JUMO IMAGO 500 Operating Manual

JUMO IMAGO 500
Multi-channel Process and
Program Controller
Operating Manual
70359000T90Z001K000
V2.01/EN/00403546
Please read these Operating Manual before starting up the instrument. Keep these operating manual in a place which is accessible to all users at all times.
These operating manual are valid from software version 162.03.05.
Please assist us to improve these operating manual, where necessary. Your suggestions will be welcome. All necessary settings are described in these operating manual. If any difficulties should still
arise during start-up, you are asked not to carry out any unauthorized manipulations on the unit. You could endanger your rights under the instrument warranty!
Please contact the nearest subsidiary or the head office in such a case.
E
The regulations of EN 61340-5-1 and EN 61340-5-2 “Protection of electronic devices from electrostatic phenomena” must be observed when returning modules, assemblies or components. Use only the appropriate ESD packaging for transport.
Please note that we cannot accept any liability for damage caused by ESD (electro­static discharge).
Contents
1 Introduction 5
1.1 Description .................................................................................................... 5
1.2 Typographical conventions ......................................................................... 6
2 Identifying the instrument version 7
2.1 Type designation .......................................................................................... 7
2.2 Accessories .................................................................................................. 8
2.3 Nameplate ..................................................................................................... 9
3 Mounting 11
3.1 Location and climatic conditions .............................................................. 11
3.2 Dimensions ................................................................................................. 11
3.3 Fitting ........................................................................................................... 12
3.4 Cleaning the front panel ............................................................................ 12
4 Electrical connection 13
4.1 Installation notes ........................................................................................ 13
4.2 Electrical isolation ...................................................................................... 14
4.3 Connection diagram .................................................................................. 15
5 Operation 17
5.1 Operation: General ..................................................................................... 17
5.1.1 Displays and controls ................................................................................... 17
5.1.2 Overview of operation .................................................................................. 19
5.1.3 Entering values and selecting settings ......................................................... 22
5.1.4 Setpoint input ............................................................................................... 23
5.1.5 Recording ..................................................................................................... 24
5.2 Operation: Controller ................................................................................. 25
5.2.1 Altering the setpoint ..................................................................................... 25
5.2.2 Manual mode ............................................................................................... 26
5.3 Operation: Program controller/generator ............................................... 26
5.3.1 Program editor ............................................................................................. 27
5.3.2 Starting the program .................................................................................... 30
5.3.3 Overview of operation .................................................................................. 32
5.3.4 Shifting the program profile .......................................................................... 34
Contents
6 Parameterization 35
7 Configuration 37
7.1 Analog inputs .............................................................................................. 41
7.2 Controller .................................................................................................... 46
7.3 Generator .................................................................................................... 49
7.4 Limit comparators ...................................................................................... 53
7.5 Outputs ........................................................................................................ 56
7.6 Logic functions ........................................................................................... 58
7.7 Math and logic module .............................................................................. 63
7.8 C-level control ............................................................................................ 65
7.8.1 C-level control example ............................................................................... 66
7.9 Display ......................................................................................................... 67
7.10 Interfaces .................................................................................................... 70
7.11 Device data ................................................................................................. 71
7.12 Recording .................................................................................................... 72
7.13 Timers .......................................................................................................... 73
8 Optimization 75
8.1 Self-optimization ........................................................................................ 75
8.2 Check of the optimization ......................................................................... 78
9 Retrofitting of modules 79
10 Appendix 83
10.1 Technical data ............................................................................................. 83
11 Index 87
5
1 Introduction
1.1 Description
Type 703590 is a process and program controller with up to eight controller channels or four program channels. The instrument is built to the format 144 mm × 130 mm for a standard 92 mm × 92 mm panel cut-out and a mounting depth of 170 mm.
The display is a 5" color screen with 27 colors. The layout of the screen templates can be individually adapted and adjusted. Two freely configurable screen templates make it possible to customize the placing of texts, process values, background pictures and icons.
A maximum of eight analog inputs and 6 logic inputs are available, as well as six expansion slots for switched or analog outputs. Four of these slots can be used alternatively for analog inputs or outputs.
A setup program is available for comfortable configuration from a PC. Linearizations for the usual transmitter outputs are stored within the instrument, four customer-specific linearization tables can be programmed.
A math and logic module can be used to adapt the instrument to a very wide range of control tasks.
A serial interface RS422/485 or PROFIBUS-DP can be used to integrate the instrument into a data network.
Modules can be retrofitted quite simply by the user. The electrical connection is made at the back, via plug-in screw terminals.
Analog input 3
Analog input 4
Logic inputs 1 — 6
for floating contacts
Interface COM 2
RS422/485
Output board 1
(standard: 2 relays)
Output board 2
Output board 3
2 external relay modules ER8
Output board 4
Output board 5
Output board 6
Expansion slots
Supply voltage
AC 110 to 240 V AC/DC 20 to 30 V
PROFIBUS DP-
Interface COM 1 setup / RS422/485
= standard version
Analog input 2
Analog input 1
(standard: analog output)
Analog inputs:
- resistance thermometers
- thermocouples
- standard signals
- potentiometer
- heating current
Output boards:
- 2 relays (make)
- 1 relay (changeover)
- 2 logic outputs 0/14 V
- 1 logic output 0/22 V
- 1 solid state relay
- 1 analog output
- 1 supply for 2 wire transmitter 22 V/30 mA
-
-
= option = accessory
Analog input 5
Analog input 6
Analog input 7
Analog input 8
1 Introduction
6
1.2 Typographical conventions
Warning signs
V
Danger This symbol is used when there may be danger to
personnel if the instructions are ignored or not
followed correctly!
Caution This symbol is used when there may be damage to
equipment or data if the instructions are ignored or
not followed correctly!
E
Caution This symbol is used where special care is required
when handling components liable to damage through electrostatic discharge.
Note signs
H
Note This symbol is used when your special attention is
drawn to a remark.
v
Reference This symbol refers to further information in other
operating manuals, chapters or sections.
H
Action This symbol indicates that an action to be performed
is described. The individual steps are marked by this asterisk, e.g. h Press
Representation Menu items Texts relating to screen representations are shown in
italics, e.g. Edit program
7
2 Identifying the instrument version
2.1 Type designation
a
The board for the 0/22 V logic output and the supply for a 2-wire transmitter are identical, and are detected by the instrument and the setup program as “Logic output 0/22 V”.
b
List extra codes in sequence, separated by commas.
Standard version
Basic type extensions
No. of controller and program channels
2 2 controller channels with max. 2 program channels 4 4 controller channels with max. 4 program channels 8 8 controller channels with max. 4 program channels
Version
8 standard, with factory settings 9 customized programming, as specified
Language for instrument texts
1German 2English 3French 9 customer-specific language (Italian, Hungarian, Czech, Russian, Dutch, Swedish)
1234
Analog inputs
000 0not used 8 8 8 8 universal input (configurable) 3 3 3 3 input for zirconium dioxide sensor 0 to 2 V
123456
Outputs and analog inputs
000 0 0 0none 1 111111 relay (changeover) 2222221 solid-state relay 1A 230V 3333332 relay (n.o.) make 4444441 logic output 0/22V
a
5 555551 analog output 6666661 supply for 2-wire transmitter 22V/30mA
a
7777772 logic outputs 0/14V 8888- -1 universal input
Supply voltage
2 3 AC 110 to 240 V +10/-15 % 48 to 63 Hz 2 5 AC/DC 20 to 30 V 48 to 63 Hz
Interface COM2
0 0not used 5 4 RS422/485 with Modbus/Jbus protocol 64PROFIBUS-DP 8 0 Ethernet (under development)
Extra codes
0 0 0 no extra code 2 1 2 C-level control 213recording function 214math and logic module 1to8 215math and logic module 9to16
(requirement: extra code 214)
703590/ / , ...
b
Basic type
703590 Type 703590: Process snd program controller
2 Identifying the instrument version
8
2.2 Accessories
External relay module
PC interface
Setup program
Program editor
1. Requirements: Windows® 2000, XP, Vista, 7 (32-bit and 64-bit); PC with 512 MByte RAM, 60 MByte free on HD, CD-ROM, 1 free serial or USB interface
One of the RS422/485 interfaces is required to operate one or two external relay modules (external relay or logic outputs).
Versions: Voltage supply AC 110 to 240 V Relay version: Part no. 00405292 Logic version: Part no. 00439131
Voltage supply AC/DC 20 to 53 V Relay version: Part no. 00405297 Logic version: Part no. 00471459
Error
Power
(L+) (L-)
L1PE N
97
TxD
RxD RxD
TxD GND
98 99
K5 K6 K7 K8
4
4
1
4
4
2
4
4
3
2
4
1
2
4
2
2
4
3
1
4
1
1
4
2
1
4
3
K1 K2 K3 K4
3
4
1
3
4
2
3
4
3313233
8
4
1
8
4
2
8
4
3
7
4
1
7
4
2
7
4
3
6
4
1
6
4
2
6
4
3
5
4
1
5
4
2
5
4
3
PC interface for setup program (TTL/RS232 converter) Part no. 00301315
PC interface for setup program (USB/TTL converter) Part no. 00456352
Versions: Setup program with program editor
1
Part no. 00399795 Setup program with program editor
and startup
1
Part no. 00403094 Setup program with program editor, startup
and Teleservice
1
Part no. 00400012
Program editor (software)
1
Part no. 00400460
9
2 Identifying the instrument version
PC evaluation software
2.3 Nameplate
Position The nameplate is glued onto the instrument.
Contents It carries important infomation, for instance:
Type Compare the type that has been delivered with that specified in your order
documentation. You can use Chapter 2.1 “Type designation” to identify the type.
TN The part no. is an unambiguous designation in the catalog. It is used for com-
munication between the sales department and the customer.
F-Nr The factory serial number also reveals the date of production (year/week) and
the hardware version number.
Production date
Example. F-Nr = 0070033801207270006 The positions 12 – 15 (from the left) indicate that the instrument was manufac­tured in week 27 of 2007.
Hardware Example: F-Nr = 0070033801207270006 If the 11th position (from the left) has a 2 or higher, then the instrument has been fitted with the new analog input cards.
PCC+PCA (software) under
Windows® XP, Vista, 7 (32-bit and 64-bit)
Description Designation
on nameplate
Example
Instrument type Typ 703590/281-8800-350000-23-00/000 Part no. TN 00394875 Serial No. F-Nr 0070033801207270006 Supply voltage AC 110 ... 240 V +10/-15 %,
48 ... 63 Hz
2 Identifying the instrument version
10
11
3 Mounting
3.1 Location and climatic conditions
The conditions at the location must meet the requirements specified in the Technical Data. The ambient temperature at the location can be -5 to +50 °C, with a relative humidity of not more than 75 %.
3.2 Dimensions
Close mounting
Minimum spacing of panel cut-outs horizontal 54 mm vertical 41 mm
3 Mounting
12
3.3 Fitting
h From the back, fit the seal that is supplied onto the instrument. h Insert the instrument from the front into the panel cut-out. h From behind the panel, slide the mounting brackets into the guides on the
sides of the housing. The flat faces of the mounting brackets must lie against the housing.
h Push the mounting brackets up to the back of the panel, and tighten them
evenly with a screwdriver.
3.4 Cleaning the front panel
Cleaning The front panel can be cleaned with normal commercial washing, rinsing and
cleaning agents. It has a limited resistance to organic solvents (e.g. methylated spirits, white spirit, P1, xylol etc.). Do not use high-pressure cleaning equip­ment.
13
4 Electrical connection
4.1 Installation notes
• The choice of cable, the installation and the electrical connection must con­form to the requirements of VDE 0100 “Regulations on the Installation of Power Circuits with Nominal Voltages below 1000 V” or the appropriate local regulations.
• At maximum load, the cables must be heat resistant up to at least 80 °C.
• The electrical connection may only be carried out by qualified personnel.
• The instrument must be disconnected on both poles from the electrical supply if contact with live parts is possible.
• The load must be fused for the maximum relay current, in order to prevent the contacts of the output relay becoming welded in the event of a short­circuit.
• The user must not replace internal safety devices. The instrument must be returned to the supplier for repair in the event of a fault.
• Electromagnetic compatibility conforms to the standards and regulations cited in the technical data.
vChapter 10.1 “Technical data”
• Run input, output and supply cables separately and not parallel to one ano­ther.
• All input and output cables without connection to the mains supply must be arranged as twisted and screened cables. Ground the screen on the instrument side to the potential earth.
• The PE terminal on the instrument must be earthed. This cable must have at least the same conductor cross-section as used for the supply cables. Grounding and earthing leads must be wired in a star configuration to a common earth point that is connected to the protective earth of the electri­cal supply. Do not loop earth or ground connections, i.e. do not run them from one instrument to another.
• Do not connect any additional loads to the supply terminals of the instru­ment.
• The instrument is not suitable for use in areas with an explosion hazard (Ex areas).
• In addition to faulty installation, incorrect settings on the controller (set­point, data of the parameter and configuration levels, internal alterations) can also interfere with the correct operation of dependent processes, or even cause damage. Safety devices should always be provided that are in­dependent of the controller (such as overpressure valves or temperature monitors/limiters) and only capable of adjustment by specialist personnel. Please observe the relevant safety regulations for such matters. Since ad­aptation (self-optimization) cannot be expected to handle all possible con­trol loops, an unstable parameterization is theoretically possible. The stabi­lity of the actual value that is produced should therefore be checked.
4 Electrical connection
14
• Since the instrument is short-circuit proof only to a limited extent, an exter­nal fusing and a switch-off facility must be provided. Depending on the sup­ply voltage, the following values apply to the external fusing: AC/DC 20 to 53 V, 48 to 63 Hz fuse 4 A slow (only for operation in SELV or PELV current circuits) AC 110 to 240 V +10/-15 %, 48 to 63 Hz fuse 0.8 A slow
• The measurement inputs of the controller must not exceed a maximum po­tential of AC 30 V or DC 50 V against PE.
4.2 Electrical isolation
Analog outputs
»
30 V AC 50 V DC
»
Voltage supply 110 to 240 V
Analog inputs
Logic inputs
3700 V AC
Relay outputs
»
3700 V AC
»
30 V AC 50 V DC
»
30 V AC 50 V DC
COM 2: PROFIBUS-DP or RS422/485
Solid-state relay outputs
»
3700 V AC
Logic outputs 0/14 V, 0/20 mA
COM 1: RS422/485 or
setup interface
Logic outputs 0/22 V, 0/30 mA supply for transmitter
30 V AC 50 V DC
»
»
30 V AC 50 V DC
»
Voltage supply 20 to 30 V
30 V AC 50 V DC
»
»
»
15
4 Electrical connection
4.3 Connection diagram
.
V
The electrical connection must only be carried out by qualified personnel.
The instrument version can be identified by means of the type code.
See nameplate on the housing. Supply voltage as on nameplate! The diagram shows the stock version.
PE
N
(L-)
L1
(L+)
1 2 3 4
1 2 3 4
OUT1/IN5
OUT4/IN8
IN 2
IN 1
OUT3/IN7
OUT 5
OUT2/IN6
OUT 6
IN 3
IN 4
COM 2
COM 1 29-32
BIN INPUT 33-44
Terminals 34, 36, 38, 40, 42, 44 are internally linked.
The shielding for the bus cable must be connected to PE on the instrument side (e.g. in switchgear cabinet).
Analog inputs (slots: IN1to 8)
.
With current input, care must be taken that the max. input current of 50 mA is not exceeded.
4 Electrical connection
16
1 analog
output
1 logic output
0/22 V *
1 solid-state relay
1 A / 230 V
2 logic outputs
0/14 V
1 changeover 2 make
X X X X
5 6
K1
7 8
K2
9 10 11 12
S Ö
P
13
15
GND
A1
16 17
19 20
GND
A
22
24
-
+
0/2 to 10 V
0/4 to 20 mA
* or supply for two-wire transmitter
23
21
18
14A2
Outputs (slots: OUT1to 6)
Output board “2 make contacts”
It is not permissible to combine supply circuits and circuits with safety extra-low voltage on one board.
Slot Plug-in pcb with
1 output
Plug-in pcb with 2 outputs
OUT1 Output 1 Output 1+7 OUT2 Output 2 Output 2+8 OUT3 Output 3 Output 3+9 OUT4 Output 4 Output 4+10 OUT5 Output 5 Output 5+11 OUT6 Output 6 Output 6+12
PE
N
(L-)
L1
(L+)
PE
N
L1
AC 110 bis 240 V
PE
L-L+AC/DC 20 bis 30 V
Voltage supply
25 26
27 28
RxD + RxD ­TxD + TxD -
RxD/TxD + RxD/TxD -
RS 422
RS 485
PROFIBUS-DP
Pin Assignment
3RxD/TxD-P (B) 4RTS 5DGND 6VP 8RxD/TxD-N (A)
Interface COM 2
17
5 Operation
5.1 Operation: General
5.1.1 Displays and controls
Front view
Displays and controls
EXIT
(1)
(2)
(3) (4)
(5)
(6)
(7)
(8)
(9)
(10)
No. Meaning
1
Status line
with time, date, name of screen template and instrument name.
2 Color screen (screen templates can be configured)
Factory setting for fixed-setpoint controller: process value, setpoint, output level (bar graph). Factory setting for program controller: process value, setpoint, program number/name, segment number, remaining program time
3 Info/alarm symbol
4 Current meaning of the softkeys
5 Keys
(Softkeys) with various interpretations in the color screen.
6 Info/alarm display
Display of infos (blue) or alarms (red).
7 EXIT/manual key
for manual mode, navigation, and for a program pause.
8 Operating mode/state
9 Power LED
lights up green when voltage is applied.
10 Status indicators of the outputs (configurable)
5 Operation
18
Symbols in display
Symbol Bedeutung
Info
Alarm is present Alarm messages must be acknowledged (see explanation for
“screen operating loop”)
Automatic mode/Program is running
Manual (“Hand”) operating mode Enables setpoint and control contact definition in the case of a program controller.
Controller manual mode Enables output definition in the case of a fixed-setpoint or program controller.
Self-optimization is active (symbol flashes)
Ramp function is active
Program pause
Open actuator (modulating controller)
Close actuator (modulating controller)
19
5 Operation
5.1.2 Overview of operation
(>2 s)
= back to the screen operating loop
Time-out = If no key is pressed, the display will automatically return
to the screen operating loop after a definable time.
Setpoint
Manual output
Program times
Limit comparators
Setpoint+Parameter set
Control contacts
Analog signals
Logic inputs+Logic
Logic outputs
Custom picture 2
Custom picture 1
Recording
Collective picture 2
Collective picture 1
Channel 8
Channel 1
Event list
Service mode
Device info
Configuration level
Parameter level
Operating level
User level
Program start menu
Program editor
for program controller/ generator
for fixed-setpoint controller version
v Chapter 7.9 “Display”
EXIT
5 Operation
20
Screen operating loop
The operating loop contains the screen templates for a maximum of four con­troller channels, the collective picture of all the active controller channels, the recording function as well as two freely definable screen templates. The screen templates can be individually switched into display.
v Chapter 7.9 “Display”
Meaning of the keys:
- additional functions of the softkeys
- start/cancel self-optimization for the channel that is displayed
- acknowledge alarm messages and limit comparators
- step on one segment (program controller)
- controller manual mode (program controller)
- key can be freely assigned (only through setup program)
Details The states and values of a large variety of process variables are shown clearly
and in a structured form.
- scroll screen down
EXIT
Custom picture 2
Custom picture 1
Recording
Collective picture 2
Collective picture 1
Channel 8
Channel 1
Program times*
Limit comparators
Setpoint+Parameter set
Control contacts* Analog signals
Logic inputs+Logic
Logic outputs
* only for program controller/
generator
21
5 Operation
Menu
User level
With the help of this screen template, the user can compile parameters that have to be frequently altered, through the setup program. This screen template is only displayed when appropriately configured.
v Operating Manual 703590.6
Operating level
Here the setpoints for all eight controller channels are defined and self­optimization is started. In the case of a program controller, system states can additionally be set in the manual (“Hand”) operating mode.
v Chapter 8.1 “Self-optimization”
Parameter level
The controller parameters for the controller channels are defined here. v Chapter 6 “Parameterization”
Configuration level
The instrument is adapted to the control task here. v Chapter 7 “Configuration”
Device info
Information on hardware equipment, software version and instrument options are shown here.
Service mode This screen template can only be accessed by service personnel.
Event list
The last 16 events with date, time and designation are displayed here.
•Supply ON/OFF
• Overrange/underrange and probe break
• Math error
• Freely definable alarms
Event list
Service mode
Device info Configuration level Parameter level
Operating level
User level
EXIT
5 Operation
22
5.1.3 Entering values and selecting settings
Entering values Parameters can be altered in a number of screen templates.
h Select parameter h Increase parameter value with h Decrease parameter value with
The longer the key is pressed the faster the value changes. Approx. 2sec after releasing the key, the entry will be automatically accepted.
Parameters can be altered within their range of values or within the maximum displayable values (e. g. two decimal places: -99.99 to +99.99).
Shifting the decimal point
h Increase decimal place with h Decrease decimal place with
Selecting h Select parameter
h Move up in selection list with h Move down in selection list with h Confirm entry with
Entering codes and times
Times and codes are entered digit by digit. h Increase or decrease value (digit) with
and
h On to the next digit with or h Confirm entry with
23
5 Operation
5.1.4 Setpoint input
Configuration in controller
Each controller channel has four setpoints which can be switched by logic sig­nals. Setpoints for the controller are defined as shown below.
v Chapter 7.2 “Controller” v Chapter 7.6 “Logic functions”
* Exception: configuration of a program controller with external
setpoint input. In this case, setpoint 2 corresponds to the program setpoint.
5 Operation
24
5.1.5 Recording
Screen template
The recording function can be used to show the traces of up to four analog signals and the switching actions of up to three logic signals.
Keys - call up history
- switch display for the analog signal scalings
History Data that have already been recorded can be viewed here. The recorded time
span is shown on the time axis. The recorded time span depends on the sam­pling rate (adjustable). The ring memory contains 43200 measurement points.
h Shift the trace with , , ,
h Call up zoom function with
(key field is switched)
Momentary values of up to four analog signals
Graphical representation of the analog signals
Scaling of the analog signals (switchable)
Time axis (format hh:mm:ss)
Graphical representation of the logic signals
Time grid
25
5 Operation
h Zoom in /zoom out of trace with or h Return to the scroll functions with h Quit history with
5.2 Operation: Controller
If the instrument has been configured as a fixed-setpoint controller, the follow­ing actions can be performed in automatic/manual mode:
5.2.1 Altering the setpoint
The active setpoint of a controller channel can be altered in the corresponding screen template or at the operating level. The controller must be in automatic mode.
h Alter setpoint using and
(the meaning of the softkeys changes, an input window appears)
h Shift the decimal point using and h New setpoint is automatically accepted after 2 sec or by using
EXIT
5 Operation
26
5.2.2 Manual mode
Altering the output
The control loop of the controller channel that is displayed can be interrupted by switching to manual mode.
h Switch to manual mode with (hold key down for at least 2 sec!)
(the symbol for manual mode appears in the operating mode display) h Alter the output with and (the meaning of the softkeys changes, an input window appears)
h Shift the decimal point using and h The new output is automatically accepted after about 2 sec or by using
Altering the output for modulating controllers
In the case of modulating controllers, the keys are used to directly influence the right and left motion of a motorized actuator. The output is only indicated if the output feedback is connected.
- open actuator
- close actuator
The manual mode can be inhibited.
5.3 Operation: Program controller/generator
If the instrument is configured as a program controller/generator, programs have to be created first, by using the internal program editor or the setup pro­gram.
Setpoint limiting for the program channels is performed via the setpoint limita­tion for the controller channels. There is a fixed 1 to 1 assignment, which is in­dependent of the program setpoint channel that has actually been selected. Example: Setpoint limiting for program channel 2 is always performed via the setpoint limitation of controller channel 2.
v Chapter 7.3 “Generator”
EXIT
27
5 Operation
5.3.1 Program editor
Input template h Call up with Edit program
h Select program using the cursor keys h Select program channel using the cursor keys
1. Control contacts 9 to 16 can only be displayed in the setup program
Number of program channel
Program number and name
Number of program segments
Entry mode
- edit
- temporary alteration
Segment number
- call up additional softkey functions
Segment setpoint
Segment time
Control contacts 8 to 1 (1=On)
1
Number of repeat cycles (Cy) with start segment (No.)
Lower and upper tolerance band
Parameter set
number
5 Operation
28
General 50 programs with up to 99 segments each can be programmed; a total of 1000
segments can be implemented. Programs are created by programming setpoints and segment times, segment
by segment. Furthermore, the states of the control contacts 1 to 16 and the active
parameter set can be defined for each segment. The setpoint profiles can be output either as a ramp or a step (configurable). v Chapter 7.3 “Generator” (setpoint input) Output as a ramp has been chosen for the following diagrams.
v
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