NISSENS HP COOLERS SERIES

Transcription

1 NISSENS HP COOLERS SERIES

2 THE HP-SERIES FROM NISSENS The HP-series from Nissens is a wide range of standard products for efficient cooling of both water and oil applications. HP is short for High Performance, and Nissens HP-series is renowned for offering efficient cooling in terms of a remarkable cooling capacity. Our special fin design, perfect finish and high-quality raw materials contribute to the proven performance of this product category. Additionally, our HP-series offers very good corrosion characteristics thanks to the application of long-life alloys. The HP-series from Nissens comes with a wide selection of equipment and accessories that meet our customers requirements for flexible, efficient and customized cooling solutions at competitive pricing. For years, Nissens has been committed to developing and refining the Controlled Atmosphere Brazing technology (CAB) for aluminum coolers. Our continuous utilization of this superior production technology in our in-house production facilities has contributed to building our expert knowledge and enabled us to create a wide standard range of highperforming coolers, for multiple industrial applications. The range is called Nissens HP Cooler Series. The series of HP coolers is designed with a view to provide optimal cooling of hydraulic and lubricating oil as well as water/glycol in virtually any installation. The HP Series includes 12 cooler sizes with a large variety of equipment that may be customized for different purposes and thus made to fit any cooling need. The product programme has been divided into four categories: HPC a series fitted with a 3 x 400 V electric motor, and three HP series fitted with a 12 V, 24 V or 3 x 400 V electric motor or a hydraulic motor. High-quality raw materials, applied features like turbulators, optimally shaped tube fins and carefully selected equipment ensure that the HP series offers an excellent cooling performance and high durability. We thoroughly test all our products in Nissens in-house test center, including tests for corrosion, thermal expansion and vibration as well as a number of other real-life tests.

3 HP Coolers - High Performance in Cooling EXCELLENT COOLING PERFORMANCE The proven performance of our HP product series is based on optimal material and component selection as well as unique technology application. The HP cooler series offers an excellent thermal conduction through the aluminum core of the cooler and a high cooling capacity thanks to the use of turbulators and a special fin design in the core construction. COMPACT DESIGN The shape and size of the compact cooling package facilitate easy transportation and storage as well as a very flexible and accurate retrofitting in cooling systems for various industrial applications. Our product offer is developed to respect the specific construction requirements and limitations of any given application. LOW NOISE EMISSION The optimal selection of the equipment for the HP coolers, e.g. motors and fans, guarantees minimized noise emission generated by cooling units from Nissens. HIGH FLEXIBILITY The HP series offers a high-level flexibility when our customers need to select the right cooling solution for a specific industrial application or installation. The flexibility shows in the wide range of available HP coolers, which are suitable to match the required performance, cooler sizes and media applications (water/glycol, oil, air). Furthermore, our vast selection of equipment and accessories to be supplied with the coolers offers our customers a wide choice designed to meet any need: standard electric motors, and motors with special voltages and explosionproof, hydraulic motors, oil pumps, galvanized steel parts, thermobypass and thermoswitches. THE HIGHEST QUALITY The highest quality standards are applied in all design and manufacturing processes. We comply with the strict regulations in the automotive and environmental certifications ISO 9001/TS and ISO We only use the best raw materials to ensure the perfect product finish in every detail. HIGH DURABILITY & LOW MAINTENANCE COSTS The best raw materials, perfectly designed products with strong and durable constructions consisting of soldered aluminum cores as well as the optimized selection of the equipment guarantee a long product life, trouble-free operation and documented low service and maintenance costs. OUTSTANDING CORROSION PERFORMANCE - CORROSION CLASS C3H AS STANDARD The products in the HP series are subject to a special pretreatment applicable to all steel parts. Nissens offers steel parts that comply with the C3H corrosion class as a standard. For off-shore applications, where the C5H corrosion class is required, Nissens also offers cooling solutions in stainless steel material. Thanks to our application of longlife aluminum alloys, the HP coolers are designed for +20 years life-time, when it comes to off-shore corrosion.

4 INDEX Type Nissens HPC is a complete oil cooler unit consisting of cooler, fan and pump. HPC 3 x 400 V The HPC oil cooler is the perfect solution for hydraulic systems in which the oil flow is unstable or in which heavy pressure peaks may occur. Further, the HPC oil cooler is suitable for lubricating oil, as an integrated pressure bypass in the pump allows a very high oil viscosity - up to 2000 cst. Many thermal tests have resulted in a construction with a high cooling performance combined with a low noise level which is an absolute necessity for many indoor installations. With this generation of Nissens HP coolers with a 3 x 400 V fan, we have succeeded in raising the cooling performance and at the same time reducing the noise level of several types. HP 3 x 400 V These coolers are very suitable for stationary installations - for cooling of either hydraulic oil, lubricating oil or water/glycol The programme has been enlarged by coolers with slow-speed fans which have a very low noise level. To make the range of coolers as complete as possible, the small types can be supplied in a 1-pass as well as a 2-pass construction. In this way, the demand for cooling of a low as well as a high flow is met. In this generation of Nissens HP coolers with 12/24 V fan, the design has been changed and new high-performing fans are used. The result is a higher cooling performance. HP 12/24 V The coolers are very suitable for mobile installations - for cooling of either hydraulic oil, lubricating oil or water/glycol. To make the range of coolers as complete as possible, all 5 cooler sizes can be supplied in a 1-pass as well as a 2-pass construction. In this way the demand for cooling of a low as well as a high oil flow is met. HP HYD The range of Nissens HP coolers with hydraulic motors has been considerably enlarged - to meet small as well as high cooling requirements. The coolers are very suitable for mobile and stationary installations - for cooling of either hydraulic oil, lubricating oil or water/glycol. The programme is very flexible, as there are 6 different hydraulic motor sizes to choose from. To meet possible requirements as to the noise level, the cooling performance of the coolers is specified at various fan revolutions in order to make it possible to choose a cooler that meets the specific requirements of each application. To make the range of coolers as complete as possible, the small types can be supplied in a 1-pass as well as a 2-pass construction. In this way, the demand for cooling of a low as well as a high flow is met. HP Cores Accessories Installation guide Dimensioning - selecting the right HP product

5 Media Features Accessories Page High-performing pump with integrated pressure bypass Suitable for a high oil viscosity Oil High flexibility - i.e. can be supplied with Special motor - 60 Hz - special voltage Galvanized steel parts Offshore design etc. Thermobypass Thermoswitch 6 High flexibility - i.e. can be supplied with Oil Water / glycol Compressed air Special motor - 60 Hz - explosionproof - special voltage Galvanized steel parts Offshore design etc. Thermobypass Thermoswitch 7 Oil Water / glycol Compressed air High flexibility - i.e. can be supplied with: Galvanized steel parts Offshore design etc. Thermobypass Thermoswitch 12 Oil Water / glycol Compressed air High flexibility - i.e. can be supplied with: 6 different hydraulic motor sizes Galvanized steel parts Offshore design etc. Thermobypass

6 HPC 3 x 400 V HPC 1-3 HPC 3 x 400 V Dimensions (mm) Nissens Description A B C* D E F G H I J K L M HPC /2" 3/4" HPC " 1 1/4" HPC " 1 1/4" 100 *may vary depending on the motor Specification Nissens Description Weight [kg] Motor [kw/pol.] Noise level 1 m [db(a)] Pressure bypass [bar] Air flow [m 3 /s] Oil flow [] Cooling performance [kw/ o C] HPC / HPC / HPC / MATERIALS Cooler Aluminum, black RAL 9005 Cowling, feet Steel, black RAL 9005 Fan PPG Fan Guard Steel, chromated ELECTRIC MOTORS Voltage 3 x 400 V Frequency 50 Hz Safety class IP 55 Insulation class F Temperature class B COOLING PERFORMANCE The calculation of the cooling performances is based on an oil temperature of 60 C, and an ambient temperature of 20 C, i.e. a temperature difference of 40 C. NOISE LEVEL The indicated noise level may vary ±3 db(a). This is due to possible reflections from surrounding items, engine frequencies and the like. The noise measurements are carried out at half-spherical spreading. 6

7 HP 3 x 400 V HP 5-60 HP 3 x 400 V Dimensions (mm) & specification Nissens Description - pass A B C* D E F G H I J K Weight [kg] Motor [kw/ pol.] Noise level 1 m [db(a)] Air flow [m 3 /s] HP /2" / HP /2" / HP " / HP " / HP " / HP " / HP " / HP " / HP " / HP " / HP " / HP " / HP /4" / HP /4" / HP /2" / HP /2" / HP /2" / HP /2" / HP /2" / *may vary depending on the motor 7

8 HP 3 x 400 V HP HP 3 x 400 V Dimensions (mm) & specification Nissens Description - pass A B C* D E F G H I J K Weight [kg] Motor [kw/ pol.] Noise level 1 m [db(a)] Air flow [m 3 /s] HP " / HP " / HP " / HP " / HP " / HP " / HP " / HP " / *may vary depending on the motor MATERIALS Cooler Aluminum, grey RAL 7040 Cowling, feet Steel, black RAL 9005 Fan PPG Fan Guard Steel, chromated ELECTRIC MOTORS Voltage 3 x 400 V Frequency 50 Hz Safety class IP 55 Insulation class F Temperature class B NOISE LEVEL The indicated noise level may vary ±3 db(a). This is due to possible reflections from surrounding items, engine frequencies and the like. The noise measurements are carried out at half-spherical spreading. MAX. WORKING PRESSURE 20 bar (dynamic) 26 bar (static) 8

9 HP 3 x 400 V Cooling performance - oil HP ,35 HP20-2/400V/2pol HP20-1/400V/2pol 0,25 0,20 0,15 HP10-2/400V/2pol HP10-1/400V/2pol HP10-2/400V/4pol HP10-1/400V/4pol HP5-2/400V/2 pol HP5-1/400V/2 pol HP OIL HP ,10 0, ,45 0,40 HP40-2/400V/4pol HP30-2/400V/4pol HP40-1/400V/4pol HP30-1/400V/4pol 0,35 HP30-2/400V/6pol HP30-1/400V/6pol 0,25 0,20 HP ,15 1, ,90 0,80 0,70 0,60 0,50 0,40 HP60-2/400V/4pol HP50-2/400V/4pol HP50-2/400V/6pol HP60-1/400V/4pol HP50-1/400V/4pol HP45-1/400V/4pol HP50-1/400V/6pol HP45-1/400V/6pol HP ,50 3,00 2,50 2,00 1,50 1,00 HP100-1/400V/6pol HP90-1/400V/6pol HP100-1/400V/8pol HP90-1/400V/8pol HP80-1/400V/6pol HP80-1/400V/8pol HP70-1/400V/6pol HP70-1/400V/8pol 0,

10 HP 3 x 400 V Cooling performance - water/glycol HP ,40 HP WATER / GLYCOL 0,35 0,25 0,20 0,15 0, HP20-2/400V/2pol HP20-1/400V/2pol HP10-2/400V/2pol HP10-1/400V/2pol HP10-2/400V/4pol HP10-1/400V/4pol HP5-2/400V/2pol HP5-1/400V/2pol HP ,50 0,45 HP40-2/400V/4pol HP40-1/400V/4pol HP30-1/400V/4pol HP30-2/400V/4pol 0,40 0,35 HP30-2/400V/6pol HP30-1/400V/6pol HP ,25 1, ,00 0,90 HP60-2/400V/4pol HP50-2/400V/4pol HP60-1/400V/4pol HP50-1/400V/4pol 0,80 0,70 0,60 0,50 HP50-2/400V/6pol HP45-1/400V/4pol HP50-1/400V/6pol HP45-1/400V/6pol HP , ,50 HP100-1/400V/6pol 3,00 HP90-1/400V/6pol 2,50 2,00 HP100-1/400V/8pol HP90-1/400V/8pol HP80-1/400V/6pol 1,50 1,00 HP80-1/400V/8pol HP70-1/400V/6pol HP70-1/400V/8pol 0,

11 High Performance in Cooling

12 HP 12 V HP 5-40 / 12V HP 12 V Dimensions (mm) & specification Nissens Description - pass A B C D E F G H I Weight [kg] Motor [V/A] Noise level 1 m [db(a)] Air flow [m 3 /s] HP /2" 8 12 / HP /2" 8 12 / HP " / HP " / HP " / HP " / HP " / HP " / HP " / HP " / MATERIALS Cooler Aluminum, grey RAL 7040 Cowling, feet Steel, black RAL 9005 Fan PPG Fan Guard Steel, chromated COOLING PERFORMANCE The calculation of the cooling performances is based on an oil temperature of 60 C, and an ambient temperature of 20 C, i.e. a temperature difference of 40 C. NOISE LEVEL The indicated noise level may vary ±3 db(a). This is due to possible reflections from surrounding items, engine frequencies and the like. The noise measurements are carried out at half-spherical spreading. MAX. WORKING PRESSURE 20 bar (dynamic) 26 bar (static) 12

13 HP 24 V HP 5-40 / 24V HP 24 V Dimensions (mm) & specification Nissens Description - pass A B C D E F G H I Weight [kg] Motor [V/A] Noise level 1 m [db(a)] Air flow [m 3 /s] HP /2" 8 24 / HP /2" 8 24 / HP " / HP " / HP " / HP " / HP " / HP " / HP " / HP " / MATERIALS Cooler Aluminum, grey RAL 7040 Cowling, feet Steel, black RAL 9005 Fan PPG Fan Guard Steel, chromated COOLING PERFORMANCE The calculation of the cooling performances is based on an oil temperature of 60 C, and an ambient temperature of 20 C, i.e. a temperature difference of 40 C. NOISE LEVEL The indicated noise level may vary ±3 db(a). This is due to possible reflections from surrounding items, engine frequencies and the like. The noise measurements are carried out at half-spherical spreading. MAX. WORKING PRESSURE 20 bar (dynamic) 26 bar (static) 13

14 HP 12/24 V Cooling performance - oil HP 5-20 HP 5-40 OIL 0,25 0,20 HP20-2/12-24V HP10-2/12-24V HP20-1/12-24V HP10-1/12-24V 0,15 HP5-2/12-24V HP5-1/12-24V 0, HP ,45 0,40 HP40-2/12-24V HP40-1/12-24V HP30-2/12-24V HP30-1/12-24V 0,35 0,25 0,20 0,

15 HP 12/24 V Cooling performance - water/glycol HP ,25 0,20 HP20-2/12-24V HP20-1/12-24V HP10-2/12-24V HP10-1/12-24V HP 5-40 WATER/GLYCOL HP5-2/12-24V 0,15 HP5-1/12-24V 0, HP ,50 0,45 HP40-2/12-24V HP40-1/12-24V HP30-2/12-24V HP30-1/12-24V 0,40 0,

16 HP HYD HP HYD HP HYD Dimensions (mm) & specification Nissens Description - pass A B C D E F G H I J K Weight [kg] Motor* HP " 17 * HP " 17 * HP " 20 * HP " 20 * HP " 26 * HP " 26 * HP " 33 * HP " 33 * HP /4" 35 * HP /2" 36 * HP /2" 36 * HP /2" 45 * HP /2" 45 * *Dimensions for a 25 cm 3 / rev. hydraulic motor 16

17 HP HYD HP HYD HP HYD Dimensions (mm) & specification Nissens Description - pass A B C D E F G H I J K Weight [kg] Motor* HP " 80 * HP " 97 * HP " 113 * HP " 133 * *Dimensions for a 25 cm 3 / rev. hydraulic motor MATERIALS Cooler Aluminum, grey RAL 7040 Cowling, feet Steel, black RAL 9005 Fan PPG Fan Guard Steel, chromated HYDRAULIC MOTORS * The following hydraulic motor sizes can be chosen: 6, 8, 11, 17, 19 and 25 cm 3 /rev. Max. working pressure: bar Please note that the max. number of revolutions indicated on the graphs (page X and Y) must not be exceeded. MAX. WORKING PRESSURE 20 bar (dynamic) 26 bar (static) NOISE LEVEL The indicated noise level may vary ±3 db(a). This is due to possible reflections from surrounding items, engine frequencies and the like. The noise measurements are carried out at half-spherical spreading. COOLING PERFORMANCE The calculation of the cooling performances is based on an oil temperature of 60 C, and an ambient temperature of 20 C, i.e. a temperature difference of 40 C. 17

18 HP HYD Cooling performance - oil HP 10 0,40 HP OIL 0,35 0,25 0,20 0,15 HP10-2/3300 rpm/0.46 m³/sec./0.44 kw HP10-1/3300 rpm/0.46 m³/sec./0.44 kw HP10-2/2750 rpm/0.39 m³/sec./0.25 kw/77 HP10-1/2750 rpm/0.39 m³/sec./0.25 kw/77 HP10-2/1350 rpm/0.23 m³/sec./0.05 kw/64 HP10-1/1350 rpm/0.23 m³/sec./0.05 kw/64 HP 20 0, ,40 0,35 0,25 0,20 0,15 HP20-2/3300 rpm//0.46 m³/sec./0.65 kw HP20-1/3300 rpm/0.46 m³/sec./0.65 kw HP20-2/2750 rpm/0.38 m³/sec./0.37 kw/79 HP20-1/2750 rpm/0.38 m³/sec./0.37 kw/79 HP 30 0,10 0,80 0,70 0,60 0,50 0, HP30-2/2600 rpm/1.14 m³/sec./1.15 kw HP30-1/2600 rpm/1.14 m³/sec./1.15 kw HP30-2/2000 rpm/0.88 m³/sec./0.53 kw HP30-1/2000 rpm/0.88 m³/sec./0.53 kw HP30-2/1350 rpm/0.55 m³/sec./0.16 kw/73 HP30-1/1350 rpm/0.55 m³/sec./0.16 kw/73 HP30-2/915 rpm/0.43 m³/sec./0.05 kw/65 HP30-1/915 rpm/0.43 m³/sec./0.05 kw/65 0, HP 40 0,90 0,80 0,70 0,60 0,50 0,40 HP40-2/2600 rpm/0.97 m³/sec./1.6 kw HP40-1/2600 rpm/0.97 m³/sec./1.6 kw HP40-2/2000 rpm/0.74 m³/sec./0.72 kw HP40-1/2000 rpm/0.74 m³/sec./0.72 kw HP40-2/1350 rpm/0.49 m³/sec./0.25 kw/75 HP40-1/1350 rpm/0.49 m³/sec./0.25 kw/75 0,

19 HP HYD Cooling performance - oil HP ,50 HP50-2/2000 rpm/1.68 m³/sec./1.5 kw 1,30 HP50-1/2000 rpm/1.68 m³/sec./1.5 kw 1,10 0,90 0,70 0, HP 60 HP50-2/1400 rpm/1.16 m³/sec./0.55 kw/80 HP50-1/1400 rpm/1.16 m³/sec./0.55 kw/80 HP45-1/2000 rpm/1.36 m³/sec./1.2 kw HP45-1/1400 // rpm/0.95 m³/sec./0.38 // kw/77 HP50-2/915 rpm/0.72 m³/sec./0.18 kw/70 HP50-1/915 rpm/0.72 m³/sec./0.18 kw/70 HP45-1/900 rpm/0.61 m³/sec./0.12 kw/67 HP OIL 1,50 1,40 1,30 1,20 1,10 1,00 0,90 0,80 0,70 0,60 0, HP ,50 HP60-2/2000 rpm/1.58 m³/sec./1.5 kw HP60-1/2000 rpm/1.58 m³/sec./1.5 kw HP60-2/1400 rpm/1.11 m³/sec./0.55 kw/80 HP60-1/1400 rpm/1.11 m³/sec./0.55 kw/80 HP80-1/1600 rpm/3.9 m³/sec./5.7 kw 3,00 HP70-1/1800 rpm/3.19 m³/sec./4.6 kw 2,50 HP70-1/1500 rpm/2.68 m³/sec./2.7 kw 2,00 1,50 1,00 0, HP80-1/905 rpm/2.2 m³/sec./1.05 kw/79 HP80-1/680 rpm/1.6 kw/0.5 kw/72 db(a) 1m HP70-1/910 rpm/1.62 m³/sec./0.61 kw/77 HP70-1/680 rpm/1.18 m³/sec./0.27 kw/69 HP ,50 4,00 3,50 3,00 2,50 2,00 HP100-1/1300 rpm/5.38 m³/sec./5.4 kw HP90-1/1300 rpm/4.69 m³/sec./5.8 kw HP100-1/915 rpm/3.76 m³/sec./1.85 kw/84 HP90-1/915 rpm/3.31 m³/sec./2.1 kw/85 HP100-1/680 rpm/2.69 m³/sec./0.8 kw/76 HP90-1/680 rpm/2.36 m³/sec./0.85 kw/76 1,

20 HP HYD Cooling performance - water/glycol HP 10 0,40 HP10-2/3300 rpm/0.46 m³/sec./0.44 kw 0,35 HP10-1/3300 rpm/0.46 m³/sec./0.44 kw HP WATER/GLYCOL 0,25 0,20 0, HP10-2/2750 rpm/0.39 m³/sec./0.25 kw/77 HP10-1/2750 rpm/0.39 m³/sec./0.25 kw/77 HP10-2/1350 rpm/0.23 m³/sec./0.05 kw/64 HP10-1/1350 rpm/0.23 m³/sec./0.05 kw/64 HP 20 0,45 0,40 HP20-2/3300 rpm//0.46 m³/sec./0.65 kw 0,35 HP20-1/3300 rpm/0.46 m³/sec./0.65 kw HP20-2/2750 rpm/0.38 m³/sec./0.37 kw/79 db(a) 1m 0,25 HP20-1/2750 rpm/0.38 m³/sec. /0.37 kw/79 db(a) 1m HP 30 0, ,90 HP30-2/2600 rpm/1.14 m³/sec./1.15 kw 0,80 HP30-1/2600 rpm/1.14 m³/sec./1.15 kw 0,70 HP30-2/2000 rpm/0.88 m³/sec./0.53 kw 0,60 0,50 0,40 0, HP30-1/2000 rpm/0.88 m³/sec./0.53 kw HP30-2/1350 rpm/0.55 m³/sec./0.16 kw/73 HP30-1/1350 rpm/0.55 m³/sec./0.16 kw/73 HP30-2/915 rpm/0.43 m³/sec./0.05 kw/65 HP30-1/915 rpm/0.43 m³/sec./0.05 kw/65 HP 40 0,90 0,80 0,70 HP40-2/2600 rpm/0.97 m³/sec./1.6 kw HP40-1/2600 rpm/0.97 m³/sec./1.6 kw 0,60 0,50 0,40 0, HP40-2/2000 rpm/0.74 m³/sec./0.72 kw HP40-1/2000 rpm/0.74 m³/sec./0.72 kw HP40-2/1350 rpm/0.49 m³/sec./0.25 kw/75 HP40-1/1350 rpm/0.49 m³/sec./0.25 kw/75 20

21 HP HYD Cooling performance - water/glycol HP ,50 HP50-2/2000 rpm/1.68 m³/sec./1.5 kw 1,30 HP50-1/2000 rpm/1.68 m³/sec./1.5 kw 1,10 0,90 0,70 0, HP 60 HP50-2/1400 rpm/1.16 m³/sec./0.55 kw/80 HP50-1/1400 rpm/1.16 m³/sec./0.55 kw/80 HP45-1/2000 rpm/1.36 m³/sec./1.2 kw HP45-1/1400 // rpm/0.95 m³/sec./0.38 // kw/77 HP50-2/915 rpm/0.72 m³/sec./0.18 kw/70 HP50-1/915 rpm/0.72 m³/sec./0.18 kw/70 HP45-1/900 rpm/0.61 m³/sec./0.12 kw/67 HP WATER/GLYCOL 1,50 1,30 HP60-2/2000 rpm/1.58 m³/sec./1.5 kw 1,10 HP60-1/2000 rpm/1.58 m³/sec./1.5 kw 0,90 0,70 HP60-2/1400 rpm/1.11 m³/sec./0.55 kw/80d HP60-1/1400 rpm/1.11 m³/sec./0.55 kw/80 0, HP ,50 HP80-1/1600 rpm/3.9 m³/sec./5.7 kw 3,00 HP70-1/1800 rpm/3.19 m³/sec./4.6 kw 2,50 HP70-1/1500 rpm/2.68 m³/sec./2.7 kw 2,00 1,50 1,00 0, HP80-1/905 rpm/2.2 m³/sec./1.05 kw/79 HP80-1/680 rpm/1.6 kw/0.5 kw/72 db(a) 1m HP70-1/910 rpm/1.62 m³/sec./0.61 kw/77 HP70-1/680 rpm/1.18 m³/sec./0.27 kw/69 HP ,00 4,50 4,00 HP100-1/1300 rpm/5.38 m³/sec./5.4 kw HP90-1/1300 rpm/4.69 m³/sec./5.8 kw 3,50 3,00 2,50 2,00 1,50 HP100-1/915 rpm/3.76 m³/sec./1.85 kw/84 HP90-1/915 rpm/3.31 m³/sec./2.1 kw/85 db(a)1 1m HP100-1/680 rpm/2.69 m³/sec./0.8 kw/76 HP90-1/680 rpm/2.36 m³/sec./0.85 kw/76 1,

22 HP Cores Nissens High Performance cores can be used for many different applications. The cores are made in the Plate&Bar system and thus have a very high durability, and they can handle stable working pressures up to 26 bar and dynamic pressure up to 20 bar. Supplied in more than 20 different variants, the HPseries covers most purposes for stationary and mobile machinery. Should you require coolers similar to the HP s, but in other dimensions, please contact your local representative for special core calculations in the Plate&Bar system. HP Cores Dimensions (mm) & Specification Nissens Description - pass A B C D E F G H HP /2" HP /2" HP " HP " HP " HP " HP " HP " HP " HP " HP /4" HP /2" HP /2" HP /2" HP /2" HP " HP " HP " HP " HP " HP " HP " HP " 22

23 HP Cores - Pressure drop for oil 3 Pressure drop HP5 - HP60 Oil 2,5 HP50-2 HP60-2 Pressu ure 30 cst [bar] 2 1,5 1 HP5-2 HP10-2 HP5-1 HP30-2 HP20-2 HP10-1 HP40-2 HP30-1 HP20-1 HP45-1 HP50-1 HP40-1 HP60-1 0, Flow [] 4 3,5 3 Pressure drop HP70 - HP100 Oil HP70-2 HP80-2 HP100-2 HP90-2 ure 30 cst [bar] Press 2,5 2 1,5 HP70-1 HP100-1 HP80-1 HP , Flow [] 23

24 HP Cores - Pressure drop for water/glycol 1,8 Pressure drop HP5- HP60 Water/glycol HP40-1 1,6 Press ure cst [bar] 1,4 1,2 1 0,8 0,6 0,4 HP5-2 HP10-2 HP5-1 HP30-2 HP20-2 HP10-1 HP50-2 HP40-2 HP30-1 HP20-1 HP60-2 HP45-1 HP60-1 HP50-1 0, Flow [] 2 1,8 Pressure drop HP70 - HP100 Water/Glycol HP ,6 HP90-2 1,4 HP80-2 sure cst [bar] Press 1,2 1 0,8 0,6 HP70-2 HP70-1 HP80-1 HP90-1 HP ,4 0, Flow [] 24

25 Accessories - HP Coolers Thermoswitch A thermoswitch is used for regulation of the coolant temperature in installations in which coolers with electrically powered fans are installed. It is recommended to mount the thermoswitch in the tank, but it can also be mounted in the third cooler connection. Thermobypass A thermobypass is the ideal solution to keep a minimum coolant temperature, irrespective of the ambient temperature. The thermobypass is connected parallel to the cooler. When the oil is cold, the bypass is open and the oil will pass directly from inlet to outlet without passing through the cooler. When the coolant temperature exceeds the set-point temperature of the thermoswitch, the fan is activated. If the temperature falls to 11 C below this temperature, the fan is switched off again. The thermoswitch is available with the following set-point temperatures: 38 C, 47 C, 60 C and 70 C. A relay must be fitted, if the thermoswitch is exposed to current intensities exceeding those below. The bypass is defined on the basis of a specific temperature where it will start to close. It will be completely closed when reaching 10 C higher than the specific closing temperature mentioned below. When the bypass is completely closed, the oil is led through the cooler. The thermobypass is available with the following closing temperatures: 45 C, 55 C, 70 C and 87 C. HP Accessories Nissens Description Thread Set point "Off Temp" Max. working temp. Note Nissens Description Thread Closing temp. Closing temp. range Max. oil flow Max. working temp Thermoswitch 1/2" 47 C 36 C 120 C Relay * Thermobypass 1" 45 C 10 C C Thermoswitch 1/2" 60 C 49 C 120 C Relay * Thermobypass 1" 55 C 10 C C Thermoswitch 1/2" 38 C 27 C 120 C Relay * Thermobypass 1" 70 C 10 C C Thermoswitch 1/2" 70 C 59 C 120 C Relay * Thermobypass 1" 87 C 10 C C * relay required if the thermoswitch is exposed to current exceeding: Thermobypass 1" 38 C 10 C C Voltage specification Voltage Current Max power load* 12 V DC 10 A 24 V DC 5 A 120 V AC 15 A 240 V AC 10 A 277 V AC 7.2 A 25

26 Installation guide - HP Coolers Mounting of HP coolers The placing of the cooler must be chosen in such a way that recirculation of the heated air is avoided. The two connections at the same side can of course also be used. 2-pass coolers must be connected as shown below. Further the cooler must be placed in a way that allows a free cooling air flow in and out of the cooler. The minimum allowable distance to a wall is half the core height (A). The remaining connection can either be plugged or used for a thermoswitch - for regulation of the electric motor. In case of installation in closed rooms, sufficient ventilation must be provided in order that the heated air from the cooling will not increase the room temperature. In case of installation in open air, please note that low ambient temperatures will reduce the coolant temperature and consequently result in an increased viscosity. This may result in high pressure peaks when the machine is started, and if these pressure peaks exceed the max. allowable working pressure, a thermobypass or a pressure bypass must be mounted parallel to the cooler. The HP coolers are constructed for vertical mounting by means of the existing feet, the HP may, however, also be mounted by means of the brackets on the side of the coolers. Installation The HP coolers must be installed in the return flow of the hydraulic system. For the installation of the 1-pass coolers, the two diagonal connections are used - see below. The motor must be connected in a way that ensures that the fan rotates in the direction indicated on the cooler. The HP coolers are designed for a max. ambient temperature of 50 C and a max. temperature of 150 C. If the temperature exceeds 100 C, Nissens must, however, be contacted for approval of these conditions. Maintenance Nissens HP coolers require no special maintenance. If the coolers are working in very dirty surroundings, they should, however, be cleaned regularly, as the cooling performance will be reduced if the fins are blocked because of soiling - seeing that this will result in an increased coolant temperature. Cleaning of the air side: Cleaning is carried out by means of compressed air or water. In case of heavy dirt deposits, the core can be highpressure-cleaned with water. The working direction must be parallel to the fins in order not to damage these. It is recommended to dismount the cooler before cleaning, in order not to damage the motor. Cleaning of the coolant side: In connection with inside cleaning, the disconnected cooler can be flushed with a degreasing agent. After this, the degreasing agent must be blown out by means of compressed air, and the cooler must be flushed carefully with coolant before it is connected to the circuit again. Take care that the degreasing agent does not have a corrosive effect on aluminum. Coolant Nissens strongly recommend you to choose the correct coolant to ensure that the corrosion inhibitors match the aluminum. 26

27 Installation guide - HPC Coolers Placing of the cooler Please note that the cooler must be placed in a way that allows a free air flow in and out of the cooler. The minimum allowable distance to a wall is half the core height (A). Maintenance Nissens HPC oil coolers require no special maintenance. If the cooler is working in very dirty surroundings, it should, however, be cleaned regularly, as the cooling performance will be reduced if the fins are blocked because of soiling - due to an increased oil temperature. Cleaning of the air side: The cleaning is carried out by means of compressed air or water. In case of heavy dirt deposits, the core can be highpressure cleaned with water. The working direction must be parallel to the fins in order not to damage these. It is recommended to dismantle the cooler before cleaning, in order not to damage the electric motor. It is important that there is no recirculation of the heated air - and to ensure sufficient ventilation in the room, - if the cooler is mounted indoor. Installation of the cooler An HPC oil cooler with integrated oil pump functions as a separate cooling circuit which sucks the oil direct from the tank and back. Cleaning of the oil side: In connection with inside cleaning, the disconnected cooler can be flushed with a degreasing agent. After this the degreasing agent must be blown out by means of compressed air, and the cooler must be flushed thoroughly with oil, before it is connected to the circuit again. Take care that the degreasing agent does not have a corrosive effect on aluminum. The circuit may also be fitted with an oil filter. The filter should, however, not be mounted direct on the oil cooler. The suction height from tank to pump must not exceed 2 m, and the hose dimension must not be smaller than the dimension of the pump connection. The viscosity must not exceed 2000 cst. In case of a higher viscosity, please contact Nissens. The electric motor must be connected in a way that ensures that the pump and the fan rotate in the direction indicated on the cooler and the pump. With a view to regulating the oil temperature, it is recommended to mount a thermobypass or a thermoswitch. Thermobypass: -to be used in situations where the HPC oil cooler is used for filter circuits which require a stable oil flow. The thermobypass must be mounted parallel to the oil cooler. Thermoswitch: - to be mounted if the HPC is used for oil cooling only. It is recommended to mount the thermoswitch in the tank for registration of the tank temperature. 27

28 Dimensioning - HP & HPC Coolers SYMBOLS Q ρ oil cp Toil Tamb Vvol = cooling perfomance [kw] = oil density [0.85 kg/l] = specific heat capacity [2.1 kj/kg C] = max. oil temperature [ C] = ambient temperature [ C] = oil volume in the system [l] VALUES 1 kcal/sec. = kw 1 hp = kw 1 BTU/sec. = kw 1 cfm = 4.72 x 10-4 m 3 /sec. HPC HP Example 1: (if the cooling performance is known) Cooling performance = 14 kw Max. oil temp. = 60 C Ambient temp. = 30 C Q 14 Spec. cooling perf. = = T oil - T amb = 0.47 Option: HPC 2 Example 1: (if the cooling performance is known) Cooling performance = 65 kw Max. oil temp. = 70 C Ambient temp. = 30 C Oil flow = 250. Spec. cooling perf. Q 65 = = T oil - T amb = 1.63 Option: HP 80-1/400 V/6-pole Example 2: (if the cooling performance is not known) Normally, the heat emission to the oil will be 25-30% of the engine/motor power (diesel engine or electric motor). Example 2: (if the cooling performance is not known) Normally, the heat emission to the oil will be 25-30% of the engine/motor power (diesel engine or electric motor). Engine/motor power = 15 kw Cooling performance = 0.3 x 15 kw = 4.5 kw Max. oil temp. = 60 C Ambient temp. = 30 C Spec. cooling perf. Q 4.5 = = T oil - T amb = 0.15 Option: HPC 1 Engine/motor power = 30 kw Cooling performance = 0.3 x 30 kw = 9.0 kw Max. oil temp. = 60 C Ambient temp. = 30 C Oil flow = 35. Spec. cooling perf. Q 9.0 = = T oil - T amb = 0.30 Option: HP 30-2/400 V/6-pole Example 3: (if the cooling performance is not known) Oil volume in the system = 220 l Max. oil temp. = 60 C Ambient temp. = 30 C Working without cooling of the system results in an increase of the oil temperature by 25 C in 30 min. T = 25 C t = 30 min. = 1800 sec. Q = V vol ~ ρ oil x c p x T t Q = 220 x 0.85 x 2.1 x 25 = 5.45 kw Spec. cooling perf. = = 0.18 Option: HPC 1 Example 3: (if the cooling performance is not known) Oil volume in the system = 220 l Max. oil temp. = 60 C Ambient temp. = 30 C Oil flow = 75. Working without cooling of the system results in an increase of the oil temperature by 25 C in 30 min. T = 25 C t = 30 min. = 1800 sec. Q = V vol ~ ρ oil x c p x T t Q = 220 x 0.85 x 2.1 x 25 = 5.45 kw Spec. cooling perf. = = 0.18 Option: HP 10-2/400 V/4-pole 28

29 Dimensioning - HP 12/24V & HP HYD Coolers SYMBOLS Q ρ oil cp Toil Tamb Vvol = cooling perfomance [kw] = oil density [0.85 kg/l] = specific heat capacity [2.1 kj/kg C)] = max. oil temperature [ C] = ambient temperature [ C] = oil volume in the system [l] VALUES 1 kcal/sec. = kw 1 hp = kw 1 BTU/sec. = kw 1 cfm = 4.72 x 10-4 m 3 /sec. HP 12/24V HP HYD Example 1: (if the cooling performance is known) Cooling performance = 11 kw Max. oil temp. = 60 C Ambient temp. = 30 C Oil flow = 60 Spec. cooling perf. Q 11 = = T oil - T amb Example 1: (if the cooling performance is known) Cooling performance = 80 kw Max. oil temp. = 70 C Ambient temp. = 30 C Oil flow = 250. Spec. cooling perf. Q 80 = = T oil - T amb Option: HP 30-1 = 0.37 = 2.00 Option: HP 70-1 (1500 rpm) Example 2: (if the cooling performance is not known) Normally, the heat emission to the oil will be 25-30% of the engine/motor power (diesel engine or electric motor). Example 2: (if the cooling performance is not known) Normally, the heat emission to the oil will be 25-30% of the engine/motor power (diesel engine or electric motor). Engine/motor power = 20 kw Cooling performance = 0.3 x 20 kw = 6.0 kw Max. oil temp. = 60 C Ambient temp. = 30 C Oil flow = 50 Spec. cooling perf. Q 6 = = T oil - T amb Engine/motor power = 30 kw Cooling performance = 0.3 x 30 kw = 9.0 kw Max. oil temp. = 60 C Ambient temp. = 30 C Oil flow = 35. Spec. cooling perf. Q 9.0 = = T oil - T amb Option: HP 10-1 = 0.20 = 0.30 Option: HP 20-2 (3300 rpm) or HP 30-2 (915 rpm) Example 3: (if the cooling performance is not known) Oil volume in the system = 220 l Max. oil temp. = 60 C Ambient temp. = 30 C Oil flow = 50 Working without cooling of the system results in an increase of the oil temperature by 25 C in 30 min. T = 25 C t = 30 min. = 1800 sec. Q = V vol x ρ oil x c p x T t Q = 220 x 0.85 x 2.1 x 25 = 5.45 kw Spec. cooling perf. = = 0.18 Option: HP 10-1 Example 3: (if the cooling performance is not known) Oil volume in the system = 220 l Max. oil temp. = 60 C Ambient temp. = 30 C Oil flow = 75. Working without cooling of the system results in an increase of the oil temperature by 25 C in 30 min. T = 30 C t = 30 min. = 1800 sec. Q = V vol x ρ oil x c p x T t Q = 220 x 0.85 x 2.1 x 30 = 6.55 kw Spec. cooling perf. = = 0.22 Option: HP 10-1 (2750 rpm) 29

30 Notes 30

31 Notes 31

32 DELIVERING THE DIFFERENCE Our passion for cooling and climate solutions is fundamental to promote our customers growth and success. Nissens is meeting the needs of our customers and Delivering the Difference by offering World-class Customization - providing our customers with customized and technically advanced cooling solutions that match any application need Experience & Innovation - offering our customers the right solution the first time and reducing the time to market Global Support & Supply - ensuring sales and technical support to our customers in local regions combined with fast and smooth deliveries Quality & Technology - limiting the risk of product failure and the occurrence of quality issues by virtue of proven performance World-class Customization Experience & Innovation Global Support & Supply Quality & Technology WORLD-CLASS CUSTOMIZATION FOR ANY PRODUCT APPLICATION Throughout 90 years, we have built considerable knowledge of the growing needs of our customers in a number of industries and applications. From being an esteemed component specialist, we are today steadily heading towards the role as one of the leading cooling solution providers. Our reference list within applications driven by diesel engines covers most cooling applications in on- & off-road applications varying from forest machinery over specialized train cooling to small telescopic handlers. EXPERIENCE & INNOVATION: OFFERING FIRST-TIME-RIGHT SOLUTIONS Our experience forms an important platform for our proven performance through decades of interaction with leading industries in the world. The vast pool of knowledge that we have acquired over the years is directly reflected in our renowned ability to develop, design and manufacture innovative first-time-right solutions.

33 GLOBAL SUPPORT & SUPPLY: BETTER SERVICE & FAST DELIVERY Our focus on cooling and climate solutions has been a strong driver in our transformation from a local Danish company building upon solid craftsmanship skills to a global industrial group offering local support and global supply of technically advanced product solutions. Today, we have experienced employees, who serve our customers on a global scale. We have in-house production facilities in Denmark, Slovakia and China, as well as a logistics and support set-up in the US, to ensure high quality and short lead time, and our logistics services are second-to-none in the market. QUALITY & TECHNOLOGY: PROVEN, RELIABLE PERFORMANCE The trust of our customers builds upon our proven performance. We apply and respect the strictest international quality standards for industrial companies. We are certified according to ISO 9001/14001, TS and EN regulations. As a European manufacturer working closely with leading OEMs in the market, we know that our customers success is our success. As a result, we only supply products with excellent performance and reliability features, manufactured on the basis of highly advanced technologies. Global Support & Supply PRODUCTION SALES OFFICES CHINA DENMARK SLOVAKIA USA ASIA Nissens Cooling System (Tianjin) Co. Ltd., China Tel.: ncs-asia@nissens.com EUROPE Nissens A/S Denmark Tel.: ncs-europe@nissens.com USA Nissens Cooling Solutions Inc. USA Tel.: ncs-northamerica@nissens.com

34 For several decades, Nissens has supplied thousands of cooling components and cooling systems for industrial applications in the on- & off-road business segments and the global wind turbine industry. Our global footprint allows us to combine our in-depth knowledge of products and applications with the characteristics and needs of the markets and environment across all continents. We know cooling and are ready to offer you an excellent cooling solution. SOME OF OUR CUSTOMERS: Atlas Copco Bomag Bosch Rexroth Cargotec Group Liebherr Manitou Ponsse Sandvik Group Siemens VDL Group Vestas Volvo Wirtgen ZF...and many more

35 Cooling system components, modules and complete cooling systems for any industrial application WIND APPLICATIONS We offer cooling solutions for any on- and off-shore wind turbine application requiring cooling of gear oil, generators, transformer oil, converters, hydraulic circuits and power electronics. Passive coolers Active coolers Nacelle air conditioners Gearbox coolers Generator coolers Converter coolers Inverter coolers Main-bearing coolers Hydraulic coolers Pump stations Transformer coolers Water/oil heat exchangers ON- & OFF-ROAD APPLICATIONS We offer cooling solutions for excavators, dozers, mining and drilling rigs, forestry equipment, agricultural equipment, crushing and processing, material handling, trucks and buses, construction equipment, road construction equipment, trains, special compressors applied for cooling of diesel engines, hydraulic and transmission oil, generators and compressors as well as simple oil cooling for stand-alone applications. Radiators Charge air coolers WCAC Water-Cooled Charge Air Coolers Oil coolers Fuel coolers Trafo oil coolers Condensers Water/oil heat exchangers TYPICAL COOLING SYSTEMS DEVELOPED BY NISSENS FOR A WIND, AND AN ON- & OFF-ROAD APPLICATION: Passive cooler Gearbox cooling pump station (secondary circuit) Gearbox cooler, water/oil AluXchanger Low-temperature cooler WCAC - Water-Cooled Charge Air Cooler Power converter cooling pump station Water-oil heat exchanger Water-oil heat exchanger High-temperature cooler Power converter cooler

36 Nissens A/S Ormhøjgårdvej Horsens, Denmark Tel Fax nissens@nissens.com NCS-HP E All rights reserved Nissens A/S.