2014 Wire Wizard Brochure

WW

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201

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Wire Wizard theartofwirefeeding

Wire Guide Modules, look at page 18

Check our new website at: www.wire-wizard.eu

Productcatalog weld wire dispensing systems

2

Introduction

New Wire Guide Modules The most spectacular innovation in years are the new Wire Guide Modules. A totally new concept of feeding wire. Philosophy:

- What causes the most friction in wire transport?

- Exactly, “the bends and curves in your conduit”

- Eliminate these curves, you’ll eliminate the friction.

Within this new way of thinking the straight ends of your wire feed are made with the familiar conduits and the bends are made with these Wire Guide Modu-les. Each module has a curve of 45 degrees and can be built together with other mo-dules in order to make a 90, 135 or 180 degrees curves. In this way large distan-ces can be bridged without assist.

Dear Welding Associate,

You’re about to enter the world of the Wire Wizard. This Wizard will hand you a solution for each wire feed problem you are faced with or will be in future.

Wire Wizard is the world leading brand in wire dispensing products. Started in 1985 by Elco Enterprices, Inc. in USA and brought over to Europe in 1999. Through anticipation of customer needs and ongoing dialogue with end users Wire Wizard created a distinct product line of High quality products.

What is Wire Wizard?

Wire Wizard is a range of products to dispense welding wire from any kind of spool or drum to any kind of wire feeder. This means that whatever kind of drums you’re using; Wire Wizard has a cone especially for your type of drum. And also that whatever brand of robot or manual welding machine you use; Wire Wizard has a connector specially for your type of wire feeder. In combination with the high quality conduit you are able to connect everything to anything.

the possibilitiesThe Wire Wizard program offers a total solu-tion for all your wire feeding problems with high quality products. With a simple combina-tion of products it is possible to equip every robot or welding machine with a drum placed at a variable distance. Extra advance is that every connection is made with quick disconnections. This makes it very easy to replace or clean the conduit. To change from one type of wire to another can be done very fast.

6 steps to your solutionWire Wizard keeps things simple. Each situa-tion is connected with a universal type of con-nector and also the conduit is easy to choose. This makes it very easy to compose your own set of equipment specially for your situation. In 6 steps this catalogue takes you to a perfect set of equipment.

Step 1 - Cone’s

Features:• Four standard designs fits all current drums• Constructed of tough polyethylene and guaranteed against breakage• Dual windows provide easy access for operator• Lifetime guarantee against breakage

Round dRum cone Round drum cone for standard fiber drums.Mounted with the metal ring supplied with the drum;

Size in cm Part Number51 cm WW10200C 52 cm WW10204C-STANDARD IN EUROPE 59 cm WW10234C 66 cm WW10260C

octagon dRum cone Octagon drum cone for octagonal packs. The lip securely anchors the cone to the pack.

Size in cm Part Number52 cm WWOC205 59 cm WWOC235 H

SquaRe dRum cone Square drum cone for square packs. The lip securely anchors the cone to the pack.

Size in cm Part Number54 cm WWSC-21 61 cm WWSC-24 72 cm WWSC-28

Round dRum coneRound drum cone for Economical or Environmental fiber drums. The lip securely anchors the cone to the drum

Size in cm Part Number51 cm WW10201F 58 cm WW10231F 66 cm WW10260F

3

Unbreakable polyethylene cone’s for all available drums

Size in cm Part Number 59 cm WWOC235 L LOW PROFILE HOOD

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This table helps you to choose the right cone for the drum you are using. Drum sizes have been supplied by the manufacturer who, reserve the right to change product standards without notice.

Cross reference table wire manufacturers

Step 1 - Choose the right cone

Wire manufacturer Packaging trade name WW article no.

Air Liquide 250 Kg Blue Shield WW10204CAir Liquide 400 Kg Blue Shield WW10234CAir Liquide 250 Kg Square pack WWSC-21Air Liquide 400 Kg Square pack WWSC-24Böhler-Welding 250 Kg ECO-Drum WW10204CBöhler-Welding 250 Kg ÖKO-Multi WW10204CBöhler-Welding 400 Kg Paper-Drum WW10260CElbor 250 Kg Drum 250-270 Kg WW10204CElbor 450 Kg Drum 450 Kg (Square) WWSC-28Elga 250 Kg Octagon Pac WWOC205Esab 100 Kg Marathon Pac Mini WWOC205Esab 250 Kg Marathon Pac WWOC205Esab 475 Kg Marathon Pac Jumbo WWOC235Gedik 50 Kg Economic 50 WW10200CGedik 250 Kg Big Pack 250 WW10204CGedik 500 Kg Big Pack 500 WW10234CGrytols Bruk 250 Kg Drum WW10204CGrytols Bruk 450 Kg Drum WW10234CKobelco 200 Kg Arrow Pac WW10204CKobelco 250 Kg Arrow Pac WW10204CLincoln 100 Kg Accu Trak Cube WWSC-24Lincoln 250 Kg Accu Trak Cube WWSC-24Lincoln 400 Kg Accu Trak Cube WWSC-24Lincoln 250 Kg Accu Trak Round WW10204CLincoln 400 Kg Accu Trak Round WW10204CMig-Weld 80 Kg Eco-Drum WW10201FMig-Weld 140 kg Square Pack WWSC-24Novametal 100 Kg Nova Mini Drum WW10204CNovametal 200 Kg Nova Drum WW10204CSafilo 250 Kg Safilo Drum WW10234CSelectarc 100 Kg Selectarc WW10204CSelectarc 200 Kg Selectarc WW10204CSelectarc 250 Kg Selectarc WW10204CSelectarc 300 Kg Selectarc WW10234CSidergas 150/300 Kg PAC 150/300 WWSC-21Sidergas 450 Kg PAC 450 WWSC-28Sidergas 550 Kg PAC 550 (24-7) WWSC-28Ugitech 250 Kg Drum WW10204CHyundai 250 Kg Ball pac WW10204CUgitech 250 Kg Octagon Drum WWOC205Valk Welding 250 Kg Octagon Drum WWOC20Valk Welding 250 Kg Eco Drum WW10201FValk Welding 500 Kg Eco Drum WW10260FWDI 80/250 Kg XS/S Round Drum WW10204CWDI >325 Kg M/L Round Drum WW10234CWDI >325 Kg EcoRack M WWOC205WDI 450 Kg EcoRack L WWOC235L

4

WLI WIRe LeVeL IndIcatoR

With the WLI Wire level indicator you can quickly see how much welding wire the drum still contains!

• design for 250 kg and 500 kg drums• for all brands of welding wire in

drums• works without a power supply,

air or any other medium

The direct pull kit is the most universal cone connector of the Wire Wizard program.

For 99% of all cases this is the perfect solution to connect the conduit to the cone

The direct pull contains a female connector, a washer and a ceramic inlet guide made in a derlin holder.

Step 2 - Cone connectors

WWa5-e34-nc (normally close) WWa5-e34-no (normally open)WIRe PReSence SenSoR SWItcH-24Vwith M-12 thread. Other switches are avai-lable upon request. Please call with specifi-cations for quote.

WWSB-m12WIRe PReSence SenSoR BLocKcan be added to WWDP or WWOA kits. M-12 thread is standard. Also available in M-18

HOOD

5

dIRect PuLL KIt

WIRe detectIon

The re-usable drumcore is special designed for coreless drums. To protect the wire from flipping over in the coreless center this drum core can be put inside the drum.

oRBItaL aRm KIt

The orbital arm is developed to solve problems which can occure during the dewinding of drums. Small diameter wires and heavy tangling wire can cause nuts inside the drum. With the orbital arm these problems can be solved easily.

Re-uSaBLe dRum coRe

WW-dP

WW-qdI

WW-oa-20H

WW-Ic-11

711mm

254mm

Insulator for the drum connection

WW-dI

Universal insulato-tion sleeve for all quick disconnects

WW-dP-I Direct pull kit with insulation sleeve

cone connectoR InSuLatoR

Step 3 - Conduits for Mild Steel

extRa FLexIBLe conduIt

Liner with a hard steel inner core which is made out of oval wire for a minimal resistance for the wire to pull through. This makes that the wire easily runs trough angles. With this hard inner

core and double insulation jacket these liners are stiff enough to bridge a small distance without a support, for example to a robot arm.

6

Conduits bought at bulk length can be easily cut at the right length and can be connected with a compression connector

extRa FLexIBLe conduIt In FIxed LengHtS WItH SWaged connectoRS

All conduits in our range are also available in fixed lengths with swaged connectors. For the FC-X we have made some standards.

Length* Article Number

1,5 m FCX015

3,0 m FCX030

5,0 m FCX050

8,0 m FCX080

10,0 m FCX100

12,0 m FCX120

2 Swaged connectors

1 x side with polymer strain relief

Part Dimensions in mm Connector Use for Order Bulk

Number inside x outside wire quantity length

FC-X-SW 2,3 x 9,00 mm A-10C-S 0,6 mm Per mtr 30,5 mtr

FC-X 6,0 x 12,70 mm A-10C-X 06 -1,6 mm Per mtr 30,5 mtr

FC-XH 7,5 x 15,50 mm A-10R 1,6 - 2,4 mm Per mtr 30,5 mtr

FC-XH-LW 10,0 x 19,00 mm A9/A6 2,4 - 4,0 mm Per mtr 30,5 mtr

toRcH LIneRS

The oval liner technology is also available for torch liners.

Part Dimensions in mm Use for Order Bulk


STL-1936 1,9 x 3,6 mm 0,6 - 1,2 mm 3/4/5 mtr set 50 mtr

STL-2946 2,9 x 4,6 mm 1,2 - 1,6 mm 3/4/5 mtr set 50 mtr

Wire Wizard:NO GAPS: SMOOTH ROUND EDGES

others:OPEN GAPS: SHARP EDGES

Part Dimensions in mm Use for Connector Order Bulk


EC-3 4,5 x 8,60 mm 0,6 mm A-10C-S Per mtr 152 mtr

EC-4 7,6 x 11,70 mm 0,6 - 1,6 mm A-10C-H Per mtr 152 mtr

EC-5 10,0 x 15,20 mm 1,6 - 2,4 mm A-10R Per mtr 152 mtr

EC-6 14,0 x 19,00 mm 2,4 - 4,0 mm A9 + A6 Per mtr 152 mtr

7

BLue PoLymeR conduIt In FIxed LengHtS WItH tHRead conncectoRS

All conduits in our range are also available in fixed lenghts with Thread connectors. For the EC-4 we have made some standards.


1,5 m EC4-015

3,0 m EC4-030

5,0 m EC4-050


8,0 m EC4-080

10,0 m EC4-100

12,0 m EC4-120

*Other lengths can be made at request

Thread connector

toRcH LIneRS and acceSSoRIeS

PoLymeR LIneR InSeRt a-4L-H

Wire Wizard provides a range of heat-resistant torch liners which exceeds the quality of the common liners in the market.

Part Material Dimensions in mm Use for Order Bulk

Number inside x outside ø wire quantity length

EC-1 Polymer 2,3 x 4,57 mm 1,0 - 1,6 mm per mtr 100 mtr

PHTL-1647 Polymer-carbon 1,6 x 4,7 mm 0,6 - 1,0 mm per mtr 100 mtr

PHTL-2347 Polymer-carbon 2,3 x 4,7 mm 1,2 - 1,6 mm per mtr 100 mtr

PHTL-3247 Polymer-carbon 3,2 x 4,7 mm 1,6 - 2,4 mm per mrt 100 mtr

TTL-2039 Teflon-carbon 2,0 x 3,9 mm 0,6 – 1,2 mm per mtr 80 mtr

TTL-2747 Teflon-carbon 2,7 x 4,7 mm 1,2 – 2,0 mm per mtr 80 mtr

Conduits Stainless Steel & Aluminum

BLue PoLymeR conduIt

Known throughout the industry for its longevity and low drag coefficient this dura-ble conduit has proven to outlast aluminum and stainless steel while still providing a minimum pull on the feed motor. The EC-4 is the most common of the blue polymer conduits.

Polymer conduit

Part Number

Description Use for liner with Outside diameter

TL-EN40 Thread/clamp end-nipple to connect liner in torch connector

3,9 - 4,0 mm

TL-EN42/LE42 “ 4,2 mm

TL-EN47 “ 4,7 mm

TL-LE40 Brass thread liner-end for use at liner-end in torchbody

3,9 - 4,0 mm

TL-LE42 “ 4,2 mm

a-4L-H 2,3 x 4,5 x 100 mm

The A-4L-H is designed to prevent the wire from shaving against the steel connectors

Step 4 - Conduit connectors

connectoRS FoR extRa FLexIBLe conduIt

Conduit FC-X-SW

Conduit FC-XH

Conduit FC-XH-LW

Conduit FC-X

Compression-female Quick dis. A-10R-QD

connectoRS FoR BLue PoLymeR conduIt

Conduit EC-3

Conduit EC-4

Conduit EC-5

Conduit EC-6

For c

onne

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num

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For c

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ctor

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RePLacement FeRRuLeS FoR comPReSSIon connectoRSChoice of sizes for the right compression fit for the application.

Ferrules CONNeCTOrs

A-9-FE A-9

A-10RFE A-10R A-10RP

A-10XFE A-10C-X A-10XP

A-10CFE A-10C-H A-10HP

A-10SFE A-10C-S A-9-Fe A-10rFe A-10XFe A-10CFe A-10sFe

8

Compression- bayonet A-10C-S

Compression- bayonet A-10-CX

Compression- 1/4 thread A-10-XP

Compression- bayonet A-10C-R

Compression- 1/4 thread A-10-RP

Compression- bayonet A-9+A-6

Compression- bayonet HD A-9+A-6HD

Compression- 1/4 thread A-10-HP

Compression- 1/2 thread A-10HM

Compression- Union A-10RU

Compression- Union A-9U

Compression- 1/4 thread A-10-RP

Compression bayonet A-10-CS

Compression bayonet A-10-CH

Compression bayonet A-10-R

Compression bayonet A-9+A-6

Self-treading- bayonet A-16F-3




Compression- Union A-10RU

Compression- Union A-9U

Compression- 1/4 thread HD A-9+A-6HD

Compression-inline 1/2 thread A-10-XM

the a-14 bulkhead connector

a-4 female connector 1/4” - nPt-m

The A-14 bulkhead connector has a 1/4” NPT female thread at both sides, and can therefore be used at both sides as well.

a-14B Bracket

95 mm

The A-14 bulkhead connector in combination with the A-4 female connector is used to make an insulated connection in a steel plate for example a wire feeder box. The A-14B is a universal bracket which can be used to mount the bulkhead connector.

Step 5 - Feeder connectors 1

PLate oR BuLKHead connectIon

9

a-14 BK Bulkhead connector kit

quIcK dISconnectS (FemaLe) Bayonet tHRead connectoR

tHRead adaPteRS BSP (gaS)

maLe Bayonet eSaB dRum con.

Hd HeaVy duty connectoRS FoR SuBmeRged aRc WeLdIng

use only for Hd (large) bayonet connectors

a-4 a-4St a-4S a-5 Brass -copper Steel Ring + Nut Brass-copper 1/4” NPT 1/4” NPT 1/4”BSP-M (GAS) 1/2” NPT-M

a-4S for non isolated plate connection

WWtt-dP for plate connection + ceramic insert

a-4Hd a-3Hd a-3Hd12 a-3Hd34 a-6Hd3/8”NPT-M 3/8”NPT-F 1/2”BSP-F 3/4”BSP-F 1/2”NPT-F

A-15 A-16F3 A-16F5 1/4” BSP (GAS) 1/8” NPT-F 3/8” NPT-F A-15-1 7/16”– 20 A-16F4 A-16F6 A-15-2 1/4” NPT-F 1/2” NPT-F 9/16”– 20

9/16”-18 UNF

1/4 BSP (GAS)

quIcK dISconnect WItH InSIde tHRead to mount dIRectLy at tHe InLet guIde oF tHe FeedeR

A-3 A-3 A-3QDF-1 A-3QDF-2 A-3QDF-3 A-3QDF-4 A-3QDF-5 A-3QDF-6 OTC Motoman Panasonic

a-15e 3/8”BSP-M

a-17g 1/4”F 3/8” M

a-18g 1/4”F 1/2” M

a-18g1 3/8”F 1/2” M

InLet guIdeS WItH quIcK dISconnect SPecIaL FoR one BRand


13,00 60,00

2,20

13,00

55,00

5,00

12,00

47,00

3,20

9,50

33,00

a-1otc-Fx a-1FRo a-2FRo a-1FRo-B a-1mot-HP a-1na-5 a-1B-c OTC Fronius Feeder Fronius Feeder Fronius Feeder Motoman Lincoln Miller Wire Hyper Feeder Feeder Straightener & PFA Models

70,00

2,00

13,00

3,20

14,00

2,20

40,00

3,209,50

70,00

3,20

8,50

70,00

5,00

9,50

44,50

3,20

8,00

70,00

3,20

9,50

a-1a* a-1aH330 a-1a-c a-1a-d a-1aH a-1a-4.5 9,5 mm Probe 8,5 mm Probe 9,5 mm Probe 9,5 mm Probe 8,0 mm Probe 9,5 mm Probe Miller Wire Feeder Miller Wire Miller Series 74 Feeder (Sm. Wire) Wire Feeder

3,00

9,50

5,00

8,00 M8

23,00

44,50

114,00

A-1MOT-Au A-1lN-23A A-1lN-23B Motoman Lincoln Wire Lincoln Cloos Cebora ESAB ESS

2,20

12,00

37,00

6,40

12,00

35,00

3,2011,20

103,00

6,90

4,00

a-3 a-3qdF-4

a-2Pa a-8m PaWFS-12

15,00

41,0063,50

2,00

9,50

19,00

17,40

10

11


InLet adaPteRS WItH FemaLe tHRead

5,00

12,70

44,50

9,50

31,50

51,00

19,70

40,00

1/4" NPT-F

1/4" NPT-F

1/4" NPT-F

1/4" NPT-F

6,90

6,905,005,00

22,00

32,00

1/4" NPT-F

1/4" NPT-F

4,00

17,40

63,50

1/4" NPT-F

a-2e a-1e a-1H a-1Ln a-1m a-1Pa a-1otc a-8F ESAB 4-48 ESAB All Hobart Lincoln Miller Panasonic OTC Miller

6,90

53,50

1/4" NPT-F

5,00

12,00

38,00

22,00

44,50

21,00

A-4A-5

deRLIn InLet guIde ceRamIc InSeRt

3,2012,70

44,50

A-1HC

9,50

3,20

A-1CM

29,00

9,503,20

44,50

A-1MC

12,70

3,20

A-1Cs

These Derlin inlet guides can be used for applications for Aluminium or stainless steel wires.

deRLIn InLet guIde WItH tHRead

9,50

3,00

44,50

1/2"-14

NPT-F

A-1Ds-1

1/2"-14

NPT-F

A-1Ds-2

12,70

3,20

20,00

12,70

3,00

44,50

1/2"-14

NPT-F

A-1Ds-3

3/8"-18

NPT-F

A-1Ds-4

12,70

3,20

29,00

20,00

use a-4 (1/4” nPt-m)

A-17G 1/4”F 3/8”M

A-18G 1/4”F 1/2”M

A-18G1 3/8”F 1/2”M

1/4"

NPT-M3/8"-18

NPT-M

1/2"-14

NPT-M

for HD Bayonet

A-4HD

A-1Ds-4 pFA

19,00

5,00

30,00

3/8"-18

NPT-F

in/o

ut P

Fa-u

nit

A-1Cs pFA

5,019,20

30,00

in/o

ut P

Fa-u

nit

Inline connectorsThe conduit runs through the whole connector into the plastic inlet guide.In this way the wire is prevented from shaving against the metal connector. Thread=1/2” NPT-M

The A-10-XM is used for the FC-X conduit. The A-10-HM is used for the EC-4 conduit.

FeedeR InLet cRoSS-ReFeRence cHaRt

12


22,00

a-1a-4.5 (see page 10) 9,50

3,20

a-1SKS

FeeDer wire wizArDTM

MANuFACTurer FeeDer Type iNleT GuiDe p/N

ESAB ALL (except 4-48) A-1LN-23B 4-48 A-2E and A-4

Fanuc Servo Torch A-3QDF-6 and A-23

Fronius Feeder without Set Screw A-1FRO-B Feeder with Set Screw A-1FRO Feeder with Stripped Set Screw A-2FRO

Hobart Series 27 A-1H and A-4 A-1A, A-1A-4.5 Models with 3/4"-16 Thread A-1A and A-22 A-1AH330 and A-1MOT

Kobelco Male Threaded Inlet 1/2"-20 A-3QDF-4

Lincoln Electric PF Series A-1LN and A-4 LN-7, LN-9, and LN-25 A-1A LN-8 A-1H and A-4 NA-3 and NA-5 A-1NA-5 Synergic 7 A-1B-C LF-72 A-1LN and A-4 Series 10 A-1LN and A-4 Servo Torch A-2LN-AK

Miller Most Models A-1A-C, A-1M and A-4, or A-1A 22A A-1AK Auto Axcess A-1A-C Series 74 A-1A-4.5 Series 75 PAWFS-12 and A-3 RAD 400 A-1LN-S and A-3

Motoman Female Inlets A-1AH330 and A-1MOT Male Threaded Inlets A-3QDF-3 Hyper Feeder A-1MOT-HP

OTC/ Male Threaded Inlet 7/16"-20 A-3QDF-2 DAIHEN Male Threaded Inlet 9/16"-18 A-3QDF-4

Panasonic Female Inlet A-1PA and A-4 Female Inlet A-2PA and A-3QDF-4 Male Threaded Inlet A-3QD F-4

SKS All Types A-1SKS and A-1A-4.5 Cloos 12 mm A-1LN-23B EWM 12 mm A-1LN-23B Cebora 12 mm A-1LN-23B

a-1a (see page 10) 9,50

3,20

3/4" – 16a-22

SKS FeedeR adaPteR

3,20

8,50a-1aH330 (see page 10)

3/4" – 16

a-1mot

connectoR LIneR FoR aLu

a-4L-H 2,3 x 4,5 mm

Designed to avoid any metalic contactinside the connectors. Used for Aluminum and other non-ferrous metals.

The A-1AK universal inlet kit is an inlet adapter with four phenolic bushings to make a solid and stable fitting in several sizes of holes.

unIVeRSaL InLet guIde WItH quIcK dISconnect

Id x od 15,90 x 22,20 mm

Id x od 15,90 x 22,20 mm

Id x od 15,90 x 19,00 mm

Id x od 15,90 x 19,00 mm

Id x od 9,5x 12,70 mm

Id x od 9,5 x 15,90 mm

Id x od 9,5 x 15,70mm

Id x od 9,5 x 12,70 mm

Id x od 9,5 x 12,00 mm

a-1aK

a-1aKe

a-7e = BuSHIngS onLy

a-7 = BuSHIngS onLy

SPecIaL eSaB

HoBaRt adaPteRKIt

motoman adaPteRKIt

13

Wire straighteners

sMAll wire sTrAiGHTeNer FiTTiNGs

Wire WizardTM manufactures four versions of wire straighteners that can be used to straighten or recast all types of wire. The main body is constructed of aluminum, making our straighteners some of the lightest in the market. All models are equipped with a locating calibration on the face of the unit and a fine adjust-ment scale on the tension knob. This results in an extremely fast and accurate setting of wire cast. Our full range of fittings and inlet guides guarantee a trouble-free fit for any application or system.

sMAll wire sTrAiGHTeNers MODels ws-1000 & ws-1000AFor wire sizes 0,8 - 1,6mm (Order WS-1000A for Aluminum Wire)Dimensions: 95mm W x 78mm H x 41.3mm D

Weight: 450 gr

MeDiuM wire sTrAiGHTeNer MODel ws-1000HFor wire sizes 1.6 - 2.4mm Dimensions: 145mm W x 84.7mm H x 47.63mm D

Weight: 800 gram

STEEL WIRE STRAIGHTENER

A-1M-sMILLER

A-1lNs

SAME ID & OD AS A-1lNs

LINCOLN INLET (A-1LN)OR A-3 DISCONNECT

lArGe wire sTrAiGHTeNer MODel ws-1000lFor wire sizes 3,2 - 6,0 mm Dimensions: 220mm W x 103.8mm H x 57.2mm D

Weight: 1800 gram

iNsulATeD MOuNTiNG KiTs Available for all models

wss-100-iKSmall

wsM-100-iKMedium

wsl-100-iKLarge

FiTTiNGs FOr ws-1000H

A-16M-sTAttaches to QD

A-16M-sT-HDAttaches to QD

A-4 Quick Disconnect

FiTTiNGs FOr ws-1000l

A-1lN Inlet Guide

A-4HD Quick Disconnect

A-1lN-lw Inlet Guide

ws-1000 Drive rollsU-Groove Drive Rolls for Steel Wire

ws-1000-A Drive rollsV-Groove Drive Rolls for Aluminum Wire

Order A-1lN-K for Inlet/Outlet Kit (includes two A-1LN’s)

Order A-1lN-K-lw for Inlet/Outlet Kit (inc. two A-1LN-LW’s)

a-1qd

25,40 12,70

12,70

12,70

12,70

17,50

17,50

32,00

4,00

3,20

2,80

3,20

1/4 NPT Thread

1/2 NPT Thread

End view of ceramic

insert

End view of ceramic

insert

a-1LnS

a-1c-S DERLIN

a-1c-S DERLIN

WS-1000

WS-1000a

12,70

12,70

4,00

4,00

2,30

2,80

2,80

9,50

2,80

25,40

25,40

65,00

32,0012,70

9,00

44,00

1/4 NPT Thread

1/4 NPT Thread

1/2 NPT Thread

direct pull page 5

Pneumatic Feed assist for long conduit runs

page 16-17

Wire guide modules

page 18-19

direct pull with wire detection

page 5

All these options can be used in combination with a cone of your choise

WIRe FeedeR

A-10C-X A-10R A-9/A-6

FC-XSTANDARD, EXTRA FLEXIBLE

FC-XH-LWLARGE-WIRE, EXTRA FLEXIBLE

FC-XHHEAVY-DUTY, EXTRA FLEXIBLE

EC-3, 4, 5 or 6CONDUIT BLUE POLYMER

14

page 6 & 7

page 8









Combination of femaleconnector and bulkhead.Perfect for plate mounting. page 9

Universal inlet kitSet of 1 inlet adapterand 4 adapter bushings page 12.

Inlet adapter for specificbrand. Choose one at

page 10.

A-14 A-4

a-1aK

a-1FRo

a-14 A-4

a-14B (Bracket) page 9

A-9/A-6 A-10R A-10C-X

15





page 6 & 7

page 8

page 8

With step 1 to 5 you already made a complete set of Wire Wizard products to equip one installation. The last thing you might need to think about is the distance you want to cross with the conduit. Wire Wizard offers you the possibility to bridge bigger distances than you have done up till now.

A great advance of the Wire Wizard system is the distance, which can be bridged by this system. Everybody knows that normally the distance from the wire feeder to the spool or drum can be maximum 5 to 10 meters. This makes that for large installations it’s difficult to get the drum close enough to the feeder, and sometimes it’s even impossible to work with drums. This forces us to use small spools, which means that production will stop with every use of 15 kg of welding wire. A great loss of production time.

Wouldn’t it be great if the distance between drum and feeder were just no problem at all? Wire Wizard hands you the solution to all these problems. By using the Pneumatic Feed Assist (PFA) you can bridge distances up to 30 meters.

This opens lots of opportunities to place the drum at a large distance to avoid great loss of time by replacing and handing the drums. Its even possible to leave the drum at the pallet and don’t move it at all.

The PFA-Unit must not be compared with the traditional Push-Pull systems. Trough the years Push-pull systems got a bad reputa-tion in the market because they damage the wire, are very sensitive for technical trouble and very fragile. The great advance of the PFA-Unit is that it works with one unit only, and works completely independent from the wire feeder of the machine. This makes that you can add it to any running system you like.

The friction free transport of wire, which these systems create has the advance that wearing of the liners will be reduced to mi-nimum and rasping of the wire feed rollers will be history.

By using a feed assist you can even put the wire conduit in the drag chain or cable car-rier together with the other cables leading to the robot arm.

Step 6 -Wire feed assist 1

unLImIted dIStance WItH PneumatIc WIRe Feed aSSISt

tHe PFa-unIt

FeatuReS

• Works independent and requires only shop air to operate

• Enables long conduit runs (up till 30 metres)

• Reduces wire drag in the conduit and extends conduit life

• Prevents drive roll “slippage” and prevents burn back

• Increases arc-on time

• Ideal for soft metals like Aluminium and Silicon bronze

• Works with any kind of wire packaging

• Works also in combination with another PFA in the same conduit.

16

aPPLIcatIon


17


The Solenoid double kit is used in cases where the PFA needs to be able to run in two direc-tions.With this kit the PFA is not only able to feed the wire but also to pull back the wire. This option is used for robots with a Arc-restart function.Arc-restart means that the wire is pulled back in order to make a restart.If the feeder pulls the wire backwards the PFA need to run backwards too in order to avoid wire deformation.

Includes valve, hose, connectors and cable.

PFa-unIt StandaRd Set Product Part number

PFA unit for 1,0 mm wire (installation set included) PFA10




Other diameters at request

Outlet guide for PFA with Quick disconnect A-1-BC

Drum mounting installation set (excl. Outlet guide) PFA-DA

Filter/Regulator/Lubricator PFA-FRL

118 ml bottle PFA lubricant PFA-OIL

U-groove Feed roll 1,0mm for PFA (per piece) WW072000





V-Knurled Feed roll 1,0mm for PFA (per piece) WW132958





A-1B-C Outlet adapter

PFA motor

PFA -FRL filer/regu-lator / lubricator

including hose

PFA-DA Drum adapter kit

Air tool lubricant included

PFA unit is supplied as a complete set to install the PFA-unit, including all the items in this drawing, except for the drumhood.

drumhood

PFa-unIt oPtIonS and acceSSoIReS

PFa-SR SILenceR/RecLaSSIFIeR 24-VoLt SoLenoId SIngLe-KIt

Separates oil from the used com-pressed air. Herewith it prevents pneumatic oil spatter.

The PFA-SR also reduces the noice of the air exhaust.

To install the PFA-SR the standard air exhaust needs to be removed.

PFa-Wm Remote mounting BracketMounts Feed Assist to walls or other surfaces

24-Volt Solenoid kit used to reduce the consumption of compressed air by the PFA.The solenoid is placed before the FRL and switches the air pressure on and off.

The signal the solenoid uses can be con-nected parallel with the gas valve, or in case of SAW welding, parallel with the powder valve.

In both cases the PFA is always running when the wire feeder is running.

PFa-WaLL-BRacKet 24-VoLt SoLenoId douBLe-KIt

PFa-SK

PFa-SK2

PFa-SR

Wire Guide Modules

installation example

• The new way of thinking in feeding wire• What causes the friction in your wire supply?... the bends ! • Eliminate the bends, you’lle eliminate the friction• Feed over 30 meters without assist

• Create any angel you like by connecting the modules.• For all kinds of wire from 0,6 to 2,4 mm • Much cheaper than other roller products• 3 YEARS GuARAnTEE (excludes damage caused by contaminants)

lightweight durable polymer body

Heavy duty rollers with bearings

Conduit connection going to feeder

Wire from source

2x 45ºdegree wire guide modules combined

to a 90º angle

45º guide module

Wire guide module & end Cap assemblies

90º guide module

Assembled with End Caps

Assembled with End Caps

To drum or bigspool or in case of SAW to turntable

WWdp

FC-x

Con

duit

ass

embl

y

a-1

0xm

Con

duit

ass

embl

y fo

r eC

-3,

eC-5

FC

-xH

, FC

-xH

-lW

& F

C-x

-sW

eC-4

Con

duit

ass

embl

y

a-1

0Hm

a-10xm For use with FC-x Conduit

a-10Hm For use with eC-4 Conduit

a-5 For use with any male connector

18

To wire feeder, choose the right adapter at page 10

Tapered end of insert always faces wire path direction

wire direction

Wire Guide Modules

19

FLOOR MOUNTING BRACKETCELL WALL MOUNTING KIT,DOUBLE SIDED

END CAP CONNECTORS90° MINI GUIDE MODULE45° WIRE GUIDE MODULES

WIRE WIZARD® POLYMER CONDUITCONDUITS & FITTINGS

WGM-1For solid wire

up to 5/64" (2mm)

WGM-1-SFor cored &

stainless wireup to 5/64" (2mm)

WGM-LW-1For large wire5/64" to 3/32"(2mm-4mm)

L-BRACKET MOUNTING KIT

Part #WGM-LBM-BRKT

CELL WALL MOUNTINGKIT, SINGLE SIDED

Part # WGM-WK-1-1

WGM-ECK-50(use -25 for A-4 orA-4-ST disconnect)

WGM-ECK-LW-50 For WGM-LW-1(use -38 for A-4HD disconnect)

FACE MOUNT BRACKET KITAllows 360° directional adjustment

GUIDE MODULE STAND FOR MEZZANINE APPLICATIONFor applications where wire source is above weld cell

Part #WGM-A-10BK

Part # WGM-WK-2-1

Part # WGM-UAAdapter Kit Only

Part # WGM-UAKIncludes Bracket

360° UNION ADAPTER KITAllows dual 360° directional

adjustment

Each kit includesone A & one B

end cap

Add WGM-A5 or order WGM-2-BRKTfor insulated connections

Part # WGM-M-1Uses same end caps as WGM-1

End CapA

End Cap B

Allows tight90° turns for

solid wires up to.052 (1.3mm)

*See catalog orwebsite for additionaloptions & accessories

6" (152mm)

Part #WGM-WK-1-3Adjustable for

up to 3" (76 mm)thick walls

Part #WGM-3-BRKT

Side Mount Bracket

Part #WGM-PFA-STANDIncludes stand and oneadjustable extension arm

Adjustableheight from50" –86"(1.3-2.2m)

Adjustablearm lengthfrom 4" –19"(102-483mm)



Wire Pilot® FeedAssist Option

Wire Wizard®Fire Resistant

Drum Covers &Dollies Available

Optionalswivel

with 90°module

Drum -or-Wood Reel Drum -or-

Wood Reel

WGM-A-10BK

Additionalarm, part #WGM-PFA-

STAND-ARM

Part #WGM-PFA-STAND

Con

duit

to w

ire fe

eder

ADJUSTABLE WALL MOUNT BRACKET

Part #WGM-FLM

Modules maybe attached to

one or bothsides

GUIDE MODULE STAND FORDRUM OR WOOD REEL APPLICATION

Wire Spool OptionWGM-PFA-STAND-4

EC-3-R (4.4mm I.D.)Fittings: A-16F-3 or A-10C-S EC-4-R (7.6mm I.D.)Fittings: A-16F-4 or A-10C-H

EC-5 (10.2mm I.D.)Fittings: A-16F-5 or A-10R

EC-6 (14mm I.D.)Fittings: A-16-F-6 or A-9

Threaded Connector

Guide Module End Cap

WGM-A5 Insulated ConnectorScrew-on Fitting(A-16F-#)

A-5 Quick DisconnectCompression(A-10##)

WIRE WIZARD® EXTRA FLEXIBLE CONDUITCONDUITS & FITTINGS


FC-X (6.1mm I.D.)Fitting: A-10C-X FC-XH (7.4mm I.D.)Fitting: A-10R

FC-XH-LW (10mm I.D.)Fitting: A-9

FC-X-SW* (2.3mm I.D.)Only for wire .035 & under

Threaded Connector


WGM-A5 Insulated ConnectorCompression(A-10##)

A-5 Quick DisconnectSwaged Fitting(Pre-cut only)

WWDPDirectPull Kit

WWDPDirectPull Kit

Part #WGM-1-BRKT

45° MODULE HANGINGBRACKET KIT

HOOD SWIVEL KIT

90° HANGING BRACKET KIT

Part #WGM-1-90-BRKT

(WGM-LW-BRKT for WGM-LW-1)

A-10HMFor EC-4-R

A-10XMFor FC-X

A-10RMFor FC-XH & EC-5

A-9For FC-XH-LW

WGM-A5Insulated Connector

with quick disconnect

A-5Quick Disconnect forWGM-1 & WGM-1-S

A-4HDQuick Disconnect for

WGM-1-LW

DRUM HOOD MOUNTING KIT

Part #WGM-DK

WELD-ON OR BOLT-ONMOUNTING BRACKET

SUPPORT BRACKET SLOTTED SUPPORT BRACKET 45° ANGLE SUPPORT BRACKET

FEEDER INLET MOUNT KITMounts to feeder through

bracket or panel

Part #WGM-024

Part #WGM-021

Part #WGM-025

Part # WGM-EA-10Extends 10" (254 mm) to 18" (457 mm)


Part #WGM-IKExcludesBracket

Sampleinstallationon bracket

Allows 360°rotation ontop of drum

cover.

Part #WGM-HSK

Part #WGM-4-BRKT

Part #WGM-044

Part #WGM-DP-LW

Includes ceramicinlet that will

not shave wire

Part #WGM-SMB-3

GUIDE MODULEDIRECT PULL INLET

STACKABLE GUIDE MODULE BRACKETAllows mounting of up to 3 stacked modules

Part #WGM-CM-1Extends 2" (51 mm) to13" (330 mm),adjustable heightup to 6.5" (165 mm)

Part #WGM-2-BRKT

ADJUSTABLE EXTENSION ARMFor installation at the top of the weld cell wall

INSULATED FACE MOUNT BRACKET KITAllows 360° directional adjustment

CONDUIT CONNECTORS

TURN TABLE MODULE ADAPTERSecures Modules to Wire Wizard® Turn Table

PIVOTING ADJUSTABLE EXTENSION ARMSBoth arms pivot upward to allow easy wire feeding from drums & reels

Part #WGM-MSK

Creates 360°rotation pointbetween two

Modules

GUIDE MODULE SWIVEL KITS ADD-ON SWIVEL KITS

Part #WGM-PFA-SWFor the WirePilot® FeedAssist

Part #WGM-NSW-SWFor theNon-Stop™DispensingSystem

DETACHABLE QD CONNECTORSTHREADED CONNECTORS

Use Part #WGM-PFA-AKfor fixed mount

Compatible withWGM-1, WGM-1-S &

WGM-LW-1

A-5 with U-005insulator sleeve

Part #WGM-FSKCreates 360°rotation pointat the feeder

Part #WGM-1-BRKT

45° MODULE HANGINGBRACKET KIT

HOOD SWIVEL KIT

90° HANGING BRACKET KIT

Part #WGM-1-90-BRKT

(WGM-LW-BRKT for WGM-LW-1)

A-10HMFor EC-4-R

A-10XMFor FC-X

A-10RMFor FC-XH & EC-5

A-9For FC-XH-LW

WGM-A5Insulated Connector

with quick disconnect

A-5Quick Disconnect forWGM-1 & WGM-1-S

A-4HDQuick Disconnect for

WGM-1-LW

DRUM HOOD MOUNTING KIT

Part #WGM-DK

WELD-ON OR BOLT-ONMOUNTING BRACKET

SUPPORT BRACKET SLOTTED SUPPORT BRACKET 45° ANGLE SUPPORT BRACKET

FEEDER INLET MOUNT KITMounts to feeder through

bracket or panel

Part #WGM-024

Part #WGM-021

Part #WGM-025



Part #WGM-IKExcludesBracket

Sampleinstallationon bracket

Allows 360°rotation ontop of drum

cover.

Part #WGM-HSK

Part #WGM-4-BRKT

Part #WGM-044

Part #WGM-DP-LW

Includes ceramicinlet that will

not shave wire

Part #WGM-SMB-3

GUIDE MODULEDIRECT PULL INLET

STACKABLE GUIDE MODULE BRACKETAllows mounting of up to 3 stacked modules

Part #WGM-CM-1Extends 2" (51 mm) to13" (330 mm),adjustable heightup to 6.5" (165 mm)

Part #WGM-2-BRKT

ADJUSTABLE EXTENSION ARMFor installation at the top of the weld cell wall

INSULATED FACE MOUNT BRACKET KITAllows 360° directional adjustment

CONDUIT CONNECTORS

TURN TABLE MODULE ADAPTERSecures Modules to Wire Wizard® Turn Table

PIVOTING ADJUSTABLE EXTENSION ARMSBoth arms pivot upward to allow easy wire feeding from drums & reels

Part #WGM-MSK

Creates 360°rotation pointbetween two

Modules

GUIDE MODULE SWIVEL KITS ADD-ON SWIVEL KITS

Part #WGM-PFA-SWFor the WirePilot® FeedAssist

Part #WGM-NSW-SWFor theNon-Stop™DispensingSystem

DETACHABLE QD CONNECTORSTHREADED CONNECTORS

Use Part #WGM-PFA-AKfor fixed mount

Compatible withWGM-1, WGM-1-S &

WGM-LW-1

A-5 with U-005insulator sleeve

Part #WGM-FSKCreates 360°rotation pointat the feeder




WGM-1For solid wire

up to 5/64" (2mm)

WGM-1-SFor cored &




Part #WGM-LBM-BRKT


Part # WGM-WK-1-1





Part #WGM-A-10BK

Part # WGM-WK-2-1




adjustment


end cap



End CapA

End Cap B




6" (152mm)



Part #WGM-3-BRKT

Side Mount Bracket









Optionalswivel

with 90°module


Wood Reel

WGM-A-10BK


STAND-ARM

Part #WGM-PFA-STAND

Con

duit

to w

ire fe

eder


Part #WGM-FLM


one or bothsides






Threaded Connector









Threaded Connector




WWDPDirectPull Kit

WWDPDirectPull Kit




WGM-1For solid wire

up to 5/64" (2mm)

WGM-1-SFor cored &




Part #WGM-LBM-BRKT


Part # WGM-WK-1-1





Part #WGM-A-10BK

Part # WGM-WK-2-1




adjustment


end cap



End CapA

End Cap B




6" (152mm)



Part #WGM-3-BRKT

Side Mount Bracket









Optionalswivel

with 90°module


Wood Reel

WGM-A-10BK


STAND-ARM

Part #WGM-PFA-STAND

Con

duit

to w

ire fe

eder


Part #WGM-FLM


one or bothsides






Threaded Connector









Threaded Connector




WWDPDirectPull Kit

WWDPDirectPull Kit

Standard module for wire up to 2,4mm

For larger wires look at pag 20

1/2” THREAD

female connector with 1/2” thread

fits directly into the module endcap

1,6mm

Submerged Arc Welding 1

20

WIRe guIde moduLeS FoR SaW

mecHanIcaL tuRn taBLeS

PFA motor

Submerged Arc Welding 2

PFa-unIt StandaRd Set Product Part number





Outlet guide for PFA for Large Wire Diameters A-1-BC HD

Drum mounting installation set (excl. Outlet guide) PFA-DA-HD

Filter/Regulator/Lubricator PFA-FRL

118 ml bottle PFA lubricant PFA-OIL




U-groove Feed roll 4,0mm for PFA (per piece) WW05M532

A-1B-C-HD Outlet adapter

Air tool lubricant included

PFA unit is supplied as a complete set to install the PFA-unit, including all the items in this drawing, except for the drumhood.

PFA-DA-HD Drum adapter kit

drumhood

21

A-1CS PFA

PFa-FRL filer/regulator/lubricator including hose

conduItS FoR StaInLeSS SteeL & aLumInIum

conduItS FoR mILd SteeL

conduItS FoR SaW

For the large diameter wires used for SAW welding, Wire Wizard has the perfect conduits. Look at page 6 & 7 for the full range. In the tables below we show you the conduits used for SAW welding.



FC-XH 7,5 x 15,50 mm 1,6 - 2,4 mm A-10-R Per meter 30,5 mtr

FC-XH-LW 10,0 x 19,00 mm 2,4 - 4,0 mm A-9 + A-6 Per meter 30,5 mtr



EC-5 10,0 x 15,20 mm 1,6 - 2,4 mm A-10-R Per meter 152 mtr

EC-6 14,0 x 19,00 mm 2,4 - 4,0 mm A-9 + A-6 Per meter 152 mtr

At page 8 you can choose the right connector to fit the conduit of your choice.With these connectors you create a male bayonet connection at each side of the conduit.These bayonets will fit all female quick disconnects of the program. accept for the HD connectors.

WWtt-dP unIVeRSaL SaW connectoRThe WWTT-DP is a universal connector kit with a ceramic insert.

Body is made of Delrin for an insulated mounting.

22

Non-Stop Wire Dispensing 1

A unique process joins the end wire form a used empty drum with the start wire of the next full drum. Both butt-welding and flash removal operations take only seconds and the two wire ends may be joined during the welding cycle.

• Eliminates downtime for wire changeover

• No operator action needed - robots can continue to weld while the next full drum is being installed

• Designed for use with optional Pneumatic Feed assist or Wire guide modules

• Works with one- and two-station robotic cells (2 or 4 drums)

• Accepts any fiber drum or cardboard wire packaging design

• Easy-to-use resistantce Butt-Welder & Wire Dresser available

• Appropriate drum-handling carts available

220 Volt hand-held Buttwelder

BW-WP

Wire Parters leaves flat wire ends for easy butt-welding.

220 Volt Mini grinder to clean the weld and assure easy passage through contact tip

BW-Wd

WW-BW

WW-gB Gauge block. Made to test the buttweld after cleaning whether it is good enough to run through the contact tip.

nSW-FF Finish flag for endless wire system. Is springloaded and locked downwards when a new drum is installed. The swing pushes the flag out of its lock letting it pop up as a signal that one of the two drums is empty and a new one can be placed.

non StoP WIRe By uSIng WIRe dIRectIon SenSoRTo welding machine

or robot

short conduit few meters only

A-14BK bracket kit or PFA-unit with wall

bracket in case of large conduit length

HoW It WoRKS• Step 1 Drum is empty and wire end passes the

sensor

• Step 2 The sensor signals stops the welding

• Step 3 Disconnect conduit at “A” and place Cone at the new drum

• Step 4 Feed the new wire through the conduit

• Step 5 Weld the old wire end to the new wire end with the butt welder

• Step 6 Push the overlength into the drum and connect the conduit again at “A”

• Step 7 Start welding again

Sensor with sensor block see page 5 for article numbers

a

Framework also available as wall-mount

New!optional Barrel empty Signal Flag

23

Non-Stop Wire Dispensing 2

Wire Whip

NSWDrumHoods

Conduit

Wire Transfer Arm

Butt Welder Docking Station

Start Wire

End Wire

Start Wire

Drum 1 Drum 2

Join the end wire from drum 1 with the start wire from drum 2 using the Butt Welder.

Remove the flash in the wire joint using the Wire Sizer (or rotary tool with stone bit).

Position the wire on the path-way between the two drums.

When wire from drum 1 runs out, the transfer arm will switch over to drum 2. Simply replace emp-ty drum and repeat steps 1-3.

COMpONeNTs & BAsiC seTup

DruMseTup

1 2

3 4

Single Torch Unit(with round drums)

2-Torch Unit(with round drums)

wire pilot®

Feed Assist

May be mounted ina fixed position or

with the Guide Module Swivel Kit to allow 360°

rotation

Guide Module(s)

Additional wire exit point Options

• eliminates productionloss caused by empty drums • eliminates downtime for wire changeover

24

RWc1111-30 POLYETHYLENE WOOD REEL COVER

WRScSTAGING CART

deReeLIng aRmS FoR Wood and PLaStIc ReeLS• Universal base plate designs fits all wood or plastic reels with 1-5/16” (33mm) or 5” (127 mm) center arbors

• Twin locking cams secure base plate to reel for stability

• Springloaded drag brake provides smooth accelaration and deceleration of feed arm and prevents wire from shingling off reel

• Outer tube radius and lead will not change wire cast

• Ceramic inlet guide provides long wear and prevents wire shaving

• Large coupler bearings resists both thrust and “G” loads

• Easy installation, typically requires little adjustment

• Kits (RW#) include arm, liner, brake, base plate & quick disconnect

c33 Base Plate Most universal base plate for

European market

Fc-x Liner for mild Steel

ec-4 Liner for non ferro

RW1030-c33WIRE ARM GUIDE UNIT

For mild steel wire up to 1,6mm

with universal base plate

RW1028-c33 WIRE ARM GUIDE UNIT

For mild steel wire up to 1,6mm


RW1030-c33 WIRE ARM GUIDE UNIT

For non ferro wire up to 1,6mm


PFA-AS

into PFA

onto guide arm

adjuStaBLe Stand FoR PFa Wood ReeL acceSSoRIeS

PFA-AS-I

Wood reel dispensing equipment

BLue magIc™ concentRate

BLue magIc antI-SPatteR & nozzLe cLeaneR

Anti-Spatter & Accessoires

A cost effective, environmentally safe product, this new generation of anti-spatter provides superb performance even in high temperature applications. Biodegrada-ble formula contains no harmful chemicals and is noncombustible. And, because it contains one of the lowest water contents available, you get protection, not

water.

• Surfactants provides excellent wetting & lubricity in torches

• Protects against spatter build-up and char residue

• Keeps clean-ups to a minimum

• Contains no silicone-easuly painted over

• Low pH level inhibits multi-metal corrosion

• Will not evaporate keeping lines and nozzles clog-free

• Containes biocide, providing longer shelf life in warm climates

To avoid high freight costs we can also sup-ply the Blue Magic™ in a concentrate.

This concentrate is sold in 19 liter jerrycans and can be mixed with de-onized water to a total of 200 liter of Blue Magic ant-spatter.

Blue magic™ concentrateeaS1000-cc

Blue magic™ Item PaRt no.

1 Liter Bottle EAS1000-C32

3,8 Liter Bottle EAS1000-C1

19 Liter Jerrycan EAS1000-C5

200 Liter Jerrycan EAS1000-C

eaS1000-ead

Universal air chuck

BLue magIc™ ReFILLaBLe SPRay can 500 mL

The Blue Magic™ Aluminium Spray Can is a refillable and recharcheable sprayer that is designed to apply the Blue Magic™ Ant-Spatter solution. This heavy duty Aluminium spray can is easy to refill with Anti-Spatter by removing the top and easy to recharge (pressurize) by shop air with the air valve at the side.

• Saves waste - no more cans to throw away

• Can be pressurerized up to 13,50 BAR

• Universal air chuck (same as car tyre)

• With each can included are 8 extra nozzles with 4 different spray

patterns and an extra air valve

Blue magic™ nozzle dip gel Item PaRt no.

500 ML (1/2 liter) EAS1000-G16

BLue magIc™ geL FoR nozzLe dIPPIngBlue Magic™ Nozzle Dip Gel for semi-automatic welding prevents spatter and cools the nozzle temperature, increasing nozzle and contact tip life. This exclusive Blue magic™ gel formula creates a protective anti-spatter coating that will not clog orifices or threads. Simply dip the nozzle into gel and repeat as necessary.

• Long lasting formula extends nozzle and contact tip life

• Enviromentally safe, contains no silicone

• Odorless, non-toxic & non-flammable

25

Conduit and cable protection

Constructed from Kevlar, these sleeves are extremely durable and protect all cables or hoses inside against mechanical wear or shaving. Besides these cable sleeves have a spatter-resistant aluminized or silicon coating.

Protects and secures:• Wire conduit• Torch cables• Cable assemblies• Control cables• Cooling lines• Gas lines• Hydraulic hoses

Heavy duty zipper

Cable or conduit

Nylon straps with velcro

Heavy duty velcro closure

Male and female sleeve-end for

chainlink

Nylon straps with velcro

Heavy duty zipper

uSe and PoSSIBILItIeS

aVaILaBLe SIzeS and modeLS

The Aluminized coating sleeves are a perfect protection for your cable assem-bly at the torch side. It protects the expensive cable assembly of shaving and wear caused by the heat and spatters of the welding. These sleeves are for more durable then the ones made of leather. The silicon coated sleeves give protection against agressive liquids.

Step 1 Choose the right sleeve from the table

Step 2 Tighten the nylon straps around the cables

Step 3 Close the heavy duty zipper

Step 4 Chain-link the sleeves if needed

Sleeve-ends are made male/female with velcro and can be chainlinked together to get the needed length.

chainlinked sleeves

aluminized sleeve used as pro-tection for torchcable assembly against welding spatters

Aluminized sleeve used as protection against welding shaving

26

Article

Aluminized

Article

Silicon Diameter Length

KCS-2-12-A KCS-2-12-S 50 mm 30 cm

KCS-2-24-A KCS-2-24-S 50 mm 60 cm

KCS-2-36-A KCS-2-36-S 50 mm 90 cm

KCS-2-48-A KCS-2-48-S 50 mm 120 cm

KCS-3-12-A KCS-3-12-S 75 mm 30 cm

KCS-3-24-A KCS-3-24-S 75 mm 60 cm

KCS-3-36-A KCS-3-36-S 75 mm 90 cm

KCS-3-48-A KCS-3-48-S 75 mm 120 cm

KCS-4-12-A KCS-4-12-S 100 mm 30 cm

KCS-4-24-A KCS-4-24-S 100 mm 60 cm

KCS-4-36-A KCS-4-36-S 100 mm 90 cm

KCS-4-48-A KCS-4-48-S 100 mm 120 cm

Conduit and cable protection Spool and Drum accesoires

27

non-FLammaBLe dRum coVeRS

Stand FoR PFa-mountIng

To make it possible to mount either your PFA-unit or Wire Guide Modules without any support from the weldcell wall, Wire Wizard offers you a universal stand. The stand is delivered with one arm and can be extended with more arms or a

Shape Size articleRound 53 cm DC-21R

Round 60 cm DC-24R

Square 54 cm DC-21S

Square 62 cm DC-24S

Octagon 53 cm DC-21O

Octagon 60 cm DC-24O

PFa-FS Support to mountthe FRL-unit directly to the PFA

description article Universal Stand : WW-uSAdditional Arm : WW-uSaSpool holder : WW-uSSH

In case of the drum standing inside the weld cell the cardboard of the drum might get on fire caused by the heat of the welding. In case of a closed weld cell this fire might be noticed much too late causing much damage and dangerous situations.

With these non-flammable drum covers Wire Wizard offers you an effective solution to eliminate this danger.

A simple solution to locate the regulator unit of the PFA. Designed for drums standing at a track or in the middle of the shopfloor.

spoolholder. The stand is adjustable in height and small to pack and send. With this stand the PFA or modules can be located freely above the drum. This makes changing drums more easy.

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Handling equipment 1

This dolly can be used with all kind of drums on skids or pallets measuring 69 cm square or smaller. Four solid Textite roller bearing wheels make transporting a drum simple. Can be assembled in a lip up or lip down configuration depending on customer needs. Larger sizes can be made on demand.

SpecificationsDeck Ht: 11,5 cm Height: 12,7cm Length: 70 cm Width: 70 cm Capacity: 453 kg Weight: 17 kg

FdL DRUM LIFTER WITH FdL-Fa

FdL DRUM LIFTER

dRum LIFteR, modeL FdL

• Spring loaded clamp holds drum firmly in place• For fiber or steel drums• Accepts diameters from 47 cm to 66 cm

SpecificationsWeight: 11,4 kg Capacity: 453 kg

NoTE: Drum rim must be within 25 mm of the top of the drum.Content weight must not exceed the drum manufacturers’ packing limit. Drums must be closed with lids properly sealed.

FoRK LIFt adaPteR, modeL FdL-Fa

• Adjustable T-handle keeps adapter from sliding off fork• Safety Style clasp secures adapter to drum lifter

• Weight: 3,5 kg Capacity: 500 kg

adjuStaBLe dRum LIFteR, modeL FdL-HS

• Model DL-HS accepts 51 to 66 cm drums incl. Accu pack and Marathon Pack

• Can be used with straps or handles• CE certified• Weight: 10 kg Capacity: 500 kg

ISo dRum LIFteR, modeL FdL-HS and 21

• Allows easy attachment to chimeless ISO drums• Can be used with straps or handles

• Model FDL-21, non-adjustable for 51/52 cm drums

• Model FDL-24, non-adjustable for 58/61 cm drums

• CE certified• Weight: 8 kg Capacity: 500 kg

PaLLet SKId doLLy, modeL WWSd

FdL-Fa

FdL-21

WWSdPALLET (SKID) DOLLY

FdL-HS

+ -marking

FdL-24

HeaVy duty dRum doLLy, modeLS Fdd-21/24/26• Ø Model FDD-21 for 50-52 cm drums

• Ø Model FDD-24 for 61 cm drums

• Ø Model FDD-26 for 66 cm drums

• Wide stance with four swivel casters for ease of mobility

• 7,5 cm non-conductive Textite wheels and roller bearings

Specifications

Deck Ht: 12 cm Capacity: 500 kg Weight: 10,4kg

Fdd

HeaVy duty dRum doLLy, modeL mdd-FdProduct Features

• Reversable design for large and small wire packages• Accomodates round, square & ocotogon wire drums up to 63 cm Use FDD-26 for larger drums

• Textile wheels and rolle bearings for ease of rollability

Specifications

Weight: 10,4 kg Deck Ht: 10,8 cm Capacity: 500 kg

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Handling equipment 2

PaRt no. deScRIPtIon

RCH-2 Conduit Balancer - 1–2 kg - 1.6 mtr



CHH-10 25 cm Conduit Hanger w/two Retaining Straps

CHH-16 40 cm Conduit Hanger w/four Retaining Straps

CHH-22 56 cm Conduit Hanger w/four Retaining Straps

CONDuiT BAlANCer3 SIzES AVAILABLE • Balancer provides easy method

of hanging conduit & cables• Conduit Hanger prevents excess droopage• Prevents conduit and cables

from hanging in areas where they could get damaged

CONDuiT HANGer3 SIzES AVAILABLE

RetRactaBLe conduIt BaLanceRS & HangeRS

build up for large drums

build up for small drums

SaFety LIFteR, modeL FdL-oSLThe new Overhead Safety Lifter is designed to safety lift drums and environmental packages of wire overhead by attaching to Wire Wizard® drum and skid dollies. Each lifter includes the lifting device, heavy duty chains and adapter kit for drum

and skid dollies. Fork lift adapter sold separately.

Product Features

• Safety lifts drums or environmental packs overhead• Ideal for overhead welding applications where drums are above the cell• Compatible with the following Wire Wizard® drum and skid dollies: FDD-21 - FDD-24 - FDD-26• Capacity 680 kg• Required for lifting drums over 10” (254mm) off the floor

manuaL gaS FLoW gauge, modeL eL-gFm Measures the actual flow of shielding gas from the MIG/TIG torch, allowing adjust-ments to be made at the cylinder gauge if necessary. An economical solution for improving overall welding performance. Also easy to use at robots with the torch in downwards position.

Benefits and cost Savings

• Simple but functional design• Measures gas flow consumption (l/min) at the nozzle• Flexible hose for easier operator readings

PRecISIon gaS FLoW SenSoR, modeL eL-gmP

This hand-held digital sensor allows the operator to verify shielding gas flow rate

at the weld tip with outstanding accuracy and response.

Product Features• With totalizing function• Includes hose and filter assembly that fits over all nozzles• Pre-calibrated for argon, C25, CO2 or any mixed inert shield gas

gaS FLoW SWItcH, modeL eL-RVmu Compact design provides reliable and accurate detection of excessive or insufficient flow rate at the weld point. Calibrated scale offers visual flow rate indication for quick and easy switch adjustment. Ideal for protecting against gas flow failure.

Product Features• Can be used as normally open or normally closed• Flow range 5,5 -20 ltr/min• Switch capacity 250 V/1A/100 VA• 1/4 gas thread connection

eL-gmP

Hose not in pro-portion to gas flow sensor

Support equipment 1 (Gas)

eL-gFm

eL-RVmu GAS FLOW SWITCH

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IneRt gaS SaVeRS• Reduces gas consumption

• Restricts gas surge upon arc starts, screen also prevents blockage

• Can be installed on the inlet or outlet side of the gas solenoid*

pArT NO. JeT 2,0 BAr 2,4 BAr 2,8 BAr 3,2 BAr 3,6 BAr 4,0 BAr

GFJ-2* 2 14,0 Ltr/Min 15,5 Ltr/Min 17,0 Ltr/Min 18,5 Ltr/Min 20,0 Ltr/Min 21,5 Ltr/Min

GFJ-3* 3 23,5 Ltr/Min 26,0 Ltr/Min 28,5 Ltr/Min 31,0 Ltr/Min 33,5 Ltr/Min 36,0 Ltr/Min Jet 2 for Mig and Tig welding /Jet 3 for heavy Mig welding

gaS SaVeR FLoW jetS

pArT NO. THreADs JeT lOCATiON

GFJ- 2D or 3D 1/4” Male NPT x 1/4” Female NPT Male End GF- F2 or F3 1/4” Male BSP-GAS x 1/4”-19 Female BSP-GAS Female End

gaS SaVeRS - IncLude ScReenS & jetS 2 or 3

GasFlow

Gas Saver with BSPP Threads (Fronius® style) GFJ-F2GFJ-F3

JETGasFlow

Gas Saver for Inlet Side of Solenoid

GFJ-2DGFJ-3D

JET

tHe BaLLoon teStCompare gas consumption after 5 seconds

of arc-on time right side = Gas saver

WP1000

(Drill not included)

Wire feed sensor, Model HHss

This hand-held battery operated tachometer is capable to measure the exact wire speed in meters per minute or meters per hour. This makes it possible to use the HHSS to calibrate your wire feeder. The HHSS also has a function to totalize the amount of wire in meters or centimeters. This function can be very helpful in order to measure the amount of welding wire used during a certain period. For example to measure the amount of wire used to weld a product. The HHSS can be placed between any male and female Wire Wizard quick disconnect. To place or remove the HHSS the wire don’t need to be cut.

Additional features• Plugs into existing wire system and conduits• Handles wire diameters from 0,8 up to 3,2 mm• Rugged aluminum construction with Delrin wire guide head• Displays wire speed with automatic floating decimal point• Also available without connector base fort hand held measuremnets at the torch.

Order articel HHSS-12 for this option

Wire drAW gAuge, Model WWPT

The electronic WWPT is designed to accurately measure the draw weight of all diameters of weld wire pulling through the conduit. This allows the operator to determine if the conduit needs to be changed by the amount of strain the wire is creating on the feed motor. Hand-held, battery powered (9-volt).

Additional features• Capable of averaging 10 pulls of wire, storing the largest draw• Measures in English or metric at the touch of a button• Easy to read 5-digit LCD display• Ergonomic plastic housing

WWPT WIRE DRAW GAUGE

HHss installed at the wire source

HHss-12 obtaining measurement at the torch end

Wire PiloT, Model WP1000

• Designed to feed weld wire from the source to the feeder• Engage/disengage wire in seconds• Accommodates 0,8 to 3,2 mm wire diameters• Changeable drive rolls

• An 800RPM or less, 10 mmvariable speed drill is recommended.

Specify wire diameters for all units when ordering

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Support equipment 2

Open wire track

Distributed locally by

[email protected] www.wire-wizard.eu

WW

cat

alog

201

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2014 Wire Wizard Brochure

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