BOC Smootharc TIG 185 DC User manual

TIG 185 DC

Service manual

Ver.1 Rev.1 . 0314

•

Important Notice

ThisdocumenthasbeenpreparedbyBOCLimitedABN95000029729(‘BOC’),

asgeneralinformationanddoesnotcontainandisnottobetakenascontaining

anyspecicrecommendation.Thedocumenthasbeenpreparedingoodfaith

andisprofessionalopiniononly.Informationinthisdocumenthasbeenderived

fromthirdparties,andthoughBOCbelievesittobereliableasatthetimeof

printing,BOCmakesnorepresentationorwarrantyastotheaccuracy,reliability

orcompletenessofinformationinthisdocumentanddoesnotassumeany

responsibilityforupdatinganyinformationorcorrectinganyerrororomission

whichmaybecomeapparentafterthedocumenthasbeenissued.NeitherBOC

noranyofitsagentshasindependentlyveriedtheaccuracyoftheinformation

containedinthisdocument.Theinformationinthisdocumentiscommercial

incondenceandisnottobereproduced.Therecipientacknowledgesand

agreesthatitmustmakeitsownindependentinvestigationandshould

considerseekingappropriateprofessionalrecommendationinreviewingand

evaluatingtheinformation.Thisdocumentdoesnottakeintoaccountthe

particularcircumstancesoftherecipientandtherecipientshouldnotrelyon

thisdocumentinmakinganydecisions,includingbutnotlimitedtobusiness,

safetyorotheroperationsdecisions.Exceptinsofarasliabilityunderanystatute

cannotbeexcluded,BOCanditsafliates,directors,employees,contractors

andconsultantsdonotacceptanyliability(whetherarisingincontract,tortor

otherwise)foranyerrororomissioninthisdocumentorforanyresultingloss

ordamage(whetherdirect,indirect,consequentialorotherwise)sufferedby

therecipientofthisdocumentoranyotherpersonrelyingontheinformation

containedherein.TherecipientagreesthatitshallnotseektosueorholdBOC

ortheirrespectiveagentsliableinanysuchrespectfortheprovisionofthis

documentoranyotherinformation.

Warranty Information

Terms of Warranty

BOCprovidesawarrantyfortheSmootharcTIG185

DCmachinesoldagainstdefectsinmanufacture

andmaterials.

•Validfor18monthsfromdateofpurchase.

•AnauthorisedBOCServiceAgentmustcarryout

warrantyrepairs.

•Freight,packagingandinsurancecostsaretobepaidfor

bytheclaimant.

•Noadditionalexpresswarrantyisgivenunlessinwriting

signedbyanauthorisedmanagerofBOC.

•Thiswarrantyisinadditiontoanyotherlegalrightsyou

mayhave.

Limitations on warranty

Thefollowingconditionsarenotcovered:

•Noncompliancewithoperatingandmaintenance

instructionssuchasconnectiontoincorrectfaulty

voltagesupplyincludingvoltagesurgesoutside

equipmentspecs,andincorrectoverloading.

•Naturalwearandtear,andaccidentaldamage.

•Transportorstoragedamage.

TheWarrantyisvoidif:

•Changesaremadetotheproductwithouttheapproval

ofthemanufacturer.

•Repairsarecarriedoutusingnon-approvedspareparts.

•Anon-authorisedagentcarriesoutrepairs.

Warranty repairs

BOCortheirAuthorisedServiceAgentmustbeinformed

ofthewarrantydefects,andtheproductreturnedwithin

thewarrantyperiod.

•Beforeanywarrantyworkisundertaken,thecustomer

mustprovideproofofpurchaseandserialnumberofthe

equipmentinordertovalidatethewarranty.

Thepartsreplacedunderthetermsofthewarranty

remainthepropertyofBOC.

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

•Nevertouch‘live’electricalparts.

•Alwaysrepairorreplacewornordamagedparts.

•Disconnectpowersourcebeforeperformingany

maintenanceorservice.

•Earthallworkmaterials.

•Neverworkinmoistordampareas.

Avoid electric shock by:

•Wearingdryinsulatedboots.

•Wearingdryleathergloves.

•Workingonadryinsulatedoorwherepossible.

Ver.1 Rev.1 . 10132BOC Smootharc TIG 185 DC Service manual

Ver.1 Rev.1 . 0314

Contents.

1.0 Fundamental schematic and circuit diagrams 4

1.1 General wiring diagram 4

1.2 First rectiﬁer board schematic 5

1.3 First rectiﬁer board circuit diagram 6

1.4 Aux. module board schematic 7

1.5 Aux. module board circuit diagram 7

1.6 U10 drive module board schematic 8

1.7 U10 drive module board circuit diagram 8

1.8 U9 control module board schematic 9

1.9 U9 control module board circuit diagram 10

1.10 U8 pulse control module schematic 11

1.11 U8 pulse control module board circuit diagram 12

1.12 Second rectiﬁer board schematic 13

1.13 Second rectiﬁer board circuit diagram 13

1.14 Filtering, high frequency board circuit diagram 14

2.0 Troubleshooting and maintenance 16

3.0 Exploded view and component parts list 17

3.1 Exploded view 17

3.2 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 . 03144BOC Smootharc TIG 185 DC Service manual

1.1 General wiring diagram

1.0 Fundamentalschematicandcircuitdiagrams

Ver.1 Rev.1 . 0314

1.2 First rectiﬁer board schematic

Ser. No. Pin Description

CON1 1 Undergasdelay,theoutputis24VwhenTIG

works

2 Controlworksthesignal,outputthehigh

frequencywhenTIG

3GND

4 DC24V

CON2 1 Pin1andPin2isshortfrequencywhenTIG

workscircuit,outputhigh

CON3 1 2T°XHighfrequency12V°A4T---Lowfrequency0V

2 DC12V

CON4 1 ConnecttogroundbyPTC-12

2 NC

3Highfrequency

CON5 1 Pin1andPin3connecttotheTIGtorch,Pin2

andPin3connecttotheMMAtorch

4 NC

CON6 1 GND

2 Theratedvoltageisadjustable

3Providepowersupplytothepotentiometer

CON7 1 GND

2 Currentfeedback

3Voltagefeedback

CON8 1 Connecttotheattenuationpotentiometer

3WhenconnecttoPin4,Itislowvoltage

4 GND

5 WhenconnecttoPin4,itismiddlevoltage

CON9 1 Connecttothethermalswitch,connecttothe

groundwhenover-heatworks

2 GND

Ser. No. Pin Description

CON10 1 DC24V

2 Thisportconnecttotheover-heatindicator

CON11 1 GND

2 Connecttothepowerindicator,thispinishigh

voltage

CON12 1 GND

2 GND

3DC5V

4 Thesignalterminalofthedigitalmeter

CON13 NC

CON14 1 GND

2 GND

3GND

4 NC

5 DC340V

6 DC340V

7 DC340V

CON15 1 Pin1andPin3outputACwave(+340Vand

-340V)

2 NC

3Pin1andPin3outputACwave(+340Vand

-340V)

CON16 1 InverterACoutput

2 InverterACoutput

3InverterACoutput

4 NC

5 InverterACoutput

6 InverterACoutput

7 InverterACoutput

CON17 1 Lowvoltage

2 Thesignalterminalofthedigitalmeter

3Thepowerterminalofthedigitalmeter

5BOC Smootharc TIG 185 DC Service manual

Ver.1 Rev.1 . 0314

1.3 First rectiﬁer board circuit diagram

6BOC Smootharc TIG 185 DC Service manual

Ver.1 Rev.1 . 0314

Pin Description

1 ConnecttotheMOS“S”

3 DC24Vturnon/off

5 DC24VStart

7 GND

9 DC24VandShutoff

12 GND

14 OutputDC24V

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 MOSoutput

2

1.6 U10 drive module board schematic

1.7 U10 drive module board circuit diagram

8BOC 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+12V

2 GND

3 Notused

4 VoltageFeedback

5 2T/4TPresetControl

6 GivenControl

7 Notused

8 Notused

9 GND

10 GND

11 Over-currentProtectionMonitoring

12 GND

13 Over-heatProtectionMonitoring

14 GND

15 DC+24V

16 Notused

17 GND

18 SG3525ShutdownControl

19 GND

20 GND

21 DC+24V

22 GND

23 SPWMOutput

24 GND

25 SPWMOutput

26 Notused

27 SPWMOutput

28 GND

29 SPWMOutput

30 DC+24V

31 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+12V

2 MMA/TIGMetercontrol

3 DC+24V

4 Notused

5 GasDelayControl

6 Notused

7 (MMA)Supplyvoltageofcurrentadjustment

8 Notused

9 SG3525ShutdownControl

10 Notused

11 (TIG)Supplyvoltageofcurrentadjustment

12 Notused

13 Attenuationtimeadjustmentterminal

14 Notused

15 Frequencyswitchterminal

16 Notused

17 Frequencyswitchterminal

18 Notused

19 ControlSignal

20 Notused

21 Attenuationtimeadjustmentterminal

22 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 Frequency

Positive

Output

Main Transformer

Ser. No. Pin Description

CON3 1 Givencontrol

2 Voltagefeedback

3 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 NC

2 Fixedgasdelaytime(2.5S)whenpresstheswitchPin2is24VvoltageontheQ3is10V,Q3openK1cling,

thegasstartstoow

CON2 1 Whenpresstheswitch,thevoltageis12V;Whentheswitchisshutoff,thevoltageis0V

2 Connecttotheground

3DC+24V

CON3 switch Presstheswitch,Pin1andPin3is12V;Whentheswitchisshutoff,Pin1andPin3is0V,Pin2isNC.

K2 Delaytimestartrelay Whenthereis24Vrelayshutsoff

K1 Solenoidvalverelay WhenthevoltageQ3isover3V,Q3isopen,therelaycling,thegasows.

RX1 Resistance Aftercontinuousswitchingonandoff,theresistanceisover-heatandshutsoff,themachinecouldwork

normallyonlyaftertheresistancecoolsdownforafewminutes

K3 Highfrequencyrelay UnderTIG,presstheswitch,thereisno-loadvoltage,Q5isopen,therelayK3cling,highfrequencyinitiates,

andstartsarc.

CON4 Risevoltage,startarcby

highfrequency

UnderTIG,presstheswitch,thereisno-loadvoltage,Q5isopen,therelayK3cling,highfrequencyinitiates,

andstartsarc.

15BOC Smootharc TIG 185 DC Service manual

Ver.1 Rev.1 . 0314

2.0Troubleshootingandmaintenance

Problem Possible Reasons Solution

1 Pressthepowerswitch,

powerindicator,meter,and

fanswithnodata,pressthe

torchwithoutresponse.

1 Checkthecircuitisnormal,andexternalpowersupply(AC240)isOK.

2 Checkthepowercable,switch,andconnectoristightlyconnected,useamulti-meter

totesttheplug(PZ01-005-O1CON10)forDC340V±5V.

1 Checktheexternalpower

supply.

2 Checktheconnector.

2 Pressthepowerswitch,the

powerindicatorandmeteris

ok,thefanisabnormal,the

machinehasnoresponse

whenpressingtheswitch.

1 ChecktheinverterboardhasDC24Voutput,useamulti-metertotesttheCON4’s

PM01-001-E12pin1and2.Ifithas24Voutput,testotherareas.

2 StartrelayK1onbottomboarddoesnotrespondproperly(itcanbeindicatedbythe

solenoidvalvejumping).

3 StartrelayK2inpowercircuitdoesnotrespondproperly,checkopticalU1,MOSFET

Z24(Q4)resistorRV1,andwhethertherelayisdamagedornot.

4 Pressingthepowerbuttoncontinuouslyinashorttime,resultsintheeld-discharge

resistancebecomingoverheatedPoweroffthemachineforseveralminutes.

1 Checkandremove.

2 Checkandremove.

3 Checkandremove.

4 Turnoffthemachinefor

severalminutes.

3 Pressthepowerswitch,

powerindicator,meter,and

fanworksnormally.Pressthe

switchofthetorchwithout

response.

1 Switchofthetorchorthecableisloose.

2 Gassocketislooseorthecableisbroken.

1 Checkandremove.

2 Checkandremove.

4 Turnonthemachine

normally,withouthigh

frequency

1 Pulloffthehighfrequencycable(PM01-001-E12CON2),useamulti-metertotest

theoutputforDC230.Ifyesandcouldstartarc,checkthestartingarcunderhigh

frequency.

 a) Checkwhetherthehighfrequencycableconnectiontothebottomboard

(PZ01-005-O1CON4)andcableforarcstartisnotloose.

 b) Checkifthehighvoltagedischargenozzleisconnectedcorrectly,orthesurfaceis

oxidized.

 c) Checkifthehighvoltagecomponents(D3-D6),highvoltageoutputcapacitors

(C7,C10,C11)arenotdamaged.

 d) Checkthehighfrequencyrelayonthebottomboardisrespondingproperly.

2 CheckfortheDC230output,possiblytheinvertercircuitisabnormal.

 a) Checkifthecontrolmodule,hasoutputforthedrivesignalorworksnormally.

 b) Checkiftheinverterandmaincurrentcableisnotloose（PM01-001-E12CON1（.

1 Checkandreplace.

2 Checkandreplace.

5 Turnonthemachine

normally,theabnormal

indicatorison.

1 Theover-heatprotectionisactivated,turnoffthemachine,andcouldrestartthe

machinesuccessfullywhilethepowerindicatorisoff.

2 Theover-heatprotectionworks,themachinewillbeokafter2-3minutes.

3 Theinvertercircuitandstartarcisabnormal,turnoffthemachineandpulloff

theplugofthehighfrequencystartarcpowerinPM01-001-E12,thenturnonthe

machineandpresstheswitch.

 a) Iftheabnormalindicatordoesnotgoon,thetransformerT1onthePZ01-005-O1

orD3-D6isdamaged.

 b) Iftheabnormalindicatorison,thenpullofftheplugCON1forpowersupply

inthePM01-001-E12Ifthelightisstillon,someoftheMOSFETcomponents

aredamaged.Ifthelightgoesoff,therectierpipeonPZ01-005-O1orthe

transformerisdamaged.

 c) Checkifthefeedbackcircuitisopen-circuit,checkthefeedbackcableisproperly

connected.

1 Themachinewillbeokafter

turningoffthemachinefor

veminutes.

2 Stopthemachineforawhile.

3 Checkandremove.

6 Turnonthemachine

normally,couldstartarc,but

theweldappearsblack.

1 Checkifthesolenoidvalveisjammedordamaged.

2 Thesolenoidvalverelay(PZ01-005-WK1)isdamaged.

3 Checkthetorchforwearordamage.

4 Tungstenelectrodeisinpoorcondition,ortheshieldinggasisincorrect.

1 Clean.

2 Checkandreplaceif

necessary.

3 Checkandreplaceif

necessary.

4 Replace.

7 Theweldingcurrentis

unstable,uncontrollable.

1 Thepotentiometerislooseordamaged.

2 FilteringcapacitorPZ01-005-O1inthebottomboardisleakingordamaged.

3 Theweldingcableistoolongandthinresultingintheunstablecurrent.

1 Checkandremove.

2 Checkandremove.

3 Increasethecrosssectionof

thecable.

8 Skipafterturningonthe

machine.

1 Therectiersiliconbridgeisdamaged.

2 Thepowercableisshort-circuited.

1 Checkandreplace.

2 Replace.

9 Thehighfrequencycouldnot

stop.

1 Highfrequencyrelay(PZ01-005-WK3)isdamaged.

2 Theoutputvoltagedisturbsthevoltage.

1 Checkandremove.

2 Addcapacitorbetween

outputandground.

16 BOC Smootharc TIG 185 DC Service manual

3.0 Explodedviewandcomponentpartslist

3.1 Exploded view

17 BOC Smootharc TIG 185 DC Service manual

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 BOCrearpanelplastic 1 R-16-910220-01-A0 R-16-910220-01-A0

2 Leftcoverplastic 1 R-17-995299-02-A0 R-17-995299-02-A0

3Rightcoverplastic 1 R-17-996299-02-A0 R-17-996299-02-A0

4 BOCbottomcase 1 R-18-261880-01-A0 R-18-261880-01-A0

5 Outputboard 1 R-18-259000-01-A0 Availableonrequest

6 Uprightgirder 2 R-22-010003-01-A0 Availableonrequest

7 Uprightgirder 2 R-22-010003-02-A0 Availableonrequest

8 Rearbeamxholder 1 R-25-020101-80-A0 Availableonrequest

9 Frontcasexholder 1 R-25-020101-79-A0 Availableonrequest

10 Topsustain 1 R-25-020101-77-A0 Availableonrequest

11 LED 1 R-04-010700-19-00 04-010700-19-00

12 Toppanelinsulation 1 R-23-010100-15-A0 23-010100-15-A0

13 Bottompanelinsulation 1 R-23-010300-16-A0 Availableonrequest

14 Topwindbreakboard 1 R-23-020102-02-A0 Availableonrequest

15 Sidewindbreakboard 2 R-23-020502-04-A0 Availableonrequest

16 Gasswitchconnector 1 R-24-031200-11-A0 24-031200-11-A0

17 Fansustain（ 2 R-25-020101-78-A0 Availableonrequest

18 Radiator/heatsink 1 R-26-010171-01-A0 GM-02A

19 LED 1 R-04-010700-19-01 04-010700-19-01

20 Radiator/heatsink 1 R-26-010172-01-A0 GM-02B

21 Switch 1 R-07-020000-12-00 R-07-020000-12-00

22 Frontpanel 1 R-15-030490-01-A0 R-15-030490-01-A0

23 Digitalmeter 1 R-37-110160-05-01 AB-05/37-110160-05-01

24 Cablegrommit 1 R-37-190400-07-00 R37-190400-07-00

25 Knob 2 R-37-231220-01-01 37-231220-01-01

26 35mmfemalesocket 2 R-40-160810-01-00 R-40-160810-01-00

27 Bottompanel 1 R-51-PZ01-005-W-RL Availableonrequest

28 Bottomwindbreakboard 1 R-52-GT-50-B-RL Availableonrequest

29 Siliconbridge10 1 R-52-QL-01-F-RL Availableonrequest

30 Siliconbridge13 1 R-52-QL-01-H-RL Availableonrequest

31 Aviationsocket 1 R-52-ZH-02-B-RL Availableonrequest

32 EMCboard 1 R-51-PH02-112-A R-51-PH02-112-A

33 Boatshapedswitch 1 R-07-020000-03-00 07-020000-03-00

34 Topboard 1 R-51-PM01-046-G1 PMB-46-D

35 Middleboard 1 R-51-PD01-065-A PDB-07-G

36 EMCinsulation 1 R-23-010800-52-A0 Availableonrequest

37 Mountingbracket 2 R-24-020700-48-A0 Availableonrequest

38 Boatshapedswitch 2 R-07-020000-05-00 07-020000-05-00

39 Frontcaseplastic 1 R-15-901492-02-A0 R-15-901492-02-A0

40 Solenoidvalve 1 R-37-140420-04-00 37-140420-04-00

41 Fan 1 R-37-120112-01-00 37-120112-01-00

42 Thermalswitch 1 R-06-030000-15-01 Availableonrequest

43 Spring 12 R-23-040000-63-A0 Availableonrequest

44 Absorbboard 1 R-23-050000-19-A0 23-050000-19-A0

18BOC Smootharc TIG 185 DC Service manual

MP12-0813-1.FDAUS.0314

believed to be correct at the time of printing. Whilst proper care has been taken in the preparation, no liability for injury or damage resulting from its improper use can be accepted.

FormoreinformationcontacttheBOCwarrantydepartmentatwarranty@boc.com

BOC Limited

10JuliusAvenue,NorthRydeNSW2113,Australia

970–988GreatSouthRoad,Penrose,Auckland,NewZealand

BOC Customer Service Centre

Australia

131262

www.boc.com.au

NewZealand

0800111333

BOC Smootharc TIG 185 DC User manual

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