Kval MLX User manual

Type
User manual
Innovation, Quality & Honesty
Service Manual
Published: April 13, 2023
MLX Multi-Point Lock Router System
With KvalCAM®
MLX Service Manual
KVAL MLX Service Manual
Proprietary Notice
This manual is confidential and contains proprietary information and intellectual property of Kval
Inc., and is to be used solely by Customer as an operating manual for Kval Inc. machines. Neither
this manual nor any of the information contained herein may be reproduced or disclosed under
any circumstances without the express written permission of Kval Inc. For authorization to copy
this information, please call Kval Technical Support at (800) 553-5825 or fax (707) 762-0485.
Manual Name: MLX Service Manual
Manual Revision: 191-MV100.2
MLX is a trademark of Kval Incorporated.
KvalCAM® is a registered trademark of Kval Incorporated.
Copyright 2022 Kval Incorporated. All rights reserved.
Beckhoff®, TwinCAT®, and EtherCat® are registered trademarks and are licensed by Beckhoff
Automation GmbH
All other products are trademarks or registered trademarks of their respective holders, all rights
reserved. Reference to these products is not intended to imply affiliation with or sponsorship of
Kval Incorporated.
Contacting Kval
For further information about this manual or other Kval Incorporated products, please contact us.
Mailing address:
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
Phone and Fax:
call: (800) 553-5825
fax: (707) 762-0485
General Office Business Hours
Mon-Thu:6:00 AM - 4:00 PM PST
Fri: 6:00 AM - 3:30 PM PST
Parts
Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web-
site at the “Contact Us” page.
KVAL MLX Service Manual
KVAL MLX Service Manual
Technical Support
For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact
Us” page.
Mon-Fri:4:00 AM - 4:00 PM PST
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For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the
“Contact Us” page.
Sales Support
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the “Contact Us” page.
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releases), learn about our machine software solutions, download machine documentation, view
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http://www.kvalinc.com
KVAL MLX Service Manual
NOTICE OF OWNERSHIP OF KvalCAM SOFTWARE AND LIMITED LICENSE TO
USE
READ THIS NOTICE CAREFULLY BEFORE USING THE KVALCAM SOFTWARE WHICH OPERATES
KVAL MACHINERY. THIS DOCUMENT CONSTITUTES NOTICE TO YOU THAT YOU HAVE A LIMITED
LICENSE TO USE THE KVALCAM SOFTWARE ON THE TERMS AND CONDITIONS APPEARING BELOW.
BY USING THE KVALCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED
LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE
KVALCAM SOFTWARE.
KVAL, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You
are the purchaser of KVAL Machinery operated by the KVALCAM Software are the “Licensee”.
The computer program(s) and related documentation and materials (herein collectively referred to as “the KvalCAM
Software” and further defined herein) which are used in the operation of the KVAL Machinery are licensed, not sold,
to you for use only upon the limited terms of this license, and Licensor reserves any rights not expressly granted to
you. Licensor retains all ownership of the KvalCAM Software.
Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with KVAL, Inc. The
KVALCAM Software is protected by copyright laws and treaties. Title and related rights in the content generated
through the KVALCAM Software are also the property of the Licensor and are protected by applicable law.
1.
Definitions.
a.“KVALCAM Software” means the KVALCAM computer application installed in the KVAL
Machinery and written documentation and materials provided to you, as well as any res or
updates of such computer application and documentation.
b.“Install” means storing of the KVALCAM Software in the computer component of the KVAL
Machinery.
c.“Use” means executing the KVALCAM Software for purpose of operating the KVAL
Machinery and use of the documentation for properly operating KVALCAM Software.
2. Grant of License.
a.Licensor hereby grants Licensee a non-exclusive, non-transferable license to Use the KVAL-
CAM Software upon payment of all amounts due for the purchase of the related KVAL Machin-
ery.
b.Licensee will make no copies of the KVALCAM Software or alter the KVALCAM Software
in any way. Title to the KVALCAM Software will remain vested in Licensor, and nothing in this
License will give or convey any right, title or interest therein to Licensee except as a licensee.
c.Licensee agrees that it will use the KVALCAM Software or related documentation directly or
indirectly for the benefit of Licensee, and only pursuant to the scope of the grant of the License
set forth herein.
d.Licensee will not decode, alter, decompile, reverse engineer, perform reverse analysis on or
disassemble the KVALCAM Software.
This License will terminate automatically if Licensee fails to comply with the limitations described
above.
MLX Service Manual
Table of Contents
Chapter 1 Introduction to the MLX
Chapter 1 at a Glance...........................................................................1-1
Overview of the MLX Multi-Point Lock Router ......................... 1-3
Options Available ..................................................................................1-3
About this Manual .................................................................... 1-4
Safety First!.............................................................................. 1-5
Safety Sheet Sign-Off Sheet.................................................................1-5
Safety Terminology of Labels................................................................1-5
Safety Guidelines..................................................................... 1-6
Training.................................................................................................1-6
Protective Gear.....................................................................................1-6
When the Machine is Powered and Running........................................1-6
Lockout/Tagout Guidelines ...................................................... 1-7
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-7
Lockout/Tagout Procedure....................................................... 1-8
Pre-Steps Before Lockout/Tagout.........................................................1-8
Lockout/Tagout Power ..........................................................................1-8
Lockout/Tagout Air Supply ....................................................................1-9
Start Maintenance.................................................................................1-9
Post Maintenance Steps.......................................................................1-9
Zero-Energy to Start-Up .......................................................... 1-11
Inspect ................................................................................................1-11
Clean Up.............................................................................................1-11
Replace Guards..................................................................................1-11
Check Controls ...................................................................................1-11
Remove Locks....................................................................................1-11
Perform Visual Checks .......................................................................1-11
Close the Cage Gate ..........................................................................1-12
Getting Help from Kval............................................................. 1-13
Kval Return and Warranty Policy............................................. 1-14
Send the Item .....................................................................................1-14
Acceptance of Return .........................................................................1-14
Refund Turnaround Time ....................................................................1-14
Kval Errors..........................................................................................1-14
Customer Errors .................................................................................1-15
Shipper Errors.....................................................................................1-15
Warranty Replacement Parts..............................................................1-15
Safety Sign-Off Sheet .............................................................. 1-17
A Note to the Operator........................................................................1-17
MLX Service Manual
Table of Contents
Chapter 2 Maintenance of MLX
Maintenance Schedule ............................................................ 2-1
Using Sensors to Trouble Shoot ...........................................................2-4
300 Cycle Maintenance Steps ................................................. 2-5
Clean, Clean, Clean!.............................................................................2-5
600 Cycle Maintenance Steps ................................................. 2-6
Check Air Gauges and Inspect Water Traps.........................................2-6
Inspect Tooling......................................................................................2-6
Lubricate inside of Hopper (990-Series Only).......................................2-7
Empty Dust Collection Units .................................................................2-7
3,000 Cycle Maintenance Steps .............................................. 2-8
Inspect Feed Belts................................................................................2-8
Inspect Screw Drop Tubes on Six Shooter (990-Series Only)..............2-8
Inspect all Photo Eyes ..........................................................................2-9
Inspect Limit Switches ..........................................................................2-9
Inspect Screw Receiver Parts (990-Series Only) .................................2-9
Inspect Airlines....................................................................................2-10
Refill Lubricators.................................................................................2-10
Grease Ball Screw Bearings...............................................................2-11
Clean Bearing Shafts..........................................................................2-11
12,000 Cycle Maintenance Steps............................................ 2-12
Inspect Chains for Proper Tension......................................................2-12
Inspect Air Cylinders...........................................................................2-12
Inspect Hydraulic Lines.......................................................................2-13
Inspect Ball Rail Shafts.......................................................................2-13
Inspect Ball Screw Axle ......................................................................2-13
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........2-14
Clean inside Hopper (990-Series Only)..............................................2-14
72,000 Cycle Maintenance Steps............................................ 2-15
Inspect Nuts and Bolts........................................................................2-15
Check Door Feeding Transition ..........................................................2-15
Electrical .............................................................................................2-15
Computer Backup...............................................................................2-15
Wash Filter and Lubricator Bowls .......................................................2-16
Maintenance NO-GOES .......................................................... 2-17
About Bearings ........................................................................ 2-18
About Pillow Block Bearing Housings.................................................2-18
About Flange Bearing Housings.........................................................2-19
About Ball Rail Bearings.....................................................................2-19
About Tapered Bearings .....................................................................2-20
MLX Service Manual
Table of Contents
Tapered Bearing Housings .................................................................2-20
Ball Screw Nut ....................................................................................2-21
Ball Screw Drive Assembly .................................................................2-21
Pulley and Idler Shafts........................................................................2-22
Lubrication Schedule ............................................................... 2-23
Kval Lubrication Kit.............................................................................2-24
Greasing the Lock Carriage Bearings...................................... 2-25
Recommended Tools ..........................................................................2-25
Lock Carriage Bearing Greasing Procedure.......................................2-25
Locations of the Lock Carriage Head Bearings ..................................2-25
Greasing the Frame Bearings.................................................. 2-27
Recommended Tools ..........................................................................2-27
Frame Bearing Greasing Procedure...................................................2-27
Locations of the Frame Bearings........................................................2-27
Greasing Lock Carriage Servo Bearings ................................. 2-29
Recommended Tools ..........................................................................2-29
Lock Servo Assembly Greasing Procedure ........................................2-29
Z–Axis Servo Assembly Part Identification .........................................2-30
Y–Axis Servo Assembly Part Identification.........................................2-31
About the Tool Kit and Tool Identification................................. 2-32
About the Tool Kit................................................................................2-32
About the Tools in the Carriage .............................................. 2-33
How to Access the Tool Config Screen.................................... 2-34
Check the Tool Config.........................................................................2-34
How to Access to Bit Assemblies........................................................2-35
Changing a Tool Bit.............................................................................2-35
Remove and Replace the Router or Pre-Drill Bits ................... 2-36
Remove Old Bit...................................................................................2-36
Inspect Collet......................................................................................2-36
Insert New Bit .....................................................................................2-37
Remove and Replace the Router or Pre-Drill Bits ..............................2-37
About the Self Lubricator Module ............................................ 2-39
How the Self Lubricator Works ...........................................................2-39
Replace the Lubricator Well................................................................2-39
Description of Air Input System................................................ 2-45
Air Input with Lubrication ...................................................................2-45
Adjusting the Air Line Lubricator ........................................................2-45
Priming the Air Line Lubricator............................................................2-46
Air Line Without Lubricator .................................................................2-46
MLX Service Manual
Table of Contents
Collet Torque Values................................................................ 2-47
Addition Collet Torque Values.............................................................2-48
Chapter 3 Troubleshooting the MLX
Get Live Technical Help ........................................................... 3-1
Troubleshooting Basics ........................................................... 3-2
Before you Adjust..................................................................................3-2
Analyze the Sub Systems.....................................................................3-4
About Motion Control ............................................................... 3-5
Sequencing...........................................................................................3-5
Point to Point ........................................................................................3-5
Incremental...........................................................................................3-5
Basic Control Circuit ................................................................ 3-6
About Typical VFD Motor Drive Control................................... 3-7
About the VFD ......................................................................................3-8
About VFD Troubleshooting..................................................................3-9
About a Typical Pneumatic Circuit ........................................... 3-10
Typical Pneumatic Assembly ..............................................................3-11
About the Coil (Solenoid)....................................................................3-11
About Cylinder Operation ...................................................................3-12
How the Pneumatic System Works ......................................... 3-13
Important Notice about Adjusting Cylinder Speed ..............................3-15
Adjusting Cylinder Extend Speed .......................................................3-15
Adjusting Cylinder Retraction Speed..................................................3-15
Air Assembly Locations............................................................ 3-17
Network System Overview....................................................... 3-18
Connections to Servo Drives ..............................................................3-18
Servo Motor Locations............................................................. 3-20
About Switches and Sensors................................................... 3-22
Using Sensors to Trouble Shoot .........................................................3-23
Download the Machine Electro-Mechanical Map................................3-23
QR CODE...........................................................................................3-24
Description of the Light Tower ................................................ 3-25
CHAPTER 1 Introduction to the MLX
This chapter provides an overview of the Kval MLX Multi-Point Lock Router. Included is important
safety Information and Lockout Tagout procedures.
Chapter 1 at a Glance
The following information is available in this chapter:
TABLE 1- 1. Summary of Chapter
Section Name Summary Page
Overview of the MLX
System
This section provides an overview of the
machine. It includes a general description and
a table of available options
page 1-3
Safety First! IMPORTANT safety information is described
in this section
page 1-5
Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-7
Zero-Energy to Start-Up Procedure to power up your machine for the
first time.
page 1-11
Getting Help from Kval This section describes the method to contact
the Kval Service Center for help. The section
includes how to get information from the
specification plate tor provide to Kval, service
center hours, and return procedures
page 1-13
Safety Sign-Off Sheet A record to track operators that are trained on
the machine.
page 1-17
Overview of the MLX Multi-Point Lock Router
Overview of the MLX Multi-Point Lock Router
1-3
Overview of the MLX Multi-Point Lock Router
The MLX is a computer controlled machine designed to rout the edge and face of a door for most types of
multi-point lock systems as well as standard cylinder locks, strike plates and simple top and bot-
tom flush bolts. The counter rotating spindles also make it possible to rout through the door edge
or an attached astragle without tear-out. Standard G code programming is used to create template
programs that can be selected directly at the touch screen.
Two counter rotating horizontal spindles rout slots for connecting rods as well as pockets for
latches. Afterwards a vertical router/drill plunges through the door stile to machine for the lock
trim holes larger than 10mm (0.397"). Servo motors are used to move the cutting head horizon-
tally (X axis) vertically (Y-Axis), and depth of cut (Z-Axis) on the edge of the door. For the lock
face machining the location and shapes are also computer controlled. The feed table will use non-
marking plastic rolls that will allow the door to be rolled into and out of the machine.
Options Available
Option Title Description
Option A 2-1/4" Door
Capacity
Door clamp system will be set to accommodate doors up to 2-1/4"
thick.
Option B: Jamb Routing Adds Exterior Jamb routing for strikes and hinge pockets using the
door face router. Not for flat or clad jambs. Jamb profile must be
standard rebated style with a section approximately 1-1/4" thick
and thin section approx. 5/8" thick.
No limit to jamb width, but thin section no more than 2-3/8" wide.
Jamb clamps in place facing downward, with the moulded stop
edge against the door backstop, and thin section overhanging the
backstop.
Option includes a touch off probe and encoder to precisely register
jamb face for routing depth. Programming available for hinges and
strike plates, including ASA and multi point plates.
Special Option 1: Raised Moulding
and 4'0" width
Machine bed upgrade to width adjusting system with multiple
support wheels. Maximum door width 4'0".
About this Manual
About this Manual
1-4
About this Manual
This manual is part of a package delivered with the machine line.
Integration Package includes the following:
Operation Manual includes the following:
Service Manual includes the following
Chapter Title Description
1Introduction Descriptions of Machine Line and
Safety Information.
2
Operation Inter-
face
Descriptions of how to power
machine line, and operator inter-
face user screens.
3Calibration Descriptions of Calibration Rou-
tines and how to use the interfaces
4Tour of MLX Identification and descriptions of
the MLX assemblies.
Chapter Title Description
1Introduction Safety Information.
3Maintenance Maintenance steps for the
machine line
4Trouble Shooting Troubleshooting tips and theory of
operation.
KvalCAM Reference Manual
Chapter Title Description
1KvalCAM reference Description of the Interface
2KvalCAM Examples Examples of Common Door Job
Features
3KvalCAM Common
Terms
Common terms associated with
KvalCAM
Safety First!
Safety First!
1-5
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-17.
Safety Terminology of Labels
In addition to the nameplate, Kval machines may have other warning labels or decals that provide
safety information to operators. Safety labels should be clearly visible to the operator and must be
replaced if missing, damaged, or illegible.
There are three types of warning labels or decals:
DANGER means if the danger is not avoided, it will cause death or serious injury.
WARNING means if the warning is not heeded, it can cause death or serious
injury.
CAUTION means if the precaution is not taken, it may cause minor or moderate
injury.
This machine is a powerful electro-mechanical motion control
system. You should test your motion system for safety under
all potential conditions. Failure to do so can result in dam-
age to equipment and/or serious injury to personnel.
Safety Guidelines
Safety Guidelines
1-6
Safety Guidelines
In addition to the caution and warning labels affixed to this machine, follow the guidelines below
to help ensure the safety of equipment and personnel.
Note: Different versions of the stickers may have been applied to the machine. The
intent of safety is the same.
Training
Ensure that all employees who operate this machine are aware of and adhere to all safety precau-
tions posted on the machine and are trained to operate this machine in a safe manner. Figure 1-1
shows a sample of safety labels addressing training.
Read the Manual
FIGURE 1-1. Read the Manual Labels
Protective Gear
Never operate the machine without proper eye and ear protection. Figure 1-2 shows a sample of
safety labels addressing safety gear.
FIGURE 1-2. protective Gear Labels
When the Machine is Powered and Running
Serious injury or death could occur if these general rules are not followed.
Never reach hands beyond safety cage. Servo motors can unexpectedly move
quickly.
Never clear screws or hinges out of the machine while it is running.
Never reach into the router area to retrieve a hinge. The router may still be running
down after shut down.
Lockout/Tagout Guidelines
Lockout/Tagout Guidelines
1-7
Lockout/Tagout Guidelines
Follow these Lockout/Tagout guidelines,
• Place a tag on all padlocks. On the tag, each operator must put their own name and
date. (These locks are only to be removed by the person who signs the tag)
• If more than one person is working on the machine, each additional person places a
lock and tag on each disconnect.
• Only each operator may remove their own lock and tag.
Important: When many people are all working on the same machine you will need a
multiple lockout device, such as the one shown here.
Follow the P-R-O-P-E-R lockout rule of thumb.
P...... Process shutdown
R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)
O...... OFF! Shut off all power sources and isolating devices
P...... Place lock and tag
E...... ENERGY: Release stored energy to a zero-energy state
R ...... Recheck controls and test to ensure they are in the “OFF” state
Lockout/Tagout Procedure
Lockout/Tagout Procedure
1-8
Lockout/Tagout Procedure
This policy is required by OSHA regulation 1910.147 and Cal OSHA’S
SB198 ruling of July 1991.
Use the following lockout procedure to secure this machine while it is
powered down. During a lockout, you disconnect all power and shut
off the air supply. Be sure to use the tagout guidelines noted below.
https://www.osha.gov/
Pre-Steps Before Lockout/Tagout
1. Evaluate the equipment to fully understand all energy sources (multiple
electrical supplies, air supply and pressure, spring tension, weight shifts,
etc.).
2. Inform all affected personnel of the eminent shutdown, and the duration
of the shutdown.
3. Obtain locks, keys, and tags from your employer’s lockout center.
Lockout/Tagout Power
Note: When multiple people are working on the machine, each person needs to have a
lock on the handle in the extra holes provided.
4. Turn the Main Power on ALL electrical panels to the OFF position.
a.Lever style Electrical Panels: ensure the lever is in the down position, insert
lock and tag into the lever hole making sure the lever cannot move, lock as per
the tagout guidelines. (see illustration below).
Lockout/Tagout Procedure
Lockout/Tagout Procedure
1-9
b.Disconnect style Electrical Panels: push the red tab to pop it out. Place a pad-
lock through the hole. Place your tag on the padlock, as per the tagout guide-
lines below. (see illustration below).
Lockout/Tagout Air Supply
5. Turn all air valves to the OFF position and place a padlock through the hole (see
illustration below).
NOTE: Place your tag on the padlock, as per the tagout guidelines.
Start Maintenance
6. Once the locks and tags are in place and all personnel are clear, attempt to operate
the machine to ensure equipment will not operate.
7. Maintenance or repairs may started.
Post Maintenance Steps
8. After maintenance is completed, the person performing the work must ensure all
tools, spare parts, test equipment, etc., are completely removed and that all guards
and safety devices are installed.
Insert Lock into hole.
Turn Switch to the
OFF position
Lock and Tag out
Lockout/Tagout Procedure
Lockout/Tagout Procedure
1-10
9. Before removing the locks and tags, the person who attached them shall inspect the
equipment to ensure that the machine will not be put in an unsafe condition when
re-energized.
10. The lock and tag can now be removed (only by the person(s) who placed them),
and the machine can be re-energized.
11. The tags must be destroyed and the locks and keys returned to the lockout center.
Zero-Energy to Start-Up
Zero-Energy to Start-Up
1-11
Zero-Energy to Start-Up
Starting the equipment properly is just as important as the Lockout/Tagout guidelines in terms of
safety.The following guidelines below should be followed to start the equipment.
Inspect
The equipment must be inspected for proper adjustment before starting equipment.
Clean Up
All materials and debris must be cleaned up. Any combustible materials or old parts used during
repairs must be cleaned up and/or properly disposed of.
Replace Guards
Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with
guard on, contact the Kval Technical Support. See “Getting Help from Kval” on page 1-13.
Check Controls
Confirm that all switches are in the “OFF” position. Please be advised that some components of
the machine may start automatically when energy is restored.
Remove Locks
Each operator must remove his or her own lock and tag. This will ensure that all operators are in a
safe place when the equipment is started.
Perform Visual Checks
If the equipment is too large to see all around it, station personnel around the area and sound the
personnel alarm before starting the equipment. If your operation is more complex, your com-
pany’s comprehensive safety procedure may involve additional steps. You will need to ask your
supervisor about these procedures. The company’s lockout procedure should be posted at each
machine. On larger or long-term maintenance or installation projects, the company’s procedures
must be explained to all new operators and a copy of the company’s procedures should be posted
on-site for the duration of the work.
The Company’s procedures should also include provisions for safely handling shift changes and
changes in operators or new operators.Comprehensive Lockout/Tagout may use a gang box or
other system to ensure that locks are secure and not removed without authorization.
Remember, Lockout/Tagout procedures work because you are the only one with the key to your
lock. Proper Lockout/Tagout can save lives, limbs, and money. Help make your work environment
safe for you and your fellow workers. Be sure to follow the P-R-O-P-E-R Lockout/Tagout proce-
dures, and that those around you do also.
Zero-Energy to Start-Up
Zero-Energy to Start-Up
1-12
Close the Cage Gate
Verify all cage gates are securely closed. Ensure all safety protocols are in effect.
Getting Help from Kval
Getting Help from Kval
1-13
Getting Help from Kval
Before you seek help, first try the troubleshooting procedures. Follow the procedures below.
If you are unable to resolve the problem:
1. Locate the machine’s Specification Plate and record the serial number, 3 phase
volts, electrical print number, and air print number.
2. Contact our customer support team:
• In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485
• Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485
• Email address is [email protected]
• Hours:
6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday
Air Driven Machines
Look for the brass plate
on pre-2019 machines.
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Kval MLX User manual

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