OM-TT4E-1.5 Tregaskiss and Bernard Owner’s Manual

OM-TT4E-1.5 Tregaskiss and Bernard

Product Information

Specifications

• Product Name: Ethernet Equipped Robotic Nozzle Cleaning Station, MIG (GMAW) Welding Peripheral
• Model Number: OM-TT4E-1.5
• Manufacturer: Tregaskiss
• Website: tregaskiss.com/TechnicalSupport
• Contact: 1-855-MIGWELD (644-9353) (US & Canada) / +1-519-737-3000 (International)

Product Usage Instructions

Installation

1. Install the Reamer following the instructions provided.
2. Install the Wire Cutter as per the installation guide.
3. Set up the Nozzle Detect feature by following the installation steps.

Setup

1. Ensure proper lubrication of the air motor as detailed in the manual.
2. Access and understand the electrical and pneumatic controls for efficient operation.
3. Make necessary wiring interface connections according to specifications.
4. Configure the Ethernet module settings for connectivity.
5. Set up the V-Block and adjust nozzle heights for cutter blade insertion.
6. Complete the setup for Nozzle Detect feature.
7. Set the IP address as required for network communication.
8. Refer to the Data Map for additional information on setup parameters.

Operation

1. Understand the LED indicators on the Ethernet module for status monitoring.
2. Follow the program logic chart for operational guidelines.
3. Program events sequence according to the desired workflow.
4. Operate manually or through the Human-Machine Interface (HMI).
5. Adjust flow control valves for optimal performance.

Maintenance

1. Regularly replace the spindle limit switch to ensure proper functioning.
2. Replace the clamp limit switch when necessary.
3. If needed, replace the air motor following maintenance procedures.
4. Change the drive belt as part of routine maintenance.

FAQs

• Q: How often should I perform scheduled maintenance on the product?
  • A: Scheduled maintenance should be performed as per the guidelines provided in the manual, typically every [specify time period]. This ensures optimal performance and longevity of the equipment.

“`

TOUGH GUN® TT4E Reamer
OWNER’S MANUAL

March 2024

OM-TT4E-1.5

Ethernet Equipped Robotic Nozzle Cleaning Station, MIG (GMAW) Welding
Peripheral

Tregaskiss.com/TechnicalSupport
1-855-MIGWELD (644-9353)(US & Canada) +1-519-737-3000(International)

Thank You for Choosing Tregaskiss®
Thank you for selecting a Tregaskiss product. Before installing, compare the equipment received against the invoice to verify that the shipment is complete and undamaged. It is the responsibility of the purchaser to file all claims of damage or loss that may have occurred during transit with the carrier. The owner’s manual contains general information, instructions and maintenance to help better maintain your MIG gun or peripheral. Please read, understand and follow all safety precautions. While every precaution has been taken to assure the accuracy of this owner’s manual, Tregaskiss assumes no responsibility for 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-MIGWELD (6449353) (US & Canada) or +1-519-737-3000 (International), fax 1-519-737-1530, or email at [email protected]. Our trained Customer Service Team is available between 8:00 a.m. and 5:30 p.m. EST, and will answer your product application or repair questions. Tregaskiss manufactures premium robotic MIG (GMAW) welding guns, peripherals and consumables. For more information on other premium Tregaskiss products, contact your local Tregaskiss distributor or visit us on the web at Tregaskiss.com.
Subject to Change ­ The information presented in this manual is accurate to the best of our knowledge at the time of printing. Please visit Tregaskiss.com for the most up-to-date information. Additional Material ­ For additional support materials such as spec sheets, troubleshooting information, how-to guides and videos, animations, online configurators and much more, please visit Tregaskiss.com. Scan this QR Code with your smart phone for immediate access to Tregaskiss.com/TechnicalSupport

SECTION 1 —

SAFETY PRECAUTIONS

— READ BEFORE USING

Protect yourself and others from injury ­ read, follow, and save these important safety precautions and operating instructions.
1-1 Symbol Usage
DANGER! ­ Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE ­ Indicates statements not related to personal injury. ­ Indicates special instructions.
This group of symbols means Warning! Watch Out!, ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions to avoid the hazards.
1-2 Arc Welding Hazards
The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in section 1-4 Principal Safety Standards on page 3, and in welding power source Owner’s Manual. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this equipment. A qualified person is defined as one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.

TOUGH GUN® TT4 Reamer safety label definitions:
Warning! CUT & CRUSH Keep hands clear of all moving parts.
Warning! ROTATING CUTTER Keeps hands clear. Disconnect power before servicing.
Warning! AUTOMATIC START Equipment starts automatically. Disconnect power before servicing or opening access door.

ELECTRIC SHOCK can kill.
l Always wear dry insulating gloves. l Insulate yourself from work and ground. l Do not touch live electrode or electrical parts. l Turn off welding power source before changing contact tip or
gun parts. l Keep all covers and handle securely in place.
MOVING PARTS can injure.
l Keep away from moving parts. l Keep away from pinch points such as drive
rolls.

DISCONNECT POWER before servicing.
CONSULT YOUR SERVICE MANUAL before servicing.

NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
l Check for noise level limits exceeding those specified by OSHA.
l Use approved ear plugs or ear muffs if noise level is high. l Warn others nearby about noise hazard.

1

OM-TT4E-1.5

READ INSTRUCTIONS.
l 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.
l Use only genuine replacement parts from the manufacturer. l Perform installation, maintenance, and service according to
the Owner’s Manuals, industry standards, and national, state, and local codes.

OM-TT4E-1.5

2

1-3 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.

1-4 Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding Society standard ANSI Standard Z49.1. Website: www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Website: www.ansi.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1. Website: www.aws.org.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2 from Canadian Standards Association. Website: www.csagroup.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B from National Fire Protection Association. Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.
SR7 2022-01

1-5 EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields may interfere with some medical implants, e.g. Pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passersby or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using
a cable cover. 2. Do not place your body between welding cables. Arrange
cables to one side and away from the operator.

3. Do not coil or drape cables around your body. 4. Keep head and trunk as far away from the equipment in the
welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as
possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source wire
feeder.
About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

PRODUCT WARRANTY

4-1 Product Warranty

Limited Warranty
Tregaskiss’ Products shall, from the date of original purchase (or, solely with respect to Low Stress Robotic Unicables packaged with any Tregaskiss® Robotic MIG Gun, from the date the product goes into production for its intended use) and for the period set forth below, be free from defects in material and workmanship. To obtain repair or replacement of any Product, the covered Product must be delivered, transportation pre-paid by Purchaser, to the address specified by Tregaskiss on its Returned Materials Authorization, with: (i) written proof of warranty coverage (e.g., Purchaser dated purchase order); (ii) serial number on product (if any); (iii) the Product’s installed location within Purchaser’s facility and usage of the Product; and (iv) written specification of any alleged defect(s). In the event the foregoing materials are not timely provided to Tregaskiss by claimant, warranty coverage will be determined by Tregaskiss, in its sole discretion. For the avoidance of doubt, the warranty period for any Product or part/component of any Product that is replaced or repaired by Tregaskiss under the foregoing warranty is not extended or renewed at the time of such replacement or repair. The Warranty against defects does not apply to: (1) consumable components or ordinary wear items; (2) products which are improperly altered, modified, stored, installed, operated, handled, used or neglected or use of the Products with equipment, components or parts not specified or supplied by Tregaskiss or contemplated under the Product documentation; or (3) Products which have not been operated, maintained, and repaired pursuant to Product documentation provided by Tregaskiss. Purchaser shall pay Tregaskiss for all warranty claim costs incurred by Tregaskiss (including inspection, labor, parts, testing, scrap and freight) due to warranty claims submitted by Purchaser which are not covered by Tregaskiss’ warranty.
l Bernard® BTB Semi-Automatic Air-Cooled MIG Guns: 1 year;
Lifetime warranty on straight handles, straight handle
switches, and rear strain relief l Bernard® W-GunTM and T-GunTM Semi-Automatic Water-
Cooled MIG Guns: 180 days l Bernard® TGX® Chassis and Bernard TGX Ready To Weld
MIG Guns: 90 days l Tregaskiss® Robotic MIG Guns and Components: 1 year
l Tregaskiss® Automatic MIG Guns: 1 year
l Tregaskiss® TOUGH GUN® Reamer: l When factory-equipped with lubricator: 2 years when
factory-equipped with lubricator l When (i) factory-equipped with lubricator and (ii) used
exclusively with Tregaskiss® TOUGH GARD® Anti-
Spatter Liquid: 3 years when both (i) and (ii) l Tregaskiss® TOUGH GUN® Robotic Peripheral (Clutch,
Sprayer, Wire Cutter, Arms): 1 year l Tregaskiss® Low-Stress Robotic Unicables (LSR+ Unicables):
6 months

Service Warranty
Tregaskiss warrants the Services shall conform to any mutually agreed upon specifications or statements of work. Purchaser’s sole remedy, and Tregaskiss’s sole liability, for a breach of the foregoing warranty is for Tregaskiss, at its option, to re-perform the Services or credit Purchaser’s account for such Services.
Limitation of Liability and Remedies
TREGASKISS WILL NOT BE LIABLE, AND PURCHASER WAIVES ALL CLAIMS AGAINST TREGASKISS FOR INDIRECT, INCIDENTAL, SPECIAL, PUNITIVE OR CONSEQUENTIAL DAMAGES, DOWN TIME, LOST PROFITS OR COMMERCIAL LOSSES, WHETHER OR NOT BASED UPON TREGASKISS’ NEGLIGENCE OR BREACH OF WARRANTY OR STRICT LIABILITY IN TORT OR ANY OTHER CAUSE OF ACTION. IN NO EVENT WILL TREGASKISS’ LIABILITY IN CONNECTION WITH THE AGREEMENT OR SALE OF TREGASKISS’ PRODUCTS OR SERVICES EXCEED THE PURCHASE PRICE OF THE SPECIFIC PRODUCTS OR SERVICES AS TO WHICH THE CLAIM IS MADE.

OM-TT4E-1.5 10

SECTION 5 —

SPECIFICATIONS

Robotic Peripheral for GMAW Welding

Rated Voltage:

24 VDC

Operating Voltage: ±10% of rated voltage

Power Consumption: Max. wattage in operation 5.3 W

Anti-Spatter Requirements:

Water-based anti-spatter liquid must be used. Oil-based anti-spatter solution will compromise performance.

Air Requirements: Min. 80 to max. 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) Protocols Supported: Ethernet/IP PROFINET Modbus TCP/IP

5-1 System Components
For complete parts list, please see Section 10 — Parts List on page 51.

11 OM-TT4E-1.5

6-1 Installing the Reamer

SECTION 6 —

INSTALLATION

WARNING: Ensure power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures.
A. To Mount TOUGH GUN TT4E 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. 1. Affix the reamer base to a sturdy platform using four (4) M10x1.5×25 mm bolts provided.
Figure 6-A

NOTE: The reamer can be mounted on an angle (no more than 45°) and can be mounted overhead, only by using the multi-feed adapter kit (part # TT4-MF-100). Ensure debris falls away from the clamp housing.
OM-TT4E-1.5 12

Figure 6-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″ NPT T-fitting located on the side of the reamer.
13 OM-TT4E-1.5

6-2 Installing the Wire Cutter
WARNING: Ensure air and power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures.
A. Mounting 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 WC-400 wire cutter base to the top of the reamer, or other sturdy platform using the same three (3) M6x1.0x20 mm Socket Head Cap Screws (SHCS) that are securing the clamp housing cover onto the reamer.(see Figure 6-D)
3. If mounting a WC-100 wire cutter to the reamer, use three (3) M6x1.0x25 mm SHCS.
4. Thread the M12 connector into the 4-Pin receptacle labelled “Wire Cutter” located on the Setup Switch plate (on the side of the reamer).
Figure 6-C
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. Remove the ¼” NPT plug on the T-fitting located on the side of the reamer.
3. Install air fitting WC-100-28 onto the top of the T-fitting. 4. Install the supplied 810-1-2 air line from the wire cutter valve
to the WC-100-28 air fitting.

Figure 6-D Figure 6-E OM-TT4E-1.5 14

6-3 Installing Nozzle Detect
WARNING: Ensure air and power supply is off and disconnected 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 ± 2% (0.1 mm). The circuit is normally open until the sensor detects a metallic part within its sensing range. The green LED on the sensor will always be on if there is power to the reamer.
A. Mounting Nozzle Detect
1. Using two (2) M3x0.5×16 mm SHCS, attach the nozzle detect to the side of the clamp housing in the two threaded holes. Torque to 8-10 in-lbs.
2. Connect the nozzle detect cable into the receptacle labeled “Nozzle Detect” located on the Setup Switch plate.

Figure 6-F

15 OM-TT4E-1.5

7-1 Air Motor Lubricator

SECTION 7 —

SETUP

WARNING: The reservoir is dry or empty and needs to be filled prior to first start of the unit. The TOUGH GUN Reamer must be operated with lubricated air using the air motor lubricator. The lubricator should be set to feed one drop of oil for every 100-150 CFM of air going through the motor (approximately 1 drop every 10-20 cycles or 1 drop per two minutes of operation).The recommended lubricant to be used is a hydraulic light oil with ISO VG 32 specification (SAE 10W).
7-2 Accessing Electrical and Pneumatic Controls

WARNING: Ensure power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures. To access the electronic circuit board for installation or service for the TOUGH GUN Reamer:
1. Loosen the two (2) M5 thumb screws to open the hinged rear access door. It is not necessary to fully remove the thumb screws.
2. The rear access door can be completely removed if accessibility is an issue. To do so, using a 3 mm Allen wrench, remove the (3) BHCS which fasten the hinge to the frame.

OM-TT4E-1.5 16

7-3 Wiring Interface Connections
WARNING: The following connection should only be performed by a qualified technician. Damage to equipment will occur if connections are incorrect.
Figure 7-A
17 OM-TT4E-1.5

7-4 Ethernet Module Specifications
WARNING: Before setup, ensure that all connections are correct, or damage to the TOUGH GUN Reamer will occur. The Ethernet module (part # TT3E-2310) is a multiprotocol communication adaptor which supports the following networking standards:
l Ethernet/IP l PROFINET l Modbus TCP/IP
The factory default setting is that all communication protocols are enabled. After power-up, a multiprotocol device is listening on all necessary ports to detect which kind of network is in use. Some key features of the Ethernet module are as follows:
l It is an integrated Ethernet switch; l 10 Mbps / 100 Mbps supported; l 3x separate I/O power supply groups that are galvanically
separated; l 24 VDC; l Up to 1A outputs; l 2x RJ45 sockets.
The TT3E-2310 wiring / pinout diagram shown in Figure 7-B is as follows:
l V1+ powers I/O 0 to 7 l V2+ powers I/O 8 to 13 l V3+ powers I/O 14 and 15 l Specific I/O functions are listed in 7-9 Data Map on page 26. l 4x Status LEDs (see for color legend):
l ERR – Status of the circuits l BUS – Connection to a network l ETH 1 & 2 – Connection speed / link

Figure 7-B

OM-TT4E-1.5 18

7-5 Setting Up V-Block

WARNING: Ensure power and air supply are off and disconnected 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.

1. Remove the four (4) cover screws at the top of the reamer. 2. Lift the clamp cover off completely. 3. Lift and rotate the v-block so the desired size faces outward from
between the front jaws.

See V-Block Size Chart below:

Part #

Nozzle Outside Diameter for each side of V-block

TR-2150 0.850″

0.938″

1.062″

1.106″

TR-2161 0.830″

0.978″

0.984″

1.125″

TR-2162 0.780″

0.813″

0.875″

1.000″

Numbers are stamped into the v-blocks. The number refers to the outside diameter of the nozzle.

Figure 7-C

19 OM-TT4E-1.5

7-6 Setting Up Nozzle Heights for Cutter Blade Insertion

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

Cutter Blade

Nozzle

404-20, 404-26, 404-30, 404-32 , D-ATSH, D-ATTH

RCT-13

3/4″ (19.05 mm)

0.375″

9.53 mm

RCT-01

5/8″ (15.88 mm)

0.225″

5.72 mm

RCT-04

1/2″ (12.7 mm)

0.125″

3.18 mm

NOTE: Using the top of the reamer as the datum, the base of the nozzle will either be above this datum depending on the nozzle configuration.

Figure 7-D

OM-TT4E-1.5 20

7-7 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. Measure the distance from the tangent face of the nozzle to the face of the nozzle detect sensor, ensuring that it is 3 mm ± 1 mm. 3. The ring crimp on the nozzle should be in line with the center of the sensor (yellow circle portion on the face of the sensor). The
vertical distance between the top of the reamer clamp housing and the base of the nozzle outer shell should be approx. 0.10″. Figure 7-E
21 OM-TT4E-1.5

B. Testing Nozzle Detect
1. Move robot into position beside the nozzle detect sensor (with a nozzle on the gun). The yellow LED should illuminate.
2. Move robot away from the nozzle detect sensor and remove the nozzle (keeping the retaining head on).
3. Move robot back to the programmed position that was used in Step 1 above. The yellow light should not illuminate, indicating that there is no nozzle on the gun.
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 7-F Figure 7-G Figure 7-H

OM-TT4E-1.5 22

7-8 Setting the IP Address
The first step that must be done in order to communicate with the Ethernet module is to change the TCP/IPv4 Properties on the computer being used. The following must be done:
1. Open Network Connection Status through the Network and Sharing Center (if the computer is using Windows based OS).
2. Select the Properties button (see Figure 7-I). 3. Select Internet Protocol Version 4 (TCP/IPv4) and click the
Properties button (see Figure 7-J).

Figure 7-I Figure 7-J

23 OM-TT4E-1.5

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. l The factory set first three octets are: 192.168.1. l The last octet must be between 1 and 254 but cannot be the same as the Ethernet module. l The Subnet mask should self-populate, but 255.255.255.0 can be inputted (see Figure 7-K).
6. Once this is completed, communication between the computer and the Ethernet module can occur.
NOTE: To return the computer settings, repeat Steps 1-3 above and then select the “Obtain an IP address automatically” option.
The Ethernet module comes from the factory address as 192.168.1.1. However, there are a number of methods that can be used to set/change the IP address of the Ethernet module. Each method is outlined below:
A. PGM-DHCP Mode (Preferred Method)
1. Ensure that the rotary switches (located at the top of the module underneath the clear plastic cover) on the module are set to 500 PGM or 600 DHCP.
2. Power on the reamer. 3. Use the TURCK IP Address Search Tool to scan for the IP address
of the module. NOTE: The TURCK IP Address Search Tool can be found online at www.tregaskiss.com/ReamerTT4E. Find the link under the Software tab or http://pdb2.turck.de/us/DE/products/0000001a000293cb0002003 a (see Figure 7-L). 4. Once the TURCK IP Address Search Tool is installed, run the program and select the “Search” button. 5. Once the Ethernet module shows up on the list, select it and click the “Change” button. 6. The IP address can then be changed to the desired address. 7. Click “Write to device” and the IP address will be stored in the module’s EEPROM memory.

Figure 7-K Figure 7-L

OM-TT4E-1.5 24

B. 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 which you
want to address (identified by the MAC address). 4. Create a new entry and assign the IP address to the Ethernet
module. 5. The IP address will be saved in the module’s EEPROM memory
and read from here when the module is powered up.
C. Rotary Switch Method
1. The rotary switches will designate the last octet of the IP address. Rotate the switches to the desired octet (must be between 1 and 254).
2. Power up the reamer. 3. The IP address is now set to the desired octet.
D. Restoring the IP Address to the Default Setting
1. Set all rotary switches to 0. 2. Cycle power. 3. Reamer IP address is now set to 192.168.1.254.
25 OM-TT4E-1.5

7-9 Data Map

WARNING: I/O 4 is configured to be able to start the reamer cycle without a signal from the PLC. Care must be taken when servicing the reamer so that no accidental short to I/O 4 happens. It is recommended that if servicing the wiring or Ethernet Block, the air supply is turned off.

Below is the Data Map for the Ethernet module (part # TT3E-2310):

I/O 15

I/O 14

I/0 13

I/O 12 I/O 11 I/0 10 I/O 9

I/O 8

I/O 7 I/O 6

I/O 5

IN

Upper Limit

Lower Limit

Fluid Level Indicator

OUT

Wire Cut

Clamp Spindle Motor Sprayer

Word Bit 15

Bit 14

Bit 13

Bit 12 Bit 11 Bit 10 Bit 9

Bit 8

Bit 7 Bit 6

0 OUT 1
2 3

0

1

IN

2

3

4

10

Enable Wire Cut

Wire Cut On

Fluid Level Indicator

Sprayer

Startup Motor Dwell from PLC (ms)

Spindle Advance Dwell from PLS (ms)

PLC Connected

Clamp On

Spindle On

Motor On

Sprayer Duration from PLC (ms)

Sprayer On

Upper Limit

Lower Limit

Current Step

Startup Motor Dwell – Total (ms)

Spindle Advance Dwell – Total (ms)

Sprayer Duration – Total (ms)

Current Program Revision

Bit 5 Enable DS
DS Enabled

I/O 4 HW Cycle Start
Bit 4

I/O 3
PLC Connected
Bit 3

I/O 2

I/O 1 I/O 0

Reset Button

Nozzle Detect

Clamped

Bit 2

Bit 1 Bit 0

Reset

Start Cycle

Clamp Open

Reset Clear

Nozzle Detect

Error Running

A. Programming to the PLC
Download .eds files from our website at www.tregaskiss.com/TT4E within the Software tab, labelled Omron PLCs and All other PLCs.

Figure 7-M

To configure the module within the PLC, add the device and use the following Connection Parameters (see Figure 7-M).

Input: Output: Configuration:

Assembly Instance 101 110 1

Size

4

(16-bit)

5

(16-bit)

0

(8-bit)

The parameters listed above are from the TOUGH GUN TT4E Reamer. For example, the reamer will send 5 outputs (for each word) to the PLC and it will receive 4 inputs (for each word) from the PLC.
NOTE: Name and IP Address shown in Figure 7-M are examples.

OM-TT4E-1.5 26

B. Programming to a Robot Controller
Using the Data Map above, all the I/Os shall be assigned according to what is available on the robot controller. The TOUGH GUN TT4E Reamer is a scanner and should be configured using the following additional information (pulled directly from the Ethernet module’s configuration .eds file):
l Vendor Code: 48 l Product Type: 12 l Product Code: 31089 l Input Size (words): 5 l Output Size (words): 4 l Assembly Instance (input): 101 l Assembly Instance (output): 110 l Configuration Instance: 1 l Major Revision: 2 l Minor Revision: 7
27 OM-TT4E-1.5

SECTION 8 —

OPERATION

8-1 Understanding L.E.D. Indicators on the Ethernet Module

LEDs are located on the front of the Ethernet module and can be accessed by opening the rear door of the reamer (see section 7-2 Accessing Electrical and Pneumatic Controls on page 16).

LED

Color

Green

ETH1 / ETH2 Yellow

N/A

Green

BUS Red

ERR I/O 0 – 15

N/A Green Red Green Green

Status On Flashing On Flashing Off On Flashing On Flashing Off On On On Off

Description Ethernet link (100 Mbps) Ethernet communication (100 Mbps) Ethernet link (10 Mbps) Ethernet communication (10 Mbps) No Ethernet link Active connection to a master Ready IP address conflict or status word is active Blink/Wink command active Power is off Diagnostics disabled Short- circuit Input / Output is active Input / Output is inactive

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 3. ERR — Illuminated solid green 4. I/O 0, 2, & 6 — Should be illuminated when at the home
position
No other LEDs should be illuminated. If there are other illuminated LEDs, consult 11-1 TOUGH GUN TT4E Reamer Network on page 53

Figure 8-A
TURCK is a registered trademark of Turck Inc. & Hans Turck GmbH & Co. K.G.

OM-TT4E-1.5 28

8-2 Program Logic Chart
The TOUGH GUN TT4E Reamer comes configured with a ream cycle programmed into the Ethernet module. See below for the program logic chart for the ream cycle as well as optional PLC initiated functions.
A. Reamer Cycle Logic
Recommended:
l Motor will not start if robot or PLC is faulted l Use 24V motion and non- motion power l Error messages & retry functions fully
configurable by user

Figure 8-B

29 OM-TT4E-1.5

B. Optional Functions Logic

Figure 8-C

Figure 8-D

EXPLANATION:
l Robot moves gun to spray location. l Sprayer is turned on and covers the gun consumables with
water-based anti-spatter liquid. l Sprayer dwell time is adjustable through the HMI.

EXPLANATION:
l Robot moves gun to nozzle detect location. l If the nozzle has come off during the welding process, the
switch will not be triggered when the robot is in nozzle detect location.

Figure 8-E

Figure 8-F

EXPLANATION:
l Robot moves gun to wire cut location. l Robot controller jogs the wire out of the contact tip past the
cutter blades. l Wire cutter is fired and cuts the weld wire before the robot
continues.

EXPLANATION:
l As the anti-spatter fluid level gets to a low level point, the float switch will close the circuit and creates a signal that fluid is low.
l PLC/Robot to manage the alert to the operator. l Once fluid is added to the reservoir, the float switch will open
and the signal will no longer be present.

OM-TT4E-1.5 30

8-3 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 7-6 Setting Up Nozzle Heights for Cutter Blade Insertion on page 20). 3. Cycle Start – Supply output signal from the robot controller / PLC. Pulse output for 0.5 seconds. 4. TOUGH GUN Reamer will perform cleaning cycle. 5. When the Cycle Start signal is supplied to the reamer, Reamer Home and Unclamped L.E.D.s will turn off. There should be no
illuminated L.E.D.s on the board until the reamer reaches the top of its stroke. At this point, the Reamer Ahead L.E.D. will illuminate for a split second before the spindle begins to retract. 6. Once the reamer reaches the bottom of the stroke again, the motor will stop spinning, the clamps will open to release the nozzle and the Reamer Home and Unclamped L.E.D.s will be illuminated again. The PLC should check for the Home signal before letting the robot move. 7. The gun can now be safely removed from the TOUGH GUN Reamer clamps and moved to its spray position.

B. Programming Sprayer Sequence
Important Note: Do not use oil-based anti-spatter solution, as this will compromise performance.
1. After reaming, center the nozzle above the hole on the cover of the spray containment unit.
2. Insert the gun directly into the spray containment unit until the crimp ring of the nozzle is flush with the top of the spray containment cover. (see Figure 8-G)
3. Supply output signal from robot controller for 0.5 seconds for initial setup. Adjust timer to increase or decrease quantity of anti-spatter compound as required by process.
4. Retract the gun from the spray containment unit once the spray is complete.
IMPORTANT: If MIG gun is equipped with air blast, DO NOT activate air blast when over the spray head. Dirt / spatter may be blown into the spray head orifice, which may hamper spray operation. Air blast can be activated during the reaming sequence.

Figure 8-G

31 OM-TT4E-1.5

8-4 Manual Operation
The manual momentary override switches allow confirmation that the lift cylinder, jaw clamping and sprayer air circuits are operational.
To manually operate the TOUGH GUN TT4E Reamer: NOTE: The HOME POSITION button should be pressed prior to manual setup to reset all circuitry 1. Locate the setup switches on the air supply side of the reamer
(opposite the reservoir). 2. Operate the switches as required.

Figure 8-H

OM-TT4E-1.5 32

8-5 Operation through the HMI
The TOUGH GUN TT4E Reamer has a built-in feature that allows the dwell times for the motor start up, spindle advance and sprayer duration to be changed to user preference. 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). IMPORTANT NOTE: The HMI will only work with an HTML5 enabled browser.
The steps to access the HMI are as follows:
1. Download the TOUGH GUN TT4E Reamer HMI and Update Program from www.tregaskiss.com/TT4E (under the Software tab), and open the local file folder.
2. Select the _View HMI.html file and open it in your default web browser (be sure your web browser supports HTML5) (see Figure 8-I).
3. Once opened, enter the IP address of the reamer you wish to operate (see Figure 8-J).

Figure 8-I
Figure 8-J Figure 8-K

33 OM-TT4E-1.5

4. In the HMI screen, there are two options in the left part of the screen. One for the Program Status and one for Program Setup (see Figure 8-K). 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 (see Figure 8-L).
5. Once in the Program Setup screen, the right side of the screen will display the various dwell time and Double Stroke options.
6. To enable/disable the Double Stroke, click “Enable Double Stroke from HMI” (see Figure 8-M).

Figure 8-L Figure 8-M

OM-TT4E-1.5 34

7. To change the dwell times for the motor start up, spindle and sprayer, insert the desired time (in milliseconds) into the white cell and click the corresponding button below it. The respective total dwell time will be updated instantly in the HMI screen (see Figure 8-N, Figure 8-O, and Figure 8-P). NOTE: There are pre-programmed minimum dwell times that cannot be changed (250ms for Motor Start Up and Spindle Advance, 1ms for Sprayer Duration). The time inputted by the user in the HMI will not be cumulative with these minimum dwell times.

Figure 8-N Figure 😯 Figure 8-P

35 OM-TT4E-1.5

8-6 Adjusting Flow Control Valves
NOTE: The flow control valve provides a smooth, constant feed of the cutting tool. The feed rate is dependent on the amount of spatter accumulated. If a smaller amount of spatter accumulates, the feed rate can be set faster. A feed rate that is set too fast may stall the motor or damage the cutter blade.
To adjust the flow control valve(s): 1. There are flow control valves located on the spindle unit for
adjusting the lift/retract speed of the spindle. They are located behind the spindle cover. 2. To increase the feed rate of the cutter blade (lift speed), pull out on the grey knob of the top flow control valve and turn counterclockwise. 3. To increase the retract speed of the cutter blade, pull out on the grey knob of the bottom flow control valve and turn counterclockwise. 4. To decrease either the lift speed or retract speed, turn the respective grey knob clockwise. 5. Once the desired setting is achieved, push the grey knob in to lock it in position.

Figure 8-Q

OM-TT4E-1.5 36

SECTION 9 —

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.
9-1 Replacing the Spindle Limit Switch

WARNING: Ensure air and power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures.
1. Open the rear cover. 2. Disconnect connectors from the wiring harness. 3. Remove the one fastener on the limit switch bracket. 4. Remove assembly and replace with new part. Ensure the
actuator is clear of all limit switches when the new assembly is installed. 5. Align the new bracket with the dowel hole on the reamer frame face, then reinstall fastener. 6. Reconnect the connectors into the wiring harness (see section 10-2 Electrical Schematic on page 50).

Figure 9-A

37 OM-TT4E-1.5

9-2 Replacing the Clamp Limit Switch
WARNING: Ensure air and power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures.
1. Remove the top plate of the reamer. 2. Open the rear cover. 3. Disconnect the 3-pin connector from the lower right corner of
the circuit board. 4. Loosen the screws and remove the wires from the circuit
board connector. NOTE: the wire colors and their positions within the connector (see section 10-2 Electrical Schematic on page 50). 5. Remove the clamp limit switch fastener and remove assembly (pull the wires through the grommet). 6. Slide the two wires through the grommet into the TOUGH GUN Reamer. 7. Fasten the new clamp limit switch into position. 8. Install the two wires into the new keyed circuit board connector (see section 10-2 Electrical Schematic on page 50). 9. Clip the circuit board connector into location on the circuit board. 10. Reinstall the top plate and close the rear cover.

Figure 9-B

OM-TT4E-1.5 38

9-3 Replacing the Air Motor

WARNING: Ensure air and power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures.
1. Open the rear cover by loosening the two (2) thumb screws or remove it completely by removing the three (3) BHCS using a 3 mm Allen wrench.
2. Remove the tension lock screw located on the side of the reamer under the reservoir.
3. Push the motor in to release belt tension, and slide the belt off the front pulley at the same time.
4. Disengage belt from the rear pulley. 5. Release the air lines from the quick disconnect air fittings at the
front of the motor. 6. Pull the motor out. IMPORTANT: Be careful not to lose the belt
tension spring. 7. Reverse the order of the above steps for reassembly.
9-4 Replacing the Drive Belt

Figure 9-C

WARNING: Ensure air and power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures.
1. Open the rear cover. 2. Loosen the tension lock screw. 3. Push the motor in to release belt tension, and slide the belt off the front pulley at the same time. 4. Remove the belt from the rear pulley. 5. Reverse the order of the above steps for reassembly.

39 OM-TT4E-1.5

9-5 Replacing the Solenoid Valves
WARNING: Ensure air and power supply is off and disconnected 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. Open the rear cover. 4. Unplug the electrical connector directly from the bottom of the
solenoid valve. 5. Loosen and remove the two (2) solenoid valve screws. 6. Remove the solenoid valve and gasket.
NOTE: New gasket (included with new valve) must be installed when replacing valve. 7. Install the new gasket and valve and tighten screws to 6 in-lbs. 8. Reconnect the electrical connector to the bottom of the solenoid valve. 9. Close the rear cover.

Figure 9-D

OM-TT4E-1.5 40

9-6 Replacing the Ethernet Module
WARNING: Ensure air and power supply is off and disconnected 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 (4x) 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 (2x) RJ45 Ethernet cables from the module. 6. Reconnect the connectors onto the new Ethernet module and
tighten the (4x) screws. 7. Reconnect the (2x) RJ45 Ethernet cables to the module. 8. Place the Ethernet module back onto the DIN rail and slide it
back into the reamer until it clicks into place. 9. Close the rear cover.
IMPORTANT NOTE: Depending on the mode selected to identify the IP address of the Ethernet module, the module may have to be re-addressed upon power up.

Figure 9-E Figure 9-F

41 OM-TT4E-1.5

9-7 Removing the Spray Containment Unit
WARNING: Ensure air and power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures. 1. Remove the two (2) thumb screws on the side of the spray
containment unit. 2. Lift the spray containment cover out of the container. 3. The baffle rests on the inside of the container and can be
pulled out once the cover is removed. 4. Remove the two (2) M5 SHCS on either side of the spray
containment unit that secure it to the spray head. 5. Lift the spray container straight up over the spray head to
remove. 6. Installation is the opposite of the removal procedures.

Figure 9-G

OM-TT4E-1.5 42

9-8 Replacing the Cutter Blade
WARNING: Ensure air and power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures.
A. To Remove the Cutter Blade
1. Remove the two (2) M5 SCHS that secure the spray containment unit onto the spray head.
2. Remove the spray containment unit. 3. Remove the cutter blade by using a 5/8″ wrench and
the supplied 9/16″ wrench to turn the cutter blade counterclockwise when viewed from above. NOTE: Considerable force may be required to loosen the cutter blade since it tightens naturally as the reamer operates. Rest the 9/16″ flat wrench against the reamer frame (below the air connection). This prevents slipping while trying to remove the cutter blade.

Figure 9-H

B. To Install the Cutter Blade
1. The cutter blade is installed by threading it clockwise into the top of the spindle shaft. Reuse the old washer. 2. Place the spray containment unit back on the spray head and tighten the two (2) M5 SHCS onto the spray head. NOTE: The application of anti-seize compound to the threads of the reamer will assist in easy removal in the future.

43 OM-TT4E-1.5

9-9 Removing the Anti-Spatter Fluid Reservoir
WARNING: Ensure air and power supply is off and disconnected before proceeding. Please follow your facility’s lockout / tagout procedures.
A. To Remove the Reservoir
1. It is suggested that the reservoir be empty prior to removing it from the reamer.
2. In the event that there is still fluid left in the reservoir, it can be emptied while still secured onto the reamer. a. Remove the front spindle cover by loosening the 4 BHCS on either side of the cover. b. On the right hand side of the sprayer check valve there is a black 5/16″ fluid supply line. Before disconnecting the supply line, have a small container ready to catch the fluid as it drains out. c. Disconnect the fluid supply line at the quick disconnect fitting. (see Figure 9-I) d. The fluid will begin to flow out of the supply line and into a container. e. Let the fluid drain until it stops.
3. Open the rear cover of the reamer and disconnect the fluid level sensor (two black wires with a 2-Pin connector on them).
4. Remove the four (4) BHCS on the side of the reamer that hold the sprayer reservoir mounting plate onto the reamer. (see Figure 9-J)
5. Carefully pull the reservoir from the side of the reamer. a. While removing, push the fluid supply line inside the reamer to help guide the reservoir connection through the opening under the mounting plate.
6. Once the reservoir is free from the reamer, remove the hose clamp that secures the fluid supply line onto the reservoir.
7. On the back side of the reservoir mounting plate will be two (2) M6 BHCS. Remove these bolts and take the mounting plate off of the reservoir. (see Figure 9-K)

Figure 9-I Figure 9-J OM-TT4E-1.5 44

B. To Install the Reservoir
1. Installation is the reverse of removal. 2. Once the fluid supply line is attached to the sprayer check valve, the reamer will have to be re-primed in order to spray liquid.
Figure 9-K
45 OM-TT4E-1.5

9-10 Scheduled Maintenance

The TOUGH GUN TT4E Reamer will require a periodic maintenance program to ensure a reliable service life, as recommended below:

CHECK CHECK CHECK CHECK CLEAN CLEAN
CHECK
CHECK CHECK CHECK CHECK CLEAN CLEAN
CHECK CHECK CHECK CHECK

DAILY The oil level in the lubricator reservoir. The life of the air motor is dependent on a consistent supply of oil. The air lines and interface cable for leaks and fraying. The alignment of the nozzle, retaining head/diffuser and gun position. The reservoir to ensure it is full of TOUGH GARD anti-spatter liquid or other water-based anti-spatter solution. The spindle cover shroud to ensure it is free of spatter. The reamer clamp jaw and v-block surfaces to ensure proper nozzle alignment.
WEEKLY 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. The lubricator to ensure it is working and is set up properly (i.e. fill oil, clean / replace filter). The LEDs to ensure reamer and controller communication. The sprayer to ensure that the spray coming out of the spray head is normal. The nozzle and retaining head/diffuser (remove from gun) for wear. The v-block, reamer clamp jaw, and spindle seal with a brush or with compressed air to eliminate blockages. Wipe clean any debris from the Nozzle Detect Proximity Sensor.
MONTHLY That the belt tension lock screw is securely tightened. That the belt tension bolt is tightened. The spindle unit for wear. The solenoids and spool them to ensure there are no leaks and that they are operating properly.

CLEAN CLEAN CLEAN CLEAN
INSPECT REPLACE CLEAN

The spray containment unit of any debris buildup inside the container. The sprayer reservoir to eliminate contamination. The sprayer head and brush away excess spatter. Under the top cover.
YEARLY The drive belt for any signs of fraying and replace as necessary. The spindle cap seal and repair any damage to the spindle. Perform a complete clean-up of the reamer and sprayer.

The TOUGH GUN Wire Cutter will require a periodic maintenance program to ensure a reliable service life as recommended below:

CHECK CHECK EMPTY LUBRICATE

DAILY
The air lines and interface cable for leaks and fraying.
WEEKLY
Check the wire cutter blades for dullness, looseness and possible breakage. The service life of the cutter blades is dependent on the type of application. In lighter duties, the blades may last indefinitely but should be inspected weekly.
The wire catcher basket.
QUARTERLY
The sliding surfaces by applying general purpose grease (NLGI Grade 1-2) through the grease fittings located on the sides of the main body.

OM-TT4E-1.5 46

9-11 Program Updating A. Updating ARGEE Software
NOTE: This method will only work for TOUGH GUN TT4E Reamer Robotic Nozzle Cleaning Stations with firmware version 3.6.4.0. The firmware version can be identified by using the TURCK Service Tool under the column labeled “Version”.

1. Install the TURCK Service Tool from www.tregaskiss.com/TT4E (under the Software tab).
   2. Search for all Tregaskiss Reamer units on the network by clicking the “Search” button.
   3. Select the reamer from the list and then click the “ARGEE” button in the menu bar. 4. Select the option to “Load Program”.
   5. Click the “Select File” button and open the ARGEE program you are updating (i.e. Reamer_5.0.arg).
   47 OM-TT4E-1.5

6. Select the box that says “Overwrite existing program”. 7. Click the “Start” button in the top left of the menu bar. The program will begin to install the new ARGEE program. Wait until the dialogue
box indicates that the program has been loaded into the module. 8. The message in the ARGEE column should say “running: Tregaskiss Reamer V5.x”, where ‘x’ represents the ARGEE program version.
This confirms that the ARGEE program was loaded successfully.
OM-TT4E-1.5 48

SECTION 10 — TECHNICAL DATA
10-1 Pneumatic Diagrams A. TOUGH GUN TT4E Reamer
49 OM-TT4E-1.5

10-2 Electrical Schematic A. TOUGH GUN TT4E Reamer
OM-TT4E-1.5 50

SECTION 10 —

PARTS LIST

A. TOUGH GUN TT4E Reamer

ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

PART # TT4-1320-2 TT4-1320-3 TT4-1320 TT4-1320-5 TT4-1325 TT4-SC-100-1 TT4-SC-100-2 TT4-SC-100-6 TT4-500-15
TR-2661 TT4-500-20
TT-2670 TT4-2110 TR-2130 TR-2120 TR-2127 TR-2128 See Section 7-5 TT3E-2321 TR-2530 TT4-2400 TR-2440 TT4-2250 TR-2910

DESCRIPTION TT4 reamer reservoir cap with tether TT4 reamer sprayer reservoir filter TT4 reamer sprayer reservoir assembly Mounting plate for TT4 reservoir TT4 reservoir fluid level sensor TT4 reamer spray containment container TT4 reamer spray containment cover M5x0.8-12mm knurled thumb screw (Qty 2) TT4 reamer spray head assembly Spindle seal TT4 reamer sprayer check valve assembly Reamer spindle cover TT4 reamer clamp cover Clamp cylinder Clamp jaw assembly Upper jaw spacer (Qty 2) V-block spacer / low jaw spacer 4 sided v-block Clamp limit switch Muffler TT4 reamer spindle assembly Reamer drive belt TT4 reamer air motor lubricator Reamer wrench

51 OM-TT4E-1.5

ITEM 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Not Shown Not Shown Not Shown

PART # TT3E-2310 TT3E-2300-1 TT4-2328 TT4-2325 TT4-2327 TT4-2326 TR-2500 TT3-2322
R-2240 TT4E-2680 TT4-707-30 TR-2411 See Section 7-6 TT3E-2344 Non-sellable Non-sellable Non-sellable Non-sellable Non-sellable Non-sellable TT4E-2300-2 TT3E-2350-10M TT3E-2345-10M

Ethernet module

DESCRIPTION

DIN rail

TT4 reamer push button switch – Reset switch

TT4 reamer push button switch – Spindle switch

TT4 reamer push button switch – Spray switch

TT4 reamer push button switch – Clamps switch

Air motor assembly

Limit switch assembly

Valve pack

Reamer rear cover assembly

TT4 reamer TCP locator pin assembly

Spindle acuator

Tregaskiss reamer cutter blade

Proximity sensor, 5mm nozzle detect

SHCS M6x1.0x20mm long

SHCS M5x0.8x20mm long

Reamer cutter blade washer – M10x40mm, zinc plated steel

Thumb screw – M5x0.8x12mm long, zinc plate (DIN 464)

Nozzle detect sensor fasteners – SHCS M3x0.5x12mm long

SHCS M5x0.8x12mm long

TT4E reamer green LED light

Ethernet 4 pin power cable

Ethernet communication cable

B. TOUGH GUN Wire Cutter (Part # WC-400)

ITEM 1 2 3 4 5 6 7

PART # WC-400-8 WC-100-20 WC-100-7-1 TT4-707-30 TR-2221 TT3-2201 WC-100-31

DESCRIPTION Wire cutter base plate Wire cutter basket – cast aluminum Wire cutter blade (Qty 2) TT4 reamer TCP locator pin assembly Breather vent (Qty 2) 1/4″ tubing, 90 degree elbow, uni-fit thread (Qty 3) Cylinder with magnet

ITEM 8 9 10 11 12 13

PART # WC-400-24 WC-400-30 Non-sellable Non-sellable Non-sellable Non-sellable

DESCRIPTION Wire cutter air valve Wire cutter installation kit SCHCS M6x1x16mm long – black oxide (Qty 8) SHCS M10x1.5x25mm long – black oxide SHCS M4x0.7x12mm long – black oxide SHCS M8x1.25x65mm long

OM-TT4E-1.5 52

SECTION 11 —

TROUBLESHOOTING

11-1 TOUGH GUN TT4E Reamer – Network

PROBLEM 1. Cannot connect to
Ethernet module.
2. BUS or ERR LEDs red (flashing or solid).
3. ETH1/ETH2 LEDs on but not flashing.
4. ETH1/ETH2 LEDs not illuminated.

POSSIBLE CAUSE 1. Loose connection of RJ45 cables. 2. Incorrect TCP/IPv4 properties.
3. Incorrect IP address.
4. Local firewall preventing connection. 1. IP address conflict. 2. Circuitry is incorrect.
1. No communication between Ethernet module and network.
1. No connection to the network.

CORRECTIVE ACTION
1. Check that connections are secure. 2. Change the properties through the network connection
status on the host computer. 3. Set rotary switches to 600 and cycle power. Then use
TURCK IP Address Tool to find correct IP address. 4. Work with network administrator.
1. Ensure IP address is not duplicated within the network. 2. Ensure I/O connector blocks are connected to the Ethernet
module.
1. Connect Ethernet module to network device so that open communication can happen.
1. a. Ensure Ethernet module is powered. b. Check that the physical network connections are secure.

11-2 TOUGH GUN TT4E Reamer – Mechanical

PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION

1. LED signals not activating.

1. Circuit board damaged. 2. Limit switch malfunctioning. 3. Input voltage is incorrect. 4. Broken switch actuator. 5. Sink/Source issue.

1. Replace circuit board. 2. Replace limit switch. 3. Check input voltage and make adjustments as required. 4. Replace actuator spindle. 5. Set switches accurately.

2. Motor stops 1. Air supply is incorrect.

during

2. Excessive spatter buildup.

operation.

1. Set at 80-100 psi at 16 CFM. 2. a. Apply or increase quantity of water- based anti-spatter liquid. Do
not use oil-based anti-spatter solution, as this will cause excessive buildup and compromise performance.

3. Lubricator not installed or adjusted

b. Increase frequency of gun cleaning or modify welding parameters. 3. Ensure lubricator is adjusted properly (see section 7-1 Air Motor

properly. 4. Water in air lines / motor. 5. Improper nozzle orientation. 6. Motor valve failed.

Lubricator on page 16). 4. Dryer required for air system. 5. Ensure consumables are concentric with cutter. 6. Replace damaged valve.

3. Pneumatic functions not operative.

1. Air lines damaged or obstructed. 2. Air supply is incorrect. 3. Faulty Home Position switch. 4. Manual switches engaged. 5. Bad valve. 6. No power.

1. Replace air line(s). 2. Check air supply, set at 80-100 psi at 16 CFM. 3. Repair or replace Home Position switch. 4. Turn off manual switches. 5. Replace faulty valve. 6. Reconnect power.

4. Broken cutter.

1. Improper cutter being used.

1. Repair or replace damaged components.

2. Flow control valve set too fast.

2. Adjust feed rate, adjust flow control valve.

3. Gun improperly aligned in TOUGH GUN 3. Check v-block / nozzle compatibility chart (refer to Cutter Blade and

Reamer.

V-Block Chart in the SP-TT4 spec sheet).

5. Reamer

1. Cutter blade is jammed in gun.

1. a. Checking proper alignment can prevent the blade from jamming.

stays in
UP position. 2. Faulty spindle limit switch. 3. Cycle Start signal held on too long.

b. Repair or replace damaged components. 2. Repair or replace spindle limit switch. 3. Revise program (0.5 sec. pulse).

53 OM-TT4E-1.5

6. Cycle Complete signal does not activate.
7. No air flow / no antispatter.

1. Faulty limit switch. 2. Faulty circuit board. 3. Missing / broken spindle actuator. 4. Faulty clamp valve.
1. Output to unit not functioning. 2. Loss of air supply.
3. Faulty solenoid valve. 4. Sink/Source. 5. Plugged valve.

8. Air flow but no antispatter.

1. Vent blocked on reservoir. 2. Spool in check valve stuck. 3. Fluid hose blocked. 4. Plugged valve.

9. Spray head 1. Debris in spray head. plugged.

1. Check or replace limit switches. 2. Check or replace circuit board. 3. Replace spindle actuator. 4. Replace faulty valve.
1. Check output signal and cable. 2. a. Check air supply.
b. Check air line and nozzle for blockage. 3. Check valve and replace if required. 4. Adjust Sink/Source switch for sprayer. 5. If using oil-based anti-spatter solution, switch to TOUGH GARD or
other water-based anti-spatter liquid.
1. Open vent. 2. Repair or replace check valve. 3. Clean or repair fluid hose. 4. If using oil-based anti-spatter solution, switch to TOUGH GARD or
other water-based anti-spatter liquid.
1. a. Clean spray head. b. If using oil-based anti-spatter solution, switch to TOUGH GARD or other water-based anti-spatter liquid.

11-3 Lubricator

PROBLEM 1. Oil fill level low. 2. Incorrect oil drip rate.

POSSIBLE CAUSE 1. Oil depleted in bowl. 1. Drip rate valve not set properly.
2. Filter element clogged. 3. Steel supply lines clogged.

3. Air leaks between the bowl and the body.
4. Air leaks from the pressure relief/drain valve.

1. Breakage of bowl o-ring. 1. Foreign matter caught in the valve.

5. Too much drain comes from the piping of the outlet side.

2. Breakage of the sealing parts of the valve.
1. Drain level reaches the baffle plate.

CORRECTIVE ACTION 1. Refill oil bowl to correct level using air motor oil. 1. Set drip rate valve so that one (1) drop of oil
occurs every 5-10 ream cycles. 2. Remove bowl assembly and clean filter element. 3. Remove steel supply lines and clean using
compressed air. If damaged, replace steel lines. 1. Replace bowl o-ring. Grease up before
assembling. 1. Remove the bowl and clean the inside of the bowl.
Flush the valve with a solvent to remove the debris. 2. Replace the bowl assembly.
1. Open the drain cock for draining and replace the element.

11-4 Spray Containment Unit

PROBLEM

POSSIBLE CAUSE

1. Over spray is

1. Misalignment of gun.

excessive.

2. Gun not inserted into the spray

containment unit far enough. 3. Baffle not installed.

2. Fluid and debris are 1. Plugged drain hose.

not draining out of

the unit.

2. Plugged container/drain hole.

CORRECTIVE ACTION
1. Center the gun to be in the center of the opening on the spray containment unit.
2. Insert gun to the depth specified in 8-3 Programming Events Sequence on page 31
3. Ensure that the internal baffle is installed properly.
1. Remove drain hose from the spray containment unit and clear blockage.
2. Remove top cover of the spray containment unit and clean out any debris that is blocking the drain hole.

OM-TT4E-1.5 54

11-5 Anti-Spatter Fluid Reservoir

PROBLEM

POSSIBLE CAUSE

1. Fluid is leaking from 1. Damaged reservoir.

the reservoir.

2. Hose clamp not installed on the

outlet tube.

2. Low fluid level

1. Wire connections are loose.

signal not present.

2. Faulty sensor. 3. Float stuck in the upward position.

4. Damaged sensor.

CORRECTIVE ACTION 1. Replace reservoir. 2. Replace hose clamp.
1. Check the 2-pin connector on the inside of the reamer, ensure that it is fully connected to it’s mating connector.
2. Replace sensor. 3. Open the cap of the reservoir and gently press the float
downward. If it does not move, replace the sensor. 4. Replace sensor.

11-6 Filter/Regulator

PROBLEM

POSSIBLE CAUSE

1. Pressure is not regulated.

1. Opposite flow direction or opposite

installation of filter/regulator. 2. Foreign materials caught in the valve

seat.

2. Set pressure does not return to zero 1. Foreign materials caught in the valve

when pressure handle is loosened.

seat.

3. Large air resistance reduces flow rate. 1. Clog of the element.

4. Air leaks from the bonnet exhaust port. 1. Diaphragm is damaged. 2. Foreign materials caught in the valve

seat. 3. Piston o-ring is damaged.

5. Air leaks between the bonnet and the body.
6. Air leaks between the bowl and the body.
7. Air leaks from the drainage cock.
8. No drainage when the drain cock is open.
9. Too much drain comes from the piping of the outlet side.

1. Loosened bonnet. 2. Diaphragm is damaged. 1. Breakage of bowl o-ring.
1. Foreign matter caught in the valve of the drain cock.
2. Breakage of the seating part of the drain cock.
1. Blockage of outlet of the drain cock due to solid foreign matter.
1. Drain level reaches the baffle plate.

CORRECTIVE ACTION 1. Install piping or filter/regulator correctly as
shown in manual. 2. Remove the valve guide to clean the valve
and valve seat. 1. Remove the valve guide to clean the valve
and valve seat. 1. Clean the element. 1. Replace the assembly. 2. Remove the valve guide to clean the valve
and valve seat. 3. Replace the piston o-ring or clean. Then
grease up the piston o-ring and sliding surface. 1. Fasten the bonnet. 2. Replace the assembly. 1. Replace bowl o-ring. Grease up before assembling. 1. Open the drain cock for a few seconds.
2. Replace the bowl assembly.
1. Replace the bowl assembly.
1. Open the drain cock for draining and replace the element.

55 OM-TT4E-1.5

11-7 Nozzle Detect

PROBLEM 1. No LED lights on sensor.
2. No signal from sensor but power LED is illuminated.

POSSIBLE CAUSE
1. Loose connection of power cable. 2. Broken cable. 3. Damaged sensor.
1. Nozzle not close enough to sensor.

3. Both LEDs are always illuminated.

1. Metallic debris on sensor. 2. Nozzle is too close to sensor.

CORRECTIVE ACTION
1. Check that the connection is secure. 2. Replace sensor. 3. Replace sensor.
1. Confirm that robot position is at the correct distance from the sensor (see section 7-7 Setting Up Nozzle Detect on page 21).
1. Wipe the face of the sensor clean with a rag. 2. Confirm that robot position is at the correct distance
from the sensor (see section 7-7 Setting Up Nozzle Detect on page 21).

OM-TT4E-1.5 56

11-8 Software
WARNING: When conducting troubleshooting on the TOUGH GUN TT4E Reamer, ensure that all safety and lockout/tagout procedures are followed. Any time service is to be done on a reamer, the reset switch must be pressed to set the program back to its start state. A testing / troubleshooting program is available for download from www.tregaskiss.com/TT4E (within the Software tab). This useful tool can help in diagnosing the error(s) that may occur as well as being able to diagnose it remotely. To run the program from any computer: 1. Download the program named “Reamer Online Tester” from
www.tregaskiss.com/TT4E (within the Software tab). 2. Open the .exe file. NOTE: If your firewall attempts to block it,
allow it and click “Run”. 3. When the program opens, you should see the dialogue box
shown in Figure 11-A. 4. Type in the IP address for the Ethernet module you wish to
connect to and click “Connect”. NOTE: Multiple units can be connected by simply running the program again and connecting to the other IP addresses. 5. Once connected, the program will display which version of software is currently installed on the module as well as which step it is on within the program logic. 6. The status lights of all the inputs/outputs will be visible through the program, so there is no need to open up the reamer to view the LEDs on the Ethernet module (see Figure 11-B). NOTE:The “Fluid Level Sensor” light will be green when the fluid level is low and will not illuminate then there is sufficient antispatter fluid in the reservoir. 7. If “Cycle Start” is pressed, the reamer will run through an entire cycle, stopping only if it encounters 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 8-2 Program Logic Chart on page 29. (see Figure 11-C) 9. This software can be used in conjunction with the Troubleshooting tables in section 11-1 TOUGH GUN TT4E Reamer – Network on page 53 to help in effectively determining and fixing an issue with the reamer.
57 OM-TT4E-1.5

Figure 11-A Figure 11-B Figure 11-C

NOTES
OM-TT4E-1.5 58

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.com. Scan the QR Code with your smart phone for immediate access to Tregaskiss.com/TechnicalSupport.

Scan to view the TOUGH GUN® TT4E Reamer Support Page Scan to view the TOUGH GUN® TT4E Reamer Owner’s Manual Scan to view the TOUGH GUN® TT4 Reamer Spec Sheet Scan to view the TOUGH GUN® Wire Cutter Owner’s Manual Scan to view the TOUGH GARD® Anti-Spatter Multi-Feed System Owner’s Manual Scan to learn about TOUGH GARD® Anti-Spatter Liquid Scan to learn about Tregaskiss® Robotic Air- Cooled MIG Guns

Tregaskiss

Phone: 1-855-MIGWELD (644-9353) (US & Canada)

2570 North Talbot Road

+1-519-737-3000 (International)

Windsor, Ontario N0R 1L0 Canada

Fax: 1-519-737-1530

For more information, visit us at Tregaskiss.com

References

• Semi-Automatic MIG Guns, Robotic MIG Guns, Fixed Automatic Torches, Nozzle Cleaning Stations, and Welding Consumables - Tregaskiss and Bernard
• American Welding Society (AWS) - Welding Excellence Worldwide
• Product Certification & Standards Development - CSA Group
• NFPA | The National Fire Protection Association
• P65Warnings.ca.gov

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