Carrier Ultra User manual

OPERATOR’S MANUAL
for
Ultra/Ultra XL, Ultima and Solara
Beginning With
S/N HAR90573670
And Extra/Ultra XT
Trailer Refrigeration Units
With
Standard Microprocessors
62--10601 Rev G
Trailer Refrigeration
FAULT
START/STOP
FUNCTION
CHANGE
UNIT
DATA
PRETRIP
CHECK
AUTOS/S
CONTINUOUS
MANUAL
DEFROST
ENTER
SETPOINT BOX TEMPERATURE
-20 34.5° F
STANDBY FAULT
STANDBY
POWER ON
1
0
START/RUN
OFF
STANDBY
ENGINE
R

MANUAL
for
OPERATOR’S
TRAILER
REFRIGERATION UNITS
WITH STANDARD
MICROPROCESSOR

CONTENTS
Page
Safety 1....................................
Unit Identification 2..........................
Unit Operation 4............................
Starting Unit 4..............................
Pretrip Check 8.............................
Changing Setpoint 10........................
Start--Stop Operation 12......................
Continuous Run Operation 14.................
Manual Defrost 16...........................
Function Change 18.........................
Unit Data 20................................
Alarm Display and Reset 22..................
Standby Operation 24........................
Stopping Unit 26............................
Pre--Trip Inspection 28.......................
Product Loading 30..........................
Recommended Transport Temperatures 32.....
Problems 33................................
Fuses 34...................................
Unit Maintenance 35.........................
Unit Maintenance Schedule 36................
Priming Fuel System 39......................
Emergency Road Service 40..................

162--10601
SAFETY
Your Carrier Transicold refrigeration unit has been designed with
the safety of the operator in mind. During all pre-trip inspections,
daily inspections, and problem troubleshooting, you may be
exposedtomovingparts;pleasestayclearofallmovingpartswhen
the unit is in operation and when the Start/Run-Off Switch is in the
START/RUN position.
AUTO-START
YourrefrigerationunitisequippedwithAuto-StartinbothStart/Stop
and Continuous Run modes. The unit may start at any time, a
buzzer will sound for 5 seconds before the unit is started. When
performing any check of the refrigeration unit (e.g., checking the
belts, checking the oil), make certain that the Start/Run-Off Switch
is in the OFF position.
ENGINE COOLANT
The engine is equipped with a pressurized cooling system. Under
normal operating conditions, the coolant in the engine andradiator
isunder highpressureandisvery hot. Contact withhot coolantcan
cause severe burns. Do not remove the cap from a hot radiator; if
the cap must be removed, do so very slowly in order to release the
pressure without spray.
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.
BATTERY
This unit is equipped with a lead-acid type battery. The battery
normally vents small amounts of flammable hydrogen gas. Do not
smoke when checking the battery. A battery explosion can cause
serious physical harm and/or blindness.

2
62--10601
UNIT IDENTIFICATION
Each unit is identified by a decal attached to the frame of the unit.
This decal is on the roadside vertical frame post behind the
roadside side door. This decal 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 decal,
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 they may
properly assist you.

362--10601
Unit
Identification
Decal

4
62--10601
UNIT OPERATION
STARTING UNIT - AUTO
FAULT STAND-BY
START/STOP
FUNCTION
CHANGE
UNIT
DATA PRETRIP
CHECK AUTO S/S
CONTINUOUS MANUAL
DEFROST
ENTER
SETPOINT BOX TEMPERATURE
FAULT
STANDBY
POWER ON
1
0
START/RUN
OFF
STANDBY
ENGINE
8
88
88
88
88
88
88
88
88
88
88
88
88
88
88
88
88
88
8*
**
*
FAULT STAND-BY
START/STOP
FUNCTION
CHANGE
UNIT
DATA PRETRIP
CHECK AUTO S/S
CONTINUOUS MANUAL
DEFROST
ENTER
SETPOINT BOX TEMPERATURE
FAULT
STANDBY
POWER ON
1
0
START/RUN
OFF
STANDBY
ENGINE
-
--
-2
22
20
00
0....0
00
03
33
34
44
4....5
55
5°
°°
°F
FF
F
1. Place the START/RUN - OFF switch to
START/RUN position.
DISPLAY
SELF TEST

562--10601
The microprocessor controller will run a self test. All of the mode
lights will light, all of the segments on the display will be turned on.
The display will then show the setpoint temperature on the left and
the box temperature of the trailer on the right. The last character
(after the degree symbol) shows the temperature units as F
(Fahrenheit) or C (Celsius).
If the unit is in Auto Start/Stop mode or Continuous Run/Auto
Operation mode, the glow plugs will energize, the buzzer will
sound, and the diesel engine will start.
If the unit is set for Continuous Run/Manual Operation mode, the
unit must be started manually.
WARNING
Under no circumstances should ether or any other
starting aids be used to start engine.
The microprocessor controller monitors box temperature, battery
voltage, and engine coolant temperature. Once the setpoint is
reached the controller will shut off the diesel engine to conserve
fuel. The controller will not shut off the engine if the battery voltage
is not sufficient to restart it.
The controller will restart the engine if any of the following criteria
have been met:
SBox temperature has changed by ¦11°F(¦6.1°C)for setpoints
in the perishable range and +11°F(+6.1°C) for setpoints in the
frozen range DURING minimum off time.
SBox temperature has moved away from setpoint by ¦3.6°F
(2.0°C) AFTER minimum off time for setpoints in the perishable
range or +3.6°F(2.0°C) for setpoints in the frozen range.
SThe battery voltage drops below 11 Vdc (12.2 Vdc for units with
EEPROM Rev 3.25 and higher -- Refer to Page 21 for unit data).
SThe engine coolant temperature drops below 34°F(1°C).

6
62--10601
STARTING UNIT - MANUAL (CONTINUOUS RUN ONLY)
FAULT STAND-BY
FUNCTION
CHANGE
UNIT
DATA PRETRIP
CHECK AUTO S/S
CONTINUOUS MANUAL
DEFROST
ENTER
SETPOINT BOX TEMPERATURE
FAULT
STANDBY
POWER ON
1
0
START/RUN
OFF
STANDBY
ENGINE
M
MM
MA
AA
AN
NN
NO
OO
OP
PP
P
Side of Control Box
4. Hold GLOW/CRANK switch in the GLOW position for
5 to 15 seconds (see chart on next page). Then hold
the GLOW/CRANK switch in the CRANK position for
up to 10 seconds to start the diesel engine.
1. Place ST
A
RT
/
RUN - OFF switch to the ST
A
RT
/
RUN
position. If START/STOP is displayed, press AUTO
S/S-CONTINUOUS toggle key to place unit in Continuous
Run Mode .
2. Press FUNCTION CHANGE key until AUTO OP or
MAN OP is displayed. If MAN OP appears, unit is in
manual start mode.
3. If AUTO OP appears, first press ENTER key, then
UP or DOWN arrow key until MAN OP is displayed.
Press ENTER key to lock in manual mode.
5. With MAN OP selected, press
AUTO S/S-CONTINUOUS key
to toggle between Auto
Start-Stop and Manual
Start/Continuous Run modes.

762--10601
Glow Time
Engine Coolant Temperature Glow Time in Seconds
Engine Coolant Temperature TV/Short
(Default) DI/ Long
Less than 32_F(0_C) 15 55
33_Fto50_F(1_Cto10_C) 10 40
51_Fto77_F(11_Cto25_C) 525
Greater than 78_F(26_C) 010
NOTE: When the unit is in Continuous Run mode and set
for Manual Operation, the unit must be started manually
WARNING
Under no circumstances should ether or any other
starting aids be used to start engine.

8
62--10601
PRETRIP CHECK 1.
FAULT STAND-BY
COOL
FUNCTION
CHANGE
UNIT
DATA PRETRIP
CHECK AUTO S/S
CONTINUOUS MANUAL
DEFROST
ENTER
SETPOINT BOX TEMPERATURE
FAULT
STANDBY
POWER ON
1
0
START/RUN
OFF
STANDBY
ENGINE
P
PP
PP
PP
PP
PP
PP
PP
P
2. Press PRETRIP CHECK key to start
PRETRIP. “PPPP” will appear on the display.
1. Start and run unit until box
temperature is 40_F(
4.4°C)or
lower.

962--10601
The PRETRIP mode is for checking unit operation and evaluating
operation of all modes. The unit will cycle thru all modes of
operation at 30 second intervals. When Pretrip is complete, Pretrip
mode is terminated and the unit returns to normal operation.
The final PRETRIP mode is Defrost. When Defrost ends,
PRETRIP will be complete.
This is not a self-diagnosing pretrip test. No specific pretrip alarms
will be generated. Pretrip must be monitored by the user to verify
that the unit operates through all cycles.
See Page 28 for more information on Pretrip.

10
62--10601
CHANGING SETPOINT
FAULT STAND-BY
FUNCTION
CHANGE
UNIT
DATA PRETRIP
CHECK AUTO S/S
CONTINUOUS MANUAL
DEFROST
ENTER
SETPOINT BOX TEMPERATURE
FAULT
STANDBY
POWER ON
1
0
START/RUN
OFF
STANDBY
ENGINE
-
--
-2
22
20
00
0....0
00
03
33
34
44
4....5
55
5°
°°
°F
FF
F
Press ENTER key when desired setpoint is
displayed to lock in new setpoint.
New setpoint will flash and then return to original
setpoint if ENTER key is not pressed.
Press UP arrow key to increase displayed
setpoint.
Press DOWN arrow key to decrease
displayed setpoint.

11 62--10601
Setpoints of -22°Fto+89°F (-30°Cto+32°C) may be entered via
the keypad. The controller always retains the last entered setpoint
in memory. If no setpoint is in memory (i.e. on initial startup), the
controller will lock out the run relay and flash “SP” on the left hand
display until a valid setpoint is entered. The setpoint may be
changed up or down in 1°increments by pressing and releasing
either the UP ARROW or DOWN ARROW key.
Youcannot change setpoint whenunit is in Pretrip or whenviewing
Unit Data or Functional Parameters.
Pressing the ENTER key will cause the new displayed setpoint
value to become active. If the display is flashing and the new value
is not entered, after 5 seconds of no keyboard activity, the display
will flash for 5 seconds and then revert back to the last setpoint.
All other keys are active at this time and may be pushed while the
display is flashing.

12
62--10601
START-STOP OPERATION
FAULT STAND-BY
START/STOP
FUNCTION
CHANGE
UNIT
DATA PRETRIP
CHECK AUTO S/S
CONTINUOUS MANUAL
DEFROST
ENTER
SETPOINT BOX TEMPERATURE
FAULT
STANDBY
POWER ON
1
0
START/RUN
OFF
STANDBY
ENGINE
-
--
-2
22
20
00
0....0
00
03
33
34
44
4....5
55
5°
°°
°F
FF
F
1. Press the AUTO S/S-CONTINUOUS
toggle key until START-STOP is
displayed. Unit is now in Automatic
Start/Stop mode.
START/STOP
Automatic start/stop is provided to permit starting/restarting of the
diesel-driven compressor as required. This gives the
microprocessor automatic control of starting and stopping the
diesel engine. The main function of automatic start-stop is to turn
off the refrigeration system near the setpoint to provide a fuel
efficient temperature control system and then restart the engine
when needed. Start-Stop operation is normally used for frozen
loads.RefertoRECOMMENDED TRANSPORT TEMPERATURES (SeePage
32).

13 62--10601
The unit will remain in low speed after engine start-up - 5 minutes
for XT products, 10 minutes for all others. If the unit fails to start,
shuts down on a safety, or fails to run for the minimum run time,
three consecutive times, the fault light is on.
Low speed Start--up for low coolant temperatures is available on
Configuration7 for all units except those with EEPROM REV3.23
and 3.24 -- Refer to Page 21 for unit data.
The microprocessor controller monitors box temperature, battery
voltage, and engine coolant temperature.
Whenever the unit starts in Start--Stop, it will run until:
SIt has run for the predetermined minimum run time.
SThe engine coolant temperature is above 122°F(50°C)
SThe box temperature is at setpoint.
The controller willnot shut offtheengine ifthe battery voltage is not
sufficient to restart it. Battery voltage above approximately 13.4
volts is required for shutdown. This varies depending on ambient.
Look at battery voltage in data list to find out whether shutdown
voltage has been reached. If there is a “+” in front of the number,
the voltage is enough to shutdown and restart. If only the number
appears, the voltage is still too low for shutdown.
The controller will restart the engine if any of the following criteria
have been met:
SBox temperature has changed by ¦11°F(¦6.1°C)for setpoints
in the perishable range and +11°F(+6.1°C) for setpoints in the
frozen range DURING minimum off time.
SBox temperature has moved away from setpoint by ¦3.6°F
(2.0°C) AFTER minimum off time for setpoints in the perishable
range or +0.5°F(0.3°C) for setpoints in the frozen range.
SThe battery voltage drops below 11 Vdc (12.2 Vdc for units with
EEPROM Rev 3.25 and higher -- Refer to Page 21 for unit data).
SThe engine coolant temperature drops below 34°F(1°C).

14
62--10601
CONTINUOUS RUN OPERATION
FAULT STAND-BY
FUNCTION
CHANGE
UNIT
DATA PRETRIP
CHECK AUTO S/S
CONTINUOUS MANUAL
DEFROST
ENTER
SETPOINT BOX TEMPERATURE
FAULT
STANDBY
POWER ON
1
0
START/RUN
OFF
STANDBY
ENGINE
-
--
-2
22
20
00
0....0
00
03
33
34
44
4....5
55
5°
°°
°F
FF
F
START/STOP Must Not Be Displayed
1. Check if START-STOP is displayed. If it
is, press the AUTO S/S-CONTINUOUS
toggle key to place unit in Continuous
Run mode.

15 62--10601
In the Continuous Run mode, the diesel engine will run
continuously providing constant air flow andtemperature control to
the product. Continuous Run operation is normally used for
perishableloads.RefertoRECOMMENDED TRANSPORT TEMPERATURES
(See Page 32).
Start-Stop and Continuous operation may be tied to the setpoint
ranges for frozen and perishable loads and the
START-STOP/CONTINUOUS key may be locked out.
The unit will remain in low speed - 5 minutes for XT products, 10
minutes for all others, after engine start-up when the Continuous
Run setpoint is below 10°F (-12°C).

16
62--10601
MANUAL DEFROST
FAULT STAND-BY
DEFROST
FUNCTION
CHANGE
UNIT
DATA PRETRIP
CHECK AUTO S/S
CONTINUOUS MANUAL
DEFROST
ENTER
SETPOINT BOX TEMPERATURE
FAULT
STANDBY
POWER ON
1
0
START/RUN
OFF
STANDBY
ENGINE
-
--
-2
22
20
00
0....0
00
03
33
34
44
4....5
55
5°
°°
°F
FF
F
DEFROST Indicator
2. Press the MANUAL DEFROST key to
initiate Manual Defrost.
1. Check that box temperature
is 40_F(
4.4°C)orlower.
NOTE: Defrost cannot be started when the Evaporator
Coil temperature is above 40°F(4.4°C).

17 62--10601
The defrost mode may be initiated in three different ways if the
evaporator coil is below 40°F(4.4°C):
1. Defrost is initiated automatically at preset intervals by the
defrost timer in the microprocessor.
2. Defrost is initiated by the defrost air switch.
3. The defrost mode may be manually initiated by pressing the
Manual Defrost Key.
The defrost mode terminates when the evaporator temperature is
higher than 55°F (12.8°C). Should the defrost cycle not complete
within 45 minutes, the defrost cycle is terminated.
After the 45 minute termination, the controller will wait 1.5 hours
before attempting another defrost cycle. Pressing the manual
defrost key will override this mode and start a defrost cycle.
If a shutdown alarm occurs, defrost will be terminated.