Lincoln Electric DC-655, IM602-A User Manual

IM602-A
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For use with machine Code Number 10501 thru 10510, 11324
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought­ful operation on your part. DO
NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most
importantly, think before you act and be careful.
DC-655
February, 2009
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
i
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.d. Keep
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.
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1.e. In so me cases it may be nece ssary t o remove guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
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1.b. Operate engines in open, well-ventilated areas
or vent the engine exhaust fumes
outdoors.
1.c. Do no t add t he fuel welding arc or when the engine is running. Stop the engine and allow it to cool before refueling 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.
all equipment safety guards, covers and devices in
1.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.
near an open flame
safety
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
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1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
ELECTRIC SHOCK can 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
gloves to insulate hands.
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.
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:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
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.
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.
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.
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.
skin or wet clothing. Wear dry, hole-free
ARC RAYS can burn.
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.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
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.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough
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 within applicable OSHA PEL and ACGIH TLV limits 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.
5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating prod­ucts.
5.d. 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.
ventilation and/or exhaust at the arc to keep
vapors
to
5.e. 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.
5.f. Also see item 1.b.
Jan ‘09
iii
SAFETY
iii
WELDING and CUTTING SPARKS can cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
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.
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.
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.
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 been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f. 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.
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 cir­cuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode if damaged.
7.a. Us e 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.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.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.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
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.
FOR ELECTRICALLY powered equipment.
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.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Jan ‘09
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
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 suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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.
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.
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.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
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.
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 lev­age, 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.
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.
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.
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.
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 rayonnement 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.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma­bles.
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, pantalons sans revers, et chaussures montantes.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
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.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
SAFETY
Electromagnetic Compatibility (EMC)
Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction 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 affect many kinds of electrical equipment; other nearby 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.
Installation and Use The 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 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. In other cases it could involve construction of 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.
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Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is compe­tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
SAFETY
Electromagnetic Compatibility (EMC)
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.
Methods of Reducing Emissions
Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of 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.
Maintenance of the Welding Equipment 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 striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
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Welding Cables The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.
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, not connected to earth because of its size and position, e.g., ships 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 the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec­tion of the workpiece to earth should be made by a 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.
Screening and Shielding 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. 1
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1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”
L10093 3-1-96H
Thank You
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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!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
CUSTOMER ASSISTANCE POLICY
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.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
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.
viii viii
TABLE OF CONTENTS
PAGE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION A
TECHNICAL SPECIFICATIONS – IDEALARC DC-655 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
GRAPHIC SYMBOLS THAT APPEAR ON RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
SELECT SUITABLE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
STACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
TILTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
ELECTROMAGNETIC COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
ELECTRICAL INPUT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
FUSE AND WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
GROUND CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
INPUT POWER SUPPLY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
RECONNECT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
OUTPUT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
ELECTRODE AND WORK CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
AUXILIARY POWER AND CONTROL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
AUXILIARY POWER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
115VAC DUPLEX RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
230V RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
14 PIN MS TYPE RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
TERMINAL STRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
__________________________________________________________________________________________
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION B
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
RECOMMENDED PROCESSES AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
DESIGN FEATURES AND ADVANTAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
WELDING CAPABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
CONTROLS AND SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
AUXILIARY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
MACHINE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
WELDING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
__________________________________________________________________________________________
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION C
FIELD INSTALLED OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
__________________________________________________________________________________________
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION D
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
__________________________________________________________________________________________
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION E
HOW TO USE TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
MACHINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
P.C. BOARD TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9, E-10
__________________________________________________________________________________________
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION F
__________________________________________________________________________________________
PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-317 SERIES
__________________________________________________________________________________________
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – DC-655
INPUT - THREE PHASE ONLY
Standard
Volatge
Input Current at Rated Output
100% Duty Cycle
60% Duty Cycle
A-1
Code
Number
230/460/60
230/460/575/60
208/416/60
460/60 575/60
230/400/50/60*
380/500/50/60
440/50/60
200/400/50/60
415/50/60
Duty Cycle
100% Duty Cycle
NEMA Class I (100)*
60% Duty Cycle
Voltage Range
13-44 DC
INPUT
VOLTAGE /
FREQUENCY
208 230 416 460 575 200 230 380 400 415 440 500
122/61
122/61/49
135/67.5
61 49
122/70
74/56
64
140/70
68
150/75
150/75/60
166/83
75 60
150/86
90/69
78
172/86
83
RATED OUTPUT
Amps
650
815
OUTPUT
Current Range
50-815
Maximum Open Circuit Voltage
46 CV Mode 68 CC Mode
See the OPERATION section
RECOMMENDED INPUT WIRE AND FUSE SIZES
HERTZ
60 60 60 60
60 50/60 50/60 50/60 50/60 50/60 50/60 50/60
INPUT AMPERE
RATING ON
NAMEPLATE
135 122
67.5 61 49
140 122
74 70 68 64 56
TYPE 80°C
COPPER WIRE
IN CONDUIT AWG(IEC-MM2) SIZES 40°C (104°F) Ambient
1 (43) 1 (43) 6 (14) 6 (14)
8 (8.4)
1/0 (54)
1 (43) 4 (21) 4 (21) 6 (14) 6 (14) 6 (14)
GROUND WIRE
IN CONDUIT
AWG(IEC-MM2) SIZES
10501
10502, 11324
10503 10504 10505 10506 10507 10508 10509 10510
Volts at Rated Amperes
44
44
Auxiliary
for Auxiliary Power
information by model
Copper
4 (21) 4 (21) 6 (14) 6 (14)
8 (8.4)
4 (21) 4 (21) 6 (14) 6 (14) 6 (14) 6 (14) 6 (14)
Power
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
250 Amp 225 Amp 125 Amp 110 Amp
90 Amp 250 Amp 225 Amp 125 Amp 125 Amp 110 Amp 110 Amp 110 Amp
1
PHYSICAL DIMENSIONS
HEIGHT
27.5 in
699 mm
* European models meet IEC974-1 standards.
1
Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.
WIDTH
22.2 in
564 mm
DC-655
DEPTH
38.0 in
965 mm
WEIGHT
720 lbs.
326 kg.
A-2
INSTALLATION
GRAPHIC SYMBOLS THAT APPEAR ON
RATING PLATE (LOCATED ON CASE BACK)
A-2
NEMA EW 1 (100%)
IEC 974-1
IP-23
3 Phase transformer with rectified DC output
INPUT POWER
THREE PHASE
Designates welder complies with National Electrical Manufacturers Association requirements EW 1 Class I with 100% duty cycle at 650Amps output. (Domestic, Canadian, and Export models)
Designates welder complies with International Electrotechnical Commission requirements 974-1. (European Models)
Designates the degree of envi­ronmental protection provided by the power sources enclosure.
S
CE
NRTL/C
Constant Voltage Output Characteristics
GMAW
FCAW
Designates welder can be used in environments with increased hazard of electric shock. (European models)
Designates welder complies with low voltage directive and with EMC directive. (European models)
Designates welder complies with
R
both Underwriters Laboratories (UL) standards and Canadian Standards Association (CSA) standards. (Canadian Model)
Constant Current Output Characteristics
SMAW
SAW
DC-655
NRTL
U
o
U
1
I
1
X
U
2
I
2
R
Designates welder complies with Underwriters Laboratories (UL) standards. (Domestic Models)
Open Circuit Output Voltage
Input Voltage Rating(s)
Input Current Rating(s)
Output Duty Cycle Rating(s)
Output Voltage Rating(s)
Output Current Rating(s)
A-3
INSTALLATION
A-3
Read entire installation section before starting installation.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
Only qualified personnel should perform this installation.
• Turn the input power OFF at the discon­nect switch or fuse box before working on this equipment.
• Turn the Power switch on the DC-655 “OFF” before connecting or disconnect­ing output cables, wire feeder or remote connections, or other equipment.
• Do not touch electrically hot parts.
• Always connect the Idealarc DC-655 grounding terminal (located on the welder near the reconnect panel) to a good electrical earth ground.
SELECT SUITABLE LOCATION
Place the welder 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 precautions can result in excessive operating temperatures and nuisance shut-downs.
STACKING
INPUT
CONTACTOR (CR1)
INPUT POWER SUPPLY CABLE WITH BUSHING
OR BOX CONNECTOR
FIGURE A.1 ELECTRICAL INPUT CONNECTIONS
RECONNECT
PANEL ASSEMBL Y
ELECTRICAL INPUT CONNECTIONS
Before installing the machine check that the input sup­ply voltage, phase, and frequency are the same as the voltage, phase, and frequency as specified on the welder nameplate.
Use input wire sizes that meet local electrical codes or see the Technical Specifications page in this manu­al.
Input power supply entry is through the hole in the Case Back Assembly. See Figure A.1 for the location of the machine’s input cable entry opening, Input Contactor (CR1), and reconnect panel.
The DC-655 may be stacked three-high provided the bottom machine is on a stable, hard, level surface. Be sure that the two pins in the roof fit into the slots in the base of the DC-655 above it.
TILTING
Do not place the machine on a surface that is inclined enough to create a risk of the machine falling over.
ELECTROMAGNETIC COMPATIBILITY (EMC)
The EMC classification of the DC-655 is Industrial, Scientific and Medical (ISM) group 2, class A.
The DC-655 is for industrial use only. (See prints L10093-1, -2 safety pages in the Front of Instruction Manual for further details).
Locate the DC-655 away from radio controlled machinery. The normal operation of the DC-655 may adversely affect the operation of RF controlled equip­ment, which may result in bodily injury or damage to the equipment.
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Technical Specifications page of this manual for the machine being used. They are also called inverse time or ther­mal/magnetic circuit breakers.
DO NOT use fuses or circuit breakers with a lower amp rating than recommended. This can result in “nuisance” tripping caused by inrush current even when machine is not being used for welding at high output currents.
GROUND CONNECTION
Ground the frame of the machine. A ground terminal marked with the symbol ( ) is located inside the case back of the machine near the input contactor. Access to the input box assembly is at the upper rear of the machine. See your local and national electrical codes for proper grounding methods. Use grounding wire sizes that meet local electrical codes or see the Technical Specifications page in this manual.
DC-655
A-4
INSTALLATION
INPUT POWER SUPPLY CONNECTIONS
A qualified electrician should connect the input power supply leads.
1. Follow all national and local electrical codes.
2. Use a three-phase line.
A-4
Multiple voltage machines are shipped connected to the highest input voltage listed on the machine’s rating plate. Before installing the machine, check that the reconnect panel in the input box assembly is connect­ed for the proper voltage.
CAUTION
3. Remove the input access door at upper rear of the machine.
4. Follow input supply connection diagram located on the inside the door. For multiple voltage machines, follow the diagram for the voltage that is within 10% of your actual input line voltage.
5. Connect the three-phase AC power supply leads L1, L2, and L3 to the input contactor terminals in the input box assembly. See Figure A.1.
RECONNECT PROCEDURE
WARNING
Electric Shock Can Kill
• Disconnect input power before perform­ing this procedure.
------------------------------------------------------------------------
Failure to follow these instructions can cause immedi­ate failure of components within the machine. When powering welder from a generator be sure to turn off welder first, before generator is shut down in order to prevent damage to welder.
------------------------------------------------------------------------
To reconnect a multiple voltage machine to a different voltage, remove input power and refer to the input connection diagram located on the inside of case back input access door. Follow the diagram for the voltage that is within 10% of your actual input line voltage.
. Figure A.2 shows a sample of the reconnect
1
instructions for a dual voltage machine.
Do not operate with covers removed
Disconnect input power before
servicing
Do not touch electrically live parts
Only qualified persons should install, use or service this equipment
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE
CR1
H3
W
V
CONTACTOR
U
H1
CONTROL
TRANSF.
H2
INPUT
LINES
LINKS
L3 L2 L1
GND
CONNECTION FOR LOWEST RATING PLATE VOLTAGE
CR1
H2
W
V
CONTACTOR
U
H1
CONTROL
TRANSF.
H3
L3
INPUT
L2
LINES
L1
GND
LINKS
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.
FIGURE A.2 Dual Voltage Machine Reconnection Procedure
DUAL VOLTAGE MACHINE
IMPORTANT: CHANGE LINK POSITIONS AND CONTROL TRANSFORMER CONNECTIONS.
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H3 CONTROL TRANSFORMER
LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN; DOUBLE OR TRIPLE STACK THE LINKS
IN THREE POSITIONS. LOOP THE FLEX LEAD IN THE POSITION SHOWN; POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H2 CONTROL TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN. CONNECT THE FLEX LEAD AS SHOWN; POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
INPUT SUPPLY CONNECTION DIAGRAM
M18225
D-UF
DC-655
A-5
T
INSTALLATION
A-5
OUTPUT CONNECTIONS
ELECTRODE AND WORK CABLES
Use the shortest possible cable lengths. See Table A.1 for recommended cable sizes based on length.
TABLE A.1
Cable Sizes for Combined Lengths of Copper
Electrode and Work Cable
Cable Length
ft. (m)
0 (0) to 100 (30.4) 100 (30.4) to 200 (60.8) 200 (60.8) to 250 (76.2)
The output terminals are located at the lower front of the welder behind a hinged door Refer to figure A.3. Route the welding cables through the slotted strain reliefs of the base to the welding terminals.
LOW INDUCTANCE TERMINAL
On the DC-655, the inside right Negative (-) output terminal is lower choke inductance. This terminal is presently only recommended for CV mode welding with NR203Ni 1% negative polarity procedures. All other processes are to be welded using the outside right Negative (-) output terminal with higher choke inductance. CC mode processes must use high inductance.
For Positive Polarity:
1. Connect the work cable to the high inductance (-) terminal (marked " ").
Parallel Cables Cable Size
2 2 2
2/0 ( 70mm2) 3/0 ( 95mm2)
4/0 (120mm2)
2. Connect the electrode cable to the positive terminal marked “+”.
3. Remove the terminal strip access cover panel on the lower case front. Refer to figure A.3 for the location.
4. Work Sense lead #21 from the 14 Pin MS-recepta­cle must be connected to “-21”on the terminal strip.
Note: This is how the DC-655 is shipped from the factory.
5. Replace the terminal strip access cover panel.
For Negative Polarity:
1. Connect the electrode cable to the appropriate high inductance (-) terminal (marked " ") or to the low inductance (-) terminal (marked " ") if using NR203Ni 1% elec­trode only.
2. Connect the work cable to the positive terminal marked “+”.
3. Remove the terminal strip access cover panel on the lower case front. Refer to figure A.3 for the location.
4. Work Sense lead #21 from the 14 Pin MS-recepta­cle must be connected to “+21”on the terminal strip.
5. Replace the terminal strip access cover panel.
POSITIVE OUTPUT TERMINAL
14 PIN MS RECEPTACLE
LOW INDUCTANCE NEGATIVE OUTPUT
TERMINAL STRIP COVER PANEL
TERMINAL
FIGURE A.3 Output Connections
DC-655
HIGH INDUCTANCE NEGATIVE OUTPU TERMINAL
A-6
INSTALLATION
A-6
AUXILIARY POWER AND CONTROL CONNECTIONS
Located at the lower front of the welder behind a hinged door is a 115VAC duplex receptacle for auxil­iary power (Domestic and Canadian Models only) and a 14 Pin MS type receptacle for connection of auxil­iary equipment such as wire feeders. Also, terminal strips with 115VAC and connections for auxiliary equipment are located behind the access panel on the lower case of the welder. A 220VAC receptacle for a water cooler (European and Export Models only) is located on the case back.
AUXILIARY POWER TABLE
Voltage and Circuit Breaker Ratings at Auxiliary Power
Connections for Various Models
Auxiliary Domestic Canadian European Export
Power Models Model Models Models
Connections (60Hz) (230/460/575V/60 Hz) (50/60 Hz) (50/60 Hz)
(Code 10502) (Code 11300) At Duplex 115V 20A 115V 15A 115V 20A No Duplex No Duplex Receptacle
Terminal strip 115V 20A 115V 15A 115V 20A 115V 15A 115V 15A terminals 31 & 32
MS-Receptacle 115V 20A 115V 15A 115V 20A Open Circuit 115V 15A pins A & J
MS-Receptacle 42V 10A 42V 10A 42V 10A 42V 10A pins I & K
At 220V No Receptacle No Receptacle 220V 2A 220V 2A Receptacle
14 PIN MS TYPE RECEPTACLE
(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)
Refer to the figure A.4 for the available circuits in the 14 pin receptacle.
42 VAC is available at receptacle pins I and K. A 10 amp circuit breaker protects this circuit.
115 VAC is available at receptacle pins A and J (Domestic, Canadian and Export Models). This circuit is protected by a circuit breaker (see Auxiliary Power Table). Note that the 42 VAC and 115 VAC circuits are electrically isolated from each other. However, on the European model one line of the 115VAC is con­nected to chassis ground.
FIGURE A.4 FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE
K=42
A=32
B=GND
L N
C=2
D=4
E=77
J=31
I=41
H=21
G=75
F=76
M
PIN LEAD NO. FUNCTION
115VAC DUPLEX RECEPTACLE (DOMESTIC AND CANADIAN MODELS ONLY)
The 115VAC duplex receptacle is protected by a cir­cuit breaker located below the receptacle (see Auxiliary Power Table). Receptacle is a NEMA 5-20R (protected by a 20 amp breaker) on Domestic and Canadian Models, except Canadian Code 10502 receptacle is a NEMA 5-15R, protected by a 15 amp breaker.
220VAC RECEPTACLE (EUROPEAN AND EXPORT MODELS ONLY)
A Continental European receptacle is located on the rear panel for supplying 220VAC to a water cooler. The receptacle has a protective cover to prevent inci­dently contact and is a Schuko type. The circuit is pro­tected by a 2 amp circuit breaker also located on the rear panel. This circuit is electrically isolated from all other circuits, but on the European Models one line is connected to chassis ground.
A 32 115 VAC B GND Chassis Connection C 2 Trigger Circuit D 4 Trigger Circuit E 77 Output Control F 76 Output Control G 75 Output Control
H 21 Work Sense Connection I 41 42 VAC
J 31 115 VAC
1.
K 42 42 VAC L --- --­M --- --­N --- ---
1.
115VAC circuit is not present on IEC 974-1 European models.
2.
As shipped from the factory Lead #21 from the 14 Pin connector is connected to “-21” on the terminal strip. This is the configuration for positive welding. If welding negative polarity, connect lead #21 to the “+21” connection point on the terminal strip.
2
DC-655
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