Testing system /i, Straightening system /i Operating instructions

1. General information

1. General information
2. General

1. General information
2. General

Testing system /i

The testing system /i is used to check MTB R robot welding torches for dimensional deviations.
The testing system /i is available in the following configurations:

Straightening system /i
44,0350,5241

With the straightening system /i dimensional deviations can be corrected on the MTB R robot welding torches.

IMPORTANT! For dimensional deviations > 5 mm, you should no longer set up the torch body on your own. Send torch body to Fronius for repair.

1. General information
2. General

IMPORTANT! In order to achieve optimal test results with the testing system /i, it is recommended that the system be calibrated by Fronius on a yearly basis.

1. General information
2. General

• Allen key size 6 mm
• Contact-tip spanner
  42,0410,0570 ... M6
  42,0410,0138 ... M8x1.5
• Torch wrench
  45,0200,1261
• Torque wrench
  42,0435,0090

1. General information
2. General

1. General information
2. General

• Steel “professional” base plate (42,0201,2064)
  e.g. for frequent testing and straightening work (only factory installation)
  
• Test shaft (xx,xxxx,xxxx)
  for checking of the testing system /i
  
• Fixing set /i G/W TX (44,0350,5242)
  for checking of gas and water-cooled TX robot welding torches

1. General information

1. General information
2. Scope of Supply

1. General information
2. Scope of Supply

1. General information
2. Scope of Supply

1. General information
2. Scope of Supply

(1)	Clamping bush
(2)	2 shoulder bolts 6h8 M5 x 20 mm
(3)	Clamp
*	Torch body
**	Torch body holder (included in the scope of delivery of the testing system)

1. General information
2. Scope of Supply

Straightening system /i - 44,0350,5241

(1)	Straightening lever
(2)	Torque wrench
(3)	Union nut
(4)	Torch wrench
(5)	Straightening cup ø 16 mm Straightening cup ø 18 mm

1. Check MTB R robot welding torch

The base plate of the testing system /i contains various positions for mounting the testing unit.

The testing unit is pre-mounted on the 0° mounting position when delivered.
For every other torch body curvature, the testing unit must be mounted on the base plate according to the torch body curvature of the welding torch that is to be tested:

1

2

1. Check MTB R robot welding torch
2. Check MTB R robot welding torch with testing / straightening system /i

The base plate of the testing system /i contains various positions for mounting the testing unit.

The testing unit is pre-mounted on the 0° mounting position when delivered.
For every other torch body curvature, the testing unit must be mounted on the base plate according to the torch body curvature of the welding torch that is to be tested:

1

2

1. Check MTB R robot welding torch
2. Check MTB R robot welding torch with testing / straightening system /i

1

2

(1) ... M6 (2) ... M8 (3) ... M8x1.5 (4) ... M10x1.25
(5) ... M10x1.25 Contec

3

1. Check MTB R robot welding torch
2. Check MTB R robot welding torch with testing / straightening system /i

1

2

If the dowel pin cannot easily be moved into or out of the centering sleeve, set up the torch body according to the chapter "Set up MTB R robot welding torch" (from page (→)).

IMPORTANT! For dimensional deviations > 5 mm, you should no longer set up the torch body on your own. Send torch body to Fronius for repair.

1. Check MTB R robot welding torch

With the testing system /i G/W System you can check complete robot welding torch systems from torch body to CrashBox for dimensional deviations.
The user is responsible for the setup and initial adjustment.

There are various possibilities available for testing, e.g.:

• Torch body
• Torch body + hosepack
• Torch body + hosepack + clamp
• Torch body + hosepack + clamp + CrashBox

1. Check MTB R robot welding torch
2. Check MTB R robot welding torch complete systems with testing system /i G/W System

With the testing system /i G/W System you can check complete robot welding torch systems from torch body to CrashBox for dimensional deviations.
The user is responsible for the setup and initial adjustment.

There are various possibilities available for testing, e.g.:

• Torch body
• Torch body + hosepack
• Torch body + hosepack + clamp
• Torch body + hosepack + clamp + CrashBox

1. Check MTB R robot welding torch
2. Check MTB R robot welding torch complete systems with testing system /i G/W System

The base plate of the testing system /i G/W contains a wide range of positions for mounting the testing unit.

The testing unit is pre-mounted on the 0° mounting position when delivered.
For every other torch neck curvature, the testing unit must be mounted on the base plate according to the torch neck curvature of the welding torch that is to be tested:

2

3

4

Unscrew adjusting sleeve

5

The mounting block is designed for mounting various robot shutoff boxes.

6

Mount the complete system on the mounting block

1. Check MTB R robot welding torch
2. Check MTB R robot welding torch complete systems with testing system /i G/W System

1

2

3

The dowel pin must fully glide into the adjusting sleeve with ease.
The dowel pin must glide out of the adjusting sleeve with ease after the spring is released due to the spring force.

If the dowel pin doesn’t glide into the adjusting sleeve or only does so with difficulty, the complete system with mounting block must be readjusted.

4

5

If the dowel pin doesn’t glide into the adjusting sleeve or only does so with difficulty, the complete system with mounting block must be readjusted.

1. Check MTB R robot welding torch
2. Check MTB R robot welding torch complete systems with testing system /i G/W System

1

2

Unscrew centering sleeve.

3

4

Mount the complete system on the mounting block

5

If the dowel pin does not easily glide into or out of the centering sleeve, the complete system must be adjusted (e.g. at the clamp).

1. Check MTB R robot welding torch

With the testing system /i G/W V, you can check customer-specific robot welding torch systems and special models for dimensional deviations.
The user is responsible for the setup and initial adjustment.

1. Check MTB R robot welding torch
2. Check customer-specific robot welding torch with testing system /i G/W

With the testing system /i G/W V, you can check customer-specific robot welding torch systems and special models for dimensional deviations.
The user is responsible for the setup and initial adjustment.

1. Check MTB R robot welding torch
2. Check customer-specific robot welding torch with testing system /i G/W

The base plate of the testing system /i G/W V contains various positions for mounting the testing unit.

The testing unit is pre-mounted on the 0° mounting position when delivered.
For every other torch body curvature, the testing unit must be mounted on the base plate according to the torch body curvature of the welding torch that is to be tested:

1

2

3

NOTE!

To distinguish between centering sleeve (2) and adjusting sleeve (1), the adjusting sleeves are equipped with two additional cross grooves.

 

4

Unscrew adjusting sleeve

5

6

1. Check MTB R robot welding torch
2. Check customer-specific robot welding torch with testing system /i G/W

1

2

3

The dowel pin must fully glide into the adjusting sleeve with ease.
The dowel pin must glide out of the adjusting sleeve with ease after the spring is released due to the spring force.

If the dowel pin doesn’t glide into the adjusting sleeve or only does so with difficulty, the torch body holder with torch body must be readjusted.

4

5

If the dowel pin doesn’t glide into the adjusting sleeve or only does so with difficulty, the torch body holder with torch body must be readjusted.

1. Check MTB R robot welding torch
2. Check customer-specific robot welding torch with testing system /i G/W

1

NOTE!

To distinguish between centering sleeve (2) and adjusting sleeve (1), the adjusting sleeves are equipped with two additional cross grooves.

 

2

Unscrew centering sleeve.

3

1. Check MTB R robot welding torch

The fixing set /i G/W TX is an add-on for checking TX robot welding torches and is used in conjunction with the following testing systems:

• Testing/straightening system /i (44,0360,0073)
• Testing system /i G/W V (44,0360,0012)

Testing units are assembled as described.
Afterwards, the fixing set /i G/W TX and the TX robot welding torch are mounted on the torch body holder.

The testing process is then carried out according to the respective testing system.

1. Check MTB R robot welding torch
2. Check TX robot welding torches with fixing system /i G/W TX

The fixing set /i G/W TX is an add-on for checking TX robot welding torches and is used in conjunction with the following testing systems:

• Testing/straightening system /i (44,0360,0073)
• Testing system /i G/W V (44,0360,0012)

Testing units are assembled as described.
Afterwards, the fixing set /i G/W TX and the TX robot welding torch are mounted on the torch body holder.

The testing process is then carried out according to the respective testing system.

1. Check MTB R robot welding torch
2. Check TX robot welding torches with fixing system /i G/W TX

1. Check MTB R robot welding torch
2. Check TX robot welding torches with fixing system /i G/W TX

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2

3

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5

Use torque wrench!

1. Set up MTB R robot welding torch

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2

3

Screw in nozzle fitting replacement and straightening sleeve

4

Unscrew centering sleeve
(1) ... M6 (2) ... M8 (3) ... M8x1.5 (4) ... M10x1.25
(5) ... M10x1.25 Contec

5

Screw in centering sleeve

1. Set up MTB R robot welding torch
2. Set up robot welding torch

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2

3

Screw in nozzle fitting replacement and straightening sleeve

4

Unscrew centering sleeve
(1) ... M6 (2) ... M8 (3) ... M8x1.5 (4) ... M10x1.25
(5) ... M10x1.25 Contec

5

Screw in centering sleeve

1. Set up MTB R robot welding torch
2. Set up robot welding torch

Preparation:

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2

* The straightening cups are only required for setup at the outer tube.

3

To set up at the outer tube, push the straightening lever over the straightening cups

4

Position straightening lever above straightening sleeve

Set up torch body horizontally and/or vertically:

5

Set up horizontally

6

Set up vertically

7

Loosen union nut and re-tighten

8

Check the torch body

If the dowel pin does not easily glide into or out of the centering sleeve, the torch body must be readjusted.

IMPORTANT! For dimensional deviations > 5 mm, you should no longer set up the torch body on your own. Send torch body to Fronius for repair.

1. Set up MTB R robot welding torch
2. Set up robot welding torch

If the torch body is okay:

1. Set up MTB R robot welding torch

The testing system /i G/W V is also designed to set up customer-specific welding torches.

1. Set up MTB R robot welding torch
2. Set up customer-specific robot welding torch with testing system /i G/W V

The testing system /i G/W V is also designed to set up customer-specific welding torches.

1. Set up MTB R robot welding torch
2. Set up customer-specific robot welding torch with testing system /i G/W V

1

2

3

Screw in nozzle fitting replacement and straightening sleeve

4

Unscrew centering sleeve
* Torch body holder not shown

5

Screw in centering sleeve

1. Set up MTB R robot welding torch
2. Set up customer-specific robot welding torch with testing system /i G/W V

1

1. Set up MTB R robot welding torch
2. Set up customer-specific robot welding torch with testing system /i G/W V

1

1. Set up MTB R robot welding torch
2. Set up customer-specific robot welding torch with testing system /i G/W V

1

Align testing unit to torch body and fix lightly with a clamp

2

Check the torch body

3

Fix testing unit with the remaining clamps

4

Check the torch body

1. Set up MTB R robot welding torch
2. Set up customer-specific robot welding torch with testing system /i G/W V