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