Miller Electric CBI 801D manual Diagram 8-1. Load Bank Connections

Page 35

Welding

Generator

Load Bank

Positive (+)

 

 

Negative (−)

 

 

 

Weld Output

+

−

Weld Output

−

+

Voltmeter

Terminal

 

 

Terminal

 

 

 

 

 

 

And

 

 

 

 

 

 

Ammeter

 

 

 

 

 

 

Weld

 

 

 

 

 

 

Cables

S-0456

Diagram 8-1. Load Bank Connections

10.Stop engine, and disconnect load bank cables.

11.Allow exhaust system to cool.

12.Inspect inside of exhaust pipe. If pipe is dry, the run-in procedure is complete. If pipe is coated with a wet, black, tar-like substance, repeat run- in procedure.

B.Run-In Procedure Using Resistance Grid (Dia- gram 8-2)

WARNING: Read and follow safety infor- mation at beginning of entire Section 8-12 before proceeding.

1.Stop engine.

2.Obtain resistance grid adequately sized for rated output of welding generator.

3.Obtain two weld cables of proper size to connect resistance grid to generator (see Section 4-7).

4.If a voltmeter and ammeter are not provided on the welding generator, obtain a voltmeter and clamp-on dc ammeter.

5.Place welding generator AMPERAGE & VOLT- AGE ADJUSTMENT control in the minimum po- sition.

6.Adjust grid switches and generator controls to provide a load approximately equal to rated gen- erator output.

For example, if rated generator output is 350 am- peres, 40 volts at 100% duty cycle, adjust switches until values indicated by meters equals rated generator output.

7.Connect one weld cable to grid input receptacle and remaining weld cable to grid output recep- tacle (see Diagram 8-2).

8.If a voltmeter and ammeter are provided on the welding generator, proceed to Step 9. If meters

are not provided, connect voltmeter and clamp- on dc ammeter as shown in Diagram 8-2.

9.Connect remaining ends of weld cables to gener- ator weld output terminals (polarity is not impor- tant).

10.Start engine as instructed in Section 7-6, and al- low engine to warm up for approximately three minutes.

CAUTION: ARCING can damage switch contacts.

•Do not change the position of the grid switches while engine is running.

Arcing causes the contacts to become pitted and eventually inoperative.

11.Check meters. Adjust load with generator con- trols or, if necessary, by changing positions of grid switches until values indicated by meters equal rated generator output.

12.Allow engine to run under load for at least one hour. Check engine and meters after the first five minutes and every 15 minutes thereafter to be sure equipment is operating properly

13.After running engine under load for at least one hour, remove load by shutting down resistance grid.

14.Allow engine to idle for approximately three min- utes to permit internal engine temperatures to equalize.

15.Stop engine, and disconnect weld cables.

16.Allow exhaust system to cool.

17.Inspect inside of exhaust pipe. If pipe is dry, the run-in procedure is complete. If pipe is coated with a wet, black, tar-like substance, repeat run- in procedure.

OM-166 941 Page 30

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Contents Per Nspr OM-166 941CProcesses DescriptionWarranty Page Table of Contents − Parts List − Maintenance− Troubleshooting − Electrical DiagramsBurn Prevention − Safety Rules for Operation of ARC Welding Power SourceGeneral Precautions IntroductionCompressed Gas Equipment Fire and Explosion PreventionRope Staging-Support User ResponsibilitiesLeaving Equipment Unattended Shock Prevention ARC WeldingBurn Protection Standards Booklet Index Safety Alert Symbol and Signal Words − Safety Precautions and Signal WordsGeneral Information and Safety SafetyOCV − SpecificationsDescription − Installation or RelocationDuty Cycle Trailer Mounting Exhaust Extension InstallationConnecting the Battery Lifting Of EquipmentEquipment Grounding Terminal GroundPositive Negative Rated Weld OutputRemote 9 Receptacle Information And Connections Figures 4-2 Remote Control ConnectionsRemote Feeder AMPERAGE/VOLTAGE Output Contactor Remote Terminal Strip 3T Information Wire remote control cord directly to terminal stripTion C Within unit according to Section BYour health AIR Compressor ConnectionsEther Starting AID Optional Posure to Ether can seriously harmGeneral − Auxiliary Power Power OutputElectric Sparks can cause fire LOW Voltage and Frequency can dam- age electrical equipment− Operator Controls Amperage and Voltage AdjustmentAmperage & Voltage Adjustment Remote Output Contactor RUNPanel Remote Fuel BatteryMagnetic Shutdown Switch Broken Cooling Belt Shutdown SwitchShielded Metal ARC Welding Smaw − Sequence of OperationARC Rays can burn eyes and skin Noise can damage hearing Fumes and Gases can seriously harm your healthStarting the Engine Auxiliary Power OperationAIR Carbon ARC Cutting and Gouging CAC-A Table AIR Compressor Operation Tables 7-2Flow Of Free Air CFM Through Orifices Of Various Diameters Stopping the EngineMiscellaneous − Maintenance Deutz F4L912 Diesel Engine Air Cleaner Service AIR Cleaner Service TableSludge Drain Plug Battery Replacement ProcedureFUEL/WATER Separator and Sludge Drain Plug Fuel/Water SeparatorGovernor MAINTENANCE-FREE Battery CHARG- INGEngine Speed Adjustments Figure Brushes and Slip Rings Figure Brush Replacement Ether Starting AID OptionalMoving Parts can cause severe injury RUN-IN ProcedureRun-In Procedure Using Load Bank Diagram Run-In Procedure Using Resistance Grid Dia- gram Diagram 8-1. Load Bank ConnectionsBooster Battery Jump Starting − TroubleshootingDiagram 8-2. Resistance Grid Connections Circuit Breaker CB1 Figure Overload Protection FigureMoving Parts can cause serious personal injury Incorrect Fuse can damage unitTrouble Probable Cause Remedy Troubleshooting Tables 9-1 ThruWeld/Power Troubleshooting Air Compressor Troubleshooting Auxiliary Power TroubleshootingAuxiliary Power Probable Cause Remedy Trouble Engine TroubleshootingOM-166 941 Diagram 10-1. Circuit Diagram For Welding Generator − Electrical DiagramsSC-168 908-B 66 Fig − Parts List11-2 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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