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Sea Frost DC 5000 Operation And Installation Instructions Manual

Sea frost refrigerator user manual
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372 ROUTE 4 BARRINGTON, NH 03825 USA
E-Mail:sales@seafrost.com
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 interpretation of these
instructions.
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
DC 5000 SYSTEM 134a
OPERATION & INSTALLATION
INSTRUCTIONS
US Patent #4,356,708
2nd Edition
134 12 volt
Copyright © 1996 by C.F. Horton & Co., Inc.
FAX (603) 868-1040
1
1-800-435-6708
www.seafrost.com

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  • Page 1 E-Mail:sales@seafrost.com 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 interpretation of these instructions.
  • Page 2 1) Locate the SEA FROST Receiver/Filter/Drier (RFD). The location of this part varies from boat to boat, but it is often found in the compartment with the DC 5000, in a locker, or beneath the cabin sole. It is a blue metal can about 9 inches high and 3 inches in diameter, with brass fittings connecting it to copper tubing.
  • Page 3 CALL US AT 603-868-5720. Inspecting the sight glass periodically for several weeks after a new installation and every time after a lay period is assurance that your SEA FROST DC 5000 system is assembled properly and is a good maintenance habit as well.

  • Page 4: Table Of Contents

    OPERATION GENERAL DESCRIPTION ICE MAKING MAINTENANCE HOW REFRIGERATION WORKS INSTALLATION COMPRESSOR INSTALLATION WATER PUMP PLATES VALVE UNIT SWAGELOK FITTINGS, MAKE-UP & RECONNECTING RECEIVER FILTER DRYER ELECTRICAL SYSTEM; WIRING; THERMOSTAT CONTROL PANEL WIRING DIAGRAM ASSEMBLY INSPECTION CHECK LIST REFRIGERANT HANDLING ACCESS TO THE SYSTEM: SERVICE PORTS GAUGES LEAK CHECKING NEW SYSTEM CHARGING...

  • Page 5: General Description

    Check the overboard discharge to be sure water is being pumped. 4. If the battery system is fitted with an amp/hr meter you will notice the DC 5000 compressor drawing about 45 amps/hr (12 volts) for the first few minutes dropping to 35 amps/hr for the remainder of the cycle.
  • Page 6 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.

  • Page 7: Ice Making

    HARVESTING VERTICAL TRAYS Plan to wait for the trays to thaw in a sink or away from the plate in the refrigerator. When the outside surface is wet invert the tray and let the ice slide out. STORAGE OF ICE CUBES After ice has been made and harvested, store it in sealable plastic bags in the refrigerator or freezer.

  • Page 8: How Refrigeration Works

    Let's look at Refrigerant-134a. R-134a will boil at minus 15 degrees F. at sea level. By evaporating liquid R-134a in the SEA FROST plate, heat is absorbed making refrigerant vapor. To dispose of this heat, a condensing phase change is necessary. By increasing the pressure (compressing) we can raise the boiling point of the refrigerant vapor at the condenser.

  • Page 9: Installation

    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.
  • Page 10 The RFD (receiver, filter, drier) should be the last component to be unpacked and fitted. INSTALLING THE DC 5000 COMPRESSOR UNIT Install the DC 5000 in a dry location where the convergence of wires, water hoses and tubing to the refrigerator area are the most convenient. Avoid installing the DC 5000 on...

  • Page 11: Compressor Installation

    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.

  • Page 12: Water Pump

    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 a through hull above the water line.

  • Page 13: Plates

    If disassembly is necessary, reassemble per drawing. 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 14: Swagelok Fittings, Make-Up & Reconnecting

    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.
  • Page 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 with a backup wrench, tighten the nut 1 1/4 turns. Watch the scribe mark, make one complete revolution and continue to the 9 BE TIGHTENED TO A TORQUE SPECIFICATION NOT INFINITE TIGHTNESS.
  • Page 16 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.

  • Page 17: Helpful Tools

    This is essential to trim the plate tubes. LINE CONNECTION PLAN Run 1/4" copper tube from the DC 5000 to the RFD. From the RFD 1/4" copper tube continues to the V/U. Run 1/2" copper tube from the large connection on the V/U to the DC 5000.

  • Page 18: Receiver Filter Dryer

    VERTICAL to ensure proper operation at various heel angles. MOUNTING THE RFD The inlet is from the DC 5000. (The sight glass is offset on the RFD toward the outlet.) The RFD is to be mounted with the bracket and mounting strap. Cable ties with screw mounts should be used to support the tubing.

  • Page 19: Cable Ties

    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.

  • Page 20: Electrical Junction Box

    Thermostat Control Panel may be spliced with 16-gauge wire. ELECTRICAL JUNCTION BOX The DC 5000 is equipped with a 4' (105 cm.) harness that is to connect to the Electrical Junction Box. Do not splice this harness. Position the Electrical Junction Box to allow proper routing of the harness.

  • Page 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 10% voltage drop.

  • Page 22: Ground Wire

    The best installation should have the shortest possible conductor lengths connecting the batteries and the Electrical Junction Box. Do not feed the DC 5000 from the boats 12-volt breaker panel. Voltage drop and power loss can occur through the supply wires, terminal ends, and switching devices.

  • Page 23: Refrigerant Handling

    REFRIGERANT The SEA FROST DC 5000 is charged with REFRIGERANT 134a. R-134a is a chemical compound called tetrafloroethane. It is odorless. Its boiling point is -15. degrees F. at sea level.
  • Page 24 Sea Frost. 4) No oil is to be added to the DC 5000 system but the PAG oil supplied by Sea Frost, labeled and capped for DC 5000 use. No oil is to be added to a system with out prior consultation with Sea Frost.

  • Page 25: Access To The System: Service Ports

    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 hand wheel valves and hoses to connect the gauges to the system. The left gauge (blue) is a compound device;...
  • Page 26 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 side and the smaller port is the suction side.
  • Page 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 the 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.

  • Page 28: Leak Checking

    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 vacuum pump. Start the pump and slowly open the suction gauge hand wheel. As the vacuum drops below 20 inches open both hand wheels fully.
  • Page 29 LEAK CHECKING A CHARGED SYSTEM ABOUT PRESSURES Refrigerant in a saturated condition, part liquid 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 pressure.
  • Page 30 2. Check to be sure the proper sea cocks are open. 3. Start the DC 5000 by turning on the thermostat. The red indicator light should light, indicating 12-volt power is available and that the system is operating. Check the overboard discharge to be sure water is being pumped.

  • Page 31: Reading The Sight Glass

    A clear sight glass when the compressor is operating signifies a sufficiently charged SEA FROST DC 5000 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 32: General Information

    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.

  • Page 33: Discharging The System

    Be sure the gauge hand wheel is off before starting the compressor. TROUBLESHOOTING The most common problems that can occur in a SEA FROST DC 5000 system are: 1. Low voltage which can cause premature motor brush wear and commutator damage.
  • Page 34 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-134a. Installation of the wrong part or oil may destroy the system.
  • Page 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! TOLL FREE IN THE UNITED STATES, Technical help 603-868-5720 CANADA, AND CARIBBEAN 800-435-6708 E-mail sales@seafrost.com...

  • Page 36: Pressure Charts

    PRESSURE CHARTS...
  • Page 37 PRESSURE CHARTS...
  • Page 38 PRESSURE CHARTS...

  • Page 39: Dc5000 Motor Maintenance

    DC 5000 MOTOR AND WATER PUMP MAINTENANCE Lubrication The DC 5000 motor and the March water 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.
  • Page 40 Tip: In a new motor with new brushes the back of the brush will be flush with the brush housing, as the brush wears the distance into the housing will increase. (See top view drawing below.) A quick measurement of the depth will be sufficient. When the brush is 5/8”...
  • Page 41 DC5000 WIRING...

  • Page 42: Drawings

    DC 5000 LAYOUT...
  • Page 43 DC 5000 WATER CIRCUIT...
  • Page 44 TWIN VALVE SYSTEMS ONLY...

  • Page 46: Voltage Monitoring Relay Wiring

    Setting The Control The control is mounted on the DC 5000 Electrical junction box. The relay has a two knobs and an indicator lamp. Initial stetting: Set the pick up point at about 3 o’clock this should be about 12 volts. Set the drop out voltage at the 3 o’clock position as a starter.

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