Sea Frost DC 5000 manual

1 372 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 DC 5000 SYSTEM 134a OPERATION & INSTALLATION INSTRUCTIONS NOTICE OF RESPONSIBILITY It is the SEA FROST/C.F. Horton & Co., Inc. int ent to provide the safest, most accurate and detailed instructions. SEA FROS[...]

2 START UP PROCEDURE AND PERIODIC INSPECTION ATTENTION new SEA FROST owner or operator! PLEASE DO NOT OPERATE THE REFRIGERATION SYSTEM UNTIL YOU READ THIS. WARNING! Your SEA FROST System can be severely damaged and your warranty will be invalid if these steps are not follow ed closely. Please read the information here before proceeding to operate y[...]

3 There are three conditions of char ge indicated by the sight glass: 1. A black or clear glass and no cooling indicates no charge. Turn off the compressor at once. 2. A white foaming glass and some cooling indicates the system is undercharged or has lost charge. Refer to the manual regarding leak checking and adding charge. 3. A black glass and pr[...]

4 TABLE OF CONTENTS OPERATION 5 GENERAL DESCRIPTION 5 ICE MAKING 7 MAINTENANCE 7-8 HOW REFRIGERATION WORKS 8-9 INSTALLATION 9 COMPRESSOR INSTALLATION 11 WATER PUMP 12 PLATES 13 VALVE UNIT 13 SWAGELOK FITTINGS, M AKE-UP & RECONNECTING 14-16 RECEIVER FILTER DRYER 18-19 ELECTRICAL SYSTEM; WIRING; THERMOSTAT CONTROL PANEL 20 WIRING DIAGRAM 21-22 AS[...]

5 GENERAL DESCRIPTION The SEA FROST DC 5000 is a cold storage refrigeration system powered by a 1/2 horsepower permanent magnet direct current 12-volt motor. Refrigerant from the compressor is piped to the SEA FROST plate in the icebox. Cold storage is attained by rapidly freezing the solution contained in t he plate, creating a c aptive (replenish[...]

6 After about one hour (with a single plate), the plate will become very cold. Starting from warm will require more running than the normal refreezing time of the plate in its usable temperature range. The concept of the SEA FROST system is to create as much frozen material in the plate as fast as possible. This "coldness" then keeps the [...]

7 ICE MAKING WITH VERTICAL TRAYS ON VERTICAL PLATE SYSTEMS Fill the vertical trays with water and hang them on the stainless steel rod on the face of the plate. Try to get some water between t he tray and the plate surface to increase the thermal contact to speed freezing. The trays may take time to freeze after the plate is frozen and the compress[...]

8 CLEANING The plate surface protects itself with a layer of oxidation. You might find after a long period of storage the plate will look chalky. This will not effect operation and is easily cleaned up with a pot scrubber and soap. HOW REFRIGERATION WORKS There are two important conc epts to understand in order to learn about refrigeration. They ar[...]

9 By causing R-134a to boil (evaporate) in the SEA FROST plate, we use the heat energy there. This activity cools the liquid solution within the plate, causing it 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 (the compressor is turned o[...]

10 TUBE CUTTING Use only a tube cutter; hacksawing or any other method will introduce chips to the system and also distort the tube, making connections difficult and leak-prone. A miniature cutter is essential for this work. CUT SLOWLY to avoid a ridge on the inside of the tube. We do not recommend reaming or dressing the cut, as it is very easy to[...]

11 a bulkhead that directly separates the living space from the machine space to avoid excessive sound radiation. The DC 5000 may be installed close to a bulkhead and overhead. Allow access to the front (as shown in the drawing above) and left end where the tubes and hoses will exit. Fasten the DC 5000 through the (4) drilled holes in the base. THE[...]

12 Install the intake through hull as low in the boat as possible. The minimum size through hull should be 1/2". In areas of floating weed and jelly fish a larger through hull might be beneficial. The sea strainer should be pos itioned above the through hull with no loops of hose that could trap air. The pump should be positioned above the str[...]

13 VALVE UNIT V/U For appearance and convenience of installation, the valve unit may be mounted outside the icebox. In certain applications and multiple plate systems it may be best to mount it inside. Location of the V/U in multiple pl ate systems is indicated in the design layout from our application engineer. On an externally mounted V/U two 1/2[...]

14 Step 2. Prior to inserting 1/2" tubing into t he Swagelok tube fitting, make a pencil mark 1" from end of tube. Prior to inserting 3/8" tubing, make a pencil mark 3/4" from the end of the tube. With 1/4" tubing make a mark 5/8" from the end. Step 3. Insert clean, smooth tubing with the penc il mark into the Swagelok[...]

15 STEP 2 Before tightening the SWAGELOK nut, scribe the nut at the six o'clock position. STEP 3 Now, while holding the fitting body steady wit h 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[...]

16 SWAGELOK PERFORMANCE Swagelok fittings have built-in spring inte raction between the ferrules. This compensates for temperature changes, vibrati on loosening and allows the fittings to be reconnected many times. As the fitting is tightened, a burnishing occurs between the body of the fitting and the ferrules and between the ferrules and the tube[...]

17 PLANNING 1. Keep tube runs as short as possible. The suction (return) line should be as direct as possible with a minimum number of bends. 2. Tape the 1/4" line and the 1/2" line together in the section between the V/U and the DC 5000. This is for thermal exchange (sub cooling). POSITIONING THE RFD • The RFD is fitted with a sight gl[...]

18 RFD (Receiver Filter Drier) DO NOT OPEN THE RFD UNTIL ALL THE OTHER CONNECTIONS HAVE BEEN MADE AND YOU ARE READY TO COMMISSION THE SYSTEM. Because the RFD contains desiccant to absorb moisture and the absorption is limited, it is important to unpack and install it after all other connections are made. Leaving the RFD installed on a partially ope[...]

19 CABLE TIES Cable Ties should be used to support the wir ing, tubing, and insulation. There is a screw hole in the end of each tie that is used for mounting. Loosely loop the tie, mount the screw loosely, snug the wrap, ti ghten the screw, and trim the excess. Be sure not to leave a sharp end on the cable tie. ELECTRICAL SYSTEM The electrical sys[...]

20 THERMOSTAT CONTROL PANEL LOCATION The Thermostat Control Panel should be outsi de the box in order to protect it and to allow observation of the indicator lamp. The length of the sensing tube dictates the location, as it must reach the plate. T he maximum length of this tube is 40" (180 mm.) (The sensing tube must be attached to the refri g[...]

21 WIRE SIZES This information is to be used as a guide only. Please make sure your wiring meets or exceeds all applicable standards. The DC 5000 must be wired with heavy gauge wire from the batteries to the Electrical Junction Box in order to supply the proper current and voltage. Follow the chart below based on the ABYC specifications allowing a [...]

22  The positive and negative cable total length must not exceed twice the distance listed above.  Be sure your wire length calculation is fr om the batteries not the connection points of the supply wires. (It is assumed that heav ier cable is used to supply an electrical junction like the battery switch or buss bar.) FUSES Fuse the 12-volt p[...]

23 [ ] 4. Check all the hose clamps for tightness. [ ] 5. Check the neatness of the installa tion, sufficient service access, secure wiring, and make sure tubing and hoses are supported to prevent damage and chafing. [ ] 6. Check the service access. The service access ports must allow attachment of the connecting service valves. [ ] 7. Check (after[...]

24 WARNING NEVER OPERATE a system WITH THE HIGH side (discharge) OPEN TO the REFRIGERANT supply. Pressurization of t he refrigerant container could cause it to burst. WARNING. When charging or working on the system installed in an engine room with the engine running, watch for MOVING BELTS AND PULLEYS. Loose clothes and long hair can pull you into [...]

25 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 hand wheel valves and hoses to connect the gauges to the system. The left gauge (blue) is a compound device; it indicates pressure and [...]

26 CONNECTING GAUGES To connect service gauges to the access service ports, remove the protective sealing caps from the service ports on the DC 5000. Note that the ports are of different sizes. The larger diameter port is the discharge si de and the smaller port is the suction side. Pull back the collar on the connecting valve and push it over the [...]

27 VENTING THE GAUGE SET To connect the gauges to a charged system if the gauge set has not been purged with refrigerant, attach the service valves to t he system and vent the hoses at the manifold body by opening the hand wheels to an open center hose for a few seconds allowing some of the system refrigerant to purge the hoses of air. If the cente[...]

28 COMMISSIONING PROCEDURE EVACUATION WITH A VACUUM PUMP Evacuation removes air, readying the system for charging. Connect a gauge set to the service access ports. Connect the gauge center hose to a high vac uum pump. Start the pump and slowly open the suction gauge hand wheel. As the vacuum drops below 20 inches open both hand wheels fully. EVACUA[...]

29 LEAK CHECKING A CHARGED SYSTEM ABOUT PRESSURES Refrigerant in a saturated condition, part li quid and part vapor will exert a pressure that is a function of its temperature. The higher the temperature, the higher the pressure. Avoid leak checking in cold weather. A refrigerant leak will show with moderate pr essure. A leak is not a function of p[...]

30 NOTE:  Propellants and solvents (sprays and foams) may upset electronic detectors.  To confirm a leak detected with a detector use bubbles and be sure it is a leak and not some erroneous vapor that is upsetting the machine.  Electronic detectors do not function below 40.F.  A good leak detector is able to pick up leaks as low as 1/2 [...]

31 8. Leak check the capped connection service ports with the leak detector. 9. Spray the acrylic coating, or similar rust inhibitor, on all the fittings and components when they are dry. 10. Finish insulating the V/U, suction line and any suction line connectors. 11. BREAK-IN PERIOD. During the first four hours of operation of a new compressor, li[...]

32 RFD SIGHT GLASS DETAIL CLEAR (or empty) STATIONARY BUBBLES FOAM (low charge) PROPER CHARGE AMOUNT THE DC 5000 SYSTEM IS DESIGNED TO HOLD 24 OUNCES. THIS IS EQUAL TO 2 CANS OF R-134a AS SUPPLIED WITH THE SYSTEM. THIS IS THE MAXIMUM CHARGE . The sight glass must clear by the time the return line to the compressor goes below 32 degrees F. GENERAL I[...]

33 DISCHARGING THE SYSTEM Before the connections or components can be disassembled, the refrigerant must be recovered with a reclaiming machine. Connect a gauge set to the suction access port and slowly recover the refrigerant. Keep the pressure under 20 psi. Do not loosen any connections until the system holds 10 inches of vacuum for 10 minutes. T[...]

34 b) If the pressure readings are over 50 psi with the 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 the system continues to operate improperly after Step 1, check for moisture or dirt plugging the valve. Run the syst em, observing closely the gau[...]

35 Recharge. Refer to "New System Charging". MOISTURE IS A SYMPTOM. Carefully leak check the low side of the system if moisture becomes a problem. Moisture leaks in! Technical help 603-868-5720 TOLL FREE IN THE UNITED STATES, CANADA, AND CARIBBEAN 800-435-6708 E-mail sales@seafrost.com[...]

36 PRESSURE CHARTS[...]

37 PRESSURE CHARTS[...]

38 PRESSURE CHARTS[...]

39 DC 5000 MOTOR AND WATER PUMP MAINTENANCE Lubrication The DC 5000 motor and the March wate r pump are supplied with lifetime lubricated ball bearings. Brushes (Leeson Motor) Motor brushes need periodic inspection and replacement as wear indicates. Brush wear is greatly influenced by individual application, voltage and heat load. It is recommended[...]

40 Tip: In a new motor with new brushes the ba ck of the brush will be flush with the brush housing, as the brush wears the distance in to the housing will increase. (See top view drawing below.) A quick measurement of t he depth will be sufficient. When the brush is 5/8” into the holder it will need replacemen t. If in doubt change the brushes. [...]

41 DC5000 WIRING[...]

42 DC 5000 LAYOUT[...]

43 DC 5000 WATER CIRCUIT[...]

44 TWIN VALVE SYSTEMS ONLY[...]

45[...]

46 DC 5000 Low Voltage Protection Relay The DC 5000 uses a Macromatic relay to monitor the voltage at the compressor motor. The relay has an adjustable pick up voltage (reset). A red indicator lamp lights when the relay is on. This lamp turns green when the relay senses low voltage and turns off. This relay is designed to protect the compressor mot[...]