Tregaskiss 293039 Iron Pro 450 Self Shielded MIG Gun User Manual

: June 9, 2024
: Tregaskiss

Tregaskiss 293039 Iron Pro 450 Self Shielded MIG Gun

Safety Depends on you!

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® MIG Guns are designed and built with safety in mind, but operators must follow prescribed safety guidelines.

SAFETY PRECAUTIONS

READ BEFORE USING

Protect yourself and others from injury – read, follow, and save these important safety precautions and operating instructions.

Symbol Usage

DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

NOTICE

Indicates statements not related to personal injury.
Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

Arc Welding HazardsThe symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in section 1-4 of Principal Safety Standards on page 3, and in welding power source Owner’s Manual. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this equipment. A qualified person is defined as one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill

Always wear dry insulating gloves.
Insulate yourself from work and ground.
Do not touch live electrode or electrical parts.
Replace worn, damaged, or cracked guns or cables.
Turn off welding power source before changing contact tip orgun parts.
Keep all covers and handle securely in place.

FUMES AND GASES can be hazardous

Keep your head out of the fumes.
Ventilate area, or use breathing device. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

MOVING PARTS can injure

Keep away from moving parts.
Keep away from pinch points such as drivers.

WELDING can cause fire or explosion

Do not weld near flammable material.
Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
Watch for fire; keep an extinguisher nearby.
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

BUILDUP OF GAS can injure or kill

Shut off compressed gas supply when not inuse.
Always ventilate confined spaces or use approved air-supplied respirator.

ARC RAYS can burn eyes and skin

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
Wear an approved welding helmet fitted with a proper shadeof filter lenses to protect your face and eyes from arc rays andsparks when welding or watching (see ANSI Z49.1 and Z87.1listed in Safety Standards).
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others fromflash, glare and sparks; warn others not to watch the arc.
Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, highshoes, and a cap.

HOT PARTS can burn

Allow gun to cool before touching.
Do not touch hot metal.
Protect hot metal from contact by others.

NOISE can damage hearing
Noise from some processes or equipment can damage hearing.

Check for noise level limits exceeding those specified by OSHA.
Use approved ear plugs or ear muffs if noise level is high.
Warn others nearby about noise hazard.

WELDING WIRE can injure

Keep hands and body away from gun tip when trigger is pressed.

READ INSTRUCTIONS

Read and follow all labels and the Owner’sManual 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.

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.

Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding Society standard ANSI Standard Z49.1. Website: www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Website: www.ansi.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1. Website: www.aws.org.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P- 1 from Compressed Gas Association. Website: www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2 from Canadian Standards Association. Website: www.csagroup.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B from National Fire Protection Association. Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.

SR7 2022-01

EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields may interfere with some medical implants, e.g. Pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passersby or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

Keep cables close together by twisting or taping them, orusing a cable cover.
Do not place your body between welding cables. Arrangecables to one side and away from the operator.
Do not coil or drape cables around your body.
Keep head and trunk as far away from the equipment in thewelding circuit as possible.
Connect work clamp to workpiece as close to the weld aspossible.
Do not work next to, sit or lean on the welding power source.
Do not weld whilst carrying the welding power source wirefeeder.

About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

Introduction

Thank you for choosing Bernard. The product you have purchased has been carefully assembled and factory tested prior to shipment. Should you experience problems with installation or performance, please refer to the “Troubleshooting Guide” in this manual. 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 manual contains general information on the operation of this Bernard product. Before installing or operating any equipment, read and understand the information and safety precautions presented in this manual. Also, note the various data plates, labels, and tags attached to the product. While every precaution has been taken to assure the accuracy of this manual, Bernard assumes no responsibility for errors or omissions. Bernard assumes no liability for damages resulting from the use of the information contained herein. Bernard shall have no liability to the buyer for consequential damages or be liable to the in tort for any negligent manufacture of the goods or for the omissions of any warning therefrom.

Commercial Warranty

The product is warranted to be free from defects in material and workmanship for 1 year after the sale by an authorized Buyer. Straight handles, straight handle switches and straight rear strain reliefs are covered by a lifetime warranty. Bernard reserves the right to repair, replace or refund the purchase price of nonconforming product. Product found not defective will be returned to the Buyer after notification by Customer Service. Bernard makes no other warranty of any kind, expressed or implied, including, but not limited to the warranties of merchantability or fitness for any purpose. Bernard shall not be liable under any circumstances to Buyer, or to any person who shall purchase from Buyer, for damages of any kind. Including, but not limited to any, direct, indirect incidental or consequential damages or loss of production or loss of profits resulting from any cause whatsoever, including, but not limited to, any delay, act, error or omission of Bernard. Genuine Bernard parts must be used for safety and performance reasons or the warranty becomes invalid. Warranty shall not apply if accident, abuse, or misuse damages a product, or if a product is modified in any way except by authorized Bernard personnel.

General Description

The IronPro™ 450 Self-Shielded MIG Gun is designed primarily for processing mild steel electrode under FCAW (Flux Cored Arc Welding).The IronPro™ 450 Self-Shielded MIG Gun provides rapid neck interchangeability, typically during production processes. Neck may also be positioned on line within a 360 degree rotation. This position allows for movements between standard horizontal welding, overhead, and hard-to-reach side angles. The neck includes an optional jump liner system that effectively reduces costs associated with one- piece liner systems. Bernard is concerned about your higher productivity.

The IronPro™ 450 Self-Shielded MIG Gun meets or exceeds NEMA (National Electrical Manufacturer’s Association) EW3 requirements.

Installation

Your gun has been shipped with a specific feeder connector, neck, and sized for electrode as per the part number indicated on its package. Please inspect the received gun against this part number for accuracy.
Turn off power prior to any installation.
Fully extend gun and cable. Press liner fully into power pin.
Safely expose approximately 2” (51 mm) of electrode beyond feeder or adaptor block.
Power Pin: Connect the power pin of the direct plug gun by sliding the electrode into the liner and the power fitting into the drive housing of the feeder. Fully seat the unit in position and tighten into place as designated in the manufacturer’s instructions. On initial installations, a thin film of silicone lubricant will aid installation and prevent o-ring damage. Attach control lead wires to the appropriate plug, terminals, or lead kit. Plug or wire into the control circuit of the feeder as designated in manufacturer’s instructions.
Pull contact tip from neck tip adapter. An unobstructed electrode path has now been established.
Safely feed electrode through the gun and approximately 1” (25 mm) beyond head.
Slide contact tip over electrode into tip adapter on the neck by hand and tighten with non-marring pliers. Torque to 30 in-lbs (3.5 Nm).
- NOTE: AccuLock™ tip tool part # T-ALTOOL is recommended.

NOTICE: Welding current and duty cycle shall not exceed published specification of this product. If such conditions exist, product life and performance will be reduced.

Helpful Operating Tips

TIP Insulation

Tip insulation could be unthreaded slightly to extend the life the of part.

Feeder

Check drive rolls for wear; be sure drive rolls and guide tubes are clean and free of debris. Do not overtighten drive rolls; set as per the manufacturer’s specifications.
Use clean, non-corroded electrode.
When installing or replacing electrode, you may: remove burrs from end of electrode, remove head/gas diffuser and contact tip, and/or straighten the first few inches of the electrode.

Cable

Periodically check torques of neck and end fittings. Loose fittings can cause overheating and premature failure of the gun.
Sharp bends and loops in the cable should be avoided. Often the best solution is to suspend the wire feeder from a boomer trolley, thus eliminating a large number of bends and keeping the cable clear of hot weldments.
Do not immerse liner into solvents for cleaning; the liner may be periodically blown out with compressed air.
Avoid rough surfaces and sharp edges that can cause tears and nicks in cable jacket which can cause premature failure.
Periodically check all cables and ground connections.6.Use anti-seize on all threaded connections.

End User Stocking Recommendations

Contact Tips ………………………… 30 for every 1 gun in service
Triggers ………………………………. 1 for every 10 guns in service
Necks …………………………………. 1 for every 10 guns in service
Handle Kits ………………………….. 1 for every 20 guns in service
Strain Relief Kits ………………….. 1 for every 20 guns in service
Power Pin Kits …………………….. Order as Necessary

These stocking recommendations are only initial guidelines based on an 80 hour work period. You should work closely with your distributor to tailor a stocking program that suits your specific needs. Results will vary.

Maintenance and Repair

WARNING: Disconnect gun from equipment, allow to cool, and remove electrode from liner before servicing.

Tregaskiss-293039-Iron-Pro-450-Self-Shielded-MIG-Gun-
FIG-1

CONVENTIONAL CABLE LINER REMOVAL

Remove neck, heat shield and heat shield nut and lay cable straight.
Remove rear guide cap, then using a 10 mm wrench, turn liner counter-clockwise until it is free from the power pin.
Remove liner from gun assembly.

SERVICE

Inspect for excessive wear and debris on the inside diameter. Do not dip liner in solvents for cleaning. Liner may be periodically blown out with shop air. Replace with new liner when excessive wear or debris produces poor electrode feed.

INSTALLATION

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.
Use a 10 mm wrench to turn liner lock clockwise to tighten into power pin, then replace guide cap.
Trim liner flush with front adapter block (as shown in the above figure).
Then reassemble neck and heat shield.

Neck and Jump Liner

Tregaskiss-293039-Iron-Pro-450-Self-Shielded-MIG-Gun-
FIG-2

Neck

Removal

Remove neck from adapter block on the front gun handle by grasping lock nut and rotate counter-clockwise. Rotation will free neck from adapter block.

Installation

Before installing, inspect neck and adapter block of the front gun handle for debris, clean if necessary. Then, take the tapered end of the neck and insert into adapter block, making sure the cable liner is inserted into jump liner.
Install neck in reverse order of removal, adjust neck by twisting into place, torque to 38in-lbs.

Jump Liner

Removal

Remove used jump liner from the back end of neck.

Service

Inspect for excessive wear and debris on the inside diameter. Do not dip jump liner in solvents for cleaning. Jump liners may be periodically blown out with shop air. Replace with new jump liner when excessive wear or debris produces poor electrode feed.

Installation

Insert jump liner making sure the liner stop is fully seated at the back of the neck. For new jump liner replacement, measure the jump liner from rear of liner lock to tip of the liner. For 12″ long necks (1370270) measure and trim to 10-7/8″. For 7″ short necks (1370271) measure and trim to 5-7/8″.

Tip Insulation

Removal

Tip insulation can be removed by turning in a counter-clockwise direction.

Service

Inspect for cracks and degradation of insulation. Replace the insulation when loose, worn, or exposing the tip of the neck.

Installation

Replace threaded fit nozzle by threading in a clockwise direction. Tip Insulation should allow about 1/4″ of the contact tip exposed.

Contact Tip

Removal

Cut electrode and remove all burrs. Remove threaded tip insulation by turning in a counter-clockwise direction. Remove contact tip by turning in a counter-clockwise direction.

Installation

Replacement is accomplished by cutting electrode and removing all burrs. Slide contact tip over electrode into tip adapter on the neck by hand and tighten with non-marring pliers. Torque to 30 in-lbs (3.5 Nm).
- NOTE: AccuLock tip tool part # T-ALTOOL is recommended.
Reinstall tip insulation.

T Series Straight Handle (Switch Only)

Tregaskiss-293039-Iron-Pro-450-Self-Shielded-MIG-Gun-
FIG-4

REMOVAL

Remove neck and heat shield.
Remove both housing screws with an 8 mm nut driver.
Ease switch out of trigger housing with needle nose pliers to grip switch.
Remove switch from switch lead connectors with needle nose pliers.

INSTALLATION

Push switch lead connectors firmly onto new switch terminals with needle nose pliers.
Depress switch into trigger housing, then nest on handle (switch leads must lay parallel).
Align housing holes with threaded holes in body and insert mounting screws first before tightening with 8 mm nut driver to even alignment.

Miller Power Pin

Removal

Remove the liner by following steps listed for cable liner

Remove pin/adapter block insulation.
Use wrenches and rotate power pin in a counter-clockwise direction to remove it from the adapter block.

Service

Lubricate o-rings with silicone lubricant. Inspect all components for cracks, debris, excessive wear, and breakage. Replace with new components if safety or performance of product is compromised.

Installation

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).
Reinstall liner by following the steps listed for cable liner.

Control Lead Cable Housing

Removal

Remove screw covers and both housing screws with an 8 mm nut driver.
(If replacing cut wires at back of the butt connectors).

Service

Test lead wires for continuity when trigger is engaged.
Inspect all components for cracks, debris, excessive wear, and breakage. Replace with new components if safety or performance of product is compromised.

Installation (If replacing, splice control lead into new butt connectors)

Lay butt connectors parallel with handle.
Align housing holes with threaded holes in adapter block and insert mounting screws first before tightening with 8 mm nut driver to even alignment.

Replacement Parts List

Gun Part Number: 293039

Tregaskiss-293039-Iron-Pro-450-Self-Shielded-MIG-Gun-
FIG-6

ITEM

| PART NUMBER|

DESCRIPTION

---|---|---
1| NS-AFLX| Nozzle Assembly, Gasless – AccuLock™
2| T-A072CH T-A078CH

T-A094CH

Shield Nut

6| 1760013| Universal Q-Neck Adaptor –

One Piece Heat Shield**

7| 1680085U| Universal Q-Neck Adaptor

Assembly

8| 410S| Short T-Series Handle
9| 411-2| Switch Housing Assembly
10| 411-3M| Screw M5x12mm Hex Head
11| 414-400| Universal Adapter Detail
12| 1620004| Hex Head Screw Cover
13| 1810053| Rear Pod, Low Profile, W/2 Butt Connectors
14| 2200137| Miller® Power Pin Assembly
15| L7A-15| Liner Assembly
16| 214-332| Guide Cap – Miller
17| 414-400-20| Power Pin Insulator
18| 2950001| Cap Plug