Product GuideInstallation, Operation & Warranty Information

ELCo Enterprises, Inc. • 5750 Marathon Drive • Jackson, MI 49201 • (517) 782-8040 • Fax (517) 782-8039www.wire-wizard.com

Product GuideInstallation, Operation & Warranty Information

For Model NSW-WM (Wall Mounted Unit)

ENTERPRISES, INC.

by

WIRE DISPENSING SYSTEM

Non-Stop Wire Dispensing System

2Rev. 5/5/14

1.0 INTRODUCTION ...............................................................................................................................31.1 Warranty ............................................................................................................................................31.2 Safety ................................................................................................................................................3

2.0 ASSEMBLY INSTRUCTIONS ....................................................................................................... 4-6

3.0 OPERATION .....................................................................................................................................7

TABLE OF CONTENTS

SEE INSTRUCTIONS THAT WERE INCLUDED WITH YOUR WIRE BUTT WELDER FOR BUTT WELDING INSTRUCTIONS.

3

Non-Stop Wire Dispensing System

Rev. 5/5/14

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, eliminat-ing 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.

1.0 INTRODUCTION

ELCo Enterprises, Inc. (hereinafter “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 excep-tion 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 immedi-ately, 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 consequen-tial 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 ordesign by ELCo and are in lieu of all other warranties, express or implied, including warranties of merchantabil-ity and fitness for a particular purpose.

1.1 WARRANTY

1.2 SAFETYThe 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.

FA

Wear Eye ProtectionWhen butt welding the wire ends together or deburring the wire after butt welding, always wear eye protection.

Wear Protective GlovesWhen butt welding the wire ends together or deburring the wire after butt welding, always wear protective gloves.

Electrical Shock HazardDo not touch wire when butt welding. The wire is not safe to touch until after the weld is finished. Keep hands and arms away from charged wire.

Always Secure Wire DrumsEnsure all wire drums are firmly secured to the Non-Stop Wire System with the provided wratch-et straps to avoid roll away hazards.

Non-Stop Wire Dispensing System

4Rev. 5/5/14

2.0 ASSEMBLY INSTRUCTIONS

A.B.

D.

E. F.

H.G.

C.

PARTS AS SHOWN: A. Drum Stop B. Drum Divider C. Wire Bridge D. Lower Post E. Upper Post F. Transfer Arm G. Transfer Arm Bracket H. Wire Liner Note: Some models may feature additional Guide Modules on top of transfer arm.

Mount the lower post to a stable wall or pole using the four bolts provided (or your own if longer bolts are needed). The bottom of the post should be 20” (508 mm) from the floor when using drums on skids or carts. Use a level on the side and front of the post to ensure it is straight. The post must be level in order for the system to function properly.

Slide the transfer arm bracket onto the bottom of the upper post. Insert the base of the transfer arm all the way into the pivot point on the bracket.

Attach the transfer arm assembly to the top post. Tighten connection point at the quick disconnect with wrenches as shown.

Insert the transfer arm bar and tighten the set screw to secure in place. The arm will require further adjustment once installed on the post.

1

2 3 4

5

Non-Stop Wire Dispensing System

Rev. 5/5/14

2.0 ASSEMBLY INSTRUCTIONS (continued)

Secure the two wire drums or boxes in place by attaching the hooks and cam straps to each side and tightening them to prevent the drums from rolling away. Wire drums should have the hoods positioned as shown:

Insert the upper post assembly with the transfer arm into the lower post. Secure in place with the two set screws located at the top of the lower post. Assembly should now look as shown in photo on the right.

Insert the drum stop bar into the bottom of the lower post. Ensure it is centered and secure in place with the two set screws. Attach the drum divider in front of the drum stop with the two bolts provided.

Install the wire bridge bracket onto the post using the two bolts provided. Insert 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 bolts on the back of the unit (requires 1/4” allen wrench) to adjust the height and the set screw at the bottom to move back and forth (using a 5mm allen wrench).

Adjust the height of the transfer arm assembly by loosening the two set screws on the base. Raise arm assembly to the desired height and tighten bolts. The 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 proper adjustment should look similar to the photo above.

5

87 9

6

Non-Stop Wire Dispensing System

6Rev. 5/5/14

Rotate bridge when changing wire

ROTATE

WIREBRIDGE

START WIRE

END WIRE

End wire staging magnet

Finished Installation

Follow operating instructions for welding the two wire ends together on page 7. Insert wire into the wire bridge and hold into place using the wire clamp as shown (magnets in the pathway will also assist in securing wire). When changing wire packages, lift and rotate the wire pathway so the start wire of the new drum is on the side with the wire clamp.

An end wire staging magnet is included for holding the end wire of the first drum if the second drum is not yet installed.

2.0 ASSEMBLY INSTRUCTIONS (continued)

10

7

Non-Stop Wire Dispensing System

Rev. 5/5/14

3.0 OPERATION

Join the end wire from drum 1 with the start wire from drum 2 using the Butt Welder. Follow instructions that came with your butt welder.

Remove the burr in the wire joint using the Wire Sizer* (recommended accessory).

Adjust wire bridge so it is in the prop-er position (see page 6). 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.

1

2

3 4

Start Wire

End Wire

Start Wire

Drum 1 Drum 2

DRUMSETUP

Wire Pilot™ FeedAssist option

* Alternatively, you may remove the burr in the wire using a rotary tool with a stone bit.

Wire Clamp If using with wire over .052 (1.3mm), disassemble and flip the clamping block around to the textured side for better gripping.

ENTERPRISES, INC.5750 Marathon Drive • Jackson, MI 49201 • (517) 782-8040 • Fax: (517) 782-8039www.wire-wizard.com | Para asistencia en Español - Tel. +521 (81) 2010-1339