Troubleshooting - Lincoln Electric OPTIMARC CV/CC 500 Operator's Manual

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CAUTION
Observe all Safety Guidelines detailed in the beginning and throughout this manual.
Problems (Symptoms)
Output Problems
Major physical or
electrical damage is
evident when the sheet
metal covers are
removed.
Machine will not power up
(no lights, no fan, etc.)
Thermal LED is lit.
Machine won't weld, can't
get any output.
Machine won't produce
full output.
Machine often "noodle"
welds (output is limited to
approximately 100 amps)
General degradation of
the weld performance
The 4-step mode is not
available
The welding arc is not stable
and soft.

TROUBLESHOOTING

If for any reason you do not understand the test procedures or are unable to
perform the tests/repairs safely, contact your local authorized Lincoln Electric
Field Service Facility for technical assistance.
Possible Areas of Misadjustment(s)
None
1. Make certain that the power to the
®
OPTIMARC CV/CC500 is energized and is
within the OPTIMARC
operating range.
1. Check for proper fan operation. (Fan
should run whenever output power is on.)
Check for material blocking intake or
exhaust louvers, or for excessive dirt
clogging cooling channels in machine.
2. Machine may have been operated above
it's duty cycle..
3.
1. Input voltage is too low or too high. Make
certain that input voltage is proper,
according to the Rating Plate.
2. If the Thermal LED is also lit, see Thermal
LED is Lit section.
3. If an error code is also present.
4. Make sure the terminal switch is ON.
1. Input voltage may be too low, limiting
output capability of the power source.
Make certain that the input voltage is
proper, according to the Rating Plate.
2. Secondary current or voltage is not
properly calibrated.
Secondary current limit has been exceeded,
and the machine has phased back to protect
itself.
1. Check for feeding problems, bad
connections, excessive loops in
cabling, etc.
2. Verify weld mode is correct for processes.
3. The power source may require calibration.
4.
1. Verify the CRATER ON/OFF toggle switch on
the front panel of machine is at ON position.
2. Verify the parameter of crater current and
voltage are set properly.
3. PC board in machine possibily at fault.
1. Verify the proper polarity is being used for the
weld procedure.
2. Check all electrode and work connections.
3. Verify the parameters of wire feeding speed,
output voltage and shielding gas are proper for
the welding procedure.
4. PC board in machine possibily at fault.
OPTIMARC
Recommended Course of Action
®
CV/CC500's
®
CV/CC500
Contact your local
authorized Lincoln Electric
Field Service facility for
technical assistance.
In a typical installation the
main power switch on the
controller is the power
switch.
Clear obstruction or repair
fan
After machine has cooled,
reduce load, duty cycle, or
both
Contact your local
authorized Lincoln Electric
Field Service facility for
technical assistance.
Correct input voltage level.
Contact your local
authorized Lincoln Electric
Field Service facility for
technical assistance.
Adjust procedure or reduce load
to lower current draw from the
machine.
If the machine need calibration,
contact an authorized Lincoln
Electric Service facility for
technical assistance.
If PC board in machine is at
fault, contact an authorized
Lincoln Electric Service facility
for technical assistance.
If PC board in machine is at
fault, contact an authorized
Lincoln Electric Service facility
for technical assistance.
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Rev. 03