TPS/i Robotics TWIN Operating instructions

The warnings and safety instructions in these instructions are intended to protect people from possible injury and the product from damage.

The warnings and safety instructions are an integral part of these instructions and must always be observed to ensure the safe and proper use of the product.

1. Safety Instructions

The warnings and safety instructions in these instructions are intended to protect people from possible injury and the product from damage.

The warnings and safety instructions are an integral part of these instructions and must always be observed to ensure the safe and proper use of the product.

1. Safety Instructions

• Injury or death to the operator or a third party
• Damage to the device and other material assets belonging to the operating company
• Inefficient operation of the equipment

• Be suitably qualified
• Have knowledge of welding
• Have completely read and followed these Operating Instructions

The Operating Instructions must always be at hand wherever the device is being used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed.

• Be kept in a legible state
• Not be damaged/marked
• Not be removed
• Not be covered, pasted, or painted over

For the location of the safety and danger notices on the device, refer to the section headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.

1. Safety Instructions

The device is to be used exclusively for its intended purpose.

The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose."

• Completely reading and obeying all instructions in the Operating Instructions
• Completely reading and obeying all safety instructions and danger notices
• Carrying out all the specified inspection and servicing work

• Thawing pipes
• Charging batteries
• Starting motors

The device is designed for operation in industry and business. The manufacture shall not be liable for any damage resulting from use in a living area.

The manufacture shall also not be liable for faulty or incorrect work results.

1. Safety Instructions

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose.

• During operation: -10°C to +40°C (14°F to 104°F)
• During transport and storage: -20°C to +55°C (-4°F to 131°F)

• Up to 50% at 40°C (104°F)
• Up to 90% at 20°C (68°F)

Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

1. Safety Instructions

• Are familiar with the basic occupational safety and accident prevention regulations and are trained in handling the device
• Have read and understood these Operating Instructions, especially the section "Safety Rules," and have confirmed this with their signature
• Are trained according to the requirements for the work results

The safety-conscious work of the personnel must be checked regularly.

1. Safety Instructions

• Follow the basic regulations for occupational safety and accident prevention
• Read these Operating Instructions, especially the section "Safety Rules," and confirm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage can occur in one's absence.

1. Safety Instructions

Devices with a high output can influence the energy quality of the grid due to their current consumption.

• connection restrictions
• criteria regarding maximum permissible grid impedance ^*)
• criteria regarding the minimum required short-circuit power ^*)

^*) both at the interface with the public grid
See technical data

In this case, the operator or the person using the device should check whether or not the device is allowed to be connected, where appropriate through discussion with the power supply company.

IMPORTANT! Ensure secure grounding of the grid connection!

1. Safety Instructions

• Flying sparks and pieces of hot metal
• Arc radiation that poses a risk of injury to the eyes and skin

• Hazardous electromagnetic fields that pose a risk of death for individuals with pacemakers

• Electrical risks from grid current and welding current

• Increased noise exposure

• Harmful welding fumes and gases

• Flame resistant
• Insulating and dry
• Covering the entire body and in good condition with no damage
• Safety helmet
• Cuffless pants

• Protecting the face and eyes from UV radiation, heat and flying sparks with a face guard featuring a regulation-compliant filter
• Wearing regulation-compliant protective goggles with side protection behind the face guard
• Wearing rigid, wet-insulating footwear
• Protecting hands with appropriate gloves (featuring electrical insulation and thermal protection)
• Wearing ear protection to reduce noise exposure and protect against injury

• Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying sparks, welding fumes hazardous to health, noise exposure, possible hazard due to grid current or welding current, etc.)
• Provide suitable protective equipment or
• Construct suitable protective walls and curtains.

1. Safety Instructions

The fumes produced during welding contain toxic gases and vapors.

Welding fumes contain substances that cause cancer, as stated in monograph 118 from the International Agency for Research on Cancer.

Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.

Keep your head out of the welding fumes and gases.

• Do not breathe them in.
• Extract them from the work area using appropriate equipment.

Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow rate of at least 20 m³ per hour.

Use a welding helmet with air supply if there is insufficient ventilation.

If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.

• The metals used for the workpiece
• Electrodes
• Coatings
• Cleaning agents, degreasers, and the like
• The welding process used

Consult the corresponding material safety data sheets and manufacturer's instructions for the components listed above.

Recommendations for exposure scenarios, risk management measures and identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).

Keep flammable vapors (such as solvent vapors) out of the arc radiation range.

When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.

1. Safety Instructions

Flying sparks can cause fires and explosions.

Never undertake welding near flammable materials.

Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or protected with a certified cover.

Keep suitable, tested fire extinguishers on hand.

Sparks and pieces of hot metal may also get into surrounding areas through small cracks and openings. Take appropriate measures to ensure that there is no risk of injury or fire.

Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums, or pipes if these have not been prepared in accordance with corresponding national and international standards.

Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/were stored. Residues pose a risk of explosion.

1. Safety Instructions

An electric shock can be fatal.

Do not touch voltage-carrying parts inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wire spool, the feed rollers, as well as all pieces of metal that are in contact with the welding wire, are live.

Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating wirefeeder holder.

Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. The temporary backing or cover must completely cover the entire area between the body and the ground potential.

All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at least 180° around the longitudinal axis and pretension.

Do not wrap cables or leads around your body or parts of the body.

• Never immerse it in liquids to cool it
• Never touch it when the welding system is switched on

The open circuit voltage of a welding system may double, for example, between the electrodes of two welding systems. Touching the potentials of both electrodes at the same time may be life-threatening in some cases.

Have the grid and device supply lead regularly inspected by an electrician to ensure that the ground conductor is functioning properly.

Protection class I devices require a grid with a ground conductor and a connector system with ground conductor contact for proper operation.

Operation of the device on a grid without a ground conductor and on a socket without a ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence.

Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.

Switch off unused devices.

When working at elevated heights, wear a safety harness to prevent falls.

Before working on the device, switch off the device and remove the mains plug.

Secure the device to prevent the mains plug from being connected and switched on again by applying a clearly legible and understandable warning sign.

• Discharge all electrically charged components
• Ensure that all components are disconnected from the power supply

If work is needed on voltage-carrying parts, bring in a second person who will switch off the main switch at the correct time.

1. Safety Instructions

• Fire
• Overheating of parts connected to the workpiece
• Irreparable damage to ground conductors
• Damage to the device and other electrical equipment

Ensure that the workpiece clamp is securely connected to the workpiece.

Secure the workpiece clamp as close to the spot to be welded as possible.

Position the device with sufficient insulation against electrically conductive environments, e.g., insulation against electrically conductive floors or electrically conductive mounts.

Observe the following when using power distribution boards, twin-head mounts, etc.: Even the electrode of the welding torch/electrode holder not in use carries electric potential. Ensure that there is sufficient insulation when the unused welding torch/electrode holder is stored.

In automated MIG/MAG applications, only guide the wire electrode from the welding wire drum, large spool, or wirespool to the wirefeeder with insulation.

1. Safety Instructions

• Are only designed for use in industrial settings
• Can cause line-bound and radiated interference in other areas

• Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage grid.

EMC device classification as per the rating plate or technical data.

1. Safety Instructions

In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g., when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers).
If this is the case, then the operating company is obliged to take appropriate action to rectify the situation.

• Safety devices
• Grid power lines, signal lines, and data transfer lines
• IT and telecommunications equipment
• Devices for measuring and calibrating

1. Grid power supply
   • If electromagnetic interference occurs despite a grid connection that complies with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
   • Keep them as short as possible
   • Route them close together (also to avoid EMF problems)
   • Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
   • If necessary, establish grounding using suitable capacitors.
5. Shield, if necessary
   • Shield other devices in the vicinity
   • Shield the entire welding installation

1. Safety Instructions

• Effects on the health of persons close by, e.g., those with pacemakers and hearing aids
• Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the welding process
• Keep distances between welding power-leads and the head/torso of the welder as great as possible for safety reasons
• Do not carry welding power-leads and hosepacks over your shoulder or wrap them around your body or body parts

1. Safety Instructions

• Fans
• Gears
• Rollers
• Shafts
• Wirespools and welding wires

Do not reach into rotating gears of the wire drive or into rotating drive parts.

Covers and side panels must only be opened/removed during maintenance and repair work.

• Ensure that all covers are closed, and all side parts have been mounted properly.
• Keep all covers and side parts closed.

The welding wire protruding from the welding torch poses a high risk of injury (cuts to the hand, facial and eye injuries, etc.).
Therefore, always hold the welding torch away from the body (devices with wirefeeder) and use suitable protective goggles.

Do not touch the workpiece during or after welding—risk of burns.

Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant protective equipment when reworking workpieces and ensure that other persons are sufficiently protected.

Leave the welding torch and other parts with a high operating temperature to cool before working on them.

Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.

Welding machines for work in areas with increased electrical hazard (e.g., boilers) must be labeled with the symbol (Safety). However, the welding machine may not be located in such areas.

Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting connections for the coolant supply or return.

When handling coolant, observe the information on the coolant safety data sheet. The coolant safety data sheet can be obtained from your service center or via the manufacturer's website.

Only use suitable load-carrying equipment from the manufacturer to transport devices by crane.

• Attach chains or ropes to all designated attachments of the suitable load-carrying equipment.
• Chains or ropes must be the smallest angle possible from vertical.
• Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

In the event of crane attachment of the wirefeeder during welding, always use a suitable, insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).

Welding with the device during crane transport is only permitted if this is clearly stated in the intended use of the device.

If the device is equipped with a carrier strap or handle, then this is used exclusively for transport by hand. The carrier strap is not suitable for transport by crane, counterbalanced lift truck, or other mechanical lifting tools.

All lifting equipment (straps, buckles, chains, etc.), which is used in association with the device or its components, must be checked regularly (e.g., for mechanical damage, corrosion, or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national standards and guidelines.

There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is used for the shielding gas connection. Use suitable Teflon tape to seal the thread of the shielding gas connection adapter on the device side before installation.

1. Safety Instructions

• Solid particle size < 40 µm
• Pressure condensation point < -20 °C
• Max. oil content < 25 mg/m³

Use filters if necessary.

1. Safety Instructions

Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding gas cylinders are an integral part of the welding equipment, so they must be handled very carefully.

Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open flames, sparks, and arcs.

Mount the shielding gas cylinders vertically and secure them in accordance with instructions so they cannot fall over.

Keep shielding gas cylinders away from welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion: Never weld on a compressed shielding gas cylinder.

Always use suitable shielding gas cylinders for the application in question and the correct matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders and accessories that are in good condition.

If a valve on a shielding gas cylinder is open, turn your face away from the outlet.

When no welding is taking place, close the valve of the shielding gas cylinder.

Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected.

Follow the manufacturer's instructions and applicable national and international provisions for shielding gas cylinders and accessories.

1. Safety Instructions

Risk of asphyxiation due to uncontrolled shielding gas leak

Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage.

• Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³ per hour.
• Please observe the safety and maintenance information for the shielding gas cylinder or the main gas supply.
• When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.
• Always check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before each start-up.

1. Safety Instructions

• The maximum permitted tilt angle is 10°.

• Follow the appropriate national and international regulations.

Use instructions and checks within the company to ensure that the vicinity of the workplace is always clean and organized.

Only set up and operate the device in accordance with the protection class shown on the rating plate.

When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to allow cooling air to circulate unhindered.

Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.

Do not lift or transport any active devices. Switch off and disconnect devices from the grid before transport or lifting.

• Wirefeeder
• Wire spool
• shielding gas cylinder

It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before commissioning. Have any damage repaired by trained service technicians before commissioning the device.

1. Safety Instructions

• Injury or death to the operator or a third party
• Damage to the device and other material assets belonging to the operating company
• Inefficient operation of the device

Safety devices that are not fully functional must be repaired before the device is switched on.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one can be put in danger.

The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.

Always secure the shielding gas cylinder well and remove before transporting by crane.

Only the original coolant from the manufacturer is suitable for use in our devices due to its properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.)

Only use appropriate original coolant from the manufacturer.

Do not mix original coolant from the manufacturer with other coolants.

Only connect system components from the manufacturer to the cooling unit circuit.

Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flammable in certain conditions. Only transport the coolant in closed original containers and keep away from sources of ignition.

Properly dispose of used coolant according to national and international regulations. The coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.

When the system is cool, always check the coolant level before starting welding.

1. Safety Instructions

It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.

• Use only original spare and wearing parts (also applies to standard parts).
• Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
• Components that are not in perfect condition must be replaced immediately.
• When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.

1. Safety Instructions

The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.

The manufacturer recommends calibrating welding systems within the same 12-month interval.

• After changes
• After alterations
• After repair, service, and maintenance
• At least every twelve months

For the safety inspection, follow the appropriate national and international standards and guidelines.

You can obtain more information about the safety inspection and calibration from your service center. The service center will provide the necessary documents upon request.

1. Safety Instructions

• Directive 2014/30/EU on electromagnetic compatibility
• Directive 2014/35/EU Low Voltage Directive
• Directive 2014/53/EU Radio Equipment Directive
• EN IEC 60974 Arc welding equipment
• and others

The full text of the EU Declaration of Conformity is available at
https://www.fronius.com .

Devices bearing the CSA label satisfy the requirements of the relevant standards for Canada and the USA.

1. Safety Instructions

• backing up any changes made to the factory settings
• saving and storing personal settings

1. Safety Instructions

Copyright of these operating instructions remains with the manufacturer.

Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information on any discrepancies in the operating instructions.

TWIN welding systems are used exclusively with automated MIG/MAG applications, e.g.:

• in rail vehicle manufacturing for longitudinal seams and profiles
• in shipbuilding for fillet welds and profiles
• in vehicle manufacturing for lap joints and wheel rim welding
• in automotive engineering
• in container construction for butt welds, longitudinal seams, lap joints and circumferential welds
• in plant construction for V, X and fillet welds
• in lifting devices for corner seams
• in earth-moving equipment and in special machine building for HV and fillet welds
• in overlay welding

1. General information

TWIN welding systems are used exclusively with automated MIG/MAG applications, e.g.:

• in rail vehicle manufacturing for longitudinal seams and profiles
• in shipbuilding for fillet welds and profiles
• in vehicle manufacturing for lap joints and wheel rim welding
• in automotive engineering
• in container construction for butt welds, longitudinal seams, lap joints and circumferential welds
• in plant construction for V, X and fillet welds
• in lifting devices for corner seams
• in earth-moving equipment and in special machine building for HV and fillet welds
• in overlay welding

1. General information
2. General

TWIN welding systems are used exclusively with automated MIG/MAG applications, e.g.:

• in rail vehicle manufacturing for longitudinal seams and profiles
• in shipbuilding for fillet welds and profiles
• in vehicle manufacturing for lap joints and wheel rim welding
• in automotive engineering
• in container construction for butt welds, longitudinal seams, lap joints and circumferential welds
• in plant construction for V, X and fillet welds
• in lifting devices for corner seams
• in earth-moving equipment and in special machine building for HV and fillet welds
• in overlay welding

1. General information

TWIN welding torch
+ Fixing bracket
+ Index disk

MTB 2x500i PA or PB
+ OPT/i MTB xx° sym.
or
MTB 900i PA or PB

CrashBox

TWIN hosepack
MHP 2x500 A W/FSC
+ TWIN Basic Kit (depending on material and wire diameter)

TWIN wirefeeder
WF 30i R /TWIN

Wirefeeder holder
WF MOUNTING TWIN

Interconnecting hosepacks
1 x HP 95i CON /W /xx m
+
1 x HP 95i CON /G /xx m

2 x wirefeeding hose (max. 3 m)
or
2 x Fronius PowerLiner (max. 10 m)

2 x welding machine
TPS 500i / 600i
+ Welding Package Pulse
+ Firmware official_TPSi_2.2.3-20789.15069.ffw and higher

Cooling unit
CU 2000i Pro /MC (2-part)

TWIN Controller
RI FB Pro/i TWIN Controller
+ Firmware official_robpro-1.8.xx-svn6108_official

2 x return lead cable

1. General information
2. Requirements

TWIN welding torch
+ Fixing bracket
+ Index disk

MTB 2x500i PA or PB
+ OPT/i MTB xx° sym.
or
MTB 900i PA or PB

CrashBox

TWIN hosepack
MHP 2x500 A W/FSC
+ TWIN Basic Kit (depending on material and wire diameter)

TWIN wirefeeder
WF 30i R /TWIN

Wirefeeder holder
WF MOUNTING TWIN

Interconnecting hosepacks
1 x HP 95i CON /W /xx m
+
1 x HP 95i CON /G /xx m

2 x wirefeeding hose (max. 3 m)
or
2 x Fronius PowerLiner (max. 10 m)

2 x welding machine
TPS 500i / 600i
+ Welding Package Pulse
+ Firmware official_TPSi_2.2.3-20789.15069.ffw and higher

Cooling unit
CU 2000i Pro /MC (2-part)

TWIN Controller
RI FB Pro/i TWIN Controller
+ Firmware official_robpro-1.8.xx-svn6108_official

2 x return lead cable

1. General information
2. Requirements

TWIN welding torch
+ Fixing bracket
+ Index disk

MTB 2x500i PA or PB
+ OPT/i MTB xx° sym.
or
MTB 900i PA or PB

CrashBox

TWIN hosepack (with TWIN drive unit WF 60i TWIN Drive)
MHP 2x450i RD/W/FSC
+ Toothed drive roller CMT
+ Toothed pressure roller CMT

TWIN wirefeeder
WF 30i R /TWIN
+ OPT/i WF TWIN R Push Pull

Wirefeeder holder

Interconnecting hosepacks
1 x HP 95i CON /W /xx m
+
1 x HP 95i CON /G /xx m

2 x wirefeeding hose (max. 3 m)
or
2 x Fronius PowerLiner (max. 10 m)

2 x welding machine
TPS 500i / 600i
+ Welding Package Pulse
+ Firmware official_TPSi_3.2.0-xxxxx.xxxxx.ffw and higher

Cooling unit
CU 2000i Pro /MC (2-part)

TWIN Controller
RI FB Pro/i TWIN Controller
+ Firmware official_robpro-1.8.0

2 x return lead cable

1. General information
2. Requirements

TWIN welding torch
+ Fixing bracket
+ Index disk

MTB 2x500i PA or PB
+ OPT/i MTB xx° sym.
or
MTB 900i PA or PB

CrashBox

TWIN hosepack (with TWIN drive unit WF 60i TWIN Drive)
MHP 2x450i RD/W/FSC
+ Toothed drive roller CMT
+ Toothed pressure roller CMT

TWIN wirefeeder
WF 30i R /TWIN
+ OPT/i WF TWIN R Push Pull

Wirefeeder holder

TWIN wire buffer set

Interconnecting hosepacks
1 x HP 95i CON /W /xx m
+
1 x HP 95i CON /G /xx m

2 x wirefeeding hose (max. 3 m)
or
2 x Fronius PowerLiner (max. 10 m)

2 x welding machine
TPS 500i / 600i
+ Welding Package Standard
+ Welding Package Pulse
+ Welding Package CMT
+ Firmware official_TPSi_3.2.0-xxxxx.xxxxx.ffw and higher

Cooling unit
CU 2000i Pro /MC (2-part)

TWIN Controller
RI FB Pro/i TWIN Controller
+ Firmware official_robpro-1.8.0

2 x return lead cable

1. General information
2. Requirements

The following mechanical requirements must be met in order to achieve a stable and reproducible TWIN welding process:

• Precise welding torch guidance by robots or single-purpose machines (e.g. longitudinal chassis)
• Exact weld preparation
• Low component tolerances

1. General information
2. Requirements

• Cables of the welding circuit laid correctly
• The max. inductance in the welding circuit must not exceed 35 µH.

1. General information
2. Requirements

• Software version min. 2.2.3 (TWIN Push) or min. 3.2.30 (TWIN Push/Pull, CMT)
• Both welding machines must have the same software status
• The IP addresses must be set correctly on the welding machines

1. General information
2. Requirements

• Payload and rated torques of the robot must be designed for the weight of all mounted system components:
  welding torch, hose package, wire feed, robot fixtures, etc.
• The CrashBox must be designed accordingly.
• Wirefeeding hoses must be laid in such a way that the movements of the robot and the wirefeed are not influenced (e.g. laying the wirefeeding hoses via balancers in the robot cell).

1. General information
2. Requirements

The use of the following devices is recommended in order to increase the system availability:

Robacta TSS /i
welding torch service station

Robacta Reamer TWIN/Single
mechanical torch cleaning device, can be used for all base materials such as steel, aluminum, CrNi steels, copper, etc.

Robacta TC 2000 TWIN
electromagnetic torch cleaning device for ferromagnetic base materials

TXi TWIN
torch body change system
(only for TWIN Push welding systems)

1. General information
2. Requirements

Use a separate return lead cable for each welding machine:

A - Separate return lead cable

B - Shared return lead cable, grounding bridge

C - Return lead cable laid in loops

D - Return lead cable coiled

Further information on connecting the return lead cable can be found from page (→).

1. General information
2. Requirements

1. General information

• Two wire electrodes (4) and (5) are welded in a weld pool in a shielding gas environment.
• The welding process is carried out via two independent welding machines (1) and (2).
  The welding machines are synchronized by the TWIN Controller.
• The wirefeed is carried out via a wirefeeder (3) with two drive units.
• The two wire electrodes are brought together in the welding torch so that there are two independent welding potentials (6).

1. General information
2. Functional principle

• Two wire electrodes (4) and (5) are welded in a weld pool in a shielding gas environment.
• The welding process is carried out via two independent welding machines (1) and (2).
  The welding machines are synchronized by the TWIN Controller.
• The wirefeed is carried out via a wirefeeder (3) with two drive units.
• The two wire electrodes are brought together in the welding torch so that there are two independent welding potentials (6).

1. General information
2. Functional principle

In the TWIN welding process, the two welding machines are referred to as the lead welding machine and trail welding machine.

• The lead welding machine is defined by the welding direction.
• During pulsed-arc welding, the lead welding machine stipulates the frequency for the trail welding machine.
• When viewed in the direction of welding, the wire electrode of the lead welding machine is the front wire electrode.
• If the welding direction changes and the torch position remains the same, the trail welding device becomes the lead welding device.
• The robot controls define lead and trail using 2 bits. Depending on the result of this process, lead or trail will also be displayed on the welding machine.

1. General information

1. General information
2. System configurations

1. General information
2. System configurations

1. General information
2. System configurations

Single wire application

WF 30i TWIN
+ MHP TWIN torch hosepack
+ TXi torch body coupling
+ Adapter TWIN-MTB Single
+ MTB Single welding torch
-------------------------------------------------------
= single wire application

With a TXi TWIN welding torch change station and the corresponding torch body couplings, an automated changeover from a TWIN welding torch to a single welding torch and vice versa can be performed.

Single wire application for different additive materials or different wire diameters

WF 30i TWIN
+ MHP TWIN torch hosepack
+ TXi torch body coupling
+ 2x adapter TWIN-MTB Single
+ 2x MTB Single welding torch
-------------------------------------------------------
= single wire application
(e.g., for different additional materials or different wire diameters)

The single welding torches must be equipped according to the wire electrode to be conveyed.
Before changing the welding line, the current wire electrode must be withdrawn and the single welding torches must be replaced.

1. System components

The wirefeeder WF 30i R /TWIN has been specially designed for automated applications in connection with a MIG/MAG TWIN welding process.

The standard 4-roller drive offers excellent wire feeding properties.

1. System components
2. WF 30i R /TWIN

The wirefeeder WF 30i R /TWIN has been specially designed for automated applications in connection with a MIG/MAG TWIN welding process.

The standard 4-roller drive offers excellent wire feeding properties.

1. System components
2. WF 30i R /TWIN

The device is intended exclusively for wirefeeding in automated MIG/MAG welding in combination with Fronius system components. Any other use does not constitute proper use. The manufacturer accepts no liability for any damage resulting from improper use.

Proper use also means:

• Reading these Operating Instructions in their entirety
• Following all instructions and safety rules in these Operating Instructions
• Carrying out all the specified inspection and servicing work

1. System components
2. WF 30i R /TWIN

The wirefeeder has safety symbols and a rating plate fitted. These safety symbols and the rating plate must not be removed or painted over. The safety symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage to property.

Do not use the functions described here until you have fully read and understood the following documents:

• These operating instructions
• All system component operating instructions, especially the safety rules

Welding is dangerous. To ensure that this device can be used correctly and safely, the following basic requirements must be met:

• Adequate welding qualifications
• Appropriate protective equipment
• Keep unauthorized people away from the wirefeeder and the welding process

Dispose of old devices in accordance with safety rules and not in normal domestic waste.

Keep hands, hair, loose clothing, and tools away from moving parts, such as:

Do not reach into rotating gears of the wire drive or into rotating drive parts.

Covers and side panels must only be opened/removed during maintenance and repair work.

• Gears
• Feed rollers
• Wire spools and wire electrodes

• Ensure that all covers are closed, and all side parts have been mounted properly.
• Keep all covers and side parts closed.

1. System components
2. WF 30i R /TWIN

Warning notices are attached to the device for certain device versions.

The arrangement of the symbols may vary.

1. System components

G = gas-cooled interconnecting hosepack, W = water-cooled interconnecting hosepack

The interconnecting hosepacks connect the welding machines to the TWIN wirefeeder or the two robot wirefeeders.
In TWIN welding systems, one water-cooled and one gas-cooled interconnecting hosepack are used.

1. System components
2. Interconnecting hosepack

G = gas-cooled interconnecting hosepack, W = water-cooled interconnecting hosepack

The interconnecting hosepacks connect the welding machines to the TWIN wirefeeder or the two robot wirefeeders.
In TWIN welding systems, one water-cooled and one gas-cooled interconnecting hosepack are used.

1. System components

The water-cooled TWIN torch hosepack connects

• the TWIN wirefeeder to the TWIN welding torch
  or
• the two robot wirefeeders to the TWIN welding torch

For TWIN Push/Pull and TWIN CMT applications, the TWIN drive unit is integrated into the torch hosepack.

1. System components
2. Torch hosepack

The water-cooled TWIN torch hosepack connects

• the TWIN wirefeeder to the TWIN welding torch
  or
• the two robot wirefeeders to the TWIN welding torch

For TWIN Push/Pull and TWIN CMT applications, the TWIN drive unit is integrated into the torch hosepack.

1. System components
2. Torch hosepack

MHP 2x500i R/W/FSC hosepack
TWIN Push

MHP 2x450i RD/W/FSC hosepack with WF 60i TWIN Drive drive unit
TWIN Push/Pull, TWIN CMT

• Inner liners
• Inlet nozzles
• Drive- and pressure rollers

1. System components

The CrashBox is a protection device for the torch body and the torch body coupling.
In the event of a collision, the CrashBox emits a signal to the robot controls, which causes the robot controls to stop the robot immediately. Due to the welding torch holder of the CrashBox, the welding torch and the installed system components are protected from damage in the event of a collision.

The magnetic coupling of the CrashBox allows for a low-force deflection with large deflection path in the event of a crash.

Example: CrashBox /i with clamp system, installed on the robot arm (TWIN Push)

The clamp system is used to hold the TWIN welding torch for TWIN Push systems.
With the index disk corresponding to the torch body curvature, the clamp system positions the welding torch so that the TCP is in the 6th axis.

A robot-specific, insulating robot flange is required for the installation of the CrashBox.

1. System components
2. CrashBox

The CrashBox is a protection device for the torch body and the torch body coupling.
In the event of a collision, the CrashBox emits a signal to the robot controls, which causes the robot controls to stop the robot immediately. Due to the welding torch holder of the CrashBox, the welding torch and the installed system components are protected from damage in the event of a collision.

The magnetic coupling of the CrashBox allows for a low-force deflection with large deflection path in the event of a crash.

Example: CrashBox /i with clamp system, installed on the robot arm (TWIN Push)

The clamp system is used to hold the TWIN welding torch for TWIN Push systems.
With the index disk corresponding to the torch body curvature, the clamp system positions the welding torch so that the TCP is in the 6th axis.

A robot-specific, insulating robot flange is required for the installation of the CrashBox.

1. System components
2. CrashBox

1. System components
2. CrashBox

1. System components
2. CrashBox

Depending on the respective robot:

• 1 x robot flange with screws

Robot flange as per price list

1. System components
2. CrashBox

Scope of supply CrashBox /i XXL (TWIN Push)

Scope of supply CrashBox /d TWIN (TWIN Push/Pull, CMT)

1. System components
2. CrashBox

1. System components
2. CrashBox

1. System components
2. CrashBox

The drive unit support is available with 30° and with 45°.

1. System components

Example: MTB 900i

The water-cooled MTB 2x500i R and MTB 900i R robot welding torches transfer the arc power to the workpiece. The TWIN welding torches are designed for use with the CrashBox /i XXL and are available in two versions:

MTB 900i R
The robust MTB 900i R is suitable for TWIN applications in harsh environments with a non-changing contact tip tilt angle.

MTB 2x500i R
The MTB 2x500i R is designed for the application of different contact tip tilt angles; for details see from page (→).
Two wear part systems are available for the MTB 2x500i R:

"Spatter Guard" wear part system—standard for all filler metals

"Sleeve" wear part system—for steel applications only, optional

The welding torches are delivered fully assembled with all wear parts.

The following components are required in order to fit the robot welding torch to the hosepack without an automatic TXi TWIN torch body change system:

• 42,0001,4833 Connector M52x1.5/M55x1.5
• 42,0001,4832 Nut TWIN TX M55x1.5
• 42,0407,0834 Shaft circlip SW50

1. System components
2. Robot welding torch

Example: MTB 900i

The water-cooled MTB 2x500i R and MTB 900i R robot welding torches transfer the arc power to the workpiece. The TWIN welding torches are designed for use with the CrashBox /i XXL and are available in two versions:

MTB 900i R
The robust MTB 900i R is suitable for TWIN applications in harsh environments with a non-changing contact tip tilt angle.

MTB 2x500i R
The MTB 2x500i R is designed for the application of different contact tip tilt angles; for details see from page (→).
Two wear part systems are available for the MTB 2x500i R:

"Spatter Guard" wear part system—standard for all filler metals

"Sleeve" wear part system—for steel applications only, optional

The welding torches are delivered fully assembled with all wear parts.

The following components are required in order to fit the robot welding torch to the hosepack without an automatic TXi TWIN torch body change system:

• 42,0001,4833 Connector M52x1.5/M55x1.5
• 42,0001,4832 Nut TWIN TX M55x1.5
• 42,0407,0834 Shaft circlip SW50

1. System components
2. Robot welding torch

Example:
Tilt angle of the contact tips toward each other = 11.5°

Depending on the application, different tilt angles of the contact tips toward each other of 0°, 4°, 8°, and 11.5° are available for the MTB 2x500i R welding torches.

Corresponding assembly components are required for each angle:

0°	OPT/i MTB TWIN 0.0° sym.
4°	OPT/i MTB TWIN 4.0° sym.
8°	OPT/i MTB TWIN 8.0° sym
11.5°	OPT/i MTB TWIN 11.5° sym.

Details of the assembly components can be found under the adjacent link in the Fronius online spare parts catalog. https://spareparts.fronius.com Search: MTB 2x500

The following assembly components are included in the OPT/i MTB TWIN xx°:

(1)	1 x gas nozzle
(2)	2 x insulating sleeve*
(3)	2 x nozzle fitting
(4)	1 x gas distributor
(5)	4 x cylinder head screws M2.5 x 16 mm
(6)	2 x nozzle fitting holder

*	The insulating sleeves are not included in the OPT/i MTB TWIN xx° Sleeve option.

Application recommendations for the tilt angles of the contact tips can be found from page (→) onwards.

1. System components

(A) hosepack side, (B) torch body side, 1 = welding line 1, 2 = welding line 2

With the aid of the TWIN-MTB Single adapter, the TWIN welding system can be operated with a single torch body.
The adapter combines gas and compressed air lines as well as the wirefeeding lines of both welding lines. The coolant lines are run and the current paths of both welding lines are merged into one.

The weld line is defined by inserting the inner liner into the respective wire inlet on the TWIN-MTB Single adapter.

If there is a torch body change system in the welding system, the changeover from the TWIN welding torch to the single welding torch and vice versa can also be automated.

1. System components
2. TWIN-MTB Single adapter

(A) hosepack side, (B) torch body side, 1 = welding line 1, 2 = welding line 2

With the aid of the TWIN-MTB Single adapter, the TWIN welding system can be operated with a single torch body.
The adapter combines gas and compressed air lines as well as the wirefeeding lines of both welding lines. The coolant lines are run and the current paths of both welding lines are merged into one.

The weld line is defined by inserting the inner liner into the respective wire inlet on the TWIN-MTB Single adapter.

If there is a torch body change system in the welding system, the changeover from the TWIN welding torch to the single welding torch and vice versa can also be automated.

Gas control

Set the same gas flow volume on both welding machines.
The entire gas flow volume must be a total of approx. 25–30 l/min.

Example:
gas flow volume = 30 l/min
==> set welding machine 1 to 15 l/min and welding machine 2 to 15 l/min

TWIN welding torch/TWIN mode:
both solenoid valves are switched

TWIN welding torch/single wire mode:
both solenoid valves are switched

Single welding torch with adapter (TXi interchangeable coupling optional):
one solenoid valve is switched
(solenoid valve for the welding machine selected by the robot controls)

Gas pre-flow/gas post-flow with TWIN welding torch:
the same value should generally be set on both welding machines.
If the values are different, the larger value is automatically applied to both welding machines.

1. Welding Technology Aspects

Gas control

Set the same gas flow volume on both welding machines.
The entire gas flow volume must be a total of approx. 25–30 l/min.

Example:
gas flow volume = 30 l/min
==> set welding machine 1 to 15 l/min and welding machine 2 to 15 l/min

TWIN welding torch/TWIN mode:
both solenoid valves are switched

TWIN welding torch/single wire mode:
both solenoid valves are switched

Single welding torch with adapter (TXi interchangeable coupling optional):
one solenoid valve is switched
(solenoid valve for the welding machine selected by the robot controls)

Gas pre-flow/gas post-flow with TWIN welding torch:
the same value should generally be set on both welding machines.
If the values are different, the larger value is automatically applied to both welding machines.

1. Welding Technology Aspects
2. Welding Technology Aspects

Gas control

Set the same gas flow volume on both welding machines.
The entire gas flow volume must be a total of approx. 25–30 l/min.

Example:
gas flow volume = 30 l/min
==> set welding machine 1 to 15 l/min and welding machine 2 to 15 l/min

TWIN welding torch/TWIN mode:
both solenoid valves are switched

TWIN welding torch/single wire mode:
both solenoid valves are switched

Single welding torch with adapter (TXi interchangeable coupling optional):
one solenoid valve is switched
(solenoid valve for the welding machine selected by the robot controls)

Gas pre-flow/gas post-flow with TWIN welding torch:
the same value should generally be set on both welding machines.
If the values are different, the larger value is automatically applied to both welding machines.

1. Welding Technology Aspects
2. Welding Technology Aspects

IMPORTANT! The R/L comparison must be carried out separately for each welding machine.

R = welding circuit resistance [mOhm]
L = welding circuit inductivity [µH]

1. Welding Technology Aspects
2. Welding Technology Aspects

Work angle of welding torch neutral to slightly leading

Select the work angle of the welding torch so that the lead wire electrode (= wire electrode of the lead welding machine) is in a neutral to slightly leading position.

Approx. 90–100° for steel applications

Approx. 100–115° for aluminum applications

1. Welding Technology Aspects
2. Welding Technology Aspects

Stick out (SO ) and distance of the wire electrodes depending on the diameter (D) of the wire electrode:

D [mm / inch]	SO [mm / inch]
1.0/0.039	15/0.591
1.2/0.047	17/0.669
1.4/0.055	18/0.709
1.6/0.063	21/0.827

(1)	Wire electrode 1
(2)	Contact tip 1
(3)	Gas nozzle
(4)	Contact tip 2
(5)	Wire electrode 2

1. Welding Technology Aspects
2. Welding Technology Aspects

By material:

According to seam geometry (for steel):

According to general criteria:

1. Welding Technology Aspects
2. Welding Technology Aspects

L = Lead wire electrode, T = Trail wire electrode

1. Both wire electrodes move towards the workpiece
2. Both wire electrodes make contact with the workpiece
3. The lead wire electrode starts the welding process, the trail wire electrode moves away from the workpiece and waits for the start signal of the lead wire electrode = welding start delay
4. As soon as the trail wire electrode receives the start signal, it also starts the welding process

A CMT TWIN welding process requires a WF 60i TWIN Drive unit and a wire buffer.

In conjunction with a WF 60i TWIN Drive unit, all TWIN characteristics ignite according to the above sequence.

1. Welding Technology Aspects
2. Welding Technology Aspects

The robot controls use the signals "Operating mode TWIN System Bit 0" and "Operating mode TWIN System Bit 1" to define

• the lead and trail process line in TWIN mode
• the active process line in single wire mode

1. Welding Technology Aspects

Only PMC TWIN characteristics with the following properties are available for the TWIN welding process:

Universal
Characteristic packages for conventional welding tasks

The characteristics are optimized for a wide range of applications in synchronized TWIN welding.
The pulse synchronization ratio and the lead/trail phase shift are supported, provided that a TWIN universal characteristic is in use at both welding machines.

Multi arc
Characteristic packages for conventional welding tasks

The characteristics are optimized for synchronized TWIN welding with multiple welding systems and reduce the mutual influence of multiple welding machines.
The pulse synchronization ratio and the lead/trail phase shift are supported, provided that a TWIN multi arc characteristic is in use at both welding machines.

PCS (Pulse Controlled Sprayarc)
These characteristics combine the advantages of pulse and standard arcs in one characteristic: a concentrated pulse arc passes directly into a short spray arc; the intermediate arc is blanked out.
The characteristic curve does not support synchronization.

Overlay welding
The characteristics are optimized for synchronized TWIN overlay welding.

A special current profile ensures a wide arc with optimized weld flow and low dilution.
The pulse synchronization ratio and the lead/trail phase shift are supported, provided that a TWIN Universal or a TWIN multi arc characteristic is in use at both welding machines.

Root
Characteristics for root passes

The characteristics are optimized for CMT welding at the lead and trail electrode.

IMPORTANT! The same TWIN characteristic must be selected on both process lines.

Prerequisites for using a PMC TWIN characteristic:

• Pulse welding package on both welding machines
• Both welding machines must be connected to the TWIN Controller

1. Welding Technology Aspects
2. TWIN Characteristics

Only PMC TWIN characteristics with the following properties are available for the TWIN welding process:

Universal
Characteristic packages for conventional welding tasks

The characteristics are optimized for a wide range of applications in synchronized TWIN welding.
The pulse synchronization ratio and the lead/trail phase shift are supported, provided that a TWIN universal characteristic is in use at both welding machines.

Multi arc
Characteristic packages for conventional welding tasks

The characteristics are optimized for synchronized TWIN welding with multiple welding systems and reduce the mutual influence of multiple welding machines.
The pulse synchronization ratio and the lead/trail phase shift are supported, provided that a TWIN multi arc characteristic is in use at both welding machines.

PCS (Pulse Controlled Sprayarc)
These characteristics combine the advantages of pulse and standard arcs in one characteristic: a concentrated pulse arc passes directly into a short spray arc; the intermediate arc is blanked out.
The characteristic curve does not support synchronization.

Overlay welding
The characteristics are optimized for synchronized TWIN overlay welding.

A special current profile ensures a wide arc with optimized weld flow and low dilution.
The pulse synchronization ratio and the lead/trail phase shift are supported, provided that a TWIN Universal or a TWIN multi arc characteristic is in use at both welding machines.

Root
Characteristics for root passes

The characteristics are optimized for CMT welding at the lead and trail electrode.

IMPORTANT! The same TWIN characteristic must be selected on both process lines.

Prerequisites for using a PMC TWIN characteristic:

• Pulse welding package on both welding machines
• Both welding machines must be connected to the TWIN Controller

1. Welding Technology Aspects
2. TWIN Characteristics

PR = Process

Stahl:

Metal Cored (flux core wire):

CrNi 19 9/19 12 3:

CrNi 18 8/18 8 6:

NiCrMo-3:

AlMg4.5 Mn (Zr):

AlMg 5:

AlSi 5:

1. Welding Technology Aspects
2. TWIN Characteristics

The SlagHammerfunction is implemented in all PMC Twin and CMT Twin characteristics.
In conjunction with a TWIN drive unit WF 60i TWIN Drive, slag is knocked off the weld seam and wire electrode end by a reversing wire movement without arc before welding.
Knocking off the slag ensures reliable and precise ignition of the arc.

A wire buffer is not required for the SlagHammerfunction.
The SlagHammerfunction is automatically executed for PMC Twin and CMT Twin characteristics.

1. Welding Technology Aspects

* activation required

IMPORTANT! There are no TWIN characteristics available for Pulse or Standard welding processes.
Welding process combinations using Pulse or Standard are not recommended!

1. Welding Technology Aspects
2. TWIN Welding Processes

* activation required

IMPORTANT! There are no TWIN characteristics available for Pulse or Standard welding processes.
Welding process combinations using Pulse or Standard are not recommended!

1. Welding Technology Aspects
2. TWIN Welding Processes

The following symbols are used in the descriptions of the TWIN welding processes below:

	Trail wire electrode
	Lead wire electrode
	Active PMC arc with droplet transfer
	Inactive PMC arc (no droplet transfer)
	Active PCS arc
	CMT weld pool
	CMT droplet melting phase
	CMT start of arcing phase
	CMT droplet detachment
IL	Welding current of the lead welding machine
IT	Welding current of the trail welding machine
	Welding direction

1. Welding Technology Aspects
2. TWIN Welding Processes

Welding current time curves and schematic representation of the material transition
P = phase shift

Time coordination of the welding machines
The PMC processes of the two process lines are synchronized with each other. This ensures a stable, consistent tandem welding process.
The relative position of the pulses/droplet detachment is stored in the characteristic but can also be freely selected.

Significantly different outputs at lead and trail wire electrode
The TPS/i TWIN welding system enables significantly different outputs or wire speeds to be used, even during synchronized PMC tandem processes.
A significantly higher output is usually selected at the lead wire electrode than at the trail wire electrode.
This results in:

• Targeted heat input
• The cold parent material melts well
• Exact recording of the root pass
• Trail wire electrode fills up the weld pool
• Extension of the gas release time (reduced proneness to porosity)
• High welding speed

IMPORTANT! Only PMC TWIN characteristics synchronize.
For synchronization, a TWIN universal, a TWIN multi arc, or a TWIN cladding characteristic must be used on the lead and trail wire electrode respectively.
A combination of PMC Single characteristics and PMC TWIN characteristics (lead/trail or trail/lead) does not lead to synchronization.

1. Welding Technology Aspects
2. TWIN Welding Processes

Welding current time curves and schematic representation of the material transition

PCS TWIN characteristics are predominantly used in order to weld with a modified spray arc at the lead wire electrode and a pulsed arc at the trail wire electrode.
Pulse synchronization is not activated when a PCS TWIN characteristic is used.

Advantages:

• High penetration by the standard arc of the lead wire electrode
• Large seam cross sections possible
• Large difference in the wire feeding speeds possible
• Visually pleasing weld seams due to the pulsed arc of the trail wire electrode

1. Welding Technology Aspects
2. TWIN Welding Processes

Schematic representation of the material transition

Advantages:

• Deep penetration of the lead wire electrode
• High deposition rate at the lead wire electrode
• Very good seam filling due to the trail wire electrode
• High process stability

The TWIN welding process PMC TWIN / CMT TWIN can be used for both welding directions.

1. Welding Technology Aspects
2. TWIN Welding Processes

Schematic representation of the material transition

In this process variant, the same characteristics are used for both wire electrodes.
The arc of the lead wire electrode is shorter than that of the trail wire electrode. This results in a higher output on the lead wire electrode.
The arc of the trail wire electrode is specifically matched to the weld pool.

The TWIN welding process CMT TWIN / CMT TWIN can be used for both welding directions.

1. Welding Technology Aspects
2. TWIN Welding Processes

Welding current time curves and schematic representation of the material transition for the lead welding machine

PMC/Pulse

LSC/Standard

CMT

Welding current time curves and schematic representation of the material transition for the trail welding machine

PMC/Pulse

LSC/Standard

CMT

Single wire welding
In single wire welding, a signal is emitted by the robot controls, meaning that only one welding machine welds.
Depending on the torch position or restricted position of the weld, single wire welding can be carried out by the lead or trail welding machine. The second welding machine pauses.

PMC, Pulse, LSC, Standard, and CMT arcs are possible during single wire welding as long as the appropriate welding package is available on the welding machine. It is not necessary to change the welding torch.

• When welding very tight radii
• When welding in difficult positions and restricted positions
• To fill up end-craters
• If there has been a switch to a single welding torch on the welding torch change station

1. Welding Technology Aspects

The following TWIN process parameters are available at the welding machines in TWIN mode under Process parameters / TWIN process control:

For PMC TWIN / PMC TWIN

For PMC TWIN / CMT TWIN

For CMT TWIN / CMT TWIN

Further TWIN process parameters

• Pulse synchronization ratio *
• Lead/trail phase shift *
  

1. Welding Technology Aspects
2. TWIN Process Parameters

The following TWIN process parameters are available at the welding machines in TWIN mode under Process parameters / TWIN process control:

For PMC TWIN / PMC TWIN

For PMC TWIN / CMT TWIN

For CMT TWIN / CMT TWIN

Further TWIN process parameters

• Pulse synchronization ratio *
• Lead/trail phase shift *
  

1. Welding Technology Aspects
2. TWIN Process Parameters

When this function is activated, the ignition point of the trail arc always depends on the present phase of the lead arc. The start parameters of the trail arc are automatically adapted to the prevailing conditions of the lead arc.
The trail arc starts without contact in TWIN Push systems and with a synchronized SFI (spatter-free ignition) in TWIN Push/Pull systems.
As a result, the start of the trail arc is significantly smoother and failed ignitions are avoided or their number reduced.

Automatic (auto) mode implements an optimum ignition delay.

When set manually, an ignition delay of 0–2 seconds can be set. The start of the trail arc is synchronized.

The function can be deactivated. In this case, the trail arc is ignited immediately and is not synchronized.

Information on the welding machine display

1. Welding Technology Aspects
2. TWIN Process Parameters

Adjustment range: auto, 1/1, 1/2, 1/3
Factory setting: auto

Only active if the same PMC TWIN characteristic is set for both wire electrodes.

The pulse synchronization ratio enables both process lines to be operated with significantly different wire speeds.
In the case of greater differences in output, the pulse frequency is adjusted in such a way that it differs between lead and trail by an integral multiple. Only every second or every third pulse is then executed for the trail arc, for example.

The characteristic for automatic ("auto") mode contains an optimum frequency ratio based on the wire speed values for both process lines. The wire speed can be set separately for each process line.

When setting the frequency ratio manually, the value can be set on both welding machines independently. The value set on the trail welding machine is applied to the process.

Information on the welding machine display

1. Welding Technology Aspects
2. TWIN Process Parameters

Adjustment range: auto, 0–95%
Factory setting: auto

Only active if the same PMC TWIN characteristic is set for both wire electrodes.

Lead/trail phase shift enables the time of droplet detachment to be freely selected for the trail arc. As the trail droplet detachment does not have to take place in the quiescent current phase of the lead arc, an arc blow between the two arcs can be counteracted.

In automatic ("auto") mode, the characteristics contain the optimum location of the two main current phases in relation to one another and this can change along the characteristic.

When set manually, the phase shift can be set between the two pulses as a percentage of the period duration. The adjustment range of 0–95% corresponds to a phase shift of 0–342°.

Information on the welding machine display

1. Welding Technology Aspects

SynchroPulse is available for all process (Standard / Pulse / LSC / PMC).
The cyclic change of the welding power between two operating points with SynchroPulse achieves a finely rippled weld appearance and a non-continuous heat input.

1. Welding Technology Aspects
2. TWIN SynchroPulse

SynchroPulse is available for all process (Standard / Pulse / LSC / PMC).
The cyclic change of the welding power between two operating points with SynchroPulse achieves a finely rippled weld appearance and a non-continuous heat input.

1. Welding Technology Aspects
2. TWIN SynchroPulse

From the firmware version "official_TPSi_4.0.0-xxxxx.xxxxx.ffw", SynchroPulse can also be used in a TWIN welding process.

For TWIN SynchroPulse, the SynchroPulse parameters Frequency and DutyCycle (high) are set and specified at the lead welding machine.
The settings for Frequency and DutyCycle (high) at the trail welding machine have no effect.

The remaining welding parameters can be selected differently on both process lines.

1. Welding Technology Aspects

Shielding gas and filler metal used:

a-dimension [mm]	Lead (L) Trail (T)	Wire speed [m/min]	Welding current [A]	Welding voltage [V]	Welding speed [cm/min]	Energy per unit length [kJ/cm]	Deposition rate [kg/h]	Sheet thickness [mm]	Micrograph/macro
3.5	L T	21.0 11.2	378 230	24.1 27.8	250	3.7	16.5	3
4.0	L T	22.5 15.0	394 326	27.3 29.7	200	6.1	19.2	6
4.5	L T	22.0 13.0	414 302	28.6 27.9	160	7.5	17.9	6
5.0	L T	24.0 15.0	430 325	27.8 27.5	125	10.0	19.9	8
6.0	L T	23.0 12.5	430 301	26.8 27.5	90	13.2	18.2	10
7.0	L T	26.2 12.0	409 273	27.6 30.0	78	15.0	19.5	10
8.0	L T	24.6 10.1	451 259	27.6 27.9	60	19.6	17.7	15
8.5	L T	20.0 10.0	369 238	24.9 27.4	45	20.9	15.3	15
9.0	L T	22.5 9.5	429 258	27.0 26.9	40	26.5	16.4	15

1. Welding Technology Aspects
2. TWIN Push welding parameter standard values

Shielding gas and filler metal used:

a-dimension [mm]	Lead (L) Trail (T)	Wire speed [m/min]	Welding current [A]	Welding voltage [V]	Welding speed [cm/min]	Energy per unit length [kJ/cm]	Deposition rate [kg/h]	Sheet thickness [mm]	Micrograph/macro
3.5	L T	21.0 11.2	378 230	24.1 27.8	250	3.7	16.5	3
4.0	L T	22.5 15.0	394 326	27.3 29.7	200	6.1	19.2	6
4.5	L T	22.0 13.0	414 302	28.6 27.9	160	7.5	17.9	6
5.0	L T	24.0 15.0	430 325	27.8 27.5	125	10.0	19.9	8
6.0	L T	23.0 12.5	430 301	26.8 27.5	90	13.2	18.2	10
7.0	L T	26.2 12.0	409 273	27.6 30.0	78	15.0	19.5	10
8.0	L T	24.6 10.1	451 259	27.6 27.9	60	19.6	17.7	15
8.5	L T	20.0 10.0	369 238	24.9 27.4	45	20.9	15.3	15
9.0	L T	22.5 9.5	429 258	27.0 26.9	40	26.5	16.4	15

1. Welding Technology Aspects
2. TWIN Push welding parameter standard values

Shielding gas and filler metal used:

a-dimension [mm]	Lead (L) Trail (T)	Wire speed [m/min]	Welding current [A]	Welding voltage [V]	Welding speed [cm/min]	Energy per unit length [kJ/cm]	Deposition rate [kg/h]	Sheet thickness [mm]	Micrograph/macro
3.5	L T	18.0 10.0	397 241	23.2 26.2	210	4.4	14.3	3
4.0	L T	20.0 11.0	396 266	27.8 29.7	150	6.8	15.9	6
4.5	L T	23.5 11.2	362 229	24.8 26.5	130	6.8	17.7	6
5.0	L T	20.5 11.0	392 253	25.7 26.2	120	8.4	16.1	8
5.5	L T	21.5 12.0	389 268	26.5 28.1	100	10.4	17.1	10
6.0	L T	22.0 12.0	392 266	27.0 28.2	90	12.1	17.4	10

1. Welding Technology Aspects

Shielding gas and filler metal used:

a-dimension [mm]	Lead (L) Trail (T)	Wire speed [m/min]	Welding current [A]	Welding voltage [V]	Welding speed [cm/min]	Energy per unit length [kJ/cm]	Deposition rate [kg/h]	Sheet thickness [mm]	Micrograph/macro
2.3	L T	7.5 3.5	215 105	23.4 21.6	200	2.4	5.8	1.5
3.0	L T	11.6 5.0	285 150	25.0 22.5	180	3.7	8.2	2.0
3.7	L T	12.5 8.0	304 220	26.1 23.6	150	5.5	10.2	3.0

1. Welding Technology Aspects
2. TWIN Push/Pull welding parameter standard values

Shielding gas and filler metal used:

a-dimension [mm]	Lead (L) Trail (T)	Wire speed [m/min]	Welding current [A]	Welding voltage [V]	Welding speed [cm/min]	Energy per unit length [kJ/cm]	Deposition rate [kg/h]	Sheet thickness [mm]	Micrograph/macro
2.3	L T	7.5 3.5	215 105	23.4 21.6	200	2.4	5.8	1.5
3.0	L T	11.6 5.0	285 150	25.0 22.5	180	3.7	8.2	2.0
3.7	L T	12.5 8.0	304 220	26.1 23.6	150	5.5	10.2	3.0

1. Welding Technology Aspects
2. TWIN Push/Pull welding parameter standard values

Shielding gas and filler metal used:

a-dimension [mm]	Lead (L) Trail (T)	Wire speed [m/min]	Welding current [A]	Welding voltage [V]	Welding speed [cm/min]	Energy per unit length [kJ/cm]	Deposition rate [kg/h]	Sheet thickness [mm]	Micrograph/macro
-	L T	7.0 6.5	210 195	23.2 23.0	245	2.7	7.0	1.5
-	L T	8.5 7.0	225 210	23.8 23.2	220	3.5	7.7	2.0
-	L T	12.0 8.5	298 225	25.8 23.8	230	4.1	9.7	3.0

1. Welding Technology Aspects

Shielding gas and filler metal used:

a-dimension [mm]	Lead (L) Trail (T)	Wire speed [m/min]	Welding current [A]	Welding voltage [V]	Welding speed [cm/min]	Energy per unit length [kJ/cm]	Deposition rate [kg/h]	Sheet thickness [mm]	Micrograph/macro
1.8	L T	10.5 7.5	295 233	18.5 17.2	330	1.68	8.78	1.5
2.5	L T	10.0 7.5	258 233	24.5 17.2	300	2.34	9.16	2.0
2.5	L T	11.5 8.0	291 244	25.4 17.5	260	3.03	10.2	3.0

1. Welding Technology Aspects
2. TWIN CMT welding parameter standard values

Shielding gas and filler metal used:

a-dimension [mm]	Lead (L) Trail (T)	Wire speed [m/min]	Welding current [A]	Welding voltage [V]	Welding speed [cm/min]	Energy per unit length [kJ/cm]	Deposition rate [kg/h]	Sheet thickness [mm]	Micrograph/macro
1.8	L T	10.5 7.5	295 233	18.5 17.2	330	1.68	8.78	1.5
2.5	L T	10.0 7.5	258 233	24.5 17.2	300	2.34	9.16	2.0
2.5	L T	11.5 8.0	291 244	25.4 17.5	260	3.03	10.2	3.0

1. Welding Technology Aspects
2. TWIN CMT welding parameter standard values

Shielding gas and filler metal used:

a-dimension [mm]	Lead (L) Trail (T)	Wire speed [m/min]	Welding current [A]	Welding voltage [V]	Welding speed [cm/min]	Energy per unit length [kJ/cm]	Deposition rate [kg/h]	Sheet thickness [mm]	Micrograph/macro
-	L T	11.5 9.0	291 266	25.4 18.0	515	1.54	9.68	1.5
-	L T	12.0 9.5	298 285	25.8 18.0	480	1.77	10.7	2.0
-	L T	11.5 9.0	291 278	25.4 17.7	300	2.7	10.1	3.0
-	L T	18.0 11.0	370 295	31.0 18.5	290	4.15	14.9	4.0

1. Operating controls, connections and mechanical components

1. Operating controls, connections and mechanical components
2. WF 30i R /TWIN

1. Operating controls, connections and mechanical components
2. WF 30i R /TWIN

1. Operating controls, connections and mechanical components
2. WF 30i R /TWIN

1. Operating controls, connections and mechanical components
2. WF 30i R /TWIN

Operating status LED

Lights up green when the device is ready for operation

Gas-test button

After pressing the gas-test button, gas is released for 30 s. Pressing the button again will end the process prematurely.

Wire-return button

There are two options available for retracting the wire electrode:

Option 1
Withdraw wire electrode at the preset wire return speed:

• Press and hold the wire-return button
• After pressing the wire-return button, the wire electrode is retracted by 1 mm (0.039 in.)
• After a brief pause, the wirefeeder continues retracting the wire electrode – if the wire-return button is kept pressed down, then the speed increases with each further second by 10 m/min (393.70 ipm) until the preset wire-return speed is reached

Option 2
Withdraw wire electrode in 1 mm steps (0.039 in. steps)

• Always press (touch) the wire-return button for less than 1 second

Wire-threading button

There are two options available for the wire threading:

Option 1
Thread the wire electrode at the preset feeder inching speed:

• Press and hold the wire-threading button
• After pressing the wire-threading button, the wire electrode will be threaded in by 1 mm (0.039 in.)
• After a brief pause, the wirefeeder continues threading in the wire electrode – if the wire-threading button is kept pressed down, then the speed increases with each further second by 10 m/min (393.70 ipm) until the preset feeder inching speed is reached
• If the wire electrode meets a ground earth connection, then the wirefeeding is stopped and the wire electrode is retracted again by 1 mm (0.039 in.)

Option 2
Thread the wire electrode in 1 mm steps (0.039 in. steps)

• Always press (touch) the wire-threading button for less than 1 second
• If the wire electrode meets a ground earth connection, then the wirefeeding is stopped and the wire electrode is retracted again by 1 mm (0.039 in.)

1. Operating controls, connections and mechanical components
2. WF 30i R /TWIN

1. Operating controls, connections and mechanical components

1. Operating controls, connections and mechanical components
2. MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W

1. Operating controls, connections and mechanical components
2. MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W

Mechanical components on the WF 60i TWIN Drive drive unit

(1)	Drive roller and clamping lever – welding line 1
(2)	Contact pressure adjustment unit For adjusting the contact pressure for both lines
(3)	Wirefeeding hose 1 lock
(4)	External wirefeeding hose 1 connection
(5)	External wirefeeding hose 2 connection
(6)	Wirefeeding hose 2 lock

1. Operating controls, connections and mechanical components
2. MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W

Control panel on the WF 60i TWIN Drive drive unit

(1)	Wire-return button* Retracts the wire electrode without gas or current
(2)	Gas-test button* For setting the required gas volume on the gas pressure regulator
(3)	Wire-threading button* For threading the wire electrode into the torch hosepack without gas or current
(4)	LEDs 1/2/TWIN/External Light up when the respective mode is selected

1. Operating controls, connections and mechanical components

W = water-cooled interconnecting hosepack
G = gas-cooled interconnecting hosepack

(1)	SpeedNet cable
(2)	Coolant hoses
(3)	Protective gas shield hose
(4)	Power cable

1. Operating controls, connections and mechanical components
2. Interconnecting hosepack

W = water-cooled interconnecting hosepack
G = gas-cooled interconnecting hosepack

(1)	SpeedNet cable
(2)	Coolant hoses
(3)	Protective gas shield hose
(4)	Power cable

1. Operating controls, connections and mechanical components

(A) Hosepack side (B) Torch body side

1. Operating controls, connections and mechanical components
2. TWIN-MTB Single adapter

(A) Hosepack side (B) Torch body side