Bernard OM-BTB-2.2 Manuale utente

Semi-Automatic, Air-Cooled, MIG (GMAW)

Welding Gun

BernardWelds.com/TechnicalSupport

1-855-MIGWELD (644-9353) (US&Canada)

+1-519-737-3000 (International)

August 2020 OM-BTB-2.2

Bernard®BTB Semi-Automatic

Air-Cooled MIG Gun

OWNER'S MANUAL

Thank You for Choosing Bernard

Thank you for selecting a Bernard product. The MIG gun you have purchased has been carefully assembled and is ready to weld and

factory tested prior to shipment to ensure high performance. 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. 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

BernardWelds.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) or fax 1-708-946-6726. 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 premium Bernard products, contact your local Bernard distributor or visit us on

the web at BernardWelds.com.

Subject to Change – The information presented in this manual is accurate to the best of our knowledge at the time

of printing. Please visit BernardWelds.com for the most up-to-date information.

Additional Material – For additional support materials such as spec sheets, troubleshooting information, how-to

guides and videos, animations, online configurators and much more, please visit BernardWelds.com.

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TABLE OF CONTENTS

DECLARATION OF CONFORMITY V

SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING 1

1-1 Symbol Usage 1

1-2 Arc Welding Hazards 1

1-3 Additional Symbols For Installation, Operation, And Maintenance 4

1-4 California Proposition 65 Warnings 6

1-5 EMF Information 6

1-6 Principal Safety Standards 6

1-7 Commercial Warranty 7

SECTION 2 — SPECIFICATIONS 8

2-1 Specifications 8

2-2 Duty Cycle and Overheating 8

SECTION 3 — INSTALLATION 9

3-1 Installing to a Feeder with a Power Pin 9

3-2 Installing to a Feeder with a Euro or a Bernard® Power Pin 9

SECTION 4 — OPERATION 10

4-1 Pulling the Trigger 10

SECTION 5 — REPLACEMENT 11

5-1 Changing Consumables 11

5-2 Changing the Liner 12

5-3 Changing the Neck 14

5-4 Changing the Handle and Switch 16

5-5 Changing the Power Pin 18

SECTION 6 — PARTS LIST 19

6-1 BSeries Regular and Small Curved Handles with Yellow Trigger 19

6-2 OSeries Small Curved Handle with Blue Trigger 20

6-3 OSeries Curved Handle with Blue Trigger 21

6-4 TSeries Small Straight Handle with Black Trigger 22

6-5 TSeries Straight Handle with Silver Trigger 23

6-6 CSeries Straight Handle with Black Trigger 24

SECTION 7 — CONSUMABLE PARTS 25

7-1 Centerfire™ Consumable Series 25

7-2 Centerfire HD Consumable Series 26

OM-BTB-2.2 iii

7-3 Quik Tip™ Consumable Series 27

7-4 Quik Tip HDConsumable Series 28

7-5 TOUGH LOCK™ Consumable Series 29

SECTION 8 — TROUBLESHOOTING 31

8-1 Troubleshooting Table 31

ADDITIONAL SUPPORT MATERIALS 33

iv OM-BTB-2.2

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 Q20 Series – 200A Q20XXXXXXXX (Configurable #)

Bernard Q30 Series – 300A Q30XXXXXXXX (Configurable #)

Bernard Q40 Series – 400A Q40XXXXXXXX(Configurable #)

Bernard Q50 Series – 500A Q50XXXXXXXX(Configurable #)

Bernard Q60 Series – 600A Q60XXXXXXXX(Configurable #)

Bernard S30 Series – 300A S30XXXXXXXX(Configurable #)

Bernard S40 Series – 400A S40XXXXXXXX(Configurable #)

Bernard S50 Series – 500A S50XXXXXXXX(Configurable #)

Bernard S60 Series – 600A S60XXXXXXXX(Configurable #)

Council Directives:

l2006/95/EC Low Voltage

l2011/65/EU Restriction of the use of certain hazardous substances in electrical and

Electronic equipment standards:

lIEC 60974-7:2013 Arc welding equipment – Part 7: Torches

Signatory:

March 16, 2014

David A. Werba

MANAGER, PRODUCT DESIGN COMPLIANCE

Date of Declaration

OM-BTB-2.2 v

Protect yourself and others from injury – read,

follow, and save these important safety precautions

and operating instructions.

1-1 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 haz-

ards 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.

1-2 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 the Principal Safety Standards

section. 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.

Touching live electrical parts can cause fatal

shocks or severe burns. The electrode and work

circuit is electrically live whenever the output is on.

The input power circuit and machine internal

circuits are also live when power is on. In semi-

automatic or automatic wire welding, the wire, wire

reel, drive roll housing, and all metal parts

touching the welding wire are electrically live.

Incorrectly installed or improperly grounded equipment is a

hazard.

lDo not touch live electrical parts.

lWear dry, hole-free insulating gloves and body protection.

lInsulate yourself from work and ground using dry insulating

mats or covers big enough to prevent any physical contact

with the work or ground.

lDo not use ACweld output in damp, wet, or confined

spaces, or if there is a danger of falling.

lUse ACoutput ONLY if required for the welding process.

lIf AC output is required, use remote output control if present

on unit.

lAdditional safety precautions are required when any of the

following electrically hazardous conditions are present: in

damp locations or while wearing wet clothing; on metal

structures such as floors, gratings, or scaffolds; when in

cramped positions such as sitting, kneeling, or lying; or

when there is a high risk of unavoidable or accidental

contact with the workpiece or ground. For these conditions,

use the following equipment in order presented: 1) a semi-

automatic DCconstant voltage (wire) welder, 2) a DCmanual

(stick) welder, or 3) an ACwelder with reduced open-circuit

voltage. In most situations, use of a DC, constant voltage

wire welder is recommended. And, do not work alone!

lDisconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power

according to OSHA 29 CFR 1910.147 (see Principal Safety

Standards).

lProperly install, ground, and operate this equipments

according to its Owner's Manual and national, state, and

local codes.

lAlways verify the supply ground – check and be sure that

input power cord ground wire is properly connected to

ground terminal in disconnect box or that cord plug is

connected to a properly grounded receptacle outlet.

lWhen making input connections, attach proper grounding

conductor first – double-check connections.

lKeep cords dry, free of oil and grease, and protected from

hot metal and sparks.

lFrequently inspect input power cord and ground conductor

for damage or bare wiring – replace immediately if damaged

– bare wiring can kill.

OM-BTB-2.2 1

SECTION 1 — SAFETY PRECAUTIONS — READ BEFORE USING

lTurn off all equipment when not in use.

lDo not use worn, damaged, undersized, or repaired cables.

lDo not drape cables over your body.

lIf earth grounding of the workpiece is required, ground it

directly with a separate cable.

lDo not touch electrode if you are in contact with the work,

ground, or another electrode from a different machine.

lDo not touch electrode holders connected to two welding

machines at the same time since double open-circuit voltage

will be present.

lUse only well-maintained equipment. Repair or replace

damaged parts at once. Maintain unit according to Manual.

lWear a safety harness if working above floor level.

lKeep all panels and covers securely in place.

lClamp work cable with good metal-to-metal contact to

workpiece or worktable as near the weld as practical.

lInsulate work clamp when not connected to workpiece to

prevent contact with any metal object.

lDo not connect more than one electrode or work cable to

any single weld output terminal. Disconnect cable for

process not in use.

lUse GFCI protection when operating auxiliary equipment in

damp or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter welding

power sources AFTERremoval of input power.

lTurn off unit, disconnect input power, and discharge input

capacitors according to instructions in Manual before

touching any parts.

HOT PARTS can burn.

lDo not touch hot parts bare handed.

lAllow cooling period before working on

equipment.

lTo handle hot parts, use proper tools and/or wear heavy,

insulated welding gloves and clothing to prevent burns.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

lKeep your head out of the fumes. Do not breathe the fumes.

lVentilate the work area and/or use local forced ventilation at

the arc to remove welding fumes and gases. The

recommended way to determine adequate ventilation is to

sample for the composition and quantity of fumes and

gases to which personnel are exposed.

lIf ventilation is poor, wear an approved air-supplied

respirator.

lRead and understand the Safety Data Sheets (SDSs) and the

manufacturer's instructions for adhesives, coatings,

cleaners, consumables, coolants, degreasers, fluxes, and

metals.

lWork in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained

watch-person nearby. Welding fumes and gases can

displace air and lower the oxygen level causing injury or

death. Be sure the breathing air is safe.

lDo not weld in locations near degreasing, cleaning, or

spraying operations. The heat and the rays of the arc can

react with vapors to form highly toxic and irritating gases.

lDo not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from

the weld area, the area is well ventilated, and while wearing

an air-supplied respirator. The coatings and any metals

containing these elements can give off toxic fumes if

welded.

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.

lWear an approved welding helmet fitted with a proper shade

of filter lenses to protect your face and eyes from arc rays

and sparks when welding or watching (see ANSI Z49.1 and

Z87.1 listed in Principal Safety Standards).

lWear approved safety glasses with side shields under your

helmet.

lUse protective screens or barriers to protect others from

flash, glare and sparks; warn others not to watch the arc.

lWear body protection made from durable, flame-resistant

material (leather, heavy cotton, wool). Body protection

includes oil-free clothing such as leather gloves, heavy shirt,

cuffless trousers, high shoes, and a cap.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up.

Sparks can fly off from the welding arc. The flying

sparks, hot workpiece, and hot equipment can

cause fires and burns. Accidental contact of

electrode to metal objects can cause sparks, explosion,

overheating, or fire. Check and be sure the area is safe before

doing any welding.

lRemove all flammables within 35 ft (10.7 m) of the welding

arc. If this is not possible, tightly cover them with approved

covers.

lDo not weld where flying sparks can strike flammable

material.

lProtect yourself and others from flying sparks and hot metal.

2 OM-BTB-2.2

lBe alert that welding sparks and hot materials from welding

can easily go through small cracks and openings to adjacent

areas.

lWatch for fire, and keep a fire extinguisher nearby.

lBe aware that welding on a ceiling, floor, bulkhead, or

partition can cause fire on the hidden side.

lDo not cut or weld on tire rims or wheels. Tires can explode

if heated. Repaired rims and wheels can fail. See OSHA 29

CFR 1910.177 listed in Principal Safety Standards.

lDo 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 Principal Safety Standards).

lDo not weld where the atmosphere can contain flammable

dust, has, or liquid vapors (such as gasoline).

lConnect work cable to the work as close to the welding area

as practical to prevent welding current from traveling long,

possibly unknown paths and causing electric shock, sparks,

and fire hazards.

lDo not use welder to thaw frozen pipes.

lRemove stick electrode from holder or cut off welding wire

at contact tip when not in use.

lWear body protection made from durable, flame-resistant

material (leather, heavy cotton, wool). Body protection

includes oil-free clothing such as leather gloves, heavy shirt,

cuffless trousers, high shoes, and a cap.

lRemove any combustibles, such as a butane lighter or

matches, from your person before doing any welding.

lAfter completion of work, inspect area to ensure it is free of

sparks, glowing embers, and flames.

lUse only correct fuses or circuit breakers. Do not oversize or

bypass them.

lFollow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA

51B for hot work and have a fire watcher and extinguisher

nearby.

lRead and understand the Safety Data Sheets (SDSs) and the

manufacturer's instructions for adhesives, coatings,

cleaners, consumables, coolants, degreasers, fluxes, and

metals.

FLYING METAL or DIRT can injure eyes.

lWelding, chipping, wire brushing, and

grinding cause sparks and flying metal. As

welds cool, they can throw off slag.

lWear approved safety glasses with side shields even under

your welding helmet.

BUILDUP OF GAS can injure or kill.

lShut off compressed gas supply when not in

use.

lAlways ventilate confined spaces or use approved air-

supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF) can

affect Implanted Medical Devices.

lWearers of Pacemakers and other Implanted

Medical Devices should keep away.

lImplanted Medical Device wearers should consult their

doctor and the device manufacturer before going near arc

welding, spot welding, gouging, plasma arc cutting, or

induction heating operations.

NOISEcan damage hearing.

Noise from some processes or equipment can

damage hearing.

lWear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode.

Since gas cylinders are normally part of the

welding process, be sure to treat them carefully.

lProtect compressed gas cylinders from excessive heat,

mechanical shocks, physical damage, slag, open flames,

sparks, and arcs.

lInstall cylinders in an upright position by securing to a

stationary support or cylinder rack to prevent falling or

tipping.

lKeep cylinders away from any welding or other electrical

circuits.

lNever drape a welding torch over a gas cylinder.

lNever allow a welding electrode to touch any cylinder.

lNever weld on a pressurized cylinder – explosion will result.

lUse only correct compressed gas cylinders, regulators,

hoses, and fittings designed for the specific application;

maintain them and associated parts in good condition.

lTurn face away from valve outlet when opening cylinder

valve. Do not stand in front of or behind the regulator when

opening the valve.

lKeep protective cap in place over valve except when cylinder

is in use or connected for use.

lUse the proper equipment, correct procedures, and

sufficient number of persons to lift, move, and transport

cylinders.

lRead and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association

(CGA) publication P-1 listed in Principal Safety Standards.

OM-BTB-2.2 3

1-3 Additional Symbols For Installation,

Operation, And Maintenance

FIRE OR EXPLOSION hazard.

lDo not install or place unit on, over, or near

combustible surfaces.

lDo not install unit near flammables.

lDo not overload building wiring – be sure power supply

system is properly sized, rated, and protected to handle this

unit.

FALLING EQUIPMENT can injure.

lUse lifting eye to lift unit only, NOTrunning

gear, gas cylinders, or any other accessories.

lUse correct procedures and equipment of

adequate capacity to lift and support unit.

lIf using fork lifts to move unit, be sure forks are long

enough to extend beyond the opposite side of unit.

lKeep equipment (cables and cords)away from moving

vehicles when working from an aerial location.

lFollow the guidelines in the Applications Manual for the

Revised NIOSH Lifting Equation (Publication No. 94-

110)when manually lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING.

lAllow cooling period; follow rated duty cycle.

lReduce current or reduce duty cycle before

starting to weld again.

lDo not block or filter airflow to unit.

FLYING SPARKS can injure.

lWear a face shield to protect eyes and face.

lShape tungsten electrode only on grinder

with proper guards in a safe location wearing

proper face, hand, and body protection.

lSparks can cause fires – keep flammables away.

STATIC (ESD)can damage PCboards.

lPut on grounded wrist strap BEFORE

handling boards or parts.

lUse proper static-proof bags and boxes to store, move, or

ship PCboards.

MOVING PARTS can injure.

lKeep away from moving parts.

lKeep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

lDo not press gun trigger until instructed to

do so.

lDo not point gun toward any part of the body, other people,

or any metal when threading welding wire.

BATTERY EXPLOSION can injure.

lDo not use welder to charge batteries or jump

start vehicles unless it has a battery charging

feature designed for this purpose.

MOVING PARTS can injure.

lKeep away from moving parts such as fans.

lKeep all doors, panels, covers, and guards

closed and securely in place.

lHave only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

lReinstall doors, panels, covers, or guards when maintenance

is finished and before reconnecting input power.

COMPRESSED AIR can injure or kill.

lBefore working on compressed air system,

turn off and lockout/tagout unit, release

pressure, and be sure air pressure cannot be

accidentally applied.

lRelieve pressure before disconnecting or

connecting air lines.

lCheck compressed air system components and all

connections and hoses for damage, leaks, and wear before

operating unit.

lDo not direct air stream toward self or others.

lWear protective equipment such as safety glasses, hearing

protection, leather gloves, heavy shirt and trousers, high

shoes, and a cap when working on compressed air system.

lUse soapy water or an ultrasonic detector to search for leaks

– never use bare hands. Do not use equipment if leaks are

found.

lReinstall doors, panels, covers, or guards when servicing is

finished and before starting unit.

lIf ANY air is injected into the skin or body, seek medical help

immediately.

4 OM-BTB-2.2

READ INSTRUCTIONS.

lRead and follow all labels and the Owner's

Manual carefully before installing, operating,

or servicing unit. Read the safety information

at the beginning of the Manual and in each section.

lUse only genuine replacement parts from the manufacturer.

lPerform installation, maintenance, and service according to

the Owner's Manuals, industry standards, and national,

state, and local codes.

H.F. RADIATION can cause interference.

lHigh-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

lHave only qualified persons familiar with electronic

equipment perform this installation.

lThe user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the

installation.

lIf notified by the FCCabout interference, stop using the

equipment at once.

lHave the installation regularly checked and maintained.

lKeep high-frequency source doors and panels tightly shut,

keep spark gaps at correct setting, and use grounding and

shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

lElectromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

lBe sure all equipment in the welding area is

electromagnetically compatible.

lTo reduce possible interference, keep weld cables as short

as possible, close together, and down low, such as on the

floor.

lLocate welding operation 100 meters from any sensitive

electronic equipment.

lBe sure the welding machine is installed and grounded

according to the Manual.

lIf interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

OM-BTB-2.2 5

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