Dometic EI1000D User Manual

Eskimo Ice

EI1000D Optional Remote DisplayDigital Display

Ice-Making System Installation & Operation Manual

FOR MODEL EI1000D USING DIGITAL CONTROLS (WITH C-19 SOFTWARE)

Dometic Group Marine Division Rev. 20140401 L-3152 English P/N 336401

No part of this publication may be reproduced, translated, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying,recording or otherwise without prior written consent by Dometic Marine. Every precaution has been taken in the preparation of this manual to insure its accuracy. However, Dometic Marine assumes no responsibility for errors and omission. Neither is any liability assumed for damages resulting from the use of this product and information contained herein.

Table of Contents

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ARNINGS AND NOTICES . . . . . . . . . . . . . . . . . . . . . . 1

ICE MAKING AND REFRIGERATION BASICS . . . . . . . . . . 2

How The EI1000D Makes Ice . . . . . . . . . . . . . . 2

The Refrigeration Process . . . . . . . . . . . . . . . . 2

HE EFFECT OF TEMPERATURE ON ICE PRODUCTION . 3

Water Temperatures . . . . . . . . . . . . . . . . . . . . . 3

Air Temperature . . . . . . . . . . . . . . . . . . . . . . . . 4

OMPONENTS OF THE ICE MAKER . . . . . . . . . . . . . . . 4

Ice-Making Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Ice-Storage Box . . . . . . . . . . . . . . . . . . . . . . . . 5

Seawater System . . . . . . . . . . . . . . . . . . . . . . . 5

Freshwater Supply . . . . . . . . . . . . . . . . . . . . . . 5

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 5

Thermal Expansion Valve (TXV) . . . . . . . . . . . . 5

INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . 6

HOOSING THE CORRECT EQUIPMENT VOLTAGE . . . . . 6

INSTALLING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . 6

Selecting the Site . . . . . . . . . . . . . . . . . . . . . . . 6

Mounting the Unit . . . . . . . . . . . . . . . . . . . . . . . 6

Installing Condensate Drainage . . . . . . . . . . . . 6

Installing Ice-Delivery Hose . . . . . . . . . . . . . . . 7

Installing the Ice-Level Sensor . . . . . . . . . . . . . 8

Installing the Feedwater System . . . . . . . . . . . . 8

Installing the Seawater Cooling System . . . . . . 9

Installing the Remote Digital Display . . . . . . . 12

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

HE DIGITAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . 13

BASIC FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Applying Power . . . . . . . . . . . . . . . . . . . . . . . . 14

On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Ice Bin Sensor . . . . . . . . . . . . . . . . . . . . . . . . 14

Operational LEDs . . . . . . . . . . . . . . . . . . . . . . 14

Operational Information For Amps & Voltage . 14

Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . 14

AULTS - EVENTS THAT INTERRUPT ICE PRODUCTION 14

FULL – Ice Bin Full . . . . . . . . . . . . . . . . . . . . . 14

H20 – Potable Water Switch . . . . . . . . . . . . . . 14

HPF – High Pressure Refrigerant . . . . . . . . . . 14

LAC – Low AC line voltage . . . . . . . . . . . . . . . 15

LPF – Low Pressure Refrigerant . . . . . . . . . . 15

OCA – Over Current Auger and Ice Delivery

Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

OCC – Overload Current Compressor . . . . . . 15

SPt – Auger Spout Blockage . . . . . . . . . . . . . 15

UCA – Under Current Auger . . . . . . . . . . . . . . 15

UCC – Under Current Compressor . . . . . . . . . 15

HE CYCLE OF OPERATION . . . . . . . . . . . . . . . . . . . 16

PROGRAMMABLE PARAMETERS FOR SOFTWARE 17

ROGRAM PARAMETER DESCRIPTIONS . . . . . . . . . . . 17

PROGRAM PARAMETER DEFAULT SETTINGS . . . . . . . 17

STARTING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 18

START-UP CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 18

START-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 18

SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . 18

TEMPORARY SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . 18

SUSTAINED SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . 18

YSTEM RESTART/RESET . . . . . . . . . . . . . . . . . . . . . 19

SERVICING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 19

EFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

R R-404A T

OOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

THERMAL EXPANSION VALVE (TXV) . . . . . . . . . . . . . 19

ECHARGING THE SYSTEM . . . . . . . . . . . . . . . . . . . . 19

System Shutdown . . . . . . . . . . . . . . . . . . . . . . 19

Evacuate Refrigerant . . . . . . . . . . . . . . . . . . . . 19

Charging the System . . . . . . . . . . . . . . . . . . . . 19

OWNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 20

EAWATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 20

RESH WATER FILTER AND Y STRAINER . . . . . . . . . . 20

VAPORATOR CLEANING . . . . . . . . . . . . . . . . . . . . . . 20

AUGER MOTOR AND GEARBOX . . . . . . . . . . . . . . . . . 20

OMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

EFRIGERANT GAS . . . . . . . . . . . . . . . . . . . . . . . . . . 21

WATER RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . 21

EEDWATER FILTER AND Y STRAINER . . . . . . . . . . . . 21

INTERIZING THE SYSTEM . . . . . . . . . . . . . . . . . . . . 21

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . 21

TECHNICAL ASSISTANCE . . . . . . . . . . . . . . . . . . . . . 22

DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

YSTEM CONNECTION . . . . . . . . . . . . . . . . . . . . . . . 23

S E

LECTRICAL WIRING FOR 230V 60 HZ MODELS & 220V

50 H

Z MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

OWNERS LIMITED WARRANTY . . . . . . . . . . . . . . . . . 25

ECTION I - WHAT’S COVERED . . . . . . . . . . . . . . . . . 25

ECTION II - WHAT’S NOT COVERED . . . . . . . . . . . . . 25

ECTION III - COVERAGE PERIOD . . . . . . . . . . . . . . . 26

S S

ECTION IV - GETTING SERVICE . . . . . . . . . . . . . . . . 26

ABLE OF WARRANTY PERIODS . . . . . . . . . . . . . . . . . 27

L-3152 ENGLISH

Eskimo Ice Installation & Operation Manual INTRODUCTION

INTRODUCTION

This manual provides installation and operation information for the EI1000D self-contained Eskimo Ice System using digital controls (software level C-19).

The ice produced by this system is not potable and should not be ingested. Do not eat, chew, suck, swallow, or put the ice into drinks. The ice produced by this system is intended solely for the refrigeration purposes of freshly caught fish stored in a fish box.

WARNINGS AND NOTICES

DANGER

This equipment is not ignition protected per CFR 183.410 and may not be installed in areas that may be exposed to flammable gas.

DANGER

The equipment referenced in this manual operates on 230 volts AC. Such voltages can be lethal, therefore proper care must be taking during installation, operation, and servicing to prevent injury or loss of life.

DANGER

The equipment referenced in this manual operates with compressed refrigerant at high pressures. Proper care must be taken during installation, operation, and servicing to prevent injury or loss of life due to improper procedures.

WARNING

Never install the unit in the bow of a boat. It must be installed in a dry area as far af t of midship as possible. If installed in a machinery space, that area must not require ignition protection.

WARNING

This manual contains essential safety information concerning the safe and proper installation, operation, and maintenance of your ice making system. It is very important that you read and understand the contents of this manual t horoughly bef ore ins talling or using the equipment. You should keep this manual on your boat for future reference. Failure to follow Dometic approved installation, start-up, operation, and troubleshooting procedures will void the warranty. If there are any statements in this manual that you do not understand, contact your local dealer for assistance or the Dometic Marine Service Department:

• Phone: +1 954-973-2477 (Monday through Friday, 8AM - 5PM US Eastern Time)

• Phone: +1 888-440-4494 (Evenings and weekends US Eastern Time)

• Fax: +1 954-979-4414

• Email: marinesales@dometic.com

• Dealer Locator: www.dometic.com/marinedealers

WARNING

The ice produced by this system is not potable and should not be ingested. Do not eat, chew, suck, swallow, or put the ice into drinks. The ice produced by this syst em is intende d solely for the ref rigeration purposes of freshly caught fish stored in a fish box.

NOTICE

Some equipment may be shipped with specific installation sheets or wiring diagrams that may supercede the information located in this manual. Dometic reserves the right to update or change any information located herein at any time and without prior notice.

NOTICE

Your ice-making system uses the environmentally safe ref r igerant R-404A. Federal law forbids the intentional release of any refrigerant gas into the environment. Make certain that any field service is performed by a specialist with the proper equipment to prevent loss of refrigerant during servicing.

L-3152 ENGLISH 1

INTRODUCTION Eskimo Ice Installation & Operation Manual

ICE MAKING AND REFRIGERATION BASICS

HOW THE EI1000D MAKES ICE

Ice production is continuous. Fresh water floods the cylindrical evaporator. Using a refrigeration process, heat is removed from the fresh water in order to

freeze it on the inner surface. A rotating auger continuously scrapes ice from the inner wall of the evaporator and moves the harvested ice through the

evaporator into an ice extrusion canal. There the ice is forced through a restrictive nozzle that squeezes out the water and creates the ice. The continuous extrusion process pushes the ices through a transport tube which runs to the ice-collection box. See Figure 1.

A solid-state PC board controls and monitors the functionality of the ice machine. In addition to sequencing electrical components, the board monitors various operational parameters. A full complement of indicator lights and digital display allow visual status of the machine’s operation.

A unique spout-clog detection system is incorporated in the Eskimo Ice machine. A switch located at the ice-discharge port of the machine detects the position of the transport tube. If the hose clogs with ice, the transport tube moves out of the normal running position, and the switch turns the ice maker off.

Figure 1: Ice-Making Process

THE REFRIGERATION PROCESS

The basic principle of an ice machine system is that a liquid refrigerant absorbs heat as it turns into a gaseous state (evaporates) and releases heat as it turns back into a liquid state (condenses). The system consists of five main components:

• Evaporator - Absorbs heat from the fresh water in the evaporator shell causing the fresh water to freeze.

• Auger - Scrapes the frozen fresh water from the interior sides of the evaporator shell and extrudes it into the discharge hose.

• Condenser - Releases heat into the system’s circulating seawater and turns the refrigerant gas back into a liquid.

• Compressor - Drives the refrigerant through the loop.

• Metering Device - Meters the flow of refrigerant to the evaporator.

2 L-3152 ENGLISH

Eskimo Ice Installation & Operation Manual INTRODUCTION

The ice maker’s refrigerant compound has a very low boiling point. It flows in a closed loop between an evaporator and a condenser, alternately absorbing and releasing heat. This process removes the heat from the fresh water in the evaporator/ auger assembly and causes the fresh water to freeze on the inside of the evaporator wall. The heat absorbed by the refrigerant is transferred to the seawater.

A water pump circulates seawater through the inner tube in the condenser coil which cools the refrigerant in the outer tube and condenses it from a gas into a liquid. The heat from the refrigerant is exchanged to the seawater and discharged overboard. The liquid refrigerant is then pumped through the evaporator coil and the cycle repeats. See Figure 2.

Table 1: Refrigerant Pressure Data

Water-cooled condensers (water temperature) 60 F / 16 C 70 F / 21 C 80 F / 27 C 90 F / 32 C 100 F / 38 C Pressure (psig) discharge / suction 193 / 30 220 / 32 237 / 33 290 / 36 308 / 38

NOTE: This data is typical but approximate.

Figure 2: Refrigeration System Diagram

THE EFFECT OF TEMPERATURE ON ICE PRODUCTION

WATER TEMPERATURES

Seawater and freshwater temperatures affect the ice machine’s efficiency and capacity. The system is most efficient when the seawater and fresh water temperatures are 55-80°F (13-27°C). The ideal temperature for both is 70°F (21.1°C). See Figure 3.

L-3152 ENGLISH 3

INTRODUCTION Eskimo Ice Installation & Operation Manual

52.5

31.4

1392

1260

1128

984

888

754

50° 60° 70° 80° 90° 100°

Condenser/Re se rvoirTemp

PoundsofIceProduction@73° Ambient

AverageIceProduction/hr

AverageIceProduction/24hr

High Temperatures - As seawater temperatures approach 90°F (32°C) and above, the water’s ability to absorb heat diminishes, so the capacity of the system decreases. Also, when seawater temperature increases above 90°F (32°C), the system could sustain a high-pressure shutdown to protect the compressor.

Low Temperatures - As the seawater temperature decreases, the system could sustain a low-pressure shut down to protect the compressor. It could also cause freeze damage if operated below the recommended minimum of 45°F (7°C).

CAUTION

Extreme care should be taken in operating any unit below seawater temperatures of 45°F (7.2°C). The seawater could freeze in the condenser tubing, possibly causing it to burst, which is not covered by the warranty.

AIR TEMPERATURE

The Effect of Ambient Air Temperature

The ambient air temperature affects the ice machine’s efficiency and capacity, but not as significantly as the water temperatures. The system is most efficient when the ambient air temperature is 55-80°F (13-27°C). At temperatures above and below this range, ice production will decrease. The machine should never be placed in an area where temperatures would be consistently above 130°F (54°C). See Figure 3.

Figure 3: Ice Production and Temperature Graph

COMPONENTS OF THE ICE MAKER

ICE-MAKING UNIT

The ice-making unit has an R-404A compressor, seawater-cooled condenser, a filter/drier, and an accumulator. The auger assembly contains the evaporator barrel, auger rotor, gearbox, motor, water reservoir, and expansion device.

4 L-3152 ENGLISH

The freshwater delivered to it is converted to ice which exits the system via an ice-delivery hose routed properly to a storage box up to 50 feet (15.25 m) away. See Figure 4 on page 7.

Eskimo Ice Installation & Operation Manual INTRODUCTION

The unit is pre-charged with refrigerant from the factory. The unit has plug-and-play electrical connections for the ice-level sensor and the optional remote display.

CONTROL BOX

The ice-making unit has an electrical control box with digital display that can be mounted on the unit or remotely mounted up to 7’ (2.1m) away.

The control box (Figure 11, page 13) contains the system function switches, digital display, and system indicator lights. It lets you control all system operations and provides visual indications of system activity, such as whether the system is running or has a fault. If a fault condition is detected, the system shuts down automatically. The control panel lets you restart the system after a sustained fault. See the “The Digital Control” on page 13 for further operating instructions.

ICE-STORAGE BOX

The ice-storage box is the destination point where the ice will accummulate via the ice-delivery hose. An ice-level sensor installed in the storage box halts ice production when the box is full.

The ice-storage box should be able to hold water and have at least 2" (51mm) of insulation to keep the ice frozen as long as possible. It is helpful to install a drain in the box at the end opposite from the ice input. To improve ice-production performance, keep the drain plugged to prevent cold air and cold water from escaping the storage box.

SEAWATER SYSTEM

Seawater is pumped into the ice-making unit to efficiently cool the hot refrigerant via a cupronickel coaxial tube design. The condensing unit may be connected to its own single-station pump or to a larger, multi-station pump via a pump relay box.

The seawater system (Figure 7, page 10) consists of a thru-hull fitting, seacock, strainer, seawater pump, seawater hose, and overboard discharge. There must be water flow of at least 3.3 GPM (maximum 4.4 GPM) or coil erosion can occur.

FRESHWATER SUPPLY

Use the 3/8" female fitting on the auger unit to supply freshwater for ice making. Provide water with pressure of at least 15 PSI. An in-line water filter (included in kit) is mandatory to comply with Dometic Warranty Regulations, to help prevent clogging of the needle valve in the water reservoir, and to help keep the auger walls from fouling with mineral deposits which will cause premature failure of water seals and bearings. See “Fresh Water Filter and Y Strainer” on page 20 for maintenance instructions.

REFRIGERANT CHARGE

The unit is pre-charged with the correct amount of R-404A refrigerant. If service is required, see data plate for correct charge amount.

THERMAL EXPANSION VALVE (TXV)

The TXV is used as the expansion valve of the refrigerant system. It allows high-pressure liquid to become low-pressure liquid and start the refrigeration process. The simple and reliable TXV provides a load-modulated system pressure over a wide range of ambient and seawater temperatures. The TXV is not adjustable.

L-3152 ENGLISH 5

INSTALLATION PROCEDURES Eskimo Ice Installation & Operation Manual

INSTALLATION PROCEDURES

This section covers the installation procedures for your ice-making system. Read the manual completely before attempting to install any equipment.

CHOOSING THE CORRECT EQUIPMENT VOLTAGE

Know the frequency and voltage provided where your ice-making system will be used and select the appropriate 60 Hz or 50 Hz model. Do not operate a 60Hz unit on 50Hz power or a 50Hz unit on 60Hz power, as this will cause damage and void the

warranty.

The voltage rating of a unit is a nominal rating. The voltage in a given location may be higher or lower by as much as 10% and the system will still operate correctly. For example, in a 60 Hz environment you may see 208 VAC to 240 VAC. In a 50 Hz environment common voltages range from 220 VAC to 240 VAC.

INSTALLING THE UNIT

SELECTING THE SITE

Never install th e unit in the bow of the boat. Dometic ice-making units are designed to be installed in any convenient location on the transom, in the aft, or in a machinery space that does not require ignition protection that is as far aft of midship as possible. The unit can be located in living areas if necessary. Some considerations:

• This equipment is not ignition protected per CFR 183.410 and may not be installed in areas that may be exposed to flammable gas.

• The unit will produce condensation, so the drip pan is necessary.

• The unit is water cooled and does not need direct ventallation, but do not install in a sealed space.

• The space around the unit may be insulated to reduce noise if necessary.

Site Location Check List

• Location is aft of midship. Never install the unit in the bow of the boat.

• Location is not exposed to flammable gas.

• Location provides adequate space for access to refrigerant, seawater, and electrical connections.

• Location provides accessibility for service and maintenance.

• Location is in a dry place and away from direct spray, from engine air intakes, and from water washdown.

• Mounting space is a flat, horizontal surface, as level as possible (while docked).

MOUNTING THE UNIT

1. Do not remove any covers, caps, or fittings that may expose any wiring or refrigerant until you are ready for those steps of the installation.

2. On a flat, horizontal surface, orient the unit so the refrigerant, seawater, and electrical connections are accessible and use the 8 provided hold-down clips to secure it.

3. If you decide to remotely mount the control box, be sure it is away from direct spray, from engine air intakes, and from water washdown.

4. If pump wires need to be extended by butt sealing connections, make sure they are tightly crimped and heat shrunk.

5. AC power source must be installed and grounded/bonded in accordance with ABYC standards.

6. Connect control wires to terminal strip with ring terminals.

INSTALLING CONDENSATE DRAINAGE

The condensate drain pan is 3.0” (77 mm) high with two front and back drain locations. During conditions of high humidity, condensate may be produced at a rate of approximately one-half gallon (1.9 liter) per hour. With this in mind, it is important to route condensate drains downward to a sump pump. It is not recommended to route condensate drains to the bilge.

After the condensate drain installation is complete, test the installation by pouring one quart (liter) of water into the pan and checking for good flow.

6 L-3152 ENGLISH

Eskimo Ice Installation & Operation Manual INSTALLATION PROCEDURES

Mount the ice-delivery

hose as high as possible

in the ice-storage box.

INSTALLING ICE-DELIVERY HOSE

Planning the Route

The maximum length of the ice-delivery hose is 50 feet (15 m) under ideal conditions and depending on route. It must be a Dometic-approved ice delivery hose.

The best hose routing provides a level but slightly upward rise from the ice maker to the ice-storage box, with very few bends. No bend should be tighter than a radius of 18" (458mm). Refer to Figure 4 below to see:

• Best Routing - A continuous uphill route of travel from the ice maker.

• Good Routing - A continuous route of travel from the ice maker, with only one high spot.

• Acceptable Routing - A route of travel from the ice maker which includes one low spot and two high spots.

Figure 4: Routing of Ice-Delivery Hose

Procedure

Figure 5: Heat & Stretch

Auger End of Hose

1. The hose delivery location should be as high as possible in the icestorage box and facilitate the best hose route from the auger (as described above and shown in Figure 4).

2. Install the proper thru-hull in the ice-storage box using the supplied fitting. The thru-hull must be large enough for the 3/4" (19.1mm) ice-delivery hose.

3. Insulate the full length of hose with 1-1/8" ID, 3/4" thick wall insul-tube, minimum.

4. Double clamp thru-hull end so the hose will not get pulled out. In addition, PVC glue may also be used at the thru-hull end.

5. In order to fit over the auger spout, the hose end must be heated with in hot water (160°F / 71°C) or with a heat gun to soften then stretched by inserting and rotating pliers inside the tube and immediately installed. See Figure 5.

6. Secure hose end with constant torque hose clamp to auger spout.

7. Securely strap hose to bulkhead every 12” (30.5cm), keeping in mind that the hose will be much heavier once filled with ice. Be careful not to kink, flatten, oval or crush hose, because any obstructions will prevent free flow of ice. It is best to spread out load with proper hose-hanging devices that do not kink, flatten, oval or crush the insulation.

L-3152 ENGLISH 7

INSTALLATION PROCEDURES Eskimo Ice Installation & Operation Manual

Mount the ice-delivery

hose as high as possible

in the ice-storage box.

INSTALLING THE ICE-LEVEL SENSOR

To prevent overflow, this sensor stops ice production when the ice in the storage box reaches the level of the sensor. Use Figure 6 below to determine placement for the ice-level sensor at the storage box location.

1. The sensor must be located 2.5” (64mm) minimum to 3” (76mm) maximum to the left or right side of the ice-delivery hole. Drill a 23/32" (19mm) hole for sensor.

2. Use the 2 lock nuts provided to secure sensor into the hole.

3. Use marine-grade sealant around the hole if desired. (Remember that the unit may have to be removed at some time.)

4. Route the cable to the ice maker’s electrical box and plug the end into the ice-bin sensor socket. See the appropriate electrical wiring diagram in this manual for the voltage model you are using.

Figure 6: Location of Ice-Level Sensor (front view)

INSTALLING THE FEEDWATER SYSTEM

Feedwater for the unit should be fresh water supplied by the boat’s potable water system. The water reservoir has a float switch to ensure the unit does not operate without a water supply.

Requirements

• Supplied feedwater must have a pressure of at least 15 PSI.

• The water system must be able to supply at least 4 GPH when the ice maker is operating.

• Install the in-line filter (supplied in kit) ju st prior to the unit to remove sediment which may clog the needle valve in the water reservoir.

• Dometic recommends installing a shut-off valve in the feedwater line between the source and the filter to facilitate filter changes.

WARNING

Use of saltwater as feedwater will damage auger components and evaporator barrel and will void the warranty.

WARNING

Failure to install and use the water filter included with the installation kit will void the warranty. Note, if unit is purchased separately you must also purchase the water filter to maintain warranty.

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+ 22 hidden pages