FAQs | TOUGH GUN G1 and G2 Series Owners Conversion

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.

Key features of the TOUGH GUN CA3 robotic air-cooled MIG gun include a replaceable conventional unicable design that offers extended service life (up to 2x) and ease of serviceability, an improved neck clamp that resists damage to accidental over-torquing, additional standard neck and mounting arm options, and compatibility with legacy product. Find more information on the TOUGH GUN CA3 robotic air-cooled MIG gun product page.

Key features of the TOUGH GUN TA3 robotic air-cooled MIG gun include an improved neck clamp that resists damage to accidental over-torquing, additional standard neck and mounting arm options, and ccompatibility with legacy product. Find more information on the TOUGH GUN TA3 robotic air-cooled MIG gun product page.

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

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

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 gun was necessary to accommodate the added features and benefits, therefore verification of tooling or fixture clearance may be required.

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.

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.

Yes, conversion is easy. Simply order a replacement chassis (connector + unicable) using your existing replacement chassis part number. 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 part number in your gun manual.

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 outlined in the chassis replacement upgrade path instructions.

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 gun 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 or if your gun as a jog switch, please contact Customer Service.

If you have not already received your specific SG details regarding the new TOUGH GUN CA3 MIG gun platform, 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.

The old G1 connector is silver (shown left) and the large and slim CA3 connectors are black (shown right).


Figure 1

IMPORTANT NOTE:
If you currently own a large TOUGH GUN CA3 robotic air-cooled MIG gun, you may want to review additional FAQs.

When you order a replacement chassis for your existing TOUGH GUN G1 series gun using the same replacement chassis part numbers as before, 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 found in your gun manual.

Please use the replacement unicable numbers in your gun manual to order and receive a replacement unicable.

We have developed a 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.

Please follow the instructions supplied in the bag with your replaceable unicable or access how-to instructions online.

Yes, existing TOUGH GUN I.C.E. necks are compatible with the slim TOUGH GUN CA3 robotic gun. If you have a large TOUGH GUN CA3 MIG gun, please refer to the additional information provided. If you aren’t sure which TOUGH GUN CA3 Robotic MIG Gun you have, please refer to Figure 1 above.

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

Simply order using your existing LSR unicable part number. The LSR unicables have not changed.

All current TOUGH GUN G2 series standard tool center point (TCP) configurations have a TOUGH GUN CA3 configuration counterpart. Configuration reference charts are available for reference. 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.

Most current TOUGH GUN ThruArm G2 series standard tool center point (TCP) configurations have a closely matched TOUGH GUN TA3 configuration counterpart. Configuration reference charts are available for reference. 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.

Please refer to the configuration reference charts 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.

Please refer to the configuration reference chartsto 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.