KTR-Group OPC Series Operating And Assembly Instruction Manual Download Page 1

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Oil/air cooler

Series OPC

Operating/Assembly instructions

KTR-N
Sheet:
Edition:

43211 EN
1 of 20
5

Please observe protection

note ISO 16016.

Drawn:

2019-10-23 Pz/Str

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-11-04 Pz

Replaced by:

Oil/air cooler

series

OPC

according to directive 2014/34/EU

Oil/air cooler; example: OPC200 to 400

Oil/air cooler; example: OPC500 to 700

Oil/air cooler; example: OPC800 to 1000

Summary of Contents for OPC Series

Page 1: ...ase observe protection note ISO 16016 Drawn 2019 10 23 Pz Str Replacing KTR N dated 2017 01 02 Verified 2019 11 04 Pz Replaced by Oil air cooler series OPC according to directive 2014 34 EU Oil air cooler example OPC200 to 400 Oil air cooler example OPC500 to 700 Oil air cooler example OPC800 to 1000 ...

Page 2: ...s of oil air cooler 8 4 2 Place of installation 9 4 3 Assembly of oil air cooler 10 4 4 Operating pressure and temperature 10 4 5 Electrical connection 11 4 6 Cooling medium 11 4 7 Cleaning 12 4 8 Standard marking of oil air cooler 12 4 9 Assembly disassembly of the oil air cooler into components 12 5 Start up 13 6 Maintenance and service 13 7 Spares inventory customer service addresses 14 8 Enclo...

Page 3: ...12D 0 75kW 16 7 0 14 OPC200 16D 0 75kW 21 4 0 15 596 OPC300 4D 0 75kW 5 5 0 20 446 550 615 65 300 OPC300 12D 0 75kW 16 7 0 22 OPC300 16D 0 75kW 21 4 0 24 638 OPC400 4D 0 75kW 5 5 0 24 446 550 645 95 300 OPC400 12D 0 75kW 16 7 0 26 OPC400 16D 0 75kW 21 4 0 28 668 OPC400 32D 0 75kW 42 7 0 34 720 Type of cooler Dimensions mm Weight kg F H I J K L M N OPC200 4D 0 75kW 115 360 174 530 100 330 426 G 35 ...

Page 4: ... 0 40 460 740 740 94 405 OPC500 25D 2 2kW 33 4 0 48 OPC500 32D 2 2kW 42 7 0 50 790 OPC500 40D 2 2kW 53 5 0 52 OPC600 16D 2 2kW 21 5 0 65 607 840 819 94 455 OPC600 25D 2 2kW 33 4 0 68 OPC600 32D 2 2kW 42 7 0 70 868 OPC600 40D 2 2kW 53 5 0 73 OPC700 40D 2 2kW 4 5 1435 56 0 0 77 608 990 973 530 Type of cooler Dimensions mm Weight kg F G H I J K L M N OPC500 16D 2 2kW 150 157 5 657 130 720 30 330 0 54...

Page 5: ... 4kW 112 1 15 1130 OPC850 80D 5 5kW 12 970 72 1 12 870 1002 1046 95 523 OPC850 100D 5 5kW 113 1 32 1081 OPC850 125D 5 5kW OPC900 80D 5 5kW 72 1 34 995 1312 1046 678 OPC900 100D 5 5kW 113 1 71 1081 OPC900 125D 5 5kW OPC1000 125D 5 5kW 113 1 88 1119 113 OPC1000 180D 5 5kW 167 2 33 1136 Type of cooler Dimensions mm Weight kg F G H I J K L M N OPC800 50D 4kW 350 340 920 280 670 20 292 829 SAE 2 112 OP...

Page 6: ...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 ...

Page 7: ...s The oil air cooler series OPC described in here corresponds to the technical status at the time of printing of these operating assembly instructions 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 la...

Page 8: ...R N dated 2017 01 02 Verified 2019 11 04 Pz Replaced by The oil air cooler series OPC is supplied ready for assembly Component Quantity Description 1 1 Oil air cooler Type OPC Illustration 4 Oil air cooler example OPC200 to 400 Illustration 5 Oil air cooler example OPC500 to 700 Illustration 6 Oil air cooler example OPC800 to 1000 4 Assembly 4 1 Components of oil air cooler ...

Page 9: ...ptimum 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 7 and 8 The height of installation should not exceed the figure 1000 m Return flow of heated air as well as assembly of the cooler core in front of heat sources should be avoided The engines have to be pr...

Page 10: ...ple OPC200 to 1000 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 for use With the inspection of the ROTEX coupling see KTR N 40210 disassembly or assembly of the bellhousing has to be performed in accordance with KTR N 41010 The maximum sta...

Page 11: ...ly with the arrows specified 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 Incorrect connections damaged cables etc may energize the components connected or make the electric motor rotate in the wrong direction The cooler has a separate g...

Page 12: ...d 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 fluid medium which is used later The oil air cooler of series OPC is marked as follows Illustration 11 Examples type plates The cooler is assembled by KTR The oil air cooler is s...

Page 13: ...f the fan housing has to be free from any objects STOP Components which are hurled may cause personal injuries damage other components or generate sparking 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 With vibrations inspect the screw connection of motor and pump If the damage ...

Page 14: ... 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 The bearings must be inspected maintained and replaced if necessary as per the specifications of the motor manufacturer We recommend to store major spare parts on site to ensure the readiness for use of the machin...

Page 15: ...ss IIA and IIB are included in IIC Temperature class Temperature class max perm medium temperature T3 80 C including gases and vapours of temperature classes T2 and T1 T4 80 C T5 80 C T6 68 C Explanation The permissible ambient temperature Ta for the use of oil air coolers is intended from 20 C to 55 C Subject to the operation the medium temperature may be considerably higher than the ambient temp...

Page 16: ...s as follows Oil air coolers OPC Year II 2G Ex h IIC T6 T3 Gb II 3D Ex h IIIC T68 C T110 C Dc 20 C Ta 55 C KTR Systems GmbH Carl Zeiss Straße 25 D 48432 Rheine Illustration 12 Examples type plates Short marking A short marking is only made if not possible differently for reason of space or functioning Oil air coolers OPC Year Deviating marking applies until 31st October 2019 Short marking II 2G c ...

Page 17: ...the cooling element and pump have to be tested for leakages after start up The electric motor is to be connected such 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 place marked equipotential bonding of cooler Inspect the oil motor for leakages Leakages have to be eliminated immediately Oil...

Page 18: ... 3 8 mm corresponds to 1 OPC600 to OPC700 520 5 2 mm corresponds to 1 OPC800 630 6 3 mm corresponds to 1 OPC850 750 7 5 mm corresponds to 1 OPC900 to OPC1000 900 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 specified in the type label have to be definitely observed Only those accessories cert...

Page 19: ...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 Machinery Directive MD 2014 ...

Page 20: ... general safety and health requirements according to enclosure II of directive 2014 34 EU The oil air cooler described in here complies with the specifications of the following standards rules DIN EN ISO 80079 36 DIN EN ISO 80079 37 IEC TS 60079 32 1 DIN EN 14986 The oil air cooler complies with the specifications of the directive 2014 34 EU According to article 13 1 b ii of directive 2014 34 EU t...

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KTR-Group OPC Series, Operating And Assembly Instruction Manual

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