Table of Contents
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Table of Contents
Summary of Contents for Kodiak G03 series
- Page 1 ® KODIAK RECIRCULATING CHILLERS TECHNICAL MANUAL RC006, RC009, RC011, RC022, RC030 and RC045 G03, H03 and J03 Series Lytron Inc., 55 Dragon Court, Woburn, MA 01801, USA Tel: +1-781-933-7305 Fax: +1-781-935-4529 www.Lytron.com © Lytron Inc., 2010 Manual # 820-0109, Rev. Y, 07/23/10...
- Page 2 Kodiak Recirculating Chiller Technical Manual {THIS PAGE IS LEFT BLANK INTENTIONALLY}...
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Page 3: Table Of Contents
PRIMING TURBINE AND CENTRIFUGAL PUMPS....................19 CONNECTING POWER (FOR UNITS WITHOUT HEATER OPTION)..............20 CHILLER OPERATION ..............................21 SYSTEM MAINTENANCE AND SERVICE ........................24 DRAINING PROCEDURE FOR KODIAK CHILLERS ....................26 COOLANT MAINTENANCE ............................27 ERROR CODES................................... 28 TROUBLE SHOOTING GUIDE............................29 KODIAK SPARE PARTS .............................. - Page 4 REFRIGERATION DIAGRAM ............................44 HOST INTERFACE DATA LINK ............................ 44 HOST INTERFACE DATA LINK ............................ 45 LYTRON COOLING SYSTEMS SERVICE POLICY ....................48 LYTRON KODIAK RECIRCULATING CHILLER STANDARD WARRANTY ............50 DECLARATION OF CONFORMITY..........................51 - 2 - Check Lytron’s website www.Lytron.com...
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Page 5: Revision History
Kodiak Recirculating Chiller Technical Manual REVISION HISTORY ECN / DATE REASON FOR CHANGE 17284 / 07/08/2010 Updated Declaration of Conformity and safety symbols. - 3 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 6: Introduction
Service Hotline Lytron has a 24-hour per day, 7 day per week service hotline to help you with questions on the startup and operation of your Kodiak recirculating chiller. (Lytron recommends consulting the troubleshooting guide +1-781- 933-7300 on page 29 before calling the service hotline.) Lytron service can be reached by dialing To facilitate your call please have the model number and serial number (located on rear of the chiller) of the unit for the Lytron Service Technician. -
Page 7: Safety Precautions
Kodiak Recirculating Chiller Technical Manual SAFETY PRECAUTIONS This system is designed to provide fluid cooling only as specified in this manual. If this system is used in a manner other than as specified, the safety protection of the system may be impaired. -
Page 8: Labels And Silkscreen Marking
Kodiak Recirculating Chiller Technical Manual LABELS AND SILKSCREEN MARKING The symbol on this label is intended to alert the user to the presence of important operating and maintenance (servicing) instructions in the literature accompanying the equipment. This symbol on this label cautions the user against the risk of electrical shock. - Page 9 Kodiak Recirculating Chiller Technical Manual The product ID label identifies the model number, serial number, electrical information, pump type, refrigerant type, charge, and date of manufacture of the product. The crossed out wheeled bin label requires that the product be disposed of or recycled with the requirements of local law.
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Page 10: Part Number Description
NOTE: Refer to the product ID label on the on the rear of your chiller for the configuration you have purchased. The table above refers to Lytron’s standard product offering for the Kodiak product line. - 8 - Check Lytron’s website www.Lytron.com... -
Page 11: Specifications
Kodiak Recirculating Chiller Technical Manual SPECIFICATIONS RC006 RC009 RC011 RC022 RC030 RC045 60Hz 60Hz 60Hz 60Hz 60Hz 60Hz Thermal Capacity 50Hz 50Hz 50Hz 50Hz 50Hz 50Hz 1,050 1,650 2,400 3,450 5,900 Watts 1,400 2,150 2,950 4,950 2,800 3,585 5,780 8,755... -
Page 12: Performance Graphs
Kodiak Recirculating Chiller Technical Manual PERFORMANCE GRAPHS Temperature represents output temperature of water assuming 20°C ambient air conditions. Performance subject to change due to variations such as: fluid type or operating conditions. - 10 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10... -
Page 13: General Information
Coolant Loop Kodiak chillers are designed to operate with continuous coolant flow through a closed loop. This loop contains the system pump, temperature sensor, reservoir, internal and external plumbing lines and fittings, and the external heat load. The external plumbing and the heat loads are provided by the end user and are generally unique to the user’s process or location. -
Page 14: Controller Display Panel Functions
Kodiak Recirculating Chiller Technical Manual CONTROLLER DISPLAY PANEL FUNCTIONS Controller Display Operation Turn on/off chiller Displays Pressure briefly Enter menu (press simultaneously and hold for 3 seconds and release) “UP” + “DOWN” + Push to display or change set point Increase set point temperature “UP”... -
Page 15: Rear Panel Components
Kodiak Recirculating Chiller Technical Manual REAR PANEL COMPONENTS (Reference Spare Parts List in this manual) FLUID OUT CIRCUIT OF CHILLER BREAKER POWER ENTRY NOTCH INDICATES RS232 FLUID IN REMOTE START & PIN 1 TO CHILLER CUSTOMER CONTACTS - 13 - Check Lytron’s website... -
Page 16: Optional System Features
Remote Start This option allows the Kodiak chiller to be started or stopped through a computer or a relay. The chiller can e run using a normally open circuit or normally closed. (Look under the section labeled Chiller Operation for more details) R.S. - Page 17 Kodiak Recirculating Chiller Technical Manual RS-232 Serial Port Communication This option allows control of the chiller via a standard 9 pin serial port connected to a computer. Lytron software is available that simulates the front control panel and all its functions. Alternatively, software can be created to interface with the system described in the section labeled Host Interface Data Link.
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Page 18: Controller Options
Kodiak Recirculating Chiller Technical Manual CONTROLLER OPTIONS ® CONTROLLER PACKAGES (1, 2, 3) FOR KODIAK CHILLERS CONTROL PACKAGE #1: 1. Auto-Restart 2. Calibration Offset 3. Deg °C / Deg °F Toggle 4. Digital Temperature Display 5. Low Flow Fault Chiller Shut-Off STANDARD OPTIONS FOR CONTROLLER PACKAGE #2: 1. -
Page 19: Installation Requirements
To safely operate the chiller, use an SJT cord set with an IEC 320/C19 receptacle and an inlet plug that is compatible to the local power grid and the power requirements of the chiller. All Kodiak chillers should use SJT 3 conductor 12 AWG minimum power cord. -
Page 20: Installation Procedure
Kodiak Recirculating Chiller Technical Manual INSTALLATION PROCEDURE Selecting and Locating Hoses • The coolant ports are located on the rear of the system and are labeled as previously shown on page 13. • To minimize the pressure loss in the coolant lines, use the largest practical diameter tubing. If substantial lengths of cooling lines are required, they should be pre-filled with coolant before connecting them to the chiller. -
Page 21: Priming Turbine And Centrifugal Pumps
Kodiak Recirculating Chiller Technical Manual PRIMING TURBINE AND CENTRIFUGAL PUMPS Running centrifugal and turbine pumps dry for even a few seconds can permanently damage the pump. This style of pump must be “primed” prior to operation. Pump priming must be performed under the following conditions: a. -
Page 22: Connecting Power (For Units Without Heater Option)
Kodiak Recirculating Chiller Technical Manual CONNECTING POWER (FOR UNITS WITHOUT HEATER OPTION) In order to avoid an electrical potential at the chiller frame due to insulation failure, a proper ground connection to the system must be provided. Failure to do so could result in damage to the equipment, personal injury, and/or death. -
Page 23: Chiller Operation
Kodiak Recirculating Chiller Technical Manual CHILLER OPERATION The following sections explain how to perform other operations with the chiller’s controller, using the keys and display on the front of the unit. Refer to the Controller Display Panel Functions section in this manual. - Page 24 Kodiak Recirculating Chiller Technical Manual AL—Audible Alarm (option) 1. To enter the menu, press and hold both the “UP” and “DOWN” arrow keys for 3 seconds. 2. Use the “SET” key to scroll to “AL.” 3. The display toggles between “AL” and its current setting.
- Page 25 Kodiak Recirculating Chiller Technical Manual Ot— Over temperature indication (option) 1. To enter the menu, press and hold both the “UP” and “DOWN” arrow keys for 3 seconds and release. 2. Use the “SET” key to scroll to “Ot.” 3. The display toggles between “Ot” and current over temperature set point.
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Page 26: System Maintenance And Service
Unqualified individuals conducting service on the chiller could result in damage to the equipment, personal injury and/or death. After your Kodiak Recirculating Chiller is up and running, it takes only a small amount of care and maintenance to keep it running well. - Page 27 Kodiak Recirculating Chiller Technical Manual Algae Lytron recommends the use of an algae inhibitor to prevent growth in the reservoir. Cleaning the System and Reservoir To clean the unit follow these steps: 1. Drain the entire unit including the hoses and equipment being cooled.
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Page 28: Draining Procedure For Kodiak Chillers
Kodiak Recirculating Chiller Technical Manual DRAINING PROCEDURE FOR KODIAK CHILLERS Always disconnect power to chiller when performing service. Failure to do so could result in damage to the equipment, personal injury and/or death. A container should be available to hold the fluid removed from the chiller. This container should be labeled in accordance with OSHA rules and regulations concerning handling of the fluid being removed from the chiller. -
Page 29: Coolant Maintenance
Kodiak Recirculating Chiller Technical Manual COOLANT MAINTENANCE Recommended coolant for use in Lytron systems • Clean water is recommended for most systems. Systems ordered with the deoinized plumbing package require that deoinized water be used. Use of deoinized water in systems with brass components may cause premature failure of the system. -
Page 30: Error Codes
Kodiak Recirculating Chiller Technical Manual ERROR CODES There are a few different error codes that can occur during the operation of the chiller. These error codes are displayed on the front keypad of the system. See below for an explanation of each error code. -
Page 31: Trouble Shooting Guide
Kodiak Recirculating Chiller Technical Manual TROUBLE SHOOTING GUIDE Possible Cause Recommended Remedy Problem Make sure the unit is plugged in. Verify power to the unit. No power to the unit, circuit breaker "off" Turn circuit breaker to the "ON" ( I ) or tripped. - Page 32 Kodiak Recirculating Chiller Technical Manual Possible Cause Recommended Remedy Problem Low temperature alarm is set too close to Adjust low temperature alarm set point. cooling set point temperature. High temperature alarm is set too close to Adjust high temperate alarm set point.
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Page 33: Kodiak Spare Parts
Kodiak Recirculating Chiller Technical Manual KODIAK SPARE PARTS Model# Series RC011/RC022 RC030/RC045 RC006/RC009 Item # Description Lytron Part Number Controller PCB 230-0874-P Circuit Breaker 115V 230-0593 230-0588 Circuit Breaker 230V 230-0592 230-0591 Pump and Compressor Relay 101903-03 Pressure Transducer, Brass... -
Page 34: Accessories For The Kodiak Recirculating Chiller
1/2 Hp Turbine Pump 115/230 V 410-0229 1/6 Hp Turbine Pump 115V “EC” 410-0336 1/6 Hp Pump 230V “EC” 410-0337 ACCESSORIES FOR THE KODIAK RECIRCULATING CHILLER Description Lytron Part Number 5” Water Filters (min order 10) 330-0022 Air Filter RC006/RC009... -
Page 35: Front View
Kodiak Recirculating Chiller Technical Manual FRONT VIEW (Reference Spare Parts List in this manual) ACCESS PANEL COVER KEYPAD UPPER FRONT SIDE FRONT GRILLE CASTERS - 33 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 36: Rear View (With Panel)
Kodiak Recirculating Chiller Technical Manual REAR VIEW (WITH PANEL) (Reference Spare Parts List in this manual) CIRCUIT BREAKER REAR PANEL - 34 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 37: Top View
Kodiak Recirculating Chiller Technical Manual TOP VIEW (Reference Spare Parts List in this manual) PUMP AND COMPRESSOR RELAY PUMP PRESSURE TRANSDUCE TEMP SENSOR TANK MOTOR FLOW SWITCH - 35 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10... -
Page 38: Rear View (Opened)
Kodiak Recirculating Chiller Technical Manual REAR VIEW (OPENED) (Reference Spare Parts List in this manual) HOT GAS FLOW BYPASS VALVE SWITCH HEAT EXCHANGER CAPILLARY TUBE - 36 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 39: Side View
Kodiak Recirculating Chiller Technical Manual SIDE VIEW (Reference Spare Parts List in this manual) FLOW SWITCH COMPRESSOR LIQUID LINE SOLENOID VALVE CONDENSER FILTER DRYER - 37 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 40: Side View (With High Pressure Cutout)
Kodiak Recirculating Chiller Technical Manual SIDE VIEW (WITH HIGH PRESSURE CUTOUT) RESET BUTTON HIGH PRESSURE CUTOUT - 38 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. - Page 41 Kodiak Recirculating Chiller Technical Manual CHILLER DIMENSIONS FOR RC006 AND RC009 ½” - 39 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information.
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Page 42: Chiller Dimensions For Rc011 And Rc022
Kodiak Recirculating Chiller Technical Manual CHILLER DIMENSIONS FOR RC011 AND RC022 ½” - 40 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 43: Chiller Dimensions For Rc030 And Rc045
Kodiak Recirculating Chiller Technical Manual CHILLER DIMENSIONS FOR RC030 AND RC045 - 41 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 44: Wiring Diagram
Kodiak Recirculating Chiller Technical Manual WIRING DIAGRAM - 42 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 45: Plumbing Diagram
Kodiak Recirculating Chiller Technical Manual PLUMBING DIAGRAM - 43 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 46: Refrigeration Diagram
Kodiak Recirculating Chiller Technical Manual REFRIGERATION DIAGRAM - 44 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information. -
Page 47: Host Interface Data Link
Kodiak Recirculating Chiller Technical Manual HOST INTERFACE DATA LINK Control Package 3 only 1.0 Host Interface Data Link The chiller supports basic host control capability through the Chiller RS-232 port. 1.1 Port Settings The host port runs at 9600 baud, 8 data bits, 1 stop bit, and no parity. - Page 48 Kodiak Recirculating Chiller Technical Manual Where: Alarm Flags Status in Bit encoded Byte (2 chars). Assignments are: Bit 7 (MSB) Over Temp: Over Temperature Alarm is lit Bit 6 Lo Temp: Low Temperature Alarm is lit Bit 5 Low Flow:...
- Page 49 Kodiak Recirculating Chiller Technical Manual 1.6.6 Set Chiller Control Plant Setpoint Temperature This command (‘P’) from the host will set the Chiller Control Temperature Setpoint. The Host command is of the form: ^JP SetTemp^M Where: SetTemp Setpoint Temperature Value (2-byte hex (°Cx100) ^J ^M ASCII Linefeed and Carriage Return 1.6.7...
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Page 50: Lytron Cooling Systems Service Policy
Kodiak Recirculating Chiller Technical Manual LYTRON COOLING SYSTEMS SERVICE POLICY Lytron’s cooling systems are the product of over 40 years of thermal engineering and manufacturing experience. We designed them to provide superior reliability, easy maintenance, and worry-free operation. However, occasionally a system may need repair. To ensure your process is back up and running quickly, Lytron has implemented the following cooling system service policy. - Page 51 Kodiak Recirculating Chiller Technical Manual Debit memos should not be issued for warranty and non-warranty repairs unless the unit is returned as a result of an out-of-box (new) failure. Lytron will warranty the repair for one year from the repair date under the terms of our standard warranty or for the balance of the original warranty, whichever is longer.
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Page 52: Lytron Kodiak Recirculating Chiller Standard Warranty
Kodiak Recirculating Chiller Technical Manual LYTRON KODIAK RECIRCULATING CHILLER STANDARD WARRANTY Lytron agrees that the apparatus manufactured by it will be free from defects in materials and workmanship for the warranty period under normal use and service and when properly installed. The warranty period for... -
Page 53: Declaration Of Conformity
Kodiak Recirculating Chiller Technical Manual DECLARATION OF CONFORMITY - 51 - Check Lytron’s website www.Lytron.com Manual # 820-0109, Rev. Y, 07/08/10 for the most current technical information.
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