TPS/i Robotics TWIN Operating instructions

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.
Your personal safety is at stake!

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." The manufacturer is not responsible for any damage resulting from improper use.

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.

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.

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.)

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.

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.

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!

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.

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.

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.

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. The manufacturer accepts no liability for any damage resulting from improper use.

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.

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.

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.

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:

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).
Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
Equipotential bonding
Workpiece grounding
- If necessary, establish grounding using suitable capacitors.
Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation

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

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.

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.

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.

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.

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.

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.

If there is damage due to use of other system components or other coolants, the manufacturer accepts no liability for this and all warranty claims are forfeited.

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.

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.

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.

Devices with the CE label satisfy the essential requirements of the low-voltage and electromagnetic compatibility directive (e.g., relevant product standards of the EN 60974 series).

Fronius International GmbH declares that the device complies with Directive 2014/53/EU. The full text of the EU Declaration of Conformity is available on the following website: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

With regard to data security, the user is responsible for:

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

Copyright of these operating instructions remains with the manufacturer.

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

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

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

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

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

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

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

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

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

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

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

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

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).

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)

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 (→).

NOTE!

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

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).

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).

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)	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)	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)	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.

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.

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.

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.

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.

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

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.

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

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.

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.

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.

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.

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

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.

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.

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.

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.

Depending on the respective robot:

1 x robot flange with screws

Robot flange as per price list

Observe torques:

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

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.

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

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

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

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.

(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.

(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.

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.

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.

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.

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

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

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

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 (→).

By material:

Application	Tilt angle
Application	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
Application	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
Application	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

L = Lead wire electrode, T = Trail wire electrode

Both wire electrodes move towards the workpiece
Both wire electrodes make contact with the workpiece
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
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.

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

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