Dometic Eskimo Ice EI540D User manual

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electronic, mechanical, photocopying,recording or otherwise without prior written consent by Dometic Marine. Every precaution has
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and omission. Neither is any liability assumed for damages resulting from the use of this product and information contained herein.
Eskimo Ice Crushed Ice System
Installation & Operation Manual
FOR MODEL EI540D
USING DIGITAL CONTROLS (WITH C-19 SOFTWARE)
EI540D Digital Optional
Remote Display
Display
Dometic Corporation
Rev. A
L-3040 English
P/N 336124

L-3040 ENGLISH
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WARNINGS AND NOTICES . . . . . . . . . . . . . . . . . . . . . . 1
ICE MAKING AND REFRIGERATION BASICS . . . . . . . . . . 2
How Ice Is Made . . . . . . . . . . . . . . . . . . . . . . . . 2
The Refrigeration Process . . . . . . . . . . . . . . . . 2
THE EFFECT OF TEMPERATURE ON ICE PRODUCTION . 3
Water Temperatures . . . . . . . . . . . . . . . . . . . . . 3
Air Temperature . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENTS OF THE ICE MAKER . . . . . . . . . . . . . . . 4
Ice-Making Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ice-Storage Box . . . . . . . . . . . . . . . . . . . . . . . . 5
Seawater System . . . . . . . . . . . . . . . . . . . . . . . 5
Freshwater Supply . . . . . . . . . . . . . . . . . . . . . . 5
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 5
Thermal Expansion Valve (TXV) . . . . . . . . . . . . 5
INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . 6
CHOOSING 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 . . . . . . . 13
Mandatory System Start-Up Test . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
THE DIGITAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . 14
BASIC FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Applying Power . . . . . . . . . . . . . . . . . . . . . . . . 15
On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ice Bin Sensor . . . . . . . . . . . . . . . . . . . . . . . . 15
Operational LEDs . . . . . . . . . . . . . . . . . . . . . . 15
Operational Information . . . . . . . . . . . . . . . . . 15
Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FAULTS - EVENTS THAT INTERRUPT ICE PRODUCTION 15
FULL – Ice Bin Full . . . . . . . . . . . . . . . . . . . . . 15
H20 – Potable Water Switch . . . . . . . . . . . . . . 15
HPF – High Pressure Refrigerant . . . . . . . . . . 15
LAC – Low AC line voltage . . . . . . . . . . . . . . . 16
LPF – Low Pressure Refrigerant . . . . . . . . . . 16
OCA – Over Current Auger and Ice Delivery
Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OCC – Overload Current Compressor . . . . . . 16
SPt – Auger Spout Blockage . . . . . . . . . . . . . 16
UCA – Under Current Auger . . . . . . . . . . . . . . 16
UCC – Under Current Compressor . . . . . . . . . 16
THE CYCLE OF OPERATION . . . . . . . . . . . . . . . . . . . 17
PROGRAMMABLE PARAMETERS FOR SOFTWARE 18
PROGRAM PARAMETER DESCRIPTIONS . . . . . . . . . . . 18
PROGRAM PARAMETER DEFAULT SETTINGS . . . . . . . 18
STARTING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 19
START-UP CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 19
START-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 19
SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . 19
TEMPORARY SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . 19
SUSTAINED SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . 19
SYSTEM RESTART/RESET . . . . . . . . . . . . . . . . . . . . . 19
SERVICING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 20
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
R-404A TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
THERMAL EXPANSION VALVE (TXV) . . . . . . . . . . . . . 20
RECHARGING THE SYSTEM . . . . . . . . . . . . . . . . . . . . 20
System Shutdown . . . . . . . . . . . . . . . . . . . . . . 20
Evacuate Refrigerant . . . . . . . . . . . . . . . . . . . . 20
Charging the System . . . . . . . . . . . . . . . . . . . . 20
OWNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 21
SEAWATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRESH WATER FILTER AND Y STRAINER . . . . . . . . . . 21
EVAPORATOR CLEANING . . . . . . . . . . . . . . . . . . . . . . 21
AUGER MOTOR AND GEARBOX . . . . . . . . . . . . . . . . . 21
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REFRIGERANT GAS . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WATER RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . 22
FEEDWATER FILTER AND Y STRAINER . . . . . . . . . . . . 22
WINTERIZING THE SYSTEM . . . . . . . . . . . . . . . . . . . . 22
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . 22
TECHNICAL ASSISTANCE . . . . . . . . . . . . . . . . . . . . . 23
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SYSTEM CONNECTION . . . . . . . . . . . . . . . . . . . . . . . 24
ELECTRICAL WIRING FOR 115V 60 HZ MODELS . . . . 25
ELECTRICAL WIRING FOR 230V 60 HZ MODELS &
220V 50 HZ MODELS . . . . . . . . . . . . . . . . . . . . . . . . 26

Eskimo Ice Installation & Operation Manual INTRODUCTION
L-3040 ENGLISH 1
INTRODUCTION
This manual provides installation and operation information for the EI540D 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 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, refer to the back cover of this manual for technical support options.
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 system is intended solely for the refrigeration
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 refrigerant 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.

INTRODUCTION Eskimo Ice Installation & Operation Manual
2L-3040 ENGLISH
ICE MAKING AND REFRIGERATION BASICS
Figure 1: Ice-Making Process
HOW ICE ISMADE
Fresh water is applied to the interior wall of the evaporator shell.
Using a refrigeration process, heat is removed from the fresh
water in order to freeze it.
As the water freezes onto the wall of the evaporator shell, the
auger scrapes it off and into a discharge port. The ice shavings
are then compressed and pushed into the ice transport tube
which runs to the ice-collection bin. See Figure 1.
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.
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.

Eskimo Ice Installation & Operation Manual INTRODUCTION
L-3040 ENGLISH 3
Figure 2: Refrigeration System Diagram
THE EFFECT OF TEMPERATURE ONICE 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.
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 45°F (7.2°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 low-
pressure shutdown to protect the compressor.
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. See Figure 3.
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.

INTRODUCTION Eskimo Ice Installation & Operation Manual
4L-3040 ENGLISH
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.
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 35 feet (10.6m) away. See Figure 4 on page 7.
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 14) 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 14 for further operating instructions.

Eskimo Ice Installation & Operation Manual INTRODUCTION
L-3040 ENGLISH 5
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 2 GPM / 7.6 LPM (maximum 2.75 GPM / 10.4 LPM) or coil erosion
can occur.
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 21 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.

INSTALLATION PROCEDURES Eskimo Ice Installation & Operation Manual
6L-3040 ENGLISH
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 the 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 and
use the 4 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 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 2.0” (51mm) high with one drain location. 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.

Eskimo Ice Installation & Operation Manual INSTALLATION PROCEDURES
L-3040 ENGLISH 7
INSTALLING ICE-DELIVERY HOSE
Planning the Route
The maximum length of the ice-delivery hose is 35 feet (10.6 m) under ideal conditions.
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
Figure 5: Heat & Stretch
Auger End of Hose
Procedure
1. The hose delivery location should be as high as possible in the ice-
storage 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.
NOTE: In cases where the EI540D is replacing an existing older Eskimo Ice
system that used a larger fitting and hose, it might be possible to insert the
newer, smaller hose inside the existing hose and use the existing ice-
discharge thru-hull.
3. Insulate the full length of hose with 1-1/8" (29mm) ID, 3/4" (19mm) 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. The hose at the auger end must be stretched in order to fit over the auger spout: Heat 1.75” (45mm) of the hose end in
hot water (160°F / 71°C) or with a heat gun to soften, then stretch it by inserting and rotating pliers inside the tube. See
Figure 5, page 7.
Mount the ice-delivery
hose as high as possible
in the ice-storage box.

INSTALLATION PROCEDURES Eskimo Ice Installation & Operation Manual
8L-3040 ENGLISH
6. The EI540D now REQUIRES a Constant Torque Hose Clamp to secure the ice delivery hose to the auger spout.
It is supplied with the machine and attached to the Auger spout with a black wire tie. The clamp must be
installed behind the 8 protruding dimples on the auger ice spout. The use of another type of clamp will void
the warranty and liability of ice overflow and damage if the hose comes off while producing ice. Secure hose
end with constant torque hose clamp to auger spout.
It is CRITICAL that you check the integrity of this hose connection when you perform the system start-up test.
(See “Mandatory System Start-Up Test” on page 13.)
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.
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. The EI540D will not operate without
the ice-level photo sensor installed.
Test the photo sensor for correct operation to avoid machine damage and avoid ice overflow. See “Mandatory System Start-Up
Test” on page 13.
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.
NOTE wiring changes from earlier Eskimo Ice models: The wiring has changed in the electrical box for the ice
sensor. There are 4 wires in the sensor harness: white, black, blue and brown. The signal wire in the center position of
the ice-level sensor plug is now a white wire, not black as before. The white wire was previously cut off at the grey
insulation. Now the black is cut off and the white is used. Note the photo sensor can be used for old as well as new. It
is just dependent how it is wired.
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.
Mount the ice-delivery
hose as high as possible
in the ice-storage box.