Wire Wizard Catalogue AU

Friction free wire transport

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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 in the USA and brought over to Europe in 1999.Trough anticipation of customer needs and ongoing dialogue with end users Wire Wizard created a distinct product line of High quality pro-ducts.

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

The qualityWire Wizard is a range of high quality products, and below we give you an overview of features, which show the quality of the products. • Lifelong guarantee at cracks in drum covers.• Female quick disconnect with 8 balls for a stabile connection.• Male connectors are made with a separate clamping ferrule, which

can be changed without buying a whole new connector.• Liner with a hard steel inner core which is made out of oval wire for

a minimal resistance for the wire to pull trough. 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 distan-ce without a support, for example to a robot arm.

The possibilitiesThe Wire Wizard program offers a total solution for all your wire fee-ding problems with high quality products. With a simple combination 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 as a quick disconnect. This makes it very easy to replace or clean the conduit. To change form one type of wire to another can be done very fast.

6 steps to your solutionWire Wizard keeps things simple. Each situation is connected with a universal type of connector 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.

2

Introduction

Step 1 Cone’s

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

ROUND DRUM CONERound drum cone for standard fi ber drums.Mounted with the metal ring supplied with the drum;

Size in cm Part Number51 cm WW10200C-252 cm WW10204C-2-STANDARD IN EUROPE 59 cm WW10234C-266 cm WW10260C-2

OCTAGON DRUM CONEOctagon drum cone for octagonal packs. The lip securely anchors the cone to the pack.

Size in cm Part Number52 cm WWOC205

SQUARE DRUM CONESquare drum cone for square packs. The lip securely anchors the cone to the pack.

Size in cm Part Number54 cm WWSC-2161 cm WWSC-2472 cm WWSC-28

ROUND DRUM CONERound drum cone for Economical or Environmental fi ber drums. The lip securely anchors the cone to the drum

Size in cm Part Number51 cm WW10201F58 cm WW10231F66 cm WW10260F

3

Unbreakable polyethylene cone’s for all available drums

Size in cm Part Number59 cm WWOC235

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 WW10204C-2Air Liquide 400 Kg Blue Shield WW10234C-2Air Liquide 250 Kg Square pack WWSC-21Air Liquide 400 Kg Square pack WWSC-24Böhler-Thyssen 250 Kg ECO-Drum WW10204C-2Böhler-Thyssen 250 Kg ÖKO-Multi WW10204C-2Böhler-Thyssen 400 Kg Paper-Drum WW10260CElbor 250 Kg Drum 250-270 Kg WW10204C-2Elbor 450 Kg Drum 450 Kg (Square) WWSC-28Elga 250 Kg Octagon Pac WWOC205Esab 100 Kg Marathon Pac Mini WWOC205Esab 250 Kg Marathon Pac Standard WWOC205Esab 475 Kg Marathon Pac Jumbo WWOC235Gedik 50 Kg Economic 50 WW10200C-2Gedik 250 Kg Big Pack 250 WW10204C-2Gedik 500 Kg Big Pack 500 WW10234C-2Grytols Bruk 250 Kg Drum WW10204C-2Grytols Bruk 450 Kg Drum WW10234C-2Kobelco 200 Kg Arrow Pac WW10204C-2Kobelco 250 Kg Arrow Pac WW10204C-2Lincoln 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 WW10204C-2Lincoln 400 Kg Accu Trak Round WW10204C-2Mig-Weld 80 Kg Eco-Drum WW10201FMig-Weld 140 kg Square Pack WWSC-24Novametal 100 Kg Nova Mini Drum WW10204C-2Novametal 200 Kg Nova Drum WW10204C-2Safilo 250 Kg Safilo Drum WW10234C-2Selectarc 100 Kg Selectarc WW10204C-2Selectarc 200 Kg Selectarc WW10204C-2Selectarc 250 Kg Selectarc WW10204C-2Selectarc 300 Kg Selectarc WW10234C-2Sidergas 150 Kg PAC 150 WWSC-21Sidergas 300 Kg PAC 300 WWSC-21Sidergas 450 Kg PAC 450 WWSC-28Sidergas 550 Kg PAC 550 (24-7) WWSC-28Ugitech 250 Kg Drum WW10204C-2Valk Welding 250 Kg Valk HP Special WW10204C-2Valk Welding 380 Kg Valk HP Special WW10234C-2Valk Welding 250 Kg Eco Drum WW10201FValk Welding 500 Kg Eco Drum WW10260FWDI 250 Kg Drum WW10204C-2WDI 300 Kg Eco-Drum WW10201F

4

WWDI CONE CONNECTOR INSULATOR

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

WWDP DIRECT PULL KIT

WIRE DETECTION

The re-usable drumcore is special desig-ned to use in the economical coreless drums which are very popular at the market these days.The absence of the innorcore can cause problems during dewinding the drum.This re-usable drum core can be put inside the drum to solve these dewin-ding problems

HOOD

WWOA20H 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.

WWIC RE-USABLE DRUM CORE

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 trough. 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 fi xed lenghts 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

Swaged connector

*Other lengths can be made at request

Part Dimensions in mm Connector Use for Order Bulk

Number inside x outside wire quantity lenght

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

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

FC-XH 7,0 x 15,50 mm A-10R 1,6 - 2,4 mm Per mtr 30,5 mtr

FC-XH-LW 9,0 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


EL-TL-140-074 1,9 x 3,6 mm 0,6 - 1,2 mm 3/4/5 mtr set 50 mtr


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-3R 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-4R 7,6 - 11,70 mm 0,6 - 1,6 mm A-10C-H Per mtr 152 mtr

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

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

BLUE POLYMER CONDUIT

Known throughout the industry for its longevity and low drag coeffi cient this durable conduit has proven to outlast alumi-num 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.

7

New in this range are the EC-3R and the EC-4R, these are po-lymer conduits with a molecular adjustment to made the liner more tough and applicable to use in situations in which the conduit is constantly moving and bending. Caused by the fact that the drag coeffi cient is a little higher we advice to only use these conduits in situations where the standrad EC-3 or EC-4 do not keep up against the movement.

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

ADVANCED POLYMER CONDUIT

BLUE POLYMER CONDUIT IN FIXED LENGHTS WITH THREAD CONNCECTORS

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

Length* Article Number

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

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

Part Dimensions in mm Use for Order Bulk





Conduits Stainless Steel & Aluminum

Step 4 Conduit connectors

CONNECTORS FOR EXTRA FLEXIBLE CONDUIT

FC-X-SW

FC-XH

FC-X-LW

A-10C-S

A9 + A6

A-10R A-10RP

FC-X A-10C-X

A-10R-QD

Conduits Compression Compression Compression Bayonet connector with thread Connector with (1/4” NPT-F) Quick disconnector

CONNECTORS FOR BLUE POLYMER CONDUIT Conduits Compression Self Threading Compression Alu Compression Bayonet connector Connector with thread connector (1/4” NPT-F)

A-16F-3EC-3

A-16F-4EC-4 A-10HP A-12A

A-16F-5EC-5 A-12B

A-16F-6EC-6

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REPLACEMENT FERRULES FOR COMPRESSION CONNECTORSChoice of sizes for the right compression fit for the application. P/N 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

A-10C-S

A-10C-H

A-10R

A9 + A6

A-10XP

A-10RP

A-10R-QD

9/16”-18 UNF

The A-14 bulkhead connector

A-4 female connector1/4” - 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-4S for non isolated plate connection

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

QUICK DISCONNECT WITH INSIDE THREAD TO MOUNT DIRECTLY AT THE INLET GUIDE OF THE FEEDER

9

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

UNIVERSAL INLET GUIDE WITH QUICK DISCONNECT

ID x OD

15,90 x 22,20 mmID x OD

15,90 x 19,00 mm

ID x OD

9,5 x 15,90 mmID x OD

9,5 x 12,70 mm

A-1AK

A-14 BKBulkhead connector kit

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 Diahen Kobelco

QUICK DISCONNECTS

A-4 A-4ST A-4-14 A-4S A-5 A-3HD A-4HD Std female QD Std female QD Std female QD Std female QD Std female QD Heavy duty female QD Heavy duty female QD1/4” thread in Brass 1/4”in Steel 1/4 BSP thread in Brass 1/4” thread in Brass 1/2” thread in Brass 3/8” thread in Brass 3/8” thread in Brass

INLET GUIDES WITH QUICK DISCONNECT SPECIAL FOR ONE BRAND


13,00 70,00

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

38,00

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

3,20

9,50

35,00

A-1A* A-1AH330 A-1A-C A-1A-D A-1AH A-1A-4.5 A-1B 9,5 mm Probe 8,5 mm Probe 9,5 mm Probe 9,5 mm Probe 8,0 mm Probe 9,5 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

8,00M8

23,00

44,50

114,00

A-1MOT-AU A-1LN-23A A-1LN-23B Motoman Lincoln Wire Fits feeder for Lincoln Cloos Cebora

2,20

12,00

44,00

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

3/8"-18

NPT-M

A-1DS-4 A-4HD

11


INLET GUIDES TO BE USED WITH SEPARATE FEMALE QUICK DISCONNECT

DERLIN INLET GUIDE CERAMIC INSERT

3,2012,70

44,50

A-1HC

9,50

3,20

A-1CM

29,0029,00

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.

The 9,5 mm inlet guides fit directly into the inlet of the PFA-Unit. The 12,7 mm inlet guides are for large wire diameters (>1,6 mm) and fit the PFA-Unit if the Nylon bushing is removed.

Ceramic Insert

DERLIN INLET GUIDE WITH THREADThe A-1DS-4 and A-4HD combination is specially for large mild steel wires.

A-1DS-0

9,50

3,20

33,00

9,50

33,00

1/2"-14

NPT-M

1/2"-14

NPT-M

9,50

3,00

44,50

1/2"-14

NPT-M

A-1DS-1 A-1DS-2

12,70

3,20

20,00

12,70

3,00

44,50

1/2"-14

NPT-M

A-1DS-3

12,70

3,20

29,00

A-12A A-12B

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1/4" NPT-F

1/4" NPT-F

1/4" NPT-F

1/4" NPT-F

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1/4" NPT-F

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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 Daihen

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1/4" NPT-F

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1/4" NPT-F

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Use A-4 (1/4" NPT-M) with fittings above for quick disconnect capability or for steel use A-4-ST quick disconnect

A-12A Aluminium compression connector for EC-4 blue polymer conduitA-12B Aluminium compression connector for EC-5 blue polymer conduitWith the A12A/B a connection can be made without wire/metal contact

A-4HD female quick disconnect with 3/8” NPT thread

20,00

FEEDER INLET CROSS-REFERENCE CHART

12


22,00

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

3,20

A-6 A-15 A-16-M-ST A-17 A-18 A-19 A-20 A-21 A-23 1/2" NPT-F 1/2" – 20 A-16M-AL 1/4" NPT-F 1/4" NPT-F 1/4" NPT-M 1/4" NPT-M 1/4" NPT-M 3/8" NPT-M A-6HD A-15-1 1/4" NPT-M x 3/8" NPT-M x 1/2" NPT-M x 1/4" NPT-M x 3/8" NPT-M x 1/2" NPT-M BSPP-M 1/2" NPT-F 7/16" – 20 (FC-XH-LW) A-15-2 9/16" – 20 HEX

BUSHINGS

ADAPTER FITTINGS

HEXNIPPLES

A-1SKS

FEEDER WIRE WIZARDTM

MANUFACTURER FEEDER TYPE INLET GUIDE P/N

ESAB ALL (except 4-48) A-1AK-E 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 and 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

HOBART ADAPTERKIT

3/4" – 16A-22

SKS FEEDER ADAPTER

3,20

8,50A-1AH330 (see page 10)

MOTOMAN ADAPTERKIT

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 Aluminumand other non-ferrous metals.

13

WS1000-A Features WS1000-A Specification > For all sizes of aluminum and non-ferrous metals Height: 76,0 mm Length: 90,0 mm> V-groove wheels prevent changes in helix Depth: 38,0 mm Weight: 0,45 kg> All fittings are non-conductive

WS-1000-H SpecificationsHeight: 76,0 mm Length: 140,0 mmDepth: 51,0 mm Weight: 1.36 kgWire: 1,2 diameter and over

A-1C-S DELRIN

A-1H-SD HOBART

A-1M-SD MILLER

1/2"–14 NPT19,05 DEEP

A-1D-S DELRIN

A-1D-S DELRIN

32,00

1/2"–14 NPT

19,05 DEEP

Wire straighteners

WS1000-A ALUMINUM WIRE

STRAIGHTENER

WS-VR7000-K

WS-1000STEEL WIRE

STRAIGHTENER

A-1C-S DELRIN

A-1M-SMILLER

A-1H-S HOBART

A-1LNS

A-1-330S

1/4"–18 NPT.75 DEEP

4,00

12,70

A-1LNS

1/4"–18 NPT

.75 DEEP

25,40

A-1QD

SAME ID & OD AS A-1LNS

3,20

12,7017,50

12,70

25,40

4,00

4,00

44,50

65,00

90,00

12,70

8,50

3,20

9,50

2,80

17,50

12,70

12,70

2,80

3,20

65,00 12,70

2,80

2,80

2,80

65,00 9,50

32.0012,70

MODELS WS-1000, WS-1000-H, WS1000A & WS-VR7000-K

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 adjustment 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.

Please refer to part numbers (must be ordered separately) and applications below.

Product Features WS-1000 Specifications > For all types of steel wire Height: 76,0 mm Length: 90,0 mm> Fittings and guides are universal to both units Depth: 38,0 mm Weight: 0,45kg> Hard chrome, U-groove wheels Wire: 1,2 diameter and under

WS-1000-H

Direct pull

Pneumatic Feed Assist for long conduit runs

Direct pull with wire detection

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-X

STANDARD, EXTRA FLEXIBLE

FC-XH-LW

LARGE-WIRE, EXTRA FLEXIBLE

FC-XH

HEAVY-DUTY, EXTRA FLEXIBLE

EC-3, 4, 5 or 6

CONDUIT BLUE POLYMER

14 15

FC-X


FC-XH-LW


FC-XH


EC-3, 4, 5 or 6


FC-X


FC-XH-LW


FC-XH


EC-3, 4, 5 or 6


Combination of femaleconnector and bulkhead.Perfect for plate mounting.

Universal inlet kitSet of 1 inlet adapterand 4 adapter bushings.

Inlet adapter for specificbrand. Choose one atpage 10.

A-14 A-4

A-1AK

A-1FRO

A-14 A-4

A-14B (Bracket)

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

14 15

FC-X


FC-XH-LW


FC-XH


EC-3, 4, 5 or 6


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 17

APPLICATION


16 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




Other diameters at reques

A-1B-COutlet 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.

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.

Look at page 11 for the range of Delrin adapters with Ceramic insert.

These adapters can be used in cases in which the wire should not be in contact with any metal at all, for example if used for Stainless steel or Aluminum.

DELRIN / CERAMIC ADAPTERS 24-VOLT SOLENOID DOUBLE-KIT

CONDUITS FOR STAINLESS STEEL & ALUMINIUM

CONDUITS FOR MILD STEEL

Submerged Arc Welding 1For 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.

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.

MECHANICAL TURNTABLE FOR ROTATING DRUMSMost drums for submerged arc welding are not spooled torsion free as the drums forMig/Mag welding, and must be rotated to unwind. Therefore the use of a turntableis recommended in order to avoid wire feeding problems. Wire Wizard provides a high quality adjustable turntable which can be used for all known drums in the market These turntables can also be used in combination with the pneumatic feed assist. (PFA)

WWTT-DP TURN TABLE DIRECT PULL KITThe WWTT-DP can also be used for other applications, like connecting the wire feed motor or as inlet guide at a spool.(Included in WWTT)



FC-XH 7,0 x 15,50 mm 1,6 - 2,4 mm A-10-R Per meter 30,5 mtr

FC-XH-LW 9,0 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

WWTT MECHANICAL TURN TABLEWidth : 76 cmLength : 66 cmHeight : Adjustable from 107 unto 167 cmWeight : 64,5 kgMax drum diameter : 66 cm

WWTT-C TURN TABLE SOFT COVERThe soft cover does not affect the accessi-bility of the drum. So can be used while the drum is turning. Protect from dust, grease a other contaminan

WTT

-C t

urn

tabl

e so

ft c

over

WTT

tur

n ta

ble

with

dru

m

18

PFA motor

19

Submerged Arc Welding 1

To make it possible to work with longer conduit runs the PFA can also be used for submerged arc welding.The PFA-unit is available for wire diameters up to 4,0mm And can be used for static and rotating drums. For large

SAW installations this can be the perfect opportunityto switch over from spools to drums. A conduit run of 20 meter is no problem at all.

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




V-knurled Feed roll 3,2mm for PFA (per piece) WW132963


A-1B-C-HDOutlet 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

Slows and stops the drum for welding applications with high wire speed. Prevents drum from over-rotating

Brake is powered by a pneuma-tic cylinder which is switchedby a 24-Volt solenoid valve.

WWTT-BR BRAKE FOR TURNTABLE(optional)

ADJUSTABLE STAND FOR PFA

A-1CS

PFA-ASPFA-AS-I

intoPFA

ontoguide arm

PFA -FRL filer/regu-lator / lubricator

including hose

20 21

RWC1111-30 REEL ASSEMBLYshown on a WRSC STAGING CART

Wood reel dispensing equipment

WIRE WIZARD REEL DISPENSING > Universal base plate design fits all manufacturers’ wood reels

> Twin locking cams secure base plate to wood reel for stability

> Braking system for smooth acceleration and deceleration of feed arm

> Outer tube radius and lead ensure wire cast remains unchanged

> Ceramic inlet guide provides long wear and prevents wire shaving

> Externally adjustable nut and jam allow for precision braking

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

> High density polyethylene liner for longer service life

WOOD REEL COVER, MODEL RWC1111-30

> Designed specifically for 76 cm spools

> Prevents access to dispensing unit during operation

> Available in both unbreakable polyethylene (RWC1111-30) or economical, soft sided models (RWC1111-30S)

> Clear side and top panels allow for easy viewing and access

> Polyethylene model comes fully assembled (commercially shipped)

RW1028-C14UFHEAVY WIRE ARM GUIDE UNIT

Used for 76cm wood reels For wire 1,6mm and larger

with universal base plate andspring-loaded fiber brake.

EC-4 Liner forAluminum or Stainless

FC-X Liner for Mild Steel

Adjustable arm to fitdifferent reel diametersAdjustable arm to fit

different reel diameters

Adjustable Brake

RW1030-C33ADJUSTABLE WIRE ARM

GUIDE UNITAdjustable from

40 to 76 cm spoolsFor aluminum and stainless wire

up to 1,6mmwith universal base plate and

adjustable braking system

RW1031-C33 ADJUSTABLE WIRE ARM

GUIDE UNITAdjustable from

40 to 76 cm spoolsFor mild steel wire up to 1,6mm

with universal base plate andadjustable braking system

RWC1111-30S SOFT COVER helps protect welding wire from

dust and other contaminants

AdjustableBrake

20 21

Data Acquisition

*Contact customer service for the appropriate inlet guides for your application

WVS-2 Optional protectiveenclosure for harsh work

environments

WIZARD VIEW WIRE CENTRAL™ MONITOR

Wizard View™ firstStep Screen Shot

P/N DESCRIPTION

WVS-1 Wire Central™ Controller

WVS-2 Optional Wire Central™ enclosure & cables (does not include WVS-1 controller)

WVS-3 Software package & PC-Controller cable

WVS-4 Wire Central™ Kit w/WVS-1, PAWFS-540* & cables

WVS-5 110v Plug-in Power Adapter

PAWFS-540 Wire Speed Sensor for standard unit (inlet guides sold separately)*

FIRSTSTEP WIZARD VIEW™ SOFTWARE WVS-3

™

The firstStep - Wizard View software is the software package used for programming, communication and monitoring Wire Central controllers. This package consists of two applications - one for configuration and the other for monitoring, and one interface application. Functions of the firstStep-Wizard View application include: Reading & modifying controller parameters; Reading, presenting and recording controller data; Sending email alerts.

WVS-1 Wire Central ControllerProduct Features> Monitors and displays wire speed and wire quantity in

either metric or U.S. measurements

> In the event of a power loss, it will pick up where it left off on the wire quantity through a built in internal memory

> Wire linear weight constant can be configured via a PC connection

> Compatible with Windows 2000 Pro, XP and Vista

> Generates three alerts:

> Notifies the operator when the wire has stopped moving

> When a pre-set amount of wire (in KG) is left in the drum

> When wire is not within the programmable wire feed speed window limits

PAWFS-540 Wire Sensor (shown with inlet guides*)

Now you can easily monitor weld wire usage information without constant manual inspections. The Wizard View Wire Central™ Data Acquisition System utilizes a wire feed sensor along with a controller to monitor critical welding wire usage information, including the quantity of wire left in the drum and the speed at which it is traveling, measured in either metric

or U.S. units. With the firstStep Wizard View™ software (sold separately), the controller may also be connected through a PC connection where alerts can be automatically emailed and monitored data can be stored in a log file. In addition, the soft-ware allows you to set custom parameters on the controller. Compatible with Windows 2000 Pro, XP and Vista.

Pneumatic Feed Assist(optional - see page 17)

FRL forFeed Assist

Wire WhipNSWDrumHoods

Conduit

Wire Transfer Arm

ButtWelder

Docking Station

Deburring Tool

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

Smooth wire joint using a de-burring tool (Wire Dresser op-tional).

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 empty drum and repeat steps 1-3.

COMPONENTS & BASIC SETUP

1 2

3 4

Start Wire

End Wire

Start Wire

Drum 1 Drum 2

DRUMSETUP

NSW-20.4-2

Fiber Drum Dispensing

22 23


22 23


NSW-SC21-2SHOWN WITH

OPTIONAL DOCK-ING STATION

(NSW-DS)

NON-STOP WIRE DISPENSING SYSTEMS & ACCESSORIES DESCRIPTION PART NO.

Dispensing System with 2 stations for 20.4" Drums (1-Torch) NSW-20.4-2

Dispensing System with 4 stations for 20.4" Drums (2-Torch) NSW-20.4-4

System w/2 stations for 1000LB Accu-Pak Drums (1-Torch) NSW-SC24-2

System w/4 stations for 1000LB Accu-Pak Drums (2-Torch) NSW-SC24-4

System w/2 stations for 26” Ø Chimeless Drums (1-Torch) NSW-26FD-2

System w/4 stations for 26” Ø Chimeless Drums (2-Torch) NSW-26FD-4

Docking Station NSW-DS

Resistance Butt Welder (Hand held) BW

Wire Dresser BW-WD

Wire Parters BW-WP

NON-STOP WIRE DISPENSING SySTEM™

A unique process joins the end wire from 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

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

> Accepts any fiber drum or cardboard wire packaging design

> Easy-to-use resistance Butt-Welder & Wire Dresser available

> Appropriate drum-handling carts available

2 Drum Specifications 4 Drum Specifications

Height: 2,13m Height: 2,13m

Width: 1,3m Width: 1,3m

Weight: 95.3kg Weight: 102kg

Diameter: 1,3m Diameter: 1,3m

Wire manufacturer must present wire end at top of dispensing drum to butt-weld beginning and ending of wires. Call customer service for information.

BW RESISTANCE BUTT WELDERWelds up to 2,0 mm ferrous

metal wire

BW-WD WIRE DRESSER

BW-WPWIRE PARTERS

Leaves flat wire ends for easy butt-welding

WGB-045* 1,2 mm WireGage Block

Wire Gage Blocks also available for other wire sizes, please specify when ordering.

*

*

24

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: 12,7cmLength: 70 cm Width: 70 cmCapacity: 453 kg Weight: 17 kg

FDL DRUM LIFTER WITH FDL-FA

WWSDPALLET (SKID) DOLLY

FDL-HS

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: 453 kg

DRUM SHARK DRUM LIFTER, MODEL FDL-C

> Lifts both chimeless and chimed fiber drums

> Locking jaws firmly “bite” the drum without causing damage

> Accepts 51 to 66 cm diameters inc. Accu Pak & Marathon Pak

> Weight: 25 kg Capacity: 453 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-HS, accepts 51 to 66 cm drums inc. Accu Pak & Marathon Pak

> Weight: 9,3 kg Capacity: 453 kg

FDL-C DRUM SHARK WITH FDL-FA

PALLET SKID DOLLY, MODEL WWSD

FDL-FA

FDL-21

FDL-HS and 21

FDL-21

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: 453kg Weight: 10,4kg

FDSC

FDD-ADJ

HEAVY DUTY DRUM DOLLY

FDD-OP OCTAGON DRUM DOLLYfor environmental packs

OCTAGON DRUM DOLLY, MODEL FDD-OP

Product Features> Designed to easily move octagon and square environmental packs

> Four rounded guide tabs for easy loading

> Four solid Textite roller bearing wheels resist wear for added life

SpecificationsDeck Ht: 11 cm Height: 16,5 cmLength: 61 cm Width: 61 cm Capacity: 453kg Weight: 12,7kg

HEAVY DUTY DRUM STAGING CART, MODEL FDSC

Designed for one person to transport up to 453kg wire drums. The hinged handle stores upright for pushing and outward to give added leverage for easy steering. Non-conductive Textite 15 cm roller bearing wheels and 7,5 cm front swivel caster

provide smooth movement. Transports drums up to 61 cm in diameter

Specifications

Deck Ht: 3,8 cm Height: 100 cmDepth: 66 cm Width: 76 cmCapacity: 453kg Weight: 19,5kg

Adjustable drum dolly, Model FDD-ADJ

> Adjusts to accommodate 52, 61, 66 cm drum diameters

> Textite wheels and roller bearings for ease of rollability

Specifications

Deck Ht: 16 cm Capacity: 453kg Weight: 9 kg

25

Handling equipment 2

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

PART NO. JET 30 PSI 35 PSI 40 PSI 45 PSI 50 PSI 55 PSI

GFJ-** 1 10 CFH 11CFH 12 CFH 13 CFH 14 CFH 15 CFH

GFJ-** 2 29 CFH 33 CFH 36 CFH 39 CFH 42 CFH 45 CFH

GFJ-** 3 51 CFH 55 CFH 61 CFH 66 CFH 71 CFH 76 CFH

INSERT 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*> Flow jets can be changed depending on application

Support equipment 1

EL-GFM

EL-RVMU GAS FLOW SWITCH

26

* 1/4 NPT thread to ensure the filter is ahead or up stream of the Flojet ** Part Number (with jets):STANDARD INLET GFJ-1, GFJ-2, GFJ-3OUTLET SOIDE OF SOLENOID GFJ-1B, GFJ-2B, GFJ-3BINLET SIDE OF SOLENOID GFJ-1A, GFJ-2A, GFJ-3A Jet #1 TIG (GTAW)Jet #2 MIG (GMAW) Light WireJet #3 MIG (GMAW) Heavy Wire

JET

SCREEN

GasFlow

GasFlow

GasFlow

GAS SAVER FOR STANDARD INLET

GAS SAVER FOR OUTLET SIDE OF SOLENOID

GAS SAVER FOR INLET SIDE OF SOLENOID

WP1000

(Drill not included)

Specify wire diameters for all units when ordering

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 cen-timeters. 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

> Large 13 test memory capacity selectable to 5 minutes or more

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 WIRE FEED SENSOR

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.

27

Support equipment 2

Distributed locally by

[email protected] www.wire-wizard.eu

WW

cat

alog

200

9

Martin

Typewritten Text

Martin

Typewritten Text

Welding Automation

Martin

Typewritten Text

Martin

Typewritten Text

t: 04 4886 5112 f: 03 9011 6203

Martin

Typewritten Text

e: [email protected]

Martin

Typewritten Text

Distribution in Australia and New Zealand by; Welding Automation Pty Ltd t: +61 4 4886 5112 f:+61 3 9011 6203 e: [email protected]

Documents

Wire Wizard Catalogue AU