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Power you Can Depend On

Receiving parameters at Installation


Safety ConcernsElectrical Hazards

� Potentially High Voltages� High Short Circuit Currents

� Remove personal metal objects� Use insulated tools� Wear full eye protection� Do Not make / break live circuits� Observe circuit polarities� Avoid exposed high voltage points


Chemical Hazards� Batteries contain sulfuric acid electrolyte� harmful to skin and eyes� corrosive to metals� electrically conductive

� Have immediate access to a “Spill Kit”� Protect your person from electrolyte contact and immediately

wash body area and neutralize if contact occurs.� Neutralize any spill

Safety Concerns


Fire Hazards� VRLA Batteries can contain an explosive mixture of gas

� Assure adequate ventilation� No smoking� No sparking� Dissipate personal static charge

Safety Concerns

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A. Visual Inspection

� Proper Ventilation� Container Damage or Excessive Deformation� Terminal Damage or Corrosion� Case to Cover Seal Integrity� General Cleanliness

Receiving conditions


Open Circuit Voltage (OCV)� OCV should be above 12.7V. Unit found below this level are need to

refresh immediately.� Units found below 12.54V are need to test further before put into

service.

Impedance• New battery/cells impedance should be within ±±±±20% of average or from

the base value.• Units found above this range should be tested further before put into

service.• As cell Aged, impedance increase indicating deterioration of internal

components / Dry out of electrolyte

Receiving conditions


� Internal Ohmic testing can be a valuable tool to assist diagnosing batteries but need to understand what the value represents and know the limitation.

� The user should know the measurement varies depending on the manufacturer of meter, model & measurement location.

� The baseline readings can be taken after the installation and must have proper connectors and torque.

� Same meter should be used to get meaningful data.� The determination of battery conditions should be the combination of

maintenance data. (voltage, float current, acid gravity, temperature…) & impedance value.

� The only surefire way to tell the batteries true healthy & the capacity to support the system load is through measured capacity Discharge Test.

Impedance - Facts


� Standby the batteries and the accessories ready for installation� Confirm the rack is ready and safety to load the batteries� Use normal lifting system or 2 persons to carry the batteries� Allow enough space (min 12.7mm) between batteries for proper

ventilation.� Identify the polarity of the battery are in a right position.� Connect the batteries accessories with proper tools and safety.� Be conscious on the polarity during connection.� Measure the voltage and confirm the readings for every string connection� Be sure not making short connection as the discharge current will be high.� Apply the right torque level as mentioned in the battery label.� Label properly on the battery for easy maintenance and troubleshoot in

future.

Installation Guidelines

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Charge & Discharging of VRLA Batteries


Constant Current (CC)An electron flow through a conductor (current) that does not vary significantly from a preset value. To recharge a battery at constant current level, the charging voltage must increase as the battery cell voltages increase.To recharge a battery, addition amount of Ah (10~30%) is required

Ahrecharge = Ahdischarged x 120%

Constant Voltage (CV)A voltage that does not vary significantly From a preset value.When recharging a battery at constant voltage., the current acceptance will decline as the battery cell voltage rises. The battery cannot be discharge at a constant voltage.The battery voltage normally declines during the discharge.


Charging Voltage Vs. Electrolyte SG

2.00

2.05

2.10

2.15

2.20

2.25

2.30

2.35

2.40

2.45

1.18 1.20 1.22 1.24 1.26 1.28 1.30 1.32

Electrolyte Specific Gravity

Vo

ltag

e

OC

Float

Equalize


Constant Voltage - Current Limited

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Recharge Time (Tr) Vs. DOD


Boost ChargeCharging the battery at a Maximum Allowable Voltage for a defined period to ensure the battery is at maximum capacity

Equalize ChargeThe restoration of power in a battery at a Maximum Allowable Voltage for a defined period of time. This brings all the series-connected cells to a maximum state of charge and equalize the charging voltage across the individual cells.

Fast ChargeThe recharge occurring at higher voltage and current capability to restore the battery to 95% State of Charge (SOC) in one to five hours.


Freshening ChargeThe charging of batteries in storage to assure they are maintained in a near maximum State of Charge (SOC) and to ensure there is no deterioration of the battery plates due to self-discharge and sulfation. This process is usually performed using the recommended equalization or cycle service charging voltage.

Initial ChargeThe charge applied to a battery when it is First installed. The initial charging voltage is typically the same as that used for equalization

Float ChargeHaving the battery on continuous charge at a low recommended voltage to maintain the battery at a full state of power while minimizing over-charge.

The voltage for float charge is call Float VoltagePower you Can Depend On

Initial ChargeAll cells are shipped fully charged from the factory with no need for a initial freshening or equalization charge. The cells should be constant voltage charged at the average float voltages as noted in Table 1 below. However, when in storage or transit for an extended period (especially at temperatures above 77°°°°F/25°°°°C) or when the number of cells is greater than 24 cells; it is recommended the battery system be given an initial freshening charge (see Table 1) at installation.

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Cell Type

Average String Float Voltage 77°F

(25°C)

Average String Freshening

Voltage

Freshening / Equalization Charging

Time

VPC VPC Hours

HC 2.25 to 2.30 2.35 +/- 0.02 12 – 16

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Power you Can Depend On18

Notes: a. Individual cell float voltages may vary by +0.10/-0.05 volts from the average

in a single string.

b. Initial battery charge current on the constant voltage recharge should notexceed 25 amps per 100 amp-hour battery rating.

c. Average string float voltage must be adjusted based on temperatures which are above or below 77°F (25°C)

d. Charging time will vary due to temperature if cell temperature is below 16°C,double the charge time for initial or equalize charge.

e. If a battery load test will be performed within 90 days of installation, an initial

freshening charge followed by a 72 hour float charge (per IEEE 1187) is required to ensure full capacity


Equalize ChargeThe restoration of power in a battery at a Maximum Allowable Voltage for a defined period of time. This brings all the series- connected cells to a maximum state of charge and equalize the charging voltage Across the individual cells.

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Under normal operating conditions, it is not necessary to equalize or freshen Liberty MSE batteries.

Equalize charge when cell OCV ≦2.12V during stocks or when cell float voltage below 2.21V


Initial Charge Records At the completion of the initial charge and after the cells have been on float charge for approximately one week, record voltages of the individual cells, the total battery voltage and ambient temperature. Retain this information in your files for future reference. This information establishes a baseline for future reference. The information below must be recorded or refer to RS-1992 found in the Appendix. Make a photocopy of the form and use it whenever necessary to record readings taken on the battery.


Initial Charge Records Battery identifications

1. Date of readings 2. Battery total float voltage 3. Ambient operating temperature 4. Date and description of initial or last equalizing charge 5. General observations from visual inspection 6. Individual cell voltages 7. Connection resistance measurement

*Optional: One of the following for cell ohmic testers: Impedance, Conductance or Resistance

*Cell ohmic readings may vary by ±±±±20% (when new) of the C&D Technologies published values. This variation does not necessarily indicate a problem with the condition of the battery.

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Dry ChargedAn individually formed plate or a completed lead acid battery drained of all electrolyte that has undergone a special drying process. The plate or battery can then be stored for indefinite periods of time with only minor degradation due to sulfation. At a later date, the plate or batter is activated by the addition of the electrolyte and application of a special charging regimen.

Opportunity ChargingUsed with batteries in Cycle Services, it is the charging of the battery between partial discharges rather than waiting for the battery to be completely discharged.

Over ChargingContinued charging of the battery after it has reached 100% capacity. This is mainly caused by a high voltage setting of the charger or the non-regulated dc supply


Temperature Effects on Batteries C&D recommends that the battery be operated at 25°°°°C ±±±± 5.5°°°°C. For ambient temperatures outside the recommended temperature range, the float voltage must be adjusted by 3.6mV per °°°°C. Add 2mV (0.002 volts) per °°°°F or 3.6mV per °°°°C below 77°°°°F (25°°°°C). Subtract 2mV (0.002 volts) per °°°°F or 3.6mV per °°°°C above 77°°°°F (25°°°°C). If the battery is operated at temperatures below the recommended range, the capacity will be reduced even with temperature compensated charging, which must be compensated for during initial system sizing.

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Battery Discharging


What determines the cell discharge voltage?

• Open circuit voltage– SG + 0.84 = OCV

• Load Current (Amps) & Cell Resistance (ohms) – Voltage drop = load current x cell resistance

• Acid (H2SO4) volume, mobility and availability to plates– SG, temperature, element compression and plate spacing

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Charge Retention / Shelf-LifeThe capacity retained following specific Storage conditions & a specific period of Time. This is also means of Shelf Life

Local Action / Shelf-DischargeA reaction between the sulfuric acid and the active materials of the plates resulting in the slow discharge of the plates and forming of lead sulfate on the plates and consumption of the acid in the electrolyte. Local action will declines electrolyte specific gravity & terminal voltage. This is also means of Shelf Discharge (See also Charge Retention). The condition can be reversed by applying a freshening charge. Local action is increased at elevated temperature


Constant Power (CP)DC power in watts = V x I. A constant power discharge occurs when the load current increased during the discharge by an amount proportional to the normal decline in battery voltage.


Standard Discharge RateA function of the intended application, the accepted rate at which the battery delivers current.

Telecom battery –8 or 10 hours rate General Purpose – 20 hours rateUPS battery – 15 mins rate


Depth of Discharge (DOD)The product, expressed as a percentage, achieved by dividing the ampere-hours removed during discharge by the total rated ampere-hour capacity of the battery.

AH discharged = ---------------- x 100%

AH rated

Over DischargingDischarge of a battery to a voltage lower than that recommended for the particular discharge rate.

A 100Ah (@C10, 1.8epv) can be discharged by 10 Amp for 10 hrs to 1.8epv if discharge the battery by 5 amp for 20 hrs,the EPV will be <1.60, the battery is Over Discharged

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Periodic Maintenance of VRLA Battery

& System Reliability


Purpose of Periodic Maintenance:

☺ Maximum System Reliability☺ Longest Battery System Life☺ Indications to Adjust the “System”☺ Indication When to Replace a Block☺ Indication When to Replace the System� Replace prior to failure

Performed in accordance with:� IEEE Std 1188 or�Dynasty VRLA Battery Periodic

Maintenance Instructions 41-7546


The VRLA battery is a lead acid battery which facilitates an Oxygen recombination cycle.

Under normal operation there is minimal gas emission and loss of water from the electrolyte

The electrolyte is immobilized in GEL or Absorbed within AbsorbentSeparator (AGM).

Maintenance Free - there is no requirement nor capacity to add water to the cell or to measure the electrolyte specific gravity.

Maintenance on a Maintenance Free Battery ?


Typical VRLA Battery Systems

� More than one 6 or 12 volt block� Blocks in series to form a higher voltage string� Strings in parallel to develop higher capacity� Chargers with adjustable output voltage� Subject to the affects of the operating environment� Performance degrades with age and conditions� Fixed maximum service life

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Safety Concerns� Electrical Hazards§ Potentially High Voltages§ High Short Circuit Currents

� Remove personal metal objects� Use insulated tools� Wear full eye protection� Do Not make / break live circuits� Observe circuit polarities� Avoid exposed high voltage points


� Chemical Hazards� Batteries contain sulfuric acid electrolyte� harmful to skin and eyes� corrosive to metals� electrically conductive

� Have immediate access to a “Spill Kit”� Protect your person from electrolyte contact and immediately wash

body area and neutralize if contact occurs.� Neutralize any spill


� Fire HazardsVRLA Batteries can contain an

explosive mixture of gas

� Assure adequate ventilation� No smoking� No sparking� Dissipate personal static charge


Periodic Maintenance - Checks√ Check battery appearance and environment√ Check system charging voltage√ Check room and battery temperature√ Check individual block float voltages√ Check high rate load voltage√ Check each blocks impedance /conductance√ Check inter-unit connections√ Check battery system actual capacity� Take corrective action when data so indicates

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Periodic Maintenance & Automated Monitoring

√ Battery Room Visual Inspection *☺ Battery Room Temperature *√ Battery System Visual Inspection *☺ Battery System Float Charging Voltage *☺ Ground Fault Voltage Presence☺ Battery System DC Float Current (if possible) *☺ Battery System AC Ripple Voltage and Current*☺ Individual Block Float Voltage*☺ Battery System Blocks Temperature *☺ Optional Block Impedance/Resistance/Conductance Test*√ Inter-unit Connection Check / Retorque Hardware*

* IEEE std 1188


A. Battery System Visual Inspection� Proper Ventilation� Container Damage or Excessive Deformation� Terminal Damage or Corrosion� Case to Cover Seal Integrity� General Cleanliness


1. System charging VoltageSystem charging voltage setting should be periodically checked as the setting could shifted during the operation.

-For difference brand of battery, they could use difference charging voltage. (eg. From 2.25V/cell to 2.28V/cell)

B. Battery System Float Voltage Check


1 2 3 4 5 6 7 8 n

Charger

System Charging Voltage

System Charging Voltage= Per cell Charge Voltage x n

Where n = No. of cells in series

If per cell charge volt = 2.25; 24 cells in seriesThen System Charging Voltage = 2.25 x 24 = 54V

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-Charging voltage should also need to be changed if the battery room temperature is being changed. (Summer to Winter) A compensation factor of-0.005V/Cell/˚C is normally applied.

-Over charging could result in “dry out”.This will shorten the life of the battery.

-Under charging should be avoided because this could reduce the back up time and also speed up the sulfating process.


2. Individual battery Float Voltage

Keep monitoring the cell float voltage can tell youHow the battery is charged.

No cell is allow to have float voltage below 2.2V/cellOr (13.2V per 6 cells blocks)

No cell is allow to have float voltage over 2.4V/cellOr (14.8V per 6 cells block)

Replace all abnormal cells immediately once found. Otherwise, the other cells in the string will also in Trouble.


3. Individual Battery Float Voltage Check

Individual Cell Voltage = System Voltage / nIf n=24 cells, then Individual cell voltage = 55.2 / 24 = 2.3V

13.9V 13.5V 13.7V 14.1V

Rectifier or Charger

55.2V


� Measure with surface sensor or IR gun� Measure temperature of battery environment

(-15˚C Min. to +50 ˚C Max.)� Measure temperature of battery

(-15˚C Min. to +50 ˚C Max.)(Max. 9 ˚C above environment)

� Measure at block side center or NEG. terminal

4. Ambient temperature(Battery pilot unit temperature)

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-Check the battery room ambient temperature. If required, re-adjust the charging voltage to suit the temperature.

-Lead Acid Battery life can be reduced by 50% for every 15F (or 9 deg C) of temperature rise aboveit’s design temperature.

-Lower the temperature will not extent the batterylife but reduce the efficiency (capacity) of the battery.


5. Battery System Ground Fault Check

� Ground Faults Can Cause Fires and Thermal Runaway

Ground Faults Can Expose you to High Voltage

� Check the voltage from the battery terminal to the rack - should be “0”


6. Battery System AC Ripple Check

∗ AC Ripple voltage will cause the float voltage to vary in amplitude at ripple voltage frequency.

∗ AC Ripple voltage results in AC ripple current through the battery system.

∗ AC Ripple current results in battery heating and reduced battery life expectancy.

∗ Watts = Current Squared X Resistance


7. Float Current CheckTypical Float Current 0f BatteryAGM = 1-2mA/Ah (@C20) Or 1.75mA ~ 375mA/Ah (@C10)GEL = 0.4 – 0.8mA/Ah (@C20) Or 0.5mA~1mA/Ah (@C10)

Float current is proportional to the battery capacity AH Double of the float current (as compare to it was new, fault is on the system)

Charger

A1

A2

At

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8. Inter-unit connection hardware resistance or tightness

Loosen terminal can result in serious thermal issuewhen battery is in discharge process.


10. Battery system capacity test

The best way to identify the remaining capacity ofA battery. This can be test by DC dummy loader or Via the system load.

Once the battery capacity < 80% of it’s rated capacityThe battery defined as fail.


11. Test and record the individual unit resistance, Impedance or Conductance.

� If the average battery system impedance increases by 50% from the original value, conduct a capacity test.

� If an individual block impedance increases by 50% or is 50% greater than the average, determine the cause and need to replace.


12. The “real test” - A Capacity Test� Capacity Test at Acceptance

� Capacity Test @ 2 Yr. Intervals to 90% Rating

� Capacity Test @ 1 Yr. Intervals After 90%Rating

� Capacity Test if 50% Increase in Impedance

� End of Life Considered to be at 80% of Rating

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13. Test and record the individual unit Ripple Voltage

1 2 3 4 5 6 7 8 n

Charger

AC Voltage = ? AC Volt


Required PM Tools and Equipment

� Digital Voltmeter� Socket & Box End Wrenches, Insulated� Torque Wrench - in.-lb.� Personal Protection Equipment� Fire Extinguisher - Class C� Optional Equipment

– 100 Amp momentary load– Micro-ohm meter– Impedance / Conductance meter– System Load Bank


Monthly Maintenance - IEEE Std 1188

√ Battery Room Visual Inspection√ Safety Equipment Available √ Battery Room Temperature√ Battery System Visual Inspection√ Battery System Float Charging Voltage√ Battery Charger Output Current


Quarterly Maintenance

√ Battery Room Visual Inspection *√ Battery Room Temperature *√ Battery System Visual Inspection *√ Battery System Float Charging Voltage and Current*√ Ground Fault Voltage Presence√ Battery System DC Float Current (if possible) *√ Battery System AC Ripple Voltage and Current√ Individual Block Float Voltage√ Battery System Blocks Temperature *√ Connection Resistance for High Rate Applications *√ Block Impedance/Resistance/Conductance Test*

* IEEE std 1188

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Semi-Annual Maintenance

√ Battery Room Visual Inspection *√ Battery Room Temperature *√ Battery System Visual Inspection *√ Battery System Float Charging Voltage *√ Ground Fault Voltage Presence√ Battery System DC Float Current (if possible) *√ Battery System AC Ripple Voltage and Current√ Individual Block Float Voltage√ Battery System Blocks Temperature *√ Connection Resistance for High Rate Applications *√ Optional Block Impedance/Resistance/Conductance Test

* IEEE std 1188


Annual Maintenance

√ Battery Room Visual Inspection *√ Battery Room Temperature *√ Battery System Visual Inspection *√ Battery System Float Charging Voltage *√ Ground Fault Voltage Presence√ Battery System DC Float Current (if possible) *√ Battery System AC Ripple Voltage and Current*√ Individual Block Float Voltage*√ Battery System Blocks Temperature *√ Connection Resistance for High Rate Applications *√ Optional Block Impedance/Resistance/Conductance Test*√ Inter-unit Connection Check / Retorque Hardware*

* IEEE std 1188


009 Annual MeetingBusiness Update

C&D Warranty Claim Procedures


Warranty Claim Procedures

1. PurposeThe purpose of this procedure is to define the standard process flow for Standard

Warranty Claims and Customer Complaints reported to C&D Field Operations Service Department.

2. ScopeThis procedure applied to claims and communication that are presented by

customer to Field Operations. The resolution may involve technical supports, warranty claim and/or corrective action from Quality Control.

3. Warranty DefinitionAll C&D batteries are warranted to be free from defects in material and

workmanship in the given warranty time. Should a claim arise, please refer to C&D limited warranty policy or the agreement/contract signed.

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a) C&D customers / end-users need to fill RS1946A form with the detail description on the claimed issues and send the claim form to C&D Sales office or C&D Shanghai factory Quality Department.

b) If the claim is cosmetic related issues, photos on the claimed issue are required to submit.c) If the claim is capacity / backup performance related, operation conditions and maintenance records are

needed for our review.d) Upon received the claim form, Field Service and QA department will review on all the received information

and feed back to customers / End-users in 5 working days.e) If the claim is accepted, C&D will issue the Credit Memo to Customer or provide the free replacement unit(s)

at ex-work conditions. Customer needs to recycle the failed batteries Locally. f) If the claim is rejected, a format reply by letter will be available.g) If there is a required of site visit, C&D will further communicate with customer / end-user to arrange. h) All claims will then be recorded and case will be closed.

4. Warranty Claim Procedures



a) All claims / complaints will be reviewed by Field Service and QA department.b) If is needed to return the suspected component(s),parts or unit(s), C&D will issue a RMA SCD-720 to

customer / end-user.c) Detail material list, ship to address and contact person will be shown on the RMA form.d) If customers / end-users agree to return the specific materials, shipment cost will be bared by C&D. e) Once the material(s) is returned to C&D, C&D will carry out the necessary tests, examination,

analysis …and the “material” will not return to customers / end-user.f) Analysis report will be available once the tests, analysis are completed. Depending on the type of test and

analysis, the process may need weeks to months.g) If the result is related to warranty claims, the warranty claim procedures on item 4 will be followed.

5. RMA Procedures


Battery Warranty Claim Procedure

Approval Procedure Notes:1 When customer has replacement claim, local technical support engineer need make

evaluation that the problem is caused by our battery quality defect or caused by customer wrong application.

2 Customer fills up claim sheet RS1946A, local engineer fills up claim sheet RS1946D.3 For replacement, need EMEA place order to buy new battery from Shanghai

Local EngineerFill up

RS1946D

Field Service

Manager Approve

QA ManagerApprove

Customer Fill up

RS1946A

Local Engineer Submit to Field

Service Manager

Microsoft Office Excel 97-2003 ¹¤×÷±í

Microsoft Office Excel 97-2003 ¹¤×÷±í

RS1946A RS1946D

Microsoft Office Word 97 - 2003 Document

P/SCD-720


To process warranty claim, customers need to follow the below procedures:

1. Fill up the warranty claim form shown below and return to C&D Sales / Service office.

2. C&D will review and process the claims, if there is any quality issue covered by the warranty terms and conditions, C&D will either return the replacement unit(s) at full warranty (or prorate) or issue the Credit Note to customer account accordingly.

Claim Sheet Filling Up Guide

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Part I - General Information:

Customer need to fill in all the requiredInformation for claim review / process.



Part II – Problem Detection:Need to “tick” on the box when the problem is detected and fill in the QTY

Example: 2 units noted failed during periodic maintenance on Jan 1.

� 2 1/1/10



Part III – Problem Symptom:Need to “tick” on the box the symptom and fill in the QTY

� 2

If the issue is related to Item A (Container) & Item B (Terminal), Please provide also “photos” for review.



Part III – Problem Symptom:Need to “tick” on the box the symptom and fill in the QTY

� 2

If the issue is related to Item C (Electrical), please provide the full system records for review


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1. Voltage Related – Need also individual unit voltage, system charging voltage set, operation temperature.

2. Impedance Related – Need to provide individual unit voltage, impedance and charging voltage set.

3. Performance Related – Need to provide the discharge log data, charging voltage and operation temperature.



Part IV – System Information:Put “ticks” in the box to best descript your system:

��

Fill in the float charging Voltage set

Number of units and Number of parallel strings

Battery RoomTemperatureProblem

descriptions



Information for claim process

Should you have Urgent Issue, send your message to

[email protected]

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