PowerPlus Energy LiFe4838P User manual

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
LiFe4838P
Installation and
Operation Manual
V2.1

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
1 Introduction .................................................................................................................................................... 5
2 Glossary .......................................................................................................................................................... 6
3 Safety .............................................................................................................................................................. 7
3.1 Transportation ...................................................................................................................................... 7
3.2 Basic Safety ........................................................................................................................................... 7
3.3 Handling ................................................................................................................................................ 8
3.4 Storage of the Battery ........................................................................................................................... 8
3.5 Life Support ........................................................................................................................................... 8
3.6 Damaged Battery .................................................................................................................................. 8
3.7 Fire ........................................................................................................................................................ 9
3.8 Qualified Person (Installer) ................................................................................................................... 9
3.9 Wet Battery ........................................................................................................................................... 9
4 Product Information ..................................................................................................................................... 10
4.1 Introduction ........................................................................................................................................ 10
4.2 Weight and Dimensions ...................................................................................................................... 10
4.3 Label and Symbols ............................................................................................................................... 11
4.4 Front Panel .......................................................................................................................................... 11
4.5 Specifications ...................................................................................................................................... 12
4.6 DC Circuit Breaker Characteristics....................................................................................................... 13
4.7 Certification / Compliance .................................................................................................................. 13
5 Installation .................................................................................................................................................... 14
5.1 Packing Items ...................................................................................................................................... 14
5.2 Location and Environment .................................................................................................................. 14
5.3 Battery Installation .............................................................................................................................. 15
5.4 Battery Connections ............................................................................................................................ 17
6 Battery Operation ......................................................................................................................................... 19
6.1 Status LED............................................................................................................................................ 19
6.2 DC Circuit Breaker ............................................................................................................................... 20
6.3 Charging and Discharging .................................................................................................................... 20
7 Troubleshooting............................................................................................................................................ 23
7.1 Over-Discharged Battery Recovery ..................................................................................................... 24
8 Maintenance ................................................................................................................................................. 25
9 Upgrading Battery Capacity .......................................................................................................................... 26
10 Capacity Testing the Battery ......................................................................................................................... 27
11 Compatible Inverters .................................................................................................................................... 28
12 End of Life ..................................................................................................................................................... 29

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
1 Introduction
PowerPlus Energy designs and manufactures Lithium Ferro Phosphate (LiFePO4 or LFP) batteries in Melbourne,
Australia, to operate in some of the world’s harshest operating environments. The LiFe4838P battery is a
simple, safe, flexible, and reliable energy storage component that is designed to be easily integrated with most
inverter and charger combinations.
It can work well as a UPS battery or as a cyclical energy storage reserve for solar, wind and other renewable
energy sources. It is designed to be connected to most DC and AC charging devices and it performs very well,
with virtually no maintenance, in both on-grid and off-grid system designs in single-, dual- and three-phase
BESS (Battery Energy Storage System) applications.
This document outlines the technical capabilities of the PowerPlus Energy LiFe4838P battery and offers
installers useful information and tips to safely integrate this product into BESS systems.
Because this product stores very large amounts of electrical energy and is capable of releasing that energy in a
very short time, it must be treated with care both during installation and operation.
When the LiFe4838P has been installed as intended, it will deliver its intended and rated electrical
performance over its long 10-year warranty life.

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
2 Glossary
BESS Battery Energy Storage System
BMS Battery Management System
BS Battery System
LED Light Emitting Diode
LFP Lithium Ferro Phosphate (LiFePO4)
MSDS Material Safety Data Sheet
PCE Power Control (or Conversion) Electronics
PCS Primary Charging Source
RJ45 An 8-way modular connector specification for connectors and cabling
SCS Secondary Charging Source
SDS Safety Data Sheet

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
3 Safety
Installers and users are responsible for familiarising themselves with this manual.
The PowerPlus Energy LiFe4838P battery is a member of the LiFe48xxP series of batteries which has a nominal
operating voltage of approximately 48V.
This battery uses high grade cylindrical Lithium Ferro Phosphate (LiFePO4 or LFP) cells which are robust and
reliable when operated in higher ambient temperatures. The battery is designed to have a long service life
when installed and operated within the specifications contained in this document.
The battery contains no heavy metals, and most components are recyclable (by licensed recycling companies).
A pair of high quality, high current Amphenol SurLok Plus DC connections enables users to install the
LiFe4838P safely and rapidly into a variety of energy storage configurations.
To meet stringent international battery safety standards, each battery is fitted with a 2-pole, non-polarised K-
Curve circuit breaker that also doubles as a circuit isolator. There is a blue status indicator light that assists
installers and users with helpful diagnostic information. There is also a volt-free alarm contact that allows the
battery to be monitored by external devices and control systems.
Each LiFe4838P battery is also fitted with an internal Battery Management System (BMS) that provides
protection against over-charging and excessive discharging. The BMS will shut down the battery when it
exceeds its over-current limit or experiences an external short circuit. The battery will also protect itself when
exposed to over-temperature or under-temperature conditions. For a long and reliable service life, the BMS
also carefully manages cell-string balancing during charging.
Installation must be carried out by a suitably qualified and experienced person who can specify the correct
cables, DC bus arrangement and additional external circuit protection. It is crucial that this battery is installed
in accordance with all necessary local and international standards.
3.1 Transportation
Although PowerPlus Energy’s LiFe4838P battery is classed as a Dangerous Goods (DG) Class 9 UN3480 product,
this battery carries a UN38.3 transport safety certificate and is therefore safe for road transport.
The battery is shipped with the terminals capped to prevent electrical short circuit and contact with metallic
objects during transportation. The batteries also leave our warehouses in a partially discharged state to
comply with international transport regulations.
Batteries where possible, should be shipped in the original manufacturer’s packaging, positioned horizontally,
and secured to a pallet. The batteries are not designed to be shipped in a vertical orientation and there should
not be more than 6 batteries in a stack when being transported.
3.2 Basic Safety
Serious injury or damage to property may result from careless handling of the LiFe4838P battery.
The following precautions should be observed:
The battery must not be exposed to temperatures above or below the temperature ratings specified
in Table 4-2 (Operating Conditions).

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
The battery must not be installed in direct sunlight.
The battery must not be exposed to strong impacts and vibrations.
The battery must not be crushed or punctured.
The battery’s connectors should not touch conductive surfaces unless intended to do so.
The battery does not contain maintainable or user-serviceable components and must not be
disassembled or opened for repair.
The battery must be kept dry at all times and must not be exposed to water or other liquids. Do not
touch the battery if it appears to be damp or wet.
The battery should be kept away from animals and children.
The battery must not be stepped on or subjected to any strong force.
The battery is intended to be lifted by 2 persons during installation and handling.
The battery should not be disposed of with household waste.
3.3 Handling
Handle the battery with care when installing or transporting. The battery is heavy and proper lifting
techniques or equipment should be applied.
Do not use the battery if it appears damaged or broken.
The surfaces of the battery can be cleaned with a rag instilled with IPA (Isopropyl Alcohol). Do not use
chemicals to clean the battery.
Do not touch the DC terminals of the battery.
3.4 Storage of the Battery
The battery must be stored horizontally and there must be no more than 6 batteries stacked on top of
each other without additional mechanical support.
The battery must be kept in a dry environment away from heat and moisture.
The battery must be stored away from incompatible substances, like liquid, chemical materials.
The battery should be stored between 0 to 35°C, however close to 25°C should be considered for long
term storage.
After 6 months of storage the battery may need cell balancing (See 6.3.2 Battery Cell Balancing for
details).
Any issues with charging after long term storage should be discussed with PowerPlus Energy.
3.5 Life Support
Our batteries should not be used in critical medical or life support applications where failure of our LiFe4838P
batteries can reasonably be expected to cause failure of the life support equipment or effect operation of such
equipment.
3.6 Damaged Battery
A damaged battery should not be used and should be returned to PowerPlus Energy or disposed of via a
recycling facility. Leaking electrolyte can cause breathing difficulties, skin irritation or chemical burns, so
contact should be avoided. Place the damaged batteries in an area where there is good ventilation, away from
heat sources. Fumes need to be evacuated by fans from enclosed spaces.

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
In case of:-
Eye Contact: Rinse gently with running water and seek medical attention if irritation develops.
Skin Contact: Rinse gently with running water and seek medical attention if irritation develops.
Ingestion: If ingested, do not induce vomiting. Contact your local poisons information centre or doctor.
Inhalation: Evacuate area and seek professional medical attention immediately.
3.7 Fire
Should the battery catch on fire or start to emit smoke, (for small fire or small emissions of smoke) use a
standard ABC or dry chemical fire extinguisher.
Evacuate the area and call emergency services.
Some toxic gases may be produced if the battery catches fire.
The battery needs to be rapidly cooled to prevent any heat or fire spreading.
3.8 Qualified Person (Installer)
This manual and task set within regarding installation should be carried out by a suitable qualified and skilled
person who should:
Have a thorough understanding of operations, design, and installation principles of battery energy
storage systems.
Have a thorough understanding of all dangers and risks associated with installing and using electrical
devices.
Hold all local, state and country base qualifications to carry out such work.
Adhere to all safety and installations requirements within this manual.
3.9 Wet Battery
Do not attempt to access the battery if it is wet or submerged in water. Seek technical assistance from
PowerPlus Energy or your distributor.

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
4 Product Information
This section provides relevant and important technical information regarding the LiFe4838P battery's physical
and electrical characteristics.
4.1 Introduction
The PowerPlus Energy LiFe4838P is a 'self-managed' battery in that it doesn’t require communication with
external Power Control Electronics (PCE) to operate. Therefore, the battery can also operate with PCE that
doesn’t require communications to operate.
The battery has an internal Battery Management System (BMS) which is designed to protect it from adverse
and incorrect operating conditions such as:
Over-charging and excessive discharging.
Over-temperature and under-temperature.
Over-current and short-circuit.
4.2 Weight and Dimensions
Weight: 43kg
Dimensions: 635mm D x 434mm W x 88mm H

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
4.3 Label and Symbols
A product specification label is attached to the left side of the battery, which is depicted here:
The symbols on the label and their meanings:
Read the manual before installation and operation.
Pay attention to the potential dangers of using the battery.
4.4 Front Panel
The front panel is depicted here:

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
4.5 Specifications
Nominal Voltage
51.2V
Operating Voltage
40V to 58.4V
Nominal Capacity
3.8kWh / 74.2Ah
Usable Energy Capacity
3.8kWh
Round
-
Trip Efficiency
>96%
Maximum Continuous Charge Current
63A
Maximum Continuous Discharge Current
63A
Minimum Peak Current (Discharge)
75A for at least 3.5s, 220A for at least 1.5s
Maximum
Peak Current (
Discharge
)
85A (<6.5s), 280A (<150ms)
Rated DC Power
3.2kW
Short
Circuit Current
2.5kA
Alarm Output
Normally Closed
contact
,
voltage free,
60V/100mA(max)
Expected Life @25°C
>
10 years when used as per warranty terms
Operating Temperature Range
-
Charging
4° to 51°C
Operating Temperature Range
-
Discharging
-
6
° to 56°C
Recommended Operating Temperature
20
° to
30
°C
Storage Temperature Range
0 to 45°C
Operating
Humidity
0% to
85%
non
-
condensing
Operating
Altitude
< 2000m
Cooling
Natural convection
Parallel connection
Unlimited
Series connection
Not Permitted
Battery Dimensions
635mm D x 434mm W x 88mm H
Lithium Composition
Lithium Ferro Phosphate (LiFeP0
4
or LFP)
T
erminal
Connections
Amphenol Sur
L
ok
Plus
1
2
0A
Weight
43kg
IP Rating
IP40
Conductor cross
-
section area
16mm
2
or 25mm
2
Connector
Amphenol SurLok Plus right
-
angle plug for 16mm
2
or 25mm2 cable

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
4.6 DC Circuit Breaker Characteristics
The integrated non-polarised DC Circuit Breaker is dual pole and a K curve type. The table below outlines the
trip times based on current.
4.7 Certification / Compliance
Safety (battery): IEC 62619:2017, UN38.3, IEC 61000-6-3:2020, IEC 62368-1:2018
Safety (internal cell-pack): UL 1642, IEC 62619:2017
Transportation: UN 38.3

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
5 Installation
This section of the document provides important information and guidance to installers to ensure a safe and
trouble-free installation process.
Installation should be carefully considered, and all aspects of the specifications should be understood to
determine a suitable location and way of installing the battery.
5.1 Packing Items
LiFe4838P Battery
5.2 Location and Environment
The location of the battery should be in accordance with the IP rating in Table 4-3 (Physical Characteristics)
and operating temperature range specified in Table 4-2 (Operating Conditions).
The LiFe4838P battery is designed to be installed in a 19-inch data rack assembly or an electrical enclosure of
your choice. The external rack assembly or electrical enclosure is considered outside the scope of the battery
product certification. If the battery is to be installed outdoors a suitable enclosure with IP54 (or greater) rating
should be used.
The location of the battery should meet the below conditions:
Due to the risk of short circuits and rapid metal corrosion, the battery should not be installed where
direct contact of salt air may be possible. If salt air is unavoidable, appropriate air filtration must be
employed to keep the battery free of salt deposits. It is highly recommended that the battery should
be installed in an indoors environment, or inside an IP66 or greater enclosure.
The floor is level and free from obstructions.
There are no explosive or flammable materials nearby.
The recommended operating temperature is between 20 and 30°C.
The temperature and humidity should remain as constant as possible.
The area is of a clean environment with minimal dust.
The area or enclosure is insect and vermin proof.
The batteries and battery cabinets/housings are not exposed to direct sunlight.
If the battery is not stored or operated within the recommended temperature range specified in Section 2.5,
the Battery Management System (BMS) may halt the operation of the battery as a protective measure. It is
important to note that if the battery is subjected to extreme temperatures frequently, there will be a negative
impact to its long-term performance and reduce its longevity.
The battery will exhibit optimal performance and lifespan if it is operated within its ideal temperature
range.

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
5.2.1 Extreme Humidity Climates
When PowerPlus Energy's LiFe4838P batteries are being installed in elevated humidity conditions, extra
precautions should be taken:
A humidity control agent (i.e., chemical which absorbs humidity) may be required inside the
enclosure, with controlled airflow to expel moist air.
The battery system could also be installed in a humidity- and climate-controlled room (example,
reverse cycle air-conditioner cooled).
The temperature of the cabinet should be always held at a temperature above dew point.
5.3 Battery Installation
PowerPlus Energy highly recommends their range of rack or SlimLine Series indoor and outdoor cabinets for
containing the batteries in a system installation. Full specification details are available on the PowerPlus
Energy website.
However, this section provides instructions which should be followed when creating a custom enclosure or
system for containing the batteries.
5.3.1 Custom Cabinets
The battery has been designed to fit into a standard 800mm deep 19-inch equipment rack.
If you are planning to design and assemble your own battery enclosure, please carefully consider the following
suggestions and recommendations:
If the battery is installed into enclosures without rails, please ensure that they are securely seated to
prevent accidental damage or tampering.
If a custom enclosure or mounting method is used, please ensure the batteries are not stacked more
than 6 high unless battery support rails are used to distribute weight.
Please ensure there is adequate air flow around the battery stack within the cabinet. Except for the
top and bottom surfaces of the stack, a clearance of at least 25mm is required around the stack (4
sides of the stack).
Please ensure the selected IP rating is correct as per your location selection.
All interconnecting battery cables for parallel connection shall be the same length and cable size.
A busbar is recommended for connection of all parallel battery connections.
An appropriate way of connecting the cabinet to the PCE should be considered.
Please follow PCE instructions for fuse, cable, and connection requirements. These will vary
depending on brand and product selected.

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
5.3.2 Battery Orientation for Stationary Applications
In stationary applications, other than resting the battery on its front face or resting it on its lid (upside down),
the battery can be mounted in any of the other four possible orientations:
5.3.3 Battery Transportation within a Pre-Assembled BESS
If the battery is to be pre-installed into a Battery Energy Storage System (BESS) in which it is shipped, the
following guidance must be followed:
The battery should be shipped horizontally and secured in place to limit movement.
If the battery is to be subjected to prolonged vibrations during transportation, a sufficient non-
flammable shock mount system (like high density foam or similar) should be installed within the BESS
under the battery.
If the guidance above cannot be followed, the battery must be removed from the BESS and shipped in the
original manufacturer’s packaging.
5.3.4 Battery Installation in Motorhomes, RV’s, Trailers, Vehicles, Trucks, Buses or Similar
The battery should be installed horizontally (with the lid upwards) and secured in place to limit
movement.
The battery should be positioned in a non-flammable section and be easily accessible and removable
from outside of the vehicle.
A sufficient non-flammable shock mount system (like high density foam or similar) should be installed
under each battery.

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
5.4 Battery Connections
5.4.1 Main DC Connections
The battery comes fitted with Amphenol SurLok Plus male connectors for easy snap on connection. The table
below outlines the battery connections and the mating cable connectors required. Each battery when ordered
separately (without a cabinet) will come supplied with mating connectors.
Each Amphenol SurLok Plus connector supplied by PowerPlus Energy can adequately seat 25mm single
insulated or 16mm double insulated cable. A 16mm reducing sleeve is provided. Crimping of SurLok Plus to the
stripped end of the cable is performed using a standard 25mm hex crimp tool.
If multiple batteries are being used in parallel, the battery cables shall all be of the same length to retain equal
impedance of each battery and cable set.
Before connecting the DC cable to the battery, you will need to remove the safety insulating cap on the
battery DC connectors and dispose of appropriately.
Do not connect the main DC cable with reversed polarity. It will cause severe damage to the battery.
5.4.2 Case Earthing
The LiFe4838P battery case is designed to be electrically floating and isolated from all internal battery
connections and in most installations will not require earthing. However, should your application require the
case to be grounded a 5mm M6 bolt should be used and is supplied with the battery.
5.4.3 Battery Alarm Output
The battery is equipped with a Battery Alarm Output that notifies an external system when the Battery
Management System (BMS) or the DC Circuit Breaker has tripped. The BMS trip will self-reset once the fault
has been resolved or removed, however if the battery’s DC Circuit Breaker has tripped, it will need manual
intervention.
The Battery Alarm Output is presented on the two RJ45 connectors on the front panel of the battery. The
Battery Alarm Output is present on pins 5 and 6 of the RJ45 connectors as a pair of volt-free contacts. These
volt-free contacts can be used to signal to an external PLC or alarm circuit.
The Battery Alarm Output is normally closed when energised by the battery (battery is ON and LED
illuminated). When the BMS or DC Circuit Breaker trips, the battery turns OFF (circuit breaker or BMS trip and
LED off) and the contacts will open.
The alarm outputs are designed to be daisy chained (using P/N COM003A comms cable), connecting the
bottom RJ45 of a battery to the top RJ45 of the battery immediately below, and so on. The battery at the end
of the chain (generally the bottom battery) will need to the have pins 5 and 6 bridged on the bottom RJ45
terminals using a bridging connector (P/N COMLBA). The top connector on the first battery in the chain
(generally the top battery) can be connected to an appropriate alarming circuit using one of our battery
comms cables.

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
Unused
Unused
Unused
Unused
Unused
Alarm
Unused
Unused
A range of cables to connect the battery alarm contacts are available for purchase.
COMLBA
COM003A
COM020A
COM050A
COM100A
COM150A

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
6 Battery Operation
Now that you have installed the batteries you are almost ready to energise the system. First you should check
your installation to ensure the below:
Check polarity of all battery connections to be correct.
Check that there is no damage to cables.
Check that all system breakers are in the off position.
Check for adequate air flow as per your installation requirements.
Check for local installation compliance if applicable.
Starting up the battery system should be done in conjunction with the PCE manufacturer’s recommendations
as well as this manual and any local or government safety requirements.
Each battery in the system is powered up separately by turning the double pole breaker to the ON position.
Once powered up, voltage will be present at the DC terminals and the Main Status LED light will glow blue.
6.1 Status LED
The Status LED indicator is used to provide a visual indication of the operation and state of the battery.
Battery is ON and allowing charge and discharge.
Battery circuit breaker is in the OFF position.
Battery BMS is in low voltage protection mode - Charge and discharge will not be permitted until
battery is recovered by a certified technician.
Battery is in the protection mode. The detailed information is listed in the next table
If a fault occurs, the battery will enter its protection mode, and the Status LED will start to flash several times
periodically to indicate the fault. The error codes in the table 4-2 can help you diagnose and troubleshoot
problems quickly and efficiently. For example, if the Status LED flashes twice periodically, it means that one or
more cells in the battery have reached an under-voltage state and the battery needs to be charged.
One or more cell-strings under-voltage.
One or more cell-strings over-voltage.
Over-current whilst charging.
Over-current whilst discharging.
Short-circuit across battery terminals OR High-level over-current whilst discharging.
Cell-pack over-temperature whilst charging.
Cell-pack over-temperature whilst discharging.
Cell-pack under-temperature whilst charging.
Cell-pack under-temperature whilst discharging.
BMS over-temperature.
BMS under-temperature.
Cell-pack under-voltage.
Cell-pack over-voltage.
Cell-pack critically under-voltage

LiFe4838P Installation and Operation Manual V2.1 (19/04/2023) Page of
6.2 DC Circuit Breaker
Each battery has an integrated DC circuit breaker. Firstly, it is the ON/OFF switch for the battery. Secondly, it
protects the battery in the event of an internal battery fault. Finally, it is also used to safely and easily isolate
the battery from the DC bus inside the rack or the Battery Energy Storage System (BESS).
If the power system has been shut down or charging source has been removed, the battery should have its
circuit breaker switched to the OFF position within 1 month.
6.2.1 Battery System Startup
The battery system should be started following the startup procedure supplied with the system.
The LiFe4838P battery does not provide an output voltage until it is turned on. In most cases powering on the
battery will be one of the first steps of starting your power system.
1) Locate and ensure your main system isolation point is OFF.
2) Check all battery connections are tight and secured.
3) Systematically turn each battery DC circuit breaker to the ON position (switch to the right when
looking at the front face of the battery).
4) Status LED will illuminate indicating voltage is present at the battery terminals.
6.2.2 Battery System Shutdown
Use the following steps to shut down the battery system:
1) Turn off the inverter.
2) Turn off each battery by turning its DC circuit breaker to the OFF position.
3) Ensure the Status LED on all batteries in the rack are no longer illuminated.
6.3 Charging and Discharging
As outlined in the Table 4-2 (Operating Conditions), whilst being charged, the battery temperature should be
between 4° and 51°C. Whilst being discharged the battery temperature should be between -6° and 56°C. When
there are multiple battery charging devices and multiple batteries in a system, please ensure that the
maximum current flowing into and out of each battery is kept below 63A (in accordance with the Maximum
Continuous Charge Current and Maximum Continuous Discharge Current given in Table 4-1).
6.3.1 Full Recharge Upon First Installation
Batteries are delivered and shipped in a partial state of charge. Prior to discharging the batteries, the entire
rack should be fully charged to the float stage.
This initial full charge to 100% will allow the battery’s Battery Management System (BMS) to perform
Battery Cell Balancing to ensure all cells are at the same state before regular cycling. See section 6.3.2
(Battery Cell Balancing) for further details.
If the battery system (external to the battery) also has an integrated SoC (State of Charge) counter, the
initial full charge may be needed to calibrate the counter to a known battery SoC (some SoC counters may
take a few cycles to learn the SoC).
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