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. Lytron’s 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
31
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 (±0.1°C)
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 (±0.5°C) 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.
32
www.Lytron.com • +1-781-933-7300
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
(±0.5°C)?
Is your heat
load less than
3,500 W?
See our ambient
cooling systems (MCS)
Page 48
Is your heat
load <5,900 W?
Facility water required
Is your set point
below your
facility water
temperature?
See our
Kodiak chillers
Page 34
See our LCS
Page 41
Standard Cooling Systems
Do you want
to use chilled
facility water
for cooling?
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
33
Kodiak® Recirculating Chillers
Cooling capacities up to 6 kW
Easy-access fill port
Large, easy-to-read,
controller display
Reservoir-level indicator
Standard Cooling Systems
Durable exterior panels
GRAPHS
36
SPECS
37
SELECT
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 ±0.1°C 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.
40
• ETL tested to UL 61010A-1, CE certified, and WEEE compliant
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
High-efficiency evaporator
Compressor
Vibration-isolating feet on
compressor and pump
Standard Cooling Systems
Split-chassis, modular design
for easy customization
GRAPHS
36
Circuit breaker
Coolant supply
IEC320 power inlet
Large capacity tank improves
temperature stability
Fault condition interface
(optional)
RS232 port (optional)
SPECS
37
SELECT
40
Coolant return
Manually adjustable flow
valve (optional)
System drain
www.Lytron.com • +1-781-933-7300
35
Kodiak Performance Graphs
Thermal Performance Graphs
RC006-RC011 Performance
2.0
60
70
RC022-RC045 Performance
90 °F
80
50
8.0
60
70
6
RC011 50 Hz
Cooling Capacity (kW)
kBTU
hr
RC011 60 Hz
1.5
RC009 60 Hz
4
RC006 60 Hz
1.0
RC006 50 Hz
RC009 50 Hz
2
0.5
90 °F
80
RC045 60 Hz
Cooling Capacity (kW)
50
kBTU
hr
25
RC045 50 Hz
6.0
20
RC030 60 Hz
4.0
15
RC030 50 Hz
RC022 60 Hz
10
RC022 50 Hz
2.0
5
0
0
5
10
15
20
25
30
Output Temperature (°C)1
35
5
10
15
20
25
30
Output Temperature(°C)1
35
System Pump Graphs2,3
Kodiak Positive Displacement Pumps4
10
BE/CE
50 Hz
70
4
BG/CG
60 Hz
BC/CC
50 Hz
30
3
2
BB/CB
60 Hz
BB/CB
50 Hz
20
90
0
5
2
3
4
Water Flow Rate (gpm)
10
15
20
GRAPHS
36
25
LPM
Bar
25
2
EC
50 Hz
1
AA
60 Hz
AA
50 Hz
4
2
6
Water Flow Rate (gpm)
0
8
RC030-RC045 Centrifugal and Turbine Pumps
LPM
Bar
90
0
5
10
15
20
25
LPM
Bar
80
EB/FB
60 Hz
60
5
4
EB/FB
50 Hz
50
40
3
EC
60 Hz
30
2
DA
60 Hz
EC
50 Hz
EB/FB
60 Hz
60
4
50
EB/FB
50 Hz
3
40
DA
60 Hz
30
2
20
20
10
5
70
Fluid Pressure (PSI)
40
Fluid Pressure (PSI)
SELECT
20
20
5
80
70
37
15
EC
60 Hz
0
1
10
10
1
RC011-RC022 Centrifugal and Turbine Pumps
SPECS
30
10
0
5
0
40
5
BG/CG
50 Hz
BC/CC
60 Hz
40
50
3
BE/CE
60 Hz
60
50
RC006-RC009 Centrifugal and Turbine Pumps
LPM
Bar
15
Fluid Pressure (PSI)
80
Fluid Pressure (PSI)
Standard Cooling Systems
90
5
0
1
DA
50 Hz
1
DA
50 Hz
10
0
0
0
2
4
6
Water Flow Rate (gpm)
8
0
2
4
6
Water Flow Rate (gpm)
8
1 Temperature represents output temperature of water assuming 20°C 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.
36
www.Lytron.com • +1-781-933-7300
Specifications and Part Number Configuration Kodiak
First select your
model number
Cooling capacity1
W
kBTU/Hr
Compressor capacity
HP
RC006
RC009
RC011
RC022
RC030
RC045
825
2.8
1050
3.6
1650
5.6
2400
8.2
3450
11.8
5900
20.1
⁄4
1
11⁄2
⁄4
⁄3
1
1
⁄2
1
3
Temperature stability2
± 0.1°C
Fluid connections
⁄2˝ FNPT
1
Reservoir capacity
1 gal/4 liters
Coolant temperature range
50°F to 95°F/10°C to 35°C
Dimensions (W x D x H)
Weight
Now, select
a pump
inches
mm
dry lbs (kg)
12.5 x 19.0 x 22.0
318 x 483 x 559
97 (44)
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
Amps
9.9
12.2
14.3
n/a
n/a
n/a
H03: 230V, 50 Hz, 1ph
Amps
4.5
5.3
6.3
9.5
13.7
17.2
J03: 208/230V, 60 Hz, 1ph
Amps
n/a
5.8
7.4
10.0
14.5
19.6
●
●
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
CC: PDP4, 5, Stainless Steel, 1.8 gpm/6.8 lpm
CE: PDP4, 5, Stainless Steel, 2.3 gpm/8.7 lpm
AA: Centrifugal, 1⁄20 HP6
DA: Centrifugal, 1⁄4 HP6
EC: Turbine, 1⁄6 HP6
EB: Turbine, 1⁄2 HP6
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.
●
●
●
●
●
●
Standard Cooling Systems
CB: PDP4, 5, Stainless Steel, 1.3 gpm/4.9 lpm
CG: PDP4, 5, Stainless Steel, 4.3 gpm/16.3 lpm
Add any
additional
options
14.8 x 24.5 x 26.5
376 x 623 x 673
100 (45)
BG: PDP4, Brass, 4.3 gpm/16.3 lpm
Select your
controller
6 gal/23 liters
40°F to 95°F/5°C to 35°C
Ambient temperature range
Next, pick an
electrical
configuration
2 gal/8 liters
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
0.1°C set point
DI water cartridge8, 10
High purity plumbing
PAO compatibility
Remote start
9
GRAPHS
36
SPECS
37
SELECT
40
● = standard = available option 1 At 20°C setpoint, 20°C 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
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
Benefit
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.
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.
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.
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 chiller’s return. It can also be used to prevent the
chiller supply from exceeding a predetermined pressure setting.
Anti-siphon system: Check and solenoid valves installed
internal to the chiller on the supply and return lines,
respectively.
Allows the chiller to be installed at an elevation below the application. Prevents backflow
and subsequent overflowing of the chiller’s vented tank (if not installed, fitting leaks in
the application can allow air to displace the coolant, resulting in backflow to the tank).
Air filter: Internally mounted on the air inlet to the
condenser coil.
Filters incoming air to the chiller’s 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.
5 micron coolant filter: Externally mounted on the
supply from the chiller.
Filters process coolant being supplied to the application, protecting equipment from
blockage or damage due to particulate buildup and extending pump life.
Standard Cooling Systems
Special Applications Options
GRAPHS
36
SPECS
37
SELECT
40
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.
Internal insulation package: Insulated tank, pump head,
and coolant lines.
Eliminates condensation forming on the components in contact with the fluid when
operating chiller at set points below the ambient dew point.
Low temperature operation: Chiller coolant temperature
range is –5°C to +25°C. (Note: internal insulation package
must also be selected.)
Optimizes performance for low temperature operation and provides additional low
temperature cooling capacity compared to standard chillers. Contact Lytron’s applications
engineering department for performance graphs.
Water-cooled condenser: Refrigerant is condensed using
water (rather than ambient air) via a liquid-to-liquid heat
exchanger.
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.
0.1°C set point: Allows 0.1°C increments of the set point
and display temperatures.
Allows more precise control of the coolant delivery temperature. Available in °C only.
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.
High purity plumbing: Includes nickel-brazed evaporator
and nickel-plated or nylon fittings compatible with DI
water. Not compatible with brass pumps.
All wetted materials are fully compatible with DI water to prevent component corrosion.
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.
All wetted materials are fully compatible with PAO. Contact Lytron for PAO
performance curves.
Convenience Options
Remote start: Chiller power can be cycled through a
computer or relay.
1
38
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.
www.Lytron.com • +1-781-933-7300
Options and Accessories Kodiak
Kodiak Controllers1
Controller Option
Functionality
Controller Package
1
2
3
Easy-to-read display in either °C or °F.
●
●
●
Calibration offset
Allows temperature display to be offset to represent the temperature at a different
point within the cooling circuit.
●
●
●
Low flow shut-off fault
Alerts user to a lack of coolant flow and shuts down the chiller to prevent the
refrigeration system from freezing.
●
●
●
Auto-restart
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.
●
●
●
°C/°F toggle
Enables temperature display to be viewed in °C or °F.
●
●
●
Audible alarm
Audible warning of all fault conditions.
●
●
Alarm mute
Silences audible alarm until the alarm is cleared or the chiller turned off.
●
●
Digital pressure sensing
Displays pump output pressure (psig or bar) and allows it to be transmitted through RS232.
●
●
Low level fault
Alerts user that the coolant level in the reservoir is at a critically low level (approaching
the level of the pump’s suction line). Switches chiller off if ‘fault shut-off’ is on.
●
●
Low/high temperature fault
Alerts user that the coolant temperature is outside of the user’s defined set-point limits.
Switches chiller off if ‘fault shut-off’ is on.
●
●
Fault shut-off
(toggle on/off)
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.
●
●
Relay contacts
(normally open or normally closed)
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
●
●
RS232 communications
Allows complete control of all the chiller’s controller features (changing/monitoring
coolant set point, monitoring pressure, and fault alarms, etc.) from a remote computer
for monitoring, control, and data logging.
●
Kodiak Accessories
Item
Description
Part Number
Coolant Filter Kit:
1
⁄2˝ fluid connections. Contains 5 micron filter, filter housing, mounting bracket ,1´ hosing,
base clamps, and assembly instructions.
200-0441
Plumbing package:
1
⁄2˝ fluid connections. Contains 50’ NylabraidTM hose, 50’ Armorflex™ insulation, male NPT
to barb fittings, hose clamps.
200-0193
External pressure
relief valve:
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.
200-0196
External manually
adjustable flow valve:
1
⁄2˝ fluid connections. For applications requiring flow control. Kit contains flow valve, 2 tees, hose
clamps, and plumbing instructions. Assembly required.
200-0298
115V power cord:
25’
250-0092
230V power cord:
25’
250-0093
RS232 cable:
10’
250-0091
Dry contact cable:
10’
250-0159
5 micron replacement coolant filters2
Air filters2
Package 2 is the standard package
GRAPHS
36
SPECS
37
SELECT
40
330-0022
RC006/RC009: 330-1541
RC011/RC022: 330-0977
RC030/RC045: 330-0683
Deionization cartridge
1
Standard Cooling Systems
Digital temperature display
430-0330
2
10 piece minimum
www.Lytron.com • +1-781-933-7300
39
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 20°C 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.
•
v = Q/(␳ · Cp · (TOUT - TIN))
•
v = fluid flow rate
␳ = fluid density
Q = heat load
Cp = fluid specific heat
TOUT = max. fluid temp. exiting the heat source
TIN = fluid temp. exiting the chiller
Example 2:
A laser head generates 2,000 Watts (6,824 BTU/Hr) of heat. The fluid temperature must not exceed 20°C (68°F).
With a cooling fluid of water, 60 Hz power, at 20°C 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 13°C (55°F). This is TIN (the temperature exiting the recirculating chiller).
Therefore, the calculation then becomes:
•
v = 2000 W /(990 kg/m3 · 4180 J/kgºC · (20ºC – 13ºC)
•
v = 6.9 x 10-5m3/s or 1.1 gpm
␳ water = 990 kg/m3, Cp = 4180 J/kgºC
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
50
8.0
SPECS
Cooling Capacity (kW)
40
60
70
80
90 °F
RC045 60 Hz
37
SELECT
Fig 2: Kodiak Positive Displacement Pumps
Fig 1: RC022-RC045 Performance
36
kBTU
hr
25
90
20
RC030 60 Hz
4.0
15
RC030 50 Hz
RC022 60 Hz
10
RC022 50 Hz
2.0
5
10
BE/CE
50 Hz
70
RC045 50 Hz
6.0
5
0
80
Fluid Pressure (PSI)
Standard Cooling Systems
•
v where:
BE/CE
60 Hz
60
5
BG/CG
50 Hz
BC/CC
60 Hz
50
30
4
BG/CG
60 Hz
BC/CC
50 Hz
40
LPM
Bar
15
3
2
BB/CB
60 Hz
BB/CB
50 Hz
20
1
10
0
5
10
15
20
25
30
Output Temperature(°C)1
35
0
1
2
3
4
Water Flow Rate (gpm)
To avoid thermal calculations, use the cooling system product selector at www.Lytron.com.
40
www.Lytron.com • +1-781-933-7300
5
Liquid-to-Liquid Cooling Systems LCS20™
Cooling capacities up to 20kW
Reservoir-level indicator
Split-chassis, modular design
for easy customization
High-efficiency counterflow
heat exchanger
Durable exterior panels
Wide variety of pump options
Lytron’s 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 ±0.5°C, 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.
Standard Cooling Systems
Heavy-duty casters
(two locking)
GRAPHS
36
SPECS
37
SELECT
40
• ETL tested to UL 61010A-1, CE certified, and WEEE compliant
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
Visual alarms for low/high temperature;
low flow; dew point (optional); pump,
power, or sensor failure; relay contacts
for each alarm
Standard Cooling Systems
Accommodates dual power feeds
GRAPHS
43
SPECS
44
SELECT
47
Redundant pump with user defined
secondary pump test frequency
and duration
Isolation valves allow for hot
swapping of pump
Control to local dew point available
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
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.
42
www.Lytron.com • +1-781-933-7300
Specifications LCS
LCS20 Thermal Performance Graph1
10
2.0
20
30
40
LPM
10 GPM
kBTU
Hr°F
3.5
100
10
Fluid Pressure (PSI)
2.5
4 GPM
1.5
0.5
1.0
2 GPM
LPM
25
Bar
EB/FB - 60Hz
2.0
1.0
20
6
8 GPM
6 GPM
15
80
3.0
1.5
Q/ITD (kW/°C)
LCS20 Pump Graph2,3
5
EB/FB - 50Hz
60
4
BG/CG - 50Hz
BG/CG - 60Hz
40
DA - 60Hz
2
20
DA - 50Hz
0.5
0
0
2
4
6
8
Process Water Flow Rate
10
0
12
GPM
0
1
2
3
4
5
6
Process Water Flow Rate
LCS50 Thermal Performance Graph1
300
200
400
19
100 GPM
18
kBTU
Hr°F
30
25
12
50 GPM
10
8
20
15
6
25 GPM
10
20
30
40
100
200
300
400
500
DE 60 Hz
3
40
DE 50 Hz
30
2
20
0
0
20
BAR
FILL VALVE
AIR VENT
Pressure Drop (psid)
16
BRAZED PLATE
HEAT EXCHANGER
1.00
14
PS
MIXING
VALVE
PROCESS
WATER RETURN
(SECONDARY)
FACILITY
WATER OUT
(PRIMARY)
GRAPHS
43
PRESSURE TEMPERATURE
SENSOR
SENSOR
12
PS
0.75
10
TS
FACILITY SIDE
SENSORS ARE
OPTIONAL
EXPANSION
TANK
8
0.50
BALL VALVE
6
SPECS
44
FLOW
CONTROL
VALVE
SELECT
47
CHECK VALVE
4
0.25
FACILITY
WATER IN
(PRIMARY)
2
0
40
60
80
100
120
GPM
Process Water Flow Rate
LCS50 Plumbing Diagram
LCS50 Facility Side Pressure Drop
18
BAR
4
50
50 60 70 80 90 100 110 120
GPM
Process Water Flow Rate
LPM
LPM
10
5
2
400
300
1
4
0
3
60
35
75 GPM
14
200
100
70
8
GPM
Standard Cooling Systems
Q/ITD (kW/°C)
16
LCS50 Pump Graph
Fluid Pressure (PSI)
100
20
LPM
7
PUMP
0
20
40
60
80 100 120
Facility Flow Rate
140 160
GPM
PRESSURE
SENSOR
PS
TS
PROCESS
WATER SUPPLY
(SECONDARY)
PS
LS
1
Facility side flow rates are represented by curves
2
Pressure relief is factory set at 90psi (6.2 bar).
Other settings available on request.
3
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
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)
inches
mm
lbs
kg
Weight
Next, pick an
electrical
configuration
Standard Cooling Systems
Now, select
a pump
And select your
controller
36
SPECS
37
Add any
additional
options
SELECT
40
G01: 100-120V, 50/60 Hz
J01: 200-240V, 50/60 Hz
Amps
Amps
7.2
3.6
N/A
N/A
L01: 208-230 VAC, 50/60 Hz, 3ph
P01: 460 VAC, 50/60 Hz, 3ph
Amps
Amps
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, 1⁄4 HP4
EB: Turbine, 1⁄2 HP4
FB: Turbine, Stainless Steel, 1⁄2 HP 3,4
DE: Centrifugal, 5 HP, 2 per system
●
Controller options (see page 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
flow rate depends on system pressure drop. 5Not available with DA pump.
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
44
●
Available options (full descriptions of these options can be found on pages 45 and 46)
4Actual
To arrive at a
part number
150 kW (512 kBTU/Hr) at
75 GPM process and
100 GPM facility and 10°C
Initial Temperature
Difference (ITD)
± 1.0°C
2˝ copper (cup) terminated
at bottom of unit
6 gal/22 liters
N/A
50°F to 122°F/10°C to 50°C
41°F to 95°F/5°C to 35°C
50°F to 95°F/10°C to 35°C
39°F to 54°F/4°C to 12°C
41°F to 104°F/5°C to 40°C
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
Electrical configurations and full load amperage1
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
LCS50
11 kW (37 kBTU/Hr) at
4.3 GPM process and
10 GPM facility and 10°C
Initial Temperature
Difference (ITD)
± 0.5°C
3
⁄4˝ FNPT
www.Lytron.com • +1-781-933-7300
Options and Controllers LCS20
LCS20 Options
Option
Benefit
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.
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.
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.
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 LCS’s return. It can also be used to prevent the
LCS supply from exceeding a predetermined pressure setting.
5 micron coolant filter: Externally mounted on the supply
from the LCS.
Filters process coolant being supplied to the application, protecting equipment from
blockage or damage due to particulate buildup and extending pump life.
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.
Internal insulation package: Insulated tank, pump head,
and coolant lines.
Eliminates condensation forming on the components in contact with the fluid when
operating LCS at set points below the ambient dew-point.
Fluid Compatibility Options
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.
High purity plumbing: Includes nickel-brazed heat
exchanger and nickel-plated or nylon fittings compatible
with DI water. Not compatible with brass pumps.
All wetted materials are fully compatible with DI water to prevent component corrosion.
LCS20 Controllers
Controller Option
Functionality
Controller Package
1
2
Digital temperature display
Easy-to-read display in either °C or °F.
●
●
°C/°F toggle
Enables temperature display to be viewed in °C or °F.
●
●
Over-temperature indicator
Alerts user that the coolant temperature is over the user’s defined set point limits.
●
●
Calibration offset
Allows temperature display to be offset to represent the temperature at a different point
within the cooling circuit.
●
●
Low level indicator
Alerts user that the coolant level in the reservoir is at a critically low level
(approaching the level of the pump’s suction line).
●
Low flow indicator
Alerts user to a lack of coolant flow.
●
Analog output
Allows user to monitor pump discharge temperature remotely
●
Standard Cooling Systems
Deionization (DI) water cartridge: LCSs come with an
externally mounted DI cartridge (no indicator light) on
the return to the LCS.
GRAPHS
36
SPECS
37
SELECT
40
www.Lytron.com • +1-781-933-7300
45
LCS50 Options and Controllers
LCS50 Options
Option
Benefit
Protection and Special Applications Options
Facility side monitoring
Provides temperature and flow monitoring of facility side loop. Facilitates troubleshooting.
Coolant filters
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.
Dual mixing valves
Incorporates a second mixing valve. In the unlikely event of a failure, the controller automatically
switches over to the redundant valve.
Alternative fluid inlet and outlet location
Allows for piping to terminate at the upper back of the LCS for overhead piping configurations.
Internal insulation package (process side)
Eliminates condensation on process side components when operating the LCS at set points below
the dew point.
LCS50 Controllers
Standard Cooling Systems
Controller Option
GRAPHS
43
SPECS
44
Controller Package
3
4
5
6
Digital temperature set point
Diplays process and set point temperatures in either °C or °F.
●
●
●
●
RS232 communications
Allows monitoring, control, and data logging of all the controller features using
RS232 protocol.
●
●
●
●
Ethernet communications
Allows monitoring, control, and data logging of all the controller features using
Ethernet protocol.
●
●
Flow, pressure, and mixing
valve status reporting
Controller displays the current process side coolant flow and pressure as well as current
position of the mixing valve.
●
●
●
●
Visual alarms for low/high
temperature
Alerts user that the coolant temperature is outside of the user’s defined set-point limits.
●
●
●
●
Low flow alarm
Alerts user that the coolant flow is below the user’s defined limit.
●
●
●
●
Pump failure alarm
Alerts user of a pump failure. System automatically switches over to secondary pump
●
●
●
●
Power failure alarm
Alerts user of a power failure. System automatically switches over to secondary
power supply.
●
●
●
●
Relay contacts for each alarm
(normally open or normally
closed)
Fault conditions of the LCS can be monitored by applying a low voltage power signal
across dry contacts.
●
●
●
●
Lockout protection
Allows user to lock-out the controller to prevent unauthorized use.
●
●
●
●
Control set point temperature
based on dew point offset
Allows user to input dew point offset such that the coolant temperature will fluctuate
based on the dew point fluctuation.
●
●
Control set point based on
fixed temperature with user
defined dew point override
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.
●
●
SELECT
47
46
Functionality
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.
vF ,TF
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:
vp ,Tp
Facility Side
LCS
Tp + ⌬T
Process Side
Heat Source, Q
• Cp⌬T
Q=m
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,
• Cp⌬T
Q
m
=
ITD
Tp + ⌬T - TF
Standard Cooling Systems
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 20°C. The heat load is 10 kW and the process water flow
rate is 5 gpm. The facility water is at 10°C.
Using the heat capacity graphs, we find that the ⌬T through the process is approximately 7.6°C for the condition
10 kW at 5 gpm.
We can now solve for Q/ITD as follows:
Q
10 kW
=
ITD
20°C + 7.6°C - 10°C
Q
kW
= 0.57
ITD
°C
GRAPHS
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
20
40
30
LPM
10 GPM
50
3.5
45
3.0
1.5
Q/ITD (KW/°C)
KBTU/Hr°F
8 GPM
6 GPM
2.5
2.0
1.0
4 GPM
1.5
0.57
0.5
1.0
2 GPM
0.5
0
0
2
4 5 6
8
Process Flow Rate
10
12
GPM
Change in Temperature (°C)
10
2.0
0
2
4
6
8
10
12
14
16
SPECS
LPM
18
°F
90
44
80
SELECT
40
70
35
60
30
50
25
40
20
30
15
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
20
10
7.6
5
0
43
10
0
1
2
3
4
5
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
Easy access
reservoir panel
Polyethylene reservoir
Stand alone housing or rack
mount configurations available
Reservoir level
indicator
Internal view of MCS
High-efficiency
heat exchanger
Rugged, all-welded
steel frame
Standard Cooling Systems
Various pumps available
GRAPHS
50
SPECS
51
SELECT
52
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.
48
Durable textured finish
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
Standard Cooling Systems
GRAPHS
50
SPECS
51
MCS10, MCS20, MCS30
19” Rack Mount
SELECT
52
MCS40, MCS50
www.Lytron.com • +1-781-933-7300
49
MCS Performance Graphs
MCS30 Thermal Performance1
5
0
70
15 LPM
10
BTU
Hr°F
4
MCS20
60 Hz
60
MCS20
50 Hz
50
3
40
30
2
MCS10
60 Hz
20
1
MCS10
50 Hz
10
Oil
60 Hz
Oil
50 Hz
50
2
30
20
1
10
Q/Initial Temperature Difference (W/°C)
Standard Cooling Systems
LPM
15
10
BTU
Hr°F
150
MCS50
60 Hz
125
MCS50
50 Hz
100
MCS40
60 Hz
200
150
100
100
4
6
BC/CC
50 Hz
60
BB/CB
50 Hz
40
BB/CB
60 Hz
8
10 LPM
Bar
5
BC/CC
60 Hz
BE/CE
50 Hz
4
BE/CE
60 Hz
3
2
20
1
3
2
4
Water Flow Rate (gpm)
1
0
5
10
DA - 60 Hz
1
2
Water Flow Rate (gpm)
0
5
MCS10 Centrifugal Pumps2
3
MCS20 Centrifugal Pumps2
LPM Bar
2.0
30
0
5
10
LPM Bar
2.0
DA - 60 Hz
SPECS
25
DA - 50 Hz
1.5
20
AB - 60 Hz
15
1.0
10
0
3
1
2
Water Flow Rate (gpm)
Oil @ 70°F, 50/50 EGW
2
AB - 60 Hz
15
10
1.0
AB - 50 Hz
0.5
5
4
0
0
0
3
1
2
Water Flow Rate (gpm)
Includes pressure drop through system. See page 53 for guidance on selecting a pump.
www.Lytron.com • +1-781-933-7300
1.5
DA - 50 Hz
20
0.5
AB - 50 Hz
5
Fluid Pressure (PSI)
25
Fluid Pressure (PSI)
2
0
GRAPHS
50
5
6
50
25
0
1
4
MCS Positive Displacement Pumps
0
80
50
0
2
3
Flow Rate (gpm)
250
MCS40
50 Hz
75
1
0
4
0
52
3
40
Fluid Pressure (PSI)
5
0
SELECT
BTU
Hr°F
4
50% EGW
50 Hz
60
MCS40 and MCS50 Thermal Performance
51
LPM
15
0
3
1
2
Water Flow Rate (gpm)
0
30
10
50% EGW
60 Hz
70
0
50
5
0
80
Q/Initial Temperature Difference (W/°C)
Q/Initial Temperature Difference (W/°C)
MCS10 and MCS20 Thermal Performance
4
0
Specifications and Part Number Configuration MCS
MCS40/50 Centrifugal Pumps2
MCS30 Centrifugal Pumps1,2
0
30
15
10
LPM Bar
2.0
Fluid Pressure (PSI)
1.5
DA, 50 Hz
EGW
15
1.0
10
AB 60 Hz
EGW
8
LPM
Bar
2.0
DA - MCS40/50
60 Hz
1.5
20
DA - MCS40/50
50 Hz
15
1.0
10
0.5
AB 50 Hz 0.5
AB 50 Hz
Oil
5
6
4
25
DA, 60 Hz, EGW
20
2
0
30
DA 60 Hz
Oil
25
Fluid Pressure (PSI)
5
EGW
5
AB, 60 Hz, Oil
DA, 50 Hz, Oil
0
1
0
3
2
Flow Rate (gpm)
1
Oil @ 70°F, 50/50 EGW
2
4
5
0
0
Rack Mount Dimensions (W x D x H)
Weight – stand alone
Weight – rack mount
Recommended coolant
Add the
ambient
package
Add any
additional
options
W
BTU/Hr
MCS10
MCS20
500
1,700
1300
4,450
2100
7,150
1
1
⁄2˝ FNPT
⁄2˝ Barb
1
1
⁄2˝ FNPT
⁄2˝ Barb
0.75 gal / 2.8 liters
131°F / 55°C
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
inches
mm
inches
mm
lbs (kg)
lbs (kg)
MCS40
MCS50
2400
8,200
3500
12,000
⁄2˝ FNPT
⁄2˝ FNPT
1
1
15 x 15 x 24
381 x 381 x 610
n/a
60 (27)
n/a
water
65 (29)
n/a
water
n/a
5.6
n/a
2.7
n/a
5.8
n/a
2.8
●
●
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
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, 1⁄16 HP 4
DA: Centrifugal, 1⁄4 HP 4
●
●
GRAPHS
50
SPECS
Package Options
51
Package 1: Ambient Package
●
●
●
●
●
Additional Options
SELECT
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 With standard pump PDP = Positive Displacement Pump
rate depends on system pressure drop. See page 53 for information on how to calculate flow rate.
1
To arrive at a
part number
MCS30
Standard Cooling Systems
Cooling capacity using water, 25°C
initial temperature difference
Fluid Inlet Connections
Fluid Outlet Connections
Reservoir capacity
Maximum liquid temperature
Dimensions (W x D x H)
Now, select
a pump
0
Includes pressure drop through system. See page 53 for guidance on selecting a pump.
First select your
model number
Next, select
an electrical
configuration
3
1
2
Water Flow Rate (gpm)
0
MCS10 G01 BB 1
2
3
Only available with high purity plumbing
4
52
Actual flow
MCS10, 115V, 60 Hz operation, with BB pump and no additional options
or
MCS20 G01 CC 1 M063
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
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 35°C.
Ambient room temperature is 20°C. 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/(35°C-20°C) = 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.
MCS Positive Displacement Pumps
70
5
0
15 LPM
10
BTU
Hr°F
4
MCS20
60 Hz
60
MCS20
50 Hz
50
46.7
3
40
30
2
MCS10
60 Hz
20
1
MCS10
50 Hz
10
100
0
2
4
6
8
10 LPM
Bar
6
80
Fluid Pressure (PSI)
Q/Initial Temperature Difference (W/°C)
Standard Cooling Systems
Thermal Performance
BC/CC
50 Hz
60
BB/CB
50 Hz
40
BB/CB
60 Hz
5
BC/CC
60 Hz
BE/CE
50 Hz
BE/CE
60 Hz
3
2
20
1
0
0
0
0.5
1
2
3
Water Flow Rate (gpm)
4
0
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
4
www.Lytron.com • +1-781-933-7300
3
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.
Centrifugal and Turbine 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 system’s pressure drop, or are
likely to use the cooling system with a variety of test
set-ups. Lytron’s 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.
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 system’s pressure drop. It is
recommended that centrifugal and turbine pumps
are replaced approximately every 28,000 hours of
operation to ensure reliable performance.
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.
Standard Cooling Systems
Positive Displacement Pumps (PD pumps)
Fluid Pressure (PSI)
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
60
4
EB/FB
50 Hz
50
3
40
EC
60 Hz
30
2
DA
60 Hz
20
1
10
EC
50 Hz
DA
50 Hz
0
0
1
Other settings available on request
2
4
6
Likely Flow Rate (gpm)
8
www.Lytron.com • +1-781-933-7300
53
Custom Cooling Systems
Custom cooling systems for
demanding applications
Custom Cooling Systems
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.
4 kW low-noise
recirculating chiller
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.
Custom shape and size
recirculating chiller to fit
within customer’s system
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 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.
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. Lytron’s
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
customer’s system. Manufacturability
and serviceability were considered
throughout the design process. Lytron
engineers worked closely with the
customer’s engineering team .
Custom Cooling Systems
Custom ‘skinless’
liquid-to-liquid cooling system
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.
Custom Cooling Systems
• 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 Lytron’s Woburn, MA, USA facility.
56
www.Lytron.com • +1-781-933-7300