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Heatcraft Refrigeration Products FLEXPACK 25006801 User's Manual
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1. aen Jayem pazunssasd ysnig Aq lt Q alva ATIVONNW INAS 5431002 LINN 17 Replacement Parts Table 3 Replacement Parts List Low Pressure Control Adjustable 2891402 Fixed 28913401 Fan Panel 46819701 46899601 46898801 18 O fo el Diagram 1 Typical Wiring Diagram lt mora 1299 LNO LND 9154 OL NI LND 9154 OL 145 54418 AC ONDINWW GNOD3S ILNNIW L IN 135 ANTON LUWLS EHS 285 195 15 CS 005 125 YOLIDYdY NI ER 199 MOTISA a MOTA ONIYIM AYOLIWS 293A 09 ISN AINO SYOLONGNOD 3440 ISN SYOLOW YISNJANOD MONIA MOTA MOTNJA L ZH 09 A O Z 807 5 YAMOd 179002510 183 MOTA Deen 19 Start up Checklist Date of Start up Location CONDENSING UNIT MODEL ELECTRICAL Check Compressor Amps for COOLER and FREEZER compressors Should match nameplate OYES ONO PIPING Is suction line trapped at the Cooler OYES ONO Is suction line trapped at the Freezer O
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4. significantly greater than most of the other piping Extra supports are relatively inexpensive as compared to refrigerant loss Figure 7 Line Insulation After the final leak test refrigerant lines exposed to high or low ambient conditions should be insulated to reduce heat loss or gain and prevent the formation of flash gas in the liquid lines Suction lines should be insulated with 3 4 wall Armstrong Armaflex or equivalent Liquid lines should also be insulated with 1 2 inch wall insulation or better The insulation located in outdoor environments should be protected from UV exposure to prevent deterioration of insulating value 10 Leak Detection And Evacuation Leak Testing After all lines are connected the entire system must be leak tested The complete system should be pressurized to not more than 150 PSIG with refrigerant and dry nitrogen The use of an electronic type of leak detector is highly recommended because of its greater sensitivity to small leaks As a further check it is recommended that this pressure be held for a minimum of 12 hours and then rechecked For a satisfactory installation the system must be leak tight Leak detection can be carried out in the conventional manner If HCFC or CFC tracer gas is used care must be taken to completely remove all traces of the gas prior to introducing 5 Electronic leak detectors are now available that will sense This is considere
5. have adequate support to avoid vibration and noise transmission into the building Units should be mounted over corridors utility areas rest rooms and other auxiliary areas where high levels of sound are not an important factor Sound and structural consultants should be retained for recommendations Refer to actual building plans for unit locations Figure 2 Condensing Unit Placement M 3 Feet minimum Clearance to 3 Feet from the Next Unit Building Wall 3 Feet minimum Clearance for Contractor to Service Unit were 3 Feet minimum Clearance from unit to an Open Block Wall or Shrubs Condensing Unit Rigging Figure 3 Condensing Unit Rigging Adequate rigging measures must be tak en to support unit weight and to protect the unit from damage during unloading and placement process Rigging holes have been provided in legs and under the unit compressor compart ment frame to assist Spreader bars may be used to protect Rigging Holes unit from damage Refrigeration Piping And Line Sizing Refrigeration Piping And Line Sizing The system as supplied by Heatcraft Refrigeration Products was thoroughly cleaned and dehydrated at the factory Foreign matter may enter the system by way of the evaporator to condensing unit piping Therefore care must be used during installation of the piping to prevent entrance of foreign matter Install all refrigeration system components in a
6. side evacuation valves with copper tube or high vacuum hoses 1 4 10 minimum If the compressor has service valves they should remain closed deep vacuum gauge capable of registering pressure in microns should be attached to the system for pressure readings A shut off valve between the gauge connection and vacuum pump should be provided to allow the system pressure to be checked after evacuation Do not turn off vacuum pump when connected to an evacuated system before closing shut off valve The vacuum pump should be operated until a pressure of 1 500 microns absolute pressure is reached at which time the vacuum should be broken with the refrigerant to be used in the system through a drier until the system pressure rises above 0 psig NOTE Refrigerant used during evacuation can not be vented Reclaim all used refrigerant EPA regulations are constantly being updated Ensure your procedures follow correct regulations Repeat this operation a second time Open the compressor s service valves and evacuate the entire system to 500 microns absolute pressure Raise the pressure to 2 psig with the refrigerant and remove the vacuum pump 11 Field Wiring WARNING All wiring must be done in accordance with applicable codes and local ordinances The field wiring should enter the areas as provided on the unit The wiring diagram for each unit is located on the inside of the electrical panel door All field wiring should be don
7. system diagram for use of building manager or owner System Balancing IMPORTANT In order to obtain the maximum capacity from a system and to ensure trouble free operation it is essential to balance each and every system So LE The critical value to be checked here is suction superheat at the compressor 1 Measure the suction pressure at the suction service valve of the compressor and determine the saturation temperature corresponding to this pressure from a Temperature Pressure chart 2 Measure the suction temperature of the suction line about one foot back from the compressor using an accurate thermometer 3 Subtract the saturated temperature from the actual suction line temperature The difference is superheat Too low a suction superheat can result in liquid being returned to the compressor This will cause dilution of the oil and eventual failure of the bearings and rings or in the extreme case valve failure or even slugging of the compressor Too high a suction superheat will result in excessive discharge temperatures which causes a break down of the oil and results in piston ring wear piston and cylinder wall damage It should also be remembered that the system capacity decreases as the suction superheat increases For maximum system capacity suction superheat should be kept as low as is practical Copeland mandates a minimum superheat of 20 F and a maximum of 45 F at the compressor Heatcraft recom
8. 3K4E TF5 208 230 ZF15K4E PFV 208 230 ZF15K4E TF5 208 230 ZF18K4E TF5 208 230 Medium Temp WW A WW GW GW W Sf 6 Al 6 Dimensional Diagrams Figure 1 End View Optional Disconnect Switch One Fan Top View 7 00 22 50 22 50 TT y E 4 6 50 47 00 Please note system positions Electrical Knockout 4 Liquid Lines Suction Lines X X 100 50 Three Fan Length Side View X 78 00 Two Fan Length X 59 00 Single Fan Length 100 50 AIR FLOW 7 00 29 00 29 00 29 00 7 00 Condensing Unit Placement Space and Location Requirements The most important consideration which must be taken into account when deciding upon the location of air cooled equipment is the provision for a supply of ambient air to the condenser and removal of heated air from the condensing unit or remote condenser area Where this essential requirement is not adhered to it will result in higher head pressures which cause poor operation and potential failure of equipment Units must not be located in the vicinity of steam hot air or fume exhausts Corrosive atmospheres require custom designed condensers Another consideration which must be taken is that the unit should be mounted away from noise sensitive spaces and must
9. 5 5600 Fax 770 465 5990 www heatcraftrpd com HEATCRAFT Worldwide Refrigeration
10. 8 230 CS27K6E TF5 208 230 CS33K6E PFV 208 230 CS33K6E TF5 208 230 RST45C1E CAV 208 230 RST55C1E CAV 208 230 RST64C1E CAV 208 230 RS70C1E PFV CFO4K6E PFV 208 230 208 230 CFO4K6E TF5 208 230 CFO6K6E PFV 208 230 CFO6K6E TF5 208 230 CFO9K6E PFV 208 230 CFO9K6E TF5 208 230 CF12K6E PFV 208 230 CF12K6E TF5 208 230 LU h lech w w w w w w w w w w Compressor Module Specifications Table 2 Scroll Compressor Module Electrical Data Scroll Compressor Compressor Data Crankcase Compressor Electrical Rating RLA MCC 1 56 Heater Refrigerant Evap Temp Model Watts ZS15K4E PFV 208 230 60 12 2 61 0 22 5 35 251 5 5 208 230 60 8 3 55 0 ZS19K4E PFV 208 230 60 14 7 73 0 ZS19K4E TF5 208 230 60 8 7 63 0 ZS21K4E PFV 208 230 60 14 7 88 0 ZS21K4E TF5 208 230 60 9 9 77 0 ZS26K4E PFV 208 230 60 18 6 109 0 ZS26K4E TF5 208 230 60 12 2 88 0 ZS30K4E PFV 208 230 60 24 0 129 0 ZS30K4E TF5 208 230 60 13 5 99 0 ZS38K4E PFV 208 230 60 28 8 169 0 ZS38K4E TF5 208 230 60 19 2 123 0 ZS45K4E TF5 208 230 60 21 5 156 0 ZFO6K4E PFV 208 230 ZFO6K4E TF5 208 230 ZFO8K4E PFV 208 230 ZFO8K4E TF5 208 230 ZFO9K4E PFV 208 230 ZFO9K4E TF5 208 230 ZF11K4E PFV 208 230 ZF11K4E TF5 208 230 ZF13K4E PFV 208 230 ZF1
11. HEATCRAFT Worldwide Refrigeration Multiple Compressor Condensing Units H IM FP April 2011 Part No 25006801 Updates to March 2004 version Installation and Operation Manual Table of Contents Nomenclature Field Wiring General Safety Information Refrigeration Charging Compressor Module Specifications Operational Checkout Dimensional Diagrams System Balancing Condensing Unit Placement Preventive Maintenance Condensing Unit Rigging Refrigeration Piping and Line sizing Wiring Diagram Leak Detection and Evacuation Start up Checklist ZR DT Solutions Efficiency Environment Nomenclature TPC1 One Condenser Fan Cabinet 2 Two Condenser Fan Cabinet TPC3 Three Condenser Fan Cabinet General Safety Information 1 Installation and maintenance to be performed only by certified personnel who are familiar with this type of equipment 2 Make sure that all field wiring conforms to the requirements of the equipment and all applicable national and local codes Avoid contact with sharp edges and coil surfaces They are a potential injury hazard Make sure all power sources are disconnected before any service work is done on units Inspection Responsibility should be assigned to a dependable individual at the job site to receive material Each shipment should be carefully checked against the bill of lading The shipping receipt should not be signed until all items listed on the bill of lading ha
12. YES ONO DRAIN LINES Are drain lines sloped properly OYES ONO 15 drain line trapped outside the Cooler OYES ONO 15 drain line trapped outside the Freezer OYES ONO Is heat tape wrapped along entire length of the drain line in the Freezer OYES ONO Is heat tape plugged in and heating the drain line OYES ONO INSULATION Are Liquid lines fully insulated OYES ONO Are Suction lines fully insulated OYES ONO SYSTEM CHECKS Check Compressor Superheat for the COOLER Should be between 20 F amp 30 F OYES ONO Check Compressor Superheat for the FREEZER Should be between 20 F amp 30 F OYES ONO Force unit into a Defrost Check heater amps Should match nameplate amps OYES ONO e Check LPS Time Delay Relays Should be set at 1 minute for both the COOLER and FREEZER OYES ONO e Check Low Pressure Switch on FREEZER Should be set at 0 psig Cut out 10 psig Cut in OYES ONO Did FREEZER and COOLER cycle off on LPS at Set point Temperature OYES ONO 20 Is the sight glass free of bubbles OYES ONO Are the COOLER and FREEZER fans at proper speeds OYES ONO Check system for refrigerant leaks Are there any leaks on the COOLER FREEZER CONDENSING UNIT or INTERCONNECTING PIPING OYES ONO e Check system piping for unusual vibration or noise Is there any unusual vibration or noise on the COOLER FREEZER CONDENSING UNIT or INTERCONNECTING PIPING OYES ONO Start up Checkl
13. ccordance with applicable local and national codes and in conformance with good practice required for the proper operation of the system The refrigerant pipe size should be selected from the tables in Refrigeration System Installation Manual Part Number 25001201 The interconnecting pipe size is not necessarily the same size as the stub out on the condensing unit or the evaporator The following procedures should be followed a Do not leave dehydrated compressors or filter driers on condensing units open to the atmosphere any longer than is absolutely necessary b Use only refrigeration grade ACR copper tubing properly sealed against contamination c Suction lines should slope 1 4 per 10 feet towards the compressor in direction of flow d Suitable P type oil traps should be located at the base of each suction riser to enhance oil return to the compressor For desired method of superheat measurement a pressure tap should be installed in each evaporator suction line in the proximity of the expansion valve bulb f When brazing refrigerant lines an inert gas should be passed through the line at low pressure to prevent scaling and oxidation inside the tubing Dry nitrogen is preferred g Use only a suitable silver solder alloy on suction and liquid lines h Limit the soldering paste of flux to the minimum required to prevent contamination of the solder joint internally Flux only the male portion of the connection never
14. d preferable since it removes the possibility of chlorine remaining in the system after leak testing with HCFC s and or HCFC s There is a view that even small quantities of chlorine may act as catalyst encouraging copper plating and or corrosion and should therefore be avoided Within the last several years manufacturers have developed fluorescent dye leak detection systems for use with refrigerants These dyes mix with the lubricant and when exposed to an ultraviolet light fluoresce to indicate the location of leaks Copeland has tested and approved the Rigid System Safe dye and found it to be compatible with the compressor materials in systems Evacuation Do not use the refrigeration compressor to evacuate the system Do not start the compressor while it is in a vacuum Due to the smaller molecule size of they will tend to leak more readily than CFC Consequently it is of the utmost importance that proper system evacuation and leak detection procedures be employed Copeland recommends a minimum evacuation to 500 microns In addition a vacuum decay test is strongly recommended to assure there is not a large pressure differential between the system and vacuum pump Good evacuation processes include frequent vacuum pump oil changes and large diameter short hose connections to both high and low sides of the system preferably using bronze braided hose A good deep vacuum pump should be connected to both the low and high
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16. e in a professional manner and in accordance with all governing codes Before operating unit double check all wiring connections including the factory terminals Factory connections can vibrate loose during shipment 1 The nameplate on the unit is marked with the electrical characteristic for wiring the unit 2 Consult the wiring diagram in the unit cooler and in the condensing unit for proper connections 3 Wire type should be of copper conductor only and of the proper size to handle the connected load 4 The unit must be grounded 5 For multiple evaporator systems follow the wiring diagrams for multiple evaporator systems carefully This will assure complete defrost of all evaporators in the system 6 If a remote defrost Timer is to be used the Timer should be located outside the refrigerated space Note Control wiring from the remote machines such as ice machines drink machines cases etc must be connected to the relays in the Control Panel to properly energize condenser fans Figure 8 System 3 System 2 System 1 12 Refrigeration Charging Refrigeration Charging 1 Install a liquid line drier in the refrigerant supply line between the service gauge and the liquid service port of the receiver This extra drier will insure that all refrigerant supplied to the system is clean and dry 2 When initially charging a system that is in a vacuum liquid refrigerant can be added directly into the receiver ta
17. ertical risers additional traps may be necessary Generally one trap is recommended for each length of pipe approximately 20 feet to insure proper oil movement See Figure 4 below for methods of constructing proper suction line P traps Figure 4 Suction P traps Slope 1 4 per 10 ft toward compressor INCORRECT CORRECT Condensate Drain Lines Copper drain lines should be used and properly protected from freezing In running drain lines provide a minimum of 4 inches per foot pitch for proper drainage Drain lines should be at least as large as the evaporator drain connection All plumbing connections should be made in accordance with local plumbing codes All condensate drain lines must be trapped and run to an open drain They must never be connected directly to the sewer systems Traps in the drain line must be located in a warm ambient We recommend a trap on all evaporators Traps located outside or extensive outside runs of drain line must be wrapped with a drain line heater The heater should be Figure 5 Drain Line connected so that it is continuously on It is recommended that the drain line be insulated to prevent heat loss A heat input of 20 watts per lineal foot of drain line for 18 C room applications and 30 watts per lineal foot for 20 F 29 C rooms is satisfactory VP LLL EL OP CLL LL ee AN RSA ASASASAAAASS Inspect the drain pan periodically to insure free drainage of condensate I
18. f the drain pan contains standing water check for proper installation The drain pan should be cleaned regularly with warm soapy water DRAIN LINE MIN PITCH 4 VAPOR SEAL before cleaning The drain pan also serves as cover for hazardous moving parts Operation DRAIN of unit without drain pan constitutes a hazard a o NOTE Always trap drain lines individually to prevent vapor migration Refrigeration Piping Figure 6 Example of Pipe Support 1 Normally any straight run of tubing must be supported in at least two locations near each end of the run Long runs require additional supports The refrigerant lines should be supported and fastened properly As a guide 3 8 to 7 8 should be supported every 5 feet 1 1 8 and 1 3 8 every 7 feet and 1 5 8 and 2 1 8 every 9 to 10 feet 2 When changing directions in a run of tubing no corner should be left unsupported Supports should be placed a maximum of 2 feet in each direction from the corner 3 Piping attached to a vibrating object such as a compressor or compressor base must be supported in such a manner that will not restrict the movement of the vibrating object Rigid mounting will fatigue the copper tubing 4 Do not use short radius ells Short radius elbows have points of excessive stress concentration and are subject to breakage at these points 5 Thoroughly inspect all piping after the equipment is in operation and add supports wherever line vibration is
19. ference f All fan motors on air cooled condensers evaporators etc should be checked for proper rotation Fan motor mounts should be carefully checked for tightness and proper alignment g Observe system pressures during charging and initial operation Do not add oil while the system is short of refrigerant unless oil level is dangerously low h Continue charging until system has sufficient refrigerant for proper operation Do not overcharge Remember that bubbles sight glass may be caused by a restriction as well as a shortage of refrigerant i Do not leave unit unattended until the system has reached normal operating conditions and the oil charge has been properly adjusted to maintain the oil level at the center of the sight glass CAUTION Extreme care must be taken in starting compressors for the first time after system charging At this time all of the oil and most of the refrigerant might be in the compressor creating a condition which could cause compressor damage due to slugging Activating the crankcase heater for 24 hours prior to start up is recommended If no crankcase heater is present then directing a 500 watt heat lamp or other safe heat source on the lower shell of the compressor for approximately thirty minutes will be beneficial in eliminating this condition which might never reoccur 13 Operational Checkout After the system has been charged and has operated for at least 2 hours at normal operating condi
20. ist RECORD OUTDOOR TEMPERATURE eee SYSTEM VOLTAGE PH System 1 Compressor Amps Ll2 B3 System 2 Compressor Amps Ll2 B3 System 3 Compressor Amps U Ll2 L3 System 1 Discharge Pressure _____ 5 System 2 Discharge Pressure _____ 5 System 3 Discharge Pressure _____ 5 System 1 Suction Pressure _____ 5 System 2 Suction Pressure System 3 Suction Pressure System 1 Suction Temp F System 2 Suction Temp Le SE System 3 Suction Temp System 1 Refrigerant Charge 165 System 2 Refrigerant Charge 165 System 3 Refrigerant Charge bs System 1 Compressor Superheat F System 2 Compressor Superheat F System 3 Compressor Superheat F System 1 Evaporator Superheat System 2 Evaporator Superheat F System 3 Evaporator Superheat a F System 1 Discharge Temp 68 S i ES 8 System 2 Discharge Temp _ system 2 System 1 System 3 Discharge Temp Ee 21 22 23 FlexPack WARNING Refrigerant can be harmful if it is inhaled Refrigerant must be used and recovered responsibly Failure to follow this warning may result in personal injury or death Since product improvement is a continuing effort we reserve the right to make changes in specifications without notice Visit our website at www heatcraftrpd com for technical literature online 2175 W Park Place Blvd Stone Mountain Georgia 30087 770 46
21. mends a superheat of 30 F 14 Preventive Maintenance Routine preventive maintenance of any mechanical equipment is critical to its long term reliability During normal operation all equipment will experience some deterioration during its lifetime caused by wear and evironmental influences For that reason regularly scheduled maintenance of your refrigeration equipment is required in order to keep it operating to its maximum efficiency while avoiding potentially costly repairs of a premature failure due to equipment neglect The following is our minimum recommendations for regularly scheduled preventive maintenance of your refrigeration system Only qualified and licensed refrigeration companies should perform all preventive and corrective maintenance on refrigeration equipment While we cannot guarantee that close adherence to these recommendations will eliminate all equipment problems it will greatly reduce the potential for mechanical and electrical failures thus providing increased reliability Refer to pages 16 and 17 for preventive maintenance guidelines 15 E gt Q suojoes Aue se pue uoisouoojue ue pue sesse amje ______ 995 0 uonu y
22. nk to break the vacuum Weighing in the charge is recommended with the initial charge consisting of approximately 2 pounds per system compressor horsepower 3 Remove the refrigerant drum and connect it to the suction side of the compressor to charge with refrigerant vapor into the low side of the system until the pressure is above atmospheric 4 Start the system and finish charging until the sight glass indicates a full charge and the proper amount has been weighed in a total of 4 to 5 pounds per system compressor horsepower 5 If refrigerant must be added to the system through the suction side of the compressor charge in vapor form only Liquid charging must be done in the high side only or with liquid metering devices to protect the compressor Check Out amp Start Up After the installation has been completed the following points should be covered before the system is placed in operation a Check all electrical and refrigerant connections Be sure they are all correct and tight b Check setting of time delay relay for low pressure switch in condensing unit It should be set at two minutes the third marker Check high and low pressure controls pressure regulating valves oil pressure safety controls and all other safety controls and adjust them if necessary d Liquid line should always be insulated e Wiring diagrams instruction bulletins etc attached to the condensing units should be read and filed for future re
23. the female After brazing remove excess flux i Wrap expansion valves with wet rags during brazing to the liquid line CAUTION If the temperature gets too high these components may be damaged Heat absorbing compounds piping line connections and the suction line sensor must be removed per above instructions j Do not use bull head tees This will cause oil return problems and can cause poor performance If isolation valves are installed at the evaporator full port ball valves should be used Refrigeration Piping Suction Lines NOTE If the suction line must rise to the point higher than the suction connection on the evaporator a suction line trap at the outlet of the evaporator must be provided Horizontal suction lines should slope away from the evaporator toward the compressor at the rate of 1 4 per 10 feet for good oil return When multiple evaporators are connected in series using a common suction line the branch suction lines must enter the top of the common suction line Suction lines that outside of refrigerated space must be insulated See Line Insulation for more information Suction Line Risers NOTE To provide proper oil return a suction trap must be provided at the base of all suction risers Prefabricated wrought copper traps are available or a trap can be made by using two street ells and one regular ell The suction trap must be the same size as the suction line For long v
24. tions without any indication of malfunction it should be allowed to operate overnight on automatic controls Then a thorough re check of the entire system operation should be made as follows a Check compressor discharge and suction pressures If not within system design limits determine why and take corrective action b Check liquid line sight glass and expansion valve operation If there are indications that more refrigerant is required leak test all connections and system components and repair any leaks before adding refrigerant c Using suitable instruments carefully check line voltage and amperage at the compressor terminals Voltage must be within 10 of that indicated on the condensing unit nameplate If high or low voltage is indicated notify the power company If amperage draw is excessive immediately determine the cause and take corrective action On 3 phase motor compressors check to see that a balanced load is drawn by each phase d The maximum approved settings for high pressure controls on Heatcraft air cooled condensing equipment is 425 psig On air cooled systems check as follows Disconnect the fan motors or block the condenser inlet air Watch high pressure gauge for cutout point e Re check all safety amp operating controls for proper operation and adjust if necessary e Check head pressure controls for pressure setting f Check crankcase heater operation if used 9 Install instruction card and control
25. ve been accounted for Check carefully for concealed damage Any shortage or damages should be reported to the delivering carrier Damaged material becomes the delivering carrier s responsibility and should not be returned to the manufacturer unless prior approval is given to do so When uncrating care should be taken to prevent damage Heavy equipment should be left on its shipping base until it has been moved to the final location 2011 Heatcraft Refrigeration Products LLC Compressor Module Specifications Table 1 Hermetic Compressor Module Electrical Data High Temp Medium Temp Hermetic Compressor Model ART82C1 CAV Compressor Data Compressor Electrical Rating 60 208 230 RLA MCC 1 56 Crankcase Heater Watts 22 10 CR18KQ PFV 208 230 CR18KQ TF5 208 230 CR24KQ PFV 208 230 CR24KQ TF5 208 230 CR37KQ PFV 208 230 CR37KQ TF5 208 230 CR53KQ PFV 208 230 CR53KQ TF5 208 230 CRN 0500 PFV 208 230 CRN 0500 TF5 208 230 RS64C2 CAV 208 230 o o O O 9 O o o o RS70C1 PFV CS10K6E PFV 208 230 208 230 CS10K6E TF5 208 230 CS12K6E PFV 208 230 CS12K6E TF5 208 230 CS14K6E PFV 208 230 CS14K6E TF5 208 230 CS18K6E PFV 208 230 CS18K6E TF5 208 230 CS20K6E PFV 208 230 CS20K6E TF5 208 230 CS27K6E PFV 20
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