Page 1
Operating instructions
EN
Power source
TPL 300 puls DC
TPL 300 puls AC/DC
099-000235-55801
Observe additional system documents!
06.11.2017
Page 2
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.
Page 3
Contents
Notes on the use of these operating instructions
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3
1 Contents
1 Contents ........................................................................................................................................................... 3
2 For 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
3 Intended 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
4 Machine description – quick overview ........................................................................................................... 15
4.1 Front view ........................................................................................................................................... 15
4.2 Rear view ............................................................................................................................................ 16
5 Design 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
6 Maintenance, care and disposal .................................................................................................................... 29
6.1 General ............................................................................................................................................... 29
Page 4
Contents
Notes on the use of these operating instructions
4
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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
7 Rectifying faults .............................................................................................................................................32
7.1 Checklist for rectifying faults ............................................................................................................. 32
7.2 Vent coolant circuit ............................................................................................................................ 34
8 Technical data ................................................................................................................................................35
8.1 LINDE ARCLINE® TPL 300 puls DC .......................................................................................................... 35
8.2 LINDE ARCLINE® TPL 300 puls AC/DC ................................................................................................... 36
Page 5
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.
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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
Page 7
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!
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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!
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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!
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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).
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For your safety
Safety instructions
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11
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.
Page 12
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!
Page 13
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.
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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
Page 15
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
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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
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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
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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
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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.
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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.
Page 21
Design and function
Transport and installation
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Figure 5-5
5.1.6.1 Stray welding currents
WARNING
Risk of injury due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage machines and electronic
devices and cause overheating of components, leading to fire.
• Check that all welding current connections are firmly secured and electrical connections are in
perfect condition.
• Set up, attach or suspend all conductive power source components such as casing, transport
vehicles and crane frames so they are insulated.
• Do not place any other electronic devices such as drills or angle grinders on the power source,
transport vehicle or crane frames unless they are insulated.
• Always put welding torches and electrode holders on an insulated surface when they are not
in use.
Figure 5-6
Page 22
Design and function
Transport and installation
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5.1.7 Mains connection
DANGER
Hazards caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
• Only operate machine using a socket that has correctly fitted protective earth.
• The mains voltage indicated on the rating plate must match the supply voltage.
• If a new mains plug must be fitted, only an electrician may do so as per the relevant national
legislation or regulations.
• Mains plug, socket and lead must be checked by an electrician on a regular basis.
• When operating the generator, always ensure it is earthed as stipulated in the operating
instructions. The network created must be suitable for operating machines according to
protection class I.
5.1.7.1 Mains configuration
The machine may be connected to:
• a three-phase system with four conductors and an earthed neutral conductor
• a three-phase system with three conductors of which any one can be earthed,
e.g. the outer conductor
Figure 5-7
Legend
Item
Designation
Colour code
L1
Outer conductor 1
brown
L2
Outer conductor 2
black
L3
Outer conductor 3
grey
N
Neutral conductor
blue
PE
Protective conductor
green-yellow
• Insert mains plug of the switched-off machine into the appropriate socket.
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Design and function
TIG welding
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5.2 TIG welding
5.2.1 Welding torch and workpiece line connection
Prepare welding torch according to the welding task in hand (see operating instructions for the torch).
Figure 5-8
Item
Symbol
Description 0
1
Welding torch
2
Welding torch hose package
3
Connection socket, "-" welding current
Welding current lead connection for TIG welding torch
4
G¼" connecting nipple
TIG welding torch shielding gas connection
5
Connection socket, welding torch control cable
> see 5.2.1.1 chapter
6
Workpiece
7
Connection socket for "+" welding current
Workpiece lead connection
• Insert the welding current plug on the welding torch into the welding current connection socket and lock
by turning to the right.
• Remove yellow protective cap on G¼ connecting nipple.
• Screw welding torch shielding gas connection tightly onto the G¼" connection nipple.
• Plug the welding torch control cable plug into the welding torch control cable connection socket and
secure.
• Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by
turning to the right.
If fitted:
• Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings:
Return line red to quick connect coupling, red (coolant return) and
supply line blue to quick connect coupling, blue (coolant supply).
Read and observe the documentation to all system and accessory components!
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Design and function
TIG welding
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5.2.1.1 Connection assignment, welding torch control cable
TIG welding machines are equipped ex works with a dedicated connection socket for the welding torch
control cable (5- or 8-pole). As mobile machines offer more free space, they may even feature two control
cable connection sockets. The functionality increases with the number of poles. One of these connection
sockets may be converted or retrofitted.
TIG standard torch
TIG up/down or potentiometer torch
Figure 5-9
5.2.2 Shielding gas supply (shielding gas cylinder for welding machine)
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.
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental
requirement for optimum welding results. In addition, a blocked shielding gas supply may result in the
welding torch being destroyed.
• Always re-fit the yellow protective cap when not using the shielding gas connection.
• All shielding gas connections must be gas tight.
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Design and function
MMA welding
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5.2.2.1 Connecting the shielding gas supply
• Place the shielding gas cylinder into the relevant cylinder bracket.
• Secure the shielding gas cylinder using a securing chain.
Figure 5-10
Item
Symbol
Description 0
1
Pressure regulator
2
Shielding gas cylinder
3
Output side of the pressure regulator
4
Cylinder valve
• Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out
any dirt.
• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.
• Screw gas hose connection crown nut onto the output side of the pressure regulator.
Figure 5-11
Item
Symbol
Description 0
1
Connecting nipple G¼, shielding gas connection
• Connect crown nut of the shielding gas line to the G¼“ connecting nipple.
Page 26
Design and function
MMA welding
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5.3 MMA welding
5.3.1 Connecting the electrode holder and workpiece lead
CAUTION
Risk of crushing and burns!
When changing stick electrodes there is a risk of crushing and burns!
• Wear appropriate and dry protective gloves.
• Use an insulated pair of tongs to remove the used stick electrode or to move welded
workpieces.
Shielding gas connection!
During MMA welding open circuit voltage is applied at the shielding gas connection (G¼"
connecting nipple).
• Place yellow insulating cap on the G¼" connection nipple (protects against electrical voltage
and dirt).
Figure 5-12
Item
Symbol
Description 0
1
Electrode holder
2
Connection socket, “-” welding current
Workpiece lead or electrode holder connection
3
Workpiece
4
Connection socket for "+" welding current
Electrode holder or workpiece lead connection
5
Connecting nipple G¼, shielding gas connection
Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.
• Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and
lock by turning to the right.
• Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and
lock by turning to the right.
• Fit yellow protective cap onto G¼" connecting nipple.
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Design and function
PC interface
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5.4 PC interface
Equipment damage or faults may occur if the PC is connected incorrectly!
Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission. The PC
may be destroyed due to high frequency ignition pulses.
• Interface SECINT X10USB must be connected between the PC and the welding machine!
• The connection must only be made using the cables supplied (do not use any additional extension cables)!
5.5 Interfaces for automation
Damage to the machine due to improper connection!
Unsuitable control leads or incorrect connection of input and output signals can cause damage to the machine.
• Only use shielded control leads!
• If the machine is to be operated with control voltages connection via suitable isolation amplifiers is
required!
• To control the main or secondary current via control voltages, the relevant inputs must be enabled (see
specification for activation of control voltage).
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Design and function
Interfaces for automation
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5.5.1 Remote control connection socket, 19-pole
Figure 5-13
Pos.
Pin
Signal shape
Designation
1 A Output
Connection for cable screen (PE)
2
B/L
Output
Current flows signal I>0, galvanically isolated (max. +- 15V/100mA)
3 F Output
Reference voltage for potentiometer 10V (max. 10mA)
4 C Input
Control value specification for main current, 0-10V (0V = I
min
, 10V = I
max
)
5 D Input
Control value specification for secondary current, 0-10V (0V = I
min
, 10V =
I
max
) 6 J/U
Output
Reference 0V
7 K Output
Power supply +15V, max. 75mA
8 V Output
Power supply -15V, max. 25mA
9 R Input
Start/Stop welding current
10 H Input
Switching between main and secondary welding currents (pulses)
11
M/N/P
Input
Activation of control voltage specification
Set all 3 signals to reference potential 0V to activate external control
voltage specification for main and secondary currents
12 G Output
Measured value I
SETPOINT
(1V = 100A)
Page 29
Maintenance, care and disposal
General
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6 Maintenance, care and disposal
6.1 General
DANGER
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to
four minutes after the mains plug is removed.
1. Switch off machine.
2. Remove the mains plug.
3. Wait for at last 4 minutes until the capacitors have discharged!
WARNING
Incorrect maintenance, testing and repair!
Maintenance, testing and repair of the machine may only be carried out by skilled and qualified
personnel. A qualified person is one who, because of his or her training, knowledge and experience,
is able to recognise the dangers that can occur while testing welding power sources as well as
possible subsequent damage, and who is able to implement the required safety procedures.
Observe the maintenance instructions
> see 6.3 chapter
.
• In the event that the provisions of one of the below-stated tests are not met, the machine must
not be operated again until it has been repaired and a new test has been carried out!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right
to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine.
Return deliveries of defective equipment subject to warranty may only be made through your dealer. When
replacing parts, use only original spare parts. When ordering spare parts, please quote the machine type,
serial number and item number of the machine, as well as the type designation and item number of the
spare part.
Under the specified ambient conditions and normal working conditions this machine is essentially
maintenance-free and requires just a minimum of care.
Contamination of the machine may impair service life and duty cycle. The cleaning intervals depend on the
ambient conditions and the resulting contamination of the machine. The minimum interval is every six
months.
6.2 Cleaning
• Clean the outer surfaces with a moist cloth (no aggressive cleaning agents).
• Purge the machine venting channel and cooling fins (if present) with oil- and water-free compressed air.
Compressed air may overspeed and destroy the machine fans. Never direct the compressed air directly at
the machine fans. Mechanically block the fans, if required.
• Check the coolant for contaminants and replace, if necessary.
6.2.1 Dirt filter
The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume. Depending
on the amount of dirt building up (at least every two months), the dirt filter has to be uninstalled and
cleaned regularly (e.g. by purging with compressed air).
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Maintenance, care and disposal
Maintenance work, intervals
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6.3 Maintenance work, intervals
6.3.1 Daily maintenance tasks
Visual inspection
• Mains supply lead and its strain relief
• Gas cylinder securing elements
• Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
• Gas tubes and their switching equipment (solenoid valve)
• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• Check correct mounting of the wire spool.
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Other, general condition
Functional test
• Operating, message, safety and adjustment devices (Functional test)
• Welding current cables (check that they are fitted correctly and secured)
• Gas tubes and their switching equipment (solenoid valve)
• Gas cylinder securing elements
• Check correct mounting of the wire spool.
• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
• Remove any spatter.
• Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
6.3.2 Monthly maintenance tasks
Visual inspection
• Casing damage (front, rear and side walls)
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Check coolant tubes and their connections for impurities
Functional test
• Selector switches, command devices, emergency stop devices, voltage reducing devices, message and
control lamps
• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
• Check coolant tubes and their connections for impurities
• Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative
impact on the welding result, ultimately causing damage to the torch.
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Maintenance, care and disposal
Disposing of equipment
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31
6.3.3 Annual test (inspection and testing during operation)
The welding machine may only be tested by competent, capable personsl. A capable person is one who,
because of his training, knowledge and experience, is able to recognise the dangers that can occur while
testing welding power sources as well as possible subsequent damage and who is able to implement the
required safety procedures.
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to
the regulations on testing given here, the relevant local laws and regulations must also be observed.
6.4 Disposing of equipment
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and electronic
components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
• According to European provisions (Directive 2012/19/EU on Waste of Electrical and Electronic
Equipment), used electric and electronic equipment may no longer be placed in unsorted municipal
waste. It must be collected separately. The symbol depicting a waste container on wheels indicates that
the equipment must be collected separately.
This machine has to be disposed of, or recycled, in accordance with the waste separation systems in use.
• According to German law (law governing the distribution, taking back and environmentally correct
disposal of electric and electronic equipment (ElektroG)), used machines are to be placed in a collection
system separate from unsorted municipal waste. The public waste management utilities (communities)
have created collection points at which used equipment from private households can be disposed of free
of charge.
• Information about returning used equipment or about collections can be obtained from the respective
municipal administration office.
Page 32
Rectifying faults
Checklist for rectifying faults
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7 Rectifying faults
All products are subject to rigorous production checks and final checks. If, despite this, something fails to
work at any time, please check the product using the following flowchart. If none of the fault rectification
procedures described leads to the correct functioning of the product, please inform your authorised dealer.
7.1 Checklist for rectifying faults
The correct machine equipment for the material and process gas in use is a fundamental requirement for
perfect operation!
Legend
Symbol
Description
Fault/Cause
Remedy
Mains fuse triggers
Unsuitable mains fuse
Set up recommended mains fuse
> see 8 chapter
.
Functional errors
Insufficient coolant flow
Check coolant level and refill if necessary
Eliminate kinks in conduit system (hose packages)
Reset automatic cutout of the coolant pump by activating
Air in the coolant circuit
Vent coolant circuit
> see 7.2 chapter
Several parameters cannot be set (machines with access block)
Entry level is blocked, disable access lock
All machine control signal lights are illuminated after switching on
No machine control signal light is illuminated after switching on
No welding power
Phase failure > check mains connection (fuses)
Connection problems
Make control lead connections and check that they are fitted correctly.
Welding torch overheated
Loose welding current connections
Tighten power connections on the torch and/or on the workpiece
Tighten contact tip correctly
Overload
Check and correct welding current setting
Use a more powerful welding torch
No arc ignition
Incorrect ignition type setting.
Ignition type: Select “HF start”. Depending on the machine, the setting is defined by the
changeover switch for ignition types or the parameter in one of the machine menus (see the
“Control operating instructions”, if applicable).
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Rectifying faults
Vent coolant circuit
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33
Bad arc ignition
Material inclusions in the tungsten electrode due to contact with filler material or workpiece
Regrind or replace the tungsten electrode
Bad current transfer on ignition
Check the setting on the "Tungsten electrode diameter/Ignition optimisation" rotary dial and
increase if necessary (higher ignition energy).
Unstable arc
Material inclusions in the tungsten electrode due to contact with filler material or workpiece
Regrind or replace the tungsten electrode
Incompatible parameter settings
Check settings and correct if necessary
Pore formation
Inadequate or missing gas shielding
Check shielding gas setting and replace shielding gas cylinder if necessary
Shield welding site with protective screens (draughts affect the welding result)
Use gas lens for aluminium applications and high-alloy steels
Unsuitable or worn welding torch equipment
Check size of gas nozzle and replace if necessary
Condensation (hydrogen) in the gas tube
Purge hose package with gas or replace
Page 34
Rectifying faults
Vent coolant circuit
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7.2 Vent coolant circuit
Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water
cooling.
To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside
the system (close to the coolant tank)!
Figure 7-1
Page 35
Technical data
LINDE ARCLINE® TPL 300 puls DC
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8 Technical data
Performance specifications and guarantee only in connection with original spare and replacement parts!
8.1 LINDE ARCLINE® TPL 300 puls DC
TIG
MMA
Setting range for welding current
5 A–300 A
Setting range for welding voltage
10.2 V–22.0 V
20.2 V–32.0 V
Max. welding current
30% DC
35% DC
60% DC
100% DC
300 A
260 A
210 A
300 A
260 A
210 A
Load cycle
10 min. (60% DC ≙ 6 min. welding, 4 min. pause)
Open circuit voltage
63 V
Mains voltage (tolerances)
3 x 400 V (–25% to +20%)
Frequency
50/60 Hz
Mains fuse (safety fuse, slow-blow)
3 x 16 A
Mains connection lead
H07RN-F4G2,5
Max. connected load
11.4 kVA
16.6 kVA
Recommended generator rating
22.4 kVA
Noise level
< 70 dB(A)
cos/efficiency
0.99/88%
Insulation class/protection classification
H/IP 23
Ambient temperature
–25 °C to +40 °C
Machine cooling/torch cooling
Fan/gas
Workpiece lead
50 mm2
EMC class
A
Safety identification
/
Harmonised standards used
see declaration of conformity (machine documentation)
Dimensions L x W x H
539 x 210 x 415 mm
21.2 x 8.3 x 16.3 inch
Weight
20.5 kg
45.2 lb
Page 36
Technical data
LINDE ARCLINE® TPL 300 puls AC/DC
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8.2 LINDE ARCLINE® TPL 300 puls AC/DC
TIG
MMA
Setting range for welding current
5 A–300 A
Setting range for welding voltage
10.2 V–22.0 V
20.2 V–32.0 V
Max. welding current
30% DC
35% DC
60% DC
100% DC
300 A
260 A
210 A
300 A
260 A
210 A
Load cycle
10 min. (60% DC 6 min. welding, 4 min. pause)
Open circuit voltage
63 V
Mains voltage (tolerances)
3 x 400 V (–25% to +20%)
Frequency
50/60 Hz
Mains fuse (safety fuse, slow-blow)
3 x 16 A
Mains connection lead
H07RN-F4G2,5
Max. connected load
11.7 kVA
17 kVA
Recommended generator rating
23 kVA
Noise level
< 70 dB(A)
cos/efficiency
0.99/84%
Insulation class/protection classification
H/IP 23
Ambient temperature
–25 °C to +40 °C
Machine cooling/torch cooling
Fan/gas
Workpiece lead
50 mm2
EMC class
A
Safety identification
/
Harmonised standards used
see declaration of conformity (machine documentation)
Dimensions L x W x H
539 x 210 x 415 mm
21.2 x 8.3 x 16.3 inch
Weight
22.6 kg
49.8 lb
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