FRONIUS TWIN Push Manuale utente

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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

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

Torch hosepack 39

EN-US

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

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 support Y-piece on the robot 112

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

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

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.

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.

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.

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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