Magnum CARIMIG 202LCD Manual Download

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WE3107 v.110413

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CARIMIG 202LCD

Multi-Process DC LCD Welder

Summary of Contents for CARIMIG 202LCD

Page 1: ... Our Customer Service staff are ready to provide assistance If a part is damaged or missing replacement parts can be shipped from our facility For help with assembly or for additional product information call our North American toll free number 1 800 567 8979 Notre personnel de service à la clientèle sera prêt à fournir assistance Si une pièce est endommagée ou manquante des remplacements seront e...

Page 2: ...ount the welder on a secure bench or cart that will keep the welder secure and prevent it from tipping over or falling 1 2 Your Welder s Condition Check ground cable power cord and welding cable to be sure the insulation is not damaged Always replace or repair damaged components before using the welder Check all components to ensure they are clean and in good operating condition before use 1 3 Use...

Page 3: ...ect all cables and cords for any exposed wire and replace immediately if found Use only recommended replacement cables and cords Always attach ground clamp to the work piece or work table as close to the weld area as possible Do not touch the welding wire and the ground or grounded work piece at the same time Do not use a welder to thaw frozen pipes Fumes and Gases Fumes emitted from the welding p...

Page 4: ...flammable gaseous or liquid combustibles in them Welding creates sparks and heat that can ignite flammable and explosive materials Do not operate any electric arc welder in areas where flammable or explosive materials are present Remove all flammable materials within 35 feet of the welding arc If removal is not possible tightly cover them with fireproof covers Take precautions to ensure that flyin...

Page 5: ... cables on the same side of your body Shielding Gas Cylinders Can Explode High pressure cylinders can explode if damaged so treat them carefully Never expose cylinders to high heat sparks open flames mechanical shocks or arcs Do not touch cylinder with MIG gun Do not weld on the cylinder Always secure cylinder upright to a cart or stationary object Keep cylinders away from welding or electrical ci...

Page 6: ...Description The CARiMIG 202 LCD is a multi process DC inverter welder with LCD screen This unit uses 1 Phase 120V or 230V 50 60HZ AC power A 15 amp time delay fuse or circuit breaker is recommended The CARiMIG 202 LCD series is ideal for Do It Yourself projects or for light maintenance MIG weld carbon steel stainless steel AlMg and AlSi Unpacking 1 1 Remove cartons bags or Styrofoam containing the...

Page 7: ...del CARiMIG 202 LCD Input power V 120 110 130 230 220 240 Frequency Hz 50 60 50 60 Rated input current A 20 36 Rated input capacitance KVA 3 5 8 6 No load voltage V 69 69 Rated working voltage V 18 5 24 MMA welding current A 10 70 10 180 LIFT Arc welding current A 10 90 10 180 MIG welding current A 40 90 40 200 Rated duty cycle 40 20 Welding current 10min A 40 90 20 200 10min 100 A 57 89 Efficienc...

Page 8: ...sk tip welding wire Know your Welder z GROUNDING CABLE Use earth clamp to connect earth cable with work piece z MIG GUN The welding wire is driven through the welding cable and MIG gun to the work piece It is attached to the drive system z POWER SWITCH In the OFF position no power is being supplied In the ON position power is supplied to the main transformer and control circuit Front Ctrl Panel MI...

Page 9: ... NAMEPALTE OF WELDER The nameplate indicate the main electrical data of welder z Front Ctrl panel 1 LCD Shows all process from function selection to welding 2 LEFT ADJUST KNOB Allows user to adjust the current and wire feeding speed accurately 3 RIGHT ADJUST KNOB Allows user to adjust the voltage accurately 4 Home Key Keep pressing home key return to home page 5 Multi function adjusting knob For f...

Page 10: ...ding functions and 1 setting Adjusting multi function knob for selecting press for confirming 2 Output setup Shows output connection under different welding mode press multi function knob for confirming 3 Electrode Wire diameter selection Adjusting multi function knob to select different electrode wire diameter press for confirming ...

Page 11: ... set wire feeding speed and voltage Adjusting Multi function knob to set electro inductance press the knob to progress basic parameter setting Note Note 1 Basic parameter setting including gas pre flow slow wire feeding gas post flow operating load and save function there is also spool gun function under Al welding Note2 In the green range of current and voltage it means recommended parameter b Un...

Page 12: ...ws language setting units setting light setting information and recover setting 7 Alarm interface It shows the machine is overloaded and the internal temperature is too high Weld output will turn off automatically but the fan will still be working When the internal temperature is decreased the alarm interface will turn off and the machine will be ready to weld ...

Page 13: ... welder must be grounded while in use to protect the operator from electrical shock Do not remove grounding prong or alter the plug in any way Do not use any adapters between the welder s power cord and the power source receptacle Make sure the POWER switch is OFF when connecting your welder s power cord to a properly grounded 120V 230Vac 50 60Hz single phase 14 amp power source 2 Extension cord D...

Page 14: ...erally easier faster and allows for better penetration If possible the work piece should be positioned so that the bead will run on a flat surface 3 2 Preparing the Joint Before welding the surface of work piece needs to be free of dirt rust scale oil or paint Or it will create brittle and porous weld If the base metal pieces to be joined are thick or heavy it may be necessary to bevel the edges w...

Page 15: ...rc flash make certain that the wire coming out of the end of the torch does not come in contact with work piece ground clamp or any grounded material during the drive tension setting process or arcing will occur 5 1 Press the trigger on the torch 5 2 Turn the drive tension adjustment knob clockwise increasing the drive tension until the wire seems to feed smoothly without slipping 6 Gas installati...

Page 16: ...fferent wire welding ways With gas shied welding output line connection without gas shield welding 6 1 1 Change the welding mode to the MIG welding mode 6 1 2 While during the solid core with gas shield welding and the flux cored welding the patch plug from the machine insert in the positive polarity output socket of the machine and the ground cable connect to the negative polarity 6 1 3 While usi...

Page 17: ...20 cfm To reduce the gas flow turn the adjustment counterclockwise left The gas valve is located on the back panel of the welder and activated by the trigger Gas flow should be heard when the trigger is activated No gas flow will result in a harsh arc with excessive spatter a smooth weld bead will be difficult to obtain Avoid unnecessary gas loss by closing the tank valve when finished welding 6 3...

Page 18: ...le of the wire spool inner hole 7 4 After the installation of wire spool rotate clockwise the adjusting nut to be re installed in the wire spool nut 7 5 higher of the pressing pressure for the adjusting nut then the greater of the wire spool rotating resistance On the opposite the the smaller the pressing pressure for the adjusting nut then the smaller of the wire spool rotating resistance User ca...

Page 19: ...p spring 8 3 Insert the wire starting end to the wire feeder through the wire tube insert the torch socket through suitable wire feeding roller groove 8 4 When the wire is led to the torch socket press the pressure roller again and then restore the pressure roller adjusting rod to press the roller 9 Replacement of roller 9 1 open the turning plate of the machine shell Please remove the wire first ...

Page 20: ...r switch supplies electrical current to the welder Whenever the power switch is in the ON position the welding circuit is activated ALWAYS turn the power switch to the OFF position and unplug the welder before performing any maintenance Voltage selector The voltage selector controls the welding heat This unit has infinite voltage control Refer to the label inside the welder side door for recommend...

Page 21: ... must be done before starting each welding job or whenever any of the following variables are changed heat setting wire diameter or wire type EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN Prolonged exposure to the welding arc can cause blindness and burns Never strike an arc or begin welding until you are adequately protected Wear flameproof welding gloves a heavy long sleeve...

Page 22: ...avy long sleeved shirt trousers with out cuffs high topped shoes and an ANSI approved welding helmet ELECTRIC SHOCK CAN KILL To prevent ELECTRIC SHOCK do not perform any welding while standing kneeling or lying directly on the grounded work 6 1 Moving the torch Torch travel refers to the movement of the torch along the weld joint and is broken into two elements Direction and Speed A solid weld bea...

Page 23: ...welding positions and is most commonly used It is best if you can weld in the flat position if at all possible as good results are easier to achieve HORIZONTAL POSITION Is performed very much the same as the flat weld except that angle B see HOLDING THE TORCH is such that the wire Directed more toward the metal above the weld joint is to help prevent the weld puddle from running downward while sti...

Page 24: ...r heat setting Also the weave bead tends to work better than the stringer 6 4 Multiple pass welding Butt Weld Joints When butt welding thicker materials you will need to prepare the edges of the material to be joined by grinding a bevel on the edge of one or both pieces of the metal being joined When this is done a V is created between the two pieces of metal that will have to be welded closed In ...

Page 25: ... shielding flux core wires when using the burn through method unless the metal is VERY thin or excessive filler metal build up and minimal penetration is acceptable Always select the HIGH heat setting with the burn through method and tune in the wire speed prior to making a spot weld 2 The PUNCH AND FILL METHOD produces a weld with the most finished appearance of the three spot weld methods In thi...

Page 26: ...1 60 000 PSI tensile strength deep penetrating applications E6013 60 000 PSI tensile strength used for poor fit up applications E7014 70 000 PSI tensile strength used for high deposition and fast travel speeds with light penetration E7018 70 000 PSI tensile strength Used for out of position and tacking 8 Selecting the proper electrode There is no golden rule that determine the exact rod or heat se...

Page 27: ...g for your job The electrode type and the thickness of the work piece metal determine the amount of heat needed in the welding process Heavier and thicker metals require more voltage amperage whereas lighter and thinner metals require less voltage amperage 2 Welding techniques The best way to teach yourself how to weld is with short periods of practice at regular intervals All practice welds shoul...

Page 28: ...cture It is important that the gap be maintained during the welding process and it should be neither too wide or too narrow If too narrow the rod will stick to the work piece If too wide the arc will be extinguished It needs much practice to maintain the gap Beginners may usually get sticking or arc extinguishing When the rod sticks to the work piece gently rock it back and forth to make them sepa...

Page 29: ... bead Used when you want to deposit metal over a wider space than would be possible with a stringer bead It is made by weaving from side to side while moving with the electrode It is best to hesitate momentarily at each side before weaving back the other way to improve penetration 2 4 Welding position Flat position is the easiest of the welding positions and is most commonly used It is best if you...

Page 30: ...ng slow enough travel speed to achieve good penetration A good starting point for your electrode angle is about 30 degrees DOWN from being perpendicular to the work piece 2 5 Judge a good weld bead When the trick of establishing and holding an arc has been learned the next step is learning how to run a good bead The first attempts in practice will probably fall short of acceptable weld beads Too l...

Page 31: ...reaction The burning coating however forms slag The slag formation appears as an accumulation of dirty metal scale on the finished weld Slag should be removed by striking the weld with a chipping hammer 9 LIFT TIG 9 1 ACCESORY Tears off the main attaching plug Turn off the power source The ground cable connect the positive electrode and screw it tighter The end of the ground cable connect the work...

Page 32: ... the welding torch built in air valve Approaches the striking the arc spot the spray nozzle to cause the tungstic electrode and the work piece is separated 2 3mm B Slowly lifts the welding torch to cause the tungstic electrode contact work piece C Lifts the welding torch to the normal position starts to weld ...

Page 33: ...n Circumstance temperature is too high It will automatically recover when the temperature low down 1 Alarm interface Using over the rated duty cycle It will automatically recover when the temperature low down Potentiometer not in the proper status Change potentiometer Nozzle is blocked up Change nozzle 2 Wire feeding motor don t work Feed roller is loosen Firm the bolts Switch broken Replace the s...

Page 34: ...sh is large Wire feeding resistance is too large Clean or replace the liner and the torch cable had better in the line direction Earth cable break Connect earth cable 5 Aarc can t be pilot Work piece has much greasy dirty or rusty stain Clean greasy dirty or rusty stain Torch is not connected well Connect the torch again Gas pipe is pressed or blocked up Check gas system 6 No shielded gas Gas syst...

Page 35: ...R1 5R1 R18 5R1 R20 5R1 G1 E1 G2 E2 NTC1 5K D3 1N5819 D4 1N5819 D9 1N5819 D7 1N5819 C5 2200uF 200V C6 C13 NTC2 5K AC 1 AC 2 3 4 Z2 S35VB100 C14 475 400V 1 2 CN2 2PIN 2 54 1 2 3 F A N FAN1 24V PMH200 10 12P23 IGP SUP 01 PMH200 10 12P23 DIS PMH200 10 12P23 MAIN G1 E1 G2 E2 3 R22 33R C18 471 2KV 3 R23 33R C19 471 2KV 2 2 C1 102 4KV Y2 C11 102 4KV Y2 EARTH R10 2K 3W C15 102 4KV Y2 1 2 3 4 5 6 7 8 1CN6 ...

Page 36: ...1 01 01 0890 Case 1 4 1 1 01 05 3233 Riser 1 5 1 2 02 01 6569 Backboard 1 6 2 03 05 275 Power line 1 7 2 04 30 102 Fixed head of cable 1 8 2 07 55 021 Gas valve 1 9 2 07 80 001 Power switch 1 10 2 07 89 057 Fan 1 11 2 02 02 044 Qas connector 1 12 1 1 05 02 0819 Mainboard 1 13 1 1 02 01 0226 Fixed plate of mainboard 1 14 2 05 05 999 Machine leg 4 15 1 1 05 07 0269 Control panel 1 ...

Page 37: ...ransportation and Storage The welder needs regular maintenance as following Periodically clean dust dirt grease etc from your welder Every six months or as necessary remove the cover panel from the welder and air blow any dust and dirt that may have accumulated inside the welder Replace power cord ground cable ground clamp or electrode assembly when damaged or worn MINOR AND ROUTINE MAINTENANCE St...

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