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 TIG185 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 TIG185 DC Service manual

Ver.1 Rev.1 . 03144BOC Smootharc TIG185 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
2
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
2
3
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
2
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 TIG185 DC Service manual

Ver.1 Rev.1 . 0314
1.3 First rectifier board circuit diagram
6BOC Smootharc TIG185 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 TIG185 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 TIG185 DC Service manual

Ver.1 Rev.1 . 0314
1.8 U9 control module board schematic
9BOC Smootharc TIG185 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 TIG185 DC Service manual

Ver.1 Rev.1 . 0314
1.10 U8 pulse control module schematic
11BOC Smootharc TIG185 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 TIG185 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
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Ver.1 Rev.1 . 0314
1.14 Filtering, high frequency board circuit diagram
14 BOC Smootharc TIG185 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 TIG185 DC Service manual

3.0 Explodedviewandcomponentpartslist
3.1 Exploded view
17 BOC Smootharc TIG185 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 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
© BOC Limited 2014. BOC is a trading name of BOC Limited, a Member of The Linde Group. Reproduction without permission is strictly prohibited. Details given in this document are
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[e-mail]
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
www.boc.co.nz