Sea Frost BG 2000 manual

372 ROUTE 4 BARRINGTON, NH 03825 USA TEL (603) 868-5720 FAX (603) 868-1040 1-800-435-6708 E-Mail:sales@seafrost.com www.seafrost.com OPERATION & INSTALLATION INSTRUCTIONS BG 2000 404a SERIES C.F. HORTON & CO., INC. 372 ROUTE 4 BARRINGTON NH 03825 U.S.A. (603) 868-5720 WWW.SEAFROST.COM SEA FROST is a registered trademark of C.F. Horton &[...]

2 TABLE OF CONTENTS BG 2000 OPERATION 4 ICE MAKING 5 MAINTENANCE 6 HOW REFRIGERATION WORKS 8-9 INSTALLATION 10 SWAGELOK FITTINGS 11-13 CONDENSING UNIT LOCATION 14 VALVE 15 PUMP INSTALLATION 16 THERMOSTAT 17 RFD 17 ACCESS TO THE SYSTEM 19 GAUGES 20 LEAK CHECKING 22-23 NEW SYSTEM CHARGING 22-23 READING THE SIGHT GLASS 25-26 CHECKING THE CHARGE / ADDI[...]

3 372 ROUTE 4 BARRINGTON, NH 03825 USA TEL (603) 868-5720 FAX (603) 868-1040 1-800-435-6708 E-Mail:sales@seafrost.com www.seafrost.com A VIEW OF THE FUTURE: As a once wonderful invention, refrigerants ar e now the latest enemy as our awareness of the universe increases. To the end regar ding conservation we have always offered a leak proof system. [...]

4 BG 2000 OPERATION The SEA FROST BG 2000 system is an electrically driven refrigeration plant. Operation of the compressor will freeze the contents of the holdover devices in the boat's icebox providing refrigeration by cold holdover for an extended period after the compressor has been turned off. A boat without continuous power can benefit f[...]

5 ICE MAKING Your SEAFROST holdover plate may be equipped with vertical ice trays. The ice trays are held in contact with the plat e by a stainless steel rod. Fill the vertical trays with water and hang them on the face of the plate. Try to get some water between the tray and the plate surface to increase the thermal contact (increasing freezing ab[...]

6 BG 2000 MAINTENANCE Like your engine, your SEA FROST needs periodic checking. ROUTINELY CHECK: 1. The refrigerant charge. See: "Checking The Charge" text. NEVER OPERATE SYSTEM WITHOUT PROPER CHARGE. 2. All components, all tubing, fittings, and hose clamps for corrosion and wear. BE SURE TO LOCATE AND INSPECT ALL FITTINGS AND COMPONENTS [...]

7 It is IMPORTANT that NO WATER flows between the plastic housing and the pump body. The screws that hold the cover also seal the housing. Water behind the housing will ruin the motor bearings. BE SURE THE PUMP HOUSING IS ABSOLUTELY DRY BEFORE DISASSEMBLY. Remove the phillips screws holding the inlet fitti ng plate (larger hose size). The impeller [...]

8 HOW REFRIGERATION WORKS There are two important conc epts to understand in order to learn about refrigeration. They are latent heat and phase changes . A great deal of heat is required to change a so lid to a liquid, and a liquid to a gas. A great deal of heat must be removed to reverse these changes. These changes are called phase changes, or ch[...]

9 By causing R-404a to boil (evaporate) in the SEAFROST plates, we absorb the heat energy there. This activity cools the liqui d solution within the plates, causing them to change phase (freezing to a solid). By freezing this solution, we have increased its heat absorption capacity more than 100 times. When the cycle is stopped (compressor is turne[...]

10 INSTALLATION Installer's care should be stressed. No matter how good SEA FROST equipment is, its performance and life are in the hands of the installer. To insure your work: 1. Read this manual. 2. Reread any aspect you don't understand. 3. Follow Swagelok fitting instructions carefully. 4. Spend enough time leak-checking to be sure th[...]

11 NOTES ON SWAGELOK FITTINGS Swagelok fittings come to you completely asse mbled, finger-tight. (Pieces a, b, and c in Drawing #1 are already together). They are ready for immediate use. Disassembly before use can result in dirt and foreign material getting into the fitting and causing leaks. If disassembly is necessary, reassemble per Drawing # 1[...]

12 DRAWING 1 STEP 1 Simply insert the tubing into the SWAGELOK tube fitting. Make sure that the tubing rest firmly on the shoulder of the fitting and that the nut is wrench snug. STEP 2 Before tightening the SWAGELOK nut, scribe the nut at the six o'clock position.[...]

13 STEP 3 Now, while holding the fitting body steady with a backup wrench, tighten the nut 1 1/4 turns. Watch the scribe mark, make one complete revolution and continue to the 9 o'clock position. By scribing the nut at the 6 o'clock position as it appears to you, there will be no doubt as to the starting position. When tightened 1 1/4 tur[...]

14 CONDENSING UNIT LOCATION AND MOUNTING The design of the BG 2000 allows placement of the unit in an enclosed space such as a cabin locker, sail locker or engine area. The BG 2000 is a high-powered unit. It produces some noise and vibration. Its duty cycle will be short however, consider that dockside operation may be noticed when the generator is[...]

15 INSTALLING THE THERMOSTATIC EXPANSION VALVE The larger fitting on the thermostatic expans ion valve connects with a Swagelok to one of the plate tubes. In a multiple plate seri es system ½” copper jumper lines will connect the plates to each other. The last plate has a ½” return line to the compressor. The feeler bulb from the valve must b[...]

16 RUNNING THE TUBING Make the connection to the compressor and RFD after all other connections are made . A 1/4" copper tube runs between the compresso r unit and the expansion valve. Multiple plate hook-ups should be assembled as indica ted by the specific diagram provided. A 1/2" line connects the plate outlet to the co mpressor. If po[...]

17 RFD (Receiver Filter Drier) The RFD contains desiccant to absorb moisture This absorption is limited . Leaving the RFD installed on a partially open system may reduce its capacity by allowing it to absorb moisture. The RFD is a reservoir for excess refrigerant. The RFD also contains a sight glass in the top . A pick-up tube extends from the bott[...]

18 WIRING THE PUMP The pump is connected by three wires at the compressor unit. The pump operation is controlled by the BG2000. REFRIGERANT HANDLING AND SAFETY Do not proceed with any aspect of a procedur e if you do not fully understand the procedure and know what result to expect. Understand that pressure exists in refrigeration systems. Be caref[...]

19 PROCEDURES FOR WORKING WITH R-404a 1) A new uncharged system must be evacuated before adding R-404a. 2) An R-404a system must only be pr essurized with R-404a or nitrogen. 3) Only service tools dedicated to R-404a are to be used. No parts, tubing, fittings, receivers, dryers, service gauges, or any refrigerant carrying components may be fitted t[...]

20 GAUGES Gauges must be used in the evacuation and c harging. They will provide information on the operation of the syst em when troubleshooting. A gauge sets consist of two gauges installed in a manifold with two valves and hoses to connect the gauges to the system. The left gauge (blue) is a compound device; it indicates pressure and also vacuum[...]

21 Disconnecting the gauge set on a static system may be done by rapidly unscrewing the hoses from the service ports. Adding charge to a working system should be done through the suction side (blue) as liquid. The suction pressure must be m onitored and not allowed to rise more then 15 PSIG above operating pressure. VENTING THE CHARGE HOSE WHEN ATT[...]

22 NEW SYSTEM CHARGING INTRODUCING INITIAL CHARGE After the evacuation leak test and pump down, shut off the manifold valves, disconnect the center hose from the pump and connect it to a cylinder of refrigerant Vent the hose from cylinder (refrigerant supply) to the m anifold. With the refrigerant can in the inverted (liquid) position, open the dis[...]

23 TO CHECK WITH BUBBLES Soap each connection and observe all sides of the connection with a bright light and a mirror. A leak will blow bubbles. Without careful examination and plenty of pressure this test is not reliable. TO CHECK WITH AN ELECTRONIC DETECTOR Use a detector designed for HFCs. Slowly trace the area with the probe. Refrigerant is he[...]

24 3. The sight glass will show a stream of foam indicating a partial charge. 4. Introduce liquid refrigerant (liquid is supplied by keeping the cylinder inverted) at a controlled pressure regulated by sli ghtly opening the blue hand wheel valve. Keep the low side pressure no more than 15 PSIG above the indicated operating pressure. Add refrigerant[...]

25 A white stream of fast moving foam with the compressor operating indicates an insufficient charge level. Watch closely fo r a transition from foam to total liquid, indicated by a clear sight glass. This trans ition point can be missed if proper attention is not given. Also, IT IS POSSIBLE for the sight glass to show large bubbles even when the c[...]

26 SPECIAL NOTE R-404a will become cloudy and indicate similar foaming in the sight glass as the pressure on the hi-pressure side of the system s becomes too great. Adding charge to clear this condition will damage the compressor. Be sure you know the pressures you should have for the corresponding water temperature. CHECKING THE REFRIGERANT CHARGE[...]

27 TROUBLESHOOTING The most common problems that can occu r in a SEA FROST BG 2000 System are: (1) Overcharge or loss of water flow swit ching off the manual reset high-pressure switch. (2) Loss of refrigerant charge resulting from leaks. (3) Moisture or dirt plugging the expansion valve. (4) Compressor damage due to loss of refrigerant charge. STE[...]

28 b) If pressure reading is over 100 psig with compressor off, proceed to check charge level via sight glass and charge if needed. CHARGE LOSS INDICATES A LEAK THAT MUST BE CORRECTED. STEP 2. If a system continues to operate inefficiently after Step 1, check for moisture or dirt plugging the valve. Run the syst em, observing closely the gauge read[...]

29 Follow the "re-make" instructions for Swagelok fittings. Reminder: To ensure the total removal of m oisture from the system use a high vacuum pump, and evacuate the system with the highest possible plate tem perature (100 degrees F.). A light bulb or heat lamp in contact with the plates is a good technique. Recharge. Refer to "Rec[...]

30 BG 2000 Specifications and Operating Characteristics 115-volt 50/60 hz 230-volt 50/60 hz Horsepower 1 HP 1HP Refrigerant 404-a 404-a Oil Polyol ester oil Polyol ester oil Locked rotor amps 76.7 45 Current draw with pump 26.8 amps 14.10 amps Electrical breaker 30 amp 15 amp double pole Maximum refrigerant charge 24 oz 24 oz Manual reset high pres[...]

31 Figure 1[...]

32 WATER CIRCUIT[...]

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36 372 ROUTE 4 BARRINGTON, NH 03825 USA TEL (603) 868-5720 FAX (603) 868-1040 1-800-435-6708 E-Mail:sales@seafrost.com www.seafrost.com THERMOSTAT CALIBRATION INSTRUCTIONS Note: Be sure that the unit is operat ing properly before making any thermostat adjustments. The sensing bulb must be in excellent thermal contact with the plate or block. The ra[...]

37 HOLDOVER PLATES STAINLESS STEEL EVAPORATOR PLATES[...]