Sea Frost DC 5000 User manual

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372 ROUTE 4 BARRINGTON, NH 03825 USA TEL [phone] FAX [phone]
E-Mail:[email protected] www.seafrost.com
DC 5000 SYSTEM 134a
OPERATION & INSTALLATION
INSTRUCTIONS
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
US Patent #4,356,708
2nd Edition
134 12 volt
Copyright © 1996 by C.F. Horton & Co., Inc.

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START UP PROCEDURE AND PERIODIC INSPECTION
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. Please read the information here
before proceeding to operate your system for the first time.
BREAK-IN PERIOD. LIMIT COMPRESSOR RUNNING TIMES TO THIRTY MINUTES
FOR THE FIRST TWO HOURS OF OPERATION. THIS SHOULD BE FOUR
SEPARATE THIRTY-MINUTE OPERATIONS WITH A REST PERIOD OF AN HOUR
OR MORE BETWEEN THEM.
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. If you do not locate the RFD
quickly, follow the route of refrigeration copper tubing, from the DC 5000 to the icebox.
Along the route you will find the RFD. The RFD has a sight glass for viewing the flow of
refrigerant.
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.
4) With the system running look at the sight glass in the RFD.
5) MONITOR THE SIGHT GLASS CONTINUALLY. White FOAM should appear in the
sight glass indicating that refrigerant is present. This foam may disappear quite quickly,
but IF NO FOAM IS EVIDENT, that is, if the sight glass does not show the presence of
refrigerant within a minute or two of operation the system is dead flat. DO NOT
CONTINUE TO OPERATE THE SYSTEM. OPERATION IN THIS MODE WILL RUIN
THE COMPRESSOR. Switch off the DC 5000 to prevent operation until the problem is
corrected. CALL US AT 603-868-5720.
6) 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”. The foam condition has velocity and direction, but the larger
bubbles are nearly stationary. If the foam does not clear, the system is low on
charge. CALL US AT 603-868-5720 for trouble shooting and correction help.

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There are three conditions of charge indicated by the sight glass:
1.A black or clear glass and no cooling indicates no charge. Turn off the
compressor at once.
2. A white foaming glass and some cooling indicates the system is undercharged or
has lost charge. Refer to the manual regarding leak checking and adding
charge.
3. A black glass and proper cooling indicates all is well.
RFD SIGHT GLASS DETAIL
EMPTY OR CLEAR STATIONARY BUBBLES FOAM/LOW
Feel the SEA FROST Plate in the icebox ten minutes after engaging the timer switch. If
the sight glass clears yet the plate temperature does not drop after 10 minutes of
operation, turn off the system and 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.

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TABLE OF CONTENTS
OPERATION 5
GENERAL DESCRIPTION 5
ICE MAKING 7
MAINTENANCE 7-8
HOW REFRIGERATION WORKS 8-9
INSTALLATION 9
COMPRESSOR INSTALLATION 11
WATER PUMP 12
PLATES 13
VALVE UNIT 13
SWAGELOK FITTINGS, MAKE-UP & RECONNECTING 14-16
RECEIVER FILTER DRYER 18-19
ELECTRICAL SYSTEM; WIRING; THERMOSTAT CONTROL PANEL 20
WIRING DIAGRAM 21-22
ASSEMBLY INSPECTION CHECK LIST 23
REFRIGERANT HANDLING 23-24
ACCESS TO THE SYSTEM: SERVICE PORTS 25
GAUGES 25-26
LEAK CHECKING 28-29
NEW SYSTEM CHARGING 28
READING THE SIGHT GLASS 31
PROPER CHARGE AMOUNT: MAXIMUM CHARGE 32
DISCHARGING THE SYSTEM 33
TROUBLE SHOOTING 33-34
PRESSURE CHARTS 37-38
DC5000 MOTOR MAINTENANCE 39-40
DRAWINGS 42-45
VOLTAGE MONITORING RELAY WIRING 46

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GENERAL DESCRIPTION
The SEA FROST DC 5000 is a cold storage refrigeration system powered by a 1/2
horsepower permanent magnet direct current 12-volt motor. Refrigerant from the
compressor is piped to the SEA FROST plate in the icebox. Cold storage is attained by
rapidly freezing the solution contained in the plate, creating a captive (replenishable)
block of ice. The system may be used when the boat’s engine is on and charging the
batteries or with a properly sized battery bank. The compressor may be controlled by
an oil pressure switch preventing operation without the engine, a lockout relay that
prevents operation without the shore power charger operating, a timer, or by a
thermostat alone. The heat removed from the icebox is discharged into the seawater at
the water-cooled heat exchanger. A separate pump below the water line controlled by
the DC 5000 pumps water through the heat exchanger and overboard above the water
line.
BREAK-IN PERIOD.
REFER TO THE START UP PROCEDURE IN THE BEGINNING OF THIS MANUAL.
EVERY TIME THE SYSTEM IS RESTARTED FROM WARM, CHECK TO BE SURE IT
IS COOLING BEFORE OPERATING THE COMPRESSOR EXTENSIVELY. THIS IS
YOUR SYSTEM. SIMPLE OBSERVATIONS OF YOUR SYSTEM AND OPERATING
CAUTION WILL PREVENT DAMAGE THAT COULD COST YOU MONEY.
OPERATION
1.This system is water-cooled and depends on water being pumped by the remote
DC 5000 pump. The proper sea cock must be open before starting the
system. Water flow is most important, therefore CHECK THE WATER FLOW
AFTER STARTING THE SYSTEM.
2.Check the battery switch position and voltage readings before starting.
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.
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.
5.After 10 minutes of operation, check for a drop in the cold plate temperature by
feeling the plate with your hand. If no noticeable cooling has occurred, turn off
the thermostat. Check the charge level (See checking the refrigerant charge
section) and check the water flow. TO PROTECT THE COMPRESSOR, DO
NOT OPERATE the system if this temperature drop is not noted. CALL US AT
603-868-5720.

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After about one hour (with a single plate), the plate will become very cold. Starting from
warm will require more running than the normal refreezing time of the plate in its usable
temperature range.
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.
The plate must be frozen. Chilling the plate without freezing it will not provide any
holdover. You will learn about the daily time required for SEA FROST operation by
using the system.
Note: Maximum holdover time will be obtained when the cabinet and contents are at
their lowest temperatures and the plate is frozen solid. There is no limit to "on" time
however, no advantage is gained by running the system beyond this point and in
refrigeration applications over running will freeze items. Over running will also produce
undue wear on the motor, compressor and pump.
Cabinet size, cabinet insulation, contents added to be cooled, cabinet opening and
closing, and climate effect the holdover time.
SUGGESTIONS
As soon as the system has stopped the plate will begin to warm up as it absorbs heat,
cooling the refrigerated box. 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.
Maximum storage will require that the plate be frozen. The plate may thaw (be above
freezing) and still not require running in refrigeration applications. Monitor the box
temperature itself not the plate temperature.
For minimum battery consumption set the thermostat at the highest (warmest) possible
setting. This would be toward one snowflake. When the engine or generator are
operating and charging, operate the DC 5000 at the maximum (coldest) setting to
increase the holdover storage and minimize battery consumption by freezing the plates
solid.
With timer operated systems two shorter periods a day may be better than a long one
once a day. When the holdover freezing is complete the benefit of running is only to
delay warming. There is some help in that cooling of the contents of the box will
increase holdover time but heat, "cold", moves slowly and it will be more efficient to wait
and run again later. Experimentation will provide the best instruction on how the SEA
FROST DC 5000 should be operated on your boat.
DEFROSTING will be required. A heavy layer of frost or ice will reduce cooling. This is
very important in freezers.

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ICE MAKING
WITH VERTICAL TRAYS ON VERTICAL PLATE SYSTEMS
Fill the vertical trays with water and hang them on the stainless steel rod on the face of
the plate. Try to get some water between the tray and the plate surface to increase the
thermal contact to speed freezing.
The trays may take time to freeze after the plate is frozen and the compressor has been
switched off.
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. Leaving the ice in trays in contact with the plate will allow the ice
to melt if the plate goes above freezing.
MAINTENANCE
Like your engine, your SEA FROST needs periodic checking.
ROUTINELY CHECK:
1. The refrigerant charge. (See Start Up Procedure text) NEVER OPERATE
SYSTEM WITHOUT PROPER CHARGE.
2. All components, bilge and engine room fittings 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.
3. Motor maintenance. Brush wear must be checked at early intervals to determine
future required inspection. Failure to inspect and replace brushes when
needed will ruin your motor. See: Motor & pump maintenance, pages 39-
40.
4. Winter storage will require that the water pump and water-cooled condenser be
drained or flushed and filled with antifreeze solution to avoid freeze damage. If
the condenser is to be left dry flushing with a large amount of fresh water to
remove salt deposits is recommended. (The pump will not self-prime. It might
be necessary to install a hose and funnel on the intake to force-feed the pump.)

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CLEANING
The plate surface protects itself with a layer of oxidation. You might find 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.
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 vapor. 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. 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 rubbing alcohol evaporates in your hand
and cools 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 vapor phase change will occur. Using
water as an example, water boils at sea level at 212.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.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-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. 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 sea water) and
converting the vapor to liquid to be evaporated again.

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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. When the cycle is stopped (the compressor
is turned off) the frozen plate 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.
INSTALLATION ~ WORK HABITS
Installer's care should be stressed. No matter how good SEA FROST equipment is, it's
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. Install the RFD last and the same day the system is charged.
5. Spend enough time leak checking to be sure there are no leaks.
6. Thanks from all of us who have to guarantee your work.
There are two contaminants that will give you problems in a refrigeration system. They
are WATER and DIRT. Moisture in the air 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 drier (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,
evacuate the system, and recharge it. This remedy takes time and is somewhat costly.
Keep the system clean and dry!
TUBE HANDLING
Installation is quite simple. All the copper tube comes to you with the ends capped.
Any routing of the tubing must be done with the tube either taped or capped. Cap both
tube ends after each cut. Work with only one line at a time, and uncap only one end at
a time.

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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 that will 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 the lines in
such a way that they are most direct but out of the way. Always leave several inches of
straight undistorted tubing leading to all Swagelok fittings to allow proper connection.
Again, keep everything sealed until you are ready to make that connection.
FIT RFD LAST
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

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a bulkhead that directly separates the living space from the machine space to avoid
excessive sound radiation.
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.
Fasten the DC 5000 through the (4) drilled holes in the base.
THE BRUSHES WILL REQUIRE PERIODIC INSPECTION AND REPLACEMENT. BE
SURE THE DC 5000 IS LOCATED WHERE BOTH BRUSH COVERS CAN BE
ACCESSED.
WATER PUMP INSTALLATION AND WATER CIRCUIT
Proper water pump installation is essential to a trouble free system.
• The pump will not self-prime.
• The pump must be well below the water line on all angles of heel.
• The pump motor must be above the pump body.
• The pump outlet must be above the pump inlet.
• The pump should have it's own intake through hull with sea cock, sea
strainer and exit through hull.

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Install the intake through hull as low in the boat as possible. The minimum size through
hull should be 1/2". In areas of floating weed and jelly fish a larger through hull might be
beneficial. The sea strainer should be positioned above the through hull with no loops
of hose that could trap air. 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.
ABOUT THE PUMP
The March 809 BR pumps are not self-priming. The coupling between the impeller and
the motor is through a pair of magnets. The impeller is water lubricated and does not
touch the housing in proper operation. The advantage of this pump is a long life, quiet
operation and low power consumption. To treat this pump properly it must be flooded at
all times. Air pockets created by rising and falling hose levels and an improperly located
pump and strainer will trap air, which the pump will not be able to displace preventing
water pumping. The only acceptable installation will not have air pockets in the water
circuit.
PLATE LOCATION
The plate size, location, and plumbing are designed for each application. This
information is provided with each system.
SEA FROST holdover plates mount with
a "Wellnut" expandable neoprene blind
hole fastener. A template or the plate
itself should be used to locate the
mounting holes. Drill 1/4" pilot holes
then increase them to 1/2". Install the
screw into the mounting tab then screw
the Wellnut onto the screw. Install the
plate pushing the rubber mounts into the
pre-drilled holes. Tighten the screws.

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VALVE UNIT V/U
For appearance and convenience of installation, the valve unit may be mounted outside
the icebox. In certain applications and multiple plate systems it may be best to mount it
inside. Location of the V/U in multiple plate systems is indicated in the design layout
from our application engineer.
On an externally mounted V/U two 1/2" Swagelok fittings fasten the V/U to tubing
protruding through the icebox wall. Before cutting the tubing:
• Leave a minimum of 1 1/4" of tube beyond the bulkhead.
• Allow room for wrench access.
On any installation:
• The Valve Unit may be mounted in any position.
• 90-degree elbows can be factory installed on the Valve Unit to reduce the space
requirements if necessary.
• The tubing will support the Valve Unit.
• The tubing must bottom in the fitting. For final installation of this unit see the
Swagelok text.
• The V/U will attract moisture. If it is mounted externally to the cabinet be sure it is
accessible for proper insulation installation after the system has been leak
checked and operationally tested.
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 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 assembly. Then tighten 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 proper connection.

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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. 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. This mark will also indicate that the tube has not moved
before tightening. (As the fitting is tightened the space from the pencil mark to the
shoulder will increase.)
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 cannot 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 one-
and-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).
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.

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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.
* SWAGELOK FITTINGS ARE TO
BE TIGHTENED TO A TORQUE SPECIFICATION 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.
* Be sure the fitting nut is not cross threaded! Cross threading will ruin the fitting. The
fittings on the V/U cannot be replaced; as a result cross threading will ruin the V/U.
RECONNECTING PRE-SWAGED FITTINGS
Connections can be disconnected and re tightened many times.
When reconnecting, insert the tubing with pre-swaged ferrules into the fitting until the
front ferrule seats in the fitting. Tighten the nut by hand to avoid cross threading.
Rotate the nut about one-quarter turn with a wrench (or to original one-and-one-quarter
tight position). Then snug slightly with the wrench.

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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.
RUNNING THE LINES
See the schematic diagram. Prior to making up connections see "Swagelok Fittings"
texts.

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PLANNING
1.Keep tube runs as short as possible. The suction (return) line should be as direct
as possible with a minimum number of bends.
2.Tape the 1/4" line and the 1/2" line together in the section between the V/U and
the DC 5000. This is for thermal exchange (sub cooling).
POSITIONING THE RFD
• The RFD is fitted with a sight glass. This glass must be visible for charging
and servicing the system. It can be viewed from the top at up to a 45-degree
angle but not from the bottom or side. A mirror installed above the glass is one
way of saving a poorly planned installation. Avoid this if possible. Be sure the
sight glass is easily visible!
• Observe the inlet/outlet on RFD when mounting it. The glass is offset toward the
outlet.
• The RFD should be unpacked and installed only after all the lines are run and all
other fittings are made.
HELPFUL TOOLS
• Coil spring-type tube benders are available for 3/8"-1/2" O.D. tube. These springs
are slid over the tube. The bend is formed in the spring, and then the spring is
removed by unscrewing.
• Lever benders for each size tube. Lever benders will make the tightest possible
bend without distorting the tube.
• Mini tube cutter: "IMP" by Gould Imperial requires less than 1 1/2" radius
clearance for the cut. 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. The two lines should be combined with tape and insulated together. See
Insulating the Lines.

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RFD (Receiver Filter Drier)
DO NOT OPEN THE RFD UNTIL ALL THE OTHER CONNECTIONS HAVE BEEN
MADE AND YOU ARE READY TO COMMISSION THE SYSTEM. Because the RFD
contains desiccant to absorb moisture and the absorption is limited, it is important to
unpack and install it after all other connections are made. Leaving the RFD installed on
a partially open system may reduce its capacity by allowing it to absorb moisture in free
air before the system is sealed.
The RFD is a reservoir for excess refrigerant. The RFD also
contains a sight glass in the top. (Please refer to the planning
section regarding location and "readability" of the sight glass)
A pick-up tube extends from the bottom of the canister to the
outlet. For proper function of the reservoir, the RFD must be
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.
INSULATING THE LINES
Insulating should be the last step after leak testing because it will cover fittings that must
be leak-checked. On long uninterrupted lengths of tubing, the insulation can be slipped
over the tube early. Insulation should be installed only on dry lines, and only after the
acrylic spray is applied to all metal parts. The suction return line is cold and will attract
moisture (as frost) when running. The suction return line includes all the exposed 1/2"
tubing and the larger fittings. The entire V/U will also frost. It is important to insulate the
1/2" line, the V/U and all the fittings along the line to prevent moisture from gathering.
INSTALL THE INSULATION IN A MANNER THAT WILL NOT TRAP WATER AROUND
A LOW POINT. Trapping salty bilge water in the insulation will reduce the operating life
of tubing and fittings. If the insulation is split and wrapped over the tube, install it with
the split side down. Tubing within the icebox need not be insulated.

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CABLE TIES
Cable Ties should be used to support the wiring, tubing, and insulation. There is a
screw hole in the end of each tie that is used for mounting. Loosely loop the tie, mount
the screw loosely, snug the wrap, tighten the screw, and trim the excess. 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.

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THERMOSTAT CONTROL PANEL LOCATION
The Thermostat Control Panel should be outside the box in order to protect it and to
allow observation of the indicator lamp. The length of the sensing tube dictates the
location, as it must reach the plate. The maximum length of this tube is 40" (180 mm.)
(The sensing tube must be attached to the refrigerator plate in a multiple plate system.)
Mount the Thermostat in a location where the wires and sensing tube can be led. Use
the cut out template packed with the Thermostat Control Panel. The harness on the
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. If the electrical junction box is closer than 4 feet,
shorten the harness.
Large battery supply cables, (See wire sizes) the thermostat control harness, and water
pump harness will all connect at the electrical junction box.