KTR Oil/air cooler series OAC eco Operating/Mounting Instructions

Oil/air cooler
Series OAC eco
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43212 EN
1 of 13
2
Oil/air cooler
series
OAC eco
Oil/air cooler; example: OAC300 eco
Oil/air cooler; example: OAC500 eco
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-01-02 Sho/Pz
2017-05-19 Pz
Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43212 EN
2 of 13
2
The oil/air cooler series OAC eco is an efficient high-performance cooler. It has a compact design and
was developed for cooling hydraulic oil, gear oil, lubricant and water-glycol.
Due to its control unit it is able to cool the entering medium efficiently, thus to save energy and reduce
noise emissions.
Table of contents
1
Technical data
3
2
Advice
4
2.1
2.2
2.3
2.4
General advice
Safety and advice symbols
General hazard warnings
Intended use
4
4
4
5
Storage, transport and packaging
5
3.1
3.2
5
5
3
4
Assembly
6
4.1
4.2
4.3
4.4
4.5
4.6
6
7
7
8
8
8
8
9
10
10
4.7
4.8
5
Storage
Transport and packaging
Components of oil/air cooler
Place of installation
Assembly of oil/air cooler
Cooling medium
Operating pressure and temperature
Electrical connection
4.6.1 Operation without temperature control TFSC - OAC… eco (24V)/nc
4.6.2 Operation with temperature control TFSC - OAC… eco (24V)
Cleaning
Diagrammes - pressure loss and power
Start-up
11
5.1
5.2
11
12
Temperature control TFSC
Operation
6
Maintenance and service
12
7
Spares inventory, customer service addresses
13
8
EC Certificate of incorporation
13
Please observe protection
note ISO 16016.
Drawn:
Verified:
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Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
43212 EN
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2
Technical data
Illustration 1:
OAC300 - 400 eco
Illustration 2:
OAC500 - 600 eco
Table 1: Dimensions
Cooler type
OAC300 eco -02
OAC400 eco -02
OAC500 eco -02
OAC600 eco -02
Cooler type
OAC300 eco -02
OAC400 eco -02
OAC500 eco -02
OAC600 eco -02
L
201
231
234.7
294.7
L1
65
95
95
95
H3
450
450
657
770
H4
14
14
70
70
L2
250
280
340
340
d
14
14
13.5
13.5
L3
200
230
280
280
d1
38
51
L4
49
55.5
40
40
C1
95
105
Dimensions [mm]
L5
B
B1
90
446
421
90
446
421
90
460
435
90
607
582
Dimensions [mm]
C2
C3
69.9
77
77.8
90
B2
200
200
130
280
C4
35.7
42.9
B3
63
63
63
63
M
M12
M12
H
500
500
670
770
F
160
160
150
225
H1
320
320
400
500
H2
200
200
G
157.5
226
E
264
264
405
455
Table 2: Power and weight
Cooler type
Drive
[V]
OAC300 eco -02
OAC400 eco -02
OAC500 eco -02
OAC600 eco -02
24
Please observe protection
note ISO 16016.
Drive
[kW]
Speed
[rpm]
Amperage
[A]
0.4
3400
11
Protection
class
Fan Ø
[mm]
305
IP 65
0.34
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Verified:
2570
13
2017-01-02 Sho/Pz
2017-05-19 Pz
380
Replacing:
Replaced by:
Weight
[kg]
20
21
34
48
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
2
Advice
2.1
General advice
KTR-N
Sheet:
Edition:
43212 EN
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2
Please read through these operating/assembly instructions carefully before you assemble the oil/air 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 oil/air
cooler. The copyright for these operating/assembly instructions remains with KTR.
2.2
STOP
!

2.3
STOP
Safety and advice symbols
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.
General hazard warnings
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 performed taking into account "safety first".
 Please make sure to switch off the power pack before you perform 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 fuse for current supply.
 Do not reach into the operation area of the machine as long as it is in operation.
 Please secure the rotating drive components against accidental contact. Please provide for the necessary
protection devices and covers.
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2017-05-19 Pz
Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
2
Advice
2.4
Intended use
KTR-N
Sheet:
Edition:
43212 EN
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You may only assemble and disassemble the oil/air cooler if you
 have carefully read through the operating/assembly instructions and understood them
 had technical training
 are authorized by your company
The oil/air cooler may only be used in accordance with the technical data (see chapter 1). Unauthorized
modifications on the oil/air 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 oil/air cooler series OAC eco 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 can be stored at a dry and roofed place for 6 - 9
months.
!
3.2
!
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 %.
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 differently each depending on size, quantity and kind of transport. Unless otherwise
contractually agreed, packaging will follow the in-house packaging specifications of KTR.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-01-02 Sho/Pz
2017-05-19 Pz
Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
43212 EN
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2
Assembly
The oil/air cooler series OAC eco is supplied ready for assembly.
4.1
Components of oil/air cooler
Component
1
2
3
4
5
6
7
8
9
10
11
Quantity
1
1
1
6
6
12
4
4
1
1
1
Description
Cooling element
Fan cover
Fan
Hexagon screw
Nyloc nut
Disk
Hexagon screw
Washer
Stand
Gasket
Sealing lip
Component
12
13
Quantity
1
1
14
1
15
1)
16
1)
17
1)
18
1)
19
1)
20
1)
21
1
5
5
2
1
1
1
Description
Type plate
Connection sheet metal
TFSC (Temperature Fan
Speed Control)
PT100 temperature sensor
Base for cable ties
Cable ties
Ferrule
Connection cable PT 100
Adapter Ducon Neutrik
Cable connector Neutrik
1) Components are attached in bulk and are not depicted
Illustration 3: Oil/air cooler; example: OAC300 eco

Illustration 4: Oil/air cooler; example: OAC500 eco
Before installing the oil/air coolers, please assemble the feet supplied separately by means
of the cap screws. Tighten the cap screws by a suitable torque key to the tightening torques
TA mentioned in table 3.
Table 3: Cap screws DIN EN ISO 4762
Cooler type
Screw size M
Tightening torque TA [Nm]
Please observe protection
note ISO 16016.
Drawn:
Verified:
OAC300 and OAC400
M8
11
2017-01-02 Sho/Pz
2017-05-19 Pz
OAC500 and OAC600
M10
22
Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
4
Assembly
4.2
Place of installation
KTR-N
Sheet:
Edition:
43212 EN
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Illustration 5: Oil/air cooler; example: OAC300 eco
In order to achieve the optimum cooling capacity the distance to the nearest wall should not fall below the height
of the cooling element (dimension A), since only in this way a proper air supply is ensured (see illustration 5).

!
!

4.3
The height of installation should not exceed the figure ≤ 1000 m.
Return flow of heated air as well as assembly of the cooling network 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.
Assembly of oil/air cooler
The oil/air cooler can be assembled in various positions,
while the vertical design should be preferred. Sufficient
fastening has to be assured.

Some motors have got covered holes
which serve for draining off condensed
water which may be generated.

Please make sure that the connections
and hoses are adapted to the oil/air
cooler with regard to pressure, flow rate,
temperature and liquidity.
Illustration 6: Oil/air cooler; example: OAC300 eco
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-01-02 Sho/Pz
2017-05-19 Pz
Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
4
Assembly
4.4
Cooling medium
KTR-N
Sheet:
Edition:
43212 EN
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The oil/air cooler is suitable for the use of mineral oil and water-glycol (other media on request).
4.5
Operating pressure and temperature
The maximum operating pressure must not exceed the load of 10 bar during operation.
!
With dynamic load pressure peaks exceeding 7 bar should be avoided.
The maximum permissible temperature of the medium to be cooled must not exceed 100 °C.

4.6
The ambient temperature and the medium to be cooled should not change suddenly. Please
note boiling and freezing point.
Electrical connection

The electric motors may only be connected to the electric supply by qualified personnel.
Please observe the specifications and electrical safety regulations that are generally
admitted!
!
The OAC eco series is exclusively selected for a power supply of 24 V. Incorrect
connections, damaged cables etc. may energize the components connected or make the
electric motor rotate in the wrong direction.

We recommend to use an overload protection for the electric motor.
The fans of the eco cooler series can generally be operated in two ways:
4.6.1 Operation without temperature control TFSC - OAC… eco (24V)/nc
With an operation without TFSC operating unit the motor
must be connected directly with the respective voltage
source and the PWM signal. The scope of delivery
includes the respective mating plug for the motor plug.
Make use of this plug to provide for the connection with
the voltage source and the PWM signal. Please observe
illustration 7 for correct wiring.
Illustration 7: Pin assignment of plug-in connection
Do not remove the plug that is connected directly with the motor cable.
!
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-01-02 Sho/Pz
2017-05-19 Pz
Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
4
Assembly
4.6
Electrical connection
KTR-N
Sheet:
Edition:
43212 EN
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4.6.1 Operation without temperature control TFSC - OAC… eco (24V)/nc
Table 4: Pin assignment of motor
Number
Colour of cable
1
Black
2
Brown
Description
+24V
Mass
2.5
2.5
2
Strength [mm ]
3
Yellow
Control input by
PWM signal
0.75
4
-
5
Blue
-
°
-
0.75
6
White
Error signal
output
0.75
If the control port PWM is connected to 24V as well, the fan will rotate at full speed. If connected to the GND wire,
the fan stops.
4.6.2 Operation with temperature control TFSC - OAC… eco (24V)
The 24V connection feeds the temperature contol TFSC
and is internally connected to the FAN connection for
operating the fan.
Subject to high currents the supply line should have a
2
minimum performance of 2.5 mm .
The fan is connected to the FAN connection via the
adapter cable that is part of the scope of delivery (see
illustration 8).
Table 5: Connector plug for TFSC
Designation
24V
FAN
PT100
Plug type
Neutrik
NAC3FX-W
Neutrik
NAC3MX-W
M12 4 poles.
plug
Specification
24V DC
(20-28V DC)
24V, max. 15A
PT100
Illustration 8
Table 6: Connection of power supply
Connection 24V
NAC3FX-W
24V
GND
Description of
connector plug
L
GND
Specification
20-28V, max. 15A
Mass
Illustration 9
Table 7: Connection of fan
Connection FAN
NAC3MX-W
24V
GND
PWM
Description of
connector plug
L
GND
N
Specification
20-28V, max. 15A
Mass
PWM signal TFSC
Connection of
SPAL motors
Black
Brown
Yellow
Illustration 10
Table 8: Connection of PT100 sensor
Connection of PT100
M12 plug 4 poles
1
1
2
2
Please observe protection
note ISO 16016.
Drawn:
Verified:
Description of
connector plug
1
2
3
4
2017-01-02 Sho/Pz
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Specification
Connection 1
Connection 1
Connection 2
Connection 2
Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
4
Assembly
4.7
Cleaning
STOP
!
KTR-N
Sheet:
Edition:
43212 EN
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Before cleaning please 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.
For cleaning the cooling network the fan may rotate opposite to its usual direction, please observe the advice
specified in chapter 5.2 Operation (reversing operation).
Side of air fins
The air fins can be cleaned with compressed air.
Oil side of cooling element
The oil side of the cooling element is cleaned by flushing with a degreasing agent. Afterwards flush with the
fluid/medium which is used later.
4.8
Diagrammes - pressure loss and power
Diagram 1: Pressure loss
Diagram 2: Power
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2017-05-19 Pz
Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
43212 EN
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Start-up
Please make sure that the oil/air cooler is connected and fastened properly.
Please observe the following procedure:
 Flush the oil/air cooler with the same fluid/medium as the other systems.
 Filter the fluid/medium after flushing.
 The oil/air cooler and the protective grid have to be free from damage.
 The fan needs to rotate freely.
 Hydraulic connections have to be tightened.
 The internal side of the fan housing has to be free from any objects.
Rotating particles may cause danger to life or damage to adjacent components.
STOP
5.1
Temperature control TFSC
The temperature control TFSC (Temperature Fan Speed Control) is part of the cooler series eco and serves for
controlling the motor speed.
The temperature figure of the thermal switch is directly assigned to a motor speed. For different loads various
characteristic curves may be selected.
Apart from the three characteristic curves illustrated the fan can be permanently switched on and off. The
operation Reversing operation shifts the motor into reversing operation during 60 seconds to clean the cooling
network. On termination of this period the operating mode preset is resumed.
During the operation the temperature of the thermal switch connected is permanently displayed.
Illustration 11
Please observe protection
note ISO 16016.
Diagramme 3: Characteristic curve
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2017-05-19 Pz
Replacing:
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KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
5
Start-up
5.2
Operation
The TSFC is operated via 3 buttons. The device is
switched on and off via the button "ON/OFF" and
operates in the control mode set before. You can
switch between the control mode and the setting
mode via the button "MENU". The button "SET"
serves for changing the parameters. The control
mode displays the current temperature of the PT
100 sensor. The setting mode displays the setting
mode selected.
In addition to the five operating modes the
reversing operation can be called by pressing the
SET button for a long time. Here the fan rotates in
opposite direction at full speed for a period of 60
seconds. The reversing operation can only be
activated in the control mode. During the reversing
operation the display counts down the balance of
time in seconds. On termination of the reversing
operation the control mode set before is resumed.
The reversing operation can be interrupted at
every time by pressing the menu button.
KTR-N
Sheet:
Edition:
43212 EN
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2
Control mode (normal operation)
Button MENU
Switching to setting mode
Mode
Display
1
LO
Function
FAN Off
2
A1
Temperature curve 40-50 °C
3
A2
Temperature curve 45-55 °C
4
A3
Temperature curve 50-60 °C
5
HI
FAN 100 %
Button SET
Button MENU
Return to controle mode
Illustration 12
Control mode (normal operation)
Button SET
2 seconds
Reversing operation (60 seconds)
Automatic return to control mode
Illustration 13
6
Maintenance and service
Preventive maintenance operations have to be performed by the user regularly.
The following items have to be reviewed:
 Unusual noise or vibrations must not be generated.
!
With vibrations inspect the screw connection of the motor. If the damage has not been
repaired in this way, please consult with KTR.
 Proper fastening 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 chapter 4.7
Cleaning).
 Inspect the oil/air cooler for damages, defective components have to be replaced.
 Inspect the cooling network for leakages on the oil/air cooler and the screwing on the pipelines.
!
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.
 Inspect the individual components of the device for electrically conductive connections.
 The motor temperature has to be inspected with the device operating.
 The bearings of the motors are permanently lubricated.

Re-lubrication is not possible. Please observe the service life of the motor bearing as per
the data sheet of the motor manufacturer.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-01-02 Sho/Pz
2017-05-19 Pz
Replacing:
Replaced by:
KTR-N dated 2015-11-05
Oil/air cooler
Series OAC eco
Operating/Assembly instructions
6
KTR-N
Sheet:
Edition:
43212 EN
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2
Maintenance and service
Illustration 14:
Examples - type plates
Please make use of the factory fitted motors.
!
7
Spares inventory, customer service addresses
A basic requirement to ensure the readiness for use of the oil/air 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.

8
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.
EC Certificate of incorporation
EC Certificate of incorporation
according to EC machinery directive 2006/42/EC dated May 17, 2006, annex II B
The manufacturer - KTR Systems GmbH, D-48432 Rheine - states that the
oil/air cooler - OAC eco
is an incomplete machine complying with the Machinery Directive 2006/42/EC. The oil/air 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 oil/air cooler as long as it is stated that the machine
which the oil/air cooler is installed in complies with all basic specifications of the Machinery Directive
2006/42/EC.
The oil/air cooler complies with the specifications of the following standards/guidelines:
2006/42/EC
2014/68/EU
2014/30/EU
DIN EN ISO 12100
Rheine,
Place
Machinery Directive (MRL)
Directive for Pressure Equipment (DGRL)
Directive for electromagnetic compatibility (EMV directive)
Safety of machines
2017-01-02
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Christoph Bettmer
Product Manager
2017-01-02 Sho/Pz
2017-05-19 Pz
Replacing:
Replaced by:
KTR-N dated 2015-11-05
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