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!

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Contact Info

If you have any comments regarding this manual, please write to us at the address below:

Grizzly Industrial, Inc.

C/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, PA 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

Identification

D E

Figure 2. Model H8154 front connections.

L.Positive Output Socket

M.Negative Output Socket

N.Remote Control Connection

O.Gas Outlet Connection

P

T

F

S

Q

R

Figure 1. Model H8154 control panel.

A.Output Current Dial

B.Square Wave Balance Dial

C.Downslope Current Dial

D.Power Light

E.Warning Light

F.Post-Flow Time Dial

G.Welding Current LED Readout

H.Stick/TIG Selector

I.2-Step/4-Step Selector

J.AC/DC Selector

K.Pre-Flow Time Dial

H8154 AC/DC Stick/TIG Welder

Figure 3. Model H8154 features on back of welder.

P.Power ON/OFF Switch

Q.Gas Inlet Connection

R.Power Cord

S.Welder Enclosure Ground Terminal

T.Cooling Fan and Cover

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1.READ THIS MANUAL. This manual con- tains proper operating and safety proce- dures for this equipment.

2.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.

4.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.

5.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 barriers 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.

6.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.

7.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.

8.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.

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, personal 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.

10.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.

11.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.

12.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.

13.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.

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.

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.

220V Operation

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:

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 quali???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

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.

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:

???Use at least a 10 gauge cord that does not exceed 50 feet in length.

Figure 4. NEMA L6-30 plug and receptacle.

The extension cord must also contain a ground wire and plug pin.

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.

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Workpiece Ground

The incoming power circuit to the welder and the working 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 (Z49.1, 11.3.2.1) specify that "Grounding [of the workpiece] shall be done by locating the work on a grounded metal ???oor or platen, or by connection to a grounded building frame or other satisfactory ground."

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.

TIG welders use a high frequency current that creates a high electro-magnetic field (EMF) around the welder. EMF disrupts elec- tronic devices. To avoid 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

Operation Safety

Damage to your eyes and lungs could result from using this machine without proper protective gear. Always wear 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.

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. 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.

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.

Welder Controls

D E

F

Figure 7. Model H8154 controls.

A.Output Current Dial: Adjust this control for the correct welding output current.

B.Square Wave Percentage: Use this dial to adjust the deposition and penetration of the AC TIG arc. The dial is incremented in per- centage of the positive square wave cycle. For example, when the dial is set at 60%, 40% of each current cycle is negative and 60% is positive.

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.

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:

???Not Lit: The welder is ready for use.

???Yellow: When the duty cycle has been exceeded, the internal thermostat will dis- able the welding circuit until the fan has sufficiently cooled the welder.

???Green: Output current is too high or the welder has failed.

???Red: Input current is incorrect.

F.Post-Flow Time Dial: This knob will control the amount of time (0???25 seconds) gas will flow through the TIG torch after the welding arc is shut off.

G.Welding Current: This LED readout shows the welding output current in amperes.

H.Stick/TIG Selector: Use this switch to select stick or TIG welding.

I.2-Step/4-Step Selector (TIG only): Select either the 2-step or 4-step sequence for TIG welding.

Note: The foot remote control can be sub- stituted for the torch thumb switch in these steps.

???2-Step

1.To 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.The 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.To 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.

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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.

J.AC/DC Selector: Use this switch to select AC or DC current output.

K.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.

2.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.

3.Have an experienced welder stand by to assist if needed.

4.Select the correct electrode, tungsten rod, and filler metal type and size for your welding project.

5.Choose the correct amperage output and be aware of the duty cycle for this amperage.

H8154 AC/DC Stick/TIG Welder

6.Decide which type of weld is correct for your project and properly prepare the metal.

7.Select the correct settings on the front control panel for your welding operation.

8.Make sure all connections, hoses, gas cylin- der, and grounds are correct and secure.

Note: Insert 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.

9.Stay aware of the work environment around you as you weld, and ensure that flying sparks do not start a fire.

10.Look slightly ahead of the arc. Even with the protection of the welder's hood, looking directly at the arc can damage your eyes.

11 . Listen to the sound of the weld. Each type of weld has its own distinct sound when it is progressing correctly.

12.During at least one hour after the welding operation is complete, check for smoldering material or fire.

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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 31???2" x 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 high 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.

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 H9748/H9746/H9745 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 9. Model G7868 welding respirators.

Figure 11. Model H3157 deluxe welding gloves.

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