Nordyne G6RL 90+, G6RC 90+, G6RD 93+ User Manual

Residential Gas Furnaces
Installation Instructions
G6RC Series 90+ Upflow Condensing Furnace G6RD Series 93+ Upflow Condensing Furnace G6RL Series 90+ Downflow Condensing Furnace
G6RC 90+, G6RD 93+ Upflow G6RL 90+ Downflow
!
WARNING:
Improper installation, adjustment, al­teration, service, or maintenance can cause injury or property damage. Re­fer to this manual for assistance. For additional information consult a quali­fied installer, service agency, or the gas supplier.
These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installa­tion/service personnel for this type of equip­ment. Read all instructions carefully before starting the installation.
DO NOT DESTROY. PLEASE READ CARE­FULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
!
FOR YOUR SAFETY:
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
!
FOR YOUR SAFETY:
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
• Extinguish any open flame.
Table of Contents
Furnace Specifications ......................................................................................................... ... 4-5
Furnace Airflow Data.......................................................................................................... 6-7
Installation Requirements ...................................................................................................... .... 8
Supply Air Plenum Installation ..................................................................................................9
Installation on a Concrete Slab ............................................................................................. 9
Installation on a Combustible Floor....................................................................................... 9
Circulating Air Supply............................................................................................................... 10
Return Air ............................................................................................................................ 11
Venting and Combustion Air Requirements .......................................................................... 11
Air Requirements for One-Pipe Installation ........................................................................ 13
Installation in An Unconfined Space ................................................................................... 13
Installation in A Confined Space ......................................................................................... 13
• Air From Inside .................................................................................................................. 1 3
• Air Directly Through An Exterior Wall ............................................................................... 14
• Outdoor Air Through Vertical Openings or Ducts ............................................................. 14
• Outdoor Air Through Horizontal Openings or Ducts......................................................... 14
Venting Requirements .............................................................................................................. 1 4
Vent Pipe Material ............................................................................................................... 14
Vent Pipe Length and Diameter .......................................................................................... 14
Vent Pipe Installation ..........................................................................................................15
Pipe Routing & Support....................................................................................................... 15
Location of Outdoor Terminations....................................................................................... 18
Horizontal Venting ............................................................................................................... 19
Vertical Venting ................................................................................................................... 20
Vent Freezing Protection..................................................................................................... 20
Concentric Vent Termination............................................................................................... 20
Drainage of Condensate From Furnace................................................................................. 21
Gas Supply and Piping........................................................................................................ 22
Leak Check.......................................................................................................................... 22
Conversion..................................................................................................................... ...... 23
High Altitude Application ..................................................................................................... 23
Natural Gas High Altitude Conversion ................................................................................ 23
LP/Propane Gas Sea Level and High Altitude Conversion ................................................ 23
Electrical Wiring ........................................................................................................................ 24
Line Voltage Wiring .............................................................................................................24
Low Voltage Wiring ............................................................................................................. 25
Start-up and Adjustments......................................................................................................... 25
Start-Up Procedure..............................................................................................................26
Verifying and Adjusting Firing Rate..................................................................................... 26
Verifying and Adjusting Temperature Rise ......................................................................... 27
Verifying Burner Operation.................................................................................................. 27
Verifying Operation of the Supply Air Limit Switch ............................................................. 29
Description of Components ..................................................................................................... 29
Maintenance ............................................................................................................................... 31
Combustion Air and Vent System ....................................................................................... 31
Air Filter(s) .................................................................................................................. ......... 31
Lubrication ........................................................................................................................... 31
Condensate Drain Assembly............................................................................................... 31
Blower Compartment........................................................................................................... 31
Heat Exchanger and Burner Maintenance.......................................................................... 31
Location of Major Components ........................................................................................... 32
System Operation Information ................................................................................................. 31
Sequence of Operation ....................................................................................................... 33
Furnace Fails to Operate .................................................................................................... 34
Twinning of Two Furnaces .................................................................................................. 34
Installation/Performance Checklist ......................................................................................... 35
4
FURNACE SPECIFICATIONS
Upflow G6RC & G6RD Furnaces
Combustion Air
Inlet
23 1/4"
A
Exhaust Vent
3/4"
3/4"
Figure 1. G6RC, G6RD Unit Dimensions
1 1/2" x 3 1/2" Dia.
43"
15"
1"
22 1/2"
19 3/4"
25 1/8"
Opening for
Gas Connection
7/8" Dia. Electric
Connection
25 1/4"
8"
Return Air Opening
(Side)
Combustion Air Vent (See Fig. 15 for sizes)
+
20 1/2"
33"
3/4"
B
C
Return Air Opening
(Bottom)
D
2 1/4"
3/4"
2" PVC Exhaust Vent (See Fig. 15 for sizes)
30 1/4"
25 1/4"
27 5/8"
1 1/2" x 3 1/2" Dia. Opening for Gas Connection
7/8" Dia. Electric Connection
+
8"
25 5/8"
1 1/4"
23"
28"
Condensate Drain Outlets
23"
Bottom Return Opening
Downflow G6RL Furnace
Combustion Air Inlet
24 1/2"
Exhaust Vent
3/4"
22 1/2"
Exhaust
Vent
2"
3/4"
A
B
3/4"
27 7/8"
3/4"
Figure 2. G6RL Unit Dimensions
24 7/8"
7/8" Dia. Electric
43"
1 1/2" x 3 1/2" Dia.
Gas Connection
1"
Connection
21 7/8"
Opening for
21 1/4"
8"
21 1/2"
15 1/2"
Condensate Drain Outlet
C
C
L
Bottom Supply Air Opening
(Side)
D
2 1/2"
Combusting
Vent
(3" for 80/100
2" for 40/60)
21 1/2"
Condensate
Drain
Outlet
24 7/8"
7/8" Dia. Electric
Connection
1 1/2" x 2 1/2"
Knockout
For Gas
Connection
21 7/8"
10 1/4"
19 3/4"
Bottom Opening
5
6
1170
1060
1160
1050
1310
1080
1630
1400
1250
1700
1480
1320
1140
1650
1480
1320
1140
2070
1760
1470
1280
1030
gh*G6RC040C-08
g
G6RC040C-12
gh*G6RC060C-12
gh*G6RC080C-12
gh*G6RC080C-16
Med-High
g
G6RC100C-16
gh*G6RC120C-16
g
G6RC120C-20
Med-High
gh*G6RD040C-10
gh*G6RD060C-10
Model Input Motor Motor
Number (Btuh) Speed HP
Table 1. Furnace Airflow Data
Heating
40,000 Medium 1/5
40,000 Medium 1/3
60,000 Medium 1/3
80,000 Medium 1/3
80,000
100,000 Med-High** 1/2
120,000 Med-High** 1/2
120,000
40,000 Medium 1/3
60,000 Medium** 1/3
Hi
Low**
Hi
h*
Low**
Hi
Low**
Hi
Low**
Hi
Med-Low**
Low
h*
Hi
Med-Low
Low
Hi
Med-Low
Low
h*
Hi
Med-Low**
Low
Hi
Low**
Hi
Low
Ex ternal Static Pressure (Inches W ater Column)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise
950 36 920 38 890 39 850 41 800 43 750 46 690 50 630 55 740 47 710 49 680 51 650 53 600 58 550 63 490 - 430 -
620 56 590 59 560 62 520 - 470 - 410 - 350 - 290 ­1330 - 1280 - 1230 ­1190 - 1160 - 1110 -
830 42 810 43 780 44 760 46 720 48 670 52 610 57 550 63 1310 - 1260 - 1210 ­1160 45 1120 46 1080 48
800 65 780 67 760 68 740 70 710 73 680 - 650 - 620 ­1490 46 1450 48 1390 50 1230 56 1200 58 1150 60
780 - 750 - 720 - 680 - 630 - 570 - 510 - 440 ­1840 - 1780 - 1700 41 1600 43 1560 44 1470 47
1/2
1380 50 1350 51 1300 53 1100 - 1050 - 1000 - 950 - 900 - 850 - 800 - 750 ­1910 45 1860 47 1780 49 1640 53 1620 53 1540 56 1440 60 1410 61 1370 63 1230 - 1210 - 1180 ­1860 56 1800 58 1730 60 1650 63 1610 65 1550 67 1440 72 1410 74 1380 75 1230 - 1210 - 1180 ­2260 - 2200 - 2140 -
3/4
1870 56 1840 56 1790 58 1540 67 1530 68 1510 69 1360 - 1330 - 1310 ­1050 - 1005 - 960 - 915 - 855 - 800 - 730 48 670 53
990 - 950 - 905 - 860 - 810 - 760 46 700 50 650 54
770 46 740 48 700 50 660 53 625 56 580 61 540 65 500 70 1175 45 1125 47 1075 49 1075 49 1040 51 995 53 950 56 900 59 840 63 790 67 720 73
800 66 770 69 745 71 710 74 670 - 630 - 580 - 530 -
- 1120 - 1030 - 940 37 850 41
- 1010 - 910 38 820 42 720 48
45 1100 47 1040 50 980 53 920 56 49 990 52 940 55 890 58 830 63
53 1210 57 1100 63 980 - 830 ­64 1010 69 910 - 810 - 680 -
42 1550 45 1470 47 1380 50 1290 54 49 1350 51 1280 54 1210 57 1150 60 55 1190 58 1120 62 1040 67 960 -
51 1620 53 1520 57 1420 61 1310 66 58 1420 61 1340 65 1250 69 1150 75 66 1270 68 1210 72 1140 - 1060 -
- 1090 - 1030 - 960 - 880 ­63 1570 66 1480 70 1380 75 1270 82 70 1410 74 1320 79 1230 84 1120 ­79 1280 81 1220 85 1150 - 1080 -
- 1090 - 1030 - 960 - 880 -
- 1990 - 1910 - 1810 57 1710 61 59 1710 61 1660 63 1610 65 1560 67 71 1430 73 1370 76 1300 80 1220 85
- 1250 - 1220 - 1190 - 1150 -
51 970 54 920 57 860 61 800 66
CAPACITIES —Furnace Airflow Data
Heating
g
Med-High
g
g
g
g
g
Med-High
1430
1295
1145
1000
1425
1265
1130
1500
1350
1195
1040
1945
1800
1540
1360
Model Input Motor Motor
Number (Btuh) Speed HP
G6RD080C-14 80,000
G6RD100C-14 100,000 Med-Hi
Table 2. Furnace Airflow Data
G6RD120C-14 120,000 Med-Hi
G6RD120C-19 120,000
G6RL040C-12 40,000 Medium 1/3
G6RL060C-12 60,000 Medium 1/3
G6RL080C-16 80,000 Med-High 1/2
G6RL100C-16 100,000 Med-High** 1/2
Hi
Med-Low**
Hi
Med-Low
Hi
Med-Low
Hi
Med-Low**
High*
Low**
High*
Low**
High*
Med-Low**
High*
Med-Low
h*
Low
h*
Low
h*
Low
h*
Low
Low
Low
1/2
h** 1/2
h** 1/2
3/4
Ex ternal Static Pressure (Inches W ater Column)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise
1620 - 1560 45 1490 47 1450 49 1400 50 1350 52 1255 56 1225 57 1180 60 1080 65 1055 67 1030 68 1620 54 1555 57 1485 59 1430 62 1375 64 1330 66 1260 70 1220 72 1170 75 1085 - 1050 - 1015 - 970 - 935 - 890 - 850 - 800 ­1700 62 1635 65 1565 67 1510 70 1455 73 1405 75 1330 79 1280 - 1240 ­1140 - 1110 - 1075 ­2140 - 2070 - 2010 ­1955 - 1900 56 1850 57 1660 64 1620 65 1575 67 1450 73 1430 74 1400 75
1280 - 1210 - 1180 - 1140 - 1090 - 1070 - 1030 - 990 ­1140 - 1090 - 1060 - 1030 - 980 35 950 36 910 37 870 39
875 39 835 41 820 41 805 42 780 43 770 44 760 45 750 45 1260 40 1190 43 1155 44 1120 45 1075 47 1030 49 980 52 940 54 1120 45 1070 48 1040 49 1010 50 960 53 930 55 890 57 850 60
855 59 815 62 800 64 780 65 760 67 730 70 710 - 690 ­1635 - 1585 - 1525 - 1460 46 1400 48 1330 51 1260 54 1180 57 1435 47 1395 49 1350 50 1300 52 1255 54 1200 56 1150 59 1090 62 1230 55 1200 56 1165 58 1130 60 1090 62 1050 65 1000 68 960 71 1050 - 1035 - 1010 - 980 - 950 - 910 - 870 - 820 ­1600 53 1555 54 1500 56 1445 59 1380 61 1310 65 1240 68 1160 73 1475 57 1435 59 1385 61 1335 63 1290 66 1240 68 1190 71 1130 75 1320 - 1290 - 1250 - 1215 - 1170 - 1120 - 1070 - 1020 ­1150 - 1130 - 1110 - 1075 - 1040 - 1000 - 950 - 890 -
49 1365 52 1300 54 1240 57 1170 60 54 1240 57 1180 60 1120 63 1060 66 61 1105 64 1060 66 1020 69 980 72 70 960 73 920 - 870 - 820 ­62 1355 65 1290 68 1220 72 1160 ­70 1210 73 1150 - 1080 - 1010 -
- 1070 - 1010 - 950 - 890 -
70 1435 74 1370 77 1310 - 1240 ­78 1290 - 1230 - 1170 - 1100 -
- 1145 - 1100 - 1050 - 1000 -
- 1010 - 980 - 940 - 910 -
- 1870 56 1800 59 1730 61 1650 64 59 1740 61 1690 62 1630 65 1570 67 69 1495 71 1460 72 1410 75 1370 77 78 1340 79 1300 81 1270 83 1230 -
** Factory Set Cooling Speed ** Factory Set Heating Speed
- Not Recommended
NOTES: 1. Airflow rates of 1800 CFM or more require two return air connections. Data is for operation with filter(s).
2. Temperature rises in the table are approximate. Actual temperature rises may vary.
3. Temperature rises and airflows for external static pressures greater than 0.5 are for reference only. These conditions are not recommended.
7
INSTALLATION REQUIREMENTS
(
)
Requirements and Codes
This furnace must be installed in accordance with these instructions, all applicable local build­ing codes, and the current revision of the Na­tional Fuel Gas Code (ANSI-Z223.1, NFPA-54). The current revision of the National Fuel Gas Code is available from:
American National Standards Institute, Inc. 1430 Broadway
New York, New York 10018 Canada installations shall comply with CAN/ CGA-B149 installation codes, local plumbing or waste water codes and other applicable codes. Additional helpful publications are:
• NFPA-90A - Installation of Air Conditioning and Ventilating Systems.
• NFPA-90B - Warm Air Heating and Air Conditioning Systems.
These publications are available from:
National Fire Protection Association, Inc. Batterymarch Park Quincy, Massachusetts 02269
!
WARNING:
This furnace is not approved for in­stallation in mobile homes. Installa­tion in a mobile home could cause fire, property damage, and/or personal injury.
Model
Number
G6R(C,D)040C 40,000 14 1/4 12 3 /4 5 1/8 11 3/ 4 133 G6R(C,D)060C 60,000 14 1/4 12 3 /4 5 1/8 11 3/ 4 140 G6R(C,D)080C 80,000 19 3/4 18 1 /4 7 7/8 17 1/ 4 172 G6R(C,D)100C 100,0 00 19 3/4 1 8 1/ 4 7 7/8 17 1/ 4 180 G6R(C, D)12 0C 120,000 22 1/2 21 9 1/4 20 204
G6RL040C 40,000 14 1/ 4 1 2 3 /4 4 5/8 12 3/ 4 135 G6RL060C 60,000 14 1/ 4 1 2 3 /4 4 5/8 12 3/ 4 135 G6RL080C 80,000 19 3/ 4 1 8 1 /4 10 18 1/4 174 G6RL100C 100,000 19 3/4 1 8 1 /4 10 18 1/4 185
Furnace
Btuh
Table 3. Furnace Dimensions and Shipping Weights
AB
Dimensions (inches)
CD
Shipping
Weight
lbs
CLEARANCES TO COMBUSTIBLE MATERIALS
This furnace is Designed Certified by AGA/CGA Laboratories for the minimum clearances to combustible material listed in Table 4. See the furnace name plate, located inside the furnace cabinet, for specific model number and clearance information.
MINIM UM CL EARANCES TO COMBUS TI BLE MATERI AL
Furn ace Cabi net Mi n imu m Cl earan ces (In ch es)
Input Width
(Btuh) (Inches) Side Vent Back Top Front
40, 000 14 1/ 4 0 0 0 1 1* 60, 000 14 1/ 4 0 0 0 1 1*
80, 000 14 1/ 4 0 0 0 1 1* 100,000 19 3/ 4 0 0 0 1 1* 120,000 22 1/ 2 0 0 0 1 1*
* 24 inches is the minimum clearance for servicing. 36 inches is the recommended clearance for service.
Table 4. Minimum Clearances to Combustible Materials
8
Location
The furnace must be installed on a level surface, and as close to the center of the air distribution system as possible. See Table 3 for overall dimensions to determine the required clear­ances in hallways, doorways, stairs, etc. to allow the furnace to be moved to the installation point. The furnace must be installed so that all electri­cal components are protected from water. Minimum clearances to combustible materials are listed in Table 4. Access for positioning and servicing must be considered when locating the unit. 24 inches is the minimum required clear­ance for servicing the unit. 30 inches is the minimum required clearance for positioning the unit. 36 inches is the recommended clearance from the front of the unit. Please note that a panel or door can be located such that the minimum clearance on the rating plate is satis­fied, but that panel or door must be removable and allow the appropriate clearance for your installation.
This furnace is certified for use on wood flooring. The furnace must be installed on a solid surface and must be level front to back and side to side. This furnace must not be installed directly on carpeting, tile, or any combustible material other than wood flooring.
DOWNFLOW WARNING (G6RL Models):
The design of the downflow furnace is certified for natural or propane gas and for installation on non-combustible flooring. A special combus­tible floor sub-base is required when installing on a combustible floor. Failure to install the sub­base may result in fire, property damage and personal injury. The special downflow sub-bases are factory supplied accessories, part numbers 902677 and 902974. When the furnace is in­stalled on a factory or site-built cased air condi­tioning coil, the sub-base is not necessary. However, the plenum attached to the coil casing must be installed such that its surfaces are at least 1" from combustible construction. A gas-fired furnace installed in a residential garage must be installed so that the bottom of the furnace is located a minimum of 15" from the floor. The furnace must be located or protected to avoid physical damage by vehicles.
HORIZONTAL INSTALLATIONS
The G6RC model furnaces are approved for horizontal installation. Installation Kit #903568 is required for horizontal applications. Follow the installation instructions in the kit for proper conversion. NOTE: The G6RD and G6RL mod­els are NOT approved for horizontal installation.
SUPPLY AIR PLENUM INSTALLATION
A. Installation on a concrete slab - G6RL
1. Construct a hole in the floor per the dimensions in Figure 3.
2. Place the plenum and the furnace as shown in Figure 4.
B. Installation on a combustible floor - G6RL
1. Cut and frame the hole in the floor per the dimensions in Figure 5.
2. Place the sub-base for combustible floors over the hole with its duct collar extended downward. Attach the supply air plenum to the base in a manner which will ensure 1" clearance to the flooring or other combustible material. Place furnace on the combustible base as shown in Figure 6.
3. When the furnace is installed on a factory or site-built cased air conditioning coil, the sub-base is not necessary. However, the plenum attached to the coil casing must be installed such that its surfaces are at least 1" from combustible material.
18.75"
19.25"
Hole in
Floor
G6RL 080/100 G6RL 040/060
Figure 3. Opening for Concrete Slab
13.25"
19.25"
Hole in
Floor
9
Concrete
Furnace
Floor
Sheet
Metal
Plenum
Figure 4. Furnace on a Concrete Slab
18.75"
or 13.25"*
16.75"
or 11.25"*
* Smaller dimensions for G6RL 040/060
9.25"
2.0"
28.38"
18.75"
19.63"
Hole in
Floor
G6RL 080/100 G6RL 040/060
Figure 5. Opening in Wood Floor
Downflow
Sub-base
Furnace
13.25"
19.63"
Hole in
Floor
Wood
Floor
Sheet
Metal
Plenum
Figure 6. Furnace on a Wood Floor
CIRCULATING AIR SUPPLY
Plenums and air ducts must be installed in accordance with the Standard for the Installa­tion of Air Conditioning and Ventilating Systems (NFPA No. 90A) or the Standard for the Installa­tion of Warm Air Heating and Air Conditioning Systems (NFPA No. 90B).
1.50"
1.58"
1 inch thick fiberglass 3 lb density
19.75"
or 14.25"*
Figure 7. Downflow Sub-Base Dimensions
If outside air is utilized as return air to the furnace for ventilation or to improve indoor air quality, the system must be designed so that the return air to the furnace is not less than 50°F (10°C) during heating operation. If a combination of indoor and outdoor air is used, the ducts and damper system must be designed so that the return air supply to the furnace is equal to the return air supply under normal, indoor return air applications.
When a cooling system is installed which uses the furnace blower to provide airflow over the indoor coil, the coil must be installed down­stream (on the outlet side) or in parallel with the furnace.
If a cooling system is installed in parallel with the furnace, a damper must be installed to prevent chilled air from entering the furnace and con­densing on the heat exchanger. If a manually operated damper is installed, it must be de­signed so that operation of the furnace is pre­vented when the damper is in the cooling posi­tion and operation of the cooling system is prevented when the damper is in the heating position.
19.63"
3"
10
!
WARNING:
Products of combustion must not be allowed to enter the return air ductwork or the circulating air supply. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous con­ditions including carbon monoxide poisoning that could result in per­sonal injury or death.
All return ductwork must be ad­equately sealed, all joints must be taped, and the ductwork must be secured to the furnace with sheet metal screws. When return air is provided through the bottom of the furnace, the joint between the furnace and the re­turn air plenum must be sealed.
The floor or platform on which the furnace is mounted must provide sound physical support of the furnace with no gaps, cracks, or sagging be­tween the furnace and the floor or platform.
Return air and circulating air ductwork must not be connected to any other heat producing device such as a fire­place insert, stove, etc.
An important consideration in selecting one or two pipe installation is the quality of the combus­tion air. Indoor air is sometimes contaminated with various household chemicals which can cause severe corrosion in the furnace combus­tion system. Some common sources of these chemicals are detergents, bleaches, aerosol sprays, and cleaning solvents. Unless indoor air is known to be free of these materials, two pipe installation is recommended.
Provisions must be made for adequate supply of air for combustion and ventilation. For United States installations, the adequacy of air provi­sions can be determined by consulting the cur­rent version of the National Fuel Gas Code (ANSI Z223.1/NPFA-54). For Canadian installa­tions, requirements are specified in the National Standard of Canada (CAN/CGA B149.1 & .2). Consult local codes for special requirements.
NOTE: If the furnace is operated without ad­equate air for combustion and ventilation, it may not perform properly. Furnace components may be strained by high temperature and could fail prematurely.
!
WARNING:
Furnace installation using methods other than those described in the fol­lowing sections must comply with the National Fuel Gas Code and all appli­cable local codes to provide sufficient combustion air for the furnace.
Return Air
The return air ductwork may be connected to any or all of the following: left side return, right side return, or bottom return. Tables 1 and 2 show the airflow data for each furnace model.
Where maximum airflow is 1800 CFM or more two openings must be used.
VENTING AND COMBUSTION AIR REQUIREMENTS
NORDYNE condensing furnaces may be in­stalled with outdoor combustion air piped di­rectly to the furnace, or without such special piping. Codes refer to the former as "direct vent" or "two pipe" installation. Installation with air taken from around the furnace is sometimes referred to as "one pipe" installation - i.e. only the vent (exhaust) pipe is provided.
G6RC/G6RD
Protective Screen
G6RL
Figure 8. Protective Screen for One Pipe
Installations
11
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