Gullco GK-200-RL User Manual

“KAT” ALL POSITION, VARIABLE SPEED TRAVEL CARRIAGE

(USING GULLCO’S GSP-2100 CONTROL)

FOR MODELS:

GK-200-RL

GK-200-RM

GK-200-RH

PARTS LIST

&

OPERATING INSTRUCTIONS

				Website: www.gullco.com
	Distributed by:	GULLCO INTERNATIONAL LIMITED – CANADA
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		GULLCO INTERNATIONAL INC. – U.S.A.
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		GULLCO INTERNATIONAL [U.K.] LIMITED -		EUROPE
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		GULLCO INTERNATIONAL PTY LIMITED -		AUSTRALIA
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		GULLCO INTERNATIONAL INDIA PRIVATE		LIMITED
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		GULLCO INTERNATIONAL SHANGHAI – LIMITED
		Phone: [phone]	Fax: [phone]	e-mail: [e-mail]
Revised: March 18, 2014				GD-033 GSP-2100

SAFETY INSTRUCTIONS

Although the Gullco “KAT” carriage is manufactured for safe and dependable operation, it is impossible to anticipate those combinations of circumstances, which could result in an accident. An operator of the “KAT” carriage is cautioned to always practice "Safety First" during each phase of operation, setup and maintenance.

Read and understand the whole operation manual (including the supplementary GSP-2100 control manual, “GD-075”) before operating or performing service of this equipment. Become familiar with the machines operation, applications and limitations. Keep the operation manual in a clean and readily available location.

This equipment is normally used to automate / semi-automate welding or cutting processes. These processes usually have any combination of the following; bright and hot arcs, flying sparks, fumes, ultraviolet and infrared radiated energy, hot work-pieces, compressed gases, etc... The onus is on the operator of this equipment to know, understand and follow all the safety precautions associated with the process being used.

A careless operator invites troubles, and failure to follow safety practices may cause serious injury or even death. Important safety precautions are given in the following:

Electrical Shock Prevention

Do not use this equipment in damp or wet locations.

Do not expose this equipment to rain.

Never carry this equipment by the cables or pull the cables to disconnect from the receptacle.

Keep all cables from heat, oil and sharp edges.

Inspect all cables periodically and replace if damaged.

Inspect the secureness of all cables periodically and repair if loose.

Disconnect the power cord when not in use.

Disconnect the power cord positively to prevent electrical shock before repair and service of the equipment.

Bodily Injury Prevention

Do not wear loose clothing, jewellery and loose, long hair, which may get caught into automatic systems or moving parts.

Ensure that the track is well secured when installed in any other position than flat on a surface.

The track must have a method of safety backup from falling when elevated, i.e., chained at the ends, welded to work-piece, etc.

Keep lifting handle dry, clean and free from oil and grease.

Keep hands away from the underside of the “KAT” carriage when there is the slightest possibility of motion.

Wherever possible, avoid (or at least protect against) objects protruding from the moving equipment, posing possible pinch-points.

There should only ever be one (1) operator working at the machine at any given time.

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SAFETY PRECAUTIONS

The following cautionary/warning label is attached to each “KAT” carriage:-

The above label pictorially represents the following:

“Warning:-

Read the manual before turning the unit on and before performing service.

Also, positively disconnect the unit from all power supplies before servicing!”

IMPORTANT

READ THIS BEFORE OPERATING THE “KAT” CARRIAGE

Ensure that an adequate and well-maintained weld return path is provided with good electrical contact. Failure to do so may result in the welding current passing through the carriage and damaging the wiring and electrical components.

Important information regarding safety and operation of the “GSP-2100” motor control used in the “KAT” carriage is contained in a supplemental manual attached at the end of this manual. It is equally important to read, understand and apply the information contained within the manual. The manual (GD-075) has a title “Technical Information For The Gullco “GSP-2100” Micro-Processor Based, 24 Volt DC Motor Control”, and it’s pages are numbered with a prefix of “T-“.

ALL THE SAFE PRACTICES AND PRECAUTIONS MAY NOT BE GIVEN IN WRITING. SOME ARE BASED ON COMMON SENSE, BUT OTHERS MAY REQUIRE TECHNICAL BACKGROUND TO EXPLAIN.

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“KAT” CARRIAGE

This parts list covers the operation and maintenance requirements of the following Gullco “KAT” all position, variable speed travel carriages:

GK-200-RL, GK-200-RM and GK-200-RH

	SPECIFICATIONS
MODEL		SPEED RANGE
GK-200-RL		0.5 – 16.4 in/min [1.2 – 41.6 cm/min]
GK-200-RM		1 – 32.7 in/min [2.5 – 83.1 cm/min]
GK-200-RH		2.7 – 88.4 in/min [6.7 – 224 cm/min]
Weight of “KAT” carriage:	29 Lbs. [13 Kg.]
Vertical load capacity:	100 lbs. [45 Kg.]
	(GK-200-RH with a high speed gear attachment = 50 lbs. [22 Kg.])
Drive motor:	24 VDC permanent magnet gear motor.
Supply voltage:	Either 42, 115 or 230 VAC, single phase, 50/60 Hz., 200 watts.
Complies with:	C.S.A. (File # LR 35006-7) & CE Certification.

GENERAL DIMENSIONS

	14.81 [376.2]
10.14 [257.6]	9.18 [233.2]
10.68 [271.3]	8.72 [221.5]
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GENERAL DESCRIPTION

The Gullco “KAT” is a heavy duty, all position travel carriage. It is an electrically powered selfpropelled carriage that travels in a forward or reverse direction, at precisely controlled speeds, along a special track. The self-aligning wheel system of the carriage grips the top and bottom of the track, enabling it to travel along any plane. The bogey wheel assembly keeps the carriage snug to the track, while allowing it to be easily mounted and removed from the track at any point. The positive drive of the “KAT” is obtained from a pinion that engages with the rack of the track, driven by a low voltage permanent magnet motor and gear-head power unit assembly. Safety is greatly enhanced by the use of Gullco’s low voltage (24 V), highly advanced control / power supply system that is available in three line voltage inputs, i.e. 42, 115 and 230 VAC, single phase, 50/60 Hz, or any unregulated 24 VDC power supply at 220 watts of power. The motor and the control operate on 24 VDC, supplied by a power supply located within the casing of the “KAT” carriage. Therefore, all operator interface devices (except the power on/off isolation switch) are subjected to signal level voltages only. The microprocessor pulse width modulation motor control offers operator interface of forward, stop, reverse and infinitely variable control of the speed, within the range of the model, as well as an L.E.D. display indicating travel speed in either in/min. or cm/min. The travel speed is electronically controlled using an optical tachometer located on the back of the gear-motor. Through the use of this, closed loop, feedback circuitry, the motor control can obtain accurate and constant speed control of the “KAT” carriage when running in any plane, regardless of the load (within the rating of the equipment).

INTENDED / FORESEEN USAGE

The Gullco “KAT” carriage is used throughout the world to automate and improve the quality and efficiency of single or multiple “head” welding / cutting operations. Welding guns or cutting torches are readily mounted on the “KAT” carriage. Its track is positioned so that the “KAT” will move the gun or torch along the desired path, then securely held in place using magnetic or vacuum activated mounting devices. With the use of Gullco’s “KAT” carriage, welding guns or cutting torches can operate with precise motion from start to finish regardless of the number of passes or the work pieces involved, Improving the quality, efficiency and repeatability of the process. Detrimental factors such as poor or awkward accessibility, operator fatigue, or inconsistent workmanship are eliminated. Required quality levels are consistently attained and productivity and profitability increased.

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INSTALLATION

ELECTRICAL CONNECTION

WARNING! Ensure proper AC earth grounding of the Gullco “KAT” carriage and all auxiliary equipment (where applicable), before applying power. Failure to do so may invalidate the Gullco Warranty.

WARNING! Before connecting the “KAT” carriage to a power source (receptacle, outlet, etc.,) be sure that the voltage supplied is the same as that specified on the product label of the carriage. If in doubt, DO NOT PLUG IN THE “KAT” CARRIAGE. Copies of the possible product labels are shown below:

As the colours of the wires in the mains lead of this equipment may not correspond with the coloured markings identifying the terminals in your plug, proceed as follows:

The Green & Yellow or Green wire must be connected to the terminal in the plug which is allocated for “Earth” / “Ground”.

The Blue or White wire must be connected to the terminal that is allocated for “Neutral”.

The Brown or Black wire must be connected to the terminal that is allocated for “Live”.

MECHANICAL INSTALLATION

WARNING! Check to ensure that no parts have become loose during transportation.

The “KAT” carriage is equipped with a handle for portability. The weight of the carriage is evenly distributed around the handle, however, if the “KAT” carriage has had other equipment attached to it, uneven weight distribution may present a hazard when lifting. Therefore we recommend care and consideration should be given to removing uneven loads and /or any additions that may make the total weight of the equipment too heavy or awkward to be comfortably lifted.

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The drive engagement lever is the 90º lever that extends out of the side of the carriage lower housing. This lever engages the drive gear with the rack and must always be disengaged when fitting or removing the "KAT" carriage from the ends of the track. It also permits free wheeling for rapid positioning. To engage the drive, push lever in towards the carriage body and turn in an anticlockwise direction. To disengage drive, push lever in towards the carriage body and turn in a clockwise direction.

WARNING! Never disengage the drive, when there is a possibility that this action may result in the equipment falling to the ground due to load.

The wheel adjustment screw moves the pivoted bogey wheel assembly relative to the track and is used to facilitate the fitting of the carriage anywhere along the track length. To fit the carriage, slacken the lock nut (item # 3 – drawing # GK-191-P-200-2B) and turn the adjusting screw (item # 2

– drawing # GK-191-P-200-2B) anti-clockwise to withdraw the wheels to their fullest extent. Fit the carriage to the track making sure that the fixed wheel assemblies are engaged on the track ways, then turn the adjusting screw clockwise until all wheels fit snugly on the track ways. The “KAT” carriage should be free to move along the track, but there should be no play between the wheels and the track. Tighten up the lock nut. To remove the carriage from the track, perform a reverse operation to that described above.

NOTE: Over-tightening of the wheel assemblies will result in overloading the drive system.

NOTE: If the carriage is being removed or fitted over the end of a length of track, then it is not necessary to withdraw the wheel bracket assembly.

NOTE: If it is necessary that the carriage is to be mounted to track in the plane shown by the following sketch, always mount the “KAT” with the fixed wheels on the top, as shown.

UP

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OPERATION

Local Control Devices

The power On/Off switch is used to disconnect the power to the rest of the control circuitry.

I = on, O = off.

WARNING! The motor control must not be continually started and stopped by the removal and reapplying of power to the control. Turning the power off to the control will not provide instant braking and continued use will damage the control. Allow ten (10) seconds after the removal of power before reapplying the power to the motor control.

On/Off Switch

Fuse Holder

The fuse holder allows accessibility to the main fuse by pushing the cap in towards the main body and twisting in a counter-clockwise direction.

GSP-2100 Control Overview

Speed & Parameter Value

Display

Speed Display Calibrated in

Forward Motion Commanded

Inches per Minute

Speed Display Calibrated in

Reverse Motion Commanded

Centimeters per Minute

Auto Cycle Mode (Constant)

Hold (Stop) Mode Active

Manual Mode (Absent)

Arc Signal Active

Speed Adjustment

Counter-Clockwise = Slower

Clockwise = Faster

Cycle Push Button

Command Forward Motion

Control in Run Mode

Neutral

Control in Hold (Stop) Mode

Command Reverse Motion

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Externally, the Gullco GSP-2100 control has switching for Forward/Neutral/Reverse, Run/Stop, Manual/Auto & program variable increment/decrement (where applicable), as well as a rotary encoder for speed control.

Please refer to the supplemental manual (GD-075) “Technical Information For The Gullco “GSP2100” Micro-Processor Based, 24 Volt DC Motor Control” (the pages are numbered with a prefix of “T-“), attached at the end of this manual, for additional, more comprehensive details than those provided in the following overview.

The Run/Stop Switch is a two (2) position toggle switch located on the GSP control. Refer to the “Manual Operation” and “Automatic Operation” sections later in this manual for further details of this switch.

= “STOP” - This over-rides all other controls and when activated will apply regenerative breaking to the motor to bring it to a dead stop, and will disallow any further operation of the motor while ever it is in this state. This position will also reset an error code once the fault has been rectified. The Run/Stop switch needs to be in this position to change between automatic and manual modes and also to alter any of the program variable parameters.

= “RUN” - This removes the “STOP” command and allows the control to assume an operational status.

WARNING! Avoid repeatedly starting and stopping the carriage in quick, short succession, as this will reduce the life expectancy of the control and the motor.

The direction selection switch allows the operator to set the travel direction. It is also used as the method to change the values/settings of the program variables. This is a three (3) position switch with the center position being "Neutral" (no direction chosen). Refer to the “Manual Operation” and “Automatic Operation” sections later in this manual for further details of this switch.

= “FORWARD” - When the switch is in this position, the control will drive the motor in the Forward direction, while in manual mode and when so permitted. It is also used as the method of adjustment for the program variables when used in conjunction with the speed adjustment knob.

= “NEUTRAL” - When the switch is in this position, the control will not drive the motor in either direction while in manual mode.

= “REVERSE” - When the switch is in this position, the control will drive the motor in the Reverse direction, while in manual mode and when so permitted. It is also used as the method of adjustment for the program variables when used in conjunction with the speed adjustment knob.

WARNING! Avoid changing the travel direction without making sure that the carriage comes to a complete stop first. Failure to comply may cause an overload.

WARNING! Avoid repeatedly starting and stopping the carriage in quick, short succession, as this will reduce the life expectancy of the control and the motor.

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The ten-turn speed adjustment knob on the control is used to change the travel speed of the carriage. Adjusting the speed control may be performed when stationary or when in motion. The travel speed may be preset, prior to any motion, by placing the Run/Stop switch to the Stop position and the Forward/Neutral/Reverse switch in the Neutral position. Then, by rotating the Variable Speed Control knob, the travel speed can be pre-set to the required value, as indicated in the L.E.D. display.

= “VARIABLE SPEED CONTROL” - By turning the ten (10) turn rotary encoder knob in a clockwise direction, the motor speed will be increased. When rotated in the counter-clockwise direction, the motor speed will decrease. The Variable Speed Control adjustment is used to set the travel speed of the “KAT” carriage in both manual mode and automatic mode.

The Cycle Push Button is a momentary device, which allows the operator to toggle between automatic and manual modes. The Cycle Push Button is also used to clear error codes

= “AUTOMATIC MODE” (“PRESET CYCLE ENABLED”) - Only by depressing the Cycle Push Button continually for one second while the Fwd/Neut/Rev switch is in the Reverse position, and while the control is in “Hold” (Stop) mode, may the Manual Mode be toggled to the Automatic Mode (pre-set cycle routine enabled), as indicated by the constant illumination of the Auto Cycle Mode L.E.D. The Cycle Push Button is also used to enter and exit parameter/variable menu.

= “MANUAL MODE” (“PRESET CYCLE DISABLED”) - Only by depressing the Cycle Push Button continually for one second while the Fwd/Neut/Rev switch is in the Reverse position, and while the control is in “Hold“ (Stop) mode, may the Automatic Mode be toggled to the Manual Mode (pre-set cycle routine disabled), as indicated by the non-illumination of the Auto Cycle Mode L.E.D. The Cycle Push Button is also used to enter and exit parameter/variable menu.

The L.E.D. Display

The GSP control has an L.E.D. display, which when factory installed on a “KAT” carriage, will be calibrated to display the travel speed in one of two units of measure, either;

1.Calibration in inches per minute (IPM L.E.D. will be illuminated and the closed loop tach feed back system is required) or;

2.Calibration in centimetres per minute (CM/MIN L.E.D. will be illuminated and the closed loop tach feed back system is required).

Whenever the control is in Stop (hold) mode and there is no Forward or Reverse direction commanded (Neutral), the speed display will indicate the preset speed.

For more information regarding the calibration scale selection, using the Motor Control Variables, Rotary Switch, refer to the supplemental manual (GD-075) “Technical Information For The Gullco “GSP-2100” Micro-Processor Based, 24 Volt DC Motor Control” (the pages are numbered with a prefix of “T-“), attached at the end of this manual.

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The display also shows the travel direction accessed as well as the status of the “Hold” (Stop) command. Arc Signal activation and Program/Cycle mode L.E.D.’s are also provided.

The Forward and Reverse L.E.D.’s indicate the motor direction commanded.

The “Hold” (stop) L.E.D. will illuminate whenever there is a “Hold” (stop) command present. This could be any combination of either the Run/Stop switch being in the Stop position, or a “Hold” (stop) command being activated through one of the interface ports, or a part of the automatic cycle. When the “Hold” (stop) L.E.D. flashes on and off, it is indicating that the control is looking for a reset before allowing any functionality. To reset this condition, initiate a “Hold” (stop) command through the Run/Stop switch or one of the interface ports. See the section regarding error codes in the supplemental manual (GD-075) “Technical Information For The Gullco “GSP-2100” Micro-Processor Based, 24 Volt DC Motor Control” (the pages are numbered with a prefix of “T-“), attached at the end of this manual for more details.

The Arc Signal L.E.D. is used as an indication that the product/application specific program has activated the output ports “CN81” and “CN83”. When the optional Gullco auxiliary relay module is connected to the “CN81” port, the relay energizes, providing an isolated signal activating the welding/cutting equipment as part of the automatic cycle. When the “CN81” port is de-activated, the relay is de-energized, instructing the welding/cutting equipment to stop and the Arc Signal L.E.D. is extinguished.

The Auto Cycle Mode L.E.D. is used to indicate whether the control is in automatic cycle mode (Preset Cycle routine enabled), or in manual mode (Preset Cycle routine disabled). When the L.E.D. is constantly illuminated the automatic mode is enabled. When the L.E.D. is not illuminated the control is in manual mode.

The various L.E.D.’s may also be used to help identify various program variable parameters and their selected settings, when the Program Variable or Motor Control Variable selector switches are accessed.

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Manual Operation

To toggle between automatic mode (Aut) and manual mode (Hnd), place the Run/Stop switch in the Stop position and the Fwd/Neut/Rev switch in the Rev position and press and hold the Cycle Push Button until the desired mode is displayed (Aut or Hnd).

In manual mode (Hnd) the Auto Cycle Mode L.E.D. located in the lower right hand corner of the display will be extinguished.

Manual mode only permits manual motion of the “KAT” carriage. The Forward/Neutral/Reverse switch selects which direction the “KAT” will travel. The Speed Adjustment knob sets the linear travel speed. When the Run/Stop switch is placed in the Run position, the “KAT” carriage will travel in the direction and speed set by the Forward/Neutral/Reverse switch and the Speed Adjustment knob. Travel motion will cease if; the Run/Stop switch is placed in the Stop position; the Forward/Neutral/Reverse switch is placed in the Neutral position; the speed is set to zero; or the optional travel limit switch is activated in the relevant direction (when installed).

Automatic Operation

To toggle between automatic mode (Aut) and manual mode (Hnd), place the Run/Stop switch in the Stop position and the Fwd/Neut/Rev switch in the Rev position and press and hold the Cycle Push Button until the desired mode is displayed (Aut or Hnd).

When the control is in automatic mode (Hnd) the Auto Cycle Mode L.E.D. located in the lower right hand corner of the display will be constantly illuminated.

In automatic mode (Aut), the activation and subsequent procedure of an automatic cycle are described below:

1.The automatic cycle is initiated by placing the Forward/Neutral/Reverse switch in either the Forward or Reverse position and the Run/Stop switch in the Run position. The cycle then proceeds to section 2.

2.Momentarily looks at the Forward/Neutral/Reverse direction switch and the optional limit switch signals.

a.If the switch is in the Forward position and the optional forward limit switch is activated, the cycle aborts, resets and displays “End”.

b.If the switch is in the Reverse position and the optional reverse limit switch is activated, the cycle aborts, resets and displays “End”.

c.Otherwise the cycle proceeds to section 3.

3.Momentarily looks at the Forward/Neutral/Reverse direction switch and the Weld Direction parameter. The setting of the Forward/Neutral/Reverse switch is ignored from this point onward, until it is placed in the Neutral position or the Run/Stop switch is placed in the Stop position.

a.If the switch is set to the opposite direction as the Weld Direction parameter, then the

“KAT” carriage will start to travel at full speed in the direction set by the switch until either; the Run/Stop switch is placed in the Stop position; the

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Forward/Neutral/Reverse direction switch is placed in the Neutral position; or the relevant optional travel limit switch is activated, at which point the travel will immediately stop and the cycle is then completed and “End” is displayed.

b.If the switch is set to the same direction as the Weld Direction parameter, or if the Weld Direction parameter is set to both Forward & Reverse, then the cycle proceeds to section 4.

4.The optional Arc Signal Relay (GK-191-P-071) is energized and the Travel Motion Delay is initiated. The cycle then proceeds to section 5.

5.Upon completion of the Travel Motion Delay, the Kat carriage starts to travel in the direction set by the Forward/Neutral/Reverse switch (detected and recorded at the onset of the cycle), at the speed set by the potentiometer. The cycle then proceeds to section 6.

6.When the Run/Stop switch is placed in the Stop position, or the Forward/Neutral/Reverse switch is placed in the Neutral position, or if the relevant forward or reverse optional limit switch is activated, then the travel motion will cease, and the Crater Fill Delay will commence. The cycle then proceeds to section 7.

7.Upon completion of the Crater Fill Delay (maintaining the Arc Signal after the weld motion has ceased, thereby filling the weld crater), The optional Arc Signal Relay is de-energized. The cycle then proceeds to section 8.

8.If the cycle was stopped via:

a.The Run/Stop switch or the Forward/Neutral/Reverse switch, the cycle is now completed and “End” is displayed.

b.If the cycle was stopped via the relevant forward or reverse optional limit switch and either the Automatic Return To Home parameter is set to Off; or the Weld Direction parameter is set to both Forward & Reverse, the cycle is now completed and “End” is displayed.

c.If the cycle was stopped via the relevant forward or reverse optional limit switch and the Automatic Return To Home parameter is set to On (and the Weld Direction parameter is not set to both Forward & Reverse), and the opposite limit switch to the Weld Direction is detected and not activated, then the Post Weld Delay timing cycle is initiated and the cycle proceeds as per section 9.

9.Upon completion of the Post Weld Delay (keeping the carriage stationary to allow time for any burn-back or post flow welding functions), the cycle will continue as per section 10.

10.The carriage will travel in the opposite direction to that of the Weld Direction parameter, at full speed, until the activation of the home limit switch (the optional limit switch in the opposite direction to that of the Weld Direction parameter). The cycle then proceeds to section 11.

11.Upon the activation of the home limit switch the carriage return travel will immediately stop and the cycle is then completed and “End” is displayed.

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The Automatic Return To Home parameter setting is ignored if the Weld Direction parameter is set to both Forward & Reverse, or if optional travel limit switches are not detected on power-up.

If the Run/Stop switch is placed in the Stop position, or the Forward/Neutral/Reverse switch is placed in the Neutral position at any time during an automatic cycle, the carriage travel will stop immediately, and upon completion of the crater fill delay the Arc Signal will reset (if applicable).

Special consideration for the Auxiliary “Hold” (Stop) Signal in Automatic Mode:

The Auxiliary “Hold” (Stop) Port - “CN12” - of the control allows an external device to place the control in the “Hold” (stop) mode. While-ever the device activates the “Hold” (stop) signal (closes the circuit between pins 1 & 2 of CN12) the carriage travel is immediately inhibited (both manual and automatic modes) and upon completion of the Crater Fill Delay the Arc Signal will reset, if applicable (automatic mode).

If the external device activates the auxiliary “Hold” (stop) signal for more than one second during an automatic cycle, the “Hold” (stop) mode is activated as described above. However, when the signal is deactivated (released), and if neither the Run/Stop switch had been placed in the Stop position nor the Forward/Neutral/Reverse switch placed in the Neutral position, the control will commence a new automatic cycle. It is important to realise that under these circumstances, even though the auxiliary “Hold” (stop) signal may have been applied while the automatic cycle was performing an Automatic Return To Home routine, when the signal is deactivated (released), the cycle will start anew (arc signal activation, followed by carriage travel in the direction set by the Forward/Neutral/Reverse switch).

If the external device activates the auxiliary “Hold” (stop) signal for less than one second during an automatic cycle, the automatic cycle performs a controlled shut down and resets (as though the Run/Stop switch has been placed in the Stop position).

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