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Everlast Cyclone 263Pi Operator's Manual
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Everlast Cyclone 263Pi Operator's Manual

Everlast Cyclone 263Pi Operator's Manual

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Publish Date: MARCH 2025
EVCYCLN 263Pi Rev. 1.0
USA/North America
©Everlast Power Equipment
DC
275A
DC
250A
DC
220A
240V
1 Phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide
Operator's Manual
FUNCTION: Pulse MIG/ DC Lift TIG/ DC Stick
PURCHASE DATE:
WELDER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:

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Summary of Contents for Everlast Cyclone 263Pi

  • Page 1 Publish Date: MARCH 2025 EVCYCLN 263Pi Rev. 1.0 USA/North America ©Everlast Power Equipment 275A Safety, Setup and General Use Guide 250A 220A FUNCTION: Pulse MIG/ DC Lift TIG/ DC Stick PURCHASE DATE: WELDER SERIAL NUMBER: OPTIONAL ACCESSORY SERIAL NUMBER: Operator’s Manual...
  • Page 2 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, OPERATING VOLTAGE AND OTHER GENERAL INFORMATION DUTY CYCLE EXPLANATION STATEMENT SPECIFICATIONS: DUTY CYCLE, PERFORMANCE SPECIFICATIONS AND INPUT AMPERAGE INFORMATION 12,13 SETUP GUIDE: GETTING STARTED, UNPACKING YOUR UNIT, ASSEMBLY AND INSPECTION...
  • Page 3 Due to multiple variables that exist in the welding eld and the changing nature of it and of the Everlast product line it- self, Everlast Power Equipment INC. does not guarantee the accuracy, complete-...
  • Page 4 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 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 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 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 quali ed 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 traf c areas. CAUTION! Welded metal can stay hot long after welding is completed.
  • Page 10 13,000 Surge Watt generators or larger. Operating the unit on under-powered generators and/or on generators not rated with 5% or less THD can damage your unit. The generator manufacturer determines this rating, not Everlast. Do not assume that a name brand generator, or a “new” generator provides clean power.
  • Page 11 6 minutes out of a 10 minute time period at the maximum output of the welder (275A MIG, 250A TIG and 220A Stick output). Everlast uses a maximum output rating to gure duty cycle on this unit. A duty cycle of 60% is considered to be a industrial duty cycle class welder and is suitable for daily commercial use for light to industrial manufacturing and production welding.
  • Page 12 Specifications Product Speci cations (Continued on next page) Welder Base Construction Type Digital IGBT Inverter-Based Design with 5” HD (720) Screen. (Full Diagonal Measurement) DC Processes GMAW, FCAW, SMAW, GTAW-P (MIG, Gasless Flux-Cored, TIG, Stick) Input Voltage/ Hertz/ Phase Dual Voltage 240V (± 10%) 50/60 Hz 1 phase Current Rating (Inrush Amps) Current Rating (Effective Rated Amps) OCV/ OCV with Voltage Reduction Device Selected...
  • Page 13 Specifications Product Speci cations Continued Spool Gun/ Push Pull Gun Options Spool Gun: Parker DSP360 Push/Pull Gun: North MPG 300A Wire Jog function Gas Purge Function Work Clamp with Cable Length 300A, 9.5 ft. (2m) DINSE 35/50mm (1/2” nominal lug diameter) Stick Electrode Holder Length 300A, 9.5 ft.
  • Page 14 NOTICE: Cosmetic damage claims made after 30 days will not be accepted. Assemble the front, middle, and rear handles with the supplied screws. Do Unless Everlast is contacted and informed of such delay with legitimate not overtighten. Handle assembly is optional for some non-portable and reason for such a required for a delay (i.e.
  • Page 15 With this type connection, the TIG torch may be connected directly to the gas regulator with a variety of couplers and ttings that are customer sup- plied. This is the customer’s responsibility. Everlast does not provide a full 18” 18”...
  • Page 16 If you are not quali ed, do not attempt to wire any outlet or make any electrical power connections or related determi- nations of electrical code. Everlast is in no way liable for any damag- es caused by improper connection of this welder. As a rule, your welder should be on a dedicated branch circuit not far from an elec- trical disconnect box.
  • Page 17 The gas flow is controlled directly on the torch handle. A combination of ttings (user supplied, locally sourced) may be required to connect the torch directly to the regulator. Everlast offers gas valve torches which are required for this style operation, but does not offer a complete connector package that directly hooks the gas line to the regulator.
  • Page 18 Gas cylinders come in a wide ranges of sizes. Cylinders range from about 20 The Cyclone 263Pi is a synergic welder which incorporates on screen Cu. Ft. to over 300 Cu. Ft. capacity. For this unit, there are at least two different recommendations for the type of gas needed for each process.
  • Page 19 Setup Guide SELECT THE PROPER TIG POLARITY AND CONNECTIONS. The electrode holder, or stick torch (also commonly called a “Stinger”) will almost always be connected to the left positive terminal of the machine Selecting the correct polarity for DC TIG is quite simple. To TIG weld any when welding in DC Mode.
  • Page 20 For dedicated Flux-Cored use or for extended periods of use, you use a Flux -Cored gun. Flux-Cored guns are available from after-market sources. Everlast does not provide Flux-Cored guns as optional equipment.
  • Page 21 There may also be problems for calibration. Use with NOTICE: Spool guns and push-pull guns connect in the same manner other brand guns not approved by Everlast will void the warranty. If a “will and are installed using the same connections and polarity. Both ver- t”...
  • Page 22 Setup Guide and dust cannot get to them. They will rust if not stored properly. How Do I Disassemble the MIG Gun? The top drive rolls are actually idler rolls used to hold tension and keep the 15 Series MIG gun wire in the groove.
  • Page 23 Setup Guide the drive roll is reinstalled, just lightly snug the screws with the screw NOTE: This unit is equipped with the 36 Series MIG Gun. However it can driver. Do not over tighten. also be used with the 24 series MIG gun or 15 series MIG gun (optional purchase.
  • Page 24 Setup Guide ent tensions. There is no exact tension that works for all wire types. How- ever, for steel wire, you will generally tension to at least 3 to 3.5 on the dial. For flux-cored wire, use 2 to 3. For Aluminum use 2 to 2.5. Wire diameter also plays a small part in the amount of required tension that is needed.
  • Page 25 This welder uses a common Euro Style Connection for the MIG gun. This this case the spool gun is the best option. Also even with .030” stainless allows any Everlast gun or any after market gun with the same connection wire there may also some dif culty feeding wire with longer guns.
  • Page 26 Setup Guide Getting Started mum size of wire that should be used with this unit is .045”. A damaged liner should be checked and replaced as soon as any damage is suspected. The wire sizes and liner color codes are as follows: A steel liner is a tightly coiled hardened wire similar to a lawn mower or Blue Liner: .023”-.035”...
  • Page 27 Setup Guide the base tting while using a wrench to do this. Do not allow the base the brass nut. Pull on the flange to remove the old liner completely. tting to unscrew. If the tting unscrews, it must be reinstalled before Once removed, set aside.
  • Page 28 Generally, for all types of welding 2% Lanthanated, should be used and prices and range of selection, so don’t rule them out until you have will perform best under most conditions in your Everlast welder. There checked. Also, there are some companies that may send you free samples are many modern “mixes”...
  • Page 29 Choosing the proper grind angle is important to achieving the weld pene- tration, bead appearance, and arc-cone width that you desire. While there Everlast uses a Live Lift-start system on this unit. This system is able to is no true one-size- ts-all angle, there are some general rules of thumb to handle several different sizes of Tungsten.
  • Page 30 Component Identification and Explanation Front Panel View Component Identi cation Function/Component Note Protective Cover Keep cover down and in place during welding activities and while in storage. Euro-Style Quick MIG Connector Connect the MIG gun to this connector. (Only one gun may be connected at a time.) Connect the Spool Gun to this connector.
  • Page 31 Water Cooler Outlet This outlet is to be used with Everlast 240V rated water coolers only. Do not use with any other application. Do not operate with 120V (240V 1Ph, 4A max)
  • Page 32 Component Identification and Explanation Control Panel Layout Component Identi cation Function/Component Note 1. Welding Process Selector Press left or right arrow key connected to the process selector LEDs to navigate back and forth to select the desired weld pro- cess. The LED will light to indicate which weld process has been selected. See Quick Setup Section. 2.
  • Page 33 · Settings may not be perfect for all positions/applications/users. The Everlast Synergic Pulse MIG design provides easy adjustment of all · Presets may takes away from Pro user’s ability to tailor the settings to pulse-related parameters through the Amp control knob. When the user individual needs or worksite applications.
  • Page 34 If any malfunction of the control screen or the welder is observed, Make sure all ttings are tight and that your gas cylinder valve is fully contact Everlast Tech Support. open. Put on proper safety equipment (PPE) and re resistant clothing.
  • Page 35 Component Identification and Explanation GENERAL INFORMATION ON SETUP AND USE. Quick Steps to Setting-Up the Welder. The main display in the upper area serves to display the status, or Selecting the Process. value of a function or parameter. (1a) At the top of the panel (1) use the process selector buttons to select the ·...
  • Page 36 Component Identification and Explanation of the unit. In the PowerSet mode, only one line may be displayed due to the simpli ed input design. When a parameter or a function is selected, the screen will display the value or status of the function in two places: At the top of the screen in the main display area.
  • Page 37 Component Identification and Explanation from gray to green and will display additional parameters related to Why Are Some Settings Limited or Blank? the function. When the items are green and the blank areas lled by There are two basic reasons some settings are limited in adjustment or additional parameter information, they are then adjustable.
  • Page 38 Component Identification and Explanation USING THE PROGRAM MENUS AND MEMORY FUNCTION. process is not selected at the top of the selector. (The selected pro- gram will override the process selector and display the saved program The memory function on this machine allows the user to save and name up and process.) to 30 different programs.
  • Page 39 Component Identification and Explanation distinctive without exceeding the character limit. Once the program has been entered, rotate the adjustment knob (3)to save selection or press cancel to exit the screen. If cancel is selected the program will not be saved on that line and the name or status of the line will not be changed.
  • Page 40 PowerSet mode the Inductance values used for setting inductance on this model vary which is a synergic, more automated mode. In PowerSet mode, from other non-pulse capable units in the Everlast lineup. These set-...
  • Page 41 This is useful for tacking up long seams on thin sheet metal such as body panels. It tings use a reciprocal value of the other Everlast models (i.e. 70% on helps to provide regular spacing between the weld as long as the other units = 30% on this model).
  • Page 42 Component Identification and Explanation Synergic Pulse MIG: set. (See the MIG Pulse PowerSet section). When the welder is switched to Synergic Pulse MIG mode, many parame- Main Right Display, Amp Display. This side displays selected welding ters are the same as they are in standard MIG welding modes. However Amps by default and is adjusted with the right adjustment knob.
  • Page 43 Inductance values used for setting inductance on this model differ For example, 2T mode only allows selection of trim settings. from other non-pulse capable units in the Everlast lineup. These set- 16. Torch. Select between the main MIG gun, Push-Pull and Spool Gun tings use a reciprocal value of the other Everlast models.
  • Page 44 Component Identification and Explanation the process used and the actual output of the machine. If improper and not AC mode. (This TIG supplies DC output only for TIG. It is not operation is observed, check this area and the information it is dis- suitable for welding Aluminum or Magnesium.) playing and con rm the polarity and gas mix being used.
  • Page 45 Component Identification and Explanation adjustment mode, the function or parameter selected will display and the display numbers/letters will turn red to indicate adjustment mode. After 5 seconds of no input or adjustment of any parameter or func- tion, the selected setting will default back to the amperage reading and return to the default white color.
  • Page 46 Component Identification and Explanation Remember: In Manual Welding Modes, What Are the Welder’s Default Settings? Any setting or value pre- The welder is designed to include many extra features and sent in the parameter area functions in the Manual mode that aren’t included with basic welders.
  • Page 47 Component Identification and Explanation Using the PowerSet Menus. ommendations as well for single pass. The unit does offer higher settings and may recommend a gas change as the wire speed and voltage enter the The PowerSet function is an advanced synergic function designed to pro- Globular and Spray transfer range to perform single pass welds (MIG C25 vide the user with a simpli ed set up process by using a combination of process selection).
  • Page 48 Component Identification and Explanation upon the parameter being adjusted, the graphic may change in ap- MIG, Syn. Pulse MIG, TIG and Stick PowerSet information. pearance. For Volts, Amps and Wire Feed Speed, the graphic appears MIG/Flux-Cored: as shown above in the picture. As the user makes progresses further away from the recommended adjustment, the graphic will also change Standard, non-pulse MIG and Flux Cored processes are similar processes color, turning from green to yellow and nally to red.
  • Page 49 Smaller diameter wires need less burn-back time. mance. The highlighted bars will change from green to yellow to red, Inductance. IMPORTANT NOTICE FOR EXISTING EVERLAST MIG as the adjustments made to the recommended setting become less OWNERS AND USERS: Inductance improves the wet-in of the weld. A desirable and less likely to provide satisfactory results.
  • Page 50 Arc Trim setting and exit adjustment mode. Polarity is indicated in 1a 13. Units. Everlast recognizes that there is a need to provide different and will always indicate Positive (+) in Pulse MIG mode. In 1b, the units of measures to different industries and regions of the world.
  • Page 51 Component Identification and Explanation Start/Fill Amps. The Start/Fill Amps settings provide a starting and ending point for Amperage over/under the welding amperage. Start Amperage is typically set higher than the welding Amperage to pro- vide a “Hot Start,” although it can be set lower than the welding Am- perage if needed for special applications.
  • Page 52 Everlast lineup. These highlighted on this machine to remind the user that this unit is DC. settings use a reciprocal value of the other Everlast models. Induct- (This TIG supplies DC output only for TIG. It is not suitable for weld- ance improves the wet-in of the weld.
  • Page 53 Component Identification and Explanation Adjust with right adjustment knob. By default this display area indi- cates the Amperage. In adjustment mode, the function or parameter selected will display and the display numbers/letters will turn red to indicate adjustment mode. After 5 seconds of no input or adjustment of any parameter or function, the selected setting will default back to the amperage reading and return to the default white color.
  • Page 54 Component Identification and Explanation DC Stick: which is a synergic, more automated mode. In PowerSet mode, some functions may not be available for adjustment and will be preset Stick performance relies upon the proper selection of the rod type/class to for best general performance.
  • Page 55 Component Identification and Explanation NOTICE: The following sections cover MIG, Synergic Pulse MIG, TIG, and Stick terms, de nitions, and basic operation. Some of the terms overlap from process to process and serve essentially the same functions. Take note that some terms will repeat from process to process, but will be described in a way that is speci c to the process being used.
  • Page 56 Component Identification and Explanation Using The Trigger/Torch Switch Remote Functions Operating the 2T/4T Remote Function The Remote Torch Control function works with both the MIG and Pulse MIG processes. The MIG Trigger is designed to allow the user to program the welder so that the stages of the weld cycle can be controlled via opera- tion of the torch switch.
  • Page 57 Component Identification and Explanation Using The Trigger/Torch Switch Remote Functions Lift-TIG arc starting requires practice and technique. However, this type of arc-start is used everyday in the eld on steel and stainless. It is a very common way of welding.
  • Page 58 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms EXPLANATION OF GENERAL WELDER FUNCTIONS. 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 Volt and Amp Settings (Short Circuit MIG).
  • Page 59 Component Identification and Explanation comes quickly with a little practice. Pushing can result in shallower pene- MIG and TIG welding requires a well prepped surface to obtain a sound tration but the molten puddle is easier to see and the arc sits easily on the weld.
  • Page 60 Component Identification and Explanation Single Pulse MIG Operation. typically set to 0.0. While one would be led to believe this would be the optimal, best setting, it typically needs to be further adjusted for best performance, operator At its core, Single Pulse MIG function is comprised of 3 parts, Pulse Voltage style, position etc.
  • Page 61 Component Identification and Explanation Spray Arc Transfer. It should be accepted that there may be a slight fall off machine gun, or slow re rattle at lower Amperages. The exact pitch or in travel speed over Spray Arc. There may be a tendency for a user to try sound should not concern the user, unless irregular feeding begins to to achieve faster or similar travel speeds to Spray Arc Transfer by adjusting occur.
  • Page 62 Component Identification and Explanation Key Notes to Remember About Synergic MIG Welding good idea to maintain a straight, even travel forward to maintain maximum weld quality and heat control. If any manipulation is required to ll or · Always adjust Amps before adjusting Arc Trim to control the weld. bridge a gap, use a Z motion and maintain steady forward travel speed.
  • Page 63 Component Identification and Explanation Arc Length and Contact Tip to Work Distance in Welding. Joint Preparation Keeping a tight, short arc for TIG and Stick is important to prevent inclu- sions in the weld, especially while weaving. It helps control the puddle. V-GROOVE (60-80°) DOUBLE V-GROOVE Keep arc length ≤...
  • Page 64 Component Identification and Explanation Drag or Push MIG? MIG Welding is fairly simple. Just keep travel angle and direction in mind when welding. A push angle is often recommended for short circuit MIG and Spray Arc Welding for the least amount of spatter and bead pro le. Push is always recommended for welding Aluminum and Pulsed MIG.
  • Page 65 Component Identification and Explanation The TIG Arc Start is a Live lift type. Starting The Stick Arc. Live Lift Start requires direct, purposeful contact with the surface of the Stick is a fairly simple process. Arc starting can be done with a scratch or metal to create continuity followed by a quick lift-off of the Tungsten to tapping method.
  • Page 66 Component Identification and Explanation Amps (TIG/Stick). Shortened from “Amperes.” Amps is a measurable value Titanium, and more. Not used with Aluminum and Magnesium. For MIG of Current. Amperage is used to refer to the magnitude of Current. Amps this is the standard method of MIG welding with all metals. This is the will also be displayed while actively welding in MIG mode as well instead preferred method of stick welding.
  • Page 67 Component Identification and Explanation operated to provide and stop gas flow. When the tungsten is touched to operating parameters such as Tungsten/Wire/Electrode Diameter, Metal the metal, continuity is sensed and the welder sends welding power as type, and Material Thickness. In return, the unit will provide a usable range soon as the continuity is broken.
  • Page 68 Component Identification and Explanation troller for tong-type Spot welders. through the welders synergic programming. The output of the pulse is based on the Amperage setting of the machine. Pulse is used to control Stitch (MIG/TIG). Whereas the Spot function is an “Arc-On” timer, the heat input without sacri cing travel speed.
  • Page 69 Component Identification and Explanation thickness of metals. Amps are controlled by wire speed, but since both wire type and wire diameter are entered, the machine automatically gures the predicted Weld Amperage. Weld Amperage in Pulse MIG mode can be set by metal thickness similar to TIG and Stick practice. The issue with using wire feed speed in Pulse MIG is that to obtain 100A with .030”...
  • Page 70 Component Identification and Explanation North SN24 SERIES MIG TORCH PARTS BREAKDOWN (MB24KD Style) North SN 24 Series MIG Gun (MB24KD Style) Item Part Number Description 200300 Gas Cone/Nozzle 12.5mm EB2206 Contact Tip .6mm M6x8x26 (.023” Heavy Style) EB2208 Contact Tip .8mm M6x8x28 (.030” Heavy Style) EB2209 Contact Tip .9mm M6x8x28 (.035”...
  • Page 71 Component Identification and Explanation North SN36 SERIES MIG TORCH PARTS BREAKDOWN (MB36KD Style) *Denotes Standard Build for Most Sales Regions...
  • Page 72 DC: 150A @ 60% Duty Cycle Typical Everlast and NOVA Torch Assembly (17,18, 26 Series) (Some parts may not appear exactly the same but are equal in assembly order and type.) Tungsten not included, but available in select Consumable Kits on the website at www.everlastwelders.com.
  • Page 73 Weld is dirty/oxidized, or porous. fan activity. Solenoid is sticking. Listen for audible click of gas solenoid. If no click is heard, then contact Everlast Support. Clean weld properly. Increase pre flow or For Flux Core, a certain amount of spatter, post flow.
  • Page 74 Check gas flow. Adjust for higher flow of gas. Listen for audible click Weld is dirty/oxidized, or porous. activity. Solenoid is sticking. Too short of pre- of gas solenoid. If no click is heard, then contact Everlast Support. Clean flow or post-flow. weld properly. Increase pre flow or post flow.
  • Page 75 Arc length too short with anti-stick turned on. Turn off anti-stick. Unstable Arc. Arc length is too long Shorten arc length and increase arc force. Metal is indirectly connected through table or Connect work clamp directly to item being welded. other item. Other. Contact Everlast.
  • Page 76 If this does not clear after releasing the switch, turn off unit immediately and check torch switch for stuck contact. If the torch trigger is engaged without attempting toweld for more than 3 seconds this will activate. OTHER CONTACT EVERLAST...
  • Page 77 11. Clean bezel vents and fan blades. Fan blades accumulate build-up which can cause reduced cooling ef ciency, vibration and eventually failure. 12. Once cleaned, reassemble unit in reverse order. IMPORTANT: Never remove the front cover or upper operator’s panel unless instructed by Everlast.