Views: 0 Author: Site Editor Publish Time: 2026-11-12 Origin: Site
At CSTHEATEXCHANGER, we specialize in high-precision, Made-to-Drawing / Made-to-Blueprint OEM Batch Manufacturing of 24 units of 400 kW Closed-Circuit Dry Coolers (delivering a combined 9.6 MW / 2,730 TR total thermal heat rejection capacity) engineered specifically for hyperscale cloud data centers, colocation server halls, modular container computing pods, and high-density AI/GPU liquid-cooling CDU secondary loops. Operating with pure water or water-glycol mixtures across flow rates of 60–85 m3/h per unit, our 400 kW dry coolers feature V-bank finned-tube coil modules with seamless copper (or stainless steel) tubes, hydrophilic blue aluminum fins (or epoxy marine coatings), high-efficiency EC variable-speed fan arrays, and heavy-duty C4/C5-M powder-coated structural steel frames. CST executes 100% drawing-to-part geometric replication, strict weld inspection, 100% helium vacuum leak testing, and coordinated multi-unit batch delivery schedules to match data center EPC milestones.
For data center general contractors and MEP consultants executing multi-megawatt facilities, a 24-unit batch order of 400 kW dry coolers requires rigorous manufacturing consistency, identical fluid dynamics, and precise mechanical tolerances:
DATA CENTER 9.6 MW ROOFTOP / GROUND DRY COOLER ARRAY (24x 400 kW)
================== 24x 400 kW MODULAR CLOSED-CIRCUIT DRY COOLER ARRAY ==================
┌──────────────────────────────────────────────────────────────────────────────────────┐
│ [ARRAY ROW A: 12x 400 kW DRY COOLERS] [ARRAY ROW B: 12x 400 kW DRY COOLERS] │
│ Unit 01 Unit 02 Unit 03 ... Unit 12 Unit 13 Unit 14 Unit 15 ... Unit 24 │
│ • 400 kW Heat Rejection per Unit (N+2/N+4) • Total Combined Thermal Load: 9.6 MW │
│ • 100% Identical Fluid-Side Pressure Drop • Synchronized Modbus RTU / EC Fan Loop │
└──────────────────────────────────────────┬───────────────────────────────────────────┘
│ [COMMON CHILLED WATER/GLYCOL MANIFOLD]
▼
================== MISSION-CRITICAL DATA CENTER SERVER HALL ============================
┌──────────────────────────────────────────────────────────────────────────────────────┐
│ • Direct-to-Chip (DTC) Liquid-Cooled CDUs and In-Row Precision Air Conditioners │
│ • Year-Round Continuous PUE < 1.15 Heat Rejection with Zero Water Consumption │
└──────────────────────────────────────────────────────────────────────────────────────┘================================================================================
CST MADE-TO-DRAWING BATCH PRODUCTION VS. OFF-THE-SHELF CATALOG DRY COOLERS
================================================================================
Evaluation Metric CST Made-to-Drawing ManufacturingOff-the-Shelf Standard Catalog Units
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Drawing & Blueprint Compliance 100% Exact Matching to Client CAD/PDFRigid standard sizes (Forces MEP redesign)
Fluid Port Location & Flange Custom Orientation & ANSI/DIN StandardFixed factory port locations (Extra piping)
Batch Hydraulic Consistency Identical Flow Balance Across All 24 Variable pressure drops between batches
Acoustic Noise Control (dBA) Custom EC Fan Curves (< 55–65 dBA @10m)Standard catalog fans (Often too loud)
Structural Frame & Lifting LugsCustom Engineered to Roof I-Beams Generic mounting rails (Field retrofits)
Corrosion Grade for Site Env. Tailored C4, C5-M, or Blygold E-CoatStandard C2/C3 basic industrial paint
Delivery Batch Coordination Phased Dispatch Aligned with Crane SkidsRigid all-at-once or delayed logistics
Factory Acceptance Test (FAT) 100% Hydrostatic, Helium & FAT WitnessLimited spot check or batch sampling
================================================================================When 24 dry coolers operate in parallel on a central 9.6 MW header manifold, uneven internal pressure drops cause fluid maldistribution and hot spots in the data center. CST strictly controls internal tube circuiting, header orifice sizing, and CNC fin punching across all 24 units, ensuring identical hydraulic flow resistance (±2% tolerance±2% tolerance) for balanced, predictable fluid distribution.
Each 400 kW dry cooler is equipped with high-efficiency electronically commutated (EC) fans. Operating under smart Modbus RTU / 0–10V building management control, the fan speed automatically tracks ambient dry-bulb temperatures, cutting fan energy consumption by up to 60%60% during nighttime and winter free-cooling operation.
CSTHEATEXCHANGER manufactures all data center dry coolers under strict ISO 9001:2015 and ASME / CE PED quality management protocols:
CST 400 KW DRY COOLER COIL & CASING METALLURGY
┌─────────────────────────────────────────────────────────────────────────┐
│ [1. TUBE MATRIX (REFRIGERANT / GLYCOL CLOSED LOOP)] │
│ • Seamless Deoxidized High-Conductivity Copper (Cu-DHP / ASTM B75) │
│ • Heavy-wall seamless AISI 304 / 316L stainless steel for DI water. │
├─────────────────────────────────────────────────────────────────────────┤
│ [2. EXTENDED SECONDARY HEAT TRANSFER SURFACES] │
│ • Corrugated Sine-Wave Hydrophilic Blue Aluminum Fins (Anti-Fouling). │
│ • Marine-Grade AlMg3 or Full Electrophoretic E-Coating for coastal sites│
├─────────────────────────────────────────────────────────────────────────┤
│ [3. HEAVY RIGID CASING & STRUCTURAL BASE SKID] │
│ • 2.5 mm to 3.5 mm Hot-Dip Galvanized Steel with Epoxy Powder Coating. │
│ • Engineered structural lifting lugs for direct tandem crane rigging. │
└─────────────────────────────────────────────────────────────────────────┘ CST 24-UNIT BATCH PRODUCTION QUALITY GATE
FROM CLIENT CAD BLUEPRINTS & DATA CENTER MEP SPECIFICATIONS
┌─────────────────────────────────────────────────────────────────────────┐
│ [ STAGE 1: DFM REVIEW & 3D SOLIDWORKS COLLISION CHECK ] │
│ Verification of lifting lug center-of-gravity, port flanges, & wiring │
├─────────────────────────────────────────────────────────────────────────┤
│ [ STAGE 2: CNC PRECISION BENDING, FIN PUNCHING & ROBOTIC EXPANSION ] │
│ Continuous fin packs expanded mechanically for 100% thermal contact │
├─────────────────────────────────────────────────────────────────────────┤
│ [ STAGE 3: AUTOMATED ORBITAL TIG WELDING & PASSIVATION ] │
│ Header manifolds welded with inert shielding gas; zero internal dross │
├─────────────────────────────────────────────────────────────────────────┤
│ [ STAGE 4: 100% HYDROSTATIC & HELIUM VACUUM MASS SPECTROMETER TEST ] │
│ Proof tested at 3.0 MPa (30 bar); helium leak rate < 1x10⁻⁶ mbar·L/s │
├─────────────────────────────────────────────────────────────────────────┤
│ [ STAGE 5: FACTORY ACCEPTANCE TEST (FAT) & STAGED BATCH DISPATCH ] │
│ Multi-point performance verification and heavy export crating │
└─────────────────────────────────────────────────────────────────────────┘
DELIVERS ZERO-DEFECT 9.6 MW TURNKEY COMMISSIONING ON SITETo guarantee that all 24 units deliver exactly 400 kW of thermal capacity over decades of continuous 24/7/365 thermal cycling, CST utilizes high-tonnage hydraulic and mechanical bullet expanders. This creates permanent metallurgical contact between the tubes and extruded fin collars, eliminating contact thermal degradation.
Data center liquid cooling loops cannot tolerate microscopic fluid leaks that cause pressure loss or fluid top-off alarms. Every single coil block of the 24-unit batch undergoes 100%100% helium vacuum mass spectrometer leak testing, ensuring absolute sealed-loop integrity.
CST 400 KW V-BANK DATA CENTER DRY COOLER (CST-DC-400KW-V)
[1. DUAL V-BANK AERODYNAMIC HEAT TRANSFER MODULE]
• High heat transfer density per square meter of rooftop or ground slab footprint.
• Modular V-angle configuration optimizes airflow distribution across both coil banks.
─────────────────────────────────────────────────────────────────────────────
[2. 4-TO-6 FAN EC VARIABLE SPEED FAN ARRAY]
• High-efficiency Ø 800 mm or Ø 910 mm composite sickle-blade fans with aerofoil diffusers.
• Redundant N+1 fan architecture ensures full capacity even if an individual fan stops.
─────────────────────────────────────────────────────────────────────────────
[3. INTEGRATED PLC SMART ELECTRICAL ENCLOSURE]
• IP55/IP65 weatherproof electrical control cabinet with internal circuit breakers.
• Modbus-RTU / BACnet IP communications for direct DCIM BMS telemetry integration.(Note: The following engineering parameters represent standard manufacturing design envelopes for the 400 kW dry cooler batch model. Dimensions, connection types, fan counts, and acoustic levels are 100% adjusted to match the client's submitted engineering drawings.)
================================================================================
CST 400 KW DATA CENTER DRY COOLER (24-UNIT BATCH SPECIFICATION)
================================================================================
Engineering Parameter Batch Specification (Per 400 kW Unit)
--------------------------------------------------------------------------------
Quantity in Batch Order 24 Units (Combined Total Capacity: 9.6 MW / 2,730 TR)
Nominal Heat Rejection Capacity 400 kW per unit (1,365,000 BTU/h) @ Standard Ambient
Process Fluid Medium Clean Water, 25%–35% Ethylene / Propylene Glycol Solution
Process Fluid Flow Rate 60 to 85 m³/h (264 to 374 GPM) per 400 kW Unit
Fluid Inlet / Outlet TemperatureTypical: +45°C (+113°F) Return / +35°C (+95°F) Supply
Design Ambient Air Temperature Designed for +35°C to +45°C Summer Peak Conditions
Design Operating Pressure Range Up to 1.6 MPa (16 bar / 232 psi) High-Pressure Rating
Hydrostatic Proof Test Pressure 2.5 MPa (25 bar / 362 psi) Leak Integrity Quality Gate
Core Tube Metallurgy Options Seamless Copper (Cu-DHP Ø 5/8" / 15.88 mm) or AISI 304/316L
Fin Metallurgy & Surface ProfileCorrugated Hydrophilic Blue Aluminum / Epoxy-Coated Al
Fin Pitch / Density Envelope 10 to 14 FPI (Optimized for dust shedding & low air dP)
Coil Form Factor & Geometry Dual V-Bank High-Efficiency Modular Geometry
Fan Type & Quantity 4x or 6x Ø 800 mm / Ø 910 mm High-Efficiency EC Inverter Fans
Total Fan Electrical Power Draw Approximately 6.5 kW to 9.5 kW per 400 kW Unit (Full Speed)
Acoustic Sound Pressure Level Standard: 62–68 dBA @ 10m; Low-Noise Pack: < 55 dBA @ 10m
Fluid Inlet / Outlet Ports DN100 / DN125 (4" / 5") PN16 / ANSI 150# Flanged Connections
Structural Enclosure & Finish 2.5 mm Heavy Galvanized Steel + C4/C5-M Powder Coat (RAL 7035)
Control & DCIM Communication Integrated IP65 Control Box with Modbus RTU / RS485 Interface
Quality Standards & Compliance CE / PED 2014/68/EU, ISO 9001:2015, ASME Sec. VIII Available
Testing & Quality Assurance 100% Helium Mass Spectrometer Testing + Factory FAT Run
================================================================================To start production of the 24-unit batch, clients typically provide 2D CAD general arrangement drawings (PDF/DWG), fluid connection port locations and flange standards, electrical schematic requirements (voltage/frequency/BMS protocol), and structural base mounting hole coordinates. CST conducts a comprehensive Design-for-Manufacturability (DFM) review and issues 3D approval models prior to fabrication.
All 24 units are manufactured in a single, dedicated production run using automated CNC fin stamping lines, automated CNC tube bending mandrels, and calibrated robotic hydraulic expansion. Every single coil block is serial-numbered and undergoes individual hydrostatic and helium mass spectrometer leak testing with traceable QA inspection records.
Yes. For large 24-unit data center projects, CST provides customized phased dispatch schedules (e.g., 6 units per batch across 4 shipments, or 12 units across 2 shipments). Each unit is packed in heavy-duty export ocean-freight steel-reinforced crating with designated rigging points for direct crane hoisting from flatbed trucks onto building rooftops.
Secure proven thermal performance, precise blueprint replication, and on-time project commissioning with CSTHEATEXCHANGER:
OEM Made-to-Drawing Manufacturing for 24 Units of 400 kW Data Center Dry Coolers (9.6 MW Total)
Seamless Copper or Stainless Steel Coils with Hydrophilic / Epoxy Blue Aluminum Fins
High-Efficiency EC Inverter Fan Arrays for Industry-Leading Ultra-Low PUE (<1.15<1.15)
100% Hydrostatic Proof Tested & Helium Mass Spectrometer Certified
Heavy-Duty Weatherproof Structural Steel Casings with C4/C5-M Protective Powder Coating
Full CE / PED & ISO 9001:2015 Compliance with Phased Global Project Delivery
Contact our specialized mission-critical data center thermal engineering team today with your 2D/3D project drawings, thermal specifications, and site delivery schedule for a comprehensive DFM review, thermal modeling confirmation, and factory-direct OEM proposal.
Website: https://www.cstheatexchanger.com/
Technical Inquiries: info@cstheatexchanger.com
