TIG 185 DC Service manual
Contents
1. 5 UE 5 58 5 Z ple Pana OE b 2 11 EI 6 e Pa 2 1 R33 039 tq L R25 5 C20 Al R54 85 010 4 35 3 dm 1 ESE 17 Oo 3 5 EE 1 8 1 07 3 t 5 gc ti C36 6014 IK Ier 1 o C24 Rao 3 J2 Es 6 CD RA 8 E lt gt RM 7 Se 1 6 amp P 2 C34 C38 Ein n 5 70 83 3 fal CD mj 3 d 4 8 HN Cru Gelb 2 5 lt 1 ER geg e T GC PHOI 046 A4 KS Re g a Can 2011 04 01 02 F D B SRD lei ra FE LEB z S E i elt pup IRCH R32 026 ag 4 H R30 1 e J aE Jio RR2 0 E 018 019 020 a4 itt e 0 ox Ge cat m m IPS C C C c c 3 21 eye EN 82 R27 R46 R47 R48 R49 R26 CONI i F 21 cm Ser No Pin Description Ser No Pin Description CON1 1 Under gas delay the output is 24V when TIG CONIO 1 DC24V works 2 This port connect to the over heat indicator 2 Control works the signal output the high CON11 GND2. 3ueursnfpe st WIEN IVY Ver 1 Rev 1 0314 BOC Smootharc TIG 185 DC Service manual 1 4 Aux module board schematic GC PHO1 054T 82 2010 11 24 afin ndn ies CN ei XC NM Ant ur ol el Je 14 fiz e 7 5i st jt Pin Description Connect to the MOS S DC24V turn on off DC24V Start GND DC24V and Shut off GND Output DC24V S ON LI LA A BN 1 5 Aux module board circuit diagram HMM H a 8 BOC Smootharc TIG 185 DC Service manual Ver 1 Rev 1 0314 1 6 U10 drive module board schematic GC PKO04 007T A3 zt IC Jw uf JC el DIR el 1 C Jo pol JL1 ja d cf 1 JC NL CICI 010 E ol DIR cl 1 C o ol JLi ja ell Jos C JC I wl JL Pin Description 1 MOS output 2 17 U10 drive module board circuit diagram cua D2 D3 Ee Ver 1 Rev 1 0314 BOC Smootharc TIG 185 DC Service manual 18 U9 control module board schematic ae o D w e gt 1 LJ LJL iL JL T 1 P 1 a o BR N D N a D D D N o nD o o N mm 2 mmm mmm LZ N LL LL D
3. N i N N kap Ww DN 2 o OI N DU Det 0 0 12 BOC Smootharc TIG 185 DC Service manual Ver 1 Rev 1 0314 1 11 U8 pulse control module board circuit diagram 9 UIC DVOAV p ll DV Ver 1 Rev 1 0314 BOC Smootharc TIG 185 DC Service manual 112 Second rectifier board schematic Positive Output Main Transformer High Frequency MMA TIG OUTPUT co h n H E H S OUTPUT 09 010 pn 013 Da O O Feedback Negative Ser No Pin Description Output CON3 1 Given control 2 Voltage feedback 3 GND 1 13 Second rectifier board circuit diagram 14 BOC Smootharc TIG 185 DC Service manual Ver 1 Rev 1 0314 1 14 Filtering high frequency board circuit diagram Torch switch E w 569 g E m gt ues 47 A3 8 Ver 1 Rev 1 0314 BOC Smootharc TIG 185 DC Service manual 15 Ser No Pin Description CON1 1 C 2 Fixed gas delay time 2 55 when press the switch Pin 2 is 24V voltage on the Q3 is 10V Q3 open K1 cling he gas starts to flow CON2 1 When press the switch the voltage is 12V
4. Wearing dry leather gloves Working on a dry insulated floor where possible 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 as general information and does not contain and is not to be taken as containing any specific 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 ha
5. requency when TIG 2 Connect to the power indicator this pin is high 3 GND voltage 4 DC24V CON12 GND CON2 1 Pin 1 and Pin 2 is short frequency when TIG 2 GND 2 works circuit output high 3 DC5V CON3 1 2T XHigh frequency 12V A4T Low frequency OV 4 The signal terminal of the digital meter 2 DC12V CON13 NC CON4 1 Connect to ground by PTC 12 CON14 GND 2 C 2 GND 3 High frequency 3 GND CON5 Pin 1 and Pin 3 connect to the TIG torch Pin 2 4 C 2 andPin3 connect to the MMA torch 5 DC340V 3 6 DC340V 4 C 7 DC340V CONG GND CON15 1 Pin 1 and Pin 3 output AC wave 340V and 2 The rated voltage is adjustable 340V 3 Provide power supply to the potentiometer 2 C CON7 GND 3 Pin 1 and Pin 3 output AC wave 340V and 2 Current feedback 340V 3 Voltage feedback CON16 1 Inverter AC outpu CON8 Connect to the attenuation potentiometer 2 Inverter AC outpu 2 3 Inverter AC outpu 3 When connect to Pind It is low voltage 4 NC 4 GND 5 Inverter AC outpu 5 When connect to Pind it is middle voltage 6 Inverter AC outpu CON9 Connect to the thermal switch connect to the 7 Inverter AC outpu ground when over heat works CON17 1 Low voltage 2 GND 2 The signal terminal of the digital meter 3 The power terminal of the digital meter Ver 1 6 1 0314 BOC Smootharc TIG 185 DC Service manual First rectifier board circuit diagram 13 Meter adjustment Current adjustment Current meter Feedback signal Abnamalled Thermoswitch
6. 01 CON4 and cab b Check i xidized heck if the C7 C10 C1 d Check the hi Check for a Check i Check i ne Py Xu 0 the the iS achine succes 35 Ey a e plug of the achine and pr v 32 or D3 D6 in the he DC230 output possi m e over heat protection e over heat pro e inverter circui If the abnorma is damaged If the abnorma PMO01 001 E12 If the ligh are damaged If the ligh 1 are not damaged gh frequency relay o bly the inver control module has output for inverter and main cu urn off t indicato is activated y while the power ection works the and start arc is high frequency sta ess the switch indicator does STU t arc power not go on th indicator is on then pull of goes off the recti he bottom er Ci the d rent cable is high voltage components D3 D6 high r is machine will be abnormal tu et tis still on som ier he machi no in P the plug e of the MOSFET components pipe on PZ01 005 01 or the ency cable connection to the bo e for arc start is not loose high voltage discharge nozzle is connected correc voltage o board cui ive 011 the machine ansfo CONI for is responding ti meter to test arc under high tom board utput capacitors properly is abnormal signal or works normally not
7. B a nD eo m wo N Cy 77 a 7 Cg C Ss 7 M Es Pin Description 1 DC 12V 2 GND 3 Not used 4 Voltage Feedback 5 21 4T Preset Control 6 Given Control 7 Not used 8 Not used 9 GND 0 GND 1 Over current Protection Monitoring 2 GND 3 Over heat Protection Monitoring 4 GND 5 DC 24V 6 Not used 7 GND 8 G3525 Shutdown Control 9 GND 20 GND 21 DC 24V 22 GND 23 SPWM Outpu 24 GND 25 SPWM Outpu 26 ot used 27 SPWM Outpu 28 GND 29 SPWM Outpu 30 DC 24V 31 GND 10 BOC Smootharc TIG 185 DC Service manual Ver 1 Rev 1 0314 19 U9 control module board circuit diagram Ke Mi TMV D5 Ke Mi Dv Ql KD Ka 2 x Q5 Se 5 gt g 3 2 5 A B g R 5 a S EES S 8 ES FLV Ver 1 Rev 1 0314 BOC Smootharc TIG 185 DC Service manual 11 1 10 U8 pulse control module schematic GC PK04 047 82 2011 04 07 Q1 R11 co LI I J1 J2 J3 U2 Pin Description DC 12V MA TIG Meter control DC 24V ot used Gas Delay Control ot used MMA Supply voltage of current adjustment ot used G3525 Shutdown Control ot used TiG Supply voltage of current adjustment ot used Attenuation time adjustment terminal ot used requency switch terminal ot used Frequency switch terminal ot used Control Signal ot used Attenuation time adjustment terminal GND O ON Ch Un P WIN WO Ch Li UH O m
8. Replace Check and remove Check and remove ncrease the cross section of he cable ace if Check and replace Replace Check and remove A 0 dd capacitor between utput and ground 17 BOC Smootharc TIG 185 DC Service manua Ver 1 Rev 1 0314 3 0 Exploded view and component parts list 3 1 Exploded view OJ Sad s i 33 vd CII cl ech 34 9 FI 10 22 7 Fle 7914 928 8 FA wo FA GOD Teo Bel ET ena EE essi pem E TU u Bi ue aff Le EE 20 ZL 91b 2 20 3 44 2 1 c te 2 Ke Zo 924 40 Ver 1 Rev 1 0314 BOC Smootharc TIG 185 DC Service manual 18 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 3 Right 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 reques 6 Upright girder R 22 010003 01 A0 Available on reques 7 Upright girder R 22 010003 02 A0 Available on reques 8 Rear beam fix holder 1 R 25 020101 80 A0 Available on reques 9 Front case fix holder 1 R 25 020101 79 A0 Available on reques 10 op sustain 1 R 25 020101 77 A0 Ava
9. Smootharc TIG 185 DC Service manual M7 BOC A Member of The Linde Group 2 BOC Smootharc TIG 185 DC Service manual Ver 1 Rev 1 1013 Recommended Safety Precautions Electrical Shock ever 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 ever work in moist or damp areas 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 on compliance with operating and maintenance instructions such as connection to incorrect faulty voltage supply including voltage surges outside equipment specs and incorrect overloading atural wear and tear and accidental damage Transport or storage damage Important Notice This document has been prepared by BOC Limited ABN 95 000 029 729 BOC Avoid electric shock by Wearing dry insulated boots
10. When the switch is shut off the voltage is 0V 2 Connect to the ground 3 DC 24V CON3 switch Press the switch Pin1 and Pin3 is 12V When the switch is shut off Pin1 and Pin3 is OV 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 flows 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 Under TIG press the switch there is no load voltage Q5 is open the relay K3 cling high frequency initiates high frequency and starts arc BOC Smootharc TIG 185 DC Service manual Ver 1 Rev 1 0314 2 0 Troubleshooting and maintenance Possible Reasons Solution Problem 1 Press the power switch power indicator meter and ans with no data press the orch without response 2 Press the powe power indica ok the fan is machine has when pressin switch the or and meter is abnormal the no response g the switch Press the power switch power indicator meter and fan works normally Press the switch of the torch without response 4 Turn on the machine normally wit freq
11. grams General wiring diagram First rectifier board schematic First rectifier board circuit diagram Aux module board schematic Aux module board circuit diagram U10 drive module board schematic U10 drive module board circuit diagram U9 control module board schematic U9 control module board circuit diagram U8 pulse control module schematic U8 pulse control module board circuit diagram Second rectifier board schematic Second rectifier board circuit diagram Filtering high frequency board circuit diagram Troubleshooting and maintenance Exploded view and component parts list Exploded view Component parts list for Smootharc TIG185 DC co oN zl Oh Bd a CO OO Os oo A BOC Smootharc TIG 185 DC Service manual Ver 1 Rev 1 0314 1 0 Fundamental schematic and circuit diagrams 11 General wiring diagram DOK 3 Contor signal JGas dday signal Ver 1 Rev 1 0314 BOC Smootharc TIG 185 DC Service manual L2 First rectifier board schematic
12. ilable on reques 11 LED 1 R 04 010700 19 00 04 010700 19 00 2 Op panel insulation 1 R 23 010100 15 A0 23 010100 15 A0 3 Bottom panel insulation 1 R 23 010300 16 A0 Available on reques 4 op windbreak board 1 R 23 020102 02 A0 Available on reques 5 Side windbreak board 2 R 23 020502 04 A0 Available on reques 6 Gas switch connector 1 R 24 031200 11 A0 24 031200 11 A0 17 Fan sustain 2 R 25 020101 78 A0 Available on reques 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 R 37 231220 01 01 37 231220 01 01 26 35mm female socket 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 op board 1 R 51 PM01 046 G1 PMB 46 D 35 iddle board 1 R 51 PD01 065 A PDB 07 G 36 EMC insulation 1 R 23 010800 52 A0 Available on request 37 ounting bracket R 24 020700 48 A0 Availab
13. le on request 38 Boat shaped switch 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 hermal switch 1 R 06 030000 15 01 Available on request 43 Spring 12 R 23 040000 63 A0 Available on request 44 Absorb board R 23 050000 19 A0 23 050000 19 A0 For more information contact the BOC warranty department at warranty boc com BOC Customer Service Centre Australia 131262 www boc com au New Zealand 0800 111 333 www boc co nz BOC Limited 10 Julius Avenue North Ryde NSW 2113 Australia 970 988 Great South Road Penrose Auckland New Zealand 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 MP12 0813 1 FDAUS 0314
14. loose PM01 001 E12 CON1 ne and could 01 001 E12 then C Check if C transformer is damaged he feedback ci connected heck if the solenoid valve is jam med or damaged restart the ok after 2 3 minutes and pull off turn on the mer T1 on the PZ01 005 01 power supply cuit is open circuit check the feedback cable is properly ly or the surface is he solenoid Check the torch he power cab High frequency he output vol ungsten electrode is in poor con he potentiometer is Filtering capacitor PZ01 005 01 in age disturbs the vol for wear or damage oose or damaged he rectifier silicon bridge is damaged e is short circuited relay PZ01 005 W age valve relay PZ01 005 W K1 is damaged K3 is damaged dition or the shielding gas is incorrect he bottom board is leaking or damaged he welding cable is too long and thin resulting in the unstable current 1 3 Wn N ejN Check the external power supply Check the connector Check and remove Check and remove Check and remove Turn off the machine for several minutes Check and remove Check and remove Check and replace Check and replace The machine will be ok after turning off the machine for five minutes Stop the machine for a while Check and remove Clean Check and replace if necessary Check and rep necessary
15. s independently verified the accuracy of the information contained in this document The information in this document is commercial in confidence 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 affiliates 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 Ver 1 Rev 1 0913 BOC Smootharc TIG 185 DC Service manual Contents 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 2 0 3 0 3 1 3 2 Fundamental schematic and circuit dia
16. uency hout high 5 Turn on the machine normally the indicator is 0 abnormal n 6 Turn on the machine normally could start arc but the weld app 7 The welding ears black current is unstable uncontrollable 8 Skip after tur machine 9 The high frequency could not Stop ning on the Ww N Aa LA FM sch Check the circui Check to test the plug Check the inver PM01 001 E12 Start relay K1 on bottom board d solenoid valve j Start relay K2 in tis PZ ter pin umping 724 Q4 resistor RV1 and whe resistance becoming overheated Power off th normal and external power supply AC240 is OK he power cable switch and connector is tightly connected use a multi meter 1 005 01 CON10 for DC340V 5V board has DC24V output use a multi meter to test the CON4 s 1 and 2 If it has 24V output test other areas oes not respond properly it can be indicated by the power circuit does not respond properly check optical U1 MOSFET her the relay is damaged or not Pressing the power button continuously in a short time results in the field discharge e machine for several minutes Switch of the to Gas socket is loose or the cable ch or the cable is loose is broken Pull off the high frequency cable PM01 001 E12 CON2 use a mu the output for DC230 If yes and could start arc check the starting frequency 3 Check whether the high frequ PZ01 005
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