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Teledyne 3000PB Operating Instructions Manual

Percent oxygen analyzer
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Percent Oxygen Analyzer
OPERATING INSTRUCTIONS FOR
Model 3000 PB
Percent Oxygen Analyzer
DANGER
HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING
SYSTEM.
PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.
HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST
P/N M66682
FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
03/29/2006
ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING. BEFORE
ECO # 06-0059
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/
MANAGER.
Teledyne Analytical Instruments
i

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  • Page 1 P/N M66682 FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED. 03/29/2006 ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING. BEFORE ECO # 06-0059 CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/ MANAGER. Teledyne Analytical Instruments...
  • Page 2 Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Teledyne at the time the order is placed.

  • Page 3: Table Of Contents

    3.3.2 Fuse Installation ............. 3-4 3.3.3 Analog Outputs ............3-4 3.3.4 Alarm Relays ............3-6 3.3.5 Digital Remote Cal Inputs ........3-7 3.3.6 Range ID Relays ............ 3-9 3.3.7 Network I/O ............3-9 3.3.8 RS-232 PorT ............3-9 Teledyne Analytical Instruments...
  • Page 4 Model 3000PB 3.3.9 Remote Sensor and Solenoid Valves ..... 3-10 3.4 Installing the Micro-Fuel Cell .......... 3-12 3.5 Gas Connections ............3-12 3.6 Testing the System ............3-14 4 Operation 4.1 Introduction ..............4-1 4.2 Using the Data Entry and Function Buttons ....4-2 4.3 The System Function .............
  • Page 5 5.7 Troubleshooting.............. 5-9 Appendix A-1 Specifications ..............A-1 A-2 Recommended 2-Year Spare Parts List ......A-3 A-3 Drawing List ..............A-4 A-5 Applicatiopn Notes on Restrictors, Pressures & Flow ..A-5 A-6 The Zero Functions ............A-8 Teledyne Analytical Instruments...
  • Page 6 Since the use of this instrument is beyond the control of Teledyne, no responsibility by Teledyne, its affiliates, and agents for damage or injury from misuse or neglect of this equipment is implied or assumed.

  • Page 7: Introduction

    Overview The Teledyne Analytical Instruments Model 3000PB Percent Oxygen Analyzer is a versatile microprocessor-based instrument for detecting oxygen in a variety of gases. This manual covers the Model 3000PB, percent oxy- gen, general purpose, bulkhead-mount units only. Typical Applications A few typical applications of the Model 3000PB are: •...

  • Page 8: Model Designations

    3000PB-M: 4-20 mA dc Signal and Range ID outputs, in addition to the standard voltage outputs. All of the above options are available in combination. For example, the -C and -V options are combined as Model 3000PB-C-V. Teledyne Analytical Instruments...

  • Page 9: Operator Interface

    Percent Oxygen Analyzer Introduction 1 Operator Interface Figure 1-1 is an illustration of the front of the Model 3000PB Oxygen Analyzer with the outer door open showing the control panel (which is also the inner door). All displays on the standard 3000PB are visible from outside the hous- ing.
  • Page 10 1 Introduction Model 3000PB (Pressing the latch button will open the Inner Door) Figure 1-1: Model 3000PB—Outer Door Open—Showing Control Panel Teledyne Analytical Instruments...
  • Page 11 Percent Oxygen Analyzer Introduction 1 Figure 1-2: Model 3000PB—Inner Door Open—Showing Internal Components Teledyne Analytical Instruments...

  • Page 12: Displays

    1 Introduction Model 3000PB 1.5.1 Displays Digital Meter Display: The meter display is a LED device that produces large, bright, 7-segment numbers that are legible in any lighting environment. It produces a continuous readout from 0-100 %. It is accurate across all ranges without the discontinuity of analog range switching.

  • Page 13: I/O Power Button

    The connectors are described briefly here and in detail in the Installation chapter of this manual. CAUTION: The power cable must be disconnected to fully remove power from the instrument. Teledyne Analytical Instruments...
  • Page 14 1 Introduction Model 3000PB 3.0 A MAX Figure 1-3: Electrical Connector Panel Electrical Connections: The electrical connections on the electrical connector panel are described briefly here, and in more detail in chapter 3 Installation. • Power Connection 115 or 230 V ac, 50 or 60 Hz.

  • Page 15: Gas Connector Panel

    Those that are optional are shown shaded in the figure. The connectors are described briefly here and in detail in the Installation chapter of this manual. Note: For Additional information, please, see page 1-4 Figure 1-4: Model 3000PB Gas Connector Panel Teledyne Analytical Instruments...
  • Page 16 3000PB electronics. Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3000PB is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. Teledyne Analytical Instruments...

  • Page 17: Operational Theory 2

    Micro-Fuel Cell Sensor 2.2.1 Principles of Operation The oxygen sensor used in the Model 3000PB series is a Micro-Fuel Cell designed and manufactured by Analytical Instruments. It is a sealed plastic disposable electrochemical transducer. The active components of the Micro-Fuel Cell are a cathode, an anode, and the 15% aqueous KOH electrolyte in which they are immersed.

  • Page 18: Anatomy Of A Micro-Fuel Cell

    2 Operational Theory Model 3000PB analyzed. The Micro-Fuel Cell is therefore a hybrid between a battery and a true fuel cell. (All of the reactants are stored externally in a true fuel cell.) 2.2.2 Anatomy of a Micro-Fuel Cell The Micro-Fuel Cell is a cylinder only 1¼ inches in diameter and 1 inch thick.

  • Page 19: Electrochemical Reactions

    It is measured and used to determine the oxygen concentration in the gas mixture. The overall reaction for the fuel cell is the SUM of the half reactions above, or: → 2PbO 2Pb + O Teledyne Analytical Instruments...

  • Page 20: The Effect Of Pressure

    2 Operational Theory Model 3000PB (These reactions will hold as long as no gaseous components capable of oxidizing lead—such as iodine, bromine, chlorine and fluorine—are present in the sample.) The output of the fuel cell is limited by (1) the amount of oxygen in the cell at the time and (2) the amount of stored anode material.

  • Page 21: Micro-Fuel Cell "Class

    Expected life in flue gas is 8 months. 2.2.6.2 Class A-5 Cell The class A-5 cell is for use in applications where it is exposed intermit- tently to carbon dioxide concentrations up to 100 % in the sample gas. Teledyne Analytical Instruments...

  • Page 22: Sample System

    Depending on the mode of operation either sample or calibration gas is delivered. The Model 3000PB sample system is designed and fabricated to ensure that the oxygen concentration of the gas is not altered as it travels through the sample system.

  • Page 23: Electronics And Signal Processing

    The power supply module is mounted underneath the bottom end of the Electrical Connector Panel. The Model 3000PB Percent Oxygen Analyzer uses an 8031 microcon- troller with 32 kB of RAM and 128 kB of ROM to control all signal pro- cessing, input/output, and display functions for the analyzer.
  • Page 24 2 Operational Theory Model 3000PB Figure 2-5: Block Diagram of the Model 3000PB Electronics In the presence of oxygen the cell generates a current. A current to voltage amplifier converts this current to a voltage, and then the voltage is amplified in the second stage amplifier.
  • Page 25 Models with the –M option also have a 4-20 mA dc percent-of-range signal output and analog range ID output. Signals from the power supply are also monitored by the microproces- sor, and the system failure alarm is activated if a malfunction is detected. Teledyne Analytical Instruments...
  • Page 26 2 Operational Theory Model 3000PB Teledyne Analytical Instruments 2-10...

  • Page 27: Installation

    Immediately report any damage to the shipping agent. Mounting the Analyzer The Model 3000PB is designed for bulkhead mounting in nonhazard- ous environments. There are four mounting lugs—one in each corner of the enclosure. The outline drawing, at the back of this manual, gives the mount- ing hole size and spacing.
  • Page 28 3 Installation Model 3000PB Figure 3-1: Front View of the Model 3000PB (Simplified) Teledyne Analytical Instruments...

  • Page 29: Electrical Connections

    Percent Oxygen Analyzer Installation 3 Figure 3-2: Required Front Door Clearance Electrical Connections Figure 3-3 shows the Model 3000PB Electrical Connector Panel. There are terminal blocks for connecting power, communications, and both digital and analog concentration outputs. Figure 3-3: Electrical Connector Panel...

  • Page 30: Primary Input Power

    3 Installation Model 3000PB For safe connections, ensure that no uninsulated wire extends outside of the connectors they are attached to. Stripped wire ends must insert com- pletely into terminal blocks. No uninsulated wiring should be able to come in contact with fingers, tools or clothing during normal operation.
  • Page 31 The signal output for concentration is linear over the currently selected analysis range. For example, if the analyzer is set on a range that was defined as 0–10 % O , then the output would be as shown in Table 3-1. Teledyne Analytical Instruments...

  • Page 32: Alarm Relays

    3 Installation Model 3000PB Table 3-1: Analog Concentration Output—Example Voltage Signal Current Signal Output (V dc) Output (mA dc) 10.4 12.0 13.6 15.2 16.8 18.4 20.0 To provide an indication of the range, a second pair of analog output terminals are used. They generate a steady preset voltage (or current when using the current outputs) to represent a particular range.

  • Page 33: Digital Remote Cal Inputs

    Remote Zero and Span Inputs: The REMOTE SPAN and RE- MOTE ZERO inputs are on the DIGITAL INPUT terminal block. They accept 0 V (OFF) or 24 V dc (ON) for remote control of calibration. (See Remote Calibration Protocol below.) Teledyne Analytical Instruments...
  • Page 34 (See Remote Calibration Protocol below.) Remote Calibration Protocol: To properly time the Digital Remote Cal Inputs to the Model 3000PB Analyzer, the customer's controller must monitor the CAL CONTACT relay. When the contact is OPEN, the analyzer is analyzing, the Remote Cal Inputs are being polled, and a zero or span command can be sent.

  • Page 35: Range Id Relays

    If you have the –C Internal valve option—which includes additional zero and span gas inputs— the 3000PB automatically regulates the zero, span and sample gas flow. 3.3.6 Range ID Relays There are four dedicated RANGE ID CONTACT relays.

  • Page 36: Remote Sensor And Solenoid Valves

    Toggling input. Stops/Starts any status message output from the RS-232, until st<enter> is sent again. The RS-232 protocol allows some flexibility in its implementation. Table 3-5 lists certain RS-232 values that are required by the 3000PB imple- mentation. Table 3-5: Required RS-232 Options...
  • Page 37 In addition, each individual line has a series FET with a nominal ON resistance of 5 ohms (9 ohms worst case). This could limit the obtainable voltage, depending on the load impedance applied. See Figure 3-9. Figure 3-9: FET Series Resistance 3-11 Teledyne Analytical Instruments...

  • Page 38: Installing The Micro-Fuel Cell

    3 Installation Model 3000PB Installing the Micro-Fuel Cell The Micro-Fuel Cell is not installed in the cell block when the instrument is shipped. It must be installed before the analyzer is placed in service. Once it is expended, or if the cell is exposed to air for too long, the Micro-Fuel Cell will need to be replaced.
  • Page 39 ZERO IN and SPAN IN: These are additional ports, included on models with the -C option, for inputting span gas and zero gas. There are electrically operated valves inside for automatic switching between sample 3-13 Teledyne Analytical Instruments...

  • Page 40: Testing The System

    Check Local, State, and Federal laws, and ensure that the exhaust stream vents to an appropriately controlled area if required. Note: If your 3000PB has the –V option, see Sample In, above, for gas pressure/flow considerations. Testing the System Before plugging the instrument into the power source: •...

  • Page 41: Operation

    • Set alarm setpoints, and modes of alarm operation (latching, failsafe, etc). Before you configure your 3000PB these default values are in effect: Ranges: LO = 1 %, MED = 5 %, HI = 10 % Auto Ranging: ON Alarm Relays: Defeated, 10 %, HI, Not failsafe, Not latching Zero: Auto, every 0 days at 0 hours Span: Auto, at 20.9 %, every 0 days at 0 hours...

  • Page 42: Using The Data Entry And Function Buttons

    4 Operation Model 3000PB Using the Data Entry and Function Buttons Data Entry Buttons: The < > arrow buttons select options from the menu currently displayed on the VFD screen. The selected option blinks. When the selected option includes a modifiable item, the Δ Δ Δ Δ Δ ∇ arrow buttons can be used to increment or decrement that modifiable item.

  • Page 43: The System Function

    Installing or Changing a Password, below, for a table of ASCII characters available.) Once a unique password is assigned and activated, the operator MUST enter the UNIQUE password to gain access to set-up functions which alter the instrument's Teledyne Analytical Instruments...

  • Page 44: Setting The Display

    4 Operation Model 3000PB operation, such as setting the instrument span or zero setting, adjusting the alarm setpoints, or defining analysis ranges. After a password is assigned, the operator must log out to activate it. Until then, anyone can continue to operate the instrument without entering the new password.

  • Page 45: Setting Up An Auto-Cal

    Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3000PB is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. To setup an Auto–Cal cycle: Choose System from the Function buttons.

  • Page 46: Entering The Password

    4 Operation Model 3000PB If you have decided not to employ password security, use the default password TBEAI. This password will be displayed automatically by the microprocessor. The operator just presses the Enter key to be allowed total access to the instrument’s features.

  • Page 47: Installing Or Changing The Password

    Δ Δ Δ Δ Δ ∇ arrow keys to change the letters to the new password. The full set of 94 characters available for pass- word use are shown in the table below. Characters Available for Password Definition: ¥ → " & < > Teledyne Analytical Instruments...

  • Page 48: Logout

    4 Operation Model 3000PB When you have finished typing the new password, press Enter. A verification screen appears. The screen will prompt you to retype your password for verification. A A A A A Retype PWD To Verify Wait a moment for the entry screen. You will be given clearance to proceed.

  • Page 49: Troubleshooting

    Operation 4 4.3.5 System Self-Diagnostic Test The Model 3000PB has a built-in self-diagnostic testing routine. Pre- programmed signals are sent through the power supply, output board and sensor circuit. The return signal is analyzed, and at the end of the test the status of each function is displayed on the screen, either as OK or as a number between 1 and 3.

  • Page 50: The Span Functions

    Zero or Span function. 4.4.1. Cell Failure When the sensor in the 3000PB begins to fail, the analyzer will usually require more and more frequent calibration. If the 3000PB analysis readings drift downward uncharacteristically, try recalibration. If recalibration raises the readings temporarily only, the cell may be failing.

  • Page 51: Span Cal

    As the span reading settles, the screen displays and updates informa- tion on Slope. Spanning automatically ends when the span concentration corresponds, within tolerance, to the value of the span gas concentration. Then the instrument automatically returns to the analyze mode. 4-11 Teledyne Analytical Instruments...

  • Page 52: Manual Mode Spanning

    The Alarms Function The Model 3000PB is equipped with 2 fully adjustable concentration alarms and a system failure alarm. Each alarm has a relay with a set of form “C" contacts rated for 3 amperes resistive load at 250 V ac. See Figure in Chapter 3, Installation and/or the Interconnection Diagram included at the back of this manual for relay terminal connections.
  • Page 53 The defeat alarm mode is incorporated into the alarm circuit so that maintenance can be performed under conditions which would normally activate the alarms. The defeat function can also be used to reset a latched alarm. (See procedures, below.) 4-13 Teledyne Analytical Instruments...
  • Page 54 4 Operation Model 3000PB If you are using password protection, you will need to enter your password to access the alarm functions. Follow the instructions in section 4.3.3 to enter your password. Once you have clearance to proceed, enter the Alarm function.

  • Page 55: The Range Function

    Med = 0–5.00 % High = 0–10.00 %. The Model 3000PB is set at the factory to default to autoranging. In this mode, the microprocessor automatically responds to concentration changes by switching ranges for optimum readout sensitivity. If the current range limits are exceeded, the instrument will automatically shift to the next higher range.

  • Page 56: Autoranging Analysis

    4 Operation Model 3000PB 4.6.2 Autoranging Analysis Set your analysis ranges as in 4.6.1, above. Leave Mode in Auto, or use the arrow buttons to change back to Auto. When operating in autoranging, if the oxygen concentration in your sample goes ABOVE your HIGHEST range setting, the analyzer will go into the special 25 % cal range.

  • Page 57: The Analyze Function

    Signal Output The standard Model 3000PB Percent Oxygen Analyzer is equipped with two 0–1 V dc analog output terminals accessible on the back panel (one concentration and one range ID). The –MA option also has two isolated 4–...
  • Page 58 4 Operation Model 3000PB The analog output signal has a voltage which depends on the oxygen concentration AND the currently activated analysis range. To relate the signal output to the actual concentration, it is necessary to know what range the instrument is currently on, especially when the analyzer is in the autoranging mode.

  • Page 59: Maintenance

    The major inter- nal component locations are shown in Figure 3-1, the cell block is illus- trated in Figure 3-2, and the fuse receptacle is shown in Figure 3-3 The 3000PB contains the following major internal components: • Micro-Fuel Cell •...

  • Page 60: Cell Replacement

    This section describes fuel cell care as well as when and how to replace it. The Class B-1 Micro-Fuel Cell is used in the standard Model 3000PB. If any other cell is supplied with your instrument, check the front of this manual for any addenda applying to your special model.

  • Page 61: Storing And Handling Replacement Cells

    To have a replacement cell available when it is needed, it is recom- mended that one spare cell be purchased 4-5 months after commissioning the 3000PB, or shortly before the end of the cell's warranty period. CAUTION: Do not stockpile cells. The warranty period starts on the day of shipment.

  • Page 62: Removing The Micro-Fuel Cell

    The “good” reading depends on the class of cell your analyzer is using. Although the B-1 cell is standard in the 3000PB, check Specific Model Information in the Front Matter in this manual for the class of cell you purchased. Then check Table 5-1, the Cell Indices table below, and do the prescribed calculations.
  • Page 63 (If worn, replace them.) Figure 5-2: Exploded View of Cell Block and Micro-Fuel Cell 5. When it is free, unscrew the cap from the nylon probe. Hold the probe vertically to prevent dropping the cell out of the probe. Teledyne Analytical Instruments...

  • Page 64: Installing A New Micro-Fuel Cell

    5.3.5 Cell Warranty The Class B-1 Micro-Fuel cell is standard in the Model 3000PB. This cell is a long life cell and is warranted for 6 months from the date of shipment. The customer should purchase only one spare cell (per section 5.3.1).

  • Page 65: Fuse Replacement

    Fuse Replacement The 3000PB requires two 5 × 20 mm, 4 A, T type (Slow Blow) fuses. The fuses are located inside the main housing on the Electrical Connector Panel, as shown in Figure 5-3. To replace a fuse: 1.
  • Page 66 5 Maintenance Model 3000PB During preamp testing there is a countdown in the lower right corner of the screen. When the testing is complete, the results are displayed. Power: OK Analog: OK Preamp: 2 The module is functioning properly if it is followed by OK. A number indicates a problem in a specific area of the instrument.

  • Page 67: Troubleshooting

    Turn the analyzer off, then back on again. Press the System key when prompted by the analyzer "Press System for default Values". This will return the analyzer to its default settings in calibration and zero values. Now proceed to carefully calibrate and zero the analyzer. Teledyne Analytical Instruments...
  • Page 68 5 Maintenance Model 3000PB 5-10 Teledyne Analytical Instruments...

  • Page 69: A-1 Specifications

    Displays: 2 line by 20 alphanumeric, VFD screen, and one 5 digit LED display. Digital Interface: Full duplex RS-232 communications port. Power: Universal power supply 110/220 VAC at 50/ 60 Hz Operating Temperature: 0-50 °C Teledyne Analytical Instruments...
  • Page 70 Appendix Model 3000PB Accuracy: ±2% of full scale at constant temperature. ±5% of full scale over operating temperature range, on factory default analysis ranges, once thermal equilibrium has been achieved. Analog outputs: 0-1 V dc percent-of-range 0-1 V dc range ID.

  • Page 71: A-2 Recommended 2-Year Spare Parts List

    (if available) and the model and serial number of the instru- ment for which the parts are intended. Orders should be sent to: TELEDYNE ANALYTICAL INSTRUMENTS 16830 Chestnut Street City of Industry, CA 91749-1580 Phone (626) 934-1500, Fax (626) 961-2538...

  • Page 72: A-3 Drawing List

    Model 3000PB A-3 Drawing List D66682 Final Assembly Drawing D66674 Outline Drawing D66675 Wiring Diagram NOTE: The MSDS on this material is available upon request through the Teledyne Environmental, Health and Safety Coordinator. Contact at (626) 934-1592 Teledyne Analytical Instruments...
  • Page 73 The first function is to limit the flow rate of the sample through the analyzer. A restrictor is chosen to operate over a range of pressures and provide a useable flow rate over that range. Teledyne Analytical Instruments...
  • Page 74 ( off scale of flow-meter), pressure drops other than the restriction device could become significant , and result in pressurizing the cell. Example 2, A 3000PB is configured for vacuum service as follows. The un-marked restrictor is placed in the sample vent port. The down stream end of the restrictor is then connected to a vacuum pump and by-pass valve.
  • Page 75 Operation without a restrictor device is not recommend as mentioned above. A 3000PB without any flow restrictor device was tested on 11-19-97. This results in a flow rate of 2.4 SLPM @ 1 PSIG. This is a cv of 0.023 for the standard sample sys.
  • Page 76 Appendix Model 3000PB Zero Cal The Zero button on the control panel is used to enter the zero calibra- tion function. Zero calibration can be performed in either the automatic or manual mode. In the automatic mode, an internal algorithm compares consecutive readings from the sensor to determine when the output is within the acceptable range for zero.
  • Page 77 30 seconds. When Slope is close enough to zero, press Enter. In a few seconds, the screen will update. Once span settling completes, the information is stored in the microprocessor, and the instrument automatically returns to the Analyze mode. Teledyne Analytical Instruments...
  • Page 78 Appendix Model 3000PB A-10 Teledyne Analytical Instruments...
  • Page 79 Product Name: Micro-Fuel Cells and Super Cells, all classes except A-2C, A-3, and A-5. Electrochemical Oxygen Sensors, all classes except R-19. Mini-Micro-Fuel Cells, all classes. Manufacturer: TELEDYNE Analytical Instruments Address: 16830 Chestnut Street City of Industry, CA 91749-1580 Phone: (818) 961-9221...
  • Page 80 Appendix Model 3000PB Section IV – Fire and Explosion Hazard Data Flash Point: Flammable Limits: LEL: UEL: Extinguishing Media: Use extinguishing media appropriate to surrounding fire conditions. No specific agents recommended. Special Fire Fighting Wear NIOSH/OSHA approved self-contained breathing Equipment: apparatus and protective clothing to prevent contact with skin and eyes.
  • Page 81 If there is liquid around the cell while in the instrument, wear eye and hand protection. Cleanup Procedures: Wipe down the area several times with a wet paper towel. Use a fresh towel each time. Contaminated paper towels are considered hazardous waste. A-13 Teledyne Analytical Instruments...
  • Page 82 NOTE: The above information is believed to be correct and is offered for your information, consideration, and investigation. It should be used as a guide. Teledyne Brown Engineering Analytical Instruments shall not be held liable for any damage resulting from handling or from contact with the above product.

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