IMA 574B
OPERATING MANUAL
CV320-I
Semi automatic arc welding machine
This manual applies to
Part No. Code Desc
KA1392 1447 CV320-I 415
KA1392-1 1473 CV320-I 380
KA1392 1509 CV320-I 415
KA1392-1 1510 CV320-I 380
KA1392 1535 CV320-I 415
Volts
SAFETY DEPENDS ON YOU
Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be increased by
proper installation . . . and thoughtful operation on your part. Read and observe the general safety precautions on
page 2 and follow specific installation and operating instructions included in this manual.
Most importantly, think before you act and be careful.
THE LINCOLN ELECTRIC COMPANY
A.C.N. 000 040 308
SYDNEY. AUSTRALIA
A Subsidiary of
(AUSTRALIA) PTY. LTD.
THE LINCOLN ELECTRIC CO. U.S.A.
Associated Subsidiaries in Australasia, Europe, North and South America.
THE WORLD’S LEADER IN WELDING AND CUTTING PRODUCTS
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FOR ENGINE powered
equipment
CYLINDER may explode if
damaged
5. a. Use only compressed gas cylinders containing the
correct shielding gas for the process used and
properly operating regulators, designed for the gas
and pressure used. All hoses, fittings, etc. should be
suitable for the application and maintained in good
condition.
7. a.Turn the engine off before troubleshooting and
maintenance work unless the maintenance
work requires it to be running.
b.Operate engines in open, well ventilated areas
or vent the engine exhaust fumes outdoors.
b. Always keep cylinders in an upright position and
securely chained to an undercarriage or fixed
support.
c.Do not add fuel near an open flame, welding
arc or when the engine is running. Stop the
engine and allow it to cool before refuelling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill
fuel when filling tank. If fuel is spilled, wipe it up
and do not start engine until fumes have been
eliminated.
c. Cylinders should be located :
• Away from areas where they may be struck or
subjected to physical damage.
• A safe distance from arc welding or cutting
operations and any other source of heat, sparks or
flame.
d. Never allow the electrode, electrode holder, or any
other electrically “hot” parts to touch a cylinder.
d.Keep all equipment, safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
e. Keep your head and face away from the cylinder
valve outlet when opening the cylinder valve.
f. Valve protection caps should always be in place and
hand-tight except when the cylinder is in use or
connected for use.
e.In some cases it may be necessary to remove
g. Read and follow the instructions on compressed gas
cylinders and associated equipment, and AS 2030
Parts 1 & 2.
safety
maintenance. Remove guards only when
necessary and replace them when the
guards
to
perform
required
maintenance requiring their removal is
complete. Always use the greatest care when
working near moving parts.
FOR ELECTRICALLY
powered equipment
6. a. Turn off input power using the disconnect switch at
the fuse box before working on the equipment.
f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
b. Install equipment in accordance with the SAA Wiring
Rules, all local codes and the manufacturer’s
recommendations.
g.To prevent accidentally starting petrol engines
while turning the engine or welding generator
during maintenance work, disconnect the
spark plug wires, distributor cap or magneto
wire as appropriate.
c. Ground the equipment in accordance with the SAA
Wiring
Rules
and
the
manufacturer’s
recommendations.
h.To avoid scalding do not remove the radiator
pressure cap when the engine is hot.
HAVE ALL INSTALLATIONS, OPERATION, MAINTENANCE AND REPAIR WORK PERFORMED BY QUALIFIED PEOPLE
For more detailed information it is strongly recommended that you purchase a copy of “Safety in Welding and Cutting - ANSI
Standard Z 49.1” and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards are available from the Welding
Technology Institute of Australia, P.O. Box 6165, Silverwater NSW 2128. For copies of various Australian Standards contact your
local S.A.A. office.
HOW TO ORDER REPLACEMENT PARTS
To ensure that you receive the correct replacement part the following procedure should be followed:
1. Quote Serial Number and Code Number.
2. Quote the Description, Item Number and Parts List Number of the desired part. When ordering parts for items
carrying brand names of other companies, such as fan motors, drive shafts, etc., be sure to include the other
company’s name and part number and other relevant information.
3. Should the primary cord be damaged, a special cord is required, and is available from Lincoln.
4. Parts should be ordered from Lincoln’s nearest authorised Field Service Shop. (The “Lincoln
Service Directory” listing these shops geographically is available on request.)
NOTE: “Hardware” in the Lincoln Parts Lists are not Lincoln stock items but can be obtained via the Field Service Shop network.
Component parts of assemblies such as stator coils or armature coils, etc., which require electrical testing or locating fixtures are
not considered replaceable items. This is to ensure that the customer receives parts which will keep the welder in the best
operating condition.
IMA 574B
CV320-I
Page 3
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WELDING, EMF AND PACEMAKERS
All welders should follow safe practices that minimize their
exposure to electric and magnetic fields (EMF).
Welders with Pacemakers
There is no question that the fields in arc welding can interfere
with a pacemakers function. Generally the interference does not
permanently damage the pacemaker. Once the wearer leaves the
arc welding environment or stops welding, the pacemaker returns
to normal functioning. The welding arc has little or no effect on the
operation of some pacemakers, especially designs that are bi-
polar or designed to filter out such interference.
For welders wearing implanted pacemakers, safe welding
practices are particularly important and additional procedures
should be followed by those who have decided to continue to
weld. (Hopefully in keeping with a doctor’s advice).
The following procedures will not eliminate exposure to EMF or
the possibility of arc welding having an effect on a pacemaker,
however if followed, they will significantly reduce exposure to
electric and magnetic fields. Electric and magnetic fields are
created any time electric current flows through a conductor,
however it is not clear whether such exposure affects ones health.
For a welder or anyone working around electrical equipment the
selection of a pacemaker is very important. Get a doctor’s advice
about which pacemaker is the least sensitive to interference from
welding while still being medically suitable.
Some researchers have reported that exposure to EMF may
cause leukemia or other illnesses. These claims originally arose in
relation to high voltage electric power lines and are very much in
dispute in the medical and scientific arena, however the best
advice is to minimise your exposure to EMF to protect your health
should doctors eventually decide there is a risk.
In addition to the normal safety precautions, the following
additional procedures should be adopted by welders with
pacemakers.
•
•
Use gas welding when the application is suitable.
Use the lowest current setting appropriate for the application.
Do not exceed 400 amps. Low current (75-200 amps) direct
current (DC) welding should be used if arc welding is
necessary. Do not TIG weld with high frequency.
There are four fundamental fact about EMF:
•
•
•
•
With direct current (DC), the field strength is relatively
constant and does not change.
With alternating current (AC), the field strength constantly
changes.
•
•
Do not use repeated, short welds. Wait about ten seconds
between stopping one weld and starting the next. When
having difficulty starting an electrode, do not re-strike the rod
repeatedly.
The greater the current flow, i.e. the higher the amps, the
stronger the field created by the current
The closer the conductor or electrical device is to the body,
the greater the exposure to the field.
If you feel light headed, dizzy or faint, immediately stop
welding. Lay the electrode holder down so that it does not
contact the work and move away from any welding being
performed. Arrange your work in advance so that, if you
become dizzy and drop the electrode holder, the electrode
holder will not fall on your body or strike the work.
Minimising Exposure
All welders should use the following procedures to minimise EMF
exposure.
•
Route electrode or gun and work cables together. Secure
them with tape if possible.
•
•
Do not work on a ladder or other elevated position or in a
cramped, confined place.
•
•
Never coil the electrode lead around your body.
Do not place your body between the electrode and work
cables. If your electrode cable is on your right side the work
cable should also be on your right side.
Do not work alone. Work only in the presence of an individual
who understands these precautions and the possible effect
welding may have on your pacemaker.
•
•
Connect the work cable to the work piece as close as possible
to the area being welded. (This is also a good practice to
eliminate a common problem on welding - a poor work
connection).
•
•
Do not work near spot welding equipment.
Do not work next to the welding power source.
If you have a pacemaker and wish to continue arc welding,
discuss this an any other questions you may have with your
physician and follow his or her advice. The doctor may wish to
contact the pacemaker manufacturer for a recommendation.
As mentioned before, the design of the pacemaker
significantly affects the degree to which it is subject to
interference from a welding circuit. Do not rely on the fact that
you know another welder with a pacemaker who has welded
for years without experiencing a problem. That welder and his
or her pacemaker may be quite different from you and your
pacemaker.
Page 4
CV320-I
IMA 574B
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INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY
The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.
WARNING
This welding machine must be used by trained operators
only. Read this manual carefully before attempting to use
the welding machine.
Methods of Reducing Emissions
Mains Supply
Conformance
Welding equipment should be connected to the mains supply
according to the manufacturers recommendations.If interference
occurs, it may be necessary to take additional precautions such as
filtering the mains supply. Consideration should be given to
shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The shielding should
be connected to the welding power source so that good electrical
contact is maintained between the conduit and the welding power
source enclosure.
Products displaying the C-Tick mark are in conformity with
Australian/New Zealand requirements for the Electromagnetic
Compatibility (EMC). They are:
•
manufactured in conformity with Australian/New Zealand
Standard (Emission):- AS/NZS 3652 ‘Electromagnetic
Compatibility - Arc Welding Equipment’ (identical to and
reproduced from, British Standard EN 50199).
•
•
for using with other Lincoln Electric/LiquidArc equipment.
designed for industrial and professional use.
Maintenance of the Welding Equipment
Introduction
The welding equipment should be routinely maintained according
to the manufacturer’s recommendations. All access and service
doors and covers should be closed and properly fastened when
the welding equipment is in operation. The welding equipment
should not be modified in any way except for those changes and
adjustments covered in the manufacturers instructions. In
particular, the spark gaps of arc initiation and stabilising devices
should be adjusted and maintained according to the
manufacturer’s recommendations.
All electrical equipment generates small amounts of
electromagnetic emission. Electrical emission may be transmitted
through power lines or radiated through space, similar to a radio
transmitter. When emissions are received by other equipment,
electrical interference may result. Electrical emissions may effect
many kinds of electrical equipment; other near by welding
equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that
interference may result and extra precautions may be required
when a welding power source is used in a domestic
establishment.
Welding Cables
The welding cables should be kept as short as possible and
should be positioned close together, running at or close to the
floor level.
Installation and Use
The purchaser/user is responsible for installing and using the
welding equipment according to the manufacturer’s instructions. If
electromagnetic disturbances are detected then it shall be the
responsibility of the purchaser/user of the welding equipment to
resolve the situation with the technical assistance of the
manufacturer. In some cases this remedial action may be as
simple as earthing (grounding) the welding circuit (see note
below). In other cases it could involve constructing an
electromagnetic screen enclosing the power source and the work
complete with associated input filters. In all cases electromagnetic
disturbances must be reduced to the point where they are no
longer troublesome.
Equipotential Bonding
Bonding of all metallic components in the welding installation and
adjacent to it should be considered. However, metallic
components bonded to the work piece will increase the risk that
the operator could receive a shock by touching these metallic
components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety,
nor connected to earth because of its size and position, eg. ship’s
hull or building steelwork, a connection bonding the workpiece to
earth may reduce emissions in some, but not all instances. Care
should be taken to prevent the earthing of work pieces increasing
the risk of injury to users, or damage to other electrical
equipment. Where necessary, the connection to the workpiece to
earth should be made by direct connection to the workpiece, but in
some countries where direct connection is not permitted, the
bonding should be achieved by suitable capacitance, selected
according to national regulations.
NOTE: The welding circuit may or may not be earthed for safety
reasons according to national codes. Changing the earthing
arrangements should only be authorised by a person who is
competent to assess whether the changes increase the risk of
injury, eg. by allowing parallel welding current return paths which
may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the purchaser/user shall make
Screening and Shielding
an assessment of potential problems in the surrounding area.
Selective screening and shielding of other cables and equipment
in the surrounding area may alleviate problems of interference.
Screening of the entire welding installation may be considered for
special applications.*
The following shall be taken into account:
a. Other supply cables, control cables, signalling and telephone
cables; above, below and adjacent to the welding equipment;
b. Radio and television transmitters and receivers;
c. Computer and other control equipment;
*
Portions of the preceding text are contained in AS./NZS3652:
‘Electromagnetic Compatibility - Arc Welding Equipment’.
d. Safety critical safety equipment, eg. guarding of industrial
equipment;
e. The health of people around, eg. the use of pacemakers and
hearing aids;;
f. Equipment used for calibration or measurement;
g. The immunity of other equipment in the environment. The
purchaser/user shall ensure that other equipment being used
in the environment is compatible. This may require additional
protection measures;
h. The time of the day that welding or other activities are to be
carried out.
IMA 574B
CV320-I
Page 5
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PRODUCT DESCRIPTION
The CV320-I is a semi-automatic Constant Voltage DC arc welding power source and wire feeder. It combines a step controlled power
source with a separate solid state controlled wire feeder.
Excellent arc characteristics are provided for both gas shielded and self shielded welding within its current range.
For instructions on operation of the wire feeder refer to the separate instruction manual included. Standard features include output volt &
amp meters, a spot timer, gas purge facilities, a dual position 2 or 4 step trigger interlock, a Magnum FM400 gun, a regulator/flowmeter
and gas hose, a 10m electrode cable and wire feeder cable, a 3m ground cable assembly, a 3m long input lead and an undercarriage on
which a gas cylinder can be mounted.
Specifications
Part No.
KA 1392 & KA1392-1
45V
Maximum Open Circuit Voltage
Output Current Range
Duty Cycle
20 to 400A
60%
30%
100%
190A/23.5V
Rated Output
320A/30V
240A/26V
Rated Input
KA1392 415V 3ph 50Hz 13.5 amps
KA1392-1 380V 3ph 50hz 14.7amps
Wire Speed Range
1-20 m/min
Weight (complete with u/c)
140 kg
H x W x L (mm) Over wire feeder,
cylinder tray & wheels
1220 x 580 x 842 mm
Operating Temperature
-20˚C to 40˚C
INSTALLATION
Location
Connection to Mains Supply
Place the welder where clean cooling air can freely circulate in
through the intake louvers and out through the exhaust louvers.
Dirt, dust or any foreign material that can be drawn into the welder
should be kept at a minimum. Failure to observe these
precautions can result in excessive operating temperatures and
nuisance thermostat trips.
Before connecting the machine to the mains supply check that the
voltage and current capacity correspond to the machine voltage
and rated input current. Use a fuse or C/B per AS3000 or local
wiring rules.
The machine is supplied with an input lead fitted. Have a qualified
electrician fit a suitable input plug.
CAUTION
Wire Feeder Mounting
Never connect the green/yellow conductor to any of the
three active supply lines from the mains. This conductor is
to earth the machine as required by Electrical Regulations.
Locate the control cable at the rear of the CV320-I and plug into
the wire feeder. The control cable is already connected to the
CV320-I. Connect the supplied 1.5m electrode cable to the wire
feeder mechconnector and to the desired polarity terminal on the
front of the CV320-I.
Once the above has been followed the machine can be plugged
into the mains outlet.
Shielding Gas Supply
(For the Gas Metal Arc Welding Process)
• Turn the input power off at the
WARNING
Refer “Safety in Welding and Cutting” - ANSI Standard Z49.1 and
WTIA Technical Note 7, available from the Welding Technology
Institute of Australia.
disconnect switch before installing
or servicing this machine.
• Do not touch electrically “hot” parts
such as output terminals or internal
wiring.
Obtain cylinder of appropriate type shielding gas for the process
being used.
1. Set gas cylinder on rear platform of the machine. Hook chain
in place to secure cylinder to rear of welder.
• Connect grounding screw ( ) to a
good earth ground.
• Do not operate with covers removed.
CYLINDER may explode
if damaged
• Turn power switch “off” before
connecting or disconnecting cables
or other equipment.
HIGH
VOLTAGE
can kill
2. Remove the cylinder cap. Inspect the cylinder valve for
damaged threads, dirt and dust. For cylinders having an
external thread fitting, remove any dust and dirt from the
threads with a clean cloth.
Only qualified personnel should install or service this
equipment.
Page 6
CV320-I
IMA 574B
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DO NOT ATTACH THE REGULATOR/FLOWMETER IF
CYLINDER VALVE IS DAMAGED! Inform your gas supplier of this
condition.
NOTE: If a gun and cable other than the Magnum FM400 gun are
to be used, they must conform to standard European-style
connector specifications. See diagram under.
3. Stand to one side away from the outlet and open the cylinder
valve for an instant. This blows away any dust or dirt which
may have accumulated in the valve outlet.
WARNING
Be sure to keep your face away from the valve outlet
when “cracking” the valve.
The gun trigger switch must be capable of switching 10 milliamps
at 60 volts DC—resistive.
4. Inspect the regulator/flowmeter for damaged threads and
seals, dirt and dust. Remove dust and dirt with a clean cloth.
DO NOT USE THE REGULATOR/FLOWMETER IF DAMAGE
IS PRESENT! Have an authorised repair station repair any
damage.
CAUTION
The gun trigger switch connected to the gun trigger
control cable must be a normally open, momentary
switch. The terminals of the switch must be insulated
from the welding circuit. Improper operation of, or
damage to, the machine might result if this switch is
common to an electrical circuit other than the machine
trigger circuit.
WARNING
Gas under pressure is explosive. Always keep gas
cylinders in an upright position and always keep chained
to undercarriage or stationary support. Refer “Safety in
Welding and Cutting” - ANSI Standard Z49-1 and WTIA
Technical Note 7 available from the Welding Technology
Institute of Australia.
Output Polarity Connection
5. Attach the regulator/flowmeter to the cylinder valve and
tighten the union nut(s) securely with a spanner.
WARNING
6. Attach the inlet gas hose to the outlet fitting of the
regulator/flowmeter, and tighten the union nut securely with a
spanner.
Turn the welder power switch off before changing output
connection.
Connect the lead from the wire feeder to the output stud of the
desired polarity.
WARNING
Connect the work lead to the other output stud.
Never stand directly in front of or behind the
regulator/flowmeter when opening the cylinder valve.
Always stand to one side.
7. Before opening the cylinder valve, turn the regulator adjusting
knob counter-clockwise until the adjusting spring pressure is
released.
8. Open the cylinder valve slowly a fraction of a turn. When the
cylinder pressure gauge pointer stops moving, open the valve
fully.
9. The regulator/flowmeter is adjustable. Set it for the flow rate
recommended for the procedure and process being used
before starting to weld.
Gun and Cable
The Magnum FM400 gun and cable provided with the machine is
set up for 0.9/1.2mm operation.
1. Lay the cable out straight.
WARNING
Turn the welder power switch off before installing gun
and cable.
2. Make sure all pins on the gun cable connector are aligned
with the proper mating sockets on the front panel gun
connector and then join the connectors and tighten the hand
nut on the gun cable connector.
IMA 574B
CV320-I
Page 7
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OPERATING INSTRUCTIONS
Pilot Light
WARNING
This light illuminates when the input mains power is switched on
Volts Control
• Do not touch electrically live parts or
electrode with skin or wet clothing.
The output voltage is controlled by two rotary switches. One rotary
switch provides four “coarse” voltage settings as well as switching
the mains power on. The other rotary switch provides the user with
a selection of eight “fine” voltage settings. The selection between
these two rotary switches allows the user to select any one of
thirty-two welding voltages.
• Insulate yourself from work and
ground.
• Always wear dry insulating gloves.
ELECTRIC
SHOCK
The approximate weld voltages for the rotary switch positions are:
can kill
Coarse Fine Volts
Coarse Fine Volts
• Keep your head out of fumes.
1
1
1
1
1
1
1
1
3
1
2
3
4
5
6
7
8
1
13.0
14.0
15.0
16.0
16.5
17.0
17.5
18.0
21.5
2
2
2
2
2
2
2
2
4
1
2
3
4
5
6
7
8
1
18.0
18.5
19.0
19.5
20.0
20.5
21.0
21.5
25.0
• Use ventilation or exhaust to remove
fumes from breathing zone.
FUMES AND
GASES can be
dangerous
• Keep flammable material away.
• Do not weld upon containers which
have held combustibles.
WELDING SPARKS
can cause fire or
explosion
3
3
3
3
3
3
3
2
3
4
5
6
7
8
22.0
22.5
23.0
23.5
24.0
24.5
25.0
4
4
4
4
4
4
4
2
3
4
5
6
7
8
25.5
26.0
26.5
27.0
28.0
29.0
30.0
• Wear eye, ear and body protection.
ARC RAYS
can burn
Current Control
IMPORTANT SAFETY NOTE: In 2T mode, this DC Constant
Voltage wire welder provides “COLD” electrode when the gun
trigger is not operated. Conversely, the output terminals are
“LIVE” when the gun trigger is “activated” when pressed in 2T
mode, or triggered on in 4T mode.
Use the wire feed speed control on the wire feeder to adjust the
speed at which the electrode wire feeds when welding. This is in
effect a current control as the power source will deliver the current
necessary to melt the wire. The higher the speed, the more current
will be required.
Refer to wire feeder manual for a description of the 2T/4T trigger
operation.
Over temperature light
Duty Cycle
The machine is rated at the following duty cycles:
Indicates that the thermostats have operated to protect unit from
over temperature.
Duty Cycle*
Output Amps
Arc Volts
Setting Up for Welding
(Also refer to the wire feeder instruction manual.)
30%
60%
320
240
190
30
26
The following items are required:
100%
23.5
1) A reel of wire of suitable size and type .
* Based on 10 min. time period (i.e., for 60% duty cycle, it is 6
minutes actual welding and 4 minutes with no welding output,
but with the input power remaining on keeping the cooling fans
operative.)
2) A suitable gun and cable assembly with a “Euro” connector
and the correct tip and, if necessary gas nozzle for the
consumable being used. (A Magnum FM400 gun is supplied).
3) A work return cable and clamp. (supplied)
4) Normal welding accessories including helmet or hand shield
with suitable lens, gloves etc.
Control Panel
Power Switch
The mains power switch is incorporated in the “coarse” output
voltage control rotary switch. In the “0” position (fully counter
clockwise) the input mains power is switched off.
5) If a gas shielded process is to be used, a cylinder of
appropriate gas is required. (Regulator/flowmeter and hose
are supplied.)
Page 8
CV320-I
IMA 574B
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If gas shielding is required, see Section 1.4. Connect the gas
hose.
General
In extremely dusty locations, dirt may clog the air passages and
cause the welder to run hot. Blow dirt out of the welder with low-
pressure air at regular intervals to eliminate excessive dirt and
dust build-up on internal parts.
Remember that gas cylinders may explode if damaged, so ensure
that all gas cylinders are securely mounted.
Ensure there are no kinks or sharp bends in the gun cable and
hold the wire inch button until the wire emerges from the gun. It is
good practice to remove the tip when first feeding a new coil of
wire, then refit over the wire and tighten.
The fan motor has sealed ball bearings which require no service.
Welding Thermal Overload Protection
The CV320-I has built-in protective thermostats that respond to
excessive temperature. They open the wire feed and welder
output circuits if the machine exceeds the maximum safe
operating temperature because of a frequent overload, or high
ambient temperature plus overload. The over temperature light
glows when the thermostats open. The thermostats automatically
reset when the temperature reaches a safe operating level.
Cut off the end of the wire leaving 10mm to 15mm stick-out.
The gun polarity is selected by connecting the wire feeder cable to
the required output stud. e.g. electrode (+) - connect the lead to
the (+) output stud. For electrode (-) - connect the lead to the (-)
output stud.
Connect the work lead to the other output stud.
Welding
Gun and Cable Maintenance
Cable Cleaning
WARNING
Clean cable liner after using approximately 150kg of electrode.
Remove the cable from the wire feeder and lay it out straight on
the floor. Remove the contact tip from the gun. Using an air hose
and approx. 350 kPa (50psi) pressure, gently blow out the cable
liner from the gas diffuser end.
When the gun trigger is pressed (2T mode) or pressed and
released the first time (4T mode), the wire is at welding
voltage. The wire should never touch the case of the wire
feeder. If it does, it is possible for the wire to arc to the case.
Any wire overrun should be avoided.
(Refer wire feeder instruction manual.)
WARNING
Excessive air pressure at the start of cable cleaning may
cause dirt to form a plug.
Put into 2T mode.
Select the output voltage required to suit the job by setting the
coarse and fine rotary switches.
Before beginning welding, ensure the wire protrudes from the gun
tip by approximately 10-15mm. Ensure welding shield and other
protective clothing are in place. Present the protruding electrode
just off the work. Maintain a steady grip on the gun, protect your
eyes with a welding shield, then press and hold the gun trigger to
create the arc.
Flex the cable over its entire length and again blow out the cable.
Repeat this procedure until no further dirt comes out.
WARNING
Turn the welder power switch off before removing gun tips
and nozzles.
If it is necessary to adjust the weld voltage, stop welding before
changing either or both of the rotary switches.
Adjust the wire feed speed as necessary to suit the job. At the
completion of the weld, release the gun trigger and pull the gun
away from the work to stop the arc.
Gun Tips and Nozzles
The gun tip should be replaced when worn. Replace with the
correct size for the wire type and diameter. Too large a tip for the
electrode wire will cause arcing within the gun cable and possible
jamming of the wire within the cable .
4T mode should only be used by experienced operators for long
welds.
Remove spatter from inside of gas nozzle and from tip after each
10 minutes of arc time or as required.
Maintenance
Safety Precautions
Procedure for Replacing PC Boards
When a PC Board is to be replaced, the following procedure must
Routine Maintenance
be followed:
Visually inspect PC Board in question.
WARNING
1. Are any of the components damaged?
2. Is a conductor on the back side of the board damaged?
• Have an electrician install and
service this equipment.
3. If there is no damage to the PB Board, insert a new PC Board
and see if this remedies the problem. If the problem is
remedied, reinstall the old PC Board and see if the problem
still exists with the old PC Board.
• Turn the input power off at the fuse
box,or unplug input lead before
working on equipment.
ELECTRIC
a) If the problem does not exist with the old board, check the
PC Board lead harness plugs.
• Do not touch electrically hot parts.
SHOCK
can kill
b) Check leads in the harness for loose connections.
IMA 574B
CV320-I
Page 9
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TROUBLESHOOTING GUIDE
WARNING
• Have an electrician install and
service this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
ELECTRIC
SHOCK
can kill
Problem
Possible Cause
What To Do
Rough wire feeding or wire
not feeding but drive rolls
turning.
Gun cable kinked and/or twisted.
Wire jammed in gun and cable.
Inspect gun cable and replace if necessary.
Remove wire from gun and cable - feed in new wire.
Note any obstructions in gun and cable. Replace gun
and cable if necessary.
Incorrectly fitted drive roll.
See Wire Drive Roll Section in this manual for proper
installation of drive roll.
Drive roll loose.
Remove, clean, install and tighten.
Clean cable or replace liner.
Replace.
Gun cable dirty.
Worn drive roll.
Electrode rusty and/or dirty.
Worn nozzle or cable liner.
Partially flashed or melted contact tip.
Incorrect idle roll pressure.
Replace.
Replace.
Replace contact tip.
Set idle roll pressure.
Variable or “hunting” arc.
Wrong size, worn and/or melted contact tip. Replace tip - remove any spatter on end of tip.
Worn work cable or poor work connection.
Loose electrode connections.
Inspect - repair or replace as necessary.
Be sure electrode lead is tight, gun cable tight in wire
feeder contact block, gun nozzle and gun tip tight. All
work lead connections must be tight.
Wrong polarity.
Check connection at output studs for polarity required
by welding process.
Poor arc striking with
sticking or “blast offs”,
weld porosity, narrow and
ropey looking bead, or
electrode stubbing into
plate while welding.
Improper procedures or techniques.
Improper gas shielding.
See “Gas Metal Arc Welding Guide”(GS100).
Clean gas nozzle. Make certain that gas diffuser is
not restricted. Make certain that gas cylinder is not
empty or turned off. Make certain gas solenoid valve
is operating and gas flow rate is correct.
Remove gun liner and check rubber seal for any sign
of deterioration or damage. Be sure set screw in
brass connector is in place and tightened against the
liner bushing.
Tip seizes in diffuser.
Tip overheating due to prolonged or
excessive high current and/or duty cycle
welding.
Do not exceed current and duty cycle rating of gun.
A light application of high temperature antiseize
lubricant may be applied to tip threads.
Page 10
CV320-I
IMA 574B
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TROUBLESHOOTING GUIDE (cont)
Problem
What To Do
Possible Cause
No wire feed, although arc
voltage is present.
Defective wire feed motor or wire drive
control PC board.
Measure the voltage between Red motor lead
(54) and the Green motor lead (53) when the
wire inch push button is depressed. If this
voltage is over 10V DC, replace the wire feed
motor. If no voltage is registered, replace the
wire drive PCB. (Refer PCB replacement
procedure at end of Trouble Shooting Guide).
No control of wire feed.
Defective wire drive control PC board.
Replace PCB. (Refer PCB replacement
procedure at end of Trouble Shooting Guide).
No wire feed and no arc voltage.
Pilot light indicates input power to
machine.
Over-temperature protection circuit
actuated due to overload or short. Over-
temperature light should be illuminated.
Allow machine to cool down and reduce on
time and/or wire feed speed.
Faulty gun trigger switch or damaged
control cable connected to gun trigger.
Repair.
Defective control PC board.
Refer Procedure for Replacing PC Boards at
end of Trouble Shooting Guide, if no fault is
detected in trigger-thermostat circuit.
Defective contactor.
Replace defective contactor.
Improper settings for wire feed speed and
volts.
Set controls correctly.
Replace rotary switch.
Poor welding characteristics
and/or cannot obtain full rated
output as per nameplate.
Faulty rotary switch either coarse control
(on/off) or fine control.
Faulty pilot transformer.
Faulty main transformer.
Faulty rectifier.
Replace.
Replace.
Replace.
Replace.
Faulty choke.
GROUND TEST PROCEDURE FOR CV320-I
Also see the LN21 wire feeder instruction manual
5) Jumper the four (4) meter terminals together.
6) Switch the fine control rotary switch to position one (1) &
switch the coarse control rotary switch to position
one (1).
WARNING
This procedure is only suitable for applications using DC
mega testers up to 500V.
7) Primary test: Connect one lead of the mega tester to the
frame of the machine and the other lead to each of the three
(3) input conductors and to the main transformer primary
leads L1A, L2A & L3A. Apply the test(s).
Note: This procedure is for ‘machines as built’ many modifications
could have taken place over the life of a particular machine, so
details of this procedure may need to be ‘adjusted’ to suit these
modifications.
8) Welding circuit test: Connect one lead of the mega tester to
the frame of the machine and the other lead to the positive
output stud. Apply the test. (Min resistance 1MΩ).
9) Welding circuit to primary test: Connect one lead of the
mega tester to the positive output stud and the other lead to
each of the three (3) input conductors and to the main
transformer primary leads L1A, L2A & L3A. Apply the test.
(Min resistance 10MΩ).
10) Transformer thermostat test: Connect one lead of the mega
tester to the frame of the machine and the other lead to the
positive output stud. Apply the test.(Min resistance 1MΩ).
11) Remove all jumper leads.
12) Refit the roof panel.
For prompt service contact your local Lincoln Field Service Shop.
The insulation resistance values listed below are from Australian
Standard AS1966.1.
ELECTRIC SHOCK
can kill
1) Disconnect input cable from power outlet.
2) Disconnect all output cables (control & weld).
3) Remove the roof panel.
4) Jumper the three (3) AC terminals and the (+) & (-) terminals
of the thre phase bridge rectifier (A total of five (5) places).
If any problems are encountered, refer to your nearest Lincoln Field Service Shop.
IMA 574B
CV320-I
Page 11
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Note: LN-21 Code Nos less than Code No. 1508 use drive roll part No.
starting with ‘AM’.
For LN-21 Code Nos greater than or equal to Code No. 1508 use drive
roll part Nos starting with ‘AS’.
DRIVE ROLLS
Machine
Machine
Code 1508
Code 1413
Wire Size
Part No.
Part No.
Solid Wire
0.6 - 0.8mm
0.8 - 1.0mm
1.0 - 1.2mm
0.9 - 1.2mm
AS4449-9
AS4449-1
AS4449-2
AS4449-8
AM3023C
AM3023D
AM3023E
Cored Wire
0.8 - 1.0mm
1.2 - 1.6mm
AS4449-3
AS4449-4
-
AM3023J
Aluminium Wire
0.8 - 1.0mm
1.0 - 1.2mm
1.2 - 1.6mm
AS4449-5
-
AS4449-6
-
AM3023F
AM3023K
Page 12
CV320-I
IMA 574B
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AP-80
Operative: 2/7/99
The Lincoln Electric Company (Australia) Propriety Limited
A.C.N. 000 040 308
Supercedes: 18/6/97
CV320-I
PARTS LIST AP-80
Do not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.
Numbers in the table below indicate which column to use in each parts list for each individual code number.
Sub Assembly
Item No.
1
2
3
Sub Assembly
Page Name
Machine
Description
Part List No.
Code No.
AP-80-C AP-80-D
CV320-I 415V 1447
380V 1473
KA1392
KA1392-1
KA1392
KA1392-1
KA1392
KA1389
KA1389
1
1
1
AL2513
AL2513
AL2513
AL2513
AL2513
AM3392
AM3392
IMA574A
IMA574A
IMA574B
IMA574B
IMA574B
IMA565A
IMA565B
2
415V 1509
1
2
1
380V 1510
1
415V 1535
1
1
LN-21
1413
1508
AP-68
AP-68
N/A
N/A
IMA 574B
CV320-I
Page 13
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AP-80-C
2/7/99
Operative:
General Assembly AP-80-C
Supercedes:
18/6/97
Roof and side panels
not shown for clarity.
Platform shown this
view only.
Ref: AG1369
Front panel not shown for clarity.
A15-5-96M
Page 14
CV320-I
IMA 574B
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AP-80-C.1
2/7/99
Operative:
Supercedes:
18/6/97
General Assembly AP-80-C.1
When ordering parts quote AP-80-C-1, Machine Serial & Code Numbers, Part Description and Item Number.
Item Part No.
Description
Qty. 1 2
Item Part No.
Description
Qty. 1
2
X
X
34
M6819-4A
Fan
1
X
X
X
X
X
1
2
3
AT3070-3
AM3423
Connector Block
1
1
1
1
2
1
1
X
X
X
Loctite #262
Fan Motor
Fan Motor Bracket
1.0mL X
Contactor SC35
35
36
M7468-2
M15562F
1
1
X
X
AL2494-1
AL2494-2
Main Transformer Assembly 415V
Main Transformer Assembly 380V
Sleeving
Rotary Switch 8 Pos.
Rotary Switch 5 Pos.
Cotton Tape 25.4mm wide
Choke Assembly
Insulation Tube
Insulation Washer
Rectifier
Liftbale Welded Assembly
Cover Seal
Resistor & Tag Strip Assembly
Blind Rivet 5⁄52˝ dia. x 5⁄16˝
Case Side Right
4˝ dia. Swivel Castor
8˝ Wheel
Push Nut
Input Lead
Box Connector
Cable Tie
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
4
6
7
X
X
X
Items Not shown
AM3388-1
AM3388-2
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
AT2980-2
T12068-1
AS4453-2
Cable Tie
9
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
1
3
1
1
1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
8
3.0m X
Insulating Splice
Resistor/Diode & Lead Assembly
Multi-Lead /41/41B
Lead /4
Lead Earth
Lead /44
Lead /43A
Lead /L1B
Lead /L1A
Lead /L2A
9
10
AM3275-1
T7028-226
AT2882
1
2
6
1
1
1
1
1
1
2
2
2
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
11
13
14
15
AL2480
AL2527
S12934
AS4525-2
AT3425-5
G2017R
AS4070
AS4071-1
AT2876
16
17
18
Lead /L3A
Lead /L1
Lead /L2
Lead /L3
19
AS4303
T9639-1
AT2980-2
AL2530
AS4407-3
T9639-2
AL2651-1
AG1358
AG1365
PT0051
Lead L3B
20
21
22
Sleeving-Aux. Tran. Leads to Fan
Sleeving-Aux. Tran. to Front Panel
Sleeving-Aux. Tran./Fan to Contactor
Sleeving-Contactor to Rotary.SW.1
Wiring Diagram
Case Rear Assembly
Amphenol & Lead Assembly 3m
Box Connector
Cable Assy 10m (Code 1535 only)
Gas Bottle & Wire Feeder Support
Base Welded Assembly
Auxiliary Transformer 415V
Auxiliary Transformer 380V
Cable - Rect. (-) to Choke
Cable - Rect. (+) to Shunt
Roof
AP80
AS4244
AT3378
23
24
26
Warning Decal
Warning Decal
Input Decal Typed
Warning Tag - Input Connection
Cable Tie
Literature Envelope
Magnum FM400 12ft Mig Gun
PT0053
X
X
X
X
X
X
X
AS3234
27
28
29
30
32
33
AM3040B108
AM3040B107
L7699R
AL2524
G2018R
G2017R
X
X
X
X
X
X
AT2980-2
AL1369-115
K476-9
61
62
Front panel Assembly
Case Side-Left
Case Side Right
63
801E30LKAR21 Argon Regulator Flowmeter 30L/min
64
65
66
AS4092-5
AS4050-1
AT3873
Ground cable assembly
Gas Hose assembly
Chain
67
AT4069
Liftbale Washer
1
[NC]
⁄
2˝ UNC. x 1⁄2˝ Hex. Hd. Screw
1
⁄
2˝ UNC. Hex. Nut.
1
⁄
2˝ UNC. Springwasher
5
⁄
16˝ UNC. x 3⁄4˝ Hex. Hd. Screw
5
⁄
16˝ UNC. Hex. Nut
16˝ dia. Flatwasher
16˝ dia. Springwasher
NOTE: All screws and bolts listed in FSS release 288
5
⁄
5
⁄
68
69
70
71
72
Plastic Bag 9˝ x 12˝
Staple
LN21
Plastic Bag
Pallet
KA1389
IMA 574B
CV320-I
Page 15
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AP-80-D
2/7/99
Operative:
Supercedes:
18/6/97
Control Panel AP-80-D
4
5
3
2
1
Ref: AL2524
(AL21-2-96M)
When ordering parts quote AP-80-D, Machine serial & Code numbers, part description and item number.
Item
1
2
3
4
5
8
9
10
11
12
13
15
16
A1
A2
Part No.
AG1355
AL2516
T14659-1
AM3397-1
AM3398-1
AM2464-1
T3960
AS1733-3Z
AS4460
T13486-1
S6602-22
Description
Front Panel
Nameplate
Fastener Button (Black)
Voltmeter
Ammeter
Moulded Output Stud
Flange Nut
Self Tapping Screw
Indicator Light
Pilot Light
Shunt
Lead / 48
Meter Lead Harness
Output Control Switch (Coarse)
Output Control Switch (Fine)
Qty. 1
1
1
4
1
1
2
2
4
1
1
1
1
1
1
1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
AM3400
AM3388-2
AM3388-1
Page 16
CV320-I
IMA 574B
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WIRING DIAGRAM CV320-I
IMA 574B
CV320-I
Page 17
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AP-68
18/6/97
26/11/96
Operative:
Supersedes:
LN21 WIRE FEEDER
PARTS LIST AP-68
Do not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not
listed.
Numbers in the table below indicate which column to use in each parts list for each individual code number.
Sub Assembly
Item No.
1
2
3
Sub Assembly
Page Name
Machine
Description
Part List No.
Code No.
AP-68-C
AP-68-C-1
LN-21
LN-21
1413
1508
KA1389
KA1389
1
2
AM3392
AM3392
IMA565A
IMA565B
Page 18
CV320-I
IMA 574B
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AP-68-C
18/6/97
26/11/96
Operative:
Supercedes:
General Assembly AP-68-C
Ref: AG1346A
(16.7.97)
Item Part Name and Description
No. Req. Part Number 1 2
1
BASE, FRONT AND REAR PANEL
BASE, FRONT AND REAR PANEL
PLASTIC FOOT
1
1
4
1
8
1
4
4
1
1
1
1
2
1
1
3
3
3
3
3
2
1
1
1
1
1
1
2
2
1
AG1344
x
-
x
x
x
x
x
x
x
x
x
-
AM3161
-
2
4
AT4084-1
AM3379
x
x
x
x
x
x
x
-
BULKHEAD
5
SELF TAPPING SCREW
GROMMET
AS1733-3Z
AS3086-9
AT3937
6
7
NUTSERT
8
SEMS SCREW
T10082-27
AS4212-4
AM3382-1
AM3382-2
AM3382-3
TI4659-1
T14659
9
PCB ASSEMBLY
10
NAMEPLATE MAXIDRIVE 2
NAMEPLATE MAXIDRIVE 4
NAMEPLATE LN21
FASTENER BUTTON
-
x
-
-
11
x
-
11A FASTENER BUTTON
x
x
x
x
x
x
-
12
13
GUN ADAPTOR
HEX HD. SCREW
SPRINGWASHER
FLATWASHER
HEX NUT
AS4456
x
-
-
-
-
13A THREAD FORMING SCREW
S9225-17
AT3561-1
AL2495
x
x
x
x
-
14
15
16
RED MICROSWITCH
HARNESS (not shown)
CASE AND DOOR ASSEMBLY
CASE AND DOOR ASSEMBLY
BUFFER GROMMET
PLUG BOTTOM (BLACK)
TOGGLE SWITCH
x
x
-
AM3378U
AM3378R
AS4404-2
AS4450
x
x
x
x
x
x
17
18
19
20
21
22
x
x
x
x
x
T13562
KNOB
T10491D
T12792-1
SEE AP-68-A
INSULATION
WIRING DIAGRAM (inside panel)
NOTE: All screws and bolts listed in FSS release 288
IMA 574B
CV320-I
Page 19
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AP-68-C.1
18/6/97
26/11/96
General Assembly AP-68-C.1
Operative:
Supercedes:
Note: 4 Wheel Shown.
See Fig.1 or Fig.2 for
two wheel drive.
Note: To upgrade from
the AM3391-1 drive
plate to AM3391-7 drive
plate you will also need
to purchase AM3390-2
plus S9225-7.
Ref: AG1346B (25.6.97)
Item Part Name and Description
No. Part Number 1 2
Req’d
25 WIRE PANEL INSULATION
27 DRIVE PLATE
1
1
1
1
1
3
1
1
2
1
1
1
1
1
4
1
1
1
1
1
2
1
1
2
1
2
1
2
1
1
1
1
1
1
1
AS4436
x
x
-
x
AM3391-1
AM3391
-
DRIVE PLATE
-
DRIVE PLATE
AM3391-8
AM3185
-
x
x
x
-
28 WIRE DRIVE MOTOR AND GEARBOX
29 CHEESE HEAD SCREW
30 DRIVE PLATE INSULATION
DRIVE PLATE INSULATION
30A DRIVE PLATE INSULATION WASHER
32 LEAD
x
x
x
-
AM3054-181
AS4435-1
AS4435
-
AT2882
-
x
x
x
x
x
x
x
-
AM3040A907
T9639-1
x
x
x
x
-
33 BOX CONNECTOR
34 SOLENOID
AM3399-1
AS4457
36 GAS SOLENOID NIPPLE
36A STRAIGHT BARB TAIL
37 SELF TAPPING SCREW
38 SPINDLE AND READI-REEL ADAPTOR
SPINDLE & SMALL MOUNTING STAND
41 DISHED WASHER
AT3730-11
S8025-73
K377
x
x
-
KA1395
x
x
x
x
x
x
x
-
AT2943Z
AS4451
x
x
x
x
x
x
x
x
x
x
x
x
-
42 WIRE REEL DUST STRIP
43 DUST STRIP RETAINING PLATE
45 SELF TAPPING SCREW
46 WARNING DECAL
AS4452
AS1733-3Z
AS4244
47 CODE AND SERIAL No. DECAL
49 SPACERS
AS4463
50 SLEEVING (over motor leads)
51 INSULATED SPLICE (motor conn)
52 DUST STRIP SUPPORT BKT. ASSY.
53 INSULATING BUSHES
54 DRIVE ROLL CAP SCREW
55 DRIVE ROLL 0.9 - 1.2mm SOLID
DRIVE ROLL 1.0 - 1.2mm SOLID
56 DRIVE ROLL ADAPTER
57 DRIVE PLATE MOUNTING BRACKET
58 CABLE END PLUG
AM3058-412
T12068-1
AM3402
x
x
x
x
x
x
-
AM3391-1S
AM3391-1R
AS4449-8
AM3023E
AM3391-3H
AM3390-2
S12020-9
S12021-1
x
-
x
x
x
x
-
x
x
58 MACHINE END CONNECTOR
NOTE: All screws and bolts listed in FSS release 288
Page 20
CV320-I
IMA 574B
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WIRING DIAGRAM LN21
IMA 574B
CV320-I
Page 21
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AP-202-G
10/3/97
New
Magnum Fastmate Guns
AP-202-G
Operative:
Supercedes:
Part No. K479-7
Magnum FM400
3.65m long
Item Part No.
1
Description
Gas nozzle, Fixed, Tip recessed:
Item Part No.
2A
Description
Nozzle insulator assembly:
S19417-1 Magnum 200FM
S19394-1 Magnum 400FM
Gas nozzle, Coarse thread, Tip recessed
M16080-1 Magnum 400FM (9.5 mm ID)
M16080-2 Magnum 400FM (12.7 mm ID)
M16080-3 Magnum 400FM (15.9 mm ID)
M16080-4 Magnum 400FM (19.1 mm ID)
Gas nozzle, Fixed, Tip flush:
M16081-1 Magnum 400FM (9.5 mm ID)
M16081-2 Magnum 400FM (12.7 mm ID)
M16081-3 Magnum 400FM (15.9 mm ID)
M16081-4 Magnum 400FM (19.1 mm ID)
Gas nozzle, Adjustable slip-on
3
4mm (requires Item 3A):
1A
2
M16830-1 Magnum 400FM (15.9 mm ID)
M16830-2 Magnum 400FM (19.1 mm ID)
3
Gas nozzle, Coarse thread, Tip recessed
12.7mm (requires Item 3A):
M16830-3 Magnum 400FM (15.9 mm ID)
M16830-4 Magnum 400FM (19.1 mm ID)
(requires Item 2A):
3A M16937-1 Nozzle Insulator Ass., Magnum 400FM
M16093-1 Magnum 200FM (15.9 mm ID)
M16082-1 Magnum 400FM (15.9 mm ID)
M16093-2 Magnum 200FM (12.7 mm ID)
M16082-2 Magnum 400FM (12.7 mm ID)
Gas nozzle, Recessed slip-on
(requires Item 2A):
M16082-3 Magnum 400FM (15.9 mm ID)
M16082-4 Magnum 400FM (12.7 mm ID)
4
Contact tip, Tapered:
S19393-5 Magnum 200FM (0.6mm)
S19393-6 Magnum 200FM (0.8mm)
S19393-1 Magnum 200FM, 400FM (0.9mm)
S19393-7 Magnum 200FM, 400FM (1.0mm)
S19393-2 Magnum 200FM, 400FM (1.2mm)
S19393-3 Magnum 400FM (1.3mm)
S19393-4 Magnum 400FM (1.6mm)
2
Page 22
CV320-I
IMA 574B
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AP-202-G.1
10/3/97
New
Magnum Gun
Replacement Parts AP-202-G.1
Operative:
Supercedes:
When ordering parts quote machine code and serial numbers, parts list number, item and part number and description.
ItemPart No.
Description
Item Part No.
Description
23 L7761-16 Cable assembly 3.6m (12ft)
Magnum 400FM
5
Contact tip, Heavy duty:
S19392-1 Magnum 200FM, 400FM (0.9mm)
S19392-6 Magnum 200FM, 400FM (1.0mm)
S19392-2 Magnum 200FM, 400FM (1.2mm)
S19392-3 Magnum 400FM (1.3mm)
S19392-4 Magnum 400FM (1.6mm)
S19392-5 Magnum 400FM (2.0mm)
Contact tip, Standard duty:
S19391-6 Magnum 200FM (0.6mm)
S19391-7 Magnum 200FM (0.8mm)
S19391-1 Magnum 200FM, 400FM (0.9mm)
S19391-8 Magnum 200FM, 400FM (1.0mm)
S19391-2 Magnum 200FM, 400FM (1.2mm)
S19391-3 Magnum 400FM (1.3mm)
S19391-4 Magnum 400FM (1.6mm)
S19391-5 Magnum 400FM (2.0mm)
Contact tip, Notched, for Aluminium:
S18697-44 Magnum 200FM (0.8mm)
S18697-45 Magnum 200FM (0.9mm)
S18697-46 Magnum 200FM (1.2mm)
Gas Diffuser assembly:
24 S18787
Strain relief, Magnum 400FM
S18787-1 Strain relief, Magnum 200FM
25 S18786
Strain relief housing, Magnum 400FM
S18786-1 Strain relief housing, Magnum 200FM
26 M15751
Handle boot, Magnum 400FM
M15751-1 Handle boot, Magnum 200FM
6
27 S18930
Boot nut (moulded)
28 S18895-1 Cable boot, Magnum 200FM
S18895-2 Cable boot, Magnum 400FM
29 T11141-8 Cable clamp, Magnum 400FM
T11141-9 Cable clamp, Magnum 200FM
30 M15808
31 S19067
Cable handle (moulded)
Incoming connector nut, Magnum 200FM
S19126-2 Incoming connector nut, Magnum 400FM
32 S19153-1 Incoming connector assembly
Magnum 200FM
6A
7
32 S19153
Incoming connector assembly
Magnum 400FM
33 S19008-1 Terminal lead assembly (feeder end)
(2 required).
S19418-2 Magnum 200FM (0.6-0.8mm)
S19418-1 Magnum 200FM (0.9-1.2mm)
S19395-1 Magnum 400M (0.6-2.0mm)
Cable Liner (trim to fit):
34 S18929
35 S18948-2 Central adaptor assembly
36 S18991 Liner nut
37 T1473-19 Screw
Collar nut (moulded)
8
M16087-2 Magnum 200FM (0.6-0.8mm)
M16087-1 Magnum 200FM (0.9-1.2mm)
M16083-1 Magnum 400FM (0.9-1.2mm)
M16083-2 Magnum 400FM (1.3-1.6mm)
M16083-3 Magnum 400FM (1.6-2.0mm)
Cable Liner for Aluminium (trim to fit):
M16107-1 Magnum 200FM (0.9-1.2mm)
Gun tube, 60˚:
8
9
M15659-1 Magnum 200FM§, 400FM (400amp)
M15659-2 Magnum 200FM§, 400FM (300amp)
S19440
Magnum 200FM (200amp)
Gun tube, 45˚:
10
10
M15685-1 Magnum 200FM§, 400FM (400amp)
M15685-2 Magnum 200FM§, 400FM (300amp)
Gun Tube Insulator
T10642-172 Magnum 200FM, 400FM
11 M15693
12 S18831
13 S9776-7
Hanger
Collar assembly
Retaining ring
14 S15921-2 Clamp for gun tube
15 G1927
G1928
Gun housing, left, Magnum 400FM
Gun housing, right, Magnum 400FM
Gun housing, left, Magnum 200FM
Gun housing, right, Magnum 200FM
G2090
G2091
16 S18825-1 #6 x 32 screw
17 T14438
18 S18932
Clamping screw
Trigger assembly
19 T13483-8 ‘O’ ring
20 S18655-1 Connector assembly, Magnum 400FM
Connector assembly includes:
Retaining ring (S9776-7)
Clamping screw (T14438)
Clamp for gun tube (S15921-2)
‘O’ ring (T13483-8)
21 S19067
Connector nut (gun tube) Magnum 200FM
S18749-2 Connector nut (gun tube) Magnum 400FM
22 S19492-2 Terminals (trigger switch)
23 L7761-11 Cable assembly, 3m (10ft)
Magnum 200FM
§ 300 & 400 amp gun tubes can be used with 200 amp guns. Use corresponding amperes gas diffuser, nozzle and nozzle insulator.
IMA 574B
CV320-I
Page 23
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Magnum Replacement Parts
CROSS REFERENCE GUIDE FOR MAGNUM MIG CONSUMABLE PARTS
FIXED GAS NOZZLES, TIP RECESSED
FIXED GAS NOZZLES, COARSE THREAD
Industry
Ref No.
21T-37
21T-50
21T-62
Lincoln
Part No.
M16294
ID
Industry
Ref No.
24CT-62-R M16830-3
M16830-3M
24CT-62-S M16830-1
M16830-1M
24CT-75-R M16830-4
M16830-4M
Lincoln
Part No.
ID
Qty
1
1
1
1
5
25
1
5
25
1
5
25
1
5
25
1
mm (Inches)
Qty
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1
mm (Inches)
9.5
12.7
15.9
(0.38)
(0.50)
(0.62)
15.9
(0.62)
(0.62)
(0.75)
(0.75)
(0.62)
(0.75)
(0.62)
(0.75)
(0.62)
(0.75)
M16684-1
M16684-1
M16080-1
M16080-1D
M16080-1M
M16080-2
M16080-2D
M16080-2M
M16080-3
M16080-3D
M16080-3M
M16080-4
M16080-4D
M16080-4M
M17256-1
M17256-1M
15.9
19.1
19.1
15.9
19.1
15.9
19.1
15.9
19.1
23-37
23-50
23-62
9.5
(0.38)
(0.50)
(0.62)
24CT-75-S M16830-2
M16830-2M
12.7
15.9
25CT-62
25CT-75
26CT-62
26CT-75
M16831-1
M16831-1M
M16831-2
M16831-2M
M16832-1
M16832-1M
M16832-2
M16832-2M
23-75
19.1
15.9
(0.75)
(0.62)
23H-62
25
1
25
1
25
26CT-62-R M16832-3
M16832-3M
26CT-75-R M16832-4
M16832-4M
FIXED GAS NOZZLES, TIP FLUSH
Industry
Ref No.
21-50-F
Lincoln
Part No.
M16294
ID
mm (Inches)
25
Qty
1
SELF-INSULATED GAS NOZZLES
12.7
(0.50)
M16081-1
M16081-1D
M16081-1M
M16081-2
M16081-2D
M16081-2M
M16081-3
M16081-3D
M16081-3M
M16081-4
M16081-4D
M16081-4M
1
5
25
1
5
25
1
5
25
1
5
Industry
Ref No.
Lincoln
Part No.
ID
mm (Inches)
23-37F
23-50F
23-62F
23-75F
9.5
(0.38)
Qty
1
5
25
1
5
25
1
5
M16970-1
M16970-1D
M16970-1M
M16970-2
M16970-2D
M16970-2M
M16970-3
M16970-3D
M16970-3M
26I-62
26I-75
26I-87
15.9
(0.62)
(0.75)
(0.87)
12.7
15.9
19.1
(0.50)
(0.62)
(0.75)
19.1
22.1
25
25
NOZZLE INSULATOR ASSEMBLIES
ADJUSTABLE SLIP-ON GAS NOZZLES
Industry
Ref No.
32
Lincoln
Part No.
Industry
Ref No.
Lincoln
Part No.
ID
mm (Inches)
Qty
5
Qty
1
S19417-1D
S19417-1M
S19394-1D
S19394-1M
M16937-1
M16937-1M
M16937-2
M16937-2M
M16937-3
M16937-3M
M16093-2
M16093-2D
M16093-2M
M16093-1
M16093-1D
M16093-1M
M16082-2
M16082-2D
M16082-2M
M16093-1
M16093-1D
M16093-1M
25
5
25
1
25
1
22-50
22-62
5
12.7
(0.50)
(0.62)
(0.50)
(0.62)
34A
25
1
34CT
35CT
36CT
5
25
1
5
25
1
15.9
12.7
15.9
25
1
25
24A-50
24A-62
5
25
RECESSED SLIP-ON GAS NOZZLES
Industry
Ref No.
Lincoln
Part No.
M16082-4
ID
mm (Inches)
Qty
1
24A-50-SS M16082-4D
M16082-4M
M16082-3
24A-62-SS M16082-3D
M16082-3M
5
25
1
5
25
12.7
(0.50)
(0.62)
15.9
Page 24
CV320-I
IMA 574B
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Magnum Replacement Parts
CONTACT TIPS STANDARD
CONTACT TIPS TAPERED
Industry
Ref No.
11-23
Lincoln
Part No.
Wire Size
mm (Inches)
Industry
Ref No.
11T-23
Lincoln
Part No.
Wire Size
mm (Inches)
Qty
10
25
10
25
10
25
10
25
10
25
10
25
10
25
10
25
10
25
10
25
10
25
10
25
Qty
10
25
10
25
10
25
10
25
10
25
10
25
10
25
10
25
10
25
10
25
10
25
25
25
25
25
25
25
S19726-1D
S19726-1M
S19726-2D
S19726-2M
S19726-3D
S19726-3M
S19726-4D
S19726-4M
S19391-6D
S19391-6M
S19391-7D
S19391-7M
S19391-1D
S19391-1M
S19391-8D
S19391-8M
S19391-2D
S19391-2M
S19391-3D
S19391-3M
S19391-4D
S19391-4M
S19391-6D
S19391-6M
S20278-1D
S20278-1M
S20278-2D
S20278-2M
S20278-3D
S20278-3M
S20278-4D
S20278-4M
S19393-5D
S19393-5M
S19393-6D
S19393-6M
S19393-1D
S19393-1M
S19393-7D
S19393-7M
S19393-2D
S19393-2M
S19393-3D
S19393-3M
S19393-4D
S19393-4M
S20476-1M
S20476-2M
S20476-3M
0.6
(0.025)
(0.030)
(0.035)
(0.045)
(0.025)
(0.030)
(0.035)
(0.040)
(0.045)
(0.052)
(1/16)
0.6
(0.025)
(0.030)
(0.035)
(0.045)
(0.025)
(0.030)
(0.035)
(0.040)
(0.045)
(0.052)
11-30
11-35
11-45
14-23
14-30
14-35
14-40
14-45
14-52
14-116
14-564
11T-30
11T-35
11T-45
14T-23
14T-30
14T-35
14T-40
14T-45
14T-52
14T-116
0.8
0.9
1.2
0.6
0.8
0.9
1.0
1.2
1.3
1.6
2.0
0.8
0.9
1.2
0.6
0.8
0.9
1.0
1.2
1.3
1.6
0.9
1.2
1.3
1.6
2.0
1.2
1.6
(1/16)
15HFC-35
15HFC-45
15HFC-52
15HFC-116 S20476-4M
15HFC-564 S20476-5M
15AHFC-364 S20476-9M
(0.035)
(0.045)
(0.052)
(1/16)
(5/64)
(3/64A)
(1/16A)
(4/64)
CONTACT TIPS HEAVY DUTY (300A & 400A)
Industry
Ref No.
14H-35
Lincoln
Part No.
Size
mm (Inches)
Qty
10
25
10
25
10
25
10
25
10
25
10
25
S19392-1D
S19392-1M
S19392-6D
S19392-6M
S19392-2D
S19392-2M
S19392-3D
S19392-3M
S19392-4D
S19392-4M
S19392-5D
S19392-5M
15AHFC-116 S20476-10M 25
0.9
(0.035)
(0.040)
(0.045)
(0.052)
(1/16)
GAS DIFFUSERS
14H-40
14H-45
14H-52
14H-116
14H-564
1.0
1.2
1.3
1.6
2.0
Industry
Ref No.
35-50
52
Lincoln
Part No.
S19728
Size
mm (Inches)
0.6 - 0.9 (0.025 - .035)
Qty
1
5
25
5
25
5
25
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1
S19418-1D
S19418-1M
S19418-2D
S19418-2M
S19395-1D
S19395-1M
S21098-2
S21098-2M
S21098-3
S21098-3M
S21098-5
S21098-5M
S21098-7
S21098-7M
S21098-1
S21098-1M
S21098-4
S21098-4M
S21098-6
S21098-6M
S20478-2
S20478-2M
S20478-1
S20478-1M
0.9 - 1.2 (0.035 - .045)
0.6 - 0.8 (0.025 - .030)
0.6 - 2.0 (0.025 - 5/64)
1.6 - 2.0 (1/16 - 5/64)
2.4 - 3.2 (3/32 - 1/8)
2.4 - 3.2 (3/32 - 1/8)
2.4 - 3.2 (3/32 - 1/8)
0.9 - 1.6 (0.035 - 1/16)
0.9 - 1.6 (0.035 - 1/16)
0.9 - 1.6 (0.035 - 1/16)
1.6 - 3.2 (1/16 - 1/8)
0.9 - 1.6 (0.035 - 1/16)
52-23
54A
(5/64)
55
DRIVE ROLLS
55H
Machine
Code 1508
Machine
Code 1413
55S-H
55S-HL
55SW
55S-SW
55S-SWL
56S-H
56S-SW
Wire Size
Part No.
Part No.
Solid Wire
0.6, 0.8mm
0.8, 1.0mm
1.0, 1.2mm
0.9, 1.2mm
AS4449-9
AS4449-1
AS4449-2
AS4449-8
AM3023C
AM3023D
AM3023E
Cored Wire
0.8, 1.0mm
1.2, 1.6mm
AS4449-3
AS4449-4
-
AM3023J
25
1
25
Aluminium Wire
0.8, 1.0mm
1.0, 1.2mm
1.2, 1.6mm
AS4449-5
-
AS4449-6
-
AM3023F
AM3023K
Note: LN-21 Code Nos. less than Code No. 1508 use drive
roll Part Nos. starting with ‘AM’.
When ordering parts, quote machine code and serial numbers,
parts list number, item and part number and description.
For LN-21 Code Nos. greater than or equal to Code No. 1508
use drive roll Part Nos. starting with ‘AS’.
IMA 574B
CV320-I
Page 25
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WARRANTY
The Lincoln Electric Company (Australia) Pty Limited (“Lincoln”) warrants all new
responsibility of the engine manufacturer which provides for warranties for
the period and subject to any limitations provided for by those
manufacturers of the respective engines and engine accessories.
machinery and equipment (“goods”) manufactured by Lincoln against defects in
workmanship and material subject to certain limitations hereinafter provided.
Certain conditions warranties and obligations are implied by law (for example
under the Trade Practices Act 1974) and cannot be excluded or modified (“the
statutory warranties”).
At the date of this warranty the details of those manufacturers warranties are as
follows:
Engine Manufacturer
Labour
Parts
Where the statutory warranties do apply then any express warranties given by
Lincoln (the “express warranties”) are given in addition and without derogation from
the statutory warranties. Apart from the express warranties and (in cases where
they apply by law but not otherwise) the statutory warranties Lincoln gives no
warranties whether express or implied by operation of law or otherwise in respect
of any goods manufactured or supplied by Lincoln or by its authorised distributor.
i) Perkins Engines and Accessories
(The Perkins Distributor Organisation
provides all warranty service (accessories
included) for the Perkins Engines powering
goods manufactured by Lincoln.)
*24 months *24 months
*Subject to conditions
imposed by Perkins
Any warranty whether express or statutory and the term of any such warranty as
set out herein commences on the date Lincoln or Lincoln’s authorised
distributorship forwards the goods from the premises of Lincoln or Lincoln’s
authorised distributor to the purchaser.
ii) Onan, Lombardini, Kubota &
Ruggerini Engines and their
12 months
12 months
Accessories
(warranty service can only be carried out by
authorised Lincoln Field Service Shop or
the engine distributors authorised by the
Lincoln branch office)
In respect of any claim under the warranty herein provided a purchaser must
furnish Lincoln with written notice of any claim under the warranty within the time
period of the warranty as further specified herein.
iii) Intermotor Engines and Accessories
(warranty services can only be carried out
by an authorised Lincoln F.S.S. or other
agency approved by the Lincoln branch
office)
12 months
12 months
The extent of Lincoln’s warranty whether express or statutory is limited to a liability
to repair, replace or pay to the purchaser an amount equal to:
a) The cost of replacing the goods;
b) The cost of obtaining equivalent goods; or
c) The cost of having the goods repaired, whichever remedy in its absolute
discretion Lincoln chooses.
iv) Briggs & Stratton Vanguard Engines
and Accessories
*24 months *24 months
•The Magnetron ignition
system is warranted by
Upon request by Lincoln the purchaser must permit Lincoln to inspect the goods
the subject of any claim under this warranty and Lincoln may at its absolute
discretion repair or replace the goods F.O.B. at its own premises or at such other
premises as Lincoln may designate provided that all freight charges to and from
Lincoln’s premises or such other premises as Lincoln may designate shall be paid
by the purchaser.
(warranty service can only be carried
out by an authorised Briggs & Stratton
service dealer).
Briggs & Stratton for 5 years.
Exclusions
Subject to the express and statutory warranties hereinbefore provided Lincoln
provides no other warranties in respect of the manufacture or sale of goods and
in particular Lincoln shall have no responsibility or liability in respect of:
Period of Warranty
The period of warranty in respect of goods covered by this warranty shall be as
follows:
a) Repairs done to Lincoln’s goods and undertaken by the purchaser outside
Lincoln’s premises without written authority from Lincoln obtained prior to any
such repair;
b) Any damage or failure of the goods as a result of normal wear and tear or the
neglect misuse abuse or failure to properly service goods by any purchaser.
a)
In respect of manual and semi-automatic and fully automatic wire feeders
and welders (except belted, engine driven welders and alternator sets) - 3
years from the date of commencement of the warranty;
b)
c)
In respect of the Invertec V130-S inverter - 1 year from the date of sale.
In respect of belted, engine driven welders and alternator sets designed for
operating speeds under 2,000 rpm - 3 years from the date of
commencement of the warranty;
The liability of Lincoln is limited as hereinbefore provided and Lincoln shall not be
liable for any incidental special or consequential damage suffered by a purchaser
whether or not arising out of circumstances known or foreseeably known by
Lincoln and in particular arising out of the supply of goods to a purchaser or the
use of goods by a purchaser whether based on breach of contract negligence or
tort.
d)
e)
In respect of Tractapac mobile rural welders mounted in approved fixtures
- 3 years from the date of commencement of the warranty;
In respect of belted, engine driven welders and alternator sets designed for
operating speeds over 2,000 rpm - 2 years from the date of
commencement of the warranty;
f)
Other goods manufactured by Lincoln including gun and cable assemblies,
undercarriages, field installed options, unattached options, welding
supplies, standard accessory sets and replacement parts -1 year from the
date of commencement of the warranty;
In respect of all alternators irrespective of the manufacturer of those
alternators - 12 months in respect of labour and parts from the date of
commencement of the warranty;
To the extent permitted by law Lincoln shall be entitled to in its absolute
discretion repair all engines and engine accessories however Lincoln shall
not be held responsible for any such repair which shall be the sole
Lincoln supplies certain batteries in connection with its supply of goods and the
purchaser acknowledges that any such battery is warranted by its manufacturer
and any claim in respect of such a battery whether as to a defect in the battery or
as to damage consequential upon a defect in a battery shall be made by the
purchaser to the manufacturer of the battery and the purchaser shall not hold
Lincoln in any way liable for the operation non-operation or malfunction of any
such battery.
g)
h)
Spare Parts Policy
As a manufacturer Lincoln undertakes to support its product with supply of spare parts. Lincoln policy in the case of light to medium duty welding equipment is to provide
full parts support for the period of 10 years from last manufacture. In the case of heavy duty industrial and fully automatic equipment, Lincoln undertakes to provide full parts
support for a period of 15 years from last manufacture date of any model.
Lincoln recognises that it is totally bound by the policy of its suppliers with regard to purchase items, however, the above policy will apply to purchase items and components
and Lincoln practice is to take into its stock appropriate levels of inventory at the time it ceases to buy for current manufacturing to ensure its overall policy is followed. Where
possible, due to common usage or availability, Lincoln will continue to supply beyond the above periods, however, Lincoln will not undertake special manufacture outside
these guidelines unless a customer is willing to accept the appropriate set up charge where tooling has been retained, and the delivery as dictated by manufacturing demand.
IN LINE WITH THE COMPANY'S POLICY OF CONTINUING PRODUCT IMPROVEMENT, SPECIFICATIONS HEREIN ARE SUBJECT TO MODIFICATION OR CHANGE WITHOUT NOTICE
In Australia, Lincoln Technical Sales Representatives are located in
Townsville, Mackay, Gladstone, Brisbane, Newcastle, Sydney, Wollongong,
Melbourne, Tasmania, Adelaide and Perth. To contact your local Lincoln
Technical Sales Representative, call 1300 728 720 (for the cost of a
local call). Lincoln products are sold primarily through its distributors. Our
The Lincoln Electric Company
Regional Office locations are:
(Australia) Pty. Ltd.
A.C.N. 000 040 308
Northern Region: 240 Evans Road, Salisbury, Qld, 4107
(07) 3277-2955
(02) 9772-7222
Central Region: 35 Bryant Street, Padstow, NSW, 2211
35 Bryant Street, Padstow, Sydney 2211, Australia
Southern Region: 1-3 Grange Road, Cheltenham, Vic, 3192 (03) 9584-9299
Western Region: 25 Barker Street, Belmont, WA, 6104
New Zealand: 152 St Georges Road, Avondale (Auckland)
Singapore: Blk 219,#02-01 Henderson Road, Singapore
(08) 9277-8744
(9) 828-5180
276-0878
Telephone:
(02) 9772-7222
Fax: (02) 9792-1387
International: Ph: +61 2 9772-7222 Fax: +61 2 9792-1387
THE LINCOLN ELECTRIC CO.
Cleveland, Ohio, U.S.A. - Subsidiary companies established in Australia, Canada, Europe, North and South America.
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