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Contents: Technology overview . . . . . . . . . . . . . . . . . . . 32 Cooling system technologies Kodiak recirculating chillers . . . . . . . . . 34 LCS Liquid-to-Liquid Cooling Systems .

. 41 MCS Modular Cooling Systems . . . . . . 48 Pump selection . . . . . . . . . . . . . . . . . . . . . . . 53 Custom cooling systems . . . . . . . . . . . . . . . . 54 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Outsourcing your cooling loop to a company that builds thousands of cooling systems a year guarantees a quality product and enables you to focus your engineering efforts on your own area of expertise. Turnkey systems also accelerate the design process, reduce inventory levels, and simplify production. End users prefer integrated systems because they are easy to install and simple to operate. Our three types of cooling systems can be tailored to your precise requirements with a range of standard options, or completely custom designed. Lytrons cooling systems are used in a variety of applications including medical and industrial lasers, analytical instruments, oncology machines, data centers, electron microscopes, printing equipment, plasma etch systems, and solder reflow ovens.

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

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Cooling Systems Technology Overview


Lytron offers three types of cooling systems compressor-based chillers, liquid-to-liquid cooling systems, and ambient cooling systems. Each unit can be modified with a wide range of standard options, and for OEM volumes, we will design and manufacture total custom systems. Our cooling system technologies include:

Recirculating Chillers (Kodiak)


Cooling capacities up to 6 kW Kodiak compressor-based recirculating chillers are an ideal solution when you need precise temperature control (0.1C) or cooling below ambient temperature. Applications include medical equipment, medical and industrial lasers, electron microscopes, analytical instrumentation, semiconductor processing, and printing equipment.

Liquid-to-Liquid Cooling Systems (LCS)

Standard Cooling Systems

Cooling capacities up to 150 kW Liquid-to-Liquid cooling systems offer precise temperature control of process water and transfer the waste heat to facility water. They are ideal for high heat load applications where precise temperature control (0.5C) is needed and chilled facility water is available. Applications include medical equipment, datacom equipment centers, industrial machine tools, printing equipment, and cabinet cooling.

Ambient Cooling Systems (Modular Cooling System MCS)


Cooling capacities up to 3.5 kW Modular Cooling Systems are non-refrigerated cooling systems. They are a cost-effective alternative to recirculating chillers for applications where precise temperature control and cooling below ambient temperature are not required. Applications include analytical equipment, cabinet cooling, medical equipment, and laser systems.

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Cooling Systems Technology Overview


This flow chart guides you through the process of selecting the most appropriate cooling system for your application. Start at the top and simply follow the yes/no prompts. Next, select the most appropriate product size using the how to select a product page at the end of each system section. Finally, modify it with your pump, controller, and additional option selections. For assistance with product selection, call a Lytron applications engineer at +1-781-933-7300 or use our interactive product selector at www.Lytron.com.

Define your cooling system requirements.

Do you need to cool below ambient temperature?

Do you need precise temperature control (0.5C)?

Is your heat load less than 3,500 W?

See our ambient cooling systems (MCS) Page 48

Standard Cooling Systems

Do you want to use chilled facility water for cooling?

Is your heat load <5,900 W?

Facility water required

Is your set point below your facility water temperature? See our LCS Page 41

See our Kodiak chillers Page 34

See our Kodiaks with water-cooled condensers Page 34

Our on-line product selector at www.Lytron.com allows you to enter your system parameters, and the software determines the best product.

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

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Kodiak Recirculating Chillers


Cooling capacities up to 6 kW

Easy-access fill port

Large, easy-to-read, controller display

Reservoir-level indicator

Durable exterior panels

Standard Cooling Systems

Heavy-duty casters (two locking)

Kodiak compressor-based recirculating chillers are the ideal solution when you need precise temperature control or cooling below ambient temperature. Kodiak chillers offer outstanding performance and high reliability as well as quiet operation and ease-of-use. Precise temperature control: Our custom PID controller, large thermal mass tank, and advanced refrigeration control circuit ensure that the Kodiak maintains 0.1C stability. Quiet operation: The components inside the Kodiak have been performance-matched for quiet operation. In addition, vibration-isolation of the pump and compressor, and foam interfaces between sheet metal panels minimize vibration noise. Advanced ergonomic design: Our chillers look as good as the equipment they cool. Our industry-leading industrial design is as functional as it is attractive. Many options and features: The Kodiak was designed for flexibility a wide variety of pumps, controllers, and additional safety and monitoring features allow you to tailor a Kodiak to your specific application. High reliability: We are so confident that our Kodiak chillers will provide years of trouble-free operation that we offer a 2-year top-to-bottom warranty. ETL tested to UL 61010A-1, CE certified, and WEEE compliant

GRAPHS

36

SPECS

37

SELECT

40

Custom Spotlight: A customer required the cooling capacity of an RC045 but their application required reduced acoustic levels. Lytron enlarged the condenser and used variable speed fans to limit the noise. We also acoustically isolated the pump. These changes provided a chiller with lower sound levels to meet their requirements. See page 54 for more custom cooling systems.
34 www.Lytron.com +1-781-933-7300

Recirculating Chillers Kodiak


Cooling capacities up to 6kW

Large alphanumeric display with temperature in C or F

Over temperature (optional) Low flow Alarm Low level (optional) Cooling on/off indicator Low temperature (optional) International fault symbols Tactile feedback buttons Pressure display (optional) Alarm mute

Pump options available for your specific application

Standard Cooling Systems

Split-chassis, modular design for easy customization

High-efficiency evaporator

Compressor

Vibration-isolating feet on compressor and pump

GRAPHS

36

Circuit breaker Coolant supply IEC320 power inlet Fault condition interface (optional) RS232 port (optional) Manually adjustable flow valve (optional) Coolant return Large capacity tank improves temperature stability
SPECS

37

SELECT

40

System drain

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Kodiak Performance Graphs


Thermal Performance Graphs
RC006-RC011 Performance
2.0 50 60 70 80 90 F 6
Cooling Capacity (kW)
RC011 60 Hz RC011 50 Hz

RC022-RC045 Performance
kBTU hr 8.0 50 60 70 80 90 F kBTU hr 25

RC045 60 Hz

Cooling Capacity (kW)

1.5
RC009 60 Hz RC006 60 Hz

6.0

RC045 50 Hz

20
RC030 60 Hz

15

1.0
RC006 50 Hz RC009 50 Hz

4.0

RC030 50 Hz RC022 60 Hz

10

0.5

2.0

RC022 50 Hz

5 0 5 10 15 20 25 30 Output Temperature (C)1 35 0 5 10 15 20 25 30 Output Temperature(C)1 35

System Pump Graphs2,3


Kodiak Positive Displacement Pumps4
90 0 5 10
BE/CE 50 Hz

RC006-RC009 Centrifugal and Turbine Pumps


50 0 5 10 15 20 25 LPM Bar 3

15

LPM Bar

Standard Cooling Systems

80 70
Fluid Pressure (PSI)

BE/CE 60 Hz BG/CG 50 Hz BG/CG 60 Hz

5 4 3 2 1
Fluid Pressure (PSI)

40

60 50 40 30 20 10
BC/CC 60 Hz BC/CC 50 Hz

30

EC 60 Hz

20
EC 50 Hz

BB/CB 60 Hz BB/CB 50 Hz

1
AA 60 Hz

10
AA 50 Hz

0 0 1 2 3 4 Water Flow Rate (gpm) 5 0

4 2 6 Water Flow Rate (gpm)

RC011-RC022 Centrifugal and Turbine Pumps


90
GRAPHS

RC030-RC045 Centrifugal and Turbine Pumps


90 80 0 5 10 15 20 25 LPM Bar

10

15

20

25

LPM Bar

36

80 70
Fluid Pressure (PSI)
EB/FB 60 Hz

5
Fluid Pressure (PSI)

70 60 50 40 30 20
DA 60 Hz EB/FB 50 Hz

5
EB/FB 60 Hz

SPECS

37

60 50 40 30 20 10 0 0
EC 50 Hz EC 60 Hz

EB/FB 50 Hz

4 3

4 3 2 1

SELECT

40

DA 60 Hz

2 1

DA 50 Hz

10 0 0

DA 50 Hz

2 4 6 Water Flow Rate (gpm)

2 4 6 Water Flow Rate (gpm)

1 Temperature represents output temperature of water assuming 20C ambient air conditions. Performance subject to change due to variations such as fluid type or operating conditions. 2 Includes pressure drop through chiller. See page 53 for guidance on selecting a pump. 3 Pressure relief is factory set at 90 psi (6.2 bar). Other settings available on request. 4 BG/CG pumps can be operated at flow rates as low as 0.5 gpm for the RC011 and RC022.

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Specifications and Part Number Configuration Kodiak


First select your model number Cooling capacity1 Compressor capacity Temperature stability2 Fluid connections Reservoir capacity Coolant temperature range Ambient temperature range Dimensions (W x D x H) Weight Next, pick an electrical configuration inches mm dry lbs (kg) 12.5 x 19.0 x 22.0 318 x 483 x 559 97 (44) 100 (45) 1 gal/4 liters W kBTU/Hr HP RC006 825 2.8
1

RC009 1050 3.6


1

RC011 1650 5.6


1

RC022 2400 8.2


3

RC030 3450 11.8 1

RC045 5900 20.1 112

2 0.1C
1

2 FNPT 6 gal/23 liters

2 gal/8 liters 40F to 95F/5C to 35C 50F to 95F/10C to 35C 14.8 x 24.5 x 26.5 376 x 623 x 673 122 (55) 166 (75)

21.4 x 27.8 x 31.9 543 x 705 x 810 260 (118) 270 (122)

Electrical configurations and full load amperage3 G03: 115V, 60 Hz, 1ph H03: 230V, 50 Hz, 1ph J03: 208/230V, 60 Hz, 1ph Amps Amps Amps 9.9 4.5 n/a 12.2 5.3 5.8 14.3 6.3 7.4 n/a 9.5 10.0 n/a 13.7 14.5 n/a 17.2 19.6

Now, select a pump

Pump options (refer to Selecting a pump page 53 and system pump graphs, page 36) BB: PDP4, Brass, 1.3 gpm/4.9 lpm BC: PDP4, Brass, 1.8 gpm/6.8 lpm BE: PDP4, Brass, 2.3 gpm/8.7 lpm BG: PDP4, Brass, 4.3 gpm/16.3 lpm CB: PDP4, 5, Stainless Steel, 1.3 gpm/4.9 lpm CC: PDP4, 5, Stainless Steel, 1.8 gpm/6.8 lpm CE: PDP4, 5, Stainless Steel, 2.3 gpm/8.7 lpm CG: PDP4, 5, Stainless Steel, 4.3 gpm/16.3 lpm AA: Centrifugal, 120 HP6 DA: Centrifugal, 14 HP6 EC: Turbine, 16 HP6 EB: Turbine, 12 HP6

Standard Cooling Systems

Select your controller

Controller options (see page 39) Package 17: Digital temperature display, calibration offset, low flow shut-off, auto-restart, C / F toggle. Package 2: Package 1 plus digital pressure sensing, low level, low/high temperature, pressure display, audible alarm and alarm mute, fault shut-off (toggle on/off), relay contacts. Package 3: Package 2 plus RS232.

Add any additional options

Available options (full description of these options can be found on page 39) External flow valve External pressure relief valve Anti-siphon system Air filter 5 micron coolant filter8 Heater9 Internal insulation package Low temperature operation Water-cooled condenser 0.1C set point DI water cartridge8, 10 High purity plumbing PAO compatibility Remote start
= standard = available option 1 At 20C setpoint, 20C ambient, 60Hz input supply 2 Assumes stable load 3 With standard pump 4 PDP = Positive Displacement Pump 5 Only available with high purity plumbing 6 Actual flow rate depends on system pressure drop. See page 53 for information on how to calculate flow rate 7 5 piece min order 8 Not available with AA and DA pump 9 Not available in G03 electrical configuration 10 Recommended when selecting high purity option
9

GRAPHS

36

SPECS

37

SELECT

40

To arrive at a part number

RC011 G03 BB 2 M

RC011 chiller with G03 (115V, 60 Hz, 1ph) electrical configuration, a BB pump, and controller package 2 Customization options (A 4 digit option code will be assigned at time of order, based on selected options. Leave blank if no additional options selected.)

Use our on-line product selector at www.Lytron.com to automatically select the right chiller based on your specifications www.Lytron.com +1-781-933-7300 37

Kodiak Options and Accessories


Kodiak Options1
Option Protection Options External flow valve: HIGHLY RECOMMENDED. A manually adjustable globe valve installed on the back of the chiller in parallel with the chiller coolant supply/return. External pressure relief valve: A manually adjustable pressure relief valve (50 to 100 psig) installed on the back of the chiller in parallel with the chiller coolant supply/return. Anti-siphon system: Check and solenoid valves installed internal to the chiller on the supply and return lines, respectively. Air filter: Internally mounted on the air inlet to the condenser coil. Allows the operator to control the flow rate to the application. As the external flow valve is opened, more of the flow bypasses the application. Benefit

Allows the chiller to continue to run and maintain temperature if the flow to the application is interrupted. When flow to the application is stopped, the pressure relief valve opens and bypasses flow to the chillers return. It can also be used to prevent the chiller supply from exceeding a predetermined pressure setting. Allows the chiller to be installed at an elevation below the application. Prevents backflow and subsequent overflowing of the chillers vented tank (if not installed, fitting leaks in the application can allow air to displace the coolant, resulting in backflow to the tank). Filters incoming air to the chillers condensing coil, preventing dust build up which can lead to decreased performance. The easy-access filter is simple to replace, reducing the need to clean the condensing coil and refrigeration components. Filters process coolant being supplied to the application, protecting equipment from blockage or damage due to particulate buildup and extending pump life.

5 micron coolant filter: Externally mounted on the supply from the chiller. Special Applications Options Heater: Submerged 2,000 Watt electric resistance heater with built-in over temperature shut-off (non-adjustable).

Allows chiller to reach elevated set points faster (useful for applications in cold start-up situations or where the coolant set point is frequently cycled). This feature does not extend the coolant temperature range of the chiller. Eliminates condensation forming on the components in contact with the fluid when operating chiller at set points below the ambient dew point. Optimizes performance for low temperature operation and provides additional low temperature cooling capacity compared to standard chillers. Contact Lytrons applications engineering department for performance graphs. Heat that would normally be rejected to the ambient environment is transferred to an external liquid coolant source, avoiding room warming and possible air conditioning overload. Also, water-cooled chillers are quieter because there is no condenser fan. Contact Lytron for required facility liquid coolant flow rate and temperature requirements. Allows more precise control of the coolant delivery temperature. Available in C only.

Standard Cooling Systems

Internal insulation package: Insulated tank, pump head, and coolant lines. Low temperature operation: Chiller coolant temperature range is 5C to +25C. (Note: internal insulation package must also be selected.) Water-cooled condenser: Refrigerant is condensed using water (rather than ambient air) via a liquid-to-liquid heat exchanger.

0.1C set point: Allows 0.1C increments of the set point and display temperatures. Fluid Compatibility Options Deionization (DI) water cartridge: Externally mounted DI cartridge (no indicator light) on the return to the chiller.

Filters ions from coolant to maintain a fluid resistivity level between 1 and 3 megohm/cm by partial flow through the resin bed. This feature does not include a resistivity indicator light. High purity plumbing is recommended with the DI water cartridge. All wetted materials are fully compatible with DI water to prevent component corrosion.

GRAPHS

36

High purity plumbing: Includes nickel-brazed evaporator and nickel-plated or nylon fittings compatible with DI water. Not compatible with brass pumps. PAO compatibility: Includes pump, fittings, hose, and oil filter compatible with polyalphaolefin (PAO). Anti-siphon system and internal insulation packages are included in this option. Convenience Options Remote start: Chiller power can be cycled through a computer or relay.

SPECS

37

All wetted materials are fully compatible with PAO. Contact Lytron for PAO performance curves.

SELECT

40

Allows an external circuit to control the chiller on/off function via dry contacts on the rear of the chiller.

Please refer to the chiller technical manual at www.Lytron.com for further discussion of these features.

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Options and Accessories Kodiak


Kodiak Controllers1
Controller Option Functionality Controller Package 1 Digital temperature display Calibration offset Easy-to-read display in either C or F. Allows temperature display to be offset to represent the temperature at a different point within the cooling circuit. Alerts user to a lack of coolant flow and shuts down the chiller to prevent the refrigeration system from freezing. Automatically returns chiller to its operating status prior to interruption of power, e.g., if the chiller was on, it will turn back on when power is restored. Enables temperature display to be viewed in C or F. Audible warning of all fault conditions. Silences audible alarm until the alarm is cleared or the chiller turned off. Displays pump output pressure (psig or bar) and allows it to be transmitted through RS232. Alerts user that the coolant level in the reservoir is at a critically low level (approaching the level of the pumps suction line). Switches chiller off if fault shut-off is on. Alerts user that the coolant temperature is outside of the users defined set-point limits. Switches chiller off if fault shut-off is on. Allows chiller to be programmed to shut down on fault (on) or continue to run during fault conditions (off). The chiller will always shut down on the low flow shut-off alarm. Fault conditions of the chiller can be monitored by applying a low voltage power signal across dry contacts at the rear of the chiller. (Power loss to the chiller is not a fault condition.)2 Mating connector AMP part number 350715-1 and 350547-1 Allows complete control of all the chillers controller features (changing/monitoring coolant set point, monitoring pressure, and fault alarms, etc.) from a remote computer for monitoring, control, and data logging. 2 3

Low flow shut-off fault

Auto-restart

C/F toggle Audible alarm Alarm mute Digital pressure sensing Low level fault

Low/high temperature fault

Fault shut-off (toggle on/off) Relay contacts (normally open or normally closed)

Standard Cooling Systems

RS232 communications

Kodiak Accessories
Item Coolant Filter Kit: Description 2 fluid connections. Contains 5 micron filter, filter housing, mounting bracket ,1 hosing, base clamps, and assembly instructions.
1

Part Number 200-0441

Plumbing package:

2 fluid connections. Contains 50 NylabraidTM hose, 50 Armorflex insulation, male NPT to barb fittings, hose clamps.
1 1 2 fluid connections. For applications requiring reduced pressure. This kit contains a pressure relief valve, 2 tees, hose clamps, and plumbing instructions. Assembly required.

200-0193

External pressure relief valve: External manually adjustable flow valve: 115V power cord: 230V power cord: RS232 cable: Dry contact cable:

200-0196

GRAPHS

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1 2 fluid connections. For applications requiring flow control. Kit contains flow valve, 2 tees, hose clamps, and plumbing instructions. Assembly required.

200-0298
SPECS

37 250-0092 250-0093 250-0091 250-0159 330-0022 RC006/RC009: 330-1541 RC011/RC022: 330-0977 RC030/RC045: 330-0683 430-0330
SELECT

25 25 10 10

40

5 micron replacement coolant filters2 Air filters2

Deionization cartridge

Package 2 is the standard package

10 piece minimum

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

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Kodiak Selecting a Recirculating Chiller


Selecting the proper recirculating chiller is a function of four factors: 1. 2. 3. 4. The heat load generated by the device being cooled (Q) The maximum acceptable temperature of the fluid exiting the heat source (TOUT) Available fluid flow rate (v ) Ambient operating conditions

Often, an equipment manufacturer will specify the set point temperature and flow rate of the required chiller. In this case, selecting a chiller is simple. Simply mark the intersection of the desired cooling capacity and the set point temperature on the chiller graph. Any chiller with a performance curve above or equal to this point will provide enough capacity. Next, use the pump graph to select a pump that meets the desired flow rate. Example 1: A chiller needs to supply 2 gpm at 20C to an x-ray tube that generates 2,000 W of heat. The power supply is 60 Hz. Marking this point on the chiller graph we can see that an RC022 would be an appropriate choice. From looking at the pump curves we see that a BE pump would provide the necessary flow rate. If the Heat Load (Q) is known, but the Flow Rate is unknown, the following equation can be used to determine the required flow rate. = Q/( C (T v p OUT - TIN)) where: v = fluid flow rate v = fluid density Q = heat load Cp = fluid specific heat TOUT = max. fluid temp. exiting the heat source TIN = fluid temp. exiting the chiller

Standard Cooling Systems

Example 2: A laser head generates 2,000 Watts (6,824 BTU/Hr) of heat. The fluid temperature must not exceed 20C (68F). With a cooling fluid of water, 60 Hz power, at 20C ambient, what is the appropriate Lytron recirculating chiller? Using the thermal performance graphs (fig 1), draw a horizontal line at the required heat load (2000 W). As shown, the RC022 would match this requirement at 13C (55F). This is TIN (the temperature exiting the recirculating chiller). Therefore, the calculation then becomes: = 2000 W /(990 kg/m3 4180 J/kgC (20C 13C) v = 6.9 x 10-5m3/s or 1.1 gpm v 3 water = 990 kg/m , Cp = 4180 J/kgC Next, determine if the recirculating chiller can meet the required flow rate. As shown on the system pump graph (fig 2), the 1.3 gpm positive displacement pump (standard on the RC022) would more than satisfy the flow requirement.

GRAPHS

36 8.0
SPECS

Fig 1: RC022-RC045 Performance


50 60 70 80 90 F kBTU hr 25

Fig 2: Kodiak Positive Displacement Pumps


90 80 70
Fluid Pressure (PSI)

10
BE/CE 50 Hz

15

LPM Bar

37
Cooling Capacity (kW)

RC045 60 Hz

6.0

RC045 50 Hz

20
RC030 60 Hz

BE/CE 60 Hz BG/CG 50 Hz BG/CG 60 Hz

5 4 3 2 1

SELECT

40

60 50 40 30 20 10
BC/CC 60 Hz BC/CC 50 Hz

15

4.0

RC030 50 Hz RC022 60 Hz

10

2.0

RC022 50 Hz

5 0 5 10 15 20 25 30 Output Temperature(C)1 35

BB/CB 60 Hz BB/CB 50 Hz

2 3 4 Water Flow Rate (gpm)

To avoid thermal calculations, use the cooling system product selector at www.Lytron.com.

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Liquid-to-Liquid Cooling Systems LCS20


Cooling capacities up to 20kW

Reservoir-level indicator

Split-chassis, modular design for easy customization

Durable exterior panels

High-efficiency counterflow heat exchanger Wide variety of pump options

Standard Cooling Systems

Heavy-duty casters (two locking)

Lytrons Liquid-to-Liquid Cooling System (LCS20) offers precise temperature control of process water and transfers the waste heat to your facility water via a liquid-to-liquid heat exchanger. It is an excellent solution for high heat-load or high ambient temperature applications where chilled facility water is available. Large cooling capacity in a compact package: An LCS is a great solution for high heat loads where space is at a premium. With 20 kW of cooling, our LCS20 provides over three times the capacity of a comparably-sized recirculating chiller. Tight temperature control: We maintain the fluid temperature to within 0.5C, despite fluctuations in the facility water temperature and flow rate. Our PID controller varies the facility water flow rate through the heat exchanger based on the process water temperature to achieve this stability. Contamination-free: The process cooling loop of the LCS is isolated from the facility water. This separation protects your equipment, keeping it free from facility water contaminants. It also eliminates the risk of condensation near your equipment if the facility water is below the dew point. Reliable, quiet, and energy efficient: The LCS system contains very few moving parts this makes it inherently reliable and quiet. The only components requiring power are the pump, motor, and controller, so it is also extremely energy efficient. ETL tested to UL 61010A-1, CE certified, and WEEE compliant

GRAPHS

36

SPECS

37

SELECT

40

Custom Spotlight: A customer had a total heat load of 25 kW and access to facility water. They needed to cool 4 independent heat sources and wanted the cooling system integrated into their machine. Lytron provided a fully-engineered skinless system that included integrated temperature and pressure sensors and was designed for serviceability. See page 54 for more custom cooling systems.
www.Lytron.com +1-781-933-7300 41

LCS50 Liquid-to-Liquid Cooling Systems


Cooling capacities up to 150 kW

Controller with digital temperature, flow, and pressure display; mixing valve status reporting; lock-out protection; and RS232 (Ethernet available) communication

Redundant pump with user defined secondary pump test frequency and duration

Visual alarms for low/high temperature; low flow; dew point (optional); pump, power, or sensor failure; relay contacts for each alarm

Isolation valves allow for hot swapping of pump

Accommodates dual power feeds

Control to local dew point available

Standard Cooling Systems


GRAPHS

The increasing heat load densities in datacom equipment centers require ever more sophisticated approaches to cooling, including liquid cooling. Designed for data center cooling, the LCS50 is a 150kW liquid-to-liquid cooling system that supplies precise temperature-controlled coolant to your liquid cooled racks and transfers the waste heat to facility water. High reliability The LCS50 is designed to be extremely reliable. Redundant pumps ensure the system always provides coolant to your racks. The controller tracks the actual operation hours for each pump and the backup pump is tested periodically to guarantee its operation if needed. The controller warns you of any system problems via various alarms and offers lockout protection and communication packages for remote monitoring. Protection and isolation of datacom equipment: According to ASHRAE, the benefits of an LCS for liquid cooling include preventing condensation by delivering coolant to the rack, equipment, or electronics above the dew point, isolating the electronics from the harsher facility water, and minimizing the coolant volume near the technology so that a coolant leak would be less catastrophic.1 Easy to install: The unit is equipped with casters for easy mobility and leveling feet that disengage the casters. The inlets and outlets of the facility (primary) and process (secondary) coolant loops can be configured for a raised floor or overhead plumbing. The flow rate is adjustable using an internal manually adjustable flow control valve. Energy efficient: Liquid cooling the electronics cabinet is significantly more energy efficient than air cooling. UL/CE/CSA, RoHS, and WEEE compliant
1

43

SPECS

44

SELECT

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American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (2006). Liquid Cooling Guidelines for Datacom Equipment Centers. Atlanta.

Custom Spotlight: A customer needed a liquid-to-liquid cooling system for medical imaging equipment. This custom unit contains four separate cooling loops, three liquid cooling and one air cooling, all managed by the unit's controller. See page 54 for more custom cooling systems.

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Specifications LCS
LCS20 Thermal Performance Graph1
2.0 10 20 30 40 LPM kBTU HrF 3.5 3.0
8 GPM 6 GPM

LCS20 Pump Graph2,3


100 5 10 15 20 25 LPM Bar 6 80
EB/FB - 60Hz

10 GPM

1.5

2.5 2.0

Fluid Pressure (PSI)

Q/ITD (kW/C)

EB/FB - 50Hz

60

BG/CG - 50Hz BG/CG - 60Hz

1.0

4 GPM

1.5 0.5
2 GPM

40

DA - 60Hz

1.0 0.5

2 20
DA - 50Hz

4 6 8 Process Water Flow Rate

10

12 GPM

2 3 4 5 6 Process Water Flow Rate

8 GPM

LCS50 Thermal Performance Graph1


20 19 18 16 100 200 300 400 LPM kBTU HrF 35 70 60

LCS50 Pump Graph


100 200 300

400

LPM

BAR

100 GPM

4
DE 60 Hz

Fluid Pressure (PSI)

30
75 GPM

50 40

Standard Cooling Systems

Q/ITD (kW/C)

14 12 10 8 6 4 2 0 20 30 40

25
50 GPM

3
DE 50 Hz

20 15

30 20

25 GPM

10 5

1 10 0

50 60 70 80 90 100 110 120 GPM Process Water Flow Rate

20

40 60 80 100 120 GPM Process Water Flow Rate

LCS50 Facility Side Pressure Drop


18 16 100 200 300 400 500 LPM BAR
FILL VALVE

LCS50 Plumbing Diagram


AIR VENT BRAZED PLATE HEAT EXCHANGER PROCESS WATER RETURN (SECONDARY) FACILITY WATER OUT (PRIMARY)

PS

MIXING VALVE

Pressure Drop (psid)

14 12 10 8 6 4 2 0 0 20 40 60 80 100 120 Facility Flow Rate

1.00
PRESSURE TEMPERATURE SENSOR SENSOR

GRAPHS

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0.75

PS

TS
EXPANSION TANK FACILITY SIDE SENSORS ARE OPTIONAL

SPECS

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0.50

BALL VALVE

FLOW CONTROL VALVE

SELECT
CHECK VALVE

47
FACILITY WATER IN (PRIMARY)

0.25
PUMP PRESSURE SENSOR

PS

TS

PROCESS WATER SUPPLY (SECONDARY)

140 160 GPM

PS LS

1 2

Facility side flow rates are represented by curves Pressure relief is factory set at 90psi (6.2 bar). Other settings available on request. Includes pressure drop through system. See LCS specifications and options for pump descriptions

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

43

LCS Specifications and Part Number Configuration


First select your model number LCS20 Cooling capacity 11 kW (37 kBTU/Hr) at 4.3 GPM process and 10 GPM facility and 10C Initial Temperature Difference (ITD) 0.5C 3 4 FNPT LCS50 150 kW (512 kBTU/Hr) at 75 GPM process and 100 GPM facility and 10C Initial Temperature Difference (ITD) 1.0C 2 copper (cup) terminated at bottom of unit 6 gal/22 liters N/A 50F to 122F/10C to 50C 41F to 95F/5C to 35C 50F to 95F/10C to 35C 39F to 54F/4C to 12C 41F to 104F/5C to 40C 2 to 10 gpm/11 to 38 lpm 25 to 100 gpm/95 to 379 lpm 100 psi/7 bar max 300 PSI/ 21 bar max 15 psi/1 bar at max flow See Pressure Drop Graph 21.4 x 27.8 x 31.9 29.0 x 36.0 x 76.0 543 x 705 x 810 737 x 914 x 1930 225 750 102 340

Temperature stability Fluid connections Reservoir capacity Coolant temperature range Facility water temperature range Ambient temperature range Facility flow rate Facility pressure Facility pressure drop Dimensions (W x D x H) Weight Next, pick an electrical configuration Electrical configurations and full load amperage1 G01: 100-120V, 50/60 Hz J01: 200-240V, 50/60 Hz L01: 208-230 VAC, 50/60 Hz, 3ph P01: 460 VAC, 50/60 Hz, 3ph Now, select a pump Amps Amps Amps Amps

inches mm lbs kg

7.2 3.6 N/A N/A

N/A N/A 18 9

Pump options (refer to Selecting a pump page 53 and system pump graph, page 43) BG: PDP2, Brass, 4.3 gpm/16.3 lpm CG: PDP2,3, Stainless Steel, 4.3 gpm/16.3 lpm DA: Centrifugal, 14 HP4 EB: Turbine, 12 HP4 FB: Turbine, Stainless Steel, 12 HP 3,4 DE: Centrifugal, 5 HP, 2 per system

Standard Cooling Systems

And select your controller

Controller options (see page 45 and 46) LCS20 Only Package 1: Digital temperature display, C/F toggle, over-temperature indicator, calibration offset LCS20 Only Package 2: Package 1 plus low level indicator, low flow indicator, analog output LCS50 Only Package 3: RS232 controller with digital temperature, flow, and pressure display; mixing valve status reporting; visual alarms for low/high temperature, low flow, pump, power, or sensor failure; relay contacts for each alarm; and lock-out protection. LCS50 Only Package 4: Package 3 plus visual alarm and relay contacts for dew point; option to control set point based on dew point offset or on fixed temperature with user defined dew point override. LCS50 Only Package 5: RS232 and Ethernet controller with digital temperature, flow, and pressure display; mixing valve status reporting; visual alarms for low/high temperature, low flow, pump, power, or sensor failure; relay contacts for each alarm; and lock-out protection. LCS50 Only Package 6: Package 5 plus visual alarm and relay contacts for dew point; option to control set point based on dew point offset or on fixed temperature with user defined dew point override.

GRAPHS

36

SPECS

37

Add any additional options

Available options (full descriptions of these options can be found on pages 45 and 46) External flow valve External pressure relief valve 5 micron coolant filter5 DI water cartridge5 High purity plumbing Heater Internal insulation package Facility side monitoring Coolant filters Alternative fluid inlet and outlet location Internal insulation package (process side) Dual mixing valves = available option 1With standard pump 2PDP = Positive Displacement Pump. 3Only available with high purity plumbing = standard
4Actual

SELECT

40

flow rate depends on system pressure drop. 5Not available with DA pump.

To arrive at a part number 44

LCS 20 G01 BG 1 M

An LCS20, 100-120V, 50/60 Hz, with BG pump and controller package 1 A 4 digit option code will be assigned at time of order, based on selected options

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

Options and Controllers LCS20


LCS20 Options
Option Protection Options External flow valve: HIGHLY RECOMMENDED. A manually adjustable globe valve installed on the back of the LCS in parallel with the LCS coolant supply/return. External pressure relief valve: A manually adjustable pressure relief valve (50 to 100 psig) installed on the back of the LCS in parallel with the LCS coolant supply/return. 5 micron coolant filter: Externally mounted on the supply from the LCS. Special Applications Options Heater: Submerged 2,000 Watt electric resistance heater with built-in over temperature shut-off (non-adjustable). Allows LCS to reach elevated set points faster (useful for applications in cold start-up situations or where the coolant set point is frequently cycled). This feature does not extend the coolant temperature range of the LCS. Eliminates condensation forming on the components in contact with the fluid when operating LCS at set points below the ambient dew-point. Allows the operator to control the flow rate to the application. As the external flow valve is opened, more of the flow bypasses the application. Benefit

Allows the LCS to continue to run and maintain temperature if the flow to the application is interrupted. When flow to the application is stopped, the pressure relief valve opens and bypasses flow to the LCSs return. It can also be used to prevent the LCS supply from exceeding a predetermined pressure setting. Filters process coolant being supplied to the application, protecting equipment from blockage or damage due to particulate buildup and extending pump life.

Internal insulation package: Insulated tank, pump head, and coolant lines. Fluid Compatibility Options Deionization (DI) water cartridge: LCSs come with an externally mounted DI cartridge (no indicator light) on the return to the LCS. High purity plumbing: Includes nickel-brazed heat exchanger and nickel-plated or nylon fittings compatible with DI water. Not compatible with brass pumps.

Filters ions from coolant to maintain a fluid resistivity level between 1 and 3 megohm/cm by partial flow through the resin bed. This feature does not include a resistivity indicator light. High purity plumbing is recommended with the DI water cartridge. All wetted materials are fully compatible with DI water to prevent component corrosion.

Standard Cooling Systems

LCS20 Controllers
Controller Option Functionality Controller Package 1 Digital temperature display C/F toggle Over-temperature indicator Calibration offset Easy-to-read display in either C or F. Enables temperature display to be viewed in C or F. Alerts user that the coolant temperature is over the users defined set point limits. Allows temperature display to be offset to represent the temperature at a different point within the cooling circuit. Alerts user that the coolant level in the reservoir is at a critically low level (approaching the level of the pumps suction line). Alerts user to a lack of coolant flow. Allows user to monitor pump discharge temperature remotely 2

Low level indicator

GRAPHS

36

Low flow indicator Analog output

SPECS

37

SELECT

40

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

45

LCS50 Options and Controllers


LCS50 Options
Option Protection and Special Applications Options Facility side monitoring Coolant filters Provides temperature and flow monitoring of facility side loop. Facilitates troubleshooting. Filters on both the facility and process side loops. Protects LCS and customer equipment from blockage or damage due to particulate buildup and extends pump life. Incorporates a second mixing valve. In the unlikely event of a failure, the controller automatically switches over to the redundant valve. Allows for piping to terminate at the upper back of the LCS for overhead piping configurations. Eliminates condensation on process side components when operating the LCS at set points below the dew point. Benefit

Dual mixing valves

Alternative fluid inlet and outlet location Internal insulation package (process side)

LCS50 Controllers
Controller Option Functionality Controller Package 3 Digital temperature set point RS232 communications Diplays process and set point temperatures in either C or F. Allows monitoring, control, and data logging of all the controller features using RS232 protocol. Allows monitoring, control, and data logging of all the controller features using Ethernet protocol. Controller displays the current process side coolant flow and pressure as well as current position of the mixing valve. Alerts user that the coolant temperature is outside of the users defined set-point limits. 4 5 6

Standard Cooling Systems

Ethernet communications

Flow, pressure, and mixing valve status reporting Visual alarms for low/high temperature Low flow alarm Pump failure alarm Power failure alarm

Alerts user that the coolant flow is below the users defined limit. Alerts user of a pump failure. System automatically switches over to secondary pump Alerts user of a power failure. System automatically switches over to secondary power supply. Fault conditions of the LCS can be monitored by applying a low voltage power signal across dry contacts.

Relay contacts for each alarm (normally open or normally closed) Lockout protection Control set point temperature based on dew point offset Control set point based on fixed temperature with user defined dew point override

Allows user to lock-out the controller to prevent unauthorized use. Allows user to input dew point offset such that the coolant temperature will fluctuate based on the dew point fluctuation. Allows user to input set point temperature and a minimum dew point offset. If the set point temperature is above the dew point offset range, the LCS will deliver coolant at the set point temperature. If the set point temperature is within the dew point offset range, the LCS will deliver coolant based on the dew point.

GRAPHS

43

SPECS

44

SELECT

47

46

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

Selecting a Liquid-to-Liquid Cooling System LCS

In most LCS sizing applications, we know the temperature of the facility water (TF), the desired process set point temperature (Tp), the flow rate through the process (vp) and the heat load of the process, Q. To determine the required capacity, Q/ITD, we first need to calculate the change in temperature, T, through the process. We can do this either by solving the heat capacity equation:

vF ,TF LCS vp ,Tp Heat Source, Q

Facility Side Tp + T Process Side

Q = m Cp T
or by using the heat capacity graphs on pages 96 and 97. Next, we calculate Q/ITD to find the required cooling capacity. Q is the process heat load. ITD, the initial temperature difference, is the difference in temperature between the warm return water, (Tp+ T) and the cold facility water (TF). So,

Q m Cp T = ITD Tp + T - TF
Finally, refer to the LCS performance graph to determine the facility process flow rate required to achieve the calculated Q/ITD. Example: A solder reflow oven requires a process set point of 20C. The heat load is 10 kW and the process water flow rate is 5 gpm. The facility water is at 10C. Using the heat capacity graphs, we find that the T through the process is approximately 7.6C for the condition 10 kW at 5 gpm. We can now solve for Q/ITD as follows:

Standard Cooling Systems

Q 10 kW = ITD 20C + 7.6C - 10C Q kW = 0.57 ITD C


Referencing the LCS performance graph, we can see that a facility flow rate above 2 gpm will meet the required performance. Thermal Performance Graph Water Temperature Change Chart
2.0 10 20 30 40 LPM KBTU/HrF 3.5 Change in Temperature (C) 3.0
8 GPM 6 GPM

GRAPHS

43

50 45 40 35 30 25 20 15 10 7.6 5 0

10

12

14

16

LPM 18 F 90 80

SPECS

44

10 GPM

SELECT

1.5

70 60 50 40 30 20 10 0 1 2 3 4 5

2.5 2.0

1.0

4 GPM

1.5
2 GPM

0.57 0.5

1.0 0.5

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

47

Q/ITD (KW/C)

4 5 6 8 Process Flow Rate

10

12 GPM

Water Flow (GPM)

Use our interactive on-line LCS product selector - simply enter your process parameters and it will pick the right product for you.
www.Lytron.com +1-781-933-7300 47

MCS Modular Cooling Systems


Ambient cooling systems with cooling capacities up to 3.5 kW

Polyethylene reservoir Internal view of MCS High-efficiency heat exchanger Reservoir level indicator

Easy access reservoir panel

Stand alone housing or rack mount configurations available

Rugged, all-welded steel frame Various pumps available

Durable textured finish

Standard Cooling Systems

Heavy-duty vibration isolation feet

Easy access inlet and outlet ports

A Modular Cooling System (MCS) is a cost-effective and reliable alternative to refrigerated chillers for applications where precise temperature control and cooling below ambient temperature are not required. It consists of a high performance Lytron heat exchanger integrated with a fan, pump, and tank in a durable metal chassis. Extremely efficient: All components are performance-matched for maximum cooling capacity. Lytron has 50 years of experience in thermal design, so you can be sure that the most critical component of the MCS, the heat exchanger, is designed for optimum performance. Easy-to-operate: This easy-to-use, turnkey cooling package takes the guesswork and effort out of building a cooling loop. All you need to do is fill the tank and flip the switch! Compatible with a range of coolants: We offer systems with copper heat exchangers for use with water, stainless steel heat exchangers for use with deionized water, or aluminum heat exchangers for use with oil or ethylene glycol/water mixture (EGW). This ensures that we have a product optimized for virtually any cooling fluid. 19 rack mount version available: Integration into your system is simple with our rack-mounted versions (MCS10, 20 and 30). Extremely reliable: All components in the MCS have been designed for long life and high reliability a Lytron MCS will provide years of trouble-free operation. ETL tested to UL 61010A-1, CE certified, and WEEE compliant Custom Spotlight: A customer needed a tightly packaged MCS to integrate inside their system. Lytron engineers selected a high-efficiency OEM Coil heat exchanger, a long-life centrifugal pump, and a compact reservoir for the unit. See page 54 for more custom cooling systems.

GRAPHS

50

SPECS

51

SELECT

52

48

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

Modular Cooling Systems MCS


Ambient cooling systems with cooling capacities up to 3.5 kW

MCS10

MCS20, MCS30

GRAPHS

50

SPECS

51

Standard Cooling Systems

MCS10, MCS20, MCS30 19 Rack Mount MCS40, MCS50

SELECT

52

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

49

MCS Performance Graphs

MCS10 and MCS20 Thermal Performance


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

MCS30 Thermal Performance1


0 80 70 60 50 40 30 20 10 0 0 1 2 3 Flow Rate (gpm) 4 5 2
Oil 50 Hz 50% EGW 60 Hz 50% EGW 50 Hz Oil 60 Hz

70 60 50 40 30 20 10 0

10
MCS20 60 Hz MCS20 50 Hz

15 LPM BTU HrF 4

10

15

LPM BTU HrF 4

2
MCS10 60 Hz MCS10 50 Hz

3 1 2 Water Flow Rate (gpm)

MCS40 and MCS50 Thermal Performance


0 5 10 15 LPM

MCS Positive Displacement Pumps


100 0 2 4 6 8 10 LPM Bar 6 80
Fluid Pressure (PSI)
BC/CC 50 Hz BC/CC 60 Hz BE/CE 50 Hz BE/CE 60 Hz

Standard Cooling Systems

Q/Initial Temperature Difference (W/C)

150
MCS50 60 Hz

BTU HrF 250 200 150

125 100 75 50 25 0 0 1 3 2 4 Water Flow Rate (gpm)

MCS50 50 Hz MCS40 60 Hz MCS40 50 Hz

5 4 3 2

60

BB/CB 50 Hz

40

100

BB/CB 60 Hz

50

20 1 0

1 2 Water Flow Rate (gpm)

GRAPHS

MCS10 Centrifugal Pumps2


30 0 5
DA - 60 Hz

MCS20 Centrifugal Pumps2


30 25
Fluid Pressure (PSI)

50

10

LPM Bar 2.0

5
DA - 60 Hz

10

LPM Bar 2.0

SPECS

51
Fluid Pressure (PSI)

25
DA - 50 Hz

1.5

DA - 50 Hz

1.5

SELECT

20
AB - 60 Hz

20 15 10 5
AB - 60 Hz

52

15 10 5 0
AB - 50 Hz

1.0

1.0

AB - 50 Hz

0.5

0.5

3 1 2 Water Flow Rate (gpm)

3 1 2 Water Flow Rate (gpm)

Oil @ 70F, 50/50 EGW

Includes pressure drop through system. See page 53 for guidance on selecting a pump.

50

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

Specifications and Part Number Configuration MCS


MCS30 Centrifugal Pumps1,2
30 25
Fluid Pressure (PSI)

MCS40/50 Centrifugal Pumps2


30 25 0 2 4 6 8 LPM Bar 2.0

10

15

LPM Bar 2.0

DA 60 Hz Oil DA, 60 Hz, EGW

1.5

Fluid Pressure (PSI)

DA - MCS40/50 60 Hz

1.5

20 15 10 5 0
AB 50 Hz Oil

DA, 50 Hz EGW

20 15 10 0.5 5 0 0
DA - MCS40/50 50 Hz

1.0
AB 60 Hz EGW AB 50 Hz 0.5 EGW

1.0

AB, 60 Hz, Oil DA, 50 Hz, Oil

1
2

3 2 Flow Rate (gpm)

1 2 Water Flow Rate (gpm)

Oil @ 70F, 50/50 EGW

Includes pressure drop through system. See page 53 for guidance on selecting a pump. MCS10 MCS20 1300 4,450 MCS30 MCS40 2400 8,200
1 1

First select your model number Cooling capacity using water, 25C initial temperature difference Fluid Inlet Connections Fluid Outlet Connections Reservoir capacity Maximum liquid temperature Dimensions (W x D x H) Rack Mount Dimensions (W x D x H) Weight stand alone Weight rack mount Recommended coolant Next, select an electrical configuration W BTU/Hr

MCS50 3500 12,000 2 FNPT 2 FNPT

inches mm inches mm lbs (kg) lbs (kg)

2100 7,150 1 1 2 FNPT 2 Barb 1 1 2 FNPT 2 Barb 0.75 gal / 2.8 liters 131F / 55C 17.3 x 15.1 x 13.3 439 x 384 x 338 19 x 15.1 x 12.3 482 x 384 x 312 33 (15) 35 (16) 37 (17) 21 (9) 23 (10) 25 (11) water water oil, EGW

500 1,700

15 x 15 x 24 381 x 381 x 610 n/a 60 (27) n/a water 65 (29) n/a water

Standard Cooling Systems

Available electrical configurations and full load amperage1 G01: 115V, 60Hz, 1ph G02: 115V, 60Hz, 1ph H01: 230V, 50/60 Hz, 1ph J02: 230V, 50/60 Hz, 1ph Amps Amps Amps Amps 5.2 n/a 2.5 n/a 5.3 n/a 2.5 n/a 5.3 n/a 2.5 n/a n/a 5.6 n/a 2.7 n/a 5.8 n/a 2.8

Now, select a pump

Pump options (refer to Selecting a pump page 53 and system pump curves, at left) BB: PDP 2, Brass, 1.3 gpm / 4.9 lpm BC: PDP 2, Brass, 1.8 gpm / 6.8 lpm BE: PDP 2, Brass, 2.3 gpm / 8.7 lpm CB: PDP 2,3, Stainless Steel, 1.3 gpm / 4.9 lpm CC: PDP 2,3, Stainless Steel, 1.8 gpm / 6.8 lpm CE: PDP 2,3, Stainless Steel, 2.3 gpm / 8.7 lpm AB: Centrifugal, 116 HP 4 DA: Centrifugal, 14 HP 4 Package Options Package 1: Ambient Package Additional Options M002: Heavy duty casters M062: Rack mount configuration M004: High purity plumbing (stainless steel heat exchanger, nickel-plated bulkhead fittings) M063: Rack mount configuration and high purity plumbing M055: High purity plumbing and heavy duty casters = standard = available option 1 With standard pump 2 PDP = Positive Displacement Pump rate depends on system pressure drop. See page 53 for information on how to calculate flow rate.
3

GRAPHS

50

Add the ambient package Add any additional options

SPECS

51
SELECT

52

Only available with high purity plumbing

Actual flow

To arrive at a part number

MCS10 G01 BB 1
or

MCS10, 115V, 60 Hz operation, with BB pump and no additional options MCS20, 115V, 60 Hz operation, with CC (stainless steel) pump, and high purity plumbing in a rack mount configuration. www.Lytron.com +1-781-933-7300 51

MCS20 G01 CC 1 M063

MCS Selecting a Modular Cooling System


MCS performance is shown as Q/ITD versus flow rate. Q is the heat load, and ITD is the initial temperature difference, or the difference between the MCS liquid inlet temperature and the ambient air temperature. To select the correct MCS system, you first need to determine Q/ITD. Then, using the MCS performance graph, draw a horizontal line at the calculated Q/ITD value. Finally, check that the pump will provide sufficient flow rate. Example: A laser produces 700 W of waste heat. The water temperature exiting the laser should be less than 35C. Ambient room temperature is 20C. The laser equipment requires a flow rate of at least 1 gpm. Which MCS system should be selected? First, determine Q/ITD

Q/ITD = 700 W/(35C-20C) = 46.7 W/C


Using the thermal performance graph, you can see that at flow rates above 0.5 gpm, the MCS20 will provide adequate performance. The standard BB pump offers a flow rate of 1.3 gpm so it will work well. If you are considering an alternative pump, use the pump flow rate calculation on page 53 to verify that with the given pressure drop, flow rate will be sufficient.

Thermal Performance

MCS Positive Displacement Pumps


15 LPM 100 0 2 4 6 8 BTU HrF 4
Fluid Pressure (PSI)

Standard Cooling Systems

Q/Initial Temperature Difference (W/C)

70 60 50 46.7 40 30 20 10 0

10
MCS20 60 Hz MCS20 50 Hz

10 LPM Bar 6

80

BC/CC 50 Hz

BC/CC 60 Hz BE/CE 50 Hz BE/CE 60 Hz

5 4 3 2

60

BB/CB 50 Hz

2
MCS10 60 Hz MCS10 50 Hz

40

BB/CB 60 Hz

20 1 0

0.5

1 2 3 Water Flow Rate (gpm)

1 2 Water Flow Rate (gpm)

GRAPHS

50

SPECS

51

SELECT

52

To avoid thermal calculations, use the cooling system product selector at www.Lytron.com.

52

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

Selecting a Pump for All Cooling Systems


The standard pump on all Lytron cooling systems is a positive displacement pump. Centrifugal and turbine pumps are also offered to precisely match your application needs.

Positive Displacement Pumps (PD pumps)


Positive Displacement pumps provide a constant flow rate regardless of pressure drop across the system. This makes them ideal if you have a high system pressure drop, require a constant flow rate regardless of changes in your systems pressure drop, or are likely to use the cooling system with a variety of test set-ups. Lytrons PD pumps are fitted with a pre-set 90 psi1 pressure relief valve to ensure safety cut-out in the event of blockages in the system. It is recommended that PD pumps are replaced approximately every 7,000 hours of operation to ensure reliable performance.

Centrifugal and Turbine Pumps


The output of a centrifugal or turbine pump varies considerably with pressure drop across the system. If the pressure drop across the system changes, the flow rate from the cooling system will also change. A centrifugal pump is suitable for small pressure drops; a turbine pump operates at higher pressure drops. If you are considering using a centrifugal or turbine pump you should verify that the flow rate is sufficient with your systems pressure drop. It is recommended that centrifugal and turbine pumps are replaced approximately every 28,000 hours of operation to ensure reliable performance.

Standard Cooling Systems

Calculating Flow Rate


To calculate the flow rate for a centrifugal or turbine pump, you need to know the pressure drop in your system. You then can use the appropriate pump graph to estimate flow rate. Example: You need a 60 Hz RC011 chiller with a flow rate of 1.5 gpm and you want to know if a centrifugal pump (the DA pump) will have sufficient flow rate. The pressure drop from the laser in your system is 30 psi at 2 gpm. Mark the graph at the intersection of these points. Draw a straight line from the origin to this point, and where it intersects the pump curve is your likely flow rate. Note that this is an approximation as flow rate is not strictly linear. In this case, the likely flow rate with a DA centrifugal pump would be 1.9 gpm. This is higher than the 1.5 gpm required, so this pump would be a good choice. If a higher flow rate was required, a PD pump or the EB turbine pump could be considered. RC011-RC022 Centrifugal and Turbine Pumps The flow rate should be matched to your application LPM 5 10 15 20 25 0 to ensure that your overall system performs as expected. 80 Bar Pump graphs are located along side the performance graphs 5 70 EB/FB for each product. 60 Hz
Fluid Pressure (PSI)

60 50 40 30 20 10 0 0 2
EC 50 Hz EC 60 Hz EB/FB 50 Hz

2
DA 60 Hz

1
DA 50 Hz

Other settings available on request

4 6 Likely Flow Rate (gpm)

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

53

Custom Cooling Systems

Custom cooling systems for demanding applications


When it comes to the expertise required to build custom cooling systems, Lytron is unrivaled. With 5 decades of heat transfer experience, including components as well as systems, our high performance, fully-engineered custom cooling systems are efficient and reliable. Our dedicated systems engineering team works with our three cooling system technologies to arrive at the optimum solution for your application. Our component experience means that we can custom design and manufacture the heat exchanger the heart of every cooling system. The result is better products, more flexibility, and a product that has been designed for your exact performance, size, and functional requirements. For example, we can design for low noise, compact size, high performance, compatibility with specific coolants, special power requirements, etc. We can easily incorporate custom sensors and instrumentation, and add a variety of safety and monitoring options to protect both the cooling system and the equipment it is cooling. We can also secure any required certification or agency approval. All our custom systems are built at Lytron in the same facility where they were designed. Our integrated approach to design and manufacturing enables us to control the entire manufacturing process, from the selection of components to assembly. This results in excellent quality. We build custom systems on dedicated assembly lines which are configured to manufacture and test a large number of different systems.
Custom shape and size recirculating chiller to fit within customers system

4 kW low-noise recirculating chiller

Custom Cooling Systems

Custom liquid-to-liquid cooling system

54

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

Cooling Systems Custom


We are able to offer very competitive pricing on custom systems because we manufacture cooling systems in high volumes and standardize on common parts where possible. Our systems are backed by outstanding service and support. We recognize that most custom systems are integrated into equipment that may end up anywhere in the world, so we offer support when and where you need it: 24/7 access to technicians and a worldwide network of service centers for installation support, service, and maintenance. Our support network is constantly expanding, and we partner with customers to set up additional service capabilities where needed. We also offer customized training programs for our OEM customers, either on-site or at our facility in Woburn, MA. This empowers your own service engineers to provide front-line support where it is required. We ship thousands of custom cooling systems every year, for applications as diverse as medical equipment, data centers, printing, imaging, lasers, semiconductor equipment, and analytical instrumentation. Let us put our thermal systems expertise to work for you call us to discuss your custom chiller requirements today.

Custom Cooling Systems

Custom skinless liquid-to-liquid cooling system

Customer Case Study: Meeting the challenge of a tight space requirement


A customer approached Lytron needing a custom cooling system with similar capacity to an RC022. The challenge: It needed to be approximately half the usual size to fit within their existing design. Lytrons engineers set to work, specially selecting compact components to fit the envelope and customizing the layout. Since it was to be integrated into a larger piece of equipment, a frameless design was chosen. RS232 control was incorporated so that it could be monitored and controlled through the customers system. Manufacturability and serviceability were considered throughout the design process. Lytron engineers worked closely with the customers engineering team . The result: A prototype which matched all the size and performance specifications.

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

55

Worldwide Service and Support


Every cooling system that we sell is backed by our world-class service operation to provide rapid and affordable service, should the need arise. Lytron offers service and support through a variety of channels: Phone: Lytron offers 24/7 access to in-house service engineers for troubleshooting assistance. Call +1-781-933-7300. Email: Email sent to service@Lytron.com will be automatically directed to one of our service engineers who will address your inquiry no later than the next business day. Web: The Service section of www.Lytron.com contains technical documentation, maintenance procedures, technical tips and service information for all of our systems. World-Wide Service and Support: Lytron has service depots in Europe, Asia, Canada, and the US. These repair centers stock a broad inventory of spare parts and are staffed by factory-certified technicians. On-Site Service: Lytron offers on-site service and service contracts. Contact our service department for details. Factory Service/Repair: System diagnosis is usually completed within 24 hours of receipt of the unit and repairs are carried out within 48 hours of service authorization. OEM Training: Since chillers are often sold as sub-systems in OEM equipment, Lytron offers OEMs customized training programs so they can provide front-line support. These training programs can be arranged either at your facilities or at Lytrons Woburn, MA, USA facility.

Custom Cooling Systems


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