Sea Frost BG 2000 Operation And Installation Instructions Manual

404a series

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372 ROUTE 4 BARRINGTON, NH 03825 USA

E-Mail:sales@seafrost.com

SEA FROST is a registered trademark of C.F. Horton & Co., Inc.

Aspects of the SEA FROST design are covered by

TEL (603) 868-5720

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

US Patent # 4,356,708

FAX (603) 868-1040

1-800-435-6708

www.seafrost.com

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Page 1 372 ROUTE 4 BARRINGTON, NH 03825 USA E-Mail:sales@seafrost.com SEA FROST is a registered trademark of C.F. Horton & Co., Inc. Aspects of the SEA FROST design are covered by Copyright © 2001 by C.F. Horton & Co., Inc. TEL (603) 868-5720 OPERATION &...
Page 2: Table Of Contents
THERMOSTAT CALIBRATION MARCH PUMP DESCRIPTION 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 interpretations of these instructions.
Page 3 372 ROUTE 4 BARRINGTON, NH 03825 USA E-Mail:sales@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.
Page 4: Bg 2000 Operation
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.
Page 5: Ice Making
BAG STYLE ICE MAKING If your SEA FROST system is not equipped with the vertical tray kit, you can still make ice. One method is to use zip-lock bags. When filled with water a clip binder or a clamp...
Page 6: Maintenance
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.
Page 7 CHECKING THE REFRIGERANT CHARGE SIGHT GLASS LOCATION The BG 2000 system is fitted with a sight glass located in the top of the RECEIVER/FILTER/DRIER (RFD). (The RFD is a round blue canister about 9 inches high and 3 inches in diameter. It is located in the left corner of the compressor housing.)
Page 8: How Refrigeration Works
Let's look at Refrigerant-404-a (R-404-a). R-404-a will boil at minus 57 degrees F. at sea level. By evaporating liquid R-404a in the SEA FROST plates heat is absorbed making refrigerant vapor. To dispose of this heat, a condensing phase change is necessary.
Page 9 The absorption will be at a constant temperature until the phase change to liquid (melting) is complete. This is the principle of holdover refrigeration and the function of your SEA FROST.
Page 10: Installation
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.
Page 11 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. Be absolutely sure that you assemble all fittings as in Drawing #1.
Page 12 DRAWING 1 STEP 2 Before tightening the SWAGELOK nut, scribe the nut at the six o'clock position. 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.
Page 13: Swagelok Fittings
* SWAGELOK FITTINGS ARE TO BE TIGHTENED TO A TORQUE SPEC, NOT INFINITE TIGHTNESS. BE SURE YOUR STARTING POINT IS WRENCH SNUG. (SEE STEP 4 on page 12.) A DISTORTED TUBE MIGHT GIVE A FALSE STARTING POINT. * Swagelok fittings have a built-in spring interaction between the ferrules. This compensates for temperature changes and allows the fittings to be reconnected many times.
Page 14: Condensing Unit Location
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.
Page 15: Valve
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.
Page 16: Pump Installation
The BG 2000 unit is shipped with some nitrogen pressure. Before removing the caps on the connection ports remove the screw caps on the access valves and depress the cores with a clean retracted pen point to vent any existing pressure.
Page 17: Rfd
THERMOSTAT WIRING The thermostat electrical leads are low voltage for safety. Connect the red thermostat wires to the two terminal screws in the BG 2000 terminal box. Use the # 8 ring terminals provided. AC LINE CIRCUIT A separate 30-AMPbreaker is required for the 110 volt AC circuit.
Page 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 procedure if you do not fully understand the procedure and know what result to expect.
Page 19: Access To The System
Sea Frost for a R-404a system will cancel all claims against Sea Frost. 4) No oil is to be added to the BG 2000 system but polyolester oil supplied by Sea Frost, labeled and capped for BG 2000 use. No oil is to be added to a system without prior consultation with Sea Frost.
Page 20: Gauges
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.
Page 21: Liquid Charging
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.
Page 22: Leak Checking
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.
Page 23: Special Note
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.
Page 24: Reading The Sight Glass
A clear sight glass when the compressor is operating signifies a sufficiently charged SEA FROST BG 2000 System. To determine the meaning of "clear", notice the appearance of the RFD sight glass when the system is at rest with the compressor off.
Page 25: General Information
STATIONARY BUBBLES FOAM/LOW PROPER CHARGE AMOUNT THE BG 2000 SYSTEM IS DESIGNED TO HOLD 24 OUNCES. THIS IS THE MAXIMUM CHARGE. The sight glass must clear by the time the return line (suction/large diameter tube) goes below 32 degrees F.
Page 26 5) Feel the SEA FROST plates in the icebox 10 minutes after start up. If the sight glass clears yet the plate’s temperature does not drop, turn the system off and follow the procedure in troubleshooting section.
Page 27: Troubleshooting
The compressor is fitted with a MANUAL RESET high-pressure switch. The switch is located on the left end of the BG 2000 unit. (See drawing). This switch will disconnect the thermostat circuit switching off the compressor and water pump. Pushing the red rubber button after the unit has rested for a few minutes will reset the switch.
Page 28 The tubing may be pulled out of the fittings. Remove the RFD. Replace only with an identical unit by size and color: THE SEA FROST RFD is a drier and also a receiver/filter. The desiccant and the oil in the Sea Frost RFD are special to this system and R-404a.
Page 29 MOISTURE IS A SYMPTOM. Carefully leak check the low side of the system if moisture becomes a problem. Moisture leaks in! CALL US WITH ANY QUESTIONS TOLL FREE IN THE UNITED STATES, INTERNATIONAL 603-868-5720 CANADA, AND CARIBBEAN 800-435-6708 FAX 603 868 1040 SHIPPING AND MAIL: SEA FROST 372 ROUTE 4 BARRINGTON NH 03825...
Page 30: Specifications
BG 2000 Specifications and Operating Characteristics Horsepower Refrigerant Locked rotor amps Current draw with pump Electrical breaker Maximum refrigerant charge Manual reset high pressure cut-out March pump Integral low voltage thermostat circuit Pressure trends: Gauge pressure PSIG Hi Pressure Low Pressure (Warm Plates)
Page 31 Figure 1...
Page 32: Water Circuit (Dwg)
WATER CIRCUIT...
Page 36: Thermostat Calibration
372 ROUTE 4 BARRINGTON, NH 03825 USA E-Mail:sales@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.
Page 37 HOLDOVER PLATES STAINLESS STEEL EVAPORATOR PLATES...