Nasarc INTELLIREAM MP Owner'S Manual Download

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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

ELECTR IC

LINCOLN

MULTI-WELD 350

Nasarc Technologies, Inc.
602 Colby Drive
Waterloo, Ontario, N2V 1A2
Tel: (519) 747-0336, Fax: (519) 886-9022

WWW.NASARC.COM

INTELLIREAM

Summary of Contents for INTELLIREAM MP

Page 1: ...ds 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 LINCOLN MULTI WELD 350 N...

Page 2: ...Intelliream_IRMPOM 3b...

Page 3: ...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 oper...

Page 4: ...r 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...

Page 5: ...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...

Page 6: ...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 Co...

Page 7: ...C 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 w...

Page 8: ...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 rob...

Page 9: ...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 th...

Page 10: ...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...

Page 11: ...ler 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 oper...

Page 12: ...zzle 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...

Page 13: ...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 am...

Page 14: ...he 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 cl...

Page 15: ...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 programm...

Page 16: ...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 configu...

Page 17: ...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 configuratio...

Page 18: ...an 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...

Page 19: ...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...

Page 20: ...his 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 th...

Page 21: ...ed for one man operation during test Note The LEDs on the control module will flash red from this point on in the sequence to indicate CAUTION for the operating devices being tested 3 MOTOR function W...

Page 22: ...not working Insufficient air supply Air line cut disconnected or twisted Intelliream in setup mode Excessive spatter buildup Dry run mode selected Defective solenoid Check error codes Set to 80 PSI 15...

Page 23: ...ten or incorrect programmed position of the nozzle not allowing the reaming bit to extend to full depth Check air inlet pressure Check extending needle valve top needle valve on lift cylinder Check ex...

Page 24: ...point Refer to the diagram below for test point locations Lead Point Lead Point Description On Voltage Off Voltage 24V_AUX FLUID Fluid Solenoid 24 V 0 V 24V_AUX GRIP Grip Solenoid 24 V 0 V 24V_AUX LI...

Page 25: ...the reaming bit item 4 Insert the new reaming bit through the flat washer item 3 Insert the reaming bit into the ream rod Hold the reaming rod from rotating with a 5 8 wrench under the washer Tighten...

Page 26: ...back plate item 5 Phillips screwdriver Remove the belly plate item 6 from the module Disconnect the user interface ribbon tail item 7 from the PC board by pulling upwards on the black locking clip an...

Page 27: ...our button head cap screws item 5 to remove front cover item 6 5 32 hex drive Remove four socket head cap screws and lock washers item 7 from bottom plate of motor carriage 3 16 hex drive Remove two s...

Page 28: ...wdriver If wire cutter option is installed remove two 10 24 flat head socket cap screws item 6 to remove wedge plate 1 8 hex drive Unfasten cylinder rod item 7 from T nut item 8 3 8 wrench Loosen and...

Page 29: ...semble Intelliream Apply medium strength thread locker to item 4 8 7 Motor Lift Clamp Solenoid Replacement Note The right solenoid is for the motor the middle solenoid is for the lift cylinder and the...

Page 30: ...e in main unit to the outside Unfasten bottom nut item 3 of compression fitting 9 16 wrench DO NOT REMOVE Remove two 4 40 socket head cap screws item 4 from spray solenoid 3 32 hex drive Raise spray s...

Page 31: ...t head cap screws item 3 that secure fluid solenoid to spray plate 9 64 hex drive Remove fluid solenoid item 4 Follow steps in reverse order to reassemble unit Note if older solenoid is being replaced...

Page 32: ...hen hose 122 becomes pressurized the clamp moves into the closed position Air flows through lines 121 122 and out of the breather vent when opening or closing As the wire cutter Appendix B is driven b...

Page 33: ...INTELLIREAM MP pg 33 10 Electrical Diagram Closeup view of terminal block board...

Page 34: ...0007 03 Optional WIRE CUTTER GUARD 2 IRW010099 00 Optional WIRE CUTTER ASSEMBLY 3 IRG010099 00 CLAMP ASSEMBLY 4 IRE020099 09 STATUS LIGHT ASSEMBLY 5 IRG010099 01 CLAMP CYLINDER ASSEMBLY 6 IRW010099 01...

Page 35: ...LY 11 REAMING BIT SEE ACCESSORIES 12 IRS010099 01 SPRAY NOZZLE ASSEMBLY 12A IRS010003 00 SPRAY NOZZLE 13 IRD010099 02 DOME ASSEMBLY 13A IRD010002 03 ROD WIPER SEAL 14 IRC010009 00 TIMING BELT 15 IRC01...

Page 36: ...INTELLIREAM MP pg 36 11 3 Rear Components 20 21 22 22 23 24 25 26A 27 28 29 29A 29B 30 26B...

Page 37: ...ENOID 27 IRW010008 00 TCP CHECK PIN 28 IRE020099 08 RIBBON CABLE ASSEMBLY 29 IRE070099 01 RCM 2 CONTROL MODULE COMPLETE 29A IRE070099 05 RCM 2 Membrane Enclosure 29B IRE070001 01 PC BOARD RCM 2 30 IRE...

Page 38: ...used to describe sinking devices include NPN Open Collector Active Low and IEC Negative Logic An active low input is connected to the positive supply 24V to detect a sinking output A sourcing output p...

Page 39: ...cutter utilizes the clamping cylinder and sensor already present on every Intelliream MP device The Intelliream will perform a wire cut operation if both the Start and the Spray outputs are turned on...

Page 40: ...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 posi...

Page 41: ...ead cap screws item 1 Apply medium strength thread locker 9 64 hex drive Reconnect air and electrical supply B 3 Wire Cutter Troubleshooting Additional troubleshooting information can be found in the...

Page 42: ...on the side opposite the fluid reservoir as shown below The nozzle detect sensor replacement assembly can be ordered with part number IRE020099 13 C 1 Nozzle Detect Position Programming In order to pe...

Page 43: ...uld be active When this happens the Complete input will be on If while the Complete input is on a nozzle is brought within range of the nozzle detect sensor the Complete input will be turned off until...

Page 44: ...e hole at the top of the spray containment unit and record this position as the Spray Target position The sprayer has a built in post flow timer Airflow from the spray nozzle will be present for set t...

Page 45: ...disconnect the power cable when making adjustments WEEKLY Clean out mesh assembly Remove the top lid using the latches on the side Remove the mesh assembly and clean the spatter off of the top Check...

Page 46: ...60 PSI Flow 10 60 SCFH For use with CO2 AR or Mixed gas AR CO2 He ELECTRICAL SPECIFICATIONS Voltage 24 VDC Current 0 01 Amp DC PHYSICAL DIMEMSIONS HEIGHT 2 5 in 64 mm WIDTH 2 5 in 64 mm LENGTH 2 8 in...

Page 47: ...has been purchased When no error is present i e the Intelliream is in its waiting state the Error signal will turn on when gas flows through the Nozzle Gas Flow Sensor at the preset flow rate E 3 NGF...

Page 48: ...low the nozzle to fully contact the cone for optimal flow transfer 3 Remove the side plate to expose the circuit board 4 Check for sensor power supply on LED4 is ON 5 Turn on gas flow through the nozz...

Page 49: ...ntelliream Error from previous Cycle 2 Gas flow turn on undetected 3 Gas flow turn off undetected Approach Position the nozzle is in line with and directly above the cone Target Position The nozzle li...

Page 50: ...m Error from previous Cycle 2 Nozzle presence undetected 3 Gas flow turn on undetected 4 Gas flow turn off undetected 5 Nozzle presence unexpected Move to Nozzle Flow Sense Target position Error on Ha...

Page 51: ...life The following schedule is recommended Shut off the air supply and disconnect the power cable when making adjustments WEEKLY Clean the inside face of the flow cone item 1 to remove surface buildu...

Page 52: ...CRIPTION 1 IRE060005 00 Flow Cone 2 IRE060006 00 Sensor Block 3 IRE060010 00 Cover Plate 4 IRE060012 00 Sensor 5 IRE060007 00 Circuit Board 6 IRE060014 00 Drain Plug 7 IRE060015 99 Cable Connector Ass...

Page 53: ...f of purchase is not available the warranty will be deemed to become effective at the time the product leaves the factory authorized NASARC warehouse Warranty repair service does not extend the period...

Page 54: ...y Card Model Name Product Name Serial Number ____________________ Purchase Date ____________________ MM DD YYYY Name ____________________ Address __________________________________ ___________________...

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