October 2022

INTELLIREAM® DD-EIP
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

OWNER’S MANUAL
Effective with serial No. IR2204045 & following. “U.S. Patent No.: 7,952,052”

Nasarc Technologies, Inc.

602 Colby Drive
Waterloo, Ontario, N2V 1A2
Tel: (519) 747-0336, Fax: (519) 886-9022
WWW.NASARC.COM

IRDDeipOM-1
IRDDeipOM-1
Safety Information
Before installation and commissioning of the INTELLIREAM® DD-EIP, 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® DD-EIP 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.

Before assembling, adjusting, or working with the INTELLIREAM® DD-EIP, ensure all equipment in the area is
disabled.

The INTELLIREAM® DD-EIP 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® DD-EIP while in operation.

Keep hands away from the clamp and INTELLIREAM® DD-EIP operating space.

Keep hands away from the wire cutter.

Keep eyes away from the sprayer.

Protective eyewear should be worn at all times while working in the vicinity of the INTELLIREAM® DD-EIP.

Protective gloves should be worn at all times when maintaining the INTELLIREAM® DD-EIP.

Disconnect the air and power supplies when adjusting the INTELLIREAM® DD-EIP.
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® DD-EIP.

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

pg. 3
Safety Information

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).

pg. 4
INTELLIREAM DD-EIP ®

Table of Contents
1. Specifications ............................................................................................................................................. 7
2. Installation .................................................................................................................................................. 8
2.1. Baseplate Dimensions ......................................................................................................................... 9
2.2. Air Connection ..................................................................................................................................... 9
2.3. Electrical Connection ......................................................................................................................... 10
3. Operation ................................................................................................................................................. 11
3.1. User Interface .................................................................................................................................... 11
3.2. Power-Up .......................................................................................................................................... 11
3.3. Network Status Indicators: ................................................................................................................. 12
3.4. Manual Operation .............................................................................................................................. 13
4. Network I/O .............................................................................................................................................. 14
4.1. Network Setup ................................................................................................................................... 14
4.2. Reamer Input Bytes (PLC Output) ..................................................................................................... 16
4.3. Reamer Output Bytes (PLC Input) ..................................................................................................... 18
5. Reamer .................................................................................................................................................... 20
5.1. Automatic Operation .......................................................................................................................... 20
5.2. Status Light ....................................................................................................................................... 21
5.3. Position Programming ....................................................................................................................... 21
5.1. Reaming Bit Replacement ................................................................................................................. 22
6. Sprayer..................................................................................................................................................... 23
6.1. Spray Position Programming ............................................................................................................. 23
6.2. Spray Adjustment .............................................................................................................................. 23
6.3. Spray Nozzle Replacement ............................................................................................................... 24
7. Ream and Spray Sequence Flow Chart .................................................................................................... 25
8. Wire Cutter Option .................................................................................................................................... 26
8.1. Wire Cutter Position Programming .................................................................................................... 26
8.2. Wire Cutter Sequence Flow Chart ..................................................................................................... 27
9. Nozzle Detect Sensor Option ................................................................................................................... 28
9.1. Nozzle Detect Position Programming ................................................................................................ 28
9.1. Nozzle Detect Sequence Flow Chart ................................................................................................. 29
10. Nozzle Gas Flow Sensor (NGFS) Option .................................................................................................. 30
10.1. NGFS Specifications ...................................................................................................................... 30
10.2. NGFS Operation ............................................................................................................................ 30
10.3. NGFS Setup .................................................................................................................................. 31
10.4. NGFS Robot Position and Sequence Flow Chart ........................................................................... 32
11. Settings .................................................................................................................................................... 33
11.1. I/O Configuration ............................................................................................................................ 33
11.2. Spray ............................................................................................................................................. 34
11.3. Extras ............................................................................................................................................ 34

pg. 5
INTELLIREAM DD-EIP ®

11.4. Running Mode ............................................................................................................................... 35

11.5. Motor Diagnostic ............................................................................................................................ 36
12. Web Server Interface (DD-EIP version only)............................................................................................. 38
12.1. Interface Screen ............................................................................................................................ 38
12.2. Settings Screen ............................................................................................................................. 40
12.3. Statistics Screen ............................................................................................................................ 42
12.4. Consumables Screen ..................................................................................................................... 43
12.5. IP address configuration ................................................................................................................ 44
13. Preventative Maintenance ........................................................................................................................ 45
14. Troubleshooting ........................................................................................................................................ 46
14.1. Error Codes ................................................................................................................................... 47
14.2. Advanced Troubleshooting ............................................................................................................ 48
15. Pneumatic Components ........................................................................................................................... 49
16. Electrical Diagram .................................................................................................................................... 50
17. Replacement Parts List ............................................................................................................................ 51
Warranty .......................................................................................................................................................... 55

pg. 6
INTELLIREAM DD-EIP®

1. Specifications

PNEUMATIC SPECIFICATIONS
Pressure: 80 PSI Flow: 18 SCFM
Caution: Use Filtered (5um), Non-Lubricated, Regulated Air

ELECTRICAL SPECIFICATIONS
Voltage: 24 VDC +/- 10% Current: 0.75 Amp DC

REAMING SPECIFICATIONS
Speed: 320 RPM Power: 0.50 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 DIMENSIONS
HEIGHT WIDTH DEPTH NET WEIGHT
19 in. 10.5 in. 12 in. 44 lbs
483 mm 267 mm 305 mm 20 kg

pg. 7
INTELLIREAM DD-EIP ®

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® DD-EIP are disconnected until the
installation is complete.
- The INTELLIREAM® DD-EIP should be installed within the weld cell at a convenient location. Be sure to
consider movable fixtures, robot envelope, and maintenance personnel accessibility.
- If using the mounting box with spatter discharge tray (optional):
- Affix the mounting box to a sturdy platform using the four bolt holes provided for 1/4”-20 Socket Head
Cap Screw (SHCS) mounting hardware.
- Affix INTELLIREAM® DD-EIP to the mounting box platform using mounting hardware provided.
- If not using the mounting box:
- Note: spatter discharge may be managed more effectively if allowed to pass through the hole in the base
plate to a customer supplied catchment device (see diagram below).
- Affix the INTELLIREAM® DD-EIP to a sturdy platform using the four bolt holes provided for 3/8” mounting
hardware.
- Before operating the INTELLIREAM® DD-EIP, ensure that the correct reaming bit for the torch nozzle is
installed.

Cobot guard

18.5”
15.3”

10.5”

3.0”
Mounting Box

12.0”
Top View Side View
with cobot guard option
and mounting box option

pg. 8
INTELLIREAM DD-EIP ®

2.1. Baseplate Dimensions

5.0” 5.0”

1.0” 1.0” 6.0”

6.0”
3.3”

4.25”

10.0” 10.0”

0.88”

1.0” 1.0”

Mounting Box Bottom View Reamer Base Bottom View

2.2. Air Connection

Use only regulated, filtered, non-lubricated air. Mount a 5-micron airline filter (not supplied) in the airline to the
INTELLIREAM® DD-EIP.
AIR SUPPLY REQUIREMENTS: 80 PSI at 22 SCFM. Connect the inlet supply line to the quick connect
pneumatic fitting located at the side of the INTELLIREAM® DD-EIP.

pg. 9
INTELLIREAM DD-EIP ®

2.3. Electrical Connection

WARNING: Damage to equipment may occur if connected improperly. Only a qualified technician should
perform the following operation.Secure the connector into the receptacle at the side of the Intelliream®DD-EIP.
Feed the other end through a strain relief into the robot controller cabinet.
Connect Robot/PLC power via the 4-pin cable according to the following description.

Colour Name Description

Brown +24VDC Connect to power supply (+)
Actuator 24VDC, 1.0A min through safety
circuit to disable solenoid power
when required.

White +24VDC Connect to power supply (+)

Control 24VDC, 0.5A min for controls and
sensor power.
Blue 0VDC Connect to power supply (-) 0VDC,
Control 0.5A min for controls and sensor
power.

Black 0VDC Connect to power supply (-) 0VDC,

Actuator 1.0A min through safety circuit to
disable solenoid power when
required.

pg. 10
INTELLIREAM DD-EIP ®

3. Operation
3.1. User Interface
The user interface is part of the Reamer Control Module (RCM-2N) and can be found on the electrical supply
side of the INTELLIREAM® DD-EIP (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
1 2
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 4

8 Network Status Network Status LED indicators

(DD-EIP version only)
5 6

7
8

3.2. Power-Up
Once the INTELLIREAM® DD-EIP 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

G Y R G

G Y R G

pg. 11
INTELLIREAM DD-EIP ®

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.

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® DD-EIP powers up, the
INTELLIREAM® DD-EIP will enter a start lock mode instead of cycling immediately and the “Error” input will
turn 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 off all controller
outputs to the INTELLIREAM® DD-EIP.

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.

3.3. Network Status Indicators:

At power up the network status indicators run a self-check sequence to show red/green functionality of each
LED. After the power up sequence the network status status indicators will operate according to the description
in the table below.

LNK/ DATA
ACT RATE

MODULE NETWORK
STATUS STATUS

LED State Status

Off Device Not Powered
Link / Green Module connected to Ethernet Network
Activity Green, flashing RX / TX activity
Alternating Red / Green Self-Test in progress
Off 10 Mbps operation
Data
Rate
Green 100 Mbps operation
Alternating Red / Green Self-Test in progress
Off Device not powered
Green Device in EtherNet / IP mode
Green, flashing Device in EtherNet / IP idle mode or no connection
Module
Status
established
Red Major Fault
Red, flashing Minor Fault
Alternating Red / Green Self-Test in progress
Off No power or no IP address
Green EtherNet / IP connection established
Green, flashing No EtherNet / IP connections established
Network
Status
Red Duplicate IP address detected
Red, flashing One of several EtherNet / IP connections has timed
out
Alternating Red / Green Self-Test in progress

pg. 12
INTELLIREAM DD-EIP ®

3.4. 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. One 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-man
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.

pg. 13
INTELLIREAM DD-EIP ®

4. Network I/O
Network I/O is communicated through the Ethernet/IP gateway. This communication module provides
integration in any ethernet based LAN via Ethernet/IP or HTTP protocols.
Features:

• 10 and 100mbit operation, Full and Half Duplex

• Up to 144 bytes of fieldbus I/O in each direction
• Adapter Class Functionality
• UCMM Capable, up to 5 explicit server connections

Ethernet/IP Connection Parameters

Input Size 128 bytes
Output Size 128 Bytes
Input Instance (aka Input Assembly) 100
Output Instance (aka Output Assembly) 150

4.1. Network Setup

Outlined below is a procedure that offers complete access to all of the network parameters. To perform the
procedure, the following items are required:
- A PC with the “Anybus IPconfig” application installed. Anybus IPconfig may be downloaded and
installed free of charge from.
http://www.nasarc.com/downloads/Intelliream/hms-IPConfig.zip
- A CAT-5E or Cat-6 cable.
- A network switch or cross-over cable (dependent on hardware setup).
The steps to configure the IP settings for the INTELLIREAM® DD-EIP outside of the standard range are:
1. While connecting directly to the INTELLIREAM® DD-EIP, a static IP address must be assigned to the
PC in the same range (first three octets) as the desired IP address to be assigned to the reamer. The
subnet mask should be set to 255.255.255.0. The gateway address can be set to 0.0.0.0. Refer to
online documentation for the PC and operating system on assigning a static IP.
2. Connect the PC to the INTELLIREAM® DD-EIP through the appropriate networking hardware.
3. Start the Anybus IPconfig application installed
on the PC.
4. The network connected to the PC will be
scanned for HMS devices. If none are found
then double check all of the connections, and
the network parameters configured. After
correcting any connectivity issues, click the
“Scan” button inside the application.

pg. 14
INTELLIREAM DD-EIP®

5. Any HMS devices that are discovered will appear in the application window. Select the device to
configure, and then right click to open the configuration menu.

6. In the configuration dialog box, set the IP address, Subnet mask, and Default gateway as desired.
Ensure that DHCP is set to “Off”. Click “Set”. Note that if configuring the INTELLIREAM® DD-EIP to
communicate with a different gateway than the default, 0.0.0.0, communication with the INTELLIREAM®
DD-EIP until the PC is reconfigured to operate on the same gateway

7. To validate the settings, cycle the 24V power to the INTELLIREAM® DD-EIP. Configure the PC to use
the same parameters as the INTELLIREAM® DD-EIP’s new configuration. Ensure that the PC and
Intelliream® DD-EIP have unique IP addresses. Use the IPconfig tool to ensure that the new settings
have been applied correctly by scanning for the device again.

pg. 15
INTELLIREAM DD-EIP ®

4.2. Reamer Input Bytes (PLC Output)

Below is the network data that will be exchanged between the PLC and the INTELLIREAM® DD-EIP.

Name Size
Address
Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0 (bytes)
Command Bits
0 Reset 1
Unused Blow-Off Dry-Run Wire Cut Spray De-Ring Ream
Error
1 Automatic Retry Maximum (0-3) 1
2 Post Flow Index (0-3) 1
Remote Activation Bits
3 Status Fluid Air Spray Air Motor Lift Clamp Remote 1
Unused
LED Solenoid Solenoid Solenoid Solenoid Solenoid Mode
Sensor Bypass Bits
4 1
Unused Unused De-Ringer Unused Extended Retracted Unused Opened
Reserved
5 1
Reserved Reserved Reserved Unused Unused Reserved Reserved Reserved

Input Address 0: Command Bits

b7 b6 b5 b4 b3 b2 b1 b0
Teach Reset
Blow-Off Dry-Run Wire Cut Spray De-Ring Ream
NGFS Error

Activate full ream cycle. This signal can be pulsed for ½ second or
maintained. If the signal is pulsed, the reamer will perform a full ream
cycle including de-ring and automatic retry with no dwell time at the top of
b0 Ream
its stroke. If the signal is maintained, the reamer will go to the top of
stroke including de-ring and automatic retry and remain there until the
ream signal is deactivated.
A pilot reaming stroke removes the spatter ring that forms on the end of a
welding nozzle, followed by a full extension reaming stroke to remove
b1 De-Ring
spatter inside the nozzle. Using this technique, the spatter ring is not
pushed into the nozzle where it could do more damage.
b2 Spray Activate spray cycle (minimum ½ second pulse).
b3 Wire Cut Activate the wire cutter (minimum ½ second pulse).
Reset the current error and return system to “Ready” state (1/2 second
b4 Reset Error
pulse).
Disable the motor when running a full ream cycle. This is useful when trial
b5 Dry-Run
running the programmed position (Toggle on/off).
Enable the Blow-off feature: The air motor runs for 3 seconds following
b6 Blow-Off the spray cycle. The motor exhaust is directed at the welding nozzle in
the spray position and servers to blow spatter away and cool the nozzle.
b7

pg. 16
INTELLIREAM DD-EIP ®

Input Address 1: Automatic retry setpoint

Specify the maximum number of times to retry extending the ream bit when blocked by spatter (0-3).

Input Address 2: Post Flow Index

Post flow keeps the air valve of the spray system active following the spray cycle providing self-cleaning to the
spray nozzle. The post flow index (0-3) will set the post flow time according to the following chart.

Index Post Flow Time (sec)

0 0
1 0.25
2 0.5
3 1.0

Input Address 3: Remote activation bits

b7 b6 b5 b4 b3 b2 b1 b0
Fluid Air Spray Air Motor Lift Clamp Remote
Unused Status LED
Solenoid Solenoid Solenoid Solenoid Solenoid Mode
b0 Remote Mode Enable Remote Mode.
b1 Clamp Solenoid Activate clamp solenoid while in remote more (bit 0).
b2 Lift Solenoid Activate lift solenoid while in remote mode (bit 0).
b3 Air Motor Solenoid Activate air motor solenoid while in remote mode (bit 0).
b4 Air Spray Solenoid Activate air spray solenoid while in remote mode.
b5 Fluid Solenoid Activate fluid solenoid while in remote mode.
b6 Status LED Activate the Status LED on top lid of unit.

Input Address 4: Sensor bypass bits

b7 b6 b5 b4 b3 b2 b1 b0
Unused Unused De-Ringer Unused Extended Retracted Unused Opened
Bypass the opened sensor. The ream cycle will function the same, ignoring the
b0 Opened
clamp open sensor.
Bypass the retracted sensor. De-ring and Auto-Retry states are timed rather than
b2 Retracted based on sensor feedback. The ream cycle will function the same, ignoring the
clamp open sensor.
Bypass the extended sensor. The Auto-Retry state is timed rather than based on
b3 Extended sensor feedback. The “Ream” command must be held on for the time required in
the extend phase of the reaming sequence (3 seconds recommended).
Bypass the retracted sensor, the de-ring function is timed rather than based on
b5 De-Ringer
sensor feedback.

Input Address 5: Reserved

pg. 17
INTELLIREAM DD-EIP ®

4.3. Reamer Output Bytes (PLC Input)

Below is the network data that will be exchanged between the INTELLIREAM® DD-EIP and the PLC.

Name Size
Address
Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0 (bytes)
Feedback Bits
0 Nozzle Nozzle Clamp 1
Extended Retracted Error Aux Power Ready
Gas Flow Detected Open
1 Error Code 1
2 Status Bits 1
Change Local
Change Remote
Refill Fluid Wire Unused Unused Unused Lockout
Ream Bit mode
Cutter Mode
3 Reserved 1

Output Address 0: Feedback Bits

b7 b6 b5 b4 b3 b2 b1 b0
Nozzle Nozzle Clamp
Extended Retracted Error Aux Power Ready
Gas Flow Detected Open

The clamp is open, the ream bit is retracted, and the previous cycle ran without
b0 Ready
error.
b1 Aux Power Auxiliary (Solenoid) power is present and within tolerance (+/- 10%).
b2 Clamp Open The clamp is open.
b3 Error An error has occurred, see output address 1 for details.
b4 Retracted The ream bit is retracted.
b5 Extended The ream bit is extended (full depth).
b6 Nozzle Detected A nozzle is detected at the inductive proximity sensor.
b7 Nozzle Gas Flow Gas flow is detected in the specified range at the Nozzle Gas Flow Sensor.

Output Address 1: Error Code

An error has occurred in the current ream cycle, the error code value is given at this address. See section
14.1 for details.

pg. 18
INTELLIREAM DD-EIP ®

Output Address 2: Status Bits

b7 b6 b5 b4 b3 b2 b1 b0
Change Local
Change Remote
Refill Fluid Wire Unused Unused Unused Lockout
Ream Bit mode
Cutter mode

Remote mode is active, the reamer will not respond to cycle commands
b0 Remote Mode
(output byte 0).
Local lockout mode is active, the reamer will only respond to commands from
b1 Local Lockout Mode the membrane keypad. The reamer will not respond to any commands from
the PLC, or robot.
The totalized wire cut cycles has reached the maximum setpoint
b5 Change Wire Cutter
(input address 16).
The totalized spray time has reached the maximum setpoint
b6 Refill Fluid
(input address12).
The totalized ream cycle count has reached the maximum setpoint
b7 Change Ream Bit
(input address 14).

Output Address 3: Reserved

pg. 19
INTELLIREAM DD-EIP ®

5. Reamer
5.1. 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

G R R R R R G

G G Y R Y G G

Clamp Raising Ream Bit Lowering Ream Bit Clamp

Ready
Closed Ream Bit at Top Ream Bit at Bottom Open

“Start” Output Pulse Off

0.5s
“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® DD-EIP 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 rear cover and adjust the top
needle valve. Turning clockwise will decrease the lift rate
(for more spatter removal) and turning counterclockwise 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 counterclockwise will increase the retracting rate.

pg. 20
INTELLIREAM DD-EIP ®

5.2. Status Light

The status light on the top lid of the INTELLIREAM® DD-EIP indicates the
current state of operation.

Color Meaning
Off Ready to cycle
Red In cycle
Flashing Red In alarm, flashing error code

5.3. Position Programming

The INTELLIREAM® DD-EIP 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 “Lift” 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
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.

pg. 21
INTELLIREAM DD-EIP ®

5.1. Reaming Bit Replacement

• Disconnect air and electrical supply.

• Remove the front ream guard cover (not shown).
• Hold the ream rod, item 2, from rotating with a 5/8”
wrench.
• Unfasten the reaming bit, item 1, with a second 5/8”
wrench.
• Remove the reaming bit.
• Insert the reaming bit into the ream rod.
• Hold the reaming rod from rotating with a 5/8”
wrench.
• Tighten the reaming bit with a second 5/8” wrench.
• Replace the front ream guard cover. 1
• Reconnect air and electrical supply.
2

pg. 22
INTELLIREAM DD-EIP ®

6. Sprayer
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.
The spray containment tube helps to manage overspray from the
spray nozzle and maintain a clean robot welding cell.

6.1. Spray Position Programming

Center the nozzle 1½ inches above the spray cone. Record this
position as the “Spray Approach” position. Move the nozzle into the
hole at the top of the spray cone 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 time (0, ¼, ½ or
1 second) after the spray output and corresponding fluid valve have
been turned off.

6.2. Spray Adjustment

The amount of spray may be adjusted with the needle valve,
item 1, located behind the rear cover. Turn clockwise for less
spray.

pg. 23
INTELLIREAM DD-EIP ®

6.3. Spray Nozzle Replacement

• Disconnect air and electrical supply.

• Lift spray cone straight up to remove.
• Unthread spray nozzle and lift straight up to remove.
• Replace in reverse order.

pg. 24
INTELLIREAM DD-EIP ®

7. Ream and Spray Sequence Flow Chart

The following flow diagram shows the recommended procedure for the reaming and spraying sequences.

(At any time)

NO
“Complete” input on
“Error” input on

YES
YES
Move to “Ream” position

Error
Pulse “Start” output for 0.5 sec

Wait for “Complete” input to turn off

Wait for “Complete” input to turn on

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

For the optional wire cutter, nozzle detector, and nozzle gas flow sensor see the following sections.

pg. 25
INTELLIREAM DD-EIP ®

8. Wire Cutter Option

The INTELLIREAM® DD-EIP offers a wire cutter as a factory installed option (IRW010099-00). The wire cutter
is used to remove the ball at the end of the wire created by the welding process. It will leave the welding wire
with a tapered point at the end of the wire stick-out for improved arc starting.

8.1. Wire Cutter Position Programming

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 position.
Once a week, the wire cutter should be inspected visually. Look for dullness and possible breakage of the
cutting blades, replace if necessary.

WARNING: Anytime the

clamp is closed, the wire
cutters will be closed as
well. Keep hands clear of
the wire cutter area and clamp area.

pg. 26
INTELLIREAM DD-EIP ®

8.2. Wire Cutter Sequence Flow Chart

The wire cutter utilizes the clamping cylinder and sensor already present on every INTELLIREAM® DD-EIP.
Following is the suggested wire cutting program logic.

(At any time)

NO
“Error” input on “Complete” input on

YES
Inch wire for 0.5 sec
Error

Move to “Wire Cut” position

Turn on “wire cut” output

Wait for “Complete” input off

Wait 0.5 sec

Turn off “Wire Cut” output

Wire cut operation complete

pg. 27
INTELLIREAM DD-EIP ®

9. Nozzle Detect Sensor Option

The INTELLIREAM® DD-EIP offers a nozzle detect sensor as a factory installed option (IRE120099-02). The
integrated nozzle detect sensor is used to validate that the nozzle remains on the torch after the reaming
process is complete.

9.1. Nozzle Detect Position Programming

The figure below illustrates the proper nozzle detect position, where the distance between the nozzle wall and
the sensor must be less than or equal to 1.5 mm.

The inductive sensor has a maximum

sensing range of 1.5 mm

<1.5 mm

When a nozzle is detected by the sensor, the “Nozzle Detect” input will turn on and the “complete” signal will
turn off.

pg. 28
INTELLIREAM DD-EIP ®

9.1. Nozzle Detect Sequence Flow Chart

The process for checking for nozzle presence is outlined in the diagram below.

“Nozzle Detect”
input off
NO
YES
Move to “Nozzle Detect”
position

“Nozzle Detect”
input on
NO
YES

Nozzle Detect operation

complete

Error

pg. 29
INTELLIREAM DD-EIP ®

10. Nozzle Gas Flow Sensor (NGFS) Option

The INTELLIREAM® DD-EIP offers a nozzle gas flow sensor as a factory installed option (IRE120099-04). The
integrated nozzle gas flow sensor measures gas flowing out the end of the torch nozzle. This method is
advantageous to an inline flow sensor installed in the gas hose as there may be undetected leaks downstream.
By measuring gas flow at the nozzle, the point of use, the system verifies adequate gas coverage for the weld
puddle where it is required.

10.1.NGFS Specifications

GAS FLOW SPECIFICATIONS

Max Pressure: 60 PSI Flow: 10 - 60 SCFH
For use with CO2, AR, or Mixed gas (AR, CO2, He)

10.2.NGFS Operation
When the welding gas solenoid turns on there is normally a surge of gas before the flow stabilizes to the
steady state flow preset by the regulator. The Nozzle Gas Flow Sensor Signal will turn on after 0.5 sec of
stable gas flow within a defined window of operation.

pg. 30
INTELLIREAM DD-EIP ®

10.3.NGFS Setup
There are two settings available to change the window of operation; (1) Flow Set point and (2) Flow Tolerance
Band. The set point adjustment (1) will move the entire band (minimum and maximum) up or down. The
tolerance band adjustment (2) will adjust the span between the maximum and minimum levels.

Setup Procedure

1. Using an independent measurement device, set the desired

welding nozzle gas flow to the desired flow rate.
2. Move the robot to bring the nozzle to the target position with the
nozzle fully engaged in the flow cone. The module has a small
amount of movement built into the spring mounts which will allow
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 nozzle at desired flow rate.
6. Adjust the Flow Set Point potentiometer (P1) until LED1 and LED2
are flashing equally. If LED1 is flashing alone turn P1 Clockwise, if
LED2 is flashing alone turn P1 counterclockwise.
7. Check for output signal active (LED3 is ON).
8. Turn off gas flow.
9. Check that the output signal deactivates (LED3 is OFF) and the
High Side (6) / Low Side (5) LEDS are also off.
10. Move the robot to bring the nozzle out of the flow cone to the
approach position.

Circuit Board Detail

Designator Description
1 P1 Flow Set point
6
1
2 P2 Tolerance Band
5
3 LED3 Output Signal Active
4
2 4 LED4 Sensor Power Supply
5 LED1 Low Side indicator
3
6 LED2 High Side indicator

pg. 31
INTELLIREAM DD-EIP ®

10.4.NGFS Robot Position and Sequence Flow Chart

To properly detect gas flow, the correct robot position must be programmed with the nozzle inserted into the
cone of the sensor. An approach position is recommended as the first step followed by the target position
inside the cone.
The following figures and flowchart show the recommended programming sequence with nozzle location for
the approach and target positions.

Nozzle Gas Flow

NO
input (“NGF”)
off?
Error1

YES

Move to Approach
Position

Move to “Flow Sense” Target

position

Turn On Gas
Approach Position: the nozzle is in-line with
and directly above the cone.
(2 sec timeout)
NO “NGF” on?
YES
Turn Off Gas Flow Detected.
Turn Off Gas

Flow Error2

(1 sec timeout)
NO “NGF” off?

YES
Flow Error3
Move to Approach
Position

Target Position: The nozzle lightly touches the Halt for Error END
inside of the cone. The nozzle is vertical. Errors:
1. INTELLIREAM® DD-EIP Error from previous Cycle
2. Gas flow turn-on undetected
3. Gas flow turn-off undetected

pg. 32
INTELLIREAM DD-EIP ®

11. Settings
Several features may be setup to optimize performance of the INTELLIREAM® DD-EIP. 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
>5 sec >7 sec >9 sec >11 sec
(I/O >13 sec
(Spray) (Extras) (Mode) (Diagnostic)
config)

(( Y )) R R Y

(( Y )) R Y G R Y

Note: The default setting for each configuration is first and last in each sequence.

11.1.I/O Configuration
The discrete I/O configuration is not applicable to the INTELLIREAM® DD-EIP

pg. 33
INTELLIREAM DD-EIP ®

11.2.Spray
The sprayer has a built-in post flow timer. Airflow from the spray nozzle will be present for set time (0, ¼, ½ or
1 second) after the spray output and corresponding fluid valve have been turned off, the default is 0 (disabled).
Follow the steps outlined in section 0 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.

(>5sec)

Clamp
Default 0 sec ¼ sec ½ sec 1 sec
status
R/G R G R G R/G

R/G R R G G R/G

Lift
status
Press &
Release Done

11.3.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.

(>7sec)

Clamp
Blow-off: OFF ON OFF ON OFF
status
R G R G R R/G

R R G G R R/G

Lift
De-Ringer OFF OFF ON ON OFF
status
Press &
Done
Release

pg. 34
INTELLIREAM DD-EIP ®

11.4.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

(>9sec)

Clamp
Mode Automatic Dry Run Timed Open Blind Auto
status
G Y G G R G R/G

G G G Y R R G R/G

Lift
status
Press & Done
Release

pg. 35
INTELLIREAM DD-EIP ®

11.5.Motor Diagnostic
This feature allows a service 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.

(>11sec)

Clamp
Diagnostic Off On OFF
status
R R G R R/G

R R G R R/G

Lift
status
Press &
Release 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® DD-EIP is at the top position (“LIFT” LED is green), release the
“LIFT” button and the reaming bit will maintain its position.

pg. 36
INTELLIREAM DD-EIP®

2. CLAMP function: Press the “CLAMP” button to close and open the clamp. Check that the
“CLAMP” LED on the control module changes from green to red when the clamp is closed.

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 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: With the reaming bit raised, press both the “CLAMP” button and “LIFT” button to
test the “Motor” solenoid.

WARNING: the motor will operate under this condition. KEEP HANDS CLEAR
of the operating area of the reaming bit. Do not operate with exposed long
hair, jewelry, or loose clothing. This device is intended for one-man operation
during test.

pg. 37
INTELLIREAM DD-EIP ®

12. Web Server Interface (DD-EIP version only)

The INTELLIREAM® DD-EIP features a Web Server Interface for enhanced setup and configuration. Any
modern web browser can be used to view the interface at the IP address chosen (see section 4.1). The
browser must be connected and communicating on the same LAN as the INTELLIREAM® DD-EIP.
The web server interface is divided into four screens; Interface, Settings, Statistics and Consumables. The
screen names appear in the header and may be selected by clicking on each. The current operating mode of
the web server is shown in the footer. If either these disappear then simply click on any blank space on the
page and they re-appear.

12.1.Interface Screen
The Interface screen is used for remote monitoring and control. Each output status from the Intelliream ® DD-
EIP is shown as being active or inactive with the indicator beside each label.

pg. 38
INTELLIREAM DD-EIP ®

Below the Output Status section, several inputs can be set from the Web Browser when in READ/WRITE
mode.

The Status of the Network LEDs is shown for information or troubleshooting communications.

When a PLC or robot controller is communicating with the Intelliream® DD-EIP via Ethernet/IP then the
webserver is placed into “Read Only Mode”. The lower banner reflects the current status of the read/write
access.

If any of the command buttons or controls are attempted while in READ ONLY mode, a popup will alert the
user that it is not possible to send commands to the Intelliream® DD-EIP at this time.

pg. 39
INTELLIREAM DD-EIP ®

12.2.Settings Screen
All of the configurations for the INTELLIREAM® DD-EIP are made available at the top of the Settings screen.
Enter the new setpoint in the numerical entry text box. If a setpoint must be written to non-volatile (EEprom)
memory then the corresponding button will become enabled once a number is entered in the setpoint field.
Click the button to reset the INTELLIREAM® DD-EIP, the new setting will take effect at reboot.

pg. 40
INTELLIREAM DD-EIP ®

Below the configuration data, several reamer inputs may be set to remotely operate individual valves and LEDs
on the membrane interface. Enable remote operation by toggling the “Remote Enable” switch. The reamer will
no longer respond to other commands while “Remote Enable” is on.

pg. 41
INTELLIREAM DD-EIP ®

12.3.Statistics Screen
The Statistic screen shows the current operations timing for the previous cycle, counts for all processes and
the Error log for the previous two occurrences.

pg. 42
INTELLIREAM DD-EIP ®

12.4.Consumables Screen
The Consumables screen shows the current usage of fluid, ream bit and wire cutter. Each consumable section
displays an alert (also mapped to an I/O bit) and the accumulated amount. The accumulated value may be
reset with a button and the alert setpoint may be changed for each item.

The firmware version of the process software is shown in the info screen.

pg. 43
INTELLIREAM DD-EIP ®

12.5.IP address configuration

An isolated screen is available to change the IP address configuration.
Enter the IP address of the INTELLIREAM® DD-EIP followed by ‘/secure/EtnConfig,shtm’ for example
192.168.0.21/secure/EtnConfig.shtm.
If asked for a password then use the following- User:nasarc, Pass:intelliream

IP address: A unique string of four numbers (0 – 255) separated by decimals that identifies the INTELLIREAM®
DD-EIP on the network.
Subnet Mask: A string of four numbers (0 – 255) separated by decimals that masks an IP address and divides
the IP address into network address and host address.
Gateway Address (optional): The IP address of the router (if used) on the network.
SMTP Server (optional): The IP address of the e-mail server of the sender. Add credentials if necessary.
Press “Save” when complete. Note: the unit must be rebooted for the settings to take effect. A reboot may be
done by power cycling the Intelliream® DD-EIP or clicking “Reboot” at the bottom of the Communications page.
Recipient Address: The email address of the person or account who should receive email alarm notifications
from the Intelliream® DD-EIP.
Sender Address: The email address of the person or account who will appear in the “from” field of the email
alarm notifications.
Press “Submit” to save these settings; a confirmation pop-up will notify of success.

pg. 44
INTELLIREAM DD-EIP ®

13. Preventative Maintenance

The INTELLIREAM® DD-EIP will require periodic maintenance to ensure a dependable service life. The
following schedule is recommended.

Shut off the air supply and disconnect the power cable before making adjustments.

DAILY
• Check the fluid level in spray reservoir.
• Check the reaming bit visually.

WEEKLY
• Dump the spatter accumulated in the drawer of the mounting box or customer supplied catchment below the
reamer.
• Check airlines for leaks and robot control cable for splits or cracks.
• Clean clamp gripping surfaces to ensure optimal nozzle gripping.

SPRAY CONTAINMENT UNIT (weekly)

• Remove and clean out spray cone and drain.
• Check collection jug.
NGFS (weekly)
• Clean the inside face of the flow cone to remove surface buildup.
• Clean debris from the main cavity by removing the plug at the bottom.
• Check the mesh filter of debris. Clean or replace as required.

pg. 45
INTELLIREAM DD-EIP ®

14. Troubleshooting

Problem Possible Cause Solution

No device status LEDs on -Power is off -Turn power on
-Fuse is blown (controller cabinet) -Replace fuse
-Reset button defective -Replace reset button
-Circuit board defective -Replace circuit board
Clamp/Motor/Lift/Cutter not -Insufficient air supply -Set to 80 PSI, 15 SCFM
working -Air line cut, disconnected, or twisted -Replace or re-connect airline
-INTELLIREAM® DD-EIP in setup -Reset INTELLIREAM® DD-EIP
mode -Ream more often
-Excessive spatter buildup -Select automatic mode
-Dry run mode selected -Replace necessary valves
-Defective solenoid -Check cable wiring
-Check error codes -Perform a visual inspection of the
equipment
Ream bit does not retract -Ream bit jammed in nozzle -Replace damaged parts
-Extended sensor defective -Replace extended sensor
-“Start” output held on -Pulse “Start” output for 0.5 sec
-Lift cylinder defective -Replace lift cylinder
-Check error codes
Controller cannot start a cycle - “Complete” input signal not -Check error codes
or controller cannot complete a responding -Reset INTELLIREAM® DD-EIP
cycle
No anti-spatter liquid and/or no -Low anti-spatter volume -Refill anti-spatter reservoir
air flow from sprayer -Reservoir not vented -Open vent if closed
-Fluid line blocked -Clean or repair fluid line
-Insufficient air supply -Set to 80 PSI
-Solenoid valve defective -Replace solenoid valve
-Spray nozzle clogged -Clean or replace spray nozzle
*HAND TIGHTEN ONLY
Wire cutter won’t cut wire, but -Insufficient air supply -Set to 80 PSI
the cutter closes -Cutters are worn or damaged -Replace damaged components
-Wire diameter too large -Check wire diameter

pg. 46
INTELLIREAM DD-EIP ®

14.1.Error Codes
The INTELLIREAM® DD-EIP reports errors using the status light. When an error is reported, the status light
flashes at a rate of 2 flashes per second.

When an error occurs during the reaming process, the clamp opens, the lift retracts, and the
diagnostic report is shown with the top sensor LED in red. The LED will flash a certain number
R of times, pause, then repeat. The error count begins at 2.
Count the number of flashes between the pause and use the following chart to find the cause of
the problem.

2: Closing Fault: The clamp took too long to close.

Y -Check air inlet pressure
-Check clamp sensor
-Check clamp air lines
-Check clamp solenoid
-Check clamp cylinder
3: Raising Fault: The lift cylinder took too long to extend from the retracted sensor.
-Check air inlet pressure
-Check extending needle valve (top needle valve on lift cylinder)
-Check retracted sensor (bottom)
-Check lift air lines
-Check lift solenoid
-Check lift cylinder
4: Extending Fault: The lift took too long to fully extend.
-Automatic retry; excessive spatter build up in the nozzle (ream more often), 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 extended sensor (top)
-Check lift air lines
-Check lift solenoid
-Check lift cylinder
5: Lowering Fault: The lift cylinder took too long to retract from the top while lowering.
-Check air inlet pressure
-Check retracting needle valve (bottom needle valve on lift cylinder)
-Check extended sensor (top)
-Check lift airlines
-Check lift solenoid
-Check lift cylinder
6: Retracting Fault: The lift cylinder took too long to fully retract.
-Check air inlet pressure
-Check retracting needle valve (bottom needle valve on lift cylinder)
-Check retracted sensor (bottom)
-Check lift airlines
-Check lift solenoid
-Check lift cylinder
7: Opening Fault: The clamp took too long to open.
-Check air inlet pressure
-Check clamp sensor
-Check clamp airlines
-Check clamp solenoid
-Check clamp cylinder
8: Short Circuit Fault: The output is short circuited.
-Check wiring to robot or PLC controller
9: Solenoid Voltage Fault: The voltage to actuate the solenoids is too low.
-Check the voltage between the solenoid voltage and 0V and adjust power supply as needed
-Check the wiring of the solenoid voltage/emergency stop circuit

pg. 47
INTELLIREAM DD-EIP ®

Note: Clearing Errors – If an error has occurred with the INTELLIREAM® DD-EIP, indicated by the “Error” input being
turned on, it is possible to clear errors so that an operator is not required to enter the robotic welding cell. For example, if
the air supply was not turned on and a ream cycle is required, the operator can simply turn on the air supply, and clear the
error from outside the cell. This can be done by pulsing the “Start” output from the controller/teach pendant.

14.2.Advanced Troubleshooting
Use the test points in the following table to take readings with a voltmeter.
Connect the (+) lead to the first test point and the (-) lead to the second test point.

Refer to the diagram below for test point locations.

(+) Lead (-) Lead Description “On” Voltage “Off” Voltage

Point Point
24V_AUX FLUID Fluid Solenoid 24 V 0V
24V_AUX GRIP Grip Solenoid 24 V 0V
24V_AUX LIFT Lift Solenoid 24 V 0V
24V_AUX MOTOR Motor Solenoid 24 V 0V
24V_AUX AIRSPRAY Air Spray Solenoid 24 V 0V
DRNG GND De-ringer Sensor 24 V 0V
EXTD GND Extended Sensor 24 V 0V
RTCD GND Retracted Sensor 24 V 0V
GND GND Clamp Sensor 24 V 0V
24V_BUS GND +24 VDC 24 V 0V
SPRAY GND N/A for DD-EIP
START GND N/A for DD-EIP
READY GND N/A for DD-EIP
ERROR GND N/A for DD-EIP
24V_BUS LED Status Light 24 V 0V

*A trace value of 6V is measured prior to activation

Note: all voltage readings +/- 10%

pg. 48
INTELLIREAM DD-EIP ®

15. Pneumatic Components

The figure below shows the location for each pneumatic component.

3 10

4 8

5 6 7

1 CLAMP CYLINDER
2 FLUID SOLENOID
3 MOTOR SOLENOID
4 MANIFOLD ASSEMBLY
5 SPRAY SOLENOID
6 CLAMP SOLENOID
7 LIFT SOLENOID
8 PNEUMATIC INLET
9 LIFT CYLINDER
10 AIR MOTOR (other side)

pg. 49
INTELLIREAM DD-EIP
®

16. Electrical Diagram

Closeup view of terminal block board

pg. 50
INTELLIREAM DD-EIP
®

17. Replacement Parts List

1

3 5 6
19
7

8
9
17
10
20
11

12

13
21

14

35
18
22

15

16

23

24

pg. 51
INTELLIREAM DD-EIP
®

ITEM PART # DESCRIPTION

1 IRE020099-09 STATUS LIGHT ASSEMBLY
2 NAC40-3R GAS FLOW TUBE REPLACEMENT ASSEMBLY
3 IRE060007-00 NGFS CIRCUIT BOARD + CABLE
4 NAC40-2R NGFS SENSOR ASSEMBLY
5 IRW010008-00 TCP CHECK PIN
6 IRW010007-03 WIRE CUTTER GUARD (option)
7 IRW010099-00 WIRE CUTTER ASSEMBLY (option)
8 IRE020099-04 OPEN SENSOR ASSEMBLY
9 IRP120099-00 CLAMP CYLINDER ASSEMBLY DD
10 IRF120003-00 BACK COVER DD
11 IRG010099-00 CLAMP ASSEMBLY
12 IRE020099-13 NOZZLE DETECT SENSOR replacement
13 IRE070099-02 RCM-2N CONTROL MODULE COMPLETE
•IRE070099-06 RCM-2N Membrane Enclosure
•IRE070001-02 PC BOARD (RCM-2N)
14 NTP32R REAM MOTOR ASSEMBLY
15 IRE010010-00 ROBOT CONNECTOR
16 IRP010006-02 PNEUMATIC FITTING 1/4in
17 NAC30-3 SPRAY CONE
18 NST-5 32OZ PLASTIC CONTAINER
19 IRG120002-00 TOP GUARD DD
20 IRF120008-00 REAMING BIT GUARD FULL DD
21 IRF120010-00 REAMING BIT GUARD OPEN DD
22 IRF120099-00 FRONT COVER DD
23 IRX120099-00 MOUNTING BOX DD with Tray (option)
24 •IRX120099-01 BOX TRAY DD

pg. 52
INTELLIREAM DD-EIP
®

25

27

29 30
26

28

31

32
35

33

34

pg. 53
INTELLIREAM DD-EIP
®

ITEM PART # DESCRIPTION

25 NAC30-2R SPRAY NOZZLE REPLACEMENT ASSEMBLY
26 IRS120099-03 FLUID RESERVOIR ASSEMBLY DD
27 IRS010005-01 FLUID RESERVOIR LID
28 IRP120099-01 FLUID SOLENOID ASSEMBLY DD
29 IRE080001-01 TERMINAL BLOCK BOARD
30 IRE020099-08 RIBBON CABLE ASSEMBLY
31 IRP120099-03 MOTOR SOLENOID ASSEMBLY DD
32 IRE010012-00 LIFT SENSOR
33 IRP120002-00 5-WAY SOLENOID (cylinders, spray)
34 IRP120099-02 MANIFOLD ASSEMBLY DD
35 IRE010014-00 M12 ETHERNET RECEPTACLE

Accessories

PART # DESCRIPTION
IRB010500-00 REAMING BIT, 1/2" (W/WASHER)
IRB010501-00 REAMING BIT, BOTTLENECK, 1/2" (W/WASHER)
IRB01M155-00 REAMING BIT, 15.5mm (W/WASHER)
IRB020625-00 REAMING BIT, 5/8” (W/WASHER)
IRB010750-00 REAMING BIT, 3/4" (W/WASHER)
IRE010090-20 ROBOT CABLE, 90 Degree 20FT
IRE010090-30 ROBOT CABLE, 90 Degree 30FT
IRT020001-00 TEST BOX
IRX120099-30 FLOOR MOUNT STAND, 30” DD with Tray
•IRX120009-00 STAND TRAY DD

pg. 54
INTELLIREAM DD-EIP ®

Warranty

NASARC Cert-Equip WARRANTY POLICY

INTELLIREAM® DD-EIP is warranted by NASARC to the original commercial or institutional end user/owner
against defects in materials and workmanship as follows:
Motor, Solenoids, circuit board, cylinders – 1 year
External parts, INTELLIREAM® DD-EIP, spray nozzle, cables, and accessories – 90 days

The warranty becomes effective on the date of purchase. During the warranty period, equipment covered by
the warranty and found to be defective will be repaired or replaced at the manufacturer’s discretion without
charge. The manufacturer’s responsibility is limited to repair or replacement of damaged or defective parts.
The equipment must be returned, transportation charges prepaid with proof of purchase date, to an authorized
service center or to NASARC. If a product warranty card has not been completed or proof 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 of warranty beyond the
original period. The warranty is not transferable.
This warranty does not cover defects in the equipment caused by ordinary wear and tear, abuse, misuse,
accident, or any other cause that is not the result of defective materials or workmanship.
Repair or replacement is the exclusive remedy for defective equipment under this warranty. This warranty is in
lieu of all other warranties written and implied, including any implied warranty of fitness for a particular purpose
of this equipment. NASARC shall not be liable for any consequential or incidental damages for breach of any
express or implied warranty of this equipment.

The month of manufacture can be found on the serial plate

+------- yy: Year
| +----- mm: Month (01 .. 12)
| | +--- nnn: Unit number within the month (001..999)
| | |
IRyymmnnn
For example, IR2208033 is the 33rd unit manufactured in August (08) of 2022 (22)

pg. 55