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Installation

Operation
Maintenance

Air-Cooled Chiller 5-18 Tons


CGAT Model 50 Hz

Models;
CGAT 065 D, CGAT 135 D
CGAT 085 D, CGAT 175 D
CGAT 105 D, CGAT 215 D

January 2009 CGAT-IOM01-EN


Model Nomenclature

C G A T 0 6 5 D 0 0 0 0 A A
1 2 3 4 5 6 7 8 9 10 11 12 13 14
DIGIT 1,2,3 - MODEL IDENTIFIER
CGA = COLD GENERATOR, AIR-COOLED

DIGIT 4 - DEVELOPMENT SEQUENCE


T = DEVELOPMENT SEQUENCE
DIGIT 5,6,7 - NOMINAL CAPACITY
065 - 65 MBH
085 - 85 MBH
105 - 105 MBH
135 - 135 MBH
175 - 175 MBH
215 - 215 MBH
DIGIT 8 - ELECTRICAL CHARACTERISTICS
D = 380-415V/3pH/50Hz
DIGIT 9,10 - FACTORY INSTALLED OPTIONS
00 = NONE
0A = FACTORY INSTALLED OPTIONS
DIGIT 11,12 - 0, 0 FOR FUTURE USE
DIGIT 13 - MINOR DESIGN SEQUENCE
A = FIRST DESIGN SEQUENCE
DIGIT 14 - SERVICE DIGIT
A = FIRST PARTS LIST

2 American Standard Inc. 2003


© CGAT-IOM01-EN
Contents

Model Nomenclature 2
General Information 4
General Data 5
Installation 6
Electrical 8
Typical Wiring Diagram 9

Trouble Shooting 10
Dimensional Data 12

CGAT-IOM01-EN 3
General Information

General General Information Before preparing the unit for lifting,


All Trane Products are identified by All model CGAT air-cooled chillers are estimate the approximate centre
a model number that Precisely designed for outdoor installation with of gravity for lifting safety. Due to the
identifies the unit. An explanation of vertical air discharge. Each refrigerant placement of internal components,
the alphanumeric identification codes circuit is provided with an operating the unit weights may be unevenly
for CGAT units is provided on the next charge of refrigerant and refrigerant distributed. Unit shipping weights
page. oil, a filler drier, high and low pressure are provided in the table below.
Its use will enable the owner /operator, schraeder valve and externally
installing contractors and service equalized thermostatic expansion Lifting Recommendations
engineers to define the operation, valve. All units are dehydrated, leak Before preparing the unit for lifting,
components and options for any tested, charged and tested for proper estimate the approximate center of
specific unit. control operation before shipment. An gravity for lifting safety. Because of
When ordering replacement parts or access panel(s) provides access to the placement of internal components,
requesting service, be sure to refer to compressor section(s), and a remov- the unit weight may be unevenly
the serial number and specific model able cover allows access to the distributed. Approximate unit weights
number stamped on the unit name- control box. are given in Table 1.
plate. The brazed plate heat evaporators
used in these units are with integral WARNING : On-sight lifting equipment
Unit Nameplate distributor. Each evaporator is fully must be capable of lifting the unit
The unit nameplate specifies the unit’s insulated. Standard capacity and weight with an adequate safety factor.
specific model number, serial number, safety controls are provided. Unit The use of under-capacity lifting
electrical characteristics, type of operation is governed by chilled water devices may result in severe personal
refrigerant and other pertinent unit temperature entering the evaporator. injury or death and can seriously
data. damage the unit.
Rigging
The crated unit can be moved using
WARNING: To prevent injury or death a forklift of suitable capacity. For lifting
and unit damage, observe handling the unit, attach lifting straps or slings
cautions and procedures given in securely to the lifting holes at each
Figure 1 when lifting the unit. Always corner. Use spreader bars to protect
test-lift the unit to determine actual the unit casing from damage. Test lift
centre of gravity. the unit to determine proper balance
and stability.

CAUTION : Use spreader bars to


prevent lifting straps from damaging
the unit,. Install bars between lifting
straps. This will prevent the straps
from crushing the unit cabinet or
damaging the unit finish.

Table 1 : Total Unit Weight and Corner Weights

Corner Weight-Kgs
Shipping Maximum Net maximum
Model Kgs Lbs Kgs Lbs #1 #2 #3 #4
CGAT065 201 442.2 181 398.2 67.5 38.1 44.0 31.4
CGAT085 224 492.8 204 448.8 76.1 42.9 49.6 35.4
CGAT105 270 594.0 250 550.0 100.4 38.2 91.0 20.4
CGAT135 441 970.2 406 893.2 107.3 97.8 95.8 105.3
CGAT175 487 1071.4 452 994.4 119.5 108.5 106.5 117.5
CGAT215 507 1115.4 472 1038.4 125.0 113.0 111.0 123.0

4 CGAT-IOM01-EN
General Data

CGAT065D CGAT085D CGAT105D CGAT135D CGAT175D CGAT215D


Unit Performance
Cooling Capacity (1) MBH 65.2 86.3 104.4 133.1 175.4 214.9
Main Power supply V/Ph/Hz 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50
Min.Brch.Cir.Ampacity A 18.1 27.3 29.8 32.7 49.4 53.9
No.of Independent circuits 1 1 1 2 2 2
Compressor
Type Hermetic Scroll
Speeds number 1 1 1 1 1 1
Motors Number 1 1 1 2 2 2
Rated Amps (2) A 13.6 20.7 22.9 13.6 20.7 22.9
Locked rotor Amps (2) A 98 130 145 98 130 145
Motor RPM rpm 2900 2900 2900 2900 2900 2900
Evaporator
Type Brazed-plate Brazed-plate Brazed-plate Brazed-plate Brazed-plate Brazed-plate
Water flowrate GPM 13.0 17.3 20.9 26.6 35.1 43.0
Water Connections
Type Male Male Male Male Male Male
Diameter 1 1/2" 1 1/2" 1 1/2" 1 1/2" 1 1/2" 1 1/2"
Outdoor Coil
Type Uncoated Corrugate
Tube size inch 3/8 3/8 3/8 3/8 3/8 3/8
Tube type Smooth Smooth Smooth Smooth Smooth Smooth
Face Area Ft2 15.10 20.00 25.00 30.20 40.00 42.50
Rows # 2 2 2 2 2 2
Fins per inch (fpf) # 16 (192) 16 (192) 16 (192) 16 (192) 16 (192) 16 (192)
Outdoor Fan
Type Propeller Propeller Propeller Propeller Propeller Propeller
Number 1 1 1 2 2 2
Diameter inch 28 28 28 28 28 28
Drive type Direct Direct Direct Direct Direct Direct
Speeds number 1 1 1 1 1 1
Air flow CFM 4900 5800 6800 9800 11600 13600
Motors Number 1 1 1 2 2 2
Motor HP (1) hp 3/4 3/4 3/4 3/4 3/4 3/4
Rated Amps (1) A 1.06 1.41 1.20 1.06 1.41 1.20
Locked rotor Amps (1) A 2.27 3.53 2.80 2.27 3.53 2.80
Motor RPM rpm 750 830 875 750 830 875
Dimensions
Height mm 1050 1050 1050 1050 1050 1050
Length mm 1060 1060 1260 2200 2200 2200
Width mm 950 950 1050 1050 1050 1050
Weight uncrated kg 181 204 250 406 452 472
R-22 Refrigerant Charge (2) kg 4.0 4.3 6.0 4.0 5.0 6.0
Notes:
(1) per motor
(2) per circuit

CGAT-IOM01-EN 5
Installation

Installation Foundation Air Vents


Verily completion of installation by Elevate the unit. Ensure the floor or Vents must be installed at high points
reviewing the following procedures. foundation of the unit is level, solid in the piping system to facilitate air
and of sufficient strength to support purging during the filling process.
Unit Dimensions And Weights General Data Page 5 for information
These are provided under General on weights. Pressure Gauges
Data on Page 5 Install pressure gauges to monitor
Unit water Piping the entering and leaving chilled water
Drainage General Piping Recommendations pressure.
Locate the unit near a large-capacity Thoroughly flush all water supply
drain to allow system drainage during piping before making the final piping CAUTION : To prevent evaporator
unit shutdown or repair. connections to the unit. damage, do not exceed 350 psig
waterside working pressure.
Location And Clearance CAUTION : If using an acidic
Requirements commercial flushing solution, Shutoff Valves
1. The surface in to be level and of construct a temporary bypass around Provide shutoff valves in the Supply
sufficient strength to support to unit to prevent damage to the and Return pipe near the chiller to
the unit. evaporator internal components. allow isolation of the gauge(s),
2. Select a location that will permit sensors, strainers, etc., during service.
free air flow into the condensing Evaporator water inlet and outlet
coils and from the vertical dis types, sizes and locations are shown Thermometers
charge. If however, the unit is to be in the Dimensional data section page
Install thermometers in the lines to
placed under an overhang, allow at 18-19 Figure 1 on page 7 illustrates
monitor the evaporator entering and
least 2.0 meters clearance above a typical water piping components.
leaving water temperatures.
the unit to prevent recirculation of
hot discharge air. Isolate the water pump from the
Balancing Valves
3. For ground level installation the unit system to avoid vibration
The is required to establish regulation
should be set on a level concrete transmission. All water piping are to
and Balancing of the water flow.
slab 100 mm thick and extending be insulated to minimize heat gain and
a minimum of 200 mm beyond the prevent condensation. Use a pipe
sealant or Teflon tape on all threaded Strainer
sides of the unit. Install a pipe strainer in the water
4. Mount vibration isolators to avoid connections.
return line to protect the components
vibration or noise transmission. from entrapped debris.
Provide a gravelled apron at least Net Positive Suction Head
300 mm wide on all sides of the Evaporator water pumps should be
slab unless other means are used located in their piping systems such
to prevent growth of vegetation that they operate with a net positive
close to the unit. The slab should suction head. This is to reduce the
be located as close to the building possibility of pump cavitation and
as possible with a minimum possible differential aeration in the
clearance conform to the water system which can rapidly result
submittals in front of air entry and in chiller internal corrosion.
access panels.
5. Provide a large capacity water drain
near the unit. It is used when the
evaporator in drained for shutdown
or repair. The water circuit is
drained thanks to the evaporator
water connections.

6 CGAT-IOM01-EN
Installation

Chiller Flow Switch


Used to prevent or stop compressor operation if the evaporator water flow drops
off dramatically.

Figure 1 - Typical Water Piping

Air Vent Pressure Gauge

Unions

Vibration
Eliminators
Thermometers
Shutoff
Valves
Water Strainer

Reeturn Line
(Inlet)
(See Note 1)

Flow Switch
Gate Valves
(See Note 2
Balancing Valve

Figure 2 : Evaporator pressure drops

100.00

065 085 105 135 175 215


Pressure Drop, feet of water

10.00

1.00
10.0 100.0
Water flowrate, gpm

CGAT-IOM01-EN 7
Electrical

Electrical Wiring 2. Refer to the unit wiring schematic


pasted to the control panel cover.
WARNING: To prevent injury or death, 3. All factory supplied wiring are
disconnect electrical power source coloured and numbered. Always
before completing wiring connections check the numbers on the wiring
to unit. to the unit terminal block against
that in the wiring diagram. Should
Table below provides the electrical there be any inconsistency, please
data for each of the units. All wiring do not hesitate to contact the
should confirm to NEC or applicable nearest Trane Service or Sales
codes as per requirements of local Organization.
codes and regulations. Wiring dia- 4. Chilled Water Pump Motor
grams are furnished with the units but The installer must provide a power
extra copies can be obtained from the supply of proper voltage and
Trane Sales Offices. The installer must a fused disconnect switch to the
provide fused disconnect switches. chilled water pump motor. Provide
Type and locations of disconnects proper equipment grounds.
must comply with all applicable 5. Flow Switch Interlock
codes. To avoid possible evaporator
freeze-up resulting from restricted
CAUTION : To avoid component water flow, install a flow switch
failure, use copper conductor wire (or other flow sensing device) in the
only between the main power evaporator water line. This sensing
distribution source and the unit’s device must be adjusted to stop
power terminals. This will prevent compressor operation if water flow
galvanic corrosion or overheating at to the evaporator drops 50% of the
the terminals. design flow rate.
1. Verify power supply available is
compatible with unit’s nameplate
ratings.

Table 2 - CGAT Unit Electrical Data

Compressor Motor Outdoor Fan Motor

Allowable Minimum Maximum Amps(each) Amps(each)

Model Electrical Voltage Circuit Fuse


Number Characteristics Range Ampacity Size Qty. RLA LRA Qty. Watt output(each) RLA LRA
CGAT065D 380-415/3/50 342-440 18.1 30 1 13.6 98.0 1 290 1.06 2.27

CGAT085D 380-415/3/50 342-440 27.3 30 1 20.7 130.0 1 420 1.41 3.53

CGAT105D 380-415/3/50 342-440 29.8 30 1 22.9 145.0 1 300 1.20 2.28

CGAT135D 380-415/3/50 342-440 32.7 30 2 13.6 98.0 2 290 1.06 2.27

CGAT175D 380-415/3/50 342-440 49.4 30 2 20.7 130.0 2 420 1.41 3.53

CGAT215D 380-415/3/50 342-440 53.9 30 2 22.9 145.0 2 300 1.20 2.28

8 CGAT-IOM01-EN
Control Panel

Compressor on/off
LED Display for water
display status
temperature and errors

Water Freeze
Leaving Water Temp
Sensor#2 display status
status display

Water Freezed Pump on/off


Sensor#1display status display status

Up/Down button
use to select which
sensor temperature or Power on/off button
settings to be shown on
LED display

Program selection button

CGAT-IOM01-EN 11
Pre-Start Procedure

Once the unit is installed, follow the Measure each leg of supply voltage
steps below to ensure the installation (3-phase) at all ling voltage disconnect
procedure is complete. When all are switches. Readings must fall within
accomplished, the unit is ready for the voltage utilization range shown on
operation. the unit nameplate.

WARNING : More than one discon- 4. Fill the chilled water circuit, leaving Voltage Imbalance
nect switch may be required to the system air vents open. Close Excessive voltage imbalance between
de-energize unit for servicing. Refer to vent after filling. phase will cause motors to overheat
unit schematic and open all electrical 5. Start the chilled water pump. With and eventually fail. Maximum allow-
disconnects to prevent injury or death water circulating through the chilled able imbalance is 2%
due to electrical shock. water system, inspect all piping
connections for leaks and make % Voltage Imbalance = 100 x [VA -VD]
1. Inspect all wiring connections; any necessary repairs. VA
electrical connections should be 6. Adjust the water flow rate through where VA is the average voltage and
clean and tight. the chilled water circuit, and check VD is the ling voltage that deviates
the water pressure drop through farthest from VA
WARNING : Use extreme care the evaporator. Refer to water
when electrically troubleshooting pressure drop data on page 8. 11. Establish a balanced water flow
compressors. If electrical power is 7. Ensure flow switch is installed and through the evaporator.
applied to a damaged fusite terminal, wired to the control panel. Adjust 12. Measure the water pressure drop
a fire or explosion could occur, the flow switch to provide proper through the evaporator at the
resulting in injury or death. operation. pressure gauge(s) on the system
water piping. Pressure drop
CAUTION : Check tightness of all NOTE : Withe the water pump readings at the gauges should
connections in the compressor power operating, throttle the water flow to approximate those indicated by
circuit (disconnects, terminal block, approximately 50 percent of the full the pressure drop charts (figure 2)
contactors, compressor junction box flow rate. Following the manufacturer’s on page 8
terminals, etc.) to prevent overheating instruction adjust the flow switch
at connections and under voltage contacts to open at this point. Use NOTE : Be sure to account for piping/
conditions at the motor. an Ohmmeter to verify opening and fittings that will create additional
closure of the switch contacts. pressure drop between the unit and
2. Check power supply voltage to the pressure gauge locations.
the unit at the main power fused 8. Stop the chilled water pump.
disconnect switch; the voltage 9. Open all fused disconnect
reading should be within the switches.
utilization range shown in Table 2
on page 9. Also, Voltage imbalance WARNING : Use extreme care when
must not exceed 2%. (Refer to item checking voltage at live terminals to
10 Unit voltage and amperage avoid serious injury or death due to
checks ) electrical shock.
3. Check the condenser fan
assemblies; the fan blades should 10. Unit Voltage and Amperage
rotate freely in the fan orifice, and Checks Voltage supply
be securely attached to the fan
shaft.

12 CGAT-IOM01-EN
Operation

Start-up Procedure CAUTION : If suction and discharge


1. Energize the evaporator water pressures are low, but subcooling is
pump. normal, no refrigerant shortage exists.
2. Energize the CGAT unit. Adding refrigerant will result in
3. Checking operating conditions overcharging.
Once the unit has been operating
for at least 15 minutes and 7. Add refrigerant vapor with the unit
the system has stabilized, running by charging through
the following procedures are to be the access port on the suction line
done. until operating pressures are
a. Re-check the evaporator water normal. Allow sufficient time
flow and pressure drop. (between 15 to 30 minutes) before
b. Measure unit suction and taking readings.
discharge pressures. The
normal operating suction CAUTION : To prevent compressor
pressure is between 63 to 68 damage, do not allow liquid refrigerant
psig while the discharge to enter the suction line.
pressure range in between 270
psig to 300 psig. 8. If operating pressures indicate
c. Check compressor amp. Draw an overcharge, slowly (to minimize
oil loss) recover refrigerant at
NOTE : Many application variables the liquid line access port.
exists which can affect operating
pressures; these include ambient dry Important note : Do not release
bulb, wind velocity, restrictions in refrigerant to the atmosphere.
airflow etc. As such, do not use Use proper refrigerant recovery
operating pressures as the sole check process.
of system operation.
WARNING : To prevent injury due to
4. Measure system superheat. Normal frostbite, avoid skin contact with
system superheat is 12 to 15 deg. F refrigerant.
for each circuit at ARI conditions
(54 deg. F entering water, 44 deg.F 9. Check compressor oil levels. At full
leaving water at 95 deg.F ambient load, oil level should be visible in
temperature). the oil level sight glass on the
5. Measure system subcooling compressor.
Normal subcooling for each circuit
is 12 to 16 deg.F at ARI conditions. 10.Inspect the unit. Remove any
6. If operating pressure, superheat debris, tools and hardware. Secure
and subcooling readings indicate all exterior panels.
refrigerant shortage, find and repair
leaks and gas-charge refrigerant
into each circuit. Refrigerant
shortage is indicated it operating
pressures are low and subcooling
is also low.

CGAT-IOM01-EN 13
Operation

Electrical Control System

The controls used on CGAT065-215 chillers are classified either as safety or


operational controls.

Refer to the following control description for control setting

Control Electrical Contacts Contact

Description designation open close

High Press. Cutout HPCO1,HPC02 398+-19 psig 310+-21 psig

Low Press. Cutout LPC01,LPC02 27+-7 psig 45.5+-7 psig

Frost controller A27m <35.6 deg.F -

Delay between TDR1,TDR2 Normally - open 3,4.5 minute

comp. Timed to close

Unit Safety Controls • Frost Controller or Low


Temperature Cutout (LTC)
• Low Pressure Cutout (LPC01, The Low Temperature Cutout is
LPC02) designed to protect the evaporator
• High Pressure Cutout (HPC01, from freeze damage in the event of
HPC02) water temperature thermostat
malfunction or if the is a restricted
• Reset relays (1R, 2R)
water flow condition. The LTC’s
remote sensing bulbs monitors
If the unit is shutdown the low pressure
Leaving water temperature.
cutout (or high pressure cutout, the
Manual reset is required. Factory
reset relay locks out the compressor
Setting : 2C.
contactor (1M, 2M). This prevents
the system from recycling until the
• Motor Overloads
condition that caused the trip is
These units have internal compressor
determined and corrected.
and condenser fan motor overloads.
These overloads protect the motors
CAUTION : To prevent unit damage,
from overcurrent and overheating
do not reset the control circuit until
conditions and automatically reset as
the cause of the safety lockout is
soon as they cool sufficiently.
identified and corrected.

To reset 1R and 2R, open and close Unit Operational Controls


the unit Low Voltage Control Circuit • Water Temperature
Breaker (MCB). Thermostat (WTT)
System operation for CGAT is
controlled either by single-stage
thermostat CGAT075 - 120 or two-
stage thermostat CGAT150 - 240

• Delay Between Compressors


Prevents compressors from starting at
the same time.

14 CGAT-IOM01-EN
Trouble Shouting

Symptom Recommended action

A. Compressor neither starts nor hums.


Probable Cause
1. No power a. Check for disconnect switch open.
b. Check for blown fuse
2. No call for cooling a. Check for defective thermostat or
b. Broken or improper control wiring
3. Unit locked out by reset relay a. Check for excessive discharge pressure
b. Check for defective thermostat
4. Compressor contactor will not close a. Check for open reset relay
b. See for defective thermostat
5. Compressor winding thermostat open a. Check compressor amp. Draw
b. See compressor winding thermostat open
B. Compressor hums, but will not start
1. Low voltage at compressor a. Check for low fine voltage
b. Check for defective compressor contactors
2. Defective compressor a. Check fro open motor winding
b. Check for excessive amp. draw on all phases.
C. 2nd. stage compressor fails to start
1. Time delay contacts fail to close Replace time delay relay
2. No call for cooling a. Check for defective thermostat
b. Check for improper control wiring
3. Locked out by reset relay a. see Symptom A.
4. Compressor contactor will not close a. see Symptom A.
D. Compressor runs continuously
1. Unit undersized for load a. Check cause of excessive load.
2. Thermostat setpoint too low a. Re-adjust thermostat setting.
3. ”Welded” contacts on compressor contactor a. Repair or replace contactors.
4. Leaky valves in compressor Replace compressor
(indicated by abnormally low discharge and
high suction pressure)
5. Refrigerant shortage (as indicated by reduced Find and repair leak. Recharge system.
capacity, high superheat, low subcooling and
low suction pressure)
E. Compressor motor winding thermostat open
1. Excessive load on evap. a. Check for excessive water flow.
b. Check for high return water temp.
2. Lack of motor cooling a. Check for improper expansion valve setting or faulty
expansion valve.
b. Check for restriction in liquid line.
3. Improper voltage at compressor a. Check for low or imbalanced line voltage, loose power
wiring or defective compressor contactor.

CGAT-IOM01-EN 15
Trouble Shouting

Symptom Recommended action


F. Noisy compressor
1. Damaged internal parts Replace compressor
2. Liquid floodback (abnormally cold suction Check and adjust superheat
line and low superheat)
3. Liquid refrigerant in compressor at start-up a. Check crankcase heater
b. Check for refrigerant overcharge.
G. System short of capacity
1. Low charge Add refrigerant
2. Clogged filter drier Replace filter drier
3. Incorrect expansion valve setting Replace expansion valve
4. Expansion valve stuck or obstructed Replace expansion valve
5. Low evaporator water flow Check strainers. Adjust water flow
6. Noncondensibles in the system Evacuate and recharge system
7. Leaky valves in compressor Replace compressor
H. Suction pressure too low
1. Short of refrigerant Find and repair leak; recharge system
2. Thermostat set too low Readjust thermostat
3. Low water flow Check strainers and adjust balancing valve.
4. Clogged filter drier Replace
5. Expansion valve faulty Replace
I. Suction pressure too high
1. Excessive cooling load Check for cause of excessive load
2. Expansion valve overfeeding a. Verify remote bulb is properly attached
b. Adjust superheat setting
3. Suction valve broken (i.e. noisy compressor) Replace compressor
J. Discharge pressure too low
1. Shortage of refrigerant Find and repair leak.
2. Broken or leaky compressor discharge valve Replace compressor
K. Discharge pressure too high
1. Condenser airflow restricted Check fan motor, clean coil
2. Air or noncondensible gas in system Evacuate and recharge system
3. Refrigerant overcharge Recover excess refrigerant
4. Excessive system load Check cause

16 CGAT-IOM01-EN
Note

CGAT-IOM01-EN 19
Trane Thailand Literature Order Number: CGAT-IOM01-EN0303
7th Floor, Ploenchit Center Building
New
2 Sukhumvit Road, Klongtoey
Bangkok 10110 Stocking Location: Bangkok, Thailand
Amair Limited
35 Mu 8, Poochaosamingprai Road ∫√‘…—∑ ·Õ¡·Õ√å ®”°—¥ 35 À¡Ÿà 8 ∂.ªŸÉ‡®â“ ¡‘ßæ√“¬ µ. ”‚√ß„µâ Õ.æ√–ª√–·¥ß ®. ¡ÿ∑√ª√“°“√ 10130
Samrong Tai, Samutprakarn 10130
http://www.trane.com Since The Trane Company has a policy of continuous product and product data improvement,
An American Standard Company it reserves the right to change design and specifications without notice.

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