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jjohn76
Senior Member
Last Activity: Today, 08:26 AM
Joined: 08-13-2018
Location: Tacoma, Washington
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  • jjohn76
    replied to Syncrowave 300 OCV weld problem
    Just to feed back to you, AC and DC get correct OCV and amperage consistently unless the HF is firing, whether continuously or in start with contactor on. Sounds like you have narrowed it to interference from the HF circuit. Have you checked continuity on the HF bypass circuits, R11-C13 and C15, C16....
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    Last edited by jjohn76; Yesterday, 02:44 PM.

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  • jjohn76
    replied to Synchrowave 300 need help
    Sounds good. Most of these things you can troubleshoot with a multimeter. If they didn't do what they said, it could either be the hall device, amplifier board (between hall device and main board), or the main board. I think you are running down two issues though, since the amperage control issues are...
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    Last edited by jjohn76; Yesterday, 11:02 AM.

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  • jjohn76
    replied to Synchrowave 300 need help
    Did they tell you what they checked? The Lo/Hi Range switch doesn't change anything on PC1. It basically just adds another couple coils on the primary side of the hall device, so the board thinks it's providing three times the current. Miller also added a second output inductor in series with the main...
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  • jjohn76
    replied to Syncrowave 300 OCV weld problem
    I would check for loose/spotty connections to or from your SCRs. It almost sounds like either one of your SCR diagonals (SCR1 and SCR3 or SCR2 and SCR4) is not firing consistently. The main board fires each diagonal individually through two separate gate drive transformers (FC1,2). I would check the...
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  • Yeah, you should be seeing 1k ohms between C and D, and pin E - D resistance should vary from ~0 ohms to 1k ohms. Pins A (power) and B (return) carry the 24V that trigger the contactor/relay, but I am pretty sure that is off the control board on the Syncrowave (relay CR2)- it could burn the traces on...
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    Last edited by jjohn76; 07-27-2020, 07:06 AM.

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  • The only way I know to test the lem modules is to power them and flow known current values through them.

    Quick glance, R90 looks like it limits current in your remote amperage circuit. If you're pedal worked fine with the machine, it could be that there is a short in your finger control...
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    Last edited by jjohn76; 07-26-2020, 09:39 PM.

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  • What is the assembly number on the board and the resistor number? That resistor looks like it is part of the SCR gate drive section. It's hard to tell what caused it to burn, but I don't see how the trigger switch was causing it unless the high voltage bypass/protection circuit on the remote input wasn't...
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  • jjohn76
    replied to Your Welding Career
    I think so. It's all relative though, given the craziness in Seattle...
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  • jjohn76
    replied to Your Welding Career
    Army. Engineer.
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  • jjohn76
    replied to Dynasty 200 DX low output
    Nice! If the CK-26 is too bulky, a TL-26 is about the size of the CK-17 but handles a much higher power rating. I use mine with the two-piece cables, and haven't had a heat problem on some 1/4" AL projects.

    Bushy, how much worse is the HF problem with higher impedance sensors? I am...
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  • jjohn76
    replied to Your Welding Career
    Not sure what to say, other than 20+ years in the military now seems less than uneventful compared to that...
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  • jjohn76
    replied to Dynasty 200 DX low output
    Sorry I hadn't seen this message before. For some reason, I was only able to see it this morning. R1 showing heat on the interconnect board is common. Those 4 matching resistors limit the current to the bootstrap power supply (zener diode) and take quite a bit of voltage across them. Over the product...
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  • jjohn76
    replied to Dynasty 200 DX low output
    Thanks Bushy. That's odd, the tech manual says it should vary 0-10V. It isn't the first typo on a pin voltage in that manual...
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  • jjohn76
    replied to Dynasty 200 DX low output
    Bushy, the reference amperage to/from the pedal is from 0-10 V, with 10V as max amperage in this case 200a. On the remote socket, pin D is your reference, pin C is the panel amperage to the pedal, 0-10V DC based on 0-200a set at the panel. Pin E is your remote amperage 0- voltage on C. That's in line...
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    Last edited by jjohn76; 07-09-2020, 09:59 PM.

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  • jjohn76
    replied to Dynasty 200 DX low output
    Have you already checked the ribbon cable from the front board to the inverter control board? What is the output voltage on the DC bus? How are you checking amps? I haven't tried it on a Dynasty 200, but usually crow bar the outputs to run my amperage tests. Start with it in stick mode, minimum amperage...
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