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E-2

THEORY OF OPERATION

E-2

 

 

FIGURE E.2 — GENERAL DESCRIPTION, BATTERY, ENGINE, ROTOR, STATOR & ENGINE PROTECTION

 

 

WORK

 

THREE-PHASE

TERMINAL

 

RECTIFIER

-

 

 

 

 

 

 

 

 

 

 

 

+

 

CHOPPER MODULE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRODE

 

 

 

 

 

 

 

 

 

 

 

 

 

IGBT

 

 

TERMINAL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

 

 

 

 

 

 

 

 

 

 

 

80 VDC

 

CHOKE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TO

 

 

 

SHUNT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STATOR

L

W

D

BOARD

POWER VRD

 

 

 

 

F

C

L

 

 

 

 

 

 

 

I

 

 

 

 

D

R

 

 

 

 

 

 

 

D

 

N

 

 

VRD FEEDBACK

 

 

E

R

D

 

 

 

 

 

 

 

 

30

 

 

 

 

 

 

 

 

 

 

 

E

I

CONTROLTO

VRD

 

 

 

 

B

E

E

 

 

 

 

 

 

 

W

 

N

R

G

 

 

VOLT FEEDBACK

A

N

 

 

 

 

 

 

 

 

 

 

VOLTAGE REDUCTION

 

PWM

 

 

 

 

 

 

 

 

 

 

 

G

 

 

VRD

 

 

C

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH

SIGNAL

 

K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(OFF)

 

 

 

 

 

 

 

 

GLOW PLUGS

 

 

 

 

POWER

 

WELD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LIGHTS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VRD

 

 

 

 

 

 

 

 

 

 

 

 

 

MECHANICAL

ROTOR

 

 

 

CONTROL

 

 

 

 

 

 

 

 

 

 

 

 

 

BOARD

 

 

 

 

 

 

 

 

ENGINE

ROTATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VOLTMETER

 

STARTER

 

SLIP

 

 

 

 

 

 

 

 

 

 

 

 

 

RINGS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

-

 

 

 

 

 

 

 

 

AMMETER

 

 

 

 

 

 

 

 

 

REMOTE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ALTERNATOR

ALT

 

 

 

 

 

 

 

 

AMPHENOL

OUTPUT

PROCESS/RANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ARC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOL

SOL

 

OIL PRESS

 

 

 

 

 

 

CONTROL

CONTROL

SELECTOR

 

 

 

 

 

RUN/STOP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE

 

10 + 30

 

 

42 VAC TO 14 PIN AMPHENOL

 

 

 

 

 

 

 

SWITCH (RUN)

 

S

 

 

 

 

 

 

 

 

 

 

 

 

 

SENSORS

 

 

 

FOR WIRE FEEDER

 

 

 

 

 

 

 

 

 

H

 

 

AUXILIARY

WINDINGS

 

 

 

 

 

 

 

 

 

 

TEMP

 

 

 

 

 

 

 

 

 

 

 

 

 

U

I

 

 

 

 

 

 

 

 

 

 

 

 

 

T

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

 

 

O

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

240 VAC

 

 

 

 

 

 

 

 

W

R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

AUX

 

 

 

 

30

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BATTERY

 

 

 

 

 

CURRENT

 

 

240VAC

 

 

 

 

 

 

 

 

-

FLASH

 

 

 

 

 

TORROID

 

 

RECEPTACLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AUX. FEEDBACK

 

 

 

 

 

 

 

 

ALT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ROTOR

 

120VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RECEPTACLED (2)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FLASH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LOW IDLE COMMAND

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

ENGINE PROTECTION

 

 

 

IDLER CONTROL

 

 

 

 

ENGINE

 

 

 

P.C. BOARD

 

 

Y

TROUBLE

 

 

LIGHT

 

 

ALTERNATOR

 

 

 

LIGHT

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GENERAL DESCRIPTION

The Vantage® 400 is a diesel engine-driven welding power source capable of producing 450 amps at 32VDC at a 100% duty cycle. The engine is coupled to a brush-type alternating current generator. This AC output is rectified and controlled by Chopper Technology to produce DC current for multi-purpose welding applications. The Vantage® 400 is also capa- ble of producing 11,000 watts of AC auxiliary power at 100% duty cycle.

BATTERY, ENGINE, ROTOR, STATOR, PULL COIL BOARD AND PERIPHERAL BOARD – ENGINE PROTECTION

The 12VDC battery powers the engine starter motor and also supplies power to the Pull Coil PC board, Peripheral PC board and associated circuitry. When the engine, which is mechanically coupled to the rotor, is started and running, the 12 VDC battery voltage is

fed through the pull coil PC board to the rotor field coil via a brush and slip ring configuration. This excitation or "flashing" voltage magnetizes the rotor lamination. This rotating magnet induces a voltage in the station- ary windings of the main alternator stator. The stator houses a three-phase weld winding, a 120/240VAC single-phase auxiliary winding, and a 42VAC wire feed- er power winding.

The engine alternator supplies charging current for the battery circuit. The Peripheral board monitors the engine sensors and will shut the engine off in the event of low oil pressure, engine over temperature, malfunc- tion of the engine’s alternator system or a low fuel con- dition. The idler solenoid is mechanically connected to the engine’s throttle linkage. If no welding or auxiliary current is being drawn from the Vantage® 400, the Pull Coil board activates the idler solenoid, which then brings the engine to a low idle state. When output cur- rent is sensed, either weld or auxiliary, the Weld Control PC board deactivates the idler solenoid, and the engine returns to high RPM.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

VANTAGE® 400

Page 42
Image 42
Lincoln Electric 400 service manual Weld

400 specifications

The Lincoln Electric 400 is a state-of-the-art multi-process welding machine designed to meet the demands of today’s industrial welding applications. Renowned for its reliability and versatility, this welder is a preferred choice among professionals in fabrication, construction, and maintenance industries.

One of the main features of the Lincoln Electric 400 is its multi-process capability. It seamlessly integrates MIG, TIG, and stick welding processes into a single unit, allowing users to switch between methods depending on the job at hand. This flexibility makes it incredibly suitable for a wide range of materials, including steel, stainless steel, and aluminum.

The welding machine boasts a robust power output, with a maximum range of 400 amps. This impressive capacity enables it to handle thick materials effectively, making it ideal for heavy-duty tasks. The machine operates on both single-phase and three-phase power, giving users the advantage of versatility depending on the power source available at the job site.

Another significant characteristic of the Lincoln Electric 400 is its advanced digital display and control interface. This user-friendly panel allows for easy adjustments to voltage and wire feed speed, ensuring precision and high-quality welds. Additionally, the machine includes built-in features to improve the consistency of welding, such as the Smart MIG technology which optimizes the welding parameters automatically based on the wire diameter and material thickness.

In terms of durability, the Lincoln Electric 400 is designed for rugged environments. Its heavy-duty construction, including a robust metal casing and protective features, ensures it can withstand the rigors of daily use in harsh conditions. Furthermore, the welder is often praised for its efficient cooling system, which prolongs the machine's lifespan and maintains optimal performance even during extended usage.

Portability is another key aspect of this welding machine. Weighing under 200 pounds, it is designed with mobility in mind. The integrated wheels allow for easy transportation between job sites, making it a practical choice for mobile welders and contractors.

In conclusion, the Lincoln Electric 400 stands out in the welding equipment market due to its multi-process capabilities, impressive power output, user-friendly interface, durability, and portability. It is engineered to exceed the expectations of professional welders, providing them with the tools needed for high-quality results across a variety of applications.