UCC28910FBEVM-526

User’s Guide SLUUAI4A Using the UCC28910FBEVM-526 6W Universal Off-Line Flyback Converter with Primary Side Regulation 1. Introduction: The UCC28910FBEVM-526 evaluation module is an offline flyback power supply that provides isolated output voltage and current regulation without the use of an optocoupler. The input accepts a voltage range of 85VAC to 265VAC. The evaluation module uses the UCC28910 CV/CC PWM HV Switcher. This device integrates a 700 V power FET and controller that processes operating information from an auxiliary flyback winding and from the power FET to provide precise output voltage and current control. Control algorithms in the UCC28910 allow operating efficiencies to meet or exceed applicable standards. Discontinuous conduction mode (DCM) with valley switching is used to reduce switching losses. A combination of switching frequency and peak primary current amplitude modulation is used to keep conversion efficiency high across the full load and input voltage range. Fig.1 below details the output V-I characteristic Low system parts count and built in advanced protection features result in a cost-effective solution that meets stringent world-wide energy efficiency requirements. This user’s guide provides the schematic, component list, assembly drawing, art work, and test set up necessary to evaluate the UCC28910 in a typical off-line converter application. Typical target output V-I Characteristic Output Voltage (V) 5 ±5% 4 ±5% 3 2 1 USB Specs. 1.1 Typical Application 0.25 0.5 0.75 1 1.25 1.5 Output Current (A) Figure1 Output voltage as a function of output load for the UCC28910EVM-526 1 of 22 User’s Guide SLUUAI4A 2.1 Applications: The UCC28910 is suited for use in isolated off-line systems requiring high efficiency and advanced fault protection features including:  USB compliant adapters for cell phones, tablets and cameras  5-7 W AC/DC power supplies 2.2 Features: The UCC28910FBEVM-526 features include:  Isolated 6W, 5V output  Universal off-line input voltage range  Exceeds Energy Star™ EPS Version 2.0 requirements for active load efficiency and noload power consumption  Meets USB specification 1.1  Meets EN 55022 Class B conducted emissions requirements  Multiple operating modes and valley switching for optimum efficiency over entire operating range  Primary side control eliminates need for optocoupler  Output over voltage protection  Input under voltage protection  Primary over current protection  Thermal Shutdown  Controlled start up and restart after fault Protection Caution High voltage levels are present on the evaluation module whenever it is energized. Proper precautions must be taken when working with the EVM. The large bulk capacitors, C1 and C2, and the output capacitors, C7 and C8, must be completely discharged before the EVM can be handled. Serious injury can occur if proper safety precautions are not followed. 2 of 22 User’s Guide SLUUAI4A 3. Electrical Performance Specifications Table1. UCC28910FBEVM-526 Electrical Performance Specifications Parameter Symbol Notes and Conditions Min Nom Max Units INPUT CHARACTERISTICS Input Voltage Frequency No Load Power Brownout Voltage Brownout Recovery Voltage Input Current VIN fLINE PNL VINUVLO 85 47 Vin =Vnom Iout = 0A IOUT = INOM VINOV IIN Vin =Vmin Iout = max 115/230 50/60 15 70 265 64 20 V Hz mW V 80 V 0.2 A OUTPUT CHARACTERISTICS Output Voltage Maximum Output Current Minimum Output Current Output Voltage Ripple Output Power VOUT IOUT(MAX) Vin =Vmin to VMAX Iout = 0 to INOM Vin =Vmin to VMAX IOUT(MIN) Vin =Vmin to VMAX ΔVOUT POUT Vin =Vmin to VMAX Iout = 0 to INOM Vin =Vmin to VMAX 4.75 5 5.25 V 1.14 1.2 1.26 A 0 A 150 mV 75 % SYSTEM CHARACTERISTICS Average Efficiency η Vin =Vnom Iout = 25%,50%,75%,100% of IOUT ENVIRONMENTAL Conducted EMI MECHANICAL DIMENSIONS Meets CISPR22B/EN55022B W L H Width Length Component Height 3 of 22 3.5 5 1 in in in User’s Guide SLUUAI4A 4. Schematic: Figure2. UCC28910FBEVM-526 schematic 4 of 22 User’s Guide SLUUAI4A 4.1 Circuit Description: A brief description of the circuit elements follows:  Diode Bridge D1, input capacitors C1 and C2, transformer T1, UCC28910 switcher U1, Schottky rectifier D5 and capacitor C7 form the power stage of the converter. Note that the UCC28910 U1 is also part of the power stage since the high voltage mosfet is internal to U1  Capacitor C8 filters the high frequency noise directly across the electrolytic output capacitor.  The input EMI filter is made up of C1 and C2 and differential mode inductors, L2 and L3.  R1,R2 serve the dual function of dampening input filter oscillations and prevent a large voltage being developed across L2 and L3 in the event of an ESD pulse.  Input current protection is provided by fusible resistor, RF1.  Resistors R5 and R6, capacitor C3, and diodes D2 and D3 make up the primary side voltage clamp. The clamp prevents the drain voltage on U1 from exceeding its maximum rating. A secondary function of the clamp is to alleviate the EMI currents associated with the turnoff voltage of U1.  Operating bias to the controller is provided by the auxiliary winding on T1, diode D4, resistor R7 and bulk capacitor C5.  Capacitor C4 is a decoupling capacitor which should always be good quality low ESR/ESL type capacitors placed as close to the IC pins as possible and returned directly to the IC ground reference.  Secondary side snubber C6 and R11are used to reduce the effects switching noise of D5.  Resistor R9 programs the start up voltage threshold.  Resistors R8 and R10 program the output voltage set point  Resistors R3 and R4 program the maximum output current  Resistor R12 is used to adjust the no load output voltage 5. EVM Test Set Up: Figure 3 shows the equipment set up when measuring the input power consumption during no load. During the no-load test, the power analyzer should be set for long averaging in order to include several cycles of operation and an appropriate current scale factor should be used. Figure 4 shows the basic test set up recommended to evaluate the UCC28910FBEVM-526 with a load. Warning High voltages that may cause injury exist on this evaluation module (EVM). Please ensure all safety procedures are followed when working on this EVM. Never leave a powered EVM unattended. 5 of 22 User’s Guide SLUUAI4A 5.1 Test Equipment: See Figures 3 and 4 for recommended test set ups.  AC Input Source: The input source shall be an isolated variable AC source capable of supplying between 85Vrms and 265Vrms at no less than 15W and connected as shown in Figures 3 and 4. For accurate efficiency calculations, a power meter should be inserted between the AC source and the EVM. For highest accuracy, connect the voltage terminals of the power meter directly across the power source. (Connecting the voltage terminals directly to the EVM will result in a small current error. This is very significant when measuring no load power)  Load: For the output load, a programmable electronic load set to constant current mode and capable of sinking 0 to 1.5ADC at 10VDC shall be used. For highest accuracy, VOUT can be monitored by connecting a DC voltmeter, DMM V1, directly across the +Vout and –Vout terminals as shown in Figure3 and Figure4. A DC current meter, DMM A1, should be placed in series with the electronic load for accurate output current measurements.  Power Meter: The power analyzer (PM1) shall be capable of measuring low input current, typically less than 100 uA, and a long averaging mode if low power standby mode input power measurements are to be taken. An example of such an analyzer is the Yokogawa WT210 Digital Power Meter. To measure the intermittent bursts of current and power drawn from the line during no-load operation, the WT210 should be set to integrate  Multimeters: Two digital multimeters are used to measure the regulated output voltage (DMM V1) and load current (DMM A1).  Oscilloscope: A digital or analog oscilloscope with a 500MHz scope probe is recommended  Recommended Wire Gauge: a minimum of AWG 24 wire is recommended. The wire connections between the AC source and the EVM, and the wire connections between the EVM and the load should be less than two feet long. 6 of 22 User’s Guide SLUUAI4A 5.2 Recommended Test Set Up for Operation Without a Load: V_HI PM1 V_LO A_HI A_LO LINE AC SOURCE NEUT + - DMM V1 Figure3. UCC28910FBEVM-526 recommended test set up without a load. 5.3 Recommended Test Set Up for Operation With a Load: V_HI PM1 V_LO A_HI A_LO + DMM A1 - LINE + AC SOURCE ELECTRONIC LOAD NEUT + - - DMM V1 Figure4. UCC28910FBEVM-526 recommended test set up with a load. 7 of 22 User’s Guide SLUUAI4A 6. Test Procedure: All tests should use the set up as described in Section 5 of this user’s guide. The following test procedure is recommended primarily for power up and shutting down the evaluation module. Never leave a powered EVM unattended for any length of time. 6.1 Applying Power to the EVM: 1. Set up the EVM as shown in Section 5 of this user’s guide a. If no-load input power measurements are to be made, set the power analyzer to long averaging or integrating power measurement mode. b. For operation with a load, as shown in Figure 4, set the electronic load to constant current mode to sink 0A. 2. Prior to turning on the AC source, set the voltage to between 85VAC and 265VAC. 3. Turn on the AC source. 4. Monitor the output voltage on DMM V1. 5. Monitor the output current on DMM A1. 6. The EVM is now ready for testing. 6.2 No-Load Power Consumption: 1. Use the test set up shown in Figure 3 a. Set the power analyzer to integrating average power mode. b. Set the current measurement scale to 0.25A c. Set the voltage range to 300V d. Set the measurement mode to RMS 2. Apply power to the EVM per Section 6.1. 3. Monitor the input power on the power analyzer while varying the input voltage. 4. Make sure the input power is off and the bulk capacitor and output capacitors are completely discharged before handling the EVM. 6.3 Output Voltage Regulation and Efficiency: 1. For load regulation: a. Use the test set up shown in Figure 4 b. Set the AC source to a constant voltage between 85VAC and 265VAC. c. Apply power to the EVM per Section 6.1. d. Vary the load current from 0A up to 1.2A, as measured on DMM A1. e. Observe that the output voltage on DMM V1 remains between 4.75V and 5.25V from no load up to 1.2A and thereafter the current remains between 1.14A and 1.26A until the output voltage drops to 2V or lower. See Figure 1 for details. 2. For line regulation: a. Set the load to sink 1.2A. b. Vary the AC source from 85VAC to 265VAC. c. Observe that the output voltage on DMM V1 remains between 4.75V and 5.25V. 8 of 22 User’s Guide SLUUAI4A 3. Make sure the input power is off and the bulk capacitor and output capacitors are completely discharged before handling the EVM. 6.4 Output Voltage Ripple: 1. For output ripple measurements, solder a 0.1uF, 50V ceramic and 4.7uF, 35V tantalum on a BNC adapter as shown in figure 5 below. Connect the red test lead to the +Vout output and the black test lead to the –Vout on the EVM 2. Connect the other end of the BNC cable to the oscilloscope and monitor the output ripple on the oscilloscope. 3. Apply power to the EVM per Section 6.1. Figure5. Typical example of tip measurement technique. 6.5 Equipment Shutdown: 1. Ensure the load is at maximum; this will quickly discharge the output capacitors. 2. Turn off the AC source. 9 of 22 User’s Guide SLUUAI4A 7. Performance Data and Typical Characteristic Curves: Figures 6 through 21 present typical performance curves for the UCC28910FBEVM-526. V-I Characterization 5.500 5.000 4.500 Vout 4.000 120V/60Hz 3.500 3.000 240V/50Hz 2.500 2.000 1.500 0 0.2 0.4 0.6 0.8 1 1.2 Iout Figure6. Typical V-I Characteristic at 25°C 10 of 22 1.4 User’s Guide SLUUAI4A 88Vin, Io 0.993 1.013 1.013 1.034 1.056 1.056 1.079 1.079 1.103 1.103 1.128 1.128 1.154 1.154 1.181 1.182 1.211 1.211 1.238 1.238 1.239 1.239 1.240 1.240 1.241 1.242 1.243 1.243 1.243 1.243 1.244 1.244 1.246 1.245 1.247 1.247 1.248 1.248 1.249 1.248 1.250 1.250 1.250 1.251 1.251 1.251 1.252 1.252 88Vin 4.951 4.950 4.950 4.949 4.949 4.949 4.949 4.949 4.949 4.949 4.949 4.949 4.950 4.950 4.950 4.950 4.951 4.951 4.939 4.937 4.820 4.821 4.701 4.700 4.580 4.582 4.463 4.462 4.340 4.338 4.220 4.220 4.100 4.100 3.981 3.981 3.861 3.860 3.737 3.735 3.615 3.615 3.493 3.493 3.370 3.369 3.246 3.248 115in, Io 0.994 1.014 1.014 1.035 1.057 1.057 1.080 1.080 1.104 1.104 1.129 1.129 1.156 1.156 1.183 1.183 1.212 1.212 1.242 1.242 1.245 1.245 1.246 1.246 1.247 1.247 1.248 1.248 1.250 1.249 1.250 1.250 1.251 1.251 1.253 1.252 1.254 1.254 1.255 1.255 1.256 1.255 1.256 1.256 1.257 1.257 1.258 1.258 115Vin 4.953 4.952 4.952 4.952 4.953 4.953 4.953 4.953 4.954 4.954 4.955 4.955 4.956 4.956 4.956 4.956 4.956 4.956 4.957 4.957 4.842 4.841 4.722 4.721 4.602 4.603 4.482 4.481 4.362 4.361 4.240 4.241 4.119 4.118 3.998 3.998 3.877 3.877 3.755 3.756 3.632 3.631 3.510 3.510 3.386 3.385 3.262 3.262 230Vin, Io 0.994 1.014 1.014 1.035 1.057 1.057 1.080 1.080 1.104 1.104 1.130 1.130 1.156 1.156 1.183 1.183 1.212 1.212 1.243 1.243 1.272 1.272 1.274 1.274 1.275 1.275 1.276 1.276 1.277 1.277 1.278 1.278 1.279 1.279 1.280 1.280 1.282 1.282 1.282 1.282 1.284 1.283 1.285 1.284 1.285 1.286 1.287 1.287 11 of 22 230Vin 4.955 4.955 4.955 4.955 4.955 4.955 4.956 4.955 4.956 4.955 4.957 4.956 4.957 4.957 4.958 4.957 4.958 4.958 4.959 4.959 4.947 4.948 4.828 4.826 4.706 4.706 4.583 4.582 4.458 4.460 4.336 4.333 4.211 4.212 4.086 4.085 3.964 3.963 3.837 3.839 3.714 3.714 3.589 3.587 3.462 3.463 3.339 3.337 265Vin, Io 0.994 1.015 1.014 1.035 1.058 1.057 1.080 1.080 1.104 1.104 1.130 1.130 1.156 1.156 1.183 1.183 1.212 1.212 1.243 1.243 1.275 1.275 1.282 1.282 1.284 1.284 1.285 1.285 1.286 1.286 1.288 1.288 1.288 1.288 1.288 1.288 1.291 1.291 1.291 1.292 1.293 1.293 1.294 1.294 1.295 1.295 1.296 1.296 265Vin 4.955 4.955 4.955 4.955 4.955 4.955 4.955 4.955 4.956 4.956 4.956 4.956 4.956 4.957 4.958 4.958 4.958 4.958 4.959 4.959 4.960 4.960 4.860 4.860 4.740 4.738 4.614 4.615 4.491 4.491 4.367 4.368 4.239 4.239 4.112 4.114 3.991 3.990 3.866 3.866 3.740 3.740 3.614 3.615 3.487 3.487 3.362 3.361 User’s Guide SLUUAI4A 1.253 1.252 1.252 1.253 1.253 1.252 1.253 1.253 1.253 1.252 1.253 1.253 1.253 1.253 1.253 1.253 1.252 1.252 1.251 1.251 1.250 1.250 1.249 1.249 1.248 1.248 1.246 1.246 1.244 1.244 1.241 1.242 0.000 3.124 3.123 2.998 3.000 2.875 2.873 2.752 2.751 2.626 2.623 2.501 2.500 2.376 2.375 2.250 2.249 2.123 2.122 1.997 1.997 1.871 1.870 1.744 1.745 1.618 1.618 1.492 1.492 1.364 1.365 1.238 1.239 0.000 1.258 1.259 1.259 1.259 1.259 1.258 1.260 1.260 1.260 1.260 1.260 1.260 1.260 1.260 1.260 1.259 1.259 1.259 1.258 1.258 1.258 1.258 1.256 1.256 1.254 1.255 1.253 1.253 1.250 1.251 1.248 1.248 0.000 3.139 3.139 3.014 3.013 2.888 2.887 2.763 2.765 2.639 2.639 2.514 2.514 2.388 2.387 2.262 2.262 2.136 2.136 2.009 2.008 1.882 1.882 1.755 1.755 1.627 1.627 1.500 1.500 1.372 1.372 1.246 1.246 0.000 1.288 1.287 1.288 1.288 1.288 1.289 1.289 1.289 1.289 1.289 1.290 1.290 1.290 1.290 1.289 1.290 1.289 1.289 1.289 1.288 1.287 1.288 1.285 1.286 1.285 1.284 1.283 1.283 1.280 1.280 1.278 1.278 0.000 3.209 3.212 3.086 3.083 2.957 2.958 2.830 2.829 2.702 2.701 2.574 2.574 2.445 2.446 2.316 2.316 2.186 2.187 2.057 2.056 1.927 1.926 1.796 1.796 1.666 1.665 1.535 1.537 1.405 1.405 1.275 1.275 0.000 Figure7. Typical V-I Test Data at 25°C 12 of 22 1.296 1.297 1.297 1.298 1.298 1.298 1.299 1.299 1.298 1.299 1.299 1.299 1.300 1.299 1.299 1.299 1.298 1.299 1.298 1.297 1.296 1.296 1.295 1.295 1.294 1.293 1.291 1.291 1.289 1.289 1.287 1.287 0.000 3.234 3.235 3.107 3.106 2.980 2.980 2.850 2.849 2.720 2.721 2.592 2.592 2.464 2.464 2.334 2.334 2.202 2.203 2.072 2.071 1.940 1.940 1.809 1.809 1.678 1.677 1.546 1.548 1.415 1.415 1.284 1.284 0.000 User’s Guide SLUUAI4A 77 75 73 115V 71 230V 69 67 65 0.1 0.3 0.5 0.7 0.9 1.1 1.3 Figure8. Efficiency Vs Iout 79 77 75 73 71 115V 69 230V 67 65 0.1 1.1 2.1 3.1 4.1 5.1 Figure9. Efficiency Vs Pout 13 of 22 6.1 User’s Guide SLUUAI4A Vin(V) 115 230 f(Hz) 60 50 Pin(W) 7.826 5.845 3.889 1.930 7.721 5.783 3.853 1.960 Iout(A) 1.201 0.901 0.601 0.301 1.201 0.901 0.601 0.301 Vout(V) Pout(W) 4.950 5.943 4.942 4.451 4.934 2.964 4.927 1.481 4.956 5.950 4.948 4.457 4.938 2.966 4.930 1.482 Eff (%) 75.94 76.15 76.19 76.73 77.06 77.07 76.97 75.60 Avg Eff (%) 76.25 76.68 Table 1 Average Efficiency Vin (V) 88 115 230 265 f(Hz) 60 60 50 50 Pin(mW) 10 10 10 12 Vout(V) 5.02 5.02 5.02 5.02 Table 2 No Load Power Consumption Figure 10 Ripple with 5V,1.2A out 85Vac in Figure 11 Ripple with 5V,1.2A out 85Vac in 20mV/div 5uS/div 20mV/div 500uS/div 14 of 22 User’s Guide SLUUAI4A Figure12 Ripple with 5V,1.2A out 265Vac in Figure 13 Ripple with 5V,1.2A out 265Vac in 20mV/div 5uS/div 20mV/div 500uS/div Figure 14 Ripple with 5V,700mA out 265Vac in Figure 15 Ripple with 5V,100mA out 265Vac in 20mV/div 500uS/div 20mV/div 500uS/div Figure 16 Output voltage start 115Vac,1.2A load Figure 17 Output voltage start, 230Vac, 1.2A load 1V/div 50mS/div 1V/div 50mS/div 15 of 22 User’s Guide SLUUAI4A Figure 18 Primary side switching waveforms Figure 19 Primary side switching waveforms 85Vac 1.2A load 265Vac 1.2A load Drain voltage (CH 3 100V/div) IPK voltage (CH4 0.5V/div) 2uS/div Drain voltage (CH 3 /div) IPK voltage (CH4 /div) 2uS/div 16 of 22 User’s Guide SLUUAI4A Figure20. EMI test results per EN55022, Class B. 115VAC input 17 of 22 User’s Guide SLUUAI4A Figure21. EMI test results per EN55022, Class B. 230VAC input 18 of 22 User’s Guide SLUUAI4A 8. EVM Assembly Drawing and Layout: The following figures show the design of the UCC28910FBEVM-526 printed circuit board. Figure22. Top side view of UCC28910FBEVM-526 19 of 22 User’s Guide SLUUAI4A Figure23. Top layer component placement. 20 of 22 User’s Guide SLUUAI4A Figure24. Bottom layer. 21 of 22 User’s Guide SLUUAI4A 9. List of Materials: C1 C2 C3 C4 C5 C6 C7 C8 D1 D2 D3 D4 D5 J1, J2 L1, L2 R1, R2, R12 R3,R5 R4 R7 R8 R9 R10 R11 RF1 T1 U1 Description CAP, AL, 6.8uF, 400V, +/-20% CAP, AL, 10uF, 400V, +/-20%, 2.864788 ohm CAP, CERM, 100pF, 500V, +5/%, C0G/NP0, 1206 CAP, CERM, 0.1uF, 25V, +10/%, X5R, 0603 CAP, AL, 10uF, 35V, +/-20% CAP, CERM, 2200pF, 50V, +/-10%, X7R, 0805 CAP, AL, 1200uF, 10V, +/-20% CAP, CERM, 0.1uF, 50V, +/-5%, X7R, 1206 Diode, Switching-Bridge, 600V, 1A Diode, TVS, Uni, 128V, 600W, SMB Diode, Switching, 600V, 1A Diode, Ultrafast, 100V, 0.15A, SOD-123 Diode, Schottky, 40V, 4A, SMC Conn Term Block, 2POS, 5.08mm PCB Inductor, Drum Core, Metal Composite, 1mH, 0.5A RES, 6.8k ohm, 5%, 0.25W, 1206 Manufacturer Nichicon Panasonic Kemet AVX Nichicon AVX Panasonic AVX Diodes Inc. ST Microelectronics Vishay-Semiconductor Diodes Inc. Vishay Phoenix Contact Wurth Elektronik eiSos Vishay-Dale PartNumber UCA2G6R8MPD1TD EEUED2G100 C1206C101JCGACTU 06033D104KAT2A UVR1V100MDD1TA 08055C222KAT2A EEUFM1A122 12065C104JAT2A DF06M SM6T150A 1N4937-E3 1N4148W-7-F SL44-E3/57T 1715721 768772102 CRCW12066K80JNEA Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 3 RES, 1.50k ohm, 1%, 0.25W, 1206 RES, 15.0k ohm, 1%, 0.25W, 1206 RES, 33.0 ohm, 1%, 0.25W, 1206 RES, 30.0k ohm, 1%, 0.25W, 1206 RES, 100.0k ohm, 1%, 0.25W, 1206 RES, 430.0k ohm, 1%, 0.25W, 1206 RES, 180 ohm, 5%, 0.25W, 1206 RES, 4.7 ohm, 5%, 1W, Fusible Transformer, EF16, 1.1mH LOW STAND-BY POWER, CV / CC PWM HV SWITCHER WITH PRIMARY SIDE REGULATION Vishay-Dale Vishay-Dale Panasonic Panasonic Vishay-Dale Yageo America Vishay-Dale Yageo America Wurth Elektronik Texas Instruments CRCW12061K50FKEA CRCW120615K0FKEA ERJ-8ENF33R0V ERJ-8ENF3002V CRCW1206100KFKEA RC1206FR-07430KL CRCW1206180RJNEA FKN1WSJR-52-4R7 750313739 UCC28910D 2 1 1 1 1 1 1 1 1 1 Table3. Bill of Materials for UCC28910FBEVM-526 10. References: 1. UCC28910 Datasheet 22 of 22 IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, enhancements, improvements and other changes to its semiconductor products and services per JESD46, latest issue, and to discontinue any product or service per JESD48, latest issue. Buyers should obtain the latest relevant information before placing orders and should verify that such information is current and complete. All semiconductor products (also referred to herein as “components”) are sold subject to TI’s terms and conditions of sale supplied at the time of order acknowledgment. TI warrants performance of its components to the specifications applicable at the time of sale, in accordance with the warranty in TI’s terms and conditions of sale of semiconductor products. Testing and other quality control techniques are used to the extent TI deems necessary to support this warranty. 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