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.

Lincoln Electric POWERPLUS 1000HD Specifications

General

Processes	MIG, Flux-Cored
Welding Process	MIG, Flux-Cored
Output Range	30-140A
Output Current Range	30-140A
Wire Feed Speed Range	50-700 IPM

Summary

Operator's Manual

Safety Depends on You

Emphasizes user responsibility for safe operation and reading the manual.

Safety Information

Electric and Magnetic Field Hazards

Discusses potential EMF interference with pacemakers and safety procedures.

Arc Ray Protection Measures

Advises on eye/skin protection from arc rays and screening nearby personnel.

Electric Shock Prevention

Details electric shock hazards and necessary precautions/equipment.

Fumes and Gases Health Risks

Covers health hazards from fumes/gases, ventilation, and respirator use.

Fire and Explosion Prevention

Warns about fire hazards from welding sparks/hot materials and preventative measures.

Electronic Equipment Power Safety

Instructions for powering off, installation, and grounding for electronic equipment.

Installation Guide

Technical Specifications Overview

Provides detailed technical specifications including input, output, and dimensions.

Input Wire and Fuse Recommendations

Details recommended wire gauges and fuse/breaker sizes for safe operation.

Physical Dimensions and Temperature Range

Lists machine dimensions and operating/storage temperature limits.

Installation Safety Precautions

General safety warnings before starting installation.

Location Selection Guidelines

Guidelines for choosing an appropriate and safe location for the machine.

Input Power and Grounding Connection

Details on connecting input power and ensuring proper grounding for safety.

Output and Wire Feeder Connections

Instructions for connecting the work lead and wire feeder for optimal performance.

Operation Guide

Operating Safety Precautions

Lists critical safety warnings for operating the equipment.

Front Panel Controls and Indicators

Identifies and describes the front panel controls and indicators.

Machine Output Stud Connections

Explains different output studs and their connection methods.

Rear Panel Components Overview

Describes components located on the rear panel, including fuses and connectors.

Advanced Features and DIP Switch Configuration

Introduces DIP switches for configuring advanced features.

DIP Switch 3: Gouging Tail Control

Configuration of DIP switch 3 for tail control in gouging mode.

DIP Switch 4: Gouging Direct Output Control

Setting DIP switch 4 for direct output control in gouging mode.

DIP Switch 5: Power Saving Mode Control

Configuration of DIP switch 5 for enabling/disabling power saving mode.

DIP Switch 6: SAW Arc Start Function

Setting DIP switch 6 for a special function in SAW mode (longer arc start).

DIP Switch 8: Input Voltage Selection

Setting DIP switch 8 to select between 380V and 415V input voltage.

Troubleshooting Guide

Troubleshooting: Contactor Issues

Steps for contactor problems like sound, no action, or incorrect operation.

Troubleshooting: High Output & Control Problems

Steps for high output with loss of control or reduced maximum output.

Troubleshooting: No Output & Indicator Issues

Steps for no output with missing status indicators or displays.

Troubleshooting: No Output with Green Status

Steps for no output with working fan/green status but no voltage meter reading.

Troubleshooting: High Output & Rover Unresponsiveness

Steps for high output when the Rover tractor is unresponsive.

Thermal LED Error: Constant On

Troubleshooting when the thermal LED is constantly on, indicating no output.

Thermal LED Error: Fast Flashes (Err 59/49)

Diagnosing/resolving "Err 59" or "Err 49" from thermal LED fast flashes.

Thermal LED Error: Slow Flashes (Err 39)

Diagnosing/resolving "Err 39" from thermal LED slow flashes.

Circuit Diagram

Important Notes