welding and cutting automation

WELDING AND CUTTING CARRIAGE - KAT® FOR RIGID TRACK

The Gullco Rigid KAT® is used

throughout the world to automate a wide
variety of welding and cutting operations.
It is a durable, reliable precision travel
carriage designed for use on rigid track
which enables it to operate along any plane.
The rigid track can be used in straight
sections or can be formed for use on curved
surfaces. Gullco manufactures several
systems and accessories designed for use
with the Rigid KAT® making it one of the
most versatile pieces of welding and cutting
automation equipment available in the
industry.

MULTI-PASS WELDS cladding overlay all position

Reliable automation that improves quality and reduces costs in welding and cutting operations
ALL POSITION - PRECISe control - variable speed

WELDING AND CUTTING

 Automated Welding System
KAT® RIGID TRACK
The Gullco Rigid KAT® carriage is used
throughout the world to automate and AUTO-WELD CARRIAGE SYSTEM
improve the quality and efficiency of The KAT® Auto-Weld Carriage option enables a wide
variety of automated welding and cutting overlay cycles
single or multiple “head” welding and that can be repeatedly performed. The GSP control in this
cutting operations. Welding guns or unit controls travel direction/speed and length of travel path
and synchronizes them with precise weld start and weld
cutting torches mounted on the KAT® stop settings. This travel carriage is pre-drilled for mounting
carriage move along Gullco standard or Auto-Weld
deep section track at precisely controlled accessories (sold separately).
It is ideal for stitch welding and
speeds along the desired path in forward seam welding applications where
or reverse direction. Gullco’s Rigid KAT® repeatability is desired. The reliability
carriage enables welding guns or cutting and precision of this automated
welding and cutting system reduces
torches to operate with precise motion cost, adds efficiency and improves
from start to finish regardless of the quality.
number of passes or the work pieces A
involved, improving the quality, efficiency
and repeatability of the process. Poor or
awkward accessibility, operator fatigue, or
inconsistent workmanship are eliminated. cladding / overlay system
This unit is designed for operation on flat The Indexing option Rigid KAT® uses a GSP control that
or curved surfaces as the track can be combines control of the carriage movement and start/
stop parameters with precise indexing of the torch at the
used in straight sections or roll formed to end of the path. This fully automates and increases the
follow the contour of the work piece. The efficiency of overlay welding operations, flame spray work,
self-aligning wheel system of the carriage hard facing etc. At the end of the path the travel carriage
grips the top and bottom of the track, automatically stops and reverses
enabling it to travel along any plane. The direction while at the same time
adjustable wheel assembly keeps the indexing the gun/torch. It can be
programmed to weld or not weld
carriage snug to the track, while allowing during indexing. Carriage is pre-
it to be easily mounted and removed from drilled or quick mounting of the
indexing unit (sold separately).
the track at any point. The positive drive
of the KAT® is obtained from a uniquely
designed rack and pinion system, driven I
by a low voltage permanent magnet motor
and gearhead power unit assembly.
oscillation welding system
The oscillator is available with a linear,
pendulum, tangential or step (square pattern) motion
to the welding gun with adjustable motorized stroke
width, infinitely variable stroke speed adjustment,
three independent position dwell times, motorized
centre line positioning and automatic wire feed start
and travel start/stop interface.

O
The Gullco Standard Platform range of controls have switching for forward / neutral / reverse, run / stop, Manual / Auto & program variable
increment/decrement (where applicable) and a rotary encoder for speed control. This micro-processor based, 24 volt DC motor control
can be supplied to provide a variety of “optional” functions such as indexing, weld oscillation and auto-weld. The selected “option’ function
and carriage travel speed/ direction are directed by a single GSP control. This ensures high levels of accuracy, quality and reliability.

Forward Motion Commanded Speed & Parameter Value Display

Reverse Motion Commanded Speed Display Calibrated In

Inches Per Minute

Hold (Stop) Mode Active Speed Display Calibrated in

Centimeters Per Minute

Arc Signal Active Auto Cycle Mode (Constant)

Programming Mode (Flashing)

Cycle Push Button Speed Adjustment

(Extended or Recessed) Clockwise = Faster
Counter-Clockwise = Slower

Control In Run Mode

Command Forward Motion

Control In Hold (Stop) Mode

Neutral

Program Variable Selector Switch Command Reverse Motion

(Extended or Recessed)

Select a speed, voltage and option to configure a KAT® specifically

suited to your needs

GK-200-
SPEED RANGES VOLTAGES
MODEL SPEED RANGE MODEL INPUT SUPPLY
RL 0.5 to 16.4 IMP (1.2 to 41.6 cm/min) A 42 VAC
RM 1 to 32.7 IPM (2.5 to 83.1 cm/min) B 115 VAC
RH 2.7 to 88.4 IPM (6.7 to 224 cm/min) C 230 VAC

SPECIFICATIONS

Weight: 29 lbs (13 kg)

Vertical Load Capacity: 100 lbs (45 kgs)
Drive Motor: 24 VDC permanent magnet gear
motor
Supply Voltage: 42, 115, 230 VAC, single phase
Complies With: CSA & CE Certification

Unique Drive System and Wheel Assemblies Enable Travel in All Positions Including Overhead

Positive drive rack and pinion system

Self-aligning wheel assemblies run on both top and bottom of track...

enabling operation on any plane.
 1

5
7
8
2 Rigid KAT® Automation Carriage Accessories
1 - Rack Arm 6 - 4 Motion Semi-
2 - Rack Box Automatic Gun Holder
3 - Clamps 7 - Remote Control
4 - Semi-Automatic Pendants
3 6 Gun Holder 8 - Idler Carriages
5 - Bronze Cutting 9 - Cable Support
Torch Holder Clamps
10 - Riser Bracket
4

rigid KAT® TRACK SYSTEMS

Gullco Rigid Track is made from precision extruded aluminum and a securely affixed steel rack. The
interchangeable end design enables fast accurate joining of the track sections. Standard Track, used
in most portable applications, is available in 48, 96 and 120 inch (1219, 2438 and 3048 mm) lengths
and can be formed to suit the work contour. Deep Section Track is used in permanent, straight run
applications. It is available in 60” and 120” (1524 and 3048mm) lengths. The track is securely mounted
on ferrous materials using round or square magnet assemblies. Vacuum mount assemblies can be
used on non-ferrous or ferrous materials.

track mounting devices Standard and Custom

Formed Track

Rare Earth On/Off

Track Magnet

Vacuum Track Formed Ring Quick

Mounting Device Installation Device

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

RKAT-11-01
 welding and cutting automation

WELDING AND CUTTING CARRIAGE - KAT® FOR Flexible TRACK

The Gullco Flexible KAT® is used

throughout the world to automate a wide
variety of welding and cutting operations.

It is a durable, reliable precision travel

carriage designed for use on flexible track
which enables it to operate on straight or
curved surfaces along any position.

Gullco manufactures several systems and

accessories designed for use with the Flex
KAT® making it one of the most versatile
pieces of welding/cutting automation
equipment available.

MULTI-PASS WELDS cladding overlay all position

Reliable automation that improves quality and reduces costs in welding and cutting operations
ALL POSITION - PRECIse control - variable speed

WELDING AND CUTTING

 Automated Welding System
KAT® FLEXIBLE TRACK
The Gullco Flex KAT® Carriage is used
throughout the world to automate and improve AUTO-WELD CARRIAGE SYSTEM
the quality and efficiency of single or multiple The KAT® Auto-Weld Carriage option enables a wide variety
“head” welding and cutting operations. of automated welding and cutting overlay cycles that can be
repeatedly performed. The GSP control in this unit controls
Welding guns or cutting torches are mounted travel direction and speed and length of travel path and
on the KAT® carriage as it moves along synchronizes them with precise weld start and weld stop
Gullco Flex Track at precisely controlled settings. This travel carriage is pre-drilled for mounting
speeds along the desired path in forward or Auto-Weld
accessories (sold separately).
reverse direction. Gullco’s Flex KAT® carriage It is ideal for stitch welding and
enables welding guns or cutting torches to seam welding applications where
operate with precise motion from start to repeatability is desired. The reliability
finish regardless of the number of passes and precision of this automated
welding and cutting system reduces
or the work pieces involved. This improves cost, adds efficiency and improves
the quality, efficiency and repeatability of quality.
the process. Poor or awkward accessibility,
operator fatigue, or inconsistent workmanship A
are eliminated.

This unit is designed for operation on

curved surfaces as the flexible track can be cladding / overlay system
positioned to follow the contour of the work The Indexing option Flex KAT® uses a GSP control that
piece. The self-aligning wheel system of the combines control of the carriage movement and start/
carriage grips the top and bottom of the track, stop parameters with precise indexing of the torch at the
end of the path. This fully automates and increases the
enabling it to travel along any plane. The efficiency of overlay welding operations, flame spray work,
adjustable wheel assembly keeps the carriage hard facing etc. At the end of the path the travel carriage
snug to the track, while allowing it to be easily
mounted and removed from the track at automatically stops and reverses
direction while at the same time
any point. The positive drive of the KAT® is indexing the gun/torch. It can be
obtained from a uniquely designed sprocket programmed to weld or not weld
that engages with slots in the track, driven by during indexing. Carriage is pre-
a low voltage permanent magnet motor and drilled for quick mounting of the
indexing unit (sold separately).
gear-head power unit assembly.

oscillation welding system

The oscillator is available with a linear,
pendulum, tangential or step (square pattern)
motion to the welding gun with adjustable motorized
stroke width, infinitely variable stroke speed
adjustment, three independent position dwell times,
motorized centre line positioning and automatic
wire feed start and travel start/stop interface.

O
The Gullco Standard Platform range of controls have switching for forward / neutral / reverse,run / stop, Manual / Auto & program variable
increment/decrement (where applicable) and a rotary encoder for speed control. This microprocessor based, 24 volt DC motor control can
be supplied to provide a variety of “optional” functions such as indexing, weld oscillation and auto-weld. The selected “option’ function and
carriage travel speed/ direction are directed by a single GSP control. This ensures high levels of accuracy, quality and reliability.

Forward Motion Commanded Speed & Parameter Value Display

Reverse Motion Commanded Speed Display Calibrated In

Inches Per Minute

Hold (Stop) Mode Active Speed Display Calibrated in

Centimeters Per Minute

Arc Signal Active Auto Cycle Mode (Constant)

Programming Mode (Flashing)

Cycle Push Button Speed Adjustment

(Extended or Recessed) Clockwise = Faster
Counter-Clockwise = Slower

Control In Run Mode

Command Forward Motion

Control In Hold (Stop) Mode

Neutral

Program Variable Selector Switch Command Reverse Motion

(Extended or Recessed)

Select a speed, voltage and option to configure a KAT® specifically

suited to your needs

GK-200-
SPEED RANGES VOLTAGES
MODEL SPEED RANGE MODEL INPUT SUPPLY
FL 0.8 to 25.8 IMP (2 to 65.4 cm/min) A 42 VAC
FM 1.5 to 51.5 IPM (3.9 to 131 cm/min) B 115 VAC
FH 4.2 to 139.1 IPM (10.6 to 353 cm/min) C 230 VAC

SPECIFICATIONS

Weight: 29 lbs (13 kg)

Vertical Load Capacity: 100 lbs (45 kgs)
Drive Motor: 24 VDC permanent magnet
gear motor
Supply Voltage: 42, 115, 230 VAC, single
phase 50/60 Hz., 200 Watts
Complies With: CSA & CE Certification

Unique Drive System and Wheel Assemblies Enable Travel in All Positions Including Overhead

Ball studded drive sprocket engages apertures in the track

Self-aligning wheel assemblies run on both top and bottom of the track...
enabling operation on any plane.
 1

5
7
8
2 Rigid KAT® Automation Carriage Accessories
1 - Rack Arm 6 - 4 Motion Semi-
2 - Rack Box Automatic Gun Holder
3 - Clamps 7 - Remote Control
4 - Semi-Automatic Pendants
3 6 Gun Holder 8 - Idler Carriages
5 - Bronze Cutting 9 - Cable Support
Torch Holder Clamps
10 - Riser Bracket
4

Flex KAT® TRACK and mounting devices Flexible-Track Stiffener

Extruded aluminum
Gullco Heavy Duty Flexible Track is specifically designed for use for attachment to
with Gullco Flexible KAT® all position travel carriages. Gullco Flexible Track
Flexible Track is made from specialty tempered spring steel sections for “rigid track”
applications. Supplied in
and can be easily mounted to conform with curved surfaces.
8 ft. sections
This Flexible Track can be used in applications involving curved
surfaces 60” (1524 mm) diameter and greater. The track is
securely mounted on ferrous materials using round or square
magnet assemblies and vacuum mount assemblies for non-ferrous
materials.

KAT® FLEXIBLE-TRACK
HEAVY DUTY FLEX-TRACK Model
Rare Earth On/Off Vacuum Track GK-192-F-054-2
Track Magnet Mounting Device Supplied in 8 ft. (2438 mm) lengths.
Also available in custom lengths up
to 8 ft. (2438 mm) with interlocking
ends to facilitate complete circles
Weight for diameter 60” (1524 mm), O.D.
Heavy Duty:
& I.D. and over. Tracks are easily
Model GK-192-F-054-2
175 lbs/ft. (2.6 Kg/m) joined for continuous runs.
Other lengths available on request.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

FKAT-11-01
welding and cutting automation

Automatic welding carriage - KAT® Auto-weld

MODEL GK-200-R*-A MODEL GK-200-F*-A

For use on KAT® Rigid Track For use on KAT® Rigid Track
Centre limit
switch for weld * See reverse side for speed and voltage requirments
start positioning
& weld on/off The KAT® Carriage Auto-Weld enables a wide
variety of automated welding cycles that can
activation
be repeatedly performed along any plane. The
Adjustable advanced Auto-Weld control monitors, via distance
return limit travelled, and responds to limit switches mounted
switch activator on the KAT® which in turn respond to adjustable
Run Stop activators mounted at appropriate positions on the
KAT® Track. Travel direction/speed and length
limit swtich
of travel path are synchronized with precise weld
start and weld stop settings. By combining different
control settings and limit switch activator positions,
End Stop a wide variety of welding cycles can be repeatedly
limit swtich performed. The KAT® Auto-Weld Combination
is ideal for stitch welding and seam welding
Adustable End applications where repeatability and accuracy
limit switch are desired. The reliability and precision of this
activator automated welding system reduces cost, adds
efficiency and improves quality.

Increase Production and Precision with Weld Automation

PRECISION And repeatable welds can be produced along any plane

WELDING AND CUTTING

 specifications
KAT® Travel Carriage Auto-Weld Combination Limit Switches - 3 limit switches are mounted on the outside of
comprises: the carriage. One each for forward, reverse and centre limit for
weld start positioning and weld on/off activation.
Gullco Auto-Weld KAT® Travel Carriage with heavy duty self-
aligning wheel assemblies and closed loop tack feedback for Adjustable Park and End Limit Switch Activators -
accurate speed control when running in any plane, regardless for mounting on Gullco KAT® Rigid or Flex Track. Centre limit
of load. Maximum 100 lbs. (45 kgs). Carriage is controlled by switch activator(s) to be supplied by the customer.
the Gullco low voltage 24 volt GSP microprocessor pulsed width
modulation motor control, interfacing with the forward/stop/reverse Optional
switch and infinitely variable 4-turn speed potentiometer. LED Remote Pendant Control Kit - Uses GSP control removed from
display in IPM or cm/min and with a ten position rotary switch to KAT® Carriage...enabling remote operator control of the Auto-
adjust various functions. Operates on 42, 115 or 230 volts, single Weld unit. See below for details
phase, 50/60 Hz A.C. power supply. Please specify voltage/speed NOTE: Gullco also has Kat Carriage models available with controls for Oscillation
when ordering. (see below) visit www.gullco.com for more information.

AUTO-WELD CONTROL SYSTEM

Provides settngs to establish:

• Operating position
• Travel start delay after arc start signal, adjustable 0 - 9.9 seconds.
• Crater fill delay, allowing the wire feed signal to stay active after carriage stop, adjustable 0- 9.9 seconds.
• Post weld delay, sets a delay adjustable 0 - 9.9 seconds after each crater fill delay for burnback or postflow to
occur.
• Weld direction- forward, reverse, or “forward & reverse”
• Center limit switch use, to enable rapid travel to weld start point using center limit switch.*
• Stitch weld electronically programmed using carriage travel distance, adjustable 0.1 - 99.9 in. or cm.
• Carriage travel distance, adjustable 0.1 - 99.9 in. or cm.
• Automatic carriage return to home. Limit switch activated.
• Continual forward and reverse of carriage using limit activators.
•
*Note: Centre Limit Switch Activator to be supplied by customer

RIGID KAT® AUTO-WELD FLEX KAT® AUTO-WELD

MODEL SPEED RANGE MODEL SPEED RANGE
REMOTE PENDANT
L 0.5 to 16.4 IPM (1.2 to 41.6 cm/min) CONTROL KIT L 0.8 to 25.8 IPM (2 to 65.4 cm/min)
M 1 to 32.7 IPM (2.5 to 83.1 cm/min) ...for use with Rigid/Flex KAT® M 1.5 to 51.5 IPM (3.9 to 131 cm/min)
Auto-Weld systems. - Com-
H 2.7 to 88.4 IPM (6.7 to 224 cm/min) prising Remote Pendant (no H 4.2 to 139.1 IPM (10.6 to 353 cm/min)
control) attached to 8 ft (843.84
Select a speed range and voltage to determine your Rigid KAT® Auto-Weld Select a speed range and voltage to determine your Flex KAT® Auto-Weld
Model Number.
cm) control cable one end Model Number.
and KAT® control blanking
VOLTAGES plate other end with internal VOLTAGES
connectors at each end. This
GK-200-R -A MODEL INPUT SUPPLY GK-200-F -A MODEL INPUT SUPPLY
remote pendant uses the GSP
A 42 VAC control removed from the A 42 VAC
KAT® Carriage. This kit can be
B 115 VAC easily field installed (or factory B 115 VAC
C 230 VAC installed at no charge) C 230 VAC

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

AW-11-01
 ®

PRODUCT APPLICATION
FILE
Saipem Uses Kat® Rings for
Oxy-Fuel Cutting

bolted to the pipe and the “rings” were

suspended from the bands and positioned
using an adjustable swivel mechanism
and clamping assembly. This allowed the
“KAT”® track ring to swivel, enabling a
cut at an angle other than 90˚ to the pipe’s
centre line.
Above: One of the 1.9 m rings during manufacture with the KAT Travel Carriage fitted on
the formed KAT track ring. The ring is suspended from the steel bands via swivel
mechanisms.

Saipem Finds Innovative Solutions

With Gullco Kat Rings ®

Several years ago Saipem was faced with welding applications. Welding guns or, in
the need to cut large diameter pipe that this case, cutting torches are mounted on
was used in “driven pile” applications. the carriage which travels at precisely Above: close-up of
The difficulty was that the oxy-fuel cut- controlled speeds on special “KAT”® clamping assembly
ting had to be parallel to the horizon track along any plane. The Saipem appli- and right: swivel
cation required several innovative modi- mechanism. A sec-
while the piles weren’t always truly
tion of the track
vertical. Saipem consequently contacted fications in order to achieve the specified
ring is visible in
Gullco International [UK] Limited horizontal cut. The Gullco solution was the bottom left of
through one of their distributors for assis- comprised of “KAT”® track formed into the picture.
tance. Gullco devised a solution using rings which enabled the “KAT”® carriage
their world famous “KAT” ® Travel to travel around the outside diameter of
carriage System. The “KAT”® is used to the pipe. Steel bands used to support the The result; accurate, cost effective,
automate a wide variety of cutting and track rings were produced. They were mechanized cutting solution for a diffi-
cult application. Gullco has recently
supplied three 3 meter systems of the
same design.

Above: Due to the elliptical path that the Kat takes around the pipe a spring-loaded float is Above: The pipes may also need to be
required to maintain the torch height to work. The completed unit is shown here being test- bevelled, as shown, a swivel nozzle makes
ed. Note how the track ring is mounted to the steel band. this easier.
 KAT, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

Distributed by:

BULLETIN Gull-PAF-SAIPEM-0806
 welding and cutting automation

Welding and cutting carriage accessories - KAT®

h A. RACK ARM
i Square with one end
turned. Heavy duty &
a Extra heavy duty

B. RACK BOX
Available with standard
g or micro adjustment.
f Cross head & Arm Mount
rack boxes also available

C. CABLE D. CLAMPS
e SUPPORT CLAMP Available as swivel or
Keeps cables clear of square.
work area

E. SEMI-AUTOMATIC F. BRONZE CUTTING G. 4 MOTION SEMI-AUTO H. RISER BRACKET I. IDLER CARRIAGE

GUN HOLDERS TORCH HOLDERS GUN HOLDER To mount rack box higher For conveying auxilliary
Suitable for most Accepts standard 1 3/8” Mounts on the KAT® horizontal than carriage when welding and cutting
semi-automatic welding (35 mm) cutting rack arm to provide 5” (127 mm) required equipment
of vertical adjustment 360˚
guns torch
torch rotation & two directonal
angle tilt

WELDING AND CUTTING

 H W L S A B C
HEAVY DUTY In. 4.25 2.0625 6 1.125 1.625 2.625 -
GK-171-650
GK-171-655* mm. 10.8 52.39 152.4 28.57 41.27 66.67 -

EXTRA HEAVY Duty In. 4.5 2.5 10 1.5 2 3.3 6

GK-190-650
gk-190-655* mm. 114.3 63.5 254 38.1 50.8 83.82 152.4

*with micro fine adjustment gear box

H W L S D
HEAVY DUTY In. 7 2.0625 6 1.125 1.75
GK-171-685
GK-171-690* mm. 177.8 52.39 152.4 28.57 44.45

EXTRA HEAVY Duty In. 7.5 2.5 10 1.5 2.25

GK-190-685
gk-190-690* mm. 190.5 63.5 254 38.1 57.15

*with micro fine adjustment gear box

HEAVY DUTY RACK ARMS EXTRA HEAVY DUTY RACK

RACK ARMS 1 1/8” (29mm) square rack arm and ARMS
rack with one end turned to 1 1/8” (29mm) 1 1/2” (38mm) square rack arm and
diameter rack with one end turned to 1 1/8” (29mm)
GK-171-047-1 12” (305mm) long diameter
GK-171-047-2 18” (457mm) long GK-190-047-2 18” (457mm) long
GK-171-047-3 24” (610mm) long GK-190-047-3 24” (610mm) long
GK-171-047-4 36” (914mm) long GK-190-047-4 36” (914mm) long
other lengths available on request other lengths available on request

CLAMPS Dia. W D A
Swivel Clamps
In. 1.125 1.625 1.25 .775
for mounting torch holders, rack HEAVY DUTY
GK-166-183
boxes and other KAT® accessories mm. 28.57 41.27 31.75 19.68

Dia. W D A
Square Clamps
HEAVY DUTY In. 1.125 1.625 1.125 1.0625
for mounting welding guns,
GK-166-236
cutting torches and other KAT® mm. 28.57 41.27 28.57 27
accessories EXTRA HEAVY In. 1.5 2.125 1.25 1.437
DUTY
GK-190-236 mm. 38 54 31.75 36.5

RACK BOX RISER BRACKET

MODEL GK-190-066
For applications that require a mounting
surface higher than the level provided
with the rack box mounted directly on
the front of the KAT® Carriage. Height
can be increased by 2, 4 or 6” (51, 102
or 152 mm).
Torch Holders and Remote Control Pendant
assemblies
Supplied with 10 ft. (304.8 cm) cable
providing control of numerous KAT®
functions.

Standard cutting Torch

Holder
Semi-automatic
4 motion welding
Gun Holder GK-165-068B
MODEL GK-165-074-2 Accepts standard 1 3/8” (35 mm)
(complete unit)... For mounting on the KAT® cutting torches with 32 pitch rack.
horizontal rack arm to provide 5” (127 mm) of vertical Supplied with calibrated angle of
adjustment, 360˚ torch rotation and two directional tilt. tilt scale and 1 1/8” (29 mm) or
Supplied complete with standard 1 1/8” (29 mm) I.D. 1 1/2” (38 mm) square clamp.
swivel clamp* and insulated linkage for the gun holder
which is suitable for most semi-automatic welding
guns. Gun holder jaws are adjustable from 5/8”
(16 mm) to 1 1/2” (38 mm) *Note: can be supplied
with 1 1/8” (29 mm) or 1 1/2” (38 mm) square clamp. CABLE SUPPORT CLAMP

GK-181-027
Swivel clamp assembly
is readily mounted on
the front or back of the
Semi-automatic KAT® Travel Carriage to
Gun Holder keep cables clear of the
work area. Clamp can
be adusted to provide
approximately 1 3/4”
diameter holding opening
MODEL GK-165-145 (complete unit)... Complete
with standard 1 1/8” (29 mm) I.D. swivel clamp* and
insulated linkage for the gun holder which is suitable
SEAM TRACKER SYSTEM
for most semi-automatic welding guns. Gun holder
jaws are adjustable from 5/8” (16 mm) to 1 1/2”
(38 mm) *Note: can be supplied with 1 1/8” (29 mm)
or 1 1/2” (38 mm) square clamp

IDLER CARRIAGES
GK-171-154
Provides an 8 3/4” x 14
7/8” platform on which
a variety of welding/
cutting equipment can
be mounted and towed
...high precision tracking system that maintain the
individually or in tandem along straight or formed
torch in optimum operating position regardless of
sections of KAT® Track by the Gullco KAT® Travel
variations in the weld seam...providing improved
Carriage. Self aligning retractable wheels enable
quality and efficiency in a wide variety of welding
easy mounting at any point along the track. Load
operations.
capacity is 100lbs.
 WORLD LEADERS IN THE DESIGN,
MANUFACTURE & DISTRIBUTION OF AUTOMATED
WELDING SYSTEMS AND ACCESSORIES
CUT COSTS, IMPROVE QUALITY, AND INCREASE EFFICIENCY WITH THESE PROVEN
GULLCO PRODUCTS

KAT® Systems Moggy® weld prep ovens ceramic backing

• Oscillators • Trackless Fillet & • Bevellers • Flux Rebake • KATBAK® Ceramic

• Torch indexers Butt Welding, Stitch • Positioners • Flux Holding Weld Backing
• Flex & Rigid KAT® Welding control • Grippers • Flux Hoppers • Impart Uniform
Programmable • Radial Oscillation • Kamel Pipe • Electrode X-Ray Quality Back
Travel Carriages Control • Turning Rolls Stabilizing Beads
• Seam Trackers • 6” V-groove Track • Eliminate Costly
• Bridge Units Available Grinding &
• Circle Cutting Re-welds
System • Knuckle Joints for
Use On Flat or
Curved Surfaces

Contact Gullco or your Gullco distributor today for information on any of these products

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE, . ALL DIMENSIONS ARE NOMINAL

KA-11-01
welding and cutting automation

all position cutting carriage - kat®II

This automated welding system* incorporates

everything required to automate your cutting and
welding operations quickly, easily and economically. It
is comprised of the KAT® II Travel Carriage, rigid 8 ft.
(2438 mm) straight track and torch or gun holder
assembly. The carriage travels in a forward or reverse
direction (vertical or horizontal) on its track, moving the
torch or welding gun along the pre-set path at precisely
controlled speeds. The accuracy, uniformity and quality
of the cut or weld is improved with this process.
Productivity is increased, and costs are reduced. It is
important to note that the KAT® II carriage is not
designed to travel on radius roll formed track. (For this
see the KAT® Carriage)

*The carriage and torch holding assemblies are sold

separately.

EASILY CONVERT YOUR KAT® II INTO AN

EXCELLENT CIRCLE CUTTING MACHINE

This Gullco accessory, comprised of an undercarriage,

radius arm and centering pin, eliminates the need for
track. The travel carriage is readily fitted on the top of
the undercarriage. Its drive system engages the

II
undercarriage gears moving the assembly in a forward
or reverse direction at desired cutting speeds along a
perfectly circular path. A slide lock on the radius arm
allows fast, easy adjustment of the circular diameter.

Inexpensive Automation Solution for Cutting and Welding Operations

ALL POSITION CUTTING AND WELDING CARRIAGE

WELDING AND CUTTING

specifications
KAT® II AUTOMATED CUTTING AND WELDING SYSTEM
The Gullco KAT® II Travel Carriage is combined with an
appropriate series of accessories to provide either the Torch
Cutting Package or Welding Package. The following briefly
describes the KAT® II carriage:

KAT® II Carriage– Model GK-189-045

A light duty, all position variable speed travel carriage with Approx. Weight: 17 lbs (7.8 kg)
electronic drive, dynamic braking and speed potentiometer
providing infinite speed selection within the range of 2-45 IPM
(5-114 cm/min.). It is equipped with Forward/Reverse switch,
GK-165-215
Run/Stop switch, slow blow fuse, and “power on” pilot light. The TRACK
carriage is designed to run only on rigid, straight KAT® track. The MOUNTING
DEVICE WITH
carriage has a vertical load capacity of 50 lbs. (23 kg.) ON/OFF
MAGNET
Safety is assured by the use of Gullco’s low voltage, (24 volt CUTTING
TORCH
D.C) highly advanced control and power supply system that is
available in three line voltage inputs: 42, 110, and 230 volt A.C
single phase, 50/60 Hz. Specify line voltage when ordering. GK-165-217
GK-165-052-1 TRACK
KAT® TRACK MOUNTING
GK-189-045 DEVICE
KAT®II WTH ANGLE
CARRIAGE BRACKET
CUTTING OR WELDING TORCH RACK ACCESSORY

welding or cutting torch rack

GK-189-054

WELDING
GUN

MODEL GK-184-200 CIRCLE CUTTING ACCESSORY

Includes Items NOT SHOWN:
Undercarriage: equipped with gear assembly that is engaged
and driven by carriage gear system. This also includes a clutch
that allows free-wheeling during set-up. Radius arm– 36” long
with slide/lock for diameter size adjustment. Magnet/Holder for
centering pin. (not shown in cover photo).

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

KATII-11-01
welding and cutting automation

HYDRAULIC KAT® Automation Carriage

The Gullco Hydraulic KAT® is a heavy duty, all position

automation carriage. It is hydraulically powered and self
propelled in both the forward and reverse direction at
precisely controlled speeds. The Hydraulic KAT® runs
along a special track using self aligning wheels to grip
the top and bottom of the track enabling travel along any
plane.

The bogy wheel assembly keeps the carriage snug

to the track, while allowing it to be easily mounted
and removed from the track at any point. The positive
drive of the KAT® is obtained from either a pinion that
engages with the rack of the rigid track, or a ball drive
gear that engages with slots in the flexible track. These
are driven by a low speed, high torque hydraulic motor
and gear-head power unit assembly.

As the Hydraulic KAT® automation carriage is most

often used in waterjet cutting applications, the KAT®
lower housing and wheel housing assembly are hard
anodized and the mating surfaces are dry lube filmed
for maximum internal moisture resistance. All gears
and metallic parts are plated for added durability and all
carriages are equipped with a lower housing gear cover.

No Electrical Components - Ideal for Waterjet Cutting

ALL POSITION CUTTING AND WELDING CARRIAGE

WELDING AND CUTTING

specifications

Carriage Weight: 23 lbs (10.4 kg)

Vertical Load Capacity: 150 lbs (68 kg)

Hydraulic Supply: 1,000 psi (69 bars) recommended,

with a flow of 4 gpm (18.2 lpm)

Certification: C.E. Certification

MODEL SPEED RANGE TRACK USED

GK-190-H-018 0 - 4.9 in/min (0 - 12.4 cm/min)* Rigid

GK-190-H-036 0.5 - 9.8 in/min (1.3 - 24.9 cm/min)* Rigid

GK- 190-H-090 1 - 26.5 in/min (0 - 19.1 cm/min)* Rigid

GK-190-H-017 0 - 7.5 in/min (2.5 - 38.1 cm/min)* Flexible

GK-190-H-035 1 - 15 in/min (2.5 - 38.1 cm/min)• Flexible

GK-190-H-089 2 - 40.5 in/min (5.1 - 102.9 cm/min)* Flexible

* The speed range given above is based on an oil pressure of 1,000 psi (69 Bars) with a flow of 4 Displacement cu. in./rev. (cu. cm./rev.) .50 (8,2)
gallons per minute (18.2 litres per minute). This is intended only as a guide and greater detail is
provided in the operation manual. Per GPM (3,8 LMP) Theo. 471

Speed (RPM) @ Continuous Flow 2000

@ Peak Flow 2500

Continuous 4 (16)
Flow GPM (LPM)
Peak 5 (20)

Per 100 Δ P (Theo.) 7.8 (0,88)

Torque lb. in. (Nm) Continuous 57 (6,44)

Peak 117 (13,2)

Continuous Δ P 1000 (69)

Pressure PSI (Bar)
Peak Δ P 2000 (138)

360 (24,8) cont.

w/o external case drain
1100 (76) Peak
Back Pressure PSI (Bar)
2000 (138) cont.
w/ external case drain
2500 (172) Peak

ACCESSORIES Weight lbs (kg) 3.5 (1,59)

GK-181-027 - Cable Support Assembly - A raised cable/hose clamp that attaches to the KAT® Δ PSI = True pressure difference between inlet and outlet ports
carriage, with an adjutable swivel clamp, used to reduce cable/hose drag and inteference.
Maximum pressure at the motor inlet port of 2500 PSI (172 Bar) without regard to
GK-166-153 - High Speed Gear Assembly - An external gear assembly is available which can Δ PSI and/or back pressure ratings or combination thereof.
easily be fitted to any of the rigid track KAT® carriages to increase the available speed range by
approximately 266.5%. This is not available for Flex KAT® carriages. Continuous rating = Motor may be run continuously at these ratings

GK-166-169 - Low Speed Gear Assembly - A similar external gear assembly to that above, for Peak operation 10% of every minute
lowering the speed range by approximately 42.6% is also available. This is not available for Flex
KAT® carriages. Recommended Viscosity = 100 SUS (20 cSt) at operating temperature

Other Accessories - The KAT® carriage is designed to incorporate rack boxes and rack box riser Recommended Maximum System Operating Temperature = 180˚ F (82˚ C)
brackets, as well as links for towing idler carriages. See www.gullco.com for more details on these
and other accessories. Recommended Filtration = 10 Micrometer

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

HK-12-01
 welding and cutting automation

track and magnets for the KAT® automation carriage

FLEXIBLE KAT® RIGID KAT®

TRACK TRACK

DEEP SECTION
TRACK

ON / OFF MAGNET ASSEMBLY SELF ALIGNING

MAGNET ASSEMBLY

VACUUM TRACK DEVICE

FORMED RING
CLAMP
A track mounting device for any material
DURABLE TRACK AND MOUNTING DEVICES FOR WELDING AND CUTTING AUTOMATION

WELDING AND CUTTING

gullco rigid KAt® TRACKS
KAT® Track is manufactured in STANDARD SECTION TRACK
“Standard” and “Deep” sections... For use with the Gullco KAT® Travel Carriage Model GK-200 in most portable
each designed to suit a specific range applications. Standard track sections are supplied in 48, 96 and 120 inch (1219, 2438
of applications. Both are made to the and 3048 mm) lengths complete with rack and interlocking ends. Standard track can
highest quality levels and incorporate the be hard anodized and also formed to desired contours by Gullco or the customer. (see
following top performance features: below)
MODEL LENGTH LENGTH
PRECISION EXTRUDED ALUMINUM GK-165-052.....................48” (1219 mm) GK-165-052-1........................96” (2438 mm)
TRACK—made from aluminum that is GK-165-054...................120” (3048 mm)
solution heat treated and artificially aged also available up to 20 ft (6096 mm) long-special order
to produce an alloy having excellent
mechanical and corrosion resistant DEEP SECTION TRACK For use with the Gullco KAT® Travel Carriage in applications
properties. The track is light but strong involving straight permanent runs where greater stiffness is required. Supplied in 60”
and the standard section can be readily and 120” (1524 and 3048 mm) lengths complete with interlocking ends. Deep Section
formed to suit the work contour. Track can also be supplied internally stiffened and hard anodized.
MODEL LENGTH LENGTH
SUPPORTING STEEL RACK—is GK-166-258.......................60” (1524 mm) GK-166-260.................120” (3048 mm)
securely fixed to the KAT® track to also available up to 20 ft (6096 mm) long-special order
provide a smooth, positive drive. The
long-life rack easily supports the Kat
carriage under maximum load when used FORMING STANDARD KAT® TRACK 6. When calculating the “Track Datum Radius”,
in a vertical position. The following information is provided as a guide allowance must be made for the method of fixing
to customers ordering Standard Section track the track to the work. The minimum allowable
END DESIGN—enables any two lengths preformed to the desired contour by Gullco, or to work to “Track Datum” distance (to permit free
of track to mate accurately and, because be formed in their own shop. movement of the KAT® carriage) is 1-1/2”
of symmetry of design, track lengths can (38 mm) and when using the standard magnet
be turned end to end. It is even possible 1. “Track Datum” always refers to the track assemblies this distance is 2-7/8” (73 mm).
to mate standard and deep track sections. surface to which the rack is fixed.
KAT® formed track may be held in position by
FAST, EASY JOINING—a dovetail 2. When the rack is on the outside of the curve, track mounting devices (i.e. magnets, steel
and taper screw that provides accurate the “Track Datum Radius” must be greater than brackets tack welded in position, or vacuum
12” (304.8 mm). cups), or it maybe permanently attached to
location between mating track lengths.
framework alongside the work piece.
The track can be joined in the time
3. When the rack is on the inside of the curve, the
it takes to tighten two knurled thumb “Track Datum Radius” must be greater than 24” If your formed track is of a very permanent nature,
screws. (610 mm). it is often advisable to have a section formed
and stiffened with welded aluminum side plates.
VERSATILE MOUNTING—Both standard 4. Always specify whether rack is on the inside or This gives the stiffness of a deep section track
and deep section tracks have fixing outside of the curve. in a formed shape. This method is often used in
holes on 6” (152.4 mm) pitch along their complete ring sections for cutting or welding large
entire length to provide ample means for 5. Standard formed track lengths are 36” diameter pipes.
mounting or securing brackets. (914 mm) and 84” (2133 mm). This is because the
first 6” (152 mm) at either end of a track cannot be
formed and is therefore removed after bending.

Shown at right are the Round and Square Magnet devices and steel bracket
assemblies used to mount either Gullco Rigid KAT® tracks or Flex-KAT®
tracks on ferrous surfaces. Gullco’s Vacuum Track Mounting system,
described in a separate bulletin, holds KAT® Tracks in position on non-
ferrous and ferrous materials.
MODEL GK-165-215 MODEL GK-165-263
ON/OFF MAGNET ASSEMBLIES - GK-165-215 feature two powerful
Consistis of two (2) GK-165-211 Consistis of two (2) GK-165-211
magnets each with 150 lbs (45 kg.) of holding power and on/off knob for magnets with on/off switch. Track magnets with on/off switch in a self
easy installation. datum height 3-1/8” (79.4 mm) aligning support bar assembly. Track
datum height 3-1/8” (79.4 mm)

SELF ALIGNING ON/OFF MAGNET ASSEMBLIES - GK-165-263 feature

two powerful magnets each with 150 lbs (45 kg.) of holding power and
positive on/off switch. The magnets are mounted in a special self aligning
bracket to allow for use on curved surfaces.

STEEL BRACKET ASSEMBLIES - GK-165-217 are used with magnet

assemblies to provide track stability. They also must be used for added
safety, tack welded to the work surface in vertical and overhead welding
MODEL GK-165-219 MODEL GK-165-217
applications. The models can be used with each of the magenet assemblies.
Consists of one (1) GK-165-211 Consists of 2 steel angle brackets.
Standard brackets are mild steel but are available in stainless steel on magnet with on/off switch, one (1) Track datum height 3-1/8” (79.4
request. steel angle bracket. Track datum mm)
height 3-1/8” (79.4 mm)
gullco KAt® flexible TRACK

KAT® FLEXIBLE TRACK HEAVY DUTY FLEXIBLE

TRACK
Model GK-192-F-054-2

Supplied in 8ft. (2438 mm) lengths. Also available in

custom lengths up to 8 ft. (2438 mm) with interlocking
ends to facilitate complete circles for diameter 60”
(1524 mm), O.D.& I.D. and over.

Other lengths available on request.

Flexible-Track STIFFENER
ADAPTS FLEX-TRACK SECTION FOR USE IN
RIGID TRACK APPLICATIONS

Provides extra stiffness and reduces the number of

magnet or vacuum track mounting devices required.

MODEL GK-192-F-057

Extruded aluminum stiffener for attachment to Gullco

Flexible-Track sections supplied in 8 ft. (2438 mm)
lengths.

Gullco Heavy Duty “Flexible Track” is specifically

designed for use with the Gullco “Flexible
KAT® All Position Travel Carriages as shown in
application at left. Flexible Track is made from
tempered spring steel and can be easily mounted
to conform with curved surfaces. This Flexible
Track can be used in applications involving
curved surfaces 60” (1524 mm) diameter and
greater.
 ON / OFF

RIGID
in. mm.
L 93/8 228.6
extra strong hold H 31/8 76.2

L 103/4 273 103/4 273

H 27/8 73 33/16 81

WEIGHT
Heavy Duty:
GK-192-F-054-2 GK-190-145
1.75 lbs/ft. (2.6 kg/m)

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

TR-11-01
welding and cutting automation

vacuum track mounting system for kat®

The Gullco vacuum mounting

systems are designed to firmly
hold the KAT Rigid and Flex
Tracks in position on ferrous
and non-ferrous materials.
The systems are durable and
dependable while incorporating
a light weight design for
portability. There are Vacuum/
KAT® carriage packages
specifically designed for
automatic welding and cutting
applications.

Quick Setup Time - Lightweight Design - Portable

VACUUM SYSTEM FOR MOUNTING CARRIAGE TRACK ON NON-MAGNETIC MATERIALS

WELDING AND CUTTING

 basic vacuum mounting components

Described on these pages are the vacuum systems

that Gullco makes available for mounting KAT®
Rigid Track and KAT® Flex Track on ferrous and
non-ferrous materials. VACUUM MANIFOLD BLOCK MOUNTING UNIT
Comprised of two vacuum cups, manifold block
The portable vacuum pump for these systems is and mounting pad. The manifold has openings
described below. At right are the basic vacuum at each end and at the centre of each side for
components used in both the rigid and flex track fittings required in assemblies such as hose
mounting assemblies. They are supplied by Gullco connectors, couplings, valves and plugs. Heat
as complete, ready-to-use assemblies or as resistance of the vacuum cup is 450°F for short
individual parts, either for standard lengths of track durations and 350°F continuous. Minimum
or for continuous runs of any specified length. temperature is -40°F.

VACUUM MANIFOLD ASSEMBLIES

Link any number of Vacuum Block Mounting
Units to provide a complete, in-line track
mounting system. The end units are supplied
with appropriate fittings for attachment to the
pump or the next series of mounting units, while
all “in-between” units have hose connectors on
each side.

PORTABLE VACUUM UNIT MOUNTING BRACKET

Model GV-168-050 Comprised of mounting pad, support bar and
Comprised of electric motor driven, 2.4 cfm capacity two stainless steel mounting angle brackets.
vacuum pump mounted on cylindrical safety This component is primarily used to provide
reservoir. Complete with vacuum gauge, filter, non- extra track stiffness to Flex-Track vacuum
return valve, necessary fittings and 10 ft. (3048 mounting assemblies and as tack welded
mm) of flexible hose with quick disconnect coupling. support to provide an extra measure of safety in
*Recommended 3 pieces of GK-165-054 Rigid or applications involving vertically mounted KAT®
GK-192-F-054-2 Flexible Track per vacuum pump. Rigid Track or Flex Track
 for mounting gullco rigid kat® track

Gullco can supply a ready-to-use kit to vacuum ASSEMBLIES FOR MOUNTING STANDARD
mount KAT® Track, providing manifold block LENGTHS OF KAT TRACK
mounting units for mounting on 30” (761 mm)
centers along with all appropriate hoses, fittings, Model GV-168-051-A for mounting 48” (1219mm)
etc. KAT Track comprised of 2 vacuum manifold block
mounting units at 30” (761mm) centers complete
For convenience, three kits are available for with flexible hose between manifolds and male
mounting standard 48”, 96” and 120” (1219, 2438 quick connect couplings for connecting the pump.
and 3048mm) lengths of KAT® Track. They are
described at right. It should be noted that these kits Model GV-168-053-A for mounting 96” (2438mm)
are supplied for use only with the designated track KAT Track- as above, but 3 vacuum manifold block
length. If lengths are to be joined, interconnecting mounting units.
fittings must be ordered.
Model GV-168-070-A for mounting 120” (3048mm)
3 lengths of 120” (3048mm) track can be handled KAT Track as above, but 4 Vacuum manifold block
by on vacuum pump (Model GV-168-050) mounting units.
depending on work surface finish.

VACUUM MOUNTED
HEIGHT KAT® Rigid
Track

Gullco Flex-Track is 8 ft. (2438 mm) and has holes ASSEMBLIES FOR MOUNTING 96” (2438 mm)
for the attachment of manifold block mounting LENGTHS OF KAT® FLEX- TRACK
units and stainless steel mounting brackets. In
some applications, the number of manifold block Model GV-192-F-409 recommended for mounting
units may be safely reduced by using brackets so on the heavy duty flex track, model GK-192-F-054-2
the number of each supplied will vary according comprised of 8 vacuum manifold block mounting
to application requirements. For convenience, units at 12” (304.8 mm) centers when complete
two kits are available for vacuum mounting KAT® with flexible hose between manifolds, intermediate
Flex-Track, one meeting minimum stiffness shut-off valve and male quick connect coupling for
requirements, the other providing standard stiffness. connection to vacuum pump hose.

ASSEMBLIES
FOR MOUNTING
96” (2438 mm)
LENGTHS OF KAT
FLEX TRACK
 vacuum manifold fittings
mounting units

GV-168-083-2 (Blocked End)

Designed for use on the track
section at the end of the vacuum
mounting system run. Equipped
with 1 mounting pad, 2 vacuum FLEXIBLE HOSE
cups, 3 plugs and 1 hose FLEXIBLE HOSE SECTIONS GV-168-072
connector CONNECTOR used in various lengths
GV-168-071 to connect manifold
For interconnecting assemblies. Secured by
vacuum mounted track hose clamps
GV-168-055 (In Between) sections 36” (914mm) long. GV-192-F-076
Designed for use as the “in be-
tween” mounting units in both PLUG
Rigid and Flex Track systems. GF-168-007 for unused
Equipped with 1 mounting pad, manifold openings
2 vacuum cups, 2 plugs and 2
hose connectors.
HOSE CONNECTOR
GV-168-083-1 (Connecting End) GF-168-005
Comprised of manifold block
equipped with 1 disconnect
coupling suited for connection QUICK CONNECT
to end of vacuum pump hose or COUPLING
to connect one track assembly GV-168-009
to a second track assembly.
Equipped with 1 mounting pad,
2 vacuum cups, 2 plugs and 1 QUICK CONNECT
male hose connector. COUPLING
GF-168-010
mounting bracket
Model GV-192-F-410
ON/OFF VALVE
Comprised of
Model GV-192-F-074
mounting pad, support
Used on-line or as
bar and 2 stainless
required in Flex-Track
steel mounting angle
Systems
brackets.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

VS-11-01
welding and cutting automation

Cladding and overlay system - KAT® Indexer

The Gullco KAT® Indexing System is typically used to

automate single or multi-head overlay and cladding welding
operations, hard surfacing, etc. The automatic routine drives a
motorized device (either the KAT® carriage or the motorized
rack arm), cycling back and forth between limit switches. When
the device that is cycling reaches a limit switch, it pauses,
and the other motorized device starts to index the gun/torch
a preset distance in a preset direction allowing for consistent
uniform weld patterns.

An Arc Signal Relay is supplied with the system to provide

integrated arc activation signals to the overlay/surfacing
equipment. Two Gullco Standard Platform (GSP) controls,
each with dedicated microprocessor chips, are used to control
the automatic, two axis indexing system. One GSP control
is the Cycle Control and the other is the Index Control. Each
control offers user programmable parameters and variables to
allow fine tuning and functional control of the automatic cycle.

Gullco Indexing Systems, enable repetitive overlay- surfacing

cycles to be preformed, with precise motion of the gun/torch
from start to finish, regardless of the number of passes of the
work pieces involved.

A Remote Control
Pendants Is Available
When Required

Automates Overlay and Cladding Welding Operations

MODELS AVAILABLE FOR USE WITH RIGID AND FLEXIBLE TRACK SYSTEMS

WELDING AND CUTTING

specifications
Main Components: KAT® Travel Carriage (Flex KAT® for use on Flex or Rigid KAT® Travel Carriage: with microprocessor pulse
flexible track or Rigid KAT® for use on rigid track), KAT® Carriage/ width modulation motor controls offering operator interface of
Indexer controls, Motorized Indexer Rack Box, Heavy Duty Rack forward, stop, reverse and infinitely variable control of the speed,
Arm, Control Cable, Limit Switch activators for Carriage and Rack within the range of the models. Travel speeds of the KAT® and rack
Arm, Torch Holder for standard MIG gun. box are electronically controlled using an optical tachometer on the
back of each gear-motor. Through the use of this closed loop,
Controls: Two GSP controls mounted in the KAT®, each with feedback circuitry, each motor control can obtain accurate and
dedicated microprocessor chips, are used to control the automatic, constant speed control of the equipment when running in any plane,
two axis indexing system. One drives the KAT® carriage; and one regardless of the load (within the rating of the equipment). The
drives the motorized rack arm. They provide: Auxiliary wire feeder length of the KAT® travel path is pre-set by positioning the Track
on/off, 16 Position Switch giving selectable index increments, Stops at each end of the desired path. They engage and activate
Maximum travel of 24” (609 mm) using 36” (914 mm) long rack arm, limit switches on the KAT® Travel Carriage to: automatically stop the
Two Digit Display indicating the time that rack arm will index, KAT® travel carriage and reverse its movement, activate the control that
Carriage Forward/ Reverse Switch and Carriage speed potentiom- indexes the rack arm and signals the welding gun to weld or not weld
eter, rack arm Jog Switch and Left/Off/Right switch, Auto On/Off during indexing.
switch, LED display.
Safety is greatly enhanced by the use of Gullco’s low voltage (24V),
Indexing Motorized Rack Box: Complete with limit switches and highly advanced controls and power supply system. Three line
activators to prevent rack arm overrun, high torque gear motor to voltage inputs, 42, 115 and 230 VAC, single phase, 50/60 Hz, are
provide precise repeatability of the rack arm indexing distance. available (see chart below).
Standard assembly combines heavy duty 8” (203 mm) long rack
box with 1-1/8” (29 mm) sq. x 36 (914 mm) long rack arm. Other
lengths available.

RIGID KAT® AUTO-WELD REMOTE PENDANT

FLEX KAT® AUTO-WELD
MODEL SPEED RANGE CONTROL KIT MODEL SPEED RANGE
L 0.5 to 16.4 IPM (1.2 to 41.6 cm/min) L 0.8 to 25.8 IPM (2 to 65.4 cm/min)
For use with the Rigid and
M 1 to 32.7 IPM (2.5 to 83.1 cm/min) Flexible Track KAT® Indexer M 1.5 to 51.5 IPM (3.9 to 131 cm/min)
H 2.7 to 88.4 IPM (6.7 to 224 cm/min) System. Comprising of Remote H 4.2 to 139.1 IPM (10.6 to 353 cm/min)
Pendant (no control) attached to
Select a speed range and voltage to determine your Rigid KAT® Indexer 8 ft. (843.84 cm) control cable Select a speed range and voltage to determine your Flex KAT® Indexer
Model Number. Model Number.
on one end and KAT® control
VOLTAGES blanking plate on the other end VOLTAGES
MODEL INPUT SUPPLY
with internal connectors at each GK-200-F -A MODEL INPUT SUPPLY
GK-200-R -A
end. This remote pendant uses
A 42 VAC the GSP controls removed from A 42 VAC
B 115 VAC the KAT® Carriage. This kit can be B 115 VAC
easily field installed (or factory installed
C 230 VAC at no charge) C 230 VAC

Remote Control Indexer for Miscellaneous Rotation Equipment

Comprising of one (1) control box with switches for rack arm jog, cycle start and speed potentiometer. Index
distance setting in a range from 0.01 to 9.99 in increments of 0.01. A single limit switch on 15 ft. (4572 mm) cable
to provide 1/8” (29 mm) rack arm 36” (914 mm) long providing 24” (609 mm) of variable speed arm travel
1 to 32.7” (25 to 83.1 cm) per minute with limit switches to prevent rack arm over-travel and to stop the wire
feeder. Two (2) adjustable rack arm limit switch stops and one (1) four-motion welding gun holder.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

IND-11-01
 welding and cutting automation

motorized weld torch positioning assembly

Improve the precision and efficiency of welding and cutting

operations with these Gullco accessories. The motorized rack box
moves the arm to the left or right and up or down when used
vertically on command from a “joystick” equipped control box. A high
speed override switch enables the operator to quickly position the
torch prior to using low speed movement to follow the weld seam.
Two assemblies can be combined to provide remote adjustment
capabilities on both the X and Y axis, both controlled by a single joy
stick. The following components are used to provide assemblies
suited to various applications requirements.

GK-190-214
An 8” (203mm) long, 1 1/8” (29mm) motorized rack box with
adjustable nylastic bearing plugs, mounting holes suited to the
Gullco KAT® carriage, a 24” (610mm) long 1 1/8” (29mm) rack arm
and a 15 ft. (4572mm) control cable with quick disconnect plug for
connection to the pendant control box.

GK-190-217
A 10” (254mm) long, 1 1/2” (38mm) extra heavy duty motorized rack
box with adjustable nylastic bearings plugs, mounting holes suited
to the Gullco KAT® carriage and a 24” (610mm) long, 1 1/2” (38mm)
rack arm with one end turned to 1 1/8” (29mm) diameter. Includes
control cable described above.

GK-190-201
Remote pendant control box for use with either of the above
models. It features a joy stick that gives the operator precise control
Motorized Rack Arm assemblies Compound Motorized Rack Arm Assembly of rack arm movement in either direction, vertically or horizontally.
mounted on KAT® carriage providing applied with support accessory provides The control incorporates direction indicator lights, high speed
both horizontal and vertical motorized horizontal and vertical torch movement.
Typical use for this “mini-torch manipulator
selector switch, and speed potentiometer providing infinite
torch movement.
system” is shown on the reverse side of adjustment of rack arm movement between .5 and 35 IPM (1.27-89
this sheet. cm/ min).

Remote Horizontal and Vertical Torch Adjustments

PRECISION WELD TORCH MOVEMENTS AUTOMATED WITH THIS MOTORIZED POSITIONING ASSEMBLY

WELDING AND CUTTING

 specifications

STANDARD APPLICATION

Gullco Motorized Rack Arm Assemblies provide an

effective, precise manipulator system for positioning cutting
torches or welding guns. A typical application is illustrated
at right:

A Compound Rack Arm Assembly (either Model

GK-190-216 or 218) is shown being used to cut or weld
two sides of a square tube. Using the joy stick-equipped
pendant control (Model GK-190-201), the vertically
mounted box in the assembly moves up the arm to
produce the vertical cut or weld. The arm of the second box
is then extended to produce the horizontal cut or weld.

Compound Assemblies:
Dimensions (per drawing)
Comprised of two motorized rack boxes mounted at right
angles to provide up/down, in/out movement of two 24”
(610 mm) long rack arms. Supplied with two 15 ft.
(4572 mm) control cables.

GK-190-216
As above with 1 1/8” (29 mm) rack boxes and arms.

GK-190-219
1 1/2” (38 mm) rack boxes and arms.
The capacity of these motorized rack arms is 50 lbs. (20.4
kg) load vertical. The extra heavy duty 1 1/2”
(38 mm) arm provides an additional 33% rigidity over the
1 1/8” (29 mm) arm. Safety is assured by the use of
Gullco’s low voltage (24 volt) micro processor based
control system for operation in either 42, 110 or 230 volt
A.C single phase 50/60 Hz power supply. Specify voltage
when ordering.

A B C D E F Limit switches and longer rack arms and control cables

are available on request. Gullco motorized rack arms
in. mm. in. mm. in. mm. in. mm. in. mm. in. mm.
can be readily adapted to any existing welding fixture
3 76.2 203.2 2 3/4 69.85 7 3/8 187.3 2 50.8 1 1/8 28.57
for operations requiring infinite precise adjustment of the
8

3 76.2 10 254 2 3/4 69.85 7 7/8 200 2 1/2 63.5 1 1/2 38.1
welding gun position.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

MR-11-01
 Gouging System welding and cutting automation
KAT® Rigid Track Carriage - GK-200-RHB-N
Heavy-duty self-aligning wheel assemblies, closed loop tack feed-back for accurate speed
control when running in any plane, regardless of load. (Maximum 100 lbs.) (45 kgs). The
carriage is controlled by the Gullco low voltage 24 volt GSP microprocessor pulse width
modulation motor control, interfacing with the forward/stop/reverse switch and infinitely
variable 4-turn speed potentiometer. The LED display is in IPM or cm/min. The motor control can be ARCAIR-MATIC N7500 GOUGING SYSTEM
upgraded to provide auto forward/reverse, limit switches and auto wire feed start.

Heavy-Duty Rack Box - GK-171-686

4” (101.6 mm) long with adjustable nylastic bearing plugs, for 1-1/8” (29 mm) square rack arm, with 3/8”
threaded stud with 1-1/8” (29 mm) swivel clamp.
The Arcair-Matic® N7500 gouging system is
Heavy-Duty Rack Box - GK-171-650 highly productive for any metal fabrication
6” (152.4 mm) long with adjustable nylastic bearing plugs, for 1-1/8” (29 mm) square rack arm. operation where gouging and welding
represents a large portion of the work
18” (457.2 mm) long heavy duty 1-1/8” (29 mm) Square Rack Arm - GK-171-047-2 schedule. This applies to almost all metals,
With rack and both ends turned to 1-1/8” (29 mm) diameter. including stainless steel, carbon, manganese,
10-1/4” (260.3 mm) long 1-1/8” (29 mm) Square Rack Arm - GK-171-047-10.25 and chrome-moly steels.
With rack and one ends turned to 1-1/8” (29 mm) diameter.
All functions can be controlled, from
Gouging Torch Adaptor Stud Attachment - GK-200-017 determining gouge parameters, start/stop
The adaptor stud is used to facility the mounting of the gouging head to the rack arm.
function, travel delay, and the capability
to manually feed or retract the electrode
Gouging Torch Adaptor Stud Attachment - GK-200-017 in the Torch Head. The operator can view
The adaptor stud is used to facility the mounting of the gouging head to the rack arm.
the amperage and voltage during gouging
sequence easily while maintaining the
Gouging System Optional Accessories electrode on the weld seam that’s being back
Rigid Track Idler Carriage - GK-171-154 gouged.
Complete with heavy duty self-aligning wheel assemblies providing 8-3/4” x 14-7/8” (222 mm x 378 mm)
flat surface for mounting equipment and can be towed behind a KAT® Travel Carriage. A single electrode contact shoe assembly
(complete with a towing kit).
accepts a full range of jointed electrodes from
Rack Box Riser Bracket - GK-190-066 5/16” (7.9 mm) through 3/4” (19.1 mm).
Provides an adjustable mounting surface – 2” (50.8 mm), 4” (101.6 mm) or 6” (152.4 mm) above the
normal KAT® Carriage Rack Box mounting surface. System complete with mounting screws and can
accommodate both rack boxes. Models GK-171-650 heavy duty 1-1/8” (29 mm) and GK-190-650 extra
heavy duty 1-1/2” (38 mm).
Five Times Faster, Ten Times Less Grinding
Cable Support Assembly - GK-181-027
Provided with a swivel cable clamp for mounting on KAT® Carriage to prevent cable drag. INSURE QUALITY AND CONSISTENCY WITH PRE-SELECTED GROOVE DEPTH

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

WELDING AND CUTTING

N7500-12-01
 Arcair®, an industry leader in air
KAT Carriage System
®
carbon-arc products, introduces the
‘‘ Designed to operate on rigid or flexible Arcair-Matic® N7500, a new and Complete N7500 System
track
improved automatic gouging system Includes Remote Pendant, Control Box
‘‘ Provides precise control of the that provides versatility, flexibility and Torch Head (Part No. 65-991-015)
application parameters
and safety features built with an
‘‘ L.E.D Display for easy visibilty of the enhanced gouging function. Combined
application parameters during operation
with the KAT® Automated Carriage
‘‘ Can be adapted for both Welding and further improvments to productivity,
Cutting applications
consistancy and quality are achieved.

Covering a broad range of applications,

Digital LCD Remote this automated gouging system can be

utilized on almost all metals, including

Pendant stainless steel, carbon, manganese,

and chrome-moly steels. It is perfect
‘‘ Ease of use – start/stop function, travel
delay, electrode diameter for work with pressure vessels, wind
‘‘ Rough machining feature to stall the feed towers, shipbuilding, railroads, bridge
of the electrode to compensate for pitted and girder manufacturing,
area or out-of-round steel rolls, thereby
maintaining the concentricity of the shaft/
and with heavy equipment used in System Cable Assembly Options*
mining industries.
roll
120V AC Power Supply Cable Motor Cable Assembly DC Power Cable
‘‘ “Travel delay” function assures excellent As a bonus feature, use the remote Part No. Description
Part No. Description Part No. Description
groove geometry at the very beginning of pendant to track actual arc time to
the groove, thereby eliminating the need 96-130-304 10 ft (3 m) 96-130-335 3 ft (0.9 m) 96-130-254 4 ft (1.2 m)
for a starting pad help schedule routine maintenance;
additionally, it enables you to monitor 220V AC Power Supply Cable 96-130-336 15 ft (5 m) 96-130-256 15 ft (5 m)
‘‘ Shock-absorbent bumper 96-130-337 25 ft (8 m) 96-130-300 25 ft (8 m)
and manage cost of the gouging project Part No. Description
‘‘ Patent Pending 96-130-338 50 ft (15 m) NOTE: Minimum 2 Power Cables
/ job. 96-130-305 10 ft (3 m)
Required
Pendant Cable Assembly Power Supply Communication
The remote pendant is enclosed in a Air Hose Assembly
Cable Assembly
Torch Head splash-proof panel design to operate
in high humidity/outside conditions and
Part No.
96-170-069
Description
14” (0.36 m) Part No. Description
Part No. Description
‘‘ Redesigned Torch Head with an 94-396-051 4 ft (1.2 m)
withstand impact from a distance of 96-170-070 15 ft (5 m) 96-130-339 15 ft (5 m)
extended front end – gives the operator 94-396-049 15 ft (5 m)
better view of the weld seam that's being three feet. 96-170-071 25 ft (8 m) 96-130-340 25 ft (8 m)
94-396-048 25 ft (8 m)
back-gouged 96-170-072 50 ft (15 m) 96-130-341 50 ft (15 m)
*Must be ordered separately
‘‘ Can be oriented 360 degrees in any The Arcair-Matic N7500 can be used
direction giving flexibility to fit the with CC/CV power supplies available in

N7500 Assembly Set-Up

application the industry. It utilizes the contactor in
the welding power supply unit thereby
eliminating the need for the external AIR HOSE
COMMUNICATION
CABLE REMOTE

N7500 Gouging System

JOG
TRV
POWER
contactor used in prior models.

START
Automatic Control
POWER SUPPLY PENDANT CABLE
SUPPLY

TUNE

ROUGH

STOP
OK
Digital Circuitry One unit can service both US (120VAC)
and International (220VAC) markets.
AIR OUT PENDANT TORCH HEAD
MOTOR
CABLE
CONTROL BOX
REMOTE
PENDANT

Control Box
TO TORCH HEAD

As a safety feature, “NO CURRENT” AIR INLET

‘‘ Redesigned digital circuitry control box

THESE CONNECTIONS
AIR LINE

ON OTHER SIDES
INCOMING
detect and low voltage functions that
‘‘ A synergic mode ensures conformity to AIR REGULATOR TORCH
shut down the system when these HEAD

N7
50
pre-determined, pre-selected groove depth

0
DC POWER CABLE (+) IN (Rear panel assembly
not shown for clarity)

and width specifications conditions are sensed. These functions AC POWER CABLE DC POWER
CONTROL BOX INPUT CABLE
ensure optimum groove quality and (+) OUT
MOUNTING
120V FIXTURE
OR CONTROL BOX
prevent damage to the equipment and 220V (VIEWED FROM CABINET RIGHT SIDE)
SIGNAL WIRE

work. GROUND CABLE (–)

WORK PIECE
welding and cutting automation

orbital pipe welding system - Pipe Kat®

Carriage System Includes:

• Linear Oscillator
• Motorized Width Adjustment
• High Deposition Rate
• Simple Setup
• Easy to Use Controls
• High Speed Positioning
(120 IMP / 3048 mm/min)

PK-200-B 115 Volt Model

PK-200-C 230 Volt Model

Increase pipe welding production and quality with this automation carriage
AUTOMATED PIPE WELDING SYSTEM WITH INTEGRATED WIRE FEEDER

WELDING AND CUTTING

 30.7in (780mm)

29.5in (750mm)

10lb. Spool

10.6in (270mm)
12in (305mm)

.8in (20mm)

The PIPE KAT® comes with a wire

spool 10 lb. capacity (4.5 kg) and can
support any wire between 0.8 mm
and 1.6 mm. System comes stan-
dard with (1.2 mm standard). With
a wire feed speed of 36 - 633 IPM
(88 - 1608 mm/min). The PIPE KAT®
is one of the most efficient ways to
weld depositing 6 lbs. (2.7kgs) of
weld per hour.

7.6in (194mm)
4.5in (114mm)

The Gullco PIPE KAT® is a practical, affordable alternative to manual welding of heavy wall pipes 10” (254 mm) O.D
and up. It produces x-ray quality welds with robotic consistency and precision, making it ideal for pipeline on-site work.
The PIPE KAT® versatility allows it to work with various power sources, keeping overall costs low while still providing
welds that meet code requirements. Total carriage weight less wire spool 42 lbs. (19 kgs). The unit is mounted on pipe
by means of quick mount pipe band, which is available for all standard and custom pipe diameters. The welding torch
is mounted on one side providing full open access to the weld joint area. The PIPE KAT® can be easily converted for
straight line welding on tanks, shipbuilding, etc.

EASY STORAGE AND MOBILITY– PROTECTIVE CASE

The PIPE KAT® is shipped in a moisture resistant protective case which will protect the
carriage and ensure that all of the components are kept secure. The PIPE KAT® and all
of its components are protected by dense reusable foam, making it easy to both remove
and replace the carriage and its accessories after the welding has been completed.
(Shipping weight 145 lbs / 70 kgs including carriage)

QUICK INSTALLATION TRACK DESIGN

The PIPE KAT® Orbital Welder uses a track

design which utilizes a quick release band
attachment to greatly decrease set-up time
and improve the stability of the carriage
during welding. Pipe bands are available
from 10” (254 mm) outside diameter or larger.
 10in (25.4 cm)
PIPE
OUTSIDE DIAMETER
AND UP*

* ABOVE PICTURE ON 24in (61cm) PIPE

The PIPE KAT® unique design allows it DETERMINING THE PIPE BAND PART NUMBER
to weld pipes as small as 10”
(254 mm) O.D up to and including flat, PB
horizontal or vertical welding. The PIPE
KAT® is equipped with a linear oscillator.
With the integrated wire feeder unit and Actual outside diameter of the pipe
the carriage incorporates 2.2 – 40 IPM (example: 24 1/2 = PB - 24.50 STAND OFF SIZE
(5.6-1016 mm/ min) welding carriage
design with quick action mounting for A B C D E F G
ease of installation. The carriage is 3/4” 1” 1 1/2” 2” 2 1/2” 3” 3 1/2”
equipped with a high speed return (19.0mm) (25.4mm) (38.1mm) (50.8mm) (63.5mm) (76.2mm) (88.9mm)
feature for fast repositioning. A linear
oscillator with adjustable weave width
joint centerline adjustment and motorized vertical slide. All motorized functions incorporate jog settings. The system
comes with a main control box on 25 ft. (7620 mm) of umbilical and remote pendant with 35 ft (10.5 m) of cable. Wire
feed spool capacity of 10 lbs (4.5 kg) with a wire speed range of 36-633 IPM (88-1608 mm / min). Wire size range
from 0.8 mm to 2 mm. The welding torch uses standard consumables.

CUTTING ATTACHMENTS
AVAILABLE

The PIPE KAT® is a versatile

carriage and can be modified in
order to complete cutting
applications. Using our rack box
and rack arm system the PIPE
KAT® is able to make clean precise
cuts whether it is flame bevelling or
horizontal cutting.
 REMOTE HAND PENDANT

WIRE FEED WELD VERTICAL

AUTO CYCLE
SPEED TRIM ENABLED / SLIDE
STOP L.E.D
OVERRIDE DISABLED ADJUSTMENT

CARRIAGE
WELD SPEED
OSCILLATION
TRIM
CENTER
OVERRIDE
POSITION
ADJUSTMENT
CARRIAGE
JOG
OSCILLATION
WIDTH
weld samples EMERGENCY ADJUSTMENT
STOP
BUTTON AUTO CYCLE
STOP PUSH
HOT PASS BUTTON
WIRE
FEED
AUTO CYCLE AUTO CYCLE
2nd PASS JOG
INDICATOR START PUSH
L.E.D BUTTON

3rd PASS

WELD TORCH AND WIRE INFORMATION: Remote pendant on 35 ft. (10.6 m) of cable incorporates
The welding torch uses standard consumables, Bernard, carriage speed and jog, wire feed speed and jog, vertical
Tregaskis or Binzel, air cooled or water cooled. Wire feed 10 lb. slide adjustments, oscillation width and centerline
(4.5 kg) spool capacity. Maximum wire speed of 36 - 633 adjustment with start/stop and emergency stop buttons.
(88 - 1608 mm/min) with a size range of .8 to 2mm Optional extensions cable 15 ft. (4570 mm).

GULLCO PIPE KAT® CARRIAGE CONTROL CARRIAGE CONTROL

Includes:
• Motorized Width Adjustment
• High Speed Return
• Motorized Weld Head Joint Positioning
• Motorized Vertical Slide
• High Speed Carriage Jog
• Up/Down Jog Switch
• Wire Feed Jog
• Weld Enabled / Disabled Switch
• Auto Start Warning Buzzer

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

PK-11-01
welding and cutting automation

Orbital welding carriage - Pipe kat® - Rigid Track

Carriage Features and Benefits Include:

• Linear or Radial Oscillation

• Remote Voltage Adjustment
• Motorized Width Adjustment
• High Deposition Rate
• Simple Setup
• Easy to Use Controls
• Gas or Water Cooled Models
• Upto 2.5” (6.35 cm) Oscillation Width

PK-500-LG/Rg - Gas/air cooled

PK-500-Lw/RW - water cooled

Self Contained Orbital Welding System

AUTOMATE AND IMPROVE PIPE WELDING AND ORBITAL WELDING APPLICATIONS

WELDING AND CUTTING

 The Pipe KAT® is a pipe welding carriage designed
for orbital welding. It is an electrically powered track
guided carriage that operates in the forward or reverse
directions at precisely controlled speeds. The carriage
operates on a track band made of durable aluminum
extrusion by engaging the track with self-aligning
wheels and a rack and pinion drive. This wheel
assembly uses a lever to engage that track making it
very quick and simple to install the carriage.

The Pipe KAT® is a fully integrated welding system

which comes with a wire feeder and wire spool holder.
SPECIFICATIONS: Driven by a 24 VDC motor which feeds wire to the
welding torch at precisely controlled speeds. The wire
Carriage Weight: 48 lbs (21 kg) spool holder accepts standard 8”/10 lbs
(20.3 cm/4.5 kg) spools.
Control Box Weight: 30 lbs (13.6 kg)

Power Requirements: 42, VAC, 115 VAC, 230 VAC A remote control pendant is provided to allow adjust-
Models available. Power consumption = 400 watts ment of the critical application parameters during the
welding process including, oscillation width, speed,
Carriage Travel Speed: 1.35” - 44.2” (3.42 cm - 112.27 dwells, wire feed speed and voltage adjustment.
cm) Per Minute

Torch Adjusment: +/- 10˚

CARRIAGE ACCESSORIES
Oscillation Speed: 0.5” - 140” (1 cm - 355.6 cm) Per
Minute CARRIAGE UMBILICAL

Dwell Times: 0 to 9.9 seconds 25ft (7.6 m)

Carriage Umbilical
Manual Slide Adjustment: 3” (7.62 cm) Vertical Extension Assembly

PK-500-163-G
Motorized Torch Adjustment: 2” (5.08 cm) Vertical PK-500-163-N
PK-500-163-W
Oscillation Width Adjustment: 4” (10.16 cm) total slide
adjustment. Max. oscillation width of 2.5” (6.35 cm)
WATER COOLER POWER
Welding Spool Size: 8”/10 lbs (20.3 cm/4.5 kg) INTERFACE KIT

Interface allows control

Operating Temperatures: 0 to 60˚C (32 - 140˚F) to automatically activate /
deactivate water cooler during
Wire Feeder Drive Rolls: 0.8 mm to 1.6 mm V-groove auto-cycle. Toggle switch
wheels, 1.0 mm to 2.0 mm V-groove knurled wheels included for manual override.
(1.0/1.2 mm V-groove knurled comes standard, see chart
on reverse for available options) PK-200-216-A 42V
PK-200-216-B 115V
PK-200-216-C 230V
Carriage Umbilical: 25 ft. (7.6 m) in length and protected
by a 500˚C (932˚F) rated cover. Contains torch power
cable, shielding gas hose, carriage power cable, arc start FLOW SWITCH KIT
cable, and water hoses if equipped
Flow switch is used to monitor
coolant flow to welding torch.
Compatible Welding Processes: All standard CV & CC
processes, MIG, TIG, Pulse PK-500-177

Comes with Pipe KAT® Waterproof Carrying Case

made by Pelican PENDANT EXTENSION CABLE

15 ft (4.6 m) Extension Cable.

PK-200-368
 CARRIAGE CONTROL LAYOUT

REMOTE HAND PENDANT CARRIAGE CONTROL

CARRIAGE WELDING WIRE FEED

WIRE FEED SPEED TRIM
WELD SPEED VOLTAGE JOG
TRIM OVERRIDE CONTROL OVVERIDE

CARRIAGE WELD
JOG ENABLED/
DISABLED

OSCILLATION
WIDTH TORCH SLIDE
ADJUSTMENT JOG

OSCILLATOR
EMERGENCY
The Remote pendant (left) is used in conjunction with the
CENTER
STOP POSITIONER main control (right) to provide adjustment during setup,
ADJUSTMENT initiate the weld cycle, provide fine adjustment during
RED & GREEN welding, and to stop the weld cycle.
L.E.D.s AUTO CYCLE AUTO CYCLE
START PUSH STOP PUSH
BUTTON BUTTON
The remote pendant is supplied with a 35ft
communication cable that connects to the right side
panel of the PIPE KAT® Main Control.

Pipe Band Ordering information

PB-500- -

Pipe Outside Diameter (inches) Stand-off Height (inches)

(2 Decimal Places) Standard = 1.75” (4.45 cm)
up to 6.00” (15.24 cm)
(2 Decimal Places)

EXAMPLE 1:
If the Pipe Outside Diameter (O.D) is 22.357” with a stand-off of 3.5” the part
number will be: PB-500-22.38-3.50

EXAMPLE 2:
If the Pipe O.D is 24” with a standard stand-off the part number will be:
PB-500-24.00-1.75

NOTE:

- Stand-off heights over 1.75” (4.45 cm) require spacers. Min. spacer height of 0.50” (1.27 cm)
- All stand-offs are adjustable to +/- 0.157” (4 mm) using the 5 mm allen tool
- Min. ø Track Datum = 17.5” (44.45 cm) [ø Track Datum = ø pipe + (2 x Stand-off Height]
- Max. ø Track Datum = 60” (152.4 cm) [Consult Factory For Larger Dimensions]

Adjustable Track
Quick Installation Track Band: Mounting Pads:

The hinged design of the Pipe The Pipe KAT® band

KAT® track band makes comes with stand off pads
installation simple and quick. which allow for +/- 0.157”
(4 mm) of adjustment.
 PK-500-LG/RG PK-500-LW/RW
For use with gas/air cooled welding torch necks and For use with water cooled welding torch necks and
consumables. Additional items are required. consumables. Additional items are required.

BINZEL
Air Cooled BINZEL
PP 36 D -Torch Water Cooled
Uses MB 36 Consumables PP 401 D -Torch
(See Drawing PK-200-270-03) BERNARD BERNARD TERGASKISS Uses MB 401 Consumables
Air Cooled Air Cooled Air Cooled (See Drawing PK-200-270-01) BERNARD BERNARD TERGASKISS
Uses Large Centerfire, Uses Small Centerfire Uses Tough Lock & Water Cooled Water Cooled Water Cooled
HD Centerfire Consumables Consumables Conventional Tip Consumables Uses Large Centerfire, Uses Small Centerfire, Uses Tough Lock &
(See Drawing PK-200-270-06) (See Drawing PK-200-270-05) (See Drawing PK-200-270-07) HD Centerfire Consumables Consumables Conventional Tip Consumables
(See Drawing PK-200-270-06) (See Drawing PK-200-270-05) (See Drawing PK-200-270-07)

wire feeder roll ordering specifications

PART # DESCRIPTION QTY.
PK-200-035-10 Feed Roll V-groove 0.8 mm + 1.0 mm 2
PK-200-035-12 Feed Roll V-Groove 1.0 mm + 1.2 mm 2
PK-200-035-16 Feed Roll V-Groove 1.2 mm + 1.6 mm 2
PK-200-035-12-K Feed Roll V-Groove 1.0 mm + 1.2 mm Knurled 2
PK-200-035-14-K Feed Roll V-Groove 1.2 mm + 1.4 mm Knurled 2
PK-200-035-20-K Feed Roll V-Groove 1.6 mm + 2.0 mm Knurled 2

*The Pipe KAT® has a selection of feeder rolls avaiable for different requirments.
The Pipe KAT® comes standard with PK-200-035-12

Pipe Kat® Part Number Configuration

OSCILLATION

PK-500- MODEL
L
TYPE
LINEAR
R RADIAL

TORCH TYPES VOLTAGES*

MODEL DESCRIPTION MODEL INPUT SUPPLY
G Gas/Air cooled torch - Binzel, Tregaskiss and Bernard A 42 VAC
W Water cooled torch - Binzel, Tregaskiss and Bernard B 115 VAC
H Water cooled torch - Dedicated Binzel torch C 230 VAC

* All above voltage supplies are single phase, 50/60 hz, 400 watts
KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

PK-12-01
welding and cutting automation

automated oscillation welding carriage - KAT®

Ideal for heavy fabrication industries

such as: Shipbuilding, Tank Welding,
Pipeline and Bridge Construction

Motorized weld center line adjustment

Motorized stroke width adjustment

Precise oscillation speed control

Stores up to 10 different weld programs

for quick recall of frequently used
processes

Linear or Radial Oscillation Capability

ALL POSITION WELDING AND CUTTING AUTOMATION CARRIAGE

WELDING AND CUTTING

 Models For All-Positions, Flat or Curved Surface Weld Oscillation

The Gullco KAT® Oscillator Package is comprised of the compact oscillator head, controls, mounting
brackets, connecting cable, 1-1/8” heavy duty micro fine rack boxes with rack arms for horizontal and
vertical adjustments and standard MIG gun holder, together with a KAT® carriage for rigid track or flex
track as shown above.
Model Series GK-200-F (left) is supplied Model Series GK-200-R Combo (right) is
with a Gullco KAT® specifically designed supplied with a KAT® specifically designed
for operation on spring steel KAT® Flexible for operation on rigid aluminum KAT® track.
Track.

All are equipped with the Gullco microprocessor-based programmable control with a closed
loop feedback system for complete speed accuracy regardless of load [0-100 lbs. (45kgs)]
when operating in any weld position.

Detailed information is provided on the back page of this brochure.

Also Available Are The Linear or Radial Separate

Remote Controlled Compact Oscillator Assembly -
Model GK-201-100-RC

This assembly is comprised of either radial or linear

Oscillator Head with MIG gun holder, Remote Control
Box, Control Cable (up to 20ft), Micro Fine Rack
Boxes, Rack Arms, and Brackets. It can be mounted
on existing KAT® All-Position Travel Carriages,
Welding Head Manipulators, Side Beam Carriages,
etc.
 TANGENTIAL / SCRIBING
TORCH MOTION

LINEAR PENDULUM
TORCH MOTION TORCH MOTION

TANGENTIAL AND PENDULUM

OR LINEAR MOTION
The oscillator heads are capable of producing three distinct
motions when mounted in either the horizontal or vertical
position. Shown in the above (right) is a tangential or scribing
motion. The other, (middle) is a pendulum motion. Combined
with the third linear straight line head they meet all welding
oscillation requirements.

MOTORIZED
CENTRELINE ADJUSTMENT The proper torch angle/position is established quickly
With independent, electronically and easily with the Gullco KAT® Oscillator Head.
controlled dwells (0-5 sec.) at each It’s simply a matter of tilting the oscillator, which can
end of the stroke and at the centre be adjusted side to
of the stroke path. side or forward and
backward this results
in the elimination of the
MOTORIZED STROKE WIDTH - Easy, precise adjustment
time consuming and
to provide the required weld pattern.
generally ineffective
procedure of tilting the
OSCILLATION SPEED CONTROL- Oscillation speed is
carriage or track.
electronically controlled by a speed potentiometer (140
inches per minutes (linear) 45˚ per second (radial).

Combining High Precision With Exceptional Versatility

High precision, state-of-the-art controls on the KAT® LED display in IPM or cm/min. The oscillator controls
carriage automatically direct the desired forward/reverse enable pre-setting of the carriage delay/start after wire
movement or dwell of the welding gun and its oscillation feed start, dwell times, stroke speed, stroke width,
motion to produce the numerous weld patterns shown program storage and cycle start.
below. The carriage control enables the carriage speed and
direction to be pre-set and shown on its Control information is available on the following page

Some of the Weld Patterns Attainable With the KAT® Oscillator System

ANGULAR OSCILLATION PATTERN STEP OSCILLATION PATTERN

KAT CARRIAGE TRAVELS CONTINUOUSLY KAT CARRIAGE TRAVELS ONLY DURING END DWELLS
 oscillator control RADIAL OSCILLATOR

DIGITAL
DISPLAY

This advanced oscillation package is designed to

increase production and improve the quality of the
weld produced in automatic mechanized welding
ARC START operations by minimizing weld defects such as poor
CONTROL penetration, incomplete fusion, overlap and undercut.

The GK-200 Series Compact Oscillator Carriage

combination comes with the option for linear or radial
oscillation head and can be equipped for use on either
rigid or flexible track.
STORE UP
TO 10 The oscillator is available with a linear, pendulum, tan-
PROGRAMS gential or step (square pattern) motion to the welding
gun with adjustable motorized stroke width, infinitely
variable stroke speed adjustment, three independent
position dwell times, motorized centre line position-
ing and automatic wire feed start and travel start/stop
MOTORIZED
interface.
WIDTH
ADUSTMENT
By combining welding gun oscillation movement with
the precision controlled travel speed of the Kat
carriage, up to 10 weld programs can be produced
and stored.
LINEAR OSCILLATOR
MOTORIZED
CENTERLINE
POSITIONING

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

OSC-11-01
 ®

Product Application File

Flex Kat Oscillator Combo &
KATBAK Ceramic Weld
Backing
For Sphere Welding

the Flex Kat carriage travel

speed/direction and the weld
gun movement/ operation. This
enables pre-setting of stroke
speed, oscillator and carriage
dwell times and carriage delay/
start after wire feed start.
When combined with the preci-
Gullco Flexible Track Kat Oscillator Combination & sion controlled travel speed of
KATBAK Ceramic Weld Backing Enable the Kat carriage, a wide range
“Single-Sided” Welding Of Spheres. of weld patterns can be pro-
duced. Gullco KATBAK
K ohimo Co. was able to
reduce production time and
improve weld quality in the
steel in Estonia. The method
used in order to reduce produc-
tion cost was single side weld-
Ceramic Weld Backings
enabled X-ray quality root
welds in one pass, full penetra-
production of spheres using ing, 60 deg. Incl angle 4-5 mm
tion welding from one side and
Gullco products and technolo- gap 2 mm root-face using 1.2
uniform backbeads of finish
gies. In this project Kohimo mm flux cored wire.
quality. Inside the sphere,
was manufacturing 18 m. diam-
strong backs were used with
eter spheres from 20 mm. thick Gullco Flex Kat Oscillator
cut-outs in them ...allowing
Combination units
running on flexible
Kat Flex Track
were used to per-
form the weld oper-
ation. This Gullco
equipment com-
bines welding gun
oscillation move-
ment with precise
travel speed to pro-
duce a wide variety
of angular and step
weld patterns. The Above: Gullco Flex Kat Oscillator
integrated control Combination runs on Gullco flexible track
Above: The top of the sphere is “tented” to protect from wind system directs both held in position using magnetic mounting
and rain during construction of the spheres. assemblies
 Katbak Below: Strong backs with cut outs for KATBAK ceramic weld backings
ceramics to are used to provide 100% X-ray quality weld from one sde.
be applied
through.
The use of Gullco KATBAK
These strong
can significantly reduce weld
backs main-
costs by eliminating the need
tained the
for costly grinding, gouging
shape of the
and re-welding.
sphere so
that 100%
weld penetra-
tion could be maintained. Above: Gullco KATBAK with self-adhesive
tape fits through cut outs in the strong backs.
The use of KATBAK in this application
Two Gullco Flex Kat Oscillator enabled single sided welding (below) on the
Combination units were mount- outside of the sphere...resulting in the root
ed on a single flexible track side of the joint inside the sphere (right)
being as good as the outside.
working into the middle of the
same joint. This, combined with
the placement of Gullco 1G93-
R Katbak ceramics on the
inside of the vessel increased
the quality and improved effi-
ciency of the weld. This process
resulted in the root side of the
joint being as good as the out
side with no defects and very
few stops and starts in the joint.

KAT, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

Distributed by:

BULLETIN Gull-PAF-SPHERE-0705
 ®

Reprinted and Amended AUTOMATION AT SWAN HUNTER

From
Welding Design & Fabrication IMPROVES QUALITY AND EFFICIENCY
September 2003

Swan Hunter (Tyneside) Ltd. of production processes and identify

Wallsend, UK are in the process of areas where automation could be
building two Alternative Landing utilized.
Naval ships for the Royal Fleet During this process, weld prep and
Auxiliary. When complete, the automated welding/cutting equip-
ships will transport troops, stores ment manufactured by Gullco
equipment and vehicles world- International was selected for sev-
wide and deploy them into battle. eral areas of production on their
They will also be suitable for dis- ships. Gullco is known throughout
aster relief and other humanitarian the world as a leader in the design
missions. and manufacture of reliable, cost
One of the main challenges faced reducing welding and cutting
by Swan Hunter in this £140M equipment.
project is to maintain high quality The highly versatile KAT travel
standards while at the same time carriage system was selected for a
reducing manufacturing costs and variety of applications including
meeting tight delivery schedules. Gullco Kat Travel Carriages are used
positional cutting. It was found
In order to meet these challenges, extensively to produce quality welds in all
positions at the Swan Hunter Shipyard. that, in this application, the KAT
Swan Hunter had to review their Coupled with Gullco Oscillators, these
was able to produce cuts equal to
units produce high quality mechanized
welds in good production times. those preformed on “ground
based” equipment. The benefit of
the Gullco KAT is that it allows
these quality cuts to be made in any
position, including horizontal, ver-
tical, and overhead. This greatly
enhanced efficiency as cutting was
easily integrated into the ship
building process. Gullco KATs are
also used for a wide variety of
multi positional welding applica-
tions. Outfitted with Gullco
Oscillators, these units provide
high quality mechanized welds in
all positions, including overhead.
This greatly reduces production
times while improving the quality
of the welds. Swan Hunter also
Alternative Landing Naval Ship under construction at Swan Hunter Tyneside
took advantage of the efficient
Ltd. shipyard in Wallsend, England. When complete the ship will have an over- Gullco Moggy trackless fillet
all length of 176.6 m, a 26.4 m beam and deep displacement of 16,000 tons.
 Swan Hunter & Gullco cont’d

welding machine in their stiffener

welding operations. These units
save hours of welding time and
improve weld quality.
Plate edge preparation was anoth-
er area of production that Swan
Hunter was able to incorporate
Gullco Technology. They decided
to use Gullco GBM-18 high speed
portable plate edge beveling
machines. This decision was based
Single sided welds were possible in many weld operations through the use of
on the GBM-18's ability to “cold Gullco KATBAK ceramic weld backings. This improves weld quality and
cut” edge bevels, saving time and reduces weld time by as much as 50%.
eliminating heat input to the
plate...improving weld quality. ceramics for use. The product International continue to find new
This feature of the GBM-18 elimi- more than pays for itself as it ways of improving quality,
nates any heat affected zone that enables high quality, single sided reducing production time and
could be “hardenable” preventing welding...producing x-ray quality adding efficiency in these ship
potentially disastrous results in the back beads without costly grind- building projects.
welding of critical structures. The ing, gouging and re-welding.
To date, Gullco equipment has
unit is operated by one man and is KATBACK’s radiused edges
proven to be very effective at the
quiet and vibration free. enable use on flat or curved sur-
Swan Hunter shipyard and at other
faces.
“Every modern” shipyard is now ship building operations around
Swan Hunter and Gullco the world.
using ceramic weld backings in
order to aid in weld quality and
facilitate single sided welding.
They chose Gullco “KATBAK”

Above: Stiffener welding using Gullco

Moggy trackless fillet welding
machines.

Left: Capping pass weld using Gullco Gullco series of GBM Plate Edge
Kat Oscillator Combination. Bevellers provide clean machined
bevels in preparation of welding.

Distributed by

BULLETIN PA-SH0604
 ®

Product Application File

“KAT” Welding Oscillation In
Shipbuilding Environment

(PE) to the vertical (PG) position. The conti-

nuity of the weld is achieved using a flexible
track. The weld is then continued up the side
of the ship in the vertical position to the main
deck, fig 5 (on back page).
When the technique was evaluated against
the previous practice, the planned manhours
allocated to welding were decreased by 72%.
In addition, the visual quality of the weld on
both root and cap was of a very high standard.

Fig 1. Large section of a ship being joined with Kat Oscillation. Feathered Edge
6 mm

Improvements in productivity and weld quality

using the oscillator welding process
Tile
Position

I t has long been considered that the most

productive and cost effective welding posi- · potentially higher defect levels on 30˚ 30˚
multi pass runs passing through access gaps.
tion within the shipbuilding industry is the flat
The alternative was to weld the connection
position (PA). To satisfy this, great emphasis
from the outside, where a free run with mini- 1
is put in at the design stage to maximize the 2
mum restrictions was available. This required 3
use of this position. However, even when 4
reversing the preparation discussed earlier and 5 6
adopting this philosophy, welding has to be 7 8
welding the bottom shell of the ship in the
carried out in a variety of other positions.
overhead position. To achieve this the follow-
Many shipyards have found major benefits
ing was carried out: 5˚
when welding a specific section of the ship
◊ Joint rooted from the inside against a round
hull in the overhead position (PE).
ceramic tile, fig 2. Direction of travel
◊ Welding carried out from the outside using
Carbon steel to carbon steel link-ups Fig 2. Joint rooted from the inside against a round
a Kat Oscillator and flux cored welding wire
Large block sections of the ship are welded ceramic tile
in the overhead (PE) position, figs 3&4.
together in the block build strategy, fig 1. On
each section there are a large number of webs, Fig 3. Welding carried out from the outside using a
As the joint moves from the bottom shell it Kat Oscillator and flux cored welding wire in the
girders and longitudinal connections to be
undergoes the transition from the overhead overhead (PE) position
made, in addition to the main hull connection.
The bottom shell of the hull has traditionally
been welded from the inside using a single V
preparation, 60° inclusive angle 6mm gap
feather edge with flat ceramic tiles on the out-
side to produce a single sided weld. This weld
requires no back gouging treatment, and for a
time was considered to be the most effective
way if completing the connection. However,
there were disadvantages such as:
· Welder access,
· Obstructions from webs, girders, etc,
and
 of corrugated bulkheads. The weld profile has
to be as smooth as possible to remove poten-
tial sites for cargo retention. The oscillator
welding process was put into operation, and
resulted in extremely high quality welds with
minimum surface discontinuities, fig 6. As the
joint to be welded was fully tracked, welds
were produced without any intermediate
stop/starts which further reduced the potential
for discontinuities, fig 7. As in the case of
mild steel, the stainless steel FCAW wire was
Fig 4. Welding in the overhead position using the
of Japanese origin.
Kat Oscillator and flux cored wire

Also radiography results are consistently bet- The amount of potential back gouging was
ter than the previous practice. These benefits reduced by welding against a ceramic backing
could not have been achieved without the fol- tile. On plate thickness of approximately
lowing key elements: 34mm, a 2/3 to 1/3 preparation was used with Fig 7. Oscillator welding process in operation join-
◊ A reliable oscillation system, and a round ceramic tile placed in the groove. It ing 316LN stainless steel. This resulted in very high
◊ a high integrity flux cored wire. was found that a larger gap was required for quality welds with minimum surface discontinuities.
To date the Kat Oscillating System has been stainless steel than for carbon steel, due to Furthermore, following the welding operation the
found to be extremely reliable in the variety of contraction effects. A gap of 8mm was used Kat Oscillator track could be used for mounting an
positions and environments within the ship- with the root run being applied with the oscil- X-ray head for NDT inspection purposes
yard. Two flux cored wires are being used, lator. When the round tile was removed a
both are of Japanese origin, one is copper good concave profile was obtained, which
coated seamless wire and the other is a more only required wire brushing prior to second oscillator has shown:
traditional seamed wire. Both wires are E71T- side welding. ◊ Significant improvements in productivity
1 type and can be used in all welding posi- when used in conjunction with a compatible
tions. General FCAW consumable.
This practice has developed from extensive The use of the Kat Oscillator within ship- ◊ Significant reduction in back gouging can
experience gained elsewhere in the shipyard building has been increased significantly, and be achieved when welding against ceramic
on carbon and stainless steel. at present, procedures are available for almost tiles.
all general welding positions. This includes ◊ Transitional areas from the overhead to the
Stainless steel to stainless steel corrugated the horizontal position (PC), which in the past vertical positions can be welded using
bulkheads has been particularly problematic, especially flexible track
To date, four chemical carriers have been built. when rooting onto a ceramic backing tile. A ◊ High integrity stainless steel weld caps can
The cargo tanks are constructed from 316LN further area being considered is the use of the be produced.
stainless steel, and are made up from a series Oscillator track to double up as an aid to radi- ◊ The track could be used as an aid to NDT,
ography inspection. The X-ray head could be by carrying an X-ray head.
Fig 5. Continuing the weld up the side of the ship in mounted onto the carriage and moved into
the vertical position using the flexible track. position for shooting as required.
Summary
The work carried out to date with the

Fig 6. Weld produced using the oscillator process in the overhead (PE) position.

KAT, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

Distributed by:

BULLETIN Gull-PAF-OSE-0804
 PRODUCT CASE STUDY FILE

UK NAVY Shipyard - Air Craft Carrier

Cammell Laird, Merseyside

THE EQUIPMENT

KAT – All position carriage, used in 1G,

2G, and 3G positions

MOGGY- Trackless carriage: Standard and

Dual Torch models
for continuous and stitch welds

KBM – 18 and 28 models for offsite steel

KAT® Welding Carriage System with Oscillator head combination used on multi suppliers, hand held model
weld application for UK Aircraft Carriers. for out of position bevels

THE PROJECT Cont.

Recently commenced is a project that will see Gullco weld- ...training and back end support, would be the
ing automation used to produce two UK Navy Air Craft critical challenge to the successful completion of
carriers in the coming months. This shipyard in Cammell this high profile project. This was combined with
Laird, Merseyside has selected Gullco equipment after a the challenge of having high integrity bevels,
list of companies where tested for their effectiveness to with consistent root face made off site by a 3rd
meet military welding inspection standards. It was agreed party company who would produce the steel for
upon by the UK Shipyards that the automation equipment the completion of the carriers.
supplied by Gullco was the most reliable and most consis-
tently met weld quality standards. It is important that the
automation produce high integrity welds at an increased
frequency to previous production methods in order to in-
crease manufacturing efficiency. This project will see vari-
ous types of welding applications throughout its comple-
tion and the welding technicians will utilize the versatility of
the KAT all position carriage to produce the majority of
these welding procedures.

THE CHALLENGE

The shipyard in Merseyside was faced with the task of pro-

ducing 2 aircraft carriers under strict deadlines, with in-
creasing quality standards. These issues are then com-
pounded with having to source, and train welding techni-
cians on the selected automation equipment which will be Moggy® trackless welding carriage producing fillet welds.
used to complete the project. Early on in this process it
became apparent that finding reliable, easy to use weld
automation equipment, which is coupled with great
onsite ...
THE SOLUTION Cont.

After several companies made proposals, the Other equipment involved in this solution were,
GULLCO International line of welding automation Moggy trackless friction drive carriages, used to pro-
equipment was selected. This was in part due to its duce the welds in the flat position, and a hand held
versatility. Through the use of a track and mounting beveling system for out of position beveling done dur-
device system the KAT carriage is able to operate in ing manufacturing. The extensive line of GULLCO
all positions, reducing the amount of equipment train- automation equipment allowed the shipyard to source
ing necessary to complete a variety of weld applica- all of it products from one company streamlining the
tions. This was especially appealing when combined process which would carry over into efficient training
with onsite training provided by Gullco’s welding tech- sessions. It was also of benefit to know that support
nicians. for the equipment could come from the one source
and cover the range of equipment.
Another key factor to this solution was Gullco’s great
back end support team for both technical questions
and equipment, giving them the peace of mind to put
the automation to the test. The solution to the steel
problem would be solved with a gift. The shipyard
would purchase two KBM beveling machines from
Gullco, which could produce the consistency neces-
sary while eliminating material distortion and give
them to the steel manufacturing facility in order to
insure quality standards and regulations were met.

Moggy® Trackless Welding Carriage System completing structural

fabrication on UK aircraft carrier.

To see the above products and more welding and

cutting automation solutions visit www.gullco.com or
send your application questions to [email protected]

www.GULLCO.com

KAT® Welding Carriage System with Oscillator head combination used to

complete long continuous weld in the flat position.

KAT, MOGGY, KATBAK, & SAM are registered trademarks of Gullco Enterprises Limted SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

CS-UKNAVY-10-01
 PRODUCT CASE STUDY FILE

Overhead Welding (4G) with KAT®

Oscillator Combination

THE PARAMETERS

• Travel speed: 22cm/min

• Arc Voltage: 24
• Amperage: 210
• Torch Angle: 5° - 10° pull
• Oscillation: root none, thereafter 4mm
• Side Dwells: none

KAT Oscillation carriage combination welding overhead on Scottish bridge

construction.

THE PROJECT

The M74 completion project will complete a vital part of the

west of Scotland's motorway network with a new eight
kilometres (five miles) stretch of road continuing the M74
from Fullarton Road Junction, near Carmyle to the M8 mo-
torway west of the Kingston Bridge. This project is part of a
massive infrastructure investment in Scotland's transport
network which includes a new rail link to Glasgow airport, a
new rail link between Airdrie in the West and Bathgate in
the East, and further improvements to the central Scotland
motorway network. The M74 project is a partnership project THE CHALLENGE
between Transport Scotland, Glasgow City Council, South
Lanarkshire Council and Renfrewshire Council.
The brief was to use welding machines already in the
possession of Cleveland Bridge, which is in line with
Gullco policy as Gullco do not manufacture or supply
welding machines, leaving the supply of such parts to
THE APPLICATION their local distributor.

At first Cleveland Bridge approached Gullco to automate In addition the following was used:-
/mechanise the overhead welding of short welds in the • Gullco Kat Oscillator Combination running on rigid
workshop to eliminate the need to turn large beams risking track (flexi track also available)
twisting and bending of the beam as well as saving time. • 1.2mm diameter gas shielded rutile flux cored wire
This was successful and the process was to be repeated • Gas: Argon 80% CO2 20%
on site where the need to automate was even greater with Cleveland Bridge are using 3 Kat® oscillator pack-
a large quantity of overhead welds to be performed on ages on a continuous basis on site in Glasgow.
joints many meters in length. The welds are partial penetra-
tion butt joints of various depths from 15mm to 20mm on Trevor Powley from Cleveland Bridge said: “We are
plates 50mm to 85mm thick with the first and second very happy with the Gullco product as well as after
passes made in one run and thereafter split weaves to suit sales service and on site welder training”.
the joint.
KAT, MOGGY, KATBAK, & SAM are registered trademarks of Gullco Enterprises Limted SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

CS-CLEV-10-01
 welding and cutting automation

electronic seam tracking system - KAT®

A high precision tracking system

that maintains the torch in optimum
operating position regardless
of variations in the weld seam.
This provides improved quality
and efficiency in a wide variety of
* Carriage sold separately welding operations.

High Precision Weld Tracking System

MAINTAIN THE TORCH IN OPTIMUM OPERATING POSITION TO PRODUCE THE HIGHEST QUALITY WELDS

WELDING AND CUTTING

The quality and efficiency achieved with today’s automated
welding systems can be impaired by material warpage,
misalignment, irregular edge fit-up, different material
thickness and other conditions that cause variations in
the weld seam. Gullco KAT® Trackers restore optimum
performance when these conditions are encountered.
They continually sense the slightest variation across the
weld seam and automatically correct the position of the
weld torch.

The trackers are designed for incorporation and use with

the Gullco KAT® travel carriage system but can readily be
used with other travelling and rotating devices employed in
automated welding operations.

The systems are effectively employed to cut costs and

increase productivity in a wide range of applications such
as tank, pressure vessel, pipe and structural component
fabrication and deep groove welding operations.
KAT® Tracker Model
Gullco KAT® Trackers are available in standard or heavy
WSG-1200 Electronic
duty models to meet virtually all requirements. A brief
description of each is provided below.
Seam Tracker

KAT® Trackers are precise, dependable and

highly versatile. They can be used with a wide
range of Gullco accessories/ systems such as
GULLCO KAT® TRACKERS oscillators, bridge units, multiple torch
These Trackers provide precise vertical and horizontal assemblies etc. Contact Gullco with your
tracking plus... requirement.
ELECTRONIC “END OF PLATE DETECTION”
- puts the tracking system on “hold”... Preventing the torch
from driving into the plate and allowing welding to continue
to the plate edge.

ELECTRONIC “TACK DETECTION”

- interrupts the automatic tracking action when a tack-
weld is encountered preventing the torch from rising
prematurely...and returns the system to normal action
when it reaches the end of the tack weld.

MODEL WSG-1200:
This model has up to 55 lb. (25kg)
vertical load capacity at 4” (100mm)
extension from the face plate. The
standard stroke is 4” x 4” (100x100mm).

MODEL WSG-2200:
The heavy duty version of model
WSG-2200 with a vertical load capacity
up to 100 lbs. (45 kg) at 6” (150mm)
extension from the face plate. The Model WSG-2200 Mounted
standard stroke is 6”x6” (150x150mm). on a side beam carriage
equipped with a submerged
Note: The above data applies to standard slide arc head
assemblies. Other slide lengths, speed and higher
capacities are available.
 Specifications ...incorporating sensing modes
that cover virtual all tracking
GULLCO MODEL WSG-1200 KAT® TRACKER requirements
SYSTEM SYSTEM COMPONENTS
Main Control Box, Pendant Remote Control Box,
Probe, Probe Micro Cross-Slide, Motorized Cross-
Slide Assembly, Probe-To-Torch Mounting Bracket,
Control Cables from Probe and Cross-Slide to Main
Control Box, Torch Holder with vertical/ horizontal
gullco kat® trackers
adjustment, Brackets for mounting Cross-Slide and model wsg-1200 & 2200
Main Control Box on KAT® Travel Carriage. single direction sensing
MAIN CONTROL BOX
Incorporates main power switch, On/Off pilot
light, signal lights indicating sensing function and
fuse. Electronic circuit components incorporated
in modular system with circuit boards for easy
maintenance.
Size: (H) 5-1/2” (W) 2” (D) 1-1/2” (140 x 50 x
38mm.)
Weight: 2 lbs. (900 grams)

PENDANT REMOTE CONTROL BOX

Incorporates manual/automatic changeover
switch and inching switch -vertical up/down and
horizontal left/right.
Size: (H) 5-1/2” (W) 2” (D) 1-1/2” (140 x 50 x
38mm. )
Weight: 2 lbs. (900 grams)

PROBE
Supplied complete with replaceable 1/8” dia.
Probe tip. The assembly incorporates a Shock
Protector that protects the system’s electronics by
breaking when heavy shock is encountered.

PROBE MICRO CROSS SLIDE

Provides precise manual pre-positioning of probe
relative to torch prior to automatic operations.
Stroke plus or minus 3/4” (20mm).
Weight: 1-3/4 lbs. (900 grams)

MOTORIZED CROSS-SLIDE ASSEMBLY

Model WSG-1200 WSG-2200
Vertical Load Capacity: up to 55 lbs. (25kg) up to 100 lbs
Standard Stroke Length: 4” (100mm) 6” (150mm)
Standard Stroke Speed: 10.16 in/min 9.8 in/min
Height 14” (355mm) 18 1/2” (472mm)
Width 14” (355mm) 18 1/2” (472mm)
Depth 4 3/4” (120mm) 6 1/2” (170mm)
Weight 22 lbs. (10kg) 50.6 lbs. (23kg)

Power Requirements: 110/115 Volt AC - Single phase 50/60 Hz

Longer slides, other speeds and higher capacity units available on request.
 Gullco Mechanical Seam Trackers and Height Sensors are designed for use
with the Gullco KAT® Travel Carriage to accurately maintain the required,
pre-set distance between the gun or torch and the workpiece in automated
welding and cutting operations.

Three models are available to effectively meet various application needs.

All are constant velocity, spring-type sensors utilizing hardened and ground
slide bars with recirculator ball bushings to provide 1-3/4” (44mm) of torch
float.*

Model GK-190-600 Height Sensor has an adjustable swivel copper guide

wheel to contact the work surface.

Model GK-190-602 Height Sensor has a stainless steel ball transfer that
is particularly useful to maintain contact on curved surfaces or vertical
applications.

Model GK-190-603 Seam Tracker is specifically designed for fillet welding

applications.

*Other float distances available on request.

MODEL GK-190-600 MODEL GK-190-603 (A) When the weld seam is below
Mechanical Height Sensor with Mechanical Seam Tracker with the Kat carriage level, the sensor
constant velocity spring, hardened constant velocity spring, hardened rack arm clamp is located below
ground rods and circulator ball ground rods and recirculator the sensor rack box.
bushings to provide 1-3/4” (44mm) ball bushings to provide 1-3/4”
of torch float. (44mm) of 45˚ torch float and (B) When the weld seam is above
1-1/4” (31.75mm) of weld seam carriage level the sensor rack arm
Supplied complete with adjustable, misalignment in both the horizontal clamp is positioned above the
swivel copper guide wheel, 1-1/8” and vertical plane. The assembly sensor rack box. Additional height
(29mm) sq. rack box, 12” (304mm) includes a Micro Cross-slide with adjustment may be required. We
rack arm and swivel mounting gun holder to provide 3/4” (19mm) recommend the use of our Rack
clamp for attachment to KAT® of XY adjustment. Supplied as Box Riser Assembly (below) to
Travel Carriage arm. standard with single copper guide increase the carriage rack arm
wheel, 1- 1/8” (29mm) sq. rack box, height by 2”, 4” or 6”
12” (304mm) rack arm and 1-1/8”
MODEL GK-190-602 (29mm) swivel mounting clamp
Mechanical Height Sensor with for attachment to KAT® Carriage
constant velocity spring, hardened rack arm.
ground rods and circulator ball
bushings to provide 1-3/4” (44mm)
of torch float. SPECIAL SENSOR GUIDE WHEEL ASSEMBLIES
For Fillet Welding applications involving tack welds
Supplied complete with hardened Model GK-190-604 Model GK-190-605
stainless steel ball assembly, 1-1/8” Dual in-line guide wheels react Dual, side-by-side guide
(29mm) sq. rack box, 12” (304mm) independently when tack welds Wheels straddle tack weld
rack arm and swivel mounting encountered on thin edge material, Line in general range of
clamp for attachment to KAT® one always in contact with the weld Fillet Weld applications.
Travel Carriage arm. seam.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

ST-13-01
welding and cutting automation

Electronic arc height sensor - E.A.H.S

Lightweight and durable components to reduce

operator fatigue.

The 4” (10.16 cm) standard slide features engraved

top, bottom and center marks for quick slide position
reference to aid setup.

Standard 25 ft. (762 cm) of remote pendant control

cable means the current sensor main control box
can be kept away from the work area reducing trip
hazards; an additional 25 ft. (762 cm) extension is
available.

Easy setup and torch calibration.

Sensor control box design allows the operator to use

their standard existing welding cables.

Extremely accurate arc detection

Slide travel speed factory set at 10 IPM
(25.4 cm/ min), programmable range of 3 IPM
(7.6 cm/min) to 17 IPM (43.2 cm/min)

Easy to use remote pendant interface with coarse and

fine slide adjustment.

High Precison Torch Height Adustment Through Current Detection

ACCURATE ARC DETECTION AND PRECISION CONTROL OVER THE TORCH HEIGHT

WELDING AND CUTTING

E.a.h.s System components
The Electronic Arc Height Sensor (E.A.H.S.) from Gullco is an automated welding system used throughout the world to
automate and improve the quality and efficiency of the weld produced in automatic mechanized welding operation. This
is achieved through minimizing weld defects such as poor penetration, incomplete fusion, overlap and undercut. Also,
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.

400 amp gk-203-400 800 amp gk-203-800

ITEM PART NO. DESCRIPTION QTY. ITEM PART NO. DESCRIPTION QTY.
1 GK-203-001 Slide Assembly 1 1 GK-203-007 Heavy Slide Assembly 1
2 GK-203-002 E.A.H.S Remote Pendant 1 2 GK-203-002 E.A.H.S Remote Pendant 1
GK-203-003-A Control Box Assembly 42V Input 1
GK-203-014-A 800 AMP Control Box Assembly 42V Input 1
3 GK-203-003-B Control Box Assembly 115V Input 1
3 GK-203-014-B 800 AMP Control Box Assembly 115V Input 1
GK-203-003-C Control Box Assembly 230V Input 1
GK-203-014-C 800 AMP Control Box Assembly 230V Input 1
4 GK-201-125 Head Cable Assembly 1
5 GC-058 Mounting Hardware 1 4 GK-201-125 Head Cable Assembly 1

6 GK-201-112 Gun Holder Assembly 1 5 GK-203-093 HD Slide Mounting Hardware 1

vertical slide capacity* Horizontal slide capacity*

AT CENTER
24 lbs (10.8 kg)
EXTENDED
12 lbs (5.4 kg)

12 lbs (5.4 kg)

* For other configuration capacities, please consult your Gullco sales representative or request info at www.gullco.com

Work Piece Ground

Dust Cover Cable Clamp
Ground Cable Current Sensor
Return path Polarity Reference
back to welding Lid Clamp Screw GK-201-112
power source Gun Holder
terminal
E.A.H.S Remote pendant control
A highly sophisticated, yet easy to use, microprocessor based control drives
a high torque, high resolution, low vibration stepper motor located in the
linear slide, allowing the height of the welding gun to be precisely controlled.
The control interfaces with the linear slide through a removable head cable
assembly and with the main control box through a fixed pendant control
cable. Controlling the height of the welding torch will allow the quality and
appearance of the weld to be perfected.

Power L.E.D

Fine Adjustment Slide Knob

Up Slide Indicator

Control Status Indicator

Down Slide Indicator

Coarse Adjustment Slide

Toggle Switch

Manual (Teach) / Auto

(Tracking) Switch

e.a.h.s unit accessories

GK-203-070: 500 AMP GK-203-086 : LINEAR

CURRENT SENSOR OSCILLATOR TO E.A.H.S
SLIDE ADAPTER
This sensor increases the
current sensing range up to 97% This adapter kit allows the Gullco Linear
of 500 AMPS (485 AMPS). It is a Oscillator (GK-201-120) to be mounted to
direct replacement for the the E.A.H.S slide (GK-203-001).
existing 400 AMP sensor Slides not included.

GK-203-092: REMOTE PENDANT EXTENSION 25 FT (762 cm)

This 25 ft. (762 cm) extension will increase the total length of control cable
between the control box and the remote pendant to 50 ft. (1.52 m)
specifications

1. GK-203-003: Control Box with 25 ft. (9 m) control cable

and 9 ft. (3 m) power cord

2. GK-203-001: Motorized Vertical Correction Slide

3. GK-203-002: Remote Control Pendant with 25 ft.

(7.62 m) control cable

4. GK-203-003: Control Box Assembly

(A– 42V, B-115V, C-230V)
Welding guns are readily mounted on the linear slide.
5. GK-201-125: Motorized Vertical Correction Slide Control This equipment is intended to automatically control
Cable - 6 ft. (1.8 m) the torch height throughout the welding process. The
longitudinal movement can be obtained from either
6. GC-058: Mounting Hardware the work piece traveling while the linear remains
stationary, or, by a travel carriage such as the Gullco
7. GK-201-112: Gun Holder Assembly KAT® carriage carrying the E.A.H.S. equipment
down the length of the work piece, which is the
norm. Combining the welding gun height control with
the precision controlled travel speed of the KAT®
carriage will ensure high quality workmanship can be
produced.

The E.A.H.S. works by measuring welding current,

comparing it to a target value that has been taught by
the operator and automatically adjusting the height of the
welding gun to maintain the target welding current.

The Model GK-203-400 is a standalone unit meaning it

does not interface with the wire feeder. The arc activation
trigger signal of the welding equipment that is used to
start/stop the welding process must come from a separate
piece of equipment, i.e. customer supplied control or other
Gullco equipment. This advanced Electric Arc Height
Sensor package uses Gullco’s sophisticated, yet easy to
use, E.A.H.S. remote pendant control, in conjunction with
a 4” linear slide assembly and current sensing control box,
to provide precision arc height control during the welding
process.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

EAHS-11-01
 PRODUCT CASE STUDY FILE

Innovative Mining and Engineering

Solutions Pty Ltd. (IMES)

Solutions for problems with abrasion or

high wear

THE PARAMETERS

• Arc Voltage: 28 Volts

• Amperage: 150 amps
• Torch Angle: 90°
• Oscillation: Linear (20mm width)

THE PROJECT THE SOLUTION

The Queensland company IMES has begun using a The use of the KAT® Welding Travel Carriage
Plasma Transfer Arc Welding (PTAW) process in the re- and Electronic Arc Height Sensor (EAHS) in
pair of their mining equipment. Through the use of Gullco combination with the PTAW welding process
International Pty Limited's KAT® Welding Travel Carriage solved the problem of reducing over all cost
and Electronic Arc Height Sensor (EAHS) combination without sacrificing weld integrity. The Gullco
IMES was able to increase production while reducing the welding automation equipment supplied leaves
overall cost. a smooth surface which does not reduce the
The precise control over the welding parameters flow of material.
helped maintain the job integrity and welding processes. The automation process involved little
Specifically the critical “arc current” was precisely main- heat transfer and as a result, very little change
tained through the use of the EAHS System which auto- in the physical properties of the parent material.
matically adjusts the torch height to maintain current The plasma arc transfer process in partner with
levels. the welding automation from Gullco tripled the
life of the steel mining equipment.
THE CHALLENGE

IMES was faced with the problem of high wear and abra-
sion on critical steel mining equipment. A solution was
needed when pressures to reduce costs where met with
the need to maintain high quality welds and welding proc-
esses. Gullco’s technical sales team assessed the appli-
cation and where able to supply the equipment neces-
sary to overcome this problem and meet the require-
ments of the welding engineers on site. It was important
that the equipment supplied for the completion of the
application be versatile enough to work with existing
welding power sources and equipment.
KAT, MOGGY, KATBAK, & SAM are registered trademarks of Gullco Enterprises Limted SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

CS-IMES-10-01
welding and cutting automation

trackless welding carriage - moggy®

Ideal for automatic horizontal fillet, lap or butt

welding applications

Controls available for continuous or stitch

welding operations

Dual gun holder assemblies make automated

simultaneous welding effecient

MOGGY® wheels can be inverted to allow

carriage to operate on v-groove track

The MOGGY® can be equipped with a variety

of accessories including: weld oscillator, cutting
torch attachment and internal radius guide
wheels

GM-03-050 - CONtinuous Weld

GM-03-100 - Stitch Weld

Automate Fillet, Lap, and Butt Welds with Precision

VERSITILE TRACKLESS AUTOMATION CARRIAGE FOR A VARIETY OF APPLICATONS

WELDING AND CUTTING

Trackless automation welding carriage
FILLET JOINT WELDING LAP JOINT WELDING

The MOGGY® The MOGGY® is

performing a fillet weld performing a lap joint
using a template, guide weld. It is guided by
or fence positioned par- Industry Standard 6”
allel to the workpiece. (152.4mm) v-groove
The MOGGY® is intended to automate and improve the The actual workpiece is track running parallel to
quality of welding and cutting operations by carrying the often used as the guide. the joint.
welding gun(s) or cutting torch(es), at precisely controlled
speeds, along the path of the joint. The MOGGY® carriage
also provided interface between the welding and cutting
motion and the arc start and stop signals. The automation
carriage is normally guided by adjustable guide wheels
which are set to always drive the carriage slightly into the
vertical member (usually either the vertical member of a
fillet joint or a template/fence placed parallel to the joint).
Industry standard 6” v-groove track may also be used to Precise Torch Alignment To The Seam
guide the parth of the MOGGY®. The carriage is flexible
enough to allow it to be easily configured for horizontal Adjustable guide rolls mounted on the front or back of
lap, butt and fillet weld joints as well as a variety of cutting the carriage monitor the slightest seam variations
processes. following straight or curved surfaces...maintaining
optimum torch positioning as the carriage travels.
Using the MOGGY® automation carriage system will add
accuracy and uniformity to welding and cutting applications
l
ve

while increasing producivity. Typical applications include

a
Tr

shipbuilding, offshore construction, steel fabrication, etc.

of
n
io
ct
ire

s
ce
D

Standard MODEL GM-03-050 MOGGY® Carriage with

rfa
control for continuous travel, and with forward/stop/reverse
su
switch, wire feed start on/ off switch, travel speed potenti-
ed
urv

ometer, auto wire feed start with delay carriage start, travel
...c

speed displayed in LED window, wire feed connector with Carriage wheel
assemblies maintain
.

15 ft. (4572mm) control cable.

r..
to

constant guide roll

igh

pressure on vertical The

a
str

component MOGGY®
Standard MODEL GM-03-100
g

guide roller
on

MOGGY® Carriage with control for continuous or stitch assemblies

Al

welding, and with a control that uses a Gullco can be

microprocessor to provide accurate repeatability configured
regardless of travel speeds for weld distance on and weld in a varity of
distance off. It has a forward/stop/reverse switch, wire feed ways enabling
start on/off switch, travel speed potentiometer, auto wire extreme
feed start with delay carriage start, wire feed connector versatility.
with 15 ft. (4572mm) control cable. All functions displayed
in an LED window.
 BUTT JOINT WELDING DUAL GUN WELDING JOINT TRACKING RADIAL OSCILLATOR

The MOGGY® is ideal for Dual gun holder assembly Adjustable height guide Replaces the standard
butt joint welding. Here the mounted on the MOGGY® roller assemblies are gun holder assembly in
MOGGY® is using a fence enables positioning of two available to track joints order to weave the gun
to guide it accurately along guns and simultaneous with a vertical member across the joint while the
the desired path. Standard activation of two wire higher or lower than the MOGGY® provides the
v- groove track can also feed signals. MOGGY® is set height of guide roller weld travel motion.
be used. guided by the workpiece. wheels.

CARRIAGE CONTROL LAYOUT

Forward Motion Commanded Speed & Parameter Value Display

Reverse Motion Commanded Speed Display Calibrated In

Inches Per Minute

Hold (Stop) Mode Active Speed Display Calibrated in

Centimeters Per Minute

Arc Signal Active Auto Cycle Mode (Constant)

Programming Mode (Flashing)

Cycle Push Button Speed Adjustment

(Extended or Recessed) Clockwise = Faster
Counter-Clockwise = Slower

Control In Run Mode

Command Forward Motion

Control In Hold (Stop) Mode

Neutral

Program Variable Selector Switch Command Reverse Motion

(Extended or Recessed)

Accessories available: Also available as a SUBMERGED ARC MOGGY®

GK-194-O-330 - Radial Oscillator complete with bracketry for
mounting on Gullco MOGGY® Carriage.
For more
GM-03-059 - Adjustable Guide Roller Assembly enables joint information on
tracking where the vertical member is lower/higher than set the subermerged
height of guide roller wheels. arc welding
carriage and
GM-01-065 - Cutting Torch Holder Assembly enables other products
automated torch cutting operations. visit.

GM-01-070 - Dual Gun Holder Assembly enables the use www.gullco.com

of two independently positioned welding guns with two wire
feed signals simultaneously activated.
 SPECIFICATIONS
Speed Range: 5.8 - 115.178 in/min (14.6 -
292.552 cm/min). *Special speed range of 3 - 54
in/min (7.6 - 137 cm/min) is also available as a
special request.

Maximum Incline: 30˚

Gun Positioning Slides: 1-3/4” (44.5 mm)

Vertical and Horizontal Stroke

Weight of MOGGY®: 31 lbs. (14.1 kg)

complete with all attachments (single gun model)

Supply Voltage: Either 42, 115, or 230 VAC,

single phase, 50/60 Hz., 30 watts

Drive Motor:
24 VDC permanent magnet gear motor

Drive Wheel Temp Range:

-65˚F to 450˚F (-54˚C to 232˚C)

Complies with: C.S.A. & N.R.T.L.

(file #LR35006-8) & C.E. Certification.

CARRIAGE DIMENSIONS

IMPERIAL METRIC
A 25.00” 635.0 mm
B 9.57” 243.1 mm
C 7.25” 184.2 mm
D 14.01” 355.7 mm
E Min 1.44” Max 7.06” Min 3.6 mm Max 179.3 mm
F 11.50” 292.1 mm
G 17.00” 431.8 mm

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

MG-13-01
welding and cutting automation

trackless welding carriage - magnetic moggy®

Magnetic base allows for out of position welding

applications

Ideal for automatic horizontal fillet, lap or butt

welding applications

Controls available for continuous or stitch

welding operations

Dual gun holder assemblies make automated

simultaneous welding effecient

The MOGGY® can be equipped with a variety

of accessories including: weld oscillator, cutting
torch attachment and internal radius guide
wheels

GM-03-300 - Continuous Welding

GM-03-350 - Stitch welding

Automate Fillet, Lap, and Butt Welds with Precision

VERSITILE TRACKLESS AUTOMATION CARRIAGE FOR A VARIETY OF APPLICATONS

WELDING AND CUTTING

Trackless automation welding carriage
FILLET JOINT WELDING BUTT JOINT WELDING

The MOGGY® The MOGGY® is ideal

performing a fillet for butt joint welding.
weld using a tem- Here the MOGGY® is
plate, guide or fence using a fence to guide
positioned parallel to it accurately along the
The Magnetic MOGGY® is intended to automate and the workpiece. The ac- desired path. Standard
improve the quality of welding and cutting operations by tual workpiece is often v- groove track can also
carrying the welding gun or cutting torch, at precisely used as the guide. be used.
controlled speeds, along the path of the joint as well as
providing the interface between the welding and cutting
motion and the arc start and stop signal. The Magnetic
MOGGY® is normally guided by adjustable guide wheels
which are used to keep a set distance from the joint path.

The carriage is flexible enough to allow it to be easily

configured for horizontal lap, butt and fillet weld joints as
well as a variety of cutting processes. The GM-03-350
model provides continuous mode welding and cutting and Precise Torch Alignment To The Seam
the GM-03-300 models also offer accurate distance stitch
weld functionality, regardless of travel speed adjustment. Adjustable guide rolls mounted on the front or back of
the carriage monitor the slightest seam variations
Using the Magnetic MOGGY® automation carriage
following straight or curved surfaces...maintaining
system will add accuracy and uniformity to welding and optimum torch positioning as the carriage travels.
cutting operations while increasing productivity. Typical
applications include shipbuilding, offshore construction,
steel fabrication industries, etc.
l
ve
a
Tr
of

Continuous Welding MODEL GM-03-350

n
io

Magnetic MOGGY® Carriage with control for

ct

continuous travel, and with forward/stop/reverse switch,

es
re
Di

wire feed start on/ off switch, travel speed potentiometer, ac

rf
su

auto wire feed start with delay carriage start, travel speed
ed

displayed in LED window, wire feed connector with 15 ft.

urv

(4572mm) control cable.

...c

Carriage wheel
The
...

Stitch Welding MODEL GM- 03-300 assemblies maintain

or

MOGGY®
constant guide roll
ht

Magnetic MOGGY® Carriage with control for guide roller

aig

pressure on vertical
continuous or stitch welding, and with a control that uses assemblies
str

component
g

a Gullco microprocessor to provide accurate repeatability can be

on

configured
Al

regardless of travel speeds for weld distance on and weld

distance off. It has a forward/stop/reverse switch, wire feed in a varity of
start on/off switch, travel speed potentiometer, auto wire ways enabling
feed start with delay carriage start, wire feed connector extreme
versatility.
with 15 ft. (4572mm) control cable. All functions displayed
in an LED window.
 LAP JOINT WELDING DUAL GUN WELDING JOINT TRACKING RADIAL OSCILLATOR

The MOGGY® is Dual gun holder assembly Adjustable height guide Replaces the standard
performing a lap joint mounted on the MOGGY® roller assemblies are gun holder assembly in
weld. It is guided by enables positioning of two available to track joints order to weave the gun
Industry Standard 6” guns and simultaneous with a vertical member across the joint while the
(152.4mm) v-groove activation of two wire higher or lower than the MOGGY® provides the
track running parallel to feed signals. MOGGY® is set height of guide roller weld travel motion.
the joint. guided by the workpiece. wheels.

CARRIAGE CONTROL LAYOUT

Forward Motion Commanded Speed & Parameter Value Display

Reverse Motion Commanded Speed Display Calibrated In

Inches Per Minute

Hold (Stop) Mode Active Speed Display Calibrated in

Centimeters Per Minute

Arc Signal Active Auto Cycle Mode (Constant)

Programming Mode (Flashing)

Cycle Push Button Speed Adjustment

(Extended or Recessed) Clockwise = Faster
Counter-Clockwise = Slower

Control In Run Mode

Command Forward Motion

Control In Hold (Stop) Mode

Neutral

Program Variable Selector Switch Command Reverse Motion

(Extended or Recessed)

Accessories available: Also available as a SUBMERGED ARC MOGGY®

GK-194-O-330 - Radial Oscillator complete with bracketry for
mounting on Gullco MOGGY® Carriage.
For more
GM-03-059 - Adjustable Guide Roller Assembly enables joint information on
tracking where the vertical member is lower/higher than set the subermerged
height of guide roller wheels. arc welding
carriage and
GM-01-065 - Cutting Torch Holder Assembly enables other products
automated torch cutting operations. visit.

GM-01-070 - Dual Gun Holder Assembly enables the use www.gullco.com

of two independently positioned welding guns with two wire
feed signals simultaneously activated.
 SPECIFICATIONS

Speed Range: 3 - 54 in/min (7.6 - 137 cm/min)

Gun Positioning Slides: 1-3/4” (44.5 mm)

Vertical and Horizontal Stroke

Weight of MOGGY®: 31 lbs. (14.1 kg)

complete with all attachments (single gun model)

Supply Voltage: Either 42, 115, or 230 VAC,

single phase, 50/60 Hz., 30 watts

Drive Motor:
24 VDC permanent magnet gear motor

Drive Wheel Temp Range:

-40˚F to 180˚F (-40˚C to 82˚C)

Complies with: C.S.A. & N.R.T.L.

(file #LR35006-8) & C.E. Certification.

CARRIAGE DIMENSIONS

IMPERIAL METRIC
A 12.90” 327.3 mm
B 9.50” 241.3 mm
C 8.45” 214.6 mm
D 14.01” 355.7 mm
E Min 1.95” Max 5.46” Min 4.93 mm Max 138.7 mm
F 11.50” 292.1 mm
G 17.00” 431.8 mm

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

MAG-13-01
welding and cutting automation

Submerged arc welding carriage - sam®

The versatility and reliability of the Gullco MOGGY® trackless travel

carriage system and a variety of quality engineered components
combine to provide a highly flexible self-contained welding unit. This
SAM® unit is designed to produce precision, quality Submerged Arc
or MIG welds.

The SAM® Carriage, friction drive heavy-duty welding carriage,

with positive chain drive on four (4) rubber tired wheels using a
closed loop tack feedback for accurate speed control. The carriage
controlled by the Gullco low voltage 24 volt GSP microprocessor
pulse width modulation motor control, all mounted in a remote
pendant control box attached to 8 ft. (243.84 cm) control cable
housing the GSP control providing the forward/stop/reverse switch
and infinitely variable 4-turn speed potentiometer. LED display in IPM
or cm/min. An interface cable assembly allows the Miller HDC 1500
DX to control the run/stop function of the SAM® Carriage. A manual
clutch enables free wheeling. The carriage comes complete with a
main mounting mast and handle assembly, mounting arm for one
wire reel. All the mounting arms are equipped with quick jaw mast
clamp assembly; vertical and horizontal manual 4” x 4” slides (with
hardened ground rods with sleeve bearings for ease of adjustment).
Control support arm and one (1) set (two[2]) adjustable guide roll
arms. For operation on either 42/115/230 volts, single phase, 50/60
Hz AC power supply. Specify voltage when placing order - B = 115 V,
C = 230 V.

SAM® Carriage comes in a model for mounting customer’s supplied

single sub-arc package. Carriage specifications same as Model
GM-02-295. No welding equipment is supplied.

Automate Submerged Arc Welding Applications

HEAVY DUTY SAM® TRACKLESS WELDING CARRIAGE FOR SUBMERGED ARC AND MIG WELDING

WELDING AND CUTTING

specifications
GM-02-250 SAM® Heavy-Duty Friction Drive Carriage
The carriage specifications are the same as that of the GM-02-295, but provided with 17” x 22”
(43.18 x 55.89 cm) aluminum plate providing full flat mounting surface for customer’s supplied wire feeder.

SAM® Submerged Arc Carriage...Shown set at 45˚ SAM® Heavy-Duty MIG Carriage...Shown supplied
for beam welding application with optional steering mechanism and mast assembly

Special track and wheels

-available upon request.

Power Supply: For operation on either 42/115/230

volts, single phase, 50/60 Hz AC.
(Specify voltage when placing order - B = 115 V,
C = 230 V).

Speed Range: 4 to 66.1 IPM (10 to 168 cm/min)

Weight: 172 lbs (78 kg)

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

SAM-11-01
 welding and cutting automation

Automated rotary weld system

Automate your circumferential welding

operations, add efficiency and increased
precision with the highly versitile Automatic
Rotary Weld System

The rotary weld table with tack feedback

interfaced with a PLC to provide precision stop/
start, weld stop/start, adjustable rotation speed,
weld overlap, multi-pass welding and tack
welding

Accurately adjustable tailstock with 6”

(152 mm) pneumatic clamping slide.

Motorized torch positioning slide to enable quick

and easy loading/unloading of the work piece.

Maximum weight capacity 300 lbs (136 kg)

Table lengths up to 20 ft (6096 mm)

Increase Weld Quality and Improve Production with Automation

IDEAL FOR AUTOMATING PRODUCTION OF CYLINDRICAL PARTS INCLUDING: FLANGES AND END CAPS

WELDING AND CUTTING

 specifications
The Gullco Automatic Rotary Weld System is a low cost
automated welding machine that produces consistent,
precision welds on cylindrical work pieces. It is designed
to provide repeatable quality welds, either in high or low
production. It is easy to operate while providing
sophisticated operational flexibility.

The Gullco Automatic Rotary Weld System comes

complete with...

- Gullco programmable Motor Control interfaced

with a PLC providing adjustable rotation speed,
rotation stop/start, weld stop/start, wire feed
stop/start and emergency stop controls, LED display for Load Capacity 300 lbs (136 kg)
all functions
Pneumatic Tailstock stroke 6” (152 mm)
- Headstock...full 360° rotation with adjustable overlap,
weld parameters controlled electronically Max. Part Length to 20 ft (6096 mm)

- Multi-pass Welding...available with automatic torch Weld Diameters to 18” (475 mm)
height adjustment
Adjustable Rotation Speed 0.25 - 15 rpm
- Torch Support with rack arm and micro-slide rack box
providing vertical torch adjustment, 4 axis torch holder Drive Motor 24 volt DC
assembly
Voltage - for operation on either 115/230 volt,
- Tailstock...accurately adjustable with 6” (152 mm) single phase, 50/60 Hz Ac power
pneumatic clamping slide supply.

- The bed is heavy duty steel construction available in SPECIFY VOLTAGE WHEN PLACING ORDER
lengths up to 20 ft (6096 mm)

The Gullco Automatic Rotary Weld System is also available as a multi-torch system

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

RS-11-01
 welding and cutting automation

overlay welding gantry system for all positions

The Welding Overlay System is designed to

operate in all positions. Ideal for use on boiler
tube walls, cladding boiler tube walls prior to
installation in the boiler, pressure vessel tanks
and other applications where overlay repair is
required.

The overlay system allows for precise control

of the travel speed which allows the operator
to achieve clean consistent weld overlay
patterns.

The entire system is made up of existing

Gullco products and can be easily
disassembled into various smaller components
for transporting or maneuvering through tighter
openings.

Gullco’s team of in-house engineers can

customize the system to meet specific
application requirements and this is used
commonly for unique circumferences or wall
applications.

The design of the overlay system is made

to optimize time with a quick track mounting
system which allows for easy alignment with
the work piece.

Precise remote control of the overlay system ensures consistent weld quality
MOUNTS EASILY TO AUTOMATE OVERLAY AND CLADDING APPLICATIONS

WELDING AND CUTTING

 Item Part Number Description Quantity

1 GS-474-024 VERTICAL TRACK ASSEMBLY 1

2 GS-474-013 UPPER IDLER CARRIAGE ASSEMBLY 1

3 GS-441-016 UPPER TOWING LINK 1

4 GS-474-035 UPPER KAT CARRIAGE ASSEMBLY 1

5 GS-474-047 MODIFIED TRACK STOP ASSEMBLY 1

6 GS-441-017 LOWER IDLER CARRIAGE ASSEMBLY 1

7 GK-191-P-061 RIGID TRACK STOP ASSEMBLY 1

8 GS-441-015 LOWER TOWING LINK 1

9 GS-474-030 LOWER KAT CARRIAGE ASSEMBLY 1

10 GS-441-021 REMOTE FOR UPPER & LOWER CARRIAGES 1

11 GS-474-055 VERTICAL KAT CARRIAGE ASSEMBLY (12-27) 1

12 GS-474-060 FRONT EXTENSION ASSEMBLY 1

13 GS-474-061 REAR EXTENSION ASSEMBLY 1

14 GK-190-066 RACK BOX RISER ASSEMBLY 1

15 GK-181-027 CABLE SUPPORT ASSEMBLY 1

16 GB-413-030 1 - 1/2” HEAVY DUTY RACK BOX 1

17 GS-474-070 1 - 1/2” RACK ARM X 48” LONG 1

18 GK-171-650 1 - 1/8” RACK BOX 2

19 GK-190-236 1 - 1/2” RACK ARM SQUARE CLAMP 2

20 GK-153-004 3/8 - 16 UNC FEMALE HAND LEVER 2

21 GK-171-047-1 1 - 1/8” RACK ARM x 12” LONG 2

22 GS-474-100 OSCILLATOR HEAD 2

23 GK-197-0-101 OSCILLATOR HEAD SWIVEL BRACKET 2

24 GK-197-0-102 BRONZE SWIVEL CLAMP ASSEMBLY 2

25 GK-171-112 ADAPTER BLOCK ASSEMBLY 2

26 GS-474-046 CABLE TRACK CLIP 1

27 GS-474-049 VERTICAL KAT REMOTE 1

OPTIONAL PRECISION COMPOUND SLIDES

AVAILABLE

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

OS-11-01
 welding and cutting automation

WORLD LEADERS IN THE DESIGN,

MANUFACTURE & DISTRIBUTION OF AUTOMATED
Custom gantry and bridge systems
WELDING SYSTEMS AND ACCESSORIES
CUT COSTS, IMPROVE QUALITY, AND INCREASE EFFICIENCY ...WITH THESE PROVEN
GULLCO PRODUCTS

Gullco Gantry Units are custom

designed assemblies that are used
in a variety of applications such as
automated seam welding, fabricated
KAT® Systems Moggy® weld prep ovens ceramic backingS assemblies, stiffener seams and
automated cutting operations such
• Oscillators • Trackless Fillet & • Bevellers • Flux Rebake • KATBAK® Ceramic as stripping and edge preparation.
• Torch indexers Butt Welding, Stitch • Positioners • Flux Holding Weld Backing Gullco will custom design a gantry
• Flex & Rigid KAT® Welding control • Grippers • Flux Hoppers • Impart Uniform or bridge unit to meet your specific
Programmable • Radial Oscillation • Kamel Pipe • Electrode X-Ray Quality Back requirements. A wide variety of
Travel Carriages Control • Turning Rolls Stabilizing Beads
custom design features and efficient,
• Seam Trackers • 6” V-groove Track • Eliminate Costly
high end Gullco systems and
• Bridge Units Available Grinding &
• Circle Cutting Re-welds components provide cost effective,
System • Knuckle Joints for reliable solutions for your welding and
Use On Flat or cutting automation needs.
Curved Surfaces

Contact Gullco or your Gullco distributor today for information on any of these productS Generate Accurate and Repeatable High Quality Weld Results
CUSTOM ENGINEERED TO AUTOMATE WELDING AND CUTTING OPERATIONS WITH PRECISION

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

WELDING AND CUTTING

GAN-11-01
 gullco gantry and bridge systems typical gantry and bridge system design

X-AXIS TRAVERSE CARRIAGE

GANTRY BEAM - made from
powered by Gullco KAT® 24volt
heavy duty track sections. spans
gear motors.
range up to 18 ft.
Y-AXIS LONGITUDINAL DRIVE
WELDING GUN/CUTTING
powered by Gullco low voltage,
TORCH OR TOOL MOUNTING
heavy duty drive systems.
SYSTEMS - tailored to suit
application requirements
CROSS DRIVE SHAFT- direct
including mounting Seam
gear drive to each longitudinal
Trackers, etc.
track ensures accurate tracking
of gantry.
GANTRY SUPPORT
CARRIAGES- Equipped with
CONTROL STATION-
heavy duty cam type roller
incorporates a touch screen 9460
bearing assemblies.
industrial flat panel PC utilizing WELDING
Citect HMI software to control This diagram shows a typical welding Gantry/Bridge unit design. The long tracks are located underneath the table providing
LONGITUDINAL TRACK
functions such as automatic protection. This also allows the work piece to be easily loaded at any point on the table as it is clear and easily accessible.
SECTIONS- interlocking design
forward/reverse travel, variable The bridge unit can be equipped to automatically position and clamp the parts to be welded. It can also be supplied with
allows unlimited longitudinal
speeds, automatic seam location/ mechanical, electronic or laser seam tracking equipment. Gullco can custom design a Gantry/Bridge system to meet your
travel.
tracking and automatic operation specific requirements.
of weld guns.
LET GULLCO ENGINEER AND BUILD A GANTRY/BRIDGE SYSTEM FOR YOU
Seam Tracking is provided by Gullco designed vertical and horizontal tracking device.

Gantry and bridge system features

Touch screen industrial PC utilizing Citect HMI Longitudinal track and cables are located Gullco Gantry system is equipped with dual Seam tracking is provided by a Gullco designed
software. underneath the table in protection. torches enabling simultaneous welds on both vertical and horizontal tracking device.
sides of aluminium trailer sidewall stiffeners in
one pass.
 ®

Product Application File

Kat-Trackers at
Caterpillar Stockton

at Gullco’s Appley Bridge, UK

facility from 60% standard
Gullco products. This enabled
Gullco to meet critical delivery
deadlines established to ensure
Caterpillar production schedules
were maintained. The machines
are controlled by Mitsubishi
PLC’s programmed by Gullco
[UK].
Gullco Equipment Used To Automate And Improve
Productivity In Side Panel Welding Dual torches are used in these
At Caterpillar machines to substantially increase
productivity and improve effi-
supply was for 4 complete,
T he Caterpillar Stockton (UK)
Ltd. plant selected Gullco
International [UK] Limited to
custom designed welding
machines to be used for different
ciency by welding two sides of a
component simultaneously.
supply weld automation equipment/ jobs at the Caterpillar Stockton
systems to improve quality and works facility. The unit pictured
efficiency in a variety of above shows a large Gullco travel
M.I.G/M.A.G. welding applica- carriage complete with wire feed
tions. Gaffney Industrial and units, fume extraction equipment,
Welding Supplies Ltd. was cho- control equipment and two
sen to support the sale and later Gullco Kat-Tracker seam
service the Gullco equipment. trackers. ITW, Miller welding
machines with Binzel water
One of the applications involved cooled M.I.G/M.A.G. welding
Side Panel welding utilizing a torches were selected for these
twin torch system. The scope of demanding welding applications.
Fume extraction
equipment was
supplied by
Nederman.

These large 6 to
12 meter long
“turnkey” units
Above: Dual torches guided by Gullco Kat-
were assembled Trackers simultaneously weld both sides of
totally “in-house” the work piece.
 Left: Gullco Kat-Tracker probe with section plates at 2m/min. This
replaceable tip can be seen in the bottom left
of the photo. They are precisely positioned rugged beveller with adjustable
relative to the torch prior to operation using bevelling head can produce bevel
a micro-cross-slide.
angles 22 1/2˚ through 55˚.
Below: Gullco Kat-Trackers continually
sense the slightest variation across the weld The rotary shear principle incor-
seam and automatically correct the position porated by this machine results in
of the weld torch. low noise/vibration and high
speed operation. This GBM-28-U
unit bevels the under side of the
plate.

Weld accuracy
and quality are
dependent on
precise seam
tracking and a
reliable electrical
Above/Below: GBM-28-U produces clean
interface of all
machined bevels on the underside of plate at
the components via the PLC. In 100mm x 100mm slides where up to 2 meters per minute using the rotary
order to meet the production and the work piece is approximately shear method of metal removal.
quality requirements at parallel to the fixture and each
Caterpillar, the Gullco Kat- joint is approximately parallel to
Tracker WSG-1200 was selected. the other. In other cases the track-
These tactile seam trackers ers were supplied with 150mm x
continually sense the slightest 350mm slides to accommodate
variation across the weld seam tapered work pieces.
and automatically correct the
position of the weld torch. They As part of this project, Caterpillar
provide precise right/left and purchased a Gullco GBM-28-U
vertical/horizontal tracking plus high speed portable, self-
automatic “tack detection” and propelled plate edge bevelling
“end-of-plate” detection. In total, machine. It is used to produce a
eight Gullco Kat-Trackers were clean machined bevel with no
used in the 4 machines. Some use thermal distortion on thick

KAT, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

Distributed by:
Website: www.gullco.com
G U L L C O I N T E R N AT I O N A L L I M I T E D - C A N A D A
Phone: 905-953-4140 Fax: 905-953-4138 e-mail: [email protected]
G U L L C O I N T E R N AT I O N A L I N C . - U . S . A .
Phone: 440-439-8333 Fax: 440-439-3634 e-mail: [email protected]
GULLCO INTERNATIONAL [U.K.] LIMITED - EUROPE
Phone: +44 (0) 1257-253579 Fax: +44 (0) 1257-254629 e-mail: [email protected]
GULLCO INTERNATIONAL PTY LIMITED - AUSTRALIA
Phone: 61 (0) 7 5496-9555 Fax: 61 (0) 7 5496-9522 e-mail: [email protected]
G U L L C O I N T E R N AT I O N A L L I M I T E D - I N D I A
Telefax: 91 (0) 20-24272212 Fax: 91 (0) 20-26120802 e-mail: [email protected]
G U L L C O I N T E R N AT I O N A L S H A N G H A I L I M I T E D
Phone: +8621-50460341 Fax: +8621-50463554 e-mail: [email protected]

BULLETIN Gull-PAF-CATER-0705
 welding and cutting automation

CERAMIC WELD BACKING TAPE - KATbak®

Impart x-ray quality back beads on the root

pass.

All radius edges for Weld one side only

curved surfaces
(no extra charge) Deposit more weld metal

Red centering Eliminate defects and rework

line
Eliminate costly unnecessary gouging and
Gas release
grinding
holes
Size 1/4” (6.3 mm) to 2” (51 mm) special sizes
and confrigurations available
Ceramic weld
backing is centered
Conveniently packaged and sealed in plastic for
on 4” wide heat moisture proof protection
receptive, pressure
sensitive coated Wider heat receptive pressure sensitive foil for
aluminum foil. improved adhesion to work piece

TANK BUILDING PIPE WELDING ship building BRIDGE BUILDING

Quality Certification To: ISO 9000

IMPROVE WELD QUALITY AND REDUCE COST WITH KATBAK® CERAMIC WELD BACKING

WELDING AND CUTTING

KATBAK® Ceramic Weld Backing Improves Weld Quality, Saves Time and Reduces Cost

Available in 1/4” to 2” (6.3 mm to 50.8 mm) tiles

 KATBAK® Ceramic Weld Backing Can Lay Root Weld & Fill In One Pass With X-Ray Quality Back Beads

(12.2m - 40ft./box)

Available in 1/4” to 2” (6.3 mm to 50.8 mm) tiles

As a manufacturer and distributor of ceramics, Gullco can provide you with a KATBAK® ceramic weld backing to
meet your needs. If you do not see the ceramic you need in this brochure contact Gullco or your Gullco distributor
to discuss your specific requirement.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

KB-11-01
welding and cutting automation

pipe welding turNing rolls - KAMEL ROLLS

Reduce pipe preparation costs with these

portable automated turning rolls which rotates pipe
from 2” to 16” (51- 406 mm) diameter. Two
models are available; Model KR-200-L has a
turning capacity of 1500 lbs (680 kg), and an
infinitely variable forward/reverse speed range of
1-35.4 IPM (2.5-89.9 cm/min). Model KR-200-M
has a turning capacity of 1500 lbs (680 kg) and an
infinitely variable forward/reverse speed range of
2.2-70.8 IPM (5.6-180 cm/min). Rotation speed is
precisely controlled and displayed in inches/mm
per minute on an LED readout. Contact Gullco
or your Gullco distributor for complete details on
these highly efficient, cost effective turning rolls.

Electronic controls are immune to damage from

high frequency and electromagnetic interference.

Portable: total weight of power and idler roll is 69

lbs. (31.3 kg). Use anywhere that 42, 115 or
220-240 volts 50/60 cycle single phase power
supply is available.

Long life, 6” (15.24 cm) diameter roller bearing

wheels with rubber tires provide friction drive and
uniformly smooth pipe rotation.

Protected on/off foot switch on 7.5 ft (2.3 m) cable

provides maximum convenience and freedom for
operator.

Great For In-shop Pipe Manufacturing Applications

AUTOMATION PIPE TURNING ROLLS WITH FOOTSWITCH: KR-200-L AND KR-200-M

WELDING AND CUTTING

specifications free standing torch supports
and torch / gun holders

MODEL KR-1000 CSB TORCH

SUPPORT 1 1/8” (28.6mm) square
rack arms providing 22” (559 mm) of
vertical adjustment and 10 1/2” (266.7
mm) of horizontal adjustment.

MODEL KR-2000 CSB TORCH

SUPPORT Same as above but 1 1/2”
(38.1mm) square rack arms providing
18” (457 mm) vertical adjustment and
POWER ROLLS
6.5” (165 mm) of horizontal adjust-
Model KR-200-L Model KR-200-M ment. Supplied with swivel mounted
TURNING CAPACITY 1500 lbs (680 kg) 1500 lbs (680 kg) standard rack-type cutting torch
LOAD CAPACITY/ROLL 750 lbs (340 kg) 750 lbs (340 kg) holder.
PIPE DIA. RANGE 2”-16” (51-406 mm) 2”-16” (51-406 mm) Weight: 42 lbs (19.05 kg)
1-35.4 IPM 2.2-70.8 IPM
SPEED RANGE MODEL KR-1000 WSB TORCH
(2.5-89.9 cm/min) (5.6-180 cm/min)
WEIGHT 48 lbs (21.8 kg) 48 lbs (21.8 kg) SUPPORT 1 1/8” (28.6 mm) square
rack arm providing 22” (559mm)
IDLER ROLLS Model KR-750
of vertical adjustment and 10 1/2”
LOAD CAPACITY 750 lbs (340 kg)
(266.7mm) of horizontal adjustment.
PIPE DIA. RANGE 2”-16” (51-406 mm) Weight: 25 lbs. (11.34kg)
WEIGHT 21 lbs (9.5 kg)
MODEL KR-2000 WSB TORCH
SUPPORT Same as above but 1 1/2”
DIMENSIONS: POWER AND IDLER ROLLS (38.1mm) square rack arms providing
18” (457 mm) vertical adjustment and
6.5” (165 mm) of horizontal
adjustment. Supplied with insulated
4 motion, semi-automatic gun holder
and swivel arm that allows adjustment
of gun angle tilt.
Weight: 42 lbs. (19.05 kg)

NOTE:
The above models can be, and often
are, supplied with the Gullco
Motorized Rack Arm, equipped with a
remote joystick control. See
www.gullco.com for more
information.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

KR-11-01
welding and cutting automation

AUTOMATED WELDING POSITIONER

These welding positioners are positive drive rotary

turn tables complete with mounting flange, drive and
tilt mechanisms which incorporates a microprocessor
based pulse width modulation motor control. Standard
and Programmable models are available. The welding
positioners are driven by a low voltage permanent
magnet motor and gear head power unit assembly. The
microprocessor motor control enables operator interface of
start, stop, clockwise rotation and infinitely variable control
of the speed, within the range of the model.

Rotation speed is electronically controlled using an optical

tachometer located on the back of the gear-motor. Speeds
within the range of the model are infinitely variable in
both clockwise and counter-clockwise directions through
a rotary speed adjustment potentiometer located on the
remote control. Table tilt is manually set at any desired
angle, from 0° through 90°, quickly and easily. Safety is
greatly enhanced with Gullco low voltage (24 V) control
and power supply system.

Increase Productivity, Quality and Profitability with Automation

AVAILABLE WITH A 2” THROUGH HOLE FOR LONGER WORK PIECES

WELDING AND CUTTING

 GP/GPP 200 SERIES POSITIONERS ARE AVAILABLE IN STANDARD OR
PROGRAMMABLE MODELS WHICH ARE EQUIPPED WITH CORRESPONDING
REMOTE CONTROLS
PROGRAMMABLE
STANDARD The Programmable Remote Control with LED
The Standard Remote readout provides
Control provides - infinitely variable rotation speed within the
- infinitely variable rotation model’s speed range,
speed within the model’s - forward/neutral/reverse switch,
speed range, - run/stop switch
- forward/neutral/reverse - programmable microprocessor providing
switch, adjustable positioning timing cycles, amount of
- run/stop switch weld rotation, weld on/weld off through 360° and
- speed potentiometer a signal to activate a pneumatically operated
weld gun holder and wire feed arc activation.

FOOTSWITCHES (optional)
Three footswitch models are available;
GP-200-024 - Run/Stop 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.

GP-200-025 - Variable Speed footswitch assembly for manual operation. This kit
provides a run/stop/variable speed 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 and
allow regulation of the rotational speed via the compression of the footswitch pedal.

GP-200-023 - Forward/Stop/Reverse footswitch assembly for manual operation. This kit provides a directional
footswitch; a footswitch guard cover; a connecting control cable; and strain relief glands. When activated, the
footswitch will provide a run signal and rotary direction signal to the control.

PURGE-EQUIPPED MODELS, Gullco offers a wide range of accessories that provide low cost
have a 1/4” (6.4 mm) hole through welding/cutting automation solutions including..
the centre of the table drive shaft KR-1000 WSB free standing support
and a gas rotary coupling mounted and welding gun holder assembly. 1- 1/8”
on the underside of the table ... the (28.6mm) square rack arms and rack
shaft having a 1/4” NTP tapped boxes provide 22” (558.8 mm) of vertical
adjustment and 10-1/2 (266.7mm) of
gas inlet hole. horizontal adjustment. Supplied with
swivel mounted, adjustable gun holder
GULLCO SELF-CENTERING WELDING GRIPPER assembly.
(optional) The WPG-250 Gripper is
quickly and easily mounted on any make KR-1000 & 2000 KR-2000 WSB Same as above, except
uses 1-1/2” (38.1mm) rack arms and
of positioner, turntable or tailstock. They WSB
rack boxes and provides 18” (457.2
are slim but durable, weighing only about mm) of vertical and 6-1/2” (165.1 mm) of
half that of a standard chuck, minimizing horizontal adjustment.
reduction in positioner capacity. Single lever operation KR-1000 CSB & KR-2000 CSB are the same as above except
provides smooth, positive self-centering action. they are supplied with swivel mounted, standard rack-type
cutting torch holder instead of welding gun holder

MOUNTING TABLE (optional) GP-200-016 CUSTOMIZED AUTOMATION

12” (305mm) diameter mounting table. This The above cutting torch and welding gun
support assemblies can be, and often
round mounting table is used to facilitate are, equipped with one or two Gullco
direct mounting of components or fixtures motorized rack arms controlled by a
and provides (6) radial mounting slots and remote joystick pendant.
various (3) hole pitch circle bolt patterns.
The mounting table is quickly and easily mounted on the
KR-1000 & 2000
positioner spindle flange. CSB
 Pass through Hole
Model GP-300/350 Workpiece Passes Through
These “Through Hole” Positioners The Positioner
models are designed with a 2.5
inch (63 mm) “through hole” so the
workpiece can be passed through
the unit (max material of 2 3/8 OD)
making production on long pieces
easier and faster.

LOAD CAPACITY/SPEEDS TABLE ROTATION

Models: Electronically controlled, infinitely variable in either
GP/GPP-(200 & 250)-M and GP (300 & 350)-M direction. Positive drive.
(Speeds 0.27 to 4.63 RPM)150 lbs. (68 kg) at 3” (76 mm) center
of gravity and 3” (76 mm) eccentricity with the table in the vertical TABLE TILT
position...300 lbs. (136 kg) with the table horizontal. 0° through 90°

Models: ROTATIONAL TORQUE

GP/GPP-(200 & 250)-H and GP (300 & 350)-H GP/GPP-(200 & 250)-M and GP (300
(Speeds 0.75 to 12.5 RPM) 75 lbs. (34 kg) at 3” (76 mm) center & 350)-M 450 inch lbs. (518 kg.cm)
of gravity and 2” (51 mm) eccentricity with the table in the vertical
position...150 lbs. (68 kg) with the table horizontal. GP/GPP-(200 & 250)-H and GP (300 &
350)-H 150 inch lbs. (172 kg.cm) through
the speed range. The maximum allowable
Vertical Table Horizontal eccentricity of “centre of gravity” on the
Gas Rotational
Model Programmable Loading @ 3” Table work piece for a given load in inches is
Purge Speed
C of G Loading calculated as follows.
GP-200 & 300-M
GPP-200-M
150 weight of work in lbs. The weight
0.27 - 4.63 150 LBS. 300 LBS.
(68 KG.) (132 KG.) must not exceed the values for overhung
GP-250 & 350-M RPM
load ratings shown below.
GPP-250-M
GP-200 & 300-H (D) Distance (L) Load

GPP-200-H IN. MM. LBS. KGS.

0.75 - 12.5 75 LBS. 150 LBS.
GP-250 & 350-H RPM (35 KG.) (68 KG.) 3 76 150 68

GPP-250-H 6 152 97 44
9 229 72 33
12 305 57 26
 B

d c

ITEM DESCRIPTION
A- Welding Positioner
B- 3 Jaw Gripper
C- Footswitch Assembly for Manual
Operation
D- Wire-feed / Arc Start Signal Kit
E- Pneumatic Gun Positioning Assembly

AN ACCURATE AND RELIABLE

AUTOMATIC ROTARY WELD PRODUCTION SYSTEM

FOR A FRACTION OF THE PRICE OF A P.L.C./SERVO SYSTEM.

Gullco’s microprocessor control not only provides improved speed regulation to Gullco’s proven
“GP” range of positioners. It also allows the positioner to be expanded into a fully automated welding cell. The
control uses a tach feedback system to ensure smooth and accurate rotation of the workpiece regardless of piece
weight and has the ability to activate a pneumatic welding gun holder and wire-feed/arc activation signal, based on
an operator defined welding cycle. The programmable microprocessor also provides adjustable positioning timing
cycles, amount of weld rotation and weld on/off through 360°.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

PS-11-01
 welding and cutting automation

Self-centering welding gripper

This 3 jaw self-centering gripper is designed

for use with all welding positioners including
Gullco’s GP/GPP-200 Series of positioners.
It provides high levels of efficiency and
versatility in operations involving welding of
fittings, flanges, and small diameter pipe.
Specifications are provided on the reverse
of this sheet. Contact Gullco or your Gullco
distributor for more detailed information.

Quickly and easily mounted on any make of

positioner, turntable or tailstock using three
bolts provided with the gripper.

Self-Centering, fast, smooth close/open action

lever to firmly lock or release workpiece.

Durable construction with a slim design,

weighing only about half as much as a
standard chuck. This feature provides minimal
reduction in positioner capacity.

Ideal for the welding of fittings, flanges and small diameter pipe
INCREASE WELD QUALITY AND PRECISION WITH THE SELF-CENTERING GRIPPER FOR WELD POSITIONERS

WELDING AND CUTTING

 DIMENSIONS - Inches - Per Diagram
MODEL GRIPPER (Inc. Handle) GRIPPER BODY Clamping Range (min./max.) WEIGHT
D L H1 H2 D1 D2 D3 D4 D5 D6 LBS
WPG-250 10.0 17.5 2.75 1.88 0.38 - 6.25 4.25 - 10 9.15 - 15 .38 - 6.25 5.5 - 11.25 9.15 - 15 20

DIMENSIONS - mm KG
WPG-250 254 444 70 48 10 - 159 108 - 254 23 - 381 10 - 159 140 - 286 232 - 381 9

Also Available From Gullco

GULLCO MODEL GP/GPP-200
WELDING POSITIONERS

Capacities up to 150 lbs. (68 kg.) in the

vertical position, 300 lbs. (132 kg.)

Horizontal 0.27 to 4.63 rpm rotation Table on the Gullco Model GP/GPP-200 Series of Welding
and 0.75 to 12.5 rpm in the “H” model Positioners (above left) is designed for mounting the
Table tilts any angle 0 - 90˚ WPG-250 Welding Gripper as indicated.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

GRIP-11-01
 welding and cutting automation

plate edge bevelling machine - Kbm-18®

KBM-18® Plate Edge Bevellers - Portable - Self Propelled

These plate bevellers produce clean machined bevels with no

thermal distortion on mild steel, stainless steel and aluminum
plate from 1/4” (6.0 mm) to 1 1/2” (38.1 mm) thick. Thinner
material can be bevelled. Please consult the factory for details.
The KBM-18® automatically bevels the topside of the plate
which results in a reduction of time and cost. Savings are further
enhanced when the KBM-18U® underside plate beveller is used
in applications where both sides of the material require bevelling.

Adjustable undercarriage for easy height adjustment.

The KBM-18® can be purchased with an adjustable height,
self-aligning, spring-loaded caster wheel assembly for
self- propelled bevelling along any length of plate maintaining
a uniform bevel and consistent root face. Undercarriage sold
separate.

Angle Bevel Pins Enable Bevel Angle Adjustment ...

KBM-18® units are supplied with angle bevel pins for
22 1/2°, 30°, 37 1/2°, 45° and 55° bevels. Pins for other bevel
angles are available upon request.

kbm-18-100

Operates at 10 feet (3 meters) per minute

with adjustable bevelling head to produce bevel angles 22 1/2° Through 55°

WELDING AND CUTTING

 HYDRAULIC ADJUSTABLE CASTER SPRING LOADED
UNDERCARRIAGE ADJUSTABLE UNDERCARRIAGE

For easy height adjustment Adjustable undercarriages come with

KBM-18® units can be supplied Gullco’s adjustable height
with two types of undercarriage. self-aligning spring loaded caster
Both are supplied with Gullco wheel assemblies for self-propelled
exclusive self-aligning caster operation. Best suited for applications
wheel assemblies to maintaining where constant machine height is
a uniform bevel and consistent required. The spring-loaded wheels
root face. Undercarriage sold KBM-18-069 help to eliminate imperfections in the
KBM-18-080 separate ground to ensure a clean consistent
bevel. Sold separate.
Maximum Bevel Width: 0.71” (18.00 mm) at standard 30° bevel angle on material with a tensile strength of 64,000 lb/
in 2 (45 Kg/mm2) KBM-18U® UNDERSIDE BEVELLING
The KBM-18U®
Maximum Bevel Depth: 0.61” (15.6 mm) at standard 30° bevel angle on material with a tensile strength of 64,000 lb/ is perfect for
in 2 (45 Kg/mm2) bevelling the
underside of the
Min. Plate Thickness: 1/4’’ (6.0mm) Thinner material can be bevelled, consult the factory for details
plate without
Max. Plate Thickness: 1 1/2” (38.1 mm) need for flipping
the work piece
Bevel Speed: 13’ (4 m) per minute* over. Safety is
increased as
Motor: 2HP, 3 Phase, available for 230, 460 and 575V~ at 60Hz and also 380 there is no need
and 400/415V~ at 50Hz supply for constant
maneuvering of heavy workloads.
Weight: 340 lbs. (154Kg.) including undercarriage assembly
Production can further be increased with
Complies With: C.S.A./N.R.T.L. (File # LR 35006-6) and C.E. Regulations use of both models simultaneously.

* top speed can vary depending on bevel depth, voltage and frequency fluctuation
ACCESORIES AVAILABLE:
- Gullco KBM-18-069 Adjustable Height Undercarriage
KBM-18® comes complete with the following standard equipment: - KBM-18-X1C: Medium Tooth Cutter (smooth finish)
1- KBM-18-X1C Deep Tooth Cutter (medium cut) - KBM-18-X1H: High Tensile Cutter
- GBM-18 (Specify Degree Required): Angle Bevel Pins for angles
1- Set Bevel Angle Pins for 22 1/2°, 30°, 37 1/2°, 45° and 55° other than those supplied as standard)
1- Tool Kit - GBM-18-0.5: Cutter Shims
- GBM-18-1.0: Cutter Shims

A
MAXIMUM W
RECOMMENDED
BEVELLING CAPACITIES D

TENSILE STRENGTH
BEVEL ANGLE
64,000 lbs/in² (45 kg/mm²) 71,000 lbs/in² (50 kg/mm²) 85,000 lbs/in² (60 kg/mm²)

A W D W D W D

22 1/2˚ 0.71” (18 mm) 0.66” (16.6 mm) 0.67” (17 mm) 0.62” (15.7. mm) 0.55” (14 mm) 0.51” (13 mm)

30˚ 0.71” (18 mm) 0.61” (15.6 mm) 0.59” (15 mm) 0.51” (13 mm) 0.51” (13 mm) 0.44” (11.2 mm)

37 1/2˚ 0.67” (17 mm) 0.53” (13.5 mm) 0.55” (14 mm) 0.44” (11.1 mm) 0.47” (11.9 mm) 0.37” (9.5 mm)

45˚ 0.67” (17 mm) 0.47” (12 mm) 0.55” (14 mm) 0.39” (9.9 mm) 0.47” (11.9 mm) 0.33” (8.4 mm) KBM-18-100
KBM-18-069
55˚ 0.59” (15 mm) 0.34” (8.6 mm) 0.55” (14 mm) 0.32” (8 mm) 0.47” (11.9 mm) 0.27” (6.8 mm)

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

KBM18-11-01
 welding and cutting automation

UNDERSIDE PLATE BEVELLING MACHINES - KBM-18U®

These plate bevellers produce clean machined bevels with no

thermal distortion on mild steel, stainless steel and aluminum
plate from 1/4” (6.0 mm) to 1 1/2” (38.1 mm) thick. Thinner
material can be bevelled. Please consult the factory for
details. The KBM-18U® automatically bevels the underside
of plate eliminating the need to flip the work piece which
results in a reduction of time and cost. Savings are further
enhanced when the KBM-18® top-side plate beveller is
used in applications where both sides of the material require
bevelling.

Adjustable undercarriage for easy height adjustment. The

KBM-18U® can be purchased with a hydraulic adjustable
height, self-aligning, spring-loaded caster wheel assembly for
self-propelled bevelling along any length of plate maintaining
a uniform bevel and consistent root face.

Angle bevel Pins...Enable bevel Angle Adjustment kbm-18u®

units are supplied with angle bevel pins for 22 1/2°, 30°, 37
1/2°, 45° and 55° bevels. Pins for other bevel angles are
available upon request.

KBM-18U® KBM-18®
kbm-18u®
...bevelling the under-side ...bevelling the top-side
of the plate of the plate

Operates at 10 feet (3 meters) per minute

wiTh AdjuSTAblE bEvElling hEAd To ProducE bEvEl AnglE 22 1/2° Through 55°

WELDING AND CUTTING

 HYDRAULIC ADJUSTABLE CASTER SPRING LOADED
UNDERCARRIAGE ADJUSTABLE UNDERCARRIAGE
   
For easy height adjustment Adjustable undercarriages come with
KBM-18U® units can be supplied gullco’s adjustable height, self-aligning
with two types of undercarriage. both spring loaded, caster wheel assemblies
are supplied with gullco exclusive for self-propelled operation. best suited for
self-aligning caster wheel assemblies applications where constant machine height
to maintaining a uniform bevel and is required. The spring-loaded wheels help
consistent root face. undercarriage to eliminate imperfections in the ground
sold separate to ensure a clean consistent bevel. Sold
separate.
kbm-18-080 KBM-18-069

Maximum Bevel Width: 0.71” (18.00 mm) at standard 30° bevel angle on material with a tensile strength of
64,000 lb/ in2 (45 kg/mm2)
KBM-18® TOPSIDE BEVELLER

The KBM-18® is
Maximum Bevel Depth: 0.61” (15.6 mm) at standard 30° bevel angle on material with a tensile strength of
perfect for bevelling
64,000 lb/ in 2 (45 kg/mm2)
the topside of the
plate without need
Min. Plate Thickness: 1/4’’ (6.0mm) Thinner material can be bevelled, consult the factory for details
for flipping the work
piece over. Safety is
Max. Plate Thickness: 1 1/2” (38.1 mm)
increased as there is
no need for constant
Bevel Speed: 120 in. (304.8 cm) per minute*
maneuvering of
heavy workloads.
Motor: 2 hP, 3 Phase, available for 230, 460 and 575v~ at 60hz and also 380
Production can
and 400/415v~ at 50hz supply
further be increased with use of both models
simultaneously.
Weight: 340 lbs. (154 kg.) including undercarriage assembly

Complies With: C.S.A./n.r.T.l. (File # lr 35006-6) and C.E. regulations

* top speed can vary depending on bevel depth, voltage and frequency fluctuation
AccESoriES AvAilAblE:
- KBM-18-069 Adjustable Height Undercarriage
KBM-18® comes complete with the following standard equipment: - KBM-18-X1C: Medium Tooth Cutter (smooth finish)
1- KBM-18-X1C Deep Tooth Cutter (Medium Cut) - KBM-18-X1H: high Tensile cutter
1- Set bevel Angle Pins for 22 1/2°, 30°, 37 1/2°, 45° and 55° - GBM-18 (Specify degree required): Angle bevel Pins for angles
other than those supplied as standard)
1- Tool kit - GBM-18-0.5: Cutter Shims
- GBM-18-1.0: Cutter Shims

MAXIMUM
RECOMMENDED
BEVELLING CAPACITY

TENSILE STRENGTH
BEVEL ANGLE
64,000 lbs/in² (45 kg/mm²) 71,000 lbs/in² (50 kg/mm²) 85,000 lbs/in² (60 kg/mm²)

A W D W D W D

22 1/2˚ 0.71” (18 mm) 0.66” (16.6 mm) 0.67” (17 mm) 0.62” (15.7. mm) 0.55” (14 mm) 0.51” (13 mm)

30˚ 0.71” (18 mm) 0.61” (15.6 mm) 0.59” (15 mm) 0.51” (13 mm) 0.51” (13 mm) 0.44” (11.2 mm)

37 1/2˚ 0.67” (17 mm) 0.53” (13.5 mm) 0.55” (14 mm) 0.44” (11.1 mm) 0.47” (11.9 mm) 0.37” (9.5 mm)

45˚ 0.67” (17 mm) 0.47” (12 mm) 0.55” (14 mm) 0.39” (9.9 mm) 0.47” (11.9 mm) 0.33” (8.4 mm)

55˚ 0.59” (15 mm) 0.34” (8.6 mm) 0.55” (14 mm) 0.32” (8 mm) 0.47” (11.9 mm) 0.27” (6.8 mm)

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

KBM18U-11-01
 welding and cutting automation

Plate Bevelling machine - Heavy Duty KBM-28®

KBM-28® Plate Edge Beveller -

Heavy Duty - Portable - Self-Propelled - No Noise

KBM-28® Bevellers produce clean machined bevels with no

thermal distortion on mild steel, stainless steel and aluminum
plate from 5/16” (8.0 mm) to 2”(50.0 mm) thick.The KBM-28®
automatically bevels the topside of the plate reducing time
and cost. Savings are further enhanced when the KBM-28U®
underside beveller is used in applications where both sides of
the plate require bevelling.

This portable plate beveller has an adjustable undercarriage

for easy height adjustment. The KBM-28® units can be
purchased with Gullco’s exclusive adjustable height,
self-aligning, spring-loaded caster wheel assembly for
self-propelled bevelling along any length of plate which helps
to maintaining a uniform bevel and consistent root face. Sold
separate

Angle bevel pins enable bevel angle adjustments

The KBM-28® units are supplied with angle bevel pins for 22
1/2°, 30°, 37 1/2°, 45° and 55° bevels. Pins for other bevel
angles are available upon request.

kbm-28-100 KBM-28® KBM-28U®

...for bevelling the top-side ...for bevelling the under-side
of plate of plate

Operates at 6.5 feet (2 meters) per minute

With adustable bevelling head to produce bevel angles 22 1/2˚ Through 55˚

WELDING AND CUTTING

 HYDRAULIC ADJUSTABLE KBM-28U® UNDERSIDE
UNDERCARRIAGE BEVELLER

For easy height adjustment KBM-28® The KBM-28U® is perfect for

units can be supplied with two types of bevelling the underside of the
undercarriages. Both are supplied with plate without need for flipping
Gullco exclusive self-aligning caster the work piece over. In com-
wheel assemblies for self-propelled bination with the KBM-28®
bevelling along the length of the plate, efficiency is greatly increased
maintaining a uniform bevel and when bevelling both the top
consistent root face. Undercarriage and bottom of the plate.
KBM-28-080 sold separate

Maximum Bevel Width: 1.10” (28.00 mm) at standard 30° bevel angle on material
with a tensile strength of 64,000 lb/in2 (45 Kg/mm2)

Maximum Bevel Depth: 0.95” (24.2 mm) at standard 30° bevel angle on material
with a tensile strength of 64,000 lb/in2 (45 Kg/mm2)

Min. Plate Thickness: 5/16’’ (8.0 mm)

Max. Plate Thickness: 2” (50.0 mm)

Bevel Speed: 78.7” (200 cm) per minute*

Motor: 3 HP, 3 phase, available for 230, 460 and 575V~

at 60Hz and also 380 and 400/415V~ at 50Hz supply

Weight: 979 lbs. (444Kg.) including undercarriage assembly

Complies With: C.S.A./N.R.T.L. (File # LR 35006-6) and C.E. Regulations

* Top speed can vary depending on bevel depth, voltage and frequency fluctuation
Accessories available:
- KBM-28-X1C: Medium Tooth Cutter (smooth finish)
- KBM-28-X1H: HighTensile Cutter
- GBM-28 (Specify Degree Required): Angle Bevel Pins for
KBM-28® comes complete with the following standard equipment: angles other than those supplied as standard)
1– KBM-28-X1C Cutter (medium cut) - GBM-28-0.5: Cutter Shims
- GBM-28-1.0: Cutter Shims
1- Set Bevel Angle Pins for 22 1/2°, 30°, 37 1/2°, 45°and 55 °
- KBM-28-080: Hydraulic Undercarriage
1- Tool Kit

MAXIMUM W

RECOMMENDED
D
BEVELLING CAPACITIES

TENSILE STRENGTH
BEVEL ANGLE
64,000 lbs/in² (45 kg/mm²) 71,000 lbs/in² (50 kg/mm²) 85,000 lbs/in² (60 kg/mm²)

A W D W D W D

22 1/2˚ 1.10” (28 mm) 1.02” (26 mm) 1.02” (26 mm) 0.95” (24 mm) 0.91” (23 mm) 0.84” (21.3 mm)

30˚ 1.10” (28 mm) 0.95” (24.2 mm) 0.98 (25 mm) 0.85 (21.6 mm) 0.89” (22.5 mm) 0.77” (19.5 mm)

37 1/2˚ 1.06” (27 mm) 0.84” (21.4 mm) 0.98” (25 mm) 0.78” (19.8 mm) 0.83” (21 mm) 0.66” (16.7 mm)

45˚ 1.02” (26 mm) 0.72” (18.4 mm) 0.94” (24 mm) 0.67” (17 mm) 0.83” (21 mm) 0.58” (14.9 mm)

55˚ 0.98” (25 mm) 0.56” (14.3 mm) 0.91” (23 mm) 0.52” (13.2 mm) 0.83” (21 mm) 0.47” (12 mm)

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

KBM28-11-01
 welding and cutting automation

UNDERSIDE Plate Bevelling machinE - KBM-28U®

KBM-28U® Underside Plate Edge Beveller - Heavy Duty

These Plate Bevellers produce clean machined bevels with no

thermal distortion on mild steel, stainless steel and aluminum
plate from 5/16” (8.0 mm) to 2” (50.0 mm) thick. The
KBM-28U® bevels the underside of the plate eliminating the
need to flip the workpiece which results in a reduction of time
and cost. Savings are further enhanced when both topside
and underside units are used when both sides of a work piece
require bevelling.

Adjustable undercarriages for easy height adjustment.

The KBM-28U® units can be purchased with Gullco’s hydraulic
adjustable height, self-aligning undercarriage for self-propelled
bevelling along any length of plate maintaining a uniform bevel
and consistent root face. Sold separate

Bevel Angle Adjustment Pins...

KBM-28U® units are supplied with angle bevel pins for
22 1/2°, 30°, 37 1/2°, 45° and 55° bevels. Pins for other bevel
angles are available upon request.
kbm-28U®

Operates at 6.5 feet (2 meters) per minute

With adustable bevelling head to produce bevel angles 22 1/2˚ Through 55˚

WELDING AND CUTTING

 HYDRAULIC ADJUSTABLE KBM-28-100
UNDERCARRIAGE
The KBM-28® is perfect for
For easy height adjustment bevelling the topside of the
KBM-28U® units can be supplied with an plate without need for flipping
undercarriage. This undercarrage uses Gullco the work piece over.
exclusive self-aligning caster wheel assemblies In combination with the
for self-propelled bevelling along the length KBM-28U® efficiency is greatly
of the plate, maintaining a uniform bevel increased when bevelling both
and consistent root face. Undercarriage sold the top and bottom of the plate.
KBM-28-080 separate.

Maximum Bevel Width: 1.10” (28.00 mm) at standard 30° bevel angle on material
with a tensile strength of 64,000 lb/in2 (45 Kg/mm2)

Maximum Bevel Depth: 0.95” (24.2 mm) at standard 30° bevel angle on material
with a tensile strength of 64,000 lb/in2 (45 Kg/mm2)

Min. Plate Thickness: 5/16’’ (8.0 mm)

Max. Plate Thickness: 2” (50.0 mm)

Bevel Speed: 78.7” (200 cm) per minute*

Motor: 3 HP, 3 phase, available for 230, 460 and 575V~

at 60Hz and also 380 and 400/415V~ at 50Hz supply

Weight: 890 lbs. (404Kg.) including undercarriage assembly

Complies With: C.S.A./N.R.T.L. (File # LR 35006-6) and C.E. Regulations

* Top speed can vary depending on bevel depth, voltage and frequency fluctuation
Accessories available:
- KBM-28-X1C: Medium Tooth Cutter (smooth finish)
KBM-28U® comes complete with the following standard equipment: - KBM-28-X1H: HighTensile Cutter
- GBM-28 (Specify Degree Required): Angle Bevel Pins for
1– KBM-28-X1C Cutter (medium cut) angles other than those supplied as standard)
1- Set Bevel Angle Pins for 22 1/2°, 30°, 37 1/2°, 45°and 55 ° - GBM-28-0.5: Cutter Shims
1- Tool Kit - GBM-28-1.0: Cutter Shims
- KBM-28-080: Hydraulic Undercarriage
- KBM-28-002: Adjustable Undercarriage

MAXIMUM
RECOMMENDED
BEVELLING CAPACITIES

TENSILE STRENGTH
BEVEL ANGLE
64,000 lbs/in² (45 kg/mm²) 71,000 lbs/in² (50 kg/mm²) 85,000 lbs/in² (60 kg/mm²)

A W D W D W D

22 1/2˚ 1.10” (28 mm) 1.02” (26 mm) 1.02” (26 mm) 0.95” (24 mm) 0.91” (23 mm) 0.84” (21.3 mm)

30˚ 1.10” (28 mm) 0.95” (24.2 mm) 0.98 (25 mm) 0.85 (21.6 mm) 0.89” (22.5 mm) 0.77” (19.5 mm)

37 1/2˚ 1.06” (27 mm) 0.84” (21.4 mm) 0.98” (25 mm) 0.78” (19.8 mm) 0.83” (21 mm) 0.66” (16.7 mm)

45˚ 1.02” (26 mm) 0.72” (18.4 mm) 0.94” (24 mm) 0.67” (17 mm) 0.83” (21 mm) 0.58” (14.9 mm)

55˚ 0.98” (25 mm) 0.56” (14.3 mm) 0.91” (23 mm) 0.52” (13.2 mm) 0.83” (21 mm) 0.47” (12 mm)

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

KBM28U-11-01
 KBM BEVELS ALUMINIUM
Portable beveler replaces large plainer

The Gullco International

customer does plenty of
plate beveling heavy
plates, 5254 and 5654
a l um i n um , t yp i c a l l y
10x30 feet x1/2 inch
weighing 2,100 pounds,
go into the manufacture
of railroad tank cars.
After plasmas tank
cutting to shape, the
plate requires a 30° bevel
with a 1/16 inch land on
all four edges. Then wire
brushes clean 12 inches
back from beveled
edges, a bending
machines rolls the plate
into cylinders, nine feet in
diameter. GMAW guns
on booms weld the
cylinders in flat position.

With the seam on the bottom, machines weld one pass at a current of 310 to 320 amps on the beveled side. The
guns move at 10 to 14 in./ min. to weld longitudinal seams. Then, with guns stationary, the cylinders rotate to
make circumferential welds. Milling backchips the joint to solid weld metal for the final pass, laid in at 340 to 360
amps from the outside of the cylinder. Fillers: 5654 or 5254 aluminum plate and 5356 or 5554 (depending on
customer specification) for 5454 plate. X-rays inspect all tank car cylinder welds. Faced with overhaul of its large
beveling plainer, at a cost of $50 000 to $80 000 the customer found that it could improve operations . Two small
portable bevellers now on the line in place of the plainer have doubled the rate of plate edge beveling at the plant.

With the plainer, an overhead crane rotated the plate, and

fixtures held it in place for beveling all four edges of each
plate. Fixturing difficulties caused uneven bevels, resulting in
excessive weld repair. The new way is easier and gives better
results. The plate lies flat on stands at a height set for the
beveling machine. The operator rolls the caster spring-loaded
wheel assembly over to the work piece, clamps it to the plate
edge, and starts the motor. The machine bevels plate as it
moves along to make a consistent smooth, clean bevel. No
more repositioning of the plate. With the increased beveling
rate on the plate line, the new machines can bevel plate in
other departments. They can cut a 22.5° or 55° bevel on alu-
minum, mild steel, or stainless steel plate.
 Small portable bevelers have enjoyed success
replacing larger plaining machines and flame
cutting equipment for beveling of aluminum, and
low carbon steel. Recently a company based
out of Ohio gave one of these small machines a
tough new assignment beveling of titanium
plate. The firm fabricates ASME Code vessels
of titanium, zirconium and tantalium. Most of the
vessels go to petroleum processing plants.

In the past the heavy section titanium plate

would be sent to an outside vendor where an
open side plaining machine would bevel the
plate edges. The company would also take part
in some in house flame cutting where operators
would flame cut thick sections. This operation
left a heat affected zone and grinders had to
remove heat-affected metal. Plate farmed out
for beveling added cost of handling, shipping
and purchased machine time.

When the company put the KBM to the test on the

heavy titanium the high speed portable plate edge
beveler proved its worth. The beveler immediately got
to work and has earned steady duty there at the fac-
tory. It machines clean cuts in titanium, taking over
work formerly done by flame cutting, outside
machining and nibbling in sections. The biggest
benefit other then the greatly reduced production cost
is that KBM bevelers eliminate heat distortion which
results in a more quality weld.

Beveling with the Gullco machine is quick and easy.

An operator wheels the machine to the work piece
and with spring loaded castor wheel assemblies the
beveling machine will accommodate for any uneven
surface making for a clean machined bevel every
time.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

KBM-07-01A
welding and cutting automation

welding electrode drying ovens

Compact In-Shop Models...

Eliminate the risk of costly rework
and rejects.

Ensure consistent physical

properties and x-ray quality welds.

Protect low hydrogen quality in

...Portable Models electrode and flux-core wire.

Protect coatings on aluminum,

bronze, cast iron stainless and
other electrodes.

Improve weld consistency and reduce cost

MAINTAIN CONSISTENT WELD ELECTRODE PROPERTIES TO INSURE HIGH QUALITY WELDS

WELDING AND CUTTING

THE PORTABLES....
They’re lightweight, durable and complete-
ly portable, easy to load, easy to carry,
ready to provide low cost control of welding
quality in the shop or in the field. Reduce
operating costs by providing your welding
operators with fast access to electrodes at
the point of work. There’s a model exactly
suited for your requirements.

Thermometer #1029-8

8” Thermometer

For use with the portable oven

models 10 A-20 and 10B-20. Fits se-
curely into the standard oven rod lifter.

70 lbs
20 LB. CAPACITY PORTABLES CAPACITY PORTABLES

MODEL 50

MODEL 10A-20 This handy portable oven, only

23” high and 11” in diameter,
Operates from any 115 volt, AC/DC source, is equipped gives fast access to up to 50
with rod lifter, pilot light and has 1” high false bottom to lbs of stabilized rods in the
prevent moisture damage to electric connections. The shop or in the field. It operates
oven temperature, not controlled by thermostat, average on 115 volt, AC. Thermostatic
275˚ F and provides absolute electrode stability when control maintains oven tem-
used in conjunction with temperature controlled ovens. perature in the 100˚ - 300˚F
range. High performance /
efficiency feature include:

- Central calrod element

MODEL 10B-20 ensures uniform distribution of
heat in oven
Operates on 115 volt, AC only.
Has rod lifters, pilot light, and thermostat that maintains - a full 2 inches of insulation
oven temperature in 100˚ F to 300˚ F range, providing surrounds oven wall
independant control of electrode welding quality.
- Equipped with two separate
rod lifters to give the welding
operator fast access to
different rod types
 ...AND COMPACT, IN SHOP MODELS

Model 125
- for operation on Model 350
115 or 220 Volt, AC. - for operation on 115 or
220 Volt, AC

These Gullco Stabilizing Ovens have gained Compact

international recognition and acceptance and
based on a variety of quality performance Stackable
features including:

• Compact, modular design with controls HIGH

recessed for protection. TEMP
TO
• Shelves easily removed to accommodate 605˚F
large size loads.
AVAILABLE
ON
• Oven fully insulated to prevent heat loss
and a pilot light indicates oven operation. MOST
MODELS Model 1000
• Thermostat control, incorporating on/off - for operation on 220/440 Volt, AC
switch, maintains oven temperature in 100˚
- 550˚ F range.
1000 Lb. CAPACITY HIGH
• Model 125 and 350 feature nesting feet
TEMPERATURE ELECTRODE
and sockets for safe, easy stacking.
RE-BAKING AND STABILIZING OVEN

Custom configured palletized multi-compartment OVENS

Do your specs
involve different
temperatures or
bake times?

Gullco has a
configuration to
suit your needs! ...available in two Models - one equipped
wth an Indicating Control System and the
Thermometer Accessory- other with an Electronic Digital Programmer
Model T23 - Thermometer with amounting bracket and screw for
and Controller.
front mounting on the Model 125 and 350 ovens.
specifications

PORTABLE OVENS COMPACT IN-SHOP MODELS

10 A-20 10 B-20 50 125 350 1000

Sixteen 12” Spools /
Capacity 10 to 20 lbs. 50 to 70 lbs. 125 to 175 lbs. 350 to 400 lbs.
1000 lbs.
39 3/4”H x 30 1/4”W x
Outside Dimensions 7” dia. X 23” high 11” dia. X 23” high 16”H x 16”W x 24 1/2”D 22”H x 22”W x 24 1/2”D
30 3/4”D
Inside Dimensions 3” dia. X 19” high 7” dia. X 19” high 8 1/4”H x 9 3/4”W x 19”D 14”H x 16”W x 19”D 24”H x 21 3/4”W x 24”D
Unit Weight (approx.) 14 lbs. 32 lbs. 58 lbs. 58 lbs. 330 lbs.
Electrode Size up to 18” up to 18” up to 18” up to 18” up to 24”
Line Cord 3 wire - 8 ft. 3 wire - 8 ft. 3 wire - 8 ft. 3 wire - 8 ft. None None
3000W - 220/440 V-1
Element 100W - 115Volt 125W - 115Volts 300W - 115 Volt 1000W - 115 Volts 1500W - 115V or 220V
Phase
Thermostat No Yes Yes Yes Yes Yes
Pilot Light Yes Yes Yes Yes Yes
Temp. Range Av. 275˚ F 100˚ - 400˚ F 100˚ - 400˚ F 100˚ - 550˚ F 100˚ - 550˚ F 100˚ - 550˚ F
Door Latch Lift Lid Lift Lid Push / Pull Push / Pull Push / Pull
Stacking No No Yes Yes Yes

All specifications are subject to change without notice Note: Weight capacity depends on electrode length

AND FOR FLUX CONDITIONING AND CONTROL...

FLUX HOPPERS
AND HOLDING OVENS

The 100 lb. capacity hopper and 600 lb. capacity

holding oven illustrated at right are just part of a
complete range of flux conditioning / control units
available from Gullco. All ovens are equipped with
low watt density elements to maintain uniform
temperature through the flux load. All hoppers and
holders are designed to assure that the most strin-
gent flux specifications are maintained.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

OV-11-01-I
welding and cutting automation

welding electrode drying ovens

Compact In-Shop Models...

Eliminate the risk of costly rework
and rejects.

Ensure consistent physical

properties and x-ray quality welds.

Protect low hydrogen quality in

...Portable Models electrode and flux-core wire.

Protect coatings on aluminum,

bronze, cast iron stainless and
other electrodes.

Improve weld consistency and reduce cost

MAINTAIN CONSISTENT WELD ELECTRODE PROPERTIES TO INSURE HIGH QUALITY WELDS

WELDING AND CUTTING

THE PORTABLES.... They’re lightweight, durable and
completely portable, easy to load, easy
to carry, ready to provide low cost control
of welding quality in the shop or in the
field. Reduce operating costs by providing
your welding operators with fast access to
electrodes at the point of work. There’s a
model exactly suited for your requirements.

Thermometer #1029-8

8” Thermometer

For use with the portable oven

models 10 A-20 and 10B-20. Fits
securely into standard oven rod lifter

31.75 kg.
CAPACITY PORTABLES

9KG. CAPACITY PORTABLES MODEL 50

This handy portable oven, only

584mm high and 280mm in
MODEL 10 A-20 diameter, gives fast access
to up to 22.7 kg. of stabilized
Operates from any 115 volt, AC/DC source, is equipped with rods in the shop or in the field.
rod lifter, pilot light and has 25.4 mm high false bottom to pre- It operates on 115 volt, AC.
vent moisture damage to electric connections. The oven tem- Thermostatic control maintains
perature, not controlled by thermostat, averages 135˚ C and oven temperature in the 38˚ to
provides absolute electrode stability when used in conjunction 204˚ C range. High
with temperature controlled ovens. performance / efficiency
feature include:

- Central calrod element

MODEL 10 B-20 ensures uniform distribution of
heat in the oven
Operates on 115 or 220 volt, AC only. Has rod lifters,
pilot light, and thermostat that maintains oven temperature in - a full 51 mm inches of insula-
38˚ C to 204˚ C range, providing independant control of tion surround the ovens walls
electrode welding quality.
- Equipped with two separate
rod lifters to give the welding
operator fast access to
different rod types
 ...AND COMPACT, IN SHOP MODELS

Model 125
- for operation on Model 350
115 or 220 Volt, AC. - for operation on 115 or
220 Volt, AC

These Gullco Stabilizing Ovens have gained Compact

international recognition and acceptance and
based on a variety of quality performance Stackable
features including:

• Compact, modular design with controls HIGH

recessed for protection. TEMP
TO
• Shelves easily removed to accommodate 313˚C
large size loads.
AVAILABLE
ON
• Oven fully insulated to prevent heat loss
and a pilot light indicates oven operation. MOST
MODELS Model 1000
• Thermostat control, incorporating on/off - for operation on 220/440 Volt, AC
switch, maintains oven temperature in 38˚ -
288˚ C range.
454 kg. CAPACITY HIGH
• Model 125 and 350 feature nesting feet
TEMPERATURE ELECTRODE
and sockets for safe, easy stacking.
RE-BAKING AND STABILIZING OVEN

Custom configured palletized multi-compartment OVENS

Do your specs
involve different
temperatures or
bake times?

Gullco has a
configuration to
suit your needs! ...available in two Models - one equipped
wth an Indicating Control System and the
Thermometer Accessory- other with an Electronic Digital Programmer
Model T23 - Thermometer with amounting bracket and screw for
and Controller.
front mounting on the Model 125 and 350 ovens.
specifications

PORTABLE OVENS COMPACT IN-SHOP MODELS

10 A-20 10 B-20 50 125 350 1000

Capacity 9 kg. 31 kg. 57 kg. 159 kg. 454 kg.
Outside Dimensions 178mm Dia x 585mm High 279 D x 584 H 407 W x 407 H x 622 L 559 W x 559 H x 622 L 768 W x 1016 H x 768 L
Inside Dimensions 76mm Dia. x 483mm High 177 dia. X 483 high 248 W x 209 H x 482 L 405 W x 356 H x 482 L 552 W x 610 H x 610 L
Unit Weight (approx.) 7 kg. 16 kg. 27 kg. 50 kg. 150 kg.
Electrode Size up to 457mm up to 457mm up to 457mm up to 457mm up to 457mm
Line Cord 2428mm 2428mm 2428mm 2428mm None None
3000W - 220/440 V-1
Element 100W - 115Volt 125W - 115Volts 300W - 115 Volt 1000W - 115 Volts 1500W - 115V or 220V
Phase
Thermostat No Yes Yes Yes Yes Yes
Pilot Light Yes Yes Yes Yes Yes
Temp. Range 135˚ C 38˚ - 148˚ C 38˚ - 148˚ C 38˚ - 228˚ C 38˚ - 288˚ C 38˚ - 288˚ C
Door Latch Lift Lid Lift Lid Push / Pull Push / Pull Push / Pull
Stacking No No Yes Yes Yes

All specifications are subject to change without notice Note: Weight capacity depends on electrode length

AND FOR FLUX CONDITIONING AND CONTROL...

FLUX HOPPERS
AND HOLDING OVENS

The 45 kg. capacity hopper and 272 kg. capacity

holding oven illustrated at right are just part of a
complete range of flux conditioning / control units
available from Gullco. All ovens are equipped with
low watt density elements to maintain uniform
temperature through the flux load. All hoppers and
holders are designed to assure that the most
stringent flux specifications are maintained.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

OV-11-01-M
welding and cutting automation

weld flux hoppers and rebake ovens

Flux Holding Ovens

Flux Rebake Ovens

Maintain critical flux specifications with

precise temperature control

Utilizes low watt density elements to

allow for accurate uniform temperature
control

Flux Hopper and Rebake Ovens for Submerged Arc Welding

FLUX HOPPERS AND FLUX HOLDING OVENS ASSURE FLUX SPECIFICATIONS ARE MAINTAINED

WELDING AND CUTTING

 FLUx hoppers flux holding ovens
100 lb. HOPPER

MODEL GOV 100 FH: MODEL

This 100 lb. Capacity Flux GOV 100 PFD:
Hopper is designed for This portable 100
mounting either directly lb. capacity Flux
above the welding head or Holding Oven
on the welding manipulator to uses the same
maintain the flux in its original flux hopper as
dry state. It is complete Model GOV 100
with mountings lugs, lift-off FH except it is
loading lid, thermometer, flux supplied complete
level window, flux screen with a portable
and a flux heating system carrier, a 25 lb.
incorporating 40 watts of capacity flux
low density elements. The bucket for transfer
temperature is controlled by a of the flux to the
thermostat. The temperature welding head. Flux
range is 100° to 400° F. All for bucket gravity feed from a positive lever
operation on 115 / 230 volts, type valve at the base of the Hopper. The
50/60 cycle AC power supply. 100 lb. Hopper can be readily detached from
Weight 27 lbs. its portable carrier and mounted directly
above the welding head or on the welding
manipulator. All for operation on 115 / 230
volts, 50/60 cycle AC power supply. Weight
50 lb.

submerged arc moggy

MODEL GM-02

This SAM®
trackless welding
carriage can
be equipped
to produce
precision, quality
submerged arc
or MIG welds.
It is guided
by adjustable
horizontal guide roller assemblies which maintain
a set distance from a vertical member or a unique
optional “handled” steering device. The unit comes
complete with a removable attachment post
that holds a wire feed head, flux hopper & valve
(submerged arc unit only), wire spool, controls and
adjustable weld positioning brackets with horizontal
and vertical slides that enable full positioning of the
weld gun either behind or beside the carriage.
 200 lb. holding oven

MODEL GOV 200 FD:

This insulated 200 lb. capacity Flux Holding

Oven is generally located in the storage area
and is used to keep the flux in its dry state or
to dry out flux that has picked up moisture. It is
complete with lifting lugs, and hinged loading
lid, thermometer and a flux heating system
incorporating 1500 watts of low density elements.
The temperature is controlled by a thermostat.
The temperature range is 100° to 550°F. All for
operation on 115 / 230 volts, 50/60 cycle AC
power supply. Weight 155 lbs.

600 lb. holding ovens

MODEL GOV 600 FD3:

This fully insulated 600 lb. capacity Flux Oven

incorporates three (3) individual 200 lb. hoppers,
enabling up to three (3) different types of flux to
be stored and dried simultaneously. It is complete
with three (3) individual thermometers and a flux
heating system incorporating 4500 watts of low
density elements. Temperature is controlled by
three (3) individual thermostats so that each hopper
is individually controlled. Temperature range 100° to
550°F. All for operation on 220 / 415 volt, 3 phase
AC power supply. Weight 250 lb.

NOTE: All above Ovens can be supplied for

operation on 220 volts or 440 volts, single
phase power supply. Please consult with
manufacturing.

600 LB FLUX BAKE OVEN Model GOV 600 FDH:

This fully insulated 600 lb. capacity high temperature

Flux Bake Oven is similar in design to the above Model
GOV 600 FD3, except incorporating high temperature
insulation, high temperature wiring and the flux heating
system which incorporates 11,400 watts of low density
elements. Temperature range 100° to 850°F. Each
hopper controlled by and individual thermostat to provide
individual temperature control. All for operation on 220,
440 or 575 volts, 3 phase power supply. Weight 350 lb. *

* Voltage must be specified at time of placing order

 THE most complete range of stabilizing ovens

PORTABLE WELDING OVENS

These electrode ovens are lightweight but durable. The design makes this oven model easy to carry and
easy to load. The welding ovens provide low cost control of welding quality in the shop or at the job site.
Available in 20 lb. capacity and 50 lb. capacity models.
model 350

model 50
50 lb Capacity
Electrode oven with
handle and wheel
assembly for easier
portability
model 125 model 10A-20

WELDING OVENS: 1000 POUND CAPACITY HIGH TEMPERATURE

COMPACT IN-SHOP MODELS ELECTRODE RE-BAKING STABILIZING OVEN
Available in two models, one
The in-shop models are designed to maintain
equipped with an Indicating
electrode integrity at a higher temperature range.
Control System and the
All in-shop models have a recessed control panel
other with an Electronic
for protection as well as removable shelves and
Digital Programmer
thermostat control. These models are available in
Controller.
125 lb., 350 lb. and 1000 lb. capacities.

KAT, KBM, MOGGY, KATBAK & SAM are registered trademarks of Gullco Enterprises Limiited SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL DIMENSIONS ARE NOMINAL

FH-11-01