Mermaid REFRIGERATION/FREEZER Installation Instructions And Owner's Manual

Text of Mermaid REFRIGERATION/FREEZER User Guide:

• KOOL-TEMP ™ MARINE REFRIGERATION/FREEZER UNITS INSTALLATION INSTRUCTIONS AND OWNER’S MANUAL PRODUCED BY: MERMAID MANUFACTURING OF S.W., FL, INC. 2651 PARK WINDSOR DRIVE SUITE 203 FORT MYERS, FL 33901 800-330-3553 239-418-0535 – P 239-418-0538 – F [email protected]

• Mermaid REFRIGERATION/FREEZER, TABLE OF CONTENTS SECTION 1 (OVERVIEW) A. Introduction to Mermaid SECTION 2 (INSTALLATION) A. Mounting Position B. Installation SECTION 3 (CONTROL MODULE) A. Electronic Control Module B. 12/24VDC, 12/24VDC & 110V w/ Auto-Changeover SECTION 4 (SAFEGUARDS) A. Low Voltage B. High Voltage C. Compressor Non-Start D. Compressor Speed Too Low E. Fan Protection F. Module Overheat G. Alarm Indicators SECTION 5 (EVAPORATORS) A. Location B. Installation C. Thermostat Sensing Tube D. Mounting SECTION 6

• Mermaid REFRIGERATION/FREEZER, SECTION 8 (ELECTRICAL) A. Power Supply B. Wire Size C. Overload Protection D. Connections, Power E. Connections, Thermostat F. Connections, Fan SECTION 9 (TROUBLESHOOTING GUIDE) A. Note B. Compressor Not Running, No Start Attempt C. Compressor Attempts To Start, Or Starts And Stops Shortly After D. System Runs, Box Temperature Too High E. System Runs, Box Temperature Too Low F. Excessive Frost Build Up SECTION 1 (OVERVIEW) A. Introduction: Congratulations!! You have just purchased one the most dependable Marine Refrigeration/Freezer units available on the market today, a MERMAID. Mermaid supplies ple

• Mermaid’s 12/24VDC model or our 12/24VDC & 110V with Auto Change-Over model, we are sure you will be pleased with their performance. Mermaid provides a one-year warranty on the refrigeration/freezer products and a five- year warranty on their marine air conditioning line. In the unlikely event of any issue, Mermaid will take the necessary steps to

• Mermaid REFRIGERATION/FREEZER, SECTION 3 (CONTROL MODULE) A: Electronic Control Module: The Electronic Control Module is an integral part of the Danfoss BD35/50F compressor system. It transforms direct current power from the vessels batteries into alternating current to run the compressor. Never attempt to run the compressor directly from the batteries or other power source. B: 12/24VDC, 12/24VDC & 110V w/ Auto Change-Over A supply voltage of either 12 or 24 volts dc is required, & the Module will run from either without any special setting

• Mermaid REFRIGERATION/FREEZER, C: Compressor Non-Start: If the compressor does not start, the Module will stop the starting process, & attempt a re- start every 60 seconds. D: Compressor Speed Too Low: If the compressor speed falls below 1900 RPM the Module will stop the compressor. E: Fan Protection: If the current draw across the fan terminals exceeds 0.7 amps 12v dc, the compressor will be stopped & a re-start attempted every 60 seconds. F: Module Overheat: If the heat sink on the module exceeds a preset temperature, the compressor will be stopped & will be re-started when normal operating temperatures are resumed. G: 4 Alarm Indicator: A LED may be installed across the + & D t

• Mermaid REFRIGERATION/FREEZER, NOTE TWO The Electronic Module, although designed for harsh & marine applications, can be damaged from either direct or incidental contact with water, & by water flowing down wires attached to the terminals. When attaching wires to the terminals on the Module, make sure that all wires approach from below the terminal, & endeavor to mount the Compressor & Module combination in a location that is clear of existing & potential water leaks. SECTION 5 (EVAPORATORS) A: Location: All types of evaporator need to be located as high as possible in the

• Mermaid REFRIGERATION/FREEZER, C: Thermostat Sensing Tube: Check to see where you need to attach the thermostat sensing tube before mounting the evaporator. The capillary tube (silver capillary tube) coming off the thermostat is the sensing device. Upon delivery, the sensing tube will be coiled up near the body of the thermostat. The entire unit – including the dial – may be installed in the refrigerator/freezer box if necessary. If you choose to mount the controls external of the box, ensure that a majority of the capillary tubing is inserted into the box. Without the capillary sensing tube, the thermostat will not operate effectively. You may use items like tie straps or small plas

• contact with any electrical component either inside or outside the ice-box. If the sensing tube needs to be bent within the confines of the refrigerator or freezer box, it must be done with great care, heeding the warnings above. C: Operation: The thermostat knob is marked from 1 to 7. The coldest setting is 7, & from this position the knob can be rotated counter-clockwise to setting

• Mermaid REFRIGERATION/FREEZER, together, they allow the refrigerant to flow through the system without leaking out to the atmosphere. If needed, they can be undone to enable a faulty component to be removed & replaced without leaking refrigerant. Never run the compressor unless all components of the system are connected together. B: Connecting the Quick Connect Fittings: Leave the clear plastic dust plugs installed until you are ready to connect the system together. After you have removed the plugs, keep them in a safe place in case you need to remove or replace a comp

• Mermaid REFRIGERATION/FREEZER, B: Wire Size: Consult ABYC tables for 3% volt drop. Never use less than 10 gauge wire. C: Overload Protection: Use either a breaker or fast-blow fuse with 15 amp rating for a 12/24v supply, and/or a 8 amp fuse for the 110v a/c side. (These items are provided on new installations from the Mermaid factory). D: Connections, Power: If wiring from the factory needs to be removed, connect the power supply to the Module to the top two terminals, observing the correct polarity. Reversing the polarity at the terminals will prevent the compressor from running but

• Mermaid REFRIGERATION/FREEZER, (3) Run all applicable tests before assuming Module or Compressor to be faulty. B: Compressor Not Running, No Start Attempt. Probable cause Action 1 Supply voltage too low Check voltage with a digital multi-meter at the terminals on the Module. This must be 11.7v or more for a 12v supply & 24v or more for a 24v supply. Inspect power supply, ground connections & components for integrity. Check wire sizing. Charge batteries if necessary. 2 Supply voltage too high If a 12v supply is faulty & delivers over 17v, the compressor will not run. If it is over 24v, it will assume

• Mermaid REFRIGERATION/FREEZER, connected retaining screw & then ensure that the 3- pin plug is seated firmly on the pins of the compressor. 9 Faulty compressor Remove the Module as above, & unplug from the compressor. Check that ohm readings are the same across all terminals of the compressor. 10 Heat sink overheated Allow components to cool down before attempting re-start. 11 Compressor too cold If compressor is below freezing temperature, allow to warm up before attempting re-start. C: Compressor Attempts to Start, or Starts Then Stops Shortly After: 1 Faulty or inadequate power suppl

• Mermaid REFRIGERATION/FREEZER, 3 Thermostat type If you are planning to convert your ice box into a freezer, or as a spillover system, a freezer thermostat (0021) must be used. 4 Evaporator type & size If the evaporator has an even coating of frost, the thermostat is set on 7, & the system is cycling, the evaporator may be too small. Either replace the evaporator with a larger model, add insulation to the bottom of the box to reduce volume, or re-locate the evaporator lower in the box. The latter may cause the temperature at the top of the box to be above acceptable levels. 5 Excessive frost build-up If an excessive layer of frost is allowed to build up on the evap

• Mermaid REFRIGERATION/FREEZER, E: System Runs, Box Temperature Too Low: 1 Thermostat setting Rotate thermostat knob to a lower number. 2 Thermostat type Check that you are using a refrigerator thermostat (0028) for a refrigerator application. 3 Faulty thermostat If system is running continuously & box temperatures are too low with thermostat set on the lowest number, first check for correct thermostat connections at the Module, then remove one connection. If compressor stops, turn off breaker, replace connection & then control system manually from the breaker until the

• Mermaid REFRIGERATION/FREEZER, F: Excessive Frost Build-Up: Note: This is the result of moist air being allowed to enter the box. Problems are compounded when cold air leaks from the lower area of the box & is replaced by warm, humid air entering elsewhere. 1 Drains & holes not plugged Make sure all drains & holes in the floor & walls of the box are sealed. 2 Circulating fan If a small fan is used to circulate air in the box, make sure that the cold air is not being blown towards & out of a door/lid seal. This could force cold air out of the box & set up

• WIRING OF DANFOSS ELECTRONIC MODULE 12/24V 12/24V + 110V FOLLOW THE WIRING DIAGRAM ABOVE AND DESCRIPTION BELOW TO MATCH WIRES. THE 12/24 + 110V MODELS WILL HAVE AN ADDITIONAL POSITIVE (L) AND NEUTRAL (N) SYMBOL FOR THE TWO 110V LEADS. MM1 AND MM2 12/24V MODELS: (-) NEGATIVE LEAD = BLACK WIRE (NEGATIVE 12/24V) (+)POSITIVE LEAD = R

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