372 ROUTE 4 BARRINGTON, NH 03825 USA TEL (603) 868-5720 FAX (603) 868-1040 E-Mail:sales@seafrost.com 1-800-435-6708 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 & Co., Inc. Aspects of the SEA FROST design are covered by US Patent # 4,356,708 Copyright © 2001 by C.F. Horton & Co., Inc.
TABLE OF CONTENTS BG 2000 OPERATION ICE MAKING MAINTENANCE HOW REFRIGERATION WORKS INSTALLATION SWAGELOK FITTINGS CONDENSING UNIT LOCATION VALVE PUMP INSTALLATION THERMOSTAT RFD ACCESS TO THE SYSTEM GAUGES LEAK CHECKING NEW SYSTEM CHARGING READING THE SIGHT GLASS CHECKING THE CHARGE / ADDING CHARGE TROUBLESHOOTING SPECIFICATIONS ACCESS PORT LOCATION (DWG) WATER CIRCUIT (DWG) SINGLE ZONE (DWG) BG2000 110-VOLT WIRING BG2000 220-VOLT WIRING THERMOSTAT CALIBRATION MARCH PUMP DESCRIPTION 4 5 6 8-9 10 11-13 14 1
72 ROUTE 4 BARRINGTON, NH 03825 USA TEL (603) 868-5720 E-Mail:sales@seafrost.com FAX (603) 868-1040 1-800-435-6708 www.seafrost.com A VIEW OF THE FUTURE: As a once wonderful invention, refrigerants are now the latest enemy as our awareness of the universe increases. To the end regarding conservation we have always offered a leak proof system. We have also always designed our systems to operate with the lowest quantity of refrigerant. We are concerned.
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 from this by operating the SEA FROST BG 2000 system when the generator plant is operated. Operation time will vary with each boat.
ICE MAKING Your SEAFROST holdover plate may be equipped with vertical ice trays. The ice trays are held in contact with the plate 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 ability). HARVESTING ICE Plan to wait some time after the trays are frozen for them to thaw in a sink or away from the plate in the refrigerator.
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 IN THE SYSTEM. KNOW THE LOCATION OF ALL CONNECTION POINTS. Spray with a rust inhibitor REGULARLY.
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 fitting plate (larger hose size). The impeller may then be removed along with it’s ceramic seal and thrust washer. Reassemble in the reverse order. (An exploded diagram is in this manual.
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-404a to boil (evaporate) in the SEAFROST plates, we absorb the heat energy there. This activity cools the liquid 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 turned off) the plates will begin to absorb the heat that leaks through the insulation in the icebox.
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. 2. 3. 4. 5. Read this manual. Reread any aspect you don't understand. Follow Swagelok fitting instructions carefully. Spend enough time leak-checking to be sure there are no leaks. Thanks from all of us who have to guarantee your work. There are two contaminants that will give you problems in any refrigeration system.
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 # 1. This is a double ferrule system. The most serious installation problem encountered with SEA FROST is the incorrect 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. 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 the fitting has been properly installed.
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 not masking the sound. Bulkhead mounting is fine, but avoid mounting on a bulkhead that may resonate into the cabin area.
INSTALLING THE THERMOSTATIC EXPANSION VALVE The larger fitting on the thermostatic expansion valve connects with a Swagelok to one of the plate tubes. In a multiple plate series 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 be strapped to this return line inside the refrigerated space. Plan the tube run to allow for the length of the capillary (about 50 “).
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 compressor unit and the expansion valve. Multiple plate hook-ups should be assembled as indicated by the specific diagram provided. A 1/2" line connects the plate outlet to the compressor. If possible run the 1/4" liquid line in contact with the 1/2” line. This will be insulated in proper sequence.
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 bottom of the canister to the outlet. THERMOSTAT For the best looking job the thermostat should be cut into a panel.
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 procedure if you do not fully understand the procedure and know what result to expect. Understand that pressure exists in refrigeration systems. Be careful. REFRIGERANT SEAFROST is charged with REFRIGERANT-404a. REFRIGERANT-404a is a blend of HFC refrigerants. It is odorless. Its boiling point is -57. Degrees F.
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 pressurized 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 to a R-404a system from a used system or from a CFC based system.
GAUGES Gauges must be used in the evacuation and charging. They will provide information on the operation of the system 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. The right gauge (red) indicates pressure only. The valves open a center port (yellow) to the left or right side respectively.
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 monitored and not allowed to rise more then 15 PSIG above operating pressure. VENTING THE CHARGE HOSE WHEN ATTACHING GAUGES TO A CHARGED SYSTEM Note: This procedure will vary with the type of gauges being used.
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 manifold. With the refrigerant can in the inverted (liquid) position, open the discharge side valve (high side) valve and weigh in about 6 oz of refrigerant.
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 heavier than air, therefore, trace below the fitting. Most units can be calibrated to home in, on a leak. (See detector instructions).
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 slightly opening the blue hand wheel valve. Keep the low side pressure no more than 15 PSIG above the indicated operating pressure. Add refrigerant for 30 seconds then turn off the supply and observe the sight glass and cooling operation for 2 minutes before adding refrigerant the same way again.
A white stream of fast moving foam with the compressor operating indicates an insufficient charge level. Watch closely for a transition from foam to total liquid, indicated by a clear sight glass. This transition 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 charge is sufficient, so it is important to differentiate between foam and bubbles.
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 systems 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 PERIODIC INSPECTION Checking the refrigerant charge must be incorporated into a routine maintenance schedule. 1) Locate the RFD (receiver filter drier).
TROUBLESHOOTING The most common problems that can occur in a SEA FROST BG 2000 System are: (1) Overcharge or loss of water flow switching 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. STEP 1. Gather information as to the nature of the problem before operating the system. A leak often leaves a trace of oil.
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 system, observing closely the gauge readings and plates temperature, noting the following. a) If system is warm upon start-up, a DIRT-PLUGGED Valve will show an immediate deep vacuum reading on low side.
Follow the "re-make" instructions for Swagelok fittings. Reminder: To ensure the total removal of moisture from the system use a high vacuum pump, and evacuate the system with the highest possible plate temperature (100 degrees F.). A light bulb or heat lamp in contact with the plates is a good technique. Recharge. Refer to "Recharging section" MOISTURE IS A SYMPTOM. Carefully leak check the low side of the system if moisture becomes a problem.
BG 2000 Specifications and Operating Characteristics Horsepower Refrigerant Oil Locked rotor amps Current draw with pump Electrical breaker 115-volt 50/60 hz 1 HP 404-a Polyol ester oil 76.7 26.8 amps 30 amp Maximum refrigerant charge Manual reset high pressure cut-out March pump Integral low voltage thermostat circuit 24 oz 325 PSIG LC-3 24-volt AC 230-volt 50/60 hz 1HP 404-a Polyol ester oil 45 14.
Figure 1 31
WATER CIRCUIT 32
372 ROUTE 4 BARRINGTON, NH 03825 USA TEL (603) 868-5720 FAX (603) 868-1040 E-Mail:sales@seafrost.com 1-800-435-6708 www.seafrost.com THERMOSTAT CALIBRATION INSTRUCTIONS Note: Be sure that the unit is operating properly before making any thermostat adjustments. The sensing bulb must be in excellent thermal contact with the plate or block. The range of this control may be changed. To access the adjustment screw, remove the four mounting screws on the thermostat panel.
HOLDOVER PLATES STAINLESS STEEL EVAPORATOR PLATES 37
