Beckhoff EP1918 Operating

Operating Instruction | EN

EP1918

TwinSAFE EtherCAT Box with 8 fail-safe inputs

2020-09-10 | Version: 1.1.0

Table of contents

EP1918 3Version: 1.1.0

Table of contents

1 Foreword ....................................................................................................................................................5

1.1 Notes on the documentation..............................................................................................................5

1.2 Safety instructions .............................................................................................................................6

1.2.1 Delivery state ..................................................................................................................... 6

1.2.2 Operator's obligation to exercise diligence ........................................................................ 6

1.2.3 Description of instructions.................................................................................................. 7

1.3 Documentation issue status ..............................................................................................................8

1.4 Version history of the TwinSAFE product..........................................................................................8

2 System description ...................................................................................................................................9

2.1 EtherCAT Box Modules .....................................................................................................................9

3 Product description.................................................................................................................................10

3.1 EP1918-0002...................................................................................................................................10

3.2 Intended use....................................................................................................................................11

3.3 Technical data .................................................................................................................................12

3.4 Safety parameters ...........................................................................................................................13

3.5 Safe inputs.......................................................................................................................................14

3.6 Dimensions......................................................................................................................................15

4 Operation..................................................................................................................................................16

4.1 Environmental conditions ................................................................................................................16

4.2 Installation .......................................................................................................................................16

4.2.1 Fixing ............................................................................................................................... 16

4.2.2 Connection....................................................................................................................... 16

4.2.3 EP1918 temperature measurement................................................................................. 23

4.2.4 Signal cables ................................................................................................................... 24

4.3 EP1918 configuration in TwinCAT...................................................................................................26

4.3.1 Adding an EtherCAT device ............................................................................................ 26

4.3.2 Inserting an EP1918 ........................................................................................................ 26

4.3.3 Using the integrated TwinSAFE Logic functions.............................................................. 26

4.3.4 Project design limits of the EP1918 ................................................................................. 27

4.3.5 Address settings on the TwinSAFE EtherCAT Box ......................................................... 28

4.3.6 Alias devices.................................................................................................................... 29

4.3.7 Parameters of the EP1918 .............................................................................................. 31

4.3.8 Process image of the EP1918 ......................................................................................... 34

4.4 TwinSAFE reaction times ................................................................................................................35

4.5 Diagnosis.........................................................................................................................................37

4.5.1 EtherCAT- Fieldbus LEDs ............................................................................................... 37

4.5.2 Status LEDs..................................................................................................................... 38

4.5.3 Diagnostic LEDs .............................................................................................................. 39

4.5.4 Flash code display ........................................................................................................... 40

4.5.5 Diagnostic objects............................................................................................................ 40

4.5.6 Cycle time of the safety project........................................................................................ 42

4.5.7 Diag History tab ............................................................................................................... 42

4.5.8 Diagnosis History............................................................................................................. 43

Table of contents

EP19184 Version: 1.1.0

4.6 Maintenance ....................................................................................................................................46

4.7 Service life .......................................................................................................................................46

4.8 Decommissioning ............................................................................................................................47

4.9 Firmware update of TwinSAFE products.........................................................................................48

5 Appendix ..................................................................................................................................................51

5.1 Protection classes according to IP code..........................................................................................51

5.2 Support and Service ........................................................................................................................52

5.3 Certificates.......................................................................................................................................53

Foreword

EP1918 5Version: 1.1.0

1 Foreword

1.1 Notes on the documentation

Intended audience

This description is only intended for the use of trained specialists in control and automation engineering who

are familiar with the applicable national standards.

It is essential that the following notes and explanations are followed when installing and commissioning

these components.

The responsible staff must ensure that the application or use of the products described satisfy all the

requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Origin of the document

This original documentation is written in German. All other languages are derived from the German original.

Currentness

Please check whether you are using the current and valid version of this document. The current version can

be downloaded from the Beckhoff homepage at http://www.beckhoff.com/english/download/twinsafe.htm.

In case of doubt, please contact Technical Support [}52].

Product features

Only the product features specified in the current user documentation are valid. Further information given on

the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative.

Disclaimer

The documentation has been prepared with care. The products described are subject to cyclical revision. For

that reason the documentation is not in every case checked for consistency with performance data,

standards or other characteristics. We reserve the right to revise and change the documentation at any time

and without prior announcement. No claims for the modification of products that have already been supplied

may be made on the basis of the data, diagrams and descriptions in this documentation.

Trademarks

Beckhoff

®

, TwinCAT

®

, EtherCAT

®

, EtherCATG

®

, EtherCATG10

®

, EtherCATP

®

, SafetyoverEtherCAT

®

,

TwinSAFE

®

, XFC

®

, XTS

®

and XPlanar

®

are registered trademarks of and licensed by Beckhoff Automation

GmbH. Other designations used in this publication may be trademarks whose use by third parties for their

own purposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications and

patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding

applications or registrations in various other countries.

Foreword

EP19186 Version: 1.1.0

EtherCAT

®

and Safety over EtherCAT

®

are registered trademarks and patented technologies, licensed by

Beckhoff Automation GmbH, Germany.

Copyright

The reproduction, distribution and utilization of this document as well as the communication of its contents to

others without express authorization are prohibited.

patent, utility model or design.

Delivery conditions

In addition, the general delivery conditions of the company Beckhoff Automation GmbH & Co. KG apply.

1.2 Safety instructions

1.2.1 Delivery state

All the components are supplied in particular hardware and software configurations appropriate for the

application. Modifications to hardware or software configurations other than those described in the

documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.

1.2.2 Operator's obligation to exercise diligence

The operator must ensure that

• the TwinSAFE products are only used as intended (see chapter Product description);

• the TwinSAFE products are only operated in sound condition and in working order.

• the TwinSAFE products are operated only by suitably qualified and authorized personnel.

• the personnel is instructed regularly about relevant occupational safety and environmental protection

aspects, and is familiar with the operating instructions and in particular the safety instructions contained

herein.

• the operating instructions are in good condition and complete, and always available for reference at the

location where the TwinSAFE products are used.

• none of the safety and warning notes attached to the TwinSAFE products are removed, and all notes

remain legible.

Foreword

EP1918 7Version: 1.1.0

1.2.3 Description of instructions

In these operating instructions the following instructions are used.

These instructions must be read carefully and followed without fail!

DANGER

Serious risk of injury!

Failure to follow this safety instruction directly endangers the life and health of persons.

WARNING

Risk of injury!

Failure to follow this safety instruction endangers the life and health of persons.

CAUTION

Personal injuries!

Failure to follow this safety instruction can lead to injuries to persons.

NOTE

Damage to the environment/equipment or data loss

Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.

Tip or pointer

This symbol indicates information that contributes to better understanding.

Foreword

EP19188 Version: 1.1.0

1.3 Documentation issue status

Version Comment

1.1.0 • Chapter EP1918 temperature measurement updated

1.0.0 • First release

0.4 • Technical data for sensor supply updated

• Technical data for current consumption updated

0.3 • Technical data updated

0.2 • Note on commissioning test added

• Version history of the TwinSAFE product added

• Note on safe inputs added

0.1 • First draft

1.4 Version history of the TwinSAFE product

This version history lists the software and hardware version numbers. A description of the changes

compared to the previous version is also given.

Updated hardware and software

TwinSAFE products are subject to a cyclical revision. We reserve the right to revise and change the

TwinSAFE products at any time and without prior notice.

No claims for changes to products already delivered can be asserted from these hardware and/or

software changes.

A description of how a firmware (software) update can be performed can be found in chapter Firmware

update of TwinSAFE products [}48].

Date Software version Hardware version Modifications

2020-05-20 01 00 First release of the EP1918-0002

System description

EP1918 9Version: 1.1.0

2 System description

2.1 EtherCAT Box Modules

The EtherCAT system has been extended with EtherCAT Box modules with protection class IP67. Through

the integrated EtherCAT interface the modules can be connected directly to an EtherCAT network without an

additional Coupler Box. The high-performance of EtherCAT is thus maintained into each module.

The extremely low dimensions of only e.g.126x30x26.5mm are identical to those of the Fieldbus Box

extension modules. They are thus particularly suitable for use where space is at a premium. The small mass

of the EtherCAT modules facilitates applications with mobile I/O interface (e.g. on a robot arm). The

EtherCAT connection is established via screened M8 connectors.

Fig.1: EtherCAT Box modules extend the EtherCAT system with IP67 protection

The robust design of the EtherCAT Box modules enables them to be used directly at the machine. Control

cabinets and terminal boxes are now no longer required. The modules are fully sealed and therefore ideally

prepared for wet, dirty or dusty conditions.

Pre-assembled cables significantly simplify EtherCAT and signal wiring. Very few wiring errors are made, so

that commissioning is optimized. In addition to pre-assembled EtherCAT, power and sensor cables, field-

configurable connectors and cables are available for maximum flexibility. Depending on the application, the

sensors and actuators are connected through M8 or M12 connectors.

Basic EtherCAT documentation

You will find a detailed description of the EtherCAT system in the Basic System Documentation for

EtherCAT, which is available for download from our website (www.beckhoff.com) under Downloads.

Product description

EP191810 Version: 1.1.0

3 Product description

3.1 EP1918-0002

The EP1918-0002 TwinSAFE EtherCAT Box is a digital EtherCAT Box for sensors with potential-free

contacts for 24V

DC

. It has eight fail-safe inputs.

The EP1918-0002 meets the requirements of the following standards:

• EN 61508:2010 (SIL 3)

• EN 62061:2005/A2:2015 (SILCL3)

• EN ISO 13849-1:2015 (Cat.4,PLe)

Fig.2: EP1918-0002 - TwinSAFE EtherCAT Box with 8 fail-safe inputs

Product description

EP1918 11Version: 1.1.0

3.2 Intended use

WARNING

Caution - Risk of injury!

TwinSAFE components may only be used for the purposes described below!

The TwinSAFE EtherCAT Box expands the application range of the Beckhoff system with functions that

enable it to be used for machine safety applications. The TwinSAFE Boxes are designed for machine safety

functions and directly associated industrial automation tasks. They are therefore only approved for

applications with a defined fail-safe state. This safe state is the wattless state. Fail-safety according to the

relevant standards is required.

The TwinSAFE EtherCAT Box allows the connection of:

24V

DC

sensors such as

• emergency stop push buttons, rope pull switches, position switches, two-hand switches, safety mats,

light curtains, light barriers, laser scanners etc.

• Safe sensors, which use a 24V

DC

supply and send safe OSSD signals.

WARNING

The fail-safe principle!

The basic rule for a safety system such as TwinSAFE is that failure of a part, a system component or the

overall system must never lead to a dangerous condition. The safe state is always the switched off and wat-

tless state.

WARNING

Power supply from SELV/PELV power supply unit!

The TwinSAFE components must be supplied with 24V

DC

by an SELV/PELV power supply unit with an out-

put voltage limit U

max

of 36V

DC

. Failure to observe this can result in a loss of safety.

WARNING

System limits

The TÜV SÜD certificate applies to this TwinSAFE component, the function blocks available in it, the docu-

mentation and the engineering tool. TwinCAT 3.1 and the TwinSAFE Loader are permitted as engineering

tools. Any deviations from these procedures or tools, particularly externally generated xml files for Twin-

SAFE import or externally generated automatic project creation procedures, are not covered by the certifi-

cate.

WARNING

Commissioning test

Before the EP1918-0002 can be used for the safety task, the user must carry out a commissioning test so

that sensor and actuator wiring faults can be ruled out.

CAUTION

Follow the machinery directive!

The TwinSAFE components may only be used in machines as defined in the machinery directive.

CAUTION

Ensure traceability!

The buyer has to ensure the traceability of the device via the serial number.

Product description

EP191812 Version: 1.1.0

3.3 Technical data

Product designation EP1918-0002

Fieldbus EtherCAT

Number of inputs 8

Connecting the inputs M12

Status display 8 (one green LED per input), 5 diagnostic LEDs, 2 LEDs for Us/Up,

2 LEDs for EtherCAT Link/Act

Response time

(read input/write to E-bus)

typically: 3ms,

maximum: see fault response time

Watchdog time adjustable from 2ms to 60s

Fault response time ≤ watchdog time

Cable length between sensor and EtherCAT Box Unshielded: 100m max. (at 0.75 or 1mm²)

Shielded: 100m max. (at 0.75 or 1mm²)

Output current of the clock outputs

(Input Power Mode parameter: Diag Testpulse)

typically 10mA

Output current of sensor supply

(Input Power Mode parameter: PowerMode A/B)

max. 250mA

Max. output current clock outputs/sensor supply in the

event of an error

max. 3A (the duration depends on the overtemperature-related shutdown of

the output driver)

Input process image 7bytes (via FSoE if using the default project)

Output process image 6bytes (via FSoE if using the default project)

Supply voltage for the EP1918 24V

DC

(–15%/+20%)

Current consumption U

S

(wired with 8 potential-free contacts)

8 channels occupied: typically 100mA

0 channels occupied: typically 91mA

(provide 4A fuse)

Current consumption U

P

(wired with 8 potential-free contacts)

8 channels occupied: approx. 60mA

0 channels occupied: approx. 35mA

(provide 4A fuse)

Power dissipation of the EtherCAT Box typically 3.8watts

Electrical isolation (between the channels) no

Electrical isolation

(between the channels and EtherCAT)

yes

Insulation voltage (between the channels and Ether-

CAT, under common operating conditions)

Insulation tested with 500V

DC

Dimensions (WxHxD) 30 mm x 126 mm x 26.5 mm

Housing material PA66-GV 30 (WELLAMID)

Flame Class: V-0

Sealing compound Polyurethane PU552L

Flame Class: V-0

Weight approx.170g

Permissible ambient temperature

(operation)

-25°C to +60°C

Permissible ambient temperature

(transport/storage)

-40°C to +85°C

Permissible air pressure

(operation/storage/transport)

750hPa to 1100hPa

(this is equivalent to an altitude of approx. -690m to 2450m above sea level

assuming an international standard atmosphere)

Inadmissible operating conditions TwinSAFE EtherCAT boxes must not be used under the following conditions:

• under the influence of ionizing radiation (exceeding the natural

background radiation)

• in corrosive environments

EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4 (EMC ZoneB)

Vibration resistance conforms to EN60068-2-6

5 Hz ≤ f < 8.4 Hz (3.5 mm peak)

8.4 Hz ≤ f < 150 Hz (10 m/s

2

peak)

Shock resistance conforms to EN60068-2-27

15g with pulse duration 11ms in all three axes

Protection class (when screwed together) IP67 (according to EN60529)

Correct installation position variable

Approvals CE, TÜV SÜD

Product description

EP1918 13Version: 1.1.0

Derating table for altitudes above 2000m

The derating table (table 8) from the IEC61131-2:2017 standard can be referred to for the use of the

TwinSAFE components above the specified maximum altitude.

Altitude in m Derating factor for the temperature

1

0 to 2000

2

1.0

3000 0.9

4000 0.8

5000 0.7

Note: Linear interpolation is permissible between the altitudes

1)

Ambient temperature of the device at an altitude of 2000m

2)

The air pressure and air density increase as the altitude decreases. Therefore the derating factor for 0 to

2000 m (1.0) is used for altitudes below sea level.

Calculation example

In the following example the calculation is performed for a TwinSAFE component at an operating altitude of

4000m.

Permissible ambient temperature up to 2000 m above sea level = 55°C

Permissible ambient temperature up to 4000m above sea level = 55°C * 0.8 = 44°C

CAUTION

Compliance with the temperature limits

The TwinSAFE component has a maximum internal temperature at which a switch-off takes place. This is

designed for the maximum permissible ambient temperature. If the derating factor for the temperature for

higher altitudes is used, the user is solely responsible for ensuring that the calculated maximum ambient

temperature is complied with.

3.4 Safety parameters

Characteristic numbers EP1918-0002

Lifetime [a] 20

Proof test interval [a] not required

1

PFH

D

5.00E-09

PFD 6.90E-05

MTTF

D

high (875a)

DC high (98,6% CAT 4)

Performance level PL e

Category 4

HFT 1

Element classification

2

Type B

1)

Special proof tests throughout the service life of the EtherCAT Box are not required.

2)

Classification according to EN 61508-2:2010 (see chapter 7.4.4.1.2 and 7.4.4.1.3)

The EP1918-0002 TwinSAFE EtherCAT Box can be used for fail-safe applications within the meaning of

IEC61508:2010 up to SIL3 and ENISO13849-1:2015 up to PLe(Cat.4).

Further information on calculating or estimating the MTTF

D

value from the PFH

D

value can be found in the

TwinSAFE Application Guide or in ENISO13849-1:2015, TableK.1.

In terms of safety-related parameters, the Safety-over-EtherCAT communication is already considered with

1% of SIL3 according to the protocol specification.

Product description

EP191814 Version: 1.1.0

3.5 Safe inputs

The safe input modules and corresponding clock outputs have a two-channel design. This has the

advantage that a two-channel safe sensor with an M12 connection can be used, and a fault such as cross-

circuit or external feed results in shutdown of the whole module.

DANGER

Clocked signals inside a sheathed cable

If clocked signals (clock outputs for the safe inputs) of different modules are used within a sheathed cable,

a fault of one module, such as cross-circuit or external feed, must lead to the switch-off of all of these mod-

ules. This is achieved by setting the Module Fault Link active parameter for all modules involved. This pa-

rameter is set to TRUE by default.

DANGER

Safe inputs in Cat.4 / PL e

If two safe input channels are to be used in a category 4 structure that are not on one M12 connector,

please make sure to combine always an even and an odd channel number.

Product description

EP1918 15Version: 1.1.0

3.6 Dimensions

Fig.3: EP1918-0002 - Dimensions

The TwinSAFE EtherCAT Box has the following dimensions.

Width 30.0 mm

Height 126.0 mm

Depth 26.5 mm

When fully wired, the connected cables increase the total depth of the module.

Operation

EP191816 Version: 1.1.0

4 Operation

4.1 Environmental conditions

Please ensure that the TwinSAFE Boxes are only transported, stored and operated under the specified

conditions (see technical data)!

WARNING

Risk of injury!

The TwinSAFE EtherCAT boxes must not be used under the following conditions.

• under the influence of ionizing radiation (that exceeds the level of the natural environmental radiation)

• in corrosive environments

NOTE

Electromagnetic compatibility

The TwinSAFE components comply with the current standards on electromagnetic compatibility with regard

to spurious radiation and immunity to interference in particular.

However, in cases where devices such as mobile phones, radio equipment, transmitters or high-frequency

systems that exceed the interference emissions limits specified in the standards are operated near Twin-

SAFE components, the function of the TwinSAFE components may be impaired.

4.2 Installation

4.2.1 Fixing

NOTE

Protect connectors against soiling!

Protect all connections from contamination during installation and operation of the modules! Protection

class IP67 is only guaranteed if all cables and plug connectors are connected, and unused connections are

protected with the appropriate cover plugs!

Connector sets see catalog.

• Modules with narrow housing are installed with two M3 screws.

• Modules with wide housing are installed with two M3 screws in the mounting holes in the corners or

two M4 screws in the central fastening holes (see also chapter Power connection and grounding).

• The bolts must be longer than 15mm. The fastening holes in the modules have no thread.

• Note when mounting that the overall height is increased further by the fieldbus connections.

4.2.2 Connection

4.2.2.1 Nut torque for connectors

M8 connector

We recommend fastening the M8 connector with a torque of 0.4Nm. A max. torque of 0.5Nm is also

permissible if using a torque screwdriver (Beckhoff article ZB8800).

Operation

EP1918 17Version: 1.1.0

Fig.4: EtherCAT Box with M8 plug connectors

M12 connector

We recommend fastening the M12 connector with a torque of 0.6Nm.

Fig.5: EtherCAT Box with M8 and M12 connectors

7/8" plug connectors

We recommend fastening the 7/8" plug connectors with a torque of 1.5Nm.

Fig.6: 7/8" plug connectors

Torque wrench

Fig.7: Torque wrench ZB8801

NOTE

Ensure the proper torque is used

Use torque wrenches available from Beckhoff to tighten the connectors (see accessories)!

Operation

EP191818 Version: 1.1.0

4.2.2.2 EtherCAT connection

The EtherCAT Box (EPxxxx) has two M8 connectors marked green for the incoming and outgoing EtherCAT

connection.

Fig.8: EtherCAT connection 30 mm housing M8

Connection

There are various different standards for the assignment and colors of connectors and cables for EtherCAT.

EtherCAT Connector Cable Standard

Signal Description M8 ZB9010, ZB9020,

ZK1090-6292

ZB903x,

ZK1090-31xx

TIA-568B

Tx + Transmit Data+ Pin 1 yellow

1

orange/white

2

white/orange

Tx - Transmit Data- Pin 4 orange

1

orange

2

orange

Rx + Receive Data+ Pin 2 white

1

blue/white

2

white/green

Rx - Receive Data- Pin 3 blue

1

blue

2

green

Shield Shield Housing Shield Shield Shield

1)

Core colors according to EN61918

2)

Core colors

4.2.2.3 EtherCAT cables

For connecting EtherCAT devices only Ethernet cables that meet the requirements of at least category 5

(CAT5) according to EN 50173 or ISO/IEC 11801 should be used.

Wiring recommendations

Detailed recommendations for EtherCAT wiring can be found in the documentation "Design recom-

mendations for EtherCAT/Ethernet infrastructure", which is available for download from www.Beck-

hoff.de.

EtherCAT uses four cable wires for signal transmission. Due to automatic cable detection (auto-crossing)

symmetric (1:1) or cross-over cables can be used between EtherCAT devices from BECKHOFF.

Operation

EP1918 19Version: 1.1.0

4.2.2.4 Power connection and grounding

This chapter provides basic information about the power supply and grounding of the EP1918 TwinSAFE

EtherCAT Box. In particular, please note that the General information on connecting the functional earth only

serves as an example.

Supply voltages (power connection)

The supply and distribution of the supply voltages takes place via the connections:

• Us/Up IN for feeding in the supply voltages

• Us/Up OUT for distribution of the supply voltages.

Both connections have an M8 thread and are located to the left (Us/Up IN) and right (Us/Up OUT) of the

TwinSAFE EtherCAT Box (see figure: EP1918 - power connection and FE).

Information: An overview of pin assignment for the two connections can be found later in this chapter.

General information for connecting the functional earth

The earth connection of the EP1918 (see figure: EP1918 - power connection and FE) and the grounding

sleeves in the fastening holes for the M3 screws for fixing the EtherCAT Box are internally connected. The

earth connection is capacitively connected to Us, Up and the shield of the EtherCAT connection.

The earthing screw is installed in the factory. An additional M3 ring cable lug and the earthing cable are

required for the installation

To provide functional earthing , if possible the connection should:

• have a large surface

• have low resistance and

• be permanent.

In order to establish a permanent connection, all operating states of the machine, such as vibrations, must

be taken into account.

NOTE

Connecting the functional earth

The functional earth connection should have low resistance and a large surface.

EP1918 – Power connection and functional earth

M8 - pin assignment

Operation

EP191820 Version: 1.1.0

Contact Voltage

1 Control voltage Us, +24V

DC

(provide a 4A fuse)

2 Peripheral voltage Up, +24V

DC

(provide a 4A fuse)

3 GND Us

4 GND Up

Connecting the functional earth

The contacts of the M8 plug connectors can conduct a maximum current of 4A.

Two LEDs indicate the status of the supply voltages.

NOTE

Do not confuse the power port with EtherCAT port!

Never connect the power cables (M8, 24V

DC

) to the green-marked EtherCAT sockets of the EtherCAT Box

Modules. This can cause the destruction of the modules!

Control voltage Us

The fieldbus and the processor logic are supplied from the 24 V

DC

control voltage Us. The control voltage is

electrically isolated from the fieldbus circuitry.

Peripheral voltage Up

The peripheral voltage Up supplies the digital clock outputs and the safe inputs.

Redirection of the supply voltages

The power IN and OUT connections are bridged in the module. Hence, the supply voltages Us and Up can

be passed from EtherCATBox to EtherCATBox in a simple manner.

CAUTION

Note the maximum current!

Also ensure when forwarding the supply voltages Us and Up that the maximum permissible current of 4A

for each contact of the M8 plug connector is not exceeded!

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Beckhoff EP1918 Operating

Beckhoff EP1918 Operating

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