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
Страница 1: ...c 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 O...
Страница 2: ...dge 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 64...
Страница 3: ...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 Hand...
Страница 4: ...uik 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 BT...
Страница 5: ...es 400A Q40XXXXXXXX Configurable Bernard Q50 Series 500A Q50XXXXXXXX Configurable Bernard Q60 Series 600A Q60XXXXXXXX Configurable Bernard S30 Series 300A S30XXXXXXXX Configurable Bernard S40 Series 4...
Страница 6: ...ire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard l Do not touch live electrical parts...
Страница 7: ...the manufacturer s instructions for adhesives coatings cleaners consumables coolants degreasers fluxes and metals l Work in a confined space only if it is well ventilated or while wearing an air supp...
Страница 8: ...d flying metal As welds cool they can throw off slag l Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill l Shut off compressed gas supply...
Страница 9: ...G PARTS can injure l Keep away from moving parts l Keep away from pinch points such as drive rolls WELDING WIRE can injure l Do not press gun trigger until instructed to do so l Do not point gun towar...
Страница 10: ...FCC about interference stop using the equipment at once l Have the installation regularly checked and maintained l Keep high frequency source doors and panels tightly shut keep spark gaps at correct s...
Страница 11: ...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 Ame...
Страница 12: ...ng but not limited to the warranties of merchantability or fitness for any purpose Bernard shall not be liable under any circumstances to Buyer or to any person who shall purchase from Buyer for damag...
Страница 13: ...elding Gas 60 400 amp with Mixed Gases 500 amp gun feeds maximum wire size of 3 32 2 4 mm Duty Cycle Rating 100 500 amp with CO2 Shielding Gas 60 500 amp with Mixed Gases 600 amp gun feeds maximum wir...
Страница 14: ...wer pin by hand and tighten drive rolls Figure 3 A 3 2 Installing to a Feeder with a Euro or a Bernard Power Pin A Euro Power Pin 1 Insert the Euro power pin to face of receptacle 2 Thread Euro hand n...
Страница 15: ...SECTION 4 OPERATION 4 1 Pulling the Trigger 1 Trigger When pressed energized wire feeds and shielding gas flows Figure 4 A Figure 4 B OM BTB 2 2 10...
Страница 16: ...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...
Страница 17: ...ten into power pin 5 Trim to dimensions shown in the New Liner Trim Lengths chart shown below 6 Remove all burrs from end of liner and replace gas diffuser retaining head contact tip and nozzle New Li...
Страница 18: ...hown in New Liner Trim Lengths chart on previous page 7 Remove all burrs from end of liner and replace gas diffuser contact tip and nozzle Figure 5 C C Changing a Jump Liner 1 Remove the nozzle contac...
Страница 19: ...1 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 Figure 5 F C Changing the Neck Fixed with T Series Straight Handle 1...
Страница 20: ...changed if switching to a neck of different bend angle or length Figure 5 H E Changing the Neck Fixed with C Series Straight Handle 1 Place neck in vise Remove both switch housing mounting screws wit...
Страница 21: ...are not pinched and movement of the trigger is not impaired 5 Position the remaining handle half in place 6 Reinstall post fasteners and screws Torque to 10 in lbs 1 1 Nm Figure 5 J B O Series Regula...
Страница 22: ...s to grip switch 3 Remove switch from switch lead connectors with needle nose pliers 4 Push switch lead connectors firmly onto new switch terminals with needle nose pliers 5 Depress switch housing int...
Страница 23: ...attaches the strain relief to the Euro block 2 Slide strain relief bottom toward cable exposing Euro block 3 Remove Euro block from end fitting using appropriate wrenches in a counterclockwise rotatio...
Страница 24: ...andard 5662L Trigger Locking 2690001 Trigger Dual Pull 3 wire with insulated terminals 11 4207 Post Fastener 1 req d Q20 Q30 5 req d Q40 2030004 N A Post Fastener Short 4 req d 12 4209 Handle Screw 5...
Страница 25: ...d 11 2280044 Handle Screw Small 2 req d 12 177272H Handle Nut 4 req d 13 2030029 Handle Nut Small 2 req d 14 M169700 12 M169700 12 M169700 12 Handle Spring N A N A 15 177488H Trigger Standard 177379 T...
Страница 26: ...1880221 Handle Kit Dual Schedule D S Std and D S Locking Trigger 10 177488H Trigger Standard MS2110 Trigger Locking 2620062 Trigger Dual Pull w Extension 177379 Trigger Standard w Extension 11 PDS Sw...
Страница 27: ...Conduit Clamp 10 412 1 Switch Connector 4 req d NS 1880262 Cable Repair Kit includes 1 7 1 8 1 9 1 Conduit Clamp 2 10 11 320 Handle Kit includes 1 13 1 14 12 211 5 Trigger Assembly 13 310 1 6 Screw Ha...
Страница 28: ...944 4944 Jacket Clamp 407709 013 407709 013 4944 4944 NS 4992 4992 4993 4993 Conduit Clamp N A N A 4993 4993 NS 1880261 1880263 513 8 513 8 Cable Repair Kit N A N A 513 8 513 8 12 410 610 Handle 13 41...
Страница 29: ...407709 013 4944 NS 4992 4992 4992 4993 Conduit Clamp 4992 N A N A 4993 NS 1880261 1880261 1880263 513 8 Cable Repair Kit 1880261 N A N A 513 8 12 1780086 Front Handle 13 1780086 Rear Strain Relief 252...
Страница 30: ...opper N 3414C 3 4 I D 1 4 Brass N 3418B 3 4 I D 1 8 Recess Brass N 3414B 3 4 I D 1 4 Recess Brass N 5800C 5 8 I D Flush Copper N 5818C 5 8 I D 1 8 Recess Copper N 5814C 5 8 I D 1 4 Recess Copper N 581...
Страница 31: ...ble 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 Centerfir...
Страница 32: ...N1B34Q Brass 3 4 N1C58Q Plated Copper 5 8 N1B58Q Brass 5 8 N1C12Q Plated Copper 1 2 N2C12HQ Plated Copper 1 2 N2C38HQ Plated Copper 3 8 N1C34HD Plated Copper 3 4 Heavy Duty N1C58HD Plated Copper 5 8...
Страница 33: ...8 T1364 3 32 2 4 mm 7 64 2 8 mm 1 8 3 2 mm 3 64 1 2 mm Series 2 Contact Tip T2023 T2030 T2035 0 023 0 6 mm 0 030 0 8 mm 0 035 0 9 mm T2045 T2364 0 045 1 2 mm 3 64 1 2 mm T2052 T2116 0 052 1 4 mm 1 16...
Страница 34: ...52 603 20 52 100 0 055 1 4 mm N A 403 20 1 4 N A N A 603 20 1 4 100 1 16 1 6 mm N A 403 20 116 N A 403 27 116 603 20 116 100 0 070 1 8 mm N A 403 20 1 8 N A N A N A 100 0 078 2 0 mm N A 403 20 78 N A...
Страница 35: ...uty 3 4 B Copper 1 062 3 00 1 4 Recess 10 401 6 75 Heavy Duty 3 4 B Copper 1 062 2 88 1 8 Recess 10 401 7 75 Heavy Duty 3 4 B Brass 1 106 2 88 1 8 Recess 10 401 42 50 Standard Duty 1 2 A Brass 0 938 2...
Страница 36: ...tact 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 properly rated Bernard MIG Gun 5 Erratic arc 1 Worn c...
Страница 37: ...se or poor power connection 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 and cable c...
Страница 38: ...n to view the BTB MIG Gun Spec Sheet Scan to view the AccuLock S Semi Auto Consumables Spec Sheet Scan to view the Centerfire Consumables Spec Sheet Scan to view the Quik Tip Consumables Spec Sheet Sc...
