TT0710-01 IPH-UCB.pdf

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TT 0710/01

TYPE TEST

OF

3 Phase Cross BondingLink Box, Type: LB.U.CB.3SA.3.1

TT0710.01 A1

Tavukçuyolu Türker Cad. No:8 Kat:3 34775 Y.Dudullu - Ümraniye - İSTANBUL - TÜRKİYE T: +90 216 364 69 40 F : +90 216 364 69 31

www.emelec.com.tr

Tested by: IPH, Berlin

RPT No : 2977.2100555.0295

Date: 01 June to 02 July, 2010Pages: 50

Appendix: ---

http://www.emelec.com.tr/



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Independent test laboratory, accredited by Deutsche Akkreditierungsstelle Technik (DATech) e.V. in the fields of h.v. apparatusand switchgear, power cables and power cable accessories, l.v. apparatus and switchgear, installation equipment andswitching and control equipment.

Institut „Prüffeld für elektrische Hochleistungstechnik“ GmbH (IPH Berlin) is a subsidiary of CESI S.p.A, Milan.

Independent, accredited testing station Member laboratory of STL and LOVAG

T E S T R E P O R T NO. 2977.2100555.0295

EM Electrical Materials Contracting Co. Tavukcuyolu, Türker Cad. No. 08 Y. Dudullu-Umraniye34776 Istanbul TURKEY

CLIENT

EM Electrical Materials Contracting Co. MANUFACTURER

Cross bonding link box TEST OBJECT

LB.U.CB.3SA.3.1 TYPE

Test sample SERIAL NO.

Rated DC withstand voltageRated lightning impulse withstand voltageRated short-time withstand current Rated duration of short-circuit Permissible values for internal arcing

Symmetrical short-circuit current Duration of short-circuit

IP code

2540 (60)

501

400.1

IPX8

kV kV kA s

kA s

RATEDCHARACTERISTICSGIVEN BY THECLIENT

Clients instructions NORMATIVEDOCUMENT

Dielectric tests Leakage current test IPX8 code test Short-time withstand current tests Test under conditions of arcing due to an internal fault Measurement of contact resistance Measurement of residual voltage

RANGE OF TESTSPERFORMED

1 June to 2 July 2010 DATE OF TEST

See Clause 11 TEST RESULT

H. GLABSCHSenior engineer

M. THOM Test engineer in charge

Berlin, 21 July 2010

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TEST REPORT NO. 2977.2100555.0295 SHEET 2

Contents Sheet

1. Present at the test................................. ................................................................... ......................................................... 4 2. Test performed................................................ ................................................................. ................................................... 4 3. Identity of the test object .................................................................... .............................................................. .......... 5 3.1 Technical data and characteristics.......................................................................................................................................................................................... 5 3.2 Identity documents .........................................................................................................................................................................................................................................5 4. Dielectric tests........................................ .............................................................. ................................................................ 6 4.1 Test laboratory ........................................................................................................................................................................................................................................................6 4.2 Normative document...................................................................................................................................................................................................................................6 4.3 Required test parameters......................................................................................................................................................................................................................6 4.4 Test arrangement...............................................................................................................................................................................................................................................6 4.5 Test and measuring circuits............................................................................................................................................................................................................... 7 4.6 Test results.....................................................................................................................................................................................................................................................................9 5. Leakage current test .......................................................... ............................................................... ........................... 12 5.1 Test laboratory ....................................................................................................................................................................................................................................................12 5.2 Normative document...............................................................................................................................................................................................................................12 5.3 Required test parameters..................................................................................................................................................................................................................12 5.4 Test arrangement...........................................................................................................................................................................................................................................12 5.5 Test and measuring circuits...........................................................................................................................................................................................................13 5.6 Test results.................................................................................................................................................................................................................................................................14 6. Proof of the degree of protection IPX8......................................................................................... ................. 15 6.1 Test laboratory ....................................................................................................................................................................................................................................................15 6.2 Normative document...............................................................................................................................................................................................................................15 6.3 Required test parameters..................................................................................................................................................................................................................15 6.4 Test arrangement...........................................................................................................................................................................................................................................15 6.5 Test and measuring circuits...........................................................................................................................................................................................................15 6.6 Test results.................................................................................................................................................................................................................................................................15 7. Short-time withstand current tests........................................................ ............................................................ 16 7.1 Test laboratory ....................................................................................................................................................................................................................................................16 7.2 Normative document...............................................................................................................................................................................................................................16 7.3 Required test parameters..................................................................................................................................................................................................................16 7.4 Test arrangement...........................................................................................................................................................................................................................................16 7.5 Test and measuring circuits...........................................................................................................................................................................................................17 7.6 Test results.................................................................................................................................................................................................................................................................18

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8. Test under conditions of arcing due to an internal fault. ................................................................. 19 8.1 Test laboratory ....................................................................................................................................................................................................................................................19 8.2 Normative document...............................................................................................................................................................................................................................19 8.3 Required test parameters..................................................................................................................................................................................................................19 8.4 Test arrangement...........................................................................................................................................................................................................................................19 8.5 Test and measuring circuits...........................................................................................................................................................................................................20 8.6 Test results.................................................................................................................................................................................................................................................................21 9. Measurement of contact resistance........................................................................... ...................................... 22 9.1 Test laboratory ....................................................................................................................................................................................................................................................22 9.2 Normative document...............................................................................................................................................................................................................................22 9.3 Test and measuring circuits...........................................................................................................................................................................................................22 9.4 Test results.................................................................................................................................................................................................................................................................23 10. Measurement of residual voltage............................................................................. ......................................... 24 10.1 Test laboratory ....................................................................................................................................................................................................................................................24 10.2 Normative document...............................................................................................................................................................................................................................24 10.3 Test results.................................................................................................................................................................................................................................................................24 11. Summary of results .............................................................. .............................................................. ........................... 25 12. Photos.................................................. .................................................................... ............................................................. .. 26 13. Oscillograms................................................................ ................................................................. ..................................... 37 14. Drawing............................................................ ............................................................ ......................................................... 50

This test document comprises 50 sheets.

Distribution Copy No. 1

Copy No. 1 in English: EM Electrical Materials Contracting Co.

The test results relate only to the object tested. This document is confidential. Its transfer to third parties as well as its reproduction in extracts require the consent of the client.

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1. Present at the test

Mr. Thom IPH test engineer in charge

Mr. Borchert, Rainer IPH test engineer

Mr. Wittwer IPH test engineer

Mr. Markhoff IPH test engineer (witnessing in Istanbul)

Mr. Erdeniz EM Electrical Materials Contracting Co.

Mr. Gürsoy EM Electrical Materials Contracting Co. (witnessing in Istanbul)

2. Test performed

Dielectric tests Leakage current test IPX8 code test Short-time withstand current tests Test under conditions of arcing due to an internal fault Measurement of contact resistance Measurement of residual voltage

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3. Identity of the test object

3.1 Technical data and characteristics

The technical data and characteristics of the test object are defined by the following parametersand specified by the client.

Test object: Cross bonding link box Type: LB.U.CB.3SA.3.1Manufacturer: EM Electrical MaterialsSerial No.: Test sample

Year of manufacture:

2010

Data:

Rated voltage Not specifiedRated DC withstand voltage 25 kV Rated lightning impulse withstand voltage Up 40 (60) kV Rated short-time withstand current Ik 50 kA Rated duration of short-circuit t k 1 sPermissible values for internal arcing

Symmetrical short-circuit current 40 kA Duration of short-circuit 0.1 s

IP code IPX8

Characteristics: Thickness of housing 3 mm

3.2 Identity documents

The manufacturer confirms that the test object has been manufactured in compliance with thedrawings given in this document. IPH did not verify this compliance in detail. The identity of the test object is fixed by the following drawings and data submitted by the client:

Name of drawing Drawing No. Date of drawing Author Notes

CROSS BONDING LINK BOX FOR UNDERGROUND USE TYPE: LB.U.CB.3SA.3.1

10.04.03Rev. 0

28.04.2010 EMELEC Sheet 50

10.04.03-LB.U.CB.3SA.3/1 -Page 3/4

13.05.2010 EMELEC 1)

10.04.03-LB.U.CB.3SA.3/1 -Page 4/5

13.05.2010 EMELEC 1)

1) These drawings are not part of this test document. They are retained in the IPH archives.

Entry of test object at IPH: 31 May and 21 June 2010

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4. Dielectric tests

4.1 Test laboratory

High-voltage test laboratory, high-voltage hall 2

4.2 Normative document

Client's instructions

4.3 Required test parameters

Active parts (L1, L2, L3, MP) against each other and against earth (F):DC 25 kV, 5 minLI 1.2/50 s, 40 kV

Active parts (L1, L2, L3, MP) against each other only LI 1.2/50 s, 60 kV

4.4 Test arrangement

See Sub-clause 4.6For the dielectric tests the surge arrestors were replaced by insulating dummy parts.

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4.5 Test and measuring circuits

DC voltage test

Technical data of test circuit

DC voltage source

Test transformer: Rated voltage 100 kV Rated power 8 kVA Rated frequency 50 Hz

Rectifier: Rated voltage 135 kV

Rated current 15 mA

Smoothing capacitor: Capacitance 10 nF

PO

1

CG

Gl

TrE

E Supply Tr Test transformer with variable transformer connected in seriesGl Rectifier CG Smoothing capacitor 1 Measuring point

PO Test object

Figure 1: Test and measuring circuit for the DC voltage test

Technical data of measuring circuit

Measuring point Measured quantity Measuring sensor/device Technical parameters

1 Test voltage Ohmic divider with

DC peak voltmeter typeMU11 (made by TuRD)

Ratio 561

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Test and measuring circuits (continued)

Lightning impulse voltage test


Impulse circuit: Number of stages n = 2Impulse capacitance CS = 70 nFLoading capacitance CB = 1.5 nFDamping resistance R D = 122 Discharge resistance R E = 1200

1C R

R

SCBE

D

PO

+/-

ZFSGl

~

Gl Rectifier R D Damping resistanceCS Impulse capacitance CB Loading capacitanceZFS Spark gap PO Test object R E Discharge resistance 1 Voltage measurement

Figure 2: Test and measuring circuit for the lightning impulse voltage test


Measuringpoint

Measured quantity Measuring sensor/device Technical parameters

1 Test voltage R divider of SMR 10/770 type(made by TuRD) with digitalmeasuring instrument of DMI 551 type (made by Haefely) and TDS 220 digital oscilloscope(made by Tektronix)

Ratio 472.3

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Test results (continued)


Date of test: 09 June 2010Front time of lightning impulse wave: 1.04 μs

Tail time of lightning impulse wave: 53.2 μs Air temperature: 21.4 C Air pressure: 100.21 kPa Air humidity (relative): 58 % Atmospheric correction of test voltage: Without atmospheric correction

Every voltage is related to an air pressure of 101.3 kPa, an air temperature of 20 C and an air humidity of 11 g/m3.

Test set-upMP

A

B

C

L1

L2

Frame

L3

S

S1

S2

S3

Impulsewithstand voltage

Test voltage 1) Number of impulses/disruptivedischarges

Configuration Voltageapplied to

Earthed kV kV

- L1 MP, L2, L3,S1, S3, F

40 +40-40

10/010/0

- L2 MP, L1, L3,S1, S2, F

40 +40-40

10/010/0

- L3 MP, L1, L2,S2, S3, F

40 +40-40

10/010/0

- MP L1, L2, L3,S1, S2, S3, F

40 +40-40

10/010/0

Notes:

1) Related to normal atmospheric conditions

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Test results (continued)


Date of test: 09 June 2010Front time of lightning impulse wave: 1.11 μs

Tail time of lightning impulse wave: 53.2 μs Air temperature: 21.4 C Air pressure: 100.21 kPa Air humidity (relative): 58 % Atmospheric correction of test voltage: Without atmospheric correction


Test set-upMP

A

B

C

L1

L2

Frame

L3

S

S1

S2

S3

Impulsewithstand voltage

Test voltage 1) Number of impulses/disruptivedischarges


Earthed kV kV

- L1 MP, L2, L3,S1, S3

60 +75-75

10/010/0

- L2 MP, L1, L3,S1, S2

60 +75-75

10/010/0

- L3 MP, L1, L2,S2, S3

60 +75-75

10/010/0

- MP L1, L2, L3,S1, S2, S3

60 +50-50

10/010/0

Notes:

1) Related to normal atmospheric conditions

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DC voltage test


DC voltage source

Test transformer: Rated voltage 100 kV Rated power 8 kVA Rated frequency 50 Hz

Rectifier: Rated voltage 135 kV

Rated current 15 mA

Smoothing capacitor: Capacitance 10 nF

PO

1

CG

Gl

TrE

2

E Supply Tr Test transformer with variable transformer connected in seriesGl Rectifier CG Smoothing capacitor 1 – 2 Measuring point PO Test object

Figure 3: Test and measuring circuit for the DC voltage test


Measuring point Measured quantity Measuring sensor/device Technical parameters

1 Test voltage Ohmic divider withDC peak voltmeter type

MU11 (made by TuRD)

Ratio 561

2 Leakage current Digital multimeter Keithley 137

--

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5.6 Test results

Leakage current test

Date of test: 09 June 2010 Testing time after having reached full amplitude: 1 min Air temperature: 21.4 C Air pressure: 100.21 kPa Air humidity (relative): 58 % Atmospheric correction of test voltage: Without atmospheric correction


Test set-up 2)

MP

L1

L2

Frame

L3

S

S1

S2

S3

DCwithstand voltage

Test voltage 1) Leakagecurrent


Earthed kV kV μ A

- L1 MP, F 5 5 <1

- L2 MP, F 5 5 <1

- L3 MP, F 5 5 <1

Notes:

1) Related to normal atmospheric conditions2) Serial No. of surge arrestors: L1: 597 L2: 598 L3: 599

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6. Proof of the degree of protection IPX8

6.1 Test laboratory

EM Elektrik Test Facilities Tavukcuyolu, Türker Cad. No. 08 Y. Dudullu-Umraniye34776 Istanbul TURKEY


Client’s instructions


IPX8

Water immersion test

Test means Pressure tank Water pressure of test 1 bar Test duration 24 hours


The test object was put into a pressure tank in horizontal position with the cables entries at the front (see Photo 7). The rubber gasket of the link box was fixed by glue, mutters tightened with 15 Nm. The pressure tank was filled with 1 bar water pressure. The feedback control is applied to sustain 1 bar water pressure for 24 hours.


None

6.6 Test results

Date of test: 01 and 02 June 2010

The test of the protection IPX8 is considered as passed, if after the test no water penetrated or only in such an amount that the correct operation of the device as well as the safety are not affected.

Result: No damage on gaskets and no water penetrated into the enclosure during the test.

The protection degree IPX8 is ensured for the tested link box.

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Test requirement

Short-time withstand current tests Test No. 110 4305 to 110 4308

Number of phases (Test circuit) 3/2

Number of poles/phases (Test object) 3

Power frequency Hz 50

Power factor cos < 0.15

Grid Not earthed

Earthing conditions Short-circuit transformer Not earthed

Short-circuit point One side earthed

E

MB MS L Tr I TO

1

U

2

R

Y

B

Earth bar

B

R

Y

E Supply I Current measurement MB Master breaker U Voltage measurement MS Making switch 1 – 2 Measuring pointsL Current-limiting reactor TO Test object Tr Short-circuit transformer

Figure 4: Test circuit (diagram of the test of the R-R'-connection)

Measuring point Symbol in theoscillograms

Measured quantity Measuring sensor/device

1 i Short-circuit current Rogowski measuring device

2 u Voltage RC divider

Recording instrument: BE 256 transient recorder system

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7.6 Test results

Test requ irement: Short-time withstand current tests

Test ob ject Cross bonding link box

Date of test: 10 June 2010

Condition of test object before test: New

Connection of test object: By cable 1 x 300 mm2 per phase

Amb ient temperature: 30 oC

Test No. 110 4305 4306 4307 4308

Conductor B – B’ B – B’ Y – Y’ R – R’

Resistance before test 153 - 144 144Peak current kA 67.7 71.2 74.9 77.0

Short-time current kA 47.4 50.6 51.1 51.0

Duration of short-circuit s 0.10 1.01 1.01 1.01

I2 t 106 A 2s - 2586 2637 2627

Equivalent 1-s current kA - 50.9 51.4 51.3

Resistance after test - 163 149 154

Variation of the resistance % - 6.2 3.6 6.9

Notes 1) 2) 2) 2)

Evaluation - OK OK OK

Notes:

1) Current setting2) Short-time withstand current test

Condition of test object after test:

OK Conductors did not show any undue deformation. The supporting insulating parts did not show any significant signs of deterioration.

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8. Test under conditions of arcing due to an internal fault

8.1 Test laboratory

High-power test laboratory, test bay 1




Short-circuit current 40 kA

Peak current 1) 56.6 kA

Duration of short-circuit 0.1 s

1) symmetrical making at voltage maximum


According to client’s instructions

Phase Y (incoming cable) energized, all other points were connected to ground.

Cf. Photo 12, Sheet 32

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Test requirement

Tests under conditions of arcing due toan internal fault

Test No. 110 4725 and 110 4726

Number of phases (Test circuit) 3/2

Number of poles/phases (Test object) 3

Power frequency Hz 50

Power factor cos < 0.15

Grid Not earthed

Earthing conditions Short-circuit transformer Not earthed

Short-circuit point Earthed

E

MB MS L Tr I TO

1

U

2

R

Y

B

Earth bar

B

R

Y

E Supply I Current measurement MB Master breaker U Voltage measurement MS Making switch 1 – 2 Measuring pointsL Current-limiting reactor TO Test object Tr Short-circuit transformer

Figure 5: Test circuit

Measuring point Symbol in theoscillograms

Measured quantity Measuring sensor/device

1 i Short-circuit current Rogowski measuring device

2 u Voltage RC divider

- P_ges Arc power Calculated value

- W Arc energy Calculated value

Recording instrument: BE 256 transient recorder system

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8.6 Test results

Test requirement:

Test under conditions of arcing due to an internal fault

Test No. 110 4725

Prospective peak short-circuit current kA 58.9

Prospective symmetrical short-circuit current kA 41.6

Duration of short-circuit ms 110

Notes 1)

Notes:

1) Current setting

Test requirement: Test under conditions of arcing due to an internal fault

Test object Cross bonding link box

Date of test: 2 July 2010

Condition of test object before test: New

Supply of test object: Two-phase to conductor Y and earthing bar;conductors R-R’, B-B’ and earthing bar connected toground

Arc initiation: Between Y (incoming cable) and earthing bar

using 0.5-mm metal wire

Test No. 110 4726

Peak current kA 60.3

Short-circuit current kA 40.2

Duration of short-circuit ms 109

Equivalent duration of short-circuit ms 110

related to a symmetrical short-circuit current of kA 40.0

Maximum power MW 39.5

Energy converted MWs 2.01

Note -

Evaluation OK

Notes:

--

Condition of test object after test:

OK The housing did not burst, no debris were ejected. There are no parts flown away whichcould cause a hazard.

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9. Measurement of contact resistance

9.1 Test laboratory

Low-voltage test laboratory, test room 1




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9.4 Test results

Date of test: 24 June 2010

Test object: Cross bonding link box

Ambient temperature: 18.4 ˚C

Contact Resistance (μΩ)

C.01 C.02 C.03 C.04 C.05 C.06 C.07

2.39 0.64 0.56 0.35 1.14 0.11 0.99

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11. Summary of results

Dielectric tests

As agreed with the client, the test object was subjected to a

DC voltage withstand voltage of 25 kV Phase-to-earth insulation andPhase-to-phase insulation

Lightning impulse withstand voltage of 40 kV Phase-to-earth insulation and60 (50) kV Phase-to-phase insulation

In the DC voltage tests no disruptive discharge occurred.

In the lightning impulse voltage test the number of disruptive discharges was 0 for every 10 impulses.

The requirements for the dielectric tests as specified by the client have been fulfilled.

Leakage current test

As agreed with the client, the test object was subjected to a

DC voltage withstand voltage of 5 kV Phase-to-earth insulation

The requirements for the leakage current test as specified by the client have been fulfilled.

IPX8 code test

The protection degree IPX8 is ensured for the tested link box.

Short-time withstand current tests

The test object was capable of carrying the rated symmetrical short-circuit current of 50 kA for aduration of short-circuit of 1 s properly. Conductors did not show any undue deformation. The

supporting insulating parts did not show any significant signs of deterioration.

Test under conditions of arcing due to an internal fault

The test object was subjected to a test under conditions of arcing due to an internal fault for aprospective value of the short-circuit current of 40 kA for a duration of short-circuit of 0.1 s. The housing did not burst, no debris were ejected. There are no parts away-flown which couldcause a hazard.

Measurement of residual voltage

The maximum residual voltage measured during the tests was 23.8 kV.

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12. Photos

Photo 1: View of the test object with closed outer cover plate

Photo 2: View of the test object with opened outer cover plate (the surge arrestors are replacedby insulating dummy parts)

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Photo 3: View of the test object with removed inner insulating cover plate and dummies in placeof surge arrestors

Photo 4: View of the test object with removed inner insulating cover plate

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Photo 5: View of the cable entry in the box

Photo 6: View of the test object with opened outer cover plate before IPX8 test

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Photo 7: View of the test equipment before the IPX8 test

Photo 8: View of the test equipment after the IPX8 test

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Photo 9: View of the test object with opened outer cover plate after the IPX8 test

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Photo 10: Test object in the test arrangement after short-time withstand current tests

Photo 11: Test object after short-time withstand current tests

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Photo 12: Test object in the test arrangement before internal arc test

Photo 13: Test object before Test No. 110 4726 (ignition wire)

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Photo 14: Test object before test

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Photo 15: Test object after test

Photo 16: Test object after test

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Photo 19: Test object after measurement of residual voltage test

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13. Oscillograms

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14. Drawing

Documents

TT0710-01 IPH-UCB.pdf