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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4

INDEX

IT

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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6

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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8

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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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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10

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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2.8 Safety devices and guards

– Before switching on the system always make sure that all safety devices and guards have been tted properly

and are functional.

– When subcomponents are delivered the plant operator must ensure that the guards are tted according to

the rules.

– You must not bypass or remove safety devices and guards or defeat them in any other way.

– Check the functioning of all the system‘s safety devices regularly.

2.9 Obligations of the plant operator

The system is used in industrial plants. The plant operator is therefore subject to the legal requirements concerning

health and safety at work.

In addition to the safety information in these manual it is necessary to comply with the safety, accident prevention

and environmental protection regulations valid for the area of application, where the system is being used. The

following applies in particular:

– the plant operator must ensure that the system is used as intended (see chapter 2.4 “Intended use“)

– the plant operator must always keep the manual in a legible and complete condition at the place where the

system is used.

– throughout the time that the system is in use the plant operator must check that the plant instructions are in

line with ofcial regulations and must update them if necessary.

– the plant operator must only let suitably qualied and authorized personnel work on the system.

– the plant operator must ensure that all personnel working on or with the system have read and understood

this operators manual. The plant operator must also train the personnel and inform them about hazards at

regular intervals.

– the plant operator must provide sufcient lighting at the control points of the system in accordance with local

health and safety regulations.

– the plant operator must make sure that individuals whose reactivity is impaired by drugs, alcohol, medication

and the like do not work on the system.

In addition, the plant operator is responsible for keeping the system in a perfect technical condition so the following

also applies:

– the plant operator must regularly check that all safety devices are functioning correctly and are complete.

2.10 Personnel requirements

The device is only allowed to be operated, maintained and repaired by persons who have been trained for this and

are authorized to do so. These persons must know the installation instructions and operators manual and act in

accordance with them. The respective authorizations for personnel must be dened clearly.

2.10.1 Responsibilities

Personnel require the following qualications for the various activities:

Personnel requiring training

Personnel requiring training, such as trainees or temporary workers, are not aware of all hazards that operation

of the system can entail. They are only allowed to work on the system under the supervision of skilled personnel.

Instructed personnel

Instructed personnel have been instructed by the plant operator about their tasks and the potential risks of

inappropriate behavior.

Skilled personnel

Skilled personnel are able to do their work and recognize/avoid potential hazards on their own as a result of their

training, knowledge and experience and their familiarity with regulations.

Electrical specialists

Electrical specialists are able to work on electrical equipment and recognize/avoid potential hazards on their own

as a result of their training, knowledge and experience and their familiarity with standards and regulations. Electrical

specialists have been trained for their specic point of deployment and know the relevant standards and regulations.

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2.11 Instruction

Personnel must receive regular instruction from the plant operator. Keep a record of all instruction given in order

to keep track of matters.

Date Name Type of instruction Instruction given by Signature

2.10.2 Qualiﬁcations required by personnel

Personnel must consist of individuals who can be expected to perform their work reliably. Individuals whose

response is impaired by drugs, alcohol, medication and the like must not work on the system.

All persons working on the system must read the operators manual and conrm with their signature that they have

understood it.

Initially, personnel requiring training are only allowed to work on the system under the supervision of skilled

personnel. The completion and success of instruction must be conrmed in writing.

All control and safety devices must only be activated by instructed persons.

In addition, particular qualications are required for the following activities:

– Installation – only allowed to be carried out by trained specialists

– Commissioning – only allowed to be carried out by trained specialists

– Instruction – only allowed to be carried out by trained personnel

– Cleaning – only allowed to be carried out by instructed personnel

– Maintenance/ serving – only allowed to be carried out by trained specialists

– Repairs – only allowed to be carried out by trained specialists

2.10.3 Obligations of personnel

Before working on or with the system, all persons undertake the following:

– to comply with basic regulations concerning health, safety and accident prevention,

– to read the safety information and warnings in this manual and to conrm with their signature that they have

understood the issues.

2.10.4 Unauthorized persons

WARNING

Injury hazard due to inadequate qualiﬁcations!

Inappropriate actions when working on the system can lead to considerable personal injury and material

damage.

All activities must therefore be carried out by qualied personnel only.

WARNING

Hazard for unauthorized persons!

Unauthorized persons who do not have the required qualications are not aware of the hazards in the

work area.

Therefore:

– keep unauthorizied persons away from the work area,

– address persons in case of doubt and eject them from the work area if applicable,

– interrupt work while any authorizied persons are in the work area.

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3. TRANSPORT AND STORAGE

For the multitude of possible system components, only general information can be given here. For transport

specialists and experienced tters these are usually sufcient. If in doubt, please consult us.

3.1 Transport

The system is supplied in pre-assembled modules and in different packaging units. These are to be secured by

suitable devices against slipping and tilting during transport. Avoid shocks and impacts. The components may only

be transported by appropriately qualied and instructed per- sonnel and in compliance with all safety instructions.

Wear protective clothing, safety shoes, protective gloves and a safety helmet during the work. Also read section

2 “Safety”.

When selecting suitable lifting and transport equipment, always take into account the weight of the heaviest

component. When transporting by hand, take into account the reasonable human lifting and carrying forces.

3.2 Storage

If the system components are not installed immediately after delivery, they must be carefully stored in a

protected place. The components must be temporarily stored in such a way that they are protected from

cold, moisture, dirt and mechanical inuences.

Before installation, store the components where they will be installed so that their temperature can adapt

to the environment.

WARNING

Risk of injury from components with high weight and sharp edges!

Improper transport and non-compliance with the safety instructions can lead to crushing or cutting injuries.

IMPORTANT INFORMATION

No liability will be accepted for damage caused by improper storage.

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4. ASSEMBLY INSTRUCTION

The Top climate system is generally supplied in components as a modular system. Each system is designed to

meet the individual requirements of the customer.

4.1 Installation of the pump unit

Place the pump unit on a even, horizontal, clean oor that is easily accessible and adequately ventilated. Instead

of placing the pump unit on the oor, it can alternatively be mounted to a at vertical wall using the optional wall

mounting kit (art. 7290). Depending on the wall, suitable dowels/screws must be used for horizontal mounting of

the bracket. The machine feet can be screwed to the angle plate in prefabricated holes. The pump unit is then

suspended from the holder in a vibration-decoupled manner and xed with nuts.

Remove the protective foil from the attached high-pressure hose and connect it to the connecting pipe by means

of a cutting ring tting (remove union nut and cutting ring on one side). Alter natively, a PressFix tting with a suitable

connection for the hydraulic hose can be used for the connection (Art. 7409). If optional modules are used, the

hydraulic hose is connected to the respective module (see chapter 3.3 “Installation of additional modules”).

The pump unit is designed for connection to a LUBING Touch Controller. Without the LUBING Touch Controller no

correct function of the system can be guaranteed. The pump unit must not be connected to the power supply until

the electrical components have been fully installed. The pump unit is equipped with a Mo gate protection switch.

IMPORTANT INFORMATION

The system must always be thoroughly ushed before being put into operation. For this purpose, the ball

valves at the ends of the nozzle lines are opened after the assembly of the lines and all lines are thoroughly

ushed. The rst ushing of the system must take place without nozzles. Only after ushing the mounting

of the nozzles is the last step to complete the system.

IMPORTANT INFORMATION

Check whether a red transport plug still closes the pump housing. If this is the case, replace it with the

supplied oil vent screw. Check the oil level and rell if necessary (15W-40).

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Example: art. 7126-V1-B

Further safety measures must be provided by the customer according to the valid regulations. As a general rule:

• The pump unit must be earthed.

• The power supply must be designed in accordance with Section 9 “Technische Daten/Technical data”.

• If a Vario pump unit is connected to a TT or TN network with a residual current circuit breaker, a universal

current-sensitive residual current circuit breaker type B with a leakage current of 300 mA must be used.

• To connect a Vario pump unit to an IT network, the jumper is set to CY=OFF. This, however, impairs the radio

interference suppression of the frequency inverter (see chapter 7 “Troubleshooting”).

The pump unit must not be connected to the power supply until “First start-up” (chapter 5.1)!

4.2 Installation of the water supply

Selection of the ﬁlter unit:

If a pump unit is connected directly, a lter unit with integrated main valve is required (the valve plug is connected

to the Touch Controller). A 1/2”-valve is sufcient for up to 25 l/min, a 3/4”- valve is required for more than 25 l/min.

A pressure gauge is installed behind the valve. While the pump is running, it must be ensured under all operating

conditions that the pressure at this pressure gauge (inlet pressure of the pump) is 1...4 bar. Filter units with bypass

can be used for the dosing of additives, in which any 3/4” dosing units can be installed. Usually lter units with 4

lters are used, only with very good water quality on site, lter units with only 2 lters can be used. The smallest

required ltration degree is 1 micron.

Mount the prefabricated lter battery horizontally on a wall or bracket near the pump unit.

Be sure to observe the installation direction! Filter sizes are pressed into the lter inserts (25 micron, 10 micron, 5

micron, 1 micron). The water must ow through the lter battery in this direction. This ensures optimum ltration of

the supply water and a long service life of the lter cartridges.

The supply line is connected to the input of the lter unit (3/4” IT). The supply line should at least correspond to the

diameter of the pump suction connection, preferably larger, and should be as free as possible of resistances and

throttling points. There is a hose connector at the outlet of the lter unit. Here the 3/4” hose of the pump unit (or a

hose to a tank) is connected. The hose must be laid in such a way that it is not bent too much and does not rub.

The valve connector cable is connected to the Touch Controller according to the “Wiring plans” (chapter 7). After

the connection, the manual shut-off valve can be opened and the lters can be put under water. Before switching

on the system, the lters need to be vented: Open the breather valves on the lter head until only water emerges.

When later replacing used lter cartridges, make sure that the O-ring is cleaned and lightly greased (e.g. with

Vaseline).

IMPORTANT INFORMATION

Make sure that the order of the lter cartridges is correct.

Check the condition of the lter cartridges regularly. If they are very dirty, replace them. Regular replacement

(e.g. once a year) is recommended. Dirty lters can lead to an insufcient inlet pressure below 1 bar.

When using a chem. lter cartridge (5 micron chem.), it must be replaced regularly (twice a year or after

150 m3 ow).

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4.3 Installation of additional modules

The pressure relief module for connection to the connection pipe (art. 7113) is

mounted between the hydraulic hose of the pump unit and the connection pipe. For

the connections of the T-piece, the information in chapter 3.5.2 “Cutting ring ttings”

must be observed. The mounting position of the valve should be with the solenoid

upwards. The hose at the connector should be led into the drain. The cable of the

valve connector is connected to the Touch Controller according to the specications

in the chapter 7 “Wiring plans”.

The additional module 2-house without pressure relief (art. 7114) is mounted near the

pump unit on a wall or alternatively in the pump unit on the rear wall of the angle plate.

The mounting position of the valves should be with the solenoids pointing upwards.

The connector between the valves is connected to the hydraulic hose of the pump

unit. The two hydraulic hoses behind the valves are connected to the connecting

pipes to the two compartments. The cable of the double valve connector is connected

to the Touch Controller according to the specications in the chapter 7 “Wiring plans”

(version LC-2 or LCS-2 required!).

The additional module 2-house with pressure relief (art. 7115) is mounted near the

pump unit on a wall or alternatively in the pump unit on the rear wall of the angle

plate. The mounting position of the valve block should be with the solenoids pointing

upwards. The right connection (P) is connected to the hydraulic hose of the pump unit.

The hose at the nozzle (R) is led into the drain. The two hydraulic hoses behind the valve

block (A1 and A2) are connected to the connecting pipes to the two compartments.

The cables of the double valve connectors are connected to the Touch Controller

according to the specications in the chapter 7 “Wiring plans” (version LC-2 or LCS-2

required!). The two valves at the inlet of the valve block control the two outputs. The

two valves at the block outlet each serve as pressure relief.

IMPORTANT INFORMATION

The hoses must be installed in such a way that they cannot rub against other components/sharp edges.

The hoses must not be bent too much. Non-observance will reduce the lifetime of the hose.

NOTE

All protective conductors of the modules must be connected to the protective conductor terminal in the

touch controller. The multicore cables must be connected according to the wire colors in the chapter 7

“Anschlusspläne/Wiring plans”. For the double valve connectors of the 2-house modules, the position of

the respective connectors must be taken into account (compare the function of the valves in the wiring

plans).

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4.4 Installation LUBING Touch Controller

The LUBING Touch Controller should be installed in a dry, clean and easily accessible location near the pump

unit. For mounting, the cover must be opened and the housing is fastened with suitable screws through the holes

intended for xation.

The LUBING Touch Controller has a wide voltage input (85-264 V, 50/60 Hz). The voltage supply is usually made

via a multi-core connection cable of the pump unit and must usually be 220-240 V to supply the valves. Other

cables (e.g. from additional modules, pressure switches, climate computers, etc.) are also inserted into the Touch

Controller. Depending on the pump unit and the additional modules, the appropriate Touch Controller must be

selected (for pump units with frequency inverter, the “LCM vario” version is required).

The cables are connected according to the wiring plans (see chapter 7 “Wiring plans”).

The multi-core cables of the pump unit are labelled with numbers. In the circuit

diagrams, the numbering is marked as shown in the adjacent detail. Coloured cables

are marked accordingly (abbreviations according to IEC 60757). GNYE (green/yellow)

identies the protective conductor. The protective conductors of all components must

be connected to each other!

IMPORTANT INFORMATION

The LUBING Touch Controller is essential for controlling the Top climate system. The manufacturer

accepts no liability for the installation of a system without the Touch Controller.

NOTE

Suitable cable glands must be used to ensure good sealing and strain relief of the cables.

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.

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

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

– 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.

IMPORTANT INFORMATION

Make sure that the mainboard and the IO-Card are not confused when connecting the cables. Mainboard

and IO-Card are marked in the circuit diagrams. Attention: Sometimes there is the same name of the

terminals on both boards.

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IO-Card

Mainboard

4.4.1 Connection of external climate computers and sensors

The correct pin assignment for external climate computers and sensors can be found in the wiring plans (see

chapter 7 “Wiring plans”).

External climate computer

The potential-free switching contact of an external climate computer is connected to the prescribed input terminals

of the controllers (e.g. DI1 and 24V for LC-1; see chapter 7 “Wiring plans”). These cables must be laid separately

and should be shielded. Only potential-free cables are allowed for connection. If the potential-free contact is closed

(24V are applied to the input), the system cools/humidies.

Sensors

Sensors are also connected to the input terminals. These cables must also be installed separately. The cables must

have a low resistance (1.5 mm2).

4.4.2 CAN connection

In the LCM vario version (art. 7745), the controller can be connected to extension boxes (art. 7750) if required.

Eight additional outputs are available for each box. The connection is made via CAN bus. The corresponding

mainboard and IO-Card terminals must be connected as shown in the wiring plans (see chapter 7 “Wiring plans”).

– The CAN connection must be looped through. Do not use stub lines!

– Jumper J12 must be plugged into the last extension box (terminating resistor).

– Only twisted pair cables may be used for the connection.

– For longer cables, we recommend using shielded cable.

– The addresses of the IO-Cards must be set with the DIP switches as shown in the wiring plans.

4.5 Installation of connecting pipes and nozzle lines

The pipes must rst be positioned with brackets or suspension material. Only then both the connecting pipes and

the nozzle pipes are connected with cutting ring ttings or alternatively with PressFix ttings.

CAUTION

To avoid malfunctions, lay all cables in the controller close to the base plate.

Never connect or disconnect components when the controller is switched on.

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IMPORTANT INFORMATION

Make sure that no impurities or dirt get into the pipe system. This will ensure that the nozzles will work

properly later on.

4.5.1 Positioning and orientation of nozzle lines

The following details are recommendations which have often proven themselves in practice. Depending on the

ambient conditions (air ow, barn equipment, etc.), the optimum installation of the nozzle lines may differ from the

recommendations.

The following illustration shows in principle a possible arrangement of the components in a system. In addition

there are components in the supply line to the pump unit (lter unit etc.). The ball valves at the ends of the lines can

be opened for ushing and venting.

Depending on the size of the barn and the ventilation system, the layout of the nozzle lines is determined. Generally

applies:

– the nozzles should not spray against the air ow.

– the minimum distance to the ceiling of at least 0.5m should be maintained.

– there should be a free space of at least 3m in the spraying direction of the nozzle. In case of obstacles in this

free space, these adapters can be closed with plugs (Art. 7326).

– the line lengths should be kept as short as possible to minimize pressure losses (espe cially with high ow

rates!).

The following sketches show examples of possible layouts:

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– Rotate the nozzle lines so that the nozzle orientation is 5-10° upwards.

– In case of alternating nozzle lines also ensure that the nozzles are pointing

a little bit upwards.

4.5.2 Cutting ring ﬁttings

The following cutting ring ttings can be used to connect the connection pipes and nozzle pipes with an outside

diameter of ø12mm:

Nozzle line in line

Nozzle line alternating

Art. no. 7401 Art. no. 7402 Art. no. 7403

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Lubing LC-2 Operation and maintenance manual

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