Miller Electric CBI 801D manual ARC Welding, Burn Protection, Shock Prevention

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1-3. ARC WELDING

Comply with precautions in 1-1, 1-2, and this section. Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and in- frared energy radiates, weldments are hot, and com- pressed gases may be used. The wise operator avoids unnecessary risks and protects himself and others from accidents. Precautions are described here and in stan- dards referenced in index.

A. Burn Protection

Comply with precautions in 1-2.

The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas- shielded arcs are more severe and painful. DON’T GET BURNED; COMPLY WITH PRECAUTIONS.

1.Protective Clothing

Wear long-sleeve clothing (particularly for gas-shielded arc) in addition to gloves, hat, and shoes (1-2A). As nec- essary, use additional protective clothing such as leather jacket or sleeves, flame-proof apron, and fire-re- sistant leggings. Avoid outer garments of untreated cot- ton.

Bare skin protection. Wear dark, substantial clothing. Button collar to protect chest and neck and button pock- ets to prevent entry of sparks.

2.Eye and Head Protection

Protect eyes from exposure to arc. NEVER look at an electric arc without protection.

Welding helmet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc.

Protect filter plate with a clear cover plate.

Cracked or broken helmet or shield should NOT be worn; radiation can pass through to cause burns.

Cracked, broken, or loose filter plates must be replaced IMMEDIATELY. Replace clear cover plate when broken, pitted, or spattered.

Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision.

3.Protection of Nearby Personnel

Enclosed welding area. For production welding, a sepa- rate room or enclosed bay is best. In open areas, sur- round the operation with low-reflective, non-combusti- ble screens or panels. Allow for free air circulation, par- ticularly at floor level.

Viewing the weld. Provide face shields for all persons who will be looking directly at the weld.

Others working in area. See that all persons are wearing flash goggles.

Before starting to weld, make sure that screen flaps or bay doors are closed.

B. Toxic Fume Prevention

Comply with precautions in 1-2B.

Generator engine exhaust must be vented to the out- side air. Carbon monoxide can kill.

C. Fire and Explosion Prevention

Comply with precautions in 1-2C.

Equipment’s rated capacity. Do not overload arc weld- ing equipment. It may overheat cables and cause a fire.

Loose cable connections may overheat or flash and cause a fire.

Never strike an arc on a cylinder or other pressure ves- sel. It creates a brittle area that can cause a violent rup- ture or lead to such a rupture under rough handling.

D. Compressed Gas Equipment

Comply with precautions in 1-2D.

E. Shock Prevention

Exposed hot conductors or other bare metal in the weld- ing circuit, or in ungrounded, electrically-HOT equip- ment can fatally shock a person whose body becomes a conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding, without suitable protection.

To protect against shock:

Wear dry insulating gloves and body protection. Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when dampness or sweat can not be avoided. Sweat, sea water, or moisture be- tween body and an electrically HOT part or grounded metal reduces the electrical resistance, and could en- able dangerous and possibly lethal currents to flow through the body.

A voltage will exist between the electrode and any con- ducting object in the work circuit. Examples of conduct- ing objects include, but are not limited to, buildings, elec- trical tools, work benches, welding power source cases, workpieces, etc. Never touch the electrode and any metal object unless the welding power source is off.

1.Grounding the Equipment

Arc welding equipment must be grounded according to the National Electrical Code, and the work must be grounded according to ANSI Z49.1 “Safety In Welding And Cutting.”

When installing, connect the frames of each unit such as welding power source, control, work table, and water cir- culator to the building ground. Conductors must be ade-

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