D/F Utilities Combination

D/F Utilities Combination

Overview Ordering Manuals &
More Info


Typical modern torch setups utilize a unitized cable assembly with the gas, water, power and conduit combined into a single replaceable unit. When one cable goes bad the whole unit is replaced. This can be expensive. Also, this approach does not allow for a large enough inner power cable needed for necessary high amperages, and it is restricted in size by small passages for water, gas and wire. Water-cooling and gas coverage are both limited by the size restrictions.

D/F torches take an alternative approach to the setup. The torches use a separate gas hose, water in hose, Water Out & Power Cable, and casing/conduit. When one cable goes bad it is simply replaced instead of attaching an entire new unitized cable assembly; a huge cost saver! This is also where the D/F Utility Station comes into play. The gas hose, water-in hose, and Water Out & Power Cable are interfaced with the customer's existing lines via the Utility Station. The D/F torch leads plug into the front. Into the back go the customer's utilities along with a 4/0 power cable. This is how the D/F barrels are powered, NOT with a power cable to the wire feeder. The power must travel through the Utility Station and down to the torch via the Water Out & Power Cable, hence the name.

D/F Utilities Combination

Ordering Information

46620 .030"-.035" Utility Combination (46350 Casing - Requires Liner)
46621 .035"-1/16" Utility Station (46370 Casing - Requires Liner)
46621 3/64"-3/32" AL Utility Combination (46370 Casing - Requires Liner)
46622 .035"-.045" Utility Combination (46420 Casing - Single Piece)
46623 .045"-1/16" Utility Combination (46440 Casing - Single Piece)
46624 5/64"-3/32" Utility Combination (46460 Casing - Single Piece)
46625 7/64"-1/8" Utility Combination (46480 Casing - Single Piece)

Manuals & Downloads

Other Documents

Torch Connection Options
Utilities Combinations

Directly and Remotely Mounting D/F Torches

Not only are D/F torches water-cooled on the inside of the body, the nozzle is also water-cooled. The water cooled nozzle (the front of the D/F torch) is insulated from the body that is carrying the current. If a torch is properly mounted on the insulated body and not touching metal, you can actually grab the front of the torch because it is not hot. Since the water-cooled nozzle is insulated from the hot body, and because of the superior water cooling, the front nozzle will also be cool to the touch after welding at high amperage and preheat. This installation allows everything to run cooler and last longer.

Using the D/F #45196 utility station allows the torches to be connected in two completely different ways--directly or remotely. To directly connect a D/F torch to the wire feeder, simply thread the correct feeder adapter for the power source into the top of the D/F torch and plug the torch into the wire feeder. The utilities leave the torch at a 90 degree angle and can be connected to the utility station.

Remote connection of a D/F torch requires a mounting bracket or robotic mounting arm to grab the torch. This arm or bracket is then mounted on a robot, fixture, gantry, x- y- z axis, or above a positioner or manipulator. The wire is brought into the torch through a conduit/casing (usually from 4ft-15ft). Remote mounting enables customers to get the wire feeder away from the pre-heat, torch heat, and the work. It also allows the end user to access hard to reach areas. Furthermore, it allows for all of the utilities to be protected together inside a fire resistant sheath.

A third mounting variation exists that somewhat combines direct and remote mounting and includes the utility station. A direct mount torch can be remotely mounted. We make this possible by putting an adapter on the top of the direct mount torch. This adapter will allow you to now attach a casing/conduit on the top of the torch and get the torch anywhere from 1-15 feet away from the heat. This method of remotely mounting a direct mount torch is preferred in installations where there is limited room for mounting and running the lines. This allows for easy access to the casing/conduit to be changed out, and for ease in changing liners. This method is used in hard banding applications by mounting a “dog bone” on the front of the water-cooled nozzle of the torch, and off of that mount will come the cold wire feed or sub arc attachments.

Examples of the two main mounting methods, direct and remote, and the third optional method are listed below:

Direct Mount Torches

The torch is directly connected to (plugged into) the wire feeder.

Direct Mount Water-Cooled-to-the-Tip Torches

Direct Mount Torch

Remote Mount Torches

The torch is directly connected to (plugged into) the wire feeder.

Remote Mount Water-Cooled-to-the-Tip Torches

Direct Mount Torch

Remotely Mounted Direct Mount Torches

Remotely mount a direct mount torch.

Remotely Mounted Direct Mount Torch