TOUGH GUN CA3 and TOUGH GUN TA3 Robotic Air-Cooled MIG Guns

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FAQs for Current TOUGH GUN G1 and G2 Series MIG Gun Owners

IMPORTANT NOTE:
If you currently own a large TOUGH GUN CA3 MIG Gun, please click here for additional FAQs.

  1. Why did you introduce the TOUGH GUN™ CA3 and TOUGH GUN™ TA3 Robotic Air-Cooled MIG Guns?
  2. What are the key features of the TOUGH GUN CA3 Robotic Air-Cooled MIG Gun?
  3. What are the key features of the TOUGH GUN TA3 Robotic Air-Cooled MIG Gun?
  4. What do CA3 and TA3 stand for?
  5. Will I need to adjust my TOUGH GUN Reamer Robotic Nozzle Cleaning Station(s) as a result of these gun improvements?
  6. Will any reprogramming be necessary when converting from the TOUGH GUN G1 Series MIG Gun to the TOUGH GUN CA3 MIG Gun?
  7. How have you extended the service life of the new TOUGH GUN CA3 MIG Gun unicable by almost 2 times?
  8. Why is the jog switch no longer being offered?

Gun and Unicable Replacement for Existing TOUGH GUN G1 Series MIG Guns

  1. Can I convert my legacy TOUGH GUN G1 Series Conventional Robotic MIG Gun to a TOUGH GUN CA3 Conventional Robotic MIG Gun?
  2. How do I order a replacement gun for my TOUGH GUN G1 Series (5400 Series) Conventional Robotic Gun?
  3. How do I replace my existing SG (Special) TOUGH GUN G1 Series Robotic MIG Gun?
  4. How do I know if I have an old G1 connector, a large CA3 connector, or a new slim CA3 connector?
  5. How do I order a replacement chassis (connector + unicable) for my existing (pre-October 2014) TOUGH GUN G1 Series Conventional Robotic MIG Gun?
  6. How do I order a replaceable unicable for my new TOUGH GUN CA3 Robotic MIG Gun?
  7. How do I install the new connector and replaceable unicable to my existing (pre-October 2014) TOUGH GUN G1 Series Conventional Robotic MIG Gun?
  8. How do I install the new replaceable unicable?
  9. Can I use the existing TOUGH GUN I.C.E.™ setup from my current TOUGH GUNG1 Series MIG Gun when converting to a new TOUGH GUN CA3 Robotic MIG Gun?

TOUGH GUN TA3 Robotic Air-Cooled MIG Guns

Gun and LSR Unicable Replacement for Existing TOUGH GUN ThruArm G1 Series MIG Guns

  1. How do I order a replacement gun for my existing TOUGH GUN ThruArm™ G1 Series Robotic MIG Gun?
  2. How do I order a replacement LSR Unicable for my existing TOUGH GUN ThruArm G1 Series Robotic MIG Gun?

Converting from TOUGH GUN G2 Series or TOUGH GUN ThruArm G2 Series to TOUGH GUN CA3 or TOUGH GUN TA3 Series MIG Guns

  1. How do I replace my TOUGH GUN G2 Series Conventional MIG Gun with a TOUGH GUN CA3 Robotic MIG Gun?
  2. How do I replace my TOUGH GUN ThruArm G2 Series MIG Gun with a TOUGH GUN TA3 Robotic MIG Gun?
  3. How do I replace my TOUGH GUN G2 Series Conventional Robotic MIG Gun with wire brake with a TOUGH GUN CA3 Robotic MIG Gun?
  4. How do I replace my TOUGH GUN ThruArm G2 Series Robotic MIG Gun with wire brake with a TOUGH GUN TA3 Robotic MIG Gun?

1. Why did you introduce the TOUGH GUN™ CA3 and TOUGH GUN™ TA3 Robotic Air-Cooled MIG Guns?

We continuously strive to improve the reliability, repeatability and throughput results that our products achieve for our customers. For this reason, as our customers' needs evolve, we carefully listen and then design our products to meet and surpass these requirements. In this case, we have brought together top features, as identified by our customers, from our existing TOUGH GUN G1 and G2 Series MIG Guns to introduce this third evolution of our product line.

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2. What are the key features of the TOUGH GUN CA3 Robotic Air-Cooled MIG Gun?

Key features of the TOUGH GUN CA3 Robotic Air-Cooled MIG Gun include the following:

  • NEW! Replaceable conventional unicable design offeres extended service life (up to 2x) and ease of serviceability
    • New dual layer cable outer jacket, re-engineered cable guide and increased copper content contribute to extended service life
    • Reduced costs and downtime due to simplified unicable replacement process
    • New wiring connections simplify unicable replacement
    • Connector and neck remain in mounting arm during cable replacement, mitigating the need for TCP touch-ups
  • Improved neck clamp resists damage to accidental over-torqueing
  • Additional standard neck and mounting arm options
    • Expands the range of tool center point options and variety of working envelopes
    • Reduces costs and lead times for necks and arms that were previously specials
    • Simplifies transition from standard TOUGH GUN G2 Series configurations while maintaining TCP
  • Compatible with legacy product
    • Compatible with existing TOUGH GUN G1 Series necks, gun mounts, power pins and consumables
    • Replacement for TOUGH GUN G1 Series with no effect on TCP*
    • Gun part numbers are unaffected by these changes
    • New black gun body simplifies identification of upgraded vs. legacy guns

*An increase to the length of the gun housing was necessary to accommodate the added features and benefits. Verification of tooling or fixture clearance may be required.

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3. What are the key features of the TOUGH GUN TA3 Robotic Air-Cooled MIG Gun?

Key features of the TOUGH GUN TA3 Robotic Air-Cooled MIG Gun include the following:

  • Improved neck clamp resists damage to accidental over-torqueing
  • Additional standard neck and mounting arm options
    • Expands the range of tool center point options and variety of working envelopes
    • Reduces costs and lead times for neck and arms that were previously specials
    • Simplifies transition from standard TOUGH GUN ThruArm™ G2 Series configurations while maintaining TCP
  • Compatible with legacy product
    • Compatible with existing TOUGH GUN ThruArm G1 Series necks, gun mounts, power pins and consumables
    • Drop-in replacement for TOUGH GUN ThruArm G1 Series MIG Guns with no effect on TCP
    • Gun part numbers are unaffected by these changes
    • New black gun body simplifies identification of upgraded vs. legacy guns

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4. What do CA3 and TA3 stand for?

The letter and numbers do signal product application and cooling differences:

  • CA3 stands for Conventional Air-Cooled generation 3
  • TA3 stands for ThruArm Air-Cooled generation 3

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5. Will I need to adjust my TOUGH GUN Reamer Robotic Nozzle Cleaning Station(s) as a result of these gun improvements?

No adjustments should be needed as a result of these product improvements.

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6. Will any reprogramming be necessary when converting from the TOUGH GUN G1 Series MIG Gun to the TOUGH GUN CA3 MIG Gun?

TCP will not be affected, however, a small increase in the length of the TOUGH GUN CA3 Gun as compared to the TOUGH GUN G1 Series was necessary to accommodate the added features and benefits, therefore verification of tooling or fixture clearance may be required. See Question 12 for dimensional information.

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7. How have you extended the service life of the new TOUGH GUN CA3 MIG Gun unicable by almost 2 times?

Our new unicable has been engineered specifically for automation with a new design that features a dual layer outer jacket. The inner layer is specially formulated to resist fatiguing and withstand the heat of the internal copper conductors. The outer jacket formulation has been changed to increase the unicable's resistance to wear and ultraviolet radiation. The copper content of the unicable has also been increased by 10% to allow for operation at higher current ranges.

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8. Why is the jog switch no longer being offered?

The gun mounted jog switch option is no longer being offered due to the lack of demand resulting from changes in technology. Many robotic welding customers are now using the robot pendant or other cell control options to initiate wire jog.

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9. Can I convert my legacy TOUGH GUN G1 Series Conventional Robotic MIG Gun to a TOUGH GUN CA3 Conventional Robotic MIG Gun?

Yes, conversion is easy. Simply order a replacement chassis (connector + unicable) using your existing replacement chassis part number (see Column A of chart in Question 13). As of October 13, 2014, these part numbers ship as conversion kits complete with a new connector and unicable. Once the new connector and unicable are installed, you can continue to order this chassis using the same part number or you can enjoy cost and time savings by ordering only the new replacement unicable (see part numbers in Column B of chart in Question 13).

Overview of Chassis Replacement Upgrade Path

All existing TOUGH GUN G1 Conventional MIG Guns can easily be upgraded to become a TOUGH GUN CA3 MIG Gun at the time of your next cable replacement as follows:

  1. Time to replace the chassis on your TOUGH GUN G1 Series Conventional Gun? Remove your gun from the robot. Disconnect the neck and power pin from the chassis and set them aside.

  1. Order a replacement chassis using your current part number (e.g. 513-XXX) to receive a kit that includes the new replaceable unicable plus the new CA3 connector. Reinstall your neck and power pin and your gun will now be a TOUGH GUN CA3 MIG Gun! Reinstall the gun to the robot using your existing mounting arm and your TCP will also remain unchanged.

  1. Time to replace the unicable on your upgraded TOUGH GUN CA3 Gun? Order only the replaceable unicable using one of the new part numbers (e.g. CA3UXX) and enjoy faster replacement time since the gun can now remain mounted to the robot.

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10. How do I order a replacement gun for my TOUGH GUN G1 Series (5400 Series) Conventional Robotic Gun?

The TOUGH GUN CA3 Robotic Gun was designed to be a replacement for TOUGH GUN G1 Series Robotic MIG Guns. This means that we were able to keep part numbering of the guns the same in most cases and you will be able to reuse your current mounting arm, air-cooled neck, clutch, insulating disc and power pin if you choose to do so. Simply use the existing TOUGH GUN G1 Series part number in your system, or configure a gun using our online configurator, to order a replacement gun.

Exceptions:

  • If your gun part number begins with SG, please see Question 11
  • If your gun has a jog switch, please see Question 8

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11. How do I replace my existing SG (Special) TOUGH GUN G1 Series Robotic MIG Gun?

If you have not already received your specific SG details regarding the new TOUGH GUN CA3 MIG Gun platfrom, please contact a Customer Service Representative at 1-855-MIGWELD (644-9353) or +1-519-737-3030. However, in many cases, former SG (Special) MIG guns are now configurable within the new standard part numbering system to reduce the need for an SG number.

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12. How do I know if I have an old G1 connector, a large CA3 connector, or a new slim CA3 connector?

The old G1 connector is silver and the large and slim CA3 connectors are black. Please see images below:


IMPORTANT NOTE:
If you currently own a large TOUGH GUN CA3 MIG Gun, please click here for additional FAQs.

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13. How do I order a replacement chassis (connector + unicable) for my existing (pre-October 2014) TOUGH GUN G1 Series Conventional Robotic MIG Gun?

When you order a replacement chassis for your existing TOUGH GUN G1 Series Gun using the same replacement chassis part numbers as before (see Column A in following chart), you will receive a kit that includes a new connector and a new replaceable unicable that will allow you to convert your existing gun to the new CA3 system.

Once the new connector and unicable are installed, you can continue to order this chassis using the same part number or you can enjoy cost and time savings by ordering only the new replacement unicable (see part numbers in Column B in following chart).

Replacement Unicable Part Numbers Chart
 

A

B

Existing Part Numbers
Include New Connector
and Unicable

New Part Numbers
Include New Unicable
and Adaptor Only

Standard Unicable Assemblies

For G1 to CA3
Conversion –
1st Time Only

For CA3 and
Converted
G1 Series Guns

Clutch

513-2XX

CA3UXX

Clutch (Euro)

E513-2XX

ECA3UXX

Clutch with Jog Switch
(513-2XXJ Discontinued; use 513-2XX)

N/A

N/A

Clutch with Jog Switch (Euro)
(E513-2XXJ Discontinued; use E513-2XX)

N/A

N/A

Clutch with Wire Brake and Jog Switch
(513-4XXJ Discontinued; use 513-4XX)

N/A

N/A

Clutch with Wire Brake and Jog Switch (Euro)
(E513-4XXJ Discontinued; use 513-4XX)

N/A

N/A

Solid Mount

513-5XX

CA3UXXS

Solid Mount (Euro)

E513-5XX

ECA3UXXS

XX = Gun Unicable Length
E = Euro

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14. How do I order a replacement unicable for my new TOUGH GUN CA3 Robotic MIG Gun?

Please use the replacement unicable numbers in your gun manual or as shown in Column B of the chart in Question 13 above to receive a replacement unicable.

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15. How do I install the new connector and replaceable unicable to my existing (pre-October 2014) TOUGH GUN G1 Series Conventional Robotic MIG Gun?

Please see the following series of steps and diagrams to assist you in installing the new TOUGH GUN CA3 connector and unicable in place of your existing TOUGH GUN G1 Series MIG Gun:

  1. Remove the nozzle, retaining head and liner (parts not shown).
  2. Loosen the neck clamp SHCS using a 5 mm Allen wrench (see 'A' in Figure 1).
  3. Remove the neck (see 'B' in Figure 1).

  1. Loosen the 2x SHCS in the gun mount using a 5 mm Allen wrench (see 'C' in Figure 2).
  2. Remove the old TOUGH GUN G1 Series unicable (see 'D' in Figure 2).

  1. Line up the key of the new TOUGH GUN CA3 MIG Gun with the keyway in the gun mount and insert the new unicable connector and unicable into the gun mount as shown in Figure 3.

  1. Tighten the 2x SHCS in the gun mount using a 5 mm Allen wrench (see Figure 4).

  1. Line up the key of the neck with the keyway in the unicable connector and install as shown in 'E' of Figure 5.
  2. Tighten the neck clamp SHCS using a 5 mm Allen wrench (see 'F' in Figure 5).

  1. Install and trim a new QUICK LOAD™ Liner, and reinstall the consumables.

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16. How do I install the new replaceable unicable?

Please follow the instructions supplied in the bag with your replaceable unicable or click here to access How-To instructions online.

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17. Can I use the existing TOUGH GUN I.C.E.™ setup from my current TOUGH GUN G1 Series MIG Gun when converting to a new TOUGH GUN CA3 Robotic MIG Gun?

Yes, existing TOUGH GUN I.C.E. necks are compatible with the slim TOUGH GUN CA3 Gun. If you have a large TOUGH GUN CA3 MIG Gun, please click here for additional information. If you aren't sure which TOUGH GUN CA3 Robotic MIG Gun you have, please refer to Question 12.

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18. How do I order a replacement gun for my existing TOUGH GUN ThruArm™ G1 Series Robotic MIG Gun?

Simply order using your existing gun part number and you will automatically receive the new, improved version.

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19. How do I order a replacement LSR Unicable for my existing TOUGH GUN ThruArm G1 Series Robotic MIG Gun?

Simply order using your existing LSR Unicable part number. The LSR Unicables have not changed.

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20. How do I replace my TOUGH GUN G2 Series Conventional MIG Gun with a TOUGH GUN CA3 Robotic MIG Gun?

All current TOUGH GUN G2 Series standard tool center point (TCP) configurations have a TOUGH GUN CA3 configuration counterpart. Please refer to the configuration reference charts that are provided online via the Tregaskiss.com/CA3 webpage. A Tregaskiss Customer Service Representative can also assist you with your conversion at 1-855-MIGWELD (644-9353) or +1-519-737-3030. To complete the conversion, you will need to purchase a complete gun with mounting arm and either a clutch clamp or solid mount clamp.

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21. How do I replace my TOUGH GUN ThruArm G2 Series MIG Gun with a TOUGH GUN TA3 Robotic MIG Gun?

Most current TOUGH GUN ThruArm G2 Series standard tool center point (TCP) configurations have a closely matched TOUGH GUN TA3 configuration counterpart. Please refer to the configuration reference charts that are provided online via the Tregaskiss.com/TA3 webpage. A Tregaskiss Customer Service Representative can also assist you with your conversion at 1-855-MIGWELD (644-9353) or +1-519-737-3030. To complete the conversion, you will need to purchase a complete gun with clutch or solid mount option.

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22. How do I replace my TOUGH GUN G2 Series Conventional Robotic MIG Gun with wire brake with a TOUGH GUN CA3 Robotic MIG Gun?

Please refer to the configuration reference charts that are provided online at Tregaskiss.com/CA3 to select the configuration that most closely matches your current tool center point (TCP). NOTE: Robotic TCP reprogramming will need to be touched up due to geometric differences.

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23. How do I replace my TOUGH GUN ThruArm G2 Series Robotic MIG Gun with wire brake with a TOUGH GUN TA3 Robotic MIG Gun?

Please refer to the configuration reference charts that are provided online at Tregaskiss.com/TA3 to select the configuration that most closely matches your current tool center point (TCP). NOTE: Robotic TCP programming will need to be touched up due to geometric differences.

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