Miller Electric CBI 801D manual Troubleshooting, Diagram 8-2. Resistance Grid Connections

Page 36

Welding

Generator

Voltmeter And

Ammeter (If so equipped)

Weld Output

Terminals

(Polarity Not

Important)

Weld

Cables

Resistance Grid

Input And Output

Receptacles

♦ Clamp-On

V

♦Voltmeter

♦Required if welding generator is not equipped with meters.

A

DC Ammeter

S-0457

Diagram 8-2. Resistance Grid Connections

SECTION 9 − TROUBLESHOOTING

9-1. GENERAL

It is assumed that proper installation has been made, according to Section 4 of this manual, the operator is fa- miliar with the function of controls, the welding generator was functioning properly, and the trouble is not related to the welding process.

9-2. BOOSTER BATTERY JUMP STARTING

If it is necessary to jump start this unit, use the following safety precautions and the step-by-step procedures in order of appearance.

WARNING: BATTERY GASES OR A DAM- AGED BATTERY can explode thereby shat- tering the battery; BATTERY ACID can burn eyes, skin, destroy clothing, and damage other material; MOVING PARTS AND IM- PROPER CONNECTIONS can cause serious personal injury and damage equipment.

•Keep sparks, flames, cigarettes, and other ig- nition sources away from battery.

•Ensure that all personnel are a safe distance from batteries and clear of moving parts while starting.

•Do not jump start a frozen or completely dis- charged battery.

•Do not jump start a battery which has loose terminals or one having evidence of damage such as a cracked case or cover.

•Be sure that vent caps are tight and level on both batteries and cover both batteries with a damp cloth.

•Wear correct eye and body protection, and remove all metal jewelry.

•Keep jumper cables clear of moving parts.

•Ensure that both batteries are of the same voltage.

•Do not jump start a trailer mounted welding generator with the towing vehicle battery un- less the trailer is completely disconnected from the towing vehicle.

•Do not jump start a vehicle mounted welding generator from the vehicle battery.

•If booster battery is installed in vehicle, do not allow vehicle to make contact with welding generator case or frame.

•Do not jump start by applying power to weld output receptacles or terminals.

•Do not allow jumper cables to contact any other metal while attaching or removing ca- bles.

1.Use properly insulated jumper cables of ade- quate size.

2.Connect ends of one cable to positive (+) termi- nals of each battery.

3.Connect one end of other cable to negative (−) terminal of booster battery.

4.Connect remaining end of cable to welding gen- erator engine block at least 18 inches (457 mm) from battery (do not connect to welding generator case, frame, or equipment grounding terminal as damage to equipment can result).

5.Wait at least one minute after connecting cables before starting engine.

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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 EquipmentUser Responsibilities Leaving Equipment UnattendedRope Staging-Support ARC Welding Burn ProtectionShock Prevention Standards Booklet Index − Safety Precautions and Signal Words General Information and SafetySafety Safety Alert Symbol and Signal Words− Specifications OCV− Installation or Relocation Duty CycleDescription Exhaust Extension Installation Connecting the BatteryLifting Of Equipment Trailer MountingGround Equipment Grounding TerminalRated Weld Output Positive NegativeRemote Control Connections Remote Feeder AMPERAGE/VOLTAGE Output ContactorRemote 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 and Voltage Adjustment Amperage & Voltage Adjustment− Operator Controls RUN Panel RemoteRemote 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 Plug MAINTENANCE-FREE Battery CHARG- ING Engine Speed Adjustments Figure Governor Brush Replacement Ether Starting AID Optional Brushes and Slip Rings FigureRUN-IN Procedure Run-In Procedure Using Load Bank DiagramMoving Parts can cause severe injury Diagram 8-1. Load Bank Connections Run-In Procedure Using Resistance Grid Dia- gram− Troubleshooting Diagram 8-2. Resistance Grid ConnectionsBooster Battery Jump Starting Overload Protection Figure Moving Parts can cause serious personal injuryIncorrect Fuse can damage unit Circuit Breaker CB1 FigureTroubleshooting Tables 9-1 Thru Weld/Power TroubleshootingTrouble 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 − Parts List 11-266 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
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