ABB GWT C9 Product Manual

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ROBOTICS

Product manual

GWT C9

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Summary of Contents for ABB GWT C9

Page 1 ROBOTICS Product manual GWT C9...
Page 2 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...
Page 4 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.
Page 5: Table Of Contents
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 ...............
Page 6 Bolt, screws, tightening torques ................7.4.1 Bolt and screws ..................7.4.2 Standard tightening torques ..............Standard toolkit ....................Special tools ....................Lifting accessories and lifting instructions .............. Index Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 7: Overview Of This Manual
• 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...
Page 8: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several product models, can be illustrated with illustrations that show a different product model than the one that is described in the current manual. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 9: Safety
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.
Page 10 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.
Page 11: Protective Stop And Emergency Stop
1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 12: Safety Actions
1.2.1 Fire extinguishing 1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 13: Make Sure That The Main Power Has Been Switched Off
Wait for 5 minutes to let the capacitors discharge after the power has been switched off. DANGER Even if the main switch is switched off, the capacitors can cause electric shock if not given the time to discharge. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 14: Safety Risks
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.
Page 15 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.
Page 16: Risks Associated With Live Electric Parts
Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 17: Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 18: Safety Signals
Signal word used to indicate important facts and conditions. Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 19: Product Description
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.
Page 20: Terminology
Explanation abbreviation GWT C9 Gun Weld Technique - Generation 9 MFDC Medium Frequency Direct Current MTBF Mean Time Between Failures MTTR Mean Time To Repair Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 21: Concept
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.
Page 22 2 Product description 2.3.1 Principle Continued Installation The GWT C9 can be installed on a robot or attached to a pedestal as shown in the images below. xx1900001709 xx2200000307 Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 23: Detailed Views
2.3.2 Detailed views Overview xx2200000360 Robot attachment Gun body Arm unit Centering ring Protective cover Electrode bushing Electrode shaft Electrode cap Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 24 Leaf shunt, movable Leaf shunt, fixed Water distributor Cooling pad Actuator Power, transformer Transformer Rail Ball carriage Power and signal, LeanID Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 25 2.3.2 Detailed views Continued Arm unit xx2200000308 Arm/beam Electrode holder Electrode cap/Tip (2 pcs, one on each electrode holder) Insert coupling Water hoses Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 26: Electrical Connectors
The 3 circular sockets are prepared for direct connection to the LeanID DressPack. xx1600000791 R3.CPS: Transformer, current sensor and temperature sensor Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 27 2 Product description 2.3.2.1 Electrical connectors Continued R4.FB: Resolver Sin, Cos, Ref. Temperature sensor R3.SP: Motor: U, V, W phases. Brake Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 28: Water Cooling
The illustration below shows the water circuits in a welding gun in general. Green hose is water inlet. Red and black are water outlets. xx1900001657 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 29 Water into the electrode runs through the green hose. Water out from the electrode runs through the red hose. xx1900001693 xx1900001692 xx1900001694 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 30 From the electrode the water then returns along the path visualized below as a black dashed line. xx1900001695 Figure 2.1: Water in Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 31 2 Product description 2.3.2.2 Water cooling Continued xx1900001659 Figure 2.2: Water out xx1900001658 Figure 2.3: Cooling pipes Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 32 Connect PROC2 to LeanID DressPack Water outlet from mobile arm (DN10) Connect PROC4 (black) to LeanID DressPack Water outlet from fixed arm (DN10) Connect PROC3 (red) to LeanID DressPack Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 33: Variants And Offers
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.
Page 34: Standard Offer
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...
Page 35: Interface Brackets
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: •...
Page 36 2 Product description 2.4.2.2 Interface brackets Continued Interface plate Possible position: • Side (E in illustration). xx1700001410 xx1900000034 Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 37: Customized Offer
2 Product description 2.4.3 Customized offer 2.4.3 Customized offer Customized gun arms The GWT C9 can be ordered with customized gun arms. The illustration below shows some examples of different customized gun arms. xx2200000314 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A ©...
Page 38 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.
Page 39: Accessories
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.
Page 40: Technical Details And Requirements
Parameter Value Required voltage 400 VAC Weight 12 kg Stroke length 250 mm Actuator speed Max. 300 mm/s MTBF (Mean Time Between Failures) 10x10 cycles Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 41: Transformer Mfdc
Details and requirements Parameter Value Primary voltage 600 V Secondary voltage 11.1 V For further information about the transformer, see drawing provided with the delivery. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 42: Water Cooling System
To ensure the lifetime of diodes in the transformer, the transformer must be cooled in the correct way by water flow. Welding without water supply, or with predefined values lower than minimal water flow, is strictly forbidden. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 43: Temperature And Hygrometry
Ambient temperature, operating 10°C to 50°C Ambient temperature, storage 5°C to 30°C Maximal ambient humidity at constant 80 % temperature (for operating and storage condition) Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 44: Robot And Controller Requirements
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.
Page 45: Safety Risks Related To Spot Welding
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.
Page 46 CAUTION When lifting and moving machinery and equipment, the moving parts must be secured from sudden movements, and only approved lifting equipment may be used. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 47: Installation And Commissioning
• 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. •...
Page 48 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.
Page 49: Unpacking And Handling
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...
Page 50 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.
Page 51 3.2.1 Unpacking and acceptance Continued Cleaning If the unit seems to have been contaminated by impurities during the transport, clean it with a clean lint-free cloth. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 52: Handling/Lifting
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.
Page 53 Remove the protecting cover (pos. xx1900001679 Attach lifting slings around the arm and angle bracket and lift the welding gun carefully. xx1900001702 Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 54: Mechanical Installation
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.
Page 55 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.
Page 56 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...
Page 57 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-...
Page 58 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 Product manual - GWT C9 3HAA010198-001 Revision: A ©...
Page 59: Connecting Electricity And Media
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.
Page 60 Connect the Robifix to the weld power cable. xx1900001656 Electrical connectors on page Connect the three water connections to the corresponding water hoses. xx1900001683 Water cooling on page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 61: Controllers Settings
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.
Page 62 This page is intentionally left blank...
Page 63: Maintenance
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.
Page 64 4 Maintenance 4.1 Introduction Continued Bolts, screws and tightening torques Bolt, screws, tightening torques on page 118. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 65: Maintenance Planning
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.
Page 66 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...
Page 67 118. • Replace damage leaf shunts by following proced- Replacement of the leaf shunts on page xx2200000327 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 68 Inspect the condition of the arms and electrode holders and check tightening torques of the screws. Bolt, screws, tightening torques on page 118. xx2200000326 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 69 Inspect the condition of the robot attachment and check ment tightening torques of the screws. Bolt, screws, tightening torques on page 118. xx2200000329 xx2200000330 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 70 Bolt, screws, tightening torques on page 118. In order to get access to all 8 screws the movable electrode can be operated. xx2200000322 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 71 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...
Page 73: Trouble Shooting
Welding current is too low. above Welding force too Perform a force calib- See Application high ration. manual - Spot options 3HAC050979-001. Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 74 Sheet geometrical is- Check/change the program. Unstable force at Bad parameters Check parameters, electrode tips level reload if it is neces- sary. Do a parameter tun- ing. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 75: Repair
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.
Page 76 Special tools on page 122. references to these in the step-by-step in- structions below. Bolts, screws and tightening torques Bolt, screws, tightening torques on page 118. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 77: Spare Parts
The required spare parts can be found on the Customer doc. drawing provided with the delivery. Parts should always be replaced by approved parts delivered by ABB. Use of unauthorized parts will void the warranty. Product manual - GWT C9 3HAA010198-001 Revision: A ©...
Page 78: General Procedures
5.3 General procedures 5.3 General procedures Introduction This section describes the general procedures necessary for all repair work described in this chapter. Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 79: Remove/Reassemble The Protective Cover
If the welding gun is attached to a robot, move the robot so the welding gun is posi- tioned in a good working high. Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 80 Tighten the knurled screw by hand (pos. 1). Make sure that the working space is cleaned and that all equipment is removed before restarting the welding. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 81: Replacement Of The Electrode Holders And Water Hoses
To obtain sufficient power transfer between the sleeve and the electrode holder, the contact surfaces should be lubricated with contact paste. Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 82 The insert couplings are reached through the holes in the arms. xx1900001665 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 83 (position 4). Before replacing the electrode holder, remove the insert couplings from the old electrode holder (position 5). xx1900000005 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 84 1) with contact paste. Assemble the electrode bushing (pos. 1) to the electrode holder (pos 3). Use a tightening torque of 60 Nm. xx2000002659 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 85 Gently push the electrode holder back into the arm. Reconnect the water hoses (pos. 1). This is done by pushing the hoses into the couplings. xx2000002665 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 86 TCP check is required. Tighten the screws and nuts alternately to evenly distribute the force over the clamping connection. xx1900000019 Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 87: Replacement Of The Leaf Shunts
Open movable gun arm to large opening position, with the actuator rod fully retrac- ted inside the actuator. xx2200000334 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 88 Lubricate the contact surfaces with con- tact paste. Spread the paste evenly over the entire contact surfaces using a brush. xx2000002668 xx2000002667 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 89 Use standard tightening torque according toBolt, screws, tightening torques on page 118. xx2200000336 When parts are reassembled, reassemble Remove/reassemble the protective the protective cover. cover on page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 90: Replacement Of The Actuator
Loosen all the connecting media (power Connecting electricity and media on cable, and temperature sensor). page Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 91 Illustration Illustration to the right shows start posi- tion before disassembly. xx2200000337 Disconnect the LeanID connectors and remove from actuator. xx2200000338 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 92 If flange nuts are used there is no need to apply Loctite 243. Tighten the nuts with a tightening torque of 23 Nm. xx2200000341 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 93 9.8 Nm. xx2200000339 Reconnect the LeanID connectors. xx2200000338 When parts are reassembled, reassemble Remove/reassemble the protective the protective cover. cover on page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 94: Replacement Of The Transformer
Disconnect the three water hoses at the water distributor. xx2200000343 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 95 Disconnect the two water hoses connect- ing to the secondary leader and the X- coupling. xx2200000346 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 96 (pos. 2) connecting to the fixed and movable leaf shunts. xx2200000349 Remove the two screws (pos. 2) holding the transformer (pos. 1). xx2100000253 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 97 Remove the screws (pos. 1) holding the secondary leaders (pos. 2) Remove the water couplings (pos. 3). Replace the transformer. xx2100000256 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 98 (pos. 2), two on each side. Use standard tightening torque according Bolt, screws, tightening torques on page 118. xx2200000352 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 99 Tighten the screws (pos. 3) with reduced torque of 30 Nm. xx2200000354 Reconnect the three water hoses at the water distributor. xx2200000355 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 100 X- coupling. xx2200000357 Reconnect the current sensor and temper- ature connector (pos. 1) to the trans- former (pos. 2). xx2200000358 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 101 If the protective cover does not fit, adjust the two screws (pos. 1) holding the sec- ondary leader. Keep in mind the alignment of the mov- able leaf shunt. xx2200000359 Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 102: Replacement Of The Welding Gun Arm
Remove the cover plate (pos. 1) by remov- ing all screws (pos. 2) holding it in place. xx2000002675 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 103 (pos. 2) connecting to the fixed leaf shunt. Let the cooling pad (pos. 3) stay connec- ted to the cooling hoses. xx2200000284 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 104 The dowel pin (pos. 1) will most likely stick to the arm. Remove it by pulling it out using a puller tool. xx2200000286 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 105 Protect the hose ends so no contamin- ants enter. xx2000002692 Inspect the new arm for defects. Make sure all contact surfaces are clean. xx2200000287 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 106 Lubricate the contact surface on the leaf shunt and cooling pad with contact paste. Spread the paste evenly over the entire contact surface using a brush. xx2200000289 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 107 Bolt, screws, tightening torques on page 118. xx2200000293 Reroute the signal cable through the arm, marked with red in illustration. xx2200000294 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 108 Use standard tightening torque according Bolt, screws, tightening torques on page 118 xx2200000295 Reconnect the two water hoses distribut- ing water to the arm. xx2200000296 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 109 Use a set square (right-angled) and hold it to the fixed arm and align the loose electrode holder with the scale. xx2000002715 Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 110 TCP check is required. xx2000002716 Reassemble the protective cover. Remove/reassemble the protective cover on page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 111: Storage And Decommissioning
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.
Page 112: Storage
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...
Page 113: Decommissioning
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...
Page 114: Environmental Information
Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 115: Reference Information
7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 116: Applicable Safety Standards
Electromagnetic compatibility (EMC). Part 6-4: Generic stand- 4:2007/A1:2011 ards. Emission standard for industrial environments EN 61000-6-2, edt Electromagnetic compatibility (EMC) - Part 6-2: Generic 3:2005/C1:2005 standards - Immunity for industrial environments Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 117: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 118: Bolt, Screws, Tightening Torques
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.
Page 119: Standard Tightening Torques
Simply screw in the R-thread by hand and tighten it with 1 or 2 turns with a spanner. NPQH fittings G-thread dimension Tightening torque [Nm] - Nominal G1/8 6 Nm G1/4 7.5 Nm G3/8 9 Nm G1/2 9 Nm Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 120: Standard Toolkit
Set of spanners 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 19 mm, 24 mm, 27 mm and 32 mm Torque wrench 10-100 Nm Continues on next page Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 121 T-handle Hex keys 6 mm Hex keys (Allen key) 1.5-10 mm Hammer with plastic head A clean cloth Brush Thread-locking fluid - Loctite 243 Contact paste - Lubripaste DS-ES Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 122: Special Tools
Scotch brite wheel, very fine grade. xx2000002657 Spot welding gun tip removal tool xx2000002673 Hand drill machine Hot air gun Thread sealant - Scantech 4000T Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 123: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 124 This page is intentionally left blank...
Page 125: Index
EN, 116 safety, 116 nation specific regulations, 9 steel disposal, 114 symbols safety, 18 disposal, 114 system integrator requirements, 9 plastic validity and responsibility, 9 Product manual - GWT C9 3HAA010198-001 Revision: A © Copyright 2022 ABB. All rights reserved.
Page 128 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2022 ABB. All rights reserved. Specifications subject to change without notice.

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