Miller Boost Circuit Board Assembly NO. 200841

Hello friend, I congratulate you on the tremendous task of doing reverse engineering to a printed circuit.

I bought a bad Dynasty 200 machine in a mess.

When I opened it, I found faults in the 200841 card where it has the Q3 transistor exploded, the resistance R7 charred and C5 as well.

The transistor is a 2N3304 (I don't know if it's PNP or NPN), the C5 seems to be 1 nano Farad / 400V.

Also the 207818H board has the R6 burst / charred resistor and the IGBT Q11 (G4PH50UD) shorted.

If you could help me with the values of the resistors it would be great.

Here there are many who have the original service manual with the circuit diagram but nobody helps you, finally buy it for a specific case like this but not even that. !!

Anyway, I hope you can help me please.

(R6 = 0.27ohms 3W) (R7 = 1.5K) (C5 = 1nF) (Q3 = 2n3904 NPN) 

hi Mister, 

I was able to repair the two cards of the Dynasty 200, BUT I had the unpleasant surprise that the machine did not work when I turned it on.

I followed the Pre-Power Check procedures manual and the igbt controlled PM1 is damaged (PC2 board). (Semikron SKiiP 33NEC125T2). attached photos.

Do you know who can sell it?

From already thank you very much.

Official Miller Authorized repair center " IF" they have one in stock.

Get ready to spend approx. $1500 for the part ( that price 4 years ago )

Now days because of Covid ,  no availability components in general  and if someone has one in stock I would say 2000k +  ( for that price you could get new alternative unit. )

I got mine of supplier from China for $700 

There is also a problem: To obtain a IGBT component datasheet! This specific part has copy wright by Miller and Original manufacturer won't release it. 

Remember -> any DX 2000 series welder equipment has been release early of 2003 therefore no manufacture will continue make obsolete part for 19 years.

I was trying to use new type of IGBT/FETS to replace this old garbage and wasn't able to get datasheet for pinout.

There was other option to use bottom power distribution board that lays on top of IGBT... to reverse engineer... but I would need actual DX 2000 schematic from Miller. you know my chances of me getting actual datasheet? = 0

Good luck with hunting. 

if I understand what you say.

How was your experience with the Chinese copy of that IGBT bridge?
or was it used?
I have seen several ads on Aliexpress for this component and they cost what you say (U$ 700 approx.).

my fear is that it's pirated junk, a painted case that doesn't work. In China there is a lot of Counterfeit electronics, for this we have the page UTSOURCE and MANYCHIPS famous for their scams.

let me know how it went with the one you bought in china and the details of who sold it to you.

Thank you.

From China used tested part. ( we have supplier in China and yes, in the past we received fake parts like everyone else )

When you realize that you can't purchase original IGBT, regardless of the reasons only then you will start search for alternative IGBT replacement. 

DX200 It is outdated excellent unit with original price sticker $5K +

Now because of single IGBT component entire welder  can be used for scrap.

So.... instead of finding original IGBT I can build better one with new type IGBT FET and with higher amperage.

IGBT contains:

1. FETS
2. DIODS
3. Temperature resistor.

However, without original IGBT datasheet or Miller DX200 series schematic I can't move forward.

if decided to reverse engineer the Power Module to replace w/ ext IGBTs then count me in if help w/ the project needed. 

As I've located it's a MiniSKiiP3 form factor with: 1200 V up to 150 A IGBTs
some general info can be found at: docplayer.net/101233838-Miniskiip-power-modules.html

But as custom made for Miller it may or may not include pfc (power factor correction) IGBT... and possibly isolated thermo resistor from the -DC

I have a feeling it shouldn't be much different from standard NEC below except it seems has less than 6 IGBTs in package

I have one none working IGBT, however, in general I understand what and how inside of IGBT but I am not a component engineer.

Most important is to pinout correctly oem IGBT.

I have one none working IGBT, however, in general I understand what and how inside of IGBT but I am not a component engineer.

Most important is to pinout correctly oem IGBT.

In market You can't find any similar IGBT module, don't waste time. Module is very specific, it has PFC and also active snubbers IGBT. 

I started make my own PCB on external IGBT, but not finished yet......

https://drive.google.com/drive/folders/1MjTxi0BoNROP2rk7OWY194t6Mi4Pvw8m?usp=sharing

Wow! You actually got it done Jon! Have you got it to work or still in design phase? What was your plan, to bolt the new PCB right to radiator on the same spot as original power module or some other way externally? If so, then I guess  the rectifiers are on a separate module placed next to IGBTs? 

hmmm...

The project looks interesting, but I have doubts about how you can get there and impose a certain IGBT, not knowing the electrical parameters of the ORIGINAL.

Semikron does not provide this information because it signed an OEM contract with MILLER, that is, it is SECRET.

I'm more open to finding a Semikron replacement by reverse engineering its components than buying overpriced counterfeit Chinese junk on Aliexpress.

or in the worst case replace that module with IGBTS singles.

The subject is very tedious and complex ...

Will it be worth so much effort for an old machine?

Wouldn't it be better to buy it used at a Miller disarmament store in AMERICA?

Also, if you see any here, it makes the technical manual available, knowing that the patent has ALREADY EXPIRED.
they don't even want to sell it.!!

I really appreciate the help of some who contribute.

I feel helpless knowing that there is no one who sells this module, not even Miller responds to my messages.

Can someone here buy this module in Germany and test the pinout with the original SKiiP 33 NEC 125 T2??

www.tme.eu/.../SKIIP35NAB12T4V1.pdf

www.semikron-shop.com/.../skiip-35nab12t4v1.html

By nomenclature, the ORIGINAL is 50A/1200Vdc, I don't know the curves and so on, but according to the pre-CHECK power manual, the review of the PM1 module does have a three-phase bridge, a T° sensor, and 6 igbts with anti-parallel diodes.

I therefore suspect that this Semikron 35NAB module could be an ideal candidate to replace the Miller original.

What do you think of the pinout that needs to be modified ??

General pinout has been completed and (untested).

PCB in the image incomplete ( no heat dissipation, however, idea is correct )

Work is still in design phase,  My idea is make aluminium oxide PCB, and screw pcb straight to radiator instead  original module. And after solder wires.

Because there is a lof of space, i think to mount 3 phase bridge on radiator side like this 

https://www.amazon.in/Anbau-MDS100-16-3-Phase-Rectifier-MDS100A/dp/B07GLXB5HH            

guillermo said:

I have doubts about how you can get there and impose a certain IGBT, not knowing the electrical parameters of the ORIGINAL.

If You have understanding welding machines architecture and principles, this task is not very difficult. This project not first to  me. Before  i made my own pcb for Kemppi Minarc Evo 200 module, welder working over 2 years. 

So You need know module made on Mosfet or IGBT. In this case Miller use IGBT.

Because DC bus is +840V, so IGBT needs for 1200V. 

Miller 200 Dynasty output amperage is 200, so one IGBT 40A  is enough. 

Next important parameter is input capacitance.... It's easy to measure on damaged module. So i don't see big seecrets. 

guillermo said:

Will it be worth so much effort for an old machine?

Of course not, but it's my hobby, for me it's interesting and challenge. 

Guys, please let me know if anything I can help with, I do have an old power module, original. Anything need to be checked measured? I'd be glad to help. 

Idea is-------->>>>>>> Walk away from overpriced or obsolete SKIPP technology all together and not to pray on single company when their product is no longer available.

However, Skipp  product line of IGBT modules are reliable and some units work for over 15 years.

Reason why IGBT going bad:

Answer: 90% LDO Fails on Booster Board sending across entire board 20-30 volts.

Alvideo,

I would disagree about your answer: 

Will it be worth so much effort for an old machine?