MMC combined cooler
Operating/Assembly instructions
350200000xxx
KTR-N
Sheet:
Edition:
43510 EN
1 of 17
1
MMC combined cooler
The MMC combined cooler is a powerful high-performance cooler made of aluminium in a plate
and bar version for harsh operating conditions. It has a compact design and was developed for
cooling water, oil, charge air and fuel. Each cooler is selected pursuant to customised
specifications. Depending on the application various media can be combined in one housing.
Please observe protection
note ISO 16016.
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MMC combined cooler
Operating/Assembly instructions
350200000xxx
KTR-N
Sheet:
Edition:
43510 EN
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1
Table of contents
1
Technical data
3
2
Advice
3
2.1
2.2
2.3
2.4
2.5
2.6
3
4
4
4
5
5
3
4
General advice
Safety and advice symbols
General hazard warnings
Intended use
Reference to EC Machinery Directive 2006/42/EC
Directive for Pressure Equipment 2014/68/EU
Storage, transport and packaging
5
3.1
3.2
5
6
Storage
Transport and packaging
Assembly
7
4.1
4.2
4.3
4.4
4.5
4.6
4.7
7
8
9
10
10
11
12
Components of MMC combined cooler
Place of installation
Assembly of MMC combined cooler
Operating pressure and temperature
Cooling medium
Connection of media hoses
Electrical connection
5
Start-up
13
6
Breakdowns, causes and elimination
13
7
Maintenance and service
15
7.1
16
Cleaning
8
Spares inventory, customer service addresses
16
9
Disposal
16
10
Enclosure A
17
10.1 Type code
17
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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KTR-N
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Edition:
43510 EN
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1
Technical data
An MMC combined cooler is structured individually and consequently application-specific. Subject to the
large number of possible variations, these operating and assembly instructions focus on a compact overall
system with oil, water and charge air cooler as well as fan including hydraulic drive.
Illustration 1
The MMC combined cooler serves for thermal power transmission and is intended for fixed mounting in a
plant. It may only be started up if the overall plant or machine that the MMC combined cooler is installed in
complies with the relevant national provisions, safety regulations and standards.
For detailed information on the MMC combined cooler, e. g. fastening points and total weight, refer to the
project documentation, dimensional drawing or type label. The permissible operating range is specified in the
type label.
The application limits of the type label must absolutely be observed. If the specified figures
are exceeded, the cooler may be damaged.
!
The specifications entered in the dimensional drawing, project documentation and type
label have to be primarily observed.
STOP
There is the risk of cutting on threads, laminas and burrs. That is why you should
always wear protective equipment with transport, assembly and maintenance.
2
Advice
2.1 General advice
Please read through these operating/assembly instructions carefully before you mount the MMC combined
cooler.
Please pay special attention to the safety instructions!
The operating/assembly instructions are part of your product. Please store them carefully and close to the
MMC combined cooler. The copyright for these operating/assembly instructions remains with KTR.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Advice
2.2 Safety and advice symbols
STOP
!
Warning of personal injury
This symbol indicates notes which may contribute to
preventing bodily injuries or serious bodily injuries that
may result in death.
Warning of product damages
This symbol indicates notes which may contribute to
preventing material or machine damage.
General advice
This symbol indicates notes which may contribute to
preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to
preventing burns with hot surfaces resulting in light to
serious bodily injuries.
2.3 General hazard warnings
STOP
With assembly and disassembly of the MMC combined cooler it has to be made sure that
the entire drive train is secured against accidental switch-on. You may be seriously hurt by
rotating parts and hot surfaces. Please make absolutely sure to read through and observe
the following safety indications.
• All operations on and with the MMC combined cooler have to be performed taking into account "safety
first".
• Make sure to switch off the power pack and depressurize the system before you perform your work on the
MMC combined cooler.
• Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of
switch-on or removing the fuse for current supply.
• Do not reach into the operation area of the machine as long as it is in operation or stand by mode.
• Please secure the rotating drive components against accidental contact. Please provide for the necessary
protection devices and covers.
• Make sure to wear safety clothing that protects you against mechanical, thermal and toxic features of the
flow media.
2.4 Intended use
You may only assemble, disassemble, operate and maintain the MMC combined cooler if you
• have carefully read through the operating/assembly instructions and understood them
• are technically qualified and specifically trained (e. g. safety, environment, logistics)
• are authorized by your company
The MMC combined cooler may only be used in accordance with the technical data (see dimensional
drawing, project documentation and type label). Unauthorized modifications on the combined cooler are not
admissible. We will not assume liability for any damage that may arise. In the interest of further development
we reserve the right for technical modifications.
The MMC combined cooler described in here corresponds to the technical status at the time of printing of
these assembly instructions.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Advice
2.5 Reference to EC Machinery Directive 2006/42/EC
The MMC combined cooler is defined as an incomplete machine within the terms of Machinery
Directive 2006/42/EC. The MMC combined cooler is exclusively intended for installation in a machine
so that it does not comply with all specifications of the Machinery Directive.
It is forbidden to start up the MMC combined cooler until it is stated that the machine which the MMC
combined cooler is installed in complies with all basic specifications of the Machinery Directive
2006/42/EC.
2.6 Directive for Pressure Equipment 2014/68/EU
The individually selected and designed MMC combined coolers are classified in accordance with the
Directive for Pressure Equipment 2014/68/EU (PED) and subject to the relevant standards.
Please refer to the type label for relevant details.
The EC declarations of incorporation (KTR-N 43501) are generated project-related and attached to the
project documentation. The Directive for Pressure Equipment 2014/68/EU (PED) requires an assessment of
each customer- and application-specific MMC combined cooler.
!
3
The application limits of the type label must absolutely be observed. If the specified figures
are exceeded, the cooler may be damaged.
Storage, transport and packaging
3.1 Storage
The MMC combined coolers are supplied in preserved/painted condition and can be stored in a dry and
roofed place in their transport packaging for 6 - 9 months. The connections must be kept closed to avoid dirt
and corrosion inside. The connection seals must only be removed during mounting.
!
The storage rooms must not include any ozone-generating devices like e. g. fluorescent
light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less
than 65 %.
!
With special paintings, e. g. CDP coating, the MMC combined cooler is to be protected from
sunlight. The UV resistance of this coating is limited.
!
Make sure firm stand when storing the MMC combined cooler. Combined coolers standing
upright must be protected from dropping subject to their high centre of gravity.
With an interim storage the MMC combined cooler needs to be protected from environmental impacts
(moisture, solar radiation, etc.) as well as excessive dust exposure. Before storage provide for connection
seals protecting from dirt and corrosion inside.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Edition:
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Storage, transport and packaging
3.2 Transport and packaging
!
In order to avoid any injuries and any kind of damage please always make use of proper
transport and lifting equipment.
!
The MMC combined cooler has a very high weight. Make sure to use adequately
dimensioned lifting equipment.
Secure the transport area and do not step beneath suspended load.
STOP
The MMC combined coolers are packed differently each depending on size, number and kind of transport.
Unless otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Edition:
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Assembly
The MMC combined cooler has a customised design. The extent of the system complies with the provisions
given in the customer specification. The large number of variations allows for delivery units ranging from
unpainted individual cooling segments to multiple circuit combined coolers with fan, protective grid, sensor
technology and drive.
The customised combined coolers are basically supplied ready for installation. If possible resp. requested,
the individual components (see illustration 2) are supplied mounted, inspected and packed as a unit.
4.1 Components of MMC combined cooler
Components/subassemblies of MMC combined cooler
(example: air-water-oil cooler with hydraulic motor)
Component
1
2
3
4
5
6
7
8
9
10
Quantity
1
1
1
1
1
1
1
1
1
1
Description
Hydraulic motor
Motor bracket
Fan grid
Fan
Fan cover
Side panel
Expansion tank
Charge air cooler
Water cooler
Oil cooler
Illustration 2: Components of MMC combined cooler (example: air-water-oil cooler with hydraulic motor)
Alternatively the fan can be provided with an electric motor resp. a direct drive of the I. C.engine can be used.
Please observe protection
note ISO 16016.
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Assembly
4.1 Components of MMC combined cooler
Vibration-damped fastenings are not part of the scope of delivery as a standard.
Example: Structure of a vibration-damped fastening (optionally)
Illustration 3: Example of a vibration-damped fastening
Every vibration-damped fastening has a customised structure. For components and
quantities of single parts refer to the dimension sheet.
4.2 Place of installation
Positioning of the combined cooler often follows the geometrical options within the machine so that the
fastening points for designing (see dimension sheet) are defined project-related.
!
To make sure the calculated cooling power (see project documentation), unimpeded inflow,
outflow and throughflow of the energy absorbing air must be ensured.
!
Preheating the aspirated cooling air through the selection parameters (see product
documentation) reduces the thermal performance of the combined cooler, too.
!
Return flow of heated air (air short-circuit) as well as excessive preheating of aspired air
must be avoided.
The set-up/application height affects the performance of the combined cooler and is part of
the selection of the application-specific MMC combined cooler.
A disadvantageous place of installation of the combined cooler may increase the noise level
by reflection of sound.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Edition:
43510 EN
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Assembly
4.2 Place of installation
Consider with positioning of the MMC combined cooler that the system may be vented after
installation and an expansion tank, if not included in the scope of delivery, can be arranged
over the combined cooler.
For combined coolers with an integrated drive horizontal arrangement of the motor hub
should be preferred to minimize the axial forces on the motor bearing.
4.3 Assembly of MMC combined cooler
With assembly make sure that all provided fastenings (see dimensional drawing) were
mounted. Make use of proper tools.
To avoid damages on the MMC combined cooler, the system must be fastened adequately.
For that purpose consider the total weight of the combined cooler in filled condition.
!
Protect the combined cooler from dropping.
!
The MMC combined cooler can be assembled in various positions. The asssembly is based on the specific
fastening points that are explicitly specified in the dimensional drawing.
•
Align the MMC combined cooler properly. Observe sufficient distance to adjacent components.
•
Screw the MMC combined cooler to all fastening points specified in the dimensional drawing.
•
Only valid if vibration-damped fastening is used:
Make sure correct arrangement of the single parts (see illustration 3 and dimensional drawing).
The cooler's fan cover includes holes serving to have drained condensation water that
might be generated.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Edition:
43510 EN
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Assembly
4.4 Operating pressure and temperature
The MMC combined cooler was particularly selected and designed pursuant to the operating conditions and
media specified by you. The selection parameters are listed in the project documentation.
The permissible operating range is recorded in the type label (illustration 4). Deviating from the permissible
operating conditions and media results in voiding of warranty and operating licence.
Illustration 4: Example - type label
With dynamic load pressure peaks and systemic pulsations must be avoided.
!
The maximum permissible temperature and pressures of the medium to be cooled are listed
in the type label and must not be exceeded.
The temperature of the ambiance and the medium to be cooled should not change rapidly.
4.5 Cooling medium
STOP
The flow media may have features and/or temperatures hazardous to health. This may
result in risk of acid burns, frostbite or poisoning. Please wear special protective
equipment.
An MMC combined cooler allows for combining several circuits within one housing. Cooling segments of
water-glycol mixture, system oil, charge air and fuel coolers can be individually combined and selected
pursuant to the customers' specifications.
!
High temperatures and toxic reactions may arise with emitting media. Inspecting the
corrosion resistance of the MMC combined cooler with the media is part of the project
phase. Changing the medium may affect the corrosion resistance.
LLC = Charge air cooler (with charged engines)
WK = Water cooler (content of glycol 40 % at the minimum)
High surface temperatures are to be expected on the MMC combined cooler and the pipes.
Emitting steam must additionally be watched out for with the water cooler segment. Be
specifically cautious when opening the pressure valve of the expension tank.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Edition:
43510 EN
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Assembly
4.6 Connection of media hoses
Illustration 5: Connection of a multiple circuit cooler to an I. C.-engine (example of application)
Suitable hose clamps ensure safe and leakage-free connection to the combined cooler.
Select those pursuant to the provisions of the hose connections.
Make sure that the connections and hoses are adapted to the cooler with regard to
pressure, flow rate, temperature, liquid, vibration and pulsation.
In addition you have to use flexible hoses for connecting the individual cooling segments
with mobile machines and stationary machines exposed to vibrations.
For details on the hose diameter and type of connection refer to the dimensional drawing.
With screw connections and the use of hose clamps please observe the tightening torques
specified. This refers to the connection of hydraulic motor and accessories, too.
Before you remove the connection seal of the connection pipes make sure that no particles
of dirt penetrate inside the open pipes and the single components with assembly.
•
Remove the seal of the connection pipes.
•
Connect all hoses with suitable hose clamps to the matching connection pipes of the MMC combined
cooler (see dimensional drawing).
Please observe protection
note ISO 16016.
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Assembly
4.6 Connection of media hoses
Illustration 6: Connection of an expansion tank (example)
•
Make sure that the expansion tank must in every case be above the connected cooling
segment in order to ensure proper venting operation of the MMC combined cooler.
Unless part of the scope of delivery, connect the expansion tank to the matching connection on the combined
cooler (see illustration 6 and dimensional drawing).
4.7 Electrical connection
In addition to a direct drive, separate hydraulic and electrical fan drives can be selected with the MMC
combined coolers.
Before connecting the motor to the electricity supply network compare the specifications given in the type
label of the motor to the voltage and frequency of the mains.
The direction of rotation of the fan must be inspected upon connection of the motor. A wrong direction of
rotation reduces the air performance and consequently the required cooling capacity considerably.
!
The electric motors may only be connected to the electric supply by qualified personnel.
Please observe the universal specifications and electrical safety regulations!
Incorrect connections, damaged cables etc. may energize the connected components or
make the electric motor rotate in the wrong direction.
Please observe the operating instructions of the electric motor used by you.
We recommend to use an overload protection for the electric motor.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Edition:
43510 EN
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Start-up
Before start-up make sure that the combined cooler is undamaged, properly connected and fastened.
Please observe the following procedure:
• The MMC combined cooler and the protective grid, if available, must be undamaged.
• Make sure the fan can rotate freely while not touching the fan grid or fan cover.
• All connections and fastenings must be properly mounted.
• The inside of the fan housing has to be free from any objects.
• The different cooling segments must be filled and vented as specified.
Free throughflow of laminas must be ensured. Dirty resp. blocked laminae channels must be
cleaned (see chapter 7.1).
!
Components which are ejected may cause personal injuries or damage other components.
STOP
Make sure that protection against accidental contact is provided.
STOP
During operation of the MMC cooler, please pay attention to
• different operating noise
• vibrations occurring.
6
Breakdowns, causes and elimination
The below-mentioned failures can lead to a use of the MMC combined cooler other than intended. In addition
to the specifications given in these operating/assembly instructions make sure to avoid such failures.
The errors listed can only be clues to search for the failures. When searching for the failures the adjacent
components must generally be considered.
General failures with use other than intended:
•
Important data for the selection of the MMC combined cooler were not forwarded.
•
Application limits of the combined cooler listed in the type label and project documentation were not
observed.
•
An MMC combined cooler with damage occurred during transport is assembled.
•
Connections and hoses were not mounted properly.
•
Tightening torques have been fallen below/exceeded.
•
Components are mixed up by mistake/assembled incorrectly.
•
No original KTR components (purchased parts) are used.
•
Maintenance intervals are not observed.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Edition:
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Breakdowns, causes and elimination
Breakdowns
Causes
Diminished heat transfer, diminished
cooling capacity
Leakage
Vibration
Increased noise emission
Please observe protection
note ISO 16016.
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Elimination
1) Set the combined cooler out of
Dirty cooler core laminas
operation
2) Clean the laminas
Impeded air volume flow by restricted air 1) Set the combined cooler out of
inflow, air throughflow résp. air outflow,
operation
for example caused by blocked fan grids 2) Clean the combined cooler
1) Set the combined cooler out of
Impeded air volume flow by defective
operation
fan geometry
2) Replace fan
1) Set the combined cooler out of
Mechanical destruction of cooling
operation
segment
2) Drain medium
3) Replace cooler core
1) Set the combined cooler out of
operation
Connection of hoses on the connection
2) Drain medium
pipes are not firmly screwed together
3) Inspect screw connections, replace
gaskets, if necessary
1) Set the combined cooler out of
operation
Overpressure in the system
2) Inspect and adapt operation
parameters, eliminate blockage in the
system, if necessary
1) Set the combined cooler out of
operation
Defective motor bearing/cooler fastening
2) Inspect fastenings and bearings of the
overall system and fasten as specified
1) Set the combined cooler out of
operation
Geometry or position of fan not correct - 2) Clean the combined cooler acc. to
imbalance
chapter 7.1 Cleaning
3) Re-balance resp. replace the fan incl.
hub
1) Set the combined cooler out of
operation
2) Inspect the system for unimpeded
Pulsation in the fluid system
flow, venting, pump capacity;
synchronise operating parameters
(flow rate) with selection parameters
and adapt, if necessary.
1) Set the combined cooler out of
operation
Defective fan
2) Clean the fan acc. to chapter 7.1
Cleaning
3) Re-balance resp. replace the fan
1) Set the combined cooler out of
operation
Too high speed
2) Synchronise operating parameters
with operating limits and adapt, if
necessary
1) Set the combined cooler out of
operation
System is not operating freely, dragging 2) Make sure sufficient distance
of fan
between fixed components and fan;
provide for protective grid, if
necessary; align cover
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Maintenance and service
Preventive maintenance operations have to be regularly performed by the user.
The following items of inspection are the main components of maintenance work:
• Unusual noise or vibrations must not be generated. If higher noise emissions or vibrations are generated,
eliminate the cause acc. to chapter 6 Breakdown, causes and elimination.
!
Vibrations may cause severe damages on components and a failure of the MMC combined
cooler.
• Make sure the fan can rotate freely while not touching the fan grid or fan cover.
• The fan must not have any imbalance.
!
Dirt on the MMC combined cooler or diminished inflow or outflow of cooling air reduce the
air flow. Reduced air flow affects the heat dissipation and may cause thermal problems on
the system to be cooled.
• Inspect the cooling laminas and the overall MMC combined cooler for dirt. If any components are dirty,
the MMC combined cooler needs to be cleaned acc. to chapter 7.1 Cleaning. The frequency of inspection
and cleaning of the combined cooler depends on the operating conditions.
• Inflow and outflow of cooling air must be ensured.
• Inspect the MMC combined cooler regularly for damages.
!
Leakages have to be eliminated immediately. Media which have escaped have to be
removed properly, since residues of media may ignite on hot components and endanger the
environment. In addition, leakages may cause severe damage and a failure of the system.
• The MMC combined cooler must be regularly inspected for leakages.
!
!
Media which have escaped have to be collected and removed acc. to chapter 9 Disposal
immediately.
Connection leakages of media on the inlet and outlet can often be found with the power
pack operating only. With this inspection pay special attention to the safety regulations. Do
not reach into the operation area of the machine.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Edition:
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Maintenance and service
7.1 Cleaning
Before cleaning make sure that the combined cooler has cooled down.
Touching the heated components causes burns.
STOP
With cleaning processes, e. g. with water, disconnect the combined cooler from the power
supply. The protection class needs to be observed.
Side of air laminas
The air laminas can be cleaned with compressed air. If seriously soiled, cleaning should be done by means
of a high-pressure cleaner and a proper detergent, if necessary. The jet should be kept carefully, keeping
sufficient distance and in parallel with the air lamina.
To avoid damage on the cooler, make sure the detergent is compatible with the materials
used, e. g. aluminium.
!
Medium side of cooling element
If soiled inside, e. g. caused by longer downtime with open combined cooler or soiling of media resulting in
depositions in the filigree channel system, cleaning of the medium side of the cooling element by flushing is
recommended. Always flush with the liquid/medium which is used later.
8
Spares inventory, customer service addresses
Since the MMC combined cooler is a customised unit, the components are manufactured order-related. A
basic requirement to ensure the readiness for use of the combined cooler is a stock of the most important
spare parts on site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage
at www.ktr.com.
!
9
KTR does not assume any liability or warranty for the use of spare parts and accessories
which are not provided by KTR and for the damages which may incur as a result.
The combined coolers are selected and designed application-specifically. All components
are coordinated with each other with regard to performance. Replacing components by
those with different parameter characteristics changes the selection of the overall system
and may cause serious damage on the system to be cooled.
Disposal
In respect of environmental protection we would ask you to dispose of the products on termination of their
service life in accordance with the legal regulations and standards that apply, respectively.
•
Metal
Any metal components have to be cleaned and disposed of by scrap metal.
•
Gaskets
Gaskets can be disposed of by residual waste.
•
Media
Media have to be collected in suitable tanks and disposed of by a waste disposal company.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
Enclosure A
10.1 Type code
Extract from KTR standard 03510 (edition 3):
MMC combined cooler
35
020
0
05
0000
Serial number
00 = Combined/water/air/oil cooler
01 = Fan cover
02 = Cooling element - KSK / (prev.) coolant cooler
03 = Cooling element - oil / (prev.) oil cooler
04 = Cooling element - water / (prev.) water cooler
07 = Cooling element - combined / (prev.) combined cooler
08 = Cooling element - air / (prev.) air cooler
09 = EGR (exhaust gas recirculation)
10 = Donut - oil
12 = Vaporiser
13 = Protective grid
17 = Type label
18 = General metal sheets
22 = Motor bracket
23 = Expansion tank
32 = Oil tank
Material
Combined cooler
Product type
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43510 EN
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">
