Bernard 195399 Operation Manual page 5

Part II Installation
1. Your gun has been shipped with a specific feeder connector,
neck, and sized for electrode as per the part number indi-
cated on its package. Please inspect the received gun against
this part number for accuracy.
2. Turn off power prior to any installation.
3. Fully extend gun and cable. Press liner fully into power pin.
4. Safely expose approximately 2" (51 mm) of electrode
beyond feeder or adaptor block.
5. Power Pin
Connect the power pin of the direct plug gun by sliding
the electrode into the liner and the power fitting into the
drive housing of the feeder. Fully seat the unit in position
and tighten into place as designated in the manufacturer's
instructions. On initial installations, a thin film of silicone
lubricant will aid installation and prevent o-ring damage.
Attach control lead wires to the appropriate plug, terminals,
or lead kit. Plug or wire into the control circuit of the feeder
as designated in manufacturer's instructions.
If a gas hose is provided, connect to the feeder's solenoid
circuit to deliver shielding gas to the arc. If no gas hose is
provided, gas is delivered through the power pin. Refer to
the manufacturer's instructions for proper gas connection at
the feeder block or solenoid.
6. Remove nozzle from head assembly.
7. Pull contact tip from head/gas diffuser. An unobstructed
electrode path has now been established.
Part III Helpful Operating Tips
Nozzles:
1. If anti-spatter is used, do not coat nozzle insulator as this
may degrade insulating material.
2. Nozzle should be cleaned as often as possible. Spatter
buildup can often lead to poor gas shielding or short circuit-
ing between the contact tip and the nozzle.
3. Spatter should be removed with the proper tools designed
for spatter removal.
4. In high temperature welding applications, heavy duty con-
sumables are recommended.
Contact Tips, Gas Diffusers:
1. Contact tips may be removed and rotated in gas diffuser,
providing an additional wear surface and extending the
service life of the product.
2. Inspect nozzle for spatter adhesion, blocked gas ports, and
carburized contact surfaces. Clean as often as possible.
3. If anti-spatter is used, periodically check gas ports for block-
age.
8. Safely feed electrode through the gun and approximately 1"
(25 mm) beyond head/gas diffuser.
9. Reinstall the contact tip over the electrode and lock into
position by reinstalling the nozzle.
4. When using dual shield electrode, periodically check gas
ports in gas diffuser for clogging caused by flux from within
the electrode.
Cable:
1. Periodically check torques of neck and end fittings. Loose
fittings can cause overheating and premature failure of the
gun.
2. Sharp bends and loops in the cable should be avoided. Often
the best solution is to suspend the wire feeder from a boom
or trolley, thus eliminating a large number of bends and
keeping the cable clear of hot weldments.
3. Do not immerse liner into solvents for cleaning; the liner
may be periodically blown out with compressed air.
4. Avoid rough surfaces and sharp edges that can cause tears
and nicks in cable jacket which can cause premature failure.
5. Periodically check all cables and ground connections.
6. Use anti-seize on all threaded connections.
Welding current and duty cycle
shall not exceed published
specification of this product. If such
conditions exist, product life and
performance will be reduced.
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