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REFRIGERATION PARTS SOLUTION
Assembly and Installation Manual
Full Gauge Digital Thermostat Retrofit Kit
Digital Thermostat Upgrade for Danfoss BD Series of DC
Compressor Systems with Analog Thermostat
DATE
REV
DESCRIPTION
8-1-14
0.0
New Manual Version– Full Gauge
9-16-14
1.0
Modified configuration instructions for Full Gauge MT-511RiL
2-14-15
1.1
Added Cross Reference Table
4-16-16
2.0
Added configuration instructions for the new Full Gauge MT-512RiL
10-31-16
2.1
Corrected connection number for 12V from toggle switch (page 7) should be connection #8
3-6-17
2.2
Corrected MT-512RiL instructions, Step 4. Configure the differential (previous version had incorrect F06 should be F05)
"Do It Yourself" Kit
Part Number 011-1021
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Summary of Contents for RParts 011-1021
- Page 1 “Do It Yourself” Kit Assembly and Installation Manual Full Gauge Digital Thermostat Retrofit Kit Digital Thermostat Upgrade for Danfoss BD Series of DC Compressor Systems with Analog Thermostat Part Number 011-1021 DATE DESCRIPTION 8-1-14 New Manual Version– Full Gauge 9-16-14...
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Page 2: Table Of Contents
TABLE OF CONTENTS______________________________ List of Parts Required Tools Introduction Preparation Assembly Instructions: Electrical Wiring Connections Connection on the Full Gauge Thermostat End Connection on the Danfoss Control Module End Determining Thermostat Temperature Settings Installation Instructions: Mounting the Thermostat Unit Assembly Instructions: Temperature Sensor Attachment to Evaporator MT-512RiL Digital Thermostat Configuration Instructions MT-511RiL Digital Thermostat Configuration Instructions Wiring Tables... -
Page 3: List Of Parts
List of Parts: Complete List (included with Kit)__________ Item Part No. Description 015-0000 SS Mounting Bracket for Digital Thermostat 015-0010 Full Gauge (SPDT) Digital Thermostat 015-0012 Full Gauge NTC Temperature Probe 017-2000 1 1/4" x 1/4" Fast Acting AGC Fuse - 2 amp 017-2011 10 amp In-Line Fuse Holder 017-3101... -
Page 4: Required Tools
Required Tools_______________________________ The following tools are required and are not included with the kit. Electric drill and assorted drill bits • Jig saw and fine tooth saw blade • Matches, Butane lighter, or heat gun • Pencil • Scissors • Small flat blade and Phillips screwdrivers •... -
Page 5: Introduction
Introduction_____________________________________ Any small DC refrigeration system using a Danfoss BD series of DC compressors controlled by a “dial” or analog thermostat will benefit with an upgrade from the standard thermostat to a Full Gauge electronic digital thermostat. Using the Full Gauge digital thermostat allows complete control of both the set point and differential of the thermostat operation. -
Page 6: Preparation
shut off voltage. A table of the resistor values for low battery protection is included at the end of this manual. Speed control: The compressor speed can be changed by adding a resistor (R1) in series with the thermostat. If the system came with a resistor, the original resistor value is usually the best choice and should be retained unless there is a good reason to change it. -
Page 7: Assembly Instructions: Electrical Wiring Connections
Assembly: Electrical Wiring Connections______________ Connection on the Full Gauge Thermostat End Locate the stainless steel thermostat mounting bracket (015-0000) and mount the On/Off rocker switch (017-3101) and the Full Gauge digital thermostat (015-0010) into the bracket. The “O” on the On/Off rocker switch should be below the “l”. - Page 8 the rocker switch attaches via another insulated female spade terminal (290- 0005) to a short length of wire (cut from red wire from the multi-conductor cable) which then attaches to connection 8 on the Full Gauge thermostat (also red in the photo). The other end of the positive, red wire of the multi- conductor cable will connect to the Danfoss compressor control module large “+”...
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Page 9: Connection On The Danfoss Control Module End
Connection on the Danfoss Control Module End The wires (241-0001, red and black) supplying power to the Full Gauge thermostat use insulated female spade terminals (290-0001 and 290-0021) to connect to the double male-female adapter terminals (290-0902) included in the kit and “piggyback” with the Danfoss power supply cable (with a insulated female spade terminal) on the large “+”... - Page 10 The Full Gauge positive (+) 12 volt DC supply wire (241-0001, red) connects to a waterproof AGC inline fuse holder (017-2011) with an adhesive lined heat shrink butt connector (290-0212) before continuing to the Danfoss control module installation location. Heat the butt connector with a match, lighter, or heat gun after making the electrical connections to activate the adhesive and shrink the insulation around the wires, making a waterproof connection.
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Page 11: Determining Thermostat Temperature Settings
Determining Thermostat Temperature Settings_________ The digital thermostat for refrigeration systems utilizing a roll bond evaporator can be installed and programmed in either of two methods. In one method, the thermostat senses and regulates the temperature of the evaporator, which has a low setting with a large rise in temperature before the compressor restarts. -
Page 12: Installation Instructions: Mounting The Thermostat Unit
tubing is located within the plate. This can be observed visually when the plate first cools from ambient temperature. The serpentine pattern of the tubing in the plate is visible in the frost pattern as the plate begins to chill, usually within 20 minutes of starting the system. The holding plate system needs to run until the plate liquid is completely frozen, and not restart until the frozen plate completely thaws. -
Page 13: Assembly Instructions: Temperature Sensor Attachment To Evaporator
Assembly: Temperature Probe Sensor Attachment_______ The thermostat must sense the temperature of what it is trying to regulate. Usually this will be the evaporator or holding plate temperature. The oval end of the temperature probe should be attached to the holding plate in an area that is out of the way of normal access to the food in the box, yet in an area that most accurately senses the state of the plate, either frozen or liquid. - Page 14 Attach the third piece of foam in the same manner as second piece. Press the layers of foam tape together firmly to assure good contact between the layers. The same foam tape method of probe attachment can be used on the roll bond evaporator. Mount the thermostat probe on a large flat area away from the evaporator tubes and near the exit of the suction line on the roll bond evaporator.
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Page 15: Mt-512Ril Digital Thermostat Configuration Instructions
FG MT-512RiL Digital Thermostat Configuration Instructions Initially, there are protected items that must be configured in the thermostat by unlocking the unit. Those items are units (C or F), defrost timer, and differential. Once those are configured the setpoint may be changed at any time without using the unlock code. For the protected items, do step 1 to 5 and then finish by setting the setpoint in step 6. - Page 16 Full Gauge MT512 RiL Table of recommended values for all function registers Here are the recommended values: F02 : 00 Indication offset F03: -05 Minimum Setpoint F04: 35 Maximum Setpoint F05: 15 Differential F06: 20 Delay in seconds for restarting (20 is default) F07: 240 Max cooling time in minutes (240 is default) F08: 0...
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Page 17: Mt-511Ril Digital Thermostat Configuration Instructions
FG MT-511RiL Digital Thermostat Configuration Instructions There are four items that must be configured in the thermostat. The items are units (C or F), setpoint (the temperature to shutoff the compressor), differential (the temperature rise from setpoint to restart the compressor), and function (cooling or heating). The system must be powered on and the thermostat switch should be in the off position during the configuration process. -
Page 18: Wiring Tables
Wiring Tables____________________________________ This section provides tables for wire dimensions, optional compressor speed control resistor values, optional battery voltage protection resistor values, and LED operational error codes. WIRE DIMENSIONS Fuse Breaker Size Wire Size Max Length* 12 volt 24 volt Cross Section 12 volt 24 volt 15 Amps... -
Page 19: Wiring Cross Reference
WIRING CROSS REFERENCE If replacing an existing Digital Thermostat then use the cross reference table below to match the connections on the Digital Thermostats the RPARTS offers. Digital Thermostat Connections Cross Reference Move wire from screw number on old to screw number on new... -
Page 20: Optional Compressor Speed Control Resistor (R1) Values Table
OPTIONAL COMPRESSOR SPEED CONTROL RESISTOR VALUES (R1) Compressor Mo del Electronic U nit Resistor (R1) (Ω) Motor Speed (RPM) BD35F and BD 50F 101N0210 2000 101N0220 2500 101N0500 3000 BD50F ONLY 101N0230 1523 3500 2000 101N0300 BD35F and BD 50F 2500 with AEO 3000... -
Page 21: Optional Battery Voltage Protection Resistor (R2) Values Table
OPTIONAL BATTERY VOLTAGE PROTECTION RESISTOR VALUES (R2) For Danfoss BD35F, BD50F and BD80F compressors 12V max. 24V max. Resistor (R2) 12V cut-out 12V cut-in 24V cut-out 24V cut-in Voltage Voltage [kΩ] 10.9 17.0 21.3 22.7 31.5 11.0 17.0 21.5 22.9 31.5 11.1 17.0... -
Page 22: Optional Led Operational Error Codes Table
OPTIONAL LED OPERATIONAL ERROR CODES Number of Error Type Flashes Thermal cut-out of electronic unit (If the refrigeration system has been too heavily loaded, or if the ambient temperature is high; the electronic unit will run too hot). Minimum motor speed error (If the refrigeration system is too heavily loaded, the motor cannot maintain minimum speed at approximately *1,850 rpm). -
Page 23: Warranty Information
Components expressly excluded from this warranty are: o Danfoss power module o Sea water pump RParts shall not be liable for consequential damages resulting from the use of this product. Coverage for any incidental damage to vessel, equipment or supplies caused, either directly or indirectly, by the failure of any RParts component is specifically excluded.
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