Thank you for chosing this machine. To get the best use from your machine, please read the following carefully :
The PEARL 190.2 / PEARL 190.4 XL is a semi-automatic welding unit; it is ventilated for semi-automatic welding (MIG
or MAG) It is capable of welding steel, stainless steel and aluminium, and with it’s « synergic wire speed » function
adjustment is easy and fast.
ELECTRICITY SUPPLY
The absorbed current (I1eff) is indicated on the device at maximum usage. Check that the power supply and its
protection (fuse and/or circuit breaker) are compatible with the current needed for use. In some countries, it might be
necessary to change the plug to allow maximum performance. The device must be installed so that the mains socket
is accessible.
Do not use an extension cable with a diameter of less than 1.5mm². PEARL 190.2/PEARL 190.4 XL is delivered with a
16amp plug (TYPE CEE7-7), and the machine features a highly efcient PFC and Flexible Voltage technology.
This machine must be connected to an EARTHED power supply between 110V and 230V, 50/60 Hz, and protected by
a 16A circuit breaker (32A on 110V 30mA trip)
- When using on a voltage below 165vEFF this will limit the current draw to 16A
- If the voltage is <85V or >265V, the machine will not start
- Protected against surges - PEARL will shut off automatically in case of overvoltage
EN
DEVICE PRESENTATION (FIG I)
1 : Push-button setting for welding mode (Manual or
Synergic).
2 : Wire Reel holder - Ø 100/200 mm (PEARL 190.2) or
200/300mm (PEARL XL 190.4)
3 : European standard torch connection.
SEMI-AUTOMATIC WELDING FOR STEEL / STAINLESS STEEL (MAG MODE)
PEARL 190.2 & PEARL 190.4 XL can weld Steel wire 0.6/0.8/1.0mm, and Stainless Steel of 0.8/1.0mm
The machine is originally equipped to function with Ø 0.8mm Steel, or Stainless Steel wire. The contact tube, the
groove of the roller and the sleeve of the torch are all compatible with 0.8mm wire. Should you wish to weld 0,6
wire, use a torch of maximum 3m long. You will also need to change the contact tip (Fig II A). The wire reel is reversable (0.6 / 0.8mm) and will need to be inserted so that the gure 0.6 is visible.
For use with Steel, the gas requirement is argon + CO2. (Ar+CO2).. The proportion of CO2 required will vary depending on the use. For Stainless Steel, use the combination of 2% CO2 For specic gas requirements, please contact
your gas distributor. The gas ow in steel is between 8 and 12 Litres/minute depending on the environment.
SEMI-AUTOMATIC WELDING FOR ALUMINIUM (MIG MODE)
This machine is capable of welding Aluminium wire of 0.8 and 1.0mm
For use with aluminium, the gas requirement is pure argon (Ar). For the specic gas requirements please contact
your distributor. The gas ow in Aluminium is between 15 and 25 Litres/minute depending on the environment, and
the experience of the welder.
The differences between use with Steel and Aluminium are :
- Rollers : Use specic rollers for Aluminium welding.
- Pressure : Adjust the pressure of the drive rolls to prevent the wire being crushed.
- Capillary Tube : Only use a capilliary tube for welding with Steel or Stainless Steel.
- Torch : Use a special Aluminium Torch with a teon sheath to reduce friction. DO NOT cut the sheath close to the
joint, it is used to guide the wire from the the rollers.
- Contact tube : Use a special aluminium contact tube specic to the diameter of wire being used.
4 : Earth clamp socket.
5 : On/Off switch.
6 : Solenoid Valve.
7 : Power Cable (2.10 m)
GASLESS WIRE WELDING
PEARL 190.2 & PEARL 190.4 XL is capable of gasless wire welding up to 0.9mm, provided that the polarity is reversed (g C) respecting a maximum pressure of 5Nm. For parameters of use, please refer to the instructions indicated
on page 7. Welding gasless wire with a standard nozzle can lead to overheating and deterioration of the torch. It is
recommended to use a “No Gas” nozzle (ref. 041868), or remove the genuine nozzle (Fig. III D).
10
SETTINGS PANEL (FIG V)
+
4
+
5 et
4
+
5 et
4
Synergic
mode
PEARL 190.2 PEARL 190.4 XL
• SETUP button + Button (4) : to select
the SYNERGIC or MANUAL mode
• SETUP button + Button (5) : switching
to material settings (see table page 7)
• SETUP button + Button (4) : to select
the type of material, the recommanded
gas is then displayed
• SETUP button + Button (5) : to enter
into the settings of the Ø of the wire
• SETUP button + Button (4) : to choose
the diameter of the wire. List based on
other criteria informed
EN
4
4
5
4
5
5
et
4
• Button (4) : to change the thickness to
be welded
• Button (5) : to change the arc length
The values U and I appear on the display
when welding
Advices
This mode allows quick and easy welding and has been optimised for welding angled pieces.
To obtain an identical butt weld, it is recommended to slightly reduce the setting of metal thickness.
The arc length: Lengthens (0 -> +9) or shorter (0 -> -9) to allow more or less penetration of the
metal. The display will show the changes to allow more comprehensive setting. If you are welding
for the rst time, we recommend you set the arc length to 0.
Choice of welding angle : only on SYNERGIC mode
+
5 et
4
• Angle button + Button (4) : to select
the torch position
• Angle button + Button (5) : to select
butt weld or llet weld
4
5
4
5
11
PEARL 190.2 PEARL 190.4 XL
T spotT delay
gâchette
• SETUP button + Button (4) : to select
SYNERGIC or MANUAL mode
EN
4
Manual
mode
SPOT
/
DELAY
+
5
et
4
4
• Button (4) : to adjust the wire speed
• Button (5) : to adjust the welding vol-
5
4
tage
5
The values U and I appear on the display
when welding
Advices
The wire speed adjustment is often determined « by the noise »: the arc must be stable and have a
low crackling.
If the speed is too low, the arc is not continuous.
If the speed is too high, the arc crackles and the wire pushes back the torch.
Cycle management of the torch
• Button SPOT / DELAY + button (4): to
adjust the «SPOT» parameter. Switch to
+
5 et
«2T» position when the value is zero
4
• Button SPOT / DELAY + button (5): to
adjusts the «Delay» parameter. Inactive
5
when the value is zero
Trigger
4
PROCESS OF REELS AND TORCHES ASSEMBLY (FIG IV):
• Remove the contact tube and its support (g D), and the nozzle (g E) from the torch.
Fig A : • Position the wire reel on the reel support :
- PEARL 190.4 XL : Pay attention to the driving pin when positionning the reel. For a 200mm reel assembly, tighten
(3) to the maximum.
- PEARL 190.2 : the adapter (1) is to be used only for 200mm wire reel assembly
• Adjust the reel brake (2) to avoid reel movement tangling the wire when welding stops. Be careful not to tighten
too much.
Fig B : • The drive rollers included have 2 grooves (0,6 and 0,8). The visible diameter indicated on the roller when
tted in place is the diameter currently in use (ie. 0.8mm is visible for use with 0.8mm wire). To weld aluminium or
gasless wire, use the appropriate drive rollers.
Fig C : To select the adjustment of the drive rollers
• Loosen the drive roller knob (4) as far as possible and insert the wire, tighten the knob again slightly
• Start the motor by pressing the trigger of the torch
• Tighten the knob whilst pressing the trigger until the wire starts to move.
Nb : When welding with Aluminium, use the minimum possible pressure to avoid crushing the wire
12
PEARL 190.2 PEARL 190.4 XL
• Let about 5cm of wire out of the torch, then put the contact tube (g. D), and the nozzle (g. E) adapted to the
wire to be used at the extremity.
GAS COUPLING
The PEARL is equipped with a fast connection. Use the adapter supplied with your machine.
EN
Displayed
on screen
ProcessMAGMAGMIGMAGMAGMIGMIGMIGMIG
GasAr+CO²
Possible Ø0.6 - 0.8
DUTY CYCLE & WELDING ENVIRONMENT IN USE
• The welding unit describes a at output characteristic (constant voltage). The duty cycles following the standard
EN60974-1 (at 40°C on a 10mn cycle) are indicated in the table here below:
PEARL 190.222% @ 190 A120 A90 A
PEARL 190.4 XL22% @ 190 A120 A90 A
Note : The machines’ duty cycle has been tested at room temperature (40°C) and has been determined by simulation.
• These are Class-A devices. They are designed to be used in an industrial or professional environment. In a different
environment, it can be difcult to ensure electromagnetic compatibility, due to conducted disturbances as well as
radiation. The devices PEARL 190.2 et PEARL 190.4 XL comply with IEC 61000 -3-12.
FEFEALG 5SSFCCuSi 3CuAL 8ALSi 5ALSi 12
CO²ArAr+CO² 2%ArArArAr
- 1.0
0.6 - 0.8
- 1.0
0.8 - 1.0 0.8 - 1.00.9 -1.20.8 - 1.00.81.01.0
ADVICE & THERMAL PROTECTION
This device is equipped with a multi-speed ventilator, regulated by the inside temperature. When the machine’s thermal protection is activated, it will not deliver any current. The over-heating icon will appear on the screen, and will
ash until the temperature of the machine has returned to normal.
• Do not block/cover the ventillation holes, ensure free ow of air.
• Whilst in thermal protection mode leave the machine plugged into the mains after welding to allow it to cool.
General observations
• Always respect the basic rules of welding
• Always work in an adequately ventillated area
• Do not work on a damp surface.
MAINTENANCE / ADVICE
• Maintenance should only be carried out by a qualied person.
• Switch the machine off, ensure it is unplugged, and that the ventilator inside has stopped before carrying out maintenance work. (DANGER High Voltage and Currents).
• GYS recommends removing the steel cover 2 or 3 times a year to remove any excess dust. Take this opportunity to
have the electrical connections checked by a qualied person with an insulated tool.
• Regularly check the condition of the power supply cord. If damaged, it will need to be replaced by the manufacturer,
its’ after sales service or a qualied person.
13
PEARL 190.2 PEARL 190.4 XL
SAFETY
Arc welding can be dangerous and can cause serious and even fatal injuries.
Protect yourself and others.
Ensure the following safety precautions are taken:
Arc radiationProtect yourself with a helmet tted with lters in compliance with EN169 or EN 379.
Rain, steam, dampUse your welding unit in a clean/dry environment (pollution factor ≤ 3), on a at
surface, and more than one meter from the welding work-piece. Do not use in rain or
snow.
Electric shockThis device must only be used with an earthed power supply. Do not touch the parts
under tension. Check that the power supply is suitable for this unit.
FallsDo not move the unit over people or objects.
Burns"Wear protective (re-proof) clothing (cotton, overalls or jeans).
Wear protective gloves and a re-proof apron.
Ensure other people keep a safe distance from the work area and do not look directly
at the welding arc.
Protect others by installing re-proof protection walls."
Fire risks
Remove all ammable products from the work area. Do not work in
EN
presence of ammable gases.
Fumes
Do not inhale welding gases and fumes. Use the device in a well ventilated environment, with articial extraction if welding indoors.
Additional precautions"Any welding operation undertaken in precautions
- rooms where there is an increased risk of electric shocks,
- Poorly ventilated rooms,
- In the presence of ammable or explosive material, should always be approved by a
«responsible expert», and made in presence of people trained to intervene in case of
emergency.
Technical protection as described in the Technical Specication CEI/IEC 62081 must
be implemented. Welding in raised positions is forbidden, except in case of safety
platforms use."
People wearing Pacemakers are advised to see their doctor before using this device.
Do not use the welding unit to unfreeze pipes.
Handle gas bottles with care - there is increased danger if the bottle or its valve are damaged.
14
PEARL 190.2 PEARL 190.4 XL
TROUBLESHOOTING
SYMPTOMSPOSSIBLE CAUSES REMEDIES
The welding
wire speed is not
constant.
Debris is blocking 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-compatible with roller
• Covering wire guide in the torch non-compatible."
EN
The wire-feeder
motor doesn’t operate.
Bad wire feeding.Covering wire guide dirty or da-
No welding currentBad connection to the main supply.Check the mains connection and look if the plug is fed
The wire jams (after
the rollers)
The welding bead is
porous
Very important
ashing particules.
No gas ow at the
end of the torch.
The display shows
- - The machine turns
on but nothing
appears on the
screen
Reel or roller brake too tight.Release the brake and rollers.
Electrical supply problem.Check that the power switch is in the "On" position.
Clean or replace
maged.
The drive roller is too looseTighten the drive roller knob
Reel brake too tightRelease the brake
by 400 V (3PH) power socket.
Bad earth connection.Check the earth cable (connection and clamp condi-
tion).
Torch trigger inoperative.Check the torch trigger / replace torch
Guide wire sheath crushed.Check the sheath and torch body.
Wire jammed in the torchClean or replace.
No capillary tube.Check the presence of capillary tube.
Wire speed too fastReduce the wire speed
The gas ow rate is not sufcient.Adjust ow range 15 to 20 L / min.
Clean the working metal.
Gas bottle empty.Replace it.
Gas quality unsatisfactory.Replace it.
Air ow or wind inuence.Prevent drafts, protect welding area.
Gas nozzle dirty.Clean or replace the gas nozzle.
Poor quality wire.Use suitable WIRE for MIG-MAG welding.
Surface to weld in bad condtion.
(rust, etc…)
Arc voltage too low or too high.See welding settings.
Bad earth connection.Adjust the earth cable for a better connection.
Insufcient gas ow.Adjust the gas ow.
Bad gas connection.Check the gas connection at the welding machine.
Overvoltage detected.Check the voltage at the mains
The mains voltage is < 85V or >
265v
Clean the metal before welding.
Check the owmeter and the solenoid valves.
Check the voltage at the mains
15
PEARL 190.2 PEARL 190.4 XL
CONDITIONS DE GARANTIE FRANCE
• La garantie n’est valable que si le bon a été correctement rempli par le vendeur.
• La garantie couvre tout défaut ou vice de fabrication pendant 1 an, à compter de la date d’achat (pièces et main
d’œuvre).
• La garantie ne couvre pas les erreurs de tension, incidents dus à un mauvais usage, chute, démontage ou toute
autre avarie due au transport.
• La garantie ne couvre pas l’usure normale des pièces (Ex. : câbles, pinces, etc.).
En cas de panne, retournez l’appareil à la société GYS (port dû refusé), en y joignant :
• Le présent certicat de garantie validé par le vendeur
• Une note explicative de la panne.
Après la garantie, notre SAV assure les réparations après acceptation d’un devis.
Die Garantieleistung des Herstellers erfolgt ausschließlich bei Fabrikations- oder Materialfehlern, die binnen 12 Monate
nach Kauf angezeigt werden (Nachweis Kaufbeleg). Nach Anerkenntnis des Garantieanspruchs durch den Hersteller
bzw. seines Beauftragten erfolgen eine für den Käufer kostenlose Reparatur und ein kostenloser Ersatz von Ersatzteilen. Der Garantiezeitraum bleibt aufgrund erfolgter Garantieleistungen unverändert.
Ausschluss:
Die Garantieleistung erfolgt nicht bei Defekten, die durch unsachgemäßen Gebrauch, Sturz oder harte Stöße sowie
durch nicht autorisierte Reparaturen oder durch Transportschäden, die infolge des Einsendens zur Reparatur, hervorgerufen worden sind. Keine Garantie wird für Verschleißteile (z. B. Kabel, Klemmen, Vorsatzscheiben etc.) sowie bei
Gebrauchsspuren übernommen.
Das betreffende Gerät bitte immer mit Kaufbeleg und kurzer Fehlerbeschreibung ausschließlich über den Fachhandel
einschicken. Die Reparatur erfolgt erst nach Erhalt einer schriftlichen Akzeptanz (Unterschrift) des zuvor vorgelegten
Kostenvoranschlags durch den Besteller. Im Fall einer Garantieleistung trägt GYS ausschließlich die Kosten für den
Rückversand an den Fachhändler.
34
PEARL 190.2 PEARL 190.4 XL
DÉCLARATION DE CONFORMITÉ :
Gys atteste que les postes de soudure PEARL 190.2 et PEARL 190.4 XL sont fabriqués conformément aux exigences
des directives Basse tension 2006/95/CE du 12/12/2006, et aux directives CEM 2004/108/CE du 15/12/2004.
Cette conformité est établie par le respect des normes harmonisées EN60974-1 de 2005, EN 50445 de 2008, EN
60974-10 de 2007.
Le marquage CE a été apposé en 2013.
DECLARATION OF CONFORMITY :
The equipment described on this manual is conform to the instructions of low voltage 2006/95/CE of 12/12/2006, and
the instructions of CEM 2004/108/CE of the 15/12/2004.
This conformity respects the standards EN60974-1 of 2005, EN 50445 de 2008, EN60974-10 of 2007.
CE marking was added in 2013.
KONFORMITÄTSERKLÄRUNG :
GYS erklärt, dass die Schweißanlage PEARL 190.2 und PEARL 190.4 XL richtlinienkonform mit folgenden europäischen Bestimmungen hergestellt wurden: Niederspannungsrichtlinie 2006/95/CE –12.12.2006 und EMV- Richtlinien
2004/108/CE – 15.12.2004 elektromagnetische Verträglichkeit- hergestellt wurden. Dieses Gerät stimmt mit den harmonisierten Normen EN60974-1 von 2005, EN 50445 von 2008, EN60974-10 von 2007 überein.
CE Kennzeichnung: 2013.
DECLARACIÓN DE CONFORMIDAD :
Gys certica que los aparatos de soldadura PEARL 190.2 y PEARL 190.4 XL son fabricados en conformidad con las
directivas baja tensión 2006/95/CE del 12/12/2006, y las directivas compatibilidad electromecánica 2004/108/CE del
15/12/2004. Esta conformidad está establecida por el respeto a las normas EN60974-1 de 2005, EN 50445 de 2008,
EN 60974-10 de 2007.
El marcado CE fue jado en 2013.
ДЕКЛАРАЦИЯ О СООТВЕТСТВИИ:
Gys заявляет, что сварочные аппараты PEARL 190.2 и PEARL 190.4 XL произведены в соответствии с
директивами Евросоюза 2006/95/CE о низком напряжении от 12/12/2006, а также с директивами CEМ 2004/108/
CE от 15/12/2004.
Данное соответствие установлено в соответствии с согласованными нормами EN60974-1 2005 г, EN 50445 2008
г, EN 60974-10 2007 г.
Маркировка ЕС нанесенна в 2013 г.
01/08/2013
Société GYS
134 BD des Loges
53941 Saint-Berthevin
France
Nicolas BOUYGUES
Président Directeur Général
35
PEARL 190.2 PEARL 190.4 XL
PIÈCES DE RECHANGE / SPARE PARTS / ERSATZTEILE/ PIEZAS DE RECAMBIO/ ЗАПЧАСТИ
Cache interrupteur / Switch cover / Schalterdeckel / Tapa de interruptor / Крышка переключателя
Nappe /Ribbon cable /Bandkabel /Cable plano / ленточный кабель
PEARL
190.2
5110851135
51469
51931
97262C
97141C
97263C97267C
51032
71140
21489
73083
73084
52467
52463
53105
PEARL
190.4 XL
36
PEARL 190.2 PEARL 190.4 XL
SCHÉMA ÉLECTRIQUE / CIRCUIT DIAGRAM /SCHALTPLAN/ DIAGRAMA ELECTRICO/ЭЛЕКТРИЧЕСКАЯ СХЕМА
37
PEARL 190.2 PEARL 190.4 XL
ICONES / SYMBOLS / ZEICHENERKLÄRUNG
AAmpères - Amps - Ampere - Amperios - Ампер
VVolt - Volt - Volt - Voltios - Вольт
HzHertz - Hertz - Hertz - Hertz - Герц
- Soudage MIG/MAG (MIG: Metal Inert Gas / MAG: Metal Active Gas)
- MIG/MAG Welding (MIG: Metal Inert Gas / MAG: Metal Active Gas)
- MIG/MAG Schweißen (MIG: Metal Inert Gas/ MAG: Metal Active Gas)
- Soldadura MIG/MAG (MIG: Metal Inert Gas / MAG: Metal Active Gas)
- Полуавтоматическая сварка MIG/MAG (MIG: Metal Inert Gas / MAG: Metal Active Gas)
- Convient au soudage dans un environnement avec risque accru de choc électrique. La source de courant elle-même ne doit
toutefois pas être placée dans de tels locaux.
- Adapted for welding in environment with increased risks of electrical shock. However, the welding source must not be placed
in such places.
- Geeignet für Schweißarbeiten im Bereich mit erhöhten elektrischen Risiken. Trotzdem sollte die Schweißquelle nicht unbedingt in solchen Bereichen betrieben werden.
- Adaptado a la soldadura en un entorno que comprende riesgos de choque eléctrico. La fuente de corriente ella misma no
debe estar situada dentro de tal locales.
- Адаптирован для сварки в среде с повышенным риском электрошока. Однако сам источник питания не должен быть
расположен в таких местах.
- Protégé contre l’accès aux parties dangereuses avec un doigt, et contre les chutes verticales de gouttes d’eau
- Protected against rain and against ngers access to dangerous parts
IP21
U0
U1
I1max
I1eff
EN60 974-1
1
X(40°C)
...%
I2
- Geschützt gegen Berührung mit gefährlichen Teilen und gegen senkrechten Wassertropfenfall
- Protegido contra el acceso a las partes peligrosas con los dedos, y contra las caídas verticales de gotas de agua
- Аппарат защищен от доступа рук в опасные зоны и от вертикального падения капель воды Сварка на постоянном
токе
- Courant de soudage continu.
- Welding direct current.
- Gleichschweißstrom.
- La corriente de soldadura es continua.
- Сварка на постоянном токе.
- Alimentation électrique monophasée 50 ou 60Hz
- Single phase power supply 50 or 60Hz
- Einphasige Netzversorgung mit 50 oder 60Hz
- Alimentación eléctrica monofásica 50 o 60 Hz
- Однофазное напряжение 50 или 60Гц
- Tension assignée à vide - Rated no-load voltage - Leerlaufspannung - Tensión asignada de vacío - Напряжение холостого
хода.
Tension assignée d’alimentation. - rated supply voltage. - Netzspannung. - Tensión de la red. - Напряжение сети.