ABB GWT C9 User manual

ROBOTICS
Product manual
GWT C9

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

Product manual
GWT C9
Document ID: 3HAA010198-001
Revision: A
© Copyright 2022 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
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.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2022 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
7Overview of this manual ...................................................................................................................
8How to read the product manual ......................................................................................................
91 Safety
91.1 General safety information ..................................................................................
91.1.1 Limitation of liability .................................................................................
111.1.2 Protective stop and emergency stop ...........................................................
121.2 Safety actions ...................................................................................................
121.2.1 Fire extinguishing ....................................................................................
131.2.2 Make sure that the main power has been switched off ....................................
141.3 Safety risks ......................................................................................................
141.3.1 Safety risks during installation and service work on GWT C9 ...........................
161.3.2 Risks associated with live electric parts .......................................................
171.3.3 Hot parts may cause burns .......................................................................
181.4 Safety signals ...................................................................................................
181.4.1 Safety signals in the manual ......................................................................
192 Product description
192.1 Overview .........................................................................................................
202.2 Terminology .....................................................................................................
212.3 Concept ..........................................................................................................
212.3.1 Principle ................................................................................................
232.3.2 Detailed views ........................................................................................
262.3.2.1 Electrical connectors ....................................................................
282.3.2.2 Water cooling .............................................................................
332.4 Variants and offers ............................................................................................
332.4.1 Complete offer ........................................................................................
342.4.2 Standard offer ........................................................................................
342.4.2.1 Gun arms ...................................................................................
352.4.2.2 Interface brackets ........................................................................
372.4.3 Customized offer .....................................................................................
392.4.4 Accessories ...........................................................................................
402.5 Technical details and requirements ......................................................................
402.5.1 Actuator ................................................................................................
412.5.2 Transformer MFDC ..................................................................................
422.5.3 Water cooling system ...............................................................................
432.5.4 Temperature and hygrometry ....................................................................
442.5.5 Robot and controller requirements .............................................................
452.5.6 Safety risks related to spot welding ............................................................
473 Installation and commissioning
473.1 Introduction ......................................................................................................
493.2 Unpacking and handling .....................................................................................
493.2.1 Unpacking and acceptance .......................................................................
523.2.2 Handling/lifting .......................................................................................
543.3 Mechanical installation .......................................................................................
593.4 Connecting electricity and media ..........................................................................
613.5 Controllers settings ...........................................................................................
634 Maintenance
634.1 Introduction ......................................................................................................
654.2 Maintenance planning ........................................................................................
734.3 Trouble shooting ...............................................................................................
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Table of contents

755 Repair
755.1 Introduction ......................................................................................................
775.2 Spare parts ......................................................................................................
785.3 General procedures ...........................................................................................
795.3.1 Remove/reassemble the protective cover ....................................................
815.4 Replacement of the electrode holders and water hoses ............................................
875.5 Replacement of the leaf shunts ............................................................................
905.6 Replacement of the actuator ................................................................................
945.7 Replacement of the transformer ...........................................................................
1025.8 Replacement of the welding gun arm ....................................................................
1116 Storage and decommissioning
1116.1 Introduction ......................................................................................................
1126.2 Storage ...........................................................................................................
1136.3 Decommissioning ..............................................................................................
1146.4 Environmental information ..................................................................................
1157 Reference information
1157.1 Introduction ......................................................................................................
1167.2 Applicable safety standards ................................................................................
1177.3 Unit conversion .................................................................................................
1187.4 Bolt, screws, tightening torques ...........................................................................
1187.4.1 Bolt and screws ......................................................................................
1197.4.2 Standard tightening torques ......................................................................
1207.5 Standard toolkit ................................................................................................
1227.6 Special tools ....................................................................................................
1237.7 Lifting accessories and lifting instructions ..............................................................
125Index
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Table of contents

Overview of this manual
About this manual
This manual contains instructions for:
• the characteristics of the GWT C9
• mechanical and electrical installation for the GWT C9
• maintenance instructions for the GWT C9
• mechanical repair of the GWT C9.
Usage
This manual should be used during:
• installation, from lifting the equipment to its work site, to making it ready for
operation
• maintenance work
• repair work
• decommissioning.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• 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 nameDocument description
3HAC050979-001Application manual - Spot options
Customer documentationGWT C9 mechanical drawing
Customer documentationGWT C9 electrical drawing
RobiFix-MA311Product manual for Robifix (electrical connector)
-Product manual for Robot (in question)
-Product manual for DressPack (in question)
-Product manual of the tool changer (optional)
Revisions
DescriptionRevision
First revision.A
Product manual - GWT C9 7
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© Copyright 2022 ABB. All rights reserved.
Overview of this manual

How to read the product manual
Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 9.
Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
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.
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How to read the product manual

1 Safety
1.1 General safety information
1.1.1 Limitation of liability
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.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
To be observed by the supplier of the complete system
The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Continues on next page
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1 Safety
1.1.1 Limitation of liability

The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
work cell motion, each emergency stop button must be marked and placed so there
is no risk for using the wrong button stop. If more than one emergency stop is
provided, each should indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
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.
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1 Safety
1.1.1 Limitation of liability
Continued

1.1.2 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.
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1 Safety
1.1.2 Protective stop and emergency stop

1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
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1 Safety
1.2.1 Fire extinguishing

1.2.2 Make sure that the main power has been switched off
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
personal injuries, switch off the main power on the controller before proceeding
work.
Note
Switch off all main power switches in a MultiMove system.
Spot welding cabinet
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.
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1 Safety
1.2.2 Make sure that the main power has been switched off

1.3 Safety risks
1.3.1 Safety risks during installation and service work on GWT C9
Requirements on personnel
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.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
•Those who install or service/maintain the GWT C9 must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
• Personnel should be trained on responding to emergency or abnormal
situations.
General risks during installation and service
The instructions in the product manual must always be followed.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
To avoid damaging the GWT C9, make sure that there are no loose screws, turnings,
or other parts inside the product after work has been performed.
If any part of the safety system is not working as intended, commissioning or test
run shall not be performed until the issues are resolved by authorized personnel.
Safety risks during operational disturbances
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
Spare parts and special equipment
ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the GWT C9 and as a result of that
affect the active or passive safety operation. ABB is not liable for damages caused
by the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the GWT C9.
Continues on next page
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1 Safety
1.3.1 Safety risks during installation and service work on GWT C9

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. When handling such parts, use protective gloves.
Hearing protection
Material handling, surrounding processes and operations can cause high noise
levels. User hearing protection when being near the production cell.
Goggles
There might be a risk of weld spatter from near by weld process which can cause
eye injuries. There might also be a risk of processing chips/dust being spread due
to the cleaning functionality of the cutter. Use goggles within the production cell.
Protective shoes
At a workplace where lifting and handling of parts occur, protective shoes shall
always be used.
Padlock
When intervention is needed, the power supply must be turned off to the machines
within the danger area and the main safety switch padlocked.
Allergenic material
See Environmental information on page 114 for specification of allergenic materials
in the product, if any.
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1 Safety
1.3.1 Safety risks during installation and service work on GWT C9
Continued

1.3.2 Risks associated with live electric parts
Voltage related risks, general
Work on the electrical equipment of the robot must be performed by a qualified
electrician in accordance with electrical regulations.
Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the main switch to
OFF) when repairing faults, disconnecting electric leads, and disconnecting or
connecting units.
The main supply to the robot must be connected in such a way that it can be turned
off from outside the working space of the robot.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot during installation,
commissioning, and maintenance is guaranteed if the valid regulations are followed.
Voltage related risks, IRC5 controller and spot welding cabinet
A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (weld timer in the spot welding cabinet,
DC link and Ultracapacitor bank unit) in the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The main supply/main switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for
the machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.
Voltage related risks, tools, material handling devices, etc.
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.
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1 Safety
1.3.2 Risks associated with live electric parts

1.3.3 Hot parts may cause burns
Description
During normal operation, many parts become hot. Touching these may cause
burns.
There is also a risk of fire if flammable materials are put on hot surfaces.
Safe handling
Always use your hand, at some distance, to feel if heat is radiating from the
potentially hot component before actually touching it.
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.
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1 Safety
1.3.3 Hot parts may cause burns

1.4 Safety signals
1.4.1 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
SignificanceDesignationSymbol
Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
DANGER
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in serious
injury.
WARNING
Signal word used to indicate a potentially hazardous
situation related to electrical hazards which, if not
avoided, could result in serious injury.
ELECTRICAL
SHOCK
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in slight
injury.
CAUTION
Signal word used to indicate important facts and
conditions.
NOTE
Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.
TIP
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1 Safety
1.4.1 Safety signals in the manual

2 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. The welding gun is able to produce
high forces at the electrode tips for welding of high strength steels.
The GWT C9 is designed to suit the ABB welding robots. This includes the interface
plugs and connections to the standard ABB DressPack. The GWT C9 comes with
the actuator tuned and the Equalization parameters already prepared.
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.
• Electrodes of various standard or custom made shapes.
• Fluid and electrical connections.
• Protection cover (for environmental exposure).
Design
The GWT C9 is designed to ease the welding procedure. Its fundamental
characteristics can be categorized as below:
• Easy customization.
• Low weight.
• High weld force.
• Less spare parts.
• Easy maintenance.
• Low MTTR (Mean Time To Repair).
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2 Product description
2.1 Overview

2.2 Terminology
Description
In the table underneath there are some explanations regarding the terms and
abbreviations used in this manual.
ExplanationTerm/
abbreviation
Gun Weld Technique - Generation 9GWT C9
Medium Frequency Direct CurrentMFDC
Mean Time Between FailuresMTBF
Mean Time To RepairMTTR
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2 Product description
2.2 Terminology