Instruction Manual 599 - D/F Machine Specialties, Inc.

Instruction Manual 599 - D/F Machine Specialties, Inc.
Instruction Manual 599
NCM-WC-T/HTM-WC-T
Revised 07/2014
D/F MACHINE SPECIALTIES, INC.
MIG & TIG Welding Products, Consumables & 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
5” & 8”
Standard Nozzles
A5” & A8”
Series A
High Capacity Nozzles
DIRECT MOUNT
DOCKING SPOOL®/WATER-COOLED-TO-THE-TIP
MODEL NCM-W/C-T (Slip-In Tip)
MODEL HTM-W/C-T (Threaded Tip)
INSTRUCTIONS, PARTS & SPECIFICATIONS MANUAL
D/F MACHINE SPECIALTIES is a world leader in the design, development, and manufacture of “MIG” (GMAW) & “TIG” (GTAW) welding 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 application. The following 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, mentoring, 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, build and deliver 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 flexibility. 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, participation in working and study groups within the field of welding
technology and intensive cooperation with institutes and universities.
Teamwork
Striving for excellence is a commitment that is an integral component 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
Introduction, (Table 1) Spare Parts, (Table 2) Gas Nozzles...........................................5
Required Tools List for Disassembly & Assembly........................................................6-7
How Do I Cut, Fit, and Install a New Liner?...................................................................8
What is the Proper Use of the Nozzle Thread Chaser Tap?...........................................9
Disassembly, Assembly................................................................................................10
Direct Mount Machine Barrels - 5” & 8” - Parts............................................................ 11
Direct Mount Machine Barrels - A5” & A8” - Parts........................................................12
(Table 3) Current Tips...................................................................................................13
Complete Assemblies & Utilities - NCM (Slip-In Current Tip).......................................14
Complete Assemblies & Utilities - HTM (Threaded Current Tip)..................................15
Utility Station................................................................................................................16
Transfer Fitting (D/F #40025) Installation.....................................................................17
Feeder Adapters...........................................................................................................18
Troubleshooting.......................................................................................................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 danger 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.
• 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.
• The load data given are maximum limit figures. Overloading will inevitably damage the torch!
• Before changing wear parts, disconnect for the power supply.
• The operating instructions for the individual welding components - e.g. power source, wire feed and cooling unit must be followed.
• Never pull the cable assembly across sharp edges or set down close to weld spatter or on a hot workpiece.
• Those not involved in the welding process should be protected by curtains or partitions from radiation and the danger of being dazzled.
• When handling gas cylinders, consult the instructions issued by the manufacturers and the suppliers of the pressurized gas.
• 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.
• 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 appropriate 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.
• ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society, 2501 N.W. 7th St., Miami, FL 33125.
• ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY - TOE FOOTWEAR obtainable from the American National Standards Institute, 1430 Broadway,
New York, NY 10018.
• ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018.
• OSHA, SAFETY AND HEALTH STANDARDS, 29CRF 1910, obtainable from the U.S. Government Printing Office, Washington, D.C. 20402.
• 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.
• NFPA Standard 70-1978, NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA
02210.
• ANSI Standard Z88.2, “Practice for Respiratory Protection” obtainable from the American National Standards Institute, 1430 Broadway, New York, NY
10018.
• 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.
• 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.
• 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 & power cable is
not cooled until the coolant has gone through the torch and out the water out & 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 & 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 water out & 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 accepts 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-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 action 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
Gas Nozzle
Current Tip
Collet Nut
Spatter Disc
Body Liner
Insulation Tube
Transfer Fitting
CODE NO.
To Be Selected
To Be Selected
To Be Selected
To Be Selected
To Be Selected
To Be Selected
To Be Selected
MIN QTY.
2
25
1
2
2
1
2
1
2
TABLE 2 - GAS NOZZLES
Gun Model
NC/HT
(Std. Capacity)
NC/HT
(Hi Capacity
Series A)
Ref.
1
2
3
4
5
6
Nozzle Type
Copper Tapered
Copper Straight
Copper Straight
Copper Tapered
Copper Short Taper
Copper Short Taper
Copper Short Taper
O.D.
I.D.
Code No.
15/16”
5/8”
10362
1”
3/4”
10340
5/8”
7/16”
10374
15/16”
5/8”
10359
1-3/8” 11/16”
16749
16750
1-3/8” 13/16”
16751
1-3/8” 15/16”
Copper Full Taper
Copper Full Taper
Copper Full Taper
1-3/8”
1-3/8”
1-3/8”
11/16”
13/16”
15/16”
3
4
5
6
18030
18031
18032
5
REQUIRED TOOLS LIST FOR DISASSEMBLY & ASSEMBLY
1. 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
lbs., or as snug as hand tightened. Never use another wrench to apply more torque to this wrench.
2. D/F Nozzle Thread Chaser Tap - This is used to re-tap damaged threads that have been improperly cleaned or cross threaded. Always 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
3. Socket Wrench & 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)
4. 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 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. 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)
5. Long 7/16” Open Ended Wrench - This is used to secure the water in hose to the torch’s inner body. (see #4)
6. 9/16” & 1/2” Open Ended Wrench
A. This is used on the inner body’s water out & 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 & 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
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 instead, but due to the large size of crescent wrenches, we prefer the smaller size of the open ended wrenches.
7. Long 1/2” & 9/16” Open Ended Wrench
A. This is used to secure the water out & 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.
8. 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.
9. Standard Flat Head Screwdriver - This is used to tighten or secure the torch’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.
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.
6
REQUIRED TOOLS LIST FOR DISASSEMBLY & ASSEMBLY
7
HOW DO I CUT, FIT, AND INSTALL A NEW LINER?
1. Be sure the MIG Gun cable is arranged in a straight line, free from twists, when installing or removing a wire liner.
2. Remove the old liner by first removing the MIG gun’s contact tip.
3. 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.
4. If 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.
5. Make sure you have a good sharp cut off with no material sticking out!
6. To get the correct length of the new liner, insert the liner into the feeder adapter and feed it through the conduit/casing.
7. Once again be sure the MIG Gun cable is arranged in a straight line, free from twists, when installing a new wire liner.
8. 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.
9. If 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.
10.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.
11. Now you have the overall length of the liner, you still have to take out the length of the contact tip.
12.Carefully remove the liner one more time.
13.After removing the liner hold the gun end of the liner up against the tip.
14.Cut off the length off the tip plus the set back of the tip (1/8” or 3/8” tip setbacks)
15.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.
16.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.
17.We always recommend replacing the spatter disc/gas diffuser, contact tip, and nozzle, after installing a new liner.
18.Tighten the flat head set screw in the inner body, or the Allen set screw in the docking spool onto the conduit/casing to prevent backward movement or an unwanted pumping action.
8
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:
1. 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.
• Improper support can cause the spigots to twist off the top of the rear nozzle collar, or damage the torch internal body parts.
• 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.
• Best practice is to hold the water-cooled nozzle in a vice with soft jaws, perpendicular to the spigots.
• Over-tightening of the vice can cause damage in general.
2. Remove the tip from the front of the torch before tapping.
3. Lightly lubricate the nozzle and nozzle thread chaser tap before tapping.
4. Be sure to start the tap very carefully. Do not cross thread the nozzle.
5. 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.
6. Blow out the nozzle after tapping. Wire brush and blow off the gas cup before threading it back into the nozzle.
7. If 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).
ORDERING INFORMATION - NOZZLE THREAD CHASER TAPS
CODE NO.
DESCRIPTION
USED WITH
NOZZLE ASSEMBLY
USED FOR
GAS NOZZLE
14610
Nozzle Thread Chaser Tap
for Standard A/C & W/C
Nozzle Assembly Front
13197
16184
11117, 45101
11118, 45102
11119, 45103
45114
45107
NCC-N/HTC-N
NCC-LRN, HTC-LRN
10340
10359
10362
10374
14611
Nozzle Thread Chaser Tap
for BIG MIG & BIG TIG
Nozzle Assembly Front
11123
10382
10387
10389
10390
10392
14612
Nozzle Thread Chaser Tap
for Nozzle Body
Assembly Rear
13196
13197
13198
16184
14614
Nozzle Thread Chaser Tap
for Series A High-Capacity
Nozzle Assembly Front
11142, 45120
11138, 45121
45127
11132, 45129
45125
16748
16749
16750
16751
18030
18031
18032
14615
Nozzle Thread Chaser Tap
for Nozzle Body
Assembly Front
13198
10379
14617
Nozzle Thread Chaser Tap
for Tandem Nozzle
Assembly Front
41641
41667
41668
9
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 transfer fitting height (1.410”). The transfer fittings will break if they are tightened 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 assemblies, 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. 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.
10
DIRECT MOUNT WATER-COOLED MACHINE BARRELS
MODELS NCM-WC/T (Slip-In Tip), HTM-W/C-T (Threaded Tip)
WATER-COOLED NOZZLES 5” & 8” Standard
2
25
1
24
6
3
4
5
REF. CODE NO.
1
2
3
4
5
6
7
7
8
8
10
9
11
12
13
15
17
18
14
19
7
8
9
10
11
12
13
20
16
21
22
23
45176-NCM
45172-NCM
45179-HTM
45174-HTM
14712
40022
40023
40024
14180
14181
14182
14200
14201
14203
14205
14186
13921
40025
40010
13912
12516
40001
45103
48183
14
45114
48185
15
16
17
18
19
20
21
22
23
24
12303
18371
42276
18262
12111
14610
45846
45847
45844
45845
14050
25
11
DESCRIPTION
Slip-In Tip Docking Spool® W/C-T - 5” Noz.
Slip-In Tip Docking Spool® W/C-T - 8” Noz.
Th’d Tip Docking Spool® W/C-T 5” Noz.
Th’d Tip Docking Spool® W/C-T 8” Noz.
Socket Set Screw
Spring
Ball
Seat
Body Liner .030”-.035” Hard/Cored
Body Liner .035”-.045” Hard/Cored
Body Liner .045”-1/16” Hard/Cored
Body Liner .030”-.035” Soft
Body Liner 3/64” Soft
Body Liner 1/16” Soft
Body Liner 3/32” Soft
Body Liner /564”-1/8” Hard/Cored
O-Ring (4 req’d)
Transfer Fitting
Insulating Collar
Internal O-Ring
External O-Ring
Nut
Water-Cooled Nozzle - 5” Standard (ONLY)
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
DIRECT MOUNT WATER-COOLED MACHINE BARRELS
MODELS NCM-WC/T-A (Slip-In Tip), HTM-W/C-T-A (Threaded Tip)
WATER-COOLED NOZZLES A5” & A8” Series A High-Capacity
2
26
1
25
6
3
4
5
REF. CODE NO.
1
2
3
4
5
6
7
7
8
8
10
9
11
12
13
17
18
7
8
9
10
11
12
13
45176-NCM
45172-NCM
45179-HTM
45174-HTM
14712
40022
40023
40024
14180
14181
14182
14200
14201
14203
14205
14186
13921
40025
40010
13912
12516
40003
45127
48184
15
14
19
20
16
14
45129
48186
15
16
17
18
19
20
21
22
23
24
25
18383
18384
18253
19335
18262
21
22
23
24
12111
14614
45846
45847
45844
45845
14050
26
12
DESCRIPTION
Slip-In Tip Docking Spool® W/C-T - 5” Noz.
Slip-In Tip Docking Spool® W/C-T - 8” Noz.
Th’d Tip Docking Spool® W/C-T 5” Noz.
Th’d Tip Docking Spool® W/C-T 8” Noz.
Socket Set Screw
Spring
Ball
Seat
Body Liner .030”-.035” Hard/Cored
Body Liner .035”-.045” Hard/Cored
Body Liner .045”-1/16” Hard/Cored
Body Liner .030”-.035” Soft
Body Liner 3/64” Soft
Body Liner 1/16” Soft
Body Liner 3/32” Soft
Body Liner /564”-1/8” Hard/Cored
O-Ring (4 req’d)
Transfer Fitting
Insulating Collar
Internal O-Ring
External O-Ring
Nut
Water-Cooled Nozzle - A5” High Capacity (ONLY)
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” & 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 (Th’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
All NC, NCC, NCM
(Tip provides 1/8” set back)
All NC, NCC, NCM
(Tip provides 3/8” set back)
All NC, NCC, NCM
(Tip provides 1/8” set back)
Wire Size
.030”
.035”
.045”
.052”
1/16”
5/64”
3/32”
7/64”
1/8”
.035”
.045”
.052”
1/16”
5/64”
3/32”
7/64”
1/8”
3/64”
1/16”
5/64”
3/32”
Wire Type
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Cored
Cored
Cored
Cored
Cored
Cored
Cored
Cored
Soft
Soft
Soft
Soft
Code No.
10883
10884
10885
10886
10887
10888
10889
10904
10933
10893
10894
10895
10896
10897
10898
10899
10900
10902
10935
10888
10936
CURRENT TIPS - 7/16” DIAMETER THREADED
Gun/Barrel Model
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,
MTW
(Tip provides 1/8” set back)
Wire Size
.035”
.045”
.052”
1/16”
5/64”
3/32”
7/64”
1/8”
.035”
.045”
.052”
1/16”
5/64”
3/32”
7/64”
1/8”
3/64”
1/16”
5/64”
3/32”
1/8”
Wire Type
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Cored
Cored
Cored
Cored
Cored
Cored
Cored
Cored
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Code No.
15116
15117
15121
15118
15119
15120
15122
15105
15101
15106
15112
15107
15108
15109
15110
15111
15126
15125
15087
15148
15123
13
DIRECT MOUNT DOCKING SPOOL®/WATER-COOLED-TO-THE-TIP
WATER-COOLED NOZZLES - 5”, 8”, A5” & A8”
5/16” SLIP-IN CURRENT TIP
1
4
3
2
5
Lincoln
NA-3/NA-5
9.250”
Standard 5”
&
Series A5”
12.312”
Standard 8”
&
Series A8”
Description
Standard
Nozzle
Dia. 1.125”
Series A
Nozzle
Dia. 1.445”
Direct Mount 5” Standard Nozzle
Docking Spool®/Water-Cooled-to-the-Tip
Model NCM-W/C-T
Code No.
40134
Direct Mount 8” Standard Nozzle
Docking Spool®/Water-Cooled-to-the-Tip
Model NCM-W/C-T
40135
Direct Mount A5” High-Capacity
Docking Spool®/Water-Cooled-to-the-Tip
Model NCM-W/C-T-A
40136
Direct Mount A8” High-Capacity
Docking Spool®/Water-Cooled-to-the-Tip
Model NCM-W/C-T-A
40137
NOTE: Add Footage to Code Number for Length Desired
Example: Complete Assembly with 4 Ft. Utilities - 40134-4
Ref.
Code No.
3
4
5
46300
46260
46320
1
2
45196
14430
Description
Utility Station (see p. 16)
Optional Cable/Water Hose
Power Coupling
Water In Hose Assembly
Gas Hose Assembly - Standard
Water Out Hose & Power
Cable Assembly
NOTE: Add Footage to Code Number for Length Desired
Example: 5 Ft. Water In Hose Assembly - Code No. 46300-5
14
DIRECT MOUNT DOCKING SPOOL®/WATER-COOLED-TO-THE-TIP
WATER-COOLED NOZZLES - 5”, 8”, A5” & A8”
7/16” THREADED CURRENT TIP
1
4
3
2
5
Lincoln
NA-3/NA-5
9.250”
Standard 5”
&
Series A5”
12.312”
Standard 8”
&
Series A8”
Description
Standard
Nozzle
Dia. 1.125”
Series A
Nozzle
Dia. 1.445”
Direct Mount 5” Standard Nozzle
Docking Spool®/Water-Cooled-to-the-Tip
Model HTM-W/C-T
Code No.
40246
Direct Mount 8” Standard Nozzle
Docking Spool®/Water-Cooled-to-the-Tip
Model HTM-W/C-T
40247
Direct Mount A5” High-Capacity
Docking Spool®/Water-Cooled-to-the-Tip
Model HTM-W/C-T-A
40248
Direct Mount A8” High-Capacity
Docking Spool®/Water-Cooled-to-the-Tip
Model HTM-W/C-T-A
40249
NOTE: Add Footage to Code Number for Length Desired
Example: Complete Assembly with 4 Ft. Utilities - 40246-4
Ref.
Code No.
3
4
5
46300
46260
46320
1
2
45196
14430
Description
Utility Station (see p. 16)
Optional Cable/Water Hose
Power Coupling
Water In Hose Assembly
Gas Hose Assembly - Standard
Water Out Hose & Power
Cable Assembly
NOTE: Add Footage to Code Number for Length Desired
Example: 5 Ft. Water In Hose Assembly - Code No. 46300-5
15
UTILITY STATION - STANDARD
DIMENSION SPECIFICATIONS
ORDERING INFORMATION
Description
Utility Station
Utility Station - Dual Power Cable
Code No.
45196
45188
Base Length
Overall Length
Base Width
Overall Width
Overall Height
Mounting Hole Center Distance
Overall Weight
3.75”
5.75”
2.25”
2.5”
3.125”
2.75”
3.5 lbs.
UTILITY STATION SIDE VIEW WITH COVER
D/F TORCH CONNECTION
Water In
Hose
5.75”
Water Out &
Power Cable
Gas
Hose
3.125”
3.75”
2.5”
FROM LEFT: D/F TORCH CONNECTION
FROM RIGHT: CUSTOMER UTILITIES CONNECTION
CUSTOMER UTILITIES CONNECTION
Water Out
(3/8” Hose Shank)
Water In
(3/8” Hose Shank)
Water Out &
Power Cable
Water Out
(3/8” Hose Shank)
Water In Hose
Voltage
Sensing
Lead
Shielding Gas
(3/16” Hose Shank)
Water In (3/8” Hose Shank)
Gas Hose
Shielding Gas
(3/16” Hose Shank)
4/0 Power
Cable
1.125”
2.75”
2 ea.
1/4”-20 Screws,
Lock Washers,
Nuts
16
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 transfers 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 factory, 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.
1.395”
1.410”
Measure from Top
of Nylon Collar to
Top of Stainless
Transfer Fitting
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 transfer 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 ½ 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.
17
WIRE FEEDER ADAPTERS & INLETS
Remote Mount Adapter
Manufacturer
ESAB®
Models
D20 (20mm)
Wire Diameter
.030”-3/32” H/C/AL
5/64”-1/8” H/C
Hard
or AL
13098
Cored
13099
Direct Mount
Adapter
Stub*
Liner
Hard
or AL
*
*
13096
Cored
13097
ESAB®
18246
18247
18248
18249
EURO
18493
18493
18540
18540
Hobart®
All
Models
.030”-3/32” H/C/AL
5/64”-1/8” H/C
13067
Lincoln®
LN-7, LN-8,
NA5-R
.030”-3/32” H/C/AL
5/64”-1/8” H/C
13110
LN-9
.030”-3/32” H/C/AL
5/64”-1/8” H/C
16581
NA3, NA5
.030”-3/32” H/C/AL
5/64”-1/8” H/C
16879
“BIG MIG”
NA3, NA5
.030”-3/32” H/C/AL
5/64”-1/8” H/C
16879
Lincoln®
Power-Feed
10, LF-72,
LF-74
.030”-3/32” H/C/AL
5/64”-1/8” H/C
13479
Linde®
SWM31
SWM34
SWM37
SWM38
EH8
Casing to Feeder
(Accepts Linde®
Outlet Guide)
13046
13046
13047
13048
13047
13048
Mavrix
®
13050
EH10
.030”-3/32” H/C/AL
5/64”-1/8” H/C
13043
PA-10
.030”-3/32” H/C/AL
5/64”-1/8” H/C
16556
.030”-3/32” H/C/AL
5/64”-1/8” H/C
16557
.030”-1/8”
.030”-1/8”
18268
Miller®
(50 Series)
OTC®
D/F Insert
.035”-.045” Hard
.045”-1/16” Hard
5/64”-3/32” Cored
3/64”-1/16” AL
Requires
Insert
CMRE-741
*
*
13068
13112
*
*
13113
16582
*
*
16528
16878
*
*
16880
16878
*
*
16888
13469
*
*
13480
13049
13050
13052
*
*
13080
16568
Requires
Inlet
16559
*
*
16558
*
*
PME-12X
YW50AKW1
.030”-1/16”
.030”-1/16”
13090
13466
TWECO®
#4
.030”-3/32” H/C/AL
5/64”-1/8” H/C
13479
.030”-3/32” H/C/AL
5/64”-1/8” H/C
16225
13116
16529
16881
16888
13468
13049
13079
16560
18282
Requires Inlet
13469
*
*
13480
Requires Liner
Requires Inlet
13486
*Stub liners only required in feeder adapter when single-piece casing is used.
18
FEEDER ADAPTER INLETS
Wire Size
.030”
.035”
.045”
.052”
1/16”
5/64”
3/32”
7/64”
1/8”
3/64” AL
1/16” AL
3/32” AL
Steel
Code No.
Brass
Code No.
13801
13803
13806
13844
13809
13812
13814
13816
13842
16417
16418
16419
16420
16421
16422
16422
Nylon
Code No.
13807
13810
13815
Esab®, Hobart®, Lincoln®, Linde®, Miller®, OTC®, Panasonic® ABB®, Fanuc®, Kuka®, Mavrix®, Motoman®, Thermal Arc®, TWECO®, & 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.
18275
18282
Panasonic®
Welding
Alloys®
16087
ORDERING INFORMATION
Each D/F gun is fully assembled and ready to install. In order to make the installation complete,
the code number, wire size & type, make/model
of wire feeder, and inlet as needed must be specified when ordering. If special welding tools or accessories other than those listed previously are
required, please consult with the factory.
13468
13486
TROUBLESHOOTING: POROSITY (SUMMARY)
NOTE: Most POROSITY is caused by gas problems, followed by base metal contamination.
Causes of Porosity
Possible Solutions
BASE METAL CONTAMINATION
Impurities on base metal
a. Remove contamination; clean surfaces
b. Use of specific wire/gas mix for specific types of impurities
FILLER METAL CONTAMINATION
Impurities on filler metal (wire)
a. Replace wire
b. Install wire-cleaning system
c. Prevent industrial dust/dirt/grit from contaminating wire during 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 plastic bag when not in use for long periods
ATMOSPHERIC CONTAMINATION
Drafts, wind, fans, etc.
a. Protect weld from drafts (curtains/screens)
b. Use tapered or bottleneck gas nozzles when drafts cannot
be avoided
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
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
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 rapidly and create return effect at end of nozzle
5.Gas diffuser/nozzle insulator missing
6. Too high a gas flow causing the venturi effect
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
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 I.D.
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 I.D.;
use suitable wider gas nozzle
4. Reduce voltage
5. Reduce speed
4. Arc voltage too high
5. Too high a travel speed
19
TROUBLESHOOTING: SPATTER
Possible Solutions
Problems/Causes
SPATTER
Too fast or too slow wire feed for the arc voltage
Set the wire feed rate and voltage in accordance with good welding practices as recommended by a qualified welding engineer.
Too long an arc
Adjust the wire feed and voltage so that the arc is in accordance
with good welding practice for the joint to be welded. The distance from the current tip to the workpiece should be 15 times
the welding wire diameter. If the arc is too long there will be spatter, usually in the direction of the weld.
Damaged current tip
If 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.
Inclination of welding gun too great
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.
Faulty power source
Have the power source checked for faulty conditions such as
broken wires and faulty contacts.
Incorrect start
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.
Incorrect pulse parameters
Check the user manual for your power supply or consult a qualified welding engineer.
Uneven wire feed
Uneven wire feed gives rise to heavy spatter. Find the cause of
the disturbance and correct the condition before proceeding.
Impurities on the base metal
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.
Poor ground contact
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 surface first. POOR GROUND CONTACT IS THE MOST COMMON CAUSE OF UNSTABLE MIG WELDING CONDITIONS.
Too long stick-out (short-arc welding)
The stick-out should be 15 times the diameter of the wire electrode being used. With increasing stick-out, the current is reduced and the arc voltage rises, giving a longer unstable arc
and increased spatter.
Incorrect polarity
Check for correct polarity. Follow the electrode manufacturer’s
recommendations.
20
TROUBLESHOOTING: GENERAL GUIDE
Problems/Causes
ERRATIC WIRE FEED
Slipping feed rolls
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.
Clogged or worn gun liner
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 procedures are followed in order to avoid possible serious eye injury.
Liners too long or too short
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.
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 workpiece or loose power connection
Stick-out too long
An unprotected coil of wire quickly collects dust and other airborne contamination. 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 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.
A more precise distance is 15 times the wire diameter.
21
TROUBLESHOOTING: GENERAL GUIDE
Problems/Causes
AIR-COOLED GUN RUNNING TOO HOT
Poor ground
Possible Solutions
Inspect ground cable for loose connections, fraying and cuts. Correct any problem 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.
Loose power connection
Check to make sure the power connection on the power source is tight, the connection 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.
Consumable items loose or worn
Remove nozzle from gun and inspect current tip, collet nut (tip holder) and spatter disc (gas diffuser) for wear and tightness; replace or tighten as necessary.
Capacity of gun being exceeded
Note complete weld parameters, including welding current (Amps), welding voltage, 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.
Dirty connection
Remove torch and inspect parts for dirt build-up. Periodic cleaning is necessary.
22
D/F MACHINE SPECIALTIES, INC.
MIG & TIG Welding Products, Consumables & 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 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 warranted 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 limited 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 SPECIALTIES, 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.
Rev. 140612-2
1750 Howard Drive
North Mankato, MN 56003
Phone: (507) 625-6200
Fax: (507) 625-6203
www.dfmachinespecialties.com
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