Modine PDP 30, PDP 50, PDP 75, PDP 100, PDP 125 Installation Manual

...
February, 2004
INSTALLATION AND SERVICE MANUAL
gas-fired unit heaters
model PDP
6-579.2
5H78211A Rev. C
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death, and could cause exposure to substances which have been determined by various state agencies to cause cancer, birth defects or other reproductive harm. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.
All models approved for use in California by the CEC (when equipped with IPI), in New York by the MEA division, and in Massachusetts. Unit heater is certified for non-residential applications.
Inspection on Arrival
1. Inspect unit upon arrival. In case of damage, report immediately to transportation company and your local Modine sales representative.
2.
Check rating plate on unit to verify that power supply meets available electric power at the point of installation.
3. Inspect unit received for conformance with description of product ordered (including specifications where applicable).
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Don’t touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
CAUTION
To prevent premature heat exchanger failure do not locate ANY gas-fired units in areas where chlorinated, halogenated, or acid vapors are present in the atmosphere.
IMPORTANT
The use of this manual is specifically intended for a qualified installation and service agency. A qualified installation and service agency must perform all installation and service of these appliances.
FOR YOUR SAFETY
The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.
THIS MANUAL IS THE PROPERTY OF THE OWNER.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
2
SPECIAL PRECAUTIONS
THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE, EFFICIENT AND TROUBLE-FREE OPERATION. IN ADDITION, PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW. FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS, PERSONAL INJURY, OR DEATH. THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES.
HAZARD INTENSITY LEVELS
1. DANGER: Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
2. WARNING: Indicates a potentially hazardous situation which,
if not avoided, COULD result in death or serious injury.
3. CAUTION: Indicates a potentially hazardous situation which,
if not avoided, MAY result in minor or moderate injury.
4. IMPORTANT: Indicates a situation which, if not avoided,
MAY result in a potential safety concern.
SPECIAL PRECAUTIONS / TABLE OF CONTENTS
IMPORTANT
1. To prevent premature heat exchanger failure, do not locate ANY gas-fired appliances in areas where corrosive vapors (i.e. chlorinated, halogenated or acid) are present in the atmosphere.
2. Do not attempt to attach ductwork of any kind to propeller models.
3. Start-up and adjustment procedures should be performed by a qualified service agency.
4. To check most of the Possible Remedies in the trouble­shooting guide listed in Table 29.1, refer to the applicable sections of the manual.
5. To prevent premature heat exchanger failure, the input to the appliance, as indicated on the serial plate, must not exceed the rated input by more than 5%.
Table of Contents
Inspection on Arrival . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Special Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SI (Metric) Conversion Factors . . . . . . . . . . . . . . . . . . . . . . .3
Unit Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Combustible Material and Service Clearances . . . . . . . .3
Combustion Air Requirements . . . . . . . . . . . . . . . . . . . .3
Unit Lifting and Unit Mounting . . . . . . . . . . . . . . . . . . . .4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pilot Burner Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 9
Main Burner Adjustment . . . . . . . . . . . . . . . . . . . . . . . .10
Control Operating Sequence . . . . . . . . . . . . . . . . . . . . 11
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . 14
Performance Data Options/Accessories . . . . . . . . . . . . . . . 14
Dimensions Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 17
Model Nomenclature/Serial Plate . . . . . . . . . . . . . . . . . . . .19
Commercial Warranty . . . . . . . . . . . . . . . . . . . . . . Back Page
CAUTION
1. Purging of air from gas supply line should be performed as described in ANSI Z223.1 - latest edition “National Fuel Gas Code”, or in Canada in CAN/CGA-B149 codes.
2. Do not attempt to reuse any mechanical or electronic ignition controllers which has been wet. Replace defective controller.
3. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% less than the rated voltage.
DANGER
Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere.
WARNING
1. Gas fired heating equipment must be vented - do not operate unvented.
2. A built-in power exhauster is provided - additional external power exhausters are not required or permitted.
3. All field gas piping must be pressure/leak tested prior to operation. Never use an open flame. Use a soap solution or equivalent for testing.
4. Gas pressure to appliance controls must never exceed 14" W.C. (1/2 psi).
5. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage.
6. All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property.
7. Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105°C.
8. When servicing or repairing this equipment, use only factory-approved service replacement parts. A complete replacement parts list may be obtained by contacting Modine Manufacturing Company. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not approved by the factory will be at the owners risk.
9. To reduce the opportunity for condensation, the minimum sea level input to the appliance, as indicated on the serial plate, must not be less than 5% below the rated input, or 5% below the minimum rated input of duel rated units.
10. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% greater than the rated voltage.
3
SI (METRIC) CONVERSION FACTORS / UNIT LOCATION
DANGER
Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere.
SI (METRIC) CONVERSION FACTORS
Table 3.1
IMPORTANT
To prevent premature heat exchanger failure, do not locate ANY gas-fired appliances in areas where corrosive vapors (i.e. chlorinated, halogenated or acid) are present in the atmosphere.
UNIT LOCATION
Location Recommendations
1. When locating the furnace, consider general space and heating requirements, availability of gas and electrical supply, and proximity to vent locations.
2. Avoid installing units in extremely drafty locations. Drafts can cause burner flames to impinge on heat exchangers which shortens life. Maintain separation between units so discharge from one unit will not be directed into the inlet of another.
3. Be sure the structural support at the unit location site is adequate to support the weight of the unit. For proper operation the unit must be installed in a level horizontal position.
4. Do not install units in locations where the flue products can be drawn into the adjacent building openings such as windows, fresh air intakes, etc.
5. Be sure that the minimum clearances to combustible materials and recommended service clearances are maintained. Units are designed for installation on non­combustible surfaces with the minimum clearances shown in Figure 3.1 and Tables 3.2 and 3.3.
6. Units exposed to inlet air temperatures of 40°F or less, may experience condensation, therefore, provisions should be made for disposal of condensate.
7. When locating units, it is important to consider that the exhaust vent piping must be connected to the outside atmosphere.
8. In garages or other sections of aircraft hangars such as offices and shops that communicate with areas used for servicing or storage, keep the bottom of the unit at least 7 feet above the floor unless the unit is properly guarded to provide user protection from moving parts. In parking garages, the unit must be installed in accordance with the standard for parking structures ANSI/NFPA 88A, and in repair garages the standard for repair garages NFPA #88B. In Canada, installation of heaters in airplane hangars must be in accordance with the requirements of the enforcing authority, and in public garages in accordance with the current CAN/CGA-B149 codes.
9. Do not install units in locations where gas ignition system is exposed to water spray, rain, or dripping water.
10. Do not install units below 7 feet, measured from the bottom of the unit to the floor, unless properly guarded to provide protection from moving parts.
11. In aircraft hangars, keep the bottom of the unit at least 10 feet from the highest surface of the wings or engine enclosure of the the highest aircraft housed in the hangar and in accordance with the requirements of the enforcing authority and/or NFPA No. 409 - Latest Edition.
Figure 3.1 Combustible Material and Service Clearances
Table 3.2 Combustible Material Clearances
Provide sufficient room around the heater to allow for proper
combustion and operation of fan. Free area around the heater must not be less than 1-1/2 times the discharge area of the unit.
Table 3.3 Recommended Service Clearances
Combustion Air Requirements
Units installed in tightly sealed buildings or confined spaces must be provided with two permanent openings, one near the top of the confined space and one near the bottom. Each opening should have a free area of not less than one square inch per 1,000 BTU per hour of the total input rating off all units in the enclosure, freely communicating with interior areas having, in turn adequate infiltration from the outside. For further details on supplying combustion air to a confined (tightly sealed) space or unconfined space, see the National Fuel Gas Code ANSI Z223.1 of CAN/CGA B149.1 or .2 Installation Code, latest edition.
To Convert Multiply By To Obtain
"W.C. 0.24 kPa
psig 6.893 kPa
°F (°F-32) x 0.555 °C
inches 25.4 mm
feet 0.305 meters
CFM 0.028 m
3
/min
To Convert Multiply By To Obtain
CFH 1.699 m3/min
Btu/ft
3
0.0374 mJ/m
3
pound 0.453 kg Btu/hr 0.000293 kW/hr
gallons 3.785 liters
psig 27.7 "W.C.
Access Non-Access
Side Side
(A) (B)
30-100 116123
125 113122
150-175 114122
200-300 115123
350-400 115123
Model
Size
Top
(C)
Bottom
(D)
Access Non-Access
Side Side
(A) (B)
30-50 18 18 6 15 1
75-100 18 18 6 20 1
125-175 18 18 6 22 1
200-400 18 18 6 25 1
Model
Size
Top
(C)
Bottom
(D)
Top of Power
Exhauster
(Not Shown)
Top of Power
Exhauster
(Not Shown)
C
Access
Slide
B
A
D
4
UNIT LOCATION
Sound and Vibration Levels
All standard mechanical equipment generates some sound and vibration that may require attenuation. Libraries, private offices and hospital facilities will require more attenuation, and in such cases, an acoustical consultant may be retained to assist in the application. Locating the equipment away from the critical area is desirable within ducting limitations. Generally, a unit should be located within 15 feet of a primary support beam. Smaller deflections typically result in reduced vibration and noise transmission.
UNIT LIFTING
All standard units are shipped fully boxed. Larger units are also supplied with skid supports on the bottom of the box. The larger units may be lifted from the bottom by means of a fork lift or other lifting device only if the shipping support skids are left in place and the forks support the whole depth of the unit. If the unit must be lifted from the bottom for final installation without the carton in place, be sure to properly support the unit over its entire length and width to prevent damage. When lifting units, make sure the load is balanced.
UNIT SUSPENSION
Be sure the method of unit suspension is adequate to support the weight of the unit (see Weights for base unit and factory installed option weights). For proper operation, the unit must be installed in a level horizontal position. Combustible material and service clearances as specified in Figure 3.1 and Tables 3.2 and 3.3 must be strictly maintained. To assure that flames are directed into the center of the heat exchanger tubes, the unit must be level in a horizontal position. Use a spirit level to ensure that the unit is suspended correctly.
The most common method of suspending Modine gas unit heaters is to utilize 3/8” threaded rod. On each piece of threaded rod used, screw a nut a distance of about one inch onto the end of the threaded rods that will be screwed into the unit heater. Then place a washer over the end of the threaded rod and screw the threaded rod into the unit heater weld nuts on the top of the heater at least 5 turns, and no more than 10 turns. Tighten the nut first installed onto the threaded rod to prevent the rod from turning. Drill holes into a steel channel or angle iron at the same centerline dimensions as the heater that is being installed. The steel channels or angle iron pieces need to span and be fastened to appropriate structural members. Cut the threaded rods to the preferred length, place them through the holes in the steel channel or angle iron and secure with washers and lock nuts or lock washers and nuts. A double nut arrangement can be used here instead of at the unit heater (a double nut can be used both places but is not necessary). Do not install standard unit heaters above the maximum mounting height shown in table 14.1.
On all propeller units, except sizes 350 and 400, two tapped holes (3/8-16) are located in the top of the unit to receive threaded rods.
Units with two point suspension, sizes 30 through 300, incorporate a level hanging feature. Depending on what options and accessories are being used, the heater may not hang level as received from the factory. Do not hang heaters with deflector hoods until referring to the “installation manual for deflector hoods” and making the recommended preliminary adjustments on the heater. These preliminary adjustments need to be made with the heater resting on the floor.
Propeller sizes 30 through 300 units without deflector hoods that do not hang level after being installed, can be corrected in place. Simply remove both outer side panels (screws to remove are on back flange of side panel) and you will see the (adjustable) mounting brackets (Fig. 4.1). Loosen the set screws holding the mounting brackets in place and using a rubber mallet or something similar, tap the heater into a position where the unit hangs level. Re-tighten set screws and replace the outer side panels.
Propeller sizes 350 and 400 have four mounting holes. On all blower units, except the 350 and 400, two tapped holes are provided in the top of the unit and two holes in the blower support bracket. The 350 and 400 have four tapped holes in the top of the unit and two in the blower support bracket for mounting.
NOTE: A pipe hanger adapter kit, shown in Figure 4.2 is
available as an accessory. One kit consists of two drilled 3/4” IPS pipe caps and two 3/8 - 13 x 1-3/4” capscrews to facilitate threaded pipe suspension.
Figure 4.1 Adjustable Mounting Brackets - To Adjust:
Figure 4.2 Suspension Methods
1. Remove outer side panels.
2. “Set screws” - loosen and position bracket where needed – then tighten set screws.
3. Re-attach outer side panels.
5
Venting
Note: A vent is the vertical passageway used to convey flue gases from the unit or the vent connector to the outside atmosphere. A vent connector is the pipe which connects the unit to a vent or chimney. Vent connectors serving Category I appliances shall not be connected into any portion of mechanical draft systems operating under positive pressure.
General Venting Air Instructions
1. Installation of venting must conform with local building codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - Latest Edition. In Canada, installation must be in accordance with CAN/CGA-B149.1 for natural gas units and CAN/CGA­B149.2 for propane units.
2. All vertically vented units are Category I. All horizontally vented units are category III. The installation must conform to the requirements from Table 5.1 in addition to those listed below.
3. From Table 15.1, select the size of vent pipe that fits the flue outlet for the unit. Do not use a vent pipe smaller than the size of the outlet or vent transition of the appliance. The pipe should be suitable corrosion resistant material. Follow the National Fuel Gas Code for minimum thickness and composition of vent material. The minimum thickness for connectors varies depending on the pipe diameter.
4. For Category I vent systems limit length of horizontal runs to 75% of vertical height. Install with a minimum upward slope from unit of 1/4 inch per foot and suspend securely from overhead structure at points no greater than 3 feet apart. For best venting, put vertical vent as close to the unit as possible. A minimum of 12''straight pipe is recommended from the power exhauster outlet before turns in the vent system. Fasten individual lengths of vent together with at least three corrosion-resistant sheet-metal screws.
5. It is recommended that vent pipes be fitted with a tee with a drip leg and a clean out cap to prevent any moisture in the vent pipe from entering the unit. The drip leg should be inspected and cleaned out periodically during the heating season.
6. The National Fuel Gas Code requires a minimum clearance of 6 inches from combustible materials for single wall vent pipe. The minimum distance from combustible materials is based on the combustible material surface not exceeding 160°F. Clearance from the vent pipe (or the top of the unit) may be required to be greater than 6 inches if heat damage other than fire (such as material distortion or discoloration) could result.
7. Avoid venting through unheated space . When venting does pass through an unheated space, insulate runs greater than 5 feet to minimize condensation. Inspect for leakage prior to insulating and use insulation that is noncombustible with a rating of not less than 350°F. Install a tee fitting at the low point of the vent system and provide a drip leg with a clean out cap as shown in Figure 6.1.
8. When the vent passes through a combustible wall or floor, a metal thimble 4 inches greater than the vent diameter is necessary. If there is 6 feet or more of vent pipe in the open space between the appliance and where the vent pipe passes through the wall or floor, the thimble need only be 2 inches greater than the diameter of the vent pipe. If a
thimble is not used, all combustible material must be cut away to provide 6 inches of clearance. Any material used to close the opening must be noncombustible.
9. Do NOT use dampers or other devices in the vent pipes.
10. Precautions must be taken to prevent degradation of building materials by flue products.
11. For category I vent systems the outlet of the vent should extend as shown in Figure 6.1 and Table 5.2 if the following conditions are met: Vent diameter is less than 12 inches, vent is of double wall construction and is a listed product, and the vent does not terminate within 2'of a vertical wall or similar obstruction.
For vents that have a diameter of 12 inches or larger, constructed of single wall, or terminate within 2'of a vertical wall or similar obstruction, the vent pipe shall extend at least 2'higher than any portion of a building within a horizontal distance of 10'(refer to Figure 6.2).
12. Use a listed vent terminal to reduce downdrafts and moisture in vent.
13. For instructions on common venting refer to the National Fuel Gas Code.
14. The vent must terminate no less than 5'above the vent connector for category I vent systems.
15. A unit located within an unoccupied attic or concealed space shall not be vented with single wall vent pipe.
16. Single wall vent pipe must not pass through any attic, inside wall, concealed space, or floor.
17.
Do NOT vent this appliance into a masonry chimney.
18. When condensation may be a problem, the venting system
shall not terminate over public walkways or over an area where condensation or vapor could create a nuisance or hazard or could be detrimental to the operation of regulator/relief openings or other equipment.
WARNING
1. Gas fired heating equipment must be vented - do not operate unvented.
2. A built-in power exhauster is provided - additional external power exhausters are not required or permitted.
INSTALLATION
Table 5.1 ANSI Venting Requirements
Rise Roof Pitch Min Height
X (in) H (ft)* 0-6 Flat to 6/12 1.00 6-7 6/12 to 7/12 1.25 7-8 7/12 to 8/12 1.50 8-9 8/12 to 9/12 2.00 9-10 9/12 to 10/12 2.50 10-11 10/12 to 11/12 3.25 11-12 11/12 to 12/12 4.00 12-14 12/12 to 14/12 5.00 14-16 14/12 to 16/12 6.00 16-18 16/12 to 18/12 7.00 18-20 18/12 to 20/12 7.50 20-21 20/12 to 21/12 8.00
Table 5.2 Minimum Height from Roof to Lowest Discharge Opening
* Size according to expected snow depth.
Appliance Venting
Category Description Requirements
I Negative vent pressure Follow standard venting
Non-condensing requirements.
II Negative vent pressure Condensate must be
Condensing drained.
III Positive vent pressure Vent must be gastight.
Non-condensing
IV Positive vent pressure Vent must be liquid and
Condensing gastight. Condensate must
be drained.
19. In cold ambient conditions, such as Canada, the following items are recommended for proper operation and equipment life:
· The vent pipe must not pass through an unheated space or interior part of an open chimney unless the vent pipe is insulated.
· Where the vent pipe may be exposed to extreme cold, or come into contact with snow or ice, the entire vent must be insulated or double wall (includes outdoors). It is preferred that the double wall vent is one continuous piece but a joint is allowed outside the building.
· The vent terminal must extend 16 inches beyond the exterior surface of an exterior wall and be supported as shown in figure 7.1.
· The heater system shall be checked at least once a year by a qualified service technician.
20. If left hand (facing front of heater with air blowing in face) power exhauster discharge is desired, the power exhauster may be rotated 180°. To do this, remove screws in vent colar, rotate power exhauster, replace screws.
Additional Requirements for Horizontally Vented Category III units.
1. Seal the joints with a metallic tape or silastic suitable for temperatures up to 350°F. (3M tapes433 or 363 are acceptable.) Wrap the tape two full turns around the vent pipe.
2. Refer to Table 6.1 for total minimum and maximum vent lengths making the vent system as straight as possible. Refer to Table 6.2 for equivalent vent lengths for elbows.
Table 6.1 Vent Pipe Diameters,Transitions, and Total Equivalent Vent Pipe Lengths for Horizontal Vent Systems.
Vent transition is included but not required for this vent size, Please discard the vent transition.
Table 6.2 Equivalent Vent Lengths for 90° Elbows
3. The vent terminal must be a Gary Steel 1092, Breidert Type L, Tjernlund VH1 (sizes 150-400 only), Starkap, Selkirk, or Constant Air-Flo 2433 style terminal or equivalent.
4. If a Gary Steel 1092 or Breidert Type L vent terminal or equivalent is used, the vent must extend 6 inches beyond the exterior surface of an exterior wall as shown in Figure
7.2. Precautions must be taken to prevent degradation of building materials by flue products.
5. If a Tjernlund VH1 or equivalent vent terminal is used the vent may be flush with the exterior surface of an exterior wall. Precautions must be taken to prevent degradation of building materials by flue products. Where the terminal is not available in the appropriate size for the unit to be installed, use a transition and the next larger size terminal.
6. If a Constant Air-Flo, Starkap, Selkirk, or equivalent vent terminal is used the vent must extend 12 inches beyond the exterior surface of an exterior wall. Precautions must be taken to prevent degradation of building materials by flue products.
7. The vent system shall terminate at least 3 feet above any forced air inlet (except direct vent units) located within 10 feet, and at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building. The bottom of the vent terminal shall be located above the snow line or at least 1 foot above grade; whichever is greater. When located adjacent to public walkways the vent system shall terminate not less than 7 feet above grade.
8. The venting system must be exclusive to a single unit, and no other unit is allowed to be vented into it.
6
INSTALLATION
Figure 6.2 Unit Venting Category I (obstructed)
Figure 6.1 Unit Venting Category I (pitched roof)
Model Vent Transition Vent Pipe Minimum Maximum
Size Included Diameter Eqv Length Eqv Length
30 4" to 3" 3" 2
'
25
'
30 Not Required 4" 2
'
35
'
50 4" to 3" 3" 2
'
30
'
50 Not Required 4" 2
'
40
'
75 Not Required 4" 2
'
40
'
100-125 Not Required 4" 2
'
55
'
150, 175 4" to 5" 5" 2
'
60
'
200 6" to 5" 5" 2
'
60
'
250- 400 Not Required 6" 2
'
70
'
Elbow Diameter Equivalent Vent Length
3" 1'
4" 5'
5" 6'
6" 7'
Listed Terminal
H
Roof Flashing
Use Thimble
Through Ceiling
Drip Leg with Cleanout Cap
Unit
x
12
Roof Pitch is x/12
1/4"
1'0"
Slope 1/4" to
The Foot
Listed
Terminal
Roof Flashing
Unit
10"
Slope 1/4" to
The Foot
*Size according to expected snow depth
1/4"
2 Min.
To wall or adjoining building
2*
Min.
Use Thimble Through Ceiling
Drip Leg with Cleanout Cap
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