TRUCK REFRIGERATION UNIT Integra 40S Integra 50S
Contents
1. Carrier Transicold Truck Refngeration Integra 40S Integra 50S Operator s Manual Carrier Gu TRANSICOLD i OPERATOR S MANUAL TRUCK REFRIGERATION UNIT Integra 40S Integra 50S Carrier Transicold A member of the United Technologies Corporation family Stock symbol UTX Carrier Transicold Division Carrier Corporation P O Box 4805 Syracuse N Y 13221 U S A Carrier Corporation 2003 D Printed in U S A 0703 Z Carrier A United Technologies Company Integra 40 50s OPERATOR S MANUAL This guide has been prepared for the operator of Carrier Transicold truck refrigeration units It contains basic instructions for the daily operation of the refrigeration unit as well as safety information and other information that will help you to deliver the load in the best possible condition Please take the time to read the information contained in this booklet and refer to it whenever you have a question about the operation of your Carrier Transicold Integra 40 505 unit Your refrigeration unit has been engineered to provide long trouble free performance when it is properly operated and maintained A comprehensive maintenance program will help to insure that the unit continues to operate reliably Such a maintenance program will also help to control operating costs increase the unit s working life and improve performance This guide is intended as an introduction to your unitand to provide g2. condition remains 18 STANDBY OPERATION GUIDELINES For safe reliable operation in Standby mode it is important to follow a few guidelines D Always check that the unit is OFF Cab Command before connecting or disconnecting the unit from power source D The circuit breaker and power cord used for Standby operation must comply with legislation currently applicable on site of use and with unit specifications in table below Maximum Unit Operating Amperage 230V Single phase 60 hz 24A 230V Three phase 60 hz 14A 230V Single phase 60 hz 25A 230V Three phase 60 hz 15A Unit Operating Voltage Integra 40S Integra 50S Power Cord Length and Wire Gage Voltage 230 1 60 208 1 60 230 3 60 D When multiple units are in use each unit must be operated on its own electrical circuit You should never operate more than one unit on a circuit breaker Important note This information is provided as a guideline only When preparing a circuit for operation of the refrigeration unit a licensed electrician should be contracted A licensed electrician is familiar with all local ordinances and special requirements for your area and can ensure that the circuits are properly designed installed and connections are correct 19 FUSES To access the road and standby fuses remove the left side cover fastened by 4 screws Note See Fuse Table for Item Number 230 60 hz 230 60 hz
3. this unitis equipped with brushless fan motors which don t need to be maintained 23 EMERGENCY RoAD SERVICE At Carrier Transicold we re working hard to give you complete service when and where you need it That means a worldwide network of dealers that offer 24 hour emergency service These service centers are manned by factory trained service personnel and backed by extensive parts inventories that will assure you of prompt repair Should you experience a unit problem with your refrigeration unit during transit follow your company s emergency procedure or contact the nearest Carrier Transicold service center Consult the Shortstop Service Centers directory to locate the service center nearest you This directory may be obtained from your Carrier Transicold dealer If you are unable to reach a Service Center call our 24 hour Action Line 800 448 1661 When calling please have the following information ready for fastest service S Your name the name of your company and your location S A telephone number where you can be called back S Refrigeration unit model number and serial number S Box temperature set point and product Brief description of the problem you are having and what you have already done to correct the problem We will do everything we can to get your problem taken care of and get you back on the road 24 Index A Alarm Display 16 Alarm List 17 Alarm Reset 18 C Changing Display Brig
4. 3ph 1 ph Road Supply Fuse 50 A 50 A Standby Supply Fuse a 50A 50A Main Standby Fuse FB x3 16A 12A Main Standby Fuse FB x3 20A 16A Heating Resistor Fuses F4 F5 F6 6 3A 3 15 A Transformer Primary Fuses F1 F 2 F3 3 15A 2A Main Road Fuse 4 60A 60A a On road standby unit only b If located in standby box c If located in standby plug not shown d Not shown this fuse is located close to the vehicle battery 12 v Purpose E 2 1 2 3 4 5 6 7 RR A 20 To access the fuses in the control box remove the left side cover then open the control box fastened by 4 screws With Electrical Heating Option 21 Unit MAINTENANCE WARNING Before working on unit check that D the unit cab command is OFF D itis impossible for unit to automatically start up during maintenance Refrigerant Charge R404A 6 lbs Integra 40S 6 5 lbs Integra 50S Compressor oil Oil Charge Approved 01 Road Standby Mobil Arctic EAL 68 250cc 53 pint 1200cc 2 5 pint For the most reliable operation and for maximum life your unit requires regular main
5. anually by pressing the OFF key on the Cab Command STARTING ENGINE OPERATION 1 Press ON key Start up is time delayed for 40 seconds 2 Check if box temperature is displayed 3 Check if road operation light is on NOTE If standby power cord is plugged in the unit will run in standby mode STARTING STANDBY OPERATION U SET 2 SSS 1 Press the OFF key and plug in power supply 2 Press the ON key Start up is time delayed for 40 seconds 3 Check that the standby operation light is on TEMPERATURE SETPOINT TRANSICOLD 1 Press SET key 2 Press plus key to increase setpoint or press minus key to decrease setpoint 3 Press SET key when desired setpoint is displayed to lock in new setpoint MANUAL DEFROST 1 Check that box temperature is 40 F or lower 2 Press Manual Defrost key to initiate manual defrost STOPPING UNIT TRANSICOLD 1 Press the OFF key DEFROST INTERVAL Defrost interval in hours 1H 2H 3H 4H 5H amp 6H AUT microprocessor optimized automatic defrost according to type of cargo 1 Press the OFF key 2 Press Defrostand ON key to display the previously selected defrost interval 3 Press minus or plus key to select defrost interval 4 Press SET key to validate modified value 10 CHANGING DisPLAY BRIGHTNESS 1 Press ON key 2 Press within 5 seco
6. eneral assistance when needed More comprehensive information can be found in the Operation and Service Manual for your unit This manual can be obtained from your Carrier Transicold dealer When having your unitserviced be sure to specify genuine Carrier Transicold replacement parts for the highest quality and best reliability At Carrier Transicold we are continually working to improve the products that we build for our customers As a result specifications may change without notice CONTENTS Page Salely ia eine A AE AAA RARE 1 Unit Identification 0 cece eee ees 2 Symbols used on Cab Control 4 Unit Operation eee 5 Product Loading 0c cece eens 13 Recommended Transport Temperatures 14 Problems amp Alarms ccc cece e eens 15 Standby Operation Guidelines 19 FUSS ich aan ak A ostro sn 20 Unit Maintenance 0 ccc cece eee ees 22 Emergency Road Service 24 SAFETY Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind During normal operation all moving parts are fully enclosed to help prevent injury During all pre trip inspections daily inspections and problem troubleshooting you may be exposed to moving parts please stay clear of all moving parts when the unit is in operation WARNING Beware of unannounced starting of the fans caused by the thermostat and the star
7. htness 11 Continuous Airflow 12 D Defrost Interval 10 Emergency Road Service 24 Emergency Switch 1 F Fuses 20 M Manual Defrost 9 Minimum M aximum Setpoint 12 0 Operating principle 5 Out of Range 12 P Problems 15 Product Loading 13 R Recommended Transport Temperatures 14 Refrigerants 1 S Safety 1 Setpoint 8 Standby Operation G uidelines 19 Starting Engine Operation 6 Starting Standby Operation 7 Stopping Unit 9 Symbols used on Cab Control 4 T Temperature Setpoint 8 U Unit Identification 2 Unit Maintenance 22 Unit Operation 5 Index 1
8. is will remove moisture accumulated on the evaporator coil DURING LOADING D Turn the unit off D Check product temperature during loading D Ensure that the air return and supply opening remain unobstructed D Leave approximately 4 to 5 inches between the load and the front wall for air return to the unit D Leave at least 10 to 12 inches between the top of the load and the ceiling to ensure that there is nothing to prevent airflow to the rear of the body D Load product on pallets to provide free air return to unit and improve product protection Proper air circulation in the truck body air that can move around and through the load is a critical element in maintaining product quality during transport If air cannot circulate completely around the load hot spots or top freeze can occur The use of pallets is highly recommended Pallets when loaded so air can flow freely through the pallets to return to the evaporator help protect the product from heat passing through the floor of the truck When using pallets it is important to refrain from stacking extra boxes on the floor at the rear of the truck this will cut off the airflow Product stacking is another important factor in protecting the product Products that generate heat fruits and vegetables for example should be stacked so the aircan flow through the product to remove the heat this is called air stacking the product Products that do not create heat mea
9. nds the plus or minus key to increase or decrease display brightness 11 Minimu M MAXIMUM SETPOINT OuT OF RANGE AND CONTINUOUS AIRFLOW Minimum Setpoint Settings 32 F 0 C or 20 F 29 C Maximum Setpoint Settings 68 F 20 C or 86 F 30 C Out of Rang Settings 1 2 or 3 C 3 6 5 4 or 7 2 F Continuous Airflow Settings F ON or F OFF 1 Turn unit on and Press plus key z Press minus key 3 Press Defrost key 4 Check that the light flashes green 5 The operator can select a Minimum Setpoint The selections are 32 F 0 C or 20 F 29 C Press plus key or minus key to change setting 6 Press SET key to save setting Next Maximum Setpoint setting will appear 7 Press plus key to increase Maximum Setpoint setting Press minus key to decrease setting 8 Press SET key to save Maximum Setpoint setting 9 Next setting is Out of Range Press plus key to increase Out of Range setting Press minus key to decrease setting 10 Next setting is Continuous Airflow This is select able to fan on or fan off at setpoint Press plus or minus key to select desired operating mode Press SET key to save fan mode setting 12 PRODUCT LOADING BEFORE LOADING D Pre cool the body This will remove much of the heat from the inside of the body and give the product better protection when itis loaded D Place the unitin a defrostcycle immediately before loading Th
10. t stop cycling of the unit REFRIGERANTS The refrigerant contained in the refrigeration system of your unit can cause frostbite severe burns or blindness when in direct contact with the skin or eyes For this reason and because of legislation regarding the handling of refrigerants during system service we recommend that whenever your unit requires service of the refrigeration system you contact your nearest Carrier Transicold authorized repair facility for service EMERGENCY SWITCH D The unit can be completely shut down manually by the emergency switch inside the frame of the condenser unit The emergency switch has to be reinitiated to allow the unit to restart with the ON key of the cab command Emergency Switch UNIT IDENTIFICATION Integra 40S 50S unit is identified by a nameplate attached to the frame of the unit This nameplate identifies the complete model number of the unit the serial number the refrigerant charge and quantity and the date the unit was placed in service If a problem occurs please refer to the information on this plate and make a note of the model and serial number before calling for assistance This information will be needed when you contact a technician or Carrier Transicold Service Engineer so that he or she may properly assist you nameplate e mmuoo27 Evaporator Condenser Cab control Compressor mounting kit Vehicle battery Standby plug Main road f
11. ted but are now not active 16 ALARM LIST ALARM DESCRIPTION No Malfunction Low Pressure Switch Open High Pressure Switch Open Standby Compressor Over Heated Road Compressor Clutch Standby Contactor high amps draw Condenser Fan Motor high amps draw Fan Speed Alarm Hot Water Solenoid high amps draw Hot Gas Valve HGS1 high amps draw Liquid Injection Valve high amps draw Condenser Closing Valve HGS2 Out of Range High Temperature Out of Range Low Temperature Defrost Cycle 245 minutes Setpoint out of range 20 F to 86 F Drain Water Resistor Heater DWR1 Standby Compressor or Diode Overload Electrical Heating Relay high amps draw Liquid Solenoid Valve high amps draw Standby Low P ressure Switch Open Compressor Contactor Open Condenser Fan Motor Open Circuit Hot Water Solenoid Open Circuit Hot Gas Valve HGS1 Open Circuit Liquid Injection Valve Open Circuit Hot Gas Valve HGS2 Open Circuit Drain Water Resistor DWR 1 Open Circuit Heating Relay EHR Open Circuit Return Air Sensor Low Battery Voltage Using Road amp Standby Compressors atthe Same Time Programming mistake of maximum setpoint by user Setpoint lower than maximum setpoint but in the range 20_F to 86 F ALARM RESET TRANSICOLD 1 Press the OFF key to clear Active Alarm list Unit can now be restarted if no Active Alarm
12. tenance Maintenance should be performed on the following schedule 100 1000 2000 3000 4000 5000 6000 7000 EER a ee RE PEN RENTENE NE FETE ae se a pen ESA 22 SERVICE A SERVICE B SERVICE C SERVICE D Service Schedule S Check the tension of the alternator belt s S Check that the vehicle engine runs correctly at low speed and that the compressor kit is correctly tightened belt tension S Check the tightness of bolts and screws and that the unit is correctly fastened onto the box S Clean the condenser and the evaporator S Replace the Road compressor belt S Replace the filter drier S Clean the TXV or fice filter S Check the standby compressor oil level S Check the operation of the cab control S Check the defrost Cut in Fanshut down Cut out Defrost water drain S Check the water tighness of the emergency switch cap S Check the bearings of the belt tension pulleys and bearing of the mechanics kit Change the spring if there is one S Change the shockmounts if any installed on the road compressor mounting kit S Check the operation of the evaporator and condenser fans Change the condenser motor brushes S Change the compressor oil Only use Ester oil POE approved by CARRIER See the technical information sheets for the recommended quantities and types of oil S Change the removable fuses and capacitor if any in the control box Note The evaporator of
13. ts and frozen products should be stacked tightly in the center of the trailer 13 All products should be kept away from the side walls of the body to allow air flow between the body and the load this prevents heat filtering through the walls from affecting the product Itis importantto check the temperature ofthe product being loaded to ensure that it is at the correct temperature for transport The refrigeration unit is designed to maintain the temperature of the product at the temperature at which it was loaded it was not designed to cool warm product RECOMMENDED TRANSPORT TEMPERATURES Below are some general recommendations on product transport temperatures and operating modes for the unit These are included for reference only and should not be considered preemptive of the set point required by the shipper or receiver More detailed information can be obtained from your Carrier Transicold dealer Setpoint Range F C Bananas 56 to 58 13 to 14 Product Fresh fruits and vegetables 33 to 38 0 5 to 3 Fresh meats and seafood 28 to 32 2to 0 Dairy P roducts 33 to 38 0 5 to 3 Ice 15to20 10to 7 Frozen fruits and vegetables 10to0 23 to 18 Frozen meats and seafood 10to0 23 to 18 Ice Cream 20 to 15 29 to 26 During delivery cycles that include frequent stops and door openings it is recommended that the unit be turned off during the time the body doors are open to help conser
14. use SYMBOLS USED ON CAB CONTROL 2 0 P g B amp co m F XX Readout Standby operation display Road operation display Manual defrost control key Unit start up key Unit shut down key Data selection key Selected data decrement key Selected data increment key Unit operation display SGreen in range left half SRed malfunction right half TRANSICOLD Unit OPERATION OPERATING PRINCIPLE After starting up the refrigeration unitby pressing the ON key on the Cab Command unit start up and shut down are automatic S On Road operation an open type compressor is driven by the engine of the vehicle The vehicle battery powers the evaporator and condenser fans The unit automatically shuts down when the engine is switched off with the ignition key S On Standby a standby compressor is energized and a transformer is used to power the evaporator and condenser fans The power network connection is detected by the Cab Command which automatically starts up the unit in Standby mode S Ifthe ignition key is switched on while the unit is connected to the power network or vice versa the Cab Command triggers a visual alarm in the form of a flashing red malfunction light and readout In this case the unit will start in road operating mode As soon as one operating mode is inhibited the unit automatically starts up in the other mode S Inallcases the unitcan be completely shutdown m
15. ve the product temperature Variations may be necessary for very high or very low ambient temperatures 14 PROBLEMS amp ALARMS Everything possible has been done to ensure that your unit is the most reliable trouble free equipment available today If however you run into problems the following section may be of assistance If you do not find the trouble that you have experienced listed please call your Carrier Transicold dealer for assistance General Problems Unit won t power Check battery condition up Check battery connections Check all fuses Unit won t start Check all fuses Unit won t run Check all fuses Unit shut down Check alarm codes Unit not cooling Check minimum setpoint setting see page 12 properly Defrost unit Check evaporator for airflow restriction Check condenser for airflow restriction Check body for damage or air leaks Check product is loaded properly Check refrigerant charge 15 ALARM DISPLAY 1 When an Alarm is activated the light flashes red The light flashes green when the unit is operating correctly 2 Press the SET key for 5 seconds to display alarms 3 Press or key to view additional alarms 4 Press SET key to return to box temperature display NOTE There are two types of Alarms Axx example A02 P xx example P 02 Axx Designates Active Alarms Pxx Designates Past Alarms These are Alarm conditions that exis
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