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Miller Electric CBI 801D Owner's Manual

Engine driven welding generator
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CBI 801D
(Per NSPR 10202)
OM-166 941C
July 1999
Processes
Stick (SMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator

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Summary of Contents for Miller Electric CBI 801D

  • Page 1 CBI 801D (Per NSPR 10202) OM-166 941C July 1999 Processes Stick (SMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator...
  • Page 2 Warranty Effective January 1, 1999 (Equipment with a serial number preface of “KK” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, warrants to its original retail purchaser that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is...

  • Page 4: Table Of Contents

    Section No. SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. Introduction ..........1-2.
  • Page 5 SECTION 7 − SEQUENCE OF OPERATION 7-1. Shielded Metal Arc Welding (SMAW) 7-2. Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW) 7-3. Air Carbon Arc Cutting And Gouging (CAC-A) 7-4. Auxiliary Power Operation 7-5. Air Compressor Operation 7-6. Starting The Engine 7-7.

  • Page 6: Section 1 − Safety Rules For Operation Of Arc Welding Power Source

    SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. INTRODUCTION We learn by experience. Learning safety through per- sonal experience, like a child touching a hot stove is harmful, wasteful, and unwise. Let the experience of others teach you.
  • Page 7 atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene. C. Fire and Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag or heated mate- rial;...
  • Page 8 Locate or secure cylinders so they cannot be knocked over. Passageways and work areas. Keep cylinders clear of areas where they may be struck. Transporting cylinders. With a crane, use a secure sup- port such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets.

  • Page 9: Arc Welding

    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.

  • Page 10: Standards Booklet Index

    quate to carry ground currents safely. Equipment made electrically HOT by stray current may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or flammable liquid such as oil or fuel. Three-phase connection. Check phase requirements of equipment before installing.

  • Page 11: Section 2 − Safety Precautions And Signal Words

    ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROC- ESSES obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018.

  • Page 12: Section 3 − Specifications

    Table 3-1. Welding Generator Specifications Maximum Rated Output Open-Circuit Welding At 100% Voltage Range Duty Cycle 95 Volts DC 800 Amperes 100 to 800 At 36 Volts DC Amps DC 80 Volts DC Nominal Conforms with NEMA EW1 (ANSI C87.1), “ELECTRIC ARC WELDING POWER SOURCES,” Class I (100). 47 in.

  • Page 13: Duty Cycle

    3-1. DUTY CYCLE The duty cycle of a welding generator is the percentage of a ten minute period that a welding generator can be operated at a given output without causing overheating and damage to the unit. This welding generator is rated at 100 percent duty cycle when operated at 800 am- peres.

  • Page 14: Exhaust Extension Installation

    A. Lifting Of Equipment WARNING: INCORRECT LIFTING will dam- age internal parts; FALLING EQUIPMENT can cause serious personal injury and equipment damage. Use lifting eye to lift unit only, NOT gas cylin- ders, trailer, or any other heavy options, ac- cessories, or devices.

  • Page 15: Fuel

    4-4. FUEL WARNING: REMOVE FUEL CAP SLOWLY; FUEL SPRAY may cause injury; FUEL may be under pressure. Rotate fuel cap slowly and wait until hissing stops before removing cap. ENGINE FUEL can cause fire or explosion. Stop engine before checking or adding fuel. Do not spill fuel;...

  • Page 16: Weld Output Connections

    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.

  • Page 17: Remote Control Connections

    For Shielded Metal Arc Welding (SMAW) and Air Carbon Arc Cutting and Gouging (CAC-A) (Elec- trode Positive/Reverse Polarity), connect weld cables as follows: a. Connect one end of work cable to NEGATIVE (−) weld output terminal. b. Connect end of electrode holder cable to POSI- TIVE (+) weld output terminal.
  • Page 18 If supplied remote control cord is not suitable for con- necting to the REMOTE 9 receptacle RC3, proceed with one of the following alternatives; Wire a plug or cord to interface with REMOTE 9 receptacle RC3 using socket information in Sec- tion C.

  • Page 19: Air Compressor Connections

    4-9. AIR COMPRESSOR CONNECTIONS This unit delivers 12 cfm of air at a pressure of 100 psi whenever the engine is running. A 1/2 in. NPT fitting for air compressor connections is provided on the top cover of the unit. To make connections to the air compressor, obtain and install a quick-connect connector onto the air compres- sor fitting.

  • Page 20: Section 5 − Auxiliary Power

    POWER OUTPUT WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause serious injury; IMPROPER AIR FLOW AND EXPOSURE TO ENVIRONMENT can damage internal parts. Do not touch live electrical parts. Stop the engine and disconnect negative (−) battery cable from battery before making in- ternal inspection or reconnection.

  • Page 21: Section 6 − Operator Controls

    A. Auxiliary Equipment Connections To Terminal Strip 3T (Figure 4-2) WARNING: Read and follow safety infor- mation at beginning of entire Section 5-2 before proceeding. Terminal strip 3T is provided to directly wire the auxiliary power cord(s) into the unit. To make connections, pro- ceed as follows: Remove plug from auxiliary equipment cord(s), if applicable.

  • Page 22: Remote Amperage & Voltage Control Switch

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

  • Page 23: Fuel Gauge

    6-9. FUEL GAUGE (Figure 6-1) FUEL The FUEL Gauge indicates the level of fuel remaining in the fuel tank. The unit is equipped with a 30 gallon (114 L) fuel tank. 6-10. MAGNETIC SHUTDOWN SWITCH An internal switch automatically shuts down the engine if oil pressure drops to an unsafe level or oil temperature becomes too high.

  • Page 24: Section 7 − Sequence Of Operation

    SECTION 7 − SEQUENCE OF OPERATION WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause serious injury; IMPROPER AIR FLOW AND EXPOSURE TO ENVIRONMENT can damage internal parts. Do not touch live electrical parts. Stop the engine and disconnect negative (−) battery cable from battery before inspecting or servicing.

  • Page 25: Air Carbon Arc Cutting And Gouging (Cac-A)

    If remote amperage or voltage control is not used, place AMPERAGE & VOLTAGE switch in the PANEL position. If remote amperage or volt- age control is to be used, place AMPERAGE & VOLTAGE switch in the REMOTE position. If remote contactor control is not used, place OUTPUT(CONTACTOR) switch in the ON posi- tion.

  • Page 26: Stopping The Engine

    b. Fuel Level WARNING: REMOVE FUEL CAP SLOWLY; FUEL SPRAY may cause injury; FUEL may be under pressure. Rotate fuel cap slowly and wait until hissing stops before removing cap. Check fuel level. If necessary, fill tank with fresh, clean fuel (see engine Owner’s Manual for fuel specifications).
  • Page 27 Table 7-3. Approximate Air Consumption (Cubic Feet) Required To Operate Various Pneumatic Equipment At Pressure Range 70-90 P.S.I.G. Percent Use Factor And MISCELLANEOUS Compressed Air Consumption (CF) PORTABLE TOOLS 9 sec 15 sec Drill, 1/18” to 3/8” 3.75 6.25 Drill, 3/8” to 5/16” 5.25 8.75 Screwdriver,...

  • Page 28: Section 8 − Maintenance

    8-1. ROUTINE MAINTENANCE (Table 8-1) IMPORTANT: Every six months inspect the labels on this unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when necessary. See the Parts List for part numbers of precautionary labels.
  • Page 29 20W-20 Figure 8-1. Engine Maintenance Label OM-166 941 Page 24...

  • Page 30: Air Cleaner Service

    8-2. AIR CLEANER SERVICE (Table 8-2) CAUTION: DIRTY AIR can damage engine. Do not operate engine with dirty air cleaner element in place. Do not operate engine without air cleaner ele- ment in place. The air cleaner is one of the most important parts of the engine from the standpoint of engine life.

  • Page 31: Fuel/Water Separator And Sludge Drain Plug

    8-3. FUEL/WATER SEPARATOR AND SLUDGE DRAIN PLUG WARNING: ENGINE FUEL can cause fire or explosion. Do not drain fuel tank while engine is running. Do not smoke while handling fuel. Do not allow fuel to drain onto the engine or other components.

  • Page 32: Maintenance-Free Battery Charging

    8-6. MAINTENANCE-FREE BATTERY CHARG- WARNING: CHARGING A FROZEN BAT- TERY can cause the battery to explode and result in serious personal injury or damage to equipment. Allow battery to warm up to 60 F (16 C) be- fore charging if battery is frozen. BATTERY ACID can burn eyes and skin and destroy clothing and other materials;...

  • Page 33: Brushes And Slip Rings

    When the weld/power speed reaches 1860 rpm, prevent the adjustment screw from turning, and tighten the securing nut. Stop engine. Close and secure side door. 8-9. BRUSHES AND SLIP RINGS (Figure 8-3) WARNING: ELECTRIC SHOCK can kill Do not touch live electrical parts. Stop engine, and disconnect negative (−) bat- tery cable from battery before inspecting, maintaining, or servicing.

  • Page 34: 8-12. Run-In Procedure

    Removal of the device from the exhaust system is not necessary for servicing. Proceed as follows to service spark arrestor: Stop the engine, and allow the exhaust system to cool. Remove the cleanout plug from the bottom of the spark arrestor. If a crust has formed over the hole, break it loose with a screwdriver or similar tool.

  • Page 35: Diagram 8-1. Load Bank Connections

    Welding Generator Positive (+) Weld Output Terminal Stop engine, and disconnect load bank cables. Allow exhaust system to cool. 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.

  • Page 36: Diagram 8-2. Resistance Grid Connections

    Welding Generator Voltmeter And Ammeter (If so equipped) Weld Output Terminals (Polarity Not Important) Voltmeter Required if welding generator is not equipped with meters. 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.

  • Page 37: Overload Protection

    Start engine following procedures outlined in Section 7 (Sequence of Operation) of this man- ual. If the unit does not start after cranking for twenty seconds, stop the jump starting proce- dure. More than twenty seconds seldom starts the engine unless some mechanical adjustment is made.

  • Page 38: Troubleshooting

    9-5. TROUBLESHOOTING (Tables 9-1 Thru 9-4) WARNING: ELECTRIC SHOCK can kill. Do not touch live electrical parts. Stop engine, and disconnect the negative (−) battery cable before inspecting, maintaining, or servicing. MOVING PARTS can cause serious injury. Keep away from moving parts such as fans, and rotors.

  • Page 39: Table 9-2. Auxiliary Power Troubleshooting

    AUXILIARY POWER TROUBLE No 120 volt output at 3T termi- Circuit breaker CB1 open. nals L and M. Poor contact between slip rings and brushes. High auxiliary power output High engine speed. voltage. TROUBLE Engine does not start. Out of fuel. Battery problem.
  • Page 40 NOTES OM-166 941 Page 35...

  • Page 41: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Diagram 10-1. Circuit Diagram For Welding Generator OM-166 941 Page 36...
  • Page 42 SC-168 908-B OM-166 941 Page 37...

  • Page 43: Section 11 − Parts List Figure 11-1A. Main Assembly

    SECTION 11 − PARTS LIST Figure 11-1A. Main Assembly ST-800 491-B (1 of 2) OM-166 941 Page 38...
  • Page 44 Item Dia. Part Mkgs..... . . 134 834 ..... . 131 123 .
  • Page 45 Item Dia. Part Mkgs..... . . 073 433 ....0456660009309 .
  • Page 46 Item Dia. Part Mkgs....1448720009309 ..... . 006 086 .
  • Page 47 Figure 11-1B. Main Assembly ST-800 491-B (2 of 2) OM-166 941 Page 42...
  • Page 48 Item Dia. Part Mkgs..... . . 089 351 ....1532480009309 .
  • Page 49 *Includes Item 4 OM-166 941 Page 44 Figure 11-2. Panel, Front w/Components ST-800 490-A...
  • Page 50 Item Dia. Part Mkgs... . 1346300009880 ....1183400010202 ....072 462 .
  • Page 51 28 29 ST-147 320-F Figure 11-3. Panel, Lower Front w/Components OM-166 941 Page 46...
  • Page 52 Item Dia. Part Mkgs....0386120009309 ..... . 601 840 .
  • Page 53 Item Dia. Part Mkgs....1186380009309 ... 0700700009309 ....090 246 .
  • Page 54 Item Part ....018 614 ....*151 299 .
  • Page 55 Notes...

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