Lincoln Electric OPTIMARC CV/CC 500 User manual

Rev. 03
IM7025-1
Feb, 2018
Rev. 03
OPTIMARC®CV/CC500
For use with machine Part Number K60128-1, Code 76341
•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®CV/CC500
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®CV/CC500
Rev. 03

ii SAFETY ii
OPTIMARC®CV/CC500
Rev. 03

iii SAFETY iii
OPTIMARC®CV/CC500
Rev. 03

A-1 INSTALLATION A-1
OPTIMARC®CV/CC500
Rev. 03
TECHNICAL SPECIFICATIONS –OPTIMARC®CV/CC500
INPUT –THREE PHASE ONLY
Standard Voltage / Phase / Frequency
380V ~ 415V (±10%) / 3 / 50 or 60 Hz
RATED OUTPUT –DC ONLY
Max Input Power at Rated Output ( SMAW )
23 kVA @ 60% Duty Cycle
Welding Mode
Duty Cycle
Amperes
Volts at Rated Amperes
GMAW
60%
100%
500A
390A
39V
33.5V
SMAW ( STICK )
60%
100%
500A
390A
40V
35.6V
GTAW ( TIG )
60%
100%
500A
390A
30V
25.6V
OUTPUT RANGE
Welding Mode
Welding Current Range
Open Circuit Voltage
Welding Voltage Range
GMAW
50A ~ 500A
60V
16 V ~ 39V
SMAW ( STICK )
15A ~ 500A
60V
20.6 V ~ 40V
GTAW ( TIG )
5A ~ 500A
60V
10.2 V ~ 30V
RECOMMENDED INPUT WIRE AND FUSE SIZES
OPTIMARC®CV/CC500
Input Voltage/
Frequency
(Hz)
380~415 V/
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®CV/CC500
Height
Width
Depth
Weight
540mm
340mm
800mm
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-2 INSTALLATION A-2
OPTIMARC®CV/CC500
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-3 INSTALLATION A-3
OPTIMARC®CV/CC500
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.
GMAW PROCESS ( CV MODE ) WIRE FEEDER CONNECTION
1. LWF WIRE FEEDER ( FIGURE A.2 )
Set the rotary switch to FCAW-GS mode or GMAW mode;
Set the control switch to Feeder
FIGURE A.2
WARNING

A-4 INSTALLATION A-4
OPTIMARC®CV/CC500
Rev. 03
2. LN-25 PRO FEEDER ( FIGURE A.3 )
Remote control methods
Set the rotary switch to OPTIONAL (Default FCAW-SS);
Set the control switch to Feeder;
The remote control box with order part numbers K60030-8M/-15M/-30M should be used to control the machine output
and set the voltage, Use the wire feed speed pot on LN-25 to set the current.
FIGURE A.3
Local control methods
Set the rotary switch to OPTIONAL / FCAW-GS or GMAW;
Set the control switch to Local;
A summary list for all of wire feeders connections and controls
Items
Modes
Controls
Wire feeders
Voltage control
WFS/Current
control
Remote
control box
Polarity
connections
1
OPTIONAL
(Default
FCAW-SS)
Local
LN-25 Pro
Front panel of
CV/CC500
LN-25 Pro
DCEN
2
Feeder
LN-25 Pro
Remote
control box
K60030-8M/-
15M/-30M
3
FCAW-GS
Local
LN-25 Pro
Front panel of
CV/CC500
DCEP
4
Feeder
LWF-22
LWF-24 PLUS
LWF-22 / LWF-24 PLUS
5
GMAW
Local
LN-25 Pro
Front panel of
CV/CC500
LN-25 Pro
6
Feeder
LWF-22
LWF-24 PLUS
LWF-22 / LWF-24 PLUS

A-5 INSTALLATION A-5
OPTIMARC®CV/CC500
Rev. 03
3. GTAW PROCESS ( CC MODE ) CONNECTION ( FIGURE A.4 )
Set the rotary switch to GTAW mode;
Set the control switch to REMOTE
Recommended to use Foot Amptrol K870.
Set the control switch to LOCAL
Machine output the maximum current set by local output pot
FIGURE A.4
4. SMAW PROCESS ( CC MODE ) CONNECTION ( FIGURE A.5 )
Set the rotary switch to SMAW mode;
Set the control switch REMOTE;
Max. output will be limited by panel output set, display always shows remote setpoint.
Set the control switch LOCAL;
Max. output current can be setted by panel output pot, arc force can be setted by arc control.
FIGURE A.5
The actual output current would be set by the remote device up to the maximum current set by local output pot.
Note：When the machine set to 4 step, turning the crater current and voltage, the crater value will be shown on the
display, then change back to the weld preser value.
TIG torch with handle switch can be used while the switch connect correctly to the remote connector.