Section TOC

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E-3

THEORY OF OPERATION

E-3

 

 

 

 

FIGURE E.3 — WELD WINDINGS, RECTIFIER, CHOPPER MODULES & FEEDBACK

 

 

WORK

 

THREE-PHASE

TERMINAL

 

RECTIFIER

-

 

 

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GLOW PLUGS

 

STARTER

 

ENGINE

 

ALTERNATOR

ALT

 

 

 

 

 

 

 

RUN/STOP

SOL

SOL

 

OIL PRESS

 

 

ENGINE

SWITCH (RUN)

S

 

 

SENSORS

 

 

 

H

 

 

TEMP

 

U

 

I

 

T

 

D

 

 

D

 

 

 

 

L

 

+

O

 

E

 

W

 

 

 

R

 

 

N

 

 

 

 

 

 

BATTERY

 

 

 

 

-

 

 

 

 

ALTFLASH

 

 

 

 

 

 

 

 

 

+

 

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)

 

 

 

 

 

 

 

 

 

 

POWER

LIGHTS

WELD

 

 

 

 

 

 

 

 

 

 

VRD

 

 

 

 

 

 

 

MECHANICAL

ROTOR

 

 

 

CONTROL

 

 

 

 

 

 

 

BOARD

 

 

 

 

 

ROTATION

 

 

 

 

 

VOLTMETER

SLIP

 

 

 

 

 

 

 

 

 

 

 

 

RINGS

 

 

 

 

 

 

 

 

 

 

 

+

-

 

 

 

 

 

 

 

 

AMMETER

 

 

 

REMOTE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AMPHENOL

OUTPUT

PROCESS/RANGE

 

 

 

 

 

 

 

 

 

 

ARC

 

 

 

 

 

 

 

 

 

 

CONTROL

CONTROL

SELECTOR

 

 

 

 

 

10 + 30

 

 

42 VAC TO 14 PIN AMPHENOL

 

 

 

 

 

 

 

AUXILIARY

WINDINGS

FOR WIRE FEEDER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

240 VAC

 

 

 

 

 

 

 

AUX

 

 

 

 

30

 

 

 

 

 

 

 

CURRENT

 

 

240VAC

 

 

 

 

 

 

 

 

 

TORROID

 

 

RECEPTACLE

 

 

 

 

 

 

 

 

 

 

 

AUX. FEEDBACK

 

 

 

 

 

 

 

ROTOR

 

120VAC

 

 

 

 

 

 

 

 

 

 

FLASH

 

RECEPTACLED (2)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LOW IDLE COMMAND

 

 

 

 

 

 

 

 

 

 

Return

 

Y

 

ENGINE PROTECTION

 

 

IDLER CONTROL

 

 

 

ENGINE

 

 

P.C. BOARD

 

 

Y

TROUBLE

 

 

LIGHT

 

 

ALTERNATOR

 

 

 

LIGHT

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WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK

The three-phase stator weld windings are connected to a three-phase rectifier bridge. The resultant DC voltage is applied to four paralleled capacitors incorporated within each of the two power modules. There are two capacitors in each module. These capacitors function as filters and also as power supplies for the IGBTs. See IGBT Operation in this section. The IGBTs act as high-speed switches operating at 20KHZ. These devices are switched on and off by the Weld Control PC board through pulse width modulation circuitry. See Pulse Width Modulation in this section.

This "chopped" DC output is applied through choke coils and a shunt to the welding output terminals. The

choke functions as a current filter, and it helps to bal- ance the outputs of the two power modules. Free- wheeling diodes are incorporated in the power mod- ules to provide a current path for the stored energy in the choke when the IGBTs are turned off. See Chopper Technology in this section.

Output voltage and current feedback information is fed to the Weld Control PC board. This information is sensed from the output terminal circuits and the shunt.

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

VANTAGE® 400

Page 43
Image 43
Lincoln Electric 400 service manual Weld WINDINGS, RECTIFIER, Power Modules and Feedback, Return to To Section TOC

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.