Ceramic Nozzle
D/F Tube Mill Water-Cooled Robotic

Water-Cooled Automatic TIG Torch
Ceramic Gas Nozzle

Overview Ordering Manuals &
Drawings
Accessories More Info

Overview

D/F Machine Specialties machine-held water-cooled TIG torches or GTAW torches are designed to meet the stringent and continuous demands of precise, high-amperage mechanized welding applications. The D/F Machine Specialties TM500-CN (Tube Mill) Top Load TIG Automated Machine Barrel is intended for semi-automatic or automatic machine applications of the tungsten inert arc process. The barrel accommodates top load of tungsten with a tubular dual collet design providing clamping pressure at two points.

The TM 500 Machine Torch Series features a heavy-duty 500 amp water-cooled power cable. This water-cooled automated TIG barrel has the unique feature of the nozzle assembly water passages being serially connected to the inner body water chamber by means of sliding removable connectors. This allows ease of maintenance and eliminates the use of o-rings or gaskets in the water passage system.

D/F Nozzles (also called gas cups) provide a given amount of shielding gas coverage to the weld pool, according to their size (anywhere from 1/4- to 5/8-inch ID). For example, a smaller nozzle provides less gas coverage than a larger one. Nozzles also vary in price and performance. Built-in gas lens/gas difusser improves gas coverage to eliminate shielding gas turbulence and improve weld quality (all models). The TM 500 Back Load TIG Torch is available in 12.5" barrel lengths to meet exact welding requirements on precise mechanized jobs. Front or back tungsten loading/tightening eases tungsten changeover and extension adjustments (all models). Internal tungsten adjustment eases fine positioning of tungsten and allows for axial movement of 1/4 inch (all models).

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.

Lava nozzles cost more than alumina oxide nozzles and are more resistant to cracking. These nozzles work well on medium to high amperage applications.

The bottom line when choosing TIG consumables is to look for factory OEM parts that provide you with the durability and performance you need. A wide variety of options exist for back caps, collets and collet bodies, gas lenses and nozzles, all of which offer distinct advantages, disadvantages and cost considerations. For less critical applications, the less expensive alumina nozzles provide adequate performance. However, if you need high performance, it is well worth your while to purchase more expensive, long-lasting lava nozzles or cups. Doing so minimizes the chance of consumable failures that could ultimately increase the cost for rework associated with weld inconsistencies.

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.

Features

  • Water-Cooled Inner Body & Nozzle
  • 500 Amp Top Load
  • Adaptable to Any Power Source & Robotic Application
  • Withstands Preheat & Extreme Conditions
  • Dual Clamping Collet Provides Pressure at Two Points
  • Tungsten Range .040"-5/32" (1mm-4mm)
  • Gas Cup Range 1/4"-5/8" (#4-#10, 6.5mm-16mm)

Model Explanation

  • TM500-CN - Tungsten Machine Barrel, 500 Amp - Ceramic Nozzle

Model Specifications

MODEL CURRENT
CAPACITY
WEIGHT (APPROX.) COOLING REQUIRED RECOMMENDED TUNGSTEN
ELECTRODE RANGE
INSTRUCTION
MANUAL
TM500-CN 500 amps 2.5 lbs 3 quarts/min .040"-5/32" (1mm-4mm) 64TM

Barrel Dimensions

MODEL LENGTH DIAMETER OF BODY HOUSING
TM500-CN 12.5" 1.625"

Ordering Information

Complete Barrel Only

DESCRIPTION CODE NO.
TM500 15499

Complete Assemblies

DESCRIPTION CODE NO.
2 Ft. 3 Ft. 4 Ft. 5 Ft. 6 Ft. 7 Ft. 8 Ft. 10 Ft. 12 Ft. 15 Ft.
TM500 15192
TM502
15193
TM503
15194
TM504
15195
TM505
15196
TM506
15197
TM506
15198
TM508
15199
TM510
15200
TM512
15201
TM515

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
TM500-CN 64TM

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
TM500-CN 15499 15499 15499

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options
W/C TIG Machine Barrel
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

Consumables

Tungsten Collet Sizes

DESCRIPTION CODE NO.
.040"
(1mm)
1/16"
(1.6mm)
3/32"
(2.4mm)
1/8"
(3.2mm)
5/32"
(4mm)
Collet for Tungsten 15871 15872 15873 15874 15875

TIG Gas Nozzle Sizes

DESCRIPTION CODE NO.
1/4"
(No. 4)
3/8"
(No. 6)
1/2"
(No. 8)
5/8"
(No. 10)
Ceramic Gas Nozzle 15895 15896 15897 15898
Metallic Nozzle
D/F Tube Mill Water-Cooled Robotic TIG Barrel - Metallic TM500

Water-Cooled Automatic TIG Torch
Ceramic Gas Nozzle

Overview Ordering Manuals &
Drawings
Accessories More Info

Overview

The TM500L-MN (Tube Mill) Metallic Top Load TIG Machine Barrel is intended for semi-automatic or automatic machine applications of the tungsten inert arc process. The barrel accommodates top load of tungsten with a tubular dual collet design providing clamping pressure at two points.

This water-cooled TIG barrel has the unique feature of the nozzle assembly water passages being serially connected to the inner body water chamber by means of sliding removable connectors. This allows ease of maintenance and eliminates the use of o-rings or gaskets in the water passage system.

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.

Features

  • Water-Cooled Inner Body & Nozzle
  • 500 Amp Top Load
  • Adaptable to Any Power Source & Robotic Application
  • Withstands Preheat & Extreme Conditions
  • Dual Clamping Collet Provides Pressure at Two Points
  • Tungsten Range .040"-5/32" (1mm-4mm)
  • Gas Cup Range 1/4"-5/8" (#4-#10, 6.5mm-16mm)

Model Explanation

  • TM500L-MN - Tungsten Machine Barrel, 500 Amp Long - Metallic Nozzle

Model Specifications

MODEL CURRENT
CAPACITY
WEIGHT (APPROX.) COOLING REQUIRED RECOMMENDED TUNGSTEN
ELECTRODE RANGE
INSTRUCTION
MANUAL
TM500L-MN 500 amps 2.5 lbs 3 quarts/min .040"-5/32" (1mm-4mm) 60TM

Barrel Dimensions

MODEL LENGTH DIAMETER OF BODY HOUSING
TM500L-MN 14.575" 1.625"

Ordering Information

Complete Barrel Only

DESCRIPTION CODE NO.
TM500L-MN 15500

Complete Assemblies

DESCRIPTION CODE NO.
3 Ft. 4 Ft. 5 Ft. 6 Ft. 8 Ft. 10 Ft.
TM500L-MN 15294
TM500-3
15295
TM500-4
15296
TM500-5
15297
TM500-6
15298
TM500-8
15299
TM500-10

Manuals & Downloads

Instruction Manuals

TORCH MODELS DOWNLOAD
TM500-CN 60TM

CAD Files & Drawings

TORCH MODELS CODE NO. CAD FILE PDF DRAWING
TM500L-MN 15500 15500 15500

Other Documents

DESCRIPTION DOWNLOAD
Torch Connection Options
W/C TIG Machine Barrel
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

Consumables

Tungsten Collet Sizes

DESCRIPTION CODE NO.
.040"
(1mm)
1/16"
(1.6mm)
3/32"
(2.4mm)
1/8"
(3.2mm)
5/32"
(4mm)
Collet for Tungsten 15871 15872 15873 15874 15875

TIG Gas Nozzle Sizes

DESCRIPTION CODE NO.
3/8" 1/2" 5/8" 3/4"
Metallic Gas Nozzle 15901 15902 15903 15904