D/F Water-Cooled-to-the-Tip 5" & 8" Sub-Arc MIG Torches

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

Overview Ordering Manuals &
Drawings
Accessories More Info

Overview

The D/F Direct Mount Water-Cooled-to-the-Tip Sub-Arc (SAW) Torches are the same as the Direct Mount Water-Cooled-to-the-Tip Torches. These torches feature the 1.125" smaller O.D. water-cooled nozzle for hard-to-reach, limited access areas. The D/F Machine Automatic Sub-arc positive contact assemblies are designed to provide long trouble-free service and are ideal for beam-mounted, portable tractor or semi-automatic systems for heavy fabrication environments. Submerged arc welding guns for subarc welding from D/F provide maximum control over deposition and penetration. These D/F heavy duty water-cooled weld automation torches are ideal and have been used for metal build up, hard facing, metal spray applications, and pipeline construction, or even retrofit with a flux delivery system for sub arc applications, and applications where flux and carbide is added.

The direct mount fully Water-Cooled-to-the-Tip Docking Spool® accommodates two (2) water-cooled nozzle assemblies. This arrangement is readily adaptable to dedicated or automatic welding applications such as the Lincoln Electric NA3, NA4, NA5, NA5R, Power Feed 10, LF72, LF74 automatic wire feeders, Miller series power pins, ESAB, Euro and Tweco #4. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®, and a Water Cooled Nozzle. The Docking Spool® 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 with superior water cooling. 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®. 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.

Features

  • Water Cooled Internally - Tip Recessed in Water Cooling
  • Water Cooled Externally - Gas Cup Recessed in Water Cooling
  • Up to 650 Amps Continuous Duty Cycle
  • Up to 850 Amps Continuous with Dual Power Cables
  • Adaptable to Any Wire Feeder or Power Source
  • Withstands Preheat Upwards of 900 Degrees

Model Explanation

  • NCM-W/C-T - Normal Duty, Collet Action (Slip-In Tip), Machine Barrel - Water-Cooled-to-the-Tip
  • HTM-W/C-T Series-A - Heavy Duty, Threaded Tip, Machine Barrel - Water-Cooled-to-the-Tip

Model Specifications

MODEL CURRENT
CAPACITY
WEIGHT w/ 5"
NOZ. (APPROX.)
WEIGHT w/ 8"
NOZ. (APPROX.)
COOLING
REQUIRED
RECOMMENDED WIRE
DIA. RANGE
INSTRUCTION
MANUAL
NCM-W/C-T 450 amps 2.8 lbs 3.5 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL
599
HTM-W/C-T 850 amps 2.8 lbs 3.5 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL
HTM-W/C-T
(with Dual Power Cable)
850 amps 2.8 lbs 3.5 lbs 3 quarts/min .030"-5/32" Hard/Cored,
3/64"-1/8" AL

Barrel Dimensions

MODEL LENGTH W/ 5" NOZZLE LENGTH W/ 8" NOZZLE DIAMETER OF DOCKING SPOOL BODY DIAMETER OF W/C NOZZLE
NCM-W/C-T, HTM-W/C-T 9.25" 12.25" 1.625" 1.125"

Ordering Information (Complete Assemblies)

DESCRIPTION CODE NO. (NCM) CODE NO. (HTM)
5" Nozzle 40134 40246
8" Nozzle 40135 40247
Add Footage Digit to Item Code Number for Length Required.
Example: Require 40134 with 4 Ft. Water-In Hose Assembly: 40134-4

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
NCM-W/C-T, HTM-W/C-T 599

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
NCM-W/C-T 5" 40134 40134 40134
HTM-W/C-T 5" 40246 40246 40246
NCM-W/C-T 8" 40135 40135 40135
HTM-W/C-T 8" 40247 40247 40247

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options
W/C Direct Mount Water-Cooled-to-the-Tip
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


D/F #30421 Sub-Arc Attachment

The D/F Water-Cooled-to-the-Tip Machine Barrels used with the D/F Submerged Arc Attachment are the industry's most advanced sub-arc torches for mobile, hard automation, and robotic feeding equipment, and will help achieve new levels of welding performance and operational efficency. Whether your application is bridge decking, pressure vessels, panel line, seamers, pipe mill integrator solutions, or submerged arc robotic welding, the D/F sub arc choices are designed to improve weld quality, reduce welding and operational costs, and increase weld team productivity.

Sub-Arc

D/F Water-Cooled-to-the-Tip Sub-Arc - More Information

The D/F Water-Cooled-to-the-Tip automatic Remote Mount and Direct Mount Machine Barrels are ideal for submerged arc (SAW) welding applications. They are repairable and easy to maintain. Our consumables are always in stock and are 1/3 of the cost of competitiors'. Customers have been perpetually pleased to find out that we ship every order within 3 days of receipt of a purchase order, and that we are always willing to do our best to ship our equipment for next-day delivery.

The direct mount fully Water-Cooled-to-the-Tip Docking Spool® accommodates two (2) water cooled nozzle assemblies. This arrangement is readily adaptable to dedicated or automatic welding applications such as the Lincoln Electric NA-3, NA-4, NA-5, NA-5R, Power Feed 10, LF-72, LF-74 automatic wire feeders, Miller series power pins, ESAB, Euro and Tweco #4. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®, and a Water Cooled Nozzle. The Docking Spool® 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 with superior water cooling. 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®. 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.

The W/C Tip Torches can run the complete line of D/F standard size C122 DHP contact tips and the complete line of D/F standard size CrZr (chromium zirconium) long-life contact tips, as well as any custom current tip configuration you may need. .030" (.8mm), .035" (.9mm), .045" (1.2mm), .052" (1.4mm), 1/16" (1.6mm), 3/64" (1.2mm), 5/64" (2mm), 3/32" (2.4mm), 1/8" (3.2mm) and other diameters.

W/C Tip D/F Machine Specialties torches are standard equipped with 1 water/out & power cable are rated at 650 amps (continuous duty cycles). These ratings are, however, dictated by the contact tip. The NCM (slip-in) series of contact tips is rated up to 450 amps (continuous duty cycles). If your welding application requires amperages above 450, you must change to the heavy duty threaded CrZr (chromium zirconium) series of contact tips.

These automatic machine welding assemblies are designated by torch models. The model NCM (slip-in Contact Tip) has a current capacity 450 amps in argon shielding. Like the ESAB ST-12, these accommodate slip-in current tips fastened by a collet action nut. The wire diameter range with hard wire is .030"-1/16", cored wire .035"-1/8", and aluminum wire range of .035"-3/32".

The torch model HTM (Threaded Contact Tip) 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 CrZr (chromium zirconium copper) current tips and will accommodate .030" - 1/16" hard wire, .035" – 1/8" cored wire and 3/64" - 3/32" aluminum wires.

In some instances C122 DHP is adequate, but for stainless steel and stiff, high column strength or abrasive wires such as flux cored / metal cored, CrZr is the correct choice. D/F Machine Specialties can increase several key characteristics creating a higher-quality consumable with increased conductivity, even higher softening temperature and improved hardness. This means a reduction in "arc start failures" and increased tip life. Copper chromium zirconium (CuCrZr) contact tips increase productivity.

W/C Tip model torches can also be retrofit to have 2 water/out & power cables increasing the continuous duty cycle rating to 850 amps. These amperages require the use of the HTM or threaded series of chromium zirconium (CrZr) current tips.

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.

Fixed automation is a process that uses mechanized machinery to perform repetitive operations in order to produce a high volume of similar parts. In fixed automation, the sequence of processing operations is fixed by the equipment layout.

Programmable automation is an applied form of fixed automation that is capable of repeating motion, in a series of steps, for producing products in batches. Applied products in a programmable automation system are made in batch quantities ranging from several dozen to several thousand units at a time. For each new batch, the programmable automation equipment must be reprogrammed and changed over to accommodate the new product style. Programmable automation may commonly include one to three axes of torch motion and/or multiple welding arcs.

D/F Machine Specialties is the world leader in the manufacture of water-cooled torches for hard automation systems which encompasses fixed automation and programmable automation.

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.