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Heliocentris Nexa 1200 Instruction Manual

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Nexa® 1200
Instruction Manual

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Summary of Contents for Heliocentris Nexa 1200

  • Page 1 Nexa® 1200 Instruction Manual...
  • Page 2 Windows is a registered trademark of Microsoft Corporation in the USA and other countries. CAN-USB Converter is a trademark of PEAK-System Technik Gmbh, Germany HydroKnowz is a trademark of Neodym Technologies Inc. Nexa ® 1200 is a trademark of Heliocentris Academia International GmbH, Germany. We reserve the right to make changes.
  • Page 3 Content 1  About This Document ..................5  1.1  Notices and Symbols ....................5  1.1.1  Symbols ..................... 5  1.1.2  Warnings ....................6  1.1.3  Tips ......................6  1.2  Accompanying Documents ..................6  2  Safety Instructions ....................7  2.1  General Information on Safety & Responsibility ............7  2.2 ...
  • Page 4 Content 4.6.1  How to Connect the Load Relay ..............26  4.6.2  How to Connect the Reverse Current Diode ..........27  4.7  How to Install Safety Devices ................. 29  4.7.1  How to Install the Safety Chain ..............29  4.7.2  How to Connect the Equipotential Bonding Conductor ........ 30  4.8 ...
  • Page 5 Content 7.2  Storage and Transportation of the Nexa ® 1200 ............52  7.2.1  How to Disassemble the Hydrogen Supply........... 52  7.2.2  How to Shut Down the External Load ............53  7.2.3  How to Disconnect Electrical Contacts ............53  7.2.4  How to Disconnect Data Interfaces ............. 54  7.2.5 ...
  • Page 6 Content 11  Technical Data ....................81  11.1  Complete System ....................81  11.2  Startup Kit ......................82  11.3  Standards and Guidelines ..................83  11.4  PC Requirements ....................83  11.5  Abbreviations ....................... 84  Index ..........................85  Nexa® 1200 - Instruction Manual...
  • Page 7 About This Document If only the masculine or feminine form is used in parts of this manual, this is only used for readability and simplicity. Persons of the respec- tive other gender are always included. The operating manual is intended to help you use the product. It is structured as follows.
  • Page 8 About This Document action Instructions in a specific sequence Result of an action List Refers to a switch, key, button or icon WITCH Reference to further information Reference to page Table 1-1 Symbols in the instruction manual 1.1.2 Warnings The following warnings are used:  ...
  • Page 9 Safety Instructions In this chapter you will find information on the safe handling of the product. It is essential that you read and understand this chapter. General Information on Safety & Responsi- bility Danger of injury due to improper use! WARNING Improper use of the product can result in serious injuries. ...
  • Page 10 If an inverter is used, do not feed the current into the electric power grid. • Installation of the unit in a position other than horizontal. Components or products delivered by or purchased from Heliocentris are not approved for use in aeronautics or aerospace applications (including models). Hazards During Approved Use For proper handling of all chemical or hazardous substances, it is necessary to exercise appropriate care;...
  • Page 11 Safety Instructions Danger of injury due to explosion! DANGER Escaping hydrogen can ignite and burn the skin. Escaping hydrogen can reduce the oxygen content and cause  breathing difficulty.  Do not inhale hydrogen.  The lab must be equipped with a suitable ventilation system  for the use of hydrogen.  The lab must be equipped for hydrogen monitoring.  Avoid heat in the vicinity of the system and the hydrogen  source.  No smoking, no naked flames.  Comply with local safety regulations.  Comply with regulations for handling of compressed hydro‐ gen cylinders.  In the case of escaping gas, keep away and keep inflamma‐ ble materials away.  Prevent electrostatic charges.  Ensure proper installation of the hydrogen supply.  Check the hydrogen lines and connectors regularly for leak  tightness.  Comply with local safety regulations.  Electricity The unit poses no special electrical hazards as long as the following instructions are observed: Damage due to electricity! NOTICE...
  • Page 12 Safety Instructions The safety instructions and warnings listed in this instruction manual must be observed. The owner/operator is responsible for compliance with local safety regulations. Furthermore, the owner/operator is responsible for: • Proper installation of the hydrogen supply by a specialized company •...
  • Page 13 Safety Instructions • Persons who can demonstrate proof of training in chemistry, physics, electronics, electrical engineering or comparable qu- alifications and who are familiar with the local regulations for safe handling of hydrogen and who have experience in work- ing with hydrogen. Personnel must be familiar with and comply with the local ap- plicable accident prevention and safety regulations.
  • Page 15 Components ® Nexa 1200 is a complete fuel cell unit which, with an output voltage between 20…36 V and a maximum output current of 65 A, delivers a power output of 1200 W. The Nexa ® 1200 (also referred to as the unit) includes an air-cooled PEM fuel cell stack and the necessary peripheral components.
  • Page 16 Components Fig. 3-1 Nexa ® 1200 front side On the back there is a connection panel (1) with the connections for communication, control of external components and configuration of the unit. Below the connection panel are the power outputs and the hydrogen supply (2).
  • Page 17 Via the CAN interface the controller provides the process data for monitoring and analysis to the PC and/or the Heliocentris control and visualization unit Overall System Controller (OSC). 3.1.1...
  • Page 18 Components Nexa ® 1200 Startup Kit In order to start, the unit needs an external power supply; for opera- tion, a hydrogen supply, an external hydrogen valve and a load relay are also necessary. ® The Nexa 1200 Startup Kit consists of a connection and communi- cation set and includes an external hydrogen valve, a load relay and the connecting lines.
  • Page 19 Components Fig. 3-5 Startup Kit communications set 1 CAN cable 2 Driver CD 3 CAN-USB converter 4 Resistors 3.2.1 External Power Supply For the external power supply, either an AC adapter or a battery with a voltage of 9...36°VDC can be used. A 3-pin plug connector for connecting the external power supply is included in the Startup Kit.
  • Page 20 Components Fig. 3-6 Heat sink with mounted reverse current diode and connected load relay 3.2.4 Communication For connecting a PC or the OSC, the Startup Kit also includes a CAN-USB converter, CAN cable and 2 terminating resistors. Fig. 3-7 CAN-USB converter, 2 terminating resistors and CAN cable 3.2.5 Nexa ®...
  • Page 21 Components Fig. 3-8 Nexa ® 1200 RCS ® Communication with the Nexa 1200 and the PC takes place via a CAN interface. The software allows measuring of all relevant operating parameters, e. g. stack voltage and stack current. Nexa® 1200 - Instruction Manual...
  • Page 23 Table 4-1 Scope of delivery Additional Supplemental Components The following components are also recommended for connecting the unit – they are not included in the scope of delivery, but can be pur- chased from Heliocentris. Nexa® 1200 - Instruction Manual...
  • Page 24 Getting Started • Connecting set for hydrogen supply • HydroKnowz hydrogen sensor Installation Location The unit must be operated in a lab which complies with the local reg- ulations (see Requirements for the Location / Installation Location on page 10). The installation location must also meet the following requirements: •...
  • Page 25 1. Grasp unit on profile side to lift it out of the packaging. 2. Check the unit for obvious transport damage to the packaging and to the product itself. In the event of damage, inform the ship- ping company and Heliocentris or your supplier about the dam- age immediately. −...
  • Page 26 Getting Started System Design ® Fig. 4-2 Assembly instructions for the Nexa 1200 Nexa® 1200 - Instruction Manual...
  • Page 27 How to Connect an External Load An external load can be connected to the unit. For this purpose, the electronic loads (EL 2400 or EL 1500) of Heliocentris are suitable: While the black (-) power cable is connected directly to the load, the red (+) power cable is routed through the load relay and the reverse current diode.
  • Page 28 Getting Started Power output of the The power outputs are below the connection panel on the back of the unit. The power outputs are designed as screw terminals. unit Proceed as follows to connect an external load to the unit: Pre-assembled power supply cable for battery, load and load relay The external load is switched off...
  • Page 29 Getting Started Pre-assembled solenoid valve Philips-head screwdriver Fig. 4-5 Connect the load relay as follows 1. Connect the positive power cable coming from the unit (8, Fig. 4- 4) to positive contact 1 (+) of the load relay. 2. Connect the angled side of the positive power cable (7, Fig. 4-4) to negative contact 2 (-) of the load relay.
  • Page 30 Getting Started The heat sink enlarges the heat-emitting surface of the reverse current diode, therefore preventing the possibility of damage from overheat- ing. The heat sink can be positioned anywhere near the unit as long as it can dissipate the heat efficiently. NOTICE ! Damage from reverse current! Install a reverse current diode between the unit's power outputs and the power in- puts of the connected load.
  • Page 31 Getting Started How to Install Safety Devices 4.7.1 How to Install the Safety Chain Danger of injury due to hydrogen! WARNING Escaping hydrogen can ignite and cause severe burns to the body.  Escaping hydrogen can be hot and burn the skin.  Escaping hydrogen can reduce the oxygen concentration and cause  respiratory difficulties.  A safety chain must be installed.  The safety chain is based on a current loop. This allows every partici- pant in the safety chain to detect or create an interruption. An inter- ruption in the safety chain switches the system to an intrinsically safe state.
  • Page 32 3. Tighten nut. 4. Fasten the other end of the equipotential bonding cable to a fur- ® ® ther Heliocentris product (e.g. a further Nexa 1200 or Nexa DC 1200) or to the rack system. Equipotential bonding is established. Nexa® 1200 - Instruction Manual...
  • Page 33 Getting Started How to Connect the Hydrogen Supply Hydrogen gas with a minimum purity of 4.0 (=99.99 %) is necessary for operation of the stack. The permissible hydrogen inlet pressure is 1…15 bar. The unit can be supplied with hydrogen by means of all options, e.g. lab supply, metal hydride canister or electrolyzer which fulfill the above conditions.
  • Page 34 Getting Started The recommended hydrogen inlet pressure for optimal opera- tion is between 3 and 8 bar. Electrical connection of Connect the solenoid valve as follows: solenoid valve 1. Insert plug connector (Fig. 4-12) in the (Fig. 4-11, 1) connection. 2.
  • Page 35 Getting Started 5. Insert lab plug of the power supply cable into the AC adapter. The external power supply with the AC adapter is now estab- lished. For the allocation of the contacts, see Chapter Allocation of Plugs and Jacks on the Connection Panel on page 78.
  • Page 36 1200 or Nexa ® DC 1200 A CAN interface (3) is provided for service purposes. The following data interfaces can optionally be connected to the unit: • RS232 interface can be enabled by Heliocentris if needed. RS232 Nexa® 1200 - Instruction Manual...
  • Page 37 Getting Started Fig. 4-14 Data interfaces (PC) (connection for further unit) RS232 (CAN) ERVICE Fig. 4-15 Components for connection of PC and terminal connection of CAN-Bus 1 CAN cable 2 Driver CD 3 CAN-USB converter 4 Resistors Fig. 4-16 Assembly instructions for establishing communication Nexa®...
  • Page 38 The unit is now connected to the PC. CAN-Bus terminal The CAN-Bus must have a terminal connection if the unit is the last or only Heliocentris product connected to the bus. Establish the terminal connection connection as follows: Terminating resistor 1.
  • Page 39 Getting Started Install the PCAN-USB 6. Follow the instructions of the setup program from the PCAN USB (software) driver. Driver The PCAN USB (software) driver is installed. 7. Restart the PC 8. Open in the Windows >A > N RC04 ROGRAMS NSTALLER Start menu.
  • Page 41 Operation ® The unit can be controlled via the Nexa RCS software, buttons on the unit or remote control. To start the unit and the software and to establish communication between the unit and the software, proceed as follows: • Start unit •...
  • Page 42 Operation Standby After successful initialization and completion of the system test, the system automatically switches to and also switches to STANDBY MODE internal power supply. If the unit continues to operate and communicate in the event of a  faulty stack, for example as a result of insufficient hydrogen, it is rec‐ ommended to leave the external power supply switched on while the  unit is in operation. This maintains external communication when the  unit switches to  .  ERROR MODE 5.1.1 Information for the Commissioning: The system can reach 50…60 % of the full capacity right after startup. To regenerate the system, a longer warm-up period may be neces- sary, depending on the past operation.
  • Page 43 Operation Designation Description Supply the minimum quantity of hydrogen still remaining in the stack diffuses after a maximum period of 30 minutes. The unit is ready for operation. The start signal (button External TANDBY on the unit or Start button in software) switches the unit to R .
  • Page 44 Operation 5.3.2 LED Display of the Mode or Process The LEDs on the front of the unit indicate the operating mode or cur- rent process of the unit. Fig. 5-2 LED display LED (from left to right) Operating mode or process Green Green Initializing (after application of an external...
  • Page 45 Operation How to Reset an Error The operating parameters are displayed in the software flow chart. If the parameters are not within the specified values, the unit switches to mode. Warnings and error messages (2) are displayed in the RROR field next to the button.
  • Page 46 Operation Power cables are connected Load relay is connected Reverse current diode is connected System is in TANDBY MODE 1. Press button. Unit Fig. 5-5 Button Software 1. Click the button in the area. TART YSTEM 2. Switch on load. Load relay closes and power can be tapped.
  • Page 47 Software The function of the software is to switch the to the various operating modes and to visualize all relevant operating parameters. The operat- ing parameters, e.g. stack voltage and stack current, can be saved. Software Views The software is divided into 2 views: Flowchart and Timechart. The status display, navigation bar and control area are maintained in each view.
  • Page 48 ESET ESET When the button is clicked, a service file is created, RROR EQUEST RROR EQUEST which can be sent to Heliocentris Service for error remedy. This file is saved in the directory C:\D OCUMENTS AND ETTINGS 1200\E RROR EPORT Beneath the area you will find the area for recording the data.
  • Page 49 Software Area Displayed parameters Definition Units / states Fuel cell temperature °C TEMPERATURE Fan speed 1/min PEED Exhaust air Flush valve Green (active), URGE blue (inactive) Power Total power output CURRENT FC-V OLTAGE Hydrogen supply Power supply, external / inter- Green (active), UPPLY and consumption...
  • Page 50 Software Fig. 6-3 Timechart view 1 Time history of the individual para- IMECHART meters 3 History of the time chart 4 Displayed parameters with respective display mode This view visualizes the measured values and system data in the form of graphs. Data is displayed in time curves. The following parameters are displayed: •...
  • Page 51 Software How to Record Data Activate the recording of the data in the operating area as fol- lows: 1. Click the drop-down field AMPLE 2. Set the desired time interval for performing the recording (e.g. 30 s: a measurement is recorded every 30 seconds). −...
  • Page 52 Software The recorded data is saved. How to Uninstall the Software To uninstall the software, use the integrated software management functions in the Windows operating system. 1. In > open the folder. TART ONTROL PANEL OFTWARE dialog opens with a list of the installed soft- OFTWARE ware.
  • Page 53 Decommissioning ® How to Shut Down the Nexa 1200 The following steps must be performed to shut down the unit: • Switch off the unit • Disconnect unit from the power supply • Shut down the hydrogen supply 7.1.1 How to Switch off the Nexa ®...
  • Page 54 Decommissioning The hydrogen supply has been shut down Storage and Transportation of the ® Nexa 1200 The following steps must be performed if the unit is to be stored or transported: • Switch off unit − (see How to Switch off the Nexa® 1200 page 51) •...
  • Page 55 Decommissioning As soon as the solenoid valve has cooled and the contacts on the load relay have been disconnected, the solenoid valve can be packed. 7.2.2 How to Shut Down the External Load After switching off the power supply, a residual amount of hydrogen is still present in the stack.
  • Page 56 Decommissioning Equipotential bonding 4. Loosen nut with open-end wrench. conductor 5. Disconnect equipotential bonding cable from the threads. 6. Tighten nut. Equipotential bonding is now disconnected. The following electrical contacts must optionally be disconnected: • Monitoring device for the safety chain •...
  • Page 57 Decommissioning Disconnect an additional unit from the data interface as follows: 1. Loosen locking screws from with a flat-head screwdriv- CAN OUT 2. Pull out the cable. The additional unit has now been shut down and can be packed. Peripheral devices 1.
  • Page 58 Decommissioning The position of the unit during transport is not important. When pack- ing the single components, they must be sufficiently padded to protect them against impact and fast acceleration. Nexa® 1200 - Instruction Manual...
  • Page 59 Troubleshooting 1. Where is the firmware version of the Nexa ® 1200 firmware? Open the PCAN View USB program and view the messages of ® the Nexa 1200. In ID 010 you can read the version in the last 4 bytes. 2.
  • Page 60 Troubleshooting During the firmware upload the LEDs of the Nexa ® 1200 are out and only illuminate once you press the button in the TART upload software. 4. What must I take into consideration or think about for the opera- tion of the fuel cell? Since the fuel cell involves an electrochemical energy conver- sion based on hydrogen and oxygen, the characteristic of a...
  • Page 61 Troubleshooting 11. Can an error memory be read out for Heliocentris Service? Yes. For this purpose, see Software Views on page 46. 12. How can I provide the supply voltage to an external H sensor from the unit. Connect the supply voltage of the external H...
  • Page 62 Troubleshooting Error / Error message Possible cause Solution ® ® Incorrect ID address of the Nexa 1200 Check the ID addresses of the Nexa 1200 with the PCAN USB monitor soft- ware. They must always end with 0 so that they are recognized by the RCS. In the case of IDs ending with a 1 or 7 the DIP switches on the rear connection panel are in the wrong position.
  • Page 63 110 W. The use start purge of the Nexa ® 1200 power supply availa- ble from Heliocentris is recommended. The Nexa ® 1200 goes Too low hydrogen inlet pressure Check whether sufficient hydrogen is...
  • Page 64 If a negative output can be detected after the switch, there is a defect of the internal fuse of the elec- tronics. Contact Heliocentris Service. Nexa ® 1200 repeatedly Problem with internal electronics...
  • Page 65 Visually inspect the air filter regularly for dirt. In the event of a visible accumulation of dirt and each year, no later than after 1000 operat- ing hours, it must be replaced. For this purpose, contact Heliocentris. Implementation The replacement can be carried out at any time. The system does not have to be shut down for this.
  • Page 66 Maintenance, Service and Disposal Replace the air filter as follows: Air filter for replacement Open-ended wrench / socket wrench 1. Loosen the two screws of the air filter cover on the fuel cell mod- ule. − Keep the screws available for re-use. 2.
  • Page 67 If you return the unit for repair or replace- ment, you must ship the unit sufficiently secured and packaged. Heliocentris is not responsible for damage which has been caused by improper packaging and / or improper shipment. You must bear the costs yourself for the shipment of units with expired warranty.
  • Page 68 With proper operation a minimum service life of 1500 hours can be expected, which is guaranteed by Heliocentris. Warranty claims against Heliocentris cannot be made if: • The customer has caused the damage by improper use or in- correct operation •...
  • Page 69 600 mm. In a 19" rack system, the unit is always installed horizontal- The following components are also available for connecting the unit – they are not included in the scope of delivery, but can be purchased from Heliocentris. • 19" mounting bracket •...
  • Page 70 2. Tighten the locking screws hand-tight. The additional unit is now connected CAN-Bus terminal The CAN-Bus must have a terminal connection if the unit is the last Heliocentris product connected to the bus. Establish the terminal con- connection nection as follows: Terminating resistor 1.
  • Page 71 Integration 10.4 How to Change the Configuration of the Nexa ® 1200 On the connection panel on the back of the unit there are DIP switch- es (1). The DIP switches can be used to change the configuration of the unit. The basic setting for all DIP switches is When operating several units in one CAN Bus, they can be assigned different IDs by means of the DIP switch.
  • Page 72 Integration 10.6 Protocol Definition of CAN Interface This chapter contains the protocol definition of the CAN interface for the communication of the fuel cell system Nexa ® 1200 with an exter- nal control unit. The communication of the device is carried out through a CAN bus (Controller Area Network) without an advanced implementation of protocol, i.e.
  • Page 73 Heliocentris Service for debug- ging. Table 10-2 CAN message transferred from external control to fuel cell system The following specified CAN IDs are reserved for further Heliocentris’ components in the Controller and must not be used for integration by the integrator.
  • Page 74 Identifier 0x500 The CAN message ID 0x500 transfers system commands to the con- ® trol unit of the Nexa 1200 (Start, Stop, Error Reset). Fig. 10-4 Description of the frame 0x500 Identifier 0x520 The stack operating time in the format hours, minutes, seconds is requested by the external control unit with CAN message ID 0x520 (Request);...
  • Page 75 Integration can thereby be displayed on a range of values between 1…255. Re- quest IDs of the value 0 is ignored. Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Request-ID Command Command LB Frame # Sequence ID, which can Commands 0 ..
  • Page 76 Integration Identifier 0x110 The Frame with the identifier 0x110 is sent cyclically every 100 ms. It transfers stack temperature, H concentration and warning flags. Fig. 10-7 Description of the frame 0x110 Identifier 0x120 The frame with the identifier 0x120 is sent on request the ID 0x520. Fig.
  • Page 77 Integration Byte0 Multiplexer reserved Stack hours (HB) Byte 1 reserved Stack hours (LB) Byte 2 reserved Stack minutes Byte 3 reserved Stack seconds Byte 4 reserved Byte 5 reserved Byte 6 reserved Byte 7 Table 10-6 Description of the content of frame 0x120 Identifier 0x200 The frame with the identifier 0x200 is sent cyclically every 50 ms.
  • Page 78 Integration Fig. 10-10 Description of the Frame 0x210 Identifier 0x300 The frame with the identifier 0x300 contains the error messages and is sent once an error appears. Fig. 10-11 Description of the frame 0x300 Nexa® 1200 - Instruction Manual...
  • Page 79 Integration Identifier 0x330 The frame with the identifier 0x330 is sent after a request (0x550) every 25ms, until the entire error log is transmitted. Fig. 10-12 Description of the Frame 0x330 The portion of data that begins with Data[0], is written linearly into memory.
  • Page 80 Integration • Storage and continuation of the error protocol after a firm- ware update Information Structure Error Frame Fig. 10-14 Data structure of the error frame How the error in the field has to be stored, can be gathered from the following table. Error-Flag Description SE-Error 1...
  • Page 81 Integration Plug Signal Specification CAN_H 1, 3-6, 8-9 Housing Shield Shield Table 10-8 Allocation of plugs CAN IN and CAN OUT Jacks Jack Contact Color of Signal Specification the line RS232 RS232 RS232 RS232 1, 4, 6-9 Housing Shield Shield Power VDC IN + I / 9…36 V...
  • Page 82 Integration DIP switch Signal Table 10-10 Allocation of the DIP switches 10.8 Data for the System Integration Designation Specification Current ramp 1 A / Sec Table 10-11 Notes for the System Integration Nexa® 1200 - Instruction Manual...
  • Page 83 Technical Data 11.1 Complete System Designation Definition Specification Physical data Dimensions (H x W x D) 220 x 400 x 550 mm Weight ca. 22 kg Protection type IP22 Power output Output voltage 20…36 V Rated current 60 A max. Rated output 1200 W @ 5…25 °C Rated output...
  • Page 84 Technical Data Parameter Specification Comment Communications Baud rate protocol kBaud Identifier 11 bit Protocol Helio- centris Recom- PEAK Required in combi- ® mended nation with Nexa converter 1200 RCS Data interface CAN IN SUB D9 Male If the unit is the last unit in the CAN SUB D9 Male bus, the CAN OUT...
  • Page 85 Technical Data Designation Property Specification External hydrogen valve Nominal diameter 1.5 mm Pressure 0…25 bar Connection Parker quick coupling Coil voltage 24 V Power consumption < 8 W Control logic NC, currentless closed Hydrogen hose Hose length Hose diameter 6 mm Sliding blocks Table 11-3 Specification of startup kit components 11.3...
  • Page 86 Identifier (also Identification) Low byte Not connected Normally Open Light Emitting Diode Overall System Controller: control and visualiza- tion device from Heliocentris PEM fuel cell Polymer Electrolyte Membrane fuel cell Remote Control Software SUB D D shaped subminiature Lower explosion limit Table 11-5 Abbreviations Nexa®...
  • Page 87 Index Electronic load A  disconnect communication ..53 Electronic Load Abbreviations ....... 84 connecting ......25 Air filter Equipotential bonding Replace ........63 disconnect....... 54 Air supply ........14 Error ........... 41 reset ......... 43, 46 C  Error remedy Service ........46 Error Request button .....
  • Page 88 Index N  description ......18 flowchart ......... 46 Nexa ® 1200 installation ......36 description ......13 starting ........39 Nexa ® 1200 uninstall ........50 unpacking ....... 22 using ........49 Nexa ® 1200 RCS ......18 Solenoid valve connecting ......
  • Page 90 Heliocentris Academia International GmbH Rudower Chaussee 30 12489 Berlin Germany http://www.heliocentrisacademia.com...