Lubing LC-2 Operation and maintenance manual

Climate

systems

Assembly instruction

and operator manual

Top climate system with LUBING Touch Controller

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Top climate system

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Document data

File name: 0986_Assembly instruction and operators manual Top climate system with LUBING Touch Controller

Version: 2.1

First issued: 01.05.2019

Last modication: 07.12.2020

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 Modiﬁcation

1.1 25.11.2019 Update clamping plans

2.0 01.08.2020 Updated safety information

New controller settings

Update clamping plans

Chapter “Transport and storage”

2.1 07.12.2020 Technical data reviewed

Tank module added

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INDEX

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

1.1 Description LUBING Top climate system......................................................................................6

1.2 Notational conventions................................................................................................................6

1.3 Warranty and liability....................................................................................................................7

1.4 Copyright....................................................................................................................................7

1.5 Guarantee terms.........................................................................................................................7

2. SAFETY......................................................................................................................................8

2.1 General safety information...........................................................................................................8

2.2 Safety measures before startup...................................................................................................8

2.3 Safety measures during normal operation....................................................................................8

2.4 Intended use...............................................................................................................................8

2.5 Hazards due to electricity.............................................................................................................9

2.6 Further hazards...........................................................................................................................9

2.7 Personal protective equipment...................................................................................................10

2.8 Safety devices and guards.........................................................................................................11

2.9 Obligations of the plant operator................................................................................................11

2.10 Personnel requirements...........................................................................................................11

2.10.1 Responsibilities..............................................................................................................11

2.10.2 Qualications required by personnel................................................................................12

2.10.3 Obligations of personnel.................................................................................................12

2.10.4 Unauthorized persons....................................................................................................12

2.11 Instruction...............................................................................................................................12

3. TRANSPORTANDSTORAGE.................................................................................................13

3.1 Transport..................................................................................................................................13

3.2 Storage.....................................................................................................................................13

4. ASSEMBLY INSTRUCTION....................................................................................................14

4.1 Installation of the pump unit.......................................................................................................14

4.2 Installation of the lter unit.........................................................................................................14

4.3 Installation of additional modules...............................................................................................16

4.4 Installation LUBING Touch Controller..........................................................................................17

4.4.1 Connection of external climate computers and sensors....................................................18

4.4.2 CAN connection...............................................................................................................18

4.5 Installation of connecting pipes and nozzle lines.........................................................................18

4.5.1 Positioning and orientation of nozzle lines..........................................................................19

4.5.2 Cutting ring ttings...........................................................................................................20

4.5.3 PressFix ttings................................................................................................................22

4.5.4 Wall mounting of connecting pipes and nozzle lines..........................................................22

4.5.5 Suspended mounting of nozzle lines with tension wire......................................................23

4.5.6 Suspended mounting of nozzle lines with support pipe (for height adjustment)..................23

4.5.7 Installation of nozzles........................................................................................................25

4.5.8 FlexClamp system............................................................................................................25

4.5.9 Installation of section valves (Vario systems).......................................................................26

4.6 Last steps of the assembly........................................................................................................26

5. OPERATORS MANUAL..........................................................................................................27

5.1 First start-up.............................................................................................................................27

5.2 Temporary shut-down and restarting.........................................................................................27

5.3 Water quality.............................................................................................................................27

5.4 Disinfection/medication.............................................................................................................27

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5.5 Operation pump system............................................................................................................28

5.5.1 Pressure regulator/bypass valve.......................................................................................29

5.5.2 Pressure switch/sensor....................................................................................................29

5.5.3 Thermo valve...................................................................................................................29

5.5.4 Additional fan...................................................................................................................29

5.6 Further system components......................................................................................................29

5.6.1 Pressure relief...................................................................................................................29

5.6.2 High pressure nozzles.......................................................................................................29

5.7 Operation Touch Controller........................................................................................................30

5.7.1 Function keys..................................................................................................................30

5.7.1.1 Examples standard screen: LC-1...........................................................................30

5.7.1.2 Examples standard screen: LCM vario....................................................................31

5.7.2 Menu overview.................................................................................................................32

5.7.3 Start-up...........................................................................................................................32

5.7.4 Change values.................................................................................................................33

5.7.5 Operating principle of temperature - and humidity - control LCS controller........................34

5.7.6 Special functions..............................................................................................................35

5.7.7 System parameter............................................................................................................36

5.7.8 Software update performance..........................................................................................38

6. MAINTENANCE......................................................................................................................38

7. TROUBLESHOOTING..................................................................................................................39

7.1 Faults Touch controller...............................................................................................................39

7.2 Faults pump system..................................................................................................................40

7.3 Faults with Vario-pumps............................................................................................................41

7.4 Faults with pumps with belt-drive...............................................................................................42

7.5 Faults high-pressure valves/electric pressure relief.....................................................................42

8. WIRING PLANS......................................................................................................................43

8.1 Touch Controller LC-1...............................................................................................................43

8.2 Touch Controller LCS-1.............................................................................................................44

8.3 Touch Controller LC-2...............................................................................................................45

8.4 Touch Controller LCS-2.............................................................................................................46

8.5 Touch Controller LCM...............................................................................................................47

8.6 Touch Controller LCM Vario.......................................................................................................48

8.7 Extension boxes........................................................................................................................49

8.8 Connection scheme Vario-system.............................................................................................50

8.9 Pump incl. LC-1........................................................................................................................51

8.10 Pump special voltage..............................................................................................................52

8.11 Pump Vario incl. LCM vario......................................................................................................53

9. TECHNICAL DATA..................................................................................................................54

9.1 Dimensions D-Line pump unit...................................................................................................50

9.2 Diagram no. of nozzles – necessary ow rate............................................................................50

9.3 Technical data LUBING Touch Controller...................................................................................50

9.3.1 Electrical data..................................................................................................................50

9.3.2 Environment.....................................................................................................................51

9.3.3 Weight and dimensions (LC-1, LC-2, LCS-1, LCS-2)........................................................51

9.3.4 Weight and dimensions (LCM vario)..................................................................................51

9.3.5 Software overview............................................................................................................51

10. NOTES.....................................................................................................................................52

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Top climate system

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1. INTRODUCTION

This manual contains all information you need for the installation and the operation of the LUBING Top climate

system. The manual facilitates the understanding and shows the intended use of the system.

This manual provides all information you need to install and later run the system safely, appropriately and economically.

Following the instructions helps avoiding hazards, reducing repair costs and downtime and increasing lifetime.

All persons responsible for running the system must read, understand and heed the manual. This applies in

particular to the safety information that is given. After reading this manual you will be able to:

– install the Top climate system properly,

– operate the Top climate system safely,

– maintain the Top climate system according to the rules,

– clean the Top climate system according to the rules,

– take the necessary action in the event of a fault.

In addition to this operators manual, it is necessary to comply with general laws and other regulations concerning

accident prevention and environmental protection in the country of use.

This manual is part of the pump unit. It must be kept within reach throughout the system’s service life and must

also stay with the system if it is sold. This manual is not subject to a change service. You can nd out about the

current status at:

Lubing System srl

via Marco Polo, 33

35011 Campodarsego (Padova) - IT

Telephone: +39 0499202290 Fax: +39 0499201234 Email: [email protected]

Internet: www.lubingsystem.com

1.1 Description LUBING Top climate system

The LUBING Top-Climate-System is designed for an effective and efcient cooling, humidifying and cleaning of

the air inside a building. The working principle is direct evaporative cooling by misting water. It can also be used to

soak dirty surfaces before cleaning. It is also possible to clean with a high-pressure lance. Additives or medicines

can be added to the water in low concentrations - in this case the recommendations and limits in this manual must

be observed. It can also be used to suppress smoke and delay the spread of re.

The main components of the system are a high pressure pump unit with an electronic controller which supplies

water with a pressure of 70 bar. The water is distributed in stainless steel pipes to high pressure fogging nozzles

which atomize the water. The extremely small droplets evaporate immediately. The necessary heat energy is

extracted from the air – the air cools down. This cooling effect can reduce the necessary ventilation rate which can

save energy. The LUBING Top climate system is also used to increase the humidity during heating periods and

after the date of entry of young animals.

The electronic controller is responsible for the evaluation of the applied electrical signals from a climate computer

or its own humidity and temperature sensors. The controller switches the pump and the valves accordingly. In

addition, control functions are integrated into the controller to ensure safe, reliable and long-lasting operation of

the system.

The Top climate system is intended exclusively for evaporative cooling or air humidication, for example in stables.

Any use beyond this is considered not intended. The manufacturer is not liable for any resulting damage. The risk

is borne solely by the user. Intended use also includes observance of all instructions in these assembly instruction

and operation manual. Non-observance of the instructions or improper use will void any warranty claims.

Installation, maintenance and repair work may only be carried out by qualied personnel.

1.2 Notational conventions

Passages of this operators manual that require special attention or that are a direct hazard warning are shown as

follows:

NOTE

The system must be monitored regularly despite the built-in control and alarm function several times a

day on climatically extreme days.

DANGER!

Warning of electrical hazard!

This warning indicates an electrical hazard.

Only qualied and authorized specialists are allowed to work on electrical equipment.

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The following notational conventions are also used:

- text following this mark represents an item in a list,

“” text in double quotation marks refers to other chapters, sections or documents,

text following this mark represents a result of the above mentioned action.

1.3 Warranty and liability

The obligations under the supply contact, the general and delivery terms and conditions of LUBING SYSTEM

SRL and the legal regulations in force at the time the contact was signed will apply. All information in this manual

has been compiled in line with the applicable standards and regulations, the state of the art and longstanding

knowledge and experience. Warranty and liability claims for personal injury and material damage are excluded if

they are attributable to one of the following causes:

– unintended or inappropriate use of the controller,

– inappropriate installation, commissioning, operation, maintenance or cleaning of the controller,

– operation of the controller with defective safety devices or with improperly tted or non-functional safety

devices and guards,

– failure to heed information in the installation instructions regarding installation, commissioning, operation,

maintenance and cleaning of the controller,

– deployment of untrained personal,

– structural alterations to the controller (conversions or other alterations to the controller are not allowed to be

made without prior written permission from LUBING SYSTEM SRL; any breach of this causes the controller

to lose its EC conformity),

– technical alterations,

– improperly executed repairs,

– use of nonpermitted spare parts or of spare parts that do not satisfy the technically established requirements,

– disasters, effects of extraneous elements and force majeure.

We reserve the right to make technical alterations in the course of further development and improvement of

features.

1.4 Copyright

This operators manual is protected by copyright and intended for internal use only.

This manual or parts thereof must not be passed or disclosed to any third party or be reproduced or exploited in

any form without the prior written consent of LUBING SYSTEM SRL except for internal use.

Contravention is an offense and results in liability for damages (German Copyright Act UrhG; German Civil Code –

BGB). All right are reserved in the event of the grant of patent or the registration of a utility model or design.

1.5 Guarantee terms

The guarantee terms are contained in the general terms and conditions of LUBING SYSTEM SRL.

DANGER!

This warning indicates a direct hazard which, unless avoided, involves a high risk of death or (serious)

injury.

WARNING

This warning indicates a potential hazard which, unless avoided, may involve a medium risk of death or

(serious) injury.

WARNING

This warning indicates a hazard which, unless avoided, could involve a low risk of slight or medium injury.

NOTE

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

IMPORTANT INFORMATION

This symbol indicates information about the controller function or setting, or information that care is

required.

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Top climate system

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2. SAFETY

The following safety information must be read carefully before working on the system and must be heeded. It

concerns your safety and is intended to prevent hazards and/or injuries.

2.1 General safety information

The following general safety information has to be observed:

– always read and understand the operators manual before operating the system;

– only use the system for its intended purpose (see chapter 2.4 “Intended use“);

– never operate the system without associated guards and safety devices. Never take tted safety devices out

of operation;

– always keep the work area around the system clean and tidy to prevent hazards due to dirt and things lying

around;

– do not exceed the technical data (see chapter 8 “Technical data”);

– only trained personnel are allowed to operate or work on the system;

– do not start the system if other persons are in the danger zone;

– take the system out of operation immediately if a fault occurs. Have faults rectied by appropriately qualied

personnel;

– always keep the operators manual at the place where the system is used. It must be ensured that all persons

dealing with the system are able to view the operators manual at any time.

2.2 Safety measures before startup

Familiarize yourself with the systems‘s:

– operating and control elements,

– features,

– working principles,

– immediate environment,

– safety devices,

– measures for an emergency.

Carry out the following activities before every startup:

– inspect the system for visible damage; rectify any detected defects immediately or report them to the

supervisory staff – the system must only be operated in a perfect condition.

– remove all objects and other materials that are not needed to operate the system out of its work area.

2.3 Safety measures during normal operation

Carry out the following inspection activities every day:

– inspect the system for externally visible damage.

– also pay attention to the instructions and information in or concerning the higher-level operating manual or

control systems.

2.4 Intended use

The safety of the system is only ensured if it is used as intended. The system is made for cooling and humidifying

the air inside a building. Other applications are described in chapter 1.1.

The system is not intended for another use than as described here; other use counts as inappropriate, e.g.

pumping liquids other than water. Treatment with aggressive/corrosive substances which are not in accordance

WARNING

Failure to observe the safety information below may have serious consequences:

– risk to persons due to electrical, mechanical or chemical effects,

– failure of important functions of the system.

Read the safety and hazard information in this section thoroughly before putting the system into operation.

In addition to the information specied in this manual always comply with general safety and accident

prevention regulations.

In addition to the information specied in this manual the plant operator/machine operator must comply with

national occupational, health and safety regulations. It is also important to follow internal rules and regulations.

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Top climate system

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with good professional practice is considered to be misuse. The manufacturer/supplier is not liable for any resulting

damage. The risk is borne solely by the user.

Intended use also includes:

– heeding all information from the operators manual,

– complying with the inspection and maintenance intervals,

– complying with the operating and maintenance conditions,

– taking foreseeable misconduct into consideration.

It is necessary to comply with the technical specications in chapter 8 “Technical data“ without exception.

The system is not allowed to be converted or otherwise altered without prior written permission from LUBING

SYSTEM SRL.

Any breach of this causes the system to lose its EC conformity. Such a breach absolves the manufacturer of the

machine from warranty. Any parts not in a perfect state must be replaced immediately. Parts and special features

not delivered by LUBING SYSTEM SRL are not released for use with the system.

2.5 Hazards due to electricity

2.6 Further hazards

IMPORTANT INFORMATION

Only use the system as intended; otherwise there is no guarantee of safe and reliable operation.

It is not the manufacturer but the plant operator who is responsible for any and all personal injuries and

material damage resulting from unintended use

DANGER!

Warning of electrical hazard!

Touching live parts or parts that have become live due faults, poses a direct risk of death. Damage to the

insulation or individual parts can be fatal hazard. Short-circuits and overloading pose the risk of being hit

by ejected molten parts.

– Always keep the control cabinet and all electricity supply units locked. Access is only allowed for

authorized persons with a key or special tool.

– Always run the controller with the correct electrical voltage.

– Only electrical specialists are allowed to work on the controller’s electrical equipment.

– Regularly inspect the controller’s electrical equipment for defects such as loose connections or

damaged insulation.

– If there is a damage, switch off the power supply immediately and have the damage repaired.

– When working in the electrical equipment always shut off the power and verify safe isolation.

– Switch off the power supply during maintenance, cleaning and repair work and prevent unexpected

restoration on power.

– Never bypass fuses or take them out of operation. When replacing fuses, pay attention to the

correct amperage.

– Keep moisture away from live parts as it can cause short-circuits. Never clean the electrical

equipment with water or similar liquids.

– Have the electrical equipment and xed electrical apparatuses tested by an electrical specialist

every four years at least.

– Alterations made after testing must comply with DIN EN 60204-1.

– Observe the regulations of VDE (Verband der Elektrotechnik Elektronik Informationstechnik e.V.)

or IEC (International Electronical Commission) and the national accident prevention regulations for

electrical systems and equipment.

WARNING

Injury hazard from hydraulics/pneumatics!

Work on hydraulic equipment may only be done by qualied personnel. All lines, hoses and ttings must

be properly installed and checked regularly for leaks and externally visible damage. Damage must be

repaired immediately. Splashing liquids can lead to injuries.

Before starting repair work depressurize system sections and pressure lines to be opened. Secure the

system against being switched on again.

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Top climate system

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Procure spare parts via LUBING SYSTEM SRL.

The system starts automatically. The personnel must be informed of this. Before working on the system, it must be

switched off and secured against being switched on again.

2.7 Personal protective equipment

WARNING

Injury hazard due to incorrect spare parts!

Incorrect or faulty spare parts may cause damage, malfunctioning or total failure, and may also give rise

to safety hazards.

Use original spare parts only.

CAUTION

Danger due to contamination and/or leaking liquids.

Parts lying around can lead to tripping and/or falling and must be removed before the system is put into

operation.

Water may occasionally escape from the following system parts during operation of the system:

- Water occasionally escapes at the pressure relief valve of the pump unit or at the pressure relief of

individual compartments, especially when the system is switched off.

- Water with a temperature of more than 60°C may escape at the thermovalve.

It must be ensured that the escaping water can be drained off safely and does not cause dam- age due

to local water accumulation.

If liquids leak out due to damage, these must be removed immediately, otherwise they may cause the unit

to slip and/or fall.

IMPORTANT INFORMATION

If the system is switched off for special work such as maintenance and repair work, it must be secured

against being switched on again unexpectedly.

WARNING

Restart after power failure!

The system can restart automatically after a power failure.

CAUTION

Injury hazard from sharp edges!

Wear suitable protective clothing (incl. protective gloves).

CAUTION

Danger from hot surfaces!

Some system components can heat up to over 60°C during operation.

WARNING

Danger from aerosols and biological/microbiological substances!

Aerosols produced by the plant can potentially cause breathing difculties. Especially after long periods

of standstill and increased temperatures, microorganisms can multiply and cause a hazard. Observe any

existing legal regulations.

To reduce the risk, ensure that the water quality is sufcient for hygienic operation and rinse the system

after long periods of inactivity.

WARNING

The following instructions must be observed for all work on the system:

– Wear close-tting protective work clothing and safety shoes.

– Use protective gloves if there is a risk of hand injuries.

– Wear protective goggles if there is a risk of eye injury.

– Do not wear rings, chains, watches, scarves or other objects that can get caught in the system

parts.

– Do not work with long, open hair, as this can get caught in driven system parts and lead to serious

injuries.

– Always wear a safety helmet when working under the system.

– Wear suitable hearing protection when reaching or exceeding the applicable limits fo the sound

pressure level.

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