9090 User`s Manual - Future Design Controls
Contents
1. 6 seconds LCAL HEAL E 4 Level 3 Long 6 seconds oe Level 4 IC T Supplemental Instruction for the New Version V7 3 ONLY NOTE This procedure does NOT have to be performed unless the LLit and or Hlit have been changed from the factory setting This routine properly adjusts the calibration values IF the Llit and or Hlit parameters have been changed from factory default Setting the PVL and PVH correctly allows proper operation of unit No additional calibration is required The unit with firmware version V3 7 has two additional parameters PVL and PVH located in the level 4 as parameters flow chart on the left hand side indicates When you need to change the LLit value to a higher value or change the HLit value to a lower value the following procedures MUST be performed to make the PVL value equivalent to one tenth of LCAL value and the PVH value equivalent to one tenth of HCAL value Otherwise the measured process values will be out of specification 1 Follow the Setup Parameter procedure and scroll down to the LLit parameter Change parameter using the up and down arrow to new desired value you require 2 Press and release the Scroll Key HLit appears on the PV Display Use Up and Down Keys to set the HLit value to the new desired value you require 3 Turn the power OFF wait 5 seconds and re power the unit 4 Following the Setup parameter entry routine advance until the2. Index advanced continuously and cyclically by pressing this keypad 19 Up Key Increases the parameter K Down Key Decreases the parameter Return Key G Press for 6 seconds Press 6 for 6 seconds Output Percentage Press and 5 Monitor 9 o Long Return Resets the controller to its normal status Also stops auto tuning output percentage monitoring and manual mode operation Long Scroll Allows more parameters to be inspected or changed 1 Executes auto tuning function 2 Calibrates control when in calibration level Allows the set point display to indicate the control output value Press and Manual Mode for 6 seconds Execution Allows the controller to enter the manual mode UM9090Rev3 0 7 4 RAMP amp DWELL The FDC 9090 controller can be configured to act as either a fixed set point controller or as a single ramp controller on power up This function enables the user to set a pre determined ramp rate to allow the process to gradually reach set point temperature thus producing a Soft Start function A dwell timer is incorporated within the FDC 9090 and the alarm relay can be configured to provide either a dwell function to be used in conjunction with the ramp function The ramp rate is determined by the rr parameter which can be adjusted in the range 0 to 200 0 C minute The ramp rate function is disabled when the 7f parameteris set to O The soak
3. Press and release the scroll key the display reads rtdH Now set the RTD simulator to 300 ohms with ridH on the display press and hold the scroll key for 6 seconds then release the scroll key The display will blink momentarily and a new value will be obtained If the display does not blink or the value equals 199 9 or 199 9 then calibration fails If successful RTD calibration is complete Disconnect the RTD and program as needed Cold Junction Calibration Perform this calibration if Thermocouple input is to be used on the unit NOTE Solder Gap G5 MUST be CIOSED to perform this calibration 1 Connect a K thermocouple simulator wired as shown below Terminal 5 is the Positive lead Yellow and terminal 4 is negative lead Red 2 Set the K simulator to simulate 0 0 C degrees FDC 9090 AC power to unit Alarm F1 S1 under calibration Com 9v0 90 o o emperaus ium LY 90 264 VAC 50 60HZ Calibrator no 2 T KTC K 3 8 E c 9 ieee 10 K 2 If you exited the calibration mode enter as performed in the main calibration routine and scroll down to the parameter CJLo With 0 0C simulated on input use the Up and Down arrow key to obtain a reading of 40 0 Once value at unit is set to 40 0 press and hold the scroll key for 6 seconds then release key The display should blink momentarily and a new value is obtained If display does not blink and a value equals 5 00 or 40 00 the calibration fai
4. S break Replace RTD or sensor 5 b E 7 Sensor break error Use manual mode operation Process display beyond i L L Er the low range set point Re adiust L L E value Process display beyond adi 1 HL Er the high range set point Re adjust HL E value AHE Analog hybrid module Replace module Check for r outside source of damage damage such as transient voltage spikes Incorrect operation of Repeat procedure Increase Rt E r auto tune procedure Prop Band to a number larger Prop Band set to 0 than 0 Manual mode is not PE r allowable for an ON OFF Increase proportional band o control system t 5 E esci ea values Check and reconfigure the r changed accidentally control parameters UM9090Rev3 0 7 5 MANUAL TUNING PROCEDURE Step 1 Adjust the integral and derivative values to 0 This inhibits the rate and reset action Step 2 Set an arbitrary value of proportional band and monitor the control results Step 3 If the original setting introduces a large process oscillation then gradually increase the proportional band until steady cycling occurs Record this proportional band value Pc Step 4 Measure the period of steady cycling PV PV Process value I4 Record this value Tc in seconds TIME Step 5 The Control Settings are determined as follows Proportion Band PB 1 7 Pc Integral Time T1 0 5 Tc Derivative Time TD 0 125 Tc 7 6 Flow Chart PROCESS VALUE DISPLAY SET
5. the new P I D settings are automatically entered into the controller s non volatile memory 7 3 MANUAL P I D ADJUSTMENT Whilst the auto tuning function selects control settings which should prove satisfactory for the majority of processes you may find it necessary to make adjustments to these arbitrary settings from time to time This may be the case if some changes are made to the process or if you wish to fine tune the control settings It is important that prior to making changes to the control settings that you record the current settings for future reference Make slight changes to only one setting at a time and observe the results on the process Because each of the settings interact with each other it is easy to become confused with the results if you are not familiar with process control procedures TUNING GUIDE Proportional Band Symptom Solution Slow Response Decrease PB Value High Overshoot or Oscillations Increase PB Value Integral Time Reset Symptom Solution Slow Response Decrease Integral Time Instability or Oscillations Increase Integral Time Derivative Time Rate Symptom Solution Slow Response or Oscillations Decrease Deriv Time High Overshoot Increase Deriv Time With power on it has to wait for 12 seconds to memorize the new values of parameters once it been changed TOUCHKEYS FUNCTION DESCRIPTION Scroll Key Advance the index display to the desired position
6. value if A A 72 3 6 to 11 Ramp Rate for the process value to limit an abrupt change of process Soft Start rr 0 to 200 0 C 360 0 F minute if 1 n20t09 0 C min 0 to 3600 unit minute if m 710 32F min Offset Value for Manual Reset if E 0 0 09 oF5t 0 to 100 aie SH F Offset shift for process value oc 111 C to 111 C 32F P Proportional Band 10C b 0 to 200 C set to 0 for on off control 50F Integral Reset Time t 0 to 3600 seconds 120 sec Derivative Rate Time Ed 0 to 1000 seconds 30506 Local Mode L o CL 0 No control parameters can be changed 1 1 Control parameters can be changed Parameter Selection allows selection of additional parameters to be accessible at level 0 security 0 None 4 H5P 4 rr SEL nsp 5 R5P oF SE 0 2 rr rr oF St 3ioF SE 7 ASP I or aFSE Relay 20 CE Proportional Cycle Time 0 to 120 seconds Pulsed Voltage 1 Linear Volt mA 0 Input Mode Selection 0 J type T C 6 S type T C T C 0 1 K type T C 7 N type T C 2 T type T C 8 PT100 DIN n 3 E type T C 9 PT100 JIS RTD 8 4 B type T C 10 Linear Voltage or Current 5 R type T C Note T C Close solder gap G5 RTD Open G5 Linear 10 Alarm Mode Selection 0 Process High Alarm 8 Outband Alarm 1 Process Low Alarm 9 inband Alarm 2 Deviation High Alarm 10 Inhibit Outband Alarm AL n l 3 Deviation Low Alarm 11 Inhibit Inband Alarm 0 4 Inhibit Pro
7. 9090 User s Manual FDC 9090 Self Tune Fuzzy PID Process Temperature Controller CONTROLS Warning Symbol This Symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in personal injury or damage to or destruction of part or all of the product and system Do NOT proceed beyond a warning symbol until the indicated conditions are fully understood and met Use the Manual e Specifications Page 3 e Wiring Page 4 e Programming Page 6 e Warranty Page 11 NOTE It is strongly recommended that a process should incorporate a LIMIT like L91 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system Copyright a August 2001 Future Design Controls all rights reserved No part of this publication may be reproduced transmitted transcribed or stored in a retrieval systern or translated into any language in any form by any means without the written permission of Future Design Controls UM9090Rev3 0 Model FDC 9090 Instruction Manual 3 FRONT PANEL DESCRIPTION Process Value Display CONTENTS 1 INTRODUCTION 2 NUMBERING SYSTEM 3 FRONT PANEL DESCRIPTION 4 INPUT RANGE amp ACCURACY 5 SPECIFICATIONS 6 INSTALLATION 6 1 DIMENSIONS amp PANEL CUTOUT 6 2 WIRING DIAGRAM 7 OPERATION 7 1 KEYPAD OPERATION 7 2 AUTOMATIC TUNING 7 3 MANUAL P I D ADJUSTMENT 7 4 RAMP
8. ID FUZZY CONTROL Set point Warm Up Load Disturbance Time Up Key 4 INPUT RANGE amp ACCURACY Input Type Range C F 50 999C 58 1830F Chromel Alumel 50 1370C 58 2498F 2 C 4F K T Copper Constantan 270 to 400 C 454 752F 2 C 4F E B Accuracy 2 C 4F IN Sensor J Iron Constantan Chromel Constantan 50 750C 58 1382F 2 C 4F Pt30 RH Pt6 RH R Pti3 RH Pt 0 1750C 32 3182F 6 S Pt10 RH Pt 0 1750C 32 3182F 2 C 4F 7 N Nicrosil Nisil 50 1300C 58 2372F 2 C 4F 8 RTD PT100 ohms DIN 200 400C 328 752F 0 4 C 8F 9 RTD PT100 ohms JIS 200 400C 328 752F 0 4 C 8F 10 Linear 10mV to 60mV 1999 to 9999 0 05 5 SPECIFICATIONS INPUT Thermocouple T C J K T E B R S N RTD PT100 ohm RTD PTDN or JIS Linear 10 to 60 mV configurable input attenuation Range User configurable refer to Table above Accuracy Refer to Table above Cold Junction Compensation Sensor Break Protection 0 1 C C ambient typical Protection mode configurable External Resistance 100 ohms max In addition this instrument has functions of single stage ramp Normal Mode Rejection 60 dB and dwell auto tunung and manual mode execution Ease of use me also an essential feature with it Co
9. LCAL appears on the PV Display Record the LCAL value 5 Press and release the Scroll Key then HCAL appears on the PV Display Record the HCAL value 6 Press the Scroll Key for at least 6 seconds and then release PVL appears on the PV Display Use UP and Down Keys to set the PVL value to one tenth of LCAL value 7 Press and release the Scroll Key PVH appears on the PV Display Use UP and Down Keys to set the PVH value to one tenth of HCAL value 8 Adjustment is complete Exit by depressing the Return Key 9 Unit should display the proper process value Proper setting of the PVL and PVH parameters can be confirmed by entering the Setup parameter routine and scrolling through the complete parameter listing and verifying the PVL and PVH parameters are set to the required one tenth the value of LCAL and HCAL respectively UM9090Rev3 0 7 0 Manual Calibration Procedures All units are factory calibrated If field calibration is required you must use NIST traceable calibration equipment to meet specifications If proper equipment is not available please return to factory for proper service Equipment required is 1 A Millivolt source 0 100Mv 0 005 accuracy 2 K thermocouple simulator 0 01 accuracy 3 RTD simulator 0 300 ohms 0 01 accuracy Main A to D Calibration This calibration procedure requires a Millivolt source This calibration must be done for ALL input types 1 Connect the Millivolt source as shown belo
10. POINT VALUE DISPLAY Long 6 seconds ASP 1 rr e oF SE C 5H Pb ti Ed Long ce 6 seconds fa 3 0 O Level 2 Parameters are factory set If change is required see page 6 for cS proper setting of PVL amp PVH A 6 seconds I All Units are factory calibrated LCAL calibration follow HCAL proper procedure See page 4 and 5 igPr 9 P7 g P g panga Long s Level 3 Long co 6 seconds Please turn to Page 6 for P UL proper setting of these parameters Failure to evel 4 proper set can cause loss of P UH calibration of unit The return key can be pressed at any time This will prompt the display to return to the Process value Set point value Power Applied 1 9090 3B Displayed for 4 seconds Software Version 3 6 or higher 2 8688 BBBB LED test All LED segments must be lit for 4 seconds 3 Process value and set point indicated 7 7 PARAMETER DESCRIPTION INDEX DESCRIPTION DEFAULT CODE ADJUSTMENT RANGE SETTING Set point Value Control SV Low Limit to High Limit Value Undefined Alarm Set point Value Low Limit to High Limit Value if A A 0 1 4 or 5 ASP 10103600 minutes if Ai m 12 or 13 200C Low Limit minus set point to high Limit minus set 392F point
11. al Support E mail csr futuredesigncontrols com Website _http futuredesigncontrols com Version3 0 Dated 6 2013 JONUDW S Jesf pj JejJ oJUO2 einjpieduue sseoold 0606 2104 NOIS3UO03WunRALns S 104 1 N O 2 0 ASY 0606UJn
12. amp DWELL 7 5 MANUAL TUNING PROCEDURE 7 6 FLOW CHART 7 7 PARAMETER DESCRIPTION 8 CALIBRATION 9 ERROR MESSAGES Control Output Alarm Output Scroll Key 0 4 red LED Set point Value Display 0 3 green LED Down Key Return Key 1 INTRODUCTION This manual contains information for the installation and operation of the Future Design Control s model FDC 9090 Fuzzy Logic micro processor based controller The Fuzzy Logic is an essential feature of this versatile controller Although PID control has been widely accepted by industries it is difficult for PID control to work with some sophistic systems efficiently for example systems of second order long time lag various set points various loads etc Because of disadvantage of controlling principles and fixed values of PID control it is inefficient to control the systems with many variables and the result is unacceptable control for some systems The Fuzzy Logic control can overcome the disadvantage of PID control only It controls the system in a efficient way by experiences it had before The function of Fuzzy Logic is to adjust the PID values indirectly in order to making the manipulation output value MV adjusts automatically and quickly to adapt to various processes It enables a process to reach its set point in the shortest time with minimum overshooting during tuning or external disturbance PID control with properly tuned PID Fuzzy control P
13. cess High Alarm 12 Alarm Relay OFF as 5 Inhibit Process Low Alarm Dwell Time Out 6 Inhibit Deviation High Alarm 13 Alarm Relay ON as T Inhibit Deviation Low Alarm Dwell Time Out Hysteresis of Alarm 1 9 AHY 0 to 20 of SPAN 0 5 CF C F Selection 1 OF 1 C Resolution Selection 0 No Decimal Point 2 2 Digit Decimal r E 5g 1 1 Digit Decimal 3 3 Digit Decimal 0 2 amp 3 may only be used for linear voltage or current 1 P210 A Control Action 4 Co n 0 Direct Cooling Action 1 Reverse Heat Action Error Protection Er Pr 0 Control OFF Alarm OFF 2 Control ON Alarm OFF 1 1 Control OFF Alarm ON 3 Control ON Alarm ON H 5 Hysteresis for ON OFF Control 0 5 g E 0 to 20 of SPAN aid LL E LowLimitof Range 50 C 58F HL E High Limit of Range 1000C 1832F LEAL Low Calibration Figure 0 C 32F HEAL High Calibration Figure 800 C 1472F put Low Calibration Figure Set to One Tenth the LCAL Value 0 C 32F PYH High Calibration Figure Set to One Tenth the HCAL Value 80 C 176F Adjusting Range of the Parameter Factory settings Process alarms are at fixed temperature points Deviation alarms move with setpoints NOTE Parameters are for Version 3 7 ONLY UM9090Rev3 0 PROCESS VALUE DISPLAY SET POINT VALUE DISPLAY Long 6 seconds o lt o Level 1 Long 6 seconds LLL s n 0111 Level 2
14. esign Controls shall not be liable for any damages or losses whether direct indirect incidental special consequential or any damages costs or expenses excepting only the cost or expense of repair or replacement of Future Design Controls products as described below Future Design Controls sole responsibility under the warranty at Future Design Controls option is limited to replacement or repair free of charge or refund of purchase price within the warranty period specified The warranty does not apply to damage resulting from transportation alteration misuse or abuse Future Design Controls reserves the right to make changes without notification to purchaser to materials or processing that does not effect the compliance with any applicable specifications Return Material Authorization Contact Future Design Controls for Return Material Authorization Number prior to returning any product to our facility Future Design Controls 7524 West 98th Place RO Box 1196 Bridgeview IL 60455 USA 888 751 5444 Office 888 307 8014 Fax 866 342 5332 Technical Support E mail csr futuredesigncontrols com Website http futuredesigncontrols com FDC 9090 Users Manual version 3 0 6 4 2013 jONUDW ses 1eJo1u02 einjp1eduue sseooid 0606 204 NOISS303unins pj fd FuTUREDEsIGN Future Design Controls 7524 West 98th Place PO Box 1196 Bridgeview IL 60455 USA 888 751 5444 Office 888 307 8014 Fax 866 342 5332 Technic
15. function is enabled by configuring the alarm output to act as a dwell timer The parameter fj A needs to be set to the value 12 The alarm contact will now operate as a timer contact with the contact being closed at power up and opening after the elapsed time set at parameter ASP I If the controller power supply or output is wired through the alarm contact the controller will operate as a guaranteed soak controller In the example below the Ramp Rate is set to 5 C minute ALA 1212 and H5P 15 minutes Power is applied at zero time and the process climbs at 5 C minute to the set point of 125 C Upon reaching set point the dwell timer is activated and after the soak time of 15 minutes the alarm contact will open switching off the output The process temperature will eventually fall at an undetermined rate BC 150 125 100 75 50 25 Process Value 15 minutes ke l Alarm Output Jon I I I I l I l t minutes 0 10 20 30 40 50 60 70 80 90 The dwell function may be used to operate an external device such as a siren to alert when a soak time has been reached HL n 1 need to be set to the value 13 The alarm contact will now operate as a timer contact with the contact being open on the initial start up The timer begins to count down once the set point temperature is reached After the setting at pgp has elapsed the alarm contact closes 9 ERROR MESSAGES Symptom Cause s Solution s
16. ls If unit can not be field calibrated return to factory for evaluation repair NOTE All units are shipped typically in thermocouple mode If RTD input is required you must OPEN the solder gap G5 on processor board You do NOT need to recalibrate as ALL calibration procedures were performed at factory Solder Gap G5 is found on the small tail like PC board inside of unit To remove unit from housing push up on the release tab on the bottom from of display bezel and pull bezel forward Observer PC board where solder gap G5 is located 9 UM9090Rev3 0 This Page Intentionally Left Blank Warranty and Return Statement WARRANTY Future Design Controls products described in this manual are warranted to be free from functional defects in materials and workmanship at the time the products leave Future Design Controls Facilities and to conform at that time to the specifications set forth in the relevant Future Design Controls manual sheet or sheets for a period of 3 years after delivery to the first purchaser for use There are no expressed or implied Warranties extending beyond the Warranties herein and above set forth Limitations Future Design Controls provides no warranty or representations of any sort regarding the fitness of use or application of its products by the purchaser Users are responsible for the selection suitability of the products for their application or use of Future Design Controls products Future D
17. mentarily a new value will be obtained If the display does not blink or the value is equal to 199 9 or 199 9 then calibration fails If calibrations fails check equipment connections and setting and repeat If unsuccessful return to manufacturer If calibration is successful then proceed to next page for Cold Junction Calibration for thermocouples and RTD calibration if using RTD input 7 0 Manual Calibration Procedures continued RTD Input calibration Perform this calibration if RTD input is to be used on the unit Solder Gap G5 MUST be OPENED prior to performing RTD calibration 1 Connect a 3 wire RTD simulator to the RTD input as shown below The hot lead connects to terminal 3 The 2 common leads go to terminals 4 amp 5 FDC 9090 6 2 WIRING DIAGRAM Alarm F 81 AC power to unit Com 6 o_o under calibration Alarm 1 X 90 264 VAC 50 60HZ Lo Hot lead N O 3 RTD LE Si lat Common lead RTD Input 4 Control Output 1 Imularor Common lead fg 2 Set the RTD simulator to simulate 100 ohms 3 If you exited the calibration mode Re enter as described in the parameter setup routine and scroll down until display reads rtdL With rtdL on the display and 100 ohm input from simulator press and hold The scroll key for 6 seconds then release The display will blink momentarily and a new value will be obtained If the display does not blink then calibration fails 4
18. mmon Mode Rejection 120dB 2 Model Order Matrix Sample Rate 3 times second FDC CONTROL 1 2 3 4 5 6 7 8 Proportion Band 0 200 C 0 360F 1 Power Input Reset Integral 0 3600 seconds 4 190 264VAC Rate Derivative 0 1000 seconds 5 20 32VACINDC Ramp Rate 0 200 0 C minute 0 360 0 F minute 9 Other Dwell 0 3600 minutes 2 Signal Input ON OFF With adjustable hysteresis 0 20 of SPAN 5 Configurable Universal Cycle Time 0 120 seconds Tomar Control Action Direct for cooling and reverse for heating 3 Range Code 1 Configurable POWER 9 Other Rating 90 264VAC 50 60Hz 4 Control Mode Consumption Less than 5VA 3 PID ON oFF Control 5 Output 1 Option 0 None ENVIRONMENTAL amp PHYSICAL T Relay rated 3A 240VAC resistive Approvals UR File E196206 CSA 209463 2 SSR Drive rated 20mA 24V CE RoHS Compliant 3 4 20mA linear max load 500 ohms Module OM93 1 EMC Emission EN50081 1 4 0 20mA linear max load 500 ohms Module OM93 2 EMC Immunity EN50082 2 5 0 10V linear min impedance 500K ohms Module OM93 3 Operating Temperature 10to 50 C 9 Other Humidity 0 to 90 RH non codensing 6 Output 2 Option Insulation 20M ohms min 500 VDC 0 None Breakdown AC 2000V 50 60 Hz 1 minute 7 Alarm Option Vibration 10 55 Hz amplitude 1 mm 0 None Shock 200 m s 20g 1 Relay rated 2A 240VAC resistive Net Weight 170 grams 9 Other Housing Ma
19. terials Poly Carbonate Plastic 8 Communication 0 None UM9090Rev3 0 6 INSTALLATION 6 1 DIMENSIONS amp PANEL CUTOUT 45 mm 1 77 t ER oe z 94 mm Figure 6 1 Mounting Dimensions 6 2 WIRING DIAGRAM FDC 9090 F1 1 L ono o o o 90 264 VAC 50 60HZ c gt Control Output 1 F1 Fuse S1 Power Switch 7 OPERATION 7 1 KEYPAD OPERATION 7 2 AUTOMATIC TUNING Ensure that controller is correctly configured and installed N Ensure Proportional Band Pb is not set at 0 w Press Return Key for at least 6 seconds maximum 16 seconds This initializes the Auto tune function To abort auto tuning procedure press Return Key and release 4 The Decimal point in lower right hand corner of PV display flashes to indicate Auto tune is in progress Auto tune is complete when the flashing stops 5 Depending on the particular process automatic tuning may take up to two hours Processes with long time lags will take the longest to tune Remember while the display point flashes the controller is auto tuning NOTE If an AT error A Er occurs the automatic tuning process is aborted due to the system operating in ON OFF control PB 0 The process will also be aborted if the set point is set to close to the process temperature or if there is insufficient capacity in the system to reach set point e g inadequate heating power available Upon completion of Auto tune
20. w Positive lead to terminal 5 and negative lead to terminal 4 Set the Millivolt source for 0 00 MV Millivolt wiring Diagram FDC 9090 AC power to unit F1 S1 under calibration o o 90 264 VAC 50 60HZ Millivolt Lead Simulator Lead 2 Enter into the setup parameter menu and set the following parameters to the settings shown below IN 1 LLIT 50 0 HLit 1370 3 With HLit on the display press and hold scroll key for 6 seconds then release The display should read LCAL set this value to 0 0 using up down arrow keys to obtain 0 0 4 Press and release scroll key the display reads HCAL set this value to 800 0 using arrow keys 5 Press and hold the scroll key for 6 seconds then release the display will read PVL set this value to 0 0 using the arrow keys 6 Press and release scroll key display reads PVH set this value to 80 0 using the arrow keys 7 Press and hold the scroll key for 6 seconds then release The display will read AdLo Input a 0 0 MV signal then press and hold the scroll key for 6 seconds then release The display will blink momentarily and a new value will be obtained If the display does not blink or the value is equal to 199 9 or 199 9 then calibration failed 8 Press and release scroll key The display will read AdHi Input a 60 0 MV signal then press and hold the scroll key for 6 seconds then release The display will blink mo
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