Wire Wizard

the art of wire feeding

New !!
Wire Guide Modules
look at page 18

Productcatalog
weld wire dispensing systems
 Introduction

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 quality
Wire 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 possibilities
The 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 solution

Wire 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
 Step 1 Cone’s
Unbreakable polyethylene cone’s for all available drums

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 Number

51 cm WW10200C
52 cm WW10204C-STANDARD IN EUROPE
59 cm WW10234C
66 cm WW10260C

ROUND DRUM CONE

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

Size in cm Part Number

51 cm WW10201F
58 cm WW10231F
66 cm WW10260F

8- les
e 1 du
19
ag Mo
kp e
ec uid
C h i re G
W

SQUARE DRUM CONE

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

Size in cm Part Number

54 cm WWSC-21
61 cm WWSC-24
72 cm WWSC-28

OCTAGON DRUM CONE

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

Size in cm Part Number

52 cm WWOC205
59 cm WWOC235 H

Size in cm Part Number

59 cm WWOC235 L LOW PROFILE HOOD

3
 Step 1 Choose the right cone
Cross reference table wire manufacturers
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.

Wire Manufacturer Packaging Trade Name WW article no.

Air Liquide 250 Kg Blue Shield WW10204C
Air Liquide 400 Kg Blue Shield WW10234C
Air Liquide 250 Kg Square pack WWSC-21
Air Liquide 400 Kg Square pack WWSC-24
Böhler-Welding 250 Kg ECO-Drum WW10204C
Böhler-Welding 250 Kg ÖKO-Multi WW10204C
Böhler-Welding 400 Kg Paper-Drum WW10260C
Elbor 250 Kg Drum 250-270 Kg WW10204C
Elbor 450 Kg Drum 450 Kg (Square) WWSC-28
Elga 250 Kg Octagon Pac WWOC205
Esab 100 Kg Marathon Pac Mini WWOC205
Esab 250 Kg Marathon Pac WWOC205
Esab 475 Kg Marathon Pac Jumbo WWOC235
Gedik 50 Kg Economic 50 WW10200C
Gedik 250 Kg Big Pack 250 WW10204C
Gedik 500 Kg Big Pack 500 WW10234C
Grytols Bruk 250 Kg Drum WW10204C
Grytols Bruk 450 Kg Drum WW10234C
Kobelco 200 Kg Arrow Pac WW10204C
Kobelco 250 Kg Arrow Pac WW10204C
Lincoln 100 Kg Accu Trak Cube WWSC-24
Lincoln 250 Kg Accu Trak Cube WWSC-24
Lincoln 400 Kg Accu Trak Cube WWSC-24
Lincoln 250 Kg Accu Trak Round WW10204C
Lincoln 400 Kg Accu Trak Round WW10204C
Mig-Weld 80 Kg Eco-Drum WW10201F WLI WIRE LEVEL INDICATOR
Mig-Weld 140 kg Square Pack WWSC-24
With the WLI Wire level indicator you
Novametal 100 Kg Nova Mini Drum WW10204C can quickly see how much welding
Novametal 200 Kg Nova Drum WW10204C wire the drum still contains!
Safilo 250 Kg Safilo Drum WW10234C
Selectarc 100 Kg Selectarc WW10204C • design for 250 kg and 500 kg drums
Selectarc 200 Kg Selectarc WW10204C • for all brands of welding wire in
drums
Selectarc 250 Kg Selectarc WW10204C
• works without a power supply,
Selectarc 300 Kg Selectarc WW10234C
air or any other
Sidergas 150/300 Kg PAC 150/300 WWSC-21
medium
Sidergas 450 Kg PAC 450 WWSC-28
Sidergas 550 Kg PAC 550 (24-7) WWSC-28
Ugitech 250 Kg Drum WW10204C
Hyundai 250 Kg Ball pac WW10204C
Ugitech 250 Kg Octagon Drum WWOC205
Valk Welding 250 Kg Octagon Drum WWOC20
Valk Welding 250 Kg Eco Drum WW10201F
Valk Welding 500 Kg Eco Drum WW10260F
WDI 80/250 Kg XS/S Round Drum WW10204C
WDI >325 Kg M/L Round Drum WW10234C
WDI >325 Kg EcoRack M WWOC205
WDI 450 Kg EcoRack L WWOC235L
4
 Step 2 Cone connectors

DIRECT PULL KIT

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. WW-DP-I
Direct pull kit with
WW-DP insulation sleeve

CONE CONNECTOR INSULATOR ORBITAL ARM KIT

Insulator for WW-QDI The orbital arm is developed to
the drum solve problems which can
connection occure during the dewinding
of drums. Small diameter wires
WW-DI and heavy tangling wire can
Universal insulato- cause nuts inside the drum.
tion sleeve for all With the orbital arm these
quick disconnects problems can be solved easily.

WW-OA-20H

RE-USABLE DRUM CORE

HOOD
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. 711mm

WW-IC-11

254mm

WIRE DETECTION

WWA5-E34-NC (Normally close)

WWSB-M12 WWA5-E34-NO (Normally open)
WIRE PRESENCE SENSOR BLOCK WIRE PRESENCE SENSOR SWITCH-24V
can be added to WWDP or WWOA kits. with M-12 thread. Other switches are avai-
M-12 thread is standard. lable upon request. Please call with specifi-
Also available in M-18 cations for quote.

5
 Step 3 Conduits for Mild Steel

EXTRA FLEXIBLE CONDUIT

Liner with a hard steel inner core which is made out of oval wire core and double insulation jacket these liners are stiff enough
for a minimal resistance for the wire to pull trough. This makes to bridge a small distance without a support, for example to a
that the wire easily runs trough angles. With this hard inner robot arm.

Wire Wizard: Others:

NO GAPS: SMOOTH OPEN GAPS:
ROUND EDGES SHARP EDGES

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

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 2 Swaged connectors

10,0 m FCX100 1 x side with polymer

12,0 m FCX120 strain relief

TORCH LINERS
The oval liner technology is also available for torch liners.

Part Dimensions in mm Use for Order Bulk

Number inside x outside wire quantity length
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

6
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.
Part Dimensions in mm Use for Connector Order Bulk
Number inside x outside wire quantity length
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

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.

Length* Article Number Length* Article Number

1,5 m EC4-015 8,0 m EC4-080
3,0 m EC4-030 10,0 m EC4-100 Thread connector
5,0 m EC4-050 12,0 m EC4-120
*Other lengths can be made at request

POLYMER LINER INSERT A-4L-H

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

The A-4L-H is designed to prevent the wire

Polymer conduit
from shaving against the steel connectors
A-4L-H

TORCH LINERS AND ACCESSORIES

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

Part Description Use for liner with

Number Outside diameter
TL-EN40 Thread/clamp end-nipple to connect 3,9 - 4,0 mm
liner in torch connector
TL-EN42/LE42 “ 4,2 mm
TL-EN47 “ 4,7 mm
TL-LE40 Brass thread liner-end for use at liner- 3,9 - 4,0 mm
end in torchbody
TL-LE42 “ 4,2 mm

7
 Step 4 Conduit connectors

CONNECTORS FOR EXTRA FLEXIBLE CONDUIT

For connectors with a strain relief add -SR to the articel number
Conduit Compression-
FC-X-SW bayonet A-10C-S

Conduit Compression- Compression- Compression-inline

FC-X bayonet A-10-CX 1/4 thread A-10-XP 1/2 thread A-10-XM

Conduit Compression- Compression- Compression- Compression-female

FC-XH bayonet A-10C-R 1/4 thread A-10-RP Union A-10RU Quick dis. A-10R-QD

Conduit Compression- Compression- Compression-

FC-XH-LW bayonet A-9+A-6 bayonet HD A-9+A-6HD Union A-9U

CONNECTORS FOR BLUE POLYMER CONDUIT

For connectors with a long strain relief add -SRL to the articel number
Conduit Compression Self-treading-
EC-3 bayonet A-10-CS bayonet A-16F-3

Conduit Compression Self-treading- Compression- Compression-

EC-4 bayonet A-10-CH bayonet A-16F-4 1/4 thread A-10-HP 1/2 thread A-10HM

Conduit Compression Self-treading- Compression- Compression-

EC-5 bayonet A-10-R bayonet A-16F-5 1/4 thread A-10-RP Union A-10RU

Conduit Compression Self-treading- Compression- Compression-

EC-6 bayonet A-9+A-6 bayonet A-16F-6 1/4 thread HD A-9+A-6HD Union A-9U

REPLACEMENT FERRULES FOR COMPRESSION CONNECTORS

Choice 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-9-FE A-10RFE A-10XFE A-10CFE A-10SFE A-10SFE A-10C-S

8
 Step 5 Feeder connectors 1

PLATE OR BULKHEAD CONNECTION

The A-14 bulkhead A-4 female connector 95 mm

connector 1/4” - NPT-M

The A-14 bulkhead connector in combination with the A-4 female A-14B Bracket
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.

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-14 BK
A-4S WWTT-DP
Bulkhead connector kit
for non isolated for plate connection
plate connection + ceramic insert

QUICK DISCONNECTS (FEMALE) BAYONET THREAD CONNECTOR

A-15 A-16F3 A-16F5

1/ 4” BSP (GAS) 1/8” NPT-F 3/8” NPT-F
A-4 A-4ST A-4-14 A-4S A-5 A-15-1
Brass -copper Steel Brass-copper Steel+Nut Brass-copper 7/16 ”– 20 A-16F4 A-16F6
1/4” NPT 1/4” NPT 1/4 BSP-M (GAS) 1/4” NPS-M 1/2” NPT-M A-15-2 1/4” NPT-F 1/2” NPT-F
9/16 ”– 20

QUICK DISCONNECT WITH INSIDE THREAD TO MOUNT DIRECTLY AT THE INLET GUIDE OF THE FEEDER
1/4 BSP (GAS)
9/16”-18 UNF

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

THREAD ADAPTERS MALE BAYONET HD HEAVY DUTY CONNECTORS FOR

BSP (GAS) ESAB DRUM CON. SUBMERGED ARC WELDING
use only for HD (large) bayonet connectors

A-17G
1/4”F 3/8” M
A-18G
1/4”F 1/2” M
A-18G1 A-15E A-4HD A-3HD A-3HD12 A-3HD34 A-6HD
3/8”F 1/2” M 3/8”BSP-M 3/8”NPT-M 3/8”NPT-F 1/2”BSP-F 3/4”BSP-F 1/2”NPT-F

9
 Step 5 Feeder connectors 2

INLET GUIDES WITH QUICK DISCONNECT SPECIAL FOR ONE BRAND

2,00
2,20 5,00
13,00
13,00
12,00 5,00

3,20 2,20 8,00 3,20

70,00 60,00 M8
14,00 13,00 55,00 9,50
23,00
40,00 47,00 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
3,20
9,50

3,20 3,20 3,20

9,50 5,00
8,50 3,00 8,00

9,50 9,50 114,00

70,00 70,00 70,00

44,50 44,50

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
6,90
Feeder (Sm. Wire) Wire Feeder
3,20
11,20 17,40
6,40 4,00

12,00 15,00 2,00

2,20 9,50
103,00
35,00
63,50
12,00 41,00
19,00

37,00

A-2PA A-8M PAWFS-12

A-1MOT-AU A-1LN-23A A-1LN-23B

Motoman Lincoln Wire Lincoln
Cloos
Cebora
ESAB
ESS
A-3QDF-4 A-3

10
 Step 5 Feeder connectors 3

INLET ADAPTERS WITH FEMALE THREAD

6,90
17,40
Use A-4 5,00 5,00
(1/4 ” NPT-M) 5,00
12,70 9,50
6,90 6,90 12,00
22,00 5,00 19,70
63,50
4,00 31,50 44,50
44,50 38,00
22,00
53,50 21,00 51,00
32,00 40,00

1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4"

NPT-F NPT-F NPT-F NPT-F NPT-F NPT-F NPT-F 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

DERLIN INLET GUIDE CERAMIC INSERT

3,20
9,50 3,20 These Derlin inlet guides can be used for applications
12,70 for Aluminium or stainless steel wires.
3,20
3,20
9,50
12,70 5,0
19,20
44,50 44,50
in/out PFA-unit

29,00 20,00

30,00

A-1CM A-1MC A-1CS A-1HC A-1CS PFA

DERLIN INLET GUIDE WITH THREAD

3,20 3,00 3,00 A-17G
3,20
9,50 9,50 5,00 1/4”F 3/8”M
12,70
3,20 A-18G
12,70 19,00 1/4”F 1/2”M
12,70
33,00 44,50 44,50 A-18G1
20,00 3/8”F 1/2”M
in/out PFA-unit

29,00 30,00

1/2"-14 1/2"-14 1/2"-14 1/2"-14 3/8"-18 3/8"-18

NPT-F NPT-F NPT-F NPT-F NPT-F NPT-F

A-1DS-0 A-1DS-1 A-1DS-2 A-1DS-3 A-1DS-4 A-1DS-4 PFA

1/4"
Inline connectors NPT-M
1/2"-14 3/8"-18
The conduit runs through the whole
NPT-M NPT-M
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 for HD

conduit. Bayonet
The A-10-HM is used for the EC-4
conduit. A-5 A-4HD A-4

11
 Step 5 Feeder connectors 4
UNIVERSAL INLET GUIDE WITH QUICK DISCONNECT

A-1AK

ID x OD ID x OD
The A-1AK universal inlet kit is an inlet adapter with ID x OD ID x OD
9,5 x 15,90 mm 15,90 x 22,20 mm
four phenolic bushings to make a solid and stable
9,5 x 12,70 mm 15,90 x 19,00 mm
fitting in several sizes of holes.
A-7 = BUSHINGS ONLY

A-1AKE
ID x OD ID x OD
SPECIAL ESAB 9,5x 12,70 mm 15,90 x 19,00 mm
ID x OD ID x OD ID x OD
A-7E = BUSHINGS ONLY 9,5 x 12,00 mm 9,5 x 15,70mm 15,90 x 22,20 mm

HOBART ADAPTERKIT FEEDER INLET CROSS-REFERENCE CHART

FEEDER WIRE WIZARD TM
3,20 MANUFACTURER FEEDER TYPE INLET GUIDE P/N

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

4-48 A-2E and A-4
A-1A (see page 10) 9,50
Fanuc Servo Torch A-3QDF-6 and A-23
Fronius Feeder without Set Screw A-1FRO-B
3/4" – 16 Feeder with Set Screw A-1FRO
A-22 Feeder with Stripped Set Screw A-2FRO
Hobart Series 27 A-1H and A-4
SKS FEEDER ADAPTER A-1A, A-1A-4.5
Models with 3/4"-16 Thread A-1A and A-22
3,20 A-1AH330 and A-1MOT
Kobelco Male Threaded Inlet 1/2"-20 A-3QDF-4
Lincoln Electric PF Series A-1LN and A-4
A-1A-4.5 (see page 10) 9,50 LN-7, LN-9, and LN-25 A-1A
LN-8 A-1H and A-4
22,00 NA-3 and NA-5 A-1NA-5
Synergic 7 A-1B-C
A-1SKS LF-72 A-1LN and A-4
Series 10 A-1LN and A-4
Servo Torch A-2LN-AK
MOTOMAN ADAPTERKIT
Miller Most Models A-1A-C, A-1M and A-4,
3,20 or A-1A
22A A-1AK
Auto Axcess A-1A-C
A-1AH330 (see page 10) 8,50 Series 74 A-1A-4.5
Series 75 PAWFS-12 and A-3
3/4" – 16 RAD 400 A-1LN-S and A-3
Motoman Female Inlets A-1AH330 and A-1MOT
A-1MOT Male Threaded Inlets A-3QDF-3
Hyper Feeder A-1MOT-HP
CONNECTOR LINER FOR ALU 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
A-4L-H 2,3 X 4,5 MM
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
Designed to avoid any metalic contact Cloos 12 mm A-1LN-23B
inside the connectors. Used for Aluminum EWM 12 mm A-1LN-23B
and other non-ferrous metals.
Cebora 12 mm A-1LN-23B

12
 Wire straighteners
MODELS WS-1000 FOR MIG WELDING OF MILD AND STAINLESS STEEL
Wire WizardTM manufactures three 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.
9,50
44,50
A-1M-S
2,80
MILLER
A-1QD 12,70
65,00
25,40 12,70 A-1H-S
4,00
HOBART
1/4"– 18
NPT 8,50
.75 DEEP 90,00
4,00
A-1LNS 3,20
17,50 12,70 WS-1000
A-1-330S
STEEL WIRE
STRAIGHTENER WS-1000 Specifications
Height: 76,0 mm Length: 90,0 mm
3,20 Depth: 38,0 mm Weight: 0,45 kg
Wire: 1,6 diameter and under
A-1C-S DELRIN
Wheels: Hard chrome U-groove

MODELS WS-1000-A FOR MIG WELDING OF ALUMINIUM

65,00 12,70
32,00
12,70
2,80
A-1H-SD
1/2"– 14
HOBART
NPT
19,05 65,00 9,50
2,80
DEEP
2,80
A-1M-SD
A-1D-S2 DELRIN MILLER
17,50 12,70
12,70 32.00
WS1000-A
ALUMINUM WIRE 1/2"–14 NPT
3,20 STRAIGHTENER 19,05 DEEP
2,80
A-1C-S DELRIN WS-1000-A Specifications
Height: 76,0 mm Length: 90,0 mm A-1D-S2 DELRIN
Depth: 38,0 mm Weight: 0,45 kg
Wire: 1,6 diameter and under
Wheels: V-groove prevents changes in helix

MODELS WS-1000-H FOR SAW WELDING OF LARGE WIRE

WS-1000H Specifications
WS1000-H Height: 76,0 mm Length: 140,0 mm
Depth: 51,0 mm Weight: 1,36kg
Wire: 1,6 diameter and under
Wheels: Hard chrome U-groove
76,00
A-1LNS-HD

For large wire application

you can add “HD” to all
140,00
other partnumbers Example of WS-1000-H equiped with conduit
and connectors

13
 FC-X
STANDARD, EXTRA FLEXIBLE

FC-XH
page 6 & 7
HEAVY-DUTY, EXTRA FLEXIBLE

FC-XH-LW
LARGE-WIRE, EXTRA FLEXIBLE

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

page 8

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

WIRE FEEDER

Direct pull
page 5

Direct pull with Pneumatic Feed Assist Wire Guide

wire detection for long conduit runs Modules
page 5 page 16-17 page 18-19
All these options can be used in combination with a cone of your choise

14
 FC-X FC-X FC-X
STANDARD,
DARD, EXTRA EXTRA EXTRA
STANDARD,
FLEXIBLEFLEXIBLE
FLEXIBLE

FC-XH FC-XHFC-XH
HEAVY-DUTY, EXTRA EXTRA
FLEXIBLE
page 6 & 7
DUTY, EXTRA
HEAVY-DUTY,
FLEXIBLE FLEXIBLE

FC-XH-LW
FC-XH-LW FC-XH-LW
LARGE-WIRE,
WIRE, EXTRA EXTRA EXTRA
LARGE-WIRE,
FLEXIBLEFLEXIBLE
FLEXIBLE

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

page 8

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

A-14 A-4

A-14B
(Bracket)
page 9

A-14 A-4

Combination of female
connector and bulkhead.
Perfect for plate mounting.
page 9

page 8
A-1AK

Universal inlet kit

Set of 1 inlet adapter
and 4 adapter bushings
page 12.

A-1FRO

Inlet adapter for specific

brand. Choose one at
page 10.
15
 Step 6 Wire feed assist 1
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.

UNLIMITED DISTANCE WITH PNEUMATIC WIRE FEED ASSIST

A great advance of the Wire Wizard system Wouldn’t it be great if the distance between
is the distance, which can be bridged by this drum and feeder were just no problem at
system. Everybody knows that normally the all? Wire Wizard hands you the solution to
distance from the wire feeder to the spool all these problems. By using the Pneumatic
or drum can be maximum 5 to 10 meters. Feed Assist (PFA) you can bridge distances
This makes that for large installations it’s up to 30 meters.
difficult to get the drum close enough to the
feeder, and sometimes it’s even impossible This opens lots of opportunities to place the
to work with drums. This forces us to use drum at a large distance to avoid great loss
small spools, which means that production of time by replacing and handing the drums.
will stop with every use of 15 kg of welding Its even possible to leave the drum at the
wire. A great loss of production time. pallet and don’t move it at all.

THE PFA-UNIT
The PFA-Unit must not be compared with The friction free transport of wire, which
the traditional Push-Pull systems. Trough the these systems create has the advance that
years Push-pull systems got a bad reputa- wearing of the liners will be reduced to mi-
tion in the market because they damage the nimum and rasping of the wire feed rollers
wire, are very sensitive for technical trouble will be history.
and very fragile. The great advance of the
PFA-Unit is that it works with one unit only, By using a feed assist you can even put the
and works completely independent from the wire conduit in the drag chain or cable car-
wire feeder of the machine. This makes that rier together with the other cables leading
you can add it to any running system you to the robot arm.
like.

APPLICATION

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
 Step 6 Wire feed assist 2
PFA-UNIT STANDARD SET Product Part
number
PFA unit is supplied as a complete set to install the PFA unit for 1,0 mm wire (installation set included) PFA10
PFA-unit, including all the items in this drawing,
PFA unit for 1,2 mm wire (installation set included) PFA12
except for the drumhood.
PFA unit for 1,4 mm wire (installation set included) PFA14
PFA unit for 1,6 mm wire (installation set included) PFA16
A-1B-C
Outlet adapter 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
PFA U-groove Feed roll 1,0mm for PFA (per piece) WW072000
motor
U-groove Feed roll 1,2mm for PFA (per piece) WW053701
PFA -FRL filer/regu-
lator / lubricator U-groove Feed roll 1,4mm for PFA (per piece) WW053702
including hose U-groove Feed roll 1,6mm for PFA (per piece) WW053706
Other diameters at request
dr
um

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

ho
od

V-Knurled Feed roll 1,2mm for PFA (per piece) WW132957

V-Knurled Feed roll 1,4mm for PFA (per piece) WW132956
Air tool lubricant PFA-DA Drum V-Knurled Feed roll 1,6mm for PFA (per piece) WW132955
included adapter kit Other diameters at reques

PFA-UNIT OPTIONS AND ACCESSOIRES

PFA-SR SILENCER/RECLASSIFIER 24-VOLT SOLENOID SINGLE-KIT
Separates oil from the used com- 24-Volt Solenoid kit used to reduce the
pressed air. Herewith it prevents consumption of compressed air by the
pneumatic oil spatter. PFA.
The solenoid is placed before the FRL and
The PFA-SR also reduces the noice switches the air pressure on and off.
of the air exhaust.
The signal the solenoid uses can be con-
To install the PFA-SR the standard nected parallel with the gas valve, or in
air exhaust needs to be removed. case of SAW welding, parallel with the
powder valve.

In both cases the PFA is always running

PFA-SR when the wire feeder is running. PFA-SK

PFA-WALL-BRACKET 24-VOLT SOLENOID DOUBLE-KIT

PFA-WM The Solenoid double kit is used in cases where
Remote Mounting Bracket the PFA needs to be able to run in two direc-
Mounts Feed Assist to tions.
walls or other surfaces 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. PFA-SK2
Includes valve, hose, connectors and cable.
17
 Wire Guide Modules
• The new way of thinking in feeding wire
• What causes the friction in your wire supply?... the angels!
• Eliminate the angels, you’lle eliminate the friction
• Feed over 30 meters without assist

Two 45º wire guide modu-

Lightweight durable les combined
polymer body to a 90º angle

Will soon also be avai-

Heavy duty rollers lable for Submerged A 45º wire guide
with bearings Arc Welding. module mounted at
Add “HD” to the part a drum cover
Wire from source no.

• 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)

INSTALLATION EXAMPLE
45º GUIDE
MODULE
A-5 For use with any male connector

Assembled
with End Caps
A-10HM For use with EC-4 Conduit

A-10XM For use with FC-X Conduit

90º GUIDE MODULE
To wire feeder, choose the
Assembled right adapter at page 10
WIRE GUIDE MODULE & with End Caps
END CAP ASSEMBLIES
A-10HM

A-10XM

To drum or bigspool
Conduit Assembly for EC-3, EC-5

or in case of SAW to
FC-XH, FC-XH-LW & FC-X-SW

turntable
FC-X Conduit Assembly
EC-4 Conduit Assembly

WWDP

18
 Wire Guide Modules

Components and accessoires Standard = 0,6 to 2,4 mm

• Will soon be available for submerged arc welding Use Part no. (as mentioned)
• For SAW components Add “HD” to the part number SAW = 2,4 to 4,8 mm
Use Part no. +HD

45º WIRE GUIDE DRUM MOUNTING KIT MALE & FEMALE END
MODULE CONNECTORS

Part #
WGM-DK

Part #
WGM-1 Part #
WGM-ECK
-25, -38 & -50

45º MODULE HANGING 90º HANGING BRACKET KIT L-BRACKET KIT MOUNTING KIT
BRACKET KIT

Part # Part # Part #

WGM-1-BRKT WGM-1-90-BRKT WGM-LBM-BRKT

CELL WALL MOUNTING KIT, CELL WALL MOUNTING KIT, 360º UNION ADAPTER KIT FEEDER INLET MOUNTED KIT
SINGLE SIDE DOUBLE SIDED Allows dual 360º directional Mounts to feeder trhough
adjustment bracket or panel

Part # Sample
WGM-UAK installation
Includes Bracket on bracket

Part # Part # Part # Part #

WGM-WK-1-1 WGM-WK-2-1 WGM-UA WGM-IK
Adapter Kit Only Excludes
Bracket
FACE MOUNT BRACKET KIT SIDE MOUNT
Allows 360º directional adjustment BRACKET

ADJUSTABLE EXTENSION ARMS

Part # Part # WGM-EA-10
WGM-FM Extends 10” (254 mm) to 18” (457 mm)
Part # WGM-EA-20
Part #
Extends 20” (508 mm) to 36” (914 mm)
WGM-A-10BK
Both arms pivot upwards to allow easy wire feeding form drums & reels

SUPPORT BRACKET SLOTTED SUPPORT BRACKET 45º ANGLE SUPPORT BRACKET

Part #
Part # WGM-024
WGM-021
Part #
WGM-025

19
 Submerged Arc Welding 1

MECHANICAL TURNTABLES

WWTT-DP TURN TABLE DIRECT PULL KIT

WWTT-500 The WWTT-DP can be used for

applications, like connecting
the wire feed motor or as inlet
guide at a spool.

BRACKET FOR PFA SUPPORT

Bracket to mount a PFA-unit for as-
sists at a turntable.
WWTT-500 The PFA makes it possible to feed
Length : 76 cm SAW wire over large distances.
Widht : 66 cm
Weight : 64,5 kg Find your PFA-unit on the next
Max load: 500 kg page.The support units fits all out
turntables.

PFA Bracket for turntable

WTT-PB

1000 kg Stem-pack
for use at turntable-

WWTT-1000 WWTT-1000-SP
Length x Width : 100x100 cm Length x Width : 100x100 cm
Weight: 95 kg Weight: 95 kg
Max load: 1000 kg Max load: 1000 kg

20
 Submerged Arc Welding 2

PFA-UNIT STANDARD SET Product Part

number
PFA unit is supplied as a complete set to install the PFA unit for 2,0 mm wire (installation set included) PFA20
PFA-unit, including all the items in this drawing,
PFA unit for 2,4 mm wire (installation set included) PFA24
except for the drumhood.
PFA unit for 3,2 mm wire (installation set included) PFA32
PFA unit for 4,0 mm wire (installation set included) PFA40
A-1B-C-HD
Outlet adapter Other diameters at request

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
PFA
118 ml bottle PFA lubricant PFA-OIL
motor

U-groove Feed roll 2,0mm for PFA (per piece) WW053704

PFA-FRL
filer/regulator/lubricator U-groove Feed roll 2,4mm for PFA (per piece) WW053703
including hose U-groove Feed roll 3,2mm for PFA (per piece) WW053707
A-1CS U-groove Feed roll 4,0mm for PFA (per piece) WW05M532
PFA
dr

Other diameters at request

um
ho
od

V-Knurled Feed roll 2,0mm for PFA (per piece) WW132960

V-Knurled Feed roll 2,4mm for PFA (per piece) WW132961
Air tool lubricant PFA-DA-HD Drum V-knurled Feed roll 3,2mm for PFA (per piece) WW132963
included adapter kit Other diameters at request

CONDUITS FOR SUBMERGED ARC WELDING

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.

CONDUITS FOR MILD STEEL

Part Dimensions in mm Use for Connector Order Bulk
Number inside x outside wire quantity length
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

CONDUITS FOR STAINLESS STEEL & ALUMINIUM

Part Dimensions in mm Use for Connector Order Bulk
Number inside x outside wire quantity length
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.

21
 Wood reel dispensing equipment

WIRE WIZARD REEL DISPENSING

• Universal base plate design fits all manufacturers’ wood reels RW1028-C33
ADJUSTABLE WIRE ARM
• Twin locking cams secure base plate to wood reel for stability
GUIDE UNIT
• Braking system for smooth acceleration and Adjustable from
deceleration of feed arm 40 to 76 cm spools.
For large diameters
• Outer tube radius and lead ensure wire cast remains unchanged up from 1,6 mm
• Ceramic inlet guide provides long wear and prevents wire shaving with universal base plate and
adjustable braking system FC-X Liner for
• Externally adjustable nut and jam allow for precision braking Mild Steel
• Large coupler bearings resists both thrust and “G” loads Adjustable arm
• High density polyethylene liner for longer service life to fit different
reel diameters
Adjustable
C33 Base Plate Brake
Most universal base plate
for European market

RW1030-C33
ADJUSTABLE WIRE ARM RW1031-C33
GUIDE UNIT ADJUSTABLE WIRE ARM
Adjustable from GUIDE UNIT
40 to 76 cm spools Adjustable from
For aluminum and stainless wire EC-4
40 to 76 cm spools
up to 1,6mm Liner for FC-X Liner for Mild Steel
For mild steel wire up to 1,6mm
with universal base plate and Aluminum or
Stainless with universal base plate and
adjustable braking system adjustable braking system Adjustable arm to fit
Adjustable arm to fit different reel diameters
different reel diameters
Adjustable
Adjustable Brake
Brake

ADJUSTABLE STAND FOR PFA WWTT-DP TURN TABLE DIRECT PULL KIT

RWC1111-30
into POLYETHYLENE WOOD
PFA REEL COVER

onto
WRSC
guide STAGING CART
arm
PFA-AS-I
PFA-AS

22
 Non-Stop Wire Dispensing
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 NSW-2
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 Two Drum setup
drum is being installed
NSW-4
• 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 Four Drum setup
• Appropriate drum-handling carts available

220 Volt Wire Parters

hand-held leaves flat wire
Buttwelder ends for easy
butt-welding.
BW-WP

WW-BW

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

1 2 3 4

Join the end wire from drum 1 Smooth wire joint using a de- Position the wire on the path- When wire from drum 1 runs
with the start wire from drum 2 burring tool (Wire Dresser op- way between the two drums. out, the transfer arm will switch
using the Butt Welder. tional). over to drum 2. Simply replace
empty drum and repeat steps

NON STOP WIRE BY USING WIRE DIRECTION SENSOR

HOW IT WORKS To welding machine
or robot
• 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 Sensor with
at the new drum sensor block
see page 5
• Step 4 Feed the new wire through the conduit
for article A
A-14BK bracket kit
• Step 5 Weld the old wire end to the new wire end numbers or PFA-unit with wall
with the butt welder bracket in case of
• Step 6 Push the overlength into the drum and large conduit length
connect the conduit again at “A”
short conduit few
• Step 7 Start welding again
meters only

23
 Anti-Spatter & Accessoires

BLUE MAGIC ANTI-SPATTER & NOZZLE CLEANER

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

Blue Magic™ • Protects against spatter build-up and char residue
• Keeps clean-ups to a minimum
ITEM PART NO.
• Contains no silicone-easuly painted over
1 Liter Bottle EAS1000-C32
• Low pH level inhibits multi-metal corrosion
3,8 Liter Bottle EAS1000-C1 • Will not evaporate keeping lines and nozzles clog-free
19 Liter Jerrycan EAS1000-C5 • Containes biocide, providing longer shelf life in warm climates
200 Liter Jerrycan EAS1000-C

BLUE MAGIC™ CONCENTRATE EAS1000-EAD

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™ Concentrate

EAS1000-CC
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™ GEL FOR NOZZLE DIPPING

Blue 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.
Blue Magic™ Nozzle Dip Gel
ITEM PART NO. • Long lasting formula extends nozzle and contact tip life
500 ML (1/2 liter) EAS1000-G16 • Enviromentally safe, contains no silicone
• Odorless, non-toxic & non-flammable

24
 Anti-Spatter & Accessoires

5-GALLON MANIFOLD Model 5GMK

This popular industrial size also dispenses Blue Magic™ anti spatter to Torch Wizard™
pneumatic reamers and nozzle mist applicators. Easily integrated into any wld cell
stations.

• Smaller footprint is ideal where space is an issue

• Pneumatic pump supplies 7 Liter per minute ia 5 Bar
• Bulk dispensing system easily supplies up to 15 work stations

Specifications
Height : 68 cm Width : 28,5 cm
Depth : 36 cm Weight : 3,6 kg

HAND-HELD SPRAY UNIT Model TS-H

Designed fort spot-spray applications of Blue Magic™ or Blue Chill™
anti-spatter, this hand-held spray gun is ideal for coating ‘weld zone’ areas.
Can be used with our bulk dispensing kits.

ANTI-SPATTER MULTI-STATION DISPENSING OPTIONS

G.
A. B.
D.
C. F.

H.

5GMK

DMK G. EL-NCS-AC TS-E-24 Nozzle EAS1000-EAD TS-H

Reaming Station Spray Station Refillable Can Spray Unit
A.

Use the 5 Gallon (19 Liter) Manifold kit (5GMK) or the drum (200 Liter) Manifold kit (DMK) to easily set
up multiple anti-spatter dispensing stations. The pneumatic pump at the 5GMK and the DMK supplies 7
liters per minute at 75 PSI and easily supplies up to 15 work stations.

A. DMK (or 5GMK) Manifold Kit E. 1J-351-01 1/4” Spatter-Resistant Tubing

B. 1J-352-007-01 3/8” Spatter-Resistant Tubing F. 2U01008 1/4x1/4” NPT Push-in
C. 40021-04 1/4” Ball Valve G. 2U31013 1/4 NPT x 3/8” Elbow
D. 2U32013 1/4” NPT x 3/8” Branche tee H. EAS1000-FS Sprayer Refill Spigot

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.

Heavy duty Male and female

Protects and secures: zipper sleeve-end for
chainlink
• Wire conduit
Cable or
• Torch cables
conduit Nylon straps
• Cable assemblies
• Control cables with velcro
Nylon straps
• Cooling lines
with velcro Heavy duty
• Gas lines
• Hydraulic hoses zipper
Heavy duty
velcro closure

USE AND POSSIBILITIES

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 teh heavy duty zip-
per
Step 4 Chain-link the sleeves if
needed

Sleeve-ends are made male/female

with velcro and can be chainlinked Aluminized sleeve used as pro-
together to get the needed length. tection for torchcable assembly
against welding spatters

chainlinked
sleeves

Article Article
AVAILABLE SIZES AND MODELS Aluminized 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
Aluminized sleeve used as protection
against welding shaving
26
 Spool and Drum accesoires

NON-FLAMMABLE DRUM COVERS

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 danger-
ous situations.

With these non-flammable drum covers Wire Wizard offers

Shape Size Article
you an effective solution to eliminate this danger.
Round 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 mount

the FRL-unit directly to the PFA

STAND FOR PFA-MOUNTING

To create the possibility to easily change
drums or change between a spool and
drum Wire Wizard made the PFA-Stand.
With this stand the PFA can be located
freely above the drum. This makes that
the PFA does not need to be removed
when a new drum is installed. it also A simple solution to locate the regula-
give the possibility to switch from drums tor unit of the PFA. Designed for drums
to spools which can be interesting in standing at a track or in the middle of
case of welding a special alloy. the shopfloor.

PFA-SDS
Adjustable stand in use in use
to use with spool with drum
for spools and
drums

27
 Handling equipment 1

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

Specifications
Weight: 11,4 kg
Capacity: 453 kg
FDL DRUM LIFTER
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. FDL DRUM LIFTER WITH FDL-FA

FORK LIFT ADAPTER, MODEL FDL-FA FDL-HS

• Adjustable T-handle keeps adapter from sliding off fork

• Safety Style clasp secures adapter to drum lifter
• Weight: 3,5 kg Capacity: 500 kg FDL-FA

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 -Marking
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 FDL-21 FDL-24
• Weight: 8 kg Capacity: 500 kg

PALLET SKID DOLLY, MODEL WWSD

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.

Specifications
Deck Ht: 11,5 cm Height: 12,7 cm
Length: 70 cm Width: 70 cm
Capacity: 453 kg Weight: 17 kg
WWSD
PALLET (SKID) DOLLY

28
 Handling equipment 2

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
• Ø Model FDD-28 for 72 cm drums
FDD • 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: 453 kg Weight: 10,4 kg
FDSC
HEAVY DUTY DRUM STAGING CART, MODEL FDSC
Designed for one person to transport up to 453 kg 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 cm Capacity: 453 kg
Depth: 66 cm Width: 76 cm Weight: 19,5 kg

LOW COST OCTAGON DRUM DOLLY, MODEL FDD-OC

Product Features
• Designed to easily move octagon drums of 250 kg
• Low cost model of wood

Specifications
FDD-OC OCTAGON DRUM DOLLY Deck Ht: 11 cm Height: 14 cm Capacity: 250 kg
Low cost model made of wood Depth: 61 cm Width: 61 cm Weight: 5,0 kg

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
Specifications
FDD-OP OCTAGON DRUM DOLLY Deck Ht: 11 cm Height: 16,5 cm Capacity: 453 kg
for environmental packs Lenght: 61 cm Width: 61 cm Weight: 12,7kg

CONDUIT
BALANCER
RETRACTABLE CONDUIT BALANCERS & HANGERS
3 SIZES
AVAILABLE • Balancer provides easy method PART NO. DESCRIPTION
of hanging conduit & cables RCH-2 Conduit Balancer - 1–2 kg - 1.6 mtr
• Conduit Hanger prevents RCH-4 Conduit Balancer - 2–4 kg - 2.0 mtr
excess droopage RCH-8 Conduit Balancer - 6–8 kg - 2.0 mtr
CONDUIT HANGER • Prevents conduit and cables CHH-10 25 cm Conduit Hanger w/two Retaining Straps
3 SIZES AVAILABLE from hanging in areas where CHH-16 40 cm Conduit Hanger w/four Retaining Straps
they could get damaged CHH-22 56 cm Conduit Hanger w/four Retaining Straps

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 Support equipment 1 (Gas)
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*

Gas Saver for Inlet Side of Solenoid Gas Saver with BSPP Threads (Fronius® style)
Gas Gas
GFJ-2D Flow
JET
GFJ-F2 JET Flow
GFJ-3D GFJ-F3

GAS SAVERS - INCLUDE SCREENS & JETS 2 or 3

(JETS INDICATED NUMERICALLY IN PART NUMBER)
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 SAVER FLOW JETS

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 THE BALLOON TEST
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 Compare gas consumption after 5 seconds
Jet 2 for Mig and Tig welding /Jet 3 for heavy Mig welding of arc-on time
right side = Gas saver

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 EL-GFM
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
EL-GMP
PRECISION GAS FLOW SENSOR, MODEL EL-GMP Hose not in pro-
portion to gas flow
This hand-held digital sensor allows the operator to verify shielding gas flow rate sensor
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
EL-RVMU
• Switch capacity 250 V/1A/100 VA
GAS FLOW SWITCH
• 1/4 gas thread connection

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 Support equipment 2

WIRE PILOT, MODEL WP1000

• Designed only to feed wire from the source to the

feeder and remove it after that
• Engage/disengage wire in seconds
• Accommodates 0,6 to 3,2 mm wire diameters
• Changeable drive rolls
• An 800RPM or less, 10 mm
variable speed drill is recommended.
Specify wire diameters for all units when ordering
WP1000
(Drill not included)

open wite track

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 centime-
ters. 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 Wi-
zard 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
HHSS WIRE FEED SENSOR

WIRE DRAW GAUGE, MODEL WWPT

The electronic WWPT is designed to accurately measure the draw weight of all diam-
eters 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

31
 sales@wire-wizard.eu
www.wire-wizard.eu

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WW catalog 2012