Miller Blue Star E-2 automatic throttle control

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I have a friend who has a Miller Blue Star welder and the automatic throttle control isn't working. The control has a solenoid with 2 wires going to it. Can someone explain to me how and from where from the control voltage is generated? I know nothing about welding but a little about electricity. Is the voltage variable or constant? Thanks for any information.   Bill
Reply:Welcome to the forum shu7241.

The Auto Idle solenoid recieves its power from the ignition (RUN/STOP) switch and the ground is controlled by the Auto Idle ON/OFF switch or Auto Idle control board.  The ground signal to the solenoid is either on (weld) or off (idle).  The Blue Star circuitry is fairly simple and to get a copy of the manual that includes the wiring diagrams and all the information needed to troubleshoot it can be found here http://www.millerwelds.com/service/ownersmanuals.php by selecting the correct unit and entering its SN.Good luck and keep us posted.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110

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Reply:Thanks Duane. The welder has a drawing on it but it doesn't show the control board. I will look at welder later and get serial number to use site you suggested. There is a heavy wire coiled around a bracket, near a coil. I believe the coil picks up a voltage and sends it to the control board where it is rectified and sent to the solenoid. I believe the rectifiers are bad but the control board is hard to get to and I wanted someone to confirm my thinking before trying to get control board off the welder. I hope that isn't to confusing. Thanks again for info and any other help I receive.   Bill
Reply:The coil you refer to could be the current transformer (CT1) that senses weld output and signals the Auto Idle control whenever a load is placed on the welder.  When you get the wiring diagram you'll see what I'm talking about.Keep us posted.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110

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Reply:My son has a miller big 40 and the smaller CT that sends the signal to the control board is open. Called miller and they no longer make this part. Any ideas how I can get a replacement one part # is miller ct1 081-359 idle control transformer.
Reply:I may have one on a parts machine.  Let me look a bit later and I'll get back to you.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110

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