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PlasmaSonic™ III SSTC Corrections

Corrections for Class-E PCB Board (2009 Version)

1. For the VU meter to work correctly, you will need to install a wire jumper
between Pin 2 and Pin 4 of U71, LM391x IC. This can be easily done using a
small piece of wire on the bottom of the board.

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PlasmaSonic™ III Corrections
PlasmaSonic
 III SSTC Instructions

PlasmaSonic III
Class-E 4MHz
Solid State Tesla Coil

Instruction Manual
By Daniel McCauley

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PlasmaSonic III Instructions
PlasmaSonic
 III SSTC Instructions

DISCLAIMER
The author of this document is an amateur, not a professional. The information,
both technical and safety related, provided in this document should be interpreted
with this distinction clearly in mind. The author hereby disclaims any liability for
injury to persons or property that may result due to the construction and use of the
PlasmaSonic SSTC board and other high voltage apparatus. This document is for
informational purposes only, and makes no claims to its completeness or accuracy.
While many of the dangers associated with the construction and use of the
PlasmaSonic SSTC board have been pointed out in this document, other potential
hazards may exist. Solid state tesla coils are inherently very dangerous devices and
should only be constructed and operated by individuals familiar enough with these
dangers.

PORTABLE AUDIO SOURCE WARNING


The use of portable audio devices, MP3 players, IPODs, Iphones, etc…
is NOT RECOMMENDED. The RF fields and noise generated by the
coil can potentially damage these types of devices.

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 III SSTC Instructions

ELECTRICAL WARNING
This circuit utilizes dangerous line voltages up to 115VAC. Failure to
handle this circuit in a safe manner may result in injury or death!

EXPLOSION WARNING
This is a solid state power device. Components may fail explosively at
any time and eject high velocity projectiles.
EYE PROTECTION IS REQUIRED AT ALL TIMES!

RF HAZARD WARNING
This device when connected to a resonator will produce strong electric
and magnetic fields. Exposure to this field should be limited.
NO BIOMEDICAL DEVICES WITHIN 50 FEET!

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PlasmaSonic III Instructions
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 III SSTC Instructions

Completed Plasmasonic III System

Introduction
The Plasmasonic III is an advanced 4MHz Class-E Solid State Tesla Coil capable of
producing high quality audio through plasma modulation. The Plasmasonic III can be
used by itself or in conjunction with a second unit for stereo operation, to create beautiful
plasma displays which also produce incredibly clear and high quality audio without the
use of external speakers. This document will outline the various configurations, how to
implement them, and how to test and operate the PlasmaSonic III SSTC. This document
assumes you have a basic understanding of electronics, test equipment, troubleshooting
experience, and above all, a clear understanding of the dangers involved in
constructing and operating such a device.

Please read this manual in its entirety before building, testing, or operating your
PlasmaSonic III SSTC board!

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PlasmaSonic III Instructions
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 III SSTC Instructions

Test Equipment
You will need the following test equipment to properly configure and test the board:

Digital Multimeter
Dual Channel Oscilloscope (optional but recommended)
Signal Generator (optional)

Heatsink

A heatsink is required for the proper cooling of Q2 and Q24. This can either be a smaller
local heatsink (which may require additional fan cooling to keep cool), or a large heatsink
that spans the entire length of the PCB board. Also, a rectangular piece of aluminum may
be used (as shown below) to act as a heatsink as well. Aluminum rectangular bars can be
purchased at hardware distributors such as McMaster-Carr. (http://www.mcmaster.com)

A small 12V computer fan is also required to properly cool components Q22 and Q23. A
small fan is recommended as these are audibly quiet and won’t interfere with the audio
reproduction of the coil.

Proper cooling is absolutely necessary for reliable operation of the PlasmaSonic III
SSTC board. Failure to properly cool the MOSFETs and associated switching
devices during operation will result in component failure!

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PlasmaSonic III Instructions
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 III SSTC Instructions

Building the PlasmaSonic III SSTC Board


The following steps should be followed when building your board. These instructions
assume you already have good soldering and electronics assembly skills.

Plasmasonic III Kit

1. Using a scroll saw, cut-out the indicated rectangular cut-outs for Q2 and Q24 on the
PCB board. Use a file to square and smooth up the rectangular holes. Be sure not to cut
any traces that are on the board near these cut-outs. (It is okay to cut through the ground
plane on the rear of the board.)

2. Solder all components to the board as shown on the schematic and parts list. The
easiest approach is to first solder all resistors, then ceramic capacitors, LEDs and ICs, and
then finally the remainder of the larger components. Do not install Q2 or Q24 at this
time. (An updated silkscreen drawing for the PCB is provided at the end of this
document for reference.)

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 III SSTC Instructions

Completed Plasmasonic III PCB with Components (Note Q2 and Q24 are not installed at this point)

3. Build and wind drive transformer, T21, as shown on the


schematic using 26 AWG wire. Solder T21 to the board,
making sure proper phasing is followed. The transformer
can then be secured to the board using wire ties.

4. Build and wind drain choke, L21, as shown on the


schematic using 20 AWG wire. Solder L21 to the board and
secure using wire ties. (Drain choke, L21, shown to the left)

5. Install Q2 and Q24 as shown below. The first step is to secure Q2 / Q24 to the
heatsink using machine screws. The heatsink can be drilled and tapped with the
appropriate screw thread size, or you can drill completely through the heatsink and secure
using a nut. The included thermal insulator MUST be used between Q2 / Q24 and
the heatink to ensure proper electrical isolation. Failure to do this will result in a
direct short and you will permanently damage your circuit. Once Q2 / Q24 are securely
fastened to the heatsink, attach the heatsink to the PCB board and bend the leads so they
fall properly on their associated solder pads. When the fit is proper, solder all leads of Q2
/ Q24. Be sure that the leads for Q2 are raised above the board as not to touch the trace
between Q2 Drain and R8.

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MOSFETs Q2 and Q24 shown in their respective locations on the aluminum heatsink with thermal pads.

Cross-sectional diagram of how Q2 and Q24 are attached to the heatsink and PCB.

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 III SSTC Instructions

Q2 and Q24 attached to the PCB board. (Note the bend in leads for Q2 to clear the board trace)

6. Finally, a small 12V fan (i.e. computer fan) will need to be used to properly cool
components Q22 and Q23. This fan can be connected directly to the +12V output of
U51. This is most easily accomplished by simply attaching the fan wires across VR51.
Be sure to follow proper polarity when doing so or damage to the fan can result. Also, be
sure to use a low power fan (Radio Shack sells these for a few dollars each) on the order
of a few hundred mA as the current capability of U51 is limited. Likewise, a 120V large
muffin fan could be used, but the air noise it creates will degrade audio quality. (Note the
fan in the photo below is much larger than it needs to be.)

Finished PCB Board with 12V DC Fan

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PlasmaSonic III Instructions
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 III SSTC Instructions

Building the Resonator


The resonator should be built based on the dimensions below.

Note: Always add at least an extra 0.25” of winding length to your resonator
initially to provide headroom for proper tuning. Its always easier to remove
windings when tuning then having to rewind a completely new secondary if you
don’t have enough windings.

You can also use other wire sizes if necessary. The following chart shows
approximate winding lengths of the secondary when using different size wires.
Information in this table was calculated using WinTesla simulation program.
WinTesla can be downloaded for free on the internet.

(Left: Completed Resonator)

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 III SSTC Instructions

Wire Size Secondary Dia. Winding Length


20 AWG 2.276” (See note below) 5.70”
21 AWG 2.276” (See note below) 4.90”
22 AWG 2.276” (See note below) 4.20”
23 AWG 2.276” (See note below) 3.60”
24 AWG 2.276” (See note below) 3.00”
25 AWG 2.276” (See note below) 2.50”
26 AWG 2.276” (See note below) 2.10”

Winding Dimensions vs. Winding Size Table

Note: Secondary diameter is based on 2.1” (inside) diameter rocket airframe tubing from
Public Missiles. This can be purchased at http://www.publicmissiles.com and is part
number PT-2.1.

Resonator Assembly Parts

Other primary / secondary coilform sizes can be utilized, however, you will need to
retune the Class-E switching circuit for proper operation, and therefore, we only
recommend the above coilform sizes for this particular design.

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Testing the PlasmaSonic III SSTC Board


The following steps should be followed in order to properly test and tune your
Plasmasonic III system. Please read all steps before testing and ensure you understand
them all before proceeding. The system has already been optimized and tuned for the
given resonator size, so there should be little tweaking required to get everything working
properly.

Please be sure to wear safety glasses when testing and operating the Plasmasonic III.

1. Ensure that all components are properly installed and thermal insulators are utilized
between Q2 / Q24 and the heatsink. Using a multimeter check that there is no short
between the heatsink and the Drain connections on Q2 / Q24. This is the middle lead of
Q2 / Q24. This ensures the thermal insulator is installed properly and not damaged.
Also, make sure the 12V fan is running and providing airflow across Q22 and Q23.
(Note: The 12V fan won’t run until the control power is connected in Step 4)

2. The resonator should not be installed at this time.

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3. Connect a 115VAC plug to terminals 120VAC (HOT), NEUTRAL (NEUTRAL), and


(GND). This is the control power input. DO NOT connect anything to the +IN or –IN
terminals at this time.

4. Plug in the control power plug to a proper 115VAC socket.

5. Verify the 12V DC fan is running. If it is not, unplug the control power and
troubleshoot accordingly.

6. Verify D51 and D52 LEDs are illuminated.

7. Using a multimeter verify that approximately +14-18V is measured at pin 1 (input) of


U51 to pin 2 (GND) of U51. Verify that +12V is measured at pin 3 (output) of U51 to
pin 2 (GND) of U51. Verify that +5.0V-5.4V is measured across CR21. If these
voltages are not correct, you will need to troubleshoot accordingly.

8. If you have an oscilloscope, check to ensure the waveforms shown in the end of this
document are present at the various points in the circuit.

9. If all tests above check out, you are ready to tune the resonator. If you have access to
an oscilloscope and signal generator, you may begin tuning process using the tuning
procedure described at the end of this document.

10. Short out the connection between Q2 Source and Q2 Drain. This
are pins 3 and 2 of Q2 respectively. This can be done by soldering wire
directly to the leads of Q2 or using a jumper connection. This will
disable the high side linear modulator and provide the full 50VDC to the
Q24 Drain.

11. Connect the primary wire of the resonator to OUT+ and OUT-.
Polarity is not important. However, the primary wire should be twisted
tightly together from the PCB board to the primary coil for best results.

12. Tuning the resonator must be done experimentally and will be


somewhat tedious. However, its fairly simple to do. If you do have
access to an oscilloscope and signal generator, you can do a rough tune
of the resonator prior to hooking it to the circuit. This tuning procedure
is located at the end of this document.

13. Connect the output of the 36VAC transformer to the IN+ / IN-
connections of the PCB board. Do NOT plug in at this time.

14. Start tuning by forming an 8” high wire sticking up at the top of the
secondary. This is the top electrode and shown in the diagram on the
right.

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15. Apply power to the 36VAC transformer. However, only have power applied for a
short amount of time (a few seconds at a time) Check to see if there is any corona
coming from the electrode.

16. Trim the wire by 0.25” and reapply 36VAC power. Check to see if corona is visible.
If there is not, continue this process in 0.25” steps.

Be sure to TURN OFF all power before trimming or touching the resonator!

17. If you begin to see corona, skip to step 19 below.

18. If the wire is already cut completely to the bottom and no corona was seen, you need
to increase resonant frequency a bit more of the coil. This can be done by removing
about 10 turns of the secondary coil from the top. Once you remove 10 turns, repeat this
process beginning at step 14 above.

19. If you start seeing a little bit of corona, you are close to the proper tuning point.
Continue trimming the wire in 0.1” increments until maximum arc length is seen.
Maximum arc length will be around 0.5” for this particular design. If you start trimming
wire and arc length begins decreasing, you are past the optimum tuning point. In this
case, simply lengthen the electrode wire (just a little bit) by unraveling the top turn of the
secondary and making the wire a little higher again. Continue to repeat this process until
you are satisfied you have a good tuning point. When finished, unplug the 36VAC and
control power.

20. At this time, you use electrical tape, epoxy, varnish, to secure the windings on your
secondary. Just don’t make it so permanent that you are unable to retune in the future.

21. Now you are ready to configure the VU meter. Connect a CD player RCA (line-
level) output to the input, J1, of the PCB board.

22. Connect control power to the PCB board and play music through the CD player.
Adjust R72 so that the VU meter provides the adequate range of operation for the input
source provided. 36VAC power SHOULD NOT be connected at this time.

23. Disconnect control power

24. Remove the short across drain-source of Q2.

25. Disconnect one lead of L21. This disconnects Q24 from the power.

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26. Connect a multimeter across R12.

27. Connect control power and connect 36VAC to the PCB board.

28. Adjust R10 until you get about 35V across R12. This sets the proper biasing for the
linear modulator.

29. Disconnect 36VAC and control power.

30. Re-connect L21.

31. Now you are ready to play audio through your tesla coil. Connect control power and
36VAC to your PCB board. Do not apply audio at this time. You should still see an
output arc on the coil, although it will be a little bit smaller as you’re now operating at a
midpoint bias condition of 30-35V vs. 50V previously.

32. Play audio through the CD player. You should be able to hear audio through the arc.
Now adjust R4 and R6 until audio volume is maximized. This is mostly done through
trial and error so adjust away until you find the best settings. Typically R4 is set at its
maximum setting, so if you don’t hear audio right away, turn R4 all the way in both
directions. Likewise, the same can be done for R6. It’s a trial and error process to find
the correct potentiometer settings for best audio.

33. You have now completed the initial testing of the Plasmasonic III.

Important Things to Remember


The following is a list of important things to remember when operating your Plasmasonic
III system.

1. Always ensure the 12V DC fan is operating and blowing air across Q22 and Q23. If
Q22 and Q23 get too hot, the system will just stop running. If you find your coil just
stops suddenly, this is the likely cause. Turn it off for awhile, let it cool down, and turn it
back on. Try to improve cooling if possible of these two components.

2. Always wear safety glasses

3. Never touch electrical components or resonator (arc) when power is applied.

4. NEVER exceed more than 36VAC at the IN+/IN- terminals.

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5. Always ensure that the primary is properly spaced above the secondary. Ideally this
should be about 0.275”. You can adjust this height up and down to change coupling.

Tips / Fine Tuning


Use the following tips to fine tune your system and maximize performance.

1. The most important thing you can do to improve performance is two run two (2) coils
in stereo. I cannot stress how much of a difference this makes in both volume and sound
quality. The imaging is absolutely incredible and the sound is both louder and much
higher quality as well.

2. Ensure primary is always centered

3. Raising and lowering primary can improve arc length and increase output. However,
if primary is raised too high, and you start hearing distortion, you are likely operating
outside the Class-E range of proper operation. If this occurs, simply lower the primary
winding slightly. Also, with increased coupling, you will draw more current from your
36VAC transformer. If you have an oscilloscope, you can verify correct tuning and
coupling by comparing the Q24 Drain-to-Source waveforms to those in the end of this
instruction manual.

4. Retune the secondary periodically to maintain maximum tune. Follow the process
outlined above. Although since you are already tuned, you only need to adjust the
existing height by very slight amounts.

5. Also note that the location of nearby objects can affect the tuning point. For example,
your hands, a metallic object, wall, etc… can affect the tuning. So if you tune in one
location and then move to another, you may have to adjust the tune slightly.

Stereo Operation
The only change required for stereo operation is that one of the coil’s oscillators needs to
be run at a different frequency that’s at least 40kHz different than the other coil.

So if one coil is operating with a 4MHz oscillator, the other can be run at 3.8MHz for
example. If they are operating at the same frequency, you may get crosstalk between the
two. However, it is important to note that increasing the frequency will increase the heat
dissipation and losses in the MOSFETs. For stereo operation, its recommended to use a
4MHz oscillator, and then a 2nd oscillator around 3.7 – 3.9 MHz.

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Improving Audio Quality


There are a few ways to vastly improve the audio quality of your PlasmaSonic III SSTC.

1. The number one way to increase both audio quality and volume is to use a stereo pair
of PlasmaSonic III SSTCs. The stereo imaging from this arrangement is absolutely
incredible and guaranteed to be like nothing you’ve heard before. Each SSTC acts as a
omni-directional point source (unlike traditional uni-directional axial tweeters), and with
your eyes closed, it is impossible to determine the location of where the audio is coming
from.

2. Use an equalizer. With an equalizer, you can vary the gains of various frequencies
and reduce the distortion that may be produced. You will also increase the bass response
of your system by tuning it with an equalizer. An equalizer also has a pre-amp which can
boost the output level of the audio source. This is especially important for audio sources
which have a low output level.

3. Experiment with many CDs. Each CD has its own mixing characteristics and will
work differently with your PlasmaSonic III SSTC. Find a CD which performs best and
use that one for your demonstrations.

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Initial Resonator Tuning with an Oscilloscope


The following method shows how to get a ballpark (initial) tune on your Tesla resonator
using a signal generator and oscilloscope. Special Thanks to Richie Burnett for
providing this method of measuring the resonant frequency of a high frequency
secondary.

1. Hook the 50 ohm output of a signal generator (oscillator) to the RF ground lead of the
secondary coil. Set amplitude of signal generator to maximum. Signal generator should
have frequency range to at least 5MHz.

2. Locate the Channel 1 probe of the oscilloscope approximately 18-24” away from the
secondary coil. The probe and ground clip should not be tied to anything.

3. Vary the frequency of the signal generator noting the amplitude of the E-field as
measured by the oscilloscope probe.

4. The resonant frequency of the secondary will be the point where amplitude is at its
maximum. Note that this frequency will change depending on nearby objects to the
secondary, including your hands and body.

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5. Tune the secondary, by lengthening or trimming the electrode wire until you get close
to the proper resonant frequency (i.e. 4MHz)

6. Once this “rough” tune is accomplished, you can proceed with the main kit
instructions above to get a final tune of the resonator.

Drive Waveforms
If you have an oscilloscope, you can verify that the following waveforms are seen at the
locations specified. Note, that due to bandwidth settings, etc…, you’re waveforms may
be slightly different, however, they should be on the order of the same magnitude and
timescale.

Note that in all waveforms, the center grid line on the oscilloscope is GND reference.

Output of 4MHz Oscillator, U21 (4MHz, 5V p-p) (2V/div)

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Base-to-GND of Q22 / Q23 (2V/div)

Emitter-to-GND of Q22 (5V/div)

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Gate-to-Source of Q24 (4MHz 20V p-p Sinewave) (5V/div)

Class-E Waveforms
If you have an oscilloscope, you can verify that the following Class-E Drain waveforms
are seen at the locations specified. Note, that due to bandwidth settings, etc…, you’re
waveforms may be slightly different, however, they should be on the order of the same
magnitude and timescale. (If your oscilloscope is equipped, please turn on 20MHz
Bandwidth feature – this will reduce bandwidth of your oscilloscope and provide a
“cleaner” looking signal for comparison)

Channel 1: Attach probe to Drain of Q24, GND clip to Source of Q24.

Channel 2: Attach probe to Gate of Q24, GND clip to Source of Q24

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Proper Class-E Drain / Gate Waveform (No audio)


The larger signal is the Drain Voltage and the sinusoidal signal is the Gate voltage.
Drain Voltage (20V/div) – Gate Voltage (5V/div) – 20Mhz Bandwidth Limited

Proper Class-E Drain Waveform (approx. 100V peak) (No Audio)


Drain Voltage (20V/div) – 20Mhz Bandwidth Limited

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Proper Class-E Drain Waveform with Audio Applied


The audio modulation of the drain waveform is clearly seen in this photo.
Also note that there is some slight “bump” in the drain and gate waveform. These
“bumps”, for a lack of a better term, are normal and still within the recommended
operating region for Class-E operation.
Drain Voltage (20V/div) – Gate Voltage (5V/div) – 20Mhz Bandwidth Limited

Troubleshooting Class-E Waveforms


The following waveforms provide examples of conditions of operation which fall outside
the normal Class-E mode of operation. If the Drain-to-Source waveforms of Q24
resemble any of the following, please follow the steps as provided to resolve the issue.

Channel 1: Attach probe to Drain of Q24, GND clip to Source of Q24.

Channel 2: Attach probe to Gate of Q24, GND clip to Source of Q24

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As stated before, this is a proper Class-E Drain and Gate waveform of Q24. The
“bumps” seen in these waveforms are within the normal operational limits of Class-E
operation for this design. (No audio)
Drain Voltage (20V/div) – Gate Voltage (5V/div) – 20MHz Bandwidth Limited

In this example, the Class-E switching Drain waveform is very distorted and outside the
normal operational limits of Class-E operation.
To resolve this problem, you must reduce coupling between primary and secondary. This
is accomplished by simply raising the the secondary until the proper Class-E waveforms
are seen. The extra fainter traces are simply a triggering artifact with the oscilloscope.
Drain Voltage (20V/div) – 20Mhz Bandwidth Limited

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In this example, the Class-E switching Drain waveform is slightly distorted but still
outside the normal operational limits of Class-E operation.
To resolve this problem, you must reduce coupling between primary and secondary. This
is accomplished by simply raising the the secondary until the proper Class-E waveforms
are seen.
Drain Voltage (20V/div) – 20MHz Bandwidth Limited

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Additional Resources
The links provided were current at the date of this document release. I am not
responsible for non-working or changed internet links.

Tesla Coil Class-E Theory


Richie Burnett’s Tesla Coil Pages
http://www.richieburnett.co.uk/hfsstc.html

Datasheet for MIL M39014 Ceramic Capacitors


Useful for identifying some of the MIL type ceramic capacitors that could be included in
your kit.
http://www.avx.com/docs/Catalogs/ckr04-24.pdf

WinTesla Simulation Software (FREE)


WinTesla can be used to determine winding configurations for the resonator coil if you
decide to use different primary and secondary sizes.
http://www.easternvoltageresearch.com/oldwebsite/teslasoftware.htm

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