Miller Boost Circuit Board Assembly NO. 200841

Hello everyone,

Let me tell you small story

While back I have purchased dead "MIller Dynasty 200DX"

After some repairs I have found damage to Boost Board that has internal ground planes burnedout.

I have realisedthat i would need board replacement, however, board is dicontiniued and replacement board will cost me 2000 dollars if I found one.

After fiew hundret emails and phone calls to different suppliers without even one ansfer I have desided recreate board from scrach and make my own.

Fiew month later after reverse engineering pcb to schematic and later on from schematic to PCB i have finally received new boards.

I have solder necesseryparts and run test on new assembled board, however, I have forgot take a maguments from resistor R86

Could some one be so kind and provide value number between pin 2 & 3 on R86?

Here is some pictures from original board and final my creation:

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jw0752 over 3 years ago +4

Hi Alex,

Reverse engineering a board of this size and complexity is a monumental task. Congratulations on what you have accomplished. Sorry I don't have the information you are looking for but your work…
lanuser over 3 years ago in reply to jw0752 +2 suggested

Josh,
First of thank you for your reply.
Is to easy to reverse engineering this board, however, it is time consuming a speacially when team of one working on entire project.
I'm planing some changes for Rev…
alvideo 4 months ago in reply to guillermo +2

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…

Parents

0 johnconnor 8 months ago

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.
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0 A3JBNE 8 months ago in reply to johnconnor
(R6 = 0.27ohms 3W) (R7 = 1.5K) (C5 = 1nF) (Q3 = 2n3904 NPN)
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0 alvideo 4 months ago in reply to guillermo

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.
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0 mb443 4 months ago in reply to alvideo

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.
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0 lanuser 4 months ago in reply to guillermo

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.
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0 lanuser 4 months ago in reply to alvideo

Alvideo,

I would disagree about your answer:

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

Of course not,

DX200

It is reliable unit with really interesting analog design and not some digital 90% crap with fail rate of 60% in first couple years regardless of the brand.
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0 guillermo 4 months ago in reply to alvideo

very insteresting...
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0 lanuser 4 months ago in reply to mb443

Is your IGBT working condition?

Do you have equipment to run some test?

We need to test some electrical Characteristics of the IGBT.

Or tell us what type of IGBT test you are able to complete?
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0 guillermo 4 months ago in reply to lanuser

how do you do it to replace the IGBT Q11 (IRG4PH50UD) when it fails if it is obsolete for years?
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0 lanuser 4 months ago in reply to lanuser

Don't know about you, however, check ARROW I have purchased couple OEM.

Since this part available IRG4PH50UD I have not looked for alternative, waste of time at this point.

If I gonna search for alternative replacement for IRG4PH50UD there will be way better replacement part buy the time this part become 100% obsolete.
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0 mb443 4 months ago in reply to alvideo

Idea of aluminum PCB sounds ideal for this application! And standalone bridge is also makes more sense.
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0 mb443 4 months ago in reply to lanuser

I can try to test my PM which is in "Unknown" condition, tomorrow, hope at least one IGBT is there alive. You may need to give me small direction on what need to be tested. Can try to measure gate - emitter capacitance. Will wait for directions...
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0 mb443 4 months ago in reply to lanuser

I can try to test my PM which is in "Unknown" condition, tomorrow, hope at least one IGBT is there alive. You may need to give me small direction on what need to be tested. Can try to measure gate - emitter capacitance. Will wait for directions...
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0 lanuser 4 months ago in reply to mb443

As of now this project needs New Topic.

Become a mess for topic: Miller Boost Circuit Board Assembly NO. 200841

This should only discuss Boost Circuit Board and NOT entire DX200

@mb443 Start new topic some like: Miller Dx200 IGBT project, I will follow.
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0 lanuser 4 months ago in reply to mb443

By any chance, does anyone here has a schematic for foot pedal control?
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0 mb443 4 months ago in reply to lanuser

@lanuser sure, I opened a new discussion: "Miller DX200 Welder Power Module SEMIKRON SkiiP 33NEC125T2

community.element14.com/.../197337
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0 mb443 4 months ago in reply to lanuser

As of pedal I have a schematic diagram, but never compared with original, not 100% sure if this fits DX200
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0 lanuser 4 months ago in reply to mb443

Awesome,

Thank you for the Miller "foot control" information!
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Miller Boost Circuit Board Assembly NO. 200841

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@mb443 Start new topic some like: Miller Dx200 IGBT project, I will follow.