Tregaskiss TOUGH GUN TT3E User manual

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 N0R 1L0
Canada
Phone: 1-855-MIGWELD (644-9353) (US & Canada)
[phone] (International)
Fax: [phone]
For more information, visit us at Tregaskiss.com

Thank You for Choosing Tregaskiss
Thank you for selecting a Tregaskiss product. The TOUGH GUN™ TT3E Reamer you have purchased has been designed and
engineered to be a reliable tool to support high production within a robotic cell. The TOUGH GUN TT3E Reamer is made from durable
materials and components engineered to perform in a demanding robotic welding environment. 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 le 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 TOUGH GUN TT3E
Reamer. 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 (644-9353) (US & Canada) or [phone] (International) or fax [phone]. 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.
For additional support materials such as spec sheets, troubleshooting information, how-to guides
and videos, animations, online congurators and much more, please visit Tregaskiss.com.
Scan this QR Code with your smart phone for immediate access to
Tregaskiss.com/TechnicalSupport
2

TABLE OF CONTENTS
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.
3
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING ..................................................................... 4
1-1 Additional Safety Warnings for Installation, Operation and Maintenance ....................................................................................4
1-2 California Proposition 65 Warnings.............................................................................................................................................4
1-3 Principal Safety Standards ..........................................................................................................................................................4
1-4 Commercial Warranty..................................................................................................................................................................5
SECTION 2 – SPECIFICATIONS.......................................................................................................... 6
2-1 System Components ...................................................................................................................................................................6
SECTION 3 – INSTALLATION ........................................................................................................... 7
3-1 Installing TOUGH GUN™ TT3E Reamer .......................................................................................................................................7
3-2 Connect Air Blast.........................................................................................................................................................................8
3-3 Installing TOUGH GUN Wire Cutter..............................................................................................................................................8
SECTION 4 – SETUP ...................................................................................................................... 9
4-1 Air Motor Lubricator....................................................................................................................................................................9
4-2 Accessing Electrical and Pneumatic Controls..............................................................................................................................9
4-3 Wiring Interface Connections ......................................................................................................................................................9
4-4 Ethernet Module Description .....................................................................................................................................................10
4-5 Setting Up V-Block .................................................................................................................................................................10
4-6 Setting Nozzle Heights 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 Replacing the Air Motor.............................................................................................................................................................20
6-4 Replacing the Ethernet Module..................................................................................................................................................21
6-5 Replacing the Cutter Blade ........................................................................................................................................................21
6-6 Replacing the Drive Belt ............................................................................................................................................................21
6-7 Replacing the Solenoid Valves...................................................................................................................................................22
6-8 Replacing Air Blast Valves..........................................................................................................................................................22
6-9 Scheduled Maintenance.............................................................................................................................................................23
6-10 Program Updating....................................................................................................................................................................24
SECTION 7 – TECHNICAL DATA ....................................................................................................... 26
7-1 Pneumatic Diagrams .................................................................................................................................................................26
7-2 Electrical Schematic ..................................................................................................................................................................27
SECTION 8 – PARTS LIST.............................................................................................................. 29
8-1 TOUGH GUN TT3E Reamer........................................................................................................................................................29
8-2 TOUGH GUN Sprayer Assembly ................................................................................................................................................30
8-3 TOUGH GUN Wire Cutter...........................................................................................................................................................31
SECTION 9 – TROUBLESHOOTING.................................................................................................... 32
9-1 TOUGH GUN TT3E Reamer - Network .......................................................................................................................................32
9-2 TOUGH GUN TT3E Reamer - Mechanical...................................................................................................................................32
9-3 Lubricator..................................................................................................................................................................................33
9-4 Filter/Regulator..........................................................................................................................................................................33
9-5 Air Blast.....................................................................................................................................................................................34
9-6 Software....................................................................................................................................................................................34

4
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
1-1 Additional Safety Warnings for
Installation, Operation and Maintenance
READ INSTRUCTIONS
• Read and follow all labels and the
Owner’s Manual carefully before
installing, operating, or servicing the
unit. Read the safety information at
the beginning of the manual and each
section.
• Use only genuine replacement parts from the manufacturer.
• Perform maintenance and service according to the Owner’s
Manual, industry standards and national, state/provincial and
local codes.
FIRE OR EXPLOSION hazard
• Do not install or place unit on, over or
near combustible surfaces.
• Do not install unit near ammables.
• Do not overload building wiring – be
sure power supply system is properly
sized, rated and protected to handle
this unit.
HOT PARTS can burn
• Do not touch hot parts barehanded.
• Allow cooling period before working
on equipment.
• To handle hot parts, use proper tools
and/or wear heavy, insulated welding
gloves and clothing to prevent burns.
NOISE can damage hearing
• Noise from some processes or
equipment can damage hearing.
• Wear approved ear protection if noise
level is high.
1-2 California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause birth
defects and in some cases, cancer. (California Health & Safety
Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to the
State of California to cause cancer, and birth defects or other
reproductive harm. Wash hands after use.
1-3 Principal Safety Standards
Safety in Welding, Cutting, and Allied 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: [phone], website:
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Quincy, MA 02269 (phone: [phone]-
3555, website: www.nfpa.org and www.sparky.org).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales,
5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National
Standards Institute, 25 West 43rd Street, New York, NY 10036
(phone: [phone], website: www.ansi.org).
OSHA, Occupational Safety and Health Standards for General
Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, from U.S. Government
Printing Ofce, Superintendent of Documents, P.O. Box 371954,
Pittsburg, PA 15250-7954 (phone: [phone]) (there are
10 OSHA Regional Ofces – phone for Region 5, Chicago, is 312-
353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH),
1600 Clifton Road, Atlanta, GA 30333 (phone: [phone],
website: www.cdc.gov/NIOSH).
MOVING PARTS can injure
• Keep away from moving parts such as
fans and blades.
• Keep all doors, panels, covers and
guards closed and securely in place.
• Have only qualied persons remove
doors, panels, covers or guards for
maintenance and troubleshooting as
necessary.
• Reinstall doors, panels, covers or
guards when maintenance is nished
and before reconnecting input power.
• Keep away from pinch points.

5
1-4 Commercial Warranty
Seller’s Products specied below shall be free from defects
in material and workmanship for the period specied below
from the delivery to an authorized Buyer provided the
Products are operated, maintained, and repaired properly
and pursuant to Product documentation provided by the
manufacturer. The Warranty against defects does not apply
to: (1) consumable components or ordinary wear items; or
(2) use of the Products with equipment, components or parts
not specied or supplied by Seller or contemplated under the
Product documentation.
Should there be a defect please refer to our Return Merchandise
Policy.
Seller reserves the right to inspect any allegedly defective
Product for the alleged deciencies and that the deciencies
were not caused by accident, misuse, neglect, improper
installment, unauthorized alteration or repair or improper
testing.
In the event of a defect covered by the above warranty, Seller
will, at its option, repair, replace or refund the purchase price
of the defective Product. Product found not defective will be
returned to Buyer at Buyer’s cost after notication by Seller’s
Customer Service Department. Any TOUGH GUN Reamer
component part 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,
BUT NOT LIMITED TO ANY, DIRECT, INDIRECT, SPECIAL,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES OR LOSS OF
PRODUCTION OR LOSS OF PROFITS RESULTING FROM ANY
CAUSE WHATSOEVER, INCLUDING, BUT NOT LIMITED TO,
ANY DELAY, ACT, ERROR OR OMISSION OF SELLER.
Genuine Bernard and Tregaskiss parts must be used for
safety and performance reasons or the warranty above shall
not be valid. Warranty shall not apply if accident, abuse, or
misuse damages a product, or if a product is modied in any
way except properly and by authorized Seller personnel.
Product Warranty
Tregaskiss TOUGH GUN™ Robotic MIG
Guns and Components
1 year
Tregaskiss TOUGH GUN Reamer
• When factory-equipped with
Lubricator
• When both (i) factory-equipped
with Lubricator and (ii) used only
with Tregaskiss™ TOUGH GARD™
Anti-Spatter Liquid
1 year
2 years when factory
equipped with Lubricator
3 years when both (i)
and (ii)
Tregaskiss TOUGH GUN Robotic
Peripherals (Clutch, Sprayer, Wire
Cutter, Arms)
1 year
Tregaskiss Low-Stress Robotic
Unicables (LSR Unicables)
2 years

6
SECTION 2 – SPECIFICATIONS
2-1 System Components
For complete parts list, please see SECTION 8 – PARTS LIST 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)

7
SECTION 3 – INSTALLATION
3-1 Installing TOUGH GUN™ TT3E Reamer
Mounting Hole Locations and Footprint
1.125”/ 28.6 mm
Dowel
7.13”/ 181.1 mm
2.49”/ 63.2 mm
0.50”/ 12.7 mm
Front of Reamer
(Top View)
11.00”/ 279.4 mm
Dowel
4.00”/ 101.6mm
2.49”/ 63.2mm
11.00”/ 279.4 mm
12.00”/ 304.8 mm
0.44”/ 11.2 mm
5.25”/133.4 mm
2x ø.382”/ 9.7 mm
4x ø.41”/ 10.4 mm
4x ø.41/10.4 mm
2.63”/ 66.7 mm
11.87”(301.5 mm)
Dimensions
13.24”(336.2 mm)
22.84”(580mm)
WARNING: Ensure power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / 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.
• Afx 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
NOTE: Push reset button before connecting
air line.
1. Use only dry, ltered, 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
elbow located on the side of the TOUGH
GUN Reamer.

8
WARNING: Ensure power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
A. To Connect Air Blast
1. If congured with air blast there will be two air blast ports on the Comm
Plate of the Reamer.
2. Remove the two plastic plugs from the quick connect ttings (see Figure 1).
3. Insert the air blast air lines going to the welding gun into the quick connect
tting (see Figure 2).
B. Programming the Air Blast
1. The Ethernet module is already pre-programmed to be able to run the air blast
option and can support one or two welding gun air blast functions.
2. Using the data map in Section 4-8 Data Map, the PLC can be programmed to
re the respective air blast valves in the Reamer.
3-2 Connect Air Blast
3-3 Installing the TOUGH GUN Wire Cutter
4.75”
4.25”
Figure 2
Figure 1
AUX Port
Plugs
Ports
WARNING: Ensure power supply is off and disconnected 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 xtures and the
connes of the robot.
2. Attach the wire cutter base to the top of the Reamer, or other
sturdy platform using three (3) M5x0.8x25 mm long bolts in the
holes provided.
B. To Connect Air Supply
1. Use only ltered lubricated 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” female NPT inlet located on the side of the valve.
C. To Connect Power Supply
1. The TOUGH GUN TT3E Reamer Ethernet module can support the wire cutter
function and as such can be connected directly to the Reamer. Once mounted to
the top of the Reamer, take the 4-Pin M12 connector and attach it to the AUX port
on the Comm Plate.
(more on page 9)

9
4-1 Air Motor Lubricator
SECTION 4 – SETUP
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). The lubricant can be air motor oil or light grade hydraulic oil with a
viscosity rating of 150 VC 15-20 (SAE 5W).
4-2 Accessing Electrical and Pneumatic Controls
4-3 Wiring Interface Connections
(continued from page 8)
2. If the Reamer is equipped with a nozzle detection system in
addition to the wire cutter, splitter part number TT3E-2343 will be
required, and will receive the 4-Pin M12 connector. Splitter
(TT3E-2343)
4-Pin Power Connector (24V)
Wiring schematic is:
• Brown Wire – 24VDC Switched;
• White Wire – 24VDC Constant;
• Blue Wire – 0VDC Switched; and
• Black Wire – 0VDC Constant.
4-Pin AUX Connector
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 referenced to the server being montiored;
Transmit (TX) FROM this server, and Receive (RX) TO this server
WARNING: Ensure power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
To access the electronic controls for installation or service for the TOUGH GUN Reamer
1. Remove reservoir (if equipped) and loosen the 2 BHCS using a 3 mm Allen wrench to open the hinged rear access door.
2. The rear access door can be completely removed if accessibility is an issue. Using a 3 mm Allen wrench, remove
the 3 BHCS which fasten the hinge to the frame.
WARNING: The following connection should only be performed by qualied technicians.
Damage to equipment will occur if connections are incorrect.

10
WARNING: Before start-up, ensure that all connections are correct or damage to the TOUGH GUN Reamer may occur.
The TT3E-2310 is a multiprotocol communication adapter which supports networking standards:
• EtherNet/IP
• PROFINET
• 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:
• It is an Integrated Ethernet switch
• 10 Mbps / 100 Mbps supported
• 3 x separate I/O power supply groups that are galvanically separated
• 16 congurable PNP channels
• 24VDC
• Up to 1A outputs
• 2 x RJ45 sockets
The TT3E-2310 Wiring/Pinout diagram is as follows:
• V1+ powers I/O 1 to 8
• V2+ powers I/O 9 to 14
• V3+ powers I/O 15 and 16
• Specic I/O functions are listed in Section 4-8 Data Map
• 4 x Status 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” 0.978” 25 mm 1.125”
TR-2162 0.780” 0.813” 0.875” 1.000”
TT3E-2310 Wiring/Pinout Diagram
*Part stamped as 1060, not according to it’s O.D. of 1.062”
TURCK is a registered trademark of Turck Inc. & Hans Turck GmbH & Co. K.G.
WARNING: Ensure power and air supply are off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
To Change V-Blocks
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 forward.
See chart below for V-Block Size Chart.
Numbers are stamped into the v-blocks. The number refers to the outside
diameter of the nozzle (i.e. 0.938 = 0.938” O.D.)

11
Setting Nozzle Heights
See the chart below in order to nd the correct height to set your nozzle for proper
cutter blade insertion:
4-6 Setting Nozzle Heights 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
TURCK is a registered trademark of Turck Inc. & Hans Turck GmbH & Co. K.G.

12
4-7 Setting the IP Address
The rst 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 steps 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 1).
3. Select Internet Protocol Version 4 (TCP/IPv4) and
click the Properties 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 rst three octets the same as the Ethernet module.
- The factory set rst 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 Figure 3)
6. Once this is completed communication between the computer
and the Ethernet module can occur.
7. To return the computer settings, repeat steps 1 to 3 and then
select “Obtain an IP address automatically” option.
Figure 1
Figure 2
Figure 3

13
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 of the methods is outlined below:
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.
The TURCK IP Address Search Tool can be found online at:
http://pdb2.turck.de/us/DE/products/0000001a000293cb0002003a
or visit www.tregaskiss.com/ReamerTT3E to access the link
from the Software Downloads tab (see Figure 4).
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 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 which you want to address (identied 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.
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.
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
Figure 4
TURCK is a registered trademark of Turck Inc. & Hans Turck GmbH & Co. K.G.

14
4-8 Data Map
I/O 16 I/O 15 I/O 14 I/O 13 I/O 12 I/O 11 I/O 10 I/O 9 I/O 8 I/O 7 I/O 6 I/O 5 I/O 4 I/O 3 I/O 2 I/O 1
IN Upper
Limit
Lower
Limit
HW
Cycle
Start
Reset
Button
Nozzle
Detect Clamped
OUT Wire
Cut
Air
Blast 2 Clamp Spindle Motor Sprayer
OUT
Word Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
Enable
Wire
Cut
Air
Blast 2
Air
Blast
1
Sprayer Enable
DS Reset Start Cycle
1 Startup Motor Dwell from PLC (ms)
2 Spindle Advance Dwell from PLC (ms)
3 Sprayer Duration from PLC (ms)
0Wire Cut
On
Air
Blast 2
Air
Blast 1
Clamp
On
Spindle
On
Motor
On
Sprayer
On
Upper
Limit
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 congure the module within the PLC, add the device
and use the following Connection Parameters
(right side of Figure 1):
Assembly
Instance Size
Input: 101 4 (16-bit)
Output: 110 5 (16-bit)
Conguration: 1 0 (8 bit)
NOTE: Name and IP Address shown here in
Figure 1 are examples.
WARNING: I/O 5 is congured 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 5 happens. It is recommended
that if servicing the wiring or Ethernet Block that the air supply is turned off.
Figure 1

15
SECTION 5 – OPERATION
5-1 Understanding L.E.D. Indicators on the Ethernet Module
LED Colour Status Description
ETH1 / ETH2 Green On Ethernet link (100 Mbps)
Flashing Ethernet communication (100 Mbps)
Yellow On Ethernet link (10 Mbps)
Flashing Ethernet communication (10 Mbps)
N/A Off No Ethernet link
BUS Green On Active connection to a master
Flashing Ready
Red On IP address conict or status word is active
Flashing Blink/Wink command active
N/A Off Power is off
ERR Green On Diagnostics disabled
Red On Short-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.
3. ERR – Not illuminated at all.
4. I/O 1, 3, & 7 should be illuminated when at the home position.
No other LEDs should be illuminated. If there are other LEDs illuminated then consult
troubleshooting Section 9-1 TOUGH GUN TT3E Reamer - Network.
TURCK is a registered trademark of Turck Inc. & Hans Turck GmbH & Co. K.G.

16
5-2 Program Logic Chart
The TOUGH GUN TT3E Reamer comes congured 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.
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

17
Optional Functions Logic
EXPLANATION:
• Robot moves gun to spray
location.
• Sprayer is turned on and
covers the torch consumables
with anti-spatter spray.
• Sprayer dwell time is adjustable
through the HMI.
EXPLANATION:
• Robot moves gun to nozzle detect
location.
• If the nozzle has come off during
the welding process, the switch
will not be triggered when the
robot is in N.D. location.
EXPLANATION:
• Air blast can 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 locations.
EXPLANATION:
• Robot moves gun to wire cut location.
• Robot Controller jogs the wire out of the
contact tip past the cutter blades.
• Wire Cutter is red and cuts the weld wire
before the robot continues.

18
The manual override setup switches allow the conrmation that the spindle, jaw clamping and sprayer air circuits are operational.
It also allows for the verication of nozzle placement within the jaws after the nozzle height has been set.
To Manually Operate the TOUGH GUN TT3E Reamer
The RESET switch should be pressed prior to manual operation to reset all circuitry.
1. Locate the setup switches on the rear cover of the Reamer.
2. Operate the switches as required.
5-3 Manual Operation
5-4 Operation through the HMI
The TOUGH GUN TT3E 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 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. Open the le folder, downloaded from our website at: www.tregaskiss.com/ReamerTT3E
(under the Software Downloads tab), labelled TOUGH GUN TT3E Reamer HMI and Update Program.
2. Select the HMI .html le and open it in your default web browser.
(see Figure 1)
3. Once opened, enter the IP address of the Reamer you wish to operate.
(see Figure 2)
Figure 1
Figure 2
Reset Switch
Setup Switches

19
NOTE: The ow control valve provides a smooth and constant feed to
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 and consumables.
To Adjust the Flow Control Valve(s)
1. There is a ow control valve for adjustment of the lift speed of the
spindle located behind the spindle shroud cover. The retract speed is
xed. The feed rate may require adjusting for different applications.
2. To increase the feed rate of the cutter blade, the valve would have to be
opened.
3. To decrease the feed rate of the cutter blade, the valve would have to be
closed.
5-5 Adjusting Flow Control Valves
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. (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 Double Stroke press the button “Enable Double Stroke from HMI”. (Figure 5)
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 press the corresponding button below it. The respective total dwell time will be updated instantly in the HMI screen.
(see Figures 6, 7 and 8)
8. There are pre-programmed minimum dwell times that cannot be changed (250ms – Motor Start Up and Spindle Advance,
500ms for Sprayer Duration). The time inputted by the user in the HMI will not be cumulative with these minimum dwell times.
Figure 3
Figure 4
Figure 5
Figure 6 Figure 7
Figure 8

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SECTION 6 – MAINTENANCE
6-1 Replacing the Spindle Limit Switch
6-2 Replacing the Clamp Limit Switch
6-3 Replacing the Air Motor
Belt
Air
Motor
Tension
Lock Screw
Wire with connectors
Limit switch bracket
Fastener
Dowel hole
Fastener
Clamp Limit Switch
Rubber Grommet
WARNING: Ensure 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 holes on the Reamer frame face, then
reinstall fastener.
6. Re-connect the connectors into the wiring harness.
(see Section 7-2 Electrical Schematic).
WARNING: Ensure 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 clamp limit switch connector from the wiring harness. 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 clamp housing.
7. Fasten the new clamp limit switch into position.
8. Reconnect the clamp limit switch connector to the wiring harness
(see Section 7-2 Electrical Schematic).
9. Reinstall the top plate and close the rear cover.
WARNING: Ensure power supply is off and disconnected before proceeding.
Please follow your facility’s lockout / tagout procedures.
1. Open the rear cover or remove it completely by removing the ve (5) screws using a
3 mm Allen wrench.
2. Remove the tension lock screw located on the side of the Reamer frame.
3. Push the motor in to release belt tension, and slide the belt off of the front pulley at
the same time.
4. Disengage belt from the rear pulley.
5. Release the air lines from the quick disconnect air ttings 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 steps above for reassembly.