Sea Frost BG 2000 User Manual

372 ROUTE 4 BARRINGTON, NH 03825 USA TEL [phone] FAX [phone]

E-Mail:[e-mail] www.seafrost.com

OPERATION & INSTALLATION

INSTRUCTIONS

BG 2000

404a SERIES

C.F. HORTON & CO., INC.

372 ROUTE 4

BARRINGTON NH 03825

U.S.A.

[phone]

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 4
ICE MAKING 5
MAINTENANCE 6
HOW REFRIGERATION WORKS 8-9
INSTALLATION 10
SWAGELOK FITTINGS 11-13
CONDENSING UNIT LOCATION 14
VALVE 15
PUMP INSTALLATION 16
THERMOSTAT 17
RFD 17
ACCESS TO THE SYSTEM 19
GAUGES 20
LEAK CHECKING 22-23
NEW SYSTEM CHARGING 22-23
READING THE SIGHT GLASS 25-26
CHECKING THE CHARGE / ADDING CHARGE 26-27
TROUBLESHOOTING 28-30
SPECIFICATIONS 31
ACCESS PORT LOCATION (DWG) 32
WATER CIRCUIT (DWG) 33
SINGLE ZONE (DWG) 34
BG2000 110-VOLT WIRING 35
BG2000 220-VOLT WIRING 36
THERMOSTAT CALIBRATION 37
MARCH PUMP DESCRIPTION 39

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 interpretations of these
instructions.

2

372 ROUTE 4 BARRINGTON, NH 03825 USA TEL [phone] FAX [phone]

E-Mail:[e-mail] 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.

There is a global impact from all refrigerants and it is time now to address the concept
of "invisible pollutants".

Your new R-404a system has little environmental impact that we know of at this time.
This not to say those millions of tons of refrigerant won't make some problem in the
future. We must enjoy the benefits of refrigeration but be conscious of the
maintenance of the machinery to avoid unnecessary leaks and waste. Everyone must
be involved.

Thank you for supporting our product. We are proud to be providing what we feel is the
best equipment available, bar none.

Cleave Horton

3

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.

A little time-spent learning about your system and some experimentation will be best.
Maximum holdover will be reached when the cabinet is at the desired temperature and
the holdover plates are frozen. Running times beyond this have no advantage other
than to delay warming the plates.

The system is water-cooled. Water should begin to flow from the discharge at the same
time the unit starts. Be sure the water is flowing. If no water flows, stop the system and
inspect the water pump and strainer for obstructions. (See "Troubleshooting" and
"Maintenance" sections.)

After starting a warm system check the plates for a temperature drop. If a temperature
drop is not indicated, stop the unit and read; "Checking The Charge", and; "Reading
The Sight Glass".

CONTROLS

The BG 2000 thermostat control is labeled with "off", one, two, and three snowflakes.
When the boat’s breaker panel is switched on and AC power is available, turning the
knob from "off" to one snowflake will start the compressor. Turning the knob to three
snowflakes will increase the time the compressor operates, making the temperature
cooler. Experiment with the control position to obtain the best setting.

4

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. 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 resealable plastic bags in the
refrigerator or if so equipped in the freezer. Ice trays left in contact with the plate will
melt rapidly if the plate goes above freezing.

DEFROSTING

It is important to defrost the holdover plate regularly; this will maximize the efficiency of
the system and ice making performance. It is not necessary to turn off the system to
defrost. Scrape off any frost with a piece of wood or galley utensil. A noticeable drop in
the cabinet temperature will occur.

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
of your own invention can hold the bag in contact with the plate.

5

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. Corrosion unchecked in the marine environment will severely
reduce the life of your system.

CLEANING

The holdover plate surface protects itself with a layer of oxidation. You might find
that 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.

WATER STRAINER

The water pump must be protected from damage and blockage by a seawater
strainer. This strainer must be inspected and cleaned routinely.

ROUTINE SERVICE AND INSPECTION

We recommend sea strainer inspection before leaving the boat unattended dockside
with the unit on. A visual inspection may be adequate depending on the type of
strainer. To clean most types of strainers, close the seacock, open the strainer, remove
the screen or basket, clean, reassemble and open the seacock. Operate the system
and check for water flow and leaks around the strainer opening.

PUMP IMPELLER INSPECTION (if pump is inoperative)

The LC-3P pump is a sealed liquid cooled magnetic drive centrifugal pump. The
impeller may be inspected for obstructions and wear by first closing the seacock. Drain
the pump housing by removing a hose.

6

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.) Observe the "O" ring that
seals the housing cover plate. Make sure it is in good condition. Open the seacock.
Inspect for leaks.

NEVER OPERATE THE PUMP WHILE DRY. IF IT IS SUSPECTED THAT THIS
CONDITION HAS OCCURRED, INSPECT THE IMPELLER AND HOUSING FOR
WEAR.

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.)

The charge level should be inspected to be sure refrigerant is of the proper amount and
that there are no slow leaks. Switch the unit on and immediately inspect the sight glass.
White foam with high velocity should be observed and after a minute or two show a
black or clear condition. A clear glass and an empty glass will look the same. A
transition must be seen to be sure that refrigerant is present. Do not operate a low or
empty system. See; "Leak Checking” and “Adding Charge". (Page 22)

LAY-UP (Winterizing)

Flush the pump and condenser with plenty of fresh water. Pressure water should be
flushed through the inlet side of the water pump. In freezing climates antifreeze should
be pumped through, after flushing, by operating the system for a very brief period.
Connect a short hose to the suction side of the pump to draw from a bucket. Run the
pump (switch on unit) until antifreeze is discharged. (The pump is not self-priming and
may require filling the hose and pump with a funnel). DO NOT RUN THE PUMP DRY.
It is water lubricated.

7

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. For instance, ice melts at 32 degrees F, water freezes at 32 degrees F also.
Ice and water will remain at 32 degrees F until the freezing or melting process is
complete. Latent heat is this hidden energy required to make or break the bonds in a
phase change.

By evaporating liquid to a vapor, we can absorb heat. By condensing a vapor to a
liquid, we give up heat. Refrigeration is the use of these phase changes to move heat
out of the icebox (cooling it).

We all know that cold is the absence of heat. A practical example of heat absorption by
evaporation is that of rubbing alcohol evaporating in your hand and cooling it. The
alcohol is actually using the heat from your hand to boil. The absorption of heat cools
your hand.

Pressure affects the temperature at which a gas phase change will occur. Using water
as an example, water boils at sea level at 212 degrees F. On top of Mt. Everest it boils
at a much lower temperature. The air pressure is lower allowing the water-to-steam
phase change to occur more easily. A pressure cooker increases the pressure on water
to restrict boiling to a higher temperature. A pressure cooker will cook food faster
because the temperature is higher. Remember that a phase change involves latent
heat. The temperature of boiling water is only 212 degrees F. at sea level. The
evaporation action is absorbing heat at a rate equal to the rate of heat applied,
preventing further temperature rise.

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. By increasing the pressure (compressing) we can raise the boiling point of
the gas vapor. Heat is removed from the pressurized gas vapor at the condenser.
Seawater passing the condenser coils removes the heat, forcing the vapor to a liquid
state again. Pressure, therefore, is the key that allows passing the heat we have taken
from the icebox to a warmer place (the seawater) and converting the gas to a liquid to
be re-evaporated again.

8

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. 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.

9

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.

3. Follow Swagelok fitting instructions carefully.

4. Spend enough time leak-checking to be sure there are no leaks.

5. Thanks from all of us who have to guarantee your work.

There are two contaminants that will give you problems in any refrigeration system.
They are WATER and DIRT. Moisture is always present and cannot be eliminated,
water in this case refers to puddles and drops. Dirt is any solid. The installer's habits
will be most important in ensuring a trouble-free start-up. We have added a large
receiver filter dryer (RFD) to take care of all dirt and moisture that might get into the
system during a careful installation. Moisture in the system is boiled off when the
system is evacuated, or it is captured in the desiccant. There is a screen in the
expansion valve to prevent dirt from plugging it.

Excess moisture that the RFD can't handle will plug the expansion valve with ice. This
ice stops the cycle. The only cure is to discharge the refrigerant, replace the RFD, re­evacuate the system, and recharge it. This remedy takes time and is somewhat costly.
Keep the system clean when installing it to save time for something more fun.

TUBE HANDLING

Installation is quite simple. All the copper tube comes to you with the ends capped.
Any routing of the tube must be done with the tube either taped or capped. Cap both
tube ends after each cut. (Spare caps have been included). Work with only one line at
a time, and only uncap one end at a time.

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, which may cause trouble.

TUBE BENDING

Make all but the long sweep bends with a spring bender; one kink and the line must be
rerun. Don't add any more fittings than are absolutely necessary. Route all lines in
such a way that they are most direct but out of the way. Again, keep everything sealed
until you are ready to make that connection.

10

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. Be absolutely sure that you
assemble all fittings as in Drawing #1.

To ease assembly slacken the fitting nut slightly before pushing onto the tube, then
retighten with fingers before tightening with a wrench. (This is to avoid cross threading.)

Step 1. Always leave two inches of straight, undistorted tubing leading to all Swagelok
fittings to allow a proper connection.

Step 2. Prior to inserting 1/2" tubing into Swagelok tube fitting, make a pencil mark one
inch from the end of the tube. Prior to inserting 3/8" tubing, make a pencil mark 3/4"
from the end of the tube. With 1/4" tubing make the 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.

Step 4. Tighten the Swagelok nut to a wrench snug* position. Scribe the nut with a
pencil at the 6:00 o'clock position. (See drawing #1 step # 2.)

* Wrench snug is the first point in the assembly tightening when the tube can not be
pulled from the fitting, (i.e. when the ferrules tighten enough to contact the tubing).

Step 5. Now, while holding the fitting body with a back-up wrench, tighten the nut one­and-one-quarter turns (1-1/4). To do so, watch the scribe mark, make one complete
revolution, and continue to the 9:00 o'clock position. (See drawing # 1, step #3.)

11

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.

12