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
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
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
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.
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