Raypak 1000.57A Installation And Operating Instructions Manual

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This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference.
Catalog No: 1000.57A Effective: 02-28-07 Replaces: 02-24-06 P/N 241275 Rev. 2
INSTALLATION AND OPERATING
INSTRUCTIONS
COLD WATER START & COLD WATER RUN
For Hi Delta & MVB
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GENERAL SAFETY
To meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water, the rec­ommended initial setting for the temperature control is 125°F.
Safety and energy conservation are factors to be con­sidered when setting the water temperature on the thermostat. The most energy-efficient operation will result when the temperature setting is the lowest that satisfies the needs of the application.
Water temperature over 125°F can cause instant severe burns or death from scalds. Children, disabled and elderly are at highest risk of being scalded.
Feel water before bathing or showering.
Temperature limiting valves are available.
Maximum water temperatures occur just after the heater’s burner has shut off. To determine the water temperature being delivered, turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer.
3
NOTE: When this water heater is supplying general purpose hot water for use by individuals, a thermo­statically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information.
Time/Temperature Relationships in Scalds
The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.
Table A: Time to Produce Serious Burn
Water temperature over 125°F can cause instant severe burns or death from scalds.
Children, disabled, and elderly are at highest risk of being scalded.
See instruction manual before set­ting temperature at water heater.
Feel water before bathing or show­ering.
Temperature limiting valves are available, see manual.
Table courtesy of The Shriners Burn Institute
Water
Temp.
Time to Produce
Serious Burn
120°F More than 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 seconds
155°F About 1 second
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COLD WATER START
Before arriving at the job site to begin the installation, it's important to first inspect the system and determine what materials you will need. Some parts are includ­ed with the controller while others you will need to provide.
1 Control Box 1 Temperature Sensor 1 Valve assembly with actuator (Shipped separately) Wiring and mounting hardware (Provided by installer)
INSTALLATION
Check the Power Source
Check the power source:
AC = 108 VAC Minimum, 132 VAC MAX AB = 108 VAC Minimum, 132 VAC MAX
BC = <1 VAC Maximum
Mounting the Control Box
The control box should be mounted on the side of the heater to which the system piping and valve assembly are to be attached. The controller should be mounted
so as to provide maximum support by using the mounting holes provided on the base of the controller to the side center brace on the heater. You will need to drill mounting holes and holes through the heater side panel for the routing of wiring and the sensor. A tem­plate is supplied for field-installed kits to locate the control box properly.
Attaching the Temperature Sensor
Avoid routing wiring on or near other electrical wires, conduit, motors, spark igniters or other sources of high, intermittent voltage or current. The sensor should be placed in the dry well on the inlet header. Ensure it is installed using thermopaste (field supplied) and it is held firmly at the bottom of the well.
Connecting the Valve Assembly
Connect valve assembly “T CONNECTION “ into the piping with the actuator input wiring facing the heater side panel, as shown below. Route wiring to the con­trol thru the bottom panel knockouts to TB2. Refer to the wiring diagram provided on the inside of control cover assembly.
NOTE: Four knockouts are located on the bottom of the control for ease of installation.
WARNING: Using a multi-meter, check the follow­ing voltages at the circuit breaker panel prior to con­necting any equipment. Make sure proper polarity is followed and house ground is proven.
Fig. 1: Wiring Connections
Fig. 2: Multi-meter
CAUTION: Do not use for swimming pool applica­tions
BLACK
CIRCUIT
BREAKER
WHITE
GREEN
GROUND
AB C
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Connecting Power to the Controller
Supply power from the 120 VAC power input from the heater to the controller power inputs Terminal Block (TB1). This is accomplished by connecting wiring from the control box to the heater TB1 board 120 VAC power input connections. Refer to wiring diagrams.
Fig. 3: Component Locations — Hi Delta
Fig. 4: Location of TB1 in Control Box
NOTE: If a “DIP” switch is provided on the control PCB, verify that the switch settings are correct: 1 = OFF, 2 = ON, 3 = OFF.
OPERATION
Verify the following upon a CALL FOR HEAT signal from the heater:
1. CALL FOR HEAT LED on PCB illuminates GREEN.
2. START UP MODE LED on PCB illuminates YEL­LOW. Before 7 minutes it should go out if boiler inlet temperature is approaching the set point tem­perature.
3. The “ACTUATOR” should be in the fully open posi­tion or move to the fully open position if not already there. (Actuator at the fully CCW position)
4. Before 7 minutes time has elapsed if the control is operating properly the “START UP MODE” LED should go out. The inlet water temperature should be stable at a temperature between 105° F and 120° F (Normally set to 110° F) cooresponding to the Set Point Pot setting on the PCB. The actuator should have stopped moving.
Fig. 5: Control PCB
Models X
302B-902B
7.0
992B-2342B
13.20
LEFT SIDE
Reset Switch
CALL FOR HEAT START UP MODE INLET TEMP ERROR SENSOR OUT OF RANGE
Set Point Pot
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Cold Start Sequence of Operation
1) 120VAC to heater sends 120VAC to Cold Start control on terminal block 1.
2) 120/24VAC transformer and 120VAC-12VDC con­verter are powered.
3) 120/24VAC transformer outputs 24VAC to pin 2 of terminal block 2
4) 24VAC leaves pin 2 of terminal block 2 and goes to the modulating three way valve on the 20­30VAC lead, and to the NO contacts of the SPST relay located in the cold start control panel.
5) 120VAC-12VDC converter outputs 12VDC to pin 3 of terminal block 2.
6) The 12VDC signal leaves pin 2 of terminal block 2 and goes to the common terminal of the reset switch, located on the bottom of the cold start con­trol panel.
7) The 12VDC signal crosses over the reset switch and goes to Pin FS on cold start circuit board.
8) Cold start control remains on standby until a Call for heat occurs at heater.
9) TRIG terminal of Economaster connection on heater CPW board outputs 24VAC to terminal 4 of terminal block 3 located in Cold Start controller.
10) Terminal 4 of TB 3 sends 24VAC to the coil of the SPST relay located in the cold start control panel.
11) The SPST relay coil is energized and closes the contacts allowing 24VAC to energize the CFH pin on the cold start circuit board.
a) A two second delay occurs from the CFH signal
waiting to send power from terminal MC of the cold start circuit board.
12) J9 terminal on the heater CPW board (interlock connection) outputs a 24 VAC signal to terminal 2 of terminal block 3 located in the cold start con­troller.
13) 24 VAC is sent from terminal 2 of terminal block 3 to the NO contacts of the DPST relay located in the cold start control panel.
14) After the two second delay on the cold start circuit board, pin MC outputs a 24 VAC signal to the coil of the DPST relay located in the cold start control panel.
15) The DPST relay coil energizes and closes the NO contacts.
16) Once the NO contacts of the DPST close, the heater 24 VAC is sent back to the heater to com­plete the Economaster circuit (pin 3 of terminal block 3) and the interlock circuit (pin 1 of terminal block 3) allowing the heater to fire.
17) Pin FR on the TVC board outputs 10VDC to the modulating three way valve actuator to drive it fully open for two-minutes waiting for the heater to reach full fire.
18) After the two-minute delay the 10VDC output sig­nal from pin FR reduces to approximately 8VDC at the inverter thus slowing the pump to approxi­mately 50 Hz.
19) The output signal continues to vary depending on the heater inlet temperature.
The heater will lockout and shut down if the set point on the inlet temperature is not achieved within seven­minutes from a call for heat.
The DIP switches on the 3-way valve actuator must be set as indicated in the Fig. 6.
Fig. 6: Set Dip Switch Settings — Delta Actuator
NOTE: The minimum return water temperature to the heater to prevent condensate is 105°F on stan­dard heaters and 120°F on 87% Efficiency heaters. Ensure that during operation the Set Point Pot is adjusted properly.
Fig. 7: Delta Actuator — Actuator Shown in Full System
Flow Position
DIP SWITCH SETTINGS FOR 3-WAY ACTUATOR
VDC
0-10
DA
FIXED
~
mA
2-10
RA
AUTO
6-9
MODE SELECTION SWITCH
DIRECT ACTING, ON INCREASING SIGNAL
SWITCH MUST BE IN THIS POSITION TURN CLOCKWISE TO FURTHEST STOP
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NOTE: Elodrive actuator is Nema 4 rated.
TROUBLESHOOTING
Check your power source using a Volt-Ohm meter; check the following voltages at TB1 terminal block:
TB1-1 to TB1-2 = 108 VAC Minimum, 132 VAC Maximum
TB1-1 to TB1-3 = 108 VAC Minimum, 132 VAC Maximum
TB1-2 to TB1-3 = Must be less than .6 VAC
IF CALL FOR HEAT LED does not illuminate when the heater has a CFH signal, check for 24VAC at the heater CPW Board (J17-TRIG) output. If voltage is present, check wiring using the wiring diagram. If volt­age is not present, the problem exists in the heater.
IF VALVE DOES NOT MOVE: Check for voltage out at TB2-1: Should be a 1VDC to 10VDC output to the actuator valve. If no voltage is present, check for volt­age at TB2-3, there should be a 12VDC signal. If the 12VDC signal is not present, verify that the converter is wired correctly using the wiring diagram.
IF SENSOR OUT OF RANGE LED is illuminated: The set point temperature has not been reached within the 7 minute time period.
Push the Reset Switch (see Fig. 4) or remove power and watch for proper operation.
Check pump sizing and valve/piping sizing and cor­rect as necessary.
Replace sensor.
Check wiring using wiring diagram.
Fig. 8: Elodrive Actuator — Rotation Knob Setting
Fig. 9: Elodrive Actuator — Actuator Shown in Full
System Flow Position
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Cold Water Start Troubleshooting Guide
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Wiring Diagram
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COLD WATER RUN
Purpose
The Cold Water Run system utilizes a variable-speed pump to inject the proper amount of water from the main system loop into the boiler to maintain the opti­mum inlet temperature. This approach allows the full capacity of the boiler to be utilized to meet the system load, while at the same time continuously maintaining the optimum inlet water temperature to prevent con­densation.
Typical Cold Water Run Applications
Swimming pools.
Snow melting.
Low temperature radiant panel.
Water source heat pumps.
Any system with steady state return water temper­ature below 105°F.
CWR vs. CWS
Cold water start is for transient cold water opera­tion.
Cold water run is for continuous operation below 105°F system return temperature.
Cold water start maintains design flow rate at sys­tem design temperature but reduces bolier flow rate during heavy by-pass operation.
Cold water run maintains constant design flow rate in the boiler.
INSTALLATION
Before arriving at the job site to begin the installation, it's important to first inspect the system and determine what materials you will need. Some parts are includ­ed with the controller while others you will need to provide.
Installation Codes
Installations must be in accordance with local, state, provincial, and national codes, laws, regulations and ordinances. In the absence of local codes, installa­tions must be in accordance with the latest editions of the:
National Fuel Gas Code, ANSI Z223.1/NFPA 54
National Electrical Code, ANSI/NFPA 70
For Canada only: CAN/CGA B149.1 installation Code (B149.1) and CSA C22.1 C.E.C. Part 1 and Part 2
Mounting the Control Box
The control box should be mounted on the side of the heater to which the system piping and pump assem­blies are to be attached. The controller should be mounted so as to provide maximum support by using the mounting holes provided on the base of the con­troller to the side center brace on the heater. You will need to drill mounting holes and holes through the heater side panel for the routing of wiring and the sen­sor. A template is supplied for field-installed kits to locate the control box properly.
Indoor and Outdoor Installations
The cold water run control panel is rated for indoor use only. Do not mount or install the control panel in areas where dripping, flooding, rain, snow or spraying water may come in contact with the enclosure. If the injection pump is located outdoors, the optional outdoor cover must be installed according to the instructions in the following section. For outdoor installations mount the control panel indoors and route the wiring to the appro­priate connection points. Wire length is not to exceed 25 feet in any one direction. Contact your local sales representative for further information.
NOTE: The heater should not be located in an area where possible water leakage will result in damage to the area adjacent to the heater or to the structure. When such locations cannot be avoided, it is rec­ommended that a suitable drain pan, with adequate drainage, be installed under the heater. The pan must not restrict combustion air flow.
CAUTION: Remote mounted controller must be installed within 25 feet of the heater.
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Injection & Heater Pump Comparison — Hi Delta
Heater Pump Injection Pump
Heater
Model
Flow Temp. Rise Press. Drop Flow Temp. Rise
Injection
Pump
Heater Pump
302 32 16 2 13 40 1911-1⁄4 hp 11 2
402 34 20 2 17 40 1911-1⁄4 hp 11 2
502 42 20 2.3 22 40 1911-1⁄4 hp 1630 4.0
652 55 20 4.1 28 40 1911-1⁄4 hp 1630 4.0
752 63 20 5.7 32 40 1911-1⁄4 hp 1630 4.2
902 76 20 8.4 38 40 1911-1⁄4 hp 1630 4.2
992 83 20 5.2 42 40 1911-1⁄4 hp 1630 4.7
1262 107 20 9.6 54 40 1911-1⁄3hp 1630 4.7
1532 120 22 12.4 62 42 1911-1⁄3hp 1632 5.6
1802 120 25 13 68 45 1911-1⁄3hp 1632 5.6
2002 132 26 19 74 46 1935-3⁄4hp 1634 6.1
2072 132 27 19 75 47 1935-3⁄4hp 1634 6.1
2342 132 30 21.4 80 50 1935-3⁄4hp 1634 6.1
Table B: Injection and heater pump specifications
Check the Power Source
Check the power source:
AC = 108 VAC Minimum, 132 VAC MAX AB = 198 VAC Minimum, 250 VAC MAX BC = 108-132 VAC Maximum
WARNING: Using a multi-meter, check the follow­ing voltages at the circuit breaker panel prior to con­necting any equipment. Make sure proper polarity is followed and house ground is proven.
Fig. 10: Wiring Connections
Fig. 11: Multi-meter
BLACK
BREAKER
WHITE
GREEN
AB C
CIRCUIT
GROUND
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Fig. 13: Remove the pump body
Fig. 14: Be sure not to damage the seal when removing
or replacing the pump body
Injection Pump Cover Installation
Before Starting
1) Turn off power to the unit at the circuit breaker.
2) Turn off gas supply.
3) Shut off the water supply to the heater and, if nec­essary, drain water from the system.
4) Allow heater to cool down before attempting work.
In order to install the pump cover, you will need to rotate the pump body so that the electrical box is point­ing downward, as outlined in the following steps:
1. Loosen and remove the eight (8) 9/16” wrench bolts holding the pump body in place. See Fig. 12.
Fig. 12: Remove the eight bolts holding the pump body
in place
2. Remove the pump body then rotate it so that the electrical box is pointing downward, ensuring not to damage the seal. See Fig. 13, 14 and 15.
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3. Insert and tighten all eight (8) wrench bolts, secur­ing the pump body in place.
4. You will now be able to install the pump cover. See Fig. 18 and 19.
Fig 15: Reposition the pump body so that the electrical
box points downward
Fig. 16: Place the cover on the pump
Fig 17: Pump cover - angle view
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Typical Boiler Piping (Hi Delta shown)
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START-UP PROCEDURE
Run full system flow for two minutes.
Initiate PID pump control to achieve target inlet
temperature by slowing injector pump.
Boiler ΔT will not increase during bypass operation.
If target temperature is not achieved after seven
minutes from “call for heat”, the system will shut down.
Sequence of Operation
1) Supply separate 220VAC, 1 Ø, 60 Hz power to Cold Run control.
2) Call for heat occurs at heater.
3) TRIG terminal of Economaster connection on heater CPW board outputs 24VAC to terminal 4 of terminal block 3 located in Cold Run controller.
4) Terminal 4 of TB 3 sends 24VAC to the coil of the SPST relay located in the cold run control panel.
5) The SPST relay coil is energized and closes the contacts allowing 24VAC from the Cold Run con­trol transformer to be sent to the CFH terminal of the Cold Run circuit board.
a) A two second delay occurs from the CFH signal
waiting to send power from terminal MC of the cold run circuit board.
6) J9 terminal on the heater CPW board (interlock connection) outputs a 24 VAC signal to terminal 2 of terminal block 3 located in the cold run con­troller.
7) 24 VAC is sent from terminal 2 of terminal block 3 to the NO contacts of the DPST relay located in
the cold run control panel.
8) After the two second delay on the cold run circuit board, pin MC outputs a 24 VAC signal to terminal AL0 of the Hitachi inverter.
9) The AL0 relay closes and outputs a 24 VAC signal to the coil of the DPST relay located in the cold run control panel.
10) The DPST relay coil energizes and closes the NO contacts.
11) Once the NO contacts of the DPST close, the heater 24 VAC is sent back to the heater to com­plete the Economaster circuit (pin 3 of terminal block 3) and the interlock circuit (pin 1 of terminal block 3) allowing the heater to fire.
12) Pin SC of the cold run circuit board sends 24VAC to Pin 1 (Forward) on Hitachi Inverter.
13) PCS terminal on Inverter outputs 12VDC signal to the common terminal of the reset switch located on the bottom of the cold run control panel.
14) The 12VDC signal crosses over the reset switch and goes to Pin FS on cold run circuit board.
15) 12VDC on pin FS is jumpered to pin S1 on the cold run circuit board.
16) Pin FR on the TVC board outputs 10VDC to the Inverter to drive injector pump at full speed two­minutes waiting for the heater to reach full fire.
17) After the two-minute delay the 10VDC output sig­nal from pin FR reduces to approximately 8VDC at the inverter thus slowing the pump to approxi­mately 50 Hz.
18) The output signal continues to vary depending on the heater inlet temperature.
The heater will lockout and shut down if the set point on the inlet temperature is not achieved within seven­minutes from a call for heat.
The DIP switches on the Hitachi Inverter must be set as indicated on Fig. 19 below.
Fig. 18: Control Board
Fig. 19: DIP Switch Settings
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Wiring Diagram
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Cold Water Run Troubleshooting Guide
p
Step 1
Does TB1 of cold run
controller have 120
VAC?
YES
YES
NO
Is there a Call For
Heat at t he heater?
NO
Verify 120VAC from
TB1 on the heater
Heater is in standby mode
and correct
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Is the 220VAC inver ter in t he cold run c ontroll er powered?
Does the cold run invert er output
12VDC from PCS to
YES
Is 24VAC present at Poolstat connection on cold run circuit
Does cold run relay K-6
coil receive 24VAC from
MC on circuit board?
Are the Economaster and
Interlock leads connected to
N.O. contacts of r elay K-6?
Are the Economaster
and Interlock le ads
connected correctly to
heater CPW board?
board?
YES
YES
YES
in FS?
NO
NO
NO
NO
YES
NO
NO
Replace circuit board
Correct wiring
Correct Wiring
Replace inverter or install jumper
and correct switc h settings
Check 24VAC output at J17 of
heater circuit board and correct
Correct wiring
Replace sensor
Call our T echnical Service Department
1-800-927-2975 O utside California
1-800-627-2975 Inside Calif ornia
YES
Is sensor resistance correct?
NO
Correct 3Ø pump wiring
NO
YES
Is the injector pump
Step 8
Step 9
modulati ng after 2-1/2
NO
Is 0-10VDC present at
connection FR of cold ru n circuit
board?
Step 10
YES
YES
YES
NO Replace cold run circuit board
Does cold run circuit bo ard lock-out on
Is the heater tripping the high
limit?
NO
“Sensor out of Range”?
Verify pump is rotating in proper
YES
The unit is okay
NO
direction
Pump must decrease
RPM’s on decreasing 0-
YES
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ILLUSTRATED PARTS LISTS
Cold Water Start
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3-M
NOTE: Sizing is specific to this application.
2-M
1-M
4-M
CALL OUT DESCRIPTION HI DELTA MVB
3-C POWER SUPPLY 120VAC/12VDC 011719F 011719F
30900F930900V42 TDPS-YALERC-5
7-C TEMP SENSOR 10K (NOT SHOWN) 010787F 010787F
1-M PUMP-WATER BR 2" FLANGE, 1/4 HP 007226F 007226F
PUMP-WATER CI 2" FLANGE, 1/4 HP 007232F 007232F
PUMP-WATER BR 2" FLANGE, 1/2 HP N/A 007347F
PUMP-WATER CI 2" FLANGE, 1/2 HP N/A 007353F
PUMP-WATER BR 2-1/2" FLANGE, 3/4 HP 007348F 007348F
PUMP-WATER CI 2-1/2" FLANGE, 3/4 HP 007354F 007354F
PUMP-WATER BR 2-1/2" FLANGE, 1 HP 007348F 007348F
PUMP-WATER CI 2-1/2" FLANGE, 1 HP 007354F 007354F
PUMP-WATER BR 2-1/2" FLANGE, 1.5 HP N/A 007937F
PUMP-WATER CI 2-1/2" FLANGE, 1.5 HP N/A 007938F
F939110vC 42 TPN 2 EVLAV YAW-3M-2
YAW-3
3-WAY VALVE 2-1/2 NPT 100 Cv 011724F 011724F
REHTM-4
1-S CONTROL BOX SHEET METAL 011716F 011716F
F717110F717110LORTNOC-YSSA DRAOB CPC-1
F817110F817110REMROFSNARTC-2
F027110F027110V42 TDPD-YALERC-4
F9
F551700F551700GUL DNUORGC-6
F146500F146500HCTIWS TESERC-8
F939110
F127110F127110vC 83 TPN 2 EVLAV YAW-3
F227110F227110vC 75 TPN 2 EVLAV
F327110F327110vC 47 TPN 2/1-2 EVLAV YAW-3
F438110F438110ROTAUTCAM-3
919000919000LACITREV-RETEMOM
F879110A/NREVOC XOB LORTNOCS-2
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Cold Water Run
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CALL
NOTE: Sizing is specific to this application.
OUT
0F930900CAV42 TDPS-YALERC-3
AV 032/511-REMROFSNARTC-5
6-C TEMPERATURE SENSOR 10K (NOT SHOWN) 010787F 010787F
-PMUPM-1
PUMP-WATER BR 2-1/2" FLANGE, 3/4 HP 007348F 007348F
PUMP-WATER CI 2-1/2" FLANGE, 3/4 HP 007354F 007354F
3-M INJECTOR PUMP, BR 302B-902B (NOT SHOWN) 951414 N/A
INJECTOR PUMP, CI 302B-902B (NOT SHOWN) 951415 N/A
INJECTOR PUMP, BR 992B-1802B (NOT SHOWN) 951394 N/A
INJECTOR PUMP, CI 992B-1802B (NOT SHOWN) 951413 N/A
INJECTOR PUMP, BR 2002B-2342B (NOT SHOWN) 951411 N/A
INJECTOR PUMP, CI 2002B-2342B (NOT SHOWN) 951416 N/A
ATEM TEEHS XOB LORTNOCS-1
BVMATLED IHNOITPIRCSED
F717110F717110LORTNOC-YSSA DRAOB CPC-1
F027110F027110CAV42 TDPD-YALERC-2
F93090
F538110F538110PH 2/1-RETREVNIC-4
F638110F638110PH 1-RETREVNI
F817110F817110C
F146500F146500HCTIWS TESER MRALAC-7
F622700F622700PH 4/1 ,EGNALF "2 RB RETAW
F232700F232700PH 4/1 ,EGNALF "2 IC RETAW-PMUP
F153700F153700PH 1 ,EGNALF "2/1-2 RB RETAW-PMUP
F753700F753700PH 1 ,EGNALF "2/1-2 IC RETAW-PMUP
919000919000LACITREV-RETEMOMREHTM-2
F617110F617110L
F879110A/NREVOC XOB LORTNOCS-2
Page 22
www.raypak.com
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468
Raypak Canada Limited, 2805 Slough St., Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 Fax (905) 677-8036
Litho in U.S.A.
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