Everlast Cyclone 200E Operator'S Manual Download

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TABLE OF CONTENTS

SPECIAL NOTICE AND CALIFORNIA PROPOSITION 65 WARNING

CUSTOMER GREETING AND EXPLANATION OF PROCEDURES

WARRANTY AND CONTACT INFORMATION

SAFETY DISCLAIMER AND HF WARNING

SAFETY WARNINGS, DANGERS, CAUTIONS AND INSTRUCTIONS

GENERATOR OPERATION INFORMATION

SPECIFICATIONS, INCLUDING DUTY CYCLE AND INPUT AMPERAGE INFORMATION

DUTY CYCLE EXPLANATION

GETTING STARTED, UNPACK YOUR UNIT, CHECK FOR GAS LEAKS

CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION

CONNECTING YOUR UNIT TO THE SHIELDING GAS

ADJUSTING YOUR REGULATOR

GUN INSTALLATION AND CONNECTING YOUR UNIT AND READYING TO WELD (POLARITY AND PANEL CONNECTIONS)

WIRE SPOOL INSTALLATION

DRIVE ROLL INFORMATION; HOW TO FEED THE WIRE THROUGH THE MIG GUN

TENSIONING AND TRIMMING THE WIRE

COMPONENT IDENTIFICATION AND EXPLANATION; FRONT PANEL

COMPONENT IDENTIFICATION AND EXPLANATION; REAR PANEL

COMPONENT IDENTIFICATION AND EXPLANATION; CONTROL PANEL LAYOUT AND USE

COMPONENT IDENTIFICATION AND EXPLANATION; MANUAL FUNCTION AND SCREEN LAYOUT

COMPONENT IDENTIFICATION AND EXPLANATION; POWERSET FUNCTION AND SCREEN LAYOUT

COMPONENT IDENTIFICATION AND EXPLANATION; POWERSET EXPLANATION AND PURPOSE

WELDING INFORMATION AND TIPS; EXPLANATION OF WELDER FUNCTIONS

TROUBLESHOOTING ERROR CODES

TROUBLESHOOTING COMMON ISSUES

BLANK, FOR NOTES

Summary of Contents for Cyclone 200E

Page 1: ...h America Everlast Power Equipment GMAW FCAW 120 240V 1 Phase Welders Plasma Cutters Multi Process Safety Setup and General Use Guide FUNCTION 200A MIG Welder with PowerSet Mode PURCHASE DATE WELDER SERIAL NUMBER OPTIONAL ACCESSORY SERIAL NUMBER MIG Flux Cored Spool Gun ...

Page 2: ...ALLATION AND CONNECTING YOUR UNIT AND READYING TO WELD POLARITY AND PANEL CONNECTIONS 17 WIRE SPOOL INSTALLATION 18 DRIVE ROLL INFORMATION HOW TO FEED THE WIRE THROUGH THE MIG GUN 19 TENSIONING AND TRIMMING THE WIRE 20 COMPONENT IDENTIFICATION AND EXPLANATION FRONT PANEL 21 COMPONENT IDENTIFICATION AND EXPLANATION REAR PANEL 22 COMPONENT IDENTIFICATION AND EXPLANATION CONTROL PANEL LAYOUT AND USE ...

Page 3: ...rsation or business by any Everlast employee or subsidiary The owner of this product assumes all liability for its use and maintenance Everlast Power Equipment INC does not warrant this product or this document for fitness for any particular purpose for performance accuracy or for suitability of application Furthermore Everlast Power Equipment INC does not accept liability for injury or damages co...

Page 4: ...is unit to work as soon as possible Any issue should be reported within 48 hours 72 if on the weekend or holiday Everlast will not be liable for any shipping after that time What to do within the next 30 days Visit our website US customers Go to www everlastwelders com Navigate to the resources tab and to the product registration page to register your product While keeping your receipt proof of pu...

Page 5: ...ccessories are covered by a separate warranty and detailed infor mation can also be found at the link above Canada Customers Only For full details on the 3 year parts and labor warranty terms of sale and related policies and procedures please visit https www everlastwelders ca terms php Who do I contact USA Technical Support Email tech everlastwelders com 1 877 755 9353 ext 207 9am 5pm Eastern Clo...

Page 6: ...t use this machine until proper training has been received While accidents are never planned preventing an accident requires careful planning Stay alert Please carefully read this manual before you operate your Everlast unit The warranty does not cover damage or harm created by improper use neglect of the machine or failure to follow safe operating practices NOTICE Welding and cutting operations m...

Page 7: ...or steel toe leather shoes and long sleeved flame resistant clothing i e denim Do not wear Poly Nylon blend materials DANGER Welding poses shock and electrocution risks Keep this welding equipment dry Do not weld in the rain or where moisture accumulates Use dry rubber soled shoes gloves and clothing when welding Do not rest or contact work clamp ground when weld ing Keep all parts of the body ins...

Page 8: ...er related equipment in the area being welded The heating of this cleaner and its residue will create highly toxic phosgene gas Small amounts of this vapor are harmful and can lead to organ failure and death If degreasing of a part is necessary use Acetone or an approved pre weld cleaner Use the proper personal protec tive equipment PPE when handling any cleaners solvents DANGER People with pacema...

Page 9: ...Minimize direct skin and eye exposure to this intense form of radiation by using proper PPE and sun screen where appropriate CAUTION Do not allow bystanders Do not allow others without proper Personal Protec tion Equipment PPE suitable for welding to stand in the welding area or to observe weld ing and welding related activities If protection is not readily available use a welding screen to separa...

Page 10: ...not produce sine wave output is prohibited and doing so will also void the warranty Use only with generators inverters converters that produce an equivalent type of sine wave used in shops homes and shore type systems WARNING Do not start or stop the generator with the welder switched on Never use the generator in ECO mode or an auto idle mode Even with a clean power rated generator this action ca...

Page 11: ...r temperature warning light error code will be dis played on the panel If a duty cycle event is regis tered do not turn the unit off Allow the welder to continue to run at idle for at least 10 15 minutes until the temperature has fallen enough to reset the sensor and over temperature warning light Even if the unit resets allow the unit to cool for a full 15 minutes or the duty cycle will be more q...

Page 12: ...egistered do not turn the unit off Allow the welder to continue to run at idle for at least 10 15 minutes until the temperature has fallen enough to reset the sensor and over temperature warning light Even if the unit resets allow the unit to cool for a full 15 minutes or the duty cycle will be more quickly triggered since the unit resets just below the heat threshold The fan s must continue to ru...

Page 13: ...ll not be accepted unless Everlast is contacted and informed of such delay and reason for such a required delay ie Overseas in deployment CHECK FOR GAS LEAKS Be sure to check for gas leaks before attempting to weld You can test this by first installing both back caps into the torch head from both sides Next install the regulator and tighten to both cylinder and unit see section on regulator instal...

Page 14: ...ngth with consideration given to inrush amper age rated amperage and duty cycle Do not modify or attempt to rewire your unit Standard Plug Configuration 1 Phase 240V NEMA 6 50P serves as G Ground Red will not typically be used as a conductor on a dedicated welder circuit There is no need for a neutral so white is used as the other hot conductor in this instance It is recommend ed to either install...

Page 15: ...it connection The residue and debris may get into the gas solenoid Install the cylinder on the cart or chain it to the wall closest to the welder Do not overtighten If leaks persist remove regulator from cylinder and inspect fittings for dirt or debris Do not attempt to repair a leaking regulator Contact Everlast for a warranty replacement if a leak is discovered in the regulator itself Use a mixt...

Page 16: ...have some hidden porosity in your welds creating weak welds Always change the cylinder out when gas levels reach 75 psi NOTICE If you are planning on welding during holidays or during week ends always take notice of the cylinder pressure well before hand This will allow you time to get another cylinder before stores close for the holi days or weekends If possible you may want to purchase a 20CFH c...

Page 17: ... Pull the trigger to check that the drive mechanism is turning If it does not turn check the MIG gun connection once again If the drive wheel fails to rotate contact technical support for further assistance Selecting Polarity Choosing the correct polarity for the welding process that you are welding is important Without the correct polarity weld quality and weldability of a metal will be an issue ...

Page 18: ...be installed so that the wire unwraps and feeds from the bottom of the spool It should never be installed so the wire comes over the top When installed properly the spool will turn counter clock wise See the following illustration for proper rotation direction Tension the spring with the finger nut until the spool will only free wheel 1 4 turn when spun by hand Do not let the spool free wheel comp...

Page 19: ...ing make sure that the square locating key is not dismounted If the key falls out replace it before replacing the drive roll Guiding the Wire Through the Feeder and Gun Once the wire spool has been installed flip the tensioner lever down and raise the top drive roll to the upper position See the illustration below Gently guide the wire from the spool over through the wire feeder and into the front...

Page 20: ...ollow the process below and refer to the following illustration Turn the unit on and pull the trigger so that the wire extends approximately 1 beyond the gas nozzle Find a small block of wood such as a two by four and secure it to the welding table or other solid object Do not test this on metal Hold the gun approximately 2 inches off the wood Aim the gun at the block of wood so that the nozzle is...

Page 21: ... 8 approximate dia This cable and DINSE connector is used to select the polarity of the wire feeder This connects internally to the wire feeder to supply power to the torch The unit will not weld without connecting this to either the Positive Terminal or Negative Terminal and connecting the work clamp to the remaining opposing Terminal 5 2 Pin Control Connector This connector is the control connec...

Page 22: ...kets Other markets may use a hose barb connection 3 Fan location Periodically check for proper fan function and cleanliness 4 HF Ground Service Bolt For use in a combined effort to mitigate any electrical interference that may be caused by this unit 5 Power Cord and NEMA 5 15 Plug 12 Gauge 6 ft This plug and cable is correctly sized for the rated amps duty cycle and length of the cable Consult Art...

Page 23: ...inum in manual mode when spool gun is selected or for stainless if it is to be used 3 Parameter Input Selection Buttons These buttons are used to select the parameters for the PowerSet mode The left button selects Wire Diameter The right button Selects Metal thickness When the unit is not in PowerSet mode these buttons serve no function 4 Spool Gun Mode Button Select this button when you wish to u...

Page 24: ... you at any time The unit may also be adjusted while weld ing without causing harm to the machine Using Manual Mode To use the mode 1 Choose the Gas Type Mode i e MIG25 MIG 100 or Flux Cored This is important You will always need to select this whether you intend to use the PowerSet function or not to ensure that the correct gas programming and arc force inductance is being used 2 Select the spool...

Page 25: ...limited range Don t worry about not being able to fine tune the units setting enough The limited range accommodates plen ty of adjustment but it is designed to help prevent you from making a completely unworkable setting The range is typically one full volt higher or Using Power Set To use the PowerSet mode 1 Choose the Gas Type Mode i e MIG25 MIG 100 or Flux Cored NOTE If you select gas type afte...

Page 26: ...onsible for providing settings in Pow erSet mode that may cause poor weld results or unusable weld settings If you do not find satisfactory results in PowerSet mode use manual mode Why Are Some Choices Blocked in PowerSet Mode You many notice that some of the setting choices are blocked or unavail able to you on this machine This is normal There are several reasons why this can happen 1 This unit ...

Page 27: ...a con should be heard The actual frying sound can vary somewhat and may have somewhat of a higher pitch whine to it If these sounds are present look at the arc to see if it is steady and producing low amounts of spatter If large amounts of spatter are present the puddle seems fluid appears wet and the wire speed is within the targeted range decrease volts a little at a time to reduce the spatter I...

Page 28: ... of a cursive e motion are best to begin with Other weave patterns can be used of course C s V S U s Trian gles and many more weave patterns can be used depending upon the application Weaves are employed for a number of reasons Weaves are often considered to have a more pleasing appearance and can help bridge gaps where fit up is a problem A weave is also frequently used to manage heat build up Fo...

Page 29: ...ROOVE 60 80 DOUBLE V GROOVE DOUBLE U GROOVE U GROOVE BEVEL GROOVE DOUBLE BEVEL GROOVE J GROOVE What Are the Different Kinds of Welds Besides a butt joint Flat edge to flat edge and lap joint overlapping edges which are often used for thinner metal gauges consider using one of these groove joints for best welding results When grinding or cutting the bevels especially with a single V groove it may b...

Page 30: ...n a near vertical position A variance of 5 degrees or less is acceptable from side to side The purpose is to prevent the arc from being concentrated on one side of the weld joint or the other This balances the heat on both sides of the joint and keeps the bead centered Don t confuse this with push or pull angle in the travel direction Correct Technique The gun is angled toward the back of the weld...

Page 31: ...nit is unplugged for 30 minutes before opening up for cleaning 02 OVER CURRENT Check to make sure input power cable is correct length and size Internal unit fault or low input voltage Possible issue running on generator with dirty power Identify cause plug directly into the receptacle Cycle the switch one time If the code does not clear call Everlast Tech Support OTHER CONTACT EVERLAST Troubleshoo...

Page 32: ...tor Check for kinks in tubing Increase post flow time Reduce stick out to less than 1 4 Increase gas nozzle size Clean metal thoroughly with approved metal cleaner or use acetone and a rag to clean metal 6 Weld quality is poor Weld is dirty oxidized or porous Drafty conditions The welder is located on the workpiece and is blowing gas off due to fan activity Solenoid is sticking Eliminate drafts Mo...

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