Language: English

MMA UNITS
Date Creation: Mar. 2005
160A
Rev.: 00

Service Manual

PRESTO 190 GC

1204

1.0 REPAIR INSTRUCTIONS
1.1 REPAIR INSTRUCTIONS
Remove the machine shell and clean care-
fully with compressed air
1.2 MACHINE: VISUAL INSPECTION.
Check the general conditions of the genera-
tor, particularly:
1. On the electronic circuit ref. 20:
• the varistor (fig. 1) if it presents bursting
marks
• the state of precharge ptc (fig. 1)
FIG. 1.
PTC
VARISTOR
2. On the circuit ref. 21 check:
• for the presence of cracks or breaks on the
transformers T1 and T2
• the state of the levelling condensers (fig. 2)
and check if there are swellings or breaks
on the container
FIG. 2.
• the presence of burned tracks or electric
discharge marks on the printed circuit
1204
INVERTERS MMA/TIG 160A C.
3. Check on all the harnesses the insulation of
the cables and the state at the connection
points.
1.3 CHECK OF THE MAIN COMPONENTS
WITH TESTER (OHMMETER)
1. On circuit ref. 20 check for the presence of
short circuits on the rectifier bridge and the
correct value of precharge ptc (6 ohm) (fig. 3)
FIG. 3.
• In case of faults or short circuits replace the
corresponding electronic circuit.
1.4 REPAIR OF FAULTS INDICATED BY YEL-
LOW PROTECTION LED
Connect the generator to the power supply (230
Vac), switch it on: if the yellow led on the front
panel is on, after the relay have been closed, one
of the generator protections has intervened. More
precisely:
1. Thermostatic protection: this intervenes when
the machine overheats; if it is also on when
the machine is cold it means:
• the harness of the thermostatic probe is
interrupted or the same probe is welded or
connected wrongly.
• the circuit regulating the protection does not
work correctly.
2. Over and under voltage protection: this inter-
venes when the machine is fed with a wrong
voltage; if the feed voltage is correct, but the
led is on, the circuit for the voltage reading is
broken.
3. Current overload protection; this means that
the current passage is wrong on the power
circuit of the generator (ref. 21); this is due to
a component fault: Check
Pag. 3
 INVERTERS MMA/TIG 160A C.

• mosfet of the primary circuit and diodes of FIG. 6.

recycle: test points 1-2, 1-3, 2-3 of compo-
nents A,B,C and D (fig.4)
FIG. 4.

C
A 23
1 2 3

2 3 1 23
• the presence on test points: XT1, XT2 and
B XT4 between points 1 GND) - 2 (probe) of
D the wave form as shown in fig. 7: if the wave
form differs from the one in the figure, the
electronic circuit ref. 21 is broken and it has
to be replaced;
• diodes of the secondary circuit: check
points 1-k on the components E, F and G FIG. 7.
(fig. 5)
1 2 2 1
FIG. 5.

E F
1

• if any of these components present short

circuits replace the circuit ref. 21

1.5 CHECK OF GENERATOR OPERATION

WITH OSCILLOSCOPE AND VOLTMETER
1. Disconnects the connections + and - on the
board ref. 20 (fig. 6), connect the generator to
the power supply (230 Vac) and switch it on;
set the oscilloscope on a time base of 5 uS
and a range of 0.5 V/Div with probe x10 and
verify:
2. Switch off the generator and disconnect it
from the power supply; set the oscilloscope
with a range of 1V/Div and connect the probe
X100 between points M (GND) and P (Probe)
(fig. 8); connect the generator to the power
supply, switch it on:
• the motor fan starts up, and after approx. 2
seconds a wave will appear as in fig. 8.

1204 Pag. 5

FIG. 8.
• check with a voltmeter that the output vol-
tage is approx. 80Vdc
Carry out the final test after the repair.
2.0 FINAL TEST
Carry out the safety test according to our ope-
rative instruction N. SLL12, before proceeding
act as follows:
• short-circuit the two phases of the feeder
• on the circuit ref. 20 disconnect the faston
of the ground cable and insert an insulating
thickness to avoid discharges between the
turret and the circuit (fig. 9).
1204
INVERTERS MMA/TIG 160A C.
FIG. 9.
INSULATING
THICKNESS
• on the circuit ref. 21 disconnect the faston
of the ground cable (fig. 10)
FIG. 10.
• short-circuit the output dinse.
• switch on
After the test remove all the short circuits and
restore the connections.
1. Connect the generator to the power supply
(230 Vac), switch it on and check that:
• the yellow led switches on for at least two
seconds
• the green led is on
• the voltage of the outputs is 80Vdc (+/- 5%),
when the yellow led turns off.
2. Switch off the generator and disconnect it
from the power supply; regulate the resistive
load so that the voltage on the load, with
m a ximu m cu r re n t, is b e tw ee n 23 V a n d
27Vdc. Apply oscilloscope probe as in fig. 8
3. Set the regulation knob to the centre of the
scale, connect and switch on the generator,
turn the knob to the maximum welding current
and check that the amperometer reading cor-
Pag. 7
 INVERTERS MMA/TIG 160A C.

responds to the maximum current indicated
on the technical table with +/- 5% tolerance.
Check that the oscilloscope shows a wave-
form as in fig. 11.
FIG. 11.
9. Carry out TIG - LIFT welding tests, verify the
correct working of the lift start (touch with the
electrode tig, by pushing the torch button, the
piece to be welded, and verify a current of
25A, disconnect the electrode and verify the
presence of an arc with a current equal to the
one set)

4. If the value of the current is not within the tole-

rance adjust with trimmer T1 and on circuit
ref. 1 (fig. 12)
FIG. 12.

T1

5. Regulate the resistive load to measure the

minimum current (5A - 20V), set the minimum
current on the frontal panel and check, with
the amperometer, for a value of approx. 5A.
6. Disconnect the probe, switch off the genera-
tor and with the load at maximum current, let
the machine work at the greatest capacity till
the thermostatic protection intervenes (the
thermostatic protection led turns on).
7. Disconnect the machine from the resistive
load and wait until the machine starts working
again (the thermostatic protection led turns
off).
8. Carry out MMA welding tests either with a
RUTILE or basic electrode or with a citoflex
electrode and check the Arc-force interven-
tions using the appropriate potentiometer.

1204 Pag. 9
 LISTA PEZZI DI RICAMBIO - SPARE PARTS LIST - PIÈCES DÉTACHÉES - ERSATZTEILLISTE - LISTA DE LAS PIEZAS DE RECAMBIO

56 13

12 54

21

14

69

11
36

09
48

08
10

03

01

1204
PRESTO 190 GC
 LISTA PEZZI DI RICAMBIO - SPARE PARTS LIST - PIÈCES DÉTACHÉES - ERSATZTEILLISTE - LISTA DE LAS PIEZAS DE RECAMBIO

PRESTO 190 GC

R. Code DESCRIZIONE DESCRIPTION DESCRIPTION BESCHREIBUNG DESCRIPCIÓN

CIRCUITO ELETTRONICO CIRCUIT ÉLECTRONIQUE CIRCUITO
01 W000232523 CIRCUIT BOARD HF 340 STEUERPLATINE HF 340
HF 340 HF 340 ELECTRÓNICO HF 340
CIRCUITO ELETTRONICO CIRCUIT ÉLECTRONIQUE CIRCUITO
03 W000232520 CIRCUIT BOARD HF 338 STEUERPLATINE HF 338
HF 338 HF 338 ELECTRÓNICO HF 338
08 W000050196 CAVO ALIMENTAZIONE POWER CABLE CABLE D’ALIMENTATION NETZKABEL CABLE DE ALIM.

09 W000227612 PRESSACAVO CABLE CLAMP SERRE-CABLE KABELSHELLE PRENSACABLE

09 W000227620 DADO NYLON NUT NYLON ECROU SERRE-CABLE SECHSKANTMUTTER TUERCA NYLON
BLOCCHTTO DI
10 W000070008 BLOCK FIXING GUIDE CARTE BEFESTIGUNGSLAGER BLOQUE DE FIJACIÓN
FISSAGGIO
11 W000050197 COMMUTATORE SWITCH COMMUTATEUR WAHLSCHALTER CONMUTADOR

12 W000236856 RACCORDO USCITA COUPLING RACCORD VERSCHRAUBUNG EMPALME

13 W000050011 MANOPOLA MEDIA KNOB VOLANT POIGNÉE DREHKNOPF VOLANTE PERILLA

13 W000228005 CAPPUCCIO HOOD CAPUCHON KAPPE CAPUCHÓN

14 W000227820 MOTOVENTILATORE ELECTRIC FAN MOTOVENTILATEUR MOTORLÜFTER VENTILADOR ELÉC.

CIRCUITO ELETTRONICO CIRCUIT ÉLECTRONIQUE CIRCUITO
21 W000232525 CIRCUIT BOARD HF 341 STEUERPLATINE HF 341
HF 341 HF 341 ELECTRÓNICO HF 341
CIRCUITO ELETTRONICO CIRCUIT ÉLECTRONIQUE CIRCUITO
36 W000232521 CIRCUIT BOARD HF 339 STEUERPLATINE HF 339
HF 339 HF 339 ELECTRÓNICO HF 339
ALBERINO PER
48 W000050196 TRIMMER SHAFT ARBRE POUR TRIMMER TRIMMER-WELLE EJE PARA TRIMMER
TRIMMER
54 W000050153 PIEDINO FOOT PIED FUSS PATA

56 W000236609 MANOPOLA POCCOLA KNOB VOLANT POIGNÉE DREHKNOPF VOLANTE PERILLA

56 W000228004 CAPPUCCIO HOOD CAPUCHON KAPPE CAPUCHÓN

69 W000050201 IMPEDENZA OUTPUT CHOKE IMPÉDANCE IMPEDANZ IMPEDANCIA

1204
PRESTO 190 GC
 SCHEMA ELETTRICO - WIRING DIAGRAM - SCHÉMA ÉLECTRIQUE - STROMLAUFPLAN - ESQUEMA ELÉCTRICO
PRESTO 190 GC

1204 TAV. 2 A
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 21 - HF 341 - COD. W000232525

1204 TAV. 3 A
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 21 - HF 341 - COD. W000232525

1204 TAV. 3 B
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 01 - HF 340 - COD. W000232523

1204 TAV. 4 A
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 01 - HF 340 - COD. W000232523

1204 TAV. 4 B
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 01 - HF 340 - COD. W000232523

1204 TAV. 4 C
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 03 - HF 338 - COD. W000232520

1204 TAV. 5 A
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 03 - HF 338 - COD. W000232520

1204 TAV. 5 B
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 03 - HF 338 - COD. W000232520

1204 TAV. 5 C
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 36 - HF 339 - COD. W000232521

1204
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 36 - HF 339 - COD. W000232521

1204