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Maersk Container Industry Star Cool SCU-40 User Manual

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

Table of Contents

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Maersk Container Industry Star Cool SCU-40 Specifications

General IconGeneral
WeightApprox. 4, 500 kg
Temperature Range-30°C to +30°C
Width2.438 m (8 ft)
RefrigerantR134a or R513A
Refrigeration Capacity7.5 kW at -18°C

Summary

1. Preface

2. Warnings

4. Legend

5. General description

6. Function description

6.1 Start-up procedure

Describes the 5 modes of the unit's start-up sequence.

6.2 Temperature control

Explains the container temperature control modes (Chill and Frozen).

6.3 Capacity control and limiter

Details how the unit controls capacity and the different limiter types.

6.4 Electrical control

Illustrates accepted volt/Hz range and alarm set-off values.

6.5 Expansion valve

Explains the function of the expansion valve and its sub-functions.

6.6 Economizer valve

Describes the economizer valve's function and control modes.

6.7 Dehumidification

Explains the dehumidification function and its operating modes.

6.8 Condenser fan

Details the condenser fan control and its modes.

6.9 Evaporator fan

Explains the evaporator fan control modes (Normal and Economy).

6.10 Defrost function

Describes the evaporator defrosting function, initiation, and execution modes.

6.11 Alarm Action System (AAS)

Defines how the system reacts to defective sensors.

6.12 Datalog

Explains the unit's datalogging capabilities and data retrieval.

7. Tests

7.1 Function test

Describes the unit component test procedure and its items.

7.2 Full PTI

Lists the test items included in a Full Pre-Trip Inspection.

7.3 Short PTI

Lists the test items included in a Short Pre-Trip Inspection.

7.4 CA PTI

Lists the test items included in a Controlled Atmosphere Pre-Trip Inspection.

8. Refrigeration system data

8.1 Refrigerant charge

Specifies the refrigerant charge amount.

8.2 General specification

Provides general specifications like weight, dimensions, and noise.

8.3 Compressor – motor assembly

Details the compressor and motor assembly specifications.

8.4 Frequency converter (FC)

Lists specifications for the frequency converter.

8.5 Evaporator coil

Details the specifications of the evaporator coil.

8.6 Evaporator coil heaters

Lists specifications for the evaporator coil heaters.

8.7 Evaporator fan

Details specifications for the evaporator fan.

8.8 Evaporator fan motor

Lists specifications for the evaporator fan motor.

8.9 Condenser coil

Details specifications for the condenser coil.

8.10 Condenser fan

Lists specifications for the condenser fan.

8.11 Condenser fan motor

Details specifications for the condenser fan motor.

8.12 Water cooled condenser (optional)

Provides specifications for the optional water-cooled condenser.

8.13 Fresh air exchange

Details fresh air exchange capabilities.

8.14 Air exchange motor

Lists specifications for the air exchange motor.

8.15 Economizer

Details specifications for the economizer.

8.16 Refrigeration controls

Lists components related to refrigeration controls.

8.17 Vacuum pump, including heating element

Details specifications for the vacuum pump and heating element.

8.18 Electrical data

Provides electrical specifications for the unit.

8.19 Circuit breaker

Specifies the circuit breaker details.

8.20 Contactors

Lists specifications for the contactors.

8.21 High pressure cut out switch

Details the high pressure cut out switch specifications.

8.22 Fusible plug, receiver

Specifies the fusible plug details.

8.23 Fuses

Lists fuse specifications.

8.24 Power plug

Details the power plug specifications.

8.25 Power cable

Specifies the power cable details.

8.26 USDA socket requirements

Details the USDA socket requirements.

8.27 O2 sensor

Lists specifications for the O2 sensor.

8.28 CO2 sensor

Details specifications for the CO2 sensor.

8.29 Temperature sensors, including USDA

Specifies temperature sensor details, including USDA.

8.30 Relative humidity sensor

Lists specifications for the relative humidity sensor.

8.31 CA pressure transmitter

Details specifications for the CA pressure transmitter.

8.32 Pressure transmitters

Lists specifications for pressure transmitters.

8.33 Miscellaneous

Lists miscellaneous components and specifications.

9. User interface

9.1 Indicator lights

Explains the function of the alarm and in-range indicator lights.

9.2 Display

Describes the unit display layout and icons.

9.3 Keypad

Details the keypad layout and navigation keys.

10. Menu overview

10.1 General page layout

Describes the layout of the main operation screen.

10.2 Using the cursor

Explains how to navigate menus using the cursor.

10.3 Changing a parameter value

Details the process of changing parameter values.

10.4 Activating a function

Explains how to activate functions via the menu.

10.5 Air exchange page

Describes the air exchange display page.

11. Operation

11.1 Menu structure

Outlines the hierarchical structure of the unit's menus.

11.2 General operation

Provides a general description of operating menus and editing parameters.

11.3 Temperature setting

Explains how to adjust the temperature setpoint.

11.4 Wake-up mode

Describes the unit's wake-up mode and battery operation.

11.5 Contrast adjustment of the display

Explains how to adjust the display contrast and brightness.

11.6 °C and °F temperature scale showing

Details how to switch between Celsius/Fahrenheit and Bar/Psi units.

11.7 Viewing graph of supply and return temperature

Explains how to view temperature graphs.

11.8 Water-cooling activation/deactivation

Details how to activate and deactivate water-cooling.

11.9 PTI or Function test execution

Guides on how to initiate and perform PTI or Function tests.

11.10 Information menu

Explains how to access and use the information menu.

11.11 Raw sensors

Describes how to view raw, unfiltered sensor values.

11.12 Operation parameter settings

Covers setting key operation parameters like setpoint and control mode.

11.13 Programs

Introduces the different operating programs available.

11.13.1 Multiple Temperature Setpoints program, MTS

Explains the MTS program for changing setpoints at intervals.

11.13.2 Automatic Cold Treatment program, ACT

Details the ACT program for cargo treatment.

11.13.3 Bulb mode

Explains the Bulb mode functionality and settings.

11.14 Application settings

Covers application-specific settings.

11.14.1 AV/AV+

Explains the AV/AV+ application for regulating container atmosphere.

11.14.2 CA

Details the CA application for controlled atmosphere.

11.15 Manual defrost

Guides on initiating manual defrost cycles.

11.16 Alarms

Explains the alarm system, levels, and handling.

11.17 Service function settings

Covers access to service functions and sub-menus.

11.18 Manual operation

Details how to manually operate unit components.

11.18.1 FC self-test

Explains how to perform a self-test on the frequency converter.

11.19 Datalog view

Describes how to view logged datalog information.

11.20 Time adjust

Explains how to adjust the unit's date and time settings.

11.21 Run time counters

Describes how to view operational run time counters.

11.22 Configuration

Covers unit configuration settings.

11.22.1 StarConomy

Explains the StarConomy energy-saving function.

11.23 Serial numbers

Lists serial numbers for various unit components.

11.24 USB menu

Details functions related to USB connectivity.

11.25 Maintenance

Covers maintenance procedures.

11.26 Modem

Describes modem settings and status.

12. External interfaces

12.1 General requirements

Specifies general requirements for serial port setup.

12.2 List of terms used for external interfaces

Defines terms related to external interfaces.

12.3 Functions overview

Provides an overview of functions supported by different interfaces.

13. Events

14. Detailed alarm description

14.1 Alarm list

Provides a comprehensive list of all unit alarms with descriptions.

15. Star Cool unit installation dimensions

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

17. Location of valves

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

19. Controller unit illustration

20. Locations of AV and CA components

21. Replacements

21.1 Replacement of evaporator motor and fan

Details the procedure for replacing the evaporator motor and fan.

21.2 Replacement of condenser motor and fan

Details the procedure for replacing the condenser motor and fan.

21.3 Replacement of evaporator

Describes the steps for replacing the evaporator.

21.4 Replacement of heating elements

Outlines the procedure for replacing heating elements.

21.5 Replacement of FC

Details the procedure for replacing the Frequency Converter (FC).

21.6 Replacement of compressor

Explains the procedure for replacing the compressor.

21.7 Replacement of compressor valve plate/cylinder head gasket

Details replacing compressor valve plate and head gasket.

21.8 Replacement of filter dryer

Outlines the procedure for replacing the filter dryer.

22. Service and maintenance

22.1 Evacuation of refrigerant

Describes the procedure for evacuating refrigerant from the unit.

22.2 Compressor pump down and operation

Explains compressor pump down and operation procedures.

22.3 Compressor pump down (replaced)

Details pump down procedure for a replaced compressor.

22.4 Pump down of unit

Outlines the procedure for pumping down the entire unit.

22.5 Pressure test

Describes the procedure for performing a pressure test on the piping system.

22.6 Charging of refrigerant

Details how to charge refrigerant into the unit.

22.6.1 Charging of an empty unit

Explains the process for charging an empty unit.

22.6.2 Charging of unit low on charge

Details how to charge refrigerant when the unit is low.

22.7 Leakage detection

Explains methods for detecting refrigerant leaks.

22.8 Compressor

Covers compressor maintenance.

22.8.1 Check of oil level

Details how to check the compressor oil level.

22.8.2 Draining of oil from compressor

Explains how to drain oil from the compressor.

22.8.3 Charging of oil

Details how to add oil to the compressor.

2.9 Soldering

Provides guidelines for soldering components.

22.9.1 Welding

Outlines precautions for welding on the unit.

23. CA service and troubleshooting

23.1 Container venting procedure

Describes how to vent the container for CA operations.

23.2 Vacuum pump service

Details the service procedure for the vacuum pump.

23.3 Trouble shooting the vacuum system

Provides steps to troubleshoot vacuum system faults.

23.4 Replacement of the vacuum pump heating element

Outlines replacing the vacuum pump heating element.

23.5 CA preparation

Details the preparation steps for CA operation.

23.6 Curtain track installation

Describes how to install the CA curtain track.

23.7 Curtain installation

Details the procedure for installing the CA curtain.

23.8 Container leak test

Explains how to perform a container leak test.

23.9 CA+ flushing

Describes the CA+ flushing process with nitrogen and CO2.

24. General trouble shooting

25. Emergency operation

25.1 FC bypass

Explains how to bypass the Frequency Converter (FC).

25.1.1 FC 1.0 and FC 1.1

Details FC bypass procedure for versions 1.0 and 1.1.

25.1.2 FC 2.0

Details FC bypass procedure for version 2.0.

25.2 Controller bypass

Explains how to bypass a defective controller.

25.3 Evaporator fan motor bypass

Details bypassing a defective evaporator fan motor.

26. Tables

26.1 Datalog description

Explains datalog loggings and retrieved data.

26.2 Temperature sensor - resistance table

Provides a table correlating temperature sensor resistance to temperature.

26.3 Temperature sensor - voltage table

Provides a table correlating temperature sensor voltage to temperature.

26.4 Air exchange sensor table voltage - m3/h for 35 CMH

Voltage table for 35 CMH air exchange sensor.

26.5 Air exchange sensor table voltage - m3/h for 75 CMH

Voltage table for 75 CMH air exchange sensor.

26.6 Voltage – pressure table, LP transmitter (NSK) + DST

Voltage to pressure table for LP transmitter (NSK) + DST.

26.7 Voltage – pressure table, LP transmitter (AKS)

Voltage to pressure table for LP transmitter (AKS).

26.8 Voltage – pressure table, HP transmitter (NSK) + DST

Voltage to pressure table for HP transmitter (NSK) + DST.

26.9 Voltage – pressure table, HP transmitter (AKS)

Voltage to pressure table for HP transmitter (AKS).

26.10 Pressure - temperature table for R134a

Pressure-temperature table for R134a refrigerant.

26.11 Pressure - temperature table for R513A

Pressure-temperature table for R513A refrigerant.

26.12 Tightening torques

Lists tightening torques for various fasteners and components.

27. Diagrams

27.1 P & I diagram

Piping and Instrumentation diagram of the refrigeration unit.

27.2 CA function overview - two versions

Functional overview of CA system in two versions.

28. Overall wiring schematic - CIM 6.0 with sub-controller

29. Overall wiring schematic - CIM 6.1

30. Overall wiring schematic - CIM 6.2

31. Overall wiring schematic - CIM 6.2 with sub-controller

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