GE Medical Systems

Technical
Publications

Direction 2358902-100
Revision 3

GEMS Coolix 4000

Recirculating Chiller
GE Medical Systems Part Number 2228054
Model #2358587-2
Lytron Manual Number 820-0082 Rev F

Advanced Service Manual

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

Safety Requirements

WARNING • 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 other than specified
might impair safety protection, void the warranty, and can result in permanent
damage to the unit, significant property damage, personal injury and/or death.

• Be sure to read, understand, and follow all instructions and safety precautions
listed in this manual before operating the unit. If there are any questions
concerning the operation of the unit or the information in this manual, please
contact our Applications Engineering Department at (781) 933-7300.

• Never place the unit in a location where excessive heat, moisture, or corrosive
materials are present.

• The unit must be properly grounded at the power source.

• Do not connect the SUPPLY or RETURN fitting to your building water supply
or any pressurized source.

• Performance 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.

• Transport the unit with care. Sudden jolts or drops can damage the unit.

• Observe all warning labels. Never remove warning labels.

• Do not operate damaged or leaking equipment.

• Do not operate the unit without fluid in the reservoir.

• Always turn the unit "OFF" and disconnect the power cord from the power
source before performing any service, maintenance procedures, or before
moving the unit.

• Do not operate equipment with damaged power cords.

• A qualified technician should perform service and repairs.

• This is not an outdoor chiller. It must be operated inside a building.

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 GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

Customer Service Support

24 hours / 7 days service hotline

Lytron has 24 hours per day, 7 days per week service hotline to help you with questions on the startup and
operation of your recirculating chiller.
Lytron is committed to servicing the customer, both during and after the sale.

If you have any questions concerning the operation of your unit, please contact:

LYTRON INC.
55 Dragon Court
Woburn, Massachusetts 01801-1039
(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 Application Engineer or Service
Technician.

Safety Requirements
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.

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

Chiller Requirements
The Coolix 4000 chillers is in agreement with the following standards:
• CSA C22.2 No. 601 (this includes UL 2601 & IEC 601-1 applied for medical devices)
• EMC/EMI compliance to IEC 60601-2
• EHS: non-ozone depleting substance, CFC free and non-forbidden products.
• CE marking certifying compliance with EMC and LVD directives and applicable standards.

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

Table of Contents

CHAPTER 1 - INTRODUCTION..................................................................................................................... 1

CHILLER APPLICATION...................................................................................................................................... 1
RECEIVING YOUR CHILLER................................................................................................................................ 1
ABOUT THE WARRANTY..................................................................................................................................... 1
CUSTOMER SERVICE SUPPORT .......................................................................................................................... 1
24 HOUR / 7 DAY SERVICE................................................................................................................................... 1

CHAPTER 2 - LABELS AND MARKINGS .................................................................................................... 2

CHAPTER 3 - CHILLER SPECIFICATIONS ................................................................................................ 3

CHAPTER 4 - CHILLER DIMENSIONS........................................................................................................ 4

OVERALL DIMENSIONS ...................................................................................................................................... 4

EARTHQUAKE TIE-DOWN LOCATIONS .............................................................................................................. 5

CHAPTER 5 - FACILITY REQUIREMENTS ................................................................................................ 6

FLOOR SPACE ..................................................................................................................................................... 6

FLOOR SPACE DIAGRAM .................................................................................................................................... 6
ELECTRICAL REQUIREMENTS............................................................................................................................ 7
PLUMBING REQUIREMENTS ............................................................................................................................... 7
SHIPPING REQUIREMENTS ................................................................................................................................. 7

CHAPTER 6 - CHILLER START UP.............................................................................................................. 8

ELECTRICAL INSTALLATION.............................................................................................................................. 8
50 HZ SETUP ....................................................................................................................................................... 8
HOSE INSTALLATION.......................................................................................................................................... 9
FILLING THE CHILLER WITH WATER ................................................................................................................ 9
INITIAL POWER UP ........................................................................................................................................... 10
FAULT LIGHTS.................................................................................................................................................. 11
CHANGING SET POINT...................................................................................................................................... 11

CHAPTER 7 - REGULARLY SCHEDULED MAINTENANCE.................................................................. 12

ALGAE .............................................................................................................................................................. 12
CLEANING THE RESERVOIR ............................................................................................................................. 12
CLEANING THE CONDENSER ............................................................................................................................ 12

CHAPTER 8 - TROUBLESHOOTING.......................................................................................................... 13

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Rev 3 Manual# 2358902-100

CHAPTER 9 - ERROR CODES ..................................................................................................................... 15

ERR 01 – CONTROLLER INITIALIZATION ERROR ............................................................................................ 16

ERR 03 – CONTROLLER OPERATIONAL ERROR .............................................................................................. 16

CHAPTER 10 - SYSTEM SCHEMATICS..................................................................................................... 17

ELECTRICAL SCHEMATIC ................................................................................................................................ 17

WIRING DIAGRAM............................................................................................................................................ 18
PLUMBING SCHEMATIC .................................................................................................................................... 19
REFRIGERATION SCHEMATIC .......................................................................................................................... 20

Main Controller Schematic 21

Coolix Interface Schematic 22
Series4000 Schematic 23

CHAPTER 11 – FIELD REPLACEABLE UNITS (FRU) ............................................................................. 25

CHAPTER 11 - LYTRON RECIRCULATING CHILLER SERVICE POLICY......................................... 26

LYTRON'S STANDARD WARRANTY .................................................................................................................. 26

REPLACEMENT PARTS...................................................................................................................................... 26
WARRANTY ...................................................................................................................................................... 27

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

REVISION HISTORY

REV DATE REASON FOR CHANGE

A 4/24/01 Initial Release
B 10/11/02 Change manual to GEMS format.
Update refrigerant charge in manual. Replace electrical box with bracket.
C 1/31/03 Add interconnect circuit board to electrical bracket. Update crate dimensions.
Initial release of RC7141G3. Add missing photos to manual.
Update picture of test switch. Add electrical schematic, refrigeration
D 7/15/03 schematic and P&ID. Add labels to terminal block picture on p. 8. Add
description of lights on monitoring relay.
E 1/6/04 Add error codes to page 14.
F 7/7/04 Update troubleshooting guide and Parts list , add schematics

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Rev 3 Manual# 2358902-100

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

CHAPTER 1 - INTRODUCTION

Chiller Application
The aim of the chiller (Product name: Coolix 4000) is to cool the X-ray tube assembly. The chiller supplies
chilled water to an oil-to-water heat exchanger mounted on the X-ray tube that removes the heat produced by the
device. Hot water returning from the tube must be cooled to a temperature of 20°+5° C to a keep the tube
temperature below 50° C. The chiller has two main functions:
1. Circulate water through the x-ray tube heat exchanger.
2. Cool down the water returning to the chiller from the X-ray tube assembly.

Receiving your 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 hour / 7 day service

Lytron has a 24 hours per day, 7 days per week service hotline to help you with questions on the startup and
operation of your recirculating chiller. 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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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

CHAPTER 2 - LABELS AND MARKINGS

RETURN This label identifies the connection where heated fluid is returns from the
X-ray tube.

SUPPLY
This label identifies the connection where chilled fluid is supplied to the
X-ray tube.

The Protective Earth (ground) Terminal.

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.

Attention: This symbol tells the user to consult accompanying

documents before servicing equipment.

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GE MEDICAL SYSTEMS
Rev 3
CHAPTER 3 - CHILLER SPECIFICATIONS
Subject
Overall Dimensions
Shipping Crate Dimensions
Weight
Shipping Weight
Center of Gravity
Tank Volume
Pump Capacity
Recommended Fluid
Fluid Connections
Electrical Requirements
Recommended Circuit Breaker
Refrigerant
Refrigerant Charge
Normal Condenser Pressure
Maximum Condenser Pressure
Normal Evaporator Pressure
Maximum Air Temperature
Cooling Capacity
(@ sea level)
Heat Output
Noise Level
COOLIX 4000 CHILLER
Manual# 2358902-100
Specifications
21.9” (55.6 cm) wide x 32.7” (83.1 cm) deep x 43.0” (109.2 cm) high
28” (71 cm) wide x 41” (104 cm) deep x 52” (132 cm) high
350 pounds (160 kg)
500 pounds (225 kg)
Approximately 18 in (46 cm) from floor
2 gallons (7.5 liters)
4.0 gallons (15.1 liters) per minute @ 60 Hz
3.3 gallons (12.5 liters) per minute @ 50 Hz
Chloramine-T solution GE P/N 2351579
5/8” (16 mm) barb fittings, pointed toward floor
480 volt, 3 phase, 60 Hz
380 volt, 3 phase, 50 Hz
10 amps minimum
R-404a
3 pounds, 4 ounces
350 – 400 psi
450 psi
95 – 105 psi
104° F (40° C)
6000 W @ 60 Hz and 68° F (20° C) air temperature
5000 W @ 60 Hz and 104° F (40° C) air temperature
5100 W @ 50 Hz and 20° C air temperature
4250 W @50 Hz and 40° C air temperature
Approximately 8 kW maximum
57 dB (A)
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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

CHAPTER 4 - CHILLER DIMENSIONS

Overall Dimensions

Figure 1

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

Earthquake Tie-Down Locations

Figure 2

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

CHAPTER 5 - FACILITY REQUIREMENTS

Floor Space
The chiller should be installed in a location that allows airflow around the unit. In a room of ambient temperature
77° F (25° C) or less, the chiller must have at least 5 inches (13 cm) of clearance at the front and the back and 16
inches (40 cm) on one side. If the chiller is installed in a room where the ambient temperature is between 77° F
(25° C) and 104° F (40° C), the chiller must have at least 16 inches (40 cm) of clearance at the front and the back
and 33 inches (84 cm) on one side. This space must be provided for proper airflow.

If the seismic mounting bolts are used the floor should be laid out as shown below.

Floor Space Diagram

Figure 3

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

Electrical Requirements
The chiller must be supplied with a dedicated, fused circuit. The circuit breaker should be 10 amp minimum. The
chiller requires 480 volt, 60 Hz, 3 phase power or 380 volt, 50 Hz, 3 phase power. An appropriate ground wire
must be installed to the terminal block in the back of the chiller. The chiller is also supplied with a 6 pin Amp
connector mounted to the rear. This must be connected to the X-ray tube generator in order for the chiller to
operate correctly.

Plumbing Requirements
The chiller is supplied with 16 mm barb connections. The chiller should be connected to the x-ray tube with
hoses that are no longer than 100 feet (30 m). The chiller shall be no more than 10 feet (3 m) below or above the
x-ray tube.

Shipping Requirements
Whenever the chiller is going to be transported it should be packaged in the original shipping crate. This crate is
designed to protect the chiller from potential damage during transit. If the original packaging is unavailable the
chiller should be packaged such that the weight is supported off of the wheels. If this is not done it is possible for
the wheels to be damaged.

The shipping crate is a wooden box 34 in. (86 cm) wide x 45 in. (114 cm) deep x 53 in. (135 cm) tall. It weighs
500 pounds (225 kg) with the chiller in the package.

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

CHAPTER 6 - CHILLER START UP

Electrical Installation
Connect the building 3-phase power supply to the chiller by inserting the power cord through the strain relief and
attaching the leads to the terminal block at the rear of the chiller, labeled L1, L2 and L3. Ring lugs should be
used to ensure that the power cord does not come loose from the terminal block. The chiller must also be
supplied with an appropriate ground wire of at least the same gauge as the main power. It should be attached to
the terminal marked with the ground symbol next to L3.

50 Hz Setup
The chiller is shipped from Lytron configured for 60 Hz operation (480 V). If the system will be run at 50 Hz
(380 V), a few minor changes must be made.
• Disconnect the 480/400 V power from the system.
• Remove the rear access panel from the chiller. There is a switch in the middle of the rear electrical
bracket. Change the switch to the 50 Hz setting to operate the chiller at 50 Hz 380 V. Reassemble the
cover. See Figure 4 below for details.

L1

L2

L3

Ground

50/60 Hz Switch

Phase Loss
Protection Relay

Figure 4

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

• Open the cover on the phase loss protection relay at the back of the chiller. See Figure 5 below for
details.

Figure 5
• The DIP switches inside the cover should be set as follows:
Frequency SW1 SW2 SW3 SW4
50 Hz ON OFF ON ON
60 Hz ON OFF OFF OFF
The left side is on and the right side is off for all of the DIP switches.
• After the DIP switches have been set, close the cover. Attach the panel to the lower rear of the chiller.
• When the switches are set properly, the correct voltage is applied, and L1, L2 and L3 are properly
sequenced on the terminal block there will be two green lights illuminated. If there is a problem with any
of these things there will be one green light and one red light illuminated on the phase loss protection
relay.

Hose Installation
The chiller has two 16 mm barb fittings at the rear. These fittings are labeled supply and return. When installing
the hoses to connect the chiller to the x-ray tube be careful to connect the supply hose from the chiller to the inlet
of the X-ray tube. Hose clamps must be used to ensure that there is no leakage from the connections.

Filling the Chiller with Water

After the chiller has been connected to the power supply and the hoses have been installed, the chiller must be
filled with chloramine-T solution (GE P/N 2351579). It takes approximately 4 to 6 gallons (15-23 liters) to fill
the entire system, including the hoses. Open the access panel on the top of the chiller and remove the cap on the
reservoir and pour water into chiller tank.

While filling the chiller with fluid it will become necessary to briefly run the pump in order to push the air out of
the hoses. In order to do this turn on the power to the unit by closing the circuit breaker, remove the top cover
and the right side panel, and push the switch labeled “Test”. See Figure 6 and Figure 7 below for details. This
will run the pump, compressor and fans while the switch is held in. When the tank nears empty release the
switch. Fill the chiller tank to the top with fluid. Repeat this procedure until the tank remains full. If the unit does
not operate when the switch is pushed, then the power phasing for the unit may be incorrect. If there is no
circulation reverse two of the wires L1, L2 or L3.

NOTE: If the tank runs out of water the pump will need to be changed.

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

Figure 6
Test Switch. Push to
start.

Figure 7

Initial Power Up
After the chiller is connected to the power supply, the hoses have been installed and the tank and hoses are filled,
it is ready for operation. Turn on the power to the system by closing the circuit breaker. At this point the green
light on the front of the unit will come on. This shows that the chiller has power. Push the ON button on the
front of the chiller. If the chiller has been upgraded with the “ever-on” upgrade, the chiller will start immediately.
If the chiller has not been upgraded it will be in standby mode. When it receives the start signal from the service
loop the chiller will start. This start signal should be 230 V 50/60 Hz applied to pins 3 and 4 on the 6-pin
connector at the rear of the chiller.

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Rev 3 Manual# 2358902-100

Fault Lights
The chiller is equipped with two fault lights on the front of the unit. They are for low flow and over temperature.
The low flow light will go on if the flow rate of water returning to the chiller from the X-ray tube is less than 2.5
gallons per minute (9.5 liters per minute). This may happen if the lines from the chiller to the X-ray tube are
blocked, they are too long, or at initial startup when the hoses are empty. If the chiller does not sense flow
returning, it will turn on the red low flow light and open the safety loop connection.

The second fault light is for over temperature. This alarm is set to go off if the water temperature is above 30° C.
When the temperature is above this point the red light will come on and the safety loop will be opened. These
two warnings will remain lit until the water temperature is below 30°.

Over Temperature and Low Flow Symbols

The chiller also has an automatic start feature. While the chiller is in standby mode it is constantly monitoring the
water temperature. If the temperature is above 25° C the chiller will start automatically to cool the water. It will
run until the water has been cooled to 15° C. This ensures that the water is always ready to cool the X-ray tube as
soon as required.

Changing Set Point

The chiller is equipped with a password lockout to prevent unauthorized set point adjustment. In order to access
the set point feature, hold down the “Test” button for 10 seconds. The display will change to - -. It is now ready
to enter the password. Push the “ON” or “OFF” button until the first digit change to 6. Then push the “Test”
button. Press the “ON” or “OFF” button until the second digit is 5, then push “Test” again. The set point can
now be changed. Adjust it to the desired set point, using the “ON” and “OFF” buttons, then push “Test” to accept
the change.

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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

CHAPTER 7 - REGULARLY SCHEDULED MAINTENANCE

There are a few things you can do to your chiller to make sure that it will operate at peak efficiency. The
following steps should be taken every 6 months or as described below.

Algae
GEMS requires the use of a chloramine-T solution kit (GE P/N 2351579) to prevent algae growth. Follow the
instructions that accompany the kit to change the fluid in the system. Use the “Manual Purge” switch as shown in
Figure 7.

Cleaning the Reservoir

To clean the system, drain the unit and replace with clean water. Run the unit for 5 minutes with the clean water.
Drain the unit again. Refill unit with chloramine-T solution.

Cleaning the Condenser

Periodic cleaning of the condenser, located at the front of the chiller, will be required. This should be done every
three months or as required by the environment. Especially dirty or dusty environments may require more
frequent cleaning. Remove the front panel by loosening the screws. Use a vacuum cleaner or to brush clean any
dirt and dust that has collected on the heat exchanger coil. Replace the front panel.

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GE MEDICAL SYSTEMS
Rev 3
CHAPTER 8 - TROUBLESHOOTING
COOLIX Troubleshooting Guide
Problem Possible Cause
No Power to the unit
Low Voltage
Fuse in Control Box burned out,
Interconnect PCB
Power phases wired incorrectly
High Pressure cut-out switch.
X-Ray not turned on. Units without
Ever-on Upgrade
Unit does not start Interconnect between X-Ray and
chiller broken or disabled. Units
without Ever-on Upgrade
50/60 Hz switch on rear of unit in
wrong position
LED D9 on Control PCB illuminated?
LED D2 on Interconnect PCB
illuminated?
Unit has tripped the high-pressure
cutout
Condenser coil fouled with dust or
debris
Compressor has tripped its thermal
cut-out.
Ambient Temperature too high
Insufficient airflow
Unit does not cool Low coolant level
Fans not working properly
LED D11 Illuminated?
LED D11 Illuminated?
LED D11 Illuminated?
LED D13 Illuminated?
COOLIX 4000 CHILLER
Manual# 2358902-100
Recommended Remedy
Verify power cord is properly wired to the unit and power source
Have a qualified electrician check the electrical service to the unit.
Replace fuse. If fuse burns out again, have a qualified electrician
check the electrical service to the unit.
Ensure the 3-phase wires are connected properly. No Error light on
phase loss relay (rear of unit)
Reset switch on rear of unit.
Turn on X-Ray - allow to warm up and require cooling.
Check cabling and operation of X-Ray
Place switch in correct position.
If yes - 12 VDC power at control board OK. If no - no 12 VDC - Check
input voltage to controller, replace Controller PCB
If yes - Ever-on cable OK or interface to X-Ray OK. Possible relay or
Controller failure.
Remove air obstructions from around the unit. Manually reset the
high-pressure control, located at the rear of the unit
Remove front panel and vacuum dust/debris from coil.
Let the unit cool. The overload will reset itself in about 30 minutes.
Check fan operation. Check condenser coil for dust/debris. Clean as
required
Ensure ambient temperature is less than 35C @ sea level, 27C @
1200 meters, 20C @ 3000meters
Remove air obstructions from around unit.
Fill reservoir with coolant
Clean fan blades or replace fan unit
If yes - relay for Compressor and Pump should be active. Is
compressor and Pump running? If not - possible bad relay.
If no - is D15 illuminated? - if yes, Low flow or overtemp error.
If no - Possible bad Control PCB
If Yes - HG Solenoid valve active (Bypass-cooling). If no - possible
temperature sensor (RTD) failure Error 02, Control PCB failure.
Continued…..
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GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

Problem Possible Cause Recommended Remedy

Leaking Pump Pump shaft seals are worn Replace Pump/motor kit GE part number 2356133

Pump fuses burned out Replace fuses and restart.

Obstruction in pump head or Shut down unit. Disconnect power supply. Clear obstruction
coolant lines from lines. Restart unit
Pump/motor seized Replace Pump/motor kit GE part number 2356133
Pump inoperative
LED D11 Illuminated? If yes,
If no pump/Compressor relay defective - replace relay
does compressor run?
LED D11 Illuminated? If yes,
If yes, pump/ motor assembly failed. Replace assembly.
does compressor run?
Pump shaft seal damaged Replace Pump/motor kit GE part number 2356133
Pump/motor alignment
Replace Pump/motor kit GE part number 2356133
incorrect
Noisy Pump Motor
Coolant lines obstructed or too long. Remove obstruction.
Excessive pressure drop
Shorten lines.
Mounts broken or worn, Replace Pump/motor kit GE part number 2356133
Low coolant level in the
Check for leaks in chiller and X-Ray, repair and fill reservoir
reservoir
Disconnect power. Check motor fuses at rear of chiller.
Pump motor not running
Replace burned out fuses.
Low Coolant flow. Low Pump does not rotate
Replace Pump/motor kit GE part number 2356133
flow alarm will trigger smoothly or is seized
at 2.5 Gallons ( 9.5 L) Pump worn out Replace Pump/motor kit GE part number 2356133
or less. Drain coolant, flush with clean water, drain and refill with
Coolant contaminated with
250cc Cloramine T solution and water. GE part number
foreign matter
2351579
Low flow through internal flow switch. Check fluid level. Purge
Air trapped in coolant lines
air from lines.
Check phase loss relay for error light. Have a qualified
Power interruption
electrician check the electrical service to the unit.
Fuse in Control Box burned Have a qualified electrician check the electrical service to the
out unit and replace fuse.
Interconnect between X-Ray
and chiller broken or disabled. Check cabling and operation of X-Ray
Unit turns off after
Units without Ever-on Upgrade
running
X-Ray turned off. Units without
Turn on X-Ray
Ever-on Upgrade
LED D4 on Interconnect PCB
If yes, controller or relay problem
illuminated?
LED D4 on Interconnect PCB If no, power issue, Ever-on cable or interconnect to X-Ray
illuminated? defective.

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 GE MEDICAL SYSTEMS COOLIX 4000 CHILLER

Rev 3 Manual# 2358902-100

Problem Possible Cause Recommend Remedy

Noise from fan area
Excessive noise Noise from compressor shortly
after initial power on
Noise from Compressor area
Clean fan blades, blow out dust from condenser. Check
fan blade rotation, replace if necessary
Some noise may occur during start-up. Should become
quiet after a few minutes of running. If noise continues,
please contact Lytron.
Isolation mounts damaged. Contact Lytron.

Blocked condenser, clean condenser coil. Ambient

Compressor shuts-off, Thermal overload turns temperature too high, ventilate room or move chiller for
pump works, fans compressor off improved airflow. Compressor should cool and restart in 30
work minutes. High pressure cut-out inoperative. Contact Lytron.
Compressor failure Return to Lytron for service.
Unit displays Error
and both low flow and Temperature too high / flow too Verify pump working, verify compressor and fans
high temp LED's light. low. functional. See Unit does not cool. Pump Inoperative.
Error 6
Temperature sensor
Reconnect Temp sensor (RTD)
disconnected
Temperature sensor is damaged Replace Temp sensor (RTD)
Error 2 LED D15 on Controller PCB
If yes, Temp sensor (RTD) failure
illuminated?
LED D15 on Controller PCB
If no, Controller PCB failure. Replace controller PCB
illuminated?

Controller boards firmware

Error 3 Replace Control Board,
damaged
Unit designed to with Set-point of Temperature may vary from 15 to 25 Degrees. This is
20 + - 5 degrees normal condition.
Low coolant level in Tank Check for leaks in chiller and X-Ray, add coolant
Low coolant flow under high heat
Contaminated coolant, flush and replace coolant.
load
Temperature stability
Solenoid valve and / or Hot-gas bypass valve inoperative,
Failure Refrigeration system failure
verify valve energized. Call Lytron for service.
See also:
Compressor shuts-off, pump
works, fans work
Unit does not cool
LED Functions
D9 12 VDC power when illuminated
D11 Pump and Compressor "run" signal sent to relay
Controller PCB
D13 Hot gas bypass valve energized ( in cooling mode )
D15 External contacts active - alarm state
Start - Illuminated when "Purge" switch on Interconnect
D2 ":Start" PCB is depressed. Not active in units with "Ever-on" cable
Interconnect PCB installed.
Run- Illuminated when "Ever-on" active or interconnect
D4 "Run"
cable from X-Ray is connected and x-ray turned on

CHAPTER 9 - ERROR CODES

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There are a few different error codes that can occur during the operation of the chiller. These error codes are
displayed on the front keypad of the system. See below for an explanation of each error code.

Err 01 – Controller Initialization Error

This error code signifies an error in the controller software initialization during power up. Replace Controller or
Electrical Box.Err 02 – RTD Error
This error codes means that the resistance temperature device (RTD) is disconnected or damaged. The controller
will display error 02 when the resistance of the RTD is outside of the expected range. This can be caused by a cut
wire, a short to the RTD, an internal malfunction in the RTD or if the wires are disconnected. Contact the Lytron
Service Department for a replacement part number.

Err 03 – Controller Operational Error

This error code signifies an error in the controller software while the chiller is running. Replace Controller or
Electrical Box.Err 06 – Low Flow Error and Hi Temperature Alarm
This error code signifies a low flow condition and a high temperature condition exist simultaneously.

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CHAPTER 10 - SYSTEM SCHEMATICS

Electrical Schematic

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Wiring Diagram

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Plumbing Schematic

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Refrigeration Schematic

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Main Controller Schematic Pg. 1 of 2

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Main Controller Schematic Pg. 2 of 2

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Coolix 4000 Interface Schematic

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Series 4000 Display Schematic

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CHAPTER 11 – FIELD REPLACEABLE UNITS (FRU)

The following parts can be replaced in the field in the event of a failure of the chiller.

Part Description Lytron Part Number GEMS Part Number

Chloramine-T Solution NA 2351579
Pump Kit 200-0739 2356133
Fan Kit 200-0740 2356134
Keypad 230-0863 2356135
Display Board 230-0848 2356136
Electrical Box 200-0741 2356137
Phase Loss Protection Relay 230-0932 2356138
Three Phase Relay 220-0029 2356139
Pump Fuse 2 Amp 230-0884 2356140
Littelfuse 160mA, 250V,
230-1009 2391630
slow blow fuse, #218.160
Controller Fuse Kit 205-0012 -

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CHAPTER 11 - LYTRON RECIRCULATING CHILLER SERVICE POLICY

Lytron's Standard Warranty

Lytron's warranty is set forth at the end of the manual.

To return a chiller, the customer must obtain a Lytron Return Material Authorization (RMA) number from Lytron
application engineering or service department and indicate this number on the outside packaging of the returned
unit. Chillers must be returned clean, dry and free from any chemicals to the Lytron factory, shipping costs
prepaid. The customer will be responsible for any damage incurred in the return shipment.

Lytron ordinarily will evaluate the unit within 3 business days of receipt. If upon examination, Lytron
determines the part/unit is defective in materials or workmanship, Lytron will fix or replace the part and pay the
return freight costs. Lytron will use reasonable effort to repair the unit promptly and in most cases within one
week of receiving all the required parts.

If upon examination Lytron finds the chiller has a customer-induced defect, an evaluation fee will be charged.
Lytron will provide a firm cost to fix the unit. Lytron will warranty the repair, only, for one year from the repair
date under the terms of our standard warranty or for the balance of the warranty whichever is longer.

Replacement Parts
Alternatively, at no cost to the customer, Lytron will attempt to diagnose the problem over the phone. Service
technicians are available 24 hours/7 days for consultation at no charge. The customer should recognize that phone
diagnose is often difficult and may actually be a trial and error process. Lytron will not assume any liability for
misdiagnosis when diagnosing over the phone.

The customer can order replacement parts (a PO number must be supplied) at the list price. The customer can
then return the old parts, using a Lytron issued RMA number. If the parts are found to be defective and the claim
is within the warranty period, the customer's account will be credited for the sales price of the parts and one-way
ground shipping charges. If the parts are not defective or indicate customer damage, no credit will be issued.
Customers opting for air shipment of replacement parts will be responsible for the incremental cost, regardless of
warranty status.

In-stock parts normally will be shipped the next business day; non-stocked parts will be shipped as quickly as
reasonably possible.

If customer-arranged labor installs the replacement parts, Lytron does not warranty the parts or work and it
potentially voids any remaining warranty.

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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 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
OR 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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GE Medical Systems
GE Medical Systems: Telex 3797371
P.O. Box 414, Milwaukee, Wisconsin 53201 U.S.A
(Asia, Pacific, Latin America, North America)
283, rue de la Miniere, B.P. 34, 78533 Buc Cedex
France