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GULLCO GP-200 Technical Manual

Welding positioner
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WELDING
POSITIONER
(USING GULLCO GSP‐1100
SERIES CONTROLS)
MODELS:
GP-200, GPP-200
TECHNICAL
MANUAL
Website: www.gullco.com
Distributed by:
Revised: July 4, 2018
GD-044-T

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  • Page 1 WELDING POSITIONER (USING GULLCO GSP‐1100 SERIES CONTROLS) MODELS: GP-200, GPP-200 TECHNICAL MANUAL Website: www.gullco.com Distributed by: Revised: July 4, 2018 GD-044-T...

  • Page 3: Safety Instructions

    SAFETY INSTRUCTIONS Although the Gullco welding positioner 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 welding positioner is cautioned to always practice "Safety First" during each phase of operation, setup and maintenance.

  • Page 4: Safety Precautions

    Positioner 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 that manual. supplemental manual (GD-084) has a title “Technical Information For The Gullco “GSP-1100” Microprocessor Based Motor Control”, and it’s pages are numbered with a prefix of “T-“.

  • Page 5: Specifications

    WELDING POSITIONER This parts list covers the operation and maintenance requirements of the following Gullco welding positioners: GP-200-M, GP-200-H, GPP-200-M & GPP-200-H SPECIFICATIONS MODEL 0.27 – 4.62962 RPM 0.75 – 12.5000 RPM † PURGE SYSTEM  GP-200-M  GP-200-H ...

  • Page 6: General Dimensions

    GENERAL DIMENSIONS...

  • Page 7: Installation

    INSTALLATION ELECTRICAL CONNECTION WARNING! Ensure proper AC earth grounding of the Gullco welding positioner and all auxiliary equipment (where applicable), before applying power. Failure to do so may invalidate the Gullco Warranty. WARNING! Before connecting the welding positioner to a power source (receptacle, outlet, etc.,) be sure that the voltage supplied is the same as that specified on the nameplate of the positioner.

  • Page 8: Mechanical Installation

    WARNING! Check to ensure that no parts have become loose during transportation. The Gullco positioner is equipped with handles for portability. The weight of the positioner is evenly distributed around the handles when tilted and locked in the upright position (as shown adjacent).

  • Page 9: Maintenance

    37 in drawing GP-200 & item# 38 in drawing GPP-200). Then loosen the jam nut and adjust the motor tensioning screw as required (items # 31 & 43 in drawing GP-200 & items 32 & 44 in drawing GPP-200). Once the desired tension has been set, re-tighten the jam nut and the four (4) motor mounting screws.
  • Page 10 STORAGE The Gullco welding positioner should be kept in a dry environment with no possibility of impact or damage due to stacking of heavy objects on top of the equipment. SHIPPING When shipping the Gullco welding positioner, the rotary table should be locked in the horizontal plane and the mounting table removed and safely packaged.

  • Page 11: Also Available

    NOTE: The above cutting torch and welding gun support assemblies can be, and often are, equipped with one (1) or two (2) Gullco motorized rack arms controlled by a remote joystick pendant. Ask your local Gullco representative for further details.
  • Page 12 WELDING POSITIONER PARTS BREAKDOWN DRAWING GP-200 Specify model and serial numbers when ordering parts.
  • Page 13 WELDING POSITIONER PARTS BREAKDOWN DRAWING GP-200...
  • Page 14 WELDING GAS PURGE POSITIONER PARTS BREAKDOWN DRAWING GPP-200 Specify model and serial numbers when ordering parts.
  • Page 15 WELDING GAS PURGE POSITIONER PARTS BREAKDOWN DRAWING GPP-200...
  • Page 16 POSITIONER POWER SUPPLY ASSEMBLY PARTS BREAKDOWN ITEM PART No. DESCRIPTION DRAWING GP-200-018 GP-200-004 BOTTOM COVER GK-165-134 FUSE HOLDER ASSEMBLY GK-191-P-022 POWER ON/OFF SWITCH GK-191-P-050 ON/OFF NAME PLATE GK-191-P-019-A 42V TRANSFORMER GK-191-P-019-B 115V TRANSFORMER GK-191-P-019-C 230V TRANSFORMER GK-191-P-218 TRANSFORMER MTG. PAD GK-191-P-105 TRANSFORMER MTG.
  • Page 17 POSITIONER MOTOR ASSEMBLY PARTS BREAKDOWN DRAWING GP-200-011 & GP-200-015 ITEM PART NO. DESCRIPTION GP-200-011 POSITIONER MOTOR ASSEMBLY (200:1) GP-200-131 24VDC GEARMOTOR 200:1 GK-191-P-035 ENCODER SENSOR, INCLUDING WIRING & CONNECTOR GK-191-P-038 ENCODER DISC GK-112-060 #4-40UNC x 1/4" ROUND HEAD SCREW GK-106-063 #4-40UNC x 3/16"...
  • Page 18 OPTIONAL RUN/STOP FOOTSWITCH PARTS BREAKDOWN DRAWING GP-200-024 GP-200, GPP-200, GP-300 GP-250, GPP-250 OR GP-350 (NOT INCLUDED) ITEM PART No. DESCRIPTION KR-179-113 FOOT SWITCH COVER KR-179-115 NON-SLIP FOOT SWITCH PAD KR-179-122 FOOT SWITCH GK-125-055 #8-18 x 3/8" TAP SCREW GK-135-057 #10-32UNF LOCK NUT...
  • Page 19 OPTIONAL FORWARD/STOP/REVERSE FOOTSWITCH PARTS BREAKDOWN DRAWING GP-200-023 GP-200, GPP-200 OR GP-300 (NOT INCLUDED) ITEM PART No. DESCRIPTION GP-200-023-1 FWD/STOP/REV FOOTSWITCH RM-111-110 4 CONDUCTOR SHIELDED CABLE 10'-6" GK-148-017 STRAIN RELIEF LOCK NUT GK-148-015 STRAIN RELIEF 7/8"Ø GK-156-033 WIRE CONNECTOR 4 POSITION FEMALE...
  • Page 20 OPTIONAL VARIABLE SPEED FOOTSWITCH PARTS BREAKDOWN DRAWING GP-200-025 GP-200, GPP-200 OR GP-300 (NOT INCLUDED) ITEM PART No. DESCRIPTION GP-150-020-A VARIABLE SPEED FOOT SWITCH RM-111-110 4 CONDUCTOR SHIELDED CABLE 10'-6" GK-148-017 STRAIN RELIEF LOCK NUT GK-148-015 STRAIN RELIEF 7/8"Ø GK-156-032 WIRE CONNECTOR 3 POSITION FEMALE...
  • Page 21 WELDING POSITIONER POWER SUPPLY SCHEMATIC Drawing Number GP-150-029 GP-200 & GPP-200 BASE WELDING POSITIONER BLOCK WIRING DIAGRAM Drawing Number GP-200-038...

  • Page 22: Additional Notes

    Updated Gullco contact details Page 3 & 5 Removed welding ground amperage rating. ADDITIONAL NOTES Specifications and products are subject to change without notice. KAT, Moggy, Sam, KATBAK & KBM are registered trademarks of Gullco International Enterprises Ltd. Only use genuine/authorized replacement parts.
  • Page 24 www.GULLCO.com...
  • Page 25 GULLCO INTERNATIONAL INC. – U.S.A. Phone: 440-439-8333 Fax: 440-439-3634 e-mail: ussales@gullco.com GULLCO INTERNATIONAL [U.K.] LIMITED – EUROPE Phone: +44 1257-253579 Fax: +44 1257-254629 e-mail: uksales@gullco.com GULLCO INTERNATIONAL PTY LIMITED – AUSTRALIA Phone: 61 (0) 7 3348-5515 Fax: 61 (0) 7 3348-5510 e-mail: ausales@gullco.com...
  • Page 27 IMPORTANT READ THIS BEFORE OPERATING THE “GSP-1100” CONTROL Read and understand the operation manual 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. The motor control must not be continually started and stopped by the removal and reapplying of power to the control.
  • Page 28 Diagnostic LED Table Flash Rate Reason Flashes Normal Closed Loop Operation - No problems detected. every 2 seconds Open Loop Operation - No problems detected which would prevent the motor from running Flashes safely, however a travel speed encoder has not been detected and as such the control will every 2 run in open loop mode.

  • Page 29: General Specifications

    It is designed to run 24 vdc motors and requires a 24 to 42 vdc, no-load, supply (30 to 42 vdc is usually required for Gullco products to meet specifications), usually derived form a full bridge rectified 22-24 vac source. The required wattage of the supply depends upon the size of the motor.

  • Page 30: Operation

    Command Reverse Motion OPERATION Local Control Devices Externally, the Gullco “GSP-1100” controls have switching for Forward/Neutral/Reverse and Run/Stop, as well as a speed control potentiometer. = “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.
  • Page 31 = “REVERSE” - When the switch is in this position, the control will drive the motor in the Reverse direction when so permitted. = “VARIABLE SPEED CONTROL” - By turning the ten potentiometer knob in a clockwise direction, the motor speed will be increased. When rotated in the counter- clockwise direction, the motor speed will decrease.
  • Page 32 “GSP-1100” CIRCUIT BOARD DETAILS Major Circuit Board Component Details F1 - Replaceable, 15 Amp 57 volt automotive fuse. VR2 – Current Limit setting potentiometer. Pin 1 of CN21 Pin 1 of CN11 Pin 1 of CN50 Flash Programming Port Pin 1 of CN12 Pin 1 of CN15 Pin 1 of CN14 Control Connection Details...
  • Page 33 Note: Pins 1 and 2 may be swapped to reverse polarity (only necessary to match the forward and reverse of the motor with those of the control). Note: CN11, CN12, CN14 & CN15 are Molex KK, or equivalent, 0.1” [2.54mm] spaced series connectors/headers CN11 –...
  • Page 34 Wiring Connector Details BOARD MOUNTED WIRING CONNECTOR HEADER CONNECTOR MOLEX PART MOLEX PART GULLCO PART DESIGNATOR NUMBER NUMBER NUMBER 1 x "22-01-2035" 1 x GK-156-032 CN11 & CN12 1 x "22-23-2031"...
  • Page 35 GSP-1100 CONTROL ASSEMBLY BREAKDOWN *SEE NOTES...
  • Page 36 GSP-1100 CONTROL CIRCUIT BOARD SCHEMATIC DRAWING G1100-RB REV-B T-10...
  • Page 37 REVISIONS LIST July, 2016 Overall First release. ADDITIONAL NOTES Specifications and products are subject to change without notice. KAT, Moggy, Sam & KATback are registered trademarks of Gullco International Enterprises Ltd. Only use genuine/authorized replacement parts. T-11...
  • Page 38 www.GULLCO.com...

This manual is also suitable for:

, gpp-200

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