Bernard OM-BTB-2.2 Owner's Manual
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Bernard OM-BTB-2.2 Owner's Manual

Semi-automatic air-cooled mig gun
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Bernard
BTB Semi-Automatic
Air-Cooled MIG Gun
OWNER'S MANUAL
OM-BTB-2.2
August 2020
Semi-Automatic, Air-Cooled, MIG (GMAW)
Welding Gun
BernardWelds.com/TechnicalSupport
1-855-MIGWELD (644-9353) (US & Canada)
+1-519-737-3000 (International)

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Summary of Contents for Bernard OM-BTB-2.2

  • Page 1 ® Bernard BTB Semi-Automatic Air-Cooled MIG Gun OWNER'S MANUAL OM-BTB-2.2 August 2020 Semi-Automatic, Air-Cooled, MIG (GMAW) Welding Gun BernardWelds.com/TechnicalSupport 1-855-MIGWELD (644-9353) (US & Canada) +1-519-737-3000 (International)
  • Page 2 Thank You for Choosing Bernard Thank you for selecting a Bernard product. The MIG gun you have purchased has been carefully assembled and is ready to weld and factory tested prior to shipment to ensure high performance. Before installing, compare the equipment received against the invoice to verify that the shipment is complete and undamaged.

  • Page 3: Table Of Contents

    2-2 Duty Cycle and Overheating SECTION 3 — INSTALLATION 3-1 Installing to a Feeder with a Power Pin 3-2 Installing to a Feeder with a Euro or a Bernard® Power Pin SECTION 4 — OPERATION 4-1 Pulling the Trigger SECTION 5 — REPLACEMENT...
  • Page 4 7-3 Quik Tip™ Consumable Series 7-4 Quik Tip HD Consumable Series 7-5 TOUGH LOCK™ Consumable Series SECTION 8 — TROUBLESHOOTING 8-1 Troubleshooting Table ADDITIONAL SUPPORT MATERIALS OM-BTB-2.2...

  • Page 5: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products Bernard, 449 West Corning Rd., Beecher, IL 60401 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

  • Page 6: Section 1 - Safety Precautions - Read Before Using

    – double-check connections. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill. OM-BTB-2.2...
  • Page 7 If this is not possible, tightly cover them with approved gases to which personnel are exposed. covers. If ventilation is poor, wear an approved air-supplied Do not weld where flying sparks can strike flammable respirator. material. Protect yourself and others from flying sparks and hot metal. OM-BTB-2.2...
  • Page 8 Compressed Gas Association (CGA) publication P-1 listed in Principal Safety Standards. BUILDUP OF GAS can injure or kill. Shut off compressed gas supply when not in use. Always ventilate confined spaces or use approved air- supplied respirator. OM-BTB-2.2...

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    Use proper static-proof bags and boxes to store, move, or Reinstall doors, panels, covers, or guards when servicing is ship PC boards. finished and before starting unit. If ANY air is injected into the skin or body, seek medical help immediately. OM-BTB-2.2...
  • Page 10 Be sure the welding machine is installed and grounded according to the Manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. OM-BTB-2.2...

  • Page 11: California Proposition 65 Warnings

    Chicago, is 312-353-2220, website: www.osha.gov). Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website: www.cganet.com). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232- 4636, website: www.cdc.gov/NIOSH). OM-BTB-2.2...

  • Page 12: Commercial Warranty

    1-7 Commercial Warranty Product is warranted to be free from defects in material and Bernard shall not be liable under any circumstances to Buyer, or to workmanship for 1 year after the sale by an authorized Buyer. any person who shall purchase from Buyer, for damages of any...

  • Page 13: Section 2 - Specifications

    Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Using mixed gases other than CO reduces duty cycle ratings 10-50% depending on gas mixture and welding parameters. Please reference Section 2 — Specifications on page 8 for duty cycle ratings by amperage. OM-BTB-2.2...

  • Page 14: Section 3 - Installation

    Figure 3-A 2. Insert control plug into feeder. 3. Feed welding wire into power pin by hand and tighten drive rolls. ® 3-2 Installing to a Feeder with a Euro or a Bernard Power Pin A. Euro Power Pin Figure 3-B 1.

  • Page 15: Section 4 - Operation

    SECTION 4 — OPERATION 4-1 Pulling the Trigger 1. Trigger - When pressed, energized wire feeds and shielding Figure 4-A gas flows. Figure 4-B OM-BTB-2.2...

  • Page 16: Section 5 - Replacement

    Remove threaded nozzle by turning in a counterclockwise direction. 2. Pull the Centerfire contact tip from the gas diffuser. To replace, slide the contact tip over electrode into gas diffuser and lock by installing nozzle onto gas diffuser. Nozzle is used to secure contact tip. OM-BTB-2.2...

  • Page 17: Changing The Liner

    5/8" 15.9 mm D114Q 9/16" 14.3 mm D118 3/4" 19.1 mm D118Q 3/4" 19.1 mm D118QLL 1-5/16" 33.3 mm D1FQ 7/8" 22.2 mm D218 7/8" 22.2 mm TOUGH LOCK Retaining Head Part Number Liner Trim Length 3/4" 19.1 mm OM-BTB-2.2...
  • Page 18 5. Install the neck. 6. Trim jump liner to dimensions shown in New Liner Trim Lengths change on previous page. 7. Deburr the jump liner past the nozzle end of the neck. 8. Install gas diffuser, contact tip and nozzle. OM-BTB-2.2...

  • Page 19: Changing The Neck

    (3.2 mm) spacing between cable connection and neck. 5. Install the switch and reposition handle and switch housing. 6. Reinstall switch housing mounting screws. 7. Liner may need to be changed if switching to a neck of a different bend angle or length. OM-BTB-2.2...
  • Page 20 (3.2 mm) spacing between the cable connection and neck. 7. Install the switch and reposition handle and switch housing. 8. Reinstall switch housing mounting screws. 9. Liner may need to be changed if switching to a neck of a different bend angle or length. OM-BTB-2.2...

  • Page 21: Changing The Handle And Switch

    2. Pry open bottom side of handle halves with a flat blade screwdriver. Trigger should be able to be removed. 3. To replace trigger, install into handle halves with pivot posts inserted into handle cavities so movement is not impaired. 4. Tighten screws. Torque to 10 in-lbs (1.1 Nm). OM-BTB-2.2...
  • Page 22 5. Push lead connectors onto new switch using needle nose pliers. 6. Depress switch housing into nest on handle (switch leads must lay parallel). 7. Align the holes of body housing with the holes in the handle to start screws by hand. Finish tightening with a Phillips screwdriver. OM-BTB-2.2...

  • Page 23: Changing The Power Pin

    Torque to 18 ft-lbs (24 Nm). Adaptor nut should rotate freely. 7. Strip the cable control leads 1/4" (6.5 mm) and re-terminate with appropriate butt connectors. 8. Align strain relief bottom with threaded hole in Euro block and install screw, assemble strain relief and liner. OM-BTB-2.2...

  • Page 24: Section 6 - Parts List

    2520041 Spring, Strain Relief Straight Rear Strain Relief Clamshell Rear Strain Relief (Euro 2520069 Power Pin) Clamshell Rear Strain Relief with 2520073 installed Gas Pin (Bernard Power Pin) 414-400 Adaptor Block See SP-BTB Power Pin See SP-BTB Power Pin Cap...

  • Page 25: O Series Small Curved Handle With Blue Trigger

    Spring, Strain Relief 2520056ˆ 2520056ˆ Straight Rear Strain Relief Clamshell Rear Strain Relief 2520069 (Euro Power Pin) Clamshell Rear Strain Relief 2520073 (Bernard Power Pin) 414-400 Adaptor Block See SP-BTB Power Pin See SP-BTB Power Pin Insulator See SP-BTB Liner...

  • Page 26: O Series Curved Handle With Blue Trigger

    N/A* 2520041* Spring, Strain Relief N/Aˆ N/Aˆ 2520056ˆ Straight Rear Strain Relief Clamshell Rear Strain Relief 2520073 (Bernard Power Pin) Clamshell Rear Strain Relief 2520069 (Euro Power Pin) 414-400 Adaptor Block See SP-BTB Power Pin See SP-BTB Power Pin Insulator...

  • Page 27: T Series Small Straight Handle With Black Trigger

    310-1-6 Screw, Handle Handle Collar 320-6 M169700-12 Spring, Handle 320-3 Handle Cap, Locking, Rear Clamshell Rear Strain Relief with installed gas pin (Bernard 2520073 Power Pin) 2520069 Clamshell Rear Strain Relief (Euro Power Pin) 2520033 Spring Strain Relief 216-1 Control Plug Block...

  • Page 28: T Series Straight Handle With Silver Trigger

    1880263* 513-8* 513-8* Cable Repair Kit N/Aˆ N/Aˆ 513-8ˆ 513-8ˆ Handle Rear Strain Relief Clamshell Rear Strain 2520073 Relief (Bernard Pin) Clamshell Rear Strain 2520069 Relief (Euro Pin) 411-1 Switch 411-2 Trigger, Standard 411-4 Trigger, Locking 411-11 Trigger, Dual Pull...

  • Page 29: C Series Straight Handle With Black Trigger

    513-8* Cable Repair Kit 1880261ˆ N/Aˆ N/Aˆ 513-8ˆ 1780086 Front Handle 1780086 Rear Strain Relief Clamshell Rear Strain 2520073 Relief (Bernard Pin) Clamshell Rear Strain 2520069 Relief (Euro Pin) 411-1 Switch 2690077 Trigger, Standard 1690088 Trigger, Dual Pull Screw, Trigger 2280064...

  • Page 30: Section 7 - Consumable Parts

    T-109 7/64" (2.8 mm) T-039 0.039" (1.0 mm) T-072 0.072" (1.8 mm) T-125 1/8" (3.2 mm) 'TT' Series Contact Tip TT-023 0.023" (0.6 mm) TT-039 0.039" (1.0 mm) TT-052 0.052" (1.4 mm) TT-030 0.030" (0.8 mm) TT-045 0.045" (1.2 mm) TT-062 1/16" (1.6 mm) TT-035 0.035" (0.9 mm) OM-BTB-2.2...

  • Page 31: Centerfire Hd Consumable Series

    7-2 Centerfire HD Consumable Series Centerfire HD Consumable Series is not configurable and will need to be ordered separately. Couple the Centerfire HD nozzle body with a Centerfire HD nozzle cone to form a complete Centerfire HD nozzle. OM-BTB-2.2...
  • Page 32 N2C38HQ (Plated Copper, 3/8") N1C34HD (Plated Copper, 3/4" Heavy Duty) N1C58HD (Plated Copper, 5/8" Heavy Duty) N1C34 (Copper, 3/4") N1C58 (Copper, 5/8") N1C12 (Copper, 1/2") N2C12 (Copper, 1/2") N2C38 (Copper, 3/8") NSQT-1200 (Copper, 1/2" I.D., Flush) NSQT-1218 (Copper, 1/2" I.D., 1/8" Recess) OM-BTB-2.2...
  • Page 33 7-4 Quik Tip HD Consumable Series Quik Tip HD Consumable Series is not configurable and will need to be ordered separately. Couple the Quik Tip HD nozzle body with the Quik Tip HD nozzle cone to form a complete Quik Tip HD nozzle. OM-BTB-2.2...
  • Page 34 SINGLE TAPER PART NUMBER DUAL TAPER PART NUMBER Heavy Duty 404-20-25 404-26-25 Heavy Duty 404-20 404-26 Heavy Duty 404-20-250 404-26-250 Standard Duty 404-14-25 404-18-25 Standard Duty 404-14 404-18 THREAD-ON RETAINING HEADS FOR NEW STYLE THREAD-ON NOZZLES Heavy Duty 404-53-25 OM-BTB-2.2...
  • Page 35 2.74" Flush 401-40-38 Standard Duty 3/8" Brass 0.938" 2.81" 1/16" Recess 401-4-62 Standard Duty 5/8" Copper 0.938" 2.88" 1/8" Recess 401-8-62 Standard Duty 5/8" Copper 0.938" 2.63" 1/8" Stick-Out 401-9-62 Standard Duty 5/8" Copper 0.938" 2.51" 1/4" Stick-Out 401-4-75 Standard Duty 3/4" Copper 0.938" 2.88" 1/8" Recess OM-BTB-2.2...
  • Page 36 1. Replace with proper size. 2. Electrode eroding contact tip. 2. Inspect and/or change drive rolls. 3. Exceeding duty cycle. 3. Replace with properly rated Bernard MIG Gun. 5. Erratic arc. 1. Worn contact tip. 1. Replace contact tip. 2. Buildup inside of liner.
  • Page 37 See Section 5 — Replacement on page 11. 9. Gun running hot. 1. Exceeding duty cycle. 1. a. Replace with properly rated Bernard MIG Gun. b. Decrease parameters to within gun rating. 2. Loose or poor power connection. 2. a. Clean, tighten or replace cable grounding connection.
  • Page 38 ADDITIONAL SUPPORT MATERIALS For additional support materials such as Spec Sheets, troubleshooting information, how-to guides and videos, animations, online configurators and much more, please visit Bernard. Scan the QR Code with your smart phone for immediate access to BernardWelds.com/TechnicalSupport. Scan to view the BTB MIG Gun Owner’s Manual Scan to view the BTB MIG Gun Spec Sheet Scan to view the AccuLock™...

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