GYS 210-4 XL Multi-Pearl MIG Welder Instruction Manual

GYS 210-4 XL Multi-Pearl MIG Welder

GENERAL INSTRUCTIONS

Read and understand the following safety recommendations before using or servicing the unit. Any change or servicing that is not specified in the instruction manual must not be undertaken. The manufacturer is not liable for any injury or damage caused due to non-compliance with the instructions featured in this manual . In the event of problems or uncertainties, please consult a qualified person to handle the installation properly.

ENVIRONMENT

This equipment must only be used for welding operations in accordance with the limits indicated on the descriptive panel and/or in the user manual. The operator must respect the safety precautions  that apply to this type of welding. In case of inedaquate or unsafe use, the manufacturer cannot be held liable for damage or injury. This equipment must be used and stored in a place protected from dust, acid or any other corrosive agent. Operate the machine in an open, or well-ventilated area. Operating temperature: Use between -10 and +40°C (+14 and +104°F). Store between -20 and +55°C (-4 and 131°F). Air humidity Lower or equal to 50% at 40°C (104°F). Lower or equal to 90% at 20°C (68°F). Altitude: Up to 1000 meters above sea level (3280 feet).

PROTECTION OF THE INDIVIDUALS
Arc welding can be dangerous and can cause serious and even fatal injuries. Welding exposes the user to dangerous heat, arc rays, electromagnetic fields, noise, gas fumes, and electrical shocks. People wearing pacemakers are advised to consult with their doctor before using this device. To protect oneself as well as the other, ensure the following safety precautions are taken :

• In order to protect you from burns and radiations, wear clothing without cuffs. These clothes must be insulated, dry, fireproof and in good condition, and cover the whole body.
• Wear protective gloves which guarantee electrical and thermal insulation.
• Use sufficient welding protective gear for the whole body: hood, gloves, jacket, trousers… (varies depending on the application/operation). Protect the eyes during cleaning operations. Do not operate whilst wearing contact lenses.
• It may be necessary to install fireproof welding curtains to protect the area against arc rays, weld spatters and sparks.
• Inform the people around the working area to never look at the arc nor the molten metal, and to wear protective clothes.
• Ensure ear protection is worn by the operator if the work exceeds the authorised noise limit (the same applies to any person in the welding area).
• Stay away from moving parts (e.g. engine, fan…) with hands, hair, clothes etc…
• Never remove the safety covers from the cooling unit when the machine is plugged in – The manufacturer is not responsible for any accident or injury that happens as a result of not following these safety precautions.
• The pieces that have just been welded are hot and may cause burns when manipulated. During maintenance work on the torch or the electrode holder, you should make sure it’s cold enough and wait at least 10 minutes before any intervention. The cooling unit must be on when using a water cooled torch in order to ensure that the liquid does not cause any burns. ALWAYS ensure the working area is left as safe and secure as possible to prevent damage or accidents.

WELDING FUMES AND GAS
The fumes, gases and dust produced during welding are hazardous. It is mandatory to ensure adequate ventilation and/or extraction to keep fumes and gases away from the work area. An air fed helmet is recommended in cases of insufficient air supply in the workplace. Check that the air intake is in compliance with safety standards. Care must be taken when welding in small areas, and the operator will need supervision from a safe distance. Welding certain pieces of metal containing lead, cadmium, zinc, mercury or beryllium can be extremely toxic. The user will also need to degrease the workpiece before welding. Gas cylinders must be stored in an open or ventilated area. The cylinders must be in a vertical position secured to a support or trolley. Do not weld in areas where grease or paint are stored.

FIRE AND EXPLOSION RISKS
Protect the entire welding area. Compressed gas containers and other inflammable material must be moved to a minimum safe distance of 11 meters. A fire extinguisher must be readily available. Be careful of spatter and sparks, even through cracks. It can be the source of a fire or an explosion. Welding of sealed containers or closed pipes should not be undertaken, and if opened, the operator must remove any inflammable or explosive materials (oil, petrol, gas…). Grinding operations should not be directed towards the device itself, the power supply or any flammable materials.

GAS BOTTLE
Gas leaking from the cylinder can lead to suffocation if present in high concentrations around the work area. Transport must be done safely: Cylinders closed and product off. Always keep cylinders in an upright position securely chained to a fixed support or trolley. Close the bottle after any welding operation. Be wary of temperature changes or exposure to sunlight. Cylinders should be located away from areas where they may be struck or subjected to physical damage. Always keep gas bottles at a safe distance from arc welding or cutting operations, and any source of heat, sparks or flames. Be careful when opening the valve on the gas bottle, it is necessary to remove the tip of the valve and make sure the gas meets your welding requirements.

ELECTRIC SAFETY
The machine must be connected to an earthed electrical supply. Use the recommended fuse size. An electrical discharge can directly or indirectly cause serious or deadly accidents .
The machine must be connected to an earthed electrical supply. Use the recommended fuse size. An electrical discharge can directly or indirectly cause serious or deadly accidents .

Do not touch any live part of the machine (inside or outside) when it is plugged in (Torches, earth cable, cables, electrodes) because they are connected to the welding circuit.
Before opening the device, it is imperative to disconnect it from the mains and wait 2 minutes, so that all the capacitors are discharged. Do not touch the torch or electrode holder and earth clamp at the same time. Damaged cables and torches must be changed by a qualified and skilled professional. Make sure that the cable cross section is adequate with the usage (extensions and welding cables). Always wear dry clothes in good condition, in order to be insulated from the electrical circuit. Wear insulating shoes, regardless of the environment in which you work in.

EMC CLASSIFICATION
These Class A devices are not intended to be used on a residential site where the electric current is supplied by the public network, with a low voltage power supply. There may be potential difficulties in ensuring electromagnetic compatibility on these sites, because of the interferences, as well as radio frequencies. This equipment complies with IEC 61000-3-11 if the power supply network’s impedance at the electrical installation’s connection point is inferior to the network’s maximum admissible impendance Zmax = 0.186 Ohms. This equipment complies with the IEC 61000-3-12 standard.

ELECTROMAGNETIC INTERFERENCES
The electric currents flowing through a conductor cause electrical and magnetic fields (EMF). The welding current generates an EMF field around the welding circuit and the welding equipment.

The EMF fields may disrupt some medical implants, such as pacemakers. Protection measures should be taken for people wearing medical implants. For example, access restrictions for passers-by or an individual risk evaluation for the welders. All welders should take the following precautions in order to minimise exposure to the electromagnetic fields (EMF) generated by the welding circuit::

• position the welding cables together – if possible, attach them;
• keep your head and torso as far as possible from the welding circuit;
• never enroll the cables around your body;
• never position your body between the welding cables. Hold both welding cables on the same side of your body;
• connect the earth clamp as close as possible to the area being welded;
• do not work too close to, do not lean and do not sit on the welding machine
• do not weld when you’re carrying the welding machine or its wire feeder.

People wearing pacemakers are advised to consult their doctor before using this device. Exposure to electromagnetic fields while welding may have other health effects which are not yet known.

RECOMMENDATIONS TO ASSESS THE AREA AND WELDING INSTALLATION

Overview
The user is responsible for installing and using the arc welding equipment in accordance with the manufacturer’s instructions. If electromagnetic disturbances are detected, it is the responsibility of the user of the arc welding equipment to resolve the situation with the manufacturer’s technical assistance. In some cases, this remedial action may be as simple as earthing the welding circuit. In other cases, it may be necessary to construct an electromagnetic shield around the welding power source and around the entire piece by fitting input filters. In all cases, electromagnetic interferences must be reduced until they are no longer bothersome.

Welding area assessment
Before installing the machine, the user must evaluate the possible electromagnetic problems that may arise in the area where the installation is planned. In particular, it should consider the following:

1. the presence of other power cables (power supply cables, telephone cables, command cable, etc…)above, below and on the sides of the arc welding machine.
2. television transmitters and receivers ;
3. computers and other hardware;
4. critical safety equipment such as industrial machine protections;
5. the health and safety of the people in the area such as people with pacemakers or hearing aids;
6. calibration and measuring equipment
7. The isolation of the equipment from other machinery. The user will have to make sure that the devices and equipments that are in the same room are compatible with each other. This may require extra precautions;
8. make sure of the exact hour when the welding and/or other operations will take place.
   The surface of the area to be considered around the device depends on the building’s structure and other activities that take place there. The area taken in consideration can be larger than the limits determined by the companies.

Welding area assessment
Besides the welding area, the assessment of the arc welding systems installation itself can be used to identify and resolve cases of disturbances. The assessment of emissions must include in situ measurements as specified in Article 10 of CISPR 11: 2009. In situ measurements can also be used to confirm the effectiveness of mitigation measures.

RECOMMENDATION ON METHODS OF ELECTROMAGNETIC EMISSIONS REDUCTION

1. National power grid : The arc welding machine must be connected to the national power grid in accordance with the manufacturer’s recommendation. If interferences occur, it may be necessary to take additional preventive measures such as the filtering of the power suplly network. Consideration should be given to shielding the power supply cable in a metal conduit. It is necessary to ensure the shielding’s electrical continuity along the cable’s entire length. The shielding should be connected to the welding current’s source to ensure good electrical contact between the conduct and the casing of the welding current source..
2. Maintenance of the arc welding equipment: The arc welding machine should be be submitted to a routine maintenance check according to the manufacturer’s recommendations. All accesses, service doors and covers should be closed and properly locked when the arc welding equipment is on.. The arc welding equipment must not be modified in any way, except for the changes and settings outlined in the manufacturer’s instructions. The spark gap of the arc start and arc stabilization devices must be adjusted and maintained according to the manufacturer’s recommendations.
3. Welding cables : Cables must be as short as possible, close to each other and close to the ground, if not on the ground.
4. Electrical bonding : consideration shoud be given to bonding all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the riskof electric shock if the operator touches both these metal elements and the electrode. It is necessary to insulate the operator from such metal objects.
5. Earthing of the welded part : When the part is not earthed – due to electrical safety reasons or because of its size and its location (which is the case with ship hulls or metallic building structures), the earthing of the part can, in some cases but not systematically, reduce emissions It is preferable to avoid the earthing of parts that could increase the risk of injury to the users or damage other electrical equipment. If necessary, it is appropriate that the earthing of the part is done directly, but in some countries that do not allow such a direct connection, it is appropriate that the connection is made with a capacitor selected according to national regulations.
6. Protection and plating : The selective protection and plating of other cables and devices in the area can reduce perturbation issues. The protection of the entire welding area can be considered for specific situations.

TRANSPORT AND TRANSIT OF THE WELDING MACHINE
The machine is fitted with handle(s) to facilitate transportation. Be careful not to underestimate the machine’s weight. The handle(s) cannot be used for slinging. Do not use the cables or torch to move the machine. The welding equipment must be moved in an upright position. Do not place/carry the unit over people or objects. Never lift the machine while there is a gas cylinder on the support shelf. A clear path is available when moving the item. The removal of the wire reel from the machine is recommended before undertaking any lifting operation. Stray welding currents/voltages may destroy earth conductors, damage electrical equipment or cause components to warm up which may cause a fire.

• All welding connections must be firmly secured, check regularly !
• Check that the metal piece fixation is strong and without any electrical problems !
• Attach or hang all the electrically conductive elements, such as the trolley and slinging equipment, in order to insulate them
• Do not place any electrical equipment, such as drills or grinders, on top of the welding machine without insulating them !
• Always place welding torches or electrodes holders on an insulated surface when they’re not in use !

EQUIPMENT INSTALLATION

• Put the machine on the floor (maximum incline of 10°.)
• Ensure the work area has sufficient ventillation for welding, and that there is easy access to the control panel.
• The machine must be placed in a sheltered area away from rain or direct sunlight.
• The machine must not be used in an area with conductive metal dusts.
• The machine protection level is IP21, which means :
  • Protection against acess to dangerous parts from solid bodies of a ≥12.5mm diameter and,
  • Protection against vertically falling drops.
• The power cables, extensions and welding cables must be fully uncoiled to prevent overheating.

The manufacturer does not incur any responsability regarding damages to both objects and persons that result from an incorrect and/or dangerous use of the machine .

MAINTENANCE / RECOMMENDATIONS

• Maintenance should only be carried out by a qualified person. Annual maintenance is recommended.
• Ensure the machine is unplugged from the mains, and wait for two minutes before carrying out maintenance work. DANGER High Voltage and Currents inside the machine.
• Remove the casing 2 or 3 times a year to remove any excess dust. Take this opportunity to have the electrical connections checked by a qualified person, with an insulated tool.
• Regularly check the condition of the power supply cable. If the power cable is damaged, it must be replaced by the manufacturer, its after sales service or an equally qualified person.
• Ensure the ventilation holes of the device are not blocked to allow adequate air circulation.
• Do not use this equipment to thaw pipes, to charge batteries, or to start any engine.

RISK OF INJURY DUE TO MOVING PARTS!
The wire feeders contain moving parts that may catch hand, hair, clothes or tools which can lead to injuries! Take extra care.

• Do not place your hand on mobile/pivoting/wire feeding parts of the machine!
• Make sure that all panels remain closed when in use !
• Do not wear gloves when feeding the wire through or changing reel.

Minimum and maximum filler metal diameter : 0,6 – 1,2 mm Minimum and maximum wire speed: 1 m/min à 15 m/min Maximum gas pressure : 0.5 MPa (5 bars). MANUAL

DESCRIPTION

This manual contains safety and operating instructions. Read it carefully before using the device for the first time and retain for future reference. MULTIPEARL 210-2 / 210-4 XL / 211-4 are multiprocess welding machines (MMA, TIG & MIG/MAG) with Synergy Technology for MIG/MAG. They are suitable for welding steel, stainless steel and aluminium. Easy and quick to set up thanks to the Synergic mode It is recommended to use the welding cables supplied with the unit in order to obtain the optimum product settings..

POWER SUPPLY

This machine is fitted with a 16A socket type CEE7/7 which must be connected to a single-phase 230V (50 – 60 Hz) power supply fitted with three wires and one earthed neutral.
The absorbed effective current (I1eff) is displayed on the machine, for optimal use. Check that the power supply and its protection (fuse and/or circuit breaker) are compatible with the current needed by the machine. In some countries, it may be necessary to change the plug to allow the use at maximum settings. Do not use an extension cord with a cross-section of less than 2.5 mm².

MACHINE DESCRIPTION

1. Control panel
2. Positive Dinze connector
3. Negative Dinze connector
4. Polarity reversal cable
5. Euro torch connector
6. Reel adaptor 100/200mm (210-2) or 200/300mm (210-4 XL / 211-4)
7. Power lead (2.10 m)
8. Quick release gas connector.
9. ON/OFF switch

DESCRIPTION IHM

SWITCHING ON
The ON/OFF switch is located at the back of the machine. Turn the switch on the “I” position to start the generator. This switch must not be turned off (to “O”) while welding.

MIG MANUAL

MIG SYNERGIC

SECONDARY MENU

SEMI-AUTOMATIC STEEL / STAINLESS STEEL WELDING (MAG)
The device is suitable for welding 0.6/0.8/1.0 steel wire and 0.8/1.0 stainless steel wire. The device is delivered with contact tip, liner and a torch set up for 0.8 steel or stainless steel wire. For welding 0.6 wire use a torch no longer than 3m. To change the contact tip (see fig II A). The roller is reversible 0.8/1.0. The indication on the visible side of the roller is the diameter in use. For a 0.6 wire use the 0.6 groove. Welding Steel or Stainless Steel requires using a specific gas mix – Argon + CO2 (Ar + CO2). The proportion of CO2 will vary depending on application. The gas flow for steel welding is between 8 and 12 L/min depending on the environment and experience of the welder. For specific requirements seek advice from your gas distributor. For polarity see page 4.

SEMI-AUTOMATIC ALUMINIUM WELDING (MIG)
This welding machine is suitable for welding 0.8 and 1mm aluminium wires . To weld aluminium, neutral gas “Pure Argon” (AR) is required. For choosing gas, ask a gas distributor for advice. The gas flow for welding aluminium is between 15 and 25 L/min depending on the environment and experience of the welder. Machine set-up for aluminium welding:

• Use specific rollers for Aluminium
• Set the pressure on the rollers to the minimum to avoid pinching the wire.
• Remove the capillary tube before connecting the aluminium torch with a teflon liner.
• When welding aluminium use a special aluminium torch with Teflon liner to reduce friction. Do not cut the liner near the connector!It is used to guide the wire from the rollers. (Fig II B)
• Contact Tip: Use a SPECIAL aluminium contact tip corresponding to the diameter of the wire. For polarity see page 4.

“NO GAS” WELDING
To set up the machine for “No Gas” see the instructions on page 4. Welding cored wire with a standard nozzle can overheating and damage the torch. Use a nozzle special “No Gas” (ref. 041868) or remove the original nozzle (Fig III D). For polarity see page 4.

PROCEDURE FOR CHANGING REELS AND TORCH ASSEMBLY

• Open the machine’s side door.
• Place the reel on the driving pin (fig A) of the reel support. For a 200mm wire reel tighten the reel to the maximum. The adaptor (1) is only to be used for a 200mm reel.
• Adjust the reel brake (2) to avoid the reel inertia tangling the wire when welding stops. In general, do not over-tighten! Then screw in the reel support (3).
• Fit the roller(s) suitable for your application. The rollers supplied are double grooved rollers (0.8/1.0). The indication on the visible
  side of the roller is the diameter in use. For a 0.8 wire, use the 0.8 groove. For Aluminium or cored wire welding use the appropriate rollers

To adjust the roller tension (fig C), process is as follows: loosen the tensioner to the maximum (4), start the motor by pressing the torch trigger, tighten the tensioner whilst pressing the trigger. Bend the wire where it comes out of the nozzle and hold it in place to stop its progress. The pressure adjustment is ideal when the guide roller slides over the wire even when it is blocked at the end of the torch.

NB: for aluminium wire set the tension to the minimum not to pinch the wire.

Adjust the wire so 5cm protrudes from the torch then fit the contact tip (correct tip for the wire) (fig D) and the nozzle (fig E).

GAS CONNECTION
The device is designed with a quick release gas connection. Use the adaptor supplied with the machine

MMA

ELECTRODE WELDING

• The reverse polarity cable must be disconnected in MMA (stick welding) mode in order to connect the electrode holder and earth clamp. Connect the electrode holder and earth clamp as indicated on the electrode packaging.
• Respect the basic rules of welding
• This device has 3 features specific to Inverter machines :
  • Hot Start : Increases the current to assist the initial striking of the arc.
  • Arc Force : A ponctual increase of current avoiding the electrode to be stuck in the welding pool.
  • Anti-Sticking : Enables easy removal of the electrode from the metal.

TIPS :
Low Hot Start for thin metal sheet and high Hot Start for more difficult metal to weld (dirty metal or oxidised).

TIG EASY (VALVE TORCH)

TIG LIFT WELDING
DC TIG welding requires the use of gas (Argon). Connecting a valve torch will allow to manually adjust the supply of gas and connecting a EURO torch will also offer capability to adjust downslope and post gas settings. For TIG welding please follow the stages below :

TIG Lift Pro welding with a Euro torch| TIG Lift EASY welding with a Valve torch
---|---
•  See connection page 4.

•  Connect the gas hose to the back of the machine and to the gas bottle regulator.

•  Adjust the gas flow on the gas bottle regulator.

•  To strike an arc touch the piece of metal to weld and press the torch trigger.

•  Downslope and Post-gas start automatically once the trigger is released. They can be adjusted on the device.

| •  See connection page 4.

•  Connect the gas hose from the torch to the gas bottle regulator.

•  Adjust the gas flow on the gas bottle regulator and then open the torch valve.

•  Striking :

Touch the piece of metal to weld with the electrode

•  At the end of the weld :

Lift the electrode to between 2 to 5 mm from the metal.

Only stop the gas once the Tungsten electrode has cooled down.

Adjustable Downslope (Euro torch only)
Time needed to shift from welding current to minimum current. Avoids cracks and craters at the end of welding. By default this feature is set up at 0 sec.

Adjustable Post-Gas (Euro torch only)
This parameter determines the time in which gas is released after the arc has stopped. It protects the weld pool and the electrode against oxidisation whilst the metal is cooling after welding.

Recommended settings / Electrode grinding

****| Current (A)| ø Electrode (mm) = ø wire (filler rod)| ø Nozzle (mm)| Flow (Argon L/min)
---|---|---|---|---
0,5-5| 10-130| 1,6| 9,8| 6-7
4-7| 130-190| 2,4| 11| 7-8

DUTY CYCLE AND WELDING ENVIRONMENT
The machine has a specification with a “dropping current output” (MMA & TIG). The machine has a specification with a “constant current output” (MIG). Its duty cycle following the norm EN60974-1 is indicated in the table below :

THERMAL PROTECTION AND GUIDANCE
While under intensive use (superior to the duty cycle) the thermal protection can activate, in that case, the arc switches off and the thermal protection indicator switches on.

• Ensure the machine’s vents are clear enabling air circulation.
• Leave the device plugged in after welding to enable cooling.

In general :

• Respect the basic rules of welding.
• Ensure the air circulation is good.
• Do not work in a wet area.

TROUBLESHOOTING

| SYMPTOMS| POSSIBLE CAUSES| REMEDIES
---|---|---|---
MIG/MAG| The welding wire speed is not constant.| Cracklings block up the opening.| Clean out the contact batch or change it and replace the anti- adherence product. Ref.041806

The wire skids in the rollers.

| Control the roller pressure or replace it. Wire diameter non-consonant with roller.

Covering Wire guide in the torch non-consonant.

The unwinding motor doesn’t operate.| Reel or roller brake too tight.| Release the brake and rollers.
Electrical supply problem.| Check that the running button is on the position on.
Bad wire unwinding.| Covering wire guide dirty or damaged.| Clean or replace
Reel brake too tight| Release the brake

No welding current

| Bad connection to the main supply.| See the branch connection and look if the plug is fed by 3 phases.
Bad earth connection.| Control the earth cable (connection and clamp condition).
Power contactor inoperative.| Control the torch trigger.

The wire rubs down after the rollers.

| Covering wire guide crushed.| Check the covering and torch body.
Locking of the wire in the torch| Clean or replace.
No capillary tube.| Check the presence of capillary tube.
Wire speed too fast| Reduce the wire speed
The welding cord is porous| The gas flow rate is not sufficient.| Adjusting flow range 15 to 20 L / min. Clean the

working metal.

Gas bottle empty.| Replace it.
Gas quality non-satisfying.| Replace it.
Air flow or wind influence.| Avert air blast, protect welding area.
Gas nozzle too full.| Clean or replace the gas nozzle.
Bad wire quality.| Use adapted WIRE for MIG-MAG welding.
Surface to weld in bad condtion. (rust, etc, …)| Clean the working parts before welding.

Very important flashing particules.

| Arc voltage too low or too high.| See welding settings.
Bad earth connection.| Check and place the earth cable to have a better connection.
Protecting gas insufficient.| Adjust the gas flow.

No gas at the torch output.

| ****

Bad gas connection.

| See if the gas coupling beside the engine is well connected. Check the flowmeter and the solenoid valves.
In general| The machine does not deliver any current and the thermal overload indicator lamp lights up.| The welder thermal protection has turned on.| Wait for the end of the cooling time, around 2 minutes. The indicator lamp turns off.
The display is on but the device does not deliver any current.| The cable of the earth clamp or electrode holder is not connected to the welder.| ****

Check the connections.

If, when the unit is on and you put your hand on the welding unit’s body, you feel tingling sensation.| ****

The welding unit is not correctly connected to the earth.

| ****

Check the plug and the earth of your electrical network.

The display is on but the device does not deliver any current.| The cable of the earth clamp or electrode holder is not connected to the welder.| ****

Check the connections.

When starting up, the display indicates  .| The input voltage is outside of the range (230V + 15% for single

phase or 400V + 15% for 3-phase).

| ****

Have the electrical installation checked.

TIG| ****

Instable arc

| Default coming from the tungsten electrode| Use a tungsten electrode with the adequate size
Use a well prepared tungsten electrode
Too important gas flow rate| Reduce gas flow rate
The tungsten electrode gets oxidised and tern at the end of welding.| Welding zone| Protect welding zone against air flows
Default coming from post-gas or the gas has been stopped prematurely.| Check and tighten all gas connections. Wait until the electrode cools down before stopping the gas.
The electrode melts| Polarity error| Check that the earth clamp is really connected to +

WARRANTY

The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour). The warranty does not cover:

• Transit damage.
• Normal wear of parts (eg. : cables, clamps, etc..).
• Damages due to misuse (power supply error, dropping of equipment, disassembling).
• Environment related failures (pollution, rust, dust).

In case of failure, return the unit to your distributor together with:

• The proof of purchase (receipt etc …)
• A description of the fault reported

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