KTR Oil/air cooler series OPC Operating/Mounting Instructions
KTR Oil/air cooler series OPC is a high-performance cooler designed for cooling hydraulic oil, gear oil, and lubricating oil. It features a compact design and is suitable for use in potentially explosive atmospheres. The cooler is available in various sizes, from OPC200 to OPC1000, and offers a range of cooling capacities.
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Oil/air coolers Series OPC Operating/Assembly instructions KTR-N Sheet: Edition: 43211 EN 1 of 20 6 Oil/air coolers series OPC according to directive 2014/34/EU Oil/air cooler; example: OPC200 to OPC400 Oil/air cooler; example: OPC500 to OPC700 Oil/air cooler; example: OPC800 to OPC1000 Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions KTR-N Sheet: Edition: 43211 EN 2 of 20 6 The oil/air cooler series OPC is an efficient high-performance cooler. It has a compact design and was developed for cooling hydraulic oil, gear oil and lubricating oil. Table of contents 1 Technical data 3 2 Advice 6 2.1 2.2 2.3 2.4 General advice Safety and advice symbols General hazard warnings Intended use 6 6 6 7 Storage, transport and packaging 7 3.1 3.2 7 7 3 4 Storage Transport and packaging Assembly 8 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 8 9 10 10 11 12 12 12 12 Components of oil/air cooler Place of installation Assembly of oil/air cooler Operating pressure and temperature Electrical connection Cooling medium Cleaning Standard marking of oil/air cooler Assembly - disassembly of the oil/air cooler in components 5 Start-up 13 6 Maintenance and service 13 7 Spares inventory, customer service addresses 14 8 Enclosure A Advice and instructions regarding the use in atmospheres 8.1 8.2 Intended use in potentially explosive 15 potentially explosive atmospheres 15 Marking for potentially explosive atmospheres 8.3 Start-up for the use in 8.4 8.5 8.6 Permissible accessories for the use in EC Certificate of incorporation EU Declaration of conformity Please observe protection note ISO 16016. Drawn: Verified: 16 potentially explosive atmospheres 17 potentially explosive atmospheres 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: 18 19 20 KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 1 KTR-N Sheet: Edition: 43211 EN 3 of 20 6 Technical data Type OPC200 to OPC400 Illustration 1: OPC200 to OPC400 Table 1: Dimensions - Type OPC200 to OPC400 Voltage OPC200-4D-0.75kW OPC200-12D-0.75kW OPC200-16D-0.75kW OPC300-4D-0.75kW OPC300-12D-0.75kW OPC300-16D-0.75kW OPC400-4D-0.75kW OPC400-12D-0.75kW OPC400-16D-0.75kW OPC400-32D-0.75kW Type of cooler OPC200-4D-0.75kW OPC200-12D-0.75kW OPC200-16D-0.75kW OPC300-4D-0.75kW OPC300-12D-0.75kW OPC300-16D-0.75kW OPC400-4D-0.75kW OPC400-12D-0.75kW OPC400-16D-0.75kW 230/400V 50 Hz Type of cooler Current [A] 1.8 Speed [rpm] l/min. kW/°C 1400 5.5 16.7 21.4 5.5 16.7 21.4 5.5 16.7 21.4 42.7 0.12 0.14 0.15 0.20 0.22 0.24 0.24 0.26 0.28 0.34 F H I 115 360 174 160 160 450 450 200 200 B 350 460 446 Drawn: Verified: 255 65 300 95 300 645 446 550 530 330 2021-02-15 Pz/Str 2021-06-24 Pz 63 638 100 100 75 330 668 720 M N 426 G ¾“ 435 G 1“ 464 G ¾“ 473 G 1“ 465 G ¾“ 474 G 1“ SAE 1 ½“ 400 OPC400-32D-0.75kW Please observe protection note ISO 16016. 615 550 L 550 572 E 596 Dimensions [mm] J K 530 Dimensions [mm] C D A Replacing: Replaced by: Weight [kg] 35 42 46 KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 1 KTR-N Sheet: Edition: 43211 EN 4 of 20 6 Technical data Type OPC500 to OPC700 Illustration 2: OPC500 to OPC700 Table 2: Dimensions - Type OPC500 to OPC700 Type of cooler Voltage l/min. kW/°C 0.40 0.48 0.50 0.52 0.65 0.68 0.70 0.73 0.77 4.5 1435 F G H I 150 157.5 657 130 Type of cooler OPC500-16D-2.2kW OPC500-25D-2.2kW OPC500-32D-2.2kW OPC500-40D-2.2kW OPC600-16D-2.2kW OPC600-25D-2.2kW OPC600-32D-2.2kW OPC600-40D-2.2kW OPC700-40D-2.2kW Speed [rpm] 21.5 33.4 42.7 53.5 21.5 33.4 42.7 53.5 56.0 230/400V 50 Hz OPC500-16D-2.2kW OPC500-25D-2.2kW OPC500-32D-2.2kW OPC500-40D-2.2kW OPC600-16D-2.2kW OPC600-25D-2.2kW OPC600-32D-2.2kW OPC600-40D-2.2kW OPC700-40D-2.2kW Current [A] 225 Please observe protection note ISO 16016. 4.9 226.0 1410 770 B 460 740 280 795 94 819 607 840 94 868 608 30 30 455 990 973 L M N Weight [kg] 547 G 1“ 75 568 SAE 1 ½“ 77 626 G 1“ 96 647 SAE 1 ½“ 98 330.0 367.5 732 2021-02-15 Pz/Str 2021-06-24 Pz 405 790 920 Drawn: Verified: E 740 Dimensions [mm] J K 720 Dimensions [mm] C D A Replacing: Replaced by: 530 130 KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 1 KTR-N Sheet: Edition: 43211 EN 5 of 20 6 Technical data Type OPC800 to OPC1000 Illustration 3: OPC800 to OPC1000 Table 3: Dimensions - Type OPC800 to OPC1000 Type of cooler Voltage OPC800-50D-4kW OPC800-80D-4kW OPC850-80D-5.5kW OPC850-100D-5.5kW OPC850-125D-5.5kW OPC900-80D-5.5kW OPC900-100D-5.5kW OPC900-125D-5.5kW OPC1000-125D-5.5kW OPC1000-180D-5.5kW 400/690V 50Hz 8.2 Type of cooler OPC800-50D-4kW OPC800-80D-4kW OPC850-80D-5.5kW OPC850-100D-5.5kW OPC850-125D-5.5kW OPC900-80D-5.5kW OPC900-100D-5.5kW OPC900-125D-5.5kW OPC1000-125D-5.5kW OPC1000-180D-5.5kW Current [A] 12 Speed [rpm] 1460 970 l/min. kW/°C 69 112 72 1.00 1.15 1.12 113 1.32 72 1.34 113 1.71 113 167 1.88 2.33 A 701 870 995 Dimensions [mm] C D 1096 981 140 1130 1046 1002 1081 95 1046 B 1312 1119 1136 Dimensions [mm] J K F G H I 350 340 920 280 670 292 910 350 590 180 L 20 373 Please observe protection note ISO 16016. 390 1182 440 615 1081 210 M 829 845 804 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: 521 523 678 113 N SAE 2“ Weight [kg] 112 113 146 824 160 804 189 824 844 854 Drawn: Verified: E SAE 3“ 203 217 220 KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 2 Advice 2.1 General advice KTR-N Sheet: Edition: 43211 EN 6 of 20 6 Please read through these operating/assembly instructions caref ully bef ore you assemble the oil/air cooler. Please pay special attention to the saf ety instructions! The oil/air cooler is suitable and approved f or the use in potentially explosive atmospheres. With the use in potentially explosive atmospheres observe the special notes and instructions regarding saf ety as per enclosure A. The operating/assembly instructions are part of your product. Please store them caref ully and close to the oil/air cooler. The copyright f or these operating/assembly instructions remains with KTR. 2.2 Safety and advice symbols Warning of potentially explosive atmospheres This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death caused by explosion. 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 surf aces resulting in light to serious bodily injuries. 2.3 General hazard warnings STOP With assembly and disassembly of the oil/air 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. Please make absolutely sure to read through and observe the following safety indications. • All operations on and with the oil/air cooler have to be perf ormed taking into account "saf ety f irst". • Make sure to switch of f the power pack bef ore you perf orm your work on the oil/air cooler. • Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on or removing the f use f or current supply. • Do not reach into the operating area of the machine as long as it is in operation. • Secure the rotating drive components against accidental contact. Please provide f or the necessary protection devices and covers. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 2 KTR-N Sheet: Edition: 43211 EN 7 of 20 6 Advice 2.4 Intended use You may only assemble and disassemble the oil/air cooler if you • have caref ully read through the operating/assembly instructions and understood them • are technically qualif ied and specif ically trained (e. g. saf ety, environment, logistics) • are authorized by your company The oil/air cooler may only be used in accordance with the technical data (see chapter 1). Unauthorized modif ications on the oil/air cooler are not admissible. We will not assume liability f or any damage that may arise. In the interest of f urther development we reserve the right f or technical modif ications. The oil/air cooler series OPC described in here corresponds to the technical status at the time of printing of these operating/assembly instructions. 3 Storage, transport and packaging 3.1 Storage The oil/air coolers are supplied in preserved condition and with painting and can be stored at a dry and roof ed place f or 6 - 9 months. ! 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 %. 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 oil/air coolers are packed dif ferently each depending on size, number and kind of transport. Unless otherwise contractually agreed, packaging will f ollow the in-house packaging specif ications of KTR. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43211 EN 8 of 20 6 Assembly The oil/air cooler series OPC is supplied ready f or assembly. 4.1 Components of oil/air cooler Component 1 Quantity 1 Description Oil/air cooler „Type OPC“ Illustration 4: Oil/air cooler; example: OPC200 to OPC400 Illustration 5: Oil/air cooler; example: OPC500 to OPC700 Illustration 6: Oil/air cooler; example: OPC800 to OPC1000 Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43211 EN 9 of 20 6 Assembly 4.2 Place of installation Illustration 7: Oil/air cooler; example: OPC200 to OPC400 Illustration 8: Oil/air cooler; example: OPC500 to OPC1000 In order to achieve the optimum cooling capacity the distance to the nearest wall should not f all below the height of the cooling element (dimension A), since only in this way a proper air supply is ensured (see illustration 7 and 8). ! ! The height of installation should not exceed the figure ≤ 1000 m. Return flow of heated circulated air as well as assembly of the cooler core in front of heat sources should be avoided. The engines have to be protected from direct solar radiation. An unfavourable place of installation may increase the noise level by reflection of sound. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43211 EN 10 of 20 6 Assembly 4.3 Assembly of oil/air cooler The oil/air cooler can be assembled in various positions, while the vertical design should be pref erred. Suf f icient f astening has to be assured. Some motors have got covered holes which serve for draining off condensed water that may be generated. Please use proper hydraulic hoses to connect the oil/air cooler. These are connected on the discharge side of the cooling element (see illustration 9). Make sure that the connections and hoses are adapted to the oil/air cooler with regard to pressure, flow rate, temperature and liquidity. Illustration 9: Oil/air cooler; example: OPC200 to OPC1000 With the use in potentially explosive atmospheres only those hydraulic hoses which comply with the specifications of the overall approval of the machine may be used. Motor and pump are supplied by KTR ready f or use. With the inspection of the ROTEX ® coupling (see KTRN 40210) disassembly resp. assembly of the bellhousing has to be perf ormed in accordance with KTR-N 41010. 4.4 Operating pressure and temperature The maximum static operating pressure must not exceed the load of 26 bars during operation. With sizes OPC850 to OPC1000 the maximum static operating pressure is reduced to 21 bars. With dynamic load maximum torque peaks of 14 bars must not be exceeded. ! The maximum permissible temperature of the medium to be cooled must not exceed +90 °C (standard arrangement, NBR gasket). Please consult with KTR when using the FKM gasket (up to +110 °C). Depending on the pump gasket the maximum permissible medium temperature is +80 °C (NBR gasket) or +110 °C (FKM gasket). The temperature of the ambiance and the medium to be cooled should not change rapidly. Please note boiling and freezing point. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43211 EN 11 of 20 6 Assembly 4.5 Electrical connection Bef ore connecting the motor to the power supply compare the specif ications in the type label (see illustration 12 or 13) of the motor to the voltage, f use and f requency of the mains. With the use in potentially explosive atmospheres only electric motors and pumps with ATEX approval may be used. The torsional direction of the f an and the air f low have to comply with the arrows specif ied on the oil/air cooler (see illustration 10). The electric motors may only be connected to the electric supply by qualified personnel. Please observe the universal specifications and electrical safety regulations! Illustration 10: Torsional direction - fan ! Incorrect connections, damaged cables etc. may energize the connected components or make the electric motor rotate in the wrong direction. The cooler has a separate grounding connection. It has to be connected to the grounding of the machine. Please observe the operating instructions of the electric motor used by you. Please observe the operating instructions of the pump used by you. We recommend to use an overload protection for the electric motor. Standard three-phase asynchronous motor As a star connection As a delta connection Illustration 11: Electrical connection- three-phase asynchronous motor Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43211 EN 12 of 20 6 Assembly 4.6 Cooling medium The oil/air cooler is suitable f or the use of mineral oil, synthetic oil and water glycol. 4.7 Cleaning STOP ! Before cleaning make sure that the oil/air cooler has cooled down. Touching the heated components causes burns. With cleaning processes, e. g. with water, disconnect the cooler from the main 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 degreasing agent. The jet should be kept caref ully and in parallel with the air f in. Oil side of cooling element The oil side of the cooling element is cleaned by f lushing with a degreasing agent. Af terwards f lush with the f luid/medium which is used later. 4.8 Standard marking of oil/air cooler The oil/air cooler of series OPC is marked as f ollows: Illustration 12: Examples - type label 4.9 Assembly - disassembly of the oil/air cooler in components The cooler is assembled by KTR. The oil/air cooler is supplied ready f or use. A repair of the cooler by the plant operator/an external f itter is only permissible upon written authorization by KTR. With an interim storage the oil/air cooler needs to be protected against environmental impacts (moisture, solar radiation, etc.) as well as excessive dust exposure. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 5 KTR-N Sheet: Edition: 43211 EN 13 of 20 6 Start-up Make sure the oil/air cooler is properly connected and f astened. A grounding cable has to be connected to the oil/air cooler in the position marked (on the yellow grounding symbol). Please observe the following procedure: • Flush the oil/air cooler with the same liquid/medium as the other systems. • Filter the liquid/medium af ter f lushing. • Vent the cooling element af ter f illing (see illustration 9). • The oil/air cooler and the protective grid have to be f ree f rom damage. • The f an needs to rotate f reely. The minimum gap (as per chapter 8.3) f or f ixed components needs to be observed. • Hydraulic connections have to be tightened. • The inside of the f an housing has to be f ree f rom any objects. • The cooler has to be f ree of ice and snow. Ice or snow on the impeller may cause imbalance, vibrations and damage on the machine. STOP 6 Components which are hurled may cause personal injuries, damage other components or generate sparking. Maintenance and service Preventive maintenance operations have to be regularly perf ormed by the user. The following items have to be reviewed: • Unusual noise or vibrations must not be generated. ! ! The oil/air cooler has to be regularly inspected for mechanical vibrations and monitored, if necessary, to prevent leakages and fatigue fracture of liquid supply and drainage reliably. In case if vibrations arise inspect the screw connection of motor and pump. If the damage has not been repaired in this way, consult with KTR. During operation pay attention to changes in operating noise of the ROTEX ® coupling. • Proper f astening of the oil/air cooler has to be assured. • Impurity of the oil/air cooler reduces the cooling power, make sure to clean your cooler (see item cleaning). • Inspect the oil/air cooler f or damages, def ective components have to be replaced. • Inspect the cooler core, the pump and the screw connection on the pipeline f or leakages. ! Leakages have to be eliminated immediately. Oil which has escaped has to be removed properly, since oil residues may vaporize on hot components and ignite. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 6 KTR-N Sheet: Edition: 43211 EN 14 of 20 6 Maintenance and service • Inspect distances between f an and protective grid (see chapter 8.3). • Inspect the individual components of the device f or electrically conductive connections (including the grounding cable connection). • The motor temperature has to be inspected with the device operating. • It must not exceed the temperature class specified in the type label (see illustration 13). The bearings of the motors are permanently lubricated. 7 Re-lubrication is not possible. Please observe the service life of the motor bearing as per the data sheet of the motor manufacturer. The bearings must be inspected, maintained and replaced, if necessary, as per the specifications of the motor manufacturer. Spares inventory, customer service addresses We recommend to store major spare parts on site to ensure the readiness f or use of the machine in case if a cooler f ails. Contact addresses of the KTR partners f or spare parts and orders can be obtained f rom the KTR homepage at www.ktr.com. 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. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 8 KTR-N Sheet: Edition: 43211 EN 15 of 20 6 Enclosure A Advice and instructions regarding the use in explosive atmospheres Sizes: potentially OPC200 to OPC1000 8.1 Intended use in potentially explosive atmospheres Conditions of operation in potentially explosive atmospheres The oil/air coolers are suitable f or the use according to EU directive 2014/34/EU. Industry (with the exception of mining) • • • • Equipment group II of category 2 and 3 (oil/air cooler is not approved/not suitable for equipment group 1) Medium class G (gases, mist, vapours), zone 1 and 2 (oil/air cooler is not approved/not suitable f or zone 0) Medium class D (dusts), zone 22 (oil/air coolers are not approved/not suitable f or zones 20 and 21). Explosion group IIC (explosion class IIA and IIB are included in IIC) Temperature class: Temperature class of the oil/air cooler (excluding drive and pump) 1) T3 T4 T5 T6 Max. perm. medium temperature ≤ +110 °C ≤ +108 °C ≤ +80 °C ≤ +68 °C Max. surf ace temperature of the oil/air cooler to be considered (excluding drive and pump 1) +110 °C +108 °C +80 °C +68 °C 1) Other surface temperatures and temperature classes may appear on the attachments of the device, e. g. on the motor or pump. T he highest surface temperatures resp. temperature classes on the overall machine each have to be considered. Explanation: • The permissible ambient temperature T a for the use of oil/air coolers is intended from -40 °C to +55 °C. • Subject to the operation the medium temperature may be considerably higher than the ambient temperature. • The component with the lowest temperature class is decisive for the operation. In potentially explosive atmospheres • the ignition temperature of dusts generated must at least be 1.5 times the surf ace temperature to be considered • the glow temperature must at least be the surf ace temperature to be considered plus a saf ety distance of 75 K. • the gases and vapours generated must amount to the temperature class specif ied. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 8 43211 EN 16 of 20 6 Enclosure A Advice and instructions regarding the use in explosive atmospheres 8.2 KTR-N Sheet: Edition: potentially Marking for potentially explosive atmospheres The ATEX marking of the oil/air coolers series OPC is made on one component. For the complete marking ref er to the operating/assembly instructions. Marking is as follows: II 2G Ex h IIC T6 … T3 Gb X II 3D Ex h IIIC T68 °C … T110 °C Dc X -40 °C ≤ T a ≤ +55 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Oil/air coolers OPC <Year> Illustration 13: Examples - type label Short marking: (A short marking is only made if not possible differently for reason of space or functioning.) Oil/air coolers OPC <Year> Comments on marking Equipment group II Equipment category 2G Equipment category 3D D G Ex h IIC IIIC T6 … T3 T68 °C … T110 °C -40 °C ≤ Ta ≤ +55 °C Gb, Db X Please observe protection note ISO 16016. Non-mining Equipment ensuring a high level of saf ety, suitable f or zone 1 Equipment ensuring a normal level of saf ety, suitable f or zone 22. Dust Gases and vapours Nonelectrical explosion protection Gases and vapours of class IIC (including IIA and IIB) Electrically conductive dusts of class IIIC (including IIIA and IIIB) Temperature class to be considered, depending on the ambient temperature Maximum surf ace temperature to be considered, depending on the ambient temperature Permissible ambient temperature -40 °C to +55 °C. Equipment protection level, analogous to the equipment category Special conditions apply f or a saf e use of the oil/air cooler. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 8 KTR-N Sheet: Edition: 43211 EN 17 of 20 6 Enclosure A Advice and instructions regarding the use in explosive atmospheres 8.2 potentially Marking for potentially explosive atmospheres Substance group - gases, mists and vapours: The marking with explosion group llC includes the explosion groups llA and llB. Substance group - dusts: The marking with explosion group lIlC includes the explosion groups lIlA and lIlB. 8.3 Start-up for the use in ! potentially explosive atmospheres The oil/air cooler may only be used in the locations marked in the type label of the oil/air cooler and motor and pump. The element with the least favourable class is decisive. The decision of assessment of the place of operation is subject to the user. The start-up of the coolers is permissible by qualified personnel only. • It has to be made sure that oil supply and discharge are properly connected. • The connections as well as the cooling element and pump have to be tested f or leakages af ter start -up. • The electric motor is to be connected in that the torsional direction marked on the oil/air cooler is observed as described in Electrical connection. • The cooler has to be grounded separately in the position marked (equipotential bonding of cooler). • Inspect the oil motor f or leakages. ! • Leakages have to be eliminated immediately. Oil which has escaped has to be removed properly, since oil residues may vaporize on hot components and ignite. When the motor is running vibrations and unusual noise (f rictional noise, squeaking, etc.) must not arise. ! ! The oil/air cooler has to be regularly inspected for mechanical vibrations and monitored, if necessary, to prevent leakages and fatigue fracture of liquid supply and drainage reliably. In case if vibrations arise inspect the screw connection of motor and pump. If the damage has not been repaired, the oil/air cooler must not be operated any longer. Please consult with KTR. During operation pay attention to changes in operating noise of the ROTEX ® coupling. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 8 KTR-N Sheet: Edition: 43211 EN 18 of 20 6 Enclosure A Advice and instructions regarding the use in explosive atmospheres 8.3 Start-up for the use in potentially potentially explosive atmospheres • The oil/air cooler may be set up vertically only and must be screwed to the base through all f astening holes. • It has to be assured that the suction distances and discharge distances (distance A, as described in place of arrangement) are observed. • The cooler core must not be sealed by f oreign substances. • Inspect distances between f an and protective grid. The minimum gap width between rotating components and non-mobile components is at least 1 % of the relevant contact diameter (see table 4). Table 4 Fan Ø [mm] 280 380 520 630 750 900 Size of cooler OPC200 OPC300 to OPC500 OPC600 to OPC700 OPC800 OPC850 OPC900 to OPC1000 • Minimum gap to be observed > 2.8 mm (corresponds to 1 %) > 3.8 mm (corresponds to 1 %) > 5.2 mm (corresponds to 1 %) > 6.3 mm (corresponds to 1 %) > 7.5 mm (corresponds to 1 %) > 9.0 mm (corresponds to 1 %) With the trial run make sure that the permissible motor temperature is not exceeded. The temperature classes of cooler and motor specif ied in the type label have to be def initely observed. 8.4 Permissible accessories for the use in potentially explosive atmospheres Only those accessories certif ied by ATEX and complying with the temperature class (example: thermal switch, etc.) may be mounted on the oil/air cooler. Any modifications on the design of the oil/air cooler intended for the use in potentially explosive atmospheres are not permissible. ! The customer bears the sole responsibility for all machining processes performed subsequently by the customer. KTR does not assume any warranty claims. Please observe protection note ISO 16016. Drawn: Verified: 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 8 KTR-N Sheet: Edition: 43211 EN 19 of 20 6 Enclosure A Advice and instructions regarding the use in explosive atmospheres potentially 8.5 EC Certificate of incorporation EC Certificate of incorporation according to EC machinery directive 2006/42/EC dated May 17, 2006, annex II B The manuf acturer - KTR Systems GmbH, D-48432 Rheine - states that the Oil/air cooler - OPC described in the present operating/assembly instructions is an incomplete machine complying with the Machinery Directive 2006/42/EC. The oil/air cooler is exclusiv ely intended f or installation in a machine so that it does not comply with all specif ications of the Machinery Directive. It is f orbidden to start up the oil/air cooler until it is stated that the machine which the oil/air cooler is installed in complies with all basic specif ications of the Machinery Directive 2006/42/EC. The oil/air cooler complies with the specif ications of the f ollowing standards/rules: 2006/42/EC 2014/30/EU 2014/35/EU 2014/68/EU Machinery Directive (MD) Directive f or electromagnetic compatibility (EMC direc tive) Low-voltage directive (LVD) Directive f or Pressure Equipment (PED) DIN EN ISO 12100 Saf ety of machines Rheine, Place 2021-02-15 Date Please observe protection note ISO 16016. Drawn: Verified: i. V. Christoph Bettmer Product Manager 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 Oil/air coolers Series OPC Operating/Assembly instructions 8 KTR-N Sheet: Edition: 43211 EN 20 of 20 6 Enclosure A Advice and instructions regarding the use in explosive atmospheres potentially 8.6 EU Declaration of conformity EU Certificate of conformity corresponding to EU directive 2014/34/EU dated 26 February 2014 and to the legal regulations The manuf acturer - KTR Systems GmbH, D-48432 Rheine - states that the Oil/air cooler - OPC in an explosion-proof design described in these operating/assembly instructions are devices corresponding to article 2, 1. of directive 2014/34/EU and comply with the general saf ety and health requirements according to enclosure II of directive 2014/34/EU. This declaration of conf ormity is issued under the sole responsibility of the manuf acturers KTR Systems GmbH. The oil/air cooler described in here complies with the specif ications of the f ollowing standards/rules: DIN EN ISO 80079-36:2016-12 DIN EN ISO 80079-37:2016-12 IEC/TS 60079-32-1:2020-01-24 DIN EN 14986:2017-04 The oil/air cooler complies with the specif ications of the directive 2014/34/EU. According to article 13 (1) b) ii) of directive 2014/34/EU the technical documentation is deposited with the notif ied body (type examination certif icate IBExU10ATEXB011 X): IBExU Institut f ür Sicherheitstechnik GmbH Identif ication number: 0637 Fuchsmühlenweg 7 09599 Freiberg Rheine, Place 2021-02-15 Date Please observe protection note ISO 16016. Drawn: Verified: i. V. Christoph Bettmer Product Manager 2021-02-15 Pz/Str 2021-06-24 Pz Replacing: Replaced by: KTR-N dated 2018-09-27 ">

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Key features
- High-performance cooling
- Compact design
- ATEX certified
- Various sizes (OPC200-1000)
- Suitable for mineral, synthetic oil, and water glycol
Frequently asked questions
The oil/air cooler is suitable for cooling mineral oil, synthetic oil, and water glycol.
The maximum permissible temperature is +90 °C for standard arrangement with NBR gasket. If using FKM gasket, it can be up to +110 °C. Consult with KTR for further details.
The maximum static operating pressure is 26 bars, except for OPC850 to OPC1000 where it is 21 bars. Dynamic load peak torque should not exceed 14 bars.