SPECIALIZED REFRGERATION

OPERATING AND INSTALLATION INSTRUCTIONS FOR12/24V DC220V AC RANGE

FITTED WITH BD35F TYPE COMPRESSOR

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

1.0INDEX

  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 ANDWIRING DIAGRAM
  7. FAULT FINDER
  8. DO'S AND DON'TS

IMPORTANT

REMEMBER TO COMPLETE THE WARRANTY CARD AND RETURN IT TOTHE ABOVE ADDRESS. FAILURE TO DO SO MAY LEAD TO DIFFICULTY INPROCESSING 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

2.0INTRODUCTION

OPERATING INSTRUCTIONS

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

B40 "Caravelle"-Portable Chest TypeFreezer for off-road vehicle use

B60 "Safari"-Portable Chest TypeFreezerfor off-road vehicle use

B60 "Namib"-Portable Chest TypeFreezerfor off-road vehicle use

B115 "Bushmaster"-Portable Chest TypeFreezerfor off-road vehicle use

B150 "Kalahari"--Portable Chest TypeFreezerfor 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 usedas a refrigerator or freezer. The desired temperature should be set on thethermostat dial before use. Temperatures in the range +10°C to –25°C canbe maintained. It isimportant to note that the lower the temperature settingthegreater the battery power consumed.The following table can be used as a temperature setting guideline:

PRODUCTSTORAGE TIMETEMPERATURE

Uncooked meat,1 - 2 days8 to 10°C

Milk, cheese,3 - 4 days5 to 8°C

Vegetables, etc.7 days +5 to 9°C

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

Vegetablesup to 14 days-8 to –4°C

Pre-prepared foodsnot more than-15 to –12°C

(30 days)

3.0CHECK THE FOLLOWING AFTER UNPACKING

  • Check for any transport damaged.
  • Mount the unit on a reasonably level surface and ensure that air circulationaroundthe compressor compartment is free. (The unit should not be placedcloser than80mm 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 (-).
  • Connecttheleads to a 12/24 Volt battery; red to positive, black to negative.Incorrect connection will result in the unit not switching on.

4.0PRE-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 tobe preserved, once the refrigerator/freezer has reached the set temperature.

NBNote that the Light Emitting Diode does not glow whilst unit isoperating. It will only emit light flashes during a fault finding process

(SeeFAULT FINDER on page4-5)

5.012/24 VOLT OPERATION

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

5.1USES IN VEHICLE

  • If the unit is to be used mainly in a vehicle then it is recommended that anadditional battery - other thanthe vehicle battery - be fitted for use solely with the freezer. The additionalbattery should belocated as close as possible to the freezer. This willprevent the additional drain on the vehicle's main battery which could prevent thevehicle 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 electricalsystem. All 12 volt electrical wiring should be carried out according to the following table:

TABLE1

CABLE LENGTH*WIRE CROSS SECTIONAL AREA

UP TOIN MM2

2.5metre2.5 mm2

4.0metre4.0 mm2

6.0metre6.0 mm2

10.0metre10.0 mm2

16.0metre16.0 mm2

  • Total length of wire from the vehicle’s electrical system - via battery - to connection onelectronic controller.
  • For short periods of operation a connection may be made directly to the vehicle'selectrical system. As a precaution it is recommended that the unit be switched offwhen 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 afterswitching off.
  • When using the unit as a freezer it is advisable to turn the thermostat downto-25° minimum when the vehicle engine is running. This allows maximumuse of current available from the alternator. When the vehicle’sengine isswitched off the thermostat must be set to a higher setting (e.g. –8°C).This will reduce running time and hence prolong batterylife.

5.2FOR USE WITH SOLAR PANELS

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

6.0ELECTRICAL 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 notrunning.
  • This often results in the fridge being condemned as useless, despite the fact thatfactory tests prove the unit's

6.0ELECTRICAL 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 ensurereliable running.
  • The battery must provide an adequate power reserve to operate the fridgewhen the vehicle is stationary.
  • The wiring system between battery and fridge should be designed to minimize voltagedrop.
  • Opening of the fridge or freezer must be carefully controlled.

6.1BATTERY SELECTION:

6.1.1Other than for very limited periods the vehicle's main battery should not beused to operate a fridge/freezer. A properly installed dual battery systemutilizing a Low Maintenance, Deep Cycle Battery ofapproximately 100Ahcapacity should be used. A Deep Cycle Battery will tolerate the constantdischarging and recharging cycle associated with fridge use far better than anautomotive battery which can be expected to expire after 15 or 20 dischargecycles. In addition the Deep Cycle battery provides a greater portion of itsstored charge (up to 70% in some makes) before the voltage drops to the levelat which the fridge low voltage cut out operates.

6.1.2With dual batteries it is advisable to ensure that only the auxiliary battery isleft in circuit when the engine is switched off. Most splitcharging systemswillensure that this is accomplished. Alternatively a relay operated by theignitioncircuit should be fitted to connect the auxiliary battery to thealternatorcharging circuit when the engine is running. With the correctbattery systemproperly charged all thatremains is to transfer powerefficiently to thefridge/freezer.

6.2WIRING SYSTEM

  • Danfoss BD35F compressor operated fridges have a built in battery protection cut outwhich will stop the fridge when the voltage at the compressor terminalreaches either 10.4 (12V operation) or 22.8 (24V operation).
  • It is not generally realized that a 12/24V DC fridge compressor can draw upto 10 to 15 Amps for a few seconds on start up. This high current will cause avoltage drop due to the resistance found in the wiring between the batteryand the fridge.
  • The wiring circuit, its connections and any switches usedshould be able to carry the 10 to 15Amps starting current with a voltage drop notexceeding 10 to 15 Volts.
  • If the voltage drop in the wiring is higher than this and the battery is not fullycharged, the voltage at the compressor can drop below the cut off voltagewhenstarting. The compressor then cuts out, and the voltage at thecontroller boxterminals rises because there is now no load and hence novolt drop. The batteryprotection cut out now allows the fridge to attempt tore-start and the whole cyclerepeats itself.
  • Prolonged operation in this waycould damage the compressor and electrical components.
  • As a general rule, all plugs and switches in the circuit should have a 20AmpDC rating and wiring should have a cross section area of not less than2.5mm2.
  • 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.

7.0OPERATION

  • To obtain best results from the limited power resources of the battery a fewbasic steps shouldbe 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 andrunning from the battery only,turn the thermostat to –8°Cto just maintain frozen conditions.
  • Limit lid openings to a minimum. Take frozen food out to defrost in acooler 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.

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

8.0FAULT FINDER

FAULTPOSSIBLE REASONCORRECTION

1. COMPRESSOR DOES NOTRUNANDRED LIGHTEMITTING DIODE FLASHES

1.1 Once every 4 Sec.Low voltage protection cut outCheck wiring

due to too low voltage supplythickness as permanual

Check for looseconnections inplugs or leads

Battery charge lowCheck for low battery and re-chargewith fridgedisconnected from battery.

1.2 Twice every 4 Sec.Fan motor high current cut out.Disconnect fan at F. Ifproblem goes away,replace fan motor.Ifpersists contact yourMinus 40 Dealer/Agent.

1.3 Three times everyMotor start error due tohighSwitch fridge off for 15minutes to allow

4 Sec.differential pressurepressures to equalize inthe Refrigeration system. Restartfridge.

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

refrigeration system too heavilyCheck thatambient temperaturedoes

loadednotexceed 55°C.Pre-cool the unit beforeloading

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

Fridge/freezer too heavilyambient temperature not exceed 55°C

loaded & too high ambientPre-cool the unit before loading

temperature

8.0FAULT FINDER Continues

2. COMPRESSOR DOESFaulty thermostatReplace thermostat.Reconnect T or C

NOT RUN AND REDLIGHTLoose connection at T or CReconnect T or C

EMITTINGDIODEDOESWrong polarityCheck that Positive ofbattery is connected to red wire and negative to black wire

Fault at speed regulating resistorReplace with 820 ohmresistor or temporarilyreplace resistor with a conductor

NO OR REDUCED

COOLING CAPACITYGas leakage or blockage inContact Minus 40Agent/Dealer or refrigeration system have the unit repaired by a qualified refrigerationtechnician

Faulty fan motorReplace fan motor

9.0 DO'S AND DON'TS

9.1Do not operate the fridge/freezer inside the boot of a vehicle or in a standingvehicle with no open windows as the temperatures can rise to +70°C.

9.2Do not operate the unit at an angle of more than 30° to the horizontal.

9.3Do not allow the fridge/freezer to be placed upside down.

9.4Do not drill any holes on the main insulated casing as a pipe may bepunctured.

9.5Do not allow anyone to perform repairs to a Minus 40 unit without priorapproval from the factory as this may render the warranty null and void.

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

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