• Designing a Wire Delivery System

Designing a Wire Delivery System

Designing a Wire Delivery System – 8 Steps

The following steps are designed to help guide you through the basics of setting up and optimizing a wire delivery system.

Click here for a printable version (PDF) of this guide. Additionally, there are some examples of wire delivery configurations on our Wire Delivery Kits page. For further assistance, contact Customer Service or talk to your Wire Wizard® Technical Sales Expert.

  • What is the wire type?
  • What is the wire diameter?
    • These two questions will help determine the appropriate conduit and size
  • Will the welding be done robotically?
    • If so, is the main wire feed motor mounted on the robot arm or in a fixed (non-moving) position?
  • Is the welding a semi-automatic welding application?
    • If so, will the feeder be mobile such as on a swing boom, or on a power-source that is moved around the welding area?
  • Is this a fixed automation application?
    • If so, does the feeder move or is it stationary?
  • Where will the weld wire package be placed?
  • Is the package in a direct line with the main feed motor during the weld process, or will it be offset?
    • Every bend radius and plane change in a conduit run will add skid friction coefficient.
  • Are obstacles interfering that will cause tight radial bends or multiple bends and plane changes in the conduit unless avoided?
    • Power sources, controllers, overhead cranes, gas piping, parts supply totes, torch maintenance equipment, home position of a robot / weld system, can all influence the layout and parts needed in a wire delivery system.

Click here for a quick reference table for recommended conduit types and sizes for most welding applications.

DETERMINING FACTORS FOR CONDUIT SELECTION:

  • Wire Type and Composition
  • Wire Diameter
  • Application
  • Single conduit run or dual conduit run (static to dynamic)
  • Distance wire is traveling

WIRE TYPE & COMPOSITION

  • Solid Carbon MIG Wire — any conduit material of appropriate I.D. for wire size.
  • Cored Wires — any conduit material of appropriate I.D. for wire size.
    • Metal lined conduits generally allow greater longevity than a polymer conduit.
  • Aluminum — green polymer conduits or flexible steel conduits lined with a polymer liner.
  • Stainless Steel Wires — any conduit material of appropriate I.D. for wire size.
    • Green polymer conduits are optimal if ferrous contamination is of concern.
  • Silicon Bronze — green polymer conduits or flexible steel conduits lined with a polymer liner.

WIRE DIAMETER

  • .030″ (0.8 mm) diameter and smaller wires use the FC-X-SW or EC-3-R conduits.
  • .035″ – .052″ (0.9 mm – 1.3 mm) diameter wires use EC-4-R, FC-X, or FC-E conduits.
    • These three conduits are optimal for the majority of high-volume welding applications in the industry.
  • .062″ – 1/8″ (1.6 mm – 3.2 mm) diameter wires use EC-5 or FC-XH conduits.
  • 1/8″+ (3.2 mm+) diameter wires use EC-6 or FC-XH-LW.
    • These wire sizes are used in submerged arc (SAW) applications, see our SAW Wire Delivery Equipment section on our website for large wire delivery products

APPLICATION

  • Static Application — use of the EC line of green polymer conduits is optimal.
  • Dynamic Application — use of the Flexible line of Wire Wizard conduit is recommended.
    • EC-3-R and EC-4-R conduits are suitable for flexible applications as well.
  • Hybrid Application — use of both the EC line of green polymer conduit and Wire Wizard Flexible Conduits.

Ready to choose your conduit?

  • All male bayonets fit all female quick disconnects.
    • Male bayonet conduit connectors are tapered for ease of feeding and to reduce wear points.
    • Available compression connectors with attached strain relief support the weight of conduits to prevent added weight on connection point and potential re-casting of wires.

POLYMER CONDUIT CONNECTORS

  • Self-threaded connectors easily connect for a snug fit on static applications. They also can be removed and re-used on a new piece of conduit.
  • Compression connectors offer a tight and locked connection. Bayonet and nut can be re-used with a new replacement ferrule. Used in dynamic conduit applications.

FC-X CONNECTORS

  • Compression connectors offer a tight and locked connection. Bayonet and nut can be re-used with a new replacement ferrule. Used in dynamic conduit applications.
  • Hydraulically swaged connectors are a permanent connection and only available in pre-cut lengths that have been assembled at Wire Wizard.

FC-E CONNECTORS

  • Compression connectors offer a tight and locked connection. Bayonet and nut can be re-used with a new replacement ferrule. Used in dynamic conduit applications.
    • Reinforcement tube required in conduit I.D. when using a compression connector.
  • Hydraulically swaged connectors are a permanent connection and only available in pre-cut lengths that have been assembled at Wire Wizard.

  • Who is the wire feeder manufacturer?
  • Is the feeder inlet a slip fit-thru hole with set screw or is it a threaded connection?
    • If a threaded connection, is it a male or female threaded connection?
    • If threaded, knowing the thread count is also very useful information.

Click here to see our selection of wire feeder inlet guides.