Everlast Cyclone 262 Use Manual Download Page 10

10

 

Important Information: Operating this unit with a generator or other off-grid service. 

MINIMUM REQUIRED SURGE WATT RATING: 12,500W

 

MINIMUM REQUIRED THD: 5% or Less

 

This welder unit should only be operated on a generator certified by its manufacturer to produce clean power.   Clean power is equivalent 
to the quality of household or shop/garage type power.  This means the generator must have 5% or less total harmonic distortion (THD) 
of the Sine wave.  If you are unsure of the power output type of the generator, contact the manufacturer of the generator for verification. 

Do not operate on square wave or modified square wave generators or converters/inverters or damage or malfunction may occur. Dam-
age caused by running this unit off of 

dirty

” 

power or modified sine waves may not be readily apparent and can be cumulative in nature.  

However, damage may present itself immediately. The damage caused by running this unit on 

dirty

” 

power usually leaves internal tell

-

tale 

signs and damages specific parts. 

 

NOTICE! Operation of this unit with generators not rated by its manufacturer as providing clean power (5% or less THD) is prohibited and 
will void the warranty.  Operation with modified sine wave, or square wave generators and inverters/converters/UPS that do 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. 

The generator manufacturer determines the THD rating, not 

Everlast. 

Do not assume that a name brand generator, or a 

new

” 

generator automatically provides clean power.  Price paid does not 

guarantee a clean power output either.  There are multiple brands at various price points capable of producing clean power.  Investigate 
this before purchasing a generator. The manufacturer will usually state that a unit is clean power in the advertising information and will 
state actual THD.  If the manufacturer does not state it, contact the manufacturer directly for a statement concerning actual THD. 

 

WARNING! Do not start or stop the generator with the unit switched on. Never use the generator in ECO mode or an auto

-

idle mode.  

Even with a clean power rated generator, this action can damage the unit. 

Turn the unit on only after full generator R.P.M. has been 

achieved and the engine is sufficiently warmed up.

 Closely monitor generator fuel level so that the engine R.P.M doesn

t drop or com-

pletely shut down with the unit plugged in.  For best practice: do not start or stop the generator with this unit plugged in, even if it is 
turned off.  Unplug the unit before shutting down the generator. 

 

If using with a welder/generator, make sure the manufacturer has determined that the generator portion produces a clean sine wave.  
Many older models do not.   Some newer models use 

divided

” 

power between welding and generating and cannot supply the full power 

to the unit unless the fine current control knob is turned to maximum. Do not use this unit with such welder/generators unless the Power/
fine current control is turned to 100%. Some welder generators do have a separate alternator for generating power. If this is the case, be 
sure not to weld or load the machine while this unit is in use.  

 

WARNING! Always make sure any generator or welder generator is properly wired and grounded, according to local and national code.  
Ground the machine per the generator manufacturers instructions to meet code requirements. Improperly grounded generators may dam-
age the machine and more importantly may cause severe injury or death.

 

240V Operation: 

This unit is designed for 240V (±10%) 50/60Hz single phase operation.  This is the standard single phase, Voltage in the North American 
market used for most welders. If your voltage is derived from 208V 3 phase Wye Type power (or your local power company provides 
measured voltage 216V or less across each hot leg of power), then it is recommended that you install a buck

-

boost type transformer.  If 

you are not sure which voltage you have, contact your local electrician and/or power company. Operation on 208V will affect accuracy of 
adjustment and output.  If the voltage drops below 205V under load or during peak periods, damage may occur to the unit.  Damage 
caused by using on undervoltage power sources or inaccuracy in operation is not covered by the warranty.  Always be aware of the volt-
age output and the quality of the power source being used.

 

Rear Outlet Use and Warning: 

WARNING: If equipped, never use the electrical power outlet on the back of this machine for anything other than powering an Everlast 
brand water cooler.  This is a special outlet designed to produce 240V with limited amperage draw.  No other device or brand should be 
used in conjunction with this unit

s outlet. This outlet is designed to supply 240V only.  Do not attempt to modify, or change this outlet 

for use with anything else other than an Everlast brand water cooler designed for 240V operation. Severe damage, fire or injury may oc-
cur if other devices or other brand equipment is connected. 

 

Summary of Contents for Cyclone 262

Page 1: ...USA North America Everlast Power Equipment 240V 1Ph Welders Plasma Cutters Multi Process Safety Setup and General Use Guide For The Cyclone 262 FUNCTION MIG Stick Welder PURCHASE DATE MODEL NAME SERI...

Page 2: ...GETTING STARTED UNPACKING YOUR UNIT AND INSPECTION 14 CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION 15 SHIELDING GAS REGULATORS AND TORCH INSTALLATION AND POLARITY INFORMATION 16 INS...

Page 3: ...sation 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...

Page 4: ...s 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...

Page 5: ...cessories 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 a...

Page 6: ...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 ope...

Page 7: ...reinforced or steel toe leather shoes and long sleeved flame resistant clothing i e denim Do not wear Poly Nylon blend materials DANGER Welding cutting poses shock and electrocution risks Keep this we...

Page 8: ...s 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 hand...

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...

Page 10: ...R P M doesn t drop or com pletely shut down with the unit plugged in For best practice do not start or stop the generator with this unit plugged in even if it is turned off Unplug the unit before shut...

Page 11: ...ith a heat sensor located on a heat sink near the critical power components of the welder If the operating temperature of the unit is exceeded welding output will stop and an over temperature warning...

Page 12: ...ult of the high frequency interference that is possible with the operation of the inverter switching and operation the HF service bolt should be connected directly to a 12 gauge wire that is bonded di...

Page 13: ...is not controlled by a timer Rather a heat sensor located on a heat sink near the critical power components of the welder signals overheat If the operating temperature of the unit is exceeded welding...

Page 14: ...mounted handle Screws may be found in the consumable bag If present remove the cap screws from the center of the machine and install the center handle and install the handle If screws are not pre inst...

Page 15: ...onsult and or employ a locally licensed electrician be fore installing this unit to make sure all national and local codes are followed Do not wire connections for this machine if you are not qualifie...

Page 16: ...throughout the industry However in the industry this unit is designed to be used with 98 2 Ar CO2 blend when welding Stainless Steel While there are other gas choices such as TriMix this is typically...

Page 17: ...be correct in polarity Drop open the cover on the left side of the MIG to access the wire spool and feeder Just above the feeder the are two terminal lugs The lower is positive and the upper is negati...

Page 18: ...larity or affect the stick welding function If the MIG gun is removed when welding in Stick mode the cable connecting the wire feeder under the cover to the polarity terminal can remain in place The t...

Page 19: ...g When not in use keep these spares put up where moisture and dust cannot get to them They will rust if not used and stored properly The top drive rolls are actually idler rolls used to hold tension a...

Page 20: ...erent types of wires require different tensions There is no exact tension that works for all wire types However for steel wire you will generally tension to at least 3 to 3 5 on the dial Wire diameter...

Page 21: ...35 50 Type For Stick connect to the Torch For MIG this remains vacant For Flux Cored connect the work clamp 4 Negative Terminal DINSE 35 50 Type For Stick connect to the work clamp For MIG connect to...

Page 22: ...a 1 phase connection to the unit Use Black for L1 White for L2 and Green for ground not neutral use Red is not typically used in wiring a welder circuit This is in accordance with North American code...

Page 23: ...ge or adjust The actual direction may go either up and down or left and right depending upon the function level you are adjusting or selecting 9 PowerSet The PowerSet function when selected enters a s...

Page 24: ...ers will bright en and will be able to be adjusted Of course if you continue to navi gate completely through the left or right side functions and parame ters you will eventually cycle back to the defa...

Page 25: ...m If the program needs to be fine tuned the set tings may be adjusted or changed while in use However if changes are made to the program unless the program is resaved these set tings will not be autom...

Page 26: ...r the wire until after the arc is started This improves the arc starting ability This indicator reminds you whether you have it selected or not 6 Wire Feed Speed Indicator Adjust with Right adjustment...

Page 27: ...eft Up and Down navigation keys to navigate and highlight turn green this setting Use the left adjustment knob to turn the setting on or off In Flux Cored mode this feature will be unavailable and be...

Page 28: ...side adjust ment This is the default setting If no adjustment is made to selected functions or parameters the machine will automatically default back to the Amperage setting after 4 to 5 seconds 6 Arc...

Page 29: ...will illuminate This will activate the Pow erSet Screen for the process you are using Each process allows the use of PowerSet Once activated you will be ready to begin entering the information you ne...

Page 30: ...such as Pre Post Flow or Inductance simply copy the suggested settings into manual mode You are then free to make any adjustment you need to any parameter or function permitted In Stick PowerSet mode...

Page 31: ...ht Hold the torch more vertical with less than a 15 degree deviation from vertical and reduce stick out of wire to 3 8 or less If this still does not help reduce the wire speed Some spatter is normal...

Page 32: ...such as grease should be done before welding Stick welding is more forgiving of rust and mill scale but when MIG welding contaminates will result in porosity and inclusions in the weld weakening it I...

Page 33: ...er can later be ground or cut off However in many cases a plain open root can be used as a backer plate adds to the time and labor involved A knife edge is also acceptable so long as the joint is full...

Page 34: ...ance 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 t...

Page 35: ...hange A spool gun is the preferred method to weld Aluminum but a polymer liner may be used with guns10ft and under to weld aluminum In this case you will need to change the standard liner intended for...

Page 36: ...80 for best results The arc force control setting will vary from person to per son as well with different rod angles positions and arc lengths all factoring into the arc force control performance If...

Page 37: ...el speed Allow the metal to fill the puddle as the rod travels forward Be sure to try to separate the difference between the slag and the molten pool of metal The slag will coalesce behind the puddle...

Page 38: ...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 F...

Page 39: ...to under 3 8 for short circuit 5 Porosity of the Weld Discolored weld color Tungsten is discolored Low flow rate of shielding gas High flow rate of shielding gas Possible gas leaks internally or exter...

Reviews: