Gullco GK-200-RLx-I User Manual

“KAT”®

CARRIAGE

INDEXING

SYSTEM

(USING GULLCO GSP CONTROLS)

FOR MODELS:
GK−200−RL*−I − GK−200−FL*−I

GK−200−RM*−I − GK−200−FM*−I
GK−200−RH*−I − GK−200−FH*−I

(* 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 LIMITED – INDIA
GULLCO INTERNATIONAL SHANGHAI – LIMITED

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

Revised: March 20, 2012 GD-041-O.doc

SAFETY INSTRUCTIONS

Although the Gullco “KAT”® carriage indexing system 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”
during each phase 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 Control Manual, “GD-031”) 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

¾ Do not use this equipment in damp or wet locations.
¾ Do not expose this equipment to rain.
¾ Never carry this equipment by the cables or pull the cables to disconnect from the

receptacle.

¾ Keep all cables from heat, oil and sharp edges.
¾ Inspect all cables periodically and replace if damaged.
¾ Inspect the secureness of all cables periodically and repair if loose.
¾ Disconnect the power cord when not in use.
¾ Disconnect the power cord positively

of the equipment.

carriage is cautioned to always practice "Safety First"

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to prevent electrical shock before repair and service

Bodily Injury Prevention

¾ Do not wear loose clothing, jewellery and loose, long hair, which may get caught into

automatic systems or moving parts.

¾ Ensure that the track is well

surface.

¾ The track must have a method of safety backup from falling when elevated, i.e., chained at

the ends, welded to work-piece, etc.

¾ Keep lifting handle dry, clean and free from oil and grease.
¾ Keep hands away from the underside of the “KAT”

possibility of motion.

¾ Wherever possible, avoid (or at least protect against) objects protruding from the moving

equipment, posing possible pinch-points.

¾ There should only ever be one (1) operator working at the machine at any given time.
¾ On Flex “KAT”

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

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

¾ Protective gloves should be worn when handling Flex Track to prevent injury from sharp

edges.

secured when installed in any other position than flat on a

carriage when there is the slightest

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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 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 INDEXING SYSTEM

When used with electric arc welding or cutting equipment, ensure that an adequate and well­maintained power return path is provided with good electrical contact. Failure to do so may result in
the welding/cutting current passing through the carriage and damaging the wiring and electrical
components.

Important information regarding safety and operation of the “GSP” motor controls used in the
“KAT”
Technical Manual. It is equally important to read, understand and apply the information contained
within that manual. The supplemental manual (GD-031) has a title “Technical Information For The
Gullco “GSP” Micro-Processor Based, 24 Volt DC Motor Control”, and it’s pages are numbered with
a prefix of “T-“.

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

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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 INDEXING SYSTEM

This manual covers the operating instructions of the following Gullco “KAT”® carriage indexing
systems, using Rigid or Flex “KAT”

, all position, variable speed travel carriages (* indicates voltage

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reference):

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

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

GENERAL DESCRIPTION

The Gullco “KAT”® indexing system is typically used to automate an overlay/surfacing process. The
automatic routine drives a motorized device (either the “KAT”
back and forth between limit switches (cycling). Each time the cycling device reaches a limit switch
it pauses while the other motorized device is activated to carry the overlay/surfacing gun/torch a
preset distance in a preset direction (indexing). An “Arc Signal Relay” is supplied with the system to
provide integrated arc activation signals to the overlay/surfacing equipment. Two GSP controls,
each with dedicated microprocessor chips, are used to control the automatic, two axis indexing
system. One GSP control is set up to be the “Cycle Control” (master) and the other GSP control is
set up to be the “Index Control” (slave). Each control offers user programmable
parameters/variables to allow fine-tuning and functional control of the automatic cycle.

carriage or the motorized rack arm†),

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The Gullco “KAT”

indexing system comprises of a heavy duty, all position “KAT”® travel carriage

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and a motorized rack arm.
The travel carriage is an electrically powered self-propelled 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”

is obtained from

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either a pinion that engages with the rack of the 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.

The motorized rack arm consists of a rack arm driven through a motorized rack box. The rack arm
is basically a square profile arm with gear racking imbedded along its length. The rack arm is
guided through the motorized rack box by Nylastic glide bearings. A low voltage permanent magnet
motor and gear-head drive a pinion which engages with the rack of the arm, propelling the arm and
ultimately the overlay/surfacing gun/torch, in a straight line.

Safety is greatly enhanced by the use of Gullco’s low voltage (24 V), highly advanced controls and
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 motors and
the controls operate on 24 VDC, supplied by a power supply located within the casing of the “KAT”

†

This manual makes the assumption that the “KAT”® carriage provides the cyclic motion, while the

motorized rack box provides the indexing motion. See the diagrams under “Special Reverse Indexing
Configuration” in the Technical Manual for details of how to reverse/alternate this arrangement.

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carriage. Therefore, all operator interface devices (except the power on/off isolation switch) are
subjected to signal level voltages only. Two Gullco GSP motor controls are used; one to drive the
“KAT”

carriage; and one to drive the motorized rack arm. These microprocessor pulse width

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modulation motor controls offer operator interface of forward, stop, reverse and infinitely variable
control of the speed, within the range of the models, as well as an L.E.D. display indicating travel
speeds in either in/min. or cm/min. The travel speeds are electronically controlled using an optical
tachometer located on the back of each gear-motor. Through the use of this, closed loop, feedback
circuitry, each motor control can obtain accurate and constant speed control of the equipment when
running in any plane, regardless of the load (within the rating of the equipment).

INTENDED / FORESEEN USAGE

The Gullco “KAT”® carriage indexing system is used throughout the world to automate and improve
the quality and efficiency of single or multiple “head” overlay/surfacing operations.
Overlay/surfacing guns/torches are readily mounted on the end of the motorized rack arm, which is
mounted to the “KAT”
the “KAT”

will move the gun (or torch) along the desired path, then usually secured in place using

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magnetic or vacuum activated mounting devices. With the use of Gullco's “KAT”
system, repetitive overlay/surfacing cycles may be performed, with precise motion of the gun/torch
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.

perpendicular to its travel direction. The “KAT”® track is positioned so that

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carriage indexing

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OPERATION

The electrical and mechanical installation of the “KAT”® carriage indexing system 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.
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.

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.

Fuse Holder

On/Off Switch

Arc Signal Activation Connector

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