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 coeffi cient of effi ciency 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 s during welding operation. Features Technical Specifi cations 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 Output @ 60% Duty Cycle Air Cooled 230 Amp Air Cooled 300 Amp Water Cooled 300 Amp Water Cooled 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 A B D E C G F D Inlet-outlet guide 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 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. 2 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 Tip I.D. Tip Length Part Number.030 (0.8mm).040 (1.01mm) 1.25 (31.75mm) 64-1230AL.035 (0.9mm).048 (1.22mm) 1.25 (31.75mm) 64-1235AL.040 (1.0mm).052 (1.32mm) 1.25 (31.75mm) 64-1240AL.045 (1.2mm).060 (1.52mm) 1.25 (31.75mm) *64-1245AL.052 (1.4mm).073 (1.85mm) 1.25 (31.75mm) 64-1252AL 1/16 (1.6mm).081 (2.05mm) 1.25 (31.75mm) 64-1262AL Heavy Duty Nozzles Gas Cooled Nozzle Size Part Number 1/2 I.D. (1/8 recess) 65-2550 5/8 I.D. (1/8 recess) 65-2562 3/4 I.D. (1/8 recess) 65-2575 5/8 I.D. (1/4 recess) *64-2562 3/4 I.D. (1/4 recess) 64-2575 * Standard Diffuser Desc. Part Number Diffuser A/C 63-3103-2 Diffuser W/C 63-3101 Head Insulator Desc. Part Number Insulator 030-0029 Liners Desc. Part Number Wire Size Tefl on-carbon Liner I.D. 2mm 68-P540 Wires up to.045 Tefl on-carbon Liner I.D. 3mm 68-P541 Wires.040 1/16
Goosenecks Gooseneck Rotation Part Number Amps 45 Degree Gas Cooled 68-P553 360 60 Degree Gas Cooled 68-P555 360 40 Degree Water Cooled 68-P556 400 60 Degree Water Cooled 68-P557 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# 360A 45 O SHORT 68-P553 360A 60 O SHORT 68-P555 400A 40 O W/C 68-P556 400A 60 O W/C 68-P557 INLET-OUTLET GUIDES DIA WIRE PART# 0.6-0.8 (.023-.030 STEEL 68-P601 0.9-0.12 (.035-.045) STEEL 68-P609 1.6 (.062) FLUX 68-P610 0.6-0.8 (.023-.030) ALUM. 68-P605 0.9-0.12 (.035-.045) ALUM. 68-P611 1.6 (.062) ALUM. 68-P612 GUIDE HOLDER GAS 68-P615 GUIDE HOLDER WATER 68-P616 GASKET 68-P621 NECK CONNECTOR NUT 68-P620 NUT 68-P639 MOTOR CRADLE GAS 68-P618 MOTOR CRADLE WATER 68-P617 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 HANDLE COVER 68-P619 501 PLANETARY HEAD 68-P600 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 NUT 68-P639 SCREW 68-P INSULATING GASKET 68-P648 CORK HANDLE PLUG 68-P624 TRIGGER 68-P649 SCREW 68-P638 POTENTIOMETER 68-P650 HANDLE SHELL L.H. 68-P622 SPACER RUBBER TUBE 68-P626 SPEED ED CONTROL KNOB 68-P627 SCREW 68-P641
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 LINER SEE CHART QUICK CONNECT POWER PIN 68-P125 BARB ADAPTOR 68-P127 BALL JOINT 68-P120 SPRING CABLE SUPPORT 68-P121 OUTSIDE SUPPORT 68-P107 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 COLLET 68-P539 LINER SEE CHART QUICK CONNECT POWER PIN 68-P125 BARB ADAPTOR 68-P105B BALL JOINT 68-P120 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 DIAMETER MM INLET GUIDES OUTLET GUIDES 4000 & 5000 AL 0.6-0.8 68-P659 68-P605 4000 & 5000 AL 0.9-1.0 68-P661 68-P606 4000 & 5000 AL 1.2 68-P663 68-P609 4000 & 5000 AL 1.6 68-P664 68-P612 TENSION SPRING SELECTION TABLE WIRE TYPE P/N GUN DRIVE FEEDER DRIVE WHITE BLUE RED WHITE BLUE RED 4000 ALUM 68-P654 68-P655 68-P656 68-P654 68-P655 68-P656 0.8/1.0MM X --- --- X --- --- 1.2/1.6MM --- X --- --- X --- 5000 ALUM 0.8/1.0MM --- X --- X --- --- 1.2MM --- --- X --- X --- 1.6MM --- --- X --- --- X
CYCLONE FRONT TORCH ASSY. SPARE PARTS 65-2550 Nozzle HD 1/2 1/8 recess 65-2562 Nozzle HD 5/8 1/8 recess 65-2575 Nozzle HD 3/4 1/8 recess 64-2562 Nozzle HD 5/8 1/4 recess 64-2575 Nozzle HD 3/4 1/4 recess 65-1130AL Contact Tip HD Al.040 65-1135AL Contact Tip HD Al.048 65-1140AL Contact Tip HD Al.052 65-1145AL Contact Tip HD Al.060 65-1152AL Contact Tip HD Al.073 65-1162AL Contact Tip HD Al.081 N/A Gas Diffuser N/A Tip Holder N/A Insulation Washer 68-P540 Tefl on-carbon Liner I.D.=2mm O.D.=5.2 MM (up to.045).2m 68-P541 Tefl on-carbon Liner I.D.=3mm O.D.=5.2 MM (.040-1/16 ).2m 68-P553 Gooseneck Assy.45 Degree short, gas cooled 300A 68-P555 Gooseneck Assy.60 Degree short, gas cooled 300A 68-P556 Gooseneck Assy. Cyclone W/C 40 Degree 68-P557 Gooseneck Assy. Cyclone W/C 60 Degree 68-P647 O-Ring, 6x1, #3578-80 68-P600 501 Planetary feeding head 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 fl ux cored wire 68-P605 Inlet-Outlet guide, 0.6-0.8mm alum. wire 68-P606 Inlet-Outlet guide, 0.9-1.0 mm alum wire 68-P607 Inlet-Outlet guide, 1.2mm alum. wire 68-P608 Inlet-Outlet guide, 1.6mm alum. wire 68-P609 Inlet-Outlet guide, 0.9-1.2mm steel wire (verb) 68-P610 Inlet-Outlet guide, 1.6mm flux cored wire (verb) 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 68-P624 Cork, Handle Plug 68-P625 Handle Shell R.H. 68-P626 Spacer Rubber Tube 5/16x1/2 68-P627 Speed Control Knob 68-P628 Motor 68-P629 Insulating Gasket 68-P630 Screw Fillister Head 68-P631 Busing Gas 68-P632 Bushing Water 68-P633 Spacer 68-P634 Bushing Gas 68-P635 Bushing Water 68-P636 Bushing Insulating set for Gas Cooled 68-P637 Bushing Insulating set for Water Cooled 68-P638 Screw #6-32x1/2 68-P639 Nut #6-32 68-P640 Screw #6-32x1 68-P641 Screw M3x6 Din 913 68-P642 Brushes set (x2) Black + Red with screws plastic set (x2) 68-P643 Screws Plastic set (x2) 68-P644 Brushes Holder for Red brushes 68-P645 Brushes Holder for Black brushes Cyclone Main Assemblies 68-P025 502BG PP Kit Torch Gas 68-P050 502W PP Kit Torch Water 68-P075 Auxillary Transformer 68-P100 Dione Control Box 68-P105 Wire Feeder Mini Saturn 68-P110 Plastic Spool Protector
CYCLONE CABLING, REAR END & FEED HEAD CYCLONE Cabling & Rear End Cyclone Cyclone Feed Head 68-P107 Outside support 68-P117 EURO ADAPTOR PIN, LINCOLN (ALPHA) 68-P118 EURO ADAPTOR PIN, MILLER (ALPHA) 68-P119 Euro Handle Shell, gas cooled 68-P120 Ball Joint, gas cooled 68-P121 Spring, Cable Support 68-P122 Screw for handle clamshell 68-P123 Sealing Ring for handle clamshell 68-P124 Connector Nut, Euro 68-P125 Quick connect power pin eruo 68-P538 Liner positioning nut 68-P539 Collet 68-P542 Tefl on-carbon liner 15 2mm ID 68-P543 Tefl on-carbon liner 25 2mm ID 68-P546 Tefl on-carbon liner 15 3mm ID 68-P547 Tefl on-carbon liner 25 3mm ID 68-P670 Clamp 64-7115 Unicable 68-P674 Sheathing (alternate sheathing small ) 68-P652 Nut 68-P653 Cone 68-P654 Spring (White) (1mm, 040 wire) 68-P655 Spring (Blue) (1.2mm, 040 wire) 68-P656 Spring (Red) (1.2mm, 045 wire) 68-P657 Spring (Black) (Steel wire) 68-P658 Inlet guide 0.6-0.8 Steel wire 68-P659 Inlet guide 0.6-0.8 Al wire 68-P660 Inlet guide 0.9-1.0 Steel wire 68-P661 Inlet guide 0.9-1.0 Al wire 68-P662 Inlet guide 1.2 Steel wire 68-P663 Inlet guide 1.2 Al wire 68-P664 Inlet guide 1.6 Al wire 68-P665 Inlet guide 1.6 Flux core wire 68-P666 Housing 68-P667 Arm Assembly 68-P668 Pin 1.5x13.8 68-P669 Spring 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 fi tting, 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 Gun G - Gas W - Water P G M Power Pins T - Tweco E - Euro M - Miller LN - Lincoln 36 40 15 45 Length 15-15 ft. 25-25 ft. 50-50 ft. 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) Specifi cations 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: Sales@attcusa.com Webiste: americantorchtip.com Rev 4 1/ 18/ 2008