GULLCO GP-175-006 Parts List & Operating Instructions

Automatic cycle cantilevered welding positioner

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AUTOMATIC CYCLE

OPERATING INSTRUCTIONS

Distributed by:

Revised: September 25, 2002

CANTILEVERED

WELDING

POSITIONER

MODELS:

GP-175-006

GP-175-015

PARTS LIST

GULLCO INTERNATIONAL LIMITED - CANADA

Phone: 905-953-4140

GULLCO INTERNATIONAL INC. – U.S.A.

Phone: 440-439-8333

GULLCO INTERNATIONAL [U.K.] LIMITED - EUROPE

Phone: +44 1257-253579

GULLCO INTERNATIONAL PTY LIMITED - AUSTRALIA

Phone: 61 (0) 7 5496-9555

GULLCO INTERNATIONAL LIMITED - INDIA

Phone: 91-20-4272212

GPP-175-006

GPP-175-015

Fax: 905-953-4138

Fax: 440-439-3634

Fax: +44 1257-254629

Fax: 61 (0) 7 5496-9522

Fax: 91-20-4272212

Website: www.gullco.com

e-mail: sales@gullco.com

e-mail: kat@apk.net

e-mail: sales@gullco.co.uk

e-mail: katoz@ozemail.com.au

e-mail: Gullco@vsnl.com

GD-032.DOC

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Summary of Contents for GULLCO GP-175-006

Page 1 Fax: 905-953-4138 e-mail: sales@gullco.com GULLCO INTERNATIONAL INC. – U.S.A. Phone: 440-439-8333 Fax: 440-439-3634 e-mail: kat@apk.net GULLCO INTERNATIONAL [U.K.] LIMITED - EUROPE Phone: +44 1257-253579 Fax: +44 1257-254629 e-mail: sales@gullco.co.uk GULLCO INTERNATIONAL PTY LIMITED - AUSTRALIA Phone: 61 (0) 7 5496-9555 Fax: 61 (0) 7 5496-9522 e-mail: katoz@ozemail.com.au...
Page 3: Safety Instructions
SAFETY INSTRUCTIONS Although the Gullco cantilevered 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 cantilevered welding positioner is cautioned to always practice "Safety First"...
Page 4: Safety Precautions
It is equally important to read, understand and apply the information contained within the manual. The 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-“.
Page 5: Specifications
CANTILEVERED WELDING POSITIONER This parts list covers the operation and maintenance requirements of the following Gullco cantilevered welding positioners: GP-175-006, GP-175-015, GPP-175-006 and GPP-175-015 SPECIFICATIONS AUTOMATIC CYCLE POSITIONER WITH GAS MODEL AUTOMATIC CYCLE POSITIONER PURGE SYSTEM GP-175-006 GP-175-015 GPP-175-006 GPP-175-015...
Page 6: General Dimensions
Safety is greatly enhanced by the use of Gullco's low voltage (24 V) control 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.
Page 7: Installation
INTENDED / FORESEEN USAGE Gullco cantilevered welding positioners are widely applied to reduce the cost of welding pipe circumferential components, such as flanges and fittings. They are compact, portable and provide fast positioning and smooth rotation. Through automation / semi-automation, the quality, efficiency and repeatability of the weld produced is greatly improved.
Page 8: Mechanical Installation
Check that the grounding block on the underside of the rotary table is correctly located and well seated. Gullco cantilevered welding positioners are shipped from the factory with the mounting table removed to reduce the possibility of shipping damages. Use the four (4) ¼”-20 x 1” flat head socket cap screws and the hexagonal key supplied to securely mount the table to the spindle face (see drawing GP-175-001 later in this manual, for further details).
Page 9: Operation
OPERATION Through the use of the optical tachometer closed loop feedback circuitry, the motor control can obtain constant speed control of the cantilevered welding positioner, as well as determine the amount of rotational distance travelled. The motor and the control operate on 24 VDC, supplied by a power supply located in the base of the positioner tower.
Page 10: Manual Operation
The controls ten-turn speed adjustment knob is used to change the rotary speed of the positioner turntable. When the adjusting knob is turned counterclockwise, the rotary speed will be reduced, and when it is turned clockwise, the speed will be increased, as indicated in the LED display. Adjusting the speed control may be performed when stationary or when in motion.
Page 11 The automatic cycle is initiated by placing the Run/Stop switch in the Run position. If the programmable Weld Cessation (P. 9) parameter is set to “2” the automatic cycle will continue as described in section 2-1 to 2-14. If the Weld Cessation (P. 9) parameter is set to “1” the automatic cycle will proceed as described in section 1-1 to 1-14.
Page 12 1-8-1. Example, the Stitch Weld Angle parameter is set to 20º and the No-Weld Angle is set to 40º. The no-weld rotation would stop at 60º, 120º, 180º, 240º etc. 1-9. Upon completion of the fixed delay, the optional arc signal relay will be re-energized and the programmable Rotation Start Delay (P.
Page 13 2-5. The optional arc signal relay will de-energize when the angular rotation reaches the initial value set in the programmable Stitch Weld Angle (P. 7) parameter or every time it reaches the sum of the initial Stitch Weld Angle (P. 7) value plus the accumulative sums of each Stitch Weld Angle (P.
Page 14 any burn-back and or post-flow functions, prior to the retraction of the optional pneumatic gun positioning slide (where applicable). 2-14. Upon completion of the Post Weld Delay, the optional gun slide solenoid relay will be de- energized and the automatic cycle will be complete. “End” will be displayed to indicate the completion.
Page 15 Description of Programmable Parameters/Variables The following describes the Program Variable Selector Switch settings for the GSP motor control using Gullco’s GSP-2004-2 micro-processor chip, as rotated clockwise from zero (0) top dead center. P. 0 Normal Operating Position - The control needs to be in this position to allow normal operation (top dead center).
Page 16: Maintenance
MAINTENANCE The Gullco cantilevered welding positioner is a heavy duty, robust piece of equipment, and under normal conditions, it will give you years of trouble free service, if it is operated within the limits of its expected use and if the following maintenance points are adhered to: Clean all excess dust, spatter, slag etc.
Page 17 These inspections should be performed with greater frequency if conditions and usage requires. STORAGE The Gullco cantilevered 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 cantilevered welding positioner, the rotary table should be locked in the horizontal plane and the mounting table removed and safely packaged.
Page 18 ACCESSORIES GP-175-030 GP-175-025 WPG-250 GP-175-020 GP-175-025 Arc signal relay kit. This kit provides an internal wiring harness; an isolated relay and quick connect receptacle circuit board assembly; and an external cable with mating quick connect plug. It is used to provide an isolated closed circuit signal to activate the welding/cutting equipment at appropriate times during the automatic cycle.
Page 19 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 20 CANTILEVERED WELDING POSITIONER PARTS BREAKDOWN DRAWING GP-175-037 ITEM PART No. DESCRIPTION QTY. ITEM PART No. DESCRIPTION QTY. GK-105-078 1/4"-20 x 1" F. H. S. C. SCREW GK-129-012 # 10 INT. TOOTH LOCK WASHER GP-150-008 12" [304mm] Ø MOUNTING TABLE GP-150-034 POWER SUPPLY MOUNTING PLATE GK-108-050 1/4"-20 x 5/8"...
Page 21 CANTILEVERED WELDING POSITIONER PARTS BREAKDOWN DRAWING GP-175-037 GPP-150-010 - Gas Purge Adaptor Kit This kit replaces item numbers 7, 8 & 9 and converts a regular GP positioner into a gas purge model GPP positioner.
Page 22 ROTARY TABLE MOUNTING DETAILS Drawing Number GP-150-008...
Page 23 CANTELEVERED WELDING POSITIONER, POWER SUPPLY SCHEMATIC 5A (42V ) OR 2.5A (115V ) OR 25 AMP, 50 V PIV, 350 SURGE MPS, BRIDGE RECTIFIER 1.25A (230V ) SLOW BLOW FUSE 3 AMP @ 250V S.P.D.T. SWITCH BROWN OR BLACK LIVE 42, 115 OR 230V 200W STEP DOWN TRANSFORMER...
Page 24 OPTIONAL MANUAL FOOTSWITCH & ARC SIGNAL RELAY KIT PARTS BREAKDOWN, DRAWING GP-175-038 Footswitch Assembly – GP-175-020 ITEM PARTNUMBER DESCRIPTION KR-179-113 FOOT SWITCH COVER KR-179-115 NON-SLIP FOOT SWITCH PAD KR-179-122 FOOT SWITCH Footswitch Wiring Schematic GK-125-055 #8-32 x 3/8" SELF TAPPING SCREW GK-135-057 #10-32 LOCK NUT KR-190-112...
Page 25 OPTIONAL THREE JAW SELF-CENTERING GRIPPER ASSEMBLY PARTS BREAKDOWN, WPG-250 ITEM PART NUMBER DESCRIPTION WPG-250-002 10" DIA. GRIPPER BODY WPG-250-003 GRIPPER JAWS (SET OF 3) WPG-250-004 10" DIA. GRIPPER SPIRAL SCROLL GK-119-060 6.250" SHAFT DIA. RETAINING RING GK-107-074 5/16"-18 x 1 1/4" SOCKET HEAD CAP SCREW GK-107-106 M8 x 30mm SOCKET HEAD CAP SCREW (NOT SHOWN) 3 GBM-15-002-E...
Page 26 OPTIONAL AUTOMATIC WELDING GUN POSITIONING SUPPORT STAND ASSEMBLY PARTS BREAKDOWN, GP-175-030 ITEM PART NUMBER DESCRIPTION KR-2000-A VERTICAL 1-1/2" RACK ARM BRACKET KR-2000-B HORIZONTAL 1-1/2" RACK ARM BRACKET GK-108-065 3/8"-16 x 1" HEX BOLT GK-136-063 3/8" SPLIT LOCK WASHER GK-108-076 3/8"-16 x 5/8" HEX BOLT GPS-150-007 1-1/2"...
Page 27 OPTIONAL AUTOMATIC WELDING GUN POSITIONING SUPPORT STAND ASSEMBLY PARTS BREAKDOWN, GP-175-030...
Page 28 REVISIONS LIST September, 2002 Overall First release.
Page 29: Parts List
Fax: 905-953-4138 e-mail: sales@gullco.com GULLCO INTERNATIONAL INC. – U.S.A. Phone: 440-439-8333 Fax: 440-439-3634 e-mail: kat@apk.net GULLCO INTERNATIONAL [U.K.] LIMITED - EUROPE Phone: +44 1257-253579 Fax: +44 1257-254629 e-mail: sales@gullco.co.uk GULLCO INTERNATIONAL PTY LIMITED - AUSTRALIA Phone: 61 (0) 7 5496-9555 Fax: 61 (0) 7 5496-9522 e-mail: katoz@ozemail.com.au...
Page 31 Program Variable Selector Switch (recessed below, or extending through the faceplate) and relevant hardware. Gullco has a range of various product and application specific micro-processor chips, which can be used with any three variations of the “GSP” controls, providing Program Variable various degrees of functionality to the application.
Page 32: Error Table
Error Table Error Code Reason for Error Er.1 The “GSP” control was set to run when; electrical power was initially supplied to the control (powered-up); or upon exiting either the Program Variable or Motor Control Variable settings. To prevent unexpected motion generated from the “GSP” control, the motor output is disabled and the error code displayed until the control is placed in “Hold”...
Page 33: General Specifications
“H”-Bridge, pulse width modulation controls with regenerative braking. They are designed to run 24 vdc motors and require a 24 to 38 vdc no-load supply (30 to 38 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 34 (Extended or Recessed) OPERATION Local Control Devices Externally, the Gullco range of GSP controls have switching for Forward/Neutral/Reverse, Run/Stop, Manual/Auto & program variable increment/decrement (where applicable), as well as a rotary encoder for speed control. = “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 35 = “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.
Page 36: Local Control Operation
The Arc Signal L.E.D. is typically used as an indication that the product/application specific micro-processor chip has activated the output ports “CN303A” and “CN303B”. When a Gullco auxiliary relay module (optional on most equipment) is connected to the “CN303A” port, the relay energizes, providing an isolated signal activating the welding/cutting equipment.
Page 37 the direction selected at the speed set by the Variable Speed Control Knob. The speed may be adjusted at any time and the manual motion may be stopped by placing either the Run/Stop switch in the Stop position or by placing the Forward/Neutral/Reverse switch in the Neutral position. AUTOMATIC MODE - To place the control in automatic mode (enable the preset cycle), with the power on, place the Run/Stop switch in the Stop position.
Page 38 MOTOR CONTROL VARIABLE ADJUSTMENTS Motor Control Variables are adjustable parameters that affect the core operation of the motor control and its relationship with the motor. These variables are generic, regardless which product/application specific micro-processor chip is installed. The Motor Control Variable Rotary Switch is located on the underside of the control circuit board and is identified as SW404.
Page 39 Descriptions of the Motor Control Variable parameter settings: The following describes the switch settings as rotated clockwise from zero (0) top dead center. P. 0 Normal Operating Position - The control needs to be in this position to allow normal operation (top dead center).
Page 40 The Gullco “GSP” motor controller needs to have the speed display calibrated to match that of the equipment driven by the motor. This is required so that the speed displayed is equal to that of the motion and also so that the control may calculate engineering units (counting and scaling of tach feedback pulses, used to measure distance travelled).
Page 41 18”, it would have, in fact travelled an extra 0.3125”. Therefore, there would be a 3.125” [7.94mm] error on 180” [457.2mm] of theoretical travel. STANDARD GULLCO PRODUCT SPEED CALIBRATION TABLE PRODUCT...
Page 42 “GSP” CIRCUIT BOARD DETAILS Major Circuit Board Component Details CN201 CN101 F101 - Replaceable, 15 Amp automotive fuse. U401 CN202 U401 - Product/application specific micro-processor chip (in socket). CN304A SW404 - Motor Control Variable F101 CN304B Rotary Switch. CN303B CN303A CN301 CN302 SW404...
Page 43 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: CN202 & CN301 to CN304B are Molex KK, 0.1” [2.54mm] series connectors, or equivalent spaced headers CN202 - Tach Feed Back Connection Pin 1 - Common Pin 2 - Signal...
Page 44 Depending upon the product/application specific micro-processor chip installed, this port, in conjunction with one of Gullco’s optional auxiliary relay modules, may be used to activate such things as pneumatic solenoid valves, safety circuits, etc. that may be part of the automatic cycle routine.
Page 45 GSP-2000 CONTROL ASSEMBLY BREAKDOWN ITEM PART NUMBER DESCRIPTION GSP-2005 GSP CONTROL FACEPLATE GK-191-P-223 DISPLAY BEZEL GSP-2003 GSP DISPLAY BOARD GSP-2002 GSP MAIN BOARD (INCLUDES ITEMS 5-9) GK-191-P-235 ROTARY SPEED ENCODER GK-191-P-236 CYCLE PUSH BUTTON (EXTENDED) GSP-2007 FORWARD/NEUTRAL/REVERSE SWITCH GSP-2011 PROGRAM VARIABLE SELECTOR SWITCH (RECESSED) GSP-2008 RUN/STOP SWITCH GSP-2006...
Page 46 GSP-2001 CONTROL ASSEMBLY BREAKDOWN ITEM PART NUMBER DESCRIPTION GSP-2005 GSP CONTROL FACEPLATE GK-191-P-223 DISPLAY BEZEL GSP-2003 GSP DISPLAY BOARD GSP-2002 GSP MAIN BOARD (INCLUDES ITEMS 5-9) GK-191-P-235 ROTARY SPEED ENCODER GSP-2009 CYCLE PUSH BUTTON (RECESSED) GSP-2007 FORWARD/NEUTRAL/REVERSE SWITCH GSP-2011 PROGRAM VARIABLE SELECTOR SWITCH (RECESSED) GSP-2008 RUN/STOP SWITCH GSP-2006...
Page 47 GSP-2010 CONTROL ASSEMBLY BREAKDOWN ITEM PART NUMBER DESCRIPTION GSP-2005 GSP CONTROL FACEPLATE GK-191-P-223 DISPLAY BEZEL GSP-2003 GSP DISPLAY BOARD GSP-2002 GSP MAIN BOARD (INCLUDES ITEMS 5-9) GK-191-P-235 ROTARY SPEED ENCODER GK-191-P-236 CYCLE PUSH BUTTON (EXTENDED) GSP-2007 FORWARD/NEUTRAL/REVERSE SWITCH GSP-2012 PROGRAM VARIABLE SELECTOR SWITCH (EXTENDED) GSP-2008 RUN/STOP SWITCH GSP-2006...
Page 48 GSP DRIVER BOARD SCHEMATIC (GSP-2002) Drawing Revision E PCB Revision D T-18...
Page 49 GSP DISPLAY BOARD SCHEMATIC (GSP-2003) Drawing number GK-191-224 T-19...
Page 50 REVISIONS LIST September, 2002 Title Page Updated Gullco Australia’s phone & fax numbers. Page T-11 Changed Kat carriage part numbers in table from GK-191-P to GK-200-R series and from GK-192-F to GK-200-F series. Page T-17 Added GK-151-005, selector knob grommet.
Page 51 ® Gullco Kat Travel Carriages The Gullco Kat all position variable speed travel carriage is used throughout the world to automate single and multiple head welding and cutting operations. The Kat travels at pre- cisely controlled speeds in forward or reverse direction along a special track. Two models are available...one for operation on rigid aluminum track and the other for use on flexible...

This manual is also suitable for:

Gp-175-015 Gpp-175-006 Gpp-175-015