Nasarc INTELLIREAM MP Owner's Manual

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Effective with serial No. IR2006001 & following.

Nasarc Technologies, Inc.

602 Colby Drive

Waterloo, Ontario, N2V 1A2

Tel: (519) 747-0336, Fax: (519) 886-9022

WWW.NASARC.COM

INTELLIREAM

OWNERS MANUAL

Safety Depends on You

DO NOT INSTALL, OPERATE, OR REPAIR

THIS EQUIPMENT WITHOUT READING THIS

MANUAL AND THE SAFETY PRECAUTIONS

CONTAINED THROUGHOUT.

ELECTRIC

LINCOLN

MULTI-WELD 350

ELECTR IC

MULTI-WELD 350

LINCOLN

"U.S. Patent No.: 7,952,052"

Intelliream_IRMPOM-3b

June, 2022

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Page 1 ® MULTI-WELD 350 ELECTR IC MULTI-WELD 350 LINCOLN ® OWNERS MANUAL “U.S. Patent No.: 7,952,052” Effective with serial No. IR2006001 & following. Nasarc Technologies, Inc. 602 Colby Drive Waterloo, Ontario, N2V 1A2 Tel: (519) 747-0336, Fax: (519) 886-9022 WWW.NASARC.COM Intelliream_IRMPOM-3b...
Page 2 Intelliream_IRMPOM-3b...
Page 3 Safety Information Before installation and commissioning of the INTELLIREAM MP, please read and understand all of the following ® safety information. Failure to follow these instructions may result in damage to the equipment or personal injury. The INTELLIREAM MP is constructed to be safe to operate provided: ®...
Page 4 Safety Information Moving parts can crush and cut. Keep hands away from the operating area of the reaming bit, clamp, and wire cutter Rotating Cutter. Keep hands away from the operating area of the cutter. Entanglement Hazard. Do not operate with exposed long hair, jewelry, or loose clothing. Disconnect power before servicing.
Page 5: Table Of Contents
INTELLIREAM ® Table of Contents Specifications ............................. 7 Installation ..............................8 2.1. Air Connection ............................. 9 2.2. Electrical Connection ........................... 9 Operation ..............................10 3.1. User Interface ............................ 10 3.2. Power-Up ............................10 3.3. Manual Operation ..........................11 3.4. Automatic Operation .......................... 12 Robot Programming ..........................
Page 6 INTELLIREAM ® 10. Electrical Diagram ............................ 33 11. Parts List ..............................34 11.1. Gripper Head ..........................34 11.2. Front Components ......................... 35 11.3. Rear Components .......................... 36 Appendix A: Discrete I/O Explanation ......................38 Appendix B: Wire Cutter ..........................39 B.1 Wire Cutter Programming ........................
Page 7: Specifications
INTELLIREAM ® 1. Specifications PNEUMATIC SPECIFICATIONS Pressure: 80 PSI Flow: 16.5 SCFM Caution: -Use Filtered (5um), Non-Lubricated, Regulated Air ELECTRICAL SPECIFICATIONS Voltage: 24 VDC Current: 0.75 Amp DC REAMING SPECIFICATIONS Speed: 1100 RPM Power: 0.6 HP WIRE CUTTING SPECIFICATIONS Minimum wire diameter: 0.030” (0.8mm) Maximum wire diameter: 0.063”...
Page 8: Installation
INTELLIREAM ® 2. Installation Danger of accident when connecting the pneumatic or electrical supply! - Prior to installation ensure that all protective measures have been taken and will remain in place while performing the installation. ® - Ensure that the air supply and electrical power to the Intelliream are disconnected until the installation is complete.
Page 9: Air Connection
INTELLIREAM ® 2.1. Air Connection Use only regulated, filtered, non-lubricated air. Mount a 5-micron airline filter (not supplied) in the airline to the ® Intelliream AIR SUPPLY REQUIREMENTS: 80 PSI at 16.5 SCFM. Connect the inlet supply line to the quick connect ®...
Page 10: Operation
INTELLIREAM ® 3. Operation 3.1. User Interface The user interface is part of the Reamer Control Module (RCM) and can be found on the electrical supply side ® of the Intelliream (opposite the reservoir). The user interface provides the following features: •...
Page 11: Manual Operation
INTELLIREAM ® Start Lock: The start lock feature is a safety measure that blocks a command signal during power-up when it is unsafe to begin an operation. If a command is present while the Intelliream powers up, the INTELLIREAM ® ®...
Page 12: Automatic Operation
INTELLIREAM ® 3.4. Automatic Operation The following diagram shows the 7-step reaming sequence and color of the device status LEDs at each stage. The LEDs show the position of the clamp and lift cylinders on the control module. Clamp Raising Ream Bit Lowering Ream Bit...
Page 13: Robot Programming
INTELLIREAM ® 4. Robot Programming The following flow diagram shows the recommended procedure for the reaming and spraying sequences. The recommended procedure for configuring the position programming points for the ream cycle and sprayer is outlined on the following pages. For the wire cutter operation see Appendix B: Wire Cutter. (At any time) “Complete”...
Page 14: Position Programming
INTELLIREAM ® 4.1. Position Programming MP features a “no trial, no error” position programming technique as described below: The INTELLIREAM ® 1. Hold the “LIFT” button to raise the reaming bit without spinning. WARNING: the lift cylinder will operate under this condition. KEEP HANDS CLEAR of the operating space of the reaming bit.
Page 15 INTELLIREAM ® 5. Press the “LIFT” button to exit programming mode. The reaming bit will lower without spinning. WARNING: the lift and clamp will operate under this condition. KEEP HANDS CLEAR of the operating space of the reaming bit. This device is intended for one-man operation during setup.
Page 16: Settings
INTELLIREAM ® 5. Settings Several features may be setup to optimize performance of the INTELLIREAM MP. To access the ® configuration menus, press and hold the settings button for the required time as shown below. The device status LEDs will change their color pattern to indicate the menu that is accessible at a specific time. Release the settings button when the color pattern for the desired configuration menu is shown.
Page 17: I/O Configuration
INTELLIREAM ® 5.1. I/O Configuration The INTELLIREAM MP automatically detects sinking or sourcing inputs and outputs from the controller. For ® more information on discrete I/O See Appendix A: Discrete I/O Explanation. To disable the automatic-detect feature and manually configure the I/O types, use the following procedure: Press and hold the settings button for at least 3 seconds (until the LIFT bottom LED is solid red).
Page 18: Extras
INTELLIREAM ® (>5sec) Clamp Default 0 sec ¼ sec ½ sec 1 sec status Lift status Press & Done Release 5.3. Extras 1. Blow-off: The motor spins and exhausts (blowing off over spray) for two seconds after spraying. 2. De-Ringer: A pilot reaming stroke removes the spatter ring that forms on the end of a welding nozzle, followed by a full extension reaming stroke.
Page 19: Running Mode
INTELLIREAM ® 5.4. Running Mode Several running modes are available to select from. Automatic: Every aspect of the cycle is commanded, monitored, and checked by the control module. Dry Run: The motor and fluid solenoid are disabled. Timed: Bypass the "extended" sensor on the lift cylinder. The robot must hold the start signal on for the reaming time.
Page 20: Motor Diagnostic
INTELLIREAM ® 5.5. Motor Diagnostic This feature allows a technician to test the air motor function manually. Follow the steps outlined below to access the motor diagnostic configuration menu. Upon releasing the settings button, the LEDs will flash red on top and bottom. This is the first in the sequence of teachable configurations.
Page 21 INTELLIREAM ® 2. CLAMP function: Press the “CLAMP” button to close and open the clamp. Check that the “CLAMP” LED on the control module changes from green to red when the clamp is closed. WARNING: the clamp will operate under this condition. KEEP HANDS CLEAR of the operating space of the clamp and wire cutter.
Page 22: Preventative Maintenance
INTELLIREAM ® 6. Preventative Maintenance The INTELLIREAM MP will require periodic maintenance to ensure a dependable service life. The following ® schedule is recommended. Shut off the air supply and disconnect the power cable when making adjustments. DAILY • Check the fluid level in spray reservoir. •...
Page 23: Error Codes
INTELLIREAM ® 7.1. Error Codes ® The INTELLIREAM MP reports errors using the status light. When an error is reported, the status light flashes at a rate of 2 flashes per second. When an error occurs during the reaming process, the clamp opens, the lift retracts, and the diagnostic report is shown with the top sensor LED in red.
Page 24: Advanced Troubleshooting
INTELLIREAM ® Note: Clearing Errors – If an error has occurred with the INTELLIREAM ® MP, indicated by the “Error” input being turned on, it is possible to clear errors so that an operator is not required to enter the robotic welding cell. For example, if the air supply was not turned on and a ream cycle is required, the operator can simply turn on the air supply, and clear the error from outside the cell.
Page 25: Parts Replacement
INTELLIREAM ® 8. Parts Replacement 8.1. Reaming Bit Replacement • Disconnect air and electrical supply. • Hold the ream rod, item 1, from rotating with one of two 5/8” wrenches, item 2, under the washer, item 3. • Unfasten the reaming bit, item 4, with a second 5/8”...
Page 26: Pc Board Replacement
INTELLIREAM ® 8.3. PC Board Replacement • Disconnect air and electrical supply. • Remove four #8-32 socket head cap screws, item 1, to remove the module, item 2. (9/64” hex drive) • Disconnect the ribbon cable, item 3, from the module.
Page 27: Belt Replacement
INTELLIREAM ® 8.4. Belt Replacement • Disconnect air and electrical supply. • Open back door, item 1. • Check and note the belt tension, item 2. • Loosen three 6mm hex head bolts, item 3, connected to motor. LOOSEN ONLY (10 mm wrench) •...
Page 28: Clamp Cylinder Replacement
INTELLIREAM ® 8.5. Clamp Cylinder Replacement • Disconnect air and electrical supply. • Open back door, item 1. • Remove five socket head cap screws, item 2, and TCP check pin to remove top lid, item 3. (3/16” hex drive) •...
Page 29: Air Motor Replacement
INTELLIREAM ® 8.6. Air Motor Replacement • Disconnect air and electrical supply. • Open back door, item 1. • Disconnect hoses 141 and 142, item 2, from the motor. Check and note the belt tension, item 3. • Hold the motor from below and remove two 6mm hex head bolts, item 4.
Page 30: Spray Solenoid Replacement
INTELLIREAM ® 8.8. Spray Solenoid Replacement • Disconnect air and electrical supply. • Open back door, item 1. • Remove two black wires, item 2, from left terminal block. (position 102 and 112, 2nd from the top). Pull wires through the hole in main unit to the outside.
Page 31: Fluid Solenoid Replacement
INTELLIREAM ® 8.9. Fluid Solenoid Replacement • Disconnect air and electrical supply. • Remove anti spatter fluid reservoir, item 1. (3/4” wrench) • WARNING: Contents may spill. • Remove bottom nut, item 2, of compression fitting. (9/16” wrench) • Disconnect wires from the terminal block board (refer to the wiring diagram included) •...
Page 32: Pneumatic Diagram
INTELLIREAM ® 9. Pneumatic Diagram Additional pneumatic troubleshooting information: • Air enters the Intelliream ® through hose 100 and is distributed to the solenoids through the manifold. • Hose 110 feeds the spray solenoid. Air flows through the piping when the sprayer is on. Fluid flows through the fluid solenoid and piping when sprayer is on.
Page 33: Electrical Diagram
INTELLIREAM ® Electrical Diagram Closeup view of terminal block board pg. 33...
Page 34: Parts List
INTELLIREAM ® Parts List 11.1. Gripper Head ITEM PART # DESCRIPTION IRW010007-03 (Optional) WIRE CUTTER GUARD IRW010099-00 (Optional) WIRE CUTTER ASSEMBLY IRG010099-00 CLAMP ASSEMBLY IRE020099-09 STATUS LIGHT ASSEMBLY IRG010099-01 CLAMP CYLINDER ASSEMBLY IRW010099-01 (Optional) WEDGE ASSEMBLY IRG010001-14 GRIPPER HOUSING, FRONT PLATE pg.
Page 35: Front Components
INTELLIREAM ® 11.2. Front Components ITEM PART # DESCRIPTION IRS010005-00 FLUID RESERVOIR IRS010005-01 RESERVOIR LID IRP040099-00 FLUID SOLENOID ASSEMBLY IRP020099-04 SPRAY SOLENOID ASSEMBLY REAMING BIT (SEE ACCESSORIES) IRS010099-01 SPRAY NOZZLE ASSEMBLY IRS010003-00 SPRAY NOZZLE IRD010099-02 DOME ASSEMBLY IRD010002-03 ROD WIPER SEAL IRC010009-00 TIMING BELT IRC010099-02...
Page 36: Rear Components
INTELLIREAM ® 11.3. Rear Components pg. 36...
Page 37 INTELLIREAM ® ITEM PART # DESCRIPTION IRF020099-00 BACK COVER ASSEMBLY IRE020099-04 OPEN SENSOR ASSEMBLY IRP010099-06 EXHAUST MUFFLER ASSEMBLY IRE080001-01 TERMINAL BLOCK BOARD IRC010099-01 AIR MOTOR ASSEMBLY IRP010006-00 BULKHEAD 5/16 IRP020099-03 MANIFOLD ASSEMBLY IRP020011-00 CYLINDER SOLENOID IRP020012-00 MOTOR SOLENOID IRW010008-00 TCP CHECK PIN IRE020099-08 RIBBON CABLE ASSEMBLY IRE070099-01...
Page 38: Appendix A: Discrete I/O Explanation
INTELLIREAM ® Appendix A: Discrete I/O Explanation The terms sinking and sourcing describe the direction of DC current flow in a load. A sinking output provides a path to 0V for the load. Common terms used to describe sinking devices include NPN, Open Collector, Active Low, and IEC Negative Logic.
Page 39: Appendix B: Wire Cutter
INTELLIREAM ® Appendix B: Wire Cutter The Intelliream MP offers an optional wire cutter (IRW010099-00) used to cut off the ball created by the ® welding process. It will leave the welding wire with a tapered point at the end of the wire stick-out for improved arc starting.
Page 40 INTELLIREAM ® Wire Cutter Programming Cont’d WARNING: Anytime the clamp is closed, the wire cutters will be closed as well. Keep hands clear of the wire cutter area and clamp area. To obtain the “Wire Cut” position mentioned in the procedure outlined, center the nozzle at the desired stick-out height above the wire cutter and record this position.
Page 41: Wire Cutter Replacement
INTELLIREAM ® B.2 Wire Cutter Replacement • Disconnect air and electrical supply. • Unfasten (4) #8-32 button head cap screws, item 1. (9/64” hex drive) • Remove wire cutter guard, item 2. • Remove wire cutter module, item 3. • Insert new wire cutter module. NOTE: The cutters will close slightly when positioning the rollers against the wedge.
Page 42: Appendix C: Nozzle Detect Sensor
INTELLIREAM ® Appendix C: Nozzle Detect Sensor The Intelliream MP provides for an optional nozzle detect assembly (IRE120099-02). The integrated nozzle ® detect sensor is used to validate that the nozzle remains on the torch after the reaming process is complete. The nozzle detect sensor is integrated into the gripper housing on the side opposite the fluid reservoir as shown below.
Page 43 INTELLIREAM ® When a nozzle is detected by the sensor, the “Complete” input (green wire) will reflect the change. To utilize ® the nozzle detect sensor, the Intelliream MP must be in its ready state and no outputs from the controller should be active.
Page 44: Appendix D: Spray Containment Unit
INTELLIREAM ® Appendix D: Spray Containment Unit The Spray Containment II assembly (IRS020099-00) helps to manage overspray from the spray nozzle and maintain a clean robot welding cell. This unit may be factory installed or purchased and installed as a kit. D.1 Spray Position Programming Center the nozzle 1½...
Page 45: Spray Containment Parts Diagram
INTELLIREAM ® D.2 Spray Containment Parts Diagram ITEM PART # DESCRIPTION IRS020099-07 Spray Containment II Top Assembly IRS020099-06 Spray Containment II Mesh Assembly IRS010009-00 Spray Containment Drain Quick Connect D.3 Spray Containment Preventative Maintenance The spatter containment unit will require periodic maintenance to ensure a dependable service life. The following schedule is recommended.
Page 46: Appendix E: Nozzle Gas Flow Sensor (Ngfs)
INTELLIREAM ® Appendix E: Nozzle Gas Flow Sensor (NGFS) ® The Intelliream MP offers an optional nozzle gas flow sensor (IRE060099-00) that will measure gas flow at the end of the nozzle. This method is advantageous to an inline flow sensor installed in the gas hose as there may be undetected leaks downstream.
Page 47: Ngfs Operation
INTELLIREAM ® Signal Description Addendum The following explains the normal and additional functionality ® Interface Receptacle of the Intelliream MP with the Nozzle Gas Flow Sensor. Wire Color Name Description Blue Error Robot input. The robot can check this input after a reaming cycle to ensure error free operation.
Page 48: Ngfs Setup
INTELLIREAM ® E.4 NGFS Setup There are two settings available to change the window of operation; (1) Flow Set point and (2) Flow Tolerance Band. The set point adjustment (1) will move the entire band (minimum and maximum) up or down. The tolerance band adjustment (2) will adjust the span between the maximum and minimum levels.
Page 49: Ngfs Robot Programming
INTELLIREAM ® E.5 NGFS Robot Programming In order to properly detect gas flow, the correct robot position must be programmed with the nozzle inserted into the cone of the sensor. An approach position is recommended as the first step followed by the target position inside the cone.
Page 50: Ngfs Robot Programming With Nozzle Detect
INTELLIREAM ® E.5 NGFS Robot Programming with Nozzle Detect “Complete” on? The following flowchart describes the “Error” off? recommended programming sequence Error when a Nozzle Detect option is installed with a Nozzle Gas Flow Sensor. Note: the target position must also comply within the Move to Approach sensing range (1.5 mm) of the Nozzle Position...
Page 51: Ngfs Preventative Maintenance
INTELLIREAM ® E.6 NGFS Preventative Maintenance The nozzle gas flow sensor will require periodic maintenance to ensure a dependable service life. The following schedule is recommended. Shut off the air supply and disconnect the power cable when making adjustments. WEEKLY •...
Page 52: Ngfs Parts Diagram
INTELLIREAM ® E.7 NGFS Parts Diagram ITEM PART # DESCRIPTION IRE060005-00 Flow Cone IRE060006-00 Sensor Block IRE060010-00 Cover Plate IRE060012-00 Sensor IRE060007-00 Circuit Board IRE060014-00 Drain Plug IRE060015-99 Cable / Connector Assembly IRE060016-00 Nylon Brush (not shown) pg. 52...
Page 53: Warranty
The equipment must be returned, transportation charges prepaid with proof of purchase date, to an authorized service center or to NASARC. If a product warranty card has not been completed or proof of purchase is not available, the warranty will be deemed to become effective at the time the product leaves the factory authorized NASARC warehouse.
Page 54 Please fill in the Product Warranty Card below, cut out, and send to NASARC for full warranty registration of your product. Nasarc Technologies, Inc. 602 Colby Drive Waterloo, Ontario, N2V 1A2 Product Warranty Card Model Name: Product Name Serial Number:...