Solar system full Wiring || Solar system off grid connection diagram | Showrob Electronics Project
The prices of solar panels have been falling gradually but the cost of an off-grid solar system setup is steadily rising. However, anyone with basic knowledge of Electricity and a toolbox can install it on their own. This will reduce the overall system cost significantly and you will learn a lot.
In order to build a basic off-grid solar system, you will need the following components:
1.Solar panel
2. Charge Controller
3.Battery
4. Inverter
5. Balance Of System (Cable, Breaker, Meter, Fuses, and MC4 connectors)
In this Instructable, I will guide you step-by-step on how to choose the appropriate components of your Off-Grid Solar System and then guide you on how to connect and set them up properly.
My Book: DIY Off-Grid Solar Power for Everyone
You can order my Book on Off-Grid Solar Power from Amazon
eBook
Paperback - Black & White
Paperback - Color Print
Support me On Patreon:
If you enjoy my work here on Instructables, consider joining my Patreon, it will be a great help for me to make more interesting projects in the future.
The off-grid solar system means you are not connected in any way to the utility grid. The system utilizes batteries to store energy produced from solar panels.
Solar Panel:
The solar panel converts sunlight into electricity. Photovoltaic cells on the solar panel absorb the sun’s energy and convert it to DC electricity.
Charge Controller:
The current from the solar panel feeds into a charge controller, which controls how much current goes to a battery. Charge controllers prevent batteries from being over-charged and over-discharged.
Battery:
It stores energy generated from the solar panel during the day.
Inverter:
It converts the DC (Direct Current) power from the battery bank or solar panels to AC (Alternating Current) so that you can run your AC appliances, such as TV, Fan, Fridge, Water Pump, etc.
Ohms Law Relationship
Current (I) = Voltage (V) / Resistance (R)
It is easier to remember the Ohms law relationship by using the above picture (Ohms Triangle). By knowing any two values of the Voltage, Current, or Resistance quantities we can use Ohms Law to find the third missing value.
The following 6 steps are required for building a DIY Off-Grid Solar System:
1. Calculate Daily Energy Consumption
2. Select the Battery
3. Select the Solar Panel
4. Select Charge Controller
5. Select Inverter
6.Balance of System (BOS)
In the next steps, we will discuss in detail the above points.
Figuring out your daily energy consumption (Watt-Hours) is the first step for designing an off-grid solar system.
Energy Consumption (Watt-Hours) = Power (Watts) × Time (Hours)
You can get the power rating from the power label (Name Plate) of the appliance or you can measure the actual power consumption by using a wattmeter. I have used my wattmeter to measure the power consumption of a few appliances.
Manual Calculation:
If you're running a 2 Nos of 6W LED bulb for 5 hours a day, 1 No of Fan (80W) for 4 hours, 1 No of Laptop (65W) for 3 hrs, and a WiFi Router (6W) for 24 hours .
1. LED Bulb: 2 x 6W x 5 hr = 60WH
2. LED TV: 1 x 65W x 3 hr = 195WH
3. Ceiling Fan: 1 x 80W x 4 hr = 320WH
4. WiFi Router: 1 x 6W x 24 hr = 144WH
The battery is used to store the energy produced by the Solar Panel during the day. It is an essential part of an off-grid solar system, and provides a constant source of stable and reliable power that allows to power devices when the sun is down.
The cost of the battery is contributing a large portion of the entire project cost. Here we will discuss in detail so that you can select the right battery for your off-grid solar installation.
Batteries are categorized according to 1. Application & Construction 2. Chemistry
1. Applications: Automotive and Deep-Cycle
2. Chemistry: Lead Acid, Lithium, and NiCd
Automotive Battery:
This type of battery is designed to provide a very large amount of current for a short period of time. This surge of current is needed to turn the engine over during starting. Therefore lots of thin plates are employed to achieve maximum surface area and as a result higher starting current in starting batteries.
Application: Automobiles ( Car & Bike )
Deep-Cycle Battery:
A deep cycle battery is designed to provide a constant amount of current over a long period of time. This type of battery is also designed to be deeply discharged over and over again. To accomplish this, a deep cycle battery uses thicker plates. This will lead to lower surfaces and accordingly less instant power, unlike the starting batteries.
Application: Renewable Energy
Two of the most common battery chemistry types are lithium-ion and lead-acid. Apart from these NiCd is also used for the renewable application, but here I will discuss only the first two.
Lead-acid batteries are made with lead, while Lithium batteries are made with the metal lithium. m and lead-acid batteries can both store energy effectively, but each has unique advantages and drawbacks.
1.Lead-acid Battery:
The lead-acid battery is a tried-and-true technology that costs less, but requires regular maintenance and doesn’t last as long.
Flooded Lead-Acid (FLA):
These types of batteries are submerged in water. These must be checked regularly and refilled every 1-3 months to keep them working properly. It also needs to be installed in a ventilated place to allow battery gases to escape.
Sealed Lead-Acid (SLA):
SLA batteries come in two types, AGM (Absorbent Glass Mat) and Gel, which have many similar properties. They require little to no maintenance and are spill-proof. The key difference in AGM vs. Gel batteries are that gel batteries tend to have lower charge rates and output. Gel batteries generally can’t handle as much charge current, which means they take longer to recharge and output less power.
2.Lithium Battery:
Lithium is a premium battery technology with a longer lifespan and higher efficiency, but you’ll pay more money for the boost in performance.
The Lithium batteries that are used in solar systems are Lithium Iron Phosphate (LiFePO4) which have great thermal stability, high current ratings, and a long cycle life. This new technology lasts longer and can be put through deeper cycles. They also require no maintenance or venting, unlike lead-acid batteries. The main downside for lithium batteries is their higher price compared to lead-acid batteries at the moment.
Which Battery Should You Choose?
If you need a battery backup system, both lead-acid and lithium-ion batteries can be effective options. However, it’s usually the right decision to install a lithium-ion battery given the many advantages of the technology – longer lifespan, higher efficiencies, and higher energy density.
If you are planning to live off the grid full-time, you should go with Flooded Lead Acid (if you don’t mind regular maintenance) or the premium Lithium option for heavy use.
If you want to install the solar in a small cabin or a vacation home, you’ll only be there a few times a year. In this case, you won’t be able to provide the regular maintenance which is required for Flooded Lead-acid batteries. Then, I will recommend spending some extra amount to buy a Sealed Lead Acid battery instead.
The following factors determine the battery bank size:
1. Daily power consumption
2. System voltage (12V / 24V /48V)
3. Depth of Discharge ( DOD )
In the previous step, we have already calculated the daily power consumption. In the next few steps, we will learn more details above factors.
A battery is recognized with its voltage (V) and capacity measured by amp-hours (AH). To provide the desired system voltage, one can wire the batteries in series and parallel.
Series Connection:
Connecting batteries in series adds the voltage of the two batteries, but it keeps the same amperage rating (also known as Amp-Hours).
Example: Connecting two 12V /100AH batteries in series will produce 24V, but the total capacity remains the same (100AH).
Parallel Connection:
Parallel connections will increase your current rating (Amp-Hours), but the voltage will stay the same. It's important to note that because the amperage of the batteries has increased, you may need a heavier-duty cable to keep the cables from burning out.
Example: Connecting two 12V /100AH batteries in parallel will produce 12V, but the total capacity will be increased to 200AH.
The battery’s Depth of Discharge (DOD) is the percentage of the battery capacity that can be safely drained without damaging the battery.
As you can see in the above figure, the more a battery is allowed to discharge, the shorter its lifespan. Deep cycle batteries are designed to discharge 80% of their capacity but are recommended to choose a value of around 50% as a good trade-off between longevity, cost.
For a deep cycle battery, 50% and for a lithium battery 80% DOD is considered as good practice.
Battery Capacity (AH) = Daily Energy Consumption (Watt-Hour) / (System Voltage x DOD)
Example:
Daily energy consumption =719WH (Calculated in the earlier step)
System Voltage = 12V
DOD = 50% for Flooded Lead Acid Battery
Battery Capacity = 719WH / (12V x 0.5) = 119.8AH
You have to select a battery with a capacity of more than 119.8AH. The nearest value available in the market is 120AH.
Battery Selected: 12V/120AH
I have purchased 150AH by considering future expansion.
Solar Panel converts the sunlight into electricity. A specific amount of the sun’s energy can be converted to electricity by the solar panel since they are not 100% efficient and they cannot trap the full energy of sunlight. Most of the solar panels are less than 20% efficient, which means that they can just trap about 20% of sunlight energy.
Commonly they are 3 types: Monocrystalline, Polycrystalline, and Thin Film.
1. Monocrystalline:
Monocrystalline solar cells are more efficient because they are cut from a single source of silicon.
As monocrystalline solar cells are made out of a single crystal of silicon, electrons are able to flow easier through the cell, which makes the efficiency higher than other types of solar panels. The efficiency can range from 17% to 22%.
Because of the way that monocrystalline panels are manufactured, they end up costing more than other types of solar panels.
2. Polycrystalline:
Polycrystalline solar cells are blended from multiple silicon sources and are slightly less efficient. The multiple silicon crystals in each solar cell make it harder for electrons to flow. This crystal structure makes the efficiency rate of polycrystalline panels lower than monocrystalline panels. Polycrystalline panel efficiency ratings will typically range from 15% to 17%.
Polycrystalline solar panels are cheaper to produce than monocrystalline solar panels. Most of the residential installations use Polycrystalline solar panels.
3.Thin Film:
Thin-film solar panels are made by depositing a thin layer of a photovoltaic substance onto a solid surface, like glass. Examples of these photovoltaic substances include Amorphous silicon (a-Si), Cadmium telluride (CdTe), Copper indium gallium selenide (CIGS), Dye-sensitized solar cells (DSC).
The main advantage of amorphous solar cells is that they can generate electricity in weak light conditions. However, the main problem of amorphous solar cells is the low photoelectric conversion efficiency, which is only about 10-13%.
Which One You Should Choose?
For most residential solar panel installations, it makes the most sense to install monocrystalline panels. Although you have to pay a higher price, you get better efficiency and a sleeker aesthetic than you would with polycrystalline panels.
If you're on a tight budget, however, polycrystalline panels might make more sense for you.
Thin-film solar cells are mostly used in large scale operations, such as utility or industrial solar installations because of their lower efficiency ratings.
I will always recommend purchasing a good brand solar panel. A good brand solar panel company always invests heavily in the quality of its manufacturing process, as well as in its reputation.
Factors Determine the Solar Panel Sizing
The sizing of the solar panel used in an off-grid system depends on the following factors:
1. Daily energy consumption
2. Number of Peak sun hours
3. Solar panels efficiency
The first step for sizing the solar panel is to determine the amount of sunlight received where you live. While the amount of sunlight your panels receive is important, a more accurate representation of the amount of energy your panels can produce is peak sun-hours.
What is Peak Sun-Hours?
The peak sun hours is the number of hours per day during which the average solar irradiance (sunlight) is 1000 watts per square meter (W/m2) or 1 kilowatt per square meter (kW/m2).
One peak sun hour = 1000 W/m2 or 1kWh/m2 of sunlight
Example: If a given location receives a total of 6,650 Wh/m2 of solar radiation over the course of a day, then that location gets 6.65 peak sun hours. You can see the above picture for a clear understanding.
The following factors affect the number of peak sun hours:
1. Geographical Location: Solar panels installed at a different location, receive different amounts of sunlight. The panel installed near the equator receives maximum sunlight, as it is closer to the sun.
2. Time of Day: The amount of sunlight falling on the solar panel, varies throughout the day, based on the sun’s position in the sky. It receives maximum at noon and a minimum during the morning and evening.
3. Season: Maximum amount of sunlight received during the summer and minimum amount during the winter.
The solar irradiance map can show you the amount of solar energy your location receives on an average day during the worst month of the year.
To find out the amount of solar insulation in your area, you can use the Global Solar Atlas. Follow the following steps:
Step-1: Search your location
Step-2: Choose the PV system configuration (e.g. - Small residential)
Step-3: Click on Annual Average ( Daily Average in kWh/m2 per day)
Step-4: The number is the peak sun hours
As per the Global Solar Atlas, New Delhi, India receives 5.093 kWh/m2 per day
Peak Solar Radiation = 1 kW/m2 (Solar Panels are rated at an input rating of 1kW/m2.)
Peak Sun Hours = 5.093/1 = 5.093 Hours
If we consider the worst scenario, we have to choose a number less than that obtained in the above. So here I have chosen 4.5 Hours.
If you are located in North America, you can use this reference chart, to get the number of peak sun hours.
Solar system full Wiring || Solar system off grid connection diagram | Showrob Electronics Project
The prices of solar panels have been falling gradually but the cost of an off-grid solar system setup is steadily rising. However, anyone with basic knowledge of Electricity and a toolbox can install it on their own. This will reduce the overall system cost significantly and you will learn a lot.
In order to build a basic off-grid solar system, you will need the following components:
1.Solar panel
2. Charge Controller
3.Battery
4. Inverter
5. Balance Of System (Cable, Breaker, Meter, Fuses, and MC4 connectors)
In this Instructable, I will guide you step-by-step on how to choose the appropriate components of your Off-Grid Solar System and then guide you on how to connect and set them up properly.
My Book: DIY Off-Grid Solar Power for Everyone
You can order my Book on Off-Grid Solar Power from Amazon
eBook
Paperback - Black & White
Paperback - Color Print
Support me On Patreon:
If you enjoy my work here on Instructables, consider joining my Patreon, it will be a great help for me to make more interesting projects in the future.
The off-grid solar system means you are not connected in any way to the utility grid. The system utilizes batteries to store energy produced from solar panels.
Solar Panel:
The solar panel converts sunlight into electricity. Photovoltaic cells on the solar panel absorb the sun’s energy and convert it to DC electricity.
Charge Controller:
The current from the solar panel feeds into a charge controller, which controls how much current goes to a battery. Charge controllers prevent batteries from being over-charged and over-discharged.
Battery:
It stores energy generated from the solar panel during the day.
Inverter:
It converts the DC (Direct Current) power from the battery bank or solar panels to AC (Alternating Current) so that you can run your AC appliances, such as TV, Fan, Fridge, Water Pump, etc.
Ohms Law Relationship
Current (I) = Voltage (V) / Resistance (R)
It is easier to remember the Ohms law relationship by using the above picture (Ohms Triangle). By knowing any two values of the Voltage, Current, or Resistance quantities we can use Ohms Law to find the third missing value.
The following 6 steps are required for building a DIY Off-Grid Solar System:
1. Calculate Daily Energy Consumption
2. Select the Battery
3. Select the Solar Panel
4. Select Charge Controller
5. Select Inverter
6.Balance of System (BOS)
In the next steps, we will discuss in detail the above points.
Figuring out your daily energy consumption (Watt-Hours) is the first step for designing an off-grid solar system.
Energy Consumption (Watt-Hours) = Power (Watts) × Time (Hours)
You can get the power rating from the power label (Name Plate) of the appliance or you can measure the actual power consumption by using a wattmeter. I have used my wattmeter to measure the power consumption of a few appliances.
Manual Calculation:
If you're running a 2 Nos of 6W LED bulb for 5 hours a day, 1 No of Fan (80W) for 4 hours, 1 No of Laptop (65W) for 3 hrs, and a WiFi Router (6W) for 24 hours .
1. LED Bulb: 2 x 6W x 5 hr = 60WH
2. LED TV: 1 x 65W x 3 hr = 195WH
3. Ceiling Fan: 1 x 80W x 4 hr = 320WH
4. WiFi Router: 1 x 6W x 24 hr = 144WH
The battery is used to store the energy produced by the Solar Panel during the day. It is an essential part of an off-grid solar system, and provides a constant source of stable and reliable power that allows to power devices when the sun is down.
The cost of the battery is contributing a large portion of the entire project cost. Here we will discuss in detail so that you can select the right battery for your off-grid solar installation.
Batteries are categorized according to 1. Application & Construction 2. Chemistry
1. Applications: Automotive and Deep-Cycle
2. Chemistry: Lead Acid, Lithium, and NiCd
Automotive Battery:
This type of battery is designed to provide a very large amount of current for a short period of time. This surge of current is needed to turn the engine over during starting. Therefore lots of thin plates are employed to achieve maximum surface area and as a result higher starting current in starting batteries.
Application: Automobiles ( Car & Bike )
Deep-Cycle Battery:
A deep cycle battery is designed to provide a constant amount of current over a long period of time. This type of battery is also designed to be deeply discharged over and over again. To accomplish this, a deep cycle battery uses thicker plates. This will lead to lower surfaces and accordingly less instant power, unlike the starting batteries.
Application: Renewable Energy
Two of the most common battery chemistry types are lithium-ion and lead-acid. Apart from these NiCd is also used for the renewable application, but here I will discuss only the first two.
Lead-acid batteries are made with lead, while Lithium batteries are made with the metal lithium. m and lead-acid batteries can both store energy effectively, but each has unique advantages and drawbacks.
1.Lead-acid Battery:
The lead-acid battery is a tried-and-true technology that costs less, but requires regular maintenance and doesn’t last as long.
Flooded Lead-Acid (FLA):
These types of batteries are submerged in water. These must be checked regularly and refilled every 1-3 months to keep them working properly. It also needs to be installed in a ventilated place to allow battery gases to escape.
Sealed Lead-Acid (SLA):
SLA batteries come in two types, AGM (Absorbent Glass Mat) and Gel, which have many similar properties. They require little to no maintenance and are spill-proof. The key difference in AGM vs. Gel batteries are that gel batteries tend to have lower charge rates and output. Gel batteries generally can’t handle as much charge current, which means they take longer to recharge and output less power.
2.Lithium Battery:
Lithium is a premium battery technology with a longer lifespan and higher efficiency, but you’ll pay more money for the boost in performance.
The Lithium batteries that are used in solar systems are Lithium Iron Phosphate (LiFePO4) which have great thermal stability, high current ratings, and a long cycle life. This new technology lasts longer and can be put through deeper cycles. They also require no maintenance or venting, unlike lead-acid batteries. The main downside for lithium batteries is their higher price compared to lead-acid batteries at the moment.
Which Battery Should You Choose?
If you need a battery backup system, both lead-acid and lithium-ion batteries can be effective options. However, it’s usually the right decision to install a lithium-ion battery given the many advantages of the technology – longer lifespan, higher efficiencies, and higher energy density.
If you are planning to live off the grid full-time, you should go with Flooded Lead Acid (if you don’t mind regular maintenance) or the premium Lithium option for heavy use.
If you want to install the solar in a small cabin or a vacation home, you’ll only be there a few times a year. In this case, you won’t be able to provide the regular maintenance which is required for Flooded Lead-acid batteries. Then, I will recommend spending some extra amount to buy a Sealed Lead Acid battery instead.
The following factors determine the battery bank size:
1. Daily power consumption
2. System voltage (12V / 24V /48V)
3. Depth of Discharge ( DOD )
In the previous step, we have already calculated the daily power consumption. In the next few steps, we will learn more details above factors.
A battery is recognized with its voltage (V) and capacity measured by amp-hours (AH). To provide the desired system voltage, one can wire the batteries in series and parallel.
Series Connection:
Connecting batteries in series adds the voltage of the two batteries, but it keeps the same amperage rating (also known as Amp-Hours).
Example: Connecting two 12V /100AH batteries in series will produce 24V, but the total capacity remains the same (100AH).
Parallel Connection:
Parallel connections will increase your current rating (Amp-Hours), but the voltage will stay the same. It's important to note that because the amperage of the batteries has increased, you may need a heavier-duty cable to keep the cables from burning out.
Example: Connecting two 12V /100AH batteries in parallel will produce 12V, but the total capacity will be increased to 200AH.
The battery’s Depth of Discharge (DOD) is the percentage of the battery capacity that can be safely drained without damaging the battery.
As you can see in the above figure, the more a battery is allowed to discharge, the shorter its lifespan. Deep cycle batteries are designed to discharge 80% of their capacity but are recommended to choose a value of around 50% as a good trade-off between longevity, cost.
For a deep cycle battery, 50% and for a lithium battery 80% DOD is considered as good practice.
Battery Capacity (AH) = Daily Energy Consumption (Watt-Hour) / (System Voltage x DOD)
Example:
Daily energy consumption =719WH (Calculated in the earlier step)
System Voltage = 12V
DOD = 50% for Flooded Lead Acid Battery
Battery Capacity = 719WH / (12V x 0.5) = 119.8AH
You have to select a battery with a capacity of more than 119.8AH. The nearest value available in the market is 120AH.
Battery Selected: 12V/120AH
I have purchased 150AH by considering future expansion.
Solar Panel converts the sunlight into electricity. A specific amount of the sun’s energy can be converted to electricity by the solar panel since they are not 100% efficient and they cannot trap the full energy of sunlight. Most of the solar panels are less than 20% efficient, which means that they can just trap about 20% of sunlight energy.
Commonly they are 3 types: Monocrystalline, Polycrystalline, and Thin Film.
1. Monocrystalline:
Monocrystalline solar cells are more efficient because they are cut from a single source of silicon.
As monocrystalline solar cells are made out of a single crystal of silicon, electrons are able to flow easier through the cell, which makes the efficiency higher than other types of solar panels. The efficiency can range from 17% to 22%.
Because of the way that monocrystalline panels are manufactured, they end up costing more than other types of solar panels.
2. Polycrystalline:
Polycrystalline solar cells are blended from multiple silicon sources and are slightly less efficient. The multiple silicon crystals in each solar cell make it harder for electrons to flow. This crystal structure makes the efficiency rate of polycrystalline panels lower than monocrystalline panels. Polycrystalline panel efficiency ratings will typically range from 15% to 17%.
Polycrystalline solar panels are cheaper to produce than monocrystalline solar panels. Most of the residential installations use Polycrystalline solar panels.
3.Thin Film:
Thin-film solar panels are made by depositing a thin layer of a photovoltaic substance onto a solid surface, like glass. Examples of these photovoltaic substances include Amorphous silicon (a-Si), Cadmium telluride (CdTe), Copper indium gallium selenide (CIGS), Dye-sensitized solar cells (DSC).
The main advantage of amorphous solar cells is that they can generate electricity in weak light conditions. However, the main problem of amorphous solar cells is the low photoelectric conversion efficiency, which is only about 10-13%.
Which One You Should Choose?
For most residential solar panel installations, it makes the most sense to install monocrystalline panels. Although you have to pay a higher price, you get better efficiency and a sleeker aesthetic than you would with polycrystalline panels.
If you're on a tight budget, however, polycrystalline panels might make more sense for you.
Thin-film solar cells are mostly used in large scale operations, such as utility or industrial solar installations because of their lower efficiency ratings.
I will always recommend purchasing a good brand solar panel. A good brand solar panel company always invests heavily in the quality of its manufacturing process, as well as in its reputation.
Factors Determine the Solar Panel Sizing
The sizing of the solar panel used in an off-grid system depends on the following factors:
1. Daily energy consumption
2. Number of Peak sun hours
3. Solar panels efficiency
The first step for sizing the solar panel is to determine the amount of sunlight received where you live. While the amount of sunlight your panels receive is important, a more accurate representation of the amount of energy your panels can produce is peak sun-hours.
What is Peak Sun-Hours?
The peak sun hours is the number of hours per day during which the average solar irradiance (sunlight) is 1000 watts per square meter (W/m2) or 1 kilowatt per square meter (kW/m2).
One peak sun hour = 1000 W/m2 or 1kWh/m2 of sunlight
Example: If a given location receives a total of 6,650 Wh/m2 of solar radiation over the course of a day, then that location gets 6.65 peak sun hours. You can see the above picture for a clear understanding.
The following factors affect the number of peak sun hours:
1. Geographical Location: Solar panels installed at a different location, receive different amounts of sunlight. The panel installed near the equator receives maximum sunlight, as it is closer to the sun.
2. Time of Day: The amount of sunlight falling on the solar panel, varies throughout the day, based on the sun’s position in the sky. It receives maximum at noon and a minimum during the morning and evening.
3. Season: Maximum amount of sunlight received during the summer and minimum amount during the winter.
The solar irradiance map can show you the amount of solar energy your location receives on an average day during the worst month of the year.
To find out the amount of solar insulation in your area, you can use the Global Solar Atlas. Follow the following steps:
Step-1: Search your location
Step-2: Choose the PV system configuration (e.g. - Small residential)
Step-3: Click on Annual Average ( Daily Average in kWh/m2 per day)
Step-4: The number is the peak sun hours
As per the Global Solar Atlas, New Delhi, India receives 5.093 kWh/m2 per day
Peak Solar Radiation = 1 kW/m2 (Solar Panels are rated at an input rating of 1kW/m2.)
Peak Sun Hours = 5.093/1 = 5.093 Hours
If we consider the worst scenario, we have to choose a number less than that obtained in the above. So here I have chosen 4.5 Hours.
If you are located in North America, you can use this reference chart, to get the number of peak sun hours.
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