Grizzly G0548ZP 2 HP Canister Dust Collector Owner Manual

Grizzly G0548ZP 2 HP Canister Dust Collector Owner Manual

MODEL G0548ZP G1028Z2/G1029Z2/G1029Z2P DUST COLLECTOR

OWNER'S MANUAL

(For models manufactured since 12/12)

247570

G0548ZP G1028Z2/G1029Z2

COPYRIGHT © FEBRUARY, 2012 BY GRIZZLY INDUSTRIAL, INC. REVISED MARCH, 2017 (MN)

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#BL14676 PRINTED IN TAIWAN

This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators. Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death.

The owner of this machine/tool 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 compre hension, application of safety devices, cutting/sanding/grinding tool integrity, 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.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints.

• Crystalline silica from bricks, cement and other masonry products.

• Arsenic and chromium from chemically-treated lumber.

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 dust masks that are specially designed to filter out microscopic particles.

Table of Contents

INTRODUCTION ............................................... 2

Manual Accuracy ........................................... 2 Contact Info.................................................... 2 Machine Description ...................................... 2

Components and Terminology ....................... 3

Machine Data Sheets .................................... 4 Machine Data Sheets .................................... 4

SECTION 1: SAFETY ....................................... 7

Safety Instructions for Machinery .................. 7

Additional Safety for Dust Collectors ............. 9

SECTION 2: POWER SUPPLY ...................... 10

SECTION 3: SETUP ....................................... 14

Needed for Setup ......................................... 14 Unpacking .................................................... 14

G0548ZP Inventory ...................................... 15

G1028Z2/G1029Z2/G1029Z2P Inventory .... 16

Site Considerations ...................................... 17 G0548ZP Assembly ..................................... 17

G1028Z2/G1029Z2/G1029Z2P Assembly ... 20

Power Connection........................................ 23

Test Run ...................................................... 24

SECTION 4: DESIGNING THE SYSTEM ....... 25

General ........................................................ 25 Duct Material ................................................ 25

System Design ............................................. 27

System Grounding ....................................... 32

SECTION 5: OPERATIONS ........................... 33

General ........................................................ 33 Machine Storage .......................................... 33

SECTION 6: ACCESSORIES ......................... 34

SECTION 7: MAINTENANCE ......................... 36

Schedule ...................................................... 36 Lubrication ................................................... 36 Cleaning Bags.............................................. 36

Replacing Bags ............................................ 37 Cleaning Canister Filter ............................... 37

SECTION 8: SERVICE ................................... 38

Troubleshooting ........................................... 38

SECTION 9: WIRING ...................................... 40

Wiring Safety Instructions ............................ 40

G0548ZP Wiring Diagram ............................ 41

G1028Z2 Wiring Diagram ............................ 42

G1029Z2/G1029Z2P Wiring Diagram .......... 43

SECTION 10: PARTS ..................................... 44

G0548ZP Main Breakdown .......................... 44

H5783 Canister Filter Assembly .................. 46

G1028Z2/G1029Z2 Main Breakdown .......... 47

G1029Z2P Main Breakdown ........................ 49

WARRANTY AND RETURNS ........................ 53

INTRODUCTION Contact Info

We stand behind our machines! If you have ques tions or need help, contact us with the information below. Before contacting, make sure you get the serial number and manufacture date from the machine ID label. This will help us help you faster.

Grizzly Technical Support 1815 W. Battlefield Springfield, MO 65807 Phone: (570) 546-9663 Email: techsupport@grizzly.com

We want your feedback on this manual. What did you like about it? Where could it be improved? Please take a few minutes to give us feedback.

Grizzly Documentation Manager P.O. Box 2069 Bellingham, WA 98227-2069 Email: manuals@grizzly.com

Machine Description

This machine is designed to capture dust and wood chips from woodworking machines, such as table saws, jointers, and planers. The air drawn in by the dust collector is filtered before it returns to the workspace.

A wide variety of accessories for setting up a stationary or mobile dust collection system are available through Grizzly.

The G0548ZP features an upper canister filter; models G1028Z2 and G1029Z2/Z2P feature an upper filter bag. Polar Bear models G0548ZP and G1029Z2P are white; G1028Z2 and G1029Z2 are green.

Manual Accuracy

We are proud to provide a high-quality owner’s manual with your new machine!

We made every effort to be exact with the instruc tions, specifications, drawings, and photographs in this manual. Sometimes we make mistakes, but our policy of continuous improvement also means that

sometimes the machine you receive is

slightly different than shown in the manual.

If you find this to be the case, and the difference between the manual and machine leaves you confused or unsure about something, check our website for an updated version. We post current manuals and manual updates for free on our web site at www.grizzly.com.

Alternatively, you can call our Technical Support for help. Before calling, make sure you write down the Manufacture Date and Serial Number from the machine ID label (see below). This information is required for us to provide proper tech support, and it helps us determine if updated documenta tion is available for your machine.

Manufacture Date Serial Number -2 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

Canister Filter Outlet Connector

Components and Terminology

G0548ZP

Filter Cleaning Handle Outlet Connector Hose Collector

G1028Z2, G1029Z2/Z2P

Filter Bag Collection Bag 3-Port Inlet Connector Caster 2-Port Inlet Connector Motor ON/OFF Paddle Switch

To reduce your risk of serious injury, read this entire manual BEFORE using machine.

Figure 1. Rear view identification.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -3-

Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901 MODEL G0548ZP, G1028Z2, G1029Z2, G1029Z2P DUST COLLECTORS G0548ZP G1028Z2 G1029Z2/G1029Z2P Model Number Product Dimensions

Weight Width (side-to-side)/Depth (front to-back)/Height Foot Print (Width/Depth)

Shipping Dimensions Carton 1

Type Content Weight Width (side-to-side)/Depth (front to-back)/Height

Carton 2

Type Content Weight Width (side-to-side)/Depth (front to-back)/Height

Electrical

Power Requirement 145 lbs.

37 x 27 x 71 in.

126 lbs.

36 x 23 x 23 in.

Cardboad Canister 29 lbs.

22 x 22 x 23 in.

240V, Single-Phase, 60 Hz 37 x 27 x 76 in.

33-1/2 x 21-1/4 in.

35 x 23 x 23 in.

95 lbs.

Not Applicable 126 lbs.

36 x 23 x 22 in.

240V, Single-Phase, 60 Hz Not Applicable 9A Not Applicable 9A Prewired Voltage Full-Load Current Rating Minimum Circuit Size Switch Switch Voltage Cord Length Cord Gauge Plug Included Included Plug Type Recommended Plug/Outlet Type for Alternate Voltage 240V NEMA 6-15 Not Applicable 12A at 120V, 6A at 240V 15A Safety Paddle Switch 120V/240V 6 ft.

14 AWG Yes NEMA 5-15 for 120V NEMA 6-15 for 240V 240V NEMA 6-15 Not Applicable -4 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

Model Number Main Motor

Type Horsepower Voltage Phase Amps Speed Cycle Power Transfer Bearings

Operation Information

Type Air Suction Capacity Maximum Static Pressure Main Inlet Size Inlet Adapter Included Inlet Adapter Inlets Inlet Adapter Inlet Size Maximum Material Collection Capacity Canister or Upper Bag Filtration

Bag Information

Number of Upper Bags Upper Bag Material Upper Bag Capacity Upper Bags Total Area Upper Bag Diameter Upper Bag Length Number of Lower Bags Lower Bag Material Lower Bag Capacity Lower Bags Total Area Lower Bag Diameter Lower Bag Length

Canister Information

Number of Canister Filters Canister Material Canister Filter Diameter Canister Filter Length

Impeller Information

Impeller Type Impeller Construction Material Impeller Size Impeller Blade Thickness

G0548ZP

2 HP 240V 9A Canister 1700 CFM 10 in.

3 4.5 cu. ft.

1 micron Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable 1 Spun Bond Polyester 19-5/8 in.

23-5/8 in.

G1028Z2 G1029Z2/G1029Z2P

TEFC Capacitor Start Induction 1.5 HP 120V/240V Single-Phase 12A/6A 3450 RPM 60 Hz Direct Drive Shielded & Permanently Lubricated 2 HP 240V 9A Bag 1300 CFM 9 in.

6 in.

Yes 4 in.

2 1550 CFM 11 in.

5.7 cu. ft.

2.5 micron 1 Clear Plastic 5.7 cu. ft.

5.7 cu. ft.

19-1/2 in.

33 in.

1 Fabric 5.7 cu. ft.

5.7 cu. ft.

19-1/2 in.

33 in.

Not Applicable Not Applicable Not Applicable Not Applicable Radial Fin Cast Aluminum 12-3/4 in.

1/8 in.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -5-

Model Number Construction

Base Frame Caster Paint

Other Specifications

Height with Bags Inflated Country of Origin Warranty Serial Number Location Assembly Time Awards

G0548ZP G1028Z2 G1029Z2/G1029Z2P

Fabricated Sheet Metal Fabricated Sheet Metal with Casters Formed Steel High Density Plastic Powder Coated 71 in.

78 in.

Taiwan 1 Year On ID Label 45 Minutes Wood Magazine Top Value 1997, Popular Woodworking Editor's Choice, Popular Woodworking Readers' Choice -6 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

SECTION 1: SAFETY 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 impor tance 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. Always use common sense and good judgment.

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.

NOTICE

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. It may also be used to alert against unsafe practices.

This symbol is used to alert the user to useful information about proper operation of the machine.

Safety Instructions for Machinery

OWNER’S MANUAL. Read and understand this owner’s manual BEFORE using machine. TRAINED OPERATORS ONLY. Untrained oper ators have a higher risk of being hurt or killed. Only allow trained/supervised people to use this machine. When machine is not being used, dis connect power, remove switch keys, or lock-out machine to prevent unauthorized use—especially around children. Make workshop kid proof!

ELECTRICAL EQUIPMENT INJURY RISKS. You can be shocked, burned, or killed by touching live electrical components or improperly grounded machinery. To reduce this risk, only allow qualified service personnel to do electrical installation or repair work, and always disconnect power before accessing or exposing electrical equipment.

DANGEROUS ENVIRONMENTS. Do not use machinery in areas that are wet, cluttered, or have poor lighting. Operating machinery in these areas greatly increases the risk of accidents and injury.

MENTAL ALERTNESS REQUIRED. Full mental alertness is required for safe operation of machin ery. Never operate under the influence of drugs or alcohol, when tired, or when distracted.

DISCONNECT POWER FIRST. Always discon nect machine from power supply BEFORE making adjustments, changing tooling, or servicing machine. This prevents an injury risk from unintended startup or contact with live electrical components.

EYE PROTECTION. Always wear ANSI-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are NOT approved safety glasses.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -7-

­­ WEARING PROPER APPAREL.­ Do­ not­ wear­ clothing,­ apparel­ or­ jewelry­ that­ can­ become­ entangled­ in­ moving­ parts.­ Always­ tie­ back­ or­ cover­long­hair.­Wear­non-slip­footwear­to­avoid­ accidental­slips,­which­could­cause­loss­of­work piece­control.

FORCING MAChINERY.­Do­not­force­machine.­ It­ will­ do­ the­ job­ safer­ and­ better­ at­ the­ rate­ for­ which­it­was­designed.

NEVER sTANd ON MAChINE.­ Serious­ injury­ may­ occur­ if­ machine­ is­ tipped­ or­ if­ the­ cutting­ tool­is­unintentionally­contacted.­ hAzARdOus dusT. Dust­ created­ while­ using­ machinery­ may­ cause­ cancer,­ birth­ defects,­ or­ long-term­ respiratory­ damage.­ Be­ aware­ of­ dust­ hazards­associated­with­each­workpiece­material,­ and­always­wear­a­NIOSH-approved­respirator­to­ reduce­your­risk.

hEARING PROTECTION.­ Always­ wear­ hear ing­ protection­ when­ operating­ or­ observing­ loud­ machinery.­ Extended­ exposure­ to­ this­ noise­ without­ hearing­ protection­ can­ cause­ permanent­ hearing­loss.

REMOVE AdJusTING TOOLs.­ Tools­ left­ on­ machinery­ can­ become­ dangerous­ projectiles­ upon­startup.­Never­leave­chuck­keys,­wrenches,­ or­ any­ other­ tools­ on­ machine.­ Always­ verify­ removal­before­starting!

INTENdEd usAGE.­ Only­ use­ machine­ for­ its­ intended­purpose­and­never­make­modifications­ not­ approved­ by­ Grizzly.­ Modifying­ machine­ or­ using­ it­ differently­ than­ intended­ may­ result­ in­ malfunction­or­mechanical­failure­that­can­lead­to­ serious­personal­injury­or­death!

AWKWARd POsITIONs.­ Keep­ proper­ footing­ and­balance­at­all­times­when­operating­machine.­ Do­not­overreach!­Avoid­awkward­hand­positions­ that­ make­ workpiece­ control­ difficult­ or­ increase­ the­risk­of­accidental­injury.

ChILdREN & BYsTANdERs. Keep­children­and­ bystanders­at­a­safe­distance­from­the­work­area.

Stop­using­machine­if­they­become­a­distraction.

sTABLE MAChINE. Unexpected­movement­dur ing­ operation­ greatly­ increases­ risk­ of­ injury­ or­ loss­of­control.­Before­starting,­verify­machine­is­ stable­and­mobile­base­(if­used)­is­locked.

usE RECOMMENdEd ACCEssORIEs.­Consult­ this­owner’s­manual­or­the­manufacturer­for­rec ommended­ accessories.­ Using­ improper­ acces sories­will­increase­the­risk­of­serious­injury.

uNATTENdEd OPERATION. To­ reduce­ the­ risk­ of­ accidental­ injury,­ turn­ machine­ while­unattended.­ off­ and­ ensure­ all­ moving­ parts­ completely­ stop­ before­ walking­ away.­ Never­ leave­ machine­ running­ MAINTAIN WITh CARE.­Follow­all­maintenance­ instructions­ and­ lubrication­ schedules­ to­ keep­ machine­ in­ good­ working­ condition.­ A­ machine­ that­ is­ improperly­ maintained­ could­ malfunction,­­ leading­to­serious­personal­injury­or­death.­ ChECK dAMAGEd PARTs.­ Regularly­ inspect­ machine­ for­ any­ condition­ that­ may­ affect­ safe­ operation.­Immediately­repair­or­replace­damaged­ or­mis-adjusted­parts­before­operating­machine.

MAINTAIN POWER CORds. When­ disconnect ing­ cord-connected­ machines­ from­ power,­ grab­ and­pull­the­plug—NOT­the­cord.­Pulling­the­cord­ may­ damage­ the­ wires­ inside.­ Do­ not­ handle­­ cord/plug­with­wet­hands.­Avoid­cord­damage­by­ keeping­it­away­from­heated­surfaces,­high­traffic­ areas,­harsh­chemicals,­and­wet/damp­locations.

GuARds & COVERs.­Guards­and­covers­reduce­ accidental­ contact­ with­ moving­ parts­ or­ flying­ debris.­ Make­ sure­ they­ are­ properly­ installed,­ undamaged,­and­working­correctly.

EXPERIENCING dIFFICuLTIEs. If­ at­ any­ time­ you­experience­difficulties­performing­the­intend ed­operation,­stop­using­the­machine!­Contact­our­ Technical­Support­at­(570)­546-9663.

-8 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

Additional Safety for Dust Collectors

Long-term respiratory damage can occur from using dust collectors without proper use of a respirator. Fire or explosions can result in smoke inhalation, serious burns, or death—if machine is used to collect incorrect materials, is operated near potential explosion sources, or ducting is improperly grounded. Entanglement, amputation, or death can occur if hair, clothing, or fingers are pulled into the inlet. To reduce the risk of these hazards, operator and bystanders MUST completely heed the hazards and warnings below.

INTENDED USE. Collecting the wrong materi als can result in serious inhalation hazards, fire, explosions, or machine damage. This machine is ONLY designed to collect wood dust and chips from woodworking machines. DO NOT use it to collect silica, polyurethane, toxic fumes, metal dust or shavings, lead paint, drywall, asbestos, biohaz ards, explosive dusts, flammable or combustible liquids or fumes, nor burning or smoking material. WEAR A RESPIRATOR. Fine dust that is too small to be caught in filter will be blown into ambi ent air. Always wear a NIOSH-approved respira tor during operation and for a short time after to reduce your risk of permanent respiratory damage. Never collect dust from any hazardous material.

POWER DISCONNECT. Turn machine OFF, dis connect from power supply, and allow impeller to completely stop before leaving machine unat tended, or doing any maintenance or service.

REGULAR CLEANING. To reduce risk of start ing a fire, regularly check/empty collection bags or drum to avoid buildup of fine dust, which can increase risk of fire. Regularly clean surrounding area where machine is operated—excessive dust buildup on overhead lights, heaters, electrical pan els, or other heat sources will increase risk of fire.

SUSPENDED DUST PARTICLES. To reduce risk of death or injury caused by explosions or fires, DO NOT operate in areas where these risks are high, including spaces near pilot lights, open flames, or other ignition sources.

IMPELLER HAZARDS. To reduce risk of entan glement or contact with impeller, DO NOT place hands, hair, clothing, or tools in or near open dust collection inlet during operation, and keep small animals and children away. The powerful suction could easily pull them into impeller. HAZARDOUS DUST. Dust exposure created while using machinery may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece material, and always wear a NIOSH-approved respirator.

AVOIDING SPARKS. To reduce risk of fire, avoid collecting any metal objects or stones. These can possibly produce sparks when they strike impeller, which can smolder in wood dust for a long time before a fire is detected. If you accidentally cut into wood containing metal, immediately turn dust collector, disconnect from power, and wait for impeller to stop. Then empty bag or drum into approved airtight metal container.

OFF EMPTYING DUST. When emptying bag or drum, wear respirator and safety glasses. Empty dust away from ignition sources and into approved container.

FIRE SUPPRESSION. Only operate dust collector in locations that contain fire suppression system or have fire extinguisher nearby.

STATIC ELECTRICITY. To reduce risk of fire or explosions caused by sparks from static electricity, ground all ducting using grounding wire. OPERATING LOCATION. To reduce respiratory exposure to fine dust, locate permanently installed dust collectors away from working area or in anoth er room. DO NOT place dust collector where it can be exposed to rain or moisture, which creates a shock hazard and will reduce life of machine.

DUST ALLERGIES. Dust from certain woods will cause an allergic reaction. Make sure you know what type of wood dust you will be exposed to in case of an allergic reaction.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -9-

SECTION 2: POWER SUPPLY

Availability

Before installing the machine, consider the avail ability and proximity of the required power supply circuit. If an existing circuit does not meet the requirements for this machine, a new circuit must be installed. To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring must be done by an electrican or qualified service personnel in accordance with all applicable codes and standards.

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 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.)

Electrocution, fire, or equipment damage may occur if machine is not correctly grounded and connected to the 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.

G0548ZP/G1029Z2/G1029Z2P Current Rating at 240V ................................................... 9 Amps G1028Z2 Current Rating at 120V....... 12 Amps G1028Z2 Current Rating at 240V ........ 6 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.

For your own safety and protection of property, consult an electrician if you are unsure about wiring practices or electrical codes in your area.

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.

-10 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

Serious injury could occur if you connect the machine to power before completing the setup process. DO NOT connect to power until instructed later in this manual.

Circuit Requirements for G0548ZP/ G1029Z2/G1029Z2P

Nominal Voltage ........................................240V

Cycle ..........................................................60 Hz Phase ........................................... Single-Phase Circuit Rating ...................................... 15 Amps Plug/Receptacle ............................. NEMA 6-15

This machine is equipped with a power cord that has an equipment-grounding wire and a ground ing plug (similar to the figure below). 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.

G0548ZP & G1029Z2/Z2P

GROUNDED 6-15 RECEPTACLE

Current Carrying Prongs

6-15 PLUG

G1028Z2 Circuit Requirements for 120V Operation (Prewired)

This machine is prewired to operate on a 120V power supply circuit that has a verified ground and meets the following requirements:

Nominal Voltage ........................................ 120V Cycle ..........................................................60 Hz Phase ........................................... Single-Phase Circuit Rating ...................................... 15 Amps Plug/Receptacle ............................. NEMA 5-15

This machine is equipped with a power cord that has an equipment-grounding wire and a ground ing plug (similar to the figure below). 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

5-15 PLUG

Neutral Hot Figure 3. Typical 5-15 plug and receptacle.

Grounding Prong Figure 2. Typical 6-15 plug and receptacle.

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.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

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.

-11-

G1028Z2 Circuit Requirements for 240V Operation

This machine can be converted to operate on a 240V power supply (refer to the following requirements: Voltage Conversion instructions) that has a verified ground and meets

Nominal Voltage ........................................240V

Cycle ..........................................................60 Hz Phase ........................................... Single-Phase Circuit Rating ...................................... 15 Amps Plug/Receptacle ............................. NEMA 6-15

For 240V operation: The plug specified in the 240 Circuit Requirements has a grounding prong that must be attached to the equipment-grounding wire on the included power cord. The plug must only be inserted into a matching receptacle (see following figure) that is properly installed and grounded in accordance with all local codes and ordinances.

GROUNDED 6-15 RECEPTACLE

Current Carrying Prongs

6-15 PLUG

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:

Minimum Gauge Size ...........................14 AWG Maximum Length (Shorter is Better).......50 ft.

Grounding Prong Figure 4. Typical 6-15 plug and receptacle.

-12 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

120 VOLT (PREWIRED)

Run Capacitor 45MFD 250VAC Ground

Voltage Conversion (G1028Z2 Only)

The voltage conversion MUST be performed by an electrician or qualified service personnel. The voltage conversion procedure consists of rewiring the motor and installing the correct plug. A wiring diagram is provided on Page 42 for your reference.

IMPORTANT: If the diagram included on the

motor conflicts with the one on Page 42, the motor may have changed since the manual was printed. Use the diagram included on the motor junction box cover instead.

Items Needed

Qty

Phillips Head Screwdriver #2 ..................... 1 • • • Electrical Tape ............................ As Needed Wire Nut (14 AWG x 3) ............................... 1 Plug 6-15 .................................................... 1

To convert the Model G1028Z2 to 240V:

1. DISCONNECT MACHINE FROM POWER!

2. Cut off the included plug.

Run Capacitor 45MFD 250VAC Remove Remove Start Capacitor 300MFD 4. Connect the motor wires, as shown in Figure 6, with wire nuts. Once snug, wrap electrical tape around each wire nut and the connected wires, to reduce the likelihood of the wire nut

240 VOLT (REWIRED)

Run Capacitor 45MFD 250VAC Re-Connect and Tighten Connect and Tighten Re-Connect and Tighten Ground Figure 6. Motor wires repositioned for 240V.

Start Capacitor 5. Close and secure the motor junction box.

6. Install a 6-15 plug on the end of the cord, according to the instructions and wiring dia grams provided by the plug manufacturer.

—If the plug manufacturer did not include instructions, the wiring of a generic NEMA 6-15 plug is illustrated in the Wiring sec tion on Page 42.

120V Hot

Ground Figure 5. Location of wire nuts to be removed.

Capacitor 300MFD 125VAC

Ground 5-20 Plug (Prewired) Hot

Rewired 240V Gn

Hot

G

240V Ground 6-15 Plug (As Recommended)

240 VOLT (REWIRED)

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) 45MFD 250VAC -13-

Neutral Hot 120V Ground 5-20 Plug (Prewired) Hot

Rewired 240V Gn

Hot

G

240V Ground 6-15 Plug (As Recommended)

Ground Start Capacitor 300MFD 125VAC

SECTION 3: SETUP

This machine presents serious injury hazards to untrained users. Read through this entire manu al to become familiar with the controls and opera tions before starting the machine!

Wear safety glasses during the entire setup process!

HEAVY LIFT!

Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk, get help from other people and use a forklift (or other lifting equipment) rated for weight of this machine.

Needed for Setup

The following are needed to complete the setup process, but are not included with your machine:

Description Qty

• Additional People ....................................... 1 • Safety Glasses (for each person) ............... 1 • • Open End Wrench 12mm ........................... 1 Phillips Head Screwdriver........................... 1

Unpacking

Your machine was carefully packaged for safe transportation. Remove the packaging materials from around your machine and inspect it. If you discover any damage, please call us immediately 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 condi tion of your shipment, inventory the contents.

Serious injury could occur if you connect machine to power before completing setup process. DO NOT connect to power until instructed later in this manual.

SUFFOCATION HAZARD!

Keep children and pets away from plastic bags or packing materials shipped with this machine. Discard immediately.

-14 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

G0548ZP Inventory

The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them.

If any non-proprietary parts are missing (e.g. a nut or a washer), we will gladly replace them; or for the sake of expediency, replacements can be obtained at your local hardware store.

Box 1: (Figure 7)

F. Collection Bag & Clamp

Qty

A. Motor & Impeller Assembly ........................ 1 B. Collector ..................................................... 1 C. Base ........................................................... 1 D. Inlet Connector 6" w/Three 4" Ports .......... 1 E. Rubber Gaskets ......................................... 2 — Collection Bag Clamp ............................. 1 — Collection Bags ....................................... 2 G. Canister Support ........................................ 1 H. Hardware Bag — Casters.................................................... 4 — Flange Bolts 5 ⁄ 16 "-18 x 1 ⁄ 2 " ...................... 40 — Tap Screw #10 x 3 ⁄ 8 " ............................... 1 — Combo Wrench 10/12mm ....................... 1 — Hex Wrench 5mm ................................... 1 I. Outlet Connector ........................................ 1

Box 2: (Figure 8) Qty

J. Canister Filter ............................................. 1 K. Foam Adhesive Bag ................................... 1 — Wide Foam Strip 5 x 42mm .................... 1 — Narrow Foam Strip 4 x 20mm ................ 1 L. Canister Belt Clamp ................................... 1 M. Canister Cleaning Handle .......................... 1 J K M L Figure 8. Model G0548ZP box 2 inventory.

NOTICE

If you cannot find an item on this list, care fully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpack ing or they are pre-installed at the factory.

A B I C D G F H E Figure 7. Model G0548ZP box 1 inventory.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -15-

G1028Z2/G1029Z2/ G1029Z2P Inventory

The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them.

If any non-proprietary parts are missing (e.g. a nut or a washer), we will gladly replace them; or for the sake of expediency, replacements can be obtained at your local hardware store.

Box Components: Qty

A. Motor & Impeller Assembly ........................ 1 B. Collector Body Assembly ........................... 1 C. Y-Inlet ......................................................... 1 D. Base ........................................................... 1 E. Outlet Flange .............................................. 1 F. Rubber Gasket ........................................... 1 G. Flex Hose ................................................... 1 H. Hose Clamps .............................................. 2 I. Casters ....................................................... 4 J. Foam Strips ................................................ 2 K. Bag Clamps ................................................ 2 L. Lower Support Brackets ............................. 2 M. Upper Support Bracket ............................... 1 N. Lower Bag (Plastic) .................................... 1 O. Upper Bag (Fabric) ..................................... 1

Not Shown: Qty

Flange Bolts 5 ⁄ 16 "-18 x 1 ⁄ 2 " ................................ 36

NOTICE

If you cannot find an item on this list, care fully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpack ing or they are pre-installed at the factory.

A B C D O F E G H N I M J K L

Figure 9.

G1028Z2/G1029Z2/G1029Z2P inventory.

-16 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

Site Considerations

Floor Load

Refer to the operator.

Machine Data Sheet for the weight and footprint specifications of your machine. Some residential floors may require additional reinforcement to support both the machine and

Placement Location

Consider existing and anticipated needs, size of material to be processed through each machine, and space for auxiliary stands, work tables or other machinery when establishing a location for your new machine. See Figure 10 for the mini mum working clearances.

G0548ZP Assembly

To assemble your dust collector:

1. Place the base upside down on a flat, pro tected surface.

2. Attach the casters to the base with (16) 5 ⁄ 16 -18 x 1 ⁄ 2 " flange bolts, as shown in Figure 11.

x 16 37" 27" Figure 11. Caster installed on base.

3. Turn the base over, align the motor and impeller assembly with the mounting holes, then secure the assembly with (4) 5 ⁄ 16 -18 x 1 ⁄ 2 " flange bolts, as shown in Figure 12.

x 4 Figure 10. Minimum working clearances.

Children and visitors may be seriously injured if unsuper vised around this machine. Lock entrances to the shop or disable start switch or power connection to prevent unsupervised use.

Figure 12. Motor and impeller assembly installed onto the base.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -17-

4. Place a rubber gasket around the impeller outlet rim, as shown in Figure 13.

Gasket 6. Align the canister support with the mounting holes on the base, as shown in Figure 15, then secure it in place with (2) flange bolts.

5 ⁄ 16 -18 x 1 ⁄ 2 " Canister Support x 2 Figure 13. Positioning impeller outlet gasket.

5. Secure the outlet connector to the impeller outlet with (8) 5 ⁄ 16 -18 x 1 ⁄ 2 " flange bolts, as shown in Figure 14.

Outlet Connector x 8 Figure 15. Canister support installed.

7. With the help of another person, position the remaining rubber gasket on the rim of the outlet connector, mate the rim of the collec tor with the connector, and secure it in place with (8) 5 ⁄ 16 -18 x 1 ⁄ 2 " flange bolts, as shown in Figure 16.

Collector x 2 Put Gasket Here Figure 14. Outlet connector installed.

Canister Support x 8 Figure 16. Collector installed.

8. Attach the top of the canister support to the collector with the remaining two 5 ⁄ 16 -18 x 1 ⁄ 2 " flange bolts, as shown in Figure 16.

-18 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

9. Apply the 5 x 42mm wide foam strip to the outside top of the collector, as shown in Figure 17, and trim the excess so that the ends of the strip come together evenly, as shown in Figure 18.

5 x 42mm Foam Strip 10. Place the cleaning handle on the canister shaft, align the hex bolt with the flat portion of the shaft and tighten the bolt, as shown in Figure 19.

Hex Bolt Canister Shaft Flat Figure 17. Applying the wide foam strip to the collector.

Ends Matched Evenly Figure 19. Installing the canister cleaning handle.

11. Position the belt clamp around the base of the canister, place the canister over the collector (as shown in Figure 20), then tighten the belt clamp so it evenly compresses against the wide foam strip.

Figure 18. Wide foam strip ends matched evenly.

Canister Belt Clamp 6 x 20 Foam Strip Figure 20. Canister installed.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -19-

12. Apply the 6 x 20mm foam strip to the bottom of the collector, then trim the excess and evenly match the ends (see Figure 20).

13. Attach a collection bag to the hooks around the bottom of the collector, then tighten the collection bag clamp around the foam strip to hold the bag in place, as shown in Figure 21.

G1028Z2/G1029Z2/ G1029Z2P Assembly

To assemble your machine:

1. Mount the casters to the base plate using (16) 5 ⁄ 16 "-18 x 1 ⁄ 2 " flange bolts, as shown in Figure 23.

x 4 Bag Clamp Collection Bag Figure 21. Collection bag installed.

14. Insert the inlet connector over the impeller intake hole, then secure it in place with the #10 x 3 ⁄ 8 " tap screw, as shown in Figure 22.

Figure 23. Mounting casters to base.

2. Set the collector body on top of the base plate so the intake portion is near the edge of the base plate and the bolt holes are aligned, as shown in Figure 24. Secure the collector body to the base plate with (4) 5 ⁄ 16 "-18 x 1 ⁄ 2 " flange bolts.

x 1 x 4 -20 Figure 22. Inlet connector installed.

Figure 24. Mounting collector to base.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

3. Insert the rubber gasket between the collec tor and outlet flange, and secure the flange with (8) 5 ⁄ 16 "-18 x 1 ⁄ 2 " flange bolts, as shown in Figure 25.

Note:

ket applied to the mounting surface, always tighten the fasteners in a crisscross man ner to ensure the gasket does not become crimped and the seal compromised.

Put Gasket Here Outlet Flange 5. Secure the front lower support bracket to the collector with (2) 5 ⁄ 16 "-18 x 1 ⁄ 2 " flange bolts. 6. Place the upper support bracket over the rear lower support bracket, and secure them to the collector with (2) 5 ⁄ 16 "-18 x 1 ⁄ 2 " flange bolts, as shown in Figure 27.

x 4 Upper Support Bracket Lower Support Bracket x 8 Figure 25. Mounting outlet flange to collector body.

4. Attach the lower collector support brackets to the top edge of the base plate using (4) 5 ⁄ 16 " 18 x 1 ⁄ 2 " flange bolts, as shown in Figure 26.

x 4 Lower Support Brackets Collector Figure 27. Mounting collector to brackets.

Note:

port bracket. The inside of the collector is funnel shaped and directs the air around in a cyclone motion. Make sure that the inside taper (funnel) is faced downward and the col lector inlet faces toward the motor, as shown in

Figure 28.

Collector Body Inside Taper Inlet Figure 26. Mounting support bracket to base.

Figure 28. Collector attached to support brackets.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -21-

7. Slip a loosened hose clamp over each end of the flex-hose, and position the hose ends over the outlets, as shown in Figure 29. Tighten each hose clamp until snug.

Flex Hose Ends Matched Evenly Hose Clamps Figure 29. Attaching flex hose onto collector body outlet.

8. Apply the 5 x 42mm foam strip to the out side top of the collector, as shown in

Figure

30, and trim the excess so that the ends of the strip come together evenly, as shown in Figure 31.

5 x 42mm Foam Strip Figure 31. Example of wide foam strip ends matched evenly.

9. Hook the upper filter bag (fabric) on the sup port bracket, as shown in Figure 32.

Figure 32. Attaching upper filter bag.

10. Secure the upper bag to the collector body with the clamp shown in Figure 33.

Clamp Figure 30. Example of applying the wide foam strip to the collector.

-22 Figure 33. Upper collection bag secured.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

11. Apply the 6 x 20 foam strip to the bottom of the collector, then trim the excess and evenly match the ends (see Figure 34). 6 x 20 Foam Strip Figure 34. Example of 6 x 20 foam strip installed.

12. Slip the plastic collection bag over the bottom edge of the collector, snag it on the metal hooks, and then tighten the clamp at the tight est notch possible ( Figure 35). Note: DO NOT force the clamp, If it is too

tight, choose the next notch over, then clamp it in place.

Power Connection

After you have completed all previous setup instructions and circuit requirements, the machine is ready to be connected to the power supply.

To prevent accidental damage to the power cord, make sure it is kept away from potential damage sources at all times —whether connected or not. Potential damage sources include high traffic areas, sharp objects, heat sources, harsh chemi cals, water, damp areas, etc.

To avoid unexpected startups or property dam age, use the following steps whenever connecting or disconnecting the machine.

Connecting Power

1. Turn the machine power switch OFF.

2. Insert the power cord plug into a matching power supply receptacle. The machine is now connected to the power source.

Figure 35.

Installing the lower bag.

13. Remove the pre-installed screw from the inlet cover, and secure the adapter to the cover flange with the screw (see Figure 36).

x 1

Figure 37.

Connecting power.

Disconnecting Power

1. Turn the machine power switch OFF.

2. Grasp the molded plug and pull it completely out of the receptacle. Do not pull by the cord as this may damage the wires inside.

Figure 36. Installing "Y" inlet.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

Figure 38.

Disconnecting power.

-23-

Test Run

Once the assembly is complete, test run your machine to make sure it runs properly and is ready for regular operation. The test run consists of verifying the following: 1) The motor powers up and runs correctly, and 2) the safety disabling mechanism on the switch works correctly.

If, during the test run, you cannot easily locate the source of an unusual noise or vibration, stop using the machine immediately, then review Troubleshooting on Page 38. If you still cannot remedy a problem, contact our Tech Support at (570) 546-9663 for assistance.

To test run the machine:

1. Make sure you have read the safety instruc tions at the beginning of the manual and that the machine is setup properly.

2. Make sure all tools and objects used during setup are cleared away from the machine.

3. Connect the machine to power.

4. Verify that the machine is operating correctly by turning the machine ON.

—When operating correctly, the machine runs smoothly with little or no vibration or rubbing noises.

— Investigate and correct strange or unusual noises or vibrations before operating the machine further. Always disconnect the machine from power when investigating or correcting potential problems.

5. Turn the machine OFF.

6. Remove the switch disabling key, as shown in Figure 39.

Figure 39. Removing switch key from paddle switch.

7. Try to turn the start the machine with the paddle switch.

—If the machine DOES NOT start, the switch disabling feature IS working as designed.

—If the machine DOES start, immediately stop the machine. The switch disabling feature IS NOT working correctly. This safety feature must work properly before proceeding with regular operations. Call Tech Support for help.

-24 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

SECTION 4: DESIGNING THE SYSTEM General Duct Material

Always guard against static electrical build up by grounding all dust col lection lines.

This dust collector can be operated as either a stationary, central dust collector or a mobile unit. There are advantages and disadvantages to both setups. The advantage of the mobile system is eliminating the cost of many ducts and fittings. On the other hand, the stationary system is more efficient and customizable. If using this dust collector as a stationary system, put the dust collector in an out-of-the way location such as a corner or separate room. The dust col lector is capable of collecting dust from up to two machines running simultaneously. Grizzly offers a complete line of dust collection accessories for setting up a stationary, central dust collector sys tem. Additionally, Grizzly offers a complete guide book entitled Dust Collection Basics. Whatever system you choose, always make sure there are no open flames or pilot lights in the same room as the dust collector. There is a risk of explosion if dust is dispersed into the air.

You have many choices regarding main line and branch line duct material. For best results, use metal duct for the main line and branch lines, then use short lengths of flexible hose to connect each machine to the branch lines.

Plastic duct is also a popular material for home shops. However, be aware that there is a fire or explosion hazard if plastic duct material is used for dust collection without being grounded against static electrical charge build-up. This topic will be discussed later in this section. Another problem with using plastic is that it is less efficient per foot than metal.

Plastic duct generates static electrical buildup that can cause fire or shock. Properly ground it to reduce this risk.

Plastic Duct

The popularity of plastic duct is due to the fact that it is an economical and readily available product. It is also simple to assemble and easily sealed against air loss. The primary disadvantage of plastic duct for dust collection is the inherent danger of static electrical build-up.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) Figure 40. Examples of plastic ducting components.

-25-

Metal Duct

Advantages of metal duct is its conductivity, effi ciency, and that it does not contribute to static electrical charge build-up. However, static charg es are still produced when dust particles strike other dust particles as they move through the duct. Since metal duct is a conductor, it can be grounded quite easily to dissipate any static elec trical charges.

Flexible Duct

Flexible hose is generally used for short runs, small shops and at rigid duct-to-tool connections. There are many different types of flex hose on the market today. These are manufactured from materials such as polyethylene, PVC, cloth hose dipped in rubber and even metal, including steel and aluminum.

The superior choice here is metal flex hose that is designed to be flexible, yet be as smooth as pos sible to reduce static pressure loss.

Figure 41. Examples of metal pipe and components.

There are a number of options when it comes to metal duct, but metal duct that is specially manu factured for dust collection is the best choice. When selecting your metal duct, choose high quality metal duct with smooth welded internal seams that will minimize airflow resistance. This type of duct usually connects to other ducts or elbows with a simple, self-sealing clamp, is very quick and easy to assemble, and can be readily dismantled and re-installed. This is espe cially important if you ever need to change things around in your shop or add more tools.

Avoid inferior metal duct that requires you to cut it to length and snap it together. This type of duct is time consuming to install because it requires you to seal all the seams with silicone and screw the components on the ends with sheet metal screws. Another disadvantage is the rough internal seams and crimped ends that unavoidably increase static pressure loss.

Figure 42. Example of flexible metal duct.

There are also many kinds of pure plastic flexible hose, such as non-perforated drainage type hose and dryer vent hose. Drainage type hose, while being economical, does not quite have the flex ibility required for dust collection. The inside of the duct is also deeply corrugated and can increase the static pressure loss by as much as 50% over smooth wall duct. Dryer vent hose, while being completely flexible, is non-resistant to abrasion and has a tendency to collapse in a negative pressure system. We DO NOT recommend using dryer vent hose in your dust collection system.

If using flex-hose, you should choose one of the many types that are designed specifically for the movement of solid particles, i.e. dust, grains, and plastics. However, the cost of specifically designed flexible duct can vary greatly. Grizzly offers polyethylene hose, which is well suited for the removal of particulate matter, especially saw dust, since it is durable and completely flexible. Polyethylene is also very economical and avail able in a wide variety of diameters and lengths for most applications.

-26 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

System Design

Decide Who Will Design

For most small-to-medium sized shops, you can design and build the dust collection system your self without hiring engineers or consultants. We have included some basic information here to get you started on a basic design.

If you have a large shop or plan to design a com plicated system, we recommend doing additional research beyond this manual or seeking the help of an expert.

Sketch Your Shop Layout

When designing a successful dust collection sys tem, planning is the most important step. In this step, sketch a basic layout of your shop, including space requirements of different machines.

Before you get out your pencil and paper, we rec ommend you visit our FREE Workshop Planner, at http://www.grizzly.com/workshopplanner. Our Workshop Planner will allow you to quickly and easily design and print a basic shop layout. Don't worry, non-Grizzly brand machines can be substituted with Grizzly machines for layout pur poses. Note: After you're finished, make sure to

save your layout for later modification.

Your sketch only needs the basic details of the shop layout, similar to the figure below, includ ing all your current/planned machines and your planned placement of the dust collector.

Sketch a Basic Duct Layout

For the next step, sketch how you will connect your machines to the dust collector. Consider these general guidelines for an efficient system: 1. Machines that produce the most saw dust should be placed nearest to the dust collector (i.e. planers and sanders).

2. Ideally, you should design the duct system to have the shortest possible main line and sec ondary branch ducts. See the figures below for ideas of efficient versus inefficient duct layouts.

Branch Line Ducts Main Line Duct

GOOD

Dust Collector Figure 44. Efficient duct layout.

BAD

Dust Collector Dust Collector Figure 45. Inefficient duct layout.

Figure 43. Basic sketch of shop layout.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -27-

3. Directional changes should be kept to a mini mum. The more directional change fittings you use directly increases the overall resis tance to airflow.

4. Gradual directional changes are more effi cient than sudden directional changes (i.e. use the largest corner radius possible when changing hose or pipe direction).

5. Each individual branch line should have a blast gate immediately after the branch to control suction from one machine to another.

6. The simpler the system, the more efficient and less costly it will be.

Determine Required CFMs

Since each machine produces a different amount of sawdust, the requirements for the minimum amount of CFM to move that sawdust is unique to the machine (for example, a planer produces more sawdust than a table saw). Knowing this required CFM is important to gauging which size of duct to use.

Refer to the figure below for a close estimation of the airflow each machine requires. Keep in mind that machines that generate the most sawdust should be placed closest to the dust collector. If the machine has multiple dust ports, the total CFM required is the sum of all ports.

Machine Dust Port Size

2" 2.5" 3" 4" 5" 6" 7" 8" 9"

Approximate Required CFM

98 150 220 395 614 884 1203 1570 1990 10" 2456 Figure 46. Approximate required airflow for machines, based on dust port size.

If the machine does not have a built-in dust port, use the following table to determine which size of dust port to install.

Machine Average Dust Port Size

Table Saw ......................................................4" Miter/Radial-Arm Saw ....................................2" Jointer (6" and smaller) .................................4" Jointer (8"-12") ...............................................5" Thickness Planer (13" and smaller) ...............4" Thickness Planer (14"-20") ............................6" Shaper ...........................................................4" Router (mounted to table) ..............................2" Bandsaw ........................................................4" Lathe ..............................................................4" Disc Sander (12" and smaller) .......................2" Disc Sander (13-18") ......................................4" Belt Sander (6" and smaller) .........................2" Belt Sander (7"-9") ........................................3" Edge Sander (6" x 80" and smaller) ..............4" Edge Sander (6" x 80" and larger) ................5" Drum Sander (24" and smaller) ...............2 x 4" Drum Sander (24" and larger) .................4 x 4" Widebelt Sander (18" and smaller) ................5" Widebelt Sander (24"-37" single head) ...2 x 6" Widebelt Sander (24"-51" double head) ..5 x 4" Figure 47. Dust port size and quantity per average machine.

Write the required CFM for each machine on your sketch, as shown in the figure below.

Miter Saw 98 Planer/ Moulder 395 Jointer Sander 395 790 Dust Collector 220 395 614 Shaper Table Saw Planer Figure 48. CFM requirements labeled for each machine.

-28 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

Determining Main Line Duct Size

The general rule of thumb for a main line duct is that the velocity of the airflow must not fall below 3500 FPM.

For small/medium sized shops, using the inlet size of the dust collector as the main line duct size will usually keep the air velocity above 3500 FPM and, depending on your system, will allow you to keep multiple branches open at one time.

Mark your drawing, as shown in the figure below, but using the inlet size for your dust collector as the main line.

Miter Saw 98 Planer/ Moulder 395 Jointer 395 Sander 790 5" 6" 7" Dust Collector 220 395 614 Shaper Table Saw Planer Figure 49. Main line size labeled on sketch.

Determining Branch Line Duct Size

The general rule of thumb for a branch line duct is that the velocity of the airflow must not fall below 4000 FPM.

For small/medium sized shops, using the dust port size from the machine as the branch line duct size will achieve the correct velocity in most appli cations. However, if the dust port on the machine is smaller than 4", make the branch line 4" and neck the line down right before the dust port.

Note: Systems with powerful dust collectors work

better if multiple blast gates are left open. This also allows you to run two machines at once. Experiment with different combinations of blast gates open/closed to find the best results for your system.

Write your determined branch line sizes on your drawing, as shown in the following figure.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) Planer/ Moulder 395 4" Jointer 395 4" Sander 790 6" Miter Saw 98 4" 5" 6" 7" Dust Collector 4" 220 4" 395 5" 614 Shaper Table Saw Planer Figure 50. Branch line duct sizes labeled.

If two machines will connect to the same branch line and both will operate at the same time, then add the required CFM for each machine together and find the closest total CFM in the table below to determine the correct branch size.

If both machines will never run at the same time, reference the machine with the biggest dust port in the table below and add blast gates after the Y-branch to open/close the line to each machine.

Total CFM

400 500 600 700 800 900 1000

Branch Line Size

4" 4" 5" 5" 6" 6" 6" Figure 51. Sizing chart for multiple machines on the same branch line.

-29-

Planning Drop Downs

Plan the drop downs for each machine, using blast gates wherever possible to control airflow.

Rigid Pipe (Main Line) Y Branch Clamp Flex Pipe Elbow Rigid Pipe Blast Gate To Planer Figure 52. Drop down setup.

Calculating Duct Resistance

Adding duct work, elbows, branches and any other components to a duct line increases airflow resistance (static pressure loss). This resistance can be minimized by using rigid (smooth) pipe and gradual curves, as opposed to flexible pipe and 90˚ elbows. To help you think about this resistance, imagine riding a bicycle in a tunnel that is an exact replica of your duct work. If the inside of the tunnel is very bumpy (flexible pipe) and has a lot of sharp turns (90˚ elbows), it will take a lot more effort to travel from one end to the other.

The purpose of calculating the resistance is to determine if it is low enough from the machine to the dust collector to meet the given CFM require ment for the machine. Use the following tables to calculate the resistance of duct work.

Duct Dia.

2" 2.5" 3" 4" 5" 6" 7" 8" 9"

Approximate Static Pressure Loss Per Foot of Rigid Pipe

Main Lines at 3500 FPM Branch Lines at 4000 FPM 0.091

0.08

0.071

0.057

0.046

0.037

0.029

0.023

0.017

0.122

0.107

0.094

0.075

0.059

0.047

0.036

0.027

0.019

Approximate Static Pressure Loss Per Foot of Flex Pipe

Main Lines at 3500 FPM Branch Lines at 4000 FPM 0.35

0.306

0.271

0.215

0.172

0.136

0.106

0.08

0.057

0.453

0.397

0.352

0.28

0.225

0.18

0.141

0.108

0.079

Fitting Dia.

90˚ Elbow 45˚ Elbow 45˚ Wye(Y) 90˚ Wye(Y)

3" 4" 5" 0.47

0.45

0.531

0.235

0.225

0.266

0.282

0.375

0.354

0.188

0.225

0.236

6" 7" 0.564

0.468

0.282

0.234

0.329

0.324

0.235

0.216

8" 0.405

0.203

0.297

0.189

Figure 53. Static pressure loss charts.

In most small/medium shops it is only necessary to calculate the line with the longest duct length or the most fittings (operating under the assumption that if the line with the highest resistance works, the others will be fine).

To calculate the static pressure of any given line in the system, follow these steps:

1. Make a list of each size duct in the line, including the length, and multiply those num bers by the static pressure value given in the previous table.

2. List each type of elbow or branch and multiply the quantity (if more than one) by the static pressure loss given in the previous table.

-30 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

3. Add the additional factors from the following table to your list.

Additional Factors

Seasoned (well used) Dust Collection Filter Entry Loss at Large Machine Hood

Static Pressure

1" 2" Figure 54. Additional factors affecting static pressure.

4. Total your list as shown in the example below to come up with your overall static pressure loss number for that line.

Note: Always account for a seasoned filter,

so you don't end up with a system that only works right when the filter is clean.

Main Line

6" Rigid Pipe (0.037) at 20' ................ 0.740

Branch Line

4" Rigid Pipe (0.075) at 10' ................ 0.750

4" Flex Pipe (0.28) at 5' ........................ 1.400

Elbows/Branches

6" 45˚ Y-Branch ................................ 0.329

4" 45˚ Elbow ........................................ 0.225

Additional Factors

Seasoned Filter ................................ 1.000

Total Static Pressure Loss ................ 4.444

Figure 55. Totaling static pressure numbers.

Note: When calculating static pressure loss

to determine if multiple lines can be left open at the same time, only include the main line numbers once.

5. Compare the total static pressure loss for that line to the maximum static pressure loss found on the data sheet for your machine (located toward the front of this manual).

—If the CFM for your static pressure loss is above the requirement of the machine, then the line will most likely be success ful. Congratulations! You’ve just designed your own dust system. Compile a list of materials and refer to your system a reality.

with 45˚ elbows.

Accessories to start buying the components necessary to make —If the CFM for your static pressure loss is below the requirement of the machine, then that line will not effectively collect the dust. You must then modify some of the factors in that line to reduce the static pressure loss. Some of the ways to do this include 1) installing larger duct, 2) reducing amount of flexible duct used, 3) increasing machine dust port size, 4) moving machine closer to dust collector to eliminate duct length, and 5) reducing 90˚ elbows or replacing them

Compile Materials List

After the system is designed, create a materials list of all the items you will need to build your dust collection system. This will make it easy when it comes time to purchase the materials.

Below is an example of some items that might be needed. Refer to Accessories for dust collection components available through grizzly.com.

Description

6" Rigid Pipe at 20' 4" Rigid Pipe at 10'

Model

G7364 G6162

Quantity

4" Flex Hose at 5' 6" 45 ° Y-Branch H7215 G7353 4" 45 ° Elbow G6167 Figure 56. Example materials list.

4 2 6 6 6 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -31-

System Grounding

Since plastic hose is abundant, relatively inex pensive, easily assembled and air tight, it is a very popular material for conveying dust from woodworking machines to the dust collector. We recommend using flexible hose (flex-hose) to connect the woodworking machine to the dust collector. However, plastic flex-hose and plastic duct are an insulator, and dust particles moving against the walls of the plastic duct create a static electrical build up. This charge will build until it discharges to a ground. If a grounding medium is not available to prevent static electrical build up, the electrical charge will arc to the nearest grounded source. This electrical discharge may cause an explosion and subsequent fire inside the system.

To protect against static electrical build up inside a non-conducting duct, a bare copper wire should be placed inside the duct along its length and grounded to the dust collector. You must also confirm that the dust collector is continuously grounded through the electrical circuit to the elec tric service panel. If you connect the dust collector to more than one machine by way of a non-conducting branching duct system and blast gates, the system must still be grounded as mentioned above. We recom mend inserting a continuous bare copper ground wire inside the entire duct system and attaching the wire to each grounded woodworking machine and dust collector.

Be sure that you extend the bare copper wire down all branches of the system. Do not forget to connect the wires to each other with wire nuts when two branches meet at a “Y” or “T” connec tion. Ensure that the entire system is grounded. If using plastic blast gates to direct air flow, the ground ing wire must be jumped (see the figure grounding system.

below) around the blast gate without interruption to the Plastic Blast Gate Metal Duct Copper Ground Wire Figure 57. Ground jumper wire when using plastic blast gates and metal duct.

We also recommend wrapping the outside of all plastic ducts with bare copper wire to ground the outside of the system against static electrical build up. Wire connections at Y’s and T’s should be made with wire nuts.

Attach the bare ground wire to each stationary woodworking machine and attach to the dust collector frame with a ground screw as shown in the figure below. Ensure that each machine is continuously grounded to the grounding terminal in your electric service panel.

Always guard against static electrical build up by grounding all dust collection lines.

Internal Ground Wire External Ground Wire Flex-Hose Ground Screw Figure 58. Flex-hose grounded to machine.

-32 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

SECTION 5: OPERATIONS

To reduce your risk of serious injury, read this entire manual BEFORE using machine.

To reduce risk of eye injury from flying chips or lung damage from breathing dust, always wear safety glasses and a respirator when operating this machine.

General

Operating a dust collector is simple and straight forward. Turn the dust collector ON, then turn the dust producing machine machine ON. When you are finished with the machine operation, turn the OFF, then turn the dust collector OFF.

Blast gates can be used at the start of each branch line to control the air flow from the woodworking machine to the dust collector. If a machine is not being used, keep the blast gate closed to maintain higher levels of efficiency throughout the system.

If you are not experienced with this type of machine, WE STRONGLY RECOMMEND that you seek additional training outside of this manual. Read books/magazines or get formal training before beginning any proj ects. Regardless of the content in this sec tion, Grizzly Industrial will not be held liable for accidents caused by lack of training.

Machine Storage

When the dust collector is not in use, unplug the power cord from the power source. Place the cord away from potential damage sources, such as high traffic areas, sharp objects, heat sources, harsh chemicals, water, damp areas, etc.

Do NOT put hands or small objects near inlet openings during opera tion. Objects sucked into the inlet will meet with the impeller blade. Failure to heed this warning could result in property damage or per sonal injury.

-33 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

SECTION 6: ACCESSORIES

Installing unapproved accessories may cause machine to malfunction, resulting in serious personal injury or machine damage. To reduce this risk, only install accessories recommended for this machine by Grizzly.

NOTICE

Refer to our website or latest catalog for additional recommended accessories.

T20543— 41" x 31" Flat 19.75" Dia. Plastic Bottom Bag

Replacement plastic lower bag for G0548ZP, G1029Z2/G1029Z2P, and G1028Z2.

H5783—Extra 1 Micron Canister

Replacement canister for Grizzly G0548ZP, G0562Z/G0562ZP, G1028Z/Z2, G1029Z/Z2/ Z2P, and G1030Z/Z2/Z2P Dust Collectors.

G5556—2.5 Micron Dust Bag

Replacement top bag for Grizzly G1028Z2 and G1029Z2/G1029Z2P dust collectors. These offer the largest airflow, least differ ential pressure and best overall efficiency available. Micro-porous to shed dust and dirt, so bags empty quickly and completely. 2.5 Microns! Captures the finest, most hazard ous dust.

Figure 60. G5556 2.5 Micron Dust Bag.

G1536—Black Flexible Hose 4" x 10' G2974—Wire Hose Clamp 4" G1843—Plastic Blast Gate 4" G4679—Anti-Static Grounding Kit

We've hand picked a selection of commonly used dust collection components for machines with 4" dust ports.

G2974 G1536 G1843 G4679 Figure 59. Replacement canister.

Figure 61. Dust collection accessories.

order online at

www.grizzly.com

or call

1-800-523-4777

-34 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

H5293—4" Metal Duct Starter Kit H5295—5" Metal Duct Starter Kit H5297—6" Metal Duct Starter Kit

Save over 20% with this great starter kit. Includes: (2) machine adapters, (10) pipe clamps, (3) 5' straight pipes, (1) branch, (3) pipe hangers, (1) end cap, (3) adjustable nipples, (1) 90˚ elbow, and (1) 60˚ elbow.

H7215—4" x 5' Rigid Metal Flex Hose H7216—5" x 5' Rigid Metal Flex Hose H7217—6" x 5' Rigid Metal Flex Hose

This flex hose provides just enough flexibility to make difficult connections while still keep ing the inside wall as smooth as possible to minimize static pressure loss.

Figure 65. Rigid Metal Flex Hose.

Metal Elbows

These industrial metal elbows are available from 4"–8" with 90˚, 60˚, 45˚, or 30˚ curves.

Figure 62. Metal Duct Starter Kit.

G6163—4" Clamp G7343—5" Clamp G7361—6" Clamp

These clamps feature lever latches and foam seals, and secure around the rolled ends of fit tings and pipe.

90° 90° Long Radius 30° 45° Figure 66. Metal elbow examples.

60°

Reducers & Adapters

We carry a multitude of reducers and elbows to cover most applications from 4" through 9".

Figure 63. Dust collection pipe clamps.

G6162—4" x 5' Straight Metal Pipe G7346—5" x 5' Straight Metal Pipe G7364—6" x 5' Straight Metal Pipe

These laser welded straight pipes ensure a super smooth internal seam. Ends easily clamp together for a sealed fit without screws or silicone.

Figure 67. Metal Reducers & Adapters.

Metal Branches

We carry a selection of different branches.

Figure 64. Straight Metal Pipe.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) Figure 68. Metal Branches.

-35-

SECTION 7: MAINTENANCE

Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious person al injury.

Schedule

For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section.

• • • •

Daily Check:

• Loose mounting bolts.

• Worn switch.

Worn or damaged wires.

Clean canister filter (G0548ZP only). Check collection bag.

Any other unsafe condition.

Lubrication

Since all bearings are shielded and permanently lubricated, simply leave them alone until they need to be replaced. Do not lubricate them.

Always wear a respirator and safety glasses when emptying the dust collection bags on the dust collector. Sawdust may cause allergic reactions or respiratory problems.

Cleaning Bags

Always empty the collection bags on a regular basis. Emptying the collection bags allows the machine to operate at a much higher level of efficiency. Always wear the appropriate respirator or dust mask and safety glasses when emptying the col lection bags. Small dust particles can escape the bags during emptying, causing them to become airborne and easily inhaled. This microscopic air borne dust is extremely unhealthy to breathe and can cause serious health problems.

While this dust collector excels at collecting the majority of wood dust produced by your machines, it is not an air filter; therefore,

we strongly rec-

ommend the supplemental aid of a shop air filter such as the Grizzly G0572 or G9956. Air filters are designed to collect the smaller dust particles that dust collector bags cannot trap.

-36 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

Replacing Bags

Replacement plastic lower collection bags are available through Grizzly as Model T20543. Replacement top dust bags are available for the Model G1028Z2/G1029Z2/Z2P as Model G5556.

To replace the collection bag:

1. DISCONNECT MACHINE FROM POWER!

2. Make sure you are wearing safety glasses and a respirator.

3. Release the belt clamp securing the collec tion bag, then unhook the bag from the col lector.

4. Securely close the top of the bag and safely dispose of it according to local and federal standards.

5. Install a new collection bag.

Cleaning Canister Filter

To clean the canister filter on the Model G0548ZP, move the canister cleaning handle back-and-forth to free the trapped dust particles from the filter pleats (see Figure 69). The particles will fall into the collection bag.

The replacement canister for the G0548ZP is the Model H5783, which can also be installed on the G1028Z2/G1029Z2/Z2P, if you would ever like to upgrade.

Figure 69. Canister cleaning handle directions.

NOTICE

The use of compressed air or liquids to clean the canister filter will damage the filtration pleats of the filter. Use ONLY the cleaning handle or, if necessary, a soft brush to clean the inside of the canister filter.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -37-

SECTION 8: SERVICE

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. To reduce the risk of serious personal injury or damage to the machine, any repairs not covered in this manual should only be performed by or with the assistance of qualified service personnel.

Troubleshooting

Motor & Electrical

Symptom Machine does not start or a breaker trips.

Possible Cause 1. Switch disabling key removed.

2. Power supply switched OFF or is at fault.

3. Wall fuse/circuit breaker is blown/tripped.

4. Wiring is open/has high resistance.

Machine has vibration or noisy operation.

5. Motor ON/OFF switch is at fault.

6. Motor is at fault.

1. Motor, motor mount, or other mounting component is loose or broken.

2. Machine is incorrectly "mounted" or sits unevenly on its casters.

3. Motor fan is rubbing on fan cover.

4. Impeller is loose or damaged and unbalanced.

5. Motor bearings are at fault.

Possible Solution 1. Install switch disabling key.

2. Ensure power supply is switched ON; ensure power supply has the correct voltage.

3. Ensure circuit size is suitable for this machine; replace weak breaker.

4. Check for broken wires or disconnected/ corroded connections, and repair/replace as necessary. 5. Replace faulty ON/OFF switch.

6. Test/repair/replace.

1. Retighten. Use thread locking fluid if necessary. Replace stripped fasteners or damaged components if necessary. 2. Tighten/replace anchor studs in floor if mounted; chock machine casters if mobile.

3. Replace dented fan cover; replace loose/ damaged fan.

4. Disconnect dust collector from power, and inspect the impeller for dents, bends, loose fins. Replace the motor and impeller as a set if the motor shaft and the impeller hub are damaged.

5. Test by rotating shaft; rotational grinding/loose shaft requires bearing replacement.

-38 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

Dust Collector Operation

Symptom Dust collector does not adequately collect dust or chips; poor performance.

Possible Cause 1. Dust collection bags are full.

2. Canister is dirty.

3. Restriction in duct line.

4. Dust collector is too far away, or there are too many sharp bends in the ducting.

Sawdust being blown into the air from the dust collector.

5. Lumber is wet and dust not flowing through ducting smoothly.

6. Leaks in ducting or too many open ports.

7. Not enough open branch lines, causing a velocity drop in the main line.

8. Ducting or machine dust ports are incorrectly sized.

9. The machine dust collection design is inadequate.

10. The dust collector is too small for the dust collection system, or ducting layout design inadequate.

1. Duct clamps or dust collection bags are not properly clamped and secured.

Possible Solution 1. Empty collection bags.

2. Clean canister.

3. Remove restriction in the duct line. A plumbing snake may be necessary.

4. Relocate the dust collector closer to the point of suction, and rework ducting without sharp bends. Refer to System Design, beginning on Page 27.

5. Process lumber with less than 20% moisture content.

6. Rework the ducting to eliminate all leaks. Close dust ports for lines not being used. 7. Open 1 or 2 more blast gates to different branch lines to allow the velocity in the main line to increase.

8. Re-install correctly sized ducts and fittings. Refer to System Design beginning on Page 27 for more solutions.

9. Use a dust collection nozzle on a stand.

10. Install a larger dust collector to power your dust collection system.

1. Re-secure ducts and dust collection bag, making sure duct and bag clamps are tight and completely over the ducts and bags.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -39-

machine

SECTION 9: WIRING

These pages are current at the time of printing. However, in the spirit of improvement, we may make chang es to the electrical systems of future machines. Compare the manufacture date of your machine to the one stated in this manual, and study this section carefully.

If there are differences between your machine and what is shown in this section, call Technical Support at (570) 546-9663 for assistance BEFORE making any changes to the wiring on your machine. An updated wiring diagram may be available. Note: Please gather the serial number and manufacture date of your

machine before calling. This information can be found on the main machine label.

Wiring Safety Instructions

SHOCK HAZARD. Working on wiring that is con nected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical com ponents!

WIRE/COMPONENT DAMAGE. Damaged wires or components increase the risk of serious per sonal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components.

MODIFICATIONS. Modifying the wiring beyond what is shown in the diagram may lead to unpre dictable results, including serious injury or fire. This includes the installation of unapproved after market parts.

MOTOR WIRING. The motor wiring shown in these diagrams is current at the time of printing but may not match your machine. If you find this to be the case, use the wiring diagram inside the motor junction box.

WIRE CONNECTIONS. All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires dis connected or connected during any wiring task to ensure tight connections.

CAPACITORS/INVERTERS. Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors.

CIRCUIT REQUIREMENTS. You MUST follow the requirements at the beginning of this man ual when connecting your machine to a power source.

EXPERIENCING DIFFICULTIES. If you are expe riencing difficulties understanding the information included in this section, contact our Technical Support at (570) 546-9663.

-40-

The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.grizzly.com.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

G0548ZP Wiring Diagram

240 VOLT

Run Capacitor 30MFD 250VAC

MOTOR

Ground PADDLE SWITCH (viewed from behind) Start Capacitor 300MFD 125VAC

Hot Hot

240V

Ground

G

6-15 Plug (As Recommended)

Figure 70. G0548ZP start capacitor.

Figure 71. G0548ZP junction box, switch and run capacitor.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

READ ELECTRICAL SAFETY ON PAGE 40!

-41-

G1028Z2 Wiring Diagram

120 VOLT (PREWIRED)

Run Capacitor 45MFD 250VAC Neutral Hot

MOTOR

Ground PADDLE SWITCH (viewed from behind) Ground Start Capacitor 300MFD 125VAC

120V 5-15 Plug (Prewired) Hot

Rewired 240V Gn

Hot

G

240V Ground 6-15 Plug (As Recommended)

240 VOLT (REWIRED)

Run Capacitor 45MFD 250VAC

MOTOR

Figure 72. G1028Z2 start capacitor.

PADDLE SWITCH (viewed from behind) Ground Start Capacitor 300MFD 125VAC Figure 73. G1028Z2 junction box, switch and run capacitor at 120V.

-42-

READ ELECTRICAL SAFETY ON PAGE 40!

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

G1029Z2/G1029Z2P Wiring Diagram

240 VOLT

MOTOR

Ground PADDLE SWITCH (viewed from behind)

Hot Hot

Start Capacitor 300MFD 125VAC

240V Ground

G

6-15 Plug (As Recommended)

Figure 74. G1029Z2 start capacitor.

Figure 75. G1029Z2 junction box and switch.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

READ ELECTRICAL SAFETY ON PAGE 40!

-43-

SECTION 10: PARTS G0548ZP Main Breakdown

14 27A H5783 Parts Breakdown on

Page 46

-44 23 2 17-2 17-1 17-3 17-4 17-5 17-6 17 17V2 30 19 2 2 40 21 21V2 25 15 12 43 12 18 31 31V2 28 35 35V2 34 24 41 36 37 39 44 28 11 22 2 10 10V2 9 45 7V2 6 5 13 29 42 2 1 4 26 32 29-1 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

G0548ZP Main Parts List

REF PART # DESCRIPTION

1 2 4 5 P1028Z2001 PFB01 P1028Z2004 PS06 6 P0548ZP006 7V2 P1028Z2007V2 9 10 P0548009 P1029Z2010V2 CASTERS FLANGE BOLT 5/16-18 X 1/2 BASE PLATE PHLP HD SCR 10-24 X 3/8 6" INLET COVER CAP SCREW M6-1 X 30 LH PRE-COATED IMPELLER WASHER 7 X 40 X 4 IMPELLER 12-3/4" ALUMINUM V2.09.11

11 12 13 14 P0548ZP011 PW07 PS06 PFB01 COLLECTOR BODY FLAT WASHER 5/16 PHLP HD SCR 10-24 X 3/8 FLANGE BOLT 5/16-18 X 1/2 15 17 PB03 P0548ZP017 HEX BOLT 5/16-18 X 1 MOTOR 2HP 220V 1PH 17-1 P0548ZP017-1 MOTOR FAN COVER 17-2 P0548Z017V2-2 MOTOR FAN 17-3 P0548ZP017-3 17-4 PC300B 17-5 P0548ZP017-5 17-6 PC030C 18 19 21 PN02 P0548ZP019 P1030Z2015V2 CAPACITOR COVER S CAPACITOR 300M 125V 1-3/4 X 3-3/8 MOTOR WIRING JUNCTION BOX R CAPACITOR 30M 250V 1-3/8 X 2-3/8 HEX NUT 5/16"-18 OUTLET CONNECTOR PADDLE SWITCH V2.09.11

REF PART # DESCRIPTION

39 40 41 42 43 44 45 22 23 24 25 T20543 P0548Z023 P0548ZP024 P0548Z025 26 PAW05M 27A H5783 28 29 P1028Z2028 P0548ZP029 COLLECTION BAG COLLECTOR SUPPORT COLLECTOR SPACER WRENCH HEX 5MM COMPLETE CANISTER ASSY RUBBER GASKET INLET 29-1 P0548Z029-1 30 PK28M 31 32 INLET CAP KEY 7 X 7 X 29 P1029Z2013V2 PWR CORD 14G 3W 6' 6-15 V2.09.11

PWR1012 WRENCH 10 X 12MM OPEN-END 34 35 36 37 P1028Z2031 P0548ZP035 PLABEL-12 PLABEL-57 BELT CLAMP MACHINE ID LABEL READ MANUAL 2W X 3.3H

EYE/LUNG LABEL PLABEL-59 PLABEL-14 P0548Z041 P0548Z042 PPAINT-24 PLABEL-81 PLW03M NO HAND IN INLET LABEL ELECTRICITY LABEL 1.4W X 1.2H

FOAM STRIP 5 X 42MM FOAM STRIP 4 X 20MM POLAR BEAR PAINT POLAR BEAR LOGO 1 X 3-3/4 LOCK WASHER 6MM G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -45-

H5783 breakdown

H5783 Canister Filter Assembly

3 2 7 1 20 21 22 23 5 4 6 15 14 16 12 17 18 19 7 9 26 5 6 8V2 24

REF PART #

1 2 3 4 5 6 7 8V2 9 12 14

DESCRIPTION

PH5783001 PB83M PH5783003 PH5783004 PH5783005 CLEANING HANDLE HEX BOLT M6-1 X 16 CANISTER FILTER HEX SPINDLE THRUST BEARING 12 X 14 X 6 PH5783006 PS09M BEARING PLATE PHLP HD SCR M5-.8 X 10 PH5783008V2 PLASTIC FLAP BOARD V2.09.11

PS68M PS20M PH5783014 PHLP HD SCR M6-1 X 10 PHLP HD SCR M5-.8 X 15 BOTTOM PLATE -46-

REF PART #

15 16 17 18 19 20 21 22 23 24 26 PH5783015 PN06M PW06 PS68M PH5783019 PH5783020 PH5783021 PH5783022 PH5783023 PH5783024 PW03M

DESCRIPTION

SUPPORT TAB HEX NUT M5-.8

FLAT WASHER 1/4 PHLP HD SCR M6-1 X 10 SPONGE GASKET 10 X 15MM HANDLE SLEEVE HANDLE CAP QUICK RELEASE CLAMP FOAM STRIP 20MM X 156CM FOAM STRIP 42MM X 156CM FLAT WASHER 6MM G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

G1028Z2/G1029Z2 Main Breakdown

26 2 27 23 2 17V2-1 17V2-3 17V2-5 17V2-2 17V2-6 (G1028Z2) 17V2-4 102 101 21 20 2 3 17V2 25 103 104V2 105 16V2 15 12 106 12 14 13V2 31 30 24 20 2 23 2 19 28 22 11 10V2 2 9 35 7V2 6 5 18 29 2 1 4 33 32 29-1

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 Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.

G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -47-

REF

1 2 3 4 5 6 7V2 9 10V2

PART #

P1028Z2001 PFB01 PK32M P1028Z2004 PS06 P1028Z2006 P1028Z2007V2 P1028Z2009 P1028Z2010V2 11 12 13V2 14 15 16V2 17V2 P1028Z2011 PW07 P1028Z2013V2 PN02 PB03 P1028Z2016V2 P1028Z2017V2 17V2-1 P1028Z2017V2-1 17V2-2 P1028Z2017V2-2 17V2-3 P1028Z2017V2-3 17V2-4 PC300G 17V2-5 P1028Z2017V2-5 17V2-6 P1028Z2017V2-6 18 PS06

G1028Z2 Main Parts List

DESCRIPTION

CASTER FLANGE BOLT 5/16-18 X 1/2 KEY 6 X 6 X 28 BASE PLATE PHLP HD SCR 10-24 X 3/8 INLET COVER 6" CAP SCREW M6-1 X 30 LH PRE-COATED IMPELLER WASHER IMPELLER 12-3/4"D X 85MM H X 3/4" ALUM V2.09.11

COLLECTOR BODY FLAT WASHER 5/16 POWER CORD 14G 3W 6' 5-15 V2.09.11

HEX NUT 5/16-18 HEX BOLT 5/16-18 X 1 PADDLE SWITCH V2.09.11

MOTOR 1-1/2HP 120V/240V 1PH V2.09.11

MOTOR FAN COVER MOTOR FAN CAPACITOR COVER S CAPACITOR 300M 125V 1-3/4 X 3-3/8 JUNCTION BOX R CAPACITOR 45M 250V 1-3/4 x 2-3/8 PHLP HD SCR 10-24 X 3/8

REF

19 20 21 22 23 24 25 26 27 28 29 29-1 30 31 32 33 35 101 102 103 104V2 105 106

PART # DESCRIPTION

P1028Z2019 P1028Z2020 P1028Z2021 T20543 P1028Z2023 P1028Z2024 P1028Z2025 P1028Z2026 G5556 OUTLET HOSE CLAMP 5" HOSE 5" LOWER PLASTIC BAG COLLECTOR SUPPORT COLLECTOR SPACER UPPER BAG SUPPORT 2.5 MICRON FILTER BAG P1028Z2028 P1028Z2029 P1028Z2029-1 P1028Z2030 P1028Z2031 PWR1012 PAW05M PLW03M GASKET Y-INLET 6 X 4 X 4" INLET CAP 4" FOAM STRIP 5 X 20MM BELT CLAMP WRENCH 10 X 12MM OPEN-END WRENCH HEX 5MM LOCK WASHER 6MM PLABEL-14 PLABEL-59 PLABEL-12A READ MANUAL LABEL P1028Z2104V2 MACHINE ID LABEL CSA V2.09.11

PLABEL-57 EYE/LUNG LABEL PPAINT-1 ELECTRICITY LABEL HANDS/OUTLET LABEL GRIZZLY GREEN PAINT

G1029Z2 Main Parts List

REF PART # DESCRIPTION REF

1 2 3 4 5 6 7V2 9 10V2 P1028Z2001 PFB01 PK28M P1028Z2004 PS06 P1028Z2006 P1028Z2007V2 P1028Z2009 P1029Z2010V2 CASTER FLANGE BOLT 5/16-18 X 1/2 KEY 7 X 7 X 29 BASE PLATE 19 20 21 22 PHLP HD SCR 10-24 X 3/8 INLET COVER 6" CAP SCREW M6-1 X 30 LH PRE-COATED 23 24 25 IMPELLER WASHER 26 IMPELLER 12-3/4"D X 95MM H X 7/8" ALUM 27 11 12 13V2 14 P1028Z2011 PW07 P1029Z2013V2 PN02 V2.09.11

COLLECTOR BODY FLAT WASHER 5/16 POWER CORD 14G 3C 6' 6-15 V2.09.11

HEX NUT 5/16-18 15 16V2 17V2 PB03 P1030Z2015V2 P1029Z2017V2 HEX BOLT 5/16-18 X 1 PADDLE SWITCH V2.09.11

MOTOR 2HP 220V 1PH V2.09.11

17V2-1 P1028Z2017V2-1 MOTOR FAN COVER 17V2-2 P1028Z2017V2-2 MOTOR FAN 17V2-3 P1028Z2017V2-3 CAPACITOR COVER 17V2-4 PC300G S CAPACITOR 300M 125V 1-3/4 X 3-3/8 17V2-5 P1029Z2017V2-5 JUNCTION BOX 18 PFS03 FLANGE SCREW 10-24 X 3/8 28 29 29-1 30 31 32 33 35 101 102 103 104V2 105 106

PART # DESCRIPTION

P1028Z2019 P1028Z2020 P1028Z2021 T20543 P1028Z2023 P1028Z2024 P1028Z2025 P1028Z2026 G5556 P1028Z2028 P1028Z2029 P1028Z2029-1 P1028Z2030 P1028Z2031 PWR1012 PAW05M PLW03M PLABEL-14 PLABEL-59 OUTLET HOSE CLAMP 5" HOSE 5" LOWER PLASTIC BAG COLLECTOR SUPPORT COLLECTOR SPACER UPPER BAG SUPPORT 2.5 MICRON FILTER BAG GASKET 6" X 4" X 4" Y-INLET INLET CAP 4" FOAM STRIP 5 X 20MM BELT CLAMP WRENCH 10 X 12MM OPEN-END WRENCH HEX 5MM LOCK WASHER 6MM ELECTRICITY LABEL HANDS/OUTLET LABEL PLABEL-12A READ MANUAL LABEL P1029Z2104V2 MACHINE ID LABEL CSA V2.09.11

PLABEL-57 EYE/LUNG LABEL PPAINT-1 GRIZZLY GREEN PAINT -48 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

G1029Z2P Main Breakdown

107 102 26 2 27 23 2 17-2 17-1 17-3 17-4 17-5 21 20 2 3 16 17 25 101 103 104 105 15 12 106 12 14 13 31 30 24 20 23 2 2 19 28 11 22 2 10 9 35 7V2 6 5 18 29 2 1 4 33 32 29-1 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+) -49-

G1029Z2P Main Parts List

REF PART # DESCRIPTION

1 2 3 4 5 6 7V2 9 10 11 12 P1028Z2001 PFB01 PK28M P1028Z2004 PS06 P1029Z2P006 P1028Z2007V2 P1028Z2009 P1029Z2010V2 P1029Z2P011 PW07 CASTER FLANGE BOLT 5/16-18 X 1/2 KEY 7 X 7 X 29 BASE PLATE PHLP HD SCR 10-24 X 3/8 INLET COVER 6" CAP SCREW M6-1 X 30 LH PRE-COATED IMPELLER WASHER IMPELLER 12-3/4" ALUMINUM V2.09.11

COLLECTOR BODY FLAT WASHER 5/16 13 14 15 P1029Z2013V2 PN02 PB03 16 17 P1030Z2015V2 P1029Z2P017 17-1 P1029Z2P017-1 POWER CORD 14G 3C 6' 6-15 V2.09.11

HEX NUT 5/16-18 HEX BOLT 5/16-18 X 1 PADDLE SWITCH V2.09.11

MOTOR 2HP 220V 1PH MOTOR FAN COVER 17-2 P1028Z2017V2-2 MOTOR FAN 17-3 P1029Z2P017-3 CAPACITOR COVER 17-4 PC300G S CAPACITOR 300M 125V 1-3/4 X 3-3/8 17-5 P1029Z2P017-5 18 PFS03 19 P1029Z2P019 JUNCTION BOX FLANGE SCREW 10-24 X 3/8 OUTLET

REF PART #

20 21 22 23 24 25 26 27 28 29 29-1 30 31 32 33 35 101 102 103 104 105 106 107 P1028Z2020 P1028Z2021 T20543 P1028Z2023 P1029Z2P024 P1028Z2025 P1028Z2026 G5556 P1028Z2028 P1028Z2029 P1028Z2029-1 P1028Z2030 P1028Z2031 PWR1012 PAW05M PLW03M PLABEL-14 PLABEL-59 PLABEL-12A P1029Z2P104 PLABEL-57 PPAINT-24 PLABEL-81

DESCRIPTION

HOSE CLAMP 5" HOSE 5" LOWER PLASTIC BAG COLLECTOR SUPPORT COLLECTOR SPACER UPPER BAG SUPPORT 2.5 MICRON FILTER BAG GASKET 6" X 4" X 4" Y-INLET INLET CAP 4" FOAM STRIP 5 X 20MM BELT CLAMP WRENCH 10 X 12MM OPEN-END WRENCH HEX 5MM LOCK WASHER 6MM ELECTRICITY LABEL HANDS/OUTLET LABEL READ MANUAL LABEL MACHINE ID LABEL EYE/LUNG LABEL POLAR BEAR PAINT POLAR BEAR LOGO 1 X 3-3/4

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 Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.

-50 G0548ZP, G1028Z2, G1029Z2-Z2P (Mfg. 12/12+)

WARRANTY CARD

Name _____________________________________________________________________________ Street _____________________________________________________________________________ City _______________________ State _________________________ Zip _____________________ Phone # ____________________ Email _________________________________________________ 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 confidential.

1. How did you learn about us?

____ Advertisement ____ Card Deck ____ Friend ____ Website ____ Catalog ____ Other: 2. Which of the following magazines do you subscribe to?

____ Cabinetmaker & FDM ____ Family Handyman ____ Hand Loader ____ Handy ____ Home Shop Machinist ____ Journal of Light Cont.

____ Live Steam ____ Model Airplane News ____ Old House Journal ____ Popular Mechanics ____ Popular Science ____ Popular Woodworking ____ Precision Shooter ____ Projects in Metal ____ RC Modeler ____ Rifle ____ Shop Notes ____ Shotgun News ____ Today’s Homeowner ____ Wood 3. What is your annual household income?

____ $20,000-$29,000 ____ $50,000-$59,000 ____ $30,000-$39,000 ____ $60,000-$69,000 ____ Wooden Boat ____ Woodshop News ____ Woodsmith ____ Woodwork ____ Woodworker West ____ Woodworker’s Journal ____ Other: ____ $40,000-$49,000 ____ $70,000+ 4. What is your age group?

____ 20-29 ____ 50-59 ____ 30-39 ____ 60-69 ____ 40-49 ____ 70+ 5. How long have you been a woodworker/metalworker?

____ 0-2 Years ____ 2-8 Years ____ 8-20 Years 6. How many of your machines or tools are Grizzly?

____ 0-2 ____ 3-5 ____ 6-9 ____ 20+ Years ____ 10+ 7. Do you think your machine represents a good value? 8. Would you recommend Grizzly Industrial to a friend? _____Yes _____Yes _____No _____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, INC.

P.O. BOX 2069 BELLINGHAM, WA 98227-2069

FOLD ALONG DOTTED LINE Send a Grizzly Catalog to a friend: Name_______________________________ Street_______________________________ City______________State______Zip______ TAPE ALONG EDGES--PLEASE DO NOT STAPLE Place Stamp Here

WARRANTY AND RETURNS 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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