Gullco GK-200-RLx-A User Manual

AUTOWELD “KAT”®

ALL POSITION,

VARIABLE SPEED

TRAVEL CARRIAGE

(USING GULLCO’S GSP-2100 CONTROL)

FOR MODELS:
GK-200-RL*-A - GK-200-FL*-A
GK-200-RM*-A - GK-200-FM*-A
GK-200-RH*-A - GK-200-FH*-A

(* indicates voltage reference)

OPERATING

INSTRUCTIONS

Website: www.gullco.com

Distributed by:

Phone: [phone] Fax: [phone] e-mail: [e-mail]

Phone: [phone] Fax: [phone] e-mail: [e-mail]

Phone: [phone] Fax: [phone] e-mail: [e-mail]

Phone: [phone] Fax: [phone] e-mail: [e-mail]

Phone: [phone] Fax: [phone] e-mail: [e-mail]

GULLCO INTERNATIONAL LIMITED – CANADA
GULLCO INTERNATIONAL INC. – U.S.A.
GULLCO INTERNATIONAL [U.K.] LIMITED - EUROPE
GULLCO INTERNATIONAL PTY LIMITED - AUSTRALIA
GULLCO INTERNATIONAL INDIA PRIVATE LIMITED
GULLCO INTERNATIONAL SHANGHAI – LIMITED

Phone: [phone] Fax: [phone] e-mail: [e-mail]

Revised: March 18, 2014 GD-037-O

SAFETY INSTRUCTIONS

Although the Gullco AutoWeld “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”
of operation, setup and maintenance.

Read and understand the whole Operating Instructions manual (as well as the additional Technical
Manual complete with 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.

carriage is cautioned to always practice "Safety First" during each phase

®

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”

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.
 On Flex “KAT”

models, the track is made from spring steel. Therefore extreme caution

®

should be exercised with respect to the hazards of injury due to whipping.

 Protective gloves should be worn when handling Flex Track to prevent injury from sharp

edges.

carriage when there is the slightest

®

1

SAFETY PRECAUTIONS

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

The above label pictorially represents the following:

“Warning:­Read the manuals 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”
Manual. It is equally important to read, understand and apply the information contained within that
manual. The supplemental 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-“.

carriage is contained in a supplemental manual attached at the end of the Technical

®

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.

2

AUTOWELD “KAT”® carriage

This manual covers the operating instructions of the following Gullco AutoWeld, Rigid and Flex
“KAT”

all position, variable speed travel carriages (* indicates voltage reference):

®

GK-200-RL*-A, GK-200-RM*-A, GK-200-RH*-A

GK-200-FL*-A, GK-200-FM*-A and GK-200-FH*-A

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 adjustable 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”
rigid track, or a uniquely designed sprocket that engages with slots in the flex track. Both of these
systems are 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”
regardless of the load (within the rating of the equipment).

is obtained from either a pinion that engages with the rack of the

®

carriage when running in any plane,

®

®

The Gullco AutoWeld “KAT”

system combines

®

the above carriage with travel limit switches,
adjustable track actuators, Arc Signal Relay(s)
and an AutoWeld GSP micro-processor chip.
The Gullco GSP control with the AutoWeld micro­processor chip allows the operator to select a
variety of multi-functional settings, which when
activated, will sequence the desired starting and
stopping of the weld arc signal in conjunction with
welding motion. The automated cycles can be
configured to provide automated cycles with
sequence functions such as stitch welding,
automatic return to park position, full speed to
weld start location etc. These versatile operator
selected settings are designed to allow various
semi and fully automatic cycles to be achieved to
suit job after job with the same, standard off-the­shelf, piece of equipment.

3

INTENDED / FORESEEN USAGE

The Gullco AutoWeld “KAT”® carriage is used throughout the world to automate and improve the
quality and efficiency of single or multiple “head” welding (or cutting) operations. Welding guns (or
cutting torches) are readily mounted on the “KAT”
“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 AutoWeld "KAT”

carriage. Its track is positioned so that the

®

®

carriage, repetitive welding cycles may be performed, with precise motion of the welding gun from
start to finish, regardless of the number of passes or the work pieces involved. 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.

OPERATION

The electrical and mechanical installation of the AutoWeld “KAT”® is explained in the Technical
Manual.

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.

On/Off Switch

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.

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 Control Overview

The AutoWeld series of “KAT”® carriages use Gullco’s sophisticated “GSP-2100” microprocessor
motor controls.

Externally, this Gullco GSP control has switching for Forward/Neutral/Reverse, Run/Stop,
Manual/Auto & program variable increment/decrement, 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 the Technical Manual, for additional, more comprehensive details than
those provided in the following overview.

4