Wire wizard NSW-20.4F-18B-2 User manual

INSTALLATION
& OPERATION
MANUAL
Installation,
Maintenance
and Warranty
Information
SHIP DATE SERIAL #
5750 Marathon Drive • Jackson, Michigan 49201
517.782.8040 • [e-mail] wire-wizard.com
Models
NSW-20.4F-18B-2
NSW-20.4F-18B-4
NSW-SC24-18B-2
NSW-SC24-18B-4

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Product Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.0 BUTT WELDING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.0 PORTABLE BUTT WELDER INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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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 operate and maintain the Non-Stop® Wire
Dispensing System. This manual provides specific information on installation, safety, basic operation, and maintenance.
Please read, understand and follow all safety procedures.
The Non-Stop® Wire Dispensing System utilizes a unique process that joins the end wire from an empty drum with the start
wire of the next full drum, eliminating costly downtime for wire changeover and optimizing production time. A smooth
operating wire guide arm handles the wire transfer during the automatic change, with no manual operator action required.
With our easy-to-use Butt Welder, both butt-welding and flash removal operations take only seconds and the two wire ends
may even be joined during the welding cycle. The Non-Stop® Wire Dispensing System works with either one or two station
robotic cells (2 or 4 drums). A convenient Docking Station that holds the Butt Welder and a deburring tool is also available
for this package. Made in the U.S.A..
1.1 WARRANTY
ELCo Enterprises, Inc. (hereinaer “ELCo”) shall warrant the Non-Stop® Wire Dispensing System 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. ELCo will at
its option, repair, replace or issue a credit for the value of the defective Non-Stop Wire System.
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 status is determined.
ELCo’s warranty is limited to replacing any goods that are proved to be defective and in no event shall ELCo 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.
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: ________________________

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
1.3 SAFETY
The Non-Stop® Wire Dispensing System 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.
WARNING: WEAR EYE PROTECTION
When butt welding the wire ends together or deburring the wire aer butt welding, always wear eye protection.
WARNING: WEAR PROTECTIVE GLOVES
When butt welding the wire ends together or deburring the wire aer butt welding, always wear
protective gloves.
WARNING: ELECTRIC SHOCK HAZARD
Operators should always wear dry welding gloves and protective clothing when welding. Do not contact
electrically live parts. Keep welding guns and other welding equipment away from moisture and water.
Ensure ground connections are secure and compatible with the required electric current. When welding
under wet conditions or where perspiration is a factor, the use of automatic controls for reducing the no
load voltage is recommended to reduce the risk of electric shock. Accidental contact must be prevented
with open circuit voltage exceeding 80 volts AC, or 100 volts DC by using insulation or other means. When
welding gun is not in use, turn o power supply to prevent any accidental contact.
Welding equipment should be installed and maintained in accordance with National Electrical Code
(NFPA 70) and in compliance with local codes. Equipment should only be serviced by qualified or trained
personnel only. Do not disassemble torch or change welding consumables with the power supply on.
WARNING: ALWAYS SECURE WIRE DRUMS
Ensure all wire drums are firmly secured to the Non-Stop Wire System with the provided wratchet straps
to avoid roll away hazards.

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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2.0 ASSEMBLY INSTRUCTIONS
1. Insert the Bottom Post (B) into the Base (A) and tighten the two set screws
to secure in place. It is highly recommended the base is secured to the floor
for better stability (floor bolts not included).
2. Slide the Wire Bridge Assembly (C) onto the Bottom Post (B) and secure in
place by tightening the two set screws.
3. Insert the Top Post (D) into the Bottom Post (B) and tighten the set screws to
secure in place. The height of the stand may be adjusted later by loosening
these set screws and sliding the Top Post (D) up or down.
4. Slide the Guide Arm Assembly (E) onto the Top Post (D) and tighten all
set screws on the two sleeves to secure in place. Finished Post and Guide
Arm Assembly should appear as shown.
5. Install the included Non-Stop® Wire System Drum Hoods on the first two
drums of wire that will be used with the system.
A
E
D
C
B
A
B

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
6. Insert the two wire drums or boxes into place on the le and right side of the Wire Bridge. If needed, adjust the height
of the top arm assembly by loosening the two set screws. Raise arm assembly to the correct height and tighten bolts.
Height should be adjusted so that the transfer arm swings freely between the two drums, with the liner going into each
slot in the drum covers. The drum covers should face each other as shown:
7. Secure the two wire drums or boxes in place by activating the brake on your
drum dolly (if applicable).
8. Adjust the wire bridge between the two drums so the top of the bridge is
level with the bottom of the opening on each of the drum hoods. Use the
two set screws on the Wire Bridge Assembly Sleeve (requires 1/4” Allen
wrench) to adjust the height and the set screw at the bottom to move
forwards or backwards (using a 5mm Allen wrench). When properly adjusted,
the transfer arm should swing from one drum to the other staying within the
slots on the drum covers.
9. Follow the instructions for butt welding the two wire
ends together on page 5 (or page 7 if using a portable
butt welder). Insert welded wire into the wire bridge
and hold into place using the wire clamps as
shown. When changing wire packages, always
place the joined wires back into the channel
and clamps on the wire bridge. An end wire
staging magnet is included for holding the
end wire of the first drum if the second
drum is not yet installed.
Active drum Next full drum
EndEnd
wirewire
WireWire
bridgebridge
StartStart
wirewire
End wire staging magnet
Finished Assembly
Butt Welder
Sold Separately

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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1. Ensure the Wire Size Select switch is in the OFF position(center). Connect Butt Welder to power supply.
2. Pull down both locking knobs to open wire clamps.
3. Pull and turn the Weld/Open switch to the “Open” position.
4. Snip o each end of the wire using a pair of Wire Parters (included). Insert each wire end in groove
until centered in the space between the 2 jaws. Lock wire into place one side at a time by pulling
the locking knobs back into place. Ensure the wire butts are flat and evenly spaced.
5. Turn the Weld/Open switch to the “Weld” position.
6. Turn switch on base unit to appropriate setting for wire size.
7. Press green Cycle Start button on the front panel to weld the wire ends together
(there will be a slight delay). If the Reset is popped out, push back in to weld.
CAUTION! Keep hands clear of butt welder components and wire when welding.
8. Open wire clamps by pulling down both locking knobs. Remove wire (may be hot!).
9. Remove the burr in the wire joint using the optional Wire Sizer (see below) or other method of
creating a smooth joint. Check the joint using the Wire Gage Block to ensure smooth wire feeding.
10. Insert wire onto pathway between the two wire packages. Repeat process when replacing
empty drums.
JawsJaws
Weld/OpenWeld/Open
SwitchSwitch
LockingLocking
KnobsKnobs
Front Panel Butt Welder
IMPORTANT!
Ensure wire ends are
evenly aligned prior
to butt welding.
Butt Welder Docking
Station with
Wire Sizer option
1 2
BURR REMOVAL FROM WIRE JOINT
USING THE WIRE SIZER
To remove the burr in the wire joint, open
clamps on the wire sizer and position wire
as shown in step 1. The wire joint should
be positioned outside of the cutting plate
(circled). Close and tighten clamps. Pull
the handle firmly to the right to remove the
burr. Unlock the clamps and remove wire.
3.0 BUTT WELDING INSTRUCTIONS

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
4.0 OPERATION
End
Wire
Start
Wire
Start
Wire
DRUM SETUP
DRUM 2DRUM 1
1
2
34
Join the end wire from drum 1
with the start wire from drum 2
using the Butt Welder. Follow butt
welding instructions on page 5.
Remove the burr in the wire joint
using the Wire Sizer (recommended
accessory). Alternatively, you may
remove the burr in the wire using a
rotary tool with a stone bit.
Adjust wire bridge so it
is in the proper position
(see page 5). Push in
spring clamp on the
wire bridge and insert
wire along the groove
between the two drums.
Release spring clamp to
hold wire in place.
When wire from drum
1 runs out, the transfer
arm will switch over to
drum 2. Simply replace
empty drum and repeat
steps 1-3. Flip the wire
bridge when changing
drums so the spring
clamp side is always
opposite the side of the
active drum.
Wire Pilot™ Feed
Assist option
Wire Clamp
If using with wire over 0.052 (1.3
mm), disassemble and flip the
clamping block around to the
textured side for better gripping

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TORCH WIZARD INSTALLATION & OPERATION MANUAL
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5.0 PORTABLE BUTT WELDER INSTRUCTIONS
1. Ensure the Wire Size Select switch is in the OFF position
(center). Connect Butt Welder to power supply.
2. Pull down both locking knobs to open wire clamps.
3. Pull and turn the Weld/Open switch to the “Open” position.
4. Snip o each end of the wire using a pair of Wire Parters
(included). Insert each wire end in grooves until centered in
the space between the 2 jaws. Lock wire into place one side
at a time by pulling the locking knobs back into place. Ensure
the wire butts are flat and evenly spaced.
5. Turn the Weld/Open switch to the “Weld” position.
6. Turn switch on base unit to appropriate setting for wire size.
7. Press black weld button on the handle to weld the wire ends
together (there will be a slight delay). If the Reset is popped
out, push back in to weld. CAUTION! Keep hands clear of
butt welder components and wire when welding.
8. Open wire clamps by pulling down both locking knobs.
Remove wire (may be hot!).
9. Remove the burr in the wire joint using the optional Wire
Sizer (see below) or other method of creating a smooth joint.
It is recommended to check the joint using a Wire Gage Block
to ensure smooth wire feeding.
10. If using with the Non-Stop Wire Dispensing System, insert wire
onto pathway between the two wire packages. Repeat process
when replacing empty drums
IMPORTANT!
Ensure wire ends are
evenly aligned prior
to butt welding.
Butt Welder
Butt Welder (jaws open)
Jaws
Weld/Open
Switch
Wire Grooves
Locking
Knobs
Weld
Button
BURR REMOVAL FROM WIRE JOINT
USING THE WIRE SIZER
To remove the burr in the wire joint, open
clamps on the wire sizer and position wire
as shown in step 1. The wire joint should
be positioned outside of the cutting plate
(circled). Close and tighten clamps. Pull
the handle firmly to the right to remove the
burr. Unlock the clamps and remove wire.
1 2

ELCo Enterprises, Inc. • Jackson, Michigan USA
Service & Support: 517.782.8040
wire-wizard.com
NSW-Standalone_Manual | Rev. 2.0