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Refrigeration for
the Cruiser
Dave McCampbell
Wayne Romberg
St Francis 44
Davao Gulf
2015
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Refrigeration for the Cruiser
Dave McCampbell Wayne Romberg
Bright Ayes Underway Offshore
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Sensible Cruising Equipment Recommendations
Dave McCampbell
Wayne Romberg
Refrigeration for
the Cruiser
CSY 44
Marquesas,
F Polynesia
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Why- keep foods & drinks longer, beer, ice
Refrigeration vs Ice
Storage- Short trips ice, cruising refrigeration
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My Refrig Goals: -easy owner install -steady box temps -minimize heat load -efficient heat removal -easy box content removal Side Loading
Refrig Box
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Tecumseh HG 1000 compressor mounted to 12v ¾ HP Leeson motor
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Nightmares: Tecumseh HG-1000 compressor partial tear down
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Very efficient but very expensive
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Side loading box- separate refrig & freezer boxes, 3 cold plates, R20
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Top load 3 cf freezer box, 2 cold plates, R22
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Danfoss Compressor Evaporator Plate Systems
Sealed connections, variable speed, bendable evap plates, almost silent, light weight, tight box temp delta
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Danfoss BD BD 50 compressor w/ ECM attached
Speed capacities
Compressors- lots of makers, Danfoss now Secop,
3 sizes: BD 35, 50, 80 capacities, variable speed
Sealed connections
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Rear of BD50, two heat sinks, filter dryer
Heat sinks
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Installation- big ventilated compressor space with digital speed control, thermostat, R134a can
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Electronic Control Module w/electrical connects, note only 2 power connections
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Evaporator Plate- Large vertical, vertical ice trays
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Evaporator Plate- Flat Bendable
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Using heat gun prior to bending new freezer evap plate
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Bending new freezer evap plate around 1.5” PVC pipe
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Air cooled condenser Adler Barbour Cold Machine Air Cooled Condenser
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Air Cooled Condenser Unit
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Frigoboat Pumped Water Cooled Condensor/Compressor
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Keel Cooler with Zincs
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Keel Cooler without Zincs
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Frigoboat Keel Coolers
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Installing a Keel Cooler 1.5” hole in hull
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Danfoss BD 50F 12v compressor- self sealing SS connectors, RPM vs amps
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Frigoboat Digital Thermostat w/ Temp display
Expensive
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Internet Digital Thermostat w/ temp display
About $15
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Digital Thermostat Rear Electrical Connections
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Digital Thermostat and Manual Speed Control Combination w/ Fault Light
Expensive
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Separate digital thermostat and auto speed control mounted
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Smart Compressor Speed Control Auto speed adjustment, soft start
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Manual Compressor Speed Control
Manual speed adjustment- most efficient if left on lowest speed, inexpensive
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Mechanical Thermostat- no temp display, freezer/refrig
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Old 30 lb can of R-12 w/ Schrader valve, $1000
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R134a Refrigerant Options
12 oz Can
22 oz Kit
30 lb Cylinder
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Diagnostic LED Fault Light Assembly
Worth having or make your own if not included on unit
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Box Construction
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Freezer insulation thickness values
1”=R5
Efficiency Goals: -Freezer R30 -Refrig R20
Problem- Insulation thickness vs bigger box size
Per day
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Problem- deteriorated CSY refrig/freezer separation shelf, old foam insulation, freezer insulation only 4”
Example One
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Rebuilt separation shelf, added one new freezer plate
--12 cans of new R5 refrigeration foam to replace original foam, ¼” holes
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Rebuilt 8.5cf side loading refrig up, 2.5 cf freezer below, --later changed to all refrigerator w/ holes in separation shelf, --removed freezer holding plates--lo--foam
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New Freezer Box- Inner box 3 cuft ½” fiberglassed plywood and outer 1” varnished hardwood
Example Two
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New freezer box components
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Original plastic sheet covered expanded polystyrene, ~R15, not good insulation, all available in Guatemala
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Freezer inner box- single cold plate, attached tubing, TXV and probes
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3 cf freezer box, later 2 cold plates
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Later Freezer Box- w/ Extruded Polystyrene insulation, evap plate & compressor
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Freezer Extruded Polystyrene insulation sealed in mylar
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reezeFr w/ Extruded Polystyrene and evap plate
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Ship’s carpenter sanding solid oak table top in PHarbor
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Final CSY freezer box- mounted in main cabin table, top loading, R22 w/ Extruded Polystyrene
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Refrig project in cat- replace small, 2.5 cu ft, air cooled RV refrig/freezer
Thin insulation
Example Three
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New 8 cuft side loading refrig in fwd half of bunk, big box pantry storage in aft half of bunk
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Outer ½” fiberglass/epoxied ply & inner ½” expanded PVC boxes in yard workshop
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Inner expanded PVC box w/ evap plate mounted
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Fitting door trim & box front in workshop
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Refrig box painted & temp assembled with screws
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Completely disassembled box pieces, before assembly onbd
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Sealed box tubing and wiring hole w/ Extruded Polystyrene
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Refrig box w/ one door and no gasketing yete
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Carpenters Gilbert and Alfredo w/ finished side loading 8 cuft refrig box onboard
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Expanded PVC- colors, lightweight, paint, glue, inexpensive
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Dow Blue board or Owens Corning Pink board- NC R6.5
Extruded Polystyrene
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EPDM rubber ribbed door gasketing weather strip- best for refrig doors, double gaskets for freezers
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Minus 40 4 cf freezer box: air cooled BD 35, only 3” R5 insulation, foam gasket
Final Project
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220v or 12v, auto shift to 12v if 220v shuts down, 50%= 54 ahr!
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Refrigeration for the Cruiser (Wayne)
• Heat Transfer-
– BTU = Energy to raise temp 1# water 1 deg F
– BTU trans = ∆ Temp x Thermal conductivity x Time
– By Design:
» Min BTU’s heat transferred into box
» Max BTU’s heat transferred out of box
» Optimize heat transfers in refrigeration cycle
• Vapor-Compression Refrigeration cycle - – Water boils at 32 deg F @ 29.74”Hg vac (1000 BTU/lb)
– R134a boils at -15deg F@ 0 psig (93 BTU/lb)
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Capillary tube
Holding Plate
Keel Cooler
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R134a Pressure – Temperature
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Refrigeration for the Cruiser • Maintenance-
– Defrosting Evaporator: as needed, no sharp tools
– Warm water/hair dryer
– Condenser cleaning: vacuum & paint brush
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Refrigeration for the Cruiser Maintenance-
Keel cooler condenser- bio fouling, antifoul paint, change zincs
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Refrigeration for the Cruiser • Maintenance-
– Tools- v pump, gage set, temp gage, R-134a, charging rig with Schrader connection, Pocket Refrigeration manual
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Refrigeration for the Cruiser • Maintenance-
– Adding refrigerant: (134a)
– 12 oz cans, no leak detector fluid or oil
– Add vapor not liquid to compressor suction
– Frost line vs gages & superheat (4 psig=-5 deg)
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Refrigeration for the Cruiser • Maintenance-
– Superheat method setting freon charge can be found in any Refrig Handbook or on internet.
– Will provide the optimum freon charge defined by a suction press at a given box temp & condenser temp.
– Freezer: 2 psig suction press @18deg
– Refrig: 17 psig suction press @38deg
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Refrigeration for the Cruiser • Maintenance-
– Leaks???
– Soap solution vs leak detector? Amazon- $25
– Quick connection O-rings,
– Become hard with age & don’t seal as well, especially when cold & at low press
– Spares- rated for 134a?
– O-ring tool?
– Alum evaporator plate, tubing leaks?
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Refrigeration for the Cruiser • Maintenance-
– Electrical faults- cool/dry mounting, spade connectors, BD series LED diagnosis, spare motor controller
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Refrigeration for the Cruiser • Maintenance-
BD series LED diagnosis
– One Flash –Low Voltage, <10.4v
– Two Flashes ‐ Overload on the Fan output.
– Three Flashes –Compressor cannot start due to high delta press
– Four Flashes –Compressor cannot reach min speed of 1,850 RPM.
– Five Flashes –Motor controller has exceeded 212 deg F
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Refrigeration for the Cruiser • Maintenance-
Blocked cap tube- dreaded, most likely frozen
– Hair dryer or warm cloth on cap -you will hear it
– Vacuum- temp vs time, min 2 hours, heat compressor, R134a hydroscopic & hard to remove moisture
– Install filter/dryer,
– Foreign matter-replace cap tube/evap plate
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Refrigeration for the Cruiser • Improvements-
– Compressor muffin fan across top to remove heat
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Refrigeration for the Cruiser • Improvements-
– Filter dryer in HP line before cap tube
– Separate systems: freezer & refrig-
• Each can operate at best design point
– Interior fans- freezer, refrig, pros & cons
– Keel cooler & air cooling combo unit
– Air cooled unit- ventilate the space with a fan
– Box insulation- added at bottom better than top
– Better gasketing- dollar bill test, double for freezer
– Dark hull color/box side - added heat gain
– Seal tubing/wiring box refrigerant entrance hole well
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Refrigeration for the Cruiser • Improvements-
– Cold box drain- adds heat load, foot pump system
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Refrigeration for the Cruiser • Improvements-
– Digital controls
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Refrigeration for the Cruiser • Improvements-
– Freezer, heat xfer tube
– Do not blanket evap plate with stuff.
– Mesh bags for food, no plastic bags against evap plate.
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Purchase Advice
– Be suspicious of dealers’ claims of ‘most efficient’, ask for proof
– Similar size box, equipment and insulation value equals similar efficiency
– Explore company websites- Coastal Climate Control
– Ask owners about satisfaction and maintenance help
– Explore internet forums
– See engineering and construction quality at shows
– Buy new unit and keel cooler condenser for best efficiency
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1 Boatowners’ Mechanical & Electrical Manual 3rd/4th ed- Nigel Calder 2 Refrigeration Installation, service and repair manuals 3 SVSoggypaws.com/refrigeration.htm 4 Frigoboat website- www.coastalclimatecontrol.com
References