SuperFreeze SF2500 - Freezer RIDGID - Free user manual and instructions

USER MANUAL SuperFreeze SF2500 RIDGID

• Français – 13• Castellano – pág. 27 WARNING! Read this Operator’s Manualcarefully before using this tool.Failure to understand and fol-low the contents of this manualmay result in extensive prop-erty damage and/or seriouspersonal injury. SF-2300/SF-2500 Manual SuperFreeze

Pipe Freezing Units Record Serial Number below and retain product serial number which is located on control panel. Serial No. SuperFreeze

Pipe Freezing Units General Safety Rules WARNING Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

• Keep your work area clean and well lit. Cluttered or dark areas invite accidents.

• Do not operate tools in explosive atmospheres, such as in the presence of flam mable liquids, gases, or dust. Tools create sparks which may ignite the dust or fumes.

• Keep children and by-standers away while operat- ing a tool. Distractions can cause you to lose control. Electrical Safety

• Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in doubt as to whether the out- let is properly grounded. If the tool should electrical- ly malfunction or break down, grounding provides a low resistance path to carry electricity away from the user.

• Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electrical shock if your body is grounded.

• Do not expose the equipment to rain or wet con- ditions. Water entering a tool will increase the risk of electrical shock.

• Do not abuse the cord. Never use the cord for car- rying, pulling or unplugging the tool. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Dam aged or entangled cords increase the risk of electric shock.

• When operating a tool outside, use an outdoor extension cord marked “W-A” or “W”. These cords are rated for outdoor use and reduce the risk of elec- tric shock. Personal Safety

• Stay alert, watch what you are doing and use com- mon sense when operating a tool. Do not use a tool while you are tired or under the influence of drugs, alcohol, or medication. A mo ment of inat- tention while operating tools may result in serious personal injury.

• Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. Safety Symbols In this operator’s manual and on the product, safety symbols and signal words are used to communicate important safe- ty information. This section is provided to improve understanding of these signal words and symbols. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE indicates information that relates to the protection of property. This symbol means read the operator’s manual carefully before using the equipment. The operator’s manual contains important information on the safe and proper operation of the equipment. This symbol means always wear safety glasses with side shields or goggles when handling or using this equipment to reduce the risk of eye injury. This symbol indicates the risk of frostbite from a cold surface. This symbol indicates the risk of electrical shock. NOTICEDANGERWARNINGCAUTION3 SuperFreeze

• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. Tool Use and Care

• Do not force the tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.

• Do not use tool if the switch does not turn it ON and OFF. Any tool that cannot be controlled with the switch is dangerous and must be repaired.

• Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally.

• Store idle tools out of the reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.

• Maintain the tools. Check for misalignment or bind- ing of moving parts, breakage of parts and any other condition that may affect the tool’s operation. If damaged, have the tool re paired before use. Many accidents are caused by poorly maintained tools.

• Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool, may become hazardous when used on another tool. Service

• Have your tool serviced by a qualified repair per- son using only identical replacement parts. This will ensure that the safety of the tool is maintained. Pipe Freezing Unit Safety Warnings WARNING This section contains important safety information that is specific to this tool. Read these precautions carefully before using the SuperFreeze units to reduce the risk of electri- cal shock or other serious injury. SAVE THESE INSTRUCTIONS! The SuperFreeze

units include space in the unit to keep this manual with machine for use by the operator.

• This tool is used to freeze a water plug inside cop per, steel or other thermally conductive metal- lic tubes or pipes. Do not use on plastic pipe or tube. Follow instructions on proper use. Other uses may increase the risk of injury.

• Do not touch the freeze heads while frosted. Touch - ing the freeze heads while frosted can cause frostbite. Wear gloves if handling during use.

• Before opening piping system, test to confirm that the ice plugs are fully formed and stable. Opening the piping system before a complete plug is frozen or allowing the plug to thaw while the system is open could cause burns, electric shock or other serious injury or result in flooding or other property damage.

• Do not twist, kink or pull hoses. Do not open refrig erant piping. This can lead to refrigerant leaks and cause frostbite, asphyxiation and other serious injury. If a leak occurs, leave the area until the refrig- erant dissipates. The EC Declaration of Conformity (890-011-320.10) will accompany this manual as a separate booklet when required. If you have any question concerning this RIDGID

product: – Contact your local RIDGID distributor. – Visit www.RIDGID.com or www.RIDGID.eu to find your local RIDGID contact point. – Contact Ridge Tool Technical Service Department at [e-mail], or in the U.S. and Canada call [phone]. Description, Specifications and Standard Equipment Description The RIDGID

Pipe Freezing Units are used to freeze plugs in water piping systems to allow mainte- nance without shutting down or draining the system. The units are self-contained refrigeration units that circulate refrigerant to the aluminum freeze heads. The freeze heads, attached to the piping system, can freeze a plug in metallic tubing or pipes. Once the work is complete, the SuperFreeze unit is turned OFF and the ice plugs melt, returning the system to operation. The SuperFreeze units do not use CO

or Nitrogen, and do not require the release of refrigerants. They use specially designed compressors with overload protection. The SF- 2500 also includes quick restart capabilities. The freeze head hoses are leak free flexible rubber. The units are enclosed in a portable carry case.4 SuperFreezer

Pipe Freezing Units Figure 2 – SF-2300 SuperFreeze Unit Figure 3 – Unit Serial Number The machine serial number is located on the control panel. An additional decal is supplied that indicates the month and year of manufacture. (05 = Month, 13 = Year) Icons Specifications Standard Equipment All SuperFreeze pipe freezing units come with the fol- lowing:

• Two Velcro Straps with D-Ring

inch CTS 12 to 54 mm DN* 12 to 42 mm DN Capacity: Steel Pipe

The freeze head cavities on these units are specifically sized for copper tube sizes. They may be used on steel pipe sizes with adherence to the instructions.

• The freeze head cavities on these units are specifically sized for steel pipe sizes. They may be used on copper tube sizes with adherence to the instructions. Power ONPower OFFLabelON/OFF (I/O)SwitchFreezeHeadsHosesCondenserSprayBottleBushingsFreeze Gel Quick Grip ClampVelcro StrapLabelMachine and Work Area Set-Up WARNING Set up the pipe freezing units and work area accord-ing to these procedures to reduce the risk of burns,electrical shock and other injuries and preventmachine damage.

1. Check work area for:

• Flammable liquids, vapors or dust that may ignite. If present, do not work in area until sources have been identified and corrected. The Pipe Freezing Units are not explosion proof and can cause sparks.

• Clear, level, stable, dry location for all equipment and operator.

• Properly grounded electrical outlet of the correct voltage. A three-prong or GFCI outlet may not be properly grounded. If in doubt, have outlet inspect- ed by a licensed electrician.

• Clear path to electrical outlet that does not contain any potential sources of damage for the power cord.

• Clear path for access to the work area.

2. Inspect the system and determine if the Pipe Freezing

• Determine the system fluid – the unit will only work on systems containing water. Know what additives are in the water. Additives can change liquid freeze tem- perature and make freezing difficult or impossible.

• Determine the system material and size – the unit will only work on metallic piping systems. For pipe and tube material and size see Specifications

• Determine the system water temperature and air temperature in the area of the desired plug. If temperatures exceed up to 1" (25 mm) sizes – 110°F (43°C)

" (42 mm) sizes – 90°F (32°C) 2" (54 mm) and larger sizes – 80°F (27°C) The water/air must be cooled to below these tem- peratures for the SuperFreeze unit to be used.

• Determine if there is flow in the system – the pipe freezing unit will not work on flowing water. If there is flow in the section of pipe to be frozen, the flow needs to be stopped by shutting a valve, turning OFF a circulating pump, or other appropriate means.

Pipe Freezing Units This product is used to freeze ice plugs in water piping systems. The ability to freeze plugs is dependant on a wide variety of factors as discussed in this manual. Depending upon the exact set of circum- stances, this product may not work in all cases. Pre-Operation Inspection WARNING Before each use, inspect your pipe freezing unitand correct any problems to reduce the risk of seri-ous injury from electrical shock and other causesand prevent unit damage.

1. Make sure that the pipe freezing unit is unplugged and

the ON/OFF switch is in the OFF position.

2. Clean any oil, grease or dirt from all equipment and

controls. This aids inspection and control of the unit.

3. Inspect the pipe freezing units for the following:

• Inspect the cord and plug for damage or modifi- cation.

• Proper assembly, maintenance and completeness.

• Any broken, worn, missing, misaligned or binding parts.

• Presence and readability of the warning label. (See Figures 1 and 2.)

• Any other condition, which may prevent safe and normal operation. If any problems are found, do not use the pipe freez- ing unit until the problems have been repaired.

4. Check the hoses to the freeze heads for cracks, kinks,

breaks or other issues. The hoses can be coiled and flexed when not frosted. Care must be taken not to twist or kink hoses. This prevents hose damage.

5. Inspect the fan grille and louvers into the condenser

housing to make sure that nothing is blocking the air- flow. Lack of airflow through the unit can cause per- formance issues or damage the unit.

6. With dry hands, plug cord into properly grounded out-

let, Move the switch to ON position. Confirm that the compressor motor starts and that the fan runs. Move the switch to OFF position and unplug the unit. NOTICEModel Freeze Head Copper Tube (CTS) Steel Pipe

Cavity Req’d Bushing

• Determine if the piping is filled with water. A plug cannot be frozen into partly filled pipes.

• Determine where the piping system needs to bro- ken for the work that needs to be done.

• Locate piping system shut-off valves or determine other methods to shut off system fluid flow to be used in case of emergency.

3. Determine location for freeze plug(s).

• The location must allow access for at least one freeze head. If only a single plug is required, it is preferred that there be enough space for both freeze heads. Freeze heads should not contact more than one pipe.

• If the system will be soldered, brazed, welded, or other heat adding processes performed, the freeze plug(s) must be located as far away from the repair as possible. Excess heat can prematurely thaw the ice plug and allow water to flow while the system is open. The freeze plugs should be a minimum of one foot (0.3 m) away from the heat for each inch (25 mm) of diameter for steel pipe or tube. For all other materials, the plug should be at least three feet (0.9 m) away for each inch of pipe or tube diameter.

• Ice plugs must be more than one foot (0.3 m) away from end caps, elbows, closed valves, other ice plugs or similar obstructions. Placing an ice plug closer can cause splitting of the pipe or tube.

• Do not place ice plugs closer than 5 feet (1.5 m) from a circulating hot water (water hotter than ambient air but cooler than 100°F (38°C)) main for pipe sizes 1" (25 mm) and smaller or closer than 8 feet (2.4 m) from a circulating hot water main 1

(30 mm) or larger. Plugs placed closer to a circu- lating hot water main can prevent plug formation or can cause plug thawing.

4. Prepare the freeze plug locations. Remove all insula-

tion and coatings from the pipe down to bare metal. If needed, remove any corrosion with a wire brush. Coatings and corrosion insulate the pipe and can slow or prevent the freezing process.

5. Place the unit so that freeze heads can reach desired

plug points. Locate SuperFreeze on a solid, level sur- face, in an upright position. If the unit is not upright and level, it can cause damage to the compressor. Make sure the air inlet/outlet to condenser are not blocked. Blocked condenser openings will slow or prevent the freezing process. Be sure to locate the pipe freezing unit away from where the repair will occur and not under the freeze heads. This will help prevent the entry of water into the freezing unit and help prevent electrical shock.

6. Uncoil the hoses to the freeze heads. Use care not to

twist or kink the hoses, this can damage the hose and prevent proper operation.

7. Choose the appropriate freeze head cavity for the

size of pipe or tube to be frozen. The capacities for copper tube and steel pipe are listed in the chart that follows. Adapter bushings are required in some appli- cations. If using on pipe or tube other than listed sizes, the pipe/tube diameter cannot be smaller than the freeze head/bushing diameter -1/8" (3.2 mm).

8. Apply freeze gel to the freeze head cavity. If using end

adapter or bushings, apply freeze gel between the freeze head and the adapter and to the adapter sur- face that contacts the pipe. The freeze gel improves Capacities for Copper Tube and Steel Pipe Model Freeze Head Copper Tube (DN)* Steel Pipe Cavity End Adapter 22 mm

• See Specifications* See Specifications SF-2500, 115V Domestic (68967) and 230V Domestic Export (68962)Forming a single freeze plug with freeze heads positioned opposite to each other and using freeze gel and quick grip clamp is the preferred method for use on more difficult applications (higher tem- peratures, larger pipe sizes, etc.). If two freeze plugs are required in a difficult application, it may be necessary to use two pipe freezing units, one for each plug.

• Two freeze plug applications – When two separate freeze plugs are required to isolate a section of the system, one freeze head is attached at each point (Figure 6) . Tightly secure the freeze heads to the pipe with either Quick Grip clamp or Velcro straps. If using the Quick Grip clamp do not over tighten the clamp and deform the pipe. Figure 6 – Two Freeze Plug Application

• If the standard freeze head cannot be used, adap - ters are available. Freeze gel (if being used) is applied to the back of the adapter and to the sur- face that contacts the tube. Tightly secure the freeze heads to the tube with either the Quick Grip clamp or the Velcro straps. If using the Quick Grip clamp do not over tighten the clamp and deform the tube. See Figure 7.

Pipe Freezing Units the thermal conductivity between the freeze head and the pipe and decreases the time required to freeze a plug. If no freeze gel is available, use the spray bottle to spray water generously before and during the pipe freezing process. Figure 4 – Attaching Freeze Heads Using Quick Grip Clamp Figure 5 – Applying Freeze Head with Velcro Strap

9. Attach the freeze heads to the pipe.

• Single freeze plug applications – In single freeze plug applications, both freeze heads should be applied opposite each other to form the plug. This will decrease the time required to freeze the plug. Use the Quick Grip clamp (Figure 4) or Velcro Strap (Figure 5) to secure the freeze heads to the pipe. If using the Quick Grip clamp do not over tighten the clamp and deform the pipe. Model Freeze Head Copper Tube (DN)

Pipe Freezing Units Figure 7 – Freeze Head with End Adapter Attached withVelcro StrapFigure 8 – Freeze Heads with Various Adapters

10. Run cord along previously identified clear path. With

dry hands, plug the SuperFreeze into the previously identified properly grounded outlet. If the power cord is not long enough, use an extension cord that

• Is in good condition.

• Has a three prong plug similar to that supplied on the Pipe Freezing Unit.

• Is rated for outdoor use and contains a W or W-A in the cord designation (i.e. SOW), or complies with H05VV-F, H05RN-F types or IEC type design (60227 IEC 53, 60245 IEC 57).

) for 50' – 100' (15.2 m – 30.5 m) long). Undersized wires can overheat, melting the insulation or causing a fire or other damage. Operating Instructions WARNING Before opening system, test to confirm that the iceplugs are fully formed and stable. Opening the pipingsystem before a complete plug is frozen or allowingthe plug to thaw while the system is open couldcause burns, electric shock or other serious injury orresult in flooding or other property damage. Makesure the machine is properly set up and do not allowthe Pipe Freezing Unit to shut OFF during use. The freeze heads and hoses get extremely coldand can cause frostbite if touched during operation.Wear gloves if handling during use. Always wear eye protection to protect your eyesfrom dirt and other foreign objects. Always wearappropriate protective equipment for the pipingcontents. Follow operating instructions to reduce the risk ofinjury from burns, frostbite, electrical shock andother causes.

1. Make sure that machine and work area is properly set

up and that the work area is free of bystanders and other distractions.

2. Turn the machine ON.

3. Allow the machine to run for 2-3 minutes. Freeze

heads should start to frost. Use spray bottle to spray water between freeze heads and pipe. The water will freeze and fill any gaps between the freeze head, pipe and any adapters used. This improves thermal conductivity and will improve freeze times, while gaps between the freeze head and pipe will prevent freeze plug formation. Make sure that any dripping water does not cause a hazard. If freeze gel was used, then water spray may not be necessary. If the freeze heads do not become cold and cov- ered with ice and frost after approximately 7 min- utes, turn the unit OFF for 3 minutes and restart. If the freeze heads still do not become cold, see the “Troubleshooting” section.

4. Once the freeze heads are frozen to the pipe, allow

the ice plug to form. If the ambient temperature is high, but not above 100°F (38°C), the freeze heads can be wrapped with pipe insulation or other insulation to improve freeze times.9 SuperFreeze

Pipe Freezing Units Do not leave the unit unattended. Pipes can freeze and split during the freezing process and monitoring can minimize the hazard and damage. If for some rea- son the power to the freezing unit is interrupted, turn the ON/OFF switch to OFF and do not restart for at least 30 seconds to prevent compressor damage. Figure 9 – Freeze Head Frozen to Pipe Time to freeze a fully formed ice plug depends on a variety of factors, including water temperature, ambi- ent temperature, distance from heat sources, pipe size and wall thickness, pipe material, number of freeze heads, quality of contact between freeze heads and pipe, and other conditions. The following table of freeze times is based on water temperature being the same as ambient temperature, use on copper tube, use of freeze gel and use of two freeze heads. Freeze times for steel pipe will be longer. Freeze times for other less optimal conditions may be double those shown or greater. Freeze times are only provided as a general guide.

5. Carefully test the system to make sure that the plugs

are complete and there is no flow before opening the system. This can be done by opening a valve downstream of the plug and verifying that there is no flow. Another method is to use a saddle tap valve (similar to those used to install icemakers) to pierce a copper tube and check for water flow. If there is flow, close the system and continue the freezing process. Wait at least five more minutes after confirmation that there is no water flow to proceed with opening the system for work. On high temperature applications, water temperature over 90°F (32°C) but below 100°F (38°C), wait at least 15 minutes. Do not shut OFF the freezing unit.

6. Once the ice plug has been completely formed and

enough time has passed since confirmation that there is no flow in the pipe, the pipe can be opened. When opening the system, be prepared for the possibility of liquid coming out of the line and wear proper protec- tive equipment in case a plug fails. Be sure to follow the guidelines in the set up section for distance from plug to heating of system for soldering, brazing, etc. Do not shut OFF the freezing unit while making repairs. This will help insure that the plug does not melt while the system is open.

7. When the repair is complete and system is closed,

shut OFF and unplug pipe freezing unit, and allow ice and frost to melt off the freeze heads and hoses. Do not try to remove the freeze heads from the pipe or coil the hoses until they are completely thawed. This can result in damage to the hoses and freeze heads. If freeze heads and hoses must be removed more quickly, a heat gun can be used to thaw them. Cleaning After each use, clean the freeze heads with a soft cloth. Clean the condenser fan grilles to remove dirt. Wipe frost/water from the fully thawed freeze heads and hoses. Freezing Times Nominal Copper Ambient/Water Approx. Freezing Times Tube Diameter Temperature (Minutes)CTS Inches DN mm °F °C SF-2500 SF-230070 21 6 5

Pipe Freezing Units Accessories WARNING To reduce the risk of serious injury, only use acces-sories specifically designed and recommended foruse with the SuperFreeze Pipe Freezing Units suchas those listed below. Other Accessories suitablefor use with other tools may be hazardous whenused with the Pipe Freezing Units. Further information on accessories specific to the tool can be found in the RIDGID Catalog and online at www.RIDGID.com or www.RIDGID.eu. Machine Storage The RIDGID SuperFreeze Pipe Freezing Units must be stored in a dry secure, locked area, out of the reach of chil- dren and people unfamiliar with the Units. Wipe frost/water from the fully thawed freeze heads and lines. Coil the hose in the adjacent compartment. Do not cross the hoses. The aluminum freeze heads should be protected from impact, sharp objects and rough han- dling. Do not store the pipe freezing unit in a vehi- cle. Excessive vibration and shock can damage the unit. Firmly secure the unit when transporting. Service and Repair WARNING Improper service or repair can make the SuperFreezePipe Freezing Units unsafe to operate. RIDGID SuperFreeze Pipe Freezing units contain refrig- erant which requires certified service people. Service and repair of the SuperFreeze Pipe Freezing Units must be performed by a RIDGID Independent Authorized Service Center. For information on your nearest RIDGID

Independent Service Center or any service or repair questions:

• Contact your local RIDGID distributor.

• Visit www.RIDGID.com or www.RIDGID.eu to find your local RIDGID contact point.

• Contact Ridge Tool Technical Service Department at [e-mail] or in the U.S. and Canada call [phone] Disposal Parts of the RIDGID SuperFreeze Pipe Freezing Units contain valuable materials and can be recycled. There are companies that specialize in recycling that may be found locally. Dispose of the components in compliance with all applicable regulations. Contact your local waste man- agement authority for more information. For EC Countries: Do not dispose of elec- trical equipment with household waste! According to the European Guideline 2002/ - 96/ EC for Waste Electrical and Electronic Equipment and its implemen tation into nation- al legislation, electrical equipment that is no longer usable must be collected separately and disposed of in an environmentally correct manner. NOTICE Catalog No. Description For SF-2500:69712 SF-2500R

" CTS Bushings (set of 2)70652 SF-2500R 1

" CTS Bushings (set of 2)69717 SF-2500R 2" CTS Bushings (set of 2)68857 SF-2500R

" End Adapters (set of 2)68862 SF-2500R

" Fe (28 mm)66986 Set of 2 End Adapters 12 mm to 16 mm65976 Set of 2 End Adapters

" Fe (22 mm)For SF-2300:42838 12mm Bushings (set of 2)42853 15mm Bushings (set of 2)42843 22mm Bushings (set of 2)42833 35mm Bushings (set of 2)For SF-2500 and SF-2300:65942 Quick Grip Clamp69707 Velcro Straps (set of 2)74946 RIDGID Freeze Gel60776 Spray Bottle, 8 oz. (0.25 liter)11 SuperFreeze

Freeze heads do not be- come frost-covered after 7 minutes. The freeze heads get cold and frost covered but the pipe will not freeze. Tripping of the unit. Troubleshooting Unit has been stored in a cold location; unit has not been used for long time. No power supply. No air circulation to the condenser unit. Pipe Freezing unit has lost its charge. Water flow in the pipe. Poor contact between heads and pipe. Pipe is not completely full of water. System is filled with something other than water. Water temperature is too high. Air temperature is too high. Overloading of the compressor. If freeze heads are not cold and frost-covered after 7 minutes, turn the unit OFF. Keep the unit OFF for 3 minutes, and then restart. Make sure of proper power supply without any in- terruption & compressor fan running. Check that there is unrestricted air circulation to the condenser unit. Check the condenser unit’s inlet air ports and clean. Contact Technical Service Department at Ridge Tool (see Service and Repair)

Check for water flow. If this exists, stop the flow. Use the water spray bottle or freeze gel to build an ice bridge and provide the contact for heat transfer. The slightest air gap will prevent freezing Make sure system is full of water. Pipe freezing unit will not work. Allow the system to cool off or freeze heads are too close to circulating main, stop flow in circulat- ing main. After freeze head is frozen to pipe, wrap with insu- lation. The compressor is thermally protected; it will take time for automatic restart.12 SuperFreezer

ANOMALIE CAUSES POSSIBLES SOLUTION

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Parts are available online at RIDGIDParts.com