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Summary of Contents for Bernard Clean Air CL30
- Page 1 ® Bernard Clean Air™ Fume Extraction MIG Gun OWNER'S MANUAL OM-CA-2.0 July 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.
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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 3-3 Installing to a Fume Extraction Unit SECTION 4 — OPERATION... -
Page 4: 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 5: Section 1 - Safety Precautions - Read Before Using
SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING Protect yourself and others from injury – read, follow, and save these important safety precautions ELECTRIC SHOCK can kill. and operating instructions. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work 1-1 Symbol Usage circuit is electrically live whenever the output is on. - Page 6 Turn off all equipment when not in use. Read and understand the Safety Data Sheets (SDSs) and the Do not use worn, damaged, undersized, or repaired cables. manufacturer's instructions for adhesives, coatings, Do not drape cables over your body. cleaners, consumables, coolants, degreasers, fluxes, and If earth grounding of the workpiece is required, ground it metals.
- Page 7 Be alert that welding sparks and hot materials from welding ELECTRIC AND MAGNETIC FIELDS (EMF) can can easily go through small cracks and openings to adjacent affect Implanted Medical Devices. areas. Watch for fire, and keep a fire extinguisher nearby. Wearers of Pacemakers and other Implanted Be aware that welding on a ceiling, floor, bulkhead, or Medical Devices should keep away.
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Page 8: Additional Symbols For Installation, Operation, And Maintenance
MOVING PARTS can injure. 1-3 Additional Symbols For Installation, Operation, And Maintenance Keep away from moving parts. Keep away from pinch points such as drive rolls. FIRE OR EXPLOSION hazard. WELDING WIRE can injure. Do not install or place unit on, over, or near combustible surfaces. - Page 9 READ INSTRUCTIONS. Read and follow all labels and the Owner's Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the Manual and in each section. Use only genuine replacement parts from the manufacturer. Perform installation, maintenance, and service according to the Owner's Manuals, industry standards, and national, state, and local codes.
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Page 10: California Proposition 65 Warnings
1-4 California Proposition 65 Warnings WARNING: This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm. For more information, go to www.P65Warnings.ca.gov. 1-5 EMF Information Electric current flowing through any conductor causes localized 3. -
Page 11: 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 12: Section 2 - Specifications
SECTION 2 — SPECIFICATIONS 2-1 Specifications Fume Extraction MIG (GMAW) Welding Gun 300 amp gun feeds maximum wire size of 5/64" (2.0 mm) Duty Cycle Rating: 100%: 300 amp with CO Shielding Gas 60%: 300 amp with Mixed Gases 400 amp gun feeds maximum wire size of 5/64" (2.0 mm) Duty Cycle Rating: 100%: 400 amp with CO Shielding Gas... -
Page 13: 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 Figure 3-B A. Euro Power Pin 1. -
Page 14: Installing To A Fume Extraction Unit
Figure 3-C B. Bernard Power Pin 1. Insert the Bernard power pin to face of receptacle. 2. Engage and rotate locking sleeve to tighten. 3-3 Installing to a Fume Extraction Unit 1. Thread coupler into hose connected to fume extraction unit. -
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. 4-2 Adjusting the Vacuum Chamber Figure 4-B 1. Vacuum chamber - The vacuum chamber can be adjusted to any of four set positions. -
Page 16: Adjusting The Vacuum Control Knob
4-3 Adjusting the Vacuum Control Knob Figure 4-C 1. Vacuum control knob - The vacuum control knob can be used to adjust the amount of vacuum at the front of the gun. 2. Rotate clockwise to increase vacuum and counterclockwise to decrease vacuum. -
Page 17: Section 5 - Replacement
SECTION 5 — REPLACEMENT 5-1 Changing Consumables Figure 5-A A. Changing Quik Tip™ Consumables 4. Pull the Centerfire contact tip from the gas diffuser. To replace, slide the contact tip over electrode into gas diffuser 1. Remove vacuum chamber. and lock by installing nozzle onto gas diffuser. Nozzle is used 2. -
Page 18: Changing The Liner
5-2 Changing the Liner Figure 5-B A. Changing Conventional Liner 1. Remove front-end consumables and lay cable straight. 2. Using a 10 mm wrench, turn liner counterclockwise until it is free from the power pin. Remove liner from gun assembly. 3. - Page 19 ® Figure 5-C B. Changing QUICK LOAD Liner 1. Remove the front-end consumables and lay the cable straight. 2. Pull the QUICK LOAD Liner from the end of the neck using pliers. 3. Remove the protective cap from the new QUICK LOAD Liner and insert it through the neck using the wire as a guide.
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Page 20: Changing The Neck And Switch
5-3 Changing the Neck and Switch Figure 5-D A. Changing the Neck - Straight Handle Model 1. Remove the two top pods screws (see 'A' in Figure 5-D) on the side of the gun. 2. Slide the top pod (see 'B' in Figure 5-D) up and back toward the rear of the handle and pull the trigger (see 'C' in Figure 5- D) down. - Page 21 Figure 5-E C. Changing the Neck - Curved Handle Model 1. Remove the vacuum chamber and front-end consumables (see 'A' in Figure 5-E). 2. Remove the screws (see 'B' in Figure 5-E) to remove the vacuum tube (see 'C' in Figure 5-E). 3.
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Page 22: Changing The Vacuum Hose
5-4 Changing the Vacuum Hose Figure 5-G A. Vacuum Hose on Straight Handle Model 1. Open the handle and remove the neck and trigger by following the steps listed in steps A. and B. in section 5-3 Changing the Neck and Switch on page 16 2. -
Page 23: Changing The Power Pin
5-5 Changing the Power Pin Figure 5-I A. Universal Power Pin 1. Remove the liner by following the steps listed in section 5-2 Changing the Liner on page 14. 2. Remove the screw and vacuum hose from rear strain relief and slide rear strain relief back over power pin. - Page 24 Figure 5-K C. Bernard Quick Disconnect 1. Remove the liner by following the steps listed in section 5-2 Changing the Liner on page 14. 2. Remove vacuum hose. 3. Viewing quick disconnect from cable end, align wave spring and large snap ring with opening access slot.
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Page 25: Section 6 - Optimizing Fume Capture
SECTION 6 — OPTIMIZING FUME CAPTURE 6-1 Optimizing Fume Capture Figure 6-A Follow the diagram below for optimizing the efficiency of fume capture from your fume extraction MIG gun. The joints and positions of welds will affect the efficiency of fume capture. Optimal capture efficiency is achieved when fume gun is positioned directly above the weld puddle. -
Page 26: Section 7 - Parts List
SECTION 7 — PARTS LIST 7-1 Straight Handle Model - 300, 400, 500, 600 amp OM-CA-2.0... - Page 27 Clamp 2280069 Screw 2950012 Screw cover 1010039 Adaptor block (Miller, Lincoln, Tweco) 1010027 Adaptor block (Bernard, Euro) GN2021 Electrical plug, non-D/S (Miller, Lincoln, Tweco power pins) See SP-CLA spec sheet Liner Se SP-CLA spec sheet Power pin components SCL1N Trigger cable adaptor, Lincoln lead (configurator power pin options L, S) SCT1N Trigger cable adaptor, spade terminals (configurator power pin options T, W)
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Page 28: Curved Handle Model - 300, 400 Amp
7-2 Curved Handle Model - 300, 400 amp OM-CA-2.0... - Page 29 1010039 Adaptor block (Miller, Lincoln, Tweco) 1040083 Neck, 60 degree, 2-inch radius (medium length) 1010027 Adaptor block (Bernard, Euro) Handle kit (includes Items 10 (x4), 11 (x4), 12 (x1) Electrical plug, non-D/S (Miller, Lincoln, Tweco 1880257 GN2021 and 13 (x1))
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Page 30: Additional Support Materials
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 Clean Air™ Fume Extraction MIG Gun Owner’s Manual Scan to view the Clean Air Fume Extraction MIG Gun Spec Sheet Scan to view the Centerfire™...
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