Getting Started, Unpack Your Unit, Check For Gas Leaks - Everlast CYCLONE 140E Operator's Manual

UNPACK YOUR UNIT.
Upon arrival, you will need to completely unpack your unit, and
check things over. This is a time sensitive matter. Do not delay or
hold the welder unopened in the box. First, make sure the unit is
opened from the top. Be careful with using knives and sharp objects
so you won't cut cords and cables inside the boxes. Lay all items out
and inspect them.
You should have the following in your box:
1. Welder
2. 15 Series MIG Gun 3m (9.5 ft.)
3. Work Clamp 1.5m (5 ft)
4. Floating Ball Type Regulator with Gas Line (4a)
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4a
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Inspect the welder for damage. Check for the presence and general
condition of the accessories. Some slight rubbing or chaffing of
some of the accessories may be present, but this is considered nor-
mal. If any item is damaged or missing, please inform Everlast within
72 hours of product receipt. See pages 4 and 5 for more details.
Assemble the front, middle and rear handles with the supplied
screws. Do not overtighten the screws.
NOTICE:
This unit is shipped with a .023" and .030" drive roll intended to feed
solid MIG wire. While the unit is designed for use with Flux-cored, self-
shielded wire, the flux core drive roll is optional. The same is true if you
desire to .035" solid MIG wire. The .030" diameter wire is the best
choice for the widest range of use with steel. If desired, you will need
to purchase additional drive rolls. Additionally, for best results a flux-
core nozzle may be purchased for use with your 15 series MIG gun.
These may be bought locally. Currently Everlast does not offer the Flux
-Cored only nozzles for sale. (Subject to change).
POWER UP AND TEST YOUR UNIT.
You will need to fully test the unit as soon as possible. Within 72
hours after receipt of the unit, be sure to have every thing you need
at hand to test the unit. Make sure the correct input power, wiring,
and plug configuration is being used. Then, power up your machine
without any accessories installed. Allow the unit to idle for 15
minutes. Check and observe operation of knobs, controls and but-
tons, cycling through each as required. Make sure the fan is running
at full speed. After the test is completed, turn the unit off, connect
the accessories, shielding gas (customer supplied) and conduct live
testing of all the functions and features of the machine. For testing
and welding make sure work clamp is connected directly to the part
being welded (work). Check for arc starting and stability. If prob-
Setup Guide
Getting Started
4
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lems are observed, contact Everlast. See page 5 for more infor-
mation. NOTICE: Cosmetic damage claims after 30 days will 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 installation). After the regulator is
secured, the gas flow should be set and tested. First, release all
tension on the wire feeder so the wire does not feed through the
gun. Next trigger the gas flow with the torch switch by holding the
torch switch down, while observing the ball on the regulator. It will
float while the torch switch is held. If the trigger is released, after the
post flow(2-3 seconds), the ball will sink and settle to the bottom. If
the ball continues to flow after 2-3 seconds, or if you hear or suspect
leaks, use warm, soapy water (or a dedicated leak testing solution
available from welding suppliers) and spray on all connections, in-
cluding the torch connections at the head and handle. If any leaks are
present, bubbles will form around the area of the leak. Tighten any
clamps or fittings found to be leaking. If the problem cannot be rem-
edied, contact Everlast.
DISTANCE YOUR WELDER FROM YOUR WORK.
As a best practice technique, be sure to locate your welder away from
the immediate area you are welding. The fan found in your unit is
powerful enough to create strong air turbulence in the weld area.
This will disrupt the smooth, even flow of shielding gas around your
weld creating unstable arcs, and a porous look to the weld. If possi-
ble the welder should be located at least 4-5 feet away from the weld
area and should be on a different level to prevent weld porosity and
defects being created by the welder's fan system. Keep in mind the
fan draws air in from the rear and exhausts out the front and the
sides of the unit. If welding outdoors, and a breeze is present, erect
a wind screen around your weld area, using a tarp, plywood or simi-
lar material.
GIVE YOUR WELDER SPACE TO COOL.
The welder needs room to cool itself. Place the unit in a place that
will allow 18" from all sides to allow for proper cooling. The welder
pulls air in from the rear, and pushes it through the unit's heat sinks
to cool the electronics. The air is then exhausted through the front
panel and side louvers of the unit. If the sides are blocked or re-
stricted, the duty cycle will be reduced, and overheating will occur,
leading to possible damage if the restriction is severe enough. Never
attempt to restrict air flow by attaching filters to the vents. Do not
modify the unit for "on demand" fan service, or the warranty will be
voided.
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