INSTALLATION, OPERATION & MAINTENANCE
Congratulations on the purchase of your GRUNERT POLAR MATE. No matter which of the following features was the reason for your purchase of this refrigeration system, we are sure it will meet your needs and will give you many years of efficient and trouble free use. The POLAR MATE units are high efficiency refrigeration systems designed for marine applications incorporating the following features:
Cupro-nickel condenser coil on the water cooled units
Marine grade polyurethane paint
Hermetically sealed compressor for quiet efficient operation
Units can be shelf or bulkhead mounted
Charge Guard® protection to insure refrigeration circuit integrity during
handling and installation
The Polar Mate units are covered under the warranty policy contained in this manual. In the interest of product improvement, Grunert's specifications and design are subject to change without prior notice.
This manual is intended to provide the information necessary for the proper installation operation and maintenance of the Grunert Polar Mate refrigeration systems. Before you proceed be sure to read this manual completely. This should ensure trouble free installation and operation.
Grunert is a manufacturer of refrigeration equipment for the marine industry. Grunert, established in 1954, is committed to innovative technology, competitively priced products and market leadership. The Grunert team has many years of experience in the design, manufacture, application and support of marine refrigeration. Our practical experience and design capability allows our application engineers and customer support team to offer optimum solutions for your refrigeration requirements. Grunert is a Marine Air Systems company. Marine Air Systems, Inc. is A Member of the Taylor Made GroupTM.
When the equipment is received, all items should be carefully checked against the packing list to ensure all cartons have been received. Move units to the normal "up" orientation as indicated by the arrows on each carton. Examine cartons for shipping damage, removing the units from the cartons if necessary. If the unit is damaged, the carrier should make the proper notation on the delivery receipt acknowledging the damage.
CAUTION: When unpacking and installing the thermostat, care must be taken not to kink or break the copper cap tube when uncoiling the sensing bulb. The cap tube is hollow and kinking or sharp bends will inhibit system operation.
Installation and servicing of this system can be hazardous due to system pressure and electrical components. When working on this equipment, always observe precautions described in the literature, tags, and labels attached to the unit. Follow all safety codes. Wear safety glasses and work gloves and place a fire extinguisher close to the work area.
Screw drivers including stubby Phillips head, 1-3/16" open end wrench, large crescent wrench, pipe wrench, wire cutter/crimper, drill with assorted bits including 1/8", 13/16" and 1-3/4" hole saw, hole punch, hammer, tape measure, jig saw, duct tape, electrical tape and teflon tape. The customer shall supply hardware to secure unit, pump, strainer, grille, ducting and thermostat. Bedding compound must be used to seal thru-hull fittings. If pump wire is not long enough to connect to unit, #16 gauge stranded tinned copper wire should be used.
1) Plan tubing and wire run before starting.
2) Consider location of thru-hulls, pump and plumbing for water cooled units.
3) Avoid getting dirt or moisture on coupling ends. Leave dust caps on until
ready to connect.
4) Provide sufficient air circulation for air cooled condenser.
5) Use a dedicated 10 amp circuit breaker for Polar Mate unit.
The evaporator should be mounted vertically on a side wall near the top of the box, accessible from the box opening. The evaporator may also be mounted horizontally on the top of a side loading box. In positioning the evaporator consider:
1) The routing of the refrigerant lines out of the box.
2) Accessibility inside the box for securing a thermostat sensor to the side of the unit.
Use the evaporator mounting template to locate and mark the mounting holes. Tape the template in place on the desired wall. Mark the wall at the four holes indicated. Drill the four holes with a " drill bit (for best results, make a starter hole with a hole punch and hammer). Drill through the box surface into the insulation, but do not go completely through the insulation.
When the evaporator mounting holes are completed, locate the exit hole for the refrigerant lines. Use a 1¾" diameter hole saw to make a passage way through the box for the copper tubing. In locating the hole, consider the routing of the tubing, both inside and outside the box. Try to avoid sharp bends outside the box which will make it difficult to run the tubing to the condensing unit. Before bending the tubing near the evaporator, slide back the insulation (away from the freezer) to expose the aluminum to copper transition joint. Do not make a hard bend at this location. The aluminum tube may be bent to a minimum of 1½" radius by hand. Repeated bending should be avoided.
Uncoil the refrigerant lines from the evaporator, passing the copper tubing progressively through the hole. To feed the coupling through, stagger them one behind the other. Route the refrigerant lines to the condensing unit location. Avoid flattening, kinking, or bending the tubing sharply. The excess tubing should be recoiled in a horizontal plane and secured to prevent vibration. Mount the evaporator using the four 1 inch delron spacers with the four #10, 1¾" stainless steel screws and washers provided. A stick of latex putty is provided to seal the hole through the box wall.
If separate refrigerator and freezer compartments are desirable, the optional spillover fan kit or damper must be used. The spillover fan kit includes a thermostat that must be wired to the condensing unit. See the wiring diagrams on page 18 and the installation diagram on page 9.
When locating the thermostat make sure it is in a dry area and will not be subjected to damage. After mounting the thermostat housing, turn the control knob completely counterclockwise to the off position. Uncoil the required length of capillary tubing and secure the excess in a coil. Avoid bending or twisting the capillary tube repeatedly to prevent kinking or cracking the tube. The capillary tube should be clamped between the two plastic plates on the side of the evaporator compartment. The capillary tube should not touch any part of the evaporator.
Use the included wires to connect to terminals #3 and #4 (#4 has two spades bridged together) of the thermostat to the condensing unit control module at positions T & C. The thermostat completes a ground circuit for the relay, so polarity does not apply. If the spillover fan kit option is selected, connect the refrigerator thermostat and fan to the DC power input on the Polar Mate terminal strip (water cooled) or control module per the wiring diagrams included in this manual on page 18.
The Polar Mate series condensing units are available as an air cooled unit, water cooled unit, or combination air/water cooled unit. The proper unit should be selected based on unit location, available power and efficiency requirements.
It is very important that the AIR COOLED unit has plenty of air ventilation. The unit must be installed in an area where the ambient air temperature is less than 95ºF and there is at least 100 cubic feet of space in the enclosed area. If this criteria cannot be met then the efficiency and capacity of the unit will be greatly reduced and the optional ducting kit (or a water cooled) unit must be utilized. The fan on the condensing unit can be reversed to either blow air through or draw air across the condenser coil. The Polar Mate is shipped with the fan drawing air across the coil from the inside of the unit and blowing outward.
If the unit is located in a warm area (above 95ºF ambient air temperature) disconnect the fan and rotate it so that it blows air through (into) the condenser coil. Connect the ducting to the fan using the coupling enclosed in the optional ducting kit. Route the ducting to a cooler area and install the 4" round grille by cutting a 4" diameter hole through to the return air supply area. There should be a minimum clearance of 6" behind the grille to accommodate the ducting connection. See example 1 on page 8.
If the unit is installed in a cool but small enclosed area (less than 100 cubic feet) then the warm discharge air must be ducted out into another area so as not to overheat the unit. There is no need to rotate the fan in this application. Connect the ducting to the fan using the coupling and route the duct to an area where the warm discharge air will not be a problem. See example 2 on page 8.
In either case, whether cool air is ducted in or warm air is ducted out, there still needs to be adequate air ventilation through the area where the unit is installed. In other words, the Air Cooled Polar Mate is not to be installed in an air tight area even if the optional ducting is used. There should be at least 50 square inches of open area for ventilation into the area in question.
The following is a summary of proper ducting connections:
1. Slide the duct hose around the mount ring until it bottoms out.
2. Screw 3 or 4 stainless steel sheet metal screws through the duct hose into the ring catching the wire in the duct hose with the heads of the screws. Do not use band clamps.
3. Remove excess ducting and use the same connection method at the grille.
The WATER COOLED unit must be installed above the sea water pump. The pump must be below the water line and above the strainer. The strainer must be installed above the sea cock. See page 7.
The condensing unit should be installed lower than the evaporator and there should be no vertical loops or traps in the copper tubing. If the copper tubing is longer than needed, coil the excess and secure it in a horizontal plane. Oil circulating with the refrigerant must be returned to the compressor; a downhill tubing run assists in this return. Keep the tubing clear of bilge water, steering cables and similar obstructions. Secure tubing approximately every 12" to prevent vibration or chafing.
The condensing unit can be either base mounted or bulkhead mounted by using the mounting flange on the horizontal or vertical edge of the condenser frame. The condensing unit must be mounted upright.
Making the Refrigerant Connection
The evaporator is supplied with 15 feet of precharged copper tubing, terminating with self-sealing quick connect couplings, one male and one female. The condensing unit also has these couplings. By joining the quick connect couplings together, the refrigerant circuit is completed without any refrigerant being lost to the atmosphere.
Make certain all quick connect couplings are free of dirt and moisture when removing the dust caps. Save the caps in the event that one portion of the system should need to be removed for service.
Thread the clean couplings together by hand until you are sure the couplings are properly mated. Continue tightening with a 1-3/16" open end wrench (or suitably large crescent wrench) until positive resistance is felt. Remove the wrench and mark a single line (using a marker or pen) lengthwise along both couplings. Tighten the female coupling another 1/6 to 1/4 turn to insure a leak proof joint. If a torque wrench is used, apply 35 foot pounds of pressure.
REMINDER: Keep all lines away from any moving or sharp objects, avoid sharp bends, kinks, or flattening of tubing.
|System Installation DiagramWater Cooled System
The model P-800 sea water pump, supplied with the Grunert sea water kit, is recommended for the Polar Mate. This is a centrifugal pump and must be mounted below the water line. All plumbing for the pump, strainer, thru hull, and condensing unit should be " I.D. reinforced vinyl hose. All fittings should be double/reversed clamped with stainless steel hose clamps. The " I.D. reinforced hose used to plumb the system should be on an uphill grade from the intake thru hull, the sea cock, the sea water strainer, the pump, and then to the condensing unit in that order. By maintaining this upward slope, any air entering the thru hull will be able to travel unobstructed up and through the pump. If loops or traps are left in the circuit, the pump may become air-locked, causing poor performance, shutting down the system or causing component failure. The use of a forward facing clam shell scoop is mandatory to overcome the suction pressure (siphon effect) occurring when the boat is moving through the water. INSTALL THE SEA WATER SPEED SCOOP INTAKE AS FAR BELOW THE WATER LINE AND AS CLOSE TO THE KEEL AS POSSIBLE IN ANY APPLICATION, BUT ESPECIALLY ON A SAIL BOAT, TO KEEP THE INTAKE IN THE WATER WHEN THE BOAT HEELS OVER SO THAT AIR DOES NOT GET INTO THE SYSTEM. Use a 13/16" drill bit for both thru-hull fittings. Sharing a thru hull for the pump circuit is not recommended because of the pump's tendency to pull both air and water out of the second circuit, and subsequently losing its prime.
A pump on/off switch should be used with an air/water cooled unit to turn the pump off while still using the refrigeration system air cooled condenser when the boat is hauled in dry dock.
For quiet vibration free operation, the pump assembly should be mounted to a solid surface. The mounting position of the pump should always be horizontal, with the discharge outlet oriented at the top of the wet end assembly.
The DC motor in the compressor runs by electronic commutation. Due to this design, it is necessary for the current to travel freely between the unit and battery. The unit should be connected directly to the battery selector switch terminals. Do not connect other electrical devices (i.e. AC or DC converters, generators, etc.) between the control unit, the selector switch, and the battery. Any deviation from this procedure could damage the compressor or the control module and would not be covered under the Grunert warranty policy.
When connecting the electronic control module to the battery selector switch, maintain correct wire size as shown in the table below, keep wire runs as short as possible to avoid unnecessary resistance or voltage drop. Do not forget to maintain proper color coding, (red = positive, black = negative) to aid in future electrical troubleshooting. If the wires are incorrectly connected (positive and negative reversed), the electronic control module fuse will be blown by the reverse polarity and will have to be replaced. To replace the fuse, remove the gray plastic cap at the bottom of the module.
A 10 amp circuit breaker (preferred) or a toggle switch and a 10 amp fuse, is recommended between the battery selector switch and electronic control module. This will provide protection from possible short circuits. Because there is a constant milli-amp current applied to the control module even when the thermostat is off, it is recommended to turn the circuit breaker or toggle switch off to protect your battery from discharge when the unit is not in use. Place the breaker with the positive (+) lead as close to the battery selector switch as possible. When dockside, the Polar Mate can operate against the batteries while using the AC battery charger as a backup (most marine battery chargers will shut off when the battery is fully charged).
Use the included wires to connect to terminals #3 and #4 (#4 has two spades bridged together) of the thermostat to the condensing unit control module at positions T & C. The thermostat completes a ground circuit for the relay, so polarity does not apply.
See the wiring diagrams on page 18.
* Table revised 3/2/98 according to ABYC section E9.14 for 12 volt DC systems. These specifications were calculated using a 3% voltage drop and a maximum Polar Mate current draw of 6.4 amps.
A minimum of 100 amp hours of additional battery capacity should be provided for the refrigeration system, and more when cruising off-shore for extended periods. Without this additional capacity, batteries may have to be recharged more than once a day. Deep cycle batteries are highly recommended because they are specifically designed for long life under deep discharge and cycling operations. A minimum of two batteries, one for engine starting and the other for the house, is required. For extended cruising, three batteries are recommended.
As batteries age, their peak voltage lowers and they discharge quicker. This, of course, can affect refrigerator performance as well as other DC devices. The battery condition should be maintained and monitored regularly and weak batteries should be replaced.
A battery isolator or selector switch between any two batteries will allow simultaneous charging while preventing the discharge of a fully charged battery into a depleted one.
When the installation is complete, make a final inspection. Check all hoses for kinks and leaks. Disconnect the hose from the discharge port of the pump and open the sea cock until water flows through the pump and then reconnect the hose to the pump. Check wiring connections for correct polarity.
The thermostat control knob will rotate almost one complete revolution (turning it fully clockwise would be the coldest setting). Initially rotate the knob one-half turn. At this point, the unit will run until the box temperature satisfies the thermostat and then it will cycle off. Adjust the thermostat for warmer or cooler box temperatures as required.
The warmer the setting, the more efficient (less work being done) the condensing unit will operate. The coldest thermostat setting should be reserved for quicker pull down or ice making; this is best done while the alternator or battery charger are compensating for the load. Allow a reasonable time span for all warm food and liquid to chill.
The Polar Mate compressor is equipped with an electronic protection system. The system is activated when the compressor is overloaded and fails to start for any reason. It is also activated if the batteries are under/over charged.
To avoid permanent battery damage, due to deep discharge, the protection system will shut off the compressor or current when the input voltage of the electronic module is above 15.5 volts or below 10.3 volts. The compressor will not start again until the input voltage drops below 15.5 volts or is maintained at 11.5.
Turn the unit off by disconnecting power from the unit by switching the circuit breaker or toggle switch off. Open the door or hatch and allow for defrost. Do not clear ice off of evaporator with sharp or metal objects. To speed up thawing, place a container of hot water in the evaporator or use a hair dryer. If frost builds up quickly on the evaporator or the box, this would indicate a poor seal on the door or hatch gaskets.
Insure that your pump receives adequate sea water flow by regularly cleaning the strainer basket.
There are several methods of winterization, some of which work better than others. The four various methods employed using a 50/50 non-polluting biodegradable anti-freeze/water solution are:
1. Pumping of anti-freeze solution into the overboard thru-hull fitting, and discharging through the intake thru-hull fitting.
2. Use of the sea water pump to pump anti-freeze solution through the system and discharging through the overboard thru-hull fitting. Close sea cock, remove hose from strainer discharge, raise hose above pump (so pump does not lose its prime) and pour in anti-freeze solution. Pump solution through system. The strainer and hose to sea cock will also need to be drained of water.
3. Use of pressurized air injected at the overboard discharge fitting and the water being discharged through the sea water intake fitting.
4. Use of pressurized air to force water from the intake through the overboard discharge.
Note: Collect all discharged liquids and recycle or dispose of in a proper manner.
Any method which causes the anti-freeze solution to flow downward is the method of choice. By this means, the anti-freeze solution will displace any water trapped and eliminate the possibility of freezing in hidden areas. In addition, since the sea water pump utilizes a magnetically driven impeller, the impeller should be removed from the wet end assembly, wiped with an alcohol solution, and stored in a warm, dry area until commissioning takes place.
Once a year, remove the condenser fan and clean the condenser coil fins with a soft bristled brush, be sure to brush up and down in line with the fins, or use a vacuum cleaner taking care not to bend the fins. Wipe the fan blades clean as needed.
Check terminal fittings and crimps to ensure tight and proper connections. Avoid the use of ammonia cleaning agents, which may cause the silver contacts to corrode and reduce the life of the thermostat.
Drain and clean box of excess water when system is shut down or while defrosting. Plug box after cleaning.
Condenser Coil Cleaning (water cooled)
Coils can become fouled over a period of time due to marine growth or scale build-up. This both obstructs water flow and prohibits proper heat transfer. To clean coils, flush with a 5% muriatic or hydrochloric acid and fresh water solution. Disconnect system hoses from coil and pump solution through until clean. Rinse with fresh water and reconnect hoses. Follow manufacturer's safety guidelines for all cleaning solutions.
1 compressor & fan 2 compressor, fan & pump 3 compressor & pump
Evaporating temperature: -31ºF to 23ºF (-35ºC to -5ºC)
Refrigerant - R-134A: 4 oz. (113.4g) Polar Mate Air Cooled
4 oz. (113.4g) Polar Mate Water Cooled
5 oz. (141.7g) Polar Mate Air/Water Cooled
2 oz. (56.7g) Evap I
3 oz. (85.0g) Evap II
Refrigerant metering device: capillary tube 0.025" x 10.8' (0.63 x 3550 mm)
Voltage range: 12V: 10.3 - 15.5V
24V: 21.3 - 31.0V
Condensing temperature: Max. 140ºF (60ºC) at stable conditions
Max. 158ºF (70ºC) at peak load
4 Rating conditions Air/Water & Water Cooled Air Cooled
Evaporating temperature 5ºF (-15ºC) 5ºF (-15ºC)
Condensing temperature 100ºF (37.8ºC) 120ºF (48.8ºC)
Troubleshooting Guidelines Continued
The following warranty is extended to cover the POLAR MATE series of refrigeration units manufactured or supplied by Grunert, and is subject to qualifications as indicated.
Grunert warrants for the periods set forth below that products manufactured or supplied by it will be free from defects in workmanship and material, provided such products are installed, operated and maintained in accordance with Grunert's written instructions.
ALL IMPLIED WARRANTIES INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE TERMS AND PERIODS OF WARRANTY SET FORTH BELOW AND, TO THE EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED.
Components comprising a complete system on a new installation are covered by a limited one (1) year warranty from the date of purchase, not to exceed two (2) years from date of manufacture, and labor costs are covered for six (6) months from the date of purchase. OEM installed components comprising a complete system (pump excluded) are warranted for a period of two (2) years from the date of sale of the vessel, not to exceed three (3) years from the date of manufacture, and labor is covered for a period of one (1) year from the date of sale of the vessel. Warranty will be paid in accordance with our established schedule of allowances.
Grunert will repair or replace at its option, components found to be defective due to faulty materials or workmanship, when such components, examined by an authorized service dealer or a factory service representative, are found to have a defect for which the company is responsible. In addition, Grunert will pay labor costs as outlined in its Schedule of Limited Warranty Allowances for removal and re-installation of such components. Refer to Manufacturer's Limited Warranty Policy for complete coverage and exclusions. Replacement components are warranted for the duration of the remaining warranty period in effect on the original component.
This limited warranty is extended in lieu of all other warranties, agreements or obligations, expressed or implied, concerning Grunert's components. This limited warranty is extended only to the original purchaser and is not transferable. This warranty shall be governed by the laws of the State of Florida and gives the original first end user definite legal rights.
This warranty does not cover damages incidental and or consequential to the failure of Grunert's equipment including but not limited to; normal wear, accident, misuse, abuse, negligence or improper installation, lack of reasonable and necessary maintenance, alteration, civil disturbance or act of God.
No person or dealer is authorized to extend any other warranties or to assume any other liabilities on Grunert's behalf, unless made or assumed in writing by an officer of Grunert.
WATER & AIR COOLED KITS
Grunert is a Marine Air Systems, Inc. company.
Copyright 1997 Marine Air Systems, Inc., All Rights Reserved
Every precaution has been taken in the preparation of this manual to
insure its accuracy. However, Marine Air Systems assumes no responsibility
for errors or omissions. Neither is any liability assumed for damages
resulting from the use of this product and information contained herein.
Grunert is a Marine Air Systems, Inc. company.
Copyright 1997 Marine Air Systems, Inc., All Rights Reserved
Every precaution has been taken in the preparation of this manual to insure its accuracy. However, Marine Air Systems assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of this product and information contained herein.