E6X Manual i Warnings 1. This system is capable of controlling either “intelligent” igniters which have in-built dwell control or “dum
E6X Manual 10 Injection pulses usually occur one or more times per engine cycle. The ECU uses a trigger signal locked to engine speed in order to dete
E6X Manual 100 A.6 Full Power Problems If the engine gasps under full throttle then the mixture may be too lean. If the engine bogs down and blows sm
E6X Manual 101 If the cold start map is supplying too much fuel on warm-up this will also affect the fuel consumption of the vehicle.
E6X Manual 102 APPENDIX B IGNITION AND INJECTION OUTPUTS B.1 Distribution of Outputs The ECU has five injection/ignition outputs, or channels. The
E6X Manual 103 B.2 Ignition Output Configurations The E6X ignition outputs can be fired differently, depending on the Spark mode, which can be found
E6X Manual 104 This gives a mid point, half way between the minimum and maximum timing, of 25°. Rotate the engine to this value (25°) BTDC. Align the
E6X Manual 105 B.2.2 Direct Fire Ignition There are two forms of Direct Fire Ignition: 1) One coil per cylinder (usually mounted on top of the spar
E6X Manual 106 1 3 4 2 1 3 4 2 IGNITION # 1IGNITION # 2IGNITION # 3IGNITION # 4 Figure B1. Ignition output allocation layout for 4 cylinder
E6X Manual 107 Below is how the ignition outputs will be allocated in the Direct Fire Ignition output mode. Connection / Function Number of Cyli
E6X Manual 108 4 Cylinder Waste Spark Ignition Configuration Coil 1Coil 21324 1 3 4 2 IGNITION # 1IGNITION # 21 3 4 2 IGNITION # 1IGNITION #
E6X Manual 109 8 Cylinder Waste Spark Ignition Configuration Coil 1Coil 2Coil 3Coil 413572468 1 2 7 8 4 5 6 3 IGNITION # 1IGNITION # 2IGN
E6X Manual 11 SECTION 1 Getting Started CHAPTER 1 HALTECH ECU INSTALLATION 1.1 The ECU and Associated Hardware The Haltech E6X system comprises t
E6X Manual 110 4 Cylinder Ignition Toggle The E6X does have the ability to run a 4-cylinder engine in sequential injection mode as well as running t
E6X Manual 111 B.7 Ignition Outputs The ignition outputs of the ECU are designed to provide the appropriate signal to drive an ignitor. The ECU is c
E6X Manual 112 Constant Charge The Constant Charge Module (dumb) charges the Ignition Coil with a constant charge time no matter what RPM the engine
E6X Manual 113 The majority of modern ignition modules are the Constant Charge type with inbuilt current control. Current control limits the primary c
E6X Manual 114 Ignition Setup page showing Spark Output mode Setup Spark Output Mode Setting
E6X Manual 115 Ignition Spark Edge The ignition “Spark Edge” in the Haltech software sets the natural state of the ignition waveform. Spark Edge can
E6X Manual 116 B.7.2 Alternate Ignition Systems The output of the Haltech Ignition Module can be used to trigger after-market ignition systems such
E6X Manual 117 G.M. Direct Fire Ignition The G.M. Direct Fire Ignition module (DFI), as used in the V6 Buick, can be connected directly to the E6X E
E6X Manual 118 Ford Thick Film Ignition (TFI) The Ford TFI module is fitted to distributors used with Ford’s EEC IV engine management computer syste
E6X Manual 119 B.3 Sequential Injection Sequential injection allows fuel to be delivered to the engine at a time that produces best combustion. Sinc
E6X Manual 12 1.3 Expanded Installation Guide 1.3.1 Manifold Absolute Pressure (MAP) Sensor The MAP sensor is used to convert the manifold pressur
E6X Manual 120 B.3 Semi Sequential Injection The ECU can only provide up to 4 separate fuel outputs. For engines with more than 4 cylinders config
E6X Manual 121 Fue l Se tup page showing Inje ction Mode Se tup Note: Sequential injection on 5 and 10 cylinder motors is not possible with the
E6X Manual 122 Summary Table The list that follows shows the different types of output configurations that may be employed. Note that in some cases,
E6X Manual 123 B.6 Rotary Engines The ECU is capable of providing fuel and spark to twin-rotor Wankel engines, through staged injection and also thr
E6X Manual 124 The leading and trailing sparks are generated separately, with a programmable ignition split time. The split is programmed through th
E6X Manual 125 APPENDIX C INJECTORS C.1 Injector Impedance Injectors, when classified electrically, fall into 2 categories: Saturation Injector
E6X Manual 126 C.2 The Injector Drivers The ECU uses switched injector drivers that can control the current passing through an injector by switching
E6X Manual 127 Appendix D Fuel Systems & Staging The best ECU installation will yield poor results if the fuel system does not meet the demands
E6X Manual 128 so the absolute maximum injection time at 6000 RPM on this engine is 10 ms. If the injection time needs to be greater than this, then y
E6X Manual 129 D.2 Fuel Requirement If you can estimate the power output of a gasoline engine, you can make a reasonable guess at the fuel flow requi
E6X Manual 13 Mounting The MAP sensor is usually mounted high on the engine bay firewall or inner guard using two screws and with the hose nipple fac
E6X Manual 130 D.3 Injector Staging Another way of increasing injector flow, without compromising good drivability and fuel economy is to employ sta
E6X Manual 131 firing both sets of injectors at once and fires them with the same duration. This means that if both primary and secondary injectors ar
E6X Manual 132 D.4 Fuel Pump Capacity You should ensure that your fuel pump is capable of supplying sufficient fuel to feed the engine at maximum po
E6X Manual 133 APPENDIX E TRIGGER INTERFACE Trigger Interface The ECU is capable of accepting many different trigger patterns and trigger types. T
E6X Manual 134
E6X Manual 135 E.1.2 Reluctor Triggers A reluctor trigger produces a signal trace that looks like an upward or positive pulse followed immediately by
E6X Manual 136 E.3 Trigger Edge Trigger Edge The ECU uses the signal transitions from low to high called rising edges and high to low called fallin
E6X Manual 137 Some trigger devices have uneven pulse widths to indicate the position of a specific cylinder (often cylinder 1). If rising edges were
E6X Manual 138 Trigger Angle The trigger angle is simply the angle before top dead centre (BTDC) at which the trigger event occurs. The trigger devi
E6X Manual 139 Engine at 70 deg BTDCCYL 1REFTDCHarmonic BalancerEngine Timing MarkSensor PickupReference lining up with pickup70 deg Trigger Setup p
E6X Manual 14 sensor holes, it is often possible to mount the Haltech sensor in one of these holes. A thread adapter is sometimes necessary. In some e
E6X Manual 140 Tooth Offset The tooth offset is the number of teeth from the Home signal to the tooth that is chosen to be the trigger tooth. The t
E6X Manual 141 Trigger Pull up The Trigger Pull up setting is only used when in Hall Effect mode. The Trigger pull up is needed for most Hall Effect
E6X Manual 142 E.4 Trigger Gain and Reluctor Adaptor Tuning Motronic Filter The Motronic Filter setting defines the level of filtering used to cor
E6X Manual 143 Motronic signal with Motronic Filter = 2 Trigger Setup page with Motronic Filter setting Motronic Filter Setting
E6X Manual 144 Reluctor Gain The Trigger Gain defines the amplification of the signal from the Internal Reluctor pickup required to trigger to the E
E6X Manual 145 Fig 3. Clean Motronic signal after Motronic filter with Reluctor Gain = 5 As it can be seen in the scope traces above, the increase
E6X Manual 146 E.5 Synchronisation When the ECU is configured to operate an engine that uses direct fire ignition or sequential injection, the ECU n
E6X Manual 147 E.6 Trigger Type The ECU is capable of triggering from various trigger formats as used on a number of production vehicles other than
E6X Manual 148 For Example a 4-cylinder engine with a 24-tooth wheel on the cam and a corresponding home would have the following setup values: Tri
E6X Manual 149 E.6.2 Motronic Style Triggers Motronic style triggers are a type of multi-tooth trigger but are distinct in that they use a missing t
E6X Manual 15 Once a suitable position has been located for the air temperature sensor a hole should be drilled and tapped to accept the sensor. Remo
E6X Manual 150 The Motronic magnetic sensor has two wires, one positive (+), and the other negative (-). The wires are sometimes marked as such, but m
E6X Manual 151 Wiring a reluctor (magnetic) type Motronic Sensor: Positive wire (+): Connect to “Ground” on the Haltech flying wire harness or “Grou
E6X Manual 152 Hints for Setting up Motronic The first thing required is to obtain a good RPM signal which can be checked by viewing on the engine d
E6X Manual 153 E.2.3 2 Hall Effect Sensors The E6X can be triggered using the output from various Hall Effect sensors. Some OEM engines as well as a
E6X Manual 154 E.1.3 Haltech Hall Effect Sensors The Haltech Hall Effect sensor is a two-channel device that can be used to trigger the Haltech rang
E6X Manual 155 Checking the Sensor If you need to check that the Haltech Hall Effect sensor is operating correctly, then this can be done easily wit
E6X Manual 156 in place with a strong and durable fixing compound such as high strength epoxy, Loctite stud locking compound eg 603, or JBweld. Some u
E6X Manual 157 Typical set-ups – S3 4 cylinder / 2 rotor engine For a four cylinder 2 magnets are required in total, positioned exactly 180° apart
E6X Manual 158 8 Cylinder engine For an eight cylinder 4 magnets are required in total, positioned exactly 90° apart. Figure 3: Typical 8 cyli
E6X Manual 159 The S4 Hall Effect Sensor The S4 sensor, which is identifiable by a grey cable gland, operates in the following way: As a south pole
E6X Manual 16 1.3.5 Mount Ignition Module. The ignition module is used to drive the high currents required to energize the ignition coils. All vehic
E6X Manual 160 6 cylinder engine For a six cylinder 4 magnets are required in total. The three north poles are positioned exactly 120° apart while
E6X Manual 161 SENSOR PIN OUTS A BLUE GROUND B YELLOW PRIMARY TRIGGER C N/C D N/C E GREEN SECONDARY (HOME) TRIGGER F RED + 12 VOLTS Trigg
E6X Manual 162 E.6.3 Twin Triggers The Twin Trigger is designed for two purposes. It can be used to provide direct fire ignition on 2 cylinder engine
E6X Manual 163 Mitsubishi Triggers The Mitsubishi trigger comes in a few different forms, but the output waveforms are very similar. It is a cam sen
E6X Manual 164 E.6.4 Nissan Triggers The Nissan optical trigger sensor is used by almost every ECU controlled Nissan engine. It is a cam sensor and
E6X Manual 165 There are 3 common patterns for Nissan triggers, but for each pattern, there is always a unique window. You do not need to know what t
E6X Manual 166 Pattern 2 The second pattern is similar to the first but instead of having different size trigger windows for each cylinder it has pa
E6X Manual 167 Pattern 3 The first pattern has trigger windows sizes that are related to the cylinder number, which they precede and can be calcula
E6X Manual 168 Possible Trigge r Se tup page configuration for Nissan Cam Angle Se nsor Home Window Teeth Setting Nissan Toot
E6X Manual 169 E.6.5 Subaru A Triggers (1989-2000) All factory-injected 4-cylinder Subaru engines manufactured before 2001 use a combined crank-angl
E6X Manual 17 or cut a new hole to suit. Use a rubber grommet or similar device to protect the harness from being damaged by rubbing on the sharp edge
E6X Manual 170 E.6.9 MGF Trigger The 4-cylinder MG-F uses a unique trigger system similar to that of the Subaru engines. This trigger system uses us
E6X Manual 171 APPENDIX G HALTECH E6X SPECIFICATIONS Engine Suitability • Up to 16,000 rpm • 1, 2, 3, 4, 5, 6, 8, 10, 12 cylinders (1-2 rotors)*
E6X Manual 172 • Throttle Position Sensor 10 kΩ rotary potentiometer driven from throttle shaft • Inte rnal Barometric Pre ssure Sensor Barometric
E6X Manual 173 Adjustable Features • Base Fuel Map 22 Fuel ranges, every 500 RPM to 10,500, or 17 Fuel ranges, every 1000 rpm to 16,000 32 Load
E6X Manual 174 • Rugged Aluminium Casing Black anodised with integral cooling fins and mounting brackets. • US or Metric Units. E6X Hardware Optio
E6X Manual 175 LIMITED WARRANTY Lockin Pty Ltd trading as Haltech warrants the HaltechTM Programmable Fuel Injection System to be free from defe
E6X Manual 176 APPENDIX H WIRING DIAGRAMS
E6X Manual 18 1.3.9 Fuse Block Assembly The fuse block assembly holds the fuses that protect the various components of the Haltech system. The fus
E6X Manual 19 Red (Battery Supply +12V) Locate a source of continuous +12 volts and connect the red wire. Connecting direct to the positive battery
E6X Manual ii Contents INTRODUCTION ...
E6X Manual 20 It does not matter which example is used, as both will operate correctly. Note that the orange wires are connected internally within the
E6X Manual 21 PIN FUNCTION A GROUND B Trigger or Trigger Positive C Trigger Negative D Home Negative E Home or Home Positive F +13.8
E6X Manual 22 CHAPTER 2 INSTALLING THE SOFTWARE Now that your ECU is installed the programming software must be installed so that tuning can begin.
E6X Manual 23 3. Double click on the CD-ROM icon to open the CD-ROM. If the setup software does not automatically open, then double click on the “S
E6X Manual 24 5. Click on ‘Next >’ to continue and follow the instructions given to you on the windows that appear. 6. When prompted for whic
E6X Manual 25 CHAPTER 3 OPERATING THE SOFTWARE Once the ECU is installed, the programming software allows the user to change the settings currently
E6X Manual 26 3.1.1.1 Load From File Load From File allows the user to load a file that contains all the “set-up” and “map” data the ECU requires to
E6X Manual 27 NOTE: When the save function is used it saves the current map loaded in the programming software. If the ECU is “Offline” the map avail
E6X Manual 28 3.1.2 The Map Menu The map menu allows access to the maps contained in the ECU. The following is a description of the map menu and is
E6X Manual 29 The individual ranges represent different engine speeds; in the example above the map shown is from the 2000rpm range. The Fuel map me
E6X Manual iii CHAPTER 4 Configuring the ECU ... 36 4.1 Using the EC
E6X Manual 30 3.1.2.3 Fuel Correction Maps Fuel correction maps allow the ECU to calculate corrections to the amount of fuel injected based on the in
E6X Manual 31 3.1.3 The Set-up Menu The set-up menu allows access to the ECU set-up pages (which contain most of the information about the engine tha
E6X Manual 32 3.1.6 Password Protection The maps in the ECU can be password protected at the user’s choice. To Set the password the user selects Setu
E6X Manual 33 3.2 Online and Offline Operation The programming software can be used in two ways: “Online” and “Offline”. In the Online mode, all the
E6X Manual 34 Press the Go Online button in the top left hand corner. This will start communications with the ECU. The Status bar will indicate the lo
E6X Manual 35 3.3 Hot Key Summary Many of the menu items have shortcut keys or “Hot Keys” which allow the user to access a menu item directly from
E6X Manual 36 CHAPTER 4 CONFIGURING THE ECU 4.1 Using the ECU Set-up Pages The Set-up pages of the programming software tell the ECU essential info
E6X Manual 37 whose vacuum signal is small, or fluctuates greatly. If you are unsure what to use, contact your Haltech dealer. MAP Sensor The ECU ne
E6X Manual 38 Never This causes the ECU to only use the primary base fuel and ignition maps. Always This causes the ECU to only use the secondary ba
E6X Manual 39 Injection Mode The ECU can operate in 4 different injection modes depending on the application these are: Multipoint injection fires a
E6X Manual iv 6.5.3 Useful Software Mapping features... 62 6.5.4 Tuning for Idle ..
E6X Manual 40 Staging Bar Number This field sets the point at which the staged injectors are enabled. If the injection mode is not "Staged Injec
E6X Manual 41 4.2.3 Ignition Set-up Page The Ignition set-up page contains the information about the ignition and trigger system the ECU is to contro
E6X Manual 42 Coil Charge Time (ms) This field is only applicable when constant charge is selected. The value of this field is a measure of time in
E6X Manual 43 Number of Teeth This field is only applicable if the trigger type is Multi-tooth or Motronic. Multi-tooth The number of teeth on the mu
E6X Manual 44 when the installation is complete. The lowest Trigger gain possible to achieve steady ignition should be used. Home Input This field is
E6X Manual 45 O2 Sensor Display only (does not affect ECU operation). The reading appears on the Engine Data Page as mV.
E6X Manual 46 WARNING: WHEN CONFIGURING YOUR SYSTEM TAKE CARE TO SET THE SPARE INPUT FUNCTION CORRECTLY. IF THE SPARE INPUT FUNCTION FIELD IS SET TO
E6X Manual 47 Ignition Bypass Bypass signal compatible with some General Motors ignition systems. This function allows the ignition system to provide
E6X Manual 48 CHAPTER 5 HALTECH MAPS 5.1 What are Maps? The Fuel and Ignition requirements of an engine at a given point in time are based on the
E6X Manual 49 The map above shows the fuel requirements for the engine across the load range at 2500rpm. The yellow bar shows that the engine requir
E6X Manual v 12.3 Dual Intake Valve Control (DIV)... 88 12.4 Torque Converte
E6X Manual 50 Multiple bars can be selected to apply changes to a set of bars. This is achieved by highlighting the first bar in a series of bars by
E6X Manual 51 To reduce the bar to 4ms again by using the percentage change function 33% must be used since. 6ms x -33% = 4ms 5.2.4 Linearise When tu
E6X Manual 52 All the bars between the 2 extreme bars are highlighted: The map above shows the heights of the bars after the linearise function h
E6X Manual 53 In numerical mode only a fraction of the entire map is shown on the screen but the whole display can be accessed. To navigate the map
E6X Manual 54 5.2.6 3D View The 3D view is available for the 3D Fuel and Ignition maps. An example of the 3D maps is shown in this figure below.
E6X Manual 55 5.3 The Haltech Maps The Maps that the ECU uses to calculate fuel and ignition requirements are explained in detail here. 5.3.1 Fuel M
E6X Manual 56 Map 1. The second map represents ignition timing split for engine speeds above 2000rpm. This is found in Ignition Trailing Split Map 2.
E6X Manual 57 5.3.4.6 Barometric Pressure Map The barometric pressure correction map is accessed through the menu structure and can be found in the ma
E6X Manual 58 5.3.5.3 Coolant Temperature cranking map The coolant temperature cranking map is accessed through the menu structure and can be found in
E6X Manual 59 diaphragm to control the boost pressure. Each map has 32 bars distributed across engine speed in the range 0rpm to 16000rpm and each ba
E6X Manual vi Print Version: 3.03a...Date: 10 Aug 20
E6X Manual 60 SECTION2 Tuning The Engine CHAPTER 6 STARTING THE ENGINE Once the ECU is installed and the set-up has been completed it is time to t
E6X Manual 61 To check the base timing you should now start the engine with the Timing Lock “on” and set to an angle that allows the user to accuratel
E6X Manual 62 It is helpful, when first starting the engine, to have a “Trim Control” connected to the ECU loom to allow quick changes to fuelling ref
E6X Manual 63 To jump to the current range in a 2-dimensional and 3-dimensional map press: HOME 6.5.4 Tuning for Idle The idle mixture is very
E6X Manual 64 6.5.6 Loading the Engine Once the engine has been tuned properly for no load conditions it is possible to begin loading the engine. The
E6X Manual 65 6.5.7 Fine Tuning the Engine When fine-tuning the engine for the road, the same principles apply to all engines. Under full load at al
E6X Manual 66 CHAPTER 7 THROTTLE EFFECTS 7.1 Throttle Response Where the procedures described in the previous chapter tune for constant load runnin
E6X Manual 67 The final parameter on the Throttle Pump page is the Coolant Factor. Generally, when the engine is cold, accelerator pump values need t
E6X Manual 68 CHAPTER 8 COLD STARTING AND RUNNING The ECU has four features to correct fuel delivery and ignition timing to aid in starting and run
E6X Manual 69 CHAPTER 9 CORRECTION FACTORS Note: The following correction factors should not be altered unless you have a detailed knowledge of you
E6X Manual 7 Introduction Congratulations on your decision to choose a Haltech Engine Management System. Haltech EFI systems have been successfully
E6X Manual 70 9.4 The Ignition Inlet Air Temperature Map This Map allows up to 10° advance or retard of the spark timing based on the inlet air tempe
E6X Manual 71 The ECU begins with the basic idea that there are three ways to measure barometric pressure variations. 1. The ECU uses a user program
E6X Manual 72 In this case, the ECU will use the last measured pressure, which is stored in memory with the maps. To complete Method 2 follow these s
E6X Manual 73 When the ECU is configured to measure load by MAP sensor the external MAP sensor is connected to the Spare A/D input. 9.6 Post Start En
E6X Manual 74 SECTION 3 Software Features CHAPTER 10 DATA LOGGING 10.1 The Data log Option Data logging is simply recording the engine data as i
E6X Manual 75 10.1.2 Selecting the Data Channels Once you have opened the Log Data window, you will need to select which channels to log. Select a cha
E6X Manual 76 This dialog will be familiar to experienced users of the Windows operating system. Type the file name that you wish to save your logge
E6X Manual 77 10.1.4.1 Displaying Channels To display one of the channels that you have logged, click on one of the view buttons. Alternatively the
E6X Manual 78 To adjust the colour or channel properties the user selects the desired channel and can then select the Channel Colour button or Propert
E6X Manual 79 10.1.4.5 Data Values The Data Values window displays the numerical values of each data trace at the cursor position. The cursor is displ
E6X Manual 8 DO NOT CHARGE THE BATTERY WITH A 24VOLT TRUCK CHARGER OR REVERSE THE POLARITY OF THE BATTERY OR ANY CHARGING UNIT DO NOT CHANGE THE BATTE
E6X Manual 80 10.1.4.7 Changing the Trace Width To modify the width of the traces the user can select Data->Select Pen Width or the user can press
E6X Manual 81 SECTION4 Inputs & Outputs The ECU has a number of optional inputs and outputs other than the available injection and ignition chan
E6X Manual 82 CHAPTER 11 OUTPUT OPTIONS SET-UP The output options and PWM set-up pages are used to program settings for the output functions of the
E6X Manual 83 Number of Steps This field controls the number of steps that the idle control will operate over. If you have a stepper motor that uses s
E6X Manual 84 Hot Min Position Exactly the same as for when the engine is cold, except the value is used for when the engine is hot, that is the tempe
E6X Manual 85 sensor. If the closed loop function is responding erratically, constantly overdriving to the adjustment limits, or if there is insuffici
E6X Manual 86 11.2 The PWM Options Page The PWM options page contains the set-up information for the four PWM (pulse width modulation) outputs and th
E6X Manual 87 CHAPTER 12 DIGITAL OUTPUTS & PWM OUTPUTS The digital outputs and PWM outputs can be programmed to operate a wide variety of funct
E6X Manual 88 of map one and map two. The conditions for waste-gate map usage when “Advanced” is selected are: If the ECU is using the primary fuel a
E6X Manual 89 Off RPM should be set to at least 200 RPM below On RPM, forcing hysteresis in the switching to prevent the solenoid from oscillating whe
E6X Manual 9 Wire Cutters and Pliers Crimping Tool and assorted terminals Drill with assorted drill bits 3/8" NPT Tap 14mm x 1.5 Tap Electrical T
E6X Manual 90 12.7 Shift Light Illumination (SL) This function can be used to drive a light or buzzer to indicate the engine speed exceeds a program
E6X Manual 91 12.10 Staging Signal Function (SS) This function causes the output to turn on when the engine load exceeds the “Staging Bar” value. St
E6X Manual 92 If the RPM is below this value the NOS system will not be activated. Minimum Throttle 0 – 100 % The NOS system will be turned on above
E6X Manual 93 The anti-lag system is can be enabled by a switch connected to Aux. In or by meeting all three operating conditions stated above (the la
E6X Manual 94 12.16 VTEC This function controls the solenoid used to control the variable valve timing with which some engines are equipped. This fe
E6X Manual 95 Cold Idle Temp. 0 – 127 °C / 32 - 261 °F This value is the coolant temperature above which the “hot” base duty cycle value is used an
E6X Manual 96 Active Sw. Posn. HIGH or LOW This defines the active level or polarity of the signal. When this field is set to HIGH the active output
E6X Manual 97 SECTION 5 Appendices APPENDIX A TROUBLESHOOTING This Appendix is devoted to trouble shooting problems that may occur during installa
E6X Manual 98 A.1 Control Program Problems Haltech Programming Software will not start The Haltech programming software should run on any computer th
E6X Manual 99 A.3 Starting problems Fuel Pump doesn't prime when ignition switched on The Haltech E6X will attempt to run the Fuel pump for abo
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