Bernard MIG Gun Configurator User manual

©2008 Bernard Printed in U.S.A.
Barrel and Cable Length
MIG gun configurator allows easy, precise
customization of just the right A/C Automatic
MIG gun for your welding job.
Amperage ratings at 100% duty cycle with CO2
gas: 300 and 500 amps.
Power cable equipped guns available in lengths
to fit many applications.
Necks available in numerous length and bend
angles for maximum accessibility.
Contact tip options include Centerfire™ and Quik
Tip™ and are available in wire sizes from .023"
(0.6 mm) to 1/8" (3.2 mm).
Direct plugs connect to wire feeders and
machines from most major manufacturers.
Air-Cooled Automatic MIG
gun without cable shown with
Centerfire™ consumables
Issued March 2008 • Index No. SPEC ACA-1.1
Air-Cooled Automatics
MIG Gun Configurator
U
SA
Made with
Pride and without
Compromise in the
All Guns are Not Created Equal.
A MIG gun should be durable, easy to
use and customized to your specific
application. Our MIG guns put you in
control: you choose the options you
need and we'll build a gun to last.
Bernard®
An Illinois Tool Works Company
449 West Corning Road, Box 667
Beecher, Illinois 60401 USA
Phone: [phone] (US Only) 708-946-2281 (Outside US)
Fax: [phone]
For more information, visit us at BernardWelds.com
FIGURE A FIGURE B FIGURE C
Barrel
Length
Cable
Length
Barrel
Length
Barrel Without
Spring
(spring replaced
with end cap)
Pitch Rack
• Pitch rack kit includes 2 mounting
screws and rack
• Note: only fits guns with 9-5/8" barrel
• 32 pitch
Pitch rack kit part number: 1880159

Guns With CableGuns Without Cable
0
Neck
0No
Neck
ACA
Gun Type
ACA No
Neck
00
Amperage
00 No Cable
000
Cable
Length
000 No
Cable
8
Contact
Tip
8Centerfire
5Quick Tip
Note: Centerfire
includes D-1
gas diffuser and
N5818-C nozzle.
Quick Tip
includes D118Q
gas diffuser and
N1C58Q nozzle.
A
Wire Size
A.023" (0.6 mm)
B.030" (0.8 mm)
C.035" (0.9 mm)
D.039" (1.0 mm)
E.045" (1.2 mm)
H.052" (1.4 mm)
I1/16" (1.6 mm)
K5/64" (2.0 mm)
L3/32" (2.4 mm)
M7/64" (2.8 mm)
N1/8" (3.2 mm)
Aluminum Wire
Size
Q.035" (0.9 mm)
R3/64" (1.19 mm)
S1/16" (1.6 mm)
M
Direct
Plug
MMiller®
LLincoln®
TTweco 4®
WTweco 5®
0
Neck
0No
Neck
ACC
Gun Type
ACC No
Neck
30
Amperage
30 300 amp
50 500 amp
048
Cable
Length
048 48" (1.2 m)
060 60" (1.5 m)
072 72" (1.8 m)
096 96" (2.4 m)
120 120" (3.0 m)
180 180" (4.6 m)
See Fig. B on back page
Note: Other lengths
available. Contact
Cusomer Service for
details.
C
Barrel Length
A3-5/8" (9.2 cm)
B6-5/8" (16.8 cm)
C9-5/8" (24.5 cm)
Barrel Without
Spring
D3-5/8" (9.2 cm)
E6-5/8" (16.8 cm)
F9-5/8" (24.5 cm)
See Fig. C on back page
8
Contact
Tip
8Centerfire
5Quick Tip
Note: Centerfire
includes D-1
gas diffuser and
N5818-C nozzle.
Quick Tip
includes D118Q
gas diffuser and
N1C58Q nozzle.
E
Wire Size
A.023" (0.6 mm)
B.030" (0.8 mm)
C.035" (0.9 mm)
D.039" (1.0 mm)
E.045" (1.2 mm)
H.052" (1.4 mm)
I1/16" (1.6 mm)
K5/64" (2.0 mm)
L3/32" (2.4 mm)
M7/64" (2.8 mm)
N1/8" (3.2 mm)
Aluminum Wire
Size
Q.035" (0.9 mm)
R3/64" (1.19 mm)
S1/16" (1.6 mm)
B
Direct
Plug
BBernard®
MMiller®
LLincoln®
TTweco 4®
EEuro®
WTweco 5®
C
Barrel Length
A3-5/8" (9.2 cm)
B6-5/8" (16.8 cm)
C9-5/8" (24.5 cm)
See Fig. A on back page
D
Neck
ARotatable,
Short
30° QT2-30
BRotatable,
Short
45° QT2-45
CRotatable,
Medium
30° QT3-30
DRotatable,
Medium
45° QT3-45
EStraight, 3"
(7.6 cm)
180° QT-180-3
FStraight, 5"
(12.7 cm)
180° QT-180-5
ACB
Gun Type
ACB With
Neck
00
Amperage
00 No Cable
000
Cable
Length
000 No
Cable
8
Contact
Tip
8Centerfire
5Quick Tip
Note: Centerfire
includes D-1
gas diffuser and
N5818-C nozzle.
Quick Tip
includes D118Q
gas diffuser and
N1C58Q nozzle.
B
Wire Size
A.023" (0.6 mm)
B.030" (0.8 mm)
C.035" (0.9 mm)
D.039" (1.0 mm)
E.045" (1.2 mm)
H.052" (1.4 mm)
I1/16" (1.6 mm)
K5/64" (2.0 mm)
L3/32" (2.4 mm)
M7/64" (2.8 mm)
N1/8" (3.2 mm)
Aluminum Wire
Size
Q.035" (0.9 mm)
R3/64" (1.19 mm)
S1/16" (1.6 mm)
M
Direct
Plug
MMiller®
LLincoln®
TTweco 4®
WTweco 5®
C
Barrel
Length
A3-5/8"
(9.2 cm)
B6-5/8"
(16.8 cm)
C9-5/8"
(24.5 cm)
See Fig. A on back
page
D
Neck
ARotatable,
Short
30° QT2-30
BRotatable,
Short
45° QT2-45
CRotatable,
Medium
30° QT3-30
DRotatable,
Medium
45° QT3-45
EStraight, 3"
(7.6 cm)
180° QT-180-3
FStraight, 5"
(12.7 cm)
180° QT-180-5
ACD
Gun Type
ACD With
Neck
8
Contact
Tip
8Centerfire
5Quick Tip
Note: Centerfire
includes D-1
gas diffuser and
N5818-C nozzle.
Quick Tip
includes D118Q
gas diffuser and
N1C58Q nozzle.
I
Wire Size
A.023" (0.6 mm)
B.030" (0.8 mm)
C.035" (0.9 mm)
D.039" (1.0 mm)
E.045" (1.2 mm)
H.052" (1.4 mm)
I1/16" (1.6 mm)
K5/64" (2.0 mm)
L3/32" (2.4 mm)
M7/64" (2.8 mm)
N1/8" (3.2 mm)
Aluminum Wire
Size
Q.035" (0.9 mm)
R3/64" (1.19 mm)
S1/16" (1.6 mm)
B
Barrel
Length
A3-5/8"
(9.2 cm)
B6-5/8"
(16.8 cm)
C9-5/8"
(24.5 cm)
Barrel With-
out Spring
D3-5/8"
(9.2 cm)
E6-5/8"
(16.8 cm)
F9-5/8"
(24.5 cm)
See Fig. C on back
page
B
Direct
Plug
BBernard®
MMiller®
LLincoln®
TTweco 4®
EEuro®
WTweco 5®
30
Amperage
30 300 amp
50 500 amp
060
Cable
Length
048 48"
(1.2 m)
060 60"
(1.5 m)
072 72"
(1.8 m)
096 96"
(2.4 m)
120 120"
(3.0 m)
180 180"
(4.6 m)
See Fig. B on back
page
Note: Other lengths
available. Contact
Cusomer Service
for details.
Building an Air-Cooled Automatic Gun
Bernard® makes it easy to customize the right gun for your specific application. Simply find the configurator that matches the power cable and neck
set-up you require. Then, build a part number for a new Air-Cooled Automatic gun by selecting: Gun Type, Amperage, Cable Length, Barrel Length,
Neck, Contact Tip, Wire Size and Direct Plug.
Air-Cooled Automatic Part Number
ACD40060BD8IB is an example of a typical configuration. It was built using the Guns With Cable and Neck configurator and consists of a 400 amp
60" power cable, 6-5/8" barrel, rotatable medium 45˚ neck, Centerfire™ 1/16" contact tip and Bernard® direct plug.

Guns With CableGuns Without Cable
0
Neck
0No
Neck
ACA
Gun Type
ACA No
Neck
00
Amperage
00 No Cable
000
Cable
Length
000 No
Cable
8
Contact
Tip
8Centerfire
5Quick Tip
Note: Centerfire
includes D-1
gas diffuser and
N5818-C nozzle.
Quick Tip
includes D118Q
gas diffuser and
N1C58Q nozzle.
A
Wire Size
A.023" (0.6 mm)
B.030" (0.8 mm)
C.035" (0.9 mm)
D.039" (1.0 mm)
E.045" (1.2 mm)
H.052" (1.4 mm)
I1/16" (1.6 mm)
K5/64" (2.0 mm)
L3/32" (2.4 mm)
M7/64" (2.8 mm)
N1/8" (3.2 mm)
Aluminum Wire
Size
Q.035" (0.9 mm)
R3/64" (1.19 mm)
S1/16" (1.6 mm)
M
Direct
Plug
MMiller®
LLincoln®
TTweco 4®
WTweco 5®
0
Neck
0No
Neck
ACC
Gun Type
ACC No
Neck
30
Amperage
30 300 amp
50 500 amp
048
Cable
Length
048 48" (1.2 m)
060 60" (1.5 m)
072 72" (1.8 m)
096 96" (2.4 m)
120 120" (3.0 m)
180 180" (4.6 m)
See Fig. B on back page
Note: Other lengths
available. Contact
Cusomer Service for
details.
C
Barrel Length
A3-5/8" (9.2 cm)
B6-5/8" (16.8 cm)
C9-5/8" (24.5 cm)
Barrel Without
Spring
D3-5/8" (9.2 cm)
E6-5/8" (16.8 cm)
F9-5/8" (24.5 cm)
See Fig. C on back page
8
Contact
Tip
8Centerfire
5Quick Tip
Note: Centerfire
includes D-1
gas diffuser and
N5818-C nozzle.
Quick Tip
includes D118Q
gas diffuser and
N1C58Q nozzle.
E
Wire Size
A.023" (0.6 mm)
B.030" (0.8 mm)
C.035" (0.9 mm)
D.039" (1.0 mm)
E.045" (1.2 mm)
H.052" (1.4 mm)
I1/16" (1.6 mm)
K5/64" (2.0 mm)
L3/32" (2.4 mm)
M7/64" (2.8 mm)
N1/8" (3.2 mm)
Aluminum Wire
Size
Q.035" (0.9 mm)
R3/64" (1.19 mm)
S1/16" (1.6 mm)
B
Direct
Plug
BBernard®
MMiller®
LLincoln®
TTweco 4®
EEuro®
WTweco 5®
C
Barrel Length
A3-5/8" (9.2 cm)
B6-5/8" (16.8 cm)
C9-5/8" (24.5 cm)
See Fig. A on back page
D
Neck
ARotatable,
Short
30° QT2-30
BRotatable,
Short
45° QT2-45
CRotatable,
Medium
30° QT3-30
DRotatable,
Medium
45° QT3-45
EStraight, 3"
(7.6 cm)
180° QT-180-3
FStraight, 5"
(12.7 cm)
180° QT-180-5
ACB
Gun Type
ACB With
Neck
00
Amperage
00 No Cable
000
Cable
Length
000 No
Cable
8
Contact
Tip
8Centerfire
5Quick Tip
Note: Centerfire
includes D-1
gas diffuser and
N5818-C nozzle.
Quick Tip
includes D118Q
gas diffuser and
N1C58Q nozzle.
B
Wire Size
A.023" (0.6 mm)
B.030" (0.8 mm)
C.035" (0.9 mm)
D.039" (1.0 mm)
E.045" (1.2 mm)
H.052" (1.4 mm)
I1/16" (1.6 mm)
K5/64" (2.0 mm)
L3/32" (2.4 mm)
M7/64" (2.8 mm)
N1/8" (3.2 mm)
Aluminum Wire
Size
Q.035" (0.9 mm)
R3/64" (1.19 mm)
S1/16" (1.6 mm)
M
Direct
Plug
MMiller®
LLincoln®
TTweco 4®
WTweco 5®
C
Barrel
Length
A3-5/8"
(9.2 cm)
B6-5/8"
(16.8 cm)
C9-5/8"
(24.5 cm)
See Fig. A on back
page
D
Neck
ARotatable,
Short
30° QT2-30
BRotatable,
Short
45° QT2-45
CRotatable,
Medium
30° QT3-30
DRotatable,
Medium
45° QT3-45
EStraight, 3"
(7.6 cm)
180° QT-180-3
FStraight, 5"
(12.7 cm)
180° QT-180-5
ACD
Gun Type
ACD With
Neck
8
Contact
Tip
8Centerfire
5Quick Tip
Note: Centerfire
includes D-1
gas diffuser and
N5818-C nozzle.
Quick Tip
includes D118Q
gas diffuser and
N1C58Q nozzle.
I
Wire Size
A.023" (0.6 mm)
B.030" (0.8 mm)
C.035" (0.9 mm)
D.039" (1.0 mm)
E.045" (1.2 mm)
H.052" (1.4 mm)
I1/16" (1.6 mm)
K5/64" (2.0 mm)
L3/32" (2.4 mm)
M7/64" (2.8 mm)
N1/8" (3.2 mm)
Aluminum Wire
Size
Q.035" (0.9 mm)
R3/64" (1.19 mm)
S1/16" (1.6 mm)
B
Barrel
Length
A3-5/8"
(9.2 cm)
B6-5/8"
(16.8 cm)
C9-5/8"
(24.5 cm)
Barrel With-
out Spring
D3-5/8"
(9.2 cm)
E6-5/8"
(16.8 cm)
F9-5/8"
(24.5 cm)
See Fig. C on back
page
B
Direct
Plug
BBernard®
MMiller®
LLincoln®
TTweco 4®
EEuro®
WTweco 5®
30
Amperage
30 300 amp
50 500 amp
060
Cable
Length
048 48"
(1.2 m)
060 60"
(1.5 m)
072 72"
(1.8 m)
096 96"
(2.4 m)
120 120"
(3.0 m)
180 180"
(4.6 m)
See Fig. B on back
page
Note: Other lengths
available. Contact
Cusomer Service
for details.
Building an Air-Cooled Automatic Gun
Bernard® makes it easy to customize the right gun for your specific application. Simply find the configurator that matches the power cable and neck
set-up you require. Then, build a part number for a new Air-Cooled Automatic gun by selecting: Gun Type, Amperage, Cable Length, Barrel Length,
Neck, Contact Tip, Wire Size and Direct Plug.
Air-Cooled Automatic Part Number
ACD40060BD8IB is an example of a typical configuration. It was built using the Guns With Cable and Neck configurator and consists of a 400 amp
60" power cable, 6-5/8" barrel, rotatable medium 45˚ neck, Centerfire™ 1/16" contact tip and Bernard® direct plug.

©2008 Bernard Printed in U.S.A.
Barrel and Cable Length
MIG gun configurator allows easy, precise
customization of just the right A/C Automatic
MIG gun for your welding job.
Amperage ratings at 100% duty cycle with CO2
gas: 300 and 500 amps.
Power cable equipped guns available in lengths
to fit many applications.
Necks available in numerous length and bend
angles for maximum accessibility.
Contact tip options include Centerfire™ and Quik
Tip™ and are available in wire sizes from .023"
(0.6 mm) to 1/8" (3.2 mm).
Direct plugs connect to wire feeders and
machines from most major manufacturers.
Air-Cooled Automatic MIG
gun without cable shown with
Centerfire™ consumables
Issued March 2008 • Index No. SPEC ACA-1.1
Air-Cooled Automatics
MIG Gun Configurator
U
SA
Made with
Pride and without
Compromise in the
All Guns are Not Created Equal.
A MIG gun should be durable, easy to
use and customized to your specific
application. Our MIG guns put you in
control: you choose the options you
need and we'll build a gun to last.
Bernard®
An Illinois Tool Works Company
449 West Corning Road, Box 667
Beecher, Illinois 60401 USA
Phone: [phone] (US Only) 708-946-2281 (Outside US)
Fax: [phone]
For more information, visit us at BernardWelds.com
FIGURE A FIGURE B FIGURE C
Barrel
Length
Cable
Length
Barrel
Length
Barrel Without
Spring
(spring replaced
with end cap)
Pitch Rack
• Pitch rack kit includes 2 mounting
screws and rack
• Note: only fits guns with 9-5/8" barrel
• 32 pitch
Pitch rack kit part number: 1880159