Dometic Refer Recall - Possible Fire Hazard -Update 2/13/07

[MELM]

Click here to go directly to Updates.
Update Number 1 Nov 23, 2006
Update Number 2 Dec 5, 2006
Update Number 3 Jan 10, 2007
Update Number 4 Jan 19, 2007 - Recall Instructions - click here: Dometic Recall You need your model and serial numbers.
Update Number 5 Feb 13, 2007 - Added links to new info on the NHTSA website including the info/form for claiming reimbursement for a failure. These are at the end of the post below where all the updates are posted.

Also, edited the below Recall to include the change made prior to the Dec 5 update showing the proposed remedy.

Below is information from the NHTSA website on a recall of certain Dometic refrigerators. This recall is in its very early stages, and there is no resolution in place as of Nov 1, 2006.

From the NHTSA website:

Dometic Recall NHTSA Campaign ID 06E076000

Make / Models : Model/Build Years:
DOMETIC / NDR1062 9999
DOMETIC / RM2652 9999
DOMETIC / RM2662 9999
DOMETIC / RM2663 9999
DOMETIC / RM2852 9999
DOMETIC / RM2862 9999
DOMETIC / RM3662 9999
DOMETIC / RM3663 9999
DOMETIC / RM3862 9999
DOMETIC / RM3863 9999

Manufacturer : DOMETIC CORPORATION

NHTSA CAMPAIGN ID Number : 06E076000 Mfg's Report Date : AUG 28, 2006

Component: EQUIPMENT: RECREATIONAL VEHICLE

Potential Number Of Units Affected : 926877

Summary:
CERTAIN DOMETIC TWO-DOOR REFRIGERATORS MANUFACTURED BETWEEN APRIL 1997 AND MAY 2003: SERIAL NOS.
713XXXXX THROUGH 752XXXXX;
801XXXXX THROUGH 852XXXXX;
901XXXXX THROUGH 952XXXXX;
001XXXXX THROUGH 052XXXXX;
101XXXXX THROUGH 152XXXXX;
201XXXXX THROUGH 252XXXXX;
301XXXXX THROUGH 319XXXXX,
INSTALLED IN CERTAIN RECREATIONAL VEHICLES AS ORIGINAL EQUIPMENT AND SOLD AS AFTERMARKET EQUIPMENT. A FATIGUE CRACK MAY DEVELOP IN THE BOILER TUBE WHICH MAY RELEASE A SUFFICIENT AMOUNT OF PRESSURIZED COOLANT SOLUTION INTO AN AREA WHERE AN IGNITION SOURCE (GAS FLAME) IS PRESENT.

Consequence:
THE RELEASE OF COOLANT UNDER CERTAIN CONDITIONS COULD IGNITE AND RESULT IN A FIRE.

Remedy:
THE VEHICLE MANUFACTURERS WILL NOTIFY OWNERS OF RECREATIONAL VEHICLES THAT HAD THE REFRIGERATORS INSTALLED AS ORIGINAL EQUIPMENT AND DOMETIC WILL NOTIFY OWNERS OF THE AFTERMARKET REFRIGERATORS. DOMETIC WILL INSTALL A SECONDARY BURNER HOUSING FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN BETWEEN APRIL AND JUNE 2007. OWNERS MAY CONTACT DOMETIC AT 888-446-5157.

Notes:
CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

The following is extracted from the notice provided by Dometic to the NHTSA dated 8/26/06:

The potential defect is associated with cooling unit at the back of the refrigeration cabinet.

A fractional percentage of the potentially affected refrigerators have experienced a fatigue crack that may develop in the boiler tube in the area of the weld between the boiler tube and the heater pocket. A fatigue crack may release a sufficient amount of pressurized coolant solution into an area where an ignition source (gas flame) is present. Dometic's investigation has shown that a simulated release of cooling solution (refrigerant) in the area of the boiler, under certain conditions, could be ignited by the presence of an open flame. A boiler fatigue crack with the loss of cooling solution without ignition would result in a non-operational refrigerator that is not a safety issue. Under certain conditions, the released coolant could ignite and result in a fire. In order to have a fire, at a minimum, all of the following conditions must exist:

1. The refrigerator must be on and normally operating and gas burner must be lit;
2. 'There must be an oversized heating element in the refrigerator;
3. The boiler tube must develop a throughway fatigue crack of a
specific size;
4. There must be a release of the cooling solution at a rate which will
allow the accumulation of the cooling solution at a concentration within its range of flammability; and
5. There must be ignition source (gas flame) present.

If any of these conditions are not present, a release of the cooling solution will not result in a fire.

In April of 1997 Dometic modified the design of the affected refrigerators by increasing the wattage of the heating element from 325 watts to 354 watts. All production of the affected units from April 1997 through May of 2003 utilized the 354 watt heating element. In May of 2003, in order to improve the operating life of the refrigerators, Dometic returned to the use of the 325 watt heating element which it continues to use today. It is now believed that the use of the higher wattage heater contributed to abnormal fatigue in the boiler tube.

The products in question are all refrigerators used in the original manufacture of recreation vehicles or as replacement equipment for recreation vehicles. The total population of refrigerators potentially containing the defect is 926,877. Dometic estimates a potential maximum incident rate of 0.01% related to boiler fatigue cracks that leak and may result in a fire. There have been no incidents of injury or death related to the affected population of Dometic refrigerators.

Dometic became aware of the occurrence of fires which may have involved their products and retained an independent engineering testing laboratory to fully evaluate and investigate any potential defect in their refrigerators which might result in a fire. A number of returned units were analyzed and microscopic fatigue cracks which could release coolant into the area of the burner were identified in the boiler tube metal in the area of the weld between the heater pocket and boiler tube. Tests simulating the cracks were conducted the week of August 18, 2006 and confirmed a possible cause of fire in the refrigerators under certain conditions. These test results prompted the preparation of this notice.

Dometic continues to gather information on the potential defect and will forward additional relevant information as it becomes available.

Dometic has not yet identified a proposed remedy for the potential defect. Dometic will continue a testing program designed to identify and evaluate possible remedies. This evaluation will take place both in the United States and in Sweden. Once a remedy has been identified, Dometic will initiate or participate in a remedy campaign initiated by the original equipment manufacturers and aftermarket suppliers who have purchased, sold, and distributed these products. A list of original equipment manufacturers and aftermarket suppliers to whom Dometic has sold the potentially defective refrigerators is being prepared and will be provided to the NHTSA upon its
completion.

The following is extracted from the NHTSA response on 9/18/06:

Please provide the following additional information and be reminded of the following requirements:

Dometic must provide an estimated dealer notification date as well as an owner notification date including the day, month, and year. You are required to submit a draft owner notification letter to this office no less than five days prior to mailing it to the customers. Also, copies of all notices, bulletins, dealer notifications, and other communications that relate to this recall, including a copy of the final owner notification letter and any subsequent owner follow-up notification letter(s), are required to be submitted to this office no later than 5 days after they are originally sent (if they are sent to more than one manufacturer, distributor, dealer, or purchaser/owner).

Dometic must file a sample of the envelope which you intend to use to mail the recall notice to owners. The words "SAFETY", "RECALL", "NOTICE" in any order must be printed on the envelope in larger font than the customers name and address.

[Puddles]

karode wrote:
I am still very confused why people are stating that using LP Gas eliminates (or reduces) the recall issue. Whether the "fatigue crack" is due to the weight of the larger element or the energy generated, there is no problem unless there is a source of ignition (gas burner lit). Therefore, if anything, I would limit usage to AC power to eliminate the ignition source.

What am I missing?


1. The refrigerator must be on and normally operating and gas burner must be lit;
2. 'There must be an oversized heating element in the refrigerator;
3. The boiler tube must develop a throughway fatigue crack of a
specific size;
4. There must be a release of the cooling solution at a rate which will
allow the accumulation of the cooling solution at a concentration within its range of flammability; and
5. There must be ignition source (gas flame) present.

My thought was, if your refrigerator is working properly.. there's no crack yet... leave the electric element turned off to ensure it doesn't crack. If there's no crack to let the refrigant leak... NO FIRE.

[Paul_G_]

The fix they have proposed does not impress me at all.

DOMETIC WILL INSTALL A SECONDARY BURNER HOUSING FREE OF CHARGE

It appears they are putting a Band-Aid on it versus fixing it.

If the heating element is too high or hot, why not replace it with the one the lable describes ie: 2.7 amp. versus the 3.1 amp. which they decided to install.

Just how many fires have there been as a result of the heating element.

Having prior knowledge of this situation and not fixing it, would lead me to think, one lawsuit resulting in injury or death would pretty well wipe them out.

I certainly don't feel comfortable going to sleep knowing this situation exists. I suppose a person could shut the fridge off at night but that doesn't seem quite right either.

I sure hope they come up with a better solution.


Paul....

[karode]

Hi Phil,

Hope that works out, I would still be concerned about potential ignition but perhaps the heat from the electric element could do that as well.

I must say though I am not impressed with their "fix". Rather than addressing the point of failure by replacing the element, they are going to add a secondary housing to contain the subsequent leakage. I expect this will prevent the fire but the fridge isn't going to work very well after failure.

Oh well, I guess it can't be that frequent an occurrence or we would have heard a LOT more about it before now.

Best Regards,

Ken

[Phils]

Karode,

From what I read in Mel's copied info, the problem isn't so much a "fatigue" crack but corrosion (pinhole leak) because of using the higher wattage heating element. The original info mentioned "fatigue crack" and I figured 'no problem' with mine since they never move. It was only after reading through the latest pages linked by Mel that it appears that it's more of a "hi-temp corrosion leak" than a "fatigue leak".

One of the best things about this forum is getting relevant info sooner than any other way. Of course, this thread was started before Dometic had even published the exact cause of the problem. IF those latest documents are the final word on "cause" then I'll relax and discontinue all AC usage.

As an alternative I could replace the heating elements with the lower wattage (not likely to happen).

Unless I read it wrong.... in which case someone please correct me! I'd rather be embarrassed by misinterpretation than have my house burn.

Phil

[karode]

I am still very confused why people are stating that using LP Gas eliminates (or reduces) the recall issue. Whether the "fatigue crack" is due to the weight of the larger element or the energy generated, there is no problem unless there is a source of ignition (gas burner lit). Therefore, if anything, I would limit usage to AC power to eliminate the ignition source.

What am I missing?


1. The refrigerator must be on and normally operating and gas burner must be lit;
2. 'There must be an oversized heating element in the refrigerator;
3. The boiler tube must develop a throughway fatigue crack of a
specific size;
4. There must be a release of the cooling solution at a rate which will
allow the accumulation of the cooling solution at a concentration within its range of flammability; and
5. There must be ignition source (gas flame) present.

[Phils]

Thanks, Mel, for posting the info.

From what I read (and contrary to what I originally speculated) the problem occurs when the higher wattage 115V element is used.

And their "fix" will be another burner housing AROUND the existing burner housing.

So thanks for bringing this to all our attention. Since my two units are mounted in the kitchen of my house there'll be NO taking them to a service center.

However... because of Mel's info it appears that I just need to limit the operation to LP use and there'll be no problem with this leak/fire thing. I've only this past summer started operating one of the friges on AC during the days that my solar panels are generating more juice than the batteries need to recharge. Guess I'll stop doing that. Dang. It saved a little propane. But better to not burn the house down.

Phil

[MELM]

rsq33 - my browser didn't show that, and I now remember what I have to do to get it.

I'll leave your post for now for those who want to see the "whole thing".

I have scanned the documents and excerpted the main info and put it in the Updates post (second reply in this message). I also added the new line to the Recall.

Mel

[rsg33]

Mel, here is the link to the latest info. Two letters from Dometic. Transfer it to your update page and delete this post if you like.
http://199.79.180.163/prepos/files/Artemis/Public/Recalls/2006/E/RCORRD-06E076-5152.pdf

[MELM]

n6mhg - thanks for posting that update to the recall. They have also added another document with more details on the site, but I could not access it until tonight. I'll try to get it into a text format and post it in the updates as I did the others.

Paul G. - you have to get the Recall site: Recalls Defects. You can enter the ID number in the right hand box. (There website does not allow me to post the Results page as a separate link.)

If you go to that site and then do the search, at the bottom of the document is a link for Document Search. There you will find the documents that I converted to text for the original post, and now the new one outlining the Dometic plan.

Mel

[rsg33]

There really isn't any weight difference between the two elements. From what I understand, the damage is done by the higher wattage which produced degradation in the metal pocket the element sits in and caused the weld to deteriorate.

If your particular model has been equipped with the 325 watt element (the lesser of the two), it may have not suffered any damage. Only the results of the testing will verify this, so it looks like we have to wait til sometime in January for the official word.

[Puddles]

karode wrote:

WilleyB wrote:
Quote: " Any thoughts? "

Just thinking (not my best asset):B but it seems that the problem is caused by the increased wattage of the electrical heating element. Now if you haven't been using it much on 120 shore power much, then the piping that cracks should be still relatively ok yet. Using that reasoning there should be no problem with using it on LP gas.
As I've said, not one of my best points, but hey it's an idea

Cheers

Actually, the way I read it, it sounds like the weight of the larger electric element causes cracking in the tubing and a leak of fluid from there can be ignited by the lp gas flame. Therefore, the worst thing you could do is use it on lp gas as that is the ignition source for the fire.

Well, what's the consenses of opinions? I thought running on gas only was a good idea... Hadn't even considered the weight issue...

[karode]

WilleyB wrote:
Quote: " Any thoughts? "

Just thinking (not my best asset):B but it seems that the problem is caused by the increased wattage of the electrical heating element. Now if you haven't been using it much on 120 shore power much, then the piping that cracks should be still relatively ok yet. Using that reasoning there should be no problem with using it on LP gas.
As I've said, not one of my best points, but hey it's an idea

Cheers

Actually, the way I read it, it sounds like the weight of the larger electric element causes cracking in the tubing and a leak of fluid from there can be ignited by the lp gas flame. Therefore, the worst thing you could do is use it on lp gas as that is the ignition source for the fire.

[Paul_G_]

I tried going to HTTP://WWW.SAFERCAR.GOV and could find nothing. I tried typing in Dometic and it showed Domestic. I tried putting in the ID number 06E076000 and it said not found.

I was there a couple of weeks ago and was able to locate the notice but not today. Could someone post a direct link.

Thanks.

Paul....

[Dusty_R]

WilleyB wrote:
Quote: " Any thoughts? "

Just thinking (not my best asset):B but it seems that the problem is caused by the increased wattage of the electrical heating element. Now if you haven't been using it much on 120 shore power much, then the piping that cracks should be still relatively ok yet. Using that reasoning there should be no problem with using it on LP gas.
As I've said, not one of my best points, but hey it's an idea

Cheers

I didn't say this but you have a good point.

[WilleyB]

Quote: " Any thoughts? "

Just thinking (not my best asset):B but it seems that the problem is caused by the increased wattage of the electrical heating element. Now if you haven't been using it much on 120 shore power much, then the piping that cracks should be still relatively ok yet. Using that reasoning there should be no problem with using it on LP gas.
As I've said, not one of my best points, but hey it's an idea

Cheers