Elpress LDC-Q User manual

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
1
Booster unit LDC-Q
User Manual and Tec
hnical Manual

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
2
This user manual applies to the following installations:
LDC-Q 65/20
LDC-Q 100/20
LDC-Q 130/20
LDC-Q 190/20
LDC-Q 240/20
Option
Option
Option
Break tank
Enclosure
BLOCKSAT satellite

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
3
Contents
Contents .......................................... 3
Conditions ........................................ 3
Instructions for reading...................... 3
Safety.............................................. 4
Safety regulations ............................. 5
Technical specifications .....................10
Installation requirements...................12
Dismantling and removal...................21
Faults..............................................21
Declarations.....................................28
Chemicals......................................... 1
Spare parts......................................30
Conditions
This user manual is intended to enable
you to work safely and expertly with and
on your equipment. It is therefore
necessary to read and thoroughly
understand every part of this document
prior to operating the installation. All
relevant local and national regulations
must be strictly observed whenever
waste water or the residue of waste
water is present in the installation. This
is in order to avoid injury to people and
damage to the environment. This user
manual must be accessible at all times.
This user manual has been compiled with
the greatest care and is based on the
level of technology at the time of
compilation. Elpress BV accepts no
liability for direct and/or indirect damage
resulting from the application and/or
interpretation of the information given.
The attachments do not form part of this
manual.
Trading name of Elpress BV. Copyright©
2016 Elpress BV.
Instructions for reading
•The instructions are basically suitable
for all of the installations listed on
page 2.
•Exceptions for a specific type of
installation are listed as follows:
A symbol means that it applies to the
corresponding type of installation.
The above text applies to the types of
installations mentioned in the dotted
area.

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
4
Safety
For safety reasons, changes and
modifications to the installation are not
permitted without the written consent of
Elpress BV. The manufacturer will not be
liable for any damage arising from the
failure to obtain such consent. This also
applies to components that are used and
possibly sealed by Elpress BV.
Safety symbols
The safety conditions, regulations and
instructions described in this chapter are
to be strictly complied with at all times.
National safety regulations must also be
adhered to in each country. The
following symbols are used in this user
manual:
1.
Danger: When an operating or
maintenance instruction can result in
danger to people and the environment
when not complied with precisely or
when not supervised. Please follow the
instructions and proceed with extreme
caution.
2.
Comment: This symbol is shown if an
operation, maintenance instruction or
situation requires special attention.
3.
Danger from rotating parts.
4.
Caustic (corrosive) substance.
5.
Beware: Risk of injury to hands
6.
Hazard from automatically starting
installation.
7.
Danger: contact with electrical voltage.
8.
Hot surface.
9.
Safety gloves compulsory.
10.
Refer to the user manual.
11.
Eye protection compulsory.
12.
Ear protection compulsory.
13.
Face mask compulsory.
14.
Safety shoes compulsory.
15.
Smoking prohibited.
16.
Eating and drinking prohibited.
17.
Advice to protect the environment or to
encourage recycling.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
5
Safety regulations
•The operating personnel must be
familiar with the contents of this
manual and be able to carry out all
instructions given.
•The manual must be available at all
times to the personnel operating the
installation.
•The electrical cabinet must be closed
at all times and may be opened by
authorised persons only.
•The installation is designed to
operate in a frost-free environment.
If the system freezes up, its
functionality must be thoroughly
checked.
•Safety items including safety gloves,
clothing, goggles, etc., must always
be available for the operating and
maintenance personnel.
•It is strictly forbidden to smoke, eat
or drink while operating and/or
carrying out maintenance on the
installation.
•Incorrect operation and use of the
installation may cause damage to the
system.
•Do not use the installation after it
has been damaged. Have it inspected
by an authorised machine engineer
and repaired when necessary.
The transfer, (re)location and
initial commissioning of the
installation must be carefully
carried out. Transfer, locating or initial
commissioning that is incorrectly carried
out can be dangerous for both people
and the environment. Expert installation
and operation are conditions for a
trouble-free operation.
Each product manufactured by
Elpress BV, only leaves the
factory after having been
tested. If the equipment is not going to
be installed immediately, it should be
stored in a dry and frost-free area that is
suitable for its design
structure.
The LDC-Q starts up automatically. The
installation can start up unexpectedly.
Radiated airborne noise emission
•Maximum measured noise level A -
weighted to noise pressure at a
distance of 1 metre from the
installation: <79 dB, with 11 kW
pump.
•From 80 dB(A), the employer must
provide hearing protection aids.
•From 85dB(A) the employee is
obliged to wear hearing protection
aids.

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
6
Intended use
•The installation is solely intended to
be used for performing cleaning
activities with the associated
components.
•The optionally integrated satellite is
solely intended for providing a single
satellite point for cleaning, foaming
and any disinfection activities with
the associated components and
approved cleaning agents.
•The installation is switched on and off
with the main switch [1].
•The installation may only be used
when the pressurised water
connection complies with a complete
cleaning set in accordance with the
installation specifications. These
include water lines, hose reels,
cleaning hoses, spray guns, lances,
nozzles, etc.
•In order to avoid slipping, the
standing position should be on a solid
floor. Moreover, any fluids that are
released should preferably be lead off
via a drain.
•High pressure water jets should not
be directed at electric cabling, control
panels, electrical components and
breakable, vulnerable surfaces.
People under the age of 18 are
forbidden to spray fluids using high
pressure equipment.
BLOCKSAT
1
1

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
7
Instruction table
LDC
-Q
LDC
-Q RF
LDC
-Q RFD
Rinsing generally
•Before commencing with cleaning activities, connect the
installation according to the instructions in the section:
Installation requirements
•When the personnel start on the cleaning activities, a pressure drop in
the pipework causes the pump to start.
•The installation will now start running in order to generate the set
pressure within the capacity curve of the pump.
•In the break tank version, the pump will stop when the two level
switches at the top have not responded after a set time. A pump without
a break tank stops when the flow sensor emits a no-flow signal. In both
cases, the pump then switches to stand-by mode.
√√√
Satellite: Closed
•When no cleaning activities are being performed, the lever on the
Blocksat must be in the stop position (grey). [3]
√√
Satellite: Rinsing
•Connect the rinsing lance (blue) to the ball valve or to the spray gun.
•Set the lever to the rinse position (blue). [4]
•Start rinsing.
•After rinsing, always set the lever to the stop position (grey). [3]
√√
Satellite: Foaming
•Insert the connection hose (white) into the jerry can containing the foam
cleaning agent.
•Connect the foam lance (white) to the ball valve or to the spray gun.
•Set the lever to the foaming position (white). [5]
•Start foaming.
•After foaming, always set the lever to the stop position (grey). [3]
The foam quality should be adjusted during commissioning. To adjust the
foam settings, go to the section: Changing settings.
√√

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
8
Satellite: Disinfecting
•Insert the suction hose (red) into the jerry can containing the
disinfectant.
•Connect the disinfecting lance (red) to the ball valve or to the spray gun.
•Set the lever to the disinfecting position (red). [6]
•Start disinfecting.
•After disinfecting, always set the lever to the stop position (grey). [3]
√
Satellite: After use
•After each use, the injectors must be flushed through with clean water.
To do this, immerse the chemical suction hose into a basin of clean water
and, using the correct lance, operate the shut-off valve or the spray gun
for a minimum of 2 minutes so that the water rinses the injector,
thereby avoiding the formation of crystals in the injector/suction lines.
•Always set the lever to the stop position (grey) after use. [2]
•
Turn the main switch of the installation to [OFF].
√√
3
5
4
6

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
9

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
10
Technical specifications
The installation is constructed from the following components:
•The booster unit consists of 1 Grundfos centrifugal pump of type CRIE. This is a
normally aspirating, vertical, multi-stage centrifugal pump with an in-line design and
fitted with a directly coupled 380-480V electric motor. The electric motor has an
integrated frequency controller. All important components that come into contact with
the medium, such as impellers, pump shaft, enclosure and separating chamber are
manufactured from stainless steel. The pump bearings are lubricated by the pumped
medium. The mechanical shaft seal is made of cemented carbide. The maximum
operating pressure is approx. 20 bar. Further details on this pump are enclosed
elsewhere in this documentation.
•A non-return valve is installed immediately downstream of the pump to ensure that
the pressure is maintained in the pipework. A pressure sensor is also installed on the
pressure line. The signal from the pressure sensor goes directly to the frequency
controller, which controls the pump.
•A switch box with main switch.
•The centrifugal pump has a supply line on the suction side. A pressure switch is
installed on this line to monitor the minimal flow pressure. A pressure gauge is also
installed.
•The unit provides protection against excessively high water temperatures by means
of a thermostat on the pump which switches off the installation when the water
temperature exceeds 70°C.
•All components are mounted on a frame which, if necessary, should be anchored to
the wall or set up level using the adjustable feed supplied (option).
•The centrifugal pump is connected to a break tank. The level in the break tank is
regulated by means of three level regulators and a solenoid valve. The lowest level
regulator is for the low level signal, which switches off the installation completely. A
bypass line is installed at the top of the pump which constantly pumps a small
quantity of water back into the break tank as a way of continually venting the pump.
OPTION: BREAK

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
11
Recommended water quality
Quality
Potable water as required by generally accepted standards
EC98/83
Hardness
<12° DH (210 mg CaCO3/l)
Conductivity
> 250 and < 2000 μS/cm
Iron
< 200 ppb
Silicates
< 5 ppm
Chloride
< 50 ppm
* For dimensions, weight, electricity and water supply connections, see the layout drawing in the appendix.
Technical details apply for factory settings and a flow pressure of 3 bar.
** For a standard installation. Values dependant on possible options.
Name plate
The name plate is located on the assembly frame, the break tank or the main switch.
A
Type of installation
B
Construction year
C
Voltage / frequency
D
Maximum protection
E
Weight
F
Kilowatt
G
Operating pressure
H
Operating temperature
I
Serial number
Type of installation*
LDC
-Q 65/20
LDC
-
Q 65/20 +
BREAK TANK
LDC
-
Q 100/20
LDC
-
Q 130/20
LDC
-
Q 130/20 +
BREAK TANK
LDC
-
Q 190/20
LDC
-
Q 190/20 +
BREAK TANK
LDC
-
Q 240/20
BLOCKSAT RF
BLOCKSAT RFD
Number of users (max.)
3
3
3
6
6
8
8
12
-
-
Operating pressure / bar (max.)**
20
20
20
20
20
20
20
20
20
20
Number of pumps
1
1
1
1
1
1
1
1
1
1
l / pump / minute
67
67
100
133
133
200
200
240
-
-
l / total / minute
67
67
100
133
133
200
200
240
-
-
m3 / total / hour (max.)
5
5
9,5
10
10
14
14
15
-
-
Pump brand
Grundfos
-
-
Pump type
CRIE
-
-
Total power / kW
3
4
4
5.5
7.5
7.5
11
11
-
-
Voltage / V
380-480
-
-
Frequency / Hz
50/60
-
-
Fuse / A
3 x
16
3 x
16
3 x
16
3 x
16
3 x
25
3 x
25
3 x
32
3 x
32
-
-
Max. operating temperature / °C
70
Ambient temperature / °C
<0 - >40
Break tank capacity / l ***
-
70
-
-
70
-
70
-
-
-

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
12
Installation requirements
Elpress BV advises to always have the installation, (re)location and initial
commissioning done by an Elpress BV service engineer.
Installing
•Remove the packaging material and any protective film.
•Check that the installation is not damaged. If you find any damage, contact your
supplier immediately and do not use the installation.
•Install a non-return fitting in the water supply as prescribed by local
legislation if the installation does NOT have a break tank.
•Use any supplied fixings for tension and vibration-free operation.
•Before installation, check the screw thread and sealing rings for cracks and drying
out.
•Place the installation level on a stable surface.
•Place the installation in a dry, frost-free room.
•Should the unit require installation on a wall, ensure the wall is strong enough to
support the weight of the unit.
•Installations with preparations for anchoring to the floor must follow the directions for
fixing them in place.
Before the unit is connected to the pipework, flush the pipework to prevent dirt
from entering the unit.
Connecting
The water supply may be 70 °C maximum with a water pressure according to
the supplied layout. The water supply should be at least 10% above the stated
maximum water consumption.
•Inspect cables for cracks and drying out.
•Connect the water inlet [7] to the inlet valve/suction line.
Please see the lay-out drawing in the annex(es) for connection
values.
•Connect the water outlet [8] using the correct tool.
Please see the lay-out drawing in the annex(es) for connection
values.
7
8

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
13
A coupling hose should preferably be installed between the high-pressure cleaner and
the supply network.
•Only connect the installation to an electrical supply using the values indicated on the
name plate. Also see the layout drawing in the annex(es). Ensure that the electricity
supply is properly fused with the correct safety fuses.
•Ensure that the correct main fuses are placed in the building’s primary supply circuit.
•Connect the earth cable to the earthing point indicated on the installation [9].
•Connect the water outlet [10] of the satellite according to the enclosed layout
drawing.
•Place the connection hoses [11] in the jerry cans. Red for disinfecting and white for
foaming. Ensure that the ends of the intake hoses are immersed completely in the
liquid.
•Connect the compressed air supply [12]. The compressed air supply must have a
constant pressure of between 6 and 8 bar and a capacity of min. 240 nl / min.
•Ensure when starting up the installation that the indicated direction of rotation on the
pump is also the actual direction of rotation. This is in relation to the build-up of
pressure. If the direction of rotation is incorrect, switch off the installation
immediately and notify Elpress BV.
•The overflow pipe [13], which is attached to the break tank, must be connected to
the drains, with an open connection, or placed above a drain / gulley. This is to
prevent any disasters being caused by the break tank overflowing in the machine
room or the room in which the installation is installed.
LDC-Q RF / RFD
LDC-Q RF / RFD
LDC-Q RF / RFD
OPTION: BREAK TANK
13
12
10
11
9

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
14
CAUTION: The pump must be bled the first time it is started. The bleed screw
[14] is situated on the top of the pump. Open the bleed screw while the pump is
running. Close it again when the medium flows evenly out of the vent.
CAUTION: Always set the main switch of the installation to [OFF] before inserting
or removing the plug from the power outlet.
Changing settings
Control panel
The pumps are fitted with this control panel as standard. [15]
The buttons are locked by default and can be unlocked only using an iPod with
Grundfos application or R-100 infrared reader.
1
Grundfos Eye Shows the operating status of the pump.
2
-
Light fields for indication of setpoint.
3
Up and down. Changes the setpoint.
4
Allows radio communication with Grundfos GO and other products of the
same type. When you try to establish radio communication between the
pump and Grundfos GO or another pump, the green indicator light in
Grundfos Eye on the pump flashes continuously. Press on the pump control
panel to allow radio communication with Grundfos GO and other products
of the same type.
5
Makes the pump ready for operation or starts and stops the pump.
Start
If you press the button when the pump is stopped, the pump only starts if
no other functions with higher priority have been enabled.
Stop
If you press the button when the pump is running, the pump always stops.
The "Stop" text next to the button is on.
16
14
15

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
15
Setting the foam quality
If the foam quality is in adequate, it can be adjusted:
•Ensure that the locking nut has room and is unscrewed free from the block.
•Improve the foam quality by turning the air reducer. [16]
More air = Drier foam
Less air = Wetter foam
•Save the settings after making the adjustments by turning the locking nut tight
against the block again.
•This setting only has to be applied once, as long as the type of chemical remains the
same.
Instruction and training
The owner of the installation is responsible for the training and instruction of the
maintenance engineers.
The outside of the terminal box can reach temperatures in excess of 70 °C when
the pump is running.
Before maintenance can be performed on the installation, ensure that the
installation is fully depressurised.
Safety conditions for the maintenance engineers
Safety
•All safety devices including safety switches and safety covers must be properly
reinstalled and functioning normally at all times after maintenance has been carried
out.
•The installation should NEVER be operated when all or even part of the safety system
has been turned off.
Maintenance
•The installation may only be maintained by authorised personnel.
•The maintenance engineers must be familiar with the contents of this technical
documentation and be able to carry out all the instructions given.
•The main switch must be turned off and locked during cleaning and repairing of the
mach installation ine.

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
16
•The electric switchboard can be closed off. This must remain closed at all times and
may only be opened by authorised persons. He/she must be familiar with the
electrical switchgear and the danger it presents.
•The installations control panel must never be cleaned with a jet of liquid (e.g. garden
hose or high-pressure cleaner). This could lead to irreversible damage being caused
to the installation.
•Maintenance may only be carried out when the control panel's main switch is
switched off. The main switch must be locked with a padlock so that it is impossible
to switch on.
•It should be clearly stated when people are working on the installation.
Cleaning preparations
The switchboard of the installation must never be cleaned with a spray. This
could lead to irreversible damage being caused to the installation.
The following points are important when cleaning the installation:
•Switch off the main switch and any other electrical supplies.
•The main switch must be locked using a padlock and it must have a notice stating
that it is forbidden to switch it on.
•Protective equipment, such as good gloves, safety goggles and face mask are to be
available to the operators at all times.
The installation starts up automatically. The installation can start up
unexpectedly.
The chemicals used can be corrosive and have a caustic action on skin
resulting in serious burns. Caustic substance reacts with metal
(corrosive). Prevent accidents, avoid skin contact and wear safety
clothing.
High pressure water jets should not be directed at electric cabling, control
panels, electrical components and breakable, vulnerable surfaces. People under
the age of 18 are forbidden to spray fluids using high pressure equipment.

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
17
Corrosion protection
The stainless steel components have been treated optimally to withstand corrosion.
Damage to the corrosion-proof covering caused by, e.g. welding, scratches, dents, etc.,
should be treated with a certified and approved corrosion-proof and passivating material.
Depending on external influences, the layers of paint applied to pumps and pump
components must be regularly repaired or renewed.

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
18
Weekly maintenance
Check the installation weekly for:
•Leaks and loose parts
•Insulation defects; visually inspect for ageing and
damage
•Soiling of the supply tank
•Operation of the valves, spray guns, pulsation
dampeners, electrical cabinet
•Ageing of the hose pack
•Cleaning of the motor cooling vanes [17].
Maintenance of the Blocksat satellite
•Regularly check the chemical suction hose and the
injector for contamination [18]. Contamination influences
the operation of the Blocksat. If the venturi does not let
enough litres through (when foaming approx. 8.0 litres of
water per minute must flow through the venturi and when disinfecting approx. 5.5
litres per minute), it probably has an internal blockage. Stop the pump and shut off
the water supply to the installation. Set the lever to the foam position (white) and
depressurise the hose and any mounted reel by operating the pistol until no more
liquid comes out of it. Use a screwdriver to remove the injector(s) which is/are
screwed to the side. The injector(s) can now be removed from the block and cleaned.
Check before reassembly that the O-rings are undamaged and free from dirt; screw
the injector all the way in until it stops.
•Regularly check the non-return valves [19] for
operation. If they are not functioning correctly, there is
a risk that water will enter the air supply network.
•Water and/or compressed air flowing out of the overflow
valve [21] is an indication that the non-return valve[20] is broken. Replace of repair
it.
•If the venturi lets sufficient water through, but does not draw any agent, the
restriction in the suction sleeve must be checked for blockage. Removal: unscrew the
18
18
17
19
21
19
22
23

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
19
coupling nut from the suction hose, then unscrew the restriction [23] and clean the
hole. Reinstall the parts again afterwards.
•If water is leaking into the jerry can, the non-return valve [22] is dirty or damaged.
Unscrew the non-return valve and restriction out of the block and pull them apart as
shown in the drawing [24]. Clean the parts and check them for damage. If there is
no damage evident, the non-return valve can be replaced in the block. If damage is
found, install a new non-return valve.
•Regularly check the nozzles, hoses and spray guns for wear.
24

User manual & technical documentation – LDC-Q – EN – Rev 1.1 - 20022018
20
1500 hours / annual service
Every 1500 operating hours or once a year (is used less than 1500 hours
per year), the installation should be fully inspected by an installation
engineer of Elpress BV. The installation will be entirely inspected for function and quality.
Based on this inspection, he will make recommendations for maintenance and repairs.
The installation should undergo a repeat inspection according to VDMA 24413 at least
once every 12 months.
Service life of hose pack (2000 hours)
The service life of the hose pack is dependent upon pressure, temperature and the -
conditions in which it is used. The hose is not resistant to external forces, such as forces
in excess of 25 kg. Therefore inspect the hose pack at least 1x per week. The high-
pressure hoses should be replaced after 2000 hours. The hose packs should be connected
by a professional using the proper tools.
After maintenance, all covers and taps need to be positioned or closed off before the
installation is put into operation again.
Motor bearings
•The pump bearings and axle seal are maintenance-free.
•Motors without lubricating nipples are maintenance-free.
•Motors with lubricating nipples should be lubricated with a high-temperature, lithium-
based grease. Consult the instructions on the protective cap of the fan.
•In the case of seasonal operation (when the motor will not be used for longer than 6
months per year), we advise lubricating the motor each time the pump is put out of
use.
•Depending on the ambient temperature, the motor bearings are replaced or
lubricated on the basis of the table below. The table applies to 2-pole motors. The
indicated number of operating hours before replacement of the bearings is only a
guideline.
•For 4-pole motors, the interval is twice as long as for 2-pole motors.
•If the ambient temperature is lower than 40 °C, the bearings must be
replaced/lubricated at the moments indicated under 40 °C.