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Basic PLC Programming Table of Contents Cover eBook Table of Contents cittadelmonte.info Page 1 Basic PLC Programming The Role of. PLC Definition Programmable Logic Controllers (PLC) are often defined as miniature industrial computers that contain hardware and software used to perform control functions. The PLC or Programmable Logic Controller has revolutionized the automation industry. Thoroughly practical introduction to PLC use and application - not device specific , ensuring Belanja Buku di Google Play . Tentang pengarang ().
Please click the image below or click here to request your free e-Book. PLC Definition Programmable Logic Controllers PLC are often defined as miniature industrial computers that contain hardware and software used to perform control functions. They are designed for multiple … Read More. Instead what existed was a unique set of challenges that needed a solution. In order to understand the … Read More. What controls you? Instead, think of your body as an industrial control system.
Visualization is the representation statuses of machine for instance the control program being executed, through display or monitor. Also controlling, i. It also became required to interconnect and harmonize individual systems controlled via PLC by means of automation technology.
Therefore a master computer makes easy the means to issue higher- level commands for program processing to some PLC systems.
The networking of some PLCs as well as that of a master computer and PLC is affected through special communication interfaces. To this effect, a lot of the more current PLCs are well-matched with open, standardized bus systems, for instance Profibus to EN The PLCs presently on offer in the market place have been modified to customer demands to such an extent that it has become possible to buy a highly suitable PLC for virtually any application.
Special PLCs are available for shipping or mining, safety technology tasks. Yet further PLCs are capable to process numerous programs concurrently or multitasking. Lastly, PLCs are coupled with other automation components, accordingly creating significantly wider areas of application. Both the PC and its associated peripherals are designed so that they can be easily integrated into an industrial control system and easily used in all their intended functions.
The input module function is to convert incoming signals into signals, which can be processed by the PLC, and to pass these to the central control unit. The reverse task is executed by an output module. This converts the PLC signal into signals appropriate for the actuators. The actual signals processing is affected in the central control unit in compliance with the program saved in the memory.
The PLC program can be created in a variety of methods: In Europe, the use of function block diagrams based on function charts with graphic symbols for logic gates is extensively used.
In America, the ladder diagram is the chosen language by users. Depending on how the central control unit is linked to the modules of input and output, differentiation can be created between compact PLCs input module, central control unit and output module in one housing or modular PLCs.
This took into account non-networked systems of PLC, which mainly perform logic operations on binary signals.
Previously, no comparable, standardized language parts existed for the developments of PLC and system expansions created in the eighties, for example interconnection of intelligent modules, processing of analogue signals, networked PLC systems etc.
Since , an international standard now exists for programmable logic controllers and associated peripheral devices programming and diagnostic tools, testing equipment, man-to-machine interfaces etc. In this context, a device built by the user and consisting of the above components is known as a PLC system. Part 1: General information Part 2: Equipment requirements and tests Part 3: Programming languages Part 4: User guidelines in preparation with IEC Part 5: Messaging service specification in preparation with IEC program-plc.
These components are integral to the controller of PLC. This is shown in a block diagram below: Dependent on the PLC system type i.
Additionally they are modular, allowing simple replacement and addition of units. The choice of the CPU depends on the process to be controlled. Generally 8 or 16 bit CPUs fulfill the requirements sufficiently. The RAM memory is required for the program operation and the input and output data temporary storage. A lot of PLC would support easy memory upgrades. The CPU steps through the control program in another section of the memory and fetches the input variables from the input RAM.
PLC Programming One of the major benefits of the PLC controller is that it is a programmable device, which builds it possible, unlike in the relay logic, to simply design and adapt the control program or process without any changes in the wiring. To create the PLC systems programming easy and efficient, industry standards defining the programming languages and the programming approach used were adopted.
This reduces the requirement for personnel training by creating a set of languages standard for all platforms of PLC on the market. Knowing the PLC programming standards and programming languages is consequently one of the most important considerations for anyone involved in the area of PLC. They are the program mode or some variation of the Run mode.
Program mode may be used to Enter a new program Upload and download files Edit or update existing program Change software configurations Document programs. Variations of the Run mode Run Mode — it is used to execute the user program. Input devices are monitored and output devices are energized accordingly.
Test Mode — it used to operate, or monitor the user program without energizing any outputs. Remote Mode — it allows the PLC to be remotely changed between program and run mode by a personnel computer connected to PLC processor. They are more complex than basic input contacts and output coils and they rely upon data stored in the memory of the PLC. The memory of the PLC is organized to hold different types of programs and data. This chapter will discuss these memory types.
The memory in a PLC is divided into program and variable memory. The program memory contains the instructions to be executed and cannot be changed while the PLC is running.
The variable memory is changed while the PLC is running. In ControlLogix the memory is defined using variable names also called tags and aliases. Additional programs can be created that are called as subroutines.
The power up programs are used to initialize the controller on the first scan. Fault programs are used to respond to specific failures or issues that may lead to failure of the control system. Normally these programs are used to recover from minor failures, or shut down a system safely. IO modules digital, analog or safety module have a variety of requirements, depending on the product.
For IO module solutions: Numerous bit timers with input capture function for time stamping. The division into defined sections leads to targeted, systematic operation and provides clearly set out results, which can be checked against the task. The phase model consisting of the following sections: The phase model can be applied to control programs of varying complexity; for complex control tasks the use of such a model is absolutely essential.
The individual phases of the model are described below. Specification Problem formulation In this phase, a precise and detailed description of the control task is formulated. The specific description of the control system function, formalized as much as possible, reveals any conflicting requirements, misleading or incomplete specifications.
The following are available at the end of this phase: Design Concrete form of solution concept A solution concept is developed on the basis of the definitions established in phase 1.
The method used to describe the solution must provide both a graphic and process oriented description of the function and behavior of the control system and be independent of the technical realization.
Starting with a representation of the overall view of the controller rough structure of the solution , the solution can be refined step by step until a level of description is obtained, which contains all the details of the solution refinement of rough structure. In the case of complex control tasks, the solution is structured into individual software modules in parallel with this. These software modules implement the job steps of the control system.
These can be special Functions such as the realization of an interface for visualization or communications systems, or equally permanently recurring job steps. The displacement-step diagram represents another standard form for the description of control systems apart from the function chart to DIN 40 Phase 3: Realization Programming of solution concept The translation of the solution concept into a control program is effected via the programming languages defined in IEC These are: A sequential function chart, in as far as possible, uses the same program-plc.
Ladder diagram, function block diagram and statement list are the programming languages suitable for the formulation of basic operations and for control systems which can be described by simple operations logic operations or Boolean signals.
The high-level language structured text is mainly used to create software modules of mathematical content, such as modules for the description of control algorithms. In so far as PLC programming systems support this, the control programs or parts of a program created should be simulated prior to commissioning. This permits the detection and elimination of errors right at the initial stage. Phase 4: Commissioning Construction and testing of the control task This phase tests the interaction of the automation system and the connected plant.
In the case of complex tasks, it is advisable to commission the system systematically, step by step. Faults, both in the system and in the control program, can be easily found and eliminated using this method. Established by the International Electro technical Commission IEC a worldwide standard organization founded in and recognized worldwide for standards in the controls industry by over 50 countries.
The standard is already well established in Europe and is rapidly gaining popularity in North America and Asia as the programming standard for industrial and process control. The adoption of IEC by the industry is driven by the increasing software complexity of control and automation requirements. The time to create, labor cost, and maintainability of control software has a major impact on control projects which can be improved using the IEC vendor independent programming language standard.
Applying a standard programming language has a positive impact on the software life-cycle that includes requirements analysis, design, construction, testing validation , installation, operation, and maintenance. The impact on program-plc. The IEC standard combined with new powerful free scale chip architectures enables an entire controller to be delivered in an embedded device.
Control programs can run distributed and independently rather than concentrated in large controllers. No longer are thousands of lines of control programs required running in one controller for complex automation applications. This increases performance, improves reliability, and simplifies programs. IEC provides multiple language support within a control program.
The control program developer can select the language that is best suited to a particular task, greatly increasing their productivity. Plus with a standardized programming interface that is completely independent of the hardware platform, users can greatly reduce the cost of program maintenance and training across company wide automation applications.
IEC is hardware independent. The ability to transport automation solutions to other platforms is vastly improved over PLC applications offering users and System Integrators a level of reusability never before available. IEC increases the efficiency and speed of implementing new automation solutions by using readily available control components developed on other projects and by outside developers. Companies that have chosen to implement IEC find that they reduce human resource costs in training, debugging and maintenance, and improve productivity from the higher reusability.
The unification and standardization of these five languages represent a compromise of historical, regional and branch-specific requirements. Provision has been made for future expansion, such as the function block principle or the language Structured Text plus necessary information technology details data type etc. Two sensors are used to establish whether a work piece with correctly drilled holes is available at the machining position.
If the valve to be machined is of type A or type B — this is set via two selector switches — the cylinder advances and presses the sleeve into the drilled hole. Ladder Diagram LD Ladder diagram is a graphic programming language derived from the circuit diagram of directly wired relay controls. Function Block Diagram FBD In the function block diagram, the functions and function blocks are represented graphically and interconnected into networks.
The function block diagram originates from the logic diagram for the design of electronic circuits. Instruction list is formulated from control instructions consisting of an operator and an operand.
They are however limited to basic functions as far as their elements are concerned. This separates them essentially from the company dialects used today. The competitiveness of these languages is maintained due to the use of functions and function blocks.
Structured Text ST Structured text is high-level language based on Pascal, which consists of expressions and instructions. Instructions can be defined in the main as: Selection instructions such as IF ELSE etc. Structured text enables the formulation of numerous applications, beyond pure function technology, such as algorithmic problems high order control algorithms etc.
Sequential Function Chart SFC The sequential function chart is a language resource for the structuring of sequence-oriented control programs. The elements of the sequential function chart are steps, transitions, alternative and parallel branching. Each step represents a processing status of a control program, which is program-plc.
A step consists of actions which, identical to the transitions, are formulated in the IEC languages. Actions themselves can again contain sequence structures. This feature permits the hierarchical structure of a control program. The sequential function chart is therefore an excellent tool for the design and structuring of control programs. The primary concept behind a FBD is data flow. In these types of programs the values flow from the inputs to the outputs, through function blocks. A sample FBD is shown in figure below.
The result of this calculation is compared to C. If the calculated value is less than C then the output X is turned on, otherwise it is turned off.
Many readers will note the similarity of the program to block diagrams for control systems. It is possible to disable part of the FBDs using enables.
These are available for each function block but may not be displayed. Figure shows an XOR calculation. The connecting lines will have a data type that must be compatible on both ends. The inputs and outputs of function blocks can be inverted. This is normally shown with a small circle at the point where the line touches the function block, as shown in figure below.
Consider the basic addition function shown in figure below. The function block on the right is equivalent. By convention the inputs are on the left of the function blocks, and the outputs on the right. Some functions allow a variable number of arguments.
In Figure below there is a third value input to the ADD block. This is known as overloading. In the second function the MX value is not defined and will default to 0. Both of the ST functions relate directly to the function blocks on the right side of the figure. Creating Function Block When developing a complex system it is desirable to create additional function blocks. Figure below shows a divide function block created using ST. The input variables a and b, and the output variable c are declared.
In the function the denominator is checked to make sure it is not 0. If not, the division will be performed; otherwise the output will be zero. Invented to replace hardwired relay control systems, Ladder Diagram programming is a mainstay in the U. Ladder Diagram language has experienced such widespread adoption that almost every programmer in any country or industry can read and write this language. Because it resembles the familiar electric circuit format, even a non-programmer with an electrical background can follow the program for purposes of troubleshooting a problem.
With just a basic outline of input and output signals, one can sit down are start churning out code. Most of the other IEC languages require more preparation, such as flowcharting all the potential process flows.
Finally, most implementations of Ladder Diagram allow a program to be organized into folders or subprograms that are downloaded to the PLC, allowing for easy segmentation. Ladder Diagram programming is ideal for a simple material handling application, for example, where a sensor detects the presence of a box, other sensors check for obstructions, and then an output fires an actuator to push the box to another conveyor. Digital inputs are checking for various program-plc.
There may be timers in the program, or some basic comparisons or math, but there are no complex functions involved. As the complexity of PLC functionality has grown, however, Ladder Diagram language has been challenged to meet these advances and still maintain the paradigm of easy visualization and understanding.
Functions such as PID, trigonometry and data analysis are commonly required in many control applications, but difficult to implement.
Finally, implementing full processes in Ladder Diagram can be daunting — picture a ladder rung with an output used in several phases of a process with many input conditions attempting to control exactly when that output needs to turn on.
This language consists of many lines of code, with each line representing exactly one operation. Thus, it is very step-by-step in layout and format, which makes the entry of a series of simple mathematical functions easy. In addition, if the programmer uses only the IEC defined instructions, a program written in this language can be moved easily between hardware platforms. These advantages make this language very popular in Europe, a fact that is surprising to many U.
Instruction List language is a low level language and as such, will execute much faster in the PLC than a graphical language, like Ladder. This language is also much more compact and will consume less space in PLC memory.
The simple one line text entry method supported by this language also allows for very fast program entry — no mouse required, no tab to click! In legacy systems, programs written in this language are easier to display and edit on a handheld programming unit, with no software or laptop required.
Perhaps because it is less visual than Ladder, and Therefore more difficult to get a sense of what the program is doing and what errors it is experiencing. This also applies to complex mathematical computations. Instruction List does not lend itself well to any form of structured programming, such as state programming or step ladder, further limiting its usefulness for implementing large programs.
It is also arguable that the advantages of speed and compactness are less relevant, given the processing speeds of modern PLCs and the large amounts of memory available. Therefore mentioned Control Engineering survey indicated that of all the IECdefined programming languages, Structured Text has seen the greatest increase in adoption.
This language perhaps best embraces the growing complexity of PLC programming, such as the process control functions involved in plastics or chemical manufacturing.
Trigonometry, calculus, and data analysis can be implemented far easier in this language than in Ladder or Instruction List. Decision loops and pointers variables used to do indirect addressing allow for a more compact program implementation than can be achieved in Ladder. The flexible Structured Text editor that is common in most programming packages makes it easy to insert comments throughout a program, and to use indents and line spacing to emphasize related sections of code.
This makes the task of structuring a complex program easier. The text-based, non-graphical nature of Structured Text, similar to Instruction List, also runs much faster than Ladder. An additional benefit of Structured Text is that it comes closer than most of the other languages in achieving the transferability promise of the IEC standard.
Copying and pasting Structured Text from the editor of one programming package to another can often be done with just a few changes, emancipating a programmer from the hardware platform. A final benefit is that many students currently graduating from engineering studies have a better background in computer languages than in the basics of electrical wiring, and therefore can be more proficient in Structured Text than Ladder programming.
Text environment is somewhat unfamiliar and unsuitable for troubleshooting. In many ways, the code and structure necessary to make this code maintenance friendly can reduce some of the advantages gained from its compactness.
Thus the programmer is most likely to encapsulate a Structured Text program inside an instruction called on in Ladder. Structured Text ST is a high level textual language that is a Pascal like language. Structured Text is very flexible and intuitive for writing control algorithms. Structured Text uses operators such as logical branching, multiple branching, and loops.
People trained in computer programming languages often find it the easiest language to use for programming control logic.
When symbolic addressing is used, ST programs resemble sentences, making it highly intelligible to beginner users as well. The concept of SFC Is simple: The current action box is for appropriate applications which have a repeatable multi-step process or series of repeatable processes, this form of programming is the easiest to implement. An example would be a pick and place application, where product is constantly picked up from one area, moved through a specific path, and placed in another area.
While exceptions exist, since there is typically only one active piece of code and one transition to be concerned with, condition checking and the control of the process should be achievable without large rungs.
The language is also very friendly to maintenance engineers because the visual nature of the program plus code segmentation makes it easy to troubleshoot. On the downside, this style of programming is not suitable for every application, as the structure that is forced on a program could add unneeded complexity.
A large amount of time must be spent up front preparing and planning before any programming is attempted or else the functions charts could become unwieldy and difficult to follow. The overhead required for this type of program causes it to execute slower than the other languages. A final consideration is the inability to convert to other languages. Instruction List, Function Block and Ladder programs can easily be converted into each other, allowing a piece of code to be displayed in the way most comfortable to the user.
It cannot be converted. Therefore, you may want to consider this language only for end users who are comfortable with the language and are unlikely to display it in a different format or for applications where the hardware has the speed and memory necessary to store and execute an SFC program. In general, a control system is a collection of electronic devices and equipment hich are in place to ensure the stability, accuracy and smooth transition of a process or a manufacturing activity.
It takes any form and varies in scale of implementation, from a power plant to a semiconductor machine. As a result of rapid advancement of technology, complicated control tasks accomplished with a highly automated control system, which may be in the form of PLC Programmable Logic Controller and possibly a host computer etc. Besides signal interfacing to the field devices such as, motors, sensors, solenoid valves, operator panel and etc, capabilities in network communication enable a big scale implementation and process co-ordination besides providing greater flexibility in realizing distributed control system.
With a control application program in execution, the PLC constantly monitors the state of the system through the field input devices feedback signal. It will then based on the program logic to determine the course of action to be carried out at the field output devices.
The PLC may be used to control a simple and repetitive task, or a few of them may be interconnected together with other host controllers or host computers through a sort of communication network, in order to integrate the control of a complex process. Push buttons, keypad and toggle switches, which form the basic man-machine interface, are types of manual input device. On the other hand, for detection of work piece, monitoring of moving mechanism, checking on pressure and or liquid level and many others, the PLC will have to tap the signal from the specific automatic sensing devices like proximity switch, limit switch, photoelectric sensor, level sensor and so on.
Output Devices An automatic system is incomplete and the PLC system is virtually paralyzed without means of interface to the field output devices. Some of the most commonly controlled devices are motors, solenoids, relays indicators, buzzer and etc. These type of output devices are the mechanism of an automated system and so its direct effect on the system performance.
The program controls the PLC, so that when an input signal from an input device turns ON, the appropriate response made. The response normally involves turning ON an output signal to some sort of output devices. Memory There are various types of memory unit. It is the area that hold the operating system and user memory. It is therefore unsuitable.
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It is least popular as compared with others memory type. The data in the volatile RAM would be normally be lost if the power source is removed. However its content can be erased by exposing it to ultraviolet light. Its contents can be erased and reprogrammed electrically, however, to a limit number of times. These relays were all hardwired together inside the control panel was so huge that it could cover the entire wall.
Every connection in relay logic must be connected. Wiring is not always perfect, it takes time to troubleshoot the system. It is a very time consuming affair. Disadvantage of conventional control panel In this panel we can observe the below points: There are too many wiring work in the panel.
Modification can be quite difficult. Troubleshooting can be quite troublesome as you may require a skillful person. Power consumption can be quite high as the coil consumes power. Machine downtime is usually long when problems occur, as it takes longer time to troubleshoot the control panel.
Drawings are not updated over the years due to changes. It causes longer downtime in maintenance and modification. Advntages of PLC control panel Here are the major advantages that can be distinguishably realized. The power consumption is greatly reduced as PLC consumes much less power. The PLC self diagnostic functions enable easy and fast troubleshooting of the system. In PLC system spare parts for relays and hardware timers are greatly reduced as compared to conventional control panel.
The machine cycle time is improved tremendously due to the speed of PLCs operation is a matter of milliseconds. The PLC reliability is higher than the mechanical timers and relays. The CPU Unit has 6 inputs and 4 outputs built in. CPU unit has 8 input points and 6 output points. CPU unit has 12 input points and 8 output points. CPU unit has 18 input points and 12 output points. CPU unit has 24 input points and 16 output points.
CPU unit has 36 input points and 24 output points. The following components are to be used. LS2 4. MO1 program-plc. MO2 5. First, however, the functions of the ladder program will be described. Operation The ladder program to be created will open and close a garage shutter. Entering the Garage program-plc. The shutter can be opened, closed, and stopped with buttons. A self-maintaining bit is used to achieve this. When the shutter is fully opened or fully closed, it will be stopped by a limit switch.
When the shutter is opening, the de-escalation motor will be interlocked to prevent damage. A light detection sensor detects light from headlights pointed at the garage. When 3 headlight flashes are detected by a counter instruction, the shutter escalation motor is activated. After the first headlight flash, a timer is activated by a timer instruction.
After 5 seconds, a reset command is given to the counter instruction. A car detection sensor will detect full car entrance into the garage, and activate the shutter de-escalation motor. When pulling the car out of the garage, use the buttons to operate the shutter. When pulling the car out of the garage, a differentiated up contact should be used as the car detection sensor, so that the shutter does not close immediately upon fully opening.
A ladder program will be set forth hereafter based on the description above. Ladder Program The ladder program for the example application is shown below.
The title screen will be displayed, followed by the main window. For details on using CX-Programmer. Place the mouse cursor over an icon to display the corresponding function name.
Drag the toolbars to change their position. Displays the following information: Displays program check results. Displays search results for contacts, instructions, and coils. Displays errors which occurred while loading a project file.
If an online connection error or other errors occur and are recorded by the error log while online, a blinking red error message will be displayed. Diagram Workspace 1 Rung number 2 Program address 3 Rung header If a rung is incomplete, a red line will be displayed to the right of its rung header.
This is covers the functions of the highest specification PLC. For this reason, the following indicator is included to show which PLCs applies to: FX Family This is a generic term which is often used to explain all programmable controllers without identifying individual types or model names. Because of the nature of PLCs, that can be likened to industrial computers, changes sometime occur within the units main CPU.
These changes are similar to those experienced by office and home computer users, that is going to a version up processor. The following lists identify the CPU versions that had significant upgrades or new functions and features added.
N network. CPU Ver 1. The following device ranges were added: Total combined input and output points is CPU Ver 3. The following instructions were removed: However, programming certain standard applied instructions in conjunction with specially auxiliary coils M coils can achieve the same effective instructions as the new instructions. The following tables identify which version of peripheral software will program-plc.
A program is a connected series of instructions written in a language that the PLC can understand. There are three forms of program format, instruction, ladder and SFC? Generally hand held programming panels only work with instruction format while most graphic programming tools will work with both instruction and ladder format.
Specialist programming software will also allow SFC style programming. This Displays the main program window: The usual buttons for minimizing and resizing the program window and exiting the program are located at the right hand end of the title bar. Clicking on a menu title displays a drop-down menu with a list of options that you can select.
Toolbars Many of the most frequently used program functions can be accessed directly with the tools icons in the toolbars.
Status bar The status bar displays some useful information, including the current PLC type and editing mode. You can also activate and deactivate the status bar in the View menu. Editing screen The editing screen is where you do your programming and documentation work.
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You can have multiple editing and dialog windows open at the same time. Project data list The program, its documentation and the parameters for the FX controller are stored together in a project.
The project data list shows the directories in which the components of the current project are stored. The default name assigned to this program is MAIN. You can rename MAIN if you want. To do this select the MAIN entry and then right click on it to display the context menu and select Rename. These comments can be displayed in the program. You can enter and edit these comments by opening the Device comment file in the project data list.
Parameter Double-clicking on PLC parameter in the project data list opens a dialog in which you can enter and adjust all the settings necessary for the operation of the PLC. To create a device memory file select Device memory in the project data list and right-click to display the context menu. Then select New…and enter the name of the file you want to create. To open the file containing the device memory values just double-click on its name in the project data list.
You can select between a variety of data display formats and you can also switch between hexadecimal and decimal modes. Each device has its own unique use. Account Options Login. Koleksiku Bantuan Penelusuran Buku Lanjutan. Lihat eBuku. Access Online via Elsevier Amazon. Programmable Logic Controllers. William Bolton. This is the introduction to PLCs for which baffled students, technicians and managers have been waiting.
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In this straightforward, easy-to-read guide, Bill Bolton has kept the jargon to a minimum, considered all the programming methods in the standard IEC - in particular ladder programming, and presented the subject in a way that is not device specific to ensure maximum applicability to courses in electronics and control systems.
Now in its fourth edition, this best-selling text has been expanded with increased coverage of industrial systems and PLCs and more consideration has been given to IEC and all the programming methods in the standard. The new edition brings the book fully up to date with the current developments in PLCs, describing new and important applications such as PLC use in communications e. Ethernet - an extremely popular system , and safety - in particular proprietary emergency stop relays now appearing in practically every PLC based system.
The coverage of commonly used PLCs has been increased, including the ever popular Allen Bradley PLCs, making this book an essential source of information both for professionals wishing to update their knowledge, as well as students who require a straight forward introduction to this area of control engineering.
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