Lincoln Electric OPTIMARC CV500P User manual

Rev. 03
IM7025-3
Feb, 2018
Rev. 03
OPTIMARC®CV500P
For use with machine Part Number K60129-1, Code 76343
•World’s Leader in Welding and Cutting•
THE SHANGHAI LINCOLN ELECTRIC COMPANY
No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907
www.lincolnelectric.com.cn
Copyright © 2018 The Shanghai Lincoln Electric Company
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 you 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.

Rev. 03
Thank you for selecting QUALITY Lincoln Electric products.
Please examine the packaging and equipment for damage. Claims for material damaged in shipment must be
notified immediately to the authorized dealer from whom you purchased the machine.
For future reference,please record your equipment identification information in the table below. Model Name,
Code & Serial Number can be found on the machine rating plate.
Model Name
□OPTIMARC®CV500P
Code & Serial number
Date & Where Purchased
Authorized dealer’s shop
Declaration of conformity
THE SHANGHAI LINCOLN ELECTRIC COMPANY
Designed in conformance with the following norm:
GB/T 15579.1-2013
EN 60974-1
THE SHANGHAI LINCOLN ELECTRIC COMPANY
No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907

i SAFETY i
OPTIMARC®CV500P
Rev.03

ii SAFETY ii
OPTIMARC®CV500P
Rev.03

iii SAFETY iii
OPTIMARC®CV500P
Rev.03

A-1 INSTALLATION A-1
OPTIMARC®CV500P
Rev.03
TECHNICAL SPECIFICATIONS –OPTIMARC®CV500P
INPUT –THREE PHASE ONLY
OPTIMARC®CV500P
Standard Voltage/Phase/Frequency
380V ~ 415V(±10%)/3/50 or 60 Hz
Input Power at Rated Output
23kVA @ 60% Duty Cycle
RATED OUTPUT –DC ONLY
OPTIMARC®CV500P
Duty Cycle
60%
100%
Amperes
500A
390A
Volts at Rated Amperes
39V
33.5V
OUTPUT
OPTIMARC®CV500P
Welding Current Range
50A ~ 500A
Open Circuit Voltage
60V
Welding Voltage Range
16 V ~ 39V
RECOMMENDED INPUT WIRE AND FUSE SIZES
OPTIMARC®CV500P
Input
Voltage/
Frequency
(Hz)
342V ~
456.5V/
50Hz or
60Hz
Maximum
Input
Ampere
51A
Maximum
Effective
Supply
Current
40A
60°C Copper
Wire in
Conduct
Sizes
12mm2
Fuse or
Breaker Size
(Super Lag)
60A
Grounding
Conductor
Size
10mm2
PHYSICAL DIMENSIONS
OPTIMARC®CV500P
Height
540mm
Width
340mm
Depth
800mm
Weight
47Kg
Temperature Range
Operating Temperature Range
-10°C ~ +40°C
Storage Temperature Range
-25°C ~ +55°C
For any maintenance or repair operation it is recommended to contact the nearest technical service center or directly
consult machine division of the Shanghai Lincoln Electric. Maintenance or repairs performed by unauthorized service
center or personnel will void the manufacturer’s warranty.

A-2INSTALLATION A-2
OPTIMARC®CV500P
Rev.03
SAFETY PRECAUTIONS
Read the entire installation section before starting
installation.
ELECTRIC SHOCK can kill.
Only qualified personnel
should perform this
installation.
Turn the input power OFF at
the main switch or fuse box
before working on this equipment. Turn off the
input power to any other equipment connected to
the welding system at the main switch or fuse
box before working on the equipment.
Do not touch electrically “Hot”parts.
Always connect the OPTIMARC®grounding lug
(located at the rear of the case) to a proper safety
(Earth) ground.
SELECT SUITABLE LOCATION
This power source should not be subjected to falling
water, nor should any parts of it be submerged in water.
Doing so may cause improper operation as well as
pose a safety hazard. The best practice is to keep the
machine in a dry, sheltered area.
The bottom of machine must always be placed on a
firm, secure, level surface. There is a danger of the
machine toppling over if this precaution is not
taken.
Place the welder where clean cooling air can freely
circulate in through the back louvers and out through
the case sides. Water,dirt, dust or any foreign material
that can be drawn into the welder should be kept to a
minimum. Failure to observe these precautions can
result in excessive operating temperatures and
nuisance shutdowns.
Locate the OPTIMARC®machine away from radio
controlled machinery. Normal operation of the welder
may adversely affect the operation of RF controlled
equipment, which may result in bodily injury or damage
to the equipment.
STACKING
The OPTIMARC®machine can not be stacked. Be
sure to locate the machines on a firm level surface.
LIFTING
The OPTIMARC®machine can be moved using the
handles .
INPUT POWER AND GROUNDING
CONNECTION
Only a qualified electrician should connect the
input leads to the OPTIMARC®. Connections
should be made in accordance with the connection
diagram. Failure to do so may result in bodily injury
or death.
Open the input box on the rear of the case. Use a
three-phase supply line, the three live wires should go
through the three holes of the input wire holder and be
securely clamped and fixed. Connect L1, L2, L3 and
ground according to the Input Supply Connection
Diagram decal, refer to Figure A.1 on this page.
Make sure the amount of power available from the input
connection is adequate for normal operation of the
machine. Refer to the Technical Specifications at the
beginning of this Installation section for recommended
fuse and wire sizes.
WARNING
CAUTION
WARNING
FIGURE A.1

A-3INSTALLATION A-3
OPTIMARC®CV500P
Rev.03
PROCESS SELECTIONS AND
CONNECTIONS
ELECTRIC SHOCK can kill.
Only qualified personnel
should perform this
installation.
Turn the input power OFF at
the main switch or fuse box before working on
this equipment. Turn off the input power to any
other equipment connected to the welding
system at the main switch or fuse box before
working on the equipment.
Do not touch electrically “Hot”parts.
Always connect the OPTIMARC®grounding lug
(located at the rear of the case) to a proper safety
(Earth) ground.
Work Connection
Connect a work lead of sufficient size between the
proper output stud on the power source and the work.
Be sure the connection to the work makes tight metal to
metal electrical contact. Poor work lead connections
can result in poor welding performance.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work and wire feeder. Avoid
excessive lengths and do not coil excess cable.
Cable sizes are increased for greater lengths primarily
for the purpose of minimizing cable drop.
Minimum work and electrode cable sizes are as follows:
TABLE A.1
Current (60% Duty Cycle)
Minimum Copper
Work Cable Size
200A
300A
400A
500A
Up To 30m Length
30 mm2
50 mm2
70 mm2
95 mm2
Note: The recommended cable size may need to
change depending on its quality. When the rated
current flow goes through, the total voltage drop on
ground cable and electrode cable must not exceed 4
volts.
LWF wire feeder connection ( FIGURE A.2 ).
When the machine set in PULSE mode, It is required to
choose LWF-24 PLUS wire feeder. Use 90%Ar、
10%CO2 for steel weld and 98%Ar、2%CO2 for
stainless steel weld .
WARNING
FIGURE A.2

A-4 INSTALLATION A-4
OPTIMARC®CV500P
Rev.03
Turn the OPTIMARC®CV machine’s power switch
“OFF”.
Connect the control cable from the LWF wire feeder
to the 6-pin connector.
Connect the electrode cable.
Note: GMAW or FCAW-GS, electrode cable should be
connected to positive output stud;
For secure electrical connection, the screws
connecting the output terminals and cables must
be tightened. Damage may occur to the output stud
or welding performance maybe compromised.
6-pin connector instruction
Please see FIGURE A.3 and TABLE A.2 for more
details.
CAUTION
FIGURE A.3
TABLE A.2
Power Source
Wire Feeder
Pin
Function
Lead #
Pin
Function
Lead #
1
“ + ” pulse signal for motor control.
91
1
Positive terminal of motor.
91
2
“ + ” pulse signal for gas solenoid.
92
2
Connected to one lead of gas
solenoid.
92
3
“ + ” control signal for gas purge, cold
inch and trigger.
93
3
Control signals output ( gas purge,
cold inch and trigger ).
93
4
+/- 10V control signal for arc current
and arc voltage.
94
4
Control signals output (arc current
and arc voltage ).
94
5
GND for arc current, arc voltage, gas
purge, cold inch and trigger control.
95
5
Common GND.
95
6
GND for gas solenoid and motor
control.
96
6
Negative terminal of motor; and
connected to another lead of gas
solenoid.
96

A-5 INSTALLATION A-5
OPTIMARC®CV500P
Rev.03
SAFETY PRECAUTIONS
Read this entire section of operating
instructions before operating the machine.
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.
FUMES AND GASES can be
dangerous.
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.
ARC RAYS can burn eyes and
skin.
Wear eye, ear and body
protection.
PLEASE SEE ADDITIONAL WARNING
INFORMATION AT THE FRONT OF THIS
OPERATOR’S MANUAL.
DUTY CYCLE
The duty cycle of a welding machine is the percentage
of time in a 10 minute cycle at which the welder can
operate the machine at rated welding current.
60% duty cycle:
Weld for 6 minutes
Break for 4 minutes
Excessive extension of the duty cycle will cause the
thermal protection circuit to activate.
THERMAL PROTECTION
The OPTIMARC®machine is equipped with a thermal
protection device. When the machine has gone into
thermal overload, the output will be turned off and the
thermal indicator light will be turned “ON“. When the
machine has cooled to a safe temperature, the Thermal
Indicator Light will go out and the machine may resume
normal operation.
Note: For safety reasons the machine’s welding output
will not come on after a thermal shutdown until the
output is disabled and re-enabled.
WARNING