Miller Electric CBI 801D manual Installation or Relocation, Duty Cycle, Description

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3-1. DUTY CYCLE

The duty cycle of a welding generator is the percentage of a ten minute period that a welding generator can be operated at a given output without causing overheating and damage to the unit. This welding generator is rated at 100 percent duty cycle when operated at 800 am- peres. This means that the welding generator can be op- erated at 800 amperes continuously without causing damage to the unit.

3-2. VOLT-AMPERE CURVES (Chart 3-1)

The volt-ampere curves show the voltage and amper- age output capabilities of the welding generator at mini- mum and maximum of each coarse range. Curves of other settings fall between the curves shown.

Chart 3-1. Volt-Ampere Curves

and Air Carbon Arc Cutting And Gouging (CAC-A) pro- cesses.

The unit is equipped with a four-cylinder, air-cooled, Deutz diesel engine (F4L-912). The air compressor in this unit is mounted on the front of the engine, and it op- erates whenever the engine is running. The compressor delivers 12 cfm of air at a pressure of 100 psi (see Chart 3-2).

In addition to welding and air compressor operation, this unit can provide up to 3 kVA/kW of 120 volts (26 am- peres) ac electrical power for operating 50/60 Hz or 60 Hz auxiliary equipment while welding.

This unit is specially prepared for operation in harsh and corrosive environments.

An optional Ether Starting Aid can be provided on the welding generator and is covered within this Owner’s Manual.

Chart 3-2. Air Output Curve

SB-168 387

3-3. DESCRIPTION

This unit is a constant current (CC) dc arc welding gen- erator designed for use with the Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW),

SB-143 883

SECTION 4 − INSTALLATION OR RELOCATION

IMPORTANT: Unless otherwise specified, all direc- tions, such as left or right, are with respect to the opera- tor facing the welding generator front panel.

4-1. LOCATION (Figure 3-1)

A proper installation site should be selected for the weld- ing generator if the unit is to provide dependable service and remain relatively maintenance free.

WARNING: ENGINE EXHAUST GASES can kill.

•Operate in open, well-ventilated areas or if operated indoors, vent engine exhaust out- side the building.

•Keep engine exhaust vent outlet away from building air intakes.

CAUTION: RESTRICTED AIRFLOW causes overheating and possible damage to inter- nal parts.

•Maintain at least 18 inches (457 mm) of unre- stricted space on all sides of unit, and keep underside free of obstructions.

•Do not place any filtering device over the intake air passages of this welding generator.

Warranty is void if any type of filtering device is used.

The service life and operating efficiency of this unit are reduced when the unit is subjected to extreme levels of dust, dirt, moisture, corrosive vapors, and extreme heat.

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Contents Processes OM-166 941CDescription Per NsprWarranty Page Table of Contents − Troubleshooting − Maintenance− Electrical Diagrams − Parts ListGeneral Precautions − Safety Rules for Operation of ARC Welding Power SourceIntroduction Burn PreventionCompressed Gas Equipment Fire and Explosion PreventionLeaving Equipment Unattended User ResponsibilitiesRope Staging-Support Burn Protection ARC WeldingShock Prevention Standards Booklet Index General Information and Safety − Safety Precautions and Signal WordsSafety Safety Alert Symbol and Signal WordsOCV − SpecificationsDuty Cycle − Installation or RelocationDescription Connecting the Battery Exhaust Extension InstallationLifting Of Equipment Trailer MountingEquipment Grounding Terminal GroundPositive Negative Rated Weld OutputRemote Feeder AMPERAGE/VOLTAGE Output Contactor Remote Control ConnectionsRemote 9 Receptacle Information And Connections Figures 4-2 Tion C Wire remote control cord directly to terminal stripWithin unit according to Section B Remote Terminal Strip 3T InformationEther Starting AID Optional AIR Compressor ConnectionsPosure to Ether can seriously harm Your healthElectric Sparks can cause fire − Auxiliary Power Power OutputLOW Voltage and Frequency can dam- age electrical equipment GeneralAmperage & Voltage Adjustment Amperage and Voltage Adjustment− Operator Controls Panel Remote RUNRemote Output Contactor Magnetic Shutdown Switch BatteryBroken Cooling Belt Shutdown Switch FuelARC Rays can burn eyes and skin Noise can damage hearing − Sequence of OperationFumes and Gases can seriously harm your health Shielded Metal ARC Welding SmawAIR Carbon ARC Cutting and Gouging CAC-A Table Auxiliary Power OperationAIR Compressor Operation Tables 7-2 Starting the EngineFlow Of Free Air CFM Through Orifices Of Various Diameters Stopping the EngineMiscellaneous − Maintenance Deutz F4L912 Diesel Engine Air Cleaner Service AIR Cleaner Service TableFUEL/WATER Separator and Sludge Drain Plug Battery Replacement ProcedureFuel/Water Separator Sludge Drain PlugEngine Speed Adjustments Figure MAINTENANCE-FREE Battery CHARG- INGGovernor Brushes and Slip Rings Figure Brush Replacement Ether Starting AID OptionalRun-In Procedure Using Load Bank Diagram RUN-IN ProcedureMoving Parts can cause severe injury Run-In Procedure Using Resistance Grid Dia- gram Diagram 8-1. Load Bank ConnectionsDiagram 8-2. Resistance Grid Connections − TroubleshootingBooster Battery Jump Starting Moving Parts can cause serious personal injury Overload Protection FigureIncorrect Fuse can damage unit Circuit Breaker CB1 FigureWeld/Power Troubleshooting Troubleshooting Tables 9-1 ThruTrouble Probable Cause Remedy Auxiliary Power Probable Cause Remedy Trouble Auxiliary Power TroubleshootingEngine Troubleshooting Air Compressor TroubleshootingOM-166 941 Diagram 10-1. Circuit Diagram For Welding Generator − Electrical DiagramsSC-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 6563 62 21 22 15 14 8111532480009309 Panel, Front w/Components 18 17 16 Includes ItemPanel, 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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