Voltage Withstand Test: Exposed to 2.0kV (phase-to-neutral) and 3.0kV (phase-to-phase) for 5 minutes without electrical breakdown, confirming its ability to handle unexpected voltage spikes.
Insulation Resistance Test: Measures ≥100 MΩ at 20°C using a megohmmeter, ensuring minimal leakage current and efficient power transmission—critical for industrial processes where energy waste directly impacts operational costs.
Short-Circuit Current Test: Withstands a 15 kA short-circuit current for 1 second, protecting the cable and connected industrial equipment (e.g., circuit breakers, variable frequency drives) from damage during fault conditions.
Salt Spray Electrical Test: After 1,000 hours of salt spray exposure (per ASTM B117), the cable maintains ≥80% of its initial insulation resistance, verifying electrical performance in corrosive coastal environments.
At 30°C ambient temperature: 70–80 amps (sufficient to power a 30kW three-phase motor, common in coastal manufacturing plants).
At 40°C (typical in coastal summer months): 65–75 amps (maintaining performance during peak temperature and load periods).
Improves Flexibility, allowing the cable to be routed around industrial infrastructure (e.g., storage tanks, conveyor systems) without conductor damage.
Enhances mechanical strength, with a minimum breaking strength of 3.2 kN—resisting tension from strong coastal winds or accidental pulls during maintenance.
Thermal Stability: Operates reliably across -40°C to 90°C, adapting to coastal temperature fluctuations (e.g., cold winter fog to hot summer sun) and industrial heat sources (e.g., nearby boilers, machinery exhaust). Unlike PVC Insulation (which softens at 70°C), XLPE maintains structural integrity at 90°C, preventing insulation melting in high-temperature industrial zones.
Corrosion Resistance: Resists degradation from saltwater spray (≤0.1% water absorption after 24 hours of immersion) and industrial chemicals (e.g., 50 ppm chlorine from desalination plants, 100 ppm sulfur dioxide from manufacturing emissions). In Chemical Resistance tests, the insulation shows no cracking, swelling, or discoloration after 500 hours of exposure to these contaminants.
UV Resistance: Maintains 90% of its tensile strength after 2,000 hours of UV exposure (per ISO 4892-3), protecting against sunlight degradation in open-air industrial yards.
Thickness and Durability: 1.2mm insulation thickness per core—calibrated to meet the 0.6/1kV voltage rating while providing a physical barrier against salt, dust, and industrial debris. The insulation’s shore hardness (D scale) of 65–70 ensures resistance to abrasion from industrial equipment or installation tools.
Bundled Configuration: Integrates four Insulated Conductors into a single compact unit (outer diameter: 18–22mm), reducing clutter on utility poles and minimizing the risk of damage from industrial operations (e.g., falling cargo, heavy machinery movement). The conductors are twisted in a helical pattern with a pitch of 20–25 times the cable’s outer diameter (300–350mm), enhancing flexibility for navigating tight spaces between industrial buildings or equipment.
Galvanized Steel Messenger: Most variants include a 12mm² galvanized steel messenger wire, integrated into the bundle to provide mechanical support for overhead installation. The messenger’s key properties for coastal industrial use:
Corrosion Resistance: Coated with a zinc-aluminum alloy (55% Al, 43.5% Zn, 1.5% Si) via hot-dip galvanizing, maintaining 95% of its tensile strength after 1,000 hours of salt spray exposure.
Mechanical Strength: Tensile strength of 1.8–2.2 kN, enabling spans of up to 50 meters between utility poles—ideal for large industrial yards where pole spacing is wide to accommodate heavy equipment.
Vibration Resistance: Damping properties reduce vibration from industrial machinery or strong coastal winds, preventing conductor fatigue and extending the cable’s service life.
Aluminum Alloy Corrosion Resistance: The alloy’s magnesium and silicon additives form a dense, self-healing oxide layer that blocks salt ions and industrial chemicals. In accelerated tests, it outperforms pure aluminum by 40% in corrosion resistance—critical for coastal industrial sites where unprotected conductors fail within 5–7 years.
System - Level Anti - Corrosion Design: All metal components (conductors, messenger, connectors) are treated with multi-layer protection:
Conductors: Cerium conversion coating (0.5–1μm thick) before insulation, enhancing XLPE adhesion and adding a secondary corrosion barrier.
Messenger: Zinc-aluminum alloy coating (8–10μm thick), resisting pitting corrosion from saltwater and industrial pollutants.
Connectors: Compression connectors made of the same aluminum alloy, pre-coated with conductive, anti-corrosive grease (containing molybdenum disulfide) to prevent galvanic corrosion between dissimilar metals.
Industrial - Grade Durability: The cable’s XLPE insulation and alloy conductors withstand mechanical abuse common in industrial settings—such as impacts from tools, abrasion from conveyor belts, and exposure to oil or grease—without performance degradation.
Compatibility with Industrial Hardware: Designed to work with standard industrial electrical components, including:
600V industrial circuit breakers (e.g., Siemens 3VA series).
Waterproof cable glands (IP68 rated) for outdoor industrial enclosures.
Heat-shrinkable termination kits (for connecting to motor terminals or switchgear).
Port and Maritime Facilities:
Coastal Manufacturing Plants:
Desalination Facilities:
Offshore Support Infrastructure:
Chemical and Petrochemical Plants:
Aluminum Alloy Conductors:
Corrosion Resistance: The alloy (Al-Mg-Si-Cu) forms a stable oxide layer that blocks salt ions—unlike pure aluminum, which develops porous corrosion. In ASTM B117 salt spray tests, the alloy maintains 90% conductivity after 1,000 hours, vs. 65% for pure aluminum.
Mechanical Strength: Tensile strength of 180–220 MPa (30–40% higher than pure aluminum), resisting damage from industrial machinery vibration or coastal winds.
Cost and Weight Efficiency: 40–50% less expensive than copper, reducing upfront costs for large industrial projects. At 2.7 g/cm³ (same density as pure aluminum), it is 3x lighter than copper, simplifying installation on tall industrial poles or over wide yards.
XLPE Insulation:
Chemical Resistance: Outperforms PVC in resisting chlorine, sulfur dioxide, and saltwater—PVC degrades 50% faster in these environments.
Thermal Stability: Wider operating temperature range (-40°C to 90°C) than rubber (which hardens below 0°C) or PE (which softens above 60°C).
Longevity: 25–30 year service life (vs. 10–15 years for PVC), aligning with the typical lifespan of industrial equipment and reducing replacement cycles.
Galvanized Steel Messenger:
Corrosion Resistance: 5x more resistant to saltwater corrosion than standard zinc, per ASTM B117 tests.
Adhesion: Bonds tightly to the steel core, preventing flaking in industrial environments where vibration is common.
Anti - Corrosion Additives:
Compact Bundled Layout: The 18–22mm outer diameter fits through tight spaces in industrial facilities (e.g., between equipment racks, inside conduit runs) and reduces wind load on utility poles—critical in coastal areas prone to hurricanes or strong gales.
Color - Coded Cores: Each core is color-coded (red, yellow, blue for phases; black for neutral) to simplify installation and maintenance. Industrial electricians can quickly identify conductors during repairs, minimizing downtime for critical industrial processes.
Reinforced Insulation at Stress Points: The insulation is 10% thicker (1.3mm vs. 1.2mm) at the cable’s ends and messenger attachment points—areas prone to mechanical stress during installation or industrial use—preventing insulation tearing.
Smooth Outer Surface: The bundled cable’s smooth XLPE outer sheath (optional in some variants) repels salt, dust, and industrial debris, making cleaning easier and reducing the risk of corrosion from trapped contaminants.
Alloy Melting and Casting: High-purity aluminum ingots (99.7% purity) are melted in a gas-fired furnace at 660°C, then mixed with magnesium (1.5%), silicon (0.8%), and copper (0.2%) to form the corrosion-resistant alloy. The molten alloy is cast into 12mm diameter billets.
Wire Drawing: Billets are extruded into 1.0mm diameter wires using a diamond die, then drawn through a series of cold-drawing dies to refine diameter and improve tensile strength. The drawing process is conducted in a controlled atmosphere to prevent oxide formation on the wire surface.
Stranding: 19 wires are twisted into 16mm² conductors using a stranding machine operating at 120–150 RPM. The twist pitch is set to 12–15mm to balance flexibility and strength, with constant tension monitoring to ensure uniform stranding.
Anti - Corrosion Coating: Conductors are dipped in a cerium conversion coating bath (50°C) for 2–3 minutes, forming a 0.5–1μm thick protective layer. The coated conductors are dried in a nitrogen-filled oven at 120°C to cure the coating and prevent oxidation.
Material Preparation: XLPE resin is mixed with UV stabilizers (2.5%), corrosion inhibitors (1.5%), and cross-linking agents (dicumyl peroxide, 1.0%) in a high-speed mixer. The mixture is pelletized to ensure uniform additive distribution.
Extrusion: Pellets are fed into a twin-screw extruder heated to 160–180°C, where they melt into a viscous fluid. The molten XLPE is extruded over the aluminum alloy conductors via a cross-head die, forming a 1.2mm thick insulation layer. The die is precision-calibrated to ensure uniform thickness—critical for electrical safety and corrosion resistance.
Cross - Linking (Curing): Insulated conductors are passed through a vertical curing tube heated to 200–250°C for 5–10 minutes. The high temperature activates the cross-linking agent, transforming the linear XLPE polymer into a three-dimensional network with enhanced thermal and chemical resistance.
Cooling and Quality Check: Conductors are cooled in a water bath at 20–30°C to solidify the insulation, then dried with compressed air. Each insulated conductor is inspected for insulation thickness (via laser micrometers) and surface defects (via visual inspection cameras).
Core Bundling: Four insulated conductors (three phases + one neutral) are fed into a bundling machine, which twists them into a single bundle with a 20–25x pitch (300–350mm). The machine applies constant tension (50–70 N) to ensure tight, uniform bundling without damaging the insulation.
Messenger Integration: The 12mm² galvanized steel messenger wire is fed into the bundling machine and bonded to the core bundle using a small amount of molten XLPE (180°C). The bonding process ensures the messenger and cores move as a single unit, preventing relative movement that could cause wear in high-vibration industrial environments.
Optional Outer Sheath Extrusion: For industrial sites with high debris or chemical exposure, an additional 0.8mm thick XLPE outer sheath is extruded over the bundled cable. The sheath is colored black (for UV resistance) and with the cable’s specifications printed on it (e.g., “0.6/1kV 4×16mm² XLPE”) for easy identification.
Electrical Tests:
Insulation resistance: Measured at ≥100 MΩ (20°C) using a 1kV megohmmeter.
Voltage withstand: Exposed to 3.0kV (phase-to-phase) for 5 minutes, with no breakdown.
Conductor resistance: ≤1.15 Ω/km (20°C) for 16mm² alloy conductors.
Mechanical Tests:
Tensile strength: Conductor breaking strength ≥3.2 kN; messenger breaking strength ≥1.8 kN.
Flexibility: Bent 180° around a 22mm mandrel (10 times), with no insulation cracks.
Corrosion Tests:
Salt spray: 1,000 hours per ASTM B117, with ≥80% insulation resistance retention.
Chemical resistance: 500 hours exposure to 50 ppm chlorine, with no insulation swelling.
Reels:
500-meter reels: Outer diameter 1.5m, hub diameter 0.6m, weight (empty) 80kg. Suitable for small to medium projects (e.g., a 500m section of a port warehouse).
1000-meter reels: Outer diameter 1.8m, hub diameter 0.8m, weight (empty) 120kg. Ideal for large-scale installations (e.g., 1km of cable for a desalination plant).
Protective Layers:
Inner layer: 0.1mm thick LDPE (low-density polyethylene) film, sealed to prevent moisture and saltwater ingress.
Outer layer: UV-resistant polypropylene woven fabric, protecting against sunlight degradation during outdoor storage.
Product Identification: Clear text stating “ABC Cable 0.6/1kV 4×16mm² Aluminum Alloy/XLPE for Coastal Industry,” part number, and batch number.
Technical Specifications: Voltage rating, conductor size, insulation type, messenger size, and length (500m/1000m).
Compliance Marks: Symbols for IEC 60502-1, ASTM B233 (aluminum alloy conductors), and IP68 (waterproof termination compatibility).
Handling Warnings: Bold text highlighting “Store in dry, ventilated area,” “Avoid saltwater contact before installation,” and “Use gloves when handling to prevent oil transfer to insulation.”
Traceability Info: Production date, QC signature, and a QR code linking to the batch’s test report (accessible via the manufacturer’s website).
Indoor Storage:
Temperature: 5°C–30°C (to prevent insulation brittleness or softening).
Relative humidity: ≤60% (to avoid condensation on the cable or reel).
Elevation: Placed on wooden pallets (10cm high) to prevent contact with damp floors.
Outdoor Storage:
Covered with a waterproof, UV-resistant tarpaulin (minimum 20-ounce weight), secured with bungee cords to prevent wind damage.
Placed on concrete blocks (15cm high) to avoid water pooling around the reel base.
Inspected weekly for signs of moisture ingress (e.g., dampness on the fabric layer) or corrosion on the reel.
Pre - Installation Inspection:
Insulation damage (cracks, punctures) from storage or transportation.
Conductor corrosion (discoloration, pitting) visible at the cable ends.
Messenger coating integrity (no flaking or rust).
Road Transportation:
Steel straps (12mm thick) tensioned to 80 N·m, with rubber edge protectors to prevent reel flange damage.
Wooden blocking (10×10cm) placed between reels to prevent shifting during turns.
Rail Transportation:
Chain binders (rated for 500kg) attached to the railcar’s tie-down points.
VCI foam pads between reels to prevent abrasion and corrosion.
Sea Transportation:
20-foot container: Holds 8–10 reels of 500m cable (total weight ≈4,000kg) or 4–5 reels of 1000m cable.
Protection Measures: Containers are lined with VCI film to maintain a corrosion-inhibiting environment, and reels are separated by foam padding to prevent shifting during rough seas.
Climate Control: For shipments to extreme climates (e.g., Middle Eastern summer temperatures exceeding 45°C), refrigerated containers set to 25–30°C are used to prevent XLPE insulation softening.
Air Transportation:
Loading Protocols:
Pre-Load Inspection: The logistics team inspects each reel for damage (dented flanges, torn protective layers) and verifies that VCI paper/film is intact. The transport vehicle/container is checked for moisture (using a humidity meter) and cleaned of debris.
Equipment Setup: A forklift with a reel clamp attachment (rated for 1,000kg) or a crane with a spreader bar is used. The clamp/spreader bar is wrapped in non-abrasive rubber to avoid scratching the reel’s powder coating.
Positioning: Reels are placed with their flanges perpendicular to the direction of travel. For sea containers, reels are secured to the container floor using bolt-down brackets (4 brackets per reel) to prevent movement during storms.
Unloading Protocols:
Site Preparation: The coastal industrial site must have a flat, concrete unloading area (to avoid reel tipping) and be cleared of saltwater puddles (to prevent cable contact with saltwater).
Controlled Lifting: The same equipment used for loading is deployed, with a spotter guiding the operator to avoid collisions with industrial infrastructure (e.g., port cranes, storage tanks).
Post-Unloading Check: The customer’s on-site team inspects reels for transit damage (e.g., moisture inside the protective layer, corrosion on reel flanges) and signs a delivery receipt. Any damage is documented with photos, and a claim is filed with the carrier within 24 hours.
Bill of Lading (BOL): A legal document from the carrier, detailing the shipment’s origin, destination, number of reels, and total weight. For sea shipments, a “clean on board” BOL is required to confirm reels were loaded in good condition.
Commercial Invoice: Lists the product’s unit price, total cost, and HS code (3926.90.90 for Insulated power cables) for customs duty assessment. It includes a note confirming the cable’s corrosion-resistant properties (critical for duty exemptions in some coastal industrial zones).
Certificate of Compliance (CoC): Issued by the manufacturer, this document verifies the cable meets IEC 60502-1, ASTM B233, and local coastal industrial standards (e.g., UAE’s ESMA standards for corrosion resistance).
Test Report Summary: A condensed version of the batch’s test results, including salt spray resistance, insulation resistance, and tensile strength data—required by many industrial clients for quality audits.
Order Confirmation: Upon receiving an order, the sales team sends a confirmation email within 24 hours, outlining the order details (quantity, length, messenger inclusion) and providing a lead time:
Standard orders (500m/1000m reels, no customizations): 2–3 weeks (in-stock materials).
Custom orders (e.g., 300m reels with extra VCI protection): 3–4 weeks (requires adjusted production runs).
Production Scheduling: The production team prioritizes orders for critical coastal industrial projects (e.g., a desalination plant with a government-mandated startup date) by allocating dedicated production slots.
Pre-Shipment Notification: 3–5 days before dispatch, the logistics team sends an email with the tracking number, carrier details, and expected delivery date (EDD), allowing the customer to prepare the unloading site.
Online Portal: A secure login on the manufacturer’s website displays the shipment’s location (e.g., “At Jebel Ali Port, Dubai”), transit status, and EDD. For sea shipments, it integrates with container tracking tools (e.g., Maersk Line’s Track & Trace).
SMS/Email Alerts: Automated updates are sent at key milestones: “Shipment dispatched from Shanghai factory,” “Container cleared customs in Singapore,” “Delivery scheduled for 10 AM tomorrow.”
Dedicated Logistics Coordinator: For large orders (≥50 reels), a coordinator is assigned to address questions (e.g., “Will the shipment arrive before the plant’s startup date?”) and resolve delays (e.g., rerouting due to port congestion).
Order Size | Road (300km) | Rail (1500km) | Sea (Shanghai-Singapore) | Air (Dubai-Oman) |
5 reels (500m) | \(400–\)600 | \(1,200–\)1,500 | \(1,800–\)2,200 | \(900–\)1,200 |
20 reels (1000m) | \(1,500–\)2,000 | \(3,500–\)4,000 | \(5,000–\)6,000 | \(3,500–\)4,500 |
Coverage: 1.5% of the total order value (e.g., \(150 for a \)10,000 order) covers full replacement of damaged reels.
Claims Process: If damage occurs, the customer submits photos and a completed claim form within 48 hours. The manufacturer processes claims within 5–7 days, with replacement reels shipped via air for emergency cases.
Online Form: A form on the manufacturer’s website asks for:
Company details (name, address, contact person for the coastal industrial project).
Project scope (e.g., “port warehouse expansion in Jeddah,” “desalination plant in Perth”).
Sample specifications (length: 1–5m, messenger inclusion: yes/no, extra VCI protection: yes/no).
Sales Representative: Direct requests to the assigned rep, who can arrange for customized samples (e.g., 3m lengths with exposed conductors to test corrosion resistance).
Industrial Trade Shows: Samples are available at events like the International Port & Terminal Expo, where clients can test the cable’s flexibility and inspect the alloy conductor’s finish.
In-stock samples (1m, standard specs): Shipped within 1–2 business days.
Custom samples (5m, extra VCI): Shipped within 3–4 business days.
Physical Specifications: A 1m sample of the 4×16mm² cable includes:
4 Insulated Cores (1.2mm XLPE insulation), each with 19 strands of 1.0mm aluminum alloy wire.
12mm² galvanized steel messenger (if requested), with zinc-aluminum coating.
VCI paper wrapping (for coastal samples) to prevent corrosion during transit.
Included Documentation:
A “Sample Datasheet” summarizing key specs (voltage rating, ampacity, corrosion resistance test results).
A “Compatibility Guide” listing recommended industrial connectors (e.g., IP68-rated compression lugs) and termination tools.
A small vial of the same anti-corrosive grease used in production, allowing clients to test compatibility with their hardware.
Cost: Standard 1m samples are free for qualified coastal industrial clients (licensed contractors, industrial facility operators). Custom samples (5m, extra VCI) cost \(40–\)70, refundable if an order of ≥500m is placed within 30 days.
Shipping: Domestic shipping (within the same country) is free via courier (e.g., Aramex for Middle Eastern clients, DHL for European clients). International shipping costs \(30–\)80 (e.g., \(30 to Saudi Arabia, \)80 to Australia) and includes VCI packaging to protect against saltwater during transit.
Installation Manual: Every order includes a 70-page, illustrated manual (print and digital PDF) with:
Step-by-step guides for coastal industrial installation: “Tensioning the messenger for 50m spans in high-wind areas,” “Waterproof termination for saltwater-exposed connections,” “Inspecting for corrosion during installation.”
Safety protocols: “Wearing corrosion-resistant gloves when handling conductors,” “Using insulated tools near saltwater,” “Avoiding cable contact with industrial chemicals.”
Troubleshooting section: Solutions for common coastal issues (e.g., “Insulation discoloration from salt spray,” “Messenger tension loss due to humidity”).
Technical Hotline: A 24/7 toll-free hotline connects clients to engineers with expertise in coastal industrial applications. For example, if a client struggles with corrosion on conductor terminations, the engineer can recommend a specialized anti-corrosive tape and provide video guidance for application.
On-Site Support: For orders ≥1000m or complex projects (e.g., cable installation near a saltwater intake for a desalination plant), the manufacturer dispatches a technical specialist to the site for 2–3 days. The specialist:
Trains the installation team on handling the aluminum alloy conductor (e.g., avoiding scratches that could compromise corrosion resistance).
Inspects the first 100m of installed cable for compliance with coastal industrial standards.
Provides a “Corrosion Prevention Checklist” to guide long-term maintenance.
Material Defects: Issues arising from substandard materials, such as:
Aluminum alloy conductors corroding within 15 years (in non-extreme coastal conditions).
XLPE insulation cracking or swelling due to manufacturing flaws (not chemical exposure beyond rated limits).
Messenger wire coating flaking off due to poor galvanizing.
Workmanship Errors: Problems caused by manufacturing mistakes, such as:
Uneven insulation thickness (deviating >0.1mm from 1.2mm).
Weak bonding between the messenger and core bundle, leading to separation.
Damage from improper installation (e.g., using non-corrosion-resistant connectors, installing the cable below the high-tide line).
Wear from extreme industrial conditions (e.g., direct contact with concentrated saltwater, exposure to industrial acids beyond rated limits).
Vandalism or natural disasters (e.g., hurricane-force winds snapping utility poles).
The client notifies the after-sales team within 48 hours of discovering the defect, providing photos, the order number, and installation date.
A technical specialist reviews the claim and may request a 1m sample of the defective cable for laboratory testing (e.g., analyzing corrosion levels via electron microscopy).
If approved:
Minor defects (e.g., small insulation tears): Replacement insulation tape and anti-corrosive grease are shipped free of charge.
Major defects (e.g., widespread conductor corrosion): The manufacturer replaces the defective section (up to 200m) and sends a technician to install it, covering all costs (parts, labor, shipping).
Preventive Maintenance Packages:
Annual Corrosion Inspection: Technicians visit the site to:
Visually inspect conductors and messenger for corrosion (using a magnifying glass to check for pitting).
Test insulation resistance (target: ≥50 MΩ for cables older than 5 years) and conductor continuity.
Clean the cable with a mild, corrosion-inhibiting detergent to remove salt deposits.
5-Year Comprehensive Plan: Includes annual inspections plus:
Every 2 years: Applying a UV-resistant, anti-corrosive coating to the cable’s insulation (in high-sunlight areas).
Every 3 years: Retensioning the messenger wire and replacing anti-corrosive grease on terminations.
Every 5 years: Conducting a salt spray test on a small cable sample (to predict future corrosion risk).
Repair Services:
Minor Repairs:
Insulation damage (≤5mm): Clean the area with isopropyl alcohol, apply a heat-shrinkable XLPE patch (with VCI lining), and seal with anti-corrosive tape. Cost: \(120–\)180 per repair.
Corroded terminations: Replace the connector with a corrosion-resistant alloy connector and reapply anti-corrosive grease. Cost: \(150–\)220 per termination.
Major Repairs:
Conductor damage: Cut out the corroded section (2–3m), splice with an aluminum alloy compression connector, and insulate with a dual-layer heat-shrink tube (inner VCI layer, outer XLPE layer). Cost: \(500–\)700 per repair.
Messenger failure: Replace the entire affected cable span (up to 50m) with a new cable, ensuring proper tension and corrosion protection. Cost: \(1,200–\)1,800 per span.
Emergency Repairs: For critical failures (e.g., a cable break halting port operations), a team is dispatched within 4–8 hours (depending on location). Repairs are completed within 24 hours, with costs 50% higher than standard repairs (waived for clients with the 5-Year Comprehensive Plan).
Hongtai Cable Technology Co., Ltd
Correo electrónico: export@qlcables.com
sales@qlcables.com
Tel/WhatsApp:+86-18032066271
Agregue: Zona de desarrollo industrial de Xiaokou, condado de Ningjin, ciudad de Xingtai, provincia de Hebei, China
Copyright © Hongtai Cable Technology Co., Ltd Apoyo técnico:Tecnología Ronglida
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