Xantrex™ GT500 E 500 kW and Xantrex GT630 E 630 kW Grid-Tied Photovoltaic Inverters Xantrex GT500 E Xantrex GT500 E GI Xantrex GT630 E Xantrex GT630 E GI Xantrex GT630 E GI 1K Planning, Installation, Troubleshooting and Maintenance Manual www.schneider-electric.
Xantrex GT500 E 500 kW and Xantrex GT630 E 630 kW Grid-Tied Photovoltaic Inverters Planning, Installation, Troubleshooting and Maintenance Manual www.schneider-electric.
Trademarks Schneider Electric, the Schneider Electric logo, and Xantrex are trademarks or registered trademarks of the Schneider Electric group of companies. Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only. Notice of Copyright Copyright © 2009, 2010 Xantrex Technology Inc. All rights reserved.
About This Manual Purpose The purpose of this Planning, Installation, Troubleshooting and Maintenance Manual is to provide explanations and procedures for planning and installing the Schneider Electric Xantrex GT500 E 500 kW and Schneider Electric Xantrex GT630 E 630 kW Grid-Tied Photovoltaic Inverters. Scope The Manual provides safety guidelines, detailed planning and setup information, and procedures for installing the inverter.
About This Manual Conventions Used The following conventions are used in this guide. WARNING Warnings identify conditions or practices that could result in personal injury or loss of life. CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment. Important: These notes describe things which are important for you to know, but not as serious as a caution or warning.
Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS - DO NOT DISCARD This manual contains important safety instructions for the Xantrex GT500 E 500 kW and Xantrex GT630 E 630 kW Grid-Tied Photovoltaic Inverters — Xantrex inverter — that must be followed during installation and maintenance procedures. WARNING: Risk of electric shock, explosion, and arc flash Before installing the Xantrex inverter read all instructions, cautionary markings, and all other appropriate sections of this manual.
Safety WARNING: Limitations on use The Xantrex inverter is not intended for use in connection with life support systems or other medical equipment or devices. The Xantrex inverter may only be used in grid-interconnected PV systems; it is not suitable for any other application areas. WARNING: Explosion hazard The IGBT module may explode in the event of a major malfunction. Do not operate the inverter with the doors open.
Safety CAUTION: Risk of overheating The inverters have supply air and exhaust air areas, which must remain unobstructed. The inverter can overheat and will cease operation if the installation, maintenance and clearance instructions are not adhered to. Ensure you remove the tracks required for transportation located at the top of the inverter. CAUTION: Risk of equipment damage Inverter electronics can be destroyed by static charge.
Safety Lock-out and Tag-out Safety requirements mandate that this equipment not be serviced while energized. All power sources for the Xantrex inverter must be locked-out and tagged-out prior to servicing. A padlock and tag should be installed on the disconnect device for each energy source prior to servicing.
Safety 6. Remove fuses -F6 and -F7 from their fuseholders to further isolate the Auxiliary AC input power. See Figure ii for the location of the fuses. 7. Using a voltmeter with minimum ratings of 1000 Vdc and 600 Vac, tested on a known voltage source before use, verify that all incoming energy sources are de-energized by checking for zero voltage at all of the following locations as shown in Figure ii. In all cases, measure between the terminals listed, and from each of the terminals to ground.
Safety ti AC Interface Enclosure +H0 DC Interface Enclosure +H2 3 stand-by/ power-on Switch E-STOP Pushbutton Main Inverter Enclosure (+H1) Figure i External Lock-out and Tag-out Components x 975-0581-01-01 This manual is for use by qualified personnel only
Safety ti -F6, -F7 -F35 -X4 UPS Terminals (-X4:1, -X4:8) AC Disconnect Switch (-Q1) DC Disconnect Switch (-Q11) -X2 Aux AC Voltage Terminals (-X2:L1, -X2:L2) L1, L2, L3 DC bus- UPS Terminal (-X2:24) UPS Terminal (-X2:26) UPS Breaker (-F5) DC bus+ PV+, PV- PV- PV+ Figure ii Internal Lock-out and Tag-out Components 975-0581-01-01 xi This manual is for use by qualified personnel only
Safety xii 975-0581-01-01 This manual is for use by qualified personnel only
Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v Lock-out and Tag-out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii 1 Introduction Description of the Xantrex inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Operator Interface Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents 4 Verification Verification Procedure Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Visual Inspection of Mechanical Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Visual Inspection of Electrical Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Corrective Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E
Figures Figure i Figure ii Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 2-1 Figure 2-2 Figure 2-3 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7 Figure 3-8 Figure 3-9 Figure 5-1 Figure 6-1 Figure 6-2 Figure A-1 External Lock-out and Tag-out Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - x Internal Lock-out and Tag-out Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - x Xantrex inverter Operator Interface
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Tables Table 5-1 Table A-1 Table A-2 Table A-3 Table A-4 Table A-5 Table A-6 Fault Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4 Physical and Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2 Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3 Over/Under-Voltage and Over/Under-Frequency Ranges - - - - - - - - - - - - -
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1 Introduction Chapter 1, “Introduction” provides information about the features and functions of the Xantrex inverter. The Xantrex GT500 E 500 kW Grid-Tied Photovoltaic Inverter with optional Ridethrough Capability and optional VAR Control is a utility interactive, three-phase power conversion system for gridconnected photovoltaic arrays with a power rating of 500 kW.
Introduction Description of the Xantrex inverter Designed to be easy to install and operate, the Xantrex GT500 E 500 kW and Xantrex GT630 E 630 kW Grid-Tied Photovoltaic Inverters automate start-up, shutdown, and fault detection scenarios. With user-settable power tracking that matches the inverter to the array and adjustable delay periods, users are able to customize start up and shut down sequences.
Operator Interface Controls Operator Interface Controls The Xantrex inverter comes in a set of 3 enclosures to house the electronics described above. The left 1-door section is the AC interface enclosure (+H0). The center 2-door section is the inverter enclosure (+H1). The right 1-door section is the DC interface enclosure (+H2). The 3 enclosures are constructed and delivered as one complete assembly. Operator interface controls are located on the front door of the main inverter enclosure.
Introduction 3 stand-by/power-on Switch The Xantrex inverter incorporates a maintained position 3 (stand-by/power-on) switch (called ON/OFF on older models) located on the right center door, under the main control display. Under normal conditions, the 3 (stand-by/power-on) switch is in the 2 (power-on) position. Turning the switch to the 1 (stand-by) position initiates an immediate controlled shutdown of the Xantrex inverter and opens both the main AC contactor and DC disconnect switch within the unit.
Operator Interface Controls Emergency Stop (E-STOP) The Xantrex inverter incorporates a maintained position E-STOP pushbutton located on the inverter enclosure. Under normal conditions, the E-STOP pushbutton is in the CLOSED (extended) position. Pushing the pushbutton to the OPEN (depressed) position initiates an immediate controlled shutdown of the Xantrex inverter and opens both the main AC contactor and DC disconnect switch within the unit.
Introduction AC and DC Disconnect Switches WARNING: Multiple sources with risk of electric shock, explosion, and arc flash The Xantrex inverter is energized from the PV array, from the AC grid, and from an auxiliary AC source (backed up with a Xantrex UPS for Xantrex GT500 E & Xantrex GT630 E units with low-voltage ride-through capability).
AC and DC Disconnect Switches DC Disconnect Switch (-Q11) AC Disconnect Switch (-Q1) AC Interface Enclosure DC Interface Enclosure AC Disconnect Switch DC Disconnect Switch UPS Breaker (-F5) Located in +H1 center enclosure Internal AUX Fuses (-F6, -F7) Located in +H0 enclosure Figure 1-4 AC and DC Disconnect Switches, UPS Breaker and AUX Fuses 975-0581-01-01 1–7 This manual is for use by qualified personnel only
Introduction Communication Features and Methods The Xantrex inverter provides two types of information to you: • system status and/or fault information, and • data logging information. System status and fault information can be accessed using the Universal Front Panel Control Unit (UFCU) or an optional monitoring system. Data logging access requires the use of an optional monitoring system.
Communication Features and Methods Types of status information include: • Current Operating State or Goal State • Fault Code (if applicable) • Inverter State • Line Voltage and Current • Inverter Matrix Temperature • Inverter Power • PV State • PV Voltage and Current • PV Power • Grid Frequency • Peak Power Tracker Enabled • Software Upgrade • Configurable Parameters Data Logging The inverter stores data values and software metrics for debugging.
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2 Planning Chapter 2, “Planning” provides information to help plan the installation of the Xantrex inverter.
Planning Overview of Xantrex inverter Installation WARNING: Risk of electrical shock, explosion, arc flash, and fire Installations of this equipment should only be planned and performed by qualified personnel in accordance with all applicable installation codes. See page iii for the definition of qualified personnel.
Conduit Entry Conduit Entry Conduit and cable entry is from the underside of the unit. Figure 2-1 shows a top view of the maximum allowable area and location in which electrical conduits may penetrate the enclosures of the Xantrex inverter. Conductor size must be pre-determined when the conduit is installed.
Planning Anchoring the Xantrex inverter The Xantrex inverter is designed to be installed in an indoor location. It must be placed on and anchored to a level concrete floor or pad. The concrete floor or pad, upon which the Xantrex inverter is anchored, must be structurally designed to meet any local, state, or national requirements for weight, seismic, and wind sheer loading if applicable. Twelve 16 mm holes are provided in the feet of the enclosure for anchoring to the floor or pad.
Utility Side Isolation Transformer Requirements Utility Side Isolation Transformer Requirements The Xantrex inverter must be used with a custom, high-efficiency, line-frequency isolation transformer between the inverter and the grid. This transformer is not provided and must be supplied as a separate component. The utility side winding of the isolation transformer may be configured Wye or Delta and must match the voltage at the utility interconnection point.
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3 Installation Chapter 3, “Installation” describes the procedures needed to install the Xantrex inverter. This section includes unpacking and moving instructions, mounting instructions, and cabling instructions.
Installation Unloading WARNING: Risk of death, injury and equipment damage • The Xantrex inverter weighs approximately 1800 kg. Attempting to lift or move the equipment by other than the recommended lifting points and methods may cause the equipment to drop or fall over, and may cause death or severe personal injury or property and equipment damage. • Keep all the doors closed and latched when moving the enclosures.
Unloading Moving with a Forklift Refer to Figure 3-1 for center of gravity information and Figure 3-2 for forklift locations. Figure 3-2 Forklift Lifting Locations - Underneath Unit Moving with a Crane To move the Xantrex inverter with a crane: 1. Attach the crane to the four anchor points on the rails. 2. Lift the enclosure into position. 3. Remove the lifting rails on top of the Xantrex inverter before operating the inverter.
Installation Mounting and Anchoring the Units To mount and anchor the Xantrex inverter: 1. Predrill the floor or pad to accept masonry anchors for 12 mm bolts, or ensure it has pre-installed anchoring bolts that will fit the 16 mm mounting holes. See Figure 2-2 on page 2–4. 2. Lift the Xantrex inverter from beneath with a forklift or pallet jack as shown in Figure 3-2 on page 3–3, or lift the Xantrex inverter from above with a crane as shown in Figure 3-3 on page 3–3. Move the enclosure into place. 3.
Wiring - General Wiring - General All wiring methods and materials shall be in accordance with applicable electrical installation codes, for example the US National Electrical Code ANSI/ NFPA 70, IEC 60364, CENELEC HD 384, or DIN VDE 0100. WARNING: Risk of electric shock, explosion, and arc flash The Xantrex inverter enclosures contain exposed conductors and parts operating at lethal voltage and at high enough energy to create an arc flash. Electrocution or severe burns may result.
Installation Conductor Termination The Xantrex inverter has terminals and bus bars for making all wiring connections required for the installation. All terminals used for making AC and DC connections require the use of copper conductors with an insulation rating of 90 °C (or higher). If conductors with insulation rated higher than 90 °C are used, base the wire size on the requirements for 90 °C wire, to prevent excessive heating of the busbars, terminals, and connected devices.
Wiring - General Grounding The connection point for the AC grounding conductor (also known as PE – protective earth) is a copper grounding bar with several 12 mm bolts located in the AC interface enclosure and marked with PE. The ground conductor size depends on the size of the main circuit breaker. Refer to local applicable electrical installation codes for grounding requirements for your system. Grounding terminals for PV array frames are provided in the DC interface enclosure.
Installation Wiring - Specific This section provides information for connecting the AC and DC conductors and the ground conductors. Table A-5 and Table A-6 on page A–5 show the specifications of the AC and DC wiring.
Wiring - Specific The auxiliary supply transformer (-T6) has several primary taps. The tap must be selected to match the auxiliary control voltage supplied to the unit, 230, 315, 375 or 400 V depending on model and system details. The control voltage transformer comes pre-wired based on the output voltage.
Installation Auxiliary AC Voltage Terminals (-X2:L1, -X2:L2) Remove links between -X2:23 and -X2:24 as shown Remote E-STOP Terminals (-X2:6, -X2:7) UPS Terminal -X2:24 UPS Terminal -X2:26 Remove links between -X2:25 and -X2:26 as shown Figure 3-7 Auxiliary AC Voltage Terminal Connections Control Voltage Taps Figure 3-8 Control Voltage Transformer Primary and Secondary Wiring 3–10 975-0581-01-01 This manual is for use by qualified personnel only
Wiring - Specific 1000 Vdc Input Option If you have a Xantrex GT630 E with 1000 Vdc input option your inverter is configured with the following pre-installed conductors: • 1 cable with cross section of 35mm² (coming from PV+) • 3 cables with cross section of 10mm² coming from the chopper IGBT's These conductors are located cabinet +H2, coiled on the bottom. You must connect these wires to the resistor that was installed in the sub-floor of the concrete PV box or pad as described on page 2–3.
Installation PV Array Connections To make the connections from the PV array/combiner to DC interface enclosure: 1. Follow the lock-out and tag-out procedures on page viii. 2. Open the door of the DC interface enclosure. 3. Route the POSitive (PV+) and NEGative (PV-) PV array conductors through the conduit to the DC interface enclosure and enter through the opening on the bottom. 4. The DC power conductors should be terminated at the PV+ and PVterminals. Polarity must be observed. See Figure 3-9. 5.
4 Verification Chapter 4, “Verification” provides a checklist to ensure the installation of the Xantrex inverter is correct and complete.
Verification Verification Procedure Summary The following procedures are intended to verify correct installation and proper wiring of the Xantrex inverter. Prior to performing the following verification steps on the Xantrex inverter, review all safety requirements and procedures outlined in this manual and on any cautionary markings on the components within the system.
Visual Inspection of Mechanical Connections Inspect the following items prior to completion of the installation: 1. Visually inspect all the mechanical connections. This would include both electrical conduit fittings, as well as enclosure anchoring and seismic bracing if required. 2. Visually inspect the electrical connections and verify proper tightness of all terminations. 3. Visually inspect the utility transformer connections. The inverter-side windings of the transformer can be Wye or Delta.
Verification Corrective Action Perform after initial inspection (if required): 1. Take minor corrective actions as per instructions outlined in the previous paragraphs. For more significant corrective actions, contact Schneider Electric customer service. 2. Ensure that the AC and DC disconnect switches, as well as any utility interconnect circuit breaker, main disconnect circuit breaker and/or AC control power disconnect are left locked-out and tagged-out. 3.
5 Advanced Troubleshooting Chapter 5, “Advanced Troubleshooting” contains information and procedures for qualified personnel to troubleshoot the Xantrex inverter. It provides descriptions of common situations and errors that may occur and provides possible solutions for resolving fault conditions. It also provides instructions for clearing faults manually, if required.
Advanced Troubleshooting WARNING: Multiple sources with risk of electric shock, explosion, and arc flash The Xantrex inverter is energized from the PV array, from the AC grid, and from an auxiliary AC source (backed up with a Xantrex UPS for Xantrex GT500 E & Xantrex GT630 E units with low-voltage ride-through capability).
General Troubleshooting General Troubleshooting Respond to any Xantrex inverter alarm or fault as follows: 1. Note and document the alarm or fault code and brief text description. 2. Determine the source of the alarm or fault by referring to Table 5-1 on page 5–4. 3. Rectify the alarm or fault condition and attempt to clear the fault from the display. See page 5–3 for instructions on this procedure. 4.
Advanced Troubleshooting Display Showing Fault Code UFCU Keypad Figure 5-1 Display Showing Fault Code Important: If the fault does not clear, the fault condition has not been corrected. Fault Code Descriptions Table 5-1 provides a complete description of all the fault conditions that may occur on the Xantrex inverter. Default values are shown, but some limits are useradjustable.
Fault Code Descriptions Table 5-1 Fault Codes Error Code Fault Source(s) Fault Type H=Hardware S=Software Fault Description 0012 AC Voltage Low S Possible Causes This fault indicates that the utility grid voltage is below or fell below the setting of Min AC Volt%: of nominal Vac for greater than 6 cycles. Xantrex inverter units with the low voltage ride-through option are able to continue to supply current through the fault for 1600 ms as long as the voltage does not drop below 5% of nominal Vac.
Advanced Troubleshooting Table 5-1 Fault Codes Error Code Fault Source(s) Fault Type H=Hardware S=Software Fault Description 0017 Phase Error S The calculated frequency is negative indicating the phase rotation of the grid is incorrect. The correct rotation is L1, L2, L3 Phase Rotation of the incoming grid connections is wrong. 0018 AC Contactor Circuit Fault S Xantrex GT500 E GI and Xantrex GT630 E GI only: An Auxiliary contact is used to determine the state of -K1.
Fault Code Descriptions Table 5-1 Fault Codes Error Code XX30 Fault Source(s) Matrix OverCurrent Fault Type H=Hardware S=Software Fault Description H This fault indicates that the Xantrex inverter has detected that the AC current on one or more phases of the inverter output has exceeded the maximum allowed value of 2000Apk.
Advanced Troubleshooting Table 5-1 Fault Codes Error Code Fault Source(s) Fault Type H=Hardware S=Software Fault Description Possible Causes 0040 Programming Software S This code indicates that the Xantrex inverter has detected that the system is in Programming mode. This fault does not indicate any malfunction with the Xantrex GT500 E & Xantrex GT630 E, but is merely an indication that the system software is in the process of being downloaded into the EEPROMs of the control unit.
Fault Code Descriptions Table 5-1 Fault Codes Fault Type H=Hardware S=Software Fault Description Error Code Fault Source(s) 0045 Interrupt 2 Timeout S This fault indicates that the Xantrex inverter has detected that an interrupt 2 timeout has occurred. The control unit controller board performs a conversion validation of analog-to-digital data within the A to D converters. If validation of the conversion is not performed within 500mS, an interrupt 2 timeout fault occurs.
Advanced Troubleshooting Table 5-1 Fault Codes Error Code Fault Source(s) Fault Type H=Hardware S=Software Fault Description 0072 Local E-STOP S Control unit has detected a loss of 15 VDC at terminal J2-1. Local E-STOP button is depressed. 0073 Remote E-STOP S Control unit has detected a loss of 15 VDC at terminal J2-5. Remote E-STOP button is depressed.
Fault Code Descriptions Control Unit Disconnect Errors These errors cause the inverter to disconnect from the grid and shut down. They are reported to the control unit. Should these situations occur, contact Schneider Electric Customer Service. Fault 0152 IGBT Over-current Cause: The current has exceeded 2000 Arms. Fault 0252 Switch Fault Cause: An IGBT was activated, but no feedback signal was received confirming activation.
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6 Preventative Maintenance Chapter 6, “Preventative Maintenance” contains information and procedures for qualified personnel to performing preventative maintenance on the Xantrex inverter.
Preventative Maintenance Maintenance Safety WARNING: Risk of electric shock, explosion, and arc flash Before performing maintenance on the Xantrex inverter read all instructions, cautionary markings, and all other appropriate sections of this manual. Exercise extreme caution at all times to prevent accidents. Failure to follow these instructions will result in death or serious injury.
Maintenance Intervals Customers should follow the maintenance intervals at a minimum, however the environmental degree of pollution at the installation may mean that maintenance needs to be performed more frequently. Schneider Electric recommends that the following preventative maintenance procedures be carried out on the Xantrex inverter. Monthly Intervals or As Required Visually inspect the intake air ducts and external cooling fans for accumulation of dirt and debris.
Preventative Maintenance 5 year Interval Control Transformer Fuses The control transformer fuses are located in the inverter’s AC interface enclosure. -F6 and -F7 Fuses Figure 6-1 Control Transformer Fuses 10 year Interval Facilities will be maintained after ten years. Replace the inverter’s interior fan and the power element fan. Clean the control cabinets thoroughly. All fans will only be replaced as a whole. Power Element Fans The power element fans are located in the inverter enclosure.
A Specifications Appendix A provides the environmental and electrical specifications for the Xantrex inverter. WARNING: Risk of electric shock, explosion, and arc flash. Risk of equipment damage Unsafe conditions and damage to the inverter may result if the instructions, and electrical, physical, and environmental installation specifications in this manual are not obeyed.
Specifications System Specifications The Xantrex inverter has been designed for photovoltaic power systems, which operate within the following specifications.
System Specifications WARNING: Risk of electric shock, explosion, and arc flash. Risk of equipment damage Unsafe conditions and damage to the inverter may result if the inverter is energized with condensation present inside the unit. Storage, transportation, and operational conditions must ensure that internal condensation is not created, or that the inverter is dry before energizing. Obey the environmental specifications and classifications in Table A-2 and Table A-3.
Specifications Regulatory Specifications Regulatory specifications for the Xantrex inverter are as follows: • CE marked for the Low Voltage Directive per EN50178 • CE marked for the EMC Directive per EN61000-6-4 (emissions) and EN61000-6-2 (immunity) • Complies with RD1663/2000 and 661/2007 (Spain) • Complies with Decree from 23 April 2008; “Arêté du 23 Avril 2008” (France) • Low voltage ride-through version complies with BDEW medium voltage grid connection requirement; "Technische Richtlinie - Er
System Specifications Bolt Sizes and Torque Requirements Table A-5 provides acceptable bolt sizes and torque values for AC terminal connections. Table A-5 AC Terminal Bolt Size, and Torque Values AC Terminal Connections Max. # of Conductors per Terminal Bolt (Hardware) Size Torque Requirements PE (Enclosure Ground) 2 1/M12 75 Nm (55 lb ft) L1, L2, L3 6 3/M12 75 Nm (55 lb ft) -X2:L1, -X2:L2 to AC aux input transformer 1 cable cross section 0.5 - 10 mm² use appropriate ferrules 0.6 – 0.
Specifications Dimensions Dimensions in mm +H0 KÜHLLUFT/ COOLING AIR +H2 88 +H1 .G1.SP +H1K10 Xantrex GT500 E -A22 -S2 2002 -S3 A SK3326.100 SK3326.100 SK3326.100 SK3326.100 SK3326.100 SK3326.100 SK3326.100 SK3326.
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