GALAGAR GPS DR ADVANCED Instruction Manual
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GALAGAR GPS DR ADVANCED Instruction Manual

Industrial mig/mag welding equipment of pulsed-synergic control
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GPS DR ADVANCED
TECHNICAL INSTRUCTIONS MANUAL. GPS MODULAR SYSTEM.
EN
INDUSTRIAL MIG/MAG WELDING EQUIPMENT OF PULSED-SYNERGIC CONTROL.
THIS EQUIPMENT SHOULD BE USED ONLY BY PROFESSIONALS.
EN
GALA PULSE SYNERGIC 4000 DR ADVANCED
GALA PULSE SYNERGIC 5000 DR ADVANCED
TO HELP YOU IN YOUR WORK
READ THIS MANUAL CAREFULLY.
(3Ph - 400V 50/60 Hz); Ref. 42381200
(3Ph - 440V 50/60 Hz); Ref. 42355200
(3Ph - 400V 50/60 Hz); Ref. 42600200
(3Ph - 440V 50/60 Hz); Ref. 42650200
Jaime Ferrán 19 50014 ZARAGOZA (Spain)
Tel.: 00 34 976473410 - Fax: 00 34 976472450
Ref.: 42617247 V0

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  • Page 1 GPS DR ADVANCED TECHNICAL INSTRUCTIONS MANUAL. GPS MODULAR SYSTEM. INDUSTRIAL MIG/MAG WELDING EQUIPMENT OF PULSED-SYNERGIC CONTROL. THIS EQUIPMENT SHOULD BE USED ONLY BY PROFESSIONALS. TO HELP YOU IN YOUR WORK READ THIS MANUAL CAREFULLY. GALA PULSE SYNERGIC 4000 DR ADVANCED (3Ph - 400V 50/60 Hz);...

  • Page 3: Table Of Contents

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 1. GPS MODULAR SYSTEM - GENERAL DESCRIPTION ---------------------------------------------------- 3 1.1. TECHNICAL FEATURES ------------------------------------------------------------------------------------------------------------- 5 1.2. COOLING MODULE WCS 520 -------------------------------------------------------------------------------------------------------- 5 1.3. D-GPS WIRE FEEDER --------------------------------------------------------------------------------------------------------------------- 6 1.4. RECOMMENDED ACCESSORIES ------------------------------------------------------------------------------------------------------- 6 2. TRANSPORT AND INSTALLATION ----------------------------------------------------------------------- 7 2.1.

  • Page 4: Gps Modular System - General Description

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 1. GPS MODULAR SYSTEM - GENERAL DESCRIPTION. TECHNICAL FEATURES. Multiprocessing equipment, MIG / MAG (STD-PULSED), TIG (STD-PULSED) and MMA (STD-PULSED), recommended for welding all types of materials (carbon steels, aluminium, stainless steels and all those applications in which a reduction in heat input and deformation is necessary).
  • Page 5 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 1- AIR-COOLED INSTALLATION 2- COOLED INSTALLATION REFERENCE DESCRIPTION 42381200 GPS 4000 DR ADVANCED (400 V – 50/60Hz) 42355200 GPS 4000 DR ADVANCED (440 V – 50/60Hz)   Select Select 42600200 GPS 5000 DR ADVANCED (400 V – 50/60Hz) Model Model 42650200...

  • Page 6: Technical Features

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 1.1. TECHNICAL FEATURES. TECHNICAL FEATURES GPS 4000 DR ADVANCED GPS 5000 DR ADVANCED Reference 42381200 42355200 42600200 42650200 Input voltage U1 (3 Ph, 50/60Hz) 400 V 440 V 400 V 440 V Maximum primary intensity I1max 35 A 32 A 40 A...

  • Page 7: D-Gps Wire Feeder

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 1.3. D-GPS WIRE FEEDERS. They have a Universal Welding Control. Enables setting and viewing of parameters. (Except for Blind model).  3 welding regulation variables. (Wire speed, piece thickness and amperes).  Arc correction (Voltage). ...

  • Page 8: Transport And Installation

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 2. TRANSPORT AND INSTALLATION. HANDLE THE EQUIPMENT CAREFULLY, IT WILL LAST LONGER! 2.1. TRANSPORT AND PACKAGING. Knocks and sudden movements must be avoided when transporting the equipment. The transport position will be shown by arrows on the packaging. In any case, the packaging must be protected from water. 2.2.

  • Page 9: Assembly And Dimensions

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 2.3. ASSEMBLY AND DIMENSIONS. ASSEMBLY PROGRAMME. GPS EQUIPMENT OVER TRANSPORT TROLLEY/BASE. There are some openings in the four lower corners used to secure the machine to the carriage, observe arrows on fig. ASSEMBLY PROGRAMME. WELDING EQUIPMENT MOUNTED ON TOP OF THE COOLING MODULE. There are some openings in the four lower corners used to secure the machine to the carriage, observe arrows on fig.

  • Page 10: Start-Up. Operation And Adjustments

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3. START-UP. OPERATION AND ADJUSTMENT CONTROLS. 3.1. OPERATION CONTROLS. FRONT CONTROL PANEL REAR CONTROL PANEL DESCRIPTION Control panel Negative terminal ON/OFF switch Pre-installation Panel Kits INTERFACE INTERFACE CONTROL CONTROL Wire Feeder Signal Connector Power supply cable 3 Ph Positive terminal...
  • Page 11 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.2.1. IDENTIFICATION AREA. It is possible to view the current configuration of our equipment at all times. Only the icons of each process and configuration appear. POSITION DESCRIPTION Welding process. Torch operation mode. Setting details of Operation mode.
  • Page 12 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.2.4. D-GPS UNIVERSAL CONTROL. (See D-GPS Manual). The system is used in remote controls and wire feeders. LD10 LD10 LD11 LD11 LD12 LD12 LED INDICATORS LD 3 Regulation by Reference Thickness. LD 4 Welding Intensity Regulation. LD 5 Wire Speed Regulation.

  • Page 13: Main Menu Screen

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.3. EQUIPMENT START-UP SEQUENCE. In this chapter of the manual, we will develop the process selection, as well as the regulation of the equipment control parameters. When we switch on our equipment, it will carry out an initial check with the configuration installed in it. We can view the configured parameters on the power-up screen: Below we detail the sequence of appearance of icons on the home screen: ICON...

  • Page 14: Mig/Mag Welding. Installation, Start-Up And Operation

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.4. MAIN MENU SCREEN. The home screen or Main Menu allows the user to select the desired welding process as well as the adjustment of equipment configuration parameters. LABEL ACTION Enter to DC TIG Welding Mode Enter to MMA Welding Mode Enter to MIG-MAG Welding Mode Enter to DATA...

  • Page 15: Equipment Configuration Setup

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.5. EQUIPMENT CONFIGURATION SETUP. Before using the equipment, it is recommended to adjust the equipment configuration parameters to our usage preferences. LABEL ACTION Return to Main Menu. Access to Module Enabling. Navigation Right by SEPUP. Navigation Left by SEPUP.
  • Page 16 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.5.1. SETUP CONFIG. PROCESS DESCRIPTION (E1) VARIABLE RANGE (E2) RESET SPANISH-ENGLISH-FRENCH-FRENCH-GERMAN- LANGUAGE SPANISH    ITALIAN COOLING MODE SWITCH-ON/OFF-AUTOMATIC   WIRE THREADING SPEED 1-24 10 M/MIN   SECURITY LEVEL 0 OPEN-1-2-3 CLOSED ...
  • Page 17 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.5.1.2. SECURITY LEVEL SELECTION. The parameter setting limits the actions available to the user per action area. It does not require an access confirmation password, only level selection. ICON REGULATION E2 DESCRIPTION DESCRIPTION Allows modification of all available parameters.
  • Page 18 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.5.1.3. 2ND TORCH BUTTON ACTION. When we use torches that incorporate a double button system, we can choose the action controlled by the secondary button: REGULATION E2 DESCRIPTION Correction We will act on the correction value selected in the equipment.. e.g. Pulsed frequency Increase or decrease for each press 1 programme from the list of available Programme programmes.
  • Page 19 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.5.2. SETUP DATE. DESCRIPTION (E1) VARIABLE RANGE (E2) RESET Year 2000-2099 Month 1-12 1-31 Hour 0-23 Minutes 0-59 Time zone UTM-12 ÷ UTM+12  The factory RESET does not affect the calendar SETUP.
  • Page 20 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.5.3. SETUP GAS CONTROL. DESCRIPTION (E1) VARIABLE RANGE (E2) RESET FLOW CONTROL MODE MANUAL-SYNERGIC-OFF ❶ GAS FLOW 0 ÷ 50 12 l/min. SYNERGIC CORRECTION -10.0 ÷ 10.0 0 l/min. The installation of an external module is required. ❶...
  • Page 21 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.5.4. SETUP CALIBRATE. DESCRIPTION (E1) VARIABLE RANGE (E2) RESET VOLTAGE 12.0 ÷ 42.0 --- V Current 10 ÷ 500 --- A WIRE SPEED 1.0 ÷ 24.0 --- m/min The installation of an external module is required. ❶...
  • Page 22 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 3.5.5. MODULE EDIT. This menu allows the activation of the different welding modules available in the equipment. Each enabling code is independent per module and is associated with the serial number of the equipment, so you must request the modules from your commercial agent.

  • Page 23: Mig Process

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4. MIG PROCESS. Continuous wire, semiautomatic or wire welding, also known as MIG-MAG (Metal Inert-Active Gas), GMAW or 135-136 process, forms part of the welding processes by electric arc. Therefore, before starting the requested welding jobs, we must bear in mind the basic principles of the process.
  • Page 24 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.1.1. START-UP. PRELIMINARY OPERATIONS FOR MIG/MAG WELDING. 1st) Make sure the mains voltage is 400V/ 440V. 2nd) Change the polarity if it is necessary. Polarity to negative (with Flux-cored wire without gas). 3rd) Depending on the wire diameter, fit the groove of the suitable drive roll to the work to be carried out.

  • Page 25: Mig Process - Operation Mode Selection

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.2. MIG PROCESS – OPERATION MODE SELECTION. Starting from the standard configuration, we will access the OPERATION MODE Menu, where we can select different welding modes and arc types. WELDING MODE Time-controlled weld Bead intervals with Standard Use bead.
  • Page 26 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.2.1. MIG PROCESS - PROGRAMME LIST. ACTION DESCRIPTION Return to Main Menu Load Synergy Programme Sort by No. / Description (Filler material) / Group (Shielding gas) Navigate up in programme list. Navigate down in programme list.
  • Page 27 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.2.2 MIG PROCESS (STD + PULSED ARC). THE PULSED ARC TYPE REQUIRES THE ENABLING OF A SPECIFIC PROCESS MODULE. THE APPLICATION OF THE PULSED CURRENT PERMITS ADAPTING THE HEAT INPUT TO THE WELDING DEMANDS, MARQUED FOR THE POSITION, TYPE OF JOINT AND THICKNESS, AS WELL AS A CONSIDERABLE REDUCTION IN THE NUMBER OF SPATTERS.
  • Page 28 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.2.3 MIG PROCESS – MANUAL CONTROL (STD + PULSED ARC). It allows to regulate the wire speed and the welding tension independently of the synergic curve. ACTION DESCRIPTION Return to Main Menu Access to Programme Library Access to Operation Mode / Synergic Programme Selection Access to Cycle Parameters It access to the specific cycle of selected mode.
  • Page 29 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.2.4 MIG PROCESS - DOUBLE ARC (STD + PULSED). THIS REQUIRE THE ENABLING OF A SPECIFIC PROCESS MODULE. The purpose of this type of arc is to obtain greater control over the filler metal. The result is a succession of 2 intensities that overlap like a bead, each impulse guaranteeing its penetration and partial hardening.
  • Page 30 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.2.5 MIG PROCESS – SPOT MODE (STD + PULSED ARC). This mode of operation permits carrying out welding beads of a given time (TON control). ACTION DESCRIPTION Return to Main Menu Access to Programme Library Access to Operation Mode / Synergic Programme Selection Access to Cycle Parameters It accesses to the specific cycle of selected mode.
  • Page 31 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.2.6. MIG PROCESS – INTERVAL MODE (STD + PULSED ARC). It allows the performance of correlative weld beads of determined duration (TON) and controlled time between them (TOFF). ACTION DESCRIPTION Return to Main Menu Access to Programme Library Access to Operation Mode / Synergic Programme Selection Access to Cycle Parameters...

  • Page 32: Cycle Parameters - Mig Process

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.3. CYCLE PARAMETERS – MIG PROCESS. From this screen we will adjust the values that define the welding cycle. The cycle graph and parameter selection table will change based on the welding mode selection. ACTION DESCRIPTION Return to Source Process...
  • Page 33 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.3.1. CYCLE PARAMETERS – MIG PROCESS. From this screen we will adjust the values that define the welding cycle. The cycle graph and parameter selection table will change based on the welding mode selection. ACTION DESCRIPTION Return to Source Process...

  • Page 34: Hold Mode

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 4.4. HOLD MODE. At the end of the welding process, the HOLD icon will appear automatically on the regulation screen. ACTION P1-P2-P3-P4-P5-P6 Return to no-load regulation screen. E1-E2...

  • Page 35: Tig Process

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5. TIG PROCESS. Welding with tungsten or wolfram electrode, also known as TIG (Tungsten Inert Gas), GTAW or 141 process, forms part of the welding processes by electric arc. Therefore, we must bear in mind the basic principles of the process before starting the requested welding jobs.

  • Page 36: Tig Welding Installation And Start-Up

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.1. TIG WELDING. INSTALLATION AND START-UP. Before starting to read the next section, we recommend you recall the identification of elements and connectors described in section 3.1. Operating controls. The equipment has a TIG welding system with contact arc striking or Lift Arc, in other words, it will be necessary to establish contact the between the tungsten and the plate to establish the electric arc.
  • Page 37 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.1.3. COOLED TIG SYSTEM INSTALLATION. We confirm the selection of polarity and connect the mass in the opposite pole to that selected. We will use specific torches to manage the passage of the current and the solenoids valve control from the torch button.

  • Page 38: Dc Tiig Process - Operation Mode Selection

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.2. DC TIG PROCESS – OPERATION MODE SELECTION. Starting from the standard configuration, we will access the OPERATION MODE Menu, where we can select different welding modes and arc types. WELDING MODE Standard Use Time-controlled weld bead.
  • Page 39 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.2.1. DC TIG PROCESS STD ARC. The start and end welding mode is controlled by the pulse torch system. (See Operation Mode for selection - Cycle Parameters for viewing), the arc is a direct current standard. ACTION DESCRIPTION Return to Main Menu...
  • Page 40 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.2.1.1. DC TIG PROCESS - STD ARC - CONTINUOUS MODE - 4SS. This torch pulse mode allows the use of a 2nd welding intensity (Control I₂ s) that will be managed after pressing the torch button.
  • Page 41 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.2.3. DC TIG PROCESS - STD ARC - SPOR MODE. This mode of operation permits carrying out welding beads of a given time (TON control). ACTION DESCRIPTION Return to Main Menu Access to Program File Access to Operation Mode Access to Cycle Parameters It accesses to the specific cycle of selected mode.
  • Page 42 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.2.4. DC TIG PROCESS - PULSED ARC. THIS REQUIRE THE ENABLING OF A SPECIFIC PROCESS MODULE. The purpose of this type of arc is to obtain greater control over the filler metal. The result is a succession of 2 intensities that overlap like a bead, each impulse guaranteeing its penetration and partial hardening.
  • Page 43 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.2.5. DC TIG PROCESS - STD ARC - SPOR MODE. This operation mode permits carrying out welding beads, with a pulsed arc, of a given time (TON control). The pulsed frequency regulation (Control Fpulse) adjusts the number of times the intensity is changed per second. ACTION DESCRIPTION Return to Main Menu...
  • Page 44 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.2.6. DC TIG PROCESS - DOUBLE PULSED ARC. This arc combines two welding currents (Control I2 DBP), both pulsed arc (Control F press), alternated in a defined time (Control frequency BP). In this manner we can obtain two beads with superficial finishes to suit our needs. ACTION DESCRIPTION Return to Main Menu...
  • Page 45 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.2.7. DC TIG PROCESS - WIRE INPUT MODE = ON. This mode of operation allows the use of the equipment wire feeder as an automatic wire input system to the TIG process. The wire input speed (VH1) and its frequency (FVH) will be adjusted. THIS REQUIRE THE ENABLING OF A SPECIFIC PROCESS MODULE.

  • Page 46: Cycle Parameters - Dc Tig Process

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.3. CYCLE PARAMETERS – DC TIG PROCESS. From this screen we will adjust the values that define the welding cycle. The cycle graph and parameter selection table will change based on the welding mode selection. ACTION DESCRIPTION Return to Source Process...
  • Page 47 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.3.1. CYCLE GRAPHICS – DC TIG PROCESS. Selected segment Unselected segment Identity Parameter Selected parameter Unselected parameter PULSED ARC - CONTINUOUS MODE 2S TORCH MODE 2SS TORCH MODE 4S TORCH MODE WIRE INPUT = ON STD ARC - CONTINUOUS MODE 2S TORCH MODE 2SS TORCH MODE...
  • Page 48 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual BIPULSED ARC - CONTINUOUS MODE 2S TORCH MODE 2SS TORCH MODE 4S TORCH MODE WIRE INPUT = ON SPOT MODE PULSE 2S TORCH MODE PARAMETER DESCRIPTION FUNCTION REMARKS UNIT RESOLUTION Secondary Wire It permits the use of a 2nd wire speed Speed If WIRE = ON only Time ON wire 1...

  • Page 49: Hold Mode

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 5.4. HOLD MODE. At the end of the welding process, the HOLD icon will appear automatically on the regulation display. ACTION P1-P2-P3-P4-P5-P6 Return to no-load regulation screen. E1-E2...

  • Page 50: Mma Process

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 6. MMA PROCESS. Welding with coated electrode, also known as MMA (Manual Metal Arc), SMAW or 111 process, forms part of the welding processes by electric arc. Therefore, before starting the requested welding jobs, we must bear in mind the basic principles of the process.

  • Page 51: Mma Process - Operation Mode Selection

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 6.3. MMA PROCESS – OPERATION MODE SELECTION. Starting from the standard configuration, we will access the OPERATION MODE Menu, where we can select different welding modes and arc types. ACTION DESCRIPTION Return to Main Menu Access to Programme File Parameter RESET.
  • Page 52 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 6.3.1. STANDARD MMA PROCESS. ACTION DESCRIPTION Return to Main Menu Access to Programme Library Access to Operation Mode Access to Cycle Parameters It accesses to the specific cycle of selected mode. Modify Main Value It adjusts the welding Intensity.
  • Page 53 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 6.3.2. PULSED MMA PROCESS. The purpose of this type of arc is to obtain greater control over the filler metal. The result is a succession of 2 intensities that overlap like a bead, each impulse guaranteeing its penetration and partial hardening. The bottom intensity (Control lb on cycle parameters) is used to preheat and prepare the melting pool, whilst the peak intensity (Control l2) will cause the material to melt.

  • Page 54: Cycle Parameters - Mma Process

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 6.4. CYCLE PARAMETERS – MMA PROCESS. From this screen we will adjust the values that define the welding cycle. The cycle graph and parameter selection table will change based on the welding mode selection. ACTION DESCRIPTION Return to Source Process...

  • Page 55: Hold Mode

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 6.4.1. CYCLE GRAPHICS – MMA PROCESS. Selected segment Unselected segment Identity Parameter Selected parameter Unselected parameter PULSE 6.5. HOLD MODE. At the end of the welding process, the HOLD icon will appear automatically on the regulation display. ACTION P1-P2-P3-P4-P5-P6 Return to no-load regulation screen.

  • Page 56: Programme Files

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 7. PROGRAMME FILE …. From this screen we can manage the file of welding programmes by process which is available on the equipment. ACTION DESCRIPTION Return to Source Process Return to no-load regulation screen. Consult file It accesses the Programme Consult List Save file...

  • Page 57: Save File

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 7.1. SAVE FILE. Once the welding modes and parameters have been adjusted, if we wish, we can generate programme files so that this regulation is available in future applications. ACTION DESCRIPTION Return to Source Process. No changes will be saved.

  • Page 58: Consult File

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 7.2. CONSULT FILE. The file management will be carried out by means of a selection table which allows the global viewing of all the available files. ACTION DESCRIPTION Exit. Return to File Menu. Sort.

  • Page 59: Upload File

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 7.3. UPLOAD FILE. Programme loading will be carried out by means of a selection table which allows the global visualization of all the available files. ACTION DESCRIPTION Exit. No changes will be saved. Upload programme.
  • Page 60 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 7.3.1. FILE PLAYBACK MODE. The file playback mode will display the programme data and allows full viewing and regulation of programme parameters. ACTION DESCRIPTION It will ask if the changes are saved in the Exit the programme programme.

  • Page 61: Recommendations For Welding

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8. WELDING RECOMMENDATIONS. In the next chapter of this manual we will develop in depth the actual welding process aspects associated with the equipment, as well as the recommendations for use and most commonly used applications. We must remember that to achieve more efficient results with GPS, it is essential to know the basic regulation concepts explained in this manual, general knowledge of the process to be used, the practical welding recommendations and the general applications of each one of the programmes available in the equipment.

  • Page 62: Mma Process. Recommendations

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.1. MMA PROCESS. RECOMMENDATIONS. 1. Depending on the type of electrode to be used, we will adapt their welding intensity, always respecting the manufacturer’s recommendations indicated on the electrode box. 2. We will select type of current and polarity as indicated by the electrode designations (printed on each unit). Nº...
  • Page 63 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 6. We must assure a good heart connection, because a bad contact of the mass will cause this to heat up, the current passage will be interrupted and the arc will disappear. It is advisable for this cable to be as short as possible. We will thus reduce the electromagnetic disturbances. Whenever electric current circulates, a circular magnetic field is generated around the conductor.

  • Page 64: Tig Process. Recommendations

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.2. TIG PROCESS. RECOMMENDATIONS. This process is used to weld materials with high thermal conductivity, such as copper, but also to weld steel where the use of tungsten electrodes alloyed with thorium or lanthanum cerium, etc. is advised, with different percentages depending on their application, which are given a touch colour based on the alloying percentage and characteristic, such as for instance 2% red or grey: the electrode diameter changes depending on the welding current chosen.

  • Page 65: Mig-Mag Process Recommendations

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.3. MIG-MAG PROCESS. RECOMMENDATIONS. Before analysing in depth the different welding options that GPS develops, we must contemplate a series of data that have a general influence on all the work programmes. The wires must be free from dust, grease, impurities and humidity. The metal dust adheres easily to the wire on the reels, and may even saturate the liner of the torch giving rise to the appearance of problems.
  • Page 66 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual Due to the increase in temperature absorbed by the torch, as during the pulsed arc welding its heating temperature increases, it is recommended to continuously cool the welding torch, thus reducing the use of consumables, faults and downtimes.

  • Page 67: Welded Applications According To Synergic Programme

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 7. The end of the liner must be brass to prevent the heat from the pistol burning the Teflon sleeve, permitting the distribution of the current along 100 mm, thus avoiding current concentration at the contact tip. Possible energy concentration in the wire will produce short circuits that will slow it down when it comes out of the pistol, producing jamming in the entry of the liner and the rollers.
  • Page 68 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.4.3. WELDING WITH COPPER FREE FILLER MATERIAL. Applications welded with copper-free wires are similar to those associated with traditional carbon steel welding. The basic difference lies in the lack of copper in the coating of the filler material. In traditional applications, depending on the pressure level, the wire surface suffers the loss of copper particles, producing irregular wire feeding, the saturation of the torch and possible arc instability problems, welding defects (it can produce a greater risk of hot cracking and a reduction of the impact properties), increase of repairs, loss of...
  • Page 69 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.4.5. WELDING WITH FLUX-CORED WIRE AND SHIELDING GAS. On a production level, these are more economical processes than the normal ones as the production capacity increases, reducing the general manufacturing costs derived from the use of a more economical shielding gas (Argon - CO 15%).
  • Page 70 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.4.7. STAINLESS STEELS WELDING. In general lines, the execution of welded joints in applications with stainless steel does not differ too much from welding carbon steels. It is true that the intensity adjustment values are similar, however, the great difference lies in the basic need for gaseous protection or backing elements in the welding penetration.
  • Page 71 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.4.9. WELDING WITH 316LSi FILLER METAL. The 316 stainless steels are very resistant to pitting caused by corrosion in the presence of sulphurous acid is indifferent concentrations and perform well at low amperage. With a service temperature of up to 350ºC, it can weld steals types 308, 310Mo, 309Mo, CrNiMo steel, austenitic stainless type 316 and 316L, and stabilised, type 316Ti.
  • Page 72 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.4.12. GALVANISED STEELS AND DISSIMILAR MATERIALS WELDING. In joint welding processes with copper alloys, the same or similar. Welding is heterogeneous, as it is carried out with different filler materials to the base material. In this type of joints, the preparation of the parts to be welded becomes especially important, as to permit gases, produced during the welding, to escape, and for no pores or defects to appear in the welding bead, a slight separation must be maintained between the parts to be joined together.
  • Page 73 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.4.14. WELDING WITH CuAL8 FILLER METAL. It improves applications welded with CuSi and its joints are characterised by being mechanically resistant and suitable for cold deformation, also having good corrosion resistance. The resistance to atmospheric corrosion of these alloys is good; they resist corrosion in saline atmospheres well, too. Copper aluminium joints are less sensitive than brass to corrosion under stress in ammonia atmosphere;...
  • Page 74 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 8.4.16. WELDING WITH AlMg5 FILLER METAL. The use of aluminium wires with a 5.5% of magnesium presents great resistance to corrosion. Used to weld alloys type 5050, 5052, 5083, 5356, 5654 and 5456, it is recommended to weld AlMg 3, AlMg 5, AlMgMn, AlZnMg 1, AlMg 3Si, AlMg 5Si, AlMg 10, AlMg 1SiCu, AlMgSi 0.7.

  • Page 75: Maintenance Operations. Recommendations

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 9. MAINTENANCE OPERATIONS. RECOMMENDATIONS. In order for the equipment to have a long life we must follow some essential rules for maintenance and use. Abide by these recommendations. CORRECT MAINTENANCE OF THE EQUIPMENT WILL AVOID A GREAT PERCENTAGE OF FAULTS. 9.1.

  • Page 76: Anomalies. Probable Causes. Possible Solutions

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 10. ANOMALIES. PROBABLE CAUSES. POSSIBLE SOLUTIONS. SYMPTOM. ANOMALY. PROBABLE CAUSE. POSSIBLE SOLUTION. 1. Observe that there is voltage at the machine input. Otherwise, change the socket. It is advisable to see if any magnetothermal has "blown".
  • Page 77 GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual SYMPTOM. ANOMALY. PROBABLE CAUSE. POSSIBLE SOLUTION. When welding normal steels we advise the use of a gas Unsuitable shielding gas. mixture Ar-CO2. Excessive pinch rollers pressure Reduce the tightening knob pressure. Filler material is dirty or oxidized. Remove remains of impurities, oils, oxides, etc.

  • Page 78: Safety Measures

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual 11. SAFETY MEASURES. The use of this equipment requires a maximum amount of responsibility with respect to their use and maintenance. Read this safety chapter carefully as well as the rest of the instructions manual. The correct use of the equipment will depend on this.

  • Page 79: Appendices. Electrical Diagrams And Parts List

    GALA PULSE SYNERGIC DR ADVANCED. Instructions Manual EN APPENDICES. ELECTRICAL DIAGRAMS AND PART LISTS. DECLARATION OF CONFORMITY FOR THE EC MARKING.  ELECTRICAL WIRING DIAGRAMS.  DETAIL DRAWINGS AND REFERENCE LISTS.  FORMULA FOR MAKING ORDERS FOR SPARE PARTS: Please indicate: 1st.
  • Page 80 DECLARACION DE CONFORMIDAD PARA EL MARCADO "CE" APPROVAL CERTIFICATE FOR THE EEC STANDARD CERTIFIQUÉE DE CONFORMITÉE POUR LE MARQUEE CE Jaime Ferrán 19 tlfn.-34/976473410 fax.-34/976472450 50014 ZARAGOZA (España) GALA GAR S.L. DECLARA, QUE EL PRODUCTO SUMINISTRADO Y REFERENCIADO EN EL MANUAL DE INSTRUCCIONES, ES CONFORME A LAS DIRECTIVAS COMUNITARIAS APLICABLES PARA EL MARCADO CE: GALA GAR S.L.
  • Page 81 DECLARACION DE CONFORMIDAD PARA EL MARCADO "CE" APPROVAL CERTIFICATE FOR THE EEC STANDARD CERTIFIQUÉE DE CONFORMITÉE POUR LE MARQUEE CE Jaime Ferrán 19 tlfn.-34/976473410 fax.-34/976472450 50014 ZARAGOZA (España) GALA GAR S.L. DECLARA, QUE EL PRODUCTO SUMINISTRADO Y REFERENCIADO EN EL MANUAL DE INSTRUCCIONES, ES CONFORME A LAS DIRECTIVAS COMUNITARIAS APLICABLES PARA EL MARCADO CE: GALA GAR S.L.
  • Page 82 DECLARACION DE CONFORMIDAD PARA EL MARCADO "CE" APPROVAL CERTIFICATE FOR THE EEC STANDARD CERTIFIQUÉE DE CONFORMITÉE POUR LE MARQUEE CE Jaime Ferrán 19 tlfn.-34/976473410 fax.-34/976472450 50014 ZARAGOZA (España) GALA GAR S.L. DECLARA, QUE EL PRODUCTO SUMINISTRADO Y REFERENCIADO EN EL MANUAL DE INSTRUCCIONES, ES CONFORME A LAS DIRECTIVAS COMUNITARIAS APLICABLES PARA EL MARCADO CE: GALA GAR S.L.
  • Page 83 DECLARACION DE CONFORMIDAD PARA EL MARCADO "CE" APPROVAL CERTIFICATE FOR THE EEC STANDARD CERTIFIQUÉE DE CONFORMITÉE POUR LE MARQUEE CE Jaime Ferrán 19 tlfn.-34/976473410 fax.-34/976472450 50014 ZARAGOZA (España) GALA GAR S.L. DECLARA, QUE EL PRODUCTO SUMINISTRADO Y REFERENCIADO EN EL MANUAL DE INSTRUCCIONES, ES CONFORME A LAS DIRECTIVAS COMUNITARIAS APLICABLES PARA EL MARCADO CE: GALA GAR S.L.
  • Page 84 SELECTOR PLACA ALIMENTACION 400V / 440V U1: 440V-50/6HZ 440V O O---O U1: 400V-50/6HZ 400V O---O O POTENCIA 98.43 LINEA TRIFASICA FERRITA FERRITA FILTRO EMI (FN2) I ON/OFF F - EMI 3PH PZ6 PZ7 +VDC M_FASE PRE_CAR PZ2 PZ3 (*1)KIT TELENET CN 19V H - REMOTE CN 12V H INTERFACE SER_A...
  • Page 85 TERM2 TA3_B AVSS TERM3 AM/VE AM/VE TERM1 4.7nF 250V Y2 4.7nF 250V Y2 N.C. 10R 25W 10nF 1500V KP N.C. Th TRAFO P.E. SONDA HALL TA3_A AVSS TERM2 TRF INV TERM3 10R 25W 10nF 1500V KP N.C. N.C. MODULO SECUNDARIO R 470 Ohm /25 W +VDC +VDC...
  • Page 90 REPUESTOS. GPS 4000 DR ADVANCED REF: 423.81.200 4-12--19 HR:42381200 V0 PARTS LIST. GPS 4000 DR ADVANCED 3Ph- 400V; 50/60 Hz...
  • Page 91 REPUESTOS. GPS 4000 DR ADVANCED REF: 423.81.200 4-12--19 HR:42381200 V0 PARTS LIST. GPS 4000 DR ADVANCED 3Ph- 400V; 50/60 Hz Nº REF. DESCRIPCION Nº REF. DESCRIPCION 42312103 CONJUNTO TAPA 31 00531221 CONECTOR HEMBRA 19V 63112005 MANDO POTENCIÓMETRO 32 42610563 TAPA CONECTORES OPCIONALES 42313003 FRENTE PLÁSTICO 33 49716220 TUERCA PRENSAESTOPAS 47716035 CONECTOR HEMBRA...
  • Page 92 REPUESTOS. GPS 5000 DR ADVANCED HR:42600200 V0 REF: PARTS LIST. GPS 5000 DR ADVANCED 04/12/19 426.00.200 LISTE DES PIÈCES. GPS 5000 DR ADVANCED 3Ph- 400V ; 50/60 Hz...
  • Page 93 REPUESTOS. GPS 5000 DR ADVANCED HR:42600200 V0 REF: PARTS LIST. GPS 5000 DR ADVANCED 04/12/19 426.00.200 LISTE DES PIÈCES. GPS 5000 DR ADVANCED 3Ph- 400V ; 50/60 Hz Nº REF. DESCRIPCION Nº REF. DESCRIPCION 42312103 CONJ.TAPA GPS 30 49716120 PRENSAESTOPAS 63112005 MANDO POTENCIÓMETRO 31 49716220...
  • Page 94 REPUESTOS. MODULO SECUNDARIO GPS REF: HR:42312023 V1 PARTS LIST. SECONDARY MODULE GPS 13-01-12 423.12.023 LISTE DES PIÈCES. MODULE SECONDAIRE GPS Nº REF. DESCRIPCION DESCRIPTION DESCRIPTION 42316123 DISIPADOR DISSIPATER DISSIPATEUR 44016123 DIODO RECTIFICADOR RECTIFYING DIODE DIODE RECTIFICATIVE 552057 TERMICO DE 70º (N.C.) THERMAL DEVICE TERMIQUE DISPOSITIF 42312033 CJTO.CONEXION UNION 4 DIODOS CONNECTION SET UNION 4 DIODES ENSEMBLE CONNECTION UNION 4 DIODES...
  • Page 96 REPUESTOS. MODULO PRIMARIO GPS 5000 REF: 426.12.015 24-02-23 HR:42612015 V1 PARTS LIST. PRIMARY MODULE GPS 5000 Nº REF. DESCRIPCION 42616115 DISIPADOR MÓDULO PRIMARIO GPS 5000 00552059 TERMICO DE 60º (N.C.) (RST45ºC)-FAST6,3 00555006 RECTIFICADOR TRIFASICO 100A/1200V 42618325 PLETINA UNION MODULO PRIMARIO 00557025 LECTOR CORRIENTE MODULO PRIM.GPS5000 00554402...
  • Page 97 REPUESTOS. MODULO PRIMARIO GPS 5000 REF: 426.12.023 03-12-19 HR:42612015 V0 PARTS LIST. SECONDARY MODULE GPS 5000 Nº REF. DESCRIPCION 42616123 DISIPADOR MÓDULO SECUNDARIO GPS 5000 00550027 RESISTENCIA 10R/25W 00551047 CONDENSADOR KP 10 nF/1500V 00555113 DIODO SALIDA ISOTOP 600V 00552060 TERMICO DE 70º (N.C.) (RST55ºC)-FAST6,3 42618035 CONEXION UNION 3 DIODOS GPS 5000 42318036...
  • Page 98 REPUESTOS. CONJ. PLACA FRONTAL-GPS-TFT 5000 DR HR:42612091 V0 REF: PARTS LIST. CONJ. PLACA FRONTAL-GPS-TFT 5000 DR 04/06/20 426.12.091 LISTE DES PIÈCES. CONJ. PLACA FRONTAL-GPS-TFT 5000 DR 3Ph- 400V ; 50/60 Hz...
  • Page 99 REPUESTOS. CONJ. PLACA FRONTAL-GPS-TFT 5000 DR HR:42612091 V0 REF: PARTS LIST. CONJ. PLACA FRONTAL-GPS-TFT 5000 DR 04/06/20 426.12.091 LISTE DES PIÈCES. CONJ. PLACA FRONTAL-GPS-TFT 5000 DR 3Ph- 400V ; 50/60 Hz Nº DESCRIPCION 42616191 TECLADO ADHESIVO TFT GPS 00010159 TORNILLO DIN 963 M-3X8 ZINCADO 42613291 PLACA METACRILATO FRONTAL 47013391...
  • Page 100 REPUESTOS. CONJ. PLACA FRONTAL-GPS-TFT 4000 DR HR:42381191 V0 REF: PARTS LIST. CONJ. PLACA FRONTAL-GPS-TFT 4000 DR 04/06/20 423.81.191 LISTE DES PIÈCES. CONJ. PLACA FRONTAL-GPS-TFT 4000 DR 3Ph- 400V ; 50/60 Hz...
  • Page 101 REPUESTOS. CONJ. PLACA FRONTAL-GPS-TFT 4000 DR HR:42381191 V0 REF: PARTS LIST. CONJ. PLACA FRONTAL-GPS-TFT 4000 DR 04/06/20 423.81.191 LISTE DES PIÈCES. CONJ. PLACA FRONTAL-GPS-TFT 4000 DR 3Ph- 400V ; 50/60 Hz Nº DESCRIPCION 42616191 TECLADO ADHESIVO TFT GPS 00010159 TORNILLO DIN 963 M-3X8 ZINCADO 42613291 PLACA METACRILATO FRONTAL 47013391...
  • Page 104 Gala Gar, S.L. c/Jaime Ferrán, 19 | 50014 ZARAGOZA (+34) 976 47 34 10 | info@galagar.com www.galagar.com...

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