High coefficient of efficiency – producing big push force to the wire with very ...
Saturn mini wire feeder, with the Cyclone gun, the potentiometer controls the wire
...
The Innovation
The Planetics drive feeder transports the wire by means of two hyperbolically profiled rollers that in a planetary manner rotate around the welding wire. The drive power is transmitted from the motor to the rollers and from the rollers to the wire along two opposite lines, thus producing a feeding and straightening effect. The contact pressure of the rollers on the wire is automatically calibrated.
Benefits
High coefficient of efficiency – producing big push force to the wire with very minimum power from the motor. Larger area of contact, meaning big pushing force with less damage to the surface of the wire. Rotational oscillation is exerted on the wire during the process of moving the wire forward, which drastically reduces the friction resistance in the liner. Precision positioning of the electrode “Sick-Out” in the zone of the welding arc. Long life of the contact tip due to the vibration (oscillation) of the wire which results in a continuous multi touching of the contact tip. Increase in productivity over competing feeders. Uniform welding penetration. Low spatters during welding operation.
Features Technical Specifications
Goose necked torch equipped with planetary drive feeder which is universal for feeding wire of any diameter and type of material, without the need to change the feed rollers. WIRE CAPACITY 0.023”-0.045” (0.6mm – 1.2mm) solid hard wire and cored wire 0.33”-1/16” (0.8mm – 1.6mm) aluminum WIRE SPEED 40-800 IPM (1-20mm/min.) WELDING CURRENT RATING: Output @ 100% Duty Cycle Air Cooled 230 Amp Water Cooled 300 Amp
Output @ 60% Duty Cycle Air Cooled Water Cooled
300 Amp 400 Amp
Gun weight (0.69kg) 1.52 lbs. with highly-rated ergonometric comfort for the welder. Welding hose length up to 25 meters (80 feet) 360 degree neck positioning. Most reliable feeding action and straightening effect. Wire feed speed potentiometer in a convenient position as well as an optional second potentiometer for welding voltage. Run-in speed function included in the torch assembly (optional). Works with any planetary or conventional feeder. Option to include very simple synchronizing box for interfacing with conventional feeder.
Support Equipment Required
C.V. or C.C. Power source of sufficient capacity for your needs. Regulated gas supply and hoses. Properly sized power leads from power source to wire feeder and ground. Water source and hose capable of providing an minimum of .5 gal/min. (2L/min.)
Gun Lead Connections
POWER CABLE – AIR COOLED A 500 amp unicable is crimped with an inch and one half copper clamp over a threaded nipple that houses the Hytrel conduit for the liner. The threaded nipple screws securely into the back housing supplying wire and current. A separate gas line connects to barbed gas fitting at the back housing. POWER CABLE – WATER COOLED The Cyclone back housing has three tubes for transmission of water and gas. One water line also supplies the current through a rope copper cable that is secured to the tube with a nut. The other water line is secured over the barbed tube with a crimp. The wire guide tube is connected to the back housing tube with a nut.
Conduit
The Cyclone gun comes standard with a Carbon Teflon conduit, for feeding wire.
Operation General
The Cyclone gun maintains a constant, steady and uniform wire feed speed, regardless of a curved or looped wire conduit. The reason for all this is the planetary drive. Its drive rollers are positioned in such a way that they are at a 90 degree angle to one another which rotate around the electrode wire. There is a large area of contact between rollers and wire in the planetary feeder which means more powerful force transmission, better protection for the surface of the wire and wires are straightened as they leave the rollers. At the same time, a rotational oscillation is exerted upon the wire. This not only moves the wire forwards, but also greatly reduces the frictional resistance in the liner.
Potentiometer
The conveniently located potentiometer allows for adjustments for wire speed from 40-800 IPM. In addition, a second potentiometer can be added for voltage control. When using the Cyclone Saturn mini wire feeder, with the Cyclone gun, the potentiometer controls the wire feed. The wire feed speed on the wire feeder is only functional in the push mode without the Cyclone gun.
Planetary head replacement parts
The Cyclone gun allows for optimally fine tuned wire feeding by sizing the correct spring, inlet and inlet-outlet wire guides for the type of wire being used.
PARTS REPLACEMENT
D E
A B
C
Inlet-outlet guide
G
F
D
1. Remove the adjustable gooseneck via the knurled nut A. 2. Loosen and remove the inlet/outlet guide holder B. 3. Remove the black inlet-outlet guide C and replace with desired size.
Inlet guide replacement
4. Repeat steps 1 and 2 5. Disengage the rollers via the knurled nut D located at the rear of the centrifugal adjustment cone. This is accomplished by rotating the nut clockwise as you hold the front of the gun away from you. This pushes the cone forward and away from you. 6. Uncouple the head from the motor shaft by holding the shaft with an 8mm open end wrench and turning the head clockwise. Be careful as you remove the head not to lose the inlet guide E located in the shaft of the head. Often it falls out or remove the guide with a center tool inserted through the head on the opposite end. Replace with desired size.
Spring replacement 7. After removing the head remove the knurled nut D and remove the cone nut F. Both flats on the cone nut must be in alignment of the centrifugal adjustment arms. Remove the spring G and replace with desired size. 1
X
X + 10MM
Liner replacement
2
1. Stretch the gun cable out straight. Remove the liner retaining nut and pull out old liner. 2. Insert new liner being sure liner is all the way inside of gun. 3. Install liner collet onto liner leaving small length outside of the Central connector. Measure the length of X at 1. Take out the liner and cut the tip (front ) of liner X plus 3/8” at 2. Replace liner and retaining cap.
Feeding wire to gun 1. Remove nozzle and contact tip 2. Stretch the gun cable out straight. 3. Round off the wire tip so it is not sharp 4. Insert wire into Teflon liner at end of gun cable. 5. Open the Planetary head in the gun turning the knurled nut clockwise to press the nut forward. The spring is pressed up. 6. Switch on the wire feeder and pull the trigger. The wire will feed. 7. After the wire comes out of gooseneck replace tip and nozzle. 8. The planetary knurled nut has to be turned back to the motor side and the spring will be depressed.
Accessories Heavy Duty Contact Tips Gas Cooled Wire Size .030” (0.8mm) .035” (0.9mm) .040” (1.0mm) .045” (1.2mm) .052” (1.4mm) 1/16” (1.6mm)
Tip I.D. .040” (1.01mm) .048” (1.22mm) .052” (1.32mm) .060” (1.52mm) .073” (1.85mm) .081” (2.05mm)
Tip Length 1.25” (31.75mm) 1.25” (31.75mm) 1.25” (31.75mm) 1.25” (31.75mm) 1.25” (31.75mm) 1.25” (31.75mm)
Heavy Duty Nozzles Gas Cooled Nozzle Size 1/2” I.D. (1/8” recess) 5/8” I.D. (1/8” recess) 3/4” I.D. (1/8” recess) 5/8” I.D. (1/4” recess) 3/4” I.D. (1/4” recess)
Part Number 65-2550 65-2562 65-2575 *64-2562 64-2575
* Standard
Diffuser Desc. Diffuser A/C Diffuser W/C
Part Number 63-3103-2 63-3101
Head Insulator Desc. Insulator
Part Number 030-0029
Liners Desc. Teflon-Carbon Liner I.D. 2mm Teflon-Carbon Liner I.D. 3mm
Part Number 68-P540 68-P541
Wire Size Wires up to .045” Wires .040” – 1/16”
Part Number 64-1230AL 64-1235AL 64-1240AL *64-1245AL 64-1252AL 64-1262AL
Goosenecks Gooseneck Rotation 45 Degree Gas Cooled 60 Degree Gas Cooled 40 Degree Water Cooled 60 Degree Water Cooled
Part Number 68-P553 68-P555 68-P556 68-P557
Amps 360 360 400 400
Note: Turn off water circulator prior to loosening and removing gooseneck. Be sure power is also off to gun. Loosen gooseneck connector nut just enough so as to turn the gooseneck by hand. Set your position and retighten connector nut. Yes, it is that simple. Danger: Do not attempt to weld without the gooseneck being tightly secured in the gun body, or damage to the gooseneck or body may result.
Maintenance Maintenance of the gun will normally consist of a general cleaning of the head and motor assembly inside the gun housing, including wire guide system, drive rolls and conduit. Normal wear, are the conduit, contact tips, nozzles, diffuser, liners, wire guides and drive rolls. A supply of these parts should be kept on hand for replacement.
Troubleshooting Guide Testing the gun
Motor Check
Remove the 7 pin amphenol connector located at the back end of the leads. To check the Motor set ohm meter on pins 4 and 5. The continuity should read approximately 10 ohms. If an open or short exist, check the motor leads and motor independently.
Testing the Potentiometer
Set your ohm meter on pins 1 and 7. Your ohm reading should range between 0 and 5K as you rotate the potentiometer.
Testing the switch
Set your ohm meter on pins 3 and 7. Pull the trigger switch and your ohm reading should be a low ohm continuity.
Testing the Reed Switch
Set your ohm meter on pins 6 and 7. You should read open. The Reed switch is a normally open switch. When it senses over 500 amps it closes, therefore it should read open in a normal operation.
Diagrams/Parts List
GOOSENECKS (SWIVEL) AMPERAGE PART# O 360A 45 SHORT 360A 60O SHORT 400A 40 4 O W/C 400A 60O W/C
INLET-OUTLET GUIDES DIA 0.6-0.8 (.023-.030 0.9-0.12 (.035-.045) 1.6 (.062) 0.6-0.8 (.023-.030) 0.9-0.12 (.035-.045) 1.6 (.062)
WIRE PART# STEEL 68-P601 STEEL 68-P609 FLUX 68-P610 ALUM. 68-P605 ALUM. 68-P611 ALUM. 68-P612
68-P553 68-P555 68-P556 68-P557
GUIDE HOLDER GAS 68-P615 GUIDE HOLDER WATER 68-P616 GASKET 68-P621 MOTOR CRADLE GAS 68-P618 MOTOR CRADLE WATER 68-P617 NECK CONNECTOR NUT 68-P620
NUT 68-P639
HANDLE SHELL R.H. 68-P625
HOOK 68-P623 SCREW 68-P640
68-P643 SCREWS 2 68-P644 BRUSHES HOLDER FOR RED 68-P645 BRUSHES HOLDER FOR BLK 68-P642 BRUSHES SET 2 BLK 2 RED W/SCREWS 501 PLANETARY HEAD 68-P600
HANDLE COVER 68-P619
MOTOR 68-P628 BUSHING INSULATION SET GAS 68-P636 BUSHING INSULATION SET GAS 68-P637 INSULATING GASKET 68-P629
SCREW 68-P638 BUSNING 68-P631
SCREW 68-P INSULATING GASKET 68-P648 NUT 68-P639
TRIGGER 68-P649 CORK HANDLE PLUG 68-P624
POTENTIOMETER 68-P650 HANDLE SHELL L.H. 68-P622 SPACER RUBBER TUBE 68-P626
SPEED CONTROL KNOB 68-P627 SCREW 68-P641
SCREW 68-P638
Rear End/Parts List (GAS) 68-P542 TC 15’ 2MM ID 68-P543 TC 25’ 2MM ID 68-P546 TC 15’ 3MM ID 68-P547 TC 25’ 3MM ID
POSITIONING NUT 68-P125
COLLET 68-P539
BARB ADAPTOR 68-P127
QUICK CONNECT POWER PIN 68-P125
BALL JOINT 68-P120
OUTSIDE SUPPORT 68-P107
LINER SEE CHART
SPRING CABLE SUPPORT 68-P121
NIPPLE 68-P109
FERRUL 68-P111
RUN-IN MAGNETIC SWITCH NOT SHOWN SEALING RING 68-P123
HOUSING NUT 68-P124
HOUSING POWER PIN EURO 68-P119
UNICABLE 64-7115
Rear End/Parts List (WATER) 68-P542 TC 15’ 2MM ID 68-P543 TC 25’ 2MM ID 68-P546 TC 15’ 3MM ID 68-P547 TC 25’ 3MM ID
POSITIONING NUT 68-P125
QUICK CONNECT POWER PIN 68-P125
BALL JOINT 68-P120
COLLET 68-P539
LINER SEE CHART
BARB ADAPTOR 68-P105B
SPRING CABLE SUPPORT 68-P121
RUN-IN MAGNETIC SWITCH NOT SHOWN SEALING RING 68-P123
HOUSING NUT 68-P124
HOUSING POWER PIN EURO 68-P119
UNICABLE 64-7115
CYCLONE PUSH-PULL WELDING SYSTEM INLET OUTLET GUIDES SATURN FEEDER AND CYCLONE GUN WIRE TYPE 4000 & 5000 AL 4000 & 5000 AL 4000 & 5000 AL 4000 & 5000 AL
DIAMETER MM 0.6-0.8 0.9-1.0 1.2 1.6
INLET GUIDES 68-P659 68-P661 68-P663 68-P664
OUTLET GUIDES 68-P605 68-P606 68-P609 68-P612
TENSION SPRING SELECTION TABLE WIRE TYPE P/N WHITE 68-P654
GUN DRIVE BLUE 68-P655
WHITE 68-P654
FEEDER DRIVE BLUE 68-P655
RED 68-P656
RED 68-P656
4000 ALUM 0.8/1.0MM 1.2/1.6MM
X ---
--X
-----
X ---
--X
-----
5000 ALUM 0.8/1.0MM 1.2MM 1.6MM
-------
X -----
--X X
X -----
--X ---
----X
CYCLONE FRONT TORCH ASSY. SPARE PARTS 65-2550
Nozzle HD 1/2” 1/8” recess
68-P624
Cork, Handle Plug
65-2562
Nozzle HD 5/8” 1/8” recess
68-P625
Handle Shell R.H.
65-2575
Nozzle HD 3/4” 1/8” recess
68-P626
Spacer Rubber Tube 5/16x1/2
64-2562
Nozzle HD 5/8” 1/4” recess
68-P627
Speed Control Knob
64-2575
Nozzle HD 3/4” 1/4” recess
68-P628
Motor
65-1130AL
Contact Tip HD Al .040
68-P629
Insulating Gasket
65-1135AL
Contact Tip HD Al .048
68-P630
Screw Fillister Head
65-1140AL
Contact Tip HD Al .052
68-P631
Busing Gas
65-1145AL
Contact Tip HD Al .060
68-P632
Bushing Water
65-1152AL
Contact Tip HD Al .073
68-P633
Spacer
65-1162AL
Contact Tip HD Al .081
68-P634
Bushing Gas
N/A
Gas Diffuser
68-P635
Bushing Water
N/A
Tip Holder
68-P636
Bushing Insulating set for Gas Cooled
N/A
Insulation Washer
68-P637
Bushing Insulating set for Water Cooled
68-P540
Teflon-Carbon Liner I.D.=2mm O.D.=5.2 MM (up to .045).2m
68-P638
Screw #6-32x1/2
68-P541
Teflon-Carbon Liner I.D.=3mm O.D.=5.2 MM (.040-1/16”).2m
68-P639
Nut #6-32
68-P553
Gooseneck Assy .45 Degree short, gas cooled 300A
68-P640
Screw #6-32x1”
68-P555
Gooseneck Assy .60 Degree short, gas cooled 300A
68-P641
Screw M3x6 Din 913
68-P556
Gooseneck Assy. Cyclone W/C 40 Degree
68-P642
Brushes set (x2) Black + Red with screws plastic set (x2)
68-P557
Gooseneck Assy. Cyclone W/C 60 Degree
68-P643
Screws Plastic set (x2)
68-P647
O-Ring, 6x1, #3578-80
68-P644
Brushes Holder for Red brushes
68-P600
501 Planetary feeding head
68-P645
Brushes Holder for Black brushes
68-P601
Inlet-Outlet guide, 0.6-0.8mm steel wire
68-P602
Inlet-Outlet guide, 0.9-1.0mm steel wire
68-P603
Inlet-Outlet guide, 1.2mm steel wire
68-P604
Inlet-Outlet guide, 1.6mm flux cored wire
68-P605
Inlet-Outlet guide, 0.6-0.8mm alum. wire
68-P025
502BG PP Kit Torch Gas
68-P606
Inlet-Outlet guide, 0.9-1.0 mm alum wire
68-P050
502W PP Kit Torch Water
68-P607
Inlet-Outlet guide, 1.2mm alum. wire
68-P075
Auxillary Transformer
68-P608
Inlet-Outlet guide, 1.6mm alum. wire
68-P100
Dione Control Box
68-P609
Inlet-Outlet guide, 0.9-1.2mm steel wire (verB)
68-P105
Wire Feeder Mini Saturn
68-P610
Inlet-Outlet guide, 1.6mm flux cored wire (verB)
68-P110
Plastic Spool Protector
68-P611
Inlet-Outlet guide, 0.9-1.2mm alum. wire (verB)
68-P612
Inlet-Outlet guide, 1.6mm alum. wire (verB)
68-P613
Bushing, Guide Holder, Gas Cooled
68-P614
Bushing, Guide Holder, Water Cooled
68-P615
Bushing, Ver B Guide Holder Gas Cooled
68-P616
Bushing, Ver B Guide Holder Water Cooled
68-P617
Base Water Motor Cradle
68-P618
Base Gas Motor Cradle Ver B
68-P619
Handle Cover
68-P620
Neck Connector Nut
68-P621
Gasket
68-P622
Handle Shell L.H.
68-P623
Hook, Gun Hanger
Cyclone Main Assemblies
CYCLONE CABLING, REAR END & FEED HEAD CYCLONE Cabling & Rear End Cyclone
Cyclone Feed Head
68-P107
Outside support
68-P652
Nut
68-P117
EURO ADAPTOR PIN, LINCOLN (ALPHA)
68-P653
Cone
68-P118
EURO ADAPTOR PIN, MILLER (ALPHA)
68-P654
Spring (White) (1mm, 040 wire)
68-P119
Euro Handle Shell, gas cooled
68-P655
Spring (Blue) (1.2mm, 040 wire)
68-P120
Ball Joint, gas cooled
68-P656
Spring (Red) (1.2mm, 045 wire)
68-P121
Spring, Cable Support
68-P657
Spring (Black) (Steel wire)
68-P122
Screw for handle clamshell
68-P658
Inlet guide 0.6-0.8 Steel wire
68-P123
Sealing Ring for handle clamshell
68-P659
Inlet guide 0.6-0.8 Al wire
68-P124
Connector Nut, Euro
68-P660
Inlet guide 0.9-1.0 Steel wire
68-P125
Quick connect power pin eruo
68-P661
Inlet guide 0.9-1.0 Al wire
68-P538
Liner positioning nut
68-P662
Inlet guide 1.2 Steel wire
68-P539
Collet
68-P663
Inlet guide 1.2 Al wire
68-P542
Teflon-carbon liner 15’ 2mm ID
68-P664
Inlet guide 1.6 Al wire
68-P543
Teflon-carbon liner 25’ 2mm ID
68-P665
Inlet guide 1.6 Flux core wire
68-P546
Teflon-carbon liner 15’ 3mm ID
68-P666
Housing
68-P547
Teflon-carbon liner 25’ 3mm ID
68-P667
Arm Assembly
68-P670
Clamp
68-P668
Pin 1.5x13.8
64-7115
Unicable
68-P669
Spring
68-P674
Sheathing (alternate “sheathing small”)
68-P670
Gear-set Assy.
68-P671
{om 1.5x9.8
68-P672
Bearing 681xyz
68-P673
Arm
68-P674
Pin 4x15.8
68-P675
Spacer
68-P676
Roller
68-P677
Piston
Ordering Information
MIG Feeder with Control (CV Version) Includes control module, planetary drive unit set up for .045 in./1.2mm 5000 aluminum wire, spool cover, gas hose fitting, and .045/1.2mm inlet/out guides (installed).
Gun Selection
Ready-to-Weld Air/Water-Cooled gun assemblies for 4000/5000 series aluminum wire, include tension spring, liners, gooseneck, nozzle and contact tip.
Cyclone Push Pull Gun Numbering System Gun Amperage
Push Pull
P
G
M
36 40
Gun G - Gas W - Water
15
45
Length
Power Pins
15 - 15 ft. 25 - 25 ft. 50 - 50 ft.
T - Tweco E - Euro M - Miller LN - Lincoln
Wire Size 23-.023 (0.6mm) 30-.030 (0.8mm) 35-0.35 (0.9mm) 40-.040 (1.0mm) 45-.045 (1.2mm) 52-.052 (1.4mm) 116-116 (1.6mm)
Specifications
MIG Wire Feeder Wire Diameter Capacity Steel/Stainless Steel…................ .030 - .045 in. (0.8 - 1.2mm) Aluminum…………...............… .030 - 1/16 in. (0.8 - 1.6mm) Flux Cored…………................... .030 - .045 in. (0.8 - 1.2mm) Input Voltage…………………... 42 vac
Air-Cooled & Water-Cooled Guns Gas-Cooled
Mixed Gas..........................Pure Argon 360 Amp (60%).................230 Amp (100%)
Water-Cooled
Mixed Gas..........................Pure Argon 400 Amp (100%).................350 Amp (100%)
American Torch Tip 6212 29th Street East Bradenton, FL 34203 Phone: 941-753-7557 E-mail:
[email protected] Webiste: americantorchtip.com Rev 4 1/ 18/ 2008