Dometic Eskimo Ice Remote Ice Crushing, Eskimo Ice System Installation And Operation Manual

Eskimo Ice
Remote Ice Crushing System Installation & Operation
Remote Ice Crushing System Revised: 6-21-06 L-2448B
TABLE OF CONTENTS
INTRODUCTION
Drawings and Diagrams .................................................... 3
Ice Making and Refrigeration Basics 3
Ice Maker Components ...................................................... 3
INSTALLATION
Choosing the Correct Voltage Equipment ......................... 5
Installing the Condensing Unit 5
Selecting the Site ............................................................... 5
Site Location Check List .................................................... 5
Mounting the Condensing Unit .......................................... 5
Installing the Auger Unit
Site Location Check List .................................................... 5
Mounting the Auger Unit .................................................... 5
Installing the Ice Level Sensor ........................................... 6
Installing Ice Delivery Hose ............................................... 6
Installing the Refrigerant Linesets 6
Connecting the Quick Connect Fittings ............................. 6
Installing the Feed Water System
Water Quality ...................................................................... 7
Use of Saltwater as the Evaporator ................................... 7
Installing the Seawater Cooling System 7
Through-Hull Inlet Fitting .................................................... 7
Seacock .............................................................................. 7
Strainer ............................................................................... 7
Seawater Pump .................................................................. 8
Required Seawater Flow Rate ........................................... 8
Manifolds ............................................................................ 8
Overboard Discharge ......................................................... 8
Seawater Piping ................................................................. 8
Bonding .............................................................................. 8
Pump Relay ........................................................................ 8
Installing the Control Panel 8
Maintenance 11
Seawater System .............................................................. 11
Refrigerant Gas ................................................................ 11
Compressor ...................................................................... 11
Auger Motor ...................................................................... 11
Auger Gearbox ................................................................. 11
Water Reservoir ................................................................ 11
Water Filter ....................................................................... 12
Evaporator Cleaning ........................................................ 12
Winterizing the System ..................................................... 12
Troubleshooting Guide 12
Limited Warranty Periods 16
Description of Figures and Diagrams 17
OPERATION
Start-up Check List 9
Servicing the System 10
Refrigerant ........................................................................ 10
R134a Tools...................................................................... 1 0
Constant Pressure Valve (CPV) ....................................... 10
Quick Connect Fittings (QC) ............................................ 10
Recharging the System 10
System shutdown ............................................................. 10
Evacuate Refrigerant ....................................................... 10
Charging the System ........................................................ 11
Setting the Constant Pressure Valve (CPV) .................... 11
Constant Pressure Valve (CPV) Replacement................ 11
Copyright 2006 Dometic Environmental Corporation, All Rights Reserved - Every precaution has been taken in the preparation of this manual to insure its accuracy. However, Dometic Environmental Corporation 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.
L-2448B
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INTRODUCTION

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 the Dometic Service Department or your local dealer for assistance.
Phone 804-746-1313 or 954-973-2477 (8am-5pm US Eastern Time), Fax 804-746-7248 or 954-979-4414, or email sales@dometicusa.com.
NOTICE
Your ice making system uses the refrigerant R134a. Federal law forbids the intentional release of refriger­ant gas to the environment. You should make certain that any field service is performed by a specialist with the proper equipment to prevent loss of refriger­ant during servicing.
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.

Drawings and Diagrams

The figures, drawings, or diagrams that are referenced in this manual can be found directly after the warranty section. In addition, 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.
Ice Making and Refrigeration Basics
To produce crushed ice, heat must be moved from the ice making water source to the seawater condensing medium. The condensing unit contains both the com­pressor and condenser coil. The compressor adds pressure to the refrigerant gas, which causes an increase in temperature. The condenser coil removes heat and condenses the refrigerant gas into liquid. The liquid is pumped to the expansion device which lowers the pressure and allows the refrigerant to expand in the evaporator. When the refrigerant expands in the evapo­rator, it actually boils from a liquid to a gas. This change of state allows for a large energy exchange. After the refrigerant is fully boiled off into a gaseous state, it flows back to the compressor again.
The evaporator in the ice maker allows cold refrigerant gas to remove heat from the water. As the water freezes onto the wall of the evaporator shell, it is scraped off by the auger, and pushed to the box.
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.
DANGER
This equipment is not ignition protected per CFR
183.410 and may not be installed in areas that may be exposed to flammable gases.
L-2448B Introduction

Ice Maker Components

The system consists of two main components: the condensing unit and the auger unit. They are con­nected by copper linesets or flexible lines. Other parts include the control panel, seawater system, and ice level sensor.
Condensing Unit (Figure 1)
All units have R134a compressors, water-cooled condensers, a receiver/filter/drier, an accumulator, and a sight glass/moisture indicator. The condensing unit also has the logic control/electrical component box (control box) attached. The control box is attached to the condensing unit by an eight foot cable. It has plug­and-play electrical connections to the auger unit and control panel. The control box may be remotely mounted, but must be mounted in the same orientation as when it was shipped. The unit comes with quick connect refrigerant fittings and is pre-charged with refrigerant from the factory.
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Auger Unit (Figure 2)
The auger unit contains the evaporator barrel, auger rotor, gearbox, motor, water reservoir, and expansion device. The unit comes with quick connect refrigerant fittings and is pre-charged with refrigerant from the factory. The unit has plug-and-play electrical connec­tions to the control box and the ice level sensor.
Control Panel (Figure 3)
The control panel contains the system function switch as well as system indicator lights. It is a user interface that enables a visual indicator of system activity, such as whether the system is running or has a fault.
Linesets
Linesets are generally made of copper tubing which is connected to the auger at one end and the condensing unit at the other. The liquid line is ¼" copper tubing, while the suction line is ½" copper tubing. The suction line comes pre-insulated to prevent frost. Flexible sections are available where one part moves in relation to another, such a lifting deck.
System Controls
The ice maker system is controlled by logic that is programmed into the SmartRelay. The SmartRelay controls all operations of the system, and gives visual indications of activity to the user via the control panel. The logic system takes into account low refrigerant pressure, high refrigerant pressure, low feedwater for ice making, blocked ice delivery system, and auger motor start error. The control box contains a System Reset switch for use when the control locks out due to a sustained fault.
Ice Box
The ice box where the ice is to be dumped should be insulated, if possible, with at least 2" of insulation to help keep the ice as long as possible. It is also helpful to install a drain at the opposite end of the box from the ice input.
Seawater System (Figure 1)
The cupro-nickel coaxial tube design allows for effi­cient exchange of heat between the seawater and the hot refrigerant. The condensing unit may be hooked up to either its own single-station pump, or to a larger, multi-station pump via a pump relay box. The seawater system should consist of a through-hull fitting, seacock, strainer, seawater pump, seawater hose, and overboard discharge.
Freshwater Supply
Freshwater supply for ice making should be provided via the ¼" male flare fitting on the auger unit. Provide water with pressure of at least 15 PSI. An in-line water filter is required to help prevent clogging of the needle valve in the water reservoir.
Refrigerant Charge
The condensing unit, the auger unit, and the linesets are all pre-charged with the correct amount of R134a refrigerant. No charge adjustment should be necessary upon installation.
Sight Glass/Moisture Indicator (Figure 1)
A sight glass is provided on the condensing unit to provide quick access to a couple of pieces of system information. The sight glass will provide visual identifi­cation of refrigerant charge status (empty or full.) The sight glass also houses a moisture indicating element which can help in troubleshooting.
Quick Connect Fittings (Figure 1)
The quick connect (QC) fittings allow for all parts of the unit to be factory evacuated and precharged with refrigerant. They allow for easy and quick installation in the field. They are polarized so they can’t be hooked up incorrectly. They can be reused over time and again if the unit is ever relocated.
Constant Pressure Valve (Figure 4)
The constant pressure valve 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 constant pressure valve is very simple and reliable, and provides for a constant system pressure over a wide range of ambient and seawater temperatures. The valve pressure is set at the factory, and generally needs no field adjustment. The recommended pressure is 9-10 PSI.
Misadjustment of the valve can cause reduced ice production, damage to components, and voiding of the warranty.
L-2448B Introduction
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INSTALLATION

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

Choosing the Correct Voltage Equipment

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, at 60 Hz, you will sometimes 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.
When choosing your system, the voltage and fre­quency must be known. While this 60 Hz equipment can be run at 50Hz, it will experience a 17% drop in performance. When using this equipment on 50 Hz, the voltage must be the lower of the two voltages given (100 or 200) on the data plate due to buildup of heat in the motor.
Installing the Condensing Unit

Selecting the Site

Dometic ice making units are designed to be installed in any convenient location. The unit is normally located in the engine room or other machinery space, but can be located in living areas if necessary. The condensing unit will produce some condensation, so the drip pan is necessary. The space around the unit may be insulated to reduce noise if necessary. The unit is water cooled, and does not need ventilation.
Use screws or bolts through the holes in the four corners of the pan to secure the unit. You may remove the pan and turn to get the proper orientation of the drain stub.
Do not remove any covers, caps, or fittings that may expose any wiring or refrigerant until you are ready for that step of the installation.
If you decide to remotely mount the control box, be
sure to mount in the same orientation in which the unit was shipped.
system failure.
Failure to do so could cause

Installing the Auger Unit

The auger is designed to be installed close to the ice box. This minimizes the amount of tubing between the box and auger, and minimizes the time required for ice to start entering the box. It also helps to reduce the amount of melting taking place in the hose and reduce the chance for ice clogging. The auger unit has an elbow on the top, right-hand side which is where the ice exits the auger itself. The elbow can rotate 360 accommodate the location of the hose to the ice box. It is important that the elbow is oriented in an upward direction to allow water to re-enter the auger barrel instead of running to the ice box.

Site Location Check List

• Choose a location as close to the ice box as possible
• Orient the unit so that refrigerant, water, and electrical connections are accessible
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Site Location Check List

• Adequate space for access to refrigerant, seawa­ter, and electrical connections
• Accessible for service and maintenance
• Away from direct spray from engine air intakes or water washdown
• Flat, horizontal surface
• Maximum refrigerant tubing run is 50 feet (15m)

Mounting the Condensing Unit

Orient the unit so the refrigerant, seawater, and electri­cal connections are accessible.
L-2448B Installation
• Orient the unit so that the front and/or top cover may be removed for service and maintenance
• Choose a substantial vertical surface, or a flat, horizontal surface
• Do not place in an area of direct salt spray

Mounting the Auger Unit

Orient the unit so that the refrigerant, water, and electrical connections are accessible. Plan for enough space in front of and on top of the unit for panel removal. Securely fasten to a sturdy vertical wall using the keyhole slots in the rear of the unit, or secure to a flat, horizontal surface using the tabs provided on the bottom of the unit.
Do not remove any caps, covers, or fittings until you are ready for that step of the installation.
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Installing the Ice Level Sensor

Use Figure 5 to determine placement for the Ice Level Sensor. The sensor must be located below the ice delivery hole and to the side, per Figure 5. Drill 23/32" hole for sensor. Use two lock nuts provided to secure sensor into hole. Use marine grade sealant around the hole if desired. Remember that the unit may have to be removed at some time. Route the cable to the auger unit, and plug into the matching plug.

Installing Ice Delivery Hose

Figure 5 and 6 shows the proper ice delivery hose
connection. The first step is to install the proper through-hull in the ice box (Figure 5). This through-hull must be large enough for the 1¼" ice hose to fit inside the fitting (use supplied part). It should be installed in such a manner as to provide (Figure 6):
1) A continuous uphill route of travel from the auger unit (BEST)
2) A continuous route of travel, with only one high spot (GOOD)
3) A route of travel which includes one low spot and two high spots (ACCEPTABLE)
The best routing provides for a level, but slightly upward rising hose from the auger toward the box, with very few bends. No bend should be tighter than a radius of 12". Insulate the full length of hose with
5
/8" ID, ¾" thick wall insul-tube, minimum. Provide a
1 ¼" hole for an air vent where instructed as in Figure 6. Do not block with insulation. If there are any dips in the hose, we suggest that you drill a ¼" hole in the hose for a water relief. While the water will not prevent ice flow, it could freeze in low ambient conditions, preventing ice delivery. Do not block the hole with insulation. Secure at each end with double hose clamps, so that the line will not get pulled out. In addition, PVC glue may also be used at the thru-hull end. Strap hose to bulkhead securely, keeping in mind that the hose will be much heavier once filled with ice. Be careful not to kink or crush hose, because any obstructions will prevent free flow of ice.
Installing the Refrigerant Linesets
The refrigerant lines may run uphill, downhill, or sloping as necessary. They can have bends as necessary, but avoid sharp bends which could result in kinking of the tubing. Once connections are made, the suction line should be fully insulated from unit to unit.

Connecting the Quick Connect Fittings

The linesets, auger and condensing unit all have quick connects (QC). QC fittings allow for connection and disconnection of the system with no loss of refrigerant. Route the lines directly to each unit, and approach the QC in a straight line. Do not try to screw fittings together which are not mated correctly, as doing so will destroy the fittings. Connect the fittings together in the following method:
• Lubricate the male fitting face and thread lightly with refrigeration grade oil.
• Hand thread the nut of the female QC onto the male threaded QC by rotating the union nut clockwise.
• Tighten the female thread connection with a wrench while holding the opposite coupling with a wrench. Exception: The male QC is held by a metal bracket at each unit, and does not need a wrench on it.
• Tighten each assembly to 35 ft. lbs.
• If you don’t have a torque wrench, then tighten each assembly until the fittings “bottom out.” Then use a marker to make a line on each coupling half hex. Turn with wrenches an additional to completely seal the assembly.
1
/6 to ¼ turn
IMPORTANT If fittings are cross-threaded together by not using the steps above, the fittings will be destroyed and the warranty voided.

Installing the Feed Water System

The feed water for the auger unit should be fresh water supplied by potable water system of the boat. Use of saltwater is not recommended because of the damage it causes to the components of the auger and evapora­tor barrel. Feed water should be supplied with pressure of at least 15psi. The water system must be able to supply at least 4 gallons per hour when the ice maker is operating. Use of an in-line filter just prior to the auger unit is required to remove sediment which may cause occlusion of the needle valve in the water reservoir, and to reduce scale buildup which will inhibit system performance, and may cause damage to the auger components. We suggest a filter that will remove dirt, rust, odor, and scale, such as Dometic Part #3150707. Dometic recommends that a shut-off valve be installed in the feedwater line, between the source and the filter, to help facilitate filter removal. Run copper tubing or equal from the water source to the auger unit, and connect with the supplied connection
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on the unit. Ensure that there are no leaks in the field installed portion of the system. The water reservoir has a float switch to ensure that the unit does not operate without water supply.
without any dips of loops, and with only one high point in the system. This is called self-draining because all the water will drain out of the piping if the boat were taken out of the water.

Water Quality

No water which comes from municipalities is ‘pure’ water. Water from the water maker on board a vessel will come as close as you will probably see. The problem is that water contains suspended and dis­solved solids. Pure water freezes first, leaving the solids to increase in concentration in the unfrozen water. Solids also bond to the evaporator wall during freezing, forming scale. Eventually, built up scale will shorten machine life. A filter should always be used, preferably one approved by Dometic for use with ice makers. The filter should be replaced at least twice yearly, or more often if the machine is used often. While filters will help clean the water, a yearly cleaning of the evaporator barrel is required, see the Mainte­nance section, under Evaporator Cleaning.

Use of Saltwater as the Evaporator

Saltwater use in the evaporator to make ice is not approved by Dometic, even though the machine can freezer salt water. Salt water is very corrosive in itself, plus it contains many more dissolved and suspended solids than freshwater. If you wish to have brine solution for your catch, we suggest sprinkling some salt over the ice in the catch box. USE OF SALT­WATER IN ANY DOMETIC ICE MAKER WILL VOID THE WARRANTY!
Installing the Seawater Cooling System
The following installation instructions apply to ice maker units as well as general air conditioning units.
Importance of a Self-Draining System
A poorly plumbed seawater system is one of the most common installation problems on marine refrigeration and air conditioning. When water flow is lost, not only with the ice maker cease to produce ice, but the pump could be damaged from running with no water flow.
When using a centrifugal seawater pump, it is impera­tive that the seawater piping be routed continually uphill from the through-hull to the condenser, then smoothly up or down to the overboard discharge,
Whenever air gets into the system, which can happen in heavy seas or a sharp turn, it can become trapped in the pump. Because centrifugal pumps cannot pump air, water flow is lost.
A self-draining system will allow air in the piping to rise naturally through the pump and then be expelled. It will also make winterizing the system much easier. Figure 7 shows a properly plumbed system and some common mistakes.

Through-Hull Inlet Fitting

A separate through-hull fitting must be installed for each seawater pump. Do not attempt to draw water from an engine, generator, or other through-hull fitting.
A scoop-type through hull should be installed facing forward, as far below the water line and as close to the keel as possible.
Drill a properly sized hole for the through-hull fitting. Bed the scoop with marine sealant designed for underwater use, and tighten the nut onto the through­hull to secure it.

Seacock

A full-flow seacock should be installed directly onto the through-hull fitting. Use Teflon tape or equivalent to seal the threads. The seacock must be accessible and easy to close in case of emergency, of to clean the strainer.

Strainer

A seawater strainer must be installed between the seacock and the pump, and should be situated to provide easy access for cleaning. The strainer must be located vertically above the seacock and below the pump so any air that gets into the strainer can get out.
Make sure the water flow through the strainer is in the correct direction. Some strainers have an arrow that shows correct flow direction.
Mount the strainer to a bulkhead so it is properly supported before connecting hoses. Use Teflon tape or equivalent on pipe threads.
L-2448B Installation
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Seawater Pump

Centrifugal pumps are not self-priming, and must be mounted so that they are below the heeled waterline in any given operating condition. The pump should be accessible for future service.
Mount the pump so that the outlet is directed upward. The head on some pumps can be rotated to allow mounting on a vertical bulkhead, see Figure 8. Self­priming pumps are available if the pump cannot be mounted below the waterline.

Required Seawater Flow Rate

The Dometic ice maker requires 2.5 GPM or 150 GPH of seawater flow for rated performance.

Manifolds

If a pump is serving multiple units, then a seawater manifold will be needed to supply water to all units. This can be as simple as a tee for two units, or a custom manifold for seven to eight units.
It is very important to consider manifold orientation so that all units get their required flow. See Figure 9 for proper orientation tips.
A manifold can also be used on the outlets of the units when using a single overboard discharge.

Overboard Discharge

The overboard discharge should be located between 1 and 2 inches (25-50 cm) above the waterline. This is to facilitate visual confirmation of water flow, but also to keep it close to the waterline to minimize splashing.
If the overboard is located below the waterline, then a valve must be installed per ABYC guidelines.
• Use the correct size hose, fittings, and compo­nents. See Figure 9 for proper sizing. pump inlet piping (including through-hull and strainer) may need to be larger than the outlet pipe size. Do not use pump connections to determine hose size.
• The “pump inlet” recommended pipe size includes all fittings and hose up to the pump connection (through-hull, seacock, strainer, hose, manifold). The “pump discharge” recommended pipe size includes all fittings and hose from the pump discharge up to the overboard discharge.
Note that the

Bonding

Bond all metallic parts (through-hull, valves, strainer, manifolds, etc.) that are in contact with seawater to the vessels’ bonding system in accordance with ABYC standards. Items should only be bonded or grounded once. If an item is in contact with an electrically grounded part (pump, seawater condenser) then it should not be bonded again.

Pump Relay

The pump relay is generally located in the engine room or mechanical space near the seawater pump, but can be mounted anywhere that is convenient and acces­sible. It must be in a dry location, away from water spray, with some room for heat dissipation.
Choose your pump relay based on the number of units that will be operating off one pump. Choose each trigger to reflect the voltage of the unit it serves. The polarity of the signal from the unit does not matter to the trigger, but the voltage is very important.

Seawater Piping

• Only use reinforced marine grade hose or other suitable piping (PVC, CPVC, cupronickel, or stainless steel).
• Double clamp all hose connections.
• Use only plastic, bronze, or stainless steel fittings (do not use brass).
• Avoid loops or dips in all hose runs.
• Make sure enough hose is used to allow for future removal of components.
L-2448B Installation

Installing the Control Panel

The control panel may be installed wherever desired, however, it may not be exposed to saltwater spray. The panel comes with a plug on the back. Use extension cables (purchased separately) to run between the panel and the control box. They may be extended up to 100'. Use the cutout dimensions provided in Figure 10. Route cable to control box on condensing unit, and plug into the mating connector.
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OPERATION

This section of the manual refers to essential safe operation for all Dometic ice makers. For any opera­tional problems, call your dealer, or our service depart­ment at 804-746-1313.

Start-up Check List

A) Before you start the system
• Check that all refrigerant connections are tightened per installation manual
• Check to make sure that all refrigerant lines are secured so as not to rub against other objects during operation
• Ensure that all portions of the suction line, including connections, are insulated to prevent ice build-up
• Confirm that electrical connections are correct and tight.
• Make sure that the ice level sensor is mounted securely and the cable is routed safely.
• Make sure that all units are mounted securely.
• Check seawater connections to make sure that they have correct flow direction, and that all connections are tight.
• Confirm that all metallic parts are bonded correctly
• Make sure there are no loops or dips in the seawater system
• Confirm that frequently accessed parts are acces­sible i.e. control box, constant pressure valve, refrigerant ports, etc.
• Check ice delivery hose for insulation, air hole, and drain hole, if required. Make sure that the hose is securely fastened.
B) Starting the system
• Turn on the designated circuit breaker for the unit, and also the one for the pump if it is on a sepa­rate breaker at the boat’s electrical panel
• Open the seacock on the pump intake
• Turn the switch on the ice maker unit to ‘ON’
• When the unit starts (after the two minute delay) watch the sightglass for flowing refrigerant
• Check the sightglass after 15 minutes to make sure that the indicator inside shows green (no moisture)
• Confirm that water is flowing through the overboard discharge
L-2448B Operation
• Watch for ice within five minutes of starting, plus approximately one minute for each foot of hose between the box and auger unit
NOTE: The seawater pump should cycle automatically whenever the unit is running. Regularly check for seawater flow by observing the overboard discharge. If you do not observe any flow when the system is running, check for obstructions in the seawater cooling system.
C) Control Operation
• The control system works off pre-programmed logic to operate the condensing unit and auger unit within the assigned parameters. The logic uses sensors, timers, and counters to protect system components from failure due to loss of freshwater, loss of seawater, ice clogs, low refrigerant, or auger motor start failures. It also controls system operation based on ice bin level.
• Input and output starts at the control panel. The panel contains the system on/off switch, system running indicator light, pressure fault light, ice clog failure light, and the freshwater feed failure light. These indicators help determine system function, and failure mode, if one occurs.
• System failures that result in sustained shutdown, as indicated by one of the red failure lights on the control panel, can be reset with the Reset switch on the control box at the condensing unit. If the Reset switch needs to be used, it is a good indication of an actual problem, not just a passing event.
• Required events for sustained shutdown (in need of Reset switch operation)
1) High pressure switch operation of three (3) times within 45 minutes.
2) Low pressure switch operation of six (6) times within 45 minutes.
3) Freshwater feed fault each time level the fault occurs.
4) Ice clog indicator switch on ice discharge nozzle each time the fault occurs.
5) Auger motor start error each time the fault occurs.
NOTE: If system needs to be reset more than twice within one day, please have the system serviced.
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