Nasarc INTELLIREAM MP User manual

Intelliream_IRMPOM-3b
June, 2022
OWNERS MANUAL
Effective with serial No. IR2006001 & following. “U.S. Patent No.: 7,952,052”
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
ELECTRIC
LINCOLN®MULTI-WELD 350
Nasarc Technologies, Inc.
602 Colby Drive
Waterloo, Ontario, N2V 1A2
Tel: [phone], Fax: [phone]
WWW.NASARC.COM
INTELLIREAM®MP

Intelliream_IRMPOM-3b

Safety Information
pg. 3
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:
•Only authorized personnel may perform installation, commissioning, and maintenance in observance of all
safety precautions contained in these operating instructions.
•Accident prevention regulations, as well as the safety specifications referenced below are observed.
•ANSI/RIA R15.06-2012 Industrial Robots and Robot Systems –Safety Requirements
For additional safety information see references below:
This product shall be integrated into a robot cell with an independent safety system. This product shall be installed
within a secured area, which is only to be entered by qualified personnel for maintenance work or robot
programming.
Before assembling, adjusting, or working with the Intelliream®, ensure all equipment in the area is locked out and
disabled.
The Intelliream®is to be used only for torch cleaning within the technical operating specifications outlined in this
document.
Do not exceed the specified operating pressure of 80 PSI.
Keep hands away from Intelliream®while in operation.
Keep hands away from the clamp and Intelliream®operating space.
Keep hands away from the wire cutter.
Keep eyes away from the sprayer.
Protective eye-wear should be worn at all times while working in the vicinity of the Intelliream®.
Protective gloves should be worn at all times when maintaining the Intelliream®.
Disconnect the air and power supplies when adjusting the Intelliream®.
Use only OEM parts and accessories.
Do not use corrosive or aggressive chemicals without first obtaining approval from the manufacturer.
Do not remove or deface warning and instruction labels on the Intelliream®.
For additional safety information, refer to the following publications:
•ANSI/RIA R15.06-2012 Industrial Robots and Robot Systems –Safety Requirements
Robotic Industries Association, 900 Victors Way, Suite 140, Ann Arbor, Michigan, USA 48108
•ANSI Z49.1:2012 Safety in Welding, Cutting, and Allied Processes,
American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126
•CAN/CSA-Z434-14 Industrial robots and robot systems,
Canadian Standards Association, 5060 Spectrum Way, Mississauga, Ontario, L4W 5N6, CANADA

Safety Information
pg. 4
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.
Disconnect air supply before servicing.
Do not use damaged, frayed, or deteriorated air hoses and fittings.
Maintain safe operating pressure (80 psi).

INTELLIREAM®MP
pg. 5
Table of Contents
1. Specifications.............................................................................................................................................7
2. Installation..................................................................................................................................................8
2.1. Air Connection.....................................................................................................................................9
2.2. Electrical Connection...........................................................................................................................9
3. Operation .................................................................................................................................................10
3.1. User Interface....................................................................................................................................10
3.2. Power-Up..........................................................................................................................................10
3.3. Manual Operation..............................................................................................................................11
3.4. Automatic Operation..........................................................................................................................12
4. Robot Programming .................................................................................................................................13
4.1. Position Programming.......................................................................................................................14
5. Settings....................................................................................................................................................16
5.1. I/O Configuration...............................................................................................................................17
5.2. Spray.................................................................................................................................................17
5.3. Extras................................................................................................................................................18
5.4. Running Mode...................................................................................................................................19
5.5. Motor Diagnostic ...............................................................................................................................20
6. Preventative Maintenance........................................................................................................................22
7. Troubleshooting........................................................................................................................................22
7.1. Error Codes.......................................................................................................................................23
7.2. Advanced Troubleshooting................................................................................................................24
8. Parts Replacement...................................................................................................................................25
8.1. Reaming Bit Replacement.................................................................................................................25
8.2. Spray Nozzle Replacement...............................................................................................................25
8.3. PC Board Replacement.....................................................................................................................26
8.4. Belt Replacement..............................................................................................................................27
8.5. Clamp Cylinder Replacement............................................................................................................28
8.6. Air Motor Replacement......................................................................................................................29
8.7. Motor/Lift/Clamp Solenoid Replacement............................................................................................29
8.8. Spray Solenoid Replacement............................................................................................................30
8.9. Fluid Solenoid Replacement..............................................................................................................31
9. Pneumatic Diagram..................................................................................................................................32

INTELLIREAM®MP
pg. 6
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......................................................................................................................39
B.2 Wire Cutter Replacement......................................................................................................................41
B.3 Wire Cutter Troubleshooting..................................................................................................................41
Appendix C: Nozzle Detect Sensor..................................................................................................................42
C.1 Nozzle Detect Position Programming....................................................................................................42
Appendix D: Spray Containment Unit ..............................................................................................................44
D.1 Spray Position Programming.................................................................................................................44
D.1 Spray Nozzle Replacement...................................................................................................................44
D.2 Spray Containment Parts Diagram........................................................................................................45
D.3 Spray Containment Preventative Maintenance......................................................................................45
Appendix E: Nozzle Gas Flow Sensor (NGFS)................................................................................................46
E.1 NGFS Specifications .............................................................................................................................46
E.2 NGFS Integration ..................................................................................................................................46
E.3 NGFS Operation....................................................................................................................................47
E.4 NGFS Setup..........................................................................................................................................48
E.5 NGFS Robot Programming....................................................................................................................49
E.5 NGFS Robot Programming with Nozzle Detect .....................................................................................50
E.6 NGFS Preventative Maintenance ..........................................................................................................51
E.7 NGFS Parts Diagram.............................................................................................................................52
Warranty..........................................................................................................................................................53

INTELLIREAM®MP
pg. 7
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” (1.6mm)
ANTI SPATTER FLUID SPECIFICATIONS
Use recommended water based anti-spatter fluid in this product.
Do not use oil based anti-spatter fluid.
PHYSICAL DIMEMSIONS
HEIGHT
25.5 in., 648mm
(with Reservoir)
WIDTH
8 in.
203mm
DEPTH
12.1 in.
308 mm
NET WEIGHT
58 lbs
26.3 kg

INTELLIREAM®MP
pg. 8
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.
- The Intelliream®should be installed within the weld cell at a convenient location. Be sure to consider movable
fixtures, robot envelope, and maintenance personnel accessibility.
- Affix Intelliream base to sturdy platform using the four bolt holes provided for 3/8” mounting hardware.
- Before operating the Intelliream®, ensure that the correct reaming bit for the torch nozzle is installed.
Bottom View
Side View

INTELLIREAM®MP
pg. 9
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
pneumatic fitting located at the side of the Intelliream®.
2.2. Electrical Connection
Damage to equipment may occur if connected improperly. Only a qualified technician should perform the
following connections. Secure the 6-pin connector by threading the connector to the receptacle near the base
of the Intelliream®. The Intelliream®is powered through this connection and requires a 24 VDC, 0.75 Amp DC
power supply. It is recommended that power to the Intelliream®(both +24VDC and 0VDC) is wired to safe
power (i.e. concurrent with robot servo power), interruptible by an emergency stop condition.
Signal Description
Connect cable wires according to the following description
Wire Colour
Name
Description
Red
+24 VDC
Power supply (+24 VDC,
0.75 Amp DC)
White
0 VDC
Power supply return.
Orange
Start1
Robot output. Pulse this output for
a minimum of 0.5 sec to start the
ream cycle.
Black
Spray1
Robot output. Pulse this output for
a minimum of 0.5 sec while
positioned over the sprayer.
Green
Complete2
Robot input. The robot should
check this input before and after a
reaming cycle.
Blue
Error3
Robot input. The robot can check
this input after a reaming cycle to
ensure error free operation. Refer
to the “Troubleshooting” section
for error codes.
The INTELLIREAM®MP automatically detects sinking or sourcing inputs and outputs from the controller. It is
not necessary to reconfigure the inputs and outputs of the INTELLIREAM®MP. Refer to the “I/O
Configuration”, section for more details.
1NOTE: To activate the wire cutter, turn on both the “Start” and “Spray” outputs simultaneously. For further information
regarding the wire cutter operation, refer to Appendix B: Wire Cutter
2NOTE: The “Complete” signal has additional functionality when the nozzle detect option has been purchased. For further
information regarding the nozzle detect option, see Appendix C: Nozzle Detect Sensor
3NOTE: The “Error” signal functionality is changed with the Nozzle Gas Flow Sensor option installed, see Appendix E:
Nozzle Gas Flow Sensor (NGFS).
1
2
3
4
5
6
Interface Receptacle
Wiring
1. 0 VDC (WHT)
2. +24 VDC (RED)
3. Complete (GRN)
4. Start (ORG)
5. Spray (BLK)
6. Error (BLU)

INTELLIREAM®MP
pg. 10
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:
•Manual operation of the clamp, lift and spray system.
•The status of each solenoid is shown on its respective button.
•Monitor sensor operation of the clamp and lift reed switches
•Input / Output configuration and other feature settings
•Control logic reset
Item
Name
Description
1
SETTINGS
Settings mode and status
2
RESET
Device and control logic reset
3
CLAMP
Solenoid activation and status
4
CLAMP
SENSOR
Status (Red / Green)
5
LIFT
Solenoid activation and status
6
LIFT Sensor
Status (Red / Amber / Green)
7
SPRAY
Solenoid activation and status
3.2. Power-Up
Once the Intelliream®is wired into the controller and power is applied, the device status LEDs will display the
power up sequence (green –yellow –red) and then show positions of the cylinders according to the legend
next to the LEDs.
Power Up LED check
If the sensor LEDs are not reporting the clamp open and the lift at the bottom, then check the air pressure or
sensor positions. If the sensor LEDs are flashing yellow and green check for start lock (see below). If the
LEDs are flashing yellow, ensure the settings pushbutton is not pressed or defective.
1
2
3
4
6
5
7
G
Y
R
G
G
Y
R
G

INTELLIREAM®MP
pg. 11
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®
MP will enter a start lock mode instead of cycling immediately and the “Error” input will be turned on. During
power up, the device status LEDs will display the power up sequence (green-yellow-red) and then flash
yellow/green if an output from the controller is present. To resume operation, turn all controller outputs to the
Intelliream®off.
Robot Input: If the device has completed the power up sequence, and is not in cycle, then with the clamp
open, and lift at the bottom, the “Complete” input to the robot controller will be on. Similarly, if an error has
occurred during a machine operation, the “Error” input will be on.
Robot Output: If no action occurs by turning on the “Start” or “Spray” output from the robot controller, check
the wiring of the sourcing outputs at the controller.
3.3. Manual Operation
Operation of the clamp, lift and spray valves is possible with the buttons on the user interface. The green LED
indicator at the top left shows button feedback and solenoid operation. The sensor LED indicators to the right
indicate the sensor feedback of the corresponding device.
Note: a “Local Lockout” mode is enabled for 5 seconds following the press of any of these buttons. Robot I/O
is disabled and the LEDs blink slowly during this time. The lockout will cancel itself after 5 seconds or if the
“Settings” button is pressed. 1 second before the lockout is cancelled, the user interface LEDs will be turned
on to indicate the lockout expiry.
WARNING: the clamp will operate under this condition.
KEEP HANDS CLEAR of the operating space of the clamp
and wire cutter. This device is intended for one-man
operation during setup.
WARNING: the lift cylinder will operate under this
condition. KEEP HANDS CLEAR of the operating space of
the reaming bit. This device is intended for one-m an
operation during setup.
WARNING: the spray will operate under this condition. KEEP FACE
and HANDS CLEAR of the operating space of the sprayer. This device
is intended for one-man operation during setup.

INTELLIREAM®MP
pg. 12
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.
1
2
3
4
5
6
7
Ready
Clamp
Closed
Raising
Ream Bit
Ream Bit
at Top
Lowering
Ream Bit
Ream Bit
at Bottom
Clamp
Open
“Start” Output
Pulse
0.5s
Off
“Complete” Input
On
On
Off
On
The above chart shows the robot inputs and outputs as the sequence progresses.
Automatic Retry
If excessive spatter is built up in the nozzle, or the programmed position of the nozzle is off center not allowing
the reaming bit to extend to the full depth inside the nozzle within a specific amount of time, the
INTELLIREAM®MP will automatically perform a single retry.
Cycle Optimization
The lift rate of the reaming bit will determine how many reaming
revolutions will occur within the nozzle. This setting should be
adjusted based on the amount of spatter buildup in the nozzle
between reaming cycles. More spatter buildup will require a
slower lift rate. Less spatter buildup will allow a faster lift rate.
To set the lift rate, remove the front cover and adjust the top
needle valve. Turning clockwise will decrease the lift rate (for
more spatter removal), and turning counter clockwise will
increase the lift rate (for a shorter cycle time).
To set the retracting rate, adjust the bottom needle valve.
Turning clockwise will decrease the retracting rate, and turning
counter clockwise will increase the retracting rate.
G
R
R
R
R
R
G
G
G
Y
R
Y
G
G

INTELLIREAM®MP
pg. 13
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.
.
Error
(At any time)
“Error” input on
YES
Move to “Spray” position
Turn “Spray” output on
Wait for desired amount of spray time
Turn “Spray” output off
Finished with ream cycle,
move to next position
NO
Move to “Ream” position
“Complete” input on
Pulse “Start” output for 0.5 sec
Wait for “Complete” input to turn off
Wait for “Complete” input to turn on
YES

INTELLIREAM®MP
pg. 14
4.1. Position Programming
The INTELLIREAM®MP features a “no trial, no error” position programming technique as described below:
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. This device is intended for one-man operation during
setup.
Once the reaming bit is at the top position (“LIFT” LED is red), release the “Settings” button.
2. Using the robot, move the torch nozzle into the clamp so the reaming bit is inset to the full depth required
inside the nozzle.
3. Press and release the “CLAMP” button to verify the clamp engages the cylindrical body of the nozzle
equally, and the nozzle does not change orientation or position when clamped.
WARNING: the clamp will operate under this condition. KEEP HANDS
CLEAR of the operating space of the clamp and wire cutter. This device is
intended for one-man operation during setup.
4. Register this position in the robot controller using a fine position level as the “Ream” position described in
the programming chart above.
Ream Position

INTELLIREAM®MP
pg. 15
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.
6. Spray Position: Center the nozzle approximately 25mm above the spray nozzle. Record this position as the
“Spray” position described in the programming chart above. The sprayer may use a built-in post-flow timer of 0,
¼, ½, or 1 second. Airflow from the spray nozzle will be present for the post flow time after the spray output
and corresponding fluid valve have been turned off.
Spray Position

INTELLIREAM®MP
pg. 16
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.
>3 sec
(I/O
config)
>5 sec
(Spray)
>7 sec
(Extras)
>9 sec
(Mode)
>11 sec
(Diagnostic)
>13 sec
Note: The default setting for each configuration is first and last in each sequence.
R
R
Y
R
Y
G
R
Y
(( Y ))
(( Y ))

INTELLIREAM®MP
pg. 17
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).
Upon releasing the settings button, the sensor LEDs will show the present I/O configuration. This is the first in
the sequence of teachable configurations. Subsequent pressing and releasing of the settings button will
sequence the following configurations in order of appearance. To register the desired configuration, press the
reset button when that configuration is displayed.
The top LED shows the controller input type (green = Active low, red = Active high).
The bottom LED shows the controller output type (green = Sinking, red = Sourcing).
Present
Input
Active
High
Active
Low
Active
High
Active
Low
Auto
Clamp
status
Present
Output
Sinking
Sinking
Sourcing
Sourcing
Auto
Lift
status
Done
AUTO: Enable the automatic I/O configuration feature. The sinking and sourcing outputs in the Intelliream®are
short circuit protected with integrated over-current circuitry between 0.65-1.4 Amp DC. If a short circuit occurs,
error code #8 will flash. (see Maintenance and Troubleshooting section 7).
5.2. Spray
The sprayer has a built-in post-flow timer. Airflow from the spray nozzle will be present for set time (0, ½ or 1
second) after the spray output and corresponding fluid valve have been turned off.
Follow the steps outlined in section 5 to access the spray settings menu. Upon releasing the settings button,
the LEDs will show the current spray setting. This is the first in the sequence of teachable configurations.
Subsequent pressing and releasing of the setting button will sequence the following configurations in order of
appearance. To register the desired configuration, press the reset button when that configuration is displayed.
R/G
R
G
R
G
Y
R/G
R/G
G
G
R
R
Y
R/G
Press &
Release
(>3sec)

INTELLIREAM®MP
pg. 18
Default
0 sec
¼ sec
½ sec
1 sec
Clamp
status
Lift
status
Done
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. Using this technique, the spatter ring is not pushed into the nozzle
where it may become lodged.
The features in the “extras” menu can be configured by the following procedure.
Follow the steps outlined above to access the “extras” 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.
Subsequent pressing and releasing of the settings button will sequence the following configurations in order of
appearance. To register the desired configuration, press the reset button when that configuration is displayed.
Blow-off:
OFF
ON
OFF
ON
OFF
Clamp
status
De-Ringer
OFF
OFF
ON
ON
OFF
Lift
status
Done
R/G
R
G
R
G
R/G
R/G
R
R
G
G
R/G
R
G
R
G
R
R/G
R
R
G
G
R
R/G
(>7sec)
Press &
Release
(>5sec)
Press &
Release

INTELLIREAM®MP
pg. 19
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. Auto Retry is disabled in this and the following modes.
Open: Bypass the "extended" and "retracted" sensor. The robot must hold the start signal on for the reaming
time and hold the robot in the clamp until the reaming bit is fully retracted.
Blind: Bypass all sensors. The robot must hold the start signal on for the ream time and hold the torch in the
jaws until the reaming bit is fully retracted and the clamp is fully opened.
Mode configuration: A specific running mode can be configured by the following procedure.
Follow the steps outlined above to access the mode configuration menu. Upon releasing the settings button,
the LEDs will flash green on top and bottom. This is the first in the sequence of teachable configurations.
Subsequent pressing and releasing of the settings button will sequence the following configurations in order of
appearance. To register the desired configuration, press the reset button when that configuration is displayed.
Mode
Mode
Automatic
Dry Run
Timed
Open
Blind
Auto
Clamp
status
Lift
status
Done
G
Y
G
G
R
G
R/G
G
G
G
Y
R
R
G
R/G
Press &
Release
(>9sec)

INTELLIREAM®MP
pg. 20
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. Subsequent pressing and releasing of the settings button will sequence the following
configurations in order of appearance. To register the desired configuration, press the reset button when that
configuration is displayed.
Diagnostic
Off
On
OFF
Clamp
status
Lift
status
Done
Motor Diagnostic Configurations:
Off: This feature is disabled.
On: This feature is enabled.
Note: Running the motor diagnostic will disable the feature so that it can only be run once each time it is
enabled.
Motor Diagnostic Operation: Once the reset button is released, the unit will display the power-up sequence.
Follow this procedure to test the air motor manually:
1. LIFT function: Press and hold the “LIFT”button to raise the reaming bit (without spinning) until it
reaches the top position. Check that the “LIFT”LED on the control module is green.
WARNING: the lift 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 test.
Once the Intelliream®is at the top position (“LIFT” LED is green), release the “LIFT” button and the reaming
bit will maintain its position.
R
R
G
R
R/G
R
R
G
R
R/G
Press &
Release
(>11sec)