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
{THIS PAGE IS LEFT BLANK INTENTIONALLY}

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
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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
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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
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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.

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 9 - Check Lytron’s website www.Lytron.com
for the most current technical information.
SPECIFICATIONS1
RC006 RC009 RC011 RC022 RC030 RC045
Thermal Capacity260Hz
50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz
Watts 825
685 1,050 875 1,650 1,400 2,400 2,150 3,450 2,950 5,900 4,950
BTU/hr 2,800
2,330 3,585 2,988 5,780 4,760 8,755 7,310 12,070 10,030 20,230 16,830
115V~ 60Hz 1ph G03 G03 G03 N/A N/A N/A
230V~ 50Hz 1ph H03 H03 H03 H03 H03 H03
230V~ 60Hz 1ph NA J03 J03 J03 J03 J03
Full Load Amps3
G03 9.9 A 12.2 A 14.3 A --- --- ---
J03 --- 5.8 A 7.4 A 10.0 A 14.5 A 19.6 A
H03 4.5 A 5.3 A 6.3 A 9.5 A 13.7 A 17.2 A
Compressor Size ¼ Hp 1/3 Hp ½ Hp ¾ Hp 1 Hp 1 ½ Hp
Refrigerant Type R134A R134A R134A R134A R134A R134A
Temperature
Stability ± 0.2°F
(0.1°C) ± 0.2°F (0.1°C) ± 0.2°F (0.1°C) ± 0.2°F (0.1°C) ± 0.2°F (0.1°C) ± 0.2°F (0.1°C)
Operating
Environment 50°F to 95°F
(10°C to 35°C) 50° F to 95°F (10°C to 35°C) 50°F to 95°F (10°C to 35°C) 50°F to 95°F (10°C to 35°C) 50°F to 95°F (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 95°F (5°C to 35°C)
Reservoir Capacity 1 gal (3.8 l) 1 gal (3.8 l) 2 gal (7.6 l) 2 gal (7.6 l) 6 gal (22.6 l) 6 gal (22.6 l)
Dimensions5
Width 12.5" (318) 12.5" (318) 14.8" (376) 14.8" (376) 21.4" (543) 21.4" (543)
Depth 19.0" (483) 19.0" (483) 24.5" (622) 24.5" (622) 27.8" (705) 27.8" (705)
Height 22.0" (559) 22.0" (559) 26.5" (673) 26.5" (673) 31.0" (787) 31.0" (787)
Connection ½” FNPT ½” FNPT ½” FNPT ½” FNPT ½” FNPT ½” FNPT
Weight 97 lbs (44 kg) 100 lbs (45 kg) 122 lbs (55 kg) 166 lbs (75 kg) 260 lbs (118 kg) 270 lbs (123 kg)
Process Coolant
Delivery Pressure Factory preset to 90 psig max (for PD and turbine pumps only)
1Specifications are subject to change.
2Capacity is for 20°C delivery water at a 20°C ambient.
3Full load amperage for air -cooled models with standard pumps without the optional heater. Standard pumps are the BB
for the RC006, RC009, RC011, RC022 and BG for the RC030 and RC045. Contact Lytron for current draw of other models.
4Chiller will shut down when coolant temperature reaches 10°C above the coolant temperature range.
5Dimensions do not include filters or external valves.

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 10 - Check Lytron’s website www.Lytron.com
for the most current technical information.
PERFORMANCE GRAPHS
1
1Temperature 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.

Kodiak Recirculating Chiller Technical Manual
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GENERAL INFORMATION
Chiller System Description
Your chiller consists of a refrigeration system, a coolant loop, associated controls and plumbing. The
pump draws coolant from the internal reservoir and pumps it out to cool the process equipment, and
then the coolant flows back to the chiller. The fluid then flows through the evaporator, where the heat is
removed, and then back to the reservoir.
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.
Refrigeration System and Hot Gas Bypass
The chiller uses a standard refrigeration system to keep the coolant at the process temperature set
point. The compressor compresses the refrigerant vapor. The vapor then passes through the
condenser where it is cooled and turns to a liquid. The refrigerant then passes through the evaporator.
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 vapor returns to
the compressor and continues the cycle.
Many refrigeration systems, such as those used in household refrigerators, control the temperature by
turning the compressor on and off. This is a simple, inexpensive method of controlling the cooling, but
its temperature control is not precise and the frequent on-off cycles causes wear on the compressor
motor.
Lytron’s recirculating chillers use a better method for controlling the cooling rate: a hot-gas bypass
system. This employs a liquid line solenoid valve and a hot-gas bypass valve to meter the refrigerant
flow through the evaporator when cooling is needed. When the coolant reaches its set point
temperature, the liquid line solenoid valve closes, causing the hot-gas bypass valve to open. The hot-
gas valve lets hot gas from the compressor discharge into the evaporator, adjusting the temperature in
the evaporator to maintain the correct coolant temperature. When refrigeration is needed the liquid line
solenoid valve opens, the hot-gas valve closes and the cycle starts again.
This hot gas bypass control method provides precise temperature control. It also minimizes wear on
the compressor motor, since the compressor runs continuously and does not experience the stress of
repeated cycling.

Kodiak Recirculating Chiller Technical Manual
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CONTROLLER DISPLAY PANEL FUNCTIONS
Controller Display
Key Operation
Turn on/off chiller
Displays Pressure briefly
“UP” + “DOWN” + Enter menu (press simultaneously and hold for 3 seconds and
release)
Push to display or change set point
“UP” arrow Increase set point temperature
“DOWN” arrow Decrease set point temperature
Alarm Sound disabled or Muted (alarm will stay muted until error
is corrected, then resets)
DESCRIPTION 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 Indicator Solenoid valve is open and chiller is cooling the process fluid when this light is
illuminated.
Low Flow Indicator Indicates that the minimum flow requirement of the chiller is not being satisfied.
Alarm Indicator Illuminates to indicate an alarm fault condition.
Low-Level Indicator Illuminates to indicate a low fluid level in the tank.
Over Temperature
Indicator Illuminates to indicate water temperature is above high temperature alarm set
point.
Low Temperature
Indicator Illuminates to indicate water temperature is below low temperature alarm set
point.

Kodiak Recirculating Chiller Technical Manual
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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 START &
CUSTOMER CONTACTS
RS232 FLUID IN
TO CHILLER
NOTCH
INDICATES
PIN 1
1- -
4
2- -
5

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 14 - Check Lytron’s website www.Lytron.com
for the most current technical information.
OPTIONAL SYSTEM FEATURES
Coolant Water Filter
The factory installed water filter removes particulate from the coolant water. The water filter is not recommended
with centrifugal pumps or turbine pumps. For replacement filters, call Lytron’s Customer Service at 781-933-
7300.
Deionization Package
The Deionization Package consists of a factory-installed deionization cartridge. The deionization cartridge
requires replacement only when the mixed bed is depleted. For replacement cartridges, Call Lytron’s Customer
Service at 781-933-7300. This package is offered for deionized water applications where the resistance of the
water does not exceed 1 Mega-ohm-cm. The deionization package is not recommended with centrifugal pumps.
External Customer Contacts
This option will send a signal indicating there is a problem with the chiller. It can be wired to open on fault or
close on fault. This connector is located on the rear left of the system. Pin 5 is the common, Pin 6 closes on
fault, and pin 4 opens on fault. The mating connector is Amp part number 350715-1, and the pins for the
connector are Amp part number 350547-1. These contacts are rated for 250 V, ½ amp maximum.
External Manually Adjustable Flow Valve
This option allows the flow rate to the equipment to be controlled with a globe valve. Opening the valve allows
the flow to bypass from the supply to the return. By adjusting the valve a precise flow rate can be set. To be
sure the process equipment is receiving the appropriate flow install a flow meter at the outlet from the process
equipment.
External Pressure Relief Valve
This option is for applications 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 open and allow the flow to bypass from the supply to the return. The standard valve has an adjustment
range from 50 psi to 100 psi.
Fault Chiller Shut-off
This option will shut the chiller off in the event that there is an alarm condition. It will turn off the power to the
pump and compressor and give an error signal on the front panel of the chiller. To reset the system after a fault
the main power must be turned off at the circuit breaker.
Heater Package RC011, RC022, RC030 and RC045
The heater package is for applications requiring coolant temperature well above ambient temperature. This
package is a single set point type. The heater is activated when the water temperature is 3F below set point.
The heater option is not intended to provide tight temperature control, but to bring coolant temperature up to an
application's requirement faster than the refrigeration cycle (hot gas bypass).
High Purity Plumbing
This option is intended for use with deionized water. Only stainless steel and/or plastic components and a
nickel-brazed heat exchanger come in contact with the coolant. This option must be specified before the chiller
is purchased. It cannot be upgraded in the field.
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. contacts are located on the rear left of the chiller shown previously. It is a six-pin connector with
pins 1 and 2 controlling R.S. The mating connector is an Amp 350715-1 plastic housing. The pins are Amp
350547-1. The controlling relay should have SPDT type contacts rated for low current less than or equal to
5VDC at 0.1 milliamp.

Kodiak Recirculating Chiller Technical Manual
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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.
Water Cooled Condenser RC011, RC022, RC030 and RC045
This feature replaces the standard condenser and fan with a water-cooled condenser. This requires cooling
water to be supplied to the chiller at 75F (25C). The facility water pressure must be less than 100 psi.
Minimum flow rates are as follows:
Model Flow Rate (min)
RC011 1.4 gpm
RC022 1.4 gpm
RC030 1.9 gpm
RC045 3.4 gpm

Kodiak Recirculating Chiller Technical Manual
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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. 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 Fault Chiller Shut-Off
10. Low Level Fault
11. Low Temp / High Temp Fault
12. Relay Contacts
STANDARD OPTIONS FOR CONTROLLER PACKAGE #3:
This option has the same features as Package 2 with the addition of:
RS-232 Serial Port Communications

Kodiak Recirculating Chiller Technical Manual
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for the most current technical information.
INSTALLATION REQUIREMENTS
Coolant Requirements
Lytron recommends using filtered clean water above 10°C/50°F as coolant.
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 will shut the chiller down during a low
flow situation to prevent freezing.
Do 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.
Avoid using water with a high mineral content.
If the coolant is exposed to sunlight add an algaecide to control organic growth in lines.
Electrical Requirements (for units without heater option)
Refer to the Specification section and to the product ID label on the rear of the chiller for the specific electrical
requirements of your unit. The chiller power module is configured with a standard international IEC320/C20
inlet. 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.
Selecting Chiller Location
Do not operate or store Kodiak chillers outside. These systems are not intended for outdoor
use.
To minimize the heat gain and pressure drop through the connecting hoses, the chiller unit should be located as
close as possible to the heat load (user equipment). This is more important for units with centrifugal pumps as
they are not capable of high head pressures. Coolant lines are best run at or near the same level as the cooling
system. Once the chiller is in position lock the casters.
Airflow is critical to optimize performance of the chiller. The front and one side or the back of the unit MUST be
kept clear and unobstructed. The remaining two sides or back must have minimum clearance of 18" (456 mm).
The top clearance must be at least 6" (152 mm). Ensure that the hot air exiting the chiller does not recirculate
into the inlet openings. The front of the unit must have a free supply of ambient-temperature air.
Before moving the chiller cap all ports to prevent any coolant leakage. Unlock the casters and move to new
location. Once in the new location lock the casters. To prevent freezing during storage drain water if the chiller
is located in an area below 10C (50F).

Kodiak Recirculating Chiller Technical Manual
Manual # 820-0109, Rev. Y, 07/08/10 - 18 - Check Lytron’s website www.Lytron.com
for the most current technical information.
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.
To minimize heat gain, all lines should be as short as possible. Keep them away from heat sources such as
radiators and hot water pipes. Lines that cannot be routed away from heat sources should be protected
with thermal insulation, preferably at least 1/2" (12.7mm) thick.
Flexible tubing should be of heavy wall or reinforced construction. All tubing should be rated to withstand
125 psig (9 bar) at 86°F (30°C). Make sure all tubing connections are secured and leak-tight. Also,
whenever possible use opaque lines to prevent algae growth during prolonged non-operating periods.
Connecting 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 lines to the supply and return ports on the rear panel. Fittings should either be brass,
stainless steel or nylon. Never use steel or cast iron fittings, as the corrosion will damage
the chiller. For chillers with de-ionization cartridges or high purity plumbing Lytron recommends the use of
either stainless steel or nylon fittings. The supply port provides chilled coolant to the user’s equipment. The
return port connects to the outlet of the user’s equipment.
3. Check that fittings are tight to prevent leaks.
4. Remove water filler cover on top of the unit to access the reservoir.
5. Fill the reservoir. Use the reservoir sight tube on the front of the unit to see the coolant level in the tank
during filling. Be sure to allow for the volume of coolant needed to fill the cooling lines between the chiller
and the equipment, if they were not filled with coolant before installation.
6. If the system is a water-cooled chiller, connect facility water to connections labeled "City Water In" and "City
Water Out". Minimum flow rate of facility water is shown on page 15. Facility water flow must be started
before chiller is turned on.