Product Guide: Clean Air E™ – Changing the Y Connector
Keep your Bernard® Clean Air E™ Fume Extraction MIG Gun performing at its best by replacing the Y-connector when needed. This quick guide walks you through the simple steps to ensure a secure fit and maintain optimal fume extraction efficiency. Watch now to keep your system running smoothly and your workspace cleaner.
Instructions
Separate connector halves.
Push rear hose swivel forward to slide it out of the cavity. Slide the hose assembly forward and remove the remaining Y Connector half.
Place the new rubber boot into the new Y Connector set.
Position the cable assembly in the Y Connector channel, ensuring proper alignment with rubber boot.
Pull the hose assembly back into the swivel cavity and ensure it is taut (no slack).
Confirm the hose and cable assemblies are properly seated and secure.
Align the Y Connector halves and reinstall screws.
Find more resources at www.startsatthesource.com
Product Guide: Clean Air E™ – Connecting to a Fume Extraction Unit
Product Guide: Clean Air E™ – Connecting to a Fume Extraction Unit
Properly connecting your Bernard® Clean Air E™ Fume Extraction MIG Gun to a fume extraction unit is key to maximizing performance and maintaining a cleaner work environment. In this video, we walk you through the simple steps to ensure a secure and efficient connection, helping you get the most out of your fume extraction system.
Instructions
Thread hose onto the fume port of the fume extraction unit and tighten securely.
Attach the opposite end of hose to the 1-3/4” port on the Y Connector, ensuring all connections are tight.
Find more resources at www.startsatthesource.com
Product Guide: Clean Air E™ – Replacing the Neck and Trigger
Product Guide: Clean Air E™ – Replacing the Neck and Trigger
Maintaining your Bernard® Clean Air E™ Fume Extraction MIG Gun is quick and easy! Watch as we walk through the simple process of replacing the neck and trigger, ensuring your gun stays in top working condition. Designed for durability and performance, the Clean Air E™ makes maintenance hassle-free so you can focus on the job.
Instructions
Changing the Inner Neck Assembly
Remove the Shroud and Consumables: Unthread the knurled smoke shroud from the smoke tube assembly and remove the front end consumables.
Separate the Handle Halves: Remove the socket head cap screws (7/64″ hex) and keep them for later.
Remove the Smoke Tube Assembly: Slide it forward and off the inner neck assembly.
Loosen the Lock Nut: Place the neck in a vise (don’t over-tighten). Use 3/4” wrenches to loosen the lock nut on the neck.
Unthread the Neck: Once the lock nut is loose, unthread the neck from the end fitting by hand.
Replace the Neck: Add the lock nut to the new neck, thread it into the cable end fitting, and tighten by hand. Secure the neck in a vise and torque the lock nut/end fitting connection to 30 ft-lbs (40.7 Nm).
Reassemble the Handle: Position the neck and smoke tube assembly into the handle. Ensure the trigger components and vacuum slide are correctly placed, with trigger wires routed properly.
Secure the Handle Halves: Use the handle screws and torque them to 10 in-lbs (1.1 Nm).
Changing the Switch – Button Model
Separate the Handle Halves: Remove the screws completely.
Remove the Terminals: Use needle nose pliers to remove the terminals from the trigger switch.
Attach the New Trigger: Secure the terminals to the new trigger, position it in the right handle half, and ensure the wires are routed correctly.
Reassemble the Handle: Reinstall the second handle half, tighten all screws, and torque to 10 in-lbs (1.1 Nm).
Changing the Switch – Lever Model
Separate the Handle Halves: Remove the screws completely.
Remove the Switch Assembly: Use needle nose pliers to disconnect the terminals and carefully remove the lever.
Attach the New Switch: Secure the terminals to the new switch assembly, install it into the mounting cavity, and reinstall the lever.
Reassemble the Handle: Ensure all components are correctly positioned, then reinstall the second handle half, starting with the lever screw. Tighten all screws and torque to 10 in-lbs (1.1 Nm).
Changing the Vacuum Slide Switch
Separate the Handle Halves: Remove the screws completely.
Remove the Slide Switch: Carefully take it out of the channel in the handle half.
Install the New Slide Switch: Position it in the channel, ensuring it moves freely.
Reassemble the Handle: Keep the slide switch properly aligned and reinstall the screws, tightening them evenly and torquing to 10 in-lbs (1.1 Nm)
Find more resources at www.startsatthesource.com
Product Guide: Clean Air E™ – Changing Shrouds to Maximize Fume Extraction
Product Guide: Clean Air E™ – Changing Shrouds to Maximize Fume Extraction
We designed the Bernard® Clean Air E™ Fume Extraction Gun with interchangeable shrouds, giving you the flexibility to optimize fume capture for your specific welding application. Choose from a longer shroud for maximum fume extraction, a medium shroud for the perfect balance of weld access and fume capture, or a short shroud for maximum weld access while still extracting fumes.
Instructions
Simply unthread the fume shroud from the neck tube and rethread your desired shroud based on your nozzle size and welding application.
Find more resources at www.startsatthesource.com
Product Guide: Clean Air E™ – Changing Out the Hose
Product Guide: Clean Air E™ – Changing Out the Hose
Need to replace the hose on your Clean Air E™ fume extraction gun? We’ve got you covered! Follow these simple steps to swap it out quickly and keep your fume extraction system performing at its best. Watch now and ensure clean, efficient welding every time.
Instructions
1. If replacing the vacuum hose assembly, remove all screws to separate the handle halves and remove the front hose swivel from its cavity.
2. Remove screw covers and two screws securing the rear handle, then slide the rear handle and strain relief backward to remove them.
3. Remove screws on the Y Connector and open to expose the cable assembly and rear hose swivel.
4. Pull the vacuum hose assembly backward to remove it from the cable assembly.
5. Slide the new vacuum hose assembly forward over the cable assembly until the front hose swivel rests in its cavity. Align the handle halves and reinstall all screws to retain hose assembly within handle.
6. With the cable straight, pull the hose and position it into the Y Connector, ensuring no slack. Tighten Y Connector screws, correctly positioning rubber boot within the Y Connector.
7. Slide rear handle and strain relief forward onto the cable assembly and secure with screws and screw covers.
Find more resources at www.startsatthesource.com
PRODUCT IMPROVEMENT – Bernard Conventional Liners
PRODUCT IMPROVEMENT –
Bernard Conventional Liners
Bernard has implemented a material change to all Bernard conventional liners. All liners were previously produced from high carbon music wire. All liners will now be produced from high carbon music wire with tin zinc plated coating.
Liners are still available in lengths of up to 25 feet (7.6 m) for various wire sizes. Part numbers will remain the same as released on June 2, 2014.
Please see the chart below for part numbers and wire sizes:
| Wire Size | Liner Color | 15′ (4.57 m) | 25′ (7.62 m) |
|---|---|---|---|
| 0.023″- 0.030″ | Yellow | L1A-15 | L1A-25 |
| 0.030″- 0.035″ | Green | L2A-15 | L2A-25 |
| 0.035″- 0.045″ | White | L3A-15* | L3A-25* |
| 0.045″- 1/16″ | Red | L4A-15** | L4A-25** |
| 5/64″ | Blue | L6A-15 | L6A-25 |
| 3/32″ | Grey | L7A-15 | L7A-25 |
| 7/64″ – 1/8″ | Black | L8A-15 | L8A-25 |
*Standard Liner for 0.035″-0.045″ Guns
**Standard Liner for 1/16″ Guns
Bernard has transitioned these products to a new supplier! Customers can contact Hopkin Manufacturing directly to place orders for these products. Hopkin Manufacturing: +1-800-524-1458 | hopkinsmfg.com
Learn more on the Clean Air™ fume extraction gun product page
Although no new neck insulators are being introduced due to implementation of the BTB semi-automatic air-cooled MIG gun platform on June 2, 2014, users should be aware that neck insulator replacement for these guns will be based on several variables including: Please use the following chart when selecting the appropriate replacement neck insulator:
New BTB platform MIG guns, launching on June 2, 2014, will feature a common straight rear strain relief (shown right) on almost all configurations. This straight rear strain relief was originally introduced on Tregaskiss TOUGH GUN semi-automatic MIG guns and allows expansion or maintenance of several key features: Only BTB platform guns configured with Bernard or Euro power pins will incorporate the black clamshell rear strain relief originally introduced on Bernard Q-Gun and S-Gun MIG Guns. This rear strain relief is also now covered by the same Lifetime Warranty offered on the straight rear strain relief (above) for BTB platform guns. Please note the following liner compatibility:
Please note that not all Bernard necks will have this new dual thread. Necks that will NOT have the new dual thread include: There is a subtle difference to the appearance of the threads on the necks as shown below: Please click here for more details on necks offered through the BTB MIG gun platform. The Bernard necks spec sheet can be downloaded in PDF format by clicking here.
Beginning on June 2, 2014, Bernard’s new BTB MIG gun platform brings our Q-Gun™, S-Gun™ and T-Gun™ MIG Guns into a single gun line and single configurator. To combine the gun lines, it was necessary to standardize the back ends of all BTB MIG guns with the straight rear strain relief found on Bernard® T-Gun™ MIG guns (formerly Tregaskiss® TOUGH GUN® semi-automatic MIG guns). Similarly, the Tregaskiss power pins that mate with the T-Gun series have now been adopted with some slight modifications as the Bernard power pins for both Bernard semi-automatic and Tregaskiss robotic MIG guns. The slight modifications include a new overall hex shape (see image on right) and fixed gas barbs. Bernard MIG gun lines that are compatible with these pins include: Due to the expanded compatibility of these pins, some distributors and end users will be able to reduce inventories of Bernard replacement parts. For additional information on power pin kits and power pins, please click here to access the spec sheets in PDF format.
Launched on June 2, 2014, the new Bernard® conventional liners are compatible with all legacy Q-Gun™, S-Gun™ and T-Gun™ MIG guns and all BTB platform guns, which allows you to simplify and reduce your inventory. The image to the right shows how the previous liner locks were merged in the design of the new Bernard conventional liner to maximize backwards compatibility. Due to this customer-friendly backwards compatibility, the part numbers below supersede previous Bernard conventional liner part numbers. Made of high carbon music wire for smooth wire feed and long life, Bernard conventional liners are available in lengths of up to 25 feet (7.6 m) and are color coded for your convenience to indicate a variety of wire sizes. Please see the chart below for part numbers, wire sizes, and color coding information: *Standard Liner for 0.035″-0.045″ Guns NOTE: Tregaskiss conventional liner numbers will continue to be offered due to their continued use in Tregaskiss robotic MIG guns.
B Series Small Curved Handle B Series Large Curved Handle O Series Small Curved Handle O Series Large Curved Handle T Series Small Straight Handle T Series Large Straight Handle C Series Straight Handle Please note that all handle and trigger combinations previously offered continue to be available within the BTB MIG gun platform. To view a summary of trigger options and other features by handle, please click here. .
Along with the new Bernard® semi-automatic MIG guns BTB platform launching on June 2, 2014, Bernard is pleased to announce the launch of the improved Q-Nut used on all Bernard rotatable necks. It has been completely redesigned to offer a significant increase in durability. Please note that the new silicone ring, Q-Nut cover and silicone insulator are now installed from the back of the neck instead of the front. “How to install the new Q-Nut” instructions are available on our website in the How-To Guides and Videos area of our Technical Support section. Please click here to access this How-To article.
Former Q-Gun™ and S-Gun™ MIG guns will require an additional character added to the end of the existing part numbers to allow for new liner selection options. Former T-Gun™ semi-automatic air-cooled MIG guns will be adopting Q-Gun style part numbering for consistency across all guns within the new single configurator. Example old and new part numbers are shown below: Q-Gun MIG Guns Q4015GE8CM Q4015GE8CMC S-Gun MIG Guns S3012TF5CM S3012TF5CMC T-Gun MIG Guns M3010-35 Q3010MP3CMC For a limited time from June 2 until August 1, 2014, both old and new part numbers will be supported in our system to allow our distribution partners to update their computer systems. To assist our customers in converting old gun part numbers to new Best of the Best Platform part numbers, we have created an online conversion tool. To populate the data in the tool, Q-Gun, S-Gun and T-Gun MIG Gun part numbers configured between April 2011 and April 2014 were pulled and converted to the new part numbering system. Click here to access this conversion tool.
We have added internal stops to all Centerfire™ and Quik Tip™ diffusers to improve alignment between the liner and contact tip for enhanced wire feedability. This product improvement is being implemented as a running change. The new internal stop inside Centerfire and Quik Tip diffusers prevents the liner from going all the way through the diffuser, therefore changing how liners need to be installed. Liner installation will now require the removal of the diffuser. Please note that trim lengths will also be affected. See product insert INS-DIFF for more information. How can I tell the difference between Centerfire and Quik Tip diffusers with the NEW internal stop vs. the original style Centerfire and Quik Tip diffusers? To help distinguish Centerfire diffusers (shown below, left) with the new internal stop, users can check the orientation of the roll mark. In original style diffusers, the roll mark is readable when the tip end is at the top. In diffusers with the new internal stop, the roll mark is readable when the neck end is at the top. To distinguish Quik Tip diffusers (shown above, right) with the new internal stop, users can check the roll mark. In the original style diffusers, the roll mark has one Bernard starburst stamped before the part number. In diffusers with the new internal stop, the roll mark has a Bernard starburst stamped before AND after the part number. For both Centerfire and Quik Tip diffusers, a second simple method to check for an internal stop would be to insert a liner into the diffuser. If the liner will not pass all the way through the diffuser, then an internal stop is present. Please note that it is important to understand which diffuser you are using as this affects liner trim length during replacement. Please refer to the insert inside of your diffuser bag or click here for additional information about liner replacement and trim length details.
The improved swivel design on the Bernard® FILTAIR™ fume extraction MIG gun now uses threads to retain the vacuum hose and eliminates the front band-it clamp from both amperage models. This redesign will improve performance and avoids replacing the hose clamp with a larger head. The new design threads into the vacuum hose and cannot be removed unless the hose is cut to remove it from the threads. Removing the front band-it clamp also eliminates the possibility of the clamp getting snagged on other equipment, gloves, clothing, etc. Did any part numbers change? Answer: The new threaded swivels are backwards compatible with existing guns. As a result, swivel part numbers did not change. How can you tell the difference between the old version and the new 2013 design? Answer: New 2013 design will not have the metal front band-it clamp located on the hose near the rear of the handle. See Figure below:
Learn more on the Bernard Quik Tip Series product page.
November 12, 2012 The QUICK LOAD® liner AutoLength™ system from Tregaskiss is designed specifically to minimize downtime, wire feeding and quality issues commonly associated with the liner being cut to an incorrect length. Short liners are a common root cause of poor wire feeding. Further, a short liner does not have a chance of properly seating in the retaining head — often resulting in “bird-nesting” of the welding wire or premature contact tip failure and wear. Wire feeding challenges reduce efficiency of the welding process and cause undesirable (and expensive) downtime. A system upgrade to this new innovative product can help improve welding efficiency and reduce costly downtime. Learn more about the QUICK LOAD liner AutoLength system.
Learn more on the 250 amp S-Gun MIG gun product page.
Learn more about this new product on the Dura-Flux self-shielded flux-cored gun product page.
An improved switch design for Bernard® T-Gun™ MIG guns (formerly Tregaskiss® TOUGH GUN® semi-automatic MIG guns) is now available to improve the performance and the life of the extended lever switch over previous versions. The switch casing design has been updated to allow for improved retention tabs between two switch halves, which also reduces the chance of switches tearing apart during use. This updated lever design is more robust with improved strength. How can you tell the difference between the old version and the new 2011 design? Our new 2011 switch is red (shown below in the comparison between current design and new 2011 design).
DISCONTINUED PRODUCT – Manual Products
DISCONTINUED PRODUCT –
Manual Products: Cable Connectors, Lugs and SplicersAs of August 4, 2014, the manual product line (cable connectors, lugs and splicers) from Bernard has been discontinued.
NEW PRODUCT – Bernard Clean Air Fume Extraction Gun
NEW PRODUCT –
Bernard Clean Air Fume Extraction GunNew Clean Air™ Fume Extraction Series
Reduce smoke at the source with an industrial-duty fume extraction gun that is comparable in size and weight to a regular welding gun.
PRODUCT UPDATE – Neck Insulators for BTB MIG Guns
PRODUCT UPDATE –
Neck Insulator Selection for BTB MIG Guns
Neck / Handle Consumables Insulator Part Number 200A 300A 400A 500A 600A Fixed neck for T series handles TOUGH LOCK® 402-11 Quik Tip™ 4423R Centerfire™ 4323R 4423R Rotatable neck for O, B, T series handles TOUGH LOCK 10012 Quik Tip 4423R Centerfire 4323R 4423R Fixed necks for O, B series handles TOUGH LOCK 10012 Quik Tip 4423R Centerfire 4323R 4423R PRODUCT UPDATE – Common Straight Rear Strain Relief for BTB MIG Guns
NEW PRODUCT –
Common Straight Rear Strain Relief for the BTB MIG Gun Platform
Exceptions: Black Clamshell Rear Strain Relief with Bernard and Euro Power Pins
PRODUCT IMPROVEMENT – Dual Thread Necks for BTB MIG Guns
PRODUCT IMPROVEMENT –
Dual Thread Necks for BTB MIG Guns
Beginning on June 2, 2014, Bernard’s new BTB MIG gun platform brings our Q-Gun™, S-Gun™ and T-Gun™ semi-automatic air-cooled MIG guns into a single gun line and single configurator. As a part of this launch, all fixed and rotatable necks offered through the new BTB MIG gun configurator will now feature a dual thread that allows the installation of your choice of consumables – TOUGH LOCK®, Centerfire™ or Quik Tip™ – without the need for special adaptor parts.How can I tell the difference between single and dual thread necks?
PRODUCT CHANGE – Bernard Power Pins
PRODUCT CHANGE –
Bernard Power Pins
NEW PRODUCT – Bernard Conventional Liners
NEW PRODUCT –
Bernard Conventional LinersCompatible with BTB Semi-Automatic MIG Guns and Legacy Q-Gun, S-Gun, & T-Gun Series MIG Guns
New Bernard Conventional Liners
Wire Size Liner Color 15′ (4.57 m) 25′ (7.62 m) 0.023″-0.030″ Yellow L1A-15 L1A-25 0.030″-0.035″ Green L2A-15 L2A-25 0.035″-0.045″ White L3A-15* L3A-25* 0.045″- 1/16″ Red L3A-15** L4A-25** 5/64″ Blue L6A-15 L6A-25 3/32″ Grey L7A-15 L7A-25 7/64″-1/8″ Black L8A-15 L8A-25
**Standard Liner for 1/16″ GunsBernard and Tregaskiss Conventional Liner to New Bernard Conventional Liner Cross Reference Chart for Bernard Semi-Automatic MIG Guns
Wire Size Bernard Liner Part Number Tregaskiss Liner Part Number New Bernard Conventional Liner Part Number 0.023″-0.030″ 43015 415-23-15 L1A-15 0.030″-0.035″ 43015 415-30-15 L2A-15 0.035″ – 0.045″ 44115 415-35-15 LS3-15 0.035″- 0.045″ 43115 — L3B-15 0.045″ – 1/16″ 44215 415-116-15 L4A-15 0.045″ – 1/16″ 43215 — L4B-15 5/64″ 44315 415-564-15 L6A-15 3/32″ 45415 415-332-15 L7A-15 7/64″ 45615 615-18-15 L8A-15 1/8″ 46715 615-18-15 L8A-15 PRODUCT UPDATE – New Handle Names for the BTB MIG Gun Platform
PRODUCT UPDATE –
New Handle Names for the BTB MIG Gun Platform
Beginning on June 2, 2014, Bernard’s new Best of the Best Platform brings our Q-Gun™, S-Gun™ and T-Gun™ semi-automatic air-cooled MIG guns into a single gun line and single configurator. Since we now have six gun handle styles within a single configurator, we have developed the following naming scheme for our handles per the chart below:
PRODUCT IMPROVEMENT – Q-Nut for BTB MIG Guns
PRODUCT IMPROVEMENT –
Improved Q-Nut Launching with the BTB MIG Gun Platform
SYSTEM UPDATE – New Gun Part Numbers for BTB MIG Guns
SYSTEM UPDATE –
New Gun Part Numbers for BTB MIG Gun PlatformAll Bernard Semi-Automatic Air-Cooled MIG Guns under the new BTB Platform will have new part numbering as of June 2, 2014.
Gun Line Old Part Number New Part Number PRODUCT UPDATE – New Internal Stop in Centerfire and Quik Tip Diffusers
PRODUCT UPDATE –
New Internal Stop in Centerfire and Quik Tip Diffusers
What’s Changed?
Frequently Asked Questions
PRODUCT IMPROVEMENT – New Swivel Design on the Bernard FILTAIR Fume Extraction Gun
PRODUCT IMPROVEMENT –
New Swivel Design on the Bernard FILTAIR Fume Extraction GunWhat Changed?
Frequently Asked Questions
NEW PRODUCT – Bernard Quik Tip HD Series Consumables
NEW PRODUCT –
Bernard Quik Tip HD Series
Designed for shipbuilding, trailer fabrication and other heavy equipment manufacturing operations.
NEW PRODUCT – QUICK LOAD Liner AutoLength System
NEW PRODUCT —
Tregaskiss QUICK LOAD Liner AutoLength System
NEW PRODUCT – Bernard 250 amp S-Gun MIG Gun
NEW PRODUCT –
Bernard 250 amp S-Gun MIG Gun
NEW! Ideal for shipbuilding and construction industries to reduce downtime and increase productivity!
NEW PRODUCT – Bernard FILTAIR Fume Extraction MIG Gun
NEW PRODUCT –
Bernard FILTAIR Fume Extraction GunKeeping a clean working environment is important.
That’s why Bernard engineered the FILTAIR™ fume extraction gun.
Get right to the source and extract fumes at the weld bead with this new gun!
NEW PRODUCT – Dura-Flux Self-Shielded Flux Cored Gun with Replaceable Cable Liner
NEW PRODUCT – Bernard Dura-Flux Self-Shielded Flux Cored Gun with Replaceable Cable Liner
NEW! Built to meet the needs of harsh and demanding environments, Bernard introduces the Dura-Flux™ Gun with replaceable power cable liner that is extremely durable yet comfortable to hold and use.
PRODUCT IMPROVEMENT – New 211-5-8 Extended Lever Switch
PRODUCT IMPROVEMENT –
New 211-5-8 Extended Lever Switch
What Changed?
Frequently Asked Questions
Current design (top) vs.
New 2011 design (bottom)
