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810900B_March_Operating and service manual.indd

1. mH lli Wi ED U qy Cool Thinking STARECOOL Version 810900B March 2008 STAR COOL Item No 810900B Operating and service manual Preface This version of the manual is dated March 2008 edited by Maersk Container Industri AS All rights reserved This user s manual is valid for software version 0240 or newer versions The information herein is subject to change without notice and does not represent a commitment on any part of Maersk Container Industri AS While the information herein is assumed to be accurate Maersk Container Industri AS assumes no responsibility for any errors or omissions that may appear in this documentation Model version This manual is valid for Model SC MCI40 and SC MCI40 WC Release Date 01 03 2008 Part number 810210A and 810200B Software version 0240 0249 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 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 release R1
2. Psuc TO and Tevap Only electrical defrosting TO constant Tsuc Only electrical defrosting TO constant Tamb and Tinternal Always electrical defrosting PO Electrical control Following graphical illustration shows the accepted volt Hz range and the set off values for the alarms AL 414 Fatal Alarm AL 415 Fatal Alarm AL 416 Fatal Alarm AL 417 AL 418 AL 419 AL 427 AL 428 and AL 429 Fatal Alarm based on the table below Volt max voltage AL414 AL415 AL416 600 4 alarm U f AL428 max U f AL429 500 7 400 5 300 5 alarm U f AL427 min U f AL429 200 4 min voltage AL417 AL418 AL419 100 1 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 19 of 221 pages STAR 3E COOL Item No 810900B Operating and service manual Frequency AL417 AL418 AL 429 AL 427 AL 428 AL 429 Al414 f Hz AL419 at voltage at voltage at voltage at voltage AL415 Min voltage U V U V U V U V AL416 U V Fatal Alarm Fatal Alarm Max voltage U V Fatal Alarm o WwW o w Ko W e A eo AB ui U j U N Ui U1 U01 N Ui WIN Wi_W Ww CO Blefeyelde oJj ojojo A A AIS MINI H H OlwI NI o uy ul NI NIN uy ul Ww Ui N CJ nin e Ww w n ojo A co n N Ui o w w Ble ojo AYALA o uj oy A N Ui DA Oo Oo 52 Ww n eo Ui
3. If the cable for MevapiOH by inspection is defect replace cable Disconnect the cable for Mevap1OH from the connector PCB 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 defect and should be replaced If the resistance is less than lt 5 kQ the cable and motor should be Ok 5 Check resistances on the interface terminal block PCB above X33 and X34 They must be 220 kQ 6 Turn unit on again Measure the voltage over the connector for Mevap1OH It should be between 4 80V DC and 5 05V DC a If the voltage is inside the above range connect sensor again Measure the voltage over the sensor and check the voltage If the voltage is less than lt 2 5V DC the measurement is ok If the alarm after 30 sec is still active on the display the controller PCB is defect replace controller door If the voltage is outside the range controller PCB is defect or another error might affect the voltage Check other alarms before replacing controller door Criteria Both evaporator fan motors are stopped Frequency controller is stopped and unit stops Controller action 107 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 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
4. Reference voltage Pdis above 5 20V DC None Controller n teret tog X Aor Alarm light Consequence Log data m a Active Inactive High limit Actual value A D channel 178 of 221 pages STAR COOL Item No 810900B Operating and service manual 963s Psuc sens sup LO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect Psuc pressure sensor e Defect controller PCB 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 RY 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 80 and 5 05V DC 3 While displaying U Psuc remove the connector at Psuc If U Psuc is now inside the correct above range 4 80 5 05 V DC the Psuc pressure sensor is defect Replace the Psuc pressure sensor If U Psuc is still outside the above range proceed to next step 4 While displaying U Psuc disconnect Pdis from the terminals according to wiring schematics inside in the control cabin
5. 23 H N Econorrizer b Electronical Expansion Valve Evaporator Vap Evaporator Evaporator Fan Retum Air Sensor Tret Evaporator Terrperature Sensor Tevap 6 xa 9 24 24 Heating Elerrents Supply Air Sensors Tsup1 Tsup2 Suction Terrperature Sensor Tsuc Suction Service Valve 5 7 Evacuation Point Suction Pressure Transmitter Psuc Economizer Suction Terrperature Sensor Teco Econorrizer Suction Service Valve Intermediate Pressure Transmitter Peco Hot Gas Valve Vhg Humidity Sensor RH Controller 34 j i Communication Slot Arrbiert Terrperature Sensor Tanb Plug for Cargo Terrperature Sensor YRRRUREBBBNERSUNNY Refrigerant R134a Note Please be advised that the sensors Peco and Teco can appear in this diagram eventhoug they are out of use for Units with software ver 0240 and forward Legend Low Pressure Stage High Pressure Stage Cu pipes according to EN 12735 1 Suction Gas Line Liquid Line Electrical Line weibeig 179 d 1002 ALS 8006018 ON UJoiT enueui dnos pue bunededo STAR COOL Item No 810900B Operating and service manual Star Cool Unit installation dimensions 2025 1974 7 6x298 45 1790 7 30x 618 2235 6x248 45 1190 7 219 of 221 pages
6. Alarm light Consequence Log data 3 m Active Inactive High limit Actual value A D channel 184 of 221 pages STAR COOL Item No 810900B Operating and service manual Pspare sens sup HI Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 Access the special menu by pressing RY for more than 3 sec Scroll down until you see the label U Pspar in the display The value of U Pspar should be in the range between 4 80 and 5 05V DC 3 While displaying U Pspar remove the connector at Pspar f U Pspar is now inside the correct above range 4 80 5 05V DC the Pspar pressure sensor is defect Replace the sensor connected to Pspar If U Pspar is still outside the above range proceed to next step 4 While displaying U Pspar disconnect sensor from the terminals according to wiring schematics inside in the control cabinet JIf U Pspar is now inside the above range the cable for Pspare is defect Mount connector correctly or replace connector cable for Pspar If U Pspar
7. x 52 of 221 pages STAR LOOL Item No 810900B Operating and service manual Erase datalog memory popu Update controller software via x bootloader Update controller software via x protocol Operate controller in manual mode P x x 1 Basic data Tset Tsup Tret RH Tusdal 3 Tcargo Operation mode Ubat x Not all information is visible on the controllers display Location of valves Description Discharge pressure stop valve Intermediate pressure stop valve Hot gas valve Service valve economizer Electronical expansion valve evaporator 53 of 221 pages STAR COOL Item No 810900B Operating and service manual 6 Electronical expansion valve economizer Suction pressure stop valve Location of temperature sensors humidity sensor and air exchange potentiometer ERE DNE 2 Supply temperature sensor Tsup 2 outside 54 of 221 pages STAR COOL Item No 810900B Operating and service manual Economizer Suction Tempera Teco 1 Outside ture optional Ambient temperature sensor Tamb 1 Outside E Air Exchange potentiometer Behind fresh air cover panel Location of pressure transmitters
8. Main power failure Main Power Fault S Description Main Power Fault 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 action Alarm light Consequence S Log data Active Inactive o Jo o Battery voltage LO Low Battery Voltage Indication of defective battery Trouble Possible causes shooting e Battery too old 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 7V None Controller action 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 m um 912 Battery voltage HI High Battery Voltage Cause Pd 168 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Battery defect e Battery cables defect Accompanied
9. Menus are selected by pressing a menu key or by pressing the Enter key on a sub menu line shown in the display 28 of 221 pages STAR LOOL Item No 810900B Operating and service manual General Page layout ous O01 Setpoint 9 9 C Menu icon Menu title Cursor line OPERATION 003 Airflow mode NORMAL 004 Humidity setpoint OFF 005 Datalog interval 15 m 006 Programs Parameter ID Parameter name D Value Unit M p IM Using the cursor The parameter ID is only used for identifying each displayed line of the menu system Pressing the 4 and y 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 2 3 5 6 First move the cursor up press or down press to the line of the parameter to be changed Then press the Enter key The cursor will now highlight the parameter value instead of the ID 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 If not pressing any key for 5 sec or if pressing the Cancel key 6o the value will not be changed The cursor returns to the ID column and can now be moved to other lines Activating a function 1l First move cursor Up press 4
10. Off Everything is turned off Start up If cooling is required the FC is starting at default frequency before shifting to correct cooling mode PWM On Off regulation of compressor Maximum cooling capacity with use of economizer Only the heaters are used May also be active in hotgas mode Defrost Heaters are always used and hotgas 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 by means of the FC and the hotgas valve for minimum capacity control 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 10 of 221 pages STAR COOL Item No 810900B Operating and service manual Below figure indicates the ranges for the capacity and compressor speed frequency Compressor frequency Hz METTRE ee EAEE D a Set point Set point 20 Hz 600 rpm gt 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 or hotgas regulated older than 0241 Line 3 The area where heating is requested controlled by pulsing of heating elements The limiter function secures that the co
11. Mount the cable for AirEx in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on the interface terminal block PCB If the voltage is below 0 2V DC sensor or connection between sensor and cable is defect If the voltage is between 0 0V DC and 4 0V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND If the voltage is between 0 2V DC and 4 0V DC and this alarm is still active continue to 5 Check controller see Trouble shooting for Star Cool Controller p 56 before replacing controller door Controller r consequence S 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 i Active Inactive PP 306 High press switch Warning High pressure switch is active Discharge pressure is too high and the high pressure switch off 104 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting 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 Fuse F6 blown High pressure switch or cable is defective Wrong pressure transmitter in relation to controller settings Pressure transmitter defect X1 cable is defect Controller
12. PTI defrost Alarm PTI Defrost Fault Cause 161 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting Defect Tevap temperature sensor Defect Psuc pressure sensor Defect heaters Defect hotgas 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 defect 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 defect 3 The hotgas valve is not working properly and the heaters may be defective Check trouble shooting for the hotgas valve in alarm AL 844 4 See if the evaporator is filled with ice through the inspection holes Be careful with the fans of the evaporators Criteria Defrost terminated on 45 min time out None Controller action Alarm light slow Rash Test failed Elimination Alarm may then be deleted after test completed Log data 162 of 221 pages STAR COOL Item No 810900B Operating and service manual PTI Tset 18 Alarm PTI 18 C Set Fault Indication of insufficient performance Trouble Possible causes shooting e Doors are open e The cooling capacity is too limited e There may n
13. Replacement by new value from AAS system Controller P d y ti ae 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 5 ActivefInactive CT o y 77 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 118 Tcargo open Warning Cargo Temperature Sensor Open Circuit Cause Indication of loose connection defect or lack of cargo temperature sensor Trouble Possible causes shooting Temperature sensor Tcargo or its cable defective X1 cable is defect Defect plug inside or cable on the unit backside Controller PCB defective Accompanied alarms e N A Trouble shooting 1 Disconnect the sensor cable for sensor Tcargo from the connector on the interface terminal block PCB 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 the plug inside in the unit or the sensor is defect Check plug before replacing sensor and cable b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tcargo It should be between 4 80 and 5 05V DC a If the voltage is inside the above range
14. STAR LOOL Item No 810900B Operating and service manual 944 Sealing Gaske s e Oo 9 O eE I o TES E ATEI lo 5 B B s a ie e o o o o o o o o o o o o o o jo oo o oe ojo o oo a
15. Value below alarm limit 0 1 BarE 2 Psi or above 31 9 BarE 462 Psi Value invalid for sec for alarm activation Replacement by new value from AAS system Controller P y y n im Alarm light consequence 1 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 Active Inactive P 93 of 221 pages STAR COOL Item No 810900B Operating and service manual 204 Psuc open Warning Compressor Suction Pressure Sensor Open Circuit Cause Indication of loose connection defect or complete lack of compressor suction pressure sensor Trouble Possible causes shooting Connector for Psuc not correctly mounted High pressure sensor Psuc defective Cable for high pressure sensor Pdis defective X1 cable is defect Controller PCB defective Accompanied alarms e AL 200 or AL 201 may also be active Trouble shooting Disconnect the cable for Pdis from the connector PCB according to the wiring schematics inside the control cabinet and from the high pressure sensor 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 dupu 2 Ground OUTPUT Figure for AKS Figure for NSK Check the cable measure the resistance in the ca
16. 09C 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 the 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 5 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 221 pages STARIS COOL Item No 810900B Operating and service man
17. 9 wl 2 3 8 4 66 78 22 2 0 67 01 22 3 150 58 14 18 7 67 24 22 4 P 0 2 A Y 7 0 67 70 22 6 67 92 68 15 68 37 224 67 47 22 6 0 0 2 8 2 9 3 0 2d 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 4 0 4 1 4 2 4 3 4 4 4 5 7 1 209 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 4 9 21 02 5 0 21 57 51 22 12 5 2 22 65 9 49 23 Fra Temperature F Pressure Psi Table R134a Psi REI Si HET Psi ISR Psi R Psi F Psi EET Psi RE 45 36 11 60 70 15 46 72 203 05 57 91 48 07 204 50 149 27 48 64 49 41 205 95 149 68 133 25 133 75 134 24 134 73 26 23 26 72 27 20 10 15 8 70 7 25 5 80 4 35 2 90 1 45 165 15 203 05 204 50 205 95 41 12 50 70 87 62 133 25 261 07 150 12 314 73 164 77 34 73 47 86 51 98 101 53 88 41 133 75 262 52 150 53 316 18 1 210 30 21176 213 21 214 66 zs 261 07 75 260 50 76 54 46 90 00 211 76 134 73 19 68 55 67 90 77 213 21 151 79 320 53 166 24 15 57 56 86 91 53 214 66 152 20 321 98 166 62 T3618 268 77 es za 272 67 1 274 12 29 15 49 31 53 22 102 98 89 20 56 64 114 35 210 30 134 24 263 97 150 96 317 63 165 51 24 18 50 76 151 38 319 08 165 88 1 45 2 90 4 35 5 80 7 25 8 70 11 78 55 11 58 03 f 108 78 92 28 162 44 116 71 216 11
18. CJ WwW WwW e e ATA N u o N M N N ui U Ui M Ww Ww WwW Ble ojo o uje O Co WIN Ul N ul Ui AJA AIA DA DA ALT AT ATA A ln o EE OlLOINIDAD A pa Ww o A oO AJAJAJA A A A Annn ana AJAJ A A Annn N N hN N N N N N hN N AIA AJAJ A A A AJA A A A AJAn U1 01 0U1 Anana 01 01 UJ o ul I e n Ul N N NIN CJ n eo ul oO Ww o Ui o oO ojo o WIN Wi WwW WwW ejeje O10 0O N N N HR o Ui www ojojo Oo N Wi Ww w Blele eIicJ o Ui NTN Ui N eo Ww nin e Refrigeration system data Refrigerant charge R134a 4 5 kg with water cooled and non water cooled condenser General specification Total unit weight 460 kg or 420 kg or 415 kg dependend 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 20 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Compressor motor assembly Bitzer Semi hermetic two stage reciprocating 2 High stage cylinders Variable FC controlled S4BCF 5 2 5 5 kW Reniso Triton SEZ 55 or equivalent 1 5 liter Sea water resistant aluminium unpainted 58 Kg Frequency converter FC Danfoss FEM 375 15 110 Hz 450 3300 rpm Sea water resistant aluminium unpainted IP 54 High Pressure cut out switch 22 5 BarE 3
19. 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 mm Adive matie Mehimt cure 401 Mevap2 overheat Warning Evaporator Motor 2 Overheat Indication of an overheated motor or a loose thermistor cable connection Trouble Possible causes shooting Evaporator motor 2 defect Defect resistances on the interface terminal block PCB Cable for measuring evaporator motor 2 overheat defect Controller PCB defective 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 defect If the cable for Mevap2OH by inspection is defect replace cable Disconnect the cable for Mevap2OH from the connector PCB 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 defect and should be replaced If the resistance is less than lt 5 kQ the cable and motor should be Ok 5 Check resistances on the interface terminal block PCB above X33 and X34 They must be 220 kQ 6 Turn unit on again Measure the voltage over the connector for Mevap2OH
20. Default is NORMAL 004 Reference relative humidity setting Humidity setpoint Function Setting of reference relative humidity Note that container relative humidity is only reducable 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 005 Datalog interval setting Datalog interval Function 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 40 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Programs 006 Programs selection menu PROGRAMS Function Leads to the programs sub menu Value Press to go to the programs sub menu PO1 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 DO1 Settings per step DO6 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 temperatu
21. It should be between 4 80V DC and 5 05V DC a If the voltage is inside the above range connect sensor again Measure the voltage over the sensor and check the voltage If the voltage is less than lt 2 5V DC the measurement is ok If the alarm after 30 sec is still active on the display the controller PCB is defect replace controller door If the voltage is outside the range controller PCB is defect or another error might affect the voltage Check other alarms before replacing controller door Criteria Value above high alarm limit 10 K Ohm 108 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Both evaporator fan motors are stopped Controller action og x em x mi 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 z EX Active Inactive honimt current o y o 109 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 402 Mcond overheat Warning Condenser Motor Overheat Indication of an overheated motor or a loose thermistor cable connection Trouble Possible causes shooting Condenser motor defect
22. if not done yet RUN if still running test PASS if test finished successfully FAIL if the test failed ABORT if the test was aborted by the user See specific description for alarm 820 821 in Test alarms p 154 T11 Test result 80 Compressor 80 Compressor Function Shows the status of the test of the compressor Value df not done yet RUN if still running test PASS if test finished successfully FAIL if the test failed ABORT if the test was aborted by the user See specific description for alarm 845 and 846 in Test alarms p 158 T12 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 T13 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 alarm 855 in Test alarms p 160 T14 Test result 110 Temperature set point 0 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 running
23. the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Value above high alarm limit 140 C 284 F Replacement by new value from AAS system Controller r consequence S When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data em Active Inactive Mehimt cure ooo o 82 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 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 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 interface terminal block PCB 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
24. 221 pages STAR 2 COOL Item No 810900B Operating and service manual 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 Refrigeration controls Expansion valves 2 solenoid valves electronically controlled from controller Filter Drier Danfoss DML 164 with O ring or equivalent Hot gas valve Solenoid valve electronically controlled from controller Moisture indicator Incorporated in receiver sight glass Material Brass acc to EN 12164 CW602N Solid copper tubes according to EN 12735 1 Pipe coating Primer Epoxy resin zf a120 Top coat Polyurethane resin Hipon 50 Electrical data Input power 3x 350 V 460 V 50Hz 3 x 400 V 500 V 60 Hz Control circuit voltage AC 24 Vac Nominal varies with power supply 18 Vac 350 V 30 Vac 500 V Control circuit voltage DC 24 V DC Nominal varies with power supply 15 V DC 350 V 30 5 V DC 500 V Circuit Breaker Contactors 9 amp at 40 C 104 F amp 400 volt a 7 amp at 70 C 158 F amp 520 volt Fuses Secondary main fuses 10 A tube fuse Control circuit supply 0 4 A tube fuse 24 V AC circuit 6 3 A tube fuse Power plug Type CEE 17 4 pole with earth 32 amp 400 460 V 50 60 Hz 23 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Power Cable 4x 25 4 mm 450 750 V PU s
25. 76 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Tusda 3 invalid Warning USDA 1 Temperature Sensor Invalid Cause Indication of defective supply air temperature sensor or its measuring circuitry or sensor not mounted correctly in unit Trouble Possible causes oong Active alarms AL 115 AL 116 or AL 901 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 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 Check that sensor Tusda1 is mounted correct by its mounting hole 3 If AL 901 is active see trouble shooting for AL 901 4 Disconnect the sensor cable for sensor Tusdal from the connector on the interface terminal block PCB 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 starting p 204 the temperature sensor and cable are defect and should be replaced b If the resistance is within range perform controller door check Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Activated by UWS or AL 901
26. 91 417 71 423 51 429 31 435 11 440 91 446 72 232 06 Voltage Pressure Table High pressure transmitter NSK Vcc 5V Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure V BarE Psi V BarE Psi 0 5 0 0 00 2 05 15 50 224 874 0 55 0 50 7 254 24 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 5224 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 65 286 2 5 20 00 290 16 1 5 00 72 54 2 55 20 50 297 414 1 05 5 50 79 794 12 6 21 00 304 668 311 922 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 00 377 208 214 of 221 pages STAR COOL Item No 810900B Operating and service manual 1 6 11 00 159 588 3 15 26 50 384 462 1 65 11 50 166 842 3 2 27 00 391 716 1 7 12 00 174 096 3 25 27 50 398 97 1 75 12 50 181 35 35 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
27. A Trouble shooting 1 Check cables for sensors for damages 2 The controller PCB is defect Replace the controller door Criteria Idle current exceeds limit of 0 3A with only controller running None Controller action Alarm light slow Aash Test failed Elimination Alarm may then be deleted after test completed Log data R 810 Mevap cur LO speed Alarm Evaporator motor low speed current fault Indication of defective motor or defective supply cables to motor Trouble Possible causes shooting Evaporator motor jammed or defect Evaporator motor cables defect 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 Alarm light slow Aash Test failed Elimination Alarm may then be deleted after test completed Log data 150 of 221 pages STAR COOL Item No 810900B Operating and service manual 811 Mevap cur HI speed Alarm Evaporator motor high speed current fault Indication of defective motor or defective supply cables to motor Trouble Possible cau
28. Alarm Fatal Alarm Fatal Alarm HE w E g D RE el TE JS re Ui ARIA NIO 1 Warning 18 U2 3 under voltage Warning 19 UES under voltage Warning 2 2 22 Fatal alarm Power frequency Phase Frequency Error t 425 warning 426 Alarm 2 Alarm Alarm 429 Fatal alarm 30 Alarm FC FC missing Fatal Alarm 01 FC local contro Alarm 08 FC short cre FC Short Circuit Fault Aarm Alarm 09 FC 24V faut Fc Internal 24V Supply Fault Alarm Alarm 10 FC earth faut FC Earth Fault Alarm aem FCovercur FC Overcurrent Fault Alarm Aem FC motor therm FC Compressor Motor Over temperature Alarm 3 FCoverload FC Overload Fault arm aem 514_ FC under volt FC Voltage Low Fault Alarm Alarm 15 FC over vot FC Voltage High Fault Alarm aarm 516 _ FC phase loss FC Phase Loss Fault Alarm Alarm D co D o AY A L L L D N Hd N AJW og og og og og EH N 0o ays Ui ol o ui U1 U1 O Ui Oyu 2 Nie Ui E 3 3 wn Ui Ui 58 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 522 FC high temp 2 FC phase loss FC current limit FC overload FC setup error 66 FC undefined alarm FC Trip Lock ration alarms No control sensors 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 Ala
29. Cause Phases may be lacking or there may be extremely high noise in one or more phases in the detection moment Trouble Possible causes shooting The unit is supplied with an unstable voltage The voltage is unstable unmeasurable The power frequency is out of specified range Loose flat cable between power meas PCB and terminal PCB Defect Power Meas PCB Accompanied alarms e AL 424 may also be active Trouble shooting 1 Check or and replace flat power cable between power meas PCB and terminal PCB 2 Check if voltage on all 3 phases is within specified range 3 Verify that all 3 phases are applied to the unit 4 Verify that power frequency is within specified range 5 Verify that correct voltage is applied to the unit 6 Check replace power meas PCB 7 If 1 to 6 are ok then replace the controller door or set the correct phase direction on the Configuration menu FO5 to clockwise or counterclockwise Criteria Impossible to detect phase sequence in power supply Controller breaks s action Alarm light Quick flash 116 of 221 pages STAR COOL Item No 810900B Operating and service manual 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 CW_ No of ccw Min no ox 425 Frequency too high Warning Power Frequency Too High Warning Power generator adjusted to too high frequency T
30. DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND If the voltage is between 0 2V DC and 4 0V DC and this alarm is still active continue to 5 Check controller see Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Value above high alarm limit 225 m hour None Controller action Alarm light Consequence When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data Tm Active Inactive Hoh mt cure ooo Air Exchange Sensor Short Circuit Not implemented yet Indication of short circuited air exchange sensor 102 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting AirEx is out of calibration Air exchange sensor AirEx or cable defective X1 cable is defect Controller PCB defective Accompanied alarms e AL 305 Trouble shooting 1 If the cable by inspection is defect replace cable 2 Calibrate AirEx see p 188 If the value shown in controller is wrong or alarm still active then disconnect the cable for AirEx from the connector PCB 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 interface terminal block PCB Measure voltage between wire and GND on the interface terminal block PCB If
31. Database Fault Log oo 907 Real time Clock Unreliable Ko ct E 2 o E E Cy 3 Uu BB Co A Ko Ojo 8 Realtime invalid Real time Clock Unavailable Display error Display Unavailable oO e Ko 11 Low Battery Voltage i 1 High Battery Voltage Syl Controller Internal Voltage Reference Fault 52 Controller Internal Voltage Reference Fault 5 Controller Internal Voltage Reference Fault 5 Controller Internal Voltage Reference Fault 955 Controller Internal Voltage Reference Fault 5 Controller Internal Voltage Reference Fault Warning Log 1 Main power failure Main Power Fault og Ko N xo xo xo 0 AJU Ui XO XO NIO Controller Internal Voltage Reference Fault 58 Controller Internal Voltage Reference Fault 59 Controller Internal Voltage Reference Fault Controller Internal Voltage Reference Fault xo 0 Ko 6 Controller Internal Voltage Reference Fault 962 Controller Internal Voltage Reference Fault Controller Internal Voltage Reference Fault 6 Controller Internal Voltage Reference Fault 65 Controller Internal Voltage Reference Fault Controller Internal Voltage Reference Fault Controller Internal Voltage Reference Fault 70 Controller Internal Voltage Reference Fault Controller Internal Voltage Reference Fault LO 972 Pspare sens sup HI Controller Internal Voltage Reference Fault PF 80 Tinternal LO Controller Internal Voltage Reference Fault 981 Tinternal HI Controller Interna
32. FC and compressor 4 The FC needs repair and should be replaced Criteria FC temperature not increased by15 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 159 of 221 pages STAR LOOL Item No 810900B Operating and service manual 850 PTI test failed Alarm PTI Test Fault 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 Controller Alarm light slow Aash Test failed Elimination Alarm may then be deleted after test completed Log data Ativemadwe i Testtme sec 855 PTI Tset 5 Alarm PTI 5 C Set Fault Indication of insufficient performance Trouble Possible causes shooting Doors are open The heaters do not operate normally The cooling capacity is too limited There may not be enough refrigerant in the unit 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 defect Start the heaters in manual mode and see if the current
33. Internal Voltage Reference Fault Cause Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 24V DC and 5V signals to see if power supply has an open circuit or other damages If voltages are ok the controller PCB is defect Replace controller door Criteria Ground reference voltage above 0 2V DC None Controller r Consequence OOOO Log data i E Active Inactive High limit Actual value A D channel The measured voltage is internal on the controller PCB and cannot easily be measured 174 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 959 RHsens sup LO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect relative humidity sensor e Defect controller PCB Accompanied alarms e There may be sensor alarms especially AL 302 e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if there are other active sensor alarms Clear
34. No 810900B Operating and service manual 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 and tray heating elements are turned on Compressor runs at a constant frequency at 83 of full speed Expansion valve control is deactivated Hotgas valve is used to heat the evaporator from the inside with the hot gas from the compressor 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 divideable into two parts Evaporator re freezing preventing remaining water drops on evaporator from blowing into container upon evaporator fan initiation Termination ensuring low evaporator
35. No 810900B Operating and service manual 969 AirEx sens sup LO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect sensor pulling power supply down e Defect controller PCB 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 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 80 and 5 05V DC 3 While displaying U AirEx remove the connector at AirEx potentiometer If U AirEx is now inside the correct above range 4 80 5 05V DC the AirEx potentiometer is defect 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 If U AirEx is now inside the above range the cable for AirEx is defect Mount connector correctly or replace connector cable for AirEX If U AirEx is still outside correct the above range The controller PCB is defect
36. 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 Runthe 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 the 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 Cap the oil outlet from the oil pump 12 Set the 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 wN Soldering When soldering and desoldering components on the unit please observe the following T3 Use the following material for soldering 203 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 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 t
37. Operation A Warning High Voltage Unit must be disconnected from power Only to be done by trained personnel FC dismounted If FC is defective and no replacement part is available compressor may be run in the on off mode Defective FC is dismounted and the 3 phases are directly applied to the compressor supply termi nals Also a wire jumper has to be fitted on the remaining 3 terminals see below figure In the service 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 ON Normal Connection Menu S05 lt F03 gt FC type DAN UN puc Frequency Converter 7 ee from Compressor Frequency Converter Bypass Top ea N Menu S05 lt F03 gt FC type None l ee T 2 n 2 s Ten N O 965 rT ui T i u 270 7 Isolated l PNG MEN Jg i em CONTROLLER Boe Bottom 7 ae 815594C 50 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual External interfaces The Star Control can be accessed externally in the following ways socket RS 232 Retriever Binary logfile n v mme es R E ns Ee as ce RE le i StarCool Unit Y p oo s ood mE 1 d Vd RefCon RCCU 5 iacu iden oo ae logfile i x J S m l 9 l Controller I amp I Dat
38. Pobe eae bor oxi eidgue on i pala unzo iux qnse ou teRM t DeRue hnES RRUEUPNEESgS Fa MEER UD M RUP rO 216 Controller Unit Illustrati iret reeoteeoe N Rr P s ERE QU MOINDRE NN ERERINNE FUSE EDS 217 P amp I Diagram EIE 218 Star Cool Unit installation dimensions sssssssssssssseeee eene nhe o Aaaa o iEn a nnn 219 Overall Wiring Schematic osse cessa resa EE a AEEA Tiia a Pri N LEEN a EN ANEDE N 221 5 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual A sh Nm aks Danfoss pressure transmitter feat_ iBattery CalUsi Calibration USDA sensori Pw Power O RMM Remote Monitoring Modem NN A CoO e 2 Current prase2 m Current phases a Current in DC Frequency Converter me Gurentin AC Compressor Motor 6 of 221 pages STAR COOL Item No 810900B Operating and service manual Frequency Heater Current Motor Pressure Power Relative humidity Switch contact key Super heat Temperature Saturated suction tem perature Voltage Ic Smi ias E ROAN RN D TIT o aE a Valve o gt cr Ambient Battery Condenser Compressor Discharge Economizer Evaporator Frequency converter Compressor motor Power Return Suction Supply Actual I Input Overheat Output Requested Setpoint O ct 7 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Genera
39. Replace the controller door Criteria Reference voltage AirEx below 4 80V DC None Controller n Mii tog X aam Alarm light Consequence Log data z HE Active Inactive High limit Actual value A D channel The measured voltage is internal on the controller PCB and cannot easily be measured 182 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual AirEx sens sup HI Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 24V DC and 5V signals to see if power supply has an open circuit or other damages If voltages are ok the controller PCB is defect Replace controller door Criteria Reference voltage AirEx above 5 20V DC None Controller n consequence OOOO Log data ERE z T Active Inactive High limit Actual value A D channel The measured voltage is internal on the controller PCB and cannot easily be measured 183 of 221 pages STAR COOL Item No 810900B Operating and service manual Pspare sens sup LO Warnin
40. The red balls in the sight glass for the receiver are constantly at bottom level 2 Veco is more than gt 80 open for hour 3 Vexp will steadily increase to 100 4 Psuc 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 1 Install a service gauge manifold on the unit to the two evacuation points pos 6 amp 27 P amp I diagram 200 of 221 pages STAR COOL Item No 810900B Operating and service manual 2 Connect the low pressure valve of the service gauge manifold to the suction stop valve pos 26 P amp I diagram Connect the service gauge manifold to the refrigerant bottle Purge as needed 4 Close the compressor suction stop valve pos 26 P amp I diagram fully and open approx 4 turns 5 Setthe refrigerant bottle for liquid charging 6 Operate compressor in manual mode as described in this manual compressor speed 25 Hz 7 Open the low pressure valve of the service gauge manifold 8 Read the suction pressure 9 Open hand valve on refrigerant bottle slowly allowing the suction pressure to increase with 1 5 Bar 10 Add refrigerant until the sight glass balls float in top of the sight glass 11 Close hand valve on refrigerant bottle 12 Open the compressor suction stop valve pos 26 P amp I diagram fully 13 Setthe unit for automatic operation as d
41. Trouble Possible causes shooting Temperature sensor Tusda2 or its cable defective X1 cable is defect Defect plug inside or cable on the unit backside Controller PCB defective Accompanied alarms e N A Trouble shooting 1 Disconnect the sensor cable for sensor Tusda2 from the connector on the interface terminal block PCB 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 the plug inside in the unit or the sensor is defect Check the plug before replacing sensor and cable b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tusda2 It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value above high alarm limit 140 C 284 F and the sensor reading has been in the valid area since power up None Controller n iu Alarm light Consequence May be incomplete
42. Trouble Possible causes shooting e Active alarms AL 124 AL 125 or AL 901 e Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 4 284 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 interface terminal block PCB 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 starting p 204 the temperature sensor and cable are defect and should be replaced b If the resistance is within range perform controller door check see Trouble shooting for Star Cool Controller p 56 before replacing controller door 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 Tight Superheat control deactivation When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data Acive Imacive P 86 of 221 pages STAR COOL Item No 810900B Operating and service manual Tamb open Warning Ambient Temperature Sensor
43. Tsuc from the connector on the interface terminal block PCB 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 230 Q the cable or the sensor is defect replace sensor and cable b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tsuc It should be between 4 80 and 5 05V 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 section Tables starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value above high alarm limit 140 C 284 F Replacement by new value from AAS system Alarm light Superheat control deactivation When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Active Inactive High mie Current CS 85 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 126 Tsuc invalid Warning Suction Temperature Sensor Invalid Cause Indication of defective suction temperature sensor or its measuring circuitry
44. 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 Active Inactive High limit Current 73 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 414__ Tusda 2 invalid Warning USDA 1 Temperature Sensor Invalid Cause Indication of defective supply air temperature sensor or its measuring circuitry or sensor not mounted correctly in unit Trouble Possible causes Soon Active alarms AL 112 AL 113 or AL 901 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 112 AL 113 or AL 901 may also be active Trouble shooting 1 If alarms AL 112 or AL 113 are active check their trouble shooting section first 2 Check that sensor Tusdai is mounted correct by its mounting hole 3 If AL 901 is active see trouble shooting for AL 901 4 Disconnect the sensor cable for sensor Tusdal1 from the connector on the interface terminal block PCB 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 st
45. 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 10V None Controller n aa ecg Hs p jm mim If main power is removed data logging may not be possible Log data 3 ER aa Internal Voltage Reference Alarms 951 PowerrefLO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect sensor pulling power supply down e Defect controller PCB 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 24V AC and 5V signals to see if power supply has a short circuit or other damages If ok the controller PCB is defect Replace controller door Criteria Power ref below 2 25V DC None Controller n consequence S 169 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Log data ER RR Active Inactive High limit Actual value A D channel The measured voltage is internal on the controller PCB and cannot easily be m
46. and economizer valves are all closed and compressor is running Trouble Possible causes shooting e Repeated high pressure alarms Accompanied alarms e Alarm 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 n ix eee a a a Ee ee PERENNI Quick flash Consequence Unit Unitstop o 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 r ActivefInactive oo oo oo AirEx open freeze Fatal Alarm Description Air exchange valve open in the frozen mode Indication of user having left air exchange open Trouble Possible causes shooting e AirExchange valve open in freeze mode e AirExchange valve open in 50 60 RH e Cable or airexchange sensor defect Accompanied alarms e Possibly AL 305 Trouble shooting 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 defect see AL 305 for trouble shooting Calibrate the air exchange see Controller System Menu decal for AirEx calibration Criteria Air exchange is open while unit being in the frozen mode Controller action Alarm Tight Quick fash Deteriorated control precision in the frozen mode Alarm will be marked as inactive in alarm list when air e
47. backside Controller PCB defective Accompanied alarms e N A Trouble shooting 1 Disconnect the sensor cable for sensor Tusda3 from the connector on the interface terminal block PCB 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 the plug inside in the unit or the sensor is defect Check the plug before replacing sensor and cable b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tusda3 It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value above high alarm limit 140 C 284 F and the sensor reading has been in the valid area since power up None Alarm light 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
48. change on TO 20 K Tret is less than 15 C Min change on TO 10 K None Test failed Elimination Alarm may then be deleted after test completed Log data Active Inactive TO diff Pdis old 156 of 221 pages STAR COOL Item No 810900B Operating and service manual 843 Economizer valve Alarm Economizer Valve Fault Indication of non operating economizer valve Trouble shooting Possible causes Cable for economizer valve mounted on wrong valve Cable for economizer valve defect Economizer valve defect Driver circuit for economizer valve defect 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 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 defect and should be replaced Check that the cable for the expansion valve is not defect 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 If there is no voltage the controller PCB is defect Replace the controller door Criteria Tsuc not changed at least 10 C 50 F when opening economizer
49. controller door b If there is signal The FC is defect and must be replaced If there is no FC replacement available the unit can be rewired for emergency operation See Emergency Operations p 50 Criteria Communication with FC not possible Mcond Mevapi and Mevap2 fan motors forced to low speed Controller action Alarm ight Quick flash When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data z z 501 FClocal control Alarm FC setting in Local Mode Indication of FC set in the local control mode 121 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Cable FC com periodically defective e Internal fault in the FC e Defect 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 Switch off the unit and wait 10 min before switching on the unit again 3 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 Operations p 50 Criteria FC in the local mode Mcond Mevapi and Mevap2 fan motors forced to low speed Controller r Consequence vm Unit stop o Alarm will be marked as inactive in alarm list when local mode is reset on frequency converter Alarm may then be
50. defect e Controller PCB defective Accompanied alarms e AL 302 Trouble shooting Disconnect the cable for RH from the connector PCB according to the wiring schematics inside the control cabinet and from the RH sensor 1 If the cable by inspection is defect replace cable 2 Dismount the sensor from the cable Dismount the cable from terminal 22 in X35 on the interface terminal block Measure the resistance between the signal wire coming from the sensor and terminal 21 and terminal 23 at the interface terminal block If the resistance is less than 230 Q the cable is defect and must be replaced Mount the cable for RH in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on the interface terminal block PCB If voltage is below 0 5V DC sensor or connection between sensor and cable is defect If voltage is between 0 5V DC and 10V DC continue to 4 4 Mount signal wire Measure voltage between SIGNAL and GND If voltage is between 0 5V DC and 10V DC and this alarm is still active replace controller door Before replacing controller door see Trouble shooting for Star Cool Controller p 56 Criteria Value below low alarm limit 5 None Controller ti Loin Alarm light Dehumidification impossible When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data Active Inac
51. defect If voltage is between 0 37V DC and 4 0V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND AKS If voltage is between 0 5V DC and 4 5V DC and this alarm is still active replace controller door NSK If the voltage is between 0 37V DC and 4 0V DC and this alarm is still active replace controller door Before replacing controller door see Trouble shooting for Star Cool Controller p 56 Criteria Value below low alarm limit 0 1 BarE 2 Psi Replacement by new value from AAS system Controller P y y n Bai Alarm light consequence 91 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data Uu Active Inactive High limit Current 203 Pdisinvalid Warning Compressor Discharge Pressure Sensor Invalid Indication of defective compressor discharge pressure sensor or its measuring circuitry 92 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting Connector for high pressure sensor Pdis not correctly mounted High pressure sensor Pdis defective Cable for high pressure sensor Pdis defective X1 cable is defect Controller PCB defective Accompanied alarms e AL 200 or AL 201 may also be active Trouble
52. defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Value below low alarm limit 60 C 76 F Replace ne lue from AAS t Controller placed by new value fro 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 ga Active Inactive High limit Curent i 61 of 221 pages STAR COOL Item No 810900B Operating and service manual 101 _ Tret short Warning Return Air Temperature Sensor Short Circuit Indication of short circuited return air temperature sensor Trouble Possible causes shooting e Temperature sensor Tret or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 102 Trouble shooting 1 Disconnect the sensor cable for sensor Tret from the connector on the interface terminal block PCB 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 defect replace sensor cable b If the resistance matches the resistance and temperature in Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tret it should be between 4 80 and 5 05V
53. deleted Log data FC Short Circuit Alarm 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 defect 2 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 Operations p 50 Criteria Short circuit in compressor or its terminals Motor current has been above 40 Amp FC shut down Controller d i aes tog x Alarm x Alarmilight_ slow flash Unit stop 122 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Adwemadwe rearc ire CS 509 FC 24V fault Alarm FC Internal 24V Supply Fault Alarm Indication of problems with FC Trouble Possible causes shooting AL5 e Internal fault in the FC 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 replacemen
54. differs the power meas PCB may be defect Replace or bypass power meas PCB by pressing RY selecting 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 Controller action og x Wem Wemhgh Log data Em mE Active Inactive High limit A D Channel This alarm is used for service purposes The fuses are protecting the unit 421 2 over current I2 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 action og x Wem mim Log data m Active Inactive High limit A D Channel This alarm is used for service purposes The fuses are protecting the unit 115 of 221 pages STAR LOOL Item No 810900B Operating and service manual 422 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 action og p Wem mim Log data Ee m Active Inactive High limit A D Channel This alarm is used for service purposes The fuses are protecting the unit No phase direction Fatal Alarm Description Phase direction not detectable
55. e Controller PCB defect 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 alarms with sensors 3 The power supply or power cable for controller PCB defect Measure voltage for the controller PCB a If voltage is ok the controller PCB is defect and controller door must be replaced Measure voltage for all sensors Should be between 4 80V DC and 5 20V DC for temperature and pressure sensors Humidity sensor must be between 12 00V DC and 34 00V DC If not ok the sensor or cable is defect Replace sensor Measure outlet on transformer between T3 and T4 Correct range 15 30V AC 24 30V AC Measure between T5 and T6 Correct range 18 86V AC 30 00V AC If within range transformer is ok d Replace controller door Criteria One or more of the internal reference voltages are out of limits FC will soon trip with error 516 and stop compressor Controller P P P action Alarm light sio Rash Test failed Elimination Alarm may then be deleted after test completed Log data 7 z Unit idle overcurrent fault Case OOS 149 of 221 pages STAR LOOL Item No 810900B Operating and service manual Trouble Possible causes shooting e There is a short circuit in the controller PCB e The power meas PCB is defect Accompanied alarms e N
56. high pressure switch and oil outlet port 0 Pos Description Shertname Number Location Discharge Pressure transmitter optional 5 jOlouletprt i Outside General trouble shooting Hints for general trouble shooting 1 Unit will not start up Check that power is applied to the unit Check that the power fuses are not blown Check that 24VAC fuse F6 is 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 amp is set to NONE for emergency operation but the wires 55 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual have not been correctly mounted for emergency operation 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 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 tak
57. if still running test PASS if test finished successfully FAIL if the test failed ABORT if the test was aborted by the user See specific description for alarm 801 in Test alarms p 149 TO7 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 alarm 805 in Test alarms p 149 TO8 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 alarm 810 813 in Test alarms p 150 TO9 Test result 50 Condenser fan 50 Cond fan Function Shows the status of the test of the condenser fan Value if not done yet RUN if still running test PASS if test finished successfully FAIL if the test failed ABORT if the test was aborted by the user See specific description for alarm 815 817 in Test alarms p 152 34 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual T10 Test result 60 Evaporator heater 60 Evap heater Function Shows the status of the test of the evaporator heater Value
58. is still outside correct the above range The controller PCB is defect Replace the controller door Criteria Reference voltage Psuc above 5 20V DC None Controller n conseguen O Log data ER ae Active Inactive High limit Actual value A D channel Tinternal LO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault 185 of 221 pages STAR LOOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 controller PCB is defect Replace the controller door Criteria Internal temperature sensor below 40 C 40 F None Controller r consequence S Log data ae 3 Jm Active Inactive High limit Actual value A D channel The measured temperature is internal on the controller PCB and cannot be measured 981 Tinternal HI Warning Controller Internal Temperature Sensor High Temperature Fault Indication of controller internal temperature sensor fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble
59. o0 90 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Compressor Discharge Pressure Sensor Short Circuit Indication of short circuited compressor discharge pressure sensor Possible causes shooting Connector for high pressure sensor Pdis not correctly mounted High pressure sensor Pdis defective Cable for high pressure sensor Pdis defective X1 cable is defect Controller PCB defective Accompanied alarms e AL 203 Trouble shooting Disconnect the cable for Pdis from the connector PCB according to the wiring schematics inside the control cabinet and from the high pressure sensor 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 SUPPLY VOLTAGE 024 0 TYP OUTPUT Figure for AKS Figure for NSK Check the cable measure the resistance in the cable If the cable is defect replace cable Mount the cable for Pdis in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on interface terminal block PCB AKS If voltage is below 0 5V DC sensor or connection between sensor and cable is defect If voltage is between 0 5V DC and 4 5V DC continue to 4 NSK If voltage is below 0 37V DC sensor or connection between sensor and cable is
60. of a new replaced compressor is done by the following procedure 1 Connect a vacuum pump with a service gauge manifold to the two evacuation points pos 6 amp 27 P amp I diagram 2 Close the compressor discharge and compressor suction servicevalves pos 5 amp 26 P amp I diagram 3 Pump down the pressure in the compressor to vacuum indicated on the gauges of the service gauge manifold Continue vacuum pumping for at least 2 hours Switch off the vacuum pump and close the stopvalve for the suction line to the vacuum pump on the service gauge manifold Observe the vacuum for minimum hour 6 If the vacuum is maintained then the compressor discharge servicevalve and compressor suction servicevalve pos 5 amp 26 P amp I diagram can be fully opened If the vacuum pressure is not maintained there is a possible leak somewhere Check all hose connections between compressor and vacuumpump If these are ok check the compressor 7 Disconnect the service gauge manifold and operate the unit as normal o gt Pump down of unit Main power supply to unit shall be switched off during pump down of unit Pump down of unit is done by the following procedure 1 Connect a vacuum pump with a service gauge manifold to the two evacuation points pos 6 amp 27 P amp I diagram 2 Close the compressor discharge and compressor suction servicevalves pos 5 amp 26 P amp I diagram 4 turns 3 Remove the
61. or Down press y to the line of the function to be activated Then press the Enter key The cursor will now highlight the function value instead of the ID Do the activation by pressing the Enter key once more If not pressing any key for 5 sec or if pressing the Cancel key 69 no function will be activated The cursor returns to the ID column and can now be moved to other lines 29 of 221 pages STAR LOOL Item No 810900B Operating and service manual 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 221 pages STAR COOL Item No 810900B Operating and service manual Operation Menu Structure 888m h Press X to leave o 9 INFORMATION Relative humidity Air exchange Last defr interval USDA 1 temp USDA 2 temp USDA 3 temp Cargo temp Time to defrost Ambient temp Supply air 1 temp Supply air 2 temp Return air temp Evaporator temp Suction temp Suction press Discharge press Expansion valve Evap superheat Compressor freq Power frequency Current phase 1 Current phase 2 Current phase 3 Voltage phase 1 2 Voltage phase 2 Voltage phase 1 Phase direction Battery v
62. plate cylinder head gasket sssssssessssee nne 197 Service and maintenant inicis iste tna ERR GR i n RRRESRR A RGGGR RR d SR SR 3 RIARRSARA Rf Ri KG KGX aini aidr GIGA E ee 197 Evacuation of refrigerant uou desde cet etapa a aa dida asas edite lile dt rd addens RF REM FINES Mata dis d Kann aU 197 Compressor pump GOWN Operationen esaii ue enia RR r er IR AA A EEEO pasa ars Fra ec ARS FEN 198 Compressor pump down replaced 2 2 2x eroe reete enr T ru aat prxa esi gere Pi Da FuppH DE rr SURE Ure RE DESEE 199 PUMP COWROF URI HEU 199 PrESSUPE Test asco v b ek shes ai VPETRR ise REEEORREA TE AR Cea EVA TERREECGUERECU AE FREE AiE Re IET S REPE EE EUERPERRE ET ETEEN 199 Charging of refrigebalit isss i orti netus aa ia iaa lA NERA Pec Oei nal Ue XR EEEa ERE C KC ULL athe 200 Charging of empty UM sess EP T 200 Charging OF UNIT TOWSON Charge ees cccd ccedicangssneieacis rh abaci Rue nun RARE RR sesmadacede dag n Ep Aae ai DnS 200 LE GakaGG dOteCHIOM aM m 201 FAM MOCOMSs ives PLUMIS 201 Drying fet icdecscids T SEOD 202 Replacing of drying MISH i cis secnecct eect sedhecatasaceatens ss teen te tkerk ix iR PARI saanecisaneteaddasimcaiea ances Pr a cage RE ER PHAR RARE ENS 202 efejss eprcicle gee E 202 reine doro 202 Charging Of Oil sagasa reia oodd halen setae peser Rina re meet nea EN E pat HU ae PEN UE NUN DuEp Ea dE LERNEN 203 Draining Of Oil from Compressor 3 5 es onse iiias aiaa RR P
63. sensor Tsup1 from the connector on the interface terminal block PCB 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 defect replace sensor and cable b If the resistance matches the resistance and temperature in Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tsup1 it should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value below low alarm limit 609C 769F Replacement by new value from AAS system 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 Active Inactive High ime Current id 64 of 221 pages STAR COOL Item No 810900B Operating and service manual 104 Tsup 1 short Warning Supply Air Temperature Sensor 1 Short Circuit Indication of short circuited supply air temperature sensor Trouble Possible causes s
64. 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 written in the display see Display p 26 When Cold Treatment is done with 3 sensor failures CT fail is written in the display see Display p 26 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 Change in Treatment set point during active Cold Treatment has been limited to a decrement of 2 C 36 F 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 unde
65. shooting Disconnect the cable for Pdis from the interface terminal block PCB according to the wiring schematics inside the control cabinet and from the high pressure sensor 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 SUPPLY VOLTAGE A 90 95 024 0 TYP OUTPUT Figure for AKS Figure for NSK Check the cable measure the resistance in the cable If the cable is defect replace cable Mount the cable for Pdis in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on interface terminal block PCB AKS If voltage is below 0 5V DC sensor or connection between sensor and cable is defect If voltage is between 0 5V DC and 4 5V DC continue to 4 NSK If voltage is below 0 37V DC sensor or connection between sensor and cable is defect If voltage is between 0 37V DC and 4 0V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND AKS If voltage is between 0 5V DC and 4 5V DC and this alarm is still active replace controller door NSK If the voltage is between 0 37V DC and 4 0V DC and this alarm is still active replace controller door Before replacing controller door see Trouble shooting for Star Cool Controller p 56
66. shooting 1 Check if there are other active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24V DC and 5V signals to see if power supply has an open circuit or other damages If voltages are ok the controller PCB is defect Replace controller door Criteria Internal temperature sensor above 70 C 158 F None Controller r Eum He p Wem emis consequence O O OOOO Log data mam aoe Active Inactive High limit Actual value A D channel The measured temperature is internal on the controller PCB and cannot be measured 186 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Software test ver Warning Software test version Indication of Software test version loading into controller Trouble Possible causes shooting e Test sw in the controller PCB Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 There is a wrong sw version in the controller PCB Update the software in the controller to the latest version 2 There is a wrong sw version in the controller PCB Replace the controller door None Controller action Alarm light Consequence Elimination Replace software Log data 996 Software CRC error Alarm Prom CRC Fault Case OOOO Trouble Possible causes shooting e Validity check of the program failed Accompanied alarms e A
67. 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 chap De tailed alarm description p 56 together with a description of the specific test alarms Test alarms p 149 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 TO1 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 4 or y and press e which initiates the test The PTI test is autom
68. than 3 min 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 Check that sensor Tusdai is mounted correct by its mounting hole 3 If AL 901 is active see trouble shooting for AL 901 4 Disconnect the sensor cable for sensor Tusdal1 from the connector on the interface terminal block PCB 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 starting p 204 the temperature sensor and cable are defect and should be replaced b If the resistance is within range perform controller door check Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Activated by UWS or AL 901 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 Active Inactive CE o y 72 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 113 Tusda 2 short Warning USDA 2 Temperature Sensor Short Circuit Indication of short circuited USDA 2 temperature sensor
69. 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 meas PCB may be defect Replace or bypass power meas PCB by pressing RY selecting 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 30 sec the unit restarts with a normal Controller x procedure action DENEE NN 8 ENNENCO 0 Alarm light Consequence y Unitstops eee Alarm will be marked as inactive if another phase voltage measuring is above limit It may then be deleted Log data EP e Active Inactive High limit Voltage A D channel 418 U2 3 under voltage Warning U2 3 Under voltage Indication of error in container supply voltage between phases 2 and 3 113 of 221 pages STAR COOL Item No 810900B Operating and service manual 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 se or 0085 Alarm light Consequence Unit Unitstops 0 Alarm will be marked as inactive if another phase voltag
70. 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 starting p 204 the temperature sensor and cable are defect and should be replaced b If the resistance is within range perform controller door check Trouble shooting for Star Cool Controller p 56 before replacing controller door Sensor is defect and the missing sensor reading has been substituted by a value from AAS system See AAS system p 18 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 r ActivefInactive o y y 63 of 221 pages STAR COOL Item No 810900B Operating and service manual 103 Tsup1open Warning Supply Air Temperature Sensor 1 Open Circuit Indication of loose connection defect or lack of supply air temperature sensor Trouble shooting Controller action Consequence Log data Possible causes e Temperature sensor Tsupi or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 105 Trouble shooting 1 Disconnect the sensor cable for
71. view of all alarms as listed on the display and a longer text Id Display text Description Alarm type 1 Temperature sensor alarms 00 Return Air Temperature Sensor Open Circuit 101 Return Air Temperature Sensor Short Circuit Return Air Temperature Sensor Invalid Supply Air Temperature Sensor 1 Open Circuit 104 Supply Air Temperature Sensor 1 Short Circuit 105 Supply Air Temperature Sensor 1 Invalid Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning oO N m CJ Tsup 2 open Supply Air Temperature Sensor 2 Open Circuit 0 Tsup 2 short Supply Air Temperature Sensor 2 Short Circuit 108 Tsup 2 invalid Supply Air Temperature Sensor 2 Invalid o en Ko 0 USDA 1 Temperature Sensor Open Circuit 10 USDA 1 Temperature Sensor Short Circuit ial USDA 1 Temperature Sensor Invalid 112 USDA 2 Temperature Sensor Open Circuit il USDA 2 Temperature Sensor Short Circuit USDA 3 Temperature Sensor Open Circuit 116 USDA 3 Temperature Sensor Short Circuit 118 Cargo Temperature Sensor Open Circuit Cargo Temperature Sensor Short Circuit 2 Evaporator Temperature Sensor Open Circuit 122 Evaporator Temperature Sensor Short Circuit Evaporator Temperature Sensor Invalid Suction Temperature Sensor Open Circuit 125 Suction Temperature Sensor Short Circuit 126 Suction Temperature Sensor Invalid 2 Ambient Temperature Sensor Open Circuit 2 Ambient Temperature Sensor Short Circuit 129 Ta
72. we sees 225 263950 108 991 00 s 11420 00 722 010 00 us smos zs 206491900 ss 10278700 s 1092270 73 194210 153 20608 232 Le3117300 o 6 415 00 o 9572 00 79 i75160 158 456 76 237 1200 7320 72 692700 7 605600 ss 1 530 28 165 acoso 24 mazao 7 65 198 00 s 772090 ss 12012 167 30008 246 033 619 00 69 61693 00 40 740170 so rasrs7 160 38859 248 737 310 00 60 azoo io 60120 oo 1 216 23 ws 34082 257 208 of 221 pages STAR 3E COOL Item No 810900B Operating and service manual 1 177 75 180 1 140 71 181 1 104 99 183 1 070 58 185 1 037 40 187 332 11 259 323 67 261 315 48 262 307 53 264 299 82 266 1 005 40 189 292 34 268 974 56 190 285 08 270 944 81 192 278 03 271 916 11 194 271 19 273 888 41 196 264 54 275 604 36 219 193 57 298 587 31 221 189 12 300 719 74 698 82 678 63 659 10 156 199 00 18 146 959 00 317 Pres Temp Pres Temp Pres Temp Pres Temp Pres Temp Pres Temp Pres liec BarE C BarE C BarE C BarE C BarE C BarE 6 Z 7 7 8 8 8 0 5 65 62 21 7 0 jee c rm E 0 4 65 85 21 8 66 09 21 9 217 218 14 5 18 2 aia 66 32 221 22 3 22 3 s 65 67 68 39 69 7o zi 72 1345 73 ier 74 i446 75 to 7 6 74 77 36 78 79 80 rra 82 83 6 5 7 7 0 l 7 2 ae 66 55 22 1 7 4 7 5 7 7 7 8
73. 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 55 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 44 1 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 3 1 8 49 123 22 1 5 337 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 3 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 Voltage Pressure Table High pressure transmitter AKS Vcc 5V Pressure is relative CERT O CNN V BarE Psi oso oso uso 26s 1720 ne4e oso s asa zs seo zs427 ioo fao sso sos 2o40 25588 zs eo s s30 4o 32488 213 of 221 pages STAR COOL Item No 810900B Operating and service manual se 110 23 116 03 121 83 127 63 133 43 139 24 145 04 150 84 156 64 162 44 168 24 174 05 179 85 185 65 191 45 197 25 203 05 208 85 214 66 226 26 3 55 3 60 3 65 3 70 3 75 3 80 3 85 3 90 3 95 4 00 4 05 4 10 4 15 4 20 4 25 4 30 4 35 4 45 4 50 359 69 365 50 371 30 377 10 382 90 388 70 394 50 400 30 406 11 411
74. 00 420 732 1 9 14 00 203 112 3 45 29 50 427 986 1 95 14 50 210 366 3 5 30 00 435 24 2 15 00 217 62 Temperature Sensor Voltage Table Temperature sensors except for reference temperature sensor Vcc 5V V C F V C F V C F 5 fe pes pu ferns bz ar 1 5 m s o 15 1e 2 19 I2 21 3 78 3 73 3 67 3 62 d w T Ul Is a 215 of 221 pages STAR COOL Item No 810900B Operating and service manual Tightening torques frexHeadook wuts S Chex nead Bore mu me OOS exwemrRotemu S A E exneerBetemu mg OSC Hex Socket Counters nemdBo me O O Hex Socket Counters Heed so me o fa E Flare Nut 1 2 Brass Senrader valve ug SSS MEE mts Mod Oooo o o o Ianwut 8 Fan ut po Air Exchange Potentiometer Slotted Cheese Head Screw M3 Damper for Fresh Air Wing Screw M6 FC Mounting Slotted Cheese Head Screw M6 C FC Mounting Hex Lobular Socket Screw M6 CE E eed 8 water inlet Coupling Female E T 8 Detcevave eaa ft Evaporator Cover Plate Hex Lobular Tapping Screw 94 8 216 of 221 pages 5 2 2 7 2 4 STAR LOOL Item No 810900B Operating and service manual Controller Unit Illustration Po
75. 10900B Operating and service manual Replacement Evaporator motor and fan Note Turn off main power supply for unit before replacing evaporator motor and fan Note Due to high aerodynamic requierements decreased energy consumption sharp edges is located in this area Note The displayed model may be different from the acual model Disconnect the power supply to the motor by removing the motor cover and unscrew the earthwire placed directly on the motor Do not disconnect the other cable connection which is con nected directly in the motor cover Remove the 4 x M8 bolts that hold the evaporator motor brack et incl motor and fan Then the evaporator motor bracket with motor and fan can slide right through the inspection hatch of the unit by dragging it towards yourself The evaporator bracket has to be tilted slightly downwards to pass by the gasket Strap fo hold inspection hatch Fig 1 4 x 8M bolts Earthed wire on bolt Replace the defect parts and reinstall the evaporator fan module Prior to mounting the motor cover check the sealing for any damages If damaged the sealing must be replaced 190 of 221 pages STAR COOL Item No 810900B Operating and service manual Replacement Condenser motor and fan Note Turn off main power supply for unit before replacing condenser motor and fan Remove the condenser grill and disconnect the power supply to th
76. 136 18 269 77 152 62 323 43 166 98 8 25 56 56 59 18 110 23 93 04 163 89 117 28 217 56 136 65 271 22 153 03 324 88 167 34 al 8762 88 41 89 20 90 00 9977 33 e153 160 78 92 28 162 44 116 71 23 93 04 163 89 117 28 217 56 494 58 02 60 33 272 67 153 45 326 33 167 72 113 13 94 53 16679 118 44 220 46 137 58 19527 221 91 95 99 223 36 96 73 224 81 139 9743 172 226 26 139 98 15 22771 139 98 85 229 16 140 15 95 68 85 140 86 100 26 232 06 141 233 51 141 234 96 142 236 41 142 237 86 143 239 31 143 240 76 242 21 1 82 59 47 61 45 13 13 94 53 166 79 118 44 220 46 137 61 274 12 153 86 327 79 168 08 1 11 60 92 62 55 114 58 95 27 168 24 118 99 221 91 138 07 275 57 154 26 329 24 168 44 Taoa 120 86 23 8275 Faz en 20 31 22 33 73 97 71 82 127 63 101 62 181 30 123 98 234 96 142 23 288 63 157 87 342 29 171 64 182 75 124 52 236 41 5571 157 288 63 15787 34229 21 76 72 77 142 68 172 00 275 57 27847 210 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 33 36 38 03 6702 80 10 40 69 10756 194 35 128 73 248 01 14625 Etkrbeeepeeneepenus esee ues Air exchange Sensor table Voltage m3 h There is an offset of 0 2V due to mech
77. 26 3 psi 0 7 Bar 10 2 Psi 15 9 Bart 230 6 psi 0 7 Bar 10 2 Psi Fusible plug receiver Economizer Manufacturer SWEP WTT Danfoss Brazed plate heat exchanger Stainless steel AISI 316 L Evaporator coil Condenser coil ECO DunAn Tube material Copper inner grooved Fin Material 21 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Coating tube fin Cataphoresis treatment with additional acrylic resin Evaporator fan Condenser fan Water cooled condenser optional Operating water pressure max 8 BarE 115 Psi Water temperature max cooling cap 30 C 86 F 22 7 30 2 min 6 8 gal m Pressure drop 0 9 Bar 13 05 Psi 1 2 Bar 17 4 Psi at 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 22 of
78. 34a 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 221 pages STAR 2 COOL Item No 810900B Operating and service manual Contents dalle 1 Warning RESCUE LLLI ERN 1 ETIQDEETMT EEEUEEM 6 General GEScriptiOn ee mE 8 FUNCTION description c cece cc cece ee ee eee EEE AEE EEE EEE EERE EEE EE REED EEE DEEL DEAE DEED EEE EN NENE Ea EnaA EEE E EEE ES EEE ES 9 cinsqUsHejgorerfe Ug em EC 9 Climate Control FUNCUON ciicssrsisktatavavicadenun tenes cae poniree du se sbxidpe eR oor tali nnODI IV stwhas Oor Ea NANa 10 Temperature Coptrol ES 10 Capacity Control and Eimiter soos dene so aarte tad sates a a s nM Riu a S 10 Expansion Valve parsone EIE EE 11 Economizer zii eR TE EL LE LII ILLI IM 12 bI inaifopeisl eer MI M 12 Condenser Fa Musiiorsr roisia nnno AEE E aa IUO LEOA E T eN 13 EVaporator Falsa aae a E E E EA 13 Defrost FUNCOM iicicicnscscescsrcniceanederansacnnenaniasmeananemeimnareuns beacashadaadinanattinnssedsraniadanesanndadseantniaeanstecanateamedadannas 13 OUEST Optional aici isiathcmseicaescammeranacu
79. 4 turns Run the compressor in manual operation on 50 Hz as described in manual operation section Observe the pressure indication on the display for the suction pressure when the suction pressure reaches 0 5 BarE 7 3 Psi in value Close the compressor discharge pressure stopvalve entirely and turn off the power to the unit SETPOINT CT SUPPLY Suction pressure indicator Open the valves for the vacuum pump The evacuation points pos 6 amp 27 P amp I diagram are open when the compressor stop valves pos 5 amp 26 P amp I diagram are closed Evacuate the compressor through the vacuum pump for a minimum of 2 hours Switch off the vacuum pump and close the stopvalve for the suction line to the vacuum pump on the service gauge manifold Observe the vacuum for minimum hour If the vacuum is maintained then the compressor can be either changed see replacing of compressor or the unit can be started in normal operation If the vacuum pressure is not maintained there is a possible leak somewhere Check all hose connections between unit and vacuumpump If these are ok check the unit Open compressor suction stopvalve compressor intermediate pressure stopvalve and com pressor discharge stopvalve pos 5 25 amp 30 P amp I diagram Disconnect the service gauge manifold 198 of 221 pages STAR COOL Item No 810900B Operating and service manual Compressor pump down replaced Pump down
80. 5 2 TR2 2 l4 At gs 51 ag TRI 3 le i RMM York a e 2e AWG 18 2 pee Power line 12 agg Cl modem PHE i p al n mH H 42 x T 10 lI l s Outside Box a E a T gd f Eo do SE 32 45 I 1 5 Inside Box BMM OVAG OVAC cun 2 i 1 1 Red tdas 2 n RMM 24VAC 2 2 Bed 2 MENS Hevap 8 ANAS 3 yh A FK Note Heater element for Tray and Fed TRAFO T1 approx voltages id 4 X60 wires 13 and 14 are optional 4 4 whit 4 Terminal 1 2 440V AC ale 2 a Terminal 3 4 20V AC 313 3 1 L Vee m Terminal 5 6 24V AC a x4 4 7 Gom sio e Red RMM 24VAC F 8 8 4 s 2 Whitey RMM OVAC FC com i 1 RX Inside Box 2 8 x0 50mm2 RMM com a ND Dita da bak i Inside Box LM front a Hone amp 88 A n Retriever plu c plug NOTES CHR BUR Vexp 24VDC D atfrontof unit 1 Please be advised the shown sensors Peco and Teco are Vexp _V lt an Ep out of use for units with software ver 0240 and forward 1 1 Vhg 24VDC 2 LM A RS232 Vng V s GND 3 amp Retriever plug ave P in container z Veco H i Vec V lt ND 424VDC s GND 1 1 45VDC JE Inside Box Pis _ 3 2 gt uson Pds P SIGNAL 1 o Controller Hatch 2 Tusdai 9x 075mm2 GND l2 1 Rar g 9xAWG 18 45VDC 1 Tubs 2E SF _Juspa2 x Peco P Ec fe 2 3 SIGNAL NOTET gez auo dE 1 SW5 SWITCH PCB 1 ENDO d ba 2 l JE d OE usbas i Psuc_ s E 1 3 Psuc P C SIGNAL amp aes ih cargo F E 24VDC 2 m a Shp t T Rh Rh SIGNAL Meva
81. AS 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 Hui me Tmu O up Tsup2 and Tret Tact Tvapscontam Freeze mode Defect sensor s Substitution sensor Action Alarm Tet Tect Tevap constant Tret Tevap and Tsupt Tact Tsup2 constant xx no more available sensors for substitution Expansion valve control Defect sensor s Substitution sensor Action Alarm sss Emergency injection 611 Too many sensor err Condenser fan control Defect sensor s Substitution sensor Action Alarm ssi 18 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Start up Condenser fan speed slow Chill Freeze mode Condenser fan speed depends on ambient temperature Tamb Tinternal Tret Tevap and Tsup1 Tact Tsup2 constant Po Tamb and Tinternal mim S o Dehumidification control If dehumidification is active Defect sensor s Substitution sensor Action Alerm O Stop dehumidification 614 Humidity deactivated Defrost control Defect sensor s Substitution sensor Action Alarm Heap me He ezcem Ps zT
82. 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 BarE High pressure 1 0 12 0 BarE Low and inter side mediate pressure side 0 69 9 8 BarE Low and intermediate pressure side Ratiometric pressure transmitter with sealed gauge measur ing principle 4 in female flare connection with deflator Miscellaneous Tin plated electrical 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 25 of 221 pages STAR COOL Item No 810900B Operating and service manual User Interface Indicator lights Alarm indicator light In range indicator light In range SLOW FLASH if there are active NORMAL FLASH when controlling alarms temperature probe is inside the QUICK FLASH if there are fatal c acceptable range alarms Red 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 FLA
83. C replacement is available the unit can be rewired for emergency operation See Emergency Operations p 50 Criteria Supply voltage of FC has exceeded 535V AC 760V DC 130 of 221 pages STAR COOL Item No 810900B Operating and service manual None Controller action Alarm light If not solved this problem can cause FC to stop due to alarm 515 Warning will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data z Active Inactive Frea FC 522 FChightemp st FC Overtemperature Warning Indication of problems with compressor or FC Trouble Possible causes shooting W36 e FC operates at operating limits e Insufficient cooling for the FC e Defect FC Accompanied alarms e None Trouble shooting 1 The FC is getting too hot 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 unsufficient If this alarm comes 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 Operations p 50 Criteria FC temperature has exceeded warn
84. 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Value above high alarm limit 140 C 284 F Replaced by new value from AAS system Controller P y y 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 um Active Inactive Mehimt cure o 102 Tret invalid Warning Return Air Temperature Sensor Invalid Cause Indication of defective return air temperature sensor or its measuring circuitry 62 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes Shooting e Active alarms AL 100 AL 101 or AL 901 e Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F 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 interface terminal block PCB according
85. Defect resistances on the interface terminal block PCB Cable for measuring condenser motor overheat defect Controller PCB 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 defect If the cable for McondOH by inspection is defect replace cable Disconnect the cable for McondOH from the connector PCB 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 defect and should be replaced If the resistance is less than lt 5 kQ the cable and motor should be Ok 5 Check resistances on the interface terminal block PCB above X33 and X34 They must be 220 kQ 6 Turn unit on again Measure the voltage over the connector for McondOH It should be between 4 80V DC and 5 05V DC a If the voltage is inside the above range connect sensor again Measure the voltage over the sensor and check the voltage If the voltage is less than lt 2 5V DC the measurement is ok If the alarm after 30 sec is still active on the display the controller PCB is defect replace the controller door If the voltage is outside the range controller PCB is defect or another error might affect the voltage Check other alarms before replacing controller door Criteria Value a
86. Evaporator fan Mevap Condenser fan Mcond Heating element Hevap and Htray Probe check not implemented in ver 0240 Compressor FC valve test Vexpansion Vhotgas and Veconomizer Test completion status OS OX UTC oe IE ES 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 5 C 41 F test 0 C 32 F test 18 C 0 4 F test Defrosting Test completion status ee ue Short PTI Short PTI includes the following test items Function test 5 C 41 F test 0 C 32 F test Defrosting Test completion status i eS Data Log The controller has a data log to record operation of the unit The data log includes 4 items Data 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 graphi
87. I status Function Shows the status of the PTI 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 See specific description for alarm 850 in Test alarms p 161 I nfo Menu Viewing By pressing Dire info menu is selected The icon is displayed The info menu includes the following parameters 101 Relative humidity Relative humidity Function Shows current relative humidity in the container Value Shown as a percent value 102 Air exchange in m3 h Air change m3 h Function Shows current opening of air exchange valve Value Shown as m3 h 103 Last defrost interval Last defr interval Function Show current interval between last two defrostings Value Shown in hours 104 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 Ge 105 USDA 2 temperature USDA 2 temp Function Shows current temperature for USDA 2 sensor Value Shown in temperature scale C or F Switching by pressing D 106 USDA 3 temperature USDA 3 temp Function Shows current temperature for USDA 3 sensor 36 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Value Shown in temperature scale C or F Switch by pressing C 107 Cargo temperature Car
88. Item No 810900B Operating and service manual 121 Tevap open Warning Evaporator Temperature Sensor Open Circuit Cause Indication of loose connection defect or lack of evaporator temperature sensor Trouble Possible causes shooting e Temperature sensor Tevap or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 123 Trouble shooting 1 Disconnect the sensor cable for sensor Tevap from the connector on the interface terminal block PCB 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 defect replace sensor and cable b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tevap It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Value below low alarm limit 60 C 76 F Replacement b
89. L 801 will be activated during FT or PTI test Trouble shooting 1 There is a fault on the controller PCB Update the software in the controller to the latest version 2 There is still a fault on the controller PCB Replace the controller door None Controller action Alarm light Siow flash Consequence Log data 187 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Eeprom error Alarm EEPROM fault Cause Trouble Possible causes shooting e Check of validity of program storage failed Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 There is a fault on the controller PCB Replace the controller door Controller action Alarm light Slow flash Consequence O None Log data Calibration of air exchange sensor Air exchange sensor calibration 1 Close the fresh air cover plate 2 Inthe Service menu line FO6 Air exchange calibration select START and press the Enter button 3 Calibration is done 188 of 221 pages STAR COOL Item No 810900B Operating and service manual Replacing of unit Handling of 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 e o 189 of 221 pages STAR 2 COOL Item No 8
90. MM Accompanied alarms e AL 306 AL 500 AL 801 will be activated during FT or PTI test Trouble shooting 1 Check that the RMM com cable is intact and installed internally 2 If alarm AL 306 High press switch or AL 500 FC missing are also active the fuse F6 inside in the control cabinet is most likely blown Replace the fuse If there is no light in the Power LED of the RMM Check that power is applied to the RMM If power is applied the RMM is defect and must be replaced Check the status LED s of the RMM Power must be ON Error must be off Replace RMM if not ok Check cable to controller door If AL 903 is still active replace controller door Criteria Powerline monitor communication not possible None Controller action Aam igat slow fash Container may drop out of remote monitor system Elimination Check replace modem or connection Log data 904 Datalog error Alarm RCCU Data log Fault Circuit for storing the datalog is faulty Trouble Possible causes shooting e Datalog in controller has become defect 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 Controller PCB is defect Replace controller door Criteria Controller data log corrupted Controller action Alarm light Slow flash Data logging unreliable Temperature contro
91. OFF Condenser Motor Off Current Fault 2 Hevap current ON Evaporator Heater On Current Fault 2 Hevap current OFF Evaporator Heater Off Current Fault 840 Valve leaks Valve Leak Fault Fatal Alarm Warning Alarm Alarm Warning Not implemented yet The Compressor Has Been Restarted Cold Treatment out of range Manually Selected Phase Direction Blown Fuse OV OV OY WININ o ju rn Oo FC trouble 620 Cpr start failed Cpr restarted CT outrange Manual phase dir Fuse blown e Alarm Alarm Alarm Alarm Function Test Fault Controller Internal Voltage Reference Fault Unit Idle Overcurrent Fault Evaporator Motor Low Speed Current Fault BB amp O Ui Co js js Evaporator Motor High Speed Current Fault Alarm Alarm Alarm Alarm Co na a Ui N Co E o Condenser Motor High Speed Current Fault Alarm Co A N Alarm Alarm Alarm Alarm Co e Co E nm CJ 59 of 221 pages STAR COOL Item No 810900B Operating and service manual 860 PTI Tset 0 PTI 0 C Set Fault 870 PTI defrost PTI Defrost Fault 880 PTI Tset 18 PTI 18 C Set Fault Co User stop was executed from PC program Fatal Alarm 01 Error in measurement of condensator on circuit board 902 Battery Battery Malfunctioning Alarm malfunction 903 Remote mon Remote Monitor Modem Missing Alarm missing 0 Datalog error RCCU Data log Fault 905 Database corrupt RCCU
92. Open Circuit Cause Indication of loose connection defect or lack of ambient temperature sensor Trouble Possible causes shooting e Temperature sensor Tamb or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 129 Trouble shooting 1 Disconnect the sensor cable for sensor Tamb from the connector on the interface terminal block PCB 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 defect replace sensor and cable b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tamb It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Value below low alarm limit 60 C 76 F Replacement by new value from AAS system Controller P y y action Alarm light No consequence as to control When sensor va
93. Operating and service manual Charging of oil If during normal operation is has been observed that there is too little oil charge on the compres sor additional oil may be charged The compressor is filled with 1 5 liter Reniso Triton SEZ 55 or equivalent oil from the factory The procedure for adding oil is as follows Pump down the compressor as described 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 Ifoil is still missing repeat above E Ie QUT pup Draining of oil from compressor If the compresor has been overcharged with oil the procedure for drainage is as follows 1 Thetwo 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 Connect a service gauge manifold to the outlet port with schr der valve of the oil pump 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
94. PCB defective Accompanied alarms e AL 500 may be active alarm 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 If the 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 condenser is blocked clean the condenser to secure cludding and dirt are removed 6 If alarm AL 500 FC missing is also active the fuse F6 inside in the control cabinet is most likely blown Replace the fuse Disconnect the cable for high pressure switch from the connector PCB according to the wiring schematics inside the control cabinet 7 Measure the voltage between the two connectors for the high pressure switch on the connector PCB If the voltage is below 15V AC replace the controller door 8 Check the cable measure the resistance in the cable If the cable is defect replace cable and high pressure switch 9 Mount the cable
95. RA AR Ud i aa PE A IM iida aaien 203 SOlderiNG eR 203 Errem 204 Datalog GeSCriptiOmh MEET 204 Temperature Sensor C Resistance Table eei tren rrt orn AER EEEE E AE ONENERA 207 Temperature Sensor F Resistance Table 5i re err rt oo totes narro Spe pes k bs SianeK TEKENE DEE aai ves 208 Temperature C Pressure BarE Table R134a eene eE E ssa khen a sese 209 Temperature F Pressure Psi Table R1343a onte r uero errore aN iaa covasenaceeansescessnaas 210 Air exchange Sensor table Voltage m3 Izsiisc iie ao eese eicere E MN TM res aunmenseuetersasiedmenes 211 Relative Humidity Sensor table WRH Voltage eap sesto eteoe Ses dL e veste sat Eos eues steps pipe san eR a p OPER Ripper E AR De SR aN 211 Voltage Pressure Table L w pressure transmitter AKS iuri ieri ne xx cu tnmen g bxw x N ANN 211 Voltage Pressure Table Low pressure transmitter NSK iiis cuis ene ete nene etse nu doh des sa nine Rc pR E OFEN TERRAS RE R eis 212 4 of 221 pages STAR COOL Item No 810900B Operating and service manual Voltage Pressure Table High pressure transmitter AKS 1 ccce tasse ne hh RR Re EUR ERR As D AK INNEN REESFIIE NN REKER 213 Voltage Pressure Table High pressure transmitter NSK iode aous untra hacen em rua inda er nE kx e ko du nn airs 214 Temperature Sensor Voltage Table ence cisci pies ela u o Une eE cdam a RR E IACRI UN ILI OAM E NA 215 Tiglitening torqties siis o pepe
96. S Unit Compressor Evaporator fan Condenser fan Evaporator heater F01 F02 F03 F04 F05 F06 F07 F08 F09 CONFIGURATION Container Software version FC type FC ID Phase detection AirEx calibration Low pres type High pres type Main PCB STAR 2 COOL Item No 810900B Operating and service manual 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 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 O and keys the individual parameters are scroll able For parameter change press and the parameter is highlighted in inverse writing By pressing and y 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 amp and the previous parameter value is shown again If the keys y or e are not pressed for 5 sec setting is cancelled and the previous param eter value is shown a
97. SH is a flash every 1 sec Display fe 1 UN fr UN A UN fe E 7 Setpoint temperature PEN Setpoint control Control sensor temperature Secondary information p Bag zi 2 Suction pressure Status text 3 CL unit Discharge pressure S scale bar J WM d scale bar J Temperature and pressure unit selection Celsius Bar or Fahrenheit Psi PTI Pre Trip Inspection or Function Test is running C F Unit is operated in service mode ido Humidity control is activated H3 Water cooled condenser is activated rig Defrosting is running g Heater element is switched on KY 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 26 of 221 pages STAR COOL Item No 810900B Operating and service manual It is possible to obtain a datalog graph display see Datalog view p 46 Key pad Navigation keys Use these keys to move menu display up down and to change parameter values Cancel Leave active sub menu Cancel active parameter adjustment O Up Move menu one line up Increment parameter value in menu Increment setpoint on main display page P Down Move menu one line down Decrement parameter value in menu Decrement setpoint on main display page e Enter Select a sub menu Activate a function press twice Initiate parameter adjustment Accept parameter
98. Tables starting p 204 the temperature sensor and cable are defect and should be replaced b If the resistance is within range perform controller door check Trouble shooting for Star Cool Controller p 56 before replacing controller door Value below alarm limit 609C 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 P y y n im Alarm light consequence 1 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 P 83 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 124 Tsuc open Warning Suction Temperature Sensor Open Circuit Cause Indication of loose connection defect or complete lack of suction temperature sensor Trouble Possible causes shooting e Temperature sensor Tsuc or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 126 Trouble shooting 1 Disconnect the sensor cable for sensor Tsuc from the connector on the interface terminal block PCB 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 defect replace sensor and cable b If the resistance matche
99. Test failed Elimination Alarm may then be deleted after test completed Log data Active Inactive TO old Pdis old 842 Expansion valve Alarm Expansion Valve Fault Indication of non operating electronic expansion valve 155 of 221 pages STARS COOL Item No 810900B Operating and service manual Trouble shooting Controller action Possible causes Cable for expansion valve mounted on wrong valve Cable for expansion valve defect Expansion valve defect Driver circuit for expansion valve defect 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 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 the expansion valve is defect and should be replaced Check that the cable for the expansion valve is not defect 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 If there is no voltage the controller PCB is defect Replace the controller door Pdis more than gt 5 BarE Max change on Pdis 0 75 Bar Pdis is less than lt 5 BarE Max change on Pdis 0 30 Bar Tret more than or equal 2 to 15 C Min
100. Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Value above high alarm limit 140 C 284 F 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 Log data Em Active Inactive High timit_ Current i 88 of 221 pages STAR COOL Item No 810900B Operating and service manual 129 Tamb invalid Warning Ambient Temperature Sensor Invalid Indication of defective supply ambient sensor or its measuring circuitry Trouble Possible causes shooting e Active alarms AL 127 AL 128 or AL 901 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 the connector on the interface terminal block PCB 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 Table starting p 204 the temperature sensor and cable are defect and should be replaced b If the re
101. able from the controller door 3 After a while enter the Information Menu In here the following values shall appear a Temperature drops to 70 C b Psuc shows 12 0 BarE if AKS or 9 8 BarE if NSK c Pdis shows 32 0 BarE if AKS or 30 0 BarE if NSK d AirEx must read 220 m3 e Humidity 0 4 If one of these listed values does not appear the controller door must be replaced Detailed alarm description Alarm list 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 56 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 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 Alarm list The following list includes a
102. active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24V DC and 5V signals to see if power supply has an open circuit or other damages If voltages are ok the controller PCB is defect Replace controller door Criteria Reference voltage 2 above 5 20V DC Controller n O D Log data TEN zm Active Inactive High limit Actual value A D channel Gnd ref LO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 24V DC and 5V signals to see if power supply has a short circuit or other damages If voltages are ok the controller PCB is defect Replace controller door Criteria Ground reference voltage below 0 0V DC None Controller action og x Wem emnt Consequence O 173 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Log data ER RR Active Inactive High limit Actual value A D channel The measured voltage is internal on the controller PCB and cannot easily be measured Controller
103. active High imit_ current 1105 Tsup 1 invalid Warning Supply Air Temperature Sensor 1 Invalid Cause Indication of defective supply air temperature sensor its measuring circuitry or sensor not mounted correctly in unit 65 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting Active alarms AL 103 AL 104 or AL 901 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 Tsup1 and Tsup2 are mounted correct by their mounting holes 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 interface terminal block PCB 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 starting p 204 the temperature sensor and cable are defect and should be replaced b If the resistance is within range perform controller door check Trouble shooting for Star Cool Controller p 56 before replac
104. adjustment when done Menu keys Press key to select menu display Press again to move menu one full page down Wake up Turn on and off battery powered display operation No display backlight will be active 27 of 221 pages STARS COOL Item No 810900B Operating and service manual 200900 Tn S 3 A e o 3 uc 0 lt v C0 PTI Info Operation Alarm Service Unit Toggle Defrost Water Cool Show PRE TRIP INSPECTION menu Start stop test and view results Show INFORMATION menu Actual data read out Show OPERATION menu settings Show ALARM menu View listing of present alarms Show SERVICE menu Maintenance data and settings Direct activation and deactivation of commonly used func tions As long as the button is pressed F is shown instead of C and PSI is shown instead of BAR Permanent change is not available but requires customization Shortcut to graphical view of logged temperatures Toggles infor mation on some sub menus Press 3 sec to start and stop a manual defrost cycle 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
105. alarm 513 Warning will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Active Inactive Freq FC 529 FC setup error Warning FC Setup Warning Cause The setup of the FC is rejected by the FC Either communication problems or phase fault 134 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Defect 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 they 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 Operations p 50 Criteria FC error reports its setup data FC shut down Controller pics aoe ee tee eter Alarm light Consequence The compressor will not start ess compressor will not start Warning will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Active Inactive Freq FC 566 FC undefined alarm Warning FC Undefined Alarm The FC has an undefined alarm warning Trouble Possible causes shooting e Defect FC e Defect power cable from FC to compressor motor Accompani
106. alid for 60 sec to set alarm inactive Log data 5 Active inactive EE y 69 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 109 Tusda 1 open Warning USDA 1 Temperature Sensor Open Circuit Indication of loose connection defect or lack of USDA 1 temperature sensor Trouble Possible causes shooting Temperature sensor Tusdal1 or its cable defective X1 cable is defect Defect plug inside or cable on the unit backside Controller PCB defective Accompanied alarms e N A Trouble shooting 1 Disconnect the sensor cable for sensor Tusda1 from the connector on the interface terminal block PCB 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 plug on the backside of the unit or the sensor is defect Check plug before replacing the sensor and cable b If the resistance matches the resistance and temperature in Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tusda1 It should be between 4 80 and 5 05V 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 Tables starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the vo
107. alogger l l CSV text Software Logfile StarView HEX file With signature PC With CRC A s _ im General requirements 1 Serial port setup is 19200 8 N 1 2 Unless otherwise stated byte order is low byte first List of terms used for external interfaces Description Local Monitor serial communication port on the container unit Hand held datalog retriever terminals PC software viewer for container datalog files RCCU Reefer Container Controller Unit Star Control 51 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Functions overview It is defined in the table below which Star Cool functions each device and system will support Display basicdatat o Jx e jJ IDisPayalarmlist Display controller information bo jx do a ee IChangecontaimrID fe Change temperature setpoint x Change humidity setpoint Change controller date and time x eo e O Calibrate USDA and Cargo sensors po po Acknowledge alarms LL CC initiate manual defrost dE PR L Initiate Trip Start pope Display Function and PTI test results Retrieve datalog from unit x Save datalog file binary x e O Save datalog file RefCon x o Save datalog file csv tex x S O Display datalog file binary ooo Display datalog file RefCo o o S Display datalog file csv tex 1
108. an empty unit is done by weight by the following procedure Pump down unit as described in this manual Install a service gauge manifold on the unit to the two evacuation points pos 6 amp 27 P amp I diagram Place a refrigerant bottle on scale for weighing Record the weight of the refrigerant bottle Connect manifold service hose to refrigerant bottle and purge as needed Set refrigerant bottle for liquid charging and open refrigerant bottle hand valve Open discharge stop valve pos 5 P amp I diagram 1 turn Open the high pressure stop valve on the service gauge manifold Observe the scale and close the hand valve at the refrigerant bottle when the correct amount of refrigerant has been charged The unit refrigerant charge is 4 5 kg R134a 9 Close the valves on the service gauge manifold 10 Open the servicestop valves on the compressor pos 5 amp 26 P amp I diagram 11 Operate the unit as normal DES O NO UT e Ww 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 inrange operation it is observed that the setpoint 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
109. and the condenser fan motor have been without errors for more than 1 hour this alarm is marked inactive and can be deleted Parm 4 eres Parm 614 Humidity deactivated Alarm Humidity control deactivated Indication of defective relative humidity sensor or its measuring circuitry Trouble Possible causes shooting e Defect 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 Adive Iacive EP y Cpr start failed Fatal Alarm Description Not implemented yet 144 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble shooting None Controller ti n Alarm light Quick flash No cooling of the cargo Log data ActivefInactive oo poo ooo 621 Cpr restarted Warning The compressor has been restarted 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 Unit in emergency mode but cables not rewired for emergency mode e Compressor defe
110. anical design The air exchange must be properly calibrated before measuring V m3 h V m3 h V m3 h V m3 h Relative Humidity Sensor table RH Voltage b p Voltage Pressure Table Low pressure transmitter AKS Vcc 5V Pressure is relative Voltage Pressure Pressure Voltage Pressure Pressure V BarE Psi V BarE Psi os ues ave aes sss ees 211 of 221 pages STAR COOL Item No 810900B Operating and service manual 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 Voltage Pressure Table Low pressure transmitter NSK Vcc 5V Pressure is relative Voltage Pressure Pressure V BarE Psi Pressure Pressure Voltage V BarE Psi 1 9 4 57 66 34 0 3 1 95 4 74 68 71 0 35 2 4 90 71 08 2 05 5 06 73 45 212 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 0 45 0 16 2 38 24 5 23 75 82 0 5 0 00 0 01 2 15 5 39 78 19 0 55 0 16 2 36 22 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
111. arting p 204 the temperature sensor and cable are defect and should be replaced b If the resistance is within range perform controller door check Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Activated by UWS or AL 901 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 Active Inactive CE o y 74 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 115 Tusda 3 open Warning USDA 3 Temperature Sensor Open Circuit Indication of loose connection defect or lack of USDA 3 temperature sensor Trouble Possible causes shooting Temperature sensor Tusda3 or its cable defective X1 cable is defect Defect plug inside or cable on the unit backside Controller PCB defective Accompanied alarms e NA Trouble shooting 1 Disconnect the sensor cable for sensor Tusda3 from the connector on the interface terminal block PCB 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 the plug inside in the unit or the sensor is defect Check plug before replacing sensor and cable
112. ated control precision Alarm will be marked as inactive in alarm list when temperature change comes within limit again Alarm may then be deleted Active Inactive 1 7 Tref1 8 Tevap 9 Tsup1 10 Tret 11 Tcarco 12 Tusda1 Fog data 13 Tusda2 14 Tusda3 15 Tref2 16 Tsup2 17 Tamb 18 Tsuc 19 Trccu 902 Battery malfunction Alarm Battery Malfunctioning Indication of defective battery Trouble Possible causes shooting e The battery used for logging is defect Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting The battery is defect Replace controller door Criteria Battery voltage is below limit for low battery alarm 6V None Controller action Alarm light 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 a s Active Inactive High limit A D channel 903 Remote mon missing Alarm Remote Monitor Modem Missing Only valid for units with rem monitor 164 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Indication of missing or defective modem Trouble Possible causes noo e The communication cable RMM com is defect or unplugged e Remote Monitor Modem RMM is defect e Power not connected to the R
113. aters one by one to find the defect heater see wiring schematics inside in the controller cabinet Replace the defect heater Criteria Evaporator heater has exceeded on current limit None Controller Elimination Alarm may then be deleted after test completed Log data 821 Hevap current OFF Alarm Evaporator Heater Off Current Fault Indication of defective heater contactor or defective contactor driver circuitry Trouble Possible causes shooting e Defect heater contactor e Defect 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 cables are mounted correctly Criteria Evaporator heater has exceeded off current limit None Controller action Alarm light Slow Rash Test failed Elimination Alarm may then be deleted after test completed 154 of 221 pages STAR COOL Item No 810900B Operating and service manual Log data Valve leaks Alarm Valve Leak Fault Cause 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 defect Accompanied alarms e See other AL 84X alarms for valve failures Trouble shooting 1 Check and clear other valve alarms AL 84X Criteria Temperature indicates cooling None Controller action Alarm Tight slow fash
114. atically terminated in case of no errors Finally temperature set point will be set to the same value as before test initiation TO2 Function test start Function test Function Start function test runs to verify full functionality of the unit without performance tests Value 33 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual For starting function test START must be highlighted by pressing Pressing once more initi ates the test TO3 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 e Pressing e once more stops the test T04 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 TO5 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 test was aborted by the user TO6 Test result 20 Controller 20 Controller Function Shows the status of the test of the controller Value if not done yet RUN
115. ating and service manual 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 M02 to M08 heaters motors and valves may be manually operated In menu item MO5 compressor frequency is set In case of no keyboard activities for 5 min manual mode is automatically deactivated and unit starts automatically up Note t personnel Value Set to MANUAL or AUTOMATIC The bottom line on the menu shows the current consumption in the three phases 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 Set to ON 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 M04 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 No
116. b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tusda3 It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value below low alarm limit 60 C 76 F and the sensor reading has been in the valid area since power up None Controller isis 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 E em Active Inactive High limit_ Curent i 75 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble shooting Controller action Log data Tusda 3 short Warning USDA 3 Temperature Sensor Short Circuit Indication of short circuited USDA 3 temperature sensor Possible causes Temperature sensor Tusda3 or its cable defective X1 cable is defect Defect plug inside or cable on the unit
117. ble If the cable is defect replace cable Mount the cable for Pdis in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on interface terminal block PCB AKS If voltage is below 0 5V DC sensor or connection between sensor and cable is defect If voltage is between 0 5V DC and 4 5V DC continue to 4 NSK If voltage is below 0 37V DC sensor or connection between sensor and cable is defect If voltage is between 0 37V DC and 4 0V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND AKS If voltage is between 0 5V DC and 4 5V DC and this alarm is still active replace controller door NSK If the voltage is between 0 37V DC and 4 0V DC and this alarm is still active replace controller door Before replacing controller door see Trouble shooting for Star Cool Controller p 56 Criteria Value above high alarm limit 11 9 BarE 172 Psi Replacement by new value from AAS system Controller P y y r cis Alarm light consequence OOOO 94 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data Active Inactive High limit Current i Description Compressor Suction Pressure Sensor Short Circuit Cause Indication of short circuited compressor suction pressure sensor Trouble Possibl
118. bove top alarm limit 10 K Ohm Condenser fan motor is stopped Controller 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 evaporator fan high speed is again released Log data Active Inactive honumt current 110 of 221 pages STAR COOL Item No 810900B Operating and service manual 411 Unit over current Unit Over current Indication of short circuit Trouble Possible causes shooting e The unit is using too much power Accompanied alarms e NA Trouble shooting 1 The voltage may have been too low for too long 2 Check for loose connections 3 When cargo is unloaded run a PTI test and see if one of the motors or heater is using too much power 4 Check power cables for short circuits and damages 5 Check cables for heaters and motors for short circuits and damages Criteria Maximum current consumption has been exceeded Controll k l Cantroller ontroller breaks supply n Log data This alarm is used for service purposes the fuses are protecting the unit U1 2 over voltage Fatal Alarm Description U1 2 Over voltage Indication of error in container supp
119. cally 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 16 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 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 m seme LL E emen E emen SSCS E E emweersetwre E memeersstwe E emend E eme 2 m time SSCS C uemweres bee e fos eem 0 os mmi 1 s emm o mms 1 fs rmm s rmm Stamp Events Alarms Short Log Extended Log Type 1 17 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Extended Log Type 2 e o a gt c o o o oO o c v D x LLI 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 A
120. condenser motor cables are mounted correctly Condenser fan motor has exceeded current limit at high speed 50Hz 0 7 0 8 Amp 60Hz 1 0 1 8 Amp None Controller action Alarm light Slow fash Test failed Elimination Alarm may then be deleted after test completed Log data Mcond current OFF Alarm Condenser Motor Off Current Fault Indication of defective motor contactor or defective contactor driver circuitry Trouble Possible causes shooting e Defect condenser motor contactor e Defect contactor driver circuit Accompanied alarms e NA 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 light slow Aash Test failed Elimination Alarm may then be deleted after test completed Log data z 153 of 221 pages STAR COOL Item No 810900B Operating and service manual 820 Hevap current ON Alarm Evaporator Heater On Current Fault Indication of defective heater or defective supply cables to heater Trouble Possible causes shooting e Heaters defect e Heater power cables defect Accompanied alarms e N A Trouble shooting 1 Check the power cables for the heaters for defects Replace cables if they are defect 2 The heater s are defect Dismount the power for the he
121. connect sensor again Measure the voltage over the sensor and check voltage temperature according to table in Tables starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value below low alarm limit 60 C 76 F and the sensor reading has been in the valid area since power up None Controller ti isl 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 n m Active Inactive High limit Curent i 78 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble shooting Controller action Consequence Log data Tcargo short Warning Cargo Temperature Sensor Short Circuit Indication of short circuited cargo temperature sensor Possible causes Temperature sensor Tcargo or its cable defective X1 cable is defect Defect plug inside or cable on the unit backside Controller PCB defective Accompanied alarms e NA Trouble shooting 1 Disconnect the sensor cable for sensor Tcargo from the connector on the interface terminal block PCB according to the wiring schematics inside in the control cabinet 2 Measure the resistance between the two wires a If the res
122. consumption is higher than 5 A per phase 3 The unit may be lacking refrigerant Check if the small red balls in the sight glass in the receiver water cooling unit are not at the bottom when the unit is turned off Refill with refrigerant Criteria Set point 5 C was not reached within the 3 hour limit None Controller action Alarm light Slow flash Test failed 160 of 221 pages STAR COOL Item No 810900B Operating and service manual Elimination Alarm may then be deleted after test completed Log data PTI Tset O Alarm PTI 0 C Set Fault Indication of insufficient performance Trouble Possible causes shooting Doors are open The heaters do not operate normally The cooling capacity is too limited There may not be enough refrigerant in the unit 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 defect Start the heaters in manual mode and see if the current consumption is higher than 5 A per phase 3 The unit may need refrigerant Check if the small red balls in the sight glass in the receiver water cooing unit are not at the bottom when the unit is turned off Refill with refrigerant Criteria Set point 0 C was not reached within the 3 hour time limit None Controller Alarm light slow fash Test failed Elimination Alarm may then be deleted after test completed Log data
123. ct 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 defect and should be replaced Criteria The compressor did not start on the first attempt within 3 min None Controller action Alarm light There will be a longer start delay Elimination When the compressor has started the alarm is marked inactive and can be deleted Log data 145 of 221 pages STAR COOL Item No 810900B Operating and service manual 625 CToutrange Alarm Cold Treatment out of range Indication of insufficient yield or defective controller Trouble Possible causes shooting Difference between treatment setpoint and maximum USDA temperature too small Container doors are open Other alarms active Not enough refrigerant for the compressor Defect or jammed evaporator motors Defect 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 1 Larger difference between treatment setpo
124. ction and liquid pipe to the new evaporator Reinstall the heating elements Reinstall the sensors for evaporator temperature suction temperature humidity Reinstall pos 1 Pump down the unit see p 199 Charge unit as described in this manual see p 200 193 of 221 pages STAR LOOL Item No 810900B Operating and service manual Replacement of heating elements Dismount the back plate for the unit and replace the defect heating element After replacing heating elements reinstall back plate for unit Pleaase note that the illustrated model may be different from the actual model Optional 194 of 221 pages STAR COOL Item No 810900B Operating and service manual Replacement of FC Description Cover for FC Motor cable Cable room cover The procedure for replacing the FC is as follows 1 Dismount the cable room cover pos 4 2 Remove the cover for FC pos 1 3 Remove the FC pos 2 and motor cable pos 3 4 Reinstall motor cable Please observe that the motor cable is not damaged and squeezed be tween compressor and FC Please observe correct tightening torque 5 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 Please observe correct tightening torque 6 Reinstall cover for FC and cable room cover Please observe correct ti
125. ctive on the display replace the controller door 10 Look in display to see if pressure transmitter is according to settings see Configuration p 48 F08 and set controller according to transmitter 11 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 Controller q y PP P r m Norm Tight 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 106 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Log data Active inactive Pdis P Power Alarms AL 4XX 400 Mevap 1 overheat Warning Evaporator Motor 1 Overheat Indication of an overheated motor or a loose thermistor cable connection Trouble Possible causes shooting Evaporator motor 1 defect Defect resistances on the interface terminal block PCB Cable for measuring evaporator motor 1 overheat defect Controller PCB defective 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 defect
126. d economizer are controlled by electronic expansion valves The equipment is designed to operate on a nominal 400 460V AC 3 phase 50 60 Hz primary power source An integrated dual winding transformer supplies the control circuit voltage One winding for 24V AC and another for 18V AC converted to 24V DC in the controller The output voltage is dependent on supply 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 149F and the return temperature in the frozen mode temperature setting below 5 C 14 F Controller accuracy is 0 25 C 0 45 F The unit can operate the evaporator fans in low speed and high speed From the controller display Normal or Economy mode can be selected under operation menu In economy mode the fans allways run on low speed In normal mode the fan speed can run in high or low sp
127. e 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 3 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 manual for some time Stop compressor and see if the suction pressure rises more than normal If valve defect replace valve or top part of the 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 Sous flog TX Alarm X Alarm light Quick flash Consequence Consequence _ 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 High press trouble Fatal Alarm Description High Pressure Safety Switch is active 139 of 221 pages STAR LOOL Item No 810900B Operating and service manual Cause Hot gas valve expansion valve
128. e 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 2 Check that both sensors Tsup1 and Tsup2 are mounted correct by their mounting holes 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 interface terminal block PCB 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 starting p 204 the temperature sensor and cable are defect and should be replaced b If the resistance is within range perform controller door check Trouble shooting for Star Cool Controller p 56 before replacing controller door Value is below alarm limit 609C F or above 140 C 284 F or difference between Tsupi and Tsup2 is more than gt 1 C for 30 min or upto 10 C difference Value invalid for 30 sec for alarm activation 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 Value must be v
129. e causes shooting Connector for suction pressure sensor Psuc not correctly mounted Suction pressure sensor Psuc defective Cable for suction pressure sensor Psuc defective X1 cable is defect Controller PCB defective Accompanied alarms e AL 207 Trouble shooting Disconnect the cable for Psuc from the connector PCB according to the wiring schematics inside the control cabinet and from the suction pressure sensor 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 SUPPLY VOLTAGE 924 0 TYP OUTPUT Figure for AKS Figure for NSK Check the cable measure the resistance in the cable If the cable is defect replace cable Mount the cable for Psuc in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on interface terminal block PCB AKS If voltage is below 0 5V DC sensor or connection between sensor and cable is defect If voltage is between 0 5V DC and 4 5V DC continue to 4 NSK If voltage is below 0 37V DC sensor or connection between sensor and cable is defect If voltage is between 0 37V DC and 4 0V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND AKS If voltage is between 0 5V DC and 4 5V DC and this alarm is still act
130. e measuring is above limit It may then be deleted Log data x E SEE Active Inactive High limit Voltage A D Channel 419 U1 3 under voltage Warning 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 a L UNNNNG S Alarm light Consequence Unit Unit stops 0 Alarm will be marked as inactive if another phase voltage measuring is above limit It may then be deleted Log data Tum m Active Inactive High limit Voltage A D Channel 420 Ilovercurrent I1 Over current Indication of short circuit in electric installations of Star Cool unit 114 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e The unit is using too much power on one phase e Defect Power Meas PCB Accompanied alarms e NA Trouble shooting 1 The voltage may have been too low for too long 2 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 Measure the actual current and compare with the value in the display If the measurement
131. e 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 defect parts and reinstall the parts Prior to mounting the motor cover check the sealing for any damages if damaged the sealing must be replaced 191 of 221 pages STAR LOOL Item No 810900B Operating and service manual Replacement of evaporator Old model In order to replace the evaporator the unit has to be dismounted from the container as described in this manual After dismounting the unit there is free access to all parts on the backside of the unit Position Description 3 Evaperatorbackplate The replacing of evaporator is done in the following steps 1 2 3 4 5 6 7 8 Evacuate refrigerant as described in this manual see p 197 Remove pos 5 Remove pos 1 Remove pos 4 Disconnect tray heater from pos 3 Disconnect cable for heating element on pos 6 Disconnect drain hose from evaporator backside Remove heating elements below evaporator 192 of 221 pages STAR COOL Item No 810900B Operating and service manual Remov
132. e 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 active 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 By pressing QD the service menu is selected The icon appears in the display Service menu consists of various sub menus Use the arrow keys and v to navigate and the Enter key to open a sub menu By pressing 9 the display returns to service menu See also Using the cursor p 29 and Changing a parameter value p 29 Service menu consists of the following sub menus Manual operation MO1 MOS Manual start stop of motors etc Datalog view LO1 LO3 View of temperature log Time adjust C01 C05 Setting of date and time Run time counters RO1 R05 View of running hours for unit comp etc Configuration FO1 F09 Software version 44 of 221 pages STAR 2 COOL Item No 810900B Oper
133. e the sensors for evaporator temperature suction temperature humidity from pos 6 Disconnect evaporator fans and return air sensor Remove pos 2 Remove pos 3 Desolder the suction and liquid pipe for pos 6 Remove drill out rivets heads and remove pos 6 Punch the remaining rivet pieces into the foam using a max g5mm tool Mount new evaporator on chassis with appropriate rivets Solder the suction and liquid pipe to the new evaporator according to soldering instruction in this manual Reinstall pos 3 and 2 Reinstall the heating elements Reconnect the evaporator temperature sensor and suction temperature sensor and humidity sensor Reconnect return air sensor and evaporator fans Reinstall pos 1 4 and 5 Pump down the unit see p 199 Charge unit as described in this manual see p 200 New model Position Description 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 p 197 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 g5mm tool Mount new evaporator on chassis with appropriate rivets Connect the su
134. easured 952 Power ref HI Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 24V DC and 5V signals to see if power supply has an open circuit or other damages If voltages are ok the controller PCB is defect Replace controller door Criteria Power ref above 2 75 V DC None Controller D sib tog X aam Alarm light Consequence Log data i E Active Inactive High limit Actual value A D channel The measured voltage is internal on the controller PCB and ca not easily be measured 953 Temp ref 1 LO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault 170 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Defect power supply for controller PCB e Defect sensor pulling power supply down e Defect controller PCB Accompanied alarms e There may be sensor alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Check if the
135. ed 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 removed 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 Operations p 50 Criteria FC reports an undefined alarm FC shut down Controller n 135 of 221 pages STAR LOOL Item No 810900B Operating and service manual Warning will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Active Inactive Freq FC FC AL number 599 FC Trip Lock The FC has tripped and stopped Alarm indicates problem with compressor or frequency controller Trouble Possible causes shooting e Other alarms have tripped stopped the FC e Defect 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 e
136. eed 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 221 pages STAR COOL Item No 810900B 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 after a defrost sequence The dual system for defrost also ensures an even distribution of heat to the evaporator coil The result of this is that there is no building up of ice in corners or other places of
137. electrical coils and mount permanent magnet on the two electronically expansion valves pos 16 amp 18 P amp I diagram 4 Pump down the unit pressure to vacuum indicated on the gauges of the service gauge mani fold 5 Continue vacuum pumping for at least 2 hours 6 Switch off the vacuum pump and close the stopvalve for the suction line to the vacuum pump on the service gauge manifold Observe the vacuum for minimum hour 7 If the vacuum is maintained then the unit can be charged as described this manual If the vacuum pressure is not maintained there is a possible leak somewhere check all hose connections between unit and vacuumpump If these are ok check the unit 8 Close the compressor stopvalves pos 5 amp 26 P amp I diagram 9 Remove the permanent magnets and reinstall the electrical coils on the two electronically expansion valves pos 16 amp 18 P amp I diagram 10 Disconnect the service gauge manifold 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 pressuretest 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 amp 27 P amp I diagram The procedure for this is as follows NOTE DO NOT USE OXYGEN O FOR A PRESSURE TEST 1 Install a service gauge manifold
138. equency Converter EC Alarms CAI BS XX rorun nne inda Pieri qe s UN Rr cK Od EdCNEPM FRI DRE NN NEN UN IERI REM DM dE 120 Operation Alarms AL OXX cdacstesexadatasevea fa vusscaimani sunk o Pn AEN NUR aM Ec EP I boxExdd DEFUI Egana NR URUR NAE SEG E 136 Alans MOE MSE emm e EEUU 148 Test Alarms ALBXX s acccesinensawsntscvadacnasenstadesetas neaweaehanaduada Und T Mis a Ta UMS MUNERA IR DEERSR iaaa 148 Controller Alarms AE OXX ES 163 Internal Voltage Reference Alarms cssissrriinissriarre nera nan tna nut nk e saa En E Ea Ead FERRARI egceanend dass aneteedsemserenteecad one 169 Calibration of air exchange sensor retorica m xxu tcu ss Rage DARE NK RRUN X Ed A M NNI HU SISX KNEE NURSES EL eate ais 188 Replacing Of UMNIt MEM LnE m 189 Replacement Evaporator motor and fan esisiini EE EEE EEE EEE E EE E sese seinen nene nnn 190 Replacement Condenser motor and fan ccc EE EEE EEE eee semen nene nnns 191 Replacement of evaporator oot edid a E EE rrr E NE UN UN A TENER UA 192 Oldimodoel 2 ittune ct unarna pi putes n Tum asatattiokonse cupi a pesti neteugt mate tenovanaidutete ftdt caudtt ohm ako DR e mbOE DIS An Dses 192 New model metet UR 193 Replacement of heating elements ssssssssssseennnneneeememeeeehemememess seminis SEERA EOE nemen ne nens 194 Replacement dodo 195 Replacement of compressor neret ines AE SRM SFR POI EPEE RP RE rRFrxra Eur er UR d RR RR RET RR 196 Replacement of compressor valve
139. er 60 sec After 30 sec the unit restarts with a normal Controller startup procedure action METH a So Alarm light Quick flash Consequence Unit Unitstops 0 Alarm will be marked as inactive if another phase voltage measuring is below limit It may then be deleted Log data aE Active Inactive High limit Voltage A D Channel U1 3 over voltage Fatal Alarm Description U1 3 Over voltage Indication of error in container supply voltage between phases 1 and 3 112 of 221 pages STAR COOL Item No 810900B Operating and service manual 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 MEN NN e 8 Alarm light Quick flash Consequence Unit l Unit stops ee Alarm will be marked as inactive if another phase voltage measuring is below limit It may then be deleted Log data EE R er Active Inactive High limit Voltage A D Channel U1 2 under voltage Warning U1 2 Under voltage Indication of error in container supply voltage between phases 1 and 2 Trouble Possible causes shooting e The unit is supplied with a voltage below specified level e Defect Power Meas 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
140. er supplied Power generator adjusted to too high frequency compared to supply voltage Trouble Possible causes shooting e Overload of power supply Too long or to thin cables 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 Umean is less than lt 105 5 1 frequence Umean U1 2 U2 3 U1 3 3 None action jo wem em J Sow fash Alarm will be marked as inactive in alarm list when proper supply is established Alarm may then be deleted Log data TE 428 Voltage freq U f ratio high Alarm Bad power supply voltage regulation out of order Power generator adjusted to too high voltage Trouble Possible causes shooting e Failure in generator voltage control Accompanied alarms e AL429 Trouble shooting 1 Find a better supply 2 If no AL 429 watch the unit more often Umean is more than gt 145 5 9 frequence Umean U1 2 U2 3 U1 3 3 118 of 221 pages STAR COOL Item No 810900B Operating and service manual None Controller action a 30QStENNH e Alarm light slow flash Consequence None Alarm will be marked as inactive in alarm list when proper supply is established Alarm may then be deleted Log data NetFreg Voltage freq U f ratio Fatal Sed pore HH Bad power supply See AL 427 and AL 428 Tro
141. ercooling Warning Water cooling fault Lack of water cooling Trouble Possible causes shooting Water cooling selected and no water cooling active Insufficient water cooling capacity If program is chosen warning can occur in units without watercooling Accompanied alarms e AL 100 to AL 108 Trouble shooting 1 Verify that water cooling pipes 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 temperature exceeds limit for water cooling 60 C 140 F in more than 1 hour Water cooling is deactivated Controller g n pere Alarm light Consequence 137 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Alarm will be marked as inactive in alarm list next time water cooling is activated Alarm may then be deleted Log data Acive Imctive Tc Wcoff 602 Tset unreachable Alarm Tset Unreachable Not implemented yet Indication of insufficient yield Trouble Possible causes shooting Container doors are open or gasket defect Not enough refrigerant for the compressor Insufficient airflow though evaporator Insufficient airflow though condenser Defect 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
142. ervice manual 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 1 C 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 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 in the range 15 C to 30 C 30 F to 86 F its value can vary 49C 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 or Y to select 002 QUEST and press 3 Select OFF by using or y and press To activate QUEST 1 Press 2 Use or Y to select 002 QUEST and press 3 Select AUTO by using or y and press If O02 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 Tests The 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
143. es longer time The hotgas 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 condensor pressure will be very high The unit has been put in manual phase 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 unit One of the motors condenser or evaporator is running in the opposite direction 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 evaporator sensor Tevap is not working properly The pressure sensor Psuc is not working properly Display is blank Adjust contrast see Contrast adjustment of the display p 32 Trouble shooting for Star Cool Controller A method to check if the controller is performing correct readings If there is a problem with a sensor or a transmitter the X1 cable on the controller door must be disconnected to see if the defect is with the sensor transmitter or the controller door The proce dure is 1 Set unit to Manual Operation Mode by choosing Service Menu and Operation Mode and changing Auto to Manual 2 Disconnect the X1 c
144. escribed in this manual 14 Observe the unit running in a stable condition Add or remove refrigerant if necessary 15 When refrigerant charge is correct remove service gauge manifold and cap the two evacuation points pos 6 amp 27 P amp I diagram Caution Do not overcharge the unit Leakage detection Leakage detection is done under pressure test as described in this manual While the unit is pressurized it is possible to check all soldered and screwed joints of the piping system This is done with a leakage detection agent or with a solution with high foambuilding 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 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 201 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Drying filter Replacing of dryin
145. est current of I1 12 or I3 Not checked during defrost The evaporator motors must run 147 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual FC will soon trip with error 516 and stop compressor 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 Log data Active Inactive Eoo Alarms not used Alarms AL 7XX are not used Test Alarms AL 8XX Func test failed Alarm Function Test Fault Cause 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 Active Inactive 1D Testtime sec 148 of 221 pages STAR COOL Item No 810900B Operating and service manual Controller Internal Voltage Reference Fault Cause J shooting Possible causes e Power supply for controller PCB defect
146. et If U Psuc is now inside the above range the cable for Psuc is defect Mount connector correctly or replace connector cable for Psuc If U Psuc is still outside correct the above range The controller PCB is defect Replace the controller door Criteria Reference voltage Psuc below 4 80V DC None Controller p na tog X Alarm Alarm light Consequence Log data em mum Active Inactive High limit Actual value A D channel 964 Psuc sens sup HI Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault 179 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 20V DC None Controller n EE mors tog x Alarm Alarm light Consequence Log data m A Active Inactive High limit Actual value A D channel 965 __ Controller sup LO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB Accompanied alar
147. et 815 Mcond cur LO speed Alarm Condenser Motor Low Speed Current Fault Indication of defective motor or defective supply cables to motor Trouble Possible causes shooting Condenser motor jammed or defect Condenser motor cable defect Bad connection in plug 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 off power first Replace motor or make it turn freely again 2 Check motor cable for damages 3 Check that the condenser motor cable are mounted correctly Criteria Condenser fan motor have exceeded current limit at low speed 0 2 0 3 Amp None Controller action Alarm light Slow Rash Test failed Elimination Alarm may then be deleted after test completed Log data 816 Mcond cur HI speed Alarm Condenser Motor High Speed Current Fault Indication of defective motor or defective supply cables to motor 152 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Condenser motor jammed or defect e Condenser motor cable defect e Condenser motor cable wired wrongly in controller cabinet Accompanied alarms e NA Trouble shooting 1 Check the Condenser motor fans 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
148. f problems with compressor 124 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting much nt A13 e The compressor motor draws too much curre e Defect FC e Condenser blogged 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 defect 2 Turn off unit and wait 10 min before turning on the unit again 3 When the unit starts up again verify that the compressor starts again and is running 4 If the compressor cannot run or runs very short time before this alarm comes again the compressor is defective and must be replaced 5 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 Operations p 50 6 Clean condenser Criteria FC overloaded Current above 38Amp for approx 1 sec FC shut down Controller tion a ee He et eee Alarm light Slow flash Consequence Unit Unitstop 0 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 Compressor Motor Overtemperature Indication of defective compressor or lack
149. 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 nor mal 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 lt 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 of 221 pages STAR 2 COOL Item No 810900B Operating and s
150. for the high pressure switch again If this alarm is still active on the display replace the controller door 10 Look in display to see if pressure transmitter is according to settings see Configuration p 48 F08 and set controller according to transmitter 11 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 Controller q y PP P n 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 Log data 7 105 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 306 _ High press switch Warning High pressure switch is active Discharge pressure is too high and the high pressure switch off Trouble Possible causes shooting 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 Fuse F6 blown High pressure switch or cable is defective Wrong pressure transmitter in relation to controller settings Pressure transmitter defect X1 cable is defect Controller PCB defective Accompanied alarms e AL 500 may be acti
151. frosttime exceed Warning Max defrost time exceeded Defrost terminated on time gt 45 minutes 141 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting There has been too much ice in the evaporator The heaters are not working defect Defect Pdis pressure sensor Defect Tevap evaporator temperature sensor Accompanied alarms e Maybe alarm AL 203 is active Trouble shooting 1 Check and clear other alarms first Condenser temperature is used and is calculated from Pdis 2 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 2 is shown on the display If current is lower check if there is power for the heaters 3 Run a PTI test after the cargo is unloaded Criteria Defrost time has exceeded 45 min None Controller action 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 Log data 611 Too many sensor errors Alarm Too many controlling sensors have errors If too many controlling sensors have errors the controller cannot maintain correct temperature See also Tempreature control and Expansion valve control p 18 Trouble Possible causes shooting e One
152. g Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 Access the special menu by pressing RY for more than 3 sec Scroll down until you see the label U Pspar in the display The value of U Pspar should be in the range between 4 80 and 5 05V DC 3 While displaying U Pspar remove the connector at Pspar f U Pspar is now inside the correct above range 4 80 5 05V DC the Pspar pressure sensor is defect Replace the sensor connected to Pspar If U Pspar is still outside the above range proceed to next step 4 While displaying U Pspar disconnect sensor from the terminals according to wiring schematics inside in the control cabinet If U Pspar is now inside the above range the cable for Pspar is defect Mount connector correctly or replace connector cable for Pspar If U Pspar is still outside correct the above range The controller PCB is defect Replace the controller door Criteria Reference voltage Pspare below 4 80V DC None Controller n gc tog X aam
153. g and service manual valves pos 16 and 18 P amp I diagram Vapor recovery a Turn off unit b Close open the discharge pressure stopvalve pos 5 P amp I diagram approx 4 turns c Recovery equipment is set for vapor recovery d Open both service gauge manifold valves Liquid recovery a Continue operation of unit b Close outlet valve pos 14 P amp I diagram from receiver and do a pump down of the low pressure side of the unit to approx 0 8 BarE c Turn off the unit d Set recovery equipment for liquid recovery e Open high pressure stopvalve on service gauge manifold Remove the permanent magnets and reinstall the electrical coils on the two electronically expansion valves pos 16 amp 18 P amp I diagram Start and operate the recovery equipment as long as necessary to evacuate desired amount of refrigant from the unit Note refer to operating and service manuals for the recovery equipment Compressor pump down operation Pump down of the compressor is done by the following procedure 1 2 3 Duse 11 12 Connect the vacuum pump to the two evacuation points pos 6 amp 27 P amp I diagram Ensure that the valves on the vacuum pump are closed Close the compressor suction pressure stopvalve and compressor intermediate pressure stopvalve pos 26 amp 30 P amp I diagram Close the compressor discharge pressure stopvalve pos 5 P amp I diagram approx
154. g 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 Close the stop valve pos 14 P amp I diagram 3 Start the unit in Manual operation 4 Select compressor frequency to 40Hz 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 7 Replace the drying filter with a Danfoss DML 164 O ring or equivalent Before mounting of the filter put some drops of compressor esteroil 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 antgas to escape 11 Tighten the union nut 12 Remove the permanent magnets and reinstall the electrical coils on the two electronically expansionsvalves pos 16 amp 18 P amp I diagram 13 Open the stop valve pos 14 P amp I d
155. gain Temperature Setting Temperature set point adjustment is made from the operating menu By pressing 4 or y the set point is adjusted 0 19C 0 19F 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 and the previous set point is shown again If the keys i or e 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 and press or y to adjust the contrast of the display This can be done both i
156. ghtening torque 195 of 221 pages STAR COOL Item No 810900B Operating and service manual Replacement of compressor NEE y x M MU Kes We SST Position Description Compressor Bracket for compressor Motor cable l6 Cable room cover The procedure for replacing the compressor is as follows l 2 3 4 5 6 7 8 Dismount the cable room cover pos 6 Remove the cover for FC pos 3 Remove the FC pos 4 and motor cable pos 5 Dismount all pressure transmitters high pressure switch and temperature sensors 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 backmost compressor foot is inserted into the bracket slot Reinstall the compressor brackets Please observe correct tightening torque O Reinstall all pressure transmitters high pressure switch and temperature sensors Please observe correct tightening torque 11 Fasten all bolts for compressor stop valves Please observe correct tightening torque 12 Reinstall motor cable please observe that the motor cable is not damaged and squeezed eo 196 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 13 14 15 between compressor and FC Please observe correct tightening torque Reinstall FC Make sure that the FC is mounted correctly o
157. go temp Function Shows current temperature for cargo sensor Value Shown in temperature scale C or F Switch by pressing C 108 Time to next defrost Time to defrost Function Shows current time to the next defrosting Value Shown in hours and minutes 109 Ambient temperature Ambient temp Function Shows current ambient temperature Value Shown in temperature scale C or F Switching by pressing D air 1 temperature Supply air 1 temp Function Shows current temperature for supply 1 sensor Value Shown in temperature scale C or F Switching by pressing 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 C 112 Return air temperature Return air temp Function Shows current temperature for return sensor Value Shown in temperature scale C or F Switch by pressing C 113 Evaporator temperature Evaporator temp Function Show current temperature for evaporator Value Shown in temperature scale C or F Switching by pressing C 114 Suction temperature Suction temp Function Shows measured suction gas temperature Value Shown in temperature scale C or F Switch by pressing C Function Reserved for future use 37 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Value 116 Suction pressure S
158. he RH sensor 1 If the cable by inspection is defect 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 end If the resistance is less than lt 230 Q the cable is defect and must be replaced Mount the cable for RH in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on the interface terminal block PCB If voltage is below 0 5V DC sensor or connection between sensor and cable is defect If voltage is between 0 5V DC and 10V DC continue to 4 4 Mount signal wire Measure voltage between SIGNAL and GND If voltage is between 0 5V DC and 10V DC and this alarm is still active replace controller door Before replacing controller door see Trouble shooting for Star Cool Controller p 56 Criteria Value above high alarm limit 120 None Controller ti eise Alarm light Dehumidification impossible When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data Active Inactive High timit Curm iS Relative Humidity Sensor Short Circuit Indication of short circuited relative humidity sensor 99 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Relative humidity sensor RH or cable defective e X1 cable is
159. he cable AKS 1 Supply GROUND SUPPLY VOLTAGE a 90 95 024 0 TYP OUTPUT Figure for AKS Figure for NSK Check the cable measure the resistance in the cable If the cable is defect replace cable Mount the cable for Pdis in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on interface terminal block PCB AKS If voltage is below 0 5V DC sensor or connection between sensor and cable is defect If voltage is between 0 5V DC and 4 5V DC continue to 4 NSK If voltage is below 0 37V DC sensor or connection between sensor and cable is defect If voltage is between 0 37V DC and 4 0V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND AKS If voltage is between 0 5V DC and 4 5V DC and this alarm is still active replace controller door NSK If the voltage is between 0 37V DC and 4 0V DC and this alarm is still active replace controller door Before replacing controller door see Trouble shooting for Star Cool Controller p 56 Criteria Value below low alarm limit 0 1 BarE 2 Psi Replacement by new value from AAS system Controller p y y 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 i Active Inactive J
160. heath Temperature Range 379C to 90 C 34 6 F to 194 F USDA socket requirements Rear left side 3 pieces 1 cargo sensor Deutsch HD 10 female socket Tin Plated Evaporator fan motor Speed Dual speed 3460 2850 rpm 60 50 Hz 1760 1425 rpm 60 50 Hz Counter clockwise when viewed from shaft end Permanently lubricated sealed Bearing size Drive end Non drive end 6304 2Z C3 6201 2Z C3 Bearing lubricant Lubricant Kl berquiet BQH 72 102 or equiva lent Temp range 40 C to 140 C 40 F to 284 F Condenser fan motor 07183 Stainless steel X20CrNIL72 1 3 phases 400 460 Vac 50 60 Hz 0 25 0 07 kW at 460V 60 Hz Speed Dual speed 1740 1460 rpm 60 50 Hz 870 730 rpm 60 50 Hz Rotation Counter clockwise when viewed from shaft end Permanently lubricated sealed 24 of 221 pages Protection electrical Thermistors STAR 2 COOL Item No 810900B Operating and service manual Bearing size Drive end Non drive end 6204 2Z C3 6201 2Z C3 Bearing lubricant Lubricant Kl berquiet BQH 72 102 or equivalent Temp range 40 C to 140 C 40 F to 284 F Evaporator coil heaters 98 5 mm in stainless steel AISI 304 INMmpe 86 SS 750 W each at 400V 750W TOW Drain pan heaters optional 98 5 mm in stainless steel ATST 304 400 W at 400V 400W 510W Temperature sensors including USDA NTC 10 kohm at 25 C 77 F 10K3A1 Operating temp 40 C to 100
161. hooting e Temperature sensor Tsupi or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL105 Trouble shooting 1 Disconnect the sensor cable for sensor Tsup1 from the connector on the interface terminal block PCB 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 defect replace the sensor and cable b If the resistance matches the resistance and temperature Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tsup1 it should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Value above high alarm limit 140 C 284 F Replaced 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 s Active In
162. iagram 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 oil level is below sight glass after a period of minimum 6 hours normal operation additional oil may be added as decribed 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 202 of 221 pages STAR COOL Item No 810900B
163. id 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 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 Check that sensor Tusdal is mounted correct by its mounting hole 3 If AL 901 is active see trouble shooting for AL 901 4 Disconnect the sensor cable for sensor Tusdal from the connector on the interface terminal block PCB 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 starting p 204 the temperature sensor and cable are defect and should be replaced b If the resistance is within range perform controller door check Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Activated by UWS or AL 901 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 Active Inactive CE o y 80 of 221 pages STAR 2 COOL
164. ill be activated during FT or PTI test Trouble shooting 1 Real time clock battery defect Replace controller door Criteria Invalid reply from real time clock Controller action Alarmlight Slow fash Invalid date time setting in datalog Elimination Check replace real time clock battery Set time Alarm may then be deleted Log data 909 Display error Warning Display Unavailable Indication of defective display or defective display driver circuitry Trouble Possible causes shooting e Defect cable from controller PCB to display e Defect display e Defect controller PCB Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting The unit will continue temperature control but settings and operation are not visible on the display 1 Try to adjust contrast See Contrast adjustment of the display p 32 2 Turn unit off wait 2 min and turn it on again If the problem is still there replace the controller door Criteria Display communication not possible Controller aoa flog X Alarm X Alarm light Consequence Cannot show data for user use PC program or RMM Every 30 sec retry to reinitiate the display is made MN Alarm will be marked as inactive in alarm list if the error disappears Alarm may then be deleted Log data Active inactive EP 167 of 221 pages STAR COOL Item No 810900B Operating and service manual 910
165. ill be affected and the unit may get damaged Supply unit with power according to specification If the voltage is ok the controller PCB is defect Replace controller door Access the special menu by pressing for more than 3 sec Scroll down until you see the label U RH in the display The value of U RH should be in the range between 16 and 32 While displaying U RH disconnect RH from the terminals J f U RH is now inside the above range the RH sensor is defect Replace the relative humidity sensor RH If U RH is still outside the above range the controller PCB is defect Replace the controller door Criteria Reference voltage RH above 34 0V DC None Controller r Consequence Log data z mm i m Active Inactive High limit Actual value A D channel 176 of 221 pages STAR COOL Item No 810900B Operating and service manual 961 Pdis sens sup LO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect Pdis pressure sensor e Defect controller PCB 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
166. ing controller door Value is below alarm limit 609C 76 F or above 140 C 284 F or difference between Tsup1 and Tsup2 is more than gt 1 C 34 F for 30 min Value invalid for 30 sec for alarm activation Replacement by new value from AAS system Controller P d 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 Value must be valid for 60 sec to set alarm inactive Log data ActivefInactive CE 66 of 221 pages STAR COOL Item No 810900B Operating and service manual 106 Tsup 2 open Warning Supply Air Temperature Sensor 2 Open Circuit Indication of loose connection defect or lack of supply air temperature sensor Trouble shooting Controller action Consequence Possible causes e Temperature sensor Tsup2 or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 108 Trouble shooting 1 Disconnect the sensor cable for sensor Tsup2 from the connector on the interface terminal block PCB 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 defect replace the sensor and cable b If the resistance matches the resistance and temperature in Tables starting p 204 the tempera
167. ing limit 78 C None Controller action EEUU Alarm light If not solved this problem can cause FC to stop due to alarm 517 Log data i Active Inactive Freq FC 523 FC phase loss Warning FC Phase Loss Fault Warning Indication of defective FC or lack of phase 131 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting W36 e One or more phases are not applied to the FC e Unstable power supply generator e Defect FC Accompanied alarms e AL 417 AL 418 AL 419 AL 516 may be active Trouble shooting 1 Verify that all 3 phases are present and voltage is correct 2 Verify that voltage levels are the same for all 3 phases diffence in voltage below 14V AC 3 Supply unit with correct power voltage according to specification 4 Replace the FC If no FC replacement is available the unit can be rewired for emergency operation FC cannot maintain DC filter voltage above warning is more than 70V DC peak to peak too much ripple in DC voltage None Controller action Hoa p Wem p mm 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 i Active Inactive Frea FC 132 of 221 pages STAR COOL Item No 810900B Operating and service manual FC Current Limit Fault Warning Indication of problems with co
168. int and maximum USDA temperature Treatment setpoint must be cooler Maximum USDA temperature 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 USDA measured temperatures are no longer in range None Controller action PE Da Alarm light Quick flash 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 630 Manual phase dir Alarm Manually Selected Phase Direction Indication of insufficient yield or defective controller 146 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e The user has selected a manual phase direction Accompanied alarms e AL423 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
169. istance is less than 230 Q the cable the plug inside in the unit or the sensor is defect Check the plug before replacing sensor and cable b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tcargo It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value above high alarm limit 140 C 284 F and the sensor reading has been in the valid area since power up None 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 79 of 221 pages STAR COOL Item No 810900B Operating and service manual 120 Tcargo invalid Warning USDA 1 Temperature Sensor Invalid Cause Indication of defective supply air temperature sensor or its measuring circuitry or sensor not mounted correctly in unit Trouble Possible causes SHOES Active alarms AL 118 AL 119 or AL 901 Temperature sensor reading is out of val
170. ive replace controller door NSK If the voltage is between 0 37V DC and 4 0V DC and this alarm is still active replace controller door Before replacing controller door see Trouble shooting for Star Cool Controller p 56 Criteria Value below low alarm limit 0 9 BarE 13 Psi 95 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Replacement by new value from AAS system Controller action Alarm light Consequence S O When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data Active Inactive High ime Current CS Psuc invalid Warning Compressor Suction Pressure Sensor Invalid Cause Indication of defective compressor suction pressure sensor or its measuring circuitry 96 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting Connector for suction pressure sensor Psuc not correctly mounted Suction pressure sensor Psuc defective Cable for suction pressure sensor Psuc defective X1 cable is defect Controller PCB defective Accompanied alarms e AL 204 or AL 205 may also be active Trouble shooting Disconnect the cable for Psuc from the connector PCB according to the wiring schematics inside the control cabinet and from the suction pressure sensor 1 Check that the connector is mounted correctly according to the drawing for pressure transmitter AKS or NSK re
171. k Cool Thinking Tif 45 73 64 34 00 Fax 45 73 64 35 69 www mcicontainers com Version 810900B Copyright 2007 Maersk Container Industri AS March 2008
172. l Voltage Reference Fault 60 of 221 pages Oo O xo Oooo N DIW z STAR COOL Item No 810900B Operating and service manual Software test ver Software test version Software CRC Prom CRC Fault Alarm error EEPROM faul Temperature Sensor Alarms AL 1XX 100 Tretopen Warning Return Air Temperature Sensor Open Circuit Cause Indication of loose connection defect or lack of return air temperature sensor Trouble Possible causes shooting e Temperature sensor Tret or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 102 Trouble shooting 1 Disconnect the sensor cable for sensor Tret from the connector on the interface terminal block PCB 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 defect replace sensor and cable b If the resistance matches the resistance and temperature in Tables starting starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tret It should be between 4 80 and 5 05V 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 starting starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be
173. l description The 74 coot units models SC MCI40 and SC MCIAO WC are electric powered picture frames cooling and heating units operating on refrigerant R134a The unit is designed to maintain cargo temperatures in a range from 30 C 22 F to 30 C 86 F The unit is designed to operate in ambient temperatures from 30 C 22 F to 50 C 122 F The outer front frame is constructed of marine grade aluminium 5000 and 6000 series designed to serve adequately as the container end wall The rear bulkhead is made of food approved material The unit is designed to operate with 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 rails The unit consists of the following modules Please see exploded view Frame module Condenser compressor module Evaporator module Evaporator fan module The cooling system of the unit is equipped with a two stage compressor electrically driven through a FC The cooling system is also equipped with an economizer which performs the task of sub cooling the liquid from receiver to evaporator thereby increasing the cooling capacity of the cooling unit The evaporator an
174. l is functioning 165 of 221 pages STAR LOOL Item No 810900B Operating and service manual Log data 905 Database corrupt RCCU Database Faulty Failed validation of EEPROM backup Trouble Possible causes uod e Controller PCB defect Accompanied alarms e AL 801 will be activated during FT or PTI test Trouble shooting 1 Controller PCB is defect Replace controller door Criteria Controller database corrupted Default value preset Controller action ls x em ems Parameters may have changed Log data Realtime error Alarm Real time Clock Unreliable Real time clock battery defect Trouble Possible causes shooting e Real time clock battery defect 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 battery defect Replace controller door Criteria No acknowledge from real time clock Controller action Alarmlight Slow fash Invalid date time setting in datalog Elimination Check replace real time clock battery Set time Alarm may then be deleted Log data 166 of 221 pages STAR COOL Item No 810900B Operating and service manual Realtime invalid Alarm Real time Clock Unavailable Real time clock battery defect Trouble Possible causes shooting e Real time clock battery defect Accompanied alarms e AL 801 w
175. larm 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 Defect FC Accompanied alarms e AL 522 Trouble shooting 1 The FC is getting too hot 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 unsufficient 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 Operations p 50 FC temperature exceeds 85 C 185 F or above 78 C 172 F for more than 15 min FC shut down Controller action Alarm ight Slow flash Unit stops and restarts when FC is cooled down Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data FC Inrush Fault Alarm Indication of problems with supply voltage 129 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting A36 The FC has had too many restarts within short time Manual activation of contacto
176. 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 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 with 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 15 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Function test Function test is a unit component test Non destructive Test is based on a GO NO GO procedure All tests must be executed without failure one by one for the function test result to be PASS Note The tests can also be performed individually Function test includes the following items PTI init Controller test Power check
177. ller p 56 Value below alarm limit 10 RH or above 110 RH Value invalid for 120 sec for alarm activation None Controller n LL MEN ER 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 F Active Inactive o 101 of 221 pages STAR COOL Item No 810900B Operating and service manual 303 AirEx No connection Warning Air Exchange Sensor Open Circuit Indication of a loose connection defect or lack of air exchange sensor Trouble Possible causes shooting AirEx is out of calibration Air exchange sensor AirEx or cable defective X1 cable is defect Controller PCB defective Accompanied alarms e AL 305 Trouble shooting 1 If the cable by inspection is defect replace cable 2 Calibrate AirEx see p 188 If the value shown in controller is wrong or alarm still active then disconnect the cable for AirEx from the connector PCB 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 interface terminal block PCB Measure voltage between wire and GND on the interface terminal block PCB If the voltage is over 4 0 V DC sensor or connection between sensor and cable is defect If the voltage is between 0 2 V DC and 4 0 V
178. ltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value below low alarm limit 60 C 76 F and the sensor reading has been in the valid area since power up None Controller n iex 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 R am z fe Active Inactive High limit_ Curent i 70 of 221 pages STAR COOL Item No 810900B Operating and service manual 110 Tusda 1 short Warning USDA 1 Temperature Sensor Short Circuit Indication of short circuited USDA 1 temperature sensor Trouble Possible causes shooting Temperature sensor Tusda1 or its cable defective X1 cable is defect Defect plug inside or cable on the unit backside Controller PCB defective Accompanied alarms e N A Trouble shooting 1 Disconnect the sensor cable for sensor Tusdal from the connector on the interface terminal block PCB 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 230 Q the cable the plug inside in the unit or the sensor is defect Check the plug before replacing sensor and cable b If the resistance matches the resistance and temperature in table see Tables star
179. lue becomes valid it is marked as inactive in the alarm list and may then be deleted Log data Active Inactive High imit_ current ooo o 128 Tamb short Warning Ambient Temperature Sensor Short Circuit Indication of short circuited ambient temperature sensor 87 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Temperature sensor Tamb or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 129 Trouble shooting 1 Disconnect the sensor cable for sensor Tamb from the connector on the interface terminal block PCB 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 230 Q the cable or the sensor is defect replace sensor and cable b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tamb It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see
180. lve function includes the following sub functions 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 SHact Tsuc TO 11 of 221 pages STAR 4 COOL Item No 810900B Operating and service manual 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 subcooling 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 evapora
181. ly power from the FC Check other alarms if there have been more alarms from the FC a Ifthe ambient temperature is not high the compressor must be replaced b Ifthe 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 Operations p 50 Criteria FC overloaded Current has been above 24Amp for 20 sec FC shut down Controller action MEIN e Alarm light Slow flash Consequence Unit Unitstop 00 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 FC Undervoltage Fault Alarm Indication of problems with supply voltage 126 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting A9 e The FC is supplied with too low voltage for contiunous operation e Defect FC Accompanied alarms e AL 417 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 Emergenc
182. ly voltage between phases 1 and 2 111 of 221 pages STAR LOOL Item No 810900B Operating and service manual Trouble Possible causes shocmng 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 value in the display If the measurement differs the power meas PCB may be defect Replace or bypass power meas PCB by pressing RY selecting 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 a Alarm light Quick flash Consequence Unit Unit stops 00 Alarm will be marked as inactive if another phase voltage measuring is below limit It may then be deleted Log data nae m Active Inactive High limit Voltage A D Channel U2 3 over voltage Fatal Alarm Description U2 3 Over voltage 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 aft
183. m rri 262798100 68 122 607 00 24 12 493 70 20 215670 64 53944 ioe 12363950 se 108 993 00 22 11420 00 22 2010 80 se 51006 ro 190772800 64 96 974 00 e 10449 90 24 1 976 00 ss sess uz 763 539 00 es 91 525 00 ss 10000 00 zs sso eo sess us raszessoo eo 7712100 as 877700 s 1 626 63 72 exse us 82886500 53 5238000 653010 ss 129784 79 359 05 123 770 280 00 52 29 86300 625610 ss 125617 so 32079 ia 66782800 so jaesmoo s 577370 38 1777s e2 soi us 207 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 504 230 00 46 3618280 2 201550 22 103740 se 29982 fiso 33944500 caa 3265080 o _ asaiso as sse ea 20508 fiz 210 532 00 as 1 030 0 366 90 as sese eo zros 133 383 712 00 a2 295010 2 4 999 as wei foo forrie fra 29419300 28 2417270 s 360100 so eros foa 205 74 re 25830700 26 zenze s 333880 ss 763 79 os 2308 fro 24219500 3s 20 005 20 s 321580 ss rarse o7 mese fir 227 196 00 24 1920350 1e 300790 se nva os 22308 e 21321900 23 18073680 n 28510 ss e0882 Joo forso fua fis6199 00 28 15001 20 a6 248710 ss e0436 uos usss7 fre dell lal Sensor F Resistance Table Q Q F Q Ea EN Ense cos ea ee e pe pn 262798100 o 122 687 00 a 1240370 os 215670 17 53044 225 2423151900 s 115 613 00 s sese o 2 082 30
184. mb invalid Ambient Temperature Sensor Invalid 2 Pressure sensor alarms 0 Pdis open 01 Pdis short 03 Pdis invalid Psuc open Psuc short 07 Psuc invalid 250 Press sensor type 3 Other sensors Bele Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning m me e ai WW Ble m HA O N m N AJU N m e eo oo NIN e uje Compressor Discharge Pressure Sensor Open Circuit Compressor Discharge Pressure Sensor Short Circuit Compressor Discharge Pressure Sensor Invalid Compressor Suction Pressure Sensor Open Circuit Compressor Suction Pressure Sensor Short Circuit Compressor Suction Pressure Sensor Invalid Wrong Suction Pressure Sensor Warning Warning Warning Warning Warning Warning Alarm NIN N g 57 of 221 pages STAR COOL Item No 810900B Operating and service manual Relative Humidity Sensor Open Circuit RH short Relative Humidity Sensor Short Circuit RH invalid Relative Humidity Sensor Invalid 303 AirEx No connec Air Exchange Sensor Open Circuit Warning tion 304 AirEx short Air Exchange Sensor Short Circuit Warning Not implemented yet AirEx invalid Air Exchange Sensor Invalid Not implemented yet Warning 05 6 High press switch High pressure switch is active Warning 4 Power alarms 00 warning 401 Warning 02 Warning n Unit over current Unit overcurrent SSCS Fatal
185. menu by pressing 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 80 and 5 05V Dc 3 While displaying U Pdis remove the connector at Pdis If U Pdis is now inside the above range the Pdis pressure sensor is defect Replace the Pdis pressure sensor If U Pdis is still outside the above range proceed to next step 4 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 defect Replace cable for Pdis If U Pdis is still outside the above range the controller PCB is defect Replace the controller door Criteria Reference voltage Pdis below 4 80V DC None Controller consequence Log data mE Tu Active Inactive High limit Actual value A D channel 962 Pdis sens sup HI Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault 177 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 See Trouble shooting AL 961 Criteria
186. mergency operation See Emergency Operations p 50 Criteria The FC has stopped due to an error and must be reset FC is being reset Controller g pu og TX Alarm Alar light There is no cooling until the FC is ready again The FC may need to cool down before aa Log data 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 Tempreature control and Expansion valve control p 18 136 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting Supply Air Sensor 1 Supply Air Sensor 2 Return Air Sensor and Tevap are all malfunctioning X1 cable is defect Controller PCB 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 controller PCB Criteria No valid control sensor values Controller n 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 Active Inactive PE 601 __ No wat
187. min or a constant FC error Controller action Alarm light Slow flash Restart time for 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 z ActivefInactive o oo 613 Motor trouble Alarm Description 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 143 of 221 pages STAR lt LOOL Item No 810900B Operating and service manual 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 Change the defect motor There have been several overheating signals or a permanent overheating signal from uere esponsor ea motor or or condenser tan molor dem S SSO Restart delay increased to 10 12 min Controller action Alarm light Siow flash Consequence Evaporator fan motor There is no or limited air circulation in the container Condenser fan motor There is limited capacity in the condenser When the evaporator fan motors
188. mode Condenser pressure control has two primary modes Air cooled 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 cyclus 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 cyclus 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 when In the frozen mode or Tset is more than or equal to 0 C 32 F No fresh air exchange Dehumidification is turned off Otherwise high speed Economy The fans run at a constant low speed 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 function has 4 modes Wait Initialize Execute Terminate Wait 13 of 221 pages STAR 2 COOL Item
189. mpressor Error may be seen during pull down Possible causes shooting A12 e The compressor motor draws too much current e Defect 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 defect 2 Turn off unit and wait 10 min before turning the unit on again 3 When the unit starts up again verify that the compressor starts again and is running 4 If the compressor cannot run or runs very shortly before this alarm appears again the compressor is defective and must be replaced 5 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 Operations p 50 Criteria Motor current above 24 Amp for approx 10 sec None Controller action 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 525 FCoverload Warning FC Overload Warning Indication of problems with compressor 133 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes TL e The FC cannot sup
190. ms 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 controller PCB is defect Replace the controller door Criteria Reference voltage below 4 80V DC None Controller r consequence S Log data mum Jm Active Inactive High limit Actual value A D channel 180 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 966 _ Controller sup HI Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 24V DC and 5V signals to see if power supply has an open circuit or other damages If voltages are ok the controller PCB is defect Replace controller door Criteria Reference voltage above 5 20V DC None Controller action tog x Jom m Consequence Log data 5 mem amm Active Inactive High limit Actual value A D channel 181 of 221 pages STAR 2 COOL Item
191. n 50 External interfaces iann u aSa netu na ae EAO niooo RING SEDI PDEEE SEE RASENNE 51 General iFEQuIneMONtS erm 51 List of terms used for external interfaces icsi nnna edi aaan ea ei EA AER RE aS EEA 51 FUNCTIONS OVERVIEW ERR 52 Location of valves iaaa iad ai ioiei aia i T A ERR AER ERR RIA ADR RA rai Ir AR SEP iiin 53 Location of temperature sensors humidity sensor and air exchange potentiometer s esses 54 Location of pressure transmitters high pressure switch and oil outlet port ssssseseeee 55 General trouble shooting etre i cndepe tp IbU IARE X IND M DU DNE Roue AME E DUE Gd PIENSO S 55 Trouble shooting for Star Cool Controller nete ertet rane nprap apanr RE YE PRX a EEDEN EE ENNEN 56 Detailed alarm description iue sre erssait sereni lesu ER PR IE KE Ri ere r T AE ERATIVE ERED ete 56 3 of 221 pages STAR 4 COOL Item No 810900B Operating and service manual Temperature Sensor Alarms AL 3590 ce stncnancnsess wu yed gage sensuationnnea IM IE EMI I UE ENSE cL AH NUMAE EIER E UU RUNTIME DE EERU NE RE 61 Pressure Sensor Alarms AL 200 ritea diveaaateddeaisonddiwinseues M eed icon Od e TE END Se Senat rU dnE Tan sUE NR OA 89 Other Sensor Alanis AL 3X0 rasaan eer HRORUN cae NN Shed iur ga EE RENI EURO EROR E DI ERN MER E INED UIUEE MUNDO NEAN Amer 99 Power Alarms ALAXX ccesetenseestusheaztuupIniRDu En EE E DURISMR DI DU Eten Ein span Lal LnIbIRDMEU S UD rs DrU d iur NAE UESE 107 Er
192. n battery mode and when main power is applied Make sure contrast is properly set at all times to secure readability 32 of 221 pages STARS COOL Item No 810900B Operating and service manual PTI or Function Test Execution The test menu is opened by pressing en In the test menu press keys 4 or JU to scroll the menu For a complete PTI test START must be highlighted by pressing at menu item TO1 Pressing e 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 TOI For a short PTI test START must be highlighted by pressing at menu item TO1 Press keys or 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 1 5 hours Function test is initiated in the same way by selecting menu T02 A function test performs menu items T04 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 test Only the selected item is tested The PTI test is automatically
193. n on phase 2 for the unit excluding the compressor Value 38 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Shown in units of ampere 125 Current consumption phase 3 Current phase 3 Function Shows actual current consumption on phase 3 for the unit excluding the compressor Value Shown in units of ampere 126 Voltage between phase 1 and 2 Voltage phase 1 gt 2 Function Shows current voltage between phase 1 and 2 Value Units in volt 127 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 128 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 129 Phase direction Phase direction Function Shows current phase sequence Value Shown as CW or CCW or None Value is not user changeable If AL 423 No phase direction go to configuration F05 for settings 130 Battery voltage Battery voltage Function Shows current Battery voltage Value Shown as voltage 131 Frequency Converter temperature FC temp Function Shows current converter temperature Value Shown in temperature scale C or F Switching by pressing D 132 Condenser fan speed Condenser fan Function Shows current speed for condenser fan Value Shown as OFF LO HI or OH overheat 133 Evaporato
194. n oper ra dn aastani a usal cheeses FERAI AR RSRRR6AR RR EAEE NOEN i EE MEES Ka a a recu R dis 24 Evaporator coll IBdbelsssdeeesv ek su UU UE ton quOd Fa EN M IAN NIIS Cd ERIS VPN VNDC UU MCSEdSEE An MEMMD NE IRI IREEINNME 25 Draitpanm heaters ObtIonal usuiciue use tuce io host aiuta eur Toa TEA NR RR dRR CS DAD ZuideIIEigE NE Fed 25 Temperature sensors Including USDA sesxscunzccieee uar ixte fu umts terucciteiie E M RESMNU A UL PEU DSL Mu NN MEET CNN ECKEN RUE 25 Pressure transmitters osotoro tiem MON geqe post kOqupSER S x perde EIN DUANE USE Mta ER SE MUN RE EFE EE 25 MISCEIAIN COUS EE rt EE SELL ILL UL IL 25 User interfacce LOI ILLI TTE 26 Indicator NQMES sissies UU 26 Pil M 26 Menu OVER VICW p Pm 28 General Page lAVOUb EPUM 29 USING do Sellis lolpteeRt Em 29 Changing a parameter value rotura ERR thR ri pir ra iiair RR RI GGG aRR RA X IA A 3 AA RXR RR ERI RE ibea IR RR URIeE 29 Poveidbr idIntewc UUIpiets optet 29 PM iein e MrpDI morem 30 OD SratiON cM 31 Menu Struct ERE TOEIC DLE 31 General OPS ratlOMisccsssscacinarecssncenrarnshenscesansial nhsatardtadesimaatiacetG aO Ea E Oa o DADA REN FIER CRGO RFRS NES 32 Temperature Sebtingsssscactete ou eS MNA SUE ECIGDOQU CLAIM EINE Ic S Me ri EN edi tan B SESS NUN N RO DENM EN PIER ENS 32 Wake Up Mode S827 A Q 32 Contrast adjustment of the display ncssiicccccecccces
195. n the compressor and that there is no air gap between FC and compressor Please observe correct tightening torque Reinstall cover for FC and cable room cover Please observe correct tightening torque Evacuate the compressor before starting up as described in this manual Replacement of compressor valve plate cylinder head gasket Depressurerize the compressor Dismount cylinder head and valve plate using a rubber mallet if necessary Carefully clean all sealing surfaces Check valve plate Exchange entire valve plate if damaged Determine the cause and elimi nate it Mount the cylinder head valve plate and new gaskets correctly If located in an inconvenient mounting position use mounting pins 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 tightning torque 70Nm see bolt numbers on fig below Service and maintenance Evacuation of refrigerant Evacuation of refrigerant for the unit is done by the following procedure 1 2 3 Install a service gauge manifold on the unit to the two evacuation points pos 6 and 27 P amp I diagram Connect the recovery station with weight measurement to the service gauge manifold Remove the electrical coils and mount permanent magnet on the two electronically expansion 197 of 221 pages STAR 2 COOL Item No 810900B Operatin
196. nactive Log data RS Active Inactive High limit curet i 97 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 250 __ Press sensor type Alarm Saved FC ID does not match the current FC ID Replaced Frequency Converter or controller door Trouble Possible causes shooting Accompanied alarms e AL 207 e AL 611 Trouble shooting 1 Manually select the type of pressure transmitters in the configuration on menu FO7 and FO8 eese s The saved Frecuency Converter I does not match saved Frecuency Converter ID in the controller Replacement by new value from AAS system Controller 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 meny F07 and F08 Log data r i Active Inactive Type Low Type High 98 of 221 pages STAR COOL Item No 810900B Operating and service manual Other Sensor Alarms AL 3XX 300 RH open Warning Relative Humidity Sensor Open Circuit Indication of loose connection defect or lack of relative humidity sensor Trouble Possible causes shooting e Relative humidity sensor RH or cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 302 Trouble shooting Disconnect the cable for RH from the connector PCB according to the wiring schematics inside the control cabinet and from t
197. ng of month Value Set from 1 to 12 C03 Setting of day GMT Day 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 Setting of min GMT Minute Function Setting of min Note when min are set sec are set to 00 Value Set from 0 to 59 Run time counters RO1 Viewing of operation hours for the Star Cool unit Unit Function Viewing of Star Cool unit operation hours Value Shown as hours R02 Viewing of com peration hours Com Function Viewing of compressor operation hours Value Shown as hours RO3 Viewing of evaporator fan operation hours Evaporator fan Function Viewing of evaporator fan operation hours Value Shown as hours peration hours Condenser fan Function Viewing of condenser fan operation hours Value Shown as hours peration hours Evaporator heater Function Viewing of heater operation hours Value Shown as hours 47 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 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 Value FO3 Compressor FC type setting FC type Function Setting of actual FC
198. ntroller 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 Teco to ensure a minimum middle pressure in the compressor 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 va
199. o 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 input during soldering and desoldering 3 Use inert back gas as Nitrogen N2 during soldering and desoldering 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 D On the display menu L03 the logged temperatures can be viewed graphically e Retrieved via the program RefCon and the RMM modem and the powerline e Retrieved via a program LogMan on a PSION pda using the retriever socket e Retrieved via the StarView program using the retriever socket Data Unit Tsupply temperature Temperature from supply sensor Treturn temperature Temperature from return sensor Tusda 1 temperature Temperature from USDA sensor 1 Tusda 2 temperature Temperature from USDA sensor 2 Tusda 3 temperature Temperature from USDA sensor 3 204 of 221 pages STAR COOL Item No 810900B Opera
200. o o B uw He o o o o o o o o o oll B Ww cn m a lo o Un un o o un N o ol oj jo o o o o o o o o o o o o o o o o o o o o o ol m o o i o o o o o o 421 220 of 221 pages sobed FZZ Jo TZZ as geom i a u I Brown Bri iglu Biak id zu y Mr POWER IN n AWG 14 l f V 4x4mm2 Blue or Grey_ g q2 Main el Black w jd uu FC pur J 3 w7 Switch Ci zl L3 Black L3 5 1 I 4 x 2 5mm2 WO an Be MES 4xAWG 13 GREE Outside Box via l2 Inside Box L3 L3 Black wew qs m AWG 16 asi negro TES s Li Li Black noQ Xt Tt FC com i 3l 3
201. ode 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 frequency 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
202. of oil Trouble This alarm is not used at the moment shooting A11 Criteria Overtemperature in compressor motor FC shut down Controller tion amie Lee Ht ete eet Alarm light Slow flash Consequence Unit Unitstop o Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data i Active Inactive Freq FC 125 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 513 FCoverload Alarm FC Overload Alarm Indication of problems with compressor Trouble Possible causes shooting e The FC cannot deliver enough power to the compressor A9 e Insufficient cooling for the FC e Defect 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 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 The power cable for the compressor motor Mcpr may have been mounted incorrectly 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 defect Fasten bolts properly for better cooling The compressor is wearing down and drawing increasing
203. oller PCB and cannot easily be measured 955 Tempref2 LO Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect sensor pulling power supply down e Defect controller PCB 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 24V DC and 5V signals to see if power supply has a short circuit or other damage If ok the controller PCB is defect Replace controller door Criteria Reference voltage 2 below 4 80V DC None Controller r Consequence a Log data i R T Active Inactive High limit Actual value A D channel The measured voltage is internal on the controller PCB and cannot easily be measured 956 Tempref2 HI Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault 172 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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
204. ollowing only applies for Model SC MCIA0 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 and hold it for 3 sec The display turns off the amp 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 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 49 of 221 pages STAR 3E COOL Item No 810900B Operating and service manual 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
205. oltage FC temp Condenser fan w w Evaporator fan Evaporator heater OPERATION Setpoint QUEST Airflow mode Humidity setpoint Datalog interval Programs gt Alarm text SERVICE S01 MANUAL OPERATION gt S02 DATALOG VIEW gt S03 TIME ADJUST gt S04 RUNTIME COUNTERS gt S05 CONFIGURATION gt PR RTP p O TO1 PTI test TO2 Function test T03 Abort the test T04 Test status T05 10 Init T06 20 Controller T07 30 Power T08 40 Evap fan T09 50 Cond fan T10 60 Evap heater T11 80 Compressor T12 90 FT status T13 100 T set 5 C T14 110 T set 0 C T15 111 Hold 0 C T16 120 T set 18 C T17 130 Defrost T18 140 PTI status 31 of 221 pages PROGRA P01 Active program P02 Multi Temp setp gt P03 Cold treatment gt OLD REA 1 B01 Duration B02 Maximum USDA temp B03 Treatment setpoint B04 Final temperature B05 CT status D D Hour Set Rh D01 OFF 0 0 OFF D02 OFF 0 0 OFF D03 OFF 0 0 OFF D04 OFF 0 0 OFF D05 OFF 0 0 OFF D06 OFF 0 0 OFF MANUAL OPERATION Operating mode Evaporator heater Evaporator fan Condenser fan Compressor freq Expansion valve Hotgas valve Economizer valve L01 103 DATALOG VIEW Temperatures Graph view c01 c02 c03 c04 cos GMT Year GMT Month GMT Day GMT Hour GMT Minute RO1 R02 R03 R04 R05 RUNTIME COUNTER
206. on the unit to the two evacuation points pos 6 amp 27 P amp I diagram 2 Close the compressor discharge stopvalve and compressor suction stopvalve pos 5 amp 26 P amp I diagram 4 turns 3 Connect the pressurized gas bottle ex N to the discharge stopvalve of the service gauge manifold 199 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 4 Remove the electrical coils and mount permanent magnet on the two electronically expansion valves pos 16 amp 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 10 Ifthe pressure gauges are below 12 BarE perform a leakage detection as described in this 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 0 Q0 Charging of refrigerant Charging of empty unit The power to the unit shall be off The charging of
207. or more temperature sensors are defect e One or more pressure sensors are defect 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 other sensors measurements None Controller action Alarm ight Deteriorated control precision in the frozen mode 142 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 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 Log data Acive Imacive CE There have been several FC alarms within short time Cause 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 Operations p 50 Criteria There have been several FC errors within the last 30
208. oss Alarm FC Phase Loss Fault Alarm 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 Defect 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 lt 20V AC 3 Supply unit with correct voltage according to specification 4 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 5 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 ocsiloscope 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 pese US down Controller action ae ee Alarm light Slow flash Consequence Unit Unitstop 00 Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data Active Inactive Freq FC 128 of 221 pages STAR COOL Item No 810900B Operating and service manual FC over temp Alarm FC Overtemperature Fault A
209. ot be enough refrigerant in the unit 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 water cooling unit are not at the bottom when the unit is turned off Refill with refrigerant 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 Fatal Alarm Description User stop was executed from PC program Cause 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 poo foe 901 Measurement error Warning _ Error in measurement of condensator on circuit board The temperature measurement of the channel is faulty 163 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Measurement system of the controller is partly defective Accompanied alarms e N A Trouble shooting 1 The controller is defect Replace controller door Criteria Temperature change is greater than 0 5 C within 20 sec None Controller action Alarm light Deterior
210. p 1 ON OFF switch at front of controller door GND _ High pressure switch 4 45VDC S Normally ch Aire AirEx Air Hu SIGNAL Shp t Shp GND see 9 x 0 75mm2 Tret SIGNAL ki m AMA 9x AWG 18 Te lt GND xm Ki OW A2 medi i negus Tsupi SIGNAL zi sup K2 Red A d 2 CONTROLLER Tsup A lt ND a tp ke cow Tevap SIGNAL K3 Red Aion a Ea av Pa sels GND a2 Sp KS Hove em RE rape sou pa Tsup2 A lt GND Mond Low 9 x 0 75mm2 Tsuc SIGNAL K5 Red A Tsuc lt ub Mcond High 9xAWG 18 Tamb SIGNAL K6 Red Mon E eE S oo _A2 ee SIGNAL K7 Red M n GND Lao s Mee High IB Teco SIGNAL K8 Red Aion Teo j c 7 UE GND K8 FC 24 Noi 1j K GND White A2 LCD Display LCD DISPLAY pgs xt INTF5 INTERFACE R e 0 JA PCB Y Mevap2 7 Keypad KEYPAD a be Mevap2 8 RCCUS 8851560103 Mevapt 7 Overall Wiring Schematic x3 Mevapt 8 Mcond 7 we i ma Mcond 8 Lodam electronics a s a P N 5251560403 Rev 1 63 2jeuieu s Hu Ee49A0 7002 R AYLS 8006018 ON Wei Jenuew adiAsas pue Bunessdo STAR COOL Item No 810900B Operating and service manual www starcool dk 24 hour hotline support Call us at 45 7364 3500 or send us an e mail at service starcool dk Our service department is available 24 hours a day 7 days a week providing easy access to the answers you need M rsk Container Industri AS Bjerndrupvej 47 STARS ZO OL 6360 Tinglev I Thinking Denmar
211. peed Controller P P B action Alarm light Slow Rash Controller will retry after 1 min Log data Acive Imactive P Frequency Converter FC Alarms AL 5XX For some of the alarms in this section the FC may be faulty and must be replaced For continuing operation until replacement is possible the unit can be rewired and started for emergency opera tion See Emergency Operation p 50 120 of 221 pages STAR COOL Item No 810900B Operating and service manual Fatal Alarm Frequency Communication Missing Indication of defect 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 Defect FC X1 cable is defect Controller PCB defective Accompanied alarms e AL 306 or one or more AL 5XX may also be active Trouble shooting 1 If alarm AL 306 High press switch is also active the fuse F6 inside in the control cabinet is most likely blown Replace the fuse 2 Verify that cable FC com is mounted correctly according to wiring diagram inside the controller cabinet and not being damaged Check that power to the FC is not wired for emergency operation Verify that there are correct voltages on all 3 phases for the FC 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 controller PCB is defective Replace the
212. ply enough power to the compressor e Insufficient cooling for the FC e Defect 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 It can therefore be cooled by the refrigerant in the compressor 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 incorrectly 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 defect 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 Operations p 50 Criteria FC load has exceeded warning limit of 24 Amp None Controller action Alarm light If not solved this problem can cause FC to stop due to
213. pre SA eratac R RS 21 Eusible plug TeCelVer ieus essai rt annii n aca i AR DRRARRRRRR GA GR AR ANRPA CR eRPARRASRAR RRRRIR handtaenacedatadtoaimed bend 21 eroinle tanpa P Cm 21 Evaporator Coila spainn aane ea eai E a AE e On ra n o a iDa 21 Condenser COM iis ane n r naa eet aaa aE EA AINEA ET a A E A SEn aE EEN E SAAS 21 Evaporator fall pix rere ducet aaa aa e aAa eA RARI AES a aiian 22 GONGENSER TaN eM Em 22 Water cooled condenser opttonal nri rtedare retinent rabska Rei eR Russe ha sitne ai da E Rala e RR a aa EP rM erai Dre a dadas 22 Bi inoran p Re ET 22 Fresh air exchange iretur Ir panama Ri Rh iac IRI e n PUR PPQRMDRURRER AR RK X RI KR PA a ME PARNROARRPR RR I i ineine eiii ini 23 REPIGEKALIOMICOMEFOS cs gic it EE 23 El Ctrical Esc PER OU 23 ie reundcin i lg eM 23 CONTACTOS isses eiie tee Rie e pae PRama ARR RR aca i lg erla lr esPuRMADRARPutr RR Mme A RI RIP iaiia testes nelnewcntatewed MUNERE 23 PUSS A M Hem 23 Pwer PlUG p mm 23 I Ee s m 24 USDA socket requiretrients iiie pair kaian iia a ARR RA REX iiai aki E RI R Rc RR Pe DR Sa itii 24 2 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Evaporator fan MOO sssrinin oinean V vale E AANE E EEEE AEAEE E RT R FREE ER 24 Condenser far MOLOF se nosieussa kie eun o
214. r K8 on off too many times Loose power connection for the FC Loose FC com cable for communication with the FC Defect 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 fix a loose connection 3 Check supply power cables for the FC and fix if loose 4 The FC may be defect and should be replaced If no FC replacement is available the unit can be rewired for emergency operation See Emergency Operations p 50 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 down Controller action 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 FC High Voltage Fault Warning Indication of problems with supply voltage Trouble Possible causes shooting W7 e The unit is supplied with voltage above specification e Defect FC Accompanied alarms e AL 515 Trouble shooting 1 Measure if the power voltage to the unit is within specification Apply correct voltage if the voltage is too high 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 F
215. r fan speed Evaporator fan Function Shows current speed for evaporator fan Value Shown as OFF LO HI or OH overheat 39 of 221 pages STAR E COOL Item No 810900B Operating and service manual 134 Evaporator heating Evaporator heater Function Shows current on off cycle of evaporator heating element Pulse Wide Modulation Value Shown as a percent value on during runtime Cycle duration is 50 sec Operation Parameter Setting Q By pressing y the operation menu is selected The y icon is displayed Use the arrow keys and Y 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 edge Value 002 QUEST optional Function AUTO OFF Value FTT Airflow mode Airflow 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 lower than 65 or 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
216. r 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 setpoint 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 221 pages STAR COOL Item No 810900B Operating and service manual BO4 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
217. re are other active sensor alarms Clear these alarms first using their trouble shooting 2 Check voltage level of 24V DC and 5V signals to see if power supply has a short circuit or other damages If ok the controller PCB is defect Replace controller door Criteria Reference voltage 1 below 4 80V DC None Controller n _ 4 Log data x m m Active Inactive High limit Actual value A D channel The measured voltage is internal on the controller PCB and cannot easily be measured 954 Temp ref 1 HI Warning Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Defect controller PCB 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 24V DC and 5V signals to see if power supply has an open circuit or other damages If voltages are ok the controller PCB is defect Replace controller door None Controller n EE tog x Alarm Alarm light Consequence 171 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Log data 2 Active Inactive High limit Actual value A D channel The measured voltage is internal on the contr
218. re 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 This set point will be used as the main set point even if the program is aborted Temperature change per hour ramp is fixed for cool ing and change is done with maximum cooling capacity available Heat up is fixed to be done by 0 1 C temperature increase per hour 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 The Multiple Temperature Set points program stops automatically if the unit has been powered off for more than 48 hours 41 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Cold Treatment program CT BOI1 Duration of treatment BO5 CT Status LI L L L Loading cargo 1 L L LI L i Pull down to Cold Treatment treatment Ramp up temp passed Pd 0 1 C hour O01 set point B01 Cold Treatment 4 B03 Cold Treatment Cold Treatment done or failed Start cold treatment at 1 or 2 Cold Treatment can only be started when all Tusda
219. rm Warning Warning Warning Warning Warning Warning U1 U1 U1 N Uy BR w Ul N Ko N Ul oO 9 6 Op FC has tripped and stopped Log 06 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 the frozen mode Defrost is running Max defrost time exceeded pen No watercooling Tset unreachable In range fault High press trouble AirEx open freeze Defrost Trouble 610 Defrost time exceed 11 Too many sensor Too many controlling sensors have errors err FC trouble Motor trouble Warning Alarm Fatal Alarm Fatal Alarm Fatal Alarm Warning Warning ojo ojo WIN e N Oo e A Alarm OY E 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 control deactivated Oo E CJ p D Humidity Alarm deactivated Cpr start failed Cpr restarted CT outrange Manual phase dir 31 Fuse blown Test alarms 0 Func test failed 01 Controller Idle current Mevap cur LO speed Mevap cur HI speed Mevap current OFF Evaporator Motor Off Current Fault Mevap direction Not implemented yet Mcond cur LO Condenser Motor Low Speed Current Fault speed Mcond cur HI speed Mcond current
220. rouble Possible causes shooting e The power frequency is out 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 Mevap1 and Mevap2 fan motors forced to low speed Controller action Alarm light Reduced capacity of unit Elimination Power frequency within range again Log data z z 426 Frequencytoohigh Alarm Power Frequency Too High Alarm Power Frequency Too High Alarm 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 ti n Alarm light Reduced capacity of unit 117 of 221 pages STAR lt COOL Item No 810900B Operating and service manual Elimination Power frequency within range again Log data R Voltage freq U f ratio low Alarm Bad power supply over loaded und
221. rvice manual Events Name Parameter explanation ik a 2 m or ee re a o Temperature set point altered Old setpomt Newsetpomt a wa Sw revision 7 n Da wavs Perrest Stare prven wa v Alarms count Perrtest pass entesio ma naive v 7 a a n a a n a a n a a a Defrost Start 1 Manual 0 Not de n a n a start mand AE ema sr ae 3 Demand 2 Abnormal defrost start 3 Tsuc defrost in terval sec Trip Start 1 Auto trip SW ver low SW ver high SW revision start IEEE a ul uni start Sensor Calibrated 1 USDA 1 Old Cal New Cal Value n a n a 2 USDA 2 Value 3 USDA 3 4 CARGO Power Up Unit run Compr run Mevap run time Mcond run time Hevap run time hours time hours hours hours time hours 2 22 Power Down SW ver 2 SW ver 2 Vbatt Power up count Reset count lowest byte highest amp WDT count 2 Down Load Old sw ver Old sw ver New sw ver low New sw ver high n a low high 6 a a a Manual mode select Manual mode deselect ejeje aJ AJN Nieo 13 14 N N o 21 5 2 Howe oa e ws e vs bataloginterval ou New nia vs f Container ID change container container container digits container digits n a digits 1 2 digits 3 4 1 2 3 4 5 6 7 Pressure sensor charge Old version New version Old version New version n a low pressure low pressure high press
222. s 0 30 Bar Tret is more than or equal 2 to 15 C Min change on TO 20 K Tret is less than 15 C Min change on TO 10 K None Controller Elimination Alarm may then be deleted after test completed i 845 Cprpump down Alarm Compressor pump down fault Indication of insufficient performance in the compressor 158 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Sensor defect high pressure transmitter and or high pressure switch e One or more valves defect e Compressor needs repair Accompanied alarms e AL250 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 20 C None Controller action Alarm Tight Siow fash Test failed Elimination Alarm may then be deleted after test completed Log data 3 846 amp FC Check Alarm Internal fault in FC Indication of internal failure in the FC Trouble Possible causes shooting e Internal failure in the FC Accompanied alarms e NA 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
223. s ltem Description 35 Air Exchange Sensor 34 Cable gland M32x1 5 3 33 USDA socket cap 32 USDA socket 31 Retreiver socket cap 30 York Power Modem 29 Retreiver socket 28 High Pressure Switch 27 Cable gland M25x1 5 26 Cable gland M20x1 5 5 25 Solenaid coil 18W 24 VDC 24 Solenaid coil 14W 2 amp 4 VDC 23 Temperature sensor 22 Cover foil on off switch 21 Cover foil keypad 20 Cover foil LED 19 Neutral terminal rail 18 DIN rail 17 Battery Pack 16 Fuse 400 mAmp 2 15 Fuse 11 Amp 3 14 Keypad 13 Terminal block PCB 12 On Off PCB 11 Mech interlock for contactors 3 1 Auxiliary contact 4 Contactor CI 9 8 ain circuit breaker Transformer 145 V LED PCB isplay Cover isplay PCB Power Meas PCB Controller PCB Controller cabinet camplete M WR Ua 00 SO 217 of 221 pages sobed Zz JO 8Tz n8 Compressor Frequency Converter Discharge Pressure Transmitter Pais High Pressure Switch Discharge Service Valve 58686 37 Evacuation Point Discharge Line Condenser Fan Air Cooled Condenser Liquid Line Air Release Valve old rrodel Liquid Charging Valve new model s p Fusible Plug Receiver Water Cooled Condenser Service Valve Econonizer Drying Filter Electronical Exparsion Valve Econorrizer Veco 2 hEERERES eNO MR UNE m o
224. s the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tsuc It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Criteria Value below low alarm limit 60 C 76 F Replacement by new value from AAS system Controller P y Y 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 3 Tum um Active Inactive Hoh mt cure 84 of 221 pages STAR COOL Item No 810900B Operating and service manual 125 Tsuc short Warning Suction Temperature Sensor Short Circuit Indication of short circuited suction temperature sensor Trouble shooting Controller action Consequence Log data Possible causes e Temperature sensor Tsuc or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 126 Trouble shooting 1 Disconnect the sensor cable for sensor
225. sacamisememeeeeycneneannetwcsieneemnaimens mae E O a 15 MOSES IUS TTE AT ID LLL LLL UL ILLU I 15 PUN GCE fen Iz PRETIO LLLI E DLL LL LI 16 ilg 16 eiugsape UEM 16 Data roro TEL SI LLLI LL LLLI ILLI 16 Alarm Action Systemi AAS suicsssqeuece cde puhusx deterius piDereAdndemn v SOR KND EIN DND dO nn d Dd Du NA ER IR EIN ERU M E EU UU PNR E 18 temperature Cont Olsens EE LT LLL LUE 18 Expansi n vValNVe Control ESTEE ILC LIE SLOT 18 Condenser fan control iceiet tortas secunh tne nakaire ree o eek na i A Dai NRRERR RIEN DENRiE PRSE ABT RR RRRR KE EEE Raai ance 18 Dehumidifiication COMtrOlls EESTI UL LLLI IU MUUTEM 19 Defrost CONGO e 19 reidgfor ilgefelndgole pee DELLI ILI 19 Refrigeration system data eria roleetePivniLadu cRcu dp ae Run D UD Edu FORSE tRD DES Pel oR CEN E 20 Refrigerant Charge R13 rU 20 GeneralisSpecifiCatlOl sx dieron ose a i a E WR RES RUIN EPI NDA R NR KR RIA NA CR PLAIN DAN ann 20 Compressor motor assembly ote exea tette pre heroe eek x she rRc E DEA RR Ese nE tr PPM E E NE ETT PPAR a tec Ie PIE rx FM RES 21 Frequency converter FC iiiecucs edet ainara xt pe ae rac heu ad nhe cR x ex xa Rr nce s iain c GR AE IR Rer P dada psi aan 21 High Pressure cut out SWIECB ciere ester tex hou enean Dandi AE E aE Era ETAN ad Rr edu Etre rRS s re
226. ses shooting Evaporator motor jammed or defect Evaporator motor cables defect 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 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 50Hz 1 8 1 9 Amp 60Hz 2 6 2 1 Amp None Controller action Alarm light Slow fash Test failed Elimination Alarm may then be deleted after test completed Log data 812 Mevap current OFF Alarm Evaporator Motor Off Current Fault Indication of defective motor contactor or contactor driver circuitry Trouble Possible causes shooting e Defect evaporator motor contactor e Defect contactor driver circuit Accompanied alarms e NA 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 None Controller 151 of 221 pages STAR COOL Item No 810900B Operating and service manual Elimination Alarm may then be deleted after test completed Log data 813 Mevap direction Alarm Not implemented y
227. sistance is within range perform controller door check Trouble shooting for Star Cool Controller p 56 before replacing controller door Value below alarm limit 609C 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 P y y 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 s 2 Active Inactive doo o o Pressure Sensor Alarms AL 2XX 200 Pdis open Warning Compressor Discharge Pressure Sensor Open Circuit Cause Indication of loose connection defect or lack of compressor discharge pressure sensor 89 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting Connector Pdis not correctly mounted High pressure sensor Pdis defective Cable for high pressure sensor Pdis defective X1 cable is defect Controller PCB defective Accompanied alarms e AL 203 Trouble shooting Disconnect the cable for Pdis from the connector PCB according to the wiring schematics inside the control cabinet and from the high pressure sensor 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 t
228. spectively The earth stud must be on the opposite side of the cable AKS 1 Supply GROUND 924 0 TYP OUTPUT Figure for NSK Check the cable measure the resistance in the cable If the cable is defect replace cable Mount the cable for Psuc in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on interface terminal block PCB AKS If voltage is below 0 5V DC sensor or connection between sensor and cable is defect If voltage is between 0 5V DC and 4 5V DC continue to 4 NSK If voltage is below 0 37V DC sensor or connection between sensor and cable is defect If voltage is between 0 37V DC and 4 0V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND AKS If voltage is between 0 5V DC and 4 5V DC and this alarm is still active replace controller door NSK If the voltage is between 0 37V DC and 4 0V DC and this alarm is still active replace controller door Before replacing controller door see Trouble shooting for Star Cool Controller p 56 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 P y y n peer 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 i
229. 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 Transmitter check To ensure that the correct pressure sensor is monted and that suction gas will be free of liquid during use 5 Terminate Switching to normal temperature and valve regulation 9 of 221 pages STAR COOL Item No 810900B Operating and service manual Climate Control Function Temperature Control This function incorporates the container temperature controller The function has 2 modes Chill and Frozen Chill If Tset more than gt 5 C 23 F the chill mode is activated and Tact Tsup Frozen If Tset is less than or equal to lt 5 C 23 F the frozen mode is activated and Tact Tret The value the Tset limit is dependend 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 Upon 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 m
230. t 2 Measure the resistance between the two wires a If the resistance is less than lt 230 9 the cable or the sensor is defect replace sensor and cable b If the resistance matches the resistance and temperature in table Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tsup2 It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value above high alarm limit 140 C 284 F Replacement by new value from AAS system 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 Active Inactive High ime Current CS 68 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 108 Tsup2invaid JjWarnming circuitry or sensor not mounted correctly in unit Trouble Possible causes uon Active alarms AL 106 AL 107 or AL 901 Temperature sensor reading is out of valid range 60 C 76 F or above 140 C 284 F Differenc
231. t available the unit can be rewired for emergency operation See Emergency Operations p 50 Criteria Internal 24V supply error FC shut down Controller 4 dtes mee TEARS imem den ses em EHI Slow fash Consequence Unit Unitstop 0 Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data 123 of 221 pages STAR COOL Item No 810900B Operating and service manual FC Earth Fault Alarm 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 Defect FC e Damaged cable and or 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 defect isolation Check the cable and replace if it is defect 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 Operations p 50 Leakage current from outlets to ground of FC Current 3A for more than 10usec 0 00001 sec FC shut down Controller r a GENNDO 0 ENNSNS Consequence Unit Unitstop 00 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 Overcurrent Alarm Indication o
232. tcactsasersesderdatacescneieddccaenservesbensiescaeantdedacinensitaevaseaneveeeeeierceens 32 PTI or Function Test Execution eT 33 Info Menu VIeWIIgr ssrdsn kanp xr aie x RHDlaR rni IRR X SR e de A ER PARARI ERR REI Re RR Id RIS CR SQIMURR A Eia FRAME eda 36 Operation Parameter Setting O E E E E T 40 Multiple Temperature Set points program MES 2 2 5 acteacendieeiiena nde n E EE O Ean Ti 41 Gold Treatment progkami GT aiios cune iinne an a N E A A 42 PIE 43 Service Function Setting Viewing H HU EERRRE 44 Manual OPS ratio nStiscacacs dacnagessamtenacis Ernie fpborta tabulis nde add buDren rcv 2M Peso NND d ab koRS Ie BopUANU rao EE 45 Pru EE 46 EInIr jrim EE 46 RuN time Counter Siamane a E ULL LII LLLI LIII II 47 ferro eg uo e 68 sidexsei este ncvaxRM MERDA S TMNMCEERU MCtehobednsdUioDO UNUM UR NEUD A rud RDNE Nd 48 C and F Temperature Scale Showing Alternately Cir ee ea p een eer erer eee 49 Viewing graph of Supply and Return Temperature m shinai eed sain Ure TNUDU EUR DINRARA NS UD NSIURDOD S NUNESEU GEH SNICUE EE 49 Manual Defrost Initiation 49 Water cooling Activation Deactivation 3 49 Emergency Operation sss sse scisco eIIE cU M ERE MEN DAMM erXM M NUN E EI E mE C EIUMIAGA DERI M CUNN n PEDE C EM ANI IRR E e ereeee
233. te 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 pansion valve 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 of hotgas valve opening Hotgas valve Function Manual setting of hotgas valve opening Note that value is only accepted if control is in the 45 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual manual mode menu item MO1 is MANUAL Value Set from 0 to 100 MO8 Setting of economizer valve opening Economizer valve Function Manual setting of economizer valve opening Note that value is only accepted if control is in the manual mode menu item MO1 is MANUAL Value Set from 0 to 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 tempera
234. test PASS if test finished successfully FAIL if the test failed ABORT if the test was aborted by the user See specific description for alarm 860 in Test alarms p 161 T15 Test result 111 Hold temperature at 0 C 111 Hold O 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 alarm 860 in Test alarms p 161 T16 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 4 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 alarm 870 in Test alarms p 161 35 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual T17 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 alarm 870 in Test alarms p 161 T18 Test result 140 PTI status 140 PT
235. 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 pre defined intervals 15 30 60 or 120 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 x0 459F 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 Refcon LogView and StarView Extended Log can only be retrieved by Logman and StarView and shown in LogView and StarView Function description Start up procedure The start up procedure ensures that the
236. the right direction if no better power supply is available There is a failure in the power wiring for the unit Check that there 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 meas PCB The controller PCB is defect Replace controller door Criteria User has manually selected phase direction Use the selected phase direction Controller P action Aarm iont slow fash User controls the rotation direction of the motors Elimination When switched to automatic the alarm is marked as inactive and can be deleted Log data Active Inactive Tset Manual phase Measured net CT remain days dir CW CCW direction Blown Fuse for fan motors and heaters Indication of blown fuse Trouble Possible causes shooting e A 10A 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 defect fuse in the control cabinet Replace a defect 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 low
237. the voltage is below 0 2V DC sensor or connection between sensor and cable is defect If the voltage is between 0 2V DC and 4 0V DC continue to 4 Mount signal wire Measure voltage between SIGNAL and GND If the voltage is between 0 2V DC and 4 0V DC and this alarm is still active continue to 5 Check controller see Trouble shooting for Star Cool Controller before replacing controller door Criteria Value below low alarm limit O m hour None Controller n its Alarm light Consequence pe When sensor value becomes valid it is marked as inactive in alarm list and may then be deleted Log data RE Active Inactive High limit Current iS 305 AirEx invalid Warning Air Exchange Sensor Invalid Alarm not implemented yet Indication of defective air exchange sensor or its measuring circuitry 103 of 221 pages STAR COOL Item No 810900B Operating and service manual Trouble Possible causes shooting AirEx is out of calibration Air exchange sensor AirEx or cable defective X1 cable is defect Controller PCB defective Accompanied alarms e AL 303 or AL 304 may also be active Trouble shooting 1 If the cable by inspection is defect replace cable 2 Calibrate AirEx see p 188 If the value shown in controller is wrong or alarm still active then Disconnect the cable for AirEx from the connector PCB according to the wiring schematics inside the control cabinet and from the AirEx sensor
238. these alarms first using their trouble shooting 2 Access the special menu by pressing RY for more than 3 sec Scroll down until you see the label U RH in the display The value of U RH should be in the range between 16 and 32 While displaying U RH disconnect RH from the terminals PCB and J f U RH is now within the correct range the RH sensor is defect Replace the relative humidity sensor RH If U RH is still outside the above range the controller PCB is defect Replace the controller door Criteria Reference voltage RH below 12 0V DC None Controller p pone flog X Alarm Alarm light Consequence Log data z Em m Active Inactive High limit Actual value A D channel 175 of 221 pages Item No 810900B Operating and service manual Controller Internal Voltage Reference Fault Indication of controller internal voltage reference fault Trouble Possible causes shooting e Defect power supply for controller PCB e Too high voltage for the unit e Defect controller PCB Accompanied alarms e There may be sensor alarms 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 Check if power supply voltage for the unit is within specification If the voltage is too high temperature control and humidity control w
239. ting and service manual l6 o Tcargo temperature Temperature from cargo sensor Tset temperature Set point temperature 8 Humidity Humidity from humidity sensor o Airx airflow Airflow from AirExchange sensor Extended data No Name vue ut 1 Psucpressur Suction pressure effective Bar 1 dis pressure Discharge pressure effective Bart 5 rrowerrenency Powe eaueey CTS NM CORR RS 20 E m voltage Highest power voltage of U1 U2 ul U3 No Nam vele Unit s neuem cwennu 7 current cweni2 s frane cwenis 9 Wecure curro fa ha fesoa o F 13 Mevap status Evaporator motor OFF LO HI ERR 14 Mcond status Condenser motor OFF LO HI ERR IN a e Tfc temperature Temperature of frequency control ler Ambient temperature 30 96 Extended data 2 only retrievable by UMO No Name vie uni h mue Susysirtemperaue c _ mus Supply air temperature ec 5 reva Evaporator temperature ec a muc Suentemperatue c i isis E s vex Expansion valve opening 9s s sre Suerhetret c o meu mtematem Alarms Alarms which may occur and a detailed explanation and troubleshooting are described later in this manual 205 of 221 pages STAR 2 COOL Item No 810900B Operating and se
240. ting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tusdal1 It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value is above high alarm limit 140 C 284 F and the sensor reading has been in the valid area since power up None Controller n en 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 inactive in the alarm list and may then be deleted Log data m m Active Inactive High limit Curent i 71 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 111 Tusdalinvalid jWarning circuitry or sensor not mounted correctly in unit Trouble Possible causes SORT Active alarms AL 110 AL 109 or AL 901 Temperature sensor reading is out of valid range 60 C 76 F or above 70 C 2849F 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
241. tive High timit_ Current i Relative Humidity Sensor Invalid Indication of defective relative humidity sensor or its measuring circuitry 100 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e Relative humidity sensor RH or cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 300 or AL 301 may also be active Trouble shooting Disconnect the cable for RH from the connector PCB according to the wiring schematics inside the control cabinet and from the RH sensor 1 If the cable by inspection is defect 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 end If the resistance is less than lt 230 Q the cable is defect and must be replaced Mount the cable for RH in controller cabinet and on the sensor Disconnect signal wire on interface terminal block PCB Measure voltage between wire and GND on the interface terminal block PCB If voltage is below 0 5V DC sensor or connection between sensor and cable is defect If voltage is between 0 5V DC and 10V DC continue to 4 4 Mount signal wire Measure voltage between SIGNAL and GND If voltage is between 0 5V DC and 10V DC and this alarm is still active replace controller door Before replacing controller door see Trouble shooting for Star Cool Contro
242. tor surface temperature This is done through activation of 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 RHSet and deactivated when RH is less than RHSet 396 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 221 pages STAR 2 COOL Item No 810900B Operating and service manual The dehumidification icon 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
243. ture sensor and cable are ok Measure the voltage over the connector for Tsup2 It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range the controller PCB is defect or other sensors may be defect and pulling the voltage down Check other alarms and see Trouble shooting for Star Cool Controller p 56 before replacing controller door Value below low alarm limit 609C 769F Replacement by new value from AAS system 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 Active Inactive High mit Current id 67 of 221 pages STAR COOL Item No 810900B Operating and service manual Tsup 2 short Warning Supply Air Temperature Sensor 2 Short Circuit Indication of short circuited supply air temperature sensor Trouble shooting Controller action Consequence Log data Possible causes e Temperature sensor Tsup2 or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 108 Trouble shooting 1 Disconnect the sensor cable for sensor Tsup2 from the connector on the interface terminal block PCB according to the wiring schematics inside in the control cabine
244. tures 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 page up press or down press JU to list the previous or next page of stored set of values from the data log LO3 Viewing log of temperatures Grap Function Viewing of logged temperatures Press T 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 Y 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 Time adjust CO1 Setting of year GMT Year Function Setting of year Value 46 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Set from 1999 to 2099 C02 Setting of month GMT Month Function Setti
245. type Value Setting as DANFOSS for Danfoss VLT and NONE for no FC mounted see Emergency Opera tion p 50 for specific information FO4 Compressor frequency converter ID FC ID Function 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 FO6 Calibration of AirExchange sensor AirEx calibration 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 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 press
246. ual Alarm type Datalog Alarm list Red LED Cargo risk Yi No risk for the cargo No risk for the cargo es Yes Alarm Yes SLOW FLASH Risk for the cargo 2 ON 98 OFF Duty time of 3 sec Fatal Alarm Yes QUICK FLASH Serious risk for the 80 ON 20 9o OFF cargo Duty time of 1 sec Alarm handling 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 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 th
247. uble Possible causes Se 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 limit Umean is less than lt 90 5 0 frequence Upper limit Umean is more than gt 160 6 0 frequence Umean U1 2 U2 3 U1 3 3 All contacts are released Controller nio Le RENI Quick flash Consequence All fans forced into Low All fans forced into Low Speed 0000000000000 Alarm will be marked as inactive in alarm list when proper supply is established Alarm may then be deleted Log data 430 Cprconnection Alarm Power Cable From FC to Compressor is Faulty Cause Indication of error with power cable between FC and compressor The compressor is not using any power 119 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Trouble Possible causes shooting e The power cable between the FC and the compressor motor is defect 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 defect Criteria FC is running but the current from the FC is below alarm limit Mcond Mevapi and Mevap2 fan motors forced to low s
248. uction press Function Shows current suction pressure for compressor Value Shown in units of Bar or PSI relative to atmosphere pressure Switch by pressing D at C pres sure is shown in BarE at F in PSI 117 Function Reserved for future use Value 118 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 D at C pres sure is shown in BarE at F in PSI pansion valve o Expansion valve Function Shows current percentage of expansion valve opening Pulse Wide Modulation Value Shown as a percent value 120 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 C Value is only user changeable with system in the service mode 121 Compressor frequency Compressor freq Function Shows current compressor frequency Value Shown in units of Hz 122 Power frequency Power frequency Function Shows current power net frequency Value Shown in units of Hz 123 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 124 Current consumption phase 2 Current phase 2 Function Shows actual current consumptio
249. ure high pressure Cold Treatment CT start 0 Normal Duration CT setpoint CT high limit Final setpoint min emp temp 41 CT period start Actual temp USDA1 temp USDA2 temp USDA3 temp CT Passed Duration CT setpoint CT high limit Final setpoint min temp temp 206 of 221 pages 1 3 2 27 8 30 N o n STAR COOL Item No 810900B Operating and service manual 43 CT ramp up Actual temp USDA1 temp USDA2 temp USDA3 temp Final setpoint temp 44 Multiple Temperature Set Step number Step duration Step setpoint Step temp chg Step humid points MTS start hour ity setpoint 45 MTS step stop Step number 0 Normal Step setpoint Step temp chg Step humid 1 Aborted hour ity setpoint 47 CT Done Number of Duration CT setpoint CT high temp Final setpoint valid USDA min temp limit temp sensors 48 CT Failed 0 Sensor CT high USDA sensor 1 USDA sensor USDA sensor error temp limit temp 2 temp 3 temp 1 Aborted 50 Controller Internal Tempera T n a n a n a n a ture Debug intern use Alarm count Expected alarm count FC status Communica Last alarm code Protokol state Bus state tion rate 9 6 0 Clear off 1 Time out error 2 No reply connect 3 Recieved run stopped 4 CRC 5 Leengde 6 Data format The time is stored as minutes 360 min 6 60 min 6 hours TEMPA Sensor C Resistance Table 9 Q E E 9 9 9 Q EE Emnewcezmenrs ueueperqenem e e
250. ure transmitter 48 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual FO9 Serial number of controller board Main PCB Function Shows the serial number of the controller board Value C and F Temperature Scale Showing Alternately As long as the button C is pressed F is shown instead of C and PSI is shown instead of Bar When the button is released C and Bar is shown again Permanently change to F PSI is not available Shown pressure is relative to atmosphere pressure Viewing graph of Supply and Return Temperature 7 Press m to enter graphical view this function is a shortcut to L03 see 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 USDA 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 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 Water cooling Activation Deactivation amp The f
251. valve a certain time Controller action None Test failed Elimination Alarm may then be deleted after test completed Log data 157 of 221 pages STAR COOL Item No 810900B Operating and service manual Hotgas valve Alarm Hotgas Valve Fault Indication of non operating hotgas valve Trouble Possible causes shooting Cable for hotgas valve mounted on wrong valve Cable for hotgas valve defect Hotgas valve defect Driver circuit for hotgas valve defect 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 hotgas 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 hotgas valve is not defect Replace cable if it is damaged Disconnect the cable for valve and measure that there is voltage on the output for the hotgas valve when it should open a If there is no voltage the controller PCB is defect Replace the controller door Pdis more than gt 5 BarE Max change on Pdis 0 75 Bar Pdis is less than lt 5 BarE Max change on Pdi
252. ve alarm 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 If the 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 condenser is blocked clean the condenser to secure cludding and dirt are removed 6 If alarm AL 500 FC missing is also active the fuse F6 inside in the control cabinet is most likely blown Replace the fuse Disconnect the cable for high pressure switch from the connector PCB according to the wiring schematics inside the control cabinet 7 Measure the voltage between the two connectors for the high pressure switch on the connector PCB If the voltage is below 15V AC replace the controller door 8 Check the cable measure the resistance in the cable If the cable is defect replace cable and high pressure switch 9 Mount the cable for the high pressure switch again If this alarm is still a
253. 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 3 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 manual for some time Stop compressor and see if the suction pressure rises more than normal If valve defect replace valve or top part of the valve Criteria Tset unreachable within time limit None Controller action Alarm light Slow flash If error is detected during PTI test PTI test will fail ELM Alarm will be marked as inactive in alarm list when Tset is reached Alarm may then be deleted Log data n Active Inactive 138 of 221 pages STAR COOL Item No 810900B Operating and service manual In range fault Fatal meen HY In range fault S O Indication of insufficient yield or defective controller Trouble Possible causes shooting Container doors are open or gasket defect Not enough refrigerant for the compressor Insufficient airflow though evaporator Insufficient airflow though condenser Defect hot gas valv
254. xchange is closed and may then be deleted Log data Active Inactive oy 140 of 221 pages STAR COOL Item No 810900B Operating and service manual 609 Defrost Trouble Warning Defrost is running Defrost terminated on Tsuc Trouble Possible causes shooting e Hot gas valve not working probably e Defect Psuc e Defect 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 5 If Tevap or Tsuc behavior looks mysterious control function for Tevap follow troubleshooting for warning for Tevap AL 123 and Psuc AL 207 Criteria Defrost terminated on Tsuc above 30 C 86 F None Controller action 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 010 De
255. y Operations p 50 Supply voltage to FC is less than 330V AC with full load The minimum voltage depends on the load of the FC FC shut down Controller 3 mis eese AR IR emen ses fan RENE Slow flash Consequence Unit Unitstop 00 Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted Log data FC Overvoltage Fault Alarm Indication of problems with supply voltage Trouble Possible causes shooting A7 e The FC is supplied with too high voltage for contiuous operation e Defect 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 Operations p 50 Criteria Supply voltage of FC is more than gt 550V AC 800V DC FC shut down Controller action T GNE 8 GENES S Alarm light slow flash Consequence Unit Unitstop o Alarm will be marked as inactive in alarm list when reset by FC Alarm may then be deleted 127 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual Log data Active Inactive Freq FC 516 FC phase l
256. y new value from AAS system Controller P y y action Alarm light Consequence When sensor value becomes valid it is marked as inactive in the alarm list and may then be deleted Log data Active Inactive High imit_ current 81 of 221 pages STAR 2 COOL Item No 810900B Operating and service manual 122 Tevap short Warning Evaporator Temperature Sensor Short Circuit Indication of short circuited evaporator temperature sensor Trouble Possible causes shooting e Temperature sensor Tevap or its cable defective e X1 cable is defect e Controller PCB defective Accompanied alarms e AL 123 Trouble shooting 1 Disconnect the sensor cable for sensor Tevap from the connector on the interface terminal block PCB 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 230 Q the cable or the sensor is defect replace the sensor and cable b If the resistance matches the resistance and temperature in table in Tables starting p 204 the temperature sensor and cable are ok Measure the voltage over the connector for Tevap It should be between 4 80 and 5 05V 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 starting p 204 b If the voltage is outside the above range

810900B_March_Operating and service manual.indd

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