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Specifications 

Product Specifications

 

Construction Type

 

Inverter (IGBT based, Digital Control)

 

Input Voltage

 

120/240V(± 10%)  50/60 Hz 

 

Phase

 

1 Phase 50/60Hz

 

I1MAX  Current Rating (Inrush Amps)

 

120V @ 28.7A    240v @ 28.2A

 

I1EFF  Current Rating (Rated Amps)

 

120V @ 15A    240V @ 15A

 

OCV

 

70V

 

Processes

 

GMAW/FCAW (FCAW requires purchase of 
optional drive rolls)

 

MIG  Duty Cycle (Rated at 40

° 

C @ Max Output) *

 

120V: 25% @ 115A/19.8V, 60% @ 75A/17.8V

 

240V: 25% @ 180A/23V, 60% @120A/20V

 

MIG Output Range 

 

120: 13

-

20V/30

-

115A  

 

240V: 13

-

23V/30

-

180A (200 Max)

 

Pre Flow / Post Flow Gas Time

 

Auto Controlled

 

Burn Back Control

 

Auto

 

MIG Inductance

 

Fixed

 

Wire Spool Size

 

4” 

or 

8” (2

-

12 

lbs typically)

 

Wire Diameter Stock Drive Rolls

 

.023”

-

.030” 

(.6mm –

.9

mm)

 

Maximum Wire Diameter with Optional Drive Roll**

 

.035” 

Solid Wire,.045

” 

Flux

-

Cored/Aluminum

 

Wire Feed Speed

 

No Load: 50

-

425 IPM. 

 

Recommended Spool Gun

 

SM100N

 

PowerSet Metal/Gas Combinations

 

Steel/100% CO2, Steel/ 75/25% Ar/CO2, Flux 
Core (Gasless, Self shielded)

 

MIG Gun Type/Length/ Connector Type

 

15 Series, 9.5 ft. (3m)

 

Work Clamp with Cable Length

 

5 ft (1.5m) DINSE 25  (3/8 nom. dia.)

 

250A Stick Electrode Holder Length

 

9.5 ft (3m) DINSE 35/50  

(1/2” 

nom. dia.)

 

Power Cable Length

 

6.5 ft (2m)

 

Power Plug Type for 240V

 

NEMA 6

-

50P (North American Standard)

 

Power Adapter Plug 240V to 120V

 

NEMA 6

-

50P to NEMA 15

-

50P

 

Cooling Type

 

Full Time Fan

 

Dimensions (Approximate with handles installed)

 

12.5” 

H X 

8.5” 

W X 

17.5” 

 

Weight (Bare Unit) 

 

26.5 lbs.

 

Ingress Protection Rating 

 

IP21S

 

*Duty Cycle

 

Duty Cycle is simply the amount of time out of a 10 
minute period in which the unit can operate.  For 
example, if this unit has a duty cycle of 25%, that 
means that the unit can be operated for 2.5 minutes 
out of 10 minutes.  This may be continuously, or 
intermittently during the 10 minute period of time. 
This rating standard (United States) is based on a 
maximum ambient temperature of 40 C.  Operating 
above this point, or at lower temperatures with high 
humidity may reduce the duty cycle rating.  Of 
course, the duty cycle may increase somewhat as 
ambient temperature drops.  Regardless, this unit

duty cycle is not controlled by a timer.  Rather, this 
unit is equipped with a heat sensor located on a heat 
sink near the critical power components of the weld-
er. If the operating temperature of the unit is ex-
ceeded, welding output will stop and an over

-

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 quickly 
triggered since the unit resets just below the heat 
threshold. The fan(s) must continue to run for a full 
15 minutes to cool the unit properly after the duty 
cycle shut down has occurred.  

After 15 minutes of 

cooling, you may switch the unit off if you are fin-
ished welding.  If the unit does not automatically 
reset after 15 minutes, turn the unit off.  Wait for 15 
seconds before turning the  machine back on.  If the 
unit does not reset,  contact technical support for 
further advice and assistance. As a best practice, 
when you have completed welding and have been 
welding continuously for extended periods of time, 
keep your unit on for 10 additional minutes without 
welding to allow it to cool.

 

The intentional and/or repeated triggering of the 
duty cycle protection feature on this unit will shorten 
the lifespan of the unit

s electronics and can weaken 

internal components. The effect of overheating your 
unit repeatedly takes a cumulative toll on the unit. 

 

Breaker Sizing and Wiring Requirements

 

Before installation of this unit in any facility, always consult a licensed local electrician familiar with the requirements of properly wiring a welder into the electrical supply. 

Refer to the National Electric Code (NEC) and local codes.  If needed, refer the electrician to Article 630 of the NEC during consultation to determine proper application 
and wiring needs. Use the I1MAX  and the I1EFF  ratings listed above to determine the proper breaker and conductor (wire) sizing required. Everlast welders are designed 
around use in industrial wiring applications and are intended to be used with modern electrical systems. Household wiring may need to be upgraded before this welder 
may be installed.  Additional HF protection and isolation may be needed if this welder interferes with the operation of electrical/electronic equipment. WARNING! Do not 
modify welder wiring. This unit meets the standards for conductor sizing on the power cable and takes into account power cable length, duty cycle and rated current. 

 

**May require a liner change or different gun, or special consumables.

 

Содержание Cyclone 200E

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 33: ...33 ...

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