Flowserve OR 42 User Manual

OR 42 OR 52
Installation Instructions 810476-00
GESTRA Oil and Turbidity Detector
1
OR 42, OR 52
N
6
1
2
5 4
6 7 8 9 10
3
220 V
P
6
95
O
N
19 17 15 13 11
18 16 14 12
Fig. 1
2
220 V
P
7
O
OR 42, OR 52
85
M L
Fig. 2
78
70
CBA D E F G
K J
80
135
175200
7
H
I
Fig. 3
A
5
40
3
OR 42, OR 52
Fig. 4 Fig. 5
*)
H 500
Fig. 6 Fig. 7
*) T ap product line at the side (angle of 45°) from the bottom to pre vent air and dirt from flowing into the
bypass.
4
OR 42, OR 52
DN 100-300
H 250
Fig. 8
Fig. 9
5
OR 42, OR 52OR 42, OR 52
OR 42, OR 52
OR 42, OR 52OR 42, OR 52
Netz Mains Secteur Red Rete
Netz Mains Secteur Red Rete
0 – 20 mA R 500
Tv = 0
0 – 1 mA
R 120
Fig. 10 Fig. 1 1
A
[ppm][TE/F]
25
20
15
10
5
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12 14 16 18 20
4
5
3
2
[µl/l] = [ppm]
1
B
A
50
40
30
20
10
Fig. 12 Fig. 1 3
10
8
6
9
7
B
[µl/l] = [ppm]
6
ENGLISH
Important Safety Note
Use oil and turbidity detector OR 42/OR 52 only for monitoring of transparent liquids to detect any ingress of insoluble and refracting foreign matter, for measuring of turbidity and signal evaluation for indication and recording as well as for tripping of alarms, control valves etc. The equipment must only be installed by qualified staff. Before installing the oil and turbidity detector cut off power supply. All repairs must be performed only by the manufacturer. Misuse or any attempted modification of the equipment will endanger plant safety.
Warning
The terminal strip of the ORT4/ORT5 is live during operation. This presents the danger of electric shock. Cut off power supply before opening the equipment or undertaking any maintenance work
Purpose
The oil and turbidity detector OR 42/OR 52 consists of the sensor ORG 12/ORG 22 and the measuring transducer ORT 4/ ORT 5.
Application:
In steam boiler plants: Monitoring of condensate returned to the boiler for oil and grease contamination, in particular for boilers operating without constant supervision acc. to TRD 604 (2 detectors are required for 72 h operation)
For raw-water monitoring and water treatment (sand filters, demineralization plants, reverse-osmosis plants)
For waste-water monitoring
In breweries and the beverage industry (filtration, monitoring of wort, quality assurance etc.)
For salad oil production: Monitoring of filtering process
For marine applications: Monitoring of filtering equipment in accordance with IMO (International Maritime Organization) resolution MEPC.60(33) – when certain cold cleaning agents that split up easily are used which cannot form stable water/ oil emulsions
Types
Turbidity Detector Transducer Sensor OR 42/3 ORT 4 ORG 12 OR 42/4 ORT 4 ORG 22 OR 52/3 ORT 5 ORG 12 OR 52/4 ORT 5 ORG 22
Design
With three ball valves, three screwed
unions and screwed-in vent nipple
Drying cartridge and turbidity standard
20 ppm (OR 52: also turbidity standard 40 TU/F*) are also supplied
Spare parts kit separately available, see
“Spare Parts”
*) TU/F = turbidity units of Formazin suspension
Operation
The oil and turbidity detector measures the intensity of the scattered light produced by foreign matter that is not dissolved in trans­parent liquids and exposed to incident light, with emulsified oils scattering incident light mainly in the forward direction. In the oil and turbidity detector the forward scattered-light principle is applied which provides a high sensitivity for emulsified greases and oils and other organic matter.
Tec hnical Data ORG
Approvals
Feedwater monitoring
TÜV – approval no. 09-96-0132
Feedwater monitoring in marine
applications GL 94855-94 HH Seeberufsgenossenschaft GL-OG-94-352002
15 ppm oil detector for bilge monitoring in
engine rooms GL 85486-94 HH Seeberufsgenossenschaft 320023
Nominal size
DN 10, connections BSP to DIN ISO 228
Nominal pressure
PN 10
Flowrate
0.5 ... 50 l/min
3
/8"
Light emitter
At a flowrate of 2 l/min and V-shaped flow through the sensor with a pipe length of 1 m (DN 10 mm) and four bends: approx. 5 mbar (ζ = 6.1)
Fluids
Water, condensate, drinks etc.
pH value
Up to 10.5 (a pH value of 11 and above will lead to wear of the glass, depending on the temperature)
Fluid temperature ranges
0 ... 60°C with drying cartridge 60 ... 120°C with vent nipple
Protection
IP 65
Max. ambient temperature
60°C
Materials ORG 12 ORG 22
Cover flange GG-25 1.4580 Wetted parts 0.6025 1.4580
galvanized Ball valves Ms 58 1.4436 Screwed unions St 1.4571 Glass cylinder Duran 50 Duran 50 O-rings EPDM EPDM Housing 0.6025 0.6025
galvanized galvanized Cleaning disc EPDM EPDM
Light emitter
Glow lamp 12 V/10 W BA 15 s cable connection via 4 pole connector
Light receiver
Two silicon photo-electric cells, cable connection via 4 pole connector
Approx. weight
6.8 kg
Dimensions
See Fig. 2
Spare Parts
The spare parts kit for OR contains:
Designation Number Glass cylinder 1
O-ring 25 x 3 2 O-ring 30 x 2 2 O ring 37 x 2 4 Glow lamp 2 For cleaning unit: Cleaning plunger 1 Ring 1 Cleaning disc 1 Retaining ring 19 x 1.2 1 Fixing disc 1
7
Tec hnical Data ORT
ORT 4 ORT 5
Wiring 3 cable glands with integral cable clamps PG 11, 3 cable glands with integral cable clamps PG 11,
Mains supply 230 V ± 10 %, 50/60 Hz 230 V ± 10 %, 50/60 Hz
Fuse Thermal fuse M 0.1 A Thermal fuse M 0.2 A Power consumption 15 VA 25 VA Measured quantity Turbidity Turbidity Measuring range 0 – 25 ppm Range I: 0 – 50 TU/F*)
Lamp voltage for light emitter No-load voltage 14 V No-load voltage 14 V
Actual-value output 0 – 1 mA 0 – 20 mA (option 4 – 20 mA)
Output 1 volt-free relay contact 2 volt-free relay contact
Switchpoint Adjustable over complete measuring range Adjustable over complete measuring range Delay of response 0 s with external wire linke, 10 s 0.5 – 15 min. adjustable, see name plate
Indicators and adjustors 1 LED
Protection IP 54 to DIN 40050 IP 65 to DIN 40050 Max. admissible ambient 0 – 55°C 0 – 55°C
temperature Housing material Sheet steel, hammer enamel finish Die-cast aluminium, blue enamel finish Weight 1.6 kg 5.4 kg Dimensions See Fig. 1 See Fig. 1
*) TU/F = turbidity units of Formazin suspension, ppm = parts per million
screw-type terminals with wire guard, screw-type terminals with wire guard, max. conductor size 1.5 mm² max. conductor size 1.5 mm²
115 V ± 10 %, 50/60 Hz (option) 115 V ± 10 %, 50/60 Hz (option)
124 V ± 10 %, 50/60 Hz (option) 124 V ± 10 %, 50/60 Hz (option)
Rated voltage see name plate Rated voltage see name plate
Measuring range see name plate Range II: 0 – 25 ppm*)
Measuring range see name plate
with light emitter connected: < 12 V AC, 10 W with light emitter connected: < 12 V AC, 10 W
load 0 ... 120 load 0 ... 500
Max. contact rating with a switching Max. contact rating with a switching voltage of 24/115/230 V AC: voltage of 24/115/230 V AC: resistive 4 A, inductive 0.75 A at cos ϕ = 0.5 resistive 4 A, inductive 0.75 A at cos ϕ = 0.5 Max. contact rating with a switching Max. contact rating with a switching voltage of 24 V DC: 4 A voltage of 24 V DC: 4 A Life or relay: 10 x 10
6
switching cycles Life of relay: 10 x 106 switching cycles
Contact material: AgCdO 5 µ hard-gold plated Contact material: AgCdO 5 µ hard-gold plated
without wire link, see name plate
ALARM, 1 LED OPERATION, 1 LED ALARM (INSTANTANEOUS), 1 LED ALARM (DELAYED),
1 LED
MALFUNCTION, 1 potentiometer for switchpoint, 1 LED OPERATION, 1 LED MALFUNCTION,
2 potentiometers for adjustment 0/100 % 1 LED analogue display
RESOLUTION 3 %,
1 potentiometer for switchpoint, 2 potentiometers for adjustment 0/100 %, 1 potentiometer for adjustment of delay of response, 1 change-over switch for measuring range I/II, 1 change-over switch for switchpoint/measured value
Installation
ORG 12/ORG 22
Install and wire ORG 12/ORG 22 in accordance with the examples given in figures 4 to 9.
Mount ORG 12/ORG 22 in a bypass at a lower level than the main line so that any air and flash steam can pass through the main line.
To ensure a flow through the bypass a throttling point should be provided in the main line, e. g. GESTRA non-return valve type RK 66.
Tap product line at the side from the bottom to prevent air and dirt from flowing into the bypass.
Any pressure drop upstream of the sensor which might lead to the release of gases or to flashing must be avoided.
8
Screw in vent nipple when the fluid
L
temperature is above the max. ambient temperature (Fig. 2).
When the fluid temperature is below the ambient temperature remove the plastic lid from the drying cartridge (blue colour)
M
and screw in the drying cartridge. (Fig. 2) If the fluid temperature is very high provide
a non-insulated pipe upstream of ORG 12/ ORG 22 which will allow the fluid to cool down to 120 °C when reaching the sensor.
The second inlet at the lid must be open for the rinsing water or the calibrating fluid.
In the presence of large amounts of gas the tapping point must be at the bottom of the line – use a welding pocket in accordance with DIN 2618 (Fig. 7, Pos.*)
In the case of very contaminated condensate: downward flow of the fluid through the glass cylinder
If the condensate contains suspended solids (scratching of the glass) installation as per Fig. 5 should be chosen. If this does not help and/or a large amount of flash steam escapes install a separator upstream of the sensor (Fig. 8)
F K
1. Lid and base can be screwed turned through 90°.
2. Screw in nipples , screwed unions
E D
and ball valves supplied with the
C
sensor (use teflon tape or hemp for sealing).
3. They have to be fitted into the lid and
K
base or directly at the inlet, outlet or
F
purging point.
4. The screwed unions facilitate positioning of the ball valves so that the levers can be arranged in one plane (front).
5. Fit the ORG 12/ORG 22 with the mounting bracket provided in an accessible place. If the sensor is used on ships weld mounting bracket to its support.
6. Use 12 mm OD Ermeto (screwed 12 mm copper tubing or 10 mm OD gas pipe (screwed
3
/8") for the inlet and outlet
3
/8") or
lines of the sensor. For rinsing pur poses suitable flexible tubes should be provided.
7. Fit the light receiver in an accessible
H
place. It can then be easily removed, so that visual inspection of the fluid is possible. The interchange of light emitter and light receiver is possible after loosening the union nuts (inside). When refitting, take care of correct fit of locating pins in the grooves provided in light emitter and receiver. Tighten union nuts. Take care of tightness against moisture – condensate on the outside of glass cylinder results in too high measured values.
ORT 4, ORT 5
Wall mounting within reasonable distance from ORG 12/ORG 22. Installation dimensions see Fig. 1. The spacing between the holes is indicated on the back of the housing. ORT 5: Unscrew lid
N
screw and remove lid to gain access to the holes for mounting.
Wiring
ORT 4, ORT 5
1. ORT 4: Turn screw through 90° and open lid, see wiring diagram on operating panel. ORT 5: Unscrew lid screw and open lid, see wiring diagram on the inside of the lid.
2. Pull cable through cable glands .
3. Connect conductors according to wiring diagram (Fig. 10/11). Connect control circuits to output contacts and fuse separately with T 2.5 A.
4. Tighten cable gland to provide sealing.
5. Seal unused cable glands.
6. Replace lid, tighten screw , in doing so pay attention to correct position of lid gasket.or to flashing must be avoided.
ORG 12, ORG 22
Connect light emitter and receiver in accordance with Fig. 3.
1. Connect light emitter. A two-core cable (conductor size 1.5 mm²) for distances up to 90 m can be used.
2. Connect light reciver. A screened four­core cable, e. g. 2x2x0.8 mm or 4 x 0.5 mm² is required. Max. length 90 m.
N
N
O
O
N
Attention
To protect the switching contacts fuse
circuit with T 2.5 A or according to TRD regulations (1.0 A for 72 hrs operation).
Connect screen only to terminal 12
(ORT 4) / terminal 6 (ORT 5).
The screen must not make contact with
any metal part of the installation.
When switching off inductive loads,
voltage spikes are produced that may impair the operation of control and measuring systems. Inductive loads should be provided with commercial arc suppressor RC combinations, e. g.
0.1 µF/100 .o flashing must be avoided.
Commissioning
1. Switch on ORT 4/ORT 5.
2. Rinse ORG 12/ORG 22 for at least 15 minutes. Operate cleaning device if
J
required.
3. Check visually whether ORG 12/ORG 22 is completely vented. For this purpose unscrew union nuts (inside) and remove light receiver . When screwing in light
H
receiver ensure that the locating pin fits into the groove provided on the front collar of the light receiver.
4. Calibrate zero point (0 %) and measuring range (100 %).
5. Adjust switchpoint.
6. Set time delay.
o flashing must be
avoided.
Calibration of Zero Point (0%)
Use tap water (in case of low fluid temperature) or oil-free condensate as turbidity zero.
ORT 4
1. Set switchpoint adjustor to 0 ppm.
2. Turn measuring range adjustor (100 %)
2
to medium position.
3. Turn zero point adjustor (0 %) until the red LED extinguishes and the green LED just lights up. If the green LED
5
4 4
does not light up clean the pipework.
ORT 5
1. Set change-over switch for measuring
2. Loosen stop screws / of 0 %
3. Loosen stop screw of time delay
4. Turn 0 % adjustor until the LED
5. Slightly tighten stop screws .
19
range to position I and selector switch
10
in position “measured value”.
adjustor and 100 % adjustor by half a turn.
adjustor and turn the latter against the
13
left stop. Set 100 % adjustor on graduation 4.5.
analogue display is just no longer illuminated. If zero indication cannot be obtained: clean pipework. If this does not help: add remaining turbidity value when calibrating measuring range (100 %).
1
3
16 18
14
15
17
6
18
Calibration of Measuring Range (1 00%)
Fitting of turbidity standard
1. Choose turbidity standard supplied with the equipment: ORT 4: 20 ppm ORT 5: Measuring range I: 40 TU/F*)
Measuring range II: 20 ppm
*) TU/F = Turbiditiy units of Formazin
TU/F = suspension
2. Unscrew union nuts (inside) and remove light emitter from sightglass. Place
B
turbidity standard on black tube so that the screen fitted in the standard exactly fits the diaphragm in the tube.
3. Screw in light emitter ensuring that the locating pin on the sightglass fits into the groove of the light emitter. Tighten union nut (inside).
4. Make sure that the liquid used for the calibration of the zero point stays in the glass cylinder.
4. Make the following adjustments on the ORT 4/ORT 5:
ORT 4
6. Set switchpoint adjustor to 20 ppm.
7. Turn 100 % adjustor just until the red
5
LED lights up.
8. Remove turbidity standard and store carefully. Make sure that it cannot be scratched.
1
2
ORT 5
6. Set change-over switch for measuring
7. Loosen stop screw of 100 % adjustor
8. Slightly tighten stop screws .
9. Remove turbiditiy standard and store
19
range to position I or II dependent on the turbidity standard used. Set selector
10
switch to “Measured value”.
16
and turn the adjustor until the LED analogue display indicates 40 TU/F or
15
6
20 ppm. If required, add remaining turbidity value – see “Calibration of Zero Point (0 %)”, item 4.
16
carefully. Make sure that it cannot be scratched.
Adjustment of Switchpoint
An alarm is given when the actual value exceeds the adjusted switchpoint.
Tool: Screwdriver
ORT 4
1. Set switchpoint adjustor to the desired ppm value.
ORT 5
1. Set change-over switch for measuring
2. Set selector switch measured value/
3. Loosen stop screw of switchpoint
4. Turn adjustor until the LED analogue
5. Slightly tighten stop screw.
6. Set selector switch measured value/
19
range to position I (top scale) or position II (bottom scale) dependent on the desired switchpoint.
switchpoint to “Switchpoint”.
10
adjustor.
display indicates the turbidity value
11
desired as switchpoint.
switchpoint back to “Measured value”.
10
1
12
9
Adjustment of Time Delay
ORT 4
A time-delayed alarm is given when the switchpoint is exceeded. The time delay prevents temporary variations in the turbidity of the fluid from raising an alarm.
Time delay set at our factory: 10 s To eliminate the time delay provide an exter-
nal wire link between terminals 19 and 20.
ORT 5
The ORT 5 features two alarm channels:
Channel A 1 operates without delay:
The corresponding relay contact can be used for triggering a three way valve, so that contaminated fluid is immediately discharged from the system.
Channel A 2 operates with a delay which
is adjustable between 0.5 and 15 minutes for start-up and purging purposes, when at the beginning the turbidity is very high without representing a case of alarm.
Tool: Screwdriver
1. Loosen stop screw of adjustor and set required time delay.
2. Slightly tighten stop screw .
14 13
14
Functional T est
1. After applying mains voltage the green
2. Operate cleaning device . The green
3. Set cleaning device back to its initial
4 9
LED / must be permanently illuminated (Fig. 1). ORT 5: If a three-way valve is connected the fluid must flow straight through.
4 9
LED / must extinguish. ORT 4: The red LED must light up. ORT 5: The red LED and after the set time delay the red LED must light up. If
J
5 8
7
a three-way valve is connected it must open to discharge the fluid.
position. The red LEDs must extinguish.
J
Maintenance
Clean glass cylinder at regular intervals – at least once a week, dependent on the degree of contamination of the fluid.
Replace glass cylinder if it is strongly contaminated.
st lightup.
ORT 5: The red LED and after the set time delay the red LED must light up. If a three-way valve is connected it must
open to discha
With fluids having a normal transparency the service life of the glow lamp is more than 10 000 hrs. It is, however, recommended to replace the glow lamp each time the glass cylinder is being cleaned.
When the content of the drying cartridge
M
has assumed a pink colour it can no longer absorb moisture and must be replaced.
If frequent replacing is necessary check equipment for tightness:
O-rings on light emitter and receiver .
Cable entries on light emitter and receiver .
Gaskets of terminal boxes , gaskets of
H
B H
B
A
glass cylinder, oil-seal rings.
Cleaning of Glass Cylinder
1. Move the disc of the cleaning device up and down. Note that dependent on the adjusted time delay a temporary alarm may be given.
2. Move the disc of the cleaning device back to its initial position (operating bar protrudes approx. 70 mm from the sightglass). In case of strong contamination of glass cylinder replace plunger of the cleaning device.
J
J
Exchange of Glass Cylinder
1. Close ball valves for inlet and outlet. Open ball valve for rinsing .
2. Loosen hexagon head screws and remove base with cleaning device.
3. Remove glass cylinder from below.
4. Check whether housing, lid and base are completely dry inside. If not, dry with compressed air. In case of cold fluids, any moisture remaining in the housing would lead to the glass cylinder becoming covered with mist and therefore faulty measurements.
5. Loosen screws and withdraw housing from lid .
F
6. Remove O-rings, clean sealing surfaces and insert new O-rings.
7. Replace housing and fix lid with
G
screws .
8. Hold new and dry glass cylinder at the rim and push into housing from below until it is located in the upper O-ring.
9. Insert plunger of the cleaning device into glass cylinder. Screw base to housing by using hexagon screws.
D
I
K
G
F
J
K
10.Close ball valve for rinsing , open ball
D
valves for inlet and outlet.
I
11. Check zero-point adjustment and calibration of the ORT 4/ORT 5.
Replacement of Glow Lamp
1. Unscrew union nut (outside) of the lid
of the light emitter and remove lid.
2. Exchange glow lamp.
3. Replace lid of the light emitter. Take care
that locating pin fits the groove provided on the light emitter. Tighten union nut.
4. Repeat calibration of zero point (0%) and
measuring range (100 %).
A
Replacement of Mains Fuse
1. Turn fuse carrier to the left and take off
(Fig. 1).
2. Exchange fuse. Required types:
230 V M 0.1 A 5 x 20 M 0.2 A 5 x 20 115 V M 0.2 A 5 x 20 M 0.4 A 5 x 20
3. Replace fuse carrier and turn to the
right.
P
ORT 4 ORT 5
P
Replacement of Cleaning Device
T ools: Spanner
Screwdriver
1. Close ball valves for inlet and outlet.
Open ball valve for rinsing .
2. Loosen hexagon head screws and
remove base with cleaning device.
3. Use screwdriver for bending open the
inside serrations of the fixing disc and remove fixing disc.
4. Withdraw plunger and insert new plunger.
5. Mount new fixing disc. Make sure that the
serrations do not point towards the plunger.
6. Remove O-rings from base, clean sealing
surfaces and insert new O-rings.
7. Push plunger of the cleaning device
into glass cylinder. Screw base to housing by using hexagon screws.
8. Close ball valve for rinsing , open ball
D
valves for inlet and outlet.
9. Check zero-point adjustment and
calibration of the ORT 4/ORT 5.
D
I
K
J
K
I
10
Fault Finding
Fault Finding
Fault Possible reason Remedy
No lighting up of LEDs Mains fuse defective Replace mains fuse Lamp “Malfuncion” on Basic turbidity of fluid too high Refer to “Basic turbidity too high” in this table
Glass cylinder highly contaminated Clean or replace glass cylinder Glass cylinder scratched (solids in condensate) Replace glass cylinder. Install ORG 12/ORG 22
Glow lamp in light emitter defective Replace glow lamp Cable leading to light emitter defective Check cable
Calibration of zero point Cable leading to light receiver defective Measuring of lamp voltage < 12 V only possible (0 %) not possible if lamp intact
Glass cylinder highly contaminated Clean or replace glass cylinder Glass cylinder scratched (solids in condensate) Replace glass cylinder. Install ORG 12/ORG 22
Glass cylinder covered with condensation Check gaskets of terminal boxes and glass cylinder,
Drying cartridge assumed pink colour ? Replace drying cartridge Extremely eccentric position of glow lamp filament Insert glow lamp with central filament position Basic turbidity of fluid too high Add indicated value of 100 % calibration to turbidity
No indication of measured Cable leading to light receiver defective Check cable value
Basic turbidity too high Presence of gas or steam bubbles (flashing) Throttle outlet (indication must drop)
Basic turbidity specific of fluid To measure basic turbidity: Repeat calibration of 0 %
Measured value rises If ingress of foreign matter can be excluded, Operate cleaning device more frequently continually 1 ppm/day growing contamination of glass cylinder
Glow lamp often defective Heat accumulation in light emitter since fluid Remove drying cartridge and install vent nipple
temperature > 60 °C and drying cartridge mounted
acc. to mounting suggestion Fig. 5
acc. to mounting suggestion Fig. 5
O-rings of light emitter and light receiver
standard value
and 100% with distilled water
If faults occur that are not listed above, please contact our subsidiary or agency in your country.
11
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®
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D-28215 Bremen
Tel. + 49 (0) 421 35 03 -0 Fax +49 (0) 421 35 03- 393 Internet www.gestra.de E-mail
gestra.gmbh@flowserve.com
A Unit of Flowserve Corporation
12
810476-00/999c · ©1996 GESTRA GmbH · Bremen · Printed in Germany
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Tel.00 44 14 44 / 31 44 00 Fax00 44 14 44 / 31 45 40
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Tel.00 39 02 / 66 32 51 Fax00 39 02 / 61 51 863
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GESTRA POLONIA Spolka z o.o.
Ul. Schuberta 104 PL-80-172 Gdansk Tel. (058) 306 10 02 Fax (058) 306 1003
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Av. Dr. Antunes Guimarães, 1159 P-4100 Porto Tel.0 03 51 22 / 6 19 87 70 Fax0 03 51 22 / 6 10 75 75
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