Bernard BTB MIG Guns 200, 300, 400, 500, 600 amp

OM-BTB-1.5

Feb. 2016

Processes

MIG (GMAW) Welding

Description

Semi-Automatic, Air-Cooled, MIG

(GMAW) Welding Gun

Bernard BTB MIG Guns

OWNER’S MANUAL

Bernard

A Division of Miller Electric Mfg. Co.

449 West Corning Road, Box 667

Beecher, Illinois 60401 USA

Phone: 1-855-MIGWELD (644-9353)

(US & Canada)

1-519-737-3030

(International)

Fax: 708-946-6726

For more information, visit us at BernardWelds.com

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) (Canada & US) or 1-519-737-3030 (International) or fax 1-708-946-6726. Our trained

Customer Service Team is available between 8:00 a.m. and 4:30 p.m. CST, and will answer your product application or repair questions.

Bernard manufactures premium semi-automatic GMAW (MIG) 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

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

Scan this QR Code with your smart phone for immediate access to

BernardWelds.com/TechnicalSupport

TABLE OF CONTENTS

DECLARATION OF CONFORMITY.....................................................................................................

SECTION 1 - SAFETY PRECAUTIONS FOR GMAW WELDING GUNS - READ BEFORE USING. .........................

1-1 Fume and Gas Hazards................................................................................................................................................

1-2 Arc Rays and Welding Hazards..................................................................................................................................

1-3 Additional Safety Warnings for Installation, Operation and Maintenance.............................................................

1-4 California Proposition Warning...................................................................................................................................

1-5 EMF Information...........................................................................................................................................................

1-6 Principal Safety Standards..........................................................................................................................................

1-7 Commercial Warranty...................................................................................................................................................

SECTION 2 - SPECIFICATIONS .......................................................................................................................

2-1 Specifications................................................................................................................................................................

2-2 Duty Cycle and Overheating........................................................................................................................................

SECTION 3 - INSTALLATION...........................................................................................................

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

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

SECTION 4 - OPERATION...............................................................................................................

4-1 Pulling the Trigger.........................................................................................................................................................

SECTION 5 - REPLACEMENT...........................................................................................................

5-1 Changing Consumables...............................................................................................................................................

5-2 Changing the Liner.......................................................................................................................................................

5-3 Changing the Neck.......................................................................................................................................................

5-4 Changing the Handle and Switch...............................................................................................................................

5-5 Changing the Power Pin..............................................................................................................................................

SECTION 6 - PARTS LIST...............................................................................................................

13

14

15

17

9

10

10

11

8

8

8

9

7

7

6

7

6

6

4

6

2

2

1

2

6-1 200, 300, 400 amp

B Series Small & Large

Handle with yellow trigger

Pg. 17

6-2 200, 300, 400 amp

O Series Small Handle with blue trigger

Pg. 18

6-3 400, 500, 600 amp

O Series Large Handle with blue trigger

Pg. 19

6-4 300 amp

T Series Small Handle with black trigger

Pg. 20

6-5 300, 400, 500, 600 amp

T Series Large Handle with silver trigger

Pg. 21

SECTION 7 - CONSUMABLE PARTS.................................................................................................

7-1 Centerfire™ Consumable Series.................................................................................................................................

7-2 Quik Tip™ Consumable Series....................................................................................................................................

7-3 Centerfire HD Consumable Series..............................................................................................................................

7-4 Quik Tip HD Consumable Series................................................................................................................................

7-5 TOUGH LOCK™ Consumable Series..........................................................................................................................

SECTION 8 - TROUBLESHOOTING...................................................................................................

8-1 Troubleshooting Table.................................................................................................................................................

24

25

26

26

22

22

23

24

Subject to Change – The information presented in this owner’s 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.

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

Bernard Welding, 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

Bernard Q20 Series – 200A





Bernard S30 Series – 300A




Stock Number

Q20XXXXXXX (Configurable #)





S30XXXXXXX (Configurable #)




Council Directives:

• 2006/95/EC Low Voltage

• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:

• IEC 60974-7:2013 Arc welding equipment – Part 7: Torches

Signatory:

_____________________________________ ___________________________________________

David A. Werba Date of Declaration

May 16, 2014

MANAGER, PRODUCT DESIGN COMPLIANCE

Page 1

SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING

1-1 Fume and Gas Hazards

WELDING AND CUTTING can cause fire or explosion

FUMES AND GASES can be hazardous

Welding and cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

Welding or cutting on closed containers, such as tanks, drums or pipes can cause them to blow up. Sparks can fly off from the welding or cutting arc. The flying sparks, hot work piece 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 or cutting.

• Keep your head out of the fumes. Do not breathe the fumes.

• If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding and cutting 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.

• If ventilation is poor, wear an approved air-supplied respirator.

• Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes and metals.

• Work 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 and cutting fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

• Do not weld or cut in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

• Do not weld or cut 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.

1-2 Arc Rays and Welding Hazards

ARC RAYS can burn eyes and skin

Arc rays from welding and cutting processes produce intense visible and invisible

(ultraviolet and infared) rays that can burn eyes and skin. Sparks fly off from the weld.

• Wear 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, cutting or watching (see ANSI

Z49.1 and Z87.1 listed 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 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.

• Remove all flammables within 35 ft (10.7 m) of the welding or cutting arc. If this is not possible, tightly cover them with approved covers.

• Do not weld or cut where flying sparks can strike flammable material.

• Protect yourself and others from flying sparks and hot metal.

• Be alert that welding sparks and hot materials from welding and cutting can easily go through small cracks and opening to adjacent areas.

• Watch for fire, and keep a fire extinguisher nearby.

• Be aware that welding or cutting on a ceiling, floor, bulkhead or partition can cause fire on the hidden side.

• Do not weld or cut 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).

• Do not weld or cut where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).

• Connect work cable to the work as close to the welding or cutting area as practical to prevent welding or cutting current from traveling long, possibly unknown paths and causing electric shock, sparks and fire hazards.

• Do not use welder to thaw frozen pipes.

• Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

• Wear 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.

• Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding or cutting.

• After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.

• Use only correct fuses or circuit breakers. Do not oversize or bypass them.

• Follow requirements in OSHA 1910.252 (a) (2) (iv) and

NFPA 51B for hot work and have a fire watcher and 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.

Page 2

ELECTRIC SHOCK can kill

Touching live electrical parts can cause fatal shock or servere 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 semiautomatic 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.

• Do not touch live electrical parts.

• Wear dry, hole-free insulating gloves and body protection.

• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

• Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

• Use AC output ONLY if required for the welding or cutting process.

• If AC output is required, use remote output control if present on unit.

• Additional 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, 2) a

DC manual (stick) welder or 3) an AC welder with reduced open-circuit wolage. In most situations, use of a DC, constant voltage wire welder is recommended and do not work alone!

• Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety

Standards).

• Properly install, ground and operate this equipment according to its Owner’s Manual and national, state/ provincial and local codes.

• Always 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.

• When making input connections, attach proper grounding conductor first and double-check connections.

• Keep cords dry, free of oil and grease and protected from hot metal and sparks.

• Frequently inspect input power cord for damage or bare wiring. Replace cord immediately if damaged. Bare wiring can kill.

• Turn off all equipment when not in use.

• Do not use worn, damaged, undersized or poorly spliced cables.

• Do not drape cables over your body.

Page 3

• If earth grounding of the workpiece is required, ground it directly with a separate cable.

• Do not touch electrode if you are in contact with the work, ground or another electrode from a different machine.

• Do not touch electrode holders connected to two welding machines at the same time since double open circuit voltage will be present.

• Use only well maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

• Wear a safety harness if working above floor level.

• Keep all panels and covers securely in place.

• Clamp work cable with good metal-to-metal contact to workpice or worktable as near the weld as practical.

• Insulate work clamp when not connected to workpiece to prevent contact with any metal object.

• Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process when not in use.

CYLINDERS CAN EXPLODE if damaged

Compressed gas cylinders contain gas under high presure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

• Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks and arcs.

• Install cylinders in an uprigth position by securing to a stationary support or cylinder rack to prevent falling or tipping.

• Keep cylinders away from any welding, cutting or other electrical circuits.

• Never drape a welding electrode or cutting torch over a gas cylinder.

• Never allow a welding electrode or cutting torch to touch any cylinder.

• Never weld on a pressurized cylinder – explosion will result.

• Use only correct compressed gas cylinders, regulators, hoses and fittings designed for the specific application; maintain them and associated parts in good condition.

• Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve.

• Keep protective cap in place over valve except when cylinder is in use or connected for use.

• Use the right equipment, correct procedures and sufficient number of persons to lift and move cylinders.

• Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed

Gas Association (CGA) publication P-1 listed in Safety

Standards.

1-3 Additional Safety Warnings for

Installation, Operation and Maintenance

HOT PARTS can burn

• Do not touch hot parts bare handed.

• Allow cooling period before working on

equpment.

• To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves

and clothing to prevent burns.

FLYING METAL or DIRT can injure or kill

• Welding, cutting, chipping, wire brushing and

grinding cause sparks and flying metal. As

welds cool, they throw off slag.

• Wear approved safety glasses with side shields even under your welding helmet.

BUILDUP OF GAS can kill

• Shut off compressed gas supply when not in

use.

• Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF) can affect implanted Medical Devices

• Wearers of Pacemakers and other Implanted

Medical Devies should keep away.

• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cuting or induction.

NOISE can damage hearing

• Noise from some processes or equipment can

damage hearing.

• Wear approved ear protection if noise level is

high.

FIRE OR EXPLOSION hazard

• Do not install or place unit on, over, or near

combustible surfaces.

• Do not install unit near flammables.

• Do not overload building wiring – be sure power supply system is properly sized, rated and protected to handle this unit.

MOVING PARTS can injure

• Keep away from moving parts such as fans.

• Keep all doors, panels, covers and guards closed and securely in place.

• Have only qualified persons remove doors, panels, covers or guards for maintenance and troubleshooting as necessary.

• Reinstall doors, panels, covers or guards when maintenance is finished and before reconnecting input power.

• Keep away from pinch points such as drive rolls

FLYING SPARKS can injure

• Wear a face shield to protect eyes

and face.

• Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand and body protection.

• Sparks can cause fire – keep flammables away.

READ INSTRUCTIONS

• Read 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.

• Use only genuine replacement parts from the manufacturer.

• Perform maintenance and service according to the

Owner’s Manual, industry standards and national, state/provincial and local codes.

WELDING WIRE can injure

• Do not press gun trigger until

instructed to do so.

• Do not point gun toward any part of

the body, other people or any metal when threading welding wire.

Page 4

COMPRESSED AIR can injure or kill

• Before working on compressed air system,

turn off and lockout/tagout unit, release

pressure and be sure air pressure cannot be

accidentally applied.

• Relieve pressure before disconnecting or

connecting air lines.

• Check compressed air system components and

all connections and hoses for damage, leaks

and wear before operating unit.

• Do not direct air stream toward self or others.

• Wear 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.

• Use soapy water or an ultrasonic detector to search for leaks

— never use base hands. Do not use equipment if leaks are found.

TRAPPED AIR PRESSURE AND WHIPPING

HOSES can injure

• Release air pressure from tools and system

before servicing, adding or changing

attachments or opening compressor oil drain or oil fill cap.

H.F. RADIATION can cause interference

• High-frequency (H.F.) can interfere with radio

navigation, safety services, computers and

communications equipment.

• Have only qualified persons familiar with electronic equipment perform this installation.

• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

• Have the installation regularly checked and maintained.

• If notified by the FCC about interference, stop using the equipment at once.

• Keep 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 AND PLASMA CUTTING can cause interference

• Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment such as robots.

• Be sure all equipment in the welding area is electromagnetically compatible.

• To reduce possible interference, keep cables as short as possible, close together, and down low, such as on the floor.

• Locate welding or cutting operation 100 meters from any sensitive electronic equipment.

• Be sure welding machine or plasma cutter is installed and grounded according to its Owner’s Manual.

• If interference still occurs, the user must take extra measures such as moving the welding or cutting machine, using shielded cables, using line filters, or shielding the work area.

OVERUSE CAN CAUSE OVERHEATING

• Allow cooling period; follow rated duty cycle.

• Reduce current or reduce duty cycle before

starting to weld again.

• Do not block or filter airflow to unit.

Page 5

1-4 California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases, cancer. (California Health & Safety Code

Section 25249.5 et seq.)

1-5 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:

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.

This product contains chemicals, including lead, known to the state of California to cause cancer, and birth defects or other reproductive harm. Wash hands after use.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.

5. Connect work clamp to 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 while carrying the welding power source or wire

feeder.

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.

1-6 Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard

Z49.1, is available as a free download from the American

Welding Society at http://www.aws.org or purchased from Global

Engineering Documents (phone: 1-877-413-5184, website: www.

global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for

Welding and Cutting, American Welding Society Standard AWS

F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-1, from Compressed Gas Association, 14501 George Carter Way,

Suite103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.

cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, from Canadian Standards Association, Standards Sales,

5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

1-7 Commercial Warranty

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 rear strain relief are covered by a lifetime warranty.

Bernard reserves the right to repair, replace or refund the purchase price of non-conforming 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

Safe Practice For Occupational And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National

Standards Institute, 25 West 43rd Street, New York, NY 10036

(phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other

Hot Work, NFPA Standard 51B, from National Fire Protection

Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General

Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,

Subpart Q, and Part 1926, Subpart J, from U.S. Government

Printing Office, Superintendent of Documents, P.O. Box 371954,

Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are

10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-

353-2220, website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The

National Institute for Occupational Safety and Health (NIOSH),

1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).

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.

Page 6

SECTION 2 - SPECIFICATIONS

2-1 Specifications

Air-Cooled MIG Guns for GMAW Welding

200 amp gun feeds maximum wire size of 1/16” (1.6 mm)

Duty Cycle Rating:

100%: 200 Amp with

CO

2

Shielding gas

60%: 200 Amp with Mixed Gases



100%: 300 Amp with

CO

2

Shielding Gas




100%: 400 Amp with

CO

2

Shielding Gas




100%: 500 Amp with

CO

2

Shielding Gas




100%: 600 Amp with

CO

2

Shielding Gas


2-2 Duty Cycle and Overheating

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

Using mixed gases other than CO

2 reduces duty cycle ratings 10-50% depending on gas mixture and welding parameters.

Please reference chart above for duty cycle ratings by amperage

Continuous Welding

0

15

Minutes

A or V

OR

Reduce Duty Cycle

Page 7

SECTION 3 - INSTALLATION

3-1 Installing to a Feeder with a Power Pin

1. Insert power pin to shoulder and

secure tightly.

2. Insert control plug into feeder.

3. Feed welding wire into power

pin by hand and tighten drive rolls.

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

Euro Power Pin

1. Insert the Euro power pin to face of

receptacle. Thread Euro hand

nut clockwise to tighten.

Bernard Power Pin

1. Insert the Bernard power pin to face

of receptacle. Engage and rotate

locking sleeve to tighten

Page 8

4-1 Pulling the Trigger

SECTION 4 - OPERATION

1

1

1. Trigger - When pressed,

energized wire feeds and

shielding gas flows.

Page 9

SECTION 5 - REPLACEMENT

5-1 Changing Consumables

3

2

1

3

2

A

1

3

2

B

1

C

A. Changing Quik Tip

™

Consumables

1. Remove threaded nozzle by turning in a counterclockwise

direction. Slip-on nozzle can be removed with a slipping

and pulling motion

2. Cut electrode and remove all burrs before removing

contact tip. Remove the Quik Tip contact tip from the gas

diffuser with a 1/4 turn counterclockwise. To replace slide

the contact tip over electrode into gas diffuser and lock

with a 1/4 turn clockwise rotation.

3. Gas diffuser may be removed with an appropriate wrench

in a counterclockwise rotation. To install firmly secure

gas diffuser with an appropriate wrench in a clockwise

rotation, torque to 144 in-lbs.

B. Changing Centerfire

™

Consumables


contact tip. Remove threaded nozzle by turning in a

counterclockwise direction.

2. Pull the Centerfire contact tip from the gas diffuser. To

replace slide the contact tip over electrode into gas

diffuser and lock by installing nozzle onto gas diffuser.

Nozzle is used to secure contact tip.

3. Gas diffuser may be removed with an appropriate

wrench in a counterclockwise rotation. To install

firmly secure gas diffuser with an appropriate wrench

in a counter clockwise rotation, torque to 144 in-lbs.

C. Changing TOUGH LOCK

™

Consumables

1. Remove the slip-on nozzle with a twisting and pulling

motion.


contact tip. Remove the TOUGH LOCK contact tip from

the retaining head with a counterclockwise turn.

To replace slide the contact tip over electrode into gas

diffuser and lock with a clockwise rotation.

3. Retaining head may be removed with an appropriate

wrench in a counterclockwise rotation. To install firmly

secure gas diffuser with an appropriate wrench in a

clockwise rotation, torque to 144 in-lbs.

Page 10

5-2 Changing the Liner

A. Changing Universal Conventional Liner

1. Remove nozzle, contact tip, and gas diffuser/

retaining head and lay cable straight. Using a 10

mm wrench, turn liner lock counterclockwise until

it is free from the power pin. Remove liner from

gun assembly.

2. 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.

3. Trim to dimensions shown in the liner chart

below. Remove all burrs from end of liner and

replace gas diffuser/retaining head, contact tip

and nozzle.

New Liner Trim Lengths

Centerfire

™

Diffuser Part Number

D-1

D-1T

Liner Trim Length

9/16"

14.3 mm

13/16"

20.6 mm

D-1T-5

DS-1

DS-1T

DW-1

Quik Tip

™


D114

D114Q

D118

D118Q

D118QLL

D1FQ

13/16"

20.6 mm

9/16"

14.3 mm

5/8"

1/4"

15.9 mm

6.4 mm


5/8"

15.9 mm

9/16"

7/8"

14.3 mm

3/4"

19.1 mm

3/4"

19.1 mm

1-5/16"

33.3 mm

22.2 mm

7/8"

22.2 mm

D218

TOUGH LOCK

™

Retaining Head

Part Number

ALL


3/4"

19.1 mm

1/4"

0 in.

1 1/2"

1 1/4"

5/16"

1"

13/16"

7/8"

3/4"

9/16"

5/8"

1/2"

38.1

33.3

31.75

25.4

22.2

20.6

15.9

14.3

19.05

12.7

6.35

0 mm

Page 11

New Liner Trim Lengths

Centerfire

™


D-1

D-1T


9/16"

14.3 mm

13/16"

20.6 mm

D-1T-5

DS-1

DS-1T

DW-1

Quik Tip

™


D114

D114Q

D118

D118Q

D118QLL

D1FQ

13/16"

20.6 mm

9/16"

14.3 mm

5/8"

1/4"

15.9 mm

6.4 mm


5/8"

15.9 mm

9/16"

7/8"

14.3 mm

3/4"

19.1 mm

3/4"

19.1 mm

1-5/16"

33.3 mm

22.2 mm

7/8"

22.2 mm

D218

TOUGH LOCK

™

Retaining Head

Part Number

ALL


3/4"

19.1 mm

B. Changing QUICK LOAD

™

Liner

1. Remove the nozzle, contact tip and gas diffuser

and lay cable straight. Pull the QUICK LOAD liner

from the end of the neck using pliers.

2. Remove the protective cap from the new QUICK

LOAD liner and insert it through the neck using

the wire as a guide. Feed the liner through the

gun using short strokes to prevent kinking.

3. Once the liner stops feeding, give it an extra

push to ensure it is seated correctly. Push

liner into gun and trim to dimensions shown

on ‘New Liner Trim Lengths’ chart on p. 11.

Remove all burrs from end of liner and replace

gas diffuser, contact tip and nozzle.

C. Changing a Jump Liner

1. Remove the nozzle, contact tip, gas diffuser and

neck. Remove used jump liner from the back

end of neck.

2. Insert new jump liner making sure the

liner stop is fully seated at the back of the neck.

3. Take the tapered end of the neck and insert

into end fitting of the gun handle. Install the

neck.

4. Trim jump liner to dimensions shown on ‘New

Liner Trim Lengths’ chart on p. 11. Deburr the

jump liner past the nozzle end of the neck.

5. Install gas diffuser, contact tip and nozzle.

Page 12

5-3 Changing the Neck

Locking

Collar

Jam Nut

Brass Nut

Lock Nut

A. Changing the Neck - Rotatable

1. To remove neck, grasp lock nut and rotate

counterclockwise. Rotation will free neck from end

fitting. To install the neck, perform the above

instructions in reverse order and torque to 38 in-lbs.

2. Liner may need to be changed if switching to a neck

of a different bend angle or length.

B. Changing the Neck - Fixed with Curved Handle

1. To remove neck, remove the nut insulator.

2. Using a wrench, rotate brass nut counterclockwise,

rotation will free neck from end fitting.

3. To install the neck, perform the above instructions

in reverse order and tighten lock nut to 16 ft-lbs

(21.7 Nm). Be sure nut insulator is in place.

4. Liner may need to be changed if switching to a

neck of a different bend angle or length.

C. Changing the Neck - Fixed with T Series Large

Straight Handle

1. Place neck in vise. Remove both switch mounting

housing screws with an 8 mm nut driver.

2. Slide handle back exposing the cable connection.

Loosen the cable/neck connection using a 7/8”

wrench.

3. Remove from vise and unthread neck by hand.

4. Thread the neck into the cable connection

(hand tighten). Place neck in vise and tighten with a

wrench to within 1/8” (3.2 mm) spacing between the

cable connection and neck.

5. Install the switch and reposition handle and switch

housing.

6. Reinstall switch housing mounting screws.

7. Liner may need to be changed if switching to a neck

of a different bend angle or length.

D. Changing the Neck - Fixed with T Series Small

Straight Handle

1. Loosen and remove locking collar.

2. Place neck in vise, twist handle lock nut

counterclockwise and pull away from handle.

3. Remove screw from handle. Separate handle

halves exposing jam nut and front of unicable.

4. Loosen jam nut using two 19 mm wrenches and

unthread neck. Remove from vise and unthread

neck by hand.

5. Thread jam nut onto new neck. Thread neck into

unicable to desired orientation. Place neck in vise,

tighten unicable and jam nut.

6. Reposition switch and handle. Reinstall handle lock

nut, locking collar and screw.

7. Liner may need to be changed if switching to a

neck of a different bend angle or length.

Page 13

5-4 Changing the Handle and Switch

Locking

Collar

Lock

Nut

A. B Series Small and Large Curved Handle

1. Remove screws and post fasteners

from handles.

2. Separate handle halves and remove trigger.

Remove switch lead connectors with needle

nose pliers.

3. To replace trigger, connect switch lead

connectors onto terminals. Position handle

half and trigger on cable so trigger leads are

not pinched and movement of the trigger is

not impaired.

4. Position the remaining handle half in place.

Reinstall post fasteners and screws; torque

to 10 in-lbs (1.1 Nm).

B. O Series Small and Large Curved Handle

1. Loosen screws, but do not fully remove.

2. Pry open bottom side of handle halves with

a flat blade screw driver. Trigger should be

able to be removed.

3. To replace trigger, install into handle halves

with pivot posts inserted into handle cavities so

movement is not impaired. Tighten screws;

torque to 10 in-lbs (1.1 Nm).

C. T Series Small Straight Handle

1. Loosen and remove locking collar.

2. Twist handle lock nut counterclockwise.

Slide handle lock nut away from handle.

3. Remove screw from handle and separate

handles halves.

4. Remove switch from switch lead connectors

with needle nose pliers.

5. Connect switch lead connectors firmly onto

switch terminals with needle nose pliers.

6. Place gun assembly into handle half

positioning neck in desired position. Fit switch

into switch nest on handle (switch lead must

lie parallel). Reinstall second handle half.

7. Reinstall handle lock nut and locking collar on

handle.

8. Insert screw and tighten.

Page 14

5-5 Changing the Power Pin

D. T Series Large Straight Handle (Switch Only)

1. Remove both housing screws with an

8mm nut driver.

2. Ease switch out of switch

housing with needle nose pliers to grip

switch. Remove switch from switch lead

connectors with needle nose pliers.

3. Push switch lead connectors firmly onto switch

terminals with needle nose pliers.

4. Depress switch housing into nest on handle

(switch leads must lie parallel). Align housing

holes with threaded holes in body and insert

mounting screws. Start both screws first before

tightening with 8 mm nut driver to even

alignment.

A. Universal Power Pin

1. Remove the liner by following the steps listed in the

‘Changing the Liner’ section.

2. Remove the screw and assembly from rear strain

relief and slide rear strain relief back over power

pin. Position control lead wires as necessary to avoid

damaging them.

3. Use wrenches and rotate power pin in a

counterclockwise direction to remove it from the

adapter block.

4. Thread new power pin into adapter block and

use wrenches in a clockwise direction to thread power

pin into adapter block. Torque to 13 ft-lbs (17.6 Nm).

5. Slide rear strain relief over power pin and locate

onto adapter block, aligning flats and screw hole.

Secure with screw, position control lead wires in

cutout on side of strain relief, close strain relief top

and secure assembly by rotating clockwise 1/4 turn.

6. Reinstall liner by following the steps listed in the

‘Changing the Liner’ section.

Page 15

Adaptor Nut

B. Euro Power Pin

1. Remove liner and strain relief from gun assembly. Disconnect

the Euro block leads from gun by cutting as close as possible

on both sides of the butt connectors in order to preserve wire

for later retermination.

2. Slide adaptor nut toward cable, thus exposing the Euro

block. Remove Euro block from end fitting using appropriate

wrenches in a counterclockwise rotation.

3. Test lead wires for continuity when trigger is engaged.

4. Slide adaptor nut over cable with internal threads facing

toward rear of the gun.

5. Assemble Euro block onto end fitting in a clockwise rotation

using appropriate wrenches. Torque to 17 ft-lbs (23 Nm). Seat

adaptor nut on Euro block. Adaptor nut should rotate freely.

6. Strip the control leads ¼” (6.5 mm) and reterminate with

appropriate butt connectors.

7. Install strain relief and liner.

Small Snap

Ring

Large

Snap

Ring

Contact

Pin

Wave

Spring

Gas Pin

C. Bernard Quick Disconnect

1. Remove liner from gun assembly. Viewing quick disconnect

from cable end, align wave spring and large snap ring with

opening access slot. Compress large snap ring with internal

snap ring pliers and remove locking sleeve. Remove small

external snap ring with external snap ring pliers from power

pin.

2. 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.

3. 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.

4. Test contact pins for continuity when trigger is engaged.

5. Inspect all components for cracks, debris, excessive wear

and breakage. Replace with new components if safety or

performance of product is compromised.

6. Thread power pin onto cable end fitting and torque to 17 ft-lbs

(23 Nm) minimum.

Page 16

SECTION 6 - PARTS LIST

6-1 Replacement Parts 200, 300, 400 amp with B Series Small and Large Curved Handles

with yellow trigger

ITEM # PART # DESCRIPTION

Q20 Q30 Q40

1

1

401-6-62

401-6-62

NS-5818C

Nozzle, TOUGH LOCK

™

Series, Standard

Nozzle, TOUGH LOCK Series, Heavy Duty

Nozzle, Centerfire

™

“N” Series

TL

N/A

NS-1218B

11

11

9

6

5

14

8

8

3

2

7

13

16

9

4

12

9

CF

10

QT

10 10

2

3

4

NS

NS

9

5

6

7

8

10

11

12

13

14

N1C58Q

See TOUGH LOCK ™ Consumable Section

Pg. 28

See TOUGH LOCK Consumable Section

Pg. 28

See Centerfire

™

Consumable Section

Pg. 25

See Quik Tip

™


Pg. 26

404-18

404-26

Nozzle, Quik Tip

™

Series

Contact Tip, TOUGH LOCK, Standard

Contact Tip, TOUGH LOCK, Heavy Duty

Contact Tip, Centerfire

Contact Tip, Quik Tip

DS-1

D118Q

See BTB Spec Sheet*

D-1

Retaining Head, TOUGH LOCK, Standard

Retaining Head, TOUGH LOCK, Heavy

Duty

Gas Diffuser, Centerfire

Gas Diffuser, Quik Tip

Neck Insulator

4213B

4305

See BTB Spec Sheet*

See BTB Spec Sheet*

4313B

Neck

Jump Liner

End Fitting, Front

Cone Nut

1880155

4939

4992

1540003

N/A

Jacket Clamp

Conduit Clamp

1880198 Handle Kit, Standard, Locking & Dual

Pull Trigger

DSA-1 Handle Kit, D/S Std and D/S Locking

Trigger

5662

5662L

2690001

2030004

4209

2660001

2520074

4207

N/A

Trigger, Standard

Trigger, Locking

Trigger, Dual Pull, 3 Wire (With Insulated

Terminals)

Post Fastener (1 Req’d - Q20, Q30) (5

Req’d - Q40)

Post Fastener, Short (4 Req’d)

Handle Screw (5 Req’d)

Terminal, Quick Disconnect (2 Req’d)

2520042 Handle Spring

15

15

1680087 1680088 End Fitting, Rear

16

17

412-1 Switch Connector (2 Req’d)

17

18

18

19

24

23

17

18

18

19

20

21

22

23

24

25

2520033

410

2520069

2520073

414-400

See BTB Spec Sheet*

See BTB Spec Sheet*

See BTB Spec Sheet*

1810053

1810054

411-3M

1620004

2520041 Spring, Strain Relief

Straight Rear Strain Relief

Clamshell Rear Strain Relief (Euro Power

Pin)

Clamshell Rear Strain Relief with Installed

Gas Pin (Bernard Power Pin)

Adapter Block

Power Pin

Power Pin Insulator

Liner

Terminal Housing

Terminal Housing, Dual Schedule

Screw, Trigger Housing (2 Req’d)

Screw Cover, Rear Pod

25

20

20

21

*Scan this code for immediate access to the BTB Spec Sheet

22

20

Page 17

18

6-2 Replacement Parts 200, 300, 400 amp with O Series Small Curved Handle with blue

trigger

1 TL


Q20 Q30/S30 Q40/S40

2

CF

1 401-6-62 Nozzle, TOUGH LOCK

™

Series, Standard

3

QT

N/A 401-6-62 Nozzle, TOUGH LOCK Series, Heavy Duty

NS-1218B NS-5818C Nozzle, Centerfire

™

“N” Series

22

10

11

20

9

6

22

5

17

20

23

8

21

24

8

7

14

18

9

16

4

12

26

25

15

13

27

*Scan this code for immediate access to the

BTB Spec Sheet

22

19

20

2

3

4

5

6

7

8

NS

NS

9

21

22

23

24

25

10

11

12

13

14

15

16

17

18

19

20

26

27

N1C58Q

See TOUGH LOCK

™


Pg. 28

DS-1

404-18

404-26

D118Q

D-1

Nozzle, Quik Tip

™

Series


See TOUGH LOCK Consumable Section

Pg. 28


See Centerfire

™

Consumable Section Pg. 25 Contact Tip, Centerfire

See Quik Tip

™

Consumable Section Pg. 26




Duty



Q20

4213B

Q20

4305

Q20

4992

Q20

M169700-12

Q20

1680087

Q20

2520023

See BTB Spec Sheet*

See BTB Spec Sheet*

See BTB Spec Sheet*

Q30

4213B

S30

1680064

Q30

1540003

S30

1540007

Q40

4313B

S40

1680064

Q40

1540003

S40

1540008

Q30

4992

S30

Not Needed

4939

1880219

177379

Q40

4992

S40

Not Needed

203296-005

2280044

177272H

2030029

Q30

M169700-12

S30

Not Needed

177488H

MS2110

177271H

Q30

1680088

S30

1680090

412-1

Q30

2520023

S30

2520056

410

2520073

2520069

414-400

1810053

1810054

411-3M

1620004

Q40

M169700-12

See BTB Spec Sheet*

See BTB Spec Sheet*

See BTB Spec Sheet*

S40

Not Needed

Q40

1680088

S40

1680090

Q40

2520041

S40

2520056

Neck Insulator

Neck

Jump Liner

End Fitting, Front

Cone Nut

Conduit Clamp (2 Req’d)

Jacket Clamp

Handle Kit, Standard and Locking

Handle Kit, Standard Trigger with

Extension

Handle Screw, Large (4 Req’d)

Handle Screw, Small (2 Req’d)

Handle Nut (4 Req’d)

Handle Nut, Small (2 Req’d)

Handle Spring

Trigger, Standard

Trigger, Locking

Trigger Pin (2 Req’d)

End Fitting, Rear

Switch Connector (2 Req’d)

Spring, Strain Relief





Pin)

Adapter Block

Power Pin

Power Pin Insulator

Liner

Terminal Housing




Page 18

18

21

6-3 Replacement Parts 400, 500, 600 amp with O Series Large Curved Handles with blue

trigger


Q40/S40 Q50/S50 Q60/S60

1

1 401-6-62 N/A N/A Nozzle, TOUGH LOCK

™

Series, Standard

3

2

TL

N-5818C

401-6-62

N-5814C

401-6-75

N-3414C

Nozzle, TOUGH LOCK Series, Heavy Duty

Nozzle, Centerfire

™

“N” Series

CF

N1C58Q N1C34HQ N1C34HQ Nozzle, Quik Tip

™

Series

2

12

9

6

15

5

16

8

8

7

17

13

9

4

11

19

10

14

9

QT

3

4

5

6

7

8

NS

NS

9

See TOUGH LOCK

™

Consumable Section Pg. 24 Contact Tip, TOUGH LOCK, Standard

See TOUGH LOCK Consumable Section Pg. 24 Contact Tip, TOUGH LOCK, Heavy Duty

See Centerfire

™



See Quik Tip

404-18

D118Q

™ Consumable Section Pg. 23

N/A

404-26

D-1

D114Q

N/A



Retaining Head, TOUGH LOCK, Heavy Duty



See BTB Spec Sheet*

See BTB Spec Sheet*

Q40

1680049

S40

1680065

Q40

1540003

S40

CB9201

Q40

4992

S40

Not Needed

Q40

4939

S40

407709-013

See BTB Spec Sheet*

Q50

1680050

S50

1680066

Q50

1540004

S50

20038

Q50

4993

S50

Not Needed

Q50

4944

S50

407709-013

1880220

Q60

1680050

S60

1680066

Q60

1540004

S60

CB9206

Q60

4993

S60

Not Needed

Q60

4944

S60

407709-013

Neck Insulator

Neck

Jump Liner

End Fitting

Cone Nut

Conduit Clamp (2 Req’d)

Jacket Clamp

Handle Kit, Standard, Locking and Dual Pull

Trigger

19

19

21

22

20

23

25

24

26

21

18

19

10

11

12

13

14

15

16

17

18

19

Q40

1680088

S40

1680090

1880221

177488H

MS2110

2620062

177379

PDS

177272H

203296-005

20005

177271H

Q50

1680089

S50

1680091

412-1

Q60

2520041

S60

2520056

410

2520073

Q60

1680089

S60

1680091

Handle Kit, D/S Std. and D/S Locking Trigger

Trigger, Standard

Trigger, Locking

Trigger, Dual Pull w/ Extension

Trigger, Standard w/ Extension

Switch Assembly, Dual Schedule (Includes:

Switch, Housing, & Screws)

Handle Nut (4 Req’d Non-D/S, 3 Req’d D/S)

Screw (4 Req’d Non-D/S, 3 Req’d D/S)

Screw Modified (1 Req’d D/S)

Trigger Pin (2 Req’d)

End Fitting, Rear




BTB Spec Sheet

20

21

22

23

24

25

26

2520069

414-400

See BTB Spec Sheet*

See BTB Spec Sheet*

See BTB Spec Sheet*

1810053

1810054

411-3M

1620004





Pin)

Adapter Block

Power Pin

Power Pin Insulator

Liner

Terminal Housing




Page 19

6-3 Replacement Parts 400, 500, 600 amp with O Series Large Curved Handles with blue

trigger

6-4 Replacement Parts 300 amp with T Series Small Straight Handle with black trigger

14

5

6

8

7

9

9

8

7

4

3

2

1

10

11

10

16

15

16

TL

CF

QT

12

13

11

12

13

14

15

16

17

18

19

20

21

22

23

4

8

9

NS

10

NS

5

6

7

ITEM #

1

2

3

PART #

Q30

401-6-62

401-6-62

NS-5818C

N1C58Q

See TOUGH LOCK Consumable

Section Pg. 24

See TOUGH LOCK Consumable

Section Pg. 24

See Centerfire Consumable

Section Pg. 22

See Quik Tip Consumable Section

Pg. 23

404-18

404-26

DS-1

D118Q

See BTB Spec Sheet*

See BTB Spec Sheet*

208-2

318

319

4939

4992

412-1

1880262

320

211-5

320-1-6

320-6

M169700-12

320-3

2520073

2520069

2520033

216-1

See BTB Spec Sheet*

See BTB Spec Sheet*

See BTB Spec Sheet*

See BTB Spec Sheet*

DESCRIPTION

Nozzle, TOUGH LOCK

™

Series, Standard

Nozzle, TOUGH LOCK

™

Series, Heavy Duty

Nozzle, Centerfire

™

“N” Series

Nozzle, Quik Tip

™

Series






Retaining Head, TOUGH LOCK, Heavy Duty



Neck Insulator

Neck

Jam Nut

End Fitting

Cone Nut

Jacket Clamp

Conduit Clamp


Cable Repair Kit (Includes: (1) #7, (1) #8, (1)

#9, (1) Conduit Clamp, (2) # 10)

Handle Kit (Includes: (1) #13 and (1) #14)

Trigger Assembly

Screw, Handle

Handle Collar

Spring, Handle

Handle Cap, Locking, Rear


Gas Pin (Bernard Power Pin)


Pin)

Spring Strain Relief

Control Plug Block

Power Pin

Liner

Power Pin Insulator

Trigger Control Plug Assembly

15

18

18

*Scan this code for immediate access to the BTB Spec Sheet

20

17

6

20

14

22

21

19

13

23

20

17

Page 20

23

21

6-5 Replacement Parts 300, 400, 500, 600 amp with T Series Large Straight Handles with

silver trigger


Q30/S30 Q40/S40 Q50 Q60

3

2

1

TL

CF

1 401-6-62

401-6-62

N/A Nozzle, TOUGH LOCK ™

Standard

Series,

401-6-75 Nozzle, TOUGH LOCK

™

Series, Heavy

Duty

NS-5818C N-5818C N-5814C N-3414C Nozzle, Centerfire

™

“N” Series

12

13

13

5

6

7

20

4

19

21

22

9

10

11

11

10

13

9

5

4

8

8

17

16

12

18

14 15 16


BTB Spec Sheet

21

24

13

QT

2

3

4

18

19

20

21

22

23

5

6

7

8

9

10

11

NS

NS

12

13

14

15

16

17

Q30

308

S30

1680090

Q30

509

S30

1540007

Q30

4939

S30

407709-013

Q30

4992

S30

N/A

Q30

1880261

S30

N/A

N1C58Q N1C34HQ N1C34HQ Nozzle, Quik Tip

™

Series

See TOUGH LOCK

™



Duty

See TOUGH LOCK

™


Contact Tip, TOUGH LOCK, Heavy

Duty

See Centerfire Consumable Section Pg. 22


See Quik Tip Consumable Section Pg. 23

404-18 N/A

DS-1

D118Q

404-26

D-1

D114Q


Retaining Head, TOUGH LOCK,

Standard


Duty



See BTB Spec Sheet*

See BTB Spec Sheet*

See BTB Spec Sheet*

See BTB Spec Sheet*

1840057

1680085

Q40

408T

412-1

S40

1680090

Q40

409

S40

1540008

Q40

4939

S40

407709-013

Q40

4992

S40

N/A

Q40

1880263

S40

N/A

410

410

2520073

608-1

609

4944

4993

513-8

610

616

Neck Insulator, TOUGH LOCK

Neck Insulator, Centerfire

Neck Insulator, Quik Tip

Neck

Rotatable Nut Cover

Rotatable Neck Adapter


End Fitting

Cone Nut

Jacket Clamp

Conduit Clamp

Cable Repair Kit (Includes: (2) #8,

(1) #9, (1) #10, (1) #11, (1) Conduit

Clamp)

2520069

411-1

411-2

411-4

411-11

411-12

411-13

Handle


Clamshell Rear Strain Relief with

Installed Gas Pin (Bernard Power Pin)

Clamshell Rear Strain Relief (Euro

Power Pin)

Switch

Trigger Housing, Standard

Trigger Housing, Locking

Trigger Housing, Dual Pull

Trigger Housing, Dual Schedule

Trigger Housing, Dual Schedule w/

Locking

2520033

411-3M

1810052

1810054

1620004

414-400

See BTB Spec Sheet*

See BTB Spec Sheet*

See BTB Spec Sheet*

2520041


Trigger Control Plug Terminal

Trigger Control Plug Terminal, Dual

Schedule

Screw Cover, Rear Housing

Adapter Block

Power Pin

Power Pin Insulator

Liner


Page 21

SECTION 7 - CONSUMABLE PARTS

7-1 Centerfire

™

Consumable Series

Small Centerfire Gas Diffusers and Nozzles

NS-5800C (5/8" I.D., Flush, Copper)

NS-5818C (5/8" I.D., 1/8" Rec., Copper)

NS-5800B (5/8" I.D., Flush, Brass)

NS-5818B (5/8" I.D., 1/8" Rec., Brass)

'T' Series Tip

-see chart

NS-1218C (1/2" I.D., 1/8" Rec., Copper)

NS-1200B (1/2" I.D., Flush, Brass)

NS-1218B (1/2" I.D., 1/8" Rec., Brass)

4523R

Insulator

DS-1

Diffuser

'TT' Series Tip

-see chart

Large Centerfire Gas Diffusers and Nozzles

NST-3800B (3/8" I.D., Flush, Brass)

NST-3818B (3/8" I.D., 1/8" Rec., Brass)

NST-38XTB (3/8" I.D., 1/8" Extension, Brass)

'T' Series Tip

-see chart

4423R

Insulator

D-1

Diffuser

Centerfire Contact Tips

1.50

[38.1 mm]

T-023

T-030

T-035

T-039

T-045

T-052

T-062

T-072

T-078

T-094

T-109

T-125

'T' Series Tip

.023" (.6 mm)

.030" (.8 mm)

.035" (.9 mm)

.039" (1.0 mm)

.045" (1.2 mm)

.052" (1.4 mm)

1/16" (1.6 mm)

.072" (1.8 mm)

5/64" (2.0 mm)

3/32" (2.4 mm)

7/64" (2.8 mm)

1/8" (3.2 mm)

'TT' Series Tip

-see chart

2.00

[50.8 mm]

TT-023

TT-030

TT-035

TT-039

TT-045

TT-052

TT-062

'TT' Series Tip

.023" (.6 mm)

.030" (.8 mm)

.035" (.9 mm)

.039" (1.0 mm)

.045" (1.2 mm)

.052" (1.4 mm)

1/16" (1.6 mm)

N-3400C

(3/4" I.D., Flush, Copper)

N-3418C

(3/4" I.D., 1/8" Rec., Copper)

N-3414C

(3/4" I.D., 1/4" Rec., Copper)

N-3418B

(3/4" I.D., 1/8" Rec., Brass)

N-3414B

(3/4" I.D., 1/4" Rec., Brass)

N-5800C


N-5818C

(5/8" I.D., 1/8" Rec., Copper)

N-5814C

(5/8" I.D., 1/4" Rec., Copper)

N-5818B

(5/8" I.D., 1/8" Rec., Brass)

N-5814B

(5/8" I.D., 1/4" Rec., Brass)

NT-3800C


Page 22

7-2 Quik Tip

™


Quik Tip Gas Diffusers and Nozzles

D114Q

1/4” Recess

D118Q

1/8” Recess

D1FQ

Flush

4423R

Insulator

D114

1/4” Recess

D118

1/8” Recess

D1F

Flush

Series 2 Tip

-see chart

Series 1 Tip

-see chart

D218

1/8” Recess

4323R

Insulator

DS-QT

Quik Tip Contact Tips

Series 2 Tip

-see chart

Series 1 Tip

-see chart

N1C34HQ

Plated Copper, 3/4 " Heavy Duty

N1C58HQ


N1C34Q


N1B34Q

Brass, 3/4 "

N1C58Q

N1B58Q

Plated Copper, 5/8 "

Brass, 5/8 "

N1C12Q


N2C12HQ


N2C38HQ


N1C34HD

Plated Copper, 3/4 " , Heavy Duty

N1C58HD

Plated Copper, 5/8 " , Heavy Duty

N1C34

Copper, 3/4 "

N1C58

Copper, 5/8 "

N1C12

Copper, 1/2 "

N2C12

Copper, 1/2 "

N2C38

Copper, 3/8 "

NSQT-1200

Flush, Copper, 1/2 " I.D.

NSQT-1218

Copper, 1/2 " I.D., 1/8 " Rec.

Page 23

7-3 Centerfire

™

HD Consumable Series

Centerfire HD Consumable Series is not configurable and will need to be ordered separately. Couple the Centerfire HD nozzle body with a Centerfire HD nozzle cone to form a complete Centerfire HD nozzle.

4423R D-1

'T' Series Tip

- See chart on

page 22

N-HDC

3414

(3/4" I.D., 1/4" Recess)

3418

(3/4" I.D., 1/8" Recess)

5814

(5/8" I.D., 1/4" Recess)

5818

(5/8" I.D., 1/8" Recess)

7-4 Quik Tip

™

HD Consumable Series

Quik Tip HD Consumable Series is not configurable and will need to be ordered separately. Couple the Quik Tip HD nozzle body with a Quik Tip HD nozzle cone to form a complete Quik Tip HD nozzle.

4423R

D114Q

Series 1 Tip

- see chart on

page 23

N-HDQ

3418

(3/4" I.D., 1/4" Recess)

5818

(5/8" I.D., 1/4" Recess)

4423R

D118Q

Series 1 Tip

- see chart on

page 23

N-HDQ

3418

(3/4" I.D., 1/8" Recess)

5818

(5/8" I.D., 1/8" Recess)

Page 24

7-5 TOUGH LOCK

™


TOUGH LOCK™ CONTACT TIP PART NUMBERS

WIRE SIZE STANDARD DUTY

0.023" (0.6 mm) 403-14-23

0.030" (0.8 mm) 403-14-30

0.035" (0.9 mm) 403-14-35

0.040" (1.0 mm) 403-14-1.0

0.045" (1.2 mm) 403-14-45

3/64" (1.2 mm) N/A

0.052" (1.3 mm) N/A

0.055" (1.4 mm) N/A

1/16" (1.6 mm) N/A

0.070" (1.8 mm) N/A

0.078" (2.0 mm) N/A

5/64" (2.0 mm) N/A

3/32" (2.4 mm) N/A

7/64" (2.8 mm) N/A

1/8" (3.2 mm) N/A

HEAVY DUTY HEAVY DUTY TAPERED

N/A

403-20-30

403-20-35

N/A

403-21-30

403-21-35

403-20-1.0

403-21-1.0

403-20-45 403-21-45

403-20-364 N/A

403-20-52 N/A

403-20-1.4

N/A

403-20-116 N/A

403-20-1.8

N/A

403-20-78 N/A

403-20-564 N/A

403-20-332 N/A

N/A N/A

N/A N/A

TOUGH LOCK RETAINING HEAD PART NUMBERS

DESCRIPTION

Heavy Duty

Heavy Duty

Heavy Duty

Standard Duty

Standard Duty

Heavy Duty

SINGLE TAPER PART NUMBER

404-20-25

DUAL TAPER PART NUMBER

404-26-25

404-20

404-20-250

404-14-25

404-14

404-26

404-26-250

404-18-25

404-18

THREAD-ON RETAINING HEADS FOR NEW STYLE THREAD-ON NOZZLES

N/A 404-53-25

N/A

N/A

N/A

N/A

N/A

N/A

EXTENDED LIFE HEAVY DUTY

N/A

403-27-30

403-27-35

403-27-1.0

403-27-45

403-27-364

403-27-52

N/A

403-27-116

QTY

25

100

250

25

100

25

TOUGH LOCK NOZZLE PART NUMBERS

PART NUMBER NOZZLE TYPE BORE TYPE MATERIAL O.D.

LENGTH

401-6-50 Heavy Duty

401-48-62 Heavy Duty

401-5-62

401-6-62

Heavy Duty

Heavy Duty

1/2"

5/8"

5/8"

5/8"

C

A

C

C

Copper

Copper

Copper

Copper

1.062" 2.88"

1.062" 2.76"

1.062" 3.00"

1.062" 2.88"


401-7-62 Heavy Duty



401-5-75

401-6-75

401-7-75

Heavy Duty

Heavy Duty

Heavy Duty

401-42-50 Standard Duty






401-4-62

401-8-62

401-9-62

Standard Duty

Standard Duty

Standard Duty


5/8"

5/8"

5/8"

5/8"

3/4"

3/4"

3/4"

1/2"

1/2"

1/2"

1/2"

3/8"

3/8"

3/8"

5/8"

5/8"

3/4"

C

C

C

C

C

C

C

C

C

B

B

A

A

A

C

C

D

Brass

Brass

Copper

Brass

Copper

Copper

Brass

Brass

Copper

Brass

Brass

Copper

Brass

Copper

Copper

Copper

Copper

1.106" 2.88"

1.106" 3.00"

1.162" 2.63"

1.162" 2.63"

1.162" 3.00"

1.162" 2.88"

1.106" 2.88"

0.938" 2.88"

0.938" 2.88"

0.938" 2.50"

0.938" 2.63"

0.938" 2.74"

0.938" 2.81"

0.938" 2.88"

0.938" 2.63"

0.938" 2.51"

0.938" 2.88"

RECESS

1/8" Recess

Flush

1/4" Recess

1/8" Recess

1/8" Recess

1/4" Recess

1/8" Stick-Out

1/8" Stick-Out

1/4" Recess

1/8" Recess

1/8" Recess

1/8" Recess

1/8" Recess

1/4" Stick-Out

1/8" Recess

Flush

1/16" Recess

1/8" Recess

1/8" Stick-Out

1/4" Stick-Out

1/8" Recess

10

10

10

10

10

10

10

10

10

10

10

10

10

10

10

10

10

QTY

10

10

10

10

EXTRA HEAVY DUTY

N/A

N/A

N/A

603-20-1.0

603-20-45

603-20-364

603-20-52

603-20-1.4

603-20-116

N/A

N/A

603-20-564

603-20-332

603-20-764

603-20-18

100

100

100

100

100

100

QTY

100

100

100

100

100

100

100

100

100

Page 25

A. BOTTLENECK B. LONG TAPER C. SHORT TAPER D. STRAIGHT

SECTION 8 - TROUBLESHOOTING

8-1 Troubleshooting Table

PROBLEM

1. Electrode does not feed

POSSIBLE CAUSE

1. Feeder relay.

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 liner.

CORRECTIVE ACTION

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 proper size.

6. Adjust tension at feeder.

7. See ‘Contact Tip Burn Back’.

8. Replace with correct size.

9. Replace liner, check condition of electrode.

2. Contact tip burn back

1. Improper voltage and/or wire feed speed.

2. Erratic wire feeding.

3. Improper tip stickout.

4. Improper electrode stickout.

5. Faulty ground.

1. Set parameters.

2. See ‘Erratic Wire Feeding’.

3. Adjust nozzle/tip relationship.

4. Adjust gun to base metal relationship.

5. Replace cables and/or connections.

3. Tip disengages from gas diffuser 1. Worn gas diffuser/retaining head.

2. Improper tip installation.

3. Extreme heat or duty cycle.

4. Short contact tip life

5. Erratic arc

6. Erratic wire feeding

1. Contact tip size.

2. Electrode eroding contact tip.

3. Exceeding duty cycle.

1. Worn contact tip.


3. Wrong tip size.

4. Not enough bend in neck.


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 tip and/or gas diffuser/retaining head.

2. Install as per ‘Changing Consumables’

(Section 5 pg. 10).

3. Replace with heavy duty consumables. See appropriate spec sheet for details.

1. Replace with proper size.

2. Inspect and/or change drive rolls.

3. Replace with properly rated Bernard MIG Gun.

1. Replace.


3. Replace with correct size tip.

4. Replace with 45º or 60º neck.


2. Replace with new liner of proper size.

3. Replace with proper size drive roll.

4. a. Replace with new drive roll.

b. Stone edge of groove on drive roll.

5 a. Adjust/replace guide as close to drive rolls as possible.

b. Eliminate all gaps in electrode path.

6. Replace with proper guide diameter.

7. a. Replace with new liner trimming as per

‘Changing the Liner’ (Section 5, pg. 11).

b. Replace guide tube/liner, trim as close to

mating component as possible.

8. Consult feeder manufacturer.

9. Inspect and replace.*

Page 26

PROBLEM POSSIBLE CAUSE

7. Extreme spatter 1. Improper machine parameters.

2. Improper tip installation.

3. Improper shielding.

4. Contaminated wire or work piece.

CORRECTIVE ACTION

1. Adjust parameters.

2. Adjust nozzle/tip relationship.

3. a. Verify shielding gas coverage.

b. Verify gas mixture.

4. Clean wire and work piece.

8. Porosity in weld

9. Gun running hot

10. Liner is discolored full length

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. Exceeding duty cycle.

2. Loose or poor power connection.

1. Short circuit to electrode.

2. Broken copper stranding in power cable.

1. Replace nozzle/insulator.

2. Replace 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 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 specified torque. See ‘Replacement’

(Section 5).

1. a. Replace with properly rated Bernard

MIG Gun.

b. Decrease parameters to within gun rating.

2. a. Clean, tighten or replace cable

grounding connection.

b. Tighten gun & cable connections to specified torque. See ‘Replacement’

(Section 5).

1. Isolate electrode reel from feeder and drive block. Consult feeder manufacturers manual.

2. Replace MIG Gun.

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.

c. Replace the neck and jump liner.

3. Adjust drive rolls as per feeder

manufacturer’s manual.

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

Page 27

NOTES

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. Scan this QR Code with your smart phone for immediate access to BernardWelds.com/TechnicalSupport

Scan to view BTB (Best of the Best) Spec Sheet

............................................

OWNER’S MANUAL

Bernard

A Division of Miller Electric Mfg. Co.

449 West Corning Road, Box 667

Beecher, Illinois 60401 USA

Phone: 1-855-MIGWELD (644-9353)

(US & Canada)

1-519-737-3030

(International)

Fax: 708-946-6726

For more information, visit us at BernardWelds.com

©2015 Bernard Printed in U.S.A.

Bernard

™

, Clean Air

™

, Centerfire

™

, Quik Tip

™ and other names are trademarks of Bernard, a division of Miller Electric Mfg. Co.

TOUGH LOCK

™

and QUICK LOAD

™

are trademarks of Tregaskiss, a division of ITW Canada Inc.

Bernard BTB MIG Guns 200, 300, 400, 500, 600 amp

OM-BTB-1.5

Processes

Description

Bernard BTB MIG Guns

OWNER’S MANUAL

Thank You for Choosing Bernard

TABLE OF CONTENTS

13

14

15

17

9

10

10

11

8

8

8

9

7

7

6

7

6

6

4

6

2

2

1

2

24

25

26

26

22

22

23

24

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

Bernard Welding, 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

Bernard Q20 Series – 200A

Bernard Q30 Series – 300A

Bernard Q40 Series – 400A

Bernard Q50 Series – 500A

Bernard Q60 Series – 600A

Bernard S30 Series – 300A

Bernard S40 Series – 400A

Bernard S50 Series – 500A

Bernard S60 Series – 600A

Stock Number

Q20XXXXXXX (Configurable #)

Q30XXXXXXX (Configurable #)

Q40XXXXXXX (Configurable #)

Q50XXXXXXX (Configurable #)

Q60XXXXXXX (Configurable #)

S30XXXXXXX (Configurable #)

S40XXXXXXX (Configurable #)

S50XXXXXXX (Configurable #)

S60XXXXXXX (Configurable #)

Council Directives:

• 2006/95/EC Low Voltage

• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:

• IEC 60974-7:2013 Arc welding equipment – Part 7: Torches

Signatory:

_____________________________________ ___________________________________________

David A. Werba Date of Declaration

May 16, 2014

MANAGER, PRODUCT DESIGN COMPLIANCE

SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING

1-1 Fume and Gas Hazards

1-2 Arc Rays and Welding Hazards

1-3 Additional Safety Warnings for

Installation, Operation and Maintenance

1-4 California Proposition 65 Warnings

_ _______