TIG 185 DC Service manual
Ver.1 Rev.1 . 0314
•
Important Notice
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Warranty Information
Terms of Warranty
BOCprovidesawarrantyfortheSmootharcTIG185DCmachinesoldagainstdefectsinmanufactureandmaterials.
• Validfor18monthsfromdateofpurchase.
• AnauthorisedBOCServiceAgentmustcarryoutwarrantyrepairs.
• Freight,packagingandinsurancecostsaretobepaidforbytheclaimant.
• NoadditionalexpresswarrantyisgivenunlessinwritingsignedbyanauthorisedmanagerofBOC.
• Thiswarrantyisinadditiontoanyotherlegalrightsyoumayhave.
Limitations on warranty
Thefollowingconditionsarenotcovered:
• Noncompliancewithoperatingandmaintenanceinstructionssuchasconnectiontoincorrectfaultyvoltagesupplyincludingvoltagesurgesoutsideequipmentspecs,andincorrectoverloading.
• Naturalwearandtear,andaccidentaldamage.
• Transportorstoragedamage.
TheWarrantyisvoidif:
• Changesaremadetotheproductwithouttheapprovalofthemanufacturer.
• Repairsarecarriedoutusingnon-approvedspareparts.
• Anon-authorisedagentcarriesoutrepairs.
Warranty repairs
BOCortheirAuthorisedServiceAgentmustbeinformedofthewarrantydefects,andtheproductreturnedwithinthewarrantyperiod.
• Beforeanywarrantyworkisundertaken,thecustomermustprovideproofofpurchaseandserialnumberoftheequipmentinordertovalidatethewarranty.
ThepartsreplacedunderthetermsofthewarrantyremainthepropertyofBOC.
Modification of the 15A primary input plug or fitment of a lower rated primary input plug will render the warranty null and void.
Recommended Safety Precautions
Electrical Shock
• Nevertouch‘live’electricalparts.
• Alwaysrepairorreplacewornordamagedparts.
• Disconnectpowersourcebeforeperforminganymaintenanceorservice.
• Earthallworkmaterials.
• Neverworkinmoistordampareas.
Avoid electric shock by:
• Wearingdryinsulatedboots.
• Wearingdryleathergloves.
• Workingonadryinsulatedfloorwherepossible.
Ver.1 Rev.1 . 10132 BOC Smootharc TIG 185 DC Service manual
Ver.1 Rev.1 . 0314
Contents.
1.0 Fundamental schematic and circuit diagrams 41.1 General wiring diagram 41.2 First rectifier board schematic 51.3 First rectifier board circuit diagram 61.4 Aux. module board schematic 71.5 Aux. module board circuit diagram 71.6 U10 drive module board schematic 81.7 U10 drive module board circuit diagram 81.8 U9 control module board schematic 91.9 U9 control module board circuit diagram 101.10 U8 pulse control module schematic 111.11 U8 pulse control module board circuit diagram 121.12 Second rectifier board schematic 131.13 Second rectifier board circuit diagram 131.14 Filtering, high frequency board circuit diagram 14
2.0 Troubleshooting and maintenance 16
3.0 Exploded view and component parts list 173.1 Exploded view 173.2 Component parts list for Smootharc TIG 185 DC 18
Ver.1 Rev.1 . 1013 3BOC Smootharc TIG 185 DC Service manual
Ver.1 Rev.1 . 03144 BOC Smootharc TIG 185 DC Service manual
1.1 General wiring diagram
1.0 Fundamentalschematicandcircuitdiagrams
Ver.1 Rev.1 . 0314
1.2 First rectifier board schematic
Ser. No. Pin Description
CON1 1 Undergasdelay,theoutputis24VwhenTIGworks
2 Controlworksthesignal,outputthehighfrequencywhenTIG
3 GND4 DC24V
CON2 1 Pin1andPin2isshortfrequencywhenTIGworkscircuit,outputhigh2
CON3 1 2T°XHighfrequency12V°A4T---Lowfrequency0V2 DC12V
CON4 1 ConnecttogroundbyPTC-122 NC3 Highfrequency
CON5 1 Pin1andPin3connecttotheTIGtorch,Pin2andPin3connecttotheMMAtorch2
34 NC
CON6 1 GND2 Theratedvoltageisadjustable3 Providepowersupplytothepotentiometer
CON7 1 GND2 Currentfeedback3 Voltagefeedback
CON8 1 Connecttotheattenuationpotentiometer23 WhenconnecttoPin4,Itislowvoltage4 GND5 WhenconnecttoPin4,itismiddlevoltage
CON9 1 Connecttothethermalswitch,connecttothegroundwhenover-heatworks
2 GND
Ser. No. Pin Description
CON10 1 DC24V2 Thisportconnecttotheover-heatindicator
CON11 1 GND2 Connecttothepowerindicator,thispinishigh
voltageCON12 1 GND
2 GND3 DC5V4 Thesignalterminalofthedigitalmeter
CON13 NCCON14 1 GND
2 GND3 GND4 NC5 DC340V6 DC340V7 DC340V
CON15 1 Pin1andPin3outputACwave(+340Vand-340V)
2 NC3 Pin1andPin3outputACwave(+340Vand
-340V)CON16 1 InverterACoutput
2 InverterACoutput3 InverterACoutput4 NC5 InverterACoutput6 InverterACoutput7 InverterACoutput
CON17 1 Lowvoltage2 Thesignalterminalofthedigitalmeter3 Thepowerterminalofthedigitalmeter
5BOC Smootharc TIG 185 DC Service manual
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1.3 First rectifier board circuit diagram
6 BOC Smootharc TIG 185 DC Service manual
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Pin Description
1 ConnecttotheMOS“S”3 DC24Vturnon/off5 DC24VStart7 GND9 DC24VandShutoff12 GND14 OutputDC24V
1.4 Aux. module board schematic
1.5 Aux. module board circuit diagram
7BOC Smootharc TIG 185 DC Service manual
Ver.1 Rev.1 . 0314
Pin Description
1 MOSoutput2
1.6 U10 drive module board schematic
1.7 U10 drive module board circuit diagram
8 BOC Smootharc TIG 185 DC Service manual
Ver.1 Rev.1 . 0314
1.8 U9 control module board schematic
9BOC Smootharc TIG 185 DC Service manual
Pin Description
1 DC+12V2 GND3 Notused4 VoltageFeedback5 2T/4TPresetControl6 GivenControl7 Notused8 Notused9 GND10 GND11 Over-currentProtectionMonitoring12 GND13 Over-heatProtectionMonitoring14 GND15 DC+24V16 Notused17 GND18 SG3525ShutdownControl19 GND20 GND21 DC+24V22 GND23 SPWMOutput24 GND25 SPWMOutput26 Notused27 SPWMOutput28 GND29 SPWMOutput30 DC+24V31 GND
Ver.1 Rev.1 . 0314
1.9 U9 control module board circuit diagram
10 BOC Smootharc TIG 185 DC Service manual
Ver.1 Rev.1 . 0314
1.10 U8 pulse control module schematic
11BOC Smootharc TIG 185 DC Service manual
Pin Description
1 DC+12V2 MMA/TIGMetercontrol3 DC+24V4 Notused5 GasDelayControl6 Notused7 (MMA)Supplyvoltageofcurrentadjustment8 Notused9 SG3525ShutdownControl10 Notused11 (TIG)Supplyvoltageofcurrentadjustment12 Notused13 Attenuationtimeadjustmentterminal14 Notused15 Frequencyswitchterminal16 Notused17 Frequencyswitchterminal18 Notused19 ControlSignal20 Notused21 Attenuationtimeadjustmentterminal22 GND
Ver.1 Rev.1 . 0314
1.11 U8 pulse control module board circuit diagram
12 BOC Smootharc TIG 185 DC Service manual
Ver.1 Rev.1 . 0314
1.12 Second rectifier board schematic
1.13 Second rectifier board circuit diagram
Feedback
Negative Output
Rectifier
MMA/TIGHigh FrequencyPositive OutputMain Transformer
Ser. No. Pin Description
CON3 1 Givencontrol2 Voltagefeedback3 GND
13BOC Smootharc TIG 185 DC Service manual
Ver.1 Rev.1 . 0314
1.14 Filtering, high frequency board circuit diagram
14 BOC Smootharc TIG 185 DC Service manual
Ver.1 Rev.1 . 0314
Ser. No. Pin Description
CON1 1 NC2 Fixedgasdelaytime(2.5S)whenpresstheswitchPin2is24VvoltageontheQ3is10V,Q3openK1cling,
thegasstartstoflowCON2 1 Whenpresstheswitch,thevoltageis12V;Whentheswitchisshutoff,thevoltageis0V
2 Connecttotheground3 DC+24V
CON3 switch Presstheswitch,Pin1andPin3is12V;Whentheswitchisshutoff,Pin1andPin3is0V,Pin2isNC.K2 Delaytimestartrelay Whenthereis24VrelayshutsoffK1 Solenoidvalverelay WhenthevoltageQ3isover3V,Q3isopen,therelaycling,thegasflows.RX1 Resistance Aftercontinuousswitchingonandoff,theresistanceisover-heatandshutsoff,themachinecouldwork
normallyonlyaftertheresistancecoolsdownforafewminutesK3 Highfrequencyrelay UnderTIG,presstheswitch,thereisno-loadvoltage,Q5isopen,therelayK3cling,highfrequencyinitiates,
andstartsarc.CON4 Risevoltage,startarcby
highfrequencyUnderTIG,presstheswitch,thereisno-loadvoltage,Q5isopen,therelayK3cling,highfrequencyinitiates,andstartsarc.
15BOC Smootharc TIG 185 DC Service manual
Ver.1 Rev.1 . 0314
2.0 Troubleshootingandmaintenance
Problem Possible Reasons Solution
1 Pressthepowerswitch,powerindicator,meter,andfanswithnodata,pressthetorchwithoutresponse.
1 Checkthecircuitisnormal,andexternalpowersupply(AC240)isOK.2 Checkthepowercable,switch,andconnectoristightlyconnected,useamulti-meter
totesttheplug(PZ01-005-O1CON10)forDC340V±5V.
1 Checktheexternalpowersupply.
2 Checktheconnector.
2 Pressthepowerswitch,thepowerindicatorandmeterisok,thefanisabnormal,themachinehasnoresponsewhenpressingtheswitch.
1 ChecktheinverterboardhasDC24Voutput,useamulti-metertotesttheCON4’sPM01-001-E12pin1and2.Ifithas24Voutput,testotherareas.
2 StartrelayK1onbottomboarddoesnotrespondproperly(itcanbeindicatedbythesolenoidvalvejumping).
3 StartrelayK2inpowercircuitdoesnotrespondproperly,checkopticalU1,MOSFETZ24(Q4)resistorRV1,andwhethertherelayisdamagedornot.
4 Pressingthepowerbuttoncontinuouslyinashorttime,resultsinthefield-dischargeresistancebecomingoverheatedPoweroffthemachineforseveralminutes.
1 Checkandremove.2 Checkandremove.3 Checkandremove.4 Turnoffthemachinefor
severalminutes.
3 Pressthepowerswitch,powerindicator,meter,andfanworksnormally.Presstheswitchofthetorchwithoutresponse.
1 Switchofthetorchorthecableisloose.2 Gassocketislooseorthecableisbroken.
1 Checkandremove.2 Checkandremove.
4 Turnonthemachinenormally,withouthighfrequency
1 Pulloffthehighfrequencycable(PM01-001-E12CON2),useamulti-metertotesttheoutputforDC230.Ifyesandcouldstartarc,checkthestartingarcunderhighfrequency.
a) Checkwhetherthehighfrequencycableconnectiontothebottomboard(PZ01-005-O1CON4)andcableforarcstartisnotloose.
b) Checkifthehighvoltagedischargenozzleisconnectedcorrectly,orthesurfaceisoxidized.
c) Checkifthehighvoltagecomponents(D3-D6),highvoltageoutputcapacitors(C7,C10,C11)arenotdamaged.
d) Checkthehighfrequencyrelayonthebottomboardisrespondingproperly.2 CheckfortheDC230output,possiblytheinvertercircuitisabnormal. a) Checkifthecontrolmodule,hasoutputforthedrivesignalorworksnormally. b) Checkiftheinverterandmaincurrentcableisnotloose(PM01-001-E12CON1(.
1 Checkandreplace.2 Checkandreplace.
5 Turnonthemachinenormally,theabnormalindicatorison.
1 Theover-heatprotectionisactivated,turnoffthemachine,andcouldrestartthemachinesuccessfullywhilethepowerindicatorisoff.
2 Theover-heatprotectionworks,themachinewillbeokafter2-3minutes.3 Theinvertercircuitandstartarcisabnormal,turnoffthemachineandpulloff
theplugofthehighfrequencystartarcpowerinPM01-001-E12,thenturnonthemachineandpresstheswitch.
a) Iftheabnormalindicatordoesnotgoon,thetransformerT1onthePZ01-005-O1orD3-D6isdamaged.
b) Iftheabnormalindicatorison,thenpullofftheplugCON1forpowersupplyinthePM01-001-E12Ifthelightisstillon,someoftheMOSFETcomponentsaredamaged.Ifthelightgoesoff,therectifierpipeonPZ01-005-O1orthetransformerisdamaged.
c) Checkifthefeedbackcircuitisopen-circuit,checkthefeedbackcableisproperlyconnected.
1 Themachinewillbeokafterturningoffthemachineforfiveminutes.
2 Stopthemachineforawhile.3 Checkandremove.
6 Turnonthemachinenormally,couldstartarc,buttheweldappearsblack.
1 Checkifthesolenoidvalveisjammedordamaged.2 Thesolenoidvalverelay(PZ01-005-WK1)isdamaged.3 Checkthetorchforwearordamage.4 Tungstenelectrodeisinpoorcondition,ortheshieldinggasisincorrect.
1 Clean.2 Checkandreplaceif
necessary.3 Checkandreplaceif
necessary.4 Replace.
7 Theweldingcurrentisunstable,uncontrollable.
1 Thepotentiometerislooseordamaged.2 FilteringcapacitorPZ01-005-O1inthebottomboardisleakingordamaged.3 Theweldingcableistoolongandthinresultingintheunstablecurrent.
1 Checkandremove.2 Checkandremove.3 Increasethecrosssectionof
thecable.8 Skipafterturningonthe
machine.1 Therectifiersiliconbridgeisdamaged.2 Thepowercableisshort-circuited.
1 Checkandreplace.2 Replace.
9 Thehighfrequencycouldnotstop.
1 Highfrequencyrelay(PZ01-005-WK3)isdamaged.2 Theoutputvoltagedisturbsthevoltage.
1 Checkandremove.2 Addcapacitorbetween
outputandground.
16 BOC Smootharc TIG 185 DC Service manual
3.0 Explodedviewandcomponentpartslist3.1 Exploded view
17 BOC Smootharc TIG 185 DC Service manual Ver.1 Rev.1 . 0314
Ver.1 Rev.1 . 0314
3.2 Component parts list for Smootharc TIG 185 DC
Item Description Qty Material Part No. BOC Part No.
1 BOCrearpanelplastic 1 R-16-910220-01-A0 R-16-910220-01-A02 Leftcoverplastic 1 R-17-995299-02-A0 R-17-995299-02-A03 Rightcoverplastic 1 R-17-996299-02-A0 R-17-996299-02-A04 BOCbottomcase 1 R-18-261880-01-A0 R-18-261880-01-A05 Outputboard 1 R-18-259000-01-A0 Availableonrequest6 Uprightgirder 2 R-22-010003-01-A0 Availableonrequest7 Uprightgirder 2 R-22-010003-02-A0 Availableonrequest8 Rearbeamfixholder 1 R-25-020101-80-A0 Availableonrequest9 Frontcasefixholder 1 R-25-020101-79-A0 Availableonrequest10 Topsustain 1 R-25-020101-77-A0 Availableonrequest11 LED 1 R-04-010700-19-00 04-010700-19-0012 Toppanelinsulation 1 R-23-010100-15-A0 23-010100-15-A013 Bottompanelinsulation 1 R-23-010300-16-A0 Availableonrequest14 Topwindbreakboard 1 R-23-020102-02-A0 Availableonrequest15 Sidewindbreakboard 2 R-23-020502-04-A0 Availableonrequest16 Gasswitchconnector 1 R-24-031200-11-A0 24-031200-11-A017 Fansustain( 2 R-25-020101-78-A0 Availableonrequest18 Radiator/heatsink 1 R-26-010171-01-A0 GM-02A19 LED 1 R-04-010700-19-01 04-010700-19-0120 Radiator/heatsink 1 R-26-010172-01-A0 GM-02B21 Switch 1 R-07-020000-12-00 R-07-020000-12-0022 Frontpanel 1 R-15-030490-01-A0 R-15-030490-01-A023 Digitalmeter 1 R-37-110160-05-01 AB-05/37-110160-05-0124 Cablegrommit 1 R-37-190400-07-00 R37-190400-07-0025 Knob 2 R-37-231220-01-01 37-231220-01-0126 35mmfemalesocket 2 R-40-160810-01-00 R-40-160810-01-0027 Bottompanel 1 R-51-PZ01-005-W-RL Availableonrequest28 Bottomwindbreakboard 1 R-52-GT-50-B-RL Availableonrequest29 Siliconbridge10 1 R-52-QL-01-F-RL Availableonrequest30 Siliconbridge13 1 R-52-QL-01-H-RL Availableonrequest31 Aviationsocket 1 R-52-ZH-02-B-RL Availableonrequest32 EMCboard 1 R-51-PH02-112-A R-51-PH02-112-A33 Boatshapedswitch 1 R-07-020000-03-00 07-020000-03-0034 Topboard 1 R-51-PM01-046-G1 PMB-46-D35 Middleboard 1 R-51-PD01-065-A PDB-07-G36 EMCinsulation 1 R-23-010800-52-A0 Availableonrequest37 Mountingbracket 2 R-24-020700-48-A0 Availableonrequest38 Boatshapedswitch 2 R-07-020000-05-00 07-020000-05-0039 Frontcaseplastic 1 R-15-901492-02-A0 R-15-901492-02-A040 Solenoidvalve 1 R-37-140420-04-00 37-140420-04-0041 Fan 1 R-37-120112-01-00 37-120112-01-0042 Thermalswitch 1 R-06-030000-15-01 Availableonrequest43 Spring 12 R-23-040000-63-A0 Availableonrequest44 Absorbboard 1 R-23-050000-19-A0 23-050000-19-A0
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