Custom Fluid Cooler | CCAT Observatory

Berg Chilling Systems specializes in custom-engineered cooling solutions for extreme environments, supporting industries such as aerospace, food processing, and industrial manufacturing. With over 50 years of expertise, Berg delivers high-performance fluid coolers tailored for harsh conditions, ensuring reliability, energy efficiency, and seamless integration into mission-critical applications.

In 2020, Berg Chilling Systems was selected to design and supply a custom fluid cooler module for the CCAT Observatory telescope at an altitude of 18,000 feet in Chile. The system was engineered to withstand extreme temperatures ranging from -21°C to 9°C (-5.8°F to 48.2°F) while ensuring stable cooling for the telescope’s compressors and cabinets.

Client Challenge:

The CCAT-Prime telescope required a high-altitude, dust-resistant, and modular cooling system that could:

• Operate reliably in extreme temperature fluctuations.
• Fit within a 40' shipping container mechanical room for transportation up the mountain.
• Be scalable for future expansion to 450kW cooling capacity.
• Support remote monitoring and control due to the remote location.
• Comply with Chilean electrical standards and high-altitude operational requirements.

Berg’s Tailored Solution:

Berg developed a modular dry cooler system designed for high reliability and seamless future expansion. Key features included:

• Cooling Capacity: One 150kW dry cooler, scalable up to 450kW with additional modules.
• Fluid Cooling System:
  • Dowfrost 50% glycol solution supplying 55-58°F (12.7-14.4°C) at 80 GPM for four compressors and five cabinets.
  • Expansion/buffer tank and air separator to maintain system integrity.
• Pump System:
  • Two pumps (one primary, one backup) controlled by VFDs for pressure regulation.
• Advanced Control & Monitoring:
  • PLC system with touch screen HMI, supporting remote communication and control.
  • Leak detection and manual glycol make-up system.
• Durable Construction:
  • Epoxy-coated coils for corrosion resistance.
  • Pre-fabricated stainless steel piping for seamless on-site assembly.
  • Shipping container integration, ensuring safe transport up the mountain.

To find out more about the project, click here:   

Download PDF

About Berg Chilling Systems 

Berg custom designs, manufactures, installs, and services cost-effective chilling solutions for various applications and industries including food & beverage, manufacturing. Berg’s refrigeration experts know chilling down to the core. Putting the customer’s challenges at the heart of every design, Berg sales engineers apply unmatched energy management experience to create built up or skid mounted systems using both ammonia and synthetic refrigerants.  

Wherever unique cooling needs exist, in multiple industries and in varying environments around the globe, clients trust Berg expertise. Contact us today to find out more.