Tregaskiss TOUGH GUN TT3 Reamer Owner's Manual
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Tregaskiss TOUGH GUN TT3 Reamer Owner's Manual

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TOUGH GUN
TT3 Reamer
OWNER'S MANUAL
OM-TT3-1.4
August 2020
Serial #TT-22000 and above | Robotic
Nozzle Cleaning Station, MIG 
(GMAW) Welding Peripheral
Tregaskiss.com/TechnicalSupport
1-855-MIGWELD (644-9353) (US & Canada)
+1-519-737-3000 (International)

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  • Page 1 ® TOUGH GUN TT3 Reamer OWNER'S MANUAL OM-TT3-1.4 August 2020 Serial #TT-22000 and above | Robotic Nozzle Cleaning Station, MIG  (GMAW) Welding Peripheral Tregaskiss.com/TechnicalSupport 1-855-MIGWELD (644-9353) (US & Canada) +1-519-737-3000 (International)
  • Page 2 Thank You for Choosing Tregaskiss Thank you for selecting a Tregaskiss product. The MIG gun you have purchased has been carefully assembled and is ready to weld and factory tested prior to shipment to ensure high performance. Before installing, compare the equipment received against the invoice to verify that the shipment is complete and undamaged.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING 1-1 Symbol Usage 1-2 Arc Welding Hazards 1-3 Additional Symbols For Installation, Operation, And Maintenance 1-4 California Proposition 65 Warnings 1-5 EMF Information 1-6 Principal Safety Standards 1-7 Commercial Warranty SECTION 2 —...
  • Page 4 6-7 Replacing the Solenoid Valves 6-8 Scheduled Maintenance SECTION 7 — TECHNICAL DATA 7-1 Pneumatic Diagrams 7-2 Electrical Schematic SECTION 8 — PARTS LIST SECTION 9 — TROUBLESHOOTING 9-1 TOUGH GUN TT3 Reamer 9-2 Lubricator 9-3 Filter/Regulator 9-4 Nozzle Detect NOTES ADDITIONAL SUPPORT MATERIALS OM-TT3-1.4...

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING Protect yourself and others from injury – read, follow, and save these important safety precautions ELECTRIC SHOCK can kill. and operating instructions. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work 1-1 Symbol Usage circuit is electrically live whenever the output is on.
  • Page 6 Turn off all equipment when not in use. Read and understand the Safety Data Sheets (SDSs) and the Do not use worn, damaged, undersized, or repaired cables. manufacturer's instructions for adhesives, coatings, Do not drape cables over your body. cleaners, consumables, coolants, degreasers, fluxes, and If earth grounding of the workpiece is required, ground it metals.
  • Page 7 Be alert that welding sparks and hot materials from welding ELECTRIC AND MAGNETIC FIELDS (EMF) can can easily go through small cracks and openings to adjacent affect Implanted Medical Devices. areas. Watch for fire, and keep a fire extinguisher nearby. Wearers of Pacemakers and other Implanted Be aware that welding on a ceiling, floor, bulkhead, or Medical Devices should keep away.

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    MOVING PARTS can injure. 1-3 Additional Symbols For Installation, Operation, And Maintenance Keep away from moving parts. Keep away from pinch points such as drive rolls. FIRE OR EXPLOSION hazard. WELDING WIRE can injure. Do not install or place unit on, over, or near combustible surfaces.
  • Page 9 READ INSTRUCTIONS. Read and follow all labels and the Owner's Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the Manual and in each section. Use only genuine replacement parts from the manufacturer. Perform installation, maintenance, and service according to the Owner's Manuals, industry standards, and national, state, and local codes.

  • Page 10: California Proposition 65 Warnings

    1-4 California Proposition 65 Warnings WARNING: This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm. For more information, go to www.P65Warnings.ca.gov. 1-5 EMF Information Electric current flowing through any conductor causes localized 3.

  • Page 11: Commercial Warranty

    1-7 Commercial Warranty Product is warranted to be free from defects in material and Tregaskiss reserves the right to repair, replace, or refund the workmanship for the period specified below after the sale by an purchase price of non-conforming product. Product found not authorized Buyer.

  • Page 12: Section 2 - Specifications

    SECTION 2 — SPECIFICATIONS 2-1 System Components Robotic Peripheral for GMAW Welding Air Requirements: Rated Voltage: 24 VDC Min. 80 to max. 100 psi (5.5 to 7.0 bar) at 16 CFM (450 LPM) Operating Voltage: ±10% of rated voltage Air Motor (at min. air requirement): Power Consumption: Max.

  • Page 13: Section 3 - Installation

    WARNING: Ensure power supply is off and disconnected before proceeding. Please follow your facility's lockout / tagout procedures. A. To Mount TOUGH GUN TT3 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.

  • Page 14: Installing The Wire Cutter

    Figure 3-B B. To Connect Air Supply NOTE: Push the HOME POSITION button before connecting air line. 1. Use only dry, filtered, lubricated air. IMPORTANT: Requirements: 80-100 psi at 16 CFM (5.5-7.0 bar at 450 LPM) at the reamer during operation. 2. Use an air supply line with an inside diameter of 3/8". Connect to a 1/4"...
  • Page 15 Figure 3-E B. Connecting Air Supply 1. Use only dry filtered air. IMPORTANT: Requirements – 80-100 psi at 16 CFM (5.5-7.0 bar at 450 LPM) at the wire cutter. 2. Use an air supply line with an inside diameter of 1/4” and connect to 1/8”...

  • Page 16: Installing Nozzle Detect

    3-3 Installing Nozzle Detect WARNING: Ensure air and power supply is off and disconnected Figure 3-F before proceeding. Please follow your facility's lockout / tagout procedures. NOTE: This nozzle detect sensor has a sensing range of 5 mm and can detect any metallic part that comes within this sensing range. The accuracy is ±...

  • Page 17: Section 4 - Setup

    SECTION 4 — SETUP 4-1 Air Motor Lubricator WARNING: The TOUGH GUN Reamer must be operated with lubricated air using either the air motor lubricator option or a suitable alternative system installed by the customer. The lubricator should be set to feed one drop of oil for every 50-75 CFM of air going through the motor (approximately 1 drop every 5-10 cycles or 1 drop per minute of operation).

  • Page 18: Wiring Interface Connections

    4-3 Wiring Interface Connections WARNING: The following connection should only be performed by a qualified technician. Damage to equipment will occur if connections are incorrect. To interface the TOUGH GUN Reamer with the controller, five Figure 4-A (5) electrical connections are required: ORANGE LEAD: Cycle Start output from PLC / controller (0.25 amp) WHITE LEAD: 0 VDC supply 0.5 amp constant...

  • Page 19: Inversing Circuit Board Logic

    2. Move the switches to the desired positions (SRC or SNK). 3. Connect power back into the reamer. IMPORTANT NOTE: Although the circuit board is protected, Tregaskiss suggests disconnecting the power before moving the switches. The switches are located on the top left hand corner of the...

  • Page 20: Setting Up V-Block

    4-5 Setting Up V-Block WARNING: Ensure power and air supply are off and disconnected Figure 4-C before proceeding. Please follow your facility's lockout / tagout procedures. PRO TIP: Removing and/or installing the top cover will be difficult if the air has not been disconnected. Disconnect the air prior to removing and/or installing the top cover.

  • Page 21: Setting Up Nozzle Heights For Cutter Blade Insertion

    4-6 Setting Up Nozzle Heights for Cutter Blade Insertion Figure 4-D A. Setting Nozzle heights See the chart below in order to find the correct height to set your nozzle for proper cutter blade insertion: Retaining Head / Gas Diffuser 404-20, 404-26, Cutter Nozzle...

  • Page 22: Setting Up Nozzle Detect

    4-7 Setting Up Nozzle Detect WARNING: Please follow your facility's lockout / tagout procedures. IMPORTANT: In order for the system to operate properly, the sensor signal must be monitored. A. Setting Up Nozzle Detect 1. With a nozzle on the gun, move the robot into position beside the nozzle detect sensor. 2.
  • Page 23 Step 1 above. The yellow light should not illuminate, indicating that there is no nozzle on the torch. NOTE: Adjustments may be necessary if you are not using genuine Tregaskiss® consumables. The setup distances may change but the procedure does not change. Figure 4-G Figure 4-H OM-TT3-1.4...

  • Page 24: Section 5 - Operation

    SECTION 5 — OPERATION 5-1 Understanding L.E.D. Indicators The L.E.D. indicators mounted on the circuit board of the TOUGH Figure 5-A GUN Reamer supply visual information regarding cycle status. This information may be used for both installation and maintenance to verify proper operation. When the TOUGH GUN Reamer is Home, L.E.D.

  • Page 25: Programming Events Sequence

    5-2 Programming Events Sequence A. Programming Cutter Blade / Reamer Sequence 1. Verify the TOUGH GUN Reamer L.E.D. is showing Unclamped and Reamer Home. 2. Position the robot to place the MIG gun nozzle so it is tangent to the two (2) angled faces of the v-block, at the proper insertion depth and concentric with the cutter blade (see section 4-6 Setting Up Nozzle Heights for Cutter Blade Insertion on page 17).

  • Page 26: Manual Operation

    The manual override switches allow confirmation that the lift Figure 5-C cylinder, jaw clamping and sprayer air circuits are operational. To manually operate the TOUGH GUN TT3 Reamer: NOTE: The HOME POSITION button should be pressed prior to manual setup to reset all circuitry 1.

  • Page 27: Section 6 - Maintenance

    SECTION 6 — MAINTENANCE NOTE: For ease of maintenance, the reamer can be removed from the welding environment and serviced in a proper maintenance area. Being able to move the reamer around will assist in the replacement of some parts, such as the motor, spindle limit switch, solenoid valves, etc.

  • Page 28: Replacing The Clamp Limit Switch

    6-2 Replacing the Clamp Limit Switch WARNING: Ensure air and power supply is off and disconnected Figure 6-B before proceeding. Please follow your facility's lockout / tagout procedures. 1. Remove the top plate of the reamer. 2. Open the rear cover. 3.

  • Page 29: Replacing The Air Motor

    6-3 Replacing the Air Motor WARNING: Ensure air and power supply is off and disconnected Figure 6-C before proceeding. Please follow your facility's lockout / tagout procedures. 1. Open the rear cover, or remove it completely by removing the five (5) BHCS using a 3 mm Allen wrench. 2.

  • Page 30: Replacing The Cutter Blade

    6-5 Replacing the Cutter Blade WARNING: Ensure air and power supply is off and disconnected Figure 6-E before proceeding. Please follow your facility's lockout / tagout procedures. A. To Remove the Cutter Blade 1. Remove the cutter blade by using a 5/8" wrench and the supplied 9/16"...

  • Page 31: Replacing The Solenoid Valves

    6-7 Replacing the Solenoid Valves WARNING: Ensure air and power supply is off and disconnected Figure 6-F before proceeding. Please follow your facility's lockout / tagout procedures. 1. Shut off the power to the reamer. 2. Shut off the air supply to the reamer. 3.

  • Page 32: Scheduled Maintenance

    6-8 Scheduled Maintenance The TOUGH GUN TT3 Reamer will require a periodic maintenance program to ensure a reliable service life, as recommended below: DAILY The oil level in the lubricator reservoir. The life of the air motor is dependent on a consistent supply of oil. CHECK CHECK The air lines and interface cable for leaks and fraying.

  • Page 33: Section 7 - Technical Data

    SECTION 7 — TECHNICAL DATA 7-1 Pneumatic Diagrams A. TOUGH GUN TT3 Reamer B. TOUGH GUN TT3 Reamer with Lubricator OM-TT3-1.4...

  • Page 34: Electrical Schematic

    7-2 Electrical Schematic A. TOUGH GUN TT3 Reamer OM-TT3-1.4...

  • Page 35: Section 8 - Parts List

    SECTION 8 — PARTS LIST A. TOUGH GUN TT3 Reamer ITEM PART # DESCRIPTION ITEM PART # DESCRIPTION RR-707-31 TCP locator assembly TR-2530 Muffler TR-2127 Upper jaw spacer TT-LUB-SMC Lubricator with bracket TR-2120 Clamp jaw assembly TR-2440 Reamer drive belt TR-2130 Clamp cylinder R-2310-2 M4 standoff - reamer TT3-2322...
  • Page 36 B. TOUGH GUN Sprayer Assembly ITEM PART # DESCRIPTION TT3-001-5 Sprayer steel line kit RR-1320 Reservoir TT3E-500-20 Sprayer check valve TS-500-15 Spray block with fittings Not Sellable 1/4" sprayer hose SR-500-1 Sprayer bracket OM-TT3-1.4...
  • Page 37 C. TOUGH GUN Wire Cutter (Part # WC-100) ITEM PART # DESCRIPTION ITEM PART # DESCRIPTION WC-100-8 Wire cutter base plate Not Sellable M10x1.5x25mm SHCS Not Sellable M6x1x16mm SCHCS Not Sellable M8x1.25x55mm SCHCS WC-100-20 Wire catcher basket Not Sellable M8x1.25x50mm SHCS WC-100-27 Backing plate TR-2221...

  • Page 38: Section 9 - Troubleshooting

    3. Gun improperly aligned in TOUGH 3. Check v-block / nozzle compatibility chart (refer to Cutter Blade GUN Reamer. and V-Block Chart in the SP-TT3 TOUGH GUN TT3 Reamer spec sheet at www.Tregaskiss.com/spec). 5. Reamer stays in 1. Cutter blade is jammed in gun.

  • Page 39: Lubricator

    9-2 Lubricator PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 1. Oil fill level low. 1. Oil depleted in bowl. 1. Refill oil bowl to correct level using air motor oil. 2. Incorrect oil drip rate. 1. Drip rate valve not set properly. 1.

  • Page 40: Nozzle Detect

    9-4 Nozzle Detect PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 1. No LED lights on sensor. 1. Loose connection of power cable. 1. Check that the connection is secure. 2. Broken cable. 2. Replace sensor. 3. Damaged sensor. 3. Replace sensor. 2. No signal from sensor but 1.

  • Page 41: Notes

    NOTES OM-TT3-1.4...

  • Page 42: Additional Support Materials

    ADDITIONAL SUPPORT MATERIALS For additional support materials such as Spec Sheets, troubleshooting information, how-to guides and videos, animations, online configurators and much more, please visit Tregaskiss. Scan the QR Code with your smart phone for immediate access to Tregaskiss.com/TechnicalSupport. Scan to view the TOUGH GUN ®...

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