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 •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
OPERATOR’S MANUAL
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For use with machines having code number 11172
IM866
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
6
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 -
G
G
Clamp
Open
Closed
Lift
Top
Bottom
R R G
G
Y Y R
R
G
R
WELDING
ROBOT CELL
WIRES IN
CONTROL PANEL
0V
+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*
0V
+24V
Input
Circuitry
(<1mA)
ROBOT
POWER REAM
SOURCING
OUTPUT
0V
+24V
Input
Circuitry
ROBOT
POWER REAM
ACTIVE LOW
INPUT
0V
+24V
Input
Circuitry
ROBOT
POWER REAM
ACTIVE HIGH
INPUT*
0V
Max. current is 1A
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
G
G
R R R Y G
G/R
G/R
(3 sec.)
Power up sequence
(1 sec.)
I/O configuration
-Release setup
pushbutton
Y Y R R R
G
G
Y
Y
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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