Buhler ELK Series Owner's manual

Fluidcontrol
Installation and Operation Instructions
Original instructions
Oil/air cooler
ELK
BE350034
08/2022
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2022
Document information
Document No..........................................................BE350034
Version........................................................................ 08/2022

ELK
Contents
1 Introduction.....................................................................................................................................................................................................................2
1.1 Intended use .........................................................................................................................................................................................................2
1.2 Model key...............................................................................................................................................................................................................2
1.3 Scope of delivery ..................................................................................................................................................................................................2
2 Safety instructions ......................................................................................................................................................................................................... 3
2.1 Important advice .................................................................................................................................................................................................3
2.2 General hazard warnings .................................................................................................................................................................................4
3 Transport and storage .................................................................................................................................................................................................. 5
4 Installation and connection ........................................................................................................................................................................................6
4.1 Requirements to the installation site............................................................................................................................................................6
4.2 Installing the unit................................................................................................................................................................................................6
4.2.1 Installing swivel nuts in the fitting body ......................................................................................................................................6
4.3 Hydraulic connection ......................................................................................................................................................................................... 7
4.4 Electrical connections......................................................................................................................................................................................... 7
4.4.1 Electrical connection temperature switch TSA (accessory)......................................................................................................8
5 Operation and control ..................................................................................................................................................................................................9
5.1 Before starting......................................................................................................................................................................................................9
5.2 During starting ....................................................................................................................................................................................................9
6 Maintenance..................................................................................................................................................................................................................10
6.1 Cleaning and disassembly of the cooler matrix........................................................................................................................................11
6.2 Cleaning the cooler matrix inside .................................................................................................................................................................11
6.3 Cleaning the fan case........................................................................................................................................................................................11
6.4 Replacing fan parts............................................................................................................................................................................................11
7 Service and repair......................................................................................................................................................................................................... 12
7.1 Troubleshooting ................................................................................................................................................................................................ 12
8 Disposal ........................................................................................................................................................................................................................... 13
9 Appendices ..................................................................................................................................................................................................................... 14
9.1 Technical data .................................................................................................................................................................................................... 14
9.1.1 Basic data.............................................................................................................................................................................................. 14
9.1.2 Power and pressure loss graphs .....................................................................................................................................................15
9.2 Dimensions ......................................................................................................................................................................................................... 16
9.3 Functional diagram ..........................................................................................................................................................................................16
9.4 Installation torques and clamping range for cable fitting ....................................................................................................................17
9.5 Screw torques ......................................................................................................................................................................................................17
9.6 Hose torques ........................................................................................................................................................................................................17
9.7 Calculations..........................................................................................................................................................................................................17
9.7.1 Calculating viscosity...........................................................................................................................................................................17
9.7.2 Table of operational viscosity for VG oil...................................................................................................................................... 18
9.7.3 Calculating the pressure loss.......................................................................................................................................................... 18
9.8 Pressure loss in straight pipes....................................................................................................................................................................... 19
10 Attached documents .................................................................................................................................................................................................. 20
iBühler Technologies GmbHBE350034 ◦ 08/2022

ELK
1 Introduction
1.1 Intended use
ELK oil/air coolers are used to cool oils in hydraulic and lubrication circuits. Their scope is indicated in the specifications. Any
other applications require the prior approval of Bühler Technologies GmbH.
1.2 Model key
To also have a thermal contact, the specification will be added to the type designation:
Temperature switch T50, T60
T70, T80
Temperature in °C, specification see
separate data sheet
ELK 300-4-50/60Hz-xxx
Number of motor contacts
Frame size
Motor frequency
ELK 300-4-50/60Hz-T50
(on the ELK 600, the 50 and 60 Hz versions are different, see table "Basic data")
1.3 Scope of delivery
– 1 x oil/air cooler
– Product documentation
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2 Safety instructions
2.1 Important advice
Operation of the device is only permitted if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
In this manual, the following warning signs are used:
Warning against hazardous situations Warning against high pressure
Warning against electrical voltage Warning against potentially explosive atmospheres
Warning against hot surface General notice
Warning against environmental hazard Disconnect from mains
Warning against rotating parts Wear protection gloves
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2.2 General hazard warnings
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal,
– compliance with national installation regulations.
– Nearby equipment is EMC protected, e.g. through shielding.
– The current and voltage supply for the aggregate has a (mains) separator with adequate switching capacity. National re-
quirements must be observed.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
– Do not install damaged or defective spare part. If necessary, visually inspect prior to installation to determine any obvious
damage to the spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
CAUTION Hot surface
Burning hazard
Let the device cool down before maintaining.
CAUTION High pressure
Hazard of injury due to flung off parts or oil, environmental hazard due to oil.
a) Before starting any maintenance or repair to the oil circuit, make sure that the device
is depressurized. This applies to the threaded plugs as well.
b) Avoid environmental pollution (oil spills) during cleaning or maintenance of the oil
circuit.
c) Use drip pans.
DANGER Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive at-
mospheres.
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3 Transport and storage
Only transport the product inside the original packaging or a suitable alternative. Ensure secure fastening and mooring.
Air coolers have M8 or M10 eye bolts at the top of the cooler housing for transport. Please note, due to the variety of versions the
mounting bracket is not located at the centre of gravity and the cooler may swing when hoisted.
Only use the motor transport eyes to hoist the motor without add-ons.
Do not use the eye bolts according to DIN 580 in ambient temperatures below -20°C. The eye bolts could fracture in these tem-
peratures, injuring personnel and/or damage the system.
Do not strain the eye bolts more than 45° in the thread direction.
When not in use, the equipment must be protected from moisture and heat. It must be stored in a covered, dry, dust-free room
at room temperature.
WARNING Crushing hazard
Crushing hazard during equipment transport and set-up.
Use the correct hoisting gear to prevent injuries during hoisting.
Be sure the hoisting gear is free from defects and approved for the weight of the device.
Ensure secure fastening and mooring when transporting.
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4 Installation and connection
4.1 Requirements to the installation site
Aggregate
The aggregate must be set up to allow for unobstructed air flow and adequate room for maintenance/repairs. When installed
outdoors, be sure to consider the motor protection rating (standard: IP 55) and ensure adequate protection from the weather.
Air cooler
The cooler must be located in such a way that the air flowing through the matrix has free flow on entry and exit. The distance
between air intake or air outlet to the nearest surrounding obstacle should be at minimum half the height of the matrix. Free
air flow must be provided.If the cooler is to be sited near to working personnel, the effect of hot draught and noise emissions
must be taken into account.
If the cooler is installed in closed space, ensure sufficient air circulation. Avoid back flow of warmed air. If necessary, the room
must be vented.
Due to lower temperatures with respect to closed rooms, the cooling capacity outside raises, but on the other hand higher start
up pressure may result due to higher oil viscosity. In this case, consider a bypass valve and / or a heating.
The rotating fan might lead to static charging. Therefore sensitive equipment like electronics should be kept away from the
device.
4.2 Installing the unit
The units are screwed in place at the attachment points using screws. Be sure the support structure is sized adequately. To pro-
tect the system from damage, the connections must be stress free. We recommend using flexible hoses. Be sure the hose is
stable against negative pressure, e.g. steel wire reinforced. Avoid possible leaks in the circuit to prevent environmental dam-
ages. If necessary, use an oil pan. Protect the aggregate from mechanical impact.
4.2.1 Installing swivel nuts in the fitting body
Proceed as follows:
– Carefully slide the preinstalled pipe end into the 24° cone on the fitting body.
– Tighten the swivel nut until a considerable increase in force can be felt (fixed point).
– Use a suitable spanner to tighten the swivel nut a 1/12 turn more (30°) beyond the fixed point. A marker line on the swivel
nut and the fitting body facilitates observing the correct tightening angle.
Tube
A.D.
Thread Torque (Nm) for straight
screwed plug
Torque (Nm) sealing plug
6 G 1/8" 18 13
8 G 1/4" 35 30
10 G 1/4" 35 30
12 G 3/8" 70 60
15 G 1/2" 90 80
18 G 1/2" 90 80
22 G 3/4" 180 140
28 G 1" 310 200
35 G 1 1/4" 450 400
42 G 1 1/2" 540 450
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4.3 Hydraulic connection
Carry out the hydraulic connection as described in the attached data. Connect the lines stress and vibration free, so typically us-
ing hoses.
Be sure to use suitable lines (with regard to pressure, fluid resistance, environmental influences, fire) when connecting to the
hydraulic-, lubrication circuit. Tighten the hose lines with a suitable torque (see appendix).
Contaminated fluids impact the life of the cooling system, we therefore recommend a purity class of minimum 3/19/13 per
ISO4406.
If your hydraulic system is equipped with control or shut-off valves, we recommend protecting the cooling system with a pres-
sure relief valve. No pressure relief valves are factory installed in the cooler.
When installing an air cooler in return lines, sudden changes to the flow rate can potentially cause significant pressure peaks
which even safety relief valves cannot dampen. The limits for the static pressure must not exceed max. 21bar, or 15bar for dy-
namic pressure peaks. Otherwise an off-line cooler must be used.
4.4 Electrical connections
CAUTION Electrical voltage
Wrong mains voltage may damage the device.
Installation of the device shall be performed by trained staff only. Regard the voltage
given on the type plate. Make sure that the cables have sufficient strain relief.
Fusing
Fusing has to be done due to local standards!
Polarity
Take care of the directional rotation of the motor. The fan rotates counter clockwise
when regarded form the motor’s side!
Watch the direction arrow on the sticker.
The direction of rotation can be changed by reversing any two phases.
Use the applicable local regulations to determine the safety values and the cross-sections of connection leads. The motor and, if
equipped, starting devices must be connected to protective earth.
Lead fuses protect the cables in case of a short circuit, but are not sufficient to protect the motor coils from burning due to over-
load. Therefore, install an adequate motor circuit breaker with high precision range of adjustment for thermal protection to pro-
tect the motor against overload and operation with two phases
Adjust the motor circuit breaker according to the nominal value specified on the type plate of the motor. Operation outside the
specified mains voltage and frequency range limits is prohibited.
Take appropriate measures to protect energised parts from being touched by persons and/or interference from foreign objects.
The operator of the equipment is responsible for ensuring lightning protection.
Connect the protective earth of the motor to the protective earth on site. Protective earth per DINVDE0100 must be connected
to the marked earth lead terminal.
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4.4.1 Electrical connection temperature switch TSA (accessory)
The temperature switch TSA is installed in a cooling circuit with an oil/air cooler ELK as a typical application. Through reaching
the switching temperature the fan-motor is switched-on and the oil will be cooled. After falling under the hysteresis the motor
shuts off.
If the cooling matrix has an optional temperature contact type TSA, the maximum values (see below) must not be exceeded. If
connecting it to a relay, a free wheel circuit has to be added. Carry out the connection according to the following specifications
(numbering inside the connector):
Terminal 1 – 2 Contacts
Terminal 3 Not used
Terminal PE Protective earth
Temperature switch TSA T50
T60
T70
switching temperature 50 °C
60 °C
70 °C
max. voltage 230 V AC/D
max. switching current 2 A, contact load max. 100 VA
switching function NC
Hysteresis approx. 10 °C
protection class IP 65
Example wiring with temperature switch
F1 Fuse K1 Relay
F2 Fuse K2 Circuit breaker
F3 Fuse S1 Protecting device
H1 Mains switch S2 Protecting device
Relay, circuit breaker and protecting devices are not part of the delivery.
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