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Gardner Denver RHP Series User manual

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1
SERVICE DEPARTMENT: (724) 746-1100
Contents
GENERAL SAFETY INFORMATION .................................... 1
1.0 INSTALLATION .............................................................. 2
2.0 OPERATION ................................................................... 3
3.0 MAINTENANCE ............................................................. 4
ENGINEERING DATA .......................................................... 5
DIMENSIONS / WEIGHTS ................................................... 7
TROUBLESHOOTING .......................................................... 9
PARTS LIST .......................................................................... 10
WARRANTY .......................................................................... 12
MAINTENANCE INSTRUCTIONS
1. Air cooled models - Condenser coil - Clean off
accumulated dust and dirt monthly.
2. Models RHP64, RHP93, RHP100, and RHP178 - Moisture
separator - Replace filter sleeve yearly, or when pressure
drop across dryer is excessive, whichever occurs first.
3. Check daily to be sure automatic drain is discharging.
4. Manually drain separator weekly by pushing manual
override switch on drain timer.
GENERAL SAFETY INFORMATION
1. PRESSURIZED DEVICES
This equipment is a pressure containing device.
• Do not exceed maximum operating pressure as
shown on equipment serial number tag.
• Make certain equipment is depressurized
before servicing.
2. ELECTRICAL
This equipment requires electricity to operate.
• Install equipment in compliance with national and
local electrical codes.
• Standard equipment is supplied with NEMA 1
electrical enclosures and is not intended for
installation in unprotected outdoor or
hazardous environments.
• Disconnect power supply to equipment when
performing any electrical service work.
3. BREATHING AIR
• Air treated by this equipment may not be
suitable for breathing without further purification.
Refer to OSHA standard 1910.134 for the require-
ments for breathing quality air.
7610.478.38C 4/04
18-2-680
RHP SERIES HIGH PRESSURE
REFRIGERATED COMPRESSED AIR DRYERS
MODELS: RHP13 through RHP178
INSTRUCTION MANUAL
Internal Use Only
7610.482.11C/040417
2
1.0 INSTALLATION
1.1 Location
A. Air compressor intake - Locate air compressor so that
contaminants potentially harmful to the dryer (e.g.
ammonia) are not drawn into the air system.
1. Location - locate the dryer so that the coolest
ambient air possible will be drawn across
the condenser.
B. Free air flow - Do not block either side of the
cabinet. Leave 12 inches (305 mm) on each side of
cabinet for free air flow.
1.2 Mounting
A. Models RHP50 and larger - Feet are supplied as
standard. Feet may be removed if floor or shelf
mounting is desirable.
B. Models RHP13 and RHP20 include wall mounting
bracket. See Illustration.
1.3 Piping connections
A. Air Inlet - Connect compressed air line from air
compressor to air inlet.
Refer to Serial Number Tag for maximum
working pressure. Do not exceed unit’s Maximum
Working Pressure.
NOTE: For maximum capacity, install unit in air
system at highest pressure possible (e.g. before
pressure reducing valves).
NOTE: For maximum capacity, install unit at coolest
compressed air temperature possible.
NOTE: Maximum inlet compressed air temperature:
120°F (49°C). If inlet air exceeds this temperature,
precool the air with an aftercooler.
)
AIR INLET AIR OUTLET
AIR OUTLET
AIR INLET
MODELS RHP64
RHP100
MODELS RHP13 & RHP20
AIR INLET
MODELS RHP93
RHP178
MODEL RHP50
AIR OUTLET
)
AIR OUTLET
AIR INLET
B. Air Outlet - Connect air outlet to downstream
air lines.
C. By-pass piping - If servicing the unit without
interrupting the air supply is desired, piping should
include inlet and outlet isolation valves and an air by-
pass valve.
D. Drain - It is advisable to connect the automatic drain
outlet to the condensate drainage system.
NOTE: Drain discharge is at system pressure. Drain
line should be anchored to prevent whipping.
E. Water cooled models - cooling water inlet and outlet
1. Connect inlet water line to strainer.
2. Connect outlet piping.
NOTE: Strainer and water regulating valve are supplied on
water cooled models.
1.4 Electrical connections
A. Dryer is designed to operate on the voltage, phase,
and frequency listed on the serial number tag.
B. Dryer is supplied with an electrical cord and plug.
NOTE: Refrigeration condensing unit is designed to
run continuously and should NOT be wired to cycle
on/off with the air compressor.
Wall Mounting Bracket For Models RHP13 & RHP20
Hanger
Lockwasher
3/8" Bolt
Locking Clip
Cabinet
Mounting Slot
Wall
SERIAL NUMBER TAG
* Models RHP50, RHP64, RHP93, RHP100 and RHP178 only
SUCTION PRESSURE
GAUGE*
ON/OFF SWITCH*
3
b. Observe the drain when discharging to see if
all the liquid present has been removed. This
is evident if some air escapes after the liquid
has been discharged and before the valve
closes. If liquid is still present when valve
closes, increase “on time”. If excessive
air flows after liquid has been discharged,
decrease “on time”.
NOTE: The amount of liquid present can
change as operating conditions change
(compressed air and ambient temperatures,
flow rates, ambient relative humidity).
Observe drain periodically to make certain
that drain is remaining open long enough
to discharge collected liquids.
2. Valve closed time:
a. Using knob marked “off time (min)”, turn
knob until triangle on knob aligns with
desired time.
b. If all liquid cannot be removed during time
valve is open, increase valve “on time”. If
this is not possible, decrease “off time” so
that less liquid collects between operations.
C. Manual Override
Manual override allows manual operation of the valve.
To open valve, depress manual override switch.
D. Status lights
1. “Power” light - light illuminates when timer is
energized. If light is not illuminated, check that
power supply is on and electrical connections are
sound.
2. “On” light - light illuminates when output to
solenoid coil is energized. Valve should be open
when this light illuminates; if valve doesn’t open,
service is required.
NOTE: Coil is designed for continuous duty
service. However, when solenoid is energized for
a long period, the coil enclosure becomes hot
and can be touched with the hand for only an
instant. This is a safe operating temperature.
COMPRESSOR SEPARATOR OIL
RECEIVER REMOVAL
FILTER
AFTERCOOLER AUTOMATIC DRYER
DRAIN
Typical Compressed Air System
2.0 OPERATION
NOTE: Unit is adjusted to operate in altitudes up to 4500
feet (1370 meters). If unit is installed in an altitude above
this and has not been preset at the factory for this
altitude, contact manufacturer’s Service Department.
2.1 Minimum/maximum operating conditions
A. Maximum inlet air pressure: refer to unit serial
number tag.
B. Minimum inlet air pressure: 5 psig (0.3 bar).
C. Maximum inlet air temperature: 120°F (49°C).
D. Maximum ambient temperature: 110°F (43°C).
E. Minimum ambient temperature: 35°F (1.7°C).
2.2 Start-up
Models RHP13 and RHP20 - Energize compressor by plugging
in power supply cord. Power-on light will illuminate.
Models RHP25 and larger - Energize the compresser by
positioning the on/off switch in the on position ("I"
button depressed). Power-on light will illuminate.
2.3 Condensate drain
A. Condensate is discharged by an electrically operated
solenoid valve. The valve is opened and closed by a
solid state electronic timer that can be adjusted
within the following time limits:
Valve open, “ON” time: 1 to 15 seconds.
Valve closed, “OFF” time (time between valve
operations): 1 to 45 minutes.
B. Timer adjustment -
1. Valve open time:
a. Using knob marked “on time (sec)”, turn
knob until triangle on knob aligns with
desired time.
ELECTRIC DRAIN VALVE
4
2.4 Operating check points
Check the following on a periodic basis:
A. Green power-on light is illuminated.
B. Red high air temperature warning light is out.
The high air temperature warning light will illuminate
when unit is energized. Light should go out approxi-
mately 15 minutes after start-up. If light remains lit
after 30 minutes or illuminates after going out, refer
to Troubleshooting Guide.
C. Models RHP50 and larger - Suction pressure
gauge reads in green area.
D. Condensate is discharging from drain.
3.0 MAINTENANCE
3.1 Maintenance Check Points
A. Air-cooled models - Condenser coil - Clean off
accumulated dust and dirt monthly.
B. Water-cooled models - Maintain strainer in order to
ensure a free flow of cooling water at all times.
C. Moisture separator (Models RHP64, RHP93, RHP100
and RHP178). Replace filter sleeve when pressure
drop across dryer is excessive. See 3.2.
D. Check daily to be sure automatic drain is discharging.
E. Manually drain separator weekly by using manual
override switch on drain timer.
3.2 Models RHP64, RHP93, RHP100 and RHP178
Moisture Separator Maintenance
A. Filter Sleeve Replacement - The separator assembly
contains a coalescing filter sleeve which requires
replacement yearly or when excessive pressure
drop is experienced across the dryer, whichever
occurs first.
B. Procedure for filter element replacement:
Separator is a pressure containing
device. Isolate dryer from air system and depressurize
by blowing down separator (manual overide)
before servicing.
1. Disassemble separator housing by unscrewing
the collar holding the filter bowl to the head and
remove the filter bowl, collar and cartridge.
2. Replace filter sleeve as follows:
1) Remove wing nut and bottom cap
from cartridge.
2) Slide disposable filter sleeve down over
separator core.
SEPARATOR HEAD
HEAD "O" RING
CARTRIDGE "O"
RING
SEPARATOR
(PERMANENT)
FILTER SLEEVE
(REPLACEABLE)
SPACERS
BOTTOM CAP
NUT
3) If necessary, clean separator core with soap
and water.
4) Slide new filter sleeve over separator core.
5) Replace bottom cap and wing nut.
6) Reassemble
NOTE: Use new O-ring supplied with replacement sleeve
when reassembling cartridge to separator head.
NOTE: It is only necessary to finger tighten the filter
cartridge into position to insure the seal. DO NOT
WRENCH TIGHTEN.
NOTE: Make sure that large O-ring in filter
head is in place before reassembling bowl to head.
5
ELECTRICAL SCHEMATIC
Models RHP13 & RHP20
Min.- Max. Inlet Air Pressure ( compressed air at inlet to dryer ) 5 psig (0.3 bar) - See Serial Number Tag for Maximum Pressure
Max. Inlet Air Temp. (compressed air at inlet to dryer) 120°F (49°C)
Min.-Max. Ambient Temperature 35°F (1.7°C) - 110°F (43°C)
Refrigeration System Data RHP13 RHP20
Compressor Type Hermetic - Resistance Start, Induction Run - Non-Cycling
Refrigeration Compressor Horsepower 1/6 1/5
BTU/HR - Refrigeration Only @ 35°F Evaporator & 100°F Ambient 60 Hz / 50 Hz 1010 / 842 1380 / 1150
Outlet Air Temperature (nominal at rated conditions) 40°F (4.4°C) 40°F (4.4°C)
Refrigerant Type R-134a R-134a
Refrigerant Charge See dryer serial number tag
Suction Pressure Setting (controlled by hot gas by-pass valve) - psig (barg) 31.5 (2.2) 31.5 (2.2)
Air Flow Across Condenser (cfm) 60 Hz / 50 Hz 235 / 196 235 / 196
Minimum - Maximum Operating Conditions
1) 115-1-60 115/1/60 208-230/1/60 220-240/1/50 115/1/60 208-230/1/60 220-240/1/50
Max.- Min. Voltage 127-104 253-187 264-198 127-104 253-187 264-198
Rated Load Amps 3.4 1.8 1.6 3.9 2.1 1.8
Locked Rotor Amps 18.0 8.5 8.7 22.0 13.7 10.7
Minimum Circuit Ampacity 4.0 2.2 2.0 4.7 2.6 2.2
Branch Circuit Fuse Size (amps) 15 15 15 15 15 15
Watts @ 35°F Evaporator & 100°F Ambient 280 280 223 290 290 257
Overload Thermal & Current (Auto reset)
Electrical Data Model RHP13 Model RHP20
ENGINEERING DATA
LEGEND
1LT - Power On Light
2LT - High Temperature Light
SR - Start Relay
MTR - Compressor
FM - Fan Motor
HTS - High Temperature Switch
OL - Overload
SOL - Electric Drain Valve
6
ENGINEERING DATA
Min.-Max. Inlet Air Pressure (compressed air at inlet to dryer) 5 psig (0.3 bar) See Serial Tag for Maxium Pressure
Max. Inlet Air Temp. (compressed air at inlet to dryer) 120°F (49°C)
Min.-Max. Ambient Temperature Air-cooled: 35°F (1.7°C)-110°F (43°C) / Water-cooled: 35°F (1.7°C)-130°F (54°C)
Refrigeration System Data
Compressor Type Heremetic - Resistance Start, Induction Run - Non-Cycling
Refrigeration Compressor Horsepower 1/4 1/2 3/4
BTU/HR-Refrigeration Only
@ 35°F Evaporator & 100°F Ambient 60 Hz / 50 Hz 2160 / 1800 4430 / 3692 6020 / 5017
Refrigerant Type R-134a
Refrigerant Charge See dryer serial number tag
Suction Pressure Setting (controlled by hot gas by-pass valve) - psig (barg) 31.5 (2.2)
Condenser Fan Switch Setting (in-out) - psig (barg) N/A N/A 180-130 (12.4-9.0)
Air Flow Across Condenser (cfm) 60 Hz / 50 Hz 275 / 229 350 / 292 530 / 440
Condenser Cooling Water Requirements (water-cooled
models only) gpm@85°F (40 psig min. Pressure) 60 Hz / 50 Hz NA NA 2.2 / 1.8
Electrical
Nominal Voltages 115/1/60
Max.-Min. Voltage 127-104
Rated Load Amps 5.9 10.3 14.7
Locked Rotor Amps 28.0 48.0 66.3
Minimum Circuit Ampacity 7.3 12.4 17.5
Branch Circuit Fuse Size (amps) 15 20 25
Watts @ 35°F Evaporator & 100°F Ambient 465 815 1060
Overload Thermal & Current (Auto reset)
Nominal Voltages 208-230/1/60
Max.-Min. Voltage 253-207 253-187 253-197
Rated Load Amps 3.0 5.1 8.3
Locked Rotor amps 14.4 23.0 33.5
Minimum Circuit Ampacity 3.7 5.2 10.5
Branch Circuit Fuse Size (amps) 15 15 15
Watts @ 35°F Evaporator & 100°F Ambient 465 815 1060
Overload Thermal & Current (Auto reset)
Nominal Voltages 220-240/1/50
Max.-Min. Voltage 264-198
Rated Load Amps 2.6 4.2 7.6
Locked Rotor Amps 14.5 21.0 53.0
Minimum Circuit Ampacity 3.2 5.2 9.9
Branch Circuit Fuse Size (amps) 15 15 15
Watts @ 35°F Evaporator & 100°F Ambient 395 669 930
Overload Thermal & Current (Auto reset)
Minimum-Maximum Operating Conditions RHP50 RHP64 & RHP93 RHP100 & RHP178
ELECTRICAL SCHEMATIC
Models RHP50, RHP64, RHP93,
RHP100 and RHP178
LEGEND
PBS - Push Button Switch
1LT - Power On Light
2LT - High Temperature Light
SR - Start Relay
MTR - Compressor
FM - Fan Motor
HTS - High Temperature Switch
OL - Overload
SOL - Programmable Electric Drain
CAP - Start Capacitor
FPS - Fan Pressure Switch
CT - Contactor w/115v coil
SW - On/Off Switch
RHP64 & RHP93
RHP50 RHP100 & RHP178
31
OL MTR
SR
SR
R
CS
FM
HTS
SOL
L2L1
R
G
2LT
1LT
PBS
208/230-1-60
ONLY
FOR
FPS
31
OL MTR
SR
SR
R
CS
FM
HTS
SOL
L2L1
R
G
2LT
1LT
PBS
CAP
FPS
7
SHIPPING WEIGHTS
LBS. [kg]
MODEL RHP13 RHP20
Weight 57 [25.9] 65 [29.5]
DIMENSIONS
INCHES [mm]
MODEL RHP13 RHP20
A14 [356] 14 [356]
B16 1/8 [410] 16 1/8 [410]
C15 [381] 15 [381]
D2 [51] 2 [51]
E8 1/16 [204] 8 1/16 [204]
F2 [51] 2 [51]
G2 1/16 [52] 2 1/16 [52]
H2 1/8 [54] 2 1/8 [54]
J 2 [51] 2 [51]
K1 3/4 [44] 1 3/4 [44]
L12 [305] 12 [305]
M5 3/8 [137] 5 3/8 [137]
P2-1/2 [64] 2-1/2 [64]
OUTLET
FAN AIR FLOW
INLET
B
FRONT VIEW
TOP VIEW
C
MINIMUM CLEARANCE
FOR FREE AIR FLOW
BOTH SIDES
E
D
M
A
L
RIGHT SIDE VIEW
POWER ON (GREEN)
HIGH TEMP.
(RED) ELECTRICAL
BOX
SEPARATOR
(INSULATED)
K
H
J
G F
KEY SLOTS (FOR
WALL MOUNTING ON
CABINET BACK)
P
WALL MOUNTING SLOT (BACK)
(USED WITH HANGER BRACKET
ASSEMBLY ONLY)
AIR INLET/OUTLET
(3/8" OD)
CONDENSATE
DRAIN
(1/4" OD TUBE)
DIMENSIONS / WEIGHTS
Models RHP13 and RHP20
NOTE: Dimensions and Weights are for reference only.
Request certified drawings for construction purposes only.
8
Model A B C D E F G H I J K L M N P Q R S
RHP50(500) 17 22-1/4 16 19-1/2 11-1/4 1-3/8 1-3/8 2 3-3/8 - 1 2 7-5/16 16 3-1/8 6 1/4 1/2
(432) (565) (406) (495) (286) (35) (35) (51) (86) (25) (51) (186) (406) (79) (152) NPT
RHP93(500) 23-3/16 32-1/4 19-1/2 29 15-1/2 1-5/8 1-1/2 3-1/16 2-1/2 - 2-9/16 3-7/8 9-1/16 - - - 1/2 1
(589) (819) (495) (737) (394) (41) (38) (78) (64) - (65) (98) (230) - - - NPT
RHP64(900) 23-3/16 32-1/4 19-1/2 29 15-1/2 1-5/8 1-1/2 3-5/8 2-1/2 12-1/4 2-1/16 3-3/16 9-1/16 - - - 1/2 1
(589) (819) (495) (737) (394) (41) (38) (92) (64) (311) (52) (81) (230) - - - NPT
RHP178(500) 23-3/16 32-1/4 19-1/2 29 15-1/2 1-5/8 1-1/2 2-1/4 2-1/2 - 2-1/2 3-7/8 9-1/16 - - - 3/4 1-1/2
(589) (819) (495) (737) (394) (41) (38) (57) (64) - (64) (98) (230) - - - NPT
RHP100(900) 23-3/16 32-1/4 19-1/2 29 15-1/2 1-5/8 1-1/2 3-5/8 2-1/2 12-1/4 2-1/16 3-3/16 9-1/16 - - - 3/4 1
(589) (819) (495) (737) (394) (41) (38) (92) (64) (311) (52) (81) (230) - - - NPT
DIMENSIONS / WEIGHTS
Models RHP50 thru RHP178
Inches (mm)
Model Weight
lb (kg)
RHP50 (500) 104 (47.2)
RHP93 (500) 206 (93.6)
RHP64 (900) 186 (84.5)
RHP178 (500) 235 (106.8)
RHP100(900) 208 (94.5)
NOTE: Dimensions and Weights are for reference only. Request certified drawings for construction purposes only.
9
POSSIBLE CAUSES CORRECTIVE ACTION
A) Water downstream of dryer 1. Residual free moisture remaining in downstream
pipelines
2. Air by-pass system is open
3. Inlet and Outlet connections are reversed
4. Temperatures surrounding air lines downstream of
dryer have dropped below dryer's dew point rating
5. Excessive free moisture (bulk liquid) at dryer inlet
6. Condensate not being automatically drained
Drain mechanism is clogged or inoperative.
Drain line is restricted or frozen.
Electric drains - timer not set to allow for
sufficient condensate removal
7. Dryer overloaded resulting in elevated dew point.
8. Refrigeration system not functioning properly
resulting in elevated dew point.
1. Excessive air flow
2. Freezing of moisture in evaporator because of
refrigeration system improperly functioning.
3. Separator filter clogged
(Models RHP64, RHP93, RHP100 & RHP178)
1. Dryer overloaded resulting in high air outlet
temperature.
2. Refrigeration system not functioning properly
resulting in high air outlet temperature.
3. Unit functioning normally but thermostatic switch
is malfunctioning or not securely mounted.
a. Power failure
b. Line disconnect switch open
c. Blown fuses, open breaker
d. Faulty wiring, loose terminals
a. Refrigeration compressor not running
b. High inlet air temperature
c. High ambient air temperature
d. Hot gas by-pass valve improperly set
a. Hot gas by-pass valve improperly set
b. Low on refrigerant
a. High or low ambient conditions
b. Air-cooled models - Dirty, clogged condenser
fins, obstructed air flow across condenser, or non
functioning fan motor or fan control switch.
c. Water-cooled models - Cooling water temperature too
high, or flow too low, faulty water regulating valve,
clogged water strainer.
• Blow out system with dry air
• Check valve positions
• Check for correct connection
• Insulate or heat trace air lines exposed to low
ambients or dry air to lower dew point
• Install separator ahead of dryer
• Replace drain mechanism if inoperative
• Open drain line
• Electric drains - reset time so that all liquid is
discharge
• Check inlet air temperature and pressure, flow
rate (compressor capacity) and ambient air or
water temperature.
• See D below
• Check flow rate
• See D below
• Replace filter sleeve
• See A 7
• See D below
• Contact qualified refrigeration repairman or
manufacturer’s service department
• Check power to unit
• Close disconnect switch
• Check for continuity
• Have electrician check electrical connections
• Contact qualified refrigeration repairman or
manufacturer’s service department.
• Contact qualified refrigeration repairman or
manufacturer’s service department.
• Check minimum /maximum temperature ranges
• Clean condenser and check for free air flow, if
problem persists contact qualified refrigeration
repairman or manufacturer’s service department.
• Clean strainer, check water flow and temperature,
if problem persists contact qualified refrigeration
repairman or manufacturer’s service department.
3. Refrigerant compressor cycles on and off
2. Models RHP64, RHP93, RHP100, &
RHP178 - Refrigerant Suction Pressure
Gauge in red area
B) High pressure drop across dryer
SYMPTOM
Models HP64, RHP93, RHP100, & RHP178 -
Refrigerant Suction Pressure Gauge in blue
area
TROUBLESHOOTING GUIDE
D) Refrigeration system not functioning
properly
1. Power on light off
C) High Temperature Alarm
10
PARTS LIST
RHP13 RHP20
PARTS DESCRIPTION 115/1/60 208-230/1/60 220-240/1/50 115/1/60 208-230/1/60 220-240/1/50
100/1/50 100/1/50
Condensing unit (air-cooled) G4130-120-5 G4130-120-8 G4130-120-9 G4130-121-11 G4130-121-9 G4130-121-10
Compressor G4130-108-34 G4130-108-61 G4130-108-35 G4130-108-38 G4130-108-39 G4130-108-40
Overload G5925-570-2 G5925-578-24 G5925-570-3 G5925-578-1 G5925-578-2 G5925-578-3
Start relay G5945-655-5 G5945-683-24 G5945-655-6 G5945-683-1 G5945-683-2 G5945-683-3
Fan motor G6105-239-1 G6105-237-4 G6105-237-4 G6105-238-27 G6105-238-28 G6105-238-28
Fan blade G4140-228-2 G4140-228-2 G4140-228-2 G4140-227-17 G4140-227-17 G4140-227-17
Condenser (air-cooled) G4130-110-26 G4130-110-26 G4130-110-26 G4130-111-18 G4130-111-18 G4130-111-18
Dryer/Strainer G4130-165-14 G4130-165-14 G4130-165-14 G4130-165-14 G4130-165-14 G4130-165-14
Hot gas by-pass valve G9802-1 G9802-1 G9802-1 G9802-1 G9802-1 G9802-1
Sensor, hi temp. G5930-189-1 G5930-189-1 G5930-189-1 G5930-189-1 G5930-189-1 G5930-189-1
Dual Light assy. G6350-454-8 G6350-454-9 G6350-454-9 G6350-454-8 G6350-454-9 G6350-454-9
Separator/Drain/Filter assy. G03-7076-01 G03-7076-01 G03-7076-01 G03-7076-01 G03-7076-01 G03-7076-01
Auto drain G0530-11 G0530-12 G0530-12 G0530-11 G0530-12 G0530-12
Solenoid valve G4810-747-4 G4810-747-10 G4810-747-10 G4810-747-4 G4810-747-10 G4810-747-10
Timer G5945-693-4 G5945-693-4 G5945-693-4 G5945-693-4 G5945-693-4 G5945-693-4