GULLCO GP-175-006 User manual

Revised: September 25, 2002 GD-032.DOC
AUTOMATIC CYCLE
CANTILEVERED
WELDING
POSITIONER
MODELS:
GP-175-006 GPP-175-006
GP-175-015 GPP-175-015
PARTS LIST
&
OPERATING INSTRUCTIONS
Website: www.gullco.com
Distributed by: GULLCO INTERNATIONAL LIMITED - CANADA
Phone: [phone] Fax: [phone] e-mail: sal[email protected]
GULLCO INTERNATIONAL INC. – U.S.A.
Phone: [phone] Fax: [phone] e-mail: [e-mail]
GULLCO INTERNATIONAL [U.K.] LIMITED - EUROPE
Phone: [phone] Fax: [phone] e-mail: sal[email protected].uk
GULLCO INTERNATIONAL PTY LIMITED - AUSTRALIA
Phone: [phone] Fax: [phone] e-mail: [e-mail]
GULLCO INTERNATIONAL LIMITED - INDIA
Phone: [phone] Fax: [phone] e-mail: Gul[email protected]

1
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" during each phase of operation, setup and maintenance.
Read and understand the whole operation manual (including 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
 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 cantilevered positioner is well secured to the bench, tabletop, etc., to
prevent it from tipping over when subjected to over hung loading.
 Never loosen the tilt-locking lever, nor try to tilt the rotary welding table, when there is a load
mounted to the table generating large radial moments.
 Keep hands away from the rotary table when it is in motion, or when there is the slightest
possibility of motion.
 Wherever possible, avoid mounting devices, etc., that protrude from the rotating mass, and
pose possible pinch-points.
 Make certain that work-piece/mounting device protrusions will not strike the floor, positioner
frame or any other object during rotation.
 There should only ever be one (1) operator working at the machine at any given time.

2
SAFETY PRECAUTIONS
The following cautionary/warning labels are attached to each welding positioner:-
The adjacent label pictorially represents the following:
Warning:-
Do not loosen the tilt clamp lever when there is a load applied to
the table, which may result in an uncontrolled radial action!
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 WELDING POSITIONER
Important information regarding safety and operation of the “GSP” motor control used in the
Cantilevered Welding 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 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-“.
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.

3
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
MODEL AUTOMATIC CYCLE POSITIONER
AUTOMATIC CYCLE POSITIONER
WITH GAS
PURGE SYSTEM
GP-175-006 


GP-175-015 


GPP-175-006 


GPP-175-015 


MODEL
ROTATIONAL
SPEED
ROTATIONAL
TORQUE
VERTICAL
TABLE
LOADING @ 3”
C OF G
HORIZONTAL
TABLE
LOADING
OVERHUNG LOAD RATING
TABLE VERTICAL
GP-175-006 &
GPP-175-006
0.27 – 4.62962
RPM
450 INCH.LBS
[518 KG.CM]
@ 3”
ECCENTRICITY
150 LBS.
[68 KG.]
300 LBS.
[136 KG.]
GP-175-015 &
GPP-175-015
0.75 – 12.5000
RPM
150 INCH.LBS
[172 KG.CM]
@ 2”
ECCENTRICITY
75 LBS.
[34 KG.]
150 LBS.
[68 KG.]
DISTANCE LOAD
IN. MM. LBS. KGS.
3 76 150 68
6 152 97 44
9 229 72 33
12 305 57 26
Stand alone weight: 70 Lbs. [31.8 Kg.]
Supply voltage: Either 42, 115 or 230 VAC, single phase, 50/60 Hz., 200 watts.
Rotary table: 12" [305mm] diameter machined aluminum table with six (6) radial slots,
3/8" [9.5mm] wide, and 5/16"-18 U.N.C. tapped holes for mounting Gullco
WPG-250 self centering grippers.
Tilt angle: 180 degrees total, 0-90 degrees left and right from horizontal.
Welding ground: 500 Amp, sprung loaded, rotary ground on the underside of the table.
Drive motor: 24 VDC permanent magnet gear motor.
Complies with: C.S.A. and NRTL/C (File # LR 35006-4) & C.E. regulations.

4
GENERAL DIMENSIONS
GENERAL DESCRIPTION
The Gullco cantilevered welding positioners are electrically powered, rotary turn tables, that consist
of a rotary mounting table, drive and tilt mechanisms, micro-processor based, pulse width
modulation motor controls and a 7-1/2 feet (2.3 mtr.) power cable. The positive drive of the rotary
table is obtained from a one-stage reduction, gear train, driven by a low voltage permanent magnet
motor and gear-head power unit assembly. The microprocessor motor control offers operator
interface of start, stop, clockwise rotation, neutral, counter-clockwise rotation and infinitely variable
control of the speed, within the range of the model, as well as an L.E.D. display indicating rotational
speed in revolutions per minute and operational status. The GP-175 & GPP-175 series of welding
positioner also provides programmable automatic welding cycles (including stitch welding) and
through the use of optional equipment can interface with such items as welding trigger signals,
pneumatic gun positioning slides, manual activation footswitches, and gas purge solenoids. 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. A power supply on/off isolation switch is
provided. The rotation speed is electronically controlled using an optical tachometer located on the
back of the gear-motor and is infinitely variable in both clockwise and counter-clockwise directions,
within the range of the model, by a rotary speed adjustment encoder located on the faceplate of the
cantilevered welding positioner. Table tilt is manually set at any position through 180° and at any
desired angle from 0-90° either side of horizontal, quickly and easily.
Purge equipped models have a 1/4" (6.4mm) hole through the center of the table spindle and a
rotary gas coupling mounted to the underside of the spindle, providing a female 1/4" N.P.T. gas inlet
port.

5
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. 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.
INSTALLATION
ELECTRICAL CONNECTION
WARNING! Ensure proper AC earth grounding of the Gullco cantilevered welding positioner and
all auxiliary equipment (where applicable), before applying power. Failure to do so
may invalidate the Gullco Warranty.
WARNING! Before connecting the cantilevered 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. If in doubt, DO NOT PLUG IN THE WELDING
POSITIONER. Copies of the possible nameplates 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”.
EQUIPMENT
FOR AUTOMATED
WELDING AND CUTTING
FUSE:
MANUFACTURED:
FREQUENCY:
SERIAL NO.:
www.gullco.com
SUPPLY:
WATTS:
PHASE:
MODEL:
V
NRTL/C
R
Hz.
GULLCO INTERNATIONAL INC.
CLEVELAND, OHIO, U.S.A.
TEL. [phone]
GULLCO INTERNATIONAL PTY LIMITED
KARIONG, NSW, AUSTRALIA
TEL. [phone]
TEL. [phone]
GULLCO INTERNATIONAL (U.K.) LTD.
GULLCO INTERNATIONAL LIMITED
PUNE, INDIA
TEL. [phone]
NEWMARKET, ONTARIO, CANADA
GULLCO INTERNATIONAL LIMITED
TEL. [phone]
42
200
1
50/60
5 AMP SLOW BLOW
2002
GULLCO INTERNATIONAL (U.K.) LTD.
TEL. [phone]
GULLCO INTERNATIONAL PTY LIMITED
KARIONG, NSW, AUSTRALIA
TEL. [phone]
SERIAL NO.:
FREQUENCY:
MANUFACTURED:
EQUIPMENT
FOR AUTOMATED
WELDING AND CUTTING
GULLCO INTERNATIONAL LIMITED
NEWMARKET, ONTARIO, CANADA
GULLCO INTERNATIONAL LIMITED
PUNE, INDIA
TEL. [phone]
TEL. [phone]
www.gullco.com
SUPPLY:
PHASE:
WATTS:
MODEL:
115
1
200
V
FUSE: 2.5 AMP SLOW BLOW
TEL. [phone]
CLEVELAND, OHIO, U.S.A.
GULLCO INTERNATIONAL INC.
NRTL/C
R
50/60
2002
Hz.
EQUIPMENT
FOR AUTOMATED
WELDING AND CUTTING
MANUFACTURED:
FREQUENCY:
SERIAL NO.:
GULLCO INTERNATIONAL PTY LIMITED
KARIONG, NSW, AUSTRALIA
TEL. [phone]
TEL. [phone]
GULLCO INTERNATIONAL (U.K.) LTD.
GULLCO INTERNATIONAL LIMITED
PUNE, INDIA
TEL. [phone]
NEWMARKET, ONTARIO, CANADA
GULLCO INTERNATIONAL LIMITED
TEL. [phone]
www.gullco.com
SUPPLY:
WATTS:
PHASE:
MODEL:
230
200
1
V
FUSE:
Hz.
GULLCO INTERNATIONAL INC.
CLEVELAND, OHIO, U.S.A.
TEL. [phone]
1.25 AMP SLOW BLOW
NRTL/C
R
50/60
2002

6
WARNING! Ensure that the weld ground is properly attached to the ground bracket on the
positioner, maximum 500 Amps. A poor welding ground circuit will cause the weld
ground to pass through the cantilevered positioner, causing damage to the motor
control, cables, gear teeth and the main spindle bearings. This will invalidate the
Gullco warranty.
Depending on any optional accessories that may have been supplied with the unit, further
installation may be required. This typically consists of any combination of simple mechanical
erection and simple cable connection (usually through multi-pin connectors). If an auxiliary relay
module has been supplied to provide weld activation signals, the black & white wires of the cable
(connected to pins A & C of the connector) provide a normally open connection to an isolated relay,
which closes whenever the welding signal is to be activated. These wires are usually connected to
the trigger signal connectors of the wire feeder or welding power source.
MECHANICAL INSTALLATION
WARNING! Check to ensure that no parts have become loose during transportation.
Bolt the cantilevered welding positioner to a fixed table using four (4), 3/8" or 10mm bolts (not
supplied). The center distances of these boltholes are 9-3/4" [247.65mm] wide by 19" [482.6mm]
long.
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).
Depending on any optional accessories that may have been supplied with the unit, further
installation may be required. This typically consists of any combination of simple mechanical
erection and simple cable connection (usually through multi-pin connectors).

7
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. Therefore, all operator interface devices
(except the power on/off switch) are subjected to signal level voltages only.
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 counterclockwise direction.
The direction selection switch allows the operator to set the manual direction of rotation. This is a
three (3) position switch with the center position being "Neutral" (no direction chosen).
WARNING! Avoid changing the direction of rotation without making sure that rotation comes to a
complete stop first. Failure to comply may cause an overload.
Command Forward Motion
Speed & Parameter Value
Display
Speed Display Calibrated in
Inches per Minute
Speed Display Calibrated in
Centimeters per Minute
A
uto Cycle Mode (Constant)
Programming mode (Flashing)
Speed Adjustment
Counter-Clockwise = Slower
Clockwise = Faster
Neutral
Command Reverse Motion
Program Variable Selector Switch
(Extended or Recessed)
Control in Run Mode
Cycle Push Button
(Extended or Recessed)
A
rc Si
g
nal Active
Hold
(
Sto
p)
Mode Active
Reverse Motion Commanded
Forward Motion Commanded
Control in Hold
(
Sto
p)
Mode

8
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. 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.
WARNING! Avoid repeatedly starting and stopping the positioner in quick, short succession, as
this will reduce the life expectancy of the control and the motor.
Manual Operation
To toggle between automatic mode (Aut) and manual mode (Hnd), place the Run/Stop switch in the
Stop position and press and hold the Cycle Push Button until the desired mode is displayed (Aut or
Hnd).
In manual mode (Hnd) the Preset Cycle L.E.D. located in the lower right hand corner of the display
will be extinguished.
Manual mode only permits manual rotation of the turntable. The Forward/Neutral/Reverse switch
selects which direction the turntable will rotate. The Speed Adjustment knob sets the rotational
speed. When the Run/Stop switch is placed in the Run position (and the optional footswitch is
depressed, when installed), the turntable will rotate in the direction and speed set by the
Forward/Neutral/Reverse switch and the Speed Adjustment knob. Rotation 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 footswitch is released (when installed).
The optional remote foot switch [GP-175-020] is used to manually start and stop rotation of the
positioner turntable. Depressing the foot switch will activate rotation and releasing the foot switch
will deactivate the rotation and apply braking. The Run/Stop switch must be in the Run position and
a rotation direction must be selected for the unit to operate when the footswitch is depressed.
Automatic Operation
To toggle between automatic mode (Aut) and manual mode (Hnd), place the Run/Stop switch in the
Stop position and press and hold the Cycle Push Button until the desired mode is displayed (Aut or
Hnd).
In Automatic mode (Hnd) the Preset Cycle L.E.D. located in the lower right hand corner of the
display will be constantly illuminated.
In automatic mode (Aut), every time the Run/Stop switch is placed in the Run position, the
programmed automatic cycle will execute. The Forward/Neutral/Reverse switch (and optional
footswitch) is totally ignored. The turntable welding speed will be set by the Speed Adjustment
knob.
If the Run/Stop switch is placed in the Stop position at any time during an automatic cycle, the
automatic cycle will perform a controlled, sequential shut down as described from section 1-12 or 2-
12 depending upon the setting of the programmable Weld Cessation (P. 9) parameter.

9
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.
1. Programmable Weld Cessation (P. 9) = “1” (typical for Mig applications).
1-1. The optional gun slide solenoid relay (connected to CN304A of the GSP control) will be
energized and the programmable Gun Slide Extend Delay (P. 1) timing cycle will
commence. This allows time for the optional pneumatic gun slide [GP-175-030] (where
applicable) to position the welding gun before activating the arc.
1-2. Upon completion of the Gun Slide Extend Delay (P. 1), the optional arc signal relay [GP-
175-025] (connected to CN303A of the GSP control) will be energized and the
programmable Rotation Start Delay (P. 2) timing cycle will commence. This provides time
for any pre-flow function as well as allowing the arc to establish prior to commencing the
weld motion.
1-3. Upon completion of the Rotation Start Delay (P. 2), the weld rotation will start to travel in
the forward direction at the speed set by the Speed Adjustment knob.
1-4. If the programmable Stitch Weld (P. 6) parameter is set to Off (continuous weld), the cycle
will continue as described in section 1-12. If the Stitch Weld (P. 6) parameter is set to On
(stitch weld), the cycle will continue as described in section 1-5.
1-5. The weld rotation will stop 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. 7) and No-Weld Angle (P. 8). The programmable Crater-Fill/Slope-Out Delay
(P. 4) timing cycle will commence. When the programmable Weld Cessation (P. 9)
variable is set to “1”, the Crater-Fill/Slope-Out Delay is used to keep the arc signal active
for a programmable duration, after the rotation has ceased, thereby filling in the weld
crater.
1-5-1. Example, the Stitch Weld Angle parameter is set to 20º and the No-Weld Angle is
set to 40º. The weld rotation would stop at 20º, 80º, 140º, 200º etc.
1-6. Upon completion of the Crater-Fill/Slope-Out Delay (P. 4), the optional arc signal relay will
de-energize and the programmable Post Weld Delay (P. 5) timing cycle will commence.
This allows time for any burn-back and or post-flow functions, prior to the table rotating to
the start of the next weld.
1-7. Upon completion of the Post Weld Delay, the no-weld rotation will start in the forward
direction at full speed.
1-8. The no-weld rotation will stop every time that the angular rotation reaches an
accumulative value of the sum of the programmable Stitch Weld Angle (P. 7) and the
programmable No-Weld Angle (P. 8). A fixed delay of 0.7 seconds will then commence.
This delay ensures that the turntable has come to a complete stop, prior to starting the
next weld.

10
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. 2) timing cycle will commence again. This
provides time for any pre-flow function as well as allowing the arc to establish prior to
commencing the weld motion.
1-10. Upon completion of the Rotation Start Delay (P. 2), the weld rotation will start to travel in
the forward direction at the speed set by the Speed Adjustment knob.
1-11. The cycle will continue as described between section 1-5 and section 1-10 until the total
angular rotation reaches the value set by the programmable Degrees Of Rotation (P. 3)
parameter, at which point the cycle will closedown as described in section 1-12.
1-12. Regardless of whether the automatic cycle is performing a continuous weld or a stitch
weld routine, when the angular rotation reaches the same value as the programmable
Degrees Of Rotation (P. 3) parameter, the rotation ceases and the programmable Crater-
Fill/Slope-Out Delay (P. 4) timing cycle will commence. When the programmable Weld
Cessation (P. 9) variable is set to “1”, the Crater-Fill/Slope-Out Delay is used to keep the
arc signal active for a programmable duration, after the rotation has ceased, thereby filling
in the weld crater
1-13. Upon completion of the Crater-Fill/Slope-Out Delay (P. 4), the optional arc signal relay will
de-energize and the programmable Post Weld Delay (P. 5) timing cycle will commence.
This allows time for any burn-back and or post-flow functions, prior to the retraction of the
optional pneumatic gun positioning slide (where applicable).
1-14. 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.
2. Programmable Weld Cessation (P. 9) = “2” (typical for Tig applications).
2-1. The optional gun slide solenoid relay (connected to CN304A of the GSP control) will be
energized and the programmable Gun Slide Extend Delay (P. 1) timing cycle will
commence. This allows time for the optional pneumatic gun slide [GP-175-030] (where
applicable) to position the welding gun before activating the arc.
2-2. Upon completion of the Gun Slide Extend Delay (P. 1), the optional arc signal relay [GP-
175-025] (connected to CN303A of the GSP control) will be energized and the
programmable Rotation Start Delay (P. 2) timing cycle will commence. This provides time
for any pre-flow function as well as allowing the arc to establish prior to commencing the
weld motion.
2-3. Upon completion of the Rotation Start Delay (P. 2), the weld rotation will start to travel in
the forward direction at the speed set by the Speed Adjustment knob.
2-4. If the programmable Stitch Weld (P. 6) parameter is set to Off (continuous weld), the cycle
will continue as described in section 2-12. If the Stitch Weld (P. 6) parameter is set to On
(stitch weld), the cycle will continue as described in section 2-5.

11
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. 7) and No-Weld Angle (P. 8). The programmable Crater-Fill/Slope-
Out Delay (P. 4) timing cycle will commence. When the programmable Weld Cessation
(P. 9) variable is set to “2”, the Crater-Fill/Slope-Out Delay is used to keep the turntable
rotating for a programmable duration, after the arc signal has been de-activated, providing
a slope-out function.
2-5-1. Example, the Stitch Weld Angle parameter is set to 20º and the No-Weld Angle is
set to 40º. The weld rotation would stop at 20º, 80º, 140º, 200º etc.
2-6. Upon completion of the Crater-Fill/Slope-Out Delay (P. 4), the weld rotation will stop and
the programmable Post Weld Delay (P. 5) timing cycle will commence. This allows time
for any burn-back and or post-flow functions, prior to the table rotating to the start of the
next weld.
2-7. Upon completion of the Post Weld Delay, the no-weld rotation will start in the forward
direction at full speed.
2-8. The no-weld rotation will stop every time that the angular rotation reaches an
accumulative value of the sum of the programmable Stitch Weld Angle (P. 7) and the
programmable No-Weld Angle (P. 8). A fixed delay of 0.7 seconds will then commence.
This delay ensures that the turntable has come to a complete stop, prior to starting the
next weld.
2-8-1. 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.
2-9. Upon completion of the fixed delay, the optional arc signal relay will be re-energized and
the programmable Rotation Start Delay (P. 2) timing cycle will commence again. This
provides time for any pre-flow function as well as allowing the arc to establish prior to
commencing the weld motion.
2-10. Upon completion of the Rotation Start Delay (P. 2), the weld rotation will start to travel in
the forward direction at the speed set by the Speed Adjustment knob.
2-11. The cycle will continue as described between section 2-5 and section 2-10 until the total
angular rotation reaches the value set by the programmable Degrees Of Rotation (P. 3)
parameter, at which point the cycle will closedown as described in section 2-12.
2-12. Regardless of whether the automatic cycle is performing a continuous weld or a stitch
weld routine, when the angular rotation reaches the same value as the programmable
Degrees Of Rotation (P. 3) parameter, the optional arc signal relay will de-energize and
the programmable Crater-Fill/Slope-Out Delay (P. 4) timing cycle will commence. When
the programmable Weld Cessation (P. 9) variable is set to “2”, the Crater-Fill/Slope-Out
Delay is used to keep the turntable rotating for a programmable duration, after the arc
signal has been de-activated, providing a slope-out function.
2-13. Upon completion of the Crater-Fill/Slope-Out Delay (P. 4), the rotation ceases and the
programmable Post Weld Delay (P. 5) timing cycle will commence. This allows time for

12
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.
Programming The Automatic Cycle Parameters/Variables
The Program Variable Selector Switch is used to select the different programmable parameters that
allow the operator to change their values and settings and so define how the automatic cycle will
function. The Program Variable Selector Switch is located between and below the Run/Stop switch
and the Forward/Neutral/Reverse switch of the GSP control. Some GSP controls are equipped with
extended Program Variable Selector switches, which come through the faceplate of the control.
Others are recessed and require the removal of a hole-plug for access and a small flat-bladed
screwdriver for adjustment.
Zero (0) (top dead center) is the normal operating location for the switch. When in any position
other than zero (0) the control is in programming mode, the round, Preset Cycle L.E.D. in the bottom
right hand corner of the display will flash and the motor control will not allow normal operation.
To make changes to the program variables, remove the hole plug on the front face which covers the
recessed Program Variable Selector switch (where applicable). With the power turned on and the
Run/Stop switch in the Stop position, rotate the Program Variable Selector switch to the variable
(parameter) to be altered (the Preset Cycle L.E.D. will flash on and off). The number of the variable
parameter will be displayed when the Forward/Neutral/Reverse switch is in the Neutral position. I.e.
“P. 1”, “P. 2”, “P. 3”, etc. To see the current value/setting of the variable, place the
Forward/Neutral/Reverse switch in either the Forward or Reverse position. To increment the
value/setting, place the Forward/Neutral/Reverse switch in the Forward position and press the
Cycle Push Button. To decrement the value/setting, place the Forward/Neutral/Reverse switch in
the Reverse position and press the Cycle Push Button. Pressing the Cycle Push Button briefly will
increment/decrement the value/setting by one, whereas keeping the Cycle Push Button depressed
will scroll through the values/settings until released. The speed display and or the individual
L.E.D.’s will indicate the chosen value/setting. When all of the program variables are set, place the
Program Variable Selector switch back to the zero position (the Preset Cycle L.E.D. will stop
flashing) and re-insert the hole-plug (where applicable).
The values/settings of the variables are stored on the product/application specific micro-processor
chip. If the chip is replaced, the values/settings of the variables will need to be re-entered.
C
y
cle Push Button
Program Variable
Selector Switch

13
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).
P. 1 Gun Slide Extend Delay - This sets a delay after the activation of the optional gun
positioning slide solenoid relay, prior to activation of the optional arc signal relay, to allow
the pneumatic slide to position the welding gun before activating the arc. The variable
value range is from 00.0 to 09.9 seconds, in increments of 00.1 seconds.
P. 2 Rotation Start Delay - This sets a delay after the activation of the optional arc signal
relay, prior to starting rotation, to allow for shielding gas pre-flow and to allow the arc to
establish before starting the weld motion. The variable value range is from 00.0 to 09.9
seconds, in increments of 00.1 seconds.
P. 3 Degrees Of Rotation - This sets the total rotation angle that will take place in an
automatic cycle before the final close-down sequence of the welding cycle. The variable
value range is from 045 to 999 degrees, in increments of 001 degree.
P. 4 Crater-Fill/Slope-Out Delay - When the programmable Weld Cessation (P. 9) variable is
set to “1”, the Crater-Fill/Slope-Out Delay is used to keep the optional arc signal relay
energized for a programmable duration, after the rotation has stopped, providing a
crater-fill function. When the programmable Weld Cessation (P. 9) variable is set to “2”,
the Crater-Fill/Slope-Out Delay is used to keep the turntable rotating for a programmable
duration, after the arc signal has been de-activated, providing a slope-out function. The
variable value range is from 00.0 to 09.9 seconds, in increments of 00.1 seconds.
P. 5 Post Weld Delay - This sets a delay after each crater-fill or slope-out delay (described
above) prior to de-energizing the optional gun positioning slide solenoid relay, or starting
the no-weld rotation (used in stitch welding routines). This is to allow the welding gun to
remain stationary over the end of the weld for any burn-back or post-flow to occur. The
variable value range is from 00.0 to 09.9 seconds, in increments of 00.1 seconds.
P. 6 Stitch Weld (Enable/Disable) - This allows the operator to choose whether the weld will
be continuous (Off) or stitched/spaced (On). If continuous is chosen the parameters P. 7
and P. 8 will not be available to the operator and “- - -” will be displayed. The variable
setting is either On or Off.
P. 7 Stitch Weld Angle – This sets the rotation angle of each stitch weld. The variable value
range is from 001 to 999 degrees, in increments of 001 degree.
P. 8 No-Weld Angle – This sets the rotational angle of each space between stitch welds (no-
weld). The variable value range is from 001 to 999 degrees, in increments of 001
degree.
P. 9 Weld Cessation – This allows the operator to choose the closedown sequence of the
welding process. The variable setting is either:
"1" Crater-fill – Rotation stops prior to de-activation of arc signal (typical for Mig
applications).
"2" Slope-out – Arc signal de-activated prior to stopping the rotation (typical for Tig
applications).

14
LOADING
Before mounting any load to the rotary table, the tilt locking adjustable lever should be tested for
tightness. When loading the work piece onto the table, take account of the weight, centroid
eccentricity and centroid height of both the work piece and all clamping fixtures. When the work
piece is large and its weight is one sided at the peripheral portion, inertia start and stop is severe
and can cause an overload situation. Wherever possible, counterbalance weights should be used
to reduce this stress. Take into consideration the additional weight and distribution of the
counterbalance.
WARNING! Lower work pieces onto the turntable gently. Impact and shock loads are many
times greater than the "dead-weight” of the work-piece. Dropping loads onto the
table can result in damage!
WARNING! Do not use impact or shock techniques to clamp and unclamp self-centering grippers
mounted to the positioner turntable. The shock will be transferred to the drive
system resulting in damage!
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. from the positioner regularly. Do not allow any foreign
material to impede operation. Pay particular attention to the following paragraph regarding
inspection.
INSPECTION
The welding ground should be inspected for a secure, clean electrical contact from the welding
power source to the grounding bracket of the positioner before the start of each new days welding.
The fasteners of the positioner grounding assembly should be inspected for secureness. A visual
check of the grounding block, springs and ground strap should be performed to ensure that the
ground block is seating flat against a clean rotary spindle and that there are no signs of obvious
damage occurring.
Frequent inspections should be performed with respect to the stability and rigidity of the positioner
mounting. Also, the gear teeth and spindle bearings should be inspected for signs of wear and
replaced if necessary.
The tachometer feed-back encoder sensor assembly located on the back of the motor, should be
inspected for dirt accumulation and cleaned where necessary. It is common for the armature shaft
of a fatiguing motor to develop excessive axial float. This float sometimes causes the tachometer
feed-back sensor wheel to rub on one of the encoder sensor faces, causing damage and failure.
Check that the sensor disk is located centrally within the slot of the encoder sensor when the
armature shaft is pressed in and pulled out. Adjust as necessary. The frequency of this inspection
should increase with the accumulated use and or workload of the gear-motor.
At least once per year, the equipment should be taken out of service, stripped down and all moving
parts should be cleaned, greased and inspected for wear and damage. All cables must be

15
inspected for breaks and abrasion and must be well secured. All damaged and worn parts should
be replaced. All fastening devices should be inspected for tightness.
NOTE: 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. Packing should be placed
in-between the flat base and the cantilevered arm to offer support. There should be sufficient room
around the perimeter of the shipping box to allow packing to be placed to help protect susceptible
parts from being damaged in shipping. If possible, the whole positioner should be bolted to a flat
piece of wood.

16
ACCESSORIES
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. Arc signal relay kits can be paralleled together to provide simultaneous arc
activation signals to multiple welding/cutting machines.
GP-175-030 Automatic gun positioning support stand assembly. This kit provides an internal
wiring harness; a 24 VAC output relay and quick connect receptacle circuit board
assembly; a 24 VAC pneumatic solenoid valve complete with control cable with
mating quick connect plug; a 4” [101mm] stroke pneumatic gun positioning slide;
a semi-automatic adjustable gun clamp assembly; a free-standing/bolt-down
support stand, a 1-1/2” [38.1mm] micro-fine rack box and rack arm assembly for
vertical adjustment; a 1-1/2” [38.1mm] micro-fine rack box and rack arm assembly
for horizontal adjustment; a 1-1/8” [28.6mm] micro-fine rack box and rack arm for
horizontal cross adjustment; and an adjustable cable/hose clamp assembly. It is
used to clamp and position the welding gun for repetitive operations as well as
providing automatic gun extension at the start of each automatic cycle and
automatic gun retraction at the end of each automatic cycle to facilitate easy
loading and unloading of the work-pieces.
GP
-
175
-
020
GP
-
175
-
030
GP
-
175
-
025
WPG
-
250

17
GP-175-020 Footswitch assembly for manual operation. This kit provides a run/stop
footswitch; a footswitch guard cover; a connecting control cable; and strain relief
glands. When activated, the footswitch will provide a run signal to the control
allowing manual rotation when the control is in manual mode (the footswitch has
no affect in automatic mode).
WPG-250 Gullco Self-Centering Welding Grippers are quickly and easily mounted on the
positioner turntable. They are slim but rugged, weighing only about half of that of
a standard chuck, minimizing reduction in positioner capacity. A single lever
provides smooth, positive, self-centering open/close action.
External clamping range = 0.38" [10mm] to 11.25" [286mm]
Internal clamping range = 4.25" [108mm] to 15" [381mm]
Weight 20 Lbs. [9 Kg.]
Detailed information is provided in the Gullco sales bulletin, number GG-694.
GPP-150-010 This gas purge adaptor kit provides a rotary gas coupling; a replacement through-
bored spindle; and a replacement drive gear. When installed, this kit allows pre-
welding gas purging by providing a path for the gas through the rotary coupling
and through the center of the table spindle.
KR-1000 CSB A free standing support and cutting torch holder assembly. 1-1/8" [28.6mm]
square rack arms and rack boxes provide 11-1/2" [292.1mm] of vertical
adjustment and 10-1/2" [266.7cm] of horizontal adjustment. Supplied with swivel
mounted, standard rack-type cutting torch holder.
Detailed information is provided in the Gullco sales bulletin, number KR-1094.
KR-2000 CSB Same as above, except uses 1-1/2" [38.1mm] rack arms and rack boxes and
provides 7-1/2" [190.5mm] of vertical and 6-1/2" [165.1mm] of horizontal
adjustment.
Detailed information is provided in the Gullco sales bulletin, number KR-1094.
KR-1000 WSB A free standing support and welding gun holder assembly. 1-1/8" [28.6mm]
square rack arms and rack boxes provide 11-1/2" [292.1mm] of vertical
adjustment and 10-1/2" [266.7mm] of horizontal adjustment. Supplied with swivel
mounted, adjustable gun holder assembly.
Detailed information is provided in the Gullco sales bulletin, number KR-1094.
KR-2000 WSB Same as above, except uses 1-1/2" [38.1mm] rack arms and rack boxes and
provides 7-1/2" [190.5mm] of vertical and 6-1/2" [165.1mm] of horizontal
adjustment.
Detailed information is provided in the Gullco sales bulletin, number KR-1094.
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.
ALSO AVAILABLE:
Gullco frequently designs and manufactures custom welding systems, often utilizing the
cantilevered welding positioner. These systems normally use some, or all of the following; a
programmable logic control, a programmable operator interface (that allows the user to easily adjust
any of the timed and counted preset values etc.), pneumatic or motorized slide/slides, interfacing
with welding/cutting equipment, external safety devices, auxiliary process equipment etc. Your
local Gullco representative would welcome the opportunity to discuss how we may assist in
automating your specific application.

18
CANTILEVERED WELDING POSITIONER PARTS BREAKDOWN
DRAWING GP-175-037
ITEM PART No. DESCRIPTION QTY. ITEM PART No. DESCRIPTION QTY.
1 GK-105-078 1/4"-20 x 1" F. H. S. C. SCREW 4 45 GK-129-012 # 10 INT. TOOTH LOCK WASHER 4
2 GP-150-008 12" [304mm] Ø MOUNTING TABLE 1 46 GP-150-034 POWER SUPPLY MOUNTING PLATE 1
3 GK-108-050 1/4"-20 x 5/8" HEX BOLT 6 47 GK-191-P-020 BRIDGE RECTIFIER 1
4 GK-111-051 1/4" FLAT WASHER 12 48 GK-171-032 POWER CORD (SPECIFY VOLTAGE) 1
5 GP-150-032 LARGE DRIVE TRAIN COVER 1 49 GP-150-030 BASE AND TOWER FRAME 1
7 GP-150-013 TABLE SPINDLE 1 50 GK-165-134 FUSE HOLDER 1
8 GP-150-011 96 TOOTH DRIVE GEAR 1 GK-165-098 5 AMP SLOW BLOW FUSE (42VAC)
9 GK-117-034 3/16" x 1-1/2" SPIROL SPRING PIN 1 GK-165-099 2.5 AMP SLOW BLOW FUSE (115VAC)
10 GP-150-037 PINION COVER MOUNTING BRACKET 1 GK-165-097 1.25 AMP SLOW BLOW FUSE (230VAC)
11 GK-108-075 5/16"-18 x 1" HEX BOLT 6 52 GK-141-014 6-32 x 5/16" FLAT HEAD SCREW 4
12 GK-136-055 5/16" SPLIT LOCK WASHER 14 53 GK-155-007 7/8" HOLE PLUG 3
13 GK-111-054 5/16" FLAT WASHER 14 62 GK-148-015 STRAIN RELIEF 7/8"Ø 1
14 GP-150-019 SPINDLE BEARING 2 63 GK-148-017 STRAIN RELIEF LOCK NUT 1
15 GP-150-015 MOTOR MOUNTING BLOCK 1 64 GP-150-010 GROUND BLOCK 1
16 GP-150-012 40 TOOTH MOTOR DRIVE PINION 1 65 GK-116-012 SPRING 3
17 GK-117-029 3/16" x 1-1/2" SPRING PIN 1 66 GP-150-023 GROUND STRAP 1
GSP-191-P-133 MOTOR & GEARHEAD (4.6 RPM) 67 GK-108-059 1/4"-20 x 3/4" HEX BOLT 2
GSP-191-P-131 MOTOR & GEARHEAD (12.5 RPM) 68 GP-150-009 GROUNDING BRACKET 1
19 GK-156-003 2 POSITION MALE CONNECTOR 1 69 GP-150-039 GROUNDING BLOCK LOCATOR 1
20 GK-156-016 FEMALE 0.093 CRIMP TERMINAL 2 70 GP-150-033 SMALL DRIVE TRAIN COVER 1
21 GK-156-027 2 POSITION FEMALE CONNECTOR 1 71 GP-150-035 CANTILEVERED ARM 1
22 GK-156-015 MALE 0.093 CRIMP TERMINAL 2 GSP-2000-2 GSP CONTROL (Recessed Selector)
23 GK-136-053 1/4" SPLIT LOCK WASHER 6 GSP-2010-2 GSP CONTROL (Extended Selector)
24 GK-108-072 1/4"-20 x 1-1/2" HEX BOLT 4 73 GK-191-P-022 POW ER ON/OFF SW ITCH 1
25 GK-112-065 10-32 x 3/8" ROUND HEAD SCREW 4 74 GK-191-P-050 POWER ON/OFF NAMEPLATE 1
26 GK-136-058 # 10 SPLIT LOCK WASHER 5 75 GP-150-040 BOTTOM COVER PLATE 1
27 GK-107-063 10-32 x 1/2" S. H. CAP SCREW 3 76 GK-112-089 8-32 x 1/4" ROUND HEAD SCREW 2
28 GK-160-003 1/2"-13 x 2" CARRIAGE BOLT 1 77 GK-125-056 # 6 x 1/4" SELF TAPPING SCREW 1
29 GK-112-095 8-32 x 7/16" ROUND HEAD SCREW 4 78 GK-117-006 3/32"Ø x 1/2" SPRING PIN 1
30 GP-150-031 LID 1 79 GK-112-103 10-32 x 3/4" R.H. BRASS SCREW 1
31 GK-109-052 5/16"-18 HEX NUT 8 80 GK-191-P-035 SENSOR ASSEMBLY 1
32 GP-150-021 NYLASTIC BEARING PLATE 2 81 GK-156-073 3 POSITION 0.098 INLINE CONNECTOR 1
33 GP-150-036 TILT ADJUSTMENT HUB 1 82 GK-156-074 MALE 0.098 CRIMP TERMINAL 3
34 GK-160-004 5/16"-18 x 1" CARRIAGE BOLT 8 83 GK-156-032 3 POSITION KK FEMALE CONNECTOR 1
35 GK-153-008 BALL KNOB 1 84 GK-156-017 KK MALE CRIMP TERMINALS 3
36 GP-150-038 TILT POSITIONING LEVER 1 85 GK-112-060 4-40 x 1/4" ROUND HEAD SCREW 2
37 GK-153-007 ADJUSTABLE HAND LEVER 1 86 GK-191-P-038 SENSOR WHEEL 1
38 GK-135-057 10-32 LOCK NUT 4 87 GK-106-063 4-40 x 3/16" SET SCREW 3
39 GK-111-068 # 10 FLAT WASHER 3 88 GK-105-086 8-32 x 7/8" FLAT HEAD SCREW 2
40 GK-191-P-105 TRANSFORMER MOUNTING PLATE 1 89 GK-190-111 SENSOR COVER 1
41 GK-191-P-218 TRANSFORMER MOUNTING RUBBER 2 90 GK-156-024 TRANSFORMER CONNECTOR TO AC 1
GK-191-P-019-A TRANSFORMER - 42VAC INPUT 91 GK-156-025 AC TO TRANSFORMER CONNECTOR 1
GK-191-P-019-B TRANSFORMER - 115VAC INPUT 92 GK-191-P-103 DISCHARGE RESISTOR HARNESS 1
GK-191-P-019-C TRANSFORMER - 230VAC INPUT 93 GK-156-015 WIRE CONNECTOR CRIMP - MALE 5
43 GK-191-P-062 CAPACITOR 1 94 GK-156-016 WIRE CONNECTOR CRIMP - FEMALE 5
44 GK-191-P-063 CAPACITOR CLAMP 1
1A GP-150-025 ROTARY GAS COUPLING 1 8A GPP-150-011 DRIVE GEAR FOR GAS PURGE 1
2A GK-106-069 1/4"-20 x 3/16" SET SCREW 2 9A GK-117-034 3/16" x 1-1/2" SPIROL SPRING PIN 1
7A GPP-150-013 TABLE SPINDLE FOR GAS PURGE 1
42 1
51 1
72 1
18 1
Notes:
 The GSP-2000-2 motor control is typically supplied unless the GSP-2010-2 is specificall
y
requested at time of order (Item 72).
 Items 90 to 94 are not shown on drawing.
 Specify model and serial numbers when ordering parts.