BERNARD 600 Amp W-Gun Series MIG Guns User Manual

600 Amp W-Gun Series MIG Guns
User Manual

600 Amp W-Gun shown with one-piece HD straight handle with rubber over- mold.
600 Amp W-Gun shown with curved handle and hang-up hook.

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 synthetic rubber hoses prevents water leakage and provides increased water flow and reduced gas leakage.
A newly designed back end and a water block with interchangeable direct plugs and trigger lead connect to wire feeders and machines from major manufacturers and allow for simple maintenance.
Multiple handles and trigger options to increase operator comfort.
Heavy-duty water-cooled necks are offered in multiple lengths and bend configurations to allow for optimal weld accessibility and improved operator comfort.
Contact tip options include Centerfire™, Elliptical, and 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.

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 that, 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 that, 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 Hazards

The 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-  Principal Safety Standards on page 3, and in the 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 the 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 the ground.
• Do not touch live electrodes or electrical parts.
• Replace worn, damaged, or cracked guns or cables.
• Turn off the welding power source before changing the contact tip or gun parts.
• Keep all covers and handle securely in place.

FUMES AND GASES can be hazardous.

• Keep your head out of the fumes.
• Ventilate the area, or use a breathing device. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel is 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 drive rolls.

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 the compressed gas supply when not in use.
• Always ventilate confined spaces or use an 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 proper shade of filter lenses to protect your face and eyes from arc rays sparks when welding or watching (see ANSI Z49.1 and Z87listed in Safety Standards).
• Wear approved safety glasses with side shields under your helmet.
• Use protective screens or barriers to protect others from flash, 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, a heavy shirt, cuffless trousers, high shoes, and a cap.

HOT PARTS can burn.

• Allow the gun to cool before touching it.
• 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 earplugs or earmuffs if the noise level is high.
• Warn others nearby about noise hazards.

WELDING WIRE can injure.

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

READ INSTRUCTIONS.

• Read and follow all labels and the Owner’s
  Manual carefully before installing, operating, or servicing the 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.

California Proposition 65 Warnings

WARNING:  This product can expose you to chemicals including lead, which is 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 FaceProtection, ANSI Standard Z87.1, from American National
Standards Institute. Website: www.ansi.org.
Safe Practices for the Preparation of Containers and Piping forWelding 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.
The 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 an individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep the head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect the work clamp to the workpiece as close to the weld as possible.
6. Do not work next to, sit, or lean on the welding power source.
7. Do not weld whilst carrying the welding power source wire feeder.

About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctors 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.

General Description

The Bernard W-Gun is a water-cooled gun that is designed for processing mild steel electrodes under GMAW (Gas Metal Arc Welding), MIG (Metal Inert Gas), and MAG (Metal Active Gas), FCAW (Flux Cored Arc Welding), and MOG (Metal without Gas).
The Bernard W-Gun provides longer consumable life while reducing operator fatigue, which can increase overall welding effectiveness. Bernard W-Guns can reduce the downtime and expenses associated with changing consumables during the welding process. The lightweight and flexible design allow for easier movement during welding between standard horizontal welding, overhead, and hard-to-reach side angles. Bernard W-Guns can effectively reduce your operating cost and improve the productivity of your welding operation.
The Bernard W-Gun meets or exceeds NEMA (National Electrical Manufacturer’s Association) EW3 and CE EN50078 requirements for guns used in a wide variety of applications including aluminum, silicon bronze, and hard facing alloys to name a few. With Bernard’s flexibility, many applications can be accommodated with field-installed options, increasing performance and maneuverability.

Installation

1. Your gun has been shipped with a specific feeder connector and sized for an electrode as per the part number indicated on its package.
   Please inspect the received gun against this part number for accuracy.

2. Turn off power prior to any installation.

3. Fully extend gun and cable. Press liner fully into power pin.

4. Safely expose approximately 2” (51 mm) of electrode beyond the feeder or adaptor block.

5. 5a. Bernard Quick Disconnect
   If you have purchased a Bernard Quick Disconnect gun, it is necessary to connect this unit to an adaptor kit providing the shielding gas, control circuit, and arc power. If this is a new installation, install the adaptor kit as per the kit instructions. With the Bernard adaptor installed, perform the following:
   Orient the power pin and gas pin with the adaptor receptacle. Slide the electrode into the liner and push the power pin into the socket.
   Rotate the locking sleeve until the locking pins of the adaptor drop into the receiver of the locking sleeve. Continue to engage the power pin while twisting the locking sleeve to make the connection. Shielding gas, control circuit, and power are now engaged.
   5b. Direct Plug
   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 it 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 the manufacturer’s instructions.
   If a gas hose is provided, connect to the feeder’s solenoid circuit to deliver shielding gas to the arc. If no gas hose is provided, gas is delivered through the power pin. Refer to the manufacturer’s instructions for proper gas connection at the feeder block or solenoid.

6. Connect water lines to a water coolant source. Each hose is identified for proper connection by a tethered drip cap (blue: water inlet, red: water outlet) and label. If a water hose hook-up kit is used, make all runs as short as possible. Always use hoses with at least a 3/16” inside diameter for extended runs. Reinforced hoses of high quality are recommended to prevent damage due to operating pressures, heat, and hose contamination. The coolant system must produce a minimum of 0.5 gpm at 60 psi. Run coolant through the gun for approximately 2 minutes to purge the system of entrapped air before applying power. Water must flow through the gun at all times while the power supply is on.

7. Remove the nozzle from the gas diffuser.

8. 8a. Centerfire Tip – Remove tip holder by turning counterclockwise and then pull tip from a gas diffuser. An unobstructed electrode path has now been established.
   8b. Elliptical Tip – Remove tip with a 1/8-1/4 turn counterclockwise while pulling. An unobstructed electrode path has now been established.
   8c. Quik Tip – Remove tip with a 1/4 turn counterclockwise. An unobstructed electrode path has now been established.

9. Safely feed electrode through the gun and approximately 1” (25 mm) beyond the gas diffuser.

10. 10a. Centerfire Tip – Reinstall the tip over the electrode and lock it into position by reinstalling the tip holder. Reinstall nozzle.
    10b. Elliptical and Quik Tip – Reinstall the tip over the electrode locking into position with a clockwise motion. Reinstall nozzle.

Coolant must flow through the gun prior to and during welding. The welding current and duty cycle should not exceed the published specifications of this product. If such conditions exist, product life and performance will be reduced.

Helpful Operating Tips

Nozzles:

1. If anti-spatter is used, do not coat the nozzle insulator as this may degrade the insulating material.
2. The nozzle should be cleaned as often as possible. Spatter buildup can often lead to poor gas shielding or short-circuiting between the contact tip and the nozzle.
3. Spatter should be removed with the proper tools designed for spatter removal.
4. In high-temperature welding applications, heavy-duty consumables are recommended.

Contact Tips, Gas Diffusers:

1. Centerfire and Elliptical contact tips may be removed and rotated in a gas diffuser, providing additional wear surfaces and extending the service life of the product.
2. The electrical stick out of the elliptical contact tip can be altered by positioning the contact tip in the desired location of the gas diffuser and rotating clockwise locking in place.
3. Inspect the nozzle for spatter adhesion, blocked gas ports, and carbonized contact surfaces. Clean as often as possible.
4. If anti-spatter is used, periodically check gas ports for blockage.
5. When using a dual shield electrode, periodically check gas ports for clogging caused by flux from within the electrode.

Cable:

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

Feeder:

1. 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 manufacturer’s specifications.
2. Use clean, non-corroded electrodes.
3. When installing or replacing electrodes, you may: remove burrs from the end of the electrode, remove the gas diffuser and tip, and/or straighten the first few inches of the electrode.

End-User Stocking Recommendations:
Nozzles ……………………………….. 5 for every 1 gun in service
Tips ……………………………………. 30 for every 1 gun in service
Gas Diffusers ………………………. 4 for every 1 gun in service
Triggers ………………………………. 1 for every 10 guns in service
Necks …………………………………. 1 for every 20 guns in service
Handle Kits ………………………….. 1 for every 20 guns in service
Replacement Cables ……………… 1 for every 20 guns in service
Strain Relief Kits ………………….. 1 for every 20 guns in service
Adaptor Kits ………………………… Order as Necessary
Direct Plug 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

See the Replacement Parts page of www.BernardWelds.com for complete parts lists and specs
Disconnect the gun from equipment, allow the gun to cool, and remove the electrode from the liner before servicing.

Section 1. General Inspection

1. Inspect the gun periodically for worn or loose parts. Tighten, repair, or replace as necessary.
2. Periodically inspect the outer cable cover for nicks or cuts that can cause short-circuiting or allow the cable assembly’s internal components to become exposed. Replace as necessary.
3. Inspect adapter and direct plug connection for wear that may cause overheating. Replace as necessary.
4. Change or rotate contact tip when arc tracking or arc instability is incurred. Please note; that a tip may look worn but produce a stable arc with good results.
5. Clean the nozzle as often as possible to prevent spatter build-up. Excess spatter can lead to poor gas shielding or short-circuiting. Replace the nozzle when worn.
6. Periodically check torques of all water connections to maintain cool and dry operation. Tighten as described in the following sections.
7. Replace the liner system as electrode feeding becomes erratic.

Section 2. Nozzle

A. Removal
The nozzle is a friction fit that can be removed with a twisting and pulling motion.
B. Service
Inspect the nozzle for cracks and degradation of insulation. Clean the nozzle as often as possible to prevent spatter build-up which can lead to poor gas shielding or short-circuiting. Replace the nozzle when loose, worn, or producing erratic gas shielding.
C. Installation
Replace with a pushing and twisting motion.

Section 3. Contact Tip

Bernard has designed its contact tips to allow rapid installation and adjustment.
A. Removal
Cut electrode and remove all burrs before removing the tip.
Centerfire Tip – Remove tip holder by turning counterclockwise and then pull tip from the gas diffuser.
Elliptical Tip – Remove tip with 1/8-1/4 turn counterclockwise.
Quick Tip – Remove tip with a 1/4 turn counterclockwise.
B. Service
To extend contact tip life, reface the front of the tip and clean the bore.
Centerfire and Elliptical tips may be rotated in a gas diffuser socket providing additional wear surface and extending the service life of the product. Electrical stick out may be altered when using Elliptical tips by positioning the contact tip in the desired location of the gas diffuser before locking it into place.
C. Installation
Centerfire Tip – Reinstall the tip over the electrode and lock it into position by reinstalling the tip holder. Reinstall nozzle.
Elliptical and Quik Tip – Reinstall the tip over the electrode locking it into position with a clockwise motion. Reinstall nozzle.

Section 4. Gas Diffuser

A. Removal
The gas diffuser may be removed with an appropriate wrench in a counterclockwise rotation.
B. Service
Inspect gas diffuser and Centerfire tip holder for spatter, blocked gas ports, and carburized surfaces. Clean as often as possible. Replace with a new gas diffuser or Centerfire tip holder when wear prevents engagement of contact tip or nozzle.
C. Installation
Firmly secure gas diffuser with an appropriate wrench in a clockwise rotation. Always reinstall the gas diffuser insulator to decrease the chances of short- circuiting. Note that the Centerfire gas diffuser does not require a gas diffuser insulator.

Section 5. Liner

A. Removal
Remove nozzle, contact tip, and gas diffuser. Lay cable straight. Grasp the liner lock which protrudes from the power pin (some direct plugs may require the removal of additional components to access the liner lock) and remove it from cable assembly by pulling.
B. Service
Inspect for excessive wear and debris on the inside diameter. Do not dip liner in solvents for cleaning. The liner may be periodically blown out with compressed air. Replace with the new liner when excessive wear or debris produces poor electrode feed.
C. Installation
Insert liner into power pin with cable laying straight. Continue until the liner lock is fully seated into the power pin. A twisting motion may be necessary to seat the o-ring (some direct plugs may require the installation of additional components to secure the liner). Trim and deburr the liner 3/8” (9.5 mm) past the nozzle end of the neck. Install gas diffuser and nozzle.

Section 6. Handle/Switch Assembly

I Curved Handle
A. Removal
Remove screws, post fasteners, and hang-up hook (See Figure 1). Separating handle halves will expose interior connections and trigger switch assembly. Slide switch assembly out of the cavity and remove terminals from the trigger.

B. Service
Inspect for cracks, deformation of hex areas, debris, holes, loose or missing threaded inserts, excessive wear, exterior heat deformation, and warpage. If any of the above conditions exist, replace it with a new handle or clean all surfaces with mild detergent and reinstall. Test switch for continuity. Clean any debris from the trigger, if necessary, replace it with a new trigger.
C. Installation
Begin assembly by placing the hexagon portion of the neck within the rear hexagon portion of the handle half. The hex bushing will be cradled within the forward hex locators. Install switch assembly by pressing control wire terminals fully onto terminals of the switch assembly and slide assembly into the switch cavity. Route hoses, cable, control wires, and switch so as not to be pinched when reinstalling the second handle half. Install hang-up hook, post fasteners, and handle screws. Tighten screws while being aware not to pinch the cable jacket in the joint between the handle halves.

II Legacy Straight Handle

A. Removal
Remove switch and screws from handle (See Figure 2). Remove

terminals from the switch assembly. Slide the handle down the cable to gain access to neck connections. The neck must be removed to replace the handle on all-around handled guns except those with straight necks.
B. Service
Inspect for cracks, debris, holes, loose or missing threaded inserts, excessive wear, exterior heat deformation, and warpage. If any of the above conditions exist, replace with a new handle or clean all surfaces with mild detergent and reinstall. Test switch for continuity. Clean any debris from the trigger, if necessary, replace it with a new trigger.
C. Installation
Slide handle over the power cable. Reinstall neck (See Figure 3). Place the hexagon bushing on the neck. Install aluminum spacers over the bushing and secure it with screws. Install insulation spacers on the hexagon water block and secure using a pop rivet. Top mount switch assemblies require insulation spacers to be mounted on the bottom of the hexagon water block. Bottom mount switch assemblies require insulation spacers to be mounted on the top of the hexagon water block. Route control wires as not to be pinched when reinstalling the handle. Align spacers and secure with screws. Install switch assembly into position by installing terminals onto the switch assembly and then secure with screws.

III HD Straight Handle

A. Removal
Remove switch and screws from handle (See Figure 4). Cut wires from the switch assembly to remove the switch. Slide the handle down the cable to gain access to neck connections. The neck must be removed to replace handle on all straight handled guns.

B. Service
Inspect for cracks, debris, holes, loose or missing threaded inserts, excessive wear, exterior heat deformation, and warpage. If any of the above conditions exist, replace it with a new handle or clean all surfaces with mild detergent and reinstall. Test switch for continuity. Clean any debris from the trigger, if necessary, replace it with a new trigger.
C. Installation
Slide handle over the power cable. Reinstall neck (See Figure 5). Locate aluminum spacer set as shown with machined flat-facing switch assembly. Secure to neck with screws. Do not over tighten screws to prevent neck armor from being pierced. Route control wires as not to be pinched when reinstalling the handle. Secure handle onto cable assembly using screws. Connect switch assembly by connecting control wires to the switch with insulated butt connectors. Secure switch assembly to handle with a screw.

Section 7. Neck

A. Removal
Remove liner from cable assembly. The gas diffuser should remain installed to protect neck threads. Remove the handle from the gun assembly. Disconnect power cables and return hoses using a counterclockwise motion with one 5/16” and one 3/8” wrench. Do not allow the power cable and return hose fittings to twist. Using a 5/64” (2 mm) hex key, remove the conduit set screw. Remove conduit from the neck.
B. Service
Inspect neck for damaged threads, leaky water connections, excessive spatter build-up on armor or armor that is damaged. If any of the above conditions exist, replace the neck to ensure safe and reliable operation.
C. Installation
Install conduit into the neck and secure with conduit set screw. See the next section for specific conduit installation instructions. Install and tighten power cable and return hose fittings to 35 in-lbs to prevent leakage. Avoid twisting power cable and return hose fittings during installation. Install handle and liner.

Section 8. Cable

I Power Cable/Return Hose
A. Removal
Remove handle, switch assembly, and open rear strain relief. Remove outer cover ties from both ends. Disconnect power cables and return hoses using a counterclockwise motion with one 5/16” and one 3/8” wrench. Do not allow the power cable, return hose, or rear water block fittings to twist which could result in breakage.
B. Service
Inspect power cable and return hose for leaks or hose material that has been damaged. If any of the above conditions exist, replace power cable or return the hose to ensure safe and reliable operation.
C. Installation
While the old cable is in place, fasten the new cable to the end of the old cable using the cable tool that ships with replacement cables or tape. The old cable may now be used to pull the new through the outer cover. Install and tighten the cable to 35 in-lbs using appropriate wrenches in a clockwise rotation to prevent leakage. Before installing the handle or strain relief, circulate coolant through the unit checking for leaks; reinstall outer cover ties on both ends and reassemble all remaining components.
II Conduit
A. Removal
Remove handle, switch assembly, liner, and open rear strain relief. Remove outer cover ties from both ends of the outer cable covering. Use a 5/64” (2 mm) hex key to remove conduit set screws and release conduit connections (both ends).
B. Service
Inspect conduit assembly for cracks or gas leakage. If any of the above conditions exist, replace conduit assembly to ensure reliable operation.
C. Installation
While the old conduit is in place, tape or splices the new conduit to the end of the old conduit. The old conduit may now be used to pull the new through the outer cover. Moisten o-rings with water or soap. Do not use silicone or petroleum-based lubricants. Slide conduit into the socket on the end of the neck. Care must be taken not to nick or cut o-ring during installation. Look through the set screw hole to verify that the fitting has slid completely into the neck. Secure conduit with conduit set screw.
Conduit attachment is similar at the direct plug end. Reinstall outer cover ties (both ends) and reassemble handle, strain relief, and liner.
III Control Leads
A. Removal
Remove handle, switch assembly, and open rear strain relief. Remove outer cover ties from both ends of the outer cable covering. Be sure to cut leads at the direct plug end as close to the butt connector as possible to make certain there is enough wire to make the new connection.
B. Service
Inspect control leads for nicks, cuts, or shorts. If any of the above conditions exist, replace control leads to ensure safe and reliable operation.
C. Installation
While old control leads are in place, tape or splice new control leads to the end of the old control lead. The old control lead may now be used to pull the new through the outer cover. Strip wires and crimp terminals as necessary to make proper connections. Leads should be looped at both ends to provide any extra length necessary for cable stretch and
expansion. Reinstall outer cover ties (both ends) and reassemble handle, strain relief, and liner. Be careful not to pinch leads during assembly as this could cause a short circuit of the control system.

IV Outer Cable Cover

A. Removal
Removal of the outer cable cover requires the removal of either the neck or the direct plug, as well as the removal of the handle or strain relief on the opposite end. Remove ties holding outer cable cover to internal components. Anchor either hex of neck or rear water block lightly in a vise to retain internal cable components. Slowly slide outer cable covering off of the cable cluster approximately 6” at a time. Tape internal components every 6” to retain hose alignment for new installation.
Remove from vise.
B. Service
Inspect outer cable cover for major nicks or cuts which expose inner cables. If any of the above conditions exist, replace the outer cable cover to ensure safe and reliable operation.
C. Installation
With all cable, and internal components taped together, use a welding electrode or wire as a lead. Whatever is used must be as long as or longer than the outer cable cover being applied. Slide wire through the outer cable cover first, then anchor one end of the wire in a vise. Connect another end to cable cluster’s disconnected end using tape. Slide the outer cable cover over the cable cluster and into position (remove the tape as the outer cable cover is fitted over components). When the outer cable cover is completely installed, fasten the cover into position using cable ties. Install either the neck or the direct plug, whichever was removed.

Section 9. Rigid Strain Relief

A. Removal
Rotate the rear strain relief spring assembly in a counterclockwise rotation to remove rigid strain relief. Slide the spring further onto the cable assembly and remove the screw securing strain relief to the adapter block.
B. Service
Inspect all components for cracks, debris, excessive wear, and breakage. Replace with new components if safety or performance of the product is compromised.
C. Installation
Align flats in rigid strain relief with flats on adapter block. Slide strain relief onto adapter block and secure with screw. Using the arrows on the cap to align with mating grooves, slide the strain relief spring assembly toward the rigid strain relief until seated and turn in a clockwise rotation until an engaging snap is felt.

Section 10. Direct Plug

I Bernard Quick Disconnect
A. Removal
Remove liner from the gun assembly. Viewing quick disconnect from feeder end, align wave spring and snap ring with opening access slot (See Figure 6). Compress large snap ring with internal snap ring pliers and remove locking sleeve. Remove medium external snap ring from power pin using external snap ring pliers. Open rigid strain relief and remove wire assemblies from the assembly by compressing the locking tabs on the contact pins with needle nose pliers and pulling the wire assemblies from the back. Unthread the power pin from the rear water block with appropriate wrenches in a counterclockwise rotation. Inlet and outlet hoses can be removed from rear water block by cutting Oetiker clamps with cutting pliers. The gas pin may be removed from the rigid strain relief by removing the small snap ring and pulling the pin from the rigid strain relief.

B. Service
Test contact pins for continuity when the trigger is engaged. Lubricate o-rings with silicone lubricant. Inspect all components for cracks, debris, excessive wear, and breakage. Replace with new components if the safety or performance of the product is compromised.
C. Installation
Assemble gas pin into rigid strain relief and secure with a small snap ring. Install inlet and outlet hoses by pushing the hose onto the barbed fitting on the rear water block and secure with an Oetiker clamp. Install power pin onto a rear water block with appropriate wrenches in a clockwise rotation. Install wire assemblies into the two symmetrical holes on the backside of the rigid strain relief. Do not cross control wires from side to side. Make sure control pins are fully seated to ensure proper gun functionality. Slide the power pin back into the rigid strain relief. Rotate the power pin until the barbed fittings on the rear water block are facing upward and away from the bottom of the rigid strain relief. (See Figure 7) Once the power pin is fully seated, secure it by installing the medium snap ring into the groove on the power pin. Close rigid strain relief and secure by installing the strain relief spring assembly. Position wave spring and large internal snap ring in opening access slot. With internal snap ring pliers inserted through the locking sleeve, compress the snap ring and slide the sleeve into place. The Snap ring must be fully seated in the locking sleeve. The locking sleeve must be able to rotate freely around rigid strain relief. Install liner.

II Euro Direct Plug
A. Removal
Remove liner from the gun assembly. Follow the steps required to remove the complete cable assembly from the rear water block. Inlet and outlet hoses can be removed from the rear water block by cutting Oetiker clamps with cutting pliers. Disconnect the Euro block lead set from the gun by cutting as close as possible on both sides of the butt connectors in order to preserve the wire for later determination. Remove the screw that secures Euro block assembly to rigid strain relief. Slide adapter nut back in order to expose the machined flats on the Euro block assembly. Remove Euro block from rear water block and rigid strain relief by using the appropriate wrenches in a counterclockwise rotation.

B. Service
Test contact pins for continuity when the trigger is engaged. Lubricate o-rings with silicone lubricant. Inspect all components for cracks, debris, excessive wear, and breakage. Replace with new components if the safety or performance of the product is compromised.
C. Installation
Place adapter nut onto rigid strain relief and secure by threading rear water block into Euro block assembly. Using the appropriate wrenches, tighten the Euro block assembly onto the rear water block by rotating clockwise. Continue tightening the connection until barbed fittings on the rear water block are facing upward and away from the bottom of the rigid strain relief. (See Figure 7) Secure Euro block assembly to rigid strain relief using a screw. Connect Euro block leads to control leads by connecting with insulated butt connectors. Install inlet and outlet hoses by pushing the hose onto the barbed fitting on the rear water block and secure with an Oetiker clamp. Follow the steps required to reassemble the complete cable assembly to the rear water block. Close rigid strain relief and secure by installing the strain relief spring assembly. Install liner.

III All Other Direct Plugs
A. Removal
Remove the liner and rigid strain relief from the gun assembly. Inlet and outlet hoses can be removed from the rear water block by cutting Oetiker clamps with cutting pliers. Position control lead wires as necessary so as not to damage them. Remove power pin from adapter block using appropriate wrenches in a counterclockwise rotation.
Note: For OXO direct plugs, rigid strain relief must be held gently in a vise while using the appropriate wrench in a counterclockwise rotation to remove the power pin. Be careful not to crush or deform rigid strain relief while being held in a vise.
B. Service
Test contact pins for continuity when the trigger is engaged. Lubricate o-rings with silicone lubricant. Inspect all components for cracks, debris, excessive wear, and breakage. Replace with new components if the safety or performance of the product is compromised.
C. Installation
Assemble power pin onto adapter block by using appropriate wrenches in a clockwise rotation. Make sure that the barbed fittings on the rear water block are facing upward and away from the bottom of the rigid strain relief. (See Figure 7) Install inlet and outlet hoses by pushing the hose onto the barbed fitting on the rear water block and secure with an Oetiker clamp. Reinstall rigid strain relief and liner.
Note: For OXO direct plugs, rigid strain relief must be held gently in a vise while using the appropriate wrench in a clockwise rotation to install the power pin. Be careful not to crush or deform rigid strain relief while being held in a vise.

Troubleshooting Guide

2. Broken control lead.
3. Poor adaptor connection.
4. Worn or broken switch.
5. Improper drive roll size.
6. Drive roll tension misadjusted.
7. Burn back to contact tip.
8. Wrong size liner.
9. Buildup inside of the liner.| 1. Consult feeder manufacturer.
2 a. Test & connect spare control lead.
b. Install new cable.
3. Test & replace leads and/or contact pins.
4. Replace.
5. Replace with the proper size.
6. Adjust tension at the feeder.
7. See ‘Contact Tip Burn Back’.
8. Replace with the correct size.
9. Replace the liner, and check the condition of the electrode.
2. Contact tip burn back| 1. Improper voltage and/or wire feed speed.
2. Erratic wire feeding.
3. Improper tip sticks out.
4. Improper electrode stick out.
5. Faulty ground.| 1. Set parameters.
2. See ‘Erratic Wire Feeding’.
3. Adjust nozzle/tip relationship.
4. Adjust gun to the base metal relationship.
5. Repair all cables & connections.
3. Tip disengages from the gas diffuser| 1. Worn gas diffuser.
2. Improper tip installation.
3. Extreme heat or duty cycle.| 1. Replace tip and/or gas diffuser.
2. Install as per ‘Maintenance & Repair’ (Section 3).
3. Replace with heavy-duty consumables. See the appropriate spec sheet for details.
4. Short contact tip life| 1. Contact tip size.
2. Electrode eroding contact tip.
3. Exceeding duty cycle.| 1. Replace with proper size.
2. Inspect and/or change drive rolls.
3. Replace with a properly rated Bernard gun.
5. Erratic arc| 1. Worn contact tip.
2. Buildup inside of the liner.
3. Wrong tip size.
4. Not enough bend in the neck.| 1. Replace.
2. Replace the liner, and check the condition of the electrode.
3. Replace with correct size tip.
4. Replace with 45º or 60º neck.
6. Erratic wire feeding| 1. Buildup inside of the liner.
2. Wrong size liner.
3. Improper drive roll size.
4. Worn drive roll.
5. Improper guide tube relationship.
6. Improper wire guide diameter.
7. Gaps at liner junctions.
8. Feeder malfunction.
9. Contact tip.| 1. Replace the liner, and check the condition of the electrode.
2. Replace with a new liner of proper size.
3. Replace with proper size drive roll.
4 a. Replace with a new drive roll.
b. Stone edge of the groove on drive roll.
5 a. Adjust/replace guide as close to driving rolls as possible.
b. Eliminate all gaps in the electrode path.
6. Replace with proper guide diameter.
7 a. Replace with new liner trimming as per ‘Maintenance & Repair’ (Section 5).
b. Replace guide tube/liner, and trim as close to the mating component as possible.
8. Consult feeder manufacturer.
9. Inspect and replace.
7. Extreme spatter| 1. Improper machine parameters.
2. Improper tip installation.
3. Improper shielding.
4. Contaminated wire or workpiece.| 1. Adjust parameters.
2. Adjust nozzle/tip relationship.
3 a. Verify shielding gas coverage.
b. Verify gas mixture.
4. Clean wire and workpiece.
8. Porosity in weld| 1. Insulator worn.
2. Gas diffuser damaged.
3. Extreme heat or duty cycle.
4. Solenoid faulty.
5. No gas.
6. Flow improperly set.
7. Gas ports plugged.
8. Ruptured gas hose.
9. Control circuit loss.
10. Worn, cut, or missing O-rings.
11. Loose fittings.| 1. Replace nozzle/insulator.
2. Replace the gas diffuser.
3. Replace with heavy-duty consumables.
4. Replace solenoid.
5 a. Install full tanks.
b. Check supply.
c. Hose leaks.
6. Adjust.
7 a. Clean or replace the gas diffuser.
b. Clean nozzle.
8. Repair or replace cable or line.
9. See ‘Electrode Does Not Feed’.
10. Replace O-rings
11. Tighten gun & cable connections to the specified torque. See ‘Maintenance & Repair’ (Section 8).
9. Gun running hot| 1. Exceeding duty cycle.
2. Loose or poor power connection.
3. Improper water flow
4. Exceeds water cooler capacity| 1. a. Replace with properly rated Bernard gun.
b. Decrease parameters to within gun rating.
2. a. Clean, tighten or replace cable grounding connection.
b. Tighten gun & cable connections to the specified torque. See ‘Maintenance & Repair’ (Section 8).
3. Verify proper water flow
4. Replace with a properly rated water cooler
10. Liner is discolored full length| 1. Short circuit to the electrode.
2. Broken copper stranding in the power cable.| 1. Isolate electrode reel from feeder and drive block. Consult feeder manufacturers manual.
2. Replace power cable assembly as per ‘Maintenance & Repair’ (Section 8).
11. Sporadic feeding of aluminum electrode| 1. Tip galling.
2. Synthetic liner melting.
3. Wire deformed by feed rolls.| 1. Inspect & replace.
2. a. Replace liner.
b. Replace with composite liner.
3. Adjust drive rolls as per feeder manufacturer’s manual.

*In some cases with aluminum and mild steel, it may be necessary to use a contact tip with either a larger or smaller bore size.

NOTES

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 smartphone for immediate access to Tregaskiss.com/TechnicalSupport.

http://DELIVR.COM/2BPH6-QR

Bernard
449 W. Corning Rd.
Beecher, IL 60401
Tregaskiss.com
Phone: 1-855-MIGWELD (644-9353) (US & Canada)
+1-519-737-3000 (International)
Fax: 1-708-946-6726

References

• Semi-Automatic MIG Guns, Robotic MIG Guns, Fixed Automatic Torches, Nozzle Cleaning Stations, and Welding Consumables - Tregaskiss and Bernard
• American Welding Society (AWS) - Welding Excellence Worldwide
• Semi-Automatic MIG Guns, Robotic MIG Guns, Fixed Automatic Torches, Nozzle Cleaning Stations, and Welding Consumables - Tregaskiss and Bernard
• Product Certification & Standards Development - CSA Group
• NFPA | The National Fire Protection Association
• P65Warnings.ca.gov

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