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Rev. 1
RP 500/900 Pag. 1 / 24
RP 500/900
2. Introduction
This manual describes the necessary information for a correct use of the refrigerant transfer pump RP 500 or
900. A careful reading is recommended before use.
3. Scope
The refrigerant transfer pumps RP are volumetric pumps, with two balanced and contrasted pistons, to
transfer refrigerant fluids in liquid phase. They are designed to suck the refrigerant fluid from storage
cylinders or reservoirs, near which the pump is normally installed, and transfer the pressurized fluid to the
distribution pipes or directly to refrigerant charging machines for refrigerators, conditioners and so on.
The exclusive design of the RP assures equal delivery pressure and flow of the refrigerant fluid into the two
pumping cylinders, with an only regulating device; all this in an extremely compact execution.
The special shape of the piston heads together with the refrigerant output valves, assure a high efficiency of
volumetric flow.
The pumping pistons are self-cooling and assure a very good performance, even after a long time.
The pumping system requires only compressed air not lubricated.
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4. Technical data
RP 900 RP 500
Kg/min 9 5
MAX DELIVERABLE
g/s 150 80
FLOW 3
m /h 0,45 0,25
3
CUBIC CAPACITY cm 982 589
DIMENSIONS
( length x width x mm 1035 x 235 x 330 735 x 235 x 330
height)
WEIGHT Kg 55 45
NUMBER OF PUMPING
CYLINDERS 2 balanced and contrasted
VOLUMETRIC RATIO
FLUID/COMPRESSED AIR 5,25
ASPIRATION LINK
G female (optional pipe L= 2 mt with quick connector Hansen for
COUPLING
refrigerant cylinder)
FILTER CONNECTION G female
COMPRESSED AIR
FEEDING Compressed filtered air not lubricated; pipe 8x10 mm or 3/8G
COMPRESSED AIR
Kpa/bar
PRESSURE 500-700 ( min. 200 ) / 5-7 ( min. 2 )
COMPRESSED AIR
Nlitri/
CONSUMPTION Flow x fluid lift x 1,25
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The free section of valve outflow or of the pipe union must have a nominal diameter at last DN12.
If it has a lower section, you will may use more cylinders, connected in parallel to a collector.
The cylinder or the tank must be in a raised position as regards the refrigerant transfer pump RP ( at
least 1 meter).
The pipeline between reservoir and RP must be as short as possible (max 4 m total) without narrowing,
possibly all in descent, avoiding or reducing to the minimum the siphons formation.
We recommend to you an inside diameter for the pipeline DN20, however not lower than DN12.
In the pipeline between the tank and the RP you must insert the furnished filter with micro-filtering
cartridge (Optional).
If the cylinder or the tank are equipped with anti-storaging devices, it is necessary to insert a
safety valve on the aspiration line at 22-28 bar; 38-40 bar in case of R410 .
The RP is scheduled for the inside use. If you install it outside, make it waterproof and protect it from the
sun rays, by roofs or box with aeration.
Set UP
Before starting the pump, you have to verify the following:
a. The refrigerant fluid must be the same as the one written on the CE nameplate.
b. The RP must be put on a solid horizontal support.
c. If the RP is equipped with oil rooms, check the oil level and, if it is necessary, provide for add
the oil.
d. Get ready both the aspiration and delivery line connecting them properly.
Start UP
After checking all the points above, proceed with the operating of the refrigerant transfer pump as
follows:
1. open the manual cut off valve on the feeding line of the refrigerant fluid.
2. open the manual cut off valve on the feeding line of the compressed air.
3. regulate the pressure of the compressed air for driving of the pneumatic section in order to
have the desired pressure on the delivery line of the refrigerant fluid.
Quickly the RP will stop after it has reached the set up pressure.
When the outlet circuit doesnt need refrigerant fluid, the RP isnt working, i.e. it doesnt unload
compressed air but it maintains pressurized the outlet circuit at the set up pressure; instead when outlet
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circuit needs refrigerant fluid, the pump transfers the refrigerant fluid in alternate way from the two
cylinders and the pneumatic system changes the feeding.
In this phase there is the compressed air discharge and you can see a temporary falling of the pressure
on the delivery line, if you have not used the stabilizer tank (optional).
In case of regular working, it needs at least 3 seconds between two discharge phases; in case of higher
frequencies, read the chapter 9 Trouble shooting.
Pay particular attention during the substitution of the feeding tank of the
refrigerant fluid in order to avoid that the air comes into the pipeline of the
refrigerant fluid.
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RP 500/900
The plunger shaft, that acts in phase opposition on the two cylinders, moves together with a double
action pneumatic cylinder of notable potentiality (1400 nl/min), able to assure the flow and pressure
stability to the delivered refrigerant fluid.
At the two cylinder extremities there are two pneumatic interrupters, directly driven by the pneumatic
piston, provide for the inversion of its motion through the control of the valve 5 /2 .
On each heading of the pumping cylinders there are two unidirectional valves able to open and to remain
open in case of least differences of pressure.
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One of the two unidirectional valves lets the communication between the cylinder and the aspiration line
of the refrigerant fluid and it opens only when the cylinder is in depression as regards the aspiration line;
the second lets the communication between the cylinder and the delivery line of the refrigerant fluid and
it opens only in presence of an overpressure inside the cylinder.
A safety valve connects the discharge line, downstream from the relative unidirectional valves, with the
aspiration line, upstream from the relative unidirectional valves.
This safety valve allows the automatic unloading, if it is necessary, of possible overpressures higher than
22 bar ( 35 bar in case of R410A) (as regards the pressure on the aspiration line) that could be
produced on the delivery line, safeguarding the RP and the integrity of the other following devices
against the risk of explosion or damage.
The opening pressure has been predetermined in the assembling phase by Esa Service S.r.l.; as a
consequence, it is not scheduled any calibration to avoid tampering and wrong regulations.
This opening pressure value is predetermined depending on the refrigerant fluid used because it is
influenced by the thermodynamic behaviour of that fluid.
It is fundamental that the pump is used only with the fluid previously settled.
Nevertheless, if you want to change fluid, verify the compatibility between the new fluid and the one
written on the nameplate. In case of incompatibility avoid to blend the two fluids and proceed as follows:
Empty the two cylinders of the RP and the micro-filtration filter (if any).
Replace the lubricating oil and the gaskets of the RP that worked in contact with the old
refrigerant fluid.
Verify with Esa Service S.r.l. the real possibility to use the new fluid and, if necessary, the
replacement of the overpressure safety valve according to the new fluid which you want to use.
We recommend you that the RP dismantling and reassembling must be made by
experienced and trained personnel equipped with the necessary working tools and with
individual accident prevention means as: gloves, glasses, safety clothing and footwears.
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9. Trouble shooting
We are now describing the most common faults, the possible causes and how you can solve them.
1. The RP isnt working, it generates overpressure on the delivery line but it doesnt discharge
compressed air.
Verify that the valves on the delivery line and/or on the charging machine are open.
Mechanical blockage
2. The RP isnt working, it doesnt generate overpressure on the delivery line but it doesnt discharge
compressed air.
Verify that the pressure of the compressed air on the manometer is regulated well.
Verify that there is sufficient compressed air pressure, reading the manometer.
Verify that there are no sudden bends on air pipes.
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11. Calibrations
The overpressure valve is the only part subject to calibration. It is regulated during the assembling phase
by Esa Service personnel in order to avoid tampering or wrong regulations.
The opening pressure generally is regulated around 23 bar or 35 bar for R 410A.
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Dimensional Check ..
CONCLUSION
The RP refrigerant transfer pump is working and in conformity with what indicated/requested by
Customer
SUPERVISORs Signature..
CUSTOMERs signature
..
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RP 500/900
1. ESA products conform with the European machinery standards (Machinery directive 2006/42/EC) and
comply with safety regulations when they leave the factory. An EC conformity declaration is supplied with
each delivery.
2. Before operating the machinery read this document carefully and, obviously, the enclosed setup, start-up,
operating and maintenance instructions.
3. The mains supply and the compressed air must be disconnected when starting to assemble or when
working on a component. Observe the warnings in the enclosed setup, start-up, operating and
maintenance instructions. Do not touch any live parts.
4. All transport vehicles and used packages must be capable of handling the weight of the component.
Position indicators, solenoid valves, connectors or cables must not be used for hoisting the units.
5. Check that the component has not been damaged during transport. If this has happened, contact us on
0363-301550. Check also that the delivered goods correspond with your order.
6. Installation must only be carried out by specialised personnel.
7. The packing materials must be removed just before the component is installed.
8. Before starting mechanical installation, check that the mains supply and the compressed air have been
disconnected.
Wear clean, dust-free gloves when touching the components.
If an earth wiring has been specified in the instructions, this must be provided following the instructions
carefully.
9. Avoid using the components incorrectly. Handle the component only according to the operating conditions
found in the setup, start-up, operating and maintenance instructions. ESA SERVICE will not be liable for
any damage caused through improper use of the component.
10. Follow the preventive maintenance and service procedures specified in the setup, start-up, operating and
maintenance instructions. Use only original ESA SERVICE spare parts to ensure that the component
continues to work safely and reliably.
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WARNING !
With this symbol we indicate actions relating to control, installation and maintenance, and
also norms and regulations that the Customer must pay attention to and observe with
great care and diligence to the details so as to protects and keep the plant in good
operation for a long time. With such care the plant shall always be reliable and there shall
be no risk for the operators, the structures and components as well as for the site and
ambient
GENERAL CONSIDERATIONS
The RP refrigeration transfer pump has been designed and manufactured with the idea of reducing to the
minimum unavoidable number all dangerous points that could have risks for the operator as well as for other
exposed people. Those dangerous zones have been clearly identified, separated and protected by safety
systems that could eliminate further risks of accident during all phases of installation, operation and maintenance.
During the normal working the fluids, that is air or refrigerant one, are in pressure. Therefore all the
dismantling and reassembling operations must be made by experienced and trained personnel.
Do not begin a transfer pump dismantling before the removal of the refrigerant fluid and compressed
air inside the RP.
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Stability
Transport, handling and setting up of the RP must be performed according to the instructions given in this
manual.
The RP transfer pump has been designed and manufactured in order that in normal work conditions there
are no risks of eventual upsetting, falls of pieces or sudden shifting.
contain the fluid, there could be situations in which there is a notable and uncontrolled increase of the
refrigerant fluid pressure, because of its incompressibility in these conditions.
The RP have therefore a safety valve, that allows to unload the overpressure of the discharge line upstream
from the unidirectional aspiration valves. Such device allows to avoid the damage of inside organs and the
RP integrity.
For the effectiveness of such protection device it is necessary that no unidirectional valve prevents the
refrigerant reflux upstream from RP aspiration coupling, toward the feeling cylinder ( which is working as an
expansion vase).
Because of its working principle, the RP is not able to assure any protection font in presence of an
anomalous high pressure on the feeding line; this protection will be only insured by the installation of a
special safety valve that unloads the exceeding pressure.
This is not necessary when the feeding is obtained by commerce cylinders of limited ability (max. 60 kg),
placed in covered areas, duly protected from the risk of fire.
The safety valve is instead necessary when the RP feeling is obtained by big tanks without thermic
insulation.
As concerns the program of inspections and maintenance necessary to keep a high level of
reliability and safety, see the section Maintenance program; whereas for parts subject to
increased wear , see the section Spare parts.
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CUSTOMER DATA:
CUSTOMER:
TEL. ..
CONTACT NAME:
PRODUCT DATA:
N.CATALOGUE:
SERIAL NUMBER
PROBLEM NOTICED:
DATE: .. SIGNATURE:
Nb. This form has to be properly filled and sent via fax to Esa Service or enclosed in the packing list.
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