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Service Manual: COLT 130G COLT 150G
Service Manual: COLT 130G COLT 150G
COLT 150G
Service Manual
COLT 130G
COLT 150G
MAIN TEST POINTS
Perform an accurate visual control of the assembled PCB; make sure there are no visible assembly errors,
short-circuits or other discrepancies.
(i) Before to start the testing procedures described below, upload the correct revision of the software
to the flash memory of the microcontroller.
Connect a suitable source of regulated voltage 15 − 16 Vdc between the test point TP4 and grounding
plane (GND = TP35). Remember to limit the maximum output current of the used voltage source to
approximately 750 mA.
Verify if the bi-color LED L1 emittes the GREEN / YELLOW light during the initialization phase
(approximately 1½ s) and after this time, the color of emitted light is changed to GREEN. This
can be done visually or automatically, measuring the appropriate control signals present at TP27
(YELLOW) and TP30 (GREEN) with reference to GND.
Verify if the contact of soft-start relay RL1 is closed after approximately 1 s since the supply
voltage was connected. This can be done visually or automatically, measuring the signal at TP1
with reference to TP4 (when the contact of relay is closed, the value of the differential voltage
appeared between these two points is close to the supply voltage).
Verify the functionality of a cooling fan. The fan must be automatically enabled after 1½ s since
the supply voltage was connected. The verification can be performed visually or automatically,
measuring the differential voltage between the test points TP23 and TP24. When the fan is
enabled, the differential voltage appeared between the test points TP23 and TP24 is in range
13,2 − 14,2 Vdc.
Using the DC voltmeter verify, if the value of voltage measured between the test point TP19 and
GND is in range 4,4 − 4,6 Vdc.
Using the DC voltmeter verify, if the value of voltage measured between the test point TP8 and
GND is in range 4,4 - 4,6 Vdc and voltage measured between the test point TP12 is near or equal
to 0 Vdc.
PCB TEST SPECIFICATION
Connect the voltage probe between the test point TP10 and grounding plane (TP35). Recommended
oscilloscope setup: Horizontal axis (Time base) = 2 µs per division; Vertical
axis = 1 V per division; Trigger at positive edge; Bandwidth at least 1 MHz. Verify the presence of
synchronization signal and referring to the Fig. 1 verify the following parameters of measured
waveform:
Re-connect the probe between the test point TP21 and GND (recommended oscilloscope setup
is the same as in step before, except the setup of vertical axis – this must be set to 5 V per
division in this case). Referring to the Fig. 2 verify the following parameters of the measured
waveform:
Disconnect the voltage probe connected between the test point TP21 and GND. Connect two
probes between TP38, TP35 (bottom channel) and TP34, TP26 (top channel) and measure the
waveform of gate drive signals. Remember to use a differential probe at least to measure the
signal of top channel to lift the ground. Recommended oscilloscope setup: Horizontal axis (Time
base) = 5 µs per division; Vertical axis = 5 V per division; Trigger at positive edge; Bandwidth at
least 1 MHz. Verify the following parameters of measured waveform (refer to Fig. 3):
Leave the two voltage probes between TP38, TP35 and TP34, TP26 connected as in previous step. Connect
a small-signal resistor with nominal value 680 Ω (maximum allowed tolerance of the nominal value should
not exceed ± 10 %) between the test points TP17 and TP19; verify if the waveform disappears and front
panel bi-color LED emittes a continuous YELLOW light.
5 Disconnect the source of regulated voltage 15 − 16 Vdc, small-signal resistor and all the measurement
equipments connected to the PCB.
PCB TEST SPECIFICATION
Connect the nominal power supply voltage 230 V / 50 Hz between the pins PZ_AC1 and PZ_AC2.
Using the DC voltmeter verify, if the value of voltage measured between the test point TP4 and GND is
in range 14,75 − 15,85 Vdc.
(!) IN CASE OF FAILURE OR INTERRUPTED TEST, ALWAYS WAIT AT LEAST 5 MINUTES FOR
DECREASE OF MAIN BULK CAPACITORS VOLTAGE BEFORE TO MANIPULATE WITH THE
PCB AGAIN. BEFORE TO TOUCH THE PCB, COMPLETELY DISCHARGE MAIN BULK
CAPACITORS WITH 47 – 100 Ω / 10 W RESISTOR.
Connect voltage probe between the test points TP26, TP37 to measure the waveform of the
voltage applied across the primary winding of the main transformer. Recommended oscillo-scope
setup: Horizontal axis (Time base) = 5 µs per division; Vertical axis = 100 V per division; Trigger
at positive edge; Bandwidth at least 1 MHz. Verify if the measured waveform is in accordance
to the reference waveform shown on Fig. 4. Verify if the peak-to-peak value of the measured
waveform is in range 360 − 380 V.
Re-connect the voltage probe from test points TP26, TP37 to TP32, TP36 and measure the
waveform of the output no-load voltage. Recommended oscilloscope setup: Horizontal axis (Time
base) = 5 µs per division; Vertical axis = 50 V per division; Trigger at positive edge; Bandwidth at
least 1 MHz. Verify if the measured waveform is in accordance to the reference waveform shown
on Fig. 5. Verify if the averaged value of the measured waveform is in range 48 − 55 V.
Disconnect the power supply voltage and re-connect the voltage probe between the test point TP38 and
grounding plane (TP35). Connect the power supply voltage between the pins PZ_AC1 and PZ_AC2 again
and perform the following operations:
Adjust the RMS value of mains to 265 V and check if the measured waveform is in accordance to
the reference waveform shown on Fig. 6. Recommended oscilloscope setup: Horizontal axis (Time
base) = 5 µs per division; Vertical axis = 5 V per division; Trigger at positive edge; Bandwidth at
least 1 MHz. Verify the following parameters of measured waveform:
• Duty cycle must not be lower than 32,5 % and higher than 35,5 %
• The active width of pulse must not be lower than 5 µs and higher than 5,5 µs.
Adjust the RMS value of mains to 300 V and check if the measured waveform is in accordance to
the reference waveform shown on Fig. 7. Recommended oscilloscope setup: Horizontal axis (Time
base) = 5 µs per division; Vertical axis = 5 V per division; Trigger at positive edge; Bandwidth at
least 1 MHz. Verify the following parameters of measured waveform:
9 Disconnect the power supply voltage. Set the shaft of current regulation potentiometer to the middle
position. Connect the differential voltage probe between the test points TP26, TP37. Connect to the
output circuit AVG voltmeter and suitable current probe. Connect a resistive load with the nominal value
0,35 Ω and power rating no less than 1,5 kW to the output terminals BS1 (W-) and BS2 (W+). Connect the
nominal power supply voltage 230 V / 50 Hz between the pins PZ_AC1 and PZ_AC2.
10 LOADING TEST
Carefully rotate the current regulation knob until the measured average value of the output current
reaches 65 A / ± 2 A.
Verify if the differential voltage waveform measured between the test points TP26, TP37 is in
Verify if the waveform of the output current is in accordance to the reference waveform shown
on Fig. 9.
(i) EXACT OSCILLOSCOPE SETUP DEPENDS ON THE USED TYPE OF CURRENT SENSING;
RECOMMENDED SETUP OF HORIZONTAL AXIS (TIME BASE) IS 5µs.
(!) DURING THE MEASUREMENT PAY ATTENTION TO MINIMIZE THE LOADING TIME TO
AVOID THE POSSIBLE OVERHEATING OF THE TESTED PCB OR THE RESISTIVE LOAD.
Using the suitable tool make a short circuit across the resistive load and check, if the output current
waveform is in accordance to the reference waveform shown on Fig. 10.
(i) EXACT OSCILLOSCOPE SETUP DEPENDS ON THE USED TYPE OF CURRENT SENSING;
RECOMMENDED SETUP OF HORIZONTAL AXIS (TIME BASE) IS 200 ms.
12 FINAL OPERATIONS
Disconnect the power supply voltage 230 V / 50 Hz, remove the loading resistor and short circuit. Remove
all the measurement equipments connected to the PCB.
CALIBRATION IN AUTONOMICAL SERVICE MODE
(PERFORMED BY AFTER SALE SERVICE DEPARTMENT IF REQUIRED)
Step OPERATIONS EFFECTS
Preparation and Powering-ON of the equipment Verify if after the start-up of the machine the LED
on the front panel gives blinking green light.
Carefully disassemble the top cover of the The blinking green light indicates that the
equipment. Use the soldering machine to tie autonomical service mode has been enabled.
together test points TP10 and TP40 on the bottom
side of PCB. Solder also an external switch
between points PZ_SW1 and PZ_SW2.
Calibration of the maximum output current Rotate the current regulation knob present on
the front panel of the equipment to calibrate the
Connect to the output welding terminals the average value of the output current as in step 3.0.
resistive load and AVG ampere-meter as in step When the requested average value of the output
2.0 2.0. current is adjusted, revert the position of the
external switch.
Calibration data will be stored automatically in
FLASH memory and the front panel diode starts to
light continuously.
3.0 Turn-OFF the equipment by the main switch, remove the connection between the test points TP10 and
TP40, desolder the external switch and clean the PCB if required.
Verification of the stored calibration data Verify if the average value of the output current is in
range for:
Rotate the current regulation knob to the position
MAX. COLT 130G - 130 A – 132 A
4.0 Turn-ON the main power switch. Connect to the COLT 150G - 140 A – 142 A
output welding terminals the resistive load and AVG
ampere-meter as in step 3.0. If the average value of the output current is out of
the requested range, repeat the procedure from
step 2.0 again.
TEST POINTS
REFERENCE WAVEFORMS
Fig. 2: Waveform of square-wave signal present at the output of PWM controller (measured between TP21 and GND)
Fig. 3: Waveform of drive signal between TP38, TP35 (the same as between TP34, TP26)
Fig. 5: Output no-load voltage waveform measured between the test points TP32 and TP36
Fig. 6: Gate drive voltage waveform measured between TP38 and TP35 (GND), power supply voltage increased to 275 Vac
Fig. 7: Gate drive voltage waveform measured between TP38 and TP35 (GND), power supply voltage increased to 300 Vac
Fig. 8: Differential voltage waveform measured between TP26 and TP37 at output current 65
REFERENCE WAVEFORMS
Fig. 10: Output current waveform when the value of load is decreased near to zero – output
current increases during the first 0,5 s time period and after decreases to its minimum value
SPARE PARTS / PIÈCES DÉTACHÉES / LISTA DE LAS PIEZAS DE RECAMBIO / LISTA PEZZI DI RICAMBIO / ERSATZTEILLISTE / PEÇAS SOBRESSELENTES
RESERVDELAR / WISSELSTUKKEN / LISTE AF RESERVEDELE / LISTE OVER RESERVEDELER / VARAOSALUETTELO / LISTA PIESE COMPONENTE
ZOZNAM NÁHRADNÝCH DIELOV / SEZNAM NÁHRADNÍCH DÍLŮ / PÓTALKATRÉSZEK LISTÁJA / LISTA CZĘŚCI ZAMIENNYCH
ΚΑΤΑΛΟΓΟΣΑΝΤΑΛΛΑΤΙΚΩΝ / ПЕРЕЧЕНЬ ЗАПАСНЫХ ЧАСТЕЙ
COLT 130 G
R. CODE DESCRIPTION DESCRIPTION DESCRIPCIÓN DESCRIZIONE
01 W000272986 CIRCUIT BOARD CIRCUIT ÉLECTRONIQUE CIRCUITO ELECTRÓNICO CIRCUITO ELETTRONICO
05 W000352034 POTENTIOMETER POTENTIOMÈTRE POTENCIÓMETRO POTENZIOMETRO
07 W000352085 HANDLE POIGNÉE MANILLA MANIGLIA
08 W000273038 POWER CABLE CÂBLE ALIMENTATION CABLE DE ALIMENTACIÓN CAVO ALIMENTAZIONE
09 W000352000 CABLE CLAMP SERRE-FIL PRENSACABLE PRESSACAVO
11 W000352016 SWITCH INTERRUPTEUR INTERRUPTOR INTERRUTTORE
12 W000050023 DINSE COUPLING RACCORD SORTIE RACOR DE SALIDA RACCORDO USCITA
14 W000270554 FAN UNIT MOTOVENTILATEUR MOTOR DEL VENTILADOR MOTOVENTILATORE
38 W000263386 FRONT PLASTIC FRAME PROFIL ARÊTE ANTÉRIEUR PERFIL DEL MARCO ANTERIOR CORNICE ANTERIORE
38.1 W000263383 REAR PLASTIC FRAME PROFIL ARÊTE DERRIÈRE PERFIL DEL MARCO POSADERAS CORNICE POSTERIORE
56 W000352082 HOOD HOOD CAPUCHÓN CAPPUCCIO
56.1 W000352038 KNOB BOUTON PERILLA MANOPOLA
72 W000050027 MOUNT SUPPORT SOPORTE SUPPORTO
II
SPARE PARTS / PIÈCES DÉTACHÉES / LISTA DE LAS PIEZAS DE RECAMBIO / LISTA PEZZI DI RICAMBIO / ERSATZTEILLISTE / PEÇAS SOBRESSELENTES
RESERVDELAR / WISSELSTUKKEN / LISTE AF RESERVEDELE / LISTE OVER RESERVEDELER / VARAOSALUETTELO / LISTA PIESE COMPONENTE
ZOZNAM NÁHRADNÝCH DIELOV / SEZNAM NÁHRADNÍCH DÍLŮ / PÓTALKATRÉSZEK LISTÁJA / LISTA CZĘŚCI ZAMIENNYCH
ΚΑΤΑΛΟΓΟΣΑΝΤΑΛΛΑΤΙΚΩΝ / ПЕРЕЧЕНЬ ЗАПАСНЫХ ЧАСТЕЙ
COLT 150 G
R. CODE DESCRIPTION DESCRIPTION DESCRIPCIÓN DESCRIZIONE
01 W000272985 CIRCUIT BOARD CIRCUIT ÉLECTRONIQUE CIRCUITO ELECTRÓNICO CIRCUITO ELETTRONICO
05 W000352034 POTENTIOMETER POTENTIOMÈTRE POTENCIÓMETRO POTENZIOMETRO
07 W000352085 HANDLE POIGNÉE MANILLA MANIGLIA
08 W000273038 POWER CABLE CÂBLE ALIMENTATION CABLE DE ALIMENTACIÓN CAVO ALIMENTAZIONE
09 W000352000 CABLE CLAMP SERRE-FIL PRENSACABLE PRESSACAVO
11 W000352016 SWITCH INTERRUPTEUR INTERRUPTOR INTERRUTTORE
12 W000050023 DINSE COUPLING RACCORD SORTIE RACOR DE SALIDA RACCORDO USCITA
14 W000270554 FAN UNIT MOTOVENTILATEUR MOTOR DEL VENTILADOR MOTOVENTILATORE
38 W000263386 FRONT PLASTIC FRAME PROFIL ARÊTE ANTÉRIEUR PERFIL DEL MARCO ANTERIOR CORNICE ANTERIORE
38.1 W000263383 REAR PLASTIC FRAME PROFIL ARÊTE DERRIÈRE PERFIL DEL MARCO POSADERAS CORNICE POSTERIORE
56 W000352082 HOOD HOOD CAPUCHÓN CAPPUCCIO
56.1 W000352038 KNOB BOUTON PERILLA MANOPOLA
72 W000050027 MOUNT SUPPORT SOPORTE SUPPORTO
III
DUTY CYCLE / FACTEUR DE MARCHE / CICLO DE TRABALHO / CICLO DI LAVORO / EINSCHALTDAUER / CICLO DE TRABAJO / INTERMITTENSFAKTOR
BEDRIJFSCYCLUS / ARBEJDSCYKLUS / ARBEIDS SYKLUS / KÄYTTÖJAKSO / DUTY CYCLE / PRACOVNÝ CYKLUS / PRACOVNÍ CYKLUS
MUNKACIKLUS / CYKL ROBOCZY / ΚΥΚΛΟΣ ΕΡΓΑΣΙΑΣ / РАБОЧИЙ ЦИКЛЅЕ
WELDING CURRENT / COURANT DE SOUDAGE / CORRIENTE DE SOLDATURA / FLUSSO DI SALDATURA
SCHWEIßSTROM / CORRENTE DE SOLDAGEM / SVETSSTRÖM / SNIJSTROOM / SVEJSNINGS STRØM
170
160
SVEISE STRØM / HITSAUSVIRTA / CORENT DE TAIERE / ZVÁRACÍ PRÚD / SVÁŘECÍ PROD
150 140A
140
130
120
110
120A
PRĄD SPAWANIA / ΡΕΥΜΑΣΥΓΚΟΛΛΗΣΗΣ / СВАРОЧНЫЙ ТОК
100
90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
DUTY CYCLE / FACTEUR DE MARCHE / CICLO DE TRABALHO / CICLO DI LAVORO / EINSCHALTDAUER / CICLO DE TRABAJO / INTERMITTENSFAKTOR / BEDRIJFSCYCLUS
/ ARBEJDSCYKLUS / ARBEIDS SYKLUS / KÄYTTÖJAKSO / DUTY CYCLE / PRACOVNÝ CYKLUS / PRACOVNÍ CYKLUS / MUNKACIKLUS / CYKL ROBOCZY / ΚΥΚΛΟΣ ΕΡΓΑΣΙΑΣ
IV
VOLT-AMPERE CURVES / COURBES VOLT-AMPERE / CURVA VOLTIOS-AMPERIOS / CURVE VOLT-AMPERE / KURVEN VOLT-AMPERE
CURVAS VOLTAMPÉRICA / VOLT-AMPERE CURVES / KURVOR VOLT-AMPERE / DA / NO / FI / CURBE VOLT-AMPERE / VOLT-AMPÉROVÉ KRIVKY
VOLT-AMPÉROVÉ KŘIVKY / HU / KRZYWE VOLT-AMPER / ΚΑΜΠΥΛΕΣ VOLT-AMPERE / ВОЛЬТАМПЕРНЫЕ ХАРАКТЕРИСТИКИ
COLT 130G
60
50
Vout
40
V out (V)
30
Vmma
20
Vtig
10
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
I out (A)
VOLT-AMPERE CURVES / COURBES VOLT-AMPERE / CURVA VOLTIOS-AMPERIOS / CURVE VOLT-AMPERE / KURVEN VOLT-AMPERE
CURVAS VOLTAMPÉRICA / VOLT-AMPERE CURVES / KURVOR VOLT-AMPERE / DA / NO / FI / CURBE VOLT-AMPERE / VOLT-AMPÉROVÉ KRIVKY
VOLT-AMPÉROVÉ KŘIVKY / HU / KRZYWE VOLT-AMPER / ΚΑΜΠΥΛΕΣ VOLT-AMPERE / ВОЛЬТАМПЕРНЫЕ ХАРАКТЕРИСТИКИ
COLT 150G
60
50
Vout
40
V out (V)
30
Vmma
20
Vtig
10
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
I out (A)
V
WIRING DIAGRAM / SCHÉMA ÉLECTRIQUE / ESQUEMA ELÉCTRICO / SCHEMA ELETTRICO / STROMLAUFPLAN / ESQUEMAS ELÈCTRICOS
ELSCHEMOR / ELEKTRISCHE SCHEMA´S / TILSLUTNINGSSKEMA / KOBLINGSSKJEMA / KYTKENTÄKAAVIO / SCHEMA ELECTRICA
ELEKTRICKÁ SCHÉMA / ELEKTRICKÁ SCHÉMA / BEKÖTÉSI RAJZ / SCHEMAT ELEKTRYCZNY / ΗΛΕΚΤΡΙΚΟ ΔΙΑΓΡΑΜΜΑ / ЭЛЕКТРИЧЕСКАЯ СХЕМА
VI
CIRCUIT BOARD CE 22710
ELECTRONIC CIRCUIT BOARD CE 22710 page 1
ELECTRONIC CIRCUIT BOARD CE 22710 page 2
ELECTRONIC CIRCUIT BOARD CE 22710 page 3
CIRCUIT BOARD CE 22711
ELECTRONIC CIRCUIT BOARD CE 22711 page 1
ELECTRONIC CIRCUIT BOARD CE 22711 page 2
ELECTRONIC CIRCUIT BOARD CE 22711 page 3