Grizzly H8154 Welder User Manual
Contents
1. 21 INTRODUCTION Foreword We are proud to offer the Model H8154 AC DC Stick TIG Welder This machine is part of a grow ing Grizzly family of fine metalworking equipment When used according to the guidelines set forth in this manual you can expect years of trouble free enjoyable operation and proof of Grizzly s com mitment to customer satisfaction The specifications drawings and photographs illustrated in this manual represent the Model H8154 when the manual was prepared However owing to Grizzly s policy of continuous improve ment changes may be made at any time with no obligation on the part of Grizzly For your convenience we always keep current Grizzly manuals available on our website at www grizzly com Any updates to your machine will be reflected in these manuals as soon as they are complete Visit our site often to check for the lat est updates to this manual Contact Info If you have any comments regarding this manual please write to us at the address below Grizzly Industrial Inc o Technical Documentation Manager P O Box 2069 Bellingham WA 98227 2069 Email manuals grizzly com We stand behind our machines If you have any service questions or parts requests please call or write us at the location listed below Grizzly Industrial Inc 1203 Lycoming Mall Circle Muncy PA2. 7 Grounding for Welding ennemie time 8 SECTION S INVENTORT 8 9 cs Seca 10 Operatiom Safety 10 Welder Duty Cycle 10 Weld r Controls aie tome eee eee NEN 11 General 13 SECTION 5 dre ne anensnns 14 SECTION 6 SERVICE lt 15 15 Replacement Parts amp Labels 17 WARRANTY AND RETURNS
3. The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty Please feel free to write or call us if you have any questions about the machine or the manual Thank you again for your business and continued support We hope to serve you again soon CONTE TOOL WEBSITE Buy Direct and Save with Grizzly Trusted Proven and a Great Value Visit Our Website Today And Discover Why Grizzly Is The Industry Leader e SECURE ORDERING gt ORDERS SHIPPED WITHIN 24 HOURS E MAIL RESPONSE WITHIN ONE HOUR Call Today For A FREE Full Color Catalog FOUT Es
4. 4 Industrial MODEL H8154 AC DC STICK TIG WELDER OWNER S MANUAL COPYRIGHT MAY 2007 BY GRIZZLY INDUSTRIAL INC WARNING NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL INC TS9402 PRINTED IN CHINA WARNING This manual provides critical safety instructions on the proper setup operation maintenance and service of this machine equipment Failure to read understand and follow the instructions given in this manual may result in serious personal injury including amputation electrocution or death The owner of this machine equipment is solely responsible for its safe use This responsibility includes but is not limited to proper installation in a safe environment personnel training and usage authorization proper inspection and maintenance manual availability and comprehension application of safety devices blade cutter integ rity and the usage of personal protective equipment The manufacturer will not be held liable for injury or property damage from negligence improper training machine modifications or misuse WARNING Fumes created by welding cutting grinding drilling and other metal working activities may contain hazardous chemicals that can cause cancer birth defects or other reproductive harm Some examples of these chemicals are e Galvanized metal welding and cutting Lead from lead based paint
5. 17756 Phone 570 546 9663 Fax 800 438 5901 E Mail techsupport grizzly com Web Site http www grizzly com H8154 AC DC Stick TIG Welder Specifications Stick Welding 5 130A sas 35 130A AC Welding 20 160 Duty 35 160A Square Wave Balance 30 70 AC TIG Square Wave Frequency 20 100Hz DC Welding 5 160 TIG Duty Cycles 35 160A DC Current 0 2 sec DC Current Downslope 1 10 sec Gas 0 10 TIG Gas 1 25 Power Consumption 23 8A 220VAC O tp t POW EV ue 60 80VDC Length Width Height 21 9 16in sn ns 22 lbs Identification INVERTER AC D TIG maigre c Figure 1 Model H8154 control panel Output Current Dial Square Wave Balance Dial Downslope Current Dial Power Light Warning Light Post Flow Time Dial Welding Current LED Readout Stick TIG Selector 2 Step 4 Step Selector AC DC Selector Pre Flow Time Dial gt H8154 AC DC Stick TIG Welder a aN O Figure 2 Model 8154 front connections Posi
6. dis lt able the welding circuit until the fan has Figure 7 Model H8154 controls sufficiently cooled the welder A Output Current Dial Adjust this control for Green Output current is too high or the the correct welding output current welder has failed AC DC Stick 5 130 Input current is incorrect 20 160 Post Flow Time Dial This knob will control the amount of time 0 25 seconds gas will DC Welding 5 160 flow through the TIG torch after the welding arc is shut off B Square Wave Percentage Use this dial to adjust the deposition and penetration of the G Welding Current This LED readout shows AC TIG arc The dial is incremented in per the welding output current in amperes centage of the positive square wave cycle For example when the dial is set at 60 H Stick TIG Selector Use this switch to select 40 of each current cycle is negative and stick or TIG welding 60 is positive Continued on next page gt C Downslope Current Dial Use this dial to control the amount of time 0 10 seconds the welding current decreases from the selected output current to OFF D Power Light This will light when the power is turned ON H8154 AC DC Stick TIG Welder o 11 2 Step 4 Step Selector only Select either the 2 step or 4 step sequence for TIG welding Not
7. 4 513 742 2020 Website www acgih org Threshold Limit Values Booklet AWARNING Like all equipment there is potential danger when operating this welder Accidents are frequently caused by lack of familiarity or failure to pay attention Use this welder with respect and caution to lessen the possibility of operator injury If normal safety precau tions are overlooked or ignored serious personal injury may occur A CAUTION No list of safety guidelines can be complete Every shop environment is different Always consider safety first as it applies to your individual working conditions Use this and other equipment with caution and respect Failure to do so could result in serious per sonal injury damage to equipment or poor work results H8154 AC DC Stick TIG Welder SECTION 2 CIRCUIT REQUIREMENTS 220V Operation AWARNING Serious personal injury could occur if you connect the machine to the power source before you have completed the set up pro cess DO NOT connect the machine to the power source until instructed to do so Amperage Draw The Model H8154 welder draws the following amps under maximum load Draw at 220V Single Phase 23 8 Amps Circuit Requirements Connect your welder to a dedicated and grounded circuit that is rated for the amperage given below Never replace a circuit breaker on an existing cir cuit with one of higher amperage without consult ing a qualifi
8. 8154 AC DC Stick TIG Welder Replacement Parts amp Labels 12 13 17 18 5 i 4 2 1 2 4 Yo 8 9 REF PART DESCRIPTION REF PART DESCRIPTION 1 PH8154001 GAS INLET TUBE 10 PH8154010 COLLET 2MM 2 PH8154002 COLLET BODY PH8154011 TIG TORCH amp CABLE ASSEMBLY 3 PH8154003 GAS NOZZLE 4 PH8154012 WORK CLAMP amp CABLE 4 PH8154004 GAS NOZZLE 5 PH8154013 ELECTRODE CLAMP amp CABLE 5 PH8154005 GAS NOZZLE 6 PH8154014 FOOT REMOTE CONTROL 6 PH8154006 LONG COLLET BACKCAP PLABEL 14 ELECTRICITY LABEL 7 PH8154007 SMALL COLLET BACKCAP PLABEL 12 READ MANUAL LABEL 8 PH8154008 COLLET 1 6MM PH8154017 WELDER ID LABEL 9 PH8154009 COLLET 1 8MM PH8154018 SHOCK WARNING LABEL AWARNING Safety labels warn about machine hazards and ways to prevent injury The owner of this welder MUST maintain the original location and readability of the labels on the welder If any label is removed or becomes unreadable REPLACE that label before using the welder again Contact Grizzly at 800 523 4777 or www grizzly com to order new labels H8154 AC DC Stick TIG Welder o 17 CUT ALONG DOTTED LINE Grizzly NARRANTY CARD Industrial Inc Name Street 2 City State Zip Phone Email 2 Invoice Model Order Serial The following information is given on a voluntary basis It will be used for marketing purposes to help us develop better products and services Of course all information is strictly confi
9. C DC Selector Use this switch to select AC or DC current output Pre Flow Time Dial This knob will control the amount of time 0 10 seconds gas will flow through the TIG torch before the welding current in turned on H8154 AC DC Stick TIG Welder General Welding Operations Becoming a good welder takes a lot of practice and experience If you are a novice read books and get help from an experienced welder before beginning a welding operation Practice on scrap metal and expect to spend con siderable time learning the many aspects of good welding Although it is beyond the scope of this manual to instruct how to weld here are some general steps for successful welding 1 Read and understand this manual and ensure that all safety instructions are followed Establish a safe and efficient welding envi ronment and ensure that you are properly protected for the welding operation Ensure that there is a working fire extinguisher read ily available Have an experienced welder stand by to assist if needed Select the correct electrode tungsten rod and filler metal type and size for your welding project Choose the correct amperage output and be aware of the duty cycle for this amperage H8154 AC DC Stick TIG Welder 10 11 12 Decide which type of weld is correct for your project and properly prepare the metal Select the correct settings on the front control panel for your welding operation Make s
10. Practices for the Preparation for Welding and Cutting of Containers and Piping AWS F4 1 National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 617 770 3000 Website www nfpa org and www sparky org National Electrical Code NFPA Standard 70 Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 703 412 0900 Website www cganet com Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 Website www csa international org Code for Safety in Welding and Cutting CSA Standard W117 2 American National Standards Institute ANSI 11 West 42nd Street New York NY 10036 8002 212 642 4900 Website www ansi org Practice for Occupational and Educational Eye and Face Protection ANSI Standard Z87 1 U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 312 353 2220 Website www osha gov OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1929 Subpart J American Conference of Government Industrial Hygienists ACGIH 1330 Kemper Meadow Drive Suite 600 Cincinnati OH 45240 163
11. Shutdown will be evident by the loss of welding circuit and the illumination of the yellow warning light on the face of the welder When the welder has cooled sufficiently the internal thermostat will re establish the welding circuit and the yellow warning light will go out Note Most electrodes used with stick welding are consumed within a few minutes so the welder has a chance to cool down when the welding cir cuit is stopped to install a new electrode However with TIG welding the operator needs to plan his work within the duty cycle constraints of the welder AWARNING Always treat the welding components as if they carry live welding current even when the welder reaches the duty cycle limit and shuts down When the welder re establishes the welding current the electrode and work leads will immediately carry live welding cur rent Ignoring this warning could result in death or serious personal injury H8154 AC DC Stick TIG Welder Welder Controls NOTICE After completing the welding operation keep the power to the welder ON for a period of time to let the welder fan cool the welder down To avoid damage to your welder never shut the power OFF before the welder enclosure is completely cool to the touch E Warning Light Lit The welder is ready for use WELDING CURRENT A INVERTER ACIDE TIG MMA Yellow When the duty cycle has been exceeded the internal thermostat will
12. Use correct type and size of electrode tungsten rod Use the correct gas for the welding operation adjust the gas flow as necessary Make tack welds along joint before starting opera tion select lower amperage for electrode increase travel speed weld in small segments and allow cool ing between welds Select lower amperage use smaller electrode increase and or maintain steady travel speed Material too thick joint preparation must provide access to bottom of groove Keep arc on leading edge of weld puddle reduce travel speed Increase amperage select larger electrode Use the correct gas for the welding operation adjust the gas flow as necessary 15 Possible Cause Possible Solution Failure of weld to 1 Insufficient heat applied to weld fuse completely with 2 Improper welding technique base metal or prior weld bead Unstable arc Arc wanders Arc start 16 is difficult to Workpiece dirty Duty cycle exceeded Weld circuit polarity is incorrect Tungsten rod is contaminated TIG Arc too long Workpiece is dirty or damp Incorrect gas or gas settings TIG Improper gas flow TIG Arc too long Contaminated electrode tungsten rod Workpiece is dirty or damp Incorrect gas or gas settings TIG Weld circuit not complete No or inadequate gas flow TIG Incorrect electrode tungsten rod used Workpiece is dirty or damp Incorr
13. ar safety glasses welder s helmet and a respirator when oper ating this welder NOTICE If you have never used this type of machine or equipment before WE STRONGLY REC OMMEND that you read books trade maga zines or get formal training before begin ning any projects Regardless of the con tent in this section Grizzly Industrial will not be held liable for accidents caused by lack of training Welder Duty Cycle As the welder produces the desired power output for the welding operation some of the power is converted to heat In order to protect the welder components from over heating each welder has an established duty cycle The duty cycle is vari able depending upon the amperage output being used 310 A duty cycle is the number of minutes out of 10 minutes that the welder can safely operate at the current amperage output without over heating For instance the Model H8154 has a stick duty cycle of 35 at 130A output This means that the welder can operate continuously for 3 5 minutes at 130A output then the arc must be stopped for at least 6 5 minutes to allow the welder to cool off before starting the arc again It is important to leave the main power to the welder ON so that the cooling fan can speed the cooling process The Model H8154 operates with an efficient cool ing fan at the rear of the welder and has an internal thermostat that will shut the welder down if the maximum duty cycle has been reached
14. dential 1 How did you learn about us Advertisement Friend Catalog Card Deck Website Other 2 Which of the following magazines do you subscribe to Cabinet Maker ____ Popular Mechanics ____ Today s Homeowner Family Handyman Popular Science Wood Hand Loader Popular Woodworking Wooden Boat ____ Handy ____ Practical Homeowner ____ Woodshop News Home Shop Machinist Precision Shooter ____ Woodsmith Journal of Light Cont Projects in Metal Woodwork Live Steam ____ Modeler ____ Woodworker West Model Airplane News Rifle ____ Woodworkers Journal Modeltec Shop Notes Other Old House Journal Shotgun News 3 What is your annual household income 20 000 29 000 30 000 39 000 40 000 49 000 50 000 59 000 60 000 69 000 70 000 4 What 15 your age group ____ 20 29 _____ 30 39 40 49 50 59 _____ 60 69 70 5 How long have you been a woodworker metalworker 0 2 Years 2 8 Years 8 20 Years 20 Years 6 How many of your machines or tools are Grizzly 0 2 3 5 6 9 10 7 Do you think your machine represents a good value Yes No 8 Would you recommend Grizzly Industrial to a friend Yes No 9 Would you allow us to use your name as a reference for Grizzly customers in your area Note We never use names more than 3 times __ Yes No 10 Comments FOLD ALONG DOTTED LINE Grizzly Industrial Ic GRIZZLY INDUSTRIAL INC P O BOX 2069 BELLINGHAM WA 98227 2069 FOLD ALONG DOTTED LINE Send a Grizzly Ca
15. e The foot remote control can be sub stituted for the torch thumb switch in these steps 2 Step 1 start the sequence press and hold the torch thumb switch 2 Gas flows for 0 5 seconds to purge the torch line of air 3 welding current starts with a preset upslope time of 0 2 seconds from the pre set starting current of 15A to the selected output current 4 Release the thumb switch to end the welding sequence 5 The welding current decreases from the selected output current to the preset fin ish current over the preset downslope time then the welding current shuts off 6 The shielding gas continues to flow for the post flow time selected 4 Step 1 start the sequence press the torch thumb switch 2 The welding current starts at the preset starting current of 15 amps and stays at that level while the torch thumb switch is depressed 3 Gas flows for 0 5 seconds to purge the torch line of air 4 Release the torch thumb switch at any time to raise the welding current to the selected output current over the preset upslope time of 0 2 seconds 5 Press the thumb switch again to end the welding operation 6 The welding current decreases to the pre set finish current and stays at the level while the thumb switch is depressed 7 Release the thumb switch at any time to shut off the welding current 8 The shielding gas continues to flow for the post flow time selected A
16. ect gas or gas settings TIG Increase amperage select larger electrode Widen groove to access bottom during welding keep arc on leading edge of weld puddle place stringer bead in proper location at joint during weld ing Remove all grease oil moisture coatings rust and dirt from workpiece before welding Shut down welder and allow it to cool Switch cable polarity at welder Remove 1 2 of contaminated tungsten rod prop erly repoint rod Shorten arc lower torch electrode closer to workpiece Remove all grease oil moisture coatings rust and dirt from workpiece before welding Use the correct gas for the welding operation adjust the gas flow as necessary Adjust gas flow as necessary Shorten arc lower torch electrode closer to workpiece Replace electrode TIG Remove 12 of contami nated tungsten rod and properly repoint rod Remove all grease oil moisture coatings rust and dirt from workpiece before welding Use the correct gas for the welding operation adjust the gas flow as necessary Check clamps and cables tighten all connections Check all gas hoses and connections for leaks and tighten replace as necessary adjust gas flow as necessary Use correct type and size of electrode tungsten rod Remove all grease oil moisture coatings rust and dirt from workpiece before welding Use the correct gas for the welding operation adjust the gas flow as necessary H
17. ed electrician to ensure compliance with wiring codes If you are unsure about the wiring codes in your area or you plan to con nect your machine to a shared circuit consult a qualified electrician Minimum 220V Circuit Requirement 30 Amps Plug Receptacle Type Recommended Plug Receptacle NEMA 16 30 Grounded Outlet Box Grounding Blade Has Carrying Blades Figure 4 NEMA L6 30 plug and receptacle H8154 AC DC Stick TIG Welder Grounding In the event of an electrical short grounding reduces the risk of electric shock The grounding wire in the power cord must be properly connected to the grounding prong on the plug likewise the outlet must be properly installed and grounded All electrical connections must be made in accor dance with local codes and ordinances AWARNING Electrocution or fire could result if this machine is not grounded correctly or if your electrical con figuration does not com ply with local and state codes Ensure compliance by checking with a quali fied electrician Extension Cords We do not recommend the use of extension cords Instead arrange the placement of your equipment and the installed wiring to eliminate the need for extension cords If you find it absolutely necessary to use an exten sion cord at 220V with your machine e at least 10 gauge cord that does exceed 50 feet in length e The extension cord must also conta
18. etra tion of base metal Lack of penetration H8154 AC DC Stick TIG Welder Plug receptacle is at fault or wired incor rectly Wiring is open has high resistance ON OFF switch is at fault Duty cycle has been exceeded Arc length is too long Workpiece is dirty or damp Damp electrodes Inadequate gas flow TIG Incorrect electrode filler metal used Loose fittings in torch gas hoses TIG Amperage too high for electrode Voltage too high arc length too long Incorrect electrode tungsten rod used Incorrect gas or gas settings TIG Excessive heat applied to base metal Excessive heat applied to base metal Improper joint preparation Improper weld technique Insufficient heat applied to weld Incorrect gas or gas settings TIG Test for good contacts correct the wiring Check for broken wires or disconnected corroded connections and repair replace as necessary Replace faulty ON OFF switch Let the fan cool the welder Reduce length of arc Remove all grease oil moisture coatings rust and dirt from workpiece before welding blow out all air and moisture from gas lines Use dry electrodes Adjust gas flow rate as necessary Use correct type and size of electrode filler metal Tighten torch gas hose fittings check gas hoses and connections for leaks replace if necessary Select large electrode or decrease amperage Reduce voltage or arc length
19. h loading capacity for metal fumes with out increasing breathing resistance Heavy duty adjustable headstrap and soft closed cell foam face seal offers maximum comfort protection and fit 5 pack Figure 9 Model G7868 welding respirators Call 1800 5234777 To 14 H9745 Leather Shoe Covers H9746 Leather Knee Pads H9748 Leather Jacket Medium 40 42 H9887 Leather Jacket Large 44 46 H9888 Leather Jacket X Large 48 52 These leather jackets knee pads and shoe cov ers provide full protection from welding sparks and spatter Gloves not included Figure 10 Models 9748 9746 9745 leather welding protection H3157 Deluxe Welding Gloves Top grain leather gloves protect against welding hazards Extra long to protect wrists and fore arms One size fits all Figure 11 Model H3157 deluxe welding gloves H8154 AC DC Stick TIG Welder SECTION 6 SERVICE Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem devel ops If you need replacement parts or you are unsure of your repair skills then feel free to call our Technical Support at 570 546 9663 Troubleshooting Symptom Possible Cause Possible Solution Welder does not power up or the breaker trips Porosity small cavi ties or holes caused from gas pockets in weld poor weld bead color Excessive spatter Distortion of base metal Burn through or excessive pen
20. id damage keep elec tronic devices at least 50 feet from the welder when it is powered on Workers who have pacemakers must consult with their physician before using this equipment or being within 50 feet of welding operations H8154 AC DC Stick TIG Welder SECTION 3 INVENTORY The Model H8154 was carefully packed when it left our warehouse If you discover the machine is damaged or a is missing after you have signed for delivery please immediately call Customer Service at 570 546 9663 for advice Save the containers and all packing materials for possible inspection by the carrier or its agent Otherwise filing a freight claim can be difficult When you are completely satisfied with the condition of your shipment inventory the contents Figure 6 Model H8154 inventory Model H8154 AC DC Stick TIG Welder Gas Nozzles 4 5 and 6 Collets 1 6 1 8 and 2 0mm Gas Tubing Inlet Collet Body TIG Torch Assembly Cable Gas Tubing Small Collet Backcap and Torch Remote Control Long Collet Backcap Foot Remote Control Work Clamp and Cable Stick Electrode Clamp and Cable nmoowx gt H8154 AC DC Stick TIG Welder o 9 SECTION 4 OPERATIONS Operation Safety AWARNING Damage to your eyes and lungs could result from using this machine without proper protective gear Always we
21. in a ground wire and plug pin e A qualified electrician MUST size cords over 50 feet long to prevent damage to the weld er Grounding for Welding Safety There are two or more electrical circuits involved in any welding operation The practice of safely grounding these circuits is documented in vari ous codes and standards refer to Additional Sources for Welding Codes and Standards on Page 6 Welding Machine Ground When properly connected to a power source the Model H8154 welder is grounded through the power cord and local power grid The internal welding circuit of the welder is insulated from the external enclosure However to avoid shocking hazards if this internal insulation fails you must establish a separate earth ground for the welder s external enclosure This ground will ensure that if a short does occur and the metal enclosure becomes integrated with the welding current the current will safely dissipate directly through the ground instead of through you Note Refer to the publication NFPA 70 National Electric Code Article 250 Grounding and your local electrical codes for the correct method of establishing this ground The grounding terminal for the H8154 external enclosure is located on the left rear of the welder see Figure 5 Figure 5 Location of external enclosure grounding terminal on the rear of the Model H8154 Workpiece Ground The incoming power circuit to the welder and the working
22. nal injury or death Always use safe methods when moving gas cylinders Always secure a gas cylinder to a wall or approved cylinder cart with a chain before using or storing PROTECT GAS CYLINDERS FROM HEAT OR DAMAGE An excess of heat can cause the pressurized gas to expand and explode the cylinder Never weld on the gas cylinder Damaging the outside of the cylinder can cause the cylinder to crack and explode Exploding pressurized gas cylin ders can cause serious property damage personal injury or death ELECTRIC AND MAGNETIC FIELDS EMF Welding operations create EMF around the welding equipment and workpieces Workers who have pacemak ers must consult with their physician before using this equipment or being within 50 feet of welding operations EQUIPMENT MAINTENANCE Make sure equipment inspections and maintenance are performed by a qualified person as required Stop the welding operation and disconnect the welder from power if the equipment is damaged or malfunctions EXPERIENCING DIFFICULTIES If you are experiencing difficulties performing the intended operation stop using the equip ment Contact our Technical Support Department at 570 546 9663 Additional Sources for Welding Codes and Standards American Welding Society 550 N W LeJeune Road Miami FL 33126 305 443 9353 Website www aws org Safety in welding Cutting and Allied Processes ANSI Standard 249 1 Recommended Safe
23. proce dures for this equipment WELDING FUMES Breathing welding fumes can cause suffocation or poisoning without warning Keep your head out of welding fumes Use adequate ventilation at the arc to safely remove the fumes from your breathing zone and the general area Use ANSI approved respirators for the type of welding operation Protect others from these fumes 3 WELDING IN A CONFINED SPACE CAN BE HAZARDOUS Always open all covers sustain forced ventilation remove toxic and hazardous materials and provide a power disconnect to the welder inside the work space Always work with someone who can give you help from outside the space Welding can displace oxygen Always check for safe breathing atmosphere and provide air supplied respirators if necessary Keep in mind that all normal welding hazards are intensified in a confined space H8154 AC DC Stick TIG Welder AWARNING ELECTRIC SHOCK DO NOT touch live electrical parts Connect welder to power source with approved earth ground Make sure all electrical connections are tight clean and dry Connect workpiece to approved earth ground The work lead is NOT a ground connection and is to be used only to complete the working welding circuit PREVENT FIRES Welding work zones must be kept clear of flammable liquids such as gasoline and solvents combus tible solids such as paper and wood and flammable gases such as acetylene and hydrogen Provide approved fire ba
24. rriers and fire extinguishing equipment for the welding zone Stay alert for sparks and spatter thrown into cracks and crevices that can start a smoldering fire PERSONAL PROTECTIVE EQUIPMENT Wear eye ear and body protection approved for welding operations Wear complete body protection such as clean and oil free protective clothing leather gloves protective cap heavy long sleeve shirt cuffless pants and high leather boots DO NOT wear jewelry or frayed clothing Use a welding helmet with correct shade of filter for the operation Protect other people and property in your working zone from exposure to arc radiation sparks and spat ter WORKING AREA Keep working area clear of any material not involved in the welding operation Keep all equipment workpieces and work surfaces clean dry and free of entanglements Keep lead cables orga nized and away from your body AVOID EXPLOSION HAZARD Never weld on closed containers or containers with fumes inside Containers should be prepared per American Welding Society Publication F4 1 Section 7 H8154 AC DC Stick TIG Welder 9 HANDLING GAS CYLINDERS Regardless of content pressurized gas cylinders can explode Always secure a protector cap in place over the outlet valve assembly when moving the cylinder A broken off valve could release the pressurized contents and cause the cylinder to be hurled about at dangerously high speeds causing serious property damage perso
25. s Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals Work in a well ventilated area and work with approved safety equip ment such as those respirators that are specially designed to filter out microscopic particles and gases Table of Contents INTRODUCTION 2 Le LEA WONG RO Te 2 Contact in 2 rS 3 eerie 3 SECTION 1 SAFETY 4 Safety Instructions for Stick TIG Welders 4 Additional Sources for Welding Codes and Standards 6 SECTION 2 CIRCUIT REQUIREMENTS 7 220V OP RATION ee
26. talog to a friend Street TAPE ALONG EDGES PLEASE DO NOT STAPLE WARRANTY AND RETURNS Grizzly Industrial Inc warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase This warranty does not apply to defects due directly or indirectly to misuse abuse negligence accidents repairs or alterations or lack of maintenance This is Grizzly s sole written warranty and any and all warranties that may be implied by law including any merchantability or fitness for any par ticular purpose are hereby limited to the duration of this written warranty We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants In no event shall Grizzly s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington County of Whatcom We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our products To take advantage of this warranty contact us by mail or phone and give us all the details We will then issue you a Return Number which must be clearly posted on the outside as well as the inside of the carton We will not accept any item back without this number Proof of purchase must accompany the merchandise
27. tive Output Socket Negative Output Socket Remote Control Connection Gas Outlet Connection ozar Figure 3 Model H8154 features on back of welder Power ON OFF Switch Gas Inlet Connection Power Cord Welder Enclosure Ground Terminal Cooling Fan and Cover Hp ADANGER AWARNING A CAUTION SECTION 1 SAFETY AWARNING For Your Own Safety Read Instruction Manual Before Operating this Machine The purpose of safety symbols is to attract your attention to possible hazardous conditions This manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages The progression of symbols is described below Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures against unsafe practices NOTICE Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury It may also be used to alert This symbol is used to alert the user to useful information about proper operation of the machine AWARNING Safety Instructions for Stick TIG Welders READ THIS MANUAL This manual con tains proper operating and safety
28. ure all connections hoses gas cylin der and grounds are correct and secure Note nsert the welding cable connectors into the welder output sockets and twist clockwise until fully secure For TIG weld ing connect the additional remote connector torch or foot and gas hose to the appropri ate connections Stay aware of the work environment around you as you weld and ensure that flying sparks do not start a fire Look slightly ahead of the arc Even with the protection of the welder s hood looking directly at the arc can damage your eyes Listen to the sound of the weld Each type of weld has its own distinct sound when it is progressing correctly During at least one hour after the welding operation is complete check for smoldering material or fire 13 SECTION 5 ACCESSORIES H7786 Auto Darkening Welding Helmet Automatic UV and IR filters protect eyes from harmful visible and invisible light during welding Switching time is less than or equal to 2 millisec onds so there s no need to flip the helmet up to see your work under normal light conditions Full face protection features adjustable head suspen sion and adjustable delay time sensitivity and dark shade protection Viewing area is 3 2 11 2 Includes 2 AAA batteries Figure 8 Model H7786 welding helmet G7868 Welding Respirators Flame retardant outer shell is recommended for welding applications Special depth filter pro vides hig
29. welding circuit are two separate circuits that must have separate grounds The weld ing circuit consists of the internal components of the welder the welding cables the electrode holder torch assembly the work clamp and the workpiece ANSI Welding Standards 749 1 11 3 2 1 specify that Grounding of the workpiece shall be done by locating the work on a grounded metal floor or platen or by connection to a grounded building frame or other satisfactory ground AWARNING Always ensure that the ground for the incom ing power circuit to the welder and the ground for the working welding circuit are never connected Failure to comply with this warning could result in death serious per sonal injury or property damage You must also avoid double grounding the workpiece ANSI Z49 1 states that Care shall be taken to avoid the flow of welding current through a connection intended only for safety grounding since the welding current may be of a higher mag nitude than the grounding conductor can safely carry Note The work lead from the welder is some times incorrectly referred to as the ground lead The work lead from the welder is NOT a ground The work lead and the ground connection to the workpiece are separate and must NOT be con nected in any way AWARNING TIG welders use a high frequency current that creates a high electro magnetic field EMF around the welder EMF disrupts elec tronic devices To avo
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