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Related Manuals for Bernard Clean Air MIG Gun Series
Summary of Contents for Bernard Clean Air MIG Gun Series
- Page 1 ® Bernard Clean Air™ Fume Extraction MIG Gun OWNER'S MANUAL OM-CA-2.3 February 2022 Semi-Automatic, Air-Cooled, MIG (GMAW) Welding Gun Tregaskiss.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. Before installing, compare the equipment received against the invoice to verify that the shipment is complete and undamaged. It is the responsibility of the purchaser to file all claims of damage or loss that may have occurred during transit with the carrier. The owner’s manual contains general information, instructions and maintenance to help better maintain your MIG gun or peripheral. Please read, understand and follow all safety precautions. While every precaution has been taken to assure the accuracy of this owner’s manual, Bernard assumes no responsibility for errors or omissions. Bernard assumes no liability for damages resulting from the use of information contained herein. The information presented in this owner’s manual is accurate to the best of our knowledge at the time of printing. Please reference Tregaskiss.com for updated material. For customer support and special applications, please call the Bernard Customer Service Department at 1-855-MIGWELD (644-9353) (US & Canada) or +1-519-737-3000 (International), fax 1-708-946-6726, or email at cs@itwmig.com. Our trained Customer Service Team is available between 8:00 a.m. and 5:30 p.m. EST, and will answer your product application or repair questions. Bernard manufactures premium semi-automatic (GMAW) and FCAW (flux-cored) welding guns, consumables, accessories and manual arc products. For more information on other Bernard products, contact your local Bernard distributor or visit us on the web at Tregaskiss.com. Subject to Change – The information presented in this manual is accurate to the best of our knowledge at the time of printing.
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Page 3: Table Of Contents
SECTION 3 — PRECAUCIONES DE SEGURIDAD — LEA ANTES DE USAR 3-1 Uso de símbolos 3-2 Peligros en soldadura de arco 3-3 Advertencias de la Proposición 65 del estado de California 3-4 Estándares principales de seguridad 3-5 Información sobre los campos electromagnéticos (EMF) SECTION 4 — PRODUCT WARRANTY 4-1 Product Warranty SECTION 5 — SPECIFICATIONS 5-1 Specifications 5-2 Duty Cycle and Overheating SECTION 6 — INSTALLATION 6-1 Installing to a Feeder with a Power Pin 6-2 Installing to a Feeder with a Euro or a Bernard® Power Pin 6-3 Installing to a Fume Extraction Unit SECTION 7 — OPERATION 7-1 Pulling the Trigger 7-2 Adjusting the Vacuum Chamber 7-3 Adjusting the Vacuum Control Knob OM-CA-2.3... - Page 4 SECTION 8 — REPLACEMENT 8-1 Changing Consumables 8-2 Changing the Liner 8-3 Changing the Neck and Switch 8-4 Changing the Vacuum Hose 8-5 Changing the Power Pin SECTION 9 — OPTIMIZING FUME CAPTURE 9-1 Optimizing Fume Capture SECTION 10 — PARTS LIST 10-1 Straight Handle Model - 300, 400, 500, 600 amp 10-2 Curved Handle Model - 300, 400 amp ADDITIONAL SUPPORT MATERIALS OM-CA-2.3...
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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). Product/Apparatus Identification: Product Stock Number Bernard Clean Air MIG Gun – 300A... -
Page 6: Section 1 - Safety Precautions - Read Before Using
SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING Replace worn, damaged, or cracked guns or cables. Protect yourself and others from injury – read, follow, Turn off welding power source before changing contact tip or and save these important safety precautions and gun parts. ... - Page 7 Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and WELDING WIRE can injure. sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Keep hands and body away from gun tip when Wear approved safety glasses with side shields under your trigger is pressed. helmet. Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. READ INSTRUCTIONS. Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing Read and follow all labels and the Owner's such as leather gloves, heavy shirt, cuffless trousers, high Manual carefully before installing, operating, shoes, and a cap. 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. HOT PARTS can burn. Perform installation, maintenance, and service according to the Owner's Manuals, industry standards, and national, state, ...
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Page 8: 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 Safety in Welding, Cutting, and Allied Processes, CSA Standard Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association. Website: www.csagroup.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standard for Fire Prevention During Welding, Cutting, and Other Hot Standards Institute. Website: www.ansi.org. -
Page 9: 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 ces consignes relatives aux précautions de sécurité et UN CHOC ÉLECTRIQUE peut tuer. au mode opératoire. - Page 10 Lire et comprendre les fiches de données de sécurité et les Avertir les personnes à proximité au sujet du danger inhérent instructions du fabricant concernant les adhésifs, les au bruit. revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux. LES FILS DE SOUDAGE peuvent provoquer L'ACCUMULATION DE GAZ risquent de des blessures.
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Page 11: 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 Safety in Welding, Cutting, and Allied Processes, CSA Standard Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association. Website: www.csagroup.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National ... -
Page 12: 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. ... - Page 13 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.
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Page 14: Advertencias De La Proposición 65 Del Estado De California
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 Safety in Welding, Cutting, and Allied Processes, CSA Standard Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association. Website: www.csagroup.org. Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National ... -
Page 15: Section 4 - Product Warranty
Purchaser which are not covered by Tregaskiss’ warranty. ® Bernard BTB Semi-Automatic Air-Cooled MIG Guns: 1 year; Lifetime warranty on straight handles, straight handle switches, and rear strain relief ® ... -
Page 16: Section 5 - Specifications
SECTION 5 — SPECIFICATIONS 5-1 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 60%: 400 amp with Mixed Gases 500 amp gun feeds maximum wire size of 3/32" (2.4 mm) Duty Cycle Rating: 100%: 500 amp with CO Shielding Gas 60%: 500 amp with Mixed Gases 600 amp gun feeds maximum wire size of 1/8" (3.2 mm) Duty Cycle Rating: 100%: 600 amp with CO Shielding Gas 60%: 600 amp with Mixed Gases 5-2 Duty Cycle and Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. -
Page 17: Section 6 - Installation
6-1 Installing to a Feeder with a Power Pin 1. Insert power pin to shoulder and secure tightly. Figure 6-A 2. Insert control plug into feeder. 3. Feed welding wire into power pin by hand and tighten drive rolls. ® 6-2 Installing to a Feeder with a Euro or a Bernard Power Pin Figure 6-B A. Euro Power Pin 1. Insert the Euro power pin to face of receptacle. 2. Thread Euro hand nut clockwise to tighten. ... -
Page 18: Installing To A Fume Extraction Unit
Figure 6-C B. Bernard Power Pin 1. Insert the Bernard power pin to face of receptacle. 2. Engage and rotate locking sleeve to tighten. 6-3 Installing to a Fume Extraction Unit 1. Thread coupler into hose connected to fume extraction unit. Figure 6-D 2. Slide coupler onto fume port on rear strain relief and secure by tightening clamp. OM-CA-2.3... -
Page 19: Section 7 - Operation
SECTION 7 — OPERATION 7-1 Pulling the Trigger 1. Trigger - When pressed, energized wire feeds and shielding Figure 7-A gas flows. 7-2 Adjusting the Vacuum Chamber Figure 7-B 1. Vacuum chamber - The vacuum chamber can be adjusted to any of four set positions. 2. Adjust the vacuum chamber by pulling it back or pushing it forward until it locks into the desired position. OM-CA-2.3... -
Page 20: Adjusting The Vacuum Control Knob
7-3 Adjusting the Vacuum Control Knob Figure 7-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. OM-CA-2.3... -
Page 21: Section 8 - Replacement
SECTION 8 — REPLACEMENT 8-1 Changing Consumables Figure 8-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 and lock 1. Remove vacuum chamber. by installing nozzle onto gas diffuser. Nozzle is used to secure 2. Remove threaded nozzle by turning in a counterclockwise contact tip. direction. 5. Gas diffuser may be removed with an appropriate wrench in a 3. Cut electrode and remove all burrs before removing the counterclockwise rotation. To install, firmly secure gas diffuser contact tip. Remove Quik Tip contact tip from the gas diffuser with an appropriate wrench in a counterclockwise rotation. with a counterclockwise turn. To replace, slide the contact tip Torque to 144 in-lbs. over electrode into gas diffuser and lock with a turn in clockwise rotation. 4. Gas diffuser may be removed with an appropriate wrench in a ® C. Changing TOUGH LOCK Consumables counterclockwise rotation. To install, firmly secure gas diffuser ... -
Page 22: Changing The Liner
8-2 Changing the Liner Figure 8-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. With cable laying straight, insert new liner into power pin and feed through gun using short strokes to prevent kinking. Twist liner clockwise if necessary. 4. Use a 10 mm wrench to turn liner lock clockwise to tighten into power pin. 5. Push liner through front of gun and trim to dimensions shown in the New Liner Trim Lengths chart shown below. 6. Remove all burrs from end of liner and replace front-end consumables. New Liner Trim Lengths Centerfire Diffuser Part Number Liner Trim Length 9/16"... - Page 23 ® Figure 8-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. 4. With cable laying straight, feed the liner through the gun using short strokes to prevent kinking. 5. Once the liner stops feeding, give it an extra push to ensure it is seated correctly. 6. Push liner into gun. You should feel the o-rings click into the retainer. Trim to dimensions shown in New Liner Trim Lengths chart above. 7. Remove all burrs from end of liner and replace front-end consumables. OM-CA-2.3...
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Page 24: Changing The Neck And Switch
8-3 Changing the Neck and Switch Figure 8-D A. Changing the Neck - Straight Handle Model 1. Remove the two top pods screws (see 'A' in Figure 8-D) on the side of the gun. 2. Slide the top pod (see 'B' in Figure 8-D) up and back toward the rear of the handle and pull the trigger (see 'C' in Figure 8-D) down. 3. Remove the two handle screws (see 'D' in Figure 8-D) and rotate the handle locking cap 1/4 turn counterclockwise to open the handle. 4. After removing the vacuum chamber and front-end consumables, the vacuum tube (see 'E' in Figure 8-D) will slide forward. 5. Hold the neck (see 'F' in Figure 8-D) snug in a vise (be careful not to damage the neck by over tightening) and loosen cable/neck connection using a wrench. 6. Remove from vise and unthread neck by hand. 7. Thread new neck into cable end fitting and tighten by hand. 8. Hold neck in vise and secure cable/neck connection using a wrench. Torque to 13 ft-lbs (17.6 Nm). - Page 25 Figure 8-E C. Changing the Neck - Curved Handle Model 1. Remove the vacuum chamber and front-end consumables (see 'A' in Figure 8-E). 2. Remove the screws (see 'B' in Figure 8-E) to remove the vacuum tube (see 'C' in Figure 8-E). 3. Remove screws and nuts (see 'F' in Figure 8-E) and gently spread the handle (see 'E' in Figure 8-E) apart, keeping hold of the trigger (see 'G' in Figure 8-E). 4. Remove the trigger and left side of handle, then gently pry the wire ends off of the right side handle (see Figure 8-F) and remove. 5. Place the neck (see 'D' in Figure 8-E) snug in a vise (be careful not to damage the neck by over tightening) and use a wrench to loosen the cable connection to the neck. Remove from vise and unthread by hand. 6. To replace the neck, thread into the cable end fitting and tighten by hand. Secure the neck in a vise, then torque cable/neck Figure 8-F connection to 13 ft-lbs (17.6 Nm). 7. Position the neck, vacuum tube and handle swivel (see 'H' in Figure 8-E) into the handle. Make sure the trigger wires are located at the bottom cutouts in the handle, then push the wire ends into the right side handle (see Figure 8-F). 8. Place the trigger between handle halves with the pivot posts inserted into the cavities, and reassemble with screws and nuts ...
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Page 26: Changing The Vacuum Hose
8-4 Changing the Vacuum Hose Figure 8-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 8-3 Changing the Neck and Switch on page 19 2. With a 1/4 counterclockwise rotation, remove the vacuum hose rear cap from the rear strain relief. 3. Slide the old vacuum hose forward and remove from cable. 4. Slide the new vacuum hose over the cable and secure the vacuum hose rear cap to the rear strain relief with a 1/4 clockwise rotation. 5. Reassemble the handle and front-end components by following the steps listed in steps A. and B. in section 8-3 Changing the Neck and Switch on page 19. Figure 8-H B. Vacuum Hose on Curved Handle Model 1. Open the handle and remove the neck. Follow the steps listed in C. and D. in section 8-3 Changing the Neck and Switch on ... -
Page 27: Changing The Power Pin
8-5 Changing the Power Pin Figure 8-I A. Universal Power Pin 1. Remove the liner by following the steps listed in section 8-2 Changing the Liner on page 17. 2. Remove the screw and vacuum hose from rear strain relief and slide rear strain relief back over power pin. Position control lead wires as necessary as not to damage them. 3. Use wrenches and rotate power pin in a counterclockwise direction to remove it from the adaptor block. 4. Thread new power pin into adaptor block and use wrenches in a clockwise direction to thread power pin into adaptor block. Torque to 18 ft-lbs (24 Nm). 5. Slide rear strain relief over power pin and locate onto adaptor block, aligning flats and screw hole. 6. Secure with screw. 7. position control lead wires in cutout on side of strain relief. 8. Close strain relief top and secure with vacuum hose by rotating clockwise 1/4 turn. 9. Reinstall liner by following the steps listed in section 8-2 Changing the Liner on page 17. Figure 8-J B. Euro Power Pin 1. ... - Page 28 Figure 8-K C. Bernard Quick Disconnect 1. Remove the liner by following the steps listed in section 8-2 Changing the Liner on page 17. 2. Remove vacuum hose. 3. Viewing quick disconnect from cable end, align wave spring and large snap ring with opening access slot. 4. Compress large snap ring with internal snap ring pliers and remove locking sleeve. 5. Remove small external snap ring from power pin with external snap ring pliers. 6. Remove the control leads from the rigid strain relief by compressing the locking tabs on the contact pins with needle nose pliers and pulling the lead wire to unseat cap and sleeve assembly. 7. Unthread power pin from end fitting with appropriate wrenches in a counterclockwise rotation. The gas pin may be disassembled by removing the small retaining ring and pulling the pin from the rigid strain relief. 8. Test contact pins for continuity when trigger is engaged. 9. Inspect all components for cracks, debris, excessive wear and breakage. Replace with new components if safety or performance of product is compromised. 10. Thread power pin into adaptor block and torque to 18 ft-lbs (24 Nm). 11. Install locking sleeve components and vacuum hose.
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Page 29: Section 9 - Optimizing Fume Capture
SECTION 9 — OPTIMIZING FUME CAPTURE 9-1 Optimizing Fume Capture Figure 9-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. OM-CA-2.3... -
Page 30: Section 10 - Parts List
SECTION 10 — PARTS LIST 10-1 Straight Handle Model - 300, 400, 500, 600 amp OM-CA-2.3... - Page 31 Vacuum hose adaptor kit (includes 2-1/8" to 1-1/2" threaded hose fitting (x1) and Item 25 (x1)) 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 32: Curved Handle Model - 300, 400 Amp
10-2 Curved Handle Model - 300, 400 amp OM-CA-2.3... - Page 33 1040081 Neck, 30 degree, 2-inch radius (medium length) Clamp 1040082 Neck, 45 degree, 2-inch radius (medium length) 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 Electrical plug, non-D/S (Miller, Lincoln, Tweco 1880257 GN2021 (x1) and 13 (x1)) power pins) 203296-005 Screw, handle (2 req'd) See SP-CLA spec sheet Liner ...
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Page 34: 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 Tregaskiss.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™ Consumables Spec Sheet Scan to view the Quik Tip™ Consumables Spec Sheet Scan to view the TOUGH LOCK ® Consumables Spec Sheet Scan to view the QUICK LOAD ® Liner and AutoLength™ Pins Spec Sheet Scan to view additional Bernard ® Owner's Manuals and Spec Sheets Phone: 1-855-MIGWELD (644-9353) (US & Canada) Bernard +1-519-737-3000 (International) ...
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