APC MGE GALAXY PW 20 - 200 KVA User Manual

MGE™ Galaxy™ PW

20 - 200 kVA

User manual

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Contents

Introduction

General characteristics of MGE™ Galaxy™ PW UPSs ......................................... 5

System description .................................................................................................. 6

Different types of MGE™ Galaxy™ PW systems ................................................... 7

Isolation and protection devices .............................................................................. 7

Operation in on-line mode ....................................................................................... 8

Operation in "eco" mode ......................................................................................... 10

Operation with an engine generator set .................................................................. 11

Inverter shutdown or overload ................................................................................ 12

Output voltage quality and continuity ...................................................................... 12

Description of MGE™ Galaxy™ PW cubicles

UPS cubicle............................................................................................................. 13

Battery cubicle ........................................................................................................ 14

Control panel

General ................................................................................................................... 14

Presentation ............................................................................................................ 15

Start-up

System start-up ....................................................................................................... 17

Start-up of a module ............................................................................................... 18

Shutdown

Shutdown of the inverter ......................................................................................... 19

Shutdown of a rectifier/charger ............................................................................... 19

Control-panel display

General organisation ............................................................................................... 20

Display of messages ............................................................................................... 20

Measurement system .............................................................................................. 24

Voltage measurementsi .......................................................................................... 24

Current measurements ........................................................................................... 24

Power and frequency measurements ..................................................................... 24

Battery measurements ............................................................................................ 25

Selections and settings ........................................................................................... 25

Alarms

General ................................................................................................................... 28

Maintenance bypass ............................................................................................... 28

Environment information

Signal reception ...................................................................................................... 29

Signal transmission ................................................................................................. 29

Logging and time-stamping

Presentation of event time-stamping by MGE™ Galaxy™ PW .............................. 30

Utilisation via the MGE™ Galaxy™ PW display ..................................................... 30

Utilisation via Teleservice ....................................................................................... 33

Maintenance

Maintenance configuration ...................................................................................... 34

Battery maintenance ............................................................................................... 37

Visual check ............................................................................................................ 37

Functional check ..................................................................................................... 37

Training center ........................................................................................................ 38

Options

Isolating and voltage matching transformer for the normal and bypass AC

Source and the load ................................................................................................ 39

Harmonics filter and power factor improvement ..................................................... 39

Safety of life and property ....................................................................................... 39

Empty cubicles ........................................................................................................ 40

Electrical supervision .............................................................................................. 40

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All products in the MGE™ Galaxy™ PW range are protected by patents. They implement original technology not available to competitors of APC by Schneider Electric.

To take into account evolving standards and technology, equipment may be modified without notice. Indications concerning technical characteristics and dimensions are not binding unless confirmed by APC by Schneider Electric.

This document may be copied only with the written consent of APC by Schneider Electric. Authorised copies must be marked "MGE™ Galaxy™ PW User Manual, N° 51028230XT".

Introduction

General characteristics of MGE™ Galaxy™ PW UPSs

UPS power rating in kVA 20 30 40 50 60 80 100 120 160 200 Normal AC input

number of conductors 3 phases rated voltage and tolerances 380 V or 400 V or 415 V ± 10% (adjustable to ± 15%) rated frequency and tolerances 50 Hz or 60 Hz / ± 10% THDI with THM filter < 4% power factor with THM filter up to 0,96

Bypass AC input

number of conductors 3 phases + neutral rated voltage and tolerances 380 V or 400 V or 415 V / ± 10% rated frequency and tolerances 50 Hz or 60 Hz / ± 10%

Load

number of conductors 3 phases + neutral Ph/Ph voltages 380 V or 400 V or 415 V (according to setting) Ph/N voltages 220 V or 230 V or 240 V (according to setting) voltage fluctuations ± 0,5% adjustable frequency and tolerances (on battery power) 50 Hz or 60 Hz ± 0,05 Hz synchronisation with bypass ± 0,5 Hz (adjustable from ± 0,25 Hz to ± 2 Hz) voltage variation for 0 to 100% load step change ± 2% ((with battery) permissible overloads 150% for 1 minute, 125% for 10 minutes Isc Ph/Ph (% of I rated) 4.2 2.8 2.1 2.5 2.1 3.1 2.5 2.1 2.6 2.1 Isc Ph/N (% of I rated) 6.6 4.4 3.3 4 3.3 5 4 3.3 4 3.3 THDU Ph/Ph and Ph/N for linear load < 1,5% Ph/Ph, < 2% Ph/N THDU Ph/Ph and Ph/N for non-linear load < 2% Ph/Ph, < 3% Ph/N (at 80% of Pn) (1)

Battery

standard battery type gas-recombination sealed lead-acid battery

UPS characteristics

active power (kW) 16 24 32 40 48 64 80 96 128 160 efficiency at 50% load (%) 87.5 90.5 91.5 92.5 93 91 91.5 92 93 93.2 (values ± 1%) efficiency at 100% load (%) 91.5 92 91.5 93 92 92.5 92 91.5 92.8 92.5 (values ± 1%) heat losses (2) in KW 1.5 2.1 3.4 3.6 4.7 6.2 8.1 10.1 12.2 14.8

in cal./s 360 504 816 864 984 1488 1950 2420 2930 3550 storage temperature range -25 °C to +70 °C operating temperature range 0 °C to 35 °C (40 °C for 8 hours) relative humidity 95% maximum maximum operating altitude without derating < 1000 meters noise level (dBA) 58 58 58 60 60 62 64 65 67 68 dimensions (mm) width 715 1015 1215

depth 825

height 1400 or 1900 ± 10 1900 ± 10 weight (kg) (3) 450 450 450 490 490 800 800 800 1200 1200 recommended upstream earth-fault protection 1 A standards design IEC 146

product ENV 50091 safety IEC 950, ENV 50091 protection IEC 521 (cubicles 1400 mm high = IP 21, cubicles 1900 mm high = IP 20) electromagnetic compatibility IEC 62040, ENV 50091

(1): As per standards ENV 50091-3 / IEC 62040-3. (2): The losses indicated are those produced at full rated load with the battery float charging. They must be taken into account when sizing the ventilation system. (3): Not including any built-in options, such as harmonic filters or a bypass AC-source isolation transformer.

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Introduction (cont.)

System description

(see figure 1)

◗ a rectifier/charger module (A)

converts 3-phase AC power from the normal AC source supply (1) into DC power for the normal inverter input and float charges or recharges the battery;

◗ a battery unit (D) provides backup

power for the inverter in the event of a voltage drop or a normal AC source failure;

◗ an inverter module (B) converts the

DC power supplied by the rectifier/ charger module or the battery unit into 3-phase AC power for the load;

◗ a static bypass module (C) ensures

the instantaneous transfer of the load to the bypass AC source input in the event of an inverter shutdown (initiated by the user or by a protective device) or a sudden overload;

◗ a maintenance bypass isolates the

UPS for maintenance and transfers the load to bypass AC source input without interrupting the supply of power. The maintenance bypass is made up of three manual switches (Q3BP, Q4S and Q5N).

Note

◗ the normal AC input and the bypass

AC input have different functions and, depending on the installation, may be protected differently upstream and/or come from different sources.

◗ frequency converters are available

without backup batteries;

◗ the static bypass line and the

maintenance bypass line do not exist in

The system may also include :

◗ an isolating transformer on bypass

AC input;

◗ a passive harmonic filter (FAH) on

the normal AC input;

◗ an active harmonic conditioner on the

normal AC input;

◗ different remote control, indication

and display systems.

installations where the load frequency and the bypass AC source frequency are different (for example in frequency converters);

◗ when increased power is required,

several MGE™ Galaxy™ PW units may be connected in parallel. In this configuration, an "isolation" function is added for the UPS system as a whole for maintenance purposes, without interrupting the supply of power to the load.

Schematic diagram of the MGE™ Galaxy™ PW system

inverter (B):

DC to AC power

QF1: isolation and protection

isolation and protection:

FUS Q5N

normal AC input

(1)

Q1 FUE :

isolation and protection

rectifier/ charger (A):

AC to DC power

load

bypass AC input

Fig. 1

(2)

isolation:

Q4S

maintenance bypass:

Q3BP

battery (D):

backup power

static bypass (C):

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Introduction (cont.)

Different types of MGE™ Galaxy™ PW systems

Fig. 2

Single-UPS unit

Fig. 3

Frequency converter with battery backup power

Fig. 4

Frequency converter without battery backup power

Parallel UPS system

Fig. 5

See figure 5 showing two parallelconnected (redundant) UPS units. A static bypass (C) does not exist in parallel-connected frequency-converter

Q4S

Galaxy 1

1 2

Galaxy 2

1 2

Galaxy 3

1 2

Galaxy 4

Q3BP

Q5N

configurations. When increased power is required (two to four parallel units), an external bypass must be added (see figure 6).

Isolation and protection devices

(See figure 1 on previous page):

◗ Q1 (switch):

◗◗ isolation of the rectifier/charger (A)

from the normal AC source (1);

◗◗ rectifier/charger (A) start-up;

◗ QF1 (circuit breaker):

◗◗ battery (D) protection and isolation;

◗ Q5N (switch):

◗◗ isolation of the UPS (B) from the

load;

◗ Q4S (switch):

◗ ◗ isolation of the static bypass (C) from

the bypass AC source (2);

◗ Q3BP (switch):

◗◗ bypass switch for maintenance;

◗ FUE (fuses):

◗◗ protection of the rectifier/charger (A)

from the normal AC source;

◗ FUS (fuses):

◗◗ protection of the inverter (B) from the

load.

Note:

◗ switch Q3BP does not exist on

parallel UPS systems constituted to increase available power;

◗ the "Q3BP" and "Q4S" switches do

not exist on frequency converters;

◗ circuit breaker QF1 does not exist on

installations without batteries.

External bypass for parallel UPSs and the hot-swap option

Fig. 6

See figure 6.

◗ Q5N (switch): isolation of the

inverters of all the parallel UPS systems from the load;

◗ Q4S (switch): isolation of the static

bypasses (C) on each parallel unit from the bypass AC source (2);

◗ Q3BP (switch): bypass switch for

maintenance.

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Introduction (cont.)

Operation in on-line mode

Normal operation

Normal AC source power is available (see figure 7).

◗ lights 1 , 4 and 5 shine green on

the control panel;

◗ the power necessary for the load is

provided by the normal AC source (1) through the rectifier/charger (A) and the inverter (B);

◗ the rectifier/charger (A) also supplies

the power to float charge and recharge the battery if any. The rectifier/charger output voltage (DC) is regulated to supply:

◗◗ the float-charging or the recharging

voltage for vented lead-acid or Ni/Cd batteries,

◗ ◗ a single charge voltage for sealed

lead-acid batteries. The voltages depend on the number of

battery cells and the battery manufacturer. Factory set, they may also be adjusted by after-sales support technicians. An electronic board continuously measures the battery temperature and automatically adjusts the voltages.

Note:

In parallel MGE™ Galaxy™ PW systems, the power drawn by the load is equally shared between the different

Fig. 7

units.

Operation with the normal AC source down

See figure 8. In the event of a normal AC source failure or voltage outside specified tolerances of ±10% in amplitude (±15% optionally), the rectifier/charger (A) stops and the battery (D) supplies the necessary backup power to the load via the inverter (B). The battery, floatconnected between the rectifier/charger and the inverter, discharges during this operating mode.

2 , 4 and 5 shine green.

Lights The user is warned of battery operation by the slow beeping of the buzzer (see figure 19) and the message "LOAD PROTECTED, BATTERY DISCHARGING", followed by the remaining backup time and the percent load. This information is also available via volt-free changeover contacts for remote control devices.

Note:

In the event of a normal AC source failure, frequency converters without a battery shut down and the load is no

4 52

Fig. 8

longer supplied.

Battery time

The available battery time during a normal AC source outage depends on the:

◗ rated capacity of the battery; ◗ power consumed by the load; ◗ temperature of the battery; ◗ age of the battery.

The specified battery time corresponds to a minimum duration at full rated load. The actual backup time can therefore be greater if the system operates below its full rated load during the normal AC source outage. Operation on battery power can be extended beyond the specified time by reducing the load power consumption (by disconnecting non-critical loads). A "low battery" warning signal is sent via volt-free changeover contacts for remote control devices when the battery voltage reaches a level slightly above the minimum level. This signal warns the user of the imminent end of battery power. On the device itself, the buzzer beeps rapidly. The message "LOW-BATTERY SHUTDOWN WARNING" is displayed, followed by the remaining backup time and the percent load. Light and flashes. Battery power stops when the voltage supplied by the battery reaches the minimum threshold (335 V). This results in inverter shutdown and transfer of the load without interruption to the bypass AC source. Light shines red (not flashing). The message "LOAD NOT PROTECTED, ON-LINE MODE" is displayed and the buzzer sounds continuously. If the bypass AC source also fails, the load is no longer supplied. The inverter automatically shuts down when the time on battery power exceeds three times the specified backup time.

Note:

The "low battery shutdown" warning signal can be sent with an adjustable time delay prior to the effective end of battery power.

2 turns red

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Introduction (cont.)

Operation with the normal AC source restored

See figure 9. When normal AC source power (1) is restored or its voltage returns to within specified tolerances, the system automatically returns to its normal operating mode described above (on the condition it did not reach the end of battery power). If the end of battery power was reached (with the resulting inverter shutdown), the rectifier/charger (A) restarts automatically, but the inverter (B) must be restarted manually. The rectifier/charger recharges the battery (D) which was discharged during the mains outage. During battery charging, light The message "BATTERY CHARGING" is displayed, together with the value of the recharging current and battery voltage.

2 flashes green.

4 521

The battery charge cycle takes place in two steps (see figure 10):

◗ step 1: the battery is recharged at a

constant current limited to 0.1C10 (i.e. 1/10th of the battery capacity specified for a 10 hour discharge). The DC voltage increases with the battery charge until the charge level is reached;

◗ step 2: the battery is recharged at

constant voltage equal to the charge level (maximum value 463 V). The charging current gradually decreases until reaching a specified low value (floating current). For vented lead-acid batteries, the rectifier/charger supplies the charging voltage for 0 to 255 hours (parameter defined by the after-sales support department) and then the floating voltage. For sealed lead-acid batteries, the charging and floating voltages are the same.

Battery charge cycle

U/I

voltage

Note 1:

If the normal AC source failure is shorter than 0 to 255 seconds (default value = 30 seconds) (parameter defined by after-sales support department), the charger automatically supplies the floating voltage given the low battery discharge.

Note 2:

In frequency converters without battery power, the return of normal AC source power results in the automatic restart of the rectifier/charger and the inverter.

U charge/floating (sealed batteries)

Fig. 9

Fig. 10

current limiting

0,1 C10

constant voltage decreasing current

current

U "floating" (vented batteries)

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Introduction (cont.)

Operation in "ECO" mode

Normal operation

See figure 11. The power required by the load is supplied by the bypass AC source (2), via the static bypass (C). The rectifier/ charger (A) supplies the power required to float charge and recharge the battery

(D).

1 , 3 and 5 shine green and

Lights

4 flashes green. The message

light "LOAD PROTECTED, ECO MODE" is displayed.

Operation with the bypass AC source outside tolerances

Whatever the status of the normal AC source, operation of the rectifier/ charger (A) with the battery (D) is identical to that presented in the section on on-line mode operation above. When bypass AC source (2) characteristics are outside tolerances (voltage: ±10%; frequency as per personalisation; phase sync with inverter ±3°), the load is supplied via the inverter (B). From then on, the minimum operating time on the inverter (B) is 2 minutes even if the bypass AC source returns to within specified tolerances. Refer to figure 7 in the general appendix if the normal AC source is present, and to figure 8 if it is absent. After this 2 minute period, the load is immediately transferred to the bypass AC source when the latter returns to within specified tolerances.

Note:

The maximum transfer time of the load from the static bypass (C) to the inverter (B) is 15 ms.

41 3

Operation with bypass AC source restored

◗ no battery discharge (see figure 11).

When bypass AC source power supply (2) is restored or returns to within specified tolerances, the load is transferred back to the static bypass (C), without an interruption in the supply of power.

Note: this operating mode does not depend on the status of the normal AC source, which may be within or outside the specified tolerances.

◗ after battery discharge (see figure

12). Operation of the rectifier/charger (A) with the battery (D) is identical to that presented in the section on on-line mode operation above.

3 5

Fig. 12

Forced transfer and return transfer

◗ forced transfer. When the load is

supplied via the static bypass (C), it may be transferred to the inverter (B) by pressing pushbutton 2 19 in the "control panel" section). The message "FORCED TRANSFER TO INVERTER REQUESTED, POWER TO LOAD MAY BE INTERRUPTED" is displayed. Confirmation by pressing pushbutton 1

2 is required to effectively

force transfer. The message "LOAD FORCED TO INVERTER, ECO MODE" is displayed. Whatever the status of the bypass AC source, a return to normal operation in "ECO" mode is possible only through a forced return transfer to the static bypass (C).

◗ forced disconnection: as the load is

supplied by the inverter (B), it can be transferred to the bypass AC source (M2) via the static bypass (C) by pressing the pushbutton 2 message "FORCED TRANSFER TO M2 REQUESTED, POWER TO LOAD MAY BE INTERRUPTED" is then displayed. Confirmation by pressing pushbutton 1

2 is required for

disconnection.

Note:

There are two possibilities: the bypass AC source is within tolerances or outside tolerances. In the first case, the UPS in "ECO" mode returns to normal operation. In the second case, the transfer will take place with a power cut to the load if the bypass AC source is present, or the load will cease to be supplied if it is absent. In both cases, the display reads "LOAD NOT PROTECTED, ECO MODE".

Caution: Return to normal operation of the installation in the "ECO" mode is possible only after the bypass AC source has returned to within specified tolerances.

0 (see figure

0 . The

Fig. 11

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Introduction (cont.)

Inverter shutdown or overload

See figure 13 for devices or installations operating in on-line mode with a bypass AC source.

3 5

Fig. 13

Single-UPS unit (on-line or "ECO" mode)

◗ in the event of a UPS shutdown

(initiated by the user or by an internal protective device), the load is automatically transferred to the bypass AC source. If transfer conditions are satisfied, transfer takes place instantly, without interruption to the load; Note: transfer conditions are not satisfied when bypass AC source characteristics are outside tolerances (voltage: ±10%; frequency as per personalisation; phase sync with inverter ±3°);

◗ in the event of a major transient

overload (greater than 1.65 In), immediate transfer takes place as above, without interruption to the load. The return to the inverter is automatic when the overload disappears if the number of possible returns has not been reached (0 to 255, programmable by personalisation). If this number has been reached, the load continues to be supplied by the bypass AC source. This operating mode allows start-up of load devices causing high inrush currents. This system requires satisfied transfer conditions.

If the conditions are not satisfied, the inverter will current limit to 165% of its rated current for 1 second before stopping;

◗ in the event of a small but extended

overload (i.e. a continuous level of power exceeding the full rated load), the inverter will continue to supply power for a period depending on the magnitude of the overload (10 minutes for a 125% overload, 1 minute for a 150% overload). See the overload curve in figure 14;

◗ in all three of the above cases,

inverter shutdown and supply of the load via the bypass AC source results in the following on the control panel:

◗◗ light 4 goes off, ◗ ◗ activation of the buzzer (continuous

beep),

◗ ◗ light 3 shines green, ◗ ◗ the message "LOAD NOT

PROTECTED, ON-LINE MODE" is displayed.

Parallel UPSs without redundancy

The shutdown of one inverter results in overload on the other inverters in operation. Two cases may then arise:

◗ if the overload on each remaining

inverter is > than 1.65 ln, the load is immediately transferred to the bypass AC source;

◗ if the overload is less than 1.65 ln,

the remaining inverters support the overload (see curve in figure 14), and the load is transferred to the bypass AC source;

◗ after this transfer:

◗◗ the light 4 goes off, ◗ ◗ the buzzer is activated and sounds

continuously,

◗ ◗ the light 3 goes on and turns green, ◗◗ the message "LOAD NOT

PROTECTED, PARALLEL ON-LINE MODE" is displayed.

1,5 In

1,35 In

Parallel UPSs with redundancy

◗ the shutdown of one UPS unit is of

no consequence for the load. The others each take up an equal amount of load power and the load continues to be supplied normally; Unit shutdown results in the following on the control panel:

◗◗ lights 4 and 5 go off, ◗◗ activation of the buzzer (continuous

beep),

◗◗ the message "LOAD NOT

PROTECTED, PARALLEL ON-LINE MODE" is displayed;

◗ in the event of an overload, the

system only loses its redundancy as long as the overload is less than the total rated power of the functioning units. If the overload is greater, the operating mode is that previously described for systems without redundancy.

Frequency converters

◗ in the event of a shutdown, the load

is no longer supplied with power;

◗ in the event of a major transient

overload (greater than 1.65 In), the inverter will current limit to 165% of their rated current for 1 second before stopping;

◗ in the event of a smaller but

prolonged overload, the inverter respects the same overload curve as the single inverter and shuts down;

◗ in all three of the above cases,

inverter shutdown results in the following:

◗◗ lights 4 and 5 go off, ◗ ◗ activation of the buzzer (continuous

beep),

◗◗ the message "LOAD NOT

PROTECTED, ON-LINE MODE" is displayed.

Fig. 14

1,25 In

1,15 In 1,10 In 1,05 In

12345678910

30 120

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(min)

Introduction (cont.)

Operation with an engine generator set

See figure 15 below. If a stand-by generator is included in the installation, it is generally started automatically in the event of a normal AC source failure and connected to the main low voltage switchboard. It is disconnected when normal AC source power is restored. With such a system, the required battery time may be reduced to the time necessary for starting and bringing on line the stand-by generator. The battery (D) supplies power to the inverter (B) during the transfers:

◗ normal AC source to the generator; ◗ generator to the normal AC source.

The transfer sequences described above (normal AC source ➜ battery, battery ➜ generator, generator ➜ battery, and battery ➜ normal AC source) are fully automatic. They in no way affect the load and require no manual operation by the user.

Note:

To avoid load surges on the generator, the rectifier/charger is started with a 10 second maximum current consumption walk-in (lasting 3 to 10 seconds, depending on the percent load). To avoid overloading an undersized engine generator set, it is possible to set a maximum power level drawn by the normal AC input. Any additional power required is supplied by the battery. This modification can be made on site by an APC by Schneider Electric technician.

Output voltage quality and continuity

The output voltage is stable in amplitude and frequency and is free of interruptions or transients outside specified tolerances, irrespective of normal AC source or load disturbances (outages, load step changes, etc.).

Steady state voltage regulation

For stable or slowly varying load conditions, the inverter output voltage is regulated to within ±0.5% in amplitude. The frequency of the output voltage can theoretically be regulated to within

0.1% of the rated value, however the output frequency range may be intentionally extended to a maximum of ±2 Hz so that the inverter can remain synchronised with the bypass AC source and its inherent frequency fluctuations, thus enabling transfer of the load to the bypass line at any time.

Note:

The output frequency range can be personalised and if necessary modified on the customer site by a qualified APC by Schneider Electric support technician from ±0.25 Hz to ±2 Hz in

0.25 HZ steps. When the bypass AC source voltage moves outside this frequency range, the inverter is desynchronised and operates in "free running" mode, with the output frequency regulated to a high level of accuracy by a quartz oscillator.

When the bypass AC source frequency returns to within the specified tolerances, the inverter is gradually resynchronised to the bypass line at a rate of 0.5 Hz to 2 Hz/s (as per the value personalised by the after-sales support department), thus avoiding exposing the load to sudden frequency variations.

Transient voltage regulation

The inverter output voltage is not notably affected by instantaneous major variations in load characteristics. This is made possible by the PWM (Pulse Width Modulation) chopping technique and the microprocessorbased regulation system that instantly compensates for any variation. In particular, the inverter output voltage remains within +/- 2% of the rated voltage for load step changes of 0 to 100% or of 100 to 0%.

12 - E-51028230XT/BG

Example of an installation with an engine generator set

MGE Galaxy PW

generator

HV system

Fig. 15

main LV switchboard

Mains 2

Mains 1

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