Hobart Multi-Handler 200 Owner's Manual
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Hobart Multi-Handler 200 Owner's Manual

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OM-285922B
2020−08
Processes
Multiprocess Welding
Description
Arc Welding Power Source And
Wire Feeder
Hobart
)
t
Multi-Handler 200
www.HobartWelders.com

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  • Page 1 OM-285922B 2020−08 Processes Multiprocess Welding Description Arc Welding Power Source And Wire Feeder Hobart Multi-Handler 200 www.HobartWelders.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 3 TABLE OF CONTENTS SECTION 6 − OPERATION ..............6-1.

  • Page 4: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2020−02 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 5 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 6: Additional Hazards For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 7: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 8: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2020−02_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 9 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 10: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 11: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 12: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.

  • Page 13: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Lift-Arc Operation Amperage Remote (GTAW) Voltage Gas Tungsten Arc Circuit Breaker Welding Rated No Load Positive Voltage (OCV) Wire Feed Spool Direct Current Negative (DC) Self-Shielded Flux Cored Arc Alternating Welding (FCAW) Current (AC) Duty Cycle Shielded Metal Arc Welding Primary Voltage...

  • Page 14: Section 4 − Specifications

    A complete Parts List is available at www.HobartWelders.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back of unit. Use rating label to determine input power requirements and/or rated output.

  • Page 15: Environmental Specifications

    4-7. Environmental Specifications A. IP Rating IP Rating IP21S This equipment is designed for indoor use and is not intended to be used or stored outside. IP21S 2014−06 B. Temperature Specifications Operating Temperature Range* Storage/Transportation Temperature Range 14 to 104°F (−10 to 40°C) −4 to 131°F (−20 to 55°C) *Output is degraded at temperatures above 104°F (40°C).

  • Page 16: Duty Cycle And Overheating For Mig (Gmaw)

    A complete Parts List is available at www.HobartWelders.com 4-9. Duty Cycle And Overheating For MIG (GMAW) Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again.

  • Page 17: Duty Cycle And Overheating For Tig (Gtaw)

    4-10. Duty Cycle And Overheating For TIG (GTAW) Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again.

  • Page 18: Duty Cycle And Overheating For Stick (Smaw)

    A complete Parts List is available at www.HobartWelders.com 4-11. Duty Cycle And Overheating For Stick (SMAW) Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again.

  • Page 19: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting A Location Do not move or operate unit where it could tip. Movement Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 20: Multi−Voltage Plug (Mvp) Connection

    A complete Parts List is available at www.HobartWelders.com 5-2. Multi−Voltage Plug (MVP) Connection Selecting Plug Do not cut off power cord con- nector and rewire. The power cord connector and plugs will work with standard NEMA re- ceptacles. Modifying power cord, connector, and plugs will void product warranty.

  • Page 21: Electrical Service Guide

    5-3. Electrical Service Guide Elec Serv 2020-02 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.

  • Page 22: Connecting 120 Volt Input Power

    A complete Parts List is available at www.HobartWelders.com 5-5. Connecting 120 Volt Input Power Installation must meet National and Local Codes − have only qualified persons make this installation. Special installation required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 23: Connecting 1-Phase Input Power For 240 Vac

    5-6. Connecting 1-Phase Input Power For 240 VAC Installation must meet National and Local Codes − have only qualified persons make this installation. Tools Needed: Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Follow es- tablished procedures regarding =GND/PE Earth Ground the installation and removal of lockout/tagout devices.

  • Page 24: Generator / Inverter Requirements

    A complete Parts List is available at www.HobartWelders.com 5-7. Generator / Inverter Requirements Minimum auxiliary power require- ment at rated load is 10 KW continu- ous/12.5 KW peak at 240 volts AC for full output. Smaller generators Generator settings, if applicable. will reduce output capability.

  • Page 25: Stick Welding Connections

    5-8. Stick Welding Connections Turn off unit and disconnect input power before making connections. Do not use worn, damaged, undersized, or repaired cables. Negative (−) Weld Output Terminal Positive (+) Weld Output Terminal Stick Electrode Holder And Cable Work Clamp And Cable Insert connectors fully into termi- nals.

  • Page 26: Tig Welding Connections

    A complete Parts List is available at www.HobartWelders.com 5-9. TIG Welding Connections Turn off unit and disconnect input power before making connections. Do not use worn, damaged, undersized, or repaired ca- bles. Negative (−) Weld Output Terminal Positive (+) Weld Output Terminal TIG Torch And Cable Work Clamp And Cable...

  • Page 27: Process/Polarity Table

    5-10. Process/Polarity Table Cable Connections Process Polarity Wire Drive Assembly Cable Work Cable GMAW − Solid wire with shielding gas DCEP − Reverse polarity Connect to positive (+) Connect to negative (−) output receptacle output receptacle FCAW − Self-shielding wire − no DCEN −...

  • Page 28: Mig Gun Connection Inside Unit

    A complete Parts List is available at www.HobartWelders.com 5-12. MIG Gun Connection Inside Unit Make sure that gun end is tight against drive assembly. Gun Securing Knob Gun Block Gun Outlet Wire Guide Gun End Loosen knob. Insert end of gun through opening in front panel until gun end bottoms against gun block.

  • Page 29: Connecting Shielding Gas Supply

    5-13. Connecting Shielding Gas Supply Obtain gas cylinder and chain to running gear, wall, other stationary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve.

  • Page 30: Installing Wire Spool And Adjusting Hub Tension

    A complete Parts List is available at www.HobartWelders.com 5-14. Installing Wire Spool And Adjusting Hub Tension Retaining Nut − For 8 in. (203 mm) Spool Only 4 in. Wire Spool 8 in. Wire Spool Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set.

  • Page 31: Threading Welding Wire

    5-15. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Tools Needed: Pressure Adjustment Knob Drive Roll Gun Input Liner Gun Conduit Cable Lay gun cable out straight. Hold wire tightly to keep it from unraveling. 6 in. (150 mm) Open pressure assembly.

  • Page 32: Removing Mig Gun To Replace With A Spool Gun

    A complete Parts List is available at www.HobartWelders.com 5-16. Removing MIG Gun To Replace With A Spool Gun Cut Off End Of Wire. Open Pressure Assembly. Turn Off Power. Knob Hold wire tightly to keep it from unraveling. Loosen Knob, Disconnect Gun Trigger Plug, Rewind Wire Onto Spool, Fasten And Remove Gun From Unit.

  • Page 33: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls Rear View Ref. 500578-A Display Positive Output Receptacle Wire Feed/Amperage Knob Voltage Control Knob Negative Output Receptacle Controls wire feed speed in MIG process and amperage in the stick or TIG process. Controls voltage in MIG process. See weld TIG Remote Receptacle See weld parameter chart for initial set- parameter chart for initial setting.

  • Page 34: Screen, Power-Up Mode

    A complete Parts List is available at www.HobartWelders.com 6-2. Screen, Power-Up Mode Power Switch Push toggle to ON position. Display Three seconds into the power up process, the screen will display the input voltage (either 120V or 240V). Ref. 287758-A 6-3.

  • Page 35: Controls, Mig Mode (Menu 1 Of 5)

    6-4. Controls, MIG Mode (Menu 1 Of 5) Process Select Button Push button to enter MIG process. Check weld parameter chart for correct polarity at positive (+) and negative (−) receptacles. See section 5-11 for proper cable placement. Voltage Knob Adjust voltage knob per weld pa- rameter chart for initial setting.

  • Page 36: Controls, Flux Cored Mode (Menu 2 Of 5)

    A complete Parts List is available at www.HobartWelders.com 6-5. Controls, Flux Cored Mode (Menu 2 Of 5) Process Select Button Push button to enter Flux-cored process. Check weld parameter chart for correct polarity at positive (+) and negative (−) receptacles. See section 5-11 for proper cable placement.

  • Page 37: Controls, Tig Mode (Menu 3 Of 5)

    6-6. Controls, TIG Mode (Menu 3 Of 5) Process Select Button In the TIG process when the option- al foot control is not being used, the output is on when the TIG process is selected. Push button to enter TIG process. Check weld parameter chart for correct polarity at positive (+) and negative (−) receptacles.

  • Page 38: Controls, Tig Mode With Foot Pedal(Menu 4 Of 5)

    A complete Parts List is available at www.HobartWelders.com 6-7. Controls, TIG Mode With Foot Pedal(Menu 4 Of 5) Process Select Button In the TIG process when the option- al foot control is being used, the out- put is controlled by the foot pedal. Push button to enter TIG process.

  • Page 39: Controls, Stick Mode (Menu 5 Of 5)

    6-8. Controls, Stick Mode (Menu 5 Of 5) Process Select Button Push button to enter Stick process. Check weld parameter chart for correct polarity at positive (+) and negative (−) receptacles. See section 5-8 for proper cable placement. Amperage Knob Adjust amperage knob per weld pa- rameter chart for initial setting.

  • Page 40: Screen, Power-Down Mode

    A complete Parts List is available at www.HobartWelders.com 6-9. Screen, Power-Down Mode Power Switch Push toggle to Off position. Display The screen displays the Powering Down message when the switch is powered off. Ref. 287758-A Notes OM-285922 Page 37...

  • Page 41: Section 7 − Weld Parameter Charts

    SECTION 7 − WELD PARAMETER CHARTS 7-1. Welding Parameters 120 Volt Ref. 287984-B OM-285922 Page 38...
  • Page 42 A complete Parts List is available at www.HobartWelders.com Ref. 287984-B OM-285922 Page 39...

  • Page 43: Welding Parameters 240 Volt

    7-2. Welding Parameters 240 Volt Ref. 287984-B OM-285922 Page 40...
  • Page 44 A complete Parts List is available at www.HobartWelders.com Ref. 287984-B OM-285922 Page 41...

  • Page 45: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Maintain more often Disconnect power before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Damaged Or Unreadable...

  • Page 46: Changing Drive Roll Or Wire Inlet Guide

    A complete Parts List is available at www.HobartWelders.com 8-3. Changing Drive Roll Or Wire Inlet Guide Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place.

  • Page 47: Error Displays

    8-4. Error Displays Thermal Error Indicates a malfunction in the primary power thermal protection circuit. If this display is shown, contact a Factory Authorized Service Agent. Thermal Error Indicates a malfunction in the secondary thermal protection circuitry. If this display is shown, contact a Factory Authorized Service Agent.

  • Page 48: Error Messages

    A complete Parts List is available at www.HobartWelders.com 8-5. Error Messages Message Error Remedy Internal temperature of welder has exceeded the Wait for unit to cool down. If the fan is not running, Overtemp−Please wait while the welder cools down. maximum limit.

  • Page 49: Troubleshooting

    8-6. Troubleshooting Trouble Remedy No weld output; unit completely Place line disconnect switch in On position. inoperative. Check and replace line fuse(s), if necessary, or reset supplementary protector. Be sure power cord is plugged in and that receptacle is receiving input power. No weld output;...
  • Page 50 Notes OM-285922 Page 47...

  • Page 51: Section 9 − Electrical Diagram

    SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram OM-285922 Page 48...
  • Page 52 287757-A OM-285922 Page 49...

  • Page 53: Section 10 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 10 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2018-01 Whenever possible and practical, use DC weld output instead of AC weld output. 10-1. Selecting Tungsten Electrode ( Wear Clean Gloves To Prevent Contamination Of Tungsten A.

  • Page 54: Preparing Tungsten Electrode For Dc Electrode Negative (Dcen) Welding Or Ac Welding With Inverter Machines

    10-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information.

  • Page 55: Section 11 − Guidelines For Tig Welding (Gtaw)

    SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) Ref. gtaw_Phase_2018−01 11-1. Positioning The Torch Grinding the tungsten elec- trode produces dust and fly- ing sparks which can cause injury and start fires. Use lo- cal exhaust (forced ventila- tion) at the grinder or wear an approved respirator.

  • Page 56: Torch Movement During Welding

    11-2. Torch Movement During Welding Tungsten Without Filler Rod ° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod ° ° Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool.

  • Page 57: Lift-Arc And Hf Tig Start Procedures

    11-4. Lift-Arc And HF TIG Start Procedures Lift-Arc Start When Lift-Arct button light is On, start arc as follows: TIG Electrode Workpiece Touch tungsten electrode to work- piece at weld start point, enable out- put and shielding gas with torch trig- ger, foot control, or hand control.

  • Page 58: Section 12 − Gmaw Welding (Mig) Guidelines

    SECTION 12 − GMAW WELDING (MIG) GUIDELINES 12-1. Typical GMAW (MIG) Process Connections Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/...
  • Page 59 12-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trig- ger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned cor- rectly on seam.
  • Page 60 12-5. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −...
  • Page 61 12-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.
  • Page 62 12-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.
  • Page 63 12-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand.
  • Page 64 12-16. Common GMAW (MIG) Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Short Short...
  • Page 65 12-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. Wire feed motor operates, but wire does not feed. Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match wire size and type if necessary.

  • Page 66: Section 13 − Guidelines For Stick Welding (Smaw)

    SECTION 13 − GUIDELINES FOR STICK WELDING (SMAW) 13-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. Weld current can damage electronic parts in vehicles. Disconnect both battery Equipment Needed: Tools Needed: cables before welding on a vehicle.

  • Page 67: Electrode And Amperage Selection Chart

    13-2. Electrode And Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 SMOOTH, EASY, FLAT 7024 EP,EN 6013...

  • Page 68: Positioning Electrode Holder

    13-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle After learning to start and hold an arc, practice running beads of weld metal on flat plates using a full electrode. ° ° Hold the electrode nearly per- pendicular to the work, although tilting it ahead (in the direction of °...

  • Page 69: Conditions That Affect Weld Bead Shape

    13-7. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle Angle Too Large ° - ° Angle Too Small Electrode Angle Drag Spatter Arc Length Normal Too Long Too Short...

  • Page 70: Welding Groove (Butt) Joints

    13-10. Welding Groove (Butt) Joints Tack Welds Prevent butt joint distortion by tack welding the materials in position before final weld. Workpiece distortion occurs when heat is applied locally to a joint. One side of a metal plate will curl up toward the weld.

  • Page 71: Weld Test

    13-12. Weld Test Vise Weld Joint Hammer Strike the weld joint in the direction shown. A good weld bends over but does not break. If the weld breaks, examine it to determine the cause. If the weld is porous (many holes), the arc length was probably too long.
  • Page 72 Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Remedy Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle.

  • Page 73: Section 14 − Parts List

    Dia. Part Mkgs. Description Quantity Multi-Handler 200 ..287964 Circuit Card Assy, LCD ..........
  • Page 74 Notes...
  • Page 75 Effective January 1, 2020 Warranty Questions? 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Call serial number preface of NA or newer. 1-800-332-3281 8 AM − 5 PM EST This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied.
  • Page 76 (Date which equipment was delivered to original customer.) Distributor Address City State Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, op- eration, or service, contact us! Resources Available Always provide Model Name and Serial/Style Number.

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