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