Lubing Pad-climate-system User manual

Climate

Systems

Assembly instruction and

operating manual

PAD-climate-system

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Spare part list

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Manufacturer’s data

Manufacturer:

LUBING Maschinenfabrik GmbH & Co. KG Am Kampe 60

49406 Barnstorf / GERMANY

Tel.: +49 (0) 5442 / 9879 - 0

Fax: +49 (0) 5442 / 9879 - 33

e-mail: [email protected]

Sito web: www.lubing.de

Service:

LUBING SYSTEM S.r.l.

Via Marco Polo, 33 (Z.I.) 35011 Campodarsego (PD) / ITALY

Tel.: +39 049 9202290

Fax: +39 049 9201234

Document data

File name: 0948_Climate systems - PAD-climate-system

Version: 4.0

Last modied: June 2020

Dear Reader,

Permanent development of our products and innovative new designs mean that our assembly and operating

instructions as well as spare parts sheets are regularly updated. If you have any queries, please contact us or your

LUBING dealer.

Current status online at: www.lubingsystem.com

Version Date Changes

2.2.1 22.01.2018 Table “Technical data pump type 4/type 11” replaced

3.0 13.03.2018 Various changes

4.0 June 2020 General revision, various changes

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TABLE OF CONTENTS

1. INTRODUCTION...............................................................................................................................6

1.1 Short description LUBING Pad-climate-system.................................................................................6

1.2 Preface for the manual....................................................................................................................6

2. GENERAL INFORMATION.................................................................................................................6

2.1 Warnings and symbols...................................................................................................................6

2.2 Intended use.................................................................................................................................7

2.3 General safety directives - purpose..................................................................................................7

2.4 Obligations...................................................................................................................................7

2.5 Warranty and liability......................................................................................................................7

2.5 Electrical system............................................................................................................................8

3. ASSEMBLY.......................................................................................................................................8

3.1 Assembly information.....................................................................................................................8

3.2 Installation position in the building....................................................................................................8

3.3 Preparation of the attachment opening.............................................................................................8

3.4 Assembly instructions....................................................................................................................9

3.5 Recommended tools......................................................................................................................9

3.6 Installation procedure.....................................................................................................................9

3.6.1 Installation of the pipe, bottom, and baracket holders................................................................9

3.6.2 Assembly of the supply unit and holder for the water trough.......................................................9

3.6.3 Assembly of the pipe holders................................................................................................10

3.6.4 Glue connection..................................................................................................................11

3.6.4.1 Preparation of the parts...........................................................................................11

3.6.4.2 Pre-treatment of the adhesive surfaces......................................................................11

3.6.4.3 Processing.............................................................................................................11

3.6.4.4 Waiting times/pressure test......................................................................................11

3.6.4.5 Installation notes about Tangit...................................................................................12

3.6.4.6 Disposal.................................................................................................................12

3.6.4.7 Glue instructions.....................................................................................................12

3.6.5 Bonding of the water trough.................................................................................................13

3.6.6 Assembly of the pipe holders................................................................................................13

3.6.7 Assembly of the riser...........................................................................................................13

3.6.8 Assembly and alignment of the spraying pipe.........................................................................14

3.6.9 Installation of the guide rail...................................................................................................14

3.6.10 Coupling for deector.........................................................................................................14

3.6.11 Covers of the water trough..................................................................................................16

3.6.12 End cover.........................................................................................................................17

3.6.13 End cover of deector.........................................................................................................17

3.6.14 Insertion of the pads..........................................................................................................17

3.6.15 Splash protection...............................................................................................................18

3.6.16 Insertion of the pads...........................................................................................................19

3.6.17 Opening of the guide rail.....................................................................................................19

3.7 Instructions for the bleed-off function..............................................................................................19

3.7.1 End cover with overow.......................................................................................................20

4. OPERATING INSTRUCTIONS..........................................................................................................20

4.1 Concept of evaporation cooling.....................................................................................................20

4.2 Initial commissioning....................................................................................................................20

4.3 Operation of the system................................................................................................................21

4.4 Notices on national/international regulations.....................................................................................22

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4.5 Troubleshooting...............................................................................................................................22

5. TECHNICAL PUMP DATA................................................................................................................23

5.1 Type 4/type 11............................................................................................................................23

5.2 Type 25......................................................................................................................................25

6. NOTE..............................................................................................................................................28

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1. INTRODUCTION

1.1 Short description LUBING Pad-climate-system

The LUBING Pad-climate-system is a cooling and humidifying system for agricultural buildings for animal breeding

and for industrial complexes.

The system essentially comprises a pump that pumps water into a spraying pipe. Water is sprinkled against a

deector at certain distances. This leads to optimal water distribution across the pads. The water ows through

the pads in cascades, with part of the water evaporating. The excess water collects in the water trough and is

recirculated by a pump. A oat valve keeps the water level even.

1.2 Preface for the manual

This manual facilitates use of the Pad-climate-system and indicates the intended use of the system. The manual

contains important notes for safe, proper and economic operation of the system. Your attention will help avoid

dangers and reduce repair costs and downtimes while increasing reliability and the service life of the system. The

manual should be supplemented by the applicable national provisions on accident prevention and environmental

protection. The manual is part of the pad climate system. It must be kept accessible throughout the service life of

the pad climate system and must remain with the system even if the system is sold.

The manual must be read and used by everyone who works on the system or installs the system, e.g. at:

– operation, including preparation, troubleshooting in the course of work, cleaning, care, disposal of operating

and auxiliary substances,

– maintenance (servicing, inspection, repair) and/or

– deactivation.

The manual is part of the pad climate system. It must be kept accessible throughout the service life of the pad

climate system and must remain with the system even if the system is sold.

In addition to the manual, the statutory provisions on accident prevention in the country of use and at the location

of use, as well as the accepted technical provisions for safety and professional processing shall apply.

2. GENERAL INFORMATION

2.1 Warnings and symbols

The present instructions use the following symbols:

DANGER!

Warning of electrical hazard!

Warns of dangerous electrical current.

DANGER!

Warns of cold.

DANGER!

Warns of corrosive substances.

DANGER!

Warns of general danger.

DANGER!

Warns of ammable substances.

WARNING

Substances detrimental to health.

WARNING

This warning indicates a hazard which, unless avoided, could involve a low risk of material damage.

NOTE

Mandatory sign indicating protective gloves.

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2.2 Intended use

The LUBING Pad-climate-system is only intended for cooling stables.

Any other use is deemed non-intended. The manufacturer shall not be liable for any damage. This danger shall be

assumed by the user alone.

Indicate use shall also include that:

– All information in the operating manual is read and,

– All service and maintenance work are to be performed as required.

LUBING pad air conditioning systems must only be operated, serviced and used by personnel familiar with such

measures and dangers.

2.3 General safety directives - purpose

This operating manual contains the most important information for safe operation of the pad air conditioning

system.

Check that the safety and functional equipment works safely and correctly:

– Previous commissioning,

– At the corresponding intervals,

– After conversion or maintenance.

Also observe the specications provided by the water and power supply companies.

The system is intended for cooling/air conditioning only. Any other use, e.g. pumping other liquids than water, is

deemed non-intended. The manufacturer/supplier shall not be responsible for any damage resulting from this. This

risk shall be borne by the user alone.

Proper use shall also include the manual and compliance with the inspection and maintenance provisions.

2.4 Obligations

Knowledge of the basic safety and safety directives shall be a basic requirement for safe handling and smooth

operation of this pad air conditioning system. This operating manual and specically the safety notes must be

observed by all persons working on the pad air conditioning system. Additionally, all provision and directives on

accident prevention and for the respective site must be observed.

The Pad Climate System must only be used when it is in an impeccable technical condition. Any problems that

may impair safety must be removed without delay.

Organizational measures:

– All parts and devices must be reviewed at regular intervals.

2.5 Warranty and liability

Generally, LUBING “general and delivery terms” shall apply.

Warranty and liability claims in case of injury and property damage shall be excluded if they are due to one or

several of the following causes:

– Non-intended use of the pad air conditioning system,

– Improper assembly, commissioning, operation and service of the system,

– Operation of the system in spite of defective safety equipment or safety and protective equipment that is

defective or not functional,

DANGER!

The relevant provisions on accident prevention and any other generally accepted technical safety and

health provisions for the workplace must be observed.

WARNING

Information in the operating instructions must be observed.

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– Non-observation of the information in the operating manual regarding transport, storage, assembly,

commissioning, operation, service and equipment of the system,

– Independent structural changes to the system,

– Defective monitoring of wear parts,

– Incorrectly performed repairs,

– Disaster due to foreign bodies and force majeure.

2.5 Electrical system

Any tasks exceeding the scope of system maintenance must only be performed by qualied staff.

Turn off the power supply and secure it against reactivation when work on the device is to be performed. Check

electrical cables for visible damage before commissioning. Replace any damaged cables before taking the device

into operation. Damaged or destroyed plug-in units must be replaced by a qualied electrician. Do not pull any

plugs from the sockets by pulling the cable. Covering electrical parts may cause high temperatures that in turn may

destroy the equipment and cause res.

3. ASSEMBLY

3.1 Assembly information

Please read the following pages with care. The instructions in this manual shall apply to various Pad-climate-

system designs. For this reason, please select and use the sections that apply to you.

When using this manual for LUBING standard versions, please observe any changes to and/or deviations from the

scope of delivery.

3.2 Installation position in the building

The pad surface design should be designed based on the maximal required cooling. The system should be

attached to the building in order to best avoid detriments air swirls or air leaks. Additionally, the resulting air speed

should not exceed the comfort level for the animals kept.

3.3 Preparation of the attachment opening

The attachment opening should have a height of:

PAD HEIGHT (max. 2500 mm) – 77 mm

and a length of:

PAD LENGHT - 60 mm (e.g.: pad length 24000 mm opening = 23940 mm)

DANGER!

Warning of electrical hazard!

Always interrupt power supply before performing any work on the electrical system.

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3.4 Assembly instructions

Use the table of contents to nd the desired assembly section.

The assembly section describes the individual work steps in the

assembly order. Individual components are applied with item

numbers in the drawings.

3.5 Recommended tools

Find a list of tools below that are needed to install your LUBING

pad air conditioning system.

– measuring tape,

– hand saw,

– chalk line/cord,

– jig saw or circular saw,

– spirit level,

– cordless screwdriver,

– socket wrench (for clamps),

– ladder/stilts,

– cutter knife.

3.6 Installation procedure

The opening in the stable should have a wood frame of waterproof

wood.

For systems <12 m/40 ft. in length, the supply unit may be placed

at the end of the system. For longer system and generally, the

supply unit should always be positioned at the center of the

frame.

3.6.1 Installation of the pipe, bottom,

and bracket holders

Start assembly from the center. Mark the center with a line at

the upper and lower section. You can nd the holder positioning

points in the following gures.

3.6.2 Assembly of the supply unit and holder for the water trough

Start assembly by installing the supply unit. The supply unit should always be placed at the center of the entire

frame if possible. The impact edge of the plastic housing should be precisely centered on the frame. For positioning

of the bracket holders, see illustration below.

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3.6.3 Assembly of the pipe holders

Measure and mark the distance for the upper holder above the supply unit. Measure and mark the distance for

the upper holder at the end. Then mark the horizontal connection between these points with a chalk line. Atta-

ch the upper holders at a distance of max. 75 cm (30 in). The distance from the end should be 37.5 cm (15 in).

Attach every upper holder with two screws and washers.

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The holders for the water trough must be placed horizontally at even intervals of max. 75 cm, and in the horizontal

alignment. For further distances, see the illustration below. Recommended tools for installation are a chalk cord

and a cordless drill.

3.6.4 Glue connections

LUBING recommends “Tangit” glue for glue connections.

3.6.4.1 Preparation of the parts

The pipe ends must be cut off rectangular, chamfered and deburred to 15°. Missing

or improper pipe chamfers will prevent permanently tight connections.

3.6.4.2 Pre-treatment of the adhesive surfaces

Clean the adhesive surfaces (pipe end and water trough outside, ttings and couplings inside) of gross dirt rst.

Remove any adhering ice by heating (hand-warm). Then the adhesion length of the tting must be marked on the

pipe end so that the required glue application and complete insertion of the pipe can be reviewed. Fine cleaning

takes place with Tangit cleaner. For this, a white, lint-free roll-crepe paper is soaked with cleaner and used to clean

the surfaces to be bonded thoroughly to make them grease- and dirt-free. The paper must be replaced after each

cleaning process. The surfaces cleaned with Tangit cleaner must be dried before application of glue.

3.6.4.3 Processing

Stir Tangit well before use. The glue should ow off slowly from a rod held diagonally and form a kind of glue vane.

Apply an even, uninterrupted glue layer inside the sleeve and then on the pipe in the axial direction. Thinly coat the

inside of the sleeve with Tangit in order to avoid detrimental bead formation in the pipe; apply it thickly to the pipe

end. Tangit PVC-U can be used to bridge tolerances up to +0.6 mm according to DIN EN 14814.

Push together the pipe ad sleeve to the stop or to the full sleeve depth at once without twisting/canting against

each other and hold them in this position for a few seconds until the glue has cured.

Remove excessive glue with the cleaning paper directly after joining. Due to the quick curing of the glue, the joined

parts must be pushed together within 4 minutes after application of the glue commences.

The open time of Tangit, i.e. the time from starting to apply glue to joining of the parts, depends on the lm

thickness of the glue and/or the ambiance temperature.

At a lm thickness of 1 mm, the processor will have the following times depending on the processing temperature:

3.6.4.4 Waiting times/pressure test

The pipes must not be moved during the rst ve minutes after bonding. For temperatures below +10 °C, this time

will increase to at least 15 minutes.

The lines should only be lled and pressure tests up to a test pressure of 1.5 x PN should only be performed 24

hours after the last bonding. It is recommended to ush lines that are not taken into operation at once well and to

TECHNICAL DATA

Outer pipe diameter d(mm) Dimensions for b in mm bonding with ttings (approx.)

up to 15 2

20-50 3

63-110 5

125-200 5

225-310 5

TEMPERATURE PROCESSING TIME ADHESIVE FILM

THICKNESS

20 °C ~ 4min. 1mm

25 °C 3min. 1mm

30 °C 2min. 1mm

40 °C 1min. 1mm

> 40 °C < 1min. 1mm

WARNING

The load from the system after start of operation is 75 kg / m (165 lb / m)!

The load may vary depending on pad type.

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let them stand lled with water.

NOTE

Before commissioning, ush the pipes thoroughly in order to remove any remaining sol- vent vapors.

Tangit PVC-U is ready for use and therefore must never be diluted. Tangit PVC-U and Tangit cleaner affect

PVC-U. Plastic parts therefore must be kept away from any spilled glue/cleaner.

Close any containers not in use well at once in order to avoid solvent loss and thickening. Remove any

glue skin. Wipe off any thickened glue adhering to the brush with dry eece paper. Cleaned brushes must

be dry before reuse.

3.6.4.5 Installation notes about Tangit

Installation at lower temperatures requires extreme care. Pipes and ttings tend to be more sensitive to impact

(brittling) at temperatures below +5 °C, so that long-term effects of solvent vapors, as it occurs, e.g., when closing

the lines during the drying phase, may damage the system.

Furthermore, Tangit PVC-U binds physically, which may delay the strength development a lot.

The minimum durability of Tangit PVC-U in the unopened original package at 20 °C is at least 24 months from the

manufacturing date.

The manufacturing date and batch number can be found on the edge of the can or on the fold of the pipe and the

insertion tab of the folding box.

Tangit PVC-U and Tangit cleaner are re-hazardous. The solvent vapors are heavier than air, may collect on the

oor and form explosive vapors. Therefore, ensure sufcient ventilation and venting in processing and drying, also

after bonding.

DANGER!

Do not weld! Do not use open light and re; avoid any spark formation under all circum- stances. Before

performing any welding work, remove any collections of solvent vapors and explosive mixtures. Fill pipes

with water, ush them and blow them out well. Do not close lines during the drying phase. Extended

inhalation of the solvent vapors may dam- age health.

DANGER!

In the working area: Do not smoke!

Keep used cleaning paper in closed containers (e.g. buckets with lids), in order to keep the stress from solvent

vapors low.

We recommend preventive use of protective gloves to avoid skin contact and greatest cleanliness (wash hands

in between and apply greasing skin protection cream or emul-sion). After contact with the eyes, rinse thoroughly

with water and seek medical advice. Change clothing contaminated with glue. Provisions and rules of the trade

associations and information in the safety data sheet must be observed.

For detailed information on safety-technical and work-hygienic questions for handling of Tangit PVC-U, see the

leaet “Handling of Tangit”. The safety data sheet is available at http://mymsds.henkel.com.

3.6.4.6 Disposal

Fully fried product residue may be disposed of in the household waste/commercial waste. Dispose of large amounts

separately. Waste key/ EAK code on request. Recycle empty packaging.

3.6.4.7 Glue instructions

1. Clean all glue areas thoroughly with Tangit cleaner! The cleaned

areas must remain free of fat, dirt and moisture – do not touch them

again after cleaning.

2. Coat the glue points of the water trough with Tangit glue.

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3. Fill the gap of the coupling (bilateral)/end piece with Tangit glue.

Observe the general notes on handling of Tangit in chapter 3.6.3.3 (in

particular the processing time: 4 min. at 20°C)

4. When joining the parts, Tangit glue must protrude from the gap to

produce a connection without any leaks.

5. Spread protruding Tangit glue with a brush at the transfers. Ready

for drying. Please note the drying times in chapter 3.6.3.3.

Required materials and tools:

3.6.5 Bonding of the water trough

Start bonding of the water trough from the position of the supply unit.

From there, glue the troughs to each other until the ends. The end cover is glued on at the end of the system

instead of a coupling. Bonding of the water trough is described in detail in chapter 3.6.4.

Tangit

cleaner Tangit glue Rag Brush

WARNING

Adhesive areas must dry for 24 hours!

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14

3.6.6 Assembly of the pipe holders

Measure and mark the distance for the upper holder above the supply unit. Measure and

mark the distance for the upper holder at the end. Then mark the horizontal connection

between these points with a chalk line. Attach the upper holders at a distance of max. 75

cm (30 in). The distance from the end should be 37.5 cm (15 in).

Attach every upper holder with two screws and washers.

3.6.7 Assembly of the riser

Connect the pump to the spraying pipe. The enclosed 2.5 m long PVC pipe must be cut to the desired length on

site. For a recommendation on the length cutting of the individual parts, see the following gure.

Cut and bond the entire piping system from the pump to the spraying pipe. Then place the pump cover on the

supply unit in order to prevent dirt and splashing water at the pump. Observe the arrangement of the construction

units as in the sketch.

The oat valve in the housing should be connected to the pressurized water at a later time, so that the system will

not be lled by accident. Ensure that the oat of the valve can move freely.

WARNING

Ensure straight cuts when sawing the pipes. Then clean the front of the pipes and deburr them to 15°.

Contamination or splinters in the hose system may considerably reduce the system’s efciency and/or

cause damage!

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3.6.8 Assembly and alignment of the spraying pipe

Start with gluing on the spraying pipe together with the T-adhesive coupling of the riser. The tee should be centered

here on the system center. Starting at the tee, glue on the riser to the pump.

3.6.9 Assembly of the deﬂector

Click the deector onto the pipe holders. Ensure that the deector is correctly installed in all pipe holders.

3.6.10 Installation of the guide rail

Attach the guide rail on the wall side by attaching it to the pipe holder. Make sure that the guide rail is correctly

installed in all pipe holders.

WARNING

The holes of the spray pipe must be at an angle of 30 degrees against

the air ow from the outside

Air ow

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3.6.11 Assembly of the couplings

The spraying pipes are connected by soft PVC couplings. Then the spraying pipes are connected to each other

with the couplings and screw-thread clamps.

The spraying pipes are connected by soft PVC couplings. Then the spraying pipes are connected to each other

with the couplings and screw-thread clamps.

Use the slider coupling to connect the guide rails. It can be opened and closed with the slider, e.g. to remove the

pads or to clean the system.

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3.6.12 Covers of the water trough

After the required drying time for all glue connections, install the covers on the water trough. The covers should be

placed ush on top of each other.

3.6.13 End cover/end cap for the water trough

Glue the end cap onto the end of the water trough. For adjustment of the end cover, rst cut the end cover to the

desired length. The maximum length of the end cover is 2,500 mm. The rule of thumb for cutting the end cover is:

length = pad height minus 50 mm. Then cut the lower corner facing the wall to 30° from the end cover (see gure

below). Then attach the end covers with 6 screws each spread evenly across the length.

3.6.14 End cover of deﬂector

Now put on the end cover for the deector and glue the transfer piece to the spraying tube. After drying of the glue

points, the at seal and closure cap can be attached.

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3.6.15 Splash protection

Some pad types/kinds may experience increased splash water. The “splash protection” may be installed optionally

if necessary. It is simply plugged in between the trough cover and the pad (see gure below).

This is a plug-in assembly for which no glue is needed. The inserted pads must have a wall thickness of 100 mm

±1 mm (for 4“-systems) or 150 mm ±1 mm (for 6” systems) for a secure plug-in connection at the water trough.

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3.6.16 Insertion of the pads

The rst pad is pushed into the lateral end cover. Then the following pads are inserted ush against the previous

one. The second-to-last pad is pushed into the opposite end cover, so that the last pad can be inserted into the

still-open gap.

Once the pads are inserted, the front guide rails should be inserted. The coupling of the guide rail can be opened

and closed with the slider.

3.6.17 Opening of the guide rail

In order to open the guide rail, move the slider sideways. Then the guide rail can be disconnected.

3.7 Instructions for the bleed-off function

Use the bleed-off function to continually drain water. Continuous drainage of water improves the water quality on

demand.

Depending on the region and local water quality, continually drain 5-10

% of the entire water ow rate. This value should be increased at higher

mineral contamination.

For example: If the oat valve conveys 20 liters/minute, about 1 liter/

minute should be drained additionally. An additional water dial may be

installed in the supply line for measurement through the oat valve.

The desired setting should be determined during commissioning by

“calibration”: With the system running, set the 1/2” ball valve so that a

5-liter bucket can be lled in 5 minutes (cf. example above).

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3.7.1 End cover with overﬂow

In order to prevent a too-high water volume, the end cover of the water trough has over-ow bores. The bores must

not be clogged, since the function will not be ensured other-wise. The maximum water level should not exceed

20 cm or 7 4/5 inch. Ensure that the oat valve can switch according to its function. Generally, water should not

escape from the overow bores. The bores only serve as an overow for strong precipitation.

4. OPERATING INSTRUCTIONS

4.1 Concept of evaporation cooling

LUBING pad air conditioning systems are used with great success in order to compensate for extreme temperatures

that affect the air inside the building. The advantages of pad cooling are achieved by air exchange in combination

with evaporation cooling. Hot, dry air absorbs water. The energy used by this cools off the air. This method of

cooling can offer reliable reduction of heat stress in times of extreme temperatures. Suitable for any geographic

location, a LUBING Pad-Climate-System offers the greatest economic use in areas where higher temperatures for

longer periods are the default status.

The LUBING pad-climate-system consists of three module groups:

– supply unit,

– central element,

– end set.

4.2 Initial commissioning

1. Connect the oat valve to a suitable water supply.

2. Adjust the oat valve with the adjustment screw so that the

height of the water level in the water trough, measured from the

bottom, is no more than 20 cm (7 4/5 in).

3. On connection of the pump, please read the original operating

instructions of the manufacturer which are enclosed with every

delivery.

4. After starting the pump, the water volume must be set. For

this, the deector is re-moved and the height of the water column

is measured (see gure).

WARNING

Check if all closures are closed before use.

Livello d’acqua massimo

20cm/ 74/5 inch

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Lubing Pad-Climate-System User manual

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