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Trane Intellipak 2 Service Manual

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    							Installation
    RT-SVX24K-EN91
    Figure 59. Typical field wiring diagram for 90 to 162 ton VAV control options 
    						
    							Installation
    92RT-SVX24K-EN
    Figure 60. Typical field wiring diagram notes for 90 to 162 ton VAV and CV control options 
    						
    							Installation
    RT-SVX24K-EN93
    Figure 61. Typical GBAS analog input wiring diagram for 90 to 162 ton CV and VAV control options
    Note:See Figure 64, p.  101 
    						
    							Installation
    94RT-SVX24K-EN
    Table 35. GBAS voltage vs. setpoint
    SetpointGBAS 0-5 VDCGBAS 0-10 VDCValid Range
    Occ Zone Cooling Setpoint(CV only)0.5 to 4.5 VDC0.5 to 9.5 VDC50 to 90°F
    Unocc Zone Cooling Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 50 to 90°F
    Occ Zone Heating Setpoint(CV only)0.5 to 4.5 VDC0.5 to 9.5 VDC50 to 90°F
    Unocc Zone Heating Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 50 to 90°F
    SA Cooling Setpoint (VAV only)0.5 to 4.5 VDC0.5 to 9.5 VDC40 to 90°F
    SA Cooling Setpoint (SZVAV only) 0.5 to 4.5 VDC 0.5 to 9.5 VDC 40 to 70°F
    Zone Cooling Setpoint (SZVAV only)0.5 to 4.5 VDC0.5 to 9.5 VDC50 to 80°F
    Zone/Return Critical Temperature Setpoint (RR only) 0.5 to 4.5 VDC 0.5 to 9.5 VDC 75 to 95°F
    SA Heating Setpoint (VAV only)0.5 to 4.5 VDC0.5 to 9.5 VDC40 to 180°F
    SA Heating Setpoint (SZVAV only) 0.5 to 4.5 VDC 0.5 to 9.5 VDC 65 to 95°F
    Space Static Pressure Setpoint0.5 to 4.5 VDC0.5 to 9.5 VDC-0.20 to 0.30 IWC
    SA Static Pressure Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 0.7 to 5.1 IWC
    Min OA Flow Setpoint 10.5 to 4.5 VDC0.5 to 9.5 VDC0 to Unit Max Flow
    MWU Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 50 to 90°F
    Econ Dry Bulb Enable Setpoint0.5 to 4.5 VDC0.5 to 9.5 VDC50 to 140°F
    SA_Reheat_Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 60 to 90°F
    Minimum Position Setpoint 30.5 to 4.5 VDC0.5 to 9.5 VDC0 to 100%
    Occ Dehumidification Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 40 to 65%
    Unocc Dehumidification Setpoint0.5 to 4.5 VDC0.5 to 9.5 VDC40 to 65%
    Occ Humidification Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 20 to 50%
    Unocc Humidification Setpoint0.5 to 4.5 VDC0.5 to 9.5 VDC20 to 50%
    Notes:  1. If DCV is enabled this is used for Design Minimum OA Flow Setpoint
     2. If DCV is enabled, this is used for Design Minimum OA Damper Position Setpoint
    Table 36. GBAS 0-10 VDC output range
    SetpointGBAS 0-10 VDCValid Range
    Outdoor Air Temperature0.5 to 9.5 VDC-40 to 200°F
    Zone Temperature 0.5 to 9.5 VDC -40 to 200°F
    Supply Air Temperature (VAV only)0.5 to 9.5 VDC-40 to 200°F
    Supply Air Pressure (VAV only) 0.5 to 9.5 VDC 0.0 to 7.91 wc
    Space Pressure0.5 to 9.5 VDC-0.67-0.67 wc
    Space RH 0.5 to 9.5 VDC 0-100%
    OA RH0.5 to 9.5 VDC0-100%
    Space CO2 Level 0.5 to 9.5 VDC 50-2000 PPM
    Cooling Capacity %0.5 to 9.5 VDC0-100%
    Heating Capacity % 0.5 to 9.5 VDC 0-100%
    Outdoor Air Damper Position0.5 to 9.5 VDC0-100%
    Outdoor Airflow 0.5 to 9.5 VDC 0 to 65,000 CFM 
    						
    							Installation Checklist
    RT-SVX24K-EN95
    Installation Checklist
    General Checklist (applies to all units)
    
    Unit checked for shipping damage and material
    shortage
    Verify that the installation location of the unit will
    provide the required clearance for proper operation
     Roof curb assembled and installed
    Roof curb level and square
    Ductwork secured to curb, or unit
    Corners of duct adapters sealed on units with horizontal
    supply or return
    Horizontal supply or return ductwork is self supporting
    Pitch pocket installed for units with power supply
    through building roof
    Unit set on curb and checked level
    Unit-to-curb seal checked to ensure it is tight and
    without buckles or cracks
    Condensate drain lines installed to each evaporator
    drain connection
    Verify that all access doors open 100% and are not
    obstructed by drain lines etc.
    Shipping hardware removed from each compressor
    assembly
    Shipping hold-down bolts and shipping channels
    removed from the supply and exhaust/return fans with
    spring isolators
    Supply and exhaust/return fans spring isolators
    checked for proper adjustment
    Plastic coverings (paint shields) removed from all
    compressors (if present)
    Verify all discharge, suction, and liquid line service
    valves are back seated
    Compressor crankcase heaters energized for a
    minimum of 12 hours prior to unit refrigeration system
    startup
    Verify that unit literature (IOM, PTG) are left inside
    control box for startup
    Unit Rigging and Placement (Two-Piece—
    addition to General Checklist)
    
    First, rig and set the low side unit on the roof curb
    (aligned with return end)
     Remove the rail connector splice brackets and install
    the brackets on the low side unit base rails
    Take off the side panels (these are labeled) and the top
    cover of the high side unit and set aside to be assembled
    later
    Rig and set the high side unit on roof curb pedestal
    Lift the unit and position it over the pedestal
    Use the rail splice bracket as an alignment aid to
    connect the Low and high side units. The Low and high
    side unit rails should be butted together with a maximum
    2 (preferably 1) separation
    Remove the left upper and lower louvered panels of the
    high side unit as well as the corner panels on each side to
    aid in tubing and wiring connections
    Close refrigeration shut off valves as indicated in this
    manual—Liquid, discharge, hot gas bypass (if present),
    and hot gas reheat (if present).
    For Evaporative Condensers
    Recover/transfer charge from tubing between shut
    valves and stub point.
    For 2 and 3 piece Air-Cooled condensers add field
    charge per nameplate.
    Braze refrigerant piping connections and leak test
    Low side and high side evacuated to 500 microns
    Standing vacuum does not rise over 200 microns in 15
    minutes
    Open service valves to allow refrigerant flow
    Refrigerant released from discharge to suction until
    suction pressure is approximately 60 PSIG
    Power wires connected in connection box
    Control wires connected in connection box
    Seal air gaps around wiring and refrigerant tubing
    through bulkhead
    Side panels and top cover assembled between high and
    low side
    Verify line dampening weights are installed on each
    discharge line.
    Unit Rigging and Placement (Three-piece
    unit) (in addition to Two-piece unit rigging
    and placement)
    
    Rail guide attached to evaporator section base rails
    Evaporator section rigged and set onto roof curb,
    aligned with supply end
    Removed and discarded shipping protection panels
    and top blockoffs from evaporator section
    Removed side panels and roof cap from evaporator
    section
    Applied gasket and butyl tape as indicated in the IOM
    Removed and discarded shipping protection panels
    and top block off from outside air section
    Rigged and set outside air section onto roof curb to
    within 2 of evaporator section 
    						
    							Installation Checklist
    96RT-SVX24K-EN
    Using 0.75 x 24 threaded rod pull and secure
    evaporator section and outside air section together
    Using .375 bolts, nuts and washers pull and secure the
    roof rails together
    Installed roof splice plate
    Added bullwrap to electrical wiring between
    evaporator and outside air section
    Connected power and control wiring between
    evaporator and outside air section
    Gasket applied and side panels installed on unit split
    Butyl tape applied on top of unit split along roof seam
    and roof cap installed
    Field Installed Control Wiring—Complete the field
    wiring connections for constant volume or variable air
    volume controls as applicable. Refer to “Field Installed
    Control Wiring” for guidelines
    Electric Heat Units
    Inspect the heater junction box and control panel;
    tighten any loose connections
    Check electric heat circuits for continuity
    Two and Three piece units only) Route power wiring to
    high side junction box
    Gas Heat Units
    Gas supply line properly sized and connected to the unit
    gas train
    All gas piping joints properly sealed
    Drip leg Installed in the gas piping near the unit
    Gas piping leak checked with a soap solution. If piping
    connections to the unit are complete, do not pressurize
    piping in excess of 0.50 psig or 14 W.C. to prevent
    component failure
    Main supply gas pressure between 7 and 14 W.C.
    Flue Tubes clear of any obstructions
    Factory-supplied flue assembly installed on the unit
    Connect the 3/4 CPVC furnace drain stub-out to a
    proper condensate drain
    Install field provided heat tape to furnace drain line
    Hot Water Heat
    Route properly sized water piping through the base of
    the unit into the heating section
    Install the factory-supplied, 3-way modulating valve
    Complete the valve actuator wiring
    Steam Heat
    Route properly sized steam piping through the base of
    the unit into the heating section
    Install the factory-supplied, 2-way modulating valve
    Complete the valve actuator wiring
    Install 1/2, 15-degree swing check vacuum breaker(s)
    at the top of each coil section. Vent breaker(s) to the
    atmosphere or merge with return main at discharge side of
    steam trap
    Position the steam trap discharge at least 12 below the
    outlet connection on the coil
    Use float and thermostatic traps in the system, as
    required by the application.
    O/A Pressure Sensor and Tubing Installation (All VAV
    units and CV units with return fan or StatiTrac)
    O/A pressure sensor mounted to the roof bracket
    Factory supplied pneumatic tubing installed between
    the O/A pressure sensor and the connector on the vertical
    support
    (Units with StatiTrac) Field supplied pneumatic tubing
    connected to the proper fitting on the space pressure
    transducer located in the filter section, and the other end
    routed to a suitable sensing location within the controlled
    space
    Electrical
    Verify that the power supply to the unit complies with
    the unit nameplate specification
    Properly ground the unit
    Inspect all control panel components and tighten any
    loose connections
    Connect properly sized and protected power supply
    wiring to a field supplied/installed disconnect and the unit
    (copper wiring only to the unit)
    Verify that phasing to the unit is correct (ABC)
    Turn the 1S2 toggle switch off to prevent accidental unit
    operation
    Turn on power to the unit
    Press the STOP button on the Human Interface (1U2)
    Verify that all compressor crankcase heaters are
    energized for at least 12 hours prior to unit startup
    Evaporative Condenser
    Remove fan bracket
    Hookup inlet and drain piping
    Install Heat tape if needed
    Setup drain hold or drain on power loss
    Setup Mechanical Float
    Setup drain time
    Setup water quality management (3rd party or Trane
    factory-installed Dolphin Water Care System)
    Options setup
    Calibrate Conductivity Controller
    Setup blowdown set points on the conductivity
    sensor 
    						
    							Installation Checklist
    RT-SVX24K-EN97
    Energy Recovery Wheel
    Verify that the wheel turns freely though a full rotation
    Confirm that all wheel segments are fully engaged in
    the wheel frame and that the segment retainers are
    completely fastened
    Confirm the seal adjustment and proper belt tracking on
    the wheel rim 
    						
    							98RT-SVX24K-EN
    Unit Startup
    Sequence of Operation
    Cooling Sequence of Operation
    Time delays are built into the controls to increase
    reliability and performance by protecting the compressors
    and maximizing unit efficiency.
    SZVAV Cooling Sequence of Operation
    Single Zone VAV units will be equipped with a VFD
    controlled supply fan which will be controlled via the 0-
    10VDC RTM VFD output and the RTM Supply Fan output.
    With the RTM Supply Fan output energized and the RTM
    VFD output at 0Vdc the fan speed output is 37% (22Hz) from the VFD motor, by default, and at 10VDC the Fan
    Speed output is 100% (60Hz). The control scales the 0-
    10Vdc VFD output from the RTM linearly to control
    between the 37%-100% controllable range.
    If the RTM determines that there is a need for active
    cooling capacity in order to meet the calculated
    Temperature Setpoint (Tset), the unit will begin to stage compressors accordingly once supply fan proving has
    been made. Note that the compressor staging order will be
    based on unit configuration and compressor lead/lag
    status.
    Once theTset calculation has reached its bottom limit (Tset
    Lower Limit Setpoint) and compressors are being utilized
    to meet the demand, theTset value continues to calculate
    below theTset Lower Limit Setpoint and the algorithm will
    begin to ramp the Supply Fan Speed up toward 100%.
    Note that the supply fan speed will remain at the
    compressor stage’s associated minimum value (as
    described below) until the Tset value is calculated below
    the Tset Lower Limit Setpoint.
    As the cooling load in the zone decreases the zone cooling algorithm will reduce the speed of the fan down to
    minimum per compressor stage and control the
    compressor outputs accordingly. As the compressors
    begin to de-energize, the Supply Fan speed will fall back to
    the Cooling Stage’s associated minimum fan speed, but
    not below. As the load in the zone continues to drop
    cooling capacity will be reduced in order to maintain the
    discharge air within the ± ½ Tset deadband.
    Cooling Stages Minimum Fan Speed
    As the unit begins to stage compressors to meet thecooling demand, the following minimum Supply Fan
    Speeds will be utilized for each corresponding Cooling
    Stage. Note that the Supply Fan Speed will be allowed to ramp up beyond 37% as determined by the active Tset
    calculation; the speeds below are only the minimum
    speeds per cooling stage. Note that when transitioning
    between active cooling stages, compressors may energize
    prior to the supply fan reaching the minimum speed for the
    associated step.
    1. 2-Stage DX Cooling -The minimum fan speed for units
    with 2 stages of DX Cooling will be 37% of the unit’s full
    airflow capacity. At Stage 1 of DX Cooling the
    minimum Fan Speed will be 37% and at Stage 2 of DX
    Cooling the Fan Speed will be at a minimum of 67%.
    2. 3-Stage DX Cooling - There are no IntelliPakapplications with 3 stages of DX Cooling.
    3. 4-Stage DX Cooling -The minimum fan speed for units with
     4 stages of DX Cooling will be 37% of the unit’s
    total airflow. At Stage 1 the minimum Supply Fan
    Speed will be 37%, at Stage 2 the minimum Supply Fan
    Speed will be 58%, and at Stages 3 & 4 the minimum
    Supply Fan Speed will be 67%.
    Rapid Restart
    This feature will occur after every power cycle. Once power is restored (e.g., via a backup generator), the RTM
    will maximize cooling capacity within 3-5 minutes. Once
    the space has returned to its Zone Temperature Setpoint,
    the RTM controls the load using normal capacity control
    algorithms. The supply fan will be turned on immediately
    after a power cycle, module initialization, or after the Unit
    Start Delay has timed out. The supply fan proving switch
    input must be closed prior to continuing with Rapid
    Restart.
    Once the supply fan proving switch input has closed, the
    unit will consider the outside air temperature to determine
    whether economizing or DX mechanical cooling will be
    utilized to provide the necessary cooling. If the outside air
    temperature is less than 50°F and economizing is enabled,
    the outside air damper will be utilized. If the outside air
    temperature is above 50°F, the outside air damper will
    remain closed and DX mechanical cooling will occur for
    the duration of Rapid Restart.
    Compressor Sequence of Operation
    Each compressor is equipped with a crankcase heater and
    is controlled by a 600 volt auxiliary switch on the
    compressor contactor. The proper operation of the
    crankcase heater is important to maintain an elevated
    compressor oil temperature during the “Off” cycle to
    reduce oil foaming during compressor starts.
    When the compressor starts, the sudden reduction in crankcase pressure causes the liquid refrigerant to boil
    rapidly causing the oil to foam. This condition could
    damage compressor bearings due to reduced lubrication
    and could cause compressor mechanical failures.
    NOTICE:
    Compressors Failure!
    Unit must be powered and crankcase heaters energized
    at least 8 hours BEFORE compressors are started. This
    will protect the compressors from premature failure. 
    						
    							Unit Startup
    RT-SVX24K-EN99
    Low Ambient Compressor Operation
    Certain applications require compressor operation at
    lower ambient conditions than standard units. Low
    ambient compressor operation is a factory configured
    option that allows units to operate down to -10°F by
    extending the low ambient compressor lockout setpoint
    range.
    Standard configuration units are limited to a minimum
    low ambient compressor lockout setpoint of 40° F. In
    conditions below 40°F the low-pressure cutout (LPC)
    switch can open in the first few minutes of initial
    compressor operation due to refrigerant circulation
    characteristics. To prevent nuisance LPC events at startup
    in these conditions the unit controller will bypass LPC
    processing for a varying period of time as defined below:
    – For ambient temps below 20°F LPC events will bebypassed for the first 170 seconds of compressor
    operation.
    For ambient temps between 20° and 40°F the bypass time
    reduces linearly from 170 seconds at 20°F to 0 seconds at
    40°F. LPC events are not bypassed at initial compressor
    start in ambient conditions above 40°F.
    – An open LPC switch detected at compressor startwill result in a manual-reset compressor lockout
    condition.
    – 4 consecutive LPC trip occurrences after the bypass time expires without a minimum of 3 minutes of
    compressor operation between trips will result in a
    manual-reset compressor lockout.
    In addition to alternate LPC event processing, the second
    compressor to start on each refrigerant circuit will be
    disabled for 40 minutes each time a circuit starts in
    ambient conditions less than 40°F. To properly maintain
    head pressure control in low ambient conditions one
    condenser fan on each refrigerant circuit will be controlled
    by a Variable-frequency motor drive (VFD).
    This fan will always be the first fan active. The VFD will control fan speed at all times compressors are active to the
    HI-adjustable Low Ambient Control Point. If head pressure
    control requires additional condenser fan stages to
    maintain proper Saturated CondenserTemperature within
    limits they will be activated as necessary according to the
    standard head pressure control fan-staging algorithm.
    Units with Evaporative Condenser
    Sequence of Operation
    Upon a power up without water in the sump, the
    condenser sump drain will be controlled to allow the sump
    to hold water.The fill relay will be energized if there is a call
    for mechanical cooling and if the outdoor air temperature
    is greater than 10°F on units with a sump heater installed
    or greater than 40°F on units without sump heat. Once the
    fill solenoid is energized, the sump will begin to fill. The
    minimum water level switch will close and the fill relay will
    be de-energized. The sump water temperature sensor is
    invalid unless the minimum water level switch is closed.
    If the sump water temperature is less than the setpoint
    (default is 38°F), the sump heater will be energized until
    the water temperature reaches the setpoint plus 5 degrees
    (43°F for default).The fill solenoid will remain closed for 20
    minutes or until the water temperature is greater than 35°F.
    Once a water temperature of 35°F or greater is achieved,
    the fill solenoid is energized, the sump will continue to fill,
    and a five minute timer is started.
    When the timer expires, the compressor lockout will be released and mechanical cooling will be allowed. Head
    pressure control will be regulated by a variable speed fan
    until the liquid line pressure from either circuit reaches the
    upper limit, which is set on the Human Interface under the
    setup menu 120°F default. The liquid line pressure is
    converted to a temperature for display at the Human
    Interface. When the temperature exceeds the upper limit,
    the condenser sump pump will be energized. When the
    sump pump is energized, water is pumped from the sump
    and sprayed over the condenser coil. If the liquid line
    pressure from either circuit falls below the lower limit the
    sump pump will be de-energized.
    When the sump pump is energized or de-energized a change in state is observed from an auxiliary contactor to
    ensure proper sump pump operation. A change in states
    must be observed by the auxiliary contactor within 6
    seconds of the command to change states or mechanical
    cooling will be locked out on a sump pump failure causing
    a manual reset diagnostic to be set.
    The fill solenoid will remain energized and the water level will be controlled by the mechanical float valve. If the
    maximum level float ever closes, an information-only
    diagnostic is set and the fill solenoid is de-energized. This
    is an indication that the mechanical float is not adjusted
    properly or a failure of the mechanical float valve has
    occurred. If the maximum level input is open for two
    continuous minutes, the diagnostic will be cleared and the
    fill solenoid will be energized.
    If the sump water temperature ever drops below 35°F, the
    drain actuator will be controlled in order to drain the water
    from the sump. If there is a call for mechanical cooling and
    the outdoor air temp is greater than 10°F on units with
    sump heat installed or greater than 40°F on units without
    sump heat, the unit will be allowed to refill the sump.
    00F20F40F
    170
    Outdoor Air Temp(° F)
    LPC Bypass Time (sec) 
    						
    							Unit Startup
    10 0RT-SVX24K-EN
    The drain control can be configured via the Human
    Interface, and by the drain actuator installation, to hold or
    drain water on power loss; the default is set to drain.
    Periodic purge is a cyclic opening of the drain to remove
    debris and buildup from the sump and add additional
    fresh water to the sump. Periodic purge has an adjustable
    interval from the setup menu on the Human Interface with
    a range of 1-12 hours or can be set to disabled - the default
    position if periodic purge is not required. The duration of
    the blowdown, or the time that the drain valve is opened,
    is adjustable to a range of 5 - 255 seconds, with 120
    seconds being the default.
    The optional conductivity controller also uses this timer to open the drain, when required, based on water quality.
    During this purge, the fill solenoid will remain energized to
    provide fresh water to the sump to replace water being
    released during the blowdown. Water treatment
    blowdown is provided by shorting the designated input on
    the customer-supplied terminal strip. This gives the
    customer more flexibility in determining water conditions
    via external controls. Once the input is detected closed, the
    drain valve will be opened for a time equal to the Human
    Interface adjustable periodic purge duration.
    Once the duration timer expires, or if the minimum level
    switch opens, the drain valve will be closed and the water
    treatment blowdown input will be ignored for 15 minutes.
    During this blowdown the fill relay will remain open to
    provide fresh water to the sump. The adjustable duration
    time period should be set so that during drain operation 1
    inch of water is drained from the sump with the fill
    solenoid valve closed. If the minimum water level switch
    opens during a blowdown cycle, the unit will de-energize
    the sump pump in order to protect the compressors and
    sump heater from insufficient water levels. Once the water
    level reaches the minimum level input and this input
    closes for 10 seconds, the compressors and sump heater
    operations will be allowed to restart.Evaporative Condenser Drain Valve Setup
    The drain valve is shipped to “Drain During Unit PowerLoss Conditions.” This means that when the unit
    disconnect is turned off, the 1S2 toggle switch is turned off,
    or the unit loses power, the drain will open. The valve is
    spring loaded and will travel from fully closed to fully open
    in approximately 25 seconds.
    This is desirable in cold climates where a risk of freezing exists. In milder climates it may be desirable to keep the
    water in the sump when unit power is off to avoid
    unnecessarily wasting water whenever the unit
    disconnect is turned off.
    To convert the unit to “Hold During Unit Power Loss Conditions”:
    1. Remove power from the unit.
    2. Remove the weather shield cover (Figure 62, p.10 0).
    3. Loosen the shaft set screw (Figure 62, p.10 0), remove
    the locking clip, remove the shaft adapter ( Figure63,
    p. 101 ).
    4. Lift the drain valve actuator and rotate it to the “hold during
     power loss” position. (Figure 64, p.101)
    5. Reinstall the shaft adapter and locking clip and reinstall the
     actuator onto the base. Make sure the arrow on the
    shaft adapter is set to 0°.
    6. Make sure the valve is in the fully closed position, then tighten
     the shaft set screw.
    7. Reinstall the weather shield cover.
    8. Restore power to the unit.
    9. At the Human Interface, press SETUP, NEXT until Head P
     ressure Control Setup Submenu” is seen. Press
    ENTER.
    10. Change the “Sump Drain Valve Relay Control” from Drain
     to Hold.
    Figure 62. Drain valve actuator with weather shield
    Weather Shield
    Shaft Set ScrewDrain Valve Actuator 
    						
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