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Hercules MIG Welding Gun

Hercules MIG welding system logo

Boldly Go Beyond the Welding Productivity You Thought Was Possible

The Tregaskiss Hercules MIG Welding Gun

Hercules MIG Welding Torch

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


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

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.

quality

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 50% or more

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.


Salesperson demonstrating the robotic welding equipment

Learn More

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


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:

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.

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:

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

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.


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.


Group of three different BTB semi-automatic air-cooled MIG guns being held with gloved hands

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 disc

    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 fixture

    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 TOUGH GUN clutch

    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 mount

    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:


      Group of four power pins for MIG welding guns

      Power Pins

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


      Coiled quick-connect block

      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 plug

      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.


        Coiled AccuLock S liner

        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

        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 Autolength cutaway image

        QUICK LOAD Liner AutoLength™ System

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


        Family of color-coded Bernard conventional liners

        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

        Coiled conventional liner shown from top at 45-degree angle

        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 family including contact tip, nozzle, diffuser, liner and power pin

          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

          Image of AccuLock R consumables family including contact tips, nozzle and diffuser

          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 consumables platform™ designed for maximum compatibility across MIG gun series, types and amperages


          TOUGH LOCK consumables family

          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 family shown with contact tips, nozzle and diffuser

          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 family showing contact tips, nozzle and diffuser

          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


            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.

              Tregaskiss MIG Guns, Consumables and Robotic Peripherals

              Learn more about AccuLock R consumables and how they offer longer service live and fewer replacements

              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.


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

                Bernard MIG Guns, Consumables and Accessories

                Learn more about how AccuLock S consumables reduces wire-feeding and bird-nesting problems

                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!


                AccuLock S consumables family including contact tip, nozzle, diffuser, liner and power pin
                MIG Gun Consumables
                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 pathAccuLock 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

                  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:

                  1. What amperage and gun length do you need? This determines the required chassis. Refer to the Chassis section below.
                  2. What model of wire feeder are you using? This determines the required power pin and control plug. Refer to the Power Pin section below.
                  3. 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.

                  Amperage10 ft Length12 ft Length15 ft Length
                  180 amp (XS)XS1810XS1812XS1815
                  260 amp (XS)XS2610XS2612XS2615
                  300 amp (XS)XS3210XS3212XS3215
                  300 amp (XL)XL3010XL3012XL3015
                  400 amp (XL)XL4010XL4012XL4015

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

                  Feeder BrandPower PinEuro AdaptorControl Plug
                  Hobart®214 (Tweco® #4)N/A419-8
                  Miller®214-1 (Miller)N/A419-4
                  Lincoln®214-2 (Lincoln)N/A419-6
                  Euro214 (Tweco #4)417-65419-8
                  Euro214-1 (Miller)417-64419-4
                  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 SizeSD Contact Tip*HD Contact Tip**Liner
                  0.023″ (0.6 mm)403-14-23-05N/A415-23-15
                  0.030″ (0.8 mm)403-14-30-05403-20-30-05415-30-15
                  0.035″ (0.9 mm)403-14-35-05403-20-35-05415-35-15
                  0.045″ (1.2 mm)403-14-45-05403-20-45-05415-116-15
                  0.052″ (1.3 mm)N/A403-20-52-05415-116-15
                  1/16″ (1.6 mm)N/A403-20-116-05415-116-15
                  *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 SizePower PinControl CableGun 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)419-8XS1810-30XS1812-30XS1815-30
                    0.030″ (0.8 mm)214-1 (Miller®)419-4MXS1810-30MXS1812-30MXS1815-30
                    0.030″ (0.8 mm)214-2 (Lincoln®)419-6LNXS1810-30LNXS1812-30LNXS1815-30
                    0.035″ (0.9 mm)214 (Tweco #4)419-8XS1810-35XS1812-35XS1815-35
                    0.035″ (0.9 mm)214-1 (Miller)419-4MXS1810-35MXS1812-35MXS1815-35
                    0.035″ (0.9 mm)214-2 (Lincoln)419-6LNXS1810-35LNXS1812-35LNXS1815-35

                    Brand names shown above are trademarks of their respective owners

                    Wire SizePower PinControl CableGun Part Number
                    (10 ft Length)
                    Gun Part Number
                    (12 ft Length)
                    Gun Part Number
                    (15 ft Length)
                    0.035″ (0.9 mm)214 (Tweco® #4)419-8XS2610-35XS2612-35XS2615-35
                    0.035″ (0.9 mm)214-1 (Miller®)419-4MXS2610-35MXS2612-35MXS2615-35
                    0.035″ (0.9 mm)214-2 (Lincoln®)419-6LNXS2610-35LNXS2612-35LNXS2615-35
                    0.045″ (1.2 mm)214 (Tweco #4)419-8XS2610-45XS2612-45XS2615-45
                    0.045″ (1.2 mm)214-1 (Miller)419-4MXS2610-45MXS2612-45MXS2615-45
                    0.045″ (1.2 mm)214-2 (Lincoln)419-6LNXS2610-45LNXS2612-45LNXS2615-45

                    Brand names shown above are trademarks of their respective owners

                    Wire SizePower PinControl CableGun Part Number
                    (10 ft Length)
                    Gun Part Number
                    (12 ft Length)
                    Gun Part Number
                    (15 ft Length)
                    0.035″ (0.9 mm)214 (Tweco® #4)419-8XS3210-35XS3212-35XS3215-35
                    0.035″ (0.9 mm)214-1 (Miller®)419-4MXS3210-35MXS3212-35MXS3215-35
                    0.035″ (0.9 mm)214-2 (Lincoln®)419-6LNXS3210-35LNXS3212-35LNXS3215-35
                    0.045″ (1.2 mm)214 (Tweco #4)419-8XS3210-45XS3212-45XS3215-45
                    0.045″ (1.2 mm)214-1 (Miller)419-4MXS3210-45MXS3212-45MXS3215-45
                    0.045″ (1.2 mm)214-2 (Lincoln)419-6LNXS3210-45LNXS3212-45LNXS3215-45

                    Brand names shown above are trademarks of their respective owners

                    Wire SizePower PinControl CableGun Part Number
                    (10 ft Length)
                    Gun Part Number
                    (12 ft Length)
                    Gun Part Number
                    (15 ft Length)
                    0.035″ (0.9 mm)214 (Tweco® #4)419-8XL3010-35XL3012-35XL3015-35
                    0.035″ (0.9 mm)214-1 (Miller®)419-4MXL3010-35MXL3012-35MXL3015-35
                    0.035″ (0.9 mm)214-2 (Lincoln®)419-6LNXL3010-35LNXL3012-35LNXL3015-35
                    0.045″ (1.2 mm)214 (Tweco #4)419-8XL3010-45XL3012-45XL3015-45
                    0.045″ (1.2 mm)214-1 (Miller)419-4MXL3010-45MXL3012-45MXL3015-45
                    0.045″ (1.2 mm)214-2 (Lincoln)419-6LNXL3010-45LNXL3012-45LNXL3015-45

                    Brand names shown above are trademarks of their respective owners

                    Wire SizePower PinControl CableGun Part Number
                    (10 ft Length)
                    Gun Part Number
                    (12 ft Length)
                    Gun Part Number
                    (15 ft Length)
                    0.035″ (0.9 mm)214 (Tweco® #4)419-8XL4010-35XL4012-35XL4015-35
                    0.035″ (0.9 mm)214-1 (Miller®)419-4MXL4010-35MXL4012-35MXL4015-35
                    0.035″ (0.9 mm)214-2 (Lincoln®)419-6LNXL4010-35LNXL4012-35LNXL4015-35
                    0.045″ (1.2 mm)214 (Tweco #4)419-8XL4010-45XL4012-45XL4015-45
                    0.045″ (1.2 mm)214-1 (Miller)419-4MXL4010-45MXL4012-45MXL4015-45
                    0.045″ (1.2 mm)214-2 (Lincoln)419-6LNXL4010-45LNXL4012-45LNXL4015-45
                    1/16″ (1.6 mm)214 (Tweco #4)419-8XL4010-116XL4012-116XL4015-116
                    1/16″ (1.6 mm)214-1 (Miller)419-4MXL4010-116MXL4012-116MXL4015-116
                    1/16″ (1.6 mm)214-2419-6LNXL4010-116LNXL4012-116LNXL4015-116

                    Brand names shown above are trademarks of their respective owners

                      Semi-Automatic Water-Cooled MIG Guns

                      Choose between two fully configurable industrial-duty semi-automatic water-cooled MIG gun lines, both engineered for superior performance in production environments requiring extremely high-heat applications.


                      W-Gun semi-automatic water-cooled MIG gun

                      W-Gun™ MIG Guns

                      • 600 amp model available
                      • Curved handle design with multiple trigger options to accommodate operator preference and comfort

                      Family of two T-Gun semi-automatic water-cooled MIG Guns

                      T-Gun™ MIG Guns

                      • 400 (compact series), 450 and 600 amp models available
                      • Straight handle design to accommodate operator preference and comfort

                        Semi-Automatic MIG Guns

                        Choosing the right tool for the job is important!

                        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?

                        Bernard industrial semi-automatic air- and water-cooled MIG welding guns are designed specifically to accommodate a variety of welding styles, preferences and applications, while keeping related parts and consumables to a minimum. Happy welders are productive welders – a win-win for all involved!

                        Image showing three different hand-held BTB MIG guns
                        BTB Semi-Automatic Air-Cooled MIG Guns
                        Industrial-duty
                        200-600 amp models
                        250 amp S-Gun semi-automatic air-cooled MIG gun
                        S-Gun™ Semi-Automatic Air-Cooled MIG Guns
                        Ideal for shipbuilding and construction industries
                        250 amp models
                        Group of three TGX semi-automatic air-cooled MIG guns
                        TGX® Semi-Automatic Air-Cooled MIG Guns
                        Light- to medium-duty
                        180-400 amp models
                        T-Gun Semi-Automatic Water-Cooled MIG Guns
                        T-Gun™ Semi-Automatic Water-Cooled MIG Guns
                        Ideal for high-heat applications
                        400-600 amp models

                          Self-Shielded Flux-Cored Guns

                          Bernard offers two lines of self-shielded flux-cored welding guns to choose from, one with a fixed power cable liner and the other with a replaceable power cable liner.

                          Not sure which FCAW gun is right for you?

                          Use the chart below to determine the right tool for the job.

                          Dura-Flux self-shielded flux-cored gun with replaceable power cable linerDura-Flux self-shielded flux-cored gun with fixed power cable liner
                          FeatureDura-Flux Gun with
                          Replaceable Power Cable Liner
                          Dura-Flux Gun wtih
                          Fixed Power Cable Liner
                          Amperage350350
                          Internal trigger leadsYesNo
                          Replaceable linerYesNo
                          Fixed linerNoYes
                          Optional dual schedule switchYesNo
                          Hi-Viz™ neckYesNo
                          Centerfire™ contact tipsNoYes
                          Quik Tip™ contact tipsYesNo
                          0.045″ (1.2 mm) – 5/64″ (2.0 mm) wire sizesYesNo
                          1/16″ (1.6 mm) – 3/32″ (2.4 mm) wire sizesNoYes
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                            Robotic Air-Cooled MIG Guns

                            Our lineup of fully configurable TOUGH GUN® robotic air-cooled MIG guns are engineered to be robust, resilient and repeatable in the toughest automation applications of high volume production environments. Available for both conventional and through-arm style robots, TOUGH GUN robotic MIG guns are up for the challenge!


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

                            TOUGH GUN® TA3 MIG Guns

                            • Available in 350 amp models
                            • Runs internal to the robot arm
                            • Available as a complete package – from the power pin to the contact tip – for ABB®, COMAU®, FANUC®, Kawasaki®, KUKA®, Miller®, OTC Daihen®, Panasonic® and Yaskawa® Motoman® robots

                            TOUGH GUN CA3 robotic air-cooled MIG gun with medium length 45-degree neck

                            TOUGH GUN CA3 MIG Guns

                            • Available in 385 amp models
                            • Runs external to the robot arm
                            • Replaceable unicable reduces downtime through faster repair and extended service life
                            • Cable guide minimizes stress on cable connection as the robot articulates

                              Nozzle Cleaning Stations

                              TOUGH GUN TT4 Reamer - front view

                              Automating spatter removal helps to extend the life of your robotic MIG guns and consumables, benefiting your bottom line, production uptime and throughput. Choose between our TOUGH GUN® TT4A reamer (analog model), or our new TOUGH GUN TT4E reamer (ethernet model) further enhanced with digital ethernet communication for better integration.

                              TOUGH GUN TT4 Reamer promo tile GIF - shows spatter being reamed off a nozzle
                              FeaturesTOUGH GUN
                              TT4A Reamer (Analog)
                              TOUGH GUN
                              TT4E Reamer (Ethernet)
                              Communications protocolManual Source/SinkSignal from PLC
                              Sprayer comes standardYesYes
                              Anti-spatter fluid reservoir (comes standard)YesYes
                              Low fluid level indicator (comes standard)YesYes
                              Spray containment unit (comes standard)YesYes
                              Spindle (full stroke distance)YesYes
                              4-sided v-block for standard nozzle sizesYesYes
                              Tregaskiss® cutter blade compatibleYesYes
                              Quick-change base plateYesYes
                              Daisy chain compatibility to minimize cell wiringNoYes
                              Double stroke functionNoYes
                              Program custom ream cycleNoYes
                              Network connectionNoYes
                              Optional nozzle detect availableYesYes
                              Optional wire cutter availableYesYes
                              Compatible with TOUGH GUN® reamer stand*YesYes
                              Compatible with TOUGH GARD® anti-spatter multi-feed system*YesYes

                              *Sold separately

                              Identify TOUGH GUN TT4A reamer by part number and set switch plate
                              TOUGH GUN TT4A Reamer (side views)
                              Identify TOUGH GUN TT4E reamer by part number and set switch plate
                              TOUGH GUN TT4E Reamer (side views)

                              Robotic Water-Cooled MIG Guns | Insulating Discs

                              Refer to the table below to find the insulating disc part number you need for your Tregaskiss® 600 amp robotic water-cooled MIG gun.

                              Robot BrandRobot Model(s)Insulating Disc (for G2 style mount)Insulating Disc (for conventional style mount)
                              ABB®IRB6, 140, 1400, 1500, 1600, M97A, 2000, IRB2400L, 400059D02AS-101-2
                              ABBIRB2400/10, IRB2400/16, IRB2600, IRB4600-20/2.5, IRB440L59D04AS-101-4
                              ABBIRB4600-60/2.05, IRB4600-40/2.55, IRB4600-45/2.05N/AAS-107-11
                              ABBIRB6600, IRB6650N/AAS-107-13
                              COMAU®SmartSix 6-1459D01AS-102-10
                              COMAUSmart NS 12, Smart 5 NM 1659DT-004
                              (kit includes 59D02)
                              AS-106-14
                              FANUC®100, 100i, 100iB, 120iB, S-6, M710-20L59D02AS-101-2
                              FANUCArcMate 50iB, 50iC59D05AS-106-8
                              FANUC100iC, 120iC, M710iC-12L59DT-003
                              (kit includes 59D01)
                              AS-102-17
                              (kit includes AS-102-10)
                              FANUCM-420iAN/AAS-107-14
                              FANUCS-430i, R2000iC/125LN/AAS-102-18
                              Kawasaki®RA10L, RS10L, RS20N59DT-004
                              (kit includes 59D02)
                              AS-106-14
                              KawasakiFS-10L, FS-20N/AAS-106-9
                              Kobelco®ARCMAN-RON MKN/AAS-106-11
                              KUKA®KR5 arc, KR6, KR6-2, KR6 arc, KR6 KS, KR16 L6, KR16 L6 arc, KR16 L6 KS59D02AS-101-2
                              KUKAKR5 R1400, KR6 R700 sixx, KR6 R900 sixx, KR10 R900 sixx, KR10 R1100 sixx59D05AS-106-8
                              KUKAKR16, KR16-2, KR16 S, KR16 KS, KR30 L16-259D06AS-102-13
                              KUKAKR30, KR60, KR60 L45, KR60 L3059DT-006
                              (kit includes 59D02)
                              AS-107-11
                              KUKAKR-125, KR-150/2N/AAS-107-12
                              Miller®MRV-259D02AS-101-2
                              Motoman®HP6, HP50-20, K6A, K10S, MH50-20, MH6, SK6, SK16, SK16X, SSF2000, UP6, UP2059D02AS-101-2
                              MotomanK35, HP3, HP3C, HP3JC, MH5, MH5L, SV359D07AS-106-7
                              MotomanMH5059DT-001
                              (kit includes 59D02)
                              AS-107-4
                              MotomanMH5S, MH5LS59D08AS-106-13
                              MotomanMA1440, MA2010, MA321059DT-008
                              (kit includes 59D01)
                              AS-102-20
                              (kit includes AS-102-10)
                              MotomanEA Series59DT-002
                              (kit includes 59D03)
                              AS-102-21
                              (kit includes AS-106-4)
                              OTC Daihen®MRV-6, EX-V6, EX-V6L, EX-V16, DR-2000, DR-2000, DR-4000, DR-4200L, DR-440059D02AS-101-2
                              Panasonic®VR-008A, VR-006A, VR-005C, VR-005LII, AW-010A, AW-8010, AW-005A, AW-005C, AW-005CL, AW-006A, VR-006AL, TA-1400, TA-1800, TL-1800, TL-200059D03AS-106-4
                              PanasonicTM-1100, TM-1400, TM-1600, TM-180059DT-005
                              (kit includes 59D02)
                              AS-102-19
                              (kit includes AS-101-2)
                              Reis®RV4, RV6, RV6L, RV20-659D06AS-102-13
                              ReisRV16, RV16L, RVL16, RH16, RL16 A4, RL26 A4, RV20-1659DT-004
                              (kit includes 59D02)
                              AS-106-14

                                Robotic Water-Cooled MIG Guns | Mounting Systems

                                Refer to the charts below for mounting system information for your Tregaskiss® 600 amp robotic water-cooled MIG gun.

                                G2 Style Solid Mounts

                                G2 Style solid mount diagram for robotic water-cooled MIG guns
                                TCP-Z (mm)Neck AngleApproach AngleNeckClutchSolid Arm MountMounting Arm
                                35022 degree45 degreeRW1-1000-22N/AN/AAS-72-000-22
                                35045 degree45 degreeRW1-1000-45N/AN/AAS-72-000-45
                                40022 degree45 degreeRW1-1000-22N/AN/AAS-72-001-22
                                40045 degree45 degreeRW1-1000-45N/AN/AAS-72-001-45

                                Conventional Style Mounts

                                Conventional style solid mount diagram for robotic water-cooled MIG guns
                                TCP-Z (mm)Neck AngleApproach AngleNeckClutchSolid Arm MountMounting Arm
                                35022 degree45 degreeRW1-1000-22AS-708AS-730AS-71-000-22
                                35045 degree45 degreeRW1-1000-45AS-708AS-730AS-71-000-45
                                350180 degree45 degreeRW1-1000-180AS-708AS-730AS-71-00-180
                                40022 degree45 degreeRW1-1000-22AS-708AS-730AS-71-001-22
                                40045 degree45 degreeRW1-1000-45AS-708AS-730AS-71-001-45

                                Fixed Automatic MIG Guns

                                Tregaskiss® fixed automatic MIG guns are engineered for hard tooling applications requiring a simple, durable and repeatable MIG gun. Available in air- and water-cooled models ranging from 350 to 600 amps, these automatic torches can be configured with the same consumables as your Bernard® semi-automatic or Tregaskiss robotic MIG guns to simplify your inventory.

                                High-performance consumables plus the armored neck and body plus the simple internal connections equal a torch that is quick and easy for you to maintain for maximum uptime and throughput.

                                  Conversion Series Consumables

                                  TOUGH LOCK conversion series consumables

                                  Not currently using a Bernard® or Tregaskiss® MIG gun?

                                  You can still experience immediate benefits from AccuLock®, Centerfire™*, TOUGH LOCK® or Quik Tip™ consumables using competitive conversion parts. Enhance performance and standardize consumables for all your gun brands to minimize inventory management costs.

                                  Gun
                                  Manufacturer
                                  Gun ModelGun NeckAccuLock Conversion
                                  Diffuser
                                  Neck
                                  Insulator
                                  Adaptor
                                  Fronius®TPSiCompatible with M12x1.0 threadD-ATTH-F4C Not
                                  required
                                  Not
                                  required
                                  Gun ManufacturerGun ModelNozzle / Diffuser StyleAdaptorInsulatorDiffuser
                                  Binzel®ALPHA 3, ALPHA 3 automaticSmallNot required4323RDS-1B3
                                  BinzelALPHA 4, ALPHA 4 automaticsLargeNot required4323RD-1B4
                                  Lincoln®Magnum® 250Small13800054323RDS-1
                                  LincolnMagnum 300, Magnum 400SmallNot required4323RDS-1T
                                  LincolnMagnum 300, Magnum 400LargeNot required4423RD-1T
                                  LincolnMagnum Pro 300, Magnum Pro 400LargeNot required4323RD-1LP3
                                  Miller®XR EdgeSmall13800184323RDS-1
                                  MillerXR EdgeLarge138001810012D-1
                                  MillerXR30A, XR-W, Roughneck, PythonSmallNot required4323RDS-1
                                  MillerXR30A, XR-W, Roughneck, PythonLargeNot required10012D-1
                                  MillerAluma-Pro™SmallNot required4323RDS-1AP
                                  MillerAluma-ProLargeNot required10012D-1AP
                                  Tweco®#3, #4, Tuff-n-Lite, Supra® XT (HD consumables)SmallNot required4323RDS-1T
                                  Tweco#3, #4, Tuff-n-Lite, Supra XT (HD consumables)LargeNot required4423RD-1T
                                  TwecoSpraymaster® 450LargeNot required4423RD-1T
                                  TwecoELC 250, ELC 350, Spraymaster 250, Spraymaster 350Small13800124323RDS-1
                                  TwecoELC 250, ELC 350, Sprayermaster 250, Spraymaster 350Large138001210012D-1
                                  TwecoELC 450, EL 450, Supra XT (EL consumables)Large138001710012D-1

                                  Conversion Consumables Installation

                                  1. Install conversion adaptor (if required).
                                  2. Install insulator cap over conversion adapter.
                                  3. Proceed with Centerfire (or Centerfire HD series) installation.

                                  *Available for semi-automatic welding applications only.

                                  Gun ManufacturerGun ModelGun NeckTOUGH LOCK Retaining HeadNeck InsulatorAdaptor
                                  Binzel®ALPHA 4404-46402-11Not required
                                  Lincoln®Magnum® 300KP1928, KP1929, KP1941404-20^4423RNot required
                                  LincolnMagnum 400KP1928, KP1929, KP1941404-20^4423RNot required
                                  LincolnMagnum Pro (slip-on nozzle)404-73402-28Not required
                                  LincolnMagnum Pro (thread-on nozzle)404-75-25402-28Not required
                                  Tweco®#363J-60404-20^4423RNot required
                                  Tweco#464J-60404-20^4423RNot required
                                  TwecoSpray Master™ 350MS63-60404-20^4423RNot required
                                  TwecoSpray Master 450MS64H-60404-20^4423RNot required
                                  TwecoWeldSkill® 40064A-60404-20^4423RNot required
                                  TwecoAir-cooled roboticsQTR66-22 (with M11 thread)404-30402-19404-69
                                  TwecoAir-cooled roboticsQTR66-22 (with M12 thread)404-30402-19404-63

                                  ^The 404-20 retaining head will fit on most necks with an external 9/16″-18 thread regardless of angle

                                  Gun ManufacturerGun ModelAdaptorInsulatorCompatible DiffusersCompatible Nozzles
                                  Lincoln®Magnum® 250138000510012D1F, D118, D114N1C12, N1C58, N1C34, N1C34HD, N1C58HD
                                  Tweco®ELC 250, ELC 350, Spraymaster® 250, Spraymaster 350138001210012D1F, D118, D114N1C12, N1C58, N1C34, N1C34HD, N1C58HD
                                  TwecoELC 450, EL 450, Supra® XT (EL consumables)138001710012D1F, D118, D114N1C12, N1C58, N1C34, N1C34HD, N1C58HD
                                  Gun ManufacturerGun ModelAdaptorInsulatorCompatible DiffusersCompatible Nozzles
                                  Tweco®#3, #4, Tuff-n-Lite, Supra® XT (HD consumables), Spraymaster® 450Not requiredVL1ND118QLL, D114QLLN1C12Q, N1C58Q, N1C34Q, N1C34HQ, N1C58HQ
                                  TwecoELC 250, ELC 350, Spraymaster 250, Spraymaster 350138001210012D1FQ, D118Q, D114QN1C12Q, N1C58Q, N1C34Q, N1C34HQ, N1C58HQ
                                  TwecoELC 450, EL 450, Supra XT (EL consumables)138001710012D1FQ, D118Q, D114QN1C12Q, N1C58Q, N1C34Q, N1C34HQ, N1C58HQ
                                  Lincoln®Magnum® 250138000510012D1FQ, D118Q, D114QN1C12Q, N1C58Q, N1C34Q, N1C34HQ, N1C58HQ
                                  LincolnMagnum 300, Magnum 400Not requiredVL1ND118QLL, D114QLLN1C12Q, N1C58Q, N1C34Q, N1C34HQ, N1C58HQ

                                  Conversion Consumables Installation

                                  1. Install conversion adaptor (if required).
                                  2. Install insulator cap over conversion adaptor.
                                  3. Trim liner to correct dimension for the diffuser being used.
                                  4. Torque diffuser onto the neck to approximately 12 ft-lbs.
                                  5. Insert contact tip into the diffuser and lock into position with a clockwise motion.
                                  6. Thread nozzle onto the diffuser and tighten firmly by hand.

                                    BTB MIG Guns | Neck Options

                                    Configure your curved or straight handle BTB semi-automatic air-cooled MIG gun with your choice of a fixed or rotatable neck. Find your handle type below for available neck options and part numbers.

                                    Configurator OptionAngleLengthPart Number
                                    O45ShortQT2-45
                                    P60ShortQT2-60
                                    R45MediumQT3-45
                                    S60MediumQT3-60
                                    U45LongQT5-45
                                    V60LongQT5-60
                                    Configurator OptionAngleLengthPart Number
                                    B45ShortQT2-45
                                    C60ShortQT2-60
                                    E45MediumQT3-45
                                    F60MediumQT3-60
                                    H45LongQT5-45
                                    I60LongQT5-60
                                    Configurator OptionAngleLengthPart Number
                                    O45ShortQT2-45
                                    P60ShortQT2-60
                                    R45MediumQT3-45
                                    S60MediumQT3-60
                                    U45LongQT5-45
                                    V60LongQT5-60
                                    Configurator OptionsAngleLengthPart Number
                                    B45ShortQT2-45
                                    C60ShortQT2-60
                                    E45MediumQT3-45
                                    F60MediumQT3-60
                                    H45LongQT5-45
                                    I60LongQT5-60
                                    Configurator OptionAngleLengthPart Number
                                    O45ShortQT2-45
                                    P60ShortQT2-60
                                    R45MediumQT3-45
                                    S60MediumQT3-60
                                    U45LongQT5-45
                                    V60LongQT5-60
                                    Configurator OptionAngleLengthPart Number
                                    B45ShortQT2-45
                                    C60ShortQT2-60
                                    E45MediumQT3-45
                                    F60MediumQT3-60
                                    H45LongQT5-45
                                    I60LongQT5-60
                                    Configurator OptionAngleLengthPart Number
                                    O45ShortQT2-45
                                    P60ShortQT2-60
                                    R45MediumQT3-45
                                    S60MediumQT3-60
                                    U45LongQT5-45
                                    V60LongQT5-60
                                    Configurator OptionAngleLengthPart Number
                                    B45ShortQT2-45
                                    C60ShortQT2-60
                                    E45MediumQT3-45
                                    F60MediumQT3-60
                                    H45LongQT5-45
                                    I60LongQT5-60
                                    Configurator OptionAngleLengthPart Number
                                    O45Short305-45
                                    P60Short305-60
                                    R45Medium405-45
                                    S60Medium405-60
                                    U45Long505-45
                                    V60Long505-60
                                    Configurator OptionAngleLengthPart Number
                                    B45ShortQT2-45
                                    C60ShortQT2-60
                                    E45MediumQT3-45
                                    F60MediumQT3-60
                                    H45LongQT5-45
                                    I60LongQT5-60
                                    Configurator OptionAngleLengthPart Number
                                    O45Short205-45
                                    P60Short205-60
                                    R45Medium315-45
                                    S60Medium315-60
                                    U45Long405-45NB
                                    V60Long405-60NB
                                    Configurator OptionAngleLengthPart Number
                                    O45Short305-45CT
                                    P60Short305-60CT
                                    R45Medium405-45CT
                                    S60Medium405-60CT
                                    U45Long505-45CT
                                    V60Long505-60CT
                                    Configurator OptionAngleLengthPart Number
                                    B45ShortQT2-45
                                    C60ShortQT2-60
                                    E45MediumQT3-45
                                    F60MediumQT3-60
                                    H45LongQT5-45
                                    I45LongQT5-60

                                      BTB MIG Guns | Handle Options

                                      Choose from seven handle options when customizing your BTB semi-automatic air-cooled MIG gun. The table below provides an overview of the features available for each of the handle options in our BTB MIG gun configurator.

                                      FeaturesB SeriesB Series SmallO SeriesO Series SmallT SeriesT Series SmallC Series
                                      Handle imageB series curved handle style for BTB semi-automatic MIG gunB series small curved handle style for BTB semi-automatic MIG gunO series curved handle style for BTB semi-automatic MIG gunO series small curved handle style for BTB semi-automatic MIG gunT series straight handle style for BTB semi-automatic MIG gunT series small straight handle style for BTB semi-automatic MIG gunC series straight handle style for BTB semi-automatic MIG gun
                                      Amperage400200, 300400, 500, 600200, 300, 400300, 400, 500, 600200, 300200, 300, 400, 500
                                      StyleCurvedCurvedCurvedCurvedStraightStraightStraight
                                      Neck compatibilityFixed, RotatableFixed, RotatableFixed, RotatableFixed, RotatableFixed, RotatableFixedFixed, Rotatable
                                      Trigger optionsStandard, Locking, Dual pull, Dual schedule switch, Locking dual schedule switchStandard, Locking, Dual pullStandard, Locking, Dual pull, Dual schedule switchStandard, LockingStandard, Locking, Dual pull, Dual schedule switchStandardStandard, Locking, Dual pull, Dual schedule switch, Insight™ Ltd.
                                      CableHytrel® polymerHytrel polymerHytrel polymer, Steel monocoilHytrel polymer, Steel monocoil (300, 400 amp only)Hytrel polymer, Steel monocoil (300, 400 amp only)Hytrel polymerHytrel polymer, Steel monocoil (300, 400 amp only)
                                      Warranty1 year limited warranty1 year limited warranty1 year limited warranty1 year limited warranty1 year limited warranty, plus lifetime warranty on front handle, rear strain relief and trigger1 year limited warranty, plus lifetime warranty on front handle, rear strain relief and trigger1 year limited warranty, plus lifetime warranty on front handle, rear strain relief and trigger
                                      Double-life MIG gun systemNoNoNoNoYesNoYes

                                        BTB MIG Guns | Cable Options

                                        Cutaway of steel monocoil cable showing internal cable, trigger leads and copper
                                        Steel Monocoil Cable
                                        (cutaway shown)
                                        Cutaway of Hytrel polymer (industrial grade) cable showing Hytrel inner tube, trigger leads and copper
                                        Hytrel® Polymer Cable
                                        (cutaway shown)

                                        BTB semi-automatic air-cooled MIG guns are available with a choice of two gun cable options: Hytrel® polymer (industrial grade) or steel monocoil cable. The key difference between the two cables is the material of the inner tube at the center of the cable through which the gun liner, wire and shielding gas travels.

                                        The steel monocoil cable offers extra structural integrity to the cable, giving it superior pinch resistance which helps to ensure good gas flow and wire feedability. Users in industries or welding applications that require longer gun cables that are frequently looped or stretched around corners to the point of pinching are the ones who should consider upgrading their welding guns to our specialty steel monocoil cable.

                                        The majority of our welding gun users do not experience these issues, and enjoy long, dependable product performance with our heavy-duty Hytrel polymer cable.