Lincoln Electric IM866 User Manual

Date of Purchase:______________ Serial Number:_________________ Code Number:_________________ Model:________________________ Where Purchased:______________

POWER REAM August, 2010

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most

importantly, think before you act and be careful.

• Sales and Service through Subsidiaries and Distributors Worldwide •

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OPERATOR’S MANUAL

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For use with machines having code number 11172

IM866

POWER REAM

Safety Information - 3 -

Before installation and commissioning of the POWER REAM, 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 POWER REAM is constructed to be safe to operate provided

- Only authorized personnel shall perform installation, commissioning and maintenance and all safety precautions in these operating instructions shall be observed.

-The accident prevention regulations as well as the safety specifications referenced below are observed ANSI/RIA R15.06-1999 Industrial Robots and Robot Systems —Safety Requirements

-For additional safety information see references below

This product shall be integrated into a robot cell with independent safety system by plant engineering. Install 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 reamer, ensure all equipment in the area is locked out and disabled.

The torch-cleaning unit is to be used only for torch cleaning within the parameters of its technical specification.

Do not exceed the specified operating pressure of 80 PSI.

The torch-cleaning unit may only be operated with the cover closed when operated independently.

Keep hands away from unit while in operation. Keep hands away from the clamp and reamer operating space. Keep hands away from the wire cutter Keep eyes away from the sprayer

Shut off the air supply when making adjustment so that the equipment is not pressurized.

Additional fittings or accessories that are not offered from the manufacturer may only be installed with the approval from the manufacturer.

Do not use the reamer with corrosive or aggressive vapors or liquids without first obtaining approval from the manufacturer.

Ensure that there is nothing in the reamer unit when shutting down the system.

Warning and instruction labels from the unit are not to be removed or defaced.

For additional safety information, refer to the following publications:

ANSI STANDARD Z49.1, SAFETY IN WELDING AND CUTTING, American Welding Society, 550 LeJeune Rd. P.O. Box 351040, Miami, FL 33126

ANSI/RIA STANDARD R15.06-1999 Industrial Robots and Robot Systems —Safety Requirements

American National Standards Institute, 1430 Broadway, New York, NY 10018

Canadian Standards Association; Z434-03 Industrial Robots and Robot Systems – General Safety Requirements. 5060 Spectrum Way, Mississauga, Ontario, L4W 5N6, CANADA

POWER REAM

Safety Information - 4 -

Moving parts can crush and cut.

Keep hands away from the operating area of the reamer, 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.

Turn off power before servicing.

Turn off air supply and disconnect air supply hose before servicing.

Do not use damaged, frayed or deteriorated air hoses and fittings.

Maintain safe operating pressure (80 psi).

Safety Symbols used in this manual

POWER REAM

Table of Contents - 5 -

Page

Safety Information……………………………………………………….. 3 Specifications………………………………………………………………… 6 Installation…………………………………………………………………….. 7 I/O Configuration………………………………………………………….. 10 Robot Programming………………………………………………………. 12 Operation………………………………………………………………………. 15 Feature Setups………………………………………………………………. 16 Automatic I/O Configuration…………………………………………. 18 Maintenance and Troubleshooting………………………………… 19 Diagnostics…………………………………………………………………….. 20 Parts Replacement………………………………………………………… 21 Pneumatic Diagram………………………………………………………. 29 Electrical Diagram…………………………………………………………. 30 Parts Diagram………………………………………………………………… 32 Optional Accessories……………………………………………………… 35

POWER REAM

SPECIFICATIONS - 6 -

Pressure: 80 psi

Voltage: 24V DC

Speed: 1100 rpm

Flow: 15 scfm

Current: 0.5A DC

Power: 0.65 Hp

PNEUMATIC SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

REAMING SPECIFICATIONS

PHYSICAL DIMENSIONS

HEIGHT

19.50 in. (495mm)

without Reservoir /

24.90 in. (633mm) with Reservoir

WIDTH

8.47 in

228 mm

DEPTH

13.25 in

337 mm

NET WEIGHT

62 lbs.

28 kgs.

Nozzle inside diameter compatibility: 1/2‖, 5/8‖, 3/4‖

See section ―optional accessories‖ for product numbers

REAMING BIT SPECIFICATIONS

Minimum wire diameter: 0.030‖ (0.8mm)

Maximum wire diameter: 0.063‖ (1.6mm)

WIRE CUTTING SPECIFICATIONS

Use recommended water based anti spatter fluid in this product.

See section ―optional accessories‖ for product numbers.

Do not use oil based anti spatter fluid.

ANTI SPATTER FLUID SPECIFICATIONS

POWER REAM – (K2391-1)

Caution: Use Filtered (5 µm), Non Lubricated, Regulated Air

POWER REAM

INSTALLATION - 7 -

12.00

11.00

5.00

6.00

Mounting Hole (4x)

1.25

2.47

2.50

24.90

19.50

Installation:

Before starting installation work in the area of the robot, ensure for your personal safety that all protective measures have been taken and will remain in place while you are in the area of the robot.

Danger of accident when connecting the pneumatic or electrical supply!

-Ensure that the air supply and electrical power to the torch maintenance center are disconnected until the installation is complete.

-The torch maintenance center should be installed within the weld cell at a convenient location. Be sure to consider movable fixtures, the confines of the robot and maintenance personnel accessibility.

-Before operating the unit, ensure that the correct reaming bit for the torch is applied.

-Affix torch maintenance center base to sturdy platform using the four boltholes provided for 3/8‖

mounting hardware.

POWER REAM

INSTALLATION - 8 -

1 2 3 4 5

Wiring

1. 0V DC (WHT)

2. +24V DC (RED)

3. Complete (GRN)

4. Start (ORG)

5. Spray (BLK)

6. Error (BLU)

Interface Receptacle

Air Connection

Use only regulated, filtered, non lubricated air. Mount a 5 micron airline filter (not supplied) in the airline of the reamer. AIR SUPPLY REQUIREMENTS: 80 PSI at 15 SCFM. Connect the inlet supply line to the quick connect pneumatic fitting located on the side of the unit.

Electrical Connections

WARNING: Damage to equipment may occur if connected improperly. Only a qualified technician should perform the following operation.

-Secure the 6-pin connector into the receptacle on the base of the POWER REAM and feed the other end through a strain relief into the robot controller cabinet or other connection points on the robotic cell.

-Connect robot I/O signals according to the following description.

Electrical Diagram

Wire Color Name Description Red +24Vdc Power supply (+24Vdc, 0.5 amp)

White 0Vdc Power supply return.

It is recommended that power to the reamer be wired concurrent with robot servo power, interrupt-able by an E-stop condition.

Orange Start Robot output. Pulse this

output from the robot for

0.5sec to start the ream cycle.

Black Spray Robot output. Pulse this

output from the robot for approx. 0.5 sec while positioned over the sprayer.

To activate the Wire Cutter,

turn on both the start and spray outputs at the same time or subsequently.

Green Complete Robot input. The robot should

check this input before and after a reaming cycle.

Blue Error Robot input. The robot can

check this input after a reaming cycle to ensure error free operation. Refer to Diagnostics section for error codes.

The POWER REAM detects sinking or sourcing outputs from the robot and is capable of sinking or sourcing signals to the robot. Before connecting ensure I/O configuration is compatible with robot. POWER REAM factory setup is for robots with sinking outputs and active high inputs.

POWER REAM

INSTALLATION - 9 -

Clamp

Open

Closed

Lift

Top

Bottom

R R G

Y Y R

WELDING

ROBOT CELL

WIRES IN

CONTROL PANEL

+24V

*DI-3

*DO-3

*DO-4

*DI-4

POWER REAM

K2391-1 or similar

equipment

1 0V

2 +24V

3 Complete

4 Start

5 Spray

6 Error

2 WHITE

1 or 27 RED

4 GREEN

3 ORANGE

5 BLACK

6 BLUE

Power Ream to Lincoln Electric Welding Robot Cell

*These labels are for reference only.

Power Up Sequence: Once the unit is wired into

the robot and power is applied the LEDs will display the power up sequence (green – yellow – red) and then show positions of the cylinders according to the legend next to the LED window.

If the LEDs are not reporting the clamp open and the lift at the bottom then check the air pressure or position sensors. If the LEDs are flashing red or green check for start lock (see below). If the LEDs are flashing yellow ensure the setup pushbutton is not pressed or defective.

Start Lock: The start lock feature guards against a start signal present when the unit is powered up. If a

start signal is present, the POWER REAM will not cycle immediately after powering up. The LEDs will display the power up sequence (green-yellow-red) and then flash green / red if an output from the robot is present.

Robot Input: With the clamp open and the lift at the bottom, the ―complete‖ input to the robot will be on.

If it is not, the robot input type may need to be configured.

Robot Output: If by forcing on the ―Start‖ or ―Spray‖ output from the robot no action occurs, the robot

output type may need to be configured.

POWER REAM

I/O Configuration - 10 -

Sinking Output: 0V when active

Sourcing Output: +24V when active

Active Low Input: 0V when activated

Active High Input: +24V when activated

Fanuc robots use the following output methods

Process I/O: Sink Output Terminal I/O: Source Output Model A I/O: Source Output

ROBOT INPUT TYPE

+24V

ROBOT OUTPUT TYPE

Input Circuitry (< 1mA)

ROBOT

POWER REAM

SINKING OUTPUT*

+24V

Input Circuitry

(<1mA)

ROBOT

POWER REAM

SOURCING OUTPUT

+24V

Input Circuitry

ROBOT

POWER REAM

ACTIVE LOW INPUT

+24V

Input Circuitry

ROBOT

POWER REAM

ACTIVE HIGH INPUT*

Max. current is 1A

+24V

I/O Explanation

The terms sinking and sourcing define 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. An active low input is connected to the positive supply (+24V) to detect a sinking output.

A sourcing output provides the power to the load. Common terms used to describe sourcing devices include PNP, Open Emitter, Active High and IEC Positive Logic. An active high input is connected to 0V to detect a sourcing output.

Factory set options: Active high robot input. Sinking robot output.

POWER REAM

I/O Configuration - 11 -

Power Up

Active High/

Sinking

Active Low/

Sinking

Active High/

Sourcing

Active Low/

Sourcing

AUTO

Active Low/

Sinking

Reset button

PRESENT

Configuration

G G R

R R R Y G

G/R

(3 sec.)

Power up sequence (1 sec.)

I/O configuration

-Release setup pushbutton

Y Y R R R

The I/O types can be configured with the following procedure: Press the reset and setup pushbuttons, release the reset pushbutton and continue to hold the setup button for approximately 4 seconds (when the bottom LED is solid red).

During this time the LEDs will show the power-up sequence (green-yellow-red), then flash yellow for 3 seconds, then the bottom LED will turn solid red. Release the setup button when the bottom LED is solid red. Continuing to hold the setup button will allow access to further configurations as described in “Features Setup” section.

Upon releasing the setup push button, the lights will show the present I/O configuration. This is the first in the sequence of teachable configurations.

Subsequent pressing and releasing of the setup 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 indicator shows the robot input type (green = Active low, red = Active high*). The bottom indicator shows the robot output type (green = Sinking*, red = Sourcing).

* Factory setup conditions

Auto Active Low/Sinking is for the automatic I/O configuration, setup as active low/sinking

initially (see automatic I/O configuration section for details). Choosing one of the other configurations will disable this adaptability.

POWER REAM

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