Miller Aerowave owners, need help with identifying a resistor

[Strouty]

Anyone willing to open up the top of their machine? I have a burnt out resistor and it is not identifiable anymore. The board should be accessible from the top or maybe a side, it is shown on the diagram. I am looking for the colors on resistor R1. If I can figure out the resistor I can at least try and replace it, but with no value, I don’t dare guess. I have the technical manual from Miller and it doesn’t offer any detail of the circuit boards for this machine.

[Strouty]

I know these are a tough machine to even want to fix, but someone must own one and be willing to help a guy out.

[farmersammm]

I know these are a tough machine to even want to fix, but someone must own one and be willing to help a guy out.

https://drive.google.com/file/d/1Vcs...EzlKHUiN4/view

Shows resistor values in parts list, but who knows if it's even your Aerowave (shrug). Call Miller.

Quote: "Resistor R-1 , WW fxd 30W 25 ohm

[farmersammm]

Didn't mean to quote ya Must have hit wrong button

[Strouty]

None of the manuals break down the individual resistor values for this board, the part you are looking at is for something completely different, if you look at the diagram it isn't even in the same location. Here is what the part you are seeing looks like:

https://www.amazon.com/Miller-141424.../dp/B004HE6A18

[86turbodsl]

PM pat_h. He has one.

[Strouty]

Spoke by PM, depends on access time to get to it. May have to wait a bit.

[86turbodsl]

Glad you got a hold of him. He's the only one i know of on this board that still has one. They are pretty rare these days.

[pat h]

It's negative 7f this morning here, another place to try is instagram and search # welder repair or aerowave I know someone goes by @arc doctor or@mxrider168 and few others on there, otherwise I'll get out there as soon as I can get some help weather /health is not the greatest lately, craigslist chicago had one for sale recently but I don't know the specifics or if still there

[LtBadd]

Just a FYI there is one on the Tampa Craigslist

[86turbodsl]

It's negative 7f this morning here, another place to try is instagram and search # welder repair or aerowave I know someone goes by @arc doctor or@mxrider168 and few others on there, otherwise I'll get out there as soon as I can get some help weather /health is not the greatest lately, craigslist chicago had one for sale recently but I don't know the specifics or if still there

If it wasn't such a crappy weather week, i'd consider driving over and helping you, i'm about 3 hrs east of chi-town down I94. I'd like to see Strouty get her fixed.

[Strouty]

No rush at all, just hopeful I can figure this out. I think I may start to write up all the other components for future reference. I really thought the Technical Manual from Miller would have the list of them, but nothing more than a PN for the board, that has turned up almost no info so far on the web. Found some place saying they offer it, but no response yet, I figure it is a huge company and they don't want to deal with a little guy.

[86turbodsl]

Documenting that aerowave for public would be a huge service to the community

Sent from my LG-TP450 using Tapatalk

[Strouty]

I think it would be nice to have a record of the boards, biggest issue will be my knowledge, but I guess good photos can probably make up for that. I think there are 8 or nine boards, one of them is scary loaded with stuff, probably take hours to figure everything out.

[Strouty]

After a discussion with one of the long time Miller reps, I got more info. Miller has all the individual values for the circuits, I just had to tell them the circuit number. So now I know what I have to buy for replacement resistors. Here is a link to the Technical Manual for all you Aerowave owners, it may be helpful at a later date. Not sure how long or how well the link will work, PM me if you need more info.

https://www.dropbox.com/s/vjb0l4bm2x...anual.pdf?dl=0

[jpump5]

Any idea why the resistor failed?
Another component shorted?conductive dirt/dust
on circuit board?something connected wrong? etc.

[Drooopy]

That R6 resistor doesn't look like it enjoyed its time next to the heat. Might want to ask miller for the info on that one too.

[time1800]

Anyone willing to open up the top of their machine? I have a burnt out resistor and it is not identifiable anymore. The board should be accessible from the top or maybe a side, it is shown on the diagram. I am looking for the colors on resistor R1. If I can figure out the resistor I can at least try and replace it, but with no value, I don’t dare guess. I have the technical manual from Miller and it doesn’t offer any detail of the circuit boards for this machine.

Here is a pic of the board in my Aerowave it's main board is at the board Doctors get healed.

[time1800]

Well the pic will not upload if you still need it let me know.

[time1800]

Can get pic to upload if you still need it let me know.

[time1800]

Lets try this again, come on pic load.

[ccawgc]

pcb is the AC clamp board. only used when welding in AC. If memory is right, coiled weld leads can cause problems with the clamp pcb. Miller doesn't have many parts left for these machines. Its job is to reduce the high voltage surges in the AC weld voltage to a safe level. in DC it is not needed.

[dll6]

I have one of these machines .. Bought it with blown mosfets .. Long story short .. Upgraded mosfet's and drivers .. One bad *** machine ... To bad they have inadequate and since discontinued mosfet's, among other apparently fragile components.
AC clamp board, coiled leads, blown resistor sounds plausible.
I do know resistors don't just blow like that.

I'd love to hear from the OP on how his fix is coming along.