Operating and service manual Controlled Atmosphere · PDF file3 Operating and service manual,...

Version 810800A - Dec 2010

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Version 810800A - Dec 2010 © Copyright 2010 Maersk Container Industry AS

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Operating and service manualControlled AtmosphereStar Cool refrigeration unit Model SCI - XX - X - CA

1

Operating and service manual, Controlled Atmosphere

PrefaceThe Star Cool CA is a controlled atmosphere system designed to prolong the shelf life of perisha-bles by regulating the internal atmosphere of the container. The container’s atmosphere obtains the desired gas composition based on entered set points for O2 and CO2 via the controller.The desired atmospherical composition of the gas serves to lower the respiration of the perishables, and thereby providing a prolonged shelf life.

ATTENTION! Due to regulation of the cargo atmosphere during transport, oxygen level may be low and/or carbon dioxide level high inside the container! Please check gas levels and fl ush with fresh air before entering and unloading. Exposure to low oxygen/high car-bon dioxide may cause loss of consciousness and suffocation.

This version of the manual is dated December 2010, edited by Maersk Container Industry AS. All rights reserved. This user’s manual is valid for software version 0345 or newer versions.The information herein is subject to change without notice and does not represent a commitment on any part of Maersk Container Industry AS.While the information herein is assumed to be accurate, Maersk Container Industry AS assumes no responsibility for any errors or omissions that may appear in this documentation.

This manual is valid for:

Model SCI - XX - X - CA Release Date 01.12.2010

Warnings Do not operate or maintain this refrigeration unit until you have familiarized your-self completely with the equipment and operating of this unit by reading the in-struction in this addendum and the Operating and service manual for Star Cool units.

Do not enter the container - including opening the service hatches - when oxygen level is below 20.9%.

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 R134a into the atmosphere. Use recovery equipment according to present legislation.

During maintenance please observe that R134a is operating with high and low temperatures in combination with high pressures, which may cause personal in-juries 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.

2


ContentsPreface .......................................................................................................................................................1Warnings ....................................................................................................................................................1Legend........................................................................................................................................................3CA function overview - two versions ...............................................................................................................3Container venting procedure .........................................................................................................................5Menu structure ............................................................................................................................................7Setpoints ....................................................................................................................................................8CA function on/off ........................................................................................................................................8Additional menu information for CA ................................................................................................................8Data log ......................................................................................................................................................9Warning ......................................................................................................................................................9Pre Trip Inspection, PTI .................................................................................................................................9Manual inspection ......................................................................................................................................10Function test .............................................................................................................................................10Operation ..................................................................................................................................................10Manual mode .............................................................................................................................................10CA curtain .................................................................................................................................................11Vacuum system test ...................................................................................................................................11Problem surrounding the vacuum hose .........................................................................................................12Problem located at membrane .....................................................................................................................12Simple trouble shooting vacuum pump / controller module .............................................................................12Container leak test .....................................................................................................................................12Oil charge and drain ...................................................................................................................................13Replacement of vacuum pump heating element .............................................................................................13Locations of components .............................................................................................................................14Components ..............................................................................................................................................15Replacing the controller module ...................................................................................................................18Temperature sensor alarms (1XX) ................................................................................................................19Pressure sensor alarms (2XX) ......................................................................................................................22Other sensor alarms (3XX) ..........................................................................................................................26Power alarms (4XX) ....................................................................................................................................28Operation alarms (6XX) ..............................................................................................................................29Communication alarms (7XX) ......................................................................................................................36Test alarms (8XX).......................................................................................................................................39Controller alarms (9XX) ..............................................................................................................................47Controller overview ....................................................................................................................................49Overall wiring schematic .............................................................................................................................53Overall wiring schematic (alternate) .............................................................................................................54

3


LegendShort name Name

Pmem Membrane pressure

Tpump Vacuum pump temperature

Mpump Vacuum pump

Hpump Heating element

Mair Fresh air motor

CA function overview - two versions

Controller module SMC6

Controller module SSC6-

CA

CO2O2

Inside Container

Fresh air valveCA membrane

Vacuum pump

PTCVacuum Pump

Output

RS 485

RS 485

PTCSignals

Vacuum

PPressure sensor

Heating element

RS 485

Temperature sensor

Thermal circuit switch

Air flow

(Only available for some models)

4


Controller module SMC6.1

CO2O2

Inside Container

Fresh air valveCA membrane

Vacuum pump

PTCVacuum Pump

Output

RS 485

PTCSignals

Vacuum

PPressure sensor

Heating element

RS 485

Temperature sensor

Air flow

5


The basic principle is that the fruit will generate CO2 from O2 via respiration. This will increase the CO2 level and decrease O2 level inside the container. When the CO2 level reaches above the CO2 set point the vacuum pump will activate and evacuate CO2 with the selective membrane. In case the O2 level goes below the O2 set point the fresh air valve will open and let in ambient air (20,9% O2). This described mechanism will regulate the gas concentration within the container as illustrated below:

O2 levelCO2 level

Time

GasConcentration

Warning Due to low oxygen levels inside the container, ventilation is necessary before entering, either for repairing the unit or unloading. Stay away from doors while venting.

Container venting procedureTO BE PERFORMED WHENEVER ENTERING THE UNIT/CONTAINER IS NECESSARY

1. Press for operation and select O03 and set Air fl ow mode to “NORMAL”.2. Open fresh air module fully. AL 834 may appear.3. Wait for O2 level to reach 21% +/- 2% before entering.4. Close air module and clear AL 834.

General specifi cationAdditional components to a standard unit:

• O2 sensor• CO2 sensor• Vacuum pump• Membrane• Vacuum hose• Fresh air module incl. motor

Fresh air motorType Gear motorSupply 12-24 V DC

CO2 sensorType Nondispersive infrared sensorOperating range 0 - 20%

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Accuracy CO2 (5%) +/- 0,3% CO2 (0,5%) +/-0,1%

Supply 8-15V DCOutput RS-485

O2 sensorType Ziconium OxideOperating range 0 - 21%Accuracy At O2 (3%) +/- 0,5%, temperature ranges

from -1 - 15°CSupply 8-15V DCOutput RS-485

Pressure transmitterType RatiometricOperating range -1 - 0 BarAccuracy ±10 mBarSupply 5V DCOutput Ratiometric

Temperature sensorType NTC, 10 kOhm at 25°C (77°F) 10K3A1Operating temp. -40°C to 100°C (-40°F to 212°F)Accuracy ±0.15°C, range -30°C to 100°C (±0.5°F,

-22°F to 212°F)

Vacuum pump, including heating elementCapacity 16 m3/h at 50 Hz and 19 m3/h at 60 HzSupply 3 phase AC 50 Hz 340 – 460 Volts and 60 Hz

400-520 VoltOil (type/amount) Anderol FGC 32 - 0.35 L

7


Menu structure

MAIN PAGE

SERVICE

S01S02S03S04S05

OPERATION

SetpointQUESTAirflow modeHumidity setpointDatalog intervalPROGRAMS >O2 setpointCO2 setpointActive application

O01O02O03O04O05O06O07O08O09

Relative humidityAir exchangeO2CO2Last defr intervalUSDA 1 tempUSDA 2 tempUSDA 3 tempCargo tempTime to defrostAmbient tempSupply air 1 tempSupply air 2 tempReturn air tempEvaporator tempSuction tempSuction pressMembrane pressureDischarge pressExpansion valveEvap superheatCompressor freqPower frequencyCurrent phase 1Current phase 2Current phase 3Voltage phase 1-2Voltage phase 2-3Voltage phase 1-3Phase directionBattery voltageFC tempCondenser fanEvaporator fanEvaporator heaterPump temperature

I01I02I03I04I05I06I07I08I09I10I11I12I13I14I15I16I17I18I19I20I21I22I23I24I25I26I27I28I29I30I31I32I33I34I35I36

INFORMATION

ALARM

Alarm text...

A01A02...A16

MANUAL OPERATION

Operating modeEvaporator heaterEvaporator fanCondenser fanCompressor freqExpansion valveHotgas valveEconomizer valveAirex motorVacuum pump

M01M02M03M04M05M06M07M08M09M10

DATALOG VIEW

Text Temperatures >Text Atmosphere >Graph Temperatures >Graph Atmosphere >

L01L02L03L04

TIME ADJUST

GMT-YearGMT-MonthGMT-DayGMT-HourGMT-Minute

C01C02C03C04C05

RUNTIME COUNTERS

UnitCompressorEvaporator fanCondenser fanEvaporator heaterAirex motor sw timesVacuum pump

R01R02R03R04R05R06R07

CONFIGURATION

ContainerSoftware versionFC typeFC IDPhase detectionAirEx calibrationLow pres typeHigh pres typeMain PCBModel code

F01F02F03F04F05F06F07F08F09F10

PRE TRIP INSPECTION

PTI testLastFunction testAbort the testTest status 10: Init 20: Controller 30: Power 40: Evap fan 50: Cond fan 60: Evap heater 70: CA 80: Compressor 90: FT status105: T set 13 °C100: T set 5 °C110: T set 0 °C111: Hold 0 °C120: T set -18 °C130: Defrost140: PTI status

T01T02T03T04T05T06T07T08T09T10T11T12T13T14T15T16T17T18T19T20T21

MANUAL OPERATION >DATALOG VIEW >TIME ADJUST >RUNTIME COUNTERS >CONFIGURATION >

AIR EXCHANGE

COLD TREATMENT

DurationMaximum USDA temp.Treatment setpointFinal temperatureCT status

B01B02B03B04B05

PROGRAMS

Active programMulti. Temp setp. >Cold treatment >

P01P02P03

MULTI. TEMP. SETP.

D01D02D03D04D05D06

Hour Set %Rh OFF 0.0 OFF OFF 0.0 OFF OFF 0.0 OFF OFF 0.0 OFF OFF 0.0 OFF OFF 0.0 OFF

888m3/hPress (X) to leave

8


SetpointsSetpoints are entered via the operation menu

O2 range 3 - 21% CO2 range 5 - 12%

Setting setpoint: O2 level is set in O07 and CO2 level is set in O08 (Menu structure)

CA function on/offIf the setpoints for O2 and CO2 is set to OFF the CA function is turned off

Additional menu information for CAIn addition to the standard log the following information can be viewed in the log:Please note that it will take approx. 5 minutes before CO2 and O2 can be viewed in the display.

I03 O2 level Function:

Shows the O2 level [%] Value:

An actual value of the O2 level inside the container.

I04 CO2 level Function:

Shows the CO2 level [%] Value:

An actual value of the CO2 level inside the container.

I18 Membrane pressure Function:

Membrane pressure. Value:

Actual vacuum pressure between vacuum pump and membrane. Under normal conditions: 40-100 mBar.StarView enables the display of the following additional information.

O07 O2 set point Function:

O2 set point. Value:

-

O08 CO2 level Function:

CO2 set point. Value:

-

9


Data log

Title Info displayed

CO2Set CO2 set point [%]

O2Set O2 set point [%]

Input CO2 CO2 level [%]

Input O2 O2 level [%]

Input Pmem Membrane pressure [mBar]

Input Tpump Oil temperature in the vacuum pump [°C]

Application CAType 0 = CA off 1 = CA on

Control MpumpCA 0 = vacuum pump off 1 = vacuum pump on

Control HpumpCA 0 = heating element off 1 = heating element on

Control MairPct (time opened [%]) 0 = fresh air valve closed 100 = fresh air valve open

WarningDo NOT enter the container, including opening the service hatches, when the oxygen level is below 20.9% (equal ambient air).

Human response to oxygen low atmosphere:Oxygen content of Air Symptoms of a person exposed20.9% Level in ambient air - no effect15% - 19% May impair coordination and may induce early symptoms

in persons who have coronary, pulmonary or circulatoryproblems.

12% - 15% Respiration and pulse increase; impaired coordination, perception and judgement occurs.

10% - 12% Respiration further increases in rate and depth; poor judgement and bluish lips occur.

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

Pre Trip Inspection, PTIEnsure the following manual inspection and function test is performed before taking the Star Cool CA unit into operations.The progress of the pre trip test can be followed in the display T04 in steps.

10


Manual inspection1. Check for structural damages on sides, doors and roof on the container.2. Secure tight plugs at each of the fl oors drain plugs, placed near corners. Cut-out views from front end (left picture) and rear end (right picture)

3. Make sure service hatches are in perfect condition and installed correctly.4. Inspect the fresh air module to ensure it is in perfect condition. Make sure the butterfl y is operational and that the valves are intact.5. Check drain hose for any damage.6. Make sure lead-ins (cables and vacuum hose) are intact.7. Check oil in the vacuum pump.

After ensuring steps 1-7 the unit is now ready for PTI.Three types of pre trip inspections are available for the Star Cool CA unit: Full PTI, Short PTI and CA PTI. Please see Star Cool service manual for descriptions on Full PTI and Short PTI.

Function testTwo function tests are available for the Star Cool CA unit: STD and CA.The CA function test has the following steps: 1. STD function test2. CO2 sensor test3. O2 sensor test4. AirEx motor test

OperationSet points:CO2 and O2 set points are entered in the menu structure O07 an O08.O2 levels below 2% can not be entered.CO2 levels below 5% can not be entered.

Level readings:O2 and CO2 concentrations can be viewed in the menu structure I03 and I04. The membrane pres-sure can be viewed in the menu structure I18 - this displays the vacuum level created. Vacuum pump oil temperature can be viewed in the menu structure I36.

Manual modeThe AirEx motor can be activated in manual mode in the menu structure M09. 0%: Valve closed 100%: Valve open

11


The vacuum pump can be activated in the menu structure M10. Activating the vacuum pump should result in a pressure drop which can be viewed in the menu structure I18.Only manually activate the vacuum pump when absolutely necessary! The vacuum pump is not pre-heated if manually activated - this can cause damage to the vacuum pump over time.

CA curtainWhen CA is activated a CA curtain must be installed. Ensure the CA curtain is installed in accord-ance with the guide included with the CA curtain.

Vacuum system testNote: BE AWARE OF HOT SURFACES - when handling the vacuum pump.The vacuum system consists of a membrane connected with a hose to a vacuum pump. Below you will fi nd a step-by-step method to determine the root cause of a vacuum fault. Please be aware that there can be more than one problem in a vacuum system, and you might need to go through the tutorial several times to eliminate the problem.

A vacuum fault alarm can be caused by a single or a combination of the following:

1. Insuffi cient amount of oil in vacuum pump2. Defective pressure transmitter3. Defective or leakage in vacuum pump4. Leak in fi ttings or connections5. Leak in membrane

Method to determine the cause:

1. Check oil level in the vacuum pump. Refi ll if needed.2. Go to menu structure M10 and turn on the vacuum pump and verify that it rotates in the right direction. If vacuum pump does not activate, see section “Simple trouble shooting vacuum pump / controller module” on page 12. If vacuum pump acti vates proceed to 3.3. Disconnect the vacuum hose at the vacuum pump and plug the vacuum pump inlet. a. If the pressure is above 30 mBar, proceed to 4 b. A pressure below 30 mBar indicates the vacuum pump is OK, proceed with the following: Connect the hose to the vacuum pump again and ensure the connection is tight.4. Install a manometer at the transmitter inlet and ensure the reading is similar to the display reading. If not, the pressure transmitter is defect. If pressure is OK, change the vacuum pump. Go to menu structure M10 and turn on the vacuum pump.

If the vacuum fault alarm is still present - 2 options from here: If unit is in operation with cargo: Do nothing! Either the membrane or the connection to the membrane is leaking. It is not possible to correct this fault during operation, due to low oxygen level inside container. Do not enter the container - including opening the service hatches - when oxygen level is below 20.9%. Empty container: Disconnect the vacuum hose at the membrane and plug the hose. Go to menu structure M10 and turn on the vacuum pump. If readings are: - Above 30 mBar: ”Problem surrounding the vacuum hose” on page 12 - Below 30 mBar: ”Problem located at membrane” on page 12

12


CA membrane

P

Problem area if reading below 30 mBar

Vacuum pump

Problem area if reading above 30 mBar

Problem surrounding the vacuum hose

In case of a defective vacuum hose:1. Check hose for leaks. Repair or replace.2. After repair or replacement of the vacuum hose, perform “Container leak test” on page 12

Problem located at membrane1. Ensure vacuum hose is connected correctly.2. If this does not solve the problem, replace membrane.

Please note that this step by step only resolves one leak in the system, and may need to be repeat-ed until the leak is fully terminated. See “Container leak test” on page 12

Simple trouble shooting vacuum pump / controller module1. Check contactor coil K9.2. Measure wirering, see wire diagram.3. Measure bi-metallic switch (optional component). If no connection, replace switch.4. Pull contactor K9 manually. If pump starts, replace controller module5. Pull contactor K9 manually. If pump does not start, replace the pump.

Container leak testA container leak test needs to be performed when:• After replacing vacuum hose• After replacing wiring going through the unit• After replacing hoses and or piping going through the unit• After replacing or opening service hatch• After repairing structural damage on the unit and or container• After replacing fresh air valve and or module• When a container is suspected of leakage

13


Equipment needed:• Star Cool test damper• Test manometer - differential pressure gauge (for instance a Dwyer Magnehelic model 2002)• CA curtain• Drain plugs

Method:1. Install drain plugs2. Install CA curtain according to instructions supplied along with the curtain3. Install Star Cool test damper4. Connect test manometer5. Apply air pressure 500 Pa6. Close air supply, and wait 12 min7. Ensure pressure is min. 250 Pa after 12 min

Test criteria:Pressure drop: 2” water column to 1” water column (500 Pa to 250 Pa)Min. test time: 720 sec (12 min)If test fails, leak must be located, repaired and test performed over again.

Oil charge and drainOil fi lter should be replaced at every oil change.1. BE AWARE OFF HOT SURFACES.2. Remove cover shield from vacuum pump by the 4 bolts.3. Remove the plug for oil charge, see Vacuum pump in “Components” on page 15.4. Charge oil while watching the sight glass - do not overcharge.5. Fasten plug immediately after oil charge.

Replacement of vacuum pump heating element1. Turn power off!2. BE AWARE OFF HOT SURFACES.3. Remove cover shield from vacuum pump by the 4 bolts. Release vacuum pump from its socket4. Unplug sensor cables from terminal box on top of the vacuum pump and tilt vacuum pump to avoid oil spill when replacing the heating element.5. Attach cables to terminal box on top of the vacuum pump according to illustration below.6. Turn on power.

1

2

3

14


Locations of components

15


ComponentsCA membrane module

Pressure transmitter

CO2 sensor O2 sensor

Displayed sensors may vary from currently used models

16


Vacuum pump

Tightening torques for M6 screws at vacuum pump console: 6 NmTightening torques for plugs and heating element: 15 Nm

CA related alarmsAlarm list:Id Display text Description Alarm type1. Temperature sensor alarms130 Tpump open Vacuum pump temperature sensor open circuit Warning131 Tpump short Vacuum pump temperature sensor short circuit Warning132 Tpump invalid Vacuum pump temperature sensor invalid Warning2. Pressure sensor alarms211 Pmem open Vacuum pump pressure transmitter open circuit Warning212 Pmem short Vacuum pump pressure transmitter short circuit Warning213 Pmem invalid Vacuum pump pressure transmitter invalid Warning214 Pmem fault Pressure system fault Warning3. Other sensor alarms310 CO2 invalid CO2 sensor communication missing Alarm313 O2 invalid O2 sensor communication missing Alarm4. Power alarms403 Mpump over heat Vacuum pump motor overheat Warning6. Operations alarms650 O2 low O2 sensor measures low O2 level in container Alarm651 CO2 high CO2 sensor measures high CO2 level in container Alarm652 Vacuum fault The pressure sensor measures high pressure in

the vacuum systemAlarm

Terminal box

Pressure tranmitter connection

Pump in-let

Oil in-let

Oil fi lter

Sight glass

Temp. sensor pocket

Heating element

Oil out-let

17


653 Mpump temp low Vacuum pump operating temperature is low Alarm654 Mpump temp high Motor for vacuum pump is overheated Alarm656 Mpump service Vacuum pump needs oil change Fatal

alarm657 Mpump wrong phase Vacuum pump operating in wrong direction Fatal

alarm7. Communication alarms740 CO2 sensor

missingCO2 sensor is missing or communication lost Alarm

750 CA module missing CA module is missing or communication lost Alarm760 O2 sensor missing O2 sensor is missing or communication lost Alarm8. Test alarms826 Hpump current ON Heat vacuum pump too high or too low Alarm827 Hpump current OFF Current in off position is too high Alarm831 Pmem sensor Pmem above or below 1000 mBar (+50/-50) after

Mpump off for 300 secAlarm

832 CO2 sensor No reading or value above 1% Alarm833 O2 sensor No reading or value out of range Alarm834 Mair open Readings for fresh air valve position is outside

specifi ed rangeAlarm

835 Mair closed Readings for fresh air valve position is outside specifi ed range

Alarm

836 Pmem vacuum Unable to create vacuum Alarm837 Pmem ambient Not measuring Pmem pressure 1000 mBar

(-50/+50 mBar)Alarm

838 Mpump ON current Current failure Alarm839 Mpump OFF current Current in off position is too high Alarm890 PTI Tset-13 Unable to reach set point (13°C) (55°F) within 3

hours and staying in-range for 30 minAlarm

9. Controller alarms977 Pmem sens sup LOW Controller internal voltage reference fault Warning978 Pmem sens sup HIGH Controller internal voltage reference fault Warning998 Could not detect CA Unable to detect CA Warning

18


Replacing the controller module

SCC6-CASMC6

Defective

SSC6-CA SMC6.1

Replacement action

Or

Failure scenario

Recommended

SSC6-CASMC6

Defective

SMC6 SMC6.1Or

Recommended

SMC6

Defective

SMC6 SMC6.1Or

Recommended

SMC6.1

Defective

SMC6.1

19


Temperature sensor alarms (1XX)

130 Tpump open WarningDescription Vacuum pump temperature sensor open circuitCause Indication of loose connection, defective temperature sensorTrouble shooting

Possible causes:

• Temperature sensor Tpump or its cable is defective

• Controller module is defective

Accompanied alarms:

• AL 132

Trouble shooting:

1. Disconnect the sensor cable for sensor Tpump from the connector on the controller module, according to the wiring schematics inside in the control cabinet

2. Measure the resistance between the two wires

a) If this resistance is more than 1.5 MΩ, the cable or the sensor is defect, replace sensor

b) If this resistance matches the resistance and temperature in Tables (Star Cool manual), the temperature sensor and cable are OK

3. Measure the voltage over the connector for Tpump. It should be between 3.2 and 3.4 V DC

a) If the voltage is within the specifi ed range, connect sensor again.Measure the voltage over the sensor and check voltage/temperature according to Tables (Star Cool manual)

b) If the voltage is outside the above range, the controller module, is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Main Controller (Star Cool manual) before replacing controller door

Criteria Value below low alarm limit -35°C (-31°F)

Controller action

None

Log X Alarm X Alarm light Off

Consequence It is not possible to control the heating element in the vacuum pump

Elimination When sensor value becomes valid, it is marked as inactive in the alarm list and may then be deleted

Log dataParm 1 Parm 2 Parm 3 Parm 4 Parm 5

Active/Inactive Low limit High limit Current

20


131 Tpump short WarningDescription Vacuum pump temperature sensor short circuitCause Indication of short-circuited temperature sensorTrouble shooting

Possible causes:

• Temperature sensor Tpump or its cable defective

• Controller module defective

Accompanied alarms:

• AL 132

Trouble shooting:

1. Disconnect the sensor cable for sensor Tpump from the connector on the controller module, 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 Ω, the cable or the sensor is defect, replace sensor

b) If the resistance matches the resistance and temperature in Tables (Star Cool Manual), the temperature sensor and cable are OK.

3. Measure the voltage over the connector for Tpump, it should be between 3.2 and 3.4 V DC.

a) If the voltage is inside the above range, connect sensor again.Measure the voltage over the sensor and check voltage/temperature according to Tables (Star Cool Manual).

b) If the voltage is outside the above range, the controller module is defect or other sensors may be defect and pulling the voltage down. Check other alarms and see Trouble shooting for Star Cool Main Controller (Star Cool Manual) before replacing controller door.

Criteria Value above high alarm limit +140°C (+284°F).

Controller action

None





Active/Inactive Low limit High limit Current

21


132 Tpump invalid WarningDescription Vacuum pump temperature sensor invalidCause Indication of defective temperature sensor or its measuring circuitryTrouble shooting

Possible causes:

• Active alarms AL 130 or AL 131

• Temperature sensor reading is out of valid range: -35°C (-31°F) or above +130°C (266°F)

Accompanied alarms:

• AL 130 or AL 131 may also be active.

Trouble shooting:

1. Check accompanied alarms

2. Disconnect the sensor cable for sensor Tpump from the connector on the controller module, according to the wiring schematics inside in the control cabinet.

3. Measure the resistance between the two wires.

a) If the resistance is out of range of the resistance and temperature table in Tables (Star Cool Manual), 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 Main Controller (Star Cool Manual) before replacing controller door.

Criteria Reading below -35°C (-31°F) or above +130°C (266°F)

Controller action

None



Elimination 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.


Active/Inactive

22


Pressure sensor alarms (2XX)

211 Pmem open WarningDescription Vacuum pump pressure transmitter open circuitCause Indication of loose connection, defective or lack of vacuum pump

pressure transmitterTrouble shooting

Possible causes:

• See AL 212

Accompanied alarms:

• AL 213

Trouble shooting:

1. Check that the connector is mounted correctly according to wiring schematic.

a) Check the cable (measure the resistance in the cable).If the cable is defective, replace cable.

b) Disconnect signal wire on controller module according to wiring schematic.Measure voltage between dissconnected signal wire and GND on controller module.If voltage is above 4.7 V DC, transmitter or connection between transmitter and cable is defective.If not, then mount signal wire. Measure voltage between SIGNAL and GND.If voltage is between 0.2 V DC and 4.7 V DC and this alarm is still active, then replace controller module.

Criteria Pmem > 1150 mBar

Controller action

None


Consequence No consequence as to control

Elimination When transmitter value becomes valid, it is marked as inactive in the alarm list and may then be deleted.


Active/Inactive Low limit High limit Present

23


212 Pmem short WarningDescription Vacuum pump pressure transmitter short circuitCause Indication of short-circuited vacuum pump pressure transmitterTrouble shooting

Possible causes:

• Connector for pressure transmitter Pmem not correctly mounted

• Vacuum pump pressure transmitter Pmem defective

• Cable for vacuum pump pressure transmitter Pmem defective


Accompanied alarms:

• AL 213

Trouble shooting:

1. Check that the connector is mounted correctly according to wiring schematic.


b) Disconnect signal wire on controller module according to wiring schematic.Measure voltage between dissconnected signal wire and GND on controller module.If voltage is below 0.2 V DC, transmitter or connection between transmitter and cable is defective.If not, then mount signal wire. Measure voltage between SIGNAL and GND.If voltage is between 0.2 V DC and 4.7 V DC and this alarm is still active, then replace controller module.

Criteria Pmem < 10 mBar

Controller action

None


Consequence None

Elimination When transmitter value becomes valid, it is marked as inactive in alarm list and may then be deleted


Active/Inactive Low limit High limit Present

24


213 Pmem invalid WarningDescription Vacuum pump pressure transmitter invalidCause Indication of defective Vacuum pump pressure Transmitter or its

measuring circuitryTrouble shooting

Possible causes:

• See AL 212

Accompanied alarms:

• AL 211 or AL 212 may also be active

Trouble shooting:

1. Check that the connector is mounted correctly according to the drawing.


b) Disconnect signal wire on controller module according to wiring schematic.Measure voltage between signal wire and GND on controller module according to wiring schematic.If voltage is below 0.2 V DC, transmitter or connection between transmitter and cable is defective.If not, then mount signal wire. Measure voltage between SIGNAL and GNDIf voltage is between 0.2 V DC and 4.7 V DC and this alarm is still active, then replace controller module.

Criteria Pmem out of range for more than 30 sec

Controller action

Replacement by new value from AAS system


Consequence None

Elimination When transmitter value becomes valid, it becomes marked as inactive in alarm list may then be detected. Value must be valid for 60 sec. to set alarm inactive.


Active/Inactive

25


214 Pmem fault WarningDescription Pressure system faultCause Pressure <10 mBar or >1150 mBarTrouble shooting

Possible causes:

• See AL 212

Accompanied alarms:

• AL 213 may be active

Trouble shooting:

1. See AL 212Criteria 10 mBar or > Pmem > 1150 mBar

Controller action

None


Consequence None



Active/Inactive Low limit High limit Act 0

26


Other sensor alarms (3XX)

310 CO2 invalid AlarmDescription CO2 sensor communication missingCause Indication of defective CO2 sensor, or lack of or improper connectionTrouble shooting

Possible causes:

• Communication with CO2 sensor

• Defective CO2 sensor

• COMRH cable, RH-cable and or COMCA cable is defective


Accompanied alarms:

• AL 740

Trouble shooting:

1. Verify that cable CO2-com is mounted correctly (and is not damaged) according to wiring diagram inside the controller cabinet.

2. Verify that there are correct voltages 12 V DC between 1 and 4 on X10.

3. Measure with a multimeter that there is a small DC signal between 2 and 3 on X10.

a) If there is signal: The CO2 sensor is defective and must be replaced.

b) If there is no signal: The controller module is defective and must be replaced.

Criteria Communication with CO2 sensor not possible

Controller action

Run pump 40%

Log X Alarm X Alarm light Slow fl ash

Consequence CO2 level can not be regulated



Active/Inactive

27


313 O2 invalid AlarmDescription O2 sensor communication missingCause Indication of defective O2 sensor, or lack of or improper connectionTrouble shooting

Possible causes:

• Communication with O2 sensor


• Defective O2 sensor


Accompanied alarms:

• AL 310, AL 302 and or AL 760, (See service manual).

Trouble shooting:

1. Verify that cable O2-com is mounted correctly (and is not damaged) according to wiring diagram inside the controller cabinet.

2. Verify that plugs are properly connected.


a) If there is signal: The O2 sensor is defective and must be replaced.


Criteria Communication with O2 sensor not possible

Controller action

Open airex 4%


Consequence O2 level can not be regulated



Active/Inactive

28


Power alarms (4XX)

403 Mpump over heat WarningDescription Vacuum pump motor overheatCause Indication of an overheated motor or a loose thermistor cable connectionTrouble shooting

Possible causes:

• Vacuum pump motor defective.

• Cable for measuring vacuum pump motor overheat defect.

• Controller module defective.

Accompanied alarms:

• N/A.

Trouble shooting:

1. Turn off unit!Take of the fan cover for the vacuum pump, see if the fan can easily turn freely by fi nger. If not, perform oil check. See trouble shooting AL 656. If the motor is hot, it may be overloaded and jammed or defect.

2. If the cable for MpumpOH by inspection is defect, replace cable.

3. Disconnect the cable for MpumpOH from the controller module according to the wiring schematics.

4. Measure the resistance in the cable.If the resistance is more than 1 MΩ, the cable or the motor is defect and should be replaced.If the resistance is less than (<) 5 kΩ, the cable and motor should be OK.

5. Turn unit on again.Measure the voltage over the connector for MpumpOH. It should be between 4.80 V DC and 5.05 V 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 (<) 2.5 V DC, the measurement is OK.If the alarm after 30 sec. is still active on the display, thecontroller module is defect - replace controller module.

b) If the voltage is outside the range, controller module is defect or another error might affect the voltage. Check other alarms before replacing controller module.

Criteria Value above high alarm limit 10k Ohm

Controller action

Vacuum pump is stopped until alarm is removed


Consequence Extraction of CO2 is stopped

Elimination When overheating stops, alarm will be marked as inactive in alarm list and may then be deleted


Active/Inactive High limit Present

29


Operation alarms (6XX)

650 O2 low AlarmDescription O2 sensor measures low O2 level in containerCause The system is not able to vent fresh air into the containerTrouble shooting

Possible causes:

• Lack of oil in the vacuum pump

• Automatic Fresh air defect

• O2 sensor defect

Trouble shooting:

1. See if automatic Air Exchange valves are open. If not, try to open in manual mode

2. See if vacuum pump is running.

a) If the pump is running it will in time make sure there is enough O2 in the box. Open the damper to accelerate this, open it until O2 level is higher than O2 set point.

Criteria O2 level < O2 set point – 0.3 * O2 set point

Controller action

Run pump 40%

Log X Alarm X Alarm light X

Consequence If not fl ushed with O2 cargo might experience anaerobic respiration and thereby deteriorate



Limit Act Set point

30


651 CO2 high AlarmDescription CO2 sensor measures high CO2 level in containerCause The system is not able to extract the CO2 through the membraneTrouble shooting

Possible causes:


• Vacuum pump is not running or defective

• Membrane is defective

• CO2 sensor defective

Trouble shooting:

1. The vacuum pump is not running.

a) Check if the bi-metallic switch is connected according to the wire schematic X78 (depending on model).

b) Push the contactor in the control cabinet, if the pump is then activated replace controller module. If the pump is not running when pushing the contactor, replace vacuum pump.

2. The vacuum pump is running.

a) Check oil level in vacuum pump.

b) Read out the pump pressure I18 if > 200 mbar the vacuum system has a leak. Check entire system for air leaks. If no air leaks is found the pump might be defect. See ”Vacuum system test” on page 11

b) Read out the pump pressure I18 if < 200 mBar the membrane is defect. Replace membrane.

Criteria CO2 level > CO2 set point + 0.5 * CO2 set point (and rising)

Controller action

Run pump 100%


Consequence If not CO2 is removed from the container, this will cause damage to the cargo



Limit Act Set point

31


652 Vacuum fault AlarmDescription Vacuum pump unable to reach required pressureCause The vacuum system might have a leak or the pressure sensor is defectTrouble shooting

Possible causes:

• Lack of oil

• Leak in vacuum system or membrane

• Defective pressure sensor

• Vacuum pump is defective

Accompanied alarms:

• AL 403

Trouble shooting:

1. If AL 403 is active, see trouble shooting for AL 403.If AL 652 does not turn inactive, proceed with 2.


a) Check if the bi-metallic switch is connected according to the wire schematic X78 (depending on model)

b) Pushing the contactor in the control cabinet, if the pump is then activated replace controller module. If the pump is not running when pushing the contactor, check contactor and vacuum pump.


a) Perform “Vacuum system test” on page 11Criteria Pump on > 5 min AND Pmem > 135 mBar in 15 min, and CO2act > CO2set + 2%

Controller action

None


Consequence If the system can not achieve low pressure, the membrane does not work and therefore not able to extract CO2 from the container


Log data

Parm 1 Parm 2 Parm 3 Parm 4 Parm 5

Limit Act Pump on time

32


653 Mpump heat element AlarmDescription Vacuum pump operating temperature is lowCause The ambient temperature can be low and thereby diffi cult for the heating

element and vacuum pump to heat up. It could also be a defective heating element

Trouble shooting

Possible causes:

• Defective temperature sensor Tpump

• Defective heating element

• Defective contactor K9

Trouble shooting:

1. Check contactor

2. Ensure that Tpump is correctly mounted and inserted completely in the sensor pocket.

3. Defective heating element.

a) At the contactor measure the heating element, there should be approx 0.9 kΩ. If not replace heating element.

Criteria Heating pump on for 50 minutes; Tpump < Tamb + 5°C

Controller action

None


Consequence Condensation of water vapor in the pump housing


Log data


Limit Act Pump on time

33


654 Mpump temp high AlarmDescription Motor for vacuum pump is overheatedCause Indication of an overheated motor, this can be caused by very high

ambient temperature or a defective pumpTrouble shooting

Possible causes:

• Vacuum pump motor is overheated

• Vacuum pump is defective or jammed

Accompanied alarms:

• N/A

Trouble shooting:

1. Check if the fan for the vacuum pump can turn freely.If it cannot turn, remove any obstacle

2. Check that the vacuum housing is not blocked.

3. Check that the oil level in the pump is correct.

4. Check that heating element is turned off, and check heater contactor.

5. Check that the temperature sensor Tpump is installed correctly.

6. If none of the above solves the problem, and the pump seems to be more than 115°C (239°F) - replace vacuum pump.

Criteria Tpump > 115°C (239°F)

Controller action

Stop vacuum pump


Consequence The CA system will not be able to remove CO2 from the container

Elimination AL 654 will become invalid when temperature decreases


Active/Inactive High limit Act

34


656 Mpump service Fatal alarm

Description Vacuum pump needs oil changeCause Pump runtime > 2000 hTrouble shooting

Possible causes:

• Pump runtime > 2000 h

Accompanied alarms:

• None

Trouble shooting:

1. Replace vacuum pump oil and fi lter. Filling 0.35 L.

2. Run vacuum pump in 6 min. (manually).

3. Check if oil is clean - if not, replace oil again and go to 2).

4. When oil is still clean after running in 6 minutes, press the alarm for 10 sec, then the alarm will become inactive.

5. Press again to delete service alarm.Criteria Pump runtime > 2000 h

Controller action

None

Log X Alarm X Alarm light Quick

Consequence Unit can not pass PTI.Not performing oil-change every 2000 pump hours will decrease pump-lifetime dramatically

Elimination When alarm becomes inactive, it can be deleted


Limit Act

35


657 Mpump wrong phase Fatal alarm

Description Vacuum pump operating in wrong directionCause Pump ON > 7 sec and Pmem > 600 mBarTrouble shooting

Possible causes:

• Wrong phase direction

• Pressure tansmitter defective

• Vacuum hose leak

• Leaks in the vacuum system

• Contactor defective

• Supply voltage to pump defective

Accompanied alarms:

• AL 213, AL 214 and AL 998

Trouble shooting:

1. Check contactor K10

2. Check pump connection according to wire schematic

3. See “Vacuum system test” on page 11

4. Check pressure transmitter PmemCriteria Pump ON > 7 sec and Pmem > 600 mBar

Controller action

None

Log X Alarm X Alarm light Quick

Consequence Vacuum pump stop and CA non functionable

Elimination When alarm becomes inactive, it can be deleted


Limit Act Pump ontime

CO2

36


Communication alarms (7XX)

740 CO2 sensor missing AlarmDescription CO2 sensor is missing or communication lostCause None or bad communication with CO2 sensorTrouble shooting

Possible causes:

• Communication to CO2 sensor lost

• CO2 sensor missing

• CO2 sensor defect

• COMRH cable, RH-cable and or COMCA are defective

• Main controller defective

Accompanied alarms:

• AL 302, AL 730, AL 750, AL 751 and AL 760 may accompany this alarm

Trouble shooting:

1. Verify that cable CO2-com is mounted correctly (and is not damaged) according to wiring diagram inside the controller cabinet.


3. Measure with a multimeter that there is a small DC signal between 2 and 3 on X10.

a) If there is signal: The CO2 sensor is defective and must be replaced.


Criteria No communication for 2 min.

Controller action

None


Consequence Not possible to run CA

Elimination Alarm may be deleted when inactive


0 0 0 Err code

37


750 CA module missing AlarmDescription CA module is missing or communication is missingCause CA module sensor is missing or communication lostTrouble shooting

Possible causes:

• CA module missing

• Communication to CA module lost

• CA module defective

Accompanied alarms:

• AL 302, AL 730, AL 740 and AL 760 may accompany this alarm

Trouble shooting:

1. If one or more alarms are active, check wires, plugs and connectors.

2. Check voltage supply according to wire schematic.

3. If only AL 750 active, then check connection to CA module and correct if faulty. If no change, then replace CA module.


Controller action

None



Elimination


0 0 0 Err code

38


760 O2 sensor missing AlarmDescription O2 sensor is missing or communication lostCause None or faulty communication with O2 sensorTrouble shooting

Possible causes:

• Communication to O2 sensor missing

• Defective O2 sensor



Accompanied alarms:

• AL 313, AL 730 and AL 740 may also be active

Trouble shooting:

1. If one or more alarms are active, check wires, plugs and connectors.

2. Check voltage according to wire diagram.

3. If only AL 760 active, then check connection to O2 sensor and correct if faulty. If no change, then replace CA module.


Controller action

None



Elimination Alarm may be deleted when inactive


0 0 0 Err code

39


Test alarms (8XX)

826 Hpump current ON AlarmDescription Heat vacuum pump too high or too lowCause Measured current is too high or too low when heater is turned onTrouble shooting

Possible causes:

• Defective cables

• Defective heating element

• Defective controller module

• Defective power meas

Accompanied alarms:

• N/A

Trouble shooting:

1. Check connection according to wiring schematic.

2. Defective heating element, see AL 653.

3. Check supply [Amp] reading and compare with display reading.If reading approx. 10 times normal value, replace controller module

Criteria Current < Imin = 0,5*(U/973,2) or current > Imax = 1,5*(U/973,2).

Controller action

None


Consequence Can not pass PTI

Elimination Alarm may be deleted after test complete


Step ID ILimit I1 I2 I3

40


827 Hpump current OFF AlarmDescription Current in off position is too highCause Measured current is too high when heater is turned offTrouble shooting

Possible causes:

• Mheat controller defective

• Defective controller module

• Defective contactor

Accompanied alarms:

• AL 800, AL 812, AL 817, AL 821 and AL 828 may also be active.

Trouble shooting:

1. If no accompanied alarms, check contactor K10.Criteria 0.5 Amp if off

Controller action

None





Step ID I limit I1 I2 I3

831 Pmem sensor AlarmDescription Pmem above or below 1000 mBar (+50/-50) after Mpump off for 300 secCause Measure or hardware errorTrouble shooting

Possible causes:

• Pmem defective

Accompanied alarms:

• AL 211, AL 212, and AL 213 may also be active

• AL 214

Trouble shooting:

1. See trouble shooting for accompanied alarms AL 211 and AL 212Criteria Reading out of range. 950 mBar < normal < 1050 mBar

Controller action

None





Step ID Airex motor Pmem CO2 O2

41


832 CO2 sensor AlarmDescription No reading or value above 1%Cause No communication or defective cable or sensorTrouble shooting

Possible causes:

• See AL 740

Accompanied alarms:

• AL 740

Trouble shooting:

1. See trouble shooting for AL 740.Criteria Reading out of range. Normal range 0-1% CO2

Controller action

None






833 O2 sensor AlarmDescription No reading or value is out of rangeCause No communication or defective cable or sensorTrouble shooting

Possible causes:

• See AL 760

Accompanied alarms:

• AL 760

Trouble shooting:

1. See trouble shooting for AL 760.Criteria Reading out of range. Normal 19-22 % O2

Controller action

None






42


834 Mair open AlarmDescription Readings for fresh air valve position is outside specifi ed rangeCause Current too highTrouble shooting

Possible causes:

• Damaged or blocked airex module

Trouble shooting:

1. Check fresh air module and valves for damages.

2. If valves are open, check connections according to wiring schematic.

3. Disconnect SIGNAL wire at X23 and measure voltage between GND and disconnected SIGNAL wire. If below 1.15 V DC replace controller.

4. Mount SIGNAL wire and test Mair in manual mode, open/close.The value measured should be above 4.15 V DC when closed and below 1.15 V DC when open. If not, replace controller.

Criteria Motor potentiometer open 10 - 35 %

Controller action

None






835 Mair closed AlarmDescription Readings for fresh air valve position is outside specifi ed rangeCause Current too highTrouble shooting

Possible causes:

• Damaged or blocked airex module

Trouble shooting:

1. Check fresh air module and valves for damages.

2. If valves are open, check connections according to wiring schematic.

3. Disconnect SIGNAL wire at X23 and measure voltage between GND and disconnected SIGNAL wire. If above 4.15 V DC replace controller.

4. Mount SIGNAL wire and test Mair in manual mode, open/close.The value measured should be above 4.15 V DC when closed and below 1.15 V DC when open. If not, replace controller.

Criteria Motor potentiometer closed 70 - 95 %

Controller action

None






43


836 Pmem vacuum AlarmDescription Unable to create vacuumCause Leakage or low performance vacuum pumpTrouble shooting

Possible causes:


• Pump not running

• Leakage involving membrane, hose and or connections

• Low performance from vacuum pump

Accompanied alarms:

• AL 403, AL 652, AL 654, AL 656 and or AL 838

Trouble shooting:

1. Check if pump is running, if not, see accompanied alarms for trouble shooting fi rst.


a) Check if the bi-metallic switch is connected according to the wire schematic X78 (depending on model)

b) Pushing the contactor in the control cabinet, if the pump is then activated replace controller module. If the pump is not running when pushing the contactor, check contactor and vacuum pump.


a) Perform “Vacuum system test” on page 11Criteria Unable to reach 20 mBar < Pmem < 130 mBar

Controller action

None





Step ID Tpump Pmem CO2 O2

44


837 Pmem ambient AlarmDescription Not measuring Pmem pressure 1000 mBar (-50/+50 mBar)Cause Actual pressure measurement out of rangeTrouble shooting

Possible causes:

• Pmem defective

Accompanied alarms:

• AL 211, AL 212 and or AL 213

Trouble shooting:

1. See trouble shooting for accompanied alarms.Criteria Unable to reach Pmem. 950 mBar < Pmem < 1050 mBar

Controller action

None





Step ID Tpump Pmem CO2 O2

838 Mpump ON current AlarmDescription Current failureCause Uses less or more current than specifi edTrouble shooting

Possible causes:

• Bad power connection or supply

• Jammed or damaged vacuum pump

• Low performance from vacuum pump due to lack of oil

Accompanied alarms:

• AL 654, AL 656 and or AL 836

Trouble shooting:

1. Check oil level.

2. Run pump manually and observe current.If current outside range 0.9 - 1.3 Amp, replace vacuum pump.

Criteria Vacuum pump current is outside its limit 0.9 - 1.3 Amp

Controller action

None





Step ID Ilimit I1 I2 I3

45


839 Mpump OFF current AlarmDescription Current in off position is too highCause Measured current is too high when vacuum pump is turned offTrouble shooting

Possible causes:

• Mpump contactor K9 defective

• Defective controller module.

Accompanied alarms:

• AL 800, AL 812, AL 817, AL 821 and AL 828 may also be active

Trouble shooting:

1. If no accompanied alarms, check contactor K9. If K9 is defective, replace.

Criteria Less than 0.5 Amp

Controller action

None





Step ID Ilimit I1 I2 I3

46


890 PTI Tset 13 AlarmDescription PTI 13°C Set FaultCause Indication of insuffi cient performanceTrouble shooting

Possible causes:

• Doors are open.

• There may not be enough refrigerant in the unit.

• The heaters do not operate correctly.

Accompanied alarms:

• N/A.

Trouble shooting:

1) Verify that the doors are closed.

2) If start temperature was below +5°C, the heaters may be defective.Start the heaters in manual mode and see if the current consumption is higher than 5 A each phase.

3) The unit may be lacking refrigerant. Check if the small red balls in the sight glass in the receiver (receiver tank) are not at the bottom when the unit is turned off.Search for leaks, repair and charge the unit.

Criteria Set-point +13°C was not reached within the 3 hour limit

Controller action

None


Consequence Test failed

Elimination Alarm may then be deleted after test completed


Active/Inactive Tset Tact Tevap Tret

47


Controller alarms (9XX)

977 Pmem sens sup LOW WarningDescription Controller Internal Voltage Reference FaultCause Sensor voltage supply < 4.50 VTrouble shooting

Possible causes:

• Controller defective

Accompanied alarms:

• AL 211, AL 212, AL 213 and or AL 214

Trouble shooting:

1) See Trouble shooting for accompanied alarmsCriteria Voltage < 4.50 V DC

Controller action

None


Consequence Less accurate readings from measurement

Elimination Alarm will be marked as inactive in alarm list when supply voltage is correct. Alarm may then be deleted


Low High Act 0

48


978 Pmem sens sup HIGH WarningDescription Controller Internal Voltage Reference FaultCause Sensor voltage supply > 5.50 VTrouble shooting

Possible causes:

• Defective power supply for main controller

• Defective Pmem pressure transmitter

• Defective main controller

Accompanied alarms:

• AL 213 and or AL 214

Trouble shooting:

1) See Trouble shooting for accompanied alarmsCriteria Voltage > 5.50 V DC

Controller action

None


Consequence Less accurate readings from measurement

Elimination Alarm will be marked as inactive in alarm list when supply voltage is correct. Alarm may then be deleted


Low High Act 0

998 Could not detect CA WarningDescription Uanble to detect CACause Broken communicationTrouble shooting

Possible causes:

• COMCA cable defective (for some models)

• Heating element defective

• Contactors defective K10

• Controler module defective

Accompanied alarms:

• AL 653, AL 740 and or AL 760

Trouble shooting:

1) Check connections according to wire schematic

2) Turn unit off on

3) See Trouble shooting for AL 653Criteria Could not detect CA module in time

Controller action

Cannot run CA mode


Consequence Can not pass CA PTI


Log data


CA mode CA communi-cation

Idle currentsum

Hpump on current sum

49


Controller overview

Displayed overview may vary depending on model

50


TablesVcc = 5VVoltage [V] Pressure [Bar] Pressure [PsiA] Voltage [V] Pressure [Bar] Pressure [PsiA]0* 0.009 0.13 2.55 0.598 8.67

0.05* 0.021 0.30 2.6 0.610 8.84

0.1* 0.032 0.47 2.65 0.621 9.01

0.15* 0.044 0.63 2.7 0.633 9.18

0.2* 0.055 0.80 2.75 0.644 9.34

0.25* 0.067 0.97 2.8 0.656 9.51

0.3* 0.078 1.14 2.85 0.667 9.68

0.35* 0.090 1.30 2.9 0.679 9.85

0.4* 0.101 1.47 2.95 0.690 10.01

0.45* 0.113 1.64 3 0.702 10.18

0.5 0.125 1.81 3.05 0.714 10.35

0.55 0.136 1.97 3.1 0.725 10.52

0.6 0.148 2.14 3.15 0.737 10.68

0.65 0.159 2.31 3.2 0.748 10.85

0.7 0.171 2.48 3.25 0.760 11.02

0.75 0.182 2.64 3.3 0.771 11.19

0.8 0.194 2.81 3.35 0.783 11.35

0.85 0.205 2.98 3.4 0.794 11.52

0.9 0.217 3.15 3.45 0.806 11.69

0.95 0.228 3.31 3.5 0.818 11.86

1 0.240 3.48 3.55 0.829 12.02

1.05 0.252 3.65 3.6 0.841 12.19

1.1 0.263 3.82 3.65 0.852 12.36

1.15 0.275 3.98 3.7 0.864 12.53

1.2 0.286 4.15 3.75 0.875 12.69

1.25 0.298 4.32 3.8 0.887 12.86

1.3 0.309 4.49 3.85 0.898 13.03

1.35 0.321 4.65 3.9 0.910 13.20

1.4 0.332 4.82 3.95 0.921 13.36

1.45 0.344 4.99 4 0.933 13.53

1.5 0.356 5.16 4.05 0.945 13.70

1.55 0.367 5.32 4.1 0.956 13.87

1.6 0.379 5.49 4.15 0.968 14.03

1.65 0.390 5.66 4.2 0.979 14.20

1.7 0.402 5.83 4.25 0.991 14.37

1.75 0.413 5.99 4.3 1.002 14.54

1.8 0.425 6.16 4.35 1.014 14.70

1.85 0.436 6.33 4.4 1.025 14.87

1.9 0.448 6.50 4.45 1.037 15.04

1.95 0.459 6.66 4.5 1.049 15.21

2 0.471 6.83 4.55* 1.060 15.37

2.05 0.483 7.00 4.6* 1.072 15.54

2.1 0.494 7.17 4.65* 1.083 15.71

2.15 0.506 7.33 4.7* 1.095 15.88

2.2 0.517 7.50 4.75* 1.106 16.04

2.25 0.529 7.67 4.8* 1.118 16.21

2.3 0.540 7.84 4.85* 1.129 16.38

2.35 0.552 8.00 4.9* 1.141 16.55

2.4 0.563 8.17 4.95* 1.152 16.71

2.45 0.575 8.34 5* 1.164 16.88

2.5 0.587 8.51

* Range with non-reliable readings

51


52


Overall wiring schematic

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1

GN

D

SIG

NA

L

23 1

2

GN

D

PW

R

3 1

654

V V V

Vexp

Vhg

Veco

B A

Outs

ide C

ontr

oller

Box

Insid

e C

on

troller

Bo

x

2 1B

Outs

ide C

ontr

oller

Box

A

Insid

e C

on

troller

Bo

x

Inside Controller Box

Outside Controller Box

56 24 3 1

56 24 3 1

2 1

2 1

AWG 14

2 1

AWG 16 AWG 16

7 8

2 1

5

6

2

AWG 14

1

5

4

2

3

Y/G

R

6

431

K8

X1

Blu

e o

r G

rey

Me

vap

2 -

7M

evap

2 -

8

CL

3

CL

1

CL

2

CL

3

7

TR3S

4

x2

.5m

m2

[Re

d]

CL

2

CL

1

[White

]

[Re

d]

TR

4

TR

5

K2

TR

3

[Red]

[Re

d]

12V

5

6

GN

D /B A

K3

3

2 4

GN

D

12V

9

RS

23

2R

etr

iever

plu

g in

conta

ine

r

51

/B A

10 8

12V

GN

D

QS

1

GN

D

DD

P

X13

23 1M

1

X21

2 3

V W Z

X12

+5V

X Y

B

U

A

Mcp

r

L1

L2

L3

SIG

NA

L

GN

D

42

L1

L2

L3

5

4x

AW

G12

3

X100

1

6

Tra

fo

FC

-PW

R1 2

T1

3

1 2 3

4

CL

1

CL

2

CL

3

Insid

e C

on

troller

Box

Outs

ide

Co

ntr

olle

r B

ox

A

F1

B

GN

D

2

SIG 5V

X24

L1

2

L3

L2

GN

D

4

SIG

NA

L

GN

D

1

23

1

TR

AF

O T

1A

pp

rox v

olta

ge

sT

erm

ina

l 1-2

: 4

40V

AC

Te

rmin

al 3-4

: 2

7V

AC

Te

rmin

al 5-6

: 2

4V

AC

1 2

GN

D

1

2

3

PW

R

3 1

1

[Red]

7 8

Y/G

R

3

TR

2

TR

1

6

3

2


Inside Controller Box4

51

Y/G

RY

/GR

Bla

ck

21

Bro

wn

Y/G

R3

Overc

urr

en

tan

d M

ain

sw

itch

1 2

PO

WE

R I

N

K1

6

342

51

FC

GN

D

PW

R

3 2 1

PW

R

B A

2 1B A

1

0,4

A

X14

/ON

GN

D

2 1

2 11 2

K5

5 267

M

34 19 810

Mevap

2

Mco

nd

6

3

2 4

51

9x

AW

G1

8

6

FC

-com

LM

Fro

nt

5

GN

D

TX

D

87

Shp

-2

3 41 2 Y/G

R

X15

Shp

-1



DD

M

VB

US

On

/Off

+

3

BT

1

M

12V

NiM

HR

echa

rgea

ble

batt

ery

GN

D

/B

SIG

NA

L

GN

D

H

L1

Pdis

Mp

um

p

L2

L3

Psuc

Hp

um

p

X41

X40

X78

[Blu

e]

K9

[Blu

e]

K1

0

K-G

ND

+5V

GN

D

SIG

NA

L

K10

-

Mhea

t

K9 -

M

pum

p

1 42

A2

3

A1

A1

A2

24 3 1

GN

D

GN

D

SIG

NA

L

24 3

1

1

38

28

Y/G

R

27

37

K7B



GN

D

PW

R

K6

K7



6

5

5

8 37

[Y/G

R]

41

[Y/G

R]

CO

MC

A

4

2

33

Air

2

Air

Ex

1

4

TR4

2

1

5

2R

H

Y/G

R

43

4

1

65 8

2 1

3 741 2

RS

23

2R

etr

iever

plu

g insid

eC

trl B

ox

234 1

234

CL

1

CL

2

1

9x

AW

G1

8

B

X71

1 2

A

RX

TX

2

X72

GN

D

1B A

4 5 6

CL

3

1 32

A2

A1

CO

M

CL

1

CL

2

CL

3

GN

D

X10

TX

D

RX

D

Mco

nd

Me

vap

1

6

3

2

Me

vap

2

4

51

X11

C B

X77

12V

AD

AB

L3

GN

D

L2

L1

ON

12

V

GN

D

28

GN

D AB

Mco

nd

- 7

GN

D

SIG

NA

L

X2

27

Pm

em

X27

PP

me

m

Mco

nd

- 8

K4

37

38

GN

D

SIG

5V

X4

K5B

1

X17

K4

K5

X79

K6

A1

SIG

NA

L

GN

D

A2

A1

A2

GN

D

SIG

NA

L

GN

D

PW

R

X74

A2

Outs

ide C

ontr

olle

r B

ox

A1

Insid

e C

on

troller

Box

K-G

ND

LM

Carg

o

[Blu

e]

[Blu

e]

[Blu

e]

K4 -

M

co

nd

Lo

K6 -

M

evap

Lo

K5 -

M

co

nd

Hi

X75

CO

M

12V

X73

AB GN

D

Mevap

1

32

/B

1 65

A

6

4 7

3

2 4

X70

51

X0

O2

SE

N-

SO

R

GN

D

SIG

NA

L

24 3 1

LM

Fro

nt

L3

L1

L2

M

Air

Moto

r

AC

-IN

AC

-IN

AR

XD

Y/G

R

234 1

234 1

6

3

2

Mp

um

p

4

51

A2

A1


K-G

ND


Hig

h p

ressure

sw

itch

(Norm

ally c

losed

)

12V

GN

D

E

A B

1 32

Tsup

1

Tsup

2

Te

vap

Tsuc

Ta

mb

Mo

torP

os

Air

Ex

CO

MC

A

SMC6MAIN CONTROLLER

GN

D

SIG

NA

L

SIG

NA

L

GN

D

2 1

SIG

NA

L

SIG

NA

L

6

3

2 4

51

He

vap

6-6

B

He

vap

5-6

A

/ON

GN

D

CO

M

SUP6USERPANEL

KE

YP

AD

Insid

e C

on

troller

Box

Co

ntr

olle

r H

atc

h

Insid

e C

on

troller

Box

12

V

X80

10

KE

YP

AD

TR

4

TR

3S

[Blu

e]

K1

[Blu

e]

K2

GN

D

[Blu

e]

K3

A/B

12V

24

CL

1

CL

2

3

/ON

1

CL

3

5

12

V

ABGN

D

ON

K-G

ND

Co

ntr

olle

r H

atc

h

K3 -

H

evap

K2 -

C

W

K1 -

F

C

1 2 3 GN

D

SIG

5V

GN

D

TR

4

TR

3S

GN

D

P P

6

K-G

ND

3

2 4

51

He

vap

2-1

B

He

vap

1-1

A

GN

D

PW

R

Psuc

Pdis

CO

M

M6

X23

5 873 41 2 Y/G

R65 83

Tp

um

p

741 2

9x

AW

G1

8

4 3

Tp

um

p

12

He

vap

5-5

A

He

vap

6-5

B

Y/G

R

He

vap

5-6

A

6

3

He

vap

6-6

B

He

vap

1-1

A

He

vap

2-1

B

2 4

5

He

vap

2-2

B

He

vap

1-2

A

He

vap

4-3

B

He

vap

2-2

B

1

He

vap

4-4

B

He

vap

3-3

A

He

vap

1-2

A

He

vap

3-4

A

GN

D

SIG

NA

L

3 2

+5V

4 1

3

4

24 1

5

55

/PW

R

12

V

RM

M-c

om

PW

R

1

X5

342G

ND

AB

X19

RH

Hevap

GN

D

12

V

SIG

NA

L

GN

D

A2

A1

1 32

SSC6-CASUB CONTROLLER CA

Ta

mb

Tsup

1

Tsup

2

GN

D

SIG 5V

Te

vap

Tsuc

L1

L2

L3

1

3x

AW

G1

8

He

vap

2

SIG

NA

L

GN

D

1

7 852

Y/G

R

2

43

1

1

X18

Mp

um

p -

7M

pum

p -

8

[Blu

e]

K7

GN

D

X20

[Blu

e]

K8

PW

R

GN

D

PW

R

A1

A2

GN

D

TX

D

3 2 1

X8

X22

CL

1

CL

2

CL

3

GN

D

12V

SW

1

X9

FC

-com

AC

-IN

AC

-IN

GN

D4

RM

M-c

om

GN

D

33

TX

RX

21

4 1

2

44 3 1

L1

2

L2

L3

RX

TX

GN

D

M6

C B A

He

vap

4-3

B

He

vap

4-4

B

AWG 16

5

DE

He

vap

3-4

A

He

vap

3-3

A

873 41

GN

D

SIG

NA

L

GN

D

PW

R

2 Y/G

R

/B A

65+

5V

83 741 2

9x

AW

G1

8

GN

D

PW

R

F2

SIG

NA

L

56 2

12V

GN

D

4 3

A2

GN

D AB

1

5

A1

6 24

FC

-com

3 1

Tca

rgo

Tusd

a3

Tusd

a2

Tusd

a1

CO

MC

A

L2

L3

INT

ER

-LO

CK

INT

ER

-L

OC

K

INT

ER

-L

OC

K

53


54


Overall wiring schematic (alternate)

SC

C6

-CA

8

85

15

60

20

2

P/N

: 5

25

15

61

80

1

R

ev:

2.0

Lo

da

m e

lectr

on

ics a

/s

Ove

rall

Wir

ing

Sch

em

atic

Tre

tT

ret

K8

-

CC

W

K7

-

Me

va

p H

i

AW

G 1

4

K9

4 5 6M

oto

rPo

s2

GN

D

K1

0

B A

TR

3S

TR

4

L1

L2

L3

SPM6

POWERMEAS

MODULE

sw

itc

h

L1

L2

L3

Ou

tsid

e C

on

tro

lle

r B

ox

X1

6

[Bla

ck]

1

[Re

d]

X3

3 5

He

va

p6

-5B

He

va

p5

-5A

23 1

2

1

GN

D

SIG

NA

L

3 1

GN

D

PW

R

Vh

g

GN

D

Ve

xp

Ve

co

RX

-TX

+5

V

0,4

A

7 8

RX

D

652

Mco

nd

- 7

Mco

nd

- 8

Y/G

R

56 2

X2

5

431

4 3 1

56 24 3 1

Me

va

p1

- 7

Me

va

p1

- 8

CL

1

CL

2

2 1

CL

3

2 1

B A

GN

D

1

2 1

12

V

GN

D

RM

M 2

4V

AC

RM

M 0

VA

CX

50

(J

5)

Mp

um

p -

7

3

Mp

um

p -

8

2

24

VA

C

0V

AC

X5

1 (

J3

)

57 6 24 3

RX

1

TX

GN

D

RMM - York

Powerline

modem

Y/G

R

X6

3

X5

2 (

J1

)

21G

ND

X7

GN

D

RX

TX

1(G

ND

)

RMM-com

GN

D

TX

RX

GN

D

SIG

NA

L

GN

D

PW

R

L1

L2

SIG

NA

L

GN

D

FC

-co

m

L3

X2

6

Me

va

p2

- 7

Me

va

p1

- 8

Me

va

p1

- 7

LM

Ca

rgo

Me

va

p2

- 8

538

TX

7 4

GN

D

1 2

RX

2 3

US

DA

2

US

DA

3

Ca

rgo

US

DA

1

GN

D

SIG

NA

L

23 1

2

GN

D

PW

R

3 1

654

V V V

Ve

xp

Vh

g

Ve

co

B A

2 1B A



56 24 3 1

56 24 3 1

2 1

2 1

AWG 14

AWG 16 AWG 16

7 8

5

6

2

AWG 14

1

5

4

2

3

Y/G

R

6

431

K8

X1

Blu

e o

r G

rey

Me

va

p2

- 7

Me

va

p2

- 8

CL

3

CL

1

CL

2

CL

3

7

TR3S

4

x2

.5m

m2

[Re

d]

CL

2

CL

1

[Wh

ite

]

[Re

d]

TR

4

TR

5

K2

TR

3

[Red]

[Re

d]

5

6

K3

3

2 4

9

RS

23

2R

etr

ieve

rp

lug

in

co

nta

ine

r

51

10 8

QS

1

GN

D

DD

P

X1

3

23 1M

1

X2

1

2 3

V W Z

X1

2

+5

V

X Y

B

U

A

Mc

pr

L1

L2

L3

SIG

NA

L

GN

D

42

L1

L2

L3

5

4x

AW

G1

2

3

X1

00

1

6

Tra

fo

FC

-PW

R1 2

T1

3

1 2 3

4

CL

1

CL

2

CL

3

Insid

e C

on

tro

lle

r B

ox

Ou

tsid

e

Co

ntr

olle

r B

ox

A

F1

B

GN

D

2

SIG 5V

X2

4

L1

2

L3

L2

GN

D

4

SIG

NA

L

GN

D

1

1

TR

AF

O T

1A

pp

rox v

olta

ge

sT

erm

ina

l 1

-2 :

44

0V

AC

Te

rmin

al 3

-4 :

27

V A

CT

erm

ina

l 5

-6 :

24

V A

C

1 2

GN

D

3

PW

R

1

[Red]

7 8

Y/G

R

3

TR

2

TR

1

6

3

2



51

INT

ER

-L

OC

K

Y/G

RY

/GR

Bla

ck

21

Bro

wn

Y/G

R3

Ove

rcu

rre

nt

an

d M

ain

sw

itc

h1 2

PO

WE

R I

N

K1

6

342

51

FC

GN

D

PW

R

PW

R

B A

2 1B A

1

0,4

A

X1

4

/ON

GN

D

2 1

2 1

K5

5 267

M

34 19 810

Me

va

p 2

Mc

on

d

6

3

2 4

51

9x

AW

G1

8

6

FC

-co

m

LM

Fro

nt

5

GN

D

TX

D

87

Sh

p-2

3 41 2 Y/G

R

X1

5S

hp

-1



DD

M

VB

US

On

/Off

+

3

BT

1

M

12

V N

iMH

Re

ch

arg

ea

ble

ba

tte

ry

GN

D

/B

SIG

NA

L

GN

D

H

L1

Pd

is

Mp

um

p

L2

L3

Psu

c

Hp

um

p

X4

1X

40

1 42 3

24 3 1

GN

D

GN

D

SIG

NA

L

24 3

1

1

38

28

Y/G

R

27

37

K7

B



GN

D

PW

R

K6

K7



5

5

8 37

[Y/G

R]

41 2

Air

Air

Ex

2

TR4

2

5

112

Y/G

R

431

[Blu

e]

K9

65 8

2 1

K9

-

Mp

um

p

A2

3 741 2

A1

K-G

ND

K-G

ND

RS

23

2R

etr

ieve

rp

lug

in

sid

eC

trl B

ox

A1

A2

K1

0 -

M

he

at

CL

1

CL

2

9x

AW

G1

8

B

K1

0[B

lue

]

1 2

A

RX

TX

2

GN

D

1B A

K-G

ND

4 5 6

CL

3

1 32

A2

A1

CO

M

CL

1

INT

ER

-L

OC

K

Pm

em

CL

2

CL

3

GN

D

P

X1

0

TX

D

RX

D

Pm

em

GN

D

SIG

5V

Mco

nd

Me

va

p1

6

3

2

Me

va

p2

4

51

X1

1

C B

12

V

AD

AB

L3

GN

D

L2

L1

ON

1

GN

D

28

2 34

Mco

nd

- 7

GN

D

SIG

NA

L

X2

RH

27

X2

7

Mco

nd

- 8

K4

37

38

X4

K5

B

1

X1

7

K4

K5

K6

A1

SIG

NA

L

GN

D

A2

A1

A2

GN

D

SIG

NA

L

GN

D

PW

R

A2

Ou

tsid

e C

on

tro

lle

r B

ox

A1

Insid

e C

on

tro

lle

r B

ox

K-G

ND

LM

Ca

rgo

[Blu

e]

[Blu

e]

[Blu

e]

K4

-

Mco

nd

Lo

K6

-

Me

va

p L

o

K5

-

Mco

nd

Hi

CO

M

Me

va

p 1

32

/B

1 65

A

6

4 7

3

2 4

51

X0

GN

D

SIG

NA

L

24 3 1

LM FrontL

3

L1

L2

M

Air

Mo

tor

AC

-IN

AC

-IN

AR

XD

Y/G

R

6

3

2

Mp

um

p

4

51

A2

A1


K-G

ND


Hig

h p

ressu

resw

itch

(No

rma

lly c

lose

d)

12

V

GN

D

E

A B

1 32

Tsu

p1

Tsu

p2

Te

va

p

Tsu

c

Ta

mb

Air

Ex

SMC6.1

MAIN CONTROLLER

GN

D

SIG

NA

L

SIG

NA

L

GN

D

2 1

SIG

NA

L

SIG

NA

L

Op

tio

na

l

6

3

2 4

51

25 134

5

He

va

p6

-6B

He

va

p5

-6A

/ON

GN

D

24 1

CO

M

SUP6

USER

PANEL

3

KE

YP

AD

Insid

e C

on

tro

lle

r B

ox

Co

ntr

olle

r H

atc

h

Insid

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Operating and service manual Controlled Atmosphere · PDF file3 Operating and service manual,...

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Transcript of Operating and service manual Controlled Atmosphere · PDF file3 Operating and service manual,...