Munk psp family Gamma Series User manual
Munk GmbH
page 2
Contents
1Basic Information........................................................................................................4
1.1 Intended Use....................................................................................................................4
1.2 Improper Handling............................................................................................................4
1.3 Warranty and Liability Clause ...........................................................................................4
1.4 Function of the Power Supply...........................................................................................4
1.5 Manufacturer’s Address ....................................................................................................4
1.6 Recycling..........................................................................................................................4
2Important Safety Notes...............................................................................................5
2.1 Demands on the Operator ................................................................................................5
2.2 Importance of these Instructions.......................................................................................5
2.3 Transport and Storage......................................................................................................5
2.4 Operator’s Duties..............................................................................................................5
2.5 Structural Device Modifications.........................................................................................5
2.6 Danger Notice...................................................................................................................6
3Block Diagram.............................................................................................................7
4Description of psp Family Rectifiers.........................................................................8
4.1 Basic Information..............................................................................................................8
4.2 Switching Mode Power Supply Technology ......................................................................8
4.3 High Current Circuit ..........................................................................................................8
4.4 Closed-Loop Control.........................................................................................................8
4.5 Direct Current Output........................................................................................................9
5Installation .................................................................................................................10
5.1 Installation Site ...............................................................................................................10
5.2 Electrical Connection......................................................................................................10
5.3 Air Supply / Cooling System............................................................................................10
6Commissioning .........................................................................................................11
6.1 Visual Inspection.............................................................................................................11
6.2 Switching On ..................................................................................................................11
7Service and Maintenance .........................................................................................12
7.1 General Notes on Maintenance ......................................................................................12
7.2 Safety Disconnection before Maintaining and Cleaning ..................................................12
7.3 Cleaning of the Rectifier..................................................................................................12
7.4 Storage...........................................................................................................................12
8General Safety Instructions......................................................................................13
9Troubleshooting........................................................................................................14
9.1 Troubleshooting on the Phone........................................................................................14
9.2 Periodic Interruptions in Operation..................................................................................14
9.3 The Device does not Reach the Set Current...................................................................14
Munk GmbH
page 3
9.4 The Device does not Reach the Set Voltage...................................................................14
10 Type Code...............................................................................................................15
11 Technical Data........................................................................................................16
11.1 Electrical Data.............................................................................................................16
11.2 Dimensions .................................................................................................................17
11.3 Terminal Strip“X02” .....................................................................................................18
11.4 Connection Examples for “X02“:..................................................................................18
11.4.1 Standardized Measuring Values..............................................................................18
12 Current Carrying Capacities .................................................................................19
12.1 Overview of VDE Standards........................................................................................20
Munk GmbH
page 4
1 Basic Information
1.1 Intended Use
The power supply described herein has been
developed for applications in modern
electrochemical process engineering. These
power supplies are electrical equipment to be
applied in industrial installations. Active loads
(e.g. motors, generators, etc.) and reverse
voltage sources must not be connected to
these power supplies under any
circumstances. When installing and operating
the device, the relevant safety notes must be
observed.
1.2 Improper Handling
The power supply is to be used in the field of
application stated in section 1.1 only. It must
not be used in private households. The
warranty will expire in case of improper
handling, and Munk GmbH will not accept
liability for any damage to the load.
1.3 Warranty and Liability Clause
Supplies and services of Munk GmbH are
performed in accordance with the General
Conditions for the Supply of Products and
Services of the Electrical and Electronics
Industry (Grüne Lieferbedingungen), unless
the terms of delivery have been specified
otherwise in the contract agreement in
writing. Munk GmbH is not liable for defects
caused by improper handling and incorrect
operation of the power supply. This includes
the disregard for protection and safety
features and the non-observance of preset
device parameters.
1.4 Function of the Power Supply
According to the applied technology, the
power supply converts sinusoidal input
voltages into direct voltages.
1.5 Manufacturer’s Address
Munk GmbH Tel.: +49 2385 740
Gewerbepark 10 Fax: +49 2385 7455
59069 Hamm Mail: info@rectifier.com
Germany
1.6 Recycling
The power supply consists at more than 95 %
of recyclable materials. Depending on the
construction the device contains the following
material:
copper bars, copper windings
grain-oriented sheet-steel
clamping iron
pull rods
steel
aluminium
The remaining insulating materials consist of
compounds according to DIN EN 60893-2.
For separating the individual materials the
power supply can be dismantled into its basic
components.
Munk GmbH
page 5
2 Important Safety Notes
2.1 Demands on the Operator
This description comprises necessary
information on the proper use of the device
described therein. It is intended for
technically qualified personnel. Qualified
personnel are persons being nominated by
the person responsible for the plant safety to
perform the necessary work and being able
to recognize and prevent possible hazardous
situations. Prerequisites for this nomination
are appropriate training and instruction as
well as experience and knowledge of the
relevant safety standards, requirements,
accident prevention regulations, and
operating conditions. (Definition of qualified
personnel according to IEC 364).
2.2 Importance of these Instructions
These operating instructions explain the
intended use of the device. They contain
instructions for installing, connecting,
operating and maintaining which must be
observed. You will only be able to ensure that
the unit will work properly as described in
section 1.1 if you follow these instructions.
2.3 Transport and Storage
The equipment will be loaded and
transported either as single unit or in several
transport units, depending on the design.
The transport units must be screwed together
and electrically connected by experts on site.
If necessary, the power supply must be
stored free from frost in a dry, well-ventilated
room and covered during storage. Large
temperature deviation has to be avoided.
2.4 Operator’s Duties
The operator is obliged to convey the device
to the installation site immediately after
delivery and to ensure proper installation or
storage. Furthermore, he has to ensure that
the power supply will not be damaged by
incorrect handling and installation. Visible
defects must be reported to the forwarding
agent in writing within 24 hours.
2.5 Structural Device Modifications
The operator must not modify the power
supply in any way without the consent of the
manufacturer. This applies to mechanical and
electrical modifications such as the
installation of components which have not
been approved by the manufacturer. Such
alterations will void the warranty.
Munk GmbH
page 6
2.6 Danger Notice
The following notes serve the personal safety
of the operating staff and the safety of the
described product. The power supply may
only be used in a technically faultless state
and as specified in accordance with the
operating instructions on hand. The user
must be aware of possible dangers and
familiar with applicable safety measures.
Faults putting safety at risk must be cleared
immediately. The device must not be used
until all faults have been cleared.
Hazardous Voltage:
Non-observance may cause death, serious
physical injury or damage to property.
Always disconnect the power supply
from all supply voltages before
servicing, assembling and
disassembling the device and when
exchanging fuses.
Pay attention to the relevant accident
prevention and safety regulations
applicable in your country.
Check whether the nominal voltage of
the device corresponds to the local
mains voltage before commissioning
the device.
Terminals must be protected and
designed according to the regulations
of the local power utility.
Protective conductor connections
(safety ground connections) must be
checked for proper functioning after
they have been mounted!
Munk GmbH
page 7
3 Block Diagram
1: AC Supply
2: Control
3: Mains Contactor /
Mains Switch
(if applicable)
4: Input Filter
5: Mains Rectifier
6: Smoothing
7: High Frequency
Chopper
8: High Frequency
Transformer
9: Fast
Rectifier
10: Filter
11: Set Values
12: Controls
13: Actual Current
14: Actual Voltage
15: Shunt / Current
Converter
16: Temperature
Monitoring
17: DC-Load
Munk GmbH
page 8
4 Description of psp Family
Rectifiers
4.1 Basic Information
Psp family switching-mode power supply
rectifiers stand out because of their compact
design, high control accuracy, low ripple, low
weight, and a high efficiency.
In contrast to other electronic rectifiers, such
as thyristor rectifiers, the ripple of psp family
power supplies is constant. Thus, psp family
rectifiers generate high quality direct currents.
As the operating frequency of the switching
mode power supply rectifiers is higher than
20 kHz the wound components, such as main
transformer and smoothing filter, as well as
the capacitors can be designed much smaller
while generating the same output power.
Another outstanding characteristic is the
improved dynamic response of the output
values which allow set point value deviations
at the DC voltage output to be adjusted within
milliseconds. These specific control
properties render the output variables very
stable.
The control accuracy of the internal closed-
loop control amounts to just 1% referring to
the nominal voltage or current. The current
and voltage ripple values of the DC output
are below 1 –3% of the nominal values
across the entire control range, if not
indicated otherwise in the technical
specification.
The power section is installed in an enclosure
made from insulating material, thus
preventing direct access to live components.
Psp family rectifiers are DC power supplies
designed on the basis of switching-mode
power supply technology. The internal control
electronics facilitate very short adjustment
times in case of sudden load variations.
4.2 Switching Mode Power Supply
Technology
Switching-mode power supply technology
rectifies the mains voltage and supplies it to a
DC link consisting of capacitors and
connected to a high frequency inverter, which
converts the DC link voltage into an AC
voltage of a higher frequency. This AC
voltage is transferred to the transformer
primary circuit, which adjusts the voltage and
implements electrical isolation. The
secondary voltage of the transformer is
rectified and transferred via an output filter to
the rectifier output.
4.3 High Current Circuit
The high-current circuit includes the
transformer secondary circuit, a high-current
rectifier and a smoothing filter.
The high-current rectifier consists of rapid-
high-current diodes. The received DC voltage
is transferred via the smoothing filter to the
rectifier output. The smoothing filter filters the
superimposed high-frequency AC voltage of
the high-current rectifier. This allows a low-
ripple DC voltage to be applied to the rectifier
output.
4.4 Closed-Loop Control
Psp family rectifiers, are equipped with
current and voltage controllers. Owing to the
internal connection the controller limiting the
output variable is always the active one.
Therefore, you can only preset current and
voltage set point values or adjust them using
the potentiometers.
The rectifier operates according to a
controlled voltage/current characteristic to
DIN 41773.
Munk GmbH
page 9
Figure: Diagram of voltage/current
characteristic acc. DIN 41733
4.5 Direct Current Output
The DC output is implemented either with
polarity terminals, screw terminals or copper
bars.
The polarity (+ or -) of the DC output is either
marked by colours (i.e. red for the positive
and blue for the negative pole) or with the
symbols + and -, depending on the design.
The positive pole of the direct current output
is usually connected to the anode and the
negative pole to the cathode of the
electroplating tank.
The load (resistive load or electroplating tank)
is connected to the rectifier by an
interconnecting cable with a cross section
that corresponds to the nominal current of the
rectifier output. This interconnecting cable is
not included in the delivery with the rectifier.
You can determine the cross section of the
interconnecting cable using the table
provided in section „current carrying
capacity“. However, you can only find the
current carrying capacity of the cable you
want to use by asking your cable supplier.
Warning: If the cross section you have
chosen is too small, the interconnecting
cable may become overheated.
If several interconnecting cables are used,
the nominal current carrying capacity of the
individual conductor must be multiplied by
0.7, unless the regulations applicable in your
country require even further capacity
reductions.
Both ends of the interconnecting cable must
be equipped with cable lugs to ensure high
contact stability. Ask your cable supplier for
the cable lug and crimping types which have
to be used.
Warning: An insufficient or incorrect
connection causes overheating –fire risk!
Clean the connecting points at the DC output
and load before connecting the cable and
check them regularly. Temperature
deviations and mechanical motion, such as
tank movements, can loosen the
interconnecting cable.
Warning: Loose interconnecting cables
cause overheating –fire risk!
Munk GmbH
page 10
5 Installation
5.1 Installation Site
The power supply is designed for indoor
operation. Humidity and condensation at the
installation site must correspond to European
conditions, .i.e. a site altitude of 1,000 m
(3000 ft.) above sea level must not be
exceeded, unless otherwise stated. If the site
altitude is exceeded nevertheless, the output
must be reduced to guarantee proper
operation. If the device is installed in areas
with relatively high humidity and changing
temperatures, condensation may occur inside
the device as soon as the temperature level
drops.
The power supply is not suitable for outdoor
installation. When choosing the installation
site, always consider that free access must
be ensured from all sides for maintenance
and servicing purposes. Protect the device
from dust.
5.2 Electrical Connection
In order to put the device into operation
connect it according to the circuit diagrams to
all required mains and control lines. The
permissible voltages at the input terminals
must not be exceeded. Regulations of the
local supply companies have to be observed.
Cables for the DC output must have a cross
section that corresponds to the nominal direct
current of the device. Install the cables in
such a way that the cooling air supply for the
rectifiers remains unrestricted.
5.3 Air Supply / Cooling System
In order to ensure that the rectifier is
sufficiently cooled, neither air intake nor
discharge should be impeded. To ensure that
the fresh-air supply is sufficient do not cover
the lateral air inlet openings. Leave a
minimum clearance of 20 cm (8”) behind the
rectifier to let the exhaust air escape
unimpeded and take measures to prevent
exhaust air from building up in the area
surrounding the rectifier as insufficient air
supply may lead to failures and damage the
rectifier. The temperature of the supply air
must never exceed 40°C (104°F).
Sufficient cooling can only be guaranteed
over a long period of time if the cooling air
contains only very few dust particles.
Aggressive ambient air or dust deposits on
the heat sinks may cause insufficient cooling
of the rectifier and thus induce operational
failures requiring that the manufacturer
conducts internal cleaning.
If the maximum ambient temperature has
been reached, an impermissibly high
temperature may develop inside the power
module under unfavorable conditions after
disconnection. This impermissibly high
temperature does not damage the device but
it prevents the output of power. This
temperature-induced fault, which may result
from heat accumulation after disconnection
and which thus occurs subsequently, can be
prevented and cleared, respectively, by
switching the rectifier into the standby mode.
The standby mode should only be switched
on for approx. 60 seconds before the actual
output of power. The internal fan cooling will
then be activated in order to dissipate the
heat.
Munk GmbH
page 11
6 Commissioning
6.1 Visual Inspection
Before actually commissioning the device,
check the following items:
Visually check whether the devices
have been damaged, for instance
during transportation, and repair the
damages found.
Check the ground connections for a
correct connection.
Check whether the mains supply
corresponds to the one stated in the
Technical Data chapter and to the
information given in the cabinet’s circuit
diagrams.
Check whether the screwed
connections at the mains supply, the
DC terminal and the terminal strips of
the plant control system or remote
control unit are tight; retighten them, if
necessary.
Check whether the load at each
rectifier output is connected with the
correct polarity.
Check for a short circuit at the DC
outputs and remove this fault
immediately.
Check for the air in- and outlets, which
must not be covered
Check whether the entire air-cooling
system is fully operational.
Check the interconnecting cable to the
load for sufficient cross section, correct
installation and correct polarity.
Warning: Fire Risk
6.2 Switching On
After having considered all items mentioned
above and having taken the appropriate
measures, you may connect the mains
supply in the sub-station.
As these rectifiers are equipped with only a
few operating elements, handling psp family
devices is very easy and does not require
any special technical knowledge. After the
rectifier has been expertly installed, the
device is ready for operation. The rectifier
reaches its set point value via a soft start
function after you have started the device
either by remote control or with the integrated
mains switch.
After having switched on the rectifier, you
may increase the set point value of the
rectifier slowly from 0 to 100 % under
energized conditions. Check at the controller
whether the actual values correspond to the
set point values. Please ensure that a load is
connected to the output of each rectifier.
The bench case version of the rectifier
consists of two potentiometers (electronic
potentiometers for MFD devices) for adjusting
the current and voltage setpoints. Turned
fully to the left, the set values are set to
“zero”; turned full to the right, the nominal
values of the rectifier will be set. To receive a
signal at the device output you have to select
a voltage or current set point above zero.
If you want to control the rectifier in current
control mode, you must set the voltage
controller to the unit’s nominal value or the
maximum permissible process voltage. The
set point value of the current controller will
then be adjusted to the required process
current.
If you want to operate the rectifier in voltage
control mode, you must set the set point
value of the current controller to the unit’s
nominal value or the maximum permissible
short circuit current, depending on the
process/product. The set point value of the
voltage controller will then be adjusted to the
required process voltage.
The output values for current and voltage are
displayed on the digital instruments.
Use the optional emergency-off function
only in case of emergency.
Munk GmbH
page 12
7 Service and Maintenance
7.1 General Notes on Maintenance
psp family rectifiers normally do not require
much maintenance. How often maintenance
does need to be carried out depends on local
operating conditions.
7.2 Safety Disconnection before
Maintaining and Cleaning
Before maintaining, repairing and
cleaning the device, make sure you
keep to the basic safety rules:
Disconnect the device safely and
completely from the mains supply
and from possibly existing auxiliary
supply circuits (external control
voltage).
Secure the disconnection from the
mains supply against unintentional
restarting.
Verify the safe isolation of the
rectifier from the supply.
Cover or close off adjacent live parts
by means of barriers.
The fans (if existing) will wear out in the
course of time and must then be replaced.
The rectifier should be switched off and
allowed to cool down before maintenance
begins.
Please check the interconnecting cables to
the load and all contact or connecting points
at regular intervals (overheating risk).
7.3 Cleaning of the Rectifier
How regularly the rectifier needs to be
cleaned depends heavily on its operating
conditions. We strongly recommend that the
rectifier is not operated close to machines or
installations creating a lot of dust. The air
ventilation slots should be cleaned regularly
to prevent them from being clogged by
foreign bodies, although the inside of the
rectifier itself should not need cleaning under
normal operating conditions as the integrated
ventilation system should provide sufficient
air flow.
The operator should only ever clean the
outside of the unit. Should internal cleaning of
the rectifier become necessary - due to heavy
contamination inside the device, which may
lead to failures - send the rectifier back to the
manufacturer for cleaning and testing. The
same applies if fluid gets into the rectifier. In
this case, immediately disconnect the rectifier
from the mains and do not restart it until the
manufacturer has checked and cleaned it.
7.4 Storage
The device is equipped with electrolytic
capacitors. To prevent from aging the
following issues must be observed:
The storage temperature must not
exceed 25°C (75°F)
The device should be energized at
rated voltage with no load every 1-2
years for ca. 30 minutes
Munk GmbH
page 13
8 General Safety Instructions
Never open the housing as hazardous
voltage components are installed
inside. You may suffer an electric
shock!
None of the components inside the
casing requires maintenance. Thus
opening the enclosure is unnecessary
and strictly prohibited.
The input values must not exceed the
limit values listed in the technical
specification as otherwise the unit will
be damaged.
If fluid gets into the rectifier,
immediately disconnect it from the
power supply to avoid damage.
Clean the openings of the enclosure
and fans or heat sinks from the outside
at regular intervals. The cleaning extent
depends on the dust emitted in the area
around the power supply.
The protective earth terminal must be
connected to the power supply’s
protective earth conductor (yellow-
green wire) to ensure sufficient
protection for the operator.
Erect and connect the rectifier
according to the EMC regulations; for
example, supply and control lines must
be installed separately.
The local mains voltage must
correspond with the operational voltage
stated on the rating plate.
Observe the relevant electrical safety
regulations applicable in your country
when installing and operating the
device.
Always carry out installation work in off-
load conditions, for example, when
connecting the output terminals of the
device.
Ensure sufficient protection against
electrostatic discharge.
If the mains feeder and/or the mains
plug are obviously damaged,
immediately disconnect the unit from
the mains.
Warning: incorrect installation of the
interconnecting cable to the load
may cause a fire. Check the
interconnecting cables regularly, and
keep the contact points clean.
Munk GmbH
page 14
9 Troubleshooting
9.1 Troubleshooting on the Phone
If you cannot find the fault or the source of it,
call +49 2385 740 and we will put you
through to one of our service engineers.
Phone-No.: +49 2385 / 74-0
Fax-No.: +49 2385 / 74-55
info@rectifier.com
We will be able to help you quickly if you can
describe the fault as exactly as possible
(error message) and name the rectifier’s
device number (see Technical Data).
9.2 Periodic Interruptions in Operation
Periodic interruptions in operation and
consequent restarts indicate the response of
the overheating protection. If this is the case,
check whether the cooling air supply is
sufficient or whether the rectifier needs to be
cleaned.
If the periodic interruptions are caused by the
rectifier overheating due to heavy
contamination of the cooling components, it is
possible to operate the device temporarily
with a reduced output power (to finish a
running process for instance).
9.3 The Device does not Reach the
Set Current
The device is being operated in
voltage-limiting mode; the resistance of
the load is too high.
9.4 The Device does not Reach the
Set Voltage
The device is being operated in current-
limiting mode; the resistance of the load
is too high.
Munk GmbH
page 15
10 Type Code
Munk GmbH
page 16
11 Technical Data
11.1 Electrical Data
Mains Voltage
:
3 x 400 ± 10%, 47-63 Hz
Nominal DC Voltage
:
150 V DC
Nominal DC Current
:
50 A DC
Efficiency
:
75% … 90%
Ripple
:
< 3 % referred to nominal values
Adjustment ranges
:
0 … 100 % of Nominal Voltage / Current
Control Accuracy
:
+/- 1% referred to nominal values
Ambient Temperature
:
0 ... 35 °C (30 … 100°F)
Device Type
:
D400 G150/50 WRG-TFKX
Device No.
:
246569
Munk GmbH
page 17
11.2 Dimensions
Dimensions: (W x D x H): 537 mm x 550 mm x 397 mm
Copper output bars:
Munk GmbH
page 18
11.3 Terminal Strip“X02”
Depending on the rectifier different options for signalling and setting the voltage and current values
are available
1
2
3
4
5
6
7
8
9
10
11
Actual Current
0 …10 V DC
12
standardized
GND
13
Pulse Enable
13-14 closed
14
= Output active
15
Actual Voltage
0 …10 V DC
16
standardized
GND
11.4 Connection Examples for “X02“:
11.4.1 Standardized Measuring Values
Level: 0...10V DC
Note: Terminals 13, 14 are for external pulse enabling (bridged, when delivered)
Munk GmbH
page 19
12 Current Carrying Capacities
The values indicated in the table below are
recommended values and are taken in
simplified terms from the DIN VDE 0298-4
standard, “Application of cables and cords in
power installations –Part 4: Recommended
current-carrying capacity for sheathed and
non-sheathed cables for fixed wirings in
buildings and for flexible cables and cords”;
or they are extracts from the DIN VDE 0100-
430 standard, “Erection of power installations
with nominal voltages up to 1000 V;
protective measures; protection of cables and
cords against overcurrent” and of DIN VDE
0100-520, “Erection of power installations
with nominal voltages up to 1000 V –Part 5:
Selection and erection of equipment; chapter
52: Wiring systems”.
In borderline cases, the VDE regulations or
the regulations applicable in your country
must be observed.
Current carrying capacity acc.VDE 0100 part 430 at an ambient temperature of 30 °C (86°F)
cross-
section
mm²
group 1
group 2
group 3
Copper-
conduct
A
Fuse
A
Copper-
conduct
A
Fuse
A
Copper-
conduct
A
Fuse
A
1,50
16,50
16
16,50
16
21,00
20
2,50
21,00
20
22,00
20
29,00
25
4,00
28,00
25
30,00
25
39,00
35
6,00
36,00
35
38,00
35
51,00
50
10,00
49,00
40
53,00
50
70,00
63
16,00
65,00
63
72,00
63
94,00
80
25,00
85,00
80
94,00
80
125,00
100
35,00
105,00
100
118,00
100
154,00
125
50,00
126,00
125
142,00
125
198,00
160
70,00
160,00
160
181,00
160
205,00
200
95,00
193,00
160
219,00
200
292,00
250
120,00
223,00
200
253,00
250
344,00
315
Group 1 At least one single-core cable
runs in a conduit, for example,
PVC-insulated single-core non-
sheathed cables H 03 V../H 05
V../H07 V.. according to DIN
VDE 0281, “Polyvinyl chloride
insulated cables of rated
voltages up to and including
450/750 V”.
Group 2 Multi-strand cables, for example,
non-metallic sheathed cables,
flexible cords, metal-clad cables
in open or ventilated ducts.
Group 3 Single-core cables laid in free
air, with a minimum distance
between the cables
corresponding to the cross
section of the cable, as well as
single-core wiring cables in
switching stations, distribution
and busbar trunking systems
Munk GmbH
page 20
12.1 Overview of VDE Standards
DIN EN 60204-1 industrial machinery: “Safety of machinery – Electrical equipment of
machines –
Part 1: General requirements” (IEC 204-1)
DIN VDE 0891-1 telecommunication and information processing systems: “Use of cables and
insulated wires for telecommunication and information processing systems;
general directions”
DIN 57891-8 self-supporting telecommunication aerial cables: “Use of cables and
insulated wires for telecommunication and information processing systems;
special direction for self-supporting telecommunication aerial cables on
overhead power lines above 1kV according to DIN 57818/VDE 0818”
DIN VDE 0891-10 ribbon cables (draft standard): “Use of cables and insulated wires for
telecommunication and information processing systems; special direction for
ribbon cables with round conductors; with a pitch of 1.27 mm according to
DIN VDE 0811”
This manual suits for next models
2
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