Anda di halaman 1dari 38

Contents:

Technology overview . . . . . . . . . . . . . . . . . . . 58
Heat exchanger technologies
Copper heat exchangers . . . . . . . . . . . . 60
6000 Series and OEM Coils
Stainless steel heat exchangers . . . . . . . 70
Aspen and 4000 Series
Aluminum oil coolers . . . . . . . . . . . . . . . 80
ES Series
Plate-fin heat exchangers . . . . . . . . . . . . 84
Liquid-to-liquid heat exchangers . . . . . . 85
Heat exchanger fittings . . . . . . . . . . . . . . . . . 88
Selecting a heat exchanger . . . . . . . . . . . . . . 89
Custom heat exchangers . . . . . . . . . . . . . . . 92

With five decades of experience in heat


exchanger design and manufacture, Lytrons
expertise is second-to-none. Our heat exchangers
are used in many industries including military
and aerospace, medical and industrial lasers,
medical imaging, analytical instrumentation,
power electronics, semiconductor equipment,
machine tools and telecommunications.
Any of our heat exchanger technologies
can be customized to your exact requirements.
We also supply heat exchanger subassemblies,
adding fittings, hoses, fans, sensors, and other
instrumentation to your specification. And our
seven product ranges with over 130 standard
parts ensure that when you need an off-theshelf part we are likely to have something that
meets your requirements.

www.Lytron.com +1-781-933-7300

57

Heat Exchanger Technology Overview


Lytrons broad range of heat exchanger technologies combined with five decades of thermal transfer experience
enables us to offer tailored solutions for a wide range of applications. Our four types of heat exchangers
can all be customized and integrated into subassemblies.

Tube-Fin Heat Exchangers


6000 Series, OEM Coils, Aspen, and 4000 Series
Our tube-fin heat exchangers consist of copper or stainless
steel tubes expanded into copper or aluminum fin. Tube-fin
heat exchangers are cost effective and offer good heat removal
for a wide range of applications including lasers, electronics,
compressor cooling, semiconductor processing equipment, and
solder reflow ovens. Our copper tubed 6000 Series and OEM
coils, and stainless steel tubed Aspen and 4000 Series offer
compatibility with a wide range of common coolants.

Flat Tube Oil Coolers


ES Series

Standard Heat Exchangers

ES series oil coolers are designed for optimum cooling


with poor heat transfer fluids such as oil and ethylene glycol/water mixture (EGW). The aluminum flat tube fluid
channels are vacuum-brazed with aluminum fin and a frame
for a rugged and lightweight construction. They are ideal for
cooling x-ray tubes, aircraft engines, hydraulic fluid, and high
speed spindles.

Plate-Fin Heat Exchangers


Vacuum-brazed aluminum plate-fin heat exchangers are
our highest performing heat exchanger. They can be used for
air-to-air, air-to-liquid, and liquid-to-liquid cooling. All plate-fin
heat exchangers are custom designed to match your precise
performance and size requirements. Applications include
condensers, evaporators, environmental cooling systems, and
radar cooling. Their high performance/weight ratio also makes
them popular for airborne applications such as cooling gearbox
oil and transmission oil with ram air or jet fuel.

Liquid-to-Liquid Brazed Plate Heat Exchangers


Liquid-to-liquid brazed plate heat exchangers utilize stainless
steel plates brazed together in a counterflow configuration.
This offers high liquid-to-liquid cooling capacity in a compact
package. We offer both copper-brazed and nickel-brazed versions
for compatibility with a wide range of coolants. Applications
include district heating/cooling, heat recovery, and laser cooling.

58

www.Lytron.com +1-781-933-7300

Heat Exchanger Technology Overview

Plate-Fin
Oil Coolers

Performance (Q/ITD)

Tube-Fin

Water Flow
Performance comparison

As many heat exchangers are customized, a range of typical values is shown for each technology. All performances
are compared using water as the cooling fluid.

Fluid compatibility

Dielectric fluids
(e.g. Fluorinert)

Polyalphaolefin
(PAO)

Aluminum flat tube heat exchangers (ES Series)

Aluminum plate-fin heat exchangers

Copper-brazed liquid-to-liquid heat exchangers


Nickel-brazed liquid-to-liquid heat exchangers

EGW

Tube-fin heat exchangers with stainless steel tubing (4000 Series, Aspen)

Tube-fin heat exchangers with copper tubing (6000 Series, OEM Coils)

Water

Oil

Corrosive fluids
(e.g. Deionized water)

Coolant compatibility with wetted surfaces must be considered when selecting a heat exchanger technology. A
copper fluid path is compatible with water and most common coolants. A stainless steel fluid path is necessary
when using deionized water and other corrosive fluids. Aluminum offers excellent performance with ethylene glycol/water mixture (EGW), oils and other fluids, but is not compatible with untreated water. The table below
shows fluid/heat exchanger compatibility.

Standard Heat Exchangers

This chart compares the performance of different heat exchanger technologies. Performance is shown as Q/ITD,
the heat load divided by the difference in incoming temperature of the liquid and air. Units are not shown so that
technologies can be compared regardless of size.

www.Lytron.com +1-781-933-7300

59

6000 Series Copper Heat Exchangers

Copper tubing expanded


into copper cooling fins
for excellent heat transfer
Fluxless, silver-brazed joints
provide leak-free reliability

SELECT

89

All units supplied with built-in,


fan-ready mounting hardware
GRAPHS

64

DWG

0.028 (0.7 mm) seamless


wall tubing ensures fluid
circuit durability

66

Electro-static dip painted


for harsh environments
SPECS

Standard Heat Exchangers

68

The 6000 Series is a high performance heat exchanger with copper tubes and fin. It delivers efficient heat transfer and
maximum reliability in a compact package.
High cooling capacity in a small envelope: The 6000 Series is engineered for performance. Its high tube density
results in maximum heat transfer. The seamless copper tubes are expanded into copper fin (aluminum for the 6340)
with an extruded full collar which ensures excellent metal-to-metal contact and improves the thermal performance.
Integrated fan plate for improved performance and convenience: The 6000 Series integral fan plate acts
as a plenum to distribute the air flow uniformly through the core, thus maximizing performance. It also enables
easy fan installation.
Reliable, leak-free, and robust: Lytron heat exchangers are designed for reliability. Our thick-walled (0.028/0.7 mm)
seamless copper tubing and fluxless silver-brazed joints ensure the integrity of the fluid path. The unit is painted for
long life, even in corrosive environments. All 6000 Series heat exchangers are pressure tested to 150 psi (10.3 bar)
to guarantee reliability.
Compatible with water, ethylene glycol/water mixture (EGW), and other common coolants.

Customization Options
Custom 6000-Series style heat exchangers can be manufactured in any size
and tube configuration to match your demanding thermal requirements.
Variations in inlet/outlet position and/or fittings can be accommodated and
a selection of paints and other coatings is available. Assemblies including
fans and other components can also be supplied.
See page 92 for more custom heat exchangers.
60

www.Lytron.com +1-781-933-7300

6000 Series heat exchanger with custom circuitry, sensor ports, and inlet/outlet fittings

Copper Heat Exchangers OEM Coils

0.028 (0.7 mm) wall tubing


ensures fluid circuit durability.
Copper tubes are compatible
with water, EGW, and other
common cooling fluids
Fluxless silver-brazed joints
offer high reliability

Copper tubing expanded into


aluminum fins offers efficient
and reliable operation
SELECT

89

GRAPHS

Galvanized steel side rails and


tube sheets offer strength and
corrosion resistance

64

DWG

66

SPECS

68

Great value: We carefully selected the materials, tube layout, and fin for low manufacturing cost, and eliminated
some of the cosmetic features found in the 6000 Series. All these cost savings have been passed on to you!
Leak-free, reliable, and robust: Our OEM coils use the same thick (0.028/0.7 mm) walled copper tubing and
fluxless silver-brazed joints as our 6000 Series to ensure the integrity of the fluid circuit. Galvanized side plates
provide superior strength and are corrosion-resistant. All of our OEM coils are 100% leak tested to 150 psi (10.3 bar).
Compatible with water, ethylene glycol/water mixture (EGW), and other common coolants.

Standard Heat Exchangers

OEM coils are the ideal solution for large volume, price sensitive users who need a high quality, cost-effective part but
do not require the additional features of the 6000 Series.

Both the 6000 Series and OEM coils offer high performance and reliability. The 6000 Series uses copper fins, is
painted black for corrosion resistance, and includes a fan-plate. The OEM coil has a different tube configuration,
uses aluminum fins, and is unpainted with galvanized side plates. OEM coils are best suited for the price-sensitive,
high volume customer where the appearance is not critical, for example where the heat exchanger is hidden in
the equipment.

OEM Coil subassembly supplied with fan, finger guard, and hosing

Customization Options
OEM coils are designed for flexibility. Modified standards are available
in three standard widths and any length up to 48. For high volume
applications we can customize dimensions, tube configuration, fittings, etc.
to meet your precise thermal requirements and size envelope. Assemblies
including fans and other components can also be supplied.
See page 92 for more custom heat exchangers.
www.Lytron.com +1-781-933-7300

61

6000 Series Pictures


6105

6110

6120

6210

6220

6310

6320

SELECT

89

GRAPHS

64

DWG

66

SPECS

Standard Heat Exchangers

68

62

6340

www.Lytron.com +1-781-933-7300

Pictures OEM Coils


M05-050

M05-100

M10-080

M10-160
SELECT

89

GRAPHS

64

DWG

66

SPECS

68

Standard Heat Exchangers

M14-120

M14-240

www.Lytron.com +1-781-933-7300

63

6000 & OEM Coils Performance Graphs1


6105
Q/Initial Temperature Difference (W/C)

40

SELECT

6110

m3
3 min

M05-050

m3
3 min 0

2 gpm

2 gpm

30

m3
3 min
BTU
HRF

1 gpm

1/2 gpm

60
50

1/2 gpm

40

2 gpm

20

1/4 gpm
1 gpm

30

1/2 gpm

Muffin XL

Muffin XL

1/4 gpm

10

20

Muffin XL

10

89

20 40 60 80 100 120 0
CFM
Air Flow

20 40 60 80 100 120 0
CFM
Air Flow

20 40 60 80 100 120
CFM
Air Flow

GRAPHS

64

Standard Heat Exchangers

68

Q/Initial Temperature Difference (W/C)

SPECS

70

m3
6 min
BTU
HRF
120

2 gpm

100

2 gpm

50

1 gpm

80

40

1/2 gpm
1/2 gpm

60

30
Muffin XL
Muffin XL

20

40
20

10
0

200
Q/Initial Temperature Difference (W/C)

60

50 100 150 200 250


CFM
Air Flow

6220
0

10

m3
15min 0

50

M10-160
5

10

m3
15 min
BTU
4 gpm HRF

160
2 gpm

140
120

1 gpm
2 gpm
1 gpm

Falcon

200

Patriot

80
60

300

Falcon
Patriot

100

1/2 gpm

100

40
20
0 100 200 300 400 500 600 0 100 200 300 400 500 600
CFM
CFM
Air Flow
Air Flow

www.Lytron.com +1-781-933-7300

6210
120

m3
10 min

M10-080
0

100
2 gpm

m3
10 min
BTU
HRF
200
4 gpm
2 gpm

80

1 gpm

60

150

1 gpm

1/2 gpm

100
Falcon

Falcon

40

Patriot
Patriot

50
20

0
0

100 150 200 250


CFM
Air Flow

180

64

M05-100

m3
min

Q/Initial Temperature Difference (W/C)

66

100 200 300 400


CFM
Air Flow

6310
200
Q/Initial Temperature Difference (W/C)

6120
DWG

180

10

15

m3
20 min 0

100

200 300 400


CFM
Air Flow

M14-120
5

10

15

m3
20 min
BTU
4 gpm HRF

4 gpm

2 gpm

160
2 gpm

140
120

300

Caravel
1 gpm

1 gpm

200

100
1/2 gpm

80
60

100

40

Caravel

20
0

200 400 600 800 0


CFM
Air Flow

200

400 600 800


CFM
Air Flow

Performance Graphs1 6000 & OEM Coils

180
160

2 gpm

400
Q/Initial Temperature Difference (W/C)

Q/Initial Temperature Difference (W/C)

200

M14-240

m3
20 min
BTU
4 gpm
HRF

15

10

300

140
1 gpm

120

200

100
1/2 gpm

80
60

Caravel

100

40
20
0

20

10

6340

m3
30 min
BTU
4 gpm HRF

700
Q/Initial Temperature Difference (W/C)

6320
5

600

300

2 gpm

500
1 gpm

400

200

300
Caravel

200

100

100

20

m3
60 min
BTU
HRF
10 gpm 1200

40

600

8 gpm

1000

4 gpm

800

300

2 gpm

600

200

1 gpm

400

500
400

Caravel

200

100

SELECT

0
0

0
0 200 400 600 800 1000 1200
CFM
Air Flow

200 400 600 800


CFM
Air Flow

89

500 1000 1500 2000 2500


CFM
Air Flow
GRAPHS

64

1.25

10

6110

0.25

100

6220 50
6320

Inches of Water

6310

Pascals

Inches of Water

150
0.50

200
300
Air Flow

100

400

M05-050

10

LPM
6220

6340

25

M14-120
M10-160
50
M14-240

0.1

400

Bar
2.0

20

LPM
15
Bar

10

15

1.5

1.0

15

M14-240

6210
0

10
GPM

6120

1.0

PSI

500
CFM

OEM Coils Liquid Side Pressure Drop

0.1
1

PSI

200
300
Air Flow

100

1.2

20

68

BAR
0.2

PSI

0.8
M05-100

10

6110

M14-120
M05-050

0.6

M10-160

0.4

10
6320
6310

0.5

M10-080

6105
0

0.5

1.0

SPECS

100

6000 Series Liquid Side Pressure Drop


0

66

M10-080

M05-100

0.2

DWG

m3
min
150

12

0.3

500
CFM

30

10

0.4

6340
0

Standard Heat Exchangers

200
6210

0.5

250

0.75

0.6

300

6120
6105

1.00

OEM Coil Air Side Pressure Drop

m3
min

12

Pascals

6000 Series Air Side Pressure Drop

2.5
2.0
1.5
Water Flow

3.0 GPM

1.0

2.0
Water Flow

3.0

0.2

4.0
GPM

The solid vertical lines indicate the performance provided by our standard fans at 60 Hz and 20C. Dashed fan lines represent fan performance at 50 Hz and 20C.

www.Lytron.com +1-781-933-7300

65

6000 Series Drawings


6105

6110
7.4
(188)
5.8
(147)

2.8
(71)

6120
7.4
(188)
5.8
(147)

1.3
(33)

4.3 6.6
(109) (168)

3.8 5.8
(95) (147)

0.38
(10)

6210

89

12.2
(310)
10.5
(267)

1.8
(46)

3.3
(84)

1.8
(46)

3.8 5.8
(95) (147)
0.38
(10)

0.38
(10)

6220
11.9
(301)
9.5
(241)

SELECT

3.3
(84)

4.5
(114)

19.9
(505)
17.6
(446)

2.5
(64)

4.5
(114)

2.5
(64)

GRAPHS

64

9.0
0.4 (229)
(10)

9.0
0.4 (229)
(10)

DWG

0.38
(10)

66

0.38
(10)

SPECS

68

Standard Heat Exchangers

6310

6320
12.9
(328)
11.5
(292)

5.6
(142)

1.12 12.0
(28) (305)

2.1
(53)

5.6
(142)

0.5
(13)

1.13 12.0
(29) (305)

6340
7.0
(178)
27.5
(699)
24.8
(630)

22.2
(564)

PDFs, IGS files, and eDrawings of standard heat exchangers are available at www.Lytron.com.
Main dimensional label is inches. Dimension in parentheses is mm.

66

22.9
(583)
21.6
(549)

www.Lytron.com +1-781-933-7300

1.6
(41)

3.5
(89)
1.5
(38)

2.1
(53)

0.5
(13)

Drawings OEM Coils


M05-050

M05-100

5.75
(146)

2.2
(56)

2.0
(51)

6.3
(160)

10.75
(273)

2.2
(56)

2.0
(51)

6.3
(160)

3.9
(99)

3.9
(99)

0.38
(10)

0.38
(10)

M10-080

M10-160
8.75
(223)

3.2
(81)

2.0
(51)

16.75
(426)

3.2
(81)

2.0
(51)

SELECT

89

GRAPHS

10.6
(269)

10.6
(269)

2.2
(55)

0.5
(13)

2.2
(55)

0.5
(13)

64

DWG

66

SPECS

68

M14-120

M14-240

14.0
(356)

3.2
(81)

2.0
(51)

0.5
(13)

24.75
(630)

2.2
(55)

14.0
(356)

3.2
(81)

2.0
(51)

0.5
(13)

2.2
(55)

Standard Heat Exchangers

12.75
(325)

PDFs, IGS files, and eDrawings of standard heat exchangers are available at www.Lytron.com.
Main dimensional label is inches. Dimension in parentheses is mm.

www.Lytron.com +1-781-933-7300

67

6000 Series Specifications and Part Number Configuration


6000 Series
First select core
number

6000 Series Core Number

6105G1

6110G1

6120G1

6210G1

Fluid path
Fin material

SELECT

89

Add a fan plate


if desired

6310G3

6320G3

copper

aluminum

lbs
kg

1.5
0.7

2.0
0.9

3.5
1.6

5.0
2.3

8.5
3.9

8.5
3.9

14.0
6.4

30.0
13.6

Fluid volume

in3
ml

3
50

8
131

12.5
205

17.5
288

30.5
500

29.5
483

51.5
844

106
1737

400F/200C

Fitting Options (see page 88)


SB: stub end

BD: beaded fitting

AN: 37 AN flare

Leave blank:
0.875 O.D. union fitting
Fan plate

included

included

included

included

included

included

included

GRAPHS

64

Finally, order
fans if desired

68

6120 with beaded fittings

Muffin XL

Patriot

Falcon

Caravel

Standard Heat Exchangers

6340G1:
no fan plate
6340G2:
includes plate

Recommended Fans

66

SPECS

6120G1 BD

To arrive at a
part number1

DWG

6340G1/G2

Dry weight

Max. operating temp.


Next, select a
fitting option

6220G1

copper

# of fans
1

Note: fans, fan plugs, and fingerguards must be ordered separately. Assembly available on orders of 10+ pieces ask for details.

Fan Specifications
Description

Size

Voltage

Current
50Hz
60Hz

Fan Part
Number
Number

Fingerguard
Part Number
Number
Part

Fan
Plug Number

Muffin XL

4.71 (120 mm) square

115

0.20

Muffin XL

4.71 (120 mm) square

230

0.10

0.18

102076

101467

101466

0.09

102076-01

101467

Patriot

6.75 (171.5 mm) round

115

101466

0.27

0.26

101116-01

101116-03

Patriot

6.75 (171.5 mm) round

101466

230

0.14

0.13

101116-02

101116-03

101466

Falcon
Falcon

6.75 (171.5 mm) round

115

0.48

0.50

102070-01

101116-03

101466

6.75 (171.5 mm) round

230

0.16

0.16

102070-02

101116-03

101466

Caravel

10.00 (254 mm) round

115

0.48

0.50

100236-01

101434

101466

Caravel

10.00 (254 mm) round

230

0.24

0.25

100236-02

101434

101466

Other Accessories
Item
Push to connect adapters for
Materials: acetel bodies, nitrile o-rings, and acetel/stainless steel collets
Temp. range: -14 to 167F (-25 to 75C) for air; 33 to 140F (0 to 60C) for water.
Maximum pressure: 150 psi (10.3 bar) for air, 250 psi (1,724 kP) for water.
Packaging: 10 fittings per pack.

Suitable for
6105
6110
6120
6210
6220
6310
6320

Tube to Hose Adapter


Requires a push-to-connect adapter of the same OD to
mate with heat exchanger.

68

www.Lytron.com +1-781-933-7300

Part Number
Straight Union 38 O.D.

430-0448

Union Elbow 8 tubing O.D.

102190-01

Transition Union 38 12 tubing O.D.

102189-01

Transition Union 12 38 tubing O.D.

102189-01

Union Elbow 12 tubing O.D.

102190-02

8 tubing O.D. to 38 hose barb

102191-01

2 tubing O.D. to 38 hose barb

102191-02

2 tubing O.D. to 12 hose barb

102191-03

3
1
1

Specifications and Part Numbering Configuration OEM Coils


OEM Coils
First select core
number

OEM Coil Core Number

M05-050

M05-100

M10-080

Fluid Path
Fin Material

Add a fan plate


if desired

M14-120

M14-240

aluminum

Dry Weight

lbs
kg

2.0
0.9

4.0
1.8

5.0
2.3

8.0
3.6

10.0
4.5

16.0
7.3

Fluid Volume

in3
ml

7
115

11.5
188

19.5
320

33.5
549

37
606

66.5
1090

Max. operating temp.


Next, select a
fitting option

M10-160
copper

400F/200C

Fitting Options (see page 88)


SB: stub end

BD: beaded fitting

AN: 37 AN flare

0: no fan plate

1: fan plate attached

Fan Plate

To arrive at a
part number1

SELECT

M05-100 SB 1

GRAPHS

64

M05-100 with stub end fittings and fan plate

Recommended Fans

DWG

Muffin XL
Finally, order
fans if desired

66

Patriot

Falcon

SPECS

Caravel
# of fans

Note: fans, fan plugs, and fingerguards must be ordered separately. Assembly available on orders of 10+ pieces ask for details.

Fan Specifications
Description

Size

Voltage

Current
50Hz
60Hz

Fan Part
Number

Fingerguard
Part Number

Fan
Plug
Plug Number
Number

Muffin XL

4.71 (120 mm) square

115

0.20

Muffin XL

4.71 (120 mm) square

230

0.10

0.18

102076

101467

101466

0.09

102076-01

101467

Patriot

6.75 (171.5 mm) round

115

101466

0.27

0.26

101116-01

101116-03

Patriot

6.75 (171.5 mm) round

101466

230

0.14

0.13

101116-02

101116-03

101466

Falcon
Falcon

6.75 (171.5 mm) round

115

0.48

0.50

102070-01

101116-03

101466

6.75 (171.5 mm) round

230

0.16

0.16

102070-02

101116-03

101466

Caravel

10.00 (254 mm) round

115

0.48

0.50

100236-01

101434

101466

Caravel

10.00 (254 mm) round

230

0.24

0.25

100236-02

101434

101466

68

Standard Heat Exchangers

89

Other Accessories
Item
Push to connect adapters for
Materials: acetel bodies, nitrile o-rings, and acetel/stainless steel collets
Temp. range: -14 to 167F (-25 to 75C) for air; 33 to 140F (0 to 60C) for water.
Maximum pressure: 150 psi (10.3 bar) for air, 250 psi (1,724 kP) for water.
Packaging: 10 fittings per pack.

Tube to Hose Adapter


Requires a push-to-connect adapter of the same OD to
mate with heat exchanger.

Suitable for
M05-050
M05-100
M10-080
M10-160
M14-120
M14-240

Straight Union 38 O.D.


Union Elbow 38 tubing O.D.
Transition Union 38 12 tubing O.D.

Part Number
430-0448
102190-01
102189-01

Transition Union 12 38 tubing O.D.

102189-01

Union Elbow 12 tubing O.D.

102190-02

8 tubing O.D. to 8 hose barb

102191-01

2 tubing O.D. to 38 hose barb

102191-02

2 tubing O.D. to 12 hose barb

102191-03

1
1

www.Lytron.com +1-781-933-7300

69

Aspen Stainless Steel Heat Exchangers

Wider tube spacing


reduces cost, weight, and
liquid pressure drop.

SELECT

89

Wavy fin edge


improves fin strength

Liquid return loops


eliminate fluid
contamination
and reduce liquid
pressure drop

Welded, argon-purged
joints maximize internal
cleanliness

GRAPHS

74

DWG

76

316L stainless steel tubing


compatible with deionized
water and corrosive fluids

SPECS

Standard Heat Exchangers

78

The Aspen stainless steel tubed heat exchanger combines low price and low pressure drop with excellent heat transfer
and superior fluid integrity.
Our best value stainless steel tubed heat exchanger: The Aspen offers excellent value 80-90% the performance
of competitive products at approximately half the price. We achieved this by using fewer tubes and increasing the
fin density to balance the air and liquid sides. Our single piece formed aluminum frame/fan plate further reduces
cost and weight.
Highly reliable: Like all Lytron heat exchangers, the Aspen is designed for reliability. 316L stainless steel fluid path
with 0.02 (0.5 mm) wall thickness maintains deionized water and will not react with corrosive liquids. Aspen heat
exchangers are 100% leak tested to 150 psi (10.3 bar).
Extremely clean: Our proprietary manufacturing process expands the tubes into the copper fin without the use of
oils and our liquid return design eliminates potential particle trapping sites, which can contaminate cooling fluid.
Argon-purged welded joints further ensure cleanliness.
Low air and liquid side pressure drop: The short fluid path minimizes the liquid side pressure drop, and our tube
spacing and high performance fin reduce air side pressure drop.

Customization Options
Custom Aspen style heat exchangers can be manufactured in various sizes
and tube configurations to match your thermal and size requirements.
Variations in inlet/outlet position and/or fittings can be accommodated and
a selection of paints and other coatings is available. Assemblies including
fans and other components can also be supplied.
See page 92 for more custom heat exchangers.
70

www.Lytron.com +1-781-933-7300

Custom cupronickel tube-fin heat exchanger

Stainless Steel Heat Exchangers 4000 Series


Superior construction 316L stainless steel
tubing expanded into copper cooling fins

All-welded, argon-purged
joints maximize internal
cleanliness

SELECT

0.028 (0.7 mm) wall


tubing ensures fluid
circuit durability

89

GRAPHS

74

Pre-cleaned internal surface


eliminates fluid contamination

DWG

76

SPECS

Available with straight, beaded,


or 37AN flare fittings

High cooling capacity in a small envelope: The 4000 series is engineered for performance. It has a high tube
density for maximum heat transfer. Heavy-walled (0.028/0.7 mm), seamless stainless steel tubes are expanded into
copper fin with an extruded full collar. The copper fin and the excellent metal-to-metal contact between the tube
and the fin collar further increase performance.
Compatible with deionized water and corrosive liquids: All the wetted surfaces in the 4000 Series are 316L
stainless steel, so it is ideal for use with high purity and/or corrosive coolants such as deionized water.
Integrated fan plate for improved performance and convenience: The 4000 Series integral fan plate acts as
a plenum to ensure uniform air-flow distribution through the core, thus maximizing performance. It also enables
easy fan installation.

Standard Heat Exchangers

The 4000 Series is our highest performing stainless steel tubed heat exchanger. It is ideal for applications where
deionized water or corrosive fluids are used, and a high efficiency, compact unit is required.

78

Rugged and reliable: The argon-purged welded stainless steel frame and fan plate offer durability and strength.
4000 Series heat exchangers are 100% leak tested to 150 psi (10.3 bar).
Aspen or 4000 Series? The Aspen offers 80% the performance of the 4000 Series at approximately 50% the cost.
Where high performance in a small envelope is required, the 4000 Series is the best option. However, when a slightly
lower performance/size ratio is acceptable, the Aspen offers better value. The Aspen also has lower air and liquid side
pressure drops.

Stainless steel heat exchanger with custom inlet/outlet fittings

Customization Options
Custom 4000 Series style heat exchangers can be manufactured in any size
and circuiting to match your demanding thermal requirements. Variations in
inlet/outlet position and/or fittings can be accommodated and a selection of
paints and other coatings is available. Assemblies including fans and other
components can also be manufactured.
See page 92 for more custom heat exchangers.
www.Lytron.com +1-781-933-7300

71

Aspen Pictures
AS04-05

AS04-10

AS06-08

AS06-16

AS08-10

AS08-20

SELECT

89

GRAPHS

74

DWG

76

SPECS

Standard Heat Exchangers

78

72

www.Lytron.com +1-781-933-7300

Pictures 4000 Series


4105

4210

4110

4120

4220
SELECT

89

GRAPHS

74

DWG

76

SPECS

78

Standard Heat Exchangers

4310

4320

www.Lytron.com +1-781-933-7300

73

Aspen & 4000 Performance Graphs1


4105
Q/Initial Temperature Difference (W/C)

40

SELECT

4110

m3
3 min0

AS04-05

m3
3 min 0

m3
3 min
BTU
HRF

60

2 gpm

30

50

1 gpm
2 gpm

1/2 gpm
2 gpm

20

40

1 gpm
1/4 gpm

1 gpm

1/2 gpm

1/2 gpm
Muffin XL

1/4 gpm

10

30

1/4 gpm

20

Muffin XL

Muffin XL

10

89

20 40 60 80 100 120 0
CFM
Air Flow

20 40 60 80 100 120 0
CFM
Air Flow

20 40 60 80 100 120
CFM
Air Flow

GRAPHS

74

76

Standard Heat Exchangers

78

Q/Initial Temperature Difference (W/C)

SPECS

70

m3
min
BTU
HRF
120

60
2 gpm

50

2 gpm

1 gpm
1 gpm

1/2 gpm

30

1/2 gpm
Muffin XL

20

100
80

40

60
40
20

10
Muffin XL

50 100 150 200 250


CFM
Air Flow

4220
Q/Initial Temperature Difference (W/C)

200

10

4210
120

AS06-16
5

m3
15 min 0

10

120

10

1 gpm

80

150
1/2 gpm

2 gpm

60

Falcon
1 gpm
Falcon

40

1/2 gpm

50
20
Patriot

0 100 200 300 400 500 600


CFM
Air Flow

4310

m3
10 15 20 25 min 0

0 100 200 300 400 500 600


CFM
Air Flow

AS08-10
5

m3
10 15 20 25 min
BTU
HRF
300

2 gpm
Falcon
Patriot

Falcon

2 gpm

1 gpm
2 gpm

1 gpm
2 gpm

80

1/2 gpm

200

1 gpm

1 gpm
1/2 gpm
1/2 gpm

100

Patriot

40

1/2 gpm

Caravel

20

EBM
Caravel

0 100 200 300 400 500 600 0 100 200 300 400 500 600 0
CFM
CFM
Air Flow
Air Flow

www.Lytron.com +1-781-933-7300

100

Patriot

4 gpm

100

60

m3
15 min
BTU
HRF
200

10

100

160
140

AS06-08

m3
15 min 0
2 gpm

50 100 150 200 250


CFM
Air Flow

m3
15min 0

180

74

AS04-10

m3
min 0

Q/Initial Temperature Difference (W/C)

4120
DWG

200 400 600 800 1000 0


CFM
Air Flow

200 400 600 800 1000


CFM
Air Flow

Performance Graphs Aspen & 4000


4320

Q/Initial Temperature Difference (W/C)

200

AS08-20

m3
m3
5 10 15 20 25 30 min 0 5 10 15 20 25 30 min
BTU
4 gpm
4 gpm
HRF
Caravel

180

2 gpm

2 gpm

160

300

140

1 gpm

1 gpm

120
200

100

1/2 gpm

1/2 gpm

80

EBM

60

100

Caravel

40
20
SELECT

89

0 200 400 600 8001000 1200 0 200 400 600 800 10001200
CFM
CFM
Air Flow
Air Flow
GRAPHS

74

The solid vertical lines indicate the performance provided by our standard fans at 60 Hz and 20C. Dashed fan lines represent fan performance at 50 Hz and 20C.

DWG

76

Air Side Pressure Drop


1.25

10

12

300
250

150
0.50

AS04-05
100

Inches of Water

4210 200

0.75

20

30

4310

4220

200

100

300

400

Air Flow

300

200

0.75

AS08-10 150
4320

0.50

100
0.25

500
CFM

AS08-20 50

200

400

800

600

1000

Air Flow

Liquid Side Pressure Drop


6

78

AS06-16

AS06-08 50

SPECS

250

AS04-10
0.25

m3
min

25

1.00

Pascals

1.00

1200
CFM

Liquid Side Pressure Drop


LPM
4120

Bar
0.4

15

10 LPM
1

4220

Bar

5
0.8

0.3
4110

10

0.2

PSI

0.6
PSI

Inches of Water

1.25

15

Standard Heat Exchangers

4120
4105

4110

10

Pascals

Air Side Pressure Drop


m3
min

4210

4320

AS06-08
2
4105
AS04-10
1
0

0.4

AS08-20

0.1

4310

AS04-05

0.5

1.0
Water Flow

1.5

GPM

2.0

0.5

1.0

AS08-10

AS06-16

1.5

2.0

Water Flow

2.5

0.2

0
3.0
GPM

www.Lytron.com +1-781-933-7300

75

Aspen Drawings
AS04-05

AS04-10
8.1
(207)

3.4
(86)

5.3
(134)
3.8 5.9
(95) (151)

13.4
(339)

3.4
(86)

10.5
(267)

1.8
(47)

3.8 5.9
(95) (151)

0.38
(10)

AS06-08

1.8
(47)

0.38
(10)

AS06-16

SELECT

89

10.9
(276)

4.3
(108)

8.0
(203)

GRAPHS

74

19.0
(481)

76

2.1
(53)

6.3 9.1
(159) (230)

6.3 9.1
(159) (230)

DWG

4.3
(108)

16.1
(409)

2.1
(53)

0.38
(10)

0.38
(10)
SPECS

Standard Heat Exchangers

78

AS08-10

AS08-20
12.9
(326)

5.6
(142)

10.0
(254)

22.9
(583)
2.1
(53)

8.8 11.8
(222) (298)
0.38
(10)

www.Lytron.com +1-781-933-7300

2.1
(53)

8.8 11.8
(222) (298)

PDFs, IGS files, and eDrawings of standard heat exchangers are available at www.Lytron.com.
Main dimensional label is inches. Dimension in parentheses is mm.

76

5.6
(142)

20.1
(511)

0.38
(10)

Drawings 4000 Series


4105

4110

7.7
(194)
5.8
(147)

2.8
(71)

4120
7.8
(198)
4.9
(125)

1.3
(33)

3.4
(86)

4.3 6.6
(109) (168)

12.6
(320)
9.7
(246)

1.8
(47)

3.4
(86)

4.1 5.8
(105) (147)

4.1 5.8
(105) (147)
0.38
(10)

0.38
(10)

4210

1.8
(47)

0.38
(10)

4220
SELECT

89
10.9
(277)
8.0
(203)

4.5
(114)

19.0
(483)
16.1
(408)

2.5
(64)

4.5
(114)

2.5
(64)

GRAPHS

74

7.1 9.0
(181) (229)

7.1 9.0
(181) (229)

DWG

76
0.38
(10)

0.38
(10)

SPECS

78

4320
12.9
(328)
10.0
(254)

6.0
(153)

2.5
(64)

1.9
(48)

23.0
(584)
20.1
(510)

6.0
(153)

2.5
(64)

1.9
(48)
12.0
(305)

0.5
(13)

12.0
(305)

0.5
(13)

Standard Heat Exchangers

4310

PDFs, IGS files, and eDrawings of standard heat exchangers are available at www.Lytron.com.
Main dimensional label is inches. Dimension in parentheses is mm.

www.Lytron.com +1-781-933-7300

77

Aspen Specifications and Part Number Configuration


Aspen Series
First select core
number

Core Number

AS04-05G01

AS04-10G01

AS06-08G01

Fluid path
Fin material

copper
1.4
0.6

2.7
1.2

3.3
1.5

6.3
2.9

5.3
2.4

10.1
4.6

Fluid volume

in3
ml

2.8
45.9

4.6
75.4

5.6
91.8

9.9
162.2

8.9
145.8

16.0
262.2

400F/200C

Fitting options (see page 88)


SB: stub end

BD: beaded fitting

included

included

included

included

included

included

To arrive at a
part number1

89

AS08-20G01

lbs
kg

Fan plate

SELECT

AS08-10G01

Dry weight

Max. operating temp.


Next, select a
fitting option

AS06-16G01

stainless steel

AS08-10 G01 SB

AS08-10 with stub end fittings

Recommended Fans
GRAPHS

Muffin XL

74
Finally, order
fans if desired
DWG

Patriot

Falcon

Caravel

76

EBM 8.5
# of fans
SPECS

Standard Heat Exchangers

78

Note: fans, fan plugs, and fingerguards must be ordered separately. Assembly available on orders of 10+ pieces ask for details.

Fan Specifications
Description

Size

Voltage

Fan Part
Number
Number

Fingerguard
Part Number
Number
Part

Fan
Plug Number

Muffin XL

4.71 (120 mm) square

115

0.20

Muffin XL

4.71 (120 mm) square

230

0.10

0.18

102076

101467

101466

0.09

102076-01

101467

Patriot

6.75 (171.5 mm) round

115

101466

0.27

0.26

101116-01

101116-03

Patriot

6.75 (171.5 mm) round

101466

230

0.14

0.13

101116-02

101116-03

101466

Falcon
Falcon

6.75 (171.5 mm) round

115

0.48

0.50

102070-01

101116-03

101466

6.75 (171.5 mm) round

230

0.16

0.16

102070-02

101116-03

101466

Caravel

10.00 (254 mm) round

115

0.48

0.50

100236-01

101434

101466

Caravel

10.00 (254 mm) round

230

0.24

0.25

100236-02

101434

101466

EBM2

8.85 (225 mm) square

115

0.58

0.70

102105-01

102106

102175

EBM2

8.85 (225 mm) square

230

0.29

0.35

102105-03

102106

102175

Current
50Hz
60Hz

Requires adapter ring. Part number 508520.

Other Accessories
Item
Push to connect adapters for
Materials: acetel bodies, nitrile o-rings, and acetel/stainless steel collets
Temp. range: -14 to 167F (-25 to 75C) for air; 33 to 140F (0 to 60C) for water.
Maximum pressure: 150 psi (10.3 bar) for air, 250 psi (1,724 kP) for water.
Packaging: 10 fittings per pack.
Tube to Hose Adapter
Requires a push-to-connect adapter of the same OD to
mate with heat exchanger.

78

www.Lytron.com +1-781-933-7300

Suitable for

Part Number
Straight Union 38 O.D.

430-0448

Union Elbow 8 tubing O.D.

102190-01

Transition Union 8 2 tubing O.D.

102189-01

8 tubing O.D. to 38 hose barb

102191-01

2 tubing O.D. to 38 hose barb

102191-02

2 tubing O.D. to 12 hose barb

102191-03

All Aspen
Series

3
1
1

Specifications and Part Number Configuration 4000 Series


4000 Series
First select core
number

Core Number

4105G1

4110G10

4120G10

4210G10

Fluid path
Fin material

4310G10

4320G10

copper

Dry Weight

lbs
kg

1.5
0.7

2.0
0.9

3.5
1.6

5.0
2.3

8.5
3.9

8.5
3.9

14.0
6.4

Fluid volume

in3
ml

3
50

8
131

12.5
205

17.5
288

30.5
500

29.5
483

51.5
844

Max. operating temp.


Next, select a
fitting option

4220G10

stainless steel

400F / 200C

Fitting options (see page 88)


SB: stub end

BD: beaded fitting

AN: 37 AN flare

included

included

included

included

included

included

included

Fan plate
To arrive at a
part number1

4220G10 AN

SELECT

89

4220 with AN fittings

Recommended Fans

GRAPHS

Muffin XL
Finally, order
fans if desired

74

Patriot

Falcon

DWG

Caravel
# of fans
1

2
SPECS

Note: fans, fan plugs, and fingerguards must be ordered separately. Assembly available on orders of 10+ pieces ask for details.

78

Size

Voltage

Current
50Hz
60Hz

Fan Part
Number

Fingerguard
Fan
Plug Number
Number
Part Number Plug

Muffin XL

4.71 (120 mm) square

115

0.20

0.18

102076

101467

101466

Muffin XL

4.71 (120 mm) square

230

0.10

0.09

102076-01

101467

101466

Patriot

6.75 (171.5 mm) round

115

0.27

0.26

101116-01

101116-03

101466

Patriot

6.75 (171.5 mm) round

230

0.14

0.13

101116-02

101116-03

101466

Falcon

6.75 (171.5 mm) round

115

0.48

0.50

102070-01

101116-03

101466

Falcon

6.75 (171.5 mm) round

230

0.16

0.16

102070-02

101116-03

101466

Caravel

10.00 (254 mm) round

115

0.48

0.50

100236-01

101434

101466

Caravel

10.00 (254 mm) round

230

0.24

0.25

100236-02

101434

101466

Standard Heat Exchangers

Fan Specifications
Description

76

Other Accessories
Item
Push to connect adapters for
Materials: acetel bodies, nitrile o-rings, and acetel/stainless steel collets
Temp. range: -14 to 167F (-25 to 75C) for air; 33 to 140F (0 to 60C) for water.
Maximum pressure: 150 psi (10.3 bar) for air, 250 psi (1,724 kP) for water.
Packaging: 10 fittings per pack.

Suitable for
4105
4110
4120
4210
4220
4310
4320

Tube to Hose Adapter


Requires a push-to-connect adapter of the same OD to
mate with heat exchanger.

Part Number
Straight Union 38 O.D.

430-0448

Union Elbow 8 tubing O.D.

102190-01

Transition Union 38 12 tubing O.D.

102189-01

Transition Union 12 38 tubing O.D.

102189-01

Union Elbow 12 tubing O.D.

102190-02

8 tubing O.D. to 38 hose barb

102191-01

2 tubing O.D. to 38 hose barb

102191-02

2 tubing O.D. to 12 hose barb

102191-03

3
1
1

www.Lytron.com +1-781-933-7300

79

ES Series Aluminum Heat Exchangers: Oil Coolers


Fluxless, vacuum-brazed core
for strength and reliability

Low pressure drop due


to unique flat tube and
header designs

Welded headers, pressure


tested to 150 psi (10.3 bars)

Extended surface flat tube


design provides 2.5 times
better performance than
competitive units

SELECT

89

Available with or
without a fan plate
GRAPHS

82

Finish options:
aluminum or black paint

DWG

81

SPECS

Standard Heat Exchangers

83

Internal view of Lytrons


aluminum flat tube

ES Series oil coolers are engineered for high performance with poor heat transfer fluids such as oils and EGW. They
provide up to 2.5 times greater thermal performance per unit volume than competitive models.
High performance: The ES Series uses Lytrons unique aluminum flat tube technology, which has multiple extended
surface channels in each tube. These tubes provide maximum cooling by having a large surface area in contact with
the fluid (approximately 12 in2 (77 cm2)/linear inch of tube). Lytrons air-side fin geometry efficiently channels air
across the fin surface to further boost heat transfer capability.
Clean and reliable: The fluxless vacuum-brazed construction results in a clean, rugged, and highly reliable part with
excellent thermal contact and mechanical strength.
Low pressure drop: Our flat tube fluid channels and efficient header manifold result in a very low pressure drop so
smaller, less expensive pumps can be used.
Lightweight: The all-aluminum, vacuum-brazed construction is lightweight.

Customization Options
Oil coolers can be manufactured in different sizes and tube widths, and
with custom inlet/outlet configurations. Curved heat exchangers can be
manufactured as the flat tube can be bent without buckling or damaging
the internal channels. Assemblies including fans and other components can
also be supplied.
See page 92 for more custom heat exchangers.
80

www.Lytron.com +1-781-933-7300

Custom oil cooler with curved tubes

Pictures and Drawings ES Series


ES05051

ES0510

ES0707

ES07142

SELECT

89

GRAPHS

82

DWG

81

SPECS

83

ES0510
7.80 max
(198)
5.19
(132)

12.55 max
(319)
9.94
(254)

3.06
(77)
1.25
(32)

1.25
(32)

3.25 6.57
(83) (167)

3.25 6.57
(83) (167)

ES0707

ES0714
9.67 max
(246)
7.06
(178)

3.06
(77)
1.25
(32)

5.0 8.36
(127) (212)

3.06
(77)

Standard Heat Exchangers

ES0505

Includes optional fan plate and black paint

17.86 max
(454)
15.25
(387)

3.06
(77)

1.25
(32)

5.0 8.36
(127) (212)

Includes optional fan plate

PDFs, IGS files, and eDrawings of standard heat exchangers are available at www.Lytron.com.
Main dimensional label is inches. Dimension in parentheses is mm.
www.Lytron.com +1-781-933-7300

81

ES Series Performance Graphs1

89

100
4 gpm

40

4 gpm
1/2 gpm

175

50
1/2 gpm

20

Muffin XL

20

Muffin XL

40 60 80 100 0
CFM
Air Flow

ES0707- EGW2
Q/Initial Temperature Difference (W/C)

Standard Heat Exchangers

83

100

150

82

SPECS

60

DWG

80

GRAPHS

81

ES0510 - EGW2

m3
min
BTU
HRF

20

ES0707- Oil3

m3
min 0

150
125

75

5 gpm
3 gpm

1 gpm
2 gpm

1/2 gpm

50

1 gpm

100

1/2 gpm

Patriot

25

Patriot

0.30

6
ES0510
ES0707

0.25

ES0505

10

2 gpm
1 gpm
1/2 gpm

100

40
Muffin XL

50

Muffin XL

20

0 50 100 150 200 250 CFM 0 50 100 150 200 250 CFM
Air Flow
Air Flow

ES0714- Oil3

m3
15min 0

10

10

5 gpm

Patriot

Tarzan

3 gpm
2 gpm

150

m3
15 min
BTU
HRF
300

5 gpm

1 gpm

3 gpm

125

2 gpm

1/2 gpm

200

100

1 gpm

75

Tarzan
1/2 gpm

50

100

Patriot

25
0
0 100 200 300 400 500 CFM 0 100 200 300 400 500 CFM
Air Flow
Air Flow

10

15

Liquid Side Pressure Drop - Oil

ES0714

LPM

70
60

150
4 gpm

1/2 gpm

Liquid Side Pressure Drop - EGW

m3
8 min

m3
min
BTU
HRF

60

0 50 100 150 200 250 CFM0 50 100 150 200 250 CFM
Air Flow
Air Flow

Air Side Pressure Drop

2 gpm
1 gpm

175

200

5 gpm
3 gpm
2 gpm

ES0510 - Oil3

ES0714- EGW2

m3
min
BTU
HRF
300

Tarzan

80

Tarzan

100

m3
min

4 gpm

40 60 80 100
CFM
Air Flow

Q/Initial Temperature Difference (W/C)

SELECT

Q/Initial Temperature Difference (W/C)

100

ES0505 - Oil3

m3
min 0

Q/Initial Temperature Difference (W/C)

ES0505 - EGW2

Bar

16

0.6

14

10

15 LPM
Bar
1.0

ES0714

0.15

30

ES0510

100

150 200

0
250 CFM

Air Flow

4
0.2

10

50

2
0

0
0

50/50 EGW Flow

4 GPM

0
0

Oil Flow

The solid vertical lines indicate the performance provided by our standard fans at 60Hz and 70F. Dashed lines represent fan performance at 50 Hz and 20C.
50/50 EGW at 160F. 3 Diala at 170F.

www.Lytron.com +1-781-933-7300

0.6

ES0505 0.4

0.05

ES0707

8
6

ES0505 0.2

20

82

0.4

ES0707

0.10

0
0

0.8
ES0510

10
PSI

40

PSI

ES0714

Pascals

Inches of Water

12
50

0.20

GPM

Specifications and Part Number Configuration ES Series


First select core
number

Core Number

ES0505G

ES0510G

Fluid path

ES0714G

aluminum

Fin material

Next, select
an option

ES0707G

aluminum

Dry weight

lbs
kg

2.0
0.91

2.85
1.30

2.85
1.30

5.53
2.51

Fluid volume

in3
ml

14
229

17
278

24
393

31
508

Fittings (see page 88)

3/8 18 NPT

Max. operating temp.

400F/200C

Options
21: no paint, no fan plate

22: black paint, no fan plate

23: no paint, fan plate attached

24: black paint, fan plate attached

To arrive at a
part number1

ES0510G24

SELECT

89

ES0510 with black paint and fan plate attached

Recommended Fans

GRAPHS

Muffin XL
Finally, order
fans if desired

82

Patriot

Tarzan

# of fans
1

DWG

81

Note: fans, fan plugs, and fingerguards must be ordered separately. Assembly available on orders of 10+ pieces ask for details.
SPECS

83

Description

Size

Voltage

Current
50Hz
60Hz

Fan Part
Number

Fingerguard
Fan
Plug Number
Number
Part Number Plug

Muffin XL

4.71 (120 mm) square

115

0.20

0.18

102076

101467

101466

Muffin XL

4.71 (120 mm) square

230

0.10

0.09

102076-01

101467

101466

Patriot

6.75 (171.5 mm) round

115

0.27

0.26

101116-01

101116-03

101466

Patriot

6.75 (171.5 mm) round

230

0.14

0.13

101116-02

101116-03

101466

Tarzan

6.91 (175 mm) square

115

1.40

1.20

101578-01

101741

101466

Tarzan

6.91 (175mm) square

230

0.63

0.54

101578-02

101741

101466

www.Lytron.com +1-781-933-7300

Standard Heat Exchangers

Fan Specifications

83

Plate-Fin Heat Exchangers


Variety of finishes
available including paint
and Milspec coatings

Can be used for air-to-air, air-to-liquid,


or liquid-to-liquid cooling

Lightweight, all-aluminum
construction

Fluxless vacuum-brazed core


for good thermal contact,
strength, and reliability

Standard Heat Exchangers

Large heat transfer surface

Aluminum vacuum-brazed plate-fin heat exchangers are widely used in military, aerospace, and other
high performance applications because they offer excellent thermal transfer capacity combined with small
size and weight. They are all custom designed as every requirement is different.
Superior performance: This heat exchanger technology, which consists of finned chambers separated by flat plates,
offers our highest thermal performance. The plates and fins create a large surface area for heat transfer, and the
fins create turbulence in the fluid to further improve performance.
Lightweight: The all-aluminum construction offers superior performance/weight ratio.
Completely customizable: All our plate-fin products are custom designed so that we can supply you with the
most efficient, compact, and lightweight part possible. The number of plate and fin layers, the size of the plates
and fin, the height of the fin, and the type of fin are carefully selected for optimum performance. Manifold ducting
and mounting brackets are welded in place as required, and a wide variety of paint, Milspec, and other coatings are
available. Contact Lytron to discuss your requirements.
High reliability and cleanliness: The plates and fin are assembled in an environmentally-controlled room for
maximum reliability and cleanliness. Also, our numerically controlled vacuum brazing process and robust fixture
designs ensure complete metallurgical bonding between the fins and separator plates for ruggedness and quality.
Custom testing/certification: Complete shock and vibration testing and agency approvals are also available.

Now Available in Titanium


Lytron has developed the technology to make titanium plate-fin heat
exchangers. These combine excellent thermal performance, high strength,
and light weight and can be used at temperatures up to 1000F (537C),
overcoming the temperature limitation of aluminum products. Call
Lytron for more information.
See page 92 for more custom heat exchangers.
84

www.Lytron.com +1-781-933-7300

Custom titanium plate-fin heat exchanger

Heat Exchangers Liquid-to-Liquid


Much smaller and
lighter than conventional
shell-and-tube designs

Extremely efficient
herringbone construction
for maximum heat transfer

Copper-brazed for water,


EGW and other common
coolants, or nickel-brazed
for high purity and
corrosive coolants
SELECT

89

GRAPHS

Stainless steel sheets are


brazed together at the
edges and at a matrix
of contact points for a
reliable and rugged part

87

DWG

86

Internal view of liquid-to-liquid


brazed plate heat exchanger

High performance in a small package: Lytrons liquid-to-liquid heat exchangers are up to 80-90% smaller in
volume and weight than a conventional shell-and-tube design. The counterflow design utilizes stainless steel sheets
stamped with a herringbone pattern of grooves, stacked in alternating directions to form separate flow channels
for the two liquid streams. This allows 90% of the material to be used for heat transfer, making it extremely efficient.
High reliability: The plates are brazed together at the edges and at a matrix of contact points between sheets,
ensuring that the heat exchangers are highly reliable and rugged.
Copper- and nickel-brazed versions for compatibility with a wide range of fluids: We offer copper-brazed
units for use with water, EGW, and other common coolants. Our nickel-brazed units are appropriate for use with
deionized water, high purity, and corrosive fluids.

87

Standard Heat Exchangers

Lytrons brazed-plate heat exchangers are unsurpassed for liquid-to-liquid heat transfer. Their innovative design packs
maximum performance into a compact and reliable package.

SPECS

High operating temperatures and pressures: Copper-brazed units can be operated at temperatures of up
to 383F (195C) and pressures up to 450 psig (31 bar). Nickel-brazed units can be operated at temperatures
of up to 662F (350C) and pressures up to 232 psig (16 bar).

Liquid-to-liquid heat exchanger subassembly with custom hoses and fittings

Customization Options
Liquid-to-liquid heat exchangers can be supplied as subassemblies with
fittings, hoses, and other accessories.
See page 92 for more custom heat exchangers.

www.Lytron.com +1-781-933-7300

85

Liquid-to-Liquid Pictures and Drawings


LL510 and LL520

LL810 and LL820

LL510

LL810

SELECT

89

GRAPHS

87

DWG

86

0.8 1.4
(20) (36)

3.5
(90)

SPECS

Standard Heat Exchangers

87
0.8 1.3
(20) (33)

2.9
(74)

12.9
(328)

11.0
(279)

8.0
(204)

6.7
(170)
1.6
(40)

1.7
(43)

LL520

LL820
0.8 2.4
(20) (60)

3.5
(90)

0.8 2.2
(20) (56)

2.9
(74)

8.0
(204)

6.7
(170)

12.9
(328)

11.0
(279)

1.6
(40)
1.7
(43)

86

www.Lytron.com +1-781-933-7300

Performance, Specifications and Ordering Information Liquid-to-Liquid


Performance
The performance of our liquid-to-liquid heat exchangers vary with the fluid type, flow rate, and temperature of each
fluid. The charts below show the thermal performance for water and water (left) and water and oil (right).
Thermal Performance Using Water and Water
0

10

20

30

LPM

40

350

3000

300

LL820
Q/Initial Temperature Difference (W/C)

1600
1400

LL810
LL520

1200

10

0
BTU
HRF

2000

1000
LL510
800
600

1000

400

Q/Initial Temperature Difference (W/C)

1800

Thermal Performance Using Water and Oil


20

30

LPM

40

LL820

250

BTU
HRF
600

LL810
400

200

LL520

150

SELECT

89

LL510
200

100

GRAPHS

87
50

200

DWG

0
0

10

12 GPM

0
0

Flow Rate

10

12

86

GPM

Flow Rate

SPECS

87

Pressure Drop Using Water


10

20

30

40

LPM

10

20

40

30

35

BAR

LL810

LL810

LPM
LL510

BAR

LL510
30

30

2.0

2.0
LL820

25
1.5

20
LL820
15

1.0

Pressure Drop (PSI)

Pressure Drop (PSI)

25

1.5
20

15

10

10
LL520

0.5

0.5

1.0
LL520

Standard Heat Exchangers

0
35

Pressure Drop Using Oil

0
0

10

12

GPM

0
0

Flow Rate

6
8
Flow Rate

10

12 GPM

Part Numbers
Core Number

LL510G12

LL520G12

LL810G12

Plate material

lbs
kg

Max. operating pressure

Max. flow rate

LL810G14

LL820G14

nickel 99.7%

10

20

10

20

10

20

10

20

2.6
1.2

3.7
1.7

4.9
2.1

6.7
2.9

2.6
1.2

3.7
1.7

4.9
2.1

6.7
2.9

Fittings

Min. operating temp.

LL520G14

copper 99.9%

Number of plates

Max. operating temp.

LL510G14

AISI 316L stainless steel

Braze material
Dry Weight

LL820G12

4 MNPT

450 psi/31 bar

232 psi/16 bar

383F/195C

662F/350C
-319F/-195C
20 gpm/76 lpm

www.Lytron.com +1-781-933-7300

87

Heat Exchanger Fittings


SB FittingStub End

BD FittingBeaded End

SB INLET/OUTLET
FITTING
BD INLET/OUTLET
FITTING

NUT
FERRULE
HELEX CLAMP
FITTING BLOCK
3/8 ID HOSE

A unit with a straight tube fitting can be welded into


your system or used with a 38 self-locking torque-free
fitting such as Swagelok or Cajon.

AN Fitting37AN Flare

For a leak-free joint, Lytrons beaded tube fitting


mates with a 38 ID hose that is secured with a clamp.

AN Fitting on 6340

Standard Heat Exchangers

TUBE

AN INLET/OUTLET
FITTING

NUT
TAIL PIECE

37 AN FITTING BODY

7/8 CUP ACTUAL SIZE

Lytrons AN fitting, 37 AN female flare nut (AN-818),


mates with male JIC-SAE 37 flare fitting, 916-18
UN/UNF-2A thd for 38 tubing and 34-16 UN/UNF-2A
thd for 12 tubing.

Note: the AN fitting on the 6340 is an 0.875 I.D.


actual union and tail piece only.

ES Series Fitting

3/8-18 NPT

The fitting on our ES Series oil coolers is a 38-18


NPT thread.

88

www.Lytron.com +1-781-933-7300

Selecting a Heat Exchanger


1. Cooling Liquid
In order to select the correct Lytron heat exchanger or oil cooler, you must first determine the required thermal
performance for your application. Use the example shown below:
Step 1: Application Data
Liquid type:
Required heat load (Q):
Temp. of incoming liquid (Tliquid in):
Temp. of incoming air (Tair in):
Rate of liquid flow:

Water
3,300 W (11,263 BTU/Hr)
80C (176F)
21C (70F)
2 gpm (7.6 lpm)

Step 2: Select the heat exchanger product series


Choose an aluminum, copper, or stainless steel heat exchanger based on the fluid compatibility. Aluminum tubing is
usually used with light oils, or ethylene glycol and water solutions. Copper is normally used with water. Stainless steel
is used with deionized water or corrosive fluids.
Step 3: Calculate the initial temperature difference
Subtract the temperature of the incoming air from the temperature of the incoming liquid as it enters the heat
exchanger.
ITD = Tliquid in - Tair in
= 80C 21C = 59C (or 176F 70F = 106F)
Step 4: Calculate the required performance capability (Q/ITD)
Divide the required heat load (Q) by the ITD found above in step 3.
Performance capability = Q = 3,300 W = 56 W/C or 11,263 BTU/HR = 106 BTU/HrF
ITD
59C
106F
Step 5: Select the appropriate heat exchanger model
Refer to the thermal performance graphs for the heat exchangers selected
(Performance graphs for copper heat exchangers, stainless steel heat exchangers, and
oil coolers can be found on pages 64, 74, and 82 respectively.) Any heat exchanger
that exceeds 56 W/C at 2 gpm (using a standard fan) would be acceptable. As shown
in the following graph, Lytrons 6210 exceeds the required performance.
Step 6: Determine the liquid pressure drop
From the data given, we know our pump needs to supply water at 2 gpm. Using the
liquid side pressure drop chart for the 6210 curve, the point where a vertical line at
the 2 gpm point on the x-axis intersects with the 6210 curve reveals that the liquid
pressure drop through the 6210 is 8 psi (0.55 bars). The pump selected must
overcome this pressure drop to ensure a 2 gpm flow.

10

100

m3
15 min
BTU
2 gpm
HRF
200
1 gpm

80

150
1/2 gpm

60
56

106
100
Falcon

40

Patriot

50
20

0
0 100 200 300 400 500 600
CFM
Air Flow

Standard Heat Exchangers

Q/Initial Temperature Difference (W/C)

120

Step 7: Determine the air pressure drop


The vertical line on the thermal performance chart indicates the air flow rate (190 CFM for the Patriot fan) as
provided by our standard fans at 60 Hz. The intersection point of this air flow rate and the 6210 graph on the
air side pressure drop reveals that the air side pressure drop through the 6210 is 0.24 inches of water (55 pascals).
Liquid Side Pressure Drop
5

10

Air Side Pressure Drop


LPM Bar
2.0

1.25

PSI

20

BAR
0.2
0.1

1
0
0

15

6210
5

10
GPM

6120

1.0

6110

10

6320
6310

5
0

0.5

1.0

2.5
1.5
2.0
Liquid Flow

300

6120
6105

250

0.5

200

0.75

6210

150
0.50
6310

0.25

6220
6320

6105

m3
min

12

10

1.00
1.5

Inches of Water

PSI

25

6
6110

6220
6340

3.0 GPM

Pascals

30

100
50

6340

100

200
300
Air Flow

400

500
CFM

www.Lytron.com +1-781-933-7300

89

Selecting a Heat Exchanger


2. Cooling Air
In cabinet cooling applications, the air is hotter than the liquid. In this case, the ITD is the difference between
the hot air entering the heat exchanger and the cold liquid entering the heat exchanger. You may need to calculate
the temperature rise using the heat load and the temperature of the cool air entering the cabinet.
Example: Cabinet Cooling application
You are cooling a cabinet containing electronic components that generate 2400 W of heat. The air in the cabinet
must not exceed 55C. What heat exchanger should be selected, and what is the temperature of the cool air entering
the electronics cabinet?
Step 1: Application Data
Liquid type:
Required heat load (Q):
Temp. of incoming liquid (Tliquid in):
Max. temp of air in cabinet (Tair in):
Rate of liquid flow:

Water
2,400 W (8,189 BTU/Hr)
20C
55C (131F) This is the temperature of the hot air entering the heat exchanger
2 gpm (7.6 lpm)

Step 2: Calculate the initial temperature difference


Subtract the temperature of the incoming liquid from the temperature of the incoming air as it enters the heat
exchanger.
ITD = Tair in - Tliquid in = 55C 20C = 35C (or 131F 68F = 63F)
Step 3: Calculate the required performance capability (Q/ITD)
Divide the required heat load (Q) by the ITD found above in step 2.

Step 4: Select the appropriate heat exchanger model


Refer to the thermal performance graphs for the heat exchangers selected
(Performance graphs for copper heat exchangers, stainless steel heat exchangers and
oil coolers can be found on pages 64, 74, and 82 respectively.) Any heat exchanger
that exceeds 68.6 W/C at 2 gpm (using a standard fan) would be acceptable. Using
water as the coolant, a copper heat exchanger is recommended. As shown in the following graph, Lytrons 6310 exceeds the required performance, offering a Q/ITD of
approx. 96 W/C using our Caravel fan.
Liquid and air pressure drop can be determined the same way as in the previous
example.

180

m3
10 15 20 25 min
BTU
HRF
4 gpm

160

2 gpm

These graphs offer a simple graphical way


of estimating fluid temperature change if you
know your heat load and flow, without having
to do calculations. The graphs for water, air,
50/50 ethylene glycol/water and oil allow you
to calculate temperature changes for air and
liquid for all types of heat exchangers.

1 gpm

120

200

100
1/2 gpm

80
68.6
60

100

40

Caravel

20
0

www.Lytron.com +1-781-933-7300

70

200 400 600 800 1000


CFM
Air Flow

120

60
100
50

80

40
60

30

40

20
17
10
0

20
0

200 250

400

600
Air Flow (CFM)

800

300

140

Step 5: Calculating the temperature of the cool air entering the cabinet
Now, to calculate the temperature of the cool air entering the cabinet, use the temperature change graph for
air (page 96). With a heat load of 2,400 W, and a flow rate of 250 CFM (the flow rate of the standard Caravel fan
recommended for use with
LPM
the 6310) we can see that the
0
5
10
15
20
25
30
F
100
180
temperature change is 17C.
90
160
This means that the cool air
80
entering the cabinet will be:
140
55C 17C = 38C

90

Q/Initial Temperature Difference (W/C)

Q
2,400 W
8,189 BTU/HR
=
= 68.6 W/C or
= 130 BTU/HRF
ITD
35C
63F

Change in Temperature (C)

Standard Heat Exchangers

Performance capability =

200

1000

1200

20 kW
15 kW
10 kW
7 kW
5 kW
4 kW
3 kW
2 kW
1.5 kW
1 kW
500 W
200 W

Selecting a Heat Exchanger


Step 6: Calculating the outgoing water temperature
To determine the outgoing temperature of the water we use the Water Flow chart to find that the change in temperature is approximately 5C. Therefore the outgoing water temperature is 20C + 5C = 25C.

50

10

12

14

16

Change in Temperature (C)

45

LPM
18

F
90
80

40

70

35

60

30

50

25
40

20

30

15

20

10

10

5
0

20 kW
15 kW
10 kW
7 kW
5 kW
4 kW
3 kW
2 kW
1.5 kW
1 kW
500 W
200 W

2
3
Water Flow (GPM)

x C x T
Q=m
p
Where:

Q=
=
m
Cp =
T =

heat load
mass flow rate of the fluid
specific heat of the fluid
temperature difference between the liquid in and the liquid out

can be calculated for water and air using the following equations:
m
gal
60 min
lbs
ft3
( lbs ) =
Water: m
v(
)x(
)x( 3)x(
) where
v = volumetric flow rate
7.5 gal
hr
min
hr
ft
or
liters
60 min
kg
m3
( kg ) =
Water: m
v(
)x(
)x( 3)x(
) where
v = volumetric flow rate
1,000 liters
hr
min
hr
m

Standard Heat Exchangers

Alternative Sizing Equation


The general heat transfer equation can be used to calculate the heat load and the fluid temperature change given the
fluid flow rate and the specific heat.

ft3
60 min
lbs
( lbs ) =
Air: m
v(
)x(
)x( 3)
hr
min
hr
ft
or
m3
60 min
kg
( kg ) =
Air: m
v(
)x(
) x ( 3)
hr
min
hr
m
The temperature change graphs on pages 96 and 97 plot the above equation for common heat transfer media
(air, water, oil, and a 50% EGW mixture) providing a simple way to look up T if you know your heat load and
fluid flow rate.

www.Lytron.com +1-781-933-7300

91

Custom Heat Exchangers

High capacity oil cooler

Heat exchanger with stainless steel tubes and nickel fin

Custom plate-fin liquid-to-air heat exchanger


with chemical conversion coating

Custom Heat Exchangers

Custom heat exchangers for every application


With 50 years of experience designing and building heat exchangers for performance-critical applications, Lytrons
expertise is second-to-none. We have designed and built small ultra-lightweight plate-fin heat exchangers
for airborne military applications, large flat-tube oil coolers for medical equipment, stainless steel tubed heat
exchangers for lasers, and everything in between. Our strong engineering expertise and experience with all of the
thermal components in a liquid cooling loop makes Lytron the ideal partner for all your heat exchanger needs.
Our streamlined design process relies on a combination of advanced modeling and analysis software, and hundreds
of man-years of experience. Lytrons heavy investment in engineering results in designs that not only meet your
performance and size requirements, but are also reliable and cost effective to build. With design and manufacturing
housed under the same roof, products transition smoothly from design, through prototyping, to production. We carry
out all performance-critical manufacturing processes in-house, from fin stamping, machining, and tube bending to
vacuum brazing and heat treating. This guarantees us total control over the finished product, as well as increased
flexibility and shorter lead times.
Our engineering laboratory and well-equipped, in-house test facility enable us to fully test and validate all our
custom heat exchangers. Our facilities include three wind tunnels (including a 21,000 CFM test tunnel that can
accommodate parts up to 6 x 6 (1.8 m x 1.8 m)), flow stations, data acquisition stations, refrigeration
test equipment, and various flow, temperature, and pressure instruments. Complete shock/vibration testing and
agency approvals are also available.

Getting started
Your design will benefit the most by involving Lytron early in the engineering process. While our continual
investment in capital equipment for our factory enables us to competitively bid build-to-print jobs, when we
design to a performance specification you realize the greatest cost savings. Get started today by calling your sales
engineer, or filling out the Request a Heat Exchanger Quote form on our website.

92

www.Lytron.com +1-781-933-7300

Heat Exchangers Custom

Miniature 3(8 cm) heat exchanger


with Chemfilm coating

Custom cupronickel tube-fin heat exchanger

Custom tube-fin heat exchangers

Large 4 (1.2 m) heat exchanger with


nickel tubes and copper fin

Custom oil coolers


Lytrons vacuum-brazed, flat tube oil coolers offer many customization
possibilities. Three different flat tube widths are available, and the
length and the number of tubes can be varied. The flat tube can be
bent into a 38 (3 mm) inside radius without buckling, so heat exchangers
can be manufactured in a curved shape if needed. Custom fittings and
manifolds can be added, and oil coolers can be painted or anodized for
extra protection.

Custom Heat Exchangers

The building blocks of a tube-fin heat exchanger are tubes, fin, and frame.
We have a variety of fin patterns to choose from, and can customize the
tube configuration and frame. We frequently work with specialty materials,
such as cupronickel, nickel, Hastelloy, and Inconel. To meet the stringent
shock and vibration requirements of some military applications, we can
provide ruggedized frames and fluid connections, and insert additional
tube sheets as supporting elements within the core. Paints and coatings,
including Milspec paints, are available. Fluid inlets and outlets can be
customized with bends, fittings, hoses, etc., and additional sensors and
instrumentation can also be added.

Commercial condenser with single-piece


aluminum flat tube

Custom oil cooler with curved tubes

www.Lytron.com +1-781-933-7300

93

Custom Heat Exchangers

Aircraft oil cooler


Custom plate-fin heat exchanger with
paint and chemical conversion coating

Custom plate-fin heat exchangers


All our aluminum, vacuum-brazed, plate-fin heat exchangers are
custom-designed, as every requirement is unique. They are widely used
in military, aerospace, and other high performance applications because
they offer excellent thermal transfer capacity combined with small size
and weight. Plate-fin heat exchangers can be designed for use with any
combination of gas, liquid, and two-phase fluids.

Custom Heat Exchangers

Air-to-air plate-fin inner cooler

We carefully select the number of plate and fin layers, the size of the plates
and fin, the height of the fin and the type of fin for optimum performance.
The core is assembled and vacuum brazed in our environmentally-controlled
room to ensure high quality and reliability. Manifold ducting and mounting
brackets are welded in place as specified, and any required paint or coating
(including Milspec) added.
Lytron also offers titanium plate-fin heat exchangers for high temperature
operation. Titanium heat exchangers offer performance similar to stainless
steel or nickel-alloy plate-fin heat exchangers, but at 30-50% the weight.

Titanium plate-fin heat exchangers

Clear anodized heat exchanger subassembly


including fan and temperature sensor

Heat exchanger subassembly with integrated fans

Value-added assemblies
Our extensive experience in the design and build of complete cooling systems and subassemblies makes us your ideal partner when you need to add
components such as fans, sensors, fittings, and hoses. We can add whatever
accessories you need, or build your entire subassembly, so that your heat
exchanger arrives ready to drop into your system. This saves you time
and effort.

94

www.Lytron.com +1-781-933-7300