Standard Barrels
D/F Water-Cooled Automatic Docking Spool®/Weld Body Combination

Standard Barrels
(7/16"-3/4" Gas Cup ID)

Overview Ordering Manuals &
Drawings
Accessories

Overview

D/F Machine Specialties Docking Spool/Weld Body Combination on a BUG-O Piper PlusThese Direct Mount MIG Welding Torches - Docking Spool®/Weld Body Combination accommodate two (2) different size outside diameter gas nozzles for varying gas coverage, and five (5) different lengths of water-cooled nozzle assemblies for limited access or hard to reach areas. Whether you are running steel, metal cored, or aluminum wire, the correct torch can be chosen for a neat and clean installation, and for optimum performance for your application. This arrangement is readily adaptable to dedicated or automatic welding applications. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®/Weld Body Combination, and a Water-Cooled Nozzle. The Docking Spool®/Weld Body Combination is the principal component in this welding equipment arrangement. It accepts the utilities at the top end of the Docking Spool® and provides a means of accepting the water-cooled nozzle at the lower end. Several features important to a welding system are provided. Incorporated within the water channels of the Docking Spool® are check valves which provide a means of retaining residual water in the lines when the nozzle assembly is removed from the Docking Spool®/Weld Body Combination. In addition a Posit® Ring is provided at the upper end of the Docking Spool® which allows positive location in a mounting bracket to maintain dimensional stability.

These MIG welding torch assemblies are designated by models. The model NCM has a current capacity 400 amperes in argon shielding at 100% duty cycles. These accommodate slip-in current tips fastened by a collet action nut. The wire diameter range is .030” through 1/16” with hard wire, .035” through 1/8” with cored wire and 3/64” through 3/32” aluminum.

The model HTM has a current capacity range of 500 amperes at 100% duty cycles. Rating will be contingent on the combination of current tip and shielding gas used. The model HTM employs threaded CuCrZr current tips accommodating .030” through 1/16” hard wire, .035” through 1/8” cored wire, and 3/64” through 3/32” aluminum.

An optional D/F Torch Rack #30418 can be used on any torch with an 8" long, 1.125" diameter water-cooled nozzle. The rack slips right over the water-cooled nozzle and is secured with 4 set screws. The rack can then be dropped into a BUG-O BUG-5188 Rack Holder. The rack has a 32 pitch gear, and with the rack holder makes torch head positioning very easy. See the images below right.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 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). 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 at 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 torches internals in seconds causing a leak. It can also blow out the torches 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, high current density, high amperages, preheat, or extended periods of arc time are used, a refrigerated liquid chiller with a larger reservoir is required. 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. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Each D/F Machine Specialties welding gun is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, wire feeder make/model (Lincoln wire feeders, Miller wire feeders, Tweco wire feeders, ESAB wire feeders, & EURO Quick Disconnect wire feeders), 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. Get the right feeder adapter connection to fit your MIG wire feeder.

Features

  • Water-Cooled Docking Spool® Body & Nozzle
  • Small Frontal Area for Hard-to-Reach Locations
  • Two (2) Different-Size W/C Nozzle Assemblies for Numerous Gas Cup IDs (7/16”-3/4”)
  • Nozzle Length may be Extended by Five (5) Different-Length W/C Nozzle Assemblies
  • Withstands Preheat Upwards of 900 Degrees
  • Optional Torch Holding Rack for Easy Mounting

Model Explanation

  • NCM - Normal Duty, Collet Action (Slip-in Tip), Machine Barrel
  • HTM - Heavy Duty, Threaded Tip, Machine Barrel

Model Specifications

MODEL CURRENT
CAPACITY
WEIGHT (APPROX.) COOLING REQUIRED RECOMMENDED WIRE
DIA. RANGE
INSTRUCTION
MANUAL
NCM 400 amps 2.5-4.5 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL
510
HTM 500 amps 2.5-4.5 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL

Barrel Dimensions

MODEL LENGTH W/ 3" NOZZLE LENGTH W/ 4" NOZZLE LENGTH W/ 5" NOZZLE LENGTH W/ 8" NOZZLE LENGTH W/ 9-25/32" NOZZLE DIAMETER OF W/C NOZZLE
NCM, HTM 7.25" 8.25" 9.25" 12.25" 14.25" 1.125"

Ordering Information

Complete Assemblies

DESCRIPTION CODE NO.
NCM HTM
Short 3" 40120 40140
Inter. 4" 40121 40141
Long 5" 40122 40142
Long 8" 40131 40151
Long Reach 11" 40123 40143
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40120 with 4 Ft. Water-In Hose Assembly: 40120-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM, HTM 510

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM 3" 40120 40120 40120
HTM 3" 40140 40140 40140
NCM 4" 40121 40121 40121
HTM 4" 40141 40141 40141
NCM 5" 40122 40122 40122
HTM 5" 40142 40142 40142
NCM 8" 40131 40131 40131
HTM 8" 40151 40151 40151
NCM 11" 40123 40123 40123
HTM 11" 40143 40143 40143

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options
W/C Direct Mount Docking Spool®
Weld Body Combination One-Sheet

Utility Station #45196

45196 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. 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 (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45196D/F Utility Station #45196


Torch Rack #30418 and Rack Mount

An optional D/F Torch Rack #30418 can be used on any torch with an 8" long, 1.125" diameter water-cooled nozzle. The rack slips right over the water-cooled nozzle and is secured with 4 set screws. The rack can then be dropped into a BUG-O BUG-5188 Rack Holder. The rack has a 32 pitch gear, and with the rack holder makes torch head positioning very easy. See the images below right. See the Torch and Rack Mount product page for more information

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Torch RackD/F Torch Rack

Series-A Barrels
D/F Water-Cooled Automatic Docking Spool®/Weld Body Combination

Series A High Capacity Barrels
(11/16"-1" Gas Cup ID)

Overview Ordering Manuals &
Drawings
Accessories

Overview

The Direct Mount MIG Welding Torches - Docking Spool®/Weld Body Combination offer the same features as those described above with the capability of providing larger I.D. gas nozzles for varying gas coverage, and by its design offers a steady, smooth, non-turbulent gas flow for high-volume production welding of a repetitive nature.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 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). 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 at 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 torches internals in seconds causing a leak. It can also blow out the torches 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, high current density, high amperages, preheat, or extended periods of arc time are used, a refrigerated liquid chiller with a larger reservoir is required. 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. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Each D/F Machine Specialties welding gun is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, wire feeder make/model (Lincoln wire feeders, Miller wire feeders, Tweco wire feeders, ESAB wire feeders, & EURO Quick Disconnect wire feeders), 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. Get the right feeder adapter connection to fit your MIG wire feeder.

Features

  • Water-Cooled Docking Spool® Body & Nozzle
  • Small Frontal Area for Hard-to-Reach Locations
  • Two (2) Different-Size W/C Nozzle Assemblies for Numerous Gas Cup IDs (11/16"-1”)
  • Nozzle Length may be Extended by Five (5) Different-Length W/C Nozzle Assemblies
  • Withstands Preheat Upwards of 900 Degrees

Model Explanation

  • NCM-A - Normal Duty, Collet Action (Slip-in Tip), Machine Barrel - High Capacity (Series A)
  • HTM-A - Heavy Duty, Threaded Tip, Machine Barrel - High Capacity (Series A)

Model Specifications

MODEL CURRENT
CAPACITY
WEIGHT (APPROX.) COOLING REQUIRED RECOMMENDED WIRE
DIA. RANGE
INSTRUCTION
MANUAL
NCM-A 400 amps 2.5-4.5 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL
530
HTM-A 500 amps 2.5-4.5 lbs 3 quarts/min .030"-1/8" Hard/Cored,
3/64"-3/32" AL

Barrel Dimensions

MODEL LENGTH W/ 3" NOZZLE LENGTH W/ 4" NOZZLE LENGTH W/ 5" NOZZLE LENGTH W/ 8" NOZZLE LENGTH W/ 9-25/32" NOZZLE DIAMETER OF W/C NOZZLE
NCM-A, HTM-A 7.25" 8.25" 9.25" 12.25" 14.25" 1.445"

Ordering Information

Complete Assemblies

DESCRIPTION CODE NO.
NCM HTM
Short 3" 40125 40145
Inter. 4" 40126 40246
Long 5" 40132 40152
Long 8" 40133 40153
Long Reach 11" 40127 40147
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40125 with 4 Ft. Water-In Hose Assembly: 40125-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM, HTM 510

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM A3" 40125 40125 40125
HTM A3" 40145 40145 40145
NCM A4" 40126 40126 40126
HTM A4" 40146 40146 40146
NCM A5" 40132 40132 40132
HTM A5" 40152 40152 40152
NCM A8" 40133 40133 40133
HTM A8" 40153 40153 40153
NCM A11" 40127 40127 40127
HTM A11" 40147 40147 40147

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options
W/C Direct Mount Docking Spool®
Weld Body Combination One-Sheet

Utility Station #45196

45196 Utility StationThe D/F Utility Station is required for all D/F torch installations. Typical modern torch setups utilize a unitized cable assembly with a power pin. 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 (see right) of the Utility Station. Into the back (see below) of the Utility Station go the customer's utilities. Read more on the D/F Utility Station product page.

For more information on proper use of the D/F Utility Station, and to see the various torch connection options, please download the Torch Connection Options one-sheet.

D/F Utility Station #45196D/F Utility Station #45196