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Jennigma  
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 More options Aug 8 2012, 1:41 am
From: Jennigma <jleig...@gmail.com>
Date: Tue, 7 Aug 2012 22:41:56 -0700 (PDT)
Local: Wed, Aug 8 2012 1:41 am
Subject: Issues with new Ultimaker

Hi! I have a brand new Ultimaker, and I'm trying to get the first print to
work.  I'm stalled out trying to get the stepper motor that drives the
extruder to work correctly. I expect there is a software/firmware problem,
but don't know how to fully diagnose.

What I know:

I can get the motor to turn from the 0025-beta1 version of ReplicatorG if
it is below temp and the software puts up the error dialog asking me if I
want to turn the motor anyway. (I had the acorn nut loosened so the wooden
gear wasn't connected to the drive gear on the motor.) Once it's at temp
and I don't get the error dialog the motor won't turn from the software. At
all. Ever. Not in the same conditions, not when I try to start a print, not
at all.

I have a Macbook Air running 10.7.4.

I can drive all the X,Y,Z motors just fine from ReplicatorG 0025-beta1. I
installed the FTDI drivers even though I probably don't need them, because
I've been trying for about 6 hours to solve this problem now and have tried
all sorts of things.

I can't get ReplicatorG-0035-rc1 to recognize the printer at all.  It will
report a successful firmware upgrade, but in fact appears to corrupt it. If
I downgrade to 0025-beta1 I have to reinstall the firmware to get it to
connect to the printer.

The 2560 firmware build 1 (old 5D release) seems to be the only one that
will work on my machine at all.

I can hand advance the PLA when the heater is at temp, so I know it's
possible. The PLA seems to move smoothly. And the PLA tension shouldn't be
relevant at this point since the motor won't turn even with the wooden gear
disconnected, or with it connected and no tension on the PLA.

(I have mucked with the Java install on this computer while playing with
Processing libraries, so that's a possible area of concern. I don't think
it's related, just stating for completeness since the documentation
suggests a possible dependency. I installed the latest Oracle released
version of Java, but the computer is configured to run the standard Mac
Java.)

Things I could do, but have not:

I haven't tried Cura or Repetier host or any other packages; I was assuming
the Ultimaker build of ReplicatorG would be the best chance for success.

I haven't tried driving from a different computer. Notably, I don't have
easy access to a linux or windows box, but I can hit up friends if needed
for debugging purposes. Ultimately it needs to work from a Mac though- I
prefer to only maintain a single OS in my home.

Please help. This is extremely frustrating.


 
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Brian Garcia  
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 More options Aug 8 2012, 3:19 am
From: Brian Garcia <bjgar...@gmail.com>
Date: Wed, 8 Aug 2012 00:19:38 -0700 (PDT)
Local: Wed, Aug 8 2012 3:19 am
Subject: Re: Issues with new Ultimaker

Make sure you use the replicator G software from the below link.
http://software.ultimaker.com/

Also I find that Marlin/Print Run to be better at running the ultimaker.

If your 100% sure its not the software, then check your step motor drivers
on the PCB,   Try swapping out the E axis with the X, Y or Z that's
working.   Or before you do that you can try just swapping their wiring.

I had a bad driver board once.  

Last thought might be heat issue on the driver board,  there is a little
pot on there that you can turn to adjust the current to the motor. Just be
careful don't turn it more then 1/4 revolution or so.

Good luck !
Brian


 
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Daid  
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 More options Aug 8 2012, 3:24 am
From: Daid <daid...@gmail.com>
Date: Wed, 8 Aug 2012 00:24:16 -0700 (PDT)
Local: Wed, Aug 8 2012 3:24 am
Subject: Re: Issues with new Ultimaker

I replied on the forums. But almost all problems described by Jennigma are
known software problems in RepG.


 
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Ascended  
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 More options Aug 8 2012, 3:45 am
From: Ascended <m...@ascended.com.au>
Date: Wed, 8 Aug 2012 00:45:02 -0700 (PDT)
Local: Wed, Aug 8 2012 3:45 am
Subject: Re: Issues with new Ultimaker

Whilst others have answerd this qeustion, I'd suggest you also measure your
PLA at multiple points along the length, and also around the same point. If
you're getting variations of more than 0.1-0.2mm I would highly recommend
ordering some new PLA from a reputable local supplier. The PLA which came
with my Ultimaker has caused weeks of frustration and huge issues with
printing - mostly because of the PLA being out of spec as supplied.


 
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Jennigma  
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 More options Aug 8 2012, 9:59 am
From: Jennigma <jleig...@gmail.com>
Date: Wed, 8 Aug 2012 06:59:47 -0700 (PDT)
Local: Wed, Aug 8 2012 9:59 am
Subject: Re: Issues with new Ultimaker

Thanks, Daid. I'll go install Cura now and let you know how it works.


 
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Jennigma  
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 More options Aug 8 2012, 10:59 am
From: Jennigma <jleig...@gmail.com>
Date: Wed, 8 Aug 2012 07:59:52 -0700 (PDT)
Local: Wed, Aug 8 2012 10:59 am
Subject: Re: Issues with new Ultimaker

Ok, I got Cura installed, but the Setup Wizard won't run through; I get the
error "Missing start message." If I push through without the checks it
doesn't turn the motor in the filament test or heat the head.

Suggestions?


 
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Daid  
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 More options Aug 8 2012, 11:07 am
From: Daid <daid...@gmail.com>
Date: Wed, 8 Aug 2012 08:07:17 -0700 (PDT)
Local: Wed, Aug 8 2012 11:07 am
Subject: Re: Issues with new Ultimaker

Did the firmware install work?


 
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Jennigma  
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 More options Aug 8 2012, 11:55 am
From: Jennigma <jleig...@gmail.com>
Date: Wed, 8 Aug 2012 08:55:45 -0700 (PDT)
Local: Wed, Aug 8 2012 11:55 am
Subject: Re: Issues with new Ultimaker

On Wednesday, August 8, 2012 8:07:17 AM UTC-7, Daid wrote:

> Did the firmware install work?

It reported success.  

 
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Jennigma  
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 More options Aug 8 2012, 12:04 pm
From: Jennigma <jleig...@gmail.com>
Date: Wed, 8 Aug 2012 09:04:13 -0700 (PDT)
Local: Wed, Aug 8 2012 12:04 pm
Subject: Re: Issues with new Ultimaker

I tried something someone recommended on the forums, which was installing
RPG 0025, pushing the Marlin candidate 2 firmware, then removing RPG 0025
and installing 0035. That seemed to work, sort of. I could move all the
motors including the extruder, and control heat.

The extruder works well enough at pushing filament at 210o from the control
panel, but when I try to actually print it sets the Z axis about 15mm down
from where the printhead is moving. (I didn't measure on the first layer,
so I'm not sure exactly the distance it thinks is zero.) And it doesn't
seem to be able to extrude consistently.

Two new questions:

1) I'm not clear on what the two controls are supposed to do on the
extruder motor assembly.  There's the screw and the clutch lever thing, and
no documentation I can find.  I'm tweaking them at random, but not knowing
how they are supposed to work I have no idea if I'm making things better or
worse. Is there an explanation on how to set them anywhere?

2) I can hand advance the PLA, but it sometimes takes a good bit of
pressure to get it started. Is this evidence of a plug starting? I'm loathe
to start ripping it down to check.


 
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Dave Head  
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 More options Aug 8 2012, 12:18 pm
From: Dave Head <kibb...@gmail.com>
Date: Wed, 8 Aug 2012 17:18:41 +0100
Local: Wed, Aug 8 2012 12:18 pm
Subject: Re: Issues with new Ultimaker

the lever locks down the part that opens up and the screw the more
you tighten it the more it pushes the filament onto the extruder bolt.

i have mine quite tight and i have a bit of velco on the lever to keep it
down it dosnt really need it but it helps

http://www.flickr.com/photos/kibble0/7337925692/in/photostream


 
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Jennigma  
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 More options Aug 8 2012, 1:44 pm
From: Jennigma <jleig...@gmail.com>
Date: Wed, 8 Aug 2012 10:44:40 -0700 (PDT)
Local: Wed, Aug 8 2012 1:44 pm
Subject: Re: Issues with new Ultimaker

disassembled the extruder and there was a plug.  Cleaning that out now.
I'll start a second thread for pointers on getting a working extruder.


 
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Jensa  
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 More options Aug 9 2012, 4:05 am
From: Jensa <jens...@gmail.com>
Date: Thu, 9 Aug 2012 01:05:41 -0700 (PDT)
Local: Thurs, Aug 9 2012 4:05 am
Subject: Re: Issues with new Ultimaker

What temperature were you extruding at when you got the plug? 215C is a
good temperature :)

J


 
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Jennigma  
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 More options Aug 9 2012, 8:16 am
From: Jennigma <jleig...@gmail.com>
Date: Thu, 9 Aug 2012 05:16:30 -0700 (PDT)
Local: Thurs, Aug 9 2012 8:16 am
Subject: Re: Issues with new Ultimaker

220o.


 
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Jensa  
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 More options Aug 10 2012, 5:08 am
From: Jensa <jens...@gmail.com>
Date: Fri, 10 Aug 2012 02:08:21 -0700 (PDT)
Local: Fri, Aug 10 2012 5:08 am
Subject: Re: Issues with new Ultimaker

When I got my machine 5 months ago, I initially thought that I had plugs
several times. Upon testing, it showed that it wasn't "full plugs" but
rather "partial plugs" and I realized that by just manually extruding some
filament (by turning the large gear on the back manually) the plugs would
come loose.

I didn't really find out what caused it, but I suspect it was some poor
quality filament. I now buy most my filament from either
fabderdashery.co.uk and it's superb quality.

I don't know if this is the same for you, but you really should not need to
disassemble the entire extruder. Just using a 0.4mm (or thinner) drill bit
to pull out any plugs should be sufficient. That'll churn the plug into
small enough pieces that it'll be pushed out with the filament.

J


 
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Jennigma  
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 More options Aug 10 2012, 12:44 pm
From: Jennigma <jleig...@gmail.com>
Date: Fri, 10 Aug 2012 09:44:25 -0700 (PDT)
Local: Fri, Aug 10 2012 12:44 pm
Subject: Re: Issues with new Ultimaker

Just at the moment it's completely plugged- I can't even hand advance
filament. It got mucked up when I was working with the drive motor
yesterday.  

I'm going to turn up the heat and try to bake out the plug and then run ABS
through to see if that will seal it well enough for now. I'm leery of
driving a drill inside the head; I don't think scarring the brass would do
good things for the melted filament flow, not to mention what would happen
if I hit the tip of the nozzle, since I don't have access to a shop to make
a new one.  

Speaking of which, is there some reason I'm not seeing for why the nozzle
and pipe should be separate? I'm not seeing it, but on the other hand I'm
also not seeing a functional printer. If I did have access to a shop, I'd
machine a solid piece of brass down to match the nozzle and threaded tube
assembly and do away with that junction entirely. It serves no purpose, and
just makes for trouble.  I'd like to hear from other folks on this- would
that improve the state of the tech for Ultimakers? for RepRap's generally?

I'm not giving up on getting good seals, but I have other more thorny
problems to solve and I do think the current state of the extruder should
be good enough.

I also rebuilt and (I think) improved the assembly around the filament
drive motor. The grinding I was finding yesterday was caused by the bearing
on the opposite side from the gear wheel getting pulled into the path of
the filament. I pushed both bearings to the outside edge of the plywood,
sanded off every sharp or rough surface on the filament's path, and
reassembled with larger washers that put any pressure on the plywood, not
the bearings.I also put a washer between the acorn nut and the nut in the
center of the drive wheel, and tightened them hard against each other
towards the tip of the threads, making plenty of space for the bolt to
rotate freely in the bearings.  

I'm going to post a flickr set of how I rebuilt this later when I get the
photos off the camera, and I'll update the thread with a link once that's
live. I may not have the damned thing printing yet, but I have enough
mechanical chops to be fairly certain I've made a good improvement and
others might benefit from it.  I'm noodling on the Bowden junctions; there
has to be a good way to mechanically improve them. But that's a problem for
another day.

My partner David ("uzziel") started mucking about with Cura last night
stepping through the tests, and found that the controller appears to reboot
when the filament pushing motor is turned on. That matches behavior I was
seeing yesterday. The motor would turn weakly, then not respond, then turn
well enough to push the filament for a little while, then the box would
reboot. I think we have either bad electronics, a bad drive motor, or
faulty connections.

Today's jobs:

1) Pop the extruder head assembly open to check on the Bowden tube
junction. Melt out the plug if possible, and drive ABS filament through by
hand to try to seal it.  Since I don't want to futz with getting a better
extruder nozzle seal on the pipe I'll kludge it with ABS for the moment.

2) Work through a debugging list I got from Vincent at Ultimaker tech
support, which includes inspecting the electronics and taking a bunch of
pictures, as well as trying to get ReplicatorG working.


 
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David Roth  
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 More options Aug 10 2012, 12:45 pm
From: David Roth <uzz...@gmail.com>
Date: Fri, 10 Aug 2012 09:45:25 -0700 (PDT)
Local: Fri, Aug 10 2012 12:45 pm
Subject: Re: Issues with new Ultimaker

(crossposted from the Ultimaker forums)

My partner Jennifer and I are in the process of trying to get our Ultimaker
to work and it is a huge headache. The machine is displaying some odd
behavior, like powering up the fans and lights when we connect it to our
laptops via the USB cable - it does this even if the power cable for the
printer is not connected yet. It's definitely drawing power over the USB
connection, which neither of us thought was normal.

I tried using the latest Cura download from github last night to run a
calibration test. The first call to DoCommCommandWithTimeout in OnRun in
the configWizard.py module always fails with "Error: Missing start
message." because the output from the printer does not include a line
beginning with 'start'. The output that does come back from the printer
looks something like this:

##############################
2012 17:33:42 +0200 - b67dacdc8f1bd489e058e16d92ba29c364b2a8e5 |
Author: Build-Me-Marlin

echo: Free Memory: 4494 PlannerBufferBy?start

echo: External Reset

Marlin 1.0.0 RC2
###############################

The first line varies in length - sometimes it contains more bytes,
sometimes fewer.

I changed the code to bypass that test and get the wizard to run all the
way to the heating test, XYZ limit tests, and then the extruder test. On
the extruder test it always fails when trying to feed 1000mm of filament. I
modified the code there to print out the response from the printer, and
this is what it's returning when it tries to drive the extruder motor:

###############################
x_min:L x_max:L y_min:L y_max:L z_min:L z_max:L
ok
x_min:L x_max:L y_min:L y_max:L z_min:L z_max:H
objc[71251]: Object 0x105aa4270 of class NSConcreteMapTable
autoreleased with no pool in place - just leaking - break on
objc_autoreleaseNoPool() to debug
objc[71251]: Object 0x10a569e70 of class __NSCFString autoreleased
with no pool in place - just leaking - break on
objc_autoreleaseNoPool() to debug
objc[71251]: Object 0x10a569e70 of class __NSCFString autoreleased
with no pool in place - just leaking - break on
objc_autoreleaseNoPool() to debug
Connecting to: /dev/tty.usbmodemfd121
Serial<id=0x108b9a2d0, open=True>(port='/dev/tty.usbmodemfd121',
baudrate=250000, bytesize=8, parity='N', stopbits=1, timeout=2,
xonxoff=False, rtscts=False, dsrdtr=False)
2012 17:33:42 +0200 - b67dacdc8f1bd489e058e16d92ba29c364b2a8e5 |
Author: Build-Me-Marlin

echo: Free Memory: 4494 PlannerBufferBy?start

echo: External Reset

Marlin 1.0.0 RC2

echo: Last Updated: Marlin-Mon, 11 Jun 2012 17:33:42 +0200 -
b67dacdc8f1bd489e058e16d92ba29c364b2a8e5 | Author: Build-Me-Marlin

echo: Free Memory: 4494 PlannerBufferBytes: 1232

echo:Using Default settings:

echo:Steps per unit:

echo: M92 X78.74 Y78.74 Z533.33 E865.89

echo:Maximum feedrates (mm/s):

echo: M203 X250.00 Y250.00 Z5.00 E45.00

echo:Maximum Acceleration (mm/s2):

echo: M201 X9000 Y9000 Z100 E10000

echo:Acceleration: S=acceleration, T=retract acceleration

echo: M204 S3000.00 T3000.00

echo:Advanced variables: S=Min feedrate (mm/s), T=Min travel feedrate
(mm/s), B=minimum segment time (ms), X=maximum xY jerk (mm/s),
Z=maximum Z jerk (mm/s)

echo: M205 S0.00 T0.00 B20000 X20.00 Z0.40 E5.00

echo:PID settings:

echo: M301 P22.20 I1.08 D114.00
###############################

This looks to me like the arduino board is rebooting when the extruder head
is being activated. Am I interpreting that correctly? Does anyone know if
this would indicate a problem in the board itself?


 
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David Roth  
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 More options Aug 10 2012, 4:13 pm
From: David Roth <uzz...@gmail.com>
Date: Fri, 10 Aug 2012 13:13:35 -0700 (PDT)
Local: Fri, Aug 10 2012 4:13 pm
Subject: Re: Issues with new Ultimaker

Correction to the previous post: it's not the extruder, but the filament
drive motor.  When Cura activates the filament drive motor, the test fails
and the board appears to reboot.


 
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ddurant  
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 More options Aug 10 2012, 4:43 pm
From: ddurant <dduran...@gmail.com>
Date: Fri, 10 Aug 2012 13:43:21 -0700 (PDT)
Local: Fri, Aug 10 2012 4:43 pm
Subject: Re: Issues with new Ultimaker

Dunno about the rest of your issues but on my machine, the Arduino is
powered by USB and the rest of the machine is powered by the brick. It's
normal for the light on the printhead to go on when you plug the USB into
your computer. I don't think my fan is powered by USB too but I could be
wrong there..


 
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Jennigma  
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 More options Aug 10 2012, 6:41 pm
From: Jennigma <jleig...@gmail.com>
Date: Fri, 10 Aug 2012 15:41:56 -0700 (PDT)
Local: Fri, Aug 10 2012 6:41 pm
Subject: Re: Issues with new Ultimaker

Here are the pictures of the clean-up I did on the filament path to remove
all possible sources of scraping other than the drive bolt:

http://www.flickr.com/photos/jleigh/sets/72157631008144654/with/77554...


 
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David Roth  
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 More options Aug 13 2012, 9:53 am
From: David Roth <uzz...@gmail.com>
Date: Mon, 13 Aug 2012 06:53:10 -0700 (PDT)
Local: Mon, Aug 13 2012 9:53 am
Subject: Re: Issues with new Ultimaker

We (Jennifer and I) are pretty confident at this point that we do in fact
have a bad board.

We kept running in to problems with the extruder feeder motor.  It
would turn very, very slowly (<1 rpm) or it would jerk back and forth
without making any forward progress.  We changed the stepper motor
controller chips for the extruder feeder and the Z axis and tested
again with the same results.  We tried to tune the POT on the extruder
feeder controller but were unable to get it to respond any better.

I downloaded the Marlin 1.0.0 RC 2 firmware and edited the pins.h file
to change the pinouts for the E0 controller to match the pinouts for
the E1 controller so that we could use the extra extruder controller
on the board.  After compiling this and uploading it to the board, we
were able to successfully drive all four motors without issue.  We
tried to use the ReplicatorG build from Ultimaker as well as Cura to
control the printer but neither one would allow us to connect with the
new firmware.  Repetier-Host did connect successfully and we were able
to begin a test print.  

When I say that neither ReplicatorG nor Cura would allow us to connect to
the new firmware, I should give more detail - ReplicatorG doesn't seem to
see the printer connected at all.  I cannot get it to show any information
about the printer even after checking the machine and connection settings.
 Cura does connect enough to log messages from the printer, but every time
I try to run the extruder head test, it reboot the board.


 
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David Roth  
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 More options Aug 13 2012, 10:13 am
From: David Roth <uzz...@gmail.com>
Date: Mon, 13 Aug 2012 07:13:34 -0700 (PDT)
Local: Mon, Aug 13 2012 10:13 am
Subject: Re: Issues with new Ultimaker

Update: I just heard from Daid on the Ultimaker boards that it is normal
for Cura to reboot the board when running each step in the config wizard.
 So I may have to give Cura another look.


 
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Jennigma  
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 More options Aug 13 2012, 10:34 am
From: Jennigma <jleig...@gmail.com>
Date: Mon, 13 Aug 2012 07:34:50 -0700 (PDT)
Local: Mon, Aug 13 2012 10:34 am
Subject: Re: Issues with new Ultimaker

I'm pretty happy with Repetier-Host. It seems like the best SW for driving
a printer from a Mac, from what I've seen. I know they use it at Metrix,
our maker space, so I assume it works well for them, too. :-)


 
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