RC GROUP TRIPACK Series User manual

MULTIFUNCTION CHILLERS
series
TRIPACK
GB Installation, use and maintenance manual
I_TRP_0909_GB
Manual code:
Issue / Revision:
Serial number
:

INDEX
RC GROUP S.p.A. I_TRP_0909_GB
2
1GENERAL INFORMATION AND SAFETY............................4
1.1 OBJECTIVEOF THISMANUAL.............................................4
1.2 GLOSSARY AND TERMS......................................................5
1.3 MANUFACTURER AND MACHINE IDENTIFICATION ..........6
1.4 INTERPRETATION OF THE MODEL’S CODE ......................7
1.5 REQUEST FOR ASSISTANCE..............................................7
1.6 ENCLOSED DOCUMENTATION...........................................8
1.7 SAFETYREGULATIONS.......................................................8
2TECHNICAL INFORMATION..............................................11
2.1 GENERAL DESCRIPTION OF THE MACHINE....................11
2.2 DESCRIPTION OFTHE MAIN COMPONENTS AND
WORKING PRINCIPLE.......................................................12
2.3 OPTIONAL DESCRIPTION..................................................16
2.4 SAFETYDEVICES...............................................................16
2.5 TECHNICAL DATA ..............................................................16
3HANDLING AND TRANSPORTATION INFORMATION.....17
3.1 TRANSPORTATION............................................................17
3.2 PACKING AND UNPACKING...............................................17
3.3 HANDLING AND LIFTING....................................................18
4INSTALLATION AND TESTING INFORMATION ............... 19
4.1 SAFETYFOR INSTALLATION ANDTESTING....................19
4.2 INSTALLATION AREA.........................................................19
4.3 DIMENSIONS OFTHEPERIMETRICAL AREA...................19
4.4 PRESETTINGTHE CONNECTIONS...................................19
4.5 INSTALLINGTHE MACHINE...............................................20
4.6 HYDRAULIC CONNECTIONTO THE PLANT HEAT
EXCHANGER......................................................................21
4.7 HYDRAULIC CONNECTIONTO THE EXHAUST HEAT
EXCHANGER......................................................................23
4.8 HYDRAULIC CONNECTIONTO THE DOMESTICWATER
EXCHANGER......................................................................25
4.9 CLEANING AND FILLING THE HYDRAULIC CIRCUITS.....27
4.10 ELECTRICAL CONNECTION..............................................27
4.11 PRE-COMMISSIONING PROCEDURES.............................28
4.12 COMMISSIONING PROCEDURES.....................................29
5CALIBRATION AND TUNE-UP INFORMATION.................30
5.1 CALIBRATION ANDTUNE-UP PROCEDURES..................30

INDEX
RC GROUP S.p.A I_TRP_0909_GB
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6INFORMATION FOR USE...................................................31
6.1 RECOMMENDATION FOR USE..........................................31
6.2 CONTROLS DESCRIPTION................................................31
6.3 DESCRIPTION OFTHE MICROPROCESSOR DISPLAYAND
KEYBOARD ........................................................................33
6.4 DESCRIPTION OFTHE MICROPROCESSOR’S
FUNCTIONS .......................................................................35
6.5 SETTINGTHE CHILLEDWATERTEMPERATURE (SET-
POINT)................................................................................35
6.6 DESCRIPTION OFTHE ALARM SIGNALS..........................36
6.7 DISPLAYING ALARMS LIST................................................36
6.8 DISPLAYINGTHE HOUR-METER AND MAINTENANCE
ALARM................................................................................37
6.9 DATE AND TIMESETTING..................................................37
6.10 BACKTO MAIN MENU.........................................................38
6.11 NORMAL START-UP...........................................................39
6.12 NORMAL STOP...................................................................40
6.13 PROLONGED SHUTDOWNS OF THE MACHINE...............41
6.14 START-UP AFTER PROLONGED SHUTDOWN.................41
7MAINTENANCE INFORMATION ........................................42
7.1 MAINTENANCE INFORMATION.........................................42
7.2 SCHEDULED MAINTENANCE............................................42
7.3 TABLE OFGENERAL MAINTENANCE JOBS.....................43
7.4 TABLE OF MAINTENANCE JOBS ON SCROLL
COMPRESSOR ..................................................................44
7.5 CHECKING OF THEPRESSURE VESSELS.......................44
7.6 CHECKING OF THEWATER FLOW AND CLEANING OF
THE EXCHANGERS...........................................................44
7.7 EXTRAORDINARY MAINTENANCE ...................................44
8TROUBLESHOOTING.........................................................45
9REPLACEMENT INFORMATION........................................ 47
9.1 PATS REPLACEMENT........................................................47
9.2 MACHINE DISMISSION.......................................................47

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1 GENERAL INFORMATION AND SAFETY
1.1 OBJECTIVE OF THIS MANUAL
This manual, which is an integral part of the machine(1), has been
prepared by the manufacturer in order to provide the information
necessary to all persons authorized to interact with the machine during
its useful life: the Purchasers, Plant Designers, Carriers, Handlers,
Installers, expert Operators, specialized Engineers and Users.
Apart from adopting a good usage technique, the persons who receive
this information must read it carefully and must implement it strictly.
The time devoted to the reading of this information will allow you to
avoid any health and safety hazard, as well as any financial damage.
This information has been written by the manufacturer in its original
language (Italian) and may be translated into other languages in order
to meet any legislative and/or business requirements.
Even though this information does not fit the machine perfectly, this
does not prejudice its function.
Keep this manual in a well-known, easily accessible place, so that it will
be always available for future reference, when necessary.
The manufacturer reserves the right to modify the product without prior
notice.
In order to highlight the most important sections of this text, several
symbols have been adopted whose meaning is described below.
DANGER – FOR YOUR SAFETY
Indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING - CAUTION
Indicates that any unsafe practices must be avoided which could
prejudice health and safety and cause financial damage.
IMPORTANT
Indicates any important technical information that must not be
neglected.
(1) this term is used for the sake of simplicity, as defined in Directive
2006/42/CE

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1.2 GLOSSARY AND TERMS
Several terms that recur throughout this manual are described below,
so as to provide a more complete explanation of their meaning.
Purchaser: he is responsible for any purchase and must supervise the
organization and assignment of tasks, ensuring compliance with any
and all applicable laws.
Enthalpy: a function that can be defined as the sum of the internal
energy plus the product of the pressure multiplied by the fluid’s volume.
Installer: a competent skilled person duly authorized and responsible
for the setting-up of the machine/plant, according to project
specifications and the manufacturer’s directions and in conformity with
the applicable industrial safety laws.
Ordinary maintenance: all the jobs necessary for maintaining the
machine in perfect working order. These jobs are scheduled by the
manufacturer, who sets out the necessary core competences and
procedures.
Extraordinary maintenance: all the jobs necessary for maintaining the
machine in perfect working order. These jobs cannot be predicted, are
not scheduled by the manufacturer and must be carried out by a
specialized Engineer only.
Handlers: they arrange the machine properly and affix all the
necessary markings for safe and correct handling. On receipt of the
machine, they ensure handling to the installation point, according to the
instructions affixed on it. All these operators must have adequate skills
and must comply with the instructions provided for their safety and for
the safety of the people who could interact with these jobs.
Expert operator: a person appointed and authorized by the User or the
Purchaser to proceed with the use of the machine and the relevant
ordinary maintenance jobs, according to the manufacturer’s
instructions. In case of failures not covered by this manual, he must
request the intervention of a skilled Engineer.
Designer: a competent skilled person appointed and authorized to
prepare a project that must take into account all the legislative,
regulatory, and workmanlike performance principles applicable to the
plant as a whole. In any case, apart from conforming to the
manufacturer’s instructions, he must take into account all safety-
related matters for the people who must interact with the machine
during its expected useful life.
Skilled engineer: a person appointed and/or authorized by the
manufacturer and/or its agent to carry out any jobs on the machine
requiring a specific technical expertise and particular skills.

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Carriers: those who deliver the machine using suitable means of
transportation. They must load and position the machine properly, so as
to prevent any sudden displacement during the transportation.
When any loading/unloading means are used, these must conform to
the markings affixed on the machine to ensure their safety and for the
safety of all the people who could interact with these operations.
User: a person authorized to control the use of the machine according
to the "instructions for use" and the industrial safety laws in force.
1.3 MANUFACTURER AND MACHINE IDENTIFICATION
This identification plate is attached directly to the machine and contains
all the references and information essential for safe operation.
27010 Valle Salimbene (PV) Via Roma 5 – Italy
Tel. [phone] – Fax [phone]
Divisione di Produzione Production Division
Unità serie
Unit series
Tensione di alimentazione
Power supply
Max corrente assorbita totale
Max total absorbed current A
Refrigerante Tipo
Refrigerant kg Type
Peso netto
Net weight kg
Data
Date
Serial number
Part. Number

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1.4 INTERPRETATION OF THE MODEL’S CODE
The model’s alphanumeric code, specified in the identification plate,
represents particular technical specifications indicated in the figure.
1.5 REQUEST FOR ASSISTANCE
For any requirement, please contact an authorized centre.
For any request for technical assistance regarding the machine, please
indicate the data specified on the identification plate, in particular its
serial number, the access conditions and the perimetrical area of
installation.
Indicate also the approximate hours of use and the type of defect
identified.
In case of alarm, indicate the relevant number and the signalled
message (see § 8.0).
MODEL CODE / AN EXAMPLE
50 P 2 J7
Nominal cooling capacity (kW)
Compressor type “P” Fully-hermetic Scroll
Compressors quantity
Size

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1.6 ENCLOSED DOCUMENTATION
The following documentation is delivered to the customer together with
the machine:
- Maintenance handbook: includes the list of scheduled
maintenance operations. It is preset to record all the jobs effected,
including the extraordinary maintenance jobs.
- Assembly instructions for vibration dampening supports
(optional): describes the procedures for installing them on the
machine.
- Electrical system’s diagram: specific for this machine. It is used by
the operators working on the electrical system, in order to identify
the various components and connections.
- Recommended spare parts list: indicates the spare parts that
should be always available.
- Dimensional lay-out: indicates the dimensions of the machine.
- CE Conformity Declaration: the machines are in compliance with
2006/42/CE, 2004/108/CE, CE 97/23, 2006/95/CE norms and
subsequent modifications
1.7 SAFETY REGULATIONS
During the design and production stages, the manufacturer has paid
close attention to all possible sources of safety and health hazard to the
people who interact with the machine. Apart from complying with the
applicable laws, the manufacturer has adopted all the applicable
“workmanlike performance rules”. The aim of this information is to make
users aware of the attention necessary for preventing any hazard.
Caution is however mandatory.
Safety is also in the hands of all operators interacting with the machine.
Read the instructions included in the manual and those affixed directly
to the machine carefully; in particular, conform to safety instructions.
The time devoted to reading will prevent any nasty accident; it’s always
too late to remind of what should have been done when an event has
already occurred.
The installation of this machine within a plant requires a global project
that takes into account all “workmanlike performance” requirements, as
well as legislative and regulatory principles. Special care must be
devoted to all the technological instructions and information indicated by
the manufacturer.
Do not tamper with, remove, or bypass the safety devices installed on
the machine. Failure to meet this requirement will result in serious
safety and health hazard to people.
The personnel that carries out any type of job during the life of the
machine must be adequately qualified and skilled from a technical
standpoint and must have gained experience in this specific sector.
The lack of these requirements could prejudice the health and safety of
people.

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During the maintenance stage, wear only the clothing and/or personal
protective equipment indicated in the instructions for use provided by
the manufacturer.
During the normal use or for any job on the machine, keep the
perimetrical space in adequate conditions, so as to prevent any safety
and health hazard to people.
Some stages may require the help of one or more assistants. In these
cases, we recommend that you train and inform them properly on the
type of activity to be carried out, so as to prevent any safety and health
hazard to people.
Handle the machine according to the information provided directly on
the packaging and in the instructions for use delivered by the
manufacturer.
During handling, if necessary, seek the help of one or more assistants
in order to receive adequate signals.
The personnel that loads, unloads and handles the machine must be
adequately qualified, skilled, and experienced in this specific sector and
must be in command of the lifting equipment to be used.
During the installation stage, respect the perimetrical space indicated by
the manufacturer, considering also any other surrounding activity. This
requirement must be met also according to the applicable industrial
safety laws.
The installation and connections must be carried out, as regards the
machine, according to the manufacturer’s instructions. The person
responsible for these operations must take into account also all the
applicable regulatory and legislative requirements, ensuring the
workmanlike execution of the installation and connection jobs. Once the
installation is completed and before starting the machine, he must make
sure, through a general check, that these requirements have been met.
If the machine is to be transferred using any means of transportation,
check that these are fit for their intended use and load/ unload the
machine in such a way that there is no hazard to the operator and the
people directly involved.
Before moving the machine using the said means of transportation,
make sure that the machine and its components are anchored to such
means firmly and that their profile does not exceed the maximum fixed
volume.
The operator, apart from being well-informed about the use of the
machine, must be properly qualified and experienced, based on the
type of job to be effected.

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Use the machine only for the purposes recommended by the
manufacturer. Using the machine for any improper job may result in
serious safety and health hazard and financial damage.
The machine has been designed and manufactured in such a way that
it can satisfy all the working conditions indicated by the manufacturer.
Tampering with any device in order to obtain any different performance
may result in safety and health hazard and financial damage.
Do not use the machine if the safety devices have not been perfectly
installed and are not effective. Failure to meet this requirement may
result in serious safety and health hazard.
Keep the machine in perfect working order, carrying out the scheduled
maintenance jobs recommended by the manufacturer.
Proper maintenance will ensure better performance, longer life, and the
constant maintenance of safety requirements.
Before carrying out any regulation and maintenance job on the
machine, activate all the safety devices provided and consider whether
the personnel involved and the operators nearby must be informed
properly or not. In particular, carefully indicate the neighbouring areas
and prevent the access to all devices that, if activated, are likely to
cause unpredictable dangers, causing damage to people’s safety and
health.
The regulation and maintenance jobs must be effected by authorized
operators, who must arrange all the necessary safety conditions,
according to the procedures indicated by the manufacturer.
All maintenance jobs that require any specific technical skill or expertise
must be carries out only by qualified personnel, adequately experienced
in the relevant sector of intervention.
To carry out any maintenance jobs in areas that are difficult of access
or dangerous, ensure proper safety conditions for yourself and for other
people, according to the applicable industrial safety laws.
Replace any worn components with original spare parts only. Use the
oils and greases recommended by the manufacturer, so as to ensure
the machine performance and the expected safety level.

Chapter 2 - TECHNICAL INFORMATION
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2 TECHNICAL INFORMATION
2.1 GENERAL DESCRIPTION OF THE MACHINE
The machines of this series are designed and manufactured for being
used in air-conditioning and industrial cooling plants.
The machine must be installed inside the room or however protected by
weathering.
The machines are equipped with a microprocessor control, that allows
the monitoring of all functions and the communication with external
supervision systems.
The machines are fully factory-assembled, provided with a refrigerant
charge and control equipment, so as to reduce installation time and
costs. As a general rule, the installation simply requires hydraulic and
electrical connections.
In order to ensure top performance and safety for people, the product
and the environment, before proceeding with the installation, prepare a
complete project of the plant which the machine will belong to,
analysing all the critical points predicted or predictable during its life,
from installation to dismission.

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2.2 DESCRIPTION OF THE MAIN COMPONENTS AND WORKING
PRINCIPLE
TRIPACK
Reversible heat pump for 2 pipes plant + domestic water.
WORKING LOGIC
According to the request, the unit can produce chilled water, hot water
for heating and domestic water.
In working condition no. 4 (simultaneous request of hot water for
heating and domestic water) the system gives priority to the domestic
water production. Only when the domestic water request is satisfied, the
system will start producing hot water for heating.
The machines are basically made up of a heat exchange section and
two compressors for refrigerant, with the relevant air condensing
sections.
The primary water circuit conveys the vector fluid to the heat exchange
section, where the chilling effect is obtained through a vapour-
compression thermodynamic cycle with compressors.
CHILLED WATER PRODUCTION
The heat, subtracted in the plant heat exchanger from the vector fluid to
be chilled, is transferred to the exhaust heat exchanger and given by
this to the water. An expansion valve controls the refrigerant flow.
HOT WATER PRODUCTION
During the winter the cycle is inverted. The exhaust heat exchanger
detracts heat from the water, thus working as an evaporator, while the
water is warmed by the heat lost in the plant heat exchanger, now
working as a condenser.
DOMESTIC WATER PRODUCTION - 100%
The heat, subtracted in the exhaust heat exchanger from the vector
fluid to be chilled, is transferred to the domestic heat exchanger and
given by this to the water. An expansion valve controls the refrigerant
flow.

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TRIPACK SCHEME
A
Compressor
B Exhaust heat exchanger
C Expansion valve
D Plant heat exchanger
E Domestic water heat exchanger

Chapter 2 - TECHNICAL INFORMATION
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The graph shows the variations in the refrigerant’ pressure and
enthalpy during the entire thermodynamic cycle.
-from point (8) to point (4) the refrigerant is in the vapour phase
-from point (4) to point (5) the refrigerant is reduced from its vapour
phase to its liquid phase
-from point (5) to point (7) the refrigerant is in the liquid phase
-from point (7) to point (8) the refrigerant is reduced from its liquid
phase to its vapour phase
5/6 cooling
4/5 condensation
6-61
pressure
drops
61-7
expansion
8-9 overheating
7-8 evaporation
3-4 de-superheating
2-3 discharge
line pressure
drops
1-2
compression
9-1 suction line
pressure drops
PRESSURE
ENTHALPY

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These pictures show the main components.
compressors
electric board
domestic water heat exchanger
exhaust heat exchanger
plant heat exchanger
domestic water heat exchanger
exhaust heat exchanger
plant heat exchanger

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2.3 OPTIONAL DESCRIPTION
Because any specific requirements can be identified from the design
stage, the manufacturer is ready to make the following optional
available:
-Spring vibration-damping supports: to eliminate vibrations.
-2-way electronic valve: for condensing control.
2.4 SAFETY DEVICES
During the design and production stage, the manufacturer has installed
safety devices (active or passive) conforming to the laws and
regulations in force in the country where the machine will be used.
The various types of devices that can be installed are described below.
-Door locking switch: opens and closes the
power circuit.
-Safety valves: installed on the machine as indicated in the
diagram.
2.5 TECHNICAL DATA
The machine’s technical data are described in the enclosed
documentation (“Data Sheet” and “Dimensional Lay-out”).
Plant heat
exchanger
safety valve
Exhaust heat
exchanger
expansion
valve
compressor liquid receiver
safety valve
safety valve

Chapter 3 - HANDLING AND TRANSPORTATION INFORMATION
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3 HANDLING AND TRANSPORTATION INFORMATION
3.1 TRANSPORTATION
The means of transportation used for the machine, apart from normal
requirements, must be compatible with the loading systems adopted in
the production factory and at the unloading site.
When using road transport means, the body must be open and of the
drop-side type.
IMPORTANT
For any further information, please contact the manufacturer’s
Shipping Department.
3.2 PACKING AND UNPACKING
The machine can be transported with different types of packing,
according to its predetermined destination, transport procedures and
technical/commercial specifications.
WARNING - CAUTION
If the machine must be shipped without a commercial container, it
is necessary to provide special packaging to ensure that it remains
intact.
Unpack the machine on receipt to check whether it is intact and
conforming to the order.
IMPORTANT
In case of any damage or if some parts are missing, contact the
manufacturer’s Sales Department to agree the procedures to be
adopted.
If the machine is not installed on receipt and is stored for a long time,
store it in a protected place, at temperatures ranging between -25°C
and 50°C.
WARNING - CAUTION
If the place where the machine is stored is too hot, the refrigerant’
pressure is likely to rise too much, causing the activation of the
safety valves.

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3.3 HANDLING AND LIFTING
DANGER – FOR YOUR SAFETY
Lifting and handling operations must be carried out with suitable
means by qualified trained personnel, authorized to perform this
type of manoeuvres.
The machines, based on their size, can be lifted in several ways.
Lift and handle the machine according to the instructions provided on
the package and/or directly on the machine.
The pictures show the most common lifting and handling procedures.

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4 INSTALLATION AND TESTING INFORMATION
4.1 SAFETY FOR INSTALLATION AND TESTING
All the installation stages must be an integral part of the general project.
Before starting these stages, the person authorized to carry out these
operations, apart from identifying the technical requirements, must
implement a “safety plan”, if necessary, to protect the personal safety of
the directly involved people and must strictly implement the safety
regulations, in particular any laws on mobile yards.
4.2 INSTALLATION AREA
During the design stage, the area were the machine is to be installed
must be identified, taking into account a series of requirements, in
particular:
-the area must be perfectly flat and must ensure stability over time
-if installed on the floor of a building, this must be of adequate
capacity
-its position must not disturb the peace
-it must be easily accessible to all people who must interact with it
during its expected useful life
-all maintenance and replacement jobs (either ordinary or
extraordinary) must be carried out easily and without any hazard to
people, according to the applicable industrial safety laws.
-the volumetric spaces must be adequate to ensure the air inflow
necessary for the machine’s proper operation and ventilation.
-if the passage of people and vehicles near the machine is expected,
install a suitable fence conforming to any applicable standard,
leaving the minimum space allowed for all jobs on the machine.
4.3 DIMENSIONS OF THE PERIMETRICAL AREA
This area must be designed according to the model, the number of units
and the characteristics of the installation site.
4.4 PRESETTING THE CONNECTIONS
Before installing the machine, make sure that the electrical connection
conforms to the design specifications and the data reported in the
identification plate.
WARNING - CAUTION
The power line must be provided with a main switch, so that the
machine can be insulated from the power source.

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Regarding design connections, these must conform to the project
specifications, so as to ensure:
-a constant flow to the evaporator;
-that the variations in the inlet temperature of the condenser and
heat reclaim exchanger are compatible with the activation time of
the machine’s regulation and safety systems;
-that the amount of water in the plant can allow minimum working
times for compressor.
WARNING - CAUTION
The water pressure inside the evaporator and the reclaim
exchanger (optional) cannot exceed 10 bar, including the
hydrostatic head.
Therefore, the maximum inlet pressure may not exceed Pmax=10
bar - Pbi
Pmax=maximum allowable inlet pressure (bar)
Pbi=hydrostatic head pressure (bar)
4.5 INSTALLING THE MACHINE
IMPORTANT
Before positioning the machine, while it is still lifted, fit the
vibration dampening supports, if any, in the relevant seats.
To do so, follow the scheme included in the ”Assembly
instructions for vibration dampening supports”.
If the assembly of vibration dampening supports is not contemplated,
we recommend that you install a rubber or cork sheet between the base
and the supporting surface, covering the entire supporting surface.
Once the machine has been positioned, check levelling in the four
positions indicated in the figure.