a a 3 3 OO o TE C D Oo nl Zlo 61 of 231 pages STAR OO Operating and service manual 955 5 6 62 63 XO xo Lee OD xo xo 6 D Psuc sens sup HI Controller Internal Voltage Reference Fault 65 Controller sup LO Controller Internal Voltage Reference Fault 967 68 971 M xo Ko o 7 SUP6 SPM6 sup LO Supply voltage SUP6 SPM6 low 7 SUP6 SPM6 sup HI Supply voltage SUP6 SPM6 HI Zei Mefl e IO Ko 75 7 8 8 88 Powermeas calibration not possible brat 89 oftware test ver Software test version
83. DA sensor and then double clicks in e g CalUs1 In the popup window enter the calibration value required in order for the sensor to reach 0 C Then press enter Do this calibration for each of the USDA and Cargo sensors Max offset calibration is 3K If more is required the probe must be replaced 188 of 231 pages STAR OO 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 189 of 231 pages STAR OO Operating and service manual 1 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 earth wire placed directly on the motor Do not disconnect the other cable connection which is connected directly in the motor cover Remove the 4 x M6 bolts that hold the evaporator motor bracket incl motor and fan Then the evaporator motor bracket with motor and fan can slide right through the inspection opening of the unit by dragging it towards yourself Replace the defective parts and reinstall the evaporator fan m
84. EENEN ENEE REENEN RF Bri AE 36 Operation Parameter Setting DN E SEe d 40 PtOGratnSs sisicieacass ern kEREEE ERREUR DEREEEERRRE ea Rn LEE LEE TEE PEREDURDEEEERE ERR AREE E RRERULA OIL ARERR FCR Re TT 40 Multiple Temperature Set points program MIS t rerai aoir enne e Exc ucsc abu e EERSTEN 41 Cold Treatment program CT WEE 42 E EE 43 Service Function Setting Viewing RY See T E TULLIUM LI 44 ManualoperatioNS EE 45 Datalogi View MELLE 46 Time adj Stisnonenpennon e E E E E E NS 47 Run time COUNTE S esce eoi EE REESEN nt Saa XT E ee PRURUERE E ia ANA AEREN TEGNE EAR ERR EEN ENNER DENSE SRM LER Sa ge 47 Configuration iieri cucsx te ee sace ENER ENER REESEN SNE EE REES EENS EE ge EENS ES ee 48 Serial N tmb6ets icisecssczessssassscessozusssssvce vector orte y DNE ate RESSRSERNEECERCEERAPEFOEQUR EENS KEE EDATE AO NEEDE TEARS NEES ER 49 Sanel F Temperature Scale Showing Alternately NS assu vies eisve exe snesececnetonxm EES 50 Viewing graph of Supply and Return Temperature T E 50 Manual Defrost Initiation DI e Water cooling Activation Deactivation 3 TE 51 Emergency Operation SEENEN ESA age Ree PR AA Ea Tekid nE Aa Anaea ELEDA Te EEA RNS 51 EE EE E EE ee EE 51 Controler defectives Necronien DIL 52 External Interfaces eene EENEEEE EE aE EE SATE EA A SEER KIEK EIES ENEE EEEE SE EES 52 ELE e elle EE 52 List of terms used for ex
85. Evap heater Function Shows the status of the test of the evaporator heater 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 820 821 T12 Test result 80 Compressor 80 Compressor Function Shows the status of the test of the compressor Value jf 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 845 and 846 T14 Test result 90 FT status 90 FT status Function Shows the status of the function test 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 T16 Test result 100 Temperature set point 5 C 100 T set 5 C Function Shows the status of the performance test with temperature set point of 5 C 41 F 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 855 T17 Test result 110 Temperature set point O C 110 T set 0 C Function Shows the status of the performance test with temperature set point of 0 C 32 F Value if not done yet RUN if still
86. FC X8 cable is defective Main controller defective Accompanied alarms e AL 306 or one or more AL 5XX may also be active Trouble shooting 1 Verify that cable FC com is mounted correctly according to wiring diagram inside the controller cabinet and not being damaged 2 Check that power to the FC is not wired for emergency operation 3 Verify that there are correct voltages on all 3 phases for the FC 4 Measure with a multimeter that there is a small DC signal on the connector PCB for cable FC com a If there is no signal The main controller is defective Replace the main controller b If there is signal The FC is defective and must be replaced If there is no FC replacement available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria Communication with FC not possible Mcond Mevapi and Mevap2 fan motors forced to low speed Pid DEELER When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data i 143 of 231 pages STAR LOA Operating and service manual A ii 710 Display missing Seen in Star View Warning No communication with display Cause Indication of defective display lack of or improper connection Trouble Possible causes shooting Communication with display broken Defective display X11 cable is defective Main controller defective Accompanied alarms e AL 720 AL 721 and A
87. FC inrush FC internal 521 FC high volt 2 FC high temp 2 FC phase loss FC current limit FC overload FC setup error FC undefined alarm 599 FC Trip Lock 6 Operation alarms No control sensors Ui m N Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Warning Log Warning Warning Warning Warning Warning FC Compressor Motor Over temperature FC Overload Fault Alarm FC Voltage Low Fault Alarm FC Voltage High Fault Alarm FC Phase Loss Fault Alarm FC Over temperature Fault Alarm FC Inrush Fault Alarm FC Internal Error Fault Alarm FC High Voltage Fault Warning FC Over temperature Fault Warning FC Phase Loss Fault Warning FC Current Limit Fault Warning FC Overload Fault Warning FC Setup Fault Warning FC Undefined Alarm Ui u1 U1 uje d1 U1 O1 eile U1 UI NIN AJwj N u1 UI N oyu Ul Oo Oo FC has tripped and stopped Log oO Supply Air Sensor 1 Supply Air Sensor 2 Return Air Fatal Alarm Sensor All Malfunctioning Water cooling fault Tset Unreachable Not implemented yet In range Fault High Pressure Safety Switch is active Air exchange valve open in conflict with settings AirEx type missing Defrost is running Max defrost time exceeded No watercooling 0 Tset unreachable 03 In range fault High press trouble AirEx open Select AirEx Type Defrost Trouble 610 Defrost time exceed Too many sensor Too many controlling sensors have errors err FC troubl
88. FT or PTI test Trouble shooting 1 See Trouble shooting AL 961 Criteria Reference voltage Pdis above 5 50 V DC None Controller EE seenen e Lr U Alarm light Consequence Less accurate Less accurate readings from measurement from measurement Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data mm A TW 170 of 231 pages STAR OO Operating and service manual 1 963 Psuc sens sup LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective Psuc pressure transmitter e Defective main controller Accompanied alarms e There may be sensor alarms especially AL 207 e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Access the special menu by pressing Ki for more than 3 sec Scroll down until you see the label U Psuc in the display The value of U Psuc should be in the range between 4 50 V and 5 5 V DC While displaying U Psuc remove the connector at Psuc f U Psuc is now inside the correct above range 4 50 V 5 5 V DC the Psuc pressure transmitter is defective Replace the Psuc pressure transm
89. II 136 of 231 pages STAR OO Operating and service manual Cpr start failed Fatal Alarm Trouble Accompanied alarms shooting e AL621 Trouble shooting 1 See AL 621 None Controller ad Alarm Night Quick flash No cooling of the cargo Log data Active Inactive IT Ir 621 Cprrestarted Warning Description The compressor has been restarted Cause No signal from FC that motor is running Trouble Possible causes shooting e Too high discharge pressure at start up unit will restart after a delay e Unit in emergency mode but cables not rewired for emergency mode e Compressor defective Accompanied alarms e There may be other alarms ex AL 306 Trouble shooting 1 Check and clear AL 306 first high pressure alarm 2 The discharge pressure is too high at start up unit will restart after a delay Check and clear AL 5XX FC alarms first Check wiring for the compressor motor especially if unit is in emergency mode If this alarm remains active after several restarts the compressor is defective and should be replaced Criteria The compressor did not start on the first attempt within 3 min None Controller action EE Alarm light There will be a longer start delay Elimination When the compressor has started the alarm is marked inactive and can be deleted Parm 1 Log data Acive Imactive III 137 of 231 pages STAR LOO Operating and service manual L ii
90. L 9XX may also be active Trouble shooting 1 Verify that cable COM is mounted correctly and is not damaged according to wiring diagram inside the controller cabinet 2 Verify that there are correct voltages 12 V DC on wire 1 3 Measure with a multimeter that there is a small DC signal on the wires 2 and 3 connector PCB for cable COM a Ifthere is no signal The main controller is defective Replace the main controller b If there is signal The display is defective and must be replaced If there is no display permanent replacement available a substitution display can be used for setting values and evaluate the unit s status Criteria Communication via the display is not possible None unit can perform normally without displa Controller d d pay n When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data s Active Inactive o In Jo Errorcode 144 of 231 pages STAR OO Operating and service manual 711 Display com Seen in Star View Warning Reduced communication with display Not yet implemented Cause Indication of defective display lack of or improper connection Trouble Possible causes shooting Communication with display broken Defective display X11 cable is defective Main controller defective Accompanied alarms e AL 710 AL 730 and AL 9XX may also be active Trouble shooting 1 Verify that cable COM is mo
91. NFORMATION menu actual data read out Operation Show OPERATION menu settings Alarm Show ALARM menu view listing of present alarms Service Show SERVICE menu maintenance data and settings G Gei Gi 6 28 of 231 pages STAR OO Operating and service manual Function keys Direct activation and deactivation of commonly used func tions Gir Unit As long as the button is pressed F is shown instead of C and Psi is shown instead of Bar in the display Otherwise C and Bar is shown when pressed if software is set to F Psi default T Toggle Shortcut to graphical view of logged temperatures Toggles infor mation on some sub menus Defrost Press 3 sec to start and stop a manual defrost cycle amp Water Cool Press 3 sec to activate and deactivate water cooled condenser If no key is activated for a period of time the controller will do this 5 sec Cancel active parameter adjustment 30 sec Turn off battery powered display operation when not connected to a power supply line 5 min Leave service mode operation and return to automatic mode 10 min Return to main window in display Menu overview Menus are selected by pressing a menu key or by pressing the Enter key on a sub menu line shown in the display General Page layout 4 OPERATION O01 Trip start START Defrost interval 24 h Cursor line Line count O03 Airflow mode NORMAL O04 Humidity setpoint OFF O05 Datalog interval 15 m
92. NO 9 LX 94X T uMd uMd 1 z QNS QNO z uMd uMd v QNO QNO S uMd S 9 og 9 6X 8X T Jano uMd 1 z QNS uMd z Lex 02X aer AS Z IVNOIS mue QN QNO v We r AS S IVNOIS IWNOIS 9 og ano EZX cox HOA vul Seul oep WI 10014 WT Hd DN eng v cv 2X enal iv eV EN enal lv 4 GNO NV ONON 7 44 Jengi tY CN 8X eng iv a LI 2sogson vo xog m9 xd 8 4 episui nid R I 1 eneen ER zezSu y 1eurmjuoo A 8 4 ui Bnid DR IT d eneen ER ZEZSH 24 zy ate FEL MO amp 8 EN oF de eH S D EN S3 ZS IHdersyy Big 14 FS MOO 99 feuondo Joo La Jonsa 4 spa aru 221 of 231 pages STAR OO _ Operating and service manual a ics optional hemat iring sc Overall w HOJA SS 9de SH VS SdeA9H ap pdenoy VirgdenoH g yde eH VECOEAGL gZZde eH VZ LdeA9H ai edenoy VI LdeASH 89 9deAeH V9 GUEASH 810MV SEL de oH Xog J8JJO4jUO7 PISUJ IWNOIS 1 ONG IVNSIS ONG VNOIS 1 ONG 7VNOIS 1 ONG TNDIS 1 ONG IVNSIS 1 ONG 1 WNOIS ON na VNOIS WNOIS aNd WNOIS ONG VNOIS ON VNOIS ON VNOIS TNOIS 1 ONG Ai 24 gt Leen
93. No cooling capacity Trouble Possible causes shooting e System leak loss of refrigerant e Defective compressor valve plate s e Defective compressor e Defective valves Accompanied alarms e AL622 Trouble shooting 1 See AL 622 Compressor running AND evaporator heaters are off AND Trest is 0 5 C below Tsup AND inrange LED is off AND requested capacity is 100 All above criterias must be true for 120 min before the alarm is activated Unit stops until it is power cycled action Log aerer ight Quick flash Unit stops until it is power cycled Parm 1 Log data Tret FCType FreqAct Hevap pct 139 of 231 pages STAR OO Operating and service manual 625 CT outrange Alarm Cold Treatment out of range Cause X Indication of insufficient yield or defective controller Possible causes Trouble shooting Difference between treatment setpoint and maximum USDA temperature too small Container doors are open Other alarms active Not enough refrigerant for the compressor Defective or jammed evaporator motors Defective or jammed condenser motor Accompanied alarms e Other alarms may be active especially USDA sensor alarms AL 109 to AL 120 Trouble shooting The unit will continue the cooling but the next steps could be checked anyway Je Larger difference between treatment setpoint and maximum USDA temperature Treatment setpoint must be cooler Maximum USDA temperatur
94. PASS if test finished successfully FAIL if the test failed ABORT if the test was aborted by the user See specific description for AL 850 Info Menu Viewing By pressing OU ue info menu is selected The icon is displayed The info menu includes the following parameters I01 Relative humidity Relative humidit Function Shows current relative humidity in the container Value Shown as a percent value I02 Air exchange in m3 h Air change m3 h Function Shows current opening of air exchange valve Value Shown as m3 h IO5 Last defrost interval Last defr interval Function Show current interval between last two defrostings Value Shown in hours I06 USDA 1 temperature USDA 1 temp Function Shows current temperature for USDA 1 sensor Value Shown in temperature scale C or F Switch by pressing E 107 USDA 2 temperature USDA 2 temp Function Shows current temperature for USDA 2 sensor Value Shown in temperature scale C or F Switch by pressing E I08 USDA 3 temperature USDA 3 temp Function Shows current temperature for USDA 3 sensor Value 36 of 231 pages STAR OO Operating and service manual Shown in temperature scale C or F Switch by pressing D I09 Cargo temperature Cargo temp Function Shows current temperature for cargo sensor Value Shown in temperature scale C or F Switch by pressing D I10 Time to next defrost Time to defrost Func
95. Possible causes shooting e Active alarms AL 100 AL 101 or AL 901 if CIM5 software e Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 2849F Accompanied alarms e AL 100 or AL 101 may also be active Trouble shooting 1 If alarms AL 100 or AL 101 are active check their trouble shooting section first 2 Disconnect the sensor cable for sensor Tret from the connector on the main controller according to the wiring schematics inside in the control cabinet 3 If AL 901 is active see trouble shooting for AL 901 4 Measure the resistance between the two wires a If the resistance is out of range of the resistance and temperature table Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check Trouble shooting for Star Cool main controller p 57 before replacing main controller Sensor is defective and the missing sensor reading has been substituted by a value from AAS system See Alarm Action System AAS p 19 Replaced by new value from AAS system Controller action Alarm light Deteriorated control precision in the freeze mode When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data i Active Inactive o ooo LI y y 67 of 231 pages STAR LOO Operating a
96. R LOO Operating and service manual Location of valves s Electronics expansion valve economizer Liquid charging valve 5 Evacuonveve SOS 54 of 231 pages es STAR OO Operating and service manual Location of motors temperature sensors humidity sensor and air exchange potentiometer 1 3 3 5 10 12 11 LE AA ZA Le ps 1 tae be 1 f A ZA PORE 7 uu Zei Sa S Via o i 4 c 9 4 8 7 4 6 Accessibility Through inspection hatch 1 Suction temperature sensor Tsuc i i Through inspection hatch i 3 Evaporator temperature sensor Tevap 1 Inside Through inspection hatch 2 Supply temperature sensor Tsup 2 Jouse 5 Return temperature sensor met 1 Inside Through inspection hatch s Ambient temperature sensor amb 1 Jouse a ES i Kee a aus 3 4 5 7 Air Exchange potentiometer Behind fresh air cover panel E Condenser motor Optional Through inspection hatch Through inspection hatch Through fan grill 55 of 231 pages STAR LOA Operating and service manual A ii Location of pressure transmitters high pressure switch and oil outlet port m Wi it op ki 6 Uy L Pos Description Short name Number Location Discharge Pressure transmitter High pressure switch Suction Pressure transmitter Oil outlet port pf Outside General tro
97. R OO Operating and service manual 1 USDA socket REQUIFEMEMNES reset Er pReEiR UE enc onn Mac t RN EU IE ERIN SU DM MINE VERSES RULIR UI C cous Pos NNI ERES NUN EUE 25 Evaporator fart TOEOE es eeeeee seess eet eS EAR isa Liv SEENEN EE TA ISRELie TE aaun E EESAN NETET Ena a RR EEN EEN EEE EE 25 Condenser fanimotor custos sue russo EN ERE RE SR SKESA REGN YRXER IR IROXERIAR KRSERKSESPNRRRERRRERERRFXRRRAR E KIM ITAXESERR IER PR EY REE KE 25 Evaporator coll lhieatelS ET 26 Temperature sensors including USDA EE 26 Pressure transmlitters seii eese oniit essa nete eg EEERAEEN EAR KEREN EE NE SSES ERAN RETERRRY EE ENNER REGN SY san EES EES 26 lee UC 26 User Interface eot e ee Ee EE Eed ee 26 leie Heel TEE 26 IE E 2 UUUDEEREEEITEES 27 yaris ER 28 Menu OVERVIEW ss occhi etos On EE EA A EEE EEEE NAA ERA E ER IY 3 XY EY EIERE NEEN AER EE GA dese RU Y KFEP FE EES es 29 General Page TIU eR EEUU 29 Changing parameter Value E 30 Activating a FUN CHON 30 Alt exchange EIERE dE EE EE 30 L ET EE 31 DEE el 31 General er iepol REPE 32 Temperat re on e DEEG 32 Wake up Mode NUILLA LIU DI III ILLI 32 Contrast adjustment of the display eres usa een nena nte ener anu SSES SEET REPE RRR RR XRRSRX RETE ES cane ES EERE REES ES 32 PTI or Function Test execution eT EE 33 Info Menu Viewing x1 october Rune nixa EENS ERR RR SRRRSX RFRI YR AXG AR NRI SEENEN S
98. RATION gt S02 DATALOG VIEW gt S03 TIME ADJUST gt so4 RUNTIME COUNTERS gt S05 CONFIGURATION gt S06 SERIAL NUMBERS gt T01 PTI test T02 Last T03 Function test T04 Abort the test TOS Test status TO6 10 Init TO7 20 Controller T08 30 Power T09 40 Evap fan T10 50 Cond fan T11 60 Evap heater T12 80 Compressor T13 70 CA T14 90 FT status T15 105 T set 13 C T16 100 5 C set hold T17 110 T set 0 C T18 T19 120 T set 18 C T20 130 Defrost T21 140 PTI status PROGRAMS Active program Multi Temp setp gt Cold treatment gt COLD TREATMENT Duration Maximum USDA temp Treatment setpoint Final temperature CT status MULTI TEMP SETP MANUAL OPERATION Operating mode M02 Evaporator heater M03 Evaporator fan M04 Condenser fan M05 Compressor freq M06 Expansion valve M07 Hotgas valve M08 Economizer valve M09 Airex motor M10 Vacuum pump DATALOG VIEW Text Temperatures gt L02 Text Atmosphere gt L03 Graph Temperatures L04 Graph Atmosphere gt GMT Year c02 GMT Month C03 GMT Day c04 GMT Hour cos GMT Minute RUNTIME COUNTERS R01 Unit R02 Compressor R03 Evaporator fan R04 Condenser fan R05 Evaporator heater R06 Airex motor sw times R07 Vacuum pump CONFIGURATION F01 Container F02 SW version F03 FC type F04 F05 Phase detection F06 AirEx calibration F07 Low press type F08 High
99. Replace main controller Criteria Reference voltage sensor bus above 14 V DC None action p p Wem Wemhen Less accurate readings from measurement and damage to sensors Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data E m 181 of 231 pages STAR LOO Operating and service manual A ii Internal sup LO Warning 12 V supply voltage low on SMC6 Cause Indication of 12 V power supply fault Trouble Possible causes shooting e Defective 12 V power supply on SMC6 e Defective main controller e Short circuit on SUP6 and SPM6 or RH sensor and CO sensor Accompanied alarms e There may be sensor alarms AL 302 e AL971 and or AL 973 e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms AL 971 and or AL 972 Clear these alarms first using their trouble shooting 2 Future possibility Access the special menu by pressing Ki for more than 3 sec Scroll down until you see the label SUP6 SPM6 in the display The value of U SUP6 SPM6 should be in the range between 10 and 14 V DC While displaying U SUP6 SPM6 remove the connector at X10 If U SUP6 SPM6 is inside the correct range at X11 pin 1 and 4 the display and or power module is defective Test with another display and or power module If U SUP6 SPM6 is still outside the above range
100. SIS IVNOSIS L 2 GND ND z IVNDIS IVNSIS v aN9 v 91 OMV VG GdeneH Sr pdeASH SN Vi EUe SH g rdeAeH V Ede eH de edeneH NNN ANN VIe SI ZUEASH VI LGEASH EE Reis V9 GUEASH UI0O2 NINH jeuondo EVI gt tvasn ol e EY gt evasn ol e EVI gt evasn e e ES gt oeg Act v EI ON NO xog 4e 04u02 episino xog 48j O41uo2 apisu QVdA33 QVdA3 TANVd dasn 9dNS 30D Es oes xu s 25 Z w U9j8H 48J O u02 Aa o 3 5 lt 3 E D xog 48 O u02 episuJ x ee OV Ave 9 G euiuuo L L OV AZ v UIA HO A HOA OV Abt Z L euw saBeyon xo1ddy ERG e DVAPZ E LL OAVHL VF EdEASH iz SITT DA an9 OWAO SIMI 8E ydeAsH bou E gt sr os 4 peu SUL M Z po vul 9 U9HAS peu cur VZ IdEASH x 0 UO ar E E39 SI zde eH ES S S S zz ZS VI LdeneH H5 1 d DN WE Cm 89 9de eH Le HC B ek V9 SdEASH tgo d m 2 CH gt m ZS zal E 3901 o z i H os s 431NI eal E E i i ud A au d DI ze S MENS d zl a zi zT i tHL SIE ee i en SEH xog 1ejo2uoz episu a
101. SPM6 is still outside the above range proceed to next step While displaying U SUP6 SPM6 disconnect display and or power module from the terminals according to wiring schematics inside in the control cabinet If U SUP6 SPM6 is now inside the above range the cable for the display and or power module is defective Mount connector correctly or replace connector cable for display and or power module If the correct voltage is measured at X11 then circuit is defective Replace the main controller Criteria Reference voltage U sensor bus below 10 V DC None Controller i tog JN Aem Alarm light Consequence Log data ET mem 180 of 231 pages STAR OO Operating and service manual 1 ensor bus sup HI Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective 12 V power supply to sensor bus e Defective main controller e Short circuit between 24 V DC and 12 V DC Accompanied alarms e There may be sensor alarms AL 3XX e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24 V DC and 12 V signals to see if power supply has an short circuit or other damages If the correct voltage is measured at X11 then circuit is defective
102. Slow flash Test failed Alarm may then be deleted after test completed Log data 151 of 231 pages STAR LOO Operating and service manual m 813 Mevap direction Alarm 815 Meond cur LO speed Alarm 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 defective Condenser motor cable defective Bad connection in plug Condenser motor cable wired wrongly in controller cabinet or motor Accompanied alarms e N A Trouble shooting 1 Check the condenser motor fan can rotate freely Turn off power first Replace motor or make it turn freely again 2 Check motor cable for damages 3 Check that the condenser motor cable is mounted correctly Criteria Condenser fan motor has exceeded current limit at low speed 0 2 0 3 Amp EE action Alarm light Slow flash Test failed Elimination Alarm may then be deleted after test completed L 816 Mcond cur HI speed Alarm Condenser Motor High Speed Current Fault Cause Indication of defective motor or defective supply cable to motor Trouble Possible causes shooting e Condenser motor jammed or defective e Condenser motor cable defective e Condenser motor cable wired wrongly in controller cabinet Accompanied alarms e N A Trouble shooting 1 Check the Condenser motor fan can rotate freely Turn
103. Trouble Possible causes shooting e Overload of power supply e Bad connection in plug Accompanied alarms e 429 Trouble shooting 1 Find better cable and or plug 2 Find failure in the supply system 3 If no AL 429 watch the unit more often Er Umean is less than 40 6 2 frequency Umean U1 2 U2 3 U1 3 3 None Controller EE GE BEE Slow flash Consequence uence None Alarm will be marked as inactive in alarm list when proper supply is established Alarm may then be deleted Log data 108 of 231 pages STAR OO Operating and service manual 428 Voltage freq U f ratio high Alarm Bad power supply voltage regulation out of order Cause Power generator adjusted to too high voltage Trouble Possible causes shooting e Failure in generator voltage control Accompanied alarms e AL 429 Trouble shooting 1 Find a better supply 2 If no AL 429 watch the unit more often Umean is more than gt 140 6 2 frequency Umean U1 2 U2 3 U1 3 3 action Alarm Tight slow flash Alarm will be marked as inactive in alarm list when proper supply is established Alarm may then be deleted Log data i Voltage freq U f ratio Fatal alarm Bad power supply Cause SeeAL 427 and AL 428 Trouble Possible causes shooting e See AL 427 and AL 428 Accompanied alarms e AL 427 and AL 428 Trouble shooting 1 See AL 427 and AL 428 Lower
104. Water cooled Air cooled In the air cooled mode ventilation takes place in the following way Depending on the compressor outlet pressure the fan is Off or runs in 2 different speeds High and Low The fan runs in 4 modes Off low speed high speed and a cycle shifting between high and low speed in two minutes intervals If Tamb is more than gt 48 C 118 F or the compressor outlet pressure remains constantly high the condenser fan constantly runs at high speed Water cooled If the condenser fan is constantly on for more than 1 hour an alarm will be given The fan runs in 4 modes Off low speed high speed and a cycles shifting between high and low speed in two minutes intervals 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 Normal Economy Normal Low speed in the frozen mode or if the following three conditions are set Tset is more than or equal to gt 0 C 32 F No fresh air exchange Dehumidification is turned off or humidity set point below 65 Otherwise high speed Economy The fans run at a constant low speed Exception Tret gt Tsup 8 C 14 F then high speed until Tret gt Tsup 3 C 5 F is reached Economy mode is switched on by the operator Defrost Function Defrost function ensures regular evaporator defrosting The function is active in automatic mode The defrost functi
105. a loose thermistor cable connection Trouble Possible causes shooting e Condenser motor defective Cable for measuring condenser motor overheat defective e Main controller defective Accompanied alarms e N A Trouble shooting 1 Turn off unit See if the condenser fan can turn freely If it cannot turn replace the motor If the motor is hot it may be overloaded and jammed or defective If the cable for McondOH by inspection is defective if unable to repair cable replace it Disconnect the cable for Mcond on the main controller according to the wiring schematics inside the control cabinet Measure the resistance in the cable If the resistance is more than 1 MQ the cable or the motor is defective and should be replaced If the resistance is less than lt 5 kQ the cable and motor should be OK Turn unit on again Measure the voltage across the connector for Mcond It should be between 4 80 V DC and 5 20 V DC a If the voltage is inside the above range connect sensor again Measure the voltage across the thermistor and check the voltage If the voltage is less than 2 5 V DC the measurement is OK If the alarm after 30 sec is still active in the display the main controller is defective replace the main controller If the voltage is outside the range main controller is defective or another error might affect the voltage Check other alarms before replacing main controller Criteria Value abo
106. ainer upon evaporator fan initiation Termination ensuring low evaporator fan speed to prevent shock boiling and to ensure that the temperature controller takes over in a controlled way After termination the unit continues normal operation again with the same setpoint temperature as before defrost start General information If the Tevap sensor is not OK adaptive defrosting uses a reduced defrost interval compared to normal calculated defrost intervals Set point 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 Manual defrost termination Upon manual defrost termination termination state is entered No adaptive adjustment takes place when defrosting is manually initiated Regarding user interface Defrost icon is displayed during defrost function execution Other comments If service mode or PTI mode is selected during a defrost the defrost mode is terminated and the time for the next defrosting is set to the preset value as if a normal defrost end had occurred If the unit is shut off for some reason during a defrost and the power disappears for less than 12 hours the unit will start and try to finish the defrost again when the power returns If the unit is shut off for more than 12 hours the active defrost is terminated and the defrost function enters the wait state 14
107. alve 9 o o i pansion valve Function Manual setting of expansion valve opening Note that value is only accepted if control is in the manual mode menu item MO1 is MANUAL and compressor is not running Value Set from 0 to 100 MO7 Setting gas valve o Function Manual setting of hot gas valve opening Note that value is only accepted if control is in the 45 of 231 pages STARK LOOL Operating and service manual 1 manual mode menu item MO1 is MANUAL Value Set from O to 100 MOS Setting of economizer valve 9 o o i Economizer valve Function Manual setting of economizer valve opening Note that value is only accepted if control is in the manual mode menu item MO1 is MANUAL Value Set from O to 100 MO9 AirEx motor Function Opening Value 0 100 Datalog view LO1 Viewing log of temperatures Temperatures Function Viewing of logged temperatures Value The following temperatures can be viewed Setpoint temperature supply air temperature return air temperature relative humidity air exchange m3 hour USDA 1 2 3 temperatures and cargo temperature When entering the menu the newest logged temperatures are always shown Press to toggle between stored set of temperatures Setpoint temperature supply air tem perature return air temperature relative humidity air exchange and the other set of tempera tures USDA 1 2 3 temperatures and cargo temperature To move one pa
108. alve control p 19 Trouble Possible causes shooting e Supply Air Sensor 1 Supply Air Sensor 2 Return Air Sensor and Evaporator Sensor are all malfunctioning e X22 X23 X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 100 to AL 108 Trouble shooting 1 Verify all other sensor alarms AL 100 to AL 3XX and try to remove these alarms 2 If this alarm remains active replace main controller Criteria No valid control sensor values Controller When one of the control sensor values enters into the valid area it is again possible to control container temperature For reliability reasons at least one of the control sensor values must be valid for 30 sec before sensor may be used as control reference again Log data Acive Imctive Il LI 126 of 231 pages STAR OO Operating and service manual 601 No water cooling Warning Water cooling fault Cause Lack of water cooling Trouble Possible causes shooting e Water cooling selected and no water cooling active e Insufficient water cooling capacity e If program is chosen warning can occur in units without water cooling Accompanied alarms e Other alarms might be active Trouble shooting 1 Verify that water cooling hoses are applied and water is running when selecting water cooling 2 Verify that the water is not too hot and not able to be used for cooling the unit Compressor discharge
109. and 5 5 V DC While displaying U Motor pos remove the connector at AirEx potentiometer If U Motor pos is now inside the correct above range 4 50 5 50 V DC the motor potentiometer is defective Replace the AirMotor If U Motor pos is still outside the above range proceed to next step While displaying U Motor pos disconnect AirMotor from the terminals according to wiring schematics inside in the control cabinet f U AirEx is now inside the above range the cable for AirMotor is defective Mount connector correctly or replace connector cable for AirMotor If the correct voltage is measured at X23 then circuit is defective Replace the main controller Criteria Reference voltage AirMotor below 4 50 V DC None Controller action i tog x Jem mm Less accurate readings from measurement Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data a m 174 of 231 pages STAR OO Operating and service manual 1 AirExMot sup HI Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective main controller Accompanied alarms e There may be sensor alarms AL 3XX e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are
110. andling is made to detect abnormal situations possibly solve problems and report the problems The alarm types indicate for the operator how severe the problem is for the safety of the cargo Some problems are fluctuant where the problem may be fixed if the unit restarts Some of the alarms are only warnings but will restart the unit to try to solve the problem There is an individual time out period for the alarms A warning will not stop the unit permanently If a problem with warning type continues to be active over a period the problem seems to be of a more stable and therefore more severe character and another alarm is triggered with alarm type Alarm Yes Yes Yes es The AAS Alarm Action 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 the freeze mode but the unit is not stopped fully until there are no further sensors to substitute with The unit may try to restart to see if the malfunctioning is fluctuant For example if there is no substitution for a sensor or the substitute sensor is also faulty alarm 611 Too many sensor err is raised and the specific sensor s are listed separately in the alarm list The alarm list can include a maximum of 16 active inactive alarms In case of an empty alarm list No alarms is shown An activ
111. ange 10 14 V DC the RH and or CO2 sensor is defective Replace the sensor s connected to sensor bus cable If U sensor bus is still outside the above range proceed to next step While displaying U sensor bus disconnect sensor from the terminals according to wiring schematics inside in the control cabinet If U sensor bus is now inside the above range the cable for the RH and or CO2 sensor s is defective Mount connector correctly or replace connector cable for RH and or CO2 sensor s If the correct voltage is measured at X10 then circuit is defective Replace the main controller Criteria Reference voltage U sensor bus below 10 V DC None Controller d tog X faam Alarm light Log data 7 FED 178 of 231 pages STAR OO Operating and service manual 1 972 ensor bus sup HI Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective 12 V power supply on main controller e Defective main controller e Short circuit between 24 V DC and 12 V DC Accompanied alarms e There may be sensor alarms AL 3XX e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24 V DC and 12 V signals to see if power supply has a
112. ans will stop again e Tret lt Tset 2 C 3 6 F is not reached within 5 min both evaporator fans and compressor will run until Tret Tset 1 C 1 8 F is reached At that point evaporator fans and compressor will stop again Evaporator fans are running on LOW speed when activated Tests ZE unit has 2 3 test functions Function test PTI Pre Trip Inspection test PTI short optional The PTI test is a function test followed by a capacity test where the requested temperature must be reached within the time limit At test initiation an event is generated in the log During function and PTI test the normal alarm system remains active If an alarm is triggered dur ing test operation it appears in the display and will be written in the log as it is the case during normal operation In case of a fatal alarm during testing the test is terminated and the unit remains off Function or PTI sub test failure causes an alarm PTI FAILURE to be generated In case of Function or PTI sub test pass an event Test status is displayed 15 of 231 pages STARK LOOL Operating and service manual For more information please see event list Clear the alarm list before starting a test If there should be any active alarms in the alarm list when a function or a PTI test is started the test will always fail even if all the individual test steps PASS without failures PTI menu has a primary status and a status for each sub test wit
113. anual 1 Value Shown in units of ampere I27 Voltage between phase 1 and 2 Voltage phase 1 gt 2 Function Shows current voltage between phase 1 and 2 Value Units in volt I28 Voltage between phase 2 and 3 Voltage phase 2 gt 3 Function Shows current voltage between phase 2 and 3 Value Shown in units of volt I29 Voltage between phase 1 and 3 Voltage phase 1 gt 3 Function Shows current voltage between phase 1 and 3 Value Shown in units of volt I30 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 FO5 for settings I31 Battery voltage Battery voltage Function Shows current Battery voltage Value Shown as voltage I32 Frequency Converter temperature FC temp Function Shows current converter temperature Value Shown in temperature scale C or F Switch by pressing D I33 Condenser fan speed Condenser fan Function Shows current speed for condenser fan Value Shown as OFF LO HI or OH overheat I134 Evaporator fan speed Evaporator fan Function Shows current speed for evaporator fan Value Shown as OFF LO HI or OH overheat 135 Evaporator heating Evaporator heater Function Shows current on off cycle of evaporator heating element Pulse Wide Modulation Value Shown as a percent value on duri
114. applied After adjusting the contrast wait for a period of 25 sec before proceeding for the new setting to be saved Make sure contrast is properly set at all times to secure readability 32 of 231 pages STAR OO Operating and service manual 1 PTI or Function Test execution The test menu is opened by pressing ET In the test menu press keys 4 or y to scroll the menu For a complete PTI test START must be highlighted by pressing at menu item TO1 Pressing once more initiates the test If is not pressed within 5 sec the controller will cancel the opera tion and the cursor returns to the menu item TO1 For a short PTI test START must be highlighted by pressing at menu item T01 Press keys 4 or y to scroll the menu to select SHORT Pressing once more initiates the test A complete PTI test may take several hours First a complete function test with menu items T04 to T12 and then performance testing in menu items T13 to T17 A short PTI takes approx 1 5 hours Function test is initiated in the same way by selecting menu TO2 A function test performs menu items TO4 to T12 without performance testing and takes about 10 15 min to complete The function test will continue through all the steps even if failures should occur A PTI or function test can be aborted at T03 A single item can be tested by highlighting the item ex T09 When START is shown in inverse writing pressing again will start the te
115. as inactive in the alarm list and may then be deleted Log data 113 Tusda2 short Warning USDA 2 Temperature Sensor Short Circuit Cause Indication of short circuited USDA 2 temperature sensor Possible causes shooting Temperature sensor Tusda2 or its cable defective X24 and X25 cable is defective Defective plug inside or cable on the unit backside Main controller defective Accompanied alarms e N A Trouble shooting 1 Same trouble shooting is to be used for Tusda2 as for Tusdal in AL 110 Value above high alarm limit 140 C 284 F and the sensor reading has been in the valid area since power up Non n See Alarm light Consequence May be incomplete USDA data logging If activated Cold Treatment CT it will be affected When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data Tm m Active Inactive High limit Present i 75 of 231 pages STAR LOO Operating and service manual 114s Tusda 2 invalid USDA 2 Temperature Sensor Invalid Indication of defective supply air temperature sensor or its measuring circuitry or sensor not mounted correctly in unit Trouble Possible causes shooting e Active alarms AL 112 AL 113 or AL 901 if CIM5 software e Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F Accompanied alarms e AL112 AL113 or AL 901 may also be active Trouble shooting 1 If alarms AL 11
116. ase detecting mode and all motors are running the wrong way The compressor will pump correctly but there is very little cooling capacity in the con denser and the air flow is wrong inside in the box One of the motors condenser or evaporator is running in the opposite direction 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 5 Display is blank Adjust contrast 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 X22 X23 X24 and X25 cable on the main controller must be disconnected to see if the defective is with the sensor transmitter or the main controller The procedure is 1 Set unit to Manual Operation Mode by choosing Service Menu and Operation Mode and changing Auto to Manual 2 Disconnect the X22 X23 X24 and X25 cable from the main controller 3 After a while enter the Information Menu In here the following values shall appear a Temperature drops to 70 C b Psuc shows 1 0 BarE c Pdis shows 0 0 BarE d AirEx must read 0 m3 e Humidity 0 4 If one of these liste
117. ask 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 rotation 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 239F and the return temperature in the frozen mode temperature setting below 5 C 23 F Controller accuracy is 0 25 C x0 459F The unit can operate the evaporato
118. ation Air exchange sensor AirEx or cable defective X23 cable is defective Main controller defective Accompanied alarms e AL 305 Trouble shooting 1 Ifthe cable by inspection is defective replace cable 2 Calibrate AirEx see Calibration of air exchange sensor p 188 If the value shown in controller is wrong or alarm still active then disconnect the cable for AirEx on the main controller according to the wiring schematics inside the control cabinet and from the AirEx sensor Mount the cable for AirEx in controller cabinet and on the sensor Disconnect signal wire on main controller Measure voltage between wire and GND on the main controller If the voltage is below 0 2 V DC sensor or connection between sensor and cable is defective If the voltage is between 0 2 V DC and 4 0 V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND If the voltage is between 0 2 V DC and 4 0 V DC and this alarm is still active continue to 5 Check controller see Trouble shooting for Star Cool main controller p 57 before replacing main controller Value below alarm limit 0 m3 hour None Consequence Log data When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted 93 of 231 pages STAR OO Operating and service manual AirEx invalid Description Air Exchange Sensor Invalid Alarm not implemented yet Cause Indication of defectiv
119. attery Malfunctioning Cause Indication of defective battery Trouble Possible causes shooting e The battery used for logging is defective Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting The battery is defective Dismount main controller replace battery and remount main controller Criteria Battery voltage is below limit for low battery alarm 8 V None odit BR Slow flash Logging in the battery mode not possible When detected during test test will fail Alarm will be marked as inactive in alarm list when voltage reoccurs on battery Alarm may then be deleted Log data m 904 Datalog error pes SCCUG Data log Fault Cause Circuit for storing the datalog is faulty Possible causes shooting e Datalog in controller has become defective Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting The unit will continue its temperature control but the logging of data is unreliable 1 Replace main controller Criteria Controller data log corrupted action Nammight Siow fash Data logging unreliable Temperature control is functioning Log data 163 of 231 pages STAR LOA Operating and service manual 905 Database corrupt SCCU6 Database Faulty Cause Failed validation of EEPROM backup Trouble Possible causes shooting e Main controller defective Accompanied alarm
120. available Log data 911 Battery voltage LO Warning Low Battery Voltage Cause Indication of defective battery Trouble Possible causes shooting e Battery defective or used e Battery cables defective Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check that connectors cables for the battery are not damaged If so replace the battery Criteria Battery voltage below warning limit for low battery voltage 11 V None Controller ti cud Alarm light If main power is removed data logging may not be possible Alarm will be marked as inactive in alarm list when battery voltage reoccurs Alarm may then be deleted Log data NE 166 of 231 pages STAR OO Operating and service manual 1 912 Battery voltage HI Log Trouble Possible causes shooting e Battery defective e Battery cables defective Accompanied alarms e 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 If so replace the battery Criteria Battery voltage above warning limit for high battery voltage 18 V None action s p Wem Wem Log data R m Internal Voltage Reference Alarms 953 Temp ref 1 LO Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Pos
121. battery defective Replace main controller Criteria No acknowledge from real time clock action i Aam liont Slow fash Invalid date time setting in datalog Elimination Check real time clock battery Set time Alarm may then be deleted Log data Realtime invalid Real time Clock Unavailable Cause Real time clock battery defective Trouble Possible causes shooting e Real time clock battery defective Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Real time clock battery defective Replace main controller Criteria Invalid reply from real time clock action Alarm ight Slow fash Invalid date time setting in datalog Elimination Check replace real time clock battery Set time Alarm may then be deleted Log data 165 of 231 pages STAR LOA Operating and service manual m 910 Main power failure Cause X Indication of insufficient supply voltage Trouble Possible causes shooting e Unstable or insufficient power supply Accompanied alarms e N A Trouble shooting 1 Supply unit with power according to specification Criteria Supply voltage below warning limit Controller tries safe close down If power reappears system restarts and triggers this Controller alarm action Alarm light All contractors released unit stops Display and main controller remains active Elimination Unit starts when correct power is
122. ble Possible causes shooting e There is a short circuit in the main controller e The power module PCB is defective Accompanied alarms e N A Trouble shooting 1 Check cables for sensors for damages 2 The main controller is defective Replace the main controller Criteria Idle current exceeds limit of 0 3 A with only controller running None Controller action Alarm light slow fash Test failed Elimination Alarm may then be deleted after test completed Log data A 810 MevapcurLO speed Alarm Evaporator motor low speed current fault Cause Indication of defective motor or defective supply cables to motor Trouble Possible causes shooting Evaporator motor jammed or defective Evaporator motor cables defective Bad connection in plug Evaporator motor cables wired wrong in controller cabinet Accompanied alarms e N A Trouble shooting 1 Check the evaporator motor fans can rotate freely Turn off power first Replace motor or make it turn freely again 2 Check evaporator motor cables for damages 3 Check that the evaporator motor cables are mounted correctly Evaporator fan motors have exceeded current limit at low speed 0 6 0 7 Amp on one or more phases None Controller action aer ight slow fash Test failed Elimination Alarm may then be deleted after test completed Log data 7 150 of 231 pages STAR OO Operating and service manual 811
123. ble or the motor is defective and should be replaced If the resistance is less than 5 kQ the cable and motor should be OK Turn unit on again Measure the voltage across the connector for Mevap2 It should be between 4 80 V DC and 5 20 V DC a If the voltage is inside the above range connect sensor again Measure the voltage across the thermistor and check the voltage If the voltage is less than 2 5 V DC the measurement is OK If the alarm after 30 sec is still active on the display the main controller is defective replace main controller If the voltage is outside the range main controller is defective or another error might affect the voltage Check other alarms before replacing main controller Criteria Value above high alarm limit 10K Ohm Both evaporator fan motors are stopped Controller n PP action Alarm light Air circulation in container stops causing unit to stop When overheating ceases alarm will be marked as inactive in alarm list and may then be deleted Control is again released but fan motors will only be allowed to operate at low speed for the first 5 min If error does not reoccur problem will be considered solved and evaporator fan high speed is again released Log data m Ace mative Hioni Prese i 99 of 231 pages STAR LOO Operating and service manual A ii 402 Mcond overheat Warning Condenser Motor Overheat Cause Indication of an overheated motor or
124. by pressing Ki for more than 3 sec Scroll down until you see the label U Pdis in the display The value of U Pdis should be in the range between 4 50 V and 5 5 V DC While displaying U Pdis remove the connector at Pdis f U Pdis is now inside the above range the Pdis pressure transmitter is defective Replace the Pdis pressure transmitter If U Pdis is still outside the above range proceed to next step While displaying U Pdis disconnect Pdis from the terminals according to wiring schematics inside in the control cabinet If U Pdis is now inside the above range the cable for Pdis is defective Replace cable for Pdis If the correct voltage is measured at X22 then circuit is defective Replace the main controller Criteria Reference voltage Pdis below 5 50 V DC None action i Ho p jem em Less accurate readings from measurement Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data i ES 169 of 231 pages STAR LOA Operating and service manual L ii 962 Pdis sens sup HI Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective main controller Accompanied alarms e There may be sensor alarms especially AL 203 e AL 801 will be activated during
125. con LogView and StarView Extended Log can only be retrieved by Logman and StarView and shown in LogView and StarView Function description Start up procedure ZE start up procedure ensures that the system is started safely after the following events Unit has been out of use Main failures Defrosting PTI test Service mode Alarm mode 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 9 of 231 pages STAR ZOQL Operating and service manual 1 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 gt 5 C 23 F the chill mode is activated If Standard Tact Tsup if cooling need and Tact Tret if heating is needed If QUEST is activated see QUEST Frozen If Tset is less than or equal to x 5 C 23 F the frozen mode is activated and Tact Tret The value the Tset limit is dependent on software version This function has four modes Pull down Pull up Cool and Heat Pull Down Pull Up mode In Pull Up and Pull Down mode no in range alarm is given Upo
126. connected or not correctly mounted HP transmitter Pdis defective Cable for HP transmitter Pdis defective X22 and cable is defective Main controller defective Accompanied alarms e AL 200 or AL 201 or AL 203 may also be active Trouble shooting Disconnect the cable for Pdis from the main controller according to the wiring schematics inside the control cabinet and from the HP transmitter 1 Check that the connector is mounted correctly according to the drawing for pressure transmitter AKS or NSK respectively The earth stud must be on the opposite side of the cable AKS 1 Supply GROUND 3 dutput SES R 2 Ground SUPPLY VOLTAGE MEM be 00 95 A S 024 0 TYP 1 0 OUTPUT Figure for NSK Figure for AKS Figure for AKS Figure for NSK Check the cable measure the resistance in the cable If the cable is defective replace cable Mount the cable for Pdis in controller cabinet and on the transmitter Disconnect signal wire on main controller Measure voltage between wire and GND on main controller AKS If voltage is below 0 5 V DC transmitter or connection between transmitter and cable is defective If voltage is between 0 5 V DC and 4 5 V DC continue to 4 NSK If voltage is below 0 37 V DC transmitter or connection between transmitter and cable is defective If voltage is between 0 37 V DC and 4 0 V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND AKS
127. contactor K5B 4 Change the defective motor There have been several overheating signals or a permanent overheating signal from condenser fan motor within 30 min Restart delay increased to 10 12 min Controller action Alarm Tight Siow fash There is limited capacity in the condenser When the condenser fan motor have been without errors for more than 1 hour this alarm is marked inactive and can be deleted Parm 4 Log data Fam 4 Acie madive o o 616 Mevaptrouble Alarm en M MR generated overheat alarm within the last 30 min Trouble Possible causes shooting e Repeated evaporator fan motor s trouble Accompanied alarms e Alarms AL 400 and or AL 401 is has been active Trouble shooting 1 Check and clear AL 400 and or AL 401 first 2 Check the cabeling and that the evaporator fan can rotate freely 3 Check contactor K6 and K7 interlock and aux contactor K7B 4 Change the defective motor There have been several overheating signals or a permanent overheating signal from evaporator fan motor within 30 min Restart delay increased to 10 12 min Controller y nung flog Xx Alarm X Alarm light Slow flash There is limited air flow to cargo and possibly reduced capacity in the evaporator When the evaporator fan motor s has been running without errors for more than 1 hour this alarm is set as inactive and can be deleted Log data Aciv Imactive I
128. ctrical wires Tin plated cables 2 pieces of incorporated hinges 2 pieces of removable evaporator hatches Bolts screws and nuts in stainless steel Single viper peripheral seal Front frame is painted with polyester powder colour Ral 9003 Fresh air exchange is measured and logged in m3 h definition 5 m3 h User Interface Indicator lights Alarm indicator light In range indicator light Alarm In range A SLOW FLASH if there are active NORMAL FLASH when controlling alarms temperature probe is inside the QUICK FLASH if there are fatal e E acceptable range alarms Red Green Constant ON after 30 min in range Both lights only active when the container is connected to a power supply line During power up both lights are shortly illuminated to verify their function A Slow flash is a short flash every 3 sec A Quick flash is a flash every 1 sec A NORMAL FLASH is a flash every 1 sec 26 of 231 pages STARK LOO Operating and service manual Display Setpoint temperature X control 2 Control sensor temperature S Secondary information D icome 3 BBE Icons Jj zu A D Suction pressure V Status text Corp unit Discharge pressure NV scale bar Bi A scale bar J e F Temperature and pressure unit selection Celsius Bar or Fahrenheit Psi FTI Pre Trip Inspection or Function Test is running d Unit is operated in service mode EN Humidity control is activa
129. d clear other valve alarms AL 84X Criteria Temperature indicates cooling None Controller action Alarm light slow Rash Test failed Elimination Alarm may then be deleted after test completed Log data SE TO ol Pas ol See Function test p 16 154 of 231 pages STAR OO Operating and service manual 1 842 Expansion valve Alarm Expansion Valve Fault Cause Indication of non operating electronic expansion valve Trouble Possible causes shooting e Cable for expansion valve mounted on wrong valve e Cable for expansion valve defective e Expansion valve defective e Driver circuit for expansion valve defective Accompanied alarms e N A Trouble shooting 1 Ifthere is more than one valve failure the cables for the valves are presumably switched Mount cables for valves on the correct valve 2 Listen if the expansion valve is opening and closing If not then go to 4 If the valve is opening and closing close service valve pos 14 P I diagr Run FT again If the test now is a pass the expansion valve is defective and should be replaced Check that the cable for the expansion valve is not defective Replace cable if it is damaged Disconnect the cable for valve and measure that there is voltage on the output for the expansion valve when it should open a Ifthere is no voltage the main controller is defective Replace the main controller Pdis more than gt 5 BarE Ma
130. d values does not appear the main controller must be replaced Detailed alarm description In the following all alarms are listed with a description and their causes Alarm text is the text shown in the controller display A cross to the right of Log indicates that the alarm is logged into the data log A cross to the right of alarm indicates that error is shown in the controller alarm list To the right of Light the following texts can be shown Off indicates that the alarm diodes are de energized and there are no active alarms Slow flash indicates that the diodes are turned on shortly every 3 sec and that there are active alarm s Quick flash that the diodes are turned on 0 8 sec every 1 sec and that there is an active fatal alarm s When troubleshooting several alarms it is generally advisable to start with the active alarm that has the lowest number and then go on to the active alarms with higher numbers Remember that some alarms have a time out of 30 sec and more 57 of 231 pages STAR LOO Operating and service manual 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 www mcicontainers com Service Pages alarmlists aspx for latest update Id Display text Description Alarm type Temperature sensor alarms 100 Return Air Temperature Sensor Open Circuit 101 Return Air Temperature Sensor Short Circuit 0 Re
131. e CO2 measurement after calibration PTI is out of range Trouble Possible causes shooting e Sensor measurement out of range from last PTI calibration and CA AV4 is active Accompanied alarms Replacing AL 316 when CA AV is active Al 316 visible in log Trouble shooting 1 Replace CO2 sensor with new After a passed PTI test the CO2 measurement value should be between 0 26 and 0 34 Alarm Controller action Alarm light ERST When sensor is replaced alarm is marked as inactive in alarm list and may then be deleted Log data onmes o jojo fo d 315 Replace O2 sensor Alarm Replace O2 sensor Cause O2 measurement after calibration PTI is out of range Trouble Possible causes shooting e Sensor measurement out of range from last PTI calibration and CA AV is active Accompanied alarms Replacing AL 317 when CA AV is active Al 317 visible in log Trouble shooting 1 Replace O2 sensor with new Criteria After a passed PTI test the O2 measurement value should be between 20 4 amp 21 4 Alarm Controller action Alarm light When sensor is replaced alarm is marked as inactive in alarm list and may then be deleted Log data ama fo o b b 96 of 231 pages STAR OO Operating and service manual 316 Replace CO2 sensor Warning Replace CO2 sensor Cause X CO2 measurement after calibration PTI is out of range Trouble Possible causes shooting e Senso
132. e Motor trouble Warning Alarm Fatal Alarm Fatal Alarm Fatal Alarm Warning Warning Warning Ov OV e pI re o 07 08 o ojo Gi E Alarm pi N Alarm Alarm There have been several FC alarms within short time Evaporator Motor 1 or 2 Overheated several times or permanently within short time Humidity Humidity control deactivated Alarm deactivated Mcond trouble 1 Mevap trouble 20 Cpr start failed 2 Cpr restarted 2 Loss of cooling Loss of cooling CT outrange Manual phase dir Fuse blown Phase Missing 7 Communication alarms FC missing Alarm Alarm Fatal Alarm Warning Warning Fatal Alarm Alarm Warning Warning Fatal Alarm Condenser fan motor overheated several times Evaporator fan motor overheated several times Not implemented yet The Compressor Has Been Restarted Attempts to cool down but Tsup is above Tret Attempts to cool down but Tsup is above Tret Cold Treatment out of range Manually Selected Phase Direction Blown Fuse Phase missing Ov OV o OO o m KA Olm A CJ kA Oo OV OV Ov OV OV WININ rm ojuj c nN r CD CJ N Fatal Alarm 60 of 231 pages STAR OO Operating and service manual 710 Display missing Can only be seen in Star View Warning 711 Display com Reduced communication with display Warning 720 Communication to power module is missing Alarm missing 21 Power module com Communication to power module missing Warning 730 RH
133. e air exchange sensor or its measuring circuitry Trouble shooting Possible causes AirEx is out of calibration Air exchange sensor AirEx or cable defective X23 cable is defective Main controller defective Accompanied alarms e AL 303 or AL 304 may also be active Trouble shooting 1 If the cable by inspection is defective replace cable 2 Calibrate AirEx see Calibration of air exchange sensor p 188 If the value shown in controller is wrong or alarm still active then Disconnect the cable for AirEx on the main controller according to the wiring schematics inside the control cabinet and from the AirEx sensor Mount the cable for AirEx in controller cabinet and on the sensor Disconnect signal wire on main controller Measure voltage between wire and GND on the main controller If the voltage is below 0 2 V DC sensor or connection between sensor and cable is defective If the voltage is between 0 0 V DC and 4 0 V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND If the voltage is between 0 2 V DC and 4 0 V DC and this alarm is still active continue to 5 Check controller see Trouble shooting for Star Cool main controller p 57 before replacing main controller Value above alarm limit 225 m3 hour Value below alarm limit 0 m3 hour Controller action Log data When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Valu
134. e alarm is shown as Acc AAnnn where cc is the list number from 01 to 16 and nnn is the actual alarm number An inactive alarm is shown as Acc IAnnn where cc is the list number from 01 to 16 and nnn is the actual alarm number An active alarm is not deletable from the list but may change to inactive state by eliminating the cause of the alarm An inactive alarm is deletable from the list by pressing during alarm displaying Service Function Setting Viewing ON By pressing DN the service menu is selected The icon appears in the display Service menu consists of various sub menus Use the arrow keys and e to navigate and the Enter key to open a sub menu By pressing Gi the display returns to service menu Service menu consists of the following sub menus Manual operation MO1 M10 Manual start stop of motors etc Datalog view LO1 L04 View of temperature log Time adjust C01 C05 Setting of date and time Run time counters RO1 R07 View of running hours for unit comp etc Configuration FO1 F11 Software version and various configurations Serial numbers NO1 NO8 Serial number for various parts 44 of 231 pages STAR OO Operating and service manual 1 Manual operations MO1 Operating mode Operating mode Function Start stop of operating mode If operating mode is MANUAL controller stops and by means of menu items MO2 to MOS heaters motors and valves may be manually operated In menu item M05 co
135. e are 3 valid phases for the unit There is a fault in the phase direction detection circuit Turn unit off and on again and see if the phase can be detected now If phases still can t be detected replace the power module PCB The main controller is defective Replace main controller Criteria User has manually selected phase direction Elimination when switched to automatic the alarm is marked as inactive and can be deleted Active Inactive Manual phase dir CW CCW 141 of 231 pages STAR LOA Operating and service manual es Blown Fuse for fan motors and heaters Cause Indication of blown fuse Trouble Possible causes shooting e A10 A fuse is blown e Unit has used too much power e There is a short circuit in the power cables used in the unit Accompanied alarms e There may be other alarms Trouble shooting 1 Check the defective fuse in the control cabinet Replace a defective fuse but only once If it blows again there is a short circuit 2 Remove short circuits in the power supply or cables before applying power again Supply voltages U1 2 U2 3 U1 3 are OK Power consumption too high The average current of the 2 highest currents is more than the double of the lowest current of I1 D or I3 Not checked during defrost The evaporator motors must run FC will soon trip with error 516 and stop compressor Controller P P P action Alarm light Deteriorated control precision and capacity
136. e heating elements Reinstall the sensors for evaporator temperature suction temperature humidity Reinstall pos 1 Pump down the unit see Pump down of unit p 198 Charge unit as described in this manual see Charging of refrigerant p 199 191 of 231 pages Operating and service manual STAR COOL es Dismount the upper back plate for the unit and replace the defective heating element After replacing heating elements reinstall back plate for unit Please note that the illustrated model may be different from the actual model Replacement of heating elements 192 of 231 pages STARK LOO Operating and service manual Replacement of FC Position Description The procedure for replacing the FC is as follows Please ensure correct tightening torque is used throughout replacement 1 2 3 4 Remove the cover for FC pos 1 Remove the FC pos 2 and motor cable pos 3 Reinstall motor cable Please observe that the motor cable is not damaged and squeezed be tween compressor and FC Mount new FC Make sure that the FC is mounted correctly on the compressor and that there is no air gap between FC and compressor Reinstall cover for FC and cable room cover 193 of 231 pages STAR LOO Operating and service manual A ii Replacement of compressor Position Description 2 Bracket for compressor 5 eweferrt s WMet
137. e in the display If the measurement differs the power module PCB may be defective Replace or bypass power module PCB by pressing sepsis configuration then phase direction and then cw If condenser fan rotates in the wrong direction choose ccw This action is to be performed at every unit start up 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 action Alarm light Quick flash Alarm will be marked as inactive if another phase voltage measuring is below limit It may then be deleted Log data i em e Active Inactive High limit votas o o U2 3 over voltage Fatal Alarm U2 3 over voltage Cause Indication of error in container supply voltage between phases 2 and 3 Trouble For trouble shooting 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 action Alarm light Quick fash Unit stops Alarm will be marked as inactive if another phase voltage measuring is below limit It may then be deleted Log data mum qum Active Inactive High limit votas Jo o o y 102 of 231 pages STAR OO 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
138. e must be valid for 60 sec to set alarm inactive 94 of 231 pages STAR OO Operating and service manual 306 High press switch Warning High pressure switch is active Cause Discharge pressure is too high and the high pressure switch off Trouble shooting Controller action Possible causes e High pressure due to Ambient temperature is over spec limit 50 C 122 F Manual valve after compressor closed HP pipe damaged Condenser fan motor is not running Condenser blocked High pressure switch or cable is defective Wrong pressure transmitter in relation to controller settings Pressure transmitter defective X15 cable is defective Main controller defective Accompanied alarms e AL 604 may be or get active Trouble shooting 1 The unit uses cooling refrigerant R134a and it is very difficult to operate at temperatures above specification The unit needs cooler surroundings better ventilation or water cooling 2 Ifthe pressure rises very quickly after start of the compressor check that the valve after the compressor discharge side is not closed or only partially open Make sure valve is fully open 3 Check that there are no damages to the pipes after the compressor Repair if they are damaged and check cooling liquid level R134a 4 Check that there are no alarm for the condenser fan motor AL 402 AL 426 and that the fan is rotating and that the condenser is not blocked for airflow 5 If condense
139. e must be warmer Attention Will require a longer duration Close container doors Check and clear other alarms first Check if there is enough refrigerant in the unit Check if the condenser is filled with dirt and blocking air circulation Check if evaporator motors can rotate Watch fingers turn unit off first Check if condenser motor can rotate Watch fingers turn unit off first criteria us USDA measured temperatures are no longer in range None Controller action Already passed treatment time will be reset Alarm will be marked as inactive in alarm list when in range is reached or CT is aborted and alarm may then be deleted Log data Active Inactive CT duration CT remain days 140 of 231 pages STAR OO Operating and service manual Description Manually Selected Phase Direction Cause Indication of insufficient yield or defective controller Trouble Possible causes shooting e The user has selected a manual phase direction 630 Manualphasedr Warning Accompanied alarms e AL 423 should have been active before using manual phase direction has been used Trouble shooting 1 The quality of the power frequency is so poor that the user must decide phase direction Apply valid power supply to the unit Ensure condenser fan is running the right direction if no better power supply is available There is a failure in the power wiring for the unit Check that ther
140. e sight glass of the compressor carefully let out oil until the oil level in the sight glass has reached a mid level 9 Close the suction gauge stopvalve and discharge gauge stopvalve on the service gauge mani fold 10 Disconnect the service gauge manifold 11 Capthe oil outlet from the oil pump 12 Setthe controller to AUTOMATIC operation 13 Run the unit in normal operation 14 Observe the oil level when the unit is running minimum 6 hours in a stable condition 202 of 231 pages STARK LOOL Operating and service manual 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 Example for product name Chem weld product 550 or Castolin RB 5283 Soldering flux Due to the high content of Phosphor in the soldering rod no flux is needed For Copper Stainless connections for water cooled condenser and economiz er Soldering rod L Ag40Cd according to DIN 8513 or B Ag 1 according to AWS A 5 8 Example for product name Chem weld product 511B or Castolin 1802 or 1802 F Soldering flux F SH 1 according to DIN 8511 or FB 3A according to AWS A 5 31 Example for product name Chem weld product 110 or Castolin 1802 N Atmosin 2 Use wet cloths to protect sensitive valves and other equipment against heat inp
141. easuring evaporator motor 1 overheat defective e Main controller defective e Damage on cable for Mevap 1 Accompanied alarms e N A Trouble shooting 1 Turn off unit Open inspection hatch and see if the evaporator fan can turn freely If it cannot turn remove ice or replace the motor If the motor is hot it may be overloaded and jammed or defective If the cable for Mevapi by inspection is defective if unable to repair cable replace it Disconnect the wires for Mevap1 on the main controller according to the wiring schematics inside the control cabinet Measure the resistance in the cable If the resistance is more than 1 MQ the cable or the motor is defective and should be replaced If the resistance is less than lt 5 kQ the cable and motor should be OK Turn unit on again Measure the voltage across the connector for Mevap1 It should be between 4 80 V DC and 5 20 V DC a If the voltage is inside the above range connect cable again Measure the voltage across the thermistor and check the voltage If the voltage is less than 2 5 V DC the measurement is OK If the alarm after 30 sec is still active in the display the main controller is defective replace main controller If the voltage is outside the range main controller is defective or another error might affect the voltage Check other alarms before replacing main controller Criteria Value above high alarm limit 10K Ohm Both evaporator fa
142. ectly and therefore the cooling contact between the FC and the compressor is not good enough Check the motor cable and replace it if it is defective Fasten bolts properly for better cooling 3 The compressor is wearing down and drawing increasingly power from the FC Check other alarms if there have been more alarms from the FC a If the ambient temperature is not high the compressor must be replaced If the ambient temperature is high the compressor and FC should be OK but close to operating limit Monitor unit and see if problem continues 4 The FC is defective and must be replaced If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria FC load has exceeded warning limit of 24 Amp None ad Alarm light If not solved this problem can cause FC to stop due to AL 513 Warning will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data i Active Inactive Freq FC 123 of 231 pages STAR LOO Operating and service manual Les 529 FC setup error Warning The setup of the FC is rejected by the FC Either communication problems or phase fault Trouble Possible causes shooting e Defective FC A37 Accompanied alarms e There may be other AL 5XX alarms Trouble shooting 1 The FC reports a failure in its factory setup data See if there should be other FC alarms AL 5XX and if t
143. ediate Valve oo Evacuation Valve Oil Pump Cover HexHead Bolt M8 Jo o Pressure Transmitter Aks HexHead 18 Pressure Transmitter NSK_ HexHead 14 High Pressure Switch HexHead U U a O O OO OOOO O OOOO OO Water Outlet Coupling Male brass HexHead TO Evacuation Vekene neng ls Evaporator Cover Plate Hex Lobular Tapping Screw 04 8 5 o Evaporator Cover Plate Tsactonet em ATER molar Screw 94 0x16 Aix potentiometer Screw 04 0x25 214 of 231 pages Hex Lobular Tapping Screw 24 8 STARK LOOL Operating and service manual Controller Unit Illustration gj NS AE de CD 28 Retreiver Socket Cap 2 Retreiver Socket 26 USDA Socket Cap 25 JUSDA Socket 24 Sensor CO2 23 Sensor 02 22 Humidity Sensor X HUM digital 21 Pressure Transmitter 0 30 Bar 20 Pressure Transmitter 0 69 9 8 Bar 9 Solenoid Coll 10W 24 VAC Motor Fresh Air Air Exchange Potentiometer Temperature Sensor 18 m High Pressure Switch RMM Slave Modem York Duo Termina Transformer 105VA Battery Pac Fuse 400mA On Off Switch incl cable
144. elease 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 1 of 231 pages STAR ZOQL Operating and service manual Contents Ptreta ge 1 Warning Siene M 1 IR Lu EMO OLLI 6 General description see mr RA EE eb ER SE de ES EE e lice d iia eai P aa Ra X di d eege AE 8 FUNCTION descriptio eer i oa aa a ae a aas 9 Stant up EENEG DEE EE E N 9 Climate Control Rule e BEE 10 TEMpPerature Control ee E 10 Capacity Control ang EITTlEe EE 10 El Een mrt EP MN 11 EGONOMIZEr VaIVG MEC eM 12 DehumidificatiOEi iara SEENEN pesas ese ERNEST EE EES SER SEELEN E EE E REEE 12 CONAENSEM FAN T TETTE 13 Evaporator Bali BEE 13 Defrost FUNCTION e P 13 QUEST Optional EE 15 Re De te UE 15 Vic oreo errr RA TEILT I ec eter reer eric UI DII 15 FUNCE ON TESE e E E Ea S EnaA 16 BUI PWD E 17 haga Q 17 BIET ere ILI OI I I
145. emperature table Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check Trouble shooting for Star Cool main controller p 57 before replacing main controller Criteria Activated by UWS or AL 901 Replacement by new value from AAS system Controller P y y action Alarm light If activated Cold Treatment CT it will be affected When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data Acive Imctive o LI TI 74 of 231 pages STAR OO Operating and service manual 1112 Tusda2 open Warning USDA 2 Temperature Sensor Open Circuit Cause Indication of loose connection defective or lack of USDA 2 temperature sensor Trouble Possible causes shooting e Temperature sensor Tusda2 or its cable defective Defective plug inside or cable on the unit backside e Main controller defective Accompanied alarms e N A Trouble shooting 1 Same trouble shooting to be used for Tusda2 as used for Tusdal in AL 109 Value below low alarm limit 60 C 76 F and the sensor reading has been in the valid area since power up None action Alarm light Consequence May be incomplete USDA data logging If activated Cold Treatment CT it will be affected When sensor value becomes valid it is marked
146. en be deleted after test completed Log data i 161 of 231 pages STAR LOA Operating and service manual 880 PTI Tset 18 Alarm PTI 18 C Set Fault Cause X Indication of insufficient performance Trouble Possible causes shooting Doors are open There may not be enough refrigerant in the unit The cooling capacity is too limited Hot gas valve leaking Accompanied alarms e N A Trouble shooting 1 Verify that the doors are closed 2 The unit may need refrigerant Check if the small red balls in the sight glass in the receiver receiver tank are not at the bottom when the unit is turned off Refill with refrigerant Hot gas valve is leaking Feel both sides before and after the valve there should be a temp diff in this case Criteria Setpoint 18 C was not reached within the 3 hour time limit None Controller action Alarm light slow fash Test failed Elimination Alarm may then be deleted after test completed Log data Controller Alarms AL 9XX Description Description User stop was executed from PC program Criteria User stop was executed from PC program Controller action Alarm light Quick flash Unit stops User stop may be deleted from alarm list by means of keypad or PC program Unit will then restart Log data Active inactive EE 162 of 231 pages STAR OO Operating and service manual 1 902 Battery malfunction Alarm B
147. er is defective Replace the main controller Criteria Tsuc not changed at least 10 C 50 F when opening economizer valve a certain time None Controller Elimination Alarm may then be deleted after test completed See Function test p 16 156 of 231 pages STAR OO Operating and service manual 1 Description Hot gas valve Alarm Hot gas Valve Fault Cause Indication of non operating hot gas valve Trouble shooting Controller action Possible causes Cable for hot gas valve mounted on wrong valve Cable for hot gas valve defective Hot gas valve defective Driver circuit for hot gas valve defective Accompanied alarms e N A Trouble shooting 1 If there is more than one valve failure the cables for the valves are presumably switched Mount cables for valves on the correct valve 2 Listen if the hot gas valve is opening and closing if not go to step 4 If the valve is opening and closing disconnect power to the solenoid coil when the valve is closed and there is hot temperature after the valve pos 32 in the P I diagram the hot gas valve has a leak and should be replaced Internal parts of the hot gas valve can be replaced separately Check that the cable for the hot gas valve is not defective Replace cable if it is damaged Disconnect the cable for valve and measure that there is voltage on the output for the hot gas valve when it should open a
148. eted Parm 5 Log data Active Inactive Freq FC FC AL number 599 FCTripLock _ Log The FC has tripped and stopped Cause Alarm indicates problem with compressor or frequency controller Possible causes shooting e Other alarms have tripped stopped the FC e Defective FC Accompanied alarms e There is another alarm s especially AL 5XX alarms Trouble shooting 1 The FC has tripped due to another AL 5XX alarm and then stopped See if there should be other FC alarms AL 5XX and act accordingly to these 2 Turn the unit off for 10 min and then start it again If this alarm becomes active again the FC may have an internal fault and must be replaced If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria The FC has stopped due to an error and must be reset FC i i t E tog JN Jaam Alarm light There is no cooling until the FC is ready again The FC may need to cool down before restarting Log data s Active Inactive Freq FC 125 of 231 pages STAR LOO 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 Alarm indicates that all control relevant sensors are defective or unreliable See also Temperature control p 19 and Expansion v
149. etpoint Treatment setpoint Function Setting of the setpoint during the treatment Value Value 10 0 C to 30 0 C The setpoint must be chosen so that all USDA sensors show a temperature below the maximum USDA temperature during treatment 42 of 231 pages STAR OO Operating and service manual 1 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 sign on the main menu disappears BO5 Status of cold treatment program CT status Function Shows status of the CT program Value Values Not active Active Aborted Pass Done Fail The Cold Treatment program stops automatically if the unit has been powered off for more than 48 hours Function The bottom line shows the temperatures of USDA sensors 1 3 and the cargo sensor Value Actual temperature measured of the sensor 70 C indicates that the sensor is not mounted Check alarm list to see if there should be an USDA alarm Alarms The alarm list holds all active and inactive alarms By pressing the alarm menu is opened The icon is displayed in upper left corner of the display With any alarms in the list t
150. ettings NSK AKS e Pressure transmitter or high pressure switch defective Accompanied alarms e AL 207 AL 611 and or AL 845 Trouble shooting 1 Manually select the type of pressure transmitters in the configuration on menu F07 and F08 2 If AL 845 is accompanied see trouble shooting for AL 845 The saved Frecuency Converter ID does not match the new Frecuency Converter ID in the controller Replacement by new value from AAS system Controller P y y action Alarm light The unit will continue operation with AAS value The operator has to manually select the type of pressure transmitters in the configuration on menu F07 and F08 Log data Active Inactive LP Type HP Type 90 of 231 pages STAR OO Other Sensor Alarms AL 3XX 302 RH invalid Log Cause Indication of defective relative humidity sensor or its measuring circuitry Trouble Possible causes shooting e Relative humidity sensor RH or cable defective e X10 cable is defective e Main controller defective Accompanied alarms e AL 300 or AL 301 may also be active Trouble shooting Disconnect the cable for RH on the main controller according to the wiring schematics inside the control cabinet and from the RH sensor 1 Ifthe cable by inspection is defective replace cable 2 Dismount the sensor from the cable Dismount the cable terminals from the controller Measure the resistance between the terminals at the controller e
151. etween the two wires a If the resistance is out of range of the resistance and temperature in Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check Tables p 203 before replacing main controller Value below alarm limit 60 C 76 F or above 140 C 284 F Value must be invalid for 30 sec for alarm activation Replacement by new value from AAS system Controller action Alarm light Superheat control deactivation When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data p Acive Iacive o TI y 84 of 231 pages STAR OO Operating and service manual 127 Tamb open Warning Ambient Temperature Sensor Open Circuit Cause Indication of loose connection defective or lack of ambient temperature sensor Trouble Possible causes shooting e Temperature sensor Tamb or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 129 Trouble shooting 1 Same trouble shooting is to be used for Tamb as used for Tret in AL 100 Criteria Value below low alarm limit 60 C 76 F Replacement by new value from AAS system action Alarm light No consequence as to control When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data
152. f there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24 V DC and 5 V signals to see if power supply has an open circuit or other damages If voltages are OK the main controller is defective Replace main controller Criteria Reference voltage above 5 50 V DC action o x Mam mm Less accurate readings from measurement from sensors X22 and X23 Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data mp The measured voltage is internal on the main controller and cannot easily be measured 173 of 231 pages STAR LOA Operating and service manual A ii AirExMot sup LO Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective sensor pulling power supply down e Defective main controller Accompanied alarms e There may be sensor alarms AL 3XX e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Access the special menu by pressing Ki for more than 3 sec Scroll down until you see the label U Motor pos in the display The value of U Motor pos should be in the range between 4 50
153. g and service manual 1 Controller Internal Voltage Reference Fault Trouble Possible causes shooting e Power supply for main controller is not sufficient e Main controller defective Accompanied alarms e Check for AL 951 up to AL 996 e There may be other accompanied alarms Trouble shooting 1 See trouble shooting for accompanied alarms If none appears then proceed with 3 2 Clear other active sensor alarms 3 The power supply or power cable for main controller defective Measure voltage for the main controller a If voltage is OK the main controller is defective and main controller must be replaced Measure voltage for all sensors Should be between 4 80 V DC and 5 20 V DC for temperature and pressure transmitters Humidity sensor must be between 12 00 V DC and 34 00 V DC If not OK the sensor or cable is defective Replace sensor Measure outlet on transformer between T3 and T4 Correct range 15 30 V AC 24 30 V AC Measure between T5 and T6 Correct range 18 86 V AC 30 00 V AC If within range transformer is OK d Replace main controller Criteria One or more of the internal reference voltages are out of limits FC will soon trip with AL 516 and stop compressor action Alarm light Slow flash Test failed Elimination Alarm may then be deleted after test completed Log data 149 of 231 pages STAR LOA Operating and service manual Unit idle overcurrent fault Trou
154. g for Star Cool main controller p 57 before replacing main controller Value is below alarm limit 609C 76 F or above 140 C 284 F or difference between Tsupi and Tsup2 is more than gt 1 C 34 F for 30 min Value invalid for 30 sec for alarm activation Repl EIE eplacement by new value from AAS system action Alarm ep Consequence Deteriorated control precision in the chill mode When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data 69 of 231 pages STAR LOO Operating and service manual am 1106 Tsup 2 open Warning Supply Air Temperature Sensor 2 Open Circuit NE Indication of loose connection defective or lack of supply air temperature sensor Trouble Possible causes shooting e Temperature sensor Tsup2 or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 108 Trouble shooting 1 Same trouble shooting is to be used for Tsup2 as used for Tret in AL 100 Criteria Value below low alarm limit 609C 76 F Replacement by new value from AAS system Controller action Alarm light Deteriorated control precision in the chill mode When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data Tsup 2 short Warning Supply Air Temperature Sensor 2 Short Circuit Cause
155. g the unit on again If the compressor cannot run or runs very shortly before this alarm appears again the compressor is defective and must be replaced If the compressor can run several min without alarm the FC may be defective and must be replaced if the alarm appears again If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria Motor current above 24 Amp for approx 10 sec None Controller Ee Alarm light If not solved this problem can cause FC to stop due to alarm 511 Warning will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Active Inactive Freq FC 122 of 231 pages STAR OO Operating and service manual 1 525 FC overload Warning FC Overload Warning Cause Indication of problems with compressor Trouble Possible causes shooting W9 e The FC cannot supply enough power to the compressor e Insufficient cooling for the FC e Defective FC Accompanied alarms e AL 522 or AL 525 may also be active and should be checked first Trouble shooting At very high ambient temperatures and very low setpoint temperatures the FC may get too hot to generate enough power 1 Check that all bolts fixing the FC to the compressor are fastened and nothing is jammed between the FC and the compressor 2 The power cable for the compressor motor Mcpr may have been mounted incorr
156. ge up press or down press Y to list the previous or next page of stored set of values from the data log LO3 Viewing log of temperatures Graph Function Viewing of logged temperatures Press D on the main menu to get directly to this menu Value The following data can be viewed Setpoint temperature supply air temperature return air tem perature USDA 1 2 3 temperatures and cargo temperature When entering the menu the newest logged temperatures are always shown The number under the text Ref shows the temperature at the 4 mark ex 5 C Press m 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 Press up 4 or down e to show newer or older stored set of values from the data log Press to change between the 4 zooming levels The blank and black bar at the right most edge shows a scale of 1 C per Bar 46 of 231 pages STAR OO Operating and service manual 1 Time adjust CO1 Setting of year GMT Year Function Setting of year Value Set from 1999 to 2099 C02 Setting of month GMT Month Function Setting of month Value Set from 1 to 12 C03 Setting of day GMT Da Function Setting of day Value Set from 1 to 31 C04 Setting of hours GMT Hour Function Setting of hours Value Set from 0 to 23 CO5 Setti
157. h own indexes Only the primary status for a PTI test is memorized when supply voltage is removed When PTI is initiated a Trip start is set in the data log 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 Note If there is too much liquid in the compressor house before compressor test part of the function test the compressor test will fail because of high intermediate pressure This liquid needs to be evaporized Let the unit run under normal conditions for 10 min and activate PTI or function test as usual after this Function test includes the following items PTI init Controller test Power check Evaporator fan Mevap Condenser fan Mcond Heating element Hevap Probe check Compressor FC valve test Vexpansion Vhotgas and Veconomizer test descriptions as fol lows Test description steps Passing conditions No Compressor Max duration 5 min High pressure switch test Reached within max 5 min 20 Bar lt Pdis lt 24 Bar Pump down test If error AL250 ONAUARWNE Reached within max 5 min Tc TO gt 20 C If error AL845 81 Valve leak Max duration 5 min TOdiff 25 9C All valves reed valves included If error AL840 82 Vecon Pfc gt Pfc stabile 10 40 Testing capacity 30 C 20
158. he icon is displayed on the main menu Alarm handling is to protect the unit with cargo and inform the user in case of error conditions The main priority is to keep cargo safe Alarm handling is split in 2 parts 1 Detect an abnormal situation and report it as an alarm 2 React on the alarms and compensate for them AAS Alarm Action System An alarm can have 4 different levels Log Information for service Only in the datalog not on the display No risk for the cargo Warning Warning of an abnormal situation but the unit continues to operate with unchanged or little change in functionality in actual running mode No risk for the cargo Alarm The unit operates with reduced or changed functionality Risk for the cargo Fatal Alarm The unit needs service now Serious risk for the cargo All errors in the 4 levels can have two states Active or Inactive Active The alarm is active Inactive The alarm is no longer active The alarm can be acknowledged from the alarm list The 4 alarm levels will be treated by the controller in the following way 43 of 231 pages STARK LOOL Operating and service manual Alarm type Datalog Alarm list Red LED Cargo risk No OFF No risk for the cargo No risk for the cargo Yes Yes Alarm SLOW FLASH Risk for the cargo 2 ON 98 OFF Duty time of 3 sec Fatal Alarm Y Yes QUICK FLASH Serious risk for the 80 ON 20 OFF cargo Duty time of 1 sec Alarm h
159. hey can be removed first 2 Turn the unit off for 10 min and then start it again If this alarm becomes active again the FC has a permanent internal fault and must be replaced If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria FC error reports its setup data FC shut down Controller action Alarm light The compressor will not start Warning will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data 566 FCundefined alarm Warning FC Undefined Alarm Cause X The FC has an undefined alarm warning Trouble Possible causes shooting e Defective FC e Defective power cable from FC to compressor motor Accompanied alarms e There may be other AL 5XX alarms Trouble shooting 1 The FC reports an undefined alarm warning See if there should be other FC alarms AL 5XX and if they can be deleted first 2 Turn the unit off for 10 min and then start it again If this alarm warning becomes active again the FC has a permanent internal fault and must be replaced If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria FC reports an undefined alarm FC shut Controller SES 124 of 231 pages STAR OO Operating and service manual 1 Warning will be marked as inactive in alarm list when reset by FC Alarm may then be del
160. i Water temperature max cooling cap 30 C 86 F 227 30 2 l min 6 8 gal m above flow rate Connections Inlet Hansen B 66 or equivalent Outlet Hansen B8 HP36 VAA or equivalent Condenser tubing Cu Ni 90 10 Water specification Fresh water or Salt water without free chlo rine Defrosting Defrost initiation On demand defrost Defrosting interval The on demand defrost system is constantly monitoring the temperatures for the evaporator in order to prevent that the evaporator will block up with ice If a blocking up of the evaporator is registered by the system a demand defrost will be initi ated The minimum time between defrost is always 4 hours but it is adjusted to the actual set point Defrosting method Hot gas combined with electrical heaters 23 of 231 pages STAR LOO Operating and service manual a Fresh air exchange Fresh air exchange Adjustable 0 220 m3 h 0 121 CFM at 60 Hz adjustable by steps of 5 m3 h Equivalent to 0 170 m3 h 0 100 CFM at 50 Hz AV controlled optional 0 30 m3 h 50 Hz controlled by the controller 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 Incorporated in receiver sight glass Material Brass acc to EN 12164 CW602N Solid
161. ia nra 98 Frequency Converter FC Alarms AL BXX iiii iesus assai ne sut usaesa kx REENEN RR Ra NR RI eddy sa R4 ga g YN a RR RF AG a A ENEE radi 110 Operation Alarms AL6X9X iiseceesues cesat ege geRENEAR RER EENS tin r4 R4 DER SR IR REESEN CPSK RE TSERAId ARR RR GGG OG RESET E TUR ENER 126 Communication El CA DEE 143 Test Alarms AL 8XX J eg ed uns suse EE ee CEN saad NND deene Eege 148 Controller Alarms AL OXX eeneg eeneg eE eege nahen E Re kae pavo arda SNES EAR ae ENEE a REFERRE RIFERRIRIPR RA RR EEN 162 Calibration of air exchange sensor ene hehehe re nnne mee ere E a eines nnn 188 Sensor calibration using Star VieW sorsien cites AER dE EEN gegen 188 Replacing OF Umit iscsi EE 189 Replacement Evaporator motor and tan 190 Replacement Condenser motor and tan 190 Replacement of evaporatot EHNEN EESEEA EE SEENEN ENER EAR EAA DEER KETONEN EES NEE EEN ENEE ge 191 Replacement Of onec UT 193 Replacement of compressSOr iens KEEN he sa a ARR RERRRRNRRERERENRRRARRRRRSRARRT SR XRYaR Rire YR Rd TR EEN ENER SEENEN 194 Replacement of compressor valve plate cylinder head oasket sss 195 Service and RO EH TEE 196 Evacuation of refrigerant esee tese EEER need sata eR ERAN SEENEN EES dE RSRAYEA REMIS RRRERIKRXI RE RETE KR EEN SEN 196 Compressor pump GOWN operatio Meiere eunero ceieocx sit dosi a senes Mande seu pn Ae matres Rau PE ABE AEAEE DE 196 Compressor pump down TE EE 197 PUMP GOWN OF HR TRIE
162. id USDA 3 Temperature Sensor Invalid Indication of defective supply air temperature sensor or its measuring circuitry or sensor not mounted correctly in unit Trouble Possible causes shooting e Active alarms AL 115 AL 116 or AL 901 if CIM5 software e Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F Accompanied alarms e AL115 AL 116 or AL 901 may also be active Trouble shooting 1 If alarms AL 115 or AL 116 are active check their trouble shooting section first 2 If AL 901 is active see trouble shooting for AL 901 3 Disconnect the sensor cable for sensor Tusdal from the connector on the main controller according to the wiring schematics inside in the control cabinet 4 Measure the resistance between the two wires a Ifthe resistance is out of range of the resistance and temperature table in Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check Trouble shooting for Star Cool main controller p 57 before replacing main controller Criteria Activated by UWS or AL 901 Replacement by new value from AAS system Controller P y y action Alarm light If activated Cold Treatment CT it will be affected When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data
163. id KE r D D ld 2 SS Hor i005 Sis i Ga z episino pP T 5 GEI esch Bee E mas E B v n 1IU941n249A0 ze vum NI H3MOd Ly LSO 220 of 231 pages STAR OO Operating and service manual DS eu ZLPO9GLSZS N d S S9IUOJIoO9 9 wepo ogeuieuos DuuiM IEISAC SOLO9SLS88 999S 1007 9 amp 20 ELS xog 4eJ o4uo2 episino xog 4eJ 04 u0z episu jeuondo Hos NaS zoo HH Lr T CY HA COIN co xog 4ejj04u02 episino ieyeq e qeoBueuoeu HIN AZL peu Lig TR Xd obeo WI XL 102 24 Xd woo WWe N XL Xd ONE Xd ONE I ae NO bp no z dis Laus a 07 puooy c en h ial v S S H PUN ang ou Et SM FF OT denen anal 9 m 91 QNO x INON oe C t 099A ONE dean C t dran TNS BuA Bu t ONS xau ay ano o Sp T Z Owi 9 NOV 1 ou fe LN Be Z xxi z ano 8 ole ex ZX m sna D waa z daa QNO Y Sx vx on axa 1 z axi axi 2 og QNO AX 9x on vfi z ax g z og ano _ 6X 8X aer nzi T 2v vi a git v QNO QNO v S NO vol LLX OLX T uMd uMd T z Joe ano z X eX L wNois west z wNOIS av9 z SLX YIX T uMd uMd 1 z ou oe z uMd uMd v QNO QNO S uMd uMd S 9 og Q
164. il level is below sight glass after a period of minimum 6 hours normal operation additional oil may be added as described in this manual Note Do not overfill the compressor with oil Check if the oil level of the compressor is equivalent to the oil level after running 6 hours at set point in a steady condition 1 3 to 2 3 sight glass full Due to dissolved refrigerant the oil level shown in the compressor sight glass may be too high if the unit has not been running for a longer period of time In that case e Let the unit run for 20 minutes with set point below cargo set point e Turn off the compressor and check the sight glass e If the oil level is still too high remove oil until 1 3 to 2 3 sight glass full is obtained In case the oil level is too low in the sight glass e Run the unit at a set point above the cargo set point for 20 minutes e Then let the unit run for 20 minutes above cargo set point e Turn off the compressor and check the sight glass e If the oil level is still too low add oil until 1 3 to 2 3 sight glass full is obtained 201 of 231 pages STAR OO Operating and service manual 1 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 Pump down the compressor as desc
165. inactive in alarm list when reset by FC Alarm may then be deleted Log data a 7 Active Inactive Freq FC 115 of 231 pages STAR LOO Operating and service manual L ii big FC phase loss Alarm FC Phase Loss Fault Alarm Cause X Indication of lack of phase or defective FC Trouble Possible causes shooting A4 e One or more phases are not applied to the FC e Unstable power supply generator e Defective FC Accompanied alarms e AL 523 e AL 417 AL 418 AL 419 may be active Trouble shooting 1 Verify that all 3 phases are present and voltage is correct 2 Verify that voltage difference between the 3 phases is less than 20 V AC 3 If supply from the generator is unstable adjust supply frequency to 50 55 Hz see Info Menu Viewing p 36 I22 to avoid self oscillation 4 If 1 to 4 do not solve the problem then replace the FC If no FC replacement is available the unit can be rewired for emergency operation Remind to use oscilloscope for determination of unstable supply from generator caused by uneven torque on generator cylinders FC cannot maintain DC filter voltage or too much ripple in DC voltage AL 523 has been active for more than 50 sec FC shut d Controller STEEN n ies Le a an BEER Slow flash Consequence uence Unit unt stop Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data p R Active Inactive
166. ing has been in the valid area since power up None Sc Alarm light May be incomplete cargo data logging When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data Active Inactive High limit Present 79 of 231 pages STAR LOA Operating and service manual 120 Tcargo invalid Cargo Temperature Sensor Invalid Indication of defective supply air temperature sensor or its measuring circuitry or sensor not mounted correctly in unit Trouble Possible causes shooting e Active alarms AL 118 AL 119 or AL 901 if CIM5 software e Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F Accompanied alarms e AL 118 AL 119 or AL 901 may also be active Trouble shooting 1 If alarms AL 118 or AL 119 are active check their trouble shooting section first 2 If AL 901 is active see trouble shooting for AL 901 3 Disconnect the sensor cable for sensor Tusdal from the connector on the main controller according to the wiring schematics inside in the control cabinet 4 Measure the resistance between the two wires a If the resistance is out of range of the resistance and temperature in Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check Trouble shooting for Star Cool main controller p 57 before replacing main
167. ion with RH sensor broken Defective RH sensor X10 cable is defective Main controller defective CO2 sensor defective for some models O2 sensor defective for some models Accompanied alarms e AL 302 or one or more AL 9XX may also be active Trouble shooting 1 2 3 4 5 Verify that cable RH com is mounted correctly and is not damaged according to wiring diagram inside the controller cabinet Verify that plugs are properly connected Verify that there are correct voltages 12 V DC between 1 and 4 on X10 or between 1 and 2 on X73 If model has CO2 and or O2 sensor see troubleshooting for AL 740 and or AL 760 in Operating and service manual Controlled Atmosphere Measure with a multimeter that there is a small DC signal between 2 and 3 on X10 and between 2 and 3 on X75 a If there is no signal The main controller is defective and must be replaced b If there is signal The RH sensor is defective and must be replaced Criteria Communication with RH sensor not possible Controller action Dehumidification is overruled Dehumidification is impossible and dehumidification will stop When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data Active Inactive o In O Emorcod 147 of 231 pages STAR LOO Operating and service manual es RH sensor com Warning RH sensor communication reduced Not yet i
168. ist when supply voltage is correct Alarm may then be deleted Log data mm A TE 965 Controller sup LO Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective main controller Accompanied alarms e There may be sensor alarms especially AL 1XX and AL 2XX e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 The main controller is defective Replace the main controller Criteria Reference voltage below 4 50 V DC None Controller action Hs p m em Less accurate readings from measurement from sensors X22 and X23 Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data ERE ERE 172 of 231 pages STAR OO Operating and service manual 1 966 Controller sup HI Warning Description Controller Internal Voltage Reference Fault Cause X Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective main controller Accompanied alarms e There may be sensor alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check i
169. itter If U Psuc is still outside the above range proceed to next step While displaying U Psuc disconnect Pdis from the terminals according to wiring schematics inside in the control cabinet f U Psuc is now inside the above range the cable for Psuc is defective Mount connector correctly or replace connector cable for Psuc If the correct voltage is measured at X22 then circuit is defective Replace the main controller Criteria Reference voltage Psuc below 4 50 V DC None action us p om mim Less accurate readings from measurement Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data m 171 of 231 pages STAR LOA Operating and service manual m 964 Psuc sens sup HI Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective main controller Accompanied alarms e There may be sensor alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 See Trouble shooting for AL 963 Criteria Reference voltage Psuc above 5 50 V DC None Controller did over jo 1 See Lr U Alarm light Consequence Less accurate Less accurate readings from measurement from measurement Alarm will be marked as inactive in alarm l
170. ked as inactive in alarm list when reset by FC Alarm may then be deleted 119 of 231 pages STAR LOA Operating and service manual A ii Log data Active Inactive Freq FC 522 FChightemp stg FC Overtemperature Warning Cause X Indication of problems with compressor or FC Trouble Possible causes shooting e FC operates at operating limits W36 e Insufficient cooling for the FC e Defective FC Accompanied alarms e None Trouble shooting 1 Verify that supply voltage is not too high 2 Check that the FC is mounted and tightened correctly to the compressor If the FC is mounted correctly it should not be possible to insert an air gap gauge between FC and compressor 3 Motor cable between FC and compressor may be jammed between FC and compressor Cooling of FC is insufficient If this alarm appears more than once Dismount FC and check motor cable before mounting the FC again Fasten bolts properly for better cooling If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 Criteria FC temperature has exceeded warning limit 78 C None Controller action Alarm light If not solved this problem can cause FC to stop due to alarm 517 Log data Active Inactive Freq FC 120 of 231 pages STAR OO Operating and service manual 523 FC phase loss Warning FC Phase Loss Fault Warning Cause _ Indicatio
171. le underneath the bottle for measuring the amount of recycled refrigerant 3 Close 4 turns only service valves pos 5 and 26 P amp I diagram Pos 30 still full open 4 Replace the electrical coils with permanent magnet on pos 16 and 18 P amp I diagram 5 Check that the Recovery unit is set for Vapor recovery 6 Open both service gauge manifold valves LP HP 7 Start and operate the recovery unit as long as necessary to evacuate desired amount of refrigerant from the unit until there is no pressure left slight vacuum Close the service gauge manifold LP HP valves Connect a Vacuum pump and start 10 Open the service gauge manifold LP HP valves 11 Continue vacuum pumping for at least 2 hours 12 Switch off the vacuum pump and close all service gauge manifold valves 13 Observe the vacuum for minimum 0 5 hour 14 Ifthe vacuum is maintained then the unit can be charged as described in this manual 15 Ifthe vacuum is not maintained there is a possible leak somewhere 15a Open all service valves complete pos 5 26 and 30 P amp I diagram 15b Start the vacuum pump open all service gauge manifold valves run to max vacuum There is no connection to the unit only your tools are checked 15c Close only the service gauge manifold valve which connects the vacuum pump 15d Switch of the vacuum pump 15e Observe the vacuum for minimum 0 5 hour if the vacuum is OK the SC unit has a leak 15f Checking for leak
172. lose the stop valve pos 14 P amp I diagram Energize the fans and the compressor Carefully open the stopvalve pos 14 P amp I diagram observing the pressure readings on the service gauge manifold as this is done 8 Fora setpoint temperature of 20 C 4 0 F a suction pressure of 24 C 11 2 F is to be maintained In general the suction pressure temperature is to be 5 C 7 F below the set point temperature In general the discharge pressure temperature is to be 10 C 18 F above ambient temperature 9 If there is ice building up on the compressor it indicates that there is coming to much liquid back from the evaporator Close the stopvalve pos 14 P amp I diagram slightly Mou External interfaces The Star Cool controller can be accessed externally in the following ways l j l RefCon I 4 RS 232 Side Powerline Master RS 48 I RCCU 6 modem I modem l i l Controller l Ea I SS EES Retriever l LogMan LogView i RS 232 socket i RS 232 PC e I bj dad ed cdd anaes RS 232 Binary StarView software file PC With CRC General requirements 1 Serial port setup is 19200 8 N 1 2 Unless otherwise stated byte order is low byte first 52 of 231 pages STAKSkZO0L Operating and service manual List of terms used for external interfaces Description Local Monitor serial communication port on the container unit Hand held datalog retriever te
173. manual for some time Stop compressor and see if the suction pressure rises more than normal If valve is defective replace valve Criteria Tset unreachable within time limit None action Arm Tight Slow Rash If error is detected during PTI test PTI test will fail Alarm will be marked as inactive in alarm list when Tset is reached Alarm may then be deleted Log data 2 Active Inactive Il LI 128 of 231 pages STAR OO Operating and service manual 1 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 defective Not enough refrigerant for the compressor Insufficient airflow though evaporator Insufficient airflow though condenser Defective hot gas valve leaking Accompanied alarms e Other alarms may be active Trouble shooting The unit will continue the cooling but the next steps could be checked anyway 1 If other alarms follow troubleshooting for these alarms 2 Check container doors and gaskets Check if there is enough refrigerant in the unit Check if the evaporator is filled with ice or dirt blocking air circulation Check if evaporator motors can rotate Watch fingers turn unit off first Check if the condenser is filled with dirt and blocking air circulation Check if condenser motor can rotate Watch fingers turn unit off first
174. mplemented Cause Indication of defective RH sensor or lack of or improper connection Trouble Possible causes shooting Communication with RH sensor broken Defective RH sensor X10 cable is defective Main controller defective CO2 sensor defective for some models O2 sensor defective for some models Accompanied alarms Trouble shooting 1 Further description to follow upon implementation Criteria Communication with RH sensor not possible Dehumidification is overruled Controller SC flog x Jaam X jAlarmlight Slow flash Dehumidification is impossible and dehumidification will stop EL When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted GE po Jo jo Jo Test Alarms AL 8XX Func test failed Alarm Trouble Possible causes shooting e One or more of the individual test steps have failed Accompanied alarms e 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 Controller action Alarm light Slow flash Deteriorated control precision and capacity When currents are normal it is marked as inactive in alarm list and may then be deleted Value must be valid for 30 sec to set alarm inactive Log data R Active Inactive EP 148 of 231 pages STAR OO Operatin
175. mpressor Discharge Pressure Transmitter Open or Warning Short Circuit Compressor Discharge Pressure Transmitter Invalid Compressor Suction Pressure Transmitter Open Circuit Compressor Suction Pressure Transmitter Short Circuit ele hk NIO N ele e N ejeje NIN uj BR w N ele COIN 201 Pdis short 202 Pdis fault LA Pdis invalid Psuc open Psuc short 58 of 231 pages STARK LOOL Operating and service manual 206 Psuc fault Indication of loose connection short circuited defec Warning tive or complete lack of compressor suction pressure transmitter Psuc invalid Compressor Suction Pressure Transmitter Invalid Warning Press sensor type Wrong Suction Pressure Transmitter Alarm RH invalid AirEx No connec tion 304 AirEx short 07 5 gu e o Oth N OD S Uu D Uu o Uu Relative Humidity Sensor Invalid Air Exchange Sensor Short Circuit Warning 03 Warning LA Ww S Air Exchange Sensor Short Circuit Not implemented yet Air Exchange Sensor Invalid Not implemented yet High pressure switch is active Replace CO2 sensor Warning g 05 AirEx invalid 306 High press switch 314 Replace CO2 sen sor 315 Replace O2 sensor 316 Replace CO2 sen sor 317 Replace O2 sensor Power alarms 0 Evaporator Motor 1 overheat 0 Evaporator Motor 2 overheat 0 Condenser Motor overheat il Power supply unstable 23 Unit overcurrent 1
176. mpressor frequency is set In case of no keyboard activities for 5 min manual mode is automatically deactivated and unit starts automatically up AN hat the Star I shoul nl in the manual m rain rvi personnel Value Set to MANUAL or AUTOMATIC The bottom line on the menu shows the current consumption in the three phases fan motor and heater and for the frequency converter I1 I2 I3 FC MO2 Turn the evaporator heater on off Evaporator heater Function Manual heater on off Note that value is only accepted if control is in the manual mode menu item MO1 is MANUAL Value 0 100 or OFF MO3 Turn the evaporator fan on off Evaporator fan Function Manual evaporator fan on off Note that value is only accepted if control is in the manual mode menu item MO1 is MANUAL Value Set to OFF LO low speed or HI high speed MO4 Turn the condenser fan on off Condenser fan Function Manual condenser fan on off Note that value is only accepted if control is in the manual mode menu item MO1 is MANUAL Value Set to OFF LO low speed or HI high speed MO5 Setting of compressor frequency capacity Compressor freq Function Manual setting of compressor frequency Note that value is only accepted if control is in the manu al mode menu item MO1 is MANUAL MANUAL Compressor frequency is set Value MANUAL Set to OFF compressor stop or value between 15 and 110 Hz MOG Setting of expansion v
177. n Type Value 35 CMH or 75 CMH Serial Numbers Function Main controller Value Main controller serial no Function User panel serial no Function Power meas serial no Function Humidity sensor Value Humidity sensor serial no 49 of 231 pages STARK LOOL Operating and service manual Function O2 sensor Value O2 sensor serial no Function CO2 sensor Value CO2 sensor serial no NO7 SSC Function Sub controller Value Sub controller serial no NOS FCCP Function Frequency converter Value Frequency converter serial no C and F Temperature Scale Showing Alternately D While button C is pressed F is shown instead of C and Psi is shown instead of Bar If software is default F Psi then C and Bar is shown instead while is pressed Permanently change to F Psi is available with the use of StarView Permenatly change to C Bar for machines initially set to F Psi is also possible with StarView Thoug a power cycle will reset this back to F Psi Shown pressure is relative to atmosphere pressure Viewing graph of Supply and Return Temperature T Press m to enter graphical view this function is a shortcut to L03 Datalog view p 46 To return to main page press two times Press m to toggle between stored set of temperatures Setpoint temperature supply air tem perature return air temperature and the other set of temperatures USD
178. n be deleted Log data s Adiv Iacive O do In In 131 of 231 pages STAR LOO Operating and service manual A ii 609 Defrost Trouble Warning Cause Defrost terminated zez Trouble Possible causes shooting e Hot gas valve not working probably e Defective Psuc e Defective Tevap Accompanied alarms e Maybe AL 207 e Maybe AL 123 e Maybe AL 610 Trouble shooting 1 If companied alarms AL 207 or AL 123 run troubleshooting for these alarms first 2 Hot gas valve is not working probably Let the compressor run by 35 Hz in manual Open hot gas valve 50 and control the valve function Is the sound as usual If not control with a permanent magnet and test coil function If it looks like the hot gas valve is working as usual run function test step compressor If alarms look for troubleshooting for these alarms If no alarms run a manual activated defrost and follow the behavior of Tevap Tsuc Tret and Psuc Criteria Defrost terminated on Tsuc above 30 C 86 F None Controller Bi Alarm light If not solved the defrost takes longer time than necessary Warning will be marked as inactive in the alarm list when a defrost runs as expected Alarm may then be deleted Log data i Active Inactive Defrost time 132 of 231 pages STAR OO Operating and service manual 610 Defrost time exceed Warning Max defrost time exceeded Cause Defrost terminated on tme gt 45 minute
179. n controller Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 The main controller is defective Replace the main controller Criteria Internal temperature sensor below 40 C 40 F None n consequence Log data E nee The measured temperature is internal on the main controller and cannot be measured 183 of 231 pages STAR LOA Operating and service manual am 981 internat HI Warning Controller Internal Temperature Sensor High Temperature Fault Cause Indication of controller internal temperature sensor fault Trouble Possible causes shooting e Defective power supply for main controller e Defective main controller Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24 V DC and 5 V signals to see if power supply has an open circuit or other damages If voltages are OK the main controller is defective Replace main controller Criteria Internal temperature sensor above 70 C 158 F None Controller MES tog Jr Alarm Alarm light Consequence Log data z m ERE The measured temperature is internal on the main con
180. n motors sto Controller P p action Alarm light Air circulation in container stops causing unit to stop When overheating disappears alarm will be marked as inactive in alarm list and may then be deleted Control is again released but fan motors will only be allowed to operate at low speed for the first 5 min If the error does not reoccur problem will be considered solved and evaporator fan high speed is again released Log data Active Inactive honunt Pest O 98 of 231 pages STAR OO Operating and service manual 1 401 Mevap2 overheat Warning Description Evaporator Motor 2 Overheat Cause Indication of an overheated motor or a loose thermistor cable connection Trouble Possible causes shooting e Evaporator motor 2 defective e Cable for measuring evaporator motor 2 overheat defective e Main controller defective e Damage on cable for Mevap 2 Accompanied alarms e N A Trouble shooting 1 Turn off unit Open inspection hatch and see if the evaporator fan can turn freely If it cannot turn remove ice or replace the motor If the motor is hot it may be overloaded and jammed or defective If the cable for Mevap2 by inspection is defective if unable to repair cable replace it Disconnect the wires for Mevap2 on the main controller according to the wiring schematics inside the control cabinet Measure the resistance in the cable If the resistance is more than 1 MQ the ca
181. n of defective FC or missing phase Trouble Possible causes shooting W36 e One or more phases are not applied to the FC e Unstable power supply generator e Defective FC Accompanied alarms e AL 417 AL 418 AL 419 AL 516 may be active Trouble shooting 1 Verify that voltage levels are the same for all 3 phases difference in voltage below 14 V AC 2 Supply unit with correct power voltage according to specification 3 Replace the FC If no FC replacement is available the unit can be rewired for emergency operation Criteria More than 70 V diff in min max for phases in power supply None action Alarm light Consequence If not solved this problem can cause FC to stop due to alarm 516 Warning will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Active Inactive Freq FC 121 of 231 pages STAR LOA Operating and service manual A FC Current Limit Fault Warning Cause Indication of problems with compressor Error may be seen during pull down Trouble Possible causes shooting A12 e The compressor motor draws too much current e Defective FC Accompanied alarms e One or more AL 5XX may also be active Check these alarms also before replacing anything Trouble shooting 1 The compressor motor draws too much current from the FC The motor may be jammed or defective Turn off unit and wait 10 min before turnin
182. n short circuit or other damages If the correct voltage is measured at X10 then circuit is defective Replace main controller Criteria Reference voltage sensor bus above 14 V DC None action p p Wem Wemhen Less accurate readings from measurement and damage to sensors Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data E m 179 of 231 pages STAR OO Operating and service manual 1 SUP6 SPM6 sup LO Warning Supply voltage SUP6 SPM6 low Cause X Indication of controller voltage reference fault Trouble Possible causes shooting e Defective 12 V power supply to SUP6 or SMP6 e Defective main controller e Short circuit on SUP6 SPM6 Accompanied alarms e There may be sensor alarms AL 302 e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms AL 971 and or AL 972 Clear these alarms first using their trouble shooting 2 Access the special menu by pressing Ki for more than 3 sec Scroll down until you see the label SUP6 SPM6 in the display The value of U SUP6 SPM6 should be in the range between 11 and 14 V DC While displaying U SUP6 SPM6 remove the connector at X9 If U SUP6 SPM6 is now inside the correct above range 11 14 V DC the display and or power module is defective Test with another display and or power module If U SUP6
183. n start up defrost or another mode deactivating temperature control e g manual set point alternation PTI the temperature control is set to Pull Down or Pull Up mode depending on Tact being above or below Tset As long as temperature is not within Tset ranges the function remains in CoolPullDown or HeatPullUp mode If temperature is within range the green IN RANGE indicator light starts flashing When the temperature has been within Tset ranges for 30 min the green IN RANGE indicator light is constant on Cool Heat mode Temperature is within Tset ranges and the green IN RANGE indicator light is constant on If temperature is in out of range condition for more than 2 hours the IN RANGE indicator lights start flashing After 4 hours out of range condition an in range alarm is set On the basis of Tact and Tset the function calculates the requested capacity CapReq value by means of a PID controller CapReq is the desired chilling heating capacity CapReq value can range from 100 to 100 100 being maximum cooling and 100 being maximum heat ing Capacity Control and Limiter On the basis of requested capacity this function determines operation mode and actions of the in dividual system components compressor valves heating elements and ensures that compressor minimum off time is observed This function has 5 gears modes On the basis of requested capacity the gear is determined Compressor freq
184. nctions MSS Minimum Stable Superheat search Superheat control MOP Maximum Operating Pressure MSS This function searches for minimum stable superheat within the ranges SHmin and SHmax With a stable TO SHset is reduced and with an unstable TO SHset is raised 11 of 231 pages STARE LOU Operating and service manual 1 SHact Tsuc TO Superheating Function output is the expansion valve opening rate Vexp 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 In addition the cooling capacity is increased COP is enhanced and compressed gas temperature is reduced Function output is the economizer valve opening rate Veco The economizer control has two modes Superheat control FC cooler Superheat control Valve opening rate control is based on calculations FC cooler This function is active during compressor operation Dehumidification The dehumidification function dehumidifies air in the container by means of a heater This function is 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
185. nd If the resistance is less than lt 230 Q the cable is defective and must be replaced Mount the cable for RH in controller cabinet and on the sensor Disconnect signal wire on main controller Measure voltage between wire and GND on the main controller If voltage is below 0 5 V DC sensor or connection between sensor and cable is defective If voltage is between 0 5 V DC and 10 V DC continue to 4 4 Mount signal wire Measure voltage between SIGNAL and GND If voltage is between 0 5 V DC and 10 V DC and this alarm is still active replace main controller Before replacing main controller see Trouble shooting for Star Cool main controller p 57 Value below alarm limit 10 RH or above 110 RH Value invalid for 120 sec for alarm activation None Controller action Alarm light Dehumidification impossible When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Value must be valid for 120 sec to set alarm inactive Log data 5 Acdiv Iactive II Ir 91 of 231 pages STAR OO Operating and service manual L ii 203 AirEx No connection Warning Air Exchange Sensor Short Circuit Cause Indication of a loose connection defective or lack of air exchange sensor Trouble shooting Possible causes AirEx is out of calibration Air exchange sensor AirEx or cable defective X23 cable is defective Main controller defective Accompanied alarms
186. nd service manual m 103 Tsupiopen Warning Supply Air Temperature Sensor 1 Open Circuit SINE Indication of loose connection defective or lack of supply air temperature sensor Trouble Possible causes shooting e Temperature sensor Tsup1 or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 105 Trouble shooting 1 Same trouble shooting is to be used for Tsup1 as used for Tret in AL100 Criteria Value below low alarm limit 609C 76 F Replacement by new value from AAS system Controller action Alarm light Deteriorated control precision in the chill mode When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data 104 Tsup 1 short Warning Supply Air Temperature Sensor 1 Short Circuit Cause Indication of short circuited supply air temperature sensor Trouble Possible causes shooting e Temperature sensor Tsup1 or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 105 Trouble shooting 1 Same trouble shooting is to be used for Tsup1 as used for Tret in AL 101 Criteria Value above high alarm limit 140 C 284 F Replace new value from AAS tem Controller placed by SES Eds action Alarm light Deteriorated control precision in the chill mode When sensor value becomes valid it is marked as inactive in
187. ng of min GMT Minute Function Setting of min Note when min are set sec are set to OO Value Set from 0 to 59 Run time counters RO1 Viewing operation hours for the Star Cool unit Unit Function Viewing of Star Cool unit operation hours Value Shown as hours RO2 Viewing Function Viewing of compressor operation hours Value Shown as hours RO3 Viewing orator fan operation hours Evap Function Viewing of evaporator fan operation hours Value Shown as hours RO4 Viewing of condenser fan operation hours Condenser fan Function Viewing of condenser fan operation hours Value Shown as hours 47 of 231 pages STAR ZOQL Operating and service manual RO5 Viewing of heater operation hours Eva Function Viewing of heater operation hours Value Shown as hours RO6 AirEx motor sw times Function Total run time Value Hours Configuration FO1 Container ID viewing Container Function Viewing of container ID Value Shown in the lower display line E g MCID 000 001 2 FO2 Software version viewing Software version Function Viewing of software version and revision Value FO3 Compressor FC type setting FC type Function Setting of actual FC type Value Setting as DANFOSS for Danfoss VLT and NONE for no FC mounted Emergency Operation p 51 for specific information FO4 Compressor frequency converter ID FC ID Function
188. ng runtime Cycle duration is 50 sec 39 of 231 pages STAR ZOQL Operating and service manual Operation Parameter Setting DN By pressing the operation menu is selected The icon is displayed Use the arrow keys and e 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 Change the value to the desired value and press the enter button for 3 seconds to acknowl 002 QUEST optional Function AUTO OFF Value O03 Control mode Control mode Function Setting the control modes NORMAL or ECONOMY mode If NORMAL mode is selected In chill mode the fans run at high speed In frozen mode the fans run at low speed The evaporator fans switch to use low speed whenever a The setpoint is more than gt 0 C 32 F b The air exchange is closed c Dehumidification is off If ECONOMY mode is selected Evaporator fans run at constant low speed The operator switches manually to economy mode Value Function set to NORMAL ECONOMY Default is NORMAL O04 Reference relative humidity setting Function Setting of reference relative humidity Note that container relative humidity is only reducible Value Shown as Off or a percent value Value can be set to Off or values from 50 to 95 in 1 incre ments Default off O05 Datalog interval setting Datalog interval Function
189. nit Unitstops e Alarm will be marked as inactive in alarm list when phase sequence can be established Alarm may then be deleted Log data Active Inactive No of CH No ofCCW Min no OK 106 of 231 pages STAR OO Operating and service manual 1 424 Power frequency Log Description Phase frequency error Cause Indication of error on StarCool unit power supply Trouble Possible causes shooting e The unit is supplied with an unstable voltage e The power frequency is out of specified range Accompanied alarms e AL 423 may also be active Trouble shooting 1 Check if voltage on all 3 phases is within specified range 2 Verify that all 3 phases are applied to the unit and for example not just 2 phases 3 Verify that power frequency is within specified range 4 Apply correct voltage to the unit Criteria Value out of limits Power frequency must be between 47 5 Hz and 62 5 Hz None SC tog JN J em Alarm light Consequence At very low frequencies this error will lead to AL 423 Otherwise normal operation can take place The measuring system however will perform badly Power frequency within range again Log data x Active Inactive Sample U1 Sample U2 Sample u3 425 Frequency too high Warning Power Frequency Too High Warning Cause Power generator adjusted to too high frequency Trouble Possible causes shooting e The power frequency is out
190. num Preset o O This alarm is used for service purposes The fuses are protecting the unit 105 of 231 pages STAR OO Operating and service manual 422 I3 over current Log I3 Over current 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 Controller Log data Active inactive Honimt Preset o This alarm is used for service purposes The fuses are protecting the unit No phase direction Fatal Alarm Description Description Phase direction not detectable Phases may be lacking or there may be extremely high noise in one or more phases in the detection moment Trouble Possible causes shooting e The unit is supplied with an unstable voltage e The power frequency is out of specified range e Defective Power module PCB Accompanied alarms e AL 424 may also be active Trouble shooting 1 Check if voltage on all 3 phases is within specified range 2 Verify that power frequency is within specified range 3 Check replace power module PCB 4 If 1 to 6 are OK then replace the main controller or set the correct phase direction on the Configuration menu FO5 to clockwise or counterclockwise Criteria Impossible to detect phase sequence in power supply SEI Controller breaks supply pui c rese dest BEE Quick flash Consequence uence U
191. odule Prior to mounting the motor cover check the sealing for any damages If damaged the sealing must be replaced 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 Replace the defective parts and reinstall the parts Prior to mounting the motor cover check the sealing for any damages if damaged the sealing must be replaced 190 of 231 pages STARK LOO Operating and service manual Replacement of evaporator Back plate unit The replacing of evaporator is done in the following steps 1 2 3 4 5 6 7 8 9 Evacuate refrigerant as described in this manual see Evacuation of refrigerant p 196 Remove pos 1 Remove heating elements below pos 2 Remove the sensors for evaporator temperature suction temperature humidity Dismount cut the suction and liquid pipe for pos 2 on a proper place Remove drill out rivets heads and remove pos 2 Punch the remaining rivet pieces into the foam using a max 5 mm tool Mount new evaporator on chassis with appropriate rivets Connect the suction and liquid pipe to the new evaporator Reinstall th
192. of 231 pages STAR OO Operating and service manual 1 QUEST optional QUEST is a program based on a fixed protocol designed to reduce the energy consumption of the unit when operating in the interval 19C to 30 C 30 F to 86 F This energy saving is mainly obtained by regulating the compressors on off time and the evaporator fan speed Please note that when Tsup is in the range 1 C to 15 C 30 F to 59 F its value can vary 2 C 1 C 28 F to 34 F from setpoint Please note that when Tsup is in the range 15 C to 30 C 30 F to 86 F its value can vary 4 C 1 C 25 F to 34 F from setpoint QUEST is as default set to either AUTO or OFF depending on customer requirements To deactivate QUEST 1 Press 2 Use O or Y to select 003 QUEST and press EI 3 Select OFF by using 4 or e and Dress To activate QUEST 1 Press Use A or e to select O03 QUEST and press 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 Frozen economy Frozen economy can not be engaged if Tset gt 15 C 5 F If Tret Tset 1 C 1 8 F both compressor and evaporator fans stops After 15 min evaporator fans starts and Tret is measured If e Tret Tset 2 C 3 6 F evaporator f
193. of specified range Accompanied alarms e AL 423 may also be active Trouble shooting 1 Adjust the frequency of the power generator to a lower frequency 2 Verify that power frequency is within specified range 3 Apply correct voltage to the unit Criteria Power frequency above 66 Hz Mcond Mevapi and Mevap2 fan motors forced to low speed Controller action Alarm light Reduced capacity of unit Elimination Power frequency within range again Log data 107 of 231 pages STAR LOA Operating and service manual 426 Frequency too high Alarm Power Frequency Too High Alarm Cause Power generator adjusted to too high frequency Trouble Possible causes shooting e The power frequency is out of specified range Accompanied alarms e AL 423 or AL 425 may also be active Trouble shooting 1 Adjust the frequency of the power generator to a lower frequency 2 Verify that power frequency is within specified range 3 Apply correct voltage to the unit Criteria Power frequency above 66 Hz for 5 min or above 70 Hz Mcond Mevapi and Mevap2 fan motors forced to low speed Controller ction A Alarm light Reduced capacity of unit Elimination Power frequency within range again Log data Voltage freq U f ratio low Alarm Bad power supply over loaded under supplied Cause Power generator adjusted to too high frequency compared to supply voltage
194. off power first Replace motor or make it turn freely again 2 Check motor cable for damages 3 Check that the condenser motor cables are mounted correctly Condenser fan motor has exceeded current limit at high speed 50 Hz 0 7 0 8 Amp 60 Hz 1 0 1 8 Amp Controller action Alarm light Siow flash 152 of 231 pages STARK LOOL Operating and service manual A Test failed Elimination Alarm may then be deleted after test completed Log data Mcond current OFF Alarm Condenser Motor Off Current Fault Cause Indication of defective motor contactor or defective contactor driver circuitry Trouble Possible causes shooting e Defective condenser motor contactor e Defective contactor driver circuit Accompanied alarms e N A Trouble shooting 1 Check the condenser motor contactor for defects Replace the contactor 2 Check that the condenser motor cable is mounted correctly Criteria Condenser fan motor has exceeded off current limit None Controller action Alarm ight slow fash Test failed Elimination Alarm may then be deleted after test completed Log data n 820 Hevap current ON Alarm Evaporator Heater On Current Fault Cause Indication of defective heater s or defective supply cables to heater Trouble Possible causes shooting e Heaters defective e Heater power cable defective Accompanied alarms e N A Trouble shooting 1 Check the p
195. old Treatment CT it will be affected When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted 72 of 231 pages STAR OO Operating and service manual 1 Tusda 1 short Warning Description USDA 1 Temperature Sensor Short Circuit Cause Indication of short circuited USDA 1 temperature sensor Trouble shooting Possible causes Temperature sensor Tusdai or its cable defective X24 and X25 cable is defective Defective plug inside or cable on the unit backside Main controller defective Accompanied alarms e N A Trouble shooting 1 2 Disconnect the sensor cable for sensor Tusdal from the connector on the main controller according to the wiring schematics inside in the control cabinet Measure the resistance between the two wires a If the resistance is less than lt 230 Q the cable the plug inside in the unit or the sensor is defective Check the plug before replacing sensor and cable b If the resistance matches the resistance and temperature Tables p 203 the temperature sensor and cable are OK Measure the voltage over the connector for Tusdal It should be between 3 2 and 3 4 V DC a If the voltage is inside the above range connect sensor again Measure the voltage over the sensor and check voltage temperature according to table in Tables p 203 b If the voltage is outside the above range the main controller is defective
196. on has 4 modes Wait Initialize Execute Terminate 13 of 231 pages STAR LOOL Operating and service manual 1 Wait In the wait mode the time is refreshed for the next defrost provided that the following conditions are satisfied Compressor is running TO is less than TOmin 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 Cooling system termination results in compressor initiation only ramp up mode is executed Evaporator fan is stopped Evaporator heating elements are turned on Compressor runs at a constant frequency at 83 of full speed Expansion valve control is deactivated Hot gas valve is used to heat the evaporator from the inside with the hot gas from the compres sor Evaporator defrosting terminates when evaporator temperature Tevap is above defrost termina tion temperature for 2 min or upon elapse of max defrost time A defrost stop event is made in the data log with the current interval and Tevap temperature Terminate Terminate mode is dividable into two parts Evaporator re freezing preventing remaining water drops on evaporator from blowing into cont
197. on secures that the controller operates with valid settings to protect the unit in order to maintain the conditions for the cargo To maintain the set point temperature capacity control constantly monitors and adjusts the capacity The limiter acts as a brake to the capacity change requests from capacity control and thereby controlling how fast the capacity can change so that safe operation of the unit constantly is ensured The limiter monitors the following parameters from the unit and generates a limiter factor for each IFC to limit the maximum current draw from the FC TFC to limit the maximum internal FC temperature Tc to limit the maximum condenser pressure and temperature TO to ensure a minimum evaporator pressure The largest of the factors is used as the active limiter If the limiter factor is higher than the re quested capacity change the capacity is actually reduced instead of increased If for example the ambient temperature is very high the requested capacity may increase the FC temperature over its limits and so the limiter will reduce the capacity until a safe and stable opera tion condition for the FC has been reached Expansion Valve This function ensures optimum evaporator superheat SH and calculates the percentage of open ing SHVod and controls the valve This function is active during compressor operation Valve is closed during compressor turn off Expansion valve function includes the following sub fu
198. osed 11 Open the HP valve on the service gauge manifold slowly only allowing liquid R134a to pass 12 Observe the scale and close the hand valve located on the refrigerant bottle when the cor rect amount of refrigerant has been charged The refrigerant charge of the unit is 4 5 kg R134a 8a To speed up the charging time it is recommended to start up the unit in manual mode with a compressor speed not more than 20 Hz until finishing charging 13 Open Service valve economizer pos 14 P amp I diagram 14 Close the valves on the service gauge manifold 15 Open all the service valves full on the compressor pos 5 26 and 30 P amp I diagram 16 Remove all tools again 17 Make sure to install all valve cap s again 18 Operate the unit as normal Note If the correct amount of refrigerant is not charged by this rocedure follow the procedure described in charging of unit ow on charge in this manual Charging of unit low on charge If during normal stable in range operation it is observed that the set point temperature cannot be maintained it might be an indication of missing refrigerant Please observe the unit for a period of at least 6 hours to ensure a stable tendency During this observation time please observe the fol lowing 1 The red balls in the sight glass for the receiver are constantly at bottom level 2 Veco is more than gt 80 open for 0 5 hour 3 Vexp will steadily increase to 100 4 Ps
199. other active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24 V DC and 5 V signals to see if power supply has an open circuit or other damages If the correct voltage is measured at X23 then circuit is defective Replace main controller Criteria Reference voltage motor pos above 5 50 V DC action Hs p em mim Less accurate readings from measurement Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data gem 175 of 231 pages STAR LOO Operating and service manual A ii 969 AirEx sens sup LO Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective sensor pulling power supply down e Defective main controller Accompanied alarms e There may be sensor alarms AL 3XX e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Access the special menu by pressing Ki for more than 3 sec Scroll down until you see the label U AirEx in the display The value of U AirEx should be in the range between 4 50 V DC and 5 5 V DC 3 While displaying U AirEx remove the connector at AirEx potentiomete
200. ower cable for the heaters for defects Replace cables if they are defective 2 The heater s are defective Dismount the power for the heaters one by one to find the defective heater see wiring schematics inside in the controller cabinet Replace the defective heater Criteria Evaporator heater has exceeded on current limit None Controller action Alarm light slow Rash Test failed Elimination Alarm may then be deleted after test completed 153 of 231 pages STAR LOO Operating and service manual es Log data 821 Hevap current OFF Alarm Evaporator Heater Off Current Fault Cause Indication of defective heater contactor or defective contactor driver circuitry Trouble Possible causes shooting e Defective heater contactor e Defective contactor driver circuit Accompanied alarms e N A Trouble shooting 1 Check the heater contactor for defects Replace the contactor 2 Check that the heater power cable are mounted correctly Criteria Evaporator heater has exceeded off current limit None Controller Elimination Alarm may then be deleted after test completed Log data Valve leaks Alarm Indication of leakage of one or more of the valves or problems with the compressor Trouble Possible causes shooting e One or more valves have leaks defective Accompanied alarms e See other AL 84X alarms for valve failures Trouble shooting 1 Check an
201. placed 4 If the compressor can run several min without alarm the FC may be defective and must be replaced if the alarm comes again If there is no FC replacement available the unit can be rewired for emergency operation See Emergency Operation p 51 5 Clean condenser Criteria FC overloaded Current above 38 Amp for approx 1 sec FC shut Controller SEENEN Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Parm 5 Log data Active Inactive Freq FC FC Compressor Motor Over temperature Cause Indication of defective compressor or lack of oil Trouble This alarm is not used at the moment shooting A11 Criteria Over temperature in compressor motor FC shut Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data 7 Active Inactive Freq FC 113 of 231 pages STAR LOO Operating and service manual 513 FC overload Alarm FC Overload Alarm Cause Indication of problems with compressor Trouble Possible causes shooting 9 e The FC cannot deliver enough power to the compressor e Insufficient cooling for the FC e Defective FC Accompanied alarms e AL 522 or AL 525 may also be active and should be checked first Trouble shooting At very high ambient temperatures and very low setpoint temperatures the FC may get too hot to generate enough power Therefore it can be cooled by the
202. proceed to next step While displaying U SUP6 SPM6 disconnect RH at X10 and measure voltage If not in range SMC6 may be defective or have insufficient supply at X1 If in range check SUP6 at X80 and SPM6 at X41 Criteria Internal power supply below 10 V DC None Controller action x p Wem Wem Less accurate readings from measurements Log data mm A E 182 of 231 pages STAR OO Operating and service manual Internal sup HI Warning 12 V supply voltage high on SMC6 Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective 12 V power supply e Defective main controller e Short circuit between 24 V DC and 12 V DC Accompanied alarms e There may be other alarms AL 971 and AL 973 e AL 801 will be activated during FT or PTI test Trouble shooting 1 See trouble shooting for AL 974 Criteria Internal power supply above 14 V DC None action us p em Mmi Less accurate readings from measurements and risk for damage to sensors Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Parm 2 EST Fam Active Inactive High limit Actual value C 980 Tinternal LO Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Possible causes shooting e Defective power supply for main controller e Defective mai
203. r If U AirEx is now inside the correct above range 4 50 5 50 V DC the AirEx potentiometer is defective Replace the AirEx potentiometer If U AirEx is still outside the above range proceed to next step 4 While displaying U AirEx disconnect AirEx from the terminals according to wiring schematics inside in the control cabinet f U AirEx is now inside the above range the cable for AirEx is defective Mount connector correctly or replace connector cable for AirEx If the correct voltage is measured at X22 and at X23 then circuit is defective Replace the main controller Criteria Reference voltage AirEx below 4 50 V DC None Controller action i tog x Jem mm Less accurate readings from measurement Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data a m 176 of 231 pages STAR OO Operating and service manual 1 AirEx sens sup HI Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective main controller Accompanied alarms e There may be sensor alarms AL 3XX e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting
204. r 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 humidification function controlled by the electronic controller of 8 of 231 pages STARK LOOL Operating and service manual the unit The humidity setpoint can be set in the range from 95 65 or 50 with closed ven tilation RH The unit can control to the lowest level The de humidification 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 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 Furthermore the heating ele ments 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 af
205. r is blocked clean the condenser to secure any residues is removed Disconnect the cable for high pressure switch on the main controller according to the wiring schematics inside the control cabinet 6 Measure the voltage between the two connectors for the high pressure switch on the connector PCB If the voltage is below 15 V AC replace the main controller 7 Check the cable measure the resistance in the cable If the cable is defective replace cable and high pressure switch 8 Mount the cable for the high pressure switch again If this alarm is still active on the display replace the main controller 9 Look in display to see if pressure transmitter is according to settings see Configuration p 48 F08 and set controller according to transmitter 10 If pressure transmitter type is correct perform troubleshooting for AL 203 Pressure is above high pressure switch safety limit Cut out 22 5 BarE 0 7 Bar 326 3 psi 10 2 psi Cut in 15 9 BarE 0 7 Bar 230 6 psi 10 2 psi Frequency controller is stopped and unit stops Unit stops Log data Unit restarts after 5 min When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Active Inactive Pdis 6 sec In Psuc6 sec FCtemp 6 sec 95 of 231 pages STAR OO Operating and service manual 314 Replace CO2 sensor Alarm Replace CO2 sensor Caus
206. r measurement out of range from last PTI calibration and CA AV is active Accompanied alarms e Replacing AL 314 when CA AV is inactive Al 314 visible in log Trouble shooting 1 Replace CO2 sensor with new After a passed PTI test the CO2 measurement value should be between 0 26 and 0 34 None Controller action Alarm light mg When sensor is replaced alarm is marked as inactive in alarm list and may then be deleted Log data onmes o fo b b 1 Replace O2 sensor Warning Replace O2 sensor Cause O2 measurement after calibration PTI is out of range Trouble Possible causes shooting e Sensor measurement out of range from last PTI calibration and CA AV 4 is active Accompanied alarms e Replacing AL 315 when CA AV is inactive Al 315 visible in log Trouble shooting 1 Replace O2 sensor with new Criteria After a passed PTI test the O2 measurement value should be between 20 496 amp 21 4906 None action Alarm light or E When sensor is replaced alarm is marked as inactive in alarm list and may then be deleted Log data ames jo p b b o 97 of 231 pages STAR OO Operating and service manual am Power Alarms AL 4XX 400 Mevap 1 overheat Warning Evaporator Motor 1 Overheat Cause Indication of an overheated motor or a loose thermistor cable connection Trouble Possible causes shooting e Evaporator motor 1 defective e Cable for m
207. resie The procedure for replacing the compressor is as follows Please ensure correct tightening torque is used throughout replacement If the compressor is NOT running close all 3 stop valves and evacuate refrigerant and proceed from pt 1 If the compressor IS running but needs replacement complete the following before going to pt 1 a Close Veco and Vsuc b Go to service menu and enter the manual operation and set compressor freq to 20 Hz c Let pressure drop to vacuum d Stop the compressor by pressing Off on the controller and close discharge stop valve e Press wake up on the controller and read pressure on display corner Ensure it is O Bar Remove the cover for FC pos 3 Remove the FC pos 4 and motor cable pos 5 Dismount all pressure transmitters and high pressure switch Loosen all bolts for compressor stop valves Loosen bracket for compressor and turn it downwards Slide compressor out Slide new compressor in place Observe that the rear compressor foot is inserted firmly into NEON OI adm 194 of 231 pages STARK LOOL Operating and service manual 1 the bracket slot 8 Reinstall the compressor brackets 9 Reinstall all pressure transmitters and high pressure switch 10 Fasten all bolts for all 3 compressor stop valves 11 Reinstall motor cable please observe that the motor cable is not damaged and squeezed between compressor and FC 12 Reinstall FC Make sure that the FC is moun
208. ressure transmitter Ak 208 Voltage Pressure Table Low pressure transmitter NSK issued cen tren s aninda re EN EENS NDS RP E NES 209 Voltage Pressure Table High pressure transmitter AKS cece mene mener nenne nennen 210 Voltage Pressure Table High pressure transmitter ONSKIL ofge ae er n dSeEie ee EE tat c ionida niivie 211 Temiperadture Sensor Voltage Tab EE 212 Pressure Temperature table for R134a i iode ee rens AN SEENEN EENAA TRUE on resa REA ATP SAAR 213 Tightening torques EE 214 Controller Unit Illustration oriente E RR AER REESEN EENS BEE IS EES RPG AK 215 Star Cool Unit installation dimensions ehe hene nne he nenne en essa nsns nnn nnns 217 P Se F Cia Qra Ta a UMS 219 Overall Wiring Schemabtgsesesroesbata gess eeegesed ee dees SEENEN DEFERRI SEC MU NDA DEINEN EAE EISE 220 Overall wiring schematics optional 222 5 of 231 pages STAR OO Operating and service manual Legend Pais AirEx Air Exchange Pfc AirEx mo Air exchange motor PhDir Alarm Alarm Psuc AKS Danfoss pressure transmitter Ptot CalAex SIE Calibration Cargo sensor RMM Remote Monitoring Modem CapAct Actual capacity power line communication CapReq Requested capacity SHTV Superheat Thermo Valve High pressure switch Communication Quality FC SHReq Superheat Requested To Calculated Evaporator Tc Calculated condenser EL CN Gear n SC em emus OO 6 of 231 pages STAR COOL Operating and service manual 1
209. ribed in this manual Remove plug on top of the stop valve for the intermediate pressure Start by adding 0 25 liter of compressor oil Reinstall plug on top of the stop valve for the intermediate pressure Evacuate the compressor as described in this manual Open the compressor stopvalves pos 5 26 and 30 P amp I diagram Disconnect the vacuum pump Start up the unit Check the oil level during start up and after 6 hours in normal stable operation O If oil is still missing repeat above 0 Q MO UL AWN 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 Please observe that only one of the oil outlet ports is equipped with a schr der valve 2 Connect a service gauge manifold to the outlet port with schr der valve of the oil pump 3 Only connect the discharge hose to the outlet port of the oil pump Make sure that all stopvalves on the service gauge manifold are closed 4 Open the discharge gauge stopvalve on the service gauge manifold 5 Insert the hose from the suction gauge on the service gauge manifold into a small measuring cup 6 Run the compressor in manual operation on 25 Hz 7 Carefully open the suction gauge stopvalve on the service gauge manifold 8 While observing the oil level in th
210. rive end Non drive end Drive end Non drive end 6304 2Z C3 6201 2Z C3 6203 2CS C3 6304 2CS C3 Bearing lubricant Lubricant Kl berquiet BQH 72 102 or equivalent Temp range 40 C to 140 C 40 F to 284 F Condenser fan motor Speed Dual speed Dual speed 1740 1460 rpm 60 50 Hz 1710 1420 rpm 60 50 Hz 870 730 rpm 60 50 Hz 830 690 rpm 60 50 Hz Counter clockwise when viewed from shaft end Permanently lubricated sealed Bearing size Drive end Non drive end Drive end Non drive end 6204 2Z C3 6201 2Z C3 6203 22 C3 6202 2Z C3 Bearing lubricant Lubricant Kl berquiet BQH 72 102 or equivalent Temp range 40 C to 140 C 40 F to 284 F 25 of 231 pages STAR OO Operating and service manual 1 Evaporator coil heaters Type 28 5 mm in stainless steel AISI 304 750 W each at 400 V 750 W 10 W Temperature sensors including USDA NTC 10 kOhm at 25 C 77 F 10K3A1 Operating temp 40 C to 100 C 40 F to 212 F Accuracy 0 15 C range 30 C to 100 C 0 5 F 22 F to 212 F Pressure transmitters Danfoss AKS 32R SAGInoMIYA NSK 0 32 BarE High pressure side 0 30 Bart High pressure 1 0 12 0 BarE Low and inter side mediate pressure side 0 69 9 8 BarE Low and intermediate pressure side Ratio metric pressure transmitter with sealed gauge measur ing principle 4 in female flare connection with deflator Miscellaneous Tin plated ele
211. rminals PC software viewer for container datalog files Reefer Container Controller Unit Star Control Powerline based container monitoring system and PC software Remote Monitor Modem for power line communication Reefer container unit name PC software Star Cool unit monitor Functions overview It is defined in the table below which Star Cool functions each device and system will support mm StarView Controller Display basic data mE x Display alarm list mE Display controller information rr o Change container ID mE Change temperature setpoint DENN Change humidity setpoint BEEN Change controller date and time mE Change units from C Bar to F Psi mE Ee Calibrate USDA and Cargo sensors Acknowledge alarms Initiate manual defrost Initiate Trip Start i Initiate Function and PTI test Terminate Function and PTI test Display Function and PTI test results i x Retrieve datalog from unit Save datalog file binary Save datalog file RefCon Save datalog file CSV text Display datalog file binary Display datalog file RefCon Display datalog file CSV text Erase datalog memory Update controller software via bootloader x ol po po p d Update controller software via protocol l b jJ Operate controller in manual mode doo ee E ij 1 Basic data Tset Tsup Tret RH Tusdal 3 Icargo Operation mode Ubat x Not all information is visible on the controllers display 53 of 231 pages STA
212. roller according to the wiring schematics inside in the control cabinet 2 Measure the resistance between the two wires a If the resistance is less than lt 230 Q the cable or the sensor is defective replace sensor cable b If the resistance matches the resistance and temperature in Tables p 203 the temperature sensor and cable are OK Measure the voltage over the connector for Tret it should be between 3 2 and 3 4 V DC a If the voltage is inside the above range connect sensor again Measure the voltage over the sensor and check voltage temperature Tables p 203 b If the voltage is outside the above range the main controller is defective or other sensors may be defective and pulling the voltage down Check other alarms and Trouble shooting for Star Cool main controller p 57 before replacing main controller Criteria Value above high alarm limit 140 C 284 F Replaced by new value from AAS system Controller P y 2 action Hs p Jm x m Deteriorated control precision in the freeze mode When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data 2 m EET Active Inactive High limit Present 66 of 231 pages STAR OO Operating and service manual 1 102 Tretinvalid Warning Description Return Air Temperature Sensor Invalid Cause Indication of defective return air temperature sensor or its measuring circuitry Trouble
213. 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 860 T18 Test result 111 Hold temperature at O C 111 Hold 0 C Function Shows the status of the performance test with holding temperature set point of 0 C 32 F 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 860 T19 Test result 120 Temperature set point 18 C 120 T set 18 C Function Shows the status of the performance test with temperature set point of 18 C 0 49F 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 870 35 of 231 pages STAR OO Operating and service manual 1 T20 Test result 130 Testing of defrost 130 Defrost Function Shows the status of the performance test of defrost 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 870 T21 Test result 140 PTI status 140 PTI status Function Shows the status of the PTI test Value if not done yet RUN if still running test
214. s Trouble Possible causes shooting There has been too much ice in the evaporator The heaters are not working defective Defective Psuc pressure transmitter Defective Pdis pressure transmitter Defective Tevap evaporator temperature sensor Lack of refrigerant Accompanied alarms e Maybe alarm AL 203 is active Trouble shooting 1 Check and clear other alarms first Check refrigerant level 2 Check pressure transmitter configuration and confirm values from Psuc and Pdis by comparing them to gauge readings 3 Start a manual defrost time to remove remaining ice now See if there has been used current for the heaters on the information menu Current phase 1 2 and 3 should be above 6 A when the heater symbol e is shown on the display If current is lower check if there is power for the heaters 4 Run a PTI test after the cargo is unloaded Criteria Defrost time has exceeded 45 min None action e Alarm light All the ice may not have been melted with a deteriorated yield Alarm will be marked as inactive when a new defrosting is terminated on temperature and may then be deleted Parm 1 Parm 2 Log data Active Inactive Max defrost time Act max defr time 133 of 231 pages STAR LOA Operating and service manual 611 Too many sensor errors Alarm Too many controlling sensors have errors If too many controlling sensors have errors the controller cannot maintain correct
215. s e AL 801 will be activated during FT or PTI test Trouble shooting 1 Replace main controller Criteria Controller database corrupted Default value preset Controller P iiid ls x jom ems Parameters may have changed Log data Active Inactive Eo o 906 X Invalid date and time Alarm Invalid date and time Cause Date and time not valid Trouble Possible causes shooting e Date and time not entered correctly e Real time clock battery defective Accompanied alarms e AL 907 and AL 908 Trouble shooting 1 Set date and time Let the unit run for a couple of hours Power off unit and wait a few minutes then power on the unit again Check date and time 2 If step 1 did not correct the problem the real time clock battery is defective Replace main controller Criteria Date and time not correct None Controller action Alarm ight Siow fash Invalid time date in datalog Elimination Set time date When alarm becomes inactive it can be deleted Log data 164 of 231 pages STAR OO Operating and service manual 1 Realtime error Alarm Real time Clock Unreliable Cause Real time clock battery defective Trouble Possible causes shooting e Real time clock battery defective Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Turn on the unit and let it run for a couple of hours 2 Real time clock
216. s 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 This is done with a leakage detection agent or with a solution with high foam building soap The agent or water soap solution is sprayed upon the joints If there is a leakage bubbling foam will occur This leakage detection test can also be done while the unit is running charged with refrigerant by means of a refrigerant detector or soap solution Leakage detection is also done during pump down of unit or compressor as described in this manual Fan motors in not using plug In order to prevent a single wire from getting caught between Ground screw and junction box cover a cable tie collecting all wires except ground wire needs to be placed in the center of the junction box Furthermore is insulation tape applied on top of the Ground screw This reduces the possibility of sharp edges on the top of the Ground Screw to damage nearby wiring 200 of 231 pages STAR OO Operating and service manual 1 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 To change the drying filter follow the following procedure 1 Power off the unit 2
217. s in the sight glass in the receiver receiver tank are not at the bottom when the unit is turned off Search for leaks repair and charge the unit Criteria Set point 0 C was not reached within the 3 hour time limit None Controller action Alarm light Slow fash Test failed Elimination Alarm may then be deleted after test completed Log data 160 of 231 pages STAR OO Operating and service manual PTI defrost Alarm ase Trouble Possible causes shooting Defective Tevap temperature sensor Defective Psuc pressure transmitter Defective heaters Defective hot gas valve Evaporator was filled with too much ice Accompanied alarms e N A Trouble shooting 1 Defrosting is terminated when Tevap rises above 15 C 59 F Check Tevap and Psuc sensors according to trouble shooting in alarms AL 123 and AL 207 2 The heaters may be defective Start the heaters in manual mode and see if the current consumption is higher than 5 A per phase else the heaters or the power cables for the heaters may be defective The hot gas valve is not working properly and the heaters may be defective Check trouble shooting for the hot gas valve in alarm AL 844 See if the evaporator is filled with ice through the inspection holes Be careful with the evaporators fans Criteria Defrost terminated on 45 min time out None action Alarm light slow flash Test failed Elimination Alarm may th
218. sensor missing RH sensor is missing Alarm 8 Test alarms 0 Func test failed Function Test Fault Alarm e Controller Controller Internal Voltage Reference Fault Alarm Idle current Unit Idle Overcurrent Fault Alarm Mevap cur LO Evaporator Motor Low Speed Current Fault Alarm speed Mevap cur HI Evaporator Motor High Speed Current Fault Alarm speed 5 REB tone Oluje Co js En 812 Mevap current OFF Evaporator Motor Off Current Fault Alarm 1 Mevap direction Not implemented yet Alarm 815 Mcond cur LO Condenser Motor Low Speed Current Fault Alarm speed Mcond cur HI Condenser Motor High Speed Current Fault Alarm speed Mcond current OFF Alarm 820 Hevap current ON Evaporator Heater On Current Faut Alarm 21 Hevap current OFF Alarm 40 Valve leaks Valve Leak Faut J r 42 Expansion valve Expansion Valve fat Alarm Economizer valve Economizer Valve Fault Aem Hot gas valve Hot gas Valve Fault Leen Cpr pump down Compressor pump down fault Alarm FC check FC internal fault Leen 50 Pritest faled PTI Test Fault Alarm ss PTI Tset 5 err sec Set Fault Alarm 60 PTI Tset o err o Set Fault faem 870 PTI defrost PTI Defrost Fault aem 850 PTitset 18 PTI 18 C Set fot Alarm 9 Controller alarms User stop User stop was executed from PC program Fatal Alarm 902 Battery Battery Malfunctioning Alarm malfunction 904 Datalog error SCCU6 DatalogFaut Alam 05 Database corrupt SC
219. ser fan speed slow Chill Freeze mode Condenser fan speed depends on ambient temperature Tamb Tinternal SES Tret Tevap and Tsup1 Tact Tsup2 constant Po Tamb and Tinternal mn y y Dehumidification control If dehumidification is active Defective sensor s Substitution sensor Action Alarm O Stop dehumidification 614 Humidity deactivated Defrost control Defective sensor s Substitution sensor Action Alarm SCENE He pezem Psuc T0 Psuc TO and Tevap Only electrical defrosting TO constant Tsuc Only electrical defrosting TO constant Tinternal constant Tamb and Tinternal Always electrical defrosting Electrical control Following graphical illustration shows the accepted volt Hz range and the set off values for the alarms AL 414 AL 415 AL 416 AL 417 AL 418 AL 419 AL 427 AL 428 and AL 429 based on the table below Volt max voltage AL414 AL415 AL416 600 5 alarm U f AL428 max UN AL429 500 400 300 alarm U f AL427 min U f AL429 200 min voltage AL417 AL418 AL419 100 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 Hz 20 of 231 pages STAR OO Operating and service manual 1 Frequency AL417 AL418 AL429 AL427 AL428 AL429 AL414 f Hz AL419 at voltage at voltage at voltage at voltage AL415 Min voltage U IV U V U V U V AL
220. setpoint O2 or CO2 Module removed 1 RH 2 Old SN Old SN Old SN Old SN 02 3 CO2 4 LOM 5 LPM 6 LUP 74 Module added 1 RH 2 New SN New SN New SN New SN 02 3 CO2 4 LOM 5 LPM 6 LUP Calibration finished 3 0 Failed New O2 or CO2 Old O2 or CO2 Sign of old 1 Passed measurement measurement measure ment CO2 only 76 Calibration start denied 2 02 3 Sensor in O2 or CO2 Pmem CO2 session measurement 77 Controller moved Number of Change bit changed SN s mask Debug intern use 1 Alarm count Expected alarm count The time is stored as minutes 360 min 6 60 min 6 hours Only for some models 64 of 231 pages Es STAR OO Operating and service manual 1 Temperature Sensor Alarms AL 1XX 100 Tretopen Warning Return Air Temperature Sensor Open Circuit Cause Indication of loose connection defective or lack of return air temperature sensor Trouble Possible causes shooting e Temperature sensor Tret or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 102 Trouble shooting 1 Disconnect the sensor cable for sensor Tret from the connector on the main controller according to the wiring schematics inside in the control cabinet 2 Measure the resistance between the two wires a If the resistance is more than 1 5 MQ the cable or the sensor is defective replace sensor and cable b If the resi
221. sible causes Defective power supply for main controller Defective sensor pulling power supply down Defective main controller Accompanied alarms e There may be sensor alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24 V DC and 5 V signals to see if power supply has a short circuit or other damages If OK the main controller is defective Replace main controller Criteria Reference voltage 1 below 3 16 V DC None action js p em meme Temperature measurement to high Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Parm 1 Parm 2 Parm 3 Parm 4 Parm 5 Log data m Active Inactive Low limit High limit Actual value C ont The measured voltage is internal on the main controller and cannot easily be measured 167 of 231 pages STAR LOA Operating and service manual A 954 Tempref 1 HI Warning Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective main controller Accompanied alarms e There may be sensor alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are o
222. st Defrosting Test completion status Nome eh ps Short PTI Short PTI includes the following test items 1 Function test 2 5 C 41 F test 3 O C 32 F run test 4 0 C 32 F hold test 5 Defrosting 6 Test completion status Data Log The controller has a data log to record operation of the unit The data log includes 4 items Data 17 of 231 pages STARK LOOL Operating and service manual 1 Extended data Alarms Event data The logged data in the data log can be seen On the display menu L01 the viewable temperatures are listed On the display menu L03 the logged temperatures can be viewed graphically Retrieved via the program RefCon and the RMM modem and the power line Retrieved via a program LogMan on a PSION pda using the retriever socket Retrieved via the StarView program using the retriever socket 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 mn m Log Type Event Data Log m m m AYPWIN m NTO eil Bebe BILWIN mn JU 4 Event ID el Ui el ele el S eise NININ Ajo em ojojo o Extended Log Type 1 18 of 231 pages STAR OO Operating and service manual Extended Log Type 2 eN oO a
223. st Only the selected item is tested The PTI test is automatically terminated in case of no errors Finally temperature set point will be set to the same value as before test initiation If any error occurs during the test alarms will be shown in the alarm list Active alarms in the alarm list before start of the PTI test will lead to failure of the PTI test 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 TO4 to T18 Alarms found are logged in the datalog A detailed description and trouble shooting of an alarm can be found in this manual Detailed alarm description p 57 together with a description of the specific test alarms Test Alarms AL 8XX p 148 When the PTI test completes or is aborted all alarms found during the test are set inactive in the alarm list If the alarm list is empty the unit is completely OK If the controller is switched off only the main status of a PTI test is remembered in menu item T04 TOL PTI test start PTI test Function Start Pre Trip Inspection test run to verify full functionality of the unit and performance test at dif ferent set point temperatures Value For starting PTI test select either NORMAL or SHORT via
224. st was aborted by the user TO7 Test result 20 Controller 20 Controller Function Shows the status of the test of the controller 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 801 Test Alarms AL 8XX p 148 TOS Test result 30 Power 30 Power Function Shows the status of the test of power consumption connection 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 805 TO9 Test result 40 Evap fan 40 Evap fan Function Shows the status of the test of the evaporator fans 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 810 813 T10 Test result 50 Condenser fan 50 Cond fan Function Shows the status of the test of the condenser fan Value 34 of 231 pages STARK LOOL Operating and service manual 1 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 60
225. stance matches the resistance and temperature in Tables p 203 the temperature sensor and cable are OK Measure the voltage over the connector for Tret It should be between 3 2 and 3 4 V DC a If the voltage is inside the above range connect sensor again Measure the voltage over the sensor and check voltage temperature according to Tables p 203 b If the voltage is outside the above range the main controller is defective or other sensors may be defective and pulling the voltage down Check other alarms and Trouble shooting for Star Cool main controller p 57 before replacing main controller Criteria Value below low alarm limit 60 C 76 F Replaced by new value from AAS system action Alarm light Deteriorated control precision in the freeze mode When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data 7 gua i Active Inactive High timit Present i 65 of 231 pages STAR LOO Operating and service manual A ii 101 Tretshort Warning Return Air Temperature Sensor Short Circuit Cause Indication of short circuited return air temperature sensor Trouble Possible causes shooting e Temperature sensor Tret or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 102 Trouble shooting 1 Disconnect the sensor cable for sensor Tret from the connector on the main cont
226. t operate correctly There may not be enough refrigerant in the unit The cooling capacity is too limited Accompanied alarms e N A Trouble shooting 1 Verify that the doors are closed 2 If start temperature was below 5 C the heaters may be defective Start the heaters in manual mode and see if the current consumption is higher than 5 A each phase 3 The unit may be lacking refrigerant Check if the small red balls in the sight glass in the receiver receiver tank are not at the bottom when the unit is turned off Search for leaks repair and charge the unit Criteria Set point 5 C was not reached within the 3 hour limit None Controller action Alarm light Slow flash Test failed Elimination Alarm may then be deleted after test completed Log data 159 of 231 pages STAR LOA Operating and service manual 860 PTI Tset 0 Alarm PTI 0 C Set Fault Cause Indication of insufficient performance Trouble Possible causes shooting Doors are open The heaters do not operate normally There may not be enough refrigerant in the unit The cooling capacity is too limited Accompanied alarms e N A Trouble shooting 1 Verify that the doors are closed 2 If start temperature was below 0 C the heaters may be defective Start the heaters in manual mode and see if the current consumption is higher than 5 A each phase 3 The unit may need refrigerant Check if the small red ball
227. ted fr Water cooled condenser is activated M Defrosting is running S Heater elements are switched on Gi Alarms are present in the alarm menu Setpoint is controlled by Cold Treatment CT pro gram Setpoint is controlled by Multiple Temperature Set points MTS program CT MTS It is possible to obtain a datalog graph display Datalog view p 46 TEMPERATURE GRAPH 27 of 231 pages es wg STAR OO Operating and service manual 1 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 Up Move menu one line up Increment parameter value in menu Increment setpoint on main display page Zoom out graphical view Down Move menu one line down Decrement parameter value in menu Decrement setpoint on main display page Zoom in graphical view Left Move menu one line to the left Move left graphical view Right Move menu one line to the right Move right graphical view Enter Select a sub menu OOTA e DK Activate a function press twice Initiate parameter adjustment Accept parameter adjustment when done 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 3 lt uv PTI Show PRE TRIP INSPECTION menu start stop test and view re sults Info Show I
228. ted air circulation in the container Condenser fan motor There is limited capacity in the condenser When the evaporator fan motors and the condenser fan motor have been without errors for more than 1 hour this alarm is marked inactive and can be deleted Log data s Active Inactive ooo ooo TI 614 Humidity deactivated Alarm Humidity control deactivated Cause Indication of defective relative humidity sensor or its measuring circuitry Trouble Possible causes shooting e Defective humidity sensor Accompanied alarms e Alarms AL 302 are have been active Trouble shooting 1 Check and clear AL 400 or AL 401 first Value below alarm limit 5 or above 110 Value invalid for 120 sec for alarm activation None Controller action Alarm light slow flash Dehumidification impossible When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Value must be valid for 120 sec to set alarm inactive Log data i Adiv Iacive o 135 of 231 pages STAR LOO Operating and service manual 615 Mcondtrouble Alarm Se acca generated overheat alarm within the last 30 min Trouble Possible causes shooting e Repeated condenser fan motor trouble Accompanied alarms e Alarms AL 402 is has been active Trouble shooting 1 Check and clear AL 402 first 2 Check that the condenser fan can rotate freely 3 Check contactor K4 and K5 interlock and aux
229. ted correctly and is not damaged according to wiring diagram inside the controller cabinet 2 Verify that plugs are properly connected 3 Verify that there are correct voltages on all 3 phases for the power module 4 Measure with a multimeter that there is a small DC signal on the connector PCB for power module com a Ifthere is no signal The main controller is defective Replace the main controller b If there is signal The power module is defective and must be replaced Criteria Communication with controller not possible Mcond Mevapi and Mevap2 fan motors forced to low speed Controller P P S When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data Active Inactive o In Jo Brrorcode 721 Powermodulecom Warning Cause indication of defective power module lack of or improper connection shooting criteria communication with controller not possible SSCS Mcond Mevapi and Mevap2 fan motors forced to low speed When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data i Active Inactive Quality fo Jo bo o 1 146 of 231 pages STAR OO Operating and service manual 1 RH sensor missing Alarm Description RH sensor communication missing Cause Indication of defective RH sensor or lack of or improper connection Trouble shooting Possible causes Communicat
230. ted correctly on the compressor and that there is no air gap between FC and compressor 13 Reinstall cover for FC and cable room cover 14 Evacuate the compressor before starting up as described in this 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 elimi nate it 4 Mount the cylinder head valve plate and new gaskets correctly If located in an inconvenient mounting position use mounting pins 5 Tighten the bolts in the illustrated sequence in two steps Starting with bolt no 1 and no 2 tightened firmly by hand and then in sequence no 3 to no 10 by tightening torque 70 Nm see bolt numbers on fig below 195 of 231 pages STAR ZOQL Operating and service manual Service and maintenance Evacuation of refrigerant Evacuation of refrigerant for the unit is done by the following procedure 1 Connect a service gauge manifold to the evacuation point pos 6 and 27 P amp I diagram on the compressor 2 Connect a recovery unit to the gauge manifold a Connect a recycling bottle to the recovery unit b Use a scale underneath the bottle for measuring the amount of recycled refrigerant 3 Vapor recovery If it is NOT possible to run the compressor a Remo
231. temperature See also Temperature control p 19 and Expansion valve control p 19 Trouble Possible causes shooting e One or more temperature sensors are defective e One or more pressure transmitters are defective Accompanied alarms e Alarms AL 1XX or AL 2XX are active Trouble shooting This alarm only appears when one or more controlling sensors have failure and there are no substitute sensors 1 See alarm list for the specific sensors Criteria Can not substitute faulty sensors with value from another sensor None Controller action Namigm Deteriorated control precision in the frozen mode When a sensors slot value enters valid range it is marked as inactive in alarm list and may then be deleted Values must be valid for 120 sec to set alarm inactive Parm 4 m ama Acive madive PP poc There have been several FC alarms within short time The FC reports unstable operation within 30 min or a permanent FC error within the last 15 min Trouble Possible causes shooting e Repeated FC errors Accompanied alarms e Alarms AL 5XX are have been active Trouble shooting 1 Check and clear other FC alarms first AL 5XX Then this alarm should disappear Turn unit off and turn it on again to make a quicker start up after alarms have been removed If this alarm continues the FC must be replaced and the unit can meanwhile run in emergency mode Emergency Operation p 51 Criteria There
232. temperature sensor Trouble Possible causes shooting e Temperature sensor Tsuc or its cable defective e X24 and X25 cable is defective e Main controller defective Accompanied alarms e AL 126 Trouble shooting 1 Same trouble shooting is to be used for Tsuc as used for Tret in AL 101 Criteria Value above high alarm limit 140 C 284 F Replacement by new value from AAS system action Alarm light Superheat control deactivation When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data e Active Inactive High timit_ Present i 83 of 231 pages STAR LOO Operating and service manual L ii 126 Tsucinvalid Warning Suction Temperature Sensor Invalid Cause X Indication of defective suction temperature sensor or its measuring circuitry Trouble Possible causes shooting e Active alarms AL 124 AL 125 or AL 901 if CIM5 software e Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F Accompanied alarms e AL 124 AL 125 or AL 901 may also be active Trouble shooting 1 If alarms AL 124 or AL 125 are active check their trouble shooting section first 2 Disconnect the sensor cable for sensor Tsuc from the connector on the main controller according to the wiring schematics inside in the control cabinet 3 If AL 901 is active see trouble shooting for AL 901 4 Measure the resistance b
233. ter 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 even with one system failing 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 predefined 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 capac ity for 365 days of temperature 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 switch off of the unit continues logging in battery mode 120 times and then stops The controller is prepared for communication with Remote Monitoring Modem RMM according to ISO standard 10368 for monitoring at the ship bridge or control room Events Alarms and Short Log can be retrieved by Refcon Logman StarView and can be viewed by Ref
234. ternal interfaces i eese esa ken nha nin a sa a Ra Hu PRRNRRERRRRG RNRRRYNRRE SE SK EEE SEKR SSES 53 Functions oOVerVIQW sisescs orein riii nasa aT EFEPEDIOERESEPEESEAEUKNRRTENSK SEE ERA ERRE VEEE VENEA SES UERERLbO SRI S Sea EE 53 L catiom of Valves eC eeemm 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 3 of 231 pages STAR ZOQL Operating and service manual 1 General trouble shooting gege ee ione a REN EA EIER EE ga TERM Re Da n PINE ENDE TEN NN KERN EN NUI UE HEDA E 56 Trouble Shooting for Star Cool main controller eiae nere nn no Se aimi et nha sn ia x Ra DR AU RERE SEEE aN Pe ki 57 Detailed alarm descripti cenina te EEN rdi eese a Pr x P RR ERR Eege RS E EES NEE ERE Roue Ee 57 P Lage T 58 EVENTS EE 62 Temperature Sensor Alarms AL 1XX ciicee siesta nete EEN EEE EES nasa aaa aa RRERRRERREXR EE EEEEEE ENEE G3 SRRP RR NR RA RRIRI aX Ma aas 65 Pressure transmitter Alarms AL 2XX enge Ska eege Eh ege EE a bra ime st geg aT DAE 86 Other Sensor Alarms AL 3XX sees Eege ee nnne aan SK AVI RXRRYXRRRSERRERERRETIRSESLERIRERNEKRENERE REIR EAS 91 Power Alarms AL AEN sten SEN ege Zen EER REENEN ER Ee Prkv AR ad IRR e Ry he Ras Kin EE E ER SEAN DIRE APR REES PINK E En
235. the alarm list and may then be deleted Log data z m x m Active Inactive High limit Present 68 of 231 pages STAR OO Operating and service manual 105 Tsup 4 invalid Alarm Supply Air Temperature Sensor 1 Invalid Indication of defective supply air temperature sensor its measuring circuitry or sensor not mounted correctly in unit Trouble Possible causes shooting Active alarms AL 103 AL 104 or AL 901 if CIM5 software Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F Difference between Tsup1 and Tsup2 is larger than 1 C 1 C difference for more than 30 min up to 10 C difference in more than 3 min Accompanied alarms e AL 103 or AL 104 may also be active Trouble shooting 1 If alarms AL 103 or AL 104 are active check their trouble shooting section first 2 Check that both sensors Tsupi and Tsup2 are mounted correct in the supply air pockets 3 If AL 901 is active see trouble shooting for AL 901 4 Disconnect the sensor cable for sensor Tsup1 from the connector on the main controller according to the wiring schematics inside in the control cabinet 5 Measure the resistance between the two wires a If the resistance is out of range of the resistance and temperature table Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check Trouble shootin
236. the condenser temperature rises above 58 C 136 F the system will automatically switch to air cooling of condenser by turning the condenser fan on If the water flow is restored the controller stops air cooling of the condenser If the temperature stays at the high temperature for more than 1 hour an alarm is given The actual setting of water cooling is remembered if the unit is switched off or there should be a power loss Water cooling is only turned off when the set point temperature is changed or when water cooling is turned off manually Emergency Operation A Warning High Voltage Unit must be disconnected from power Only to be done by trained personnel FC defective If FC is defect and no replacement part is available compressor may be run in the on off mode Defect FC is dismounted and the 3 phases are directly applied to the compressor supply terminals Also a wire jumper has to be fitted on the remaining 3 terminals see below figure In the configuration menu F03 FC TYPE the parameter NONE is selected Unit will then run in the on off mode with deteriorated temperature controlling performance The connection for the FC is shown on below drawings Compressor Normal Connection Menu S05 F03 FC type m top o C d dd iu M CONTROLLER BOX munication cable from CONTROLLER BOX Compressor Freq
237. ther active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24 V DC and 5 V signals to see if power supply has an open circuit or other damages If voltages are OK the main controller is defective Replace main controller Criteria Reference voltage 1 above 3 29 V DC None action tog x Joem mim Consequence Temperature measurement to low Alarm will be marked as inactive in alarm list when supply voltage is correct Alarm may then be deleted Log data m m The measured voltage is internal on the main controller and cannot easily be measured 955 Tempref 2 LO See AL 953 The measured voltage is internal on the main controller and cannot easily be measured 956 Tempref 2 HI See AL 954 168 of 231 pages STAR OO Operating and service manual 1 961 Pdis sens sup LO Warning Description Controller Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defective power supply for main controller e Defective Pdis pressure transmitter e Defective main controller Accompanied alarms e There may be sensor alarms especially AL 203 e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Access the special menu
238. tion Shows current time to the next defrosting Value Shown in hours and minutes I11 Ambient temperature Ambient temp Function Shows current ambient temperature Value Shown in temperature scale C or F Switch by pressing Ed I12 Supply air 1 temperature Supply air 1 temp Function Shows current temperature for supply 1 sensor Value Shown in temperature scale C or F Switch by pressing I13 Supply air 2 temperature Supply 2 air temp Function Shows current temperature for supply 2 sensor Value Shown in temperature scale C or F Switch by pressing E I14 Return air temperature Return air temp Function Shows current temperature for return sensor Value Shown in temperature scale C or F Switch by pressing D I15 Evaporator temperature Evaporator temp Function Show current temperature for evaporator Value Shown in temperature scale C or F Switch by pressing C I16 Suction temperature Suction temp Function Shows measured suction gas temperature Value Shown in temperature scale C or F Switch by pressing D I17 Suction pressure Suction press Function Shows current suction pressure for compressor Value 37 of 231 pages STAR ZOQL Operating and service manual 1 Shown in units of Bar or Psi relative to atmosphere pressure Switch by pressing E at C pres sure is shown in BarE at F in Psi Function Reserved for future use Value
239. troller and cannot be measured Powermeas calibrat Warning Powermeas calibration not possible Cause Voltage difference between powermeas and frequency converter too large Trouble Possible causes shooting e Defective powermeas e Defective frequency converter Accompanied alarms e AL 414 415 416 417 418 419 424 425 426 427 428 and 429 Trouble shooting 1 Ifthere are other active alarms check these first Clear these alarms first using their trouble shooting 2 Measure the actual phase phase voltages and check with the values in the display If they are within 30 V AC proceed to step 3 3 Set the unit in manual mode Press and hold service key Go to page 6 Frequency converter and check the Udc value Take this value and divide it with 1 4142 and compare the result with the actual phase phase voltage If the voltage is not within 20 V AC replace the FC Difference between FC Udc voltage and voltage measurements from the power module PCB is too large Udc 1 4142 U1 2 U1 3 and U2 3 within 50 V AC Use old calibration value Controller k og jx Jaam LI Alarm light 184 of 231 pages STAKSkZO0L Operating and service manual A o Elimination Solve the issue according to Trouble Shooting guidelines and power cycle the controller IU og data Software test ver Warning Cause Indication of Software test version loading into controller Trouble Possible causes shooting
240. turn Air Temperature Sensor Invalid Supply Air Temperature Sensor 1 Open Circuit 104 Supply Air Temperature Sensor 1 Short Circuit 05 Supply Air Temperature Sensor 1 Invalid 0 Supply Air Temperature Sensor 2 Open Circuit 107 Supply Air Temperature Sensor 2 Short Circuit 108 Supply Air Temperature Sensor 2 Invalid USDA 1 Temperature Sensor Open Circuit USDA 1 Temperature Sensor Short Circuit Hi USDA 1 Temperature Sensor Invalid 112 USDA 2 Temperature Sensor Open Circuit N ele CH LA ele o mele O BH Im Im Tusda 2 short USDA 2 Temperature Sensor Short Circuit 1 Tusda 2 invalid USDA 2 Temperature Sensor Invalid 115 Tusda 3 open USDA 3 Temperature Sensor Open Circuit ele LA Ajo USDA 3 Temperature Sensor Short Circuit 1 USDA 2 Temperature Sensor Invalid 118 Cargo Temperature Sensor Open Circuit 119 Cargo Temperature Sensor Short Circuit 2 Cargo Temperature Sensor Invalid Evaporator Temperature Sensor Open Circuit 122 Evaporator Temperature Sensor Short Circuit Evaporator Temperature Sensor Invalid Suction Temperature Sensor Open Circuit Suction Temperature Sensor Short Circuit 126 Suction Temperature Sensor Invalid Ambient Temperature Sensor Open Circuit 2 Ambient Temperature Sensor Short Circuit 129 Ambient Temperature Sensor Invalid 2 Pressure transmitter alarms 200 Pdis open Compressor Discharge Pressure Transmitter Open Warning Circuit Compressor Discharge Pressure Transmitter Short Warning Circuit Co
241. uble shooting Hints for general trouble shooting 1 Unit will not start up Check that power is applied to the unit Check that fuses at QS1 F1 and or F2 are not blown Check alarm list and clear alarms and alarm causes The unit is wired for emergency operation but the parameter F03 FC type under service menu is not set to NONE The menu F03 under service menu is set to NONE for emergency operation but the wires have not been correctly mounted for emergency operation 2 Unit starts but stops shortly after Check that the condenser motor is rotating and that the air is blowing away from the unit Check if the high pressure switch alarm is active in the alarm list Temperature sensors not working properly Check that they are placed on the pipes and are inside the isolation 3 Unit is running but is not bringing the temperature down to temperature setpoint The cargo is very warm it takes a long time to cool it down The ambient temperature is very high the condenser can only cool a little so the cooling capacity is small and the cool down process takes longer time 56 of 231 pages STAR OO Operating and service manual 1 The hot gas valve may be leaking so that the hot gas is by passing the condenser and is pumped into the evaporator and heating it up The expansion valve is not opening and no cooling refrigerant is pumped into the evaporator The condenser pressure will be very high The unit has been put in manual ph
242. uble shooting is to be used for Tevap as used for Tret in AL 101 Criteria Value above high alarm limit 140 C 284 F Replacement by new value from AAS system action Alarm light When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data e e m Active Inactive High limit Present iS 81 of 231 pages STAR LOA Operating and service manual L ii 123 Tevap invalid Warning Evaporator Temperature Sensor Invalid Cause Indication of defective evaporator temperature sensor or its measuring circuitry Trouble Possible causes shooting e Active alarms AL 121 AL 122 or AL 901 if CIM5 software e Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F Accompanied alarms e AL 121 or AL 22 may also be active Trouble shooting 1 If alarms AL 121 or AL 122 are active check their trouble shooting section first 2 Disconnect the sensor cable for sensor Tevap from the connector on the main controller according to the wiring schematics inside in the control cabinet 3 If AL 901 is active see trouble shooting for AL 901 4 Measure the resistance between the two wires a If the resistance is out of range of the resistance and temperature table in Tables p 203 the temperature sensor and cable are defective and should be replaced b If the resistance is within range perform main controller check
243. uc TO is steadily going down If based on the above it is determined that the unit is too low on refrigerant charge additional refrigerant may be charged by following this procedure 199 of 231 pages STAR OO Operating and service manual 1 Install a service gauge manifold to the unit and connect the HP hose to the Liquid charging line pos 11 P amp I diagram and the LP to the closed suction service valve Pos 27 P amp I diagram 2 Connect the service gauge manifold to the refrigerant bottle with scale Purge as needed 3 Close the Service valve economizer pos 14 P amp I diagram 4 Set the refrigerant bottle for liquid charging and open the valve 5 Open the LP service gauge manifold valve full and check the refrigerant bottle pressure suction service valve pos 26 remain fully closed 6 Operate the unit under normal condition means it will pump down the LP 7 Open the HP valve on the service gauge manifold to allow refrigerant to enter into the sys tem 8 Charge max 0 5 kg 1 Lbs if there is a need for more Check and repair the leak first 9 Close the refrigerant bottle valve 10 Close the service gauge manifold valves and remove them 11 Open the Service valve economizer pos 14 P amp I diagram 12 Run the unit h and check the R134a level in the receiver 13 Make sure to install all valve caps again Caution Do not overcharge the unit Leakage detection Leakage detection i
244. uency Converter Bypass VT SE Top SCH m Menu S05 F03 FC type None T T CC S w L BE D 3 Power cable from v a E TEE 7 CONTROLLER BOX O MOD a mm 44A 1 z 3 II vQ Isolated Te 2 GND ends Communication cable from N eed RH ren 218 CONTROLLER BOX l Bottom z Bee 51 of 231 pages STAR OO Operating and service manual Controller defective If the controller of the unit is malfunctioning or defective and no replacement is available the unit can be run in a emergency mode with deteriorated temperature controlling performance This operation is only recommended for cargo being transported in frozen mode setpoint below 10 C 14 F If the cargo is transported in chilled mode it is recommended that the defective controller is replaced with one from a unit operating in frozen mode The emergency procedure for a unit with a defective controller running in frozen mode is as fol lows 1 Dismount the frequency converter and connect the compressor directly to the power supply Use the contactor in the controller as a main switch for the compressor 2 Connect the evaporator fans in low speed and the condenser fan in high speed directly to the power supply 3 Mount permanent magnet on the electronical expansion valve pos 18 P amp I diagram 4 Install a service gauge manifold on the unit to the two evacuation points pos 6 amp 27 P amp I diagram C
245. uency is directly dependent upon current mode Evaporator heater on the other hand is gear independent There is overlap over the modes to maintain slow mode shifting Everything is turned off Start up If cooling is required the FC is starting at default frequency before shifting to correct cooling mode On Off regulation of compressor Maximum cooling capacity with use of economizer Only the heaters are used Defrost Heaters are always used and hot gas valve is used if ambient temperature is above 5 C 41 F The capacity of the unit is controlled between maximum cooling capacity 100 capacity and maximum heating capacity 100 capacity This is done by regulation of the compressor speed 10 of 231 pages STARK LOOL Operating and service manual by means of the FC or on off regulation In maximum capacity 100 capacity the unit uses the heating elements by means of pulse width modulation to control the capacity Below figure indicates the ranges for the capacity and compressor speed frequency Compressor frequency Hz BEE EEN A 110 Hz 3300 rpm Set point Set point 20 Hz 600 rpm lt 100 20 10 100 cooling Capacity heating Line 1 The area where cooling is requested controlled by the frequency converter Line 2 The area where the compressor is on off regulated Line 3 The area where heating is requested controlled by pulsing of heating elements The limiter functi
246. unit Controller DERE tog x jaam Alarm light Consequence 00 000 0 Replace ctrl module Fatal Alarm Description Description Controller module must be replaced Cause Internal error on the main controller module which requires replacement Trouble Possible causes shooting e Internal memory error Accompanied alarms e None Trouble shooting 1 Replace controller module Criteria Type 0 parameter 1 in the event log Wrong dataflash page size None Controller pui BR Quick flash Power cycle could lead to non operating controller Possible corruption of datalog Replace main controller module Log data Type see Type 0 above Flash page size 186 of 231 pages STAR OO Operating and service manual 996 _ Software CRC error Alarm Trouble Possible causes shooting e Validity check of the program failed Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 There is a fault on the main controller Update the software in the controller to the latest version 2 There is still a fault on the main controller Replace the main controller None action Alarm light Siow flash Consequence Log data 999 Keyboard Failure Warning Indication of defective keyboard Cause Keys on the keyboard pressed without user interaction Trouble Possible causes shooting e Defective keyboard defective user panel
247. unted correctly and is not damaged according to wiring diagram inside the controller cabinet 2 Verify that there are correct voltages 12 V DC on wire 1 3 Measure with a multimeter that there is a small DC signal on the wires 2 and 3 connector PCB for cable COM a If there is no signal The main controller is defective Replace the main controller b If there is signal The display is defective and must be replaced If there is no display permanent replacement available a substitution display can be used for setting values and evaluate the unit s status Criteria Communication via the display is not possible None unit can perform normally without displa Controller S S ES n EE flog X Alarm X Alarmilight not working Unit stop When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data Aciv Iactive O do Io In 145 of 231 pages STAR LOO Operating and service manual Power module missing Alarm Cause Indication of defective power module lack of or improper connection Trouble Possible causes shooting Communication with power module SPM6 broken 12 V DC to the power module SPM6 not applied Defective power module SPM6 X11 cable is defective Main controller defective Accompanied alarms e AL 710 AL 711 AL 720 and one or more AL 9XX may also be active Trouble shooting 1 Verify that power module cable is moun
248. upply voltage Trouble Possible causes shooting A36 The FC has had too many restarts within short time Manual activation of contactor K8 on off too many times Loose power connection for the FC Loose FC com cable for communication with the FC Defective FC Accompanied alarms e There may be other AL 5XX alarms Trouble shooting 1 Verify that supply power for the unit is stable and within specification 2 Check the FC com cable for damages and loose connection 3 Check supply power cables for the FC 4 The FC may be defective and should be replaced If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operation p 51 May occur if FC is activated too many times during a one minute period the primary side FC has been switched on off more than twice within 1 minute FC shut d Controller a action pam Alarm light slow flash Unit stops and restarts after some min Alarm will be marked as inactive in the alarm list when reset by the FC The alarm may then be deleted Log data p Active Inactive Freq FC 118 of 231 pages STAR OO Operating and service manual 1 Frequency converter high voltage fault warning Cause Indication of problems with supply voltage Trouble Possible causes shooting e Defective FC W7 Accompanied alarms e There may be other AL 5XX alarms Trouble shooting 1 The FC reports an internal
249. ure 1 10 Connect a vacuum pump with a service gauge manifold to the two evacuation points pos 6 and 27 P amp I diagram Check that all service valves are still closed pos 5 26 and 30 P amp I diagram Pump down the ambient pressure in the compressor to a vacuum indicated on the gauges of the service gauge manifold Continue vacuum pumping for at least 2 hours Removing eventually moisture in the oil Close the service gauge manifold LP HP valves Switch off the vacuum pump write down the vacuum reading from the service gauge mani fold Observe the vacuum for minimum 0 5 hour If there has been no change in the vacuum open all service valves pos 5 26 and 30 P amp I diagram If the vacuum is not maintained there is a possible leak somewhere Check all service gauge manifold hoses connections between compressor and vacuum pump If these are OK check the compressor amp valves for leak Disconnect the service gauge manifold and operate the unit as normal 197 of 231 pages STAR OO Operating and service manual 1 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 amp I diagram on the compressor 2 Connect a recovery unit to the gauge manifold 2a Connect a recycling bottle to the recovery unit 2b Use a sca
250. ut during soldering and desoldering 3 Use inert back gas as Nitrogen N2 during soldering and desoldering Welding Do not perform welding on the unit before disconnecting the power plug Furthermore disconnect the power meas module and main controller and modem if present Tables Datalog description Explanations of datalog loggings Temperatures are stored in C and are converted to Fahrenheit on retrieval or listing on the dis play Pressures are stored in BarE and are converted to Psi on retrieval The logged data in the data log can be seen e On the display menu L01 the viewable temperatures are listed On the display menu L03 the logged temperatures can be viewed graphically Retrieved via the program RefCon and the RMM modem and the powerline Retrieved via a program LogMan on a PSION pda using the retriever socket Retrieved via the StarView program using the retriever socket 1 Tsupply temperature Temperature from supply sensor 177 2 Treturn temperature Temperature from return sensor 177 3 Tusda 1 temperature Temperature from USDA sensor 1 c 4 Tusda2temperature Temperature from USDA sensor 2 C 5 Tusda 3 temperature Temperature from USDA sensor 3 C_ s Teargo temperature Temperature from cargo sensor C_ 5 humidty Humidity from humidity sensor Arex airflow airflow from AirExchange sensor mh 203 of 231 pages STAR LOA Operating and service manual
251. ve the electrical coils and install permanent magnet on the 3 valves pos 16 18 and 32 P amp I diagram b Turn off unit c Close and open again the discharge service valve pos 5 P amp I diagram approx 4 turns d Check that the Recovery unit is set for Vapor recovery e Open both service gauge manifold valves LP HP Continue to 5 4 Vapor recovery If possible to run the compressor a Continue operation on compressor b Close service valve economizer pos 14 P amp I diagram from the receiver and run a pump down of the LP side of the compressor to approx 0 8 BarE c Turn off the compressor d Close the suction service valve pos 26 P amp I diagram e Check the Recovery unit is set for Vapor recovery f Remove the electrical coils and install permanent magnet on the 2 valves pos 16 and 18 P amp I diagram g Open only the HP valve on the service gauge manifold 5 Start and operate the recovery unit as long as necessary to evacuate desired amount of refrigerant from the unit until no pressure left 6 Open suction service valve fully 7 Check the service gauge manifold should be in slight vacuum 8 Close all valves and stop the recovery unit Evacuation done Note refer to operating and service manuals for the recovery equipment Service valve economizer Liquid charging valve pos 11 Compressor pump down operation Pump down of the compressor is done by the following procedure 1
252. ve top alarm limit 10K Ohm Condenser fan motor is stopped Controller PP action Alarm light Air circulation in container stops causing unit to stop When overheating disappears alarm will be marked as inactive in alarm list and may then be deleted Control is again released but fan motor will only be allowed to operate at low speed for the first 5 min If the error does not reoccur problem will be considered solved and condenser fan high speed is again released Log data i RET Active Inactive s imit_ Present_ 100 of 231 pages STAR OO Operating and service manual 1 410 Unstable supply Fatal Unit power supply is unstable Cause A drop out in the power supply has occurred Trouble Possible causes shooting e Inadequate power supply and or bad genset Accompanied alarms e AL 414 415 416 417 418 419 424 425 426 427 428 and 429 Trouble shooting 1 If there are other active alarms check these first Clear these alarms first using their trouble shooting 2 If the unit is supplied with a genset try to replace the genset first and see if error still persists 3 Ifthe unit is supplied from a stable power grid and the problem still persists replace main controller module The main controller measures the zero crosses on the supply voltage if a drop out of more than on period occurs the alarm is triggered Controller breaks supply after 5 sec After 30
253. ved to other lines Air exchange page i Air exchange 1 1 888 nn 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 102 30 of 231 pages STAR OO Operating and service manual Operation Menu Structure 888m h Press X to leave ORMA O I01 Relative humidity I02 Air exchange 103 o2 I04 co2 105 Last defr interval I06 USDA 1 temp 107 USDA 2 temp I08 USDA 3 temp I09 Cargo temp 319 Time to defrost I11 Ambient temp 112 Supply air 1 temp 113 Supply air 2 temp I14 Return air temp I15 Evaporator temp I16 Suction temp DL Suction press 118 Membrane pressure I19 Discharge press 120 Expansion valve 121 Evap superheat 122 Compressor freq 123 Power frequency 124 Current phase 1 125 Current phase 2 126 Current phase 3 127 Voltage phase 1 2 128 Voltage phase 2 3 129 Voltage phase 1 3 130 Phase direction 131 Battery voltage 132 FC temp 133 Condenser fan 134 Evaporator fan 135 Evaporator heater 136 Pump temperature OPERATIO 001 Setpoint 002 003 Control mode 004 Humidity setpoint 005 Datalog interval 006 PROGRAMS gt 007 02 setpoint 008 CO2 setpoint 009 Active application A01 Alarm text A02 A16 A01 Alarm text A02 A16 s01 MANUAL OPE
254. x change on Pdis 0 75 Bar Pdis is less than 5 BarE Max change on Pdis 0 30 Bar Tret more than or equal 2 to 15 C Min change on TO 20 K Tret is less than lt 15 C Min change on TO 10 K None Elimination Alarm may then be deleted after test completed Parm 5 See Function test p 16 155 of 231 pages STAR LOO Operating and service manual 843 Economizer valve Alarm Economizer Valve Fault Cause Indication of non operating economizer valve Trouble Possible causes shooting e Cable for economizer valve mounted on wrong valve e Cable for economizer valve defective e Economizer valve defective e Driver circuit for economizer valve defective Accompanied alarms e N A Trouble shooting 1 Ifthere is more than one valve failure the cables for the valves are presumably switched Mount cables for valves on the correct valve 2 Listen if the economizer valve is opening and closing If not then go to 4 If the valve is opening and closing close service valve pos 30 P I diagr intermediate line Run the FT again it the test now is a pass the economizer valve is defective and should be replaced Check that the cable for the expansion valve is not defective Replace cable if it is damaged Disconnect the cable for valve and measure that there is voltage on the output for the expansion valve when it should open a Ifthere is no voltage the main controll
255. y Converter Discharge Pressure Transmitter P dis High Pressure Switch Discharge Service Valve Evacuation Point Discharge Line Condenser Fan Air Cooled Condenser Liquid Line Liquid Charging Valve Fusible Plug Receiver Water Cooled Condenser Service Valve Economizer Drying Filter Electronical Expansion Valve Economizer V eco Economizer Electronical Expansion Valve Evaporator V exp Evaporator Evaporator Fan Return Air Sensor Tret Evaporator Temperature Sensor T evap Heating Elements Supply Air Sensors Tsup1 Tsup2 Suction Temperature Sensor T suc Suction Service Valve Evacuation Point Suction Pressure Transmitter P suc Economizer Suction Service Valve Hot Gas Valve Vhg Humidity Sensor RH Controller Communication Slot Ambient Temperature Sensor Tamb Plug for Cargo Temperature Sensor 219 of 231 pages STAR OO Operating and service manual Overall W A IC Schemat iring 91 9MY xog 48 o4uoz episino HA gs 9deA eH xog J8J 0 U07 9pISU a N qe E ba no Ed E CC xog 1eJJo4uo2 episino o 5 a E dens 3 P ir AST Y S IVNDIS VNOIS S 9 GND QN9 9 cox L JIVNSIS IVNOSIS L 2 GND ND z IVNDIS VNOIS v GND GND v S IVNDIS VNOIS S 9 GND aN9 9 4 WNOIS VNOIS Z 8 GND GND 8 6 IVNDIS IWNDIS 6 ONG ONG L CIVNO
256. y new value from AAS system Elimination When sensor value becomes valid it is marked as inactive in alarm list Can be deleted Log data Active Inactive Low limit High limit Present 6 sec 89 of 231 pages STAR LOO Operating and service manual Les Psuc invalid Warning Compressor Suction Pressure transmitter Invalid TN Indication of defective compressor suction pressure transmitter or its measuring circuitry Trouble Possible causes shooting Connector for suction pressure transmitter Psuc not correctly mounted Suction pressure transmitter Psuc defective Cable for suction pressure transmitter Psuc defective X22 and cable is defective Main controller defective Accompanied alarms e AL 204 AL 205 AL 206 or 250 may also be active Trouble shooting See Trouble shooting for AL 206 Value below alarm limit 0 9 BarE 13 Psi or above 11 8 BarE 171 Psi Value invalid for 30 sec for alarm activation Replacement by new value from AAS system Controller D NM Alarm light Consequence When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Value must be valid for 60 sec to set alarm inactive Log data Acie madive O JOP 250 Press sensor type Alarm Saved FC ID controller does not match the current FC ID Controller or FC has been replaced requires manually setting of pressure transmitter NSK ASK Trouble Possible causes shooting e Wrong s

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