Miller Bernand PipeWorx MIG Gun Operation Manual
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Miller Bernand PipeWorx MIG Gun Operation Manual

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OPERATIONS MANUAL
PipeWorx MIG Gun
Manufactured for Miller Global Pipe Systems
250 Amp
Part Number: 195399
300 Amp
Part Number: 195400
S
D
O
y
!
afety
epenDS
n
Ou
DO NOT INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT READING
THIS OPERATING MANUAL AND THE ARC
WELDING SAFETY PRECAUTIONS ON THE
INSIDE FRONT COVER.
Bernard
Guns are designed and built
™
with safety in mind, but operators must
follow prescribed safety guidelines.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters-USA
USA Phone: 920-735-4504 Auto-Attended
USA & Canada FAX: 920-735-4125
International FAX: 920-735-4125
European Headquarters - United Kingdom
Phone: 44 (0) 1204-593493
Fax: 44 (0) 1204-598066
MillerWelds.com
© 2021 Bernard Printed in U.S.A. DFB-OPPW-2.3

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Summary of Contents for Miller Bernand PipeWorx MIG Gun

  • Page 1 OPERATIONS MANUAL PipeWorx MIG Gun Manufactured for Miller Global Pipe Systems 250 Amp Part Number: 195399 300 Amp Part Number: 195400 afety epenDS DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS OPERATING MANUAL AND THE ARC WELDING SAFETY PRECAUTIONS ON THE INSIDE FRONT COVER.

  • Page 2: 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 and ELECTRIC SHOCK can kill. operating instructions. Always wear dry insulating gloves. Insulate yourself from work and ground. 1-1 Symbol Usage Do not touch live electrode or electrical parts. Replace worn, damaged, or cracked guns or cables. DANGER! – Indicates a hazardous situation which, if Turn off welding power source before changing contact tip or not avoided, will result in death or serious injury.
  • Page 3 ARC RAYS can burn eyes and skin. WELDING WIRE can injure. Arc rays from the welding process produce intense  Keep hands and body away from gun tip when visible and invisible (ultraviolet and infrared) rays  trigger is pressed. that can burn eyes and skin. Sparks fly off from the  weld. READ INSTRUCTIONS. Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and Read and follow all labels and the Owner's sparks when welding or watching (see ANSI Z49.1 and Z87.1 Manual carefully before installing, operating, listed in Principal Safety Standards). or servicing unit. Read the safety information Wear approved safety glasses with side shields under your at the beginning of the Manual and in each section. helmet. Use only genuine replacement parts from the manufacturer. Use protective screens or barriers to protect others from Perform installation, maintenance, and service according to flash, glare and sparks; warn others not to watch the arc. the Owner's Manuals, industry standards, and national, state, Wear body protection made from durable, flame-resistant and local codes. material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. NOISE can damage hearing. Noise from some processes or equipment can ...

  • Page 4: California Proposition 65 Warnings

    1-3 California Proposition 65 Warnings WARNING: This product can expose you to chemicals  For more information, go to www.P65Warnings.ca.gov. including lead, which are known to the state of California to  cause cancer and birth defects or other reproductive harm.  1-4 Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, American Welding  Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-  Society standard ANSI Standard Z49.1. Website: www.aws.org. 1 from Compressed Gas Association. Website: www.cganet.com. Safe Practice For Occupational And Educational Eye And Face Safety in Welding, Cutting, and Allied Processes, CSA Standard  Protection, ANSI Standard Z87.1, from American National ...

  • Page 5: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 — CONSIGNES DE SÉCURITÉ — LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr UN CHOC ÉLECTRIQUE peut tuer. ces consignes relatives aux précautions de sécurité et au mode opératoire.
  • Page 6 L'ACCUMULATION DE VAPEURS peut causer LES FILS DE SOUDAGE peuvent provoquer des lésions ou la mort. des blessures. Éloigner les mains et le corps de la buse du Quand on n’utilise pas le gaz comprimé de pistolet après avoir appuyé sur la gâchette. protection, fermer le robinet de la bouteille. Assurer toujours la ventilation des zones fermées ou utiliser un appareil respiratoire avec alimentation en air. LIRE LES INSTRUCTIONS. Lire et appliquer les instructions sur les LE RAYONNEMENT DE L'ARC peut brûler les étiquettes et le Mode d’emploi avant yeux et la peau. l’installation, l’utilisation ou l’entretien de Le rayonnement de l’arc du procédé de soudage ...

  • Page 7: Proposition Californienne 65 Avertissements

    2-3 Proposition californienne 65 Avertissements AVERTISSEMENT – Ce produit peut vous exposer à des  Pour plus d’informations, consulter www.P65Warnings.ca.gov. produits chimiques tels que le plomb, reconnus par l’État de  Californie comme cancérigènes et sources de malformations ou  d’autres troubles de la reproduction 2-4 Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, American Welding  Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-  Society standard ANSI Standard Z49.1. Website: www.aws.org. 1 from Compressed Gas Association. Website: www.cganet.com. Safe Practice For Occupational And Educational Eye And Face Safety in Welding, Cutting, and Allied Processes, CSA Standard ...

  • Page 8: Section 3 - Precauciones De Seguridad - Lea Antes De Usar

    SECTION 3 — PRECAUCIONES DE SEGURIDAD — LEA ANTES DE USAR Protéjase usted mismo y a otros contra lesiones — lea, cumpla y conserve estas importantes UNA DESCARGA ELÉCTRICA puede matarlo. precauciones de seguridad e instrucciones de utilización. Siempre use guantes aislantes secos. Aíslese usted mismo del trabajo y la tierra. No toque electrodo eléctricamente vivo o partes 3-1 Uso de símbolos eléctricamente vivas.
  • Page 9 EL AMONTONAMIENTO DE GAS puede El ALAMBRE de SOLDAR puede causarle enfermarle o matarle. heridas. Mantenga las manos y el cuerpo lejos del tubo Cierre el suministro de gas comprimido de contacto de la antorcha cuando se haya cuando no lo use. presionado el gatillo. Siempre dé ventilación a espacios cerrados o use un respirador aprobado que reemplaza el aire. LEER INSTRUCCIONES. LOS RAYOS DEL ARCO pueden quemar sus Lea y siga cuidadosamente las instrucciones ojos y piel. contenidas en todas las etiquetas y en el Los rayos del arco de un proceso de suelda  Manual del usuario antes de instalar, utilizar o producen un calor intenso y rayos ultravioletas  realizar tareas de mantenimiento en la unidad. Lea la fuertes que pueden quemar los ojos y la piel. Las ...
  • Page 10 3-3 Advertencias de la Proposición 65 del estado de California ADVERTENCIA: Este producto puede exponerlo a químicos,  Para obtener más información, acceda a  incluso plomo, que el estado de California conoce como  www.P65Warnings.ca.gov. causantes de cáncer, defectos de nacimiento u otros daños  reproductivos. 3-4 Estándares principales de seguridad Safety in Welding, Cutting, and Allied Processes, American Welding  Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-  Society standard ANSI Standard Z49.1. Website: www.aws.org. 1 from Compressed Gas Association. Website: www.cganet.com. Safe Practice For Occupational And Educational Eye And Face Safety in Welding, Cutting, and Allied Processes, CSA Standard ...

  • Page 11: Commercial Warranty

    Introduction Commercial Warranty Thank you for choosing Bernard. The product you have purchased has Product is warranted to be free from defects in material and been carefully assembled and factory tested prior to shipment. Should workmanship for 1 year after the sale by an authorized Buyer. Straight you experience problems with installation or performance, please refer handles, straight handle switches and straight rear strain reliefs are to the “Troubleshooting Guide”...
  • Page 12 Part III Helpful Operating Tips Nozzles: 4. When using dual shield electrode, periodically check gas ports in gas diffuser for clogging caused by flux from within 1. If anti-spatter is used, do not coat nozzle insulator as this the electrode. may degrade insulating material.

  • Page 13: Section 4. Neck

    Part IV Maintenance and Repair See pages 6 and 7 for parts lists B. Service To extend contact tip life, reface front of contact tip and clean the bore. Contact tips may be rotated in gas diffuser/ Disconnect gun from equipment, allow to cool, and remove head socket providing additional wear surface and extending electrode from liner before servicing.

  • Page 14: Section 5. Jump Liner (Optional)

    Part IV Maintenance and Repair (cont.) Section 5. Jump liner (Optional) Section 7. Cable A. Removal A. Inspection Remove nozzle, gas diffuser and neck. Remove used jump Replace the cable assembly if the following conditions are liner from the back end of neck. evident on the exterior of the cable: cuts and/or abrasions in cable jacketing exposing copper stranding, abrupt kinking B.

  • Page 15: Section 9. Rigid Strain Relief

    Part IV Maintenance and Repair (cont.) C. Installation Miller Power Pins Insert liner into power pin with cable laying straight. Con- A. Removal tinue until liner lock is fully seated into power pin. A twisting motion may be necessary to seat o-ring (some direct plugs...
  • Page 16 Part V 250 Amp Gun Exploded Diagram and Parts List Gun Part Number: 195399 PART ITEM NUMBER DESCRIPTION NST-3800B Nozzle TT-035 Contact Tip DS-1 Diffuser 4323R 1840057-2 Q-Nut Insulator, Front QT2-60 Neck (Includes neck and items #5, 7, 8) 1840057-1 Q-Neck Cover 1840031 Q-Neck Insulator, Rear QJL-3545...
  • Page 17 Part V 300 Amp Gun Exploded Diagram and Parts List Gun Part Number: 195400 PART ITEM NUMBER DESCRIPTION NS-5818C Nozzle T-045 Contact Tip DS-1 Diffuser 4323R 1840057-2 Q-Nut Insulator, Front QT2-60 Neck (Includes neck and items #5, #7, #8) 1840057-1 Q-Neck Cover 1840031 Q-Neck Insulator, Rear QJL-3545...
  • Page 18 Part VI Troubleshooting Guide PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 1. Electrode does not feed. 1. Feeder relay. 1. Consult feeder manufacturer. 2. Broken control lead. 2 a. Test & connect spare control lead. b. Install new cable. 3. Poor adaptor connection. 3.
  • Page 19 Part VI Troubleshooting Guide (cont.) PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 7. Extreme spatter. 1. Improper machine parameters. 1. Adjust parameters. 2. Improper contact tip installation. 2. Adjust nozzle/contact tip relationship. 3. Improper shielding. 3 a. Verify shielding gas coverage. b. Verify gas mixture. 4.
  • Page 20 Notes © 2021 Bernard Printed in U.S.A. DFB-OPPW-2.3...

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