IEC 61195 Edition 2 2 2014 09 CONSOLIDATED VERSION VERSION CONSOLIDÉE Double capped fluorescent lamps – Safety specifications Lampes à fluorescence à deux culots – Prescriptions de sécurité IE C 6 11[.]
Scope
This International Standard specifies the safety requirements for double-capped fluorescent lamps for general lighting purposes of all groups having Fa6, Fa8, G5, G13, 2G13, R17d and
Manufacturers must demonstrate compliance with this standard through a comprehensive evaluation of their entire production process, supported by test records of finished products This approach is also applicable for certification purposes.
Details of a batch test procedure which can be used to make limited assessment of batches are also given in this standard
This part of the standard covers photobiological safety according to IEC 62471 and
Blue light and infrared hazards are below the level which requires marking
Compliance with this standard focuses solely on safety criteria and does not address the performance aspects of double-capped fluorescent lamps used for general lighting, including luminous flux, color, starting, and operational characteristics For detailed information on these performance characteristics, readers should consult IEC 60081.
Normative references
This International Standard references several normative documents that form its provisions For dated references, any amendments or revisions to these publications do not apply However, parties to agreements based on this Standard are encouraged to consider the latest editions of the referenced normative documents For undated references, the most recent edition of the applicable normative document is relevant The IEC and ISO maintain registers of currently valid International Standards.
IEC 60061-1, Lamp caps and holders together with gauges for the control of interchangeability and safety – Part 1: Lamp caps
IEC 60061-2, Lamp caps and holders together with gauges for the control of interchangeability and safety – Part 2: Lampholders
IEC 60061-3, Lamp caps and holders together with gauges for the control of interchangeability and safety – Part 3: Gauges
IEC 60081, Double-capped fluorescent lamps – Performance specifications
IEC 60410, Sampling plans and procedures for inspection by attributes
IEC 60695-2-1/0, Fire hazard testing – Part 2: Test methods – Section 1/sheet 0: Glow-wire test methods – General
IEC 60921, Ballasts for tubular fluorescent lamps – Performance requirements
Definitions
For the purposes of this International Standard, the following definitions apply
The double-capped fluorescent lamp is a tubular low-pressure mercury discharge lamp that primarily emits light through a layer of fluorescent material, which is stimulated by ultraviolet radiation produced during the discharge process.
1.3.2 group lamps having the same electrical and cathode characteristics, the same physical dimensions and the same starting method
1.3.3 type lamps of the same group having the same photometric and colour characteristics
1.3.4 family lamp groups which are distinguished by common features of materials, components, lamp diameter and/or method of processing
1.3.5 nominal wattage wattage used to designate the lamp
1.3.6 design test test made on a sample for the purpose of checking compliance of the design of a family, group or a number of groups with the requirements of the relevant clause
1.3.7 periodic test test, or series of tests, repeated at intervals in order to check that the product does not deviate in certain respects from the given design
1.3.8 running test test repeated at frequent intervals to provide data for assessment
1.3.9 batch all the lamps of one family and/or group identified as such and put forward at one time for testing to check compliance
The total production of all lamp types covered by this standard over a twelve-month period must be documented in a list provided by the manufacturer for certification purposes.
1.3.11 specific effective radiant UV power effective power of the UV radiation of a lamp related to its luminous flux
NOTE 1 Specific effective radiant UV power is expressed in mW/klm
The effective power of UV radiation is determined by applying the spectral power distribution of the lamp to the UV hazard function S UV (λ), as outlined in IEC 62471 This function specifically addresses potential hazards associated with human UV exposure, without considering the effects of optical radiation on materials, such as mechanical damage or discoloration.
General
Lamps shall be so designed and constructed that in normal use they present no danger to the user or surroundings
In general, compliance is checked by carrying out all the tests specified
NOTE – Where testing can become unnecessarily difficult due to the lamp length, methods to alleviate the problem may be agreed between the supplier and the certification authority.
Marking
Lamps must have clear and durable markings that include the origin mark, which can be a trademark, the manufacturer's name, or the responsible vendor's name Additionally, the nominal wattage should be indicated as "W" or "watts," or through any other means that identifies the lamp.
NOTE – In some countries, the length of the lamp is marked in place of the wattage
2.2.2 Compliance is checked by the following: a) presence and legibility of the marking by visual inspection; b) durability of marking by applying the following test on unused lamps
The area of the marking on the lamp shall be rubbed by hand with a smooth cloth dampened with water for a period of 15 s
After this test, the marking shall still be legible.
Mechanical requirements for caps
Caps shall be so constructed and assembled to the bulbs that they remain attached during and after operation
Compliance is checked by the following tests:
2.3.1.1 For lamp types using caps G5, G13 and R17d: a) for unused lamps compliance is checked by applying a torque test to the pins, as follows:
The lamp cap must be securely fixed to the bulb, ensuring that any rotational movement between the cap's components does not exceed an angular displacement of 6° when tested against the torque levels specified in Table 1.
Table 1 – Torque values for unused lamps
The torque shall not be applied suddenly but shall be increased progressively from zero to the value specified in table 1
The test holders for torque application are detailed in Annex A Specifically, the R17d cap test holder is being evaluated; after undergoing a heating treatment of 2,000 hours ± 50 hours at 120 °C ± 5 °C, the cap must remain securely attached to the bulb Additionally, there should be no rotational movement between the cap's components exceeding an angular displacement of 6° when subjected to the torque levels outlined in Table 2.
For G13 capped lamps with a nominal wattage greater than 40 W, the heating shall be performed at a temperature of 140 °C ± 5 °C
Table 2 – Torque values after heating treatment
2.3.1.2 For lamp types using caps Fa6 and Fa8, compliance is checked by inspection on unused lamps
For lamp types using cap 2G13, it is essential that the cap remains securely attached to the bulb when subjected to an axial pull of 40 N or a bending moment of 3 Nm The bending moment should be applied uniformly at the glass tubes nearest to the cap, with the pivot point at the cap reference plane Both the pulling force and bending moment must be gradually increased from zero to the specified values Additionally, after a heating treatment of 2,000 hours ± 50 hours at a temperature of 120 °C ± 5 °C, the cap must still remain firmly attached to the bulb under the same pulling forces and bending moments.
2.3.2.1 Lamps shall use standardized caps in accordance with the requirements of
2.3.2.2 Compliance is checked by using the gauges shown in table 3
Where a cap sheet as specified in IEC 60061-1 includes information on system requirements, lamps shall not exceed the limits specified
Compliance is checked by measurement
Table 3 – Sheet references of IEC 60061
Insulation resistance
2.4.1 The insulation resistance between the metal shell of the cap and the pin(s) or contacts shall not be less than 2 MΩ
2.4.2 Compliance is checked by measurement with suitable test equipment using a d.c voltage of 500 V.
Electric strength
2.5.1 This test shall not apply to lamps having caps with internal resistors
2.5.2 The insulation between the shell of the cap and the pin(s) or contacts shall withstand the test voltage No flash-over or breakdown shall occur during the test
Compliance is verified using a 1,500 V a.c voltage that closely resembles a sine wave, operating at a frequency of either 50 Hz or 60 Hz for a duration of 1 minute Initially, only up to half of the specified voltage is applied, which is then quickly increased to the full voltage level.
Glow discharges without a drop in voltage are neglected.
Parts which can become accidentally live
2.6.1 Metal parts intended to be insulated from live parts shall not be or become live
2.6.2 With the exception of cap pins no live part shall project from any part of the cap
Compliance is verified through an appropriate measuring system, which may involve visual inspections when necessary Additionally, daily equipment checks or verification of inspection effectiveness are required.
Resistance to heat and fire
2.7.1 Insulating material of caps shall be resistant to heat
2.7.2 Compliance is checked by the following test
Samples are tested in a heating cabinet at a temperature of 125 °C ± 5 °C for a period of 168 h
For G13 caps to be used on lamps with a nominal wattage greater than 40 W, the samples shall be tested at a temperature of 140 °C ± 5 °C
At the end of the test, the samples shall not have undergone any change impairing their further safety, especially in the following respects:
– reduction in the protection against electric shock as required in 2.4 and 2.5;
– loosening of cap pins, cracks, swelling and shrinking as determined by visual inspection
At the end of the test, the dimensions shall comply with the requirements of 2.3.2
2.7.3 External parts of insulating material shall be resistant to abnormal heat and to fire
2.7.4 Compliance is checked by the following test
Parts are subjected to a test using a nickel-chromium glow-wire heated to 650 °C The test apparatus shall be that described in IEC 60695-2-1/0
The sample is positioned vertically on the carriage and pressed against the glow-wire tip with a force of 1 N, ideally at least 15 mm from the upper edge The glow-wire's penetration into the sample is restricted to a maximum of 7 mm After 30 seconds, the sample is removed from contact with the glow-wire tip.
The sample's flame or glow must extinguish within 30 seconds after removing the glow-wire, and any burning or molten drops should not ignite a horizontally spread piece of tissue paper, consisting of five layers, positioned 200 mm ± 5 mm below the sample.
Before starting the test, the glow-wire temperature and heating current must remain constant for one minute, ensuring that heat radiation does not affect the sample during this time The temperature at the glow-wire tip is measured using a sheathed fine-wire thermocouple, which is constructed and calibrated according to IEC 60695-2-1/0 standards.
NOTE – Precautions should be taken to safeguard the health of personnel conducting tests against risk of
– inhalation of smoke and/or toxic products;
Creepage distance for caps
The minimum creepage distance between contact pins or contacts and the metal shell of the cap must comply with IEC 60061-1 standards, as outlined in table 3, which provides the relevant cap standard sheet numbers.
2.8.2 Compliance is checked by measurement in the most onerous position.
Lamp cap temperature rise
Lamps equipped with G5, G13, and 2G13 caps, which operate with a starter, must not have a cap temperature rise exceeding 95 K above ambient temperature In contrast, lamps with W4.3×8.5d caps should maintain a cap temperature rise of no more than 55 K at the designated measuring point.
2.9.2 Compliance is checked by the procedure specified in annex B Conditions of compliance are given in D.4
For a specific lamp family, such as those with a 26 mm nominal bulb diameter, demonstrating that one lamp group achieves the highest cap temperature rise is sufficient Consequently, compliance testing is only required for this particular lamp group to ensure that all identically capped lamps meet the necessary standards.
Lamp minimum overall length
2.10.1 To ensure retention in luminaires, lamps shall comply with a minimum overall length specified as follows:
– for lamps with G5 and G13 caps: B min – 0,2 mm (under consideration);
– for lamps with Fa8 caps: B min;
– for lamps with R17d and Fa6 caps: C min
B min and C min are specified on the relevant data sheets of IEC 60081
For lamps not specified in IEC 60081, reference should be made to the manufacturer's data
2.10.2 Compliance is checked by measurement.
Information for luminaire design
Information for ballast design
UV radiation
The specific effective radiant UV power emitted by the lamp shall not exceed the value of
2 mW/klm For reflector lamps it shall not exceed the value of 2 mW/(m 2 ⋅ klx)
According to IEC 62471, exposure limits are defined in terms of effective irradiance values measured in watts per square meter (W/m²), with risk group classifications for general lighting lamps assessed at an illuminance level of 500 lux (lx) The threshold for risk group exemption is set at 0.001 W/m² at this illuminance level, which translates to a specific value of 0.001 divided by 500, resulting in 2 mW/(m²⋅klx) Given that lx is equivalent to lm/m², this value corresponds to 2 mW/klm of specific UV power.
Compliance is checked by spectroradiometric measurement, under the same conditions as for the lamp’s electrical and photometric characteristics as given in IEC 60081
2.14 Water contact protection of lamp glass bulb
The lamp bulb is suitable for water contact and need not be tested for this property
General
This clause outlines the procedure a manufacturer must follow to demonstrate that their product meets the standard through a comprehensive assessment of the entire production process, along with test records of the finished products This approach is also applicable for certification purposes.
Subclauses 3.2, 3.3 and 3.5 give details of assessment by means of the manufacturer’s records
The batch test procedure outlined in sections 3.4 and 3.6 provides a limited assessment of batches suspected to contain unsafe lamps While requirements for batch testing are established to facilitate this assessment, it is important to note that certain safety criteria cannot be verified through batch testing Additionally, the lack of prior knowledge regarding the manufacturer's quality means that batch testing is not suitable for certification or approval purposes If a batch is deemed acceptable, a testing agency can only conclude that there are no safety concerns warranting rejection.
Whole production assessment by means of the manufacturer’s records
The manufacturer must provide proof that their products meet the specific requirements outlined in section 3.3 To achieve this, all relevant product testing results that align with the standards must be made accessible.
3.2.2 The test results may be drawn from working records and as such may not be immediately available in collated form
The assessment will primarily focus on individual factories that meet the acceptance criteria outlined in section 3.3 However, multiple factories can be grouped together if they operate under the same quality management system For certification, a single certificate may be issued for the designated group of factories, but the certification authority retains the right to inspect each facility to review local records and quality control procedures.
For certification, the manufacturer must provide a list of origin marks along with the corresponding lamp families, groups, and types that comply with this standard and are produced in designated factories The certificate will encompass all listed lamps manufactured by the company, and any updates regarding additions or removals can be communicated at any time.
3.2.5 In presenting the test results, the manufacturer may combine results of different lamp families, groups and/or types according to column 4 of table 4
The production assessment mandates that a manufacturer's quality control procedures must meet established quality system standards for final inspection Additionally, a quality system that incorporates in-process inspection and testing allows the manufacturer to demonstrate compliance with certain standard requirements through in-process inspections rather than solely relying on finished product testing.
Table 4 – Grouping of test records – Sampling and acceptable quality levels
Test Type of test Permitted accumulation of test records between lamp groups
Minimum annual sample per accumulation AQL a)
For lamps made most of the year
2.2.2 a) Marking – legibility Running All families with the same method of marking 200 – 2,5
2.2.2 b) Marking – durability Periodic All families with the same method of marking 50 – 2,5
Construction and assembly of caps of unused lamps (except
Periodic All families using the same cement, the same cap and with the same nominal lamp diameter
Construction and assembly of caps after heating test (except
Design All families using the same cement, the same cap and with the same nominal lamp diameter
2.3.1.2 Construction and assembly of caps of unused lamps (Fa6 and
Periodic All families using the same cement and the same cap 125 80 0,65
2.3.2.2 Dimensional requirements for caps Periodic All families using the same cap 32 2,5
2.4.2 Insulation resistance Design All families using the same cap and with the same nominal lamp diameter
2.5.3 Electric strength Design All families using the same cap and with the same nominal lamp diameter
2.6.3 Accidentally live part 100 % inspection By group and type
2.7.2 Resistance to heat Design All families using the same cap and with the same nominal lamp diameter
2.7.4 Resistance to fire Design All families using the same cap and with the same nominal lamp diameter
2.8.2 Cap creepage distance Design All families using the same cap and with the same nominal lamp diameter
2.9.2 Cap temperature rise Design Lamps selected according to 2.9.3 See D.4
2.10.2 Minimum overall length Running All groups 200 80b) 0,65b)
2.13 UV radiation Design By family, group, type 4 4 -
All lamp ends must be tested, except for design tests as outlined in annex D A lamp will be deemed non-compliant if either end fails to meet the requirements For further details on this term, refer to IEC 60410 This is currently under consideration.
3.2.6 The manufacturer shall provide sufficient test records with respect to each clause as indicated in column 5 of table 4
The manufacturer's records must maintain non-conformities within the limits specified in tables 5 or 6, corresponding to the Acceptable Quality Level (AQL) values indicated in column 6 of table 4.
Number of lamps in manufacturer’s records
Acceptance number Number of lamps in manufacturer’s records
Qualifying limit for acceptance as percentage of lamps in records
Number of lamps in manufacturer’s records
Acceptance number Number of lamps in manufacturer’s records
Qualifying limit for acceptance as percentage of lamps in records
3.2.8 The period of review for assessment purposes need not be limited to a predetermined year, but may consist of 12 consecutive calendar months immediately preceding the date of review
A manufacturer that initially meets the specified criteria but later fails to do so can still claim compliance with the standard if they demonstrate that: a) they took prompt action to address the issue once it was reasonably confirmed through test records; and b) they re-established the specified acceptance level within a designated timeframe.
2) one month for other clauses
After corrective actions are implemented, any test records from lamp families, groups, or types that fail to comply will be excluded from the 12-month compliance summation for the duration of their non-compliance.
The test results relating to the period of corrective action shall be retained in the records
A manufacturer who does not meet the requirements of a clause allowing for the grouping of test results under 3.2.5 will not face disqualification for all lamp families, groups, or types if they can demonstrate through additional testing that the issue is limited to specific families, groups, or types In such cases, these specific families, groups, or types will either be addressed according to 3.2.9 or removed from the list of those the manufacturer claims conform to the standard.
If a family, group, or type has been removed from the list as per section 3.2.10, it can be reinstated if satisfactory test results are achieved from a number of lamps that meet the minimum annual sample requirements outlined in table 4 This testing can be conducted over a brief period.
For new products, features that are similar to those in existing lamp families, groups, or types can be considered compliant if the new product is included in the sampling scheme at the start of manufacturing Any features not included in this coverage must undergo testing prior to the commencement of production.
Assessment of the manufacturer’s records of particular tests
Table 4 specifies the type of test and other information which applies to the method of assessing compliance to the requirements of various clauses
A design test should only be repeated when significant alterations occur in the physical or mechanical construction, materials, or manufacturing processes of the product Testing is necessary solely for the properties impacted by these changes.
Rejection conditions of batches
Rejection occurs when any rejection number specified in Table 7, in accordance with Annex D, is met, regardless of the quantity tested A batch will be deemed rejected immediately upon reaching the rejection number for a specific test.
Table 7 – Batch sample size and rejection number
Subclause number Test Number of lamps tested Rejection number
2.3.1.3 a) Construction and assembly of caps
2.3.1.3 b) Construction and assembly of caps
2.9.2 Cap temperature rise Test not applicable a) Under consideration
Sampling procedures for whole production testing
3.5.1 The conditions of table 4 apply
3.5.2 The whole production running tests shall be applied at least once per production day
They may also be based on in-process inspection and testing
The frequency of application of the various tests may be different, providing the conditions of table 4 are met
Whole production tests must be conducted on samples that are randomly selected at a rate specified in column 5 of table 4 It is not necessary to use lamps chosen for one test in subsequent tests.
3.5.4 For whole production testing of the requirements for accidentally live parts (see 2.6), the manufacturer shall demonstrate that there is a continuous 100 % inspection.
Sampling procedures for batch testing
Lamps for testing must be chosen using a mutually agreed method to ensure accurate representation The selection process should involve random sampling from approximately one-third of the total containers in the batch, with a minimum requirement of 10 containers.
To mitigate the risk of accidental breakage, it is essential to select additional lamps beyond the test quantity These extra lamps will only be used to replace any broken lamps from the test quantities, ensuring that the required number of lamps for the tests is maintained.
If a lamp is accidentally broken but does not affect the test results, it does not need to be replaced, as long as there are enough lamps available for the next test If a replacement is made, the broken lamp should be excluded from the results calculation.
Lamps having broken bulbs when removed from the packaging after transit shall not be included in the test
3.6.3 Number of lamps in the batch sample
There shall be at least 500 lamps (see table 7)
Testing will be conducted sequentially according to the subclause numbers in table 7, concluding with 2.5.3 It is important to note that later tests may cause damage to the lamp, and each test sample must be sourced individually from the original sample.
Test holder for torsion test for G5 and G13 capped lamps
Dimension G5 mm G13 mm Tolerance mm
NOTE – The drawing illustrates the essential dimensions of the holder which need only be checked if doubt arises from the application of the test
Figure A.1 – Holder for torsion tests on lamps with bi-pin caps
To ensure proper engagement between the cap and holder during testing, a locating device must be installed at an appropriate distance from the holder to adequately support the lamp.
The face of the cap shall be in close contact with the face of the special holder
Test for lamp cap temperature rise
The test shall be carried out under the following conditions
B.1 The circuit shall use the appropriate reference ballast as specified in IEC 60921
B.2 The supply voltage shall be 110 % of the rated voltage of the reference ballast with the starter circuit continuously closed
B.3 The test lamp shall be a normal production lamp but specially produced such that its cathodes are deactivated, i.e without cathode emitter
B.4 The test lamp, in a bare condition, shall be suspended by means of nylon slings, in draught-free air, at 25 °C ± 5 °C The plane through the cap pins shall be horizontal
B.5 The electrical connections to the lamp shall be through 1 mm 2 ± 5 % copper wires attached to the cap pins
B.6 For G5, G13 and 2G13 caps, the thermocouple shall be attached to the insulating material of the cap as close to the centre as possible
B.7 The test shall continue until a stable temperature is achieved
C.1 Guidelines for safe lamp operation
To ensure safe lamp operation, it is essential to observe the following recommendations
C.2 Maximum lamp cap temperature under normal operating conditions
Relevant tests are part of IEC 60598-1
Luminaires must be engineered to ensure that the lamp cap temperature remains below 120 °C at the cap rim and insulator material during normal operation, particularly for G13 or 2G13 capped lamps with a nominal wattage exceeding the specified limit.
40 W, the maximum cap temperature should not exceed 140 °C
To accurately measure the cap rim temperature, position the thermocouple's hot junction on the cap shell, ensuring it is no more than 2 mm away from the cap-to-glass junction.
To accurately measure the temperature of the insulator material, the hot junction of the thermocouple must be positioned on the insulator section of the cap face, aligned with the line through the cap pins, and as close to the center between the contact pins as possible.
The thermocouple wires (diameter maximum of 0,2 mm each) should be insulated up to the place of attachment
C.2.2 Lamps with R17d, Fa6 and Fa8 caps
The values and the place of measurement are under consideration
The cap temperature at the measuring point shall not exceed 100 °C
The attention of luminaire designers is drawn to the dimensions for lampholder spacing in
IEC 60061-2 and the relevant gauging requirements in IEC 60061-3
Lamps designed according to this standard are suitable for exposure to water, such as drips and splashes, eliminating the need for additional protection for the bulb component.
To achieve IPX1 or better protection for lamp contact areas, luminaires must feature lampholders with the appropriate IP rating Additionally, proper sealing around the diameter of the lamp ends is essential to safeguard the components that contain the contact areas.
Conditions of compliance for design tests
For these tests, one end of the lamp shall be chosen randomly
Attachment of caps after heating (see 2.3.1.1b))
D.2 Insulation resistance and electric strength (see 2.4.2 and 2.5.3)
Each test shall be assessed separately
If one failure is found, take a second sample of 125
Rejection number: 2 Rejection number: 2 in the combined sample
Each test shall be assessed separately
First sample: 5 Accept when no failure has been found
If one failure is found, take a second sample of 5 Rejection number: 2 in the combined sample
First sample: 5 Accept if all samples have a temperature of at least 5 K below limit
In other cases, take a second sample: 5 Rejection number: 2 lamps with a cap temperature rise that exceeds 95 K in the combined sample
E.1 Guidelines for safe lamp operation
To ensure safe lamp operation, it is essential to observe the following recommendations
E.2 Lamp end temperature under abnormal operating conditions
In the case where a lamp does not start, any continuation of cathode preheating should not lead to overheating of the lamp ends
To prevent overheating of the lamp ends during partial rectification, it is essential to implement appropriate measures in the circuit when one of the cathodes is depleted or damaged while the lamp remains operational.
For G5-capped lamps with diameter 16 mm, the working voltage between any lamp terminal and earth should not exceed 430 V r.m.s
IEC 60598-1, Luminaires – Part 1: General requirements and tests
IEC 62471, Photobiological safety of lamps and lamp systems
IEC/TR 62471-2, Photobiological safety of lamps and lamp systems – Part 2: Guidance on manufacturing requirements relating to non-laser optical radiation safety
2.3 Prescriptions de résistance mécanique des culots 32
2.6 Parties pouvant devenir accidentellement sous tension 34
2.7 Résistance à la chaleur et au feu 35
2.8 Lignes de fuite des culots 35
2.9 Echauffement du culot des lampes 36
2.10 Longueur hors tout minimale de la lampe 36
2.11 Renseignements pour la conception des luminaires 36
2.12 Renseignements pour la conception des ballasts 36
3.2 Evaluation de la production globale au moyen des enregistrements du fabricant 37
3.3 Evaluation des enregistrements du fabricant concernant les essais particuliers 42
3.4 Conditions de rejet des lots 42
3.5 Procédures d’échantillonnage pour le contrôle de la production globale 43
3.6 Procédures d’échantillonnage pour le contrôle de lot 43
Annexe A (normative) Douille pour essai de torsion des lampes à culots G5 et G13 45
Annexe B (normative) Contrôle de l'échauffement du culot 46
Annexe C (informative) Renseignements pour la conception des luminaires 47
Annexe D (normative) Conditions de conformité pour les essais de conception 49
Annexe E (informative) Renseignements pour la conception des ballasts 50
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