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Schrack Technik PQC User Manual

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USER MANUAL
1
POWER FACTOR CORRECTION
Power Quality Controller PQC

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Summary of Contents for Schrack Technik PQC

  • Page 1 USER MANUAL POWER FACTOR CORRECTION Power Quality Controller PQC...

  • Page 2: Table Of Contents

    5.4 V OLTAGE MEASUREMENT 5.5 C URRENT MEASUREMENT 5.6 O UTPUT RELAYS CONTROL OUTPUTS 5.7 C ONNECTION DIAGRAMS OF ALL INSTRUMENT TYPES 5.7.1 PQC 1202401-XX ONNECTION DIAGRAM VERSION 5.7.2 PQC 1202403-XX ONNECTION DIAGRAM VERSION 5.7.3 PQC 0602401-XX ONNECTION DIAGRAM VERSION 5.7.4...
  • Page 3 5.7.7 PQC XXX480X-XX PTIONS FOR CONNECTING THE POWER SUPPLY FOR VERSIONS 6 COMMISSIONING (INITIAL START-UP) 6.1 A LARM FUNCTION 6.1.1 IST OF ALARMS AND MESSAGES 6.2 S AFETY PRECAUTIONS BEFORE START 6.3 F UNCTIONAL CHECKOUT 6.4 C ONFIGURATION 6.5 A UTOMATIC COMMISSIONING 6.5.1...
  • Page 4 Figure 8 Part of the connection diagram for 400/415 V networks with no neutral conductor 30 Figure 9 Part of the connection diagram for 690 V networks with a neutral conductor ..30 Figure 10 PQC Start screen (firmware version number may be different) ......32 Figure 11 Menu structure 1 ....................36 Figure 12 Menu structure 2 ....................
  • Page 5 Figure 26 Capacitor stage identification started ..............41 Figure 27 Start-up completed ....................41 Figure 28 PQC overview L1 (1-phase) ................. 42 Figure 29 PQC overview L1 (3-phase) ................. 42 Figure 30 Capacitor stage statuses (1-phase, 6 stages) ............42 Figure 31 Capacitor stage statuses (3-phase, 12 stages) ............
  • Page 6 Figure 65 Info / status 3/3 ..................... 60 Figure 66 PQC status overview .................... 61 Figure 67 Total corrective power Q ..................61 Figure 68 Capacitor stages table ................... 62 Figure 69 Diagram showing all stages at 100% ..............62 Figure 70 Diagram showing corrective power of all stages ..........

  • Page 7: Safety

    1.1 O BJECTIVE This operating manual has been prepared for persons who install, connect, commission and operate the PQC Power Quality Controller. 1.2 S AFETY INSTRUCTIONS No claims under guarantee shall be valid in the event of damages caused by failure to observe the instructions in this operating manual.

  • Page 8: Intended Use

    The USB port is a service interface provided solely for updating the PQC firmware. Users are not permitted to use this USB port for any other purpose, and therefore must not connect any cable or device to it. When the PQC is in operation, the USB port must not be touched.

  • Page 9: Repair

    1.5 R EPAIR Repairs may not be carried out by the customer or user. Should repair work be necessary, the customer or user must contact Schrack Technik (contact addresses see: www.schrack.com): 1.6 S YMBOLS USED Special instructions this operating manual marked symbols.

  • Page 10: Technical Data

    Normally open with common pole P Output relays (control outputs, capacitor stages) PQC version: PQC 120xxxx-xx: 12 output relays and PQC version: PQC 060xxxx-xx: 6 output relays, AC-14 250 V AC, maximum 3 A or DC-13 30 V DC, maximum...
  • Page 11 Common supply conductor P to the output relays maximum 10 Note: utilization category AC-14 / DC-13 as per IEC 60947-5-1 For all PQC versions in areas where UL / CSA standards apply: 3 A 250 V AC cos ϕ = 1 at 85 °C 3 A 30 V DC L/R = 0 ms at 85 °C...
  • Page 12 Insulation rating: min. 250 V AC, 80 °C • USB Micro-A and Micro-B ports USB for updates (service interface) • PQC version: PQC xxxxxxx-1x: Digital inputs and outputs Conductor cross section max. 1.5 mm², min. 0.14 mm Insulation rating: 50 V DC, 80 °C •...
  • Page 13 EN 61000-4-4, burst immunity, 1 kV capacitive coupling, 2 kV injection into power supply cable and voltage measurement inputs EN 61000-4-5 surge immunity, 2 kV injection into power supply cable and voltage measurement inputs Ambient conditions • -20 °C to +60 °C, noncondensing Temperature range •...

  • Page 14: Instrument Description

    (target cos phi), after an adjustable time delay one or more of the PQC control contacts are closed. The PQC thus switches capacitor stages in as required in order to restore the target power factor. If the inductive reactive power component of the loads reduces again, this causes capacitor stages to be switched out.

  • Page 15: Mounting The Instrument

    Only install the instrument in areas where there is no danger of a gas or dust explosion. The PQC is designed for mounting in a 138 mm x 138 mm cutout to IEC 61554 in the front of a control cabinet.
  • Page 16 DANGER! To prevent the PQC overheating, the following must be observed: - The PQC must be installed in an adequately ventilated space, and its rear and sidewalls must not be covered. - No sources of heat must be located in the vicinity.

  • Page 17: Installation

    If the power supply voltage and the voltage measured exceed the values specified in this operating manual and stated on the instrument, this may cause damage to the PQC. Consequential damage to other parts of the installation is also possible.

  • Page 18: Earth Connection

    • If the earthing tab has broken off, the PQC must not be started up. The instrument must either be repaired or replaced. •...

  • Page 19: Supply Voltage

    One such fuse is required when the power is from an L–N connection, but two fuses must be installed if an L–L connection is used. A disconnecting device must be installed so that the connections of the PQC can be isolated from the electrical system and building electrical installations.

  • Page 20: Voltage Measurement

    5.4 V OLTAGE MEASUREMENT Depending on the instrument type (see Section 9, Instrument versions), the PQC can measure one, two or three AC voltages. The voltage measurement inputs are electrically interconnected via high resistances. See Section 2, Technical data, for the measurement ranges. DC voltages cannot be measured.

  • Page 21: Current Measurement

    5.5 C URRENT MEASUREMENT The PQC is designed for connection to x/1 A and x/5 A current transformers. Only AC currents can be measured; DC currents cannot be measured. Depending on the instrument type (see Section 9, Instrument versions), the PQC can measure one, two or three AC currents. See Section 2, Technical data, for the measurement ranges.
  • Page 22 Instrument types with single-phase measurement (see Section 9, Instrument versions): The current in any desired phase L is measured via an external, electrically isolating current transformer. See Section 2, Technical data, for the measurement range. The terminals L1 – S1-S2 are connected as shown in the connection diagram in Figure 2.

  • Page 23: Output Relays

    Compliance with this stipulation will avoid the risk of burns. Depending on instrument type, the PQC is equipped with 6 or 12 output relays (control outputs). Capacitors are connected to these via current-amplifying electromechanical devices (relays, contactors). Connections are made to the terminals ‘Output relays Q1 to Q12, P’ as shown in the connection diagrams in Section 5.7.

  • Page 24: Connection Diagrams Of All

    Connection diagram: version PQC 1202401-XX Messspannung Versorgungsspannung voltage measurement supply voltage 100V-690VAC~ 100V-15% × 240V+10% AC~5VA Alarmrelais Ausgangsrelais alarm relais output relais 250VAC~ 3A cos phi =1 250VAC~ 3A cos phi =1 Alarm Figure 2 Connection diagram for PQC 1202401-XX...

  • Page 25: Figure 3 Connection Diagram For Pqc 1202403-Xx

    Connection diagram: version PQC 1202403-XX Messspannung Versorgungsspannung voltage measurement supply voltage 100V-690VAC~ 100V-15% × 240V+10% AC~5VA Alarmrelais Ausgangsrelais alarm relais output relais 250VAC~ 3A cos phi =1 250VAC~ 3A cos phi =1 Alarm Figure 3 Connection diagram for PQC 1202403-XX...

  • Page 26: Figure 4 Connection Diagram For Pqc 0602401-Xx

    5.7.3 Connection diagram: version PQC 0602401-XX Messspannung Versorgungsspannung voltage measurement supply voltage 100V-690VAC~ 100V-15% × 240V+10% AC~5VA Alarmrelais Ausgangsrelais alarm relais output relais 250VAC~ 3A cos phi =1 250VAC~ 3A cos phi =1 Alarm Figure 4 Connection diagram for PQC 0602401-XX...

  • Page 27: Figure 5 Connection Diagram For Pqc 1204801-Xx

    Connection diagram: version PQC 1204801-XX Messspannung Versorgungsspannung voltage measurement supply voltage 100V-690VAC~ 100V-15% × 480V+10% AC~5VA Alarmrelais Ausgangsrelais alarm relais output relais 250VAC~ 3A cos phi =1 250VAC~ 3A cos phi =1 Alarm Figure 5 Connection diagram for PQC 1204801-XX...

  • Page 28: Figure 6 Connection Diagram For Pqc 1204803-Xx

    Connection diagram: version PQC 1204803-XX Messspannung Versorgungsspannung voltage measurement supply voltage 100V-690VAC~ 100V-15% × 480V+10% AC~5VA Alarmrelais Ausgangsrelais alarm relais output relais 250VAC~ 3A cos phi =1 250VAC~ 3A cos phi =1 Alarm Figure 6 Connection diagram for PQC 1204803-XX...

  • Page 29: Figure 7 Connection Diagram For Pqc 0614801-Xx

    Connection diagram: version PQC 0614801-XX 440V Messspannung Versorgungsspannung voltage measurement supply voltage 100V-690VAC~ 100V-15% × 480V+10% AC~5VA Alarmrelais Ausgangsrelais alarm relais output relais 440VAC~ 3A cos phi =1 440VAC~ 3A cos phi =1 Alarm Figure 7 Connection diagram for PQC 0614801-XX...

  • Page 30: Figure 8 Part Of The Connection Diagram For 400/415 V Networks With No Neutral Conductor

    5.7.7 Options for connecting the AUX power supply for PQC XXX480X-XX versions Connecting the AUX terminals to a 100 to 480 V AC power supply. Version: PQC XXX480X-XX: 400 V AC / 415 V AC – networks without a neutral conductor N 5.7.7.1 Connection diagram for 400/415 V networks with no neutral conductor...

  • Page 31: Commissioning (Initial Start-Up)

    These alarm signals can comprise status signals, status of the optional digital inputs, set alarm limits exceeded or instrument faults. The assignment of the internal PQC alarm signals to the alarm relay is carried out in a menu dialogue (see Section 8.5.3.2, Alarm management).

  • Page 32: Figure 10 Pqc Start Screen (Firmware Version Number May Be Different)

    Once the power has been switched on, it takes several seconds until the PQC starts up. The backlighting of the LCD display is the first visible indication, then, after about five seconds, the PQC is ready for operation. Information is displayed on the LCD screen, and the PQC can be operated by means of the keys.

  • Page 33: Table 1 Connection Types For Current Transformers In L1, L2 And L3

    PQC automatically carries out the connection identification procedure, i.e. the instrument itself identifies in which phase angle the current and voltage paths are connected. If the PQC does not succeed in this, for example because the network is very unstable, the calibration procedure should be repeated under more stable network conditions.

  • Page 34: Table 2 C/K Settings At 400 V Ac And 50 Hz

    6.5.3 Calculation of c/k Kann die Formel etwas schöner umgesetzt Formula 1 Calculation of c/k werden? (Die nicht Kreuzprodukt gemeint.) smallest stage smallest stage × × ≈ × × 1000 1000 × × × where Response current in mA to be set Capacitor power rating of the smallest stage in var (not the total system power rating) smallest stage Network voltage in volts at the primary side of the current transformer...

  • Page 35: Table 3 Key Functions

    Select and confirm a selected element (e.g. adopt value). Info Help text The PQC can be operated in three languages, which are selected from the main menu via Initial start- up  Language (see Section 8.1): • German • English...

  • Page 36: Figure 11 Menu Structure 1

    7.1 M ENU OVERVIEW Main menu Control Manual Settings Initial start-up About PQC... Info / status overview diagram control Overview Control Factory General Set limits phase L1 profiles settings Overview Alarm Capacitor Extensions Profiles 1 to 5 phase L2 stages...

  • Page 37: Figure 12 Menu Structure 2

    Info / status V and I Manual PQC status Cap. stage power System power harmonics frequency analysis Automatic or Cap. stage power Harmonics Total manual control table diagram Q power Cap. stage power Harmonics Switching Q power sequence still available...

  • Page 38: Figure 14 Main Menu 1/3

    Main menu The following submenus can be selected from the main menu: • PQC overview • Control diagram • Manual control (password protected) • Settings (password protected) • Info / status • Initial start-up (password protected) • About PQC… Action...

  • Page 39: Figure 17 Changing The Working Language

    • Detection  Stage + Connection, Stage, Connection or Manual Stage + Connection The PQC carries out the automatic stage and connection identification procedure (see Figure 18 on page 39). Stage The PQC carries out the automatic stage identification procedure.

  • Page 40: Figure 18 Identification: Stage + Connection

    Back to Select Select Action Confirm main menu parameter + parameter - All start-up variants and their submenus Figure 18 Identification: Stage + Connection Figure 19 Identification: Connection Figure 20 Identification: Connection submenu Figure 21 Identification: Stage Figure 22 Identification: Stage submenu Figure 23 Identification: Manual Figure 24...

  • Page 41: Figure 25 Connection Identification Started

    8.2 PQC OVERVIEW In instrument types with 3-phase measurement, the phase marked with an asterisk * is the one that the PQC is using for control (see Figure 29 on page 42). Once the automatic commissioning procedure has been completed, the PQC overview screen appears.

  • Page 42: Figure 28 Pqc Overview L1 (1-Phase)

    • → Display of the momentary current  • → Sum of all 3 phases (L1, L2 and L3) (if single-phase PQC, theoretical sum assuming symmetrical loading) • → A negative value of the active power indicates regeneration Regeneration •...
  • Page 43 Description of Figure 30, capacitor stage statuses (1-phase, 6 stages) Stages 1 and 2  Permanently switched-in fixed capacitor stages Stage 3  This stage is functional but switched out Stages 4 to 6  These stages are functional and switched in Description of Figure 31, capacitor stage statuses (3-phase, 12 stages) Stages 1 and 2 ...

  • Page 44: Figure 32 Control Diagram

    8.3 C ONTROL DIAGRAM The control diagram shows the currently selected control characteristic curve (active control profile) and provides visualization of the momentary operating point. 8.3.1 Scale One scale division on the y-axis represents × smallest capacitor stage. Action Back to main menu Zoom + Zoom - Additional info...

  • Page 45: Figure 35 Manual Control

    The supply network from which the capacitor stages controlled by the PQC are operated must be monitored for resonant conditions and overvoltage whenever stages are switched in manually.

  • Page 46: Figure 38 Manual Control: Stages Menu

    8.4.1 Stages menu This menu shows the numbers of the stages (1–12) plus the status (ON/OFF), capacitive power (determined automatically or set manually) and the number of switching cycles of the selected stage. Figure 38 Manual control: Stages menu Return to Manual Switch stage Action Select stage...

  • Page 47: Figure 40 Message On Failed Attempt To Switch In A Stage

    The Settings menu is selected from the main menu. It offers the following submenus: •  Control profiles 5 profiles, see Section 8.5.1.  Capacitor stages, Set limits, Alarm management, Extensions • General •  PQC reset, Clear switching cycles Factory settings Back to main Action Select Select Open submenu menu...
  • Page 48 • Profile 3  Suitable for consumer networks where cos ϕ is close to 1 but overcorrection is to be avoided. • Profile 4  Suitable for consumer networks, as described in Profile 1, but which have their own generating facilities (e.g. CHP units) with permanent or frequent feed- in (regeneration) to the power supply network.

  • Page 49: Figure 42 Control Profiles

    Figure 42 Control profiles Action Control setting Select profile Select profile Set profile Figure 43 Control profile parameters Parameter selection Profile selection Select Select Action Back to parameter (Save Yes/No) parameter parameter selection Profile selection Increase Decrease value Back to parameter Action (Save Yes/No) value +...

  • Page 50: Figure 44 Control Response After Setting Target Cos Φ = 1, Limitation = 0, Parallel Shift = 0

    If the system operates within the band range shown, no switching operations will be activated. However, if the system operates outside the band range, the PQC will try to return to within the band range with the minimum number of switching cycles.

  • Page 51: Figure 46 Control Response After Setting Target Cos Φ = 1, Limitation = 0, Parallel Shift = +1.0

    Reactive power Switch in Active power Regeneration Switch out One division = 0.65 × smallest cap. stage Control response after setting target cos ϕ = 1, limitation = 0, parallel shift = +1.0 Figure 46 The set target cos ϕ is therefore the upper limit of the control band. Overcompensation is avoided.

  • Page 52: Figure 48 Control Response After Setting Target Cos Φ = 0.92 Ind, Limitation = +1.0

    Reactive power Switch in Regeneration Active power Switch out One division = 0.65 × smallest cap. stage Control response after setting target cos ϕ = 0.92 ind, limitation = +1.0 Figure 48 This setting has the following effects: The target power factor is attained, on average, in the upper power range. Overcorrection (capacitive, usually disruptive) is avoided in the low load range.

  • Page 53: Figure 51 Phase L1 Is The Control Phase

    Any one of the three phases L1, L2 and L3 may be selected (with single-phase PQCs, the phase L1 is a fixed setting). On the PQC overview screen, the phase marked with an asterisk * on its left is the one selected for the PQC to use for control purposes.

  • Page 54: Figure 52 General Settings Menu

    Discharge time The discharge time must be at least as long as the longest discharge time of the capacitors in use. •  Capacitor stages permanently switched in, not under PQC Fixed stages control • Choke factor (detuning)  Choke of the power factor correction system. (A value must be set for correct computation.
  • Page 55 • The residual corrective power of the stage as a percentage of its power on start-up is thus: 100% Result: The alarm is given, since the residual corrective power as a percentage is less than the set limit of 85%. ...

  • Page 56: Figure 54 Set Limits 1/2

    Figure 54 Set limits 1/2 Figure 55 Set limits 2/2 Figure 56 Change set limit for switching cycle counter Overcurrent Overcurrent is the theoretically determined ratio of the root-mean-square current to the fundamental current in the capacitor (I ). It therefore indicates how large the proportion of harmonic currents 50Hz/60Hz is in comparison with the fundamental current.

  • Page 57: Figure 57 Alarm Management

    Select alarm Select alarm Open alarm option Action Back to General option option setting submenu Figure 57 Alarm management Setting in Alarm relay, PQC trip and Display alarm submenu: Alarm Select alarm Select alarm Action ON/OFF management source source (saved immediately) Figure 58 Alarm management;...

  • Page 58: Figure 59 Extensions Menu

    Edit parameter menu parameter parameter The Modbus setting menu is navigated to as follows: Settings / General / Extensions / Modbus These settings are only possible with PQC versions xxxxx-2x. Figure 59 Extensions menu Figure 60 Modbus configuration The following parameters can be set in the Modbus configuration menu: •...

  • Page 59: Figure 61 Factory Default Settings

    Down Confirm action default settings 8.5.3.6 Password protection The PQC uses a password to prevent sensitive menu items being accessed by unauthorized persons. This is entered by means of the Up and Down keys. Protected menu items:  Settings Security level 1 ...

  • Page 60: Figure 62 Password Prompt

    Figure 62 Password prompt 8.6 I STATUS • PQC status  Overview of all required setting parameters • Total cap. power  Sum of the reactive power Q plus that still available • Cap. stages table ...

  • Page 61: Figure 66 Pqc Status Overview

    8.6.1 PQC status PQC status → Overview of all necessary setting parameters The following parameters are displayed in the PQC status menu: • PQC status  Automatic or manual control mode • Switching sequence  Display of the capacitor stages detected.

  • Page 62: Figure 68 Capacitor Stages Table

    After the instrument has been started up, this graphic shows every detected stage as 100%. With time, however, capacitor wear causes this corrective power to fall. When it falls below a set level, the PQC gives an alarm. Figure 69...

  • Page 63: Figure 72 Current Harmonics Diagram, Y-Axis 100

    8.6.6 Voltage and current harmonics diagram Back to Switch between Additional Action Info / status Zoom in Zoom out harmonics info menu 1–12 and 8–19 100% corresponds to the fundamental wave at 50/60 Hz. One scale division on the y-axis represents 5%. The harmonics are displayed graphically: Figure 72 Current harmonics diagram, y-axis 100%...

  • Page 64: Figure 75 Manual Frequency Analysis

    8.6.8 Manual frequency analysis Back to Frequency Frequency Select Action Info / status +10 Hz -10 Hz phase menu • Phase  Measurement at Lx [1 ≤ x ≤ 3] • Frequency  10–2500 Hz in increments of 10 Hz •...

  • Page 65: Figure 76 About Pqc

    SUBMENU This dialogue displays information about the instrument: Firmware version number Hardware version number Printed circuit board numbers Serial number Figure 76 About PQC 8.8 F ACTORY DEFAULT SETTINGS Table 4 Factory default settings Connection type 0 (L1-N) c/k setting...

  • Page 66: Figure 53 Capacitor Stages

    cos φ Parallel shift Limitation Settings of control profile 3 Delay time 45 s Phase Active cos φ 0.92 ind Parallel shift Limitation Settings of control profile 4 Delay time 45 s Phase Active cos φ 0.96 cap Parallel shift Limitation Settings of control profile 5 Delay time...
  • Page 67 0.43 0.41 1.76 I harmonics 100% (all) Overcurrent ratio Voltage blackout (sag) limit 2 (½ wave) Number of ¼ cycles Detecting phase Alarm ON/OFF cos φ alarm Undervoltage Undercurrent Overcurrent THDI Switching cycles Settings -> General  Alarm relay V harmonics Alarm management I harmonics Zero stage...
  • Page 68 Alarm ON/OFF cos φ alarm Undervoltage Undercurrent Overcurrent THDI Switching cycles PQC trip V harmonics I harmonics Zero stage (dud) detection Voltage blackout (sag) detection Alarm ON/OFF cos φ alarm Undervoltage Undercurrent Overcurrent THDI Switching cycles Display alarm V harmonics...
  • Page 69 The USB port is a service interface provided solely for updating the PQC firmware. Users are not permitted to use this USB port for any other purpose, and therefore must not connect any cable or device to it. When the PQC is in operation, the USB port must not be touched.

  • Page 70: Table 5 Instrument Versions

    3 A, cos φ = 1) AUX as in the connection diagrams in Section 5.7, Connection diagrams of all PQC instrument types. 85 V AC - 267 V AC (absolute limits, networks 100 V AC - 240 V AC), frequency 45 - 65 Hz or 100 V DC - 377 V DC...
  • Page 71 38-00406 PQC 1204801-0 100 V –10% single- (250 V AC, 480 V +10% AC phase approx. 5 VA 3 A, cos φ = 1) 38-00421 PQC 1204801-01 single- (250 V AC, " Temp. I/O phase 3 A, cos φ = 1)
  • Page 72 If the cleaning is restricted only to the front of the closed control cabinet, it is not necessary to isolate the PQC from the power supply, but in this case also only a dry cleaning cloth may be used.

  • Page 73: Decommissioning And Removal, Storage And Disposal

    11 Decommissioning and removal, storage and disposal 11.1D ECOMMISSIONING AND REMOVAL When decommissioning and removal work is carried out, please note the following: DANGER! The following instructions must be observed to prevent danger to life and limb or damage to equipment and other assets: •...

  • Page 74: S Torage

    • The PQC is held in place against the rear of the cabinet front wall by four retaining lugs in the corners of the instrument. These can be released by turning the retaining screws (accessible from the front) anticlockwise with a screwdriver.

  • Page 75: D Isposal

    They must be handed in at special recycling centres. One way of ensuring environmentally sound disposal is to return the instruments to Schrack Technik or the company's local representatives. Alternatively, the instruments can be given to a firm specializing in the recycling of electronic equipment.
  • Page 76 The ambient temperatures must always be within the range specified in the technical data. 12.1T ROUBLESHOOTING Faults during operation If disruptions occur during operation of the PQC, the following table provides assistance in identifying and remedying the faults. Fault Possible cause Remedial action PQC not working;...
  • Page 77 Despite inductive load, no When Check the PQC programming and change if stages are switched on programmed, c/k, switching necessary. when PQC is in automatic time delay, or discharge time mode. have been set too high. In automatic operation, the...
  • Page 78 13 Scope of supply 1 PQC instrument 4 different male connectors, supplied loose 1 operating manual...
  • Page 80 MAN_PQC_EN_2017_06 V6.0 2017_06...

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