INSTALLATION

& OPERATION
MANUAL
Installation,
Maintenance
and Warranty
Information

Models
EL-NCS-A-20
EL-NCS-AC-20
EL-NCS-AVBC-12
EL-NCS-AVB-12S
EL-NCS-AVB-LV

SHIP DATE SERIAL #

ELCo Enterprises, Inc. • Jackson, Michigan USA
517.782.8040 • [email protected] wire-wizard.com
 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 Anti-Spatter Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Sequence of Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.0 ADD-ON WIRE CUTTER INSTALLATION (IF APPLICABLE) . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.0 MAINTENANCE OF CLEANING STATION & WIRE CUTTER . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.0 ELECTRICAL SCHEMATIC (9-PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

6.0 EXPLODED VIEWS & PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 Exploded View 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Exploded View 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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

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 offer fast and efficient cleaning cycle times for high production rates. The anti-spatter
solution is applied via a venturi style sprayer on the front of the reamer.
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 8 for details.
In order to obtain the optimum cleaning performance, the interior of the nozzle should be sprayed with Blue Magic® or
Blue Chill® Anti-Spatter after cleaning.

1.1 WARRANTY
TWO YEAR EXTENDED WARRANTY TERMS AND CONDITIONS: ELCo Enterprises, Inc. (hereinafter “ELCo”) shall warrant the
Torch Wizard® Nozzle Cleaning Station (hereinafter “Torch Wizard”) to be free of defects in material and/or workmanship
for two (2) years from the date of shipment to the Buyer. This two year warranty requires the exclusive use of Blue Magic®
or Blue Chill® Anti-Spatter (or other anti-spatter supplied by ELCo Enterprises), along with an ELCo-supplied Filter/
Regulator/Lubricator (FRL) with auto-drain. The warranty shall cover 100% of all parts and labor with the exception
of misuse, abuse, neglect and typical consumables as determined by ELCo. 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®. The use of anti-spatter agents other than Blue Magic® or Blue Chill® and non-ELCo
parts and/or consumables with the Torch Wizard® may damage or limit the performance of the Torch Wizard® and will void
this extended warranty on all components.
ONE YEAR LIMITED WARRANTY TERMS AND CONDITIONS: For units using anti-spatter agents other than Blue Magic® or
Blue Chill®, 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 after 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 software 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

Models Models Model
EL-NCS-A-20 and EL-NCS-AVB-12S EL-NCS-AC-20 and EL-NCS-AVBC-12 EL-NCS-AVB-LV
▶ Base Unit ▶ Base Unit ▶ Base Unit
▶ Integrated Venturi style ▶ Integrated Venturi style ▶ Integrated Venturi style
anti-spatter spray unit anti-spatter spray unit anti-spatter spray unit
▶ Wire Cutter ▶ Wire Cutter

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

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 TORCH WIZARD INSTALLATION & OPERATION MANUAL

2.0 INSTALLATION
Internal Optional Wire Cutter Anti-spatter Reservoir
Access Panel Location
Venturi Style
Anti-spatter
Sprayer
Motor
Slide-Up
Reamer
Anti-spatter
Blade
Purge
Motor

Cover Latch

Electrical Connection Lubricated and

(9 pin) Filtered Air In
Catch Tray
Mounting Location
for optional
Tool Center Point

Figure 1: Torch Wizard Components with Venturi Style Anti-spatter Spray System (EL-NCS-A-20 shown)

2.1 MOUNTING THE TORCH WIZARD® BOLT PATTERN (same for all models)
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).
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 Figure 3
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.

Use of unfiltered, dirty air may result in damage to the unit and will void the warranty.

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 13 for detailed wiring information

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 TORCH WIZARD INSTALLATION & OPERATION MANUAL

2.4 ADJUSTING THE V-BLOCK

4

2 6
5
3

Figure 4

Figure 5

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 different 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. The graphic above represents the approximate location
of the V-Block when set up for a gas nozzle with a 1 inch
6. Tighten Low Head Socket Head Cap Screw (4). outside diameter.

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.

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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 diffuser 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 diffuser (see example in Fig. 6b). Removing the nozzle
from the torch to ensure the proper depth and clearance from the
diffuser is recommended. It is imperative that the reamer not
make contact with the gas diffuser as this will cause damage to
both the reamer and the gas diffuser. The Torch Wizard® is not 1
designed to clean the contact tip or gas diffuser.
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
Figure 6a
4
3
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).
Blade depth should be set
3. If the insertion depth is incorrect, loosen the Socket Head Cap to ream just below the gas
holes in the diffuser
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 Figure 6b
Example of typical reamer
Socket Head Cap Screws (2). Repeat steps 1 – 3 until the correct insertion depth. End of blade should
insertion depth is obtained. be set just below the gas holes on
the diffuser. This location will vary
based on the torch design.
Note: The air motor on this reaming station has a max torque of
7.3 ft/lbs @ 90 psi at the motor. Figure 6b

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 13 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.

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 TORCH WIZARD INSTALLATION & OPERATION MANUAL

2.6 ANTI-SPATTER DISPENSING

The Torch Wizard with Anti-Spatter option provides the user with the Anti-spatter
Reservoir
ability to ream then spray the nozzle using a venturi style sprayer.
The anti-spatter solution is supplied from the anti-spatter reservoir
(included with unit).

Anti-spatter Dispensing with the Reservoir

The Anti-spatter Reservoir dispensing option is shipped loose. On Back Cover
models ordered with the reservoir, simply attach the bowl to the
connection point on the side of the unit. For all others, use the following
procedure and refer to Fig. 7a on how to attach the reservoir bottle to
the Torch Wizard®:
1. Open the back cover by loosening the two screws. Remove the
Bulkhead Connector.
2. Attach Reservoir to Reaming Station using the two supplied bolts.
3. Insert the anti-spatter tube (the one that was connected to the
bulkhead) into the fitting on the Reservoir assembly.
4. Reattach back cover and ensure all screws and fittings are tight.
Figure 7a
Anti-spatter Reservoir Attachment
Once the Reservoir has been secured, remove the Fill Cap and fill
the Reservoir with Blue Magic® or Blue Chill® anti-spatter solution.
The use of other anti-spatters will void the warranty on sprayer
components. This is due to the corrosiveness of many anti-spatters,
which is not found in either Blue Magic® or Blue Chill®.
The anti-spatter liquid volume and air volume have been factory set and
should be evaluated before making any adjustments to the system. You
may also adjust the length of the spray time when programming the unit.

Anti-spatter Volume Adjustment

Note: In most cases, the factory setting for the anti-spatter
spray should be sufficient, this setting should only be adjusted if
absolutely necessary. Figure 7b
Anti-spatter Spray Block
To adjust the anti-spatter volume, unlock the two panel latches on
the back cover and open to reveal the interior of the reaming station.
The anti-spatter volume can be adjusted using the volume control
knob located on the left side of the unit (Fig. 7c). Turn the control knob
clockwise to reduce the air flow and increase the amount of anti-spatter,
turn it counter-clockwise to increase the air flow and reduce the amount
of spatter. Settings can be tested by pressing the manual Spray button
on the side of the unit, and visibly observed from the sprayer (Fig. 7b).
Replace cover when desired setting is achieved.

Figure 7c
Anti-spatter Adjustment

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 TORCH WIZARD INSTALLATION & OPERATION MANUAL

2.7 SEQUENCE OF OPERATIONS

Models EL-NCS-A-20, EL-NCS-AVB-12S or EL-NCS-AVB-LV (no Wire Cutter)
1. Verify Signal at Pin #3 is On (Home)
2. Energize Pin #4 - Motor and Clamp On
3. Verify Signal at Pin #3 is Off - Clamped & Pin #9 is Active - Nozzle Present
4. Short Delay
5. Energize Pin #5 - Vertical Slide Up
6. Short Dwell for Torch Clean
7. De-energize Pin #5 - Vertical Slide Down 1. (ORANGE) - +24 VDC
8. Short Delay 2. (BLUE) - 0 VDC
3. (RED/BLK) - NOZZLE
9. De-energize Pin #4 - Unclamp and Motor Off UNCLAMPED/SLIDE DOWN
10. Energize Pin #6 - Spatter Spray Application* 4. (GRN/BLK) - AIR MOTOR/CLAMP,
ACTIVATION OF PIN #9
11. Short Dwell 5. (WHITE) - SLIDE UP
12. De-energize Pin #6 - Spatter Spray Off 6. (RED) - SPATTER SPRAY
7. (GRN/YEL) - GROUND
13. Verify Signal at Pin #3 is On (Home) 8. (WHT/BLK) - WIRE CUTTER ADVANCE
14. Cycle Complete 9. (BLACK) - NOZZLE PRESENT

Models EL-NCS-AC-20 or EL-NCS-AVBC-12 (includes 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 Pin #3 is Off - Clamped & Pin #9 is Active - Nozzle Present
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
See Ethernet Model
13. De-energize Pin #4 - Unclamp and Motor Off supplement for operation
14. Energize Pin #6 - Spatter Spray Application* on models with
Ethernet connectivity.
15. Short Dwell
16. De-energize Pin #6 - Spatter Spray Off
Complete electrical
17. Verify Signal at Pin #3 is On (Home)
drawing is on page 13.
18. Cycle Complete

*Duration of energize determines the amount of spatter spray applied

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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 mufflers 5. Insert the wire cutter
and push-to-lock fitting solenoid plug (labeled
into the valve assembly “wire cutter sol.”) into
as shown. the right side of the
valve assembly.

2. Cut approx. 2" of tubing 6. Detach the steel guard by

and insert into the push- removing the two screws
to-lock fitting on the (Fig. A). Insert the shorter
valve assembly. guard for the wire cutter
in its place, with the two
mounting hole locations
lined up (Fig. B). Close
Figure A Figure B
and latch the cleaning
station cover down to secure
3. Open the back cover the new guard in place while
of the cleaning station installing the wire cutter.
and remove the air
outlet plug in the 7. Remove the two screws
circled location. to slide off the wire
cutter steel cover in
order to access the two
mounting bolts.
4. Install the tubing from
the valve assembly into
the push-to-lock fitting 8. Remove the two
where the plug was just black plugs for the
removed. The assembly pneumatic tubing.
should have the
solenoid plug location
on the right side. 9. Push in the two air line
reducers (8 mm to 6 mm)
into the push-to-lock
fittings on the wire cutter.

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 TORCH WIZARD INSTALLATION & OPERATION MANUAL

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 left side of the
valve assembly (port B) (Fig. 10b).

Figure C Figure D

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).

Figure E Figure F

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).

Figure G Figure H

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 ▶ Check blade for chips or cracks, replace if necessary
mechanically stressed components ▶ Check for lose parts
▶ Clean the filter ▶ Ensure the proper depth of blade in the nozzle
▶ Check that the air lines are free of leaks ▶ Ensure the blade is not making contact with the diffuser
▶ Ensure the lubricator has lubricant and fill if necessary ▶ 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.

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

4mm M6
screws Wire Back Clamping
Plate Block
Grease Zirc
Wire Location

5 mm M6 Spring
screw

Cutting
Blade

Figure 8: Wire Cutter, Exterior View Figure 9: Wire Cutter, Interior View

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 TORCH WIZARD INSTALLATION & OPERATION MANUAL

4.1 MAINTENANCE SCHEDULE

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.

4.2 RECOMMENDED SPARE PARTS

For Models EL-NCS-A-20 or EL-NCS-AC-20
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

For Model EL-NCS-AC-20 Only (unit with wire cutter)

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

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 TORCH WIZARD INSTALLATION & OPERATION MANUAL

5.0 ELECTRICAL SCHEMATIC (9-PIN)

See page 8 for

sequence of operations
for your cleaning
station model.

1. (ORANGE) - +24 VDC

2. (BLUE) - 0 VDC
3. (RED/BLK) - NOZZLE
UNCLAMPED/SLIDE DOWN
4. (GRN/BLK) - AIR MOTOR/CLAMP,
ACTIVATION OF PIN #9
5. (WHITE) - SLIDE UP
6. (RED) - SPATTER SPRAY
7. (GRN/YEL) - GROUND
8. (WHT/BLK) - WIRE CUTTER ADVANCE
9. (BLACK) - NOZZLE PRESENT

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 TORCH WIZARD INSTALLATION & OPERATION MANUAL

6.0 EXPLODED VIEWS & PARTS LIST

6.1 EXPLODED VIEW 1

14
 TORCH WIZARD INSTALLATION & OPERATION MANUAL

6.2 EXPLODED VIEW 2

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 Item No. Part No. Description Qty
1 5448T21 16MM ID ALLOY 932 FLANGE BUSHING 1 56 NCS-41 COVER 1
2 5193A2 PLASTIC HANDLE 1 57 NCS-NOZZLE-DEPTH-WARN NOZZLE DEPTH WARNING LABEL 1
3 40353 M4 ZINC FLAT WASHER 7 58 NCS-TAG-3 TAG 1
4 41451 3/8 ALUMINUM BACK UP WASHER 2 59 NCS-TAG-5 ANTI-SPATTER FLUID INLET ONLY 1
5 41293 M3-.5 X 6 BHCS ZINC 2 60 NCS-TORCH WIZARD-LABEL TORCH WIZARD EMBOSSED LABEL 1
6 24766 M5 HIGH COLLAR LOCK WASHER 8 61 EL-NCS-A-20-SERIAL TAG MODEL/SERIAL TAG 1
7 35908 M5-.8 X 55 SHCS ZINC 1 62 USA STICKER TAG 1
8 41317 M6-1.0 X 10MM BHCS ZINC 7 63 H5161-L27WHP MOVING PARTS WARNING TAG 1
9 41299 M4-.7 X 6MM BHCS ZINC 2 64 NCS-BM-BC-DECAL BLUE MAGIC/BLUE CHILL DECAL 1
10 41307 M6-1.0 X 14MM SHCS ZINC 2 65 NCS-82 LOCK 1
11 39856 M8-1.25 X 16 FPSS BLACK OXIDE 1 66 1734A12 FRONT DOOR LATCH 1
12 35879 M4-0.7 X 10 ZINC SHCS 2 67 9688K124 PLASTIC PLUG 3
13 35891 M4-0.7 X 60 ZINC SHCS 4 68 CPT-6 AIR INLET PLUG 1
14 41389 M6-1.0 X 14 FHCS ZINC 14 69 EC-18 CAPLUG 1
15 35915 M6-1.0 X 14MM SHCS ZINC 4 70 109AL-04 1/4 NPT BRASS PLUG 3
16 41391 M6-1.0 X 18 FHCS ZINC 4 71 9688K221 PLASTIC PLUG 1
17 35918 M6-1.0 X 20 SHCS ZINC 6 72 1754290000 JUMPER 1
18 35921 M5-.8 X 14 SHCS ZINC 4 73 0382860000 TERMINAL END BRACKET 2
19 40059 M6 X 20MM DOWEL 11 74 1754190000 END PLATE 1
20 41301 M4-.7 X 10 BHCS ZINC 13 75 11751 DIN RAIL 1
21 35934 M8-1.25 X 20 SHCS ZINC 2 76 IN-289-2006 WELD SPATTER COVER 2
22 41406 M8-1.25 X 25 FHCS ZINC 2 77 32191 INSULATED TERMINAL FEMALE 8
23 90597 M8-1.25 X 12 LSHCS BLACK OXIDE 2 78 1753280000 TERMINAL BLOCK 12
24 41705 M5-.8 X 90 SHCS ZINC 4 79 ULV4F2BSS335 PUSH BUTTON 1
25 40147 M4-07 NYLOC NUT ZINC 7 80 ROCCA-09-B-16C 9-PIN RECEPTACLE 1
26 41212 1/8 X 1/4 POP ALUM. RIVET 2 81 D-A93V SWITCH 2
27 41363 M4-.7 X 10MM FHCS ZINC 2 82 D-Z73 SWITCH 1
28 NCS-16-MOTOR AIR MOTOR 1 83 14RB10 WIRE END W/#10 HOLE-16 GA. WIRE 1
29 NCS-24 V-BLOCK 2 84 NCS-GPBL5 PUSH BUTTON PUSH BUTTON 1
30 NCS-25 BASE PLATE 1 85 SY100-30-4A PIG TAIL 1
31 NCS-112 TOP PLATE 1 86 74965K65 2.00" PIECE OF SHRINK TUBE 2
32 NCS-31 ADAPTER PLATE 1 87 W0970530053U 1-4 NPT SFE MUFFLER 2
33 NCS-32 SUPPORT NEST 1 88 KQ2L08-01S 90 DEGREE FITTING 4
34 NCS-34 SADDLE PLATE 1 89 AS2201F-01-08ST FLOW CONTROL 2
35 NCS-37 CATCH PAN 1 90 MGQM25-50 GUIDED AIR ACTUATOR SLIDE 1
36 NCS-38 RISER BLOCK 2 91 KQ2T08-00 8MM UNION TEE FITTING 1
37 NCS-39 THREADED ROD 1 92 KQ2P-09 SMC 5-16 TUBE PUSH-IN PLUG 1
38 NCS-40 EXTENSION FITTING 1 93 CDQ2B40-40DZ SMC 40MM BORE X 40MM STROKE 1
39 NCS-42 COVER 1 94 AS2052F-08 SMC INLINE FLOW CONTROL 1
40 NCS-45 CLAMP CYLINDER SPACER 1 95 HHB-108687 SMC 3 STATION MANIFOLD 24V 1
41 NCS-46 REAR COVER HINGE 1 96 109AL-02 1/8 NPT BRASS PIPE PLUG 1
42 NCS-47 FRONT COVER HINGE 1 97 123-4-2 1/4 NPT X 1/8 NPT MALE BRASS NIPPLE 1
43 NCS-50 VENTURI BLOCK 1 98 KQ2H08-01A 8MM STRAIGHT FITTING 1
44 NCS-81 CATCH TRAY LOCATOR 2 99 VX212CAB SOLENOID VALVE 1/8" PORT N.C. 24VDC 1
45 NCS-83-AVBC-18B FACE PLATE 1 100 KQ2E06-00A FITTING, BULKHEAD 1
46 NCS-28 SIDE PLATE (RH) 1 101 KQ2R06-08 6MM TUBE X 8MM REDUCER 1
47 NCS-86 STAINLESS FRONT COVER 1 102 TRB0604B-100 6MM FLAME RESISTANT BLACK TUBING 1
48 NCS-90 STAINLESS REAR COVER 1 103 KQB2L06-01S 1/4 NPT MALE ELBOW 1
49 NCS-27 SIDE PLATE (LH) 1 104 NCS-115 EXTENSION FITTING 2
50 NCS-97 MOTOR MOUNT 1 105 KQ2Z06-02AS 1/4 NPT MALE BRANCH ELBOW 1
51 NCS-98 MOTOR MOUNT 1 106 KQ2P-06 PLUG 2
52 NCS-102 SIDE COVER 1 107 M476-RP 10 oz RESERVOIR 1
53 NCS-105 INNER GUARD FOR NCS 1 108 PFA-27 SPACER 2
54 NCS-87-1 ANTI-SPATTER SHIELD 1 109 NCS-TAG-1 TAG 1
55 NCS-43 SIDE MOUNT BLOCK 1

Wire Cutter Replacement Parts

Item Name Part No. Item Name Part No. NOTE: Wire cutter not included on
Cutting Blade NCS-WCS-19 Clamping Block NCS-WCS-07 EL-NCS-A-20 model
Wire Back Plate NCS-WCS-16 Replacement Spring C0240-045-1000-S

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 TORCH WIZARD INSTALLATION & OPERATION MANUAL

7.0 OPTIONAL COMPONENTS & ACCESSORIES

TITANIUM NITRIDE TORCH WIZARD® ROBOTIC NOZZLE CLEANING STATIONS
STANDARD MODELS
TiN Coated for Part No. Description
Maximum Durability 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
Single Flute Double Flute EL-NCS-C-20-SC Reaming station with self-cleaning air blast for aluminum; with wire cutter
Reamer Blades Reamer Blades
Testing and MODELS WITH INTEGRATED ETHERNET
Diagnostic Box Part No. Description
EL-NCS-TB 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
Stand for Tool EL-NCS-AE-20-SC Reaming Station with Ethernet, self-cleaning air blast, integrated anti-spatter spray
Center Point EL-NCS-ACE-20-SC
Reaming Station with Ethernet, self-cleaning air blast, integrated anti-spatter spray and
wire cutter
EL-NCS-TCP-F-S
Excludes touch TORCH WIZARD® OPTIONAL ACCESSORIES
plate and point
Tool Center Part No. Description
Point EL-NCS-STAND 29.5" (749 mm) Stand (custom heights available) for EL-NCS models
Adapter Mount EL-NCS-FRL-14 Filter/Regulator/Lubricator
EL-NCS-TCP-F-R 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
Excludes touch
EL-NCS-TCP-F-R Tool Center Point Mount (attaches to reaming station stand)
plate and point
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 ft Power/Control Cable

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"
29.5" (749 mm) EL-NCS-TS-13MMF Reamer Blade 13 mm 1 Female 2.433"
EL-NCS-15MM Reamer Blade 15 mm 2 Female 2.558"
Stand for EL-NCS-17MM-L Reamer Blade (ID: .402") 17 mm 2 Female 3.564"
Torch Wizard® EL-NCS-17MM-1-L Reamer Blade (ID: .329") 17 mm 2 Female 3.564"
EL-NCS-STAND 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"
Evacuation EL-NCS-TS-50F Reamer Blade 1/2" 1 Female 2.433"
Chute EL-NCS-625 Reamer Blade 5/8" 2 Female 2.558"
EL-NCS-EC EL-NCS-TL-62F Reamer Blade 5/8" 1 Female 2.687"
Replaces catch pan EL-NCS-TS-62F Reamer Blade 5/8" 1 Female 2.433"
EL-NCS-750 Reamer Blade 3/4" 2 Female 2.558"
Nozzle brush with mandrel for
EL-NCS-BRUSH-M 5/8" — Female —
REDUCE DOWNTIME & COST aluminum welding applications
Replacement nozzle brush for
By using a multi-station bulk EL-NCS-BRUSH 5/8" — Female —
aluminum welding applications
anti-spatter dispensing system
Blades compatible with PowerBall® Torch Consumables

BLUE MAGIC® ANTI-SPATTER BLUE CHILL® ANTI-SPATTER

5-gallon Part No. Description Part No. Description
Manifold Kit EAS1000-C32 32 oz Spray Bottle EAS1000-BC32 32 oz Spray Bottle
5GMK
EAS1000-C1 1 gal Bottle EAS1000-BC1 1 gal Bottle
EAS1000-C5 5 gal Container EAS1000-BC5 5 gal Container
EAS1000-C 55 gal Drum EAS1000-BC 55 gal Drum
EAS1000-CT 275 gal Bulk Tote EAS1000-BCT 275 gal Bulk Tote
Drum EAS1000-C-CON-1L 1 l (33 oz) Concentrate
Manifold Kit EAS1000-C-CON-5 5 gal Concentrate
DMK EAS1000-C-CON 55 gal Concentrate
20 ft. (7.6 m) power/control cable included. The
EAS1000-DP Manual Drum Pump (55 gal)
reamer bit required is based on the I.D. of the gas
EAS1000-DW Drum Wrench (55 gal) nozzle being used.

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ELCo Enterprises, Inc. • Jackson, Michigan USA
Service & Support: 517.782.8040
wire-wizard.com

TorchWizard_Manual_A-AC-20 | Rev. 2.3