gala gar GALA SYNERGIC 5000 Owner's manual

GALA SYNERGIC 5000
GB TECHNICAL INSTRUCTIONS MANUAL. POWER SOURCES.
INDUSTRIAL MIG/MAG WELDING EQUIPMENT OF SYNERGIC CONTROL.
 GALA Synergic
5000
(3Ph - 230/400V 50/60 Hz)
Ref. 432.00.000
GB THIS EQUIPMENT MUST BE USED BY PROFESSIONALS.
TO HELP YOU IN YOUR WORK CAREFULLY READ THIS MANUAL.
Jaime Ferrán 19 50014 ZARAGOZA (Spain)
TLF.-34/976473410 FAX.-34/976472450
Ref. 43217545/Ed0

GALA SYNERGIC 5000 2
GB CONTENTS Page
1. GENERAL DESCRIPTION. TECHNICAL CHARACTERISTICS. --------------------------------------------------------------------- 3
1.1. POWER SOURCES: GALA SYNERGIC 5000. MODULAR SYSTEM. -------------------------------------------------- 3
1.2. WIRE-FEED UNIT D-24C SYNERGIC Ref. 627.00.000---------------------------------------------------------------- 4
1.3. EXTENSION CORDS. WELDING TORCHES. --------------------------------------------------------------------------- 4
1.4. COOLING MODULE WCS 510. Ref. 634.00.000 -------------------------------------------------------------------- 4
1.5. RECOMMENDED ACCESSORIES. ---------------------------------------------------------------------------------------- 4
2. TRANSPORT AND INSTALLATION. -------------------------------------------------------------------------------------------------5
2.1. ELECTRICAL SUPPLY INSTALLATION. ----------------------------------------------------------------------------------- 6
2.2. INSTALLATION OF SYNERGIC GALA SYSTEM WITHOUT COOLING MODULE. --------------------------------- 7
2.3. INSTALLATION OF COOLED SYNERGIC GALA SYSTEM. ------------------------------------------------------------ 8
3. START-UP. ADJUSTMENT AND OPERATION CONTROLS. ---------------------------------------------------------------------- 9
3.1 START-UP. PRELIMINARY OPERATIONS. -------------------------------------------------------------------------------- 9
3.2. OPERATION CONTROLS OF THE POWER SOURCE. ---------------------------------------------------------------- 9
3.3. FIRST START-UP. STARTING SETTINGS. -------------------------------------------------------------------------------- 11
3.3.1. WIRE-FEED SETTING PROCESS. ------------------------------------------------------------------------------ 11
3.3.2. COOLING SYSTEM SETTING PROCESS. -------------------------------------------------------------------- 12
3.4. WELDING MODE BY MEANS OF SYNERGIC PROGRAM. ----------------------------------------------------------- 12
3.5. WELDING MODE BY MEANS OF MANUAL PROGRAM. ------------------------------------------------------------- 14
3.6. SETTING MODE OF CYCLE PARAMETERS. ----------------------------------------------------------------------------- 15
3.6.1. OPERATING OF CYCLE PARAMETERS SETTINGS MENU. ------------------------------------------------- 15
3.6.2. VARIABLES OF CYCLE PARAMETER SETTING MENU. ------------------------------------------------------ 15
3.7. WELDING MODE BY MEANS OF USER PROGRAMMES (JOB). ------------------------------------------------------ 17
3.7.1 USER PROGRAM RECORDING. ------------------------------------------------------------------------------- 17
3.7.2. USER PROGRAM JOB REPRODUCTION. -------------------------------------------------------------------- 18
3.7.3. DELETING OF ALL JOB PROGRAMMES. -------------------------------------------------------------------- 18
3.8. WIRE-FEED UNITS. OPERATION CONTROLS. ------------------------------------------------------------------------- 19
3.9. WCS COOLING MODULE.----------------------------------------------------------------------------------------------- 19
3.10. RECOMMENDATIONS FOR THE USE OF THE EQUIPMENT AND
WELDING OPERATION. MATERIALS. ----------------------------------------------------------------------------- 20
4. MAINTENANCE OPERATIONS. RECOMMENDATIONS. ------------------------------------------------------------------------- 21
4.1 MACHINE MAINTENANCE. GENERAL RECOMMENDATIONS.------------------------------------------------------- 21
5. ANOMALIES. PROBABLE CAUSES. POSSIBLE SOLUTIONS. -------------------------------------------------------------------- 22
6. SAFETY MEASURES. ------------------------------------------------------------------------------------------------------------------ 24
APPENDICES. EC DECLARATION OF CONFORMITY, ELECTRICAL DRAWINGS AND
REFERENCE LISTS. ----------------------------------------------------------------------------------------------------------------------- 25

GALA SYNERGIC 5000 3
1. GENERAL DESCRIPTION. TECHNICAL CHARACTERISTICS.
This equipment forms part of a modular system (GALA SYNERGIC) that permits electric welding of carbon
steels, slightly alloyed steels, stainless steels and aluminium, which are the most commonly used metals in
modern industry, by means of the MIG-MAG semiautomatic procedure.
The main characteristic of this equipment is that it incorporates a synergic-digital control system that
facilitates operation making it possible for people not trained in manual regulation to use this equipment.
The whole modular system that makes up the installation comprises the following elements:
1.1 – Power source. (Earth cable included).
1.2 – Wire-feed unit (Independent from the power source).
1.3 - Connection extension lead between power source and wire-feed unit. Welding torch.
1.4 - Cooling module for cooled welding gun.
1.5 Bottle support.
1.6 - Auxiliary elements: Pressure reducing valve for gas bottle, gas economiser.
1.1. POWER SOURCES: GALA SYNERGIC 5000. MODULAR SYSTEM.
TECHNICAL CHARACTERISTICS GALA SYNERGIC 5000
Ref. 432.00.00
INPUT VOLTAGE U1(THREE-PHASE 50-60 Hz) (1) 230/400 V
MAXIMUM INPUT INTENSITY I1max 47 A / 27 A
EFFECTIVE MAXIMUM INTENSITY I1eff 36 A / 21 A
POWER FACTOR (Cosphi)0.95
CONTINUOUS ADJUSTMENT MARGIN MIG/MAG I2min-I2max 25-400 A
STAGGERED VOLTAGE CONTROL 3 x 10
NUMBER OF MIG REACTANCE TAPS 3
MIG WELDING INTENSITY l2 ED=100% 310 A
MIG WELDING INTENSITY l2 ED=60% 400 A
CONTROL SYSTEM MANUAL / SYNERGIC
MECHANICAL PROTECTION INDEX (IP class) IP21
VENTILATION FORCED
WEIGHT (WITHOUT WIRE-FEED UNIT) 140 kg.
ACCORDING TO UNE-EN 60974. (1) Other power supply voltage values on demand.
782
675
761
202
991
515
620
395
249
General dimensions of the GALA SYNERGIC equipment. Modular system WITHOUT COOLING.
D-24 C.
Ref. 627.00.000.
Four rollers
GALA SYNERGIC 5000
Ref. 432.00.000.
Mig/Mag Power source
BOTTLE SUPPORT
Ref. 432.12.080
Connection extension
Ref. 638.87.000

GALA SYNERGIC 5000 4
475
395
249
991
620
782
675
1420
761
202
515
518
General dimensions of the GALA SYNERGIC equipment. COOLED modular system.
1.2. WIRE-FEED UNIT D-24C SYNERGIC Ref. 627.00.000
Closed wire-feed unit for wire reels of 15 kg. Drive motor (42V/110W) with FOUR geared 30 mm φ
rollers. Wire speed control. Wire and gas purge. Cooling circuit incorporated. Refer to the instructions manual
of Wire-feed D-24C for more detailed information.
1.3. EXTENSION CORDS. WELDING TORCHES.
D-24 C (Cooled) D-24 C (without cooling)
EXTENSION CORDS Cable of 70 mm2(5 m)
Ref. 639.84.000
Cable of 50 mm2(5 m)
Ref. 638.87.000
WELDING TORCH
Water-cooled
500 A/100% CO2
450 A / 100% Mix
Self-cooled
350 A/60% CO2
320 A / 60% Mix
1.4. COOLING MODULE WCS 510. Ref. 634.00.000
WCS-510: Modular cooling system (adapted to bottle support, Ref. 432.12.080). It can be installed with
any power source. Refer to the instructions manual of WCS for more detailed information.
The electrical connection of the equipment is carried out directly to the power source.
1.5. RECOMMENDED ACCESSORIES.
-Pressure reducing valve for Argon-CO2, EN2, Ref. 376.00.000
-Pressure reducing valve for Argon CO2, EN2 WITH ROTAMETER, Ref. 376.00.500
-Shielding gas economiser valve (spotting work), Ref. 355.00.000
-Prof. electronic shield Automatic, Ref. 811104
FOR THE USE OF ANY OTHER ACCESSORY CONSULT THE MANUFACTURER.
D-24 C.
Ref. 627.00.000.
Four rollers.
GALA SYNERGIC 5000
Ref. 432.00.000.
Mig/Mag Power source
BOTTLE SUPPORT
Ref. 432.12.080
W
CS-510
Ref. 634.00.000.
Coolin
g
module
Connection extension
(COOLED)
Ref. 639.84.000

GALA SYNERGIC 5000 5
2. TRANSPORT AND INSTALLATION.
Elevation system. 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.
The power source has some lifting eyes so that it can be lifted
with a crane. To assemble the modular system follow the
assembly instructions enclosed with the transport trolley or bottle
support. The assembly will be carried out by suspending the
equipment as shown in figure 2.
DO NOT LIFT EQUIPMENT WITH GAS BOTTLE MOUNTED
ASSEMBLY PLAN FOR GALA SYNERGIC 5000 EQUIPMENT
8 TUERCAS M10
8 GROWERS M10
8 ARANDELAS PLANAS n10
4 TORNILLOS M8
4 GROWERS M8
4 ARANDELAS PLANAS n8
M10 n10
2 TORNILLOS M10
2 TORNILLOS M10
2 TORNILLOS M10
2 ARANDELAS
PLANAS DE 20
2 PASADORES ALETAS
M6
M6
n6
n6
M6
M6
M10n10