SAFETY WARNING 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. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. ELECTRIC AND ELECTRIC SHOCK MAGNETIC FIELDS can kill. may be dangerous. 1.a Electric current flowing through any conductor 3.a The electrode and work (or ground) circuits are causes localized Electric and Magnetic Field(EMF). electrically “hot” when the welder is on. Do not Welding current creates EMF fields around touch these “hot” parts with your bare skin or wet welding cables and welding machines. clothing. Wear dry, hole‐free gloves to insulate 1.b EMF fields may interfere with some pacemakers, hand. and welders having a pacemaker should consult 3.b Insulate yourself from work and ground using dry their physician before welding. insulation. Make certain the insulation is large 1.c All welders should use the following procedures in enough to cover your full area of physical contact ...
SAFETY FUMES AND GASES WELDING SPARKS can be dangerous. can cause fire or explosion. 4.a Welding may produce fumes and gases hazardous 6.a Remove fire hazards from the welding area. If this to health. Avoid breathing these fumes and gases. is not possible, cover them to prevent the welding When welding, keep your head out of fume. Use sparks from starting a fire. Remember that enough ventilation and/or exhaust at the arc to welding sparks and hot materials from welding keep fumes and gases away from the breathing can easily go through small cracks and openings to zone. When welding with electrodes which adjacent areas. Avoid welding near hydraulic lines. require special ventilation such as stainless or Have a fire extinguisher readily available. hard facing (see instructions on container or 6.b When not welding, make certain no part of the MSDS) or on lead or cadmium plated steel and electrode circuit is touching the work or ground. other metals or coatings which produce highly Accidental contact can cause overheating and toxic fumes, keep exposure as low as possible and create a fire hazard. below Threshold Limit Values (TLV) using local 6.c Do not heat, cut or weld tanks, drums or exhaust or mechanical ventilation. In confined containers until the proper steps have been taken spaces or in some circumstances, outdoors, a to insure that such procedures will not cause respirator may be required. Additional flammable or toxic vapors from substances inside. ...
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SVM7007 CONTENTS INSTALLATION …………………………………………………………….…..………………….…..…... Section A OPERATION …………………………………….……………………………………..…………..……..….. Section B MAINTENANCE ……………..……………………………………………….…..………….…….…………… Section C THEORY OF OPERATION ………..…………………………………...………………….….……………………… Section D TROUBLESHOOTING AND REPAIR …………………………………………………....………………. Section E WIRING DIAGRAMS ……………………………………………………..……..……………...…………… Section F ® OPTIMARC CV/CC500 ...
SVM7007 INSTALLATION A‐3 ground according to the Input Supply Connection SAFETY PRECAUTIONS Diagram decal, refer to Figure A.1. Read the entire installation section before starting installation. FIGURE A.1 WARNING 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 ...
SVM7007 INSTALLATION A‐4 CONNECTION DIAGRAMS GMAW PROCESS ( CV MODE ) CONNECTION (FIGURE A.2) Set the rotary switch to FCAW‐GS or GMAW mode Set the control switch to Feeder FIGURE A.2 GTAW PROCESS ( CC MODE ) CONNECTION (FIGURE A.3) Set the rotary switch to GTAW mode Set the control switch to REMOTE, the actual output current would be set by the remote device up to the maximum current set by local output pot. Recommended to use Foot Amptrol K870. Set the control switch to LOCAL, machine output the current set by local output pot. 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 preset value. FIGURE A.3 ® OPTIMARC CV/CC500 ...
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SVM7007 INSTALLATION A‐5 SMAW PROCESS ( CC MODE ) CONNECTION (FIGURE A.4) Set the rotary switch to SMAW mode Set the control switch to REMOTE, the actual output current would be set by the remote device up to the maximum current set by local output pot. Set the control switch to LOCAL, machine output the current set by local output pot. FIGURE A.4 ® OPTIMARC CV/CC500 ...
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SVM7007 INSTALLATION A‐6 6‐PIN WIRE FEEDER CONNECTOR INSTRUCTION Please see Figure A.5 and Table A.2 for more details. 6‐PIN REMOTE CONNECTOR INSTRUCTION Please see Figure A.6 and Table A.3 for more details. FIGURE A.5 WIRE FEEDER CONNECTOR FIGURE A.6 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 One lead of gas solenoid ...
SVM7007 OPERATION B‐2 SAFETY PRECAUTIONS THERMAL PROTECTION WARNING ® The OPTIMARC machine is equipped with thermal ELECTRIC SHOCK can kill. protection devices. When the machine has gone into Do not touch thermal overload, the output will be shut off and the electrically live parts or electrode ...
SVM7007 OPERATION B‐3 OPERATIONAL FEATURES AND CONTROLS FIGURE B.1 FRONT PANEL FRONT PANEL (SEE FIGURE B.1) 1. GAS SELECTION OPTIMARC® CV/CC500 is designed for CO2 and Ar/CO2. 2. WELDING MODE SELECTION FCAW It is for self‐shielded flux cored wire arc welding. FCAW‐GS It is for gas shielded flux cored wire arc welding. Setting up the machine, please see the Figure A.3 GMAW It is for gas shielded solid wire arc welding. GTAW It is for TIG mode. OPTIMARC® CV/CC500 must apply “touch start” for arc start. SMAW It is for stick mode. 3. WIRE DIAMETER SELECTION Please see FIGURE B.3 and B.4 for more details of ...
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SVM7007 OPERATION B‐4 14. ARC CONTROL 24. AUX. POWER RECEPTACLE This knob controls the arc output characteristic. Export type machine: This is a 220V/200W auxiliary When it is turned clockwise, the arc is crisper. power output socket, for gas heater. When it turned counter‐clockwise, the arc is softer. CAUTION 15. LOCAL OUTPUT CONTROL Only plug the correct gas heater into this receptacle. When the CONTROL SWITCH is set to “LOCAL”, The DO NOT plug other electric devices into the output voltage ( CV mode ) or output current ( CC mode ) will be controlled by this knob. receptacle, otherwise, damage may occur to the In TIG mode, it will control the maximum output machine. current. 25. FUSE AND FUSE HOLDER In stick mode, it will control the output current Export type machine: 250V/2A fuse is used to range. protect the auxiliary 220V power outlet. 16. NEGATIVE OUTPUT STUD 26. FUSE AND FUSE HOLDER 250V/8A fuse is used to protect the auxiliary power 17. POSITIVE OUTPUT STUD for the wire feeder. ...
SVM7007 OPERATION B‐6 4. SPECIAL FUNCTION TEST DIP SWITCH DESCRIPTIONS It enables a test procedure to test the control knobs OPTIMARC® CV/CC machine offers a DIP switch on the and the toggle switches when this DIP switch is ON control board, which allows user to have additional and the other DIP switches are OFF. This DIP switch features. After disconnecting the machine from input should be OFF when user prepares to weld. power remove the roof To set the DIP switch.See FIGURE B.7 for the right position. 5. SYNERGIC There are 8 individual switches integrated into this DIP OFF = Amps and volts knobs on feeder are switch .All the initial factory settings in the OFF independent. position. Please see FIGURE B.6. ON = Preset of volts knob is tied to the preset of the amps knob. WARNING Set the current first, then set the voltage to match the current, such as 200A/25V, then the voltage will Disconnecting the power follow the current as machine programmed when supply the current adjusted. before the roof removed. See operation feature item 8. ...
SVM7007 MAINTENANCE C‐2 SAFETY PRECAUTIONS PERIODIC MAINTENANCE Read this entire section of the operating instructions The daily maintenance frequency of the equipment before operating the machine. should be determined according to the actual working environment. Any noticeable safety hazard should be WARNING reported immediately. ELECTRIC SHOCK can kill Check to make sure the cable and related ...
SVM7007 MAINTENANCE C‐3 LAYOUT OF MAIN COMPONENTS FIGURE C.1 Ⅰ Case Front Assembly Ⅱ Divider Panel Assembly Ⅲ Base & Centre Assembly Ⅳ Case Back Assembly Ⅴ Wraparound Assembly Ⅴ Ⅳ Ⅱ Ⅰ Ⅲ ® OPTIMARC CV/CC500 ...
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SVM7007 THEORY OF OPERATION D‐1 Input Power, Input Rectifier, Aux Transformer & Fan…………………………………………………………………… D‐2 Thermostat, Switchboard, Main Transformer, Output Rectifier & Output Choke………………………… D‐3 Single‐phase Rectifier, Control Board, Setting Circuit & Display Board ……………………………………… D‐4 Operating Principle of Inverter …………………………………………………………………………………………………… D‐5 ® OPTIMARC CV/CC500 ...
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SVM7007 THEORY OF OPERATION D‐2 INPUT POWER, INPUT RECTIFIER, AUX TRANSFORMER & FAN When the input line switch on, three‐phase 342V~418V & 50/60Hz input voltage is applied to the Input Rectifier, Aux Transformer and the Fan. Two phases of the three‐phase input power are applied to the Aux Transformer by leads 20A & 21A, also applied to the Fan by leads 20B & 21B. Three 36VAC (for the export version machine, one out of the three is 220VAC) that developed by the Aux Transformer are applied to the Control Board (4 & 5), the Switchboard (8 & 9) and the Heater Receptacle (6 & 7). The initial input power is applied to the Input Rectifier through a line switch. The Input Rectifier developed a pulsed 480V~590VDC voltage to the Switchboard. FIGURE D.1 ® OPTIMARC CV/CC500 ...
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SVM7007 THEORY OF OPERATION D‐3 THERMOSTAT Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are connected to the Switchboard. One of the thermostats is located on the IGBT module heatsink and the other is located on the Diode Assembly heatsink. SWITCHBOARD, MAIN TRANSFORMER, OUTPUT RECTIFIER & OUTPUT CHOKE When the input voltage is applied to the machine, the Aux Transformer generates power supply to the Control Board and the Switchboard, and starting system self‐test and initialization. The main function of the Switchboard is to receive the pulsed DC voltage from the Input Rectifier (207/209), then filter and invert to 30 KHz AC voltage (201/204), output to the primary windings of the Main Transformer. The hi‐frequency low‐voltage AC power from the secondary windings of the Main Transformer will be rectified by the Output Rectifier, and filtered by the Output Choke, then provide a stable welding output. In addition the Switchboard monitors the status of the machine by receive current feedback signal from primary winding of the Main Transformer, over‐voltage /low‐voltage signal from the main circuit, voltage and current feedback from the output terminals. FIGURE D.2 ® OPTIMARC CV/CC500 ...
SVM7007 THEORY OF OPERATION D‐4 SINGLE‐PHASE RECTIFIER Two single-phase rectifier bridges are respectively connected to two 36VAC voltage output of the Auxiliary Transformer. The single-phase rectifier bridge rectifies the 36VAC voltage into pulsating DC voltage and supplies it to the Control Board (82/83) and the Switchboard (33/34). CONTROL BOARD ...
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SVM7007 THEORY OF OPERATION D‐5 OPERATING PRINCIPLE OF INVERTER Inverter is one of the four converter technologies in power electronics, it’s comparative to rectifier. Rectifier changes from AC to DC, so the process of DC to AC (the inverse process of rectifier) is called inverter. MAIN CIRCUIT OF INVERTER FIGURE D.4 Comparative 20KHz 50/60Hz Low Voltage High Voltage High Current Low Current Fast Recovery Rectifier IGBT Diode ® OPTIMARC CV/CC500 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐1 How to Use Troubleshooting Guide ……………………………………………………………………………………….. E‐2 PC Board Troubleshooting Procedures ………………………………………………………….………..……………… E‐3 Troubleshooting Guide ……………………………………………………………………………….….………………………. E‐4 Case Cover Removal ……..………………………….………………………………………………………..…………………… E‐7 Input Rectifier Removal …….………….…………………………………………………………….…..…….………………. E‐9 Input Rectifier Test …….……………….…………………………………………………………….…..…….………………. E‐11 Switchboard Removal ………………………………………………………………………………………………………… E‐13 Switchboard Test ….…………………………………………………………………………………………………….... E‐15 Output Rectifier Diode Removal ……………………………………………………………………………………………. E‐17 Output Rectifier Diode Test ……………………………………………………………..……………………………………. E‐20 Control Board Removal ………………………………………………………………………………………………………. E‐22 Aux Transformer Removal ………………………………………………………………………………..………..… ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐2 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three‐step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into the following categories: output problems, operating problems and welding problems. Step 2. PERFORM EXTERNAL TESTS. The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap‐around cover. ...
SVM7007 TROUBLESHOOTING AND REPAIR E‐3 PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. CAUTION Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom. 2. Check for loose connections at the PC board to assure that the PC board is properly connected. 3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐4 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION Major physical or electrical Contact your local authorized Lincoln damage is evident when the Electric Field Service facility for sheet metal covers are technical assistance. removed. The machine will not power 1. No power supply. Make sure the correct power is up. (no lights or displays, and connected to the machine and the the fan not running.) input line switch is turned on. 2. The line switch maybe faulty. Check the line switch for proper operation. Also check the associated leads for loose or faulty connections. See the Wiring Diagram. Thermal LED lights on. 1. Material blocking intake or exhaust Check and clean the cooling louvers, or for excessive dirt clogging channels. cooling channels in machine. ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐5 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION 4‐step mode does not work. 1. Problem with the current feedback Check the current feedback circuit. signal. 2. PC board may be faulty. Contact your local authorized Lincoln Electric Field Service facility for technical assistance. The welding arc is not stable 1. Incorrect wire or shielding gas. Check and correct. or too hard. 2. Bad welding cable connections. Check and correct. 3. Improper output voltage or wire feed Check and correct. speed setting.. 4. Incorrect polarity is being used. Check and correct. 5. PC board may be faulty. Contact your local authorized Lincoln Electric Field Service facility for ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐6 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION ERROR CODE ERR 031 Primary of the Switchboard over current. Contact your local authorized Lincoln Electric Field Service facility for technical assistance. ERR 032 Low input line voltage error from the Contact your local authorized Lincoln Control Board. Electric Field Service facility for technical assistance. ERR 035 Input voltage out of range. Make certain that input voltage is proper, according to the Rating Plate. ERR 036 Thermal protection. Contact your local authorized Lincoln Electric Field Service facility for technical assistance. ERR 041 Secondary of the Switchboard over Contact your local authorized Lincoln current. Electric Field Service facility for technical assistance. ERR 082 Motor overload. ...
SVM7007 TROUBLESHOOTING AND REPAIR E‐7 CASE COVER REMOVAL WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐8 CASE COVER REMOVAL (continued) FIGURE E.2 – RIGHT CASE SIDE REMOVAL FIGURE E.3 – LEFT CASE SIDE REMOVAL ® OPTIMARC CV/CC500 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐9 INPUT RECTIFIER REMOVAL WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact ...
SVM7007 TROUBLESHOOTING AND REPAIR E‐11 INPUT RECTIFIER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐12 INPUT RECTIFIER TEST (continued) FIGURE E.6 ‐ INPUT RECTIFIER 5 (207) 4 (209) 3 (21) 2 (20) 1 (19) + 4 (209) 3(21) 2(20) 1(19) ‐ 5 (207) TABLE E.1 – INPUT RECTIFIER STATIC TEST METER PROBE (+) METER PROBE (–) METER MODE EXPECTED VALUE 1(19) 4(209) DIODE 0.3-0.7V 2(20) 4(209) DIODE 0.3-0.7V 3(21) 4(209) DIODE 0.3-0.7V 4(209) 1(19) ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐13 SWITCHBOARD ASSEMBLY REMOVAL WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. CALL 400 820 9755 ...
SVM7007 TROUBLESHOOTING AND REPAIR E‐15 SWITCHBOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐16 SWITCHBOARD TEST (continued) FIGURE E.9 ‐ SWITCHBOARD 209 (+) 207 (‐) 201 204 TABLE E.2 – SWITCHBOARD STATIC TEST METER PROBE (+) METER PROBE (–) METER MODE EXPECTED VALUE 207 204 DIODE 0.25-0.7V 209 204 DIODE OPEN CIRCUIT 204 207 DIODE OPEN CIRCUIT 204 209 DIODE 0.25-0.7V 201 207 DIODE OPEN CIRCUIT 201 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐17 OUTPUT DIODE REMOVAL WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. CALL 400 820 9755 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐18 OUTPUT DIODE REMOVAL (continued) FIGURE E.10 X1、X3 Input Lead 222# Output Lead FIGURE E.11 ® OPTIMARC CV/CC500 ...
SVM7007 TROUBLESHOOTING AND REPAIR E‐20 OUTPUT DIODE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐21 OUTPUT DIODE TEST (continued) FIGURE E.13 OUTPUT DIODE A C B A C B TABLE E.3 – OUTPUT DIODE STATIC TEST METER PROBE (+) METER PROBE (–) METER MODE EXPECTED VALUE A C DIODE 0.1‐0.7V B C DIODE 0.1‐0.7V C A DIODE OPEN CIRCUIT C B DIODE OPEN CIRCUIT ...
SVM7007 TROUBLESHOOTING AND REPAIR E‐22 CONTROL BOARD REMOVAL WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. CALL 400 820 9755 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐23 CONTROL BOARD REMOVAL (continued) FIGURE E.14 ‐ CONTROL BOARD LOCATION Control Board FIGURE E.15 ‐ CONTROL BOARD REMOVAL ® OPTIMARC CV/CC500 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐24 AUX TRANSFORMER REMOVAL WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. CALL 400 820 9755 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐25 AUX TRANSFORMER REMOVAL (continued) FIGURE E.16 ‐ AUX TRANSFORMER REMOVAL ® OPTIMARC CV/CC500 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐26 AUX TRANSFORMER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. CALL 400 820 9755 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐27 AUX TRANSFORMER TEST (continued) FIGURE E.17 ‐ AUX TRANSFORMER TABLE E.4 – AUX TRANSFORMER STATIC TEST METER PROBE (+) METER PROBE (–) METER MODE EXPECTED VALUE 1 2 RESISTOR 5Ω 4 5 RESISTOR 0Ω 0Ω (code 76210) 6 7 RESISTOR 5Ω (code 76209) 8 9 RESISTOR 0Ω TABLE E.5 – AUX TRANSFORMER ACTIVE TEST METER PROBE (+) METER PROBE (–) METER MODE EXPECTED VALUE 1 2 AC VOLTAGE AC400V ±10% 4 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐28 OUTPUT RESISTANCE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. CALL 400 820 9755 ...
SVM7007 TROUBLESHOOTING AND REPAIR E‐29 FUNCTIONAL TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. CALL 400 820 9755 ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐30 FUNCTIONAL TEST (continued) TABLE E.5 – FUNCTIONAL TEST TEST ITEMS INSPECTED VALUES ACTUAL TESTED PARTS (Current meter) (Voltage meter) 1 Crater current pot 0~100 Variable 2 Crater voltage pot 0~100 Variable 3 Arc control pot 0~100 Variable 4 Feeder voltage pots 0~100 Variable 5 Feeder current pots 0~100 Variable All of switch on original position 1 Trigger on torch 33(Closed) Gas purge switch on feeder 65(Pressed) Cold feeding switch on feeder 129(Pressed) 6 2/4 step on front panel of machine 3 (4 step position) CO2 or CO2/Ar switch 9 ( CO2) Local / Feeder/Remote control 4 (Remote) ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐31 WIRE FEED SPEED CALIBRATION PROCEDURE MATERIALS NEEDED Wrench Tachometer or band tape PROCEDURE 1. Remove the input power to the OPITIMARC® CV/CC500 machine. 2. Perform the Case Cover Removal Procedure, remove the case top. 3. Set DIP switch on the Control Board as below: DIP 1~7: OFF DIP 8: ON Note: Please record the initial position of DIP switches before setting so that it can be restored after the test. 4. Turn on power to the machine, set the front panel to: GMAW / CO2 / 1.2mm / 2‐Step. 5. Turn the CURRENT knob at the feeder fully counter‐clockwise. The display will show “SPd 2.5”. 6. Press and hold the trigger, adjust the crater current pot until the measured wire feed speed matches 2.5 m/min. (LWF‐24 Plus: 23 RPM) 7. Release the trigger. Switch the crater switch to the ON position and then back to the OFF position. The speed calibration information for the low feed speed is recorded. The display will show “CAL dun”. ...
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SVM7007 TROUBLESHOOTING AND REPAIR E‐32 VOLTAGE AND AMPERE METER CALIBRATION PROCEDURE MATERIALS NEEDED Calibrated Test Voltmeter Calibrated Test Ammeter Resistive Load Bank Wrench Phillips Screwdriver PROCEDURE 1. Remove the input power to the OPITIMARC® CV/CC500 machine. 2. Perform the Case Cover Removal Procedure, remove the right case side. 3. Locate the Control Board, set all the DIP switches to OFF except 4# to ON. Note: Please record the initial position of DIP switches before setting so that it can be restored after the test. 4. Connect wire feeder or control box to the machine. 5. Connect the voltage meter between positive terminal and negative terminal. 6. Connect the current meter in the output line. 7. Turn on the power to the machine. Press and hold the trigger without connecting the load bank. 8. Tune the potentiometer R249 on the Switchboard with a Phillips screwdriver, until the OCV is 60V. See Figure E.19. 9. Connect the load bank to output terminals of the machine. 10. Adjust the load bank and output of the machine to get the output as following table: Output Current (A) 100 ±2 200 ±2 500 ±5 Output Voltage (V) ...
SVM7007 TROUBLESHOOTING AND REPAIR E‐33 RETEST AFTER REPAIR Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. CALL 400 820 9755 DESCRIPTION ...
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SVM7007 WIRING DIAGRAM F‐4 LED & ADDITIONAL DESCRIPTIONS OF PC BOARDS 控制板 LED 功能描述 DESCRIPTION OF LED FUNCTIONS ON CONTROL BOARD 颜色 Color 功能 FUNCTION LED# 1 绿色 GREEN 机器工作正常 MACHINE STATUS “OK” 红色 RED 机器出现异常 MACHINE STATUS “ERROR” 2 开关板 LED 功能描述 DESCRIPTION OF LED FUNCTIONS ON SWITCHBOARD 8 位拨码开关功能 DIP SWITCH FUNCTIONS 颜色 Color 功能 FUNCTION LED# 1 ON=PREFLOW ON 预送气功能 ON=LONG CABLE WELD MODE 长电缆焊接模式 GREEN 2 CAN 通讯电源正常 1 ...
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NOTE World’s Leader in Welding and Cutting THE SHANGHAI LINCOLN ELECTRIC COMPANY No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907 ...