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Data Center Alabushevo Zelenograd SEZ Russia

Precision air conditioning

casestudyCS_14002_GB

IT Cooling case study

Casestudy Data Center Alabushevo Zelenograd SEZ Russia

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RC GROUP S.p.A. ● CS_14002_GB

INDEX

1 INTRODUCTION ............................................................................ 3 2 DATA CENTER ALABUSHEVO ........................................................ 4

2.1 DATA CENTER NUMBERS ............................................................... 5 3 CLIMATE CONDITIONS AND COOLING SYSTEM ................................ 6 4 ENERGY CONSUMPTION MANAGEMENT .......................................... 7 5 PRECISION AIR CONDITIONERS ................................................... 10

5.1 CHILLED WATER AIR CONDITIONERS NEXT CW ............................... 11 5.1.1 PLUG FAN .................................................................................. 11 5.1.2 FINNED COILS HEAT EXCHANGER ................................................. 12 5.1.3 MICROPROCESSOR CONTROL SYSTEM ......................................... 12 5.1.4 EXTRA-CIRCUIT SYSTEM ............................................................. 12 5.2 DIRECT EXPANSION AIR CONDITIONER NEXT DX ............................ 13

6 LIQUID CHILLERS ....................................................................... 14 6.1 SCREW COMPRESSORS .............................................................. 14 6.2 SHELL AND TUBE EVAPORATOR ................................................... 15 6.3 CONDENSING COILS & FREE-COOLING .......................................... 15 6.4 CONDENSING SECTION FANS & FREE-COOLING ............................. 16 6.5 MICROPROCESSOR CONTROL SYSTEM ......................................... 16 6.6 FREE-COOLING OPERATING MODE ............................................... 17 6.7 MECHANICAL REFRIGERATION ..................................................... 17 6.8 FREE-COOLING .......................................................................... 18


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1 INTRODUCTION

Once again RC Group shows its excellence to ensure functionality and safety in air-conditioning in

large capacity IT systems.

This is the case of modern and innovative Data Center of Alabushevo at Zelenograd SEZ (Special

Economic Zone), where RC Group, whose technological proposal, accompanied by a detailed

global energy survey has been permanentely approved, has applied the best of its technology

systems and equipment able to satisfy the needs of the complex allowing the functional

management with the least energy consumption.

Zelenograd is the Russian locality where, since 1958, the Soviet electronics industry is based on,

and is still one of the most important centers of electronics, microelectronics and hi-tech of modern

Russia.

The city, whose name can be literally translated into English as "Green City", is located 35 km

north-west of Moscow and 15 km from Sheremetyevo international airport.

Zelenograd is designed as a city of the future. It has enormous potential: economic zone,

innovative producer-oriented sites, highly qualified management, advanced technical University,

considerable intellectual resources. Zelenograd is considered the smartest city in Europe:

more than half of the adult population has a higher education degree.

The territory of "Zelenograd" SEZ is divided into two main areas:

• An industrial area "Alabushevo (150.0 hectares) including a scientific and industrial area,

where is situated the Data Center of Radius Group, an ancillary infrastructure area and a

recreational area.

• Another area in which are situated the Innovative complex of Moscow University and the

Institute of Electronic Technology (5.15 acres).

MOSCOW

Alabushevo


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2 DATA CENTER ALABUSHEVO

The Alabushevo Data Center design solution takes into account all the sector’s applicable

regulations requirements. The centers’ engineering infrastructures meet completely Tier III security

requirements provided by Uptime Institute, the sector’s most authoritative independent

consultancy organization. The reliability is designed to achieve 99.98% of operational continuity,

which means no more than one hour of downtime per year.

Picture 1 – Alabushevo building: on the coverage twelve air cooled liquid chillers GLIDER FREE of RC Group are placed (rendering)

Equipment and customer data are protected by uninterrupted power systems, backup power

supplies based on diesel generators with no less than 8 hours of battery autonomy, receiving

precision air-conditioning systems of last generation technology (RC Group), physical security, fire

protection systems and automatic monitoring to videos and access control systems.

The infrastructure engineering project is used to stop any system, for scheduled maintenance work,

without stopping the main technological process. Regular scheduled maintenance works, are the

key to the data center's operational sustainability.

The modular design of the building makes possible to provide customers with a full range of

outsourcing services information infrastructure.

The cooling system made by RC Group is optimized for high density racks through equipment with

up to 12 kW cooling capacity.

The project solution of data center is designed to minimize power losses and, at the same time, the

energy use.

As a result of a greater energy efficiency of the data center’s engineering systems, we require:

equipment optimization to reduce the server energy consumption by 38%; the power systems’

optimization to reduce UPS and PDU and its energy consumption by 51%; the cooling systems’

optimization to reduce power consumption by producing cooling only for 72% of the requirements.


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2.1 DATA CENTER NUMBERS

buildings n. 3

space of each building m2 4.366

total space of buildings m2 13.098

total occupied area m2 10.000

offices area m2 1.472

total covered area m2 16.541

server racks per module n. 406

total server racks n. 1.218

total redundancy level of data center TIER III+

chilled water air conditioners n. 108

direct expansion air conditioners n. 9

free-cooling liquid chillers with pumping group n. 12

cooling capacity MW 18

total capacity MW 21


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3 CLIMATE CONDITIONS AND COOLING SYSTEM

The project plant considers that the major thermal loads are those produced by the data center IT

equipment. External Thermo hygrometric conditions affect almost exclusively the functioning of

liquid chillers. The area of application of cooling equipment is conducive to the effective use of

direct and indirect free-cooling systems. For this reason all liquid chillers installed on the

Alabushevo building coverage are supplied with free-cooling system for cooling or pre-cooling plant

water when the external air temperature is particularly rigid.

The table shows the Alabushevo extreme and medium air temperature conditions that are similar

to those of Moscow. The table shows clearly how it is possible to dispose the thermal load of the

complex even with free-cooling system in January, February, March, November and December

without the use of the electric compressors.

Table I – The table shows the values of temperature and relative humidity of Moscow. Daily average for month cooling load values are related to local data center needs in twenty-four hours of every day of every month.

Working time

Temperature MAX

Temperature MIN

Medium temperature

MAX

Medium temperature

MIN

Relative humidity

MIN

Relative humidity

MAX

Medium cooling load

Month °C °C °C °C % % kW

Jan 0,7 -18,0 -5,2 -10,2 60,1 93,0 8.400,0

Feb 2,9 -17,9 -3,1 -10,1 54,9 97,0 8.400,0

Mar 7,3 -12,4 0,0 -4,6 54,0 88,9 8.400,0

Apr 15,4 -6,3 9,5 1,5 51,4 89,7 8.400,0

May 24,1 -0,6 18,2 7,2 41,7 85,9 8.948,8

Jun 26,6 2,8 20,6 10,6 50,5 55,9 9.400,2

Jul 28,0 5,3 22,1 13,1 52,8 93,2 9.800,2

Aug 26,0 3,3 20,1 11,1 55,9 97,0 9.400,2

Sep 19,9 -0,9 13,9 6,9 58,7 93,7 8.617,2

Oct 12,9 -7,9 6,9 -0,1 65,8 97,0 8.400,0

Nov 6,2 -11,6 0,3 -3,7 69,6 97,0 8.400,0

Dec 2,7 -16,0 3,2 -8,2 66,1 97,0 8.400,0


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4 ENERGY CONSUMPTION MANAGEMENT

The careful evaluation of energy consumption of all units installed in Alabushevo guides better the

business products choice. Cooling groups can be managed using control devices to reduce the

total load, either in parallel or in sequence. In the first case, they will always be all active, at least up

to a reduction of the building required total load equivalent to the minimum capacity of each units.

In the second case, to shrink the building's request, individual units will stop progressively.

Seasonal energy consumption in two different possible plant managers, were calculated based on

the monthly average of thermo hygrometric conditions in Moscow (189 metres above sea level)

shown in table II which are invoked the statistical-based climate data available from the web1.

Each month features a day type, whose temperature profiles (T) and relative humidity profiles (RH),

hour by hour, are reconstructed on the basis of the equation:

Text = Text max * (1 - kn) + Text min * kn (1)

e:

RH = RHmax * kn + RHmin * (1 - kn) (2)

where the coefficients kn are marked hour by hour and return a dry bulb minimum temperature dry

bulb at 05:00 a.m. and a maximum temperature at 03:00 p.m. (vice versa for relative humidity).

Maximum and minimum values of the equations 1 and 2, on the other hand, correspond to the

averages of maximum and minimum values of month-to-month as from statistical tables, while

extreme temperature conditions are not taken into account. Each month is, therefore, characterized

by an average temperature statistics, with a daily temperature range corresponding to the

difference between the average of the maximum and the average of the minimum.

The profile of the building's cooling load is calculated with the following equation:

(3)

where:

DesignLoad cool is the design heat load in cooling mode and expresses the peak load of the shell

to which you should refer to in the choice of chillers. It is therefore related to the

climatic conditions of the project, which should be the harshest of the installation

location.

CL0 is the constant contribution, not influenced by time (because they multiplied ku), or

other factors. Corresponds to the fraction of endogenous load strapped to

machinery with continuous operation 24hrs/24hrs. Back to express the minimum

load always on, just like data center applications.

ku is the time factor, expressed as a percentage. When is canceled, expresses the

load reset (turned off unless it is different from zero CL0). The value considered to

vary, depending on the time, all load conditions included in bracket.

1 The most used source is www.weatherbase.com.. 2 Cooling load ratings from “Energy analysis for RC Group units”- SPECTRUM Manual ©2013 RC Group SpA Valle Salimbene Pv.


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kw is a constant (= 1) for plant on (ku > 0), and (= 0) for plant off (ku = 0)

CL1 is the load process, little influenced by climatic conditions (for application of

comfort, it is recommended that this value is zero). CL2 is the comfort loaded, mainly at the level of employment (latent loads, lighting)

and, largely, separate climatic conditions.

DCL is the reference value for the thermal indentations (thermal exchanges between

the building envelope and the outer environment).

Text is the outside air temperature at dry bulb (°C).

Tcl is the temperature to which reverses the sign of the heat exchange between

building envelope and the external environment.

Tch is the maximum temperature used for calculations: it corresponds to the average

of the maximum of all months of the year.

The total energy consumption evaluation is based on the compressors absorption of : all groups of

chillers throughout their operating period, the fans both during mechanical refrigeration and free-

cooling and the primary fluid’s circulation pump: water and ethylene glycole.

The refrigerant load adjustment of various refrigeration units is performed sequentially, in order to

progressively stop the chillers keeping those in operation able to work at their maximum capacity.

This solution allows to have a decent energy saving towards a system worked in parallel, in which

most of the units continue to work with a very low single load.


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Working time Ambient temperature Relative

humidity Load Compr. Fans Pumps EER Free

Cooling

MAX MIN Av MAX

Av MIN

MIN MAX Average Sum Sum Sum Average Average

Month h °C °C °C °C % % kW kWh kWh kWh W/W %

Gen 744 0,7 -18,0 -5,2 -10,2 60,1 93,0 8.400,0 0 110.564 75.076 33,67 100,0

Feb 672 2,9 -17,9 -3,1 -10,1 54,9 97,0 8.400,0 0 109.044 67.810 31,92 100,0

Mar 744 7,3 -12,4 0,0 -4,6 54,0 88,9 8.400,0 4.732 189.850 75.076 23,18 99,8

Apr 720 15,4 -6,3 9,5 1,5 51,4 89,7 8.400,0 595.854 194.810 72.654 7,01 58,0

Mag 744 24,1 -0,6 18,2 7,2 41,7 85,9 8.948,8 1.272.546 132.102 79.826 4,49 8,7

Giu 720 26,6 2,8 20,6 10,6 50,5 55,9 9.400,2 1.397.908 119.364 81.848 4,23 0,0

Lug 744 28,0 5,3 22,1 13,1 52,8 93,2 9.800,2 1.539.266 139.116 88.140 4,13 0,0

Ago 744 26,0 3,3 20,1 11,1 55,9 97,0 9.400,2 1.441.964 122.786 84.578 4,24 0,0

Set 720 19,9 -0,9 13,9 6,9 58,7 93,7 8.617,2 1.120.406 127.424 72.654 4,70 13,6

Ott 744 12,9 -7,9 6,9 -0,1 65,8 97,0 8.400,0 353.302 226.236 75.076 9,55 78,0

Nov 720 6,2 -11,6 0,3 -3,7 69,6 97,0 8.400,0 0 179.640 72.654 23,97 100,0

Dic 744 2,7 -16,0 3,2 -8,2 66,1 97,0 8.400,0 0 128.228 75.076 30,74 100,0

Total 8.760 Total 7.725.978 1.779.164 920.468 7,35 52,5

Total 10.425.610

Table II – The table shows the values of energy consumption (kWh) of twelve liquid chillers working in sequence. The evaluation includes energy consumption of compressors, of fans and circulation pumps (water and glycol).


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5 PRECISION AIR CONDITIONERS

The equipment of Alabushevo data center requires an overall cooling capacity of about 14 MW.

Picture 2 – Part of a data center room (rendering)

In order to satisfy the requests specific equipment, manufactured in the plant RC Group of

Zeccone, in the province of Pavia, has been applied.

• n. 108 chilled water CRAC units NEXT CW;

• n. 9 direct expansion CRAC units NEXT DX.

Picture 3 – Diagram of air distribution system between the Racks rows. Through the floating floor the NEXT units send the filtered and conditioned air in the cold aisle between the rows of Racks (blue arrows). The Racks are downloading the hot air in the hot aisle (red arrow) where there is the suction at the top of the air conditioner.


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5.1 CHILLED WATER AIR CONDITIONERS NEXT CW Each of the 108 precision air conditioning units NEXT CW are capable to produce 60kW in cooling

with airflow of about 15,000 m3/h. The chilled water units allow to obtain the best adaptation to

variable load of areas which are dedicated.

Picture 4 – Chilled water close control air conditioners NEXT CW with down-flow air delivery.

NEXT CW are suitable to be installed internally, either directly into the room where they are placed

on the data center equipment, both in an adjacent room: the air distribution is from the bottom

through the plenum between the building floor and the raised floor.

5.1.1 PLUG FAN Each unit is equipped with plug-fans with EC motors able to ensure high energy saving during

operation with reduced airflow.

Picturea 5 – Centrifugal fan (Plug Fan) directly coupled to EC electric motor. (Ziehl Abegg SE – Künzelsau - Germania).

The motor rotation control is obtained with the EC system (Electronic Commutation) that manage

the motor according to the 0÷10V proportional signal coming from the microprocessor control.


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5.1.2 FINNED COILS HEAT EXCHANGER The coils are fed with chilled water by copper tubes, aluminum fins and galvanized steel frame fins

with high heat exchange surface and high-efficiency air filters; the two-way valve adjusts the water

flow with proportional control and emergency manual control.

5.1.3 MICROPROCESSOR CONTROL SYSTEM The microprocessor control system allows the operating state and alarm’s management and

monitoring. It includes: a voltage free contact for the general alarm; an operating hour counter of

the main components with maintenance reporting; the function "data logger" for the memorization

of the intervened alarms; flash memory for data storage in case of power failure and menu

management with password protection. There is also the serial communication line for the remote

control.

Picture 7 – Mp.com microprocessor control system (RC Group Spa Valle Salimbene (PV) Italia).

Each units is also equipped with: humidifier, Dehumidification system, and extra-circuit coil.

5.1.4 EXTRA-CIRCUIT SYSTEM The extra circuit system consists of an additional chilled water cooling coil powered by a valve

directly managed through the microprocessor control system.

The additional cooling coil is placed on the air flow upstream the filter section and downstream the

main cooling coil. It is perfectly sized in order to provide with the main cooling coil’s same cooling

capacities, guaranteeing a total back-up.

The interchange between the two cooling systems is done automatically via the microprocessor

control. This system allows to solve easily and in a limited space many plant problems including:

• extra-circuit system fed by well water in emergency to the main refrigerant circuit;

• main cooling circuit is a support for the extra-circuit system connected to the external chiller;


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Picture 8 – Air cooling system of an air conditioner. The system includes a main chilled water coils (left) and an emergency auxiliary called "extra-circuit" (right).

5.2 DIRECT EXPANSION AIR CONDITIONER NEXT DX The nine precision air conditioner NEXT DX are able to produce, each, with a cooling 57kW airflow

of about 14,500 m3/h. The units are self-contained, equipped with two compressors in order to

allow a better adaptation to demand loading of areas which are dedicated and plug-fans with

brushless motor electronically commutated (EC) able to ensure high energy savings during

operation with reduced airflow. Cooling coils are refrigerant direct expansion HFC410A, match to

the condenser series Team-Mate produced by RC Group.

Picture 9 – Direct expansion close control air conditioner NEXT DX with down-flow air delivery.

Extra – Circuit System Main cooling circuit

Water flow control valve Water flow control valve

Air flow


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6 LIQUID CHILLERS

The demand for cooling of IT rooms is satisfied by the creation of a refrigeration unit consisting of

twelve liquid chillers GLIDER FREE, each of which has been selected to provide 1100 kW of

cooling capacity. Each chiller is equipped with chilled water pumping group.

Picture 10 – GLIDER FREE: air cooled liquid chiller with free-cooling produced by RC Group

6.1 SCREW COMPRESSORS GLIDER FREE, manufactured in the establishments of RC Group in Valle Salimbene in the

province of Pavia, are equipped with semi-hermetic screw compressors with bi-screw technology

and high efficiency screw profile with high peripheral speeds, optimized for refrigerant R134a.

Picture 11 – Screw compressor (Refcomp SpA - Lonigo (VI) Italia).

For a precise control of the cooling capacity supplied, screw compressors are equipped with a

control system of modulating cooling capacity. The lubrication system is equipped with an oil

pressure separator and oil flow switch.


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6.2 SHELL AND TUBE EVAPORATOR The shell and tube evaporator, which is expressly designed for R134a refrigerant, is realized with

internal corrugated pipes having a helical profile, intermediate septa positioned to ensure optimal

speed and reduced fluid pressure drops.

Picture 12 – Shell and tube evaporator (WTK SpA - Lonigo (VI) Italia).

The evaporators are characterized by single-circuit water side, and independent circuits, one for each

compressor, on the refrigerant side; coat, head, tube sheet of stainless steel; anti-condensation

insulation closed cell polyurethane; temperature sensor on water inlet and outlet. Each refrigerant

circuit is equipped with its own electronic expansion valve for high performance and system

efficiencies thanks to a timely and accurate response to variations in temperature and pressure.

6.3 CONDENSING COILS & FREE-COOLING In one finned Pack are available the condensing coil and free cooling coil. The tubes are made of

copper and aluminum fins, high efficiency specifically developed to ensure a high heat exchange

coefficient and contained losses. The combination of two factors: special fins tubes, allows to combine

optimally the maximum capacity in relation to the size of the exchanger, minimal refrigerant charge

and the reduction of the air flow necessary for heat exchange.

Picture 13 – Heat exchange finned coils made from copper tubes and aluminium fins full. The finned Pack contains both the part dedicated to the condenser and the free-cooling hydraulic circuit (NAS Srl – Albano Laziale (Roma) Italia).


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6.4 CONDENSING SECTION FANS & FREE-COOLING Axial fans with sickle-shaped blades and fan guard are optimized for low noise levels.

Brushless type synchronous EC motor with integrated electronic commutated system and

continuous variation of the rotation speed.

The motor rotation control is obtained with the EC system (Electronic Commutation) that manage the

motor according to the 0÷10V proportional signal coming from the microprocessor control.

Picture 14 – High efficiency axial fan (Ziehl Abegg SE – Künzelsau - Germania).

6.5 MICROPROCESSOR CONTROL SYSTEM MP.COM microprocessor system is completed with graphic display for control and monitor of

operating and alarms status. The system includes voltage free contact for remote general alarm,

Main components hour-meter, non-volatile “Flash” memory for data storage, menu with protection

password and LAN connection.

Figura 15 – Mp.com microprocessor control system (RC Group Spa Valle Salimbene (PV) Italia).


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6.6 FREE-COOLING OPERATING MODE

Chillers cool a mixture of water and ethylene glycol to 40% by weight from 12° C to 7° C by means

of the compression system and allow to achieve the same overall cooling capacity even with the

free-cooling coils when the external air temperature is 0° c.

The air moved by fans crosses the free-cooling coil and then the condensing coil of the refrigerant

circuit.

free-cooling coil takes advantage of low air temperature for pre-cooling water returning from the

system before submitting it to the evaporator.

In this way is possible to have a free-cooling that helps in saving electricity, since part of the

refrigerator plant load is supplied from the outside air instead of being supplied totally by the

compressors.

RC Group chillers with free-cooling have three different working modes:

1. normal mode (mechanical cooling);

2. partial free-cooling mode (free cooling + mechanical cooling);

3. total free-cooling mode.

6.7 MECHANICAL REFRIGERATION

In mechanical mode with active compressors, the butterfly valve sends the fluid directly into the

evaporator: the unit works like a traditional liquid chiller.

The microprocessor manages the outlet water temperature by adjusting the capacity of the

compressor and the condenser pressure is controlled by reducing the air flow through the coils

refrigerant gas through modulation of the fans rotation speed.

Picture 16 – During the mechanical cooling mode, the compressors are active and the water returning from the system flows directly into the evaporator.

Condensing coil and free-cooling

Evaporator

Outlet water Inlet water

Butterfly valve


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6.8 FREE-COOLING When the air temperature drops by 3° K under water temperature returning from the utilities, the

free-cooling valve feeds the free-cooling coil that pre-cools (partial free-cooling) or cools completely

(total free-cooling) the water before entering the evaporator.

The control logic handles an optimized electrical energy effort to cope with the heat load to be

disposed, minimizing the compressors’ operating time in order to make the most out of free

cooling.

Picture 17 – When the external air temperature reaches a temperature low enough to pre-cool or cool completely the water returning from the system, the fluid flows first in free-cooling coils and, subsequently, in the exchanger and the evaporator.

The water temperature control in free-cooling mode is achieved initially through the progressive

reduction of the fans’ rotation speed. If the cooling capacity in free-cooling is still excessive, the

microprocessor will stop the fans and, in case the capacity supplied by the free-cooling system is

still exuberant the microprocessor will command the free-cooling valve in closing, getting also the

total battery by-pass.

Refrigeration equipment installed at the data center of Alabushevo allow compression mechanical

mode with external air between 35° C and 10° c.

Between an air temperature of 10° C and 3° C the chillers units work with compressors and active

free-cooling batteries managed through two separate refrigerant circuits.

Under 0° C chillers units are able to fully satisfy the load of the building with free-cooling coils only,

limiting in this way power consumption only to the motorized fans assembly functioning.

Condensing coils and free-cooling

Evaporator

Outlet water Inlet water

Butterfly water


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Picture 18 – The coefficients of performance (EER) are referred to a single liquid chiller and also take into account the constant consumption of the water circulation pump.

Only Free-Cooling Free-Cooling + Compressors Only Compressors

EE

R (

kW /

kW)

External air temperature (°C)

(EER) of liquid chillers At full load with variable external air temperature

The continuous improvement of products may imply changes in the data shown in this catalogue.

RC GROUP S.p.A. • Via Roma, 5 • 27010 Valle Salimbene (PV), Italy

www.rcgroup.it • Tel. +39 (0) 382 433 811 • Fax +39 (0) 382 587 148

CS_14002_GB

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