gala gar GPS 2300 PFC BI-PULSE Owner's manual

GPS 2300 PFC BI-PULSE
EN
TECHNICAL INSTRUCTIONS MANUAL.
MULTIPROCESS INVERTER. SYNERGIC EQUIPMENT FOR MIG/MAG WELDING
Ref.: 532.00.100 GPS 2300 PFC BI-PULSE
(230V - 50/60Hz)
EN
THIS EQUIPMENT SHOULD BE USED ONLY BY PROFESSIONALS.
FOR THE BENEFIT OF YOUR WORK, PLEASE READ THIS MANUAL
CAREFULLY.
Jaime Ferrán 19 50014 ZARAGOZA (Spain)
Tel.:.[phone] - Fax: [phone]
Ref.: 532.17.147 / v0

GPS 2300 PFC BI-PULSE
2
EN
CONTENTS
1. GENERAL DESCRIPTION. TECHNICAL FEATURES 3
1.1. STANDAR ACCESORRIES INCLUDED --------------------------------------------------------------------------------------------------- 4
1.2. RECOMMENDED ACCESSORIES -------------------------------------------------------------------------------------------------------- 4
1.3. USING MODES---------------------------------------------------------------------------------------------------------------------------- 4
1.4. WELDING PROGRAMS WITH PULSED ARC 5
1.5. WELDING PROGRAMS WITH STANDARD ARC 5
2. TRANSPORT AND INSTALLATION-------------------------------------------------------------------------------------------------------------- 6
2.1. TRANSPORT AND PACKAGING --------------------------------------------------------------------------------------------------------- 6
2.2. ELECTRICAL SUPPLY INSTALLATION --------------------------------------------------------------------------------------------------- 6
3. START-UP. OPERATION AND ADJUSTMENTS ------------------------------------------------------------------------------------------------ 7
3.1. OPERATION CONTROLS ---------------------------------------------------------------------------------------------------------------- 7
3.2. FRONT CONTROL PANEL---------------------------------------------------------------------------------------------------------------- 8
3.3. WELDING PROCESSES ------------------------------------------------------------------------------------------------------------------- 9
3.4. MIG/MAG WELDING. INSTALLATION, START-UP AND OPERATION SYSTEMS --------------------------------------------------- 10
3.5. TIG WELDING. INSTALLATION, START-UP AND OPERATION CONTROLS -------------------------------------------------------- 22
3.6. MMA WELDING. INSTALLATION, START-UP AND OPERATION CONTROLS ------------------------------------------------------ 27
3.7. JOB RECORDING MODE.---------------------------------------------------------------------------------------------------------------- 29
3.8. TIMER MODE. PROCESS STATISTICS---------------------------------------------------------------------------------------------------- 30
3.9. HOLD MODE ----------------------------------------------------------------------------------------------------------------------------- 31
3.10. IGNITION MODE. OPERATIVE -------------------------------------------------------------------------------------------------------- 31
4. MAINTENANCE OPERATIONS. RECOMMENDATIONS. ------------------------------------------------------------------------------------- 32
5. ANOMALIES. PROBABLE CAUSES. POSSIBLE SOLUTIONS --------------------------------------------------------------------------------- 33
6. SAFETY MEASURES. ------------------------------------------------------------------------------------------------------------------------------ 35
APPENDICES. EC DECLARATION OF CONFORMITY, ELECTRICAL DIAGRAMS AND PART LISTS ----------------------------------------- 37

GPS 2300 PFC BI-PULSE
3
1. GENERAL DESCRIPTION. TECHNICAL FEATURES.
This equipment enable the arc-electric multiprocess welding :
Standard-arc MIG/MAG welding: Continuous, spot and interval. Manual and synergic adjustment programs.
Pulsed arc MIG/MAG welding: Continuous, spot and interval welding with synergic adjustment programs.
Bi-Pulsed MIG/MAG welding: with dual pulsed-arc feature which improve the welding bead aesthetic.
TIG DC welding with Lift-Arc striking. Pulsed TIG mode with general control of cycle parameters.
MMA welding: Rutilic, basic and stainless electrodes. MMA CEL Mode for special electrodes.
One of the main advantages of this equipment is that it has MIG/MAG processes with pulsed arc and dual pulsed arc,
enabling it to weld stainless steel and aluminium with synergic programs resulting in excellent welded seams. This makes
it possible in single-phase power networks with 16 A magneto-thermal protection. This equipment with PFC pre-inverter
stage allows high welding performance in a limited power electrical installation (3.7 KW) Its electrical efficiency level is
maximized obtaining the minimum network consumption.
The welding current is controlled by a microprocessor that enables the user to design the most suitable current form
for the welding job. For MIG/MAG and TIG procedures, this equipment is able to memorise up to 10 groups of welding
parameters (JOBS), offering more than 25 welding programs.
GPS 2300 PFC BI-PULSE Technical Features. Data according to standard EN60974-1
TECHNICAL FEATURES
GPS 2300 PFC BI-PULSE
Ref. 532.00.100
Input voltage U1(1ph. 50-60Hz) (1)
230 V ± 10%
Maximum input intensity I1max
30 A
Maximum effective intensity (I1eff)
16 A
Maximum absorbed power P1max - P1eff
6.9 KVA / 3.7 KVA
MIG/MAG adjustment margin I2min-I2max
10 ÷ 200 A
Welding voltage adjustment U2min-U2max
12 ÷ 30 V
MIG-MAG welding intensity I2
ED%
200 A
40%
165 A
60%
140 A
100%
Applicable wire diameters (mm.)
0.6 ÷ 1.0 (1.2mm Al)
Wire reels
Ø300 mm - 15 Kg
Wire speed (m/min.)
1 ÷ 15 m/min
Drive system
4 Rollers –50 W
Bi-Pulse Mode (Dual pulsed-arc)
YES
Continuous MMA adjustment margin I2min- I2max
30 ÷ 200 A (30%)
Continuous TIG adjustment margin I2min- I2max
5 ÷ 200 A (40%)
TIG pulse frequency adjustment margin
0.1 ÷ 500 Hz
Mechanical protection index (IP)
IP 23 S
Ventilation
Forced
Weight
27 Kg
ACCORDING TO UNE-EN 60974. (1) Other power supply voltage values on demand.
NEVER USE THESE WELDING MACHINES TO DEFROST TUBES.
General dimensions of GPS 2300 PFC Bi-PULSE equipment
Overall equipment dimensions
GPS 2300 PFC Bi-PULSE with WCS-510
over Mobile Workstation

GPS 2300 PFC BI-PULSE
4
1.1.STANDAR ACCESORRIES INCLUDED WITH EQUIPMENT Ref. 53200100.
REFERENCE
DESCRIPTION
532.17.147
Instructions Manual GPS 2300 PFC BI-PULSE
532.17.087
Syner Bi-Pulsed Control Panel quick guide
532.12.129
Input cable 3x2.5 mm2, 3 m (with Schuko plug incl.)
423.12.030
Machine-gas connection (2 m) / coupling
531.12.219
Earth clamp cable
517.16.520
Wire reel Ø37, 0.8-1.0 mm “V” ( 2 units)
1.2.RECOMMENDED ACCESSORIES ACCORDING TO THE WELDING PROCESS.
GALA GAR has a complete range of welding accessories where
you can find those most suited to your needs.
USE ONLY THE RECOMMENDED SPARE PARTS AND
ACCESSORIES.
MIG/MAG
MMA
TIG
Fe (Steel)
Al (Pulse)
SS (Pulse Inox.)
CuSi
FCAW (Without gas)
Standard
Cellulosic
Ø 2.0 - 2.4 mm.
Ø 2.4 - 3.2 mm.
51712090
Mobile Workstation
●
●
●
●
●
●
63400000
Water cooling system WCS-510
●
●
●
●
39200094
Torch coolant liquid 10L
●
●
●
●
51702089
WCS support with torch connection extension
●
●
●
●
252501
Complete equipment assembly
●
●
●
●
●
●
PK555040
Torch PK 550 (4 m, cooled)
●
●
●
PK4012
Torch TR 400 (4 m, self-cooled)
●
●
●
●
●
51716524
Wire reel Ø37, 0.9-1.2 mm “TUBULAR”
●
51716523
Wire reel Ø37, 1.0-1.2 mm “ALU”
●
5722
Graphite liner - 4 m (PK 550)
●
●
30144000V
Servoglas welding helmet with adjustable regulation
●
●
●
●
●
●
●
●
●
19052634
Torch TIG XT-26E EURO (4 m)
●
19051834
Torch TIG XT-18E EURO (4 m - Cooled)
●
37600000
Argon pressure regulator –Mod. EN 2
●
●
●
●
●
●
37900000
Argon-CO2 GASFREE pressure regulator
R
R
R
R
R
R
259,040
Electrode accessories (300A-35/50 )
●
●
1704V10
Stove TRC V10. Fitted with thermometer and thermostat.
R
●
Recommended use mode
2
3
3
3
1
1
1
2
3
●
Constituent element of installation
R
Recommended element.
1.3. USING MODES.
Standard use mode
On Workstation use mode
Use mode over workstation with cooling
module.
Mobile Workstation
Ref. 517.12.090
GPS 2300 PFC
BI-PULSE
Ref. 532.00.100
GPS 2300 PFC
BI-PULSE
Ref. 532.00.100
Mobile Workstation
Ref. 517.12.090
GPS 2300 PFC
BI-PULSE
Ref. 532.00.100
WCS-510
Ref. 634.00.000
WCS support with torch
connection extension.
Ref. 517.02.089

GPS 2300 PFC BI-PULSE
5
1.4. WELDING PROGRAMS WITH PULSED ARC.
Base
material
Filler material
Shielding gas
Material
display
Gas display
Display
Wire display
D1
D2
D3
mm
in
Fe
ER 70 S 6
SG II - SG III
Ar + CO2 (20%)
Fe
Ar
CO2
18%
P12
SG2
SG3
0.8
0.030
P13
SG2
SG3
---
0.035
P14
SG2
SG3
1.0
---
SS (309)
Cr Ni AISI 309
Ar + CO2 (2%)
SS
Ar
CO2
2%
P21
309
1.0
---
SS (308L)
Cr Ni 19-9
AISI 308L
Ar + CO2 (2%)
SS
Ar
CO2
2%
P22
308
LSi
0.8
0.030
P23
308
LSi
---
0.035
P24
308
LSi
1.0
---
SS (316L)
Cr Ni 18-86
AISI 316L
Ar + CO2 (2%)
SS
Ar
CO2
2%
P32
316
LSi
0.8
0.030
P33
316
LSi
---
0.035
P34
316
LSi
1.0
---
Al Mg 5
Al Mg 5
Ar (100%)
Al Mg
Ar
P44
AL
MG5 %
1.0
---
P45
AL
MG5 %
1.2
0.045
Al Si 5
Al Si 5
Ar (100%)
Al Si
Ar
P49
AL
Si5 %
1.0
---
P50
AL
Si5 %
1.2
0.045
Al Si 12
Al Si 12
Ar (100%)
Al Si
Ar
P54
Si
12%
1.0
---
P55
Si
12%
1.2
0.045
Fe
Galvanized
Cu Si 3
Ar (100%)
Cu Si
Ar
P57
Cu
Si3%
0.8
0.030
P58
Cu
Si3%
---
0.035
P59
Cu
Si3%
1.0
---
Fe
Hard surfacing
electrodes
Ar + CO2 (20%)
Fe
Ar
CO2
18%
P82
700
MC
1.0
---
Fe
ER 70 S 6
SG II - SG III
Ar + CO2 (8%%)
Fe
Ar
CO2
P90
Low
CO2
0.8
0.030
P91
Low
CO2
---
0.035
P92
Low
CO2
1.0
---
Program setting
Shielding gas
Program
No.
Wire type
Wire Ø
1.5. WELDING PROGRAMS WITH STANDARD ARC.
Base
material
Filler
material
Shielding gas
Material
display
Gas display
Display
Wire display
D1
D2
D3
mm
in
Fe
ER 70 S 6
SG II - SG III
Ar + CO2
(20%)
Fe
Ar
CO2
18%
P12
SG2
SG3
0.8
0.030
P13
SG2
SG3
---
0.035
P14
SG2
SG3
1.0
---
Fe
ER 70 S 6
SG II - SG III
CO2 (100%)
Fe
CO2
P17
SG2
SG3
0.8
0.030
P18
SG2
SG3
---
0.035
P19
SG2
SG3
1.0
---
SS (308L)
Cr Ni 19-9
AISI 308L
Ar + CO2 (2%)
SS
Ar
CO2
2%
P22
308
LSi
0.8
0.030
P23
308
LSi
---
0.035
P24
308
LSi
1.0
---
Al Mg 5
Al Mg 5
Ar (100%)
Al Mg
Ar
P44
AL
MG5 %
1.0
---
P45
AL
MG5 %
1.2
0.045
Fe
Galvanized
Cu Si 3
Ar (100%)
Cu Si
Ar
P57
Cu
Si3%
0.8
0.030
P58
Cu
Si3%
---
0.035
P59
Cu
Si3%
1.0
---
Fe
FCAW
E-71T11
Without gas
Fe
P67
NO
Gas
0.9
0.035
P68
NO
Gas
1.1
0.040
Fe
ER 70 S 6
SG II - SG III
Ar + CO2
<10%
Fe
Ar
CO2
P90
Low
CO2
0.8
0.030
P91
Low
CO2
---
0.035
P92
Low
CO2
1.0
---
Program setting
Shielding gas
Program No.
Wire type
Wire Ø

GPS 2300 PFC BI-PULSE
6
2. TRANSPORT AND INSTALLATION.
2.1. TRANSPORT AND PACKAGING
Knocks and sudden movements must be avoided when transporting the equipment. In any case, the packaging must
be protected from water.
HANDLE THE EQUIPMENT CAREFULLY, IT WILL LAST LONGER !
2.2. ELECTRICAL SUPPLY INSTALLATION.
The electrical installation of the equipment making up the system must be carried out by specialised personnel
according to the applicable standards.
The location must fulfil the following conditions:
-Place: Dry and ventilated. Far enough away from the welding area in order to prevent the dust caused by the
welding process from getting into the equipment. Never work in the rain.
-The distribution panel where the machine has to be connected must have the following elements, at least:
ELECTRICAL
SUPPLY
INSTALLATION.
HOME
CABLE PLUG
SOCKET AND ELECTRICAL PROTECTION DEVICES
“SCHUKO”
2P + T 16A
SOCKET
2P 16A + TT
MAGNETOTHERMAL
SWITCH
2P 16A-(230V)
The connection to the mains is made by the input hose. IMPORTANT! Verify that the wire is connected to a plug with
an efficient earth tap.
If you have special equipment, with power supply voltage other than 230 V, you will find the data for defining the
necessary electrical installation on the equipment characteristics plate.
Any supply voltage that is outside the rated margin gives rise to the activation of the protection system, preventing the
welding operation.
GPS 2300 PFC BI-PULSE
If it is necessary to use a longer power supply
hose or a connection to an extension, keep in
mind the values of this table. These values are for
reference and are influenced by the state of the
conductors, connections and ambient
temperature.
Length
CROSS-SECTION
5 m
2.5 mm2
Up to 25 m
2.5 mm2
>25 m
4 mm2
ELECTRICAL INSTALLATIONS SHOULD ONLY BE HANDLED BY SPECIALISED PERSONNEL.
BEFORE STARTING THE EQUIPMENT, VERIFY THAT THE ELECTRODE-HOLDER CLAMP IS
SEPARATED FROM THE WELDING EARTH CLAMP.
DO NOT FORGET TO FIT THE EARTH CONNECTION INTO THE PLUG.
MAKE SURE THE MAINS VOLTAGE AGREES WITH THAT ESTABLISHED IN THE MACHINE.

GPS 2300 PFC BI-PULSE
7
3. START-UP. OPERATION AND ADJUSTMENT CONTROLS.
3.1. OPERATION CONTROLS.
A
Controls and displays of synergic control.
B
Euro-connector. MIG and TIG welding torches connection.
C
Negative pole.
F
Positive pole.
J
Gas inlet hose.
H
Power supply cable.
G
O/I
Master switch
ON / OFF
M
Adjustment lever of wire driving
pressure.
N
Change of polarity. Positive terminal and negative terminal.
K
Drive motor
I
Connector for electrical connection of the Cooling Module
L
Support axle for wire reel 15 kg. Rotation pressure control.
The rotation resistance can be adjusted by means of the central pressure system.
1
2
3
5
4
C
F
H
J
A
B
N
K
M
L
G
I

GPS 2300 PFC BI-PULSE
8
3.2. FRONT CONTROL PANEL.
LED INDICATORS
ON
LD1
Green LED indicator of start-up.
LD2
Amber LED indicator of equipment shutdown due thermal overload or input voltage conditions outside margin.
BUTTONS OF DIGITAL CONTROL PANEL
P1
Welding process selection. Momentary pressure.
Enter/Exit to/from SETTING MODE of cycle parameters. Maintained pressure (2 s)
Enter/Exit to/from SETTING MODE –L/CBP –Pulsed MIG momentary pressure when WELDING
P2
Welding program selection (Wire –Gas). (From MIG WELDING MODE).
P3
Welding wire diameter selection. Momentary pressure from MIG WELDING MODE.
Enter to TIMER MODE (process statistic). Maintained pressure.
P4
Enter to JOB REPRODUCTION MODE from WELDING MODE. (Momentary pressure).
Exit from JOB MODE to WELDING MODE. (Momentary pressure).
Enter to JOB RECORDING MODE from WELDING MODE. (Maintained pressure, 2 s).
JOB program recording from JOB RECORDING MODE. (Momentary pressure).
P5
Bleed gas. The gas solenoid valve is activated whilst depressed. The solenoid valve activation is prolonged for
two seconds after pressing.
P6
Wire purge. The drive motor is activated whilst depressed.
BUTTONS COMBINATIONS
+
Reset the setting parameters to factory values.
1 s
1 s 1 s
+
1 s
1 s 1 s
+
1 s
1 s 1 s
Reset to zero the counters from TIMER MODE. (By keeping pressed at the same time
buttons: P1, P3 and P4)
+ON
Deleting of JOB programs. (By keeping P4 push-button pressed in start-up process).
1 s
1 s 1 s
+ON
Momentary indication (D1 display) of the number of working hours.
P3
D2
P1
D3
P2
P4
LD2
LD1
P6
E1
P5
E2
D1

GPS 2300 PFC BI-PULSE
9
ADJUSTMENT ENCODERS OF DIGITAL CONTROL PANEL
ENCODER E1
MIG WELDING MODE, MANUAL PROGRAM .
Welding voltage control. U2minU2max. The control can be carried out during the welding process.
MIG WELDING MODE, SYNERGIC PROGRAM .
It enables to vary the welding voltage value assigned by synergic table. –30% +30%
PULSED TIG WELDING MODE.
Pulse frequency control F(Hz).
SETTING MODE of cycle parameters.
It enables to change the cycle variable indicated in display D2.
ENCODER E2
MIG WELDING MODE, MANUAL PROGRAM .
Wire speed control. vhminvhmax
MIG WELDING MODE, SYNERGIC PROGRAM .
Thickness control of piece to be welded. eminemax.
JOB REPRODUCTION MODE.
It enables to select the No. of JOB program to be reproduced.
JOB RECORDING MODE.
It enables to select the No. of JOB program to be recorded.
SETTING MODE of cycle parameters.
It enables to change the cycle variable indicated on display D3.
MMA/ MMA CEL/ TIG AND PULSED TIG WELDING MODE.
Welding intensity control. I2minI2max. The control can be carried out during the welding process.
3.3. WELDING PROCESS.
PROCESS
DESCRIPTION
1st
MIG
STANDARD GMAW WELDING MODE (continuous cycle).
2nd
MIG SPOT
STANDARD GMAW SPOT WELDING MODE (spot or intermittent welding cycle)
3rd
MIG PULSE
PULSED-ARC GMAW WELDING MODE (continuous cycle).
4th
Bi-PULSED MIG
DUAL PULSED-ARC (Bi-PULSED) GMAW WELDING MODE (continuous cycle).
5th
MIG SPOT PULSE
PULSED GMAW SPOT WELDING MODE (spot or intermittent welding cycle)
6th
MMA
Coated electrode welding.
7th
MMA CEL
Special coated electrode welding (Cellulosic type)
8th
TIG
TIG welding with lift-arc striking.
9th
TIG PULSE
TIG welding with pulsed arc and lift-arc striking.
3.3.1. WELDING PROCESS SELECTION SYSTEM.
PROCESSES
MIG/MAG
PROCESSES
MMA
PROCESSES
TIG
PULSE
PULSE
PULSE
CEL
PULSE
MIG
MIG
SPOT
MIG
PULSE
MIG
Bi-
PULSE
MIG
SPOT
PULSE
MMA
MMA
CEL
TIG
TIG
PULSE
1st
2nd
3rd
4th
5th
6th
7th
8th
9th

GPS 2300 PFC BI-PULSE
10
3.4. MIG/MAG WELDING INSTALLATION, START-UP AND OPERATION SYSTEMS.
PULSE
PULSE
PULSE
MIG
MIG
SPOT
MIG
PULSE
MIG
BI-PULSE
MIG
SPOT PULSE
1st
2nd
3rd
4th
5th
Maximum time in wire approach process without generating an electric arc. (5s - Tacer: Not adjustable value).
Maximum arc interruption time During that time the arc can be re-established. (4s - Tci: Not adjustable value).
3.4.1. MIG/MAG INSTALLATIONS.
Depending on whether the installation is cooled or not, we must set the equipment during the first start-up.
AUTOMATIC COOLING : Working mode with cooled torch.
The cooling only works in welding mode and will switch off automatically 2 minutes after carrying out the welding
process.
Automatic disconnection time (120s –Troff2: Not adjustable value).
COOLING “ON” : Working mode with cooled torch.
The cooling works permanently after the first welding process starts.
COOLING “OFF” : It enables to work with torches without water cooling.
The cooling is deactivated, the protection against lack of water pressure is disabled.
Setting parameters adjustment system for (automatic) cooled installation :
P1: SELECT THE
PROCESS
P1: ENTER/EXIT TO
PARAMETERS
SETTING MODE
E1: SELECT CYCLE
PARAMETER
E2: ADJUST VALUE
P1: SAVE
PARAMETERS
SETTING
PARAMETERS
D2:
D3:
SAVED
PARAMETERS
PULSE
PULSE
PULSE