DYNACOOL DC200 FOR EVERYTHING UNDER THE SUN IN OIL HEAT TRANSFER HEAT EXCHANGERS AND ACCESSORIES. Replaces catalogues DC10, DC57, DC118, DC160, VC02

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1 FOR EVERYTHING UNDER THE SUN IN OIL HEAT TRANSFER HEAT EXCHANGERS AND ACCESSORIES Replaces catalogues DC10, DC57, DC118, DC160, VC02 DYNACOOL DC200

2 Dynacool A 2000 Available in over 30 standard model variants. Made with high performance aluminium cooling elements and heavy duty zinc seal powder coated casings for excellent appearance and durability. Stainless steel casing available on request. Available in most AC voltages, 50 & 60 Hz, hydraulic and air motor drive. Also used for air aftercooling applications. Core skirts on all models and core guards on larger models. Models with coaxially driven pump readily available. Performance to 9.0 kw/ C, flows to 800 L/min. Dynacool VT Vertical Discharge Tower. Developed for very large oil cooling applications in high ambient conditions. The VT series are equipped with multiple cooling elements manifolded for parallel oil flow. Performance to 17 kw/ C, flows to 1600 L/min. Versacool AC Electric Drive. Available in 6 basic models with 22 different electric motor variants in single or three phase. 50 or 60 Hz options. Voltages from 240 through 450. New SAMS design on AC electric models (Superior Air Management System) delivers more air flow resulting in greater performance using a smaller fan, lower noise and eliminating recycling of heated air through the matrix. Performance to 0.8 kw/ C, flows to 200 L/min. Versacool DC Electric Drive. Available in 5 asic models with 13 different electric motor variants in 12 or 24 Volt. Proven long life water resistant fan motors in high performance or low amp/noise types. Cooling elements with operating pressure to 14 ar. VC8 models now with operating pressure up to 30 ar. Performance to 0.8 kw/ C, flows to 250 L/min. Dynacool ST Steel Core Special Application. Currently available in 4 models. ST series feature heavy duty cooling elements with steel fins, rectangular steel tanks and copper tubes or now also stainless steel loop fin elements. Ideal for low air side clogging applications or for the special requirements of underground coal mines. Available with standard or antistatic fans and flame proof electric motors for intrinsically safe applications. Performance to 2 kw/ C, flows to 540 L/min. Series EKM & ECM Water Cooled Extended Surface Oil Coolers Extended surface tube bundles ensure high heat transfer capacity in small overall size and minimising required water flow. All models now available with surge relief mechanism. 90/10 Cu Ni tube materials now standard for stocked range ensuring good service life even if fresh water quality is poor. EKM Performance to 200 kw, Oil flows to 200 L/min. ECM Performance to 400 kw, Oil flows to 700 L/min. Series General Purpose Shell & Tube Heat Exchangers General Purpose Types For all general oil, air or water cooling applications where a conventional exchanger is required. Sea Water Types. Available for marine oil cooling or marine jacket water cooling. Special materials such as 90/10 Cu Ni & bronze are used for all surfaces in contact with sea water. WM High Performance Marine and WI General Purpose Shell & Tube Heat Exchangers WM - Extended surface tube bundle with Stainless Steel tube sheets, 90/10 Cu Ni tubes and stainless steel end bonnets. ronze available for single pass only. WI - Extended surface tube bundle with Steel tube sheets, 90/10 Cu Ni tubes and steel end bonnets. oth available in 1 pass, 1 pass with 90 bend or 2 pass on water side. Performance to 45 kw, Oil flows to 200 L/min. Accessories Thermoswitches for DC or AC motors, thermostatic valves for cold/hot oil flow diversion, cooler mounting brackets, water flow modulating valves & bulb wells to regulate water flow, strainers to minimise foreign material flowing into heat exchanger. DH and DFM Round Tube Mobile Coolers. Oil Flows to 400 L/min.

3 AIR COOLED EXCHANGERS Air Cooled Exchangers with Aluminium Cooling Elements Standard AC Electric Models. Dynacool A and Versacool SAMS. Page 4 to and 24 Volt DC Electric Models. Page 12 to 14 Accessories Page Hydraulic Motor Driven Dynacool A and Versacool SAMS. Page 16 to 19 Multi Element AC Electric Models. DC 70 and VT2041. Page 20 to 21 Air Cooled Exchangers With Co-axial Oil Pumps. Dynacool A. Page 22 to 23 Special Application Air Cooled Oil Coolers AC Electric Models. Dynacool S, ST, SI and VC Non Aluminium. Page 25 to and 24 Volt DC Electric Models DFM Non Aluminium Page 28 to 30 Air After Coolers Air After coolers Versacool and Dynacool models Page 31 to 33 Cooling Elements For Add-On or Replacement Non Aluminium Round Tube Mobile Series DH Page 34 to 35 All Aluminium PFA, Hi-Flow and Albraze Series Page 36 to 37 Water Cooled Heat Exchangers Page 39 Oil Pump and Pump Packages Page 51 Heat Exchanger Accessories Page 57 Product Application and Useful Formula Page 65 Faxable selection guide for customer use Page 69 & 70 To ensure best quality and competitiveness product design is continuously reviewed, therefore all information published in this brochure is subject to change without notice and should not be relied upon without confirmation from our office. Jan

4 Air Cooled Exchangers With Aluminium Cooling Elements VERSACOOL HEAT EXCHANGERS AIR COOLED AC DC HYD DRIVE New design on AC electric models (Superior Air Management System) delivers more air flow resulting in greater performance while using a smaller diameter lower noise fan. Cylindrical air jet discharge pattern eliminates recycling of heated air through matrix. Choice of new Hi-Flow low pressure drop cooling elements on all larger models. Highest performance in the smallest package allows use in confined spaces, universal top and bottom mount makes vertical, horizontal or inverted mounting easy. Accessory mounting feet (page 60) & compressor after cooling stands (page 31) are available. Ease of assembly and commonality of components makes for a large array of models. 73 models are currently available from stock. VERSACOOL MODEL CODES VC = Standard Model Range VCL= Special Applicaion Coolers Mounting feet and thermostat options page VCL 4 X A C 5 0 ASIC MODEL NUMER = 2, 4, 5, 6, 7 or 8 COOLING ELEMENT TYPE N = Aluminium Hi-Flow 65mm - Operating pressure 14 ar W = Aluminium A-plate - Operating pressure 11 ar X = Aluminium Hi-Flow 65mm - Operating pressure 14 ar P = Aluminium Hi-Flow 65mm - Operating pressure 30 ar ASIC DRIVE TYPE A = AC electric motor. D = DC electric motor. H = Hydraulic Motor. series SPECIFIC FAN MOTOR CODES A = (DC motor only) High performance DC electric motor type. = (DC motor only) DC electric motor type. Low amp/low noise C = (AC models only) Standard Three phase 240/415 volt TEFC, IP55 electric motor. D = (AC models only) Standard Single phase 240 volt TEFC, IP55 electric motor. E = Hydraulic motor MGG Gresen-Tyrone gerotor type, high speed. F = Hydraulic motor small orbit Eaton J/Sam GM/ EPMM/Danfoss OMM/etc. 16 mm shaft. G = (AC motor only) Three phase 240/415 volt TEFC, IP55 electric motor. Low speed, low fan noise. H = (AC motor only) Single phase 240 volt TEFC, IP55 electric motor. Low speed, low fan noise. M = Commercial Alpha Series M5 Gear Type Hydraulic Motor. X = Special Hydraulic Motor Mount For Customer Supplied Motor. DC VOLTAGE OR AC HERTZ ELECTRIC MOTOR CODES 1 = (DC motor only) 12 Volt power supply. 2 = (DC motor only) 24 Volt power supply. 5 = (AC motor only) 50 Hertz AC power supply. 6 = (AC motor only) 60 Hertz AC power supply. Consult sales with voltage before ordering. Omitted = No Motor Unit SPECIAL DETAILS OR FINISH 0= Standard Model. Other numbers indicate special features. 00 = No Motor unit. F = Extra corrosion resistant finish Accessories are not indicated on model identification. Order separately. 4

5 Air Cooled Exchangers With Aluminium Cooling Elements DYNACOOL Series A 2000 CLASSIC Australian designed and manufactured product with reputation for quality, reliability and technical excellence. 25 years experience, constant development and testing has produced the Series A 2000 the most compact and lowest noise oil cooler in its performance range. AIR COOLED AC DC HYD DRIVE The largest air cooled heat exchanger inventory in the southern hemisphere means that you can demand and receive the fastest delivery of new units and service parts exactly when you need them. DYNACOOL MODEL CODES ASIC MODEL NUMER = 31, 32, 33, 35 & 70 D C 32 Y H 8 AC 6 00 COOLING ELEMENT TYPE S = Hi-Flow 90mm - Operating pressure 14 ar U = Hi-Flow 95mm - Operating pressure 14 ar V = Hi-Flow 95mm - Operating pressure 20 ar X = Hi-Flow 65mm - Operating pressure 14 ar Y = Hi-Flow 65mm - Operating pressure 14 ar PORT ORIENTATION H = Horizontal V = Vertical FAN DIAMETER (mm) 5 = Ø500 6 = Ø630 8 = Ø800 9 = Ø = Ø1000 ASIC DRIVE TYPE AC = 3 Phase electric motor AD = 1 Phase electric motor HF = Hydraulic orbit motor HV = Hydraulic vane motor NM = No motor (electric motor mounting provided) GA = Air motor DP = Motor and DC30 Pump HP = Motor and Haight Pump HX = No motor (hydraulic motor mounting provided. Customer to specify motor details) DC = DC Motor MOTOR/FAN SPEED 2 = 2 Pole (2800 RPM) 4 = 4 Pole (1440 RPM) 6 = 6 Pole (960 RPM) 8 = 8 Pole (720 RPM) SPECIAL DETAILS OR FINISH 00 or none = 415V 50Hz 01 = 240V 50Hz V = 3.5 ar bypass valve F = Extra corrosion resistant finish 5

6 Air Cooled Exchangers With Aluminium Cooling Elements AC ELECTRIC HEAT EXCHANGERS AIR COOLED AC DC HYD DRIVE Electric Motor Specifications TECHNICAL SPECIFICATIONS - AC ELECTRIC MODELS Dynacool A 2000 Series. 50 Hz 3 phase asynchronous to IEC 34-1, 3 mount IP55, Insulation- Class F. Temperature rise- Class Versacool. 50Hz asynchronous to IEC 34-1, 14A mount IP55, Insulation- Class F. Temperature rise- Class 60 Hz available with reduction of fan blade angles. General Construction Cooling Elements. Aluminium furnace brazed. Ref. to pages 4 and 5 for element types. Casing and Structure. Steel (zinc seal) polyester powder coated. Stainless steel to special order. Steel core guards on Dynacool models. Coated steel fan guards on all models. Fans. Polypropylene GF or Polyamide GF. Antistatic fans available on request. Fastenings. Zinc plated. Stainless steel to special order. MODEL/ Noise level * Fan Ø Volts Phase kw Size Poles Weight Part Number d(a) at 1m (mm) (kg) VC2XAC VC2XAD VC2XAG VC2XAH VC4XAC VC4XAD VC4XAG VC4XAH VC5NAC VC5NAD VC5NAG VC5NAH VC6XAC VC6XAD VC6XAG VC7XAC VC7XAD VC7XAG VC8PAC VC8PAD VC8PAG VC8PAH DC31YH5AC DC31YH6AC DC32YH6AC L 4 90 DC32YH8AC DC32YH8AC DC32SH6AC L 4 90 DC32SH8AC DC32SH8AC DC33VH6AC L DC33VH8AC DC33VH8AC DC35YH8AC DC35YH8AC DC35YH8AC DC35YH9AC DC35YH9AC DC35UH9AC DC35UH9AC DC70YH10AC M * Noise levels listed are raw A weighted pressure representing worst case. Refer noise level statement page 67 6

7 Air Cooled Exchangers With Aluminium Cooling Elements PERFORMANCE - STANDARD & HIFLOW AC ELECTRIC MODELS kw/ C DC33VH8AC4 DC33VH6AC4/DC33VH8AC6 DC32YH8AC8 DC31YH6AC6 VC7XAC50 VC8PAG50 VC7XAG50 VC6XAC50 VC5NAC50/VC6XAG50 VC4XAC50 VC5NAG50 DC70YH10AC6 DC35YH8AC8 DC32SH8AC6 DC32SH6AC4 DC32YH8AC6 DC32YH6AC4 DC32SH8AC8 DC31YH5AC4/VC8PAC DC35UH9AC6 DC35YH9AC6 DC35YH8AC4 DC35UH9AC8 DC35YH9AC8 DC35YH8AC6 AIR COOLED AC DC HYD DRIVE 0.2 VC4XAG50 VC2XAC NOTE: 240 Volt Single Phase VC Models AD and AH. Use AC curve to find performance of AD Use AG curve to find performance of AH Oil Flow l/min 1000 P ar VC2X VC8P VC4X VC5N/6X VC7X Oil Flow l/min P ar DC31Y DC32Y DC35Y DC32S DC33V/DC35U DC70Y Oil Flow l/min OIL COOLER SIZING Step 1. Calculate ETD = TOil - TAir TOil= Temp C of oil entering the cooler (usually the same as max. allowable oil temp.) TAir= Expected Ambient Air Temp C. Step 2. Calculate kw/ C ETD = kw kw = Heat Load. ETD Step 3. Enter Cooler Performance Tables and select a cooler which meets or exceeds the required performance at the required oil flow rate. Step 4. Check pressure drop of the oil cooler selected in step 3. If the average oil viscosity is not 30 cst apply a correction for the expected viscosity. Computer model selection program available. P Correction Factor Oil Viscosity cst 7

8 Air Cooled Exchangers With Aluminium Cooling Elements DIMENSIONS - VERSACOOL AC ELECTRIC SAMS SERIES AIR COOLED AC DC HYD DRIVE MODEL VC2XA FAN 318 "C" "A" "" Slots 16 x 10 4 Places ottom And Top AIR * VC2XA Port size A C 1 1/16" 1 1/16" 1/2" Flexible hose required Ports A & are Male JIC 37 flare UN. Port C is SPP to ISO 228/1G *Nominal, Varies with motor brand. See Accessory information for foot bracket options. MODEL VC4XA, VC5NA, VC6XA & VC7XA "" A2 FAN F1 "A" E "D" "C" D2 D1 C AIR Ports C and D on model VC4XDA are on opposite side to that shown. See Accessory information for foot bracket options. A1 Slots 16 x 10 4 Places ottom And Top H G* Model A1 A2 C D1 D2 E F1 F2 G* H Liq Vol L A C D VC4XA " 1" 1" 3/4" VC5NA " 1" 1" 3/4" VC6XA " 1" 1" 3/4" VC7XA /4" 1 1/4" 3/4" *Nominal, Varies with motor brand. All ports SPP to ISO 228/1G MODEL VC8PA - Elements max operating pressure 30 ar - Twin Fan Model FAN FAN 17 "A" VC8PA Port size A C 1 1/2" 1 1/2" 3/4" All ports SPP to ISO 228/1G AIR "C" "" * See Accessory information for foot bracket options. *Nominal, Varies with motor brand. All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 8

9 Air Cooled Exchangers With Aluminium Cooling Elements DIMENSIONS - DYNACOOL SERIES A 2000 CLASSIC AC ELECTRIC MODEL DC31 & DC32 "A" H A "" Q E "C" G F AIR DYNACOOL AIR COOLED AC DC HYD DRIVE J C M1 M2 K Slots 10 x 25 All ports SPP to ISO 228/1G L *Nominal, Varies with motor brand. Model A C D E F* G H J K L M1 M2 "A" "" "C" 31Y * /4" 1 1/4" 1 1/4" 32S * " 2" 3/4" 32Y * /4" 1 1/4" 1 1/4" MODEL DC "" D * DC33 Port size A C 2" 2" 3/4" AIR "C" "A" 75 MODEL DC Y=80 U= Y=725* U=750* Slots 10 x 25 All ports SPP to ISO 228/1G *Nominal, Varies with motor brand. DC35 Port size A C 2" 2" 3/4" "A" "" AIR X "C" SLOTS 10 X25 All ports SPP to ISO 228/1G *Nominal, Varies with motor brand. All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 9

10 X HEAT EXCHANGER Air Cooled Exchangers With Aluminium Cooling Elements VERSACOOL VCL SPECIAL APPLICATION HEAT EXCHANGERS AIR COOLED AC DC HYD DRIVE Features the higher performance of the regular Versacool range with the added capacity to fit a wide range of special electric motors, larger type hydraulic motors or air motors and/or stainless steel case construction. AC motor mountings include IEC foot mounted 71,80 and 90 frame or NEMA 48, 56, and 143 frame single or 3 phase in most voltages and specifications. Where large 24 volt DC fan driven Versacool models are required such as VC6 or VC7 we can supply them as VCL6XDC20 or VCL7XDC20 models. For performance see curves shown on page 12. Where large or irregular hydraulic fan motors not available in regular Versacool models are required, VCL series may be used. VCL4, VCL6 and VCL7 models are available with 304 stainless steel casings and brackets. Stainless steel option shown. Mounting feet and thermostat options page MODEL VCL4XA, VCL5NA, VCL6XA, & VCL7XA A2 F1 "" "A" FAN F2 E "C" "D" C AIR D1 D2 Slots 16 Along 10 Across 4 Places ottom And Top A1 H J G* Mounting feet options page 60. # Port C and D is on other side on VCL4XA models Model A1 A2 C D1 D2 E F1 F2 G* H J Liq Vol L A C D VCL4XA " 1" 1" 3/4"# VCL5NA " 1" 1" 3/4" VCL6XA " 1" 1" 3/4" VCL7XA /4" 1 1/4" 3/4" - *Nominal, Varies with motor brand. All ports SPP to ISO 228/1G All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 10

11 Air Cooled Exchangers With Aluminium Cooling Elements DC ELECTRIC HEAT EXCHANGERS D Standard Performance Total of 20 stock models including 12 and 24 volts. D models are standard performance with fully weather proofed fans with interference suppression. DA models are high performance with long life SPAL fans. DC models use a foot mount DC motor and the same fans as those used on our Dynacool Series A2000 coolers. AIR COOLED AC DC HYD DRIVE Our Versacool range has the highest performance in the smallest package allows use in confined spaces, universal top and bottom mount makes vertical, horizontal or inverted mounting easy. Accessory mounting feet (page 60) and compressor after cooling stands (page 31) are available. DA High Performance Available with electric DC thermostatic fan controls to start fan when oil reaches predetermined temperature. All models are available with Wet type thermostat ranges are 46 C, 55 C and 65 C or adjustable wet thermostat systems. See pages 58 and 59. Mounting feet and thermostat options page Electric Motor Specifications Versacool DA Type. High performance, long life, motor enclosure IP54. Temp range -30 C to +80 C. Versacool D Type, Standard performance, motor enclosure IP55. Temp range -30 C to +80 C. TECHNICAL SPECIFICATIONS - DC ELECTRIC MODELS General Construction Cooling Elements. Aluminium furnace brazed. Casing. Steel (zinc seal) Polyester powder coated. Fans. Polypropylene. Fastenings. Zinc plated MODEL/ Noise level * Fan Ø Volts Amps Weight Drawing Part Number d(a) at 1m (mm) kg on page VC2XDA VC2XD VC2XD VC4XDA VC4XDA VC4XD VC4XD VC5NDA VC5NDA VC6XDA VC6XDA VCL6XDC VCL7XDC VC8PDA x VC8PDA x DC31YH5DC DC32YH6DC DC32SH6DC TM20JDA TM20JDA TM40JDA TM40JDA * Noise levels listed are raw A weighted pressure representing worst case. Refer noise level statement page 67 11

12 Air Cooled Exchangers With Aluminium Cooling Elements PERFORMANCE - DC ELECTRIC MODELS 3.0 For VCL models refer to notes shown on page 10. AIR COOLED AC DC HYD DRIVE DC32SH6DC420 DC32YH6DC420 DC31YH5DC420 VCL7XDC20 VC8PDA VCL6XDC20 VC6XDA 0.4 VC5NDA kw/ C VC4XDA VC4XD VC2XDA TM40JDA VC2XD TM20JDA Oil Flow l/min P ar VC2X/TM20 VC4X/TM40 VC5N/6X VCL7X VC8P P ar DC31Y DC32Y DC32S OIL COOLER SIZING Step 1. Calculate ETD = TOil - TAir TOil= Temp C of oil entering the cooler (usually the same as max. allowable oil temp.) TAir= Expected Ambient Air Temp C. Step 2. Calculate kw/ C ETD = kw kw = Heat Load. ETD Step 3. Enter Cooler Performance Tables and select a cooler which meets or exceeds the required performance at the required oil flow rate. Step 4. Check pressure drop of the oil cooler selected in step 3. If the average oil viscosity is not 30 cst apply a correction for the expected viscosity. Computer model selection program available Oil Flow l/min Oil Flow l/min P Correction Factor Oil Viscosity cst 12

13 Air Cooled Exchangers With Aluminium Cooling Elements DIMENSIONS - VERSACOOL DC ELECTRIC MODELS MODEL VC2XD 318 "C" FAN Slots 16 Along 10 Across 4 Places ottom And Top "A" AIR "" D Models 69 DA Models VC2XD Port size A C 1 1/16" 1 1/16" 1/2" Flexible hose required Ports A & are Male JIC 37 flare UN. Port C is SPP to ISO 228/1G See Accessory information for foot bracket options. MODEL VC4XD, VC5ND & VC6XD For dimensions of VCL models refer to page 10 AIR COOLED AC DC HYD DRIVE "" A2 FAN F1 "A" E "D" "C" D1 D2 C AIR Ports C and D are on model VC4XDA or on opposite side to that shown. See Accessory information for foot bracket options. Slots 16 Along 10 Across 4 Places ottom And Top A1 H G Model A1 A2 C D1 D2 E F1 F2 G* H Liq Vol L A C D VC4XD " 1" 1" 3/4" VC4XDA " 1" 1" 3/4" VC5NDA " 1" 1" 3/4" VC6XDA " 1" 1" 3/4" All ports SPP to ISO 228/1G MODEL VC8PDA - Elements max operating pressure 30 ar - Twin Fan Model FAN FAN "A" AIR VC8XDA Port size A C 1 1/2" 1 1/2" 3/4" All ports SPP to ISO 228/1G See Accessory information for foot bracket options. "C" "" All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 13

14 Air Cooled Exchangers With Aluminium Cooling Elements DIMENSIONS - DYNACOOL DC ELECTRIC MODELS MODEL DC31 & DC32 AIR COOLED AC DC HYD DRIVE "A" A "" DYNACOOL H QQ G F AIR "C" E D J C K M1 L M2 Slots 10 x 25 See Accessory information pages 58 & 59 for Thermoswitch options. Model A C D E F* G H J K L M1 M2 "A" "" "C" 31Y * /4" 1 1/4" 1 1/4" 32S * " 2" 3/4" 32Y * /4" 1 1/4" 1 1/4" *Nominal Varies with motor type. All ports SPP to ISO 228/1G All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 14

15 Air Cooled Exchangers With Aluminium Cooling Elements TM - TRANSIT MIXER COOLERS APPLICATION. Suitable for use in mobile equipment to cool hydraulic oil. Fan driven using 12 or 24 volt DC power supply. Optional thermoswitch available for TM models for extended fan motor life refer to page 59 for details. SPECIFICATIONS. Maximum Operating Pressure ar Maximum Operating Temperature. 150 C TM40 cooler AIR COOLED AC DC HYD DRIVE MATERIALS OF CONSTRUCTION. Cooling element... Aluminium Case (TM20 only)... Steel, powder coated white Fan/Cowl... Plastic, black Motor... Steel Case, weatherproofed MODEL TM20JDA FAN "A" AIR 4 Mounting Holes 8 "C" "" Part Number Motor voltage Amps Weight(kg) TM20JDA10 12v Port Details - A and are Male JIC 37 flare UN type 1 1/16" 12TPI TM20JDA20 24v C is 1/2" SPP to ISO 228/1G. Flexible hose required. MODEL TM40JDA FAN 30 "A" AIR "C" "" Mounting Holes 12.7 Part Number Motor voltage Amps Weight(kg) TM40JDA10 12v Port Details - A and are Male JIC 37 flare UN type 1 1/16" 12TPI TM40JDA20 24v C is 1/2" SPP to ISO 228/1G All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 15

16 Air Cooled Exchangers With Aluminium Cooling Elements HEAT EXCHANGER HYDRAULIC DRIVE COOLERS AIR COOLED AC DC HYD DRIVE Hydraulic motor fan drives are available on most Versacool and Dynacool heat exchangers Compact face mount system Hydraulic motor options include gear high speed motor or a 8cc or 12cc mini orbit motor. HX coolers available for fitting of customer supplied hydraulic motors. Consult sales office. Mounting feet and thermostat options page Overhung load adaptors can be supplied and fitted for plug-in on HX hydraulic motor types. GEAR MOTOR MINI ORIT MOTOR TECHNICAL SPECIFICATIONS - COOLERS WITH HYDRAULIC MOTORS Model Motor type Motor size Req d Motor Oil flow Motor power cc/rev speed rpm req d l/min kw VCL4XHA45 Gear VC4XHF12/19 Orbit 8.2/ / VCL5NHA45 Gear VC5NHF12/19 Orbit 8.2/ / VC6XHF12/19 Orbit 8.2/ / VC7XHF12/19 Orbit 8.2/ / DC31YH6HF612/20 Orbit 12.9/ / DC31YH5HF412/19 Orbit 8.2/ / DC32YH6HF412/19 Orbit 8.2/ / DC32YH8HX6/8* Cust. supply - 920/ /1.1 DC32SH8HX6/8* Cust. supply - 920/ /1.1 DC33VH6HF412/19 Orbit 8.2/ / DC33VH8HX400* Cust. supply DC33VH8HX600* Cust. supply DC35YH8HX6/8* Cust. supply - 920/ /1.1 DC35YH9HX600* Cust. supply DC35UH9HX600* Cust. supply *Customer to specify motor details when ordering. Performance curves and noise levels are based on required motor speed. 16

17 Air Cooled Exchangers With Aluminium Cooling Elements PERFORMANCE - HYDRAULIC MODELS DC33VH8AC4 DC33VH6AC4/DC33VH8AC6 DC31YH5HF4 DC35YH9HX DC35YH9HX8 DC35YH8HX6 DC32SH8HX6 DC32YH8HX6 DC32YH6HF4 DC32SH8HX8 DC32YH8HX8 DC31YH6HF6 VC7XHF DC35UH9HX6 AIR COOLED AC DC HYD DRIVE kw/ C VC6XHF VCL5NHA VCL4XHA VC5NHF 0.2 VC4XHF P ar Oil Flow l/min VC4X VC5N/6X VC7X P ar DC31Y DC32Y DC35Y DC32S DC33V/DC35U DC70Y 1000 OIL COOLER SIZING Step 1. Calculate ETD = TOil - TAir TOil= Temp C of oil entering the cooler (usually the same as max. allowable oil temp.) TAir= Expected Ambient Air Temp C. Step 2. Calculate kw/ C ETD = kw kw = Heat Load. ETD Step 3. Enter Cooler Performance Tables and select a cooler which meets or exceeds the required performance at the required oil flow rate. Step 4. Check pressure drop of the oil cooler selected in step 3. If the average oil viscosity is not 30 cst apply a correction for the expected viscosity. Computer model selection program available Oil Flow l/min Oil Flow l/min P Correction Factor Oil Viscosity cst 17

18 Air Cooled Exchangers With Aluminium Cooling Elements DIMENSIONS - VERSACOOL HYDRAULIC MODELS MODEL VC4XH (VCL model shown) AIR COOLED AC DC HYD DRIVE "" "D" "C" FAN 18 "A" AIR Slots 16 Along 10 Across 4 Places ottom And Top * HA - 165* HF - 145* VC4X Port size A C D 1" 1" 1" 1/2" *Nominal, Varies with motor type. All ports SPP to ISO 228/1G See Accessory information for foot bracket options. MODEL VC5NH, VC6XH & VC7XH "" A2 FAN F1 "A" E "D" "C" C AIR D1 D2 *Nominal, Varies with motor brand. All ports SPP to ISO 228/1G Slots 16 Along 10 Across 4 Places ottom And Top A1 H G* Model A1 A2 C D1 D2 E F1 F2 G* H Liq Vol L A C D VCL5NHA " 1" 1" 3/4" VC5NHF " 1" 1" 3/4" VC6XHF " 1" 1" 3/4" VC7XHF /4" 1 1/4" 3/4" - MODEL DC31 & DC32 F A G "A" H Q "" E AIR "C" D J C K M1 L M2 Slots 10 x 25 Model A C D E F* G H J K L M1 M2 Port A Port Port C 31Y * /4" 1 1/4" 1 1/4" 32S * " 2" 3/4" 32Y * /4" 1 1/4" 1 1/4" *Nominal Varies with motor type. Ports SPP to ISO 228/1G All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 18

19 Air Cooled Exchangers With Aluminium Cooling Elements DIMENSIONS - DYNACOOL SERIES A 2000 CLASSIC HYDRAULIC MODELS MODEL DC33 DC33 Port size A C 2" 2" 3/4" All ports SPP to ISO 228/1G *Dimension to motor mounting face. AIR COOLED AC DC HYD DRIVE * "A" AIR "C" "" SLOTS 10 X 25 MODEL DC35 No Motor model shown. Motor selected to suit application DC34 & 35 Port size A C 2" 2" 3/4" 1170 Y=80 U=90 Y=385* U=410* All ports SPP to ISO 228/1G *Dimension to motor mounting face. "A" "" AIR "C" SLOTS 10 X 25 All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 19

20 Air Cooled Exchangers With Aluminium Cooling Elements HEAT EXCHANGER VERTICAL DISCHARGE TOWER TYPES AIR COOLED AC DC HYD DRIVE Features Series DC70 and VT2041 vertical discharge tower type heat exchangers were developed for use in large oil cooling and air aftercooling applications. The VT series are among the largest capacity standard oil cooling packages available. These units feature single fan vertical discharge vane controlled air management systems which reduce noise levels and eliminate re-circulation of heated cooling air. The DC70 has a top mounted motor and fan. On the VT2041, the motor is bottom mounted with a drive shaft to the top mounted fan. Variable speed fan drives available. Series DC70 Performance. For performance with standard Y type cooling elements refer to model DC70YH10AC6 page 7. Suitable for compressor air aftercooling up to 2500 SCFM and 14 bar air pressure. Series DC70 Technical Data. Refer to model DC70YH10AC6 page 6. Other types are available including units fitted with U type cooling elements. Consult sales for details. oth models have a small footprint which means large space saving on big air cooled applications. The VT2041 has a foot print of 1600 mm x 1600 mm and can replace up to 4 of our largest horizontal models. For applications such as hydraulic oil cooling in sugar mills, there exists a large degree of air contamination. These units can be rigged with ducting to the roof and draw clean air down and through the cooling elements and thus eliminate the need to provide expensive air filtration systems. DIMENSIONS - SERIES DC 70 AIR 2 PORTS SAE 3" CODE 61 FLANGES 4 X M16 TAPPED HOLES HOLES All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 20

21 Air Cooled Exchangers With Aluminium Cooling Elements SERIES - VT VERTICAL DISCHARGE TOWER COOLER Series VT2041 Performance. Available in several variants. Performance ranges from 7 to 20kW/ C. Oil Flow ranges from 200 to 2000 L/min. Compressor air aftercooling to 5000 SCFM. Consult sales for details. DIMENSIONS - VT2041 Series VT2041 Technical Data. Available with 6 and 8 pole fan speeds or with variable fan speed control. Electric motor sizes to 30kW AIR COOLED AC DC HYD DRIVE SERIES VT ±4 1600±4 Air Exit Notes. Port Positions May vary please Consult Our Sales Department Air Entry 2595±3 2122±3 Rating Plate 1600±4 Oil Port Outlet 4" SPP Female Facing Down 727 Air Entry Oil Port A Inlet 4" SPP Female Facing Down Air Entry olt Down Holes 4 Places 25 mm Ø 0n 1390±3 x 1390±3 240 ase Holes 4 Places on 1390±3 1600±4 DESIGNATED FRONT POSITION Air Entry 1600±4 ASE FOOTPRINT VIEWED FROM AOVE DESIGNATED FRONT POSITION All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 21

22 Air Cooled Exchangers With Coaxial pump High performance off-line oil cooling and filtration systems for cooling hydraulics or gear drives. AIR COOLED WITH INLINE PUMP Heat transfer rating from 0.25 to 1.4 kw/ C using hydraulic or gear oil, contact sales office for suitability with very high viscosity oils viscosity. Internal relief valve for protection against over pressure or accident. VCL6XAC4DP40 APPLICATION. These units are most effective as an add on for hydraulic circuits as well as cooling gear drives. The most common application is for hydraulic circuits where there are sudden oil flow changes with cylinders where flow surges and spikes from cylinder operation do not allow the use of the cooler in the main circuit due to the risk of cooler element damage. Use of this type of cooler with its own separate circuit will avoid this problem. Please contact our sales office to have your application reviewed. PUMP PRESSURE. Pump delivery pressure to 5 bar. Higher pressure ratings available. Consult factory. PERFORMANCE RANGE. Heat transfer range is from 0.25 to 1.4 kw/ C of ETD. Performance is based on ISO 68 hydraulic oil at 30cSt, for other fluids and viscosities please contact our sales office. ETD is the difference between the entering oil and the cooling air temperature. CONNECTION. VCL models are equipped with oil delivery hose from oil pump to cooling element. Please contact our sales office if the pumping head is greater than 10m or you have any special requirements. Pump inlet must be flooded. OTHER MODELS AVAILALE. We also supply models with other types of cooling elements for special applications. DC32YH6AC4HL75 MODEL Oil flow Pump Max kw/ C kw Volts Motor Fan Ø *Noise Level Weight Part Number L/min Type cst ETD Poles Phases Size (mm) d(a) at 1m (kg) VCL4XAC4DP40 40 DCP / VCL5NAC4DP40 40 DCP / VCL6XAC4DP40 40 DCP / S VCL6XAC6HL50 50 HL / L 450 # VCL6XAC4HL75 75 HL / L 450 # VCL7XAC4DP40 40 DCP / S VCL7XAC6HL50 50 HL / L 450 # VCL7XAC4HL75 75 HL / L 450 # DC31YH5AC4DP40 40 DCP / # DC31YH5AC4HL75 75 HL / # DC31YH5AC4HL HL / # DC32YH6AC4DP40 40 DCP / # DC32YH6AC4HL75 75 HL / # DC32YH6AC4HL HL / # # Not available at time of publication. Heat transfer rating kw/ C ETD is for Mineral Oil with operating viscosity less than 100 cst. * Noise levels listed are raw A 1 metre representing worst case. Refer noise level statement page

23 Air Cooled Exchangers With Coaxial Pump DIMENSIONS - Air Cooled Exchangers with Coaxial Pumps MODEL VCL Vertical mounting feet available see Versacool Accessories page 60. F A AIRFLOW K INLET PORT "" J E OUTLET PORT "A" D2 D1 "D" "C" H AIR COOLED WITH INLINE PUMP SLOTS 10 X 16 N C MODEL A C D1 D2 E F H J K N "A" "" "C" "D" VCL4XAC4DP40# " 1" 1" 3/4" VCL5NAC4DP " 1" 1" 3/4" VCL6XAC4DP " 1" 1" 3/4" VCL6XAC6HL " 1 1/4" 1" 3/4" VCL6XAC4HL " 1 1/4" 1" 3/4" VCL7XAC4DP /4" 1" 3/4" - VCL7XAC6HL /4" 1 1/4" 3/4" - VCL7XAC4HL /4" 1 1/4" 3/4" - #Ports C and D are on model VC4X or on opposite side to that shown. Ports SPP to ISO 228/1G MODEL DC31P & DC32P PUMP INLET PUMP OUTLET F* PORT "" A PORT "D" PORT "A" PORT "E" K AIRFLOW H E "C" D SLOTS 10 X 25 K C MODEL A C D E F* H K "A" "" "C" "D" "E" DC31YH5AC4DP /4" 1" 1 1/4" 1" 1 1/4" DC31YH5AC4HL /4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" DC31YH5AC4HL /4" 1 1/2" 1 1/4" 1 1/2" 1 1/4" DC32YH6AC4DP /4" 1" 1 1/4" 1" 1 1/4" DC32YH6AC4HL /4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" DC32YH6AC4HL /4" 1 1/2" 1 1/4" 1 1/2" 1 1/4" Ports SPP to ISO 228/1G All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 23

24 24

25 Special Application Air Cooled Oil Coolers Air cooled oil heat exchangers for use where the standard aluminium element type oil coolers are not acceptable for the following reasons. Circuits where higher pressures are expected to be encountered. Where the atmosphere or the process fluids are not compatible with aluminium. Where explosive environments prevent the use of aluminium. Eg :- Coal Mines. Where lower internal film coefficient is required for use with higher viscosity oils. Where heavy dust laden environments exist. These units have anticlogging type fins SERIES S MODEL CODES SERIES S, ST, SI, VC etc. ASIC MODEL NUMER = 4, 6, 7,40, 50, 75 & 110 etc. COOLING ELEMENT TYPE R = Steel fin, copper tubes, steel tanks - Operating pressure 20 ar Z = Pin fin, Stainless tube - Operating pressure 10 ar (VC4Z up to 70 ar) PORT ORIENTATION H = Horizontal. V = Vertical FAN DIAMETER (mm) 4 = Ø450 5 = Ø500 6 = Ø630 8 = Ø800 ST 75 R H 8 AC 6 00 AIR COOLED SPECIAL APPLICATION ASIC DRIVE TYPE AC = 3 Phase electric motor AD = 1 Phase electric motor HF = Hydraulic orbit motor HV = Hydraulic vane motor HX = No motor (hydraulic motor mounting provided. Customer to specify motor details) NM = No motor (electric motor mounting provided) GA = Air motor MOTOR SPEED 4 = 4 Pole 6 = 6 Pole 8 = 8 Pole SPECIAL DETAILS OR FINISH 00 or none = 415V 50Hz 01 = 240V 50Hz 0C = with antistatic fan suitable for underground coal mine use. 0R = with relief valve. TECHNICAL SPECIFICATIONS - STEEL CORE AC ELECTRIC MODELS MODEL/ Noise level * Fan Ø Volts Phase kw Size Poles Weight Part Number d(a) at 1m (mm) (kg) VC4ZAC50# VC4ZAG50# ST40RH4AC400# ST50RH5AC400# ST75RH6AC L ST75RH8AC L ST75RH8AC M ST110RH8AC40R L * Noise levels listed are raw A weighted pressure representing worst case. Refer noise level statement page 67. # Also available with 240 volt single phase electric motor. Also available with 12 or 24 volt DC electric motor (reduced cooling capacity). 25

26 Special Application Air Cooled Oil Coolers PERFORMANCE - AC ELECTRIC SERIES S ST110RH8AC4 ST110RH8AC6 ST75RH8AC4 ST75RH8AC6 ST75RH6AC4 AIR COOLED SPECIAL APPLICATION kw/ C ST50RH5AC4 0.3 ST40RH4AC VC4ZAC Oil Flow l/min 600 P ar VC4Z S100Z ST75R ST110 ST40/50R Oil Flow l/min OIL COOLER SIZING Step 1. Calculate ETD = TOil - TAir TOil= Temp C of oil entering the cooler (usually the same as max allowable oil temp.) TAir= Expected Ambient Air Temp C. Step 2. Calculate kw/ C ETD = kw kw=heat Load. ETD Step 3. Enter Cooler Performance Tables and select a cooler which meets or exceeds the required performance at the required oil flow rate. Step 4. Check pressure drop of the oil cooler selected in step 3. If the average oil viscosity is not 30 cst apply a correction for the expected viscosity. Computer model selection program available. P Correction Factor Oil Viscosity cst 26

27 Special Application Air Cooled Oil Coolers DIMENSIONS - AC ELECTRIC SERIES S MODEL VC4ZA H Model A C D E F* G H J K L M Port A Port Port C Port D VC4Z /4" 3/4" - - *Nominal Varies with motor type. Ports SPP to ISO 228/1G MODEL ST40, ST50 & ST75 22> A DYNACOOL "" E Slots 16 Along 10 Across 4 Places ottom And Top A C Port "A" 58 "A" G AIR PRODUCT LINE F* M K 105 F* UNDER REVIEW Mounting feet and thermostat options page AIR COOLED SPECIAL APPLICATION H E AIR X C Port "" D J K M L Slots 10 x 25 Model A C D E F* G H J K L M Port A Port Port C Port D ST40R /4" 1 1/4" - - ST50R /4" 1 1/4" - - ST75R " 2" - - *Nominal Varies with motor type. Ports SPP to ISO 228/1G MODEL ST UILT IN RELIEF VALVE 30 PSI STD 60 PSI OPTIONAL * PORT "" AIR ST110 Port size A 2" 2" PORT "A" HOLES 14 All ports SPP to ISO 228/1G *Nominal, Varies with motor brand. All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 27

28 Special Application Air Cooled Oil Coolers SPECIFICATIONS - STANDARD DC ELECTRIC MOILE SERIES DFM MODEL DFM11 AIR COOLED SPECIAL APPLICATION Rugged high strength design High pressure round tube construction Damage resistant steel fins and tanks. Applications - Concrete Transit Mixers, Concrete Pumps, Cranes, Harvesters, Grain Handlers, Off-Road & Construction Machines etc. PERFORMANCE - DFM kw HEAT REMOVED MODEL DFM22 ased on ISO-VG32 oil entering 50 C higher than ambient air (50 C ETD) DFM - 11 DFM - 9 DFM - 12 DFM - 22 OIL PRESSURE DROP = 0.5 ar = 1.0 ar Water and dust resistant DC motor. OIL P MULTIPLIER DIMENSIONS - DFM MODELS DFM9 - DFM11 & DFM12 Motor Power Lead E L (2 Places) OIL FLOW - LITRES/MIN MODEL DFM22 G3/4" FAN A Motor Power Leads FAN OIL VISCOSITY - cst. L (2 Places) F J FAN A Air D E Air K # G3/4" D F 4 Holes 13.5 G C Pressure rating 21 ar Min. burst pressure 62 ar # Not available on DFM9 models Part No Volts Amps A C D E F G J K L* Wt kg 67/DFM9/ G3/4" 9 67/DFM9/ G3/4" 9 67/DFM11/ G1" 10 67/DFM11/ G1" 10 67/DFM12/ G1 1/4" 19 67/DFM12/ G1 1/4" 19 67/DFM22/ G1 1/2" 35 67/DFM22/ G1 1/2" 35 K J 4 Holes 13.5 G C All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 28

29 Special Application Air Cooled Oil Coolers THERMOSTATIC CONTROLS FOR DC ELECTRIC MOILE SERIES DFM DIMENSIONS - DFM - RELIEF VALVE MODELS MODELS DFM11R & DFM12R Motor Power Lead E L (2 Places) FLOW MODEL DFM22R A G3/4" FAN Motor Power Leads FAN L (2 Places) F J FAN A Air D FLOW E Air K # G3/4" D F 4 Holes 13.5 G C 4 Holes G K J 13.5 C Pressure rating 21 ar Min. burst pressure 62 ar Part No Volts Amps A C D E F G J K L* Wt kg 67/DFM11/12R G1" 10 67/DFM11/24R G1" 10 67/DFM12/12R G1 1/4" 19 67/DFM12/24R G1 1/4" 19 67/DFM22/12R G1 1/2" 35 67/DFM22/24R G1 1/2" 35 Standard relief valve setting is 2 ar. Inlet and outlet connections may be reversed when bypass valve is not used. AIR COOLED SPECIAL APPLICATION All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. Thermostats Are An Important Addition To DFM Models To Maximise Fan Motor Life SCT Type. DFM9 models are rigged for fitting our low cost SCT (surface conductive thermoswitch) Thermo kits which are controlled by cooler tank temperature. Available in fixed 55 C or 65 C ranges, differential is 9 to 12 C. Supplied normally open, temperature closes contacts to start motors. Kits include thermoswitch and mount bracket, harness relay, fuse, fuse holder connectors and fitting instructions. Part No. Description 67/05198 Thermo Kit 65 c For DFM 9 in 12 Volt 67/05199 Thermo Kit 65 c For DFM 9 in 24 Volt 67/05200 Thermo Kit 55 c For DFM 9 in 12 Volt 67/05201 Thermo Kit 55 c For DFM 9 in 24 Volt 17/DC Wet Type. A self contained thermostatically controlled electric switch mounted in a steel bulb well for immersion in the hot process fluid. The switch is usually supplied with normally open contacts. Kits include a fuse, fuse holder, port adaptor S , relay, wiring and fitting instructions. Part No. Description Thermo Kit 65 c For DFM 11 & 12 in 12 Volt Thermo Kit 65 c For DFM 11 & 12 in 24 Volt Thermo Kit 55 c For DFM 11 & 12 in 12 Volt Thermo Kit 55 c For DFM 11 & 12 in 24 Volt Thermo Kit 65 c For DFM 22 in 12 Volt Thermo Kit 65 c For DFM 22 in 24 Volt Thermo Kit 55 c For DFM 22 in 12 Volt Thermo Kit 55 c For DFM 22 in 24 Volt 123W wet thermoswitch also available see page 58. For more infrmation about the 17/DC wet thermoswitch see page 59. Adjustable thermoswitch see page

30 Special Application Air Cooled Oil Coolers SPECIFICATIONS - DC ELECTRIC MOILE SERIES VERSACOOL AIR COOLED SPECIAL APPLICATION Rugged high strength design. Suitable for use in mobile equipment to cool hydraulic oil at pressures up to 70 ar. Fan driven using 12 or 24 Volt DC power supply. Specifications Maximum Operating Pressure bar Maximum Operating Temperature C Materials of construction Tubes Stainless steel Header Tanks Stainless steel Fins Stainless steel Case Steel, powdercoat Wedgewood Fan/Cowl Plastic, black Motor Steel case, weatherproofed PERFORMANCE - VC4Z 10 PRODUCT LINE UNDER REVIEW ased on ISO-VG32 oil entering 50 C higher than ambient air (50 C ETD) Applications - Concrete Transit Mixers, Concrete Pumps, Cranes, Harvesters, Grain Handlers, Off-Road & Construction Machines etc kw HEAT REMOVED VC4ZDA## OIL PRESSURE DROP = 0.5 ar = 1.0 ar OIL P MULTIPLIER OIL FLOW - LITRES/MIN OIL VISCOSITY - cst. DIMENSIONS - VC4Z PORTS G 3/4" VERSA-COOL 412 Slots Ø10 x 16 Top And ottom Part Number Motor Voltage Current Draw Recommended Fuse VC4ZDA amps 20 amps VC4ZDA amps 15 amps Thermoswitches available to start fan at 55 C or 65 C oil temperature. Switches off 8-10 C lower. Mounting feet and thermostat options all models page All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 30

31 Air After Coolers With Aluminium Cooling Elements SPECIFICATIONS - VERSACOOL MODELS Notes On Selection Underlined models are usually the highest performance lowest cost options. Other models are usually low noise or special application. For more details consult our sales office. SCFM = Standard Cubic Feet Per Minute. For Standard Cubic Metres Per Minute divide CFM by Effectiveness % = T1 - T2 T1 - t1 Where: T1 = Air line temp entering cooler. T2 = Air line temp leaving cooler. t1 = Design ambient air temp to fan. P Column = Pressure drop of the air through the aftercooler in Lbs per square inch at the air flow shown in "SCFM 85%" column. Higher air flows than stated may be passed through most models. However, effectiveness % will reduce and P will increase. Data is valid for air pressure in the 100 PSIG (6.9 AR) Range. Separators Are Customer Supply. Stand Kits Are Supplied Loose With Fastenings. 12 & 24 Volt DC Fan Drives Available. Models VC6 And VC7 Will Accept Size 4 Air Motors. Three phase models 240/415v 50Hz MODEL VC2XAC50 VC2XAG50 VC4XAC50 VC4XAG50 VC5XAC50 VC5XAG50 VC6XAC50 VC7XAC50 Electric motors *AMPS kw SIZE 63b2 63b4 71a2 71a4 71a2 71a4 80a4 80a4 95% Eff % Eff % Eff Motor Enclosures are IP55. Motor Construction to IEC 34-1 Mounting To IEC 34-7 (14 Flange) *Nominal, Varies With Motor rand For 60 Hz Models Consult Sales P PSIG Max Single phase models 240v 50Hz Cap run MODEL VC2XAD50 VC2XAH50 VC4XAD50 VC4XAH50 VC5XAD50 VC5XAH50 VC6XAD50 VC7XAD50 Electric motors *AMPS SIZE b m a a a a a a4 kw Separators Are Customer Supply. Model VC4XAC50 95% Eff % Eff % Eff P PSIG Max AIR AFTER COOLERS VC2X MODEL PORTS DOWN - WITHOUT STANDS 318 "C" 16 x 10 slots FAN AIR VC2XA Port size A C 1 1/16" 1 1/16" 1/2" * Flexible hose required Ports A & are Male JIC 37 flare UN. Port C is SPP to ISO 228/1G *Nominal, Varies with motor brand. "" "A" All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 31

32 Air After Coolers With Aluminium Cooling Elements DIMENSIONS - VERSACOOL MODELS AFTERCOOLERS ON 750 AND 900 STANDS M C H 105 G C/L FANS L 229 VERSA-COOL K Slots 25 x E W AIR AFTER COOLERS Model C E G* H K L M W Ports Stand kit VC4XA# " SPP VC5XA# " SPP VC6XA# " SPP *Nominal, Varies with motor brand. SIZE 750 stand will fit VC5 and VC6 if separators are not required AFTERCOOLERS ON 1100 STANDS M C H 105 G " VERSA-COOL K H Slots 25 x E W Model C E G* H K M W Ports Stand kit VC5XA# " SPP VC6XA# " SPP VC7XA# /4" SPP *Nominal, Varies with motor brand. All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 32

33 Air After Coolers With Aluminium Cooling Elements SPECIFICATIONS AND DIMENSIONS - DYNACOOL MODELS MODEL VLNA & VLNA 31-15VLNA Weight kg 56 Electric Motor 0.75 kw 4 Pole 415VAC Also Available With Size 4 Air Motor Performance Effectiveness 220 SCFM = 97% P = SCFM = 94% P = SCFM = 92% P = SCFM = 90% P = 4.3 PSI Part Number DC31YV5AC402 MODEL DC33 Weight kg 180 Performance Effectiveness 500 SCFM = 98.5% P = SCFM = 96.5% P = SCFM = 93.5% P = 5.1 PSI Electric Motor 1.5 kw 4 Pole 415VAC Also Available With Size 5 Air Motor 32-20VLNA Weight kg 92 Electric Motor 1.5 kw 4 Pole 415VAC Also Available With Size 5 Air Motor Performance Effectiveness 400 SCFM = 98% P = SCFM = 97% P = SCFM = 96% P = SCFM = 95% P = 3.0 PSI Part Number DC32SV6AC400 Model A C D E* A C 31-15VLNA /4" 1 1/4" 1 1/4" 32-20VLNA " 2" 3/4" *Nominal, Varies with motor brand. SPP to ISO 228/1G E AIR 2 Slots 10 x 25 "" 1030 PORT "A" A X PORT "" PORT "C" 122 D 101 C Pressure Rating 14 AR (200 PSIG) 706* 72 AIR AIR AFTER COOLERS Part Number DC33VH6AC400 "C" "A" 75 Pressure Rating 20 AR (290 PSIG) Slots 10 x 25 MODEL HLN 35-20HLN Weight kg 183 Performance Effectiveness 500 SCFM = 99.8% P = SCFM = 99.5% P = SCFM = 99% P = SCFM = 98% P = 5.4 PSI Electric Motor 2.2 kw 6 Pole 415VAC nom may vary with motor type AIR PORT "" 2" SPP X PORT "A" 2" SPP 1255 Part Number DC35UH9AC600 Add P for ottom Ports Pressure Rating 14 AR (200 PSIG) PORT "C" 3/4" SPP Slots Ø10 x May e Supplied With Cooling Element Rotated 180 So That 2" Ports Are Situated At ottom (Code P) All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 33

34 Cooling Elements For Add-On or Replacement ROUND TUE MOILE SERIES DH COOLING ELEMENTS ASIC INFORMATION REQUIRED A. ESTALISH AMIENT AIR TEMPERATURE. This is the maximum air temperature in which the cooler will be operating. It may vary depending upon what locality the appliance is being called upon to operate in.. DETERMINE THE INLET OIL TEMPERATURE. This is usually equal to the maximum temperature considered to be acceptable for the oil circuit. C. DETERMINE WHAT AIR FACE VELOCITY IS AVAILALE. AFV. In many mobile applications the cooler will be placed in front of existing engine water radiator. Ensure that the increased static pressure required to draw air through the oil cooler will not reduce the effectiveness of the engine radiator. The performance graphs are based on a AFV of 5.55 Meters per second which is equal to a vehicle road speed of 20 kph. Table 6 provides static pressures in Pa for the cooler cores. Heat removal kw at 30 C ETD Heat removal kw at 30 C ETD Part No 5 6, 7, 67/073S2L Through 3. 67/524S5H 1, Litres Per Minute Oil Flow Table 1 Table Litres Per Minute Oil Flow Table 4:Pressure Drop Symbols Pressure Drop 30cSt ISO 68 Oil at 58 c (136f) x 14.5 for PSI 0.73 AR 1.46 AR 2.90 AR 4.35 AR 8. Part No 67/649S8H Table 5: Pressure Drop Factors Corrections For Oil Viscosity P Correction Factor Oil Viscosity cst D. ESTALISH THE HEAT LOAD TO E REMOVED IN KILOWATTS. Heat load in the graphs in tables 1 and 2 is expressed in Kilowatts per degree C at 30 C ETD. Heat load can be considered to be equal to the inefficiency of the system as a percentage of the power input, less the thermal dissipating capacity of the system. STEPS IN MAKING A COOLER SELECTION 1. Calculate the ETD by subtracting the A Ambient air temperature from the inlet oil temperature. The heat load performance graphs are based in a ETD of 30 C. If your ETD is other than 30 C make a correction for ETD as follows. 30 HL from "D " x ( ETD as calculated in 1 ) = Corrected HL 1 2. If available air face velocity is different than 5.55 m/s upon which the graphs are based, a further correction should be made for AFV "C". Refer to Table 3. Read off the correction factor for the AFV you intend to apply to the cooler and correct as follows. Corrected HL 1 = Corrected HL 2 AFV Correction Factor (Table 3) 3. With Corrected HL 2 enter Table 1 or Table 2 and select the cooler type equal to or greater than your application by following the appropriate lines equal to your oil flow in litres per minute and your Corrected HL 2. The number at right hand side of each curve indicates the cooler ID for the cooler type which can be read from the dimensional information on facing page. For larger coolers contact our Sales Department. 4. The Delta P (pressure drop) for the selected cooler at various oil flow rates can be established by referring to the Pressure drop symbols on each curve as explained in Table 4. These symbols are indicative of pressure drop with oil at 30 cst viscosity. Corrections for other viscosities are shown on right hand side of the graph in table 5. To correct, multiply the pressure drop established from the graph symbols by the correction factor from Table Most of our Mobile Oil Coolers are available with optional full flow built in bypass valves set to 2 AR or 4 AR. Under most circumstances these units may be used as constant bypass valves. Constant bypass arrangement permits higher than rated flow to pass the cooler core under cold start up conditions while allowing maximum flow through the core when the oil reaches a temperature where a high level of cooling is required. Operating pressure-21 ar (300 PSI). Min burst pressure-62 ar (900 PSI), Max Operating Temperature 180 C Table 3: Heat Transfer Correction Factors for Air Face Velocity In Metres Per Second = = = = = = = = = Table 6: Air Static Pressure Drop For Air Face Velocity In Pa 1 Row 2 Row Core Core in. H2O = Pa x Air Flow m/s

35 Cooling Elements For Add-On or Replacement DIMENSIONS - ROUND TUE MOILE SERIES DH LIGHT DUTY TYPES (With Steel or Aluminium Fin & Copper Tanks) E G "F" Ports HEAVY DUTY (With Steel Fin & Square Steel Tanks) E G C C H A H A 25 3 D 13 D 25 Core Width W ID Part No 67/073S2L 67/073S3L 67/084S3L 67/106S2L 67/194S3L DIMENSIONS - LIGHT DUTY With Steel Fins, Copper Tubes & Tanks - SPP Ports Cooler Type DC10318S1 DC10318R1 DC10324R1 DC10421S1 DC10618S1 Wt kg A " " " " " " " " " " C " " " " " D " " " " " E " " " " " F* 1/2" 3/4" 3/4" 1/2" 3/4" G " " " " " * All Ports Are SPP Straight Female To ISO 228/1G. Use Parallel Face Fittings. H " " " " " Ø W " " " " " ID ID Part No 67/216A3L/N 67/216A4L/N 67/249A3L/N 67/348A4L/N Part No 67/194S3H 67/216S3H 67/216S4H 67/249S4H 67/326S5H 67/425S5H 67/524S5H 67/649S8H DIMENSIONS - LIGHT DUTY With Aluminium Fins, Copper Tubes & Tanks - NPT Ports Cooler Type DH10624R1 DH10624R1 DH10924S1 DH11524S1 Wt kg A " " " " " " " " E " " " " F* 3/4" 1" 3/4" 1" G " " " " Wt kg C D " " " " " " " " * All Ports Are NPT Female. H " " " " DIMENSIONS - HEAVY DUTY With Steel Fins, RHS Steel Tanks & Copper Tubes - SPP Ports Cooler Type DC10618S1 DC10624S1 DC10624R1 DC10924R1 DC11224R1 DC11830S1 DC20924R1# DC21842R1# A " " " " " " " " " " " " " " " " C " " " " " " " " D " " " " " " " " E " " " " " " " " F* 3/4" 3/4" 1" 1" 1 1/4" 1 1/4" 1 1/4" 2" G " " " " " " " " * All Ports Are SPP Straight Female To ISO 228/1G. Use Parallel Face Fittings. # Indicates 2 row core All dimensions shown are in mm ypass Valves are available on some models - refer to sales office for details. H " " " " " " " " Ø W " " " " W " " " " " " " " COOLING À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À Rubber Squeeze lock For use on Light Duty types. Fit between two tubes in gap between tank and fins. Kit includes mtg strap and 5/16" bolt. 4 required. Kit No À@ À@ À@ À@ À@ À@ À@ À@ À Saddle racket For use on Light Duty or Heavy Duty types. Clamps to two tubes in gap between tank and fins. Kit includes mtg strap, 15 mm steel spacer and 5/16" bolt. 4 required on Heavy Duty types. Kit No L MOUNTING SYSTEMS ÀÀ 12 Tank Mount Angle racket For use on Heavy Duty types. 3 mm Steel brackets with 11 mm bolt-down hole, may be used as removable clamps or may be welded to tanks by customer. 4 required. A Pt 67/03/03839 Single Row Cores Pt 67/03/03840 Two Row Cores Mounting Strip Mounting Strips are useful for attachment applications and are made from 1.4 mm steel 173mm long 26mm wide and have 7 x 8.5mm ES holes on 25.4mm centres. They are shipped standard when Kits L or L are ordered. Port Connections Ports. All port nozzles are SPP Female to ISO 228/1G. Although SPT fitting may be used with thread sealer, the preferred fittings are SPP O Ring type. Light Duty Types. Rubber hoses must be used at the port connections. Use two wrenches when tightening fittings, one on the fitting and the other on the port nozzle hex. Heavy Duty Types. May be hard piped providing excess strain is not applied to the port nozzles. All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 35

36 Cooling Elements For Add-On or Replacement PFA AND ALUMINIUM CORES PFA SERIES ALUMINIUM CORES - JIC Ports - 11 ar Part No. 69/04209W High performance, small size and light weight oil coolers for small hydraulic systems on tractors and transmission or engine oil cooling on automotive applications. Also suitable for air line aftercooling and use with other fluids. Do not install these coolers in systems with high shock loading such as hydraulic cylinder circuits. Pressure rating 11 bar Weight 2.1kg HOLES PORTS 1 1/16" JIC MALE COOLING ELEMENTS 190 HI-FLOW SERIES ALUMINIUM CORES - JIC Ports - 14 ar Part No. 18/ bar Pressure rating Weight 4 kg Ports A and are Male JIC 37 flare UN type 1 1/16" 12TPI. C is 1/2" SPP to ISO 228/1G. Flexible hose required. PORT C PORT A PORT HI-FLOW SERIES ALUMINIUM CORES Part No. 18/ bar Pressure rating Weight 75 kg Part No. 18/ bar Pressure rating Weight 27 kg 3/4" SPP PORTS 2" SPP PARALLEL TO ISO228/1G 20 HOLES PORT G 3/4" TO ISO228/1G PORTS 1 1/2" SPP TO ISO228/1G HOLES All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 36

37 Cooling Elements For Add-On or Replacement HI-FLOW SERIES ALUMINIUM CORES HI-FLOW SERIES ALUMINIUM CORES - 14 ar TYPE A F C D F # A W L J K 14 bar Pressure rating Very low pressure drop Suitable as air aftercooler H G E # Some older models have a single flange TYPE F E C D F TYPE C /4" 12.7 A (W) H G J COOLING ELEMENTS Part No TYPE A C D E J K F G L H W Max Flow Heat Weight mm mm mm mm mm mm mm mm l/min Cap*. kw kg 21/05030 C /04778 A " 3/4" /05824 A " 1" 3/4" /04779 A " 1" /04994 A /4" 3/4" E2926 A /4" 1 1/4" E2927 A /4" 1 1/4" /04996 A " 3/4" /05031S " 3/4" / " 3/4" Ports SPP to ISO 228/1G * Heat capacity is at max oil flow, airflow of 5.1 m/s velocity through the core and oil/air inlet temp. difference of 30 C This port is on other side of the core to that shown. Part No New Equivalent Cross reference Old OEM (SP) Other (NPT) 1E / /01/ E2922 1E2928 1E / /01/ E2929 1E /01/ E2931 1E /01/ E2932 1E / /01/ (Ext d tank) 1E2966 Caution: Some original model coolers were supplied with NPT threaded ports. All new coolers have SP threaded ports. SP ports have a groove machined on the OD to assist in identifying the thread. All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 37

38 38

39 WATER COOLED EXCHANGERS Extended Surface - EK Series. Page 40 to 41 Large Capacity Extended Surface - ECM Series. Page 42 Marine and Special Application - Series. Page 43 NEW DYNACOOL Oil Coolers - WM and WI Series. Page 44 to 46 NEW SEN-DURE - Marine Oil Coolers. Page 47 Model 3712 razed plate immersion cooler. Page 48 Donut engine lube oil cooler. Page 48 Oil Pump and Pump Packages Page 51 Heat Exchanger Accessories Page 57 Product Application and Useful Formula Page 65 WATER COOLED Faxable selection guide for customer use Page 69 & 70 WATER COOLED EXCHANGERS General information. Water cooling has many advantages over air blast type heat exchangers. The main limitation to their use is availability of the coolant supply to ensure adequate heat transfer. In order to accurately select a Dynacool model it is prudent to verify coolant availability including maximum expected operating temperature and quality. Generally 90/10 CuNi will provide the best service in fresh water, sea water and potable or even non potable water supplies. Stainless steel may be more suited in some applications but not always. Dynacool can offer shell and tube units with SS(316) tubes made to order, contact our sales office for sizing. Very low noise ( no noise generated by fan motors ) Eliminates the fin clogging problems associated with air blast coolers in dusty environments Compact overall size when compared to equivalent air blast package etter ability to handle cycling pressures Heat energy is removed from local area by the cooling fluid therefore not raising the air temperature around surrounding equipment. To ensure best quality and competitiveness product design is continuously reviewed, therefore all information published in this brochure is subject to change without notice and should not be relied upon without confirmation from our office. Jan

40 Water cooled - Industrial Heat Exchangers EK SERIES - EXTENDED SURFACE EK Series Selection procedure Step 1. Determine the Heat Load. This will vary with different systems, but typically coolers are sized to remove 25 to 50% of the system s input total maximum power rating. (Example: 75kW Power Unit x.33 = 25kW Heat Load) Step 2. Determine Approach Temperature. Desired exit oil temp C - Water inlet temp C = Actual Approach Step 3. Determine Curve kw Heat Load. Enter the information from above: kw heat load x 25 x Viscosity Correction A = Curve kw load Actual approach Step 4. Find Curve Operating Point. Locate on the graph the point determined by the oil flow and the curve kw heat load. Any cooler curve above this point will have sufficient capacity. Step 5. Determine Oil Pressure Drop from Curves. = 0.5 ar = 1.0 ar = 2.0 ar Multiply pressure drop from curve by correction factor found on oil viscosity correction curve. OIL VISCOSITY CORRECTION MULTIPLIERS VISCOSITY CORRECTION A-EK TWO A-ECM TWO PASS 2:1 A-EK ONE PASS OIL VISCOSITY (Average) - Centistokes Performance curves are based on ISO VG 32 oil leaving the cooler 25 C higher than the incoming water temperature used for cooling. This is also referred to as a 25 C approach temperature. WATER COOLED Extended surface to minimise water consumption Corrosion resistant 90/10 copper nickel tubes as standard (Cu optional) Water Flow Controls & Strainers available as options see pages 58 & 59 Surge-Cushion The Surge-Cushion is a protective device (patented) designed to internally bypass a portion of the oil flow during cold start conditions, or when sudden flow surges temporarily exceed the maximum flow allowed for a given cooler. This device may replace an external bypass valve, but it is not intended to bypass the total oil flow. TECHNICAL SPECIFICATIONS Materials Shell... Steel Tubes... Copper/Nickel Tubesheets... Steel affles... Steel Fins... Aluminium Mounting rackets... Steel End Caps... Grey Iron Gaskets... Nitrile Rubber/Cellulose Fibre Nameplate... Aluminium Foil PERFORMANCE Models Part No Wt kg 1. 25EK1/1 65/EK5080S* EK1/2 65/EK508TS* EK4/1 65/EK5140S* EK4/2 65/EK514TS* EK1/1 65/EK EK1/2 65/EK708T EK2/1 65/EK EK2/2 65/EK712T EK4/1 65/EK EK4/2 65/EK718T EK2/1 65/EK EK2/2 65/EK1012T EK4/1 65/EK EK4/2 65/EK1018T EK5/1 65/EK EK5/2 65/EK1024T EK6/1 65/EK EK6/2 65/EK1036T 30.4 *To order with Surge Relief omit S to part No. Maximum Flow Rates Unit Shell Side Tube Side Litres/min. Size Litres/Min. One Pass Two Pass Four Pass 25EK N/A 35EK EK Ratings Maximum shell side pressure ar Maximum tube side pressure ar Maximum temperature C 1:1 Oil to Water Ratio One Pass Models & 2:1 Oil to Water Ratio Two Pass Models HEAT REMOVED (kw OIL FLOW (L/min) 7 8 Oil P = 0.5 ar = 1.0 ar 40

41 Water cooled - Industrial Heat Exchangers EK SERIES - DIMENSIONS EK Series 25 EK SERIES OIL H2O L A H C K OIL P Slots M D Single Pass E F M H 2O N D Two Pass Surge cushion internal bypass relief available on 25 EK series as an option. H 2O E F COMMON DIMENSIONS Single Pass Models Two Pass Models Model A C D E F H* K L M* P L M* N P 25EK /4" EK1/ /4" EK1/ /8" EK /4" EK4/ /4" EK4/ /8" *All ports are SPP female pipe thread to ISO 228/1G Mount Slots 25EK = 8.6 x 12.7 Tolerance + 3mm 35 EK SERIES L A H P N OIL H2O K OIL M E M H 2O F H 2O E F C Slots D Single Pass D Two Pass Surge cushion internal bypass relief supplied on all 35 and 50 EK series. COMMON DIMENSIONS Model A C D E F H* K 35EK /2" EK /2" EK /2" 89.4 OIL H 2 O L A K H OIL Single Pass Models Two Pass Models L M* P L M* N P 35EK1/ /4" EK1/ /4" EK2/ /4" EK2/ /4" EK4/ /4" EK4/ /4" *All ports are SPP female pipe thread to ISO 228/1G Mount Slots 35EK = 11 x 19 Tolerance + 3mm 50 EK SERIES P M E F WATER COOLED 1/4" NPT Drain OIL C L A H P Slots M D Single Pass N OIL K H 2O H 2O E F C Slots D Two Pass Surge cushion internal bypass relief supplied on all 35 and 50 EK series. COMMON DIMENSIONS Single Pass Models Two Pass Models Model A C D E F H* K L M* P L M* N P 50EK /2" EK2/ /2" EK2/ " EK /2" EK4/ /2" EK4/ " EK /2" EK5/ /2" EK5/ " EK /2" EK6/ /2" EK6/ " *All ports are SPP female pipe thread to ISO 228/1G Mount Slots 50EK = 11 x 25 Tolerance + 3mm 41

42 Water cooled - Industrial Heat Exchangers ECM SERIES - LARGE CAPACITY EXTENDED SURFACE ECM Series Extended surface to minimise water consumption Anodes, Cu Ni Tubes available as options Water Flow Controls & Strainers available as options WATER COOLED TECHNICAL SPECIFICATIONS Materials Shell... Steel Tubes... Copper or Copper/Nickel Tubesheets... Steel affles... Steel Fins... Aluminium Mounting rackets... Steel End Caps... Grey Iron Gaskets... Nitrile Rubber/Cellulose Fibre Nameplate... Aluminium Foil Anodes available as optional extra. PERFORMANCE Part No Wt kg *1. 65/ECM/1236/TSW /ECM/1724/6/T /ECM/1754/9/T /ECM/1784/14/T /ECM/1724/6/S /ECM/1754/9/S /ECM/1784/14/S * This unit suitable for seawater as coolant. Cu Ni Tubes, SS316 Tubesheet and ronze onnets. DIMENSIONS A C L ECM1724/S ECM1754/S ECM1784/S ECM1724/T ECM1754/T ECM1784/T All ports are SPP female pipe thread to ISO 228/1G Mount slots 15.7 x 22.4 in 4 places Tolerance + 3mm UNO. 1/2" SP Drains 2 Places Dia OIL Slots 15.7 x 22.4 HEAT REMOVED (kw) Performance curves are based on ISO VG 32 oil leaving the cooler 25 C higher than the incoming water temperature used for cooling. This is also referred to as a 25 C approach temperature. For correction curves see page /2" SP Drains 2 Places L A C " SPP OIL FLOW (LITRES/MIN) 3/8" SP Drains 3 Places OIL Slots 12.7 x 19 OIL S = 184 T = 179 Maximum Flow Rates Unit Shell Side Tube Side Litres/min. Size D Litres/Min One Pass Two Pass D ECM ECM Ratings Maximum shell side pressure ar Maximum tube side pressure ar Maximum temperature C Oil P 70 Oil = 0.5 ar 60 = 1.0 ar 2 = 2.0 ar Model ECM/ " SPP OIL /8" SP Drains 3 Places Model ECM/1724, ECM/1754 & ECM/1784 4" SPP 1/2" SP Drains HEAT REMOVED (kw) 178 Single Pass P = 0.5 ar = 1.0 ar = 2.0 ar OIL FLOW (LITRES/MIN) " SPP 1/2" SP Drains 2" SPP Two Pass H2O H2O H2O 79 H2O

43 Water cooled - Industrial Heat Exchangers SERIES - MARINE & SPECIAL APPLICATION Series Applications Marine rackish Water Air Aftercooling Water to Water Technical Specifications Materials Tubes...Copper Nickel (90/10) Tubesheets...rass Shell...Steel (rass optional) Shell Connections...rass affles...rass End onnets...ronze Mounting rackets...steel Gaskets...Nitrile Rubber/Cellulose Fibre Hardware...Alloy Steel/Optional SS Anodes...Zinc in Alloy Steel Design Pressure Shellside : 17 bar Tubeside : 10 bar Design Temperature : 150 C DIMENSIONS One Pass (Code 0 ) M N P Q* 0401/OSW " 0701/OSW /8" 1 1 /2" 0702/OSW /8" 1 1 /2" 1003/OSW /8" 2" 1006/OSW /8" 2" 1206/OSW /2" 3" 1608/OSW /2" 4" Ratings Max Flow Max Flow Cooling Part No. Shell Side Tube Side Capacity (L/min) (L/min) (kw)* 65/0401/OSW /0701/OSW /0701/FSW /0702/OSW /0702/FSW /1003/OSW /1003/TSW /1006/OSW /1006/TSW /1206/OSW /1206/FSW /1608/OSW /1608/FSW * Performance based on ISO68 oil in shell leaving at 22 C above cooling water entering temperature in tubes. Fluids at maximum flow rates. For capacities at other operating conditions consult our sales office. Two Pass (Code T ) M N P Q* R 1003/TSW /8" 1 1 /2" /TSW /8" 1 1 /2" 30 WATER COOLED Four Pass (Code F ) M N P Q* R S 701/FSW /8" 3 /4" /FSW /8" 3/4" /FSW /2" 1 1 /2" /FSW /2" 2" All dimensions are ± 2%. COMMON DIMENSIONS A C D E F G H J K* L Wt kg Ø /2" Ø11x25 3 /8" 1" Ø11x25 3 /8" 1" Ø11x25 3 /8" 1 1 /2" Ø11x25 3 /8" 1 1 /2" Ø11x22 3 /8" 2" Ø11x25 3 /8" 3" All ports are NPT female pipe thread. SPP available. Ports Q for cooling fluid only. Port K for oil or fluid to be cooled. 43

44 Water cooled - Heat Exchangers W SERIES - EXTENDED SURFACE W Series WOULD YOU PROTECT YOUR INVESTMENT WITH ANY OTHER OIL COOLER? WM coolers are supplied with Zinc anodes fitted. WM single pass models are supplied with 2 sacrificial anodes and WM two pass models with 1 sacrificial anode. Anode cavities are accessed via a clear cap for tell tale anode condition viewing. Rugged steel shell, electric welded to the tubesheet for resistance to pressure failure. Oil port nozzles are also electric welded to the shell. Fixed bundle oil side extended aluminium plate surface with bullet expanded Ø1/4" 90/10 Cu/Ni tubes for the highest performance in the industry in the smallest package. End bonnets are all connected to the bundle using the unique threaded gland nut design which secures the bonnets in any radial orientation especially useful when using 90 bend bonnets or difficult anode access. Sealing is by O ring. WATER COOLED Tubesheets are 11mm thick with expanded connection. WI coolers have steel tubesheets. WM coolers have 316 grade stainless steel tubesheets and 90/10 Cu/Ni tubes, the ultimate in sea water compatibility. Removable steel mounting brackets are supplied and can be adjusted for a range of mounting spacings. End bonnets available in Single pass straight, Single pass 90 bend and Two pass. Refer to drawings. WM251SSS WM252SSS WM251SSN Single pass Marine Cooler 2 pass Marine Cooler Single pass Marine cooler with straight end bonnets with a straight and a 90deg bonnet. WI - PERFORMANCE - On road or off road torque converter and power shift transmissions Note. Model WI with its high heat conversion surface, rugged construction and straight or 90 hose tail coolant connections is well suited for use with torque converter and power shift transmissions such as Allison, Clark and Funk etc. If the engine operational water flow exceeds 250 L/m, the WI unit must have a suitable parallel bypass fitted. Refer next page for engine water plumbing. Consult factory for special bypass components. Allison Transmissions up to 275 engine HP.* WT (World Transmission) Series MD 300 & 300 Old models AT540, AT1540 and MT 600/300 Conv. Use WI Oil Coolers selected by engine input HP. WI151 max 120 HP, WI251 max 180HP, WI401 max 275HP. FUNK Powershift up to 225 engine HP.* 400 Series Series, 1000 Series 2000 Series, DF Series Use WI Oil Coolers selected by engine input HP. WI151 max 110 HP. WI251 max 150HP, WI401 max 225HP. *Above selections are based on engine water entering cooler at 82 c (180 F) and oil entering at 143 c (290 F) using latent heat phase assuming steam thermal expansion characteristics. 44

45 Water cooled - Heat Exchangers W SERIES - EXTENDED SURFACE W Series W SERIES MATERIALS Description WM coolers (LUE) WI coolers (ORANGE) Shell & Ports Steel Steel Shell & Port finish Zinc powder prime & powder coat Zinc powder prime & powder coat Tubes 90/10 Copper/Nickel 90/10 Copper/Nickel Tubesheets Stainless Steel Steel affles Steel Steel Fins Aluminium Aluminium Mounting rackets Zinc Plated Steel Zinc Plated Steel End Caps Stainless Steel or ronze Zinc Plated Steel Gaskets Nitrile Rubber Nitrile Rubber Nameplate Aluminium Foil Aluminium Foil Note:WM Coolers must be grounded to ships electrical earth system. W SERIES RATINGS Maximum Flow Rates Unit Oil Side Water Side Litres/min. Size Litres/Min. One Pass Two Pass W# W# W# W SERIES PERFORMANCE HEAT REMOVED (kw) Oil P = 0.5 ar = 1.0 ar W#151 W#152 W#251 W# Oil Flow L/min ORDERING CODES W#401 W#402 Water Pressure Drop kpa Performance curves are based on ISO 68 oil entering the cooler 40 C higher than the incoming water temperature used for cooling. This is also referred to as a 40 C entering temperature difference (ETD). For single pass models Oil to Water flow ratio is 1:1 For two pass models Oil to Water flow ratio is 2:1. DYNACOOL computer selection program is available to size units at other operating conditions Ratings Maximum oil/shell side pressure ar Maximum water/tube side pressure ar Maximum oil temperature C Maximum viscosity... 80cSt actual W#402 W#252 W#152 W#401 W#251 W# Water Flow L/min WI = INDUSTRIAL - 4" Shell with 1/4" Copper Nickel tubes, aluminium fins, steel tube plate. WM = MARINE - 4" Shell with 1/4" Copper Nickel tubes, aluminium fins, 316SS tube sheet. P Correction Factor Oil Viscosity cst WM 15 1 S S S WATER COOLED COOLING STACK LENGTH 15 = 150mm - 3/4" SPP Ports 25 = 250mm - 1" SPP Ports 40 = 400mm - 1 1/2" SPP Ports NUMER OF WATER SIDE PASSES 1 = Single pass, 2" hose tail and 1 1/4" SPP 2 = Two pass, 1" SPP END ONNET MATERIALS F = Steel - WI cooler as standard, available as 1 pass in straight or 90 and 2 pass. S = Stainless - WM cooler. 1 pass in straight or 90 and 2 pass. = ronze - WM cooler. 1 pass in straight only. END ONNET COMINATIONS S = Straight. N = 90 Elbow - SS316 only - single pass unit only - 2" hose tail. Replacement anode kits for WM series -73/01/

46 Water cooled - Heat Exchangers W SERIES - DIMENSIONS W Series WI COOLER - TRANSMISSION COOLING INSTALLATION Without bypass water flow less than 250 L/m With bypass water flow exceeds 250 L/m DIMENSIONS - W Series 1 Pass L A OIL PORTS "H" P 27 (hose) 126 2"(51) hose Water 60 OIL 101 OIL C Adjustable Tube field length Water 72 E 1/8" SP Drain Plug oth ends MW DYNACOO L WATER PORTS 1 1/4" SPP FEMALE AND 2" HOSE TAIL MALE 9.5 Holes DIMENSIONS - W Series 2 Pass L AL P 52 WATER COOLED 1/8" SP Drain Plug 90Deg End onnet may be rotated to allow hose to be connected from any angle OIL 101 C Adjustable 45 Tube field length 58 DIMENSIONS - W Series 90 End bonnet P OIL E 2"(51) hose tail only WATER PORT Water IN (hose) DYNACOO L DYNACOOL MW MW Water OUT WATER PORTS 1" SPP FEMALE 9.5 Holes May be field positioned around 360 deg to suit application. COMMON DIMENSIONS Model A C E H* W# /4" W# " W# /2" Single Pass Models 90 (oth ends) Two Pass Models Weight L P L^ P L P kg W# W# W# W# W# W# * All ports are SPP female pipe thread to ISO 228/1G Tolerance + 3mm ^ Overall length for units that have 1x90 and 1xstraight bonnet is L - 28mm. Dimension C is factory preset. Mounting feet location may be adjusted to suit your application. Units may also be rotated and clamped allowing mounting in various positions e.g. -floor, wall or ceiling mounting. 46

47 Water cooled - Marine Oil Heat Exchangers SEN-DURE TECHNICAL SPECIFICATIONS Materials Shell... Copper Tubes... Copper/Nickel Tubesheets... Copper/Nickel End Caps... ronze Nameplate... Aluminium NEW Anode available. Part No. WSANODE 1/8NPT Ratings Maximum oil (shell) side pressure ar Maximum water (tube) side pressure ar Maximum temperature C Maximum Flow Rates Unit Size Shell Side l/min Tube Side l/min WS WS PERFORMANCE HEAT REMOVED (kw) WS301SS Oil P = 0.5 ar = 1.0 ar = 2.0 ar Oil Flow L/min WS151SS DIMENSIONS - WS151S weight 1.6kg 27 (1.063") 222 (8.75") (6.125") 102 (4") Water Pressure Drop kpa WS Water Flow L/min WS301 Performance curves are based on ISO 68 oil entering the cooler 40 C higher than the incoming water temperature used for cooling. This is also referred to as a 40 C entering temperature difference (ETD). DYNACOOL computer selection program is available to size units at other operating conditions. DP Correction Factor /2" SPP 1" SPP Oil Viscosity cst WATER COOLED Water OIL 54 (2.125") OIL Water Anode available. 27 (1.063") Part No. WSANODE 1/8NPT DIMENSIONS - WS301S weight 2.1kg 375 (14.75") 308 (12.125") 254 (10") 1/8" NPTF (DRAIN) 1/2" SPP 1" SPP Water OIL 54 (2.125") OIL Water Anode available. Part No. WSANODE 1/8NPT 1/8" NPTF (DRAIN) All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 47

48 Cooling Elements For Add-On or Replacement MODEL RAZED PLATE IMMERSION COOLER APPLICATION Open plate structure permits use in fresh water with moderate amount of solids in suspension. Not suitable for use with seawater or where high salt content exists. Suitable for use to cool hydraulic circuits on tanker vehicles by mounting inside tank. Also for use in water delivery pipes or for bottom radiator tank cooling of diesel engine or transmission oil. Gasket 2 Places INSTALLATION Port blocks are flat with 23 mm drilled port hole. For tank mount applications make template of ports and fixing threads and drill holes through tank from template. Weld 3/ 4" SP Sockets on outside of tank over port holes making sure that sufficient space is left for use of 3/8" UNF cap screws. Apply gaskets supplied to port faces and bolt to tank with 3/8" UNF cap screws supplied. Air test to make sure that sockets or gaskets are not leaking. Max Operating Oil Pressure Rating 11ar. MATERIAL 304 Stainless Steel. ORDERING Part Number DC070312P Shipping Weight 4 Kg Flange Fixing Threads 3/8" UNF 4 Places All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. Oil Port 23 mm Diameter 2 Places PERFORMANCE OIL FLOW - L/m WATER COOLED HEAT EXCHANGER Heat Removed kw/ C at 80 Lm Water Flow Heat Removed kw/ C at 200 Lm Water Flow Pressure Drop AR at 30 cst Operating (ISO 68 oil at 58 C) Water Cooled Exchanger Accessories "DONUT" ENGINE LUE OIL COOLER - WATER COOLED Application Our popular oil filter mounted water-cooled engine oil cooler with its distinctive "donut" shape, satisfies the lube oil cooling requirements of both diesel and petrol engines on most types of vehicular applications. The cooler is a plate type with a high level of efficiency. Applications include passenger cars, rally and race cars, four wheel drives, trucks, tractors, agricultural equipment, engine power packs and construction equipment. Not suitable for use with seawater or where high salt content exists. Hydraulics. Also available for hydraulic applications using special connection for hydraulic oil filters such as UCC and LHA. Installation The cooler is installed under the engine oil filter using a threaded connector. Connectors are available to fit engines such as GM, Ford, Toyota, Perkins, Nissan, Mazda, Mitsubishi, Izuzu, Subaru etc. The design eliminates the need for external oil lines which could fail and cause loss of engine oil. Water connection is 5/8" hoses from the water cooling system. On vehicles with cab heaters, the connection may be made by series or parallel plumbing in to the heater hot water hoses. The stock 10 plate model has a sandwich thickness of 58 mm. Refer to our leaflet DC7 for full details of selection and installation of the Donut for your application. Ordering asic Field 63/01/00180 GM 13/16" Connector 5A37267A Other 3/4" Connector 5A37266A Complete Assembly with 25 micron filter 63/01/

49 WATER COOLED 49

50 WATER COOLED 50

51 OIL PUMPS AND PUMP PACKAGES Haight Rotary Gear Positive Displacement Pumps. Page Haight pump and motor packages. Page 54 DCP oil pump and motor packages. Page 55 Heat Exchanger Accessories Page 57 Product Application and Useful Formula Page 65 Faxable selection guide for customer use Page 69 & 70 OIL PUMPS AND PUMP PACKAGES To ensure best quality and competitiveness product design is continuously reviewed, therefore all information published in this brochure is subject to change without notice and should not be relied upon without confirmation from our office. Jan

52 Pumps that Perform Rotary Gear Positive Displacement Pumps U - SERIES OIL PUMPS AND PUMP PACKAGES Series U - Universal Pumps The Universal Pump Design combines the innovation of the Universeal shaft seal, the rugged simplicity of Haight s proven gear within gear internal gear configuration, with the flexibility of a bolt-on, integral Relief Valve assembly. This combination of pump features offers pump users unsurpassed flexibility to adapt their pumps to changing system requirements. Universal Relief valve - can be added at any time. Can be used for either suction or return. Gear within Gear internal design - for nearly 70 years this design has demonstrated if effectiveness in a broad range of applications. Universeal shaft seal - the pump can easily be converted from lip to mechanical or packed gland without disconnecting the piping. Superior High Viscosity Rotary Gear Pumping Features Input drive at the inner gear provides a built in gear reduction which means less cavitation at standard motor input speeds. The inner gear drive also permits a bearing to be provided on either side of the drive shaft and also provides a balanced rotor. These features make the Haight Pump superior for high viscosity pumping. The same features also offer increased life through lower rotor surface speeds and better bearing support Most other rotary gear pumps have input drive at the rotor which increases risk of cavitation, rotor wear, rotor side load and higher bearing loads. 1. Patented Haight Gear and Rotor for more efficient Positive Displacement pumping. 2. Three Tooth Contact for smoother uninterrupted pressure discharge. 3. Extra Deep Meshing of Gears reduces noise and avoids trapping. 4. Outer Rotor Flutes lubricate and expel foreign matter. 5. Special Port Slots wash rotor continually during pumping. SELECTION INFORMATION - STANDARD PUMPS For pumping high viscosity mineral oils or vegetable oils. The standard models feature cast iron casing and cover components, steel shaft and pinion gear, high tensile iron rotor, self lubrication iron or bronze bearings and una-n lip seals. As a general rule, the Cast Iron pump will handle most liquids which have a reasonable level of lubricity providing that the liquid is compatible with ferrous components and shaft seal. These models are usually all available from Australian inventory with or without relief valves. Pressure Ratings. Pressure rating for standard una-n shaft seals is 5.2 AR for liquids less than 20 cst and 7 AR for liquids of higher viscosity not exceeding 1000 cst. It is normal practice for lip seals to weep a small amount of liquid during operation. For pressures above 7 AR, special mechanical seals are recommended. Maximum pressure with mechanical seal is 17 AR. PUMP DISPLACEMENT Per REV PUMP CC PER SIZE REV RPM L/min INPUT POWER kw* 1500 RPM Oil 43 cst RPM Oil 430 cst *Input power figures are based on use with oil at 50 PSI (350 kpa) pressure and suction at 5 ins HG. When viscosity exceeds the 430 cst stated above, contact our sales office for revised power requirements Temperature Ratings. Temperature limitation for standard pumps is 100 C with una N seals. For higher temperatures a modified standard pump with wider running clearances and Viton seals is supplied. For Double backed pumps, Hatrided Iron Pumps and Corrosion Resistant Pumps contact our sales office. INPUT SHAFT RADIAL LOADING All of the pump configurations shown below are for direct coupling applications. Where belt or chain drive is used, a special pump with overhung load adapter must be used. Consult sales office for stock options. VISCOSITY VERSES FLOW RATE AND PUMP SPEED With the Haight range of rotary gear pumps there is a direct relationship between fluid viscosity and allowable pump speed. Consult table below. The table is based on the use of oil with low levels of abrasive inclusions. Where fluids with high levels of abrasives and/ or low levels of lubricity are to be pumped, please consult our sales engineers. During start up operations for brief peak periods, a 12% increase in viscosity is acceptable New olt on reversible relief valve system for greater bypass versatility and simple field conversion 7. Pipe Plug type auxiliary ports for tank return relief or for extra circuit installations. 8. Top quality ferrous metal bodies are standard with Gramix iron bearings. New UniverSeal design allows for simple and quick seal replacement or change to an alternative shaft seal type. Max Viscosity cst to 25 Pump Speed RPM to to to ROTATION VERSES OIL FLOW Relief valve type pumps as shown are rigged for clockwise rotation when viewed from shaft end of pump. Pressure port will be A and suction port. If anti clockwise rotation is required, invert pressure relief assembly and place it in left side of pump. Port will then become pressure port and port A the suction port. Non relief valve pumps can be run in either direction as delivered. 52

53 Pumps that Perform Rotary Gear Positive Displacement Pumps U - SERIES MOUNTING OPTIONS Haight Pump Sizes 1U, 3U, 5U, 8U With Foot rackets rackets - pumps 1, 3, 5 & 8 racket Centre Height part number X 90/08071F 71 90/08080F 80 Pump size 1, 3, 5 8 E F J WT kg* *Weights are for relief valve pumps PORT "A" 3/4" NPT PORT PORT "C" "D" 1/2" NPT 1/2" NPT Relief Valve Adjustment PORT "" 3/4" NPT O41.27 Spigot Pump Shaft O12.7 (1/2") Key 3.17 (1/8") X F À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À@ À E 5 9 mm Holes 4 Places J 38 Haight Pump Sizes 10U, 15U, 20U, 24U, 30U and 40U With Foot rackets Foot brackets for pumps 10U, 15U, 20U, 24U, 30U, 40U racket part number 90/40080F 90/40090F 90/40100F 90/40112F 90/40132F Centre Height X PORT "A" 4 olts 1/2" 13 TPI UNC on 3.500" square pattern around 3.000" pilot boss on pump PORT "C" K PORT "D" PORT "" Relief Valve Adjustment (shown here on right hand side for clockwise pump) O73.02 Spigot X S G O11mm Holes 4 places J L Pump 10U 15U-20U 24U-30U-40U Ports A & 1" NPT 1 1/4" NPT 1 1/2" NPT Ports C & D 1"NPT 1"NPT 1"NPT G J with R.V *Weights are for pumps with relief valve fitted. PORTS C & D. These ports can be supplied on all sizes of relief valve type pumps. They are auxiliary ports for pressure gauges, vacuum gauges, or for secondary relief valves. The auxiliary pressure port is always the one at the opposite end to the relief valve adjustment screw. On above drawing the auxiliary pressure port is C. SAE A Flange Pump Sizes 1U, 3U, 5U, 8U Part No - 56/03/06033 J w/o R.V K L "S" Shaft Ø (5/8" x 0.187" KEY) (5/8" x 0.187" KEY) (7/8" x 0.187" KEY) U Series Pump with SAE 2 Hole Hydraulic Interfacing SAE Flange Pump Sizes 10U, 15U, 20U, 24U, 30U & 40U Part No. - 90/04025 WT-kg* OIL PUMPS AND PUMP PACKAGES (3.25") 6.35 PILOT (4.000") PILOT O13mm 2 places All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. Larger Capacity Pumps Available -- Consult Factory 53

54 Pumps that Perform Rotary Gear Positive Displacement Pumps HAIGHT PUMP AND ELECTRIC MOTOR PACKAGES Haight pump and electric motor packages come complete with pump, electric motor, base plate, flexible shaft coupling and bell housing. Haight pump and electric motor packages are available with 4 pole 415 volt AC electric motors ranging from 0.55 kw to 4 kw. Units with 6 or 8 pole motors can also be supplied on request as well as single phase 4 or 6 pole motors in sizes to 2.2kW. The standard motor rating is IP55 class F insulation. Motors with special specifications can also be supplied (eg flameproof). Electric motor dimensions vary depending on brand. To establish the final dimensions of the assembly use measurement "H" which is the position of the foot mounting bolt at shaft end of the electric motor. Use a manufacturer's drawing of the selected electric motor to establish final dimensions. CAD DXF drawing available on request. FRAME* L *To AS1360 MOTOR POWER (kw) & AMPS Y FRAME SIZE kw at 4 POLE 0.55 to to AMPS Shown with relief valve pump (UR model) Also available without relief valve (U model). kw at 6 POLE 0.37 to AMPS Motor and Pump Packages - size 1 through 8 ORDERING CODE 90H / 10 U 6P 220 Part Number HAIGHT PUMP ASSEMLY 90H PUMP/MOTOR CONNECTION ell housing edplate PUMP SIZE RELIEF VALVE With relief UR Without relief U ELECTRIC MOTOR SPEED 4P 6P 8P ELECTRIC MOTOR POWER 0.37kW kW kW kW 150 etc SPECIAL FEATURES (eg S = single phase) Note: not all combinations available, check with sales office RELIEF VALVE ADJUSTMENT PORT PORT "D" "C" 1/2" NPT 1/2" NPT STEEL J# IN OUT PORT "A" 3/4" NPT 5.08 OIL PUMPS AND PUMP PACKAGES # Varies with pump type. USES 80 FRAME MOTOR Motor and Pump Packages - size 10 through 40 Shown with relief valve pump (UR model) Also available without relief valve (U model). 30 Aluminium RELIEF VALVE ADJUSTMENT X# PORT"" 3/4" NPT HOLES O11 IN PORT WIDTH K PORT D PORTS 121 ED HOLES PORT C OUT PORT "A" Y PORT "" 30 Z F G H 4 HOLES O11 ED HOLES Motor Frame 90 Motor Frame 100 Motor Frame 112 Motor Frame F Sizes 10 through 40 G H X# Y Z Pump 10UR 15UR-20UR 24UR -30UR 40UR Ports A & 1" NPT 1 1/4" NPT 1 1/2" NPT 1 1/2" NPT Ports C & D 1"NPT 1"NPT 1"NPT 1"NPT K # Varies with pump type. All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 54

55 DCP OIL PUMP PACKAGES Our well known DCP pumping units were originally developed for use with the DYNACOOL range of heat exchangers for pumping low to medium viscosity hot mineral oils through heat exchangers for cooling purposes. The DCP pump is equipped with pump and relief valve. They are coupling connected through in bell housing to a ISO 80 frame 415 volt 4 Pole TEFC electric motor which is mounted on a bed plate. The oil pump has a cast iron body and is a positive displacement gear type unit with alloy steel gears. The internal relief valve is factory set in the 60 PSI to 70 PSI range. Filtration is an optional extra and is reccomended to extend pump and component life. Filtration is handled by a 25 micron filter and filter head with 1" SP ports. The filter can be connected to the pump using a 1" SP nipple. Part number for the filter head is ZAF Part number for the filter is AE-25 PUMP SPECIFICATIONS PUMP MODEL PUMP RELIEF VALVE SETTING FLOW LITRES PER MINUTE FLOW US GALLONS PER MINUTE ELECTRIC MOTOR POWER ELECTRIC MOTOR SPEED DCP PSI kw 1440 rpm VISCOSITY RANGE. With a flooded inlet port and 1" delivery line the DCP 40 Model will pump oils up to 500 cst actual. Where the pump inlet port has to be above the oil level to be pumped the viscosity should be limited to 320 cst. DCP40 OIL PUMP PACKAGES Part Number 90DP/40R4P # STANDARD MODEL MODEL DCP DYNACOOL " SPP to ISO 228G INLET PORT 1" SPP to ISO 228G OUTLET PORT # Nominal, Varies with motor brand OIL PUMPS AND PUMP PACKAGES IN ORDER TO CONSTANTLY IMPROVE OUR PRODUCT WE RESERVE THE RIGHT TO MAKE CHANGES WITHOUT NOTICE All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 55

56 56

57 ACCESSORIES ACCESSORIES 123W Series Temperature Control Page W Series Temperature Control and 3 Phase Junction ox Page 58 17/DC Series 12 and 24 volt Temperature control Page 59 Adjustable Temperature control Page 59 Versacool Accessories Page 60 Thermal ypass Valves Page 61 Modulating Water Valves and ulb Wells. Page 62 Water Strainer, ronze for In-Line Service. Page 63 Three-way Thermostatic Valves Page 64 Product Application Selection, application and use of Air Cooled Exchangers Page 66 to 68 ACCESSORIES Faxable selection guide for customer use Page 69 and 70 To ensure best quality and competitiveness product design is continuously reviewed, therefore all information published in this brochure is subject to change without notice and should not be relied upon without confirmation from our office. Jan

58 HEAT EXCHANGER Heat Exchanger Accessories TEMPERATURE CONTROL - SERIES 123W May be used directly to control small electric motors etc using SINGLE phase power supply to maximum of 6 amps. Also for low volt (12 or 24) DC power supplies to maximum of 6 amps, thereafter a relay is required. For THREE phase power supplies a kit including a junction box with suitable relay is available. The thermoswitches use an Australian made reliable snap action bimetallic disk type switch which is sealed for life inside a brass bulb well. Switch contacts are normally open and gold plated to provide long service life when operated in range specified. Lead is 32-1 cable with earth wire grounded to red brass bulb. ulb has male 3/4 SPP thread with O ring and retaining ring. Made to order thermoswitches with normally closed and / or longer cable and / or other temperatures available on request. Switches are fixed temperature (not adjustable). Closing temperature is + /-2 C from close temp. Switch reopens at 8 to 10 C below close temp. Thermoswitch has enclosure rating IP66. Pressure rated 17 ar. ASIC 123W SWITCH Order Code Closing Temperature 17/12463WNO 46 C 17/12553WNO 55 C 17/12653WNO 65 C /4" SPP O-Ring Connection 1 1/4" AF Hexagon 37mm Swing Cable Length 1.4 metres Enclosure IP65 To IEC 5298 To DIN DYNACOOL AIR COOLED HEAT EXCHANGER Auxiliary Port Details for thermostat mounting Heat Exchanger Auxiliary Reducer Model Port Size ush (RYCO) VC4,5,6,7 & 8 3/4" SPP None Req DC31 & DC32 1 1/4" SPP S DC32S 3/4" SPP None Req DC33 & DC35 3/4" SPP None Req HEAT EXCHANGER Heat Exchanger Accessories 3 PHASE THERMOSTATIC CONTROL For three phase power supplies, the thermoswitches must be used in conjunction with a relay. The thermoswitches may be purchased with a junction box as a kit as listed below. The junction box has a relay and three position switch all preassembled for fast easy site installation by a certified electrician. A wiring diagram is provided on inside of junction box lid. Junction box enclosure rating is IP55. Use is limited to motors that take a maximum current of 6 Amps, from 3 phase 400/415 VAC 50/60Hz power supply. Contactor relay control coil is 240VAC, and current draw 125mA. ACCESSORIES KIT with 123W SWITCH and JUNCTION OX Order Code Closing Temperature 17/J/123W/46 46 C 17/J/123W/55 55 C 17/J/123W/65 65 C DANGER 415 VOLTS ISOLATE SUPPLY EFORE OPENING 25 A 73 ON OFF AUTO MOUNTING HOLES Ø4 75 1L1 3L2 5L3 CONTACTOR 2T1 4T2 6T3 A1 A2 SWITCHING SIGNAL EARTH EARTH EARTH POWER IN SWITCH gn/y gn/y gn/y TO MOTOR 4 WIRE CALE 0.5m LONG TO ELECT. MTR TO THERMOSWITCH NORMALLY OPEN CLOSE ON HIGH TEMP 415V 3PH POWER IN VIEW A COVER REMOVED 2 HOLES Ø16 FOR CALES CAPPED All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 58

59 Heat Exchanger Accessories LOW VOLTAGE TEMPERATURE CONTROL - 12V and 24V DC GENERAL DESCRIPTION Used on 12 and 24 volt DC coolers. A self contained thermostatically controlled electric switch mounted in a steel bulb well for immersion in the hot process fluid. The bulb has a 1/2" SPP external thread. The miniature differential switch is of the snap action type actuated at preset temperature by a bimetallic disk placed in close proximity to the end of the bulb well. The switch contacts are gold plated to ensure maximum capacity and long life. The switch is usually supplied with normally open contacts but is available to special order in normally closed configuration. A relay is required to prevent damage to switch contacts if current is more than 6 amps. SPECIFICATIONS DC Current. 12 & 24 Volts 6 Amps. Temperature Range (Standard). Contacts close at 55 C + /-2 C temperature and have a differential of 8 to 10 C. Port Entry Nozzle Requirements. Thread 1/2" SPP to ISO 228/ or equivalent. Flat machined sealing face required. Pressure rating. 17 ar (250 PSI). ulb Material. Zinc plated steel. Rubber boot supplied Thermoswitch Only Part Number Description 17/DC55/WNO 1/2"SPP Wet thermoswitch contacts close at 55 C 17/DC65/WNO 1/2"SPP Wet thermoswitch contacts close at 65 C Relay Harness Kits Part Number Cooler Model Description VC2,4,5,6 & 7 17/DC55/WNO switch, 24V relay and harness kit VC2,4,5,6 & 7 17/DC65/WNO switch, 24V relay and harness kit VC2,4,5,6 & 7 17/DC55/WNO switch, 12V relay and harness kit VC2,4,5,6 & 7 17/DC65/WNO switch, 12V relay and harness kit VC8 17/DC55/WNO switch, 24V relay and harness kit VC8 17/DC65/WNO switch, 24V relay and harness kit VC8 17/DC55/WNO switch, 12V relay and harness kit VC8 17/DC65/WNO switch, 12V relay and harness kit Kits include a fuse, fuse holder, port adaptor, relay, wiring and fitting instructions. DYNACOOL HEAT EXCHANGER Auxiliary Port Details for thermostat Model Auxiliary Reducer Port Size ush (RYCO) TM20, TM40 1/2" SPP None Req VC2 1/2" SPP None Req VC4,5,6,7 & 8 3/4" SPP S DFM11, 12 & 22 3/4" SPP S DC31Y, DC32Y 1 1/4" SPP S DC32S 3/4" SPP S /2" SPP Fibre washer 1 1/8" AF Hexagon 32mm Swing Rubber oot Wires aprox, 220mm long HEAT EXCHANGER Heat Exchanger Accessories ADJUSTALE TEMPERATURE CONTROL- 12v and 24v DC This temperature controller was designed for use with DYNACOOL range of heat exchangers with low voltage motors driving the cooling fans, without requiring extensive wiring or plumbing. It provides accurate temperature control by cycling fans to maintain desired oil temperature. y reducing operating time the fan motors will not consume power unnecessarily and motor replacement periods are extended. DIMENSIONS Features: -12 or 24 volt operation -Adjustable temperature settings from 40 C to 100 C in 6 C increments -For use with one or two fan models -Temperature sensor provided. -Remote manual override possible using wiring provided. Remote switch not included. -Mounting hardware included. ACCESSORIES Part Number Description 67/96171 Electronic fan control kit 67/67524 Replacement relay only NOTE: This switch should be fused to prevent damage if ground is lost. A 30 Amp Fuse is required in the power supply. All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 59

60 Heat Exchanger Accessories VERSACOOL ACCESSORIES Vertical mounting kit Weight 6kg Model A VC4X VC5N VC6X VC7X Ordering details Models VC4 thru VC7 Part No Mobile base kit Weight 1.1kg A ottom View Universal base kit Weight 0.76kg Slots 16 x 10 Increases E y 3 MM + 60 A Ordering details Model VC2 Part No Models VC4 thru VC8 Part No Antivibration mountings Recommended for mounting of Versacool units in areas where they may be subjected to harmful vibration These antivibration mounting feet are used to protect the cooler from harmful vibration and to reduce noise associated with vibration. The antivibration mounts can be used in conjunction with the universal base kit or mobile base kits Slots 16 x 10 A1 + 4 Ordering details Models VC2 thru VC8 Part No ACCESSORIES Typical installation to basic cooler Ordering details Set of 4 antivibration feet + mounting screws Part No Retrofit type These antivibration mounts can be retrofitted to existing cooler installations due to the mounts inline construction. Recommended for mounting of Versacool units in areas where they may be subjected to harmful vibration These antivibration mounting feet are used to protect the cooler from harmful vibration and to reduce noise associated with vibration. Ordering details Set of 4 retrofit feet + mounting screws Part No All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 60

61 Heat Exchanger Accessories THERMAL YPASS ASSEMLY This thermal bypass valve is ideally suited for hydrostatic drive circuits which require fast warm-up, controlled fluid temperature, and low return line back pressure. When installed in the return line of a hydraulic circuit that employs an oil cooler, this device will modulate fluid temperature by either shifting return line flow through the cooler, or bypassing directly to the reservoir. In addition, a built-in pressure relief function automatically relieves excess pressure to the reservoir should the cooler become restricted and resultant pressure drop become too high for the cooler circuit. DIMENSIONS - Thermal ypass Cooler Port (CLR) (5.41") Tank Port Mode examples Mode 1 Cold Start-up Up to 49 C INLET COOLER TANK Graphic Symbol Reservoir #16 SAE 1 5/16-12UN-2 "O" ring Port (3 Places) 47.8 (1.88") Oil Flow INLET INLET A Mode 2 Warm-up Shifting 49 C to 63 C COOLER TANK Cooler INLET 72.9 (2.87") NOTE: If the temperature drops below 63 C the valve will shift back to modes 2 or 1. Ordering Information Part No Shift temperature Part No Shift temperature 65/ C (100 F) 65/ C (140 F) 65/ C (120 F) 65/ C (160 F) INLET A COOLER TANK FEATURES: 1. Operating Characteristics: A. Mode #1: At temperatures below the shift temperature oil flows from inlet to tank port.. Mode #2: At temperatures between the start of shift & full shift the flow from the inlet port is divided between the cooler & tank ports. C. Mode #3: At temperatures above the full shift temperature inlet flow is through cooler port. D. Mode #4: At temperatures above the full shift temperature the excess pressure is relieved through the tank port. 2. Standard Shift Temperatures: 100 F(38 C). 120 F (49 C) 140 F (60 C) and 160 F (71 C) 3. Full Shift (Cooler Port Open) Temperature: Shift temp plus 25 F (14 C) 4. Relief valve setting: 65 psi (4.5 bar). Consult factory for other settings. 5. Maximum Operating Pressure: 250 psi (17 bar) 6. Proof Pressure: 300 psi (21 bar) 7. Minimum urst Pressure: A. Up to the full shift temperature: 325 psi (22 bar). Above the full shift temperature: 600 psi (41 bar) 8. Minimum Operating Temperature: -30 F (-34 C) 9. Maximum Operating Temperature: Shift temperature plus 75 F (42 C) 10. Maximum Flow Rating: 60 gpm (227 I/m) psi (17 ar) and 60 gpm (227 l/min) Inlet Flow: A. Cooler Port: gpm (2 I/m) maximum up to 5 F (3 C) before shift temp gpm (4 I/m) maximum from 5 F (3 C) before shift to shift.. Tank Port: 0.10 gpm (0.4 I/m) maximum 12. Operating Fluid: Mineral base hydraulic fluids 13. Construction: Aluminium die-cast housing (0.42" Dia 2 Mounting holes 66.5 (2.62") Excess pressurized oil Mode 3 Fully Shifted Above 63 C & elow 450 kpa TANK INLET 89.4 (3.52") VIEW A-A Mode 4 High Pressure Above 63 C & Above 450 kpa COOLER TANK PRESSURE DROP INLET PORT THRU TANK 38 C (100 F) (300 SUS) PSID PSID FLOW - GPM INLET PORT THRU COOLER 63 C (145 F) (110 SUS) PSID FLOW - GPM INLET PORT OVER INTEGRAL RELIEF 77 C (170 F) (78 SUS) FLOW - GPM ased on Mobile DTE 26 oil Note: Pressure drop shown is added to relief valve crack pressure for total pressure drop. ACCESSORIES All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 61

62 Heat Exchanger Accessories MODULATING WATER VALVES AND UL WELLS No external power source required. Opening point setting is simply adjusted by rotating screw on top of valve housing. Turning the valve clockwise will decrease the opening temperature. Turning the shaft counter clockwise will increase the opening temperature. Valves must be adjusted correctly after installation and whilst equipment is operating under normal conditions. Factory does not preset these valves. Opening point is adjustable within standard range shown, other ranges also available. Closing point is 2-3 degrees below opening point. Differential temp is not adjustable. Maximum recommended working pressure is 150 PSI (10 AR). Not suitable for use in saltwater service. ulb well recommended & available upon request as optional extra. APPLICATION: These water modulating valves regulate the flow of water to the heat exchanger. The valve opens when the temperature increases at the sensing bulb. Cooling rate is automatically varied to allow optimum oil temperature to be maintained. Water is conserved by reducing / stopping flow when minimal or no cooling is required SPECIFICATIONS Part Number Pipe Opening point Max. Flow ulb Weight Sensing includes size# temp. range* temp. Max. size approx. ulb Valve & Sensor (NPT) Min-Max ( C) limit ( C) (L/m) L x dia (mm) (Kg) Number ACCESSORIES 65/ / x /65293S 65/ / x /65293S 65/ x /65128S 65/ / x /65128S Recommended bulb well part number is 65/65141 for all above valves. A slightly shorter length pocket is available for the 83mm long bulbs, part number is 65/ Factory recommends the longer bulb well to provide additional protection. # See form DC 107 for larger size valves. * Lower opening point range available if necessary (24-57 deg C). Valve is fully open 20 C above opening point. ORIFICE PLUG. All valves are supplied with a drilled & tapped female by-pass hole inside the regulator body. A solid plug is installed in this hole for 100% shut off. Each valve is also supplied with a drilled orifice plug, packed in a envelope for field installation, if continuous minimum flow is required. The 1/2 & 3/4 valves use a plug with a 1.6mm orifice diameter, the 1 & 1 1/4 valves have a plug with a 2.4mm diameter. 62

63 Heat Exchanger Accessories MODULATING WATER VALVES AND UL WELLS A 1/2" NPT F C Armoured capillary tube is 1.83 meters long with outside diameter of 6mm L SENSING UL D Ø17 E NOT TO SCALE 1/2" NPT InternalThread 3/4" SPP ExternalThread 32 UL WELL N M Ø21 MATERIALS of CONSTRUCTION. VALVE - ody... 3/8", 1/2" and 3/4" - Cast rass 1" through 2 1/2" - Cast Iron Valve disk... una N Disk holder... rass Valve seat... Aluminium ronze Diaphragms... Nylon Reinforced una N CAPILLARY TUE... Copper in rass sheath SENSING UL... Copper UL WELL... rass or brass & copper VALVE PORTS A C D E F L UL WELL M N Part No. NPT All dimensions in millimetres. Tolerance +/- 0.5 mm Part No 65/ / / / / / / / / Approx. weight 0.5kgs HEAT EXCHANGER Heat Exchanger Accessories WATER STRAINER. RONZE FOR IN-LINE SERVICE. Maximum recommended working pressure is 200 P.S.I. for water. Factory tested to 300 P.S.I. hydraulically. Mesh is 44% free passage (approx mesh) and can be removed & cleaned without dismantling pipework. Stainless steel mesh is grade 304, not recommended for use in saltwater service. Special material / size screens available as optional extras. APPLICATION: Designed to prevent large particles or foreign bodies from entering heat exchangers. A C D E NOT TO SCALE Item PARTS LIST Part Material ody Strainer Gasket Cap ronze Stainless Steel Fibre ronze DIMENSIONS in millimetres. Tolerances are all + / - 4% Part No. Inlet / Outlet Overall Overall Strainer Weight Screen Ordering Internal Thread Length Height Access Part Code (SPP) A C D A/F E (kg) Number 65/ /2" / / /4" / / " / / /4" / / /2" / / " /65303 ACCESSORIES All dimensions in mm unless noted otherwise 0-50 are ± are ± 3. 63

64 Heat Exchanger Accessories THREE - WAY THERMOSTATIC VALVE Flows up to 490 L/min Standard Ports 2" NPT (Opt. 1/2", 3/4", 1" & 1 1/2") Flanged Ports Optional 3", 4" & 6" Opening Temp range from 21 to 102 C. Max. Operating Pressure of 8 ar (115 PSI). ACCESSORIES General Description Three way thermostatic valves use the principle of expanding wax. A self contained power element activates a stainless steel sliding valve which provides a positive three way action. All temperature settings are factory set. Elements are field replaceable, hence valves can be altered to operate at a different temperature range or refitted with new elements of the same setting. During cold start up, total flow is through the by-pass port. Once the fluid temperature reaches the opening point, the valve begins to open and flow to the heat exchanger supply port begins. As the temperature rises the valve shifts further allowing more flow through the heat exchanger supply port and less to the by-pass port. When the fully shifted temperature is reached the valve is fully stroked and all flow is directed to the heat exchanger port. Valves can be used for oil or fresh water service Housing - Cast Iron (optional steel or bronze) THREE - WAY ORDERING CODES 65/ / 43/54 2" NPT All ports female thread. Warning: 0.5 ar (7 PSI) P across valve Ports y-pass port Code Part Type Complete valve Element only Heat exchanger port C A Inlet Port 2" NPT model weights 9 kg Heat Source A C Pump MIXING Applications O-Rings - Viton (optional, una N) Valve - Alloy steel. Applications Three way thermostatic valves may be installed for either mixing or diverting modes of operation and can be mounted in any plane and with port orientated in any direction. When installing in mixing mode, the valve must be located on the cold side of the application. Hot liquid will be mixed with cooled fluid to discharge liquid at proper temperature. Select a valve with opening point at, or just above, the minimum desired oil operating temperature. For diverting mode, the valve must be installed on the hot side of the application. Cold liquid will be bypassed until the system warms up, then flow is directed to the heat exchanger. Select a valve with full shift point at, or just below, the maximum desired oil operating temperature. Code Opening Fully Point C Shifted C 21/ / / /54* / /66* / / / / / /88* / / * Common stocked settings PRESSURE DROP TALE (ar) Flow Oil Viscosity (cst) L/min water max. flow (l/min) DYNACOOL Heat Exchanger C A Pump DIVERTING Applications Heat Source 64

65 CONVERSIONS AND USEFUL FORMULA AREA Sq Inch x = Sq cm Sq Ft x = Sq mtr LENGTH Inch x 25.4 = mm Feet x = metre MASS Oz x = gram lb x = kg Ton UK x = Tonne POWER kw x = HP HP x = kw Met HP x = kw Ton of Rfg x = kw PRESSURE PSI x = ar ar x 14.5 = PSI inh 2 O x = kpa TEMPERATURE C x = F VELOCITY Ft/s x = m/s mph x = km/h Knot UK x = km/h VISCOSITY SSU x 4.6 = cst VOLUME Gal (UK) x = Litres Gal (US) x = Litres Cu Ft x = Litres OTHER TU/hr x = W Kilocalorie x = kj CFM x = m 3 /s Power, Heat and Flow Relationships. ISO UNITS T C = kw x K kw = L/min x T C L/min = kw x K L/min K T C Where L/min = Oil flow in Litres per minute T C = Entering temp of oil minus exit temp of oil. kw = Heat to be removed K = 34.5 for Oil K = 14.3 for Water K factors above are typical only and will vary with density and temperature of fliud. Heat Load ased on Temperature Rise Over Time ISO UNITS Heat Load = V x Cp x (t2-t1) = kw T Where t1 = Initial oil temp ( C) t2 = Final oil temp ( C) T = Time for temp rise (seconds) V = System oil volume (litres) Cp = Oil heat capacity (kj/l C) Typ for oil. NO RESPONSIILITY IS ACCEPTED FOR OMISSIONS VARIATIONS OR ERRORS 65

66 PRODUCT APPLICATION PRODUCT APPLICATION Determining The Level Of Heat Load In Oil Circuits. Heat is generated through energy being wasted in the form of inefficiency. Heating in a oil circuit is usually a by-product of motive power which may be some form of engine or motor or a device such as a brake or clutch which converts rotating energy into heat energy in the oil. Another source may be by conduction, convection or radiation from either direct solar energy or any other external parasite source. In a hydraulic system, the main energy source is usually the input power entering the hydraulic pump from the engine or motor. Some portion of the input power will be wasted through inefficiency (friction and pressure losses) and will be evident as heat in the oil. The degree of inefficiency in the circuit may be established by combined analysis of the known efficiency of the circuit components. More frequently it is established by making an estimate based on previous experience with the type of circuit being considered. Typical hydraulic system circuits range in efficiency from between 80% down to 40% efficient. High efficiency pumps and motors combined with ample plumbing may deliver up to 80% efficiency. Gear pumps with gear motors or gear pumps with gerotor motors may be less than 50% efficient. The heat load required to be removed from the system will be equal to the total inefficiency in the system, less the existing thermal heat transfer capacity of the system. So with a circuit estimated to have a power input of 50 kw and an efficiency loss of 30%, there can be expected to be a requirement to cool 15 kw of heat. The components in the circuit may be able to dissipate some heat so the heat load required to be cooled with a heat exchanger will be something less than 15 kw. Power, Heat and Oil Flow Relationships. In the above example we determined that we need to remove 15 kw from a circuit. Now what does 15 kw really mean in terms of heat. The following are formulae which can be used with hydraulic mineral oils to provide relationships between power, heat and oil flow. 1 T C = kw x kw = L/min x T C L/min L/min = kw x 34.5 T C L/min = Oil flow in Litres per minute. T C = Entering temp of oil minus exit temp of oil. Applying formula 1 to the above example with oil flow at 100 L/min we get the following result. 15 x 34.5 = So we require a constant reduction in temperature of 5.2 C in our oil to dissipate 15 kw for 100 L/min. Oil and Air Temperature Relationships. For the cooling of oil with a air cooled heat exchanger it is obviously necessary to have the air temperature cooler than the entering oil temperature. The temperature difference between the entering oil and the entering cooling air is called the ETD (entering temperature difference). The larger the ETD the easier it is to cool the oil and by definition the smaller the air cooled heat exchanger will be. For purposes of sizing a suitable heat exchanger, it is usual to set the inlet temperature of the oil at the maximum temperature the system is required to operate at. Oil temperatures in modern hydraulic systems are preferred to be maintained in the 60 C to 70 C range. The temperature of the cooling air will be the ambient temperature of the air in the locality where the system is to be used. Selection of The Exchanger y Performance In this catalogue, performance shown on graphs is usually expressed in kilowatts per degree C of entering temperature difference between the oil and the cooling air (kw/ C). So if the ambient temp is 30 C and the oil temp is required to be 60 C, a 15 kw heat dissipation would require a oil cooler capable of 0.5 kw/ C at the required oil flow. Computer Model Selection Program We provide complete performance graphs for most models of our air cooled heat exchangers. However, for accurate sizing we recommend the use of our computer model selection program which covers almost all of our standard models of air cooled and water cooled exchangers. The program operates on most PC computers under Windows. Electronic Drawings Of Heat Exchangers Our computer model selection program now also includes electronic drawings of most models. These drawing are available in DXF format for customer use. Heat Load ased on Temperature Rise Over Time Example: Initial oil temp 20 C Final oil temp 85 C Time for temp rise 35 minutes System oil volume 240 litres Oil heat capacity 1.72 kj/l C Heat Load = 240 x 1.72 x (85-20) = 12.8 kw 35 x 60 66

67 Product Application Dynacool have produced Air Cooled Heat Exchanger Packages for oil cooling since Since that time many hundreds of model variations have been produced. Dynacool are acknowledged as leaders in manufacture and industry know how with air cooled heat exchangers for oil cooling. Our products are designed in Australia and our published data is developed through actual test facilities at our allina plant in NSW. Our R & D activities include heat transfer design, performance testing and evaluation, pressure drop testing, noise level monitoring and cooling air delivery measurement. Our test facilities enable us to carry out accurate design analysis which results in the constant improvement in our product and provision of accurate data for our publications. Our Dynacool A series packages and our recently developed Versacool line command high respect in the heat exchanger market. We also offer a number of other types of air cooled heat exchangers utilising element materials other than aluminium. Air Cooled Exchanger Rigged For Full Status Testing DO NOT USE IN HYDRAULIC CYLINDER CIRCUITS 83/03/05446 Noise Levels Of Air Cooled Heat Exchangers It is a fact of life that air cooled heat exchangers utilise fans to move air through the cooling matrix. High performance air cooled heat exchangers tend to have dense cooling surfaces and require relatively high levels of air movement under static pressure to achieve performance. We are now publishing measured noise levels for our air cooled models. The measurement is 1 metre. For the record, our method of measurement is to take a number of A weighted samples at 1 metre distance from the product at prescribed positions and publish the highest noise level found among the samples. The result approximates that which an inspector will get when he tests on site by survey using AS On any electric air cooled heat exchanger, the noise level will closely relate to the speed of the tips of the fan blades. We publish fan diameters and motor speeds so it is easy for our customers to calculate tip speed. So if you are comparing our product with one of our competitor s products and note his published sound levels are lower than ours then please compare the fan tip speeds. It is generally the design policy of Dynacool to use smaller diameter more efficient fans than our competitors as well as our SAMS (Superior Air Management System) which reduces fan diameters. Therefore, we claim that relative to size and performance our air cooled heat exchangers generally have lower noise levels than our competitors. Application Warnings - Aluminium Cooling Elements The furnace brazed aluminium cooling element has the highest heat transfer efficiency to cost ratio of all oil cooler types. However, care should be taken in making sure that the product is suitable for the application. The following advice applies to all makes of aluminium cooling elements. OVER PRESSURE. Never exceed rated operating pressures. Actual failure may take place at 40% to 60% above rated pressure. On hydraulic circuits under starting conditions in winter with cold oil, pressure drop figures may exceed 10 times those calculated for normal operation. If the hydraulic circuit is capable of pressures exceeding the cooler rating, a failure will occur unless a suitable relief valve is provided to bypass the cooler under these conditions. PRESSURE CYCLING AND SPIKES. Do not install aluminium oil cooler elements in circuits where sudden changes of pressure or oil flow are likely to occur. Eg:- Cylinder circuits or circuits with oscillating valves. Use of this type of cooler in such circuits will result in rupture of the tubes or cracking of tube to header joints. Aluminium is also subject to fatigue failure under high frequency pressure and/or temp cycling. ypass relief valves or accumulators are not effective against pressure spikes. For these applications refer to DP & HL off-line coolers on page 22. HAZARDOUS ENVIRONMENTS. Aluminium has autogenous sparking capability when impacted with iron or steel. For this reason aluminium is not permitted within coal mines in Australia. PRODUCT APPLICATION 67

68 Product Application Installation Of Air Cooled Heat Exchangers Plumbing. Unless approved by Dynacool, use flexible rubber hoses for connection. The hose size should be the same size or greater than the port thread size. Solid steel pipes are not recommended as they may place excessive loads on the core element. If long hoses are used support them as close to the ports as possible. Threaded connections must be fully sealed. We recommend SPP o-ring face seal type fittings. Should oil be permitted to leak it may cover the core fins and result in the collection of dust and sludge which reduces cooling performance. Note. Do not fit steel fittings to aluminium ports without lubrication as they may bind and damage the port. Site Location And Environment. Some cooling elements resist corrosive attack better than others, please consult our Engineering Dept. for details of suitability if a corrosive environment exists. For best heat transfer performance, determine the usual direction of air flow at the site and face the cooling element towards the incoming air flow without restriction from objects at air inlet or outlet. The unit should be bolted down through the base slots provided. Positioning In The Circuit. In hydraulic circuits, the cooler should always be positioned to receive return oil from the circuit. Do not install the cooler in the pressure circuit. Care should be taken to select a oil source which passes oil at a constant flow rate not exceeding maximum recommended. If operating viscosity is likely to exceed 100 cst consult our sales dept. Unrestricted oil flow path must be maintained from the outlet oil port of the cooler into the oil reservoir. DC Electric Motor Connections. Ensure the voltage supply matches that of the cooler. Wire the supply to the 2 pin connector with polarity as shown in the diagram provided in the installation instructions. Start the motor and check the direction of fan rotation, a decal shows the correct direction. All fans should pull the cooling air through the cooling element and discharge it through the fan guard. For Versacool refer to separate instruction forms VC03, VC04 or VC05 if thermostatic controls are to be fitted. AC Electric Motor Connections. Remove motor junction box and carefully check instructions on wiring which may be displayed inside or outside of junction box. Electric motors of various brands are used, some motors have star connections and others may be wired delta. After wiring has been completed start the motor and check for rotation of the fan. Rotation is usually c/w when viewed from the motor or ac/w when viewed from element. The fan should pull the cooling air through the cooling element and discharge it through the fan guard. All AC electrical wiring should be carried out by a licenced electrician. Hydraulic Motor Driven Fans. Some units are supplied fitted with Hydraulic fan motors. Hydraulic Motors fitted as fan drives must be piped to permit the fan to rotate freely after the oil flow has been shut off to the motor. Failure to provide such a device may cause the fan to be damaged due to shock loads caused by fan inertia. Maintenance Continued efficient operation of the air cooled heat exchanger is dependent on the heat transfer surface being kept clean. In dirty conditions the core element should be cleaned frequently to remove dust and dirt.. Should the fins be blocked with oil saturated dirt, use a petroleum based cleaning fluid followed by water sprayed from a medium pressure hose. Do not use high pressure hoses for cleaning heat exchangers with aluminium fins. CAUTION. DO NOT USE CAUSTIC ASED FLUIDS FOR CLEANING ALUMINIUM COOLING ELEMENTS. PERFORMANCE CORRECTION FOR AIR DENSITY ( TEMPERATURE AND ELEVATION) AIR TEMP. F ( C) ELEVATION AOVE SEA LEVEL - FEET (METERS) (305) (610) (914) (1219) (1524) (1829) (2134) (2438) PRODUCT APPLICATION 70 (21.1) (26.7) (32.2) (37.8) (43.3) (48.9) (54.4) (60.0) (65.6) Heat Transfer Performance At High Oil Viscosity Air cooled heat exchanger performance and flow capacity will degrade rapidly when oil operating viscosity exceeds 100cSt. Consult the chart inside the back cover to establish operating viscosity of your application. Please check with Dynacool before selecting heat exchangers for use with high viscosity oil. 68

69 INFORMATION FOR AIR COOLED OIL COOLER SELECTION PERFORMANCE REQUIREMENTS Air Cooled Heat Exchanger Company: Date: Address: State: Phone: Fax: Contact: Ref: The following information is required to select an air to oil cooler. 1. Heat load: kw or hp 2. Oil flow rate: L/min 3. Oil type: (eg ISO68) 4. Maximum desired oil temperature: C 5. Maximum allowable oil pressure drop: ar or PSI 6. Cooling ambient air temperature: C 7. Motor data: 12V - 24V - 240V - 415V - Hyd - no motor. 8. Maximum envelope: H W D 9. Air face velocity (mobile cores only types): m/s. 10. Maximum pressure cooler will be subject to: ar. Advise if there are any cylinders or other pressure spike producing components in the cooler circuit. If unsure of the values required the following information will help. Each number below corresponds to the number above 1. Heat load: the heat load may be determined by: A. Hydraulic oil cooling: Assume 30% of the input power will be rejected to heat. If the input power is unknown, this formula may be used: kw= (system press. ar) x (L/min flow) x Hydrostatic oil cooling: Assume 25% of the input power will be rejected to heat. C. Heat load test: the heat load can be determined by actually measuring the degree temperature rise from a cold start-up. This temperature rise is the exact amount of heat going into the oil. To run a heat load test, disconnect any heat exchanger in the test loop. Record the increase in oil temperature every 5 minutes. Review the data received, and determine the greatest temperature rise in any 5 minute period. Heat load = system volume x oil heat capacity x ( T oil temperature rise) 5 minutes x 60 sec./min For example - Initial oil temp C Final oil temp C Heat Load = 240 x 1.72 x (50-40) = 13.8 kw Time for temp rise... 5 minutes 5 x 60 System oil volume litres Oil heat capacity kj/l C 2. Oil flow rate: This is simply the flow rate of the oil circulating through the cooler. 3. Oil type: Advise oil grade or viscosity vs temperature details 4. Oil temperature: Oil coolers are typically sized using the maximum desired oil temperatures. Typical temp. ranges are: Hydraulic oil C Hydrostatic drive oil C earing lube oil C Lube oil circuits C 5 Oil pressure drop: Most systems can tolerate a pressure drop through the heat exchanger of 1.5 to 2 ar. Excessive pressure drop should be avoided. Care should be taken to limit pressure drop to ar for case drain applications where high back pressure will blow out pump shaft seals. 6. Cooling air temperature: This is the temperature of the air entering the cooler, also referred to as the ambient air temperature. A normal maximum air temperature is usually between 32 C to 38 C. Care should be taken not to install in confined space as ambient temperature will increase and cause overheating. 7. Motor data: Most models are available with a wide variety of motors. List as desired. e sure to indicate any special requirements. 8. Envelope size: This may be any height, width and depth depending on the application. Allowances should be given so as not to obstruct fan air flow. 9. Air face velocity/cooling air flow: Typically oil coolers are sized for 5.5m/s (20 kph) air velocity. When an air volume flow is given in m 3 /s, it may be converted by: AFV m/s = m 3 /s face area of core in m 2 COMPUTER SELECTION PROGRAM We provide complete performance graphs for most models of our air cooled heat exchangers. However, for accurate sizing we recommend the use of our computer model selection program which covers almost all of our standard models of air cooled and water cooled exchangers. The program operates on most PC computers under Windows. PRODUCT APPLICATION 69

70 INFORMATION FOR WATER COOLED OIL COOLER SELECTION PERFORMANCE REQUIREMENTS Shell & Tube Heat Exchanger Company: Date: Address: State: Phone: Fax: Contact: Ref: Type of application: (Seawater / Freshwater) Other: Describe the circuit 1. Heat Load (kw or Hp) 2. Flow rate (l/min or USGPM) Shell side: Water/Tube side: 3. Oil type (cst or SSU) 4. Maximum inlet fluid temp. ( C or F) Shell side: Water/Tube side: 5. Maximum allowable pressure drop (PSI or AR) Shell side: Water/Tube side: 6. Are there any circuit components which could cause sudden changes of oil flow eg cylinders or accumulators 7. What is the power source and how much power is needed to drive the hydraulics or the source of the heat The heat load may be approximated by: A. Hydraulic oil cooling: Assume 30% of the input horsepower.. Hydrostatic oil cooling: Assume 25% of the input horsepower. C. Automatic Transmission: Assume 30% of engine horsepower. D. Engine oil cooling: Assume 10% of engine horsepower. The above are only to be considered as guidelines. It is the customers responsibility to provide accurate information in order to select the most appropriate sized heat exchanger. PRODUCT APPLICATION 70

71 OIL VISCOSITY / TEMPERATURE CHART Lines shown indicate oils ISO grade Viscosity Index of 100. Lower V.I. oils will have a steeper slope. Higher V.I. oils will have a flatter slope. ISO 1500 ISO 1000 ISO 680 ISO 460 ISO 320 ISO 220 ISO 150 ISO 100 ISO 32 ISO 22 ISO 68 ISO TEMPERATURE, DEGREES CELSIUS ISO ISO 15 ISO 10 KINEMATIC VISCOSITY, CENTISTOKES

72 Oil Flow l/min VC1WD VC2WD VC3WDA VC5YDA VC5XDA VC4YDA VC4XDA VC3WD VC4YD VC2WDA VC4XD HEAT EXCHANGER DYNAGEAR AUSTRALIA Product Lines-Ask for a catalogue today Splined Components Splined hubs Couplings Shafting Stubwelds Slipsleeves available ex-stock. Components can also be manufactured to customer requirements. HDC and LDA Overhung Load Adaptors Model HDC - This model may be supplied to suit SAE 'A', SAE '' or SAE 'C' hydraulic pump motor interfacing and 10 shaft size options accommodating almost any SAE Hyd motor up to SAE "C". Model LDA - This is a low cost model with a fixed SAE "A" motor adaptor and 6 shaft size options. Disconnects Used where a hydraulic pump requires disengaging when not in use. Available in clockwise or anticlockwise versions. Supplied to suit SAE 'A', '' or 'C' hydraulic pump or motors or as a shaft to shaft version. Tractor PTO Hydraulic Pump Drives These drives were developed for use as directly driven hydraulic pump speed increasers. Maximum power is 50 horsepower at 540 RPM input for the 1:3.38 ratio model, and 65 Horsepower at 1000 RPM input for the 2.04 ratio model. The T33 is available to accept most SAE "A", SAE "" or SAE "C" hydraulic pumps. Male shaft models are available for implement mounting. Flexilock Single Pump Drives Pre-engineered single pump drives now available in four power sizes. With over 300 combinations we offer the largest standard range of direct drive kits for diesel engines. These drives utilise the clamplock spline locking mechanism and our special polymer element is formulated for optimum elasticity at engine operating temperatures to absorb engine torsional vibrations over a long cycle life. Technodrive Pump Drives These gearboxes allow a number of hydraulic pumps to be driven from the one power source. They may be driven from most power sources directly as a shaft to shaft drive through a flexible coupling or via a universal joint drive train. Double, triple and four pump. In some instances, pumps can be mounted on both the front and back of the gear box E.g. up to 9 hydraulic pumps have been fitted to the model AM450 pictured. Zinga Filters and Accessories INDUSTRIES INC. Single and multiple spin-on filter heads with the widest range of cellulose and synthetic media. Tank top reservoir filters, return and suction, with flows to 1200 l/min. Medium pressure spin-on charge pump filters. High pressure canister and manifold cartridge filters. Flexilock Couplings Developed for hydraulic pumps, includes most splined and round bore shaft connections. Feature a large gear tooth form with wide face contact between the steel gear and polymer element giving high power capacity in a small unit. Dynacool The latest version of our Dynacool heat exchanger selection program now provides quick and accurate selection of most of our standard models of air cooled package exchangers, mobile air cooled and water cooled models. A new easy find instruction manual is now also available. kw/ C TTPL HEAT EXCHANGER Dynacool Heat Exchanger Selection Program OEM Dynamics Pty Ltd Version 6.0 A DXF Drawings included Windows 95/98/NT THE DYNACOOL DIVISION An Australian Company Distributed y- DC200 PRINTED IN AUSTRALIA