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Operations Manual
W-Gun
Series MIG Guns
600 Amp W-Gun shown with one
piece HD straight handle with
rubber overmold.
Bernard
A Division of Miller Electric Mfg. LLC
449 West Corning Road
Beecher, Illinois 60401 USA
See Tregaskiss.com
for detailed specs and
replacement parts information.
Phone: 1-855-MIGWELD (644-9353)
+1-519-737-3030
Fax: 708-946-6726
For more information, visit us at Tregaskiss.com
600 Amp W-Gun shown
with curved handle and
hang up hook.
(US & Canada)
(International)
Issued May 2021 • Index No. WCMAN-1.4
All Guns are Not Created Equal.
A MIG gun should be durable, easy to
use and customized to your specific
application. Our MIG guns put you in
control: you choose the options you need
and we'll build a gun to last. We even
ship most of our guns within 24 hours.
Flexible cable assembly with reinforced syn-
thetic rubber hoses prevents water leakage and
provides increased water flow and reduced gas
leakage.
Newly designed back end and water block with
interchangeable direct plugs and trigger leads
connect to wire feeders and machines from major
manufacturers and allow for simple maintenance.
Multiple handle and trigger options to increase
operator comfort.
Heavy duty water-cooled necks are offered in
multiple length and bend configurations to allow
for optimal weld accessibility and improved
operator comfort.
Contact tip options include Centerfire
and Quik Tip
and are available in wire sizes from
TM
.023" (0.6 mm) to 3/32" (2.4 mm).
, Elliptical
TM

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Summary of Contents for Bernard W-Gun Series

  • Page 1 Quik Tip and are available in wire sizes from .023" (0.6 mm) to 3/32" (2.4 mm). See Tregaskiss.com for detailed specs and replacement parts information. Bernard Phone: 1-855-MIGWELD (644-9353) (US & Canada) A Division of Miller Electric Mfg. LLC +1-519-737-3030 (International)
  • 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: Uso De Símbolos

    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: Estándares Principales De Seguridad

    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 With Bernard’s flexibility, 8c. Quik Tip – Remove tip with a 1/4 turn counterclockwise. An many applications can be accommodated with field installed options, unobstructed electrode path has now been established.
  • Page 12 End User Stocking Recommendations: Section 3. Contact Tip Nozzles ........5 for every 1 gun in service Bernard has designed its contact tips to allow rapid installation and Tips ........... 30 for every 1 gun in service adjustment. Gas Diffusers ......4 for every 1 gun in service A.
  • Page 13 C. Installation II Legacy Straight Handle Firmly secure gas diffuser with an appropriate wrench in a clockwise A. Removal rotation. Always reinstall gas diffuser insulator to decrease the chances Remove switch and screws from handle (See Figure 2). Remove of short circuiting. Note that Centerfire gas diffuser does not require a gas diffuser insulator.
  • Page 14 III HD Straight Handle next section for specific conduit installation instructions. Install and tighten power cable and return hose fittings to 35 in-lbs to prevent A. Removal leakage. Avoid twisting power cable and return hose fittings during installation. Install handle and liner. Remove switch and screws from handle (See Figure 4).
  • Page 15 FIGURE 7 II Euro Direct Plug Section 10. Direct Plug A. Removal I Bernard Quick Disconnect Remove liner from gun assembly. Follow the steps required to remove A. Removal the complete cable assembly from the rear water block. Inlet and outlet hoses can be removed from rear water block by cutting Oetiker Remove liner from gun assembly.
  • Page 16 B. Service Note: For OXO direct plugs, rigid strain relief must be held gently in Test contact pins for continuity when trigger is engaged. Lubricate vise while using the appropriate wrench in a counterclockwise rotation o-rings with silicone lubricant. Inspect all components for cracks, to remove the power pin.
  • Page 17 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 gun. 5. Erratic arc 1. Worn contact tip. 1. Replace. 2. Buildup inside of liner.
  • Page 18 See ‘Maintenance & Repair’ (Section 8). 9. Gun running hot 1. Exceeding duty cycle. 1. a. Replace with properly rated Bernard gun. b. Decrease parameters to within gun rating. 2. Loose or poor power connection. 2. a. Clean, tighten or replace cable grounding connection.
  • Page 19 NOTES M408-1.0...
  • Page 20 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 Tregaskiss.com or scan the QR Code with your  smart phone for immediate access to Tregaskiss.com/TechnicalSupport. Bernard Phone: 1-855-MIGWELD (644-9353) (US & Canada) 449 W. Corning Rd. +1-519-737-3000 (International) Beecher, IL 60401 Fax: 1-708-946-6726 Tregaskiss.com...

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