NCL30086SMRTGEVB 8 W Smart LED Driver Evaluation Board
Contents
1. 2 4 1 1 00 1 1 83 7 8 4 1 00 4190 Designed for functional insulation OPERATING TEMPERATURE RANGE 40 C to 125 C including temp rise Wire insulation amp RoHS status not affected by wire color Wire insulation color may vary depending on availability Unless otherwise specified tolerances are as follows Wurth Electronics Midcom Inc Angles 1 Fractions 1 64 Decimals 005 127mm Footprint 001 03mm Watertown SD USA Drawing Title Toll Free 800 643 2661 Fax 605 886 4486 Transformer 750314910 00 Barada Engineer LJG 07 02 2014 o www onsemi com 10 EVBUM2293 D TEST PROCEDURE Equipment Needed Test Connections e AC Source 90 to 305 V ac 50 60 Hz Minimum 500 W 1 Connect the LED Load to the red and black Capability leads through the ammeter shown in Figure 11 e AC Wattmeter 300 W Minimum True RMS Input Caution Observe the correct polarity or the load may be damaged 2 Connect the AC power to the input of the AC wattmeter shown in Figure 11 Connect the white leads to the output of the AC wattmeter 3 Connect the DC voltmeter as shown in Figure 11 Voltage Current Power Factor and THD 0 2 Accuracy or Better e DC Voltmeter 300 V dc minimum 0 1 Alccuracy or Better e DC Ammeter 1 A dc Minimum 0 1 Accuracy or Better e LED Load 75 V 0 1 A A Constant Voltage Electronic Load is an Acceptable Substitute2. LET Y Vin 120 230 V ac Vout 75 V O 100 mA NCL30086DIMGEVB Mark Appropriate Revision Level Figure 9 Assembly Notes www onsemi com 8 EVBUM2293 D CIRCUIT BOARD FABRICATION NOTES Fabricate per IPC 6011 and IPC6012 Inspect to 1 600 Class 2 or updated standard Printed Circuit Board is defined by files listed in fileset Modification to copper within the PCB outline is not allowed without permission except where noted otherwise The manufacturer may make adjustments to compensate for manufacturing process but the final PCB is required to reflect the associated gerber file design 0 001 in for etched features within the PCB outline Material in accordance with IPC 4101 21 FR4 Tg 125 C min 11 12 13 14 15 16 Size tolerance of plated holes 0 003 in non plated holes 0 002 in All holes shall be 0 003 in of their true position U D S Construction to be SMOBC using liquid photo image LPI solder mask in accordance with IPC SM BAOC Type B Class 2 and be green in color Solder mask mis registration 0 004 in max Silkscreen shall be permanent non conductive white ink The fabrication process shall be UL approved and the PCB shall have a flammability rating of 5 Layer to layer registration shall not exceed UL94V0 to be marked on the solder side in 0 004 in silkscreen with date manufactures approved logo 6 External finished copper conductor thickness shall
3. 210 220 230 240 250 260 270 Line Voltage V ac Figure 18 Standby Power Consumption over Line Prev Noise Filter Off ait Prey Noise Filter Off JV 2 Hz hand Figure 20 Start Up with AC Applied 230 V Maximum Load www onsemi com 16 EVBUM2293 D IEC61000 3 2 TEST RESULTS Product NCL30086 Smart Serial No 27 Oct 2014 2 50 50PM Description This is a test of the NCL30086 for Class C Page 1 of 1 Voltech Pre Compliance IEC61000 3 2 Windows Software Test Date 27th Oct 2014 14 46 46 PM Type of Test IEC61000 3 2 2005 with Interharmonics to EN61000 4 7 2002 Worst Case Table Power Analyzer Voltech PM1000 100008202290 Ver 4 25 AC Source Mains AC Source Overall Result PASS Class Class C lt 25W Class Multiplier 1 Equipment rated lt 75W and Not class C L1 Reading is below limit 1 lt L2 Reading is below limit 2 x Where Class D test has failed mA W L2 A Reading is below 200 Class A Only N A Harmonic current below 0 6 of rated current or 5mA whichever is greater Or where the test is not applicable Limit1 Limit2 Avg Rdg Max Rdg L2 A PassFail N A N A N A N A N A N A 32 172mA 48 258mA 7 8119mA 7 8384mA N A N A N A N A 17 978mA 26 968mA 5 1631mA 5 1912mA N A N A N A N A 9 4625mA 14 193mA 2 0181mA 2 0335mA N A N A N A N A 4 7312mA 7 0968mA 671 74uA 691 38uA N A N A N A N A 3 3118mA 4 9678mA 1 8833mA 1 9493mA N A N A N A N A 2 8009mA 4 2013mA 1 7378mA 1 7618mA N A N A N A
4. N A 2 4224mA 3 6336mA 1 0112mA 1 0305mA N A N A N A N A 2 1385mA 3 2077mA 1 1958mA 1 2188mA N A N A N A N A 1 9114mA 2 8671mA 1 1528mA 1 1788mA N A N A N A N A 1 7316mA 2 5974mA 883 20uA 904 48uA N A N A N A N A 1 5802mA 2 3703mA 1 0104mA 1 0805mA N A N A N A N A 1 4572mA 2 1858mA 878 98uA 899 97uA N A N A N A N A 1 3436mA 2 0155mA 821 84uA 839 62uA N A N A N A N A 1 2490mA 1 8735mA 677 77uA 698 32uA N A N A N A N A 1 1733mA 1 7600mA 711 21uA 732 77UA N A N A N A N A 1 0976mA 1 6464mA 679 00uA 702 14uA N A N A N A N A 1 0408mA 1 5613mA 581 55uA 601 48uA N A N A N A N A 0 9841mA 1 4761mA 679 90uA 696 94uA N A IA N A N A 0 9273mA 1 3909mA 675 06uA 691 11uA N A N A i N N N co N e N N N gt a N o N co N O N Q ej o a co eo N m aa H A B o zZ gt e gt www onsemi com 17 db uV db uV EVBUM2293 D 70 65 60 55 50 45 40 35 30 25 20 0 15 1 5 Frequency in MHz Figure 21 Pre compliance Conducted EMI 150 kHz 1 5 MHz 70 50 40 30 20 Peak Data Class B QP Limit 10 0 1 1 10 100 Frequency in MHz Figure 22 Pre compliance Conducted EMI 150 kHz 30 MHz WWW onsemi com 18 EVBUM2293 D BILL OF MATERIALS Table 3 BILL OF MATERIALS fom me Doe
5. Output current is reduced when the voltage on the SD pin drops below 1 V Below 0 5 V on SD the controller stops Addition of series or parallel resistors with the NTC can shape the foldback curve and this can be modeled using the on line EXCEL design tool In the event that the pin is left open there is a soft voltage clamp at 1 35 V nominal While the SD pin has a current source for the OTP it can be overcome raising the voltage on the SD pin At about 2 5 V the SD pin detects an OVP and shuts down the controller Typically a zener to Vcc is used for this In this way the designer can set the OVP to a lower value that the threshold built into the Vcc pin The zener programmable OVP is not implemented on this demo board www onsemi com 3 EVBUM2293 D AUX Power Management HVDC L Rstart 1 0 Meg Rstart1 1 0 Meg Rbo 3 01 Meg Rtco 100k Ohm NTC NCL30082 R2 v 51 1k Vcc Power On Mode Vcc Power Off Mode 3 3V Power 3 3V Power Off Mode CB Dout D LED T1 Cout 4 7uF 100V 4 R20 56k Y Q3 MMBTAO6LT1G D12 eep Alive Regulator MM5Z15VT1G active in off mode Qfet ka NDDO2N60 V m T NCC A 1 0 BAS21DW5T1G C13 C15 4 7uF are NS On Mode NOTE While this is shown for the NCL30082 controller the management scheme is the same for the NCL30086S8MRTGEVB demo board Figure 2 AUX Power Management Circuit Modifications Out
6. Publication Order Number February 2015 Rev 0 EVBUM2293 D EVBUM2293 D NCL30086 Smart Dim pAg re a w Bias ver aa o 73 ETIN ni 4 R6 m d i gt id 04 Figure 1 NCL30086SMRTGEVB THEORY OF OPERATION Power Stage The power stage for the demo board is a non isolated coupled SEPIC converter The controller has a built in control algorithm that is specific to the flyback transfer function and applies to flyback buck boost and SEPIC converters Specifically Vout Duty 1 Vin 1 Duty ENS The control is very similar to the control of the NCL30080 83 with the addition of a power factor correction control loop The controller has a built in hardware algorithm that relates the output current to a reference on the primary side Vner Nps eq 2 OUT 2 Roense Nori PS eq 3 NsEc Where Primary Turns Nsec Secondary Turns We can now find for a given output current Veer Nps Rsense eq 4 2 lout Line Feedforward The controller is designed to precisely regulate output current and can be compensated to address variation due to line voltage variation R14 sets the line feedforward and compensates for power stage delay times by reducing the current threshold as the line voltage increases R14 1s also used for the shorted CS current sense pin detection At start up the controller puts out a current
7. R4 and R13 have higher static power dissipation which lowers the efficiency of the driver In general for a smart lighting application startup time may not be as critical given that intent is that the driver IC is always biased even when the lamp is off Output Voltage Sense The auxiliary winding voltage is proportional to the output voltage by the turns ratio of the output winding and the auxiliary winding The controller has an overvoltage limit on the Vcc pin at 25 5 V minimum Above that threshold the controller will stop operation and enter overvoltage fault mode This protection would normally be triggered if the LED string had an open In certain cases when the output has significant ripple current and the LED has high dynamic resistance the peak output voltage can be much higher than the average output voltage The auxiliary winding will charge the CY cc to the peak of the output voltage which may trigger the OVP sooner than expected so in this case the peak voltage of the LED string is critical The design of the auxiliary winding turns ratio needs to factor in the absolute peak LED forward voltage SD Pin The SD pin is a multi function protection input 1 Thermal Foldback Protection 2 Programmable OVP Thermal Protection There is an internal current source from the SD pin Placing an NTC from the SD pin to ground will allow the designer to choose the level of current foldback protection in the event of high temperature
8. comparator on the ZCD pin to start a new switching cycle The ZCD pin also counts rings WWW onsemi com 2 EVBUM2293 D on the auxiliary winding for higher order valley operation A failure of the ZCD pin to reach a certain threshold also indicates a shorted output condition Vcc Power The auxiliary winding forward biases D9 to provide power for the controller This arrangement is called a bootstrap Initially CY cc is charged through RA and R13 When the voltage on CVcc reaches the startup threshold the controller starts switching and providing power to the output circuit and the CVcc CVcc discharges as the controller draws current As the output voltage rises the auxiliary winding starts to provide all the power to the controller Ideally this happens before C Vcc discharges to the under voltage threshold where the controller stops operating to allow CVcc to recharge once again The size of the output capacitor will have a large effect on the rise of the output voltage Since the LED driver is a current source the rise of output voltage is directly dependent on the size of the output capacitor There are tradeoffs in the selection of Cour and CVcc A low output ripple will require a large Cour value This requires that CVcc be large enough to support Vcc power to the controller while Court is charging up A large value of CVcc requires that RA and R13 be lower in value to allow a fast enough startup time Smaller values of
9. may result in flicker of the LED without the stabilization from US The design is setup for 20 mA adjusting the value of R18 can raise or lower available current based on the specific application needs www onsemi com 5 EVBUM2293 D uonejnBay eDeyoA 91815 HO uo s Nejad 033002 JO uO N N OLLMY06ZLEININ 05 OZ OM 001 ZO 1H JU 19euuoosiq WIG 019 OLLMYO6ELINN OY LO A m 9 OY 001 DU L 916 10 8 69 149 MOd A 91815 HO 10J Y OLLASIZSININ 869598 vO wig INGQOV LS6Zd7 old d woo 1043 VI FdON qu ry E E NEL lt am vn DIZ 5 E ug lus der oA 3 ul OLLISIESV8 LLO d lt _ un 99A 9POIN HO U A OLLCAX9ISVS8 cN 9An9y U A S E Ox 00 PON eAnoy 4104 GLU 1181119 WWI OLLASLZSININ ray Sig LNOA NIA lt 22A C O c9 giu LEN lt am 3H Figure 5 Interface Schematic WWW onsemi com EVBUM2293 D GERBER VIEWS NCL30086 Smart Dim w Bias Power Vin 120 230 V ac Vout 75 V 0 100 mA NCL30086DIMGEVB Rev Figure 6 Top Side PCB Figure 7 Bottom Side PCB WWW onsemi com 7 EVBUM2293 D a NCL30086 a Smart Dim ea w Bias Power 40 0 mm Vin 120 230 Y ac Vout 75 V 100 mA NCL30086DINGEVB Rev Figure 8 PCB Outline NCL30086 Smart Dim w Bias Power
10. 0 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 Line Voltage V ac Figure 13 THD over Line and Load www onsemi com 13 Efficiency Output Current mA 85 84 83 82 81 00 o X 79 78 77 76 75 115 103 100 94 91 88 85 EVBUM2293 D 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 Line Voltage V ac Figure 14 Efficiency over Line and Load 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 Line Voltage V ac Figure 15 Regulation over Line www onsemi com 14 LED Output Current in mA 3 3 Output Voltage EVBUM2293 D 105 0 103 5 4 103 0 102 5 4 102 0 4 101 5 101 0 4 T T 0 0 2 0 4 0 6 0 8 0 10 0 12 0 14 0 16 0 18 0 20 0 3 3V Load in mA Figure 16 Cross Regulation Effect of 3 3 V Load on Output Current 3 48 3 46 E 3 36 0 10 20 30 40 50 60 70 80 90 100 LED Output Current in mA Figure 17 Cross Regulation Effect of Output Current on 43 9 V Output WWW onsemi com 15 EVBUM2293 D 600 500 Universal Mains 230V Optimized Standby Power mW 0 90 100 110 120 130 140 150 160 170 180 190 200
11. E Quantity Reference Part Number PCB Footprint Allowed OV o ATaF O 7 o ATaF O TAJB475MO35RNJ 121 o 0320 Cre ee E 3 me T H eo o H me Ye E meme 09 9 R16 40 2 kQ Yaego RCO402FR 0740k2L A a ss cr 039 e A aa o oa e f es A 5 senora oros om ACI CIS H wem Sm D H or Y osorno wem e NOTE All Components to comply with RoHS 2002 95 EC WWW onsemi com 19 EVBUM2293 D Microsoft Excel is a registered trademark of Microsoft Corporation ON Semiconductor and the ON are registered trademarks of Semiconductor Components Industries LLC SCILLC or its subsidiaries in the United States and or other countries SCILLC owns the rights to a number of patents trademarks copyrights trade secrets and other intellectual property A listing of SCILLC s product patent coverage may be accessed at www onsemi com site pdf Patent Marking pdf SCILLC reserves the right to make changes without further notice to any products herein SCILLC makes no warranty representation or guarantee regarding the suitability of its products for any particular purpose nor does SCILLC assume any liability arising out of the application or use of any product or circuit and specifically disclaims any and all liability including without limitation special consequential or incidental damages Typical parameters which may be provided in SCILLC data sheets a
12. EVBUM2293 D NCL30086SMRTGEVB 8 W Smart LED Driver Evaluation Board User s Manual ON Semiconductor www onsemi com Overview This manual covers the specification theory of operation EVAL BOARD USER S MANUAL testing and construction of the NCL30086SMRTGEVB demonstration board The NCL30086 board demonstrates an 8 W high PF SEPIC LED driver with a 3 3 V always on auxiliary voltage rail to power a MCU wireless transceiver plus other accessories A simple dimming and ON OFF control is also provided that demonstrates dimming control of the NCL30086 as well as dim to off operation Specifications ITH O ov S rerewe o Power Factor 100 Load Mn 2 T LED Output Current 100 mA dc 38 88 Standby Power 230 V 50 Hz 400 mW Universal Mains or 170 mW 230 V Optimized 120 V 60 Hz 170 mW Analog Dimming Voltage 100 Output VpiM gt 2 5 V 096 Output VpiM lt 0 1 V o ee Pint Range Freg gt 2008 A E H Key Features e Wide Mains e 3 3V Aux Voltage e EC61000 3 2 Class C Compliance over Line and Load Available in All Modes e High Power Factor across Wide Line and Load e Dim to Zero Output e ntegrated Auto Recovery Fault Protection e On Off Control Can be Latched by Choice of Options Over Temperature on Board a PCB Mounted NTC c Over Current Output and Vcc Over Voltage Semiconductor Components Industries LLC 2015 1
13. and type designation be 0 0026 in min ie 20z 17 Warp and twist of the PCB shall not exceed 7 Copper plating thickness for through holes shall be 0 0075 in per in 0 0013 in min ie loz 18 100 electrical verification required 8 All holes sizes are finished hole size 19 Surface finish electroless nickel immersion gold 9 Finished PCB thickness 0 062 in ENIG 10 All un dimensioned holes to be drilled using 20 RoHS 2002 95 EC compliance required the NC drill data ECA PICTURE NCL30086 T T la Be ii Smart Dim L E j r w Bias ver A d ed JL Lo z 12 E x kh I mn e E Figure 10 Top View www onsemi com 9 EVBUM2293 D SEPIC INDUCTOR SPECIFICATION WE W RTH ELEKTRONIK Update bobbin view at release LJG 6 20 14 Lot Code amp Date Code 9 9 9 6 9 e 75 125kH2 SEM a a e i e e SENSE 8 ELECTRICAL SPECIFICATIONS 25 C unless otherwise noted D C RESISTANCE 20 C 1 3 0 890 Ohms 10 2 4 0 835 Ohms 10 7 8 0 236 Ohms 10 DIELECTRIC RATING 1250VAC for 1 second between pins 1 4 1250VAC for 1 second between pins 1 8 INDUCTANCE 550 uH 5 10kHz 100mVAC OmADC 1 3 Ls SATURATION CURRENT 1 45A saturating current that causes 20 rolloff from initial inductance LEAKAGE INDUCTANCE 10 typ 15uH max 100kHz 100mVAC 1 3 tie 2 4 Ls 24UH typ 35uH max 100kHz 100mVAC 1 3 tie 7 8 Ls TURNS RATIO 1 3
14. for the LEDs as long as it is Stable DC Ammeter AC Power AC Source Wattmeter DC Voltmeter LED Test Load NOTE Unless otherwise specified all voltage measurements are taken at the terminals of the UUT Figure 11 Test Set Up Functional Test Procedure 1 Set the LED Load for 75 V Output 2 Set the Input Power to 120 V 60 Hz Caution Do not touch the ECA once it is energized because there are hazardous voltages present WWW onsemi com 11 EVBUM2293 D Line and Load Regulation Table 1 120 V MAX LOAD Output Current LED Output ES mA x 3 mA RES Power ES Factor RV 83VLoad 0 0 Output Voltage age O aas mmn Wem ww sav 3 SECTA REESE ET aay 30v ENE METETE asv J sw sv Table 2 230 V MAX LOAD Output Current LED Output LL mA 3 mA pon Power ER Factor RV 83VLoad 0 0 Output Voltage NEN wwe Wn Wx sav 3v ECN DETECTA asy 3o METETE aav sv TO ooo V l OUT OUT Efficiency 100 IN www onsemi com 12 EVBUM2293 D TEST DATA 1 00 0 95 0 90 0 85 Power Factor 0 80 0 75 0 70 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 Line Voltage V ac Figure 12 Power Factor over Line and Load 50 45 40 35 30 5 25 20 15 10 5 0 90 10
15. his case RA and R13 are optimized for low power consumption rather than an optimized startup time Dim Control The dim control input will accept either an analog or PWM signal The output has full range from 0 to 100 output A 0 volt input to the dim connection causes Q4 to operate in linear mode which maintains the voltage on the dim pin of the controller at its minimum level At 0 volts on the dim connection the output voltage will be 25 V which is below the forward voltage of the LEDs WWW onsemi com 4 EVBUM2293 D SCHEMATIC RDAMP 180 Q Figure 3 Input Circuit C5 100 nF DouT gt HVDC 400 V UFM15PL e LED gt E D9 BAS21DW5T1G T R5 E 56 kQ E 2D OE DE Lel eno gt gt O N Keep Alive Regulator C14 Active in Off Mode y B 12 e denos D13 VCC Lin qu V 330 Q BAS21DW5T1G C15 HTCO RSENS C13 4 7 uF 100 kQ t 100 47 WF V C12 V 1 0 uF V Figure 4 Main Schematic Available 3 3 V Power In active mode the current source U5 and shunt U4 represent a constant power load to the LED driver to ensure consistent LED current regulation regardless of the instantaneous demand on the 3 3 V output from the MCU wireless transceiver plus other accessories NCP431A was selected for the shunt regulator due to its low quiescent current For very low current draw on the 3 3 V aux output U5 may not be needed Variable loads on the 3 3 V aux output
16. nd or specifications can and do vary in different applications and actual performance may vary over time All operating parameters including Typicals must be validated for each customer application by customer s technical experts SCILLC does not convey any license under its patent rights nor the rights of others SCILLC products are not designed intended or authorized for use as components in systems intended for surgical implant into the body or other applications intended to support or sustain life or for any other application in which the failure of the SCILLC product could create a situation where personal injury or death may occur Should Buyer purchase or use SCILLC products for any such unintended or unauthorized application Buyer shall indemnify and hold SCILLC and its officers employees subsidiaries affiliates and distributors harmless against all claims costs damages and expenses and reasonable attorney fees arising out of directly or indirectly any claim of personal injury or death associated with such unintended or unauthorized use even if such claim alleges that SCILLC was negligent regarding the design or manufacture of the part SCILLC is an Equal Opportunity Affirmative Action Employer This literature is subject to all applicable copyright laws and is not for resale in any manner PUBLICATION ORDERING INFORMATION LITERATURE FULFILLMENT N American Technical Support 800 282 9855 Toll Free Semiconductor Website www
17. onsemi com Literature Distribution Center for ON Semiconductor USA Canada P O Box 5163 Denver Colorado 80217 USA Europe Middle East and Africa Technical Support Order Literature http www onsemi com orderlit Phone 303 675 2175 or 800 344 3860 Toll Free USA Canada Phone 421 33 790 2910 l Fax 303 675 2176 or 800 344 3867 Toll Free USA Canada Japan Customer Focus Center For additional information please contact your local Email orderlit onsemi com Phone 81 3 5817 1050 Sales Representative EVBUM2293 D
18. put Current The output current is set by the value of Rsens as shown above It s possible to adjust the output current by changing Rsens Since the magnetic is designed for 8 W it is possible to increase the current while reducing the maximum LED forward voltage within limits Changes of current of 10 are within the existing EMI filter design and magnetic changes of more than 10 may require further adjustments to the transformer or EMI filter Connections AC Input 1 AC Neutral 2 NC 3 AC Line Output 1 LED LED NC 33 3 V Dim Input On Off Control Signal Ground Interface Control Signals On Off Control The on off control defaults to on if left open Grounding this pin to signal ground turns the output off In off mode the output voltage will regulate to 16 V This is well below the level that will cause the LEDs to pass current resulting in a true off mode Off mode is also the standby mode The standby power consumption is greatly affected by the values of RA and R13 You can see this in Figure 22 for universal mains and 230 V optimized mains The designer may choose to trade off start up time for standby power consumption In a Smart Bulb application the mains power is left on so the bulb can be controlled remotely This designer can choose to optimize standby power by allowing the power on startup time to be longer than 0 5 s since power on timing is now a one time event In t
19. to check for a shorted pin If R14 was not present the measured voltage would be too low due to the low value of the current sense resistor and the controller will not start because it will detect a shorted pin So R14 is required for proper operation and should be greater than 250 Q2 Voltage Sense The voltage sense pin has several functions 1 Basis for the Reference of the PFC Control Loop 2 Line Range Detection The reference scaling is automatically controller inside the controller The shape of the voltage waveform on Vs is critical for the PFC loop control The amplitude of Vs is important for the range detection Generally the voltage on Vs should be 3 5 V peak at the highest input voltage of interest Voltage on Vs must not be greater than 4 V under any operating condition The voltage on Vs determines which valley the power stage will operate in At low line and maximum load the power stage operates in the first valley standard CrM operation At the higher line range the power stage moves to the second valley to lower the switching frequency while retaining the advantage of quasi resonant soft switching Auxiliary Winding The auxiliary winding has 3 functions 1 CrM Timing 2 Vcc Power 3 Output Voltage Sense CrM Timing In the off time the voltage on the transformer inductor forward biases Doyr and D9 When the current in the magnetic has reached zero the voltage collapses to zero This voltage collapse triggers a
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