Orion VAV-Zone User Manual

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VAV/Zone Contr oller
Technical Guide
Table Of Contents
Controller Overview ........................................................................................................................................ 3
Features...................................................................................................................................................................................... 3
Controller Inputs and Outputs ........................................................................................................................ 5
VAV/Zone Controller Analog Inputs ............................................................................................................................................ 5
Other Controller Connections ..................................................................................................................................................... 5
Optional - Expansion Board Outputs .......................................................................................................................................... 5
Controller Installation & Wiring ...................................................................................................................... 6
General ....................................................................................................................................................................................... 6
Controller Mounting .................................................................................................................................................................... 6
Important Wiring Considerations ................................................................................................................................................ 6
Modular Devices - Transformer Sizing ....................................................................................................................................... 7
Slaved Zone Damper Wiring ...................................................................................................................................................... 8
Expansion Board Installation & Wiring .......................................................................................................... 9
Wiring Considerations ................................................................................................................................................................ 9
Start-up & Commissioning ............................................................................................................................ 11
General ......................................................................................................................................................................................11
Controller Addressing ................................................................................................................................................................11
Power Wiring ............................................................................................................................................................................ 12
Initialization............................................................................................................................................................................... 12
Programming The Controller .................................................................................................................................................... 13
Sequence Of Operations ............................................................................................................................... 14
Initialization............................................................................................................................................................................... 14
VAV/Zone Configuration & Setup ............................................................................................................................................. 14
Scheduling ................................................................................................................................................................................ 15
Modes Of Operation ................................................................................................................................................................. 15
Damper Positions ..................................................................................................................................................................... 16
Occupied Mode Sequences ..................................................................................................................................................... 16
Unoccupied Mode Sequences .................................................................................................................................................. 17
Damper Control ........................................................................................................................................................................ 19
Tenant Override Logs ............................................................................................................................................................... 20
Zoning....................................................................................................................................................................................... 20
Alarm Detection And Reporting ................................................................................................................................................ 21
Internal Trend Logging.............................................................................................................................................................. 21
Force Modes or Overrides ........................................................................................................................................................ 21
Troubleshooting ............................................................................................................................................ 22
Using LEDs To Verify Operation ............................................................................................................................................... 22
Other Checks ............................................................................................................................................................................ 22
WattMaster Controls Inc. 8500 NW River Park Drive · Parkville , MO 64152 Toll Free Phone: 866-918-1100 PH: (816) 505-1100 · FAX: (816) 505-1101 · E-mail: mail@wattmaster.com Visit our web site at www.orioncontrols.com Form: OR-VAVZ-TGD-01C Copyright 2006 WattMaster Controls, Inc. AAON® is a registered trademark of AAON, Inc., Tulsa, OK. WattMaster Controls, Inc. assumes no responsibility for errors, or omissions. This document is subject to change without notice.
Controller Over view
T ec hnical Guide
Features
VAV/Zone Controller
This manual applies to the VAV/Zone controller that is included in the following Orion products:
OE742-XX-VAVZ VAV/Zone Package
Pressure Dependent
OE744-XX-VAVZ VAV/Zone Package
Pressure Independent
OE520-XX VAV/Zone Round Damper
Assembly - Pressure Dependent
OE521-XX VAV/Zone Round Damper
Assembly - Pressure Independent
OE736-XX VAV/Zone Rectangular Damper Kit
The VAV/Zone Controller is used for controlling airflow and operation of VAV or Zoning terminal units. It is a programmable digital controller which allows for program setpoints to be stored in non-volatile memory. The controller is connected to a room sensor via a modular cable as­sembly which monitors space temperature allowing the VAV/Zone con­troller to modulate a damper in response to space temperature, duct temperature and airflow requirements in the controlled space.
The VAV/Zone controller has four integral modular jacks for connec­tion to the actuator, airflow sensor (for pressure independent applica­tions), room sensor and relay or analog expansion boards, via modular cables. Molex cable connections are provided for the 24 VDC power and system communications. A quick connect terminal connector is also supplied for connection of the Modular Service Tool to facilitate pro-
gramming of the controller. The controller has an on-board dip switch provided for board addressing.
The VAV/Zone controller is provided with two relays for tri-state con­trol of the damper actuator. All outputs and the relay common are elec­trically isolated from all other circuitry on the board. All relay outputs are supplied with transient suppression devices across each set of con­tacts to reduce EMI and arcing. The relay output contacts are rated for pilot duty control of a maximum of 2 Amps @ 24 VAC or 24 VDC. The actuator connects via a modular cable to the board and provides the VAV/Zone controller with feedback monitoring for precise positioning of the actuator.
OE322 Output Expansion Boards
The OE322, 3 Relay with Analog Output Expansion board is used in conjunction with the VAV/Zone Controller board to allow for control of VAV and Zone terminal units, including series and parallel fan terminal units with up to 3 stages of electric heat or modulating hot water heat. The OE322, 3 Relay with Analog Output Expansion board provides 3 relay outputs for pilot duty switching control, and 1 Analog output for control of a 0-10 V modulating hot water valve.
The OE322 Output Expansion board connects to the VAV/Zone controller board by means of a modular cable provided with the expansion board. Power is supplied to the board by means of this modular cable. Screw terminals are provided for connection of field wiring to the relay and analog outputs.
The relay outputs are N.O. contacts with one common terminal. All outputs and the relay common are electrically isolated from all other circuitry on the board. All relay outputs are supplied with transient suppression devices across each set of contacts to reduce EMI and arcing. The relay output contacts are rated for pilot duty control of a maximum of 2 Amps @ 24 V AC or 24 VDC. The analog output provides a 0 – 10 VDC modulating signal output into a 1K ohm minimum load.
6.30”
U4
R21
R22
CX7
ACTUATOR
PJ2
C1
C3
R9R8R7R6R5
Q3
C9 C10 C11
PJ3
SCAN
K1 K2
IN
R10
R14
R15
D5
D1
Q1
C6
U5
REC
C8
R19
R20
R18
L1
C13
PWR
GND
AIN
RV1
AUX
TB2
D2
P1
Q2
D3
OUT
R33
R36
VR1
R37
R23
U8
HAND HELD
P3
R32
C14
P2
CX8
R16
D4
R35
4.00"
EEPROM
U1
C2
C4
VAVZ CONTROLLER
YS101854 REV.2
CX9
PAL
CX10
U9
CX11
4
U6
RN1
PJ1
1
ADD
R1
U2
JP1
CX3
R3
R4
WDOG
C5
CX4
C7
JP2
R38
C12
U7
R24
R25
U10
AIRFLOW SPACE SENSOR
U11
PJ4
NET
8
32162
CX1
SW1
X1
U3
CX6
EPROM
EXPANSION
Figure 1: V AV/Zone Controller Dimensions
V AV/Zone Controller 3
Technical Guide
Controller Over view
Figure 2: OE322 Output Expansion Boards
RAM Chip
Snap Track For Controller Mounting
Air Flow Sensor Modular Connector
Space Temp Sensor Modular Connector
AUX- Supply Air Sensor Wiring Terminals (When Used)
Power LED
Communications Driver Chip
EPROM Chip
C14
PAL Chip
U9
CX11
U11
PJ4
PJ3
TB2
AUX
R33
VR1
R32
PAL
CX10
EPROM
RN1
U10
R24 R25
U7
AIRFLOW
SPACE SENSOR
AIN
GND
PWR
RV1
C12
R22
R21
CX7
R14
D5
R15 R19
C13
U8
CX8
R20
R18
L1
D4
R35 R36
R23
R37
P3
Typical Pin 1 Indicator
VAVZ CONTROLLER YS101854 REV. 2
CX9
U3
CX6
U6
JP2
C7
CX4
R38
U4
C9 C10 C11
SCAN
REC
U5
C8
R16
HAND HELD
P2
C2
C4
CX3
C5
WDOG R3
R4 R5 R6 R7 R8 R9
Q3
C3
R10
C6
Q1
D1
D3
Q2
D2
OUT
P1
U1
X1
C1
EEPROM
CX1
SW1
NET
32
16
8 4 2
1
U2
ADD
R1
JP1
Address Switch (Set Between1&58)
Jumper For Pressure
Independent Airflow
PJ1
Operation. Must Be On
EXPANSION
For High Velocity Terminal Configurations And Removed For Low Velocity Applications
PJ2
ACTUATOR
Expansion Board Modular Connector
Damper Actuator Modular Connector
“SCAN” LED
“REC” LED
K1
Damper Actuator Positioning Relay “Open”
K2
IN
Damper Actuator Positioning Relay “Close”
Mini DIN Connector Connect Modular Service Tool Here For Programming
Figure 3: V AV/Zone Controller Component Locations
4
Modular Cable Connectors Connects To Modular Cable From Power/Com Board And Connects To Next Controller On Loop Supplies 24 VAC Power and RS-485 Communications In And Out Of Controller
V AV/Zone Controller
Controller Inputs and Outputs
T ec hnical Guide
The following inputs and outputs are available on the VAV/Zone con­troller and the OE322 Output Expansion Board that can be added by connecting it to the main controller board expansion port. For compo­nent locations of the inputs on the VAV/Zone Controller see Figure 3. For wiring of inputs and outputs see Figure 4 thru 9.
V AV/Zone Controller Analog Inputs
Input #1: Space Temperature
The Modular Room Sensor that reads space temperature is attached to this input. The Modular Sensor connects via a modular cable to the VAV/Zone controller. If the optional push-button override sensor is in­stalled, this input will detect user overrides from unoccupied back to occupied operation for a user adjustable amount of time.
Input #2: Airflow Sensor
If the VAV/Zone Controller is to be configured for pressure indepen­dent operation, you need to install the OE274 Airflow Sensor and con­nect the modular plug from the pressure sensor to this input. The pres­sure signal from the Airflow Sensor is used for CFM (airflow) calcula­tions. If an OE274 Airflow Sensor is attached to this input, the VAV/ Zone controller will automatically detect this and switch to pressure independent operation. If the sensor is not attached or becomes defec­tive, the controller automatically reverts to pressure dependent opera­tion. When the VAV/Zone controller is used for pressure independent applications, the JP2 jumper must be “ON” for high velocity systems and “OFF” for low velocity systems. Typically VAV systems are me­dium to high velocity and voting systems are low velocity . As a rule of thumb, if the velocity through the terminal unit is below 1500 FPM, remove the jumper and if above 1500 FPM, leave the jumper on. If it is a low velocity system, in addition to removing the jumper, the configu­ration option: “Is This a Voting System” must be YES, even on a VAV system. If the CFM is greater than the values listed for the terminal inlet size above, the JP2 jumper on the VAV/Zone controller must be in­stalled and the system must be configured as a “Non-Voting System. If this is a high velocity voting system the box must be configured as a” voting box” but the system must be configured as “non-voting system” in order for the airflow sensor to read correctly . See Figure 3 for jumper location on board. See Table 1 for low velocity inlet CFM informa- tion.
Maximum Inlet CFM for Low Velocity (1500 FPM)
Inlet Size
6” Dia. 260 8” Dia. 500 10” Dia. 775
12” Dia . 1100 14” D ia. 1550 16” Dia. 2025
Notes:
1.) These va lues are averages and will vary between terminal unit manuf actu rers.
Table 1: Maximum Inlet CFM for Low Velocity
Input #3: Aux - Supply Air Temperature Sensor
A Supply Air Temperature Sensor can be connected to these terminals. It should be mounted in the supply duct close to the terminal unit where the VAV/Zone controller is installed. This sensor can be used for moni­toring purposes or in place of the Supply Air Temperature Broadcast from the VCM Controller.
Note: All temperature sensors must be Thermistor Type III.
JP2 Jumper Removed
Box
CFM
Inlet Size
Box
CFM
Inlet Size
Box
CFM
Other Controller Connections
Expansion Board Modular Connector
This modular connector is used to connect the optional OE322 Output Expansion Board to the VAV/Zone controller. These boards are only required when electric or hot water heating and/or fan terminal control is required. The expansion boards are not required for cooling only terminal units.
Actuator Modular Connector
This modular connector is used to connect a modular cable from the VAV/Zone controller to a tri-state actuator.
Power/Comm Modular Connectors
These two modular connectors, (labeled P1 & P2) are used to connect modular cables from the Power/Comm board that supplies 24 V olt power and communications to the controller and to supply 24 Volt power and communications to the next controller on the local loop.
Modular Service Tool DIN Connector
This connector is used to connect a cable between the Modular Service T ool and the VA V/Zone controller for programing and configuration of the VAV/Zone controller.
Optional - OE322 Expansion Board
As previously stated when control of a fan or if heating is required the OE322 Output Expansion board must be used.
Relay Output #1 - Fan Enable
The first expansion relay on the Output Expansion boards is used for enabling the fan for Series or Parallel Fan Terminal Units.
Relay Output #2 - Stage 1 Heating
If you have at least one stage of auxiliary heating, this is the relay used to energize the 1st stage of terminal unit heating. This heating stage can either be used with electric heat or On/Off hot water valve control.
Relay Output #3 - Stage 2 Heating
If you have two stages of auxiliary heating, this relay controls the 2nd stage of electric heat. For 3 stage heating, this relay output would be energized for both the 2nd and 3rd stage of heat. See the following section for more information regarding 3 stage heating applications.
3 Stage Heating Applications
If three stages of electric heat are configured, relays #2 and #3 will stage in a staggered sequence. This allows you to achieve 3 stages of heating using only relays #2 and #3. Each of the 3 heating elements should be sized for 1/3 of the total KW output required. Both the 2nd and 3rd stage heating contactors (C2 & C3) must be connected to Relay Output #3. See Table 2 for relay sequencing information.
Stage No. Relay Output #2 Relay Output #3
#1 ON (C1) OFF (C2 & C3) #2 OFF (C1) ON (C2 & C3) #3 ON (C1) ON (C2 & C3)
Table 2: Relay Sequencing For 3 Stage Heating
24 VDC Power Terminals (+V & GND)
These terminals can supply 24 Volts DC for a 24 VDC hot water valve actuator if desired. This output is rated at 12 Watts maximum load.
Analog Output
If you are using hot water or steam heating via a modulating steam or hot water valve, this output can supply a 0-10 Volts DC signal for pro­portional control of the valve.
V AV/Zone Controller
5
Technical Guide
Hi
Lo
Controller Inputs and Outputs
Airflow Probe & Sensor
(For Pressure Independent Applications Only)
Airflow
Room Sensor
W
A R M E R
NORMAL
C O O
OVR
L E R
Supply Air Temperature Sensor
(See Note 3)
Locate In Supply Duct
Near Zone Damper
Notes:
1.) All wiring to be in accordance with local and national electrical codes and specifications.
2.) Use Orion prefabricated modular cables for connection between the VAV/Zone controller, the Power/Comm Board and between each VAV/Zone controller on the loop.
3.)The Supply Air Sensor is not required when the VAV/Zone Controller is connected to an Orion VAV/CAV Unit Controller board. A global supply air temperature is broadcast by the VAV/CAV Unit Controller. The Supply Air Sensor is only required if the VAV/Zone Controller is required to operate as a “Stand Alone” controller. It can also be used on VAV/Zone controllers that have reheat to monitor the box discharge air temperature.
VAV/Zone Controller Board
U9
R25
PJ4
AIRFLOW
PJ3
SPACESENSOR
TB2
AIN
GND
P2
P1
Power/Comm Cable To Next VAV/Zone Controller or Power/Comm Distribution Board
Zone Actuator
10
SW1
NET
32
16 8 4 2 1
ADD
PJ1
EXPANSION
PJ2
ACTUATOR
To Optional Relay Expansion Board
Power/Comm Cable From Power/Comm Distribution Board Or Previous VAV/Zone Controller
Figure 4: V AV/Zone Controller Wiring
Controller Installation & Wiring
General
Correct wiring of the VAV/Zone controller is the most important factor in the overall success of the controller installation process. The VAV/ Zone controller wiring has been simplified by the use of modular con­nectors and prefabricated modular cables.
Controller Mounting
If the Round Zone Dampers or Rectangular Zone Damper Kits were purchased from WattMaster, the controller and actuator are factory mounted and wired in the damper control enclosure. If your VAV/Zone controllers are pressure independent, an airflow probe and pressure sen­sor will also be factory mounted and wired.
Most terminal unit manufacturers will offer the option of factory mount­ing the Orion controls in their terminal units for an additional charge. An installation worksheet and instructions are available for the Orion V AV/Zone controller package which can be shipped with the V AV/Zone control(s) to the terminal unit manufacturer to simplify third party fac­tory mounting and wiring of the controller.
When the VAV/Zone controller is to be field mounted, it is important to mount the controller in a location that is free from extreme high or low temperatures, moisture, dust and dirt. The VAV/Zone controller board must be mounted within 10” of the damper actuator in order for the actuator cable to extend between the controller and the actuator.
Be careful not to damage the electronic components when mounting the controller. Remove the controller from its snap track mount. Mark the control enclosure base using the snap track as a template. Drill pilot holes in the enclosure base and secure the snap track to it using sheet metal screws. Do not allow metal shavings to fall onto the circuit board. Reattach the controller to the snap track. Mount the damper actuator to the damper shaft following the instructions supplied with the damper actuator.
Important Wiring Considerations
Please carefully read and apply the following information when wiring the VAV/CA V controller. See Figur e 4 for VA V/Zone controller wiring diagram.
1. Size and wire the Power/Comm Board transformer per the instructions. Failure to size the transformer and/or wire the Power/Comm board correctly may cause the VAV/Zone controllers to operate erratically or not at all. See Figure 5 for wiring and transformer sizing information.
2. If a Supply Air Sensor is to be connected, the minimum wire size used should be 24 gauge.
3. Do not pry on the connectors when connecting or disconnecting the modular cables. Be sure to push in on the connector release clip and then pull straight up.
6
V AV/Zone Controller
16 Devices At 6 VA = 96 VA Use 100 VA Transformer
6 Devices Maximum Per Branch Circuit
T ec hnical Guide
13 Devices At 6 VA = 78 VA Use 80 VA Transformer
Power/Comm
Board
120 / 24VAC
100 VA
Transformer
Minimum
See Warning
Note Below
12 Devices At 6 VA = 72 VA Use 75 VA Transformer
120 / 24VAC
75 VA
Transformer
Minimum
See Warning
Note Below
A
Power/Comm
Board
A
Power/Comm
Board
120 / 24VAC
80 VA
Transformer
Minimum
See Warning
Note Below
Total length of all modular cables used on each branch ( A to B) cannot exceed 240 Ft.
6 Devices Maximum Per Branch Circuit
6 Devices At 6 VA = 36 VA Use 40 VA Transformer
120 / 24VAC
40 VA
Transformer
Minimum
See Warning
Note Below
A
Power/Comm
Board
A
Total length of all modular cables used on each branch ( A to B) cannot exceed 240 Ft.
Figure 5: V AV/CAV Controller Transformer Sizing
Modular Devices - Transformer Sizing
Modular devices include the VAV/Zone Controller, Modular System Manager & MiniLink Polling Device. All of these devices connect to each other and a Power/Comm Board using prefabricated modular cables. When sizing transformers for these devices it is important to design your layout so that the fewest number of Power/Comm distribution boards and the least number of transformers can be used.
In order to simplify wiring design and layout with modular devices the following rules apply:
1. Power/Comm Board maximum transformer size = 100 VA. This is due to the board circuitry and fusing. Each modular device is to be calculated at 6 VA. This allows for a maximum of 16 devices per Power/Comm board. If more than 16 devices are required, multiple Power/Comm boards must be used. Any Slaved Zone actuators used are considered a modular device and must be accounted for at 6 VA. each. They also must be included in the branch circuit maximum quantity of 6. See rule #2 below.
2. No more than 6 modular devices allowed per branch circuit. (Each Power/Comm board has 4 branch circuits available on the board )
3. The longest total run per branch circuit is 240 Ft. This is due to voltage drop on the prefabricated cable. If cable runs longer than 240 Ft. are required, additional Power/Comm board(s) can be used. Each Power/Comm Board connected in series with the first Power/Comm Board would allow for an additional 240 Ft. of modular cable to be added to the total cable run length.
See Figure 5 for information and some examples of transformer sizing and branch circuit design.
Warning: Do not ground the 24 V transformer that is to be
used with the Power/Comm boards. Grounding of the transformer will damage the Power/Comm board and all boards connected to it. A separate transformer must be used for each Power/Comm board. No exceptions. Do not connect any other devices to the transformer used for the Power/Comm board.
V AV/Zone Controller
7
Technical Guide
Controller Installation & Wiring
HZ000095
EXPANSION
ACTUATOR
PJ2PJ1
(OE324) ZONE CONTROLLER BOARD
OE520, OE736, OE742
SLAVED- ZONE ACTUATOR #2
(WHEN USED)
OE523, OE738, OE282-03
ZONE ACTUATOR #1
(MASTER)
10
OE282
HZ000095
MODULAR CABLE
SLAVED-ZONE ACTUATOR #1
1 10 0
OE523, OE738, OE282-03
MODULAR CABLE
(PL101824) BYPASS AND
OE267
SLAVE INTERFACE CARD
CLOSE
OPEN
TB1
GND
FDBK
CLOSE
OPEN
GND
PJ2
FROM ZONE
CONTROLLER
TB2
PJ1
TOACTUATOR
LD2
OPEN
SLAVEINTERFACE
YS101824
LD1
CLOSE
BYPASSAND
OE282 OE282
MODULAR
CABLE
(PL101824) BYPASS AND
SLAVE INTERFACE CARD
TOACTUATOR
BYPASSAND
SLAVEINTERFACE
YS101824
PJ1
GND
OPEN
TB2
CLOSE
OPEN
CLOSE
FROM ZONE
CONTROLLER
PJ2
LD2
LD1
FDBK
GND
TB1
OPEN
CLOSE
HZ000095
NOT USED FOR THIS APPLICATION
(PL101824) BYPASS AND
SLAVE INTERFACE CARD
Figure 6: Slaved Zone Wiring & Connection Diagram
Slaved Zone Damper Wiring
For large zones it may be necessary to have more than one air damper controlled by a VAV/Zone controller and its associated space sensor. The Orion system allows for connecting up to two additional slaved zone dampers to the master VAV/Zone controller. Slaving is not avail-
able for pressure independent damper applications.
Note: Each slaved actuator is considered a modular device rated
at 6 VA each. This 6 VA load must be included in the transformer sizing and branch circuit calculations for the Power/Comm board. See the previous section regarding transformer sizing of the Power/Comm board for com­plete information.
MODULAR
CABLE
HZ000095
TOACTUATOR
BYPASSAND
SLAVEINTERFACE
YS101824
PJ1
GND
OPEN
TB2
CLOSE
FDBK
GND
OPEN
CLOSE
NOT USED FOR THIS APPLICATION
CLOSE
LD1
OPEN
FROM ZONE
CONTROLLER
PJ2
LD2
TB1
T wo Slave W iring Adapters (OE267) consisting of a slave wiring inter­face card and modular cable are supplied with the OE523 Round Slaved Zone Damper, OE738 Slaved VAV/Zone Rectangular Damper Kit and the OE282-03 Slaved VAV/Zone Damper Kit. These are required when attaching slave actuator(s) to the master zone damper. One slave wiring interface card should be mounted in the control enclosure of the master VAV/Zone controller. It is mounted by fastening the plastic snap-track to the control enclosure with sheet metal screws provided. The other card is mounted in the control enclosure of the slaved zone damper. Fasten it in the control enclosure of the slaved zone damper as was previously done with the master VAV/Zone controller. Run 24 AWG minimum wire between the slave wiring interface cards. Connect modu­lar cables to the slave wiring interface cards and to the zone actuators as shown. See Figure 6 for complete wiring details.
8
V AV/Zone Controller
Expansion Board Installation & Wiring
T ec hnical Guide
Figure 7: Expansion Board Wiring For Two Position Hot Water Heat Applications
Wiring Considerations
Warning: The 3 relay outputs available on the OE322
Expansion boards are used to supply extra relays and/or analog outputs to control fan and heating functions for the VAV/Zone controller.
When Round VAV/Zone Dampers or Rectangular VAV/Zone Control­ler Kits are ordered from WattMaster, the OE322 Expansion board is shipped loose for field mounting by others.
Mounting of the OE322 Expansion Board is identical to the previously described mounting for the VAV/Zone controller. Mount the Expansion board near the VAV/Zone controller using the sheet metal screws pro­vided. Be sure the mounting location is close enough so that the sup­plied modular cable will reach from the VAV/Zone controller to the Expansion board.
The wiring consideration information previously outlined for the VAV / Zone controller should be followed when wiring the OE322 Expansion Boards.
Output Expansion board are each rated for 2 Amps @ 24 VAC. If your device load exceeds these limits, a pilot duty relay (by others) must be used in the circuit.
V AV/Zone Controller
9
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