Tregaskiss TOUGH GUN TT3E Owner'S Manual Download Page 1

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OM-TT3E-1.0

March 2016

Processes

MIG (GMAW) Welding

Description

Ethernet Equipped Robotic

Nozzle Cleaning Station,

MIG (GMAW) Welding Peripheral

TOUGH GUN

™

TT3E Reamer

OWNER’S MANUAL

Tregaskiss

2570 North Talbot Road

Windsor, Ontario N

Canada

Phone: 1-855-MIGWELD (644-9353)

(US & Canada)

+1-519-737-3000

(International)

Fax: 519-737-1530

For more information, visit us at Tregaskiss.com

Summary of Contents for TOUGH GUN TT3E

Page 1: ...c Nozzle Cleaning Station MIG GMAW Welding Peripheral TOUGH GUN TT3E Reamer OWNER S MANUAL Tregaskiss 2570 North Talbot Road Windsor Ontario N0R 1L0 Canada Phone 1 855 MIGWELD 644 9353 US Canada 1 519 737 3000 International Fax 519 737 1530 For more information visit us at Tregaskiss com ...

Page 2: ...or errors or omissions Tregaskiss assumes no liability for damages resulting from the use of information contained herein The information presented in this owner s manual is accurate to the best of our knowledge at the time of printing Please reference Tregaskiss com for updated material For customer support and special applications please call the Tregaskiss Customer Service Department at 1 855 M...

Page 3: ...ghts for Cutter Blade Insertion 11 4 7 Setting the IP Address 12 4 8 Data Map 14 SECTION 5 OPERATION 15 5 1 Understanding L E D Indicators on Ethernet Module 15 5 2 Program Logic Chart 16 5 3 Manual Operation 18 5 4 Operation through the HMI 18 5 5 Adjusting Flow Control Valves 19 SECTION 6 MAINTENANCE 20 6 1 Replacing the Spindle Limit Switch 20 6 2 Replacing the Clamp Limit Switch 20 6 3 Replaci...

Page 4: ...llied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safety in Welding Cutting a...

Page 5: ...replaced or repaired pursuant to the warranty herein shall be further warranted for a period of six months after delivery of the replacement EXCEPT AS SET FORTH ABOVE SELLER MAKES NO WARRANTY OF ANY KIND EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PURPOSE SELLER SHALL NOT BE LIABLE UNDER ANY CIRCUMSTANCES FOR DAMAGES OF ANY KIND INCLUDING BU...

Page 6: ... page 29 Robotic Peripheral for GMAW Welding Rated Voltage 24 VDC Operating Voltage 10 of rated voltage Power Consumption Max wattage in operation 5 3 W Air Requirements minimum 80 to 100 psi 5 5 to 7 0 bar at 16 CFM 450 LPM Air Motor at min air requirement Stall torque at 80 psi 5 5 bar 83 in lbs 9 4 Nm ...

Page 7: ... tagout procedures A To Mount TOUGH GUN TT3E Reamer The TOUGH GUN Reamer should be installed within the weld cell where it is clear of all tooling and convenient for the robot to access the unit Affix the Reamer base to a sturdy platform using four 4 bolts provided NOTE The Reamer can be mounted overhead or on an angle as long as debris falls away from the clamp housing B To Connect Air Supply NOT...

Page 8: ...ected before proceeding Please follow your facility s lockout tagout procedures A To Mount Wire Cutter 1 The wire cutter should be installed within the weld cell where it is clear of all tooling and convenient for the robot to access the unit The base plate has been designed for mounting on top of the TOUGH GUN Reamer Be sure to consider movable fixtures and the confines of the robot 2 Attach the ...

Page 9: ...ctor Wiring Schematic is Brown Wire 24VDC Constant White Wire Wire Cutter Signal Blue Wire 0VDC Constant and Black Wire Nozzle Detect Signal Ethernet EIP 1 2 Connectors Wiring is the standard RJ45 schematic RJ45 END VIEW FEMALE END VIEW 1 WHITE ORANGE TX 2 ORANGE TX 3 WHITE GREEN RX 4 N C 5 N C 6 GREEN RX 7 N C 8 N C 1 WHITE ORANGE TX 2 WHITE GREEN RX 3 ORANGE TX 4 GREEN RX NOTE These metrics are ...

Page 10: ... LEDs meaning of the colours can be found in the Section 5 1 Understanding L E D Indicators on the Ethernet Module ERR Status of the circuits BUS Connection to a network ETH 1 2 Connection speed link 4 4 Ethernet Module Description Jaws V Block Cover Screws Clamp Cover 4 5 Setting Up V Block V Block Part Nozzle Outside Diameter for each side of V Block TR 2150 0 850 0 938 1 062 1 106 TR 2161 0 830...

Page 11: ...for Cutter Blade Insertion Retaining Head Cutter Blade Nozzle 404 3 404 20 404 26 404 30 404 32 454 1 RC 12 3 4 19 05 mm 0 110 Below 2 79 mm Below 0 375 9 53 mm 0 466 11 84 mm RCT 01 5 8 15 88 mm 0 030 0 762 mm 0 225 5 72 mm 0 716 18 19 mm RCT 04 1 2 12 7 mm 0 219 Below 5 56 mm Below 0 125 3 18 mm 0 065 1 65 mm TOUGH GUN TT3E Reamer See Chart Nozzle Cutter Blade ...

Page 12: ...es button see Figure 2 4 Once in the Properties window select the Use the following IP address option 5 The IP address must have the first three octets the same as the Ethernet module The factory set first three octets are 192 168 1 The last octet must be between 1 and 254 but cannot be the same as the Ethernet module The Subnet mask should self populate but 255 255 255 0 can be inputted see Figur...

Page 13: ...he Change button 6 The IP address can then be changed to the desired address 7 Click Write to device and the IP address is stored in the module s EEPROM memory BOOTP DHCP Mode 1 Ensure that the rotary switches located at the top of the module underneath the clear plastic cover on the module are set to 300 BOOTP or 400 DHCP 2 Power on the reamer 3 Using your BOOTP DHCP software select the device wh...

Page 14: ... Lower Limit DS Enabled Clamp Open Reset Clear Nozzle Detect Error Running 1 Current Step IN 2 Startup Motor Dwell Total ms 3 Spindle Adavance Dwell Total ms 4 Sprayer Duration Total ms 10 Current Program Revision Below is the Data Map for the TT3E 2310 Ethernet Module To configure the module within the PLC add the device and use the following Connection Parameters right side of Figure 1 Assembly ...

Page 15: ...hort circuit I O 1 16 Green On Input Output is active Off Input Output is inactive LEDs are located on the front of the Ethernet module and can be accessed by opening the rear door of the Reamer During normal operation and at the home position the following LEDs should be illuminated 1 ETH1 ETH2 Flashing either green or yellow depending on what connection speed your network is 2 BUS Flashing Green...

Page 16: ...elow for the program logic chart for the ream cycle as well as optional PLC initiated functions Reamer Cycle Logic RECOMMENDED MOTOR WILL NOT START IF ROBOT OR PLC IS FAULTED USE 24V MOTION AND NON MOTION POWER ERROR MESSAGE RETRY FUNCTIONS FULLY CONFIGURABLE BY USER LEGEND INTERVENTION AUTOMATIC MANUAL PROCESS START END DECISION ...

Page 17: ...an be used within the gun while the robot is moving from location to location before or after a ream Used to clean off front end and does so without using up costly welding gas After air blast is used the system must be purged to ensure proper gasses are used when welding starts back up Air blast could be programmed for a certain time period i e 2 seconds or when the robot is moving between locati...

Page 18: ...ows the dwell times for the motor start up spindle advance and sprayer duration to be changed to user preferences The Reamer also includes the option of Double Stroke This option will set the Reamer up to conduct two sequential plunges into the nozzle bore All of these options can be accessed through the web browser enabled Human Machine Interface HMI The steps to access the HMI are as follows 1 O...

Page 19: ...f the screen One for the Program Status and one for Program Setup Figure 3 The Program Status will give you the real time status of the Reamer and the Program Setup will allow you to change the dwell times and enable disable Double Stroke Figure 4 5 Once in the Program Setup screen the right side of the screen will display the various dwell times and double stroke option 6 To enable disable the Do...

Page 20: ...rness The connector is located on the inside of the Reamer in the top left hand corner near the valve pack 4 Remove the rubber grommet from the clamp housing and pull wires out of the grommet through the slit in the grommet 5 Remove the clamp limit switch fastener and remove assembly 6 Place rubber grommet onto wires of the replacement clamp limit switch and push grommet back into the hole in the ...

Page 21: ...sconnected before proceeding Please follow your facility s lockout tagout procedures 1 Open the rear cover 2 Grab the Ethernet module and slide it off the DIN rail 3 With a flat head screw driver loosen the 4 x screws that secure the connectors to the Ethernet module 4 Remove the connectors by using the screw driver and slightly prying the connectors free from the Ethernet module 5 Remove the 2 x ...

Page 22: ...ose the rear cover WARNING Ensure power supply is off and disconnected before proceeding Please follow your facility s lockout tagout procedures 1 Open rear cover 2 Pull the Ethernet module off of the DIN rail and allow it to hang freely 3 Remove the 2 x Air Blast bracket fasteners M6x1x12 on the outside of the Reamer 4 Carefully remove the bracket assembly from the inside of the Reamer and allow ...

Page 23: ...spatter CLEAN The Reamer clamp jaw and v block surfaces to ensure proper nozzle alignment WEEKLY CHECK The nozzle cutter blade The service life of the cutter blade is dependent on the type of application In lighter duties the blade may last indefinitely but should be inspected weekly for dullness clogging and possible breakage CHECK The lubricator to ensure it is working and is set up properly i e...

Page 24: ...erTT3E under the Software Downloads tab a HMI and Update Program b Reamer ver inserted here arg NOTE It is recommended that files are saved to a single location for ease of access 2 Establish a connection to the Reamer with a computer so that the software update can occur 3 Open up the folder where the above files were saved and then open the HMI and Update Program folder 4 In this folder there is...

Page 25: ...mer ver arg file Figure 5 8 Once the program is loaded into the Ethernet module it must be run in order for the update to take effect Press the Run heading and let the program run The final screen should look like this see Figure 6 9 The Ethernet module is now programmed and can be disconnected from the computer Figure 4 Figure 5 Figure 6 ...

Page 26: ...26 SECTION 7 TECHNICAL DATA 7 1 Pneumatic Diagrams TOUGH GUN TT3E Reamer TOUGH GUN TT3E Reamer with Lubricator ...

Page 27: ...27 TOUGH GUN TT3E Reamer with Air Blast ...

Page 28: ...the manufacture date of the TOUGH GUN TT3E Reamer units the serial number will determine what wiring diagram is correct for that specific Reamer Only Revision F for serial TT3E 1181 and up is shown below For all other wiring schematics please call Technical Support ...

Page 29: ... Bulkhead 14 TT3E CP1 Communication Plate 15 TT3E 2310 1 DIN Rail 16 TT3E 2310 Ethernet Module ITEM PART DESCRIPTION 17 TR 2500 Air Motor Assembly 18 TT3E 2335 Stainless Steel Push Button Switch 19 TT3E 2680 TOUGH GUN TT3E Reamer Rear Cover Assembly 20 TT3E 2322 TT3E Spindle Limit Switch Assembly 21 TT3E AB Air Blast Solenoid Valve Assembly 22 R 2246 5 16 Valve 23 R 2241 1 4 Valve 24 TR 2130 Clamp...

Page 30: ...3 TS 500 40 Sprayer Quick Connect 4 Not Sellable 1 4 Sprayer Hose 5 TT3E 500 20 Sprayer Check Valve SMC 6 TS 500 15 Spray Block with Fittings 7 Not Sellable 90 Degree 1 4 Port 1 4 NPT Elbow 8 Not Sellable Extruded 90 Degree Street Elbow 9 SR 500 1 Sprayer Bracket SMC is a registered trademark of SMC Corporation ...

Page 31: ...WC 100 7 Blade includes ITEM 2 7 RR 707 31 TCP Locator 8 WC 100 31 Cylinder ITEM PART DESCRIPTION 9 Not Sellable M10x1 5x25 mm SHCS 10 Not Sellable M8x1 25x55 mm SCHCS 11 Not Sellable M8x1 25x50 mm SHCS 12 TR 2221 Breather Vent 13 WC 100 24E Solenoid Valve TT3E Reamer 14 WC 100 26 Muffler 15 WC 100 18 Air Line Kit 16 WC 100 30 TOUGH GUN Reamer Wire Cutter Installation Kit 17 WC 100E Wire Cutter TT...

Page 32: ... 4 1 Air Motor Lubricator 4 Dryer required for air system 5 Ensure consumables are concentric with cutter 2 Pneumatic functions not operative 1 Air lines damaged or obstructed 2 Air supply is incorrect 3 Faulty reset switch 4 Manual switches engaged 5 Bad valve 6 No power 1 Replace air line s 2 Check air supply set at 80 10 psi at 16 CFM 3 Repair or replace reset switch 4 Turn off manual switches ...

Page 33: ...alve of the drain cock 2 Breakage of the seating part of the drain cock 1 Open the drain cock for a few seconds 2 Replace the bowl assembly 8 No drainage when the drain cock is opened 1 Blockage of outlet of the drain cock due to solid foreign matter 1 Replace the bowl assembly 9 Too much drain comes from the piping of the outlet side 1 Drain level reaches the baffle plate 1 Open the drain cock fo...

Page 34: ...ate There is a testing troubleshooting program that is available for download through the following link www tregaskiss com ReamerTT3E under the Software Downloads tab This useful tool can help in diagnosing the errors that may occur as well as being able to diagnose it remotely Follow the steps below to run the program from any computer 1 Download the program Reamer Online Tester from the above l...

Page 35: ... an error The cycle start does not have to be initiated by the PLC It can be initiated by the test program 8 If an error is encountered the step at which it is encountered will be displayed Using the Program Logic Chart in Section 5 2 the error can often be linked to one of the I Os Figure 3 9 This software can be used in conjunction with the Troubleshooting charts of Sections 9 1 to 9 5 to help i...

Page 36: ...da 1 519 737 3000 International Fax 519 737 1530 For more information visit us at Tregaskiss com Scan to view the TOUGH GARD Anti Spatter Multi Feed System Owner s Manual Scan to view the TOUGH GUN TT3 Reamer Spec Sheet Scan to view TOUGH GUN Robotic Air Cooled MIG Guns Scan to view TOUGH GUN Robotic Water Cooled MIG Guns Scan to view Tregaskiss Spec Sheets Scan to view the TOUGH GUN Wire Cutter O...

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