Instruction Manual 403-17CCA/CTA
Contents
1. 13098 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 i 5 64 1 8 H C NA3 NA5 030 3 32 H C AL 16879 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 HIC 16878 16888 Power Feed 030 3 32 H C AL 13479 13480 10 LF 72 5 64 1 8 HIC 13469 13468 LF 74 Casing to Feeder Accepts Linde Outlet Guide D F Insert 035 045 Hard 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 045 1 16 Hard 5 64 3 32 Cored Miller 030 3 32 HICIAL 16557 50 Series 5 64 1 8 H C OTC Requires 030 1 8 18268 Insert 030 1 8 18275 Lincoln 030 3 32 H C AL Mavrix 3 64 1 16 AL CMRE 741 18282 18282 Panasonic PME 12X 030 1 16 13090 Reaues net YW50AKW1 030 1 16 13466 q 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 ORDERING INFORMATION Each D F gun is fully assembled and ready to in stall2. In order to make the installation complete the code number wire size amp type make model 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 No 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 TROUBLESHOOTING POROSITY SUMMARY NOTE Most POROSITY is caused by gas problems followed by base metal contamination 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 impu
3. Nozzle Body 13197 15527 15533 Model CTA Nozzle Body 13198 15528 15534 Model CTA Nozzle Body 16384 15529 15535 When ordering specify the Model and Code No from this table Also advise of wire diameter and feeder manufacturer to be used TABLE 2 MODEL SPECIFICATIONS CURRENT BODY WEIGHT RECOMMENDED WIRE MODEL CAPACITY coro DIAMETER approx DIAMETER RANGE CCA 55 400 amps CO 030 062 Hard CTA 55 260 amps Argon 3 64 1 16 Cored DISASSEMBLY 1 When repairs are made on the production line make certain the power source and wire feeder are disconnected from primary power 2 Remove forward gas nozzle If threads are damaged or clogged up with spatter use 14610 nozzle thread chaser tap to recondition the front of nozzle bodies 16384 amp 13197 3 Remove current tip A wrench is provided for the collet holding the slip in tip on the CA C Series See page 8 for replace ment of tips and nozzles 4 Ifthe 1 4 and 5 16 collet adapters 13205 amp 13209 or 7 16 threaded tip adapter 12019 is to be replaced proceed as follows a Unscrew the nozzle body If the insulator threads off with the nozzle body it may be necessary to grip the edge of the insulator 13163 and turn it out Do not apply excessive pressure to the insulator b The nozzle body insulator 16605 can be removed by sliding it to the rear NOTE Nozzle body 13197 13198 amp 16384 rear insulator threads can
4. 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 Z88 2 Practice for Respiratory Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 e ANSI Standard Z87 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 GAS 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 INTRODUCTION The CCA CT
5. be reconditioned and re chased with 14612 rear thread chaser 5 Remove the adapter by using two 5 8 wrenches one to hold the jam nut 16202 and the other to unscrew the adapt er 6 NOTE Optional Body Bushing is provided to center up the liner located at the forward end of the inner body on guns not utilizing the inner body liner and single piece casing 7 Insulator on body tube should be inspected and replaced if worn or cut at this time 8 Remove flat head screw 12610 and insulator from the body tube 9 Release pressure on switch housing clamp 10 Grasp electrical cable and at the same time pull body tube off the curved inner body A slight twisting motion will aid in sliding the tube back 11 The casing set screw 14712 can now be released and the casing liner assembly withdrawn out of the inner body NOTE Swivel socket set is captivated by the body tube 12 Insert and replace inner body liner See page 8 for replacement 13 If the trigger switch is to be removed a Release socket set screw holding the switch in position b Drift out the roll pin holding the lever in the switch housing c Carefully pull button switch from housing inspect and replace as required ASSEMBLY 1 Care must be exercised in connecting fittings to allow sliding of the handle over the hoses when reassembling Keep the hose services as straight as possible avoiding twisting of service lines 2 If new power cable is required a Trim o
6. 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 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 overru
7. 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 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 GENERAL GUIDE 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 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
8. 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 safety D F MACHINE SPECIALTIES INC 1750 Howard Drive N
9. 8 7 16 Chrome use with Nozzle Body 13198 1 1 16 nk TABLE 4 CURRENT TIPS CURRENT TIPS 2 1 2 SLIP IN 1 4 DIAMETER Gun Barrel Model Wire Size Wire Type All NC NCC NCM Tip provides 1 8 set back All NC NCC NCM 3 64 keg 10785 Tip provides 1 8 set back 1 16 10786 CURRENT TIPS 2 1 2 SLIP IN 5 16 DIAMETER CURRENT TIPS 7 16 DIAMETER THREADED Gun Barrel Model Wire Size Wire Type Gun Barrel Model Wire Size Wire Type All NC NCC NCM All HT HTC HTM CTW CW T Tip provides 1 8 set back MTW Tip provides 1 8 set back All HT HTC HTM CTW CW T All NC NCC NCM MTW Tip provides 3 8 set back Tip provides 3 8 set back All HT HTC HTM CTW CW T Aluminum All NC NCC NCM Aluminum MTW Aluminum Tip provides 1 8 set back Aluminum Tip provides 1 8 set back Aluminum Aluminum Aluminum Aluminum Aluminum Kander lili ya e TABLE 5 LINERS Description Wire Size 2Ft 3Ft 4Ft 5Ft 6Ft 7Ft 8Ft 10Ft 12Ft 15 Ft Hard 030 Hard Cored 035 045 Hard Cored 045 1 16 Stainless 035 045 Stainless 045 1 16 Aluminum 3 64 Aluminum 1 16 Aluminum 3 32 Liners to be used with double asterisk casing TABLE 6 CASINGS Description Wire Size 2Ft 3Ft 4Ft 5Ft 6Ft Casing Assembly Flexible Select Liner 030 Select
10. A series of air cooled curved gun configurations come pre assembled and ready to install These MIG welding guns can be converted to different configurations to suit many robotic welding applications by utilizing the various nozzle bodies and gas nozzles available Consult the factory for special nozzle requirements other than those listed on page 8 All models have the feature of individual replaceable service connections When desirable a cable hose sheath is available to further add to the durability and long life of these gun assemblies All joints on these guns are low temperature brazed for strength and integrity of the design Longevity of the gun performance in provided by the well designed switch and cable assembly Each gun assembly comes with a tip and nozzle applied In order to make the installation complete the series and gun model along with wire size wire feeder make amp model and inlet as needed must be specified when ordering 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 ORDERING INFORMATION DESCRIPTION Tan sn rre en wn am ier Model CCAIGTA Specify Nozzle Body meso neo meo Model CCA Nozzle Body 19197 18524 5500 msr Model CCA Nozzle Body 13198 15525 15531 11557 Model CCA Nozzle Body 16384 15526 15532 11567 _ SSSSS E Sa Model CTA
11. Instruction Manual 403 17CCA CTA A C Robotic 55 Deg Curved Gun Revised 06 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 Email sales dfmachinespecialties com www dfmachinespecialties com AIR COOLED CURVED GUN wy EF net TERTE 55 Robotic Curved Torch Series 400 Model CCA Slip in Current Tip Model CTA Threaded Current Tip INSTRUCTION PARTS amp SPECIFICATIONS MANUAL D F MACHINE SPECIALTIES is a world leader in the design development and manufacture of MIG GMAW amp 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 to helping you select the proper tool for a given semi automatic automatic or robotic welding ap
12. Liner 035 1 16 Casing Assembly Reinforced Single Piece 035 045 Single Piece 045 1 16 Single Piece 5 64 3 32 Single Piece 7 64 1 8 Liners to be used with double asterisk casing TABLE 7 RECOMMENDED SPARE PARTS Gas Nozzle To Be Selected Current Tip To Be Selected Collet Nut To Be Selected Body Liner To Be Selected Insulation Tube To Be Selected Insulator 13163 COMPOSITE BODY LINERS Required with Single Piece Casing or Casings that Use Replaceable Liners Model CCA Pre Fit Body Liner Used with Slip In Tip CODE NO DESCRIPTION SIZEWIRE TYPE WIRE 16385 Composite Body Liner 030 035 Hard 16295 Composite Body Liner 035 045 Hard 16296 Composite Body Liner 045 052 1 16 Hard Model CTA Pre Fit Body Liner Used with Threaded Tip CODE NO DESCRIPTION SIZEWIRE TYPE WIRE 16746 Composite Body Liner 030 035 Hard 16747 Composite Body Liner 035 045 Hard 16748 Composite Body Liner 045 052 1 16 Hard sense 1 FITTING REPLACEABLE LINERS TO CASING ASSEMBLIES The recommended method of cutting liners to size is as follows 1 All repairs and adjustments to gun assemblies are made with the power source and feeder turned off 2 Place gun and casing assembly as flat as possible on workbench floor keeping service lines straight 3 Remove inlet or adapter depending on the feeder make Remove the inner body fas
13. N RUNNING TOO HOT Poor ground Loose power connection Consumable items loose or worn Capacity of gun being exceeded Dirty connection 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 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 following paragraph Such warranty is extended only to the buyer who
14. ctor 4Ft Cable Hose Protector 5Ft Cable Hose Protector 6Ft Cable Hose Protector 7Ft Socket Set Screw Socket Set Screw Flat Head Screw Washer Inner Body 55 1 0 Cable Insulation Tube Body Liner see page 10 Adapter Threaded Tip 7 16 Adapter Slip In Tip 1 4 Adapter Slip In Tip 5 16 Collet Nut 1 4 Collet Nut 5 16 Current Tip Threaded see Table 4 Insulator Nozzle Body Less Insulator Nozzle Body With Insulator Gas Nozzle see Table 3 Gas Nozzle see Table 3 Nozzle Body Thread Chaser Rear Current Tip Slip In see Table 4 Wrench Fet T codeno Deseion Nozzle Thread Chaser Tap Front Nozzle Body With Insulator Nozzle Body Less Insulator Power Cable 1 0 3 Ft Power Cable 1 0 4 Ft Power Cable 1 0 5Ft Power Cable 1 0 6 Ft Power Cable 1 0 7 Ft Power Cable 1 0 8 Ft Casing see Table 7 Gas Hose Assembly 3 Ft Gas Hose Assembly 4 Ft Gas Hose Assembly 5 Ft Gas Hose Assembly 6 Ft Gas Hose Assembly 7 Ft Gas Hose Assembly 8 Ft Liners See Table 6 Insulator Adapter Jam Nut Insulator Nozzle Body With Insulator Nozzle Body Less Insulator Gas Nozzle 546 ID Gas Nozzle 626 ID Cable Clamp Kit Bushing 030 3 32 TABLE 3 GAS NOZZLES GUN MODEL REF NOZZLETYPE O D 1D CODENO NC HT Copper Tapered 63 64 5 8 Copper Straight 1 3 4 Copper Full Taper 63 64 5 8 Copper Straight 5
15. ear 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 legal 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 Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National
16. esaeeseesaesaeecuesensasenes 6 Air Cooled Curved 55 Guns Parts rararnnnnnnnnanennnrvnnrvnnrnnnrnnnnnennnnnnnnnnnnnnnnnrnnnennsennsen T Table 3 Gas Nozzles Table 4 Current TipS cccccccccsecseeceeseeeeeeeeeeeeeseseeeeeeeeees 8 Table 5 Liners Table 6 Casings Table 7 Recommended Spare Parts 9 Body Liners Fitting Replaceable LIN rs ccc cccccecceecceeceeceeeseeceeeeeeeeeeeeseeseeeeess 10 PI SAU OM ler 11 Wire Feeder Adapters amp InletS rrarrarrarrarvarvarrnrvnrvnvenernvenernennerneenernenueruenuenuenuenusenn 12 HOUENS eee 13 16 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 with 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 w
17. ff approximately 1 off cable covering b Carefully wrap copper strands with copper sheet c Slip wrapped copper cable end with locking clip 16196 provided into the rear of the inner body assembly 3 Securely tighten socket set on the power cable assembly 4 If possible check for gas flow through gun body after applying the gas hose assembly 5 By following the procedures listed in Disassembly in reverse the gun cable can now be re assembled 6 Check to make sure that your gun assembly has the right size current tip and liners for wire to be used 7 Be sure replacement lines composite body liner is cut off a the proper length For adjustment of current tip stick out see page 10 8 When trimming liner important Remove any sharp edges outside or inside and file if necessary 9 When installing a new collet 11950 amp 18262 be careful not to over tighten with the collet wrench Excessive pressure is not required due to good gripping action of the collet 10 Current tips and nozzles should be cleaned as frequently as required A clogged nozzle will restrict the flow of shielding gas 11 Check regularly the condition of service hose and control wire connections leading from the feeder and power source AIR COOLED CURVED 55 REMOTE MOUNT TORCH SERIES 400 CA C Slip In Tip amp CA T Threaded Tip Re CodeNo Description Body Tube Sleeve Mounting Bracket Clamp Cable Hose Protector 3Ft Cable Hose Prote
18. ir 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 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 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 If the current tip becomes
19. ld 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 communities in which we operate and the industries in which we participate Thank You for Choosing D F Machine Specialties TABLE OF CONTENTS SEE 4 Introduction Table 1 Ordering Info Table 2 Model Specifications rrrrrrarrnnnnrr D Disassembly Assembly cccccceccssceecceecaseceeceeceeeceecuecasecsecueseuece
20. n 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 across 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 TROUBLESHOOTING GENERAL GUIDE Problems Causes AIR COOLED GU
21. orth Mankato MN 56003 Phone 507 625 6200 Fax 507 625 6203 Rev 140612 1 www dfmachinespecialties com
22. plication The fol lowing is only a partial listing of available semi automatic automatic and robotic guns For further information on special MIG and TIG 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 Commitment to excellence At D F Machine Specialties we commit to design bui
23. rities 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 current 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 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 Protect 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 Repa
24. tening screw The body housing may now be pulled back to expose the inner body The set screw fastening the casing may bow be released and the casing may be taken out of the inner body NOTE Use a short piece of liner material for pushing the used liners back Now carefully push new liner in at adapter end Cut liner off even at gun and casing fitting Liner is now cut to size and gun may be reassembled ots UTILITY STATION 45184 AIR COOLED BARRELS ORDERING INFORMATION Utility Station Air Cooled Barrels 45184 D F TORCH CONNECTION 1 0 or 2 0 Power Cable CUSTOMER UTILITIES CONNECTION Shielding Gas 3 16 Hose Shank 1 0 or 2 0 Power Cable 1 125 DIMENSION SPECIFICATIONS Base Length Overall Length Base Width 228 Overall Width 25 Overall Height 3 2 Overall Weight sms UTILITY STATION SIDE VIEW WITH COVER P_ 5 75 __________ B 125 3 33 __ _ FROM LEFT D F TORCH CONNECTION FROM RIGHT CUSTOMER UTILITIES CONNECTION 1 0 or 2 0 Power Cable Shielding Gas 3 16 Hose Shank Gas Hose 1 0 or 2 0 Power Cable c 2 75 _ _ 2 ea 1 4 20 Screws lt a Lock Washers lt P Nuts Gp 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
25. 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 parallel 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
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