Graco 308113D Hi-Flow In-line Dispense Valves Owner's Manual

STRUCTIONS-PARTS LIST This manual contains IMPORTANT INSTRUCTIONS and WARNINGS. READ AND RETAIN FOR REFERENCE HI-FLOW IN-LINE DISPENSEVALVES With Electronic Lubricant Meter or Unmetered 1500 psi (105 bar) MAXIMUM WORKING PRESSURE FOR USE WITH PETROLEUM-BASEDLUBRICANTS ONLY t Covered by one or more of the following US. Patents: 4,848,164; 4,883,199 Foreign Patents Pending WITHOUT METER 222-461 222-561 For Oil, includes cap For Oil, includes Hi-Flow nozzle Measures in Gallons/Quarts/Pints* 222-471 For Oil, includes cap 222-441 For Oil, includes Hi-Flow nozzle *Meter is factory-set in qua& Measures In Liters 222-571 For Oil, includes cap 222-541 For Oil, includes Hi-Flow nozzle GRACO INC. EO. BOX 1441 MINNEAPOLIS, MN 55440-1441 @COPYRIGHT1990, GRACO INC. 308-113 Rev D Supersedes B and PCN C & D CONTENTS Important Phone Numbers................................................ 2 Warnings ............................................................... 3 Operation Electronic Meter 4 Dispense Valve ........................................................ 5 Service Troubleshooting ....................................................... 6 Electronic Meter ....................................................... 7 Dispense Valve 6 Parts Lists and Drawings Bare Dispense Valve ................................................... 9 Unmetered Dispense Valves ............................................ 10 Electronic Metered Dispense Valves 10 . Electronic Meter ...................................................... 11 Technical Data.......................................................... 11 Gram Warranty Back Cover ....................................................... ........................................................ ..................................... ................................................. IMPORTANT PHONE NUMBERS TO PLACE AN ORDER. contact your Gram distributor. or call this numberto identify the distributor closest to you: 1-800-328-0211 Toll Free FOR T€CHN/CAL ASSISTANCE. service repair information or assistance regarding the applicationof Graco equipment: 1-800-543-0339 Toll Free 2 308-113 TERMS FLUID UNDERHIGH PRESSURE CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY Read and understandall Instruction manuals before operating the equipment. Be sure you read and understand each of these terms CAUTION Alerts user to avoid or correct conditions before reading the rest of the manual or using the prod- which could damage or destroy the equipment. Uct. WARNING Alerts user to avoid or correct conditions which could cause bodily injury. hei NOTE Gives more explanation of a procedure, or a ful hint. FLUID INJECTIONHAZARD NEVER put hand or fingers over the nozzle. Fluid emitted under high pressurefrom leaks or rupskin and cause extured components can penetrate the or tremely serious bodily injury, including the need for am-NEVER try to stop or deflect leaks with your hand body. putation. Also,fluid injected or splashed intoeyes the or onto the skin can cause serious damage. Medical Alert - Fluid Injection Wounds If any fluid appears to penetrate your skin, getEMERDispensing Valve Safety GENCYMEDICAL CAREAT ONCE. DO NOT TREATAS Do not modify any part of the dispensing valve. ModifyA SIMPLE CUT. Tell the doctor exactly what fluid was ing parts can cause a malfunction and result in serious injected. bodily injury. Note to Physician: Injection into the skin is a traumatic Flexible Extension Safely injury. It is Important to treat the injury surgically as Be sure you know the maximum working pressure of the soon as posslble. Do not delay treatmentto research flexible extension you are using. Never exceed that toxicity. Toxicity is a concern with some exotic coatings pressure, even if your dispensing valve or the pump is injected directly into the blood stream. Consultation with rated for higher working pressures. a plastic surgeonor reconstructive hand surgeon may be advisable. is deNever use a low pressure flexible extension, which signed for low pressure dispensing valves or hand-powPressure Relief Procedure ered lubricating equipment, on a high pressure disTo reduce the risk of serious bodily injury, includpensing valve. ing fluid injection or splashing in the eyes or on the Never attempt to force lubricant info a fiWngl If the luskin, always follow this procedure when shutting bricant is not flowing,STOP DISPENSING IMMEDIATEdown the system, and before checking or repairLYI The filting may be clogged. Forcing lubricant into a ing this valve or any part of the system. fitting may cause excessive back pressure in the flexible 1. Turn off the power supplyto the pump. extension. High back pressure could cause the extension to rupture, causing serious bodily injury, fluid injec2. Trigger the valveinto awaste containerto r e tion and eye injury. lieve pressure. General Safety 3. Open any bleed-type masterair valves and Check the operation of all equipment safety devices befluid drain valvesin the system. fore each use. 4. Leave thedrain valve open until you are ready to dispense again. NEVER point the dispensing valve at anyone or any part of the body. EQUIPMENT MISUSE HAZARD General Safety System Pressure NEVER alter or modify any part of this dispensing equip The bare meterand the dispense valves have a 1500psi ment; doingso could causeit to malfunction. (105 bar) MAXIMUM WORKING PRESSURE. NEVER exCHECK all dispensing equipment regularly and repair ceed this pressureOr the pressure Of the or replace worn or damaged parts immediately. component in your system. ALWAYS read and follow the fluid and solvent manufacturer’s recommendations regarding the use or protective eyewear, clothing, gloves and other personal equipment. IMPORTANT UnitedStatesGovemmentsafe~standardshavebeenadoptedundertheOccupationalSafehlandHea~hAct.Thesestandards,particularly the General Standards, Part 1910, and the Construction Standards,Part 1926, should be consulted. 308-113 3 OPERATION - ELECTRONIC METER CAUTION I / \ \ To Activate.The Digital Display Press the RESET key pad to clear the meter before startis the best wayto activate ing anew dispense cycle. This the meter sinceit also clears the quantity of the last dispense cycle. The digital display can also be activated by pressing the TOTAL key pad or running fluid through the meter. See Fig 4-1. NOTE: The digital display of the meter goes blank after approximately two minutes of non-use. Function of TOTAL DIGITAL DISPLAY Fig 4-1 When the digital displayis blank, press and release the TOTAL key padto display the quantity of the last dispense cycle. See Fig 4-2. To see the accumulated totalof fluid dispensed through the meter, press andhold theTOTAL key pad. The accumulated totalis shown in gallonsforthe Gallon/Quart/ Pint meter and liters for the Liter meter. The meter can accumulate a running total of up to 19999 gallons (orliters) dispensed before returning to zero. See 4-3. Fig Function of RESET Press the RESET key pad to clear the quantity of the last dispense cycle and return the digital display to all zeros. See Fig 4-1. EXAMPLE OF TOTAL FOR LAST DISPENSE CYCLE Fig 4-2 To Change The Measurement Units (GallonlQuartlPint Meteron&) EXAMPLE OF ACCUMULATED TOTAL The meter is factory-set to dispense in quarts. To change the measurement units, press and hold theREFig 4-3 SET key pad until the measurement uniton the right side ofthe digital display is flashing. Then press the TOTAL key pad until the desired measurement unitis shown. Release both key pads. See Fig 4-4. CAUTION To be sure the proper amount fluid of is dispensed, always use the same measurement unit forpar-, a ticuiar fluid. Units should be changed only by authorized employees. PINTS I 0 0.0 0 pTsl For Maximum Dispensing Accuracy (GallonlQuart/Pint Meter onk) Set the meterto dispense in pints or quarts when dispensing 1 gallon or less. Always press theRESEF key pad to clear the meter be- fore a new dispense cycle. 4 308-113 EXAMPLE OF MEASUREMENT UNITS Fig 4-4 OPERATION - DISPENSE VALVE - Metered and Unmetered ROTATE KNURLED SLEEVE OF COUPLER B CLOCKWISE TO EN IT FOR DISPENSING LA WARNiNG To reduce the risk offluid injection, always grasp the nozzle housing(B) from the threaded end, not from the front, when adjusting the nozzle. When dispensing lightweight fluids, suchas automatic transmission fluid, increasethe free play of the dispense valve trigger.This reduces the flow and reduces splashing of the fluid. To adjust the trigger free play, loosen the adjusting screw locknut(C). Back the screw(D) out until the desired flow is achieved, then tighten the locknutsecurely. See Fig 5-2. If you are not using a Hi-Flow nozzle. remove the cap To lock the control valvein the open position, engage (A) from the tube. To dispense from the Hi-Flow nozzle (E), turn the knurled sleeve clockwise untilit is open. Trigger the valve. the trigger latchingpin in the latch(E).See Fig5-2. To release the latch, squeeze and release the trigger. When the dispense cycleis completed, release the trigger and close the nozzle by screwing the knurled sleeve fully counterclockwise. For e l e c t r & a n & r e d valves, press the RESET key pad onthe meter to clear it before the next dispense cycle. See Fig4- 1. Trigger the dispense valve. Lubricant begins to flow with the slightest movementof the trigger, and continuesto flow until the trigger is released. instructions. Fig 5-2 Clean the strainer frequently. See page 8 for 308-113 5 SERVICE - TROUBLESHOOTING WARNING I Pressure Relief Procedure 2. Trigger the valve into a waste containerto relieve To reduce the riskof serious bodilviniurv, includino Dressure. fluid injection or splashing in the eyesor on the ski< always follow this procedure when shutting down the 3. Open bieed-vpe master air valves and fluid system, and before checking or repairing this valve or drain valvesin the system. any partof the system. 4. Leave thedrain vaive open until you are ready to 1. Turn off the power supplyto the pump. dispense again. ~ .. ~ NOTE: Before checking or repairing the meter, be sure all other valves, controls and the pump are operating properly, Also see the Dispense Valve Troubleshooting information on page ~.8. Problem Cause Solution Digital display will not activate Electronic controlis malfunctioning. No fluid flow Replace the electronic control. Order Part No. 222-658 for gallons/quarts/pints. Order Part No. 222-659 for liters. Metering unit is malfunctioning. Replace the metering unit. Order Part No. 222-661 for gallondquartslpints. Order Part No. 222-681 for liters. Dispense Valve strainer,if used. is clogged. Remove and clean. Battery in electronic control is worn. Replace eledronic control within approxi. mately one week of first noticing thedim. ness. See part numbers above. Iigital display is dim 6 308-113 ~~ ~ SERVICE - ELECTRONIC METER CAUTION To avoid damaging the electronic componentsOf the control: 0 ALWAYS use the personal grounding strap provided with a replacement metering unit and electronic control lzetpce removing the cover (IOI), and while replacing the parts. This strap protects the electronic components from damage due to electrostatic discharge. 0 Do not lay anything on the control. Be sure the open side of the control faces up if you layit down. 0 Do not twist or force parts. Align parts properly as instructed. 0 Do not ship the meter by air freight if the O-ring is installed. Doing so will damage the meter display due to the differential atmospheric pres- sure. 0 When installing theO-ring, the meter mustbe at themmge operating temperatureto minlmize pressure differential due to temperature change. WARNING To reduce the risk of a fire, explosion, and serious burns to the body, handle and dispose ofused a electronic control(103) properly. The electronic control contains a lithium battery. Do not short circuit, charge, force over discharge, disassemble, crush, penetrate, incinerateor heat the battery to a temperature exceeding 185" F (85%). Any misuse or abuseof the battery may cause it to leak or explode. NOTE The o-ring included with your meter protects the sensitive electronics from damage due to is humidity. Install the O-ring when the meter used in outdoor installations such as lubrication trucks, high humidity environments, and when the equipmentis cleaned by pressure washing. 1. Follow the Pressure Rellef Procedure Wernlng on page 6. 2. Attach the disposable grounding wrist strap to your m'st.Connect the adhesive-backed copperfoil at the other endto any convenient electrical ground, such as the grounding screw or metal case of a grounded electrical outlet. 3. Lift the bottom edge of the black cover (101) away from the meter and uII the cover off. Remove the screws (A). Lift off t e electronic control. Lay the control down with the open side up to prevent damage. DO NOT TOUCH ANY ELECTRICAL COMPONENTS! R 4. If you planto use the O-ring (104), place it around the flangeof the metering unit. 5. Install a new meteringunit (102) and/or electronic control (103). Align the notcheson the undersideof the electronic control with the cutaways in the top of the metering unit. Use the new screws(A) and to 10-12 in-lb torque them oppositely and evenly (1.2 - 1.4Nm). 6. Install the coverso the rolled-In edges are parallel with the Inletfluid passage of the metering unit. 308-113 7 DISPENSE VALVE - TROUBLESHOOTING AND SERVICE TROUBLESHOOTING Solution Cause Problem Adjust the valve. to flow af- Valve may be out of adjustment. Lubricant continues ter the triggeris released. Valve spring weakened, or O-rings are worn,Check internal valve parts. or valve poppetis unseated. Lubricant leaks past the push Push rod or packingis worn. lrod packing (12). I Replace push rod or packing. I I SERVICE NOTES: 1. Follow the Pressure Relief Procedureon page3 before servicing the control valve. 2. Refer to the PARTS DRAWING on page 9 while servicing the control valve. 3. Clean and check all parts thoroughly after disassembling them. Replace worn or damaged parts. 4. The reference numbers and lettersin parentheses in the text correspondto the numbers and lettersin the text, parts drawings andparts list. Check Internal Valve Parts Disconnect the valve from the hose. Remove the valve plug (22). Several other pais will come out with the plug. Clean the valve cavily and seat(18).Inspect the seat for nicks. If the seat is damaged, send the valveto a Graco-authorized service center for repair. Reassemble the valve. Replace PushRod or Packing Disconnect the valve from the hose. Push out the (2)pin of the trigger latch. Swing the trigger out of the way. Remove the guide(lo),gasket (4) and push rod(20).Use Clean the Strainer Frequently a dull instrumentto remove the packing(12).Install a 3. First follow the Pressure Relief Procedure on page new gasket and reassemble the valve. Remove the swivel(19) and unscrew the strainer(1Sa). Clean the filter in mineral spirits. Reassemble, and torque the swivel to 19-21 ft-lb (26-28 Nm). Adjust the Valve Loosen the locknut(8). Turn the adjusting screw(9) in or out as needed.To stop the fluid flow, all of the pressure of the screw(9) against the push rod (20)must be released. When the valve handleis properly adjusted, there is a small amount of free play. After adjusting the valve, hold the adjusting screw in place and securely tighten the locknut. 8 308-113 PARTS Model 224-304 - DISPENSE VALVE DISPENSE VALVE ONLY includes items1 to 23 **6 **13 14\ REF NO. PART NO. 1 2 3 108-445 101-354 101-421 4** 150-451 5"' 6** 7 8 9 10 11 1 2 ' * 13'* 155-500 156-401 157-974 158-213 158-214 158-668 158-671 158-673 158-674 DESCRIPTION PIN, spring;5/32" (4.0 mm) dia; 718" (22.2mm) long PIN, roll;3/16" (5 mm) dia; 1-118" (28.8 mm) long PIN, cotter:518"(16 mm) dia: 318"(9.5mm) long GASKET, copper O-RING; nilrile rubber O-RING; nitrile rubber WASHER, special NUT, lock:3/8-24 SCREW, slotted hdless set: 1/8-24X 9/16 GUIDE, push rod SPRING, torsion ..t~ PACKING, v-block; nitrile rubber O-RING: nitrile rubber s 214-008 k OTY 1 1 1 1 1 2 1 1 1 1 1 REF NO. PART NO. 14 159-080 15 159-118 16 159-168 17 159-484 18 160-708 19 203-275 19a 159-259 19b 20 203-977 158-658 22 158-662 23'* 217-316 24 111-853 21 Repair Kit Must be purchased separately. Includes: Ref No. 4 Qly 5 6 12 13 23 1 3 2 1 1 1 on DESCRIPTION SPRING, compression TRIGGER LATCH. trigger PIN, pivot SEAT valve ADAPTER, swivel: 112 npt Includes items19a & 19b .STRAINER SWIVEL (not sold separately) ROD, push VALVE BODY .PLUG, valve VALVE, piston GASKET 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ., .: , 308-113 9 PARTS DRAWING & LISTS 5 WITHOUT METER MODEL 222-461, Includes Cap WITH LITER METER Ret otu No. Part No. Descrlptlon 1 224-304' DISPENSE VALVE 2 186-660 SPOUT 3 224-062 CAP&CHAIN 7 172-479t TAG, WARNING, notshown 1 1 1 1 MODEL 222-561, Includes Hi-FlowNoule Ref No. Part No. Descrlptlon 1 224-304* DISPENSE VALVE 2 186-660 SPOUT 4 223-920 HI-FLOW NOZZLE seeparts lorlghl 7 172-479t TAG, WARNING, not shown QW 1 1 i 1 No. Part No. Descrlptlon 1 224-304* 2 186-660 3 224-062 5 222-560'" 6 158-491 7 172-479t DISPENSE VALVE SPOUT CAP&CHAIN METER, gallon/quwpint NIPPLE TAG, WARNING, not shown otu 1 1 i 1 1 1 MODEL 222-441, Includes Hi-Flow Nozzle Ref Part No. Descrlptlon 1 224-304" DISPENSE VALVE 2 186-660 SPOUT 4 223-920 HI-FLOW NOZZLE seeparts bright 5 222-560" METER, gallon/quWpint 6 158-491 NIPPLE 7 172-479t TAG, WARNING, notshown I O 308-113 No. No. Part No. Descrlptlon 1 224-304* DISPENSE VALVE 2 186-660 SPOUT 3 224-062 CAPBCHAlN 5 222-660"' METER, liter 6 158-491 NIPPLE 7 172-479t TAG, WARNING, not shown otu . 1 1 1 1 1 1 Qtv 1 1 1 1 1 1 MODEL 222-541, Includes Hi-FlowNoule RM No. 1 z 4 5 6 7 WITH GALLON/QUART/PINT METER MODEL 222-471, Includes Cap Ret MODEL 222-571, Includes Cap Ret Part No. Descrlptlon , 224-304" DISPENSE VALVE I." B ~ - - R ~ O wmrr -. ". 223-920 HI-FLOW NOZZLEseepartsbelow 1 222-660** METER, liter 158-491 NIPPLE 172-479t TAG,WARNING, notshown "_ QW ,1 1 1 i HIGH FLOW N O Z L E MODEL 223-920 Included with wives 222-561,222-447,222-541 Ret No. Part No. Descrlptlon 4a 186-528 STEM, nozzle 4b 186-529 SLEEVE, nozzle 4c 158-032 O-RING 4d 155-463 O-RING 4e 110-956 O-RING t Extra Waming tagsavaibble free. See pafts on page 9. ** See paris on page 11. otu 1 1 1 1 1 PARTS z2x - ELECTRONIC METER MODEL 222-560, Meter - Gallon/Quart/Pint Includes reolaceableitems 101 - 104. Ref No. Part No. Descrlptlon 101 102 222-661 109-118 COVER METERING UNIT 104 109-137 O-RING MODEL 220-660, Meter - Liter - 104. No. Part No. Descrlptlon 101 102 103 104 COVER METERING UNIT liter ELECTRONIC CONTROL liter O-RING 109-118 222-681 222-659 109-137 1 1 1 Includes replaceable items 101 Ref - aal/affDt Qtv - - 1 1 1 1 102 WARNING Use only genuine Graco replacementparts. The use of any other parts may impair the intrinsic safety of this meter. This could result in a failure which causes serious bodily injury and/orsubstantial property damage. - TECHNICAL DATA ELECTRONIC METER 0.12 - 12.0 GallonsIMinute Flow Range.. ................. .......................... 0.456 - 45.6 LitedMinute Maximum Operating Pressure...................................... 1500 psi (105 bar) Weigh (Bare Meter) ................................................ 1.9 Ib (0.95 Kg) Units of Measurement.. ........................................ Factory-set in Quarts Display shows quantityin 0.01 increments up to 19999 gallons, quarts or pints Totalizes in gallons (or liters)up to19,939 units Inlet andOutlet.. 112 npt, non-directional flow -4’ F to 13W F(-20‘ C to 5V C) Operating TemperatureRange ...................... -40“ F to 140v F (-40” C to 600 C) Storage Temperature Range...................... Battery Specifkations ........................ Rated discharge current:100 microamps Rated capacity: 1.O amp hour Maximum continuous discharge current:1 milliamp Aluminum, Nickel, Bronze, Stainless Steel #304, Wetted Pam .......................... Carbon Steel, Cast ALNICO6, Nitrile Rubber ....................................... TECHNICAL DATA - DISPENSE VALVE .................................... 12.0GalbnslMinute (45 liiedmin) at 50 psi (3.5 bar) pressureloss using hydraulic fluid Maximum Operating Pressure..................................... ,1500 psi ( i o 3bar) Weight (Without Meter)................................................. 4 Ib (1.8 Kg) Inlet and Outlet............................................................ .1/2 npt Wetted Parts ............. Aluminum. Carbon Steel, Copper, Polyurethane, Nitrile Rubber Flow Capability 308-113 11 MANUAL CHANGE SUMMARY 220-660 Meters The texton page 7 has been updated to include information on the use and installation of this new O-ring. THE GRACO ELECTRONIC DISPENSE VALVE WARRANTY Gram warrants ail equipment manufacturedby it and bearingits name to be free from defects in materialand workmanship on the date of sale by an authorizedGracodistributortotheoriglnalpurchaserforuse.Aspurchaser'ssoleremedyforbreacholthiswsnanly,Gramwill,foraperiodoftwelve monthsfromUledateol~ie,repairorreplaceanypartoltheequipmentprovendef~e,withtheexceptionofdefectsintheelectronicmeterwntrol. inciudingthebaUery,whichwiiiberepairedorreplacedfortwenty-fourmonthsfromthedateolsale.Thiswanantyappiiesoniywhenthaequipmentis installed, operated and maintained in accordanceWh Gram's written recommendations. Thiswarrantydoesnotcover,andGracoshallnotbeiiablefor,anymalfunction,damageorwearcaus~bylauityinstallation,misapplication,abresion, corrosion,inadequateorimpropermalntenance,negligence,accldanl,tamperlng,orsubst~utlonolnon-Gramomponentparts.NorshaliGracobe liable for malfunction, damage or wear caused by the lncompatibllity with GraCO equipment of StRIctum. accessories. equipmentor materials not suppiiedbyGraco,ortheimproperdesign,manufacture,lwtaliatlon,operationormalntenanceol~ctures,a~ssories,equipmentormateriaisnot supplied byGraco. ~noltha claim. Ifthe claimed defectverified, is Gram wlli repair or replacefree of chargeany defecthre parts.The equipment willbe returnedto the original If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a purchaser transportation prepaid. reasonable charge, which charges may include costs the of parls. labor and transportation. DlsclalmersandLimltatlons.THE~RMSOFTHiSWARRANPlCONSTiTUTEPURCHASER'SSOLEANDEXCUlSlVEREMEDYANDAREINLlEU OFANYOTHERWARW\NTIES(MPRESSORIMPUED),iNCLUDlNGWAR~OFMERCHANTABlUTYORWARRNTYOFF~NESSFORAPARTICULAR PURPOSE.ANDOFANY NON-CONTW\CTUALUABILITiES,lNCLUDlNGPRODUCTUABIUTIES, BASEDON NEGUGENCEORSTRICT LIABiUTY.RIERYFORMOFUABiL~FORDIRECT,SPEClALORCONSKXlENTlALDAMAOESORLOSSISEXPRESSLYMCWDEDANDDENIED. iNNOCASESHALLGRACOSLIABiLITYD(CEED~EWOUNTOFTHEPURCHASEPRICE.ANYACTlONFORBR~CHOFWARRANTYMUSTBE BROUGHT WITHINTWO (2) YEARS OF THE DATE OF SALE. Equlpment not covered by Gram Warranty. GRACO MAKES NOW A R M , AND DISCLA" ALL IMPLIED WARRANTIES OF MERCHANTABiLlNANDFlTNESSFORAPARTiCULARPURPOSE,WlTHRESPECTTOACCESSORiES.EQUIPMEKI,MATERIALS,ORCOMPONEKISSOLD BUTNOTMANUFACTUREDBYGRACO.Theseitemssold,butndmanufacturedbyGraco(suchaseiectricmotor,switches,hose,etc.)aresubJectto thewarranty,ifany,olthelrmanufacturar.GracowillprovidepurchaserwlhreasonableassistanceinmakinQanyclalmforbreachofthesewarranties. Factory Branches: Atlanta, Chicago. Dallas, Detroit, Los Angels, Mt. Arlington (N.J.) Subsldlary and Afflllate Companlee: Canada; England: Switzerland; Korea; France; Germany; Hong Kong; Japan GRACO INC. RO. BOX 1441 MINNEAPOLIS, MN 55440-1441 PRINTED IN USA. 308-1 13 2-91 Revised 7/02
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