ROPERATORS MANUALfor

Integra 30STruck Refrigeration Units

Beginning With S/N PB225225

62--10849 Rev --

Truck Refrigeration

MANUALOPERATORS

Integra 30STRUCK

REFRIGERATIONUNITS

Beginning WithS/N PB225225

Integra 30S OPERATORS MANUAL

This guide has been prepared for the operator of Carrier Transicoldtruck refrigeration units. It contains basic instructions for the dailyoperation of the refrigeration unit as well as safety information, andother information that will help you to deliver the load in the bestpossible condition. Please take the time to read the informationcontained in this booklet and refer to it whenever you have aquestion about the operation of your Carrier Transicold Integra 30Sunit.

Your refrigeration unit has been engineered to provide long,trouble-free performance when it is properly operated andmaintained. A comprehensive maintenance program will help toinsure that the unit continues to operate reliably. Such amaintenance program will also help to control operating costs,increase the units working life, and improve performance.

This guide is intended as an introduction to your unit and to providegeneral assistance when needed. More comprehensiveinformation can be found in the Operation and Service Manual foryour unit. Thismanual canbeobtained fromyour Carrier Transicolddealer.

When having your unit serviced, be sure to specify genuineCarrierTransicold replacement parts for the highest quality and bestreliability.

At Carrier Transicold, we are continually working to improve theproducts that we build for our customers. As a result, specificationsmay change without notice.

CONTENTSPage

Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Identification 2. . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols used on Cab Control 4. . . . . . . . . . . . . . .

Unit Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product Loading 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Transport Temperatures 14. . . . . .

Problems & Alarms 15. . . . . . . . . . . . . . . . . . . . . . . .

Standby Operation Guidelines 19. . . . . . . . . . . . . . .

Fuses 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Road Service 24. . . . . . . . . . . . . . . . . . .

1SAFETY

Your Carrier Transicold refrigeration unit has been designed withthe safety of the operator in mind. During normal operation, allmoving parts are fully enclosed to help prevent injury. During allpre-trip inspections, daily inspections, and problemtroubleshooting, you may be exposed to moving parts; please stayclear of all moving parts when the unit is in operation.

WARNINGBeware of unannounced starting of the unit. The unitmay cycle the fans and operating compressor unex-pectedly as control requirements dictate. Press OFFkeyon theCabCommand anddisconnect powerplug.

REFRIGERANTSThe refrigerant contained in the refrigeration system of your unitcan cause frostbite, severe burns, or blindness when in directcontact with the skin or eyes. For this reason, and because oflegislation regarding the handling of refrigerants during systemservice, we recommend that, whenever your unit requires serviceof the refrigeration system, you contact your nearest CarrierTransicold authorized repair facility for service.

2UNIT IDENTIFICATION

The Integra 30S unit is identified by a nameplate attached to theframe of the unit. This nameplate identifies the complete modelnumber of the unit, the serial number, the refrigerant charge andquantity, 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 forassistance. This information will be needed when you contact atechnician or Carrier Transicold Service Engineer so that he or shemay properly assist you.

nameplate

3A

B

C

DE

E

A : EvaporatorB : CondenserC : Cab controlD : CompressorE : Vehicle battery

D

4SYMBOLS USED ON CAB CONTROL

Readout

Standby operation display

Road operation display

Manual defrost control key

Unit start-up key

Unit shut-down key

Data selection key

Selected data decrease key

Selected data increaset key

Unit operation displayS Green = in-range (left half)S Red = malfunction (right half)

5UNIT OPERATION

OPERATING PRINCIPLEAfter starting up the refrigeration unit by pressing theON key on theCab Command, unit start--up and shut--down are automatic.

S On Road operation, an open--type compressor is driven bythe engine of the vehicle. The vehicle battery powers theevaporator and condenser fans. The unit automatically shutsdown when the engine is switched off with the ignition key.

S On Standby, a standby compressor is energized, and atransformer is used to power the evaporator and condenserfans. The power network connection is detected by the CabCommand which automatically starts up the unit in Standbymode.

S If the ignition key is switched on while the unit is connected tothe power network, or vice--versa, theCabCommand triggersa visual alarm, in the form of a flashing red malfunction lightand readout. In this case, the unit will start in road operatingmode.As soon as one operating mode is inhibited, the unitautomatically starts up in the other mode.

S In all cases the unit can be completely shut downmanually bypressing the OFF key on the Cab Command.

6STARTING -- ENGINE OPERATION

1. Press ON key.

2. Check if box temperature isdisplayed.

3. Check if road operation light is on. If not,unplug power cord from receptacle.

NOTE: If standby power cord is plugged in,the unit will run in standby mode.

7STARTING -- STANDBY OPERATION

1. Press the OFF key andplug in power supply.

3. Check that the standby operationlight is on.

2. Press the ON key.

8TEMPERATURE SETPOINT

2. Press + (plus) key to increasesetpoint or press -- (minus)key to decrease setpoint.

3. Press SET key when desiredsetpoint is displayed to lock innew setpoint.

1. Press SET key to displaysetpoint.

9MANUAL DEFROST

2. Press Manual Defrost key to initiatemanual defrost.

1. Check that box temperature is40_F or lower.

10

DEFROST INTERVALDefrost interval in hours: 0,1, 1.5, 2, 2.5, 3, 4, 5 & 6AUT: microprocessor optimized automatic defrost according totype of cargo.

1. Press the OFF key.

2. Press Defrost and ON key to display thepreviously selected defrost interval.

4. Press SET key to validate modified value.

3. Press -- (minus) or + (plus) key to selectdefrost interval.

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MINIMUM SETPOINT, OUT-OF-RANGEAND CONTINUOUS AIRFLOWMinimumSetpoint Settings: ---20_F (---28.9_C), ---4_F (---20_C), or32_F (0_C)Out-of-Range Settings: 3.6, 5.4 or 7.2_F (1, 2 or 3_C)Continuous Airflow Settings: ON or OFF

3. Press Defrost key.

1. Turn unit on and Press + (plus) key.2. Press -- (minus) key.

7. Press + (plus) key to increase out-of-range setting.Press -- (minus) key to decrease out-of-range setting.

8. Press SET key to save out-of-range setting.

4. Check that the ! light flashes green.

9. Check that the display shows ON or OFF. ONmeans the evaporator fan continues to run whensetpoint is reached for constant air flow. OFFindicates the evaporator fan stops when boxtemperature is within setpoint range.

5. The operator can select a minimum setpoint. Theselections are ---20_F (---28.9_C), ---4_F (---20_C), or 32_F(0_C)). Press + (plus) key or -- (minus) key to changesetting.

6. Press SET key to save setting. Out-of-range settingwill appear next.

10. Press + (plus) or -- (minus) key to change airflowoption. Press SET key to save fan mode setting .

12

STOPPING UNIT

1. Press the OFF key.

13

PRODUCT LOADING

BEFORE LOADING:

D Pre-cool the body. This will remove much of the heat from theinside of the body, and give the product better protection whenit is loaded.

D Place theunit in a defrost cycle immediately before loading.Thiswill 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 remainunobstructed.

D Leave approximately 4 to 5 inches between the load and thefront wall for air return to the unit.

D Leave at least 10 to 12 inches between the top of the load andthe ceiling to ensure that there is nothing to prevent airflow tothe rear of the body

D Load product on pallets to provide free air return to unit andimprove product protection.

Proper air circulation in the truck body, air that can move aroundand through the load, is a critical element in maintaining productquality during transport. If air cannot circulate completely aroundthe load, hot spots or top-freeze can occur.

The use of pallets is highly recommended. Pallets, when loaded soair can flow freely through the pallets to return to the evaporator,help protect the product from heat passing through the floor of thetruck. When using pallets, it is important to refrain from stackingextra boxes on the floor at the rear of the truck, this will cut off theairflow.

Product stacking is another important factor in protecting theproduct. Products that generate heat -- fruits and vegetables, forexample -- should be stacked so theair can flow through theproductto remove the heat; this is called air stacking the product.Products that do not create heat -- meats and frozen products --should be stacked tightly in the center of the trailer.

14

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 heatfiltering through the walls from affecting the product.

It is important to check the temperature of the product being loadedto ensure that it is at the correct temperature for transport. Therefrigeration unit is designed to maintain the temperature of theproduct at the temperature at which it was loaded; it was notdesigned to cool warm product.

RECOMMENDED TRANSPORTTEMPERATURES

Below are some general recommendations on product transporttemperatures and operatingmodes for the unit. These are includedfor reference only and should not be considered preemptive of theset point required by the shipper or receiver.

More detailed information can be obtained from your CarrierTransicold dealer.

ProductSetpoint Range

Product_F _C

Bananas 56 to 58 13 to 14

Fresh fruits and vegetables 33 to 38 0.5 to 3

Fresh meats and seafood 28 to 32 --2 to 0

Dairy Products 33 to 38 0.5 to 3

Ice* 15 to 20 --10 to --7

Frozen fruits and vegetables* --10 to 0 --23 to --18

Frozen meats and seafood* --10 to 0 --23 to --18

Ice Cream* --20 to --15 --29 to --26

During delivery cycles that include frequent stops and dooropenings, it is recommended that the unit be turned off during thetime the body doors are open to help conserve the producttemperature.* Variations may be necessary for very high or very low ambienttemperatures. 1.

15

PROBLEMS & ALARMS

Everything possible has been done to ensure that your unit is themost reliable, trouble-free equipment available today. If, howeveryou 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 ProblemsUnit wont powerup.

Check battery condition.Check battery connections.Check all fuses

Unit wont start. Check all fuses

Unit wont run. Check all fuses

Unit shut down. Check alarm codes.

Unit not coolingproperly.

Check minimum setpoint setting (see page 12).Defrost unit.Check evaporator for airflow restriction.Check condenser for airflow restriction.Check body for damage or air leaks.Check product is loaded properlyCheck refrigerant charge.

16

ALARM DISPLAY

1. When an alarm isactivated, the ! lightflashes red.

The ! light flashesgreen when the unit isoperating correctly.

2. Press the SET key for 5 seconds todisplay alarms.

3. Press + (plus) or -- (minus) key to viewadditional alarms.

4. Press SET key to return to boxtemperature display.

17

ALARM LISTALARM ALARM DESCRIPTION OPERATINGMODEA00 No Malfunction Road/StandbyA01 High or Low Pressure Switch Road/StandbyA02 High or Low Pressure Switch Road/StandbyA03 Standby Compressor Over Heated StandbyA04 Road Compressor Clutch Road/StandbyA05 Standby Contactor (high amp draw) StandbyA06 Condenser Fan Motor (high amp draw) Road/StandbyA07 Evaporator Fan Motor (high amp draw) Road/Standby

A08 Hot Water Relay or Electric Heat Contac-tor (high amp draw) Standby

A09 Hot Gas Valve HGS1 (high amp draw) Road/StandbyA10 Quench Valve (high amps draw) Road/StandbyA11 Condenser Pressure Control Valve HGS2 Road/StandbyA12 Out-of-Range High Temperature StandbyA13 Out-of-Range Low Temperature StandbyA14 Defrost Cycle >45 minutes StandbyA15 Setpoint out of range --20.2_F to 86_F Road/StandbyEE Return Air Sensor Road/StandbybAt Low Battery Voltage Road/Standby-- -- ---- -- ---- -- --

Using Road & Standby Compressors atthe Same Time. Road/Standby

Err Programming mistake of maximumsetpoint by user. Road/Standby

------ Setpoint lower than maximum setpointbut in the range --20_F to 86_F Road/Standby

18

ALARM RESET

1. Press the OFF key toclear alarm list. Unitcan now be restartedif no active alarmcondition remains.

19

STANDBY OPERATION GUIDELINES

For safe, reliable operation in Standby mode, it is important tofollow a few guidelines:

D Always check that the unit is OFF (Cab Command) beforeconnecting or disconnecting the unit from power source.

D The circuit breaker and power cord used for Standbyoperation must comply with legislation currently applicableon site of use and with unit specifications in table below.

Unit Operating Voltage Maximum UnitOperating Amperage115 V

Single phase 60 hz 18.2 A

Integra 30s230 V

Single phase 60 hz 9.0 A

230 VThree phase 60 hz 3.8 A

VoltagePower Cord Length and Wire Gage

Voltage25 ft 50 ft 75 ft 100 ft

115/1/60 14 12 10 8230/1/60 14 12 10 8230/3/60 16 14 12 10

D When multiple units are in use, each unit must be operatedon its own electrical circuit. You should never operate morethan 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, alicensed electrician should be contracted. A licensed electricianis familiar with all local ordinances and special requirements foryour area and can ensure that the circuits are properly designed,installed, and connections are correct.

20

FUSES

To access the fuses in the control box, remove the upper cowlingfrom unit, then open the control box (fastened by 3 screws).

123

Fuse Purpose 12V 24VF1 Road supply fuse 30 A 15 AF2 Standby supply fuse 30 A 15 AF3 Clutch fuse (Standby) 5 A 3 A

21

UNIT MAINTENANCE

WARNINGBefore working on unit, check that:D The unit (cab command) is OFF.

D It is impossible for unit to automatically start-up duringmaintenance.

Refrigerant Charge: R134a 4lbs

Compressor oil

Approved Oil Oil ChargeApproved OilMobil Arctic EAL 68 180cm3 (5.0702 in3)

For the most reliable operation and for maximum life, your unitrequires regular maintenance. Maintenance should be performedon the following schedule:

Miles 3000

18000

36000

54000

72000

90000

108000

126000

Service A H H H H H H H H

Service B H H H H H H H

Service C H H H

Service D H

22

Service Schedule

SERVICE A

S Check the tension of the compressor belt(s).

S Check that the vehicle engine runs correctlyat low speed and that the compressor kit iscorrectly tightened/belt tension.

S Check the tightness of bolts and screws andthat the unit is correctly fastened onto the box.

SERVICE B

S Clean the condenser and the evaporator.

S Replace the Road and Standby compressorbelts.

S Replace the filter--drier.

S Check the operation of the cab command.

S Check the defrost- Cut--in,- Fan shut--down,- Cut--out,- Defrost water drain.

S Check the water tighness of the emergencyswitch cap.

SERVICE C

S Check the operation of the evaporator andcondenser fans. Change the condenser motorbrushes.

S Change the compressor oil. Only use Ester oil(POE) approved by CARRIER. See thetechnical information sheets for therecommended quantities and types of oil.

SERVICE D S Change the removable fuses, relays andcapacitor (if any) in the control box.

Note : The evaporator of this unit is equipped with brushless fanmotors which dont need to be maintained.

23

EMERGENCY ROAD SERVICE

At Carrier Transicold were working hard to give you completeservice when and where you need it. That means a worldwidenetwork of dealers that offer 24-hour emergency service. Theseservice centers are manned by factory trained service personneland backed by extensive parts inventories that will assure you ofprompt repair.

Should you experience a unit problem with your refrigeration unitduring transit, follow your companys emergency procedure orcontact the nearest Carrier Transicold service center. Consult theShortstop Service Centers directory to locate the service centernearest you. This directory may be obtained from your CarrierTransicold dealer.

If you are unable to reach a Service Center, call our24-hour Action Line: (800)448-1661When calling, please have the following information ready forfastest 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, andwhat you havealready done to correct the problem.

We will do everything we can to get your problem taken care of andget you back on the road.

Index

Index -1

AAlarm Display, 16, 18

Alarm List, 17

CContinuous Airflow, 11

DDefrost Interval, 10

EEmergency Road Service, 23

FFuses, 20

MManual Defrost, 9

Minimum/Maximum Setpoint,11

OOperating principle, 5

Out--of--Range, 11

PProblems & Alarms, 15

Product Loading, 13

RRecommended Transport-

Temperatures, 14

Refrigerants, 1

SSafety, 1

Setpoint, 8

Standby Operation Guide-lines, 19

Starting -- Engine Operation,6

Starting -- Standby Opera-tion, 7

Stopping Unit, 12

Symbols used on Cab Con-trol, 4

TTemperature Setpoint, 8

Index

Index -2

UUnit Identification, 2

Unit Maintenance, 21

Unit Operation, 5

2004 Carrier Corporation D Printed in U. S. A. 1104

Carrier Transicold Division,Carrier CorporationTruck/Trailer Products GroupP.O. Box 4805Syracuse, N.Y. 13221 U.S A

www.carrier.transicold.com

North AmericaCarrier Transicold700 Olympic DriveAthens, GA 30601 USATel: 1--706--546--6469Fax: 1--706--546--5207

Central Americaand MexicoEjercito Nacional No. 418Piso 9, Torre YumalCol. Chapultepec Morales11570 Mexico, D.F.Tel: (5255) 9126.0300Fax: (5255) 9126.0373

A member of the United Technologies Corporation family. Stock symbol UTX

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Diesel engine exhaust and some ofits constituents are known to theState of California to cause cancer,birth defects,and other reproductiveharm.