Koolance ALR-4500 User manual

Superior Liquid Cooling Systems
®
English v1.0
www.koolance.com
ISO
9001
Printed in Korea
ALR-4500
User’s Manual
ALR-4500
User’s Manual

1
User Manual 1
A newer version of this User Manual may exist. Please be sure to check our support page
for the latest version of this guide: www.koolance.com
GENERAL PRECAUTION
Please read this manual carefully before beginning the installation of your Koolance
system.
PROHIBITED USE
This product is designed, developed and manufactured as contemplated for general use,
including without limitation: general o󰀩ce use, personal use and household use, but is not
designed, developed and manufactured as contemplated for use accompanying fatal risks or
dangers that, unless extremely high safety is secured, could lead directly to death, personal
injury, severe physical damage or other loss, including without limitation: nuclear power core
control, airplane control, air tra󰀩c control, mass transport operation control, life support,
or weapon launching control. If these products are used in such hazardous environments,
Koolance Incorporated does not warrant them.
TRADEMARKS
The Koolance name and logo are trademarks or registered trademarks of Koolance, Inc.
Other company and product names used in this publication are for identication purposes
only and may be trademarks or registered trademarks of their respective companies.
COPYRIGHT
All rights reserved. Copyright (C) Koolance Incorporated.
!WARNING:Indicates a potentially hazardous situation which, if not avoided,
could result in personal injury or be life-threatening.
!CAUTION:Indicates a potentially hazardous situation which, if not avoided,
may result in damage to equipment or property.
PROHIBITED:Indicates a prohibited action.
ABOUT SIGNS
Throughout this document, critical information is highlighted in gray-colored boxes. The
following symbols are intended to help prevent any situation which may cause personal
injury and/or damage to equipment:

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2User Manual
Table of Contents
Product Diagram ............................................................................................. 3
Positioning the System ................................................................................... 4
Tube Fittings ................................................................................................... 4
Coolant Filling and Powering-On .................................................................... 5
Draining........................................................................................................... 6
Software Feature ............................................................................................ 6
Display Panel .................................................................................................. 7
Temp/Fan Set.................................................................................................. 8
Alarm Set ........................................................................................................ 9
Relay Set ........................................................................................................ 9
Pump Set ........................................................................................................ 9
Display Set.................................................................................................... 10
Troubleshooting ............................................................................................ 11
Limited Warranty ........................................................................................... 12
WARNING: The Koolance liquid coolant contains chemicals which may
be harmful or fatal if swallowed. KEEP THIS AND ALL DANGEROUS
CHEMICALS OUT OF THE REACH OF CHILDREN. Please refer to
the coolant MSDS available on our website: www.koolance.com
!
KOOLANCE CONTACT INFORMATION
Koolance Inc. (USA)
Address: 2840 W. Valley Hwy. N., Ste. 101, Auburn, WA 98001, USA
Telephone: [phone]
Technical Support: [email protected]
Product Diagram
Display Panel
Reservoir
Fill Port
Control
Buttons
Reservoir
Light Switch
Power Switch
Reservoir
Drain
USB Port
Trigger Relay
Terminals
Thermocouple
Terminals
Main Power
Liquid
Outlet/Inlet

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4User Manual 4
Positioning the System
This product must be operated in a valid upright orientation (shown below). Invalid
orientations can prevent the coolant pump from operating properly.
Coolant Filling and Powering-On
WARNING:Most coolants are electrically conductive. Use caution
when lling the system, and keep all liquids away from electronics and
power cables. Keep the primary AC power cable unplugged whenever
lling or draining coolant.
!
CAUTION:The cooling system’s pump can not be run dry for any
period of time. Do not power-on the unit without su󰀩cient liquid in
the reservoir. Dry-running (and thereby damaging the pump) is not
covered under the Koolance product warranty.
!
Cut tubing into two segments. You
will need to connect each to the rear
ttings.
Each tubing connection will use a threaded compression
ring or tube clamp to keep it secure. Be sure to thread
the compression ring or tube clamp onto the tubing
before attaching it.
Squeeze the tube while pushing it rmly over
the tting. Tubing should completely cover the
tting or barb. This step can be eased by rst
dipping the end of the tubing in water.
Tighten the connection by sliding the compression
nut down over the tting and screwing securely.
For barbed ttings, use pliers to move the clamp
into the proper position before releasing.
Tube ttings are purchased separately.
Threading for the tube ttings is tapered 1/4-inch
NPT. Plumber’s tape (PTFE) is required to seal
them properly.
Tube Fittings
After wrapping with tape, the inlet and
outlet fittings should be inserted by
hand, then nished with a wrench for
the last 1-2 rotations.
Once all devices (cold plates, ttings,
etc.) have been connected with tubing,
the system can be lled with coolant.
The ll port is located above the reservoir. With the ll
port oriented upright, remove the large reservoir cap
by hand or with a hex wrench.

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6User Manual
• On the main screen, hold ◙for 3 seconds to change display units between
°C/°F and LPM/GPM.
• You can exit any menu and return to the main screen by holding ◙for 2
seconds.
• To reset ALL settings to default, hold ▼ + ▲ for 3 seconds.
Main Menu
To enter the main menu, briey press ◙. The selected option will begin ashing.
Use ▼ and ▲ to navigate this menu.
TEMP/FAN SET: Temperature set-point adjustment
ALARM SET: Alarm settings
RELAY SET: Relay Trigger settings
PUMP SET: Pump speed settings
DISPLAY SET: LED display settings
When in the top menu, press ◙to enter one of the above categories. To exit from
here, press ◄.
Display Panel
The Koolance display panel allows control and monitoring of various aspects of
the cooling unit. 5 buttons are used, with directional arrows to navigate or change
settings, and a center button to select/exit.
Navigate Up,
Increase Setting
Navigate Down,
Decrease Setting
Navigate
Left
Navigate
Right
Enter/Exit
◙
▲
▼
Power on the cooling unit, and increase the pump speed to move coolant if
needed. When most of the air has been pushed out of the tubing, the liquid
noise will decrease. This process can take several minutes, depending
on the lling technique and components attached to the cooling system.
During this process, liquid components (or the cooling system itself) may need to
be tilted gently to assist with air evacuation. The reservoir level will decrease during
this procedure. Remove the ll port cap and add more liquid as needed.
Slowly ll the system with coolant. To
maintain the product warranty, use
only Koolance approved coolant.
Many alternative liquids and additives
can cause permanent damage to the
cooling unit (through chemical reaction,
corrosion, biological growth, high thermal
expansion, viscosity, etc.).
Replace the ll port on the reservoir (hand tightening is recommend-
ed). Do not overtighten the ll port.
Coolant will be lled to about 1/2-inch (13mm) from the top of the reservoir. Never
completely ll or “top-o󰀨” the reservoir. An air gap must always remain to ac-
commodate thermal expansion of the liquid.
Draining
There is a drain on the rear of the unit for emptying
or replacing the coolant. Before opening the drain
plug, remove the top coolant ll port to allow air into
the reservoir.
Software Feature
This product supports Koolance’s “System Monitor” application for adjusting and
logging cooling system values from a computer via the USB port. Visit www.kool-
ance.com/software to download the latest version of the program. Please consult
the application’s readme.txt for further details.
External Sensors
This unit has an integrated liquid temperature sensor in the
reservoir. It also provides terminals for connecting up to two
K-type thermocouples (not included) for external temperature
monitoring and set point options.

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8User Manual
ALARM SET
This menu a󰀨ects when the built-in audio alarm will sound. There are seven options
which are simultaneously active. Upon entering the alarm menu, the last edited line
will ash. Press ▼ or ▲ to change it. Press ◙to edit the value, and again to return
to the previous menu. To disable an alarm, increase or decrease its setting to “ -- ”.
LIQ TEMP: Liquid Temperature (Range: 0 to 99°C)
CH1 TEMP: Thermocouple #1, if attached (Range: 0 to 119°C)
CH2 TEMP: Thermocouple #2, if attached (Range: 0 to 119°C)
FAN: Fan Speed (Range: 100-10,000RPM)
PUMP: Pump Speed (Range: 100-10,000RPM)
FLOW: Coolant Flow Rate (Range: 0.1 to 20.0LPM)
LEVEL: Low Coolant Level in Reservoir (ON, or OFF to disable)
The regular audio alarm is a repeating beep.
▲
RELAY SET
Terminals are provided for a congurable relay. Wires can be
connected as normally-open (NO), or normally-closed (NC), labeled
near the terminals.
There are seven options which are simultaneously active. Upon
entering the relay menu, the last edited value will ash. Press ▼ or ▲ to adjust
this value. Press ◙to edit the value, and again to return to the previous menu. To
disable the relay, increase or decrease its setting to “ -- ”.
LIQ TEMP: Liquid Temperature (Range: 0 to 99°C)
CH1 TEMP: Thermocouple #1, if attached (Range: 0 to 119°C)
CH2 TEMP: Thermocouple #2, if attached (Range: 0 to 119°C)
FAN: Fan Speed (Range: 100-10,000RPM)
PUMP: Pump Speed (Range: 100-10,000RPM)
FLOW: Coolant Flow Rate (Range: 0.1 to 20.0LPM)
LEVEL: Low Coolant Level in Reservoir (ON, or OFF to disable)
PUMP SET
The pump speed can be manually set from 1 (lowest) to 10 (highest):
PUMP(1-10) 7LV : Pump Speed Level
The pump speed level will ash. Press ▼ or ▲ to adjust. Press ◙ to return to the
previous menu.
LIQ TEMP= 32C Maintain coolant coming from the system at 32°C
CH1 TEMP= 50C Maintain the rst thermocouple at 50°C, if attached
CH2 TEMP= -5C Maintain the second thermocouple at -5°C, if attached.
(This is not a sub-ambient system. Without external
assistance, this temperature may not be reached.)
FAN PWR= 45% Keep fans at 45% power, regardless of temperature.
Press ◙again to exit conguration of the sensor. Press ◄ to return to the previous
menu.
CAUTION: To avoid permanent damage to the pump and other
cooling system components, do not allow the liquid temperature
to exceed 60°C (140°F) by set-point or other methods. This is the
maximum temperature supported by the cooling system.
!
▲
▲
▲
TEMP/FAN SET
Under “TEMP/FAN SET”, you can select the active set-point temperature the
system will attempt to follow, or else operate the fans at a xed power level. There
are four options to select from. Press ▼ and ▲ to scroll among them:
LIQ TEMP: Liquid Temperature (Range: -30 to 90°C)
CH1 TEMP: Thermocouple #1, if attached (Range: -20 to 120°C)
CH2 TEMP: Thermocouple #2, if attached (Range: -20 to 120°C)
FAN PWR: Static fan power setting (Range: 0 to 100%)
The sensor currently displayed in this menu is what the system will follow.
Only one can be active. Press ◙ to adjust the target value using ▼ and ▲. Below
are some examples:
▲
▼

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10 User Manual
If “CYCLIC” is chosen from the DISPLAY SET menu, multiple values can be rotated
through the front display.
The rst line will ash. Use ▼ and ▲ to navigate to other lines. Press ◙to enable
or disable each value. This will remove the asterisk, thereby hiding that line from
being shown on the main screen:
*FAN SET : (Field varies) Shows current active set-point or fan power
*LIQ TEMP : Shows reservoir liquid temperature
CH1 TEMP : Shows rst external sensor temperature (if connected)
CH2 TEMP : Shows second external sensor temperature (if connected)
FAN : Shows radiator fan RPM
*PUMP : Shows pump impeller RPM
*FLOW : Shows liquid ow rate through the unit
Press ◄to return to the previous menu, or press ► to exit DISPLAY SET.
▲
▼
We hope your Koolance system will provide you with years of reliable cooling
performance. To help avoid unnecessary RMA issues, we have prepared this list
of possible operational problems, and their most common solutions.
1. After lling the reservoir with coolant and turning on the system, there are no
visible signs of liquid movement...
Check the ow meter value (see “DISPLAY SET”). If there is no detected ow
immediately after lling the reservoir, or the ow rate is very low or periodic,
this usually indicates the pump has not nished priming. Open the ll port on
top of the reservoir and temporarily set the pump speed to 10 (see “PUMP
SET”) to help push out the air.
If possible while the pump is running, gently tilt your cold plates or other
components connected to the system in various directions to assist with
bleeding air from the cooling loop. If it becomes necessary to signicantly tilt
the unit to assist with priming, close the ll port and power-o󰀨 the unit before
doing so.
2. The temperature alarm sounds and I’m not sure why...
The o󰀨ending temperature sensor and value will ash in the front display
whenever an alarm sounds. Check that your currently selected temperature
sensor and alarm are congured as desired (see “TEMP SET” and “ALARM
SET”). If you are certain the cooling system is working properly otherwise, try
resetting all system settings by holding ▼ + ▲ for 3 seconds.
3. My system appears to be leaking uid or water...
Check that all ttings are properly installed and tightened. This product uses
NPT 1/4in threaded ttings. Plumber’s tape is required to seal the ttings.
4. The front display is locked up or not responding.
Reset all system settings by holding ▼ + ▲ for 3 seconds. After a reset, all
conguration settings (temperature, alarm, fans, etc.) must be updated again.
5. The pump is not operating at lower power level settings.
Due to variations in pumps, the motor may not always operate at the lowest
speed settings. This is more likely to occur if the speed is increased from a very
low level rather than decreased from a higher level. The pump speed must be
kept on a level that allows the motor to operate continuously. Note that during
system power-up, the pump automatically throttles to maximum speed before
dropping to the user’s preset level (to help prevent stalling).
Troubleshooting
The rst line will ash. Press ▼ or ▲ to change what this line will display:
FAN SET : (Field varies) Shows current active set-point or fan power
LIQ TEMP : Shows reservoir liquid temperature
CH1 TEMP : Shows rst external sensor temperature (if connected)
CH2 TEMP : Shows second external sensor temperature (if connected)
FAN : Shows radiator fan RPM
PUMP : Shows pump impeller RPM
FLOW : Shows liquid ow rate through the unit
Press ◙to move to line 2, and similarly use ▼ or ▲ to choose what will be
displayed on the second line. Press ◙again to exit.
▲
▼
The rst option, “FIXED”, will ash. Press ◄ or ► to change between these
options. Press ◙ to congure one of the selections, or press ▲ to exit. If “FIXED”
is selected, two lines will be shown:
FAN SET 50% : First line display option
LIQ TEMP 30.5C : Second line display option
DISPLAY SET
The display settings congure which values you wish to appear on the front display
and how they are shown:
DISPLAY
FIXED CYCLIC : Show 2 xed values or cycle multiple values

12
Limited Warranty
Disclaimer
Koolance Incorporated (“Koolance”) warrants each new Koolance liquid-cooled
system (“the system”), against defects in materials or workmanship for a period of
one year from the date of purchase, and agrees to repair or replace any defective
Koolance system without charge. Shipping costs are non-refundable.
This warranty is non-transferable. All warranty claims must be accompanied by the original
proof of purchase.
THIS WARRANTY DOES NOT COVER DAMAGE RESULTING FROM ACCIDENT,
MISUSE OR ABUSE, LACK OF REASONABLE CARE, SHIPPING DAMAGE,
MODIFICATIONS, THE AFFIXING OF ANY ATTACHMENT NOT PROVIDED WITH
THE PRODUCT, LOSS OF PARTS, OR OPERATING COMPONENTS AT SPEEDS OR
FUNCTIONS OTHER THAN THOSE SPECIFIED BY THEIR MANUFACTURERS.
Use of unauthorized replacement parts or liquids will void this warranty. Koolance
Incorporated will not pay for warranty service performed by a non-authorized repair
or diagnostic service and will not reimburse the consumer for damage resulting from
warranty service performed by a non-authorized repair service. No responsibility is
assumed for any special incidental or consequential damages due to a defective Koolance
product.
In order to obtain warranty service, contact our RMA department for information. The
product must be shipped postage prepaid to an authorized Koolance service location. It
is suggested that, for your protection, you return shipments of product by insured mail,
insurance prepaid. Damage occurring during shipment is not covered by this warranty.
Shipping costs are non-refundable. No other warranty, written or oral, is authorized by
Koolance Incorporated.
IN NO EVENT SHALL KOOLANCE INCORPORATED OR ITS EMPLOYEES, AGENTS,
SUPPLIERS, MANUFACTURERS, OR CONTRACTORS BE LIABLE FOR ANY
DAMAGES OF ANY KIND OR CHARACTER, INCLUDING WITHOUT LIMITATION
ANY COMPENSATORY, INCIDENTAL, DIRECT, INDIRECT, SPECIAL, PUNITIVE, OR
CONSEQUENTIAL DAMAGES, LOSS OF USE, LOSS OF DATA, LOSS OF INCOME OR
PROFIT, LOSS OF OR DAMAGE TO PERSONS OR PROPERTY, CLAIMS OF THIRD
PARTIES, OR OTHER LOSSES OF ANY KIND OR CHARACTER, AND WHETHER
OR NOT THE POSSIBILITY OF SUCH LOSS OR DAMAGE HAS BEEN NOTIFIED TO
KOOLANCE INCORPORATED.