Section TOC

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E-4

THEORY OF OPERATION

E-4

 

 

 

 

 

FIGURE E.4 — WELD CONTROL BOARD

 

 

 

WORK

 

THREE-PHASE

TERMINAL

 

RECTIFIER

-

 

 

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STATOR

 

GLOW PLUGS

 

 

 

 

 

 

 

MECHANICAL

 

 

 

ENGINE

ROTATION

 

STARTER

 

SLIP

 

 

 

 

 

 

 

 

 

 

 

 

RINGS

 

 

 

 

 

+

-

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

 

 

 

 

 

 

 

 

 

 

 

ROTOR

 

 

 

 

 

 

FLASH

 

 

 

 

 

 

 

 

Y

 

 

ENGINE PROTECTION

 

 

 

IDLER CONTROL

 

 

 

 

 

 

 

ENGINE

 

 

 

P.C. BOARD

 

 

Y

TROUBLE

 

 

LIGHT

 

 

ALTERNATOR

 

 

 

LIGHT

 

 

 

 

 

+

CHOPPER MODULE

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRODE

 

 

 

 

 

 

IGBT

 

 

TERMINAL

 

 

 

 

 

 

 

 

 

 

+

 

 

 

 

 

80 VDC

CHOKE

 

 

 

 

 

 

 

 

TO

 

 

SHUNT

 

 

 

 

 

BOARD

 

 

 

D

R

L

L

 

 

D

POWER VRD

 

 

 

 

 

W

I

 

 

 

 

 

F

C

I

 

D

 

N

 

 

VRD FEEDBACK

 

 

E

R

D

 

 

30

 

 

 

 

E

 

 

I

VRD

 

 

 

B

E

E

W

 

 

 

CONTROLTO

R

G

 

VOLT FEEDBACK

A

N

 

 

 

 

N

VOLTAGE REDUCTION

PWM

 

 

 

 

 

 

G

 

VRD

 

C

T

 

 

 

 

 

 

 

SWITCH

SIGNAL

 

K

 

 

 

 

 

 

 

 

(OFF)

 

 

 

 

 

 

 

 

 

POWER

LIGHTS

WELD

 

 

 

 

 

 

 

 

 

 

VRD

 

 

 

 

 

 

 

 

ROTOR

 

 

 

CONTROL

 

 

 

 

 

 

 

 

 

BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

VOLTMETER

 

 

 

 

 

 

 

 

 

AMMETER

REMOTE

 

 

AMPHENOL

OUTPUT

PROCESS/RANGE

ARC

CONTROL

CONTROL

SELECTOR

10 + 30

42 VAC TO 14 PIN AMPHENOL

FOR WIRE FEEDER

 

AUXILIARY

WINDINGS

 

240 VAC

AUX

30

CURRENT

240VAC

TORROID

RECEPTACLE

 

AUX. FEEDBACK

120VAC RECEPTACLED (2)

LOW IDLE COMMAND

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WELD CONTROL BOARD

The 80 VDC derived from the filter capacitors on the Power Modules, supplies various regulated DC volt- ages to operate the Weld Control PC board circuitry. It also supplies two regulated DC voltages to operate the IGBT driver circuitry on the two Power Modules.

The Weld Control PC board monitors the operator con- trols (arc control, output, and process/range selector). It compares these commands to the current and volt- age feedback information it receives from the shunt

and output terminal circuits. The circuitry on the Weld Control PC board determines how the output should be controlled to optimize welding results, and it sends the correct PWM signals to the IGBT driver circuits. The Weld Control PC board also commands the thermal light and the voltmeter and ammeter (some items may be optional).

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

VANTAGE® 400

Page 44
Image 44
Lincoln Electric 400 service manual Figure E.4 Weld Control Board

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.