Cooltrax UMD V3 User manual

Cooltrax Asia Pacific Pty Ltd
138b Thistlethwaite Street, South Melbourne VIC 3205
Phone: [phone] Fax: [phone]
ABN: 42 083 280 040
Version 4.4 One Way Interface Jan 2013

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Table of Contents:
Table of Contents:................................................................................................................................................... 2
UMD Installation V3: With Remote Control ........................................................................................................... 3
Standard System Kit of Parts: ......................................................................................................................... 3
Maintenance Box Kit:...................................................................................................................................... 4
Third Party Protocol Upgrade Components: .................................................................................................. 4
Hardware Installation Instructions Key Points: .................................................................................................. 5
Considerations When Installing or Servicing a Cooltrax Unit:............................................................................ 6
UMD Installation Initial Setup: .......................................................................................................................... 7
First Step –Install Antenna’s: ............................................................................................................................. 7
RF Antenna:......................................................................................................................................................... 8
RF Antenna Installation –Physical Location Inside the Trailer:...................................................................... 9
Low Profile Perspex Backed RF Antenna. ..................................................................................................... 10
Installing the UMD ............................................................................................................................................ 11
The Fridge Interface Cable:........................................................................................................................... 12
Carrier Controller Setup.................................................................................................................................... 13
Powering Up the System for the First Time:..................................................................................................... 14
Diagnostic Tests: ............................................................................................................................................... 15
Wireless Tag Installation:.................................................................................................................................. 16
Post Installation: ........................................................................................................................................... 20
Specifications: ....................................................................................................................................................... 21
FCC Compliance: ........................................................................................................................................... 23
APPENDIX A: Upgrading a Carrier ePROM Chip.................................................................................................... 24
APPENDIX B: Conditions for Making a Warranty Claim........................................................................................ 25
APPENDIX C: Installation Flow Chart .................................................................................................................... 26
APPENDIX D: Trouble-Shooting Tips and Tricks.................................................................................................... 27
APPENDIX E: Reversing the Wiring Between Serial and Data Ports ..................................................................... 31
APPENDIX F: SUPRA 850/950 INSTALLATION ....................................................................................................... 34
UMD Location: .............................................................................................................................................. 34
Antenna Location.......................................................................................................................................... 35
Fridge Interface Cable:.................................................................................................................................. 36

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Power Cable Connection:.............................................................................................................................. 36
APPENDIX G: INSTALLATION ADVICE.................................................................................................................... 38
UMD Installation V3: With Remote Control
Standard System Kit of Parts:
1. Universal Monitoring Device (UMD).
2. 3G/GSM Antenna
3. GPS Antenna
4. RF Temperature Tags –if required by the customer
5. RF Door Tag and Magnet –if required by the customer
6. RF Low Profile Antenna
7. 3m Carrier Interface Cable
8. One 1.5M UMD Power Cable.
9. Mounting Plate for UMD - optional

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Maintenance Box Kit:
1. Maintenance Box
2. Maintenance Box Harness
3. Reset Switch
Please note that the V3 UMD and Maintenance Box will be supplied with a specially made installation plate.
This plate has been designed to be easily mounted on the reefer frame for both X2500 and Vector reefer units.
Third Party Protocol Upgrade Components:
With the Carrier Fridge interface the following additional components are required.
1. Carrier ePROM for fridge units with Standard Controller
2. Data Card Option for fridge units with an Advanced Controller
Note: Check the controller type of the fridge to which the UMD is being installed as Standard Controllers
require an ePROM and Advanced Controllers require a Datacard download to enable 3rd party Protocols.
EPROM Revisions:
1. Standard Controller One way only - Revision 3.32
2. Standard Controller with 2-Way Remote Control capability - Revision 3.38
3. Standard Controller Multi-temp - Revision 4.12
Picture 1: UMD System Kit

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Hardware Installation Instructions Key Points:
The following Hardware Installation Instructions must be read in conjunction with the detailed information
that follows in the Cooltrax Hardware Installation Manual. The “Hardware” refers specifically to the Cooltrax
UMD and Wireless Tags.
NOTE: Failure to comply with these instructions will void the Hardware warranty.
1) The Hardware must be positioned:
a) in a suitable location where it is not directly exposed to outside weather elements;
b) where it is not directly exposed to any water or other liquids including water emissions from the
internal workings of refrigeration unit;
c) where it is not directly exposed to excessive heat, dirt or grease;
d) in a horizontal alignment where the UMD the LTW connectors are at the top
2) All cables must be:
a) enclosed in split tubing up to 150mm from the connectors at each end of the cable;
b) kept away from heat sources;
c) of sufficient length so that there is no tension or kinking applied to the cables.
3) All connectors must be locked into place and tested to ensure they will not come loose.
a) For the UMD the LTW black connectors with locking sleeve require a quarter-turn
4) Fixing screws are supplied with the UMD. Do not drill out mounting holes for larger screws as this may
pierce the internal seal and will void warranty.

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5) All installations must be fully validated by Cooltrax Support before the asset leaves the installation
location. Cooltrax will not be liable for costs incurred through the asset being recalled for validation at
a later time.
6) No Cooltrax Hardware or component is to be replaced without consultation and agreement from a
Cooltrax support staff member.
7) Hardware must not be opened outside of the Cooltrax Office.
Considerations When Installing or Servicing a Cooltrax Unit:
Temperature Increases Within the Trailer :
The Reefer unit MUST be turned off when installing or conducting maintenance on A Cooltrax
Unit, this will lead to increased temperatures within the trailer and if the trailer is loaded the
goods may be damaged. Always give due consideration to the temperature within the trailer,
Cooltrax will not be held responsible for any spoiled contents.
Warning Risk of Electrical Shock:
Always remove the battery cable from the negative terminal followed by the cable from the
positive terminal prior to commencing an installation or service of Cooltrax hardware. There is
danger of exposure to high electrical energy during installation procedures highlighted in this
manual and a risk of shock or injury. Only trained Technical staff should install service or
maintain Cooltrax hardware.
DANGER: Risk of Personal Injury.
This unit can be remote controlled. The unit may START and STOP at any time by remote
command. Prior to performing any maintenance to the unit, place the Maintenance Toggle
Switch (located on the Cooltrax Maintenance Box) to the MAINT MODE position to disable the
remote starting capability.
Picture 2: UMD Connections.

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UMD Installation
Initial Setup:
1. Open the front engine bay access doors
2. Open LH compartment access door to the fridge battery
3. Turn OFF the main switch on the side or front of the Carrier Controller cabinet
4. Disconnect Carrier Refrigeration System Battery.
First Step –Install Antenna’s:
GSM and GPS Antennas:
1. Locate the GSM and GPS Antennas on top of the carrier system painter steel frame as pictured below.
The base of each antenna is magnetic and they can be attached directly to the steel frame. Run a bead
of Sigaflex or a similar adhesive product around the base of the antenna to ensure that it won’t come
free with vibration.
2. Locate the antennas as pictured to ensure maximum separation between the two devices to deliver
optimal performance.
3. From the top side insert the antenna cables in split tubing and feed through the hole in the fridge
frame
4. Retrieve the cables from the hole lower down the frame just above the battery compartment close to
where the UMD Gateway unit will be installed.
5. Cable tie the co-axial cables to the Carrier system’s wiring harness or fixed hardware that does not get
hot.
6. Loop and secure the excess co-axial cable in the reefer cavity and connect and finger tighten the co-
axial connectors to the UMD.
Picture 4: GSM/GPS Antenna Location

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Antennas Located on Top Rail
GPS and GSM Antennas:
RF Antenna:
The RF antenna should be mounted inside the refrigerated trailer (the “box”) for optimal results when
receiving data from RF temperature or door tags located within the trailer. If the customer configuration is for
fridge interface only with NO internal RF Tags then the Antenna is not required.
Internal RF Antenna:
1. Drill a small pilot hole through the firewall and ensure the loom and hardware clearance from the
engine bay side is adequate.
2. If OK, enlarge the hole to 20mm and remove any drill swarf from both sides of the firewall
3. Feed the cable into split tubing up to 150mm from the connectors at each end of the cable
4. Feed the mounting plate onto the RF Antenna Cable and tighten into place using the supplied
lock-nut.
5. Feed the length of antenna cable into 20mm convoluted tubing for protection

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6. From inside the trailer feed the connector end of the RF Antenna through the prepared hole
leaving sufficient cable to reach the preferred mounting location inside the trailer.
7. Loop and secure the excess co-axial cable in the cavity and connect and finger tighten the co-axial
RF connector to the UMD
8. Cable tie the antenna cable to existing cabling or components that do not get hot near the
firewall hole and up the evaporator cavity.
9. When connecting the RF antenna cable to the UMD ensure there is sufficient length available so
that there is no tension or kinking applied to the cable at the connection point.
Avoid routing the cables any closer than three inches of pipes, valves (plumbing) or parts of the
engine that become hot during reefer operation.
RF Antenna Installation –Physical Location Inside the Trailer:
For optimal results the antenna should be mounted to the roof of the trailer in a horizontal position. Ensure
that the antenna is located out from the back wall as far as possible but where it is still protected from
damage by the internal bulkhead of the fridge unit –this provides the best opportunity for the antenna to
communicate consistently with any tags located inside the trailer.
Wherever possible the RF Antenna should be located 300mm away from any steel such as fridge supports,
internal bulk-heads etc
Use P-Clips to tidy up excess cabling and fasten to the internal wall.
Important –Recommended Antenna
The UMD is designed and certified to work with the recommended antenna 2J model 2J6A41BG. Use with any
other antenna could adversely affect the electromagnetic emission characteristics and will violate the terms of
certification and require retesting.

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Low Profile Perspex Backed RF Antenna.
UMD Power Cable:
The Cooltrax Power Cable comes complete with a 3A in-line fuse. The cable is 1.5M long and has a 6-Pin
connector at one end and eye-connectors at the other.
Fuse
Recommended replacement fuse is ATC-3 automotive 3A blade fuse from Bussmann, or equivalent.
Picture 7: Cooltrax Power Cable

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Cooltrax Power Cable
1. Power Cable Battery Connections
a. Locate the red wire on the battery cable assembly. This lead, with in-line fuse and eye terminal,
should be added to the leads coming from the Carrier system’s battery positive (+VE) terminal.
b. Locate the black wire on the battery cable assembly. This lead, with eye terminal, should be added
to the leads coming from the Carrier system’s battery negative (-VE) terminal.
2. Thread the power cable UMD connector up from the battery area to the UMD.
3. Use cable ties to ensure that the wires leading to and from the fuse holder are not subjected to strain or
tension that could cause the wires to be pulled from the fuse holder.
4. NOTE: Sufficient amounts of slack must be maintained to prevent possible disconnection, or damage to
the wires and fuse holder. In addition, care must be taken to mount the fuse holder in a position that will
allow it to be easily accessed in the event that future servicing is required.
5. DO NOT CONNECT TO THE UMD at this time but leave enough cable in the area of the UMD so that there
will be no tension on the cable when it is connected.
6. Coil and tie down any excess Power Cable Length in the UMD area.
7. Cable tie the UMD Power cable from the UMD area down to the battery area onto the existing wiring
harness or fixed hardware - keep away from any sources of excessive heat.
8. When connecting the Power cable to the UMD ensure there is sufficient length available so that there is no
tension or kinking applied to the cable at the connection point.
Note: Continuous power can also be taken from the Starter Motor rather than from the battery.
Note: Enclose the cable in split tubing up to 150mm from the connectors at each end of the cable
Avoid routing the cables any closer than three inches of pipes, valves (plumbing) or parts of the
engine that become hot during reefer operation.
Installing the UMD
1) The UMD must be positioned:
a) in a suitable location where it is not directly exposed to outside weather elements;
b) where it is not directly exposed to any water or other liquids including water emissions from the
internal workings of refrigeration unit;
c) where it is not directly exposed to excessive heat, dirt or grease;
2) The connection sequence for any of the UMD connectors to their associated cables is common :
a) Ensure that the number of circuits in the cable connector matches the number of circuits of the
connector on the UMD.
b) Align the cable end groove in the cable connector body to the ridge in the connector on the UMD.
c) Push the cable connector fully into the UMD connector receptacle.
d) Rotate the cable connector locking ring clockwise while pushing it gently towards the UMD. When
the locking ring aligns with the connector bayonet coupling the ring will go forward.

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e) Continue to rotate the locking ring a further quarter turn where the ring will come up against the
stops.
f) To disconnect the cable, rotate the connector locking ring one quarter turn anti-clockwise and pull
the connector directly away from the UMD panel. Pull only on the connector body. Never pull on
the cable.
i) in a suitable location where it is not directly exposed to outside weather elements;
ii) where it is not directly exposed to any water or other liquids including water emissions from the
internal workings of refrigeration unit;
iii) where it is not directly exposed to excessive heat, dirt or grease;
Note: If the supplied mounting plate is being used then attach the V3 UMD to the mounting plate using self
tapper screws or rivets.
•The UMD the LTW connectors are at the top
Note: Enclose all cables in split tubing up to 150mm from the connectors at each end of the cable
Avoid routing the Cable Harness any closer than three inches of pipes, valves (plumbing) or parts of
the engine that become hot during reefer operation.
The Fridge Interface Cable:
The Fridge Interface cable connects to the 4-Pin Panel COM2 Connector located on the UMD Gateway.
The other end of the cable is a 3-Pin Carrier Plug which connects to the Carrier Serial Port, a 3 Way flat plug
located in the cable loom behind the controller box. The cable must be run from the UMD on the LHS of the
refrigeration system to the Serial Port Plug’s location underneath the controller on the RHS of the refrigeration
system. The cable should be well supported and protected from damage from hot components and sharp
edges. Ensure there is enough free cable length at each end to provide tension free connections.
1. Connect the interface cable to the Carrier system’s Serial Port Plug.
2. Ensure the contacts are fully inserted, and the connector shells are locked.
3. Unplug the dust cap on the UMD COM Port 2 connector
4. Connect the Fridge Interface Cable to the Panel Connector on the UMD
5. Cable Tie and Tidy up. Be careful to keep the cables away from any excessive heat source.
6. Note: When connecting the interface cable ensure there is sufficient length available so that there is no
tension or kinking applied to the cable at the connection point.
7. Note: Enclose the cable in split tubing up to 150mm from the connectors at each end of the cable

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Picture 10: Interface Cable
Cooltrax supplied Interface Cable
Interface Cable fed into Split tubing
Interface Plug connected to Serial Port on Reefer
Carrier Controller Setup
There are at least two different types Carrier Control systems which can interface with the UMD. This
installation procedure does not cover the detail of the installation or setup requirements of the Carrier
equipment; however it outlines the general requirements for the known Controller types
Standard Controller:
1. The Standard controller requires the fitting of an EPROM Revision 3.32 and above to be fitted before
the interface will be functional –this revision has the DataTrak Communication Option. Revision 3.34
also has this option. For detailed instructions on upgrading and ePROM see Appendix at the end of the
manual.
2. For a Standard Controller with 2-Way capability enabled an EPROM with Revision of 3.38 is required.
3. For a Standard Controller on a multi-Temp reefer with 2-Way capability enabled an EPROM with
Revision of 4.12 is required

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Advanced Controller:
1. The Advance controller requires the ‘Third Party Protocol’ to be programmed into the controller using
a ‘Data Configuration Card’. The controller is then enabled using the ‘Reefer Manager’ PC application.
Scroll through the options and set the ‘Communications Protocol’ to ‘OTHER’.
2. Note: Minimum Firmware Revision for the Micro should be: 04.12
Picture 11: Carrier Datacard in Controller PCMCIA Slot
Powering Up the System for the First Time:
After all hardware and wiring is installed, power may be connected to the Cooltrax System for the first time.
IMPORTANT NOTE:
Verify that all cable and individual wiring connections are properly connected and weather-sealed before
reconnecting the cable to the positive terminal first and then to the negative terminal of the reefer battery.
Once the cables to the positive and negative terminals of the refrigerated battery are connected, the UMD will
commence its power up sequence.
Boot-Up Sequence:
1. Within approximately 30 seconds the UMD ‘Power’ LED will light up GREEN, followed closely by the
battery light.
2. Shortly after the Signal LED will begin to flash, assuming that there is GPRS or 3G service available on
the GSM/3G network.
3. The IP LED will at first flash and then remain in a constant ON State once an IP connection has been
established
4. The GPS LED will light up a constant RED to indicate that GPS has been acquired –typically in 30 secs
or less.
5. If RF Tags have been installed then the RF LED will flash every few seconds as the tags communicate
with the RF Reader section of the UMD

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Diagnostic Tests:
Testing the Fridge Interface:
After the UMD / Carrier Fridge interface cable is connected to the 3 way flat connector in the Carrier fridge
loom, with the fridge OFF, measure the resistance between the chassis (0V) and Pin 3 of the plug that will
connect into the UMD COM2 Port. This should be <10 ohms. If this is not correct, check the wiring of the Flat
Carrier loom plug back to the Fridge Controller. Turn the fridge ON and measure the voltage between the
chassis (0V) (negative of meter) and Pin 2 of the plug that will connect into the UMD COM2 Port. This should
be –8 to –10V DC. If this is not correct, check the voltage on Pin 1 of the same plug. If that is –8 to –10V DC
then the wiring to pins A & B of the carrier flat loom plug need to be swapped and the measurement re-taken.
If there is no voltage present on either pins 2 or 1, check the connections from the Carrier loom flat plug back
to the fridge controller.
Picture 12: Cooltrax Interface Plug
If these two measurements are correct, connect the fridge interface cable to the UMD COM2 Port and power
ON the UMD (If not already ON).
If the Fridge cable was connected to a UMD that was OFF and then powered ON after the connection was
made, the UMD should sense the fridge within a couple of minutes and the fridge light on the UMD should
come ON RED.
Picture 12: UMD LED’s
System Test:
1. Check the Engine Bay for any tools, fixings or off-cuts, which may have been left behind.

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2. Install and re-connect Carrier System Battery
3. Un-plug the UMD ‘POWER’ connector dust-cap and connect the UMD Power lead.
4. Within approximately 30 seconds the UMD ‘Power’ LED will light up GREEN, followed closely by the
battery light. Within a few minutes, assuming that there is GPRS or 3G service available on the
GSM/3G network, after the Signal LED will begin to flash.
5. Turn ON the Carrier Controller using the main 12V ON/OFF switch and be prepared for the
refrigeration system to start.
Please Note: Always connect the power to the UMD last!
Wireless Tag Installation:
The new RFID UMD communicates with CoolTrax remote temperature and door sensors via wireless; this
saves considerable installation time. Depending on the customers desire to have independent temperature
reading points in the trailer or a door open and close tag and magnet, CoolTrax provides RF capable tags which
communicate with our UMD, these tags should located by the installer according to the customer’s
requirements.
Picture 13: Wireless Temperature and Door Tags
Wireless Temperature Tag
Wireless Door Tag and Magnet
Cooltrax Wireless Temperature Tag:
Each CoolTrax Tag has a flanged base with holes to allow the installer to either screw or pop-rivet the tag to
the trailer wall or door. Double-sided tape is another mounting option for flexibility and ease in moving
around to different monitoring locations within the trailer.
Check with Cooltrax or the customer for information in respect to where the tags should be located in each
trailer.

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Important Note: The RFID Tags supplied with a UMD are specific for that particular UMD they must be kept
with and installed with the specific UMD. If RF Tags from another UMD Kit are installed they will not be able to
report to that UMD.
Temperature and Door Tags need to be located in a position within the trailer where they will not be damaged
in the trailers normal daily operations –by fork-lifts when loading pallets etc.
Picture 14: Wireless Temperature Tags Locations
Temperature Tag located above the load
line along the trailer wall.
Temperature Tag located next to the Return Air duct
Cooltrax Wireless Door Tag:
The location of the Door Tags and Magnet will vary according to the various body types of the trailer and
whether the fitted doors are roller or barn style. The important consideration, again, is to locate the Tag and
Magnet in a position where they will not be damaged. This requires a careful assessment by the installer on a
case by case basis as there are so many variations from trailer to trailer and even between the different door
types.
Cooltrax provides brackets for both types of door installation.
Installation Options:
1. On the Inside of the Barn doors with the magnet located on the RH door (looking from inside the trailer
out
2. If the Trailer body has a lip along the top at the rear then the tag can be located on the inside of that lip
where it is protected and the magnet attached to a bracket on the inside of the door
3. In the case of a roller type door the tag is typically located on the inside LH side wall directly adjacent
to the roller door and the magnet and spacer is located on the roller door itself –checking for
clearance when the door is “rolled up”. See picture below

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Picture 15: Wireless Door Tags
Door Tag fitted to a Roller Door Installation
Door Tag and Magnet fitted to Barn or Side Door

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Door Tag Installation Considerations:
Tag Alignment with the Magnet:
On the side of the door tag is a label “Magnet This Side”, make sure that the door tag is installed with this side
of the tag facing the magnet.
Please Note: The magnet should be vertically aligned mid-way with the side of the door tag where possible –
this may require packing the magnet up.
Distance between the Door Tag and the Magnet:
Install the door tag with a maximum of 12mm between the tag and the magnet to ensure consistent
communication.
Please Note: Make sure that the Door Tag is switched on by holding down the on/off button on the tag and
checking that the green On LED flashes to indicate an On State.

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Post Installation:
Once the physical installation of the unit is complete and the UMD is powered on contact CoolTrax Support
staff so that they can check that the unit is reporting as expected.
On contact provide the following Installation Details (via phone or fax the completed Installer Template
provided by CoolTrax):
1. The Customer Name
2. The Fleet ID of the Trailer
3. The UMD ID (located on the front of the UMD –typically UCXXXX
4. The Fridge Model
5. The Sensor location with Sensor ID –if fitted
6. The installer name and contact details –mobile phone number to call once the unit has been tested
Please ensure that CoolTrax staff confirms that the unit is reporting data as expected BEFORE the trailer leaves
the installers premises. Cooltrax will not be liable for costs incurred through the asset being recalled for
validation at a later time.
CoolTrax staff will ask you to conduct a number of fridge operations as part of the Installation Check to make
sure the unit fridge interface is correctly installed and configured.
•Power the fridge unit on and off to check the Fridge Interface is functioning as expected
•Change Set Point Temperature
•Open and Close the Rear Door to test Door Tag if fitted.
•Send some Remote Commands to ensure the Interface is working correctly
•Switch to Maintenance Mode to ensure that the Maintenance Box is connected correctly
CoolTrax Support Contacts:
Support –(613) 9686 6011
Email: [email protected]