Everlast Typhoon 500 Operator's Manual page 14

the test is completed, turn the unit off, connect the accessories, and
shielding gas (customer supplied) to conduct live testing. Test all of the
functions and features of the machine. For testing and welding, make sure
the work clamp is connected directly to the part being welded (the work).
Check for arc starting and stability. If problems are observed, contact
Everlast for further guidance. See page 5 for more information.
NOTICE: Cosmetic damage claims made after 30 days will not be accept-
ed, unless Everlast is contacted and informed of such delay and reason for
such a required delay (i.e. Overseas deployment or sudden disability).
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, remove the gas plug on the rear (save for storage use) and install
the regulator. Tighten fittings on both cylinder and unit (see section on
regulator installation). After the regulator is secured, set post flow time to
maximum. Trigger a false start with either the foot pedal or torch switch by
tapping and releasing so that post flow can flow. Observe the ball on the
regulator. It will briefly float before settling back down. If the ball continues
to flow, or if you hear or suspect leaks, use warm, soapy water (or a dedi-
cated leak testing solution available from welding suppliers) and spray on
all connections, including the torch connections at the head, and back cap.
Don't forget to check the connections underneath the torch 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 reme-
died, contact Everlast.
DISTANCE YOUR WELDER FROM YOUR WORK.
As a best practice technique, be sure to locate the welder away from the
immediate welding area. The fans found in your unit are powerful enough
to create strong air turbulence in the weld area. When the fans cycle on, it
can disrupt the smooth, even flow of shielding gas around your weld. This
creates unstable arcs and porous welds, resulting in dull finished weld. If
possible the welder should be located at least 6 feet away from the weld
area and should be placed on a different level to prevent weld porosity and
defects being created by the welder's fan system. Even though this unit
offers both thermal controlled as-needed or demanded fan settings, fans
operate at full revolutions when they are triggered into operation. Keep in
mind that air flow exits from both the front and the sides of the welder.
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 elec-
tronics. The air is then exhausted through the front panel and side louvers
of the unit. If any of sides is blocked or restricted, 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 or altering the vents in any way. Free flow of air is espe-
cially important when the "On-Demand" or Thermal control settings are
activated.
Setup Guide
Getting Started
Allow Air Flow Space of at least 18"
Keep a distance of 18" from all sides to promote cooling and preserve
duty cycle. Less air space will reduce duty cycle, accelerate overheating
and possibly decrease the service life of the welder.
18"
USING A WATER-COOLER WITH THIS UNIT.
Because of the wide range of operation of this unit this welder includes a
water-cooled torch and water cooler. The water-cooled torch cannot be
used "dry". Coolant must be circulating while welding with the water-
cooled torch. Even though an air cooled torch can be used, the 200A limit
of a 26 series (the largest common air-cooled torch) is rated for a 60%
duty cycle at 200A DC and 175A AC operation. This means that for most
intense welding applications, the water cooler and water-cooled torch must
be used. Additionally, many people find that a water- cooled torch con-
nected to a water cooler significantly improves comfort level while welding.
The water-cooler connects directly to the torch, circulating water up
through the handle and into the head before returning back through the
power cable to the cooler. The water cooler does not cool the unit or its
components. This unit is equipped with a special 240V plug on the rear
that is designed and intended only for use with Everlast-brand water cool-
ers.
The Typhoon 500 features a "cooler-on-demand" feature which can be
accessed in the background menu. In the back ground menu the cooler
can be set to "continuous run" or only to be active when the arc is struck.
The cooler will continue to run for a brief time after the arc is terminated.
In the most basic terms, the power to the cooler is switched on and off
internally within the welder as the arc is struck and terminated. This means
that the cooler itself has no internal control or programming. The cooler
can be left switched on even if the welder has been shut down since no
power is supplied to the plug when the main machine is turned off. How-
ever, when servicing the cooler, or storing long term, make sure the unit is
switched off and unplugged. See information found later in the manual on
how to access the "On Demand" feature.
IMPORTANT: Make sure the cooler pump is primed before initial use, after
extended storage or after torch has been disconnected and reconnected.
See PowerCool 375 manual for details about priming the pump.
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