Installations-, Betriebs- und Wartungshandbuch Installation
Contents
1. Ensure that the cooler is free from leaks Damaged cores or damaged seals must be replaced or repaired immediately Make sure that the warning labels are in good condition Replace any damaged missing label immediately e Check the electrical installation This must be done by a qualified electrician only e Check the cleanliness of the cooling element Dust debris etc will reduce the cooling capacity Clean the cooler if necessary CLEANING Air side A dusty environment might necessitate periodic cleaning of the heat exchanger A contaminated clogged cooling element leads to a reduction of the cooling capacity Its condition should be checked as part of daily weekly monthly inspection ATTENTION Risk of injury Prior to cleaning disconnect all power supplies to the motor ATTENTION The cooler might be hot Please allow it cool down before cleaning The cooling element can be cleaned with a soft brush compressed air or water jet ATTENTION Be careful not to damage the air fins of the element This reduces the performance of the unit When cleaning the exterior of the cooler using water disconnect from power supply Comply with the electric motor protection standard Motor and electronic devices must be protected during the cleaning process The air fins of the core can be cleaned by blowing through with compressed air If necessary a high pressure washing system and degreasing agent can be used A2. 14 19 16 Introduction Symboles Pr paration a l installation Installation Conditions de fonctionnement Avant le d marrage Lors du d marrage Pendant le fonctionnement Monitorage 10 11 Compatibilit du fluide Maintenance et Nettoyage Accessoires Stockage Annulation de la garantie Rapports de test de qualit Garantie et notification des d fauts D E F I SP 5 813 B0 06 11 CONTENUTO 1 Introduzione 2 Simboli 3 Preparazione per l installazione CONTEN IDO 4 Installazione Lia _ 5 Condizioni ea uccion di funzionamento 2 Simbolos 6 Prima dell accensione 3 Preparar la instalaci n 7 Accensione sea Instala 8 Durante E il funzionamento 5 Condiciones de funcionamiento 9 Monitoraggio 6 Antes de la puesta 10 Compatibilit en servicio del fluido 7D tel t Durante la puesta 11 Manutenzione re oe e pulizia 8 Durante 12 Accessor el funcionamiento 13 Magazzino 9 Supervisi n 14 Esonero 10 Compatibilidad di responsabilit de fluidos 15 Rapporto test 11 Mantenimiento collaudo y limpieza 16 Garanzia e notifica 12 Accesorios di errore 13 Almacenaje 14 Exoneraci n de responsabilidad 15 Informes de pruebas de calidad 16 Garant a y notificaci n de aver as VE co oO a oO m m co LO a v LL LU a 4 gt eD Installation Operation and Service Manual For
3. Installations Betriebs und Wartungshandbuch Installation Operation and Service Manual Installation operation et service manual Manuale di installazione d uso e di manutenzione Instalacion funcionamiento y manual de mantenimiento OK EL OKA EL OKAF EL OK ELC OK ELD OK ELH OK EL MI OK P SC SCA SCAF OSCA OSCAF CMS WT es ae co o a mM 2 LO a N xs LL LU x A N D E F I SP 5 813 B0 06 11 111718 HYDAC AG Hydac AG Zweigniederlassung Mezzovico Industriale 3 Via Sceresa CH 6805 Mezzovico Tel 41 91 93 55 700 Fax 41 91 93 55 701 e mail info hydac ch Web www hydac com Einbauerklarung nach Maschinenrichtlinie 2006 42 EG Declaration of Incorporation acc to Directive 2006 42 EG Firma HYDAC AG Zweigniederiassung Mezzovico Company Anschrift Zona Industriale 3 Via Sceresa address CH 6805 Mezzovico Tel 41 91 935 57 09 als Hersteller erkl rt f r folgendes Produkt unvollst ndige Maschine as manufacturer declares for the following product partly complete machinery Bezeichnung W rmetauscher Modell OK ELD OK EL OKA EL OKAF EL OK ELC designation Coolers model OK ELH SC SCA SCAF OK P OSCA OSCAF CMS WT OKELMI dass die grundlegenden Anforderungen der 0 g Richtlinie anwendbar sind und soweit f r die unvollst ndige Maschine zutreffend eingehalten werden that the essential requirements of the a m directive are ap
4. OIL Mineral HL HLP HLVP according to DIN 51524 Synthetic MIL H SKYDROL EHC according to CETOP RP 77H High viscosity HFD Ecological HETG HEPG HEE according to CETOP RP 77H Phosphate ester HFD R HFD U according to CETOP RP 77H WATER Oil water HFA according to CETOP RP 77H Water oil HFB according to CETOP RP 77H Water glycol HFC according to CETOP RP 77H ATTENTION For all other fluids please contact our Technical Department For coolers equipped with pump and pump amp filter respectively OKA OKAF SCA SCAF OSCA OSCAF please contact the Technical Department before using the above mentioned fluids ATTENTION For all mixture percentages HFA HFB HFC please contact our Technical Department Ta Ro O 2 O n 3 aL a O a N 2 Ta LU A i 11 MAINTENANCE AND CLEANING HYDAC coolers generally require low maintenance if installed and used properly The following instructions are only a guideline as individual operating conditions will determine the appropriate interval for cleaning and maintenance PREVENTIVE MAINTENANCE The following preventive maintenance should be carried out at regular intervals to ensure long lifetime Check the cooler is not damaged Replace damaged components immediately contact our After Sales Department e Check for abnormal noise or unusual vibrations Ensure the cooler is securely mounted e Check the mounting bolts are securely tightened
5. Cooler Types OK EL OKA EL OKAF EL OK ELC OK ELD OK ELH OK EL MI OK P SC SCA SCAF OSCA OSCAF CMS WT INTRODUCTION This manual is a guide for the installation maintenance and operation of HYDAC coolers To obtain the maximum efficiency optimize the performance and prevent incorrect use we strongly recommend that this entire manual is read carefully and all safety precautions are implemented before starting installation and putting the cooler into service This manual must be available at all times it is a part of the product If lost the manual should be replaced immediately The cooler may not be used for any purpose other than cooling fluids in accordance with the guidelines and instructions set out in this manual This manual illustrates a typical installation procedure for a cooler Some common options are also included Refer to separate installation drawings for additional optional equipment Review all manuals and drawings prior to assembly These documents are located inside the cooler packing carton Contact your HYDAC sales representative if questions arise SYMBOLS ATTENTION Failure to follow the indicated instruction can endanger personal safety WARNING In addition to possible serious injury or death failure to follow the indicated instruction may cause damage to equipment DANGER Failure to follow the indicated instruction may result in serious injury or death oe O 2 O n 3
6. 1 5 5 und 1 5 9 Dokumentationsbevollm chtigter Representative for documentation Name Dr P Fenyo Erich B r Anschrift HYDAC AG Zweigniederlassung name address Zona3 Via Sceresa e mail erich baer hydac com piero fenyo hydac com ER MEZ Ausstellungsort datum Mezzovico 01 01 2011 place date Funktion des Unterzeichners General Managers role of signee Name des Unterzeichners Dr P Fenyo Erich Bar name Unterschrift e a a signature gt Remark This declaration is a translation of the English original edition In case of any conflicts the English version shall prevail INHALT CONDO OO Aa 16 Einleitung Symbole Vorbereitung der Installation Installation Betriebsbedingungen Vor der Inbetriebnahme Bei Inbetriebnahme Wahrend des Betriebs Uberwachung 10 11 12 13 14 15 Medienvertr glichkeit Wartung und Reinigung Zubeh r Lagerung Haftungsausschluss Qualit tspr fungs berichte Gew hrleistung und Meldung von Defekten CONTENTS _ O O ON OO A ow n nm AIROLA oak Ww Nd Introduction Symbols Preparing for Installation Installation Operating Conditions Before Start Up At Start Up During Operation Monitoring Fluid Compatibility Maintenance and Cleaning Accessories Storage Disclaimer Quality Test Reports Warranty and Notification of Faults CONTENU 12 13
7. aL a O a N 2 Ta LU A ab al DE Re O 2 O m 3 So a o a 49 2 Ti LU QO 6 gt PREPARING FOR INSTALLATION HANDLING THE UNIT ATTENTION Sharp edges splinters and exposed fasteners can cause injuries Only properly trained and qualified technicians wearing appropriate headgear gloves and shoes should move lift unpack or prepare the unit for installation WARNING Risk of handling a unit heavier than 25kg 55lb improper lifting can cause injuries and equipment damage A lifting device or two properly trained amp qualified persons are required to lift or move the cooler When unpacking and handling the unit exercise extra care to prevent damage HYDAC recommends using a forklift or pallet jack to lift and move the cooler while it is still in its packaging If multiple units are delivered they can be shipped on the same pallet A pallet jack will be required to move these units to the installation location Do not move the pallet without lifting it otherwise it may be damaged e If using a forklift or pallet jack ensure that the fork length is suitable to safely move the packaged unit HYDAC recommends that the unit is kept in the protective packaging until it has been moved to the installation site Do not lift the unit any higher than 0 15m 6 in while moving it If it must be lifted higher than 0 15m 6 in exercise great care and keep all persons who a
8. as possible with suitable shock absorber elements and by using flexible connections see the Accessories Catalogue The cooler should be fixed to a stable surface using the bolt holes in the feet or in the cooling element Unrestricted airflow should always be ensured Please refer to the dimensions W1 amp W2 in the product catalogues for recommended clearances for the air inlet and outlet In closed rooms sufficient ventilation must be provided to prevent a rise in room temperature as a result of heated air dispelled by the cooler In case of doubt ventilation between the cooler and the outside air should be assured by installing ventilation ducts The size of the ducts must correspond at least to the frontal area of the cooler Inappropriate location of the cooler could reduce cooling capacity and increase noise level If mounted in a contaminated environment dust oil etc dirt will accumulate on the cooling surface therefore reducing cooling performance In this case frequent cleaning must be carried out Connect the cooling element using flexible hydraulic hoses and hydraulic threaded connections The inlet and outlet of the hydraulic connections are clearly labeled IN amp OUT Make sure that all connections and hoses are sized according to the working parameters pressure flow temperature and type of fluid Please refer to Table 1 for the max permitted torque rating on all the available threaded connections If
9. cooler with a preserving fluid and sealing the ports The preserving fluid see 10 must be removed completely before using the cooler again If necessary use a suitable cleaning agent Table 1 Max permitted torque rating on the threaded connections Thread Type Torque Nm Ya G 40 Y G 100 Y G 140 1 G 220 14 G 300 G 340 za 440 M6 x 1 0 10 M8 x 1 0 20 M10 x 1 0 20 M12 x 1 5 30 M14 x 1 5 50 M22 x 1 5 150 Ta Ke o o n m co te a 09 UL LU lt lt a N oO 14 DISCLAIMER ATTENTION The operating conditions and installation instructions described in this manual are the basis for safe working practice and should not be deviated from without HYDAC s permission HYDAC is not responsible for any damage due to external causes including but not limited to improper use problems with electrical power accident neglect alteration repair improper installation or improper testing Any change to the product shall invalidate the warranty ATTENTION If HYDAC labels and marks are removed or become illegible then all warranty claims shall be invalid HYDAC labels may not be changed or removed The customer must ensure traceability HYDAC reserves the right to make technical modifications without prior notice IMPORTANT Please contact us in case of faults To resolve faults without our prior written consent shall invalidate the warranty Check that the connectio
10. d vibrations 8 DURING OPERATION IMPORTANT The customer must ensure that the product is used according to this manual The customer must check that once the cooler is installed and running the operating conditions of the cooler correspond to the specified values and are not exceeded WARNING It is not permitted to use HYDAC coolers in potentially explosive areas unless the coolers have adequate ATEX certification DANGER Disregarding the warning above can cause danger to life amp limb and damage to the system ATTENTION Risk of severe burns The cooler can become extremely hot during operation Ensure that the unit is cool before touching gt gt gt Do not overload the electric motor see label on the electric motor Wear ear protection when standing in the immediate vicinity of a running cooler for long periods of time VE Ce o o m m co le a 49 LL LU a 9 MONITORING Check the specified temperatures of the fluid after commissioning If these values are not stable and the system reaches excessive temperatures please check the following Fan direction of rotation fan rpm if possible Electrical connections e Thermostats and pressure bypass valves Cooling air flow and direction if possible Fluid flow rate e O temperatures of fluid and air e Cleanliness of the cooling element surfaces e Maximum pressure of the system 10 FLUID COMPATIBILITY
11. ns are correct and the oil is flowing freely 15 QUALITY TEST REPORTS All HYDAC cooler units are subject to a final quality test The quality test report is available on written request 16 WARRANTY AND NOTIFICATION OF FAULTS AII coolers sold are subject to the HYDAC GENERAL CONDITIONS OF SALE AND DELIVERY Any notification of fault under warranty should be advised in writing using the HYDAC Complaints Form Q002 available on request We will not accept liability for improper usage Any changes and or repairs carried out on products in order to resolve faults without our prior written consent shall invalidate the warranty VE Ce o o m m co to a 49 LL LU a
12. plicable and as far as applicable for the partly complete machinery will be adhered Risikobeurteilung und analyse werden nach Anhang 2006 42 EG Artikel ausgef hrt Risk assessment and analysis are implemented according to appendix 2006 42 EG Die speziellen technischen Unterlagen gem Anhang VII Teil B Richtlinie 2006 42 EG wurden erstellt und werden der zust ndigen Beh rde auf begr ndetes Verlangen elektronisch bermittelt Relevant technical documentation in accordance with appendix VII part B directive 2006 42 EG were provided and are conveyed electronically to the responsible authority on justified demand Die Inbetriebnahme ist so lange untersagt bis festgestellt ist dass die Maschine in die die unvollst ndige Maschine eingebaut werden soll den Bestimmungen der 0 g Richtlinien entspricht The operating is not permitted until it is ascertained that the machine into which the partly complete machinery is to be built in corresponds to the regulations of the a m directives Bemerkungen Remarks Folgende Anforderungen der Richtlinie Maschinen 2006 42 EG wurden ber cksichtigt Anhang Artikel 1 1 2 1 1 3 1 1 5 1 2 1 1 3 1 1 3 2 1 3 3 1 3 4 1 3 6 1 3 7 1 3 8 1 1 3 8 2 1 4 1 1 4 2 1 1 5 2 1 5 4 1 5 5 und 1 5 9 According to the machinery directive 2006 42 EG appendix I articles 1 1 2 1 1 3 1 1 5 1 2 1 1 3 1 1 3 2 1 3 3 1 3 4 1 3 6 1 3 7 1 3 8 1 1 3 8 2 1 4 1 1 4 2 1 1 5 2 1 5 4
13. pressure washer must be set to moderate working pressure and the water jet stream should be directed parallel to the cooling air fins vertical to the cooler face area to prevent any damage Cleaning agents can increase the cleaning effect Please note that any detergent must be compatible with aluminum VE O 2 O en 3 SE a o a 49 2 Ti LU A 12 13 Filter side OKAF SCAF OSCAF coolers are fitted with an oil filter element Its contamination must be monitored Please refer to the oil filter instruction manual for cleaning and changing instructions ACCESSORIES On customer request various accessories e g AITR AITF AITF RS AITF RE AITF SS IBP IBT FU GP ESC EL BOX can be mounted on HYDAC coolers For further technical details and available accessories for each cooler type please refer to our Accessories Catalogue available on request STORAGE HYDAC coolers must be stored in dry conditions constant temperature and constant humidity Fluctuations in temperature from cold to warm and vice versa must be avoided This may result in condensation and cause potential corrosion problems When storing for less than one year we recommend flushing inside the cooling element with a suitable preserving fluid which is compatible with aluminum see 10 Take into account the intended operating fluid Always seal the ports When storing for more than one year HYDAC recommends filling the
14. re not involved in moving the unit at least 5m 16 ft away e Do not use devices other than those already described to handle the cooler UNPACKING HYDAC COOLERS Do not unpack HYDAC coolers before moving them to their final installation location Once at the location 1 Cut the plastic straps 2 Open the packing carton on the opening side 3 Remove all protective material from the package 4 A properly trained person can now lift the cooler from the package and install it WARNING For units heavier than 25kg 55lb there is the risk of them falling over causing personal injury or property damage Do not leave a cooler standing unattended on its side or end without adequate support to prevent it from falling over The cooler must be stabilized at all times or laid flat on protective material until it is installed INSTALLATION NOTE Improper installation can cause equipment damage HYDAC coolers must be installed by properly trained and qualified personnel Any operating personnel must be instructed according to this manual No cutting or drilling operations are necessary in order to install the cooler The cooler should preferably be installed vertically on the mounting feet This is the recommended configuration Other configurations must be discussed with HYDAC If strong vibration is expected during operation particularly on mobile applications the cooler must be decoupled from the machine as far
15. ted above WARNING The product must not be subject to vibration levels exceeding 4 5 mm s on each axis BEFORE START UP Before starting the cooler e Check that the cooler is securely mounted and correctly connected e Check that all cooler parts are free from damage e Check that the fan rotates freely e Check that inside the housing there are no parts that could be thrown around and cause injuries to persons or damage to property e Check that all electrical connections are made according to the motor data sheet inside the terminal box e Check that the cooler is fitted with an earthing system e Check that hoses are properly attached and tight refer to Table 1 for the max permitted torque rating on the threaded connections HYDAC recommends the following e Operate the cooler only with fluids listed under 10 Filter the fluid before it passes through the cooler Ta Ro O 2 O n 3 aL a O a N 2 Ta LU A Ce 7 AT START UP Ensure The correct fan rotation as indicated on the adhesive label on the housing Incorrect rotation may damage the cooler permanently and or reduce its cooling capacity The correct air flow direction as indicated on the label on the housing That the hoses are properly attached with no leaks The correct voltage current absorption frequency operating system pressure where applicable e That the cooler is free from abnormal noise an
16. the unit is installed outside sufficient protection against the weather should be provided electric motors in particular must be protected against climatic influences Ta Ro O 2 O n 3 aL O a 09 2 Ta LU A i VE 2 S m 5 sE o a v 2 ma LU a 8 COOLERS WITH PUMP The maximum suction pressure for coolers fitted with pumps is 0 4 bar Please ensure adequate sizing of the suction pipe hose for this value internal diameter length and pressure drop The coolers should be installed close to the tank level or below Installations above the tank level gt 2 5 m are possible but must be discussed with HYDAC ATTENTION PLEASE NOTE UNITS WITH PUMPS MUST NEVER OPERATE WITH CLOSED CONNECTIONS A short dry run with open connections to check the direction of rotation will not cause any damage COOLERS WITH HYDRAULIC MOTOR The hydraulic motor has a drain port which must be connected to the tank COOLERS WITH DC MOTOR Check the correct electrical connection positive and negative as indicated on the connectors and the applicable voltage The current draw at nominal voltage values the recommended fuse and the IP protection are indicated in the product catalogue ATTENTION Please ensure that voltage and frequency correspond to the information on the label For the ELD and CMS series the power supply must be rectified and stabilized in order to achie
17. ve the maximum service life The product must be powered with the nominal voltage that is 10 of the recommended voltage 12 V 24 V DC with a residual ripple value lower than 1 0 COOLERS WITH 3PH AND 1PH MOTOR The 3 phase motors for the OK OKA OKAF EL OK EL MI SC SCA SCAF OSCA OSCAF series are multi voltage 50 60Hz with protection class IP55 The single phase and 3 phase motors of the ELC series are single voltage 50Hz or 60Hz with protection class IP55 The electrical connection must be made according to the regulations of the country of installation and the information within the electric motor terminal box Pb OPERATING CONDITIONS The following operating conditions should never be exceeded e Min Max process liquid temperature 20 to 130 C e Min Max ambient temperature 20 to 40 C for standard coolers e Viscosity See product catalogue in accordance with the configuration e Max dynamic working pressure for oil coolers please refer to the data label on the cooler e Cleanliness class ISO 4406 1999 17 15 12 NAS 6 To reduce the effect of pressure peaks and or cold start problems on the cooling element optional devices IBP IBT can be used together with special cooling elements see Accessories Catalogue ATTENTION These devices cannot provide complete protection for the cooling element The customer must check that pressure peaks do not exceed the values indica
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