OPERATING AND INSTALLATION INSTRUCTIONS:



OPERATING AND INSTALLATION INSTRUCTIONS FOR 12/24V DC & 220V AC RANGE

FITTED WITH BD35F TYPE COMPRESSOR

SUITABLE FOR USE WITH BATTERY / SOLAR AND STANDARD 220V AC GRID SUPPLY

1.0 INDEX

1. INTRODUCTION

2. CHECK THE FOLLOWING AFTER UNPACKING

3. PRE COOLING THE UNIT PRIOR TO USE

4. 12/24 VOLT OPERATION: (a) USE IN A VEHICLE (b) USE WITH SOLAR PANELS

5. FUNDAMENTALS: (a) BATTERY SELECTION (b) WIRING SYSTEM

6. OPERATION: TEMPERATURE SELECTION AND WIRING DIAGRAM

7. FAULT FINDER

8. DO'S AND DON'TS

IMPORTANT

REMEMBER TO COMPLETE THE WARRANTY CARD AND RETURN IT TO THE ABOVE ADDRESS. FAILURE TO DO SO MAY LEAD TO DIFFICULTY IN PROCESSING WARRANTY CLAIMS.

This Minus 40 Freezer can be used on either 12/24V DC OR alternatively 220V AC. Please ensure to use the correct power supply cord for 12/24V or 220V.

Do NOT connect both at the same time

2.0 INTRODUCTION

OPERATING INSTRUCTIONS

Minus 40's range of battery refrigerators and freezers consists of:-

B40 "Caravelle" - Portable Chest Type Freezer for off-road vehicle use

B60 "Safari" - Portable Chest Type Freezer for off-road vehicle use

B60 "Namib" - Portable Chest Type Freezer for off-road vehicle use

B115 "Bushmaster" - Portable Chest Type Freezer for off-road vehicle use

B150 "Kalahari" - - Portable Chest Type Freezer for off-road vehicle use

BS115R - Upright refrigerator with 20L freezer compartment

BS225R - Upright refrigerator with 20L freezer compartment

BS80L - Chest model freezer for domestic use

B040B - Chest model freezer for bus vehicle use

With the exception of the BS115R and the BS225R all models can be used as a refrigerator or freezer. The desired temperature should be set on the thermostat dial before use. Temperatures in the range +10°C to –25°C can be maintained. It is important to note that the lower the temperature setting the greater the battery power consumed. The following table can be used as a temperature setting guideline:

PRODUCT STORAGE TIME TEMPERATURE

Uncooked meat, 1 - 2 days 8 to 10°C

Milk, cheese, 3 - 4 days 5 to 8°C

Vegetables, etc. 7 days + 5 to 9°C

Frozen meat, Poultry, up to 7 days -6 to –2°C

Vegetables up to 14 days -8 to –4°C

Pre-prepared foods not more than -15 to –12°C

(30 days)

3.0 CHECK THE FOLLOWING AFTER UNPACKING

• Check for any transport damaged.

• Mount the unit on a reasonably level surface and ensure that air circulation around the compressor compartment is free. (The unit should not be placed closer than 80mm to a wall or other obstruction on the compressor side).

• Turn the thermostat dial to the desired temperature setting.

• (For 12/24V DC use) -Uncoil the power lead noting that the red lead is connected to the positive (+) terminal of the control unit and that the black lead is Negative (-).

• Connect the leads to a 12/24 Volt battery; red to positive, black to negative. Incorrect connection will result in the unit not switching on.

4.0 PRE-COOLING THE UNIT PRIOR TO USE

• Set the thermostat to the desired temperature setting.

• Allow the unit to run for 1 - 3 hours to thoroughly pre-cool the walls and floor. Once the compressor switches off the unit is ready for use.

• Load the produce to be preserved, once the refrigerator/freezer has reached the set temperature.

NB Note that the Light Emitting Diode does not glow whilst unit is operating. It will only emit light flashes during a fault finding process

(See FAULT FINDER on page 4-5)

5.0 12/24 VOLT OPERATION

• The battery used will require re-charging periodically. This can be done using a charger operating from the mains, by using a vehicle's electrical system or by means of solar panels. A 100AH deep cycle battery is recommended to operate the unit. This size battery will operate the unit continuously for approximately 17 hours without re-charging.

5.1 USES IN VEHICLE

• If the unit is to be used mainly in a vehicle then it is recommended that an additional battery - other than the vehicle battery - be fitted for use solely with the freezer. The additional battery should be located as close as possible to the freezer. This will prevent the additional drain on the vehicle's main battery which could prevent the vehicle from starting. A "Deep Cycle" battery should be used to ensure that maximum power is available. The additional battery should be connected into the vehicle electrical charging system by a competent Auto Electrician. It may be necessary to fit a second charging regulator to the electrical system. All 12 volt electrical wiring should be carried out according to the following table:

TABLE 1

CABLE LENGTH* WIRE CROSS SECTIONAL AREA

UP TO IN MM2

2.5metre 2.5 mm2

4.0metre 4.0 mm2

6.0metre 6.0 mm2

10.0metre 10.0 mm2

16.0metre 16.0 mm2

• Total length of wire from the vehicle’s electrical system - via battery - to connection on electronic controller.

• For short periods of operation a connection may be made directly to the vehicle's electrical system. As a precaution it is recommended that the unit be switched off when the vehicle engine is switched off. This can be done by unplugging the lead from the plug socket, or by switching off at the unit by turning the thermostat to its maximum position (+30°C).

• The unit will retain a low internal temperature for up to 12 hours after switching off.

• When using the unit as a freezer it is advisable to turn the thermostat down to -25° minimum when the vehicle engine is running. This allows maximum use of current available from the alternator. When the vehicle’s engine is switched off the thermostat must be set to a higher setting (e.g. –8°C). This will reduce running time and hence prolong battery life.

5.2 FOR USE WITH SOLAR PANELS

• The supplier of the solar power system should be consulted to determine whether additional batteries or photovoltaic panels are required. Contact Minus 40 for details of Solar Panel kits selected specially for each refrigerator / freezer model.

6.0 ELECTRICAL WIRING FOR D.C REFRIGERATORS / FREEZERS FITTED TO A VEHICLE.

• One of the most often heard complaints about 12/24V fridge/freezers mounted in vehicles is that frozen food defrosts overnight when the vehicle engine is not running.

• This often results in the fridge being condemned as useless, despite the fact that factory tests prove the unit's

6.0 ELECTRICAL WIRING FOR D.C REFRIGERATORS / FREEZERS FITTED TO A VEHICLE (continued)

performance to be acceptable.

• Closer investigation of the problem indicates that in 99% of the time, the fault lies in the power supply to the fridge. A few basic rules must be followed to ensure reliable running.

• The battery must provide an adequate power reserve to operate the fridge when the vehicle is stationary.

• The wiring system between battery and fridge should be designed to minimize voltage drop.

• Opening of the fridge or freezer must be carefully controlled.

6.1 BATTERY SELECTION:

6.1.1 Other than for very limited periods the vehicle's main battery should not be used to operate a fridge/freezer. A properly installed dual battery system utilizing a Low Maintenance, Deep Cycle Battery of approximately 100Ah capacity should be used. A Deep Cycle Battery will tolerate the constant discharging and recharging cycle associated with fridge use far better than an automotive battery which can be expected to expire after 15 or 20 discharge cycles. In addition the Deep Cycle battery provides a greater portion of its stored charge (up to 70% in some makes) before the voltage drops to the level at which the fridge low voltage cut out operates.

6.1.2 With dual batteries it is advisable to ensure that only the auxiliary battery is left in circuit when the engine is switched off. Most split charging systems will ensure that this is accomplished. Alternatively a relay operated by the ignition circuit should be fitted to connect the auxiliary battery to the alternator charging circuit when the engine is running. With the correct battery system properly charged all that remains is to transfer power efficiently to the fridge/freezer.

6.2 WIRING SYSTEM

• Danfoss BD35F compressor operated fridges have a built in battery protection cut out which will stop the fridge when the voltage at the compressor terminal reaches either 10.4 (12V operation) or 22.8 (24V operation).

• It is not generally realized that a 12/24V DC fridge compressor can draw up to 10 to 15 Amps for a few seconds on start up. This high current will cause a voltage drop due to the resistance found in the wiring between the battery and the fridge.

• The wiring circuit, its connections and any switches used should be able to carry the 10 to 15 Amps starting current with a voltage drop not exceeding 10 to 15 Volts.

• If the voltage drop in the wiring is higher than this and the battery is not fully charged, the voltage at the compressor can drop below the cut off voltage when starting. The compressor then cuts out, and the voltage at the controller box terminals rises because there is now no load and hence no volt drop. The battery protection cut out now allows the fridge to attempt to re-start and the whole cycle repeats itself.

• Prolonged operation in this way could damage the compressor and electrical components.

• As a general rule, all plugs and switches in the circuit should have a 20Amp DC rating and wiring should have a cross section area of not less than 2.5mm2.

• A separate earth (negative) wire should run from the fridge to the auxiliary battery, and NOT earth to the vehicle body

DO NOT USE THE VEHICLE CHASSIS AS A NEUTRAL.

• This wire should be the same thickness as the positive wire.

7.0 OPERATION

• To obtain best results from the limited power resources of the battery a few basic steps should be followed:

• Load pre-frozen food if possible.

• When running the vehicle's engine, turn the fridge/freezer thermostat to its lowest setting i.e. (-25°C). This "stores" cold in the frozen food. When stopped and running from the battery only, turn the thermostat to –8°C to just maintain frozen conditions.

• Limit lid openings to a minimum. Take frozen food out to defrost in a cooler box and use this "cold" to cool drinks etc.

• By following all the above simple rules the performance of any 12/24V compressor driven fridge/freezer will be enhanced.

[pic]

The above example of a thermostat set to –20°C on the Set Mark

8.0 FAULT FINDER

FAULT POSSIBLE REASON CORRECTION

1. COMPRESSOR DOES NOT RUN AND RED LIGHT EMITTING DIODE FLASHES

1.1 Once every 4 Sec. Low voltage protection cut out Check wiring

due to too low voltage supply thickness as per manual

Check for loose connections in plugs or leads

Battery charge low Check for low battery and re-charge with fridge disconnected from battery.

1.2 Twice every 4 Sec. Fan motor high current cut out. Disconnect fan at F. If problem goes away, replace fan motor. If persists contact your Minus 40 Dealer/Agent.

1.3 Three times every Motor start error due to high Switch fridge off for 15 minutes to allow

4 Sec. differential pressure pressures to equalize in the Refrigeration system. Restart fridge.

1.4 Four times every 4Sec. Minimum motor speed error; Check that fan working.

refrigeration system too heavily Check that ambient temperature does

loaded not exceed 55°C.Pre-cool the unit before loading

1.5 Five times every 4Sec. Thermal cut-out of electronic unit Check that fan is working. Check the

Fridge/freezer too heavily ambient temperature not exceed 55°C

loaded & too high ambient Pre-cool the unit before loading

temperature

8.0 FAULT FINDER Continues

2. COMPRESSOR DOES Faulty thermostat Replace thermostat. Reconnect T or C

NOT RUN AND RED LIGHT Loose connection at T or C Reconnect T or C

EMITTING DIODE DOES Wrong polarity Check that Positive of battery is connected to red wire and negative to black wire

Fault at speed regulating resistor Replace with 820 ohm resistor or temporarily replace resistor with a conductor

NO OR REDUCED

COOLING CAPACITY Gas leakage or blockage in Contact Minus 40 Agent/Dealer or refrigeration system have the unit repaired by a qualified refrigeration technician

Faulty fan motor Replace fan motor

9.0 DO'S AND DON'TS

1. Do not operate the fridge/freezer inside the boot of a vehicle or in a standing vehicle with no open windows as the temperatures can rise to +70°C.

2. Do not operate the unit at an angle of more than 30° to the horizontal.

3. Do not allow the fridge/freezer to be placed upside down.

4. Do not drill any holes on the main insulated casing as a pipe may be punctured.

5. Do not allow anyone to perform repairs to a Minus 40 unit without prior approval from the factory as this may render the warranty null and void.

Read the manual carefully to ensure trouble free off road vehicle refrigeration.

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Mechanical Dial

Thermometer

▪ Fault Finder

▪ Flashing

▪ LED

Set Mark for Temperature

▪ Thermostat

▪ Temperature

▪ Control Knob

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MINUS 40 (PTY) Ltd

44 Manhattan Road

Airport Industrial Ext 2

Tel: + 21 (0) 21 386 2290

Fax: + 21 (0)21 386 2295

Web: minus40.co.za

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