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Loepfe YarnMaster Zenit Instruction Manual

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YARNMASTER
®
ZENIT
Instruction Manual
LZE
044843.003en

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Summary of Contents for Loepfe YarnMaster Zenit

  • Page 1 YARNMASTER ® ZENIT Instruction Manual 044843.003en...
  • Page 3 All rights reserved. No part of this may be repro duced in whatever form (by printing, photocopying, microfilm or other) without a written grant of Loepfe Brothers Ltd., nor may it be processed or distributed by any electronic mean.

  • Page 5: Table Of Contents

    Yarn Fault Classification Yarn Clearing Foreign Matter (F) Synthetic Foreign Matter (P) Variable CV Channel (VCV) Imperfections Surface Index SFI YarnMaster Zenit Functional Range Operating Central Unit User Interface Defining the Clearer Parameters Defining the Class Settings Assigning Changed Settings...
  • Page 6 TABLE OF CONTENTS Group Class Data Samples Class Clearing Data F Clearing Data Splice Classification Data Style (Style Memory) Base Settings Chart Repetitions Pilot Spindles Shift Calendar Data Acquisition Reset Data Diagnosis Diameter Base (Group) AWE Zenit State / Adjust Parameters Fine Adjust AWE Command Special Functions...

  • Page 7: Safety Instructions

    SAFETY INSTRUCTIONS Safety Instructions Norms and Regulations The LOEPFE YarnMaster Zenit yarn clearing system is a prod- uct which has been inspected for technical safety. It complies with the following directives: 2006/42/EC Machinery Directive 2006/95/EC Low Voltage Directive 2004/108/EC Electromagnetic Compatibility...

  • Page 8: Operational Notes

    SAFETY INSTRUCTIONS Operational Notes This yarn clearing equipment must only be installed, initiated and operated by trained personnel. Improper operation of the equipment could cause hazards. In accordance with 2006/42/EC, 2006/95/EC, 2004/108/EC this yarn clearing installation should only be operated with the covers closed (cooling, fire protection, contamination, spark interference etc.) This yarn clearing equipment must only be operated with...

  • Page 9: Yarn Clearing (General)

    YARN CLEARING GENERAL Yarn Clearing (General) Definition of Yarn Faults The spinning process supplies a relatively uniform yarn. However, differences in yarn diameter cannot be completely avoided. Thus, it is first necessary to distinguish between normal yarn irregularities and actual yarn faults. Yarn faults may be defined as yarn irregularities which can lead to difficulties in subsequent production stages or to faults in the end product.
  • Page 10 YARN CLEARING GENERAL Accumulations of Faults (Cluster) ƒ Periodic clusters (moiré) Periodic ƒ Non-periodic clusters Non-periodic in the short, long or thin fault range which repeat them- selves several times within a short distance. Off-standard Bobbins (SFI / D) Hairiness Irregularities of the surface structure such as: Neppiness ƒ...

  • Page 11: Yarn Fault Classification

    YARN CLEARING GENERAL Yarn Fault Classification Figure 1 Yarn faults are defined in terms of a transverse dimension and a longitudinal dimension. The transverse dimension is ex- pressed as a multiple of the base diameter and the longitudinal dimension in centimeters. The definition of yarn faults in terms of length and thickness suggests the representation of yarn faults in a Cartesian sys- tem of coordinates.

  • Page 12: Yarn Clearing

    YARN CLEARING GENERAL Figure 4 Neps Thick places / Short faults As already mentioned, various types of yarn faults are distin- guished according to their form. In the plane of coor dinates it is possible to distinguish areas which relate to the following types of faults (see figure 4).
  • Page 13 YARN CLEARING GENERAL Clearer Characteristics Clearer characteristics are the basic pattern of the base curve, this pattern being typical of a particular clearer type. Impor- tant factors in assessing a clearer are the shape of this base curve on the one hand, and the possibility of changing this curve on the other hand.
  • Page 14 YARN CLEARING GENERAL Short Fault and Long Fault Combined Exact inspection of a yarn fault shows that it changes along Characterized as short the longitudinal dimension. A thick place is made up of a com- when cleared according to channels bination of different thickenings.

  • Page 15: Foreign Matter (F)

    YARN CLEARING GENERAL Foreign Matter (F) The classification of foreign matter is based on the evaluation of differences in contrast. Dark Foreign matters are classified as follows: The length class- es on the horizontal axis are divided into S–I–R–O, the dark- ness levels on the vertical axis into 1–2–3–4.

  • Page 16: Imperfections

    YARN CLEARING GENERAL Imperfections Frequent yarn faults are described as Imperfections in the 0.5 1 8 cm language of the textile industry. It is generally acknowledged D 5.00 that the shorter the fault length, or the smaller the diameter deviation respectively, the more frequent the event. D 3.20 D 2.30 The source of these faults is found in the raw material or in a...

  • Page 17: Yarnmaster Zenit

    FUNCTIONAL RANGE YarnMaster Zenit Functional Range P Clearing – Clearing of Synthetic Foreign Matters PP PE etc. F Clearing – Foreign Matter Class Clearing dark and bright – Foreign Matter Cluster Clearing LabPack (Option) – Imperfections IPI – Surface Index SFI –...

  • Page 18: Operating

    OPERATING 2 2 2 Operating Central Unit Touch Screen USB Port The central unit is operated by direct inputs on the touch- USB port to transfer reports and clearer data to a server and screen. Applying light pressure on the screen surface acti- printer.

  • Page 19: User Interface

    OPERATING User Interface Menus (Overview) Input Fields / Display Fields Tapping the tabs in the header calls up the respective menus. The clearer settings and clearer data are displayed in groups. ƒ  /  More menus are called up via the left or right arrow. Dark yellow fields Clearer settings ƒ...
  • Page 20 OPERATING Edit Field Info Print Menu navigation. Further steps to be performed are displayed The clearer data or clearer settings of the open menu can be as input assistance. saved to a USB flash drive and printed as PDF. Data Source Group / Edit ƒ...

  • Page 21: Defining The Clearer Parameters

    OPERATING Defining the Clearer Parameters Defining the Class Settings Tapping a clearer setting opens the input window and the By tapping the Class Settings window, the window is dis- clearer settings can be changed. The selected input field is played in an extended mode. The class settings can then be now highlighted blue.

  • Page 22: Assigning Changed Settings

    OPERATING Assigning Changed Settings Assigning the Settings When the input window was quit with OK, the message “As- sign to group or style” is displayed in the Info field. • Tap the Assign button. The message “Choose group or style and assign or quit”...

  • Page 23: Print

    The clearer data or clearer settings of the open menu can be saved to a USB flash drive and printed as PDF. Make sure that the USB stick is virus-free. LOEPFE assumes no liability for possible damage to the system (loss of data etc.) that could be caused by viruses! •...

  • Page 24: Adjust

    OPERATING Adjust Initial Startup / Change of Software Putting into Operation / Lot Change To compensate for the deviations of the individual spindles, When putting the system into operation and for every lot an automatic Spindle Adjust on all spindles is performed change, it must be defined how the yarn to be wound is to be during the first adjustment after the startup of the equipment cleared, i.
  • Page 25 OPERATING Adjust process Display on the Adjust Button Start adjust / Quit The Adjust process calibrates the clearer for the yarn to be wound. Adjust must be performed with The Adjust button was tapped. utmost care since it affects the clearing quality. •...

  • Page 26: Dialog

    Hardware Installed central unit (LZE-II / LZE-III) sensing head types, enabled clearer options. Software Installed software version Interface Installed bus (Loepfe bus / 5-wire bus) AWE Installed AWE version Language IP Adresse 0 / 1 One each per Ethernet card. Required for identification in the network (communication with The desired user language can be selected.

  • Page 27: Access Level / Password

    DIALOG Access Level / Password Changing the Password To prevent the modification or deletion of data by unauthor- ized persons, data inputs are protected with passwords. During the startup, the foreman password is 1291, the opera- If a menu item is tapped which is protected with a password, tor password is 4711.

  • Page 28: Configuration

    CONFIGURATION Configuration Alarm Display Basic system settings. Selection of alarms to be displayed in a message box. System ƒ No alarms are displayed None CheckLen Splice ƒ All alarms are displayed ƒ Technical Only the technical alarms are displayed: Yarn length with which the splice check is performed after System Alarm, Offline, etc.
  • Page 29 AWE type and the sensing head If only AWE Zenit is displayed, this means that an type. AWE with an older, incompatible software ver- sion was used on this spindle! In this case, Loepfe can no longer guarantee the correct function of the equipment! ZENIT...

  • Page 30: Group

    GROUP Group The working range for a maximum of 12 different lots can be determined. • Select the group. • Enter the first and the last spindle of the working range. • Enter or change style and/or lot names via the alphanu- meric keyboard.

  • Page 31: Samples

    GROUP Samples Sections Groups Section 1 01-60 / AWE Zenit L2 / TK Zenit FPC Group 1 01-60 / TK Zenit FPC (subdivision possible) Section 1 01-60 / AWE Zenit L2 / TK Zenit FC Group 1 01-60 / TK Zenit FC (subdivision possible) Section 1 01-60 / AWE ZenitL2 / TK Zenit C Group 1 01-60 / TK Zenit C...

  • Page 32: Style (Style Memory)

    STYLE Style (Style Memory) • Up to 20 styles with the associated clearer settings can be Call up the Style menu. • Style List saved in the (Style memory). Select Style 9. • Name Enter “Titlis” under via the alphanumeric keyboard and confirm with OK.
  • Page 33 STYLE Copying a style to a group If a style was copied to a group, a window to enter or change the lot name is displayed. After copying a style to a group, the Yarn Structure menu is automatically called up. An adjustment has to be performed on this group.

  • Page 34: Base Settings

    BASE SETTINGS Base Settings Repetitions NSLT Startup / F Startup / P Startup It must be defined how often the exceeding of the limiting value is tolerated (0 – 9). With these settings, the bobbins with frequent faults can be Off Count Short Off Count, the maximum...

  • Page 35: Pilot Spindles

    BASE SETTINGS Pilot Spindles ƒ At a yarn change (Adjust) the yarn reference value of the first Cone With the Cone setting, the data of each individ- Monitoring Data Class 80 m of yarn are measured and stored with the pilot spin- ual cone will be shown in the Data dles.

  • Page 36: Diameter Base (Group)

    BASE SETTINGS Diameter Base (Group) Fine Adjust Diameter Mode ƒ The determined diameter basis is shown after an Adjust pro- Single After a lot change, the yarn reference value is cess. This value is equivalent to the average yarn signal of measured by a number of pilot spindles.

  • Page 37: Special Functions

    BASE SETTINGS Special Functions Splice Check ON / OFF Reduction for a Cone Change Switching the splice check on and off. At a cone change, the limits for the long fault length (LL) and the thin place length (-L) are set to 2 m. The diameter limits Note : If the Splice Check is switched off, the...

  • Page 38: Configuration Codes

    The display area of the Foreign Matter Class window can be The configuration code may be changed only in selected: agreement with LOEPFE. The incorrect setting of the configuration code can have serious conse- ƒ Dark / Bright The “dark” and the “bright” area of the...

  • Page 39: Test Mode

    BASE SETTINGS Test Mode YarnMaster Zenit has a test mode for On the following systems, the machines must also be switched to test mode: ƒ Cut Type ƒ – M 21C D Class Class cuts ƒ – Espero i F Class Foreign matter class cuts –...
  • Page 40 BASE SETTINGS D Class / F Class Depending on the yarn fault to be examined, enter the num- ber of the corresponding class as per below shown Number Code tables. Class 35 Class 110 -0.7 1.60 -1.0 1.45 -1.5 1.30 -2.0 1.20 -3.0...
  • Page 41 BASE SETTINGS Display TK * Programstate Special It can be defined what the TK is to display after a cut/spindle start. (See also “7-Segment Display”, page 77) System Info : Default settings are marked with an asterisk (*). Adjust is running If required, these settings should be altered by in- Doffing (cone change) structed personnel only!

  • Page 42: Yarn Structure

    YARN STRUCTURE Coarse Yarn Limitation Yarn Structure Coarse Yarn Limitation During startup and lot change, the parameters for convention- al clearing according to channels have to be set. For coarse yarns, the Adjust process can determine a diame- ter base larger than 868 mV. This has the effect that the com- Channel plete setting range (measuring range) is no longer available.

  • Page 43: Off Count

    YARN STRUCTURE Off Count + Cuts /– Cuts These settings make possible the detection of false bobbins or yarn with a larger off-count deviation. The number of cuts due to a positive or negative deviation of the yarn diameter are listed separately. + DiaDiff /–...

  • Page 44: Yarn Count

    YARN STRUCTURE Yarn Count Short / Long / Thin Cluster Count These settings serve to detect clusters whose individual faults are nor mally tolerated because they are outside of the The wound yarn count is entered here as information. The clearing curve.
  • Page 45 YARN STRUCTURE Diameter Faults / Observation Length Yarn diameter setting range: These two settings define the limits of the accumulation den- sity to the length unit for the faults which are above the clus- Short (DS) 1.10 – 4.00 ter curve. Long (DL) 1.04 –...

  • Page 46: Sfi/D (Option)

    YARN STRUCTURE SFI/D (Option) + Limit /– Limit (%) Principle of the SFI/D Settings: Relative to the average SFI/D value of the yarn (reference), upper and lower limits are selected. When the current SFI/D value exceeds these When the set limit values (±5% to ±40%) are exceeded, i.e. limits, the clearer performs a cut and the defect ive yarn is as soon as the SFI/D value differs from the SFI/D refer ence, drawn off the cone.

  • Page 47: Vcv (Option)

    YARN STRUCTURE VCV (Option) Variable CV Channel + Cuts /– Cuts The clearer calculates continuously the VCV values from the The number of cuts due to a positive or negative deviation of yarn pieces with the set check length and compares these the yarn diameter are listed separately.

  • Page 48: Splice

    YARN STRUCTURE Splice The values set here are active during the first 25 cm, i. e. in the range where the splice runs through the sensing head. The splice check length is automatically set to 25 cm. It can be set in the range 0–120 cm as required. (See Configuration menu.) The splice check can be switched on and off in the...

  • Page 49: Mm Lot

    YARN STRUCTURE MM Lot These fields are active only when MillMaster is connected. Running / Stop Stopped / Start Running Stopped Current status of the lot: Current status of the lot: The data acquisition of the lot can be stopped with Stop. The data acquisition of the lot can be started with Start.

  • Page 50: Setting Examples (Standard Values)

    YARN STRUCTURE Setting Examples (Standard Values) Channel Cotton and blended yarns short-staple Insensitive setting DS=2.6 LS=1.6 DL=1.32 LL=60 -D=29% -L=70 Sensitive setting N=5.5 DS=2.2 LS=1.4 DL=1.26 LL=50 -D=22% -L=50 Very sensitive setting N=4.5 DS=2.1 LS=1.3 DL=1.20 LL=40 -D=17% -L=32 Long-staple yarns Insensitive setting DS=2.6 LS=2.3...

  • Page 51: Class Clearing

    YARN STRUCTURE Class Clearing Splice Class Settings Clearing according to classes allows the creation of com- pletely optional clearer characteristics. An advantage for fan- cy yarn, core-spun yarn etc. The splice class settings are active during each spindle start for the first 0–120 cm (CheckLen splice).
  • Page 52 YARN STRUCTURE Figure 1 Figure 2 Figure 3 Coarse Yarn Limitation If a diameter base higher than 868 mV is determined during adjustment, the class settings are tightened to the next class below the coarse yarn boundary line, if required and if already switched on.

  • Page 53: Foreign Matter (F)

    FOREIGN MATTER Dark Dark/Bright Foreign Matter (F) F Class Settings Foreign matter can be cleared only by classes. Normal The foreign matter detection requires the use of the sensing To specify foreign matter clearing, the mode must be heads TK YM ZENIT F or TK YM ZENIT FP activated ().

  • Page 54: F Cluster Settings

    TITEL FOREIGN MATTER F Cluster Settings With the Foreign Matter Cluster settings fault clusters can be detected which, as single faults, are usually not considered disturbing. If, however, the faults are repeated multiple times these selected F Cluster classes relative to the length unit. within a short distance, they are disturbing.

  • Page 55: P Settings

    The reference length is used to set the fault length of the for- wound must not be wet. eign matter to be detected. Note : Existing YarnMaster Zenit F equipment can be retrofit- Setting examples (Guide values) ted by mounting the P sensor on the sensing head.

  • Page 56: Monitoring Data

    MONITORING DATA Monitoring Data Cut Data The total of all cut faults or events relative to the length dis- Thin Cluster Cuts Thin place cluster cuts played in Declaration. F Cluster Cuts Foreign matter cluster cuts VCV Cuts Cut resulting from a deviation of the This data can be optionally viewed per spindle or group.

  • Page 57: Selection

    MONITORING DATA Selection Cut Declaration Mode Display mode can be selected. The data acquisition mode (Last, First, Cone) selected in the Production Base Settings menu is displayed. The data of the current production are displayed via the length Length (Window Length) specified in Cut Declaration (e.
  • Page 58 MONITORING DATA Last Cut Display Splice cut Channel Splice CH N S L T (Neps, Short, Long, Thin) Splice cut Class Splice CL N S L T (Neps, Short, Long, Thin) Channel cut Channel N S L T (Neps, Short, Long, Thin) Nonclassified channel cut [Channel] N S L T...

  • Page 59: Variable Cv (Option)

    MONITORING DATA Variable CV (Option) The clearer calculates continuously the VCV values from the The SFI is the sum signal of the protruding fibres of a yarn yarn pieces with the set check length and compares these within a measured length of 1 cm. with its floating mean value.

  • Page 60: Imperfections Ipi (Option)

    Diameter-related Imperfections: In addition to the frequent yarn faults (Neps, Thicks, Thins), YarnMaster Zenit also clas- In yarn fault classification, seldom and frequent yarn faults sifies the so-called very fre quent events (Small), the “small”...

  • Page 61: Class Data

    Classification per spindle Class Data Class Clearing Data YarnMaster Zenit classifies all yarn faults in every group and In case of classification per spindle, the last cut fault is also for every spindle. Faults of the yarn to be cleared are assigned shown in its respective class field.

  • Page 62: F Clearing Data

    CLASS DATA F Clearing Data Splice Classification Data YarnMaster Zenit F classifies all yarn faults in every group and The classification data are acquired in a special coarse clas- for every spindle. sification raster optimized for splices. No clearing data are displayed in class BS1. This is due to the For the first 0 –...

  • Page 63: Chart

    CHART Chart Scale Grafic representation of the cut data shown in the Data Item List in form of a bar chart. Full Range Scale from zero to the highest value of the dis- Blue bars The values are scaled to the set Window Length.

  • Page 64: Shift Calendar

    SHIFT CALENDAR Shift Calendar The shifts are recorded with the shift calendar. It is possible to record, print or not to record the production and clas- sification data of the shift. Example Monday Begin 1 06.00 / Acquire Begin 2 14.00 / Idle Data of shift 1 are recorded Begin 3 22.00 / Acquire Data of shift 2 are not recorded (Data are not saved)

  • Page 65: Diagnosis

    DIAGNOSIS Diagnosis AWE Zenit State / Adjust Parameters AWE Command Spindle Adjust This information is used exclusively by the service techni- When replacing an evaluation unit (AWE) or a sensing head cians or trained personnel. (TK), a reset must be performed on the AWE. Additionally, Spindle Adjust must always be performed on this winding unit.

  • Page 66: Reports And Diagnosis

    REPORTS AND DIAGNOSIS Reports and Diagnosis Configuration Depending on the setting in the menu, the textile, the technical, all or or none alarms are displayed with a message box on the screen. Hide The alarm message is hidden. Previous The previous alarm message is displayed. The displayed alarm message is deleted Clear Dialog...
  • Page 67 REPORTS AND DIAGNOSIS Technical Alarms Message Explanation / Cause Action Adjust failed, please repeat Adjustment was not possible Select different pilot spindles and repeat Adjust. on any of the pilot spindles. adjustment. Replace TK / AWE and repeat adjustment. Coarse yarn: Settings Diameter basis >...
  • Page 68 REPORTS AND DIAGNOSIS Message Explanation / Cause Action Light sensor for scanning the yarn diameter Clean optic. Spindle x : D Sensing Light out of tolerance. Start spindle briefly. out of Range Optic dirty. Replace TK, and perform Reset AWE. TK defective.
  • Page 69 REPORTS AND DIAGNOSIS Spindle Blocking - Display / Reset Machine Type Display on Winding Unit Reset Murata 21C Start switch is lit in yellow To start spindle: Turn the Start switch by 180 degrees Orion Spindle is lit in red (red light blinks) Alarm reset: Push black button Polar...

  • Page 70: Checks And Maintenance

    Checks and Maintenance General Weekly Sensing Heads TK The yarn clearing YarnMaster Zenit installation requires hardly any maintenance. Regular checks of the yarn clearing installa- Knife (Cut control) tion are vital, not only to examine the correct settings but also to assure its proper function.

  • Page 71: Cleaning The Optics

    Forbidden Substances Loepfe strictly declines any responsibility for dam- age claims resulting from the use of un suitable cleaning substances! The substances listed below must be avoided by all means, as their use will destroy the optical system: ƒ...

  • Page 72: Service Functions

    (Power ON) or call up the Dialog menu and select Reboot System. • System Monitor for LZE after it is displayed. Loepfe YM Zenit Monitor Service Screen window opens. Screen Calibration • Touch Screen Calibration Loepfe YM Tap the button in the Zenit Monitor Service Screen window within 30 seconds.

  • Page 73: Factory Reset

    Tap the button in the Service Screen window and continue with Yes. The factory reset is performed. • Exit the Loepfe YM Zenit Monitor Service Screen window with Exit. Select YM-System dialog field opens. • Select “Zenit” and confirm with OK.

  • Page 74: Clearer Components

    SERVICE FUNCTIONS CLEARER COMPONENTS AND FUNCTION Clearer Components Central Unit LZE-II Connection at the front side USB 1.1 port for transfer of reports to a PC / printer. Connections at the back side LAN 1 EARTH MOUSE 24V = COM 1 COM 2 USB 1 1 2 3...

  • Page 75: Central Unit Lze-Iii

    LAN 0 / LAN 1 RJ45 LAN 10 / 100 / 1000 USB 0 / USB 1 USB 2.0 USB Port LOEPFE 1 Sub-D, 9 pol plug 2/5-wire-bus LED red Compact Flash drive active LED green / red Power supply OK...

  • Page 76: Sensing Head

    SERVICE FUNCTIONS CLEARER COMPONENTS AND FUNCTION Sensing Head Sensing head without detection of foreign matter TK YM Zenit TK YM Zenit F Sensing head with detection of foreign matter TK YM Zenit FP Sensing head with detection of foreign matter and detection of synthetic foreign matter (e.g. PP, PE) 1.

  • Page 77: Sensing Head Display (7-Segment Display)

    Mounting of P-Sensors Tastkopf alle Sprachen 93x137.indd 1 6.10.2009 10:21:21 Uhr • Existing YarnMaster Zenit F equipment can be retrofitted by Replace cover with yarn guide plate Tastkopf alle Sprachen 93x137.indd 2 6.10.2009 10:21:21 Uhr mounting the P-Sensor onto the sensing head.

  • Page 78: Technical Data

    TECHNICAL DATA Technical Data (Changes reserved!) System Concept Modular, integrated in winder / Components individually replaceable / Power supply by winder Control station One control station per machine / Date and time indication / Data memory in case of power failure / Serial connection to industrial PC and to evaluation units Operating Setting of the conventional clearing parameters via touch screen...
  • Page 79 TECHNICAL DATA Conventional Clearing According to Channels ZENIT ZENIT F ZENIT FP Channel / Splice Channel Diameter limit for neps Diameter limit for short faults Limit for short fault length 1.0 cm 10 cm Diameter limit for long faults 1.04 Limit for long fault length 6.0 cm 200 cm...
  • Page 80 TECHNICAL DATA Data Acquisition ZENIT ZENIT F ZENIT FP Mode FIRST : Classification window stops at selected length (10–1000 km) Mode LAST : Floating window. Selected length (10–1000 km) Mode CONE: Group: Floating window. Selected length (10–1000 km) Spindle: The data are cleared when the length is reached Clearing of Synthetic Foreign Matter (PP, PE, etc.) ZENIT ZENIT F...
  • Page 81 Central Data Collection ZENIT ZENIT F ZENIT FP Data Collection with Loepfe MillMaster Central units can be linked with Ethernet Remote control of clearer parameter Central collection of quality data up to spindle level Central collection of production data up to spindle level...
  • Page 83 Loepfe Brothers Ltd. CH-8623 Wetzikon/Switzerland Phone +41 43 488 11 11 +41 43 488 11 00 info@loepfe.com www.loepfe.com...

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