GALA INVERMIG SYNER 230 MP
GB
TECHNICAL INSTRUCTIONS MANUAL. MULTIPROCESS INVERTER EQUIPMENT.
MIG/MAG WELDING OF SYNERGIC CONTROL.
Ref. 518.00.000 GALA INVERMIG SYNER 230 MP (230V - 50/60Hz)
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.: 518.17.547 / Ed. 0
GALA INVERMIG SYNER 230 MP
GB
CONTENTS
2
Page
1. GENERAL DESCRIPTION. TECHNICAL CHARACTERISTICS. .............................................................. 3
1.1. ACCESSORIES................................................................................................................................. 4
2.
2.1.
2.2.
2.3.
2.4.
TRANSPORT AND INSTALLATION. .................................................................................................. 5
TRANSPORT AND PACKAGING ...................................................................................................... 5
ELECTRICAL SUPPLY INSTALLATION................................................................................................ 5
ELECTRICAL INSTALLATION TO ELECTRIC GENERATING SET. ........................................................ 6
USING MODES ............................................................................................................................... 6
3. START-UP. ADJUSTMENT AND OPERATION CONTROLS. ................................................................ 7
3.1. OPERATION CONTROLS. ............................................................................................................... 7
3.2. FRONT CONTROL PANEL OF GALA INVERMIG SYNER 230 MP ....................................................... 8
3.3. WELDING PROCESS........................................................................................................................ 9
3.4. MIG/MAG WELDING. INSTALLATION, START-UP AND OPERATION CONTROLS. ....................... 10
3.5. TIG WELDING. INSTALLATION, START-UP AND OPERATION CONTROLS. ................................... 16
3.6. MMA WELDING. INSTALLATION, START-UP AND OPERATION CONTROLS. ................................ 19
3.7. JOB RECORDING MODE. ............................................................................................................ 21
3.8. TIMER MODE. PROCESS STATISTICS............................................................................................. 22
3.9. HOLD MODE................................................................................................................................ 23
3.10. IGNITION MODE. OPERATING .................................................................................................. 23
4.
MAINTENANCE OPERATIONS. RECOMMENDATIONS................................................................... 24
5.
ANOMALIES. PROBABLE CAUSES. POSSIBLE SOLUTIONS.............................................................. 25
6.
SAFETY MEASURES. ...................................................................................................................... 27
APPENDICES. EC DECLARATION OF CONFORMITY, ELECTRICAL DRAWINGS AND PART LISTS. .......... 28
GENERAL GUARANTEE CONDITIONS:
GALA GAR, guarantees correct operation against all manufacturing defects of the GALA INVERMIG SYNER 230
MP products, as from the purchase date (guarantee period) of:
•
12 MONTHS
This guarantee will not be applied to components with a working life that is less than the guarantee period, such
as spares and consumables in general.
In addition, the guarantee does not include the installation, start-up, cleaning or replacement of filters, fuses
and cooling or oil refills.
If the product should present any defect during the guarantee period, GALA GAR, undertakes to repair it
without any additional charge, unless the damage caused to the product is the result of accidents, improper use,
negligence, inappropriate accessories, unauthorized servicing or modifications to product not carried out by GALA
GAR.
The decision to repair or replace parts or supply a new appliance will depend on the criterion of GALA GAR.
All replaced parts and products will be the property of GALA GAR.
In order for the guarantee to become effective the product and the purchase invoice must be handed over, duly
completed and stamped by an authorized Technical Service. Shipping and transport expenses will be on the user’s
account.
Damage or unforeseen or indirect expenses resulting from an incorrect use will not be the responsibility of
GALA GAR.
GALA INVERMIG SYNER 230 MP
3
1. GENERAL DESCRIPTION. TECHNICAL CHARACTERISTICS.
This equipment enable the electric multiprocess welding :
MIG/MAG welding: Continuous, spot and interval welding with manual and synergic adjustment programs.
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.
These equipments have a protection system, which means they can be installed, without any danger of failures, in
low quality supply networks and electrical generating sets.
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.
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 adjustment to use this equipment.
Technical characteristics of GALA INVERMIG SYNER 230 MP. Data according to standard EN 6097460974-1
TECHNICAL CHARACTERISTICS
INPUT VOLTAGE U1 (1Ph. 50-60Hz)(1)
MAXIMUM INPUT INTENSITY I1max
MAXIMUM EFFECTIVE INTENSITY I1eff
CONTINUOUS MIG/MAG ADJUSTMENT MARGIN I2min-I2max
WELDING VOLTAGE ADJUSTMENT U2MIN-U2MAX
MIG WELDING INTENSITY l2
35%
60%
100%
ED%
APPLICABLE WIRE DIAMETERS (mm.)
WIRE REELS
WIRE SPEED (m/min.)
CONTINUOUS MMA ADJUSTMENT MARGIN I2min-I2max
CONTINUOUS ADJUSTMENT MARGIN TIG I2min-I2max
ADJUSTMENT MARGIN FOR TIG PULSE FREQUENCY
MECHANICAL PROTECTION INDEX (IP class)
VENTILATION
WEIGHT (Complete equipment, wheels incl.)
ACCORDING TO UNE-EN 60974. (1) Other power supply voltage values on demand.
SYNER 230 MP
Ref. 518.00.000
230 V
46 A
27 A
10 ÷ 200 A
12 ÷ 30 V
200 A
150 A
120 A
0.6 ÷ 1.0 (1.2mm Al)
5 Kg.
(15 kg adapter inc.)
1 ÷ 15 m/min
30 ÷ 200 A (35%)
5 ÷ 200 A (35%)
0.1 ÷ 500 Hz
21
Forced
18 Kg.
NEVER USE THESE WELDING MACHINES TO DEFROST TUBES.
General dimensions
of GALA INVERMIG 230 MP
equipment
General dimensions
of GALA INVERMIG 230 MP equipment over
a Mobile Workstation (transport trolley)
381
945
468
405
418
1350
435
435
417
462
902
271
283
213
237
670
593
467
390
275
230
General dimensions of GALA
INVERMIG 230 MP with 15 kg wire reel
adapter assembly.
556
766
852
GALA INVERMIG SYNER 230 MP
4
1.1 ACCESSORIES.
SUPPLIED AS STANDARD WITH EQUIPMENT:
REFERENCE
518.17.047
503.12.029
435.12.018
531.12.219
517.16.520
DESCRIPTION
Instructions Manual - Gala Invermig SYNER 230 MP
Input cable 3x4 mm2 (1A/V) 3 m. (Plug not incl.)
Machine-gas connection (2 m) / coupling
Earth clamp cable
Wire reel Ø37, 0.8-1.0 mm “V”
RECOMMENDED IN MIG/MAG PROCESS :
REFERENCE
517.12.090
517.02.070
376.00.000
355.00.000
215.00.003
225.00.004
517.16.524
811.104
DESCRIPTION
Mobile Workstation (Please refer Section 2).
Wire reel adapter assembly 15 kg (Please refer Section 2).
Argon pressure reducing valve – Mod. EN 2
Welding shielding gas saver valve.
MIG MAXIMA MX-15 torch (3 m)
MIG MAXIMA MX-25 torch (4 m)
Wire reel Ø37, 0.9-1.2 mm “TUBULAR”
Professional Automatic electronic shield
RECOMMENDED IN TIG PROCESS :
190.51.734 TIG XT-17 E EURO torch (4 m)
376.00.000 Argon pressure reducing valve – Mod. EN 2
811.104 Professional Automatic electronic shield
RECOMMENDED IN MMA PROCESS :
259.040 Electrode 300 A-35/50 accessories
1701000 Electric electrode heater (Thermostat and Thermometer)
GALA GAR has a complete range of welding accessories where you can find those most suited to
your needs. For use of any other accessory check with the manufacturer.
USE ONLY THE RECOMMENDED SPARE PARTS AND ACCESSORIES.
GALA INVERMIG SYNER 230 MP
5
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.
ELECTRICAL SUPPLY
INSTALLATION.
HOME
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 fulfill 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:
CABLE PLUG
SOCKET AND ELECTRICAL PROTECTION DEVICES
“SCHUKO”
2P + T 16A
ELECTRICAL SUPPLY
INSTALLATION.
INDUSTRIAL
CABLE PLUG
SOCKET
2P 16A + TT
MAGNETOTHERMAL
SWITCH
2P 16A-(230V)
DIFFERENTIAL
CIRCUIT-BREAKER
2P 25A / 300
mA
SOCKET AND ELECTRICAL PROTECTION DEVICES
SOCKET
2P 32A + TT
MAGNETOTHERMAL
SWITCH
2P 25A-(230V)
DIFFERENTIAL
CIRCUIT-BREAKER
2P 25A / 300
mA
“CETAC”
2P + T 32A
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.
Length
5m
Up to 150m
GALA INVERMIG SYNER 230 MP
CROSS-SECTION
4 mm2
4 mm2
> 15 m Up to 50 m
6 mm2
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.
GALA INVERMIG SYNER 230 MP
6
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.
2.3 ELECTRICAL INSTALLATION TO GENERATING SET.
The GALA INVERMIG SYNER 230 MP equipment are suitable for electrical installation to generating set. This
equipment includes a protection system, which continuously verifies the supply voltage, so that, as soon as this
voltage is outside the margins admitted (between 196 V and 265 V), or it is dangerously distorted, the equipment will
be protected, isolating the sensitive circuits from the mains. Under these conditions, the equipment will remain
switched off or the amber coloured indicator will light up. When the voltage is suitable again, the appliance will be
ready to operate.
The table below will help you choose the power of the generating set. These data are approximate and vary with
the quality of the generating set, its adjustment and environmental conditions.
Welding current (A)
GALA INVERMIG
SYNER 230 MP
2.5 KVA set
4 KVA set
5.5 KVA set
10 KVA set
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
►
◙
►
►
►
◙
►
►
►
◙
►
►
►
►
►
►
◙
►
►
◙
►
►
◙
►
►
◙
◙
◙
►
◙
►
◙
►
◙
►
►
◙
◙
(300 rpm)
Continuous work
Possible work
2.4 USING MODES.
Three modalities for the use of this equipment exist :
Standard use mode
On Workstation use mode
With 5 kg wire reel adapter
GALA INVERMIG
SYNER 230 MP
Ref. 518.00.000
M-6
M-6
GALA INVERMIG
SYNER 230 MP
Ref. 518.00.000
Mobile Workstation
Ref. 517.12.090
ADAPTER ASSY FOR
WIRE REEL 15 Kg
Ref. 517.02.070
GALA INVERMIG SYNER 230 MP
7
3. START-UP. OPERATION AND ADJUSTMENT CONTROLS.
3.1 OPERATION CONTROLS.
A
K
Controls and displays of synergic control.
B
Euroconnector. MIG and TIG
welding torches connection.
Q
Protection fuse.
T 2 A/250V.
C
Negative pole.
F
Positive pole.
G
Gas inlet hose
H
Power supply cable.
I
Master switch
ON / OFF
M
Change of polarity.
Negative terminal.
O
N
J
L
Drive motor
O/I
1
3
5
2
4
Adjustment lever of wire driving
pressure.
Change of polarity.
Positive terminal.
Insulating bushing hole. In order to pass wire flexible guide adapter when placed the 5 kg wire reel
adapter assembly.
Support axle for wire reel 5 kg. Rotation pressure control.
The rotation resistance can be adjusted by means of the central pressure system.
GALA INVERMIG SYNER 230 MP
8
3.2 FRONT CONTROL PANEL OF GALA INVERMIG SYNER 230 MP
MANUAL Fe Ss CuSi
AlMg AlSi
Ar CO 2 18% 2% FCAW
CEL
IPM
PULSE
0.6 mm .023“
0.8 mm .030“
1.0 mm .035“
1.2 mm.045“
P3
HOLD
D2
m/ min
JOB
TIMER
mm in
h
V
%
Hz
A
S
%
P2
D1
P4
D3
ON
INDICATORS (LED’s)
ON
LD1
Green indicator LED of start-up.
Amber indictor LED of equipment shutdown due thermal overload or input voltage conditions outside margin.
LD2
BUTTONS OF DIGITAL CONTROL PANEL
Welding process selection. Momentary pressure.
P1
Enter/Exit to/from SETTING MODE of cycle parameters. Maintained pressure (2 sec.)
P2
Welding program selection (Wire – Gas). (From MIG WELDING MODE).
Welding wire diameter selection. Momentary pressure from MIG WELDING MODE.
P3
Enter to TIMER MODE (process statistic). Maintained pressure.
Enter to JOB REPRODUCTION MODE from WELDING MODE. (Momentary pressure).
Exit from JOB MODE to WELDING MODE. (Momentary pressure).
P4
Enter to JOB RECORDING MODE from WELDING MODE. Maintained pressure (2 sec.)
JOB program recording from JOB RECORDING MODE. (Momentary pressure).
Gas purge. The gas solenoid valve is activated whilst depressed. The solenoid valve activation is prolonged
for two seconds after pressing.
P5
P6
Wire purge. The drive motor is activated whilst depressed.
BUTTONS COMBINATIONS
+
Reset the setting parameters to factory values.
+
Reset to zero the counters from TIMER MODE.
+ ON
Deleting of JOB programmes. (Pressing P4 of maintained form in start-up process).
+ ON
Momentary indication (display D1) of the number of working hours.
GALA INVERMIG SYNER 230 MP
9
ADJUSTMENT ENCODERS OF DIGITAL CONTROL PANEL
MIG WELDING MODE, MANUAL PROGRAM .
Control of welding voltage. 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).
ENCODER E1
SETTING MODE of cycle parameters.
It enables to change the cycle variable indicated in display D2.
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 allows to select the Nr. of JOB program to be reproduced.
ENCODER E2
JOB RECORDING MODE.
It allows to select the Nr. of JOB program to be recorded.
SETTING MODE of cycle parameters.
It enables to change the cycle variable indicated in display D3.
MMA/ MMA CEL/ TIG AND PULSED TIG WELDING MODE.
Control of welding intensity. I2min÷I2max. The control can be carried out during the welding process.
3.3 WELDING PROCESS.
PROCESS
DESCRIPTION
MIG/MAG
GMAW WELDING MODE (continuous cycle).
MIG SPOT
GMAW WELDING MODE (spot or intermittent cycle according to SETTING MODE)
MMA
Coated electrode welding.
MMA CEL
CEL
TIG
PULSED
TIG
Special coated electrode welding (Cellulosic type)
TIG welding with lift-arc striking.
PULSE
TIG welding with pulsed arc and lift-arc striking.
3.3.1 WELDING PROCESS SELECTION SYSTEM.
CEL
PULSE
GALA INVERMIG SYNER 230 MP
10
3.4 MIG/MAG WELDING. INSTALLATION, START-UP AND OPERATION CONTROLS.
3.4.1 MIG/MAD SYSTEM INSTALLATION. TORCH TO POSITIVE POLE.
6
5
5
8
7
1
9
2 3 4
MARK
1
2
3
4
5
6
7
8
9
REF.
503.12.029
517.16.520
517.16.523
517.16.524
435.12.018
376.00.000
215.00.003
225.00.004
531.12.219
5722
DESCRIPTION
Input cable 3x4 mm2 (1A/V) 3 m. (Plug not incl.)
Wire reel Ø37, 0.8-1.0 mm “V”
Wire reel Ø37, 1.0-1.2 mm “ALU”
Wire reel Ø37, 0.9-1.2 mm “TUBULAR”
Machine-gas connection (2 m) / coupling
Argon pressure reducing valve – Mod. EN 2
MIG MAXIMA MX-15 torch (3 m)
MIG MAXIMA MX-25 torch (4 m)
Earth clamp cable
Graphite wire conduit 4 m (for aluminium welding)
ACCESSORY
INCLUDED
INCLUDED
RECOMMENDED
RECOMMENDED
INCLUDED
RECOMMENDED
RECOMMENDED
RECOMMENDED
INCLUDED
RECOMMENDED
Mark 7 is recommended for Fe Ø 0.6-0.8 wire welding and thicknesses < 2 mm.
Mark 8 is recommended for Fe Ø 0.8-1.0 wire welding and thicknesses > 2 mm.
3.4.2 INSTALLATION OF (FCAW) MIG/MAG SYSTEM WITHOUT GAS. TORCH TO NEGATIVE POLE.
8
7
1
2
MARK
1
2
3
4
7
8
9
REF.
503.12.029
517.16.520
517.16.523
517.16.524
215.00.003
225.00.004
531.12.219
3 4
DESCRIPTION
Input cable 3x4 mm2 (1A/V) 3 m. (Plug not incl.)
Wire reel Ø37, 0.8-1.0 mm “V”
Wire reel Ø37, 1.0-1.2 mm “ALU”
Wire reel Ø37, 0.9-1.2 mm “TUBULAR”
MIG MAXIMA MX-15 torch (3 m) (for Fe Ø 0.6 mm wire)
MIG MAXIMA MX-25 torch (4 m) (for Fe wire > Ø 0.8 mm)
Earth clamp cable
9
ACCESSORY
INCLUDED
INCLUDED
RECOMMENDED
RECOMMENDED
RECOMMENDED
RECOMMENDED
INCLUDED
GALA INVERMIG SYNER 230 MP
11
3.4.3 START-UP. OPERATIONS BEFORE MIG/MAG WELDING.
The system connection must be made depending on the welding process chosen, as indicated in the previous
chapter. Before definitely starting up the system, carry out the following operations:
1) Make sure the mains voltage is 230 V.
2) Change de polarity if it is necessary (according to the welding process chosen). See 3.4.1 and 3.4.2.
If the material to be welded is aluminium, change the flexible cable and the wire guide tube for the graphite cable
with the torch totally stretched. (MIG/MAG).
4) Depending on the wire diameter, fit the groove of the suitable driving wheel to the work to be carried out.
(MIG/MAG).
5) Choose suitable gas to wire type to be welded. If it has a mobile workstation, check that the gas bottle is securely
held by the bottle-holder system. Above all check that the safety chain is perfectly fastened.
6) Install the pressure-reducing valve 6 and connect gas hose 5 checking that there are no leakages, throughout the
whole circuit. (MIG/MAG y TIG).
7) Fit the wire reel into the support axle L (MIG/MAG).
8) Fit the welding wire into the driving system. Do not force the wire pressure handle M, as if this is too tight, the
motor remains on overload and does not reach the maximum speed, and if the handle is too slack, the wire could
slip. (MIG/MAG).
9) Once the welding wire has been fitted, we can then hook up the torch (7
7, 8 to euroconnector B for MIG/MAG).
10) Connect supply cable H with the suitable plug to the relevant single-phase tap. See section 2.2.
GALA INVERMIG SYNER 230 MP
12
3.4.4 MIG/MAG ADJUSTMENT PROCESS. MANUAL PROGRAM.
P1 : SELECT PROCESS
P2 : SELECT
WELDING PROGRAM
E1 : ADJUST WELDING
VOLTAGE
E2 : ADJUST WIRE SPEED
Display D1:
Display D2:
m/ min
V
MANUAL
3.4.5 MIG/MAG ADJUSTMENT PROCESS. SYNERGIC PROCESS.
P1 : SELECT PROCESS
P2 : SELECT WELDING
PROGRAM
P3 : SELECT WIRE
DIAMETER
E2 : SELECT WELDING PIECE
THICKNESS
Ss
1.0 mm
Ar CO 2
2%
mm
E1 : CORRECTING WELDING VOLTAGE
FROM -30 % TO + 30%
%
P5 : PURGING GAS
Gas purge. The gas
solenoid valve is activated
whilst depressed. The
solenoid valve activation is
prolonged for two seconds
after pressing.
P6 : PURGING WIRE
The drive motor is activated
whilst depressed.
GALA INVERMIG SYNER 230 MP
13
3.4.5.1 MIG/MAG WELDING PROGRAMS.
PROGRAM
WIRE MATERIAL
GAS
Fe (SG2/SG3)
Ar CO2 18%
SS
Ar CO2 2%
Al Mg 5%
Ar 100%
Al Si 5%
Ar 100%
CuSi 3
Ar 100%
FCAW E-71T1
Ar CO2 18%
Fe (SG2/SG3)
CO2 100%
Wire Ø
mm
in
0.6
0.023
0.8
0.030
--0.035
1.0
--0.8
0.030
--0.035
1.0
--1.0
----0.045
1.2
--1.2
0.045
--1.0
0.8
--1.0
---0.8
---
0.035
--0.030
0.035
--0.045
0.030
0.035
1.0
---
NOTES
SG 2/ SG 3 Si 1:
Non-alloy or low alloy wire
(Solid Fe)
Gas mixture Ar-CO2 12 ÷ 25 %
Cr Ni 19-9 :
Solid stainless steel wire (Stainless)
ER 308 ; E308L-16
Al Mg 5%
Aluminium wire alloyed with Magnesium.
Al Si 12%
Aluminium wire alloyed with Silicon.
CuSi3
Cu-Si wire for electrocoating welding .
FCAW 71T11
Tubular wire filled with rutile flux (TYPE 71T11)
SG 2/ SG 3 Si 1:
Non-alloy or low alloy wire.
(Solid Fe)
Gas CO2 100%
3.4.6 PARAMETERS SETTING MODE. MIG/MAG PROCESS.
PROCESS
Setting parameters
MIG
MOD; TPR; TPS; FDC; TBB ; L; Dim
MIG SPOT
MOD; TON; TOF; TPR; TPS; FDC; TBB; L; Dim
3.4.6.1 ADJUSTMENT SYSTEM FOR MIG/MAG SETTING PARAMETERS.
P1 : SELECT PROCESS
P1 : ENTER/EXIT TO
PARAMETERS SETTING
MODE
E1 : SELECT
CYCLE
PARAMETER
E2 : ADJUST
VALUE
D2 :
D3 :
SETTING PARAMETERS
P1 : SAVE
PARAMETERS
SAVED PARAMETERS
3.4.6.2 RESET SETTING PARAMETERS. FACTORY PARAMETERS BY PROCESS.
PARAMETER RESET OF SELECTED PROCESS
P1+P2:
1s
1s
D1:
GALA INVERMIG SYNER 230 MP
14
3.4.6.3 CYCLE PARAMETERS. MIG PROCESS (CONTINUOUS)
MIG PROCESS OPERATING CYCLES
MOD 2T
MOD 4T
K
K
EV
EV
I2>0
I2>0
Vh
Vh
TPR tacer
TBB
TPS
Torch
Torch
2T↑
1T↓
Parameter
MOD
TOF
TPR
TPS
FDC
TBB
Dim
tacer
tci
TBB
FDC
FDC
L
TPR tacer
TPS
1T↓
2T↑
3T↓
CYCLE PARAMETERS OF MIG WELDING MODE
CONFIGURABLE
PARAMETER DESCRIPTION
VALUE
Pulsed mode (2S / 4S)
2S – 4S
Stop time on intermittent welding mode.
OFF ; 0.1÷3.0 sec.
Gas pre-flow time.
0÷3.0 sec.
Gas post-flow time.
0÷5.0 sec.
Approach speed.
10 ÷100% Vh
After-burning time correction.
-200 ÷ 200 (ms)
Dimensional system (Ø/vh).
mm, in
-5 ÷ 5
Electronic inductance level. (dynamic)
(10 positions)
The time in approach process (Limited).
---Time of interrupted cycle (Limited)
----
4T↑
FACTORY VALUE
2S
OFF
0.3 (sec.)
0.4 (sec.)
33 (% vh)
0.00
mm
0
5 sec. max.
4 sec. max.
Explanatory notes:
MOD 4T option is disabled in spot welding mode.
tacer : The time that it is in approach process (I2=0) will be limited to 5 sec.
tci : If the arc is manually interrupted (l2=0) during the welding process, the cycle will be suspended if the
welding position (l2>0) is not recuperated in 4 seconds.
GALA INVERMIG SYNER 230 MP
15
3.4.6.4 CYCLE PARAMETERS. MIG SPOT WELDING PROCESS.
MIG SPOT PROCESS OPERATING CYCLES
MOD 2T ; TOF OFF
K
EV
I2>0
Vh
TPR tacer
TON
TBB
TPS
FDC
Torch
1T↓
2T↑
MOD 4T ; TOF ACTIVADO
MOD 2T ; TOF ACTIVADO
K
K
EV
EV
I2>0
I2>0
Vh
Vh
TPR tacer TON TOF
TPR tacer TON TOF
TBB TPS
FDC
FDC
Torch
Torch
1T↓
2T
Parameter
MOD
TON
TOF
TPR
TPS
FDC
TBB
L
Dim
tacer
tci
1T↓
2T
CYCLE PARAMETERS OF MIG SPOT WELDING MODE
CONFIGURABLE
PARAMETER DESCRIPTION
VALUE
Pulsed mode (2S / 4S)
2S – 4S
Welding time
0.2÷5.0 sec.
Stop time on intermittent welding mode.
OFF ; 0.1÷3.0 sec.
Gas pre-flow time.
0÷3.0 sec.
Gas post-flow time.
0÷5.0 sec.
Approach speed.
10 ÷100% Vh
After-burning time correction.
-200 ÷ 200 (ms)
-5 ÷ 5
Electronic inductance level. (dynamic)
(10 positions)
Dimensional system (Ø/vh).
mm, in
The time in approach process (Limited).
---Time of interrupted cycle (Limited)
----
TBB TPS
3T↓
4T↑
FACTORY VALUE
2S
2.0 (sec.)
OFF
0.3 (sec.)
0.4 (sec.)
33 (% vh)
0.00 (0.01 * vh)
0
mm
5 sec. max.
4 sec. max.
Explanatory notes:
tacer : The time that it is in approach process (I2=0) will be limited to 5 sec.
tci :
If the arc is manually interrupted (l2=0) during the welding process, the cycle will be suspended if the
welding position (l2>0) is not recuperated in 4 seconds.
GALA INVERMIG SYNER 230 MP
16
3.5 TIG WELDING. INSTALLATION, START-UP AND OPERATING CONTROLS.
3.5.1 TIG SYSTEM INSTALLATION. TORCH TO NEGATIVE POLE.
6
5
5
1
10
9
MARK
1
5
6
9
10
REF.
503.12.029
435.12.018
376.00.000
531.12.219
190.51.734
DESCRIPTION
Input cable 3x4 mm2 (1A/V) 3 m. (Plug not incl.)
Machine-gas connection (2 m) / coupling
Argon pressure reducing valve – Mod. EN 2
Earth clamp cable
TIG XT-17 E EURO torch (4 m)
ACCESSORY
INCLUDED
INCLUDED
RECOMMENDED
INCLUDED
RECOMMENDED
3.5.2 TIG SYSTEM START-UP.
1)
2)
3)
Make sure the mains voltage is 230 V.
Verify that the torch polarity is negative.
Check that the gas is Argon. If it has a mobile workstation, check that the gas bottle is securely held by the
bottle-holder system. Above all check that the safety chain is perfectly fastened.
6) Install the pressure-reducing valve 6 and connect gas hose 5 checking that there are no leakages, throughout
the whole circuit.
9) Hook TIG torch to Euroconnector. Bleed gas via the torch button, checking that the flow is between 6 and 12
l/min.
10) Connect supply cable 1 with the suitable plug to the relevant single-phase tap. See section 2.2.
GALA INVERMIG SYNER 230 MP
17
3.5.3 ADJUSTMENT SYSTEM FOR CONVENTIONAL TIG DC WELDING MODE.
P1 : SELECT
PROCESS
E2 : ADJUST WELDING
VOLTAGE I2(A)
D3 :
A
Note: Selection of 2S/4S is carried out in parameters setting mode.
3.5.4 ADJUSTMENT SYSTEM FOR PULSED TIG WELDING MODE.
P1 : SELECT PROCESS
E1 : ADJUST PULSE
FREQUENCY
E2 : ADJUST WELDING
CURRENT
D2 :
D3 :
PULSE
A
Hz
Note: Selection of 2S/4S is carried out in parameters setting mode.
P5
Gas purge. The gas solenoid valve is activated whilst depressed. The solenoid valve activation is
prolonged for two seconds after pressing.
3.5.5 PARAMETERS SETTING MODE. TIG PROCESSES.
PROCESS
Setting parameters
TIG
MOD; TPR; ISt(4T); UPS; DWS; IEn(4T); TPS; IB
PULSED TIG
PULSE
MOD; TPR; ISt(4T); UPS; DCL; IB; DWS; IEn(4T); TPS
3.5.5.1 ADJUSTMENT SYSTEM FOR TIG SETTING PARAMETERS.
P1 : SELECT PROCESS
PULSE
P1 : ENTER PARAMETERS
SETTING
E1 : SELECT CYCLE
PARAMETER
E2 : ADJUST VALUE
D2 :
D3 :
SETTING PARAMETERS
P1 : SAVE
PARAMETERS
SAVED PARAMETERS
3.5.5.2 RESET SETTING PARAMETERS. FACTORY PARAMETERS BY PROCESS.
PARAMETER RESET OF SELECTED PROCESS
P1+P2:
1s
1s
D1:
GALA INVERMIG SYNER 230 MP
18
3.5.6 CYCLE PARAMETERS. TIG PROCESS.
TIG PROCESS OPERATING CYCLES
MOD 4T
MOD 2T
GAS
GAS
UPS
TPR
DWS
UPS
DWS
TPS
I2
I2
TPR
TPS
IEn
ISt
Torch
Torch
1T ↓
2T ↑
1T ↓
2T ↑
3T↓
4T↑
CYCLE PARAMETERS – TIG PROCESS
CONFIGURABLE
Parameter description
VALUE
Pulsed mode (2S / 4S)
2S – 4S
Gas pre-flow time.
0÷5.0 sec.
Initial current (4S)
10 ÷ 100% I2
Ramp-up time
0÷10.0 sec.
Ramp-down time
0÷10.0 sec.
Crater current (4S)
10 ÷ 100% I2
Gas post-flow time.
0÷10.0 sec.
Parameter
MOD
TPR
ISt
UPS
DWS
IEn
TPS
FACTORY
VALUE
2S
0.3 (sec.)
30 (% I2)
0.4 (sec.)
0.6 (sec.)
30 (% I2)
0.4 (sec.)
3.5.7 CYCLE PARAMETERS. PULSE TIG PROCESS.
PULSE TIG PROCESS OPERATING CYCLES
MOD 4T
MOD 2T PULSE
GAS
GAS
UPS
f
TPR
DWS
I2
I2
IB
IB
TPR
TPS
TPS
1T ↓
IEn
ISt
Torch
Torch
MOD
TPR
ISt
UPS
DCL
IB
DWS
IEn
TPS
DWS
f
DCL
DCL
Parameter
UPS
2T ↑
1T ↓
2T ↑
CYCLE PARAMETERS OF PULSE TIG WELDING MODE
CONFIGURABLE
Parameter description
VALUE
Pulse mode (2S / 4S)
2S – 4S
Gas pre-flow time.
0÷5.0 sec.
Initial current (4S)
10 ÷ 100% I2
Ramp-up time
0÷10.0 sec.
Duty cycle
20 ÷ 100 %
Base current (4S)
10 ÷ 100% I2
Ramp-down time
0÷10.0 sec.
Crater current (4S)
10 ÷ 100% I2
Gas post-flow time.
0÷10.0 sec.
3T↓
4T↑
FACTORY
VALUE
2S
0.3 (sec.)
30 (% I2) (1)
0.4 (sec.)
50 %
55 (% I2)
0.6 (sec.)
30 (% I2) (1)
0.5 (sec.)
GALA INVERMIG SYNER 230 MP
19
3.6 MMA WELDING. INSTALLATION, START-UP AND OPERATING CONTROLS.
3.6.1 MMA SYSTEM INSTALLATION. ELECTRODE-HOLDER CLAMP TO POSITIVE POLE.
9
1
11
12
Note: Electrode-holder clamp polarity depend on the electrode (consult the characteristics provided by the manufacturer)
MARK
1
9
REF.
503.12.029
531.12.219
11
259.040
12
1701000
DESCRIPTION
Input cable 3x4 mm2 (1A/V) 3 m. (Plug not incl.)
Earth clamp cable MIG 1810
Accessories for electrode 300A-35/50 (face shield, electrodeholder clamp 2 m, pick, brush and earth clamp 1.5 m)
Electric electrode heater
(Thermostat and Thermometer)
ACCESSORY
INCLUDED
INCLUDED
RECOMMENDED
RECOMMENDED
3.6.2 MMA SYSTEM START-UP.
1) Make sure the mains voltage is 230 V.
2) Connect electrode-holder clamp 11 to polarity recommended by the electrode manufacturer. Normally to positive
pole.
3) Connect earth clamp 9 to welding table or piece to be welded. Check correct connection of welding masses.
4) Check that the electrodes are not damp. If necessary, preheat electrodes for at least one hour with oven 12.
12
5) Connect supply cable 1 with the suitable plug to the relevant single-phase tap. See section 2.2.
3.6.3 ADJUSTMENT SYSTEM FOR MMA / MMA CEL WELDING MODE.
P1 : SELECT PROCESS
E2 : ADJUST WELDING
CURRENT I2(A)
D1:
CEL
A
GALA INVERMIG SYNER 230 MP
20
3.6.4 PARAMETERS SETTING MODE. MMA / MMA CEL PROCESSES.
PROCESS
Setting parameters
MMA
HOT; ARF
MMA CEL
CEL
HOT; ARF
3.6.4.1 ADJUSTMENT SYSTEM FOR MMA / MMA CEL SETTING PARAMETERS.
P1 : SELECT PROCESS
CEL
P1 : ENTER/EXIT TO
PARAMETERS SETTING
MODE
E1 : SELECT
CYCLE
PARAMETER
E2 : ADJUST
VALUE
D2 :
D3 :
P1 : SAVE
PARAMETERS
SAVED PARAMETERS
SETTING PARAMETERS
3.6.4.2 RESET SETTING PARAMETERS. FACTORY PARAMETERS BY PROCESS.
PARAMETER RESET OF SELECTED PROCESS
P1+P2:
1s
1s
D1:
3.6.5 CYCLE PARAMETERS. MMA / MMA CEL PROCESSES.
Parameter
HOT
ARF
PARAMETERS OF DYNAMIC CYCLE – MMA PROCESS
Adjust.
Parameter description
Scale
range
HOT START dynamic function level
% I2 (A)
00-100
ARC FORCE dynamic function level
% I2 (A)
00-100
Lift
Anti sticking
Dynamic functions of MMA / MMA CEL
LIFT ARC (soft striking)
ANTI-STICKING
FACTORY
VALUE
50
50
GALA INVERMIG SYNER 230 MP
21
3.7 JOB RECORDING MODE.
3.7.1 PROCESSES WITH JOB RECORDING MODE. RECORDED VARIABLES.
Program
Variables of recording
MANUAL Vh(m/min) ; U2(V) ; MOD; TPR; TPS; FDC; TBB ; L y Dim.
Synergic Thickness synergic line e(mm); U2 (%); MOD; TPR; TPS; FDC; TBB ; L and Dim
MANUAL Vh(m/min) ; U2(V) ; MOD; TON; TOF; TPR; TPS; FDC; TBB ; L and Dim.
Synergic
PULSE
Thickness synergic line e(mm); MOD; TPR; TPS; FDC; TBB ; L and Dim
---
I2(A); F(Hz); MOD; TPR; TPS; SL1; SL2; IB; DCL
3.7.2 JOB PROGRAM RECORDING SYSTEM.
P4 : BURN JOB
E2 : SELECT JOB No.
P4 : SAVE JOB
2s
JOB
JOB
JOB
3.7.3 DELETING OF ALL JOB PROGRAMMES.
DELETE ALL PROGRAMS (keep pressed P4 during the ignition process)
JOB
3.7.4 ENTER/EXIT SYSTEM TO JOB MODE.
P1 : SELECT PROCESS
(for reproduction of JOB)
P4 : ENTER TO JOB
MODE
E2 : SELECT JOB No. TO
BE REPRODUCED
D1: SELECTED
JOB
2s
without
regulation activity
JOB
JOB
JOB
JOB
Note: if the message "
recorded.
" appears on display D1, this is indicative of the fact that there is no program
GALA INVERMIG SYNER 230 MP
22
3.8 TIMER MODE. PROCESS STATISTICS.
3.8.1 ENTER/EXIT OPERATION.
TIMER MODE
The indication appears after keeping
pressed for 1 sec. The indication is
maintained whilst depressed.
When it reaches 999 minutes it changes
into hours, and the minutes indication
will disappear.
Select the process:
MIG/MMA/TIG.
Wait for 2 seconds without pressing.
1s
2s
without pressing
min
AlMg
AlMg
Ar
Ar
TIMER
h
1.0 mm
1.0 mm
mm
V
mm
A
V
(thousands of hours /
A
hours)
3.8.2 RESET TO ZERO OF TIMER MODE COUNTERS.
SELECT PROCESS P1 : MIG/MMA/TIG.
(It can be carried out from JOB mode)
TIMER MODE P3
RESET TO ZERO THE COUNTER
(Press for 1 sec. P1, P3 and P4)
1s
1s
1s
1s
min
TIMER
h
TIMER
3.8.3 TOTAL WORKING HOURS.
EQUIPMENT
OFF
PULSE MAINTAINED DURING
IGNITION
TOTAL INDICATION
OF ACCUMULATED
HOURS IN THE
WELDING PROCESS
TIMER
h
GALA INVERMIG SYNER 230 MP
23
3.9 HOLD MODE.
At the end of the welding process the welding parameters are automatically memorised. This will be indicated
on the LCD screen with the word "HOLD".
D2- Will indicate the memorised value of the average welding voltage.
D3- Will indicate the memorised value of the average welding current.
3.10 IGNITION MODE. OPERATION.
2s
SWITCH ON
CEL
IPM
PULSE
0.6
0.8
1.0
1.2
mm .023“
mm .030“
mm .035“
mm .045“
HOLD
2s
MANUAL Fe Ss CuSi
AlMg AlSi
Ar CO 2 18% 2% FCAW
m/ mi n
PREVIOUS
WELDING
MODE/JOB TO
SWITCHED OFF
JOB
TIMER
mm in
h
V
%
Hz
ON
(LD1 and LD2 on)
A
S
%
Equip.
mod.;
(power)
Software release
GALA INVERMIG SYNER 230 MP
24
4 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.
4.1 MACHINE MAINTENANCE. GENERAL
RECOMMENDATIONS.
Before carrying out any operation on the machine or
welding cables, we must place the switch of the equipment
in "O" position of machine disconnected.
Specialized personnel must handle the machine to carry
out maintenance and repair operations.
BLOW THE INSIDE
INSIDE OF THE MACHINE WITH
COMPRESSED AIR FROM TIME TO TIME.
The accumulation of metal dust on the inside is one of the
main causes of breakdowns in this type of equipment as
they are subject to a great amount of pollution. As an
essential measure, the equipment must be kept separate
from the welding place, not placing it a short distance away.
Keeping the machine clean and dry is essential. The inside
must be blown as required. We must avoid any anomaly or
deterioration due to the accumulation of dust. Blow the
inside of the equipment with clean dry compressed air. As
routine to guarantee that the equipment works correctly,
check that once the machine has been blown the electrical
connections are still properly tightened.
WARNING!: SEPARATE THE MACHINE SUFFICIENTLY
SUFFICIENTLY
FROM THE WORKSTATION.
PREVENT METAL DUST ENTERING THE EQUIPMENT.
LOCATE THE EQUIPMENT IN A PLACE WHERE
CLEAN AIR IS CONSTANTLY REPLACED.
The machine ventilations must be kept free. It must be
located in a place where clean air is renewed.
THE MACHINE
MACHINE MUST ALWAYS BE OPERATED WITH THE
HOUSING ON.
DO NOT DISCONNECT THE
THE MACHINE IF IT IS
HOT.
HOT.
If you have finished the work do not disconnect the
machine immediately, wait until the inner cooling system
has totally cooled it.
KEEP THE WELDING ACCESSORIE
ACCESSORIES
ESSORIES IN GOOD
CONDITIONS FOR USE.
USE.
ONCE THE WELDING OPERATION
OPERATION HAS
FINISHED AVOID DIRECT
DIRECT CONTACT OF THE
ELECTRODEELECTRODE-HOLDER CLAMP WITH THE
THE WELDING
EARTH CLAMP AND THE OTHER PARTS CONNECTED
CONNECTED
TO IT.
KEEP THE WELDING GUN IN GOOD
CONDITIONS FOR USE.
A damaged or worn gun can cause inefficient welding.
WHEN FINISHING THE WELDING OPERATION
MAKE SURE THAT THE TORCH CATCH IS UNLOCKED. (If
mechanical lock guns are used)
4.2 RECOMMENDATIONS FOR REDUCING
ELECTROMAGNETIC COMPATIBILITY (CEM) PROBLEMS.
The user is responsible for the installation and use of the
welding material according to the instructions in this manual
and the following recommendations.
Before installing the welding material, the presence of the
following in the surrounding area must be kept in mind:
•
•
•
•
•
•
Wiring for power, control, signalling, and telephones.
Radio and television receivers and transmitters.
Computers and other control equipment.
Critical security equipment.
People with pace makers or hearing aids.
Measurement and calibration equipment.
In order to reduce EMC problems, keep in mind the time
of day when welding or other activities will be carried out.
Move possible interference victims away from the welding
installation.
ALWAYS CONNECT THE MACHINE TO POWER
USING AN EFFICIENT EARTH TAP.
IF PROTECTIVE
PROTECTIVE DEVICES OR SUPPLEMENTARY
ELECTRICAL SYSTEM FILTERS ARE NEEDED, CONSULT
OUR TECHNICAL SERVICE.
PERFORM THE MAINTENANCE OPERATIONS
DESCRIBED IN THIS MANUAL.
USE THE SHORTEST WELDING WIRES POSSIBLE AND
KEEP THEM PLACED NEXT TO EACH OTHER NEAR THE
FLOOR.
FLOOR.
EQUIPMENT FORESEEN FOR USE IN INDUSTRIAL
ENVIRONMENT. ELECTROMAGNETIC DIFFICULTIES MAY
EXIST IN OTHER ENVIRONMENTS CAUSED BY
CONDUCTED AND RADIATED DISTURBANCES.
IF THE WELDING PIECE IS GROUNDED, KEEP IN MIND
OPERATOR SAFETY AND NATIONAL REGULATIONS.
REGULATIONS.
GALA INVERMIG SYNER 230 MP
25
5. ANOMALIES. PROBABLE CAUSES. POSSIBLE SOLUTIONS.
SYMPTOM. ANOMALY.
GENERAL PROBLEM.
NOTHING WORKS.
LIMITER TRIPS
IT CAUSES NOISE
IF THE GREEN INDICATOR LD1
IS ON THE APPLIANCE DOES
NOT WELD
THE ELECTRODE BURNS IN TIG
WELDING
THE EQUIPMENT HEATS UP
ABNORMALLY.
THE THERMAL PROTECTION
ACTIVATES QUICKLY.
PROBABLE CAUSE.
Magnetothermal switch has low gauge for the
case. There may be a short circuit, which is
what causes the limiter to trip.
Loose metal casing.
Defective electrical connections.
Damaged or poorly attached fan.
Active protection system.
on.
Amber light “LD2”
Excessive welding intensity for a certain
electrode.
Use of reverse polarity.
Lack of protection gas.
The equipment is positioned so that it prevents
correct ventilation.
The fan does not work.
The equipment is located in a very hot
environment.
There is a loose connection inside the
equipment.
ALTHOUGH THE MACHINE IS
CONNECTED AND WITH THE
Failure of the pistol switch which does not
SWITCH LD1 ON, THERE IS NO make perfect contact.
REACTION WHEN PRESSED
WHEN THE GUN IS PRESSED,
Voltage does not reach the Contactor or/and
ALTHOUGH WIRE COMES OUT, solenoid valve.
THE CONTACTOR DOES NOT
WORK OR/AND THERE IS NO
SHIELDING GAS
There is impurity in the inside chamber of the
WHEN THE SHIELDING GAS IS solenoid valve which prevents the piston from
RELEASED IT CONTINUES
closing completely.
FLOWING.
The configurated value of post-flow is very
high.
WHEN FINISHING WELDING
The configurated value of burn-back is very
THE WIRE REMAINS STUCK TO
high.
THE TORCH CONTACT TUBE.
TUBE.
The configurated value of burn-back is too
low.
WHEN FINISHING WELDING
THE FINAL WIRE LENGTH IS
The torch is withdrawn immediately when torch
VERY GREAT.
pushbutton is no longer pressed.
THE EQUIPMENT DOES NOT
WELD CORRECT.
"IT ADJUSTS BADLY"
THERE ARE MANY
PROJECTIONS IN THE
WELDING PROCESS
POSSIBLE SOLUTION.
1. Make sure there is voltage at the entry to the machine, if
not the tapping must be changed. It is advisable to see if
any magnetothermal has "blown".
The machine has no voltage in one or all its 2. Check the power source fuses situated on the central
vital elements.
panel. (See Spare parts Sheet)
3. The machine panels must be removed testing the logical
points of the electrical diagram.
Change the magnetothermal for another larger gauge
one. It is important for the magnetothermal switch to have a
characteristic slow type curve. In the event that the electrical
installation has limited power the welding work must be
tested at lower current levels.
Review and screw casing.
Correctly tighten the connections.
Examine the fan.
Equipment overheated, wait until the equipment cools down.
Supply voltage outside rated margin. Change supply tap.
Decrease welding current or change electrode for one with
larger diameter.
Place electrode to negative pole.
Regulate at an appropriate flow.
Place the equipment in an area where the air is constantly
replaced.
Replace the fan.
Avoid positioning where there is direct exposure to the sun.
Review the power electrical connections.
Change the gun microswitch.
It must be established whether the fault comes from the
electronic board or if it is an electrical connection fault.
Check that the contactor coils or/and solenoid valve are not
open.
Dismantle and clean the electrovalve.
Change in the settings menu the post-flow time value TPS.
Change in the settings menu the value of the burn-back
time correction (see section 3.6.2).
Change in the settings menu the value of the burn-back
time correction (see section 3.6.2).
The final wire length control system requires the welding
torch not to be immediately withdrawn when the torch
pushbutton is no longer pressed.
Check that there is not a phase failure in the supply power.
Check that the electrical contact elements of the welding
circuit are correct: Welding mass, rusty or very dirty
Low effective welding voltage. Output wave not
surfaces, contact nozzle with greater diameter than the wire,
correct.
etc.
Test the electrical diagram of the power source.
Input and output voltages to the rectifier.
The welding wire has a mechanical resistance
Examine the welding gun. Blow the inside (cable) with
at the outlet, which prevents it from having a
compressed air.
regular speed.
Unsuitable shielding gas.
When welding normal steels we advise the use of a gas
mixture Ar-CO2.
GALA INVERMIG SYNER 230 MP
26
SYMPTOM. ANOMALY.
PROBABLE CAUSE.
POSSIBLE SOLUTION.
THE WELDING START IS VERY
AGGRESSIVE.
THERE ARE MANY
PROJECTIONS.
Aluminium is being welded with a drawing
problem, which causes incorrect arc ignition as
the wire is slowed down on knocking against
the piece.
Examine the drawing process. Prevent the gun from making
“knots”, keeping it in a straight line. The wire must not be
slowed down when it knocks against the piece
The wire length at onset of welding process is
too long.
Change in the settings menu the value of the burn-back
time correction (see section 3.6.2).
D1
D3
E01
THE
E02
E03
OUT
OUC
Error. Cause.
Overheating has occurred in the power source. The thermal protection has disconnected the
equipment.
It is detected that there is no welding voltage.
Overload.
SPECIALIZED PERSONNEL MUST CARRY OUT ANY WORK ON THE EQUIPMENT.
BOTH AT THE BEGINNING AND END OF A REPAIR CHECK THE EQUIPMENT INSULATION LEVELS.
DISCONNECT THE ELECTRONIC BOARDS WHEN MEASURING THE INSULATION.
BLOW THE INSIDE OF THE EQUIPMENT WITH COMPRESSED AIR.
The insulation-measuring device will have 500 V D.C. and will be applied to the following points of the circuit:
- Supply-Earth: Ra > 50 Mohms.
- Welding-Earth: Ra > 50 Mohms.
- Supply-Welding: Ra > 50 Mohms.
BEFORE TURNING THE EQUIPMENT ON, ENSURE THAT IT IS OFF LOAD.
DO NOT OPERATE THE ON/OFF SWITCH WITH AN ELECTRICAL LOAD
CONNECTED TO THE WELDING CONNECTORS.
GALA INVERMIG SYNER 230 MP
27
6. 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.
For your safety and that of others, remember that:
ANY PRECAUTION MAY BE INSUFFICIENT!
The welding equipment referred to in this manual are electrical. It is important therefore to
observe the following safety measures.
• Any work on the equipment must only be carried out by specialists.
• The equipment must be connected to the earth connection and this must always be
effective.
• The equipment must not be located in a damp place.
• Do not use the equipment if the welding or supply cables are damaged. Use original
spares.
• Make sure that the part to be welded makes perfect electrical contact with the equipment earth.
• During any maintenance operations or when dismantling any element from the inside of the machine, this must
be disconnected from the electricity supply.
• Do not touch the equipment switches when carrying out a welding operation.
• Never lean directly on the work part. We will always work with protection gloves.
• Any work on the welding guns and earth clamps will be done with the equipment disconnected (OFF Position (O)
on the on/off switch). Do not touch the electrically active parts (electrode-holder clamp, earth clamp, etc.) with
your bare hand.
The part to be worked on should be cleaned from possible grease or solvents as these may
decompose during the welding process giving off fumes which could be very toxic. This can
also occur with those materials which have some kind of surface coating (zinc-plated,
galvanised, etc.). Avoid inhaling the fumes given off in the process at all times. Protect
yourself from the fumes and metal dust which can be given off. Use quality approved antifume goggles. Work with this equipment must be carried out in places or working posts
where there is suitable air renewal. If welding processes are carried out in closed places the
use of suitable fume extractors is recommended.
In welding processes, the electric arc formed gives off infrared and ultraviolet type
irradiations: these are harmful for the eyes and skin, so these areas must be suitably
protected with gloves and suitable clothing. The eyes must be protected with goggles with an
quality approved protection system with a protection index of at least 11. With electric arc
welding machines use protection shield for the eyes and face. With electric cutting machine
use protection goggles. Always use quality approved protection elements. Never use contact
lenses. They may adhere to the cornea due to the great heat given off during the process.
Bear in mind that the arc is considered to be dangerous within a 15-metre radius.
Cast material projections are given off during the welding process so due precautions must
be taken. There must be a fire-extinguisher near to the working area. Do not keep
inflammable material or explosives near to the working post. Prevent fire caused by sparks or
slag. Use quality approved footwear for this type of operations. Use approved auditive
protectors in case of too high noise.
Never direct the path of an electrode-holder clamp towards people.
In environments with a high risk of electrical shock, fire, proximity of inflammable products or
height, observe relative national and international provisions.
GALA INVERMIG SYNER 230 MP
GB
•
•
•
APPENDICES. ELECTRICAL DRAWINGS AND REFERENCE PARTS LIST.
DECLARATION OF CONFORMITY & EC MARKING
ELECTRICAL DIAGRAMS.
PARTS DRAWINGS AND REFERENCE LISTS.
FORMULA FOR MAKING ORDERS FOR SPARE PARTS:
Indicate:
1. Machine, Reference and Serial no.
2. Supply Voltage / Frequency.
3. No. of parts, description and reference of it.
EXAMPLE:
GALA INVERMIG SYNER 230 MP, Ref. 518.00.000 (230V-50/60Hz)
1 U. KEYBOARD, Ref. 51816091
28
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)
EMPRESA DISTRIBUIDORA DE LOS PRODUCTOS FABRICADOS POR:
GALA GAR, S.L. AS THE SOLE DISTRIBUTOR OF THE PRODUCTS MANUFACTURED BY:
GALA GAR, S.L., SOCIÉTÈ DE DISTRIBUTION DES PRODITS FABRIQUÉS PAR:
SOL GAR, S.A. Benjamín Franklin 6 naves A y B, 50014 ZARAGOZA (España)
DECLARA, QUE EL PRODUCTO SUMINISTRADO Y REFERENCIADO EN EL MANUAL DE INSTRUCCIONES, ES
CONFORME A LAS DIRECTIVAS COMUNITARIAS APLICABLES PARA EL MARCADO CE:
DECLARES THAT THE PRODUCT SUPPLIED AND WITH THE REFERENCE NUMBER WRITTEN IN THE
TECHNICAL INSTRUCTIONS HANDBOOK COMPLIES WITH THE EEC DIRECTIVES REQUIREMENTS OF THE
EEC STANDARD:
DÉCLARA QUE LES PRODUITS PRÉSENTÉS ET RÉFERENCÉS DANS LE MANUEL D´INSTRUCTION SONT
CONFORMES AUX DIRECTIVES COMMUNAUTAIRES APPLICABLES POUR LE MARQUEE CE:
PRODUCTO:
GALA INVERMIG SYNER 230 MP
UNEEN60974-1
Equipos de soldadura eléctrica por arco Parte 1: Fuentes de potencia para
Soldadura.
UNEEN60974-10
Equipos de soldadura eléctrica por arco Parte 10: Requisitos de compatibilidad
electromagnética
UNEEN60974-5
Equipos de soldadura eléctrica por arco. Parte 5: Alimentadores de hilo.
2004/108/CE (89/336/CEE)
Directiva relativa a la Compatibilidad Electromagnética
2006/95/CE (73/23/CEE)
Directiva sobre el material eléctrico destinado a utilizarse con
determinados límites de tensión.
Zaragoza,
Zaragoza, jueves, 29 de mayo de 2008
2008
SOL GAR S.A.
Luis Gardeta Guinda
Director General
1
2
3
4
5
6
7
8
P.E.
230 V-50/60 HZ
MA
L1
AZ
0V
MA
P.E.
4
3
2
1
2
1
10
9
8
7
6
5
4
3
2
1
CN5
CN6
CN7
P5
P6 P7
NE
Pt1
Pt2
M(+)
M(-)
U. VENTILADOR
(Cara de componentes)
BL
1
2
3
4
BL
P2
29
CN3
RO
TRAFO PRIM2
1
2
3
4
0V
230V
TENSION DE ENTRADA
N
F
TRAFO I
FN2
10
9
8
7
6
5
4
3
2
1
1
2
3
4
NE
AM
GR
CN4
CN2
NE
C
VI
BL
Im=0
P1
BL
FN4
6
5
4
3
2
1
CN1
TRAFO PRIM1
FN1
Vhmin
RO
NE
AZ
FN3
1
2
62716001 PLACA CONTROL MOTOR 98.36V.1
3
4
34
5 CN1
6
7
8
AM
P8 P9
P.E.
RO
PLACA POTENCIA
C
BL
P3 P4
15
GR
47
45
Vcc
V
51712016 PLACA CONTROL 98.39
NA
2A/250V(T)
AZ
D
AM
F1
MA
EV
NE
MA
MA
P1
1
2
3
4
25 26
36
10
RO
10
9
8 CN4
7
6
5
4
3
2
1
ON/OFF
AZ
CN2
P2
BL
40
CN1
CN1
1
2
GR
AM
BL
TRAFO AUXILIAR
BL
1
2
3
4
5
6
P. E.
L1
N
O/I
1
2
3
4
5
6
7 CN3
8
9
10
48V
230V
AZ
BL
AM
MA
AM
BL
GR
NA
NE
VI
D
33
AZ
MA
39
1
2
3
4
5
6
7
8
9
10
N
CNA
CN2
10
9
8
7
6
5
4
3
2
1
BL
BL
M(+)
51812018 PLACA DISPLAY 98.40
CN1
B
RO
B
NE
NE
MOTOR48VDC
22
C2
D1
(+)
BL
(+) 11
L
D1
R1
IDEN./COLOR.
06
NE: NEGRO, BLACK
RO: ROJO, RED
MA: MARRON, BROWN
VE: VERDE, GREEN
BL: BLANCO, WHITE
AZ: AZUL, BLUE
GR: GRIS, GREY
NA: NARANJA, ORANGE
VI: VIOLET A, VIOLET
AM: AMARILLO, YELLOW
05
D1
D1
D1
D1
(-) 11
NE
MODULO SECUNDARIO
49
RO
230V - 50/60Hz
Pt2
A
N om br e
A. Serrano
R ev i s ad o
30/04/08
J. A. Oliva
A pr o ba d o
30/04/08
J. Simón
SOL GAR, S.A.
ZARAGOZA
Página
Código:
Esquema GALA INVERMIG SYNER 230 MP
6
0 de
0
Fichero: 51806032.Sch
TITULO
A3
5
GAS OUT
EV
25/04/08
Tamaño:
4
Pt2
36
F ec h a
3
Pt1
GAS IN
CAMBIO DE POLARIDAD
(+): MIG / MAG
(-): TIG / FCAW
R ea li za d o
2
Pt1
PT
(-)
SHUNT
VR1
24
(+)
BRAIDED CABLE - CABLE T RENZADO
1
MIG TORCH
D1
C1
A
EUROC ONEC TOR
WIRE FEEDER
NE
C2
Th TRAFO
THF
+
-
M(-)
7
Revisión:
518.06.032
0
8
REPUESTOS MOTOR DE ARRASTRE.
SF 15037 42V-50W Ref. 517.16.020
MARCA
1
2
3
3.1
3.2
3.3
3.4
4
5
6.1
6.2
6.3
6.4
6.5
6.6
7
8
9
10
REFERENCIA
DESCRIPCION
51716120 MECANISMO DE ARRASTRE (COMPLETO)
51716220 MOTOR DE ARRASTRE
51716320 EUROCONECTOR (COMPLETO)
51716321 CUERPO EUROCONECTOR
51716322 RACOR GAS
51716323 SOPORTE TUBO GUÍA HILO
51716324 TUBO GUÍA HILO
51716021 PROTECCIÓN FRONTAL CONECTOR
51716420 PALANCA APRIETE (COMPLETO)
51716521 RULETA Ø37, 0.6-0.8 mm "V"
51716520 RULETA Ø37, 0.8-1.0 mm "V"
51716522 RULETA Ø37, 0.9-1.2 mm "V"
51716523 RULETA Ø37, 1.0-1.2 mm “ALU”
51716524 RULETA Ø37, 0.9-1.2 mm "TUBULAR"
51716525 RULETA Ø37, 1.2-1.6 mm "TUBULAR"
51716620 TORNILLO FIJACIÓN RULETA
51716720 CANALIZADOR HILO
51716820 POMO APRIETE (COMPLETO)
51716920 CHAVETA
23-05-08
HR:51716020 V0 1/1
INCORPORACION EN EQUIPOS STANDARD
REFERENCIA
DESCRIPCION
51700000
51800000
INVERMIG 230 MP
INVERMIG SYNER 230 MP
TAMBIEN VALIDO PARA:
REPUESTOS GALA INVERMIG SYNER 230 MP
REF: 518.00.000
230V-50/60Hz
21-05-2008
HR: 51800000 V0 1/2
REPUESTOS GALA INVERMIG SYNER 230 MP
REF: 518.00.000
21-05-2008
230V-50/60Hz
MARCA REFERENCIA DESCRIPCION
1
51710001 CHASIS
2
00533011 CAPUCHON TORNILLO
3
55116012 APOYOS DE GOMA
4
00533010 ESPACIADOR HEXAGONAL
5
51712025 REACTANCIA
6
51712017 CONJUNTO MODULO SECUNDARIO
7
50310004 SOPORTE PLACA POTENCIA
8
50312086 SEPARADOR CENTRAL PLACA POTENCIA
9
51710012 CANALIZADOR
10
51712016 PLACA CONTROL
11
50712019 CONECTOR HEMBRA 35-50
12
51813008 PLACA FRENTE METACRILATO
13
51816091 TECLADO
14
63112005 MANDO POTENCIOMETRO Ø21
15
51812018 PLACA ELECTRONICA FRENTE
16
00533014 SEPARADOR METAL M/H
17
51710003 FRENTE ANTERIOR
18
51710007 TAPA LATERAL
19
43016040 PASAMUROS CIEGO (Ø38MM)
20
00315001 CIERRE DESLIZANTE
21
51700006 LATERAL MOVIL
22
51716020 SISTEMA ARRASTRE COMPLETO
23
51710015 CAJON PLACA ELECTRONICA
24
51716060 BORNE PASAMUROS
25
00552002 FUSIBLE 2 A LENTO (DIAM.5X20)
26
49216026 PORTAFUSIBLES
27
62316019 EJE SOPORTE CARRETE(BOBINA 5KG)
28
51710009 TUBO ASA
29
43516015 FICHA CONEXION
30
45716410 SOPORTE ASA Ø20
31
51702002 CONJUNTO PANEL CENTRAL
32
45006117 SEPARADOR C.I. PLASTICO 6 MM.
33
00557012 TRAFO AUXILIAR
34
62716001 PLACA ELECTRONICA CONTROL DEVANADORA
35
51702004 CONJUNTO FRENTE POSTERIOR
36
51716011 ELECTROVALVULA
37
49216014 APRIETE CABLE
38
43512018 CONEXION MAQUINA-GAS(2M)/RACOR
39
50312029 CABLE ENTRADA
40
50316085 INTERRUPTOR
41
00313003 BISAGRA
42
51710013 REFUERZO CARRETE HILO
43
51700005 LATERAL FIJO
44
00532009 TUERCA NYLON
45
50312015 PLACA ELECTRONICA POTENCIA
46
50310005 SOPORTE VENTILADOR
47
50316010 VENTILADOR
48
57211311 TUERCA BORNA M6
49
51712040 CONJUNTO SHUNT
HR: 51800000 V0 2/2
REPUESTOS CONJUNTO MÓDULO
SECUNDARIO INVERMIG 230 REF: 517.12.017
MARCA
1
2
3
4
5
6
7
8
9
10
11
12
13
REFERENCIA
51712117
51712024
00551065
50314517
00550013
00551050
57211311
00551102
00551110
50311617
00533004
51716217
50116045
21-05-2008
DESCRIPCIÓN
PCB DIODOS SALIDA
CONJUNTO TRAFO HF
CONDENSADOR CERAMICO Y2-4.7nF-250V
SOPORTE TRAFO
RESISTENCIA 10 Ohm/11W
CONDENSADOR MKP 4.7nF/1000V
TUERCA BORNA M-6
TRANSIL 1,5KE 440CA
DIODO IXYS DSEI 120-06A
TORNILLO LATON M-6X20
SEPARADOR METAL M/H M4-10MM
DISIPADOR DIODOS
BASE ADHESIVA 30x5x1,5
HR: 51712017 V0 1/1
FABRICACIÓN Y VENTA DE APARATOS DE SOLDADURA AUTÓGENA, ELÉCTRICA Y
CONSTRUCCIONES ELECTROMECÁNICAS.
MANUFACTURE AND SALE OF AUTOGENOUS, AND ELECTRIC WELDING APPLIANCES, AND
ELECTROMECHANICAL CONSTRUCTIONS.
FABRICATION ET VENTE D’APPAREILS DE SOUDAGE AUTOGÈNE, ÉLECTRIQUE ET
CONSTRUCTIONS ÉLECTROMÉCANIQUES.
FABRICO E VENDA DE APARELHAGENS DE SOLDADURA AUTOGÉNEA,
AUTOGÉNEA, ELÉCTRICA E
CONSTRUÇÕES ELECTROMECÂNICAS.
CENTRAL:
Jaime Ferrán, 19, nave 30
Apartado de Correos 5058
50080 ZARAGOZA
Teléfono 976 47 34 10
Telefax 976 47 24 50
E-mail: [email protected]
Internet: http://www.galagar.com