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Ask an Expert Forum Miller Boost Circuit Board Assembly NO. 200841
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Related

Miller Boost Circuit Board Assembly NO. 200841

lanuser
lanuser over 3 years ago

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
    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
    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
    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
  • johnconnor
    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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  • A3JBNE
    0 A3JBNE 7 months ago in reply to johnconnor

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

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  • mb443
    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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  • lanuser
    0 lanuser 4 months ago in reply to mb443

    Good idea for production but not cost effective for small quantity, there also space between radiator and Main Power Distribution Board, therefore I have a question:

    To avoid soldering any wires between boards how can we mate new w/old board?

    Jumping ahead of our self. )

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  • alvideo
    0 alvideo 4 months ago in reply to guillermo
    guillermo said:
    IRG4PH50UD

    i replaced with IRG7PH42UD about 2 years ago. Machine still working. 

     

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  • lanuser
    0 lanuser 4 months ago in reply to alvideo

    Thank you for the update.

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  • mb443
    0 mb443 4 months ago in reply to guillermo

    @lanuser I tested my PM and it turned out to be both IGBTs are dead, so now I'm more than interested to either replace burned IGBTs inside of the PM if that's kind of repair is doable at all or implement as external version based on @alvideo schema of the power module. Anybody any updates?

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  • lanuser
    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 Slight smile

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

     

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  • lanuser
    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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  • mb443
    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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  • mb443
    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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  • lanuser
    0 lanuser 4 months ago in reply to mb443

    Awesome,

    Thank you for the Miller "foot control" information!

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  • lanuser
    0 lanuser 4 months ago in reply to mb443

    Awesome,

    Thank you for the Miller "foot control" information!

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