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
o
to
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 hoseclamps, 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
L-2448B Installation
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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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