Introducing AccuLock™ S Consumables

AccuLock™ S Consumables with Bernard® Conventional Rear-Loading Liners on Miller® Packages

Image of AccuLock Conventional and Miller Deltaweld

Bernard® BTB MIG Guns with select Miller® packages will begin shipping on March 7, 2023 with a version of AccuLock that consists of a diffuser compatible with the common conventional style liners you are used to using, plus the added benefit of standard AccuLock S contact tips and nozzles.

AccuLock™ can transform the way businesses manage their MIG welding gun consumables — helping to optimize productivity, operating costs and welder confidence.

Less tip changes
Less welding troubleshooting
More beads worth bragging about

You will benefit from:

Longer Tip Life

Reduced contact tip replacement frequency
Contact tips are 60% buried within the diffuser for less exposure to the heat of the weld
Mating tapers on both tip-to-diffuser and diffuser-to-neck connection for good electrical conductivity
Shielding-gas cools contact tip tail
Less rework and ease of maintenance/replacement

Less Rework and Ease of Maintenance

Coarse thread contact tips speed tip replacement
Steel retaining ring on diffuser helps keep threaded nozzle in place during use/cleaning

AccuLock™ S Consumables with conventional rear-load liners are now available on select Miller® Packages including:

Upgrade to AccuLock S Dual-Locked Liners to receive all the benefits above plus:

Error-proof liner replacement, every time, with no measuring required!
Flawless wire feed path — AccuLock S front-load liners are locked and concentrically aligned to both the contact tip and the power pin, optimizing wire feeding, which eliminates welding liner misalignment gaps from your troubleshooting list

Yes! I want these AccuLock benefits!

Why offer conventional liners with AccuLock S consumables?

We’re offering conventional liners with AccuLock S consumables to make it as easy as possible to convert existing fleets of BTB MIG Guns from Centerfire™ or TOUGH LOCK® to AccuLock S consumables. To convert your current guns from Centerfire or TOUGH LOCK to AccuLock consumables, simply swap out the nozzle, diffuser and contact tip. You can continue to use your existing conventional liner without retrimming. Later, when you want the additional benefits offered by the AccuLock S dual-locked liner, you can upgrade your existing guns by swapping out the diffuser, liner and power pin cap or you can begin purchasing new guns with the full AccuLock S system.

Click here to download the AccuLock S Consumables Conversion Guide for Miller Packages. This detailed guide contains all the part numbers needed to convert your existing guns to AccuLock or to re-order the AccuLock consumables that came with your Miller package.

Hercules MIG Welding Gun

Boldly Go Beyond the Welding Productivity You Thought Was Possible

The Tregaskiss Hercules MIG Welding Gun

The Tregaskiss® Hercules™ Robotic MIG Gun is a key component of the Hercules system, an innovative single-arc solution that increases deposition rates by 30% or more without sacrificing weld quality or aesthetics.

Like other Tregaskiss products, the Hercules Robotic Gun is designed to maximize performance, longevity, accuracy, and ease of maintenance.

Maximized Performance

The system provides maximized electrical conductivity and optimized filler metal delivery to the weld puddle
Lightweight, durable cable jacket protects the unicable, power cable and coolant lines from wear

Long Life

Water-cooling module delivers superior cooling to the front-end consumables

Accuracy

Keyway system accurately aligns the neck to the mounting arm for repeatability
Neck checking fixture available to assess and maintain Tool Center Point (TCP)

Ease of Maintenance

Compatible with Tregaskiss reamers for automated spatter removal from front-end consumables
Automatic shut-off valves prevent water leakage during neck and cooling module replacement
Replacement parts are quickly and easily serviced

Hercules MIG Welding Gun Support

Hercules Spec Sheet

Includes information on product features, configurations, center of mass, options, components, and accessories .

Hercules Product Manual

Includes installation, maintenance, troubleshooting and replacement parts information.

What is the Hercules System?

The Hercules™ single-wire, high-deposition, automated MIG welding system significantly boosts welding productivity rates without the expense of adding more weld cells. Only the Hercules system can deliver a gain of up to 30% or more in deposition rates and up to 30% or more in productivity with no loss of weld quality — making you more productive, competitive and profitable.

Developed by Miller, Hobart and Tregaskiss, the revolutionary Hercules MIG welding system combines Miller® power source and wire-feed technology, a unique Tregaskiss® torch and a specialized Hobart® metal-cored wire. Together, they boldly go beyond the welding productivity rates you thought were possible.

Eliminate welding bottlenecks, unlock unutilized capacity

With the Hercules System, welding will no longer be the bottleneck slowing your productivity. It unlocks capacity that’s currently underutilized, all without adding more weld cells — which require additional floor space or brick and mortar. In many cases, the Hercules MIG welding system doesn’t require all-new automation allowing you to use equipment that’s currently in place.

Improve welding throughput without risking weld quality

Compared to your current solid wire or metal-cored process, the Hercule MIG welding system can improve welding throughput 30% or more — all while delivering similar (or better) weld bead profiles, heat-affected zones and weld integrity.

Increase deposition rates by 30% or more

Get welding deposition rates that beat your current single-wire GMAW system by as much as 30% or more. Time and again, the Hercules MIG welding system delivers higher welding deposition rates than our customers thought possible — even customers who believed they were at the forefront of high-deposition welding with a “state of the art” system.

Learn More

Learn how the Hercules automated MIG welding system can work for you.

Contact the Hercules Team

Visit the Hercules System site

AccuLock Consumables

Designed to address the key pains of our semi-automatic and automated MIG welding customers

Use the same AccuLock™ contact tips across your Bernard® semi-automatic and Tregaskiss® fixed automatic and robotic MIG guns.

Acculock S and R Consumable family share a common contact tip

Increase consumable life to decrease costs and increase productivity
Reduce consumables replacement errors to reduce troubleshooting, rework and downtime
Simplify consumables replacement to increase accuracy and reduce employee training requirements

Choose from AccuLock consumable series options – AccuLock S and AccuLock R to achieve the above in the most effective way possible depending upon your mix of welding applications

Which AccuLock Consumables Are Right for Your Welding Operation?

Based on discussions with customers in key industries, we found that MIG gun consumables challenges differed depending on the quantity and mix of welding applications in each customer’s facility (i.e. semi-automatic, robotic, fixed automatic).

If you have all semi-automatic or automated arcs, the choice of AccuLock consumables is more straightforward. However, with the increasing adoption of automated welding to address the ongoing welder shortage, many operations now have a mix of welding application types. Click on the tab below that best describes your welding applications mix to learn more:

All Semi-Automatic Welding Arcs
Mix of Welding Arcs
All Automated Welding Arcs

AccuLock S consumables family including contact tip, nozzle, diffuser, liner and power pin — AccuLock S Consumables

If you are experiencing the following welding challenges, we recommend using AccuLock S nozzles, diffusers, liners, power pins and power pin caps with AccuLock contact tips:

Birdnests
Burnbacks
Erratic arc
Short contact tip lifespan
Excessive rework

Many of the issues above can be traced to MIG gun liners that have been trimmed to an incorrect length or that pull out of position inside the MIG gun creating gaps along the wire feed path.

Learn More

If your primary issues center around a complex and costly inventory of MIG gun consumables, we recommend that you use AccuLock R consumables as a Common Consumables Platform™ across all your semi-automatic, robotic and fixed automatic MIG guns. Issues typically experienced include:

Frequent errors in selecting and installing replacement consumables
High inventory carrying costs
Pressure from Purchasing to reduce SKUs

If your primary welding challenges are specific to the different welding applications in your operation, we recommend that you use a mix of consumables:

AccuLock S consumables on your semi-automatic arcs
AccuLock R consumables on your robotic and fixed automatic MIG guns
The same AccuLock contact tips can be used on all your MIG guns

For issues specific to each application, please see the All Semi-Automatic Welding Arcs and All Automated Welding Arcs tabs.

AccuLock R consumables family including contact tips, nozzle and slip-on diffuser — AccuLock R Consumables

If you are experiencing the following welding challenges, we recommend using TOUGH LOCK™ nozzles, AccuLock R diffusers, QUICK LOAD liners and AccuLock contact tips:

Short contact tip lifespan – especially in pulse welding applications
Contact tip cross-threading issues
Excessive downtime for consumables replacement
Safety issues related to climbing up to access robots or wire feeders for gun liner changes

Many of the contact tip issues above can be addressed by selecting from our AccuLock copper, chrome zirconium and HDP contact tips. Our front-loading QUICK LOAD liner system cuts liner replacement time in half and allows operators to access the robot from a safe zone in the robotic cell.

Learn More

Family of three QUICK LOAD liners with liner retainers — QUICK LOAD® Liners

Family product shot of AccuLock S liner, contact tip, nozzle, power pin, gas diffuser — AccuLock™ S Consumables

Product shot of AccuLock R gas diffuser, nozzles, contact tips — AccuLock™ R Consumables

Semi-Automatic Air-Cooled MIG Guns

Bernard offers a wide range of fully configurable, industrial-duty semi-automatic air-cooled MIG welding guns designed specifically to accommodate a variety of welding styles, preferences and applications.

BTB MIG Guns

Available in 200, 300, 400, 500 and 600 amp models
Choose from a variety of necks, handles and trigger styles to optimize welder ergonomics and weld access
Standardize with a single line of consumables to simplify maintenance and contain costs

250 amp S-Gun semi-automatic air-cooled MIG gun

S-Gun™ MIG Guns

Available in 250 amp models
Designed to reduce downtime and increase productivity
Ideal for use in the shipbuilding and construction industries

Group of three TGX semi-automatic air-cooled MIG guns

TGX® MIG Guns

Available in 300 and 400 amp models180, 260 and 300 amp compact series models available
Perfect for low volume, light- to medium-duty welding
Ideally suited for lower amperage welding applications and shorter arc-on times.

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System Components and Peripherals

Clutch mount clamp for TOUGH GUN CA3 robotic air-cooled MIG guns

Solid mount clamp for TOUGH GUN CA3 robotic air-cooled MIG guns

Clamps and Mounting Arms

TOUGH GUN® clamps and mounting arms are made of tough yet resilient aluminum. These products are engineered to provide a robust and durable connection for the TOUGH GUN CA3 robotic air-cooled MIG gun.

The TOUGH GUN clutch clamp triggers an emergency stop in the event of a robotic collision and its new compact design allows for a larger working envelope. The TOUGH GUN solid mount clamp is available for clutchless models, offering the same increased working envelope.

Insulating Discs

Insulating discs help to protect your robotic investment by insulating robots and their controllers from the weld current, and are available with different bolt patterns for attaching TOUGH GUN robotic MIG guns to various brands of robots.

Neck Checking Fixtures

For applications where verification of tooling is a requirement, the TOUGH GUN neck checking fixture provides the opportunity to verify the accuracy of the neck to the intended tool center point (TCP). Further, an adjustment handle is provided to help implement minor adjustments if required.

Accommodates a wide variety of standard necks
Special kits are available for customized Tregaskiss necks

Legacy Clutch

Compatible with TOUGH GUN CA3 and legacy TOUGH GUN G1 series robotic air-cooled MIG guns, the original TOUGH GUN clutch is designed to e-stop your robot with a deflection of only 1° in the event of a robotic collision.

Solid Arm Mounts

Made of high-strength aluminum, the TOUGH GUN solid arm mount can replace a clutch on TOUGH GUN CA3 and legacy TOUGH GUN G1 series systems using collision detection software.

Feeder Connections

Bernard and Tregaskiss offer a comprehensive selection of feeder connections for the most popular wire feeder models on the market. Select from the following:

Power Pins

Power pins provide a direct connection for wire, electrical current and gas flow between various wire feeder to MIG welding guns.

Quick-Connect Blocks and Adaptors

Quick-connect blocks and adaptors provide an adaptive bridge from your existing welding gun power pin to a different kind of feeder connection.

Control Plugs

Control plugs transmit an on/off signal from the semi-automatic MIG gun trigger to the feeder as well as the dual schedule control (if equipped).

MIG Welding Gun Liners

Bernard and Tregaskiss offer various conventional rear-loading, innovative front-loading, and other revolutionary MIG welding liner solutions.

NEW!! AccuLock™ S Liners

Load and Lock for Better Productivity

Flawless wire-feed path – An essential component of the complete AccuLock S consumables system, AccuLock S liners are locked and concentrically aligned to both the contact tip and the power pin without the use of fasteners
Error-proof liner replacement every time with no measuring!

QUICK LOAD® Liners

Load your liners from the front of the MIG gun in less than half the time it takes to install conventional liners.

QUICK LOAD Liner AutoLength™ System

Minimize downtime, wire feeding and quality issues commonly associated with short liner length.

Bernard Conventional Liners

Simplify and reduce your inventory with Bernard® conventional liners
Color-coded by wire size for ease of identification
Made of high carbon music wire to achieve smooth wire feed and long life
These rear-loading liners won’t gap when bent

Conventional Liners

Ideal for aluminum, steel, stainless steel and flux-cored wire, conventional liners are made of high carbon music wire for smooth wire feed and long life.

MIG Gun Consumables

Genuine Bernard® and Tregaskiss® consumables enhance the performance of your MIG welding gun. They are manufactured to the same durable, high-performance standards as every MIG welding product we build, and they deliver the improved performance you’ve come to know and expect from us.

AccuLock™ S Consumables

Load and lock for better productivity

Flawless wire-feed path — AccuLock S liners are locked and concentrically aligned to both the contact tip and the power pin
Error-proof liner replacement every time with no measuring!
2-3x longer contact tip life due to optimized wire feeding
Reduce parts to reduce errors with a common contact tip designed for maximum compatibility across MIG gun series, types and amperages

AccuLock™ R Consumables

Load and lock for better throughput

Longer contact tip life
Eliminate contact tip cross-threading issues, resulting in reduced downtime, scrap and rework costs
Reduce parts to reduce errors with a common contact tip designed for maximum compatibility across MIG gun series, types and amperages

TOUGH LOCK® Consumables

Dual taper technology keeps consumables locked in place for accuracy and repeatability
Tapered connections provide excellent electrical conductivity for cooler temperatures and long tip life
Common consumables platform™ — use one line of consumables for both Tregaskiss® and Bernard® MIG guns

Centerfire™ Consumables

Thread-on nozzles and drop-in contact tips can be quickly replaced without tools
Spatter shield within nozzle protects diffuser and gives smoother, less turbulent gas flow
Provides better arc starts, less spatter and more consistent welds

Quik Tip™ Consumables

A quick twist is all it takes for contact tip installation
Diffusers secure contact tips in a fixed position for consistent welds
Threaded taper lock between the tip and diffuser provides excellent heat transfer and electrical conductivity

AccuLock Consumables including both AccuLock S and AccuLock R

Welding Gun Consumables – What You Need to Know

Learn everything you need to know about MIG gun consumables and how to get the most out of them in this helpful online resource.

Robotic MIG Guns

Vibration, heating and cooling cycles, severe rotational movement, the whipping action of the cable, and the occasional crash require a durable robotic MIG welding gun. Tregaskiss® robotic MIG guns are tough enough to meet the challenge! All robotic MIG guns are built-to-order and come ready to rumble right out of the box.

TOUGH GUN TA3 Robotic Air Cooled MIG Gun — TOUGH GUN® TA3 Robotic Air-Cooled MIG Guns
for through-arm style robots

Image of Tregaskiss TOUGH GUN CA3 robotic MIG gun with 45 degree neck — TOUGH GUN® CA3 Robotic Air-Cooled MIG Guns
for conventional style robots

600 amp robotic water cooled MIG gun installed on robot — Tregaskiss® 600 amp Robotic Water-Cooled MIG Guns
for conventional style robots

Tregaskiss MIG Guns, Consumables and Robotic Peripherals

Maximizing Throughput. Minimizing Costs.

Automated welding applications require flexible, repeatable solutions that maximize production uptime and throughput while minimizing costs. This is why industrial manufacturers rely on Tregaskiss and its proven track record for delivering reliable, resilient, repeatable and fully configurable robotic MIG welding guns, fixed automatic MIG guns, nozzle cleaning stations and innovative welding gun consumables.

You need reliable MIG guns, consumables and welding products that are readily available and offer consistent performance. Simplicity, ease of maintenance and durability are always part of our design specifications.

TOUGH GUN TA3 robotic air-cooled MIG gun installed on robot — Robotic MIG Guns

MA1 air-cooled and MW1 water-cooled fixed automatic MIG guns with straight necks — Fixed Automatic Guns

TOUGH GUN TT4 Reamer — Nozzle Cleaning Stations

New 2021 TOUGH GARD anti-spatter liquid product family — Anti-Spatter Liquid

Tregaskiss MA1 Fixed Automatic MIG Gun — MA1 Fixed Automatic Air-Cooled MIG Guns

Tregaskiss MW1 Fixed Automatic MIG Gun — MW1 Fixed Automatic Water-Cooled MIG Guns

Tregaskiss AW2 Fixed Automatic MIG Gun — AW2 Fixed Automatic Water-Cooled MIG Guns

TOUGH GUN TT4E Reamer side shot — TOUGH GUN® TT4E (Ethernet) Reamer

TOUGH GUN TT4A Reamer side shot — TOUGH GUN TT4 (Analog) Reamer

Bernard MIG Guns, Consumables and Accessories

Engineered for Simplicity. Built for Durability.

Consider the impact of MIG guns on your business. As much as 85% of hand-held welding costs are labor related. What is the real cost of using outdated equipment with poor ergonomics and excessive consumable and replacement part inventories?

The Bernard team can help all of your welders configure the MIG gun that is perfectly suited to their preferences and welding applications while keeping related parts and consumables to a minimum. Happy and healthy welders are productive welders – a win-win for all involved!

Group of four semi-automatic MIG welding guns — Semi-Automatic Guns

Clean Air fume extraction MIG gun with new black neck — Fume Extraction Guns

Dura-Flux self-shielded flux-cored gun with replaceable power cable liner — Self-Shielded Flux-Cored Guns

bernard short stub — Manual Welding Accessories

AccuLock™ S Consumables

Load and lock for better productivity

Flawless wire-feed path – AccuLock S liners are locked and concentrically aligned to both the contact tip and the power pin without the use of fasteners
Error-proof liner replacement every time with no measuring!
2-3x longer contact tip life due to optimized wire feeding

Image showing three different hand-held BTB MIG guns — BTB Semi-Automatic Air-Cooled MIG Guns

W-Gun semi-automatic water-cooled MIG gun — W-Gun™ Semi-Automatic Water-Cooled MIG Guns

T-Gun Semi-Automatic Water-Cooled MIG Guns — T-Gun™ Semi-Automatic Water-Cooled MIG Guns

S-Gun 250 amp Semi-Automatic Air-Cooled MIG Guns — S-Gun™ 250 amp Semi-Automatic Air-Cooled MIG Guns

Clean Air Fume Extraction MIG Guns — Clean Air™ Fume Extraction MIG Guns

Dura-Flux self-shielded flux-cored gun with fixed power cable liner — Dura-Flux Self-Shielded Flux-Cored FCAW Guns with Fixed Power Cable

TGX Easy As 1-2-3! Program

Minimize Inventory. Maximize Inventory Turns.

The TGX® Easy As 1-2-3! program offers distributors the flexibility of configuring a TGX semi-automatic air-cooled MIG gun right in their store to quickly meet the needs of their customers.

TGX semi-automatic air-cooled MIG guns are recommended for light- to medium-duty welding applications with shorter arc-on times.

Choose the Bernard® TGX semi-automatic air-cooled MIG gun that’s right for you!

To determine the parts required to configure your TGX MIG gun, you will need to know the following information:

What amperage and gun length do you need? This determines the required chassis. Refer to the Chassis section below.
What model of wire feeder are you using? This determines the required power pin and control plug. Refer to the Power Pin section below.
What wire size are you using? This determines the required contact tip and liner. Refer to the Consumables section below.

Find your amperage and gun length in the chart below to determine the TGX chassis you require. A chassis is essentially an assembled MIG gun minus the contact tip, liner, power pin and control plug.

Amperage	10 ft Length	12 ft Length	15 ft Length
180 amp (XS)	XS1810	XS1812	XS1815
260 amp (XS)	XS2610	XS2612	XS2615
300 amp (XS)	XS3210	XS3212	XS3215
300 amp (XL)	XL3010	XL3012	XL3015
400 amp (XL)	XL4010	XL4012	XL4015

Find your wire feeder brand in the chart below to determine the power pin and control plug (optional) that you require.

Feeder Brand	Power Pin	Euro Adaptor	Control Plug
Hobart®	214 (Tweco® #4)	N/A	419-8
Miller®	214-1 (Miller)	N/A	419-4
Lincoln®	214-2 (Lincoln)	N/A	419-6
Euro	214 (Tweco #4)	417-65	419-8
Euro	214-1 (Miller)	417-64	419-4

Note: The Euro adaptor is not available for 180 amp or 260 amp TGX MIG guns.

Find your wire size in the chart below to determine the contact tip and liner you require.

Wire Size	SD Contact Tip*	HD Contact Tip**	Liner
0.023″ (0.6 mm)	403-14-23-05	N/A	415-23-15
0.030″ (0.8 mm)	403-14-30-05	403-20-30-05	415-30-15
0.035″ (0.9 mm)	403-14-35-05	403-20-35-05	415-35-15
0.045″ (1.2 mm)	403-14-45-05	403-20-45-05	415-116-15
0.052″ (1.3 mm)	N/A	403-20-52-05	415-116-15
1/16″ (1.6 mm)	N/A	403-20-116-05	415-116-15

*For use with 180 (XS) and 260 (XS) amp models
**For use with 300 (XS), 300 (XL) and 400 (XL) amp models

TGX Ready To Weld Program

Pre-configured models offer a variety of our most popular Bernard® TGX® semi-automatic air-cooled MIG guns.

If you prefer a factory-built gun for your light- to medium-duty welding application, the TGX Ready To Weld program is the perfect solution. This program offers a variety of factory-assembled TGX MIG guns that are ready to weld right out of the box.

To find the MIG gun part number you need, navigate to your desired amperage below and use the charts provided, or use our configurator to help guide you through the process.

Wire Size	Power Pin	Control Cable	Gun Part Number (10 ft Length)	Gun Part Number (12 ft Length)	Gun Part Number (15 ft Length)
0.030″ (0.8 mm)	214 (Tweco® #4)	419-8	XS1810-30	XS1812-30	XS1815-30
0.030″ (0.8 mm)	214-1 (Miller®)	419-4	MXS1810-30	MXS1812-30	MXS1815-30
0.030″ (0.8 mm)	214-2 (Lincoln®)	419-6	LNXS1810-30	LNXS1812-30	LNXS1815-30
0.035″ (0.9 mm)	214 (Tweco #4)	419-8	XS1810-35	XS1812-35	XS1815-35
0.035″ (0.9 mm)	214-1 (Miller)	419-4	MXS1810-35	MXS1812-35	MXS1815-35
0.035″ (0.9 mm)	214-2 (Lincoln)	419-6	LNXS1810-35	LNXS1812-35	LNXS1815-35