Kodiak G03 series, Technical Manual

Page 1: ...5 Dragon Court Woburn MA 01801 USA Tel 1 781 933 7305 Fax 1 781 935 4529 www Lytron com KODIAK RECIRCULATING CHILLERS TECHNICAL MANUAL RC006 RC009 RC011 RC022 RC030 and RC045 G03 H03 and J03 Series Ma...

Page 2: ...Kodiak Recirculating Chiller Technical Manual THIS PAGE IS LEFT BLANK INTENTIONALLY...

Page 3: ...RAPHS 10 GENERAL INFORMATION 11 CONTROLLER DISPLAY PANEL FUNCTIONS 12 REAR PANEL COMPONENTS 13 OPTIONAL SYSTEM FEATURES 14 CONTROLLER OPTIONS 16 INSTALLATION REQUIREMENTS 17 INSTALLATION PROCEDURE 18...

Page 4: ...NED 36 SIDE VIEW 37 SIDE VIEW WITH HIGH PRESSURE CUTOUT 38 CHILLER DIMENSIONS FOR RC011 AND RC022 40 CHILLER DIMENSIONS FOR RC030 AND RC045 41 WIRING DIAGRAM 42 PLUMBING DIAGRAM 42 PLUMBING DIAGRAM 43...

Page 5: ...anual Manual 820 0109 Rev Y 07 08 10 3 Check Lytron s website www Lytron com for the most current technical information REVISION HISTORY REV ECN DATE REASON FOR CHANGE Y 17284 07 08 2010 Updated Decla...

Page 6: ...an RMA number Refer to the end of manual for the chiller warranty Units should be drained of all fluids and packaged in its original packaging Customer Service Support Lytron is committed to servicing...

Page 7: ...n should perform Service and repairs If the set point is 10 C 50 F or below a freezing point depressant such as ethylene glycol is required This unit is equipped with a low flow switch This feature wi...

Page 8: ...t the risk of electrical shock This label is mounted near of main voltages of the system External contacts have been installed Lets customer know element has been installed RS232 has been installed Id...

Page 9: ...sposed of or recycled with the requirements of local law The RoHS compliant label indicates that the product complies with the European union restriction of hazardous substances RoHS directive This la...

Page 10: ...mp DA CP 25 Centrifugal Pump EB FB 1 4 Hp Turbine Pump EC FB 1 6 Hp Turbine Pump Notes Water filter and DI cartridge not recommended with Centrifugal Turbine pumps Indicates high purity compatible pum...

Page 11: ...10 C to 35 C 50 F to 95 F 10 C to 35 C Coolant Temperature Range4 41 F to 95 F 5 C to 35 C 41 F to 95 F 5 C to 35 C 41 F to 95 F 5 C to 35 C 41 F to 95 F 5 C to 35 C 41 F to 95 F 5 C to 35 C 41 F to 9...

Page 12: ...heck Lytron s website www Lytron com for the most current technical information PERFORMANCE GRAPHS 1 1 Temperature represents output temperature of water assuming 20 C ambient air conditions Performan...

Page 13: ...vaporator The coolant also flows into the evaporator through passages separated by thin layers of metal from the refrigerant The refrigerant evaporates drawing heat from the coolant The refrigerant va...

Page 14: ...ESCRIPTION OF INDICATORS Temperature Set Point Displays coolant temperature or set point in C or F Pressure Display Displays outputs pump pressure in PSI bar digitally for a few seconds Cooling Indica...

Page 15: ...Check Lytron s website www Lytron com for the most current technical information REAR PANEL COMPONENTS Reference Spare Parts List in this manual POWER ENTRY FLUID OUT OF CHILLER CIRCUIT BREAKER REMOTE...

Page 16: ...plications with a maximum allowable pressure It can also be used where flow to the equipment being cooled needs to be shut off without stopping the chiller In this case the pressure relief valve will...

Page 17: ...he 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 Water Cooled Condenser RC011 R...

Page 18: ...rature Display 5 Low Flow Fault Chiller Shut Off STANDARD OPTIONS FOR CONTROLLER PACKAGE 2 1 Alarm Mute 2 Audible Alarm 3 Auto Restart 4 Calibration Offset 5 Deg C Deg F Toggle 6 Digital Pressure Sens...

Page 19: ...t 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 po...

Page 20: ...Plumbing To connect the fluid lines to the chiller and user equipment follow these steps 1 Remove the plastic caps covering the supply and return ports on the rear panel of the unit 2 Attach coolant l...

Page 21: ...pump is prevented by the presence of trapped air Without a way for the air to escape the fluid has no way of entering the pump housing The following are recommended procedures to prime a turbine or c...

Page 22: ...mpressor using the ON and OFF switch If your chiller is equipped with control package 2 or 3 the fault shut off may prevent the chiller from starting up If the chiller displays an alarm after pushing...

Page 23: ...cally in the event of a power failure Ot Over temperature Fault Indication option Indicator illuminates when the coolant temperature exceeds the over temperature set point The over temperature set poi...

Page 24: ...e UP and DOWN arrow keys for 3 seconds and release 2 Use the SET key to scroll to CAL 3 The display toggles between CAL and current offset setting 4 Use UP or DOWN arrows to change the calibration off...

Page 25: ...on When it is set to off the chiller acts as if it does not have the remote start feature By setting this feature to NC normally closed or run on closed the chiller will start when pins 1 and 2 on the...

Page 26: ...s no visible system leak then the loss may be due to equipment leakage elsewhere Pump Motor Some pumps may require lubrication If the pump needs lubrication lubricate annually with 20 30 drops of SAE...

Page 27: ...s inside the pump For pumps less than 2 5 gpm it is located in the pump housing For larger PD pumps it is installed in the hose between the pump and the tank Periodically inspect and clean the pump st...

Page 28: ...d Keep reservoir cap removed from reservoir until step 5 2 Using wet vac first vacuum the supply connection located at the rear of the chiller After all the fluid has been removed from the supply side...

Page 29: ...ant level There is a coolant level site tube on the front of the unit Coolant should be added as soon as this indicator approaches the half full mark Reducing the coolant volume may reduce the chiller...

Page 30: ...or code signifies an error in the controller software while the chiller is running Contact the Lytron Service Department to resolve this type of error Err 04 Low Flow Error This error code signifies a...

Page 31: ...Compressor has tripped its internal overload Let the unit cool The overload will reset itself normally in 30 minutes or less Excessive noise on startup Liquid refrigerant in the suction line to the c...

Page 32: ...has tripped Turn unit off Wait for overload to cool It will reset on its own in 30 minutes or less Leaks in external piping Repair leaks Pump motor shaft is bound Replace pump motor Low coolant flow...

Page 33: ...er 330 1139 06 330 1165 06 330 1172 06 13 Access Panel 330 0880 06 14 Side Panel 330 1138 06 330 1166 06 330 1173 06 15 Front Grille 340 0013 340 0015 340 0017 16 Casters with lock Casters without loc...

Page 34: ...230 V Motor 230 0214 1 3 Hp 115 230 V Motor 230 0215 2 1 2 Hp 115 230 V Motor 230 0203 1 20 Hp Centrifugal Pump 115 V 410 0196 1 20 Hp Centrifugal Pump 230 V 410 0197 1 4 Hp Centrifugal Pump 115 V 10...

Page 35: ...ual 820 0109 Rev Y 07 08 10 33 Check Lytron s website www Lytron com for the most current technical information FRONT VIEW Reference Spare Parts List in this manual ACCESS PANEL 13 UPPER FRONT 10 FRON...

Page 36: ...Technical Manual Manual 820 0109 Rev Y 07 08 10 34 Check Lytron s website www Lytron com for the most current technical information REAR VIEW WITH PANEL Reference Spare Parts List in this manual CIRC...

Page 37: ...0109 Rev Y 07 08 10 35 Check Lytron s website www Lytron com for the most current technical information TOP VIEW Reference Spare Parts List in this manual PUMP AND COMPRESSOR RELAY 4 TEMP SENSOR 7 MOT...

Page 38: ...anual 820 0109 Rev Y 07 08 10 36 Check Lytron s website www Lytron com for the most current technical information REAR VIEW OPENED Reference Spare Parts List in this manual FLOW SWITCH 26 HOT GAS BYPA...

Page 39: ...820 0109 Rev Y 07 08 10 37 Check Lytron s website www Lytron com for the most current technical information SIDE VIEW Reference Spare Parts List in this manual 23 CONDENSER COMPRESSOR 24 25 FLOW SWIT...

Page 40: ...ating Chiller Technical Manual Manual 820 0109 Rev Y 07 08 10 38 Check Lytron s website www Lytron com for the most current technical information SIDE VIEW WITH HIGH PRESSURE CUTOUT HIGH PRESSURE CUTO...

Page 41: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0109 Rev Y 07 08 10 39 Check Lytron s website www Lytron com for the most current technical information CHILLER DIMENSIONS FOR RC006 AND RC009...

Page 42: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0109 Rev Y 07 08 10 40 Check Lytron s website www Lytron com for the most current technical information CHILLER DIMENSIONS FOR RC011 AND RC022...

Page 43: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0109 Rev Y 07 08 10 41 Check Lytron s website www Lytron com for the most current technical information CHILLER DIMENSIONS FOR RC030 AND RC045...

Page 44: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0109 Rev Y 07 08 10 42 Check Lytron s website www Lytron com for the most current technical information WIRING DIAGRAM...

Page 45: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0109 Rev Y 07 08 10 43 Check Lytron s website www Lytron com for the most current technical information PLUMBING DIAGRAM...

Page 46: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0109 Rev Y 07 08 10 44 Check Lytron s website www Lytron com for the most current technical information REFRIGERATION DIAGRAM...

Page 47: ...nd of message delimiter Permitted message characters are in the range of 0x20 through 0x7F hexadecimal 1 4 Numeric Representation Hexadecimal numbers using ASCII characters 0 9 A F will represent all...

Page 48: ...he current setpoint temperature in a status string with the following form JS SetTemp M Where SetTempSetpoint Temperature Value 2 byte hex Cx100 J MAscii Linefeed and Carriage Return 1 6 5 Read User M...

Page 49: ...temperature Limit Note that it is the host s responsibility to determine if this option is active The Host command is of the form JY LowTempAlmLmt M Where LowTempAlmLmtLow Temp Limit Setpoint 2 byte...

Page 50: ...ial Authorization RMA number must be obtained from Lytron s service department which can be reached by calling 1 781 933 7305 and following the menu Prior to calling the system part number serial numb...

Page 51: ...ent for current rates in effect at the time All requests for On Site Services require a PO or credit card in the amount of 800 before services will be scheduled When using Lytron arranged on site serv...

Page 52: ...AR PURPOSE LYTRON S OBLIGATION UNDER THIS WARRANTY IS STRICTLY AND EXCLUSIVELY LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE COMPONENT PARTS AND LYTRON DOES NOT ASSUME OR AUTHORIZE ANYONE TO ASSUM...

Page 53: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0109 Rev Y 07 08 10 51 Check Lytron s website www Lytron com for the most current technical information DECLARATION OF CONFORMITY...