Cyclone Push Pull Gun

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


68-P625

Handle Shell R.H.

65-2575


68-P626

Spacer Rubber Tube 5/16x1/2

64-2562


68-P627

Speed Control Knob

64-2575


68-P628

Motor

65-1130AL

Contact Tip HD Al .040

68-P629

Insulating Gasket

65-1135AL


68-P630

Screw Fillister Head

65-1140AL


68-P631

Busing Gas

65-1145AL


68-P632

Bushing Water

65-1152AL


68-P633

Spacer

65-1162AL


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


68-P665

Inlet guide 1.6 Flux core wire

68-P546


68-P666

Housing

68-P547


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