Wire wizard GUIDE MODULE XL User manual

[phone] • Fax [phone] • Jackson, MI 49201 USA
www.wire-wizard.com
Last Revised: 6/22/17
End Cap
B
Tools Required: WGM-LW-1 Kit Contents:
(2) 8mm wrenches (1) 45° module
(1) Rotary tool with stone bit (2) Intermediate fasteners
(to round wire end prior to feeding) (1) Intermediate pilot pin
End Cap Kit (WGM-ECK-LW-50) Contents:
(1) “A” style end cap with threaded insert
(1) “B” style end cap with threaded insert
(4) End cap fasteners
(2) End cap pilot pins
Assembly of 90°, 135° and 180° Guide Modules
Step 1: Connecting Modules
Insert intermediate pin in one end of
module until it firmly seats (Step 1-A).
Connect the two modules using the
intermediate pin and ears to align
the modules together (Step 1-B). Use
the intermediate fasteners to
lock modules together. Continue
connecting modules until you have
created the proper bend radius.
Step 2: Connecting End Caps
Insert one end cap pilot pin into the
end of the joined module(s). This will
guide the wire into the module wire
track. Connect the appropriate end
cap over the end cap pin. The pin
will stick out approx. 1/4” (6.3mm).
Insert and tighten the end cap
fasteners to lock in place.
Repeat with the other end cap. This
is the wire exit point where wire will
be guided into the conduit.
Connect the appropriate end cap
over the pin and use end cap
fasteners to lock in place.
Step 3: End Cap Fitting Options
Pass Through Compression Fitting (recommended):Thread the pass-through compression
fitting (A-9) into the appropriate end cap, making sure to correctly follow the wire path
designated with the end cap pin. Deburr and countersink the conduit out to the conduit
edge. Push the conduit through the compression nut until the conduit bottoms out on the
end cap pin. Tighten compression nut. Doing so will pull the conduit to the face of the end
cap pin without crushing the conduit.
Quick Disconnect Option: Attach A-5HD quick disconnect into the appropriate end cap.
The pilot pin fits in the interior of the disconnect. Optional U-005 orange insulator sleeve
shown in photo not included.
90° GUIDE MODULE
45° GUIDE
MODULE
WIRE GUIDE MODULE &
END CAP ASSEMBLIES
LARGE GUIDE MODULE ASSEMBLY INSTRUCTIONS
STEP 1-A
STEP 1-B
Insert Fasteners
STEP 2
STEP 3: Compression Fitting
STEP 3: Quick Disconnect
END CAP A
Intermediate
Pin Pilot Pin
Always deburr/
countersink
conduit ends
with a stone bit
End
Cap A

[phone] • Fax [phone] • Jackson, MI 49201 USA
www.wire-wizard.com
FEEDING WIRE:
It is beneficial to round the wire end upon initial feeding. Use a stone bit with a rotary tool to deburr any sharp
edges from the wire end. This will prevent unnecessary hang-ups when feeding the wire to the feeder.
MAINTENANCE:
Wire Guide Modules should be cleaned periodically. Weld wire can deposit industrial contaminants such as dirt and dust as
well as drawing compounds from the wire package onto the Wire Guide Module track and rollers. Follow these steps to
clean the Guide Module:
Step 1: Take note of the wire path through the module. The module
should be re-installed in the position it was removed from. Using 8 mm
wrenches:
• Remove end cap fasteners
• Remove the intermediate fasteners if applicable
• Remove the 4 body fasteners
Step 2: The Guide Module will now pull apart (see disassembled unit at
right). Remove the rollers and clean the wire track and rollers with a dry
rag. You may blast the interior with compressed air to remove any
further dust and debris. Do not use solvents inside modules.
Step 3: Reassemble the module(s) making sure the intermediate and
end cap pilot pins are correctly installed, as shown on page 1.
TROUBLESHOOTING
Disassembled Guide Module & Rollers
Wire is stuck at module
PROBLEM POTENTIAL CAUSES SOLUTION
Intermediate or end cap pilot pin
incorrectly installed
Conduit not properly countersunk
or deburred
Wire end not rounded
Remove end cap or joined
module and check pin
Remove conduit and countersink
conduit ends
Round the wire end and try
feeding again
Wire still pulls hard The conduit may be crushed
causing drag inside the end cap
Conduit is not straight enough
Remove the conduit and check
the end to be sure the conduit was
not crushed upon installation
Straighten the conduit by removing
excess slack or supporting the
conduit with a balancer
ASSEMBLY & MAINTENANCE
WARRANTY
ELCo Enterprises, Inc. guarantees each Guide Module free from defects for a period of 2 years from the date of purchase. This
warranty excludes damage caused by industrial contaminants, arc shorts, improper installation or improper maintenance.