Lytron LCS20 Series User manual

Lytron Liquid Cooling System
Manual# 820-0166, Rev. J, 03/06/19
© Lytron Inc., 2010
Model: LCS20 Series
USER MANUAL
www.Lytron.com
Telephone: [phone], Fax: [phone]
55 DRAGON COURT
WOBURN, MA 01801

Liquid Cooling System LCS20 Series Technical Manual
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Liquid Cooling System LCS20 Series Technical Manual
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TABLE OF CONTENTS
TABLE OF CONTENTS ..................................................................................................................................................... 3
REVISION HISTORY.......................................................................................................................................................... 4
INTRODUCTION ................................................................................................................................................................ 5
SAFETY PRECAUTIONS .................................................................................................................................................. 6
LABEL AND SILKSCREEN MARKINGS (LOCATED IN THE BACK OF UNIT) ............................................................. 7
PART NUMBER DESCRIPTION ....................................................................................................................................... 9
INSTALLATION REQUIREMENTS ................................................................................................................................. 10
INSTALLATION PROCEDURE ....................................................................................................................................... 12
CONTROLLER................................................................................................................................................................. 13
CHANGING TEMPERATURE UNITS.............................................................................................................................. 21
STARTUP PROCEDURE & SYSTEM OPERATION....................................................................................................... 22
SYSTEM MAINTENANCE AND SERVICE ..................................................................................................................... 23
TROUBLE SHOOTING GUIDE........................................................................................................................................ 25
SPARE PARTS LIST ....................................................................................................................................................... 26
ELECTRICAL SCHEMATIC ............................................................................................................................................ 28
PLUMBING SCHEMATIC ................................................................................................................................................ 29
WARRANTY..................................................................................................................................................................... 30
DECLARATION OF CONFORMITY ................................................................................................................................ 32

Liquid Cooling System LCS20 Series Technical Manual
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REVISION HISTORY
REV
ECN
REASON FOR CHANGE
DATE
ORIGINATOR
F
17284
UPDATED DECLARATION OF CONFORMITY, SAFETY SYMBOLS,
AND NEW CONTROLLER INFORMATION.
07/08/10
G
18011
CHANGE REFERENCE FORM# ON BOTTOM OF SERVICE
POLICY AND ADD TO LYTRON WARRANTY.
01/10/12
NG
H
1023210
ADDED ENVIRONMENTAL SPECIFICATIONS AS PART OF 61010-1
3RD ADDITION CERTIFICATION. UPDATED DEC OF CONF.
01/11/16
AJL
J
201269
UPDATED DES
03/06/19
PDB

Liquid Cooling System LCS20 Series Technical Manual
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INTRODUCTION
Receiving Your Liquid Cooling System
Inspect your LCS (liquid cooling system) 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. Your LCS 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
Refer to the end of manual for the LCS standard 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. 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 LCS) for the Lytron Applications Engineer. For a detailed description
of Lytron’s LCS service policy, refer to the back of this manual.
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 LCS. (We recommend you review the troubleshooting guide
before calling our 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 LCS) of
the unit for the Lytron Service Technician. For a detailed description of Lytron’s LCS service policy,
refer to the back of this manual.

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SAFETY PRECAUTIONS
This system is designed to provide fluid cooling only as specified in this manual. If you use this system 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 LCS 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].
xDO NOT USE AUTOMOTIVE ANTI-FREEZE IN THE LCS. The rust inhibitors in the automotive
type may cause premature failure of the pump seals. Use of automotive anti-freeze in a
Lytron LCS will void the warranty.
xNever place the unit in a location where excessive heat, moisture, or corrosive materials are
present.
xThe unit must be plugged into a properly grounded power source.
xDo not connect the SUPPLY or RETURN fitting to your building water supply or any
pressurized source.
xDO NOT USE OR MAINTAIN THE LCS OUTDOORS. These units were not designed to
withstand outdoor weather conditions.
xPerformance 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.
xTransport the unit with care. Sudden jolts or drops can damage the unit.
xDrain the unit of all water when transporting, shipping, or leaving unused for long periods of
time. This will prevent freezing and algae build up while idle.
xObserve all warning labels. Never remove warning labels.
xDo not operate damaged or leaking equipment.
xDo not operate the unit without fluid in the reservoir.
xAlways turn the unit "OFF" and disconnect the power cord from the power source before
performing any service, maintenance procedures or before moving the unit.
xDo not operate equipment with damaged power cords.
xA qualified technician should perform Service and repairs.

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LABEL AND SILKSCREEN MARKINGS (Located in the back of unit)
RETURN
SUPPLY
CAUTION LABEL: The triangle symbol tells maintenance personnel
and users to consult the Technical Manual for more information. In this
example, the symbol calls attention to the High Voltage Warning in the
Control Box.
GROUND LABEL: This symbol appears on the unit next to a protective
earth ground terminal
CE LABEL: This symbol certifies that the Liquid Cooling System
conforms to the EMC Directive and all applicable directives at the time
of marking.
PRODUCT ID LABEL: Identifies the model number, serial number,
electrical information, and pump type.
SUPPLY LABEL: This label identifies the connection where
chilled fluid is supplied to the user’s machine.
RETURN LABEL: This label identifies the connection where
heated fluid is
supplied from the user’s machine.
FUNCTIONAL/EARTH LABEL: (ground) Terminal.

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FACILITY
WATEROUT
FACILITY
WATERIN
ATTENTION / WARNING LABEL
VOLTAGE LABEL: This symbol is to alert you of the presence
of dangerous voltage within the unit’s enclosure. The voltage
is of sufficient magnitude to constitute a risk of electrical
shock.
FACILITY WATER OUT LABEL: Discharge facility water
from LCS unit.
FACILITY WATER IN LABEL: Supply LCS unit with facility water
from LCS unit.
ETL LABEL: The marking 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.
CIRCUIT BREAKER LABEL: Located on the backside of chiller.
This label signifies that the 15A Circuit Breaker Switch must be in
the “ON” position to operate.
WEEE LABEL: 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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PART NUMBER DESCRIPTION
LCS20 G01 BB 1 MXXX
Basic Model No.
Electrical
Configurations
Pump Options
Controller Configuration
Std. Modification
LCS20
–20 kW
NOTE:
P
ump flows are
rated at 60Hz.
For
50Hz power
capacity is reduced
by 17%.
G01
=
100
-120V, 1Ph, 50/
60Hz
J01
=
200
-240V, 1Ph, 50
/60Hz
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*) = Turbine
Pump
* Indicates high purity
compatible pump.
† Water filter and DI
cartridge not
recommended with
Centrifugal and
Turbine pumps.
1= Temperature display,
temperature set
-
point,
over temp alarm light.
2= Same as “1” above
with the addition of :
xLow-
level alarm
light.
x
Low flow alarm
light.
xAnalog
temperature
output (0-5 V)
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 LCS product line.

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INSTALLATION REQUIREMENTS
Coolant Requirements
xLytron recommends using filtered clean water above 10oC/50oF as coolant.
xIf the set point is 10oC/50oF 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.
xDO NOT USE AUTOMOTIVE ANTI-FREEZE IN THE LCS. The rust inhibitors in
the automotive type may cause premature failure of the pump seals. Use of automotive anti-
freeze in a Lytron LCS will void the warranty.
xAvoid using water with a high mineral content.
xIf the coolant is exposed to sunlight add an algaecide to control organic growth in lines.
Environmental Requirements
Non-operating
xAmbient Temperature: –20º to 50ºC with a maximum positive/negative rate of change of 20ºC/hour.
xHumidity: Between 5% and 100%, non-condensing, with the maximum allowable positive/negative
rate of change of 30% per hour.
xAltitude: 30 m below sea level to 5000 m above sea level.
Operating
xAmbient Temperature: 10º- 35ºC, with a maximum positive/negative rate of change of 10ºC/hour.
xHumidity: Between 30% and 75%, non-condensing, with the maximum allowable positive/negative
rate of change of 5% per hour.
xAltitude: 30 m below sea level to 2500 m above sea level
Electrical Requirements
Refer to the Specification section and to the product ID label on the rear of the LCS for the specific
electrical requirements of your unit. The LCS power module is configured with a standard
international IEC320/C20 inlet. To safely operate the LCS, 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 LCS. All Kodiak chillers should use SJT 3 conductor 12 AWG minimum power cord.

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Selecting LCS Location
To minimize the heat gain and pressure drop through the connecting hoses, the LCS should be
located as close as possible to the heat load (user equipment). This is more important for units with
centrifugal pumps. Coolant lines are best run at or near the same level as the cooling system. Once
the chiller is in position lock the casters.
The top clearance must be at least 6" for removal of the cover and at least 6” around four sides for
removal of side panels and access of internal components.
Before moving the LCS cap all ports to prevent any coolant leakage. Unlock the casters and move
to new location. Once in the new location lock the casters.
Storing LCS
Do not operate or store chillers outside. These systems are not intended or outdoor
use.
To prevent freezing during storage drain water if the chiller is located in an area below
10qC (50qF).
If unit is to be out of use for more than 1 week, drain all liquid from chiller to prevent algae growth.

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INSTALLATION PROCEDURE
Selecting and Locating Hoses
xThe coolant ports are located on the rear of the system and are labeled as previously shown.
xTo 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.
xTo 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).
xFlexible tubing should be of heavy wall or reinforced construction. All tubing should be rated to
withstand 125 psig at 186oF (30oC). 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.
THE SUPPLY PORT:
Provides chilled coolant to the user’s equipment.
THE RETURN PORT:
Connects to the outlet of the user’s equipment.
*FACILITY WATER IN:
Supply LCS unit with Facilities water.
FACILITY WATER OUT:
Discharge Facility water from LCS unit.
*NOTE: To maintain a process water temperature of 120° F. (49 C), the facility water should have
a flow of 8.0 GPM minimum at a temperature of 80°. (27 C). Maximum facility water pressure
should be 100 PSI and no greater than 35 psid across LCS.
A pressure drop of greater than 35 psid across the LCS facility circuit could result in
premature valve wear and damage to 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 as you are 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.
In order to maintain process setpoint facility water must be started before the LCS is
turned on.

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CONTROLLER

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Watlow Website: For further technical information regarding Controller features and operations visit
www.watlow.com