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[jjohn76]

How far in does your tip recess?...

[jjohn76]

Burnt Hands, it doesn't look like he should need that rectifier, but if you're looking for a new home for that 400 GTSW... There was one for sale in Seattle I just missed....

[jjohn76]

Noel, if you could please include a model and serial number, we could provide further assistance. Just kidding... What does the display look like in your truck?...

[jjohn76]

Thank you Aero. I cheated on that one trace and just soldered in a jumper on the back side.



Those two ICs didn't want to solder to the board. I think it had to do with the ground and power planes needing too much heat, but couldn't explain the other leads.

I...

[jjohn76]

Oscar, I had a Miller CP-300 running that Fabco Triple 7.045 almost as fast as the R-115 could run it, just over 320 amps and somewhere around 33V, and I could not keep up with the puddle. It was holy hot on the hand for the 4" bead I ran. I'd show the cold laps, but I still want to be allowed...

[jjohn76]

Ryan, it sounds like you had the relay coil leads (the two closest to the panel) connected to the contacts' leads, and vice versa, so when you turned on the contactor, the HF primary winding energized relay CR2 and shorted the control transformer, blowing fuse F4 in the process. Does that sound right?...

[jjohn76]

Actually, nevermind, that won't work. Sorry for the confusion...

With the machine powered off and HF in start you should have continuity across those two wires. For any other HF setting you should have an open across those two wires....

[jjohn76]

I always have problems desoldering and removing chips from the board, so I typically cut the chips from the pins using a cutoff wheel on a dremel, then solder, heat and remove the pins individually. The middle of the photo shows how I cut it.

This usually works well, except when it doesn't......

[jjohn76]

Aero, I am pretty sure Voltage regulator VR4 (takes the incoming regulated 30V and drops it down to 15V for the inverter board power supply controller and the boost PFC controller) is what failed in this Dynasty 200SD. It is toast, which likely let 30V into the 15V circuits and killed the components...

[jjohn76]

No problem. One last thing you can check while there is to make sure your wiring is good from the relay to the HF switch. With your power off, put the HF switch in either "Off" or "Start" and check continuity across the other two wires on that relay. They should be open. Now turn...

[jjohn76]

The replacement relay is a Deltrol 20552-84. It looks like a special order if you buy OEM (Galco shows a 19 day lead time). It's Miller Part number 052603, and is around $40, on eBay or millerserviceparts....

[jjohn76]

Ok, so it's likely your relay. When you pull the four wires, keep track of where they go. You need to keep 63 and 64 on the right terminals, otherwise the relay coil will not work correctly. The other two wires need to be in the normally open connections (best just to take a pic...). When you remove...

[jjohn76]

Have you tried the .045 dual shield on it yet? That might be alot to ask of the wire feeder moreso than the power supply- long term it might overwork the feeder motor. There are some .035 FCAW-G options that may work well. I set up an XMT 304 with suitcase feeder to run .035 FCAW-G, which the operator...

[jjohn76]

These two actuate the relay. Note where the little black ribs are located (vertical and horizontal ones).

...

[jjohn76]

Ok, one is the one on the right side as you took the picture, it should be the closest terminal to the panel. The other one is directly to the left of it. Hopefully that makes sense.

If you can read the numbers on the wires it should be 63 (+) and 64 (-)....

[jjohn76]

I received most of the parts today, just before I realized I already had but couldn't find those parts... Thanks again Franz...

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[jjohn76]

Sounds good, please be careful checking the 163V DC, as it can be lethal voltage....

[jjohn76]

Gocha, does the top right relay click on when you press the pedal? If not, it means either power isn't getting to relay CR2 or relay CR2 is bad. It's probably difficult to get a multimeter on the relay coil inputs. The relay connectors should look similar to this



When you...

[jjohn76]

Sounds good. Hopefully my post #20 above makes sense. It is from one of the very early manuals and tells you what the relays should do depending on your settings....

[jjohn76]

Gocha, are you talking about the capacitor in the HF circuit down by the start timer and gas/water valves? That and the HF transformer are good if it works on HF continuous. Your problem is either at the HF switch on the front panel, the relays on the right side, or the wiring in between. If the components...