Laird OL 4503 User manual

Operation Manual
Oil-Air Cooling Unit OL 4503
Version 2.0

Laird Technologies GmbH
Borsigstrasse 1
D-24568 Kaltenkirchen
www.lairdtech.com
Protection Notice
Dissemination as well as copying of this document, utilization or posting of its contents is not permitted
unless formally granted. Violations entail claims for compensation. All copyrights, including rights due to
patent grant or registration of a utility model or design, are reserved.
All product names used in this manual are trademarks of the corresponding manufacturers.
Technical modifications subject to change.

Table of Contents
3
Laird Technologies GmbH
Operation Manual (Translation)
Date: 06-Jul-2015
Version: 2.0
Oil-Air Cooling Unit OL 4503
1264.00
Table of Contents
1About this Manual............................................................................................................................ 6
1.1 Termsof Guarantee.............................................................................................................................6
1.2 Contact Information..............................................................................................................................7
2Product Identification....................................................................................................................... 8
2.1 Unit Specifications................................................................................................................................8
2.2 Identification Plate................................................................................................................................8
3Safety Regulations........................................................................................................................... 9
3.1 Hazard classes......................................................................................................................................9
3.2 Safety Symbols.....................................................................................................................................9
3.3 Hints for Safe Operation.................................................................................................................. 10
3.3.1 Prevent Hazards .....................................................................................................................................................10
3.3.2 Hints Regarding the Electrical Equipment..............................................................................................................10
3.3.3 Environmental Issues..............................................................................................................................................11
3.3.4 Protective Clothing..................................................................................................................................................11
3.4 Safety Equipment.............................................................................................................................. 11
3.4.1 Safety and Signalling Equipment included in the Unit............................................................................................11
3.4.2 Guards..................................................................................................................................................................... 12
3.4.3 Caution Label.......................................................................................................................................................... 13
3.5 In Case of Accidents......................................................................................................................... 13
4Product Description....................................................................................................................... 14
4.1 Intended Use...................................................................................................................................... 14
4.2 Non-Conformity with the Intended Use........................................................................................ 14
4.3 Unit Components............................................................................................................................... 15
4.4 Specifications...................................................................................................................................... 16
4.5 Setting-up Requirements................................................................................................................. 17
4.5.1 Installation Location.................................................................................................................................................17
4.5.2 Environmental Conditions.......................................................................................................................................17
4.5.3 Infrastructure...........................................................................................................................................................17
5Transport.......................................................................................................................................... 18
5.1 Safety Indications for Transport and Setting-up........................................................................ 18
5.2 Transportation of the unit................................................................................................................. 18
5.3 Unpacking............................................................................................................................................ 18

Table of Contents
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Laird Technologies GmbH
Operation Manual (Translation)
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Version: 2.0
Oil-Air Cooling Unit OL 4503
1264.00
6Initial Operation............................................................................................................................... 19
6.1 Safety Indications Related to Initial Operation........................................................................... 19
6.2 Setting to Work................................................................................................................................... 19
6.2.1 Placement............................................................................................................................................................... 19
6.2.2 Cooling Circuit Connection and Filling.................................................................................................................... 20
6.2.3 Electrical Connections............................................................................................................................................ 22
6.2.4 Carrying out Setting-to-Work.................................................................................................................................. 23
6.3 DailyStart-up ...................................................................................................................................... 23
6.4 Setting-to-Work after Storage......................................................................................................... 23
7Controlling the Unit........................................................................................................................ 24
7.1 Safety Indications for Controlling the Unit ................................................................................... 24
7.2 Switching on the Unit....................................................................................................................... 24
7.3 Switching off the Unit....................................................................................................................... 24
7.4 Settings................................................................................................................................................. 25
7.4.1 Pressure Setting on the Angle-type Safety Valve.................................................................................................. 25
7.4.2 Setting the Thermostat............................................................................................................................................ 26
8Disruptions....................................................................................................................................... 27
8.1 Disrupt Operation............................................................................................................................... 27
8.1.1 Trouble Shooting..................................................................................................................................................... 27
9Maintenance and Cleaning......................................................................................................... 28
9.1 Maintenance Schedule................................................................................................................... 28
9.2 Cleaning of Heat Exchanger........................................................................................................... 28
9.3 Refilling of Coolant............................................................................................................................. 28
9.4 Cleaning of Unit Casing................................................................................................................... 29
10 Repair............................................................................................................................................... 29
11 Dismounting, Disposal, Storage................................................................................................. 30
11.1 Temporary Placing out of Operation............................................................................................. 30
11.2 Re-packaging the Unit...................................................................................................................... 30
11.3 Storing the Unit................................................................................................................................... 30
11.4 Disposal................................................................................................................................................ 31
11.5 Disposal of Operating Materials..................................................................................................... 31
11.6 Return of the Unit toLAIRD............................................................................................................ 31
12 Wear Parts and Spare Parts....................................................................................................... 32

Table of Contents
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Laird Technologies GmbH
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Oil-Air Cooling Unit OL 4503
1264.00
Addendum............................................................................................................................................. 34
Performance chart....................................................................................................................................... 34
Flow scheme................................................................................................................................................. 35
Wiring diagram.............................................................................................................................................. 36
History of Changes
Date
Index
Reason for Change
Name
Page
29-Nov-13
1.0
First version
Edom/Pfeiffer
06-Jul-15
2.0
Spare part numbers changed
Dany/Bitenaite
p. 33

About this Manual
Terms of Guarantee
6
Laird Technologies GmbH
Operation Manual (Translation)
Date: 06-Jul-2015
Version: 2.0
Oil-Air Cooling Unit OL 4503
1264.00
1 About this Manual
This document is the English translation of the original Operation Manual in German language for the Oil-Air
Cooling Unit OL 4503 (called unit in the following). It is based on German safety regulations. In your country
other regulations may apply.
This Operational Manual addresses the needs of the user of the unit. Its intention is to allow the safe
operation of the unit. Thus, it should be read carefully and be kept in a space accessable for the users of the
unit at any time.
All chapters of this Operation Manual can be read independently and thus can be used for look-up purposes.
1.1 Terms of Guarantee
General sale and delivery terms of LAIRD apply. The buyer accepts these terms, at the latest when signing
the contract of purchase.
The particular terms of guarantee and duration of guarantee of the unit in question can be taken from the
contract documents as well as from the order confirmation.
Warranty claims and liability are excluded in case of one of the following situations:
Use of the unit in an unintended way
Inaccurate installation, putting into service, operation, repair or maintenance of the product by people
that are not fully authorized
Use of the product despite of defect, wrongly implemented or non-functional safety devices or
protective gear
Unauthorized or forbidden modifications by the user concerning the electrical equipment of the unit
Unauthorized or forbidden modifications by the user concerning the mechanical structure of the unit
Unauthorized or forbidden modifications by the user concerning the operating parameters
Use of unauthorized tools
Use of unauthorized operating supplies
Exceedance of mandatory maintenance intervals
Cases of disaster caused by foreign matter influence or act of nature beyond control
PLEASE NOTE
Any form of unintended use of the unit and any structural change caused by the user without prior
authorization in written form by LAIRD will lead to the termination of warranty as well the termination of the
declaration of conformation and will free LAIRD from product liability. This concern includes safety devices
as well.
In case of authorized changes or when adding optional equipment it is the sole responsibility of the customer
to assure the accurate implementation of the safety devices required.

About this Manual
Contact Information
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Laird Technologies GmbH
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Version: 2.0
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1.2 Contact Information
If you have questions with respect to this unit please use the contact information given below. Always
communicate the following:
Your name and address
Name of contact at your address
Product data as on identification plate: Type of unit, serial number and year of manufacture
Company contact:
Mail:
Laird Technologies GmbH
Borsigstrasse 1
D-24568 Kaltenkirchen
Deutschland
Internet:
http://www.lairdtech.com
E-Mail:
[e-mail]
Phone:
[phone]
Fax:
[phone]

Product Identification
Unit Specifications
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Oil-Air Cooling Unit OL 4503
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2 Product Identification
2.1 Unit Specifications
Manufacturer
Laird Technologies GmbH
Type of product
Oil-air cooler
Type of unit
OL 4503
Article number
1264.00
Table 1: Unit specifications
2.2 Identification Plate
The identification plate is attached on the top of the coolant container below the unit cover.
Fig. 1: Position of identification plate
1
Identification plate
Fig. 2: Unit specific identification plate
1
Unit type
2
Article number
3
Serial number
4
Electrical specification
5
Date of manufacture
1
1
2
4
3
5

Safety Regulations
Hazard classes
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Oil-Air Cooling Unit OL 4503
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3 Safety Regulations
3.1 Hazard classes
In this document safety instructions are using standardized representation and symbols. Depending on the
probability of their incidence and the severeness of consequences three hazard classes are used.
DANGER
Reference to direct danger for humans.
Inobservance will lead to irreversible injuries or exitus.
CAUTION
Reference to noticeable danger for humans or possible damage to property.
Inobservance may lead to reversible injuries or to damage to property.
3.2 Safety Symbols
In this Operation Manual concrete safety instructions are given in order to point out unpreventable residual
risks when operating the unit. These risks include danger for
Human beings
The unit and other equipment
The environment
The safety symbols used in this manual are indicated below. The main reason for their use is to point the
reader to the safety instruction given in the text field beside.
Symbol
Meaning
Warning with respect to general danger or damage to property
Warning with respect to electrical hazard
Table 2: Warning signs
Symbol
Meaning
This symbol indicates the requirement of wearing safety gloves
This symbol indicates the requirement of disconnecting from mains.
Table 3: Signs giving orders

Safety Regulations
Hints for Safe Operation
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3.3 Hints for Safe Operation
PLEASE NOTE
Conduct inspections on a regular time base
This will ensure that the appropriate measures will be carried out indeed.
The unit is operation save. It was built according to the state-of-the-art.
Despite this the unit could cause hazards if it
is used in a way it was not intended for
is used improperly
is operated under unsuitable conditions
3.3.1 Prevent Hazards
Hazards can be prevented by safety-conscious and anticipatory behaviour of staff.
Everybody working with the unit should keep the following in mind:
Make this Operation Manual available for everybody at the operation site of the unit in a complete and
perfectly readable state!
Use the unit exclusively for what it was intended!
The unit must be operational and errorfree. Check the condition of the unit before working with it and
within a regular time frame.
Make sure that nobody can injure himself by any part of the unit!
Any disruption or recognizable change concerning the unit should be reported to the responsible
person.
Stick to accident prevention regulations as well as any regional regulations!
3.3.2 Hints Regarding the Electrical Equipment
DANGER
Danger to life through electrical shock when working on the electrical equipment of the unit!
Switch off the unit before starting your work!
Disconnect the unit from mains by pulling the mains plug!
Verify that the installation is dead (volt-free)!
Carry out earthing or short circuiting!
When working on electrical installations the following principles should be observed:
Works on the electrical installations may only be accomplished by qualified electrical staff!
When connecting electrical equipment to mains regional regulations have to be observed. Be aware of
the wiring diagram information.
The unit is powered by electricity. Electrical shock hazard exists, if the electrical installations are
defective or the insulation fails during operation.
When switched-off the unit is not disconnected from mains. This is only the case when the mains plug
is pulled.
Any changes regarding the control elements of the unit can have an influence on the save operation.
All intended changes must be authorized by the manufacturer.
After the implementation of a change the operativeness of the safeguards must be verified.

Safety Regulations
Safety Equipment
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No unauthorized changes on the unit are allowed. All intended changes must be authorized by the
manufacturer.
3.3.3 Environmental Issues
Environmentally concious and anticipatory behaviour of staff avoids environmentally hazardous impacts.
The following principles apply for environmentally conscious behaviour:
Environmentally hazardous substances must not get into the soil or into the drains. They should be
kept in appropriate containers.
Environmentally hazardous substances must be brought to utilization or disposal according to regional
regulations.
When dealing with working fluids always keep aware of the safety data sheet of the corresponding
manufacturer.
3.3.4 Protective Clothing
When doing a job that leads to contact of the skin with the coolant (e.g. filling-up of the coolant container):
Wear safety gloves made of PVC, neoprene or nitrile rubber
3.4 Safety Equipment
PLEASE NOTE
The safety equipment listed below must be integrated in the local control environment by the customer,
unless otherwise noted. These tasks must be carried out solely by trained experts. All information required
can be taken from the wiring diagram shown in the addendum.
Safety equipment must not be modified, removed or taken out of operation. All parts of the safety equipment
must be accessible at all times.
3.4.1 Safety and Signalling Equipment included in the Unit
The unit is equipped with safety equipment at critical spots:
The filling level of the coolant container is indicated in an inspection glass.
The circulated oil amount is controlled by a flow control device (flow switch) that must be integrated in
the potential-free safety circuit of the device that is to be cooled.
The oil temperature is controlled by a thermostat. When the oil temperature exceeds the maximum
setpoint this is indicated by the potential-free safety circuit.
The maximum pump pressure is limited by an angle-type safety valve that bypasses the oil stream
when the pressure pre-set is exceeded.

Safety Regulations
Safety Equipment
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Fig. 3: Safety equipment
1
Thermostat
2
Flow control device (flow switch)
3
Angle-type safety valve
4
Inspection glass, level indicator
3.4.2 Guards
Direct access to hazardous parts or areas of the unit is restricted by the unit cover. The cover may only be
removed for the purpose of maintenance or repair works and shall be replaced prior to taking the unit back to
operation. The cover is fixed by four screws which can be unscrewed using a metric AF10 wrench.
Fig. 4: Guard
1
Unit cover
1
2
3
4
1

Safety Regulations
In Case of Accidents
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3.4.3 Caution Label
Danger spots on the unit are indicated corresponding to German safety regulation BGV A8 "Sicherheits- und
Gesundheitsschutzkennzeichnung am Arbeitsplatz"
Caution labels on the unit must be easily readable at all times. Illegible caution labels must be exchanged
without delay.
Fig. 5: Caution labels on the unit
1
Hint for using the correct cap on oil filler
3.5 In Case of Accidents
Should you or an other person be injured when working with the unit:
Stay calm!
Give first aid!
Call the company’s first-aider without exception!
First aid at accidents with oil
The unit employs oil as a coolant in a closed-loop configuration. In case of damage oil can leak from the
circuit and cause hazards.
Long term or repeated contact with skin without appropriate cleaning may obstruct the skin pores and
may lead to irregularities as oil acne or folliculitis.
When exposed to oil always observe the safety data sheet of the manufacturer.
1

Product Description
Intended Use
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4 Product Description
4.1 Intended Use
The oil-air cooler OL 4503 is used for the cooling of an oil circuit. Oil circulates between the cooling unit and
the device to be cooled. The oil is recooled by an air-cooled heat exchanger. The maximum cooling capacity
depends on the ambient air temperature (see page 16 ).
The unit is exclusively intended for use in industrial and commercial environments.
The intended use also includes the observance and following of all hints given in this Operation Manual.
4.2 Non-Conformity with the Intended Use
Operation of the unit under improper operational conditions is not permitted, since otherwise the operation
safety can not be granted.
When using the unit in a way not compliant with the intended use, hazardous situations may occur.
Operation of the unit is not permitted under the following conditions:
The unit is used for a purpose other than the one it is intended for.
The unit or parts of it are damaged, the electrical installation is not correct or the insulation is broken.
Protective or safety equipment is not functional or defect, improperly installed or missing.
The unit is not working properly.
The unit was modified without authorization or modified in a way that is not permitted.
Controlling devices were modified in a way that is not permitted.
Operational parameters were changed in a way that is not permitted.
Operation in areas exposed to explosion hazards.
Operation with cooling media not according to specification.
Use of unauthorized tools.
Exceedance of the compulsary maintenance intervals.
PLEASE NOTE
The manufacturer is not liable for damage occuring when using the unit in a way it was not intended.
When using the unit in a way it was not intended for, the manufactorer’s waranty given by LAIRD will
expire.

Product Description
Unit Components
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4.3 Unit Components
Additional information can be retrieved from the flow scheme shown in the addendum. The unit consists of
the following main components:
Fig. 6: Main components
1
Cooling circuit
2
Coolant container
3
Sheet-metal hood
Cooling Circuit
In the cooling circuit the coolant (i.e. the oil) is driven by the pump to the device that is to be cooled and back
via the return flow. The heat is dissipated into the ambient air by an air-cooled heat exchanger. Exceedance
of the maximum pump pressure is prevented by a bypass circuit.The oil temperature is controlled by an
electronic thermostat. Oil throughput is controlled by a flow control device.
Fig. 7: Main components
1
Stop valve
2
Fan
3
Oil drain screw
2
1
3
1
3
2

Product Description
Specifications
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4.4 Specifications
Dimensions and weight
Length:
650 mm
Width:
350 mm
Height:
750 mm
Weight:
49.6 kg (empty)
Coolant capacity:
23 liters (Shell Diala S3-ZXIG)
Table 4: Dimensions and weight
Performance data
Cooling capacity:
4500 Watts at 22.8 K difference between the
oil outlet temperature and the ambient air
temperature
Pump capacity:
> 22 lpm at 3.5 bar
Mains voltage:
230 VAC 10% 50/60 Hz
Power input:
785 Watts (Pmax; 230 V; 50 Hz)
1058 Watts (Pmax; 230 V; 60 Hz)
Table 5: Performance data
Environmental conditions
Operating temperature:
-10°C ... +40°C
Storage temperature:
-25°C ... +70°C
Relative humidity:
20% … 90%
Table 6: Environmental conditions
Settings
Flow control device
14.0 ± 0.3 lpm
Thermostat
55 ± 3 °C
Maximum pressure
9.0 +0.5/-0.2 bar
Table 7: Settings

Product Description
Setting-up Requirements
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4.5 Setting-up Requirements
4.5.1 Installation Location
The location must be even.
When choosing the installation location the following must be kept in mind: the flow of the cooling air
must not be restricted, forward and back flow connections must be easily accessable and all hoses
must be installed without sharp bends.
4.5.2 Environmental Conditions
CAUTION
Risk of damage through unsuitable environmental conditions!
Damage to the unit and corrosion damage may result and are not covered by manufacturer’s
liability.
The unit is only authorized for use in indoor environments.
The unit must not be stored or operated in agressive, humid environments.
The unit must not be stored or operated outdoor.
Pay attention to the environmental conditions as given in the specifications on page 16.
4.5.3 Infrastructure
The following infrastructure is required for connecting the unit:
Parameter
Rated value
Operating voltage
230 VAC
Table 8: Required infrastructure

Transport
Safety Indications for Transport and Setting-up
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5 Transport
5.1 Safety Indications for Transport and Setting-up
CAUTION
Risk of injury by lifting the unit!
The weight of the unit is more than 50 kg.
Do not lift the unit manually.
Always use proper auxiliary means such as a forklift or a jack lift.
CAUTION
Risk of damage by improper transportation!
Transport the unit in upright position.
Do not tilt the unit or expose it to impacts.
5.2 Transportation of the unit
The unit is delivered shrinked in foil on a transportable pallet. Leave the unit on the pallet until bringing it into
service. Use a forklift or jacklift for transportation to the installation location.
5.3 Unpacking
Remove the foil before setting up the unit.
Inspect the unit with regard to:
Damage caused by transportation
Completeness of delivery
Lift the unit with a forklift or jack lift off the transportable pallet.
Dispose of the packaging material in accordance with regional regulations
PLEASE NOTE
LAIRD advises to keep the transportable pallet for later transportation of the unit.

Initial Operation
Safety Indications Related to Initial Operation
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6 Initial Operation
6.1 Safety Indications Related to Initial Operation
CAUTION
Danger of malfunction caused by faulty connections during initial operation!
Before switching on the unit make sure that:
All safety equipment of the unit is implemented and functional.
All connections were properly made.
Nobody is endangered by the start-up of the unit.
Please follow the rules in chapter Safety Regulations on page 9.
6.2 Setting to Work
6.2.1 Placement
Fig. 8: Minimum clearance for air entrance and air exit
1
Ventilation grid
1) Move the unit to its installation location as mentioned in chapter 5.2
2) Place the unit in a way that air entrance and air exit are not obstructed. Wall clearance must not be less
than 0.5 m, otherwise cooling capacity may be restricted
PLEASE NOTE
In case of storage of the unit at temperatures lower than 5°C or higher than 40°C for longer periods please
wait 3 hours prior to initial operation to allow for temperature adjustment.
1
min. 0.5 m
min. 0.5 m
1

Initial Operation
Setting to Work
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6.2.2 Cooling Circuit Connection and Filling
CAUTION
Risk of damage by using improper cooling hoses!
This may lead to damage to persons, damage to the unit or corrosion damage.
When choosing cooling hoses pay attention to sufficient burst strength and compatibility with coolant.
Only use cooling hoses without any signs of damage.
The cooling hoses are connected to the unit by means of screwed hose nipples.
Oil inlet and oil outlet are indicated with respective symbols.
Fig. 9: Labelling of oil inlet and oil outlet
PLEASE NOTE
When operating the unit make sure only to use the operation coolant container cap. This cap allows for
pressure equilibrium in the cooling system (breathing). Save the transportation cap for later transportation
purposes (e.g. when sending the unit back for repair).
Oil Inlet
Oil Outlet