Miller Electric CBI 801D manual Rated Weld Output, Positive Negative

Page 16

4-7. WELD OUTPUT CONNECTIONS (Table 4-1 And Figure 4-2)

RATED WELD OUTPUT

To obtain full rated output from this unit, it is necessary to select, prepare, and install proper weld cables. Failure to comply in any of these areas may result in unsatisfactory welding performance.

A. Weld Cable Selection

Use the following guidelines to select weld cables:

1.Use the shortest possible cables, and place cables close together. Excessive cable lengths may reduce output or cause unit overload due to added resistance.

2.Use weld cable with an insulation voltage rating equal to or greater than the maximum open-cir- cuit voltage (ocv) of the welding generator (see Table 3-1 for unit maximum ocv rating).

3.Select weld cable size according to maximum weld output and total length of connecting cables in weld circuit. For example, if a 25 foot (7.5 m) wire feeder or electrode holder cable is used with a 25 foot (7.5 m) work cable, select the cable size recommended in Table 4-1 for 50 feet (15 m).

4.Do not use damaged or frayed cables.

B.Weld Cable Preparation

1.Install electrode holder to cable following man- ufacturer’s instructions. Always use an insulated electrode holder to ensure operator safety.

2.Install correct size lugs onto ends of both cables for connecting to work clamp, electrode holder or wire feeder, and weld output terminals.

3.Install work clamp onto cable.

C.Weld Output Connections

POSITIVE NEGATIVE

+ −

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

•Stop engine, and disconnect negative (−) bat- tery cable before making any weld output connections.

MOVING PARTS can cause serious injury.

•Keep away from moving parts such as fans, belts, and rotors.

1.Open and secure the lower front panel access door, and route weld cables through bracket on front upright to the weld output terminals (see Figure 4-2).

Table 4-1. Weld Cable Size*

 

 

Total Cable (Copper) Length In Weld Circuit Not Exceeding

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100 ft (30 m) Or Less

150 ft

200 ft

 

250 ft

300 ft

 

350 ft

400 ft

 

(45 m)

(60 m)

 

(70 m)

(90 m)

 

(105 m)

(120 m)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Welding

10 To 60%

60 Thru 100%

 

 

10 Thru 100% Duty Cycle

 

 

Amperes

Duty Cycle

Duty Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

4

4

4

3

 

2

1

 

1/0

1/0

150

3

3

2

1

 

1/0

2/0

 

3/0

3/0

200

3

2

1

1/0

 

2/0

3/0

 

4/0

4/0

250

2

1

1/0

2/0

 

3/0

4/0

 

2-2/0

2-2/0

300

1

1/0

2/0

3/0

 

4/0

2-2/0

 

2-3/0

2-3/0

350

1/0

2/0

3/0

4/0

 

2-2/0

2-3/0

 

2-3/0

2-4/0

400

1/0

2/0

3/0

4/0

 

2-2/0

2-3/0

 

2-4/0

2-4/0

500

2/0

3/0

4/0

2-2/0

 

2-3/0

2-4/0

 

3-3/0

3-3/0

600

3/0

4/0

2-2/0

2-3/0

 

2-4/0

3-3/0

 

3-4/0

3-4/0

700

4/0

2-2/0

2-3/0

2-4/0

 

3-3/0

3-4/0

 

3-4/0

4-4/0

800

4/0

2-2/0

2-3/0

2-4/0

 

3-4/0

3-4/0

 

4-4/0

4-4/0

900

2-2/0

2-3/0

2-4/0

3-3/0

 

3-4/0

4-4/0

 

4-4/0

 

 

 

 

 

 

 

 

 

 

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

S-0007-D

 

 

 

 

 

 

 

 

 

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Contents OM-166 941C ProcessesDescription Per NsprWarranty Page Table of Contents − Maintenance − Troubleshooting− Electrical Diagrams − Parts List− Safety Rules for Operation of ARC Welding Power Source General PrecautionsIntroduction Burn PreventionFire and Explosion Prevention Compressed Gas EquipmentLeaving Equipment Unattended User ResponsibilitiesRope Staging-Support Burn Protection ARC WeldingShock Prevention Standards Booklet Index − Safety Precautions and Signal Words General Information and SafetySafety Safety Alert Symbol and Signal Words− Specifications OCVDuty Cycle − Installation or RelocationDescription Exhaust Extension Installation Connecting the BatteryLifting Of Equipment 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 Wire remote control cord directly to terminal strip Tion CWithin unit according to Section B Remote Terminal Strip 3T InformationAIR Compressor Connections Ether Starting AID OptionalPosure to Ether can seriously harm Your health− Auxiliary Power Power Output Electric Sparks can cause fireLOW Voltage and Frequency can dam- age electrical equipment GeneralAmperage & Voltage Adjustment Amperage and Voltage Adjustment− Operator Controls Panel Remote RUNRemote Output Contactor Battery Magnetic Shutdown SwitchBroken Cooling Belt Shutdown Switch Fuel− Sequence of Operation ARC Rays can burn eyes and skin Noise can damage hearingFumes and Gases can seriously harm your health Shielded Metal ARC Welding SmawAuxiliary Power Operation AIR Carbon ARC Cutting and Gouging CAC-A TableAIR Compressor Operation Tables 7-2 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 ServiceBattery Replacement Procedure FUEL/WATER Separator and Sludge Drain PlugFuel/Water Separator 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 Overload Protection Figure Moving Parts can cause serious personal injuryIncorrect Fuse can damage unit Circuit Breaker CB1 FigureWeld/Power Troubleshooting Troubleshooting Tables 9-1 ThruTrouble Probable Cause Remedy Auxiliary Power Troubleshooting Auxiliary Power Probable Cause Remedy TroubleEngine Troubleshooting 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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