Download manual - Minus40

MINUS 40 (PTY) Ltd
44 Manhattan Road
Airport Industrial Ext 2
Tel: + 21 (0) 21 386 2290
Fax: + 21 (0)21 386 2295
Web: www.minus40.co.za
SPECIALIZED REFRGERATION
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
1.
2.
3.
4.
5.
6.
7.
8.
INDEX
INTRODUCTION
CHECK THE FOLLOWING AFTER UNPACKING
PRE COOLING THE UNIT PRIOR TO USE
12/24 VOLT OPERATION:
(a)
USE IN A VEHICLE
(b)
USE WITH SOLAR PANELS
FUNDAMENTALS:
(a)
BATTERY SELECTION (b)
WIRING SYSTEM
OPERATION:
TEMPERATURE SELECTION AND WIRING DIAGRAM
FAULT FINDER
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
Uncooked meat,
Milk, cheese,
Vegetables, etc.
Frozen meat, Poultry,
Vegetables
Pre-prepared foods
3.0



STORAGE TIME
TEMPERATURE
1 - 2 days
8 to 10°C
3 - 4 days
5 to 8°C
7 days +
5 to 9°C
up to 7 days
-6 to –2°C
up to 14 days
-8 to –4°C
not more than
-15 to –12°C
(30 days)
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.
1
Minus 40 (Pty) Ltd Reg. No. 89/03489/07
Vat Ret No: 4090105521
Director: S E Davison – D N McMurray
Member of Added Asset (Pty) Ltd
MINUS 40 (PTY) Ltd
44 Manhattan Road
Airport Industrial Ext 2
Tel: + 21 (0) 21 386 2290
Fax: + 21 (0)21 386 2295
Web: www.minus40.co.za
SPECIALIZED REFRGERATION

(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
5.0

5.1

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)
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.
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*
UP TO
WIRE CROSS SECTIONAL AREA
IN MM2
2.5metre
4.0metre
6.0metre
10.0metre
16.0metre
2.5 mm2
4.0 mm2
6.0 mm2
10.0 mm2
16.0 mm2




5.2

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.
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.
2
Minus 40 (Pty) Ltd Reg. No. 89/03489/07
Vat Ret No: 4090105521
Director: S E Davison – D N McMurray
Member of Added Asset (Pty) Ltd
MINUS 40 (PTY) Ltd
SPECIALIZED REFRGERATION
44 Manhattan Road
Airport Industrial Ext 2
Tel: + 21 (0) 21 386 2290
Fax: + 21 (0)21 386 2295
Web: www.minus40.co.za
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)




6.1
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.
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.


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.
7.0
3
Minus 40 (Pty) Ltd Reg. No. 89/03489/07
Vat Ret No: 4090105521
Director: S E Davison – D N McMurray
Member of Added Asset (Pty) Ltd
MINUS 40 (PTY) Ltd
44 Manhattan Road
Airport Industrial Ext 2
Tel: + 21 (0) 21 386 2290
Fax: + 21 (0)21 386 2295
Web: www.minus40.co.za
SPECIALIZED REFRGERATION



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.
 Thermostat

Temperature

Control Knob
Set Mark for
Temperature

Fault
Finder

Flashing
MechanLicEaDl Dial
Thermometer
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
due to too low voltage supply
Battery charge low
Check wiring
thickness as per manual
Check for loose connections in plugs or
leads
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
4 Sec.
Motor start error due to high
differential pressure
Switch fridge off for 15 minutes to allow
pressures to equalize in the Refrigeration
system. Restart fridge.
1.4 Four times every 4Sec. Minimum motor speed error;
refrigeration system too heavily
loaded
Check that fan working.
Check that ambient temperature does
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
ambient temperature not exceed 55°C
Pre-cool the unit before loading
Fridge/freezer too heavily
loaded & too high ambient
temperature
4
Minus 40 (Pty) Ltd Reg. No. 89/03489/07
Vat Ret No: 4090105521
Director: S E Davison – D N McMurray
Member of Added Asset (Pty) Ltd
MINUS 40 (PTY) Ltd
44 Manhattan Road
Airport Industrial Ext 2
Tel: + 21 (0) 21 386 2290
Fax: + 21 (0)21 386 2295
Web: www.minus40.co.za
SPECIALIZED REFRGERATION
8.0
FAULT FINDER Continues
2. COMPRESSOR DOES
Faulty thermostat
NOT RUN AND RED LIGHT Loose connection at T or C
EMITTING DIODE DOES
Wrong polarity
Replace thermostat. Reconnect T or C
Reconnect T or C
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
9.0
9.1
9.2
9.3
9.4
9.5
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
DO'S AND DON'TS
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.
Do not operate the unit at an angle of more than 30° to the horizontal.
Do not allow the fridge/freezer to be placed upside down.
Do not drill any holes on the main insulated casing as a pipe may be punctured.
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.
5
Minus 40 (Pty) Ltd Reg. No. 89/03489/07
Vat Ret No: 4090105521
Director: S E Davison – D N McMurray
Member of Added Asset (Pty) Ltd