Kodiak G03 series User manual

© Lytron Inc., 2010
Lytron Inc., 55 Dragon Court, Woburn, MA 01801, USA
Tel: [phone] Fax: [phone]
www.Lytron.com
KODIAKRECIRCULATING CHILLERS
TECHNICAL MANUAL
RC006, RC009, RC011, RC022, RC030 and RC045
G03, H03 and J03 Series
Manual # 820-0109, Rev. Y, 07/23/10

Kodiak Recirculating Chiller Technical Manual
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Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 1 - Check Lytron’s website www.Lytron.com
for the most current technical information.
TABLE OF CONTENTS
TABLE OF CONTENTS.......................................................................................................................................................1
REVISION HISTORY...........................................................................................................................................................3
INTRODUCTION..................................................................................................................................................................4
SAFETY PRECAUTIONS....................................................................................................................................................5
LABELS AND SILKSCREEN MARKING.........................................................................................................................6
PART NUMBER DESCRIPTION .......................................................................................................................................8
SPECIFICATIONS................................................................................................................................................................9
PERFORMANCE GRAPHS...............................................................................................................................................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
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...................................................................................................................................................31
ACCESSORIES FOR THE KODIAK RECIRCULATING CHILLER.........................................................................32
FRONT VIEW......................................................................................................................................................................33

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 2 - Check Lytron’s website www.Lytron.com
for the most current technical information.
REAR VIEW (WITH PANEL)........................................................................................................................................... 34
TOP VIEW........................................................................................................................................................................... 35
REAR VIEW (OPENED).................................................................................................................................................... 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
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

Kodiak Recirculating Chiller Technical Manual
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 Declaration of Conformity and safety symbols.

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 4 - Check Lytron’s website www.Lytron.com
for the most current technical information.
INTRODUCTION
Receiving the New KodiakChiller
Inspect the new chiller immediately upon receiving it. If the unit shows shipping damage, contact the
transportation company and file a freight damage claim. Retain all cartons and packing material until the unit is
operated and found to be in good condition. The chiller has been fully tested at the Lytron factory with clean
water. Although the system has been drained, some residual fluid may remain. This will not hinder the
performance of the chiller.
About the Warranty
All units returned for warranty claims must have an RMA (Return Material Authorization) number on the outside
of the container. Call Lytron Customer Service at [phone] for 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 the customer, both during and after the sale. If you have any questions
concerning the operation of your unit, contact our Application Engineering Department at [phone].
To facilitate your call, please have the model number and serial number of the unit (located on the rear of the
chiller) for the Lytron Applications Engineer.
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
on page 29 before calling the service hotline.) Lytron service can be reached by dialing [phone].
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.
Kodiak is a registered trademark of Lytron, Inc.

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 5 - Check Lytron’s website www.Lytron.com
for the most current technical information.
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.
Warnings are posted throughout the manual. Read and follow these important instructions. Failure to observe
these instructions or use the chiller other than as specified may impair safety protection, void the warranty, and
can result in permanent damage to the unit, significant property damage, personal injury, and/or death.
Make sure you read, understand, and follow all instructions and safety precautions listed in this manual before
operating your unit. If you have any questions concerning the operation of your unit or the information in this
manual, please contact our Applications Engineering Department at [phone].
¾Always turn the unit "OFF" and disconnect the power cord from the power source before
performing any service, maintenance procedures or before moving the unit.
¾Do not operate equipment with damaged power cords.
¾A qualified technician should perform Service and repairs.
¾If 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 will shut the chiller down
during a low flow situation to prevent freezing.
¾DO NOT USE AUTOMOTIVE ANTI-FREEZE IN THE CHILLER. The rust inhibitors in the
automotive type may cause premature failure of the pump seals. Use of automotive anti-freeze
in a Lytron chiller will void the warranty.
¾Never place the unit in a location where excessive heat, moisture, or corrosive materials are
present.
¾The unit must be plugged into a properly grounded power source.
¾Do not connect the SUPPLY or RETURN fitting to your building water supply or any pressurized
source.
¾DO NOT USE OR MAINTAIN THE CHILLER OUTDOORS. These units were not designed to
withstand outdoor weather conditions.
¾Performance of installation, operation, or maintenance procedures other than those described
in this manual may result in a hazardous situation and may void the Lytron warranty.
¾Transport the unit with care. Sudden jolts or drops can damage the unit.
¾Drain the chiller of all water when transporting, shipping or leaving unused for long periods of
time. This will prevent freezing and algae build up while idle.
¾Observe all warning labels. Never remove warning labels.
¾Do not operate damaged or leaking equipment.
¾Do not operate the unit without fluid in the reservoir.

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 6 - Check Lytron’s website www.Lytron.com
for the most current technical information.
LABELS AND SILKSCREEN MARKING
EXTERNAL CONTACTS
.5 AMPS MAX
FILTER CARTRIDGE HAS
BEEN INSTALLED
RS-232
PUMP PRIMING VALVE
OPEN TO PRIME - CLOSE TO RUN
SUPPLY
RETURN
¾The 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.
¾This symbol on this label cautions the user against the risk
of electrical shock. This label is mounted near of main
voltages of the system.
¾External contacts have been installed.
¾Lets customer know element has been installed.
¾RS232 has been installed.
¾Identifies the location of the pump priming valve.
¾This silk-screen marking identifies the connection where
heated fluid is returned from the user’s machine.
¾This silk-screen marking identifies the connection where
chilled fluid is supplied to the user’s machine.
¾Positive earth (ground) terminal.
¾The markings on this label certifies that the equipment has
been certified to the UL standard 61010A-1 and
CAN/CSA STD C22.2 No. 1010.1 standards.
¾The symbol on this label identifies that the equipment has
been certified to regulations of the European Community.

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 7 - Check Lytron’s website www.Lytron.com
for the most current technical information.
¾The product ID label identifies the model number,
serial number, electrical information, pump type,
refrigerant type, charge, and date of manufacture of
the product.
¾The crossed out wheeled bin label requires that the
product be disposed of or recycled with the
requirements of local law.
¾The RoHS compliant label indicates that the product
complies with the European union restriction of
hazardous substances (RoHS) directive.
¾This label indicates that none of the six hazardous
substances are present in the product above the
maximum concentration values in its homogeneous
form per China RoHS.
¾This label indicates which of the six hazardous
substances are present in the product above the
maximum concentration values in its homogeneous
form and the environmental protection use period of
the product per China RoHS.

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 8 - Check Lytron’s website www.Lytron.com
for the most current technical information.
PART NUMBER DESCRIPTION
RC006 G03 BB 1 MXXX
Basic
Model No. Electrical Configurations Pump Options Controller Configuration Std. Modification
RC006 - 825 Watts
RC009 – 1,050 Watts
RC011 – 1,650 Watts
RC022 – 2,400 Watts
RC030 – 3,450 Watts
RC045 – 5,900 Watts
Note:
Cooling capacity and
pump flows are rated
at 60Hz. For 50Hz
power capacity is
reduced by 17%.
G03 = 115V~/1ph/60Hz
H03 = 230V~/1ph/50Hz
J03 = 230V~/1ph/60Hz
AA* †= CP-15
Centrifugal Pump
BB (CB†) = 1.3 gpm
Positive Displacement
Pump
BC (CC†) =1.8 gpm
Positive Displacement
Pump
BE (CE†) = 2.3 gpm
Positive Displacement
Pump
BG (CG†) = 4.3 gpm
Positive Displacement
Pump
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
pump.
CONTROLLER PACKAGE #1
1. Alarm Mute
2. Audible Alarm
3. Auto-Restart
4. Calibration Offset
5. Deg °C / Deg °F Toggle
6. Digital Temperature
Display
7. Low Flow Shut-Off Fault
CONTROLLER PACKAGE #2:
1. Alarm Mute
2. Audible Alarm
3. Auto-Restart
4. Calibration Offset
5. Deg °C / Deg °F Toggle
6. Digital Pressure Sensing &
Display
7. Digital Temperature
Display
8. Fault Shut-Off (toggle
on/off)
9. Low Flow Shut-Off Fault
10. Low Level Fault
11. Low Temp / High Temp
Fault
12. Relay Contacts
CONTROLLER PACKAGE #3:
Same as "PKG 2" above
with the addition of RS-232
communications.
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.