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 ENGINE DRIVE R-12 SYSTEM OPERATION & INSTALLATION INSTRUCTIONS NOTICE OF RESPONSIBILITY It is the SEA FROST intent to provide the safest, most accurate and detailed instructions. SEA FROST cannot be responsible for problems or damage caused by omissions, inaccuracy or interpretation of these instructions.
START UP PROCEDURE for RECENTLY COMMISSIONED SEA FROST ENGINE DRIVE SYSTEMS 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. BREAK-IN PERIOD.
5) If white foam is evident watch closely for a transition from foam to clear. A clear sight glass indicates a sufficiently charged system. This point can be missed if proper attention is not given. A FULL SIGHT GLASS AND AN EMPTY GLASS LOOK THE SAME. It is possible for the sight glass to show large, almost stationary bubbles even when the charge is sufficient, so it is important to differentiate between "foam" and larger “bubbles”.
CONTENTS OPERATION GENERAL DESCRIPTION ICE MAKING MAINTENANCE ZINC, CONDENSER: SKETCH INSTALLATION TUBE HANDLING, CUTTING, BENDING COMPRESSOR, INSTALLATION PULLEY MOUNTING BELTS, COMPRESSOR CONDENSER BLOCK VALVE CONTROL UNIT SWAGELOK FITTINGS, MAKE-UP & RECONNECTING RECONNECTING PRE-SWAGED FITTINGS HOSE-TO-COMPRESSOR FITTINGS RUNNING THE LINES; INSULATING LINES RFD (RECEIVER FILTER DRIER ELECTRICAL SYSTEM; WIRING; CONTROL PANEL; TIMER WIRING DIAGRAM ASSEMBLY INSPECTION CHECK LIST REFRIGERANT HANDLING ACCESS
OPERATION ~ GENERAL DESCRIPTION The SEA FROST Engine Drive is a cold storage refrigeration system powered by the boat's engine. Cold storage is attained by rapidly freezing the solution contained in the plate, creating a captive (replenishable) block of ice. The system uses a compressor belt-driven by the boat's engine. The compressor has an electromagnetic clutch controlled by the timer switch on the SEA FROST control panel.
A SUGGESTION As soon as the engine has stopped or the timer has run out, the plate will begin to warm up as it absorbs heat (cools) the icebox. You might decide that it is a good idea to run the unit in the last minutes of the day to provide ice for drinks. Short periods of operation whenever the engine is on for other purposes will be beneficial. Maximum storage will require that the plate be frozen. The plate may thaw (be above freezing) and still not require running in refrigeration applications.
ICE MAKING WITH THE BLOCK SYSTEM The best way to make Ice is by freezing the metal ice trays to the top of the block. Spill some water on top of the block before an insulating layer of frost builds up, and then place the trays on the block. This water under the trays provides the thermal contact necessary and freezes within minutes, holding the trays securely. If the block is well frosted, it may be necessary to allow the top surface of the Block to defrost before operating the system to make ice.
MAINTENANCE Like your engine, your SEA FROST needs periodic checking. ROUTINELY CHECK: 1. Check the refrigerant charge, never operate the system without proper charge. 2. Check belt tension and condition. 3. Check compressor mounting and compressor bracket bolts. 4. Maintain the condenser zinc. Failure to maintain the zinc anode will cause damage to the system. 5. Check all components and all bilge and engine room fittings for corrosion and wear.
DETAIL OF CONDENSER ZINC ASSEMBLY To change the zinc, first close the engine seacock. Using two 7/16 open-end wrenches, hold the brass plug and remove the outer nut. Carefully bend the ground strap away form the plug. Remove the plug. Water will drain from the condenser. Using pliers hold the zinc and unthread the plug. Should the zinc break in the holder, it may be cleaned by heating the plug holder with a propane torch to melt the remaining zinc. Thread the new zinc into the plug.
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 gas. A great deal of heat must be removed to reverse these changes. These changes are called phase changes, or changes of state. The heat removed or added at these phase changes has no effect on the temperature of the substances until the change is complete.
By causing R-12 to boil (evaporate) in the SEA FROST plate, we use the heat energy in the plate. This activity cools the liquid solution in 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 plate will begin to absorb the heat that leaks through the insulation in the icebox.
TUBE CUTTING Use only a tube cutter, hacksawing or any other method will introduce chips to the system and distort the tube, making connections difficult and leak-prone. A small 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 may cause trouble. TUBE BENDING Make all but the long sweep bends with a spring bender; one kink and the line must be rerun.
In mounting the compressor, consider the following: When mounted, the compressor must not lay over on its axle axis more than 45 degrees from vertical. The port fittings, clutch coil wire, and the ground screw indicate the top of the compressor. The two service ports at the rear of the compressor must be accessible following mounting of the compressor; servicing the system requires attaching charge hoses to these ports. These ports are ¼” flare fittings with Schrader valves and sealed with caps.
PULLEY MOUNTING ON ENGINES IT IS IMPERATIVE THAT THE EXTRA PULLEY BE MOUNTED TO THE ENGINE CRANK PULLEY USING LOCK WASHERS OR THREAD LOCK ADHESIVE. FAILURE TO LOCK ATTACHMENT BOLTS WILL ALLOW THE BOLTS TO LOOSEN, CAUSING DAMAGE AND POSSIBLE DANGER FROM FLYING PARTS. BOLTS SHOULD BE TIGHTENED TO A TORQUE SETTING RECOMMENDED FOR THE DIAMETER AND GRADE OF BOLT BEING USED. RECOMMENDED ADHESIVE/SEALANT: Loctite 271 COMPRESSOR BELTS Various belts are available with an "A" section (1/2" 60 degree V).
The zinc anode must be accessible as periodic checking is required. For best service access to the zinc, mount the condenser with the zinc away from the bulkhead. There is an alternate zinc location on the bottom allowing the plastic plug and the zinc plug to be swapped. Water must enter the bottom of the condenser and exit the top. The bracket is designed to clamp to the middle section. Be sure water fittings are made tight.
A drilling template should be made. Drill 1 1/4" holes for the refrigerant tubes completely through the icebox wall if the V/C/U is externally fitted. This allows recesses for the white nylon bulkhead fittings on the block, and also facilitates removal of the block without having to ruin the connection tubes by cutting off the Swagelok nuts and ferrules. The larger holes also allow adding a moisture seal to any wooden bulkhead that has been drilled by filling the holes with the spray foam provided.
VALVE CONTROL UNIT For appearance and convenience of installation, the valve control unit mounts outside the icebox. However, in certain applications it may be necessary to mount it inside. Two Swagelok fittings fasten it to the block tubing protruding through the icebox wall. Before cutting the tubing: 1. Leave a minimum of 1 ¼” of tube beyond the bulkhead. 2. Allow room for wrench access. Ninety-degree elbows can be factory installed on the valve control unit to reduce the space requirements if necessary.
NOTES ON SWAGELOK FITTINGS Swagelok fittings come to you completely assembled, 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. This is double ferrule system. The most serious installation problem encountered with SEA FROST is the improper assembly of these fittings.
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 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.
SWAGELOK FITTINGS ARE TO BE TIGHTENED TO A TORQUE SPEC, NOT INFINITE TIGHTNESS. BE SURE YOUR STARTING POINT IS WRENCH SNUG. A DISTORTED TUBE MIGHT GIVE A FALSE STARTING POINT. When making all connections, USE TWO WRENCHES. Don't allow the fittings to turn or twist when tightening. RECONNECTING PRE-SWAGED FITTINGS Connections can be disconnected and retightened many times. When reconnecting, insert the tubing with pre-swaged ferrules into the fitting until the front ferrule seats in the fitting.
RUNNING THE LINES PLANNING The hose assemblies connecting the compressor to the copper tubing allow for movement of the compressor after installation to enable work on and around the engine with out having to disconnect the system. Leave some slack in the hoses and have them directed the same way to allow compressor movement as necessary for access to anticipated repair areas. Hose sets without adequate slack will stress the hose fittings at the compressor causing failure of the fitting.
Helpful tools • Coil spring-type tube benders are available for 3/8"-1/2" O.D. tube. These springs are slid over the tube. Bend is formed in the spring, and then the spring is removed by unscrewing. • Ford wrench: Jaws at right angle to the handle for hard to access connections. • Mini tube cutter: "IMP" by Gould Imperial requires less than 1 1/2" radius clearance for the cut. This is essential to trim the block or plate tubing.
INSULATING THE LINES Insulating should be the last step after leak checking because it will cover fittings that must be leak-checked. On long uninterrupted lengths of tubing the insulation can be slipped over the tube before adding fittings. Insulation should be installed only on dry lines, and only after the acrylic spray procedure. The suction return line is carrying the expanded vapor to the compressor. This line is cold and will attract moisture and frost when running.
ELECTRICAL SYSTEM The electrical system for the SEA FROST system includes a control panel comprised of a timer switch, pilot light, circuit breaker, and the valve control unit. CONTROL PANEL LOCATION In choosing a location for the control panel, find the best location within the cabin nearest the cockpit and engine controls. The panel is not waterproof. The system may want to be activated whenever the engine is run.
WIRING The electrical system is shown in the diagram. The red wire is connected to a source of 12 volts (DC) and should be protected by a fuse or breaker of 10 to 15 amps. The blue wire is the power to the compressor clutch, and is connected to the black pigtail on the compressor with a butt connector. The brown wires are connected to the VCU by using the insulated female connectors. Connect the white wire to the Phillips screw on the compressor along with the 3 ft. wire in the kit. This 3 ft.
DISPLACING OIL IN NEWLY INSTALLED COMPRESSOR The compressor is shipped with the proper amount of oil for the system. The oil must be displaced from the cylinders before the compressor may be turned by the boat's engine. After completing all the connections, turn the outer face of the compressor drive disk for at least five turns by hand. ASSEMBLY INSPECTION CHECK LIST 1. Check the lines to be sure they are properly routed.
REFRIGERANT HANDLING SEA FROST is charged with REFRIGERANT-12. R-12 is the common name and number given to the chemical composition DICHLORODIFLUOROMETHANE (CC12F2). It is almost odorless, nontoxic, non-corrosive, non-irritating, and nonflammable. Its boiling point is -21.F at sea level. It was used in most household refrigerators and in auto air conditioning systems. R-12 is now available in 30 lb cylinders. Refrigerant is either a vapor or liquid.
VENTING THE CHARGE HOSE To avoid pulling air or other contaminants into the system, it is necessary to vent the air out of the hoses that are used to carry R-12 into the system. To vent the hose, open the can tap valve with the can upright (vapor) to allow pressure to escape and then make the connection as this vapor is escaping. Follow this procedure when adding refrigerant to an evacuated system or to a system low on charge. CHANGING CANS Close the valve on the empty can.
Charging with the gauges should be done through the blue side. The center hose is connected to the can tap. Be sure to vent the hoses to displace any air that might be in them. TO INSTALL GAUGES ON A CHARGED SYSTEM, with the system off, attach the hoses to the compressor. Vent the hoses at the manifold body by loosening the fittings for a few seconds. TO REMOVE THE GAUGES, turn off the compressor, wait for the pressure readings to equalize, and then rapidly unscrew the hoses at the compressor.
There are two ways to leak-check a pressurized system: 1. Soap bubbles (a solution of dish soap and water works well). 2. Electronic leak detector (probe senses presence of halide refrigerant molecules). 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 Slowly trace the area with the probe.
EVACUATION WITH A VACUUM PUMP Evacuation removes air, readying the system for charging. Evacuate the system only after pressurizing and leak checking. Connect a gauge set to the compressor service ports. If pressure is noted recover the refrigerant and when the gauge reads "O" psi, connect the center hose to a high vacuum pump. Start the pump and slowly open the gauge hand wheel. As the vacuum drops below 20 inches open the hand wheel fully. EVACUATE to the highest vacuum.
6. On a new system, turn off the compressor for several minutes after charging, and then restart it. Run the engine at slow speed, less than 1200 rpm, with several on/off compressor cycles. Allow 1 to 2 minutes "off" periods between 2 to 15 minutes operating periods. This equalizes the oil distribution. When charging is complete, stop compressor and allow entire system to equalize and for the fittings to dry: an hour in most conditions. 7.
In a warm system, when the plate is above freezing (32.F) upon start-up, the sight glass may take several minutes to clear. A cold system, in cold water, may show a clear glass within seconds of start-up. RFD SIGHT GLASS DETAIL EMPTY OR CLEAR STATIONARY BUBBLES FOAM / LOW PROPER CHARGE AMOUNT PROPER CHARGE WILL BE MORE THAN 14 OZ, TOPPING OFF THE SYSTEM TO A CLEAR SIGHT GLASS ABOUT THE TIME THE PLATE REACHES 32 DEGREES F.
SPECIAL NOTE If charging SEA FROST gear with BULK CYLINDERS, it is hard to determine how much refrigerant has been installed. The feed pressure with a bulk cylinder can be higher which may cause skipping through the condenser, causing bubbles in the sight glass. To prevent this keep the feed pressure below 20 psi. CHECKING THE REFRIGERANT CHARGE Checking the refrigerant charge must be incorporated into a routine maintenance schedule. 1) Locate the RFD (receiver filter drier).
DISCHARGING THE SYSTEM Before the connections can be disconnected, the refrigerant charge must be discharged. Connect a gauge set to the suction service port and slowly vent the refrigerant through the open hose regulating the gauge valve prevent oil or liquid from being discharged into the recovery machine. Recover all refrigerant until the system reads 10” of vacuum for 10 minutes. TROUBLESHOOTING The most common problems that can occur in a SEA FROST Engine Drive System are: 1.
If system is warm upon start-up, a DIRT-PLUGGED Valve will show an immediate deep vacuum reading on low side. Contact Sea Frost for cleaning techniques. Moisture plugged valves are indicated by deep vacuum readings on low side after 1 to 5 minutes operation from warm, followed by any combination of these symptoms: • High side compressor discharge fitting temperature drops from hot to warm • Suction line from Valve Control Unit remains warm. • Compressor load on engine drops.
MAINTENANCE FOR UNITS IN TROPICAL WATERS ZINCS This is the most important procedure. A full flow sea frost condenser without a zinc or without the bonding strap connected will last a very short time. Be sure to check the wear by inspection. Replace every six months or sooner if inspection reveals excessive wear. If the zinc breaks in the brass plug, remove the remaining zinc by melting it with a propane torch.
