Grizzly Welding System 230V User Manual

MODEL H8151  
230V MINI 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.  
#TS9041 PRINTED IN CHINA  
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Table of Contents  
INTRODUCTION............................................................................................................................... 2  
Foreword .................................................................................................................................... 2  
Contact Info................................................................................................................................ 2  
Specifications ............................................................................................................................. 3  
Identification ............................................................................................................................... 3  
SECTION 1: SAFETY....................................................................................................................... 4  
Safety Instructions for Shielded Metal Arc Welders (SMAW).................................................... 4  
Additional Sources for Welding Codes and Standards.............................................................. 6  
SECTION 2: CIRCUIT REQUIREMENTS ........................................................................................ 7  
220V Operation.......................................................................................................................... 7  
Grounding for Arc Welding Safety ............................................................................................. 8  
SECTION 3: INVENTORY................................................................................................................ 9  
SECTION 4: OPERATIONS ........................................................................................................... 10  
Operation Safety ...................................................................................................................... 10  
Welder Duty Cycle ................................................................................................................... 10  
General Arc Welding Operations ............................................................................................. 11  
SECTION 5: ACCESSORIES......................................................................................................... 12  
SECTION 6: SERVICE ................................................................................................................... 13  
Troubleshooting........................................................................................................................ 13  
Replacement Parts And Labels ............................................................................................... 14  
WARRANTY AND RETURNS........................................................................................................ 17  
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INTRODUCTION  
Foreword  
Contact Info  
We are proud to offer the Model H8151 230V  
Mini Welder. This machine is part of a growing  
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.  
If you have any comments regarding this manual,  
please write to us at the address below:  
Grizzly Industrial, Inc.  
Technical Documentation Manager  
P.O. Box 2069  
C
/
O
Bellingham, WA 98227-2069  
The specifications, drawings, and photographs  
illustrated in this manual represent the Model  
H8151 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.  
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  
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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Specifications  
Welding Current ....................................10–125A  
Duty Cycles:  
—@ 125A..............................................35%  
—@ 95A................................................60%  
—@ 75A..............................................100%  
Power Consumption...................24A @ 220VAC  
Output Power ....................................60–80V DC  
Net Weight.................................................12 lbs.  
J
K
I
L
Figure 2. Model H8151 rear view.  
Identification  
I. Power Cord  
J. ON/OFF Switch  
K. Cooling Fan and Cover  
L. Welder Enclosure Ground Terminal  
E
D
F
C
G
B
H
A
Figure 1. Model H8151 front view.  
A. Electrode Holder and Cable  
B. Negative Output Socket  
C. Power Lamp  
D. Temperature Warning Lamp  
E. Carrying Strap  
F. Variable Current Output Dial  
G. Positive Output Socket  
H. Work Clamp and Cable  
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Safety Instructions for  
Shielded Metal Arc Welders (SMAW)  
1. READ THIS MANUAL. This manual con-  
tains proper operating and safety proce-  
dures for this equipment.  
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.  
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.  
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Additional Safety Instructions for  
Shielded Metal Arc Welders (SMAW)  
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.  
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.  
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.  
8. 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.  
6. PROTECT BODY FROM ARC BURNS,  
SPARKS, AND SPATTER. Wear correct  
and approved eye, ear, and body protec-  
tion. Wear complete body protection, such  
as clean and oil-free protective clothing,  
leather gloves, protective cap, heavy long-  
sleeve shirt, cuffless pants, and high leath-  
er 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 work-  
ing zone from exposure to arc radiation,  
sparks, and spatter.  
9. 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.  
10. 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.  
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.  
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.  
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Additional Sources  
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 Z49.1  
—Recommended Safe 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 45240-1634, (513) 742-2020, Website: www.acgih.org.  
—Threshold Limit Values (Booklet)  
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Circuit Requirements  
SECTION 2: CIRCUIT REQUIREMENTS  
Grounding  
220V Operation  
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.  
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.  
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!  
Amperage Draw  
The Model H8151 welder draws the following  
amps under maximum load:  
Draw at 220V.........................................24 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 qualified 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.  
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:  
Minimum 220V Circuit Requirement .....30 Amps  
Use at least a 10 gauge cord that does not  
exceed 50 feet in length.  
Plug/Receptacle Type  
Recommended Plug/Receptacle....NEMA L6-30  
The extension cord must also contain a  
ground wire and plug pin.  
A qualified electrician MUST size cords over  
50 feet long to prevent motor damage.  
Figure 3. NEMA L6-30 plug and receptacle.  
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Workpiece Ground  
Grounding for Arc  
Welding Safety  
The incoming power circuit to the welder and  
the welding circuit are two separate circuits that  
must have separate grounds. The welding circuit  
consists of the internal components of the welder,  
the welding cables, the electrode holder, the work  
clamp, and the workpiece.  
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).  
In the publication Safety in Welding, Cutting,  
and Allied Processes, ANSI Publication Z49.1,  
11.3.2.1, it is specified 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."  
Welding Machine Ground  
When properly connected to a power source, the  
Model H8151 welder is grounded through the  
power cord and power grid. The welder's inter-  
nal welding circuit is insulated from the external  
enclosure. However, to avoid shocking hazards in  
the event that this internal insulation should fail,  
you must establish a separate earth ground for  
the welder's external enclosure. This will ensure  
that the metal enclosure of the welder and the  
internal welding circuit are at the same electrical  
potential.  
Always ensure that the ground for the incom-  
ing power circuit to the welder and the  
ground for the welding circuit are never con-  
nected. Failure to comply with this warning  
could result in serious property damage,  
personal injury, or death.  
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.  
However, you must also avoid "double grounding"  
of the workpiece. The ANSI Publication Z49.1  
publication warns that "Care shall be taken to  
avoid the flow of welding current through a con-  
nection intended only for safety grounding since  
the welding current may be of a higher magnitude  
than the grounding conductor can safely carry."  
The grounding terminal for the H8151 external  
enclosure is located on the right rear of the welder  
(see Figure 4).  
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.  
Figure 4. Location of external enclosure  
grounding terminal on the rear of the Model  
H8151.  
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SECTION 3: INVENTORY  
The Model H8151 was carefully packed when it left our warehouse. If you discover the machine is damaged  
or a part 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.  
A
B
C
E
H
D
F
G
Figure 5. Model H8151 inventory.  
A. Polyurethane Carrying Case  
B. Welder Carrying Strap  
C. 230V Mini Welder  
D. Work Clamp and Cable  
E. Utility Brush and Slag Hammer  
F. Electrode Clamp and Cable  
G. Welder's Mask  
H. Welder's Mask Handle  
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SECTION 4: OPERATIONS  
Operation Safety  
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.  
Damage to your eyes and lungs could result  
from using this machine without proper pro-  
tective gear. Always wear safety glasses and  
a respirator when operating this machine.  
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 H8151 has a duty cycle  
of 60% at 95A output. This means that the welder  
can operate continuously for 6 out of 10 minutes  
with a 95A output before the welder needs to cool  
off.  
Loose hair and cloth-  
ing could get caught in  
machinery and cause seri-  
ous personal injury. Keep  
loose clothing and long  
hair away from moving  
machinery.  
The Model H8151 operates with an efficient cool-  
ing fan (at the rear of the welder) and has an  
internal thermostat that will shut the welder down  
at the end of the duty cycle. This will be evident  
by the loss of welding circuit and the red warning  
light on the face of the welder. When the welder  
has cooled sufficiently, the internal thermostat will  
allow the welding circuit to once again be used  
and the red warning light will go out.  
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.  
Note: Most electrodes used with arc 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.  
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6. Decide which type of weld is correct for your  
General Arc Welding  
Operations  
project and properly prepare the metal.  
7. Make sure the welding cables and grounds  
are secure.  
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.  
Note: Insert the welding cable connectors  
into the welder output sockets and twist  
clockwise until fully secure.  
8. Stay aware of the work environment around  
you as you weld and ensure that flying sparks  
do not start a fire.  
Practice on scrap metal and expect to spend con-  
siderable time learning the many aspects of good  
welding.  
9. Look slightly ahead of the arc. Even with  
the protection of the welder's hood, looking  
directly at the arc can damage your eyes.  
Although it is beyond the scope of this manual to  
instruct how to weld, here are some general steps  
for successful welding:  
10. Listen to the sound of the weld. Each type  
of weld has its own distinct sound when it is  
progressing correctly.  
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.  
The above instructions are not intended to be a  
complete list of welding steps. To become a good  
welder, read books on welding, get help from  
experienced welders, and practice.  
3. Have an experienced welder stand by to  
assist if needed.  
4. Select the correct electrode type and size for  
your welding project.  
5. Choose the correct amperage output and be  
aware of the duty cycle for this amperage.  
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ACCESSORIES  
SECTION 5: ACCESSORIES  
H7786—Auto Darkening Welding Helmet  
H9748—Leather Jacket Medium (40–42)  
H9887—Leather Jacket Large (44–46)  
H9888—Leather Jacket X-Large (48–52)  
H9746—Leather Knee Pads  
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  
H9745—Leather Shoe Covers  
These leather jackets, knee pads, and shoe cov-  
ers provide full protection from welding sparks  
and spatter. Gloves not included.  
dark shade protection. Viewing area is 312" x 1 ⁄2".  
1
Includes 2 AAA batteries.  
Figure 6. Model H7786 welding helmet.  
Figure 8. Models H9748/H9746/H9745 leather  
welding protection.  
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.  
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 7. Model G7868 welding respirators.  
Figure 9. Model H3157 deluxe welding gloves.  
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Troubleshooting  
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 1. Plug/receptacle is at fault or wired incor- 1. Test for good contacts; correct the wiring.  
power up or the  
breaker trips.  
rectly.  
2. Wiring is open/has high resistance.  
2. Check for broken wires or disconnected/corroded  
connections, and repair/replace as necessary.  
3. Replace faulty ON/OFF switch.  
3. ON/OFF switch is at fault.  
Porosity; small cavi- 1. Arc length is too long.  
1. Reduce length of arc.  
ties or holes caused  
from gas packets in  
weld.  
2. Workpiece is dirty.  
2. Remove all grease, oil, moisture, coatings, rust, and  
dirt from workpiece before welding.  
3. Use dry electrodes.  
3. Damp electrodes.  
4. Incorrect electrode used.  
4. Use correct type and size of electrode.  
Excessive spatter.  
1. Amperage too high for electrode.  
2. Voltage too high; arc length too long.  
3. Incorrect electrode used.  
1. Select large electrode or decrease amperage.  
2. Reduce voltage or arc length.  
3. Use correct type and size of electrode.  
Distortion of base 1. Excessive heat applied to base metal.  
metal.  
1. 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.  
Burn through or 1. Excessive heat applied to base metal.  
excessive penetra-  
tion of base metal.  
1. Select lower amperage; use smaller electrode;  
increase and/or maintain steady travel speed.  
Lack of penetration. 1. Improper joint preparation.  
2. Improper weld technique.  
1. Material too thick; joint preparation must provide  
access to bottom of groove.  
2. Keep arc on leading edge of weld puddle; reduce  
travel speed.  
3. Insufficient heat applied to weld.  
3. Increase amperage; select larger electrode.  
Failure of weld to 1. Insufficient heat applied to weld.  
1. Increase amperage; select larger electrode.  
2. 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.  
fuse completely with  
base metal or prior  
weld bead.  
2. Improper welding technique.  
3. Workpiece dirty.  
3. Remove all grease, oil, moisture, coatings, rust, and  
dirt from workpiece before welding.  
4. Duty cycle exceeded.  
4. Shut down welder and allow it to cool.  
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Replacement Parts And Labels  
2
1
8
7
4
3
9
10  
6
11  
5
REF PART #  
DESCRIPTION  
REF PART #  
DESCRIPTION  
1
2
3
4
5
6
PH8151001  
PH8151002  
PH8151003  
PH8151007  
PH8151008  
PH8151006  
POLYURETHANE CARRYING CASE  
CARRYING STRAP  
7
PH8151004  
PLABEL-14  
PH8151009  
PH8151010  
PLABEL-12  
WELDERS MASK HANDLE  
ELECTRICITY LABEL  
SHOCK HAZARD LABEL  
MACHINE ID LABEL  
8
WORK CLAMP & CABLE  
UTILITY BRUSH & PICK  
ELECTRODE CLAMP & CABLE  
WELDERS MASK  
9
10  
11  
READ MANUAL LABEL  
Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine  
MUST maintain the original location and readability of the labels on the machine. If any label is  
removed or becomes unreadable, REPLACE that label before using the machine again. Contact  
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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.  
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.  
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