Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
1 of 14
1
Please observe protection
note ISO 16016.
Drawn:
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Replacing:
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Verified:
2020-03-30 Pz
Replaced by:
Oil/air cooler
series
OPC2
Oil/air cooler; example: OPC2-300 and OPC2-400
Oil/air cooler; example: OPC2-500 to OPC2-900
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
2 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
---
Verified:
2020-03-30 Pz
Replaced by:
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.
1 Technical data 3
2 Advice 5
2.1 General advice 5
2.2 Safety and advice symbols 5
2.3 General hazard warnings 5
2.4 Intended use 6
3 Storage, transport and packaging 6
3.1 Storage 6
3.2 Transport and packaging 6
4 Assembly 7
4.1 Components of oil/air cooler 7
4.2 Place of installation 8
4.3 Assembly of oil/air cooler 9
4.4 Operating pressure and temperature 9
4.5 Electrical connection 10
4.6 Cooling medium 10
4.7 Cleaning 11
4.8 Standard marking of oil/air cooler 11
4.9 Assembly - disassembly of the oil/air cooler into components 11
5 Start-up 12
6 Maintenance and service 12
7 Spares inventory, customer service addresses 13
8 EC Certificate of incorporation 14
Table of contents
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
3 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
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Verified:
2020-03-30 Pz
Replaced by:
Type OPC2-300 and OPC2-400
Illustration 1: OPC2-300 and OPC2-400
Table 1: Dimensions - Type OPC2-300 and OPC2-400
Type of cooler
Voltage
Engine
coolers
Engine
pump
l/min.
kW/°C
Dimensions [mm]
Current*
[A]
Speed
[rpm]
Current*
[A]
Speed
[rpm]
A
B
C
D
E
OPC2-300-4
230/400V
50 Hz
(460V
60 Hz)
1.03
1385
1.03
1385
5.5
0.13
446
570
417
65
320
OPC2-300-12
17
0.21
OPC2-400-16
1.77
1420
21.6
0.27
95
OPC2-400-32
44
0.36
Type of cooler
Dimensions [mm]
Weight
[kg]
F
G
H
I
J
K
L
M
N
O
P
Q
OPC2-300-4
160
160
500
200
720
30
330
G ¾“
SAE
1 ½“
23
51
70
53
OPC2-300-12
OPC2-400-16
G 1“
63
OPC2-400-32
SAE
1 ½“
66
* Basis 400V
1 Technical data
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
4 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
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Verified:
2020-03-30 Pz
Replaced by:
Type OPC2-500 to OPC2-900
Illustration 2: OPC2-500 to OPC2-900
Table 2: Dimensions - Type OPC2-500 to OPC2-900
Type of cooler
Voltage
Engine
coolers
Engine
pump
l/min.
kW/°C
Dimensions [mm]
Current*
[A]
Speed
[rpm]
Current*
[A]
Speed
[rpm]
A
B
C
D
E
OPC2-500-32
230/400V
50 Hz
(460V 60 Hz)
1.03
1382
1.77
1420
44
0.46
460
740
448
94
405
OPC2-500-63
3.43
1445
88
0.54
OPC2-700-40
1.77
1420
1.77
1420
53.5
0.76
607
990
563
530
OPC2-700-100
4.83
1440
141
0.98
OPC2-900-63
5.3
955
3.43
1445
88
1.50
995
1313
712
678
OPC2-900-100
4.83
1440
141
1.91
Type of cooler
Dimensions [mm]
Weight
[kg]
F
G
H
I
J
K
L
M
N
O
P
Q
OPC2-500-32
150
157.5
670
130
720
30
330
SAE
1 ½“
SAE
1 ½“
23
51
70
74
OPC2-500-63
81
OPC2-700-40
225
226
920
280
795
367.5
SAE
2“
117
OPC2-700-100
SAE
2“
340
139
OPC2-900-63
372.5
390
1270
440
925
20
400
SAE
1 ½“
SAE
3“
227
125
42
235
OPC2-900-100
SAE
2“
206
75
* Basis 400V
1 Technical data
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
5 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
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Verified:
2020-03-30 Pz
Replaced by:
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.
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.
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 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.
2 Advice
2.1 General advice
2.2 Safety and advice symbols
2.3 General hazard warnings
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
6 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
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Verified:
2020-03-30 Pz
Replaced by:
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.
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 %.
!
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.
2 Advice
2.4 Intended use
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
7 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
---
Verified:
2020-03-30 Pz
Replaced by:
The oil/air cooler series OPC is supplied ready for assembly.
Component
Quantity
Description
1
1
Oil/air cooler „Type OPC2“
Illustration 3: Oil/air cooler; example: OPC2-300 and OPC2-400
Illustration 4: Oil/air cooler; example: OPC2-500 to OPC2-900
4 Assembly
4.1 Components of oil/air cooler
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
8 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
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Verified:
2020-03-30 Pz
Replaced by:
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 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.
4 Assembly
4.2 Place of installation
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
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1
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note ISO 16016.
Drawn:
2019-11-21 Pz/Str
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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 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 that 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 KTR-N 40210) disassembly or assembly of the bellhousing has to be performed in accordance with
KTR-N 41010.
The maximum static operating pressure must not exceed the load of 26 bar during operation. With size OPC2-900
the maximum static operating pressure is reduced to 21 bar.
!
With dynamic load maximum torque peaks of 14 bar must not be exceeded.
The maximum permissible temperature of the medium to be cooled must not exceed +80 °C
(standard arrangement). Please consult with KTR for any higher temperatures.
The temperature of the ambiance and the medium to be cooled should not change rapidly.
Please note boiling and freezing point.
4 Assembly
4.3 Assembly of oil/air cooler
4.4 Operating pressure and temperature
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
10 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
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Verified:
2020-03-30 Pz
Replaced by:
Before connecting the motor to the power supply
compare the specifications in the type label (see
illustration 9) 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).
Illustration 8: Torsional direction - fan
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.
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.
The oil/air cooler is suitable for the use of mineral oil, synthetic oil and water glycol.
4 Assembly
4.5 Electrical connection
4.6 Cooling medium
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
11 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
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Verified:
2020-03-30 Pz
Replaced by:
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 fins
The air fins 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 fluid/medium which is used later.
The oil/air cooler of series OPC2 is marked as follows:
Illustration 9:
Examples - type plates
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.
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.
4 Assembly
4.7 Cleaning
4.8 Standard marking of oil/air cooler
4.9 Assembly - disassembly of the oil/air cooler into components
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
12 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
---
Verified:
2020-03-30 Pz
Replaced by:
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.
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 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.
5 Start-up
6 Maintenance and service
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
13 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
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Verified:
2020-03-30 Pz
Replaced by:
• 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 9).
• 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 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.
6 Maintenance and service
7 Spares inventory, customer service addresses
Oil/air cooler
Series OPC2
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
43213 EN
14 of 14
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-21 Pz/Str
Replacing:
---
Verified:
2020-03-30 Pz
Replaced by:
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 coolers - OPC2
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 Machinery Directive (MD)
2014/30/EU Directive for electromagnetic compatibility (EMC directive)
2014/35/EU Low-voltage directive (LVD)
2014/68/EU Directive for Pressure Equipment (PED)
DIN EN ISO 12100 Safety of machines
Rheine,
2019-11-21
i. V.
Place
Date
Christoph Bettmer
Product Manager
8 EC Certificate of incorporation
