Tregaskiss TOUGH GUN CA3 Series Owner'S Manual Download Page 1

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OM-CA3-1.7

March 2017

Processes

MIG (GMAW) Welding

Description

Robotic, Air-Cooled, Conventional

MIG (GMAW) Welding Gun

TOUGH GUN

™

CA3

Robotic Air-Cooled MIG Gun

OWNER’S MANUAL

Tregaskiss

2570 North Talbot Road
Windsor, Ontario N

Canada

Phone: 1-855-MIGWELD (644-9353)

(US & Canada)

+1-519-737-3000

(International)

Fax: 519-737-1530

For more information, visit us at Tregaskiss.com

Summary of Contents for TOUGH GUN CA3 Series

Page 1: ...ventional MIG GMAW Welding Gun TOUGH GUN CA3 Robotic Air Cooled MIG Gun OWNER S MANUAL Tregaskiss 2570 North Talbot Road Windsor Ontario N0R 1L0 Canada Phone 1 855 MIGWELD 644 9353 US Canada 1 519 737 3000 International Fax 519 737 1530 For more information visit us at Tregaskiss com ...

Page 2: ...from the use of information contained herein The information presented in this owner s manual is accurate to the best of our knowledge at the time of printing Please reference Tregaskiss com for updated material For customer support and special applications please call the Tregaskiss Customer Service Department at 1 855 MIGWELD 644 9353 US Canada or 1 519 737 3000 International or fax 1 519 737 15...

Page 3: ...7CommercialWarranty 10 SECTION 2 SPECIFICATIONS 10 2 1SystemComponents 10 SECTION 3 INSTALLATION 11 3 1 Installing Gun to Robot 11 3 2 Installing Gun to Wire Feeder 12 3 3 Installing Clutch Cable to Gun 13 3 4 Connecting Wire Brake and or Air Blast 13 SECTION 4 REPLACEMENT 14 4 1 Changing Consumables 14 4 2 Changing the Neck 15 4 3 Changing TOUGH GUN I C E Components 15 4 4 Changing the Liner 16 4...

Page 4: ...roduct Apparatus Identification Council Directives 2006 95 EC Low Voltage 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 7 2013 Arc welding equipment Part 7 Torches Signatory _____________________________________ ___________________________________________ David A Werba Date of Declaration MANAGER PRODUCT DESIGN COMPLIAN...

Page 5: ...s trousers high shoes and a cap 1 2 Arc Rays and Welding Hazards WELDING AND CUTTING can cause fire or explosion Welding or cutting on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding or cutting arc The flying sparks hot work piece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause spark...

Page 6: ...t power cord for damage or bare wiring Replace cord immediately if damaged Bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another elec...

Page 7: ... over or near combustible surfaces Do not install unit near flammables Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit MOVING PARTS can injure Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintena...

Page 8: ...ectrician promptly correct any interference problem resulting from the installation Have the installation regularly checked and maintained If notified by the FCC about interference stop using the equipment at once Keep high frequency source doors and pan els tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING AND P...

Page 9: ...tor then following the above procedures is recommended Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding S...

Page 10: ...ntability or fitness for any purpose Tregaskiss shall not be liable under any circumstances to Buyer or to any person who shall purchase from Buyer for damages of any kind including but not limited to any direct indirect incidental or consequential damages or loss of production or loss of profits resulting from any cause whatsoever including but not limited to any delay act error or omission of Tr...

Page 11: ...g pat tern see Figure 1 IMPORTANT Do not use fasteners to pull the mounting arm to the face of the insulating disc as damage will occur 3 Torque to 45 in lbs 5 Nm C Installing Clutch or Solid Mount Clamp to Mounting Arm 1 Remove the fastener and the locking pin from the mounting arm 2 Insert the clutch solid mount stud into the mounting arm on the robot until it bottoms out 3 Once the stud is full...

Page 12: ...igure 4 Flat Features 5 mm SHCS Clamp Screws 3 2 Installing Gun to Wire Feeder 1 Plug gun into feeder and lock in place see your feeder manual for details Connect external gas if required 2 OPTIONAL Connect voltage sense lead see your feeder manual for details on the replaceable unicable with the male connector on the power jumper cable 3 FOR CLUTCH INSTALLATIONS Connect clutch cable with either t...

Page 13: ...ct 3 4 Connecting Wire Brake and or Air Blast A Wire Brake 1 Route wire brake air line to designated control valve in your facility not provided 2 40 60 psi air supply required for proper operation B Air Blast 1 Route air blast air line to designated control valve in your facility not provided 2 80 100 psi air supply required for proper operation ...

Page 14: ... the nozzle ensure that it is fully seated Changing the Contact Tip 1 Thread the contact tip into the retaining head 2 Torque to 30 in lbs 3 5 Nm 3 The Tregaskiss Tip Tool part 450 18 for heavy duty tips or a pair of weld pliers are the optimal tools for contact tip installation Changing the Retaining Head 1 Thread the retaining head onto neck with a 5 8 16 mm wrench 2 Torque to 80 in lbs 9 Nm IMP...

Page 15: ...ench 7 Install and trim liner if required 8 Reinstall consumables M6 SHCS Replacement Neck Dowel Keyway Safety Clutch Mounting Arm Robot Arm 4 3 Changing TOUGH GUN I C E Components 1 Remove front end consumables see Section 4 1 Changing Consumables 2 Remove screw and remove water line bracket 3 Disconnect both water lines at quick connect couplers 4 Loosen neck bolt see Section 4 2 Changing the Ne...

Page 16: ...t Water Line Bracket 4 4 Changing the Liner A Changing QUICK LOAD Liner NOTE Ensure power supply is off before proceeding 1 Remove consumables nozzle contact tip and retaining head see Section 4 1 Changing Consumables 2 Remove existing QUICK LOAD Liner by pulling it out from the neck 3 Insert the new QUICK LOAD Liner through the neck using the welding wire as a guide short strokes will prevent kin...

Page 17: ...approximately 1 3 4 This is normal as the liner will be pushed back into the neck when the consumables are installed 7 Feed wire through the MIG gun 8 Reinstall consumables Trim Here Liner Gauge 4 5 Changing the Power Pin or AutoLength Pin IMPORTANT The thread in two piece power pin incorporates a taper to seat and lock the power pin into the rear handle block Make sure power pin is tightened in t...

Page 18: ...en the cable and front housing using a 5 mm Allen wrench see Figure 3 7 Release cable assembly by turning a 1 4 turn counterclockwise see Figure 4 8 Remove unicable 9 Remove connector from cable assembly Connector should be kept for the replacement unicable 10 Remove power pin from unicable 11 Discard old unicable and liner NOTE You will need to install a new liner to avoid discrepancies between t...

Page 19: ...eder 2 Trim and remove excess wire 3 Remove front end consumables and neck including jump liner 4 Shut off and disconnect 1 8 air supply at the wire brake pushing unit see Figure 1 5 Loosen two bolts and pull the gun assembly see Figure 2 6 Unthread and remove the wire brake pushing unit to allow the wire guide to be released see Figure 3 7 Carefully slide the wire guide using the wire guide tool ...

Page 20: ...s double check the wire guide to ensure it s the proper size Trim to proper stick out 14 Activate wire brake via robot controller and attempt to pull additional wire out from gun NOTE The wire should no longer move Figure 4 Wire Guide Tool Wire Guide SECTION 5 TECHNICAL DATA 5 1 Wiring Diagram 3 Pin Connectors Yellow Red Blue Black Brown White 1 White 24 VDC Input 5 Green Not Used 2 Brown 24 VDC O...

Page 21: ...mm 92 12 mm 11 54 mm 3 07 kg 180 Degree X Y Z Weight 294 mm TCP 405 180QC CA1801 0 49 mm 206 24 mm 40 08 mm 3 04 kg Standard Configurations Solid Mount 22 Degree X Y Z Weight 316 mm TCP 405 22QC CA2201 0 49 mm 156 75 mm 1 62 mm 2 71 kg 350 mm TCP 405 22QCL CA2202 0 47 mm 171 31 mm 6 87 mm 2 82 kg 400 mm TCP 405 22QCL CA2203 0 46 mm 170 78 mm 37 07 mm 2 83 kg 45 Degree X Y Z Weight 350 mm TCP 405 4...

Page 22: ... short length neck part 405 22QC CA2202 Mounting Arm for 22 degree medium length neck part 405 22QCL CA2203 Mounting Arm for 22 degree medium length neck part 405 22QCL CA4501 Mounting Arm for 45 degree medium length neck part 405 45QCL CA4502 Mounting Arm for 45 degree long length neck part 405 45QCL1 CA1801 Mounting Arm for 180 degree medium length neck part 405 180QC 15 See TOUGH GUN CA3 MIG Gu...

Page 23: ...ead 2 Install as per 4 1 Changing Consumables 3 Replace with heavy duty consumables See appropriate Spec Sheet for details 4 Short contact tip life 1 Contact tip size 2 Electrode eroding contact tip 3 Exceeding duty cycle 1 Replace with proper size 2 Inspect and or change drive rolls 3 Replace with properly rated Tregaskiss MIG Gun 5 Erratic arc 1 Worn contact tip 2 Buildup inside of liner 3 Wrong...

Page 24: ... Electrode does not feed 10 Replace o rings 11 Tighten gun and cable connections to specified torque See SECTION 4 REPLACEMENT 9 Gun running hot 1 Exceeding duty cycle 1 Loose or poor power connection 1 a Replace with properly rated Tregaskiss MIG Gun b Decrease parameters to within gun rating 2 a Clean tighten or replace cable grounding connection b Tighten gun and cable connections to specified ...

Page 25: ...25 NOTES ...

Page 26: ...Tregaskiss com TechnicalSupport Scan to view Tregaskiss Spec Sheets Tregaskiss 2570 North Talbot Road Windsor Ontario N0R 1L0 Canada Phone 1 855 MIGWELD 644 9353 US Canada 1 519 737 3000 International Fax 519 737 1530 For more information visit us at Tregaskiss com Scan to view the TOUGH GUN CA3 MIG Gun Owner s Manual Scan to view the TOUGH GUN CA3 MIG Gun Spec Sheet Scan to view the TOUGH LOCK Co...

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