Boyd AAVID Kodiak H02 Series Technical Manual Download Page 1 | Manualshive

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AAVID,

THERMAL

DIVISION

OF

BOYD

CORPORATION

SERVICE

ADDRESS:

9A

FORBES

ROAD

WOBURN,

MA

01801

www.boydcorp.com

Service

Phone:

+1

‐

781

‐

933

‐

7300

TECHNICAL MANUAL

KODIAK

RECIRCULATING

CHILLERS

MODELS

RC006,

RC011,

RC022,

RC030

AND

RC045

SERIES

G02/H02/J02

One

Company,

Many

Solutions

Manual# 820-0043 Rev. N, 11/06/2019

©

Boyd Corporation 2019

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Summary of Contents for AAVID Kodiak H02 Series

Page 1: ... FORBES ROAD WOBURN MA 01801 www boydcorp com Service Phone 1 781 933 7300 TECHNICAL MANUAL KODIAK RECIRCULATING CHILLERS MODELS RC006 RC011 RC022 RC030 AND RC045 SERIES G02 H02 J02 One Company Many Solutions Manual 820 0043 Rev N 11 06 2019 Boyd Corporation 2019 ...

Page 2: ...INDICATORS 11 OPTIONAL SYSTEM FEATURES 13 DEIONIZATION PACKAGE 13 COOLANT WATER FILTER 13 HEATER PACKAGE RC011 RC022 RC030 RC045 13 HIGH PURITY PLUMBING 13 EXTERNAL MANUALLY ADJUSTABLE FLOW VALVE 13 EXTERNAL PRESSURE RELIEF VALVE 13 AUTO TANK REFILL RC011 RC022 RC030 AND RC045 14 WATER COOLED CONDENSER RC022 RC030 AND RC045 14 CONTROLLER OPTIONS 15 BASIC CONTROLLER PACKAGE 1 STANDARD WITH ALL UNIT...

Page 3: ...NG SPECIFICATIONS RC006 32 DRAWING SPECIFICATIONS RC011 022 33 DRAWING SPECIFICATIONS RC030 RC045 34 WIRING DIAGRAM RC006G02 35 WIRING DIAGRAM RC011G02 36 WIRING DIAGRAM RC011H02 J02 37 WIRING DIAGRAM RC022H02 J02 38 WIRING DIAGRAM RC030H02 J02 RC045H02 J02 39 PLUMBING DIAGRAM 40 REFRIGERATION DIAGRAM 41 BOYD KODIAKTM CHILLER CONTROL 42 HOST INTERFACE DATA LINK 42 BOYD RECIRCULATING CHILLER SERVIC...

Page 4: ...781 933 7300 for an RMA number Refer to the end of manual for the chiller warranty Customer Service Support Boyd 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...

Page 5: ...w flow switch This feature will shut the chiller down during a low flow situation to prevent freezing 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 Boyd chiller will void the warranty Never place the unit in a location where excessive heat moisture or corrosive materials...

Page 6: ...d to the user s machine This symbol certifies that the chiller 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 volts amps Hz phase pump type refrigerant and charge The Protective Earth ground Terminal RETURN The triangle symbol tells maintenance personnel and users to consult the pr...

Page 7: ...itive Displacement Pump DA CP 25 Centrifugal Pump EB TB 2 Turbine Pump Water filter and DI cartridge not recommended with Centrifugal Turbine pumps 1 Temperature control calibration offset pressure indication low flow shut off 2 Temperature control calibration offset pressure indication low flow shut off a Low level indication b Low temperature indication c High temperature indication d Chiller fa...

Page 8: ...e R134A Temperature Stability 0 1 C Operating Environment 15 to 40 C 59 to 92 F 80 R H consult factory for environments below 15 C 59 F Coolant Temperature Range 40 F 95 F 5 C 35 C Reservoir Capacity Gallons Liter 1 3 8 2 7 6 2 7 6 6 22 6 6 22 6 Dimension in mm 3 Width in mm Depth in mm Height in mm 12 5 318 19 0 483 22 0 559 14 8 376 24 5 622 26 5 673 14 8 376 24 5 622 26 5 673 21 4 543 27 8 705 ...

Page 9: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 8 Performance Curves RC006 011 022 030 045 ...

Page 10: ...tings 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 and or location CAUTION Do not put valves in the system that can stop flow while the chiller is operating Refrigeration System and Hot Gas Bypass The chiller uses a standard refrigeration system to keep the coolant at the process temperature set poin...

Page 11: ... and a hot gas bypass valve to meter the refrigerant flow through the evaporator when refrigeration is needed When the coolant reaches its set point temperature the liquid line solenoid valve closes causing the hot gas valve to open The hot gas valve lets hot gas from the compressor discharge into the evaporator inlet adjusting the temperature in the evaporator to maintain the correct coolant temp...

Page 12: ...e DOWN arrow Decrease set point temperature F C Toggles between F and C Description of Indicators Pressure indicating bar Displays output pump pressure in psi bar 2 psi segment 0 14 bar segment Temperature set point Displays coolant temperature or set point in C or F Temperature set point C or F Over temperature optional Cooling on off indication Low temperature optional International fault symbol...

Page 13: ...e Low flow indicator Illuminates to indicate a low flow condition The chiller will also shut down during this condition Controller package II and III Alarm indicator Illuminates to indicate an alarm fault condition Low level indicator Illuminates to indicate a low fluid level condition Over temperature indicator Illuminates to indicate an over temperature condition Low temperature indicator Illumi...

Page 14: ...This package is a single set point type The heater is activated when the water temperature is 3 F below setpoint NOTE The heater option is not intended to provide tight temperature control but to bring coolant temperature up to an application s requirement WARNING If your unit was not built with the heater package do not attempt to retrofit it If you do severe damage will occur to the unit persona...

Page 15: ...oir This feature requires a city water connection or equivalent pressurized coolant supply Water Cooled Condenser RC022 RC030 and RC045 This feature replaces the standard condenser and fan with a water cooled condenser This requires facility cooling water to be supplied to the chiller at 75 F 25 C Minimum flow rates are as follows Model Flow Rate min RC022 1 4 gpm RC030 1 9 gpm RC045 3 4 gpm ...

Page 16: ... 4 C to 4 C 7 F to 7 F with 0 the midpoint Low flow shut off Auto Restart Package 2 option Has the same function as the basic controller and includes the following Low level indication Low temperature indication High temperature indication Audible alarm toggle on off Fault chiller shutoff toggle on off External normally closed contacts Open under fault 0 5 amp Maximum Package 3 option Has all the ...

Page 17: ...al requirements of your unit The chiller power module is configured with a standard international IEC320 C20 inlet To safely operate the chiller use a 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 CSJT 3 conductor 12 awg minimum power cord WARNING It is the user s res...

Page 18: ...l 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 Flexible tubing should be of heavy wall or reinforced construction All tubing should be rated to withstand 125 psig at 186o F 30o C Make sure all tubing connections...

Page 19: ...the cooling lines between the chiller and the equipment if they were not filled with coolant before installation 6 Centrifugal Pumps must be primed before operation To prime pumps disconnect supply line from rear of chiller allow air to vent and out of pump head and reconnect line For Water Cooled Chillers 7 Connect facility water to connections labeled City Water In and City Water Out Minimum flo...

Page 20: ... on the chiller After the chiller is operating and the coolant reaches its setpoint temperature you can enable the fault shutoff 2 Set the temperature setpoint using the controls on the keypad display as follows Press the SET key once to display the current coolant temperature set point Press the UP or DOWN arrow key until the desired coolant temperature setpoint appears on the LED display Press t...

Page 21: ...e of the coolant or the current temperature with an offset applied Changing temperature scales Press the F C key to toggle between F and C Programming Chiller Functions Entering menu Press and hold both the UP and DOWN arrow keys for 3 seconds and release Selecting and setting features 1 1 Use the SET key to scroll through the menu choices 2 When feature is displayed press the UP or DOWN arrow key...

Page 22: ...e falls below the low temperature setpoint The over temperature point must be at least 3 C 6 F below the coolant set point AL Audible alarm option When this is enabled an audible alarm sounds when any fault occurs FS Fault chiller shutoff option When enabled this turns off the chiller when any fault occurs rS Remote Start option Allows the chiller to be started and stopped with a dry contact This ...

Page 23: ... UP or DOWN arrows to change the over temperature setpoint which must be at least 3 C 6 F above the coolant set point temperature 4 Press SET to accept the setting on the display and continue to the next feature Lt Low temperature indication option 1 To enter the menu press and hold both the UP and DOWN arrow keys for 3 seconds 2 Use the SET key to scroll to Lt 3 The display toggles between Lt and...

Page 24: ...osed The electrical connector on the rear is an Amp Mate N Lok connector part number 1 480705 0 Pins 1 and 2 are for the External Contact Feature see page 15 of the manual and pins 4 and 5 are for the Remote Start Feature The mating connecting is Amp part number 1 480704 0 The mating part should use Amp pins for Mate N Lok connector such as Amp part number 350552 1 This chiller was shipped with re...

Page 25: ...olant blockage problem Investigate the cause and perform the necessary service Refer to the troubleshooting section that starts on page Error Bookmark not defined in this manual Leakage If you notice coolant on the floor near the chiller or dripping from the chiller enclosure turn off the chiller Disconnect power Find and repair any leaks immediately Coolant Level Any significant drop in the coola...

Page 26: ...ation Package The cartridge life is a function of the user s application Check the water resistivity weekly and change the cartridge as required For replacement filters contact Boyd s Customer Service at 781 933 7305 Control Box Fuse Replacement This fuse is an inline fuse internal to the control box and should only be replaced by a qualified technician To replace the fuse remove the top and side ...

Page 27: ...n water 2 Run the unit with the clean water 3 Drain the unit again 4 Replace all filters 5 Refill unit with either water or a water and freezing point depressant Pump Motor Lubrication Positive displacement pump motors use sleeve type bearings with large lubricant reservoirs Oiling instructions are posted on each motor In the absence of instructions add approximately 30 to 35 drops of SAE 20 non d...

Page 28: ...lt shutoff Start unit Enable shutoff after it is running if desired Units with controller package II and III only Low flow shut off may not allow the chiller to start Low Flow activated Fill external line prior to start up Low Voltage Have a qualified electrician check the electrical service to the unit Fuse blown in control box Have a qualified service technician replace the fuse See fuse replace...

Page 29: ...ate Ensure that at least this much is provided Excessive noise on startup Liquid refrigerant in the suction line to the compressor This should go away after the system runs for a few minutes Low voltage or wrong voltage to unit Verify power source check electrical service Noisy compressor Unit stored in cool environment for a long period may have collected liquid refrigerant in the compressor This...

Page 30: ...control package II and III only High temperature alarm set point is set too close to cooling temperature setpoint Reset high temperature set point to at least 3 degrees above set point temperature for cooling Low coolant flow Pump suction strainer is clogged Positive displacement pump only Remove strainer and reinstall Low coolant level in the reservoir Check for leaks fix leaks and fill reservoir...

Page 31: ... remove the obstruction Damaged pump Replace pump Chiller shuts down during operation Shutoff feature is enabled in the controller set up menu Controllers with options II and III Find out and correct the fault that is causing the shutoff Disable shutoff feature see controller set up Low flow switch tripped See No coolant flow Temperature display reads incorrectly Offset incorrectly set Reset tempe...

Page 32: ...3 gpm Stainless Steel Pump 410 0221 410 0221 410 0221 410 0221 4 3 gpm Stainless Steel Pump 410 0222 410 0222 410 0222 1 4 Hp 115 V Motor 230 0202 230 0202 1 4 Hp 230 V Motor 230 0214 230 0214 230 0214 230 0214 1 3 Hp 115 230 V Motor 230 0215 230 0215 230 0215 230 0215 1 2 Hp 115 230 V Motor 230 0203 230 0203 230 0203 Centrifugal Pumps 1 20 Hp Pump 115 V 60 Hz 410 0196 1 20 Hp Pump 230 V 50 Hz 410...

Page 33: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 32 Drawing Specifications RC006 ...

Page 34: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 33 Drawing Specifications RC011 022 ...

Page 35: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 34 Drawing Specifications RC030 RC045 ...

Page 36: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 35 Wiring Diagram RC006G02 ...

Page 37: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 36 Wiring Diagram RC011G02 ...

Page 38: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 37 Wiring Diagram RC011H02 J02 ...

Page 39: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 38 Wiring Diagram RC022H02 J02 ...

Page 40: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 39 Wiring Diagram RC030H02 J02 RC045H02 J02 ...

Page 41: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 40 Plumbing Diagram ...

Page 42: ...Kodiak Recirculating Chiller Technical Manual Manual 820 0043 Rev N 11 25 2019 41 Refrigeration Diagram ...

Page 43: ...out is defined as 1 second Typical response times and character pacing will be baud rate limited 1 3 Encoding All characters are to be ASCII characters All messages from the host to the control and from the control to the host will have 0x10 ASCII Line Feed as a start of message delimiter and 0x0D ASCII Carriage return as an end of message delimiter Permitted message characters are in the range of...

Page 44: ... CondenserRelayOn not used by host program Bit1 CoolValveOn light the Cool Status Bit0 LSB CelsiusDisplayOn determines the display in Low resolution AlarmFlags Status in Bit encoded Byte 2 chars Assignments are Bit7 MSB Over Temp Over Temperature Alarm is lit Bit6 LoTemp Low Temperature Alarm is lit Bit5 Low Flow LoFlow Alarm is lit Bit4 Low level LoLevel Alarm is lit Bit3 NotUsed not used Bit2 No...

Page 45: ...ed in this byte as follows Bit 7 MSB Chiller PowerOn Host signal to turn on Bit6 Chiller PowerOff Host signal to turn off Bit5 Chiller F C Host Signal to toggle F C Bit4 Fault Chiller Shut Off fault chiller shutoff is enabled lights host window Bit3 Audible Alarm Enable Audible Alarm is enabled Bit2 not used Bit1 Remote Start NC remote start contact closure to run else Off Bit0 LSB Remote Start NO...

Page 46: ...ow Temp Limit Setpoint 2 byte hex Cx100 J MASCII Linefeed and Carriage Return 1 6 9 Set Offset Calibration This command Z from the host will set the Chiller Plant Temperature Offset Calibration The Host command is of the form JZ OffsetCal M Where OffsetCalOffset Calibration 2 byte hex Cx100 J MASCII Linefeed and Carriage Return Set User Control Flags This command W from the host will set the Chill...

Page 47: ...an be difficult and may actually be a trial and error process Boyd will not assume any liability for misdiagnosis when diagnosing over the phone Warranty and Non warranty Returns To return a cooling system a Boyd Return Material Authorization RMA number must be obtained from Boyd s service department which can be reached by calling 781 933 7300 or by completing the Request for RMA form and e maili...

Page 48: ...the responsibility of the customer After non warranty repair Boyd will ship the system back using the customer s preferred shipping method Field Service Commissioning Charges Where available Boyd can arrange field service for cooling system commissioning or repair Under no circumstances does Boyd s warranty cover on site service All on site service must be arranged through Boyd s service departmen...

Page 49: ...remental cost of air shipment of replacement parts regardless of warranty status In stock parts will normally ship the next business day non stocked parts will be shipped as quickly as reasonably possible This policy is subject to change Please check with Boyd s service department for the current policy Form F7 02 25 Rev G 06 24 19 ...

Page 50: ... UNDER THIS WARRANTY IS STRICTLY AND EXCLUSIVELY LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE COMPONENT PARTS AND BOYD DOES NOT ASSUME OR AUTHORIZE ANYONE TO ASSUME FOR IT ANY OTHER OBLIGATION BOYD 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 INCONVENI...

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