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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. intent to provide the safest, most accurate
and detailed instructions. SEA FROST/C.F. Horton & Co.,Inc. cannot be responsible for
problems or damage caused by omissions, inaccuracy or interpreta
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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 followed closely. Please read the information here before proceeding to operate your system for the first time. BREAK-IN PERIOD. LIMIT COMPRESSOR RUNNING TIMES TO THIRTY MINUTES FOR THE FIRST TWO HOURS OF OPERATION. T
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There are three conditions of charge 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 proper cooling indicates all is well. RFD SIGHT GLASS DETAIL EMPTY OR CLEAR STATIONARY BUBBLES FOAM/LOW Feel the SEA FROST Plate
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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, MAKE-UP & RECONNECTING 14-16 RECEIVER FILTER DRYER 18-19 ELECTRICAL SYSTEM; WIRING; THERMOSTAT CONTROL PANEL 20 WIRING DIAGRAM 21-22 ASSEMBLY INSPECTION CHECK LIST 23 REFRIGERANT HANDLING 23-24 ACCESS TO THE SYSTEM: SERVICE PORTS 25 GAUGES 25-26 LEAK CHECKING 28-29 NEW SYSTE
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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 the plate, creating a captive (replenishable) block of ice. The system may be used when the boat’s engine is on and charging the batteries or with a properly sized battery bank. The
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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 cabinet cold. Daily running times are based on the time needed to freeze enough of the plate to maintain proper cooling. The plate must be frozen. Ch
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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 the 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 compressor has been switched off. HARVESTING VERTICAL TRAYS Plan to wait for the trays to thaw in a sink or away from the plate in the refrige
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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 concepts 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 solid to a liquid, and a liquid to a vapor. A great d
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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 off) the frozen plate will begin to absorb the heat that leaks through the insulation in the icebox. The absorption will be at a constant tempe
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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 get chips of copper in the system that will cause trouble. TUBE BENDING Make all but the long sweep bends with a spring bender; one ki
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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 BRUSHES WILL REQUIRE PERIODIC INSPECTION AND REPLACEMENT. BE SURE THE DC 5000 IS LOCATED WHERE BOTH BRUSH COVERS CAN BE ACCESSED.
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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 positioned above the through hull with no loops of hose that could trap air. The pump should be positioned above the strainer and pump up to the DC 5000. The water hose from the DC 5000 should leave the condenser and descend or remain parallel to the water line exiting
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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 plate systems is indicated in the design layout from our application engineer. On an externally mounted V/U two 1/2" Swagelok fittings fasten the V/U to tubing protruding through the icebox wall. Before cutting the tubing: • Leave a minimum of 1 1/4" of
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Step 2. Prior to inserting 1/2" tubing into the 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 pencil mark into the Swagelok tube fitting. You can be sure the tube is resting firmly on the shoulder of the fitting when the pencil mark is flush with the nut. This mark will also indicate that the t
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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 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 turns to the 9 o'clock position, you can easily see that
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SWAGELOK PERFORMANCE Swagelok fittings have built-in spring interaction between the ferrules. This compensates for temperature changes, vibration 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. This action provides a leak proof connection. RUNNING THE LINES See the schematic diagram. Prior to making up connections see "Swagel
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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 glass. This glass must be visible for charging and servicing the system. It can be viewed from the top at up to a 45-degree angle but not from
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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 open system may reduce its capacity by allowing it to absorb moisture in free air before the system is sealed. The RFD is a reservoir for
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CABLE TIES Cable Ties should be used to support the wiring, 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, tighten the screw, and trim the excess. Be sure not to leave a sharp end on the cable tie. ELECTRICAL SYSTEM The electrical system for the DC 5000 system includes a Thermostat Control Panel with pilot light, and a junction box with solenoid. 19
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THERMOSTAT CONTROL PANEL LOCATION The Thermostat Control Panel should be outside 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. The maximum length of this tube is 40" (180 mm.) (The sensing tube must be attached to the refrigerator plate in a multiple plate system.) Mount the Thermostat in a location where the wires and sensing tube can be led. Use the cut out template pac
