WAECO Question.
Submitted: Sunday, Feb 18, 2007 at 18:47
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Exploder
Spent a few nice days out at
Wedge Island with friends, now just got to wash all the salt and sand off the car.
Took a 35 litre WAECO up with me for the Food but run into some troubles with it.
When the car is running sweet no worries it cools.
Run it off the generator on 240Volts and it run’s sweet as
But
When I turn the car off, with in a few minutes the Red wanning light starts flashing, the compressor still comes on and off but the fridge struggles to maintain anything below 3-4 degrees.
I was trying to run it off a Century 780CCA Cranking battery, which is only 6 months old; one of the guys up there (Auto Sparky) suggested low battery Voltage but it Cranks The Explorer over easily. He also had a WAECO in his 80 series, running off a duel battery system and he had to turn it up as it was freezing the beer LOL
The fridge also has a Low Medium High Switch> what is this for? I just kept changing it’s setting to see if it made a difference.
I ended up just setting the fridge temperature too –3 and would run it for 4 hours on Turbo mode off the generator at night then give it another hit for 1-2 hours in the morning then if I didn’t drive anywhere another hit at around 3pm for 2hours and that kept the food cold enough.
Any knowledgeable people out there that could shed some light on the issue, I know it’s desirable to run the fridge off a second battery but my cranking battery isn’t exactly small and I would have thought it would have enough guts in it to run a fridge for a few hours during the day.
Cheers.
Reply By: Exploder - Sunday, Feb 18, 2007 at 20:25
Sunday, Feb 18, 2007 at 20:25
Ok, Plug fridge in and start the engine and it runs fine, no red waning light
Turn off the engine and with in 1 minute the waning light is flashing, 1 flash every 5 seconds.
The battery voltage gage is with in limits with the car off and with the engine running the Gauge is reading in the normal level of charging.
This is telling me that the wiring is loosing too much current when running off
battery power alone correct ?, so that means I need a dedicated fridge plug that uses heaver wiring yes?
AnswerID:
222536
Follow Up By: Jimbo 2121 - Sunday, Feb 18, 2007 at 20:44
Sunday, Feb 18, 2007 at 20:44
Yes it sounds like the voltage is dropping to much at the fridge when the engine is off. If you
check with a voltmeter at the fridge you would know for sure.
FollowupID:
483368
Follow Up By: ross - Monday, Feb 19, 2007 at 20:55
Monday, Feb 19, 2007 at 20:55
Yeah I had this problem with all 3 vehicles I own. You need to
test the voltage under load.
Its a good chance its dropping back to under 10 volts.
Since I ran a wire and plug direct to the battery,no problms
FollowupID:
483589
Reply By: DMH122 - Sunday, Feb 18, 2007 at 20:34
Sunday, Feb 18, 2007 at 20:34
Hi Exploder, I had the same problem with
mine, red led blinking, worked fine on 240 & vehicle running, after checking all wiring & connections & voltage @ fridge while it was running, could not fault the voltage supply, rang a service agent in Dubbo NSW, bingo he new straigt away, he said it is a faulty thermal fuse soldered to the circuit board, being still under warrenty i sent it off to him back 3 days later working like a charm, I Hope this is of some help, just jump on the Waeco web site & find the nearest service agent to you & give them a ring i am sure they will help you out. All the best.
AnswerID:
222540
Follow Up By: Member - Matt M (ACT) - Monday, Feb 19, 2007 at 07:48
Monday, Feb 19, 2007 at 07:48
Exploder,
If you have an AC model, it is worth pursuing DMH122's line. I had the same problem with an AC50 which Waeco fixed under warranty. The net result is that the fridge will cut out on low voltage when there are plenty of gibbers left in the battery (in my case at about 12.6v). No probs on 240v and, with the engine running, you may be still getting enough for the fuse not to cut in. Gets worse with heat as
well.
A fairly quick fix which and Waeco recognise the problem and will cover it under their warranty. Comments re quality of wiring and connections still worth pursuing first.
Matt.
FollowupID:
483431
Reply By: Robnicko - Tuesday, Feb 20, 2007 at 10:46
Tuesday, Feb 20, 2007 at 10:46
Exploder,
Spoke to a mate who's a service agent for Waeco and showed him this post. The problem is the Poly-Fuse (thermal fuse) within the control unit. Most waeco fridges have a 5amp fuse in there which is soldered to the circuit board. Once they play up they progressively get worse, especially on hot days. He has replaced about 30 or so since Christmas last year!
Although the LOW setting will cut out at 10.7V the compressor willl actually run at 9.7V. When the fuse plays up it melts internally causing a break in connection and therefore cuts power to the compressor, cooling fan will still run. It then connects again and restarts the compressor.
They are now replacing them with a larger 10amp polyfuse.
The reason why it didn't play up when plugged into 240V is because when running of 240 it goes through a power converter down to 24v. On 24V electronics run much cooler as opposed to 12V where electronics run much warmer.
He also told me that when the fuse plays up it will try to draw heaps amps just prior to cutting power and could be monitored with an ammeter.
I gave him my CF40 and he is going to put one of these heavier duty fuses in
mine even though
mine still works fine as he reckons it's only a matter of time before it does the same thing.
Rob
AnswerID:
222873
Follow Up By: hl - Tuesday, Feb 20, 2007 at 13:45
Tuesday, Feb 20, 2007 at 13:45
Hi,
If the fridge runs ok with the engine running, it won't be the polyswitch.
If the polyswitch is faulty, it will cut out regardless.
The reason it does not usually play up when running on AC is not heat, but running on 24V with only half the current i.e. it will draw about 2 amps instead of 4, and the faulty polyswitch will not trigger.
Cheers
FollowupID:
483742
Follow Up By: Member - Matt M (ACT) - Tuesday, Feb 20, 2007 at 14:11
Tuesday, Feb 20, 2007 at 14:11
hl,
Beg to differ. A faulty poly fuse will cause the fridge to cut out at higher than advertised voltages, in my case at about 12.6v. With the engine running, the available voltage generally rises above this and the poly fuse does not cause an issue, although it can vary depending on the state of the fuse.
Not too sure about the 12 vs 24v issue, but ambient temperature also plays a part in causing the fuse to cut the power. The higher the temp, the higher the cutout voltage. Ours worked fine until we got into some higher temps in the
Kimberley. In any case my fridge ran fine with the engine running, but not on battery alone. Fuse replaced - problem gone, so there must be something in that.
Rob,
I believe that the Hi/Med/Low setting works the other way around and is based on voltage at the compressor which is roughly 1 volt less than the battery. That is the low setting will cut out when the voltage drops to 10.4v at the compressor, 11.4v at the battery. This means that the fridge will not take your batteries below 11.4v which is probably at or about the minimum you would want for an AGM. Probably too low for a lead acid.
Cheers,
Matt.
FollowupID:
483747
Follow Up By: Robnicko - Tuesday, Feb 20, 2007 at 14:50
Tuesday, Feb 20, 2007 at 14:50
Matt,
Yes you are correct! The high low med is for compressor voltage. Apologies, it must be the humidity in
Melbourne at the moment.
Hl,
I am only passing on information given to me by an authorised Waeco repairer who stated that ambient heat does cause the polyfuse to play up and that running on 12V does make them run warmer. By the way he also told me that Waeco are now sending out controllers without the Polyfuse soldered in so that the agents have to manually solder in the higher rated polyfuse. Yes, when 24v only half the amps, load and heat. If you see these things they look like a piece of plastescene
with two wires coming out. The standard one is about 1.5cm square whilst the replacement is easily twice the size........personally i think they should just jump a piece of wire across and let the fuse in the power lead do the job.
Rob
FollowupID:
483749
Follow Up By: hl - Tuesday, Feb 20, 2007 at 15:33
Tuesday, Feb 20, 2007 at 15:33
Matt,
That is exactly what I was saying. When the Polyswitch is faulty, it will cut out regardless. If the fridge runs ok when the engine is on, then the Polyswitch is NOT faulty.
I figured out that problem myself about a year ago, when the WAECO rep told me it would take at least a month to look at my fridge. The Polyswitch they used at the time had a 4 amp rating and considering the the fridge can draw close to 6A in turbo mode, that component was clearly rated inadequate.
It is actually not the Polyswitch itself that triggers, but rather the increased resistance that develops before it it flips off off. It causes an increased voltage drop which in turn causes the compressor electronics to sense low voltage and turn off. I replaced
mine with a 6A type and it has run ok ever since, it will however, still turn off occasionally in turbo mode. It is not a really good idea to replace it with a piece of wire. The advantage of using a polyswitch is the fact that it will re-set when it cools down. It's purpose in the Waeco is primarily to interrupt a high current flow should the compressor stall. This can happen if the fridge is turned off and on again quickly before the pressure has equalized. Without the Polyswitch the main fuse in the lead would probably blow and that would be a real nuisance.
Cheers
FollowupID:
483754
Follow Up By: Member - Matt M (ACT) - Tuesday, Feb 20, 2007 at 15:48
Tuesday, Feb 20, 2007 at 15:48
hl,
Probably not a point worth debating at length, but the original symptons described were exactly the same as
mine, ie fridge would run OK on 240v, and when the batteries were being charged on 12v. When not being charged, once the batteries got to around 12.6v, problem started again.
I did nothing else to the wiring or fridge setup, had the poly fuse replaced and problem gone. The impression I got was that the faulty fuse would cause the fridge to cut out at higher than expected voltages (say 12.6v) and that when on charge the batteries exceeded this voltage and did not cause the fuse to open hence the fridge ran OK.
Interested in your comments on the wait for service from Waeco. My experience was excellent, noting that the fridge shouldn't have busted in the first place. The service agent in
Exmouth even lent me a fridge while he repaired
mine. I have heard enough of this problem now to suggest that Waeco should just bite the bullet and issue a product recall for what has been otherwise a great fridge.
Cheers,
Matt.
FollowupID:
483758
Follow Up By: hl - Tuesday, Feb 20, 2007 at 16:02
Tuesday, Feb 20, 2007 at 16:02
Hi Matt,
Yes, agree.
As for the warranty, when I bought
mine, it came with the "Waeco Best Mate" warranty. The blurp suggested it would be either fixed the same day or you would get a loan fridge.
When I "confronted" the local agent at the time, he thought that was very funny.......
And he could not look at it for a month. To be fair, it was January and WAECO head office suggested I should send it to
Brisbane and they would look after it.
As I have a background in electronics and I was curious why it should be so, I decided to do a bit of research and that's how I found out what the problem was.
I might add at the time Waeco were not aware of this issue and were still busily telling people if it runs ok on AC, it MUST be your wiring.
Cheers
FollowupID:
483761
Follow Up By: hl - Tuesday, Feb 20, 2007 at 20:47
Tuesday, Feb 20, 2007 at 20:47
And the quickest way to confirm if yours needs an upgraded polyswitch.
Run your fridge from a good power supply that can manage 12-14V under load or make sure the battery is
well charged and not dropping below 12V with the fridge running.
Also, make sure the fridge is at ambient temperature and not pre-cooled.
Start it and set the temperature for 2 or 3 LEDS. Press the turbo button.
If the Polyswitch is crook it will cut out in a few minutes,
well before it reaches the set temperature, and the error light will flash slowly. The fan will be running and it will cycle after a few minutes. Depending on how bad the polyswitch is, it will take a long time or it will never reach the set temperature (once it does, the turbo Led will extinguish, and the fridge will cycle normally)
If your caught on a trip, the workaround is either to run it on 240V through an inverter, or don't press the turbo button. Even though the fridge will cut out and go into error mode, if you have no wiring issues and the correct voltage it will eventually reach the preset temperature. And once it has, it will probably cycle normally unless you dump a warm slab into it.
Cheers
FollowupID:
483830
Reply By: Robnicko - Thursday, Feb 22, 2007 at 10:04
Thursday, Feb 22, 2007 at 10:04
Exploder,
Just thought I'd let you know that I took my fridge to a friend (the waeco service rep) and he replaced the 4amp polyfuse with a 10amp one (what waeco are replacing them with).
He put it through a variable 12V adaptor thet also displays amps being drawn. The only way to make the error light come on was to run fridge flat out in turbo mode and reduce the voltage going into it down to 10.6V at which point the polyfuse kicks in, as it should.
As a
test, I have it in my work car at the moment which is a falcon and have run a merit socke direct from the battery. It has been running all night on 4 LED's and when I got in the car this morning I cranked it up to 7Led's and put on the turbo mode. It has not failed. I think it is actually reaching the desired temp's quicker as
well and there definetly feels like there is less heat coming out of the side if the fridge where all the electronics are.
If your fridge is still under warranty get it done.
Rob
AnswerID:
223341