Miller 2900 CONTRO Owner's manual

2900 CONTRO
Miller
Brand
Miller
Model
2900 CONTRO
Category
Welding System
Type
Owner's manual

This manual is also suitable for

October
1977
FORM:
OM-1502B
Effective
With
Serial
No.
HH083034
MODEL
2900
Control/Feeder
3/32
Flux
Cored
Wire
7/64
Flux
Cored
Wire
1/8
Flux
Cored
Wire
STOCK
NO.
078036
078
037
078038
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
9I
H
Tf~
*~~
~
~..
~
%.~
~
i~P
~
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
s
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller
Electric
Mfg.
Co.,
Apple-
1.
Arc
welders,
power
sources,
and
components
. . .
1
year
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
2.
Original
main
power
rectifiers
3
years
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
(Labor
1
year
only)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
3.
All
welding
guns
and
feeder/guns
90
days
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
~t
accessories
or
other
items
manufactured
by
others.
Such
engines,
4.
All
other
Millermatic
Feeders
1
year
trade
accessories
and
other
items
are
sold
subject
to
the
warran-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
(30)
days
of
the
date
of
such
failure.
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL-
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
5.
Replacement
or
repair
parts
exclusive
of
labor
.
.
60
days
MILLER
warranty
does
not
apply
to
components
having
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
normal
useful
life
of
less
than
one
(I)
year,
such
as
spot
welder
AND ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
RESENTATION
AS
TO
PERFORMANCE,
AND
ANY
come
in
contact
with
the
welding
wire
including
nozzles
and
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
nozzle
insulators
where
failure
does
not
result
from
defect
in
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
workmanship
or
material.
TION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
therefor
shall
be,
at
Millers
option,
(1)
repair
or
(2)
replace-
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
the
purchase
price
(less
reasonable
depreciation
based
upon
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
actual
use)
upon
return
of the
goods
at
Customers
risk
and
cx-
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
TRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
dures
to
be
followed.
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
nal
users
warranty
claims
on
warranted
Equipment
in
the
event
WARRANTIES
DO
NOT
EXTEND
TO,
AND NO
RE
of
failure
resulting
from
a
defect
within
the
following
periods
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WAR-
from
the
date
of
delivery
of
Equipment
to
the
original
user:
RANTIES
TO,
ANY
CONSUMER.
5,
J~.5,
J5,
~
.~5,......
~.J5,
J~J5,
J1,
~
~.J5,
5,
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Effective
With
Seriat
No.
HJ159825
1NOTE
The
control/feeder
-
welding
power
source
weld
cable
terminal
as
shown
in
Figure
3-1
has
been
replac~~
,
a
new
terminal
located
on
the
left
side
of
the
reel
case
directly
behind
the
control
box
Item
Part
No.
Listed
Replaced
With
No.
In
Parts
List
Part
No.
Description
Quantity
2
602
207
602
207
WASHER,
steel
-
lock
split
1/4
(quantity
change)
5
3
601
865
601
865
NUT,
steel
-
hex
full
1/2-20
(quantity
change)
5
4
005538
053506
BASE
1
6
058
432
Deleted
Items
10
thru
17
are
still
used
but
not
available
as
an
assembly
7
605
946
Deleted
8
602
249
Deleted
9
058
434
Deleted
27
074774
074772
INSULATOR,motor
&drive
assembly
1
130
074
897
Deleted
131
010286
Deleted
132
074
869
Deleted
138
074871
Deleted
139
601
039
Deleted
140
074
868
Deleted
141
078
754
Deleted
150
073
314
073
314
TERMINAL,
cable
1/0-4/0
225
amp
(quantity
change)
2
153
073
387
Deleted
039
041
TERMINAL,
power
output
-
red
1
005
715
BOLT,
carriage
.
steel
1/4-20
x
1
2
602
241
WASHER,
flat-
steel
SAE
1/4
2
073
147
CABLE,
copper
-
bare
No.
3/0
(order
by
ft)
3
ft.
605
591
TUBING,
glass
-
acrylic
7/8
x
36
1
053
508
STRIP,
polyester-
glass
laminate
5/16
x
7/8
x
3-1/4
1
605
590
TUBING,
glass
-
acrylic
5/8
x
36
1
073
916
WASHER,
centering
1-1/2
dia
1
BE
SURE
TO
PROVIDE
STOCK.
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1502B
Page
A
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
INTRODUCTION
1-1.
General
1
1-2.
Receiving-Handling
1
1-3.
Description
1
1-4.
Safety
1
SECTION
2
INSTALLATION
2-1.
Location
1
2-2.
Installation
Of
Electrode
Wire
Gun
Connector
1
2-3.
Electrode
Wire
Inlet
&
Outlet
Guide
Installation
1
2-4.
Drive
Roll
Installation
2
2-6.
Upper
Drive
Roll
Alignment
2
2-6.
Electrode
Wire
Bail
Installation
3
2-7.
Weld
Cable
Connections
3
2-8.
Open
Circuit
Voltage
Calibration
3
2-9.
Welding
Wire
Threading
3
SECTION
3
FUNCTION
OF
CONTROLS
3-1.
Advance/Retract
Switch
4
3-2.
Arc
Control
4
3-3.
Range
Switch
3-4.
Voltmeter
SECTION
4-
SEQUENCE
OF
OPERATION
4-1.
Gas
Metal-Arc
Welding
4
4-2.
Shutting
Down
4
SECTION
5
MAINTENANCE
5-1
-
Relay
Adjustment
5
SECTION
6
TROUBLESHOOTING
PARTS
LIST
2.
Insert
the
outlet
guide
(11)
into
the
outlet
guide
hole
in
the
drive
assembly
until
the
flange
on
the
outlet
guide
contacts
the
drive
assembly.
3.
Tighten
the
outlet
guide
securing
screw
(12).
4.
Loosen
the
inlet
guide
securing
screw
(2).
5.
Insert
the
inlet
guide
(1)
point
first
into
the
inlet
guide
hole
until
the
flange
on
the
inlet
guide
(1)
seats
against
the
drive
assembly.
I
NOTE
I
The
pressure
adjustment
knob
will
have
to
be
adjusted
for
proper
tension
prior
to
operation
of
the
control!
feeder.
The
amount
of
pressure
will
vary
from
one
given
set
of
welding
conditions
to
another
and
should
be
just
tight
enough
to
prevent
drive
roll
slippage
on
the
wire.
6.
Tighten
the
inlet
guide
securing
screw
(2).
2-4.
DRIVE
ROLL
INSTALLATION
(Figure
2-2)
1.
Remove
the
pressure
adjustment
knob.
2.
Remove
nut
(item
7,
Figure
2-2),
split-lock
washer
(8),
and
flat
washer
(9)
from
the
lower
drive
roll
shaft.
NOTE
Prior
to
installing
the
lower
drive
roll,
ensure
that
the
supplied
key
is
in
the
groove
in
the
lower
drive
roll
shaft.
3.
Slide
keyed
drive
roll
(10)
onto
the
lower
drive
roll
shaft.
4.
Install
flat
washer
(9),
split-lock
washer
(8)
and
nut
(7)
Onto
the
lower
drive
roll
shaft.
5.
Remove
bolt
(6),
split-lock
washer
(5),
and
flat
washer
(4)
from
the
upper
drive
roll
shaft.
6.
Slide
un-keyed
drive
roll
(3)
onto
the
upper
drive
roll
shaft.
7.
Slide
flat
washer
(4)
and
split-lock
washer
(5)
Onto
bolt
(6)
and
insert
bolt
(6)
into
the
upper
drive
roll
shaft.
8.
Install
the
pressure
adjustment
knob.
2-5.
UPPER DRIVE
ROLL
ALIGNMENT
(Figure
2-3)
The
upper
drive
roll
mounting
bracket,
which
holds
the
upper
drive
roll,
can
be
moved
on
a
horizontal
plane
in
order
to
facilitate
alignment
of
the
groove
in
the
upper
drive
roll
with
respect
to
the
groove
in
the
lower
drive
roll.
The
upper
drive
roll
should
be
checked
for
proper
alignment
whenever
erratic
wire
feed
is
noted
or
whenever
the
drive
rolls
are
changed.
To
check
for
proper
alignment
of
the
upper
drive
roll,
remove
the
outlet
guide
and
look
into
the
outlet
guide
hole
in
the
drive
assembly.
Upon
viewing
the
groove
between
the
drive
rolls
it
should
be
noted
that
the
outer
edges
of
the
grooves
on
the
upper
and
lower
drive
rolls
should
be
precisely
aligned.
Figure
2-3
shows
examples
of
proper
and
improper
alignment.
If
the
drive
rolls
are
not
in
alignment,
proceed
as
follows
to
adjust
the
upper
drive
roll:
1.
Loosen
the
pressure
adjustment
knob.
2.
Using
a
9/16
wrench,
loosen the
outer
securing
bolt.
3.
Using
a
5/8
wrench,
rotate
the
adjustment
nut
as
re
quired.
Rotating
the
adjustment
nut
clockwise
will
move
the
drive
roll
outward
and
counterclockwise
rotation
will
move
the
drive
roll
inward.
4.
When
proper
alignment
is
achieved,
tighten
the
Outer
securing
bolt
to
lock
the
drive
roll
in
position.
5.
Tighten
the
pressure
adjustment
knob
until
the
desired
amount
of
pressure
is
obtained.
Pressure
Adjustment
Knob
Gun
Connector
Securing
Screw
3
4
5
6
12
7
11
10
9
8
Figure
2-2.
Drive
Roll
&
Wire
Guide
Installation
TB-078
036-3
Page
2
Outlet
Guide
Hole
View
2-6.
ELECTRODE
WIRE
BAIL
INSTALLATION
(Figure
3-1)
1.
Remove
the
four
wing
nuts
on
the
outside
of
the
wire
reel.
2.
Pull
the
four
reel
fingers
off
the
reel.
3.
Slide
the
wire
bail
onto
the
reel
in
such
a
way
that
the
wire
will
feed
from
the
bottom
of the
reel
when
the
reel
turns
in
a
clockwise
direction.
4.
Replace
reel
fingers,
make
sure
they
are
seated
against
the
wire
bail.
5.
Secure
the
bail
by
replacing
the
four
wing
nuts.
Tighten
the
wing
nuts
as
much
as
is
necessary
to
hold
the
wire
bail
firmly.
2-7.
WELD
CABLE
CONNECTIONS
(Figure
3-1)
A
terminal
is
provided
on
the
rear
of
the
control
assembly
to
serve
as
a
junction
point
for
joining
the
positive
weld
cable
from
the
welding
power
source
to
the
control/feeder.
Counter-
Proper
Clockwise
clockwise
Alignment
Rotation
of
Rotation
of
Adjustment
Adjustment
Nut
Required
Nut
Required
TB-078
036-5
38
volts
no
adjustment
is
required
and
the
control/feeder
should
be
ready
for
operation.
If
the
reading
is
not
in
the
34
to
38
volts
range,
proceed
to
the
remaining
steps.
5.
Shut
the
welding
power
source
down.
6.
Remove
the
two
screws
which
secure
the
front
panel
of
the
control
place
and
swing
the
front
panel
down.
7.
If
the
reading
on
the
voltmeter
was
below
34
volts,
move
the
variable
resistor
hand
in
the
control
until
down,
If
the
reading
on
the
voltmeter
was
above
38
volts,
move
the
resistor
band
up.
After
the
band
is
moved,
close
and
secure
the
front
panel,
energize
the
welding
power
source,
and
recheck
the
voltmeter
reading.
Due
to
the
fact
that
the
band
setting
is
made
by
trial
and
error
process,
it
may
be
necessary
to
move
the
resistor
band
several
times
before
the
voltmeter
reading
is
in
the
34
to
38
volts
range.
NOTE
If
the
proper
range
cannot
be
achieved,
a
welding
power
source
with
very
high
or
low
open-circuit
voltage
is
indicated.
This
condition
will
not
damage
the
control/feeder,
but
will
cause
the inch
speed
to
be
faster
or
slower than
normal.
Ensure
that
the
contacting
surfaces
of
the
weld
cable
terminals
are
kept
clean
at
all
times.
Also
ensure
that
the
bolts
on
these
terminals
are
secure.
If
either
one
of
the
above
conditions
is
not
met,
erratic
weld
current
i
could
result.
The
ground
clamp
on
the
control/feeder
must
be
attached
to
either
the
work
clamp
from
the
welding
power
source
or
to
the
negative
weld
output
terminal
on
the
welding
power
source.
2-8.
OPEN-CIRCUIT
VOLTAGE
CALIBRATION
FOR
ADVANCE/RETRACT
SWITCH
This
control/feeder
is
designed
to
operate
from
the
open
cir
cuit
and
load
voltage
of
the
welding
power
source.
Due
to
the
fact
that
all
welding
power
sources
do
not
have
the
same
open
circuit
voltage
rating
it
may
be
necessary
to
perform
some
adjustments
on
this
control/feeder
in
order
to
have
the
control/feeder
operate
properly.
Proceed
to
the
following
steps
to
check
if
the
control/feeder
is
set
for
the
open
Circuit
voltage
being
used
and
if
not,
how
to
properly
set-up
the
control/feeder.
1.
Make
all
connections
as
instructed
in
items
2-1
through
2-8.
2.
Place
the
RANGE
Switch
in
the
LO
position
3.
Rotate
the
ARC
CONTROL
to
the
5
setting.
4.
Rotate
the
ADVANCE/RETRACT
Switch
to
the
AD
VANCE
position
and
check
the
reading
on
the
control/
feeder
voltmeter.
If
the
voltage
reading
is
between
34
and
2-9.
WELDINGWIRETHREADING
~~~Il.]~IJ
Prior
to
threading
the
welding
wire
through
the
gun,
ensure
that
the
weld
cable
from
the
welding
power
source
is
not
connected
to
the
control/feeder
1
.
Install
the
wire
bail
Onto
the
reel
as
instructed
in
item
2-6.
2.
Loosen
the
pressure
adjustment
knob.
3.
Cut
off
any
portion
of
the
free
end
of
the
welding
wire
which
is
not
straight.
4.
Install
the
Electrode
Wire
Gun
Connector
as
explained
in
item
2-2.
5.
Check
the
upper
drive
roll
for
proper
alignment
as
instructed
in
item
2-5.
6.
Manually
feed
the
welding
wire
into
the
inlet
guide
and
continue
feeding
the
wire
into
the
outlet
guide.
Feed
approximately
four
inches
of
welding
wire
into
the
outlet
guide.
7.
Tighten
the
pressure
adjustment
knob
for
the
approxi
mate
amount
of
pressure
desired
on
the
drive
rolls.
Precise
adjustment
of
the
pressure
adjustment
assembly
will
have
to
be
made
when
welding
com
mences.
Figure
2-3.
Upper
Drive
Roll
Alignment
IMPORTANT
I
OM-1
502
Page
3
8.
Make
weld
cable
connections
as
explained
in
item
2-7.
9.
Lay
the
gun
cable
Out
straight.
10.
Energize
the
welding
power
source.
11.
Hold
the
ADVANCE/RETRACT
Switch
in
the
ADVANCE
position
until
approximately
one
inch
of
wire
extends
Out
of
the
gun
tip.
12.
Shut
the
welding
power
source
down
until
ready
for
welding
operation.
SECTION
3
-
FUNCTION
OF
CONTROLS
Fingers
TC.078
036-lA
3-1.
ADVANCE/RETRACT
SWITCH
(Figure
3-1)
The
ADVANCE/RETRACT
Switch
provides
a
means
of
mov
ing
the
electrode
wire
either
in
or
out
of
the
gun
without
having
to
touch
the
electrode
wire
to
the
workpiece.
3-2.
ARC
CONTROL
(Figure
3-1)
while
the
HI
position
will
provide
a
faster
and
lighter
powered
wire
feed.
The
HI
position
should
only
be
used
when
the
setting
of
the
ARC
CONTROL
is
down
to
the
2
position
and
the
desired
wire
feed
rate
is
still
not
attained.
flTAN~)
The
ARC
Control
provides
a
means
of
determining
the
rate
at
which
welding
wire
will
be
fed
into
the
weld.
Rotating
the
ARC
CONTROL
in
a
clockwise
direction
(towards
the
10
setting)
will
decrease
the
rate
of
wire
feed
and
thereby
pro.
vide
a
longer
arc.
Rotating
the
ARC
CONTROL
in
a
counter
clockwise
direction
(towards
the
0
setting)
will
increase
the
wire
feed
rate
and
thereby
provide
a
shorter
arc.
3-3.
RANGE
SWITCH
(Figure
3-1)
This
control/feeder
is
equipped
with
a
RANGE
Switch
which
will
provide
two
wire
feed
speed
ranges.
The
LO
position
of
the
RANGE
Switch
will
provide
a
slow,
powerful
wire
feed
Do
not
change
the
position
of
the
RANGE
Switch
while
the
control/feeder
motor
is
operating.
Failure
to
comply
with
this
requirement
will
result
in
damage
to
components
of
the
control/feeder.
3-4.
VOLTMETER
(Figure
3-1)
The
Voltmeter
will
indicate
the
voltage
being
applied
to
the
control/feeder
motor
when
the
ADVANCE/RETRACT
Switch
is
in
the
ADVANCE
position.
The
Voltmeter
will
indicate
load
(arc)
voltage
while
welding.
SECTION
4
-
SEQUENCE
OF
OPERATION
4-1.
GAS METAL-ARC
WELDING
1
.
Make
all
necessary
connections
as
instructed
in
Section
2
of
this
manual.
2.
Place
the
RANGE
Switch
in
the
desired
position.
3.
Rotate
the
ARC
CONTROL
to
the
desired
setting.
4.
Energize
the
welding
power
source.
Prior
to
welding,
it
is
imperative
that
proper
protective
clothing
(welding
coat
and
gloves)
and
eye
protection
(glasses
and/or
welding
helmet)
be
put
on.
Failure
to
comply
may
result
in
serious
or
permanent
bodily
damage.
6.
Touch
the
welding
wire
to
the
workpiece
to
start
feeding
wire.
7.
To
stop
wire
feed,
pull
the
gun
away
from
the
workpiece.
The
welding
wire
and
all
metal
parts
in
contact
with
it
are
energized
while
welding.
Do
not
touch
the
welding
wire
or
any
metal
part
making
contact
with
it.
I
U
4-2.
SHUTTING
DOWN
1.
Breakthearc.
2.
Advance
or
retract
the
welding
wire
so
that
one
inch
of
wire
is
extending
Out
of
the
gun
tip.
3.
Shut
the
welding
power
source
down.
Ground
(Work)
Clamp
Figure
3-1.
Control
Location
U
I
5.
Through
use
of
the
ADVANCE/RETRACT
Switch,
ad
vance
or
retract
the
welding
wire
as
required
until
only
one
inch
of
wire
is
extending
Out
of
the
gun
tip.
Page
4
Wire
feed
stops
when
inching
or
welding.
Motor
stalls.
Feed
rolls
slip,
Kink
in
wire.
If
not
possible
to
straighten
kink,
remove
by
cutting
bad
portion
of
wire
off
and
feed
through
again.
File
sharp
end
of
wire
to
avoid
jamming
in
cable
or
nozzle.
Lack
of
pressure
on
wire
between
rolls.
Increase
pressure
by
turning
pressure
adjust
ment
knob
in
a
clockwise
direction.
Too
much
pressure
may
tend
to
crush
the
wire.
Drive
rolls
out
of
alignment.
Align
drive
rolls
per
item
2-5.
Wire
feed
motor
does
not
operate
when
inching
wire.
Also
inopera-
tive
when
arc
is
struck.
Poor
ground
clamp
connections.
Check
connection
at
work.
Attach
clamp
to
the
welding
power
source
ground
connec
tion
at
the
work
piece.
Shorted
motor.
Replace
motor.
TO
WELDER
OUTPUT
Figure
6-1.
Circuit
Diagram
Circuit
Diagram
No.
A-002
792-A
TO
INSTALL
REMOTE
SWITCI-1
REMOVE
3*
JUMPERS
-
-
~
~~OPTIONAL)
Paqe
6
SECTION
5-
MAINTENANCE
CAUTION
Ensure
that
the
control/feeder
is
completely
discon
nected
from
the
welding
power
source
prior
to
per
forming
any
maintenance.
5-1.
RELAY
ADJUSTMENT
(Figure
5-1
&
5-2)
In
order
to
obtain
maximum
relay
contact
life,
proper
relay
adjustment
must
be
maintained.
Relay
adjustment
should
also
be
checked
in
the
event
that
the
control/feeder
should
malfunction.
A.
Upper
Contact
Adjustment
1.
Close
the
relay
manually
by
applying
pressure
to
the
movable
contact
mounting
board.
2.
Slowly
release
the
pressure
being
applied
to
the
contact
mounting
board.
3.
The
two
movable
outer
contacts
should
touch
the
top
outer
contacts
simultaneously
if
properly
adjusted.
4.
If
the
contacts
are
not
properly
adjusted,
bend
the
arm
of
the
movable
contact
which
is
Out
of
alignment
in
order
to
synchronize
the
two
Outer
contacts
for
simultaneous
con-
tact.
B.
Lower
Contact
Adjustment
1.
Close
the
relay
slowly
by
gradually
applying
pressure
to
the
movable
contact
mounting
board.
2.
The
three
movable
contacts
should
touch
the
three
lower
contacts
simultaneously
if
properly
adjusted.
3.
If
the
contacts
are
not
properly
adjusted,
loosen
the
lock
ing
nut
on
the
lower
contact
or
contacts
which
are
out
of
alignment
and
then
rotate
the
lower
contact(s)
as
required
in
order
to
properly
align
the
lower
contact.
Ensure
that
the
locking
nut
is
tightened
after
alignment
in
order
to
avoid
unintentional
movement
of
the
lower
Contact.
~is-Aligne~
Arm
Here
Proper
Upper
Contact
Alignment
Figure
5-1.
Upper
Contact
Adjustment
Improper
Upper
Contact
Alignment
Adjust
Here
Locking
Nut
Proper
Lower
Contact
Alignment
Figure
5-2.
Lower
Contact
Adjustment
Improper
Lower
Contact
Alignment
TA-078
036-4
SECTION
6
-
TROUBLESHOOTING
Hazardous
voltages
are
present
on
the
internal
cir
cuitry
of
this
unit
as
long
as
power
is
connected.
Disconnect
power
before
attempting
any
inspection
or
work
on
the
inside
of
the
unit.
Troubleshooting
of
internal
circuitry
should
be
performed
by
qualified
personnel
only.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
It
is
assumed
that
proper
installation
has
been
made,
according
to
Section
2
of
this
manual,
and
that
the
unit
has
been
functioning
properly
until
this
trouble
developed.
Use
this
chart
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
procedures,
the
nearest
Factory
Authorized
Service
Station
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
TROUBLE
PROBABLE
CAUSE
REMEDY
No
welding
current
Ground
cable
from
welding
power
source
does
not
make
good
contact
with
work,
Clean
area
of
work
and
clamp
ground
cable
tightly.
Electrode
cable
from
welding
power
source
does
not
make
good
contact.
Check
connections.
Erratic
weld
operation
and
arc
length
varies
Poor
ground
cable
connection
at
work.
Clean
area
of
work
and
clamp
ground
cable
tightly.
Poor
electrical
connections.
Check
and
tighten
all
electrical
connections.
I-
OM-1
502
Page
5
October
1977
FORM:
OM-15025
Effective
With
Serial
No.
HH083034
MODEL
STOCK
NO
2900
CONTROL/FEEDER
3/32
Wire
078
036
7/64
Wire
078
037
1/8
Wire
078
038
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
Factory
Part
No.
Item
No.
Description
Quantity
Figure
A
Main
Assembly
075
242
CONTROL
BOX
(See
Fig.
D
Page
6)
1
602
120
SCR
EW,
machine
.
steel
round
hd
1/4-20
x
3/4
3
2
602
207
WASHER,
steel
-
lock
split
1/4
3
3
601
865
NUT,
steel
-
hex
full
1/2-20
3
4
005
538
BASE
1
5
601
944
SCREW,
cap
-
steel
hex
hd
5/16-18
x
3/4
16
6
058
432
HUB
&
SPINDLE
ASSEMBLY
(consisting
of)
1
7
605
946
.
PIN,
cotter
1/8
x
1
1
8
602 249
.
WASHER,
flat
-
steel
SAE
5/8
1
9
058434
.SPINDLE,support-hub
1
10
010191
.WASHER,fiber5/8IDxl-1/2ODxl/8
2
11
058
628
.
WASHER,
steel
-
brake
2
12
058428
.HUB,spool
1
13
057
971
-
WASHER,
flat
-
steel
keyed
1.1/2
dia
1
14
010
233
.
SPRING,
compression
1
15
605
941
.
WASHER,
flat-steel
41/64
ID
x
1
OD
1
16
601
884
.
NUT,
steel
-
hex
jam
5/8-11
1
17
058427
.
RING,
retaining-spool
1
18
056416
REEL,wire(SeeFig.EPage7)
1
19
073
311
CASTER,
stationary
-
rubber
3
inch
bolt
down
2
20
604
537
NUT,
steel
-
hex
full
5/16-18
16
21
602
211
WASHER,
steel
-
lock
split
5/16
16
22
073
310
CASTER,
swivel
-
rubber
3
inch
bolt
down
1
23
601
967
SCREW,
cap
-
steel
hex
hd
3/8-16
x
1-1/2
3
24
602
213
WASHER,
steel
-
lock
split
3/8
3
25
010
910
WASHER,
flat
-
steel
SAE
3/8
3
26
075
150
WASHER,
shoulder
-
nylon
3
27
074
774
INSULATOR,
motor
&
drive
assembly
1
28
075 239
MOTOR
&
DRIVE
ASSEMBLY
(See
Fig.
C
Page
4)
1
See
Fig.
Fig.
C
-
Fig.
E
TD-078
036-A
Figure
A
Main
Assembly
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1502
Page
1
Control!
Feeder
Wire
Diameter
And
Type
Kit
No.
Gear,
Pressure
And
Drive
Gear
And
Bearing
Wire
Guide
No.
Fraction
Decimal
Metric
Inlet
Outlet
078
036
3/32
flux
cored
wire
.093
2.4MM
076
200
074
845
(pressure)
073
351
(bearing)
074
855
(gear)
074 860
074
791
074
836
(drive)
078
037
7/64
flux
cored
wire
.109
2.8MM
076
201
074
846
(pressure)
073
351
(bearing)
074 856
(gear)
074
860
074
791
074
837
(drive)
078
038
1/8
flux
cored
wire
.125
3.2MM
076
202
074
847
(pressure)
073
351
(bearing)
074
857
(gear)
074
860
074
791
074
838
(drive)
Figure
B
Kit,
Drive
Gear
&
Guide
Tube
Gear,
Pressure
TB-078
036-3
~Inlet
Guide
bq
Outlet
Guide
Gear,
Drive
OM-1502
Page
2
Item
No.
51
52
53
54
55
075
275
074
780
073
308
073 307
074
771
Factory
Part
No.
Description
Quantity
Figure
C
075
239
Motor
&
Drive
Assembly
(See
Fig.
A
Page
1
Item
31)
MOTOR,
drive
(consisting
of)
SHAFT,
idler
gear
BEARING,
ball
RING,
retainer-
external
GEAR,
spur
-
steel
40
pitch
43
tooth
51
2
Figure
C
Motor
&
Drive
Assembly
TD-075
239A
Page
3
Factory
Part
No.
Item
No.
Description
Quantity
Figure
C
075 239
Motor
&
Drive
Assembly
(See
Fig.
A
Page
I
Item
31)(Contd)
074
781
.
STUD,
steel
12-28
x
1-3/4
073597
BEARING
073610
.ARMATURE
073
598
.
SPRING,
brushholder
077
214
.
HOLDER,
brush
073
595
.
CAP,
brush
holder
*073611
.BRUSH,contact
073
593
.
WASHER,
spring
073596
.BEARING
073
296
.
CLAMP,
cable
-
amphenol
97-3057-12-6
073
295
-
PLUG,
amphenol
4
pin
97-3106A-20-4P-639
074
768
GEAR,
drive
073268
BEARING
WASHER,
flat
-
steel
SAE
3/8
WASHER,
lock
-
steel
3/8
LEVER,
mounting
-
drive
gear
WASHER,
flat
-
steel
SAE
5/16
WASHER,
lock
-
split
5/16
SCREW,
cap
-
steel
hex
hd
5/16-18
x
1
BUSHING,
9/16-18
x
1-13/32
w/3/4
hole
SCREW,
cap
-
steel
hex
hd
3/8-16
x
2-1/4
KNOB,
plastic
2
inch
dia
SPRING,
compression
ARM,
adjustment
-
pressure
roll
(consisting
of)
.FASTENER,
pin
BLOCK,
pressure
-
stud
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
3
2
2
2
2
1
3
4
2
1
1
1
4
2
2
2
1
010 910
602
221
074
902
604
538
602
211
601
948
074
811
605
209
073
356
073
303
074
783
076
647
076
682
010
324
074
778
056
068
073
309
073
240
074
858
602
247
602
216
601
881
602
177
601
967
602
213
078
880
079
375
078
881
078
882
078
751
078
687
078
858
073
306
074 775
078
879
075
229
073
302
073
300
-
PIN,
spring
-
compression
SHAFT,
drive
-
feed
roll
KEY,
steel
1/8x
1/8x
1/2
SEAL,
oil
-
drive
shaft
RING,
retaining
-
external
1.375
dia
x
.050
TUBING,
steel
.8750D
x
.593
ID
x
.303
WASHER,
flat
-
steel
SAE
1/2
WASHER,
lock
-
spIlt
1/2
NUT,
steel
-
hex
jam
1/2-20
SCREW,
set
-
steel
socket
hd
1/4-20
x
1/4
SCREW,
cap
-
steel
hex
hd
3/8-16
x
1-1/2
WASHER,
lock
-
steel
split
3/8
SCREW,
cap-
steel
socket
hd
5/16-18
x
1-1/2
HOUSING,
adapter
-
right
hand
gun/feeder
SCREW,
cap-
brass
hex
hd
3/8-16
x
2-1/2
WASHER,
lock
-
brass
split
WASHER,
flat
-
brass
SAE
3/8
WASHER,
lock
-
steel
split
No.
12
NUT,
steel
-
hex
full
12-28
RING,
retaining
-
internal
.594
shaft
x
.035
COVER,
bearing
SCREW,
machine
-
steel
truss
phillips
hd
10-24
x
1/2
HOUSING,
drive
(consisting
of)
BEARING,
ball
RING,
retaining
-
internal
.669
shaft
x
.035
3332
12
107
074
826
GEAR,
helical
-
bronze
12
pitch
30
tooth
108
076871
PIN,spring-compression
109
074
821
GEAR,
miter
-steel
12
pitch
110
078672
PIN,
spring,
compression
111
073
304
GASKET,
cover-
housing
drive
112
074
777
COVER,
housing
-
drive
078
687
WASHER,
lock
-
steel
split
No.
12
(attaching
motor)
078
858
NUT,
steel
-
hex
full
12-28
(attaching
motor)
*Recommended
Spare
Parts.
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1502
Page
4
3
3
1,
CD
C)
0
-p
0
w
0
CD
01
m
-a
(4
C
Item
Dia.
Factory
No.
Mkgs.
Part
No.
Description
Figure
D
075
242
Control
Box
(See
Fig.
A
Page
1
Item
1)
Quantity
*Recommended
Spare
Parts.
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1502
Page
6
126
CB1
2
~073
349
CIRCUIT
BREAKER
thermoauto
reset
l5amp
2
127
S2
011
233
SWITCH,
toggle
SPDT
10
amp
250
volts
ac
1
128
076848
PANEL,side-cabinet
1
129
CR1
073
384
CONTACTOR,
current
3P
(See
Fig.
Dl
Page
6)
1
130
074
897
CABLE,
power
1
131
010
286
WASHER,
flat
-
brass
std
1/2
2
132
074
869
WASHER,
shoulder
-
fiber
1
133
074
964
COVER,
receptacle
1
134
RC1
073
293
RECEPTACLE,
amphenol
4
hole
97-3102A-20-4S-639
1
135
073344
GROMMET,rubber3/8lD
1/2
hole
1/l6groove
2
136
R3
079015
RESISTOR,WWfixed300watt4ohm
1
137
076
258
STUD~
steel
10-32
x
9-1/2
3
138
074871
TUBING,fiberi-3/8ODx41/64IDx1/2
1
139
601
839
NUT,
brass
-
hex
full
1/2-13
140
074868
BUS
BAR
141
078
754
WASHER,
lock
-
bronze
-
split
1/2
142
052711
CABINET,control
143
R4
073343
RESISTOR,WWadj300watt4ohm
144
R2
073336
RESISTOR,Wwfixed300watt8ohm
145
601
158
BLANK,
snap
in
7/8
inch
146
010
610
CONNECTOR,
clamp
-
cable
1/2
inch
147
074
788
CABLE,ground
10
ft.
(consisting
of)
148
601
222
.CLAMP,
universal
50
amp
lead
plated
149
073
138
074
451
.
CABLE,
power
12
ga
1
conductor
600
volt
(order
by
foot)
.
TERMINAL,
ring
tongue
150
073314
TERMINAL,cable
1/0-4/0
225
amp
151
073
387
BUSHING
&
NUT,
bakelite
3/4
152
Ri
073
342
RHEOSTAT,
WW
300
watt
4
ohm
1
153
010489
TUBING,steel.275lDx1/i6wallx3/4
2
154
Si
073
385
SWITCH,
rotary
3
position
6
pole
10
amp
240
ac/i
25
volts
dc
1
155
NAMEPLATE
(order
by
stock,
model,
&
serial
numbers)
1
156
V
073260
METER,voltdcO-50
1
157
073
291
KNOB,
rheostat
1
2
3
15
ft.
Item
No.
Factory
Part
No.
Figure
Dl
Contactor
TA-073
384
Description
Quantity
Figure
Dl
073
384
Contactor
(See
Fig.
0
Page
6
Item
129)
166
167
073
394
*073
388
CONTACT,
contactor
-
movable
center
CONTACT,
contactor
-
movable
outside
1
2
168
169
170
171
*073
391
*073
390
*073
389
*073393
CONTACT,
contactor
-
flash
CONTACT,
contactor
-
stationary
outside
CONTACT,
contactor
-
stationary
outside
SPRING,contactor
1
2
2
1
Item
No.
Factory
Part
No.
Figure
E
056
416
Reel,
Wire
(See
Fig.
A
Page
1
Item
18)
Description
Quantity
181
056314
REEL
.
1
182
010
910
WASHER,
flat
-
steel
SAE
3/8
2
183
601
964
SCREW,
cap
-
steel
hex
hd
3/8-16
x
3/4
1
184
056312
FINGER,reel
4
185
604
051
NUT,
steel
-
wing
1/2-13
4
186
056
313
STUD,
steel
1/2-13
x
7
4
187
010
224
PIN,
spring
-
compression
3/16
x
1
4
188
601
880
NUT,
steel
-
hex
jam
1/2-13
4
181
186
185
TC-006
516
Figure
E
Reel
Assembly
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Page
7
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Miller 2900 CONTRO Owner's manual

2900 CONTRO
Miller
Brand
Miller
Model
2900 CONTRO
Category
Welding System
Type
Owner's manual
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