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

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

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)

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

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

图B.2

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.

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