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Trace back information: Workspace Robots and Applications version a79 (not checked in) Published 2022-03-16 at 16:53:39 Skribenta version 5.5.019...
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Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.
1.2.2 Make sure that the main power has been switched off ........Safety risks ...................... 1.3.1 Safety risks during installation and service work on GWT C9 ......1.3.2 Risks associated with live electric parts ............1.3.3 Hot parts may cause burns ...............
• repair personnel. Prerequisites A maintenance/repair/installation personnel working with an ABB robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. References Document description Document name Application manual - Spot options...
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
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Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.
Only persons who know the GWT C9 and are trained in the operation and handling of the GWT C9 are allowed to maintain the GWT C9. Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, repair, or use the GWT C9.
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1 Safety 1.3.1 Safety risks during installation and service work on GWT C9 Continued Personal protective equipment Always use suitable personal protective equipment, based on the risk assessment for the installation. Protective gloves Sheet metal parts may have sharp edges and welded parts in general may be hot after welding.
2.1 Overview Description The GWT C9 is a spot welding gun, designed in a way so that the C-gun arm is the actual gun body. There is wide range of various C-gun arms. The GWT C9 is integrated into the ABB robot as an external axis, offering improved welding quality and cycle time performance.
2 Product description 2.3.1 Principle 2.3 Concept 2.3.1 Principle Concept For the GWT C9, the gun body mainly consists of the gun arm. Its fundamental elements can be categorized as below: • Gun interface to robot. • Arms of various standard or custom made shapes.
2 Product description 2.4.1 Complete offer 2.4 Variants and offers 2.4.1 Complete offer Overview The complete GWT C9 consists of: • A standard or mirrored gun body. • Gun body with standard or customized arm/beam and electrodes. • An interface bracket.
2 Product description 2.4.2.1 Gun arms 2.4.2 Standard offer 2.4.2.1 Gun arms List of gun arms The GWT C9 has a number of standard offer for arm/beam. See some examples below. xx2200000311 xx2200000312 Figure 2.4: GWT C9 173x300 D-16 Figure 2.5: GWT C9 375x400 D-16 xx2200000313 Figure 2.6: GWT C9 260x600 D-16...
2 Product description 2.4.2.2 Interface brackets 2.4.2.2 Interface brackets Overview The GWT C9 can be attached to a robot or pedestal in six different directions using one of the two interface brackets described below. Short interface bracket Possible positions: •...
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Continued Mirrored gun body The GWT C9 can be ordered with a mirrored gun body, allowing the interface-brackets to be attached at the right side of the gun body. The illustration below shows a standard gun body to the left and a mirrored gun body to the right.
There is no need to install a tool changer if the robot only handle the GWT C9 since all maintenance and all common repair work on the welding gun can be performed when the welding gun is still attached on the robot.
2.5.5 Robot and controller requirements 2.5.5 Robot and controller requirements Overview The GWT C9 is controlled as an external axis and is design to suit the ABB IRC5 controller. For compatibility with other control systems, contact ABB. Robot cabling The GWT C9 requires the following connection cables between the IRC5/Spot weld cabinet through the manipulator to the welding gun.
Spot welding generates fumes. The GWT C9 must be used in a ventilated environment. WARNING The GWT C9 must be used in a safety cell. Access to the cell must be monitored according to local safety legislation. WARNING Welding arcs and welding sparks can emerge from the welding process.
• Make sure that the lifting device to be used is dimensioned to handle the weight of the GWT C9. See actual weight of the GWT C9 in the test protocol, delivered together with the complete welding gun documentation. •...
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3 Installation and commissioning 3.1 Introduction Continued Precautions before start-up of the GWT C9 CAUTION The precautions below should be observed before proceeding with start-up of the GWT C9: • Make sure correct water flow values are defined. This to avoid damaged welding equipment such as transformer, diodes, leaf shunts and other parts of secondary side.
To identify the delivery, read the identification plate and compare it to the delivery note. The identification plate is located on the side of the GWT C9 body and indicates in particular the welding gun type and serial number. xx1700002176...
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Document any damages on the packaging before proceeding with unpacking the GWT C9. If any damages is found, contact ABB for complaints before returning the welding gun. This is to ensure goods labeling and traceability of the welding gun. Carefully repack the welding gun to prevent further damages.
3.2.2 Handling/lifting Weight The weight of a GWT C9, including standard gun arms, varies between 65 kg - 99 kg. For information about the actual weight of the welding gun, including all components and potential accessories, see the test protocol. The test protocol is delivered together with the complete welding gun documentation.
3.3 Mechanical installation 3.3 Mechanical installation Description The GWT C9 can be installed on a robot or on a pedestal. It is connected to the robot 6 axis flange directly or via an automatic tool changer. The GWT C9 is always delivered with the interface installed onto the welding gun back plate.
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3 Installation and commissioning 3.3 Mechanical installation Continued Action Note Place the GWT C9 on a lift table. CAUTION The welding gun should be placed in a way in which the weight does not rest on sensitive parts such as the electrode holders, shunts, tips and electrical components.
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Remove the cover and connect all media like Robifix, Electrical cabling, and water supply. Replace the cover on the gun. xx1900001708 Lifting the GWT C9 on page 52 Rotate the robots 6 axis back to an upright positioning. xx1900001709 Continues on next page...
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The next step differs depending on if an long/short interface bracket or an interface plate is used. Long/short interface bracket One person grab the GWT C9 in the welding gun arms and move it to- wards the robot. The other person adjust the move-...
3.4 Connecting electricity and media Overview When the GWT C9 is attached onto an ABB robot with a DressPack LeanID all electrical connections, except for the welding power, are made through three circular connectors. The welding power is transferred through the a Robifix connection.
3.5 Controllers settings Description with ABB controller The GWT C9 is controlled as an external axis of the robot. In order for the robot to identify that the GWT C9 exists and to control it, configuration file must be loaded into the IRC5 system.
Welding arms and cooling systems are hot after welding. Let them cool down before any intervention. • All power supplies to the GWT C9 as well as to other machines within the danger zone must be turned off. • If required, the main switch should be locked.
4.2 Maintenance planning 4.2 Maintenance planning General procedure Even though the GWT C9 is designed to require few maintenance operations, it is important to follow the maintenance time intervals and instructions to ensure a fully functional and long living product.
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Every 250,000 General condi- Clean the GWT C9 protection cover from welding weld strokes tion splatters with a clean cloth. and once a year...
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Tightening torque: 7 Nm xx2200000323 Every Major overhaul Inspection and testing of the GWT C9 by an ABB expert. 10,000,000 weld Actuator Contact ABB service for scheduled maintenance of the strokes actuator. Continues on next page...
General This chapter details some common activities that may be required for a thorough inspection of the unit or in case of failure of the GWT C9. Each procedure contains information about required tools/equipment and a step-by-step instructions on how to performed the repair.
Welding arms and cooling systems are hot after welding. Let them cool down before any intervention. • All power supplies to the GWT C9 as well as to other machines within the danger zone must be turned off. • If required, the main switch should be locked.
6.2 Storage 6.2 Storage General If the welding gun should be stored, always follow the steps described in the following section. Read the introduction section before putting the GWT C9 into storage (see Introduction on page 111). Required equipment Equipment...
6 Storage and decommissioning 6.3 Decommissioning 6.3 Decommissioning Introduction Read the introduction section before decommission the GWT C9 (see Introduction on page 111). Required equipment Equipment Product (example) Standard toolkit Standard toolkit on page 120. Compressed air Other equipment may be required. See...
Maximum allowed total deviation from the specified value is 10 %! Note The bolts used on (or provided with) the GWT C9 are of 3 different classes, 8.8, 10.9, and 12.9. Unless indicated otherwise, the screws are by default of class 8.8.