Lincoln Electric POWERPLUS 1000HD User manual

IM8000-11
MAR., 2018
Rev. 01
POWERPLUS™1000HD
For use with machine Code: K60067-5 / 76339
•World’s Leader in Welding and Cutting•
THE SHANGHAI LINCOLN ELECTRIC CO.,LTD
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
your part. DO NOT INSTALL, OPERATE
OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL
AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.Most
importantly, think before you act and be
careful.

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
□POWERPLUS™ 1000HD
Code & Serial number
Date & Where Purchased
Authorized Dealer’s Chop
Declaration of conformity
THE SHANGHAI LINCOLN ELECTRIC CO., LTD
Designed in conformance with the following norm:
GB15579.1
EN 60974-1

iSAFETY i
POWERPLUSTM 1000HD
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 EQUIPMENT.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR
PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous.
1.a Electric current flowing through any conductor
causes localized Electric and Magnetic Field
(EMF). Welding current creates EMF fields
around welding cables and welding machines.
1.b EMF fields may interfere with some pacemakers,
and welders having a pacemaker should consult
their physican before welding.
1.c All welders should use the following procedures
in order to minize exposure to EMF fields from
the welding circuit:
1.c.1 Route the electrode and work cables
together –Secure them with tape when
possible.
1.c.2 Never coil the electrode lead around your
body.
1.c.3 Do not place your body between the
electrode and work cables. If the electrode
cable is on your right side, the work cable
should also be on your right side.
1.c.4 Connect the work cable to the workpiece
as close as possible to the area being
welded.
ARC RAYS can burn.
2.a Use a shield with the proper filter and cover
plates to protect your eyes from sparks and the
rays of the arc. Headshield and filter lens should
conform to ANSI Z87. I standards.
2.b Use suitable clothing made from durable flame-
resistant material to protect your skin and that of
your helpers from the arc rays.
2.c Protect other nearby personnel with suitable,
non-flammable screening and/or warn them not
to watch the arc nor expose themselves to the
arc rays or to hot spatter or metal.
ELECTRIC SHOCK
can kill.
3.a Electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do not
touch these “hot” parts with your bare skin or wet
clothing. Wear dry, hole-free gloves to insulate
hands.
3.b Insulate yourself from work and ground using dry
insulation. Make certain the insulation is large
enough to cover your full area of physical contact
with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, grating or scaffolds, when in cramped
positions such as sitting, kneeling or lying down, if
there is a high risk of unavoidable or accidental
contact with the workpiece or ground) use the
following equipment:
Semiautomatic DC Constant Voltage (Wire)
Welder.
DC Manual (Stick) Welder.
AC Welder with Reduced Open Circuit Voltage.
3.c In semiautomatic or automatic wire welding, the
electrode, electrode reel, welding head, nozzle or
semiautomatic welding gun are also electrically
“hot”.
3.d Always be sure the work cable makes a good
electrical connection with the metal being
welded. The connection should be as close as
possible to the area being welded.
3.e Ground the work or metal to be welded to a good
electrical (earth) ground.
3.f Maintain the electrode holder, work clamp,
welding cable and welding machine in good, safe
operating condition. Replace damaged
insulation.
3.g Never dip the electrode in water for cooling.
3.h Never simultaneously touch electrically “hot”
parts of electrode holder to two welders because
voltage between the two can be total of the open
circuit voltage of both welders.

ii SAFETY ii
POWERPLUSTM 1000HD
FUMES AND GASES
can be dangerous.
4.a Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your
head out of the welding fumes. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone.
When welding with electrodes which require
special ventilation such as stainless or hard
facing (see instructions on container or
MSDS) or on lead or cadmium plated steel
and other metals or coatings which produce
highly toxic fumes, keep exposure as low as
possible and below Threshold Limit Values
(TLV) using local exhaust or mechanical
ventilation. In confined spaces or in some
circumstances, outdoors, a respirator may be
required. Additional precautions are also
required when welding on galvanized steel.
4.b Do not weld in locations near chlorinated
hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and
rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other
irritating products.
4.c Shielding gases used for arc welding can
displace air and cause injury or death. Always
use enough ventilation, especially in confined
areas, to insure breathing air is safe.
4.d Read and understand the manufacturer’s
instructions for this equipment and the
consumables to be used, including the material
safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are
available from your welding distributor or from
the manufacturer.
FOR
ELECTRONICALLY
powered equipment.
5.a Turn off input power using the disconnect switch
at the fuse box before working on the equipment.
5.b Install equipment in accordance with national
standards, all local standards and the
manufacturer’s recommendations.
5.c Ground the equipment in accordance with the
national standards and the manufacturer’s
recommendations.
WELDING SPARKS
can cause fire or
explosion.
6.a Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember
that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily
available.
6.b When not welding, make certain no part of the
electrode circuit is touching the work or ground.
Accidental contact can cause overheating and
create a fire hazard.
6.c Do not heat, cut or weld tanks, drums or
containers until the proper steps have been
taken to insure that such procedures will not
cause flammable or toxic vapors from
substances inside. They can cause an explosion
even though they have been “cleaned”.
6.d Sparks and spatter are thrown from the welding
arc. Wear oil free protective garments such as
leather gloves, heavy shirts, cuffless trousers,
high shoes and a cap over your hair.

A-1 INSTALLATION A-1
POWERPLUSTM 1000HD
TECHNICAL SPECIFICATIONS –POWERPLUSTM 1000HD
INPUT –THREE PHASE ONLY
POWERPLUSTM 1000HD
Standard Voltage/Phase/Frequency
380V ~ 415V(±10%) 3/50 Hz
Input Current
100% Duty Cycle,100A @380V
60% Duty Cycle,130A @380V
RATED OUTPUT –DC ONLY
Duty Cycle
Amperes
Volts at Rated Amperes
POWERPLUSTM 1000HD
60%
100%
1200A
1000A
44V
44V
OUTPUT
Welding Current Range
Maximum Open Circuit Voltage
（RMS/Peak Value）
Auxiliary power
POWERPLUSTM 1000HD
200 A ~ 1200 A
74/ 82V
AC110V@4A
RECOMMENDED INPUT WIRE AND FUSE SIZES
Input
Voltage/
Frequency
(Hz)
Maximum
Input
Ampere
Maximum
Effective
Supply
Current
60°C
Copper
Wire in
Conduct
Sizes
Fuse or
Breaker
Size
(Super
Lag)
Grounding
Conductor
Size
POWERPLUSTM 1000HD
342 V ~
456.5 V/
50 Hz or
60 Hz
120 A
95A
25 mm2
150 A
.
25 mm2
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
POWERPLUSTM 1000HD
900 mm
600mm
970 mm
335 Kg
Temperature Range
Operating Temperature Range
- 10 ℃~ + 40℃
Storage Temperature Range
- 25℃~ + 55℃
For any maintenance or repair operation it is recommended to contact the nearest technical service center or
directly consult the machine division of the Shanghai Lincoln Electric Co. Ltd.. Maintenance or repairs
performed by unauthorized service centers or personnel will void the manufacturer’s warranty.

A-2 INSTALLATION A-2
POWERPLUSTM 1000HD
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 POWERPLUSTM grounding
lug (located at the rear of the case) to a proper
safety (Earth) ground. POWERPLUSTM is for use
on a 3 phase 4 wire system with earthed neutral.
SELECT SUITABLE LOCATION
This power source should not be subjected to rain, 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 cool air can freely
circulate in through the side and back louvers and out
through the case bottom. Water dust or any foreign
material that can be drawn into the welder should be
kept a minimum. Failure to observe these precautions
can result in excessive operating temperatures and
nuisance shutdowns.
Locate the POWERPLUSTM 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.
The machine must be located where there is least
500mm distance with barrier.
Small metal can be drawn into the machine, you
should avoidance.
INPUT POWER AND GROUNDING
CONNECTION
Only a qualified electrician should connect the
input leads to the POWERPLUSTM. 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.
FIGURE A.1 –Input Supply Connection Diagram
The POWERPLUSTM is supplied cto onnect with 50Hz
or 60Hz input.
The customer need to suppliy ≥100KVA power supply
and the power supply voltage changes of ≤10%.
The input power supply cable should be connected with
some protect equipment like fuse、breaker and air-
break switch(size 125A, 3 phase).
You should use ≥25mm2 input power supply cable
when your equipment is at fully loaded output.
When your workshop is wet or you work on the steel
plate or shelf you should install a leakage protector.
After connecting the input cable to the machine,
check the input voltage setting by opening the front
control pannel. If the input voltage is above 415V,
connect the “COM”lead to the 415V position and set
DIP SWITCH 8 to the “ON”position on the control
board.
415V
380V
If the input voltage is at the rang from 342V to 415V,
connect the “COM”lead to the 380V position and set
DIP SWITCH 8 to the “OFF”position on the control
board.
415V
380V
COM
WARNING
CAUTION
WARNING

A-3 INSTALLATION A-3
POWERPLUSTM 1000HD
OUTPUT AND WIRE FEEDER
CONNECTIONS
Connect a work lead of sufficient size and length (Per
Table A.1) between the Negative Output terminal on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal electrical contact.
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.
Minimum work and electrode cable sizes are as follows:
TABLE A.1
Current (100% Duty Cycle)
Minimum Copper
Work Cable Size
<500A
<800A
<1000A
Up To 30m Length
70 mm2
95 mm2
120 mm2
Note: Recommended cable sizes may vary due to
different cable quality.

B-1 OPERATION B-1
POWERPLUSTM 1000HD
SAFETY PRECAUTIONS
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 eyes, ear and body
protection.
PLEASE SEE ADDITIONAL WARNING
INFORMATION AT THE FRONT OF THIS
OPERATOR’S MANUAL.
GENERAL DESCRIPTION
The POWERPLUSTM Function and Control.
Front of equipment (see B.1)
1. ON/OFF POWER SWITCH
The power switch is turned ON position, it means the
power source is ready for working. The sequence of
electrical route is: Turn on switch -- The auxiliary
transformer starts to work(supply 36V and 110V) ----
Control board is powered ---- Main circuit contactor
works ---- Fan works ---- Main transformer works (SCR
is not working)
The fuse F1 is used in wire feeding circuit to provent
wire feeder from overcurrent.
2. POWER SUPPLY / THERMAL INDICATOR
This status light illuminates when the power source has
been turned on. It means control board starts to normal
work and power supply is ready to output.
3. AMPERAGE METER
During the welding process, this meter displays the
welding current value.
4. VOLT METER
During the welding process, this meter displays the
welding voltage.
5. THERMAL INDICATOR
This status light illuminates when the power source has
been driven into thermal overload. The indicator light
also glows when the POWERPLUSTM is started up. The
indicator light has an ON to OFF cycle to show that the
POWERPLUSTM has passed the initial self- test.
6. WELDING POLARITY TOGGLE
For positive polarity welding, you have to turn polarity
toggle to “+”position. At this moment your Rover
tractor will get positive polarity.
7. CONTROL POTENTIOMETER
When you use gouging function, you can use the knob
to change output.
Front Panel (Please see figure B.1)
1
2
7
6
4
5
8
3
9
8. MODE TOGGLE
The power supply has SAW(CV Constant
Voltage),gouging and SAW(CC Constant Current)
function. At the CC SAW mode, the output is on the
control of constant current.
The gouge mode also has CC character. The
machine is suit for carbon arc air gouging function.
When the toggle at gouging position the power supply
will have open circuit voltage(DIPSWITCH 4 is at on
position on the control board).
At the CV SAW mode, the output is on the control
of constant voltage .
9. PROTECTION DOOR
This door is used to protect the output terminal and wire
feeder connector. Turn off the power switch. Open the
protection door to connect the welding cables and
Rover tractor control cables.
WARNING

B-2 OPERATION B-2
POWERPLUSTM 1000HD
Do NOT operate the POWERPLUSTM machine with
this door open.
We install a limited screw to avoid protection door
from contacting with welding cable.
MACHINE OUTPUT STUD
24
13
1.NEGATIVE OUTPUT STUD
According your welding technology , make sure how to
connect the stud.
Ordinary :
DC+ : Connect positive to rover tractor,negative
connect to work piece.
DC-: Connect positive to work piece,nagative connect
to Rover tractor.
2. 14-PIN CONNECTOR
For connect to Rover tractor.
3.POSITIVE OUTPUT STUD
When you output >500A, you have to connect this stud.
Make sure you welding cable is suit for >500A and is
tightly connected with output stud.
4. A SMALL POSITIVE OUTPUT STUD
The machine increases balance inductance for small
current welding.When the output current is <500A, you
should connect to this one and make sure welding
cable is tightly connected with this stud.
REAR PANEL (PLEASE SEE FIGURE B.2)
1. 2A FUSE AND FUSE HOLDER
A 250V 2A fuse is located to protect the 36V
control board.
2. 8A FUSE AND FUSE HOLDER
A 250V 8A fuse is located to protect the 110V auxiliary
transformer .
3. INPUT BOX
Insulation box is used to cover the input connections,
offering insulating protection to the operator.
Insulation box must be installed before
turning on the main power supply.
4. INPUT CABLE HOLDING BRACKET
This bracket holds the three phase power cables
securely.
ADVANCED FEATURES
The POWERPLUSTM machine offers a DIP switch on
the PC board, which allows the user to have additional
features.
DIP SWITCH 1: FEEDER SELECTION
When the Dip switch #1 is in the “ON” position, PP
1000HD can be connected with NA5 FEEDER
SYSTEM. For other feeder, that switch should be “OFF”
position.
NA5 FEEDER
Other Feeder:
DIP SWITCH 2:
LOW VOLTAGE ARC START(DIP#2)
When the Dip switch #2 is in the “OFF” position, the
POWERPLUSTM machine arc start voltage is 75V.
When you need low voltage arc start, you can turn the
DIP switch #2 in the “ON”position, the start voltage is
68V.
Low OCV
Normal OCV
DIP SWITCH 3 : Tail control in Gouging function, if Dip
switch #3 is at the “ON” position, there’s no tail control.
WARNING
WARNING
图B.2
1
2
3
4

B-3 OPERATION B-3
POWERPLUSTM 1000HD
Tail control:
No tail control
DIP SWITCH 4 : In Gouging mode, if Dip switch #4 is at
the “ON” position, the machine has the output on the
terminals as long as the mode switch is at Gouging
position.
If Dip switch #4 is at the “OFF”position and the mode
switch is at Gouge position, the output control is
determined by trigger command(C,D pins in wire feeder
connector). That function is used in the Automatic
Gouge system conveniently. As long as the trigger is
closed, the gouging begins to work.
DIP SWITCH 5 : Powersaving control.
If that switch is set into “OFF”, the power saving
function is initiated. In that mode, if there’s no operation
for machine after 5 minutes, the machine‘s contactor
will power off.
Enable power saving mode
Disable power saving
DIP SWITCH 6: special function
In SAW mode, if that switch is set into “ON”, the arc
start period will be longer.
Longer arc start
Short arc start (in SAW)
DIP SWITCH 7: (Reserved).
DIP SWITCH 8: 380V/415V Selection
If the input voltage is above 415V, that need to set dip
switch 8 into “ON”position.
Otherwise, that switch is set into “OFF”for 380V input
voltage.
Standard setting of DIP Switch #1 -- #8 as
OFF, OFF, OFF, OFF, ON, OFF, OFF, ON
shipped from the factory:
Turn the machine off when adjusting the DIP
switch. Or restart the machine after setting.
Note: When using NA5 Feeder system, the KIT of
KP62055 should be used.