Instruction Manual 599 - D/F Machine Specialties, Inc.
Contents
1. 1 8 H C 13469 13468 LF 74 Casing to Feeder Accepts Linde Outlet Guide D F Insert 035 045 Hard 045 1 16 Hard 5 64 3 32 Cored 13080 5 64 1 8 H C 13079 PA 10 030 3 32 H C AL Requires 5 64 1 8 H C 16568 Inlet Miller 030 3 32 H C AL 16557 50 Series 5 64 1 8 H C OTC Requires 030 1 8 18268 Insert 030 1 8 18275 3 64 1 16 AL CMRE 741 S 18282 18282 Panasonic PME 12X 030 1 16 13090 13466 Requires Inlet Lincoln 030 3 32 H C AL Mavrix YWS5OAKW1 030 1 16 030 3 32 H C AL 13479 s 13480 5 64 1 8 H C 13469 13468 030 3 32 H C AL Requires Liner 13486 5 64 1 8 H C Requires Inlet 13486 Stub liners only required in feeder adapter when single piece casing is used TWECO Welding Alloys TROUBLESHOOTING POROSITY SUMMARY NOTE Most POROSITY is caused by gas problems followed by base metal contamination Possible Solutions a Remove contamination clean surfaces b Use of specific wire gas mix for specific types of impurities a Replace wire b Install wire cleaning system c Prevent industrial dust dirt grit from contaminating wire dur ing storage or use d Prevent build up of aluminum oxide on exposed aluminum wire surface by using up quickly e Remove wire from wire drive unit and store in a sealed plas tic bag when not in use for long periods a Protect2. amp ASSEMDIY cccccccecceeeceeeeeeceeeeeeeeeeeseeeaees 6 7 How Do Cut Fit and Install a New Liner cca ceceeecececeaeavaeeceseeeaeaeaeeenees 8 What is the Proper Use of the Nozzle Thread Chaser Tap ccccecsecseeeeeeeeeeeeees 9 Disassembly Assembly 10 Direct Mount Machine Barrels 5 amp 8 Parts eccceccceeeceeeseeeeeeeeseeeseeeseeeseeesees 11 Direct Mount Machine Barrels A5 amp A8 Parts 2 0 0 0 ccccccccecce cece eeceeeeseeeseeeseeeseeesees 12 Table 3 Current TOS cccctnncerroeseeunnnsanacaenonnecndecanhanemeretianaes ciasaeantonnetandseamnaanenesmtasewertns 13 Complete Assemblies amp Utilities NCM Slip In Current 14 Complete Assemblies amp Utilities HTM Threaded Current 15 16 Transfer Fitting D F 40025 Installation 4044 eecceeeeeeceeeceeeseeeeeeseeeseeeseesaees 17 Feeder Adapters 18 Troubleshooting eg arenes 19 22 SAFETY MEASURES PLEASE READ Welding is not particularly hazardous when certain safety practices are followed Anyone using this equipment should be thoroughly trained in safe welding practices Failure to observe safe practices may cause serious injury Handling welding torches presents no dan ger if the appropriate safety regulations are strictly adhered to For example Starting up procedures must be reserved for those fully conversant wi
3. force take 7 Long 1 2 Open Ended Wrench place it on the adapter and push it down counter clockwise securing the adapter to the inner body see 7 B C This is used on the inner body s gas fitting to secure the gas hose to the torch s inner body A crescent wrench could be used in stead but due to the large size of crescent wrenches we prefer the smaller size of the open ended wrenches Long 1 2 amp 9 16 Open Ended Wrench A This is used to secure the water out amp power cable to the torch s inner body A medium size adjustable crescent wrench could be used as well We prefer the use of the larger wrenches on the power cable fitting to ensure that there are no water leaks and that it has been seated correctly see 6 A B This wrench is also used to secure the adapter and jam nut to the inner body see 6 B C This is used to secure the gas hose to the torch s inner body A crescent wrench could be used instead but due to the large size of crescent wrenches we prefer the smaller size of the open ended wrenches Adjustable Crescent Wrench A medium size adjustable crescent wrench could be used as well We prefer the use of the larger wrenches on the power cable fitting to ensure that there are no water leaks and that it has been seated correctly CAUTION Never use excessive force with large wrenches for you could twist or break parts Standard Flat Head Screwdriver This is used to tighten or secure the torc
4. perpendicular to the spigots e Over tightening of the vice can cause damage in general Remove the tip from the front of the torch before tapping Lightly lubricate the nozzle and nozzle thread chaser tap before tapping Be sure to start the tap very carefully Do not cross thread the nozzle Be very careful to start threads correctly Only tap 1 2 turn at a time always backing up and removing chips 1 2 cycle at a time before moving forward Do not try to tap further into the water cooled nozzle than needed or past the factory thread depth Blow out the nozzle after tapping Wire brush and blow off the gas cup before threading it back into the nozzle nozzle is badly deformed or damaged please return to the factory for a repair estimate before disposing of product damaged parts can often be repaired 1 ORDERING INFORMATION NOZZLE THREAD CHASER TAPS USED WITH USED FOR CODE NO DESCRIPTION NOZZLE ASSEMBLY GAS NOZZLE Nozzle Thread Chaser Tap 13197 for Standard A C amp W C 16184 Nozzle Assembly Front 11117 45101 11118 45102 11119 45103 45114 45107 NCC N HTC N NCC LRN HTC LRN Nozzle Thread Chaser Tap for BIG MIG amp BIG TIG Nozzle Assembly Front Nozzle Thread Chaser Tap for Nozzle Body Assembly Rear for Series A High Capacity 11138 45121 Nozzle Assembly Front 45127 11132 45129 45125 Nozzle Thread Chaser Tap 13198 10379 for Nozzle Body Assembly Front 0 Nozzle Thread Chaser Tap 11142 4512
5. Gun cable is arranged in a straight line free from twists when installing a new wire liner Sometimes on longer conduits casings and liners it may take 2 people together one on each end to rotate and twist the conduit casing to get the liner trough the torch you have any troubles getting a liner through a torch make sure you have a good sharp cut off and if you have to you can gently sand the end of the liner on a belt sander You can remove the cast in the aluminum liner by pre bending and straightening the liner before loading After the new liner comes out the end of the torch you want to cut the new liner off flush with the end of the copper gas nozzle or Cu gas cup Now you have the overall length of the liner you still have to take out the length of the contact tip Carefully remove the liner one more time After removing the liner hold the gun end of the liner up against the tip Cut off the length off the tip plus the set back of the tip 1 8 or 3 8 tip setbacks Now that you have cut off the length of the tip plus the setback you may install the new liner and it will back up into the back of the tip chamfer We always recommend checking the condition of the insulation tube in the front of the torch and collet nut that holds the slip in tip We always recommend replacing the spatter disc gas diffuser contact tip and nozzle after installing a new liner Tighten the flat head set screw in the inner body or t
6. Nozzle Dia 1 125 12 312 Standard 8 Series A 8 Nozzle Series A8 Dia 1 445 UTILITY STATION STANDARD ORDERING INFORMATION DIMENSION SPECIFICATIONS Base Length Overall Length Base Width 2 25 Description C Utility Station Utility Station Dual Power Cable 45188 Overall Width 25 Overall Height 29 Overall Weight 35 UTILITY STATION SIDE VIEW WITH COVER D F TORCH CONNECTION 5 75 Water In Hose Water Out amp Power Cable 5 125 3 8 FROM LEFT D F TORCH CONNECTION CUSTOMER UTILITIES CONNECTION FROM RIGHT CUSTOMER UTILITIES CONNECTION Water Out Water In Water Out amp 0 P Cable S Water Out Water In 3 8 Hose Shank Voltage seats Shielding Gas 3 16 Hose Shank Cear Se g Iding G ielding Gas OPANG 3 16 Hose Shank Cable H 1 125 k 2 75 2 ea 1 4 20 Screws lt a Lock Washers cs 6 gy 1 395 1 410 Measure from Top of Nylon Collar to Top of Stainless Transfer Fitting TRANSFER FITTING D F 40025 INSTALLATION Each D F torch requires 2 of the D F Transfer Fitting part 40025 When a torch bumps into something or crashes this is the part that is designed to break to hopefully protect the rest of the torch from being destroyed We recommend having at least 2 of them in stock for every torch for extra security This is also the part of the torch that transf
7. Spool W C T 8 Noz 14712 Socket Set Screw 40022 Spring 40023 Ball 40024 Seat 14180 Body Liner 030 035 Hard Cored 14181 Body Liner 035 045 Hard Cored 14182 Body Liner 045 1 16 Hard Cored 14200 Body Liner 030 035 Soft 14201 Body Liner 3 64 Soft 14203 Body Liner 1 16 Soft 14205 Body Liner 3 32 Soft 6 14186 Body Liner 564 1 8 Hard Cored ee 13921 O Ring 4 req d 40025 Transfer Fitting 40010 Insulating Collar 13912 Internal O Ring 12516 External O Ring 40003 Nut 45127 Water Cooled Nozzle A5 High Capacity ONLY 48184 Water Cooled Nozzle A5 High Capacity COMPLETE Consists of W C Nozzle 45127 Nut Transfer Fittings Insulating Collar Insulation Tube Collet Nut Current Tip Support Tube Gas Nozzle Spatter Disc and Wrench Water Cooled Nozzle A8 High Capacity ONLY Water Cooled Nozzle A8 High Capacity COMPLETE Consists of W C Nozzle 45129 Nut Transfer Fittings Insulating Collar Insulation Tube Collet Nut Current Tip Support Tube Gas Nozzle Spatter Disc and Wrench Insulation Tube For Series A5 Nozzle Insulation Tube For Series A8 Nozzle Spatter Disc Support Tube A5 8 A8 Nozzles Collet Nut Current Tip 5 16 Slip In see p 9 Table 3 Current Tip 7 16 Threaded see p 9 Table 3 Gas Nozzle see p 5 Table 2 Wrench Nozzle Thread Chaser Tap Alignment Tube Slip In Tip Series A5 Noz 035 1 16 Alignment Tube T
8. of wire feeder and inlet as needed must be speci fied when ordering If special welding tools or ac cessories other than those listed previously are required please consult with the factory FEEDER ADAPTER INLETS Steel Brass Nylon Wire Size Code Code No Code No 030 035 045 052 1 16 5 64 3 32 7164 1 8 3 64 AL 1 16 AL 3 32 AL Esab Hobart Lincoln Linde Miller OTC Pana sonic ABB Fanuc Kuka Mavrix Motoman Ther mal Arc TWECO amp Welding Alloys are registered trademarks of their respective companies Names are mentioned for reference only D F Machine Specialties is in no way affiliated with these companies WIRE FEEDER ADAPTERS amp INLETS Direct Mount Remote Mount Adapter Adapter Manufac Models Wire Diameter turer Hardt Faas Stub Hard Cored or AL Liner or AL D20 20mm 030 3 32 H C AL 8 13096 5 64 1 8 H C 13099 13097 All 030 3 32 H C AL 13067 13068 Models 5 64 1 8 H C 16087 LN 7 LN 8 030 3 32 H C AL 13110 13113 NA5 R 5 64 1 8 H C 13112 13116 LN 9 030 3 32 H C AL 5 64 1 8 H C NA3 5 030 3 32 H C AL 9 i 16880 5 64 1 8 H C 16878 16881 ESAB ESAB Hobart Lincoln 030 3 32 H C AL 16879 16888 5 64 1 8 H C 16878 16888 Power Feed 030 3 32 H C AL 13479 13480 10 LF 72 5 64
9. stick out the current is re duced and the arc voltage rises giving a longer unstable arc and increased spaitter Check for correct polarity Follow the electrode manufacturer s recommendations TROUBLESHOOTING SPATTER Problems Causes SPATTER Too fast or too slow wire feed for the arc voltage Too long an arc Damaged current tip Inclination of welding gun too great Faulty power source Incorrect start Incorrect pulse parameters Uneven wire feed Impurities on the base metal Poor ground contact Too long stick out short arc welding Incorrect polarity TROUBLESHOOTING GENERAL GUIDE Possible Solutions Check that the feed roll size is correct for the wire size being used Increase the drive roll pressure until the wire feed is even Do not apply excessive pressure as this can damage the wire surface causing copper coating to loosen from steel wires or metal shavings to be formed from soft wires like aluminum These metal fragments or shavings can be drawn into the wire feed conduit and will rapidly clog the liner When welding with flux cored wires excessive drive roll pressure may open the wire seam and allow flux or metal powders to escape a Dust particles of copper drawing lubricants metal or flux and other forms of contamination can all clog the liner so that the wire feed is slowed or impeded A liner that has been in use for an extended period of time becomes worn and filled with dirt and must
10. 0 14617 Nozzle Thread Chaser Tap 41667 for Tandem Nozzle 41668 Assembly Front DISASSEMBLY To remove the Water Cooled Nozzle from the Docking Spool proceed as follows 1 Remove the forward gas nozzle 2 Next with the wrench remove the collet nut and current tip This will allow the insulation tube spatter disc and support tube to be removed 3 Unscrew the cone nut which fastens the Water Cooled Nozzle assembly to the Docking Spool body of the torch The Water Cooled Nozzle may now be pulled from the Docking Spool 4 If damaged the water transfer fittings may be removed from the Water Cooled Nozzle with a 7 16 open end wrench Transfer fittings are not designed to be reused If you do not have any spares and are forced to reuse a transfer fitting you must use Loc Tite to reseal the threads Examine the O rings on the water transfer fittings Make replacement if necessary Lubricate the O rings with silicone lubricant See page 17 for directions on achieving correct transfer fitting height 1 410 ASSEMBLY 1 The nylon collar should be placed over the fittings on the rear of the Water Cooled Nozzle assembly It is important that the collar alignment and indication hole viewed from the rear of the nozzle align with the small concave mark provided on the collar of the Water Cooled Nozzle Apply the water transfer fittings to the fittings provided on the Water Cooled Nozzle See page 17 for directions on achieving correct
11. 03 Water Cooled Nozzle 5 Standard ONLY 48183 Water Cooled Nozzle 5 Standard COMPLETE Consists of W C Nozzle 45103 Nut Transfer Fittings Insulating Collar Insulation Tube Collet Nut Current Tip Gas Nozzle Spatter Disc and Wrench Water Cooled Nozzle 8 Standard ONLY Water Cooled Nozzle 8 Standard COMPLETE Consists of W C Nozzle 45114 Nut Transfer Fittings Insulating Collar Insulation Tube Collet Nut Current Tip Gas Nozzle Spatter Disc and Wrench Insulation Tube For 5 Nozzle Insulation Tube For 8 Nozzle Spatter Disc Counterbore must face front of Gas Noz Collet Nut Current Tip 5 16 Slip In see p 9 Table 3 Current Tip 7 16 Threaded see p 9 Table 3 Gas Nozzle see p 5 Table 2 Wrench Nozzle Thread Chaser Tap Alignment Tube Slip In Tip 5 Noz 035 1 16 Alignment Tube Th d Tip 5 Noz 035 1 16 Alignment Tube Slip In Tip 8 Noz 035 1 16 Alignment Tube Th d Tip 8 Noz 035 1 16 Rubber Boot 5 MT T DIRECT MOUNT WATER COOLED MACHINE BARRELS MODELS NCM WCYIT A Slip In Tip HTM W C T A Threaded Tip WATER COOLED NOZZLES A5 amp A8 Series A High Capacity REF CODENO DESCRIPTION 7777 45176 NCM Slip In Tip Docking Spool WI C T 5 Noz 45172 NCM Slip In Tip Docking Spool WI C T 8 Noz 45179 HTM Th d Tip Docking Spool WI C T 5 Noz 45174 HTM Th d Tip Docking
12. AS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Printing Office Washington D C 20402 e American Welding Society Standard AWSF4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances obtainable from the American Welding Society 2501 N W 7th St Miami FL 33125 IMPORTANT The D F torch is famous for the fact that if it is chilled properly the welder can grab the front of the torch with their bare hand and it will be cold to the touch just seconds after welding This can be done even after a 4 hour arc time with the proper chiller Make certain the cooling water supply is at least the minimum flow rate of 3 quarts per minute for each inner body at 40 psi 80 psi maximum with a 5 gallon reservoir and 15 000 BTU hr cooling capacity Gun ratings are affected by shielding gas used arc time cooling time and inlet water temperature Water outlet temperature should not exceed 27 C 80 F Also the torch s water out amp power cable is not cooled until the coolant has gone through the torch and out the water out amp power cable If water is not flowing through the D F torch for a least 1 minute prior to striking an arc when you apply the power and water hits the hot water out amp power cable you will generate steam Steam can damage the torch s internals in seconds causing a leak or it can also blow out the torch s wa
13. ESHOOTING GENERAL GUIDE Possible Solutions Inspect ground cable for loose connections fraying and cuts Correct any prob lem areas found Clean clamping area to insure good contact Securely attach the ground cable to the workpiece as close as possible to the point of welding Make sure there is a good connection to the welding power source Check to make sure the power connection on the power source is tight the con nection on the wire feeder is tight the connection to the adaptor block is tight and the connection of the gun to the adaptor block is tight Remove nozzle from gun and inspect current tip collet nut tip holder and spat ter disc gas diffuser for wear and tightness replace or tighten as necessary Note complete weld parameters including welding current Amps welding volt age wire feed speed type and size of wire type of gas and flow rate of gas and consult your local Authorized D F Machine Specialties Distributor or contact the factory Remove torch and inspect parts for dirt build up Periodic cleaning is neces sary Problems Causes AIR COOLED GUN RUNNING TOO HOT Poor ground Loose power connection Consumable items loose or worn Capacity of gun being exceeded Dirty connection D F MACHINE SPECIALTIES INC MIG amp TIG Welding Products Consumables amp Accessories WARRANTY This Equipment is sold by D F MACHINE SPECIALTIES Incorporated under the warranty set forth in the followin
14. Instruction Manual 599 NCM WC T HTM WC T D Revised 07 2014 D F MACHINE SPECIALTIES INC MIG amp TIG Welding Products Consumables amp Accessories 1750 Howard Drive North Mankato MN 56003 Phone 507 625 6200 Fax 507 625 6203 www dfmachinespecialties com WATER COOLED TO THE TIP MACHINE BARRELS A J et Peco g wane 21 5 amp 8 Standard Nozzles A5 amp 8 Series A High Capacity Nozzles DIRECT MOUNT DOCKING SPOOL WATER COOLED TO THE TIP MODEL NCM WIC T Slip In Tip MODEL HTM WIC T Threaded Tip INSTRUCTIONS PARTS amp SPECIFICATIONS MANUAL D F MACHINE SPECIALTIES is a world leader in the design development and manufacture of MIG GMAW 8 TIG GTAW weld ing products consumables and accessories D F offers several types of manual Air or Water Cooled MIG welding tools and with the increased use of automated and robotic welding systems a demand has been created for welding tools of the highest quality durability and interchangeability For over forty years D F welding products have been used extensively on MIG and TIG welding applications This experience coupled with patented design features unavailable on any other competitive equipment has made D F welding tools the most advanced MIG and TIG welding guns and barrels for semi automatic automatic or robotic welding applications This Catalog is a guide t
15. The collet nut will hold the support tube spatter disc and insulation tube in the torch The collet does not have to be removed but only loosened 1 2 turn to 1 full turn to change a slip in tip When using a threaded tip the tip itself holds the support tube and inner parts in place Please remember that you do not have to remove a gas nozzle to change a tip For nozzle cleaning with the nozzle thread chaser tap see p 9 Always clean and blow out a torch before applying the current tip and gas nozzle DIRECT MOUNT WATER COOLED MACHINE BARRELS MODELS NCM WCIT Slip In Tip HTM W C T Threaded Tip WATER COOLED NOZZLES 5 amp 8 Standard Wla E i REF CODENO DESCRIPTION 7777 45176 NCM Slip In Tip Docking Spool WI C T 5 Noz 45172 NCM Slip In Tip Docking Spool WI C T 8 Noz 45179 HTM Th d Tip Docking Spool WI C T 5 Noz 45174 HTM Th d Tip Docking Spool W C T 8 Noz 14712 Socket Set Screw 40022 Spring 40023 Ball 40024 Seat 14180 Body Liner 030 035 Hard Cored 14181 Body Liner 035 045 Hard Cored 14182 Body Liner 045 1 16 Hard Cored 14200 Body Liner 030 035 Soft 14201 Body Liner 3 64 Soft 14203 Body Liner 1 16 Soft 14205 Body Liner 3 32 Soft 14186 Body Liner 564 1 8 Hard Cored 13921 O Ring 4 req d 40025 Transfer Fitting 40010 Insulating Collar 13912 Internal O Ring 12516 External O Ring 40001 Nut 451
16. be replaced b When changing the welding wire remove the tip from the front end of the gun and blow out the body liner with clean dry compressed air from the back of the gun Repeat with the casing and liner assembly Note Wear safety goggles when using compressed air to clean the liners Make sure proper safety proce dures are followed in order to avoid possible serious eye injury Check the lengths of the liners and trim or replace if too long or too short The efficient feeding of the welding wire is dependent on the liners fitting correctly An unprotected coil of wire quickly collects dust and other airborne contamina tion If grinding is being performed in the vicinity particles can become attached to the wire severely interfering with the wire feed Replace with clean wire and keep it protected with a cover Make sure spare wire rolls are stored in a clean dry place Set the brake so that the coil immediately stops rotating as soon as welding is interrupted If the brake is applied too hard it will cause the feed rolls to slip resulting in uneven wire feed If it is too loose overrun of the wire will occur causing wire tangles inconsistent tension on the feed mechanism and irregular arc Characteristics Set the wire feed in relation to the arc voltage in such a way that the arc is stable and burns evenly In spray arc welding set the wire feed so that there are no short circuits and the filler metal is transferred in a spray a
17. cross the arc Find the cause of the interference and correct it See ERRATIC WIRE FEED above When the internal diameter of the current tip becomes worn from the passage of wire through it the wire may no longer stay in continuous electrical contact with the tip This results in an unstable arc and an increase in spatter Paint mill scale silicon scale rust or flux deposits from previous weld runs may form an insulating layer causing an unstable arc Clean the surfaces to be welded Securely attach the ground cable as close to the point of welding as possible on the workpiece Clean the surfaces thoroughly to ensure good contact Check to insure the welding power connection on the power source is tight the and workpiece Connection on the wire feeder is tight the connection to the adaptor block is tight Loose power connection and the connection of the gun to the adaptor block is tight Adjust the current tip to work distance to a minimum of 3 8 for short arc welding Amore precise distance is 15 times the wire diameter Problems Causes ERRATIC WIRE FEED Slipping feed rolls Clogged or worn gun liner Liners too long or too short Spatter on the wire Coil brake incorrectly adjusted UNSTABLE ARC Incorrect setting of voltage and or current Problems in wire feeding worn current tip Impurities on the base metal Poor contact between ground cable and work piece or loose power connection Stick out too long TROUBL
18. egal maximum levels of toxic concentrations are not exceeded For more information refer to the following standards in their latest revisions and comply as applicable e ANSI Standard 249 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 2501 N W 7th St Miami FL 33125 e ANSI Standard 241 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 e ANSI Standard 249 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 e OSHA SAFETY AND HEALTH STANDARDS 29CRF 1910 obtainable from the U S Government Printing Office Washington D C 20402 e AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTABLES obtainable from the American Welding Society 2501 N W 7th St Miami FL 33125 e NFPA Standard 70 1978 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 e ANSI Standard 288 2 Practice for Respiratory Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 e ANSI Standard 287 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 e NIOSH SAFETY AND HEALTH IN ARC WELDING AND G
19. ers the water from the docking spool body to the water cooled nozzle The transfer fittings have to be set at a specific height 1 395 1 410 see right otherwise the water supply in the torch could be cut off or the torch could leak If the transfer fittings are tightened past 1 400 they can break ALWAYS use a LONG 3 8 socket when applying transfer fittings for support At the facto ry transfer fittings are set with a height of 1 400 To check the height on a transfer fitting hold the water cooled nozzle in your left hand and place your pointer finger and middle finger over the white collar like you are throwing a fork ball You want to hold the collar down tight When you know the collar is down tight measure with a micrometer from the top of the white collar to the top of the stainless tip of the transfer fitting The distance has to be in the 1 395 1 410 range preferably around 1 400 If a transfer fitting shows signs of wear or is cracked or broken it must be replaced Always make sure there is a proper amount of lubricant grease on the O rings of the transfer fittings When you put the water cooled nozzle back on the docking spool body of the torch you must make sure the water cooled nozzle is pushed up correctly and tighten the cone nut thoroughly so that everything is in the correct place and there are no leaks There should be no reason to take apart the torches and wear out the O rings on the transfe
20. escent wrench could be used instead but due to the large size of crescent wrenches we prefer the smaller size of the open ended wrenches You never want to use excessive force by using too large of a wrench You will use the Long 7 16 Open Ended Wrench for the fitting on the water in hose itself while using the 3 8 wrench to steady the inner body at the fitting see 5 Long 7 16 Open Ended Wrench This is used to secure the water in hose to the torch s inner body see 4 9 16 amp 1 2 Open Ended Wrench A This is used on the inner body s water out amp power cable fitting to secure the water out and power cable to the torch s inner body A crescent wrench could be used instead but due to the large size of crescent wrenches we prefer the smaller size of the open ended wrenches We prefer the use of the larger wrenches on the power cable fitting to ensure that there are no water leaks and that it has been seated correctly You will use the 7 Long 9 16 Open Ended Wrench for the fitting on the water out amp power cable hose see 7 A B This wrench is also used to secure the adapter and jam nut that hold the current tip to the inner body In your left hand hold the inner body and with your right hand thread up the adapter using the 1 2 Open Ended Wrench until it is tight Now place the same wrench on the jam nut and snug it up against the inner body Keeping that wrench on the jam nut and placing it on the table for
21. g paragraph Such warranty is extended only to the buyer who purchases the equipment directly from D F or its authorized distributor as new merchandise The barrel and cable assemblies are warranted by D F to be free from manufacturing defects for 90 days after delivery by D F provided that the equipment is properly operated under conditions of normal use and that regular periodic maintenance and service is performed Expendable parts are not war ranted for any specific time Expendable parts referred to herein would be the nozzles current tips spatter discs insulators casing liners and wire inlets D F s sole obligation under this warranty is lim ited to making replacement at its manufacturing facility for barrel assemblies which are returned to it with transportation charges prepaid and upon D F s examination have been found to be so defective Genuine D F MACHINE SPECIALTIES Inc Parts Accessories and Consumables must be used for safety and performance reasons The use of anything other than genuine D F MACHINE SPECIAL TIES Inc Parts Accessories or Consumables will void this Warranty All units returned for warranty repair are subject to Warranty Inspection Warranty and repair work shall not apply to goods that have been altered or repaired have been subject to misuse or used while any parts are loose broken or damaged or used with other than original D F parts consumables or accessories which may affect performance and safe
22. h d Tip Series A5 Noz 035 1 16 Alignment Tube Slip In Tip Series A8 Noz 035 1 16 Alignment Tube Th d Tip Series A8 Noz 035 1 16 Rubber Boot TABLE 3 CURRENT TIPS CURRENT TIPS 5 16 DIAMETER SLIP IN Gun Barrel Model T Wire Type All NC NCC NCM Tip provides 1 8 set back NC NCC NCM Tip provides 3 8 set back NC NCC NCM 3 64 Tip provides 1 8 set back 1 16 5 64 3 32 CURRENT TIPS 7 16 DIAMETER THREADED __Gun BarrelModel___ Wire Size Wire Type Code No All HT HTC HTM CTW CW T MTW Tip provides 1 8 set back All HT HTC HTM CTW CW T MTW Tip provides 3 8 set back All HT HTC HTM CTW CW T 3 64 Aluminum MTW 1 16 Aluminum Tip provides 1 8 set back 5 64 Aluminum 3 32 Aluminum 1 8 Aluminum DIRECT MOUNT DOCKING SPOOL WATER COOLED TO THE TIP WATER COOLED NOZZLES 5 8 A5 8 A8 Direct Mount 5 Standard Nozzle Docking Spool Water Cooled to the Tip Model NCM W C T Direct Mount 8 Standard Nozzle Docking Spool Water Cooled to the Tip Model NCM W C T Direct Mount A5 High Capacity Docking Spool Water Cooled to the Tip Model NCM WI C T A Direct Mount A8 High Capacity Docking Spool Water Cooled to the Tip Model NCM WI C T A NOTE Add Footage to Code Number for Length Desired Example Complete Assembly with 4 Ft Utilit
23. h s body screw Also the screwdriver can be used to straighten the contact tip if it is not aligned in the center of the gas cup or water cooled nozzle CAUTION This cannot be done unless the spatter disc has been removed from the torch 1 10 Long Nose Pliers 11 3 32 Allen Wrench This is used to secure the socket cap screw that holds the casing in the inner body REQUIRED TOOLS LIST FOR DISASSEMBLY 8 ASSEMBLY HOW I CUT FIT AND INSTALL A NEW LINER Be sure the MIG Gun cable is arranged in a straight line free from twists when installing or removing a wire liner Remove the old liner by first removing the MIG gun s contact tip Pull the old wire liner out of the conduit casing assembly from the feeder connector or feeder adapter plug end If you are using a feeder adapter that has an inlet the inlet must be removed first If you have any problems removing the liner you may un thread the feeder adapter first this will also back the liner out of the conduit casing you know that the old liner is the correct length or is still the original liner that was cut at the factory you may hold the new liner up against the old liner and cut off the new liner to the same size as the old liner Make sure you have a good sharp cut off with no material sticking out To get the correct length of the new liner insert the liner into the feeder adapter and feed it through the conduit casing Once again be sure the MIG
24. he Allen set screw in the docking spool onto the conduit casing to prevent back ward movement or an unwanted pumping action 1 2 10 11 12 13 14 15 16 17 18 WHAT IS THE PROPER USE OF THE NOZZLE THREAD CHASER TAP All D F Nozzles are hand checked for fit before and after plating and checked again before shipping If a nozzle has been installed on a new complete torch they have also been hand checked while being assembled The only reason to ever take a gas cup out a nozzle is to clean it The nozzle and the gas cup must be blown out and all of the threads have to be wire brushed and blown out again before hand tightening the gas cup back into the nozzle If you can t thread it in by hand then something is wrong Never force a gas cup into a nozzle When using the D F Machine Specialties nozzle thread chaser taps be sure to always follow the steps below Make sure that the nozzle is properly supported when tapping so it does not twist in the front of the torch body and cause damage e Improper support can cause the spigots to twist off the top of the rear nozzle collar or damage the torch internal body parts e Note where the water ports go down the sides of the water cooled nozzle following down in line with the spigots Too much direct pressure on these water ports could cause them to cave in and block of the flow of water e Best practice is to hold the water cooled nozzle in a vice with soft jaws
25. ies 40134 4 _Ref _ Code No Description Utility Station see p 16 Optional Cable Water Hose Power Coupling Water In Hose Assembly Gas Hose Assembly Standard Water Out Hose amp Power Cable Assembly NOTE Add Footage to Code Number for Length Desired Example 5 Ft Water In Hose Assembly Code No 46300 5 5 16 SLIP IN CURRENT TIP Series A5 Standard Nozzle Dia 1 125 12 312 Standard 8 Series A 8 Nozzle Series A8 Dia 1 445 DIRECT MOUNT DOCKING SPOOL WATER COOLED TO THE TIP WATER COOLED NOZZLES 5 8 A5 amp A8 Direct Mount 5 Standard Nozzle Docking Spool Water Cooled to the Tip Model HTM W C T Direct Mount 8 Standard Nozzle Docking Spool Water Cooled to the Tip Model HTM W C T Direct Mount A5 High Capacity Docking Spool Water Cooled to the Tip Model HTM WI C T A Direct Mount A8 High Capacity Docking Spool Water Cooled to the Tip Model HTM WI C T A NOTE Add Footage to Code Number for Length Desired Example Complete Assembly with 4 Ft Utilities 40246 4 _Ref _ Code No Description Utility Station see p 16 Optional Cable Water Hose Power Coupling Water In Hose Assembly Gas Hose Assembly Standard Water Out Hose amp Power Cable Assembly NOTE Add Footage to Code Number for Length Desired Example 5 Ft Water In Hose Assembly Code No 46300 5 15 7 16 THREADED CURRENT TIP Series A5 Standard
26. llel to the weld pool resulting in spatter in the direction of the welding Have the power source checked for faulty conditions such as broken wires and faulty contacts A great deal of spatter occurs if the stick out is too great and if the welding gun is held too far from the workpiece when striking the arc Try to start with as short a stick out as possible and with the welding gun as close to the starting point as possible If a large ball end is formed on the end of the welding wire remove it by cutting the wire with sharp wire cutters It is helpful if the wire is cut to a point Always remove the ball end before striking an aluminum arc Check the welding ground connection Check the user manual for your power supply or consult a quali fied welding engineer Uneven wire feed gives rise to heavy spatter Find the cause of the disturbance and correct the condition before proceeding Paint mill scale rust and other contamination on the base metal form an insulating layer causing an unstable arc that results in heavy spatter Clean the surfaces to be welded Inspect ground cable for loose connections fraying and cuts Correct any problem areas found and attach the ground cable directly to the workpiece after having cleaned the contact sur face first POOR GROUND CONTACT IS THE MOST COM MON CAUSE OF UNSTABLE MIG WELDING CONDITIONS The stick out should be 15 times the diameter of the wire elec trode being used With increasing
27. o helping you select the proper tool for a given semi automatic automatic or robotic welding application The fol lowing is only a partial listing of available semi automatic automatic and robotic guns For further information on special MIG and TIG Commitment to excellence At D F Machine Specialties we commit to design build and de liver premium products and superior customer support to quality driven welding professionals Customers still to this day choose D F over competitors because of our responsiveness and flex ibility Customers will continue to choose D F tomorrow for our superior hand made products and service To ensure this we need creative and competent personnel in all business divisions an intensive exchange of thoughts and ideas with all users par ticipation in working and study groups within the field of welding technology and intensive cooperation with institutes and univer sities Teamwork Striving for excellence is a commitment that is an integral com ponent of the D F Culture Our team of skilled and dedicated employees takes pride in the excellence products they produce Each of us willingly accepts personal responsibility for meeting our commitments and we hold each other to a high standard of accountability Responsibility We will continually strive to be environmentally responsible and to support the health and safety of our employees customers and neighbors We continue to support the communi
28. r fitting unless there has been a crash They will not last as long if they are taken apart and put back together over and over To properly change a contact tip you do not have to take off the gas cup Simply loosen the collet one half to one full turn and pull out the tip If you take the collet out all the way make sure to wire brush and blow out the threads in the docking spool body and on the collet The same goes for the gas cup or nozzle If you do happen to remove the gas cup for cleaning make sure to blow out water cooled nozzle and wire brush and blow out the threads of the gas cup Any preemptive maintenance will considerably extend the life of the torches and their consumables Points to Remember 1 Always make sure transfer fitting height is 1 395 to 1 410 from the white collar to the stainless spigot 2 Always use a Long 3 8 socket for support when applying transfer fittings 3 Do not take off the gas cup to change a tip Only take off the gas cup when cleaning is needed 4 Wire brush the threads on gas cups and collets for better heat transfer 5 Loosen collet 1 2 a turn to remove tip Only take out collet when cleaning is needed 6 Always make sure there is a proper amount of lubricant grease on the O rings of the transfer fittings ORDERING INFORMATION Each D F gun is fully assembled and ready to in stall In order to make the installation complete the code number wire size amp type make model
29. ter out amp power cable A flow switch can be installed after the return line ensuring that coolant is present at the return line prior to striking an arc When High Deposition GMAW or extended periods of arc time are used it is recommended that a liquid chiller be considered with a larger reservoir and a minimum of 30 000 BTU hr cooling capacity Precise temperature control maintains the cooling at a constant 13 C 55 F temperature thus prolonging the life of the welding equipment and more specifically extending the service life of the gas nozzle and current tip A refrigerated liquid chiller for GMAW may be obtained from For single torch chillers Dynaflux 800 334 4420 www dynaflux com For multiple torch cooling systems Koolant Koolers 800 968 5665 www koolantkoolers com INTRODUCTION This manual covers Direct Mounted Water Cooled Nozzles which offer a concept with interchangeability of Models for Mechanized or Robotic MIG Welding The equipment consists of four 4 basic components a utility station an intermediate utilities combination assembly and a Docking Spool Water Cooled to the Tip which is the principle component in this welding equipment arrangement It ac cepts the utilities at the top end of the Spool and provides a means of accepting the Water Cooled Nozzles at the lower end Several features important to a welding system are provided Incorporated within the water channels of the Docking Spool Water Cooled
30. th processes relating to arc welding equipment e Arc welding can prove damaging to eyes skin and hearing It is therefore imperative that the Accident Prevention Regulations UVV 26 0 and VGB 15 are fully observed and that all protective clothing eye and ear protectors specified are worn e The load data given are maximum limit figures Overloading will inevitably damage the torch e Before changing wear parts disconnect for the power supply e The operating instructions for the individual welding components e g power source wire feed and cooling unit must be followed e Never pull the cable assembly across sharp edges or set down close to weld spatter or on a hot workpiece e Those not involved in the welding process should be protected by curtains or partitions from radiation and the danger of being dazzled e When handling gas cylinders consult the instructions issued by the manufacturers and the suppliers of the pressurized gas e Workpieces which have been degreased using chlorinated solvents must be sprayed down with clean water before welding starts to avoid the risk of phosgene forming For the same reason no degreasing baths containing chlorine must be placed close to the welding point e All vapors given off by metals can cause harm and a special warning is attached to lead cadmium copper zinc and beryllium If necessary take ap propriate precautions by providing adequate ventilation or an extraction system to ensure that the l
31. ties in which we operate and the industries in which we participate requirements please consult the factory Customer satisfaction and customer benefits are the center points of all strategic contents The spirit of the D F Machine Specialties personnel is to listen to and to integrate the customer throughout the process to develop and design marketable products to present prototypes to carry out pilot tests and to prepare for and be open to new technology and tasks We attract and carefully select talented individuals who share our values Together we will nurture and sustain a work environment with two way communication training men toring and rewarding career opportunities Innovation and quality Innovation and quality come from being receptive and willing to learn from others We encourage our people to be creative and take risks in the pursuit of excellence Innovative practices are deeply rooted in every one of our employees a philosophy that leads to continuous product development and industry firsts Progress By remaining confident focused and persistent in challenging times we will discover opportunity Commitment to quality and the pursuit on innovation ensure that D F Machine Specialties will remain an industry leader for years to come Thank You for Choosing D F Machine Specialties Table Of Contents Introduction Table 1 Spare Parts Table 2 Gas 4022 68 5 Required Tools List for Disassembly
32. to the Tip are check valves which provide a means of retaining residual water in the lines when the nozzle assembly is removed from the Docking Spool Water Cooled to the Tip These welding assemblies are designated by Models Two 2 are illustrated in the parts breakdown lists The Model NCM has a current capability of 450 amperes in argon shielding These accommodate slip in current tips fastened by a collet ac tion nut This arrangement increases the versatility of the equipment by allowing tip extension beyond the gas nozzle where critical access problems to the weld area are encountered The wire diameter range for hard and cored wire is 030 1 8 and for aluminum is 3 64 3 32 The Model HTM has a current capacity range of 650 amperes Rating will be contingent on the combination of current tip and shielding gas to be used The Model HTM employs threaded current tips The wire diameter range for hard and cored wire is 030 1 8 and for aluminum is 3 64 3 32 For further information or help with D F Machine Specialties products please visit our web site at www dfmachinespecialties com or consult the factory at 1 507 625 6200 TABLE 1 SPARE PARTS ITEM CODE NO MIN QTY Gas Nozzle To Be Selected Current Tip To Be Selected Collet Nut To Be Selected Spatter Disc To Be Selected Body Liner To Be Selected Insulation Tube To Be Selected Transfer Fitting To Be Selected TABLE 2 GAS NOZZLES Gun Model_ Ref No
33. transfer fitting height 1 410 The transfer fittings will break if they are tight ened too far and they will leak if they are not tight enough Also transfer fittings are not designed to be reused If you do not have any spare transfer fittings and are forced to reuse one you must use Loc Tite to reseal the threads Examine the O rings on the water transfer fittings Make replacement if necessary and lubricate the O rings with silicone lubricant 2 The nozzle assembly may now be applied to the Docking Spool For proper orientation of the water fittings to the channels provided in the Docking Spool it is extremely important that the indicator hole in the collar align with the small concave mark provided on the face of the Docking Spool This alignment will allow the Water Cooled Nozzle to be pushed up into the Docking Spool after which the cone nut may be applied Make sure that the nozzle is all the way up and that the cone nut is very tight 3 The insulation tube should now be placed in the Water Cooled Nozzle With the high capacity water cooled nozzle as semblies the insulation tube has a shoulder on one end with a smaller ID that must be inserted up into the torch and recess inside the counter bored collar of the water cooled nozzle assembly Next insert the spatter disc into the Water Cooled Nozzle followed by pushing the support tube for high capacity nozzles up into the Water Cooled Nozzle onto the front of the Docking Spool
34. ty D F MACHINE SPECIALTIES INC 1750 Howard Drive North Mankato MN 56003 Phone 507 625 6200 Fax 507 625 6203 Rev 140612 2 www dfmachinespecialties com
35. urrent tip 2 Nozzle damage causing uneven gas coverage 3 Torch gas ports clogged or deformed 4 Super heated nozzle causing shielding gas to expand rap idly and create return effect at end of nozzle 5 Gas diffuser nozzle insulator missing 6 Too high a gas flow causing the venturi effect WELDING PARAMETERS ETC 1 Too long a wire stick out gas nozzle too far from weld puddle 2 Bad torch position too sharp a torch incline causing the venturi effect at the end of the nozzle leading to atmospheric contamination 3 Excessively wide weld pool for nozzle D 4 Arc voltage too high 5 Too high a travel speed Possible Solutions Set the wire feed rate and voltage in accordance with good weld ing practices as recommended by a qualified welding engineer Adjust the wire feed and voltage so that the arc is in accordance with good welding practice for the joint to be welded The dis tance from the current tip to the workpiece should be 15 times the welding wire diameter If the arc is too long there will be spat ter usually in the direction of the weld the current tip becomes worn the welding wire will not be in constant contact with the tip and the arc will become unstable A current tip contaminated with spatter will cause uneven wire feed resulting in further spatter The angle of the gas nozzle relative to the workpiece should be between 45 and 90 degrees If the angle is too small the wire runs para
36. weld from drafts curtains screens b Use tapered or bottleneck gas nozzles when drafts cannot be avoided 1a Reduce gas flow 1b Tighten all hose connection points 2 Increase gas flow 3 Repair or replace 4 Adjust mixer 5 Repair leaks 6 Overhaul system fit filters and or dryers 7 Regulate pressure into flow meter for consistent cfh delivery of gas 1 Clean nozzle and tip regularly spray with anti spatter fluid 2 Replace nozzle 3 Clean or replace 4 Check duty cycle rating of torch 5 Replace 6 Reduce gas flow 1 Use longer nozzle or adjust stick out 3 8 minimum or 15 times wire diameter 2 Correct torch angle 3 Width of the weld pool should be 1 3 times the nozzle D use suitable wider gas nozzle 4 Reduce voltage 5 Reduce speed Causes of Porosity BASE METAL CONTAMINATION Impurities on base metal FILLER METAL CONTAMINATION Impurities on filler metal wire ATMOSPHERIC CONTAMINATION Drafts wind fans etc GAS MIXING APPARATUS 1 Too high a gas flow causing turbulence and or sucking air at hose connections creating the venturi effect at end of gas nozzle 2 Too low a gas flow causing insufficient gas coverage 3 Damaged or kinked gas lines 4 Too high an oxygen content 5 Leaks in gas distribution system 6 Other impurities in gas moisture etc 7 Inconsistent gas flow cfh at the torch connection GAS TURBULENCE 1 Excessive spatter build up in gas nozzle and on c
37. zzle Type O D LD Code No NC HT Copper Tapered Std Capacity Copper Straight Copper Straight Copper Tapered NC HT Copper Short Taper 11 16 Hi Capacity Copper Short Taper 13 16 ANY Series A Copper Short Taper 15 16 0 3 Copper Full Taper 11 16 Copper Full Taper 13 16 Copper Full Taper 15 16 REQUIRED TOOLS LIST FOR DISASSEMBLY 8 ASSEMBLY D F 12111 Collet Tip Wrench This is the only tool that should ever be used to tighten the collet nut or the tip Pressure should be 30 Ibs or as Snug as hand tightened Never use another wrench to apply more torque to this wrench D F Nozzle Thread Chaser Tap This is used to re tap damaged threads that have been improperly cleaned or cross threaded Al ways blow out the nozzle and gas nozzle after changing gas cup or re tapping For more information on how to use the nozzle thread chaser tap use the following link www dfmachine com taps Socket Wrench amp 3 8 Long Socket This is used to tighten the transfer fittings onto the water cooled nozzle The transfer fittings have to be set at a specific height of 1 400 accepted range is 1 395 1 410 otherwise the water supply in the torch could be cut off or the torch could leak If the transfer fittings are tightened past 1 400 they can break see p 17 3 8 Open Ended Wrench This is used on the inner body s water in hose fitting to secure the water in hose to the torch s inner body A cr
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