KTR Oil/air cooler series OPC2 Operating/Mounting Instructions
KTR Oil/air cooler series OPC2 is a high-performance cooler designed for cooling hydraulic oil, gear oil and lubricating oil. The series features various models from the OPC2-300 to OPC2-900, each with different cooling capacities and dimensions. The device is equipped with a motor and pump, which can be connected to the power supply and configured for various applications.
PDF
Download
Document
Advertisement
Advertisement
Oil/air coolers Series OPC2 Operating/Assembly instructions KTR-N Sheet: Edition: 43213 EN 1 of 14 2 Oil/air coolers series OPC2 Oil/air cooler; example: OPC2-300 and OPC2-400 Oil/air cooler; example: OPC2-500 to OPC2-900 Please observe protection note ISO 16016. Drawn: Verified: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions KTR-N Sheet: Edition: 43213 EN 2 of 14 2 The oil/air cooler series OPC2 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 5 2.1 2.2 2.3 2.4 General advice Safety and advice symbols General hazard warnings Intended use 5 5 5 6 Storage, transport and packaging 6 3.1 3.2 6 6 3 4 Storage Transport and packaging Assembly 7 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 7 8 9 9 10 10 11 11 11 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 12 6 Maintenance and service 12 7 Spares inventory, customer service addresses 13 8 EC Certificate of incorporation 14 Please observe protection note ISO 16016. Drawn: Verified: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 1 KTR-N Sheet: Edition: 43213 EN 3 of 14 2 Technical data Type OPC2-300 and OPC2-400 Illustration 1: OPC2-300 and OPC2-400 Table 1: Dimensions - Type OPC2-300 and OPC2-400 OPC2-300-4 OPC2-300-12 OPC2-400-16 OPC2-400-32 Type of cooler OPC2-300-4 OPC2-300-12 OPC2-400-16 Voltage Motor cooler Current* Speed [A] [rpm] 230/400V 50 Hz (460V 60 Hz) Type of cooler Motor pump Current* Speed [A] [rpm] 1.03 1.03 1385 1385 1.77 F G H I J 160 160 500 200 720 1420 Dimensions [mm] l/min. kW/°C 5.5 17 21.6 44 0.13 0.21 0.27 0.36 Dimensions [mm] K L B C 446 570 417 D 330 G 1“ SAE 1 ½“ E 65 320 95 N O P Q SAE 1 ½“ 23 51 70 G ¾“ 30 OPC2-400-32 * M A Weight [kg] 53 63 66 Basis 400V Please observe protection note ISO 16016. Drawn: Verified: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 1 KTR-N Sheet: Edition: 43213 EN 4 of 14 2 Technical data Type OPC2-500 to OPC2-900 Illustration 2: OPC2-500 to OPC2-900 Table 2: Dimensions - Type OPC2-500 to OPC2-900 OPC2-500-32 OPC2-500-63 OPC2-700-40 OPC2-700-100 OPC2-900-63 OPC2-900-100 Type of cooler OPC2-500-32 OPC2-500-63 OPC2-700-40 OPC2-700-100 Voltage Motor cooler Current* Speed [A] [rpm] 230/400V 50 Hz (460V 60 Hz) Type of cooler 1.03 1382 1.77 1420 5.3 955 Motor pump Current* Speed [A] [rpm] 1.77 1420 3.43 1445 1.77 1420 4.83 1440 3.43 1445 4.83 1440 F G H I J 150 157.5 670 130 720 Dimensions [mm] l/min. kW/°C 44 88 53.5 141 88 141 0.46 0.54 0.76 0.98 1.50 1.91 Dimensions [mm] K L 330 SAE 1 ½“ 367.5 SAE 2“ SAE 1 ½“ SAE 2“ 30 225 226 920 280 795 372.5 390 1270 440 925 OPC2-900-63 20 400 OPC2-900-100 * M A B C 460 740 448 607 990 563 995 1313 712 N SAE 1 ½“ 23 SAE 2“ 340 SAE 3“ O D 405 94 530 678 P Q 51 70 Weight [kg] 74 81 117 139 227 235 125 206 E 42 75 Basis 400V Please observe protection note ISO 16016. Drawn: Verified: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 2 Advice 2.1 General advice KTR-N Sheet: Edition: 43213 EN 5 of 14 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 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 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 operating 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: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 2 KTR-N Sheet: Edition: 43213 EN 6 of 14 2 Advice 2.4 Intended use You may only assemble and disassemble the oil/air 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 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 OPC2 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 roofed place for 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 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. Drawn: Verified: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43213 EN 7 of 14 2 Assembly The oil/air cooler series OPC is supplied ready for assembly. 4.1 Components of oil/air cooler Component 1 Quantity 1 Description Oil/air cooler „Type OPC2“ Illustration 3: Oil/air cooler; example: OPC2-300 and OPC2-400 Please observe protection note ISO 16016. Drawn: Verified: Illustration 4: Oil/air cooler; example: OPC2-500 to OPC2-900 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43213 EN 8 of 14 2 Assembly 4.2 Place of installation Illustration 5: Oil/air cooler; example: OPC2-300 and OPC2-400 Illustration 6: Oil/air cooler; example: OPC2-500 to OPC2-900 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 and 6). ! ! 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: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43213 EN 9 of 14 2 Assembly 4.3 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 engines 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 7). Make sure the connections and hoses are adapted to the oil/air cooler with regard to pressure, flow rate, temperature and liquidity. Illustration 7: Oil/air cooler; example: OPC2-300 to OPC2-900 Motor and pump are supplied by KTR ready for use. With the inspection of the ROTEX ® coupling (see KTRN 40210) disassembly or assembly of the bellhousing has to be performed 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 size OPC2900 the maximum static operating pressure is reduced to 21 bar. ! 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). The temperature of the environment and the medium to be cooled should not change rapidly. Please note boiling and freezing point. Please observe protection note ISO 16016. Drawn: Verified: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43213 EN 10 of 14 2 Assembly 4.5 Electrical connection Before connecting the motor to the power supply compare the specifications in the type label (see illustration 10) of the motor to the voltage, fuse and frequency of the mains. The torsional direction of the fan and the air flow have to comply with the arrows specified on the oil/air cooler (see illustration 8). The electric motors may only be connected to the electric supply by qualified personnel. Please observe the universal specifications and electrical safety regulations! Illustration 8: Torsional direction - fan ! 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. 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 9: Electrical connection- three-phase asynchronous motor 4.6 Cooling medium The oil/air cooler is suitable for the use of mineral oil, synthetic oil and water glycol. Please observe protection note ISO 16016. Drawn: Verified: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 4 KTR-N Sheet: Edition: 43213 EN 11 of 14 2 Assembly 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 carefully and in parallel with the air fin. Oil side of cooling element The oil side of the cooling element is cleaned by flushing with a degreasing agent. Afterwards flush with the liquid/medium which is used later. 4.8 Standard marking of oil/air cooler The oil/air cooler of series OPC2 is marked as follows: Illustration 10: 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 for use. A repair of the cooler by the plant operator/an external fitter is only permissible after written authorization by KTR. During 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: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 5 KTR-N Sheet: Edition: 43213 EN 12 of 14 2 Start-up Please make sure that the oil/air cooler is properly connected and fastened. Please observe the following procedure: • Flush the oil/air cooler with the same liquid/medium as the other systems. • Filter the liquid/medium after flushing. • Vent the cooling element after filling (see illustration 7). • 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 inside of the fan housing has to be free from any objects. • The cooler has to be free 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 performed 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. ! With vibrations inspect the screw connection of motor and pump. If the damage has not been repaired in this way, please consult with KTR. ! During operation please pay attention to changes in operating noise of the ROTEX ® coupling. • 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 item cleaning). • Inspect the oil/air cooler for damages, defective components have to be replaced. • Inspect the cooler core, the pump and the screw connection on the pipeline for 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: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 6 KTR-N Sheet: Edition: 43213 EN 13 of 14 2 Maintenance and service • Inspect distances between fan and protective grid. The fan needs to rotate freely. • Inspect the individual components of the device for 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 10). • 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 for use of the machine in case if a cooler fails. Contact addresses of the KTR partners for spare parts and orders can be obtained from 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: 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 Oil/air coolers Series OPC2 Operating/Assembly instructions 8 KTR-N Sheet: Edition: 43213 EN 14 of 14 2 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 - OPC2 described in the present operating/assembly instructions 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/rules: 2006/42/EC 2014/30/EU 2014/35/EU 2014/68/EU Machinery Directive (MD) Directive for electromagnetic compatibility (EMC directive) Low-voltage directive (LVD) Directive for Pressure Equipment (PED) DIN EN ISO 12100 Safety of machines Rheine, Place 2021-02-15 Date Please observe protection note ISO 16016. Drawn: Verified: i. V. Christoph Bettmer Product Manager 2024-04-29 Ka/Str 2024-04-29 Ka Replacing: Replaced by: KTR-N dated 2020-03-30 ">

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- High-performance cooling
- Compact design
- Suitable for hydraulic, gear and lubricating oil
- Various models with different capacities
- Motor and pump included
- Ready for assembly
- Easy to maintain
Frequently asked questions
The cooler is suitable for cooling mineral oil, synthetic oil and water glycol.
The maximum static operating pressure must not exceed 26 bars (21 bar for OPC2-900) during operation. 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).