Grizzly T10499 Welder User Manual
Contents
1. 20 Amps Plug Receptacle NEMA 6 20 The provided power cord and the plug specified above have an equipment grounding wire and a grounding prong The plug must only be inserted into a matching receptacle outlet that is prop erly installed and grounded in accordance with all local codes and ordinances see Figure 4 GROUNDED 6 20 RECEPTACLE Current Carrying Prongs No adapter should be used with the required plug If the plug does not fit the available receptacle or the machine must be reconnected for use on a different type of circuit the reconnection must be made by a qualified electrician and comply with all local codes and ordinances Extension Cords We do not recommend using an extension cord with this machine If you must use an extension cord only use it if absolutely necessary and only on a temporary basis Extension cords cause voltage drop which may damage electrical components and shorten motor life Voltage drop increases as the extension cord size gets longer and the gauge size gets smaller higher gauge numbers indicate smaller sizes Any extension cord used with this machine must contain a ground wire match the required plug and receptacle and meet the following require ments T10499 Minimum Gauge Size 14 AWG T10500 Minimum Gauge Size 12 AWG Maximum Length Shorter is Better 25 ft Assembly Except for the2. 4 y 1 Industrial Imc MODEL T10499 T10500 PORTABLE BLADE WELDER INSTRUCTIONS For questions or help with this product contact Tech Support at 570 546 9663 or techsupport O grizzly com Introduction This portable blade welder can cut weld anneal and grind bandsaw blades which is commonly done in the following situations e re join a blade that has been purposely cut for making an internal contour cut e To repair a broken blade that is still sharp and useful e fabricate a new blade from bulk blade material Figure 1 Blade Welder Hot sparks from the welding process can damage your eyes and skin During welding operations always wear safety goggles and protective gear and keep the spark deflec tor over the welding clamps to reduce your risk Specifications T10499 Range of Blade Widths Vg 2 Range of Blade Thickness 0 02 0 035 Power Supply Requirement 115V 15 Amps Welding 1 2 KVA Shipping 50 Ibs 710500 Range of Blade Widths je A Range of Blade Thickness 0 02 0 035 Power Supply Requirement 230V 20 Amps Welding 4 2 KVA Shipping Weight Lissneneessmuaieaneinminue 69 Ibs COPYRIGHT O APRIL 2012 BY GRIZZLY INDUSTRI
3. blade shear alignment wings see Figure 5 the welder is shipped fully assembled Figure 5 Blade shear alignment wings The alignment wings keep the blade straight when cutting with the shear Tools Needed Qty Phillips Screwdriver 2 1 Wrench or Socket 10mm 1 To attach the blade shear wings 1 Remove the two Phillips head screws shown in Figure 6 and the attached hex nuts and flat washers Note Keep the spacers that separate the two plates in place Remove these Screws Figure 6 Phillips head screws to be removed 2 Use the fasteners removed in Step 1 to attach the alignment wings in the positions shown in Figure 7 Alignment Wings Figure 7 Alignment wings installed T10499 T10500 Blade Welder Operations Overview This blade welder uses electrical resistance induc tion to weld bandsaw blade ends Afterwards the annealing process gives the weld strength and flexibility AWARNING Hot sparks from the welding process can damage your eyes and skin During welding operations always wear safety goggles and protective gear and keep the spark deflec tor over the welding clamps to reduce your risk Blade Shear To use the blade shear place the back of the blade evenly against the front alignment wings of the blade shear as shown in Figure 8 then firmly pull the handle down to square off t
4. AL ING WARNING NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL INC TS14909 PRINTED IN TAIWAN Identification Strength Pressure Anneal Welding Button Switch Button Main ON OFF Switch Carrying Handle 1 of 2 Clamping Jaws Spark Deflector Grinder Switch Grinding Wheel Figure 2 Identification AWARNING To reduce the risk of serious injury when using this machine read and understand this entire manual before beginning any operations 2 o T10499 T10500 Blade Welder AWARNING Safety for Blade Welders WELDING FUMES Breathing welding fumes can cause respiratory damage Maintain adequate ven tilation during and after welding operations PREVENT FIRES Welding work zones must be kept clear of flammable liquids or gases such as gasoline or solvents and combustible solids such as paper or wood Provide approved fire extin guishing 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 and body protection approved for welding operations such as safety goggles clean and oil free protective clothing leather gloves long sleeves and cuffless pants Protect other people and property
5. HLP HD SCR M4 7 X 65 59 92 60 PT10499060 61 Pr10499061 94 62 PFH30M 95 65 PS15M 96 64 PLWOIM 97 65 518 98 66 PT10499086 99 67 PT10499067 100 68 PSS02M 101 69 PT10499069 102 70 PT10499070 JAW INSULATOR 103 PNO6M HEX NUT M5 8 72 Pr10499072 105 75 106 74 107 75 PT10499075 MOTOR 1 8HP 115V 1 PH T10499 108 75 10500075 MOTOR 1 8HP 230V 1 710500 109 76 10499076 TRANSFORMER A174 0001 1 2KVA 120V T10499 110 76 10500076 TRANSFORMER A174 0023 4 2KVA 240V T10500 111 77 PT10409077 112 78 PT10499078 113 79 PT10499078 114 80 115 81 116 82 10499082 CLAMPING PRESSURE KNOB 117 PT10499117 TOGGLE SWITCH HY29G 20 15A 125 277V T10499 T10500 Blade Welder 17 Machine Labels T10500 Grizzly Grizzl PORTABLE BLADE gas Industrial Ine mid s WELDER ad SPECIFICATIONS Power Requirement 115V 184 om Range of Blade wigi 17 47 Range of Slade Thickness 0 027 0 035 Member 126 EYE SION INJURY HAZARD Abwoys wear satety anda denies poves when uang tha machine T10499 Clamping Pressure Made Width rss Annesi Strength 1 2 Low am s me T10500 wian Camping Pressure Annesi Strength to 12 1 2 Low 1 2 to 347 Migh ap REF PART DESCRIPTION REF PART DESCRIPTIO
6. N 118 PT10499118 MACHINE ID LABEL T10499 122 PT10499122 GRINDER WHEEL ROTATION LABEL 118 _ PT10500118 MACHINE ID LABEL T10500 123 PT10409119 POWER ON OFF LABEL 124 120 PT10409120 EVE SKIN HAZARD LABEL 125 121 PTi0499121 SETTINGS LABEL 110499 126 121 PT10500121 SETTINGS LABEL T10500 127 PPAINT 11 GRIZZLY PUTTY TOUCH UP PAINT AWARNING Safety labels help reduce the risk of serious injury caused by machine hazards If any label comes off or becomes unreadable the owner of this machine MUST replace it in the original location before resuming operations For replacements contact 800 523 4777 or www grizzly com 18 10499 10500 Blade Welder WARRANTY amp 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 th
7. ceptacle As Recommended T10500 Wiring Diagram Main Anneal Power Switch Strength Switch HY29G Bh 277V ENEC T120 55 Clamp Pressure Cam Welding Button Ground 1 Transformer A174 0023 4 2KVA 240V Run 2M 250V Capacitor 230 D Grinder SN Motor pr 3 Switch CS R1328F ON 8 Grinder ON OFF d 14 9 T10499 T10500 Blade Welder REF PART Cabinet Parts DESCRIPTION PT10499001 CABINET PB18M HEX BOLT M6 1 X 15 PT10499003 HANDLE PT10499004 POWER CORD 14G 3W 5 15 710499 PT10500004 POWER CORD 14G 3W T10500 T10499 T10500 Blade Welder REF PART 19 DESCRIPTION PT10499019 UPPER SHEAR BLADE Controls amp Electrical oO T10499 T10500 Blade Welder Controls amp Electrical Parts List REF PART DESCRIPTION REF PART DESCRIPTION 51 PT10499051 FRONT CABINET COVER 84 PT10499084 WELDING BUTTON 52 85 53 86 54 87 55 88 56 89 57 PT10499057 GRINDING WHEEL COVER 90 PS64M P
8. current drawn from the machine for an extended period of time If this machine is connected to a circuit protected by fuses use a time delay fuse marked D Note The circuit requirements listed in this man ual apply to a dedicated circuit where only one machine will be running at a time If this machine will be connected to a shared circuit where mul tiple machines will be running at the same time consult a qualified electrician to ensure that the circuit is properly sized for safe operation Grounding Requirements This machine MUST be grounded In the event of certain malfunctions or breakdowns grounding reduces the risk of electric shock by providing a path of least resistance for electric current Improper connection of the equipment grounding wire can result in a risk of electric shock The wire with green insulation with or without yellow stripes is the equipment grounding wire If repair or replacement of the power cord or plug is nec essary do not connect the equipment grounding wire to a live current carrying terminal Check with a qualified electrician or service per sonnel if you do not understand these grounding requirements or if you are in doubt about whether the tool is properly grounded If you ever notice that a cord or plug is damaged or worn discon nect it from power and immediately replace it with a new one CAUTION For your own safety and protection of property consult an electrician
9. e 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 TOOL WEBSITE Buy Direct and Save with Grizzly Trusted Proven and a Great Value Since 1983 Visit Our Website Today For Current Specials ORDER 24 HOURS A DAY 1 800 523 4777 ERI rose
10. he blade end Blade Shear Wing T10499 T10500 Blade Welder Blade Preparation When welding the blade the ends must evenly butt up against each other and be square This will ensure the that the weld is of even thickness for the full width of the blade To prepare the blade for welding 1 Turn the main ON OFF switch ON it is locat ed on top of the welder 2 Be sure to grind off any teeth that are in the blade welding zone see Figures 9 10 Note Make sure the blade ends are even with each other after grinding them Welding Zone Note You can make sure that the blade ends are even with each other by stacking them together with the teeth facing in oppo site directions see Figure 11 then grinding them Regardless of the grinding angle the blade ends will match evenly for welding Figure 11 Blade ends stacked with teeth facing opposite directions Use 120 grit emery cloth or an equivalent to lightly sand the part of the blade that will contact the welder clamps This helps ensure a good electrical contact with the blade for welding Note To prevent dulling the teeth keep the emery cloth away from them when sanding the blade surface Welding 1 Turn the main ON OFF switch OFF then DISCONNECT WELDER FROM POWER Thoroughly clean the welding clamps to remove debris oily substances or flash from previous welding operations If necessary lightly sand them with 120 grit emery clo
11. if you are unsure about wiring practices or electrical codes in your area T10499 T10500 Blade Welder T10499 Circuit Requirements This machine is prewired to operate on a 115V power supply circuit that has a verified ground and meets the following requirements Nominal Voltage 115V o EE 60 2 Phase Single Phase Power Supply Circuit 15 Amps Plug Receptacle NEMA 5 15 This machine is equipped with a power cord and plug that have an equipment grounding wire and a grounding prong see Figure 3 The plug must only be inserted into a matching receptacle outlet that is properly installed and grounded in accordance with all local codes and ordinances GROUNDED 5 15 RECEPTACLE Grounding Prong SHOCK HAZARD Two prong outlets do not meet the grounding requirements for this machine Do not modify or use an adapter on the plug provided if it will not fit the outlet have a qualified electrician install the proper outlet with a verified ground T10499 T10500 Blade Welder T10500 Circuit Requirements This machine is prewired to operate on a 230V power supply circuit that has a verified ground and meets the following requirements Nominal Voltage 230V ng me 60 Hz PRESSE masi Single Phase Power Supply Circuit
12. in the welding work zone from expo sure to sparks and hot spatter ABRASION INJURIES The grinding wheel can remove skin very quickly Always keep your fingers and hands away from the spinning grinding wheel to reduce this risk ELECTRIC amp MAGNETIC FIELDS EMF Welding operations create EMF around the welding equip ment and workpieces Workers who have pace makers must consult with their physician before using this equipment or stay at least 50 feet from welding operations EQUIPMENT MAINTENANCE Make sure equip ment inspections and maintenance are performed by a qualified person Stop the welding operation and disconnect the welder from power if the equip ment is damaged or malfunctions STABLE WORK SURFACE If the welder unex pectedly moves during operation burn laceration or abrasion injuries could occur Always make sure the welder is mounted on a stable and lever sur face before operations BLADE BREAKAGE Blades that are not welded correctly can break under the stresses of using them on the bandsaw Have only one weld on a blade Always inspect the weld as instructed Make sure the annealing and grinding process does not compromise the integrity of the weld If you have any doubt about weld quality start again NOTICE If you have never used this type of welder before WE STRONGLY RECOMMEND that you read books trade magazines or get formal training before beginning any projects Regardless of the content in
13. ing the anneal button with decreasing frequency until the weld no longer glows Anneal Strength Switch ne lea Figure 18 Annealing controls For Bi Metal Blades Rapidly press and release DO NOT hold the anneal but ton until the weld zone starts to glow then release the anneal button completely T10499 T10500 Blade Welder 5 Allow the blade to completely cool 6 Remove the blade from the clamps 7 Grind the weld flat on both sides so the blade will run smoothly on the bandsaw wheels Note Make sure not to grind the teeth or blade body Do not overheat the blade during grinding this will weaken the blade 8 For Bi Metal Blades Only Repeat Steps 3 5 not Step 6 9 Test the strength and flexibility of the weld by bending the blade in an arc with the weld at the top of the arc similar in size and shape of the bandsaw wheels The blade should bend smoothly without any angles see Figure 19 Correct Not Correct Figure 19 Comparison of correct and incorrect blade weld bends lf the blade does show signs of bending or breaking at the weld use the blade shear to completely remove the weld and perform the Blade Preparation and Welding pro cedures again that begin on Page 7 10 Turnthe OFF switchOFF then DISCONNECT WELDER FROM POWER 11 Thoroughly clean the welding clamps to remove debris oily substances or flash from previous welding operations If necessary lightly
14. mp Anneal Note As you rotate the clamp pressure switch the left clamp will move and apply pressure toward the right This pressure is necessary to maintain contact between the blade ends as the metal melts during the welding operation Clamp Ferme seme es ma Pressure Switch Welding Button 9 Lower the spark deflector over the clamps 10 Put on safety goggles and heavy leather gloves 11 Connect the welder to power and turn the main ON OFF switch ON AWARNING Hot sparks from the blade welding opera tion could be thrown in all directions and cause burns or fire When using the blade welder always keep the spark deflector over the clamps and protect yourself from the flying sparks Have fire extinguishing equipment readily available DO NOT weld near flammables NOTICE For good metal to metal contact between the welding clamps and the blade make sure the blades and the clamps are free from any debris coatings or flash before and after each use of the welding station NOTICE Before welding a blade back together to per form an internal cut insulate the entire blade from the metal surfaces of the bandsaw to ensure a good flow of current through the blade 12 Press and release DO NOT hold the weld button Note A limit switch senses the electrical resistance between the blade ends If there is an adequate amount of welded material the limit switch will no
15. roperly Make sure blade ends are evenly butted against has blow holes each other in clamps use the correct clamp pressure Blade ends not even with each other Page 8 Use the blade shear to cut blades grind ends together see Note on top of Page 8 Weld breaks or is Weld not correctly annealed Correctly perform the annealing procedure on brittle Page 11 Weld is ground too thin Only grind flash even with blade body Debris or oil in weld Make sure clamps and blade ends are clean of debris oily substances and flash Blade overheated during grinding Use light passes with the grinding wheel 12 oO T10499 T10500 Blade Welder T10499 Wiring Diagram Main Anneal Power Switch Strength Switch HY29G NM 5A 277V c ENEC T120 55 Welding Button Clamp Pressure Cam 115VAC NEMA 5 15 Plug Receptacle As Recommended Ground 1 Transformer A174 0001 1 2KVA 120V Run Capacitor 2M 250V Switch CS R1328F ON Grinder ON OFF 15V Grinder Motor 4 T10499 T10500 Blade Welder o9 dias 230VAC NEMA 6 20 Plug Re
16. sand them with 120 grit emery cloth 11 Troubleshooting Review the troubleshooting and procedures in this section if a problem develops with your machine If you need replacement parts or additional help with a procedure call our Technical Support at 570 546 9663 Note Please gather the serial number and manufacture date of your machine before calling Machine does not Plug receptacle is fault or wired 1 Test for good contacts correct the wiring start or a breaker incorrectly trips Wall fuse circuit breaker is blown tripped Ensure circuit size is suitable for this machine replace weak breaker Main ON OFF switch turned OFF or is at 3 Ensure main ON OFF switch is turned ON replace fault Switch Wiring is open has high resistance Check for broken wires or disconnected corroded connections and repair replace as necessary Weld button is at fault Replace weld button Weld is mis aligned 1 Debris or flash on weld clamps or blade Remove debris oily substances or flash from weld clamps and blade Blade ends not cut off square Use the blade shear to cut blades grind ends together see Note on top of Page 8 Blade ends not evenly butted in clamps Make sure blade ends are evenly butted against each other before securing with clamp levers Page 8 Clamp pressure not set correctly Set clamp pressure correctly according to tables on Page 9 Weld not complete Blade ends not clamped p
17. t allow the weld button to activate the operation again 13 Allow the blade to cool 14 Rotate the clamp lever switch to zero to release the clamp pressure 15 Remove the blade 10 16 Inspect the weld The welded joint should be even across the width of the blade with no gaps see Figure 17 Figure 17 Blade welding joint examples lf the weld is satisfactory anneal the weld as instructed in the next subsection lf the weld is NOT satisfactory use the blade shear to completely remove the weld and perform the Blade Preparation and Welding procedures again that begin on Page 7 T10499 T10500 Blade Welder Annealing Weld When the blade ends are welded the metal becomes hard and brittle which is not suitable for a bandsaw blade that must continuously bend smoothly under stress To bring the weld strength and flexibility to accept able levels for a bandsaw blade the annealing process re heats the weld area then allows it to cool gradually To anneal the weld 1 Place the blade in the clamps so that the weld is centered between the clamps 2 Secure the blade by moving both clamp levers up 3 Make sure the anneal strength switch is in the proper position for the width of the blade refer to the charts in Step 8 on Page 9 4 For Carbon Steel Blades Rapidly press and release DO NOT hold the anneal but ton see Figure 18 until the weld zone turns a dull red color Continue press
18. th 3 Rotate the clamp pressure switch see Figure 12 to zero This spreads the clamps apart to allow proper positioning of the blade ends Clamp Pressure Figure 12 Clamping controls Pull the spark deflector up and loosen the welding clamps by pulling the clamp levers down Position the back of one blade end evenly against the back of the right welding clamp so that the end is midway between the two clamps as shown in Figure 13 Figure 13 Blade end properly position in welding clamp and locked in place Rotate the right clamp lever up to secure the blade end in place T10499 T10500 Blade Welder 7 Place the other blade end in the left welding clamp and position it so that it evenly butts up against the opposing blade end then clamp it in place by rotating the left clamp lever up see Figure 14 NE Figure 14 Blade ends in correct position for welding Note To ensure a good blade weld it is critical that the blade ends are secured in the welding clamps evenly and with no overlap see Figure 15 Blade Ends Flat w No Overlap Blade Ends Butt Evenly Figure 15 Blade ends correctly secured in welding clamps T10499 T10500 Blade Welder 8 Use the tables below to set the clamp pres sure switch and the anneal strength see Figure 16 For T10499 Clamp Anneal For T10500 Cla
19. this section Grizzly Industrial will not be held liable for accidents caused by lack of training T10499 T10500 Blade Welder Power Supply Full Load Current Rating The full load current rating is the amperage a machine draws at 100 of the rated output power On machines with multiple motors this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations T10499 Full Load Current Rating 8 Amps T10500 Full Load Current Rating 20 Amps The full load current is not the maximum amount of amps that the machine will draw If the machine is overloaded it will draw additional amps beyond the full load rating If the machine is overloaded for a sufficient length of time damage overheating or fire may result especially if connected to an undersized circuit To reduce the risk of these hazards avoid over loading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements in the following section AWARNING Electrocution fire or equipment damage may occur if machine is not correctly grounded and connected to the power supply Circuit Information A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine The power sup ply circuit used for this machine must be sized to safely handle the full load
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