Dometic EI600D, EI250D User Manual

Eskimo Ice

EI600D EI250D

INSTALLATION MANUAL FOR SELF-CONTAINED ICE-MAKING SYSTEMS

For models:

• EI600D

• EI250D

Dometic Marine Division Rev. 20140401 L-2448A English

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 . . . . . . . . . . 1

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . 1

The Effect of Seawater and Fresh Water Tem-

peratures . . . . . . . . . . . . . . . . . . . . . . . . . . 2

The Effect of Ambient Air Temperature . . . 2

OMPONENTS OF THE ICE MAKER . . . . . . . . . . . . . . . 2

Ice-Making Unit . . . . . . . . . . . . . . . . . . . . . . . . . 2

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Storage Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Seawater System . . . . . . . . . . . . . . . . . . . . . . . 2

Freshwater Supply . . . . . . . . . . . . . . . . . . . . . . 2

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 2

Constant Pressure Valve (CPV) . . . . . . . . . . . . 3

INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . 3

HOOSING THE CORRECT EQUIPMENT VOLTAGE . . . . . 3

NSTALLING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . 3

Selecting the Site . . . . . . . . . . . . . . . . . . . . . . . 3

Site Location Check List. . . . . . . . . . . . . . . 3

Mounting the Unit . . . . . . . . . . . . . . . . . . . . . . . 3

Installing Condensate Drainage . . . . . . . . . . . . 4

Installing Ice-Delivery Hose . . . . . . . . . . . . . . . 4

Planning the Route. . . . . . . . . . . . . . . . . . . 4

Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installing the Ice-Level Sensor . . . . . . . . . . . . . 5

Installing the Feedwater System . . . . . . . . . . . . 5

Requirements . . . . . . . . . . . . . . . . . . . . . . . 5

Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . 6

Water Quality and Filters . . . . . . . . . . . . . . 6

Installing the Seawater Cooling System . . . . . . 6

Self-Draining System . . . . . . . . . . . . . . . . . 6

Thru-Hull Inlet Fitting . . . . . . . . . . . . . . . . . 7

Seacock . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Seawater Piping . . . . . . . . . . . . . . . . . . . . . 7

Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Seawater Pump . . . . . . . . . . . . . . . . . . . . . 8

Connection to Ice Maker. . . . . . . . . . . . . . . 9

Overboard Discharge . . . . . . . . . . . . . . . . . 9

Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installing the Remote Digital Display . . . . . . . . 9

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TART-UP CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 10

STARTING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 10

HE DIGITAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . 10

System Shutdown . . . . . . . . . . . . . . . . . . . . . . 11

System Restart/Reset . . . . . . . . . . . . . . . . . . . 11

SERVICING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . .12

EFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

R-134a Tools . . . . . . . . . . . . . . . . . . . . . . . . . .12

Constant Pressure Valve (CPV) . . . . . . . . . . . 12

Recharging the System . . . . . . . . . . . . . . . . . .12

System Shutdown . . . . . . . . . . . . . . . . . . 12

Evacuate Refrigerant. . . . . . . . . . . . . . . . 12

Charging the System. . . . . . . . . . . . . . . . 12

Setting the CPV. . . . . . . . . . . . . . . . . . . . 13

OWNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .13

EAWATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 13

RESH WATER FILTER AND Y STRAINER . . . . . . . . . . 13

EVAPORATOR CLEANING . . . . . . . . . . . . . . . . . . . . . .13

UGER MOTOR AND GEARBOX . . . . . . . . . . . . . . . . .14

OMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

REFRIGERANT GAS . . . . . . . . . . . . . . . . . . . . . . . . . .14

ATER RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 14

EEDWATER FILTER AND Y STRAINER . . . . . . . . . . . .14

WINTERIZING THE SYSTEM . . . . . . . . . . . . . . . . . . . .14

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . .14

TECHNICAL ASSISTANCE . . . . . . . . . . . . . . . . . . . . .15

WARRANTY AGREEMENT . . . . . . . . . . . . . . . . . . . . .15

SYSTEM CONNECTION AND WIRING DIAGRAMS . . 16

YSTEM CONNECTION . . . . . . . . . . . . . . . . . . . . . . . .16

EI600D (115V/60HZ/1 & 230V/60HZ/1) . . . . . . . . . . 18

EI600D (220V/50H

Z/1) . . . . . . . . . . . . . . . . . . . . . .19

EI250D (115V/60HZ/1 & 220V/50HZ/1) . . . . . . . . . . 20

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Eskimo Ice Installation Manual - Self-Contained System INTRODUCTION

INTRODUCTION

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 115 or 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 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.

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 thoroughly before installing 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: +1 804-746-1313 or +1 954-973-2477 (8AM - 5PM US Eastern Time)

• Fax: +1 804-746-7248 or +1 954-979-4414

• Email: sales@dometicusa.com

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 refrigerant R-134a. 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 servic in g.

ICE MAKING AND REFRIGERATION BASICS

The evaporator in the ice maker evaporates liquid refrigerant to remove heat from fresh water in order to freeze it. As the water freezes onto the wall of the evaporator shell, it is scraped off by the auger and pushed to the ice-collection box.

HOW IT WORKS

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 causing the fresh water to freeze..

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

• Condenser - Releases heat into the 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.

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.

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INTRODUCTION Eskimo Ice Installation Manual - Self-Contained System

The Effect of Seawater and Fresh 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).

High Temperatures - As water 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 water temperatures approach 40°F (4.4°C) and below, the water’s ability to provide heat exchange diminishes, so the capacity of the system decreases. Also, as the water temperature decreases, the system could sustain a lowpressure shutdown to protect the compressor.

CAUTION

Extreme care should be taken in operating any unit below seawater temperatures of 40°F (4.4°C). The seawater could freeze in the condenser tubing, possibly causing it to burst, which is not covered by the warranty.

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.

COMPONENTS OF THE ICE MAKER

ICE-MAKING UNIT

The ice-making unit has an R-134a 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. The freshwater delivered to it is converted to ice which exits the system via an ice-delivery hose routed to a storage box up to 30 feet (9m) away for the EI600D and EI500D or 15 feet (4.5m) away for the EI250D.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 displ ay.

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’ (2.2m) away.

The control box (Figure 7, page 11) 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 10 for further operating instructions.

STORAGE BOX

The 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 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 3, page 7) consists of a thru-hull fitting, seacock, strainer, seawater pump, seawater hose, and overboard discharge. There must be water flow of at least 2.5 GPM for the EI600D unit and 1.25 GPM for the EI250D unit.

FRESHWATER SUPPLY

Use the 1/4" SAE male flare 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 13 for maintenance instructions.

REFRIGERANT CHARGE

The unit is pre-charged with the correct amount of R-134a refrigerant. If service is required, see data plate for correct charge amount.

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Eskimo Ice Installation Manual - Self-Contained System INSTALLATION PROCEDURES

CONSTANT PRESSURE VALVE (CPV)

The CPV 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 CPV provides a constant system pressure over a wide range of ambient and seawater temperatures. The valve pressure is set at the factory and should not require any field adjustments. On the rare occasion that an adjustment is necessary, the system must be correctly charged and operating for at least 20 minutes at an ice-making temperature before any adjustments are made. Recommended pressure is 6 to 7.5 PSI (6.8 PSI is ideal) as determined by an accurate gauge capable of reading low-pressures. Misadjustment of the valve can cause reduced ice production, damage to components, and voiding of the warranty. If under warranty, call for authorization before adjusting CPV, otherwise warranty will be voided.

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 110 VAC to 120 VAC, or 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 away from direct spray, from engine air intakes, and from water washdown.

• Mounting space is a flat, horizontal surface.

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. For the EI600D and EI500D - Use screws or bolts through the holes in the four corners of the pan to secure it. You can

remove and turn the pan to better orient the drain stub. For the EI250D - Use the 4 provided hold-down clips to secure it.

3. The auger has an elbow where the ice exits. The elbow rotates 360 degrees to let the ice-discharge hose go in any direction toward the ice box. Make sure the elbow is oriented upward so water can re-enter the auger barrel instead of flowing to the ice box. For the EI250D, the elbow is the same as above, but if the ice-discharge hose needs to go in a direction other than through the factory hole in the front cover, you will have to drill a hole for the discharge hose in the appropriate location on any of the other 3 sides or top. Be sure to remove that cover panel from the unit before drilling.

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INSTALLATION PROCEDURES Eskimo Ice Installation Manual - Self-Contained System

4. 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.

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

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

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

INSTALLING CONDENSATE DRAINAGE

The condensate drain pan is 2.0” (51mm) high with two drain locations (one drain location on the EI250D). 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.

INSTALLING ICE-DELIVERY HOSE

Planning the Route

The maximum length of the ice-delivery hose is 30 feet (9m) for the EI600D or 15 feet (4.5m) for the EI250D. The best hose routing provides a level but slightly upward rise from the auger to the box, with very few bends. No bend should

be tighter than a radius of 18" (458mm). Refer to Figure 1 below to see:

• Best Routing - A continuous uphill route of travel from the auger unit.

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

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

Figure 1: Routing of Ice-Delivery Hose

Procedure

1. Install the proper thru-hull in the ice box using the supplied fitting. The thru-hull must be large eno ugh for the 1-1/4" (32mm) ice-delivery hose, and its location should facilitate the best hose route from the auger (as described above and shown in Figure 1, page 4).

2. Insulate the full length of hose with 1-5/8" (42mm) ID, 1/2" (13mm) thick wall insul-tube, minimum.

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Eskimo Ice Installation Manual - Self-Contained System INSTALLATION PROCEDURES

3. If needed, drill a 1/4" (6.4mm) air-vent hole where shown in Figure 1, page 4 for your type of hose route. Do not block the air vent with insulation.

4. If there are any dips in the hose you may need to drill a 1/4" (6.4mm) hole in the hose for water relief. While the water will not prevent ice flow, in low ambient conditions this water could freeze which would prevent ice delivery. Do not block the hole with insulation.

5. Secure each hose end with double hose clamps so the hose will not get pulled out. In addition, PVC glue may also be used at the thru-hull end.

6. Securely strap hose to bulkhead, 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.

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 2 below to determine placement for the ice-level sensor at the storage box location.

1. The sensor must be located below and to the 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 auger unit and plug the end into the matching socket.

Figure 2: Location of Ice-Level Sensor (front view)

INSTALLING THE FEEDWATER SYSTEM

Feedwater for the auger 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) just prior to the auger 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.

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INSTALLATION PROCEDURES Eskimo Ice Installation Manual - Self-Contained System

WARNING

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

WARNING

Failure to install and use a water filter will void the warranty.

Procedure

1. Run copper tubing or equivalent from the freshwater source to the in-line water filter.

2. Run copper tubing or equivalent from the water filter to the auger water input, and connect with the supplied 1/4" SAE male flare connection on the unit.

3. Ensure there are no leaks in the field-installed portion of the system.

Water Quality and Filters

No water from a municipality is “pure” feedwater, but water from a vessel’s onboard water maker comes close. The feedwater problem is that water contains suspended and dissolved feedwater solids. Pure water freezes first, leaving the feedwater solids to increase in concentration in the unfrozen feedwater. Solids also bond to the evaporator wall during feedwater freezing, forming scale. Eventually, built-up scale will shorten machine life.

A filter must always be used, preferably one supplied by Dometic for use with ice makers. Replace the filter at least twice yearly, or more often if the machine is used frequently. While filters help clean the water, a yearly cleaning of the evaporator barrel is required. See “Evaporator Cleaning” on page 13 of the “OWNER MAINTENANCE” section.

Using saltwater to make ice is not approved by Dometic. Saltwater is very corrosive, and it contains many more dissolved and suspended solids than freshwater. If you want a brine solution for your catch, we suggest sprinkling salt over the ice in the storage box. USE OF SALTWATER AS FEEDWATER IN ANY DOMETIC ICE MAKER WILL CAUSE SEVERE DAMAGE AND VOID THE WARRANTY!

INSTALLING THE SEAWATER COOLING SYSTEM

Self-Draining System

A poorly plumbed seawater system is the most common installation problem. When water flow is lost, not only will the ice maker cease to produce ice, but the pump could be damaged from running without water flow.

When using a centrifugal seawater pump, it is imperative that the seawater piping be routed continually uphill from the thru-hull to the condenser, then smoothly up or down to the overboard discharge without any dips or loops, and with only one high point in the system. This type of routing is called self-draining because all water will drain out of the piping if the boat is taken out of the water.

If air gets into the system, which can happen in heavy seas or with a sharp turn, it can become trapped in the pump. Because centrifugal pumps cannot pump air, water flow is lost. A self-draining system, however, allows air in the piping to rise naturally through the pump and be expelled. It also makes winterizing the system much easier. Figure 3, page 7 shows a properly plumbed system and some common mistakes.

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