Miller Electric CBI 801D manual Run, Panel Remote, Remote Output Contactor

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A. START Position

Rotating the switch to the START position starts the en- gine. Release the switch as soon as the engine starts, and the switch automatically returns to the RUN posi- tion.

B. RUN Position

RUN

When the Engine Control switch is in the RUN position, engine speed remains at governed weld/power speed (1860 rpm).

C. OFF Position

Rotating the Engine Control switch to the OFF position disconnects battery voltage, thereby shutting down the engine.

6-4. REMOTE AMPERAGE & VOLTAGE CON- TROL SWITCH (Figure 6-1)

PANEL

REMOTE

A/V

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

•Do not touch the output terminals when the contactor is energized

•Do not touch welding wire or electrode and work clamp at same time.

If remote amperage or voltage control is desired, make connections to the REMOTE 9 receptacle terminal strip according to Section 4-8, and place the AMPERAGE & VOLTAGE switch in the REMOTE position. When a Re- mote Amperage or Voltage Control is being used, the re- mote control functions as a fine amperage or voltage ad- justment for the AMPERAGE & VOLTAGE ADJUST- MENT control on the welding generator. For example, if the AMPERAGE & VOLTAGE ADJUSTMENT control on the welding generator is set at midrange, the Remote Amperage or Voltage Control will provide (from mini- mum to maximum adjustment) fine amperage or voltage adjustment of one half of the welding generator output for the range selected. For complete remote control of the output, rotate the AMPERAGE & VOLTAGE AD- JUSTMENT control to the maximum position.

If remote amperage or voltage is not desired, place the AMPERAGE & VOLTAGE switch in the PANEL posi- tion. Only the AMPERAGE & VOLTAGE ADJUST- MENT control will adjust output.

6-5. OUTPUT(CONTACTOR) SWITCH (Figure

6-1)

ON

REMOTE

OUTPUT

(CONTACTOR)

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

•Do not touch the output terminals when the contactor is energized.

•Do not touch welding wire or electrode and work clamp at same time.

When the OUTPUT/CONTACTOR switch is in the ON position, open-circuit voltage is present at the weld output terminals for as long as the engine is running.

If the OUTPUT(CONTACTOR) switch is in the ON posi- tion, open-circuit voltage will be present at the output terminals whenever the engine is running.

If remote contactor control by means of a wire feeder or remote device is desired, make connections to the RE- MOTE 9 receptacle or terminal strip 3T according to Section 4-8, and place the OUTPUT(CONTACTOR) switch in the REMOTE position. Open-circuit voltage is present at the weld output terminals whenever the gun switch or remote device is closed.

6-6. SERVICE ENGINE AIR CLEANER LIGHT (Figure 6-1)

This unit is equipped with an engine air cleaner. When the SERVICE ENGINE AIR CLEANER light PL1 comes on, the air cleaner requires servicing (see Section 8-2).

6-7. CHECK ALTERNATOR (Figure 6-1)

The CHECK ALTERNATOR light PL3 comes on if the al- ternator requires servicing. If the light comes on, check for loose or broken engine belt.

6-8. HOUR METER (Figure 6-1)

This unit is equipped with an hour meter. The meter, la- beled ENGINE HOURS, registers the total hours of en- gine operation. This information is useful for routine maintenance on the engine.

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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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