2536 - Heatexchangers. Lytron - AMS

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

exchanger design and manufacture, Lytrons
expertise is second-to-none. Our heat exchangers
are used in many industries including military
and aerospace, medical and industrial lasers,
medical imaging, analytical instrumentation,
power electronics, semiconductor equipment,
machine tools and telecommunications.
Any of our heat exchanger technologies
can be customized to your exact requirements.
We also supply heat exchanger subassemblies,
adding fittings, hoses, fans, sensors, and other
instrumentation to your specification. And our
seven product ranges with over 130 standard
parts ensure that when you need an off-theshelf part we are likely to have something that
meets your requirements.
www.Lytron.com +1-781-933-7300
57
Heat Exchanger Technology Overview

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

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

ES Series
Standard Heat Exchangers
ES series oil coolers are designed for optimum cooling

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

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

Liquid-to-liquid brazed plate heat exchangers utilize stainless
steel plates brazed together in a counterflow configuration.
This offers high liquid-to-liquid cooling capacity in a compact
package. We offer both copper-brazed and nickel-brazed versions
for compatibility with a wide range of coolants. Applications
include district heating/cooling, heat recovery, and laser cooling.
58
Heat Exchanger Technology Overview
Plate-Fin
Oil Coolers
Performance (Q/ITD)
Tube-Fin
Water Flow
Performance comparison
As many heat exchangers are customized, a range of typical values is shown for each technology. All performances
are compared using water as the cooling fluid.
Fluid compatibility
Dielectric fluids
(e.g. Fluorinert)
Polyalphaolefin
(PAO)
Aluminum flat tube heat exchangers (ES Series)
Aluminum plate-fin heat exchangers
Copper-brazed liquid-to-liquid heat exchangers

Nickel-brazed liquid-to-liquid heat exchangers
EGW
Tube-fin heat exchangers with stainless steel tubing (4000 Series, Aspen)
Tube-fin heat exchangers with copper tubing (6000 Series, OEM Coils)
Water
Oil
Corrosive fluids
(e.g. Deionized water)
Coolant compatibility with wetted surfaces must be considered when selecting a heat exchanger technology. A
copper fluid path is compatible with water and most common coolants. A stainless steel fluid path is necessary
when using deionized water and other corrosive fluids. Aluminum offers excellent performance with ethylene glycol/water mixture (EGW), oils and other fluids, but is not compatible with untreated water. The table below
shows fluid/heat exchanger compatibility.
This chart compares the performance of different heat exchanger technologies. Performance is shown as Q/ITD,
the heat load divided by the difference in incoming temperature of the liquid and air. Units are not shown so that
technologies can be compared regardless of size.
59
6000 Series Copper Heat Exchangers
Copper tubing expanded

into copper cooling fins
for excellent heat transfer
Fluxless, silver-brazed joints
provide leak-free reliability
SELECT
89
All units supplied with built-in,

fan-ready mounting hardware
GRAPHS
64
DWG
0.028 (0.7 mm) seamless

wall tubing ensures fluid
circuit durability
66
Electro-static dip painted

for harsh environments
SPECS
68
The 6000 Series is a high performance heat exchanger with copper tubes and fin. It delivers efficient heat transfer and
maximum reliability in a compact package.
High cooling capacity in a small envelope: The 6000 Series is engineered for performance. Its high tube density
results in maximum heat transfer. The seamless copper tubes are expanded into copper fin (aluminum for the 6340)
with an extruded full collar which ensures excellent metal-to-metal contact and improves the thermal performance.
Integrated fan plate for improved performance and convenience: The 6000 Series integral fan plate acts
as a plenum to distribute the air flow uniformly through the core, thus maximizing performance. It also enables
easy fan installation.
Reliable, leak-free, and robust: Lytron heat exchangers are designed for reliability. Our thick-walled (0.028/0.7 mm)
seamless copper tubing and fluxless silver-brazed joints ensure the integrity of the fluid path. The unit is painted for
long life, even in corrosive environments. All 6000 Series heat exchangers are pressure tested to 150 psi (10.3 bar)
to guarantee reliability.
Compatible with water, ethylene glycol/water mixture (EGW), and other common coolants.
Customization Options
Custom 6000-Series style heat exchangers can be manufactured in any size
and tube configuration to match your demanding thermal requirements.
Variations in inlet/outlet position and/or fittings can be accommodated and
a selection of paints and other coatings is available. Assemblies including
fans and other components can also be supplied.
See page 92 for more custom heat exchangers.
60
6000 Series heat exchanger with custom circuitry, sensor ports, and inlet/outlet fittings
Copper Heat Exchangers OEM Coils
0.028 (0.7 mm) wall tubing

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

aluminum fins offers efficient
and reliable operation
SELECT
89
GRAPHS
Galvanized steel side rails and

tube sheets offer strength and
corrosion resistance
64
DWG
66
SPECS
68
Great value: We carefully selected the materials, tube layout, and fin for low manufacturing cost, and eliminated
some of the cosmetic features found in the 6000 Series. All these cost savings have been passed on to you!
Leak-free, reliable, and robust: Our OEM coils use the same thick (0.028/0.7 mm) walled copper tubing and
fluxless silver-brazed joints as our 6000 Series to ensure the integrity of the fluid circuit. Galvanized side plates
provide superior strength and are corrosion-resistant. All of our OEM coils are 100% leak tested to 150 psi (10.3 bar).
Compatible with water, ethylene glycol/water mixture (EGW), and other common coolants.
OEM coils are the ideal solution for large volume, price sensitive users who need a high quality, cost-effective part but
do not require the additional features of the 6000 Series.
Both the 6000 Series and OEM coils offer high performance and reliability. The 6000 Series uses copper fins, is
painted black for corrosion resistance, and includes a fan-plate. The OEM coil has a different tube configuration,
uses aluminum fins, and is unpainted with galvanized side plates. OEM coils are best suited for the price-sensitive,
high volume customer where the appearance is not critical, for example where the heat exchanger is hidden in
the equipment.
OEM Coil subassembly supplied with fan, finger guard, and hosing
OEM coils are designed for flexibility. Modified standards are available
in three standard widths and any length up to 48. For high volume
applications we can customize dimensions, tube configuration, fittings, etc.
to meet your precise thermal requirements and size envelope. Assemblies
including fans and other components can also be supplied.
61
6000 Series Pictures

6105
6110
6120
6210
6220
6310
6320
SELECT
89
GRAPHS
64
DWG
66
SPECS
68
62
6340
Pictures OEM Coils

M05-050
M05-100
M10-080
M10-160
SELECT
89
GRAPHS
64
DWG
66
SPECS
68
M14-120
M14-240
63
6000 & OEM Coils Performance Graphs1

6105
Q/Initial Temperature Difference (W/C)
40
SELECT
6110
m3
3 min
M05-050
m3
3 min 0
2 gpm
2 gpm
30
m3
3 min
BTU
HRF
1 gpm
1/2 gpm
60
50
1/2 gpm
40
2 gpm
20
1/4 gpm
1 gpm
30
1/2 gpm
Muffin XL
Muffin XL
1/4 gpm
10
20
Muffin XL
10
89
20 40 60 80 100 120 0
CFM
Air Flow
20 40 60 80 100 120 0
CFM
Air Flow
20 40 60 80 100 120
CFM
Air Flow
GRAPHS
64
68
SPECS
70
m3
6 min
BTU
HRF
120
2 gpm
100
2 gpm
50
1 gpm
80
40
1/2 gpm
1/2 gpm
60
30
Muffin XL
Muffin XL
20
40
20
10
0
200
60
50 100 150 200 250

CFM
Air Flow
6220
0
10
m3
15min 0
50
M10-160
5
10
m3
15 min
BTU
4 gpm HRF
160
2 gpm
140
120
1 gpm
2 gpm
1 gpm
Falcon
200
Patriot
80
60
300
Falcon
Patriot
100
1/2 gpm
100
40
20
0 100 200 300 400 500 600 0 100 200 300 400 500 600
CFM
CFM
Air Flow
Air Flow
6210
120
m3
10 min
M10-080
0
100
2 gpm
m3
10 min
BTU
HRF
200
4 gpm
2 gpm
80
1 gpm
60
150
1 gpm
1/2 gpm
100
Falcon
Falcon
40
Patriot
Patriot
50
20
0
0
100 150 200 250

CFM
Air Flow
180
64
M05-100
m3
min
66
100 200 300 400

CFM
Air Flow
6310
200
6120
DWG
180
10
15
m3
20 min 0
100
200 300 400

CFM
Air Flow
M14-120
5
10
15
m3
20 min
BTU
4 gpm HRF
4 gpm
2 gpm
160
2 gpm
140
120
300
Caravel
1 gpm
1 gpm
200
100
1/2 gpm
80
60
100
40
Caravel
20
0
200 400 600 800 0

CFM
Air Flow
200
400 600 800

CFM
Air Flow
Performance Graphs1 6000 & OEM Coils
180
160
2 gpm
400
200
M14-240
m3
20 min
BTU
4 gpm
HRF
15
10
300
140
1 gpm
120
200
100
1/2 gpm
80
60
Caravel
100
40
20
0
20
10
6340
m3
30 min
BTU
4 gpm HRF
700
6320
5
600
300
2 gpm
500
1 gpm
400
200
300
Caravel
200
100
100
20
m3
60 min
BTU
HRF
10 gpm 1200
40
600
8 gpm
1000
4 gpm
800
300
2 gpm
600
200
1 gpm
400
500
400
Caravel
200
100
SELECT
0
0
0
0 200 400 600 800 1000 1200
CFM
Air Flow
200 400 600 800

CFM
Air Flow
89
500 1000 1500 2000 2500

CFM
Air Flow
GRAPHS
64
1.25
10
6110
0.25
100
6220 50
6320
Inches of Water
6310
Pascals
Inches of Water
150
0.50
200
300
Air Flow
100
400
M05-050
10
LPM
6220
6340
25
M14-120
M10-160
50
M14-240
0.1
400
Bar
2.0
20
LPM
15
Bar
10
15
1.5
1.0
15
M14-240
6210
0
10
GPM
6120
1.0
PSI
500
CFM
OEM Coils Liquid Side Pressure Drop
0.1
1
PSI
200
300
Air Flow
100
1.2
20
68
BAR
0.2
PSI
0.8
M05-100
10
6110
M14-120
M05-050
0.6
M10-160
0.4
10
6320
6310
0.5
M10-080
6105
0
0.5
1.0
SPECS
100
6000 Series Liquid Side Pressure Drop

0
66
M10-080
M05-100
0.2
DWG
m3
min
150
12
0.3
500
CFM
30
10
0.4
6340
0
200
6210
0.5
250
0.75
0.6
300
6120
6105
1.00
OEM Coil Air Side Pressure Drop
m3
min
12
Pascals
6000 Series Air Side Pressure Drop
2.5
2.0
1.5
Water Flow
3.0 GPM
1.0
2.0
Water Flow
3.0
0.2
4.0
GPM
The solid vertical lines indicate the performance provided by our standard fans at 60 Hz and 20C. Dashed fan lines represent fan performance at 50 Hz and 20C.
65
6000 Series Drawings

6105
6110
7.4
(188)
5.8
(147)
2.8
(71)
6120
7.4
(188)
5.8
(147)
1.3
(33)
4.3 6.6
(109) (168)
3.8 5.8
(95) (147)
0.38
(10)
6210
89
12.2
(310)
10.5
(267)
1.8
(46)
3.3
(84)
1.8
(46)
3.8 5.8
(95) (147)
0.38
(10)
0.38
(10)
6220
11.9
(301)
9.5
(241)
SELECT
3.3
(84)
4.5
(114)
19.9
(505)
17.6
(446)
2.5
(64)
4.5
(114)
2.5
(64)
GRAPHS
64
9.0
0.4 (229)
(10)
9.0
0.4 (229)
(10)
DWG
0.38
(10)
66
0.38
(10)
SPECS
68
6310
6320
12.9
(328)
11.5
(292)
5.6
(142)
1.12 12.0
(28) (305)
2.1
(53)
5.6
(142)
0.5
(13)
1.13 12.0
(29) (305)
6340
7.0
(178)
27.5
(699)
24.8
(630)
22.2
(564)
PDFs, IGS files, and eDrawings of standard heat exchangers are available at www.Lytron.com.
Main dimensional label is inches. Dimension in parentheses is mm.
66
22.9
(583)
21.6
(549)
1.6
(41)
3.5
(89)
1.5
(38)
2.1
(53)
0.5
(13)
Drawings OEM Coils

M05-050
M05-100
5.75
(146)
2.2
(56)
2.0
(51)
6.3
(160)
10.75
(273)
2.2
(56)
2.0
(51)
6.3
(160)
3.9
(99)
3.9
(99)
0.38
(10)
0.38
(10)
M10-080
M10-160
8.75
(223)
3.2
(81)
2.0
(51)
16.75
(426)
3.2
(81)
2.0
(51)
SELECT
89
GRAPHS
10.6
(269)
10.6
(269)
2.2
(55)
0.5
(13)
2.2
(55)
0.5
(13)
64
DWG
66
SPECS
68
M14-120
M14-240
14.0
(356)
3.2
(81)
2.0
(51)
0.5
(13)
24.75
(630)
2.2
(55)
14.0
(356)
3.2
(81)
2.0
(51)
0.5
(13)
2.2
(55)
12.75
(325)
67
6000 Series Specifications and Part Number Configuration

6000 Series
First select core
number
6000 Series Core Number
6105G1
6110G1
6120G1
6210G1
Fluid path
Fin material
SELECT
89
Add a fan plate

if desired
6310G3
6320G3
copper
aluminum
lbs
kg
1.5
0.7
2.0
0.9
3.5
1.6
5.0
2.3
8.5
3.9
8.5
3.9
14.0
6.4
30.0
13.6
Fluid volume
in3
ml
3
50
8
131
12.5
205
17.5
288
30.5
500
29.5
483
51.5
844
106
1737
400F/200C
Fitting Options (see page 88)

SB: stub end
BD: beaded fitting
AN: 37 AN flare
Leave blank:
0.875 O.D. union fitting
Fan plate
included
included
included
included
included
included
included
GRAPHS
64
Finally, order
fans if desired
68
6120 with beaded fittings
Muffin XL
Patriot
Falcon
Caravel
6340G1:
no fan plate
6340G2:
includes plate
Recommended Fans
66
SPECS
6120G1 BD
To arrive at a
part number1
DWG
6340G1/G2
Dry weight
Max. operating temp.

Next, select a
fitting option
6220G1
copper
# of fans
1
Note: fans, fan plugs, and fingerguards must be ordered separately. Assembly available on orders of 10+ pieces ask for details.
Fan Specifications
Description
Size
Voltage
Current
50Hz
60Hz
Fan Part
Number
Number
Fingerguard
Part Number
Number
Part
Fan
Plug Number
Muffin XL
4.71 (120 mm) square
115
0.20
Muffin XL
230
0.10
0.18
102076
101467
101466
0.09
102076-01
101467
Patriot
6.75 (171.5 mm) round
115
101466
0.27
0.26
101116-01
101116-03
Patriot
6.75 (171.5 mm) round
101466
230
0.14
0.13
101116-02
101116-03
101466
Falcon
Falcon
6.75 (171.5 mm) round
115
0.48
0.50
102070-01
101116-03
101466
6.75 (171.5 mm) round
230
0.16
0.16
102070-02
101116-03
101466
Caravel
10.00 (254 mm) round
115
0.48
0.50
100236-01
101434
101466
Caravel
10.00 (254 mm) round
230
0.24
0.25
100236-02
101434
101466
Other Accessories
Item
Push to connect adapters for
Materials: acetel bodies, nitrile o-rings, and acetel/stainless steel collets
Temp. range: -14 to 167F (-25 to 75C) for air; 33 to 140F (0 to 60C) for water.
Maximum pressure: 150 psi (10.3 bar) for air, 250 psi (1,724 kP) for water.
Packaging: 10 fittings per pack.
Suitable for
6105
6110
6120
6210
6220
6310
6320
Tube to Hose Adapter

Requires a push-to-connect adapter of the same OD to
mate with heat exchanger.
68
Part Number
Straight Union 38 O.D.
430-0448
Union Elbow 8 tubing O.D.
102190-01
Transition Union 38 12 tubing O.D.
102189-01
102189-01
102190-02
8 tubing O.D. to 38 hose barb
102191-01
102191-02
102191-03
3
1
1
Specifications and Part Numbering Configuration OEM Coils

OEM Coils
First select core
number
OEM Coil Core Number
M05-050
M05-100
M10-080
Fluid Path
Fin Material
Add a fan plate

if desired
M14-120
M14-240
aluminum
Dry Weight
lbs
kg
2.0
0.9
4.0
1.8
5.0
2.3
8.0
3.6
10.0
4.5
16.0
7.3
Fluid Volume
in3
ml
7
115
11.5
188
19.5
320
33.5
549
37
606
66.5
1090

Next, select a
fitting option
M10-160
copper
400F/200C
Fitting Options (see page 88)

SB: stub end
BD: beaded fitting
AN: 37 AN flare
0: no fan plate
1: fan plate attached
Fan Plate
To arrive at a
part number1
SELECT
M05-100 SB 1
GRAPHS
64
M05-100 with stub end fittings and fan plate
Recommended Fans
DWG
Muffin XL
Finally, order
fans if desired
66
Patriot
Falcon
SPECS
Caravel
# of fans
Fan Specifications
Description
Size
Voltage
Current
50Hz
60Hz
Fan Part
Number
Fingerguard
Part Number
Fan
Plug
Plug Number
Number
Muffin XL
115
0.20
Muffin XL
230
0.10
0.18
102076
101467
101466
0.09
102076-01
101467
Patriot
6.75 (171.5 mm) round
115
101466
0.27
0.26
101116-01
101116-03
Patriot
6.75 (171.5 mm) round
101466
230
0.14
0.13
101116-02
101116-03
101466
Falcon
Falcon
6.75 (171.5 mm) round
115
0.48
0.50
102070-01
101116-03
101466
6.75 (171.5 mm) round
230
0.16
0.16
102070-02
101116-03
101466
Caravel
10.00 (254 mm) round
115
0.48
0.50
100236-01
101434
101466
Caravel
10.00 (254 mm) round
230
0.24
0.25
100236-02
101434
101466
68
89
Other Accessories
Item

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

Part Number
430-0448
102190-01
102189-01
102189-01
102190-02
102191-01
102191-02
102191-03
1
1
69
Aspen Stainless Steel Heat Exchangers
Wider tube spacing

reduces cost, weight, and
liquid pressure drop.
SELECT
89
Wavy fin edge

improves fin strength
Liquid return loops

eliminate fluid
contamination
and reduce liquid
pressure drop
Welded, argon-purged
joints maximize internal
cleanliness
GRAPHS
74
DWG
76
316L stainless steel tubing

compatible with deionized
water and corrosive fluids
SPECS
78
The Aspen stainless steel tubed heat exchanger combines low price and low pressure drop with excellent heat transfer
and superior fluid integrity.
Our best value stainless steel tubed heat exchanger: The Aspen offers excellent value 80-90% the performance
of competitive products at approximately half the price. We achieved this by using fewer tubes and increasing the
fin density to balance the air and liquid sides. Our single piece formed aluminum frame/fan plate further reduces
cost and weight.
Highly reliable: Like all Lytron heat exchangers, the Aspen is designed for reliability. 316L stainless steel fluid path
with 0.02 (0.5 mm) wall thickness maintains deionized water and will not react with corrosive liquids. Aspen heat
exchangers are 100% leak tested to 150 psi (10.3 bar).
Extremely clean: Our proprietary manufacturing process expands the tubes into the copper fin without the use of
oils and our liquid return design eliminates potential particle trapping sites, which can contaminate cooling fluid.
Argon-purged welded joints further ensure cleanliness.
Low air and liquid side pressure drop: The short fluid path minimizes the liquid side pressure drop, and our tube
spacing and high performance fin reduce air side pressure drop.
Custom Aspen style heat exchangers can be manufactured in various sizes
and tube configurations to match your thermal and size requirements.
Variations in inlet/outlet position and/or fittings can be accommodated and
a selection of paints and other coatings is available. Assemblies including
fans and other components can also be supplied.
70
Custom cupronickel tube-fin heat exchanger
Stainless Steel Heat Exchangers 4000 Series

Superior construction 316L stainless steel
tubing expanded into copper cooling fins
All-welded, argon-purged
joints maximize internal
cleanliness
SELECT
0.028 (0.7 mm) wall

tubing ensures fluid
circuit durability
89
GRAPHS
74
Pre-cleaned internal surface

eliminates fluid contamination
DWG
76
SPECS
Available with straight, beaded,

or 37AN flare fittings
High cooling capacity in a small envelope: The 4000 series is engineered for performance. It has a high tube
density for maximum heat transfer. Heavy-walled (0.028/0.7 mm), seamless stainless steel tubes are expanded into
copper fin with an extruded full collar. The copper fin and the excellent metal-to-metal contact between the tube
and the fin collar further increase performance.
Compatible with deionized water and corrosive liquids: All the wetted surfaces in the 4000 Series are 316L
stainless steel, so it is ideal for use with high purity and/or corrosive coolants such as deionized water.
Integrated fan plate for improved performance and convenience: The 4000 Series integral fan plate acts as
a plenum to ensure uniform air-flow distribution through the core, thus maximizing performance. It also enables
easy fan installation.
The 4000 Series is our highest performing stainless steel tubed heat exchanger. It is ideal for applications where
deionized water or corrosive fluids are used, and a high efficiency, compact unit is required.
78
Rugged and reliable: The argon-purged welded stainless steel frame and fan plate offer durability and strength.
4000 Series heat exchangers are 100% leak tested to 150 psi (10.3 bar).
Aspen or 4000 Series? The Aspen offers 80% the performance of the 4000 Series at approximately 50% the cost.
Where high performance in a small envelope is required, the 4000 Series is the best option. However, when a slightly
lower performance/size ratio is acceptable, the Aspen offers better value. The Aspen also has lower air and liquid side
pressure drops.
Stainless steel heat exchanger with custom inlet/outlet fittings
Custom 4000 Series style heat exchangers can be manufactured in any size
and circuiting to match your demanding thermal requirements. Variations in
inlet/outlet position and/or fittings can be accommodated and a selection of
paints and other coatings is available. Assemblies including fans and other
components can also be manufactured.
71
Aspen Pictures
AS04-05
AS04-10
AS06-08
AS06-16
AS08-10
AS08-20
SELECT
89
GRAPHS
74
DWG
76
SPECS
78
72
Pictures 4000 Series

4105
4210
4110
4120
4220
SELECT
89
GRAPHS
74
DWG
76
SPECS
78
4310
4320
73
Aspen & 4000 Performance Graphs1

4105
40
SELECT
4110
m3
3 min0
AS04-05
m3
3 min 0
m3
3 min
BTU
HRF
60
2 gpm
30
50
1 gpm
2 gpm
1/2 gpm
2 gpm
20
40
1 gpm
1/4 gpm
1 gpm
1/2 gpm
1/2 gpm
Muffin XL
1/4 gpm
10
30
1/4 gpm
20
Muffin XL
Muffin XL
10
89
20 40 60 80 100 120 0
CFM
Air Flow
20 40 60 80 100 120 0
CFM
Air Flow
20 40 60 80 100 120
CFM
Air Flow
GRAPHS
74
76
78
SPECS
70
m3
min
BTU
HRF
120
60
2 gpm
50
2 gpm
1 gpm
1 gpm
1/2 gpm
30
1/2 gpm
Muffin XL
20
100
80
40
60
40
20
10
Muffin XL
50 100 150 200 250

CFM
Air Flow
4220
200
10
4210
120
AS06-16
5
m3
15 min 0
10
120
10
1 gpm
80
150
1/2 gpm
2 gpm
60
Falcon
1 gpm
Falcon
40
1/2 gpm
50
20
Patriot
0 100 200 300 400 500 600

CFM
Air Flow
4310
m3
10 15 20 25 min 0
0 100 200 300 400 500 600

CFM
Air Flow
AS08-10
5
m3
10 15 20 25 min
BTU
HRF
300
2 gpm
Falcon
Patriot
Falcon
2 gpm
1 gpm
2 gpm
1 gpm
2 gpm
80
1/2 gpm
200
1 gpm
1 gpm
1/2 gpm
1/2 gpm
100
Patriot
40
1/2 gpm
Caravel
20
EBM
Caravel
0 100 200 300 400 500 600 0 100 200 300 400 500 600 0
CFM
CFM
Air Flow
Air Flow
100
Patriot
4 gpm
100
60
m3
15 min
BTU
HRF
200
10
100
160
140
AS06-08
m3
15 min 0
2 gpm
50 100 150 200 250

CFM
Air Flow
m3
15min 0
180
74
AS04-10
m3
min 0
4120
DWG
200 400 600 800 1000 0

CFM
Air Flow
200 400 600 800 1000

CFM
Air Flow
Performance Graphs Aspen & 4000

4320
200
AS08-20
m3
m3
5 10 15 20 25 30 min 0 5 10 15 20 25 30 min
BTU
4 gpm
4 gpm
HRF
Caravel
180
2 gpm
2 gpm
160
300
140
1 gpm
1 gpm
120
200
100
1/2 gpm
1/2 gpm
80
EBM
60
100
Caravel
40
20
SELECT
89
0 200 400 600 8001000 1200 0 200 400 600 800 10001200
CFM
CFM
Air Flow
Air Flow
GRAPHS
74
The solid vertical lines indicate the performance provided by our standard fans at 60 Hz and 20C. Dashed fan lines represent fan performance at 50 Hz and 20C.
DWG
76
Air Side Pressure Drop

1.25
10
12
300
250
150
0.50
AS04-05
100
Inches of Water
4210 200
0.75
20
30
4310
4220
200
100
300
400
Air Flow
300
200
0.75
AS08-10 150
4320
0.50
100
0.25
500
CFM
AS08-20 50
200
400
800
600
1000
Air Flow
Liquid Side Pressure Drop

6
78
AS06-16
AS06-08 50
SPECS
250
AS04-10
0.25
m3
min
25
1.00
Pascals
1.00
1200
CFM

LPM
4120
Bar
0.4
15
10 LPM
1
4220
Bar
5
0.8
0.3
4110
10
0.2
PSI
0.6
PSI
Inches of Water
1.25
15
4120
4105
4110
10
Pascals

m3
min
4210
4320
AS06-08
2
4105
AS04-10
1
0
0.4
AS08-20
0.1
4310
AS04-05
0.5
1.0
Water Flow
1.5
GPM
2.0
0.5
1.0
AS08-10
AS06-16
1.5
2.0
Water Flow
2.5
0.2
0
3.0
GPM
75
Aspen Drawings
AS04-05
AS04-10
8.1
(207)
3.4
(86)
5.3
(134)
3.8 5.9
(95) (151)
13.4
(339)
3.4
(86)
10.5
(267)
1.8
(47)
3.8 5.9
(95) (151)
0.38
(10)
AS06-08
1.8
(47)
0.38
(10)
AS06-16
SELECT
89
10.9
(276)
4.3
(108)
8.0
(203)
GRAPHS
74
19.0
(481)
76
2.1
(53)
6.3 9.1
(159) (230)
6.3 9.1
(159) (230)
DWG
4.3
(108)
16.1
(409)
2.1
(53)
0.38
(10)
0.38
(10)
SPECS
78
AS08-10
AS08-20
12.9
(326)
5.6
(142)
10.0
(254)
22.9
(583)
2.1
(53)
8.8 11.8
(222) (298)
0.38
(10)
2.1
(53)
8.8 11.8
(222) (298)
76
5.6
(142)
20.1
(511)
0.38
(10)
Drawings 4000 Series

4105
4110
7.7
(194)
5.8
(147)
2.8
(71)
4120
7.8
(198)
4.9
(125)
1.3
(33)
3.4
(86)
4.3 6.6
(109) (168)
12.6
(320)
9.7
(246)
1.8
(47)
3.4
(86)
4.1 5.8
(105) (147)
4.1 5.8
(105) (147)
0.38
(10)
0.38
(10)
4210
1.8
(47)
0.38
(10)
4220
SELECT
89
10.9
(277)
8.0
(203)
4.5
(114)
19.0
(483)
16.1
(408)
2.5
(64)
4.5
(114)
2.5
(64)
GRAPHS
74
7.1 9.0
(181) (229)
7.1 9.0
(181) (229)
DWG
76
0.38
(10)
0.38
(10)
SPECS
78
4320
12.9
(328)
10.0
(254)
6.0
(153)
2.5
(64)
1.9
(48)
23.0
(584)
20.1
(510)
6.0
(153)
2.5
(64)
1.9
(48)
12.0
(305)
0.5
(13)
12.0
(305)
0.5
(13)
4310
77
Aspen Specifications and Part Number Configuration

Aspen Series
First select core
number
Core Number
AS04-05G01
AS04-10G01
AS06-08G01
Fluid path
Fin material
copper
1.4
0.6
2.7
1.2
3.3
1.5
6.3
2.9
5.3
2.4
10.1
4.6
Fluid volume
in3
ml
2.8
45.9
4.6
75.4
5.6
91.8
9.9
162.2
8.9
145.8
16.0
262.2
400F/200C
Fitting options (see page 88)

SB: stub end
BD: beaded fitting
included
included
included
included
included
included
To arrive at a
part number1
89
AS08-20G01
lbs
kg
Fan plate
SELECT
AS08-10G01
Dry weight

Next, select a
fitting option
AS06-16G01
stainless steel
AS08-10 G01 SB
AS08-10 with stub end fittings
Recommended Fans
GRAPHS
Muffin XL
74
Finally, order
fans if desired
DWG
Patriot
Falcon
Caravel
76
EBM 8.5
# of fans
SPECS
78
Fan Specifications
Description
Size
Voltage
Fan Part
Number
Number
Fingerguard
Part Number
Number
Part
Fan
Plug Number
Muffin XL
115
0.20
Muffin XL
230
0.10
0.18
102076
101467
101466
0.09
102076-01
101467
Patriot
6.75 (171.5 mm) round
115
101466
0.27
0.26
101116-01
101116-03
Patriot
6.75 (171.5 mm) round
101466
230
0.14
0.13
101116-02
101116-03
101466
Falcon
Falcon
6.75 (171.5 mm) round
115
0.48
0.50
102070-01
101116-03
101466
6.75 (171.5 mm) round
230
0.16
0.16
102070-02
101116-03
101466
Caravel
10.00 (254 mm) round
115
0.48
0.50
100236-01
101434
101466
Caravel
10.00 (254 mm) round
230
0.24
0.25
100236-02
101434
101466
EBM2
115
0.58
0.70
102105-01
102106
102175
EBM2
230
0.29
0.35
102105-03
102106
102175
Current
50Hz
60Hz
Requires adapter ring. Part number 508520.
Other Accessories
Item
78
Suitable for
Part Number
430-0448
102190-01
102189-01
102191-01
102191-02
102191-03
All Aspen
Series
3
1
1
Specifications and Part Number Configuration 4000 Series

4000 Series
First select core
number
Core Number
4105G1
4110G10
4120G10
4210G10
Fluid path
Fin material
4310G10
4320G10
copper
Dry Weight
lbs
kg
1.5
0.7
2.0
0.9
3.5
1.6
5.0
2.3
8.5
3.9
8.5
3.9
14.0
6.4
Fluid volume
in3
ml
3
50
8
131
12.5
205
17.5
288
30.5
500
29.5
483
51.5
844

Next, select a
fitting option
4220G10
stainless steel
400F / 200C
Fitting options (see page 88)

SB: stub end
BD: beaded fitting
AN: 37 AN flare
included
included
included
included
included
included
included
Fan plate
To arrive at a
part number1
4220G10 AN
SELECT
89
4220 with AN fittings
Recommended Fans
GRAPHS
Muffin XL
Finally, order
fans if desired
74
Patriot
Falcon
DWG
Caravel
# of fans
1
2
SPECS
78
Size
Voltage
Current
50Hz
60Hz
Fan Part
Number
Fingerguard
Fan
Plug Number
Number
Part Number Plug
Muffin XL
115
0.20
0.18
102076
101467
101466
Muffin XL
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
Description
76
Other Accessories
Item
Suitable for
4105
4110
4120
4210
4220
4310
4320

Part Number
430-0448
102190-01
102189-01
102189-01
102190-02
102191-01
102191-02
102191-03
3
1
1
79
ES Series Aluminum Heat Exchangers: Oil Coolers

Fluxless, vacuum-brazed core
for strength and reliability
Low pressure drop due

to unique flat tube and
header designs
Welded headers, pressure

tested to 150 psi (10.3 bars)
Extended surface flat tube

design provides 2.5 times
better performance than
competitive units
SELECT
89
Available with or
without a fan plate
GRAPHS
82
Finish options:
aluminum or black paint
DWG
81
SPECS
83
Internal view of Lytrons

aluminum flat tube
ES Series oil coolers are engineered for high performance with poor heat transfer fluids such as oils and EGW. They
provide up to 2.5 times greater thermal performance per unit volume than competitive models.
High performance: The ES Series uses Lytrons unique aluminum flat tube technology, which has multiple extended
surface channels in each tube. These tubes provide maximum cooling by having a large surface area in contact with
the fluid (approximately 12 in2 (77 cm2)/linear inch of tube). Lytrons air-side fin geometry efficiently channels air
across the fin surface to further boost heat transfer capability.
Clean and reliable: The fluxless vacuum-brazed construction results in a clean, rugged, and highly reliable part with
excellent thermal contact and mechanical strength.
Low pressure drop: Our flat tube fluid channels and efficient header manifold result in a very low pressure drop so
smaller, less expensive pumps can be used.
Lightweight: The all-aluminum, vacuum-brazed construction is lightweight.
Oil coolers can be manufactured in different sizes and tube widths, and
with custom inlet/outlet configurations. Curved heat exchangers can be
manufactured as the flat tube can be bent without buckling or damaging
the internal channels. Assemblies including fans and other components can
also be supplied.
80
Custom oil cooler with curved tubes
Pictures and Drawings ES Series

ES05051
ES0510
ES0707
ES07142
SELECT
89
GRAPHS
82
DWG
81
SPECS
83
ES0510
7.80 max
(198)
5.19
(132)
12.55 max
(319)
9.94
(254)
3.06
(77)
1.25
(32)
1.25
(32)
3.25 6.57
(83) (167)
3.25 6.57
(83) (167)
ES0707
ES0714
9.67 max
(246)
7.06
(178)
3.06
(77)
1.25
(32)
5.0 8.36
(127) (212)
3.06
(77)
ES0505
Includes optional fan plate and black paint
17.86 max
(454)
15.25
(387)
3.06
(77)
1.25
(32)
5.0 8.36
(127) (212)
Includes optional fan plate
81
ES Series Performance Graphs1
89
100
4 gpm
40
4 gpm
1/2 gpm
175
50
1/2 gpm
20
Muffin XL
20
Muffin XL
40 60 80 100 0
CFM
Air Flow
ES0707- EGW2
83
100
150
82
SPECS
60
DWG
80
GRAPHS
81
ES0510 - EGW2
m3
min
BTU
HRF
20
ES0707- Oil3
m3
min 0
150
125
75
5 gpm
3 gpm
1 gpm
2 gpm
1/2 gpm
50
1 gpm
100
1/2 gpm
Patriot
25
Patriot
0.30
6
ES0510
ES0707
0.25
ES0505
10
2 gpm
1 gpm
1/2 gpm
100
40
Muffin XL
50
Muffin XL
20
0 50 100 150 200 250 CFM 0 50 100 150 200 250 CFM
Air Flow
Air Flow
ES0714- Oil3
m3
15min 0
10
10
5 gpm
Patriot
Tarzan
3 gpm
2 gpm
150
m3
15 min
BTU
HRF
300
5 gpm
1 gpm
3 gpm
125
2 gpm
1/2 gpm
200
100
1 gpm
75
Tarzan
1/2 gpm
50
100
Patriot
25
0
0 100 200 300 400 500 CFM 0 100 200 300 400 500 CFM
Air Flow
Air Flow
10
15
Liquid Side Pressure Drop - Oil
ES0714
LPM
70
60
150
4 gpm
1/2 gpm
Liquid Side Pressure Drop - EGW
m3
8 min
m3
min
BTU
HRF
60
0 50 100 150 200 250 CFM0 50 100 150 200 250 CFM
Air Flow
Air Flow
2 gpm
1 gpm
175
200
5 gpm
3 gpm
2 gpm
ES0510 - Oil3
ES0714- EGW2
m3
min
BTU
HRF
300
Tarzan
80
Tarzan
100
m3
min
4 gpm
40 60 80 100
CFM
Air Flow
SELECT
100
ES0505 - Oil3
m3
min 0
ES0505 - EGW2
Bar
16
0.6
14
10
15 LPM
Bar
1.0
ES0714
0.15
30
ES0510
100
150 200
0
250 CFM
Air Flow
4
0.2
10
50
2
0
0
0
50/50 EGW Flow
4 GPM
0
0
Oil Flow
The solid vertical lines indicate the performance provided by our standard fans at 60Hz and 70F. Dashed lines represent fan performance at 50 Hz and 20C.
50/50 EGW at 160F. 3 Diala at 170F.
0.6
ES0505 0.4
0.05
ES0707
8
6
ES0505 0.2
20
82
0.4
ES0707
0.10
0
0
0.8
ES0510
10
PSI
40
PSI
ES0714
Pascals
Inches of Water
12
50
0.20
GPM
Specifications and Part Number Configuration ES Series

First select core
number
Core Number
ES0505G
ES0510G
Fluid path
ES0714G
aluminum
Fin material
Next, select
an option
ES0707G
aluminum
Dry weight
lbs
kg
2.0
0.91
2.85
1.30
2.85
1.30
5.53
2.51
Fluid volume
in3
ml
14
229
17
278
24
393
31
508
Fittings (see page 88)
3/8 18 NPT
400F/200C
Options
21: no paint, no fan plate
22: black paint, no fan plate
23: no paint, fan plate attached
24: black paint, fan plate attached
To arrive at a
part number1
ES0510G24
SELECT
89
ES0510 with black paint and fan plate attached
Recommended Fans
GRAPHS
Muffin XL
Finally, order
fans if desired
82
Patriot
Tarzan
# of fans
1
DWG
81
SPECS
83
Description
Size
Voltage
Current
50Hz
60Hz
Fan Part
Number
Fingerguard
Fan
Plug Number
Number
Part Number Plug
Muffin XL
115
0.20
0.18
102076
101467
101466
Muffin XL
230
0.10
0.09
102076-01
101467
101466
Patriot
6.75 (171.5 mm) round
115
0.27
0.26
101116-01
101116-03
101466
Patriot
6.75 (171.5 mm) round
230
0.14
0.13
101116-02
101116-03
101466
Tarzan
115
1.40
1.20
101578-01
101741
101466
Tarzan
6.91 (175mm) square
230
0.63
0.54
101578-02
101741
101466
Fan Specifications
83
Plate-Fin Heat Exchangers

Variety of finishes
available including paint
and Milspec coatings
Can be used for air-to-air, air-to-liquid,

or liquid-to-liquid cooling
Lightweight, all-aluminum
construction
Fluxless vacuum-brazed core

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

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

Much smaller and
lighter than conventional
shell-and-tube designs
Extremely efficient
herringbone construction
for maximum heat transfer
Copper-brazed for water,

EGW and other common
coolants, or nickel-brazed
for high purity and
corrosive coolants
SELECT
89
GRAPHS
Stainless steel sheets are

brazed together at the
edges and at a matrix
of contact points for a
reliable and rugged part
87
DWG
86
Internal view of liquid-to-liquid

brazed plate heat exchanger
High performance in a small package: Lytrons liquid-to-liquid heat exchangers are up to 80-90% smaller in
volume and weight than a conventional shell-and-tube design. The counterflow design utilizes stainless steel sheets
stamped with a herringbone pattern of grooves, stacked in alternating directions to form separate flow channels
for the two liquid streams. This allows 90% of the material to be used for heat transfer, making it extremely efficient.
High reliability: The plates are brazed together at the edges and at a matrix of contact points between sheets,
ensuring that the heat exchangers are highly reliable and rugged.
Copper- and nickel-brazed versions for compatibility with a wide range of fluids: We offer copper-brazed
units for use with water, EGW, and other common coolants. Our nickel-brazed units are appropriate for use with
deionized water, high purity, and corrosive fluids.
87
Lytrons brazed-plate heat exchangers are unsurpassed for liquid-to-liquid heat transfer. Their innovative design packs
maximum performance into a compact and reliable package.
SPECS
High operating temperatures and pressures: Copper-brazed units can be operated at temperatures of up
to 383F (195C) and pressures up to 450 psig (31 bar). Nickel-brazed units can be operated at temperatures
of up to 662F (350C) and pressures up to 232 psig (16 bar).
Liquid-to-liquid heat exchanger subassembly with custom hoses and fittings
Liquid-to-liquid heat exchangers can be supplied as subassemblies with
fittings, hoses, and other accessories.
85
Liquid-to-Liquid Pictures and Drawings

LL510 and LL520
LL810 and LL820
LL510
LL810
SELECT
89
GRAPHS
87
DWG
86
0.8 1.4
(20) (36)
3.5
(90)
SPECS
87
0.8 1.3
(20) (33)
2.9
(74)
12.9
(328)
11.0
(279)
8.0
(204)
6.7
(170)
1.6
(40)
1.7
(43)
LL520
LL820
0.8 2.4
(20) (60)
3.5
(90)
0.8 2.2
(20) (56)
2.9
(74)
8.0
(204)
6.7
(170)
12.9
(328)
11.0
(279)
1.6
(40)
1.7
(43)
86
Performance, Specifications and Ordering Information Liquid-to-Liquid

Performance
The performance of our liquid-to-liquid heat exchangers vary with the fluid type, flow rate, and temperature of each
fluid. The charts below show the thermal performance for water and water (left) and water and oil (right).
Thermal Performance Using Water and Water
0
10
20
30
LPM
40
350
3000
300
LL820
1600
1400
LL810
LL520
1200
10
0
BTU
HRF
2000
1000
LL510
800
600
1000
400
1800
Thermal Performance Using Water and Oil

20
30
LPM
40
LL820
250
BTU
HRF
600
LL810
400
200
LL520
150
SELECT
89
LL510
200
100
GRAPHS
87
50
200
DWG
0
0
10
12 GPM
0
0
Flow Rate
10
12
86
GPM
Flow Rate
SPECS
87
Pressure Drop Using Water

10
20
30
40
LPM
10
20
40
30
35
BAR
LL810
LL810
LPM
LL510
BAR
LL510
30
30
2.0
2.0
LL820
25
1.5
20
LL820
15
1.0
Pressure Drop (PSI)
Pressure Drop (PSI)
25
1.5
20
15
10
10
LL520
0.5
0.5
1.0
LL520
0
35
Pressure Drop Using Oil
0
0
10
12
GPM
0
0
Flow Rate
6
8
Flow Rate
10
12 GPM
Part Numbers
Core Number
LL510G12
LL520G12
LL810G12
Plate material
lbs
kg
Max. operating pressure
Max. flow rate
LL810G14
LL820G14
nickel 99.7%
10
20
10
20
10
20
10
20
2.6
1.2
3.7
1.7
4.9
2.1
6.7
2.9
2.6
1.2
3.7
1.7
4.9
2.1
6.7
2.9
Fittings
Min. operating temp.
LL520G14
copper 99.9%
Number of plates
LL510G14
AISI 316L stainless steel
Braze material
Dry Weight
LL820G12
4 MNPT
450 psi/31 bar
232 psi/16 bar
383F/195C
662F/350C
-319F/-195C
20 gpm/76 lpm
87
Heat Exchanger Fittings

SB FittingStub End
BD FittingBeaded End
SB INLET/OUTLET
FITTING
BD INLET/OUTLET
FITTING
NUT
FERRULE
HELEX CLAMP
FITTING BLOCK
3/8 ID HOSE
A unit with a straight tube fitting can be welded into

your system or used with a 38 self-locking torque-free
fitting such as Swagelok or Cajon.
AN Fitting37AN Flare
For a leak-free joint, Lytrons beaded tube fitting

mates with a 38 ID hose that is secured with a clamp.
AN Fitting on 6340
TUBE
AN INLET/OUTLET
FITTING
NUT
TAIL PIECE
37 AN FITTING BODY
7/8 CUP ACTUAL SIZE
Lytrons AN fitting, 37 AN female flare nut (AN-818),

mates with male JIC-SAE 37 flare fitting, 916-18
UN/UNF-2A thd for 38 tubing and 34-16 UN/UNF-2A
thd for 12 tubing.
Note: the AN fitting on the 6340 is an 0.875 I.D.

actual union and tail piece only.
ES Series Fitting
3/8-18 NPT
The fitting on our ES Series oil coolers is a 38-18

NPT thread.
88
Selecting a Heat Exchanger

1. Cooling Liquid
In order to select the correct Lytron heat exchanger or oil cooler, you must first determine the required thermal
performance for your application. Use the example shown below:
Step 1: Application Data
Liquid type:
Required heat load (Q):
Temp. of incoming liquid (Tliquid in):
Temp. of incoming air (Tair in):
Rate of liquid flow:
Water
3,300 W (11,263 BTU/Hr)
80C (176F)
21C (70F)
2 gpm (7.6 lpm)
Step 2: Select the heat exchanger product series

Choose an aluminum, copper, or stainless steel heat exchanger based on the fluid compatibility. Aluminum tubing is
usually used with light oils, or ethylene glycol and water solutions. Copper is normally used with water. Stainless steel
is used with deionized water or corrosive fluids.
Step 3: Calculate the initial temperature difference
Subtract the temperature of the incoming air from the temperature of the incoming liquid as it enters the heat
exchanger.
ITD = Tliquid in - Tair in
= 80C 21C = 59C (or 176F 70F = 106F)
Step 4: Calculate the required performance capability (Q/ITD)
Divide the required heat load (Q) by the ITD found above in step 3.
Performance capability = Q = 3,300 W = 56 W/C or 11,263 BTU/HR = 106 BTU/HrF
ITD
59C
106F
Step 5: Select the appropriate heat exchanger model
Refer to the thermal performance graphs for the heat exchangers selected
(Performance graphs for copper heat exchangers, stainless steel heat exchangers, and
oil coolers can be found on pages 64, 74, and 82 respectively.) Any heat exchanger
that exceeds 56 W/C at 2 gpm (using a standard fan) would be acceptable. As shown
in the following graph, Lytrons 6210 exceeds the required performance.
Step 6: Determine the liquid pressure drop
From the data given, we know our pump needs to supply water at 2 gpm. Using the
liquid side pressure drop chart for the 6210 curve, the point where a vertical line at
the 2 gpm point on the x-axis intersects with the 6210 curve reveals that the liquid
pressure drop through the 6210 is 8 psi (0.55 bars). The pump selected must
overcome this pressure drop to ensure a 2 gpm flow.
10
100
m3
15 min
BTU
2 gpm
HRF
200
1 gpm
80
150
1/2 gpm
60
56
106
100
Falcon
40
Patriot
50
20
0
0 100 200 300 400 500 600
CFM
Air Flow
120
Step 7: Determine the air pressure drop

The vertical line on the thermal performance chart indicates the air flow rate (190 CFM for the Patriot fan) as
provided by our standard fans at 60 Hz. The intersection point of this air flow rate and the 6210 graph on the
air side pressure drop reveals that the air side pressure drop through the 6210 is 0.24 inches of water (55 pascals).
5
10

LPM Bar
2.0
1.25
PSI
20
BAR
0.2
0.1
1
0
0
15
6210
5
10
GPM
6120
1.0
6110
10
6320
6310
5
0
0.5
1.0
2.5
1.5
2.0
Liquid Flow
300
6120
6105
250
0.5
200
0.75
6210
150
0.50
6310
0.25
6220
6320
6105
m3
min
12
10
1.00
1.5
Inches of Water
PSI
25
6
6110
6220
6340
3.0 GPM
Pascals
30
100
50
6340
100
200
300
Air Flow
400
500
CFM
89

2. Cooling Air
In cabinet cooling applications, the air is hotter than the liquid. In this case, the ITD is the difference between
the hot air entering the heat exchanger and the cold liquid entering the heat exchanger. You may need to calculate
the temperature rise using the heat load and the temperature of the cool air entering the cabinet.
Example: Cabinet Cooling application
You are cooling a cabinet containing electronic components that generate 2400 W of heat. The air in the cabinet
must not exceed 55C. What heat exchanger should be selected, and what is the temperature of the cool air entering
the electronics cabinet?
Step 1: Application Data
Liquid type:
Required heat load (Q):
Temp. of incoming liquid (Tliquid in):
Max. temp of air in cabinet (Tair in):
Rate of liquid flow:
Water
2,400 W (8,189 BTU/Hr)
20C
55C (131F) This is the temperature of the hot air entering the heat exchanger
2 gpm (7.6 lpm)
Step 2: Calculate the initial temperature difference

Subtract the temperature of the incoming liquid from the temperature of the incoming air as it enters the heat
exchanger.
ITD = Tair in - Tliquid in = 55C 20C = 35C (or 131F 68F = 63F)
Step 3: Calculate the required performance capability (Q/ITD)
Divide the required heat load (Q) by the ITD found above in step 2.
Step 4: Select the appropriate heat exchanger model

Refer to the thermal performance graphs for the heat exchangers selected
(Performance graphs for copper heat exchangers, stainless steel heat exchangers and
oil coolers can be found on pages 64, 74, and 82 respectively.) Any heat exchanger
that exceeds 68.6 W/C at 2 gpm (using a standard fan) would be acceptable. Using
water as the coolant, a copper heat exchanger is recommended. As shown in the following graph, Lytrons 6310 exceeds the required performance, offering a Q/ITD of
approx. 96 W/C using our Caravel fan.
Liquid and air pressure drop can be determined the same way as in the previous
example.
180
m3
10 15 20 25 min
BTU
HRF
4 gpm
160
2 gpm
These graphs offer a simple graphical way

of estimating fluid temperature change if you
know your heat load and flow, without having
to do calculations. The graphs for water, air,
50/50 ethylene glycol/water and oil allow you
to calculate temperature changes for air and
liquid for all types of heat exchangers.
1 gpm
120
200
100
1/2 gpm
80
68.6
60
100
40
Caravel
20
0
70
200 400 600 800 1000

CFM
Air Flow
120
60
100
50
80
40
60
30
40
20
17
10
0
20
0
200 250
400
600
Air Flow (CFM)
800
300
140
Step 5: Calculating the temperature of the cool air entering the cabinet
Now, to calculate the temperature of the cool air entering the cabinet, use the temperature change graph for
air (page 96). With a heat load of 2,400 W, and a flow rate of 250 CFM (the flow rate of the standard Caravel fan
recommended for use with
LPM
the 6310) we can see that the
0
5
10
15
20
25
30
F
100
180
temperature change is 17C.
90
160
This means that the cool air
80
entering the cabinet will be:
140
55C 17C = 38C
90
Q
2,400 W
8,189 BTU/HR
=
= 68.6 W/C or
= 130 BTU/HRF
ITD
35C
63F
Change in Temperature (C)
Performance capability =
200
1000
1200
20 kW
15 kW
10 kW
7 kW
5 kW
4 kW
3 kW
2 kW
1.5 kW
1 kW
500 W
200 W

Step 6: Calculating the outgoing water temperature
To determine the outgoing temperature of the water we use the Water Flow chart to find that the change in temperature is approximately 5C. Therefore the outgoing water temperature is 20C + 5C = 25C.
50
10
12
14
16
Change in Temperature (C)
45
LPM
18
F
90
80
40
70
35
60
30
50
25
40
20
30
15
20
10
10
5
0
20 kW
15 kW
10 kW
7 kW
5 kW
4 kW
3 kW
2 kW
1.5 kW
1 kW
500 W
200 W
2
3
Water Flow (GPM)
x C x T
Q=m
p
Where:
Q=
=
m
Cp =
T =
heat load
mass flow rate of the fluid
specific heat of the fluid
temperature difference between the liquid in and the liquid out
can be calculated for water and air using the following equations:
m
gal
60 min
lbs
ft3
( lbs ) =
Water: m
v(
)x(
)x( 3)x(
) where
v = volumetric flow rate
7.5 gal
hr
min
hr
ft
or
liters
60 min
kg
m3
( kg ) =
Water: m
v(
)x(
)x( 3)x(
) where
v = volumetric flow rate
1,000 liters
hr
min
hr
m
Alternative Sizing Equation

The general heat transfer equation can be used to calculate the heat load and the fluid temperature change given the
fluid flow rate and the specific heat.
ft3
60 min
lbs
( lbs ) =
Air: m
v(
)x(
)x( 3)
hr
min
hr
ft
or
m3
60 min
kg
( kg ) =
Air: m
v(
)x(
) x ( 3)
hr
min
hr
m
The temperature change graphs on pages 96 and 97 plot the above equation for common heat transfer media
(air, water, oil, and a 50% EGW mixture) providing a simple way to look up T if you know your heat load and
fluid flow rate.
91
Custom Heat Exchangers
High capacity oil cooler
Heat exchanger with stainless steel tubes and nickel fin
Custom plate-fin liquid-to-air heat exchanger

with chemical conversion coating
Custom heat exchangers for every application

With 50 years of experience designing and building heat exchangers for performance-critical applications, Lytrons
expertise is second-to-none. We have designed and built small ultra-lightweight plate-fin heat exchangers
for airborne military applications, large flat-tube oil coolers for medical equipment, stainless steel tubed heat
exchangers for lasers, and everything in between. Our strong engineering expertise and experience with all of the
thermal components in a liquid cooling loop makes Lytron the ideal partner for all your heat exchanger needs.
Our streamlined design process relies on a combination of advanced modeling and analysis software, and hundreds
of man-years of experience. Lytrons heavy investment in engineering results in designs that not only meet your
performance and size requirements, but are also reliable and cost effective to build. With design and manufacturing
housed under the same roof, products transition smoothly from design, through prototyping, to production. We carry
out all performance-critical manufacturing processes in-house, from fin stamping, machining, and tube bending to
vacuum brazing and heat treating. This guarantees us total control over the finished product, as well as increased
flexibility and shorter lead times.
Our engineering laboratory and well-equipped, in-house test facility enable us to fully test and validate all our
custom heat exchangers. Our facilities include three wind tunnels (including a 21,000 CFM test tunnel that can
accommodate parts up to 6 x 6 (1.8 m x 1.8 m)), flow stations, data acquisition stations, refrigeration
test equipment, and various flow, temperature, and pressure instruments. Complete shock/vibration testing and
agency approvals are also available.
Getting started
Your design will benefit the most by involving Lytron early in the engineering process. While our continual
investment in capital equipment for our factory enables us to competitively bid build-to-print jobs, when we
design to a performance specification you realize the greatest cost savings. Get started today by calling your sales
engineer, or filling out the Request a Heat Exchanger Quote form on our website.
92
Heat Exchangers Custom
Miniature 3(8 cm) heat exchanger

with Chemfilm coating
Custom cupronickel tube-fin heat exchanger
Custom tube-fin heat exchangers
Large 4 (1.2 m) heat exchanger with

nickel tubes and copper fin
Custom oil coolers

Lytrons vacuum-brazed, flat tube oil coolers offer many customization
possibilities. Three different flat tube widths are available, and the
length and the number of tubes can be varied. The flat tube can be
bent into a 38 (3 mm) inside radius without buckling, so heat exchangers
can be manufactured in a curved shape if needed. Custom fittings and
manifolds can be added, and oil coolers can be painted or anodized for
extra protection.
The building blocks of a tube-fin heat exchanger are tubes, fin, and frame.
We have a variety of fin patterns to choose from, and can customize the
tube configuration and frame. We frequently work with specialty materials,
such as cupronickel, nickel, Hastelloy, and Inconel. To meet the stringent
shock and vibration requirements of some military applications, we can
provide ruggedized frames and fluid connections, and insert additional
tube sheets as supporting elements within the core. Paints and coatings,
including Milspec paints, are available. Fluid inlets and outlets can be
customized with bends, fittings, hoses, etc., and additional sensors and
instrumentation can also be added.
Commercial condenser with single-piece

aluminum flat tube
Custom oil cooler with curved tubes
93
Aircraft oil cooler

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

All our aluminum, vacuum-brazed, plate-fin heat exchangers are
custom-designed, as every requirement is unique. They are widely used
in military, aerospace, and other high performance applications because
they offer excellent thermal transfer capacity combined with small size
and weight. Plate-fin heat exchangers can be designed for use with any
combination of gas, liquid, and two-phase fluids.
Air-to-air plate-fin inner cooler
We carefully select the number of plate and fin layers, the size of the plates
and fin, the height of the fin and the type of fin for optimum performance.
The core is assembled and vacuum brazed in our environmentally-controlled
room to ensure high quality and reliability. Manifold ducting and mounting
brackets are welded in place as specified, and any required paint or coating
(including Milspec) added.
Lytron also offers titanium plate-fin heat exchangers for high temperature
operation. Titanium heat exchangers offer performance similar to stainless
steel or nickel-alloy plate-fin heat exchangers, but at 30-50% the weight.
Titanium plate-fin heat exchangers
Clear anodized heat exchanger subassembly

including fan and temperature sensor
Heat exchanger subassembly with integrated fans
Value-added assemblies
Our extensive experience in the design and build of complete cooling systems and subassemblies makes us your ideal partner when you need to add
components such as fans, sensors, fittings, and hoses. We can add whatever
accessories you need, or build your entire subassembly, so that your heat
exchanger arrives ready to drop into your system. This saves you time
and effort.
94

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With five decades of experience in heat

Heat Exchanger Technology Overview

Tube-Fin Heat Exchangers

Flat Tube Oil Coolers

Standard Heat Exchangers

ES series oil coolers are designed for optimum cooling

Plate-Fin Heat Exchangers

Liquid-to-Liquid Brazed Plate Heat Exchangers

Heat Exchanger Technology Overview

Aluminum flat tube heat exchangers (ES Series)

Aluminum plate-fin heat exchangers

Copper-brazed liquid-to-liquid heat exchangers

Standard Heat Exchangers

6000 Series Copper Heat Exchangers

Copper tubing expanded

All units supplied with built-in,

0.028 (0.7 mm) seamless

Electro-static dip painted

Standard Heat Exchangers

Copper Heat Exchangers OEM Coils

0.028 (0.7 mm) wall tubing

Copper tubing expanded into

Galvanized steel side rails and

Standard Heat Exchangers

6000 Series Pictures

Standard Heat Exchangers

Pictures OEM Coils

Standard Heat Exchangers

6000 & OEM Coils Performance Graphs1

Standard Heat Exchangers

Q/Initial Temperature Difference (W/C)

50 100 150 200 250

100 150 200 250

Q/Initial Temperature Difference (W/C)

100 200 300 400

200 300 400

200 400 600 800 0

400 600 800

Performance Graphs1 6000 & OEM Coils

Q/Initial Temperature Difference (W/C)

200 400 600 800

500 1000 1500 2000 2500

OEM Coils Liquid Side Pressure Drop

6000 Series Liquid Side Pressure Drop

Standard Heat Exchangers

OEM Coil Air Side Pressure Drop

6000 Series Air Side Pressure Drop

6000 Series Drawings

Standard Heat Exchangers

Drawings OEM Coils

Standard Heat Exchangers

6000 Series Specifications and Part Number Configuration

6000 Series Core Number

Add a fan plate

Fitting Options (see page 88)

BD: beaded fitting

6120 with beaded fittings

Standard Heat Exchangers

Max. operating temp.

4.71 (120 mm) square

4.71 (120 mm) square

6.75 (171.5 mm) round