SERVICE MANUAL
MODUL-LINE
BUILT-IN INDUCTION COOKERS
C
CM
86037
MODEL: IN/MO 7000
GARLAND COMMERCIAL INDUSTRIES
185 East South Street
Freeland, Pennsylvania 18224
Phone: (570) 636-1000
GARLAND COMMERCIAL RANGES, LTD.
1177 Kamato Road, Mississauga, Ontario L4W 1X4
CANADA
Enodis UK LTD.
5E Langley Business Centre
Station Road, Langley SL3 8DS Great Britain
Phone: 01753 485900
Phone: 905-624-0260
Fax: (570) 636-3903
Fax: 905-624-5669
Fax: 01753 485901
Part # 4526029 (02/22/11)
© 2008 Garland Commercial Industries, Inc.
TABLE OF CONTENTS
SECTION 1 – REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Authorized Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
“Operation Instructions“ Knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Knowledge Of Electronic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 – SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Block Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Voltage Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 3 – INITIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pan Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 4 – TROUBLE SHOOTING AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Error-Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Repair Of Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Generator Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pan detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Repair by Garland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 – APPENDIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rectifier Circuit Board C014. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CPU-Circuit Board C018 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Circuit Board C026 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rectifier And Transistor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Part # 4526029 (02/22/11)
Page 3
SECTION 1 – REQUIREMENTS
Authorized Personnel
Knowledge Of Electronic Systems
The operator has to insure that all installation, maintenance
and inspection work is carried out by authorized and
qualified personnel who has done a training course at Inducs
Ltd.
The service- and maintenance operator must have
knowledge of the following components :
•
•
•
•
Diodes
Z-Diodes (Zener-Diodes)
Rectifiers (2phases and 3phases)
Power transistor (IGBT)
“Operation Instructions“ Knowledge
In order to do service work on an induction generator,
the operator must have an extended knowledge of the
“Operating Instructions“.
The operator must know how to measure the electric
potential, current and resistors by means of a digital
multimeter. He also has to know how to check diodes with a
diodes tester.
Page 4
Part # 4526029 (02/22/11)
SECTION 2 – SYSTEM DESCRIPTION
Block Schematic
c026
230VAC
24VDC
ST1
23VAC
208VAC
300VDC
L1,L2,L3
filter coil
c014
230VAC
PE
1x,2x,3x,4 x
LED
24VDC
ST1
ST5
ST2/3,4
4
4
4
ST4
8
5
ST8
CPU
heatsink
ST6
c014
ST2/1,2
c018
coil
M
ST7
ST1/1,4
supply
24VDC
Relay
24VDC
fan
230VAC
Part # 4526029 (02/22/11)
Page 5
•
•
Coil temperature
Voltage Supply
Ambient temperature
The power board voltage supply is wired with the power
contactor. On starting the generator, voltage is supplied to
the power board. The transformer is connected directly at the
entrance of the power supply. The transformer supplies two
different voltages: 230VAC for the power contactor and the
fan as well as 23VAC for the low voltage supply. The 23VAC
are changed on the circuit board C026 to 24VDC.
The power switch (IGBT), the fan as well as the display are
managed in response to these factors.
Display
Two elements are used for this display:
1. LED-group (LED1 - LED8) on the CPU-Circuit board (C018)
2. External lamps (24V), maximum 5 pieces
The following components are supplied with 24VDC:
•
•
•
•
CPU-circuit board (C018)
IGBT (C026)
The five external lamps are connected with the five LED’s
(LED1-LED5). Please distinguish between operation lamps
and error lamps. The operation lamp shows what kind of
operation for the respective field:
Fan relay (C014)
External lamps
•
•
•
Lamp out:
Field is cut out
Power Board
Lamp flashes briefly Pan detection (pan is searched)
As already stated, the power board is supplied by the power
contactor. The mains current is measured by a current
transformer, directly at the entrance of the 3-phases-rectifier,
After the rectifier there is a direct voltage of 300V. The
inductance that follows filters high frequency (EU) current .
Lamp flashes an error code:
Messages table)
Error message (see Error
Power on
•
Lamp continuously on:
At the following power switch (IGBT) an alternating current
of approximately 20kHz is generated. This alternating current
(coil current) is transferred to the induction coil. At the exit
of the circuit board (C026), the coil current is measured by a
current transformer.
The error lamp indicates an error function.
LED1 to LED4 lead to external lamps on the outside, they are
used as operational lamps or as error lamps, depending on
the generator type. If an operation lamp or an error lamp is
shared by two fields (for example the surface covering this
induction type) the display can be overwritten from another
field. As far as the error code display is concerned, the lower
field has priority.
Control unit
The control unit is the heart of the generator. This is the CPU-
circuit board (C018) with an integrated microprocessor which
manages the whole control system.
LED5 lead to the outside for an external lamp also. This is the
general error lamp for all fields all the time.
The following data are measured:
In an error, LED6 to LED8 show the error code, but only until
error code 7. If this happens in some errors, the lower field
and the lower error code have priority.
•
•
•
•
Coil current
Phases current
Performance rate (Poti)
Heat sink temperature (IGBT)
Page 6
Part # 4526029 (02/22/11)
Error Messages
LED 8 LED 7 LED 6 Code
Signification
No error, normal function
NOTE
—
—
—
—
On
On
On
On
—
—
—
—
—
—
—
—
—
—
On
On
—
—
On
On
—
—
—
—
—
—
—
—
—
On
—
On
—
On
—
On
—
—
—
—
—
—
—
—
—
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
No coil current, overdrive caused by non induction pan
High coil current, overdrive by non induction pan
Temperature heat sink too high
Temperature heating area (coil) too high
Potentiometer defected , wiring disconnected
Temperature inside the unit too high
1
2
Heating area – coil sensor short circuit
Communication error (serial interface)
1. The induction unit can only be started again if the fault has been acknowledged (turn power
rotary knob“off“)
2. The induction unit continues working but the temperature of the cooking platform is not
controlled anymore.
Part # 4526029 (02/22/11)
Page 7
SECTION 3 – INITIAL OPERATION
Function control
Power
To check the function controls, the induction generator must
be totally connected.
Place an“induction ready”pan with a diameter of 22-24cm
(8.5”-9.5”) onto the coil. Measure the generator power
at maximum level. This should be at the nominal power
(tolerance +/- 10%). This procedure must be repeated for
every coil.
Display
1. The external lamps must be checked.
Fan
2. The operation lamp flashes if a coil is not used (Searching
function).
Place various pans on the coils and start the generator on
the highest level. After a few minutes the fan should start.
The fan is controlled by the temperature and starts when the
heat sink temperature is about 50ºC/122ºF.
3. This procedure must be repeated for every coil.
Pan Detection
To check the pan detection, two pans are needed: one with a
diameter of 8cm (3”) and the other with a diameter of 12cm
(4.75”) .Only the pan with a diameter of 12cm (4.75”) should
be detected. A coil should not start operation when it is not
being used.
This procedure must be repeated for every coil.
Page 8
Part # 4526029 (02/22/11)
SECTION 4 – TROUBLE SHOOTING AND REPAIRS
This section includes a list of the main errors, their causes and the respective steps to correct.
Trouble Shooting
Error-Code
Problem
Possible Cause
Measure
Code No.
No
No
No
W
Normal operation
Compare on another
M10 cooking platform and with
an induction type pan
No coil current
Hardware overcurrent
1
2
S01
S02
U10 Non induction type pan
U11 Coil defective
E
M11 Check coil
L
L
Power circuit board
defective
Replace power circuit
board
U12
M12
Compare on another
M10 cooking platform and with
an induction type pan
High coil current
Software overcurrent
U10 Non induction type pan
E
Power circuit board
defective
Replace power circuit
board
U12
M12
L
L
L
Error on DIP-Switch-
U13
Check DIP-Switch
M13
adjustment on CPU
adjustment
CPU-circuit board
defective
U14
M14 Replace CPU-circuit board
Air entrance/exit
U30
3
S03 Temperature heat sink
M30 Clear air transport
E/L
obstructed
U31 Dirty fan/heat sink
U32 Fan defective
M31 Clean fan
M32 Check fan
L
L
Rectifier circuite board
defective
Replace rectifier circuit
board
U33
M33
L
L
L
Check sensor and heat
sink
U34 Sensor Heat sink defective M34
CPU-circuit board
U14
M14 Replace CPU-circuit board
defective
Temperature cooking
platform
4
5
S04
U40 Empty cooking
M40 Empty pan
E
L
U41 Interruption of coil sensor
M41 Check coil sensor
Operational control
Line break
Operational control
defective
S05
U50
M50 Check operational control
L
Legend: W = Who should complete“Measure” E = End user L = Supplier
Part # 4526029 (02/22/11)
Page 9
Problem
Possible Cause
Measure
Code No.
No
No
No
W
Normal operation
Ambient temperature too
high
Check ambient
temperature
6
S06 Inside temperature
U60
U14
M60
L
L
CPU-circuit board
defective
M14 Change CPU-circuit board
Sensing element
U70 Coil temperature
Short circuit
Cooking platform
S07
Check coil sensing
element
7
M41
L
Sensing element
8
9
S08
S09
Communication error
(Serial interface)
10 S10
U100 Line break
M100 Check connection
M101 Replace operation
M14 Replace CPU-circuit board
L
L
L
Operational control
defective
U101
CPU- circuit board
defective
U14
11 S11
12 S12
13 S13
14 S14
15 S15
Legend: W = Who should complete“Measure” E = End user L = Supplier
Page 10
Part # 4526029 (02/22/11)
Additional Errors
Problem
Possible Cause
Measure
Code No.
No
No
No
W
Operation lamp is continuously “ON”
Compare on another
M10 cooking platform and with
an induction type pan
Cooking platform does not
heat enough
S20
U10 Non induction type pan
E
Check mains cable
M200
U200 1 phase is missing
L
L
L
connection
Replace power circuit
board
U12 Power board defective
M12
CPU-circuit board
defective
U14
M14 Replace CPU-circuit board
Cooking platform
S21 continuously on
maximum power
Operational control
defective
U50
M50 Check operational control
M14 Replace CPU-circuit board
L
CPU-circuit board
defective
U14
L
L
Power circuit board
defective
Replace power circuit
U12
M12
board
Empty cooking platform
switches “on“
S22
U220 Pan detection defective
M220 Check pan detection
M220 Check pan detection
M240 Use appropriate pan
L
L
E
Little metallic objects are
S23 heated on the cooking
platform
U220 Pan detection defective
No.
Operation lamp flashes
Cooking platform does not
heat at all
Pan too small (Diameter
U240
S24
less than 12cm, 4.75”)
Check connection of
M200
U200 1 phase is missing
L
L
L
mains cable
U220 Pan detection defective
M220 Check pan detection
Replace or repair
generator
U241 Short circuit on generator M241
Legend: W = Who should complete“Measure” E = End user L = Supplier
Part # 4526029 (02/22/11)
Page 11
Problem
Possible Cause
Measure
Code No.
No.
No
No
W
Operation lamp and error lamp “OFF”
Unit does not heat, no
S25 reaction, contactor does
not work
Building’s power fuses
U250 defective, error on
electrical transmission
M201 Check mains supply
L
L
Error on operational
control
U251
M251 Check operational control
Building fuses blow when
S26
Repair or replace
M241
U241 Short circuit in generator
U271 Generator defective
L
L
L
unit is switched on
generator
Some cooking platforms
do not heat
Repair or replace
M241
S27
generator
Unit does not heat, no
S28
Error on DIP-Switch-
U13
Check DIP-Switch
M13
reaction, no contactor
adjustment on CPU
adjustment
Legend: W = Who should complete“Measure” E = End user L = Supplier
Repair Of Problems
Measure
Activity
Comment
M10
•
Compare on another cooking platform and with an induction
type pan
Check if the pan is appropriate to
induction cooking or not: use a
magnet.
M11
•
•
•
•
•
•
•
•
•
•
•
Check connection of coil
Check coil on line break
Coil overheated (brown color change)
Change power circuit board
Check DIP-Switch adjustment on CPU-circuit board
Replace CPU-circuit board
Clear ventilation system
M12
M13
M14
M30
M31
M32
M33
M34
Clean fan
Connect fan directly at 230V
Change rectifier circuit board
Measure heat-sink temperature sensor resistor
At 25º Celsius (77ºF) resistor will read 20kOhm
At 70º Celsius (158ºF) resistor will read 3,5kOhm
Disconnect temperature sensor
•
•
Check short circuit to case
For a test: short-out the sensor with a 20kOhm fixed resistor
M40
•
Switch off unit, cool down and switch on again. Use a pan with
cold water
Switch off field!
Page 12
Part # 4526029 (02/22/11)
Measure
Activity
Comment
M41
•
Measure the resistance of coil temperature sensor resistor
at 25º Celsius (77º F) resistor will read 1kOhm
Disconnect sensing element
at 180º Celsius (356ºF) resistor will read 3,5kOhm
•
•
•
•
Resistor is higher on a higher temperature (PTC-resistor)
Replace sensor with a value less than 900Ohm
For a test: Short-out the sensor with a 1kOhm fixed RESISTER
M50
Measure operational control or main power control switch with Disconnect operational control
potentiometer: Potentiometer is 10kOhm and linear
(Poti)
•
•
•
•
•
•
•
On level“0”: resistor = 0 Ohm
On maximum level resistance= 10kOhm
Resistor is proportional (linear) to swing angle
Measure temperature inside the case
Admissible ambient temperature: 0°C/32ºF to appr. 70°C/158ºF
Check point is on the CPU-circuit board
M60
M100
Check connection cable for serial operational control and
CPU-circuit board
M101
M200
•
•
•
•
Change serial operational control
Check mains cable, perhaps one phase missing
Check the building fuses
M220
Disconnect ST2 on CPU-circuit board and measure resistance
between brown and blue,
Measured value: 200Ohm < R < 2kOhm
•
•
•
•
•
Replace rectifier circuit board
M240
M241
Use suitable pan material
Test with a pan with a diameter of 24cm (4.75”)
Disconnect mains power supply
Visually inspect : blackened cables, components or strip
conductors?
•
•
•
•
Transistor module: measure internal diodes (UF = 0.4V)
Rectifier: measure internal diodes (UF = 0.5V)
Control trafo: measure electric voltage
Check power supply CPU-print +24V
CPU-circuit board ST1/1 and ST1/4 (24V +/- 1V)
M251
•
Check power switch on operational control
Part # 4526029 (02/22/11)
Page 13
2. Errors can occur after wrong adjustments
3. Only small corrections can be made with adjustments
Generator Type
Adjustments
This induction unit has been correctly adjusted by the
manufacturer. Any adjustments have to be made with
caution. Please pay attention to the following points:
The generator type is adjusted in the binary code with the
DIP-switches 5 to 8 on the CPU-circuit board
1. Note the original position of the poti’s: remember the
number of turns you make.
Switch Position
DIP-Switch for
8
7
6
5
generator type
0
1
2
3
4
5
6
7
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
8
ON
ON
ON
ON
ON
ON
ON
ON
9
10
11
12
13
14
15
ON
ON
ON
ON
ON
ON
ON
ON
Turn clockwise:
acceptance of smaller pans
Switch Power
Turn counterclockwise: only bigger pans are accepted
Summary: software and generator type
Power
The following list shows the number of types of the various
generators.
Only one potentiometer per field is available on the power
circuit board to adjust the power:
Please note the positions of the power switches from the
above table.
Turn clockwise:
less power
DIP
Type
Turn counterclockwise: more power
Switch setting
MO/DU 7000, 208V
MO/DU 7000, 400V
6 and 8 on
5 and 8 on
Repair by Garland
If the generator has to be repaired by the manufacturer,
please enclose an exact description of the error. If possible,
use the original package for the return. If it isn’t available,
do not use porous material for wrapping (like styropor). This
could enter the unit and the electronic parts and is difficult
to remove.
Pan detection
The potentiometer on the rectifier circuit board is used to
adjust the pan detection:
Page 14
Part # 4526029 (02/22/11)
SECTION 5 – APPENDIX
Internal Connections
Rectifier Circuit Board C014
View solder side
poti for pan detector
9
10 11 12
230V Venti
Part # 4526029 (02/22/11)
Page 15
CPU-Circuit Board C018
View components side
external temp'sensor
optinal
1 2
field 4(8
field 4(7
field 3(6
field 3(5
field 2(4
field 2(3
field 1(2
field 1(1
coil-
sensor
1k
field 4(8
field 4(7
field 3(6
heatsink- field 3(5
sensor
20k
field 3(4
field 2(3
field 1(2
field 1(1
field 4(8
field 4(7
field 3(6
field 3(5
field 2(4
field 2(3
field 1(2
field 1(1
DIP-Switch
current-
meas.
signal
1)
2)
3)
field 4(8
field 4(7
field 3(6
field 3(5
field 2(4
4)
5)
6)
7)
8)
connection
to c026
power-
control
(poti 10k) field 2(3
field 1(2
field 1(1
1)
2)
3)
4)
connection
to c014
(4
(3
(2
(1
RS485
optional
1)
2)
3)
4)
5)
6)
7)
8)
lamp 1
lamp 2
lamp 3
lamp 4
lamp 5
3 Poti
optional
+24VDC
Page 16
Part # 4526029 (02/22/11)
Power Circuit Board C026
View components side
power
adjustment
field 1
Connection
with
c018 –
current
measure
signal
power
adjustment
field 2
IGBT pre
drive
IGBT pre
drive
POT1-4 und ST5
logic board
optional
Coil connection
Coil connection
field 1
field 2
Part # 4526029 (02/22/11)
Page 17
Transformer
supply transformer
for logic board
contactor ignition
and fan
230VAC outlet (fan)
230VAC outlet (contactor ignition)
mains supply voltage
( 208V/ 230V / 400V AC)
23VAC outlet (logic supply)
Rectifier And Transistor Module
+
C1
-
+
L3
L2
L1
C2/E1
C2/E1
E2
C1
3
2
1
-
E2
solder side view
rectifier board
solder side view
power board
Item . 1: rectifier
Item 2: transistormodul IGBT
Page 18
Part # 4526029 (02/22/11)
Part # 4526029 (02/22/11)
Page 19
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