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Summary of Contents for Swegon BlueBox Kappa Sky
- Page 1 Kappa Sky Installation, use and maintenance manual 16-02-2021...
- Page 2 THANK YOU Thank you for choosing our product. It is the result of many years’ experience and careful design and has been built with first-class quality materials and advan- ced technologies. Declaration or certificate of conformity also guarantees that the equipment meets the requirements of the European Machi- nery Safety Directive.
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Page 3: Table Of Contents
Contents Introduction Conformity Description 1.2.1 Symbols 1.2.2 Labels Safety General safety precautions 2.1.1 Discharge of the safety valves 2.1.2 Emergency stop Basic rules 2.2.1 Water flow rate at the heat exchangers 2.2.2 Water composition 2.2.3 Minimum water content in the system 2.2.4 Installing the flow switch 2.2.5... - Page 4 Unintended use Control and safety devices Principles of operation Structure Specifications Control panel 5.7.1 Switching the unit on/off 5.7.2 Change of set point in cooling operating mode Wiring diagram Installation Dimensions and weight Installation site Installation 6.3.1 External positioning 6.3.2 Anti-vibration mounts 6.3.3 Noise attenuation...
- Page 5 Temporary stop Stop for long periods of time Maintenance Adjustments External cleaning 8.2.1 Cleaning traditional finned coils in Cu/Al 8.2.2 Cleaning the microchannel coils 8.2.3 Cleaning e-coated microchannel coils Internal cleaning 8.3.1 Cleaning the unit 8.3.2 Cleaning the plate heat exchangers Periodic checks Unscheduled maintenance 8.5.1...
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Page 6: Introduction
INTRODUCTION 1.1 Conformity With regard to relevant regulations and directives, see the declaration of conformity that is an integral part of the manual. 1.2 Description 1.2.1 Symbols A description of the main symbols used in this manual and on the labels affixed to the unit is given below. Danger symbol;... -
Page 7: Labels
1.2.2 Labels For the constructional features, available models and technical data, please refer to the Technical Catalogue. The model, serial number, features, power supply voltage and so on are shown on the labels affixed to the unit (the following illustrations are shown only as an example). The Manufacturer adopts a continuous development policy and, in this perspective, reserves the right to make changes and improvements to the documentation and to the units without prior notice. -
Page 8: Safety
SAFETY 2.1 General safety precautions Access to the area around the unit must be prevented by special guarding where this is positioned in a location that is not protected and can be reached by unqualified persons. The equipment operator is responsible for complying with regulatory obligations. The equipment operator is the person who has actual control over the technical operation and free access, which means the possibility of monitoring its components and their operation and the possibility of granting access to third parties. -
Page 9: Discharge Of The Safety Valves
In units with capacitors and/or inverters, certain components can remain live for several minutes even after having turned off the main switch. Wait 10 minutes before working on the electrical parts of the unit. Circuits supplied from external sources (made with orange cable) can remain live even after the power sup- ply to the unit has been turned off. -
Page 10: Basic Rules
2.2 Basic rules All the units are designed and built in compliance with Directive 2014/68/EU of the European Parliament and of the Council of 15 May 2014 on the approximation of the laws of the Member States relating to pressure equipment. To ensure maximum safety, in order to prevent possible risks, follow the instructions below: - this product contains pressurised vessels, live components, moving mechanical parts and very hot and cold surfaces that, in certain situations, can pose a risk: all maintenance work must be carried out by skilled personnel equipped with... -
Page 11: Water Flow Rate At The Heat Exchangers
2.2.1 Water flow rate at the heat exchangers It is necessary to ensure that the water flow rate during operation is no higher than 1.5 times and no lower than 0.5 times the nominal flow rate of the unit stated in the Technical Catalogue. In any case, refer to the specific Technical Catalogue for the allowed conditions for water flow in and out of the exchangers. -
Page 12: Minimum Water Content In The System
2.2.3 Minimum water content in the system For correct operation of the unit, it is necessary to ensure a buffering on the system such as to comply with the minimum operating time considering the greater between the minimum OFF time and the minimum ON time. In short, these contribute to limiting the number of times the compressors are switched on per hour and to preventing un- desired deviations from the set point of the delivered water temperature. -
Page 13: Installing The Flow Switch
2.2.4 Installing the flow switch Normally, a differential pressure switch is installed between the inlet and outlet of the evaporator in the unit. A flow switch, that must be connected by the installer, can be supplied as accessory. The installed flow switch is provided with a 1” male connector. The unit must be installed following the arrow that shows the direction of flow. -
Page 14: Operation With Water To The Evaporator At Low Temperature
2.2.5 Operation with water to the evaporator at low temperature With temperatures below 5°C, it is mandatory to work with water and anti-freeze mixtures, and also change the safety devi- ces (anti-freeze, etc.), which must be carried out by qualified authorised personnel or by the manufacturer. The glycol percentage by weight is determined based on the desired temperature of the chilled water (see table). Minimum ambient temperature or liquid outlet temperature (°C) Freezing point (°C) -
Page 15: Hydraulic Connection To The Heat Recuperator (Dc Option)
2.2.6 Hydraulic connection to the heat recuperator (DC option) The heat recuperator must be connected to a closed hydraulic circuit. Constant renewal of water causes limescale to build up in the exchanger, which reduces its efficiency in a short time and makes it unserviceable. All units equipped with heat recuperator have water temperature control probe on the return from the system. -
Page 16: Hydraulic Connection To The Desuperheater (Ds Option)
2.2.7 Hydraulic connection to the desuperheater (DS option) The heat desuperheater must be connected to a closed hydraulic circuit. Constant renewal of water causes limescale to build up in the exchanger, which reduces its efficiency in a short time and makes it unserviceable. Part of the heat rejected in the condenser can be recovered with a “desuperheater”... -
Page 17: Condensate Drain (Only For Heat Pump Units)
2.2.8 Condensate drain (only for heat pump units) All the units in heat pump version are equipped, at the base of each condensing/evaporating coil, with a condensate col- lection tank with drain holes. The units are supplied with two drain fittings for each condensing/evaporating coil. These drain fittings can be adjusted freely and can be connected (by the customer) with appropriate drain pipes (e.g. -
Page 18: Refrigerant Leak Detector
2.2.9 Refrigerant leak detector A refrigerant leak detector with semiconductor sensor can be installed on the units. This device allows immediate detection of refrigerant leaks, with a warning or with stopping of the unit in pump down, de- pending on how it is managed. The installation of the device is in line with European F-GAS regulations and USA ASHRAE regulations. -
Page 19: Noise
2.3 Noise The starting of the unit, with activation of its components, emits a noise whose intensity varies depending on the operating level. The correct location choice and the correct installation prevent the unit causing annoying noise due to resonances, reflections and vibrations. -
Page 20: Safety Information On The Refrigerant Fluid
2.5 Safety information on the refrigerant fluid This product contains fluorinated greenhouse gases included in the Kyoto protocol. Do not release these gases into the atmosphere. Type of refrigerant: R513A. GWP value: 573. Based on "IPCC Fifth Assessment Report". Type of refrigerant: R134a. GWP value: 1300. Based on "IPCC Fifth Assessment Report". GWP is the global warming potential. -
Page 21: Receiving The Product And Storage
RECEIVING THE PRODUCT AND STORAGE 3.1 Reception On receiving the unit, check that it is undamaged, bearing in mind that it left the factory in perfect condition. Report any signs of damage immediately to the transporter and make a note of these on the Delivery Sheet before signing The relevant sales department or the manufacturer should be informed of the extent of the damage as soon as possible. -
Page 22: Handling
3.3 Handling Before each unit handling operation, check that the lifting capacity of the machinery used is compatible with the weight of the unit. Handling must be carried out by adequately equipped qualified personnel. In all lifting operations, make sure the unit is firmly secured in order to prevent accidental falls or overturning. Lifting must be carried out by qualified and authorised personnel taking the necessary precautions;... -
Page 23: Storage
Tie the ropes so that they cannot come off during the manoeuvre. After positioning, the lifting brackets can be removed. If they have to be installed again, tighten the screws to a torque of 200 Nm. Fig. 5 Handling the unit with lifting brackets 3.4 Storage There are no special requirements if the unit has to be stored temporarily before installation. -
Page 24: Ecodesign Conformity
ECODESIGN CONFORMITY 4.1 Documentation supplied with the product Listed below are the documents supplied with the machine according to its type, with particular reference to conformity with Directive 2009/125/EC of the European Parliament and of the Council, of 21 October 2009, regarding the establishment of a framework for drafting specifications for the eco-friendly design of energy-related products, and relevant Regulations (hereinafter "Ecodesign"). -
Page 25: Partly Completed Machine
4.1.3 Partly completed machine Units for which conformity with the Ecodesign Directive must be related to a 'partly completed machine plus remote heat exchanger' system. Otherwise, the unit conforms to all EC requirements. All the points described in the first paragraph apply, with the exceptions stated below. The EC Declaration is not accompanied by Attached Documents Conformity with the Ecodesign Directive depends on the combination of partly completed machine plus remote heat exchan- ger and is therefore the responsibility of the person who makes the selection and combination at the installation stage. -
Page 26: Conformity Of The Application
4.2 Conformity of the application The applications allowed as regards the documentation supplied with the unit are indicated below. This applies only in the case of units intended for installation and operation in the European Union. The customer is required to select the unit with regard to the expected operating condition and the Ecodesi- gn conformity required for that condition. -
Page 27: Product Description
PRODUCT DESCRIPTION 5.1 Intended use These units are made for cooling and/or heating (heat pump version) heat-carrying fluid and they are generally used in applications in the air conditioning and refrigeration sector. Their use is recommended within the operating limits indicated in the Technical Catalogue. Use outside the operating limits stated in the Technical Catalogue will cause the unit to stop. -
Page 28: Control And Safety Devices
5.3 Control and safety devices The unit is integrally managed by an electronic microprocessor control that, through the various temperature and pressure sensors installed in the unit, keeps its operation within the safety limits. All the parameters involved with control of the unit are shown in the “Control Manual” that is an integral part of the docu- mentation of the unit. -
Page 29: Control Panel
5.7 Control panel The unit is integrally managed by an electronic system with microprocessor, having a graphic display as interface. The display can be used to access all the functionalities of the unit starting with the setting of the parameters and manage- ment and analysis of any problems. -
Page 30: Wiring Diagram
5.8 Wiring diagram The wiring diagram is an essential part of the documentation and is present inside each unit. It is essential to refer to this document if you are unsure about anything or need further explanations regarding the auxiliary electrical connections and power connections as well as for the electrical specifications. -
Page 31: Installation
INSTALLATION During installation or whenever work must be carried out on the unit, it is essential to strictly follow the instructions in this manual, comply with the directions on the unit and in any case take all necessary precautions. The pressures in the refrigerant circuit and the electrical components can create risky situations during installation and maintenance work. -
Page 32: Installation
6.3 Installation The units are shipped from the factory already tested and only need electrical and hydraulic connections for installation. 6.3.1 External positioning A solid base on which to position the unit must be created. This base must be perfectly flat and horizontal. Its dimensions must be adequate for those of the unit. The slab must be: - made in a suitable foundation about 15-20 cm higher than the surrounding ground;... -
Page 33: Anti-Vibration Mounts
6.3.2 Anti-vibration mounts In order to reduce vibrations transmitted to the structure, it is advisable to install the unit on rubber or spring anti-vibration mounts, supplied as an accessory and to be requested when placing the order. The dimensional diagram with footprint shows the position and load of each anti-vibration mount. The anti-vibration mounts must be fixed on before positioning the unit on the ground. -
Page 34: Noise Attenuation
6.3.3 Noise attenuation The units are designed and built paying particular attention to keeping down noise emission during operation. In addition to the standard versions, there are “LN” (Low Noise) and “SLN” (Super Low Noise) versions for which further devices are used for lower noise emission. Correct installation for both the place and the components, as shown in the relevant chapter, prevents resonances, reflections and vibrations that can be particularly bothersome. -
Page 35: Hydraulic Connections
6.4 Hydraulic connections When preparing to connect the hydraulic circuit for the evaporator (refer to the diagrams included in the manual), it is good practice to comply with the following instructions and in any case to follow national or local regulations. Fit the pipes to the unit using flexible couplings in order to prevent transmission of vibrations and compensate thermal expansion. - Page 36 Fig. 8 Recommended hydraulic circuit Evaporator Water filter Thermometer Motor-driven pump Flow switch Flexible coupling System filling unit Water pressure gauge Valve Safety valve Storage tank Air valve Expansion vessel Check valve It is essential for the water to come in at the connection indicated in the dimensional diagram and with the relevant label on the unit.
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Page 37: Electrical Connections
6.5 Electrical connections All electrical operations must be carried out by personnel having the necessary legal requirements, and trained and infor- med on the risks connected with these operations. The sizing and characteristics of the power lines and relevant components must be determined by staff qualified to design electrical systems, following the international and national regulations of the place of installation of the units in conformity with the regulations in force at the time of installation. -
Page 38: Commissioning
COMMISSIONING 7.1 Preliminary operations Make sure the main disconnect switch is in the OFF position. In units with pumps, their power supply is mechanically locked. Restore functional conditions only on starting. If the pumps of the unit are not locked, electrically isolate them by operating the protective devices, to pre- vent automatic starting, in the event of antifreeze function activation, during the preliminary operations. -
Page 39: Checking The Pre-Charge Of The Expansion Vessel
The heaters in the compressor crankcase are switched on when the master disconnect switch is closed: this must be done at least 12 hours before starting the unit. To check that the heaters are working correctly, check that the lower part of the compressors is hot and in any case at a temperature of 10 - 15 °C above ambient temperature. -
Page 40: Checking The Volume Of The Expansion Vessel
7.1.2 Checking the volume of the expansion vessel As the pre-charge pressure increases, the maximum volume of the system supported by the expansion vessel supplied as standard, decreases. where - VI: volume of the system supported by the expansion vessel [l] - VVE: volume of the expansion vessel [l] - Ce: expansion coefficient of water - pVE: pre-charge pressure of the expansion vessel [barg] - pVS: calibration pressure of the safety valve [barg]... -
Page 41: First Starting
7.2 First starting When the unit is started for the first time, some important tests and checks must be done. 7.2.1 Hydraulic tests So that the unit can operate, the external OK signal device must be closed (refer to the wiring diagram provided with the unit). -
Page 42: Functional Tests
7.2.3 Functional tests With the starting of the unit, a few seconds after the starting of the pump, if managed by the control, the compressors will start according to the request of the thermoregulation. After a few hours of operation of the compressors, check that the liquid sight glass has a green ring: if it is yellow, there is moisture in the circuit. -
Page 43: System Testing
7.3 System testing Specific logics have been developed according to which the controller manages the hydraulic systems connected to the unit. The management logics are intended to increase system efficiency and save energy for water circulation at the same time. With the help of these logics, the circulating water fulfils the demands of the system, without exceeding the design flow rate limits and without jeopardising correct operation of the cooling unit. - Page 44 The pump operating speed percentage in free cooling units must be set up both when free cooling is enabled and when it is not. The operator has to repeat the manual procedure to find the pump operating speed with the free cooling valve open and then closed.
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Page 45: Flowzer Dt
7.3.2 Flowzer DT The “DT” function is designed to change the pump speed in order to have a constant temperature difference between the unit inlet and outlet. The resulting effect is that the temperature of water supplied to the system is constant. When the load is reduced, the water flow rate is reduced accordingly, which results in consumption saving. - Page 46 7.3.2.1 Setting the operating setpoint difference The units are shipped from the factory with a setpoint difference value of 5°C. The procedure below explains how to edit the factory value. - go to the main screen and press the arrow right button; - click the arrow down button to select the “Flowzer” function and then press “Enter” to confirm; - Press the button “SET”...
- Page 47 - Vmin = minimum water volume in the system/plant - UL = limit of the supply. If the operating logic of the secondary circuit includes stopping of the water flow rate, the capacity of the buffer tank must be sized against the min. volume of water required for unit operation. If user points with 3-way valves are installed in the system and water is circulated to the secondary circuit, the capacity of the buffer tank can be reduced.
- Page 48 The abbreviations present in the diagram indicate: - A2 = cooling unit controller - BT1 = unit input temperature sensor - BT2 = unit output temperature sensor - EU = heat exchanger in cooling unit - BP41= differential pressure sensor; - ΔPex = pressure difference at the ends of the unit;...
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Page 49: Flowzer Vde
7.3.3 Flowzer VDE The “VDE” function is used to set the speed of the pump to such level that the pressure difference between the unit inlet and outlet is kept constant and the water flow rate is consequently kept constant. The speed of the pump is set automatically to preserve the desired flow through the heat exchanger in the unit. This function is useful when the head of the pump aboard the unit is greater than the system requires, which would result in a higher water flow circulating. -
Page 50: Flowzer Vd
7.3.3.1 Editing the operating pressure difference in the unit The procedure below explains how to edit the factory value. - go to the main screen and press the arrow right button; - click the arrow down button to select the “Flowzer” function and then press “Enter” to confirm; - Press the button “SET”... - Page 51 - Y3V = 3-way valve servo controls - Vmin = minimum water volume in the system/plant - UL = limit of the supply. This type of system requires that the min. water flow rate is also guaranteed when there is no load. This is made possible through the installation of 3-way valves on the user points.
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Page 52: Flowzer Vfpp
7.3.5 Flowzer VFPP The “VFPP” function is designed to control variable flow systems to the primary circuit. The system keeps stable the difference in the water pressure and temperature in the system delivery line as the demand changes. The water flow rate and temperature are independent variables and not directly connected. Control of the “single pump in the system”... - Page 53 - Vmin = minimum water volume in the system/plant - UL = limit of the supply. 7.3.5.1 Setting the operating setpoint difference Below is the procedure to be followed to edit the pressure difference setpoint. - go to the main screen and press the arrow right button; - click the arrow down button to select the “Flowzer”...
- Page 54 Letter “L” appears in the first screen of the Flowzer menu to indicate that the value ΔPex is lower than the setpoint stored in parameter “PA22”. If the value ΔPex is higher than the setpoint stored in parameter “PA55”, letter “H” appears in this position, instead of “L”. 7.3.5.4 Checking the minimum flow rate Progressively close all the user points and check that the pump speed slows progressively.
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Page 55: Flowzer Vps
7.3.6 Flowzer VPS The “VPS” function modulates the flow rate to the primary circuit following the flow of the secondary circuit, taking as re- ference the difference in the water temperature measured between the outlet of the primary circuit and the bypass pipe. Water flow rate control in the primary circuit always takes place within the limits set for correct operation of the refrigerant unit. - Page 56 7.3.6.5 Setting the operating setpoint difference The value stored in the operating temperature difference parameter, as set at the factory, is the result of our experience with different systems. An incorrect value will eventually reduce the setting efficiency. Below is the procedure to be followed to edit the temperature difference setpoint. - go to the main screen and press the arrow right button;...
- Page 57 Letter “L” appears in the first screen of the Flowzer menu to indicate that the value ΔPex is lower than the setpoint stored in parameter “PA22”. If the value ΔPex is higher than the setpoint stored in parameter “PA55”, letter “H” appears in this position, instead of “L”. We reserve the right to make changes without any prior notice.
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Page 58: Calibration Of Safety Components
7.4 Calibration of safety components Any work on the unit must be carried out by qualified authorised personnel. Incorrect calibration values can cause serious damage to the unit and harm people. The control and safety equipment is calibrated and tested in the factory before the unit is shipped. However, after the unit has been started, the safety devices must be checked (only the high and low pressure switches). -
Page 59: Checks During Operation
7.5 Checks during operation With the circuits operating at 100% and stable at working conditions near the nominal ones, check: - that the electrical absorption of the unit is close to the data shown in the wiring diagram. Considerably different values may be due to the reduced capacity operation of the unit, at working conditions very different from nominal ones, or to the malfunctioning of one or more components. -
Page 60: Alarms And Malfunctions
7.6 Alarms and malfunctions Possible malfunctions will trigger the protective devices and safety devices of the unit before serious faults occur. All the “warnings” and “alarms” are recorded in the memory of the control and displayed on the display of the unit. Before resetting an alarm, the cause that triggered it must be found and eliminated. - Page 61 SYMPTOM LIKELY CAUSE POSSIBLE SOLUTION Check that the high pressure switches Opening of the valve due to failure of are working and, if necessary, replace Presence of oil on the discharge of the the protective devices to operate. them. safety valve. The valve must be replaced.
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Page 62: Temporary Stop
7.7 Temporary stop The stopping of the unit for a few hours in the day “during non-working hours” or for a few days “over the weekend” is con- sidered temporary. The unit must be stopped using the display of the control, the external OK signal or via serial if included. During the temporary stop, the unit must be powered correctly. -
Page 63: Maintenance
MAINTENANCE All the operations described in this chapter must always be carried out by qualified and authorised person- nel. Before carrying out any work on the unit or accessing internal parts, make sure you have turned off the power supply to it. The compressors and delivery pipes are very hot. -
Page 64: External Cleaning
8.2 External cleaning The component of the unit that needs most care is the finned pack heat exchanger. It is essential to keep it clean and free of dirt and/or deposits that can hinder or prevent air flow. Regular cleaning of the surface of the coil is essential for the unit to work correctly and also increases the operating life of the exchanger and the unit. -
Page 65: Cleaning The Microchannel Coils
8.2.2 Cleaning the microchannel coils Microchannel coils must be cleaned regularly (see Periodic checks section) Routine and documented cleaning is a necessary condition for maintaining the warranty on the coils. In addition to the required periodic cleaning, if the unit is used seasonally, we strongly recommend cleaning the microchannel coils at the end of seasonal use, so that no residues remain on the coils, and then again before starting the unit. -
Page 66: Cleaning E-Coated Microchannel Coils
8.2.3 Cleaning e-coated microchannel coils Microchannel coils must be cleaned regularly (see Periodic checks section) Routine and documented cleaning is a necessary condition for maintaining the warranty on the coils and on the e-coated treatment. In addition to the required periodic cleaning, if the unit is used seasonally, we strongly recommend cleaning the microchannel coils at the end of seasonal use, so that no residues remain on the coils, and then again before starting the unit. -
Page 67: Internal Cleaning
8.3 Internal cleaning It is essential to keep the installation site clean and tidy for correct maintenance of the unit and to keep it in good working order. 8.3.1 Cleaning the unit Keep the inside of the electrical control panel and (where present) the compressor compartment clean. After working on the unit, always clean the electrical control panel of any work remnants and extraneous components. -
Page 68: Cleaning The Plate Heat Exchangers
8.3.2 Cleaning the plate heat exchangers Thanks to the generally very high level of turbulence, in plate heat exchangers, a self-cleaning effect takes place in the channels. However, in some applications the tendency to scaling and/or the formation of deposits in the heat exchanger can be very high (e.g. -
Page 69: Periodic Checks
8.4 Periodic checks Carry out periodic checks to make sure the unit is working correctly: RECOMMEN- OPERATION DED FREQUEN- Check the operation of all the control and safety equipment as described previously. Monthly Check the tightness of the electrical terminals in the electrical control panel and in the terminal bo- ards of the compressors. -
Page 70: Unscheduled Maintenance
8.5 Unscheduled maintenance After correctly starting-up and carrying out the relevant checks, the units normally do not need any intervention by the cu- stomer service in order to check the charge of the refrigerant gas. 8.5.1 Special work With use of the unit, particular situations may occur that require work to be carried out promptly. Even in an emergency, work on the unit must be carried out by skilled personnel in safe conditions. -
Page 71: Decommissioning
DECOMMISSIONING With reference to the European waste management directive, we inform you of the following: - The owner of electrical and electronic equipment (EEE) is obliged not to dispose of it as non-separated municipal waste, and must dispose of it via separate collection through public or private waste collection systems as required by local regulations. - Page 72 Page intentionally blank Translation from original instructions We reserve the right to make changes without any prior notice.
- Page 73 Page intentionally blank We reserve the right to make changes without any prior notice. Translation from original instructions...
- Page 74 Page intentionally blank Translation from original instructions We reserve the right to make changes without any prior notice.
- Page 75 Page intentionally blank We reserve the right to make changes without any prior notice. Translation from original instructions...
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