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Everlast CYCLONE 140E - User Manual

Everlast CYCLONE 140E
34 pages
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Operators Manual
Publish Date: March 2021
EVCY140E2021 Rev. 1
USA/North America
©Everlast Power Equipment
GMAW
FCAW
120V
1 Phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide
FUNCTION: 140A MIG Welder with PowerSet Mode
PURCHASE DATE:
WELDER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:
MIG
Flux-Cored
Spool-Gun
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Summary

Support and Warranty Information

Warranty Details by Region

Explains warranty coverage and policies for USA and Canada, directing users to specific web links for full details.

US Contact Information

Provides phone numbers and email addresses for US technical support, welding support, and sales.

Canadian Contact Information

Provides phone numbers and email addresses for Canadian technical support and sales.

International Contact Information

Guides users in other regions on how to find relevant contact details via the website or US office.

Safety Warnings and Precautions

Pacemaker Interference Warning

Warns about High Frequency energy interfering with pacemakers and advises consulting a physician.

Eye and Skin Protection

Emphasizes using safety glasses, welding helmets, and protective clothing to prevent eye damage and injury.

Electrical Shock and Fire Hazards

Details risks of electrocution, keeping equipment dry, avoiding wet areas, and fire prevention measures.

Gas Cylinder Handling and Safety

Provides guidelines for safely handling, storing, and transporting gas cylinders, including capping and checking for leaks.

Health and Environmental Safety

Inhalation Hazards and Ventilation

Discusses inhalation hazards from welding fumes, toxic gases, and the need for adequate ventilation and medical advice.

Chemical Solvent Hazards

Warns against using chlorinated solvents like brake cleaner due to the risk of producing lethal phosgene gas.

Pacemaker Safety Precautions

Reaffirms pacemaker warnings, detailing risks from High Frequency and electromagnetic fields during welding.

Machine Guards and Safety Shields

Stresses the importance of keeping all safety guards and shields in place and not modifying them.

Operational Safety Precautions

Trip Hazards and Hot Metal Safety

Covers awareness of trip hazards and precautions for handling hot metal after welding.

UV Radiation and EMF Exposure

Details protection needed from UV radiation and precautions regarding electromagnetic fields.

Work Area Safety: Bystanders and Pets

Advises on keeping the work area clear of unauthorized persons, pets, and children.

Generator and Extension Cord Usage

Generator Power Requirements

Specifies requirements for generator power output, THD, and types of generators to use or avoid.

Generator Operation Best Practices

Provides guidelines on starting/stopping generators, ECO mode, and RPM management.

Extension Cord Guidelines

Recommends specific gauge and maximum length for extension cords to ensure safe operation.

Product Specifications

Technical Specifications List

Lists detailed technical specifications of the welder, including voltage, current, duty cycle, dimensions, and more.

Duty Cycle Explanation

Explains how duty cycle is measured, factors affecting it, and the unit's thermal protection mechanism.

Breaker Sizing and Wiring

Details electrical requirements, NEC guidelines, and recommendations for proper breaker and wire sizing.

Understanding Duty Cycle

Duty Cycle Definition and Operation

Defines duty cycle, explains the unit's heat sensor, and how to manage over-temperature conditions.

Impact of Repeated Overheating

Warns that repeatedly triggering duty cycle protection can shorten the unit's lifespan and weaken components.

Initial Setup and Preparation

Unpacking and Inspecting the Unit

Guides users on how to unpack the welder, inspect contents, and report any issues within 72 hours.

Checking for Gas Leaks

Provides instructions on how to test for gas leaks using soapy water or leak solution.

Work Area Setup: Welder Placement

Advises on positioning the welder away from the work area to prevent turbulence and ensuring adequate cooling space.

Electrical Connection

Outlet Wiring Requirements

Emphasizes consulting electricians and following NEC codes for dedicated 120V circuits for welders.

Extension Cord Usage Guidelines

Details recommended extension cord gauge and length limitations for safe and proper welder operation.

Shielding Gas Setup

Choosing the Right Shielding Gas

Explains gas options for MIG (GMAW) and notes that flux-cored wire is gasless.

Regulator Connection Procedure

Details steps for connecting the regulator to the cylinder and the unit, including checking fittings.

Adjusting Gas Flow Rate

Guides on setting the gas flow rate using the regulator adjustment knob and checking the flow meter.

Regulator Adjustment and Gas Flow

Fine-Tuning Gas Flow Rate

Explains how to adjust gas flow for different conditions and when to replace cylinders.

Cylinder Valve Safety Warning

Warns about properly closing the main cylinder valve when not in use to prevent gas accumulation.

Wire Feed and Gun Setup

MIG Gun Installation and Testing

Guides on installing the MIG gun, connecting it, and testing wire feed operation.

Polarity Selection for MIG;Flux-Cored

Explains how to select the correct polarity for MIG (Gas) and Flux-Cored (Gasless) welding processes.

Wire Spool and Gun Configuration

Installing the Wire Spool

Details the correct assembly and installation of the wire spool, including collar orientation.

Wire Spool Direction and Rotation

Illustrates the correct direction of wire unwrapping and spool rotation for proper feeding.

Choosing a Spool Gun

Discusses the SM100N spool gun for extended reach, especially for Aluminum and Stainless.

Drive Rolls and Wire Feeding

Drive Roll Identification and Replacement

Explains how to identify, select, and change drive rolls based on wire size and type.

Guiding Wire Through Feeder and Gun

Provides instructions on feeding the wire from the spool through the feeder mechanism and MIG gun.

MIG Gun Assembly and Wire Installation

Details the process of assembling the MIG gun components and installing the wire.

Wire Tensioning and Trim

Trimming Wire Before Welding

Instructs on trimming the wire to the correct length (1/4"-3/8") for optimal arc starts.

Tensioning Drive Roll Pressure

Explains how to adjust drive roll tension for proper wire feeding, using a wood block test.

Front Panel Components

Component Identification and Function

Identifies and explains the function of each numbered component on the front panel of the welder.

Rear Panel Components

Component Identification and Function

Identifies and explains the function of each numbered component on the rear panel of the welder.

Control Panel Layout and Functions

Understanding Control Panel Elements

Identifies and explains the purpose of each control and display on the welder's front panel.

Manual Welding Mode

Using Manual Mode and Controls

Explains how to operate the welder in manual mode, adjusting wire feed speed and voltage.

Manual vs. PowerSet Mode Choice

Compares Manual and PowerSet modes, guiding users on which mode to choose based on experience.

PowerSet Welding Mode

Using the PowerSet Mode

Guides users on selecting gas type, wire diameter, and metal thickness for automatic setting generation.

Understanding PowerSet Functionality

Explains what PowerSet mode is and how it simplifies setting selection for users.

PowerSet Mode Features and Limitations

Blocked Settings in PowerSet Mode

Explains reasons why certain settings might be unavailable or blocked in PowerSet mode.

Applicable Metals and Limitations

Details which metals are supported by PowerSet and discusses its operational limitations.

PowerSet Mode Settings Chart

Recommended and Range Settings Table

Provides a chart of recommended Wire Feed Speed (WFS) and Voltage ranges for various gas types, wire sizes, and metal thicknesses.

Welder Functions and Operation

Understanding Voltage and Wire Feed Speed

Explains the role of voltage in weld bead profile and wire feed speed in controlling amperage and penetration.

Starting the Arc and MIG Process

Guides on the initial steps for starting an arc, including trimming wire and gun positioning.

Welding Techniques and Best Practices

Gun Angle and Travel Direction

Discusses the effects of pushing or pulling the gun and proper angle for different welding scenarios.

Metal Preparation and Cleaning

Emphasizes the importance of cleaning metal surfaces for sound welds, especially for MIG and TIG.

Multiple Pass Welding Guidelines

Advises on using multiple passes for thicker materials and the benefits for weld quality.

Advanced Welding Concepts

Multi-Pass Weld Application

Details when to use multiple passes for welds over 1/4 inch thickness and the benefits.

Weld Joint Types and Preparation

Describes various weld joint types (V-groove, U-groove, etc.) and preparation methods for best results.

MIG Welding: Push vs. Drag Technique

Understanding Push and Drag Angles

Explains the correct gun angles (push, drag, vertical) for different welding processes and materials.

Troubleshooting Error Codes

Interpreting Error Codes and Diagnoses

Lists common error codes displayed by the unit and provides corresponding diagnostic information and solutions.

Troubleshooting Common Welding Issues

Identifying and Resolving Welding Problems

Provides a table of common welding issues, their possible causes, and recommended solutions.

Everlast CYCLONE 140E Specifications

General IconGeneral
Input Voltage120V
Input PhaseSingle Phase
Welding ProcessesStick (SMAW), TIG (GTAW)
Amperage Range10-140A
Duty Cycle @ 140A30%
Electrode Size Range1/16"

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