LogoTPS/i Robotics TWIN
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    • Legal Notice
    • General Terms & Conditions
    • Data Privacy Statement
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    • 021-03062025
    • Safety Instructions
      • Explanation of warnings and safety instructions
      • General
      • Intended Use
      • Environmental Conditions
      • Obligations of the Operating Company
      • Obligations of Personnel
      • Grid Connection
      • Personal Protection and Protection of Others
      • Danger from toxic gases and vapors
      • Danger from Flying Sparks
      • Risks from mains current and welding current
      • Stray welding currents
      • EMC Device Classifications
      • EMC measures
      • EMF measures
      • Particular hazard areas
      • Requirement for the shielding gas
      • Danger from Shielding Gas Cylinders
      • Danger Posed by Shielding Gas Leak
      • Safety Measures at the Setup Location and during Transport
      • Safety Measures in Normal Operation
      • Maintenance and repair
      • Safety inspection
      • Safety symbols
      • Data backup
      • Copyright
    • General information
      • General
        • Application areas
      • Requirements
        • TWIN Push minimum equipment
        • TWIN Push/Pull minimum equipment
        • TWIN CMT minimum equipment
        • Mechanical requirements
        • Electrical Requirements
        • Software requirements
        • Dimensioning of the robot
        • Measures to increase system availability
        • Ground connection
        • Note about the wirefeed
      • Functional principle
        • Operating principle
        • Lead welding machine and trail welding machine
      • System configurations
        • TWIN Push system overview
        • TWIN Push/Pull, CMT system overview
        • More configuration options
    • System components
      • WF 30i R /TWIN
        • Device concept
        • Intended Use
        • Warning notices on the device
        • Description of the warnings on the device
      • Interconnecting hosepack
        • Interconnecting hosepack
      • Torch hosepack
        • General
        • Scope of supply
      • CrashBox
        • General
        • Note on the correct operation of CrashBoxes
        • Note on the repair of CrashBoxes
        • Also required for the installation
        • Scope of supply
        • Scope of supply clamp system (TWIN Push)
        • Scope of supply index disk (TWIN Push)
        • Scope of supply drive unit support (TWIN Push/Pull, CMT)
      • Robot welding torch
        • Robot welding torches
        • MTB 2x500i R - contact tip tilt angle
      • TWIN-MTB Single adapter
        • TWIN-MTB Single adapter
    • Welding Technology Aspects
      • Welding Technology Aspects
        • Shielding gases for TWIN welding processes
        • Performing R/L alignment
        • Work angle of the welding torch
        • Stick out
        • Application recommendations for the tilt angles of the contact tips
        • Welding start sequence for CMT TWIN
        • TWIN operating mode
      • TWIN Characteristics
        • General
        • Available TWIN characteristics
        • SlagHammer
      • TWIN Welding Processes
        • TWIN welding processes—overview
        • Symbols
        • PMC TWIN / PMC TWIN
        • PCS TWIN / PCS TWIN
        • PMC TWIN / CMT TWIN
        • CMT TWIN / CMT TWIN
        • Single wire (with a TWIN welding torch):
          PMC/Pulse/LSC/Standard/CMT
      • TWIN Process Parameters
        • TWIN process parameters
        • Trail ignition delay
        • Pulse synchronization ratio
        • Lead/trail phase shift
      • TWIN SynchroPulse
        • SynchroPulse welding
        • TWIN SynchroPulse
      • TWIN Push welding parameter standard values
        • Standard values for fillet welds, welding position PA
        • Standard values for fillet welds, PB welding position
      • TWIN Push/Pull welding parameter standard values
        • Standard values for fillet welds, PB welding position
        • Standard values for lap joints, welding position PB
      • TWIN CMT welding parameter standard values
        • Standard values for fillet welds, PB welding position
        • Standard values for lap joints, welding position PB
    • Operating controls, connections and mechanical components
      • WF 30i R /TWIN
        • Safety
        • Wirefeeder front
        • Wirefeeder Side
        • Function of the gas-test, wire-return, and wire-threading buttons
        • Wirefeeder rear
      • MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W
        • Safety
        • MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W – mechanical components
        • MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W – control panel
      • Interconnecting hosepack
        • Interconnecting Hosepack—Connections
      • TWIN-MTB Single adapter
        • TWIN-MTB Single adapter – connectors
    • Installing the system components - TWIN Push
      • Safety—Installation and Commissioning
        • Safety
        • Insulated guiding of the wire electrode to the wirefeeder
      • Before installation and initial operation
        • Setup regulations
        • Installation overview
      • Install TWIN Wirefeeder and Accessories on the Robot
        • Installing the wirefeeder on the robot
        • Installing the side holders for the interconnecting hosepacks on the robot
      • Lay, Install and Connect Interconnecting Hosepacks
        • Connecting the interconnecting hosepacks to the wirefeeder
        • Connect the interconnecting hosepacks to the welding machine, cooling unit, and TWIN Controller
      • Install CrashBox, Torch Hosepack and TWIN Welding Torch
        • Mounting the CrashBox /i on the robot
        • Mounting the CrashBox /i Dummy on the robot
        • Installing the inner liner in the torch hosepack
        • Installing the torch hosepack
        • Mounting the torch body on the TWIN torch hosepack
        • Installing the torch body coupling
        • Checking the function of the torch body coupling
    • Installing the system components - TWIN Push/Pull, CMT
      • Safety—Installation and Commissioning
        • Safety
        • Insulated guiding of the wire electrode to the wirefeeder
      • Before installation and initial operation
        • Setup regulations
        • Installation—overview of TWIN Push/Pull, CMT
      • Mounting the balancer mounting on the Y-piece
        • Mounting the balancer mounting on the Y-piece
      • Mounting the support Y-piece on the robot
        • Mounting the support Y-piece on the robot
      • Installing the side holder on the robot
        • Installing the side holder on the robot
      • Installing wire buffers on the robot
        • TWIN-CMT - installing wire buffers on the robot
      • Install CrashBox, Torch Hosepack and TWIN Welding Torch
        • Mounting the CrashBox /d TWIN on the robot
        • Mounting the CrashBox TWIN Drive /i Dummy on the robot
        • Installing the torch hosepack with TWIN drive unit
        • Connecting the torch hosepack to the wirefeeder
        • Installing anti-kink protection rings
        • Mounting the torch body on the TWIN drive unit
      • Fitting the wirefeeding hoses and inner liners
        • Inserting the inner liner into the torch hosepack
      • Preparing the TWIN drive unit for operation
        • General
        • Basic Kits overview
        • Inserting/changing the feed rollers on the TWIN drive unit
        • Connecting wirefeeding hoses
    • Installing and preparing other system components, commissioning
      • Installing the robot welding torch
        • Inserting steel inner liner into the torch body
        • Inserting plastic inner liner into the torch body
        • Installing wear parts in the TWIN welding torch
        • Inserting the inner liner in the TWIN-MTB Single adapter
      • Preparing TWIN Wirefeeder for Operation
        • Inserting/changing feed rollers
        • Connecting wirefeeding hoses
        • Wire straightener
      • Lay, Install and Connect Interconnecting Hosepacks
        • Connecting interconnecting hosepacks to the robot wirefeeders
        • Connect the interconnecting hosepacks to the welding machine, cooling unit, and TWIN Controller
      • Connect TWIN Controller
        • Connect the TWIN Controller with the welding machines and connect the interconnecting hosepack
        • Connecting the TWIN Controller to the robot controls
      • Connecting the Protective Gas Shield and Grounding Cable
        • Connecting Protective Gas Shield
        • Connecting the return lead cable
      • Commissioning
        • Threading the wire electrode
        • Setting the contact pressure
        • Threading the wire electrode
        • Setting the contact pressure on the TWIN drive unit
        • Requirements
        • Commissioning - start of welding
    • Troubleshooting, Maintenance, and Disposal
      • Troubleshooting
        • Safety
        • Troubleshooting
        • Displayed Error Codes
      • Service, maintenance and disposal
        • General
        • Safety
        • At every start-up
        • Daily
        • Identifying defective wearing parts
        • Weekly
        • Monthly
        • Every 6 months
        • Disposal
    • Technical data
      • TWIN wirefeeder
        • WF 30i R /TWIN
      • Robot welding torch
        • MTB 900i R
        • MTB 2x500i R
        • MTB 2x500i R - dimensions depending on contact tip tilt angle
        • Water-cooled robot welding torches
      • Torch hosepack
        • MHP 2x500i R/W/FSC
        • MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W
      • Interconnecting hosepacks
        • HP 70i
        • HP 70i, HP PC Cable HD 70
        • HP 95i
        • HP 120i
      • CrashBox /i XXL
        • CrashBox /i XXL - technical data & triggering torques and weight-distance diagram
      • CrashBox /d TWIN
        • CrashBox /d TWIN - technical data & triggering torques and weight-distance diagram

    TPS/i Robotics TWIN Operating instructions

    System overview
    System requirements and minimum equipment
    Operating controls and connections
    Installation and commissioning
    Troubleshooting
    Maintenance
    Technical data
    Spare parts

    Safety Instructions

    Explanation of warnings and safety instructions

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

    DANGER!

    Indicates an immediately dangerous situation

    Serious injury or death will result if appropriate precautions are not taken.

    Action step to escape the situation

    WARNING!

    Indicates a potentially dangerous situation

    Death or serious injury may result if appropriate precautions are not taken.

    Action step to escape the situation

    CAUTION!

    Indicates a potentially dangerous situation

    Minor or moderate injury may result if appropriate precautions are not taken.

    Action step to escape the situation

    NOTE!

    Indicates impaired work results and/or damage to the device and components

    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

    Explanation of warnings and safety instructions

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

    DANGER!

    Indicates an immediately dangerous situation

    Serious injury or death will result if appropriate precautions are not taken.

    Action step to escape the situation

    WARNING!

    Indicates a potentially dangerous situation

    Death or serious injury may result if appropriate precautions are not taken.

    Action step to escape the situation

    CAUTION!

    Indicates a potentially dangerous situation

    Minor or moderate injury may result if appropriate precautions are not taken.

    Action step to escape the situation

    NOTE!

    Indicates impaired work results and/or damage to the device and components

    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

    General

    The device has been manufactured using state-of-the-art technology and according to recognized safety standards. If used incorrectly or misused, however, it can cause
    • 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
    All persons involved in the commissioning, operation, maintenance, and servicing of the device must
    • 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.

    All safety and danger notices on the device must
    • 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

    Intended Use

    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."

    Proper use also means
    • 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
    Never use the device for the following applications:
    • 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

    Environmental Conditions

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

    Temperature range of the ambient air:
    • 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)
    Relative humidity:
    • 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

    Obligations of the Operating Company

    The operating company must only allow persons to work with the device if they
    • 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

    Obligations of Personnel

    All persons who are assigned to work with the device must do the following before beginning the work:
    • 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

    Grid Connection

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

    This may affect a number of device types in terms of:
    • 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

    Personal Protection and Protection of Others

    You are exposed to numerous hazards while handling the device, for example:
    • 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
    Wear suitable protective clothing when dealing with the device. The protective clothing must have the following properties:
    • Flame resistant
    • Insulating and dry
    • Covering the entire body and in good condition with no damage
    • Safety helmet
    • Cuffless pants
    Protective clothing involves the following:
    • 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
    Keep persons, especially children, away during the operation of the devices and during the welding process. If persons are in the vicinity, however:
    • 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

    Danger from toxic gases and vapors

    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.

    Take the following precautionary measures for fumes and harmful 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 following components are factors that determine how toxic the welding fumes are:
    • 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

    Danger from Flying Sparks

    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

    Risks from mains current and welding current

    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.

    Concerning the electrode (stick electrode, tungsten electrode, welding wire, etc.)
    • 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.

    After opening the device:
    • 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

    Stray welding currents

    If the following instructions are not observed, stray welding currents may occur, which pose a risk of the following:
    • 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

    EMC Device Classifications

    Devices in emission class A:
    • Are only designed for use in industrial settings
    • Can cause line-bound and radiated interference in other areas
    Devices in emission class B:
    • 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

    EMC measures

    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.

    Test and assess the immunity of equipment in the vicinity of the device in accordance with national and international provisions. Examples of interference-prone equipment that could be affected by the device:
    • Safety devices
    • Grid power lines, signal lines, and data transfer lines
    • IT and telecommunications equipment
    • Devices for measuring and calibrating
    Supporting measures to avoid EMC problems:
    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

    EMF measures

    Electromagnetic fields may cause health problems that are not yet known:
    • 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

    Particular hazard areas

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

    During operation
    • 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

    Requirement for the shielding gas

    Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality.
    Meet the following requirements regarding shielding gas quality:
    • Solid particle size < 40 µm
    • Pressure condensation point < -20 °C
    • Max. oil content < 25 mg/m³

    Use filters if necessary.

    1. Safety Instructions

    Danger from Shielding Gas Cylinders

    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

    Danger Posed by Shielding Gas Leak

    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

    Safety Measures at the Setup Location and during Transport

    A toppling device can be deadly! Set up the device securely on an even, solid surface
    • The maximum permitted tilt angle is 10°.
    Special regulations apply in areas at risk of fire or explosion
    • 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.

    Before transporting a welding system (e.g., with a trolley, cooling unit, welding machine, and wirefeeder), completely drain the coolant and dismantle the following components:
    • 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

    Safety Measures in Normal Operation

    Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a danger of:
    • 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

    Maintenance and repair

    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

    Safety inspection

    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.

    A safety inspection by a certified electrician is recommended:
    • 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

    Safety symbols

    Devices with the CE label meet the requirements of all valid EU Directives, such as:
    • 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

    Data backup

    With regard to data security, the user is responsible for:
    • backing up any changes made to the factory settings
    • saving and storing personal settings
    1. Safety Instructions

    Copyright

    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.

    General information

    General

    Application areas

    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

    General

    Application areas

    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

    Application areas

    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

    Requirements

    TWIN Push minimum equipment

    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 Push minimum equipment

    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 Push/Pull minimum equipment

    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 CMT minimum equipment

    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

    Mechanical 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

    Electrical 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 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

    Dimensioning of the robot

    Observe the following points during the dimensioning of the robot:
    • 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

    Measures to increase system availability

    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

    Ground connection

    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


    NOTE!

    When establishing a ground earth connection, observe the following points:

    Use a separate return lead cable for each welding machine—see Figure A

    Keep positive cables and return lead cables together as long and as close as possible

    Physically separate the welding circuits of individual welding machines

    Do not route several return lead cables in parallel
    If parallel routing cannot be avoided, keep a minimum distance of 30 cm between the welding circuits

    Keep the return lead cables as short as possible and use cables with a large cross-section

    Do not cross over return lead cables

    Avoid ferromagnetic materials between the return lead cables and the interconnecting hosepack

    Do not wind up long return lead cables—coil effect!

    Route long return lead cables in loops—see Figure C

    Do not route return lead cables in iron pipes, metal cable trays, or along steel beams, avoid cable ducts
    Routing positive cables and return lead cables together in an iron pipe does not cause any problems

    If several return lead cables are being used, separate the grounding points on the component as far as possible and do not allow crossed current paths between the individual arcs

    Use compensated interconnecting hosepacks (interconnecting hosepacks with integrated return lead cable)

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

    1. General information
    2. Requirements

    Note about the wirefeed

    NOTE!

    The use of wire drums is required for a faultless working process.

    1. General information

    Functional principle

    Operating 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

    Operating 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

    Lead welding machine and trail welding machine

    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

    System configurations

    TWIN Push system overview

    (1)
    Welding wire drum
    Depending on the application, two WFi R REEL unwinding wirefeeders can be used additionally for optimal wirefeeding
    (2)
    Wirefeeding hoses
    (3)
    Robot control
    (4)
    Connection cable from robot controls to RI FB Pro/i TWIN Controller
    (5)
    Connection cable from robot controls to TWIN welding torch change station
    (6)
    Welding machine 1: TPS 500i / 600i
    + WP Pulse
    + RI FB Pro/i TWIN Controller
    + Cooling unit CU 2000i / part 1
    + Remote control RC Panel Pro
    + TU podium (screwed in place)
    (7)
    Welding machine 2: TPS 500i / 600i
    + WP Pulse
    + Cooling unit CU 2000i / part 2
    + Remote control RC Panel Pro
    + TU podium (screwed in place)
    (8)
    SpeedNet cable from RI FB Pro/i TWIN Controller to welding machine 1
    (9)
    SpeedNet cable from RI FB Pro/i TWIN Controller to welding machine 2
    (10)
    HP 95i CON /G /10 m interconnecting hosepack
    (11)
    HP 95i CON /W /10 m interconnecting hosepack
    (12)
    Robot
    (13)
    Wirefeeder WF 30i R /TWIN
    + WF Mounting wirefeeder holder
    + TWIN Basic Kit
    (14)
    MHP 2x500 A W/FSC TWIN hosepack
    (15)
    CrashBox /i XXL
    + Fixing bracket
    + Index disk
    (16)
    MTB 2x500i PA welding torch
    + OPT/i MTB 11.5° sym.
    (17)
    TWIN welding torch change station TXi TWIN
    (18)
    Connection cable from robot controls to welding torch service station
    (19)
    Robacta TSS /i welding torch service station
    1. General information
    2. System configurations

    TWIN Push system overview

    (1)
    Welding wire drum
    Depending on the application, two WFi R REEL unwinding wirefeeders can be used additionally for optimal wirefeeding
    (2)
    Wirefeeding hoses
    (3)
    Robot control
    (4)
    Connection cable from robot controls to RI FB Pro/i TWIN Controller
    (5)
    Connection cable from robot controls to TWIN welding torch change station
    (6)
    Welding machine 1: TPS 500i / 600i
    + WP Pulse
    + RI FB Pro/i TWIN Controller
    + Cooling unit CU 2000i / part 1
    + Remote control RC Panel Pro
    + TU podium (screwed in place)
    (7)
    Welding machine 2: TPS 500i / 600i
    + WP Pulse
    + Cooling unit CU 2000i / part 2
    + Remote control RC Panel Pro
    + TU podium (screwed in place)
    (8)
    SpeedNet cable from RI FB Pro/i TWIN Controller to welding machine 1
    (9)
    SpeedNet cable from RI FB Pro/i TWIN Controller to welding machine 2
    (10)
    HP 95i CON /G /10 m interconnecting hosepack
    (11)
    HP 95i CON /W /10 m interconnecting hosepack
    (12)
    Robot
    (13)
    Wirefeeder WF 30i R /TWIN
    + WF Mounting wirefeeder holder
    + TWIN Basic Kit
    (14)
    MHP 2x500 A W/FSC TWIN hosepack
    (15)
    CrashBox /i XXL
    + Fixing bracket
    + Index disk
    (16)
    MTB 2x500i PA welding torch
    + OPT/i MTB 11.5° sym.
    (17)
    TWIN welding torch change station TXi TWIN
    (18)
    Connection cable from robot controls to welding torch service station
    (19)
    Robacta TSS /i welding torch service station
    1. General information
    2. System configurations

    TWIN Push/Pull, CMT system overview

    (1)
    Robot control
    (2)
    Connection cable from robot controls to RI FB Pro/i TWIN Controller
    (3)
    Connection cable from robot controls to welding torch service station
    (4)
    SpeedNet cable from RI FB Pro/i TWIN Controller to welding machine 1
    (5)
    Welding machine 1
    + Welding Package Pulse
    + Welding Package CMT
    + RI FB Pro/i TWIN Controller
    + Cooling unit CU 2000i / part 1
    + Remote control RC Panel Pro
    + TU podium (screwed in place)
    (6)
    SpeedNet cable from RI FB Pro/i TWIN Controller to welding machine 2
    (7)
    HP 95i CON /W /10 m interconnecting hosepack
    (8)
    Welding machine 2
    + Welding Package Pulse
    + Welding Package CMT
    + Cooling unit CU 2000i / part 2
    + Remote control RC Panel Pro
    + TU podium (screwed in place)
    (9)
    HP 95i CON /G /10 m interconnecting hosepack
    (10)
    Welding wire drum 2
    (11)
    Welding wire drum 1
    Depending on the application, two WFi R REEL unwinding wirefeeders can be used additionally for optimal wirefeeding.
    (12)
    OPT/i WF Tower
    + Mounting WF Twin Tower (12a)
    (13)
    TWIN wirefeeder WF 30i R /TWIN
    + OPT/i WF TWIN PushPull
    (14)
    MHP 2x450i RD/W/FSC (with TWIN drive unit WF 60i TWIN Drive)
    + Toothed pressure roller CMT
    + Fixing bracket
    (15)
    Wirefeeding hose 1
    WF 30i R /TWIN - Wire buffer 1
    (16)
    Control cable wire buffer 1
    (17)
    Wirefeeding hose 2
    WF 30i R /TWIN - Wire buffer 2
    (18)
    Control cable wire buffer 2
    (19)
    Robot
    (20)
    Robot support Y-piece **
    (21)
    TWIN wire buffer set *
    (required for TWIN CMT applications)
    (22)
    CrashBox /d TWIN
    (23)
    MTB 2x500i PA welding torch
    + OPT/i MTB 11.5° sym.
    (24)
    Robacta TSS /i welding torch service station
    *
    Instead of mounting the wire buffers on the side of the robot, they can also be suspended from a balancer.
    **
    The balancer mounting Y-piece can also be used instead of the robot support Y-piece.
    1. General information
    2. System configurations

    More configuration options

    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.

    System components

    WF 30i R /TWIN

    Device concept

    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

    WF 30i R /TWIN

    Device concept

    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

    Device concept

    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

    Intended Use

    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

    Warning notices on the device

    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
    During operation
    • 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

    Description of the warnings on the device

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

    The arrangement of the symbols may vary.

    !
    Warning! Caution!
    The symbols represent possible dangers.
    A
    Drive rollers can injure fingers.
    B
    The welding wire and drive parts are under welding voltage during operation.
    Keep hands and metal objects away!
    1.
    An electric shock can be fatal.
    1.1
    Wear dry, insulating gloves. Do not touch the wire electrode with bare hands. Do not wear wet or damaged gloves.
    1.2
    Use a base that is insulated from the floor and work area to protect against electric shock.
    1.3
    Before working on the device, switch off the device and remove the mains plug or disconnect the power supply.
    2.
    Inhalation of welding fumes can be harmful to health.
    2.1
    Keep your face away from any welding fumes.
    2.2
    Use forced-air ventilation or local extraction to remove welding fumes.
    2.3
    Remove welding fumes with a fan.
    3.
    Welding sparks can cause an explosion or fire.
    3.1
    Keep flammable materials away from the welding process. Do not perform welding near flammable materials.
    3.2
    Welding sparks can cause a fire. Have fire extinguishers ready. If necessary, have a supervisor ready who can operate the fire extinguisher.
    3.3
    Do not weld on drums or closed containers.
    4.
    Arc rays can burn the eyes and injure the skin.
    4.1
    Wear headgear and protective goggles. Use ear protection and wear a shirt collar with button. Use a welding helmet with the correct tinting. Wear suitable protective clothing over the entire body.
    5.
    Before working on the machine or welding:
    undertake training on the device and read the instructions!
    6.
    Do not remove or paint over the sticker with the warnings.
    *
    Manufacturer order number of the sticker
    1. System components

    Interconnecting hosepack

    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
    2. Interconnecting hosepack

    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

    Torch hosepack

    General

    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

    General

    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

    Scope of supply

    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
    Not included in the scope of supply:
    • Inner liners
    • Inlet nozzles
    • Drive- and pressure rollers
    1. System components

    CrashBox

    General

    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

    General

    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

    Note on the correct operation of CrashBoxes

    NOTE!

    To avoid damage to the welding torch or the torch hosepack, or to prevent false triggering of the CrashBox, consider the following points:

    Avoid strong accelerations and maximum speeds during robot movements.

    Ensure the free movement of the torch hosepack during all robot movements;
    The torch hosepack must not tighten in any position and thus exert a strain on the CrashBox.

    The torch hosepack must not whip around or get stuck when moving.

    If possible, check all movement situations with Fronius system components in a simulation as early as the concept phase.

    1. System components
    2. CrashBox

    Note on the repair of CrashBoxes

    NOTE!

    Only complete CrashBoxes should be sent for repair!

    Incomplete CrashBoxes (e.g. without magnetic ring) cannot be checked in the course of a repair.

    1. System components
    2. CrashBox

    Also required for the installation

    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

    Scope of supply CrashBox /i XXL (TWIN Push)
    Scope of supply CrashBox /d TWIN (TWIN Push/Pull, CMT)
    (1)
    CrashBox /i holder
    (2)
    1-ear clamp *
    (3)
    Locking ring, 2-part *
    (4)
    Bellows
    (5)
    Cylinder head screws M4 x 16 mm
    (6)
    Magnetic ring
    *
    Mounted on bellows (4) on delivery

    NOTE!

    Do not assemble the CrashBox /i holder (1) and magnetic ring (6) before installing on the robot.

    It is difficult to separate the components afterwards due to the strong magnetism.

    1. System components
    2. CrashBox

    Scope of supply clamp system (TWIN Push)

    1. System components
    2. CrashBox

    Scope of supply index disk (TWIN Push)

    1. System components
    2. CrashBox

    Scope of supply drive unit support (TWIN Push/Pull, CMT)

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

    1. System components

    Robot welding torch

    Robot welding torches

    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:

    PA
    with contact tips arranged one over the other,
    welding torch angle 30° or 45°
    PB
    with contact tips arranged next to each other,
    welding torch angle 30° or 45°

    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

    Robot welding torches

    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:

    PA
    with contact tips arranged one over the other,
    welding torch angle 30° or 45°
    PB
    with contact tips arranged next to each other,
    welding torch angle 30° or 45°

    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

    MTB 2x500i R - contact tip tilt angle

    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

    NOTE!

    The tilt angle-dependent dimensions of the welding torch can be found in the technical data from page (→).

    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

    TWIN-MTB Single adapter

    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.

    NOTE!

    When operating a single welding torch on a TWIN welding system, observe the maximum welding current and the duty cycle (D.C.) of the single welding torch.

    1. System components
    2. TWIN-MTB Single adapter

    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.

    NOTE!

    When operating a single welding torch on a TWIN welding system, observe the maximum welding current and the duty cycle (D.C.) of the single welding torch.

    Welding Technology Aspects

    Welding Technology Aspects

    Shielding gases for TWIN welding processes

    Material

    Shielding gas

    Non-alloyed and low-alloy steels

    ArCO2, ArO2 and ArCO2O2 mixtures

    CrNi steels, high-alloy steels

    ArCO2 mixtures, proportion of active gas max. 2.5%
    ArO2 mixtures, proportion of active gas max. 3%
    ArCO2He mixtures, proportion of active gas max. 8%

    Aluminum

    Ar (99.9%), ArHe mixtures

    Nickel-based alloys

    Ar (100%), Ar+0.5-3% CO2 or ArHeCO2H2 mixtures


    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

    Welding Technology Aspects

    Shielding gases for TWIN welding processes

    Material

    Shielding gas

    Non-alloyed and low-alloy steels

    ArCO2, ArO2 and ArCO2O2 mixtures

    CrNi steels, high-alloy steels

    ArCO2 mixtures, proportion of active gas max. 2.5%
    ArO2 mixtures, proportion of active gas max. 3%
    ArCO2He mixtures, proportion of active gas max. 8%

    Aluminum

    Ar (99.9%), ArHe mixtures

    Nickel-based alloys

    Ar (100%), Ar+0.5-3% CO2 or ArHeCO2H2 mixtures


    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

    Shielding gases for TWIN welding processes

    Material

    Shielding gas

    Non-alloyed and low-alloy steels

    ArCO2, ArO2 and ArCO2O2 mixtures

    CrNi steels, high-alloy steels

    ArCO2 mixtures, proportion of active gas max. 2.5%
    ArO2 mixtures, proportion of active gas max. 3%
    ArCO2He mixtures, proportion of active gas max. 8%

    Aluminum

    Ar (99.9%), ArHe mixtures

    Nickel-based alloys

    Ar (100%), Ar+0.5-3% CO2 or ArHeCO2H2 mixtures


    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

    Performing R/L alignment

    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 the welding torch

    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

    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
    *
    The distance of the wire electrodes depending on the tilt angle of the contact tips and the stick out can be found in the technical data from page (→).
    1. Welding Technology Aspects
    2. Welding Technology Aspects

    Application recommendations for the tilt angles of the contact tips

    By material:

    Application

    Tilt angle

    0°

    4°

    8°

    11.5°

    Aluminum

     

     

     

    x1)
    x2)

    Steel ferritic

    x1)

    x1)

    x1)
    x2)

    x1)

    Austenitic steel, CrNi

     

     

    x2)

    x1)

     

     

     

     

     

    1)
    Lead/trail = PMC TWIN/PMC TWIN or PCS TWIN/PMC TWIN
    2)
    Lead/trail = PMC TWIN/CMT TWIN or CMT TWIN/CMT TWIN

    According to seam geometry (for steel):

    Application

    Tilt angle

    0°

    4°

    8°

    11.5°

    Fillet weld - thin sheet (< 3 mm/0.12 inch)

     

     

    x

    x 

    Fillet weld - thick sheet (> 3 mm/0.12 inch)

    x

    x 

     

     

    BUTT WELD

    x

    x 

     

    x

    Lap joint
    (high welding speed, small weld pools)

     

     

     

    x 

    According to general criteria:

    Application

    Tilt angle

    0°

    4°

    8°

    11.5°

    high welding speed for thin sheet applications

     

     

    x

    x

    high welding speed for thick sheet applications

    x

    x

    x

    Penetration - thin sheet

    x

    x

    Penetration - thick sheet

    x

    x

    x

    1. Welding Technology Aspects
    2. Welding Technology Aspects

    Welding start sequence for CMT TWIN

    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

    TWIN operating mode

    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

    TWIN Characteristics

    General

    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

    General

    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

    Available TWIN characteristics

    PR = Process

    Stahl:

    No.
    PR

    Wire diameter

    Shielding gas

    Property

    4256
    CMT

    0.9 mm

    C1 CO2 100%

    TWIN universal

    4257
    CMT

    0.9 mm

    M21 Ar + 15–20% CO2

    TWIN universal

    4258
    CMT

    0.9 mm

    M20 Ar + 5–10% CO2

    TWIN universal

    3940
    PMC

    1.0 mm

    M21 Ar + 15–20% CO2

    TWIN universal

    4019
    PMC

    1.0 mm

    M20 Ar + 5–10% CO2

    TWIN universal

    4251
    CMT

    1.0 mm

    M21 Ar + 15–20% CO2

    TWIN universal

    4254
    CMT

    1.0 mm

    M20 Ar + 8–10% CO2

    TWIN universal

    4255
    CMT

    1.0 mm

    C1 CO2 100%

    TWIN universal

    3564
    PMC

    1.2 mm

    M21 Ar + 15–20% CO2

    TWIN universal

    3565
    PMC

    1.2 mm

    M20 Ar + 5–10% CO2

    TWIN universal

    4200
    CMT

    1.2 mm

    M21 Ar + 15–20% CO2

    TWIN universal

    4221
    CMT

    1.2 mm

    C1 CO2 100%

    TWIN universal

    4250
    CMT

    1.2 mm

    M20 Ar + 5–10% CO2

    TWIN universal

    3892
    PMC

    1.3 mm

    M20 Ar + 5–10% CO2

    TWIN universal

    3845
    PMC

    1.4 mm

    M21 Ar + 15–20% CO2

    TWIN universal

    3734
    PMC

    1.6 mm

    M21 Ar + 15–20% CO2

    TWIN universal

    3735
    PMC

    1.6 mm

    M20 Ar + 5–10% CO2

    TWIN universal

    4018
    PMC

    1.0 mm

    M21 Ar + 15–20% CO2

    TWIN PCS

    4020
    PMC

    1.0 mm

    M20 Ar + 5–10% CO2

    TWIN PCS

    3833
    PMC

    1.2 mm

    M21 Ar + 15–20% CO2

    TWIN PCS

    3834
    PMC

    1.2 mm

    M20 Ar + 5–10% CO2

    TWIN PCS

    3893
    PMC

    1.3 mm

    M20 Ar + 5–10% CO2

    TWIN PCS

    3846
    PMC

    1.4 mm

    M21 Ar + 15–20% CO2

    TWIN PCS

    3840
    PMC

    1.6 mm

    M21 Ar + 15–20% CO2

    TWIN PCS

    3841
    PMC

    1.6 mm

    M20 Ar + 5–10% CO2

    TWIN PCS

    4021
    PMC

    1.0 mm

    M21 Ar + 15–20% CO2

    TWIN multi arc

    4023
    PMC

    1.0 mm

    M20 Ar + 5–10% CO2

    TWIN multi arc

    3837
    PMC

    1.2 mm

    M21 Ar + 15–20% CO2

    TWIN multi arc

    3838
    PMC

    1.2 mm

    M20 Ar + 5–10% CO2

    TWIN multi arc

     

     

     

     

    Metal Cored (flux core wire):

    No.
    PR

    Wire diameter

    Shielding gas

    Property

    3894
    PMC

    1.2 mm

    M20 Ar + 5–10% CO2

    TWIN universal

    3903
    PMC

    1.2 mm

    M21 Ar + 15–20% CO2

    TWIN universal

    3897
    PMC

    1.6 mm

    M20 Ar + 5–10% CO2

    TWIN universal

    3905
    PMC

    1.6 mm

    M21 Ar + 15–20% CO2

    TWIN universal

    3896
    PMC

    1.2 mm

    M20 Ar + 5–10% CO2

    TWIN PCS

    3901
    PMC

    1.6 mm

    M20 Ar + 5–10% CO2

    TWIN PCS

    3904
    PMC

    1.2 mm

    M21 Ar + 15–20% CO2

    TWIN PCS

    3906
    PMC

    1.6 mm

    M21 Ar + 15–20% CO2

    TWIN PCS

    CrNi 19 9/19 12 3:

    No.
    PR 

    Wire diameter

    Shielding gas

    Property

    4024
    PMC

    1.2 mm

    M12 Ar + 2–5% CO2

    TWIN universal

    4261
    CMT

    1.2 mm

    M12 Ar + 2–5% CO2

    TWIN universal

    4026
    PMC

    1.2 mm

    M12 Ar + 2–5% CO2

    TWIN PCS

    CrNi 18 8/18 8 6:

    No.
    PR

    Wire diameter

    Shielding gas

    Property

    4027
    PMC

    1.2 mm

    M12 Ar + 2–5% CO2

    TWIN universal

    4262
    CMT

    1.2 mm

    M12 Ar + 2–5% CO2

    TWIN universal

    4028
    PMC

    1.2 mm

    M12 Ar + 2–5% CO2

    TWIN PCS

    NiCrMo-3:

    No.
    PR

    Wire diameter

    Shielding gas

    Property

    4030
    PMC

    1.2 mm

    M12 Ar + 2–5% CO2

    TWIN universal

    4032
    PMC

    1.2 mm

    M12 Ar + 2–5% CO2

    TWIN PCS

    4034
    PMC

    1.2 mm

    Z Ar + 30% He + 2% H2 + 0.05% CO2

    TWIN overlay welding

    4035
    PMC

    1.2 mm

    I1 Ar 100%

    TWIN overlay welding

    AlMg4.5 Mn (Zr):

    No.
    PR 

    Wire diameter

    Shielding gas

    Property

    4147
    PMC

    1.2 mm

    I1 Ar 100%

    TWIN universal

    4287
    PMC

    1.2 mm

    I3 Ar + 30% He

    TWIN universal

    4041
    PMC

    1.6 mm

    I1 Ar 100%

    TWIN universal

    4053
    PMC

    1.6 mm

    I3 Ar + 30% He

    TWIN universal

    4289
    PMC

    1.2 mm

    I3 Ar + 30% He

    TWIN PCS

    4298
    PMC

    1.2 mm

    I1 Ar 100%

    TWIN PCS

    4044
    PMC

    1.6 mm

    I1 Ar 100%

    TWIN PCS

    4054
    PMC

    1.6 mm

    I3 Ar + 30% He

    TWIN PCS

    4284
    PMC

    1.2 mm

    I1 100% Ar

    TWIN multi arc

    4288
    PMC

    1.2 mm

    I3 Ar+30% He

    TWIN multi arc

    4290
    PMC

    1.6 mm

    I1 100% Ar

    TWIN multi arc

    AlMg 5:

    No.
    PR 

    Wire diameter

    Shielding gas

    Property

    4259
    CMT

    1.2 mm

    I1 Ar 100%

    TWIN universal

    4279
    PMC

    1.2 mm

    I1 100% Ar

    TWIN universal

    4280
    PMC

    1.2 mm

    I3 Ar+30% He

    TWIN universal

    4264
    CMT

    1.6 mm

    I1 100% Ar

    TWIN universal

    4293
    PMC

    1.6 mm

    I1 100% Ar

    TWIN universal

    4245
    PMC

    1.2 mm

    I1 100% Ar

    TWIN multi arc

    4283
    PMC

    1.2 mm

    I3 Ar+30% He

    TWIN multi arc

    4292
    PMC

    1.6 mm

    I1 100% Ar

    TWIN multi arc

    4246
    PMC

    1.2 mm

    I1 100% Ar

    TWIN PCS

    4286
    PMC

    1.2 mm

    I3 Ar + 30% He

    TWIN PCS

    4294
    PMC

    1.6 mm

    I1 Ar 100%

    TWIN PCS

    AlSi 5:

    No.
    PR

    Wire diameter

    Shielding gas

    Property

    4260
    CMT

    1.2 mm

    I1 Ar 100%

    TWIN universal

    4265
    CMT

    1.6 mm

    I1 Ar 100%

    TWIN universal

    1. Welding Technology Aspects
    2. TWIN Characteristics

    SlagHammer

    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

    TWIN Welding Processes

    TWIN welding processes—overview

    Lead wire electrode
    (= lead welding machine)

    Trail wire electrode
    (= trail welding machine)

       Welding direction

    PMC TWIN

    PMC TWIN

    PCS TWIN

    PCS TWIN

    PMC TWIN

    CMT TWIN

    PCS TWIN

    CMT TWIN

    CMT TWIN

    CMT TWIN

    Single wire
    (Pulse * / Standard * / PMC * / LSC * / CMT *)

    -

    -

    Single wire
    (Pulse * / Standard * / PMC * / LSC * /
    CMT *)

    * 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

    TWIN welding processes—overview

    Lead wire electrode
    (= lead welding machine)

    Trail wire electrode
    (= trail welding machine)

       Welding direction

    PMC TWIN

    PMC TWIN

    PCS TWIN

    PCS TWIN

    PMC TWIN

    CMT TWIN

    PCS TWIN

    CMT TWIN

    CMT TWIN

    CMT TWIN

    Single wire
    (Pulse * / Standard * / PMC * / LSC * / CMT *)

    -

    -

    Single wire
    (Pulse * / Standard * / PMC * / LSC * /
    CMT *)

    * 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

    Symbols

    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

    PMC TWIN / PMC TWIN

    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.

    NOTE!

    The TWIN process PMC TWIN/PMC TWIN should generally be used for all welding applications.

    1. Welding Technology Aspects
    2. TWIN Welding Processes

    PCS TWIN / PCS TWIN

    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

    NOTE!

    In the TWIN process PCS TWIN / PCS TWIN, only weld the lead wire electrode in the spray arc.

    1. Welding Technology Aspects
    2. TWIN Welding Processes

    PMC TWIN / CMT TWIN

    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.

    NOTE!

    In the TWIN welding process PMC TWIN / CMT TWIN, optimum welding results are achieved with a contact tip tilt angle of 8°.

    1. Welding Technology Aspects
    2. TWIN Welding Processes

    CMT TWIN / CMT TWIN

    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

    Single wire (with a TWIN welding torch):
    PMC/Pulse/LSC/Standard/CMT

    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.

    NOTE!

    In order to ensure a full gas shield during single wire welding with TWIN welding torches, the solenoid valve for the pausing welding machine is open.

    The solenoid valve is controlled via the welding machine.

    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.

    Single wire welding is used in a TWIN welding system:
    • 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

    TWIN Process Parameters

    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

    PMC lead electrode
    • Wirefeeder
    • Arc length correction
    • Pulse correction
    • Penetration stabilizer
    • Arc length stabilizer
    • Trail ignition delay *
    PMC trail electrode
    • Wirefeeder
    • Arc length correction
    • Pulse correction
    • Penetration stabilizer
    • Arc length stabilizer
    • Trail ignition delay *
    • Pulse synchronization ratio
    • Lead/trail phase shift

    For PMC TWIN / CMT TWIN

    PMC lead electrode
    • Wirefeeder
    • Arc length correction
    • Pulse correction
    • Penetration stabilizer
    • Arc length stabilizer
    • Trail ignition delay *
    CMT trail electrode
    • Wirefeeder
    • Arc length correction
    • Dynamic correction
    • Penetration stabilizer
    • Trail ignition delay *

    For CMT TWIN / CMT TWIN

    CMT lead electrode
    • Wirefeeder
    • Arc length correction
    • Dynamic correction
    • Penetration stabilizer
    • Trail ignition delay *
    CMT trail electrode
    • Wirefeeder
    • Arc length correction
    • Dynamic correction
    • Penetration stabilizer
    • Trail ignition delay *

    Further TWIN process parameters

    • Pulse synchronization ratio *
    • Lead/trail phase shift *
    *
    The following sections contain a detailed description of special process parameters for TWIN mode.
    1. Welding Technology Aspects
    2. TWIN Process Parameters

    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

    PMC lead electrode
    • Wirefeeder
    • Arc length correction
    • Pulse correction
    • Penetration stabilizer
    • Arc length stabilizer
    • Trail ignition delay *
    PMC trail electrode
    • Wirefeeder
    • Arc length correction
    • Pulse correction
    • Penetration stabilizer
    • Arc length stabilizer
    • Trail ignition delay *
    • Pulse synchronization ratio
    • Lead/trail phase shift

    For PMC TWIN / CMT TWIN

    PMC lead electrode
    • Wirefeeder
    • Arc length correction
    • Pulse correction
    • Penetration stabilizer
    • Arc length stabilizer
    • Trail ignition delay *
    CMT trail electrode
    • Wirefeeder
    • Arc length correction
    • Dynamic correction
    • Penetration stabilizer
    • Trail ignition delay *

    For CMT TWIN / CMT TWIN

    CMT lead electrode
    • Wirefeeder
    • Arc length correction
    • Dynamic correction
    • Penetration stabilizer
    • Trail ignition delay *
    CMT trail electrode
    • Wirefeeder
    • Arc length correction
    • Dynamic correction
    • Penetration stabilizer
    • Trail ignition delay *

    Further TWIN process parameters

    • Pulse synchronization ratio *
    • Lead/trail phase shift *
    *
    The following sections contain a detailed description of special process parameters for TWIN mode.
    1. Welding Technology Aspects
    2. TWIN Process Parameters

    Trail ignition delay

    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

    Pulse synchronization ratio

    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.

    1/1
    Both arcs work with the same pulse frequency. The number of droplets per time unit is identical in both process lines.
    1/2
    The trail arc works with half the pulse frequency of the lead arc. Droplet detachment only takes place at the trail arc with every other pulse.
    1/3
    The trail arc works with a third of the pulse frequency of the lead arc. Droplet detachment only takes place at the trail arc every third pulse.
    Information on the welding machine display
    1. Welding Technology Aspects
    2. TWIN Process Parameters

    Lead/trail phase shift

    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°.

    0%
    Synchronous mode—no phase shift between the two process lines, lead and trail droplet detachments take place at the same time.
    50%
    Asynchronous mode—180° phase shift, each droplet detachment takes place in the quiescent current phase of the other arc.
    Information on the welding machine display
    1. Welding Technology Aspects

    TWIN SynchroPulse

    SynchroPulse welding

    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 welding

    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

    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

    TWIN Push welding parameter standard values

    Standard values for fillet welds, welding position PA

    NOTE!

    The following data are standard values determined under laboratory conditions.

    Shielding gas and filler metal used:

    Shielding gas

    M20 Ar + 5-15% CO2

    Filler metal

    ER70S-6

    Wire diameter

    1.2 mm

    Characteristic (lead + trail)

    PMC TWIN Universal 3565

    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

    Standard values for fillet welds, welding position PA

    NOTE!

    The following data are standard values determined under laboratory conditions.

    Shielding gas and filler metal used:

    Shielding gas

    M20 Ar + 5-15% CO2

    Filler metal

    ER70S-6

    Wire diameter

    1.2 mm

    Characteristic (lead + trail)

    PMC TWIN Universal 3565

    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

    Standard values for fillet welds, PB welding position

    NOTE!

    The following data are standard values determined under laboratory conditions.

    Shielding gas and filler metal used:

    Shielding gas

    M20 Ar + 5-15% CO2

    Filler metal

    ER70S-6

    Wire diameter

    1.2 mm

    Characteristic (lead + trail)

    PMC TWIN Universal 3565

    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

    TWIN Push/Pull welding parameter standard values

    Standard values for fillet welds, PB welding position

    NOTE!

    The following data are standard values determined under laboratory conditions.

    Shielding gas and filler metal used:

    Shielding gas

    M21 Ar + 15-20% CO2

    Filler metal

    ER70S-6

    Wire diameter

    1.2 mm

    Contact tip tilt angle

    11.5°

    Characteristic (lead + trail)

    PMC TWIN Universal 3564

    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

    Standard values for fillet welds, PB welding position

    NOTE!

    The following data are standard values determined under laboratory conditions.

    Shielding gas and filler metal used:

    Shielding gas

    M21 Ar + 15-20% CO2

    Filler metal

    ER70S-6

    Wire diameter

    1.2 mm

    Contact tip tilt angle

    11.5°

    Characteristic (lead + trail)

    PMC TWIN Universal 3564

    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

    Standard values for lap joints, welding position PB

    NOTE!

    The following data are standard values determined under laboratory conditions.

    Shielding gas and filler metal used:

    Shielding gas

    M21 Ar + 15-20% CO2

    Filler metal

    ER70S-6

    Wire diameter

    1.2 mm

    Contact tip tilt angle

    11.5°

    Characteristic (lead + trail)

    PMC TWIN Universal 3564

    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

    TWIN CMT welding parameter standard values

    Standard values for fillet welds, PB welding position

    NOTE!

    The following data are standard values determined under laboratory conditions.

    Shielding gas and filler metal used:

    Shielding gas

    M21 Ar + 15-20% CO2

    Filler metal

    ER70S-6

    Wire diameter

    1.2 mm

    Contact tip tilt angle

    8°

    Characteristic

    Sheet thickness = 1.5 mm:
    Lead
    Trail

    Sheet thickness = 2 / 3 mm:
    Lead
    Trail




    CMT TWIN Universal 4200
    CMT TWIN Universal 4200


    PMC TWIN Universal 3564
    CMT TWIN Universal 4200

    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

    Standard values for fillet welds, PB welding position

    NOTE!

    The following data are standard values determined under laboratory conditions.

    Shielding gas and filler metal used:

    Shielding gas

    M21 Ar + 15-20% CO2

    Filler metal

    ER70S-6

    Wire diameter

    1.2 mm

    Contact tip tilt angle

    8°

    Characteristic

    Sheet thickness = 1.5 mm:
    Lead
    Trail

    Sheet thickness = 2 / 3 mm:
    Lead
    Trail




    CMT TWIN Universal 4200
    CMT TWIN Universal 4200


    PMC TWIN Universal 3564
    CMT TWIN Universal 4200

    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

    Standard values for lap joints, welding position PB

    NOTE!

    The following data are standard values determined under laboratory conditions.

    Shielding gas and filler metal used:

    Shielding gas

    M21 Ar + 15-20% CO2

    Filler metal

    ER70S-6

    Wire diameter

    1.2 mm

    Contact tip tilt angle

    8°

    Characteristic
    Lead
    Trail


    PMC TWIN Universal 3564
    CMT TWIN Universal 4200

    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

    Operating controls, connections and mechanical components

    WF 30i R /TWIN

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    1. Operating controls, connections and mechanical components

    WF 30i R /TWIN

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

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

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

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

    Wirefeeder front

    No.Function
    (1)
    Welding torch connection 1
    For connecting the welding torch
    (2)
    (+) Current socket with fine thread 1
    For connecting the power cable from the interconnecting hosepack
    (3)
    SpeedNet connection 1
    For connecting the SpeedNet cable from the interconnecting hosepack
    (4)
    Shielding gas connection 1
    (5)
    Welding torch connection 2
    For connecting the welding torch
    (6)
    (+) Current socket with fine thread 2
    For connecting the power cable from the interconnecting hosepack
    (7)
    Shielding gas connection 2
    (8)
    SpeedNet connection 2
    For connecting the SpeedNet cable from the interconnecting hosepack
    (9)
    Coolant connection
    For connecting the coolant connection from the interconnecting hosepack
    (10)
    Coolant supply connection (blue)
    For connecting the coolant hose from the torch hosepack
    (11)
    Coolant return connection (red)
    For connecting the coolant hose from the torch hosepack
    (12)
    Compressed air connection IN
    OPT/i WF gas purging option 16 bar
    1. Operating controls, connections and mechanical components
    2. WF 30i R /TWIN

    Wirefeeder Side

    No.Function
    (1)
    Operating status LED 1
    illuminates green if wirefeeder unit 1 is ready for operation
    (2)
    Gas-test button 1
    for setting the required gas volume on the pressure regulator
    (3)
    Wire-return button 1
    retract the wire electrode without gas or current
    (4)
    Wire-threading button 1
    for threading the wire electrode into the torch hosepack without gas or current
    (5)
    4-roller drive 1
    (6)
    Clamping lever 1
    for adjusting the contact pressure of the feed rollers
    (7)
    Protective cover of the 4-roller drive 1
    (8)
    Welding torch clamping lever 1
    (9)
    Operating status LED 2
    illuminates green if wirefeeder unit 2 is ready for operation
    (10)
    Wire-return button 2
    retract the wire electrode without gas or current
    (11)
    Gas-test button 2
    for setting the required gas volume on the pressure regulator
    (12)
    Wire-threading button 2
    for threading the wire electrode into the torch hosepack without gas or current
    (13)
    4-roller drive 2
    (14)
    Clamping lever 2
    for adjusting the contact pressure of the feed rollers
    (15)
    Protective cover of the 4-roller drive 2
    (16)
    Welding torch clamping lever 2
    (17)
    Cover
    1. Operating controls, connections and mechanical components
    2. WF 30i R /TWIN

    Function of the gas-test, wire-return, and wire-threading buttons

    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

    NOTE!

    Only retract the wire electrode a small amount at a time, to avoid the wire electrode becoming entangled on the wirespool during retraction.

    NOTE!

    If there is a ground earth connection with the contact tip, before the wire-return button is pressed, the wire electrode is retracted by pressing the wire-return button until the wire electrode is short-circuit-free—however, this must not exceed 10 mm (0.39 in.) each time the button is pressed.

    If the wire electrode needs to be retracted further, press the wire-return button again.

    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.)

    NOTE!

    If there is a ground earth connection with the contact tip, before the wire-threading button is pressed, the wire electrode is retracted by pressing the wire-threading button until the wire electrode is short-circuit-free—however, this must not exceed 10 mm (0.39 in.) each time the button is pressed.

    If after the 10 mm (0.39 in.) wire retraction there is still a ground earth connection with the contact tip, then when the wire-threading button is pressed again, the wire electrode is retracted again by a maximum of 10 mm (0.39 in.). The process is repeated until there is no longer any ground earth connection with the contact tip.

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

    Wirefeeder rear

    No.Function
    (1)
    Wire infeed tube 1
    (2)
    Wire infeed tube 2
    (3)
    Dummy cover
    (4)
    Dummy cover
    (5)
    Dummy cover
    (6)
    Dummy cover
    1. Operating controls, connections and mechanical components

    MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

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

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

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

    MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W – mechanical components

    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
    (7)
    Control panel
    (8)
    Drive roller and clamping lever – welding line 2
    (9)
    Heat shield
    1. Operating controls, connections and mechanical components
    2. MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W

    MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W – control panel

    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
    (5)
    Mode button
    For selecting the modes 1/2/TWIN/External
    Mode 1
    When the wire-return, gas-test, and wire-threading buttons are pressed, the respective functions are only carried out on welding line 1
    Mode 2
    When the wire-return, gas-test, and wire-threading buttons are pressed, the respective functions are only carried out on welding line 2
    TWIN mode
    When the wire-return, gas-test, and wire-threading buttons are pressed, the respective functions are carried out on both welding lines
    External mode
    Mode 1, 2 or TWIN is specified by the robot interface
    (6)
    Teach on LED
    Lights up when teach mode is activated
    (7)
    Status LED
    lights up green:
    Data connection to welding machine intact, no error
    lights up orange:
    No data connection to the welding machine, or the connection is in the process of being established
    lights up red:
    There is an error on one of the two TWIN lines
    (8)
    Teach on/off button
    For activating/deactivating teach mode
    Teach mode is used for creating the robot program.
    When the teach mode is active, bending of the wire electrode is avoided when setting up the robot.
    In TWIN teach mode (with both wire electrodes), the lead wire electrode has a higher scanning frequency than the trail wire electrode.
    Details on the teach mode can be found in the operating instructions "Signal descriptions interface TPS /i", 42,0426,0227,xx.
    *
    For a functional description of the wire-return, gas-test, and wire-threading buttons, see page (→).
    1. Operating controls, connections and mechanical components

    Interconnecting hosepack

    Interconnecting Hosepack—Connections

    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

    Interconnecting Hosepack—Connections

    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

    TWIN-MTB Single adapter

    TWIN-MTB Single adapter – connectors

    (A) Hosepack side (B) Torch body side
    (1)
    Current/coolant Welding line 1
    (2)
    Shielding gas
    (3)
    Wire electrode welding line 2
    (4)
    Current/coolant Welding line 2
    (5)
    Wire electrode Welding line 1
    (6)
    Compressed air
    (7)
    Common wire outlet
    (8)
    Common compressed air and inert gas output
    (9)
    Common power contacts/coolant flow
    (10)
    Common power contacts/coolant return
    1. Operating controls, connections and mechanical components
    2. TWIN-MTB Single adapter

    TWIN-MTB Single adapter – connectors

    (A) Hosepack side (B) Torch body side
    (1)
    Current/coolant Welding line 1
    (2)
    Shielding gas
    (3)
    Wire electrode welding line 2
    (4)
    Current/coolant Welding line 2
    (5)
    Wire electrode Welding line 1
    (6)
    Compressed air
    (7)
    Common wire outlet
    (8)
    Common compressed air and inert gas output
    (9)
    Common power contacts/coolant flow
    (10)
    Common power contacts/coolant return

    Installing the system components - TWIN Push

    Safety—Installation and Commissioning

    Safety

    WARNING!

    Incorrect operation and incorrectly performed work can cause serious injury and property damage.

    All work listed in this document may only be performed by trained specialist personnel.

    All functions described in this document may only be used by trained specialist personnel.

    Do not perform the work or use the functions described below until you have thoroughly read and understood the following documents:
    This document
    All operating instructions for system components, especially the safety rules.

    WARNING!

    An electric shock can be fatal.

    Before starting the described work:

    Switch the power switch on the welding machine to - O -

    Disconnect the welding machine from the grid

    Ensure that the welding machine remains disconnected from the grid until all work is complete

    WARNING!

    Danger of severe injury and damage to property due to falling objects.

    Check all screw connections listed below:

    For secure fastening after installation

    For secure fastening following unusual operating situations (for example, crash)

    For secure fastening at regular intervals

    CAUTION!

    Improper connections can cause personal injury and/or damage to equipment.

    All cables, leads, and hosepacks must be securely connected, undamaged, correctly insulated, and adequately sized.

    1. Installing the system components - TWIN Push

    Safety—Installation and Commissioning

    Safety

    WARNING!

    Incorrect operation and incorrectly performed work can cause serious injury and property damage.

    All work listed in this document may only be performed by trained specialist personnel.

    All functions described in this document may only be used by trained specialist personnel.

    Do not perform the work or use the functions described below until you have thoroughly read and understood the following documents:
    This document
    All operating instructions for system components, especially the safety rules.

    WARNING!

    An electric shock can be fatal.

    Before starting the described work:

    Switch the power switch on the welding machine to - O -

    Disconnect the welding machine from the grid

    Ensure that the welding machine remains disconnected from the grid until all work is complete

    WARNING!

    Danger of severe injury and damage to property due to falling objects.

    Check all screw connections listed below:

    For secure fastening after installation

    For secure fastening following unusual operating situations (for example, crash)

    For secure fastening at regular intervals

    CAUTION!

    Improper connections can cause personal injury and/or damage to equipment.

    All cables, leads, and hosepacks must be securely connected, undamaged, correctly insulated, and adequately sized.

    1. Installing the system components - TWIN Push
    2. Safety—Installation and Commissioning

    Safety

    WARNING!

    Incorrect operation and incorrectly performed work can cause serious injury and property damage.

    All work listed in this document may only be performed by trained specialist personnel.

    All functions described in this document may only be used by trained specialist personnel.

    Do not perform the work or use the functions described below until you have thoroughly read and understood the following documents:
    This document
    All operating instructions for system components, especially the safety rules.

    WARNING!

    An electric shock can be fatal.

    Before starting the described work:

    Switch the power switch on the welding machine to - O -

    Disconnect the welding machine from the grid

    Ensure that the welding machine remains disconnected from the grid until all work is complete

    WARNING!

    Danger of severe injury and damage to property due to falling objects.

    Check all screw connections listed below:

    For secure fastening after installation

    For secure fastening following unusual operating situations (for example, crash)

    For secure fastening at regular intervals

    CAUTION!

    Improper connections can cause personal injury and/or damage to equipment.

    All cables, leads, and hosepacks must be securely connected, undamaged, correctly insulated, and adequately sized.

    1. Installing the system components - TWIN Push
    2. Safety—Installation and Commissioning

    Insulated guiding of the wire electrode to the wirefeeder

    CAUTION!

    Danger due to uninsulated wire electrode.

    Personal injury, damage to property, and impaired welding results may result.

    In automated applications, only guide the wire electrode from the welding wire drum, large spool or wirespool to the wirefeeder with insulation (for example using a wirefeeding hose).

    A ground fault or earth leakage can be caused by:

    • a non-insulated, exposed wire electrode, that comes into contact with an electrically conductive object during the welding process
    • a lack of insulation between the wire electrode and the grounded housing limit of a robot cell
    • chafed wirefeeding hose and therefore bare wire electrodes

    In order to avoid ground faults or earth leakage:

    • use wirefeeding hoses—for insulated guidance of the wire electrode to the wirefeeder
    • do not guide wirefeeding hoses over sharp edges in order to avoid chafing of the wirefeeding hoses
    • if necessary, use a hose holder or chafe protector
    • Couplings and drum covers for welding wire drums are also recommended in order to ensure safe transport of the wire electrode
    1. Installing the system components - TWIN Push

    Before installation and initial operation

    Setup regulations

    WARNING!

    Toppling or falling devices can be deadly.

    Set up all system components, upright brackets and trolleys so that they are stable on a flat and solid surface.

    The wirefeeder has been tested according to protection class IP 23. This means:
    • Protection against the penetration of solid foreign bodies with a diameter of more than 12.5 mm (0.49 in.)
    • Protection against spraywater at any angle up to 60° from the vertical

    The WF 30i TWIN wirefeeder can be set up and operated outdoors in accordance with degree of protection IP 23. Direct moisture (e.g. from rain) must be avoided.

    1. Installing the system components - TWIN Push
    2. Before installation and initial operation

    Setup regulations

    WARNING!

    Toppling or falling devices can be deadly.

    Set up all system components, upright brackets and trolleys so that they are stable on a flat and solid surface.

    The wirefeeder has been tested according to protection class IP 23. This means:
    • Protection against the penetration of solid foreign bodies with a diameter of more than 12.5 mm (0.49 in.)
    • Protection against spraywater at any angle up to 60° from the vertical

    The WF 30i TWIN wirefeeder can be set up and operated outdoors in accordance with degree of protection IP 23. Direct moisture (e.g. from rain) must be avoided.

    1. Installing the system components - TWIN Push
    2. Before installation and initial operation

    Installation overview

    The following overview covers the installation work required for a TWIN welding system in accordance with the system overview on page (→).
    The installation of similar TWIN systems is carried out analogously to this.

    Initial situation:

    • The robot and robot controls are correctly positioned and fastened in the welding cell.
    • The welding machines are installed with the cooling units on the upright brackets and correctly positioned and fastened in the welding cell.
    • The TWIN Controller is available and fastened close to the welding machines (e.g., using a corresponding bracket directly on the welding machine).
    • The welding wire drums are correctly positioned and fixed in place.

    Installing the TWIN wirefeeder and accessories on the robot

    1Install wirefeeder holder on the robot
    2Install wirefeeder on the wirefeeder holder
    3Install side holders for the interconnecting hosepacks on the robot

    Laying, installing, and connecting interconnecting hosepacks

    1Connect interconnecting hosepacks to the wirefeeder
    2Fix interconnecting hosepacks in the side support
    3Lay interconnecting hosepacks to the welding machines
    4Connect the interconnecting hosepacks to the welding machines, cooling units, and TWIN Controller

    IMPORTANT! Maintain a minimum distance of 30–50 cm between interconnecting hosepacks to prevent any impairment of the welding results.

    Connecting the TWIN Controller

    1Connect welding machines to the TWIN Controller
    2Connect wirefeeder to the TWIN Controller (connect SpeedNet cable from the interconnecting hosepacks to the TWIN Controller)
    3Connect the TWIN Controller to the robot controls

    Installing the CrashBox, torch hosepack, and TWIN welding torch

    1Mount the robot flange and CrashBox on the robot
    2Insert the inner liners into the torch hosepack
    3Install the clamp on the CrashBox
    4Insert the torch hosepack into the clamp
    5Connect the CrashBox cable
    6Connect the torch hosepack to the wirefeeder
    7Insert the inner liners into the TWIN welding torch
    8Install the torch body coupling
    9Check the function of the torch body coupling
    10Install wear parts on the TWIN welding torch
    11Install TWIN welding torch on the torch hosepack

    Connecting the shielding gas and return lead cable

    1Connect the shielding gas supply to both welding machines
    2Connect one return lead cable per welding machine to the welding machines
    3Connect both return lead cables to the workpiece
    (see also "Ground connection" on page (→))

    Preparing the TWIN wirefeeder for operation

    1Connect the wirefeeding hoses to the welding wire drums
    2Connect the wirefeeding hoses to the TWIN wirefeeder
    3Insert the feed rollers
    4Close all covers

    Defining welding lines 1 and 2 on the welding machines

    1Switch on welding machine 2, leave welding machine 1 switched off
    2Place sticker 2 in a clearly visible location on welding machine 2
    3Set the welding parameter to 2 in the setup menu of welding machine 2 under Defaults/System/TWIN Setup
    4Switch on welding machine 1
    5Place sticker 1 in a clearly visible location on welding machine 1
    6Check that the welding parameter is set to 1 in the setup menu of welding machine 1 under Defaults/System/TWIN Setup

    Final tasks

    1Carry out an R/L comparison on both welding machines
    2Thread the wire electrodes
    3Set the contact pressure
    4 Set the TWIN characteristics on both welding machines
    (welding process/filler metal/change material settings... step 4 – select the characteristic from the characteristics available for each welding process)
    5Set stick out
    6If necessary, carry out system calibration (e.g., if there is a WF REEL unwinding wirefeeder in the system)
    7Define the lead/trail signal on the robot controls
    8Set TWIN welding parameters
    1. Installing the system components - TWIN Push

    Install TWIN Wirefeeder and Accessories on the Robot

    Installing the wirefeeder on the robot

    1
    Installation of the wirefeeder holder depends on the robot. Follow the Installation Instructions for the wirefeeder holder!
    2
    3
    Mount the hosepack holder as well
    4
    5
    Fit the hose clamps
    (for example, push in until they audibly engage)

    NOTE!

    Installation of the hose clamps depends on the robot:

    The hose clamps can

    be mounted on the hosepack holder in advance,

    be screwed to the hosepack holder,

    be inserted into the hosepack holder until they engage.

    1. Installing the system components - TWIN Push
    2. Install TWIN Wirefeeder and Accessories on the Robot

    Installing the wirefeeder on the robot

    1
    Installation of the wirefeeder holder depends on the robot. Follow the Installation Instructions for the wirefeeder holder!
    2
    3
    Mount the hosepack holder as well
    4
    5
    Fit the hose clamps
    (for example, push in until they audibly engage)

    NOTE!

    Installation of the hose clamps depends on the robot:

    The hose clamps can

    be mounted on the hosepack holder in advance,

    be screwed to the hosepack holder,

    be inserted into the hosepack holder until they engage.

    1. Installing the system components - TWIN Push
    2. Install TWIN Wirefeeder and Accessories on the Robot

    Installing the side holders for the interconnecting hosepacks on the robot

    1
    Example of a side holder on the robot for TWIN Push systems

    Installation of the side holder depends on the robot.
    Follow the Installation Instructions!

    1. Installing the system components - TWIN Push

    Lay, Install and Connect Interconnecting Hosepacks

    Connecting the interconnecting hosepacks to the wirefeeder

    NOTE!

    If the interconnecting hosepack is laid incorrectly it can have a significant influence on the welding results, a stable welding process is not guaranteed!

    As far as possible, maintain a distance of 30 - 50 cm between the two interconnecting hosepacks.

    1Route interconnecting hosepacks to the wirefeeder

    IMPORTANT! When connecting the interconnecting hosepacks, observe marks 1 and 2 on the interconnecting hosepacks and on the wirefeeder:
    1 = water-cooled interconnecting hosepack
    2 = gas-cooled interconnecting hosepack

    2
    Connecting interconnecting hosepack 1 to the wirefeeder: power cable 1, SpeedNet 1, shielding gas 1, and coolant connection
    3
    Connecting interconnecting hosepack 2 to the wirefeeder: power cable 2, SpeedNet 2, and shielding gas 2
    4

    NOTE!

    If interconnecting hosepacks are installed on the robot, make sure that there is no tension or strain in the hosepacks during any movement in a robot axis.

    Route hosepacks in a loop.

    1. Installing the system components - TWIN Push
    2. Lay, Install and Connect Interconnecting Hosepacks

    Connecting the interconnecting hosepacks to the wirefeeder

    NOTE!

    If the interconnecting hosepack is laid incorrectly it can have a significant influence on the welding results, a stable welding process is not guaranteed!

    As far as possible, maintain a distance of 30 - 50 cm between the two interconnecting hosepacks.

    1Route interconnecting hosepacks to the wirefeeder

    IMPORTANT! When connecting the interconnecting hosepacks, observe marks 1 and 2 on the interconnecting hosepacks and on the wirefeeder:
    1 = water-cooled interconnecting hosepack
    2 = gas-cooled interconnecting hosepack

    2
    Connecting interconnecting hosepack 1 to the wirefeeder: power cable 1, SpeedNet 1, shielding gas 1, and coolant connection
    3
    Connecting interconnecting hosepack 2 to the wirefeeder: power cable 2, SpeedNet 2, and shielding gas 2
    4

    NOTE!

    If interconnecting hosepacks are installed on the robot, make sure that there is no tension or strain in the hosepacks during any movement in a robot axis.

    Route hosepacks in a loop.

    1. Installing the system components - TWIN Push
    2. Lay, Install and Connect Interconnecting Hosepacks

    Connect the interconnecting hosepacks to the welding machine, cooling unit, and TWIN Controller

    IMPORTANT! When connecting the interconnecting hosepacks, observe marks 1 and 2 on the interconnecting hosepacks and on the welding machines:
    1 = water-cooled interconnecting hosepack
    2 = gas-cooled interconnecting hosepack

    NOTE!

    If the interconnecting hosepack is laid incorrectly it can have a significant influence on the welding results, a stable welding process is not guaranteed!

    As far as possible, maintain a distance of 30 to 50 cm between the two interconnecting hosepacks.

    1Lay interconnecting hosepacks to the welding machines
    2Connect the interconnecting hosepacks to the welding machines, cooling units, and TWIN Controller
    1. Installing the system components - TWIN Push

    Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Mounting the CrashBox /i on the robot

    1

    Observe the torques when fitting the robot flange:

    Tightening torque for screws with strength class 8.8

    M4
    2,3 - 3,3 Nm
    1,70 - 2,43 lb·ft
    M5
    4,4 - 6,5 Nm
    3,25 - 4,79 lb·ft
    M6
    7,70 - 11,3 Nm
    5,68 - 8,33 lb·ft
    M8
    18,5 - 27,3 Nm
    13,65 - 20,14 lb·ft
    M10
    36,0 - 54,0 Nm
    26,55 - 39,83 lb·ft
    M12
    63,0 - 93,0 Nm
    46,47 - 68,60 lb·ft
    2
    3
    4
    5
    6
    7
    8
    1. Installing the system components - TWIN Push
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Mounting the CrashBox /i on the robot

    1

    Observe the torques when fitting the robot flange:

    Tightening torque for screws with strength class 8.8

    M4
    2,3 - 3,3 Nm
    1,70 - 2,43 lb·ft
    M5
    4,4 - 6,5 Nm
    3,25 - 4,79 lb·ft
    M6
    7,70 - 11,3 Nm
    5,68 - 8,33 lb·ft
    M8
    18,5 - 27,3 Nm
    13,65 - 20,14 lb·ft
    M10
    36,0 - 54,0 Nm
    26,55 - 39,83 lb·ft
    M12
    63,0 - 93,0 Nm
    46,47 - 68,60 lb·ft
    2
    3
    4
    5
    6
    7
    8
    1. Installing the system components - TWIN Push
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Mounting the CrashBox /i Dummy on the robot

    1

    Observe the torques when fitting the robot flange:

    Tightening torque for screws with strength class 8.8

    M4
    2,3 - 3,3 Nm
    1,70 - 2,43 lb·ft
    M5
    4,4 - 6,5 Nm
    3,25 - 4,79 lb·ft
    M6
    7,70 - 11,3 Nm
    5,68 - 8,33 lb·ft
    M8
    18,5 - 27,3 Nm
    13,65 - 20,14 lb·ft
    M10
    36,0 - 54,0 Nm
    26,55 - 39,83 lb·ft
    M12
    63,0 - 93,0 Nm
    46,47 - 68,60 lb·ft
    2
    3
    1. Installing the system components - TWIN Push
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Installing the inner liner in the torch hosepack

    NOTE!

    So that the inner liner can be correctly installed, lay the hosepack out straight when installing the inner liner.

    1
    2
    2x
    3
    4
    *
    After insertion, ensure that the inner liner is right at the front in the hosepack.

    IMPORTANT! The screws for securing the inner liners must not be loosened!
    5
    2x
    6
    2x
    ***
    Screw the clamping nipple onto the inner liner up to the stop. The inner liner needs to be visible through the hole in the cap.
    7
    2x
    1. Installing the system components - TWIN Push
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Installing the torch hosepack

    1

    NOTE!

    To avoid jamming the welding torch hosepack:

    Tighten the screws crosswise

    Observe the specified sequence when tightening

    Pre-tighten screws with 1 Nm, then tighten with 4 Nm

    2
    Tighten screws crosswise, 1 Nm
    3
    Tighten screws crosswise, 4 Nm

    IMPORTANT! When connecting the torch hosepack, pay attention to marks 1 and 2 on the torch hosepack and on the wirefeeder.

    4
    5
    6

    Connect coolant hoses from the welding torch according to the color markings on the coolant supply and coolant return connections

    1. Installing the system components - TWIN Push
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Mounting the torch body on the TWIN torch hosepack

    NOTE!

    The coupling areas between the torch body and TWIN torch hosepack must always be free of oil, grease, and dust, and be dry.

    1

    Visually check that the springs are present, not deformed or otherwise damaged.

    NOTE!

    To prevent small parts from falling out or being lost, do not clean the area around the springs with compressed air.

    2
    * Special key BY2,0201,4863

    NOTE!

    Switch off the cooling unit before dismantling the torch body!

    1. Installing the system components - TWIN Push
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Installing the torch body coupling

    NOTE!

    The coupling areas between the torch body coupling and torch body must always be free of oil, grease, and dust, and be dry.

    To prevent small parts from falling out or being lost, do not clean the area marked [ * ] on the torch hosepack with compressed air!

    1
    2
    1. Installing the system components - TWIN Push
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Checking the function of the torch body coupling

    NOTE!

    Flawless operation of the interchangeable coupling can only be guaranteed with a vertical alignment facing down.

    1Actuate the torch body coupling five times using a robot signal and check whether the torch body coupling opens and closes

    If the torch body coupling opens and closes correctly, check the manual locking of a torch body in the torch body coupling.

    Checking manual locking

    1
    Torch body coupling closed
    2
    Torch body coupling open
    Torch body coupling closed
    Torch body coupling open

    NOTE!

    The locking balls of the torch body coupling are intended for dry operation.

    Do not lubricate the locking balls.

    NOTE!

    Always insert the torch body into the torch body coupling so that it is straight and until it reaches the stop.

    3
    4
    5

    If the torch body can be correctly locked in the torch body coupling by hand, then the torch body coupling is ready for use.

    Installing the system components - TWIN Push/Pull, CMT

    Safety—Installation and Commissioning

    Safety

    WARNING!

    Incorrect operation and incorrectly performed work can cause serious injury and property damage.

    All work listed in this document may only be performed by trained specialist personnel.

    All functions described in this document may only be used by trained specialist personnel.

    Do not perform the work or use the functions described below until you have thoroughly read and understood the following documents:
    This document
    All operating instructions for system components, especially the safety rules.

    WARNING!

    An electric shock can be fatal.

    Before starting the described work:

    Switch the power switch on the welding machine to - O -

    Disconnect the welding machine from the grid

    Ensure that the welding machine remains disconnected from the grid until all work is complete

    WARNING!

    Danger of severe injury and damage to property due to falling objects.

    Check all screw connections listed below:

    For secure fastening after installation

    For secure fastening following unusual operating situations (for example, crash)

    For secure fastening at regular intervals

    CAUTION!

    Improper connections can cause personal injury and/or damage to equipment.

    All cables, leads, and hosepacks must be securely connected, undamaged, correctly insulated, and adequately sized.

    1. Installing the system components - TWIN Push/Pull, CMT

    Safety—Installation and Commissioning

    Safety

    WARNING!

    Incorrect operation and incorrectly performed work can cause serious injury and property damage.

    All work listed in this document may only be performed by trained specialist personnel.

    All functions described in this document may only be used by trained specialist personnel.

    Do not perform the work or use the functions described below until you have thoroughly read and understood the following documents:
    This document
    All operating instructions for system components, especially the safety rules.

    WARNING!

    An electric shock can be fatal.

    Before starting the described work:

    Switch the power switch on the welding machine to - O -

    Disconnect the welding machine from the grid

    Ensure that the welding machine remains disconnected from the grid until all work is complete

    WARNING!

    Danger of severe injury and damage to property due to falling objects.

    Check all screw connections listed below:

    For secure fastening after installation

    For secure fastening following unusual operating situations (for example, crash)

    For secure fastening at regular intervals

    CAUTION!

    Improper connections can cause personal injury and/or damage to equipment.

    All cables, leads, and hosepacks must be securely connected, undamaged, correctly insulated, and adequately sized.

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Safety—Installation and Commissioning

    Safety

    WARNING!

    Incorrect operation and incorrectly performed work can cause serious injury and property damage.

    All work listed in this document may only be performed by trained specialist personnel.

    All functions described in this document may only be used by trained specialist personnel.

    Do not perform the work or use the functions described below until you have thoroughly read and understood the following documents:
    This document
    All operating instructions for system components, especially the safety rules.

    WARNING!

    An electric shock can be fatal.

    Before starting the described work:

    Switch the power switch on the welding machine to - O -

    Disconnect the welding machine from the grid

    Ensure that the welding machine remains disconnected from the grid until all work is complete

    WARNING!

    Danger of severe injury and damage to property due to falling objects.

    Check all screw connections listed below:

    For secure fastening after installation

    For secure fastening following unusual operating situations (for example, crash)

    For secure fastening at regular intervals

    CAUTION!

    Improper connections can cause personal injury and/or damage to equipment.

    All cables, leads, and hosepacks must be securely connected, undamaged, correctly insulated, and adequately sized.

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Safety—Installation and Commissioning

    Insulated guiding of the wire electrode to the wirefeeder

    CAUTION!

    Danger due to uninsulated wire electrode.

    Personal injury, damage to property, and impaired welding results may result.

    In automated applications, only guide the wire electrode from the welding wire drum, large spool or wirespool to the wirefeeder with insulation (for example using a wirefeeding hose).

    A ground fault or earth leakage can be caused by:

    • a non-insulated, exposed wire electrode, that comes into contact with an electrically conductive object during the welding process
    • a lack of insulation between the wire electrode and the grounded housing limit of a robot cell
    • chafed wirefeeding hose and therefore bare wire electrodes

    In order to avoid ground faults or earth leakage:

    • use wirefeeding hoses—for insulated guidance of the wire electrode to the wirefeeder
    • do not guide wirefeeding hoses over sharp edges in order to avoid chafing of the wirefeeding hoses
    • if necessary, use a hose holder or chafe protector
    • Couplings and drum covers for welding wire drums are also recommended in order to ensure safe transport of the wire electrode
    1. Installing the system components - TWIN Push/Pull, CMT

    Before installation and initial operation

    Setup regulations

    WARNING!

    Toppling or falling devices can be deadly.

    Set up all system components, upright brackets, and trolleys so that they are stable on a flat and solid surface.

    The system components have been tested according to at least protection class IP 20. This means:
    • Protection against the penetration of solid foreign bodies with a diameter of more than 12.5 mm (0.49 in.)
    • No protection against water

    The system components can be set up and operated in dry rooms in accordance with protection class IP 20.

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Before installation and initial operation

    Setup regulations

    WARNING!

    Toppling or falling devices can be deadly.

    Set up all system components, upright brackets, and trolleys so that they are stable on a flat and solid surface.

    The system components have been tested according to at least protection class IP 20. This means:
    • Protection against the penetration of solid foreign bodies with a diameter of more than 12.5 mm (0.49 in.)
    • No protection against water

    The system components can be set up and operated in dry rooms in accordance with protection class IP 20.

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Before installation and initial operation

    Installation—overview of TWIN Push/Pull, CMT

    The following overview covers the installation work required for a Push/Pull TWIN welding system in accordance with the system overview on page (→).
    The installation of similar TWIN systems is carried out analogously to this.

    Initial situation:

    • The robot and robot controls are correctly positioned and fastened in the welding cell.
    • The welding machines are installed with the cooling units on the upright brackets and correctly positioned and fastened in the welding cell.
    • The TWIN Controller is available and fastened close to the welding machines (e.g., using a corresponding bracket directly on the welding machine).
    • The welding wire drums are correctly positioned and fixed in place.

    Mounting the TWIN wirefeeder on the OPT/i WF Tower

    1Mount the OPT/i WF Tower
    2Mount the WF Twin Tower
    3Mount the TWIN wirefeeder

    Installing the balancer mounting/wire buffers

    1Mount the balancer mounting on the Y-piece
    or
    mount the support Y-piece on the robot
    2Mount the side holder on the robot

    Only for TWIN CMT applications:
    3Install the wire buffer on the wire buffer holder
    4Install the wire buffer with wire buffer holder on the side holder

    Laying, installing, and connecting interconnecting hosepacks

    1Connect interconnecting hosepacks to the TWIN wirefeeder
    2Lay interconnecting hosepacks to the welding machines
    3Connect the interconnecting hosepacks to the welding machines, cooling units, and TWIN Controller

    IMPORTANT! Maintain a minimum distance of 30–50 cm between interconnecting hosepacks to prevent any impairment of the welding results.

    Connecting the TWIN Controller

    1Connect welding machines to the TWIN Controller
    2Connect TWIN wirefeeder to the TWIN Controller (connect SpeedNet cable from the interconnecting hosepacks to the TWIN Controller)
    3Connect the TWIN Controller to the robot controls

    Installing the CrashBox, torch hosepack, and TWIN welding torch

    1Mount the robot flange and CrashBox on the robot
    2Install the fixing bracket on the CrashBox
    3Mount the TWIN drive unit on the fixing bracket
    4Connect the CrashBox cable
    5Mount the Y-piece from the torch hosepack on the support Y-piece
    or
    suspend the Y-piece from the balancer
    6Fix the torch hosepack to the side holder or to the wire buffers
    7Connect the torch hosepack to the TWIN wirefeeder
    8Insert the inner liners into the TWIN welding torch
    9Insert/route the inner liners and inlet/outlet nozzles into the TWIN torch hosepack
    10Install the torch body coupling
    11Check the function of the torch body coupling
    12Install wear parts on the TWIN welding torch
    13Install TWIN welding torch on the torch hosepack

    Connecting the shielding gas and return lead cable

    1Connect the shielding gas supply to both welding machines
    2Connect one return lead cable per welding machine to the welding machines
    3Connect both return lead cables to the workpiece
    (see also "Ground connection" on page (→))

    Preparing the TWIN wirefeeder for operation

    1Connect the wirefeeding hoses to the welding wire drums
    2Connect wirefeeding hoses from the welding wire drums to the TWIN wirefeeder
    3Connect wirefeeding hoses to the wire buffers on the TWIN wirefeeder
    4Connect wirefeeding hoses to the wire buffers
    5Connect control lines to the TWIN wirefeeder and to the wire buffers
    6Connect wirefeeding hoses to the wire buffers
    7Connect wirefeeding hoses to the TWIN drive unit
    8Insert the inner liners
    9Insert the feed rollers
    10Close all covers

    Defining welding lines 1 and 2 on the welding machines

    1Switch on welding machine 2, leave welding machine 1 switched off
    2Place sticker 2 in a clearly visible location on welding machine 2
    3Set the welding parameter to 2 in the setup menu of welding machine 2 under Defaults/System/TWIN Setup
    4Switch on welding machine 1
    5Place sticker 1 in a clearly visible location on welding machine 1
    6Check that the welding parameter is set to 1 in the setup menu of welding machine 1 under Defaults/System/TWIN Setup

    Final tasks

    1Carry out an R/L comparison on both welding machines
    2Thread the wire electrodes
    3Set the contact pressure
    4 Set the TWIN characteristics on both welding machines
    (welding process/filler metal/change material settings... step 4 – select the characteristic from the characteristics available for each welding process)
    5Set stick out
    6If necessary, carry out system calibration (e.g., if there is a WF REEL unwinding wirefeeder in the system)
    7Define the lead/trail signal on the robot controls
    8Set TWIN welding parameters
    1. Installing the system components - TWIN Push/Pull, CMT

    Mounting the balancer mounting on the Y-piece

    Mounting the balancer mounting on the Y-piece

    The balancer mounting Y-piece is used when the Y-piece is not mounted on the robot.

    1
    1. Installing the system components - TWIN Push/Pull, CMT
    2. Mounting the balancer mounting on the Y-piece

    Mounting the balancer mounting on the Y-piece

    The balancer mounting Y-piece is used when the Y-piece is not mounted on the robot.

    1
    1. Installing the system components - TWIN Push/Pull, CMT

    Mounting the support Y-piece on the robot

    Mounting the support Y-piece on the robot

    1
    Example: Y-piece on a robot

    Installation of the support Y-piece depends on the robot.
    Follow the Installation Instructions!

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Mounting the support Y-piece on the robot

    Mounting the support Y-piece on the robot

    1
    Example: Y-piece on a robot

    Installation of the support Y-piece depends on the robot.
    Follow the Installation Instructions!

    1. Installing the system components - TWIN Push/Pull, CMT

    Installing the side holder on the robot

    Installing the side holder on the robot

    1
    Example: Side holder on a robot

    Installation of the side holder depends on the robot.
    Follow the Installation Instructions!

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Installing the side holder on the robot

    Installing the side holder on the robot

    1
    Example: Side holder on a robot

    Installation of the side holder depends on the robot.
    Follow the Installation Instructions!

    1. Installing the system components - TWIN Push/Pull, CMT

    Installing wire buffers on the robot

    TWIN-CMT - installing wire buffers on the robot

    1
    Example of a side holder on a robot

    Installation of the side holder depends on the robot.
    Follow the Installation Instructions!

    2
    3

    NOTE!

    The recess marked with * must be present on the robot holder for the TWIN wire buffer set!

    If this recess is missing, the TWIN wire buffer set must NOT be mounted!

    4
    Steps 3 + 4: Attach stickers to the wire buffers and define welding lines 1 and 2 on the wire buffers;
    Example according to the figure: right wire buffer = welding line 1, left wire buffer = welding line 2

    NOTE!

    For detailed information on the wire buffer, refer to the Operating Instructions for the wire buffer (42,0410,1254).

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Installing wire buffers on the robot

    TWIN-CMT - installing wire buffers on the robot

    1
    Example of a side holder on a robot

    Installation of the side holder depends on the robot.
    Follow the Installation Instructions!

    2
    3

    NOTE!

    The recess marked with * must be present on the robot holder for the TWIN wire buffer set!

    If this recess is missing, the TWIN wire buffer set must NOT be mounted!

    4
    Steps 3 + 4: Attach stickers to the wire buffers and define welding lines 1 and 2 on the wire buffers;
    Example according to the figure: right wire buffer = welding line 1, left wire buffer = welding line 2

    NOTE!

    For detailed information on the wire buffer, refer to the Operating Instructions for the wire buffer (42,0410,1254).

    1. Installing the system components - TWIN Push/Pull, CMT

    Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Mounting the CrashBox /d TWIN on the robot

    1

    Observe the torques when fitting the robot flange:

    Max. tightening torque for screws with strength class 8.8

    M4
    3.3 Nm / 2.43 lb-ft
    M5
    5.0 Nm / 3.69 lb-ft
    M6
    6.0 Nm / 4.43 lb-ft
    M8
    27.3 Nm / 20.14 lb-ft
    M10
    54 Nm / 39.83 lb-ft
    M12
    93 Nm / 68.60 lb-ft
    2
    3
    4
    5
    6
    7
    8
    1. Installing the system components - TWIN Push/Pull, CMT
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Mounting the CrashBox /d TWIN on the robot

    1

    Observe the torques when fitting the robot flange:

    Max. tightening torque for screws with strength class 8.8

    M4
    3.3 Nm / 2.43 lb-ft
    M5
    5.0 Nm / 3.69 lb-ft
    M6
    6.0 Nm / 4.43 lb-ft
    M8
    27.3 Nm / 20.14 lb-ft
    M10
    54 Nm / 39.83 lb-ft
    M12
    93 Nm / 68.60 lb-ft
    2
    3
    4
    5
    6
    7
    8
    1. Installing the system components - TWIN Push/Pull, CMT
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Mounting the CrashBox TWIN Drive /i Dummy on the robot

    1

    Observe the torques when fitting the robot flange:

    Max. tightening torque for screws with strength class 8.8

    M4
    3.3 Nm / 2.43 lb-ft
    M5
    5.0 Nm / 3.69 lb-ft
    M6
    6.0 Nm / 4.43 lb-ft
    M8
    27.3 Nm / 20.14 lb-ft
    M10
    54 Nm / 39.83 lb-ft
    M12
    93 Nm / 68.60 lb-ft
    2
    * Dowel pin
    1. Installing the system components - TWIN Push/Pull, CMT
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Installing the torch hosepack with TWIN drive unit

    The TWIN drive unit is already mounted on the torch hosepack on delivery.
    To make things simpler, the TWIN drive unit is shown without the torch hosepack in the following illustrations.

    1
    2
    3
    4
    Do not tighten the screw connection yet!
    5
    * = Dowel pin (2x)
    6
    7
    8Connect the CrashBox cable to the drive unit and to the CrashBox

    Mounting the Y-piece from the torch hosepack on the robot support Y-piece

    1
    2
    3

    NOTE!

    The mounting position A, B, or C depends on the torch hosepack length and the robot.

    Observe the following table!

    Robot type

    Twin PP hosepack

    Mounting position

    ABB IRB2600 12 / 1.85

    4,051,611 - 613

    B

    ABB IRB260012 / 1.65

    4,051,611 - 613

    B

    ABB IRB2600 20 / 1.65

    4,051,611 - 613

    B

    ABB IRB 4600-20 / 2.50

    4,051,614 - 615

    B

    ABB IRB 2600iD 15 / 185

    4,051,611 - 613

    B

    ABB IRB 2600iD 8 / 200

    4,051,430 / 460 / 550 / 551

    A

    FANUC AM120iD

    4,051,611 - 613

    A

    YASKAWA HP20 

    4,051,430 / 460 / 550 / 551

    A

    YASKAWA AR1730

    4,051,611 - 613

    B

    YASKAWA AR2010

    4,051,430 / 460 / 550 / 551

    A

    KUKA KR16 R2010

    4,051,430 / 460 / 550 / 551

    A

    KUKA KR16 R1610

    4,051,611 - 613

    B

    KUKA KR20 R3100

    4,051,618

    B

    KUKA KR30 R2100

    4,051,614 - 615

    C

    KUKA KR50 R2100

    4,051,614 - 615

    C

    KUKA KR50 R2500

    4,051,614 - 615

    C

    KUKA KR70 R2100

    4,051,614 - 615

    C

    4


    5Route and fix the torch hosepack to the wire buffers
    or
    fix the torch hosepack to the side holder

    NOTE!

    If torch hosepacks are installed on the robot, make sure that there is no tension or strain in the hosepacks during any movement in a robot axis.

    Route hosepacks in a loop.

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Connecting the torch hosepack to the wirefeeder

    IMPORTANT! When connecting the torch hosepack, pay attention to marks 1 and 2 on the torch hosepack and on the wirefeeder.

    6Open the side panel on the TWIN wirefeeder
    7Open the clamping lever
    8Push the FSC in as far as it will go – observe the markings!
    9Close the clamping lever
    10Close the side panel
    11Connect coolant hoses to the coolant supply and coolant return connections according to the color markings

    The plug-in connection of the coolant hoses is maintained.
    12Route the torch hosepack to the wire buffers and fix it in place
    1. Installing the system components - TWIN Push/Pull, CMT
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Installing anti-kink protection rings

    The torch hosepack is equipped with anti-kink protection rings on delivery.
    These anti-kink protection rings fulfill several tasks:

    • Anti-kink protection if several rings are mounted one after the other
    • Chafe protection if one or more rings are mounted in vulnerable areas
    • Bridging of cracks or damaged areas on the corrugated protective hose
    • Connection of Y-piece to the corrugated protective hose

    The anti-kink protection rings may only be mounted according to the following illustration:

    (1)
    The first anti-kink protection ring connects the corrugated protective hose to the plastic cover of the TWIN drive unit
    (2)
    2 groove gap

    Fit the rings either
    (3)
    front face to front face
    or
    (4)
    groove to groove
    on the corrugated protective hose

    Groove to groove always follows front face to front face and vice versa!

    Do not combine groove and front face!

    At least 6 rings!

    IMPORTANT! Any deviating installation of the anti-kink protection rings will result in the loss of warranty claims.

    An anti-kink protection ring consists of two half shells, which are screwed together on the corrugated protective hose with two M4 x 10 mm Allen screws.
    Tightening torque = 1 Nm / 0.74 lb·ft

    The anti-kink protection rings are available individually as an option from Fronius.

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Install CrashBox, Torch Hosepack and TWIN Welding Torch

    Mounting the torch body on the TWIN drive unit

    NOTE!

    The coupling areas between the torch body and TWIN drive unit must always be free of oil, grease, and dust, and be dry.

    1

    Visually check that the springs are present, not deformed or otherwise damaged.

    NOTE!

    Do not clean the area around the springs with compressed air.

    2
    * Special key BY2,0201,4863

    NOTE!

    Switch off the cooling unit before dismantling the torch body!

    1. Installing the system components - TWIN Push/Pull, CMT

    Fitting the wirefeeding hoses and inner liners

    Inserting the inner liner into the torch hosepack

    For TWIN Push/Pull systems without wire buffers

    1Disconnect the wirefeeding hose from the robot wirefeeder (press white button)
    2Fit the collet
    3Insert the inner liner until it is visible at the sight hole of the drive unit
    4Cut the inner liner flush to length
    5Fit the inlet nozzle to the brass section according to the basic kit
    6Screw the brass section with inlet nozzle onto the collet
    7Reconnect the wirefeeding hose (press the white button if necessary, the button must pop out again)
    1. Installing the system components - TWIN Push/Pull, CMT
    2. Fitting the wirefeeding hoses and inner liners

    Inserting the inner liner into the torch hosepack

    For TWIN Push/Pull systems without wire buffers

    1Disconnect the wirefeeding hose from the robot wirefeeder (press white button)
    2Fit the collet
    3Insert the inner liner until it is visible at the sight hole of the drive unit
    4Cut the inner liner flush to length
    5Fit the inlet nozzle to the brass section according to the basic kit
    6Screw the brass section with inlet nozzle onto the collet
    7Reconnect the wirefeeding hose (press the white button if necessary, the button must pop out again)
    1. Installing the system components - TWIN Push/Pull, CMT

    Preparing the TWIN drive unit for operation

    General

    The feed rollers are not inserted in the system when first delivered.

    In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

    NOTE!

    Danger due to deficient feed rollers.

    This can result in poor-quality weld properties.

    Only use feed rollers which match the wire electrode.

    Only use toothed feed rollers for TWIN applications.

    An overview of the available feed rollers and their possible uses can be found in the Spare Parts Lists.

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Preparing the TWIN drive unit for operation

    General

    The feed rollers are not inserted in the system when first delivered.

    In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

    NOTE!

    Danger due to deficient feed rollers.

    This can result in poor-quality weld properties.

    Only use feed rollers which match the wire electrode.

    Only use toothed feed rollers for TWIN applications.

    An overview of the available feed rollers and their possible uses can be found in the Spare Parts Lists.

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Preparing the TWIN drive unit for operation

    Basic Kits overview

    The feed rollers are included in the TWIN Basic Kits.
    The following Basic Kits are available:

    Fe
    • 44,0350,1731 ... BK Fe ø1,0/TWIN PushPull
    • 44,0350,1732 ... BK Fe ø1,2/TWIN PushPull
    • 44,0350,1740 ... BK Fe ø1,6/TWIN PushPull
    •  
    CrNi
    • 44,0350,1742 ... BK CrNi ø1,0/TWIN PushPull
    • 44,0350,1743 ... BK CrNi ø1,2/TWIN PushPull
    • 44,0350,1751 ... BK CrNi ø1,6/TWIN PushPull
    Al
    • 44,0350,1676 ... BK Al ø1,2/TWIN PushPull
    • 44,0350,1679 ... BK Al ø1,6/TWIN PushPull

    BK = Basic Kit

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Preparing the TWIN drive unit for operation

    Inserting/changing the feed rollers on the TWIN drive unit

    1Pull the locking buttons
    2Disconnect the wirefeeding hoses
    3Open the clamping lever
    4Swing out the roller holder
    5Remove the spindle
    6Insert the toothed pressure roller
    7Insert the spindle
    8Counter with the special key
    9Unscrew the drive roller
    10Remove the drive roller
    11Insert the new drive roller
    12Screw on the new drive roller

    Install by performing the steps in the reverse order

    IMPORTANT! Check the contact pressure before recommissioning!

    1. Installing the system components - TWIN Push/Pull, CMT
    2. Preparing the TWIN drive unit for operation

    Connecting wirefeeding hoses

    Connect the wirefeeding hoses in the same way as on the TWIN Push system (see page (→)).

    The following wirefeeding hoses are required:

    • Wire drum - robot wirefeeder
    • Robot wirefeeder - wire buffer
    • Wire buffer - TWIN drive unit

    Installing and preparing other system components, commissioning

    Installing the robot welding torch

    Inserting steel inner liner into the torch body

    1
    2

    NOTE!

    The coupling area of the torch body must always be free of oil, grease, and dust, and be dry.

    3
    4
    5
    6
    7
    8
    9
    10
    11
    12
    1. Installing and preparing other system components, commissioning

    Installing the robot welding torch

    Inserting steel inner liner into the torch body

    1
    2

    NOTE!

    The coupling area of the torch body must always be free of oil, grease, and dust, and be dry.

    3
    4
    5
    6
    7
    8
    9
    10
    11
    12
    1. Installing and preparing other system components, commissioning
    2. Installing the robot welding torch

    Inserting steel inner liner into the torch body

    1
    2

    NOTE!

    The coupling area of the torch body must always be free of oil, grease, and dust, and be dry.

    3
    4
    5
    6
    7
    8
    9
    10
    11
    12
    1. Installing and preparing other system components, commissioning
    2. Installing the robot welding torch

    Inserting plastic inner liner into the torch body

    NOTE!

    The coupling area of the torch body must always be free of oil, grease, and dust, and be dry.

    When mounting a plastic inner liner, the contact tips must be mounted on the torch body.

    1
    2
    Push the inner liner in as far as it will go
    3
    4
    5
    6
    7Repeat steps 2–6 for the second wire electrode

    NOTE!

    All other available inner liners can be mounted like a plastic inner liner from the coupling side.

    1. Installing and preparing other system components, commissioning
    2. Installing the robot welding torch

    Installing wear parts in the TWIN welding torch

    Spatter Guard wear parts

    NOTE!

    For detailed information, refer to the Installation Instructions 42,0410,2487 ... OPT/i TWIN 0/4/8/11.5°

    Sleeve wear parts

    NOTE!

    For detailed information, refer to the Installation Instructions 42,0410,2932 ... OPT/i TWIN 0/4/8/11.5° Sleeve

    1. Installing and preparing other system components, commissioning
    2. Installing the robot welding torch

    Inserting the inner liner in the TWIN-MTB Single adapter

    NOTE!

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

    Fronius recommends running single applications on welding line 1.

    1
    2
    1 = welding line 1, 2 = welding line 2
    3
    Push the inner liner in as far as it will go
    4
    5
    6
    7
    1. Installing and preparing other system components, commissioning

    Preparing TWIN Wirefeeder for Operation

    Inserting/changing feed rollers

    CAUTION!

    Danger due to feed roller holders shooting upwards.

    This could result in injury.

    When unlocking the clamping lever, keep fingers away from the area to the left and right of the clamping lever.

    1
    2

    CAUTION!

    Danger due to open feed rollers.

    This could result in injury.

    After inserting/changing the feed rollers, always install the protective cover of the 4-roller drive.

    3
    4
    1. Installing and preparing other system components, commissioning
    2. Preparing TWIN Wirefeeder for Operation

    Inserting/changing feed rollers

    CAUTION!

    Danger due to feed roller holders shooting upwards.

    This could result in injury.

    When unlocking the clamping lever, keep fingers away from the area to the left and right of the clamping lever.

    1
    2

    CAUTION!

    Danger due to open feed rollers.

    This could result in injury.

    After inserting/changing the feed rollers, always install the protective cover of the 4-roller drive.

    3
    4
    1. Installing and preparing other system components, commissioning
    2. Preparing TWIN Wirefeeder for Operation

    Connecting wirefeeding hoses

    1
    2Connect wirefeeding hoses to the welding wire drums
    1. Installing and preparing other system components, commissioning
    2. Preparing TWIN Wirefeeder for Operation

    Wire straightener

    NOTE!

    When using the OPT/i WF wire straightener option, observe the information in the Operating Instructions 42,0410,1944!

    1. Installing and preparing other system components, commissioning

    Lay, Install and Connect Interconnecting Hosepacks

    Connecting interconnecting hosepacks to the robot wirefeeders

    NOTE!

    If the interconnecting hosepack is laid incorrectly it can have a significant influence on the welding results, a stable welding process is not guaranteed!

    As far as possible, maintain a distance of 30 - 50 cm between the two interconnecting hosepacks.

    1Route interconnecting hosepacks to the wirefeeder

    IMPORTANT! When connecting the interconnecting hosepacks, observe marks 1 and 2 on the interconnecting hosepacks and on the wirefeeder:
    1 = water-cooled interconnecting hosepack
    2 = gas-cooled interconnecting hosepack

    Connect the interconnecting hosepacks to the robot wirefeeders in the same way as you connect them to the TWIN wirefeeder (see page (→)).

    2Connecting interconnecting hosepack 1 to the robot wirefeeder:
    power cable 1, SpeedNet 1, shielding gas 1, and coolant connection
    3Connecting interconnecting hosepack 2 to the robot wirefeeder:
    power cable 2, SpeedNet 2, and shielding gas 2
    1. Installing and preparing other system components, commissioning
    2. Lay, Install and Connect Interconnecting Hosepacks

    Connecting interconnecting hosepacks to the robot wirefeeders

    NOTE!

    If the interconnecting hosepack is laid incorrectly it can have a significant influence on the welding results, a stable welding process is not guaranteed!

    As far as possible, maintain a distance of 30 - 50 cm between the two interconnecting hosepacks.

    1Route interconnecting hosepacks to the wirefeeder

    IMPORTANT! When connecting the interconnecting hosepacks, observe marks 1 and 2 on the interconnecting hosepacks and on the wirefeeder:
    1 = water-cooled interconnecting hosepack
    2 = gas-cooled interconnecting hosepack

    Connect the interconnecting hosepacks to the robot wirefeeders in the same way as you connect them to the TWIN wirefeeder (see page (→)).

    2Connecting interconnecting hosepack 1 to the robot wirefeeder:
    power cable 1, SpeedNet 1, shielding gas 1, and coolant connection
    3Connecting interconnecting hosepack 2 to the robot wirefeeder:
    power cable 2, SpeedNet 2, and shielding gas 2
    1. Installing and preparing other system components, commissioning
    2. Lay, Install and Connect Interconnecting Hosepacks

    Connect the interconnecting hosepacks to the welding machine, cooling unit, and TWIN Controller

    IMPORTANT! When connecting the interconnecting hosepacks, observe marks 1 and 2 on the interconnecting hosepacks and on the welding machines:
    1 = water-cooled interconnecting hosepack
    2 = gas-cooled interconnecting hosepack

    NOTE!

    If the interconnecting hosepack is laid incorrectly it can have a significant influence on the welding results, a stable welding process is not guaranteed!

    As far as possible, maintain a distance of 30 to 50 cm between the two interconnecting hosepacks.

    1Lay interconnecting hosepacks to the welding machines
    2Connect the interconnecting hosepacks to the welding machines, cooling units, and TWIN Controller
    1. Installing and preparing other system components, commissioning

    Connect TWIN Controller

    Connect the TWIN Controller with the welding machines and connect the interconnecting hosepack

    1

    Connect the welding machine to the TWIN Controller via the SpeedNet cable

     

    TPSi 1 = welding machine 1

    TPSi 2 = welding machine 2

    HP CON 1 = interconnecting hosepack 1

    HP CON 2 = interconnecting hosepack 2

    1. Installing and preparing other system components, commissioning
    2. Connect TWIN Controller

    Connect the TWIN Controller with the welding machines and connect the interconnecting hosepack

    1

    Connect the welding machine to the TWIN Controller via the SpeedNet cable

     

    TPSi 1 = welding machine 1

    TPSi 2 = welding machine 2

    HP CON 1 = interconnecting hosepack 1

    HP CON 2 = interconnecting hosepack 2

    1. Installing and preparing other system components, commissioning
    2. Connect TWIN Controller

    Connecting the TWIN Controller to the robot controls

    1

    R-C = robot controls

    NOTE!

    For detailed information, refer to the following Operating Instructions:

    For connection and installation:
    42,0426,0299,xx ... RI FB PRO/i TWIN Controller

    For signal descriptions:
    42,0410,2449 ... ProfiNet
    42,0410,2450 ... DeviceNet
    42,0410,2451 ... Ethernet IP-2P
    42,0410,2452 ... EtherCAT

    1. Installing and preparing other system components, commissioning

    Connecting the Protective Gas Shield and Grounding Cable

    Connecting Protective Gas Shield

    1Connect the protective gas shield hoses from the interconnecting hosepacks to the protective gas shield supply
    1. Installing and preparing other system components, commissioning
    2. Connecting the Protective Gas Shield and Grounding Cable

    Connecting Protective Gas Shield

    1Connect the protective gas shield hoses from the interconnecting hosepacks to the protective gas shield supply
    1. Installing and preparing other system components, commissioning
    2. Connecting the Protective Gas Shield and Grounding Cable

    Connecting the return lead cable

    CAUTION!

    Danger due to incorrect routing of the return lead cables!

    This can result in severely impaired welding results!

    Disconnect welding circuits!

    Provide a separate ground earth connection for each welding circuit!

    Do not use a common grounding cable!

    Route the return lead cable as close as possible to the interconnecting hosepack.

    Further information on routing the return lead cables can be found from page (→).

    1
    1. Installing and preparing other system components, commissioning

    Commissioning

    Threading the wire electrode

    CAUTION!

    Danger of injury and property damage due to welding current and unintentional ignition of an arc.

    Before starting work, disconnect the ground earth connection between the welding system and workpiece.

    CAUTION!

    Danger of damage to the welding torch due to sharp-edged end of the wire electrodes.

    Thoroughly deburr the end of the wire electrodes before inserting.

    CAUTION!

    Danger of injury due to spring effect of the coiled wire electrodes.

    When inserting the wire electrodes into the 4 roller drive, keep a secure hold of the end of the wire electrodes in order to prevent injuries due to wire electrodes springing back.

    1

    CAUTION!

    Danger of injury and property damage due to protruding wire electrodes.

    During work

    Position the welding torch so that the tip of the welding torch points away from the face and body

    Wear suitable protective goggles

    Do not point the welding torch at people

    Ensure that the wire electrodes do not touch any electrically conductive or grounded parts (housing, etc.)

    2
    3
    Set the appropriate stick out for the application
    1. Installing and preparing other system components, commissioning
    2. Commissioning

    Threading the wire electrode

    CAUTION!

    Danger of injury and property damage due to welding current and unintentional ignition of an arc.

    Before starting work, disconnect the ground earth connection between the welding system and workpiece.

    CAUTION!

    Danger of damage to the welding torch due to sharp-edged end of the wire electrodes.

    Thoroughly deburr the end of the wire electrodes before inserting.

    CAUTION!

    Danger of injury due to spring effect of the coiled wire electrodes.

    When inserting the wire electrodes into the 4 roller drive, keep a secure hold of the end of the wire electrodes in order to prevent injuries due to wire electrodes springing back.

    1

    CAUTION!

    Danger of injury and property damage due to protruding wire electrodes.

    During work

    Position the welding torch so that the tip of the welding torch points away from the face and body

    Wear suitable protective goggles

    Do not point the welding torch at people

    Ensure that the wire electrodes do not touch any electrically conductive or grounded parts (housing, etc.)

    2
    3
    Set the appropriate stick out for the application
    1. Installing and preparing other system components, commissioning
    2. Commissioning

    Setting the contact pressure

    1

    NOTE!

    Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding.

    Use the specified standard values on the sticker on the protective cover to adjust the contact pressure.

    Contact pressure standard values
    steel rollers

    Steel: 4 - 5
    CrNi: 4 - 5
    Al: 0.5 - 1.5
    Tubular covered electrodes: 2 - 3

    Contact pressure standard values
    plastic rollers

    Al: 3 - 4

    1. Installing and preparing other system components, commissioning
    2. Commissioning

    Threading the wire electrode

    The wire electrode can be threaded on the TWIN robot wirefeeder or on the TWIN drive unit.
    Thread the wire electrode in the same way as on the TWIN Push system (see page (→)).

    The following wirefeeding hoses are required:

    • Wire drum - robot wirefeeder
    • Robot wirefeeder - wire buffer
    • Wire buffer - TWIN drive unit
    1. Installing and preparing other system components, commissioning
    2. Commissioning

    Setting the contact pressure on the TWIN drive unit

    1

    NOTE!

    Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding.

    Use the specified standard values on the sticker on the protective cover to adjust the contact pressure.

    Set the contact pressure for both wire electrodes.

    1. Installing and preparing other system components, commissioning
    2. Commissioning

    Requirements

    NOTE!

    The following requirements must be fulfilled for commissioning a TWIN welding system:

    All components must be installed and connected in accordance with the "Installation" chapter.
    The TWIN welding system may only be fitted and operated with original Fronius components.
    Do not fit or install any third-party components!

    All necessary welding media must be connected to the wirefeeder or to the TWIN drive unit.

    Feed rollers corresponding to the wire electrodes to be welded must be inserted in the wirefeeder or the TWIN drive unit.

    Wire electrodes must be threaded in.

    Contact pressure of the feed rollers must be set.

    Motor calibration must be carried out.

    All covers must be present and closed
    All side parts must be installed
    All safety devices must be intact and installed in the location intended (for example, protective covers)

    1. Installing and preparing other system components, commissioning
    2. Commissioning

    Commissioning - start of welding

    IMPORTANT! Before starting for the first time, spray the welding torch wearing parts from the front so that they are wetted with parting agent.
    Spraying can be performed manually or automatically.

    When using a TWIN welding process, welding is started by an active welding start signal from the robot controls.

    Troubleshooting, Maintenance, and Disposal

    Troubleshooting

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electric current.

    This can result in serious personal injury and damage to property.

    Before carrying out maintenance or service work, switch off all devices and components involved and disconnect them from the power supply.

    Secure all devices and components involved against being switched on again.

    After opening the appliance, use a suitable measuring device to ensure that electrically charged components (e.g. capacitors) are discharged.

    CAUTION!

    Danger due to hot system components and/or equipment.

    This can result in burns or scalding.

    Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.).

    Wear suitable protective equipment if cooling down is not possible (e.g., heat-resistant gloves, safety goggles, etc.).

    1. Troubleshooting, Maintenance, and Disposal

    Troubleshooting

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electric current.

    This can result in serious personal injury and damage to property.

    Before carrying out maintenance or service work, switch off all devices and components involved and disconnect them from the power supply.

    Secure all devices and components involved against being switched on again.

    After opening the appliance, use a suitable measuring device to ensure that electrically charged components (e.g. capacitors) are discharged.

    CAUTION!

    Danger due to hot system components and/or equipment.

    This can result in burns or scalding.

    Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.).

    Wear suitable protective equipment if cooling down is not possible (e.g., heat-resistant gloves, safety goggles, etc.).

    1. Troubleshooting, Maintenance, and Disposal
    2. Troubleshooting

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electric current.

    This can result in serious personal injury and damage to property.

    Before carrying out maintenance or service work, switch off all devices and components involved and disconnect them from the power supply.

    Secure all devices and components involved against being switched on again.

    After opening the appliance, use a suitable measuring device to ensure that electrically charged components (e.g. capacitors) are discharged.

    CAUTION!

    Danger due to hot system components and/or equipment.

    This can result in burns or scalding.

    Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.).

    Wear suitable protective equipment if cooling down is not possible (e.g., heat-resistant gloves, safety goggles, etc.).

    1. Troubleshooting, Maintenance, and Disposal
    2. Troubleshooting

    Troubleshooting

    Make a note of the serial number and configuration of the device, and provide the service team with a detailed error description if:

    • Errors occur that are not covered in this document
    • The troubleshooting measures provided in this document are unsuccessful

    Welding machine not working
    Power switch is switched on; displays and indicators do not illuminate
    Cause:Mains lead damaged or broken, mains plug not inserted
    Remedy:Check mains lead, if necessary insert mains plug
    Cause:Mains socket or mains plug faulty
    Remedy:Replace faulty parts
    Cause:Mains fuse
    Remedy:Replace mains fuse
    Cause:Short circuit on the 24 V power supply of the SpeedNet connection or external sensor
    Remedy:Disconnect connected components
    No function after setting a welding start signal
    Power switch of the welding machine switched on, indicators light up
    Cause:Interconnecting hosepack faulty or not connected correctly
    Remedy:Check interconnecting hosepack
    Cause:No communication with the robot controls
    Remedy: Check the communication with the robot controls
    No welding current
    Power switch of the welding machine switched on, indicators light up
    Cause:Incorrect ground connection
    Remedy:Check ground connection for polarity
    Cause:Power cable in welding torch damaged or broken
    Remedy:Replace the welding torch
    no shielding gas
    all other functions present
    Cause:Gas cylinder empty
    Remedy:Change gas cylinder
    Cause:Gas pressure regulator faulty
    Remedy:Replace gas pressure reducer
    Cause:Gas hose not attached, or damaged
    Remedy:Attach or replace gas hose
    Cause:Welding torch faulty
    Remedy:Change welding torch
    Cause:Gas solenoid valve faulty
    Remedy:Inform the service team
    Irregular wire speed
    Cause:Contact tip hole too narrow
    Remedy:Use suitable contact tip
    Cause:Inner liner in the welding torch faulty
    Remedy:Check inner liner for kinks, soiling, etc.
    Cause:Feed rollers not suitable for wire electrode used
    Remedy:Use suitable feed rollers
    Cause:Incorrect contact pressure of the feed rollers
    Remedy:Optimize contact pressure
    Wirefeed issues
    For applications with long hosepacks
    Cause:Improper laying of the hosepack
    Remedy:Lay hosepack as straight as possible while avoiding tight bending radii
    Welding torch gets very hot
    Cause:Welding torch is inadequately sized
    Remedy:Observe duty cycle and load limits
    Cause:For water-cooled systems only: Coolant flow too low
    Remedy:Check coolant level, coolant flow rate, coolant contamination, etc. For more detailed information, refer to the Operating Instructions for the cooling unit
    Poor-quality weld properties
    Cause:Incorrect welding parameters
    Remedy:Check settings
    Cause:Poor ground earth connection
    Remedy:Establish good contact with workpiece
    Cause:Too little or no shielding gas
    Remedy:Check gas pressure regulator, gas hose, gas solenoid valve, welding torch gas connection, etc.
    Cause:Welding torch leaks
    Remedy:Change welding torch
    Cause:Incorrect or heavily worn contact tip
    Remedy:Change contact tip
    Cause:Incorrect wire alloy or incorrect wire diameter
    Remedy:Check wire electrode in use
    Cause:Incorrect wire alloy or incorrect wire diameter
    Remedy:Check weldability of the base material
    Cause:Shielding gas not suitable for wire alloy
    Remedy:Use correct shielding gas
    1. Troubleshooting, Maintenance, and Disposal
    2. Troubleshooting

    Displayed Error Codes

    The following error codes may be output on the welding machine in relation to a TWIN welding process:

    8
    Welding process does not start after the welding start signal has been activated
    Cause:No welding torch connected, welding torch has not been detected
    Remedy:Check the connection between the welding torch and the torch hosepack;
    if the welding torch is connected correctly, inform the service team
    37
    TX welding torch replacement not possible
    Cause:Torch hosepack not present or not connected correctly
    Remedy:Check the connection between the torch hosepack and the TWIN wirefeeder;
    if the torch hosepack is connected correctly, inform the service team
    38
    It is not possible to purge the welding torch
    Cause:Torch hosepack not present or not connected correctly
    Remedy:Check the connection between the torch hosepack and the TWIN wirefeeder;
    if the torch hosepack is connected correctly, inform the service team
    16768
    Welding process does not start
    Cause:The interconnecting hosepack connections have been mixed up
    Remedy:Connect the interconnecting hosepacks to the TWIN wirefeeder correctly (observe markings 1 and 2)
    16769
    Welding process does not start
    Cause:The torch hosepacks have been mixed up
    Remedy:Connect the torch hosepacks to the TWIN wirefeeder correctly (observe markings 1 and 2)
    18229
    Welding process does not start
    Cause:The second welding machine is not ready
    Remedy:Check whether the second welding machine is switched on;
    check whether the second welding machine is connected to the TWIN Controller.
    18230
    Welding process does not start
    Cause:Welding machines are not synchronized
    Remedy:Check whether the SpeedNet cable is connected to both welding machines and the TWIN Controller correctly
    18231
    Welding process does not start
    Cause:The welding machine is connected to the wrong port on the TWIN Controller
    Remedy:Check that welding machine 1 is connected to port 1 and welding machine 2 is connected to port 2 on the TWIN Controller
    18232
    It is not possible to thread the wire or weld (in TWIN mode)
    Cause:Single welding torch on a TWIN hosepack
    Remedy:Select single mode or switch to a TWIN welding torch
    1. Troubleshooting, Maintenance, and Disposal

    Service, maintenance and disposal

    General

    The device only requires minimal of service and maintenance under normal operating conditions. However, several points must be observed for the welding system to remain operational for years to come.

    1. Troubleshooting, Maintenance, and Disposal
    2. Service, maintenance and disposal

    General

    The device only requires minimal of service and maintenance under normal operating conditions. However, several points must be observed for the welding system to remain operational for years to come.

    1. Troubleshooting, Maintenance, and Disposal
    2. Service, maintenance and disposal

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electric current.

    This can result in serious personal injury and damage to property.

    Before carrying out maintenance or service work, switch off all devices and components involved and disconnect them from the power supply.

    Secure all devices and components involved against being switched on again.

    After opening the appliance, use a suitable measuring device to ensure that electrically charged components (e.g. capacitors) are discharged.

    CAUTION!

    Danger due to hot system components and/or equipment.

    This can result in burns or scalding.

    Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.).

    Wear suitable protective equipment if cooling down is not possible (e.g., heat-resistant gloves, safety goggles, etc.).

    1. Troubleshooting, Maintenance, and Disposal
    2. Service, maintenance and disposal

    At every start-up

    • Check all hosepacks and the ground earth connection for damage. Replace any damaged components.
    • Check feed rollers and inner liners for damage. Replace any damaged components.
    • Check wirefeeding hoses for damage. Replace any damaged components.
    • Check contact pressure of the feed rollers and adjust if necessary.
    • Check all screw connections between robot, wirefeeder holder, and wirefeeder for secure position.
    • On the TWIN welding torch, check the area between the nozzle fittings and contact tips for welding spatter accumulation - clean if necessary.
    1. Troubleshooting, Maintenance, and Disposal
    2. Service, maintenance and disposal

    Daily

    * Daily check of the contact spring

    Visually check that the springs are present, not deformed or otherwise damaged.

    NOTE!

    In case of more visible damage to the contact spring:

    Replace the contact spring

    NOTE!

    To prevent small parts from falling out or being lost, do not clean the area around the springs with compressed air.

    1. Troubleshooting, Maintenance, and Disposal
    2. Service, maintenance and disposal

    Identifying defective wearing parts

    1
    Insulating parts
    • Notches
    • Burnt or torn center strut or outer edges
    • Scorched or torn attachments
    2
    Nozzle fittings
    • Notches and penetration at the front edge
    • Heavily coated with welding spatter
    3
    Spatter guard
    • Burnt outer edges
    • Notches
    4
    Contact tips
    • Ground (oval) wire entry and wire exit bores
    • Heavily coated with welding spatter
    • Penetration at the tip of the contact tip
    5
    Gas nozzles
    • Heavily coated with welding spatter
    • Burnt outer edges
    • Notches
    1. Troubleshooting, Maintenance, and Disposal
    2. Service, maintenance and disposal

    Weekly

    Contacts of the torch identification on the welding torch interface

    Clean the welding torch interface, and especially the contacts of the torch identification, with a soft cloth

    NOTE!

    In case of more visible contamination or coolant at the welding torch interface:

    Clean the interface earlier!

    Do not use pointed or sharp objects such as a screwdriver, wire electrode or the like to clean the interface!

    1. Troubleshooting, Maintenance, and Disposal
    2. Service, maintenance and disposal

    Monthly

    Check 74 mm inner liner piece in the TWIN drive unit, replace if necessary.

    Replace 74 mm inner liner piece:

    1Remove welding torch
    2Remove the 2 M7 Allen screws
    3Pull out two 74 mm inner liner pieces using the inner liner extractor tool

    Install by performing the steps in the reverse order.

    1. Troubleshooting, Maintenance, and Disposal
    2. Service, maintenance and disposal

    Every 6 months

    CAUTION!

    Danger from compressed air at close range.

    Electronic parts may be damaged.

    Do not bring the air nozzle too close to electronic parts.

    • Open covers, dismantle device side panels, and blow the inside of the device clean with dry, reduced compressed air. After cleaning, restore the system to its original condition.
    1. Troubleshooting, Maintenance, and Disposal
    2. Service, maintenance and disposal

    Disposal

    Waste electrical and electronic equipment must be collected separately and recycled in an environmentally sound manner in accordance with the European Directive and national law. Used equipment must be returned to the distributor or through a local authorized collection and disposal system. Proper disposal of the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.

    Packaging materials
    • Collect separately
    • Observe local regulations
    • Crush cardboard boxes

    Technical data

    TWIN wirefeeder

    WF 30i R /TWIN

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1.4 A

    Welding current
    at 10 min/40°C (104°F)

    40% ED1) 650 A
    60% ED1) 600 A
    10% ED1) 500 A

    Maximum pressure of shielding gas

    7 bar/101.53 psi

    Coolant

    Original Fronius

    Maximum pressure of coolant

    5 bar/72.53 psi

    Wire speed

    1 - 30 m/min / 39.37 - 1181.10 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    1.2 - 1.6 mm/0.05 - 0.06 in.

    Protection class

    IP 23

    Mark of conformity

    S, CE, CSA

    Dimensions l × w × h

    410 x 300 x 280 mm
    16.1 x 11.8 x 11.0 in.

    Weight

    12.75 kg/28.11 Ib.

    EMC emission class

    A 

     

    1)
    ED = Duty cycle
    1. Technical data

    TWIN wirefeeder

    WF 30i R /TWIN

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1.4 A

    Welding current
    at 10 min/40°C (104°F)

    40% ED1) 650 A
    60% ED1) 600 A
    10% ED1) 500 A

    Maximum pressure of shielding gas

    7 bar/101.53 psi

    Coolant

    Original Fronius

    Maximum pressure of coolant

    5 bar/72.53 psi

    Wire speed

    1 - 30 m/min / 39.37 - 1181.10 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    1.2 - 1.6 mm/0.05 - 0.06 in.

    Protection class

    IP 23

    Mark of conformity

    S, CE, CSA

    Dimensions l × w × h

    410 x 300 x 280 mm
    16.1 x 11.8 x 11.0 in.

    Weight

    12.75 kg/28.11 Ib.

    EMC emission class

    A 

     

    1)
    ED = Duty cycle
    1. Technical data
    2. TWIN wirefeeder

    WF 30i R /TWIN

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1.4 A

    Welding current
    at 10 min/40°C (104°F)

    40% ED1) 650 A
    60% ED1) 600 A
    10% ED1) 500 A

    Maximum pressure of shielding gas

    7 bar/101.53 psi

    Coolant

    Original Fronius

    Maximum pressure of coolant

    5 bar/72.53 psi

    Wire speed

    1 - 30 m/min / 39.37 - 1181.10 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    1.2 - 1.6 mm/0.05 - 0.06 in.

    Protection class

    IP 23

    Mark of conformity

    S, CE, CSA

    Dimensions l × w × h

    410 x 300 x 280 mm
    16.1 x 11.8 x 11.0 in.

    Weight

    12.75 kg/28.11 Ib.

    EMC emission class

    A 

     

    1)
    ED = Duty cycle
    1. Technical data

    Robot welding torch

    MTB 900i R

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 900 A (2 x 450 A)
    100% ED* / 900 A (2 x 450 A)

    Wire diameter

    1.2 - 1.6 mm/0.05 - 0.06 inch

     

     

    * ED = Duty cycle

    1. Technical data
    2. Robot welding torch

    MTB 900i R

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 900 A (2 x 450 A)
    100% ED* / 900 A (2 x 450 A)

    Wire diameter

    1.2 - 1.6 mm/0.05 - 0.06 inch

     

     

    * ED = Duty cycle

    1. Technical data
    2. Robot welding torch

    MTB 2x500i R

    Welding current at 10 min / 40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 1000 A (2 x 500 A)
    100% ED* / 1000 A (2 x 500 A)

    Wire diameter

    1.2 - 1.6 mm / 0.05 - 0.06 inch

     

     

    * ED = Duty cycle

    The dimensions of the MTB 2x500i R, which depend on the contact tip tilt angle, can be found in the following section.

    1. Technical data
    2. Robot welding torch

    MTB 2x500i R - dimensions depending on contact tip tilt angle

    s
    Contact tip to workpiece distance
    L1
    TCP - edge of gas nozzle length
    α
    Contact tip tilt angle
    SO
    Stick out
    x
    Wire electrode distance

     

    H
    Height
    β
    Angle of curvature
    L
    Length

    α = 11,5°

     

     

     

     

     

     

     

     

    β = 0° / PB

    β = 30° / PB & PA

    β = 45° / PB & PA

    SO [mm]

    L1 [mm]

    s [mm]

    x [mm]

    L [mm]

    H [mm]

    L [mm]

    H [mm]

    L [mm]

    H [mm]

    15

    60.56

    10.44

    7.43

    327.01

    0.00

    327.14

    82.00

    327.30

    149.30

    16

    61.55

    10.44

    7.23

    328.00

    0.00

    328.00

    82.50

    328.00

    150.00

    17

    62.55

    10.44

    7.03

    329.00

    0.00

    328.86

    83.00

    328.70

    150.70

    18

    63.54

    10.44

    6.83

    329.99

    0.00

    329.72

    83.50

    329.41

    151.41

    19

    64.54

    10.44

    6.63

    330.99

    0.00

    330.58

    83.99

    330.11

    152.11

    20

    65.53

    10.44

    6.43

    331.98

    0.00

    331.45

    84.49

    330.81

    152.81

    21

    66.53

    10.44

    6.23

    332.98

    0.00

    332.31

    84.99

    331.52

    153.52

    22

    67.52

    10.44

    6.03

    333.97

    0.00

    333.17

    85.49

    332.22

    154.22

    23

    68.52

    10.44

    5.83

    334.97

    0.00

    334.03

    85.98

    332.92

    154.92

    24

    69.51

    10.44

    5.63

    335.96

    0.00

    334.89

    86.46

    333.63

    155.63

    25

    70.51

    10.44

    5.43

    336.96

    0.00

    335.75

    86.98

    334.33

    156.33

    26

    71.50

    10.44

    5.23

    337.95

    0.00

    336.62

    87.48

    335.03

    157.03

    27

    72.50

    10.44

    5.03

    338.94

    0.00

    337.48

    87.97

    335.74

    157.74

    28

    73.49

    10.44

    4.83

    339.93

    0.00

    338.34

    88.47

    336.44

    158.44

    29

    74.49

    10.44

    4.63

    340.93

    0.00

    339.20

    88.97

    337.15

    159.15

    30

    75.48

    10.44

    4.43

    341.93

    0.00

    340.06

    89.46

    337.85

    159.85

    α = 8,0°

     

     

     

     

     

     

     

     

    β = 0° / PB

    β = 30° / PB & PA

    β = 45° / PB & PA

    SO [mm]

    L1 [mm]

    s [mm]

    x [mm]

    L [mm]

    H [mm]

    L [mm]

    H [mm]

    L [mm]

    H [mm]

    15

    60.91

    13.65

    11.55

    327.25

    0.00

    327.44

    82.18

    327.54

    149.54

    16

    61.90

    13.65

    11.42

    328.35

    0.00

    328.30

    82.67

    328.25

    150.25

    17

    62.90

    13.65

    11.28

    329.35

    0.00

    329.17

    83.17

    328.95

    150.95

    18

    63.90

    13.65

    11.14

    330.34

    0.00

    330.03

    83.67

    329.66

    151.66

    19

    64.90

    13.65

    11.00

    331.34

    0.00

    330.89

    84.17

    330.36

    152.36

    20

    65.89

    13.65

    10.86

    332.34

    0.00

    331.76

    84.67

    331.07

    153.07

    21

    66.89

    13.65

    10.72

    333.34

    0.00

    332.62

    85.17

    331.77

    153.77

    22

    67.89

    13.65

    10.58

    334.34

    0.00

    333.49

    85.67

    332.48

    154.48

    23

    68.89

    13.65

    10.44

    335.33

    0.00

    334.35

    86.17

    333.18

    155.18

    24

    69.88

    13.65

    10.30

    336.33

    0.00

    335.21

    86.67

    333.89

    155.89

    25

    70.88

    13.65

    10.16

    337.33

    0.00

    336.08

    87.16

    334.59

    156.59

    26

    71.88

    13.65

    10.02

    338.33

    0.00

    336.94

    87.67

    335.30

    157.30

    27

    72.88

    13.65

    9.88

    339.32

    0.00

    337.81

    88.16

    336.01

    158.01

    28

    73.87

    13.65

    9.74

    340.32

    0.00

    338.67

    88.66

    336.71

    158.71

    29

    74.87

    13.65

    9.60

    341.32

    0.00

    339.53

    89.16

    337.42

    159.42

    33

    75.87

    13.65

    9.46

    332.32

    0.00

    340.40

    89.66

    338.12

    160.12

    α = 4,0°

     

     

     

     

     

     

     

     

    β = 0° / PB

    β = 30° / PB & PA

    β = 45° / PB & PA

    SO [mm]

    L1 [mm]

    s [mm]

    x [mm]

    L [mm]

    H [mm]

    L [mm]

    H [mm]

    L [mm]

    H [mm]

    15

    61.24

    17.32

    16.27

    327.68

    0.00

    327.73

    82.34

    327.78

    149.78

    16

    62.24

    17.32

    16.20

    328.68

    0.00

    328.59

    82.84

    328.48

    150.48

    17

    63.24

    17.32

    16.14

    329.68

    0.00

    329.46

    83.34

    329.19

    151.19

    18

    64.24

    17.32

    16.07

    330.68

    0.00

    330.32

    83.84

    329.90

    151.90

    19

    65.24

    17.32

    16.00

    331.68

    0.00

    331.19

    84.34

    330.60

    152.60

    20

    66.23

    17.32

    15.93

    332.68

    0.00

    332.05

    84.84

    331.31

    153.31

    21

    67.23

    17.32

    15.86

    333.68

    0.00

    332.92

    85.34

    332.02

    154.02

    22

    68.23

    17.32

    15.79

    334.68

    0.00

    333.78

    85.84

    332.72

    154.72

    23

    69.23

    17.32

    15.72

    335.68

    0.00

    334.65

    86.34

    333.43

    155.43

    24

    70.23

    17.32

    15.65

    336.68

    0.00

    335.51

    86.84

    334.14

    156.14

    25

    71.23

    17.32

    15.58

    337.68

    0.00

    336.38

    87.34

    334.84

    156.84

    26

    72.23

    17.32

    15.51

    338.68

    0.00

    337.25

    87.84

    335.55

    157.55

    27

    73.23

    17.32

    15.44

    339.68

    0.00

    338.11

    88.34

    336.26

    158.26

    28

    74.23

    17.32

    15.37

    340.69

    0.00

    338.98

    88.84

    336.96

    158.96

    29

    75.23

    17.32

    15.30

    341.68

    0.00

    339.84

    89.34

    337.67

    159.67

    30

    76.23

    17.32

    15.23

    342.67

    0.00

    340.71

    89.84

    338.38

    160.38

    α = 0°

     

     

     

     

     

     

     

     

    β = 0° / PB

    β = 30° / PB & PA

    β = 45° / PB & PA

    SO [mm]

    L1 [mm]

    s [mm]

    x [mm]

    L [mm]

    H [mm]

    L [mm]

    H [mm]

    L [mm]

    H [mm]

    15

    61.50

    21.00

    21.00

    327.95

    0.00

    327.95

    82.47

    327.96

    149.96

    16

    62.50

    21.00

    21.00

    328.95

    0.00

    328.82

    82.97

    328.82

    150.67

    17

    63.50

    21.00

    21.00

    329.95

    0.00

    329.68

    83.47

    329.38

    151.38

    18

    64.50

    21.00

    21.00

    330.95

    0.00

    330.55

    83.97

    330.08

    152.08

    19

    65.50

    21.00

    21.00

    331.95

    0.00

    331.42

    84.47

    330.79

    152.79

    20

    66.50

    21.00

    21.00

    332.95

    0.00

    332.28

    84.97

    331.50

    153.50

    21

    67.50

    21.00

    21.00

    333.95

    0.00

    333.15

    85.47

    332.20

    154.20

    22

    68.50

    21.00

    21.00

    334.95

    0.00

    334.01

    85.97

    332.91

    154.91

    23

    69.50

    21.00

    21.00

    335.95

    0.00

    334.88

    86.47

    333.62

    155.62

    24

    70.50

    21.00

    21.00

    336.95

    0.00

    335.75

    86.97

    334.33

    156.33

    25

    71.50

    21.00

    21.00

    337.95

    0.00

    336.61

    87.47

    335.03

    157.03

    26

    72.50

    21.00

    21.00

    338.95

    0.00

    337.48

    87.97

    335.74

    157.74

    27

    73.50

    21.00

    21.00

    339.95

    0.00

    338.34

    88.47

    336.45

    158.45

    28

    74.50

    21.00

    21.00

    340.95

    0.00

    339.21

    88.97

    337.15

    159.15

    29

    75.50

    21.00

    21.00

    341.95

    0.00

    340.08

    89.47

    337.86

    159.86

    30

    76.50

    21.00

    21.00

    342.95

    0.00

    338.57

    89.97

    340.94

    160.57

    1. Technical data
    2. Robot welding torch

    Water-cooled robot welding torches

    MTB 250i W/R

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 250 A
    100% ED* / 250 A

    Wire diameter

    0.8 - 1.2 mm/0.032 - 0.047 inch

     

    MTB 330i W/R (TX, TXM)

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 330 A
    100% ED* / 330 A

    Wire diameter

    0.8 - 1.6 mm/0.032 - 0.063 inch

     

    MTB 400i W/R (TX, TXM)

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 400 A
    100% ED* / 400 A

    Wire diameter

    0.8 - 1.6 mm/0.032 - 0.063 inch

    MTB 500i W/R (TX, TXM)

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 500 A
    100% ED* / 500 A

    Wire diameter

    1.0 - 1.6 mm/0.039 - 0.063 inch

     

    MTB 700i W/R (TX, TXM)

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 700 A
    100% ED* / 700 A

    Wire diameter

    1.0 - 1.6 mm/0.039 - 0.063 inch

     

     

    *
    ED = Duty cycle
    1. Technical data

    Torch hosepack

    MHP 2x500i R/W/FSC

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 1000 A (2 x 500 A)
    100% ED* / 1000 A (2 x 500 A)

    Wire diameter

    1.2-1.6 mm
    0.05 - 0.06 inches

    Hosepack length

    1.3 m / 1.55 m / 1.75 m / 2.3 m / 3.3 m
    4 ft. 3.18 in. / 5 ft. 1.02 in. / 5 ft. 8.90 in. /
    7 ft. 6.55 in. / 10 ft. 9.92 in.

    Lowest cooling capacity as per IEC standard 60974-2, depending on the hosepack length
    1.3 m
    4 ft. 3.18 in.

    1,45 m
    4 ft. 9.09 in.

    1.55 m
    5 ft. 1.02 in.

    1.75 m
    5 ft. 8.90 in.

    2.3 m
    7 ft. 6.55 in.

    3.3 m
    10 ft. 9.92 in.




    1200 W


    1250 W


    1250 W


    1300 W


    1400 W


    1700 W

    Minimum coolant flow rate

    1 l/min
    0.26 gal (US) / min

    Min. coolant pressure

    3 bar
    43.50 psi

    Max. coolant pressure

    5 bar
    72.5 psi

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Torch hosepack

    MHP 2x500i R/W/FSC

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 1000 A (2 x 500 A)
    100% ED* / 1000 A (2 x 500 A)

    Wire diameter

    1.2-1.6 mm
    0.05 - 0.06 inches

    Hosepack length

    1.3 m / 1.55 m / 1.75 m / 2.3 m / 3.3 m
    4 ft. 3.18 in. / 5 ft. 1.02 in. / 5 ft. 8.90 in. /
    7 ft. 6.55 in. / 10 ft. 9.92 in.

    Lowest cooling capacity as per IEC standard 60974-2, depending on the hosepack length
    1.3 m
    4 ft. 3.18 in.

    1,45 m
    4 ft. 9.09 in.

    1.55 m
    5 ft. 1.02 in.

    1.75 m
    5 ft. 8.90 in.

    2.3 m
    7 ft. 6.55 in.

    3.3 m
    10 ft. 9.92 in.




    1200 W


    1250 W


    1250 W


    1300 W


    1400 W


    1700 W

    Minimum coolant flow rate

    1 l/min
    0.26 gal (US) / min

    Min. coolant pressure

    3 bar
    43.50 psi

    Max. coolant pressure

    5 bar
    72.5 psi

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Torch hosepack

    MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W

    TWIN Push/Pull hosepack

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100% ED* / 2 x 450 A
    100% ED* / 2 x 450 A

    Wire diameter

    0.8 - 1.6 mm / 0.03 - 0.06 inches

    Hosepack length

    4 m / 6 m / 8 m / 10 m
    13 ft. 1.48 in. / 19 ft. 8.22 in. /
    26 ft. 2.96 in / 32 ft. 9.70 in.

    Lowest cooling capacity as per IEC standard 60974-2, depending on the hosepack length

    1100 W / 1300 W / 1500 W / 1700 W

    Minimum coolant flow Qmin

    1 l/min
    0.26 gal (US) / min

    Minimum coolant pressure pmin

    3 bar
    43.50 psi

    Maximum coolant pressure pmax

    5 bar
    72.5 psi

     

     

    *
    ED = Duty cycle

    WF 60i TWIN Drive W

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)

    C1 (EN ISO 14175)


    100% ED* / 2 x 450 A (standard)
    100% ED* / 2 x 280 A (CMT)
    100% ED* / 2 x 450 A (standard)
    100% ED* / 2 x 360 A (CMT)

    Wire diameter

    0.8 - 1.6 mm
    0.03 - 0.06 inches

    Minimum coolant flow Qmin

    1 l/min
    0.26 gal. (US) / min

    Minimum coolant pressure pmin

    3 bar
    43.50 psi

    Maximum coolant pressure pmax

    5 bar
    72.5 psi

    Supply voltage

    2 x 60 V DC

    Nominal current

    2 x 1.5 A RMS

    Wire speed

    2 x 1 - 60 m/min
    2 x 39.37 - 2362.20 ipm

     

     

    *
    ED = Duty cycle
    1. Technical data

    Interconnecting hosepacks

    HP 70i

    Welding current at 10 min/40°C (104°F)

    40% ED* / 400 A
    60% ED* / 365 A
    100% ED* / 320 A

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Interconnecting hosepacks

    HP 70i

    Welding current at 10 min/40°C (104°F)

    40% ED* / 400 A
    60% ED* / 365 A
    100% ED* / 320 A

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Interconnecting hosepacks

    HP 70i, HP PC Cable HD 70

    Welding current at 10 min/40°C (104°F)

    60% ED* / 600 A
    100% ED* / 500 A

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Interconnecting hosepacks

    HP 95i

    Welding current at 10 min/40°C (104°F)

    40% ED* / 500 A
    60% ED* / 450 A
    100% ED* / 360 A

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Interconnecting hosepacks

    HP 120i

    Welding current at 10 min/40°C (104°F)

    40% ED* / 600 A
    60% ED* / 530 A
    100% ED* / 430 A

     

     

    *
    ED = Duty cycle
    1. Technical data

    CrashBox /i XXL

    CrashBox /i XXL - technical data & triggering torques and weight-distance diagram

    Item number

    44,0350,3380

    Degree of repeatability (1)

    ± 0.05 mm a)

    Triggering torques in x/y direction

    See table on the next page

    Maximum displacement in x/y direction

    ~ 45°

    Weight

    1250 g

    Dimensions

    Ø90 mm x 60 mm

    a) A distance of 300 mm away from the robot flange

    Triggering torques and weight-distance diagram

    Max. possible displacement

    z direction [mm]

    ~ 30

     

    The values listed only apply when in a static state!

    x/y direction [°]

    ~ 45

     

    Activated within 300 mm distance

    max [°]

    1.5275

     

    max [mm]

    8

     

    min [°]

    0.664

     

    min [mm]

    3.5

     

    Weight (distance [mm]) [kg]

    400

    15.78

     

    300

    21.03

     

    200

    31.55

     

    100

    63.1

     

    50

    126.2

     

    Triggering
    torque
    (+/- 10%)

    63.1 Nm

     

    CrashBox /i XXL

     

    1. Technical data
    2. CrashBox /i XXL

    CrashBox /i XXL - technical data & triggering torques and weight-distance diagram

    Item number

    44,0350,3380

    Degree of repeatability (1)

    ± 0.05 mm a)

    Triggering torques in x/y direction

    See table on the next page

    Maximum displacement in x/y direction

    ~ 45°

    Weight

    1250 g

    Dimensions

    Ø90 mm x 60 mm

    a) A distance of 300 mm away from the robot flange

    Triggering torques and weight-distance diagram

    Max. possible displacement

    z direction [mm]

    ~ 30

     

    The values listed only apply when in a static state!

    x/y direction [°]

    ~ 45

     

    Activated within 300 mm distance

    max [°]

    1.5275

     

    max [mm]

    8

     

    min [°]

    0.664

     

    min [mm]

    3.5

     

    Weight (distance [mm]) [kg]

    400

    15.78

     

    300

    21.03

     

    200

    31.55

     

    100

    63.1

     

    50

    126.2

     

    Triggering
    torque
    (+/- 10%)

    63.1 Nm

     

    CrashBox /i XXL

     

    1. Technical data

    CrashBox /d TWIN

    CrashBox /d TWIN - technical data & triggering torques and weight-distance diagram

    Item number

    44,0350,270

    Degree of repeatability (1)

    ± 0.05 mm a)

    Triggering torques in x/y direction

    See table on the next page

    Maximum displacement in x/y direction

    min. 20°

    Weight

    2160 g

    Dimensions

    Ø90 mm x 83.3 mm

    a) A distance of 300 mm away from the robot flange

    Triggering torques and weight-distance diagram

    Max. possible displacement

    z direction [mm]

    ~ 30

    The values listed only apply when in a static state!

    x/y direction [°]

    ~ 45

    Activated within 30 mm distance

    max [°]

    1.5275

    max [mm]

    8

    min [°]

    0.4775

    min [mm]

    2.5

    Weight (distance [mm]) [kg]

    400

    15.78

    300

    21.03

    200

    31.55

    100

    63.1

    50

    126.2

    Triggering
    torque
    (+/- 10%)

    63.1 Nm

    CrashBox /d
    TWIN Pro

    1. Technical data
    2. CrashBox /d TWIN

    CrashBox /d TWIN - technical data & triggering torques and weight-distance diagram

    Item number

    44,0350,270

    Degree of repeatability (1)

    ± 0.05 mm a)

    Triggering torques in x/y direction

    See table on the next page

    Maximum displacement in x/y direction

    min. 20°

    Weight

    2160 g

    Dimensions

    Ø90 mm x 83.3 mm

    a) A distance of 300 mm away from the robot flange

    Triggering torques and weight-distance diagram

    Max. possible displacement

    z direction [mm]

    ~ 30

    The values listed only apply when in a static state!

    x/y direction [°]

    ~ 45

    Activated within 30 mm distance

    max [°]

    1.5275

    max [mm]

    8

    min [°]

    0.4775

    min [mm]

    2.5

    Weight (distance [mm]) [kg]

    400

    15.78

    300

    21.03

    200

    31.55

    100

    63.1

    50

    126.2

    Triggering
    torque
    (+/- 10%)

    63.1 Nm

    CrashBox /d
    TWIN Pro