Linde TPL 300 puls DC User manual

Operating instructions
EN
Power source
TPL 300 puls DC
TPL 300 puls AC/DC
099-000235-55801
Observe additional system documents!
06.11.2017

General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the safety
instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and repair
the machine.
•Technical changes due to further development in machine technology may lead to a differing
welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the installation site or
the intended use, please contact your sales partner.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result.
For this reason, we do not accept any responsibility or liability for losses, damages or costs arising
from incorrect installation, improper operation or incorrect usage and maintenance or any actions
connected to this in any way.
© Linde AG
Gases Division Germany
Seitnerstraße 70
82049 Pullach, Deutschland
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents........................................................................................................................................................... 3
2For your safety................................................................................................................................................. 5
2.1 Notes on the use of these operating instructions................................................................................ 5
2.2 Explanation of icons ............................................................................................................................. 6
2.3 Part of the complete documentation ................................................................................................... 7
2.4 Safety instructions................................................................................................................................ 7
2.5 Transport and installation...................................................................................................................12
3Intended use.................................................................................................................................................. 13
3.1 Applications........................................................................................................................................ 13
3.2 Documents which also apply..............................................................................................................13
3.2.1 Warranty.............................................................................................................................13
3.2.2 Declaration of Conformity ..................................................................................................13
3.2.3 Welding in environments with increased electrical hazards .............................................13
3.2.4 Service documents (spare parts and circuit diagrams)......................................................14
3.2.5 Calibration/Validation........................................................................................................14
4Machine description –quick overview........................................................................................................... 15
4.1 Front view...........................................................................................................................................15
4.2 Rear view............................................................................................................................................16
5Design and function....................................................................................................................................... 17
5.1 Transport and installation...................................................................................................................17
5.1.1 Ambient conditions ............................................................................................................ 17
5.1.1.1 In operation........................................................................................................17
5.1.1.2 Transport and storage ........................................................................................ 17
5.1.2 Machine cooling ................................................................................................................. 18
5.1.3 Workpiece lead, general.................................................................................................... 18
5.1.4 Adjusting the length of the carrying strap.........................................................................18
5.1.5 Welding torch cooling system............................................................................................19
5.1.6 Notes on the installation of welding current leads............................................................ 20
5.1.6.1 Stray welding currents .......................................................................................21
5.1.7 Mains connection ............................................................................................................... 22
5.1.7.1 Mains configuration............................................................................................22
5.2 TIG welding.........................................................................................................................................23
5.2.1 Welding torch and workpiece line connection ..................................................................23
5.2.1.1 Connection assignment, welding torch control cable........................................ 24
5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) .................................24
5.2.2.1 Connecting the shielding gas supply .................................................................25
5.3 MMA welding...................................................................................................................................... 26
5.3.1 Connecting the electrode holder and workpiece lead.......................................................26
5.4 PC interface ........................................................................................................................................27
5.5 Interfaces for automation...................................................................................................................27
5.5.1 Remote control connection socket, 19-pole...................................................................... 28
6Maintenance, care and disposal .................................................................................................................... 29
6.1 General............................................................................................................................................... 29

Contents
Notes on the use of these operating instructions
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6.2 Cleaning.............................................................................................................................................. 29
6.2.1 Dirt filter............................................................................................................................. 29
6.3 Maintenance work, intervals ............................................................................................................. 30
6.3.1 Daily maintenance tasks.................................................................................................... 30
6.3.2 Monthly maintenance tasks............................................................................................... 30
6.3.3 Annual test (inspection and testing during operation)..................................................... 31
6.4 Disposing of equipment ..................................................................................................................... 31
7Rectifying faults .............................................................................................................................................32
7.1 Checklist for rectifying faults ............................................................................................................. 32
7.2 Vent coolant circuit ............................................................................................................................ 34
8Technical data ................................................................................................................................................35
8.1 LINDE ARCLINE®TPL 300 puls DC.......................................................................................................... 35
8.2 LINDE ARCLINE®TPL 300 puls AC/DC................................................................................................... 36

For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent serious and
even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious and even fatal
injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible minor
personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general warning
symbol.
•The risk is explained using a symbol on the edge of the page.
Special technical points which users must observe.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points,
e.g.:
•Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch off machine
Release
Switch on machine
Press and keep pressed
Switch
Wrong
Turn
Correct
Numerical value –adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

For your safety
Part of the complete documentation
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2.3 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in combination with all
other parts of these instructions! Read and observe the operating instructions for all system components,
especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 2-1
Item
Documentation
A.1
Options conversion instructions
A.2
Power source
A.3
Cooling unit, voltage converter, tool box etc.
A.4
Transport cart
A.5
Welding torch
A.6
Remote control
A.7
Control
A
Complete documentation
2.4 Safety instructions
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
•Carefully read the safety instructions in this manual!
•Observe the accident prevention regulations and any regional regulations!
•Inform persons in the working area that they must comply with the regulations!

For your safety
Safety instructions
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WARNING
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low voltages can
cause a shock and lead to accidents.
•Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
•Always place torches and electrode holders on an insulated surface!
•Wear the full personal protective equipment (depending on the application)!
•The machine may only be opened by qualified personnel!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a technical specialist
may interconnect the sources as per standard IEC 60974-9:2010: Installation and use and German
Accident Prevention Regulation BVG D1 (formerly VBG 15) or country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed the
maximum permitted open circuit voltage.
•Only qualified personnel may connect the machine.
•When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
•Do not interconnect welding machines with pole reversing switch (PWS series) or machines for
AC welding since a minor error in operation can cause the welding voltages to be combined,
which is not permitted.
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user
has to be equipped with the complete personal protective equipment at all times. The protective
equipment has to include:
•Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
•Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
•Dry welding clothing (shoes, gloves and body protection) to protect against warm
environments with conditions comparable to ambient temperatures of 100 °C or higher and
arcing and work on live components.
•Hearing protection against harming noise.
Risk of injury due to radiation or heat!
Arc radiation can lead to skin and eye injuries.
Contact with hot workpieces and sparks can lead to burns.
•Use hand shield or welding helmet with the appropriate safety level (depends on the
application).
•Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with
the applicable regulations of your country.
•Persons who are not directly involved should be protected with a welding curtain or suitable
safety screen against radiation and the risk of blinding!

For your safety
Safety instructions
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WARNING
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure when
heated.
•Move containers with inflammable or explosive liquids away from the working area!
•Never heat explosive liquids, dusts or gases by welding or cutting!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during welding, there
is a risk of flames.
•Be watchful of potential sources of fire in the working area!
•Do not carry any easily inflammable objects, e.g. matches or lighters.
•Ensure suitable fire extinguishers are available in the working area!
•Thoroughly remove any residue of flammable materials from the workpiece prior to starting to
weld.
•Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!
CAUTION
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour
(chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet
radiation of the arc!
•Ensure that there is sufficient fresh air!
•Keep solvent vapour away from the arc beam field!
•Wear suitable breathing apparatus if appropriate!
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
•Wear suitable ear protection!
•Persons located within the working area must wear suitable ear protection!

For your safety
Safety instructions
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CAUTION
According to IEC 60974-10, welding machines are divided into two classes of electromagnetic
compatibility (the EMC class can be found in the Technical data) > see 8 chapter :
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas, including
residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the surrounding
area, the user must consider the following: (see also EN 60974-10 Appendix A)
•Mains, control, signal and telecommunication lines
•Radios and televisions
•Computers and other control systems
•Safety equipment
•The health of neighbouring persons, especially if they have a pacemaker or wear a hearing aid
•Calibration and measuring equipment
•The immunity to interference of other equipment in the surrounding area
•The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
•Mains connection, e.g. additional mains filter or shielding with a metal tube
•Maintenance of the arc welding system
•Welding leads should be as short as possible and run closely together along the ground
•Potential equalization
•Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly, it
should be connected by means of suitable capacitors.
•Shielding from other equipment in the surrounding area or the entire welding system
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which could affect
the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines,
power cables, signal lines and pacemakers.
•Observe the maintenance instructions > see 6.3 chapter !
•Unwind welding leads completely!
•Shield devices or equipment sensitive to radiation accordingly!
•The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).

For your safety
Safety instructions
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Obligations of the operator!
The respective national directives and laws must be complied with when operating the machine!
•Implementation of national legislation relating to framework directive 89/391/EEC on the introduction of
measures to encourage improvements in the safety and health of workers at work and associated
individual guidelines.
•In particular, directive 89/655/EEC concerning the minimum safety and health requirements for the use of
work equipment by workers at work.
•The regulations applicable to occupational safety and accident prevention in the country concerned.
•Setting up and operating the machine as per IEC 60974.-9.
•Brief the user on safety-conscious work practices on a regular basis.
•Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
•Only use system components and options (power sources, welding torches, electrode holders, remote
controls, spare parts and replacement parts, etc.) from our range of products!
•Only insert and lock accessory components into the relevant connection socket when the machine is
switched off.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains network. For
some types of machines, connection restrictions or requirements relating to the maximum possible line
impedance or the necessary minimum supply capacity at the interface with the public network (Point of
Common Coupling, PCC) can therefore apply. In this respect, attention is also drawn to the machines' technical
data. In this case, it is the responsibility of the operator, where necessary in consultation with the mains
network operator, to ensure that the machine can be connected.

For your safety
Transport and installation
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2.5 Transport and installation
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries!
•Observe the instructions from the gas manufacturer and any relevant regulations concerning
the use of compressed air!
•Do not attach any element to the shielding gas cylinder valve!
•Prevent the shielding gas cylinder from heating up.
CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by
causing connected machines to tip over and injure persons!
•Disconnect all supply lines before transport!
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself during
movement and set up. Tilt resistance is guaranteed up to an angle of 10° (according to IEC 60974-
1).
•Set up and transport the machine on level, solid ground.
•Secure add-on parts using suitable equipment.
Risk of accidents due to incorrectly installed leads!
Incorrectly installed leads (mains, control and welding leads or intermediate hose packages ) can
present a tripping hazard.
•Lay the supply lines flat on the floor (avoid loops).
•Avoid laying the leads on passage ways.
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
•Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
•Only insert and lock accessory components into the relevant connection socket when the machine is
switched off.
•Comprehensive descriptions can be found in the operating instructions for the relevant accessory
components.
•Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and damage.
•The protective dust cap must be fitted if there is no accessory component being operated on that
connection.
•The cap must be replaced if faulty or if lost!

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and standards
applicable for use in industry and trade. It may only be used for the welding procedures indicated
at the rating plate. Hazards may arise for persons, animals and material objects if the equipment is
not used correctly. No liability is accepted for any damages arising from improper usage!
•The equipment must only be used in line with its designated purpose and by trained or expert
personnel!
•Do not improperly modify or convert the equipment!
3.1 Applications
Arc welding machine for TIG DC and AC welding with lift arc (touch starting) or HF ignition (contactless) and
MMA welding as secondary process. It may be possible to expand the functionality by using accessories (see
the documentation in the relevant chapter).
3.2 Documents which also apply
3.2.1 Warranty
The statutory warranty period is one year from the date of purchase.
By registering the product, you extend the statutory warranty period to three years and, in the case of
selected product groups, to a warranty period of five years.
Please contact your sales partner if you have any questions.
3.2.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
•Low Voltage Directive (LVD)
•Electromagnetic Compatibility Directive (EMC)
•Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding
Equipment –Inspection and Testing during Operation," and/or prohibited modifications which have not been
explicitly authorised by the manufacturer, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.2.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in environments with an
increased electrical hazard.

Intended use
Documents which also apply
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3.2.4 Service documents (spare parts and circuit diagrams)
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by specialist,
skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
•Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.2.5 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as stipulated in
IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances. Recommended
calibration interval: 12 months

Machine description –quick overview
Front view
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4 Machine description –quick overview
4.1 Front view
Figure 4-1
Item
Symbol
Description 0
1
Carrying handle
2
Machine control, see the relevant control operating instructions
3
Connection socket, welding torch control cable > see 5.2.1.1 chapter
4
Connection socket, "+" welding current
•MMA: Electrode holder or workpiece lead connection
•TIG: Connection for workpiece lead
5
Cooling air inlet
6
Connection socket, "-" welding current
•TIG: TIG welding torch connection
•MMA: Electrode holder or workpiece lead connection
7
G¼” connecting nipple, “-” welding current
Shielding gas connection (with yellow insulating cap) for TIG welding torch
8
Carrying strap > see 5.1.4 chapter

Machine description –quick overview
Rear view
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4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Connection socket, 19-pole
Remote control connection
2
8-pole connection socket
Cooling unit control lead
3
4-pole connection socket
Cooling unit voltage supply
4
Cooling air outlet
5
Machine feet
6
Mains connection cable > see 5.1.7 chapter
7
G¼” connecting nipple
Shielding gas connection on the pressure regulator.
8
Main switch, machine on/off
9
PC interface, serial (D-Sub connection socket, 9-pole)
10
7-pole connection socket (digital)
For connecting digital accessory components

Design and function
Transport and installation
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5 Design and function
WARNING
Risk of injury from electrical voltage!
Contact with live parts, e.g. power connections, can be fatal!
•Observe the safety information on the first pages of the operating instructions!
•Commissioning must be carried out by persons who are specifically trained in handling power
sources!
•Connect connection or power cables while the machine is switched off!
Read and observe the documentation to all system and accessory components!
5.1 Transport and installation
WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The handles, straps or
brackets are suitable for transport by hand only!
•The machine must not be suspended or lifted using a crane.
5.1.1 Ambient conditions
T he machine must not be operated in the open air and must only be set up and operated on a suitable, stable
and level base!
•The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place
of work.
•Safe operation of the machine must be guaranteed at all times.
Unusually high quantities of dust, acid, corrosive gases or substances may damage the equipment.
•Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
•Avoid ambient air containing salt (sea air)!
5.1.1.1 In operation
Temperature range of the ambient air:
•-25 °C to +40 °C
Relative air humidity:
•Up to 50% at 40 °C
•Up to 90% at 20 °C
5.1.1.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
•-30 °C to +70 °C
Relative air humidity
•Up to 90% at 20 °C

Design and function
Transport and installation
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5.1.2 Machine cooling
Insufficient ventilation results in a reduction in performance and equipment damage.
•Observe the ambient conditions!
•Keep the cooling air inlet and outlet clear!
•Observe the minimum distance of 0.5 m from obstacles!
5.1.3 Workpiece lead, general
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece connection is
contaminated (paint, corrosion), these connections and leads can heat up and cause burns when
touched!
•Check welding current connections on a daily basis and lock by turning to the right when
necessary.
•Clean workpiece connection thoroughly and secure properly. Do not use structural parts of the
workpiece as welding current return lead!
5.1.4 Adjusting the length of the carrying strap
To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten, the strap's loops must be
inched in the opposite direction.
Figure 5-1

Design and function
Transport and installation
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5.1.5 Welding torch cooling system
Figure 5-2
Item
Symbol
Description 0
1
8-pole connection socket
Cooling unit control lead
2
4-pole connection socket
Cooling unit voltage supply
3
Cooling module
•Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the
welding machine.
•Insert and lock the 4-pole supply plug on the cooling unit into the 4-pole connection socket on the
welding machine.

Design and function
Transport and installation
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5.1.6 Notes on the installation of welding current leads
Incorrectly installed welding current leads can cause faults in the arc (flickering).
Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as
close as possible in parallel.
Lay the workpiece lead and hose package of power sources with HF igniter (TIG) for as long as possible in
parallel with a distance of 20 cm to avoid HF sparkover.
Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences
Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead + intermediate
hose package + torch lead).
Figure 5-3
Use an individual welding lead to the workpiece for each welding machine!
Figure 5-4
Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops!
Always keep leads as short as possible!
Lay any excess cable lengths in meanders.