FRO­NIUS TWIN Push User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
TPS/i Robotics welding system
TWIN Push
TWIN Push/Pull
TWIN CMT
EN-US
Operating instructions
42,0426,0277,EA 010-23112021

Table of contents
Safety Instructions 7
Explanation of Safety Instructions 7
General 7
Intended Use 7
Environmental Conditions 8
Obligations of the Operating Company 8
Obligations of Personnel 8
Grid Connection 8
Personal Protection and Protection of Others 9
Danger from toxic gases and vapors 9
Danger from Flying Sparks 10
Risks from grid current and welding current 10
Stray welding currents 11
EMC Device Classifications 12
EMC measures 12
EMF measures 13
Particular hazard areas 13
Requirement for the shielding gas 14
Danger from Shielding Gas Cylinders 14
Danger Posed by Shielding Gas Leak 15
Safety Measures at the Setup Location and During Transport 15
Safety Measures in Normal Operation 15
Maintenance and repair 16
Safety Inspection 16
Disposal 16
Safety symbols 17
Data backup 17
Copyright 17
General information 19
General 21
Application areas 21
Requirements 22
System requirements and minimum equipment TWIN Push 22
System requirements and minimum equipment TWIN Push/Pull 22
System requirements and minimum equipment TWIN CMT 23
Mechanical requirements 24
Electrical Requirements 24
Software requirements 24
Dimensioning of the robot 24
Measures to increase system availability 24
Ground connection 25
Note about the wirefeed 25
Functional principle 26
Operating Principle 26
Lead power source and trail power source 26
System configurations 27
TWIN Push system overview 27
TWIN Push/Pull, CMT system overview 28
System components 31
WF 30i R /TWIN 33
Device concept 33
Intended Use 33
Warning notices on the device 34
Description of the warnings on the device 36
Interconnecting hosepack 38
Interconnecting hosepack 38
Torch hosepack 39
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General 39
Scope of supply 39
CrashBox 40
General 40
Also required for the installation 40
Scope of supply 41
Clamp System Scope of Supply 41
Robot welding torch 42
Safety 42
Robot welding torch 42
Tilt angle of the contact tips 43
Welding Technology Aspects 45
Welding Technology Aspects 47
Shielding gases for TWIN welding processes 47
Conducting R/L comparison 47
Work angle of the welding torch 48
Stick out 48
Welding start sequence for CMT TWIN 49
TWIN mode 49
TWIN Characteristics 50
General 50
Available TWIN characteristics 50
TWIN Welding Processes 52
TWIN welding processes - overview 52
Symbols 52
PMC TWIN / PMC TWIN 53
PCS TWIN / PCS TWIN 54
PMC TWIN/CMT TWIN 55
CMT TWIN/CMT TWIN 55
Single wire (with a TWIN welding torch):PMC/Pulse/LSC/Standard/CMT 56
TWIN Process Parameters 58
TWIN process parameters 58
Pulse synchronization ratio 58
Lead/trail phase shift 59
Trail ignition delay 59
Welding parameter standard values for fillet welds 61
Standard values for welding position PA 61
Standard values for welding position PB 62
Operating controls, connections and mechanical components 65
WF 30i R /TWIN 67
Safety 67
Wirefeeder front 67
Wirefeeder Side 68
Function of the Gas-Test, Wire-Return and Wire Threading Buttons 69
Wirefeeder Rear 70
MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W 71
Safety 71
MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W - mechanical components 71
MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W - control panel 72
Interconnecting hosepack 73
Interconnecting Hosepack—Connections 73
Installation and commissioning – TWIN Push 75
Safety—Installation and Commissioning 77
Safety 77
Insulated Guiding of the Wire Electrode to the Wirefeeder 78
Before installation and initial operation 79
Setup regulations 79
Installation – overview 79
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Install TWIN Wirefeeder and Accessories on the Robot 81
Installing the wirefeeder on the robot 81
Installing the side holders for the interconnecting hosepacks on the robot 82
Lay, Install and Connect Interconnecting Hosepacks 83
Connecting the interconnecting hosepacks to the wirefeeder 83
Connect the interconnecting hosepacks to the power source, cooling unit and TWIN Controller 84
Connect TWIN Controller 85
Connect the TWIN Controller with the Power Sources and Connect Interconnecting Hosepack 85
Connecting the TWIN Controller to the robot controls 85
Install CrashBox, Torch Hosepack and TWIN Welding Torch 86
Mounting the CrashBox /i on the robot 86
Mounting the CrashBox /i Dummy on the robot 87
Installing the inner liner in the torch hosepack 88
Install the torch hosepack 90
Prepare torch body with steel inner liner 91
Installing wearing parts in the TWIN welding torch 93
Install the torch body coupling 94
Checking the function of the torch body coupling 95
Connecting the Protective Gas Shield and Grounding Cable 97
Connecting Protective Gas Shield 97
Connect the grounding cable 97
Preparing TWIN Wirefeeder for Operation 98
General 98
Inserting/changing feed rollers 98
Connecting wirefeeding hoses 99
Threading the wire electrode 99
Setting the contact pressure 101
Wire straightener 101
Commissioning 102
Requirements 102
Commissioning - start of welding 102
Installation and commissioning - TWIN Push/Pull, CMT 103
Safety—Installation and Commissioning 105
Safety 105
Insulated Guiding of the Wire Electrode to the Wirefeeder 106
Before installation and initial operation 107
Setup regulations 107
Installation - Overview of TWIN Push/Pull, CMT 108
Mounting the balancer mounting on the Y-piece 111
Mounting the balancer mounting on the Y-piece 111
Mounting the support Y-piece on the robot 112
Mounting the support Y-piece on the robot 112
Installing the side holder on the robot 113
Installing the side holder on the robot 113
Installing wire buffers on the robot 114
TWIN-CMT - installing wire buffers on the robot 114
Lay, Install and Connect Interconnecting Hosepacks 116
Connecting interconnecting hosepacks to the robot wirefeeders 116
Connect the interconnecting hosepacks to the power source, cooling unit and TWIN Controller 117
Connect TWIN Controller 118
Connect the TWIN Controller with the Power Sources and Connect Interconnecting Hosepack 118
Connecting the TWIN Controller to the robot controls 118
Install CrashBox, Torch Hosepack and TWIN Welding Torch 119
Mounting the CrashBox /i on the robot 119
Mounting the CrashBox /i Dummy on the robot 120
Installing the torch hosepack with TWIN drive unit 121
Connecting the torch hosepack to the wirefeeder 123
Installing anti-kink protection rings 124
Prepare torch body with steel inner liner 125
Installing wearing parts in the TWIN welding torch 127
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EN-US

Mounting the torch body on the TWIN drive unit 127
Mounting the torch body coupling on the TWIN drive unit 128
Checking the function of the torch body coupling 129
Fitting the wirefeeding hoses and inner liners 131
Inserting the inner liner into the torch hosepack 131
Connecting the Protective Gas Shield and Grounding Cable 132
Connecting Protective Gas Shield 132
Connect the grounding cable 132
Preparing the TWIN drive unit for operation 133
General 133
Inserting/changing the feed rollers on the TWIN drive unit 133
Connecting wirefeeding hoses 134
Threading the wire electrode 134
Setting the contact pressure 135
Commissioning 136
Requirements 136
Commissioning - start of welding 136
Troubleshooting, Maintenance, and Disposal 137
Troubleshooting 139
Safety 139
Troubleshooting 139
Displayed Error Codes 142
Service, maintenance and disposal 144
General 144
Safety 144
During Each Start-up 144
Monthly 144
Every 6 months 145
Disposal 145
Technical data 147
TWIN wirefeeder 149
WF 30i R /TWIN 149
Robot welding torch 150
MTB 2x500i R 150
Dimensions depend on the contact tip tilt angle 150
Water-cooled robot welding torches 152
Torch hosepack 154
MHP 2x500i R/W/FSC 154
MHP 2x450i RD/W/FSC incl. WF 60i TWIN Drive /W 154
Interconnecting hosepacks 156
HP 70i 156
HP 70i, HP PC Cable HD 70 156
HP 95i 156
HP 120i 156
CrashBox /i XXL 157
CrashBox /i XXL - technical data & triggering torques and weight-distance diagram 157
6

Safety Instructions
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
▶Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
▶Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
▶Minor injury or damage to property may result if appropriate precautions are not
taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
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.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.
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EN-US

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.
Environmental
Conditions
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.)
Obligations of the
Operating Com-
pany
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.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following before begin-
ning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and con-
firm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can oc-
cur in one's absence.
Grid Connection Devices with a high output can influence the energy quality of the grid due to their cur-
rent consumption.
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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!
Personal Protec-
tion and Protec-
tion 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 pace-
makers
- 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.
Danger from tox-
ic gases and va-
pors
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.
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EN-US

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.
Danger from Fly-
ing 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 pro-
tected 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 na-
tional 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.
Risks from grid
current and weld-
ing 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 wirespool, 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.
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