Wire wizard Guide Module User manual

WIRE SOURCE
WIRE WIZARD
®
GUIDE MODULE INSTALLATION COMPONENTS
See our website for additional parts www.wire-wizard.com
RUN TO WELD CELL AND/OR ADDITIONAL MODULES
CELL WALL MOUNTING OPTIONS
WELD CELL MOUNTING OPTIONS & ACCESSORIES
WIRE FEEDER
End Cap A
WGM-ECK-25 1/4" NPT End Cap Kit Use only with A-4-ST Disconnect Recommended for most applications: WGM-ECK-50 1/2" NPT End Cap Kit Use w/ A-10HM, A-10XM, A-10RM or WGM-A-5
A-10HM
A-10XM
For EC-3R or FC-X-SW Conduit, use WGM-A5 Quick Disconnect Here
EC-4-R Conduit Assembly FC-X Conduit Assembly
A-10RMFC-XH or EC-5 Conduit
Wood Reel with Wire Guide Arm
Drum or Box
WWDP
Direct
Pull Kit
WGM-DK
Drum Mounting Kit
WGM-HSK
Drum Hood Swivel Kit
WGM-021
Support Bracket
WGM-024 Slotted
Support Bracket
WGM-025 45° Angle
Support Bracket
WGM-UAK 360° Union Adapter Kit
WGM-A-10BK Face Mount Bracket Kit Allows 360° adjustment on single side
WGM-WK-2-1 Cell Wall Mounting Kit, Double Sided
WGM-WK-1-1 Cell Wall Mounting Kit, Single Sided
WGM-A-10BK with WGM-A5 Assembled on Module
WGM-UAK Assembled (Modules attach on both sides)
WGM-WK-1-1 Assembled
WGM-WK-2-1 Assembled
90° GUIDE MODULE KIT WGM-90K inc. 1/2” End Caps Other kits available include WGM-135K (135° kit) and WGM-180K (180° kit)
Assembled 90° with End Caps
WGM-LBM-BRKT
L-Bracket Mounting Kit
WGM-1 (Single WGM)
WGM-LBM-BRKT
Assembly
HANGING BRACKETS
END CAP OPTIONS Each end cap kit contains one A and one B end cap
WGM-1-BRKT
45° Hanger Kit
WGM-1-90-BRKT
90° Hanger Kit
10" (254mm) to
18" (457mm)
Allows 360° adjustment on both sides
Pivots upward to allow easy wire feeding from drums & reels
20" (508mm) to
36" (914mm)
SETUP FOR MEZZANINE APPLICATION
CELL MOUNTING BRACKET OPTIONS FOR INTERIOR OR EXTERIOR OF CELL
1/4" NPT 1/2" NPT
Strain Relief Connector
(Recommended)
Inlet Guide
360°
Rotation
End Cap B
5750 Marathon Drive • Jackson, MI 49201 • [phone] • Fax [phone]
www.wire-wizard.com
End
Cap A
Tools Required: WGM-1 Kit Contents: End Cap Kit Contents:
(1) 45° module (1) “A” style end cap with threaded insert
(2) Intermediate fasteners (1) “B” style end cap with threaded insert
(1) Intermediate pilot pin (4) End cap fasteners
Assembly of 90°, 135° and 180° Guide Modules
Step 1: Connecting Modules (for 90°, 135° or 180° turn)
Insert intermediate pin in one end of module until it firmly
seats (Step 1-A). Connect the two modules using the interme-
diate 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 the proper
bend radius. If only a 45° turn is required (one module), or if
using a WGM-M-1 Mini 90°, simply connect the end caps.
Step 2: Connecting End Caps
Connect the appropriate end cap as shown. Insert and
tighten the end cap fasteners to lock in place. Repeat with
the other end cap. Insert pins for the end caps are only
required when using the A-10RM or A-10XM fittings (caps will
be included with fitting).
Step 3: Adding End Cap Fittings & Connecting Conduit
Pass Through Compression Fitting: Thread the pass-through
compression fitting into the appropriate end cap. Debur and
countersink the conduit out to the conduit edge (a counter-
sink tool for polymer conduit, part # EC-DB, is available from
ELCo Enterprises). If you are using EC-4-R polymer conduit,
you may push the conduit directly into the module, however
be sure to countersink the ends or wire may not feed proper-
ly. Push the conduit through the compression nut until the
conduit stops at the inlet inside the module. Pull the conduit
back approx. 0.25” inches (6 mm). Tighten compression nut.
Doing so will pull the conduit to the face of the end cap pin
without crushing it.
WGM-A5 Quick Disconnect Option: Thread quick disconnect
into the appropriate end cap and attach conduit.
Last Revised: 12/15/15
90° GUIDE
MODULE
ASSEMBLY
WIRE GUIDE MODULE & END CAP ASSEMBLIES
GUIDE MODULE ASSEMBLY INSTRUCTIONS
STEP 1-A STEP 1-B
Insert Fasteners
Insert Pin
Between
Modules
Pull conduit back 0.25” (6 mm)
prior to tightening
STEP 3: Compression Fitting STEP 3: Quick Disconnect
(pt. # WGM-A5)
Intermediate
Pin
(2) 8mm wrenches*
(1) Conduit Cutter* (pt. #EC-CUTTER)
(1) Countersink Tool* (pt. #EC-DB)
*All required tools also available in the Guide Module Assembly Tool Kit, part #WGM-ATK
WGM-044 Weld / Bolt-on Bracket
WGM-A5 Insulated
QD Adapter Kit
End
Cap B
WGM-A5
Quick
Disconnect
Compression Fittings
Always countersink
conduit ends to avoid
wire hang-ups.
Countersink tool
available, pt. #EC-DB
45° GUIDE
MODULE
ASSEMBLY
FITTING CONDUIT
A-10HM EC-4-R or FC-E
A-10XM FC-X
A-10RM FC-XH or EC-5
End
Cap A
End
Cap B
Part #
WGM-3-BRKT
Side Mount Bracket
Adjustable height from 50" –86" (1.3-2.2m) Adjustable arm length from 4" –19" (102-483mm)
Wire Wizard®
Fire Resistant
Drum Covers &
Dollies Available
Drum -or-
Wood Reel
Additional
arm, part #
WGM-PFA-
STAND-
ARM
Part #
WGM-PFA-STAND
Conduit to wire feeder
WWDP
Direct
Pull Kit
A-10HM EC-4-R Conduit >>
A-10XM FC-X Conduit >>
A-10RM FC-XH / EC-5 Conduit >>
Use disconnect for other conduit sizes
WGM-FLM
Floor
Mounting
Bracket
WGM-FSK-14 Wire Feeder Swivel Kit Creates 360° rotation point at the feeder disconnect
WGM-EA-10 & WGM-EA-20 Adjustable Extension Arms (also see pt. #WGM-CM-1)

®
ELCo Enterprises, Inc. • 5750 Marathon Drive • Jackson, MI USA 49201 • [phone] • Fax [phone] • Visit www.wire-wizard.com for additional product information
Single Box or Drum, Up & Over Cell to Robot
5 - Wire Guide Modules (two 90° turns & one 45° turn)
3 - End Cap Kits
1 - Adjustable Extension Arm
1 - Slotted Support Bracket
1 - 360° Union Adapter Kit
3 - A-10HM Fittings (connects EC-4-R Conduit to WGM)
1 - WWDP Direct Pull Kit on Drum Cover
EC-4-R Conduit & FC-X Conduit with Strain Reliefs
Conduit size and type will vary depending on application
Single Box or Drum, Cell Wall Installation
2 - Wire Guide Modules (one 90° turn) -or- 3 if installing
one 45° turn on the weld cell interior
1 - End Cap Kit -or- 2 if installing WGM on the interior
1 - Cell Wall Mounting Kit, Single-Sided -or-
Double-Sided kit if installing WGM on the interior
1 - A-10HM Fitting (connects EC-4-R Conduit to WGM)
1 - WWDP Direct Pull Kit on Drum Cover
EC-4-R Conduit & FC-X Conduit with Strain Reliefs
Conduit size and type will vary depending on application
Example with Two Boxes or Drums
16 - Wire Guide Modules (eight 90° turns)
8 - End Cap Kits
2 - 360° Union Adapter Kits
4 - Slotted Support Brackets
2 - 45° Angle Support Brackets
10 - A-10HM Fittings (connects EC-4-R Conduit to WGM)
2 - WWDP Direct Pull Kits on Drum Covers
EC-4-R Conduit & FC-X Conduit with Strain Reliefs
Conduit size and type will vary depending on application
Setup with Modules
on both sides
PATENT PENDING • MADE IN USA
FEEDING WIRE:
It is usually necessary to round over the wire or use a wire end cap upon initial feeding. This will prevent hang-ups
as well as prevent the wire from gouging the conduit. Wire end caps are required for cored wires. End caps are
available from ELCo Enterprises.
WARRANTY
ELCo Enterprises, Inc. guarantees each Guide Module free from defects for a period of 3 years from the date of purchase. This
warranty excludes damage caused by industrial contaminants, arc shorts, improper installation or improper maintenance.
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 3 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 making sure any intermediate pilot pins
are correctly installed between modules, as shown on page 1.
TROUBLESHOOTING
Disassembled Guide Module & Rollers
Note: WGM-1-S Modules will have steel rollers
Wire is stuck in module
PROBLEM POTENTIAL CAUSES SOLUTION
Intermediate pilot pin not installed
between modules
Conduit not properly countersunk
or deburred
Wire not rounded over
Disassemble joined modules and
verify pin has been installed
Remove conduit and countersink to
conduit edge
Round over the wire or use wire end
cap and try feeding again
Wire still pulls hard or will not
feed at all
The conduit may be crushed
causing drag inside the end cap
Conduit is not straight enough
Wire is tangled inside the drum
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
Untangle wire and consult wire
manufacturer
Note: Examples shown display drum/box packaging, the Wire Guide Module System may also be attached
to wood reels
or
™