ST AN557 Application note

AN557
APPLICATION NOTE
EASY APPLICATION DESIGN WITH THE L4970A,
MONOLITHIC DC-DC CONVERTERS FAMILY
The L497XA series of high current switching regulator ICs exploit Multipower-BCD technology to achieve very high output currents with low power dissipation – up to 10A in the Multiwatt power package and 3.5A in a DIP package .
THE TECHNOLOGY
The technology architecture is bas ed on the vertical DMOS sil icon gate process that allows a chan nel length of 1.5 micron ; using a junction isolation technique it has be en possible to mix on the same chip Bipolar and CMOS transistors along with the DMOS power components (Fig. 2). Figure 1 shows how this process brings a rapid increase in power IC complexity compared to conventional bipolar technology. In the 70’s class B circuits and DC circuits allowed out put power in the range of 70W . By 1980, with the in­troduction of switching techniques in power ICs, output powers up to 200W were reached ; with BCD tech­nology the output power increased up to 400W.
November 2003
1/52
AN557 APPLICATION NO TE
Figure 1. BCD process and increase in power ICs complexity.
Figure 2. Cross Section of the BCD Mixed Technology.
THE STEP-DOWN CONFIGURATION
Fig. 3 shows the simp lified block di agram of the c i rcuit realizin g the s t ep-down c onfiguration. T his circuit operates as follows : Q1 acts as a switch at the frequency f and the ON and OFF ti mes are suitably c on­trolled by the pulse width modulator circuit. When Q1 is saturated, energy is absorbed from the input which is transferred to the output through L. The emitter voltage of Q1, V
, is Vi-Vsat when Q is ON and -VF (with
E
VF the forward voltage across the D dio de as indicated) when Q1 is OFF. During t his sec ond phase the current circulates again through L and D. Consequently a rectangular shaped voltage appears on the emit­ter of Q1 and this is then filtered by the L-C-D network and converted into a continuous mean value across the capacitor C and therefore across the load. The current through L consists of a continuous component, I
, and a triangular-shaped component super-imposed on it, IL, due to the voltage across L.
LOAD
2/52
AN557 APPLICATION NOTE
Figure 3. The Basic Step-down Switching Regulator Configuration
Fig. 4 shows the behaviour of the most significant waveforms, in different points of the circuit, which help to understand better the operation of the power section of the switching regulator. For the sake of simplic­ity, the series resistance of the coil has been neglected. Fig. 2a shows the behaviour of the emitter voltage (which is practically the voltage across the recirculation diode), where the power saturation and the for­ward VF drop across the diode era taken into account.
The ON and OFF times are established by the following expression :
T
ON
------------------------------- -
V
ViV
o
()
sat
=
T
+
ONTOFF
Fig. 4b shows the current across the switching tran sistor. The current shape is t rapezoida l and t he oper­ation is in continuous mode . At this stage, the phenom ena due to the c atch diode, that we consider as dynamically ideal, are neglected. Fig. 4c shows the current circulating in the recirculation diode. The sum of the currents circulating in the power and in th e diode is the current circul ating in the c oil as s hown in Fig. 4e. In balanced conditions the decrease occurring during T
OFF
+
current increase occ uring du ring TON has to be equal to the I
IL
L
. The mean value of IL corresponds to the charge current. The current rip-
ple is given by the following formula :
+
I
I
L
It is a good rule to respect to I
-
== =
L
oMIN
iVsat
----------------------------------------
IL/2 relationship, that implies go od operation in co ntinuous mode.
()V
V
o
L
T
ON
VoVF+
------------------- -
L
T
OFF
When this is not done, the regulator starts operating in discontinuous mode. This operation is still safe but variations of the switching frequency may occur and the output regulation decreases.
Fig. 4d shows the behaviour of t he voltage ac ross coil L. In b alanced conditions, the mean value of the voltage across the coil is zero. Fig. 4f shows the current flowing through the capacitor, which is the differ­ence between I
In balanced conditions, the m ean current is equ al to zero, and I
and I
L
LOAD
.
= IL. The current IC through the ca-
C
pacitor gives rise to the voltage ripple. This ripple consists of two components : a capacitive component, V
, and a resistive component, V
C
ESR
due to the ESR equivalent series resistance of the capacitor. Fig. 4g shows the capacitive component V of the voltage ripple, which i s t he i nteg ral of a triangular-shaped curren t as a function of time . Moreo ve r, it should be observed that v of charge Q
+
supplied to the capacitor is given by the area enclosed by the ABC triangle in Fig. 4f :
(t) is in quadrature with iC(t) and therefore with the voltage V
C
. The quantity
ESR
,
C
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AN557 APPLICATION NO TE
Figure 4. Principal Circuit Waveforms of the figure 1 Circuit.
4/52
Which therefore gives:
Q
V
C
1
-- -
2
Q
----
C
AN557 APPLICATION NOTE
I
T
L
------- -
---
⋅⋅=
2
2
I
L
--------==
8fc
Fig. 4h shows the voltage ripple V V
(t) = iC (t) × ESR. Fi g. 4i sh ows t he o vera ll ripple Vo, which is t he sum of the two pre vious com po-
ESR
due to the resistive component of the capacitor. This component is
ESR
nents. As the frequency increases (> 20kHz), which is required to reduce both the cost and the sizes of L and C, the VESR component becomes dominant. Often it is necessary to use capacitors with greater ca­pacitance (or more capacitors connected in parallel to limit the value of ESR within the required level.
We will now examine the stepdown configuration in more detail, referring to fig. 1 and taking the be-haviour shown in Fig. 4 into account.
Starting from the initial conditions, where Q = ON, v
= Vo and iL = iD = 0, using Kirckoff second principle
C
we may write the following expression: V
= vL + vC (V
i
is neglected against Vi).
sat
d
IL
i
------- -
L
dt
v
+ L
C
V
(1)
d
IL
+==
------- - V
dt
o
which gives :
d
------- -
dt
V
IL
()
iVo
---------------------- -=
L
(2)
The current through the inductance is given by :
ViVo–()
I
---------------------- -=
L
(3)
L
When Vi, Vo, and L are constant, IL varies linearly with t. Therefore, it follows that :
V
+
I
L
()T
iVo
---------------------------------- -=
L
ON
(4)
When Q is OFF the current through the coil has reached its maximum value, Ipeak and because it cannot very instantaneously, the voltage across the ased to allow the recirculation of the current through the load.
When Q switches OFF, the following situation is present:
vC(t) = Vo, iL (t) = iD (t) = I
peak
And the equation associated to the following loop may be written :
d
IL
------- -
where : vC = V
V
L
++ 0=
F
o
dI
L
------- -
dt
dt
V
------------------------ -=
v
FVo
C
(5)
+()
(6)
L
It follows therefore that :
+
V
FVo
t()
------------------- -
T
t=
(7)
5/52
i
L
AN557 APPLICATION NO TE
The negative sign may be interpretated with the fact that the current is now decreasing. Assuming that VF may be neglected against V
therefore :
But, because I
L
+
= I
, during the OFF time the following behaviour occurs :
o
V
o
------
t=
V
------
L
ON
(8)
L
o
T
(9)
OFF
V
oTOFF
---------------------=
L
if follows that :
L
I
L
+
I
=
L
()T
V
iVo
---------------------------------- -
L
which allows us to calculate V
:
o
T
ON
V
------------------------- -
==
V
o
i
TONT
OFF
V
where T is the switching period. Expression (10) links the output voltage V
to the input voltage Vi and to the duty cycle. The relat ion -sh i p
o
between the currents is the following :
T
ON
---------- -
I
iDCIoDC
=
T
EFFICIENCY
The system efficiency is expressed by the following formula :
P
o
------
100=
P
i
where Po = VoIo (with Io = I system. P
is g ive n by Po, plus all t he other syst em losses. Th e expression of the effic iency becomes th ere-
i
η %
) is the output power to the load and Pi is the input power absorbed by the
LOAD
fore the following :
P
---------------------------------------------------------------------------------=
η
PoP
+ ++++
satPDPLPqpsw
o
T
ON
-----------
i
T
(11)
(10)
(12)
DC LOSSES
Psat :saturation losses of the power transistor Q. These losses increase as Vi decreases.
T
ON
P
ON
T
V
o
------=
V
i
is the power transistor saturation at current Io.
sat
T
where and V
P
---------- -
: losses due to the recirculatio n diode . These loss es incr ease as Vi increases, as in this case the ON
D
sat
V
satIo
---------- -
T
+=
V
satIo
V
------
V
o
i
(13)
time of the diode is greater.
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ViVo–
VFI
----------------- -
o
V
i
P
==
D

V
1

FIo

V
o
(14)
------
V
i
where VF is the forward voltage of the recirculation diode at current Io. P
: losses due to the series resistance RS of the coil
L
AN557 APPLICATION NOTE
PL = RS I
o
2
(15)
Pq: losses due to the stand-by current and to the power driving current:
Pq = Vi Iq, (16)
in which Iq is the operat ing supply current at the operating swi tchin g frequency. Iq includes the oscillator current.
SWITCHING LOSSES
P
: switching losses of the power transistor :
sw
trtf+
------------ -
=
P
sw
ViI
o
2T
The switching losses of the recirculation diode are neglected (which are anyway negligible) as it is as­sumed that diode is used with recovery time much smaller than the rise time of the power transistor.
We can neglect losses in the coil (it is assum ed that IL is very small comp ared to I
) and in the output
o
capacitor, which is assumed to show a low ESR.
Calculation of the inductance value, L
Calculation T
ON
and T
through (4) and (9) respectively it follows that :
OFF
T
ON
+
I
L
L
----------------- -= T V
iVo
OFF
L
--------------- -=
-
I
L
V
o
But because :
+
T
ON
+ T
= T and I
OFF
L
= I
= IL, it follows tha t :
L
T
ON
IL∆ L
----------------- ­–
V
iVo
I
L
L
--------------- -+ T== V
o
(17)
Calculating L, the previous relation becomes :
V
()V
V
i
o
------------------------------
L
V
o
I
i
L
T=
(18)
Fixing the current ripple in the coil required by the design (for instance 30% of Io), and introducing the fre­quency instead of the period, it follows that :
V
()V
L
iVo
-------------------------------- -=
V
0.3 Iof⋅⋅⋅
i
o
where L is in Henry and f in Hz Vi × 0.3 × Io × f
Calculation of the output capacitor C
From the output node in fig. 3 it may be seen that the current through the output capacitor is given by:
ic (t) = iL (t) – I
o
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AN557 APPLICATION NO TE
Figure 5. Equivalent Circuit Showing Recirculation when Q1 is Turned Off.
From the behaviour shown in Fig. 4 it may be calculated that the charge curren t of the output capacitor, within a period, is I
but, remembering expression (4) :
therefore equation (19) becomes :
Finally, calculating C it follows that :
where : L is in Henrys
C is in Farads f is in Hz
Finally, the following expression should be true :
It may happen that to satisfy relation (21) a capacitance value much great er than the value calculated through (20) must be used.
/4, which is supplied for a time T/2. It follows therefore that :
L
------- -
VC∆
4C
V
+
I
L
()T
i
---------------------------------- -= T
V
I
L
V
L
C
T
---
2
o
ON
V
----------------------------- -=
I
T
L
----------- -
8C
and
()V
iVo
IL∆
--------===
8fc
ON
o
(19)
V
------
V
o
T=
i
8 Vif2LC
V
()V
C
ESR
------------------------------------- -=
8 Vi VC f
max
iVo
---------------------=
V
Cmax
o
2
L
I
L
(20)
(21)
TRANSIENT RESPONSE
Sudden variations of the load current give rise to overvoltages an d und ervo ltages on th e output v oltage. Since i
= C (dvc/dt) (22), where dvc = Vo, the instantaneous variation of the load current Io is supplied
c
during the transient by the output capacitor. During the transient, also current through the coil tends to change its value. Moreover, the following is true :
di
L
------- -
=
v
L
(23)
L
dt
where diL = Io v
= Vi – Vo for a load increase
L
= Vo for a load decrease
v
L
8/52
Calculating dt from (22) and (23) and equalizing, it follows that :
di
------- -
L
dt
dv
L
=
C
----------
C
i
C
AN557 APPLICATION NOTE
Calculating dv
and equalizing it to Vo, it follows that :
C
V
o
V
o
LI
---------------------------=
CV
LI
-------------=
C V
iVo
2 o
()
2 o
o
(24) for + ∆Io
(25) for -
Io
From these two expressions the dependence of overshoots and undershoots on the L and C values may be observed. To minimize V
it is therefore necessary to reduce the inductance value L and to increase
o
the capacitance value C. Should other auxiliary functions be required in the circuit like reset or crowbar protections and very variable loads may be p resent, it is worthwhile to t ake special care for minimi zing these overshoots, which could cause spurious operation of the crowbar, and the under-shoot, which could trigger the reset function.
DEVICE DESCRIPTION
For a better understanding of how the dev ice f unc tions , a description will be given of the prin ciple blocks that compose the device. The block diagram of the device is shown in fig.6
POWE R SU PPLY
OSCILLATOR, SYNC. AND VOLTAGE FEED-FORWARD FUNCTIONS
The oscillator block generates a sawtooh wave signal that sets the switching frequency of the system. This signal, compared with the output voltage of the error amplifier, generates the PWM signal that will then sent to the power output stag e. The oscillator also c ontains the voltage feedforward f unction that, be ing completely integrated, does not require additional external components to function. The VFF function op­erates with supply voltages from 15V to 45V. The V/t of the sawtooh is directly proportional to the supply voltage Vi.
As Vi increases, the conduction time (ton) of the power transistor decreases in such way as to provide to the coil, and therefore to the load, the product Volt x Sec constant.
Figure 6. Block Diagram of the 10A Monolithic Regulator L4970A.
9/52
AN557 APPLICATION NO TE
Figure 7. Volta ge Feeforward Wa veform.
V2
V7
D93IN006
Vi=30V Vi=15V
Vc
t
Vi=30V
Vi=15V
t
Fig. 7 shows the duty-cycle varies as a result of the changes in slope of the ramp with the input voltage Vi. The output of the error amplifier shou ld not chang e to maintain the out put voltage i n regulation. This function allows for the increas e of s peed in response to the rapid ch ange o f the supply voltage and for a greatly reduced ouput ripple at the mains frequency.
In fact, the slope of the ramp is modulated by the ripple, generally present in the order of several volts on the input of the regulator, particularly when the solution with a mains transformer is used.
Fig. 8 shows the simplified electrical diagram of the oscillator. A resistor, connected between the Rosc pin and GND, sets the current that is internally reflected in the pin
Cosc, in order to charge the external capacitor to which it is connected. The voltage to the Rosc pin is not fixed, but is tied to the instantaneous value of Vi; this is needed t o achieve th e feedforward voltage func­tion, in which the slope of the ramp is directly proportional t o the supply voltage. A comparator senses the voltage at the Cosc capacitor. Wh en the voltage reaches the val ue present at the inverting input o f the comparator, the output from the comparator goes high and is sent to the two transistors Q1 and Q2. Q1 is responsible for discharging the external Cosc capacitor with a current of approx. 20mA, while Q2 im­poses at the inverted input of the comparator a voltage of 2Vbe (approx. 1.3V) that is the low-threshold of the ramp. Some useful formulas for calculating the various parameters of the oscillator block are:
Figure 8. Osc illator Circuit.
Rosc
Cosc
PWM
COMP.
10/52
Vi
2R
13 2RR
Q1
-
+
Q2
R
CLOCK
D93IN007
AN557 APPLICATION NOTE
1) Oscillator charge current: Vi9V
I
CHARGE
-------------------------=
2) Oscillator discharge current:
3) Peak voltage ramp:
V
th H
This formula is obtained in the following way: indicating with Ve the voltage of the emitter of the NPN tran­sistor connected to Vcc, and V- the voltage at the inverted input of the comparator, one has:
V
V

V
------------------------- -

by substituting (a) into (b), one obtains:
V
i

---- - V

3
------------------------------- --------------- 2V
V
be
3
be
R
osc
I
= 20mA
DISCH
Vi9V
------------------------ - 2V
Rosc
V
i
=
---- - V
e
3
2V
e
be
3R
2V
be
+=
(For 15V < Vi < 45V)
be
+=
be
(a)
be
R
+=
be
2V
(b)
be
V
9V
i
be
------------------------- 2V
+=
9
be
4) Valley voltage ramp:
V
= 2V
th-L
be
5) Switching frequency:
SW
------------------------- -=
R
oscCosc
f
9
It should be noted that formula (5) does not take into account the discharge time of Cosc which cannot be neglected when one is working at frequencies equ al or highe r than 20 0KHz. The d ischarge tim e is also tied to the value of Cosc itsel f.
Analitycally one has:
6)
T
DISCH
V
th H
-------------------------------------- -
20 mA
V
th L
C
=
osc
from which is obta ined the mor e clo se ly ap p ro x im a te ex pr e ss io n o f the o s c illat o r fr equency:
7)
f
SW
---------------------------------------- -----------------=
R
oscCosc
----------------------------- - T
1
+
9
DISCH
During the discharge time of Cosc, a clock pulse is generated internally that is made sub sequent ly avail­able on the Sync. pin and that can be used to synchronize other regulators. (3 devices of the same family maximum). The Sync. pulse generated has a typical range of 4.5V and the current availabi lity is 4.5mA. In general, it is better that the Sync pulse is at least 300-400ns in order to be able to synchronize a range of existing regulators; to obtain this result, values of suggested capacitors, in different test circuits, have
11/52
AN557 APPLICATION NO TE
been selected. The typical duration of th e synchronizing pu lse with the suggest ed values of C
osc
are as
follo ws :
L497X Family (MULTIWATT PACKAGE)
C
(nf) - R
osc
L497X Family (POWERDIP PACKAGE)
C
(nf) - R
osc
= 16K
osc
0.68 140 1230
1.2 270
1.5 330
2.2 450
3.3 680
4.7 1100
= 30K
osc
1.2 230
1.5 280
2.2 420
3.3 600
4.7 900
Sync (ns)
Sync (ns)
Obviously, synchronize pulses of eccessive duration can greatly reduce the max duty-cycle and produce distortions in the sawtooth of the synchronized regulator working as slave.
P.W.M.
Comparing the sawtooth signal generated by the oscillator and the output of the error amplifier, generates the PWM signal which is sent to the driver of the output power stage. The PWM signal, in the path towards the output stage, also encounters a latch block to prevent other pulses from being sent at same period to the output, possibly damaging the power stage. In the PWM bl ock, a dut y-cycle limiter has al so been in­troduced. Such a limiter is obtained by taking advantage of the synchronizing pulse generated, the power output stage is inhibited. Even if the error amplifier gives a large signal to the peak of the ramp, the power stage will not b e able to op er ate in DC , but w ill be s wit ched of f at ea ch clock puls e. The max . obt ainable duty-cycle is higher than 90%; this, however depends on the working frequency and the value of Cosc. Using the formulas 6) and 7) a precise calculation can be done.
SOFT START
The Soft Start function is essential for a correct startup of the device and for an output voltage that, at the switch on, increases in a monotonous mode without dangerous output overvoltages and without over­stress for the power stage.
Soft Start operates at the startup of the system and after an intervention of the th ermal prot ection. Fig. 9 shows the simplified diagram of the startup functions. The function is carried out by means of an external capacitor connected to the Soft Start pin, which is charged with a constant current of about 100µA to a value of around 7V. During the charging time, the output of the error transcon-ductance amplifier, because of Q1, is forced to increase at the same rising edge time of the external softstart capacitor Css.
12/52
Figure 9. Soft Start Circuit.
Figure 10. Soft Start Waveforms.
Vc
AN557 APPLICATION NOTE
CLAMPED
ERROR AMPLIFIER
OUTPUT
t
OUTPUT
CURRENT
SOFT START TIME
D93IN011
t
The PWM signal begins to be generated as soon as the output voltage of the error amplifier crosses the ramp; at this point the output stage begins to commutate, slowly increasing its ON time (see fig. 10).
The charge of the Css capacitor, as already mentioned, begins each time the device is supplied with pow­er and after which an anomalou s condition is creat ed, as the intervent ion of thermal prot ection or of the undervoltage lockout.
CALCULATING THE DUTY-CYCLE AND SOFT-START TIME
Let us suppose that the discharge tim e o f the osc illator capac itor, Cos c, is neglected. This is an approx. valid for switching frequencies up to 200KHz. Let us indicate with Vr the output voltage of the error ampli­fier, and with Vc the voltage of the oscillator ramp.
Figure 11. Soft Sart Time Waveform.
13/52
AN557 APPLICATION NO TE
The PWM comparator block commutates when Vr = Vc. Therefore:
i
9
t
9V
()⋅⋅
V
9V
i
------------------------ -
be
be
9T
t== =
8)
from which is obtained
9)
V
r
V
t
V
pp
--------- -
c
T
Vr T V
------------------------------------------------ -=
The time t obtained from this equation is equal to the ON time of the power transistor. The corresponding duty-cycle is given by:
10)
Vr T V
t
on
-------
D
------------------------------------------------ -
T
9T
9V
()⋅⋅
i
be
VrVi9V
--------------------------------------- -
()
be
9
V
o
------== = =
V
i
Consequently, after leaving the discharged capacitor of Soft Start, the output of the regulator will reach its value when the voltage across the Css capacitor, charged w ith constant current, has reached the value Vr - 0.5V.
The time necessary in order that the output rises from zero to the nominal value is given by:
Vr0.5V()
11)
in which C
is the Soft Start capacitor and Iss the Soft Start current. Considering Soft Start time as tss,
ss
t
start up
C
ss
---------------------------- -
=
I
ss
the required time for the Soft Start capacitor to change itself approx from (2Vbe - 0.5V) = (1.2V - 0.5V) to Vr - 0.5V, is:
Vr1.2V()
12)
t
ss
C
ss
---------------------------- -
=
I
ss
By taking Vr from (10):
13)
V
o
------
V
r
V
i
9
------------------------ -
=
9V
V
i
be
and substituting it in (12), we obtain:
14)
o
---------
t
=
ss
------

I
V

ss
i
9
------------------------ - 1.2V 9V
V
i
be
V
C

ss
UNDERVOLTAGE LOCKOUT
The device contains the protection block of under-voltage lockout which keeps the power stage turned-off as long as the supply voltage does not reach at least 12V. At this point the device starts up with Soft Start.
The function of undervoltage is also provided with an hysteresis of 1V to make it better immune to the rip­ple present on the supply voltage.
ERROR AMPLIFIER
The error amplifier is a transconductance type and deliver an output current proportional to the voltage in­balance of the two inputs . The s i mplified diagram is presented in f i g 12. Th e pri ncipal characteristics of t hi s uncompensated operational ampl ifier are the following: Gm = 4mA/V, Ro = 2.5Mohm, Avo = 80dB, Isource­sink = 200
µ
A, Input Bias Current = 0.3µA. The frequency response of the op. amp. is given in fig. 13.
Ignoring the high frequency response and hypothesizing that the second pole is below the 0 dB axis in the all the conditions of loop compensation, it is possible to make a first approximation with the equivalent cir­cuit of fig. 14
14/52
Figure 12. Error Amplifier Circuit.
Figure 13. Ope n l oop gai n ( error amplifier onl y )
AN557 APPLICATION NOTE
Figure 14. Error amplifier equivalent circuit.
In whic h :
15) where C
Av s() Gm
R
c
--------------------------- -
=
1sRoC
+
o
= 3pF
o
The error amplifier can be easily compensated thanks to the high output impe dance (see fig. 14) The re­sulting transfer function is as in the following:
R
1sRcC
+()
(16)
Av s() Gm
---------------------------------------------------------------------------------------------------------------------
=
2
s
R
C
R
o
o
o
C
sRoCcRoCoRcC
c
c
c
++()1++
c
15/52
AN557 APPLICATION NO TE
Figure 15. Compensation network of the error ampli fier
The Bode diagram is shown in fig.16.
Figure 16. Bode plot showing gain and phase of compens ated erro r ampl ifier
The compensation circuit introduces a pole at low frequency and a zero that is generally calculated to be put in the proximity of the resonance frequency of the output LC filter.
The second pole at high frequency generally falls in a zone of no interest (for the system stability, one must consider the zero introduced by ESR characteristic of the output capacitor. Not all the designers agree on this solution).
If necessary, however, one c an turn t o m ore sophisticated compensation circuitry. An ex am ple is s hown in fig. 17.
Figure 17. One pol e, tw o ze ro com p e nsation netw ork
Such a circuit introduces a pole at low-frequency and two zeros.
17
16/52
Z1
1
-----------------------------
2Π R1 C1
Z2
1
-----------------------------==
2Π R2 C2
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