Everlast Cyclone 200E Operator's Manual
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Everlast Cyclone 200E Operator's Manual

Mig flux-cored spool-gun
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Publish Date: APRIL 2021
EVCY200E2021 Rev. 1
USA/North America
©Everlast Power Equipment
GMAW
FCAW
MIG
Flux-Cored
Spool-Gun
120/240V
1 Phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide
Operator's Manual
FUNCTION: 200A MIG Welder with PowerSet Mode
PURCHASE DATE:
WELDER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:

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Summary of Contents for Everlast Cyclone 200E

  • Page 1 Publish Date: APRIL 2021 EVCY200E2021 Rev. 1 USA/North America ©Everlast Power Equipment GMAW FCAW Flux-Cored Safety, Setup and General Use Guide Spool-Gun FUNCTION: 200A MIG Welder with PowerSet Mode PURCHASE DATE: WELDER SERIAL NUMBER: OPTIONAL ACCESSORY SERIAL NUMBER: Operator’s Manual...

  • Page 2: Table Of Contents

    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...

  • Page 3: Special Notice And California Proposition 65 Warning

    Due to multiple variables that exist in the welding field and the changing nature of it and of the Everlast product line, Everlast Power Equipment INC. does not guarantee the accuracy, completeness,...

  • Page 4: Customer Greeting And Explanation Of Procedures

    Many issues can be resolved over the phone. If the issue cannot be resolved over the phone/email, you may be given an op- tion to return the unit, or have a part shipped to you, at Everlast’s discretion. Keep in mind, you may be asked questions that seem basic, or ele- mentary to your knowledge base.

  • Page 5: Warranty And Contact Information

    Warranties and service policies and procedures vary from country to country and are maintained and supported by the region- al or in country distributor of Everlast welding equipment. USA Customers Only: For full details on the 5 year parts and labor warranty, 30 day satisfaction policy, terms of sale, and how to proceed with a war- ranty claim, please visit: https://www.everlastgenerators.com/standard-warranty.

  • Page 6: Safety Disclaimer And Hf Warning

    Safe operation and proper maintenance is your responsibility. Everlast is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and maintenance of your Everlast product, it is no substitute for observing safe welding practices and behavior. Safe welding and related cutting operations require basic knowledge, experience and ultimately the exercise of common sense.

  • Page 7: Safety Warnings, Dangers, Cautions And Instructions

    It is your responsibility to make certain that the use of this welder is restricted to per- sons who have read, understand and follow the warnings and instructions in this manual. If you or the operator needs further instruction, contact Everlast welding support at 1-877 755-9353 ext. 204 or seek qualified professional advice and training.
  • Page 8 Safety Warnings, Dangers, Cautions and Instructions DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these hazards are immediate while others are cumulative in their effect. Do not weld in enclosed spaces or in areas without adequate ventilation. Fumes and gases released in the welding and cutting operations can be toxic.
  • Page 9 Safety Warnings, Dangers, Cautions and Instructions CAUTION! Trip Hazards exist around welders. Cords, cables, welding leads and hoses pose a trip hazard. Be aware of their location and inform others of their location. Tape and se- cure them so they will stay out of high traffic areas. CAUTION! Welded metal can stay hot long after welding is completed.

  • Page 10: Generator Operation Information

    5% or less THD can damage your unit. The generator manu- facturer determines this 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.

  • Page 11: Specifications, Including Duty Cycle And Input Amperage Information

    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.

  • Page 12: Duty Cycle Explanation

    Duty Cycle Duty Cycle Duty Cycle is simply the amount of time out of a 10 minute period in which the unit can operate. For example, this unit has a duty cycle of 25%. This means that the unit can be operated for 2.5 minutes out of 10 minutes at 115 Amps maximum output while operating on 120V, and for 2.5 minutes out of 10 minutes at 180A while operating on 240V.

  • Page 13: Getting Started, Unpack Your Unit, Check For Gas Leaks

    Everlast. some of the accessories may be present, but this is considered nor- mal. If any item is damaged or missing, please inform Everlast within DISTANCE YOUR WELDER FROM YOUR WORK. 72 hours of product receipt. See pages 4 and 5 for more details.

  • Page 14: Connecting Your Unit To The Power Source And Wiring Information

    Everlast is in no way liable for any damag- ating on 120V. For best results, use this unit with a slow blow fuse, or es caused by improper connection of your welder.

  • Page 15: Connecting Your Unit To The Shielding Gas

    Do not Read the middle of the ball for the best reading. Do not confuse attempt to repair a leaking regulator. Contact Everlast for a warranty pressure on the cylinder gauge with the flow rate on the floating ball replacement if a leak is discovered in the regulator itself.

  • Page 16: Adjusting Your Regulator

    Setup Guide Getting Started is no gas flowing. • Once adjustment is completed release the trigger. The gas will delay slightly until the post flow timer automatically shuts off the gas flow. The ball will settle. • When welding it may be necessary to increase or decrease gas flow rate to compensate for conditions.

  • Page 17: Gun Installation And Connecting Your Unit And Readying To Weld (Polarity And Panel Connections)

    Setup Guide Getting Started Testing Wire-Feed Operation and MIG Gun Installation After inspecting the unit for power up, it is necessary to confirm wire feed opera- MIG/Spool Gun (Gas) Polarity + tion. This is a simple process that requires you to install the MIG gun on the unit. To install the MIG gun: •...

  • Page 18: Wire Spool Installation

    Setup Guide Getting Started Wire Spool Direction and Rotation Install the Wire Spool. The spool carrier assembly consists of several parts. Each part must be assembled correctly. See the illustration below. There are two collars that support the 8” spool. There is an inner collar and an outer collar. The roll is held in place by tension placed on the outer collar by a small spring and a small finger nut.

  • Page 19: Drive Roll Information; How To Feed The Wire Through The Mig Gun

    Setup Guide Getting Started Identifying and Changing the Drive Rolls. Guiding the Wire Through the Feeder and Gun. The unit comes equipped with .023” and .030” drive rolls. NOTICE: For Once the wire spool has been installed, flip the tensioner lever down and most purposes you will likely want to use .030”...

  • Page 20: Tensioning And Trimming The Wire

    Setup Guide Getting Started Trim the wire sticking out of the nozzle to 1/4” to 3/8” (6mm to 9mm) in is enough. length with wire cutters. See the illustration below. The gun is now ready for welding. Hint: Always make sure that you re-trim the wire before be- ginning a new weld if the wire is not already trimmed to this length.

  • Page 21: Component Identification And Explanation; Front Panel

    Component Identification and Explanation Front Panel View Number Component Identification Component Note Protective Cover Keep down and in place during welding activities and in storage. Door and Latch Keep door closed while in use. Only open for wire replacement and starting Negative Terminal (-) For MIG (GMAW): This is the location of the work clamp (DINSE 25 Type, 3/8”...

  • Page 22: Component Identification And Explanation; Rear Panel

    Component Identification and Explanation Rear Panel View Number Component Identification Component Note Power Switch This is used to switch the unit on and off. Shielding Gas Connection 5/8” CGA Fitting is used in North American Markets. Other markets may use a hose barb connection. (5/8”...

  • Page 23: Component Identification And Explanation; Control Panel Layout And Use

    MIG C100 FLUX-CORED VOLTS SELECT SELECT SPOOL CYCLONE 200E Number Component Identification Component Note Wire Feed Speed Control This is used to set the Wire Feed Speed (WFS). This controls the top center numerical value on the screen in the “X”.

  • Page 24: Component Identification And Explanation; Manual Function And Screen Layout

    FLUX-CORED SELECT SELECT SPOOL CYCLONE 200E Using Manual Mode To use the mode: 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.

  • Page 25: Component Identification And Explanation; Powerset Function And Screen Layout

    FLUX-CORED SELECT SELECT SPOOL CYCLONE 200E Using Power Set To use the PowerSet mode: Choose the Gas Type/Mode (i.e. MIG25, MIG 100, or Flux-Cored). NOTE: If you select gas type after selecting PowerSet mode, you will drop out of the PowerSet mode and return to manual mode.

  • Page 26: Component Identification And Explanation; Powerset Explanation And Purpose

    The stated capacity of this welder is greater than what is allowed in Everlast in no way can be held responsible for providing settings in Pow- PowerSet mode because of issues surrounding best-practices in the erSet mode that may cause poor weld results or unusable weld settings.

  • Page 27: Welding Information And Tips; Explanation Of Welder Functions

    Welding Information and Tips EXPLANATION OF WELDER FUNCTIONS class of wire. The ranges of volt and amp parameters generally varies somewhat from brand to brand, so be sure to read the packaging and/or manufacturer literature to determine what range of settings are recom- mended.
  • Page 28 COMPONENT IDENTIFICATION AND FUNCTION Welding Information and Tips Holding the wire too far off from the metal will result in rough starting and gaps where fit up is a problem. A weave is also frequently used to manage too long of wire stick out. heat build up.
  • Page 29 COMPONENT IDENTIFICATION AND FUNCTION Welding Information and Tips dling. A thick pass may also begin to cool before contaminates and gas When Do I Use Multi-Pass Welds? pockets have the time to float out to the surface. It’s far better to make multiple smaller passes to complete a plate weld for a higher quality result.
  • Page 30 COMPONENT IDENTIFICATION AND FUNCTION Welding Information and Tips MIG Welding is fairly simple if you keep travel angle and direction in mind when welding. See below. If you are welding flux- core, the gun direction is reversed. Remember: If it has gas, you use a push angle. If it is gas-less you use a drag angle. The old welder’s saying “If it has slag, you drag.”...

  • Page 31: Troubleshooting Error Codes

    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.

  • Page 32: Troubleshooting Common Issues

    Check gas flow. Adjust for higher flow of gas. Listen for audible click activity. Solenoid is sticking. of gas solenoid. If no click is heard, then contact Everlast Support. Clean weld properly. Increase pre flow or post flow.

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