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Journal of the Chinese Institute of Engineers, Vol. 30, No. 7, pp.

1145-1152 (2007) 1145

A VERSATILE THREE-PHASE DC-DC CONVERTER CIRCUIT


FOR FUEL CELL APPLICATIONS

Jih-Sheng Lai*, Seung-Ryul Moon, Raeyoung Kim, Feng-Yuan Lin, Yu-Hsuan Liu, and
Ming-Hsien Lin

ABSTRACT
Multiphase dc-dc converters allow current sharing among phases and high-fre-
quency ripple cancellation and are very desirable for low-voltage high-power fuel
cell applications. In this paper, a versatile three-phase dc-dc converter circuit as a
building block is proposed for different output voltage levels including non-isolated
48 V for telecom and isolated 400 V for subsequent stage dc-ac inverter applications.
For either type of application, the proposed three-phase converter circuit is controlled
by the same complementary gating control that allows synchronous rectification for
the non-isolated version and zerovoltage soft switching for the isolated version. Two
sets of 5-kW converters have been built and tested with a fuel cell simulator. Experi-
mental results are given to show the superiority of the efficiency performance in two
different applications.

Key Words: three phase dc-dc converters, fuel cells.

I. INTRODUCTION (Liu et al., 2005, and Liu et al., 2006) has demon-
strated a desired high efficiency for fuel cell voltage
For stationary applications, fuel cells were mostly less than 25 V or current higher than 200 A, the
found with low voltages such as 20 to 60 V and high threephase three-leg (V3) dc-dc converter circuit in
powers such as 3 to 10 kW. The load may be 48-V is more versatile when it comes to different applica-
dc for telecom applications or 110/220-V ac for house- tions that involve both isolated and non-isolated dc-
hold applications. For 48-V dc output, isolation is dc power conversions. The V3 converter circuit can
normally unnecessary, but for 110/220-V ac output, be used for non-isolated applications, while V6 con-
an isolated dc-dc converter is needed to serve as the verter is only limited to isolated applications.
first-stage voltage boost and galvanic isolation. For Intuitively an isolated dc-dc converter can be
a typical 5 kW stationary fuel cell power plant, the universally used for versatile applications. Fig. 1
dc-dc converter input inevitably sees more than 100 shows block diagrams of stationary fuel cell power
A for fuel cells with voltage level lower than 50 V. plant using an isolated dc-dc converter for 48-V dc
Such a high-current dc-dc converter requires multiple output and 110/220-V ac output conditions. The iso-
phases to achieve high efficiencies (Liu et al., 2005, lated dc-dc converter consists of a bridgetype con-
Liu et al., 2006, Oliveira et al., 2003, Moon et al., verter that converts dc to low-voltage high-frequency
2007, Prasad et al., 1992, and De Doncker et al., 1991). ac, a high-frequency transformer that converts low-
Although the 3-phase 6-leg (V6) dc-dc converter in voltage high-frequency ac to high-voltage high-fre-
quency ac, and an ac-dc rectifier plus a filter circuit
*Corresponding author. (Tel:(540)2314741; Fax: (540)2313362; to smooth the dc output. For 48-V dc load, the out-
Email: jslai@vt.edu) put side can be isolated from fuel cell ground or ty-
J. S. Lai, S. R. Moon, and R. Kim are with the Future Energy ing either positive or negative to the ground. For 110/
Electronics Center (FEEC), Virginia Polytechnic Institute and State 220V ac load, a high voltage conversion ratio is re-
University, Blacksburg, Virginina 24061-0111, USA.
F. Y. Lin, Y. H. Liu, and M. H. Lin are with the Tatung System
quired to boost the output voltage up to 400 V for the
Technologies, 22, Chungshan N. Rd., 3rd Sec., Taipei 104, Taiwan, dc-ac inverter to produce 220 V ac output.
R.O.C. The main problem with isolated design is the
1146 Journal of the Chinese Institute of Engineers, Vol. 30, No. 7 (2007)

48V DC
AC-DC
Fuel Bridge Rectifier a a a
Cell Vin Converter + Vdc Vdc Vdc
Filter
(a)

AC
(a) (b) (c)
AC-DC DC-AC
Fuel V Bridge Rectifier Inverter 110V220V Fig. 2 Phase-leg circuit configurations: (a) buck switch, (b) boost
Cell in Converter + + 110V
Filter Fiter switch, and (c) general-purposed half-bridge circuit.

(b)

Fig. 1 Stationary fuel cell power plant using an isolated dc-dc


converter for (a) 48-V dc output and (b) 110/220V ac output.
a a
Vdc b Vdc b
c c
cost and loss associated with the high-frequency high-
power transformer. For high voltage conversion ratio,
the transformer is unavoidable, but for 48-V dc
output, the voltage level is nearly the same as that of (a) (b)
the fuel cell voltage, it is possible to adopt non-iso- Fig. 3 Three-phase bridge circuit configurations: (a) standard
lated version to avoid the use of expensive and lossy three-phase converter circuit, (b) three-phase converter
transformer and to avoid the output rectifier stage, with added Schottky diodes to increase buck mode
which requires ultra fast reverse recovery diodes to efficiency.
be used, and the conduction loss with these diodes is
quite significant. Although the diode conduction loss
may be reduced by synchronous rectification, the switch that can perform buck and boost functions while
added device cost, and control and complexity make operating in synchronous rectification mode.
it unattractive. The half-bridge circuit can be expanded to a full
To adapt to both isolated and non-isolated high- bridge or multiphase converter circuit. Fig. 3(a)
power dc-dc applications, the proposed idea is to have shows a standard threephase converter circuit as a
a general-purpose multiple phase-leg circuit, which building block that consists of three half-bridge
can be used as an interleaved buck, boost, or buck- circuits. Each half-bridge circuit is controlled to sepa-
boost converter for non-isolated dc-dc and multiphase rate 120° apart, and the three-phase currents are in-
isolated dc-dc with zero-voltage soft switching. The terleaved to reduce the overall current ripple. If this
gating control for upper and lower switches is comple- threephase converter circuit is used only for the buck
mentary to achieve synchronous rectification for the mode operation, the bottom switched can be enhanced
non-isolated version and soft-switching for the iso- with Schottky diodes to reduce the switching loss.
lated version. A three-phase converter circuit has Similarly, if the upper switches are paralleled with
been designed, and two sets of 5-kW converter have Schottky diodes, then the efficiency can be improved
been built based on the same circuit for both non- in boost mode operation. Fig. 3(b) shows the Schottky
isolated and isolated versions. Operational wave- diode enhanced circuit for buck mode operation.
forms and efficiencies of two converters have been It is well-known that the fuel cell output volt-
tested with a fuel cell simulator to show how the pro- age varies with the load current. The studied case
posed circuit can used in different applications. has a voltage range from 37 V to 57 V, and the re-
quirement for telecom application is to have either
II. THREE-PHASE NON-ISOLATED DC-DC +48 V or –48 V output assuming the negative side of
fuel cell is grounded. To configure for –48 V output,
Figures 2(a) and 2(b) indicate that the buck and the proposed three-phase converter circuit can be ar-
boost converters can be implemented with one switch ranged as a conventional buck-boost converter with
and one diode. For low-voltage applications, the di- interleaved operation, as shown in Fig. 4. The upper
ode is normally replaced or paralleled with a power MOSFETs serve as the active switch, and the lower
MOSFET, which switches complementarily to reduce MOSFETs serve as the freewheeling diode and
the conduction loss through reverse channel conduction, synchronouse rectification. The output and input
or so-called “synchronous rectification.” Thus the share the same ground. The switch voltage stress is
half-bridge circuit in Fig. 2(c) becomes a general-purpose the sum of input and output voltages.
J. S. Lai et al.: A Versatile Three-Phase DC-DC Converter Circuit for Fuel Cell Applications 1147

L iL
S1 S3 S5
V 1:n D1 D3 D5
Fuel fc A a
cell iA ia

Inverter
input Cf b
Vfc B Co Vdc
37-57V
C c
S4 S6 S2 D4 D6 D2

Vo –48V

Fig. 6 V3 converter: three half-bridge, Y-Y transformer isolated


converter
Fig. 4 Configuration of a three-phase interleaved buck-boost con-
verter
360°
180° D
S1
S11 S13 S15 S21 S23 S25
S4
S3 120°
S6
S5 240°
S2
1 2 3 4 5 6 1 2 3 4 5 6
Fuel S14 S16 S12 S24 S26 S22
Cell +48V Vo Fig. 7 Asymmetrical duty cycle control signal for V3
Vfc
37-57V

Fig. 5 Circuit configuration of a three-phase two-stage boost-cas- is difficulty to maintain smooth transition from one
caded with buck converter for positive output mode to the other mode.

III. THREE-PHASE ISOLATED DC-DC WITH


To obtain +48 V output using the proposed ASYMMETRICAL DUTY OPERATION
generalpurposed three-phase converter circuit, we can
cascade two converter building blocks together with Figure 6 shows the schematic circuit diagram
either a buck cascaded with boost or a boost cascaded of an isolated dc-dc converter using the proposed
with buck (Chen et al., 2001). Fig. 5 shows a three- three-phase converter building block, three transform-
phase boost cascaded with buck type converter circuit. ers connected in Y-Y configuration, a three-phase
The first stage is a three-phase interleaved boost bridge rectifier, and a set of LC filter. The entire
converter, and the second stage is a three-phase in- three-phase isolated dc-dc converter is called “V3”
terleaved buck converter. converter hereafter.
Although the above circuit can have boost and With traditional pulse width modulation (PWM)
buck converters operate independently by regulating using symmetrical duty cycle, the converter operates
their respective output voltages or currents, it is pos- in hard switching. With the proposed building block
sible to increase the efficiency by running the con- and asymmetrical control, as shown in Fig. 7, upper
verter with only one stage while keeping the other and lower switches turning on and off complementarily,
stage switches in fully on or off conditions. the converter operates much like the phase-shift modu-
lation in a full-bridge dc-dc converter. When a switch
1. When V fc < 48 V, only the boost stage operates to is turned off, energy in transformer leakage induc-
regulate the output voltage. The second stage up- tance charges and discharges appropriate power switch
per switches S 21, S 23 , S 25 are fully turned on, and output capacitance. Once the respective capacitors
lower switches S 24, S26 , S22 are fully turned off. are fully charged and discharged, remaining current
2. When V fc < 48 V, only the buck stage operates. starts to flow in the anti-paralleled diode. At this time,
The first stage upper switches S11, S13, S15 are fully opposite side device can be turned on with zero-volt-
turned on, and lower switches S14, S16, S12 are fully age across the device. Three phase leg control sig-
turned off. nals are separated apart with 120º phase shift among
them.
The only drawback to such a single-stage operation This control technique allows soft switching
1148 Journal of the Chinese Institute of Engineers, Vol. 30, No. 7 (2007)

Fig. 9 Hardware circuit architecture

Auxiliary power
Fig. 8 Conversion ratio and operating mode for V3

without adding extra resonant components or semi- Gate drive PWM


FIFO
conductor devices, and it is attractive for high-power
applications because of potential efficiency improvement
without cost penalty.
A high transformer turns ratio is required to pro-
vide a high conversion ratio. For example, 1:8 turn
ratio is needed for 50 V input and 400 V output in Fig. 10 Photograph of the three-phase converter building block
ideal case. The V3 converter, as shown in Fig. 6, is
configured in Y-Y connection to avoid circulating
current in the primary side if imbalance occurs. thus can be expressed as Vdc = 3 . D . n . Vfc, where n
The V3 converter has three operating regions is the transformer turns ratio, and D is the duty cycle
and two operating modes. The voltage conversion ranging from 0 to 1/3.
ratio is shown in Fig. 8. Three operating regions can
be identified based on duty cycle: 0 < D < 1/3, 1/3 < IV. HARDWARE IMPLEMENTATION OF THE
D < 2/3 and 2/3 < D < 1. GENERAL-PURPOSE THREE-PHASE
The regions of 0 < D < 1/3 and 2/3 < D < 1 are CONVERTER BUILDING BLOCK
considered anti-symmetrical mode and have the same
voltage regulating range. The operating mode is The three-phase converter building block that
called “regulated mode” with which the duty cycle can be used for either non-isolated or isolated dc-dc
controls output voltage. When the duty cycle in- converters has been designed and implemented in
creases from 0 to 1/3, the output voltage increases hardware prototypes. Fig. 9 shows the hardware
linearly from 0 to 1. On the other side, when the duty circuit architecture. The first stage is a PWM con-
cycle increases from 2/3 to 1, output decreases lin- troller that compares the command and feedback to
early from 1 to 0. In this mode, there is a time during produce the Phase-A PWM outputs. Phase-B and Phase-
a switching period when all the upper or lower C gate signals are obtained with first-in-first-out (FIFO)
switches are on, which creates freewheeling period, circular buffers. Each FIFO produces 120° phase shift.
and the voltage across all the primary transformer There is a buffer between PWM output and the gate
terminals are zero. Thus, after the rectification, out- driver, which is not shown to simplify the explanation.
put waveform is a square waveform, and the output Figure 10 shows the photograph of the com-
is the average of square waveform. pleted threephase converter building block. A flyback
Second operating mode is identified where con- converter that takes 20 to 60-V input and produces
version ratio remains the same regardless of duty multiple isolated 15-V outputs is designed to provide
cycle. It can be called a dc-dc transformer mode, auxiliary powers. A laminated bus bar is designed to
since the output voltage is proportional to the input reduce the parasitic inductance. Major components
voltage. In this mode, at least one primary trans- used in this prototype are listed as follows:
former terminal transfers input voltage to the output Figure 11 shows recorded waveforms generated
side throughout a switching period. When the sec- by the PWM controller and FIFO at 50 kHz switch-
ondary transformer voltages are rectified, and the ing frequency. With a period (360°) of 20 ms, the
ideal voltage transferred to the output during this dc- FIFO phase-shifter produces 6.66 ms (or 120°) phase
dc transformer mode is V dc = n . V dfc and is not shift between phases.
controllable. The average output voltage during the The measurement indicates the maximum phase
regulated mode is controlled by the duty cycle and shift error between phases is ±0.02 µs. With 20 µs
J. S. Lai et al.: A Versatile Three-Phase DC-DC Converter Circuit for Fuel Cell Applications 1149

PWM Source Waveform


Itotal = 76A IL =25A

120° Phase-shifted Waveform

240° Phase-shifted Waveform


t (10 µs/div)
Measure P1 mean(C1) P2 duty(C1) P3 duty(C1) P5 mean (F3)
value 202 mV 9.57% 9.57% 75.81 A

Fig. 13 Experimental inductor currents at 90% duty cycle under


Fig. 11 Experimental waveforms for designed signal generator buck mode operation. Trace 1 shows the lower switch gate
drive signal. Traces 2, 3, and 4 are individual inductor
using FIFO circuit
currents. I total is obtained from Math.

Inductors 40
20
Magnitude (dB)
0
-20
Boost stage
-40 G.M.: 29.4 dB
-60 Freq: 1.39e+004 Hz
Stable loop
Control -80
settings 315
Phase (deg)

270
Buck stage 225
180
Fig. 12 Photograph of a two-stage boost buck converter using the 135
proposed converter building block 90 P.M.: 76.5 deg
Freq: 884 Hz
45
101 102 103 104 105
Frequency (Hz)
being one switching cycle, this error represents 0.1%,
Fig. 14 Frequency response of the boost stage control loop
which corresponds to the ratio of the FIFO clock pe-
riod and the switching period.
A. The individual phase current has a peak to peak
V. APPLICATION TO A NON-ISOLATED current ripple of 5A, but the total current ripple is
BOOST-BUCK CONVERTER much reduced because of current interleaving.

1. Hardware Prototype 2. Controller Design

The circuit diagram shown in Fig. 5 has been With two-stage power conversion, the control
implemented using the proposed three-phase con- stability and interaction are major concerns. In or-
verter building block for a 5-kW boost-buck converter der to avoid mid dc bus voltage overshoot during load
with 37 – 57 V fuel cell input and 48-V nominal transient, a voltage loop control is needed for the boost
output. Fig. 12 shows the photograph of the entire converter, which has a transfer function shown in (1).
assembly. The only added components are input and
output inductors and control setting interface board. – 0.6575(s – 2.567 × 10 5)(s + 2128) (1)
G vd =
In this test setup, both input and output inductors are s 2 + 3006s + 4.059 × 10 6
29 µH, which allows each phase current to have 10%
By selecting a crossover frequency slightly below 1
ripple at the full load.
kHz, a proportional-integral (PI) controller can be de-
Figure 13 shows experimental results of the
signed as follows.
three inductor currents running at 90% duty cycle
under buck mode condition. Due to a high core 35882(s + 1700)
tolerance, the inductor currents are not quite balanced. C(s) = (2)
s(s + 6.1 × 10 4)
With average a little more than 25-A in each phase
inductor current, I L, the total current I total is about 76 Frequency domain plot of the entire loop gain is
1150 Journal of the Chinese Institute of Engineers, Vol. 30, No. 7 (2007)

40 99.0%
20
Magnitude (dB)

98.5%
0 98.0%
-20

Efficiency
97.5%
-40 G.M.: 30.6 dB 97.0%
-60 Freq: 2.2e+004 Hz 96.5%
-80 Stable loop
96.0%
-45 95.5%
Phase (deg)

-90 95.0%
0 1000 2000 3000 4000 5000
-135
Power (W)
-180 P.M.: 78.4 deg
Freq: 1.74e+003 Hz Fig. 17 Buck converter efficiency test results
-225 1
10 102 103 104 105
Frequency (Hz)
96%
Fig. 15 Frequency response of the buck stage control loop Vin = 57V
94%
Vin = 48V

Efficiency
92%
Vin = 37V
90%

88%
Vds (50 V/div) Vgs (10 V/div)
86%
0 1000 2000 3000 4000 5000
Power (W)

ILoad = 21A ILoad = 33A Vdc= 59V Fig. 18 Overall system efficiency with different input voltages and
both boost and buck converters operating in closed-loop
condition
t (10 µs/div)

Fig. 16 Dynamic response of the mid dc bus voltage under load the control loops are stable, and the mid dc bus voltage
step Vdc is well regulated when the load current ILoad is in-
creased from 21 A to 33 A condition. The device volt-
age vds and gate-source voltage vgs indicate a small and
shown in Fig. 14. The resulting loop gain bandwidth gradual duty cycle increase after the load current step.
is 884 Hz, and the phase margin is 76.5°.
Voltage loop control is also needed for the buck 3. Efficiency Measurement Results
converter because the output voltage needs to main-
tain constant at 48 V. The buck converter transfer For efficiency measurement, all the instruments
function is shown in (3). are high precision with 0.02% accuracy. The current
sensor is a high precision current viewing resistor with
3.1 × 10 5(s + 1333) (3) 0.2% accuracy. Fig. 17 shows the buck converter ef-
G vd =
s2 + 5187s + 6.897 × 10 6 ficiency test results. The peak efficiency occurs in
between 3 kW and 4 kW. High efficiency of 98%
To avoid interaction between two stages, a crossover
power conversion can be achieved if only one con-
frequency of higher than 1 kHz is selected for the buck
verter is used.
converter. The designed PI controller is shown in (4).
The buck converter duty cycle is almost con-
43342(s + 3800) stant throughout the entire fuel cell voltage range because
C(s) = (4) the boost converter runs in closed-loop condition that
s(s + 6.1 × 10 4)
regulates the mid dc bus voltage to a constant of 60V.
Frequency domain plot of the entire loop gain is shown Thus the buck converter can have very high efficiency
in Fig. 15. The resulting loop gain bandwidth is 1.74 in a wide load range. The boost converter, however,
kHz, and the phase margin is 78.4°. Note that a volt- needs to deal with different input voltages, and its
age sensor was included in the both boost and buck efficiency will depend on the input voltage condition.
converters. The scaling factor and the cut-off frequency If the seamless transition is needed, then both boost
of the voltage sensor are 0.05 and 50 kHz, respectively. and buck converters need to operate in closed-loop
Figure 16 shows voltage and current waveforms condition, and the total system efficiency will be lower.
under dynamic load step test. Test results verify that Fig. 18 shows the overall system efficiency with
J. S. Lai et al.: A Versatile Three-Phase DC-DC Converter Circuit for Fuel Cell Applications 1151

vds1 vgs1
Rectifier 20 V/div 5 V/div
stage
vds4 vgs4
20 V/div 5 V/div
Transformer 5 µs/div
stage Zoome-in
Upper Device
ZVS
Zoom-in
Three-phase
converter Lower Device
building block ZVS
200 ns/div

Fig. 21 ZVS for V3 at high duty cycle and heavy load condition
V fc = 50 V, V dc = 400V, 50% duty cycle, 3 kW load
Fig. 19 Photograph of the V3 converter using the three-phase con-
verter building block
vgs1
5 V/div

vds1 vgs1
vgs4
20 V/div 5 V/div
5 V/div
iA
vds4 vgs4
5 V/div 10 A/div
20 V/div
5 µs/div iB
Zoome-in 10 A/div
iC
Upper Device
ZVS 10 A/div
Zoom-in t: 5 µs/div
Lower Device
ZVS Fig. 22 Gate drive signals and output phase currents of V3 con-
200 ns/div verter

Fig. 20 ZVS for V3 at low duty cycle and light load condition V fd
= 50 V, V dc = 300V, 25% duty cycle, 1 kW load 98%
97%
96%
95%
Efficiency

different input voltages and both boost and buck con- 94%
verters operating in closed-loop condition. The peak 93%
92%
efficiency drops to about 95.5%. The efficiency is
91%
generally higher with higher input voltage. 90%
89%
VI. APPLICATION TO THE V3 ISOLATED 0 1000 2000 3000 4000 5000 6000
DC-DC CONVERTER Power (W)

Fig. 23 V3 converter efficiency measurement results


The isolated V3 converter shown in Fig. 6 has
been implemented to have 37 – 57 V input and 400 V
output at 5-kW output power. Fig. 19 shows the pho- and drain-source voltages of both figures all indicate
tographs of the prototypes of V3 converter under test. that devices are switched at zero-voltage conditions.
Notice that the threephase converter building block Figure 22 shows the gate drive voltages and out-
remains the same except that additional transformers put phase current waveforms for the V3 converter.
and rectifier stages are added to obtain high voltage The top two traces indicate that the upper and lower
conversion ratio. gate drive voltages of phase-A, v gs1 and v gs4 are
Figs. 20 and 21 show experimental waveforms complementary, but not exactly with the same duty
for 25% and 50% duty cycles, respectively. The cycle. Three phase currents i A , i B , and i C are 120°
asymmetrical three-phase bridge converter operation apart. In every cycle, the phase current should have
is very similar to a full-bridge converter phase-shift two zero current regions with 60° periods where small
operation, which has upper and lower devices switch- circulating current is observed possibly due to com-
ing complementarily and allows the device to be ponent mismatch.
turned on at zero voltages. The zoom-in gate-source Figure 23 shows the efficiency measurement
1152 Journal of the Chinese Institute of Engineers, Vol. 30, No. 7 (2007)

results of the V3 converter. Again, in the test setup, voltage, and the isolated dc-dc converter efficiency
all meters and current sensors have been selected to peaks at 96.8%. Stable control loop designs are also
be 0.02% precision or better. The results indicate that shown for a two-stage power conversion. It can be
the V3 converter maintains efficiency between 95 and concluded that the proposed versatile three-phase
97% from 1 kW to 5 kW and peaks at 96.8% at 2 kW. converter building block is very well suited in low-
voltage high-power fuel cell applications.
VII. CONCLUSION
REFERENCES
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block has been applied in two fuel cell power con- Transactions on IAS, pp. 824-832.
version cases. The first case is a non-isolated dc-dc De Doncker, R. W., Divan, D. M., and Kheraluwala,
converter that requires 48-V dc output for telecom M. H., 1991, “A Three-Phase Soft-switched High
applications, and the second case is an isolated dcdc Power Density DC/DC Converter for High Power
converter that requires 400-V dc output as the front- Applications,” IEEE Transactions on IAS, pp. 63-
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produce 110/220-V ac for residential applications. Chen, J., Maksimovic, D., and Erickson, R., 2001,
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perior efficiencies that are most desired in energy dependently Controlled Switches,” Proceedings
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isolated dc-dc converter has the peak efficiency Manuscript Received: Mov. 19, 2007
between 94% and 96% depending on the fuel cell and Accepted: Mov. 19, 2007

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