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CONTENTS PAGE I. SPECIFICATIONS--------------------------------------------------------------------------------------- 1 1. SPECIFICATIONS----------------------------------------------------------------------------------- 1 [a] KMD-410MAH (air-cooled) --------------------------------------------------------------------- 1 [b] KMD-410MWH (water-cooled) ---------------------------------------------------------------- 2 II.
1. 10-MINUTE DIAGNOSTIC PROCEDURE -----------------------------------------------------27 2.
I. SPECIFICATIONS 1. SPECIFICATIONS [a] KMD-410MAH (air-cooled) AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day (kg/day) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.
[b] KMD-410MWH (water-cooled) AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day (kg/day) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) WATER COOLED CONDENSER gal./24HR (gal./100 lbs.
II. GENERAL INFORMATION 1.
[b] KMD-410MWH Water Supply Tube Drain Valve Water Supply Inlet Spray Guide Spray Tube Hot Gas Valve Cleaning Valve Water Regulator Access Valve (High Side) Thermistor Expansion Valve Access Valve (Low Side) Condenser Compressor Cube Guide Drier Water Tank Pump Motor Control Box Float Switch Harvest Water Valve Fill Water Valve Control Switch Service Switch Fuse Holder (Fuse) Bin Control Switch 4
2. SEQUENCE OF OPERATION The steps in the sequence are as outlined below. When power is supplied, a 5 second delay occurs at startup. Note that the order of the LEDs from the outer edge of the board is 5, 6, 8, 9, 4, 7. [a] ONE MINUTE FILL CYCLE LED 8 is on. HWV opens and the fill period begins. After 1 minute, the board checks for a closed LF/S. If LF/S is closed, the harvest cycle begins. If not, HWV will remain energized through additional 1 minute cycles until water enters the sump and LF/S closes.
[e] NORMAL HARVEST CYCLE LEDs 5, 6, and 8 are on. Comp continues to run, HGV remains open and HWV opens. As the evaporator warms, the thermistor reaches 9ºC. The control board then receives the thermistor’s 3.9k signal and starts the harvest timer. HWV is open during harvest for a maximum of 6 minutes or the length harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 & 8), whichever is shorter. LED 8 goes off when HWV closes.
7 HWV energized Legend: COMP - compressor DV – drain valve FMS – self-contained fan motor FWV – fill water valve HGV – hot gas valve HWV – harvest water valve LF/S – lower float switch contacts PM – pump motor UF/S – upper float switch contacts “H” board will have 5 second delay COMP energized HGV energized HWV continues FWV de-energized DV de-energized 0, 0,30, or 50 sec xMaximum harvest water valve time: 6 minutes (HWV time is 6 minutes of the length of harvest minus 0, 10, 30, or 50 sec.
3. CONTROL BOARD * A HOSHIZAKI exclusive solid-state control is employed in KMD-410MAH and KMD-410MWH Crescent Cubers. * All models are pretested and factory-adjusted. 1. Fragile, handle very carefully. 2. A control board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the unit when handling or replacing the board. 3.
[a] CONTROL BOARD LAYOUT #4 Harvest Water Valve #5 Freeze Water Valve #1, 2, 3 Float Switch Auxiliary Code Part Number Type Control Board V1 or Earlier V2 or Later P00013-02 P01771-02 HKM2006V003 9
[b] FEATURES a) Maximum Water Supply Period - 6 minutes The harvest water valve will be open during harvest for 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S dip switch 7 & 8), whichever is shorter. b) Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest cycle takes more than 20 minutes to complete. The control board will signal this problem using 2 beeps every 3 seconds.
f) LED Lights and Audible Alarm Safeties The control board includes LED indicator lights, audible alarm safeties, and an output test feature. The "POWER OK" LED indicates control voltage and will remain on unless a control voltage problem occurs. The “POWER OK” LED flashes continuously when the bin is full and DV energizes for a maximum of 5 minutes to drain the water tank. At startup, a 5 second delay occurs to stabilize the circuit.
[c] CONTROLS AND ADJUSTMENTS a) Default Dip Switch Settings The dip switch is factory-adjusted to the following positions: S1 Dip Switch No. KMD-410MAH KMD-410MWH 1 OFF OFF 2 OFF OFF 3 OFF OFF 4 OFF OFF 5 ON ON 6 ON ON 7 ON ON 8 ON ON 9 OFF ON 10 OFF OFF S2 Dip Switch * Functions of S2 dip switch nos. 2 through 6 depend on program version. Control Board Program Ver. P00013-02 2.5 or earlier 3.1 P01771-02 3.2 S2 Dip Switch No.
c) Drain Timer (S1 dip switch 3 & 4) Once every ten freeze cycles, the drain valve opens to drain the water tank for the time determined by the drain timer. These switches also determine the time to delay completion of a defrost cycle, i.e. the minimum defrost time. Do not change this setting, or the unit will not operate properly or produce high quality ice. T1: Time to drain the water tank T2: Harvest timer at drain Drain cycle always occurs on the 2nd harvest after startup.
f) Freeze Timer (S1 dip switch 9 & 10) The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze-up issues. Upon termination of freeze timer, machine initiates the harvest cycle. After 2 consecutive timer terminations, machine will shut down, possibly indicating a problem. The freeze timer is factory adjusted, and no adjustment is required.
S2 Dip Switch Setting No. 6 OFF ON Anti-Slush Control Activated (Ver. 1.0) Deactivated Control Board P01771-02 k) Harvest Promotion Control (S2 dip switch 2) [Program Ver. 3.1, Ver. 3.2] Do not adjust. This must be left in the factory default position or the unit will not operate properly. It is deactivated on the KMD-410 series. When activated, this control promotes harvest of ice on the evaporator that is hard to remove.
temperature at the end of a harvest cycle is 4K or more and if the temperature at the end of a harvest cycle is 48°F (9°C) or less, the harvest cycle is extended for 30 seconds. If the difference between the temperature at the beginning of a freeze cycle and the minimum temperature after 30 seconds in the freeze cycle is 2.5K or more and less than 3.5K, the next harvest cycle is extended for 30 seconds.
[d] CONTROL BOARD CHECK PROCEDURE Before replacing a control board that does not show a visible defect and that you suspect is bad, always conduct the following check procedure. This procedure will help you verify your diagnosis. 1) Check the dip switch settings to assure that S1 dip switch 3, 4, 7, 8, 9, & 10 and S2 dip switch 1 through 6 are in the factory default position. S1 dip switch 1, 2, 5, & 6 are cleaning adjustments and the settings are flexible.
4. HARVEST CONTROL – THERMISTOR A thermistor (semiconductor) is used as a harvest control sensor, anti-slush sensor, and overfreeze sensor. The resistance varies depending on the suction line temperatures. The thermistor detects the temperature of the evaporator outlet to start the harvest timer or momentarily stop the pump motor during the freeze cycle, or to extend the harvest cycle time. No adjustment is required.
5. FLOAT SWITCH [a] EXPLANATION OF OPERATION The float operates 2 switches within the float switch. The lower switch (black and blue wires) is used for low water safety protection, initiating the freeze cycle refill and terminating the freeze cycle. The upper switch (black and red wires) is used to terminate the freeze cycle refill only. Refill will last until the upper float switch closes or the 1 minute countdown timer ends, whichever comes first.
6. BIN CONTROL This machine uses a lever-actuated proximity switch (mechanical bin control) to control the ice level in the storage bin. No adjustment is required. [a] EXPLANATION OF OPERATION The bin control is connected to the K1 connector (pins 4 & 5) on the control board. When the bin control is calling for ice (proximity switch closed; "POWER OK" LED on), the control board continues icemaking operations.
7. SWITCHES Two different control switches are used for operation of KMD-410MAH and KMD-410MWH. These switches are referred to as the "control switch" and the "service switch" and are located on the control box. [a] CONTROL SWITCH This switch is used to place the machine into one of three modes: “OFF” (center position), “ICE” (upper position), and “SERVICE” (lower position).
III. TECHNICAL INFORMATION 1.
2. WIRING DIAGRAM 449000-01 only * The magnetic contactor wiring depends on the contactor model.
24 ON OFF ON OFF RELAY: X2 (HGV/FM) RELAY: X6 (DV) ON OFF RELAY: X1 (COMP) ON OFF ON OFF BIN CONTROL SWITCH RELAY: X5 (FWV) ON OFF UPPER FLOAT CONTACT ON OFF ON OFF LOWER FLOAT CONTACT RELAY: X4 (HWV) ON OFF CLEANING VALVE ON OFF ON OFF DRAIN VALVE RELAY: X3 (PM) ON OFF ON OFF HARVEST WATER VALVE FILL WATER VALVE ON OFF ON OFF Program Ver3.2 HOT GAS VALVE ON OFF ~Program Ver3.
4. PERFORMANCE DATA [a] KMD-410MAH APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 3 gal./day m /day FREEZING CYCLE TIME min. HARVEST CYCLE TIME min. HEAD PRESSURE PSIG kg/cm2G SUCTION PRESSURE PSIG kg/cm2G WATER TEMP. (ºF/ºC) AMBIENT TEMP.
[b] KMD-410MWH APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 3 gal./day m /day FREEZING CYCLE TIME min. HARVEST CYCLE TIME min. HEAD PRESSURE 2 PSIG kg/cm G SUCTION PRESSURE PSIG 2 kg/cm G WATER TEMP. (ºF/ºC) AMBIENT TEMP.
IV. SERVICE DIAGNOSIS 1. 10-MINUTE DIAGNOSTIC PROCEDURE The 10 minute check out procedure is basically a sequence check which can be used at unit start-up or for system diagnosis. Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 21°C or warmer air and 10°C or warmer water temperatures.
a. Lower Float Switch 1st Activation: Refill – The refill can occur at any time during the freeze cycle (1 refill per cycle). As ice builds the water level drops in the reservoir and the lower float switch activates (opens). LED 5 comes on and the control board energizes the fill water valve. The fill water valve remains energized until the upper float switch closes or the 1 minute fill timer terminates, whichever comes first. b.
2. DIAGNOSTIC CHARTS [a] NO ICE PRODUCTION 2. See "II. 6. [b] Bin Control Check Procedure." 5. See chart [a] [7].
1. See "II. 4. Harvest Control - Thermistor." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure.
1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure.
1. Adjust or replace. See "V. 9. Adjustment of Water Regulating Valve." [b] EVAPORATOR IS FROZEN UP 1. See "II. 3. [d] Control Board Check Procedure." 1. See "V. 17. Thermistor." 1. See "II. 3. [c] Controls and Adjustments, b) Harvest Timer.
1. See "II. 3. [d] Control Board Check Procedure." [c] LOW ICE PRODUCTION a) See chart [b] [1] and check float switch, fill and harvest water valves, control board, water pump, spray tubes, evaporator, and expansion valve. b) See chart [a] [1] and check dirty air filter or condenser, ambient or water temperature, refrigerant charge, water pressure, and condenser water regulating valve (water-cooled model only).
a) See chart [b] [1] & [3] and check float switch, fill and harvest water valves, control board, spray tubes, water system, refrigerant charge, and expansion valve. [e] OTHER 1. See "II. 6. [b] Bin Control Check Procedure.
V. REMOVAL AND REPLACEMENT 1. SERVICE FOR REFRIGERANT LINES [a] SERVICE INFORMATION 1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R404A] The compressor must not be opened more than 15 minutes in replacement or service. Do not mix lubricants of different compressors even if both are charged with the same refrigerant, except when they use the same lubricant. 2) Treatment for Refrigerant Leak [R404A] If a refrigerant leak occurs in the low side of an ice maker, air may be drawn in.
7) Evacuation, Vacuum Pump and Refrigerant Charge [R404A] Never allow the oil in the vacuum pump to flow backward. The vacuum level and vacuum pump may be the same as those for the current refrigerants. However, the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for R404A. 8) Refrigerant Leak Check Refrigerant leaks can be detected by charging the unit with a little refrigerant, raising the pressure with nitrogen and using an electronic detector.
2. BRAZING Note: All brazing connections inside the bin are clear coated. Sandpaper the brazing connections before unbrazing the components. Use a good abrasive cloth to remove the coating. 3. COMPRESSOR 1) Turn off the power supply. 2) Remove the panels and water tank. See "V. 14. WATER TANK.
3) Recover the refrigerant and store it in an approved container. 4) Remove the terminal cover on the compressor and disconnect the compressor wiring. 5) Remove the hold-down bolts, washers, and rubber grommets. 6) Remove the discharge and suction pipes. 7) Remove the compressor. Unpack the new compressor package. 8) Attach the rubber grommets of the prior compressor. 9) Place the compressor in position and secure it using the bolts and washers. 10) Remove the drier, then place the new drier in position.
5) Remove the drier using brazing equipment. 6) Braze the new drier, with the arrow on the drier in the direction of the refrigerant flow. Use nitrogen gas at a pressure of 20 to 30 kPa when brazing tubings. Braze in an access valve using a tee if necessary. 7) Check for leaks using nitrogen gas (970 kPa) and soap bubbles. 8) Evacuate the system and charge it with refrigerant (see "V. 1. [c] EVACUATION AND RECHARGE"). 9) Refit the panels in their correct positions. 10) Turn on the power supply.
8) Install the new drier (see "V. 4. DRIER"). 9) Check for leaks using nitrogen gas (970 kPa) and soap bubbles. 10) Evacuate the system and charge it with refrigerant (see "V. 1. [c] EVACUATION AND RECHARGE"). 11) Attach the solenoid coil to the valve body, and secure it with the screw. 12) Connect the lead wires. 13) Refit the panels in their correct positions. 14) Turn on the power supply. 6. EXPANSION VALVE 1) Turn off the power supply. 2) Remove the panels.
9) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. 10) Attach the expansion valve bulb to the suction line in the same location as the previous bulb. The bulb should be at the 12 o'clock position on the tube. Be sure to secure the bulb with the clamp and holder and to insulate it. 11) Place the expansion valve cover in position. 12) Replace the panels in their correct positions. 13) Turn on the power supply.
14) Turn on the power supply. 8. WATER REGULATING VALVE – WATER-COOLED MODEL ONLY 1) Turn off the power supply. 2) Remove the panels. 3) Close the condenser water supply line shut-off valve, then open the condenser water supply line drain valve. 4) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve. 5) Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring.
17) Check for water leaks. 18) Replace the panels in their correct positions. 19) Turn on the power supply. 9. ADJUSTMENT OF WATER REGULATING VALVE – WATER-COOLED MODEL ONLY The water regulating valve (also called "water regulator") is factory-adjusted. No adjustment is required under normal use. Adjust the water regulator, if necessary, using the following procedures. 1) Prepare a thermometer to check the condenser drain temperature. Attach a pressure gauge to the high-side line of the system.
7) Replace the panels in their correct positions. Screw (Loosen) 8) Turn on the power supply. Screw Screw (Remove) Fan Motor Fan Motor Bracket Fan Blade Cover 11. PUMP MOTOR 1) Turn off the power supply. 2) Remove the panels and front insulation. 3) Disconnect the connector of the pump motor lead. 4) Remove the thumbscrew securing the pump motor. 5) Remove the hose band connecting the discharge hose. 6) Slide the pump motor at right slightly and lift it up towards you.
7) Remove the hose band connecting the discharge outlet and pull off the rubber hose. 8) Install the new motor in the reverse order of the removal procedure. 9) Replace the panels and front insulation in their correct positions. 10) Turn on the power supply. 12. WATER VALVE 1) Turn off the power supply. 2) If replacing the harvest and/or fill water valve, close the icemaker water supply line shut-off valve. Open the icemaker water supply line drain valve. 3) Remove the panels.
7) Remove the two mounting screws. 8) Install the new valve in the reverse order of the removal procedure. 9) Open the water supply tap. 10) Plug in the icemaker or connect the power source. 11) Check for leaks. 12) Refit the panels in their correct positions. 14. WATER TANK 1) Remove the front panel, then remove the front insulation 2) Loosen the two thumbscrews securing the pump motor bracket 3) Move the control switch to the "SERVICE" position. Move the service switch to the "DRAIN" position.
10) Install the new water tank in the reverse order of the removal procedure. 11) Refit the panels in their correct positions. 12) Turn on the power supply. 15. FLOAT SWITCH 1) Remove the pump motor bracket. See "V. 14. WATER TANK." 2) Pull up the pump motor bracket from the water tank. 3) Flip over the pump motor bracket assembly, then twist off the float switch and pull out towards you.
4) Install the new float switch in the reverse order of the removal procedure. 5) Refit the panels in their correct positions. 6) Turn on the power supply. 16. BIN CONTROL SWITCH CAUTION Do not drop or impact the bin control switch. The reed switch inside may be damaged. 1) Remove the water tank. See "V. 14. WATER TANK." 2) Disconnect the connector of the bin control switch lead (black). 3) Pull out the bin control switch tab outside and slide the bin control switch towards you.
8) Connect the bin control connector to the side of the control box. 9) Replace the water tank, cube guide, pump motor bracket, pump motor and float switch in their correct positions until they snap in place. CAUTION Be sure to let the discharge hose pass behind the copper tube and connect it securely in position. Otherwise, the discharge hose may be caught in the front insulation, leading to improper results. 10) Secure the pump motor bracket with the two thumbscrews.
4) Remove the ties, insulation, thermistor holder, and thermistor in this order. 5) Remove the old sealant from the thermistor holder and suction pipe. 6) Wipe off any moisture or condensation from the suction pipe surfaces. 7) Press a tube of the sealant KE 60RTV, manufactured by Shin-Etsu Silicones, to the recess of the thermistor holder. Slowly squeeze the sealant out of the tube and spread it smoothly in the recess. Do not use any sealant other than the above.
5) Refit the removed parts in the reverse order of the removal procedure. Screws Control Box Cover Screw Control Box Note: After replacing the components inside the control box, connect and tie the wires properly in their correct position. Especially make sure that the harness does not press the push buttons on the control board.
[a] CONTROL & SERVICE SWITCH 1) Disconnect the tab terminals and remove the nut securing the power switch. 2) Install the new switch in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [b] FUSE 1) Use a phillips head screwdriver to remove the fuse holder cap and take out the fuse. 2) Install the new fuse in the reverse order of the removal procedure.
[g] STARTER 1) Disconnect the terminals, remove the mounting screw. 2) Install the new starter in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [h] RUN CAPACITOR 1) Disconnect the terminals on the starter and remove the nut securing the run capacitor. 2) Install the new run capacitor in the reverse order of the removal procedure.
Tabs Hose Band Water Supply Tube (under Spray Tube) Spray Tube Hose Hose Band 6) The spray tube is easily cleanable by removing the black rubber caps on the ends. 7) Remove the hose band connecting the water supply tube. 8) Pull the water supply tube towards you. 9) Remove the top insulation. 10) The spray guide is located under the water supply tube. Pull off the spray guide from the evaporator. Spray Guide 11) Refit the removed parts in the reverse order of the removal procedure.
VI. CLEANING AND MAINTENANCE INSTRUCTIONS 1. CLEANING [a] CLEANING PROCEDURE 1) Dilute approximately 9.5 fl. oz. (281 ml) of recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 1.8 gallon (6.8 lit.) of water. 2) Remove all ice from the evaporator and the storage bin/dispenser unit. Note: To remove cubes on the evaporator, turn off the power supply and turn it on after 3 minutes. The harvest cycle starts and the cubes will be removed from the evaporator.
7) Remove the front panel then remove the front insulation (the large insulation panel in front of the evaporator) by lifting up the panel slightly and pulling it towards you. 8) In bad or severe water conditions, clean the float switch as described below. Otherwise, continue to step 9. a. Loosen the two thumbscrews securing the pump motor bracket. b. Disconnect the discharge hose. c. Disconnect the pump motor connector and the float switch connector from the side of the control box. d.
g. Wipe down the float switch housing, shaft and float with cleaning solution. Rinse the parts thoroughly with clean water. h. Replace the float switch in its correct position. i. Replace the removed parts in the reverse order of which they were removed. 9) Pour the cleaning solution into the water tank. 10) Move the service switch to the "WASH" position. 11) Replace the front insulation and the front panel in their correct positions. 12) Turn on the power supply to start the washing process.
31) Remove the front panel. 32) Repeat steps 18 through 31 three more times to rinse thoroughly. Note: If you do not sanitize the icemaker, go to step 14 in "Sanitizing Procedure." [b] SANITIZING PROCEDURE – FOLLOWING CLEANING PROCEDURE 1) Dilute a 5.25% sodium hypochlorite solution (chlorine bleach) with water (add approximately 0.9 fl. oz. (27 ml) to 1.8 gal. (6.8 lit.) of water). 2) Remove the front insulation. 3) Pour the sanitizing solution into the water tank.
[a] STAINLESS STEEL EXTERIOR To prevent corrosion, wipe the exterior occasionally with a clean, soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. [b] STORAGE BIN AND SCOOP * Wash your hands before removing ice. Use the plastic scoop provided (bin accessory). * The storage bin/dispenser unit is for ice use only. Do not store anything else in the storage bin/dispenser unit. * Clean the scoop and the storage bin/dispenser unit liner using a neutral cleaner.
2) Move the control switch on the control box to the "OFF" position. 3) Wait 3 minutes. 4) Move the control switch to the "ICE" position. 5) Replace the front panel in its correct position and turn on the power supply. 6) Allow 5 minutes for the icemaker to fill with water and the water pump to start operating. 7) Close the condenser water supply line shut-off valve. 8) Open the condenser water supply line drain valve. 9) Allow the line to drain by gravity.
4) Turn off the power supply and remove the front panel. 5) Move the control switch to the "OFF" position. 6) Replace the front panel in its correct position. 7) Remove all ice from the storage bin/dispenser unit, and clean the storage bin/dispenser unit. 8) Close the icemaker water supply line drain valve.
