RECIRCULATING CHILLER

TECHNICAL MANUAL

MODEL# RC7024G5

Lytron, Inc. 55 Dragon Court, Woburn, MA 01801

Tel: 781-933-7300 Fax: 781-935-4529
www.Lytron.com

Serial Number:__________________________
© Lytron Inc., 2003

Manual # 820-0137 Rev. A, 9/10/03

 RC7024G5 TECHNICAL MANUAL

Table of Contents
INTRODUCTION .................................................................................................................................................... 3

Receiving your New Recirculating Chiller............................................................................................................................3

About the Warranty ..............................................................................................................................................................3

Customer Service Support .....................................................................................................................................................3

24 hrs. / 7 day service.............................................................................................................................................................3

SAFETY PRECAUTIONS ....................................................................................................................................... 4

LABELS AND SYMBOLS....................................................................................................................................... 5

GENERAL INFORMATION..................................................................................................................................... 6
Refrigeration Control ...........................................................................................................................................................6

INSTALLATION...................................................................................................................................................... 7
Quick Reference Start-Up Procedure ....................................................................................................................................7
Recording the Serial Number, Model Number and Features .................................................................................................8
Selecting Proper Location ....................................................................................................................................................8
Plumbing to Process Fluid....................................................................................................................................................8
Fluid....................................................................................................................................................................................9
Electrical Requirements .......................................................................................................................................................9

DIGITAL TEMPERATURE CONTROLLER OPERATION .................................................................................... 10

How to Set the Setpoint......................................................................................................................................................10
How to Change the Setpoint...............................................................................................................................................10

SYSTEM MAINTENANCE / SERVICE.................................................................................................................. 11

Weekly Inspections ............................................................................................................................................................11
Periodic Inspections ...........................................................................................................................................................11

TROUBLE SHOOTING ........................................................................................................................................ 13

WIRING DIAGRAM............................................................................................................................................... 15

PLUMBING FLOW DIAGRAM.............................................................................................................................. 16

REFRIGERATION SCHEMATIC........................................................................................................................... 17

SPARE PARTS / REPLACEMENT PARTS .......................................................................................................... 18

LYTRON RECIRCULATING CHILLER STANDARD WARRANTY ....................................................................... 19

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 RC7024G5 TECHNICAL MANUAL

Introduction

Receiving your New Recirculating Chiller

Inspect your 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. Your 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 (Returned Material Authorization) number
on the outside of the container. Call Lytron Customer Service at (781) 933-7300 for an RMA
number. Refer to the end of manual for the chiller warranty.

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
(781) 933-7300. 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.

24 hrs. / 7 day service

Lytron has a 24 hour a day, 7 day service hotline to help you with questions on the startup and
operation of your Kodiak recirculating chiller. (We recommend you review the troubleshooting
guide on page before calling our service hotline.) Lytron service can be reached by dialing (781)
933-7305. 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.

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Safety Precautions

General

This system is designed to provide fluid cooling only as specified in this manual. If used in a manner
other than as specified, the safety protection of the system may be impaired. Warnings are posted
throughout the manual. These warnings are printed in bold type. Read and follow these important
instructions. Failure to observe these instructions or use other than specified may impair safety
protection and can result in permanent damage to the unit, property damage, or personal injury or
death.

Make sure you read and understand 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 Customer Support Department (see After-Sale
Support).

• Never place the unit in a location above 35°C, 80% RH, or where corrosive materials are
present.
• It is the user’s responsibility to assure that a ground connection is provided.
• Never connect the SUPPLY or RETURN fitting to your building water supply or any
pressurized source.
• Performing installation, operation, or maintenance procedures other than those described in
this manual may result in a hazardous situation and may void the manufacturer’s warranty.
• Transport the unit with care. Sudden jolts or drops can damage the system.
• Observe all warning labels. Never remove warning labels.
• Never operate damaged or leaking equipment.
• Never operate the unit without water in the reservoir.
• Always turn the unit off and disconnect the power cord from the power source before
performing service, maintenance, or moving the unit.
• Never operate equipment with a damaged power cord.
• A qualified service technician must perform all repairs.
• DO NOT USE AUTOMOTIVE ANTI-FREEEZE IN THE CHILLER. The rust inhibitors
will cause premature failure of the pump seals. Use of automotive anti-freeze in a Lytron
chiller will void the warranty of the pump.

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Labels and Symbols

RETURN This symbol designates the connection port where heated fluid returns to the chiller
from the customers machine.

SUPPLY This symbol designates the connection port where chilled fluid is supplied to the
customer’s chiller.

This label is placed on the chiller to identify the model number, serial
number, volts, amps, Hz, phase, pump type, refrigerant, and charge.

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 RC7024G5 TECHNICAL MANUAL

General Information

Chiller System Description

Turning the system switch to the “ON” position energizes the pump motor and system control
circuit. The pump draws water from the internal reservoir, pumps it through the process fluid loop
(removing heat), and returns it through the refrigeration system evaporator to the reservoir tank.

Process Fluid (flow control)

The RC models are designed to operate with continuous process fluid flow through a closed loop.
This loop contains the system pump, temperature sensor, flow switch, pressure relief valve, reservoir,
internal and external plumbing lines and the heat source. The external plumbing and the heat source
are provided by the end user and are generally unique to the user’s process and/or location.

Refrigeration Control

The RC models maintain process temperature by opening and closing a solenoid valve in the
refrigeration liquid line. When this valve is closed the hot gas bypass valve opens and allows the
refrigerant to bypass the condenser and enter the evaporator directly.

Hot Gas Bypass

Starting and stopping can shorten a compressor’s life much faster than steady running. For long life,
our chillers use a refrigerant hot-gas bypass system. This eliminates the need to cycle the compressor
on and off.

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 RC7024G5 TECHNICAL MANUAL

Installation

Quick Reference Start-Up Procedure

1) Record Model Number and Serial Number of the Chiller unit on the front cover of this manual.

2) Airflow is critical for proper performance of the RC units. The front of the unit should be kept
unobstructed and the two sides and rear should have a minimum of 30” around for air circulation.
More clearance may be necessary for ambient temperatures above 25°C.

3) Remove plastic caps from the end of the supply and return hoses. Attach hoses to system.

4) Using a screwdriver remove the access panel on top of the chiller unit and fill reservoir tank with
clean water. Continue to add water until the system is filled within 2” from the top and the
reservoir remains at a constant level.

5) Trained personnel must perform all electrical wiring only. Open electrical access panel on rear of
chiller. Insert power cord though strain relief located on the electrical power bracket. Attach
white and black wire to the terminal strip. Attach ground wire to the ground stud located on the
base. Close access panel.

6) Turn on power to chiller. Turn on circuit breaker. Check all external fittings and hoses for fluid
leaks. If a leak exists, turn chiller off and take necessary action to repair the leak.

7) The chiller is equipped with a low flow shut off. In a low flow situation the compressor and fan
will shut off.

IMPORTANT
Do not operate chiller until all leaks have been repaired.

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Recording the Serial Number, Model Number and Features

Record the serial number and the date purchased on the front cover of this manual. This information
will be required when contacting Lytron for technical service. The serial number is located on the
rear panel of the chiller.

Selecting Proper Location

Locate the chiller in an area with 30” minimum clearance around sides and rear of the unit for air
circulation and ventilation. More clearance may be necessary for ambient temperatures above 25°C.
The front must be kept unobstructed.

Plumbing to Process Fluid

The process fluid connections ports are located on the rear of the system and are labeled inlet and
outlet. Connect the supply port to the input side of the heat load and the return port to the output of
the heat load. The chiller process fluid supply and return connections are standard ½” I.D. tubing.

All lines should be routed away from sources of heat such as radiators, hot water pipes, etc. and
should be as short as possible. Lines that cannot be routed away from heat sources should be
protected with insulation.

CAUTION
Never connect the SUPPLY or RETURN fitting to your
building water supply or any pressurized source.

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 RC7024G5 TECHNICAL MANUAL

Fluid

Lytron recommends using clean water in the chiller unit. Positive displacement pumps are
susceptible to damage from abrasive materials in the process fluid.

• Avoid using local water with high mineral content.

• This unit is not compatible with deionized water. It should be filled with clean tap water.
• DO NOT USE AUTOMOTIVE ANTI-FREEEZE IN THE CHILLER. The rust inhibitors
in the automotive type will cause premature failure of the pump seals. Use of automotive
anti-freeze in a Lytron chiller will void the warranty of the pump, and other components.
• Ethylene glycol may be added to the water. This unit is set to 40 degrees F, and may
experience intermittent freezing under no load conditions. A mixture of 10% ethylene
glycol will prevent this. This unit is equipped with a low flow switch. In the event that the
evaporator begins to freeze, the low flow switch will shut off the compressor. This will
protect the evaporator from freezing completely and cracking.
Allowance should be made for the internal volume of cooling lines between the chiller and the
equipment. Using a screwdriver to remove the access panel on the top of the chiller can access the
reservoir. Fill the tank within 2 inches of the top and check level after operating for a short period of
time. It may be necessary to add fluid if the level has dropped substantially.

IMPORTANT
If the fluid is exposed to sunlight, add an algaecide to the fluid to control organic growth in lines.

Electrical Requirements

This system requires a 208/230 V 60 Hz 1 phase power supply or a 200 V 50 Hz 1 phase power
supply.

• It is the user’s responsibility to ensure a ground connection is provided through the use of
a properly grounded power supply.

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Digital Temperature Controller Operation

Operating Instructions for the Digital Temperature Controller

How to Set the Setpoint

1. Push and immediately release the SET key: the display will show the Set point value.
2. Push and immediately release the SET key or wait for 5 seconds to display the probe value again.

How to Change the Setpoint

1. Push the SET key for more than 2 seconds to change the Set point value.
2. The value of the set point will be displayed and the LED * starts blinking.
3. To change the Set value push the ▲ or ▼ arrows.
4. To memorize the new set point value push the SET key again or wait 15 seconds.

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System Maintenance / Service

The RC unit has been designed to require minimal maintenance after the unit has been installed.

Unique operating conditions of each installation will influence the frequency of system inspections and/or
scheduled maintenance. Suggested guidelines are as follows:

Weekly Inspections

Noise Level

Any abnormal sound or substantial increase in noise level since the last weekly inspection may
indicate an impending problem that should be corrected.

Leakage

If there is liquid on the floor or leaking out of the system there could be a leak. Open up the chiller
and locate the source of the water. All of the lines are insulated, so there should be no condensation
inside the chiller.

Fluid Level

Any significant drop in the coolant level since the previous weekly check should be investigated
further. If there is no visual system leak, then the loss may be due to leakage elsewhere in the
equipment.

Periodic Inspections

Reservoir

Periodically inspect the fluid inside the reservoir. The fluid should be clean and free of algae growth.
If cleaning is necessary, flush the reservoir with a cleaning fluid compatible with the circulating
system and the cooling fluid. It is important to flush, drain and refill every 6 months or each time the
water filter is changed.

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Algae

To restrict growth of algae in the reservoir, it is recommended that the reservoir cover be kept in
place and that all circulation lines be opaque to ultraviolet light. This will reduce growth of algae. If
algae continues to be a problem add an algaecide to the water.

Air Filter

It is recommended that a visual inspection of the filter fins be made monthly after initial installation.
After several months, the frequency of replacement should be established. For proper operation, the
unit needs to circulate substantial amounts of air. A build up of dust or debris on the air filter will
lead to a loss of cooling capacity. The frequency of filter replacement depends on the operating
environment.

Fan Assembly

The fan assembly requires no maintenance.

Pump

The pump requires no maintenance.

Pump Motor Lubrication

After 3 years of normal use or 1 year of heavy duty service add oil annually. Use electric motor oil
or SAE 10 oil.

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Trouble Shooting
Problem Possible Cause
Unit does not start
No power to the unit.
Circuit breaker "off" or tripped.
Low Voltage.
Unit does not cool Cooling load exceeds cooling
capacity.
Condenser coil filter fouled with
dust or debris.
Compressor has tripped its internal
overload.
Air temperature is too high.
Excessive noise on Liquid refrigerant in the suction
startup line to the compressor.
Low voltage or wrong voltage to
unit.
Noisy compressor Unit stored in cool environment for
a long period may have collected
liquid refrigerant in the
compressor.
Compressor is worn out.
Leaking pump Pump shaft seal damage is worn.
Fluid is incompatible with pump
seals.
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RC7024G5 TECHNICAL MANUAL
Recommended Remedy
Make sure the unit is plugged in.
Verify power to the unit.
Turn circuit breaker to the "ON"
( I ) position.
Have a qualified electrician check
the electrical service to the unit.
Reduce the cooling load on the
unit.
Remove the chiller cover. Replace
air filter with new, clean filter.
Let the unit cool, the overload will
reset itself, normally 15 minutes or
less.
Chiller cannot operate with
entering air above 95 degrees F.
Move chiller to different area.
This is momentary and should not
recur.
Verify power source supply
voltage. Measure supply current
while running. Compare to
nameplate values.
This is momentary and should not
recur.
Replace compressor - Call Lytron
System Service Department.
Replace pump.
Drain fluid immediately and replace
with water.
 RC7024G5 TECHNICAL MANUAL

Problem Possible Cause Recommended Remedy

Improper voltage to the pump Verify and correct the voltage to

PUMP MOTOR motor. the motor.
OVERHEATS
Shut down unit, clear obstruction,
Obstruction in pump head. and restart unit. Check lines for
restrictions.
Low coolant flow Check for leaks, fix leaks, and fill
Low coolant level in the reservoir.
reservoir.
Pressure relief on the pump is set Adjust the pressure relief to 60
too low. psig.
Restriction in coolant lines external Eliminate restrictions in the coolant
to the chiller. lines.
Shut down unit. Allow evaporator
to thaw our. Restart chiller.
Frozen evaporator.
Check chiller set point is at least 40
degrees F.
Pump suction strainer fouled or Remove and clean strainer, then
clogged. reinstall.
Turn unit off. Wait for overload to
Pump overload has tripped. cool. It will reset on its own in 15
minutes or less.
Pump motor shaft is bound. Replace pump or clear obstruction.
Chiller shuts down
Damaged pump. Replace pump.
during operation
Low flow switch tripped. Turn unit off. Clear obstruction.

Service Assistance

Technical service is available for all Lytron chillers, 24 hours per day/7 days per week, if your unit
fails to operate properly. Contact our Service Department for assistance at (781) 933-7300.

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Wiring Diagram

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Plumbing Flow Diagram

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Refrigeration Schematic

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Spare Parts / Replacement Parts

for RC7024G5 Only

DESCRIPTION OF PART LYTRON P/N

Air Filter 330-0683
Caster 531-0022
Flow Switch 230-0751
Level Switch 250-0124
Pressure Relief Valve 450-0027
Pump/Motor 410-0229
Temperature Sensor 230-0569

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Lytron Recirculating Chiller Standard Warranty

Lytron agrees that the apparatus manufactured by it will be free from defects in materials and workmanship for the warranty
period under normal use and service and when properly installed. The warranty period for recirculating chillers is two years
from date of shipment of such apparatus to the original purchaser, maintenance items excluded, and one year from date of
shipment of such apparatus to the original purchaser for all other products Lytron sells. Lytron’s obligation under this
agreement is limited solely to repair or replacement, at its option, at its factories, of any part or parts thereof, returned to Lytron
with transportation charges prepaid, which examination shall disclose to Lytron’s satisfaction to have been defective. THE
FOREGOING EXPRESS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
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 ASSUME FOR IT ANY OTHER OBLIGATION. LYTRON ASSUMES NO RESPONSIBILITY
FOR INCIDENTAL, CONSEQUENTIAL, OR OTHER DAMAGES INCLUDING, BUT NOT LIMITED TO LOSS OR
DAMAGE TO PROPERTY, LOSS OF PROFITS OR REVENUE, LOSS OF THE UNIT, LOSS OF TIME, OR
INCONVENIENCE. Lytron’s liability does not include any labor charges for replacement of parts, adjustments, repairs, or any
other work done outside its factories and its liability does not include any resulting damage to persons, property, equipment,
goods or merchandise arising out of any defect in or failure of its apparatus. Lytron’s obligation to repair or replace shall not
apply to any apparatus which shall have been repaired or altered outside of its factory in any way, or which has been subject to
negligence, to misuse, or to pressures in excess of stated limits. On parts not of Lytron’s manufacture, such as motors, controls,
etc., Lytron extends only those warranties given to Lytron, Inc. to the extent Lytron can do so. Lytron’s agreement hereunder
runs only to the immediate purchaser from Lytron, Inc. and does not extend, expressly or by implication, to any other person.

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