Wire wizard TORCH WIZARD User manual

INSTALLATION
& OPERATION
MANUAL
Installation,
Maintenance
and Warranty
Information
SHIP DATE SERIAL #
Model
EL-NCS-20
wire-wizard.com
ELCo Enterprises, Inc. • Jackson, Michigan USA
517.782.8040 • [e-mail]

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Product Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Mounting the Torch Wizard® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Pneumatic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Adjusting the V-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Reamer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Sequence of Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.0 ADD-ON WIRE CUTTER INSTALLATION (IF APPLICABLE). . . . . . . . . . . . . . . . . . . . . . . . . 8
4.0 MAINTENANCE OF CLEANING STATION & WIRE CUTTER . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.0 ELECTRICAL SCHEMATIC (9-PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.0 EXPLODED VIEWS & PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Exploded View 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Exploded View 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.3 Exploded View 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.0 OPTIONAL COMPONENTS & ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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1.0 INTRODUCTION
This guide is designed to assist the user whose primary responsibility is to maintain and operate the Torch Wizard® Nozzle
Cleaning Station. This manual provides specific information on installation, safety, basic operation, and maintenance.
Please read, understand and follow all safety procedures.
Torch Wizard® Nozzle Cleaning Stations oer fast and eicient cleaning cycle times for high production rates.
The complete sequence of the Torch Wizard® Nozzle Cleaning Station must be started and controlled by a robot controller,
programmable logic controller (PLC), or some other superior control system. See sequence of operations on page 7 for details.
This model of nozzle cleaning station is designed for dry reaming applications and does not utilize anti-spatter spray.
1.1 WARRANTY
ONE YEAR LIMITED WARRANTY TERMS AND CONDITIONS: ELCo Enterprises, Inc. shall warrant the Torch Wizard® Nozzle
Cleaning Station to be free of defects in material and/or workmanship for one (1) year from the date of shipment to the
Buyer. The warranty shall cover 100% of all parts and labor with the exception of misuse, abuse, neglect and typical
consumables as determined by ELCo. This limited warranty excludes all sprayer components, which are warranted to
be free from defects and/or workmanship for 90 days from the date of shipment to the buyer. Failure to follow proper
installation and maintenance procedures specified in this operation manual will void this warranty. This includes
the use of a Filter/Regulator/Lubricator (FRL) without auto-drain functionality. ELCo will, at its option, repair, replace
or issue a credit for the value of the defective Torch Wizard®.
Buyer accepts all responsibility for compliance with any/all Local, State and Federal Laws or Regulations including
Regulations of Foreign Governments.
No equipment shall be returned to ELCo without a Return Authorization Number from ELCo. Upon evaluation and
determination of warranty, replacements or repairs will be sent to the Buyer. If a replacement is needed immediately, a
purchase order is required to cover the cost of the product until the warranty is determined.
ELCo’s warranty is limited to replacing any goods that are proved to be defective and ELCo in no event shall have any
liability for paying incidental or consequential damages including and without limitation, damages resulting in personal or
bodily injury or death, or damages to, or loss of use of any property. Notwithstanding any of these terms and conditions,
the warranties set forth shall apply in connection with any sales of goods, services or design by ELCo and are in lieu of all
other warranties, express or implied, including warranties of merchantability and fitness for a particular purpose.

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
1.2 PRODUCT REGISTRATION
Please register this product online or by phone within 14 days aer receipt.
Register this product online by going to wire-wizard.com/register or scanning the QR code on the
right, or you may call 517.782.8040 to register by phone. Registering this product will allow us to
provide firmware and soware updates via email, as well as expedited service should there be any
problems potentially covered by this warranty in the future.
Please record the following information for this product and retain for your records:
Model #: Lot #: Shipment Date:
1.3 MODEL INFORMATION
1.4 SAFETY
The Torch Wizard® Nozzle Cleaning Station is designed to be safe to operate, provided the user reads, understands and
adheres to the safety precautions listed below. Failure to adhere to these precautions may result in personal injury and/or
damage to the equipment.
1. Do not remove or deface any labels that are attached to the unit.
2. Ensure that all equipment in the area is disabled and locked out prior to entering the work zone where the
Torch Wizard® is located.
3. Ensure that all electrical and air power is disconnected prior to performing any maintenance on the Torch Wizard®.
4. Keep hands and face away from clamp, reamer and spray operating space during both automatic and manual operation.
5. Ensure that all electrical and pneumatic connections comply with the codes relevant to the country and/or state where
the Torch Wizard® is installed.
6. Do not exceed the specified operating air pressure.
7. Ensure that there is no equipment (e.g., robot) in the Torch Wizard® prior to shutting down the system.
8. Additional safety information can be found at the following websites:
 osha-slc.gov/SLTC/robotics/index.html
 ansi.org
 nfpa.org
Model
EL-NCS-20
 Base Unit
 No anti-spatter spray components
(dry ream only)
Model
EL-NCS-20-SC
 Base Unit
 No anti-spatter spray components
(dry ream only)
 Self-cleaning air blast
Model
EL-NCS-C-20
 Base Unit
 No anti-spatter spray
components (dry ream only)
 Wire Cutter

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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2.1 MOUNTING THE TORCH WIZARD
®
Select a location within the robotic workcell that
provides the robot with the shortest approach points.
It is important to consider the robot work envelope
and any fixed obstructions or potential interference.
 Mount the Torch Wizard® to a stable platform
that is parallel to the floor for best results
(an optional stand is available). Use the
(4) 11/32 mounting holes provided on
base of the Torch Wizard® to secure the
unit to the platform.
 It is recommended that (4) M8 – 1.25 SHCS
(Socket Head Cap Screws) are used to
mount the Torch Wizard® to the platform
(the optional stand provides M8 – 1.25
tapped holes for mounting).
2.0 INSTALLATION
Optional Wire Cutter
Location
Motor
Slide-Up
Cover Latch
Internal
Access Panel
Reamer
Blade
Mounting Location
for optional
Tool Center Point
Motor
Lubricated and
Filtered Air In
Electrical Connection
(9 pin)
Catch Tray
Figure 1: Torch Wizard Components (EL-NCS-20 shown)
Bolt Pattern (same for all models)
Figure 2

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
2.2 PNEUMATIC CONNECTION
We recommend “Push-to Lock” style fittings on the Torch Wizard® for supplying air to
the unit. Use an air line with a 5/16" outside diameter to supply air to the Torch Wizard®.
There is just one location that supplies air to the unit (refer to Fig. 3).
Air Supply Requirements
Air must be filtered and regulated with a Filter/Regulator/Lubricator with auto-drain
functionality and lubricated.
 Use an Air Supply Line with an inside diameter of 3/8", connect to the 1/4" N.P.T.
female inlet located on the side of the Reamer.
 Minimum 80 psi recommended at 16 CFM (5.0 – 7.0 BAR at 450 LPM) at the
Reamer during operation.
 Lubricator Adjustment: Set the lubricator to deliver one drop of pneumatic oil
for every two minutes of operation. Do not over-lubricate.
2.3 ELECTRICAL CONNECTION
The complete sequence of the Torch Wizard® Nozzle Cleaning Station must be started and controlled by a robot controller,
programmable logic controller (PLC), or other superior control system.
Electrical Draw: 0.5 Amps
See Electrical Schematic on page 12 for detailed wiring information
Figure 3
Use of unfiltered, dirty air may result in damage to the unit and will void the warranty.

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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2.4 ADJUSTING THE V-BLOCK
The Torch Wizard® Nozzle Cleaning Station incorporates an adjustable V-Block feature. This feature eliminates the need to
replace the V-Block when changing to dierent diameter gas nozzles. To adjust the V-Block, follow the procedure below (along
with Figs. 4 and 5). Ensure that there is no air pressure or electrical power to the unit before performing this procedure.
1. Open the Stainless Steel Guard (2) by unlocking the latch.
2. Install the reamer blade (7). Use the slim profile wrench provided to hold the
motor in place when securing the reamer blade.
3. Loosen Set Screw (3).
4. Loosen the Low Head Socket Head Cap Screw in the clamp (4).
5. Adjust the V-Block (6) using the Adjuster Screw (5) so that when the air motor
is at its upper point, the reamer is centered in the gas nozzle. To check this,
hold a gas nozzle in V-Block and raise the air motor slide by hand.
6. Tighten Low Head Socket Head Cap Screw (4).
7. Tighten Set Screw (3).
8. Replace the Stainless Steel Guard and Catch Tray (2) and tighten screws, or leave open if performing the initial setup
and proceed to reamer adjustment.
Figure 5
2
1
6
5
3
4
Figure 4
7
The graphic above represents the approximate location
of the V-Block when set up for a gas nozzle with a 1 inch
outside diameter.

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
2.5 REAMER ADJUSTMENT
In order to ensure adequate cleaning of the gas nozzle, it is
essential that the correct reamer insertion depth is obtained.
The reamer insertion depth will vary based upon the nozzle, tip
and diuser on the torch. In general, the reamer can be inserted up
until it is approximately 1/16" to 1/8" away from making contact
with the diuser (see example in Fig. 6b). Removing the nozzle
from the torch to ensure the proper depth and clearance from the
diuser is recommended. It is imperative that the reamer not
make contact with the gas diuser as this will cause damage to
both the reamer and the gas diuser. The Torch Wizard® is not
designed to clean the contact tip or gas diuser.
To adjust the reamer depth, use the following procedure and refer
to Fig. 6a: (Ensure that there is no air pressure or electrical
power to the unit before performing this procedure).
1. Remove the Stainless Steel Guard (refer to Fig. 4 and the
procedure for adjusting the V-Block on page 5).
2. With one hand, hold a gas nozzle in the V-Block at the position
that will be used when programming the robot. With the other
hand, raise the reamer and check the insertion depth of the
reamer bit (1).
3. If the insertion depth is incorrect, loosen the Socket Head Cap
Screws (2). Move the Air Motor (3) up or down to obtain the
correct insertion depth. If the motor will not move, screw in the
Jack Screws (4) to loosen the motor clamp.
4. Back out the Jack Screws (4) if necessary, and tighten the
Socket Head Cap Screws (2). Repeat steps 1 – 3 until the correct
insertion depth is obtained.
Note: The air motor on this reaming station has a max torque of
7.3 /lbs @ 90 psi at the motor.
Positioning Robot
The robot must be positioned such that the O.D. of the nozzle rests evenly against the V-Block. Failure to program the
robot so that the nozzle rests against the V-Block could result damage to the robot due to reactionary forces transmitted
to the robot axes when the nozzle is clamped with the air cylinder.
See page 12 for the electrical schematic for your Torch Wizard® model.
WARNING: Ensure that the adjustable V-Block and the air motor have been correctly set prior to positioning the robot
and running the Torch Wizard® in the automatic mode. Refer to sections 2.4 Adjusting V-Block and 2.5 Reamer Adjustment.
Failure to adjust these two items properly will result in damage to Torch Wizard® and possibly the robot.
1
2
34
Figure 6a
Blade depth should be set
to ream just below the gas
holes in the diuser
Figure 6b
Example of typical reamer
insertion depth. End of blade should
be set just below the gas holes on
the diuser. This location will vary
based on the torch design.
Figure 6b

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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2.6 SEQUENCE OF OPERATIONS
Model EL-NCS-20 (no Wire Cutter) Sequence of Operations
1. Verify Signal at Pin #3 is On (Home)
2. Move torch to Cleaner Position
3. Energize Pin #4 - Motor and Clamp On
4. Verify Signal at Pin #3 is O - Clamped
5. Short Delay
6. Energize Pin #5 - Vertical Slide Up
7. Short Dwell for Torch Clean
8. De-energize Pin #5 - Vertical Slide Down
9. Short Delay
10. De-energize Pin #4 - Unclamp and Motor O
11. Verify Signal at Pin #3 is On (Home)
12. Cycle Complete
Model EL-NCS-C-20 with Wire Cutter Option Sequence of Operations
1. Verify Signal at Pin #3 is On (Home)
2. Energize Pin #8 - Wire Cutter Advance
3. Short Dwell
4. De-Energize Pin #8 - Wire Cutter Retract
5. Move Torch to Cleaner Position
6. Energize Pin #4 - Motor and Clamp On
7. Verify Signal at Pin #3 is O - Clamped
8. Short Delay
9. Energize Pin #5 - Vertical Slide Up
10. Short Dwell for Torch Clean
11. De-energize Pin #5 - Vertical Slide Down
12. Short Delay
13. De-energize Pin #4 - Unclamp and Motor O
14. Verify Signal at Pin #3 is On (Home)
15. Cycle Complete
1. (ORANGE) - +24 VDC
2. (BLUE) -  VDC
3. (RED/BLK) - NOZZLE
UNCLAMPED/SLIDE DOWN
4. (GRN/BLK) - AIR MOTOR/CLAMP,
ACTIVATION OF PIN #9
5. (WHITE) - SLIDE UP
. (RED) - NOT USED
. (GRN/YEL) - GROUND
. (WHT/BLK) - WIRE CUTTER ADVANCE
. (BLACK) - NOT USED
Complete electrical
drawing is on page 12.

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
3.0 ADD-ON WIRE CUTTER INSTALLATION (IF APPLICABLE)
Tools required
 Needle-nose Pliers  4 mm Allen Wrench  5 mm Allen Wrench  Small Tube Cutters
Instructions
1. Install the two mulers
and push-to-lock fitting
into the valve assembly
as shown.
2. Cut approx. 2" of tubing
and insert into the push-
to-lock fitting on the
valve assembly.
3. Open the back cover
of the cleaning station
and remove the air
outlet plug in the
circled location.
4. Install the tubing from
the valve assembly into
the push-to-lock fitting
where the plug was just
removed. The assembly
should have the
solenoid plug location
on the right side.
5. Insert the wire cutter
solenoid plug (labeled
“wire cutter sol.”) into
the right side of the
valve assembly.
6. Detach the steel guard by
removing the two screws
(Fig. A). Insert the shorter
guard for the wire cutter
in its place, with the two
mounting hole locations
lined up (Fig. B). Close
and latch the cleaning
station cover down to secure
the new guard in place while
installing the wire cutter.
7. Remove the two screws
to slide o the wire
cutter steel cover in
order to access the two
mounting bolts.
8. Remove the two
black plugs for the
pneumatic tubing.
9. Push in the two air line
reducers (8 mm to 6 mm)
into the push-to-lock
fittings on the wire cutter.
Figure A Figure B

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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Figure F
Figure H
Figure E
Figure G
Figure DFigure C
10.Cut two pieces of approx. 10" tubing. Insert the first piece of tubing into the front hole on
cleaning station (Fig. 10a) and install into the push-to-lock fitting on the le side of the
valve assembly (port B) (Fig. 10b).
11. Insert the second piece of tubing into the back hole on cleaning station (Fig. 11a) and install
into the push-to-lock fitting on the right side of the valve assembly (port A) (Fig. 11b).
12. Install the wire cutter by securing the two mounting bolts with a 5 mm Allen wrench.
13.Using a pair of needle-nose pliers, firmly push in the two air lines into the push-to-lock
fittings on the wire cutter (Figs. 13a and 13b).
14.Re-install the steel cover on the wire cutter using the two screws to secure cover back in
place (Fig. 14).
15.Test wire cutter functionality per the instructions in the Torch Wizard® Cleaning Station
operation manual.

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
4.0 MAINTENANCE OF CLEANING STATION & WIRE CUTTER
The Torch Wizard® is for the most part, a low maintenance peripheral. However, maintenance of this unit should still be
added to your preventive maintenance schedule. The following should be checked at regular intervals:
 Visually inspect unit for damage, especially
mechanically stressed components
 Clean the filter
 Check that the air lines are free of leaks
 Ensure the lubricator has lubricant and fill if necessary
 Check blade for chips or cracks, replace if necessary
 Check for lose parts
 Ensure the proper depth of blade in the nozzle
 Ensure the blade is not making contact with the diuser
 Ensure all covers are in place before operating
Wire Cutter Maintenance (if applicable)
The wire cutter blade and back plate should be checked occasionally for wear. Replace blade (pt. #NCS-WCS-08) if worn.
If the back plate is worn, it may be removed and flipped around to the other end. To disassemble and install a new blade,
remove the two screws on the top of the cutter with a 4 mm wrench. Remove the slide piece that rests on top of the blade
and then remove the screw holding the blade with a 2.5 mm wrench. Install the new blade with the angled side facing up
as shown in Fig. 9. Reassemble unit.
The wire back plate may be flipped by removing the screw on the bottom of the cutter with a 5 mm wrench. Replacement
blades and other wire cutter components are available from ELCo Enterprises.
The wire cutter should also be greased approximately once every 10,000 cycles with multi-purpose grease.
4mm M6
screws
Grease Zirc
5 mm M6
screw
Wire Back
Plate
Cutting
Blade
Figure 8: Wire Cutter, Exterior View Figure 9: Wire Cutter, Interior View
Wire Location
Spring
Clamping
Block
Wire Cutter Replacement Parts:
Cutting Blade Pt. #NCS-WCS-19
Wire Back Plate Pt. #NCS-WCS-16
Clamping Block Pt. #NCS-WCS-07
Replacement Spring Pt. #C0240-045-1000-S

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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Description Recommended Quantity
Empty Catch Pan As needed*
Grease Wire Cutter Every 10,000 Cycles
Ensure Lubricator has Pneumatic Lubricant Daily*
Inspect and Clean Air Filter if Necessary Daily*
Inspect Reamer Blade for Wear Weekly
Inspect and Test Reaming Station for Proper Functionality Weekly
Check Wire Cutter Functionality and Inspect Blade for Wear Weekly
Check Positioning of Torch Nozzle & Reamer Blade Weekly
Inspect Cleaning Station for Excess Debris, Wipe Down if Needed Weekly
Clean Anti-spatter Lines Monthly
* It is recommended to document the frequency of these tasks as it will vary based on your welding application.
Part No. Description Recommended Quantity
Varies Replacement Reamer Blade 1 per 10 cleaning stations
VX212CAB Solenoid Valve for Anti-spatter Spray 1 per 25 cleaning stations
D-Z73 Air Actuator Sensor 1 per 50 cleaning stations
D-A93V Clamp Cylinder Sensor 1 per 50 cleaning stations
NCS-16-MOTOR Pneumatic Motor 1 per 100 cleaning stations
CDQ2B40-40DZ Clamp Cylinder 1 per 100 cleaning stations
MGQM25-50 Guided Air Actuator (Motor slide up/down) 1 per 100 cleaning stations
NCS-GPBL Green Push Button Latch On 1 per 50 cleaning stations
ULV4F2BSS335 Lighted Push Button 1 per 50 cleaning stations
Part No. Description Recommended Quantity
NCS-WCS-19 Replacement Blade for Wire Cutter 1 per 25 cleaning stations
C0240-045-1000S Replacement Spring 1 per 50 cleaning stations
CDQ2B63-10D2 Wire Cutter Cylinder 1 per 100 cleaning stations
For Model EL-NCS-20
For Model EL-NCS-C-20 Only (unit with wire cutter)
4.1 MAINTENANCE SCHEDULE
4.2 RECOMMENDED SPARE PARTS

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
5.0 ELECTRICAL SCHEMATIC (9-PIN)
SEQUENCE OF OPERATIONS*
Model EL-NCS-20 (without wire cutter)
1. Verify signal at pin #3 is On (Home)
2. Move torch to Cleaner Position
3. Energize pin #4 - Motor and Clamp On
4. Verify signal at in #3 is O - Clamped
5. Short Delay
6. Energize pin #5 - Vert Slide Up
7. Short dwell for torch clean
8. De-energize pin #5 - Vert Slide Down
9. Short Delay
10. De-energize pin #4 - Unclamp and Motor O
11. Verify signal at pin #3 is On (Home)
12. Cycle Complete
SEQUENCE OF OPERATIONS*
Model EL-NCS-C-20 (with wire cutter)
1. Verify signal at pin #3 is On (Home)
2. Energize pin #8 - Wire Cutter Advance
3. Short Dwell
4. De-energize pin #8 - Wire Cutter Retract
5. Move torch to Cleaner Position
6. Energize pin #4 - Motor and Clamp On
7. Verify signal at in #3 is O - Clamped
8. Short Delay
9. Energize pin #5 - Vert Slide Up
10. Short dwell for torch clean
11. De-energize pin #5 - Vert Slide Down
12. Short Delay
13. De-energize pin #4 - Unclamp and Motor O
14. Verify signal at pin #3 is On (Home)
15. Cycle Complete
1. (ORANGE) - +24 VDC
2. (BLUE) -  VDC
3. (RED/BLK) - NOZZLE
UNCLAMPED/SLIDE DOWN
4. (GRN/BLK) - AIR MOTOR/CLAMP,
ACTIVATION OF PIN #9
5. (WHITE) - SLIDE UP
. (RED) - NOT USED
. (GRN/YEL) - GROUND
. (WHT/BLK) - WIRE CUTTER ADVANCE (IF APPLICABLE)
. (BLACK) - NOT USED
NOT USED
WIRE CUTTER (OPT.)
NOT USED

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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CONFIDENTIAL AND PROPRIETARY
CONFIDENTIAL AND PROPRIETARY
UNCONTROLLED DOCUMENT
UNCONTROLLED DOCUMENT
6.1 EXPLODED VIEW 1
6.0 EXPLODED VIEWS & PARTS LIST

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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6.3 EXPLODED VIEW 3

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
6.4 PARTS LIST
Please reference model and serial number when ordering replacement parts.
Item No.
Part No.
Description
Qty
1 5193A2 PLASTIC HANDLE 1
2 5448T21 16MM ID ALLOY 932 FLANGE BUSHING 1
31734A12 Front Door Latch 1
4 10335A75 Lock 2
5 41451 3/8 ALUMINUM BACK UP WASHER 2
6 41406 M8-1.25 X 25 FHCS ZINC 2
7 41317 M6-1.0 X 10MM BHCS ZINC 9
8 41301 M4-.7 X 10 BHCS ZINC 13
9 40147 M4-07 NYLOC NUT ZINC 7
10 90597 M8-1.25 X 12 LSHCS BLACK OXIDE 2
11 41299 M4-.7 X 6MM BHCS ZINC 2
12 41307 M6-1.0 X 14MM SHCS ZINC 3
13 39856 M8-1.25 X 16 FPSS BLACK OXIDE 1
14 35879 M4-0.7 X 10 ZINC SHCS 2
15 41363 M4-.7 X 10MM FHCS ZINC 2
16 35915 M6-1.0 X 14MM SHCS ZINC 2
17 35891 M4-0.7 X 60 ZINC SHCS 4
18 41389 M6-1.0 X 14 FHCS ZINC 14
19 41391 M6-1.0 X 18 FHCS ZINC 4
20 35918 M6-1.0 X 20 SHCS ZINC 6
21 35921 M5-.8 X 14 SHCS ZINC 4
22 40059 M6 X 20MM DOWEL 12
23 35934 M8-1.25 X 20 SHCS ZINC 2
24 41705 M5-.8 X 90 SHCS ZINC 4
25 24766 M5 HIGH COLLAR LOCK WASHER 8
26 40353 M4 ZINC FLAT WASHER 7
27 41293 M3-.5 X 6 BHCS ZINC 2
28 H5161-L27WHP MOVING PARTS WARNING TAG 1
29 NCS-TAG-3 TAG 1
30 USA STICKER TAG 1
31 EL-NCS-A-20-SERIAL TAG MODEL/SERIAL TAG 1
32 NCS-NOZZLE-DEPTH-WARN NOZZLE DEPTH WARNING LABEL 1
33 NCS-TAG-8 TAG 1
34 NCS-TORCH WIZARD-LABEL TORCH WIZARD EMBOSSED LABEL 1
35 NCS-24 V-BLOCK 2
36 NCS-25 BASE PLATE 1
37 NCS-29 TOP PLATE 1
38 NCS-31 ADAPTER PLATE 1
39 NCS-32 SUPPORT NEST 1
40 NCS-34 SADDLE PLATE 1
41 NCS-86 STAINLESS FRONT COVER 1
42 NCS-36 STAINLESS REAR COVER 1
43 NCS-37 CATCH PAN 1
44 NCS-38 RISER BLOCK 2
45 NCS-39 THREADED ROD 1
46 NCS-40 EXTENSION FITTING 1
47 NCS-41 COVER 1
Item No.
Part No.
Description
Qty
48 NCS-42 COVER 1
49 NCS-83-AVBC-18B FACE PLATE 1
50 NCS-27 SIDE PLATE (LH) 1
51 NCS-28 SIDE PLATE (RH) 1
52 NCS-46 REAR COVER HINGE 1
53 NCS-47 FRONT COVER HINGE 1
54 NCS-45 CLAMP CYLINDER SPACER 1
55 NCS-81 CATCH TRAY LOCATOR 2
56 NCS-98 MOTOR MOUNT 1
57 NCS-97 MOTOR MOUNT 1
58 NCS-102 SIDE COVER 1
59 NCS-87 ANTI-SPATTER SHIELD 1
60 NCS-115 EXTENSION FITTING 2
61 NCS-118 COVER 1
62 9688K124 PLASTIC PLUG 5
63 EC-18 CAPLUG 1
64 CPT-6 AIR INLET PLUG 1
65 9688K127 ROUND PLUG 1
66 9688K221 PLASTIC PLUG 2
67 W0970530053U 1-4 NPT SFE MUFFLER 2
68 109AL-04 1/4 NPT BRASS PLUG 2
69 MGQM25-50 GUIDED AIR ACTUATOR SLIDE 1
70 HHB-107459 MANIFOLD & VALVES SUB ASSY 1
71 NCS-16-MOTOR AIR MOTOR 1
72 KQB2L06-01S 1/4 NPT MALE ELBOW 1
73 74965K65 2.00" PIECE OF SHRINK TUBE 2
74 TRB0604B-100 6MM FLAME RESISTANT BLACK TUBING 1
75 IN-289-2006 WELD SPATTER COVER 2
76 KQ2T08-00 8MM UNION TEE FITTING 1
77 CDQ2B40-40DZ SMC 40MM BORE X 40MM STROKE 1
78 KQ2E06-00A FITTING, BULKHEAD 1
79 AS2201F-01-08ST FLOW CONTROL 2
80 KQ2R06-08 6MM TUBE X 8MM REDUCER 1
81 KQ2L08-01S 90 DEGREE FITTING 2
82 11751 DIN RAIL 1
83 0382860000 TERMINAL END BRACKET 2
84 14RB10 WIRE END W/#10 HOLE-16 GA. WIRE 1
85 1753280000 TERMINAL BLOCK 12
86 1754190000 END PLATE 1
87 1754290000-2 JUMPER 2
88 1754290000 JUMPER 1
89 32191 INSULATED TERMINAL FEMALE 4
90 ULV4F2BSS335 PUSH BUTTON 1
91 ROCCA-09-B-16C 9-PIN RECEPTACLE 1
92 D-Z73 SWITCH 1
93 D-A93V SWITCH 1
94 PFA-27 SPACER 2
Item Name
Part No.
Cutting Blade NCS-WCS-19
Wire Back Plate NCS-WCS-16
Wire Cutter Replacement Parts
Item Name
Part No.
Clamping Block NCS-WCS-07
Replacement Spring C0240-045-1000-S
NOTE: Wire cutter not included on
EL-NCS-20 model

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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Evacuation
Chute
EL-NCS-EC
Replaces catch pan
Double Flute
Reamer Blades
Single Flute
Reamer Blades
TITANIUM NITRIDE
TiN Coated for
Maximum Durability
Stand for Tool
Center Point
EL-NCS-TCP-F-S
Excludes touch
plate and point
Tool Center
Point
Adapter Mount
EL-NCS-TCP-F-R
Excludes touch
plate and point
Testing and
Diagnostic Box
EL-NCS-TB
29.5" (749 mm)
Stand for
Torch Wizard®
EL-NCS-STAND
Order EL-NCSP-STAND
for AP Model unit and
wire cutter
7.0 OPTIONAL COMPONENTS & ACCESSORIES
Nozzle Brush
EL-NCS-BRUSH
For aluminum
welding
applications
Mandrel for
Nozzle Brush
EL-NCS-BRUSH-M
20 . (7.6 m) power/control cable included. The
reamer bit required is based on the I.D. of the gas
nozzle being used.
BLUE MAGIC® ANTI-SPATTER
Part No. Description
EAS1000-C32 32 oz Spray Bottle
EAS1000-C1 1 gal Bottle
EAS1000-C5 5 gal Container
EAS1000-C 55 gal Drum
EAS1000-CT 275 gal Bulk Tote
EAS1000-C-CON-1L 1 l (33 oz) Concentrate
EAS1000-C-CON-5 5 gal Concentrate
EAS1000-C-CON 55 gal Concentrate
EAS1000-DP Manual Drum Pump (55 gal)
EAS1000-DW Drum Wrench (55 gal)
BLUE CHILL® ANTI-SPATTER
Part No. Description
EAS1000-BC32 32 oz Spray Bottle
EAS1000-BC1 1 gal Bottle
EAS1000-BC5 5 gal Container
EAS1000-BC 55 gal Drum
EAS1000-BCT 275 gal Bulk Tote
TORCH WIZARD® OPTIONAL ACCESSORIES
Part No.
Description
EL-NCS-STAND 29.5" (749 mm) Stand (custom heights available) for EL-NCS models
EL-NCS-FRL-14 Filter/Regulator/Lubricator
EL-NCS-TB-ADR-16 Testing and Diagnostic Box for 20 and 20-SC models (9-pin)
EL-NCS-TCP-F-S Stand for Tool Center Point — 44.9" H (1,141 mm) from base to point
EL-NCS-TCP-F-R Tool Center Point Mount (attaches to reaming station stand)
EL-NCS-WCS-12 Integrated Wire Cutter (included on AC models)
EL-NCS-WCS-SA-12 Stand Alone Wire Cutter
EL-NCS-EC Evacuation Chute for High Volume Applications
EL-NCS-CC9-20-3 9 Pin, 20  Power/Control Cable
MODELS WITH INTEGRATED ETHERNET
Part No.
Description
EL-NCS-AE-20 Reaming Station with Ethernet and integrated anti-spatter spray
EL-NCS-ACE-20 Reaming Station with Ethernet, integrated anti-spatter spray and wire cutter
EL-NCS-AE-20-SC Reaming Station with Ethernet, self-cleaning air blast, integrated anti-spatter spray
EL-NCS-ACE-20-SC Reaming Station with Ethernet, self-cleaning air blast, integrated anti-spatter spray and
wire cutter
TORCH WIZARD® ROBOTIC NOZZLE CLEANING STATIONS
STANDARD MODELS
Part No.
Description
EL-NCS-A-20 Reaming Station with integrated anti-spatter spray
EL-NCS-AC-20 Reaming Station with integrated anti-spatter spray and wire cutter
EL-NCS-A-20-SC Reaming Station with self-cleaning air blast and integrated anti-spatter spray
EL-NCS-AC-20-SC Reaming Station with self-cleaning air blast, integrated anti-spatter spray and wire cutter
EL-NCS-A-TA-20 Reaming Station for tandem arc torches with integrated anti-spatter spray
EL-NCS-20 Reaming station without anti-spatter for aluminum; no wire cutter
EL-NCS-C-20 Reaming station without anti-spatter for aluminum; with wire cutter
EL-NCS-20-SC Reaming station with self-cleaning air blast for aluminum; no wire cutter
EL-NCS-C-20-SC Reaming station with self-cleaning air blast for aluminum; with wire cutter
Blades compatible with PowerBall® Torch Consumables
TORCH WIZARD® REAMER BLADES
Part No. Description Diameter Flutes Thread Height
EL-NCS-13MM Reamer Blade 13 mm 2 Female 2.558"
EL-NCS-TL-13MMF Reamer Blade 13 mm 1 Female 2.687"
EL-NCS-TS-13MMF Reamer Blade 13 mm 1 Female 2.433"
EL-NCS-15MM Reamer Blade 15 mm 2 Female 2.558"
EL-NCS-17MM-L Reamer Blade (ID: .402") 17 mm 2 Female 3.564"
EL-NCS-17MM-1-L Reamer Blade (ID: .329") 17 mm 2 Female 3.564"
EL-NCS-17MM-A Reamer Blade (ID: .467") 17 mm 2 Female 2.634"
EL-NCS-500 Reamer Blade 1/2" 2 Female 2.558"
EL-NCS-TL-50F Reamer Blade 1/2" 1 Female 2.687"
EL-NCS-TS-50F Reamer Blade 1/2" 1 Female 2.433"
EL-NCS-625 Reamer Blade 5/8" 2 Female 2.558"
EL-NCS-TL-62F Reamer Blade 5/8" 1 Female 2.687"
EL-NCS-TS-62F Reamer Blade 5/8" 1 Female 2.433"
EL-NCS-750 Reamer Blade 3/4" 2 Female 2.558"
EL-NCS-BRUSH-M Nozzle brush with mandrel for
aluminum welding applications 5/8" — Female —
EL-NCS-BRUSH Replacement nozzle brush for
aluminum welding applications 5/8" — Female —

ELCo Enterprises, Inc. • Jackson, Michigan USA
Service & Support: 517.782.8040
wire-wizard.com
TorchWizard_Manual_EL-NCS-20 | Rev. 2.3