Miller ESS-2500 Owners manual

January

1990

FORM:

OM-125

676

RIEDﬁ

FLE

RETURN

MODEL:

COPY

TO

ESS-2500

FOLDER

OWNERS

iMPORTANT:

special

Installing,

instructions

operation

operate,

understand

Read

and

emphasis

on

operating,ormaintaining

for

of

maintain

or

these

are

weiding

use

instructions.

understand

the

safety

only

by

persons

equipment.

this

unit.

Contact

the

material

this

Do

not

entire

contents

throughout

equipment.

trained

aiiow

untrained

distributor

your

This

and

experienced

MANUAL

of

this

the

manual,

persons

if

you

manual,

unit

do

before

and

in

the

to

instaii,

not

with

these

safe

fully

ERICOﬁ

fastening

Systems

PRINTED

IN

U.S.A

RECEIVING-HANDLING

OM-125

878

11/89

Before

age

claims

Assistance

from

ers

When

ways

Number.

unpacking

that

may

for

loss

the

distributor

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requesting

provide

Section

SECTION

for

the

have

or

filing

1-1.

1-2.

1-3. 1-4.

equipment,

occurred

or

settling

and/or

with

the

damage

Department.

information

Model

Description

No.

-

SAFETY

1

Introduction General

Arc

Welding

Standards

carton

check

during

shipment.

the

delivering

claims

equipment

about

this

and

RULES

Precautions

Booklet

for

any

be

may

obtained

manufactur-

equipment,

Serial

TABLE

FOR

Index

dam-

File

any

carrier.

al

or

Style

OF

OPERATION

Use

the

tion

mation

Model

Serial

DateofPurchase

following

Serial

and

is

located

_______________________________

or

Style

CONTENTS

ARC

OF

spaces

or

on

No.

WELDING

Style

the

____________________

_____________________

record

to

Number

data card

POWER

the

of

your

or

Page

SOURCE

Model

unit.

the

nameplate.

No.

1 I

4

5

Designs-

The

infor

SECTION

2-1.

2-2.

3-1.

3-2.

3-3.

4-1.

4-2.

4-3.

4-4.

5-1.

5-2.

5-3.

5-4.

5-5.

5-6.

5-7.

2-

SAFETY

General

Safety

3

SPECIFICATIONS

Volt-Ampere

Duty

Cycle

Description

4

INSTALLATION

Location

Weld

Output

Current

Electrical

OPERATOR

5-

Power Pilot

Light

Range

Current Remote

Remote

Control

Arc

PRECAUTIONS

Information

Alert

Symbol

Curves

Connections

And

Contactor

Connections

Input

CONTROLS

Switch

Adjustment

Control Control

Receptacle

Switch

And

Safety

And

Signal

Control

AND

SIGNAL

Words

Connections

Current

And

Contactor

WORDS

Control

Switch

6

7 7 8

8

8 9

9

11

11 11

12 12

12

13

SECTION

6-1.

6-2.

6

SEQUENCE

Stud

Shutting

Welding

Down

OF

OPERATION

13

14

-I

Section

SECTION

No.

7

7-1.

7-2. 7-3. 7-4.

8

Diagram Diagram Diagram

9

Figure

MAINTENANCE

Routine

Rectifier

Ovetload

Maintenance

Protection

Troubleshooting

Diagram Diagram

Diagram

Front

Card,

Side

DIAGRAMS

-

W/Components

View

ELECTRICAL

Circuit

8-1.

Circuit

8-2.

Circuit

8-3.

Feedback

PARTS

9-1.

Panel,

Circuit

9-2.

9-3.

Right

LIST

&

TROUBLESHOOTING

For

Root

For

3-Phase

Burden

Root

Board

Pass

PC2

Circuit

Board

PCI

Page

No.

14 14 14

15

17

18

19

20

22 24

Table

Chart

Table

3-1.

Specifications

3-1.

Volt-Ampere

3-2.

Duty

Cycle

4-1.

Weld

Cable

4-2.

7-1.

7-2.

Conductor

Input

Maintenance

Troubleshooting

LIST

Curves

Size

And

Schedule

OF

CHARTS

Fuse

Size

AND

TABLES

7

8

9

11

14

16

SECTION

1

-

SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

We

learn

sonal

harmful,

ers

Safe

welding

search,

evolved

tion,

by

experience,

wasteful,

teach

you.

practices

and

development,

reliable

and

servicing

equipment

the

for

son

Some

technical rules.

Read

tempting Comply

ticular

personal

Failure

ous

based

are

volumes

understand

and

to

with

equipment

safety

observe

to

or

injury

equipment

These

1-General

ting;

Reference

are

cedures

in

most

The

Health

inspection

ment

1-2.

DIfferent

and

radiation

manual,

facturers

specific

safe

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and

2-Arc

available

also

than those

Standards

the

complete.

National

Administration,

requirements

installation,

GENERAL

arc

fluxes

levels.inadditiontothe

be

Material

technical

concerning

A.

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protective

in

use

welding,

shirt

collar

and

to

avoid

entry

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helmet

shields

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experience.

child

like

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unwise.

and

developed

described

cutting

are

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improperly

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on

install,

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used

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death.

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practices

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standards:

for

indexinthis

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use,

PRECAUTIONS

welding

can

produce

to

sure

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to

explain.

these

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procedures

and

the

for

safe

these

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with

used

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additional

in

given

Code,

local

also

and

processes,

consult

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data

and

their

material.

clothing-gauntlet

and

hat,

pocket

of

sparks

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high

flaps,

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appropriate

clear

by

cover

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safety

touching

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from

and

may

sense,

safe

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their

safety

experience

in

this

field

experience

safe

installation,

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maintained.

or

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always

others

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practices

service

as

applicable

instruction

others.

of

practices

becomes

safety

confidence.

divided

to

into

arc

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and

more

this

manual.

ANSI

Occupational

industrial

provide

service.

different

flux

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a

electrode

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precautionary

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plugs

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confined

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oxygen.

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to

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or

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in

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with

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in

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in

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containing

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space.

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676

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1

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to

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guishing

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flame,

arc,

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cracks,

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operator.

prevent

equipment

electrical

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short

combustibles

if

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paint

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least

against

touching

be

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should

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equipment

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appreciable

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and

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as

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a

thorough

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followed

dioxide,

2

Page

heat.

minute

even

perchioroethylene.

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combustibles

are:

sparks,

sparks

pipes,

openings,

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hot

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gases

or

falling

through

slag

or

and

cylinders;

windows

of

out

can

fly

heated

slag

explosion:

of

and

operable,

metallic

of

area,

to

an

dip

be

moved,

of

reach

with

shields.

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do

area

tanks,

suitable

on

in

out

or

cut).

by

standing

during

combustibles

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by

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within

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orvisible)

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be

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check

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flames.

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combustibles,

toxic

or

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or

cut,

steam

unless

depending

by

purging

and

free

particles

NOT

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free

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of

storage

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of

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opposite

ceilings,

heat-resistant

with

for

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and

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manual,

HANDLING

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regulator

any

with

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other

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indicate

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when release.

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for where

recommended

as

level

container

with

preceding

or

sight

castings

atmospheres.

contain

flammable

gasoline).

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precautions.

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those

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listed

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relief

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connect

than

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faulty

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unknown

paragraph).

determineifit

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detailed

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in

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valve

overpressure;

equipment.

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externally.

valve

gauge

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produce

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assurance

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mark

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to

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by

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fuel

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to

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oft

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ing

4.

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ices

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to

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tubing

splice

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leaky

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and

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for

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to

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to

open

regularly

NOT

valve

use

a

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NEVER

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be

struck.

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a

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NOT

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opened

any

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for

as

only

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sharp

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caps

by

gases

or

than

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identification

and

black

hose

the

a

binding

standard brass

and

abuse.

run

over,

and

tangles.

edges,

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Page

1-3.

Comply

Arc

Welding,

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high

bright

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dards

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equipment

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power

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frames

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line

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equipment

ground

plug

ceptacle, ground

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hot

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to

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line

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the

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port

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equipment

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devices

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installation,

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all

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all

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in

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equipment

all

disconnect

power

DevIces

fields

Persons

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going

operations.

1-4.

STANDARDS

For

more

information,

their

latest

revisions

ANSI

Standard

1.

CUTTING

Society,

2.

NIOSH,

GAS

AND from

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ernment

3.

OSHA,

29CFR

1910,

Documents,

Washington,

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Standard

OCCUPATION

FACE

PROTECTION

National

NY

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5.

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SAFETY-TOE

American

New

way,

ANSI

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OF

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power

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power

source.

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accidental

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plugs.

circuit

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flash

or

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to

equipment.

switch

must

Wearers

change

(Pacemakers)

from

high

currents

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near

arc

welding,

BOOKLET

refer

to

and

complyasapplicable:

LeJeune

AND

SAFETY

from

HEALTh

AND

obtainable

N.W.

550

SAFETY

WELDING

Z49.1,

Superintendent

Printing

SAFETY

Standards

10018.

National

York,

CUTTING

Office,

AND

obtainable

Government

U.S.

D.C.

20402.

Z87.1,

AND

obtainable

Institute,

Z41.1,

FOOTWEAR

Standards

NY

10018.

Z49.2,

AND

EDUCATIONAL

FIRE

used

with

similar

and

with

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ON.

and

shunted

service,

line

fuses

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of

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INDEX

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WELDING

American

Miami,

IN

ARC

CUTTING

of

Documents,

Washington,

HEALTh

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STANDARDS,

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STANDARD

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PREVENTION

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PRACTICES

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near

Life

Sup

pacemaker

life

support

doctor

their

welding

spot

standards

AND

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FL

33126.

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obtainable

U.S.

Gov

D.C.

20402.

Office,

FOR

EYE

AND

American

New

FOR

MENS

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Standard

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550

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FOR

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obtainable

Standard

Association,

02269.

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from

the

American

Broadway,

A6.0,

WHICH

from

LeJeune

OXYGEN-FUEL

51,

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70,

from

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51B,

obtainable

SAFE

P-i,

GASES

IN

National

New

York,

WELDING

HAVE

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American

Miami,

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the

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AND

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HANDLING

CYLINDERS

Standards

NY

10018.

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COMBUS

Welding

FL

33126.

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SYS

AND

ALLIED

National

Park,

Quincy,

ELECTRICAL

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RECOMMENDED

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Miami,

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can

New

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booklet,

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FL

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Standard

PROTECTION,

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NY

York,

Gas

Suite

W117.2,

CUTTING

Association,

WELDING

from

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Arch

1900

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SAFE

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obtainable

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501,

Arlington,

CODE

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National

Street,

FOR

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Ontario,

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Philadelphia,

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PRACTICES

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obtainable

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550

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2-1.

GENERAL

A.

General

Information

bels,

tags,

design,

troubleshooting

followed The

nameplate

labeling

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pear

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Safety

The

installation,

shooting

and

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codes

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Section

Power

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Install

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Control CONTROL

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the

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CONTROL Sections

Place

3.

Section

4.

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sition

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Rotate

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IMPORTANT:

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in

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switchinthe

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5-7).

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5-4).

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CURRENT

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basic

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OM-125

676

Page

13

7.

8.

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dry

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flash-type

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10.

6-2.

1.

2.

3.

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the

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the

5-1).

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push

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min

7-1.

ROUTINE

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unit

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months

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FREQUENCY

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hours

40

enance

OM-125

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3

Months

6

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Page

of

service

week.

14

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7-18).

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MAINTENANCE

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OM-125

676

Page

15

Table

7-2.

TroubleshootIng

TROUBLE

Completely

weld

output.

Erratic

Low

inoperative.

output.

PROBABLE

line

Open

Fuse

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Poor

connections.

Main

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Poor

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Open

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Fl

open.

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and/or

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F2-F6

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fuse.

and/or

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line

voltage.

improper

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open.

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input

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CAUSE

Replace

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and

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RENT

Fuse

in

ADJUSTMENT

Fl

F2-F6

of

use

Remote

conjunction

open.

Current

with

CUR-

control.

Refer

to

Current

Replace

Section

Control.

Fl

(see

F2-F6

5-5

Section

as

necessary

for

proper

7-3).

use

(see

Remote

of

Section

7-3).

OM-125

676

Page

16

Cl)

m

C)

-I

z

0

iirii

C)

-I

C)

r

0

C)

Cl)

I.

384

C-089

No.

Diagram

Circuit

RECEPTACLE

(OPTIONAL-EXTRA)

lisp

Diagram

CIrcuit

8-1.

Diagram

¶

C,,

OM-125

676

Page

N

18

0

C

B

Diagram

8-3.

F<

A.

Clrcuft

Diagram

D5

L~

r~

07

09

~

For

3-Phase



__

1R2

1

Feedback-Burden

D4

D6

08

ri

Circuit

Board

Diagram

PC2

No.

A-120

005

OM-125

676

Page

19

SECTION

9-

PARTS

LIST

7



8

r

4

9

-1

10

~



I

OM-125

676

Page

9-1.

Figure

20

Panel,

Front

W/Components

Item

No

Figure

2

3

4

5

6

7 8 9

10

11

Mkgs.

9-1

Cl

Dia.

S5

R3

R4

S3

RC1

4-17

S2,4

R5

Pci

RC2

PB1

PL1

C4,5

Part

No.

011

610

091

377

052

140

030853

085

089

035 523 094 206

750

097

011

609

097926

072

623

072590

070609

035815

035

506

073 756

011

636

027645 005397 086554

605

583 086615 038

612

038613

038

847

038

900 602247 605

787

601

840

601

839

006034

-

Panel,

SWITCH,

RESISTOR

SWITCH,

front

toggle

RESISTOR,

toggle

W/Components

ASSEMBLY

carbon carbon

RECEPTACLE,

CAPACITOR

ASSEMBLY

CAPACITOR,

SWITCH,

KNOB,

toggle

pointer

POTENTIOMETER,

RI

LOCK,

CIRCUIT

TERMINAL, GUIDE, STAND-OFF, SWITCH, LIGHT,

PLATE, PANEL,

CATCH, BRACKET,

TERMINAL

TERMINAL BUS

CAPACITOR,

shaft

indicator-red

BAR

STUD, WASHER, WASHER,

brass-hex

NUT,

brass-hex

NUT,

CARD,

header

circuit

card

6-32

push

indicator

front

spring

mtg

ASSEMBLY,

BOARD

brass

1/2-13x2-1/4

flat

lock

ceramic

Description

SPOT

15

(consisting

0.5

SPST

20

5

socket

ceramic

SPDT

root

button

loaded

-

terminal

SAE

-

MS-3102A-16S-8S

0.05uf500

15

carbon

pass

29

socket

5/8

PCi

x

10

lens

power

1/2

internal

1/2-13

jam

full

1/2-13

0.003

125

amp

volts

of)

330

2.2K

125

ohm

volts

watt watt

amp

(consisting

volts

125

amp

1

(Fig

amp

volts

turn2watt

9-2)

550

volts

assembly

output

1/2

tooth

uf

3000

center

of)

dc

ohm

1000

ac

(consisting

volts

cic

off.

of)

Quantity

1 I

1 1 1

2 2 2

1

I I 2 4

1 I

1

I

2

I 1

2 2 2 4 2 2

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-125

676

Pago

21

R127

C80

~

I



________IVR5I

077

______

~I

C76

C77

D76

~Jo1]

_______

________IVR5O

I

_____________

C.)

SR50

~

~iU

+~

C79

___

_____

C96

~

151

150

T53

152

o~I

UL~)

155

154

0)

-

I

1

ASSY

0

_____

29

0

OM-125

676

Page

Rel

0.084

204.E

9-2.

FIgure

22

CIrcuit

Card,

Root

Pass

10

6

Dia.

Mk~s.

Figure

9-2

A50-59

C51-53

C54,56,59-61

.63,66,

67,68,70,73,74

C55,62,69

C57,58,64,65,71,

72,77,80,82,87

C75

C76,79

C78,81

C83,85,88-93,

95,96,99

C98

D50-52,54-56,58-60

66-66,70-72,74,75,81,86

D53,57,61

,65,69,

73,76,77,82,85

Q50

52,54,56,58,60

Q51

53,55,57,

59,61,62

Q63

R50-52,11i

R53,54,61

,112

62,68,75,76,82,

83,90,91,109,124,135

R55,63,69,77,84,92,

R56,64,70,78,85,93,

R57,65,71

79,86,94,99

R58,72,87

R59,66,73,80,88,95

R60,67,74,81

.89,96

R97,101,133

Ri

137 02 04

R98,125

R106,130,134

R107 RhO

R113,116

Ri19

Ri

20

Ri

22

RI

27

R13i

136,139

Ri

32

R138

SR5O

T50-55

VR5O

VR51

,62-64,

108,126 100,129

Part

No.

609

070

035845

035

035 833 035

053991

038 000 859 031

059

007

028

026

037

035

000088 000 885

035

035 035 825

035 035

605919

035 885 035

030024

035829 035

035 039 030

030

039 076712

039329 039331 039 335

035886 035 035 081 046 035

CIrcuit

IC,Iinear3o7

834

CAPACITOR,

835

CAPACITOR,

585

CAPACITOR,

630

CAPACITOR,

122

CAPACITOR,

742

CAPACITOR,

351

DIODE,

202

DIODE,

277

TRANSISTOR,

842

TRANSISTOR,

RESISTOR,

884

RESISTOR,

826

RESISTOR,

827

RESISTOR,

823

RESISTOR,

257

RESISTOR,

887

RESISTOR, RESISTOR, RESISTOR,

848

POTENTIOMETER,

888

RESISTOR,

108

RESISTOR,

089

RESISTOR,

045

RESISTOR,

106

RESISTOR,

RESISTOR, RESISTOR,

RESISTOR,

841

RECTIFIER,

846

TRANSFORMER,

832

IC,

932

IC,Iinear7gi5

849

TERMINAL,

Card,

linear

Description

Root

metal

mylar electrolytic

ceramic

mylar electrolytic electrolytic

ceramic

electrolytic

0.020

signal

I

400

amp

NPN

PNP

NPN

carbon

carbon carbon carbon carbon carbon carbon carbon carbon carbon carbon carbon

carbon

WW carbon carbon carbon carbon

carbon carbon

integrated

78M15

header

Pass

film

0.033

0.22uf50

amp

volts

200MA

0.6 800MA

film

0.25

0.25 film

film

0.5 film

cermet

film

0.5

fIxed

film

0.25 film

film film film

pulse

29

1.5

4.7

0.05

220 22ut50

0.01 10uf35

SP

amp

0.25

watt

0.25

watt

0.25

watt

3.25

0.25

watt

0.25

1.5

uf

75

uf

100

uf

ut

uf

volts

30

40

1K

25

2.7

watt

amp

100

500

volts

uf

500

40

watt

watt watt

270

47

watt

turnS

watt watt

watt

220K

watt

watt watt

watt

volts

35

volts

35

volts

SP

volts

10K

lOOK

6.8K 10K

1K

100

ohm

68K

3.3K

ohm

1.5K

2.2K

82K

ohm

100

470

2.7K

4.7K

47K

22K

200

volts

ohm

watt

ohm

volts

dc

ohm

ohm ohm

dc

ohm

10K

ohm

Quantity

10

3

12

3

10

1

2 2

ii

1

22

7

I

5

14

8

7

3 6

6

3

1

3

1 I

2

1

3

1

6

1

I I

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-125

676

Page

23

1II315I

Item

No.

Figure

1

2

Mkgs.

9.3

CT1-3

Dia.

F2-6

Part

No.

283

035

282 084

057

086575

088618

*012633

082976

Side

Right

CONTROL

COVER, BUSHING,

TRANSFORMER, ANGLE,

FUSE,

HOLDER,

View

BOX,

control

snap

mtg

miniature

fuse-miniature

Description

PCi

box

-

in

current

-

current

-

glass

2

H:

1/4

nylon

transformer

1

amp

ID

3/8

hole

mtg

~

Quantity

13~

12-~~

7

OM-125

676

Page

Right

Side

View

Figure

24

9-3.

Item

No.

FIgure

Mkgs.

9-3

Dia.

Part

No.

Right

Side

View

(Contd)

Description

Quantdy

3

4

5

PC2

D4-9

Ri

TEl

R6,7

6

7

8

9

10

11

12

13

TEl 089

SRi

C7-i

SCR1-6

TP1

Wi

C21-23

*Recommended

+When

BE

ordering

SURE

TO

,2

FM

Ti

Fl

12

Z

W

2

Spare

a

component

PROVIDE

053

026

007 038

038

038 038890 026

010915

601

038

088 039 032 032

089 038 602

605 601

601

086854

086

086 086 086 086656

*012

070

090

088

084 080

070 601

044 025

004

004259 004

034 089 086

086574

+089

010853 010 010357

086

026

109 035

Parts.

MODEL

CIRCUIT

908

202

264

954

622

620

846

DIODE,

RESISTOR,

TERMINAL

BLOCK,

LINK,

TERMINAL

CARD,

1

amp

terminal

jumper

STUD,brassl/4-20x2-1/8

754

INSULATION,

~WASHER,fIat-brass1/4

836

652

131

210

605

616 088

087

654

246

787

839

840

.

WINDTUNNEL, RESISTOR, MOTOR,

BLADE,

TERMINAL

brass

NUT, LINK,

jumper

TERMINAL

STUD, WASHER, WASHER,

brass-hex

NUT,

brass-hex

NUT,

SP

fan

brass

PANEL,rear

NAMEPLATE

891

TRANSFORMER,

681

682

683

639 404

474

616

005

894

160

066

267

248

104

COIL,

pri/sec

COIL,

ph/sec

COIL,

BASE

FUSE,

HOLDER,

ph/sec

cartridge

fuse

TRANSFORMER,

STABILIZER

RECTIFIER,

CAPACITOR,

THYRISTOR, THERMOSTAT,

CLAMP,

thyristor

STAND-OFF,

CONTACTOR,

COIL

.

258

821

089

144

KIT,

points

INTERLOCK,

CAPACITOR

CAPACITOR,

PANEL,sideLH

093

PANEL,

side

FASTENER,

855

RETAINER,

~NUT,speedNo.2clipon

578

COVER,

627

GASKET,

LABEL,

originally

AND

top

rubber

warning

displaying

SERIAL

feedback

400

volts

WW

fixed

ASSEMBLY,

30

-

terminal

BOARD

barrier

stud

-

hex

jam

-

primary

20

inch

WW

fixed

1/4

60Hz20

hp

230

ASSEMBLY,

BOARD

1/2-13

1/2

flat

-

lock

internal

full

jam

(order

by

power

6

amp

-

cartridge

KVA

SCR

(consisting

ceramic SCR

NC

insulator

3P

600

NO

ASSEMBLY

ceramic

RH

~consisting

screw

No.

screw

-lifting

electric

a

precautionary

NUMBER

(consisting

SP

12

watt

(consisting

pn

5

amp

pole

block

1/4-20

studs

375

watt

volts

ac

3

inch

wing

pri

(consisting

2-5/8

x

tooth

1/2-13

&

model

-

main

600

volts

30

amp

1/2

of)

0.01

uf

1200

amp

1/4-20

volts

x

(consisting

0.0022UI6000

of)

-

slottedhdNo.

2

eye

shock

can

WHEN

of)

ohm

6.6

of)

12

ohm

1625

rpm

21

degree

of)

1/2

serial

number)

(consisting

600

volts

1000

volts

dc

500

volts

1-1/4

of)

volts

2

kill

etc

the

label,

ORDERING

of)

dc

label

should

REPLACEMENT

also

be

ordered.

PARTS.

OM-125

676

I

6

2

1

18

18 18

36

6

1

2

1

I 1

3 3

3 6

6

1 1

1

2

3

1

I

1 1

6 6

1

3

6

1

i

3

1 1

3

1

2 2 2

I

1

Page

25

Miller ESS-2500 Owners manual

Specifications and Main Features

Frequently Asked Questions

User Manual