ECO-FLO EFSUB5 4 Inch Submersible Pumps Owner’s Manual

Owner’s Manual4” Submersible PumpsTwo & Three Wire, 1/2 through 1-1/2 HP

Before you start

Selecting the Correct PumpBefore you remove and reinstall your submersible well pump, let’s review our good condition and the pump’s capabilities.WELL LOG INFORMATIONThe driller that drilled you are well should have given you a ‘well log’ summarizing the:A. Depth that the well was drilled, ie 170 ft. from the surface.B. Depth to what level the water rose in well, ie 130 ft. from the surfaceC. Depth to what level the water dropped to with the test pump pumping in your well ie dropped 20’ to 150’ from the surface when pumping continuouslyD. The gallons per minute your pump pumped, ie 10 GPM

In some counties, this information is recorded at the health office or other offices of the county, and/or the driller may have retained the information inthe driller’s file. You need a copy of the good log or this information from the good log.If you can not find the good log, you will need to drop a weighted string in the well to:A. Record the depth when it hits the bottom of the well.B. The depth at which water is standing in the well, ie the length of the string from the weighted end of the string that is wet.NOTE, your pump needs to be installed at a minimum of 5’ above the bottom of the well and 15-20’ below the surface of the water column in the well.

4” PUMP DESIGN AND OPTIMUM PERFORMANCE

This pump is designed to pump 10 gallons per minute (10 GPM), which is the average size home’s (3-4 bedroom) use of water per minute. Larger homes will require larger pumps.Deeper wells require higher horsepower to deliver water to the home. See the chart at right to ensure you have chosen the correct horsepower for your application.

PROPER 4” PUMP SELECTION
HP GPM PUMP DEPTH IN WELL
1/2 10 60-100’
3/4 10 100-175’
1 10 175-250’
1-1/2 10 greater than 250’

VOLTAGE4” submersible pumps are offered in two voltages, 115 or 230V. Be sure you select a pump whose motor voltage matches the voltage at the well

NUMBER OF PUMP WIRES AND CONTROL BOXES

4” pumps are offered in either 2-wire or 3-wire, indicating the number of wires running from the pump motor.2-wire motors have 3 wires running from the motor, 2 to provide electric service, and 1 ground wire. The motor controls are in the motor in the well.3-wire motors have 4 wires running from the motor, 3 to provide electric service, and 1 ground wire. These motors require a motor control box mounted on the wall near your water pressure tank.2-wire motors are typically only used in wells less than 300’ depths and 3-wire motors can be used in wells at any depth. Some users prefer their motor controls to be readily available for service. A 3-wire pump with a control box mounted near the tank provides ease of serviceability.

3-wire start components including capacitors and relays are located in the control box for ease of service. 2-wire start components are inside the hermetically sealed pump motor and rarely fail. If failure does occur, the pump must be replaced.NOTE: Control box voltage and horsepower must match pump voltage and horsepower.

HP PUMP VOLTAGE CONTROL BOX

HP                                              VOLTAGE

1/2 115 1/2 115
1/2 230 1/2 230
3/4 230 3/4 230
1 230 1 230
1-1/2 230 1-1/2 230

CONFIRMATION OF SELECTION

  • Knowing the above and prior to installing or removing and reinstalling your 4” pump, please confirm the following:
  • The correct HP for the depth of the pump will be in the well.
  • The correct GPM (gallons per minute) for your application.
  • The correct voltage
  • The correct number of wires
  • The correct control box (if applicable)

GENERAL SAFETY

Important Safety Instructions Carefully read and follow all safety instructions in this manual and on the pump.SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during the installation, operation, and maintenance of the product. Save this manual for future reference.

Safety LabelsThis is the safety alert symbol. When you see this symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury!

Indicates a hazard that, if not avoided, will result in death or serious injuryIndicates a hazard that, if not avoided, could result in death or serious injury.CAUTION Indicates a hazard that, if not avoided, could result in minor or moderate injury.NOTICE indicates practices not related to personal injury. Keep safety labels in good condition. Replace missing or damaged safety labels.

Under certain conditions, submersible pumps canHAZARDOUS PRESSURE develops extremely high pressure. Install a pressure relief valve capable of passing the entire pump flow at 100 PSI (690 kPa).Do not allow the pump, pressure tank, piping, or any other system component containing water to freeze. Freezing may damage the system, leading to injury or flooding. Allowing pump or system components to freeze will void the warranty.

HAZARDOUS VOLTAGE Can shock, burn, or cause death. To avoid dangerous or fatal electric shock hazards, use a pump only in a water well.

ELECTRICAL

HAZARDOUS PRESSURE Can shock, burn or cause Motor is supplied with copper ground wire. Splice to the copper conductor that matches the motor wire size specified in Table 3. See “cable splicing” under installation. death. Permanently ground pump, motor, and submersible motor control before connecting power supply to the motor. Permanently ground pump, motor, and submersible motor control before connecting power cable to the power supply. Connect the ground wire to the approved ground first, then connect equipment being installed. The ground submersible motor is in accordance with all codes and ordinances that apply. Use copper ground wire at least as large as wires carrying current to motor.

Wiring ConnectionsAll wiring must meet National Electrical Code or CanadianElectrical Code and local code requirements.Use only copper wire for connections to pump and submersible motor control.Table 1: Recommended Fusing Data – 60 Hz, Single Phase, 3 Wire Submersible Pump Motors

HP Volts Fuse Size
Standard Dual Element
1/23/4 230 20 10
230 25 15
1    I   230 30 20
1-1/2 230 35 _        20

To avoid over-heating wire and excessive voltage drop at motor, be sure wire size is sufficient per NEC standards for the pump horsepower and length of wire run.

NOTICE: See installation Wiring Diagrams for typical wiring hookups and submersible motor control identification.

Table 2: Recommended Fusing Data – 60 Hz, Single Phase, 2 Wire Submersible Pump Motors

HP Volts Fuse Size

Dual Element

20

Standard
1/2 115 35
3/4 230 20 10
1 230 25 15
1-1/2 230 30 20

INSTALLATION WIRING INSTRUCTIONS

Disconnect power before working on or around submersible motor control, pipes, cable, pump, or motor. Ground submersible motor control, all-metal plumbing, and motor frame with copper wire in compliance with National Electrical Code or Canadian Electrical Code and local code requirements. Use ground wire at least as large as the wires supplying power to the motor. At the wellhead, connect the ground wire to the grounding terminal that meets Canadian Electrical Code or National Electrical Code requirements that apply. For more information, contact local code officials. Permanently close all unused openings in this and other equipment.

Single Phase, 3 Wire Installation Hazardous voltage. Can shock, burn or kill.

Three Wire- 1/2 through 2 HP Submersible Motor Control. Follow color coding when connecting submersible motor control. (Yellow to Y, Red to R, Black to B)

Note:Install submersible motor control vertically on wall with the top side up. 3-Wire pumps have three power supply wires (Red/Black/Yellow) and one ground wire (Green) 3 wire pumps will not operate without submersible motor control; attempting to do so will burn out motor. Installations must include circuit and component protection in compliance with U.S. National Electrical Code or Canadian Electrical Code, Part 1. If main overload trips, look for:

  1. Shorted Capacitor
  2. Voltage Problems
  3. Overload or locked pump

Single Phase, 2 Wire Installation Hazardous voltage. Can shock, burn or kill.

Two-wire pumps have two power supply wires (Red/Black) and one ground wire. Submersible motor control is not required.

INSTALLATION

Wire Splicing Splice wire to the motor leads using only copper wire for connections to the pump motor and control box.

  1. Tapered splice (Wire sizes No. 8 and larger):A. Cut motor lead staggering lead and wire length so that second lead is 2″ longer than first lead and third lead is 2″ longer than second.B. Cut off power supply wire ends. Match colors and lengths of the wires to colors and lengths of motor leads.C.Trim installation back 1/2″ from supply wire and motor lead ends.D. Insert motor lead ends and supply wire ends into butt connectors. Match wire colors between supply wires and motor leads.E. Using crimping pliers, indent butt connector lugs to attach the wire.F. Cut electrical “Scotchfil’M” or equivalent insulation putty into three equal parts and form tightly around butt connectors. Be sure Scotchfilrm overlaps the insulting part of the wire.G. Using #33 Scotch”‘ or equivalent tape, wrap each joint tightly; cover wire for about 1-1/2″ on each side joint. Make four passes with the tape. When finished you should have four layers of tape tightly wrapped around the wire. Press edges of tape firmly down against the wire.NOTICE. Since the tightly wound tape is the only means of keeping water out of the splice, the efficiency of the splice will depend on the care used in wrapping the tape.NOTICE: For wire sizes larger than No. 8, use soldered joint rather than Scotchfil’M putty.
  2. Heat shrink splice [for wire sizes #14, 12, and AWG (2,3 and 5mm)]A. Remove 3/8″ insulation from ends of motor leads and power supply wires.B. Put plastic heat shrink tubing over motor leads between power supply and motor.C. Match wire colors and lengths between power supply and motor.D. Insert supply wire and lead ends Into butt connector and crimp. Match wire colors between power supply and motor. Pull leads to check connections.E. Center tubing over butt connector and apply heat evenly with the torch (match or lighter will not supply enough heat).NOTICE: Keep torch moving. Too much-concentrated heat may damage the tubing.
  3. Mechanical Splice Kit with plastic insulators (for 14, 12, and 10 Gauge AWG Wire (2, 3, and 5mm):A. Cut motor leads staggering lead and wire length so that 2nd lead is 4″ (101.6mm) longer than 1st lead and 3rd lead is 4″ (101.6mm) longer than second.B. Cut wire ends matching colors and lengths of wires between power supply and motor.C. Trim insulation back 1/2″ (12.7mm) from power supply wire and motor lead ends.D. Unscrew plastic caps from insulators. Place a cap and neoprene gasket sleeve on each wire to be spliced.E. Slide insulator body onto one wire end.F. Insert wire end into butt connector and crimp. Match wire colors between power supply and motor G. Center insulator body over splice and slide gasket sleeves into the body as far as they will go. Screw caps onto the insulator body and tighten by hand for a strong, waterproof splice.

Power Supply Wire Installation

  1. To test submersible, momentarily (no more than 5 seconds) connect it to the proper power supply. Power supply frequency and voltage must match motor nameplate frequency and voltage to within ±10%.
  2. Fasten power supply wire leads securely to the pump discharge section; leave 4-5″ (100-125mm) of slack in leads at this point. Securely fasten leads to a plastic pipe within 6″ (150mm) of the pump discharge section. Use centering guides to protect wire and pipe from rubbing well casing.
  3. Connect the copper ground wire to the motor bracket. The ground wire must be as large as wires supplying current to the motor. Consult current Canadian Electrical Code and local codes for grounding information.
  4. Most 4″ pumps have an eyelet on the discharge of the pump for attaching a rope to assist in lowering into and pulling the pump from the well. Attach a nylon rope of adequate length to the eyelet
  5. Do not use submersible power supply wires supplied by the pump manufacturers to lower or lift the pump. When lowering the pump into the well using only the rope and/or discharge pipe, secure supply wires to discharge pipe at 10 ft. (3M) intervals with Scotch\’”‘ #33 or equivalent electrical tape. DO NOT damage pump wires.NOTICE: To avoid dropping the pump down well or damaging wires or splices, NEVER allow pump wires to support weight of pump.

Discharge outlet is 1-1/4” FNPT threaded. Use 100 PSI (689.5kPa) rated polyethylene plastic pipe for installations up to 100’ (30.5M) depth. Use 160 PSI (1103.2 kPa) rated polyethylene plastic for installations up to 220’ (67.1M) depth. For depths beyond 220’ (67.1M) use galvanized steel pipe for the entire drop pipe.

INITIAL START-UP/NEW WELLS

NOTICE: NEVER operate the pump with the gate valve completely closed. Pump can destroy itself if run with the valve shut off (“dead-headed”) and warranty will be void.

NOTICE:To avoid a sand-locking pump, follow the procedure below when starting the pump for the first time. NEVER start a pump with the gate valve completely open unless you have done this procedure first.

  1.  Connect a pipe elbow, a short length of pipe, and a gate valve to pump discharge at the wellhead (see Fig. 3).
  2. Mount submersible motor control (3-wire pump) or fused disconnect switch (2-wire pump) in a permanently weatherproof place. Make sure that controls will not be subjected to extreme heat or excess moisture.
  3. Make sure controls are in the OFF position.
  4. Connect motor leads and power supply to submersible motor control or magnetic starter (see Installation Wiring Diagrams).DO NOT START THE PUMP YET.
  5. Set gate valve on discharge 1/3 open; start the pump (see Fig. 3).
  6. Keep gate valve at this setting while water pumps out on the ground. Let run until the water is clear of sand or silt. (To check solids in water, fill a glass from the pump and let solids settle out).
  7. When water is completely clear at 1/3 setting, open gate valve to approximately 2/3 open and repeat process.
  8. When water is completely clear at 2/3 setting, open gate valve completely and run the pump until water is completely clear.
  9. Remove gate valve for permanent installation near the tank (Fig. 4).
  10. .Install sanitary well seal or pitless adapter unit, well unit, electrical conduit, and surface piping. Installation must meet all code requirements that apply.

TEMPORARY CONNECTIONS WHILE CLEANING WELL FOR START-UPConnecting To Tank/Water SystemHazardous pressure. Submersible pumps can develop very high pressure in some situations. To prevent tank blowup, install a pressure relief valve able to pass full pump flow at 100 PSI (690 kPa).CAUTION Pipe joint compounds can cause cracking in plastics. Use only Teflon tape on joints in plastic pipe.NOTICE:Allowing the pump or piping system to freeze may severely damage the pump and will void the warranty. Protect pump and entire piping system (including pressure tank) from freezing.

Pre-Charged Pressure Tank HookupSee Fig. 4 for piping connections to the pre-charged pressure tank.NOTICE:Check air pre-charge in the tank before starting pump. Adjust pre-charge to 2 PSI (13.8kPa) below pump cut-in setting, (ie, a pre-charge tank used with a 30-50 switch should be pre-charged with air to 28 PSI (193.1 kPa). Adjust precharge by adding or bleeding air through the Schrader valve located on top of tank. Check pre-charge annually and adjust as needed.

Important Electrical Grounding InformationHazardous voltage. Can shock, burn, or kill. To reduce the risk of electrical shock during pump operation, ground and bond the pump and motor as follows:A. To reduce the risk of electrical shock from metal parts of the assembly other than the pump, bond together all metal parts accessible at the wellhead (including metal discharge pipe, metal well casing, and the like). Use a metal bonding conductor at least as large as the power cable conductors running down the well to the pump’s motor.B. Clamp or weld (or both if necessary) this bonding conductor to the grounding means provided with the pump, which will be the equipment-groundingterminal, the grounding conductor on the pump housing, or an equipment-grounding lead. The equipment-grounding lead, when provided, will be the conductor having green insulation; it may also have one or more yellow stripes.

C. Ground the pump, motor, and any metallic conduit that carries power cable conductors. Ground these back to the service by connecting a copper conductor from the pump, motor, and conduit to the grounding screw provided within the supply- connection box wiring compartment. This conductormust be at least as large as the circuit conductors supplying the pump

SAVE THESE INSTRUCTIONS.

CUT IN  PSI (kPa) CUT OFF  PSI (kPa) PRE-CHARGE TANK  PSI (kPa)
20 (137.9) 40 (275.8) 18 (124.2)
30 (206.8) 50 (344.7) 28 (193.1)
40 (275.8) 60 (413.7) 38 (262)

TROUBLESHOOTING

PROBLEM CHECK CORRECTIVE ACTION
MOTOR WILL NOT START BUT FUSES DO NOT BLOW
No voltage. No voltage at submersible motor control or disconnect switch.

No voltage at the pressure switch.

No voltage at submersible motor control.

Cable or splices are bad.

Submersible motor control incorrectly wired.

Replace blown fuses.

Replace faulty pressure switch.

Rewire supply to submersible motor control.

Consult a licensed electrician or serviceman.

Reconnect submersible motor control correctly

(see Wiring Installation Diagrams).

FUSES BLOW OR TRIP WHEN THE MOTOR STARTS
FUSES BLOW OR TRIPS WHEN MOWrong size fuse or wrong

size time-delay fuse.

Wire size too small.

Starting capacitor defective,

blown, or wrong size.

Low or high voltage.

 

Check fuse size against the chart, Page 3.

Check wire size against the chart, Page 3.

Check submersible motor control to see if starting capacitor has blown out. Check capacitor rating. Check start relay. 

Check that line voltage is within ±10% of the nameplate

rated voltage while motor is running.

Install correct fuse or time-delay fuse.

Install correct size wire.

Replace starting capacitor. Replace start relay if

defective.

If voltage variation is greater than ±10%, call the power

company or local hydro authority to adjust the voltage.

Power supply wire leads are not correctly connected to submersible motor control.  Check submersible motor control wiring diagram against

incoming power hookup. Check power supply wire color coding. 

Reconnect leads to matching wiring diagram in submersible

motor control cover. Reconnect power supply wires so

wire color code matches motor lead color code.

Broken wire in submersible

motor control.

Pump or motor stuck or

binding.

 

Examine all connections and wiring in submersible

motor control.

Check for the locked shaft in the pump.

 

Disconnect power and repair or replace the faulty wire.

If necessary, pull the pump (make all possible above ground

checks first). If the pump is locked, replace it. Clean well

of all sand or lime before reinstalling the pump.

FUSES BLOW OR OVERLOAD PROTECTOR TRIPS WHEN MOTOR IS RUNNING
Low or high voltage.  High ambient (atmospheric)

temperature.

Check that line voltage is within ±10% of the rated nameplate

voltage while motor is running.

Check the temperature of submersible motor control.

If voltage variation is more than ±10%, call power

company to adjust the voltage.

Do not mount submersible motor control in direct sunlight.

Submersible motor control

with wrong voltage or horsepower rating. 

Wire size too small.

Compare voltage and horsepower on motor nameplate with those given on submersible motor control nameplate or

on circuit diagram inside submersible motor control cover.

Check wire size against the chart, Page 3.

Replace submersible motor control if numbers do not

match. Use only submersible motor control designed for

use with a pump.

Install correct wire size.

PUMP STARTS TOO FREQUENTLY
Leaks in the system.

Pressure switch.

Check valves leaking.

Tank waterlogged.

 

Check all tank connections with soapsuds for air leaks.

Check plumbing for leaks.

Check for the defective switch or switch out of adjustment.

Make sure check valves are not leaking back.

Pre-charged tanks: check tank pre-charge air pressure, check for leaks in the bladder.

 

System must be air and watertight.

Re-adjust or replace the pressure switch.

Replace check valves if necessary.

Pre-charge tanks: adjust air pressure to 2 PSI (13.8kPa)

less than pump cut-in pressure (when there is no water pressure on the system). Replace bladder if necessary.

 

Leak in the drop pipe.

 

Pressure switch too far from tank.

Air over water tanks: check for air leaks Check

Air Volume Control (AVC).

Raise drop pipe one length at a time until the water stands in the pipe.

Measure distance from pressure switches to tank.

Air over water tanks: repair or replace tanks,

replace AVC if necessary.

Replace pipe above that point.

Move the switch to within 1’ (.3M) of the tank.

LITTLE OR NO WATER DELIVERED
Check valve stuck

or installed backward

(standard tank only).

Low water level.

 

Examine valve.

Determine lowest water level in well while the pump is running and compare to pump depth setting.

If stuck, free valve; if installed backward, reverse it.

Lower pump further into well (but at least 5’ (1.5M)

above the bottom of well). Throttle pump discharge until discharge equals recovery rate of well.

NOTICE: Running pump while airlocked can cause loss of

prime and seriously damage pump.

Low voltage.

 

 

Plugged intake screen.

Check valve at pump

discharge stuck.

Worn impellers and diffusers.

 

Check voltage at submersible motor control with the pump running.

Check incoming wire size and power supply wire size against the chart, Page 3.

Pull pump and check the condition of the screen.

Pull pump and examine check valve.

Install larger wire from meter to submersible motor control.

Install larger wire from submersible motor control to pump.

If necessary, have the power company raise supply voltage.

Clean or replace as necessary.

Free check valve.

AIR OR MILKY WATER DISCHARGE FROM FAUCETS
Gas in well water.

 

Check for the presence of gas in well water. Remove bleeder orifices; plug tees. Be sure plugged tees do not leak. If necessary, separate gas from the air before it enters the pressure tank.
Air volume control not work-

ing (standard tanks only).

Make sure ports and ball check valves are clear. Replace control if necessary

SUBMERSIBLE PUMP REPAIR PARTS

PiO                           OWNTITY             PART MASER
1 1 EFSUP0501 Motor 1/2HP 2IN 115V
EFSUP0502 Motor 1/2HP 2IN 230V
EFSUP0503 Motor          1/2HP 3149230V
EFSUP0751 Motor 3/4HP 2W 230V
EFSUP0752 Motor 3/4HP 3W 230V
EFSUP1001 Motor 1 HP 2W 230V
EFSUP1002 Motor 1HP 3W 230V
EFSUP1501 Motor 1-1/2HP 3W 230V
EFSUP1502 Motor 1-1/2HP 2W 230V
2 1 EFSUP1003 Wire Guard
EFSUP0506 Wire Guard
EFSUP1503 Wire Guard
EFSUP0753 Wire Guard
EFSUP1004 Wire Guard
EFSUP1504 Wire Guard
3 1 EFSUP1005 Cartridge assembly 5 stages
EFSUP0508 Cartridge assembly 6 stages
EFSUP1505 Cartridge assembly 7 stages
EFSUP0754 Cartridge assembly 9 stages
EFSUP1006 Cartridge assembly 12 stages
EFSUP1506 Cartridge assembly 16 stages

WARRANTY

Retain Original Purchase Receipt for Warranty Eligibility

Limited Warranty Manufacturer warrants to the original consumer purchaser (“Purchaser” or “You”) that its products are free from defects in material and workmanship for a period of three years from the date of the original consumer purchase If, within three years from the original consumer purchase, any such product shall prove to be defective, it shall be repaired or replaced at manufacturer’s option, subject to the terms and conditions set forth herein. Note that this limited warranty applies to manufacturing defects only and not to ordinary wear and tear. All mechanical devices need periodic parts and services to perform well. This limited warranty does not cover repair when normal use has exhausted the life of a part of the equipment. The original purchase receipt and product warranty information label are required to determine warranty eligibility. Eligibility is based on the purchase date or original product — not the date of replacement under warranty. The warranty is limited to repair or replacement of originally purchased product only, not replacement product (i.e. one warranty replacement allowed per purchase) Purchaser pays all removal, installation, labor, shipping, and incidental charges. Claims made under this warranty shall be made by returning the product to the retail outlet where it was purchased or to the factory immediately after the discovery of any alleged defect. The manufacturer will subsequently take corrective action as promptly as reasonably possible. No requests for service will be accepted if received more than 30 days after the warranty expires. Warranty is not transferable and does not apply to products used in commercial/rental applications.

General Terms and Conditions; Limitations of RemediesYou must pay all labor and shipping charges necessary to replace the product covered by this warranty. This warranty does not apply to the following: (1) acts of God; (2) products which, in manufacturer’s sole judgment, have been subject to negligence, abuse, accident, misapplication, tampering, or alteration; (3) failures due to improper installation, operation, maintenance or storage; (4) atypical or unapproved application, use or service; (5) failures caused by corrosion, rust or other foreign materials in the system, or operation at pressures in excess of recommended maximums. This warranty sets forth the manufacturer’s sole obligation and the purchaser’s exclusive remedy for defective products. THE MANUFACTURER SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER. THE FOREGOING LIMITED WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING LIMITED WARRANTIES SHALL NOT EXTEND BEYOND THE DURATION PROVIDED HEREIN. Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to You. This warranty gives You specific legal rights and You may also have other rights which vary from state to state.

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1899 Cottage Street, Ashland, Ohio 44805Telephone: 1-877-326-3561Fax: 1-877-326-1994www.ecofloproducts.com

References

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