TIG 185 DC Service manual - BOC · Ver.1 Rev.1 . 1013 BOC Smootharc TIG185 DC Service manual 3. ... CON16 1 Inverter AC output ... 18 SG3525 Shutdown Control 19 GND

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


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

Ver.1 Rev.1 . 0314

1.3 First rectifier board circuit diagram

6 BOC Smootharc TIG 185 DC Service manual

Ver.1 Rev.1 . 0314

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


Ver.1 Rev.1 . 0314

Pin Description

1 MOSoutput2

1.6 U10 drive module board schematic

1.7 U10 drive module board circuit diagram


Ver.1 Rev.1 . 0314

1.8 U9 control module board schematic


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


Ver.1 Rev.1 . 0314

1.10 U8 pulse control module schematic


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


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


CON3 1 Givencontrol2 Voltagefeedback3 GND


Ver.1 Rev.1 . 0314

1.14 Filtering, high frequency board circuit diagram


Ver.1 Rev.1 . 0314


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.


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.


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


MP1

2-08

13-1

.FD

AUS

.031

4

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Documents

TIG 185 DC Service manual - BOC · Ver.1 Rev.1 . 1013 BOC Smootharc TIG185 DC Service manual 3. ... CON16 1 Inverter AC output ... 18 SG3525 Shutdown Control 19 GND