Ariston 41-116-04 User Manual

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Ariston 41-116-04 User Manual

Installation

Instructions

Type C Boilers

G.C.N: 41-116-04

LEAVE THESE INSTRUCTIONS WITH THE END-USER

Country of destination: GB

TABLE OF CONTENTS

1.GENERAL INFORMATION

1.GENERAL INFORMATION

1.1GENERAL INSTRUCTIONS

1.2OVERALL VIEW

2.INSTALLATION

2.1REFERENCE STANDARDS

2.2SITING THE APPLIANCE

2.3OVERALL DIMENSIONS

2.4CLEARANCES

2.5MOUNTING THE APPLIANCE

2.6ELECTRICAL CONNECTION

2.7GAS CONNECTION

2.8WATER CONNECTIONS

2.9FLUE CONNECTION

2.10ROOM THERMOSTAT CONNECTION

2.11ELECTRICAL DIAGRAMS

2.12GAS AND WATER CIRCUITS

3.D.H.W. STORAGE CYLINDER

3.12 PORT AND 3 PORT VALVE INSTALLATIONS

3.2DOMESTIC HOT WATER PRIORITY KIT

4.COMMISSIONING

4.1INITIAL PREPARATION

4.2CONTROL PANEL

4.3REMOVING THE FRONT PANEL

4.4INITIAL START UP

4.5OPERATIONAL ADJUSTMENTS

4.6COMBUSTION ANALYSIS

4.7FUME DISCHARGE MONITORING

4.8DRAINING THE SYSTEM

5.GAS ADJUSTMENTS

GAS ADJUSTMENT TABLE

5.1 CHANGING THE TYPE OF GAS

6.MAINTENANCE

7.TECHNICAL INFORMATION

This manual is an integral and essential part of the product. It should be kept with the appliance so that it can be consulted by the user and our authorised personnel.

Please carefully read the instructions and notices about the unit contained in this manual, as they provide important information regarding the safe installation, use and maintenance of the product.

For operating instructions please consult the separate User’s Manual.

2

1.1

GENERAL INSTRUCTIONS

Read the instructions and recommendations in these Installation Instructions

 

 

carefully to ensure proper installation, use and maintenance of the appliance.

Keep this manual in a safe place. You may need it for your own reference while our

Servicing Centre technicians or your installer may need to consult it in the future.

This is an appliance for the production of central heating (C.H.).

This appliance must be used only for the purpose for which it is designed.

The manufacturer declines all liability for damage caused by improper or negligent use.

No asbestos or other hazardous materials have been used in the fabrication of this product.

Before connecting the appliance, check that the information shown on the data plate and the table in section 7 comply with the electric, water and gas mains of the property. You will find the data plate on the reverse of the control panel.

The gas with which this appliance operates is also shown on the label at the bottom of the boiler.

Do not install this appliance in a damp environment or close to equipment which spray water or other liquids.

Do not place objects on the appliance.

Do not allow children or inexperienced persons to use the appliance without supervision.

If you smell gas in the room, do not turn on light switches, use the telephone or any other object which might cause sparks.

Open doors and windows immediately to ventilate the room.

Shut the gas mains tap (at or adjacent to the gas meter) or the valve of the gas cylinder and call your Gas Supplier immediately.

If you are going away for a long period of time, remember to shut the mains gas tap or the gas cylinder valve.

Always disconnect the appliance either by unplugging it from the mains or turning off the mains switch before cleaning the appliance or carrying out maintenance.

In the case of faults or failure, switch off the appliance and turn off the gas tap. Do not tamper with the appliance.

For repairs, call your local Authorised Servicing Centre and request the use of original spare parts. For in-guarantee repairs contact MTS (GB) Limited.

Check the following at least once a year:

1 - Check the seals for the water connections; replace any faulty seals. 2 - Check the gas seals; replace any faulty gas seals.

3 - Visual check of the entire unit.

4 - Visual check of the combustion process or analysis of combustion by-products (see section 4.5) and cleaning of the burner if needed.

5 - If called for by point. 3, dismantling and cleaning of the combustion chamber.

6 - If called for by point. 4, dismantling and cleaning of the burner jets. 7 - Visual check of the primary heat exchanger:

-check for overheating in the blade assembly;

-clean the exhaust fan if needed.

8 - Adjustment of the flow rate of the gas: flow rate for lighting, partial load and full load.

9 - Check of the heating safety systems:

-safety device for maximum temperature (overheat thermostat);

-safety device for maximum pressure (safety valve).

10Check of the gas safety systems:

-safety device for lack of gas or flame ionisation (detection electrode);

-safety device for gas cock.

11Check of the electrical connection (make sure it complies with the instructions in the manual).

12General check of the combustion by-products of the discharge/ventilation system.

13Check of the general performance of the unit.

3

1.2OVERALL VIEW

LEGEND:

1.Flue connector

2.Fan

3.Combustion chamber hood

4.Main heat exchanger

5.Safety thermostat

6.Combustion chamber

7.Combustion chamber insulation panel

8.Detection electrode

9.Ignition electrodes

10.Burner

11.Regulation thermostat

12.Frost thermostat

13.Pump pressure switch

14.Safety valve (3 bar)

15.Automatic By-pass

16.Gas valve

17.Spark generator

18.Boiler drain valve

19.Circulation pump with automatic air release valve

20.Expansion vessel

21.Air pressure take-off point

22.Air pressure switch

23.Combustion analysis points

2.INSTALLATION

2.1REFERENCE STANDARDS

FIG. 1.0

The technical information and instructions provided herein below are intended for the installer so that the unit may be installed correctly and safely.

The installation and initial start up of the boiler must be by a CORGI Registered Installer in compliance with the installation standards currently in effect, as well as with any and all local health and safety standards i.e. CORGI .

This appliance must be installed by a competent installer in accordance with current Gas Safety (installation & use) Regulations.

The installation of this appliance must be in accordance with the relevant requirements of the current Gas Safety (installation & use) Regulations, the Local Building Regulations, the current I.E.E. Wiring Regulations, the byelaws of the local water authority, and in Scotland, in accordance with the Building Standards (Scotland) Regulation and Health and Safety document No. 635 “Electricity at work regulations 1989”.

Installation should also comply with the following British Standard Codes of Practice:

BS 7593:1992

Treatment of water in domestic hot water central

 

heating systems

BS 5546:1990

Installation of hot water supplies for domestic

 

purposes

BS 5440-1:1990

Flues

BS 5440-2:1989

Air supply

BS 5449:1990

Forced circulation hot water systems

BS 6789:1987

Installation of gas fired hot water boilers of rated

 

input not exceeding 60kW

BS 6891:1989

Installation of low pressure gas pipe up to 28mm

BS 7671:1992

IEE wiring regulations

BS 4814:1990

Specification for expansion vessels

BS 5482:1994

Installation of LPG

4

2.2 SITING THE APPLIANCE The appliance may be installed in any room or indoor area, although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations, and in

Scotland, the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the appliance in a room containing a bath or shower.

Where a room-sealed appliance is installed in a room containing a bath or shower the appliance and any electrical switch or appliance control, utilising mains electricity should be situated so that it cannot be touched by a person using the bath or shower.

The location must permit adequate space for servicing and air circulation around the appliance as indicated in paragraph 2.4.

The location must permit the provision of an adequate flue and termination. For unusual locations special procedures may be necessary.

BS 6798-1987 gives detailed guidance on this aspect.

A compartment used to enclose the appliance must be designed specifically for this purpose. No specific ventilation requirements are needed for the installation within a cupboard.

This appliance is not suitable for outdoor installation.

The type C appliances (in which the combustion circuit, air vent intake and combustion chamber are air-tight with respect to the room in which the appliance is installed) can be installed in any type of room.

Secondary ventilation is not required with this boiler. The boiler must be installed on a solid, permanent wall to prevent access from the rear.

 

 

2.3

OVERALL DIMENSIONS

 

 

mm400

 

 

 

LEGEND:

 

 

 

60 mm

 

 

 

A = Central Heating Flow (3/4”)

 

 

C = Gas Inlet (3/4”)

 

 

E = Central Heating Return (3/4”)

 

 

mm = Clearances

 

 

450 mm

 

 

 

2.4

CLEARANCES

 

 

In order to allow for access to the interior of the boiler for

 

 

maintenance purposes, the boiler must be installed in

 

 

compliance with the minimum clearances indicated in FIG. 2.1

132

132

 

 

C

E

mm

 

 

 

300

 

FIG. 2.1

 

 

 

2.5MOUNTING THE APPLIANCE

2.6ELECTRICAL CONNECTION

Fasten the boiler in place using the template and anchors supplied with the unit. It is highly recommended that a spirit level be used to position the boiler so that it is perfectly level.

For additional information, please consult the instructions contained in the connection kit and the flue kit.

For safety purposes, have a competent person carefully check the electrical system in the property, as the manufacturer will not be held liable for damage caused by the failure to earth the appliance properly or by anomalies in the supply of power. Make sure that the residential electrical system is adequate for the maximum power absorbed by the unit, which is indicated on the rating plate. In addition, check that the section of cabling is appropriate for the power absorbed by the boiler.

5

FIG. 2.2

N

L

E

The boiler operates with alternating current, as indicated in the technical information table in section 7, where the maximum absorbed power is also indicated. Make sure that the connections for the neutral and live wires correspond to the indications in the diagram. The appliance electrical connections are situated on the reverse of the control panel under the inspection cover (see the servicing manual for further information)

 

 

IMPORTANT!

 

 

 

In the event that the power supply cord must be changed, replace it with one with the

 

 

same specifications. Make the connections to the terminal board located within the

 

 

control panel, as follows:

 

 

 

- The yellow-green wire should be connected to the terminal marked with the

 

 

symbol;

 

 

 

- The blue wire should be connected to the terminal marked “N”;

 

 

 

- The brown wire should be connected to the terminal marked “L”.

 

 

 

Note: The diagrams for the electrical system are indicated in section 2.12.

 

 

 

Warning, this appliance must be earthed.

 

 

 

External wiring to the appliance must be carried out by a competent person and be

 

 

in accordance with the current I.E.E. Regulations and applicable local regulations.

 

 

The microSYSTEM range of boilers are supplied for connection to a 230 V~

50 Hz

 

 

supply.

 

 

 

The supply must be fused at 3 A.

 

 

 

The method of connection to the electricity supply must facilitate complete electrical

 

 

isolation of the appliance, by the use of a fused double pole isolator having a contact

 

 

separation of at least 3 mm in all poles or alternatively, by means of a 3 A fused

 

 

three pin plug and unswitched shuttered socket outlet both complying with BS 1363.

 

 

The point of connection to the Electricity supply must be readily accessible and

 

 

adjacent to the appliance unless the appliance is installed in a bathroom when this

 

 

must be sited outside the bathroom (see section 2.2).

 

2.7

GAS CONNECTION

The local gas region contractor connects the gas meter to the service pipe.

 

 

 

If the gas supply for the boiler serves other appliances ensure that an adequate

supply is available both to the boiler and the other appliances when they are in use at the same time.

Pipe work must be of an adequate size. Pipes of a smaller size than the boiler inlet connection should not be used.

2.8

WATER CONNECTIONS

VIEW OF THE BOILER CONNECTIONS

 

 

FIG. 2.4

 

 

 

E

 

 

D

 

 

A

B

C

 

 

LEGEND:

 

 

 

A = Central Heating Flow

 

F

 

C = Gas Inlet

 

 

E = Central Heating Return

FIG. 2.3

 

 

F= Safety Valve

G= Pump transportation screw (remove before igniting the boiler)

H= Automatic By-pass pipe

SC004A

6

CENTRAL HEATING

Detailed recommendations are given in BS 6798:1987 and BS 5449-1:1990, the following notes are given for general guidance.

PIPE WORK:

Copper tubing to BS EN 1057:1996 is recommended for water pipes. Jointing should be either with capillary soldered or compression fittings.

Where possible pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps.

The appliance has a built-in automatic air release valve, however it should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air.

Except where providing useful heat, pipes should be insulated to prevent heat loss and avoid freezing.

Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.

BY-PASS:

The appliance includes an automatic by-pass valve, which protects the main heat exchanger in case of reduced or interrupted water circulation through the heating system, due to the closing of thermostatic valves or radiator valves within the system.

SYSTEM DESIGN:

This boiler is suitable only for sealed systems.

Drain Cocks:

These must be located in accessible positions to permit the draining of the whole system and should be fitted at all low points. The taps must be at least 15mm nominal size and manufactured in accordance with BS 2870:1980.

SAFETY VALVE DISCHARGE:

The discharge should terminate facing downward on the exterior of the building in a position where discharging (possibly boiling water & steam) will not create danger or nuisance, but in an easily visible position, and not cause damage to electrical components and wiring.

The discharge must not be over an entrance or a window or any other type of public access.

AIR RELEASE POINTS:

These must be fitted at all high points where air naturally collects and must be sited to facilitate complete filling of the system.

The appliance has an integral sealed expansion vessel to accommodate the increase of water volume when the system is heated.

It can accept up to 6 litre (1.3 gal) of expansion water. If the heating circuit has an unusually high water content, calculate the total expansion and add an additional sealed expansion vessel with adequate capacity. This should be located on the return pipe work as close as possible to the pump inlet.

MAINS WATER FEED - CENTRAL HEATING:

There must be no direct connection to the mains water supply even through a non-return valve, without the approval of the Local Water Authority.

FILLING:

A temporary method for initially filling the system and replacing lost water during servicing and initial filling (in accordance with current Water Regulations), is provided as an integral part of the connection kit (see FIG. 2.4). The flexible hose must be removed once the system has been filled.

RESIDUAL HEAD OF THE BOILER

7

2.9FLUE CONNECTIONS

BC

F

F D G

J

HI

A E

L K

G

FLUE SYSTEM

The provision for satisfactory flue termination must be made in accordance with BS 5440-1.

The appliance must be installed so that the flue terminal is exposed to outside air. The terminal must not discharge into another room or space such as an outhouse or lean-to.

It is important that the position of the terminal allows a free passage of air across it at all times.

The terminal should be located with due regard for the damage or discolouration that might occur on buildings in the vicinity.

In cold or humid weather water vapour may condense on leaving the flue terminal. The effect of such “pluming” must be considered.

If the terminal is less than 2 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be fitted. When ordering a terminal guard, quote the appliance model number.

A suitable terminal guard is available from:

TOWER FLUE COMPONENTS Morley Road

Tonbridge Kent TN9 1RA

The minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in FIG. 2.5.

TERMINAL POSITION

mm

A - Directly below an openable window or other opening

300

B - Below gutters, soil pipes or drain pipes

75

C - Below eaves

200

D - Below balconies or car-port roof

200

E - From vertical drain pipes and soil pipes

75

F - From internal or external corners

300

G - Above ground or balcony level

300

H - From a surface facing a terminal

600

I - From a terminal facing a terminal

1200

J - From an opening in the car port

 

(e.g. door, window) into dwelling

1200

K - Vertically from a terminal in the same wall

1500

L - Horizontally from a terminal in the same wall

300

FIG. 2.5

The boiler is designed to be connected to a coaxial flue discharge system.

Ø 60/100 mm

FIG. 2.6

8

COAXIAL SYSTEMS

FIG. 2.9

IMPORTANT!

For all flue systems, a restrictor must always be inserted into the boiler’s flue connector; the restrictor must be Ø 44 in diameter depending on the length of piping indicated in TABLE 2.1.

FIG 2.9 and FIG 2.10 illustrate some of the various designs for coaxial or twin pipe flue systems.

For fur ther information on discharge/ventilation accessories, see

the FLUE PIPE ACCESSORIES MANUAL.

 

Exhaust

Restrictor

Maximum

Risk of Condensation Forming

TABLE 2.1

10 RFFI

Type

ø 44 mm

Extension

Piping not insulated

Piping insulated

 

 

 

Exhaust/Air

ø 44 restrictor

NO restrictor

ø 44 restrictor

NO restrictor

 

Coaxial

C12 (xx)

L min = 0.5 m

L = 5 m

 

 

 

 

 

Systems

C32 (xx)

NONE

NONE

NONE

NONE

 

L max = 1 m

 

ø 60/100

C42 (xx)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.10 ROOM THERMOSTAT

 

CONNECTION

 

To connect a room thermostat and/or time clock, it is necessary

A

to:

 

1. - Open the control panel as indicated in section 4.3;

2.- Remove screws “A” and remove the inspection cover from the reverse of the control panel;

3.- For the room-thermostat connect the thermostat switching wires to the position 5 and 6 and remove the wire link (for three-wire thermostats connect the neutral to terminal N);

4. - For the time clock connect the clock switching wires to the positions 3 and 4 and connect the clock motor electrical supply to the terminals marked L and N.

Note: A frost thermostat is built-in to the appliance.

For connection to control systems with zone valves for hot water cylinders see section 3.

9

2.11 ELECTRICAL DIAGRAM

Legend:

A - On/Off Switch

B- On/Off L.E.D.

C- Heating Switch

D- Heating L.E.D.

E- Reset Button

F- Ignition Failure (Lockout) L.E.D.

A01

- Pump Pressure Switch

A02

- Frost Thermostat

A03

- Modulator

A04

- Circulation Pump

A05

- Regulation Thermostat

A06

- External Control System

A07

- Time Clock Connector

A08

- External (Room) Thermostat

A09

- Air Pressure Switch

A10

- Fan

A11

- Overheat Thermostat

A12

- Spark Generator/Gas Valve Supply

A13

- Detection Electrode

Colours:

 

Wh

- White

Bl

- Blue

Gry

- Grey

Brn

- Brown

Blk

- Black

Rd

- Red

Grn/Yll - Yellow/Green

FIG. 2.12

10

FIG. 2.13

2.12GAS AND WATER CIRCUITS

FIG. 2.14

1

2

3

4

5

6

7

8

9

10

11

LEGEND:

1.Fan

2.Main heat exchanger

3.Overheat thermostat

4.Burner

175. Ignition electrodes

6.Detection electrode

167. Regulation thermostat

 

8.

Frost thermostat

 

9.

Gas valve

 

10.

Pump pressure switch

 

11.

Safety valve (3 bar)

 

12.

Boiler drain valve

 

13.

Automatic by-pass

 

14.

Pressure gauge

 

15.

Circulation pump with automatic

 

 

air release valve

 

16.

Expansion vessel

15

17.

Air pressure switch

14

A.

Central Heating Flow

B.

Inlet Gas

13

C.

Central Heating Return

12

11

3.D.H.W. STORAGE CYLINDER

3.12 PORT AND 3 PORT VALVE

INSTALLATIONS

2 port valve installation

FIG. 3.1

FIG. 3.3

The microSYSTEM can be connected to a storage cylinder (both open-vented and unvented) for the production of domestic hot water (D.H.W.). Cylinders of different capacities can be used depending on site requirements (see TABLE 3.1 for a selection of ARISTON unvented cylinders).

3 port valve installation

FIG. 3.2

Wiring to 2 port valve installation using an external 2 channel programmer

Type Danfoss FP715 Type Honeywell ST6400C

12

FIG. 3.4

TABLE 3.1

Wiring to 3 port valve installation using an external 2 channel programmer

Type Danfoss FP715 Type Honeywell ST6400C

NOTE: When using a 3 port valve installation in conjunction with an unvented cylinder it will be necessary to use a 2 port valve on the cylinder flow connection in addition to the 3- port valve to satisfy Building Regulations.

Technical Data

Capacity

Coil

C.H.W.

D.H.W.

Max Heating

Heat Ioss

 

 

Surface

Flow/rate

Flow/rate

Output

 

MODEL

It.

m2

m3/h

It/h

kW

kWh/24h

Contract STI 125 Indirect

125

0.75

0.5

194

11.3

2

 

 

 

1

266

15.5

 

 

 

 

2

340

19.8

 

 

 

 

 

 

 

 

Comfort STI 125 Indirect

125

0.75

0.5

256

14.9

2.2

Contract STI 150 Indirect

150

0.93

1

353

20.5

 

 

 

 

2

451

26.2

 

 

 

 

 

 

 

 

Comfort STI 150 Indirect

150

0.93

0.5

256

14.9

2.4

Contract STI 210 indirect

200

0.93

1

353

20.5

 

 

 

 

2

451

26.2

 

 

 

 

 

 

 

 

Comfort STI 210 Indirect

200

0.93

0.5

256

14.9

2.9

Contract STI 300 Indirect

300

0.93

1

353

20.5

 

 

 

 

2

451

26.2

 

 

 

 

 

 

 

 

SB 125 Indirect

125

1

0.5

190

11

1.72

 

 

 

1

318

18.5

 

 

 

 

2

496

28.8

 

 

 

 

 

 

 

 

SB 150 Indirect

150

1

0.5

190

11

1.75

 

 

 

1

318

18.5

 

 

 

 

2

496

28.8

 

 

 

 

 

 

 

 

SB 200 Indirect

200

1.3

0.5

190

11

2.1

 

 

 

1

318

18.5

 

 

 

 

2

496

28.8

 

 

 

 

 

 

 

 

13

3.2DOMESTIC HOT WATER

PRIORITY KIT

Boiler

 

microSYSTEM

Cylinder

 

10 RFFI

 

 

 

Contract STI 125 Indirect

 

 

 

 

Possible

Comfort STI 125 Indirect

 

Possible

 

 

 

 

 

 

 

 

 

The microSYSTEM is able to be connected to a specially designed kit for the management of D.H.W. production. This kit gives priority to production of D.H.W. unlike traditional systems where the boiler power is split between C.H. and D.H.W. This generally enables a smaller storage cylinder to be chosen as the boiler’s full output will be channelled into the cylinder allowing for a quick heat-up.

The kit (ARISTON part number 706329) can be obtained from an ARISTON supplier.

The kit consits of:

1)Electronic module able to plug into the boiler’s P.C.B;

2)3-way priority valve with actuator for connection to the boiler’s flow outlet;

3)A limit thermostat (80˚C) to check the water temperature of the heating flow to the cylinder, to be installed within the boiler;

4)Pipes and accessories.

TABLE 3.2

4.COMMISSIONING

4.1INITIAL PREPARATION

MTS (GB) Limited support the initiative. Within the information pack you will find a copy of the logbook. It is important that this is completed in the presence of your customer, they are shown how to use it, and it is signed by them. Please instruct your customer that they must have their logbook with them whenever they contact a service engineer or us.

Preliminary electrical system checks to ensure electrical safety must be carried out by a competent person i.e. polarity, earth continuity, resistance to earth and short circuit.

FILLING THE HEATING SYSTEM:

Remove the panels of the case and lower the control panel (see section 3.3 for further information).

Open the central heating flow and return cocks supplied with the connection kit (there are two isolation points on the return connection).

Unscrew the cap on the automatic air release valve one full turn and leave open permanently.

Close all air release valves on the central heating system.

Gradually open valve(s) at the filling point (filling-loop) connection to the central heating system until water is heard to flow, do not open fully.

Open each air release tap starting with the lowest point and close it only when clear water, free of air, is visible.

Purge the air from the pump by unscrewing anticlockwise and removing the pump plug and also manually rotate the pump shaft in the direction indicated by the pump label to ensure the pump is free.

Refit the pump plug.

Continue filling the system until at least 1.5 bar registers on the pressure gauge. Inspect the system for water leaks and remedy any leaks discovered.

GAS SUPPLY:

Inspect the entire installation including the gas meter, test for soundness and purge the supply as described in BS 6891:1988.

Open the gas cock (supplied with the connection kit) to the appliance and check the gas connections on the appliance for leaks.

When the installation and filling are completed turn on the central heating system (section 4.4) and run it until the temperature has reached the boiler operating temperature. The system must then be immediately flushed through.

The flushing procedure must be in line with BS 7593:1992 code of practice for treatment of water in domestic hot water central heating systems.

During this operation, we highly recommend the use of a central heating flushing detergent (Fernox Superfloc or equivalent), whose function is to dissolve any foreign matter that may be in the system.

Substances different from these could create serious problems to the pump or other components.

The use of an inhibitor in the system such as Fernox MB-1 or equivalent is strongly recommended to prevent corrosion (sludge) damaging the boiler and system.

Failure to carry out this procedure may invalidate the appliance warranty.

14

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