-,,,,
LOW-COST SILICON SOLAR ARRAY PROJECT
5101-19
CYCLIC PRESSURE-LOAD DEVELOPMENTAL TESTING
OF SOLAR PANELS
.February 28, 1977
Donald Moore
Approved by:
R. G. Ross LSSA Engineering Manager
JET PROPULSION LABORATORY
CALIFORNIA INSTITUTE OF TECHNOLOGY
PASADENA, CALIFOINIA
I . i
-
This work was performed by the Jet Propulsion Laboratory, California
Institute of Technology, under National Aeronautics and Space Administration
Contract NAS7-100, for the U.S. Energy Research and Development Administration
(ERDA), Division of Solar Energy.
The Low-Cost Silicon Solar Array Project is funded by ERDA and forms part
of the ERDA Photovoltaic Conversion Program to initiate a major effort toward the
development of low-cost solar arrays.
ACKNOWLEDGEMENT
The author wishes to express his thanks to the following individuals for
their contributions to this effort. Tom Patrick designed and built the pressure
fill/regulation system and conducted a significant portion of the testing.
Roland Taylor designed and built the automatic panel failure detection circuit.
ii
1.0 BACKGROUND
2.0 PURPOSE AND SCOPE
3.0 TEST APPARATUS
4.0 DESCRIPTION OF PANELS TESTED
5.0 TEST RESULTS
6.0 CONCLUSIONS
CONTENTS
APPENDIX: Summary of Test Data Including Panel Mounting Sketches
1.
2.
3.
4.
5.
FIGURES
Cyclic Pressure Loading Apparatus
Block Diagram, Cyclic Pressure Loading Apparatus
Pressure Application System
Pressure Control System
Cycle Timer/Counter and Failure Monitor System
iii
1
1
2
10
12
14
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3
4
5
7
9
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ABSTRACT
Nine (9) solar panels of 5 different designs were subjected to
a 50 lb/ft2 uniform load which was alternately applied to the front and back
sides of the panel. The loading rate was slow, consistent with the fact that 1
~ ~ --t..-/.36~J.,, the loading was intended to simulate periodic recurrence of a 100 mph wind _ J_ P v·
-p- 21c )w
over the lifetime of a solar panel. Each of the 5 designs was subjected to
at least 10,000 pressure cycles. No gross structural failures occurred.
One of the designs failed regularly at the cell interconnects. Another
design shorted out one or more cells upon panel flexure. Both problems are
readily explained in terms of design deficiencies in the cell interconnects,
and therefore appear to be easily remedied in future designs.
The cyclic pressure loading apparatus developed as part of this
effort performed extremely well. The unit was relatively trouble-free from
start-up and it applied more than 130,000 cycles to the various panels tested.
V
1.0 Background
In the design of solar panels for a terrestrial environment wind
loading has been identified as an important structural consideration. For the
130 kW procurement an alternating (front and back sides) normal pressure load
2 of 50 lb/ft, corresponding to 100 mph wind, is applied to the panel 100 times
as part of the pre-production acceptance tests.
2.0 Purpose and Scope
This cyclic pressure load was not part of the acceptance test require
ment for the 46 kW procurement. It was decided, however, that some developmental
testing in this area would be mutually beneficial to the panel manufacturers
and ERDA alike. The basic reasons for conducting the subject cyclic pressure
tests using the 46 kW modules are:
1. Identify the problems associated with the design, construction and
operation of a test apparatus to perform the cyclic pressure testing.
2. Determine the sensitivity of a variety of solar panel designs to
the 50 lb/£t2 cyclic pressure loading or fatigue affects therefrom
in the areas of primary structural failures, encapsulant/substrate
delamination, cell breakage, and interconnect failures. This
information to be used in the following way:
a) To understand the kind of problems to expect
b) Determine whether the 130 kW acceptance test requirements
are difficult to satisfy
c) Feed back the nature of panel failures to the panel
manufacturers for corrective action before 130 kW designs
are finalized.
1
,...... .... ,
3.0 Test Apparatus
Design and construction of a simple, reliable means of applying a
uniform pressure load alternately to the front and back sides of the solar
panel being tested was a primary goal of this test effort.
3.1 Functional Requirements
The following requirements were imposed on the apparatus
a) solar panel size - 4 ft x 4 ft or smaller
b) pressure load applied - adjustable--50 lb/ft2
c) pressure applied alternately to front and back sides
d) pressure applied to one side only if desired
e) panel fault detection to ascertain electrical discontinuity
in panel
f) counter - to count the number of cycles to panel failure
g) automatic/untended operation to include -
• automatic cycling of pressure from front to back sides
of panels
adjustable dwell time--that is ability to hold pressure
on one side of panel for desired period of time
adjustable total cycle time
automatic fault (discontinuity) detection
automatic unit shut-down at panel failure
indication of the number of cyles at panel failure retained
h) reliable
i) low-cost
3.2 Description of Apparatus
Figure 1 shows the test apparatus in toto. The top platen is removed
to show the solar panel installation. The top platen and its air mattress are
installed above the solar panel when it is desired to apply load to tne front side
of the panel. Figure 2 is a block diagram representing the interrelationships of
the various key elements of the apparatus.
2
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Fault Cycle Timer Pressure Pressure
Detection And Counter Control Application
------ -System System System System
(Electronic) (Timer) (Pneumatic) (Mechanical)
Fig. 5 Fig. 5 Fig. 4 Fig. 3
Figure 2.
Block Diagram Cyclic Pressure Loading Apparatus
Figures 3, 4, and 5 show the above subsystems in greater detail.
3.2.1 Pressure Application System-Fig. 3
The pressure application system is the physical mechanism for applying
pressure to the panels. The solar panel is supported by a 1 in. thick plywood
mask, which is placed between two 1/2 in. plywood platens. Between each platen
and one side of the solar panel an air mattress is inserted. By pressurizing
this air mattress, a uniform pressure load equal to the pressure in the air
mattress is applied to the panel.
A word of caution is appropriate here. The distance between the solar panel and
the reaction platen must be carefully adjusted to insure that the pressure
within the mattress is applied to the panel and not reacted by membrane tensile
forces developed in the mattress itself. To accomplish this, the reaction
platen should be adjusted as close as possible to the solar panel--the air
mattress will not develop tensile stresses when constrained to appreciably less
than its normal inflated thickness. The platen should not, however, be so
close to the solar panel that it can interfere with the deformation of the panel
when the other side of the panel is loaded.
4
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3.2.2 Pressure Control System--Fig. 4
The function of the pressure control system is to pressurize the
air mattresses to the desired pressure. It also must maintain that pressure
until it receives an external command to pressurize the other side of the panel.
Before describing the operation of the system, note that this system
is completely self-contained except that the 4-way spool valve is controlled
externally by the so-called "cycle-timer" system discussed later. The cycle
timer system cause the pressure controls system to pressurize first one side
of the panel and then th~ other.
Referring to Fig. 4 the operation of the pressure control system
is described below.
a) Consider that we are just starting to pressurize the bottom bag
and its pressure switch is still made (Fig. 3 shows the bottom
bag fully pressurized with its pressure switch open)
b) With the bottom bag pressure switch made the solenoid valve
(innnediately downstream of the course regulator) is open and the
bag is filled from a shop air source regulated to about 25 psig.
The filling source must be at a comparatively high pressure
c)
2 (relative to the desired 50 lb/ft (9.6"H20) in order to fill the
bag in a reasonable length of time.
2 When the pressure in the bag reaches the 47 lb/ft (9"H20) set-point
on the pressure switch, that switch opens and interrupts current
to the solenoid valve, cutting off .the primary 25 psig "fill"
supply air. Having the pressure switch set point at 47 lb/ft2 2 .
rather than the desired 50 lb/ft eliminates "overshoot,"
"hunting" and similar problems often encountered with control
systems of this type.
6
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d) Now note that a secondary fill source regulated to the desired
50 lb/ft2 that by-passes the solenoid valve is provided. This
secondary fill source is controlled by a precision dead-end
regulation and tops-off the pressure in the air mattress to
the desired 50 lb/ft2• This make-up regulator also makes the
system insensitive to small leaks.
e) To pressurize the other side of the solar panel the 4-way spool
valve is actuated (automatically by the "timer control" system)
and the fill cycle described above (a through d) takes place for
the other air mattress while the first air mattress vents to
atmosphere.
Cycle Timer/Counter System--Fig. 5
The function of the cycle timer/counter system is to alternately
pressurize the front and back sides of the panel at a desired time interval.
This is accomplished by using a function generator which supplies a 28 VDC
square voltage pulse of the desired peripd to the solenoid operator of the
4-way spool valve of the pressure control system. In Fig. 3 if 28 VDC is
applied the top bag will be pressurized and with O VDC applied the bottom bag
will be pressurized. Additionally this 28 VDC signal furnishes the voltage
pulse which actuates an electromechanical counter that indicates the total
number of pressurization cycles applied to the panel.
3.2.4 Fault Detection System--Fig. 5
The function of the fault detection circuit is to automatically
detect an open circuit in the test panel, cause the pressurization system to
shut down, while preserving the total number of cycles at failure. In order
to detect an open circuit in the panel a 5 VDC voltage is placed across the
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panel and a 10012
across the 100 n panel.
resistor in series with the panel. The voltage drop
resistor is taken as a measure of the condition of the
A change in the voltage greater than 10% (either an increase or
decrease) causes automatic system shutdown for subsequent investigation by
the operator to determine the cause for shutdown. Thus, the apparatus stops
cycling and counting. In this way the cycle count is preserved until the
operator can determine the cause of the anomaly--i.e. panel failure or other
condition.
It should be noted, that, in operation discontinuities in the panel
are commonly detected when the back side is loaded and the panel is fully
flexed convex toward the front side. When the back side load is relieved
the continuity of the panel is coDDJ1only restored restarting the system, thus
losing the cycle count at failure. To preclude this possibility a "latching" or
"holding" circuit is incorporated in the fault detection circuit. The "holding"
circuit prevents the system from restarting when panel continuity is restored
as follows. As already mentioned, when the relay receives the 5 VDC anomaly
signal, one set of contacts opens, cutting off the 120 VAC power supply to the
cycle timer system. Additionally, the other set of contacts of the relay close,
putting 4.5 VDC battery in the circuit to hold the relay in the fault position.
Note that the only way the system can be restarted is for the operator to
push the "reset" switch.
4.0 Description of Panels Tested
Five solar panel designs were tested. A brief description of these
panels and the way they were supported in the test apparatus is provided in
Table IV. Additional support details are given in the Appendix.
10
TABLE I DEsctz.1PT1otJ oF 4~l<W .SoLAl2. PA/JELS
SKE:.TCH
TYPE I ~ ,,
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lo (lX/)(!X/) o
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7YPE. 3
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TYPES
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D ,' me n:5 /(),,~
Suhsf ra.te. Enca.pSlJ/a.n r Cell$
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5.0 Test Results
5.1 Comments on the Test Apparatus
The test apparatus performed remarkably well with a minimal number
of teething problems.
a) A few false (not panel failure) shut-downs were experienced.
These were traced to loose wires, line voltage surges, or high
frequency voltage spikes from 120 VAC pressure switch/solenoid
valve circuitry of the pressure control system fed back to the
fault detection circuit. Since this only delayed the testing
until the operator could determine that the cause of shut-down
was not panel failure, this was not considered a serious problem.
b) The pressurization system experienced no tendencies to "hunt" or
"overshoot" as is coDDDon with controls of this type.
c) Each of the two air mattresses used was inflated to 50 lb/sq. ft.
pressure, a total of approximately 130,000 cycles.
5.2 Comments on the Solar Panels
A total of 9 solar panels of 5 different designs were tested. In
general, the solar panels tested proved to be structurally capable of withstanding
the applied cyclic pressure loading. A summary of the raw data obtained is
contained in the Appendix. Certain general observations can be made.
a) All 5 designs proved to be structurally capable of withstanding the
cyclic pressure loading, even though 3 of the designs exhibited
rather large deformations due to the fact that they employed a
plastic or glass reinforced plastic substrate.
12
-
b) All 5 designs used a clear silicone potting compound as a cell
encapsulant. Encapsulant/substrate delamination did not occur
during the course of these tests.
c) Four of the five designs exhibited no failures of any sort
even though the number of cycles applied to a single panel exceeded
35,000 in two of the designs tested.
d) Design Type 4 exhibited a tendency to fail at the cell interconnects.
e)
In some cases it was clear that this failure had occurred during
thermal cycling or humidity tests, but was first noticed in the
cyclic pressure testing, because flexing the panel convex toward
the front side caused the previously cracked interconnects to
open. In some cases the failure occurred in the ribbon type inter
connect approximately midway between cells, and in other cases the
failure occurred where the interconnect was soldered to the top
of the cell.
Design Type 2 exhibited an anomaly which cannot be called failure
because it did not cause panel resistance to drop more than
about 6%. This problem was traced to the expanded metal cell
interconnects. In a few cases cutting out the mesh to produce
the interconnects produced sharp barbs which were unfortunately
located very close to the edge of a cell. Upon panel flexure
these barbs shorted the bottoms of a cell to the top of the same
cell.
13
6.0 Conclusions
6.1 Test Apparatus
a) The design, construction and operation of a device to alternately
apply a uniform pressure load to the front and back sides of
solar panels, automatically shut-down in the event of panel
failure and to retain a count of the number of load cycles in a
straight-forward task.
b) Such a device can be expected to disclose deficiencies (design,
fabrication and material) of solar panels intended for a wind
load environment.
6.2 Solar Panels
A general conclusion of the testing performed here is that design of
solar panels to sustain the 50 lb/ft2 cyclic pressure load is not difficult.
As mentioned previously, no structural failures were encountered even though
the panels tested run the gamut from very flexible (Type 3) to very stiff
(Type 5). It is also encouraging to note that the cell interconnect failure
encountered with the Type 4 panels are readily explainable in terms of
noticeable differences between this design and the other designs which employed
ribbon-type interconnects. The notable differences are:
a) The Type 4 design has very shallow strain relief loops.
b) The solder joint of the ribbon to the top of the cell was very
thick (too much solder and not enough heat).
These problems are considered easily corrected in future designs.
The interconnect anomaly experienced with the Type 2 panels, which
used expanded metal interconnects, also appears to be easily remedied. Careful
14
location of the edges of the cell interconnects with respect to the pattern of
the expanded metal mesh from which they are fabricated will eliminate the
"hangnails" which gave rise to the cell-shorting phenomena reported.
15
APPENDIX
Summary of test data including panel mounting sketches.
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46 kW Solar Panela
CYCLIC LOADING TEST DATA SUMKAI.Y SHEET .
Type No: --'--------------------Serial No.
Prior Test Hiatory of Panel:
Date(s) of Test
Mounting of Panel (see attached sketch)
Loading (see below) ---- uniform pressure on back side panel
~- uniform pressure on front side panel
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A-3
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Panel:
46 kW Solar Panela
CYCLIC LOADING TEST DATA SUMHilY SHEET
Type No: --'---------------------Serial No.
Prior Test History of Panel:
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2. P~e~ PU.\110\JSL.~ SU6J&e,T To ~"e. , .. ~..,,.. c.~c:.~ APPL.le.a TD aAc.K 110& - c.ful," ~ CtJli I~-
Date Cs) of Test &.{1~"7<.., ~ bf 2.1J1c. Mounting of Panel {see attached sketch)
Loading (see below) ---- uniform pressure on back side panel
----- uniform pressure on front side panel
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Panel:
46 kW Solar Panels
CYCLIC LOADING TEST DATA SUMMARY SHEET
Type No: ___ 2 ___________________ _
Serial No. V-14 -A, Prior Test History of Panel:
,. 100 -rue~A\... C'-fCL~S
2.. ,,s Mt.s. HLIM1D1T'i.
Date(s) of Test
Mounting of Panel (see attached sketch)
Loading (see below) ---- uniform pressure on back side panel
- uniform pressure on front side panel
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CYCLIC LOADING TEST DATA SUMMARY SHEET
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Type No: ___ 2.------------------Serial No. '/· 14-A,
Prior Test History of Panel:
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Mounting of Panel (see attached sketch)
Loading (see below) ---- uniform pressure on back side panel
--- uniform pressure on front side panel
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OPENINt:. lf..l PLYWOOD
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Panel:
46 kW Solar Panela
CYCLIC LOADING TEST DATA SUMMARY SHEET
Type No: ___ 3 ___________________ _
Serial No. 00.9~0
Prior Teat History of Panel:
~o, Pll.&."IOUSL'{ Te.~T~O .
Date(a) of Teat +l~•f,C. , 4/u{ic., 4{ul,<., 1 4'2-"j ,t-Mounting of Panel (see attached sketch)
Loading (see below) ---- uniform pressure on back side panel
----- uniform pressure on front side panel 6~
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f A' '-""-e oft. 'DILE>R. ADAT• o,..J I
A-9
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Panel:
46 kW Solar Panels
CYCLIC LOADING TEST DATA SUMMAltY SHEET
Type No: ___ 3 ____________________ _
Serial No. 00330
Prior Test History of Panel:
· 2000 PU.ssuu c:.1ca.s5(ek1e ~,pa o,.,1.1)-4/21/11,14lz{1c.J4ju{1,/f(u!14,
Date(s) of Test f j 2.1 J ;c. · ~.... . s { 11 J,, Mounting of Panel (see attached sketch)
Loading (see below) ---- uniform pressure on back side panel
---- uniform pressure on front side panel
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Panel:
46 kW Solar ~anela
CYCLIC LOADIRG UST DATA SINtAJ.Y SHEET
Type No: ___ 4 __________________ _ Serial No. 2" I 000 2.
Prior Test History of Panel:
I. 2c:> TWS1ZMA1.. e-'/cl-4~ 2.. 4 1 Tt-1&.ll~Ac. C.1 CLl!4S
'3 . f 00 TI-fEtMAt.. C.'ICC.&. I.
Date(s) of Test ~f 1ff 7C.. ~ s-/11 f ic.,. Mounting of Panel (see attached sketch) 1~ P~ · A M0"1tiJT UJt. •
Loading (see below) ---- uniform pressure on back side panel
~ uniform pressure on front side panel
60 1 • • , 1 1 • 1 • , 1 • ! N '-t-,...&......6-~~~~~~-r , : · I I I I i , I . -;
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Remarks:
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A-12
Panel:
46 kW Solar Panels
CYCLIC LOADING TEST DATA SUMMARY SHEET
Type No: ___ 4 __________________ _ Serial No. '" 30040
Prior Test History of Panel:
,. 1G,s H"MJDIT'l e'lc.LES. 2.. SI Tt+e.~AL C'/C:.C..E.S.
Date(s) of Test 5' I 1 '7 f 'J (p ,__J_ 5"118) 7'=> , Mounting of Panel (see attached sketch) TIPe. ,\ MOU'"1TlJG.
Loading (see below) ---- uniform pressure on back side panel
~- uniform pressure on front side panel 6 ,. "' I ·~ i/-i..!..!,J,1/: :f ~ i ! l ~ J ! i' I I I : ' j 1 j l ~ r 1 j I ' . . . ' . -~ -~J' _.._· -.. l ~ i · ~ l~ I; J. + 1 • t-· ~ .. . . :·-h-i ~r------ti +-1 +-.. 1 . ...j .,._
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Panel:
46 k.W Solar Panela
CYCLIC LOADING TEST DATA SUMMAllY SHEET
Type Ho: ___ 4.:...-------------------Serial No. 7" I 000 S-
Prior Teat History of Panel:
I. 2 0 THi!ll.MA&. C'(C:L&S
2. 4 I THELMA L. c'ICLe\ 3. I 00 T._.E.«MAL C:~CL.E.' •
4. I '1 S' Hf.S. t-lUMI OaT'Y.
Date(a) of Teat '-/2.if ,e,.~ ~1.3\,C.., Mounting of Panel (see attached sketch) 1'(1)6. ~ Mol.ltJTpJ(.
Loading (see below) ---- uniform pressure on back side panel
10
Rcmc1rks:
~- uniform pressure on front side panel
20
40 SEcotJDS ~t,J£ cy CL&.
30 4 tim~ - seconds
I. Pt2.e.SS\J£E. APPL1~0 7o BoT~ Sa.:)£~ OF PA>JEL..
60
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A-15
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Panel:
46 kW Solar Panels
CYCLIC LOADING TEST DATA SUMIWlY SHEET
Type No: ___ 4_._ _________________ _ Serial No. ,~ 30038
Prior Teat History of Panel:
I. I" S"' t'llS. U UM ID IT)\
2. 8 I TE.MPEfZA&TLIU. C"'/cu!. S ,
Date(s) of Test
Mounting of Panel (see· attached sketch) 'i'IPa A MOUUTl'-1 &
Loading (see below) ---- uniform pressure on back side panel
---- uniform pressure on front side panel
6 n - I I I l l . ' I I I . I •
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2.•! ~ s,~ ,. . ~, ,o . 3\4
11i8 ,,e\ ,~_, 11 \ 1s
A-16
Panel:
46 kW Solar Panels
CYCLIC LOADING TEST DATA SUMMARY SHEET
Type No: ___ 4~-------------------Serial No. 7~ 3004-S-
Prior Test History of Panel:
Date(s) of Test
Mounting of Panel (see attached sketch) l'i p£. 6 MOU~TalJG:t Loading (see below) ---- uniform pressure on back side panel
- uniform pressure on front side panel
Remarks:
I. P,t&s5 I.JR.a A PPL ae.o ,-o 80TH , , DE cf: P4#-JS. L
2.
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A-17
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Panel:
46 kW Solar Panels
CYCLIC LOADING TEST DATA SUMMARY SHEET
Type No: __ 5---------------------Serial No. 0S1"2.4
Prior Test History of Panel:
Date(s) of Test
Mounting of Panel (see attached sketch)
Loading (see below) ---- uniform pressure on back side panel
-----uniform pressure on front side panel
6G N ·- - - - . - - - . . . . . ·- _. "- - ·- . - - . . l . ' ~ ! ~ ' -- : .. ... ,. ... : ' ~ 1 ~ 40 ~~--- J......._ _____ l-+--l ____ -6-~"~--~--1----~--+- _.,._ · \. .J . .... t • - ~,\. , -. -. - .. -~---t'' -I .. . ·- . ·- -t, , ·-- ·- . - t I i --', ~ \i -· ·4-+4-l-........... .+-1-............ 4-4---11~--4--+-+-+-+-++4-~
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time - seconds oua e'/c.1.e.
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Remarks:
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2... 5 I, 71#, '2.. C.'ICL.&.~ APP C..18 0
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A-19