GULLCO Pipe Kat PK-500-LG Series User manual

Revised: July 30, 2012 GD-070
OPERATING
INSTRUCTIONS
WELDING SYSTEM
MODELS:
PK-500-LG-*
PK-500-LH-*
PK-500-LW-*
(*INDICATES VOLTAGE REFERENCE)
Website: www.gullco.com
Distributed by: GULLCO INTERNATIONAL LIMITED – CANADA
Phone: [phone] Fax: [phone] e-mail: [email protected]om
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:[e-mail]
GULLCO INTERNATIONAL PTY LIMITED - AUSTRALIA
Phone: [phone] Fax: [phone] e-mail: [email protected]m
GULLCO INTERNATIONAL LIMITED – INDIA
Phone: [phone] Fax: [phone] e-mail: [email protected]m
GULLCO INTERNATIONAL SHANGHAI – LIMITED
Phone: [phone] Fax: [phone] e-mail: [e-mail]

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1
TABLE OF CONTENTS
SAFETY INSTRUCTIONS............................................................................................................................2
SAFETY PRECAUTIONS.............................................................................................................................3
PIPE KAT® SYSTEM COMPONENTS .........................................................................................................4
GENERAL DESCRIPTION...........................................................................................................................5
PIPE BAND...................................................................................................................................................6
PIPE BAND SIZING..................................................................................................................................6
MOUNTING PIPE BAND (TRACK) ON THE PIPE...................................................................................7
MOUNTING THE CARRIAGE ON THE PIPE BAND (TRACK) ...............................................................8
CARRIAGE UMBILICAL..............................................................................................................................9
REMOTE PENDANT ..................................................................................................................................11
PIPE KAT®CARRIAGE..............................................................................................................................13
MAIN CONTROL BOX OPERATION.........................................................................................................16
FRONT PANEL.......................................................................................................................................16
LEFT SIDE PANEL .................................................................................................................................17
RIGHT SIDE PANEL...............................................................................................................................18
CARRIAGE OSCILLATOR CONTROL......................................................................................................19
OSCILLATOR CONTROL PROGRAMMING..........................................................................................20
GENERAL PROGRAMMING MODE......................................................................................................22
ADVANCED PROGRAMMING MODE ...................................................................................................25
PIPE KAT®OSCILLATOR CONTROL ERROR CODES........................................................................27
OSCILLATOR CONTROL FACTORY DEFAULTS.................................................................................29
CARRIAGE CONTROL..............................................................................................................................30
CARRIAGE CONTROL PROGRAMMING..............................................................................................34
GENERAL PROGRAMMING MODE......................................................................................................35
ADVANCED PROGRAMMING MODE ...................................................................................................36
PIPE KAT®CARRIAGE CONTROL ERROR CODES............................................................................39
CARRIAGE CONTROL FACTORY DEFAULTS.....................................................................................41
AUTOMATIC CYCLE OPERATION...........................................................................................................43
AUTOMATIC CYCLE SEQUENCE OF EVENTS.......................................................................................44
OPTIONAL EQUIPMENT...........................................................................................................................46

2
SAFETY INSTRUCTIONS
Although the PIPE KAT®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 PIPE KAT®is cautioned to always practice "Safety First" during each phase of operation,
set-up and maintenance.
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.
This equipment is normally used to automate / semi-automate welding 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 trouble, 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 security 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, jewelry and loose, long hair which may get
caught into automatic systems or moving parts.
Ensure that the Pipe Band/track is well secured when installed.
Keep lifting handles dry, clean and free from oil and grease.
Keep hands away from the underside of the PIPE KAT®carriage when
there is the slightest possibility of it moving.
Always wear protective gloves when handling the track, to prevent injury
from sharp edges.

3
SAFETY PRECAUTIONS
The following cautionary/warning label is attached to each “PIPE KAT”®main control box
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 PIPE KAT®CARRIAGE
WARNING! Always turn the main power off before connecting/disconnecting any cables
to/from the PIPE KAT®carriage and main control box. Failure to comply may
result in control damage.
Do not cycle the power on and off in quick succession to the PIPE KAT®system, as this may
have diverse affects.
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.
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.

4
THE PIPE KAT®WELDING SYSTEM COMPONENTS
This manual covers the operation instructions of the following PIPE KAT®systems
PK-500-LG-*, PK-500-LH-*, PK-500-LW-* (* indicates input voltage: “A”=42 VAC; “B” =115
VAC; “C”= 230 VAC).
PIPE KAT®CARRIAGE PIPE KAT®PIPE KAT®
WITH UMBILICAL MAIN CONTROL REMOTE PENDANT
PIPE KAT®PIPE BAND STORAGE / TRANSPORTATION CASES

5
GENERAL DESCRIPTION
The PIPE KAT®is an advanced portable travel carriage designed for orbital welding. It is
an electrically powered track guided carriage that travels in forward and reverse directions at
precisely controlled speeds. It consists of 24 VDC permanent magnet gear motor which
engages the aluminum pipe band (track) through the self-aligning wheel system. Pipe bands are
designed and manufactured to customer specific applications (pipe diameter). The band is
typically constructed from extruded aluminum which insures a long life and durability in harsh
conditions.
The onboard wire feeder and wire spool holder is driven by a 24 VDC motor which feeds
wire to the welding torch at precisely controlled speeds. The wire spool holder accepts standard
8” / 10 lbs [20.3cm/4.54kgs] spools.
The Gullco Linear Oscillator is a compact, light weight, yet durable, reciprocating device
with a high torque, high resolution and low vibration stepper motor. It imparts a linear motion to
the weld gun. The low voltage Oscillator control provides a large, easy to read, multi-page
graphical display and offers programmable and electronic adjustment over the following
functions.
Oscillation width
Oscillation speed
Independent left and right dwells
Oscillation centre positioning (steering)
Multiple oscillation program storage
The precise control of these features enables accurate and repetitive weld oscillation.
The Gullco Carriage control provides control and adjustment over vertical slide, wire
feeder and carriage drive motor.
A motorized torch slide provides 2” or 50mm of tip-to-work distance adjustment, this serves as a
fine adjustment to control and maintain the proper torch to pipe height during setup and welding.
This motorized torch slide is connected to the linear oscillator by an adjustable radial Lead &
Lag mounting bracket
The versatile torch mounting bracketry provides a greater variation of torch mounting/positioning
flexibility.
INTENDED / FORESEEN USAGE
The Gullco PIPE KAT®is intended to automate and improve the quality of the welding
operation at precisely controlled speeds, along the Pipe Band as well as providing the interface
between the welding motion and the arc start and stop signals. The PIPE KAT®operates with
precise motion from start to finish regardless of the number of passes or the work pieces
involved, improving the quality, efficiency and repeatability of the process. 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.

6
PIPE BAND
The Pipe Band is constructed from extruded aluminum and uses adjustable stand-offs
that serve as spacers to maintain the correct distance from the band to the pipe. The Pipe Band
utilizes a quick adjustment latches that allows the operator to mount and remove the band
easily. It is important that the Pipe Band is properly maintained and not subjected to any abuse
as it serves an important role in the carriages drive system. The operator must play close
attention to the condition of mating edge of the band that the PIPE KAT®carriage wheels run
on. Care must be taken to ensure that the band is kept clean from dirt and debris that could
damage the band. Also premature wear or damage to the band could result from improper
mounting of the PIPE KAT®carriage.
PIPE BAND SIZING
All Pipe Bands are manufactured to customer
specified pipe diameters & stand-off lengths.
The standard (minimum) stand-off height is 1.75”
[44.5mm]. Spacers can be used to increase the
height off the stand-offs.
The minimum spacer height can be used in
conjunction with standard stand-offs is 0.50”
[12.7mm]