Maersk Container Industry Star Cool SCI-20 Service manual

Operating and Service Manual
Star Cool Refrigeration Unit
Version 810900E May 2021
Model SCI-20/40/CA and SCU-20/40

1 of 116 pages
1. Preface
This version of the manual is dated May 2021, edited by Maersk Container Industry AS.
All rights reserved.
This user’s manual is valid for software version 0357 or newer versions.
The information herein is subject to change without notice and does not represent a commitment
on any part of Maersk Container Industry AS. While the information herein is assumed to be accu-
rate, Maersk Container Industry AS assumes no responsibility for any errors or omissions that may
appear in this documentation.
This manual is valid for:
Model SCI - 20/40/CA and SCU - 20/40
Software version 0357
2. Warnings
Do not operate or maintain this refrigeration unit until you have familiarized yourself completely with
the equipment and operation of this unit by reading the instructions in this manual.
Do not perform any welding on the unit before disconnecting the power plug. Furthermore, discon-
nect the power measurement module and main controller (and modem if present).
Disconnect the main power supply to the unit before inspecting the interior of the controller box.
The unit is charged with R134a or R513A and ester oil BSE 55. Do not use any other refrigerant or
oil. Do not use contaminated refrigerant or oil. Never release any refrigerant into the atmosphere.
Use recovery equipment according to present legislation.
During maintenance, please observe that refrigerants operate with high and low temperatures in
combination with high pressures, which may cause personal injuries if not handled properly.
During recovery and maintenance of the refrigerant, personal protection equipment must be worn.
Do not trap any liquid refrigerant inside pipes during soldering work. This may lead to an explosion
of the pipes.
Please note that some unit models do not have Schräder valves installed for Psuc and Pdis transmit-
ters.
We do not recommend cleaning the inside of a reefer container with soap/chemicals with a PH value
below 7. However, if this occurs, clean the evaporator coil through the inspection hatches with a soap
that has a PH value between 7 and 9. This cleaning is vital to reduce the risk of copper damage in
the evaporator coil.
Do not enter the container, including opening the service hatches, when the oxygen level is below
20.9%. Ventilation is necessary before entering, either for repairing the unit or unloading. Stay away
from doors while venting.
Human response to low oxygen atmosphere:
Oxygen content of air Symptoms of a person exposed
20.9% Level in ambient air - no eect.
15% - 19% May impair coordination and induce early symptoms in persons
who have coronary, pulmonary, or circulatory problems.
12% - 15% Respiration and pulse increase, impaired coordination, poor per-
ception and judgement.
10% - 12% Respiration increases further in rate and depth, poor judgement,
and bluish lips.
8% - 10% Mental failure, fainting, unconsciousness, an ash-coloured face,
blue lips, nausea, and vomiting.
6% - 8% 8 minutes - 100% fatal, 4-5 minutes - recovery with treatment.
4% - 6% Coma within 40 seconds, convulsions, respiration ceases, death.

2 of 116 pages
3. Contents
1. Preface......................................................................................................................................................... 1
2. Warnings...................................................................................................................................................... 1
3. Contents....................................................................................................................................................... 2
4. Legend ......................................................................................................................................................... 6
5. General description...................................................................................................................................... 8
6. Function description .................................................................................................................................... 9
6.1 Start-up procedure ................................................................................................................................ 9
6.2 Temperature control............................................................................................................................... 9
6.3 Capacity control and limiter ...................................................................................................................10
6.4 Electrical control...................................................................................................................................12
6.5 Expansion valve....................................................................................................................................12
6.6 Economizer valve..................................................................................................................................12
6.7 Dehumidication...................................................................................................................................13
6.8 Condenser fan......................................................................................................................................13
6.9 Evaporator fan......................................................................................................................................14
6.10 Defrost function ..................................................................................................................................14
6.11 Alarm Action System ...........................................................................................................................15
6.12 Datalog..............................................................................................................................................15
7. Te s t s ............................................................................................................................................................17
7.1 Function test ........................................................................................................................................18
7.2 Full PTI ................................................................................................................................................19
7.3 Short PTI .............................................................................................................................................19
7.4 CA PTI .................................................................................................................................................19
8. Refrigeration system data...........................................................................................................................19
8.1 Refrigerant charge ...............................................................................................................................19
8.2 General specication.............................................................................................................................19
8.3 Compressor – motor assembly ...............................................................................................................20
8.4 Frequency converter .............................................................................................................................20
8.5 Evaporator coil .....................................................................................................................................20
8.6 Evaporator coil heaters..........................................................................................................................20
8.7 Evaporator fan......................................................................................................................................20
8.8 Evaporator fan motor ............................................................................................................................21
8.9 Condenser coil......................................................................................................................................21
8.10 Condenser fan ....................................................................................................................................21
8.11 Condenser fan motor ...........................................................................................................................22
8.12 Water cooled condenser (optional) ........................................................................................................22
8.13 Fresh air exchange ..............................................................................................................................22
8.14 Air exchange motor .............................................................................................................................22
8.15 Economizer ........................................................................................................................................23
8.16 Refrigeration controls ..........................................................................................................................23
8.17 Vacuum pump.....................................................................................................................................23
8.18 Electrical data.....................................................................................................................................23
8.19 Circuit breaker....................................................................................................................................23
8.20 Contactors .........................................................................................................................................23
8.21 High pressure cut out switch ................................................................................................................23
8.22 Fusible plug, receiver ..........................................................................................................................24
8.23 Fuses.................................................................................................................................................24
8.24 Power plug .........................................................................................................................................24
8.25 Power cable........................................................................................................................................24

3 of 116 pages
8.26 USDA socket requirements...................................................................................................................24
8.27 O2sensor...........................................................................................................................................24
8.28 CO2sensor.........................................................................................................................................24
8.29 Temperature sensors, including USDA ...................................................................................................25
8.30 Relative humidity sensor......................................................................................................................25
8.31 CA pressure transmitter.......................................................................................................................25
8.32 Pressure transmitters ..........................................................................................................................25
8.33 Miscellaneous .....................................................................................................................................25
9. User interface .............................................................................................................................................26
9.1 Indicator lights .....................................................................................................................................26
9.2 Display ................................................................................................................................................26
9.3 Keypad ................................................................................................................................................27
10. Menu overview ..........................................................................................................................................28
10.1 General page layout ............................................................................................................................28
10.2 Using the cursor..................................................................................................................................29
10.3 Changing a parameter value.................................................................................................................29
10.4 Activating a function............................................................................................................................29
10.5 Air exchange page...............................................................................................................................29
11. Operation ..................................................................................................................................................30
11.1 Menu structure ...................................................................................................................................30
11.2 General operation ...............................................................................................................................31
11.3 Temperature setting ............................................................................................................................31
11.4 Wake-up mode ............................................................................................................................31
11.5 Contrast adjustment of the display........................................................................................................31
11.6 °C and °F temperature scale showing ............................................................................................31
11.7 Viewing graph of supply and return temperature .............................................................................32
11.8 Water-cooling activation/deactivation ............................................................................................32
11.9 PTI or function test execution .......................................................................................................32
11.10 Information menu..............................................................................................................................36
11.11 Raw sensors .....................................................................................................................................39
11.12 Operation parameter settings .....................................................................................................41
11.13 Programs..........................................................................................................................................42
11.13.1 Multiple Temperature Setpoints program, MTS ...................................................................................42
11.13.2 Automatic Cold Treatment program, ACT ...........................................................................................43
11.13.3 Bulb mode .....................................................................................................................................44
11.14 Application settings ...........................................................................................................................45
11.14.1 AV/AV+ settings ..............................................................................................................................45
11.14.2 CA settings ....................................................................................................................................46
11.15 Manual defrost ..................................................................................................................................48
11.16 Alarms ............................................................................................................................................48
11.17 Service function settings ............................................................................................................49
11.18 Manual operations ............................................................................................................................ 50
11.18.1 FC self test.....................................................................................................................................51
11.19 Datalog view .................................................................................................................................... 52
11.20 Time adjust ......................................................................................................................................53
11.21 Run time counters .............................................................................................................................53
11.22 Conguration....................................................................................................................................54
11.22.1 StarConomy ..................................................................................................................................56
11.23 Serial numbers..................................................................................................................................56
11.24 USB menu ........................................................................................................................................57
11.25 Maintenance .....................................................................................................................................58
11.26 Modem .............................................................................................................................................58
12. External interfaces....................................................................................................................................58
12.1 General requirements..........................................................................................................................59
12.2 List of terms used for external interfaces...............................................................................................59
12.3 Functions overview..............................................................................................................................59

4 of 116 pages
13. Events .......................................................................................................................................................60
14. Detailed alarm description ....................................................................................................................... 63
14.1 Alarm list ...........................................................................................................................................63
15. Star Cool unit installation dimensions.......................................................................................................68
16. Location of motors, temperature sensors, humidity sensor and air exchange potentiometer ..................69
17. Location of valves......................................................................................................................................70
18. Location of pressure transmitters, high pressure switch and oil outlet port ............................................71
19. Controller unit illustration.........................................................................................................................72
20. Location of AV and CA components ...........................................................................................................73
21. Replacements............................................................................................................................................76
21.1 Replacement of evaporator motor and fan..............................................................................................76
21.2 Replacement of condenser motor and fan ..............................................................................................76
21.3 Replacement of evaporator...................................................................................................................77
21.4 Replacement of heating elements......................................................................................................... 78
21.5 Replacement of FC ..............................................................................................................................79
21.6 Replacement of compressor .................................................................................................................80
21.7 Replacement of compressor valve plate/cylinder head gasket ...................................................................81
21.8 Replacement of lter dryer...................................................................................................................82
22. Service and maintenance ..........................................................................................................................82
22.1 Evacuation of refrigerant .....................................................................................................................82
22.2 Compressor pump down and operation..................................................................................................83
22.3 Compressor pump down (replaced) .......................................................................................................83
22.4 Pump down of unit .......................................................................................................................... ...84
22.5 Pressure test ......................................................................................................................................84
22.6 Charging of refrigerant ........................................................................................................................85
22.6.1 Charging of an empty unit .................................................................................................................85
22.6.2 Charging of unit low on charge...........................................................................................................86
22.7 Leakage detection...............................................................................................................................86
22.8 Compressor........................................................................................................................................86
22.8.1 Check of oil level ..............................................................................................................................86
22.8.2 Draining of oil from compressor .........................................................................................................87
22.8.3 Charging of oil .................................................................................................................................87
22.9 Soldering ....................................................................................................................................... ...88
22.9.1 Welding ...........................................................................................................................................88
22.10 Calibration of air exchange sensor .......................................................................................................88
22.11 Sensor calibration using StarView .......................................................................................................88
23. CA service and troubleshooting ................................................................................................................89
23.1 Container venting procedure.................................................................................................................89
23.2 Vacuum pump service..........................................................................................................................89
23.3 Trouble shooting the vacuum system.....................................................................................................91
23.4 Replacement of the vacuum pump heating element.................................................................................93
23.5 CA preparation....................................................................................................................................93
22.6 Curtain track installation......................................................................................................................94
22.7 Curtain installation..............................................................................................................................95
22.8 Container leak test..............................................................................................................................95
22.9 CA+ ushing.......................................................................................................................................96

5 of 116 pages
24. General trouble shooting ..........................................................................................................................97
25. Emergency operation ................................................................................................................................98
25.1 FC bypass ..........................................................................................................................................98
25.1.1 FC 1.0 and FC 1.1 .............................................................................................................................98
25.1.2 FC 2.0 .............................................................................................................................................98
25.2 Controller bypass................................................................................................................................99
25.2 Evaporator fan motor bypass................................................................................................................99
26. Tables......................................................................................................................................................100
26.1 Datalog description ...........................................................................................................................100
26.2 Temperature sensor - resistance table.................................................................................................102
26.3 Temperature sensor - voltage table.....................................................................................................103
26.4 Air exchange sensor voltage table - m3/h for 35 CMH ............................................................................104
26.5 Air exchange sensor voltage table - m3/h for 75 CMH ............................................................................104
26.6 Voltage – pressure table, LP transmitter (NSK) + DST...........................................................................105
26.7 Voltage – pressure table, LP transmitter (AKS) .....................................................................................106
26.8 Voltage – pressure table, HP transmitter (NSK) + DST ..........................................................................107
26.9 Voltage – pressure table, HP transmitter (AKS) ....................................................................................108
26.10 Pressure - temperature table for R134a ............................................................................................ 109
26.11 Pressure - temperature table for R513A ............................................................................................ 109
26.12 Tightening torques...........................................................................................................................110
27 Diagrams..................................................................................................................................................111
27.1 P & I diagram....................................................................................................................................111
27.2 CA diagram.......................................................................................................................................112
28. Overall wiring schematic - CIM 6.0 with sub-controller ..........................................................................113
29. Overall wiring schematic - CIM 6.1 .........................................................................................................114
30. Overall wiring schematic - CIM 6.2 .........................................................................................................115
31. Overall wiring schematic - CIM 6.2 with sub-controller ..........................................................................116

6 of 116 pages
4. Legend
Short name Name Short name Name
AAS Alarm Action System Mcpr Compressor motor
Act Actual Mevap Evaporator motor
ACT Automatic Cold Treatment Mevap1 Evaporator motor 1
AirEx Air exchange Mevap2 Evaporator motor 2
AKS Danfoss pressure transmitter MOP Maximum operating pressure
AL Alarm Mpump Vacuum pump motor
Atm Atmosphere MTS Multi Temperature Setpoints program
AV Automatic Ventilation NSK/DST Saigonomya/DST P100 pressure
transmitter
CA Controlled Atmosphere
CalUs1 Calibration USDA sensor 1 OH Overheat
CalUs2 Calibration USDA sensor 2 P Pressure
CalUs3 Calibration USDA sensor 3 PCB Printed circuit board
CapReq Requested capacity Pdis Discharge pressure
Com Communication Pmem Pressure membrane
Cond Condenser Psuc Suction pressure
Cpr Compressor PTI Pre Trip Inspection
CT Cold treatment PTI Short Pre Trip Inspection Short
Cur Current Ptot Power total
Err Error PWM Pulse Width Modulation
Evap Evaporator Pwr Power
FFrequency Req Requested
Fact Compressor actual frequency RH Relative humidity
FC Frequency converter RHset Relative humidity setpoint
Fcpr Compressor frequency RMM Remote Monitoring Modem
FcprAct Compressor frequency actual S Switch contact key
FcprReq Compressor frequency requested SC Star Cool
Fpower Power supply frequency converter Set Setpoint
FT Function test SH Superheat
FW Firmware Shp High pressure switch
HHeater Sup Supply
Hevap Evaporator heater TTemperature
HP High pressure Tact Actual temperature
HPS High pressure switch Tamb Ambient temperature
Hpump Vacuum pump motor heating element TC Calculated condenser temperature
I Current Tcargo Cargo temperature
I1 Current phase 1 TCmin Temperature condenser minimum
I2 Current phase 2 Tevap Evaporator temperature
I3 Current phase 3 Tfc Frequency converter temperature
Ifc Current in AC compressor motor Tint Tinternal (controller board)
Init Initialization T0 Calculated suction temperature
ITI Intelligent Trip Inspection Tret Return air temperature
ITOT Total current limit Tset Temperature setpoint
LED Light emitting diode Tsuc Suction temperature
LP Low pressure Tsup Supply air temperature average
MMotor Tsup1 Supply air temperature 1
Mcond Condenser motor Tsup2 Supply air temperature 2

7 of 116 pages
Short name Name
Tusda1 USDA 1 temperature
Tusda2 USDA 2 temperature
Tusda3 USDA 3 temperature
Ubat Battery voltage
Udc DC voltage in frequency converter
U/f Voltage/frequency ratio
VValve
Veco Economizer valve
Vexp Expansion valve
Vhg Hot gas valve

8 of 116 pages
5. General description
The STAR COO
L
units, models SCU-40 and SCI-40 are electric powered picture frames, cooling
and heating units operating on refrigerant R134a or R513A.
The unit is designed to maintain cargo temperatures in a range from -30°C (-22°F) to +30°C (+86°F).
The unit is designed to operate in ambient temperatures from -30°C (-22°F) to +50°C (+122°F).
The outer front frame is constructed of marine grade aluminum, 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 under seagoing and environmental conditions as specied below:
• Salt-laden air, sea spray, and high humidity.
• Rolling: Amplitude of 30° each side, period of 13 seconds.
• Pitching: Amplitude of 6° each side, period of 8 seconds.
• Permanent list: 15° on each side.
• Shock: 2g horizontal and 5g vertical.
• Vibrations: Of the types encountered on ships, trucks, and rail.
The unit consists of the following modules:
• Frame module
• Condenser/compressor module
• Evaporator module
• Evaporator fan module
The cooling system of the unit is equipped with a two–stage compressor, electrically driven through
a frequency converter.
The cooling system is also equipped with an economizer, which performs the task of sub-cooling the
liquid from receiver to evaporator, thereby increasing the cooling capacity of the cooling unit. The
evaporator and economizer are controlled by electronic expansion valves.
The equipment is designed to operate on a 3 phase primary power source at 50 Hz (+/- 2.5) and
360-460 V AC (max. 465 V AC) or at 60 Hz (+/- 2.5) and 400-500 V AC (max. 535 V AC), accord-
ing to ISO 1496-2. An integrated dual winding transformer supplies the control circuit voltage. One
winding for 18.6-32.0 V AC (for RMM modem supply) and another for 20.5-35.7 V AC converted to
DC-Voltage in the controller (for controller and contactor supply). The output voltage is dependent
on the supply voltage. An automatic system, power supply sensing and correction, is provided to
ensure the correct direction of rotation for the fan motors. This is done regardless of the incoming
phase sequence from the primary power supply, provided that all fan motors are wired correctly.
An optional water-cooled condenser is mounted in series with the air-cooled condenser. This
water-cooled condenser allows operation of unit below deck, where no air ventilation is possible,
provided that water connections are present.
The 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 dehumidication function controlled by the electronic controller of the
unit. The humidity setpoint can be set in the range from 95 – 65% RH (or 50 % with closed venti-
lation). The unit can control to the lowest level. The dehumidication function is active as long as
the temperature control is in setpoint range. The unit is equipped with heating elements, mounted
under the evaporator coil, for the dehumidication. The dehumidication system is also active in
Economy mode.
The unit is equipped with a dual system for defrosting. The refrigeration system has a hot gas valve
installed, for hot gas defrosting of the evaporator coil. Furthermore, the heating elements mounted
under the evaporator coil, are energized during defrost. This dual system for defrosting ensures a
fast defrost sequence and thereby only a very small input of heat to the container. 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 build up of ice in corners or other places of the evaporator coil. The two defrost systems,
hot gas and heating elements, are independent. This ensures a defrost sequence to be carried out
at any time. A demand defrost system is integrated in the software ensuring that the evaporator coil
will not ice up.
The unit is controlled by an electronic controller manufactured by Bitzer Electronics, controlling the
supply temperature probe in Chill mode (temperature setting above or equal to -5°C (+23°F) and
the return temperature in Frozen mode (temperature setting below -5°C (+23°F). Controller accu-

9 of 116 pages
racy 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 the Operation menu.
In Economy mode the fans always run on low speed. In Normal mode the fan speed can run in high
or low speed depending on running conditions.
The unit is equipped with a datalogger incorporated into the controller. The logging interval is in
predened intervals, 15, 30, 60, 120, or 240 minutes. The logging of the USDA sensors (3 pieces)
and the cargo sensor is done with an interval of one hour according to USDA requirements. With
a logging interval of one hour, there is storage capacity for 365 days of temperature loggings. Da-
talogger accuracy is ±0.25°C (±0.45°F). The datalog can be retrieved with a PC–system Starview
and Psion Logman, via high-speed serial communication port.
The controller has a battery back-up system for the datalogger, which after power down of the unit
continues logging in battery mode 120 times. For CIM 6, the battery is rechargeable. For CIM 5,
the battery is not rechargeable.
The controller is optimized for communication with Remote Monitoring Equipment, according to ISO
standard 10368. Events, alarms, and datalogs can be retrieved by various download tools such as
Refcon, Logman, StarView etc.
6. Function description
6.1 Start-up procedure
The start-up procedure has 5 modes:
1. Initialize: Self check controller.
2. Stabilize: The evaporator fan operates at high speed to ensure that temperature sensors are at
current temperature.
3. Crank case heating: If Tamb is lower than 2°C (36°F) heat is applied until Tfc is above 12°C
(54°F).
4. Ramp up.
5. Terminate: Switching to normal temperature and valve regulation.
6.2 Temperature control
This function incorporates the container temperature controller.
The function has 2 modes:
1. Chill
If Tset above or equal to -5°C (+23°F) Chill mode is activated.
If Standard Tact = Tsup if cooling need, and Tact = Tret if heating is needed.
2. Frozen
If Tset is less than -5°C (+23°F) Frozen mode is activated and Tact = Tret.
The value of the Tset limit is dependent on the software version.
The temperature control is set to Cool Down or Heat Up mode depending on Tact being above or
below Tset. As long as the temperature is not within Tset ± ranges, the function remains in Cool
Down or Heat Up mode. If the temperature is within range, the green IN-RANGE indicator light
starts ashing. When the temperature has been within Tset ± 1.5°C ranges for 30 min. the green
IN-RANGE indicator light is constantly on.
If the temperature is in out-of-range condition for more than 2 hours, the IN-RANGE indicator light
start ashing. After 4 hours in 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 Micro control-
ler. CapReq is the desired chilling/heating capacity. CapReq value can range from –100% to +100%.
–100% being maximum cooling and +100% being maximum heating.