D/F Water-Cooled BIG TIG® Machine Torch - 1000 Amp TIG Torch

Ordering Information

Complete Barrel Only

Complete Assemblies

Manuals & Downloads

Instruction Manuals

CAD Files & Drawings

Other Documents

Utility Station #45188 - Dual Power Cable

The 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 Cables 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.

More Information

The D/F "BIG TIG®" Tube Mill 1000 (TM1000) Water-Cooled TIG Torch will help reach maximum output of the tube mill with increased tube mill weld speeds, increased arc stability for optimum weld quality and consistency, and maximized number of hours for welding electrode tip life, thus reducing mill shut downs and start ups, and also reducing the amount of scrap produced. The "BIG TIG®" 1000 amp high current machine barrel is ideal for Mechanized or Robotic pipe/roll forming welding applications. Due to the fact that there are varying requirements for each TIG welding application, this series of D/F torches is tailored to fit each of these unique applications and falls under the "specialties", hence the name D/F Machine Specialties®, and requires a 2-3 week delivery upon receipt of a purchase order. We highly recommend that customers also purchase a backup torch to reduce downtime due to the fact that these are custom torches and have a 2-3 week delivery upon receipt of order.

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.

D/F Machine Specialties® has been committed to producing the finest American made welding products available on the market today. D/F's MIG (Gas Metal Arc Welding) & TIG (Gas Tungsten Arc Welding) torches have been used exclusively with welding automation equipment by Lincoln Electric, Miller Electric, Linde/ESAB, and Thermadyne for over 40 years. For automated welding systems, hard automation, high deposition, high current density, and large wire diameters that require preheat and high amperage, a D/F heavy duty water-cooled weld automation torch is ideal and has been used for large diameter aluminum welding, metal build up, hardbanding, hardfacing, metal spray applications, and pipeline construction, or even retrofit with a flux delivery system for sub-arc applications, and applications where carbide is added like with the Welding Alloys Multi Surfacer: custom designed automated welding equipment. Our torches have been designed, tested, used and continuously upgraded for more than 40 years, in almost every type of environment. The flexibility of D/F Machine Specialties® automatic welding torches makes them ideal for all fabrication applications. Our torches are suitable for GMAW, pulsed GMAW and FCAW processes. They provide a wide range of travel, wire feed, and oscillation parameters to accommodate various materials, thicknesses and joint designs.

The most cost effective are 90 or 95 percent alumina oxide nozzles, which work adequately for lower amperage applications. These nozzles, however, do not resist thermal shock on higher amperage applications very well and tend to deteriorate or crack and fall off.

Consumables

Tungsten Collet Sizes