Miller Electric CBI 801D manual Standards Booklet Index

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quate to carry ground currents safely. Equipment made electrically HOT by stray current may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or flammable liquid such as oil or fuel.

Three-phase connection. Check phase requirements of equipment before installing. If only 3-phase power is available, connect single-phase equipment to only two wires of the 3-phase line. Do NOT connect the equip- ment ground lead to the third (live) wire, or the equip- ment will become electrically HOT-a dangerous condi- tion that can shock, possibly fatally.

Before welding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections.

If a line cord with a ground lead is provided with the equipment for connection to a switchbox, connect the ground lead to the grounded switchbox. If a three-prong plug is added for connection to a grounded mating re- ceptacle, the ground lead must be connected to the ground prong only. If the line cord comes with a three- prong plug, connect to a grounded mating receptacle. Never remove the ground prong from a plug, or use a plug with a broken off ground prong.

2.Electrode Holders

Fully insulated electrode holders should be used. Do NOT use holders with protruding screws.

3.Connectors

Fully insulated lock-type connectors should be used to join welding cable lengths.

4.Cables

Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly-lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable.

Keep cable dry, free of oil and grease, and protected from hot metal and sparks.

5.Terminals And Other Exposed Parts

Terminals and other exposed parts of electrical units should have insulating covers secured before opera- tion.

6.Electrode

a.Equipment with output on/off control (contac- tor)

Welding power sources for use with the gas metal arc welding (GMAW), gas tungsten arc welding (GTAW) and similar processes nor- mally are equipped with devices that permit on- off control of the welding power output. When so equipped the electrode wire becomes elec- trically HOT when the power source switch is ON and the welding gun switch is closed. Never touch the electrode wire or any conducting ob-

ject in contact with the electrode circuit unless the welding power source is off.

b. Equipment without output on/off control (no contactor)

Welding power sources used with shielded metal arc welding (SMAW) and similar proc- esses may not be equipped with welding power output on-off control devices. With such equip- ment the electrode is electrically HOT when the power switch is turned ON. Never touch the electrode unless the welding power source is off.

7.Safety Devices

Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out.

Before installation, inspection, or service, of equipment, shut OFF all power and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Disconnect all cables from welding power source, and pull all 115 volts line-cord plugs.

Do not open power circuit or change polarity while weld- ing. If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing.

Leaving equipment unattended. Always shut OFF and disconnect all power to equipment.

Power disconnect switch must be available near the welding power source.

F.Protection For Wearers of Electronic Life Sup- port Devices (Pacemakers)

Magnetic fields from high currents can affect pacemak- er operation. Persons wearing electronic life support equipment (pacemaker) should consult with their doctor before going near arc welding, gouging, or spot welding operations.

1-4. STANDARDS BOOKLET INDEX

For more information, refer to the following standards or their latest revisions and comply as applicable:

1.ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126.

2.NIOSH, SAFETY AND HEALTH IN ARC WELD- ING AND GAS WELDING AND CUTTING ob- tainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

3.OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superinten- dent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

4.ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from the Ameri- can National Standards Institute, 1430 Broad- way, New York, NY 10018.

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Contents Description OM-166 941CProcesses Per NsprWarranty Page Table of Contents − Electrical Diagrams − Maintenance− Troubleshooting − Parts ListIntroduction − Safety Rules for Operation of ARC Welding Power SourceGeneral Precautions Burn PreventionFire and Explosion Prevention Compressed Gas EquipmentLeaving Equipment Unattended User ResponsibilitiesRope Staging-Support Burn Protection ARC WeldingShock Prevention Standards Booklet Index Safety − Safety Precautions and Signal WordsGeneral Information and Safety Safety Alert Symbol and Signal Words− Specifications OCVDuty Cycle − Installation or RelocationDescription Lifting Of Equipment Exhaust Extension InstallationConnecting the Battery Trailer MountingGround Equipment Grounding TerminalRated Weld Output Positive NegativeRemote Feeder AMPERAGE/VOLTAGE Output Contactor Remote Control ConnectionsRemote 9 Receptacle Information And Connections Figures 4-2 Within unit according to Section B Wire remote control cord directly to terminal stripTion C Remote Terminal Strip 3T InformationPosure to Ether can seriously harm AIR Compressor ConnectionsEther Starting AID Optional Your healthLOW Voltage and Frequency can dam- age electrical equipment − Auxiliary Power Power OutputElectric Sparks can cause fire GeneralAmperage & Voltage Adjustment Amperage and Voltage Adjustment− Operator Controls Panel Remote RUNRemote Output Contactor Broken Cooling Belt Shutdown Switch BatteryMagnetic Shutdown Switch FuelFumes and Gases can seriously harm your health − Sequence of OperationARC Rays can burn eyes and skin Noise can damage hearing Shielded Metal ARC Welding SmawAIR Compressor Operation Tables 7-2 Auxiliary Power OperationAIR Carbon ARC Cutting and Gouging CAC-A Table Starting the EngineStopping the Engine Flow Of Free Air CFM Through Orifices Of Various DiametersMiscellaneous − Maintenance Deutz F4L912 Diesel Engine AIR Cleaner Service Table Air Cleaner ServiceFuel/Water Separator Battery Replacement ProcedureFUEL/WATER Separator and Sludge Drain Plug Sludge Drain PlugEngine Speed Adjustments Figure MAINTENANCE-FREE Battery CHARG- INGGovernor Brush Replacement Ether Starting AID Optional Brushes and Slip Rings FigureRun-In Procedure Using Load Bank Diagram RUN-IN ProcedureMoving Parts can cause severe injury Diagram 8-1. Load Bank Connections Run-In Procedure Using Resistance Grid Dia- gramDiagram 8-2. Resistance Grid Connections − TroubleshootingBooster Battery Jump Starting Incorrect Fuse can damage unit Overload Protection FigureMoving Parts can cause serious personal injury Circuit Breaker CB1 FigureWeld/Power Troubleshooting Troubleshooting Tables 9-1 ThruTrouble Probable Cause Remedy Engine Troubleshooting Auxiliary Power TroubleshootingAuxiliary Power Probable Cause Remedy Trouble Air Compressor TroubleshootingOM-166 941 − Electrical Diagrams Diagram 10-1. Circuit Diagram For Welding GeneratorSC-168 908-B 11-2 − Parts List66 Fig 1A. Main Assembly 073 FITTING, brs barbed M 3/16tbg x 1/4NPT 0456660009309 1B. Main Assembly 811 6563 62 21 22 15 141532480009309 18 17 16 Includes Item Panel, Front w/ComponentsPanel, Front w/Components -1A Item Panel, Lower Front w/Components Panel, Lower Front w/Components 1A Item Control Box -1A Item Generator -1B Item

CBI 801D specifications

The Miller Electric CBI 801D is a robust and sophisticated multi-process welder, designed for maximum efficiency and versatility in various welding applications. This machine stands out due to its combination of advanced technology and user-friendly design, making it suitable for both seasoned professionals and those new to welding.

One of the key features of the CBI 801D is its ability to perform multiple welding processes, including MIG, TIG, and stick welding. This multi-functionality allows users to tackle a wide range of welding tasks, whether they are working on thin sheet metals or heavy fabrication. The seamless transition between processes is designed to enhance productivity and reduce downtime.

The CBI 801D is powered by Miller's innovative Auto-Set technology, which automatically adjusts the machine settings based on the material type and thickness. This feature simplifies the setup process, allowing welders to focus more on their work rather than on configuring the machine. Additionally, the user interface is designed for simplicity, featuring intuitive controls that are easy to navigate.

In terms of performance, the CBI 801D delivers impressive output, with a maximum welding output of 800 amps. This substantial power provides the capability to weld thicker materials with greater efficiency, making it an ideal choice for industrial applications. The built-in advanced cooling system ensures optimal performance during extended use, preventing overheating and maintaining consistent weld quality.

Durability is another hallmark of the Miller Electric CBI 801D. The machine is constructed with high-quality materials, providing resilience against tough working conditions. Its compact and portable design allows for easy transport to various job sites, while the built-in handles are designed for convenience.

Moreover, the CBI 801D features advanced digital readouts for real-time monitoring of welding parameters. This not only enhances precision but also allows welders to make necessary adjustments on the fly. The machine is also compatible with various accessories, which further expand its functionality and adaptability across different welding scenarios.

In summary, the Miller Electric CBI 801D is a powerful and versatile welding machine, offering multi-process capabilities, user-friendly features, and a robust design. Its combination of advanced technology and reliable performance makes it a top choice for professionals looking for efficiency and precision in their welding tasks. Whether for fabrication, repair, or maintenance, the CBI 801D proves to be an invaluable asset in any welding operation.
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