Ferroli Rendimax 23 CE, Rendimax 30 CE, Rendimax 36 CE, Rendimax 16 CE Installation And Operating Instructions Manual

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RENDIMAX CERENDIMAX CE
RENDIMAX CERENDIMAX CE
RENDIMAX CE
CAST IRON GAS-FIRED BOILERCAST IRON GAS-FIRED BOILER
CAST IRON GAS-FIRED BOILERCAST IRON GAS-FIRED BOILER
CAST IRON GAS-FIRED BOILER
for central heatingfor central heating
for central heatingfor central heating
for central heating
Installation and operating instructionsInstallation and operating instructions
Installation and operating instructionsInstallation and operating instructions
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Contents
1. Description
2. Dimensions and technical specifications
3. Installation
4. Adjustment
5. Gas conversion
6. Maintenance and cleaning
7. Troubleshooting
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Fig. 1
Version "P.V."Version "BASE"
A
850
B
L
G
H
284
1
C
E
D
590
660
E
2
3
C
510
E
F
590
660
3
2
1
4
5
1. DESCRIPTION
1.01 Introduction RENDIMAX CE boilers are heat generators for central heating and domestic hot water production.
The standard version is designed to work with natural gas. To use the boiler with L.P.G., on-site conversion must be carried out following the instructions given below. This conversion must be done by our local Customer Technical Service Center.
2. Dimensions and technical specifications
2.01 Dimensions
KEY 1 C.H. flow inlet
2 C.H. flow outlet 3 1/2" gas inlet 4 Safety valve (only PV vers) 5 Expansion vessel (only PV vers)
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112
3
11
10
8 6
13
7
9
2
4
5
Fig. 2
2.02 Components description
View with open door
KEY
1 Boiler thermostat 2 Boiler temperature / pressure gauge 3 Safety valve 4 Gas valve 5 Circulation pump (only PV version) 6 Boiler drain cock 7 Pilot burner 8 Piezo-Igniter
9 Gas-Manifold 10 Boiler main switch 11 Filling cock 12 Cock 13 Flue thermostat
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Heat output Heat rate
Boiler
Rated Adjiustable up to: Min.Rated
Rendimax 16 CE Rendimax 23 CE Rendimax 30 CE Rendimax 36 CE
kW
16,2 23,0 29,5 36,0
kcal/hr
14.000
19.800
25.400
31.000
kW
11,0 16,0 20,0 24,0
kcal/hr
9.500
13.800
17.200
20.600
Section
nr.
3 4 5 6
kW
12,7 18,4 23,0 27,6
kcal/hr
11.000
15.800
19.800
23.800
kcal/hr
15.500
22.000
28.200
34.400
kW
18,0 25,5 32,8 40,0
Natural gas
Boiler
Rendimax 16 CE Rendimax 23 CE Rendimax 30 CE Rendimax 36 CE
Nozzle
nr.
2 3 4 5
L.P.G.
Ø Main
burner
mm
2,45 2,35 2,35 2,35
Ø Pilot burner
mm
0,35 0,35 0,35 0,35
Rated
gas
pressure
mbar
13,0 15,2 14,2 13,5
Ø Main
burner
mm
1,55 1,50 1,50 1,50
Ø Pilot burner
mm
0,225 0,225 0,225 0,225
Rated
gas
pressure
mbar
35 35 35 35
Boiler weight
kg
PV
vers.
80 94
112
/
BASE
vers.
70
84 102 126
Connections
Boiler
Rendimax 16 CE Rendimax 23 CE Rendimax 30 CE Rendimax 36 CE
A
mm
400 400 500 600
B
mm
57 62 72 82
C
mm
33 33 33 58
D
mm
100 110 130 150
E
mm
63 25 36 50
F*
mm
73 35 46
-
G
mm
515 515 515 525
H*
mm 635
635 635
-
L
mm
615 615 615 625
Return
1
1" 1" 1" 1"
Flow
2
1" 1" 1" 1"
Gas inlet
3
1/2" 1/2" 1/2" 3/4"
Max working pressure
bar
4 4 4 4
Boiler water
content
lt.
7,3
9,0 10,7 12,4
Expans.
vessel
vol.
6 6 8
-
lt.
Boiler
Rendimax 16 CE Rendimax 23 CE Rendimax 30 CE Rendimax 36 CE
Rated
1,94 2,70 3,47 4,23
Min. 1,16
1,69 2,46 2,95
Gas flow rate at the
burner for L.P.G. kg/hr
Rated
1,50 2,08 2,68 3,27
Min. 0,90
1,31 1,63 1,96
Gas flow rate at the
burner for N.G. m /hr
3
Connection dimentions
*Only P.V. version*Only P.V. version
*Only P.V. version*Only P.V. version
*Only P.V. version
3. INSTALLATION
Installation must be carried out by specialist companies only in accordance with all instructions and current regulations. You are advised to include gate valves between the boiler and the C.H. system so that the boiler can be isolated from the system if necessary.
Notes: If the path followed by the C.H. flow outlet and return inlet pipes is such as to allow for the formation of air pockets at certain points, you are recommended to fit an air valve at these points.
The diameter of the flue connection pipe must not be less than that of the coupling on the draft diverter. From the draft diverter, it must have a vertical section of not less than one and a half meters. When sizing and installing flues and the flue connecting pipe, current regulations must be respected.
If the fuel duct pass through flammable wall it has been well insulated.
2.03 Technical data (Max. working temperature 100
°C)
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230V 50Hz
23
49
49
23
L
8
9
10
98
N
1
4
1
2
3
2
3
44
1
C
92
11
114
160
32
63
12
13
6
5
4
2
7
92
1
63
2
C
1
98
142
324357968 1513
10
11 12 1614
160114
32
44
230V 50Hz
LN
Fig. 3
Connection between boiler and chimney has to be sealed.
The rated flow rate of gas counter has to be sufficient for the whole connected appliance.
Be careful that the boilers connections are free of mechanical tensions.
Connect the gas using a rigid pipe and including a gas cock.
The boiler must be connected to a 230 Volt - 50 Hz single phase line (phase/neutral) by means of terminal board of approved socket. A 5 A max. fuse should be included between the boiler and line. It is important to ensure that the boiler is connected to an efficient earth system. The terminal board for connecting the boiler to the room thermostat (if used) is inside the control panel (follow the electrical wiring diagram fig. 3).
3.01 Electrical connection
The electrical connections has be carried out according the following electrical schema. If the boiler is installed below the level of the C.H. system, you are recommended to install a sensor against the water absence.
NB: The manufacturer declines all responsibility for damage to persons or things deriving from
poor earthling of the appliance.
DIAGRAM OF ELECTRICAL CONNECTION
Key
23 Thermocouple 32 C.H. pump (if fitted)
44 Gas valve coil
49 Safety thermostat 63 Boiler thermostat
BASIC ELECTRICAL WIRING DIAGRAM
92 Flue gas thermostat
98 Main switch 114 Water pressure switch (not fitted) 160 Auxiliary contact
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Fig. 4
3.02 Checking and controlling the evacuation of combustion products (total security)
The boiler is fitted with a FLUE GAS THERMOSTAT . This thermostat prevents gas from reaching the burner if the flue is not drawing properly, providing greater security and control over the discharge of combustion products. If the FLUE GAS THERMOSTAT is activated, unscrew the protective cover on the control panel (Fig. 2 part. 13) and “reset” the thermostat manually. The boiler will then operate normally again. If you replace the FLUE GAS THERMOSTAT, use original components only and make sure the electrical connections are carried out correctly. NEVER EXCLUDE THE FLUE GAS THERMOSTAT FROM THE ELECTRICAL CIRCUIT. If it keeps activating, contact qualified personnel only.
3.03 Pressure drop in relation to C.H. water flow rate (fig. 4)
Fig. 5a
3.04 Pump characteristics (only P.V. version) 1,2,3,=position of the built-in pump speed selector knob (fig. 5a)
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Fig. 5b
3.05 C.H. pump head characteristics (only P.V. version)(Fig. 5b)
NB - The diagram refers to maximum pump (Pos. 3) head/flow rate.
4. IGNITION AND SHUT-DOWN
4.01 Checks to carry out before igniting for the first time
When igniting the boiler for the first time, it is good practice to check:
- that the gate valves between the boiler and system are open;
- that the system is correctly filled and vented;
- that there are no gas or water leaks from the system or boiler;
- that the electrical connections are correct and the earth wire has been connected to an efficient earth installation;
- that there are no inflammable liquids or materials near the boiler;
- that the flue is free from obstructions.
4.02 Igniting the boiler with ELETTROSIT gas valve(fig. 6)
Position the boiler thermostat on minimum. Open the gas cock and vent the air present in the tube upstream from the gas valve by opening the pressure point screw pos1. Push down gas valve button 2 and hold it down. Ignite the pilot burner by pressing the piezoelectric igniter 8 (fig.2) on the left side of the boiler.
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HONEYWELL V4600C GAS VALVEHONEYWELL V4600C GAS VALVE
HONEYWELL V4600C GAS VALVEHONEYWELL V4600C GAS VALVE
HONEYWELL V4600C GAS VALVE
Keep gas valve button 2 pushed down for 20 seconds then let it up slowly checking that the pilot burner remains lit. If it goes out, wait 30 seconds then repeat the ignition operation. Set the button 3 as shown in the fig. 3 Turn on the electricity to the boiler. Position the boiler thermostat 1 (fig. 2) on the required temperature (not lower than 45°C). The main burner switch-on and the boiler start working controlled by regulation thermostat of room thermostat (if connected).
ELETTROSIT GAS VALVE
fig. 6
Key
1 Downstream pressure test point 2 Ignition/shut down button 3 Key for ignition 4 Shut down button 5 Upstream pressure test point 6 Pilot adjustment screw 7 Main burner adjustment screw
8 Slow opening adjustment screw
4.03 Igniting the boiler with HONEYWELL V4600C gas valve(fig 7a)
Position the boiler thermostat 1 (fig. 2) on minimum. Open the gas cock and vent the air present in the tube upstream from the gas valve by opening the pressure point screw pos 3. Turn on the electricity to the boiler. Ignite the pilot burner by pressing the piezoelectric igniter 8 (fig.2) on the left side of the boiler. Keep gas valve button 1 pushed down for 20 seconds then let it up slowly checking that the pilot burner remains lit. If it goes out, wait 30 seconds then repeat the ignition operation. Position the boiler thermostat 1 (fig. 2) on the required temperature (not lower than 45°C). The main burner switch-on and the boiler start working controlled by regulation thermostat of room thermostat (if connected).
fig. 7a
Key
1 Ignition/shut down button 2 Pilot adjustment screw 3 Downstream pressure test point 4 Upstream pressure test point 7 Main burner adjustment screw
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IgniteIgnite
IgniteIgnite
Ignite
pilotpilot
pilotpilot
pilot
burnerburner
burnerburner
burner
IgniteIgnite
IgniteIgnite
Ignite
mainmain
mainmain
main
burnerburner
burnerburner
burner
Shuth-downShuth-down
Shuth-downShuth-down
Shuth-down
completelycompletely
completelycompletely
completely
the boilerthe boiler
the boilerthe boiler
the boiler
SIT NOVA 820 GAS VALVE
4.04 Igniting the boiler with SIT NOVA gas valve(fig 7b)
Position the boiler thermostat 1 (fig. 2) on minimum. Open the gas cock and vent the air present in the tube upstream from the gas valve by opening the pressure point screw pos4. (fig 7b) Push and keep pushed the knob in the position “a”. Ignite the pilot burner by pressing the piezoelectric igniter 8 (fig.2) on the left side of the boiler. Keep gas valve button 1 pushed down for 20 seconds then let it up slowly checking that the pilot burner remains lit. If it goes out, wait 30 seconds then repeat the ignition operation. Turn the knob in the position “b”. Turn on the electricity to the boiler. Position the boiler thermostat 1 (fig. 2) on the required temperature (not lower than 45°C). The main burner switch-on and the boiler start working controlled by regulation thermostat of room thermostat (if connected).
fig. 7b
Key
1 Command knob 2 Main burner adjustment screw 3 Pilot adjustment screw 4 Inlet gas adjustment screw 5 Upstream pressure test point
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4.05 Temporary shut-down
To temporarily shut down the boiler, just position the main switch 6 on the “0” position.All the electrical part remain not energized and only the pilot burner remain alight.
4.06 Prolonged shut-down
Push the button 4 (fig 6), turn clockwise the knob 1 (fig 7a) or turn the knob 1 in the position “C” (Fig. 7b). By measn this operations the gas connection to main burner and pilot is cut out. Close the gas cock upstream from the boiler and turn off the electricity supply to the boiler. Note: If the boiler is not used for long periods in the winter, to avoid frost damage, either add antifreeze
to the system or drain completely.
4.07 Post ignition checks and controls
On igniting the boiler for the first time: Check there are no gas or water leaks. Check that pilot flame is well regulated eventually it can be adjusted by means of adjustment screw on the gas valve (fig 6 ,7a, 7b). Check the boiler ignites properly by using the regulating thermostat to ignite and shut down the boiler. Check flue efficiency during boiler operation. Check that the fuel consumption indicated on the meter corresponds to the value indicated in the table. Check that water circulates correctly between the boiler and system. Check that flue connection between boiler and chimney is properly sealed.
IMPORTANT: The pilot burner inspection hatch must remain closed during normal boiler operation.
4.08 Gas consumption
The rated gas flow is shown on the technical-table at pag. 6. To get the rated gas-flow the gas pressure has to be adjusted according the technical data sheet. Gas pressure calibration can be carried out by­means of proper screw (fig 6,7a,7b) After the gas adjustment the consumption can be verified by means of gas-meter after at least 5 min. operation at full output. Further small adjustment can be carried on the gas adjustment screw (fig 6,7a,7b).
5. Gas conversion
The following adjustment and conversion operations must be carried out by qualified personnel only. s sAs standard the boilers are calibrated for N.G.
5.01 From N.G. to L.P.G.
To convert from N.G. to L.P.G., replace the main and pilot burner nozzles then adjust main burner pressure to ensure that nozzle pressure is as indicated for L.P.G. Note: Nozzle diameters and main burner pressures are given in technical data tables.
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5.02 Check and gas pressure regulation
Gas Valve ELETTROSIT
The regulation of gas pressure at the pilot burner has to be done at sight, without instrument but checking the that flame envelope completely the thermocouple (fig. 10) without burning excessive gas. To adjust the pilot flame operate as follow: To decrease the gas flow rate rotate clockwise the screw PILOT ADJ . To increase the gas flow rate rotate anticlockwise the screw PILOT ADJ. To adjust the pressure at main burner, remove the protection cap and rotate the screw REG. ADJ (fig.
6) clockwise to increase the pressure and anticlockwise to decrease.
ATTENTION:The pressure measured at point 1 and 5 (fig. 5) has be read after 30 second and after the pressure adjustment.
5.03 Adjusting min. flow on slow-opening for N.G.
Gas Valve ELETTROSIT
5.03.1 System nr.1
loosen completely the screw “REG ADJ” (fig. 6) Operate the screw “1 STEP ADJ” (fig 6) until the main burner light-on gradually and noiseless. Adjust the screw “1 STEP ADJ” until the gas pressure is the right one. Seal the screws “1 STEP ADJ” and “REG ADJ”.
5.03.2 System nr.2
(In the even the screw “REG ADJ” is already adjusted and sealed. Tighten the screw “1 STEP ADJ” (fig. 6) Operate the screw “1 STEP ADJ” (fig 6) each time for 1/4 anticlockwise. After rotation switch over the “Pilot” position by means of button 2 (fig. 6). After 30-60 sec switch over again on “Operation” position by means the button nr. 3 (fig. 6). Repeat the previous operations until the main burner light on gradually and noiseless and than seal the screw “1 STEP ADJ”.
5.04 Adjusting min. gas flow on slow-opening for L.P.G.
Gas Valve ELETTROSIT Take out the protection cap and check that the screw “NO PR” (fig. 6) is rotate clockwise completely. Adjust the screw “REG ADJ” until the main burner gas pressure is 12 mbar. Loosen the screw “NO PR” (fig. 6) Adjust the min. gas flow on slow-opening as described on par. 5.03.02 (System nr. 2). Loosen the screw “PILOT ADJ” (fig. 6). Seal the screws “1STEP ADJ” , “REG ADJ”.and “PILOT ADJ”.
ATTENTION:The screw “NO PR” has not to remain on intermediate position.It has to be completely tighten with N.G.and loosen with L.P.G.
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Fig. 8
5.05 Check and gas pressure regulation
Gas Valve “HONEYWELL V4600C” The regulation of gas pressure at the pilot burner has to be done at sight , without instrument but
checking the flame envelope completely the thermocouple (fig. 10) without burning excessive gas. To adjust the pilot flame operate on the screw 2 (fig. 7a). To adjust the pressure at main burner, operate on the screw 7 (fig. 7a). Rotate clockwise to increase gas flow and pressure, anticlockwise to decrease gas flow and pressure. To convert from N.G. to L.P.G. replace the pilot and main nozzles, tighten completely the screw 7 (fig. 7a) and adjust the gas flow-pressure.
N.B.Complete conversion kits for various gas are supplied separately (on request).
5.06 Check and gas pressure regulation
Gas Valve “SIT 820 NOVA” The regulation of gas pressure at the pilot burner has to be done at sight , without instrument but
checking the flame envelope completely the thermocouple (fig. 10) without burning excessive gas. To adjust the pilot flame operate on the screw 3 (fig. 7b). To adjust the pressure at main burner,operate on the screw 2 (fig. 7b). Rotate clockwise to increase gas flow and pressure, anticlockwise to decrease gas flow and pressure. To convert from N.G. to L.P.G.replace the pilot and main nozzles, tighten completely the screw 2 (fig. 7a) and adjust the gas flow-pressure.
N.B. Complete conversion kits for various gas are supplied separately (on request).
5.07 Replacing the main and pilot nozzles
To replace the main and pilot burner nozzles, proceed as follows: Turn off the gas and electricity supply upstream of the boiler. Remove the whole gas assembly from the combustion chamber (see paragraph 6.03). Remove the pilot burner (fig. 8) Remove the main burners from the manifold. Replace the main and pilot nozzles. Check that the main nozzles gaskets are not damaged. If so replace them. Reassemble carefully. If necessary, calibrate gas pressure at the nozzles as described above. Check correct operation and that there are no gas leaks.
Pilot burner
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14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
163115
14
13
12
11
15
kW
10
12
14
kcal/hr x 1000
9
11
13
29
37
36
35
34
33
32
31
30
28
27
26
25
20
19
18
17
16
mbar
6
2
3
4
5
7
8
9
10
11
12
13
21
22
23
24
16
15
1
2
3
4
Fig. 9a
35
25
30
1
mbar
10
29
13
11
9
15
20
27
28
30
kcal/hr x 1000
kW
26
14
12
10
31
32
33
34
25
35
36
37
15
11
12
13
14
15
31
16
30
29
28
27
26
25
24
23
22
21
20
19
18
17
20
19
21
22
18
23
24
17
16
2 3
4
Output variability with L.P.G.
5.08 Heat output variability characteristics
To adjust furnace heat input, simply regulate the main burner via the gas valve (fig. 8). This in turn varies the heat output to the C.H. water. The diagrams in Fig. 9a and 9b show the variations in heat output to the water in relation to variations in burner working pressure. The ability to adjust boiler output to actual C.H. requirements means above all reducing heat dispersion and so saving fuel. In addition, variations in output have very little effect on efficiency and combustion characteristics.
Fig. 9b
Output variability with N.G.
1 = model 16 2 = model 23 3 = model 30 4 = model 36
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IGNITIONIGNITION
IGNITIONIGNITION
IGNITION
ELECTRODEELECTRODE
ELECTRODEELECTRODE
ELECTRODE
THERMOCOUPLETHERMOCOUPLE
THERMOCOUPLETHERMOCOUPLE
THERMOCOUPLE
6. MAINTENANCE AND CLEANING
The following operations must be carried out by qualified personnel only. The boiler requires no particular maintenance other than general control of boiler and chimney once a year.Each three years the at the end of heating season boiler burner and chimney has to be cleaned.
6.01 Seasonal control of boiler and flue
Once a year before the heating season, the following controls should be carried out:
- the burner and boiler body and chimney should be clean. To clean them, you are advised to use a soft brush or compressed air. Avoid chemical products;
- water pressure in the system (cold) should be between 0.5 and 1 bar. If not, bring it back to this value. If the system is open vessel, check the water level in the tank.
- control and safety devices (gas valve and thermostats) should be working correctly;
- the thermocouple is free from scale and the pilot flame wraps it correctly (fig. 10)
- the pumps must not be blocked;
- the system should be free of gas or water leaks;
- gas flow rate and pressure should be in line with the values given in the table;
- the complete length of the flue gas evacuation pipe (flue and flue to boiler connection pipe) should be clean and free from leaks.
6.02 Flame at pilot burner
Fig. 10
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Fig. 12
Fig. 11
6.03 Cleaning the boiler and burner
To clean the boiler and burner , proceed as follows: a) turn off the gas and the electricity supply upstream of the boiler. b) take out the boiler cover and the draft diverter cover (fig.11). c) disconnect the electric power supply cable to the valve. d) turn off the gas and the electricity supply upstream of the boiler. e) remove the four screws A (fig.12) fixing the gas input pipe to the valve. f) remove the two nuts B (fig. 12) fixing the gas assembly and combustion chamber door to the boiler. g) remove the whole gas assembly.
Now you may clean all the smoke passages in the boiler using a pipe brush 3. Remember you should check and if necessary clean the flue and its connection to the boiler. Be careful not to damage the Flue gas safety thermostat phial or capillary.
Important - Do not clean the burners with chemical or a steel brush, as these might change the air­gas mixture outlet holes. When cleaning is complete, re-assemble carefully and in the correct position. The check the seal along the gas and smoke circuits, functioning of the control and safety devices and gas pressure and rate of flow.
Key
1 Fixing screw 2 Draft diverter cover 3 Cleaning brush
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7.TROUBLE SHOOTING
Pilot burner fails to ignite No gas
Open the gas cock
Air in the pipes
vent as described in the section on ignition
Pilot nozzle blocked
Clean the nozzle with compressed air
Insufficient gas flow
Adjust flow using the screw on the valve
Pilot goes out Faulty thermocouple
Control or replace the thermocouple
Incorrect flame adjustment
Adjust the flame using the screw on the gas valve
Insufficient flame
Adjust the flame until it envelopes the thermocouple as indicated in figure 12
Poor contact with the gas valve coil
Tighten the connector on the gas valve
Main burner fails to ignite No current
Restore current
Blocked nozzles
Clean the nozzles thoroughly
Faulty gas valve
Repair or replace the gas valve
Flue gas thermostat activated
Manually reset
Blowout at main burner Insufficient gas
Control gas pressure at the main burner
Boiler dirty
Check and clean the boiler
Burner dirty
Check and clean the burner
Smell of unburnt gas Boiler dirty
Check and clean the boiler body
Insufficient flue draught
Control flue draught efficiency
Insufficient air change
Improve room ventilation
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Remember: To avoid unnecessary expense, before contacting Service Departement, make sure that any boiler failure is not due to the absence of electric power or gas supply.
Incorrect flame regulation
Check flow rate at the gas meter and pressure at the main burner
Boiler functions, but temperature fails to rise Incorrect flame adjustment
Check gas consumption is normal
Boiler dirty
Check and clean the boiler body
Boiler inadequate
Check that the boiler is the right size for the C.H. system
Thermostat trips too high Thermostat bulb out of its sheath
Check the bulb is well inserted
Faulty adjustment on the panel
See section on adjustment
Condensation in boiler Faulty thermostat adjustment
Adjust the thermostat to a higher temperature
Faulty flame adjustment
Check that the main burner flame is properly adjusted
Insufficient gas consumption
Check gas consumption is correct
The boiler becomes dirty easily Faulty flame adjustment
Check the main burner flame is adjusted properly and that gas consumption is in line with boiler output
The boiler including the pilot shut down Insufficient flame
Adjust the flame until it envelopes the thermocouple as indicated in figure 12
Check the flue gas thermostat has not been activated.If so reset it manually
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Page 20
37047 SAN BONIFACIO - VR - ITALY37047 SAN BONIFACIO - VR - ITALY
37047 SAN BONIFACIO - VR - ITALY37047 SAN BONIFACIO - VR - ITALY
37047 SAN BONIFACIO - VR - ITALY tel. 045/6139411 - tlx. 480172tel. 045/6139411 - tlx. 480172
tel. 045/6139411 - tlx. 480172tel. 045/6139411 - tlx. 480172
tel. 045/6139411 - tlx. 480172 fax 045/6100233-6100933fax 045/6100233-6100933
fax 045/6100233-6100933fax 045/6100233-6100933
fax 045/6100233-6100933
S.p.A.
Cod. 3541098/1 12/96
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