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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
CBI 801D
(Per NSPR 10202)
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Warranty Effective January 1, 1999 (Equipment with a serial number preface of “KK” or newer) This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to: warranties and is exclusive with no other guarantees or 1. Items furnished by manufacturer, but manufactured by warranties expressed or implied. others, such as engines or trade accessories. These LIMITED WARRANTY − Subject to the terms and conditions items are covered by the manufacturer’s warranty, if below
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OM-166 941C − 7/99 TABLE OF CONTENTS Section No. Page No. SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1-4. Standards Booklet Index . . .
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SECTION 7 − SEQUENCE OF OPERATION 7-1. Shielded Metal Arc Welding (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . 19 7-2. Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW) . . . . 19 7-3. Air Carbon Arc Cutting And Gouging (CAC-A) . . . . . . . . . . . . . . . . . . . 20 7-4. Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7-5. Air Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7
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SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. INTRODUCTION from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered. See 1-3A.2. We learn by experience. Learning safety through per- sonal experience, like a child touching a hot stove is Avoid oily or greasy clothing. A spark may ignite them. harmful, wasteful, and unwise. Let the experience of Hot metal such as electrode stubs and workpieces others teach you. should never be handled wi
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atmosphere or where the radiant energy can penetrate ment as recommended in A6.0. Waterfilling just below to atmospheres containing even minute amounts of working level may substitute for inerting. trichloroethylene or perchloroethylene. A container with unknown contents should be cleaned (see preceding paragraph). Do NOT depend on sense C. Fire and Explosion Prevention of smell or sight to determine if it is safe to weld or cut. Causes of fire and explosion are: combustibles reached Hollow cas
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Locate or secure cylinders so they cannot be knocked outlet away from people and sources of ignition. Wipe over. with a clean lintless cloth. Match regulator to cylinder. Before connecting, check Passageways and work areas. Keep cylinders clear of areas where they may be struck. that the regulator label and cylinder marking area, and that the regulator inlet and cylinder outlet match. Transporting cylinders. With a crane, use a secure sup- NEVER CONNECT a regulator designed for a particular port
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1-3. ARC WELDING Viewing the weld. Provide face shields for all persons who will be looking directly at the weld. Comply with precautions in 1-1, 1-2, and this section. Others working in area. See that all persons are wearing Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries flash goggles. high currents at significant voltages. The arc is very Before starting to weld, make sure that screen flaps or bright and hot. Sparks fly, fumes rise
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quate to carry ground currents safely. Equipment made ject in contact with the electrode circuit unless electrically HOT by stray current may shock, possibly the welding power source is off. fatally. Do NOT GROUND to electrical conduit, or to a b. Equipment without output on/off control (no pipe carrying ANY gas or flammable liquid such as oil or contactor) fuel. Welding power sources used with shielded Three-phase connection. Check phase requirements of metal arc welding (SMAW) and similar pro
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5. ANSI Standard Z41.1, STANDARD FOR MEN’S 11. CGA Pamphlet P-1, SAFE HANDLING OF SAFETY-TOE FOOTWEAR obtainable from the COMPRESSED GASES IN CYLINDERS obtain- American National Standards Institute, 1430 able from the Compressed Gas Association, Broadway, New York, NY 10018. 1235 Jefferson Davis Highway, Suite 501, Ar- lington, VA 22202. 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROC- 12. CSA Standard W117.2, CODE FOR SAFETY IN ESSES obtainable from the American N
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SECTION 3 − SPECIFICATIONS Table 3-1. Welding Generator Specifications Maximum Rated Output Maximum Single-Phase Weight Open-Circuit Welding At 100% Engine Speed Auxiliary Power Voltage Range Duty Cycle (No Load) While Welding Net Ship (OCV) 95 Volts DC 800 Amperes 100 to 800 3 kVA/kW 60 Hz 2150 lbs. 2280 lbs. 1860 RPM At 36 Volts DC Amps DC 80 Volts DC 26 Amperes At 120 Volts (975 kg) (1034 kg) Nominal Conforms with NEMA EW1 (ANSI C87.1), “ELECTRIC ARC WELDING POWER SOURCES,” Class I (100). 47
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3-1. DUTY CYCLE and Air Carbon Arc Cutting And Gouging (CAC-A) pro- cesses. The duty cycle of a welding generator is the percentage The unit is equipped with a four-cylinder, air-cooled, of a ten minute period that a welding generator can be Deutz diesel engine (F4L-912). The air compressor in operated at a given output without causing overheating this unit is mounted on the front of the engine, and it op- and damage to the unit. This welding generator is rated erates whenever the engine is runn
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A. Lifting Of Equipment The mounting location should allow sufficient room to remove the top cover and side panels for maintenance WARNING: INCORRECT LIFTING will dam- and repair functions. age internal parts; FALLING EQUIPMENT can cause serious personal injury and Use a properly fitting cover (optional) over the welding equipment damage. generator when not in operation to protect the unit from • Use lifting eye to lift unit only, NOT gas cylin- the environment. Be sure unit is cool before inst
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4-4. FUEL lower front panel of this unit (see Figure 4-2). If oil level is below the lower pointer when engine is running, add oil WARNING: REMOVE FUEL CAP SLOWLY; according to the recommendations in the Engine Man- FUEL SPRAY may cause injury; FUEL may ufacturer’s Manual (F4L-912 engine). The oil cap is lo- be under pressure. cated under the access door on the top cover. • Rotate fuel cap slowly and wait until hissing stops before removing cap. IMPORTANT: This engine is equipped with an Oil Pr
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4-7. WELD OUTPUT CONNECTIONS (Table 4-1 B. Weld Cable Preparation And Figure 4-2) 1. Install electrode holder to cable following man- RATED WELD OUTPUT ufacturer’s instructions. Always use an insulated electrode holder to ensure operator safety. 2. Install correct size lugs onto ends of both cables for connecting to work clamp, electrode holder or wire feeder, and weld output terminals. To obtain full rated output from this unit, it is necessary to select, prepare, and install proper weld cables
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2. For Shielded Metal Arc Welding (SMAW) and Air 4-8. REMOTE CONTROL CONNECTIONS Carbon Arc Cutting and Gouging (CAC-A) (Elec- A. Remote 9 Receptacle Information And trode Positive/Reverse Polarity), connect weld Connections (Figures 4-2 And 4-3) cables as follows: REMOTE 9 a. Connect one end of work cable to NEGATIVE (−) weld output terminal. FEEDER b. Connect end of electrode holder cable to POSI- AMPERAGE/ TIVE (+) weld output terminal. A/V VOLTAGE IMPORTANT: For Electrode Negative/Straight
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If supplied remote control cord is not suitable for con- necting to the REMOTE 9 receptacle RC3, proceed with F one of the following alternatives; G E I D H 1. Wire a plug or cord to interface with REMOTE 9 C A receptacle RC3 using socket information in Sec- B tion C. Ref. S-0706 2. Wire remote control cord directly to terminal strip Figure 4-3. Front View Of Remote 9 Receptacle within unit according to Section B. With Socket Locations B. REMOTE Terminal Strip 3T Information And Connections (Fig
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4-9. AIR COMPRESSOR CONNECTIONS IMPORTANT: Before installing the ether cylinder, clean nozzle on ether cylinder and fitting into which the ether This unit delivers 12 cfm of air at a pressure of 100 psi cylinder is inserted. If dirt is present in either of these ar- whenever the engine is running. A 1/2 in. NPT fitting for eas, the system may not work. air compressor connections is provided on the top cover of the unit. 1. Open and secure right rear side door. To make connections to the air com
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SECTION 5 − AUXILIARY POWER A brief period (less than 5 seconds) of large current draw is required for starting motor-driven equipment. This generator can supply 25% of rated current output at the terminal strip for motor starting. Disconnect motor from POWER OUTPUT generator before starting engine. Use adequate size cords so that voltage drop at the motor is not excessive. Voltage drops significantly when starting motor-driven WARNING: ELECTRIC SHOCK can kill; equipment. MOVING PARTS can cause
