GULLCO Pipe Kat PK-500-LG Series Operating Instructions Manual Download Page 25

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When in the programming mode, only the “A”, ”C” and the rotary switches and the
Programming Button will be used.



The “A” rotary switch is used to navigate forward and backward between screens
(pages).



The rotary switch is used to navigate forward and backward between adjustable
fields of the current screen (page). The contents of the selected field will flash to
indicate which field is currently selected.



The “C” rotary switch is used to change the value/setting of the currently selected
adjustable field.



The Programming Button is used to save all values and settings, exit programming
mode and return to the running (operational) mode.

While-ever the control is in programming mode, the program icon is displayed in the lower right
hand corner of the LCD screen as follows:

Summary of Contents for Pipe Kat PK-500-LG Series

Page 1: ... 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 GULLCO INTERNATIONAL LIMITED INDIA Phone 91 20 65260382 Fax 91 20 26836656 e mail India lo gullco com GULLCO INT...

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Page 5: ... 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 ...

Page 6: ... 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 ...

Page 7: ...nnecting 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 passi...

Page 8: ...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 ...

Page 9: ...ependent 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 serve...

Page 10: ...e 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...

Page 11: ...oximately 8 00 203 2 mm between the inside edge of track and the center of the weld joint NEVER use a hammer or other such object to hit the Pipe Band into position doing so will damage the edge that the self aligning wheels run on and result in poor performance 7 Back off the adjustable standoffs on the pipe band This is done by rotating the adjustment screw counter clock wise 8 Finish tightening...

Page 12: ...d turn in either direction until the lever arm is facing down Important always make sure the drive is properly engaged by verifying the lever is locked into position WARNING Never disengage the drive when there is a possibility that this action may result in the equipment moving expectantly and causing injury MOUNTING PROCEDURE 1 With both Carriage Locking Handles open both handles have a built in...

Page 13: ...esistant cover and uses a clamp to secure the umbilical assembly to the carriage see page 16 to see where the umbilical attaches to the PIPE KAT carriage Note It is important that the umbilical does not become tangled coiled or caught in anyway that would impede the motion of the carriage and possibly damage electrical cables and restrict water supply and or shielding gas supply to the torch It is...

Page 14: ...g for the shielding gas supply to the torch 4 Additional 15 ft of water cooling hoses supply return Connection to the PIPE KAT carriage includes 1 One 1 twist connect welding power supply cable connection 2 One 1 large electrical connector for carriage communication 3 One 1 quick disconnect fitting for the torch shielding gas 4 Two 2 quick disconnect fittings cooling water supply blue and return r...

Page 15: ...During setup the pendant is used to provide the following Position the carriage to the welding start position Adjust oscillator center position Adjust torch height in relation to the pipe Advance the wire towards and back from the pipe Set welding voltage During the welding operation the pendant can be used to provide the following fine adjustments Carriage speed Wire feed speed The torch height i...

Page 16: ...se the carriage jog switch to establish the proper position of the carriage to the work prior to welding When the forward or reverse jog direction is selected the carriage will travel at the set carriage weld travel speed for three 3 seconds then it will progressively ramp up to maximum travel speed The switch is automatically disabled during the auto cycle EMERGENCY STOP The emergency stop button...

Page 17: ... This 3 position momentary switch In Stop Out allows the operator to adjust the In Out distance of the torch relative to the work The torch slide provides 2 or 50 8mm of motorized travel and can be used in both auto and manual modes This serves as a fine adjustment to control and maintain the tip to work distance The linear speed of the slide can be programmed through the Carriage Control see page...

Page 18: ...Pendant and one 1 on the Main Control Box These three 3 Emergency Stop Button are wired in series so any one 1 will shut down the PIPE KAT system when activated and all three have to be released in order for the system to power up CARRIAGE DRIVE MOTOR This DC motor provides the motive propilsion that drives the PIPE KAT carriage around the Pipe Band track CARRIAGE CONTROL CONNECTION This receptica...

Page 19: ...e oscillator slide and is used to set the Lead Lag angle of the welding torch A range of 10 positive to 10 negative is permitted by rotating the knurled knob LINEAR OSCILLATOR HEAD This motorized slide is fully programmable see page 19 and provides torch positioning and linear oscillation movement of the welding torch WIRE FEEDER This compact wire feed unit uses a pair of drive rolls available in ...

Page 20: ...nd shut down the PIPE KAT unit when pressed The emergency stop will remain activated until it is reset by turning the button in a clock wise motion There are two 2 other such emergency stop buttons one 1 on the carriage assembly and one 1 on the remote control pendant These three 3 Emergency Stop buttons are wired is series so any one 1 will shut down the PIPE KAT system when activated and all thr...

Page 21: ...and arc sense lead that provides a feedback welding voltage to the welding power source this is also included on this connector The 15ft 4 6m mating cable assembly is supplied and is intended to connect to the contactor control circuit of the customers power source REMOTE WATER COOLER START OPTIONAL This connector is part of the optional Water Cooler Power Interface Kit and uses a 10 amp isolated ...

Page 22: ...ilable on units that have the remote water cooler start option installed SHIELDING GAS INPUT Shielding gas supply is connected here The PIPE KAT Main Control energizes an electric solenoid valve to open the gas flow for pre flow welding post flow and manual purge operation RIGHT SIDE PANEL The right side panel of the main control contains the following features CARRIAGE CONTROL CONNECTION Control ...

Page 23: ...djustment the A C location dwells respectively by 0 1 second increments from a minimum of zero up to a maximum of 9 9 sec seconds The current values are displayed on the LCD screen These adjustments can be changed at any time before or during operation and will take effect on the next relevant dwell location The orientation of the A C locations of the oscillator can be altered programmed to match ...

Page 24: ...ows NOTE programming can only be accessible while the PIPE KAT is stopped and not welding OSCILLATOR CONTROL PROGRAMMING There are two levels of programming mode General Programming Mode To access the General Programming Mode push the Programming Button for a minimum of two 2 seconds but no more than ten 10 seconds The screens that are accessible under this mode are o Feature Set up screen and o 1...

Page 25: ...f the current screen page The contents of the selected field will flash to indicate which field is currently selected The C rotary switch is used to change the value setting of the currently selected adjustable field The Programming Button is used to save all values and settings exit programming mode and return to the running operational mode While ever the control is in programming mode the progr...

Page 26: ...quence of level 1 General Programming Mode program screen displays is as follows Rotate the A rotary switch clockwise to move forward through the screens Rotate the A rotary switch counter clockwise to move backwards through the screens ...

Page 27: ... are 0 1 2 3 4 5 6 7 8 9 or 10 surrounded by the auto cycle symbol When the value is 0 the existing oscillation values last used will not be over written Each time the Features and Setup screen is opened the value in this field defaults to 0 2nd Field Oscillation Rest Location This setting dictates where the oscillator stops at the end of an oscillation cycle and therefore assumed location at the ...

Page 28: ...d Field The C Location Dwell Time This sets the time duration that the oscillation stroke will dwell pause each time the C location is reached The choices available are from 0 0 to 9 9 seconds in 0 1 second increments 3rd Field the Oscillation Width The value of this field sets the total width of the oscillation stroke A to C The increments of adjustment and the minimum and maximum allowable strok...

Page 29: ...ents for Radial Oscillator Heads Not applicable to this model of the PIPE KAT therefore do not adjust 4th 5th 6th 7th Fields Units of Travel Per Motor Step These numeric fields are used to program how much oscillation travel will be achieved for each step of the oscillator motor It is broken into four fields to allow the value to be easily entered Each field has a range of 00 to 99 The control wil...

Page 30: ... min 355 cm min 1 cm min 0 23 0 46 cm 0 47 6 35 cm 0 01 cm 0 00127000 PK 500 012 Standard Linear Width of Oscillation Note Linear stroke is 4 10 2cm on PK 500 012 with 2 5 6 35cm maximum oscillation width Oscillator Control Motor PK 200 300 Board Dip Switch Settings The Oscillator Control Motor Board is located inside the control box that is mounted on the PIPE KAT carriage Dip Switch S42 Switch 1...

Page 31: ...width being set too large for the stroke of the slide the starting location of the oscillator slide relative to the oscillation width and direction or through making center position adjustments steering resulting in slide over travel To reset make the necessary manual and or programming adjustments and restart the automatic cycle It is recommended that the oscillator be set so that the oscillation...

Page 32: ... control ER 46 Oscillator control motor board During normal operation of the PIPE KAT the oscillator control communicates with oscillator control motor board located on the PIPE KAT carriage if for any reason this communication stops or becomes corrupt ER 46 will be displayed on the control ER 47 Oscillator control motor board over temp During normal operation of the PIPE KAT if the oscillator mot...

Page 33: ...29 OSCILLATOR CONTROL FACTORY DEFAULTS The default factory programming when shipped General programming screen Advanced programming screen INCHES Advanced programming screen CM C B A C B A ...

Page 34: ...e adjustment on the remote pendant which allows the operator to fine tune the Actual Carriage Weld Speed to their liking by increasing or decreasing the weld speed by six 6 increments of 0 22 inches minute 0 56 cm minute The main screen displays both the mean setting of the Carriage Weld Speed and the Actual Carriage Weld Speed mean setting the trim override setting in the units of choice either i...

Page 35: ...ll take effect immediately While in programming mode this switch allows the operator to increase or decrease values in the selected flashing field by rotating the knob clockwise or counter clockwise SHIELDING GAS PURGE This momentary button is used to purge the shielding gas line prior to welding to ensure shielding gas will be present at the torch when welding commences AUTO CYCLE STOP This momen...

Page 36: ...steering direction inputs For example if the operator turns the rotary knob for the oscillator center position adjustment steering located on the remote pendant to the left and the corresponding torch movement is to the right the A C dwell orientation needs to be changed See page 33 for the display screens that depict all combinations of carriage direction and torch dwell position Note Changes in ...

Page 37: ...pect to the torch dwell position Pushing the carriage direction push button toggles the welding direction of the Pipe KAT carriage Note The carriage direction and torch oscillation dwell position can be toggled independently of one another the above four 4 screens depict all combinations of carriage direction and torch dwell position Pushing the carriage direction push button toggles the welding d...

Page 38: ...ers o Screen 3 Wire Feeder motor parameters o Screen 4 Welding power source calibration o Screen 5 Error code screen To change state from either programming mode any screen to running operational mode press the Programming Button for one 1 second or longer The various values and settings will be saved When in programming mode The Auto Cycle Stop push button is used to navigate forward and backward...

Page 39: ... to 3048 Cm P M Factory set at 158 I P M or 401 Cm P M Screen 2 Weld Travel Delay This is an adjustable time delay for carriage travel Once the arc has been established the carriage will commence travel after the programmed delay has been reached Adjustable range 0 0 to 9 9 seconds in 0 1 increments Factory set at 0 3 seconds Crater Fill Duration This is an adjustable time delay that allows the we...

Page 40: ...ctory set at 10 amps Carriage Maximum Weld Speed this variable is used to calibrate the motor control to suit the carriage drive motor used At this writing there is only one 1 carriage drive motor available which has a maximum weld speed of 44 20 inches per minute 112 0 cm min and is factory preset accordingly Carriage Braking This sets the level of motor braking from instant braking to a variable...

Page 41: ...s longer to accelerate to speed and reacts to motor speed variances slower By having a fast response the motor will accelerate to speed quickly sometimes resulting in over shooting of the preset speed and reacting to motor speed variances instantly sometimes resulting in slight speed oscillation The variable value range is from a reference value of 1 to 10 in increments of 1 A reference value of 1...

Page 42: ...tor to set the lower minimum threshold of the 0 10VDC signal to achieve the minimum welding voltage The adjustable range is 0 to 10 volts in increments of 0 1 Factory set at 0 0 volts Max WF Speed This allows the operator to set the upper maximum wire feed speed The adjustable range is 0 to 1000 IPM 2540 cm min in increments of 1 Factory set at 1000 IPM 2540cm min Max Input Volt WF This allows the...

Page 43: ...ant has malfunctioned Er 71 Carriage motor control board the control board has encountered a problem with the carriage drive motor Er 72 Carriage motor current trip motor is drawing excessive current Er 73 Carriage motor feedback no feedback from motor encoder Er 74 Carriage motor pulses loss of motor pulses from the encoder Er 77 Carriage motor control board high temp temperature of carriage moto...

Page 44: ...in control box has malfunctioned Er 52 Carriage control box I O board the I O board PK 200 308 located in the carriage control box has malfunctioned Er 53 Main control display the control display located on the main control box has encountered a problem Er 55 Hardware compatibility problem Wrong control hardware or control hardware has not been configured correctly Er 56 Software compatibility pro...

Page 45: ...L FACTORY DEFAULTS The default factory programming when shipped General programming INCHES General programming CM Screen 1 Screen 1 Screen 2 Screen 2 Advanced programming INCHES Advanced programming CM Screen 1 Screen 1 ...

Page 46: ...42 Screen 2 Screen 2 Screen 3 Screen 3 Screen 4 Screen 4 Screen 5 Screen 5 44 2 112 633 1608 ...

Page 47: ...ected plug the Main Control Box into a suitable power supply make sure the voltage and amperage match that on the Main Control Box product label 10 Release reset all three 3 Emergency Stop Buttons located on the Main Control Box the Remote Pendant and the PIPE KAT carriage 11 Turn the Main Power On Off Switch located on the left side of Main Control Box to the On position The Oscillator and the Ma...

Page 48: ... then proceeds as described in the following section 3 Audible warning buzzers located in the Remote Pendant and on the PIPE KAT will activate for the time period set by the Warning Buzzer Duration see page 36 4 Upon completion of the Warning Buzzer Duration the gas solenoid valve is energized and the Shielding Gas Pre Flow Duration timing cycle is initiated see page 35 5 Upon completion of the Sh...

Page 49: ...to detect the presence of weld current during an automatic cycle the cycle will terminate as described in sections 9 through to 12 above and Er 2 will be displayed on the Carriage Control If the signal from the optional Coolant Flow Switch Kit is lost during an automatic cycle the cycle will terminate as described in sections 9 through to 12 above and Er 3 will be displayed on the Carriage Control...

Page 50: ...ing the onus of the operator to remember to switch the cooler on before each weld and also saving energy by automatically turning the cooler off when not welding Manual override toggle switch also included P N PK 200 216 B for 115V coolers or P N PK 200 216 C for 230V coolers PENDANT EXTENSION CABLE Extension Assembly provides an additional 15ft of length to the Remote Pendant P N PK 200 368 The m...

Page 51: ... carriage umbilical assembly P N PK 500 163 G N W The maximum combined total length of Carriage Umbilical assembly and Extension assembly must not exceed 50ft Distances over 50ft will result in communication signal loss between the Main Control and Carriage causing erratic operation of the PIPE KAT system ...

Page 52: ...48 REVISION LIST July 2012 Manual release ...

Page 53: ......

Page 54: ...www GULLCO com ...

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