2536_heatexchangers. lytron -ams

www.Lytron.com • +1-781-933-7300 57

With five decades of experience in heatexchanger design and manufacture, Lytron’sexpertise is second-to-none. Our heat exchangersare used in many industries including militaryand 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 otherinstrumentation to your specification. And ourseven product ranges with over 130 standardparts ensure that when you need an off-the-shelf part we are likely to have something thatmeets your requirements.

Contents:

Technology overview . . . . . . . . . . . . . . . . . . . 58Heat exchanger technologies

• Copper heat exchangers . . . . . . . . . . . . 606000 Series and OEM Coils

• Stainless steel heat exchangers . . . . . . . 70Aspen® and 4000 Series

• Aluminum oil coolers . . . . . . . . . . . . . . . 80ES Series

• Plate-fin heat exchangers . . . . . . . . . . . . 84• Liquid-to-liquid heat exchangers . . . . . . 85

Heat exchanger fittings . . . . . . . . . . . . . . . . . 88Selecting a heat exchanger . . . . . . . . . . . . . . 89Custom heat exchangers . . . . . . . . . . . . . . . 92

Lytron’s broad range of heat exchanger technologies combined with five decades of thermal transfer experienceenables 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 removalfor a wide range of applications including lasers, electronics,compressor cooling, semiconductor processing equipment, andsolder reflow ovens. Our copper tubed 6000 Series and OEMcoils, and stainless steel tubed Aspen and 4000 Series offer compatibility with a wide range of common coolants.

Flat Tube Oil Coolers ES Series

ES series oil coolers are designed for optimum cooling with poor heat transfer fluids such as oil and ethylene gly-col/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 forcooling x-ray tubes, aircraft engines, hydraulic fluid, and highspeed 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-finheat exchangers are custom designed to match your precise performance and size requirements. Applications include condensers, evaporators, environmental cooling systems, andradar cooling. Their high performance/weight ratio also makesthem popular for airborne applications such as cooling gearboxoil and transmission oil with ram air or jet fuel.

Liquid-to-Liquid Brazed Plate Heat Exchangers

Liquid-to-liquid brazed plate heat exchangers utilize stainlesssteel plates brazed together in a counterflow configuration. This offers high liquid-to-liquid cooling capacity in a compactpackage. We offer both copper-brazed and nickel-brazed versionsfor compatibility with a wide range of coolants. Applicationsinclude district heating/cooling, heat recovery, and laser cooling.

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Heat Exchanger Technology Overview

Wat

er

EGW

Cor

rosi

ve f

luid

s (e

.g. D

eion

ized

wat

er)

Oil

Die

lect

ric

fluid

s (e

.g. F

luor

iner

t™)

Poly

alph

aole

fin

(PA

O)

Performance c omparisonThis 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 thattechnologies can be compared regardless of size.

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

Fluid compatibilityCoolant 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 gly-col/water mixture (EGW), oils and other fluids, but is not compatible with untreated water. The table below shows fluid/heat exchanger compatibility.

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

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

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 •

Water Flow

Perf

orm

ance

(Q/IT

D)

Plate-Fin

Tube-Fin

Oil Coolers

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Heat Exchanger Technology OverviewStandard H

eat Exchangers

Copper tubing expandedinto copper cooling finsfor excellent heat transfer

All units supplied with built-in,fan-ready mounting hardware

Electro-static dip paintedfor harsh environments

Fluxless, silver-brazed jointsprovide leak-free reliability

0.028” (0.7 mm) seamlesswall tubing ensures fluid circuit durability

»

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

Customization Options

Custom 6000-Series style heat exchangers can be manufactured in any sizeand tube configuration to match your demanding thermal requirements.Variations in inlet/outlet position and/or fittings can be accommodated anda selection of paints and other coatings is available. Assemblies includingfans and other components can also be supplied.

See page 92 for more custom heat exchangers.

The 6000 Series is a high performance heat exchanger with copper tubes and fin. It delivers efficient heat transfer andmaximum reliability in a compact package.

High cooling capacity in a small envelope: The 6000 Series is engineered for performance. Its high tube densityresults 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 forlong 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.

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6000 Series Copper Heat Exchangers

SPECS68

GRAPHS64

DWG66

SELECT89

Copper tubes are compatiblewith water, EGW, and othercommon cooling fluids

Copper tubing expanded intoaluminum fins offers efficientand reliable operation

0.028˝ (0.7 mm) wall tubingensures fluid circuit durability.

Fluxless silver-brazed jointsoffer high reliability

Galvanized steel side rails andtube sheets offer strength andcorrosion resistance


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. Assembliesincluding fans and other components can also be supplied.


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

»

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

Great value: We carefully selected the materials, tube layout, and fin for low manufacturing cost, and eliminatedsome 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.

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.

Copper Heat ExchangersStandard H

eat ExchangersOEM Coils

SPECS68

GRAPHS64

DWG66

SELECT89

6105 6110 6120

6210 6220

6310

6340

6320

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6000 Series Pictures

SPECS68

GRAPHS64

DWG66

SELECT89

M05-050 M05-100

M10-080 M10-160

M14-120 M14-240

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PicturesStandard H


SPECS68

GRAPHS64

DWG66

SELECT89

200

40

10

0 6040Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

20

m3min1

80

2 3

30

100 120

0

6105

2 gpm

1/4 gpm

1 gpm

1/2 gpm

Muffin XL

200 6040Air Flow CFM

m3min1

80

2 3

100 120

6110

2 gpm

1/4 gpm

1 gpm

1/2 gpm

Muffin XL


m3min1

80

2 3

50

20

10

100

BTUHR°F

40

30

60

120

0

M05-050

2 gpm

1/2 gpm

Muffin XL

500

70

20

10

0 150100

4

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

30

m3min

250

2 6

40

60

0

50

200

6120

2 gpm

1 gpm

1/2 gpm

Muffin XL

500 250150100

3

Air Flow CFM

2

200

1 4 5 6

60

40

20

80

100

120

BTUHR°F

m3min

M05-100

2 gpm

1/2 gpm

Muffin XL

1000

120

40

20

0 300200

10

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

60

m3min

400

5

80

100

0

6210

2 gpm

1 gpm

1/2 gpm

Falcon

Patriot


m3

min2

200

4 6

150

100

50

200

300

BTUHR°F

80 10

M10-080

1 gpm

4 gpm

Patriot

Falcon

2 gpm

1000

120

40

20

0 300200Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

60

m3min

400

80

100

500

140

160

180

2001050

600

15

6220

Patriot

Falcon

1/2 gpm

2 gpm

1 gpm

1000 600300200

10

Air Flow CFM

m3min5

400

0 15

200

100

300

500

BTUHR°F

Patriot

Falcon

M10-160

2 gpm

1 gpm

4 gpm4 gpm

0

120

40

20

0 400200

20

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

60

m3min10

600

0

80

100

800

140

160

180

200155

6310

1 gpm

4 gpm

2 gpm

1/2 gpm

Caravel

2000 600 800

10

Air Flow CFM

m3min5

400

0 15

200

100

300

BTUHR°F

20

M14-120

1 gpm

4 gpm

2 gpm

Caravel

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6000 & OEM Coils Performance Graphs1

SPECS68

GRAPHS64

DWG66

SELECT89

0

120

40

20

0 400200Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

60

m3min

600

200

100

300

80

100

800

BTUHR°F

140

160

180

20020100 155

6320

1 gpm

4 gpm

2 gpm

Caravel

1/2 gpm

2000

400

100

0 600400Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)CFM

200

m3min10

800

0 20 30

500

200

100

300

1000

BTUHR°F

400

300

600

1200

M14-240

1 gpm

4 gpm

2 gpm

Caravel

5000

700

200

100

0 15001000

40

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

300

m3min

2000

20 60

600

400

200

400

600

2500

BTUHR°F

0

500

800

1000

1200

6340

1 gpm

4 gpm

2 gpm

8 gpm

10 gpm

Caravel

1.00

0.25

Inch

es o

f W

ater

0.50

m3

min42 6

0.75

8


400 500

1.25

0

1210

200

50

100

150

250

300

Pasc

als

6000 Series Air Side Pressure Drop

61206105

6210

6110

6310

6320

6340

6220

20

5

PSI

10

LPM5

15

0.50 1.51.0Water Flow

GPM2.0

25

0

10

1.5

0.5

1.0

2.0Bar

2.5 3.0

300

6000 Series Liquid Side Pressure Drop

6105

6210

6110

63106320

6220

6120

PSI

BAR

GPM0 105

0

2

1

3 0.2

0.1

6340

0.4

0.1

Inch

es o

f W

ater

0.2

m3

min42 6

0.3

8


400 500

0.5

0

1210

50

100

150

Pasc

als

0.6

OEM Coil Air Side Pressure Drop

M10-080

M14-120M10-160

M05-100M05-050

M14-240

20

5

PSI

10

LPM5

15

0 1.0Water Flow GPM

2.00

10

0.6

0.2

0.4

0.8

Bar

4.03.0

0

1.2

1.0

15

OEM Coils Liquid Side Pressure Drop

M10-080

M14-120

M05-100

M05-050

M14-240

M10-160

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

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Performance Graphs1

Standard Heat Exchangers

6000 & OEM Coils

SPECS68

GRAPHS64

DWG66

SELECT89

6105

6210 6220

6310

6340

6320

6110 6120

7.4(188) 2.8

(71) 1.3(33)

5.8(147)

6.6(168)

4.3(109)

0.38(10)

1.8(46)

3.3(84)

7.4(188)

5.8(147)

5.8(147)

3.8(95)

0.38(10)

1.8(46)

3.3(84)

12.2(310)

10.5(267)

5.8(147)

3.8(95)

0.38(10)

2.5(64)

4.5(114)

11.9(301)

9.5(241)

9.0(229)0.4

(10)

0.38(10)

2.5(64)

4.5(114)

19.9(505)

17.6(446)

9.0(229)0.4

(10)

0.38(10)

2.1(53)

5.6(142)

12.9(328)

11.5(292)

12.0(305)

1.12(28)

0.5(13)

2.1(53)

5.6(142)

22.9(583)

21.6(549)

12.0(305)

1.13(29)

0.5(13)

1.6(41)

3.5(89)

7.0(178)

27.5(699)

24.8(630)

22.2(564)

1.5(38)

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.

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6000 Series Drawings

SPECS68

GRAPHS64

DWG66

SELECT89

M05-050 M05-100

M10-080 M10-160

M14-120 M14-240

3.2(81)8.75

(223)

10.6(269)

2.0(51)

2.2(55)0.5

(13)

3.2(81)16.75

(426)

10.6(269)

2.0(51)

2.2(55)0.5

(13)

3.2(81)12.75

(325)

14.0(356)

2.0(51)

2.2(55)0.5

(13)

3.2(81)24.75

(630)

14.0(356)

2.0(51)

2.2(55)0.5

(13)

2.2(56) 2.0

(51)5.75(146)

6.3(160)

3.9(99)

0.38(10)

2.2(56)10.75

(273)

6.3(160)

2.0(51)

3.9(99)

0.38(10)


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DrawingsStandard H


SPECS68

GRAPHS64

DWG66

SELECT89

6000 Series Core Number 6105G1 6110G1 6120G1 6210G1 6220G1 6310G3 6320G3 6340G1/G2

Fluid path copper

Fin material copper aluminum

Dry weight lbs 1.5 2.0 3.5 5.0 8.5 8.5 14.0 30.0 kg 0.7 0.9 1.6 2.3 3.9 3.9 6.4 13.6

Fluid volume in3 3 8 12.5 17.5 30.5 29.5 51.5 106 ml 50 131 205 288 500 483 844 1737

Max. operating temp. 400°F/200°C

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 6340G1: no fan plate

6340G2:includes plate

Recommended Fans

Muffin XL ● ● ●

Patriot ● ●

Falcon ● ●

Caravel ● ● ●

# of fans 1 1 2 1 2 1 2 4

First select core number

Next, select a fitting option

Add a fan plateif desired

Finally, orderfans if desired

To arrive at apart number1

6120G1 BD 6120 with beaded fittings

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

6000 Series

Description Size Voltage Current Fan Part Fingerguard Fan 50Hz 60Hz Number Part Number Plug Number

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

Fan Specifications

Item Suitable for Part Number

Push to connect adapters for 6105 Straight Union 3⁄8˝ O.D. 430-0448• Materials: acetel bodies, nitrile o-rings, and acetel/stainless steel collets 6110 • Temp. range: -14 to 167°F (-25 to 75°C) for air; 33 to 140°F (0 to 60°C) for water. 6120 Union Elbow 3⁄8˝ tubing O.D. 102190-01• Maximum pressure: 150 psi (10.3 bar) for air, 250 psi (1,724 kP) for water. 6210• Packaging: 10 fittings per pack. 6220 Transition Union 3⁄8˝ – 1⁄2˝ tubing O.D. 102189-01

6310 Transition Union 1⁄2” – 3⁄8” tubing O.D. 102189-016320 Union Elbow 1⁄2˝ tubing O.D. 102190-02

Tube to Hose Adapter 3⁄8” tubing O.D. to 3⁄8˝ hose barb 102191-01Requires a push-to-connect adapter of the same OD to 1⁄2” tubing O.D. to 3⁄8˝ hose barb 102191-02mate with heat exchanger.

1⁄2” tubing O.D. to 1⁄2˝ hose barb 102191-03

Other Accessories

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6000 Series Specifications and Part Number Configuration

Number Part Number Plug Number

SPECS68

GRAPHS64

DWG66

SELECT89

OEM Coil Core Number M05-050 M05-100 M10-080 M10-160 M14-120 M14-240

Fluid Path copper

Fin Material aluminum

Dry Weight lbs 2.0 4.0 5.0 8.0 10.0 16.0kg 0.9 1.8 2.3 3.6 4.5 7.3

Fluid Volume in3 7 11.5 19.5 33.5 37 66.5ml 115 188 320 549 606 1090


Fitting Options (see page 88)

SB: stub end ● ● ● ● ● ●

BD: beaded fitting ● ● ● ● ● ●

AN: 37° AN flare ● ● ● ● ● ●

Fan Plate

0: no fan plate ● ● ● ● ● ●

1: fan plate attached ● ● ● ● ● ●

Recommended Fans

Muffin XL ● ●

Patriot ● ●

Falcon ● ●

Caravel ● ●

# of fans 1 2 1 2 1 2



Add a fan plateif desired


To arrive at apart number1 M05-100 SB 1 M05-100 with stub end fittings and fan plate


OEM Coils




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

Fan Specifications


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



Other Accessories

M05-050

M05-100

Straight Union 3⁄8˝ O.D.Union Elbow 3⁄8˝ tubing O.D.

Transition Union 3⁄8˝ – 1⁄2˝ tubing O.D.M10-080M10-160M14-120M14-240

Transition Union 1⁄2” – 3⁄8” tubing O.D.

Union Elbow 1⁄2˝ tubing O.D.

430-0448102190-01102189-01

102189-01

102190-02

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Specifications and Part Numbering ConfigurationStandard H



SPECS68

GRAPHS64

DWG66

SELECT89

Stainless Steel Heat ExchangersAspen®

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SPECS78

GRAPHS74

DWG76

SELECT89


Custom Aspen style heat exchangers can be manufactured in various sizesand tube configurations to match your thermal and size requirements.Variations in inlet/outlet position and/or fittings can be accommodated anda selection of paints and other coatings is available. Assemblies includingfans and other components can also be supplied.


Custom cupronickel tube-fin heat exchanger

»

Wider tube spacingreduces cost, weight, andliquid pressure drop.

Wavy fin edgeimproves fin strength

Liquid return loopseliminate fluid contamination and reduce liquidpressure drop

Welded, argon-purgedjoints maximize internalcleanliness

316L stainless steel tubingcompatible with deionizedwater and corrosive fluids

The Aspen stainless steel tubed heat exchanger combines low price and low pressure drop with excellent heat transferand 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 thefin density to balance the air and liquid sides. Our single piece formed aluminum frame/fan plate further reducescost and weight.

• Highly reliable: Like all Lytron heat exchangers, the Aspen is designed for reliability. 316L stainless steel fluid pathwith 0.02˝ (0.5 mm) wall thickness maintains deionized water and will not react with corrosive liquids. Aspen heatexchangers 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 ofoils 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 tubespacing and high performance fin reduce air side pressure drop.

4000 SeriesStandard H

eat ExchangersStainless Steel Heat Exchangers

www.Lytron.com • +1-781-933-7300 71

SPECS78

GRAPHS74

DWG76

SELECT89

»

Stainless steel heat exchanger with custom inlet/outlet fittings


Custom 4000 Series style heat exchangers can be manufactured in any sizeand circuiting to match your demanding thermal requirements. Variations ininlet/outlet position and/or fittings can be accommodated and a selection ofpaints and other coatings is available. Assemblies including fans and othercomponents can also be manufactured.


Superior construction—316L stainless steeltubing expanded into copper cooling fins

Pre-cleaned internal surfaceeliminates fluid contamination

All-welded, argon-purgedjoints maximize internalcleanliness

0.028˝ (0.7 mm) walltubing ensures fluidcircuit durability

Available with straight, beaded,or 37°AN flare fittings

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.

• 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 intocopper fin with an extruded full collar. The copper fin and the excellent metal-to-metal contact between the tubeand the fin collar further increase performance.

• Compatible with deionized water and corrosive liquids: All the wetted surfaces in the 4000 Series are 316Lstainless 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 enableseasy fan installation.

• 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 slightlylower performance/size ratio is acceptable, the Aspen offers better value. The Aspen also has lower air and liquid sidepressure drops.

AS04-05 AS04-10

AS06-08 AS06-16

AS08-10 AS08-20

72 www.Lytron.com • +1-781-933-7300

Stan

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Aspen Pictures

SPECS78

GRAPHS74

DWG76

SELECT89

4210 4220

4310 4320

4105 4110 4120

73www.Lytron.com • +1-781-933-7300

PicturesStandard H

eat Exchangers4000 Series

SPECS78

GRAPHS74

DWG76

SELECT89

Performance Graphs1Aspen & 4000St

anda

rd H

eat

Exch

ange

rs

www.Lytron.com • +1-781-933-730074

SPECS78

GRAPHS74

DWG76

SELECT89

500

70

20

10

0 150100

4

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

30

m3min

200

2 6

40

60

0

50

250

4120

2 gpm

1 gpm

1/2 gpm

Muffin XL

500 150100

4

Air Flow CFM

m3min

200

2 6

60

40

20

BTUHR°F

0

80

100

120

250

AS04-10

2 gpm

1 gpm

1/2 gpm

Muffin XL

1000

120

40

20

0 600300200

10

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

60

m3min

400

5 15

80

100

500

0

4210

2 gpm

1 gpm

Patriot

Falcon

1/2 gpm

1000 600300200

10

Air Flow CFM

m3min

400

5 15

150

100

50

200

500

BTUHR°F

0

AS06-08

2 gpm

1 gpm

1/2 gpm

Falcon

Patriot

1000

120

40

20

0 300200

10

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

60

m3min5

400

0

80

100

500

140

160

180

200

600

15

4220

Patriot

Falcon

1/2 gpm

2 gpm

1 gpm

1000 300200

10

Air Flow CFM

m3min5

400

0 15

500 600

AS06-16

Patriot

Falcon

1/2 gpm

2 gpm

1 gpm

0 1000400200

20

Air Flow CFM

m3min10

600

0 25

800

155

4310

1 gpm

4 gpm

2 gpm

1/2 gpm

Caravel

0 1000400200

20

Air Flow CFM

m3min10

600

0 25

200

100

300

800

BTUHR°F

155

AS08-10

Caravel

EBMEBM

1 gpm

2 gpm

1/2 gpm

200

40

10

0 6040Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

20

m3min1

80

2 3

30

100 120

0

4105

2 gpm

1/4 gpm

1 gpm

1/2 gpm

Muffin XL


m3min1

80

2 3

100 120

0

4110

2 gpm

1/4 gpm

1 gpm

1/2 gpm

Muffin XL


m3min1

80

2 3

50

20

10

100

BTUHR°F

40

30

60

120

0

AS04-05

2 gpm

1/4 gpm

1 gpm

1/2 gpm

Muffin XL

Aspen & 4000Standard H

eat ExchangersPerformance Graphs

www.Lytron.com • +1-781-933-7300 75

SPECS78

GRAPHS74

DWG76

SELECT890

120

40

20

0 400200Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

60

m3min

600

80

100

800

140

160

180

20020100 155

10001200

3025

4320

1 gpm

4 gpm

2 gpm

Caravel

1/2 gpm

0 400200

20

Air Flow CFM

m3min10

600

0 30

200

100

300

800

BTUHR°F

155

10001200

25

AS08-20

Caravel

EBMEBM

1 gpm

4 gpm

2 gpm

1/2 gpm

1.00

0.25

Inch

es o

f W

ater

0.50

m3

min42 6

0.75

8

1000 300200

Air Flow CFM400 500

1.25

0

1210

200

50

100

150

250

300

Pasc

als

Air Side Pressure Drop

41204105

4210

4110

AS04-05

AS04-10

AS06-08

4

1

PSI

2

LPM2

3

0.50 1.51.0

Water FlowGPM

2.0

5

0

4

0.3

0.1

0.2

0.4Bar6

0 6

Liquid Side Pressure Drop

4110

4120

AS06-08

AS04-10AS04-05

4105

1.00

0.25

Inch

es o

f W

ater

0.50

m3

min105 15

0.75

20

2000 600400

Air Flow CFM800 1000

1.25

0

3025

200

50

100

150

250

300

Pasc

als

1200


4220

AS08-10

AS06-16

AS08-20

4320

4310

PSI

5

LPMBar

2 4

10

6

0.50 1.51.0

Water Flow GPM2.0 2.5

15

0

108

0.6

0.2

0.4

0.8

1

3.00

AS06-16


4220

AS08-20

4320

4310

AS08-10

4210

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

AS04-05 AS04-10

AS06-08 AS06-16

3.4(86)

1.8(47)

8.1(207)

5.3(134)

5.9(151)

3.8(95)

0.38(10)

3.4(86)

1.8(47)

13.4(339)

10.5(267)

5.9(151)

3.8(95)

0.38(10)

4.3(108)

2.1(53)

10.9(276)

8.0(203)

9.1(230)

6.3(159)

0.38(10)

4.3(108)

2.1(53)

19.0(481)

16.1(409)

9.1(230)

6.3(159)

0.38(10)

AS08-10 AS08-20

5.6(142)

2.1(53)

12.9(326)

10.0(254)

11.8(298)

8.8(222)

0.38(10)

5.6(142)

2.1(53)

22.9(583)

20.1(511)

11.8(298)

8.8(222)

0.38(10)


76 www.Lytron.com • +1-781-933-7300

Stan

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Aspen Drawings

SPECS78

GRAPHS74

DWG76

SELECT89

4210 4220

4310 4320

4105 4110 4120

2.8(71)

1.3(33)

7.7(194)5.8

(147)

6.6(168)

4.3(109)

0.38(10)

3.4(86)

1.8(47)

7.8(198)

4.9(125)

5.8(147)

4.1(105)

0.38(10)

3.4(86)

1.8(47)

12.6(320)

9.7(246)

5.8(147)

4.1(105)

0.38(10)

4.5(114)

2.5(64)

10.9(277)

8.0(203)

9.0(229)

7.1(181)

0.38(10)

4.5(114)

2.5(64)

19.0(483)

16.1(408)

9.0(229)

7.1(181)

0.38(10)

6.0(153)

2.5(64)

12.9(328)

10.0(254)

12.0(305)

1.9(48)

0.5(13)

6.0(153)

2.5(64)

23.0(584)

20.1(510)

12.0(305)

1.9(48)

0.5(13)


77www.Lytron.com • +1-781-933-7300

DrawingsStandard H

eat Exchangers4000 Series

SPECS78

GRAPHS74

DWG76

SELECT89

Specifications and Part Number ConfigurationAspenSt

anda

rd H

eat

Exch

ange

rs

www.Lytron.com • +1-781-933-730078

SPECS78

GRAPHS74

DWG76

SELECT89

Core Number AS04-05G01 AS04-10G01 AS06-08G01 AS06-16G01 AS08-10G01 AS08-20G01

Fluid path stainless steel

Fin material copper

Dry weight lbs 1.4 2.7 3.3 6.3 5.3 10.1 kg 0.6 1.2 1.5 2.9 2.4 4.6

Fluid volume in3 2.8 4.6 5.6 9.9 8.9 16.0 ml 45.9 75.4 91.8 162.2 145.8 262.2


Fitting options (see page 88)

SB: stub end ● ● ● ● ● ●

BD: beaded fitting ● ● ● ● ● ●

Fan plate included included included included included included

Recommended Fans

Muffin XL ● ●

Patriot ● ●

Falcon ● ●

Caravel ● ● ●

EBM 8.5 ● ●

# of fans 1 2 1 2 1 2




To arrive at apart number1 AS08-10 G01 SB AS08-10 with stub end fittings


Aspen Series




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

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

Fan Specifications


Push to connect adapters for Straight Union 3⁄8˝ O.D. 430-0448• Materials: acetel bodies, nitrile o-rings, and acetel/stainless steel collets All Aspen • Temp. range: -14 to 167°F (-25 to 75°C) for air; 33 to 140°F (0 to 60°C) for water. Series Union Elbow 3⁄8˝ tubing O.D. 102190-01• Maximum pressure: 150 psi (10.3 bar) for air, 250 psi (1,724 kP) for water. • Packaging: 10 fittings per pack. Transition Union 3⁄8˝ – 1⁄2˝ tubing O.D. 102189-01



Other Accessories

2 Requires adapter ring. Part number 508520.


4000 SeriesStandard H

eat ExchangersSpecifications and Part Number Configuration

www.Lytron.com • +1-781-933-7300 79

SPECS78

GRAPHS74

DWG76

SELECT89

Core Number 4105G1 4110G10 4120G10 4210G10 4220G10 4310G10 4320G10

Fluid path stainless steel

Fin material copper

Dry Weight lbs 1.5 2.0 3.5 5.0 8.5 8.5 14.0kg 0.7 0.9 1.6 2.3 3.9 3.9 6.4

Fluid volume in3 3 8 12.5 17.5 30.5 29.5 51.5ml 50 131 205 288 500 483 844

Max. operating temp. 400°F / 200°C

Fitting options (see page 88)

SB: stub end ● ● ● ● ● ● ●

BD: beaded fitting ● ● ● ● ● ● ●

AN: 37° AN flare ● ● ● ● ● ● ●

Fan plate included included included included included included included

Recommended Fans

Muffin XL ● ● ●

Patriot ● ●

Falcon ● ●

Caravel ● ●

# of fans 1 1 2 1 2 1 2




To arrive at apart number1 4220G10 AN 4220 with AN fittings


4000 Series




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

Fan Specifications


Push to connect adapters for 4105 Straight Union 3⁄8˝ O.D. 430-0448• Materials: acetel bodies, nitrile o-rings, and acetel/stainless steel collets 4110 • Temp. range: -14 to 167°F (-25 to 75°C) for air; 33 to 140°F (0 to 60°C) for water. 4120 Union Elbow 3⁄8˝ tubing O.D. 102190-01• Maximum pressure: 150 psi (10.3 bar) for air, 250 psi (1,724 kP) for water. 4210• Packaging: 10 fittings per pack. 4220 Transition Union 3⁄8˝ – 1⁄2˝ tubing O.D. 102189-01

4310 Transition Union 1⁄2” – 3⁄8” tubing O.D. 102189-014320 Union Elbow 1⁄2˝ tubing O.D. 102190-02



Other Accessories


Available with orwithout a fan plate

Finish options: aluminum or black paint

Welded headers, pressuretested to 150 psi (10.3 bars)

Extended surface flat tubedesign provides 2.5 timesbetter performance thancompetitive units

Internal view of Lytron’saluminum flat tube

Low pressure drop dueto unique flat tube andheader designs

Fluxless, vacuum-brazed corefor strength and reliability

»

Custom oil cooler with curved tubes


Oil coolers can be manufactured in different sizes and tube widths, and with custom inlet/outlet configurations. Curved heat exchangers can bemanufactured as the flat tube can be bent without buckling or damagingthe internal channels. Assemblies including fans and other components canalso be supplied.


ES Series oil coolers are engineered for high performance with poor heat transfer fluids such as oils and EGW. Theyprovide up to 2.5 times greater thermal performance per unit volume than competitive models.

• High performance: The ES Series uses Lytron’s unique aluminum flat tube technology, which has multiple extendedsurface channels in each tube. These tubes provide maximum cooling by having a large surface area in contact withthe fluid (approximately 12 in2 (77 cm2)/linear inch of tube). Lytron’s air-side fin geometry efficiently channels airacross 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 withexcellent thermal contact and mechanical strength.

• Low pressure drop: Our flat tube fluid channels and efficient header manifold result in a very low pressure drop sosmaller, less expensive pumps can be used.

• Lightweight: The all-aluminum, vacuum-brazed construction is lightweight.

80 www.Lytron.com • +1-781-933-7300

Stan

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Hea

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ES Series Aluminum Heat Exchangers: Oil Coolers

SPECS83

GRAPHS82

DWG81

SELECT89

ES05051 ES0510

ES0707 ES07142

ES0505 ES0510

ES0707 ES0714

3.06(77)

1.25(32)

7.80 max(198)

5.19(132)

3.25(83)

6.57(167)

3.06(77)

1.25(32)

12.55 max(319)

9.94(254)

3.25(83)

6.57(167)

3.06(77)

1.25(32)

9.67 max(246)

7.06(178)

5.0(127)

8.36(212)

3.06(77) 1.25

(32)

17.86 max(454)

15.25(387)

5.0(127)

8.36(212)

1 Includes optional fan plate and black paint 2 Includes optional fan plate


81www.Lytron.com • +1-781-933-7300

Pictures and Drawings Standard H

eat ExchangersES Series

SPECS83

GRAPHS82

DWG81

SELECT89

200

40

20

0 1006040

2

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

60

m3min1

80

0

80

100

ES0505 - EGW2

4 gpm

1/2 gpm

Muffin XL

200 1006040

2

Air Flow CFM

m3min1

80

0

100

50

150

BTUHR°F

ES0505 - Oil3

4 gpm

1/2 gpm

Muffin XL

500 150100

4

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

m3min2

200

0 6

2500

40

20

60

80

100

ES0510 - EGW2

Muffin XL

4 gpm

2 gpm1 gpm

1/2 gpm

500 150100

4

Air FlowCFM

m3min2

200

0 6

250

BTUHR°F

100

50

150

ES0510 - Oil3

4 gpm

2 gpm

1 gpm

1/2 gpm

Muffin XL

500 150100

4

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

m3min2

200

0 6

2500

75

25

100

125

150

50

175

ES0707- EGW2

Tarzan

5 gpm

1 gpm

1/2 gpm

3 gpm2 gpm

Patriot

500 150100

4

Air FlowCFM

m3min2

200

0 6

250

BTUHR°F

200

100

300

ES0707- Oil3

5 gpm

1 gpm

1/2 gpm

3 gpm

2 gpm

Tarzan

Patriot

1000 300200Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

m3min

400 5000

75

25

100

125

150

50

1751050 15

ES0714- EGW2

5 gpm

1 gpm

3 gpm

Tarzan

Patriot

1/2 gpm

2 gpm

1000 300200

10

Air FlowCFM

m3min5

400

0 15

500

BTUHR°F

200

100

300

ES0714- Oil3

5 gpm

1 gpm

3 gpm

2 gpm

Tarzan

Patriot

1/2 gpm

500

0.10

0.05

0 150100

4

Air Flow

Inch

es o

f W

ater

CFM

0.15

m3

min

200

2

0.20

250

0

0.25

0.3086

10

70

60

50

40

30

20

0

Pasc

als

ES0505

ES0510ES0707

ES0714


10

4

2

0 32

10

50/50 EGW Flow

PSI

GPM

6

LPM

4

5

8

010

15

0.6

0.4

0.2

0

Bar

ES0505

ES0510

ES0714

ES0707

Liquid Side Pressure Drop - EGW

10

4

2

0 32

10

Oil Flow

PSI

GPM

6

LPM

4

5

8

0

10

15

0.6

0.4

0.2

0

Bar

12

14

16

1.0

0.8

ES0505

ES0510

ES0714

ES0707

Liquid Side Pressure Drop - Oil

1 The solid vertical lines indicate the performance provided by our standard fans at 60Hz and 70°F. Dashed lines represent fan performance at 50 Hz and 20°C. 2 50/50 EGW at 160°F. 3 Diala® at 170°F.

82 www.Lytron.com • +1-781-933-7300

Stan

dard

Hea

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ES Series Performance Graphs1

SPECS83

GRAPHS82

DWG81

SELECT89

Fan Specifications

Core Number ES0505G ES0510G ES0707G ES0714G

Fluid path aluminum

Fin material aluminum

Dry weight lbs 2.0 2.85 2.85 5.53kg 0.91 1.30 1.30 2.51

Fluid volume in3 14 17 24 31ml 229 278 393 508

Fittings (see page 88) 3/8 – 18 NPT


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 ● ● ● ●

Recommended Fans

Muffin XL ● ●

Patriot ● ●

Tarzan ● ●

# of fans 1 2 1 2


Next, select an option


To arrive at apart number1 ES0510G24 ES0510 with black paint and fan plate attached





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

83www.Lytron.com • +1-781-933-7300

Specifications and Part Number ConfigurationStandard H

eat ExchangersES Series


SPECS83

GRAPHS82

DWG81

SELECT89

Lightweight, all-aluminumconstruction

Variety of finishes available including paint and Milspec coatings

Large heat transfer surface

Fluxless vacuum-brazed corefor good thermal contact,strength, and reliability

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

»

Custom titanium plate-fin heat exchanger

Now Available in Titanium

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


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 thefins 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 platesand fin, the height of the fin, and the type of fin are carefully selected for optimum performance. Manifold ductingand mounting brackets are welded in place as required, and a wide variety of paint, Milspec, and other coatings areavailable. 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.

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Plate-Fin Heat Exchangers

Much smaller and lighter than conventionalshell-and-tube designs

Copper-brazed for water,EGW and other commoncoolants, or nickel-brazedfor high purity and corrosive coolants

Stainless steel sheets arebrazed together at theedges and at a matrix of contact points for areliable and rugged part

Extremely efficient herringbone construction for maximum heat transfer

Internal view of liquid-to-liquidbrazed plate heat exchanger


Liquid-to-liquid heat exchangers can be supplied as subassemblies with fittings, hoses, and other accessories.


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

»

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Lytron’s brazed-plate heat exchangers are unsurpassed for liquid-to-liquid heat transfer. Their innovative design packsmaximum performance into a compact and reliable package.

• High performance in a small package: Lytron’s 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 sheetsstamped 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.

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

Heat ExchangersStandard H

eat ExchangersLiquid-to-Liquid

SPECS87

GRAPHS87

DWG86

SELECT89

LL510 and LL520 LL810 and LL820

LL510 LL810

LL520 LL820

1.6(40)

0.8(20)

1.3(33)2.9

(74)

6.7(170)

8.0(204)

1.6(40)

0.8(20)

2.2(56)2.9

(74)

6.7(170)

8.0(204)

1.7(43)

0.8(20)

1.4(36)3.5

(90)

11.0(279)

12.9(328)

1.7(43)

0.8(20)

2.4(60)3.5

(90)

11.0(279)

12.9(328)

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Liquid-to-Liquid Pictures and Drawings

SPECS87

GRAPHS87

DWG86

SELECT89

Core Number LL510G12 LL520G12 LL810G12 LL820G12 LL510G14 LL520G14 LL810G14 LL820G14

Plate material AISI 316L stainless steel

Braze material copper 99.9% nickel 99.7%

Number of plates 10 20 10 20 10 20 10 20

Dry Weight lbs 2.6 3.7 4.9 6.7 2.6 3.7 4.9 6.7kg 1.2 1.7 2.1 2.9 1.2 1.7 2.1 2.9

Fittings 3⁄4˝ MNPT

Max. operating pressure 450 psi/31 bar 232 psi/16 bar

Max. operating temp. 383°F/195°C 662°F/350°C

Min. operating temp. -319°F/-195°C

Max. flow rate 20 gpm/76 lpm

PerformanceThe performance of our liquid-to-liquid heat exchangers vary with the fluid type, flow rate, and temperature of eachfluid. The charts below show the thermal performance for water and water (left) and water and oil (right).

Part Numbers

Flow Rate

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

20 64 GPM8 12100

400

200

600

800

1000

1400

1200

1600

1800 BTUHR°F

2010 30 400

1000

3000

2000

0

LPM

LL510

LL520

LL810

LL820

Thermal Performance Using Water and Water

Flow RateQ

/Init

ial T

emp

erat

ure

Dif

fere

nce

(W

/°C)

20 64 GPM8 12100

100

50

150

200

250

350

300

BTUHR°F

2010 30 400

200

600

400

0

LPM

LL510

LL820

LL810

LL520

Thermal Performance Using Water and Oil

Flow Rate

Pres

sure

Dro

p (

PSI)

20 64 GPM8 12100

10

5

15

20

25

35

30

BAR

2010 30 400

0.5

1.5

1.0

0

2.0

LPM

LL510

LL820

LL810

LL520

Pressure Drop Using Water

Flow Rate

Pres

sure

Dro

p (

PSI)

20 64 GPM8 12100

10

5

15

20

25

35

30

BAR

2010 30 400

0.5

1.5

1.0

0

2.0

LPM

LL510

LL820

LL810

LL520

Pressure Drop Using Oil

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Performance, Specifications and Ordering InformationStandard H

eat ExchangersLiquid-to-Liquid

SPECS87

GRAPHS87

DWG86

SELECT89

SB Fitting–Stub End BD Fitting–Beaded End

AN Fitting–37°AN Flare AN Fitting on 6340

“SB” INLET/OUTLET FITTING

FITTING BLOCK

FERRULE

NUT“BD” INLET/OUTLET FITTING

HELEX CLAMP

3/8˝ ID HOSE

“AN” INLET/OUTLET FITTING

37˚ “AN” FITTING BODY

7/8˝ CUP ACTUAL SIZE

TAIL PIECE

NUT

TUBE

A unit with a straight tube fitting can be welded intoyour system or used with a 3⁄8˝ self-locking torque-freefitting such as Swagelok® or Cajon™.

For a leak-free joint, Lytron’s beaded tube fittingmates with a 3⁄8˝ ID hose that is secured with a clamp.

Lytron’s AN fitting, 37° AN female flare nut (AN-818),mates with male JIC-SAE 37° flare fitting, 9⁄16-18UN/UNF-2A thd for 3⁄8˝ tubing and 3⁄4-16 UN/UNF-2Athd for 1⁄2˝ tubing.

ES Series Fitting

Note: the AN fitting on the 6340 is an 0.875˝ I.D.actual union and tail piece only.

The fitting on our ES Series oil coolers is a 3⁄8-18 NPT thread.

3/8-18 NPT

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Heat Exchanger Fittings

20

5

PSI

10

LPM5

15

0.50 1.51.0Liquid Flow

GPM2.0

25

0

10

1.5

0.5

1.0

2.0Bar

2.5 3.0

300


6105

6210

6110

63106320

6220

6120

PSI

BAR

GPM0 105

0

2

1

3 0.2

0.1

63401.00

0.25

Inch

es o

f W

ater

0.50

m3min42 6

0.75

8


400 500

1.25

0

1210

200

50

100

150

250

300

Pasc

als


61206105

6210

6110

6310

6320

6340

6220

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1. Cooling LiquidIn 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 DataLiquid type: WaterRequired heat load (Q): 3,300 W (11,263 BTU/Hr)Temp. of incoming liquid (Tliquid in): 80°C (176°F)Temp. of incoming air (Tair in): 21°C (70°F)Rate of liquid flow: 2 gpm (7.6 lpm)

Step 2: Select the heat exchanger product seriesChoose an aluminum, copper, or stainless steel heat exchanger based on the fluid compatibility. Aluminum tubing isusually used with light oils, or ethylene glycol and water solutions. Copper is normally used with water. Stainless steelis used with deionized water or corrosive fluids.

Step 3: Calculate the initial temperature differenceSubtract the temperature of the incoming air from the temperature of the incoming liquid as it enters the heatexchanger.

ITD = Tliquid in - Tair in

= 80°C – 21°C = 59°C (or 176°F – 70°F = 106°F)

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/Hr°FITD 59°C 106°F

Step 5: Select the appropriate heat exchanger modelRefer to the thermal performance graphs for the heat exchangers selected(Performance graphs for copper heat exchangers, stainless steel heat exchangers, andoil coolers can be found on pages 64, 74, and 82 respectively.) Any heat exchangerthat exceeds 56 W/°C at 2 gpm (using a standard fan) would be acceptable. As shownin the following graph, Lytron’s 6210 exceeds the required performance.

Step 6: Determine the liquid pressure dropFrom the data given, we know our pump needs to supply water at 2 gpm. Using theliquid side pressure drop chart for the 6210 curve, the point where a vertical line atthe 2 gpm point on the x-axis intersects with the 6210 curve reveals that the liquidpressure drop through the 6210 is 8 psi (0.55 bars). The pump selected must overcome this pressure drop to ensure a 2 gpm flow.

Step 7: Determine the air pressure dropThe 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).

Selecting a Heat ExchangerStandard H

eat Exchangers

1000

120

40

20

0 600300200

10

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

6056

m3min

400

5 15

150

100106

50

200

80

100

500

BTUHR°F

0

2 gpm

1 gpm

1/2 gpm

Falcon

Patriot

2. Cooling AirIn 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 calculatethe temperature rise using the heat load and the temperature of the cool air entering the cabinet.

Example: Cabinet Cooling applicationYou are cooling a cabinet containing electronic components that generate 2400 W of heat. The air in the cabinetmust not exceed 55°C. What heat exchanger should be selected, and what is the temperature of the cool air enteringthe electronics cabinet?

Step 1: Application DataLiquid type: WaterRequired heat load (Q): 2,400 W (8,189 BTU/Hr)Temp. of incoming liquid (Tliquid in): 20°CMax. temp of air in cabinet (Tair in): 55°C (131°F) —— This is the temperature of the hot air entering the heat exchanger

Rate of liquid flow: 2 gpm (7.6 lpm)

Step 2: Calculate the initial temperature differenceSubtract the temperature of the incoming liquid from the temperature of the incoming air as it enters the heatexchanger.

ITD = Tair in - Tliquid in = 55°C – 20°C = 35°C (or 131°F – 68°F = 63°F)

Step 3: Calculate the required performance capability (Q/ITD)Divide the required heat load (Q) by the ITD found above in step 2.

Performance capability = Q = 2,400 W = 68.6 W/°C or 8,189 BTU/HR = 130 BTU/HR°FITD 35°C 63°F

Step 4: Select the appropriate heat exchanger modelRefer to the thermal performance graphs for the heat exchangers selected(Performance graphs for copper heat exchangers, stainless steel heat exchangers andoil coolers can be found on pages 64, 74, and 82 respectively.) Any heat exchangerthat exceeds 68.6 W/°C at 2 gpm (using a standard fan) would be acceptable. Usingwater as the coolant, a copper heat exchanger is recommended. As shown in the fol-lowing graph, Lytron’s 6310 exceeds the required performance, offering a Q/ITD ofapprox. 96 W/°C using our Caravel fan.

Liquid and air pressure drop can be determined the same way as in the previous example.

Step 5: Calculating the temperature of the cool air entering the cabinetNow, 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 the 6310) we can see that thetemperature change is 17°C.This means that the cool airentering the cabinet will be:

55°C – 17°C = 38°C

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Selecting a Heat Exchanger

0

120

40

20

0 1000400200

20

Air Flow

Q/In

itia

l Tem

per

atu

re D

iffe

ren

ce (

W/°C

)

CFM

60

m3min10

600

0 25

200

100

300

80

100

800

BTUHR°F

140

160

180

200155

1 gpm

4 gpm

2 gpm

1/2 gpm

Caravel

68.6

0

10

30

20

40

50

60

70

80

90

100

0 200 250

17

400 600 800 1000

Ch

ang

e in

Tem

per

atu

re (

°C)

Air Flow (CFM)

20 kW15 kW10 kW7 kW5 kW4 kW3 kW2 kW1.5 kW1 kW500 W200 W

5 10 15 20 25 300

20

40

60

80

100

120

140

160

LPM°F

180

1200

1 These graphs offer a simple graphical way of estimating fluid temperature change if youknow your heat load and flow, without havingto do calculations. The graphs for water, air,50/50 ethylene glycol/water and oil allow youto calculate temperature changes for air andliquid for all types of heat exchangers.

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Step 6: Calculating the outgoing water temperatureTo determine the outgoing temperature of the water we use the ‘Water Flow’ chart to find that the change in tem-perature is approximately 5°C. Therefore the outgoing water temperature is 20°C + 5°C = 25°C.

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

Q = m• x Cp x �T

Where: Q = heat load m• = mass flow rate of the fluid

Cp = specific heat of the fluid �T = temperature difference between the liquid in and the liquid out

m• can be calculated for water and air using the following equations:

Water: m• ( lbs ) = v• ( gal ) x ( 60 min ) x � ( lbs ) x ( ft3) where v• = volumetric flow ratehr min hr ft3 7.5 gal

or

Water: m• ( kg ) = v• ( liters ) x ( 60 min ) x � ( kg ) x ( m3) where v• = volumetric flow ratehr min hr m3 1,000 liters

Air: m• ( lbs ) = v• ( ft3) x ( 60 min ) x � ( lbs )hr min hr ft3

or

Air: m• ( kg ) = v• ( m3) x ( 60 min ) x � ( kg )hr min hr m3

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.

Selecting a Heat ExchangerStandard H

eat Exchangers

0

5

10

15

20

25

30

35

40

45

50

0 1 2 3 4 5Water Flow (GPM)

Ch

ang

e in

Tem

per

atu

re (

°C)

2 4 6 8 10 12 14 16 180

10

40

20

30

50

60

70

80

90

LPM°F

20 kW15 kW10 kW7 kW5 kW4 kW3 kW2 kW1.5 kW1 kW500 W200 W

Custom heat exchangers for every application

With 50 years of experience designing and building heat exchangers for performance-critical applications, Lytron’sexpertise 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 heatexchangers 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 hundredsof man-years of experience. Lytron’s 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 manufacturinghoused under the same roof, products transition smoothly from design, through prototyping, to production. We carryout all performance-critical manufacturing processes in-house, from fin stamping, machining, and tube bending tovacuum brazing and heat treating. This guarantees us total control over the finished product, as well as increasedflexibility 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 andagency approvals are also available.

Getting startedYour 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 salesengineer, or filling out the ‘Request a Heat Exchanger Quote’ form on our website.

Custom plate-fin liquid-to-air heat exchangerwith chemical conversion coating

Heat exchanger with stainless steel tubes and nickel fin

High capacity oil cooler

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Cust

om H

eat

Exch

ange

rsCustom Heat Exchangers

Miniature 3˝(8 cm) heat exchangerwith Chemfilm® coating

Large 4´ (1.2 m) heat exchanger with nickel tubes and copper fin

Custom cupronickel tube-fin heat exchanger

Commercial condenser with single-piece aluminum flat tube

Custom tube-fin heat exchangersThe 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 thetube configuration and frame. We frequently work with specialty materials,such as cupronickel, nickel, Hastelloy®, and Inconel®. To meet the stringentshock 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 andinstrumentation can also be added.

Custom oil coolersLytron’s 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 3⁄8˝ (3 mm) inside radius without buckling, so heat exchangerscan be manufactured in a curved shape if needed. Custom fittings andmanifolds can be added, and oil coolers can be painted or anodized forextra protection.

Custom oil cooler with curved tubes

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Heat ExchangersCustom

Heat Exchangers

Custom

Heat ExchangersCustomCu

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Custom plate-fin heat exchangersAll 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 becausethey offer excellent thermal transfer capacity combined with small size and weight. Plate-fin heat exchangers can be designed for use with anycombination of gas, liquid, and two-phase fluids.

We carefully select the number of plate and fin layers, the size of the platesand fin, the height of the fin and the type of fin for optimum performance.The core is assembled and vacuum brazed in our environmentally-controlledroom to ensure high quality and reliability. Manifold ducting and mountingbrackets 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 temperatureoperation. Titanium heat exchangers offer performance similar to stainlesssteel or nickel-alloy plate-fin heat exchangers, but at 30-50% the weight.

Value-added assembliesOur extensive experience in the design and build of complete cooling sys-tems and subassemblies makes us your ideal partner when you need to addcomponents such as fans, sensors, fittings, and hoses. We can add whateveraccessories you need, or build your entire subassembly, so that your heatexchanger arrives ready to drop into your system. This saves you time and effort.

Aircraft oil cooler

Titanium plate-fin heat exchangers

Air-to-air plate-fin inner cooler

Custom plate-fin heat exchanger withpaint and chemical conversion coating

Heat exchanger subassembly with integrated fans

Clear anodized heat exchanger subassemblyincluding fan and temperature sensor

2536_heatexchangers. lytron -ams

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