Lincoln Electric Welding System IM692 User Manual

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IM692  
October, 2000  
MULTI-SOURCE  
For use with machines Code 10668  
Safety Depends on You  
Lincoln arc welding equipment is  
designed and built with safety in  
mind. However, your overall safety  
can be increased by proper instal-  
lation ... and thoughtful operation  
on your part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED THROUGHOUT. And,  
most importantly, think before you  
act and be careful.  
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Date of Purchase:  
Serial Number:  
Code Number:  
Model:  
Where Purchased:  
OPERATOR’S MANUAL  
Copyright © 2000 Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
• AC Welder with Reduced Voltage Control.  
ventilation and/or exhaust at the arc to keep  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
3.g. Never dip the electrode in water for cooling.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
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.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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SAFETY  
zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
Mar. ‘93  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Model Name & Number _____________________________________  
Code & Serial Number _____________________________________  
Date of Purchase _____________________________________  
Whenever you request replacement parts for or information on this equipment always supply the information  
you have recorded above.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or  
loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to  
this equipment.  
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vi  
TABLE OF CONTENTS  
Page  
Installation.......................................................................................................................Section A  
Technical Specifications.......................................................................................................A-1  
Installation Instructions.........................................................................................................A-2  
Location ...............................................................................................................................A-2  
Stacking................................................................................................................................A-2  
Input and Grounding Connections........................................................................................A-2  
Output Cable, Connections and Limitations.........................................................................A-3  
Recommended Equipment and Processes..........................................................................A-3  
Multi-Source..................................................................................................................A-3  
Recommended Equipment / Interface........................................................................A-3  
Equipment Limitations................................................................................................A-3  
Distribution Box.............................................................................................................A-3  
“Pig Tail ”Leads and Connections.................................................................................A-3  
Operation.........................................................................................................................Section B  
Additional Safety Precautions .............................................................................................B-1  
General Description..............................................................................................................B-1  
Design Features-All Models .................................................................................................B-1  
Specifications, Design Features and Advantages.........................................................B-1  
Accessories.....................................................................................................Section C  
Factory Installed Options / Accessories ................................................................C-1  
Field Installed Options / Accessories ............................................................................C-1  
Maintenance.....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Routine and Periodic Maintenance........................................................................D-1  
Machine Calibration Specification .........................................................................D-1  
Troubleshooting..............................................................................................Section E  
Safety Precautions.................................................................................................E-1  
How to Use Troubleshooting Guide.......................................................................E-1  
Troubleshooting Guide...................................................................................E-2, E-3  
PC Board Troubleshooting Guide-P.C. Board ...............................................E-4, E-5  
Wiring Diagram.............................................................................................Section F-1  
Dimension Print............................................................................................Section F-2  
Parts Lists ....................................................................................................P367 Series  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - Multi-Source K1752-1  
INPUT - THREE PHASE ONLY  
Standard Voltage/Frequency  
Input Current at Rated Output  
100% Duty Cycle  
380/415/50  
400/60  
440/50  
460/60  
550/50  
99A  
98A  
79A  
83A  
66A  
69A  
575/60  
RATED OUTPUT  
60 Hz-40 kW  
Amps  
533  
Volts at Rated Amperes  
75  
Duty Cycle  
100% Duty Cycle  
@ 50°C (122°F)  
50 Hz-36 kW  
Amps  
475  
Volts at Rated Amperes  
75.8  
CURRENT RANGE  
OCV  
Maximum Open Circuit Voltage  
80V  
0-650 A  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
TYPE 75°C  
COPPER  
WIRE IN  
TYPE 90°C TYPE 75°C TYPE 90°C  
TYPE  
75°C  
FUSE  
INPUT  
HERTZ  
INPUT  
AMPERE  
RATING  
COPPER  
WIRE IN  
CONDUIT  
COPPER  
WIRE IN  
CONDUIT  
COPPER  
(SUPER  
LAG)  
OR  
VOLTAGE  
WIRE IN GROUND  
CONDUIT  
CONDUIT WIRE IN  
2
2
2
2
AWG(IEC-MM )  
AWG(IEC-MM ) AWG(IEC-MM ) AWG(IEC-MM ) CONDUIT BREAKER  
SIZES 50°C  
(122°F) Ambient  
1/0 (70)  
SIZES 50°C  
SIZES 40°C  
SIZES 40°C  
AWG(IEC-  
SIZE  
2
(122°F) Ambient (104°F) Ambient (104°F) Ambient MM ) SIZES  
(AMPS)  
150 Amp  
125 Amp  
100 Amp  
380-415  
460  
575  
50  
60  
60  
2 (35)  
3 (35)  
4 (25)  
3 (35)  
4 (25)  
4 (25)  
6 (16)  
6 (16)  
8 (10)  
2 (35)  
3 (35)  
4 (25)  
99  
83  
69  
2 (35)  
3 (35)  
PHYSICAL DIMENSIONS  
HEIGHT  
WIDTH  
22.2in  
565 mm  
DEPTH  
41 in  
1040 mm  
NET WEIGHT  
992 lbs.  
30.8 in  
781 mm  
450.5 kg.  
TEMPERATURE RANGES  
OPERATING TEMPERATURE RANGE  
-40 to +122ºF  
STORAGE TEMPERATURE RANGE  
-40 to +185ºF  
-40 to +50ºC  
-40 to +85ºC  
MULTI-SOURCE  
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A-2  
A-2  
INSTALLATION  
INPUT AND GROUNDING  
WARNING  
CONNETIONS  
ELECTRIC SHOCK can kill.  
• Have an electrician install and service  
this equipment.  
Note: A qualified electrician should connect the  
input power supply leads.  
• Turn the input power off at the fuse  
box before working on equipment.  
• Do not touch electrically hot parts.  
The Multi-Source power supply should not be used  
if the green Safe Output light is not lit. The machine  
is designed to open its input contactor if output volt-  
age peaks exceed the limits set by certain approval  
agencies. If the Safe Output light is on, the output  
voltage is within it designed operating range.  
Input conductor is brought into the machine input box  
area through a hole in the rear panel sized to accom-  
modate 2" (trade size) conduit and fittings. This is  
more than adequate for the largest conductors  
required.  
Conductors must be lugged to attach to the three 3/8"  
studs on the input reconnect panel and the 5/16"  
ground stud marked with the symbol  
. The input  
-------------------------------------------------------------------  
voltage supplied determines the position required for  
the reconnect panel jumper. The three ranges on the  
standard machine are 380-415, 440-460 and 550-575.  
The machine is rated for 50 and 60 Hz operation. See  
the Input Connection Diagram located on the inside of  
Case Back Input Access Door.  
LOCATION  
Place the power supply where clean cooling air can  
freely circulate in through the front louvers and out  
through the rear louvers. Dirt, dust or any foreign  
material that can be drawn into the welder should be  
kept at a minimum. Failure to observe these precau-  
tions can result in excessive operating temperatures  
and nuisance shut-downs.  
The conductor and fuse sizes in the Technical  
Specification Section (A-1), are per the 1999 National  
Electrical Code. The sizes are in American Wire  
Gauge (and the next largest standard metric size in  
2
mm ). National and local codes must be consulted  
STACKING  
WARNING  
before connecting a machine.  
Protect the input circuit with the super lag fuses or  
delay type circuit breakers listed in the Technical  
Specification Section (A-1). (They are also called  
inverse time or thermal / magnetic circuit breakers.)  
FALLING EQUIPMENT can cause  
injury.  
• Two Multi-Source machines can be  
stacked.  
• Lift only with equipment of adequate  
lifting capacity.  
• Be sure machine is stable when lifting.  
• Do not stack more than two high.  
• Do not stack the Multi-Source on top of any other  
machine.  
Use of fuses or circuit breakers with a lower amp rat-  
ing than recommended can result in nuisance tripping  
caused by inrush current even when machine is not  
being used for welding at high output currents.  
Machines may be paralleled for increased output.  
The S20428 Paralleling Kit permits paralleling of two  
Multi-Source power supplies for supplying currents of  
up to 1000 amps, 100% duty cycle.  
---------------------------------------------------------------------  
• Follow these guidelines when stacking:  
1. Select a firm, level surface capable of supporting  
the total weight of up to two machines (1984  
pounds/901kilograms).  
2. Set the bottom machine in place.  
3. Stack the second machine on top of it by aligning  
the two holes in the base rails on the second  
machine with the two pins on top at the front of the  
bottom machine.  
Note: The machines must be stacked with the Case  
Front of each machine flush with each other.  
MULTI-SOURCE  
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A-3  
A-3  
INSTALLATION  
RECOMMENDED EQUIPMENT / INTERFACE  
OUTPUT CABLES, CONNECTIONS  
AND LIMITATIONS  
The Multi-Weld 350 (K1752-1) is the recommended  
means by which to control the Multi-Source power  
supply. Connections between Multi-Source and Multi-  
Weld may be easily made using Twist-Mate male and  
female connectors and the K1736-1 Distribution Box.  
The Multi-Weld 350 has multi-process capability and  
may be used manual and semi-automatic processes.  
When a wire feeder is required an LN-25 (K449) is  
recommended.  
The Multi-Source has two parallel connected output  
studs for positive and negative connections. Each one  
is rated to carry the full output current. For its maxi-  
mum rated current at 100% duty cycle a minimum size  
of 4/0 AWG is recommended.  
Connection of Electrode and Work Leads to  
Output terminals.  
EQUIPMENT LIMITATIONS  
1. Set the POWER ON/OFF Toggle Switch to OFF.  
2. Raise the hinged cover protecting the output termi-  
nals.  
3. Insert the electrode lead up through the elliptical  
hole in the machine base below the positive output  
terminal. Pull through enough cable to reach the  
output terminal.  
The number of Multi-Weld 350s, the procedures used  
and the combined duty cycle of the arcs are only limit-  
ed by the 40,000 (36,000 watts on 50Hz) watt rating of  
the Multi-Source supply. The machine is IP-23S rated  
and is designed for outdoor applications.  
4. Connect electrode lead to the terminal .  
5. Tighten the output terminal nut with a wrench.  
6. Connect the work lead to the negative output termi-  
nal following steps 3-5.  
DISTRIBUTION BOX  
The Multi-Weld Distribution Box (K1736-1) is avail-  
able for interconnection of the Multi-System using the  
same "pig-tail" connection method provided with the  
Multi-Weld 350 converter. Six cable strain-relief ports  
are provided for connection of up to (12) cables for  
distribution or "daisy-chain" inter-connection to other  
boxes. Four "pig-tail" leads (see below) are included  
with the Box.  
7. Lower the cover to protect the output terminals.  
RECOMMENDED EQUIPMENT AND  
PROCESSES  
The only recommended use for the Multi-Source is to  
power the Multi-Weld welders. It is conceivable that  
the machine could be used as a constant voltage DC  
power supply up to its rating of 40,000 watts (36,000  
watts on 50Hz) output. Its output is stable with a wide  
range of inductive, resistive and capacitive loads but  
each application would have to be tested. The output  
is peak voltage regulated and at light resistive loads  
(maximum ripple) the average voltage deviates from  
peak voltage the most.  
"PIG-TAIL" LEADS AND CONNECTORS  
Accessory "pig-tail" leads and Twist-Mate connectors  
are available from Lincoln for extra connections to the  
Muli-Weld 350 or the Distribution Box:  
Order No.  
CL012705  
Description:  
2
22in.(56cm) long 2/0 (70mm ) cable  
with 0.5in.(13mm) hole lug and cut-off  
ends.  
MULTI-SOURCE  
K852-70  
K852-95  
K1759-70  
K1759-95  
Twist-Mate male insulated plug for  
1/0-2/0 (50-70mm ) cable.  
The Multi-Source 40kW (36kW on 50Hz) 80VDC buss  
power source (K1752-1) is recommended for use in  
the Multi-Weld system. The number of Multi-Weld  
Converters that may be connected to a single Multi-  
Source Power Source is determined by the following  
formula:  
2
Twist-Mate male insulated plug for  
2
2/0-3/0 (70-95mm ) cable.  
Twist-Mate female insulated recepta-  
2
cle for 1/0-2/0 (50-70mm ) cable.  
Power Source (Volts x Amps) capacity > 1.1 x Sum  
of Converters’ (Volts x Amps) arcs  
Twist-Mate female insulated recepta-  
2
cle for 2/0-3/0 (70-95mm ) cable.  
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B-1  
B-1  
OPERATION  
SAFETY PRECAUTIONS  
Other indicator lights include the amber Thermal light  
that signals when the long term output current limit  
has been exceeded. This limit is determined by a ther-  
mostat sensing the temperature of the negative output  
lead from the secondary coils. The white Power light  
indicates when the Control board is energized. The  
three lights are high intensity LEDs for improved visi-  
bility in daylight.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground.  
The Output Power display uses high intensity LEDs to  
indicate the percentage of full rated output the  
machine is supplying.  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
FUMES AND GASES can be danger-  
ous.  
Two additional thermostats protect the machine in the  
case of fan failure or blocked air flow. The SCR heat  
sink thermostat responds first to loss of air flow at nor-  
mal output loads. This thermostat will disable the  
machine output. The transformer iron rear thermostat  
senses that the lamination (and thus the coil insula-  
tion) is over heating (which can happen even if the  
output is disabled). This thermostat will interrupt  
power to the Control board causing the input contactor  
to open until the iron cools.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
------------------------------------------------------------------------  
WELDING SPARKS can cause fire or  
explosion.  
• Keep flammable material away.  
• Do not weld on closed containers.  
The only user controls are an on-off toggle Power  
switch that energizes the machine and a 10 A circuit  
breaker protecting the fan auxiliary against short cir-  
cuits.  
------------------------------------------------------------------------  
ARC RAYS can burn eyes and skin.  
• Wear eye, ear and body  
protection.  
DESIGN FEATURES - ALL MODELS  
------------------------------------------------------------  
SPECIFICATIONS, DESIGN FEATURES  
AND ADVANTAGES  
See additional warning information at  
front of this operator’s manual.  
Case parts are predominantly stainless steel, the PC  
boards are potted in trays, the controls are sealed, all  
machine coils are copper and the whole transformer is  
varnish dipped to maximize environmental withstand  
capability. The coils are all conservatively rated for  
long life.  
-----------------------------------------------------------  
GENERAL DESCRIPTION  
The Multi-Source is designed to supply power to the  
Multi-Weld welders. It has a wide range three phase  
AC input and can be operated on 50 or 60 Hz. The  
Multi-Source output peak voltage regulates against  
wide changes in output loading and input line voltage  
variations to supply a consistently stable voltage high  
enough to allow the Multi-Welds to provide good man-  
ual electrode capability.  
The Multi-Source output regulates against wide  
changes in output loading and input line voltage varia-  
tions to supply a consistently stable voltage high  
enough to allow the Multi-Welds to provide good man-  
ual electrode capability.  
Primary input voltage taps are selected by a single  
movable link on the reconnect panel. Main trans-  
former auxiliary windings power the firing circuit and  
fan motor. The control auxiliary transformer has a sin-  
gle, wide range primary and is not reconnectable.  
The Fan As Needed feature is activated by an output  
current of 20 Adc or a thermostat on the main trans-  
former iron.  
An independent safety circuit on the Control board  
monitors the voltage peaks and opens the input con-  
tactor if the limit is exceeded. The green Safe Output  
light indicates when the machine output voltage is  
within the safe operating range.  
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C-1  
C-1  
ACCESSORIES  
FACTORY INSTALLED OPTIONS /  
ACCESSORIES  
FIELD INSTALLED OPTIONS /  
ACCESSORIES  
There are no factory installed options.  
K1735-1 Multi-Weld 350, Multi-process controller.  
K857, K857-1 Remote Control, Control Multi-Weld  
remotely (25 or 100 ft.).  
K1736-1 Distribution Box, Connects up to 10 Multi-  
Welds.  
K449  
LN-25, Across the arc wire feeder.  
K1788-1 Roll Cage, Protect power source, facilitate  
moving, store cable.  
K1806-1 Multi-Weld Four Pack, Mounting / lift rack  
for M-S and four M-Ws.  
K1807-1 Multi-Weld Eight Pack, Mounting / lift rack  
for M-S and eight M-Ws.  
S20428 Paralleling Kit, Allows two machines to  
equally share double load.  
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D-1  
D-1  
MAINTENANCE  
MACHINE CALIBRATION  
SPECIFICATION  
SAFETY PRECAUTIONS  
WARNING  
Have qualified personnel do the maintenance  
work. Always use the greatest care when  
working near moving parts.  
The Multi-Source digital display is controlled by a cur-  
rent sensing circuit on the Control board. The display  
reads 100 when machine output is a little over 40 kW.  
To recalibrate the display, the machine output may  
loaded with Multi-Weld welders or resistive grids or a  
combination of both to obtain an output of 533 Adc as  
read by a calibrated standard ammeter. Trimmer  
resistor R49 may be adjusted to cause the display to  
read 100.  
If a problem cannot be corrected by following  
the instructions, take the machine to the nearest  
Lincoln Field Service Shop.  
-----------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground.  
• Always wear dry insulating gloves.  
--------------------------------------------------------------------  
EXPLODING PARTS can cause injury.  
Failed parts can explode or cause other  
parts to explode when power is  
applied.  
Always wear a face shield and long sleeves  
when servicing.  
-------------------------------------------------------------------  
See additional warning information  
throughout this operator’s manual.  
----------------------------------------------------------  
ROUTINE MAINTENANCE  
The Multi-Source needs no routine maintenance. The  
fan bearings are sealed units.  
PERIODIC MAINTENANCE  
Periodically the machine may be cleaned with low  
pressure compressed air to insure that all cooling pas-  
sages are open and that conductive foreign material  
has not built up inside.  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
Machine input contactor does not 1. Supply line fuse is blown.  
operate.  
(White Power light off)  
2. Contactor power circuit has an  
open lead.  
3. Broken power lead.  
4. T2 internal thermal breaker open  
5. Defective POWER ON/OFF  
Switch (S1).  
7. Control circuit diode bridge open  
8. Transformer iron rear thermostat open.  
(White Power light on)  
1. Open input contactor coil.  
2. Defective Control Board.  
3. Contactor moving iron binding.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
Machine input contactor operates, 1. Electrode or work lead loose or  
but no output when trying to weld.  
broken.  
2. Open main transformer (T1) pri-  
mary or secondary circuit.  
3. Firing P.C. board not connected  
or is faulty.  
4. Firing board not getting enable  
signal.  
Machine does not have maximum 1. One input fuse blown.  
output. 2. One phase of main transformer  
(T1) open.  
3. Faulty Control or Firing P.C.  
boards.  
4. Faulty SCR bridge.  
5. Input voltage too low.  
Machine has output only momentarily 1. Machine has either an internal or  
after contactor closes.Output returns  
momentarily every 75 seconds.  
external short circuit on the output.  
2. Faulty Control PC board.  
Machine has output only momen-  
tarily, contactor opens immediately  
after closing. (Green Safe Output  
light off)  
1. Output voltage peaks are too  
high because input voltage too  
high.  
2. Output voltage peaks are too  
high because output filter circuit  
not working.  
3. Output voltage peaks are too  
high because control circuit isn’t  
sensing output voltage.  
4. Control board faulty.  
5. Output SCR shorted.  
Machine output doesn’t stay on.  
(Amber Thermal light on, fan run-  
ning, digital Output display reads  
greater than 100).  
1. Machine is overloaded.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
Machine output doesn’t stay on. 1. Cooling air blocked or limited.  
(Amber Thermal light on, fan run- 2. Faulty output lead thermostat,  
ning, digital Output display never  
reads greater than 100)  
SCR heat sink thermostat or  
connecting leads.  
3. Ambient cooling air too hot.  
Machine output doesn’t stay on. 1. Faulty cooling fan or wiring.  
(Amber Thermal light on, fan not 2. Faulty wiring in shunt circuit.  
running, digital Output display  
never reads over 100)  
(Digital Output display reads  
near zero.)  
3. Faulty Control board.  
4. 115 Vac winding on main trans-  
former not providing voltage.  
5. Fan circuit breaker on front con-  
trol panel is tripped.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
Machine will not shut off.  
1. Input contactor (CR1) contacts  
are frozen.  
2. Defective POWER switch (S1).  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
5. LEDs 1 through 6 indicate gate signals are being  
PC BOARD TROUBLESHOOTING  
GUIDE - FIRING P.C. BOARD  
sent to the main SCRs 1 through 6 respectively. If  
LED2 on the Control board is bright, along with  
LEDs 7, 8, and 9 on Firing board, and LEDs 1  
through 6 are unequal in brightness, check to make  
sure lead 231 between Control board and Firing  
board is not broken. (If lead 231 is removed while  
the machine output is at open circuit, the output  
voltage peaks may be unregulated and cause the  
over-voltage protection circuit to open the input  
contactor. The over-voltage protection circuit may  
disabled by disconnecting lead 222D at the nega-  
tive output stud or at pin 1 of P2. NOTE: The  
machine may not be used for welding with the pro-  
tection circuit disabled.  
1. LEDs 1 through 9 must be lit when the Multi-Source  
is turned on and the Control board is sending an  
enable signal to the Firing board (pin 7 in P8 is low  
in reference to common at pin 12 in P5).  
2. LEDs 7, 8, and 9 indicate AC power being supplied  
to the P.C. board from auxiliary windings on the  
main transformer (T1). If a LED is not on, turn the  
machine off and unplug P8 from the firing board.  
Turn the machine back on and check the following  
voltages:  
6. If one or more of LEDs 1 through 6 are off, LEDs 7,  
8, and 9 are on and the voltage on lead 231 from  
the Control board (pin 13, P5 to pin 12, P5) is 3 to  
13Vdc replace the Firing PCB.  
3. If all voltages are present, turn power off, and plug  
P5 back into J5. Turn power back on. If LEDs 7, 8  
or 9 are still not lit, replace Firing PCB.  
4. If voltages were not present, check the circuit back  
through the external dropping resistors to the auxil-  
iary windings for a possible open resistor or wire.  
LED that was off  
Check AC voltage between  
P8 pins 2 & 1 (wires 283,284)  
Voltage should be approximately  
7
8
9
32Vac  
32Vac  
32Vac  
P8 pins 4 & 3 (wires 285,286)  
P8 pins 6 & 5 (wires 287,288)  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
7. LED6 indicates that the input to the fan motor opto  
PC BOARD TROUBLESHOOTING  
GUIDE - CONTROL P.C. BOARD  
triac driver has been energized. LED6 should be on  
as long as the fan motor runs. LED6 and the fan  
motor will be on for about 5 minutes after LED4  
goes off.  
1. The white Power light on the machine control panel  
indicates that the Control board power supply is  
being supplied by rectified secondary voltage from  
the Control transformer (T2) by way of the Power  
switch and transformer iron rear thermostat.  
8. LED7 will light when the shorted SCR circuit acti-  
vates. A positive voltage on the negative output  
stud (AC instead of DC on the output studs) will  
activate a circuit causing the input contactor to  
open. This circuit is active only when the enable  
signal to the Firing board is high (the output is off).  
The contactor will remain open (and the white  
Power light will remain on) until the Power switch is  
turned off (or the input power to the machine is oth-  
erwise removed) for about 1 second and then  
turned on again.  
2. LED1 indicates machine output voltage. At normal  
output voltages, LED1 will be brightly lit.  
3. LED2 indicates the level of the control signal to the  
Firing board. The brightness of LED2 is inversely  
proportional to machine output because the control  
signal increases as the machine output decreases.  
4. LED3 lights when the current amplifier senses an  
output current over about 10 amps and sends a sig-  
nal to turn the cooling fan on. If LED3 is on but the  
fan is not , there could be a problem with the fan  
motor or the fan motor drive circuit (see LED6).  
9. The green Safe Output light on the control panel  
when the machine output voltage is present and  
safe. It lights when the machine output is between  
40 Vdc and 113 volts peak.  
10. The yellow Thermal light on the front panel lights  
when the open thermostat signal is sent to the fan  
control and output disable circuits.  
5. LED4 says that some signal, either thermostat, out-  
put current or output over-current is calling for the  
fan to operate.  
6. LED5 tells us that the current signal from the shunt  
is too high. If LED5 is lit for 5-8 seconds, the enable  
signal to the Firing board is made high to shut off  
the output SCRs. In the case of a short duration  
current overload, LED5 may only be briefly lit  
because, in normal operation, the machine output  
immediately goes to zero. Once disabled, the out-  
put will remain off for about 75 seconds.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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F-1  
F-1  
DIAGRAMS  
0
M 1  
M 9  
0
M 1  
M 9  
M 8  
M 7  
M 6  
M 5  
M 4  
M 3  
M 2  
M 1  
M 6  
M 5  
M 4  
M 3  
M 2  
M 1  
R 1  
R 2  
R 9  
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F-2  
F-2  
DIAGRAMS  
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NOTES  
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NOTES  
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Now Available...12th Edition  
New Lessons in Arc Welding  
The Procedure Handbook of Arc Welding  
Lessons, simply written, cover manipulatory techniques;  
machine and electrode characteristics; related subjects,  
such as distortion; and supplemental information on arc  
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lesson.  
With over 500,000 copies of previous editions published  
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Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
Keep flammable materials away.  
Wear eye, ear and body protection.  
WARNING  
Spanish  
No toque las partes o los electrodos Mantenga el material combustible  
Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Gardez à l’écart de tout matériel  
inflammable.  
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
Isolez-vous du travail et de la terre.  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
Turn power off before servicing.  
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
Débranchez le courant avant l’entre- N’opérez pas avec les panneaux  
tien.  
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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World's Leader in Welding and Cutting Products •  
Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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