International Comfort Products PHD524, PHD536, PHD548, PHD560 Installation Manual

INSTALLATION INSTRUCTIONS
R410A Single Package Heat Pumps
PHD52460
Single Phase
These instructions must be read and understood completely before attempting installation
Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and NOTE
hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manual that may apply to the product.
DANGER Immediate hazards which will result in severe personal injury or death.
WARNING Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION − Hazards or unsafe practices which may result in minor personal injury or product or property damage.
NOTE − Used to highlight suggestions which will result in enhanced installation, reliability, or operation.
TABLE OF CONTENTS Page.................
SAFETY CONSIDERATIONS 2.................
RECEIVING AND INSTALLATION 2.............
Step 1 Check Equipment 2....................
Step 2 Provide Unit Support 2.................
Step 3 Provide Clearances 3..................
Step 4 Rig and Place Unit 3...................
Step 5 Select and Install Duct Connections 3....
Step 6 Provide for Condensate Disposal 8......
Step 7 Install Electrical Connections 9..........
PRESTARTUP 15............................
STARTUP 15.................................
Check Cooling and Electric Heat 15...............
Check for Refrigerant Leaks 15..................
StartUp Adjustments 16........................
Maintenance 19................................
Troubleshooting 24.............................
StartUp Checklist 27...........................
Signal Words in Manuals
The signal word WARNING is used throughout this manual in the following manner:
!
WARNING
The signal word CAUTION is used throughout this manual in the following manner:
!
CAUTION
Signal Words on Product Labeling
Signal words are used in combination with colors and/or pictures or product labels.
!
WARNING
PERSONAL INJURY, AND/OR PROPERTY DAMAGE HAZARD
Failure to carefully read and follow this warning could result in equipment malfunction, property damage, personal injury and/or death.
Installation or repairs made by unqualified persons could result in equipment malfunction, property damage, personal injury and/or death.
The information contained in this manual is intended for use by a qualified service technician familiar with safety procedures and equipped with proper tools and test instruments.
Installation must conform with local building codes and with the national Electrical Code NFPA70 current edition or Canadian Electrical Code part 1 CSA C.22.1.
518 01 2103 01 02/17/11
SAFE INSTALLATION REQUIREMENTS
FIGURE 1
Improper installation adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factoryauthorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes, the current editions of the National Electrical Code (NEC) NFPA 70.
In Canada refer to the current editions of the Canadian electrical Code CSA C22.1.
Recognize safety information. This is the safetyalert symbol . When you see this symbol in instructions or manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safetyalert symbol. DANGER identifies the most serious hazards which will result in serious injury or death. WARNING signifies a hazard which could result in serious injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which
will result in enhanced installation, reliability, or operation.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before installing or servicing system, turn off power supply to the unit and install lockout tag. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable.
!
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury or equipment damage.
R410A systems operate at higher pressures than standard R22 systems. DO NOT use R22 service equipment or components on R−410A equipment. Ensure service equipment is rated for R−410A.
PHD5 AIR CONDITIONING UNIT
!
WARNING
WARNING
!
CUT HAZARD
Failure to follow this caution may result in personal injury. When removing access panels (see Fig. 18) or performing
maintenance functions inside your unit, be aware of sharp sheetmetal parts and screws. Although special care is taken to reduce sharp edges to a minimum, be extremely careful when handling parts or reaching into the unit.
CAUTION
INTRODUCTION
This packaged heat pump unit is fully selfcontained and designed for outdoor installation (see Fig. 1). See Fig. 4 and 5 for unit dimensions. Standard units are shipped in a horizontaldischarge configuration for installation on a ground level slab. Standard units can be converted to downflow (vertical) discharge configurations for rooftop applications.
RECEIVING AND INSTALLATION
Step 1—Check Equipment
IDENTIFY UNIT
The unit model number and serial number are stamped on the unit information plate. Check this information against shipping papers.
INSPECT SHIPMENT
Inspect for shipping damage before removing packaging materials. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest equipment distribution office if any item is missing. To prevent loss or damage, leave all parts in original packages until installation.
Step 2—Provide Unit Support
IMPORTANT: The unit must be secured to the curb by installing
screws through the bottom of the curb flange and into the unit base rails. When installing large base units onto the common curb, the screws must be installed before allowing the full weight of the unit to rest on the curb. A minimum of six screws are required for large base units. Failure to secure unit properly could result in an unstable unit. See Warning near Rigging/Lifting information and accessory curb instructions for more details.
For hurricane tie downs, contact distributor for details and PE (Professional Engineering) Certificate if required.
Roof Curb
Install accessory roof curb in accordance with instructions shipped with curb. See Fig. 6. Install insulation, cant strips, roofing, and flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical for a water tight seal. Install gasketing material supplied with the roof curb. Improperly applied gasketing also can result in air leaks and poor unit performance.
Curb should be level to within ¼” (6mm) This is necessary for unit drain to function properly. Refer to accessory roof curb installation instructions for additional information as required.
Accessory kits are available to aid in installing a new metal base rail unit on an old roof curb.
Accessory kit number CPADCURB001A00, (small chassis) and accessory kit number CPADCURB002A00, (large chassis) includes roof curb adapter and gaskets for the perimeter seal and duct openings. No additional modifications to curb are required when using this kit.
2
518 01 2103 01
Slab Mount
Place the unit on a solid, level concrete pad that is a minimum of 4” (102mm) thick with 2” (51mm) above grade (see Figure 2). The slab should extend approximately 2” beyond the casing on all 4 sides of the unit. Do not secure the unit to the slab except when required by local codes.
FIGURE 2
2"
EVAP. COIL COND. COIL
Slab Mounting Details
OPTIONAL
RETURN
AIR
OPENING
OPTIONAL
SUPPLY
AIR
OPENING
Step 3—Provide Clearances
The required minimum service clearances are shown in Fig. 4 and
5. Adequate ventilation and outdoor air must be provided. The outdoor fan draws air through the outdoor coil and discharges it through the top fan grille. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48 in. (1219mm) above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 in.(1219mm).
IMPORTANT: Do not restrict outdoor airflow. An air restriction at either the outdoorair inlet or the fan discharge may be detrimental to compressor life.
Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. Do not install the unit on carpeting or other combustible materials. Slabmounted units should be at least 4 in. (102mm) above the highest expected water and runoff levels. Do not use unit if it has been under water.
Step 4—Rig and Place Unit
Rigging and handling of this equipment can be hazardous for many reasons due to the installation location (roofs, elevated structures, etc.).
Only trained, qualified crane operators and ground support staff should handle and install this equipment.
When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but not be limited to, the following:
1. Application of the lifter to the load, and adjustment of the lifts to adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work gloves.
INSPECTION
Prior to initial use, and at monthly intervals, all rigging shackles, clevis pins, and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should be paid to excessive wear at hoist hooking points and load support areas. Materials showing any kind of wear in these areas must not be used and should be discarded.
!
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal injury or death.
Never stand beneath rigged units or lift over people.
Rigging/Lifting of Unit
!
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal injury/death or property damage.
When straps are taut, the clevis should be a minimum of 36 in. (914 mm) above the unit top cover.
!
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal injury or death.
Large base units must be secured to common curb before allowing full weight of unit to rest on curb. Install screws through curb into unit base rails while rigging crane is still supporting unit.
Lifting holes are provided in base rails as shown in Fig. 4 and 5.
1. Leave top shipping skid on the unit for use as a spreader
bar to prevent the rigging straps from damaging the unit. If the skid is not available, use a spreader bar of sufficient length to protect the unit from damage.
2. Attach shackles, clevis pins, and straps to the base rails
of the unit. Be sure materials are rated to hold the weight of the unit (See Fig. 3).
3. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted level with the ground.
After the unit is placed on the roof curb or mounting pad, remove the top crating.
Step 5—Select and Install Duct Connections
The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence type air conditioning and ventilating systems, NFPA 90A or residence type, NFPA 90B and/or local codes and ordinances.
Select and size ductwork, supplyair registers, and return air grilles according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations.
The unit has duct flanges on the supply− and return−air openings on the side of the unit.
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3
!
WARNING
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal injury/death or property damage.
For vertical supply and return units, tools or parts could drop into ductwork. Install a 90 degree turn in the return ductwork between the unit and the conditioned space. If a 90 degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space. Units with electric heaters require 90 degree elbow in supply duct.
When designing and installing ductwork, consider the following:
1. All units should have fieldsupplied filters or accessory filter rack installed in the returnair side of the unit. Recommended sizes for filters are shown in Table 1.
2. Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance.
IMPORTANT: Use flexible transitions between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to ensure weather tight and airtight seal. When electric heat is installed, use fireproof canvas (or similar heat resistant material) connector between ductwork and unit discharge connection. If flexible duct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) must extend 24in. (610mm) from electric heater element.
3. Size ductwork for cooling air quantity (cfm). The minimum air quantity for proper electric heater operation is listed in Table 2. Heater limit switches may trip at air quantities below those recommended.
4. Seal, insulate, and weatherproof all external ductwork. Seal, insulate and cover with a vapor barrier all ductwork passing through conditioned spaces. Follow latest Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors Association (ACCA) minimum installation standards for residential heating and air conditioning systems.
5. Secure all ducts to building structure. Flash, weatherproof, and vibrationisolate duct openings in wall or roof according to good construction practices.
FIGURE 3
Unit Corner Weight (lbs) and Rigging
CAUTION - NOTICE TO RIGGERS PRUDENCE - AVIS AUX MANIPULATEUR
ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.
PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION.
Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition
DUCTS
MINIMUM HEIGHT: 36" (914.4 mm) HAUTEUR MINIMUM
BANDE SCELLANT DOIT ÊTRE EN PLACE AVANT DE PLACER L'UNITÉ SUR LA BASE DE TOIT
50CY502286 2.0
SEE DETAIL A VOIR DÉTAIL A
UNIT HEIGHT HAUTEUR D'UNITÉ
DETAIL A
VOIR DÉTAIL A
SEAL STRIP MUST BE IN PLACE BEFORE PLACING UNIT ON ROOF CURB
Rigging Weight
Cabinet MODEL NUMBER
Small PHD524 435 197
PHD536 501 227
Large
4
PHD548 529 240
PHD560 572 259
lb kg
518 01 2103 01
518 01 2103 01
FIGURE 4
PHD524 DIMENSIONS
Electrical
Characteristics
Unit
24 208/230-1-60 428 194.0 44-3/4 1136.7 19-3/4 501.7 14-3/4 374.7 16-5/8 422.3
UNIT Voltage
24 208/230 85.6 38.8 68.4 31.1 102.7 46.6 171.7 77.7
Unit WT. Unit HT. Center of Gravity
LB KG A X Y Z
Corner Weight LB/KG
1 2 3 4
5
6
FIGURE 5
Electrical
Characteristics
Unit
36 208/230-1-60 492 223.3 48-3/4 1238.3 19-1/2 495.3 16-1/2 419.1 16-5/8 422.3 48 208/230-1-60 520 236.0 50-3/4 1289.1 19-1/2 495.3 16-1/2 419.1 17-5/8 447.7 60 208/230-1-60 563 255.5 54-3/4 1390.7 19-1/2 495.3 16-1/2 419.1 18 457.2
UNIT Voltage
36 208/230 98.4 44.7 78.8 35.8 118.1 53.6 196.9 89.4 48 208/230 104.0 47.2 83.2 37.8 124.9 56.7 208.1 94.5 60 208/230 112.6 51.1 90.1 40.9 135.2 61.4 225.3 102.3
Unit WT. Unit HT. Center of Gravity
LB KG A X Y Z
1 2 3 4
PHD53660 DIMENSIONS
Corner Weight LB/KG
518 01 2103 01
FIGURE 6
Roof Curb Dimensions
G
HVAC unit base rails
Anchor screw field supplied
Flashing field supplied
Roofing material field supplied
Cant strip field supplied
*Provided with roofcurb
HVAC unit basepan
ROOF CURB DETAIL
B
C
Sealing
*
Gasket
Roofcurb
Wood nailer*
(field supplied)
G
C
F
A
SMALL/COMMON CURB
SUPPLY
AIR
B
H
D
Dashed lines show cross support location for large basepan units.
E
SMALL BASE UNIT
A
F
E
D
LARGE CURB
B
H
UNIT SIZE
Small
or
Large
Large
NOTES:
CATALOG
NUMBER
A
IN. (mm)
CPRFCURB010A00 11 (279)
CPRFCURB011A00 14 (356)
CPRFCURB012A00 11 (279) CPRFCURB013A00 14 (356)
1. Roof curb must be set up for unit being installed.
2. Seal strip must be applied, as required, to unit being installed.
3. Roof curb is made of 16gauge steel.
4. Attach ductwork to curb (flanges of duct rest on curb).
5. Insulated panels: 1in. (25 mm) thick fiberglass 1 lb. density.
(small/common
base)
IN. (mm)*
10 (254)
14 (356)
(large base)
IN. (mm)*
14 (356) 16 (406)
LARGE
RETURN
AIR
BASE UNIT
UNIT PLACEMENT ON
COMMON CURB
SMALL OR LARGE BASE UNIT
B
C
IN. (mm)DIN. (mm)EIN. (mm)FIN. (mm)GIN. (mm)HIN. (mm)
47.8
(1214)
32.4 (822)
43.9
(1116)
2.7 (69)
30.6 (778)
42.2
(1072)
46.1 (1170)
518 01 2103 01
7
CONFIGURING UNITS FOR DOWNFLOW (VERTICAL) DISCHARGE
FIGURE 7
Supply and Return Duct Openings
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before installing or servicing system, turn off the power supply to the unit and install lockout tag. There may be more than one disconnect switch.
1. Open all electrical disconnects and install lockout tag
before starting any service work.
2. Remove horizontal (metal) ductcovers to access vertical
(downflow) discharge duct knockouts in unit basepan. (See Fig. 7.)
3. To remove downflow return and supply knockout covers,
break front and right side connecting tabs with a screwdriver and hammer. Push cover down to break rear and left side tabs.
NOTE:These panels are held in place with tabs similar to an electrical knockout. Reinstall horizontal duct covers (Fig. 7) shipped on unit from factory. Insure openings are air and watertight.
NOTE:The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidencetype air conditioning and ventilating systems, NFPA 90A or residencetype, NFPA 90B; and/or local codes and ordinances.
Adhere to the following criteria when selecting, sizing, and installing the duct system:
1. Units are shipped for side shot installation.
2. Select and size ductwork, supplyair registers, and
returnair grilles according to American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) recommendations.
3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be screwed or bolted to duct flanges. Use suitable gaskets to ensure weathertight and airtight seal.
4. All units must have fieldsupplied filters or accessory filter
rack installed in the returnair side of the unit. Recommended sizes for filters are shown in Table 1.
5. Size all ductwork for maximum required airflow (either
heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases or performance may be affected.
6. Adequately insulate and weatherproof all ductwork
located outdoors. Insulate ducts passing through unconditioned space, and use vapor barrier in accordance with latest issue of Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors of America (ACCA) minimum installation standards for heating and air conditioning systems. Secure all ducts to building structure.
7. Flash, weatherproof, and vibrationisolate all openings in
building structure in accordance with local codes and good building practices.
Horizontal Duct Covers
Basepan Downflow (Vertical) Supply Knockout
Basepan Downflow (Vertical) Return Knockout
Provide for Condensate Disposal
NOTE:Ensure that condensatewater disposal methods comply
with local codes, restrictions, and practices.
The PHD5 units dispose of condensate through a 3/4 in. NPT female fitting that exits on the compressor end of the unit. Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations. Install a fieldsupplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. (25 mm) lower than the drainpan condensate connection to prevent the pan from overflowing. Prime the trap with water. When using a gravel apron, make sure it slopes away from the unit.
If the installation requires draining the condensate water away from the unit, install a fieldsupplied 2 in. (51mm) trap at the condensate connection to ensure proper drainage. Condensate trap is available as an accessory or is fieldsupplied. Make sure that the outlet of the trap is at least 1 in. (25 mm) lower than the unit drainpan condensate connection to prevent the pan from overflowing. Connect a drain tube using a minimum of fieldsupplied 3/4in. PVC or fieldsupplied 3/4in. copper pipe at outlet end of the 2in. (51 mm) trap. (See Fig. 8) Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1 in. (25 mm) every 10 ft (3 m) of horizontal run. Be sure to check the drain trough for leaks. Prime the trap at the beginning of the cooling season start−up.
FIGURE 8 Condensate Trap
TRAP OUTLET
1-in. (25 mm) min.
2-in. (51 mm) min.
8
518 01 2103 01
A
FIGURE 9 Unit Leveling Tolerances
B
A-B
(6.35)
1/4
Install Electrical Connections
C
MAXIMUM ALLOWABLE
DIFFERENCE in. (mm)
B-C
(6.35)
1/4
1/4
A-C
(6.35)
The unit must have a separate electrical service with a fieldsupplied, waterproof disconnect switch mounted at, or within sight from the unit. Refer to the unit rating plate, NEC and local codes for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing.
The field−supplied disconnect switch box may be mounted on the unit over the highvoltage inlet hole when the standard power and lowvoltage entry points are used (See Fig. 4 and 5 for acceptable location). Remove the high voltage knockout.
See unit wiring label, Fig. 10 and Fig. 1314, for reference when making high voltage connections. Proceed as follows to complete the highvoltage connections to the unit.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
The unit cabinet must have an uninterrupted, unbroken electrical ground. This ground may consist of an electrical wire connected to the unit ground screw in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC, ANSI/NFPA American National Standards Institute/National Fire Protection Association (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes.
!
CAUTION
UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the unit being installed.
1. Make all electrical connections in accordance with
NEC ANSI/NFPA (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.
2. Use only copper conductor for connections between
fieldsupplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE.
3. Be sure that high−voltage power to unit is within
operating voltage range indicated on unit rating plate.
4. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit, etc.
FIGURE 10
HIGH VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL)
1 PHASE USES TWO POWER LEADS
CONTROL BOX
LOW VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL)
High and Control Voltage Connections
POWER SUPPLY
EQUIP GR
SPLICE BOX
FIELD SUPPLIED FUSED DISCONNECT
)
(
W2
WHT
VIO
YEL
PNK
GRN
RED
BRN
ORN
W3
(
()
Y1
Y2
(
G
(
(
R
C
(
O
(
W2
)
W3
Y1
)
Y2
)
)
)
)
G
R
C
O
Single phase units:
1. Run the highvoltage (L1, L2) and ground lead into the control
box.
2. Connect ground lead to chassis ground connection.
3. Locate the black and yellow wires connected to the line side of
the contactor.
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L2 to yellow wire on connection 23 of the
compressor contactor.
SPECIAL PROCEDURES FOR 208V OPERATION
HIGHVOLTAGE CONNECTIONS
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before making any wiring changes, switch off the main power supply to the unit and install lockout tag.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before making any wiring changes, switch off the main power supply to the unit. Tag the disconnect switch with a suitable warning label. With disconnect switch open, move black wire from transformer (3/16 in.) terminal
!
WARNING
marked 230 to terminal marked 208. This retaps transformer to primary voltage of 208 vac.
CONTROL VOLTAGE CONNECTIONS
518 01 2103 01
NOTE: Do not use any type of powerstealing thermostat. Unit control problems may result.
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