Electrical diagrams, Vantage – Lincoln Electric VANTAGE 400 User Manual
Page 155
ELECTRICAL DIAGRAMS
G-3
VANTAGE
®
400
®
®
SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 1)
E
N
-1
70
S
O
L
ID
E
D
G
E
G5597
VANTAGE 400 (PERKINS)
MACHINE SCHEMATIC
NONE
G5388
Maglietta
BAM
DO NOT SCALE THIS DRAWING
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPROVED:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
NA
CRM22115-GA
1
PAGE ___ OF ___
2
ENGINEERING CONTROLLED
MANUFACTURER:
No
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
C
10/26/2006
t
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
ON ALL ANGLES IS ± .5 OF A DEGREE
ON 3 PLACE DECIMALS IS ± .002
ON 2 PLACE DECIMALS IS ± .02
UNLESS OTHERWISE SPECIFIED TOLERANCE:
MANUFACTURING TOLERANCE PER E2056
REVISED LEAD 208C ROUTING.
CHANGE DETAIL:
REFERENCE:
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
G55
97
LEAD COLOR CODE:
B-BLACK
OR GRAY
G-GREEN
O-ORANGE
R-RED OR PI
NK
U-BLUE
W-W HIT
E
Y-YELLOW
COM PONENT
VALUE
UNIT
S:
CAPACIT
OR: MF
D/VOLTS
RESI
STOR:
OHMS/
W ATTS
CONNECTOR PI
N NUMBERS:
VIEW
OF CONNEC
TOR ON PC BOARD
1 2
6
7
12
LATCH
EX.
12 PIN CONNEC
TOR
LABELS:
COMM ON
FRAME
GROUND
EARTH GROUND
THREE
PHASE
RECTIFI
ER
3200uf
300vdc
SHUNT
50MV=400 AMPS
206S
204S
CURRENT L
EVEL
FEED BACK SI
GNAL
POSITIVE
OUTPUT
TERMINAL
NEGATIVE
OUTPUT
TERMINAL
BY-PASS
PC BOARD
206B
208
5A
AC AUX.
POWER
42 V
OLT
AC
WIRE F
EEDER
POWER
41
42
FOUR POLE 1800
RPM ALTERNATOR
120 V
OLT
AC
POWE R F
OR
ROTOR FI
ELD CI
RCUIT
12 V
OLT
BATTERY
ENGINE
STARTER
SOLENOID
START
BUTTON
SWITCH
RUN-STOP SWIT
CH
SHOWN I
N RUN
POS.
FRAME
GROUND
W2
W2
W3
W3
W5
W4
W5
W4
W1
W1
W6
W6
3
5
6
ENGINE PROTECTION/
IDLE CONTROL
PC BOARD
(J31-9)
262
229
(J31-1)
232
(J31-6)
234
SENDER
SENDER
SWITCH
TEMPERATURE
OIL
PRESSURE
SWITCH
EN
G.
PROT.
FUEL
TEMP.
241
228
238
200 (J33
-5)
227 (B3)
IDL
E
SOL.
PULL
COIL
226 (J31
-8)
5S (
B1)
J31-2 (2
32F)
ALT.
+12
VOLTS
RUN
ENGINE
STARTER
+12
VOLTS
RUN
+12
VOLTS
RUN
201
200
200A
21
WIREFEEDER
VOLTMETER
POLARIT
Y
SWITCH
206A
208A
231
238A
+
160 V
DC
6A
5H
+
236B
232H
232D
CB 10
A
236A
C
E
CHOPPPPER PC BOARD
GATE SI
GNAL
IGBT (16)
B7
B8
B6
B3
B5
B2
B4
B1
+COM
FLYBACK
DIODES (12)
FILTE
R
CAPACIT
ORS (6)
+
7,200uF
x6
CHOKE
DC BUS
VOLTAGE
90+/-10V
DC @ HI I
DLE
ARC VOLTAGE F
EEDBACK SI
GNAL
R1
OUTPUT
CONTROL 10
K
77 (J7-
1)
76 (J7-
4)
75 (J7-
5)
R2
ARC
CONTROL 10
K
279 (J7
-6)
278 (J7
-7)
277 (J7
-8)
(J3-14)
257
(J3-7)
256
IDL
ER SWITCH
(J1-4)
2
(J1-3)
4
W ELD T
ERM.
SW.
MO DE
SWITCH
CC
CV
PI
PE
TIG
(J7-9)
214
(J7-14)
218
(J7-15)
220
(J7-16)
222
260 (J3
-4)
261 (J3
-3)
TOROID:
Senses auxiliary power load to activat
e idler.
Generator leads 3
and 6 pas
s through
torroid
3 times in
opposite di
rections.
VRD WELD CONTROL
PC BOARD
204S (J6-1)
206S (J6-2)
208C (J3-15)
2
3
(
J
3
-1
0
)
2
5
(
J
3
-9
)
5G (J2-3)
REMOTE
CONTROL 10
K
77A (J1-11)
76A (J1-14)
75A (J1-10)
10 V
0-10 V
0 V
10 V
-15 V (
W/O POT.)
0 V
0 V
15 V
15 V
0 V
(TO
AMPHENOL)
(TO
AMPHENOL)
2A
4A
(TO
AMPHENOL)
31
32
41A
A
B
C
D
E
F
77A
21
42A
75A
GND-A
4A
2A
76A
77B
76B
75B
GROUND
CONNECTOR
TO
CONNECTOR J1
115V
AC
CONTACTOR
W ORK
REMOTE
CONTROL
42VAC
GROUND
J
A
D
C
H
B
K
E
F
G
I
77B
76B
75B
GND-B
4B
2B
4B
2B
1
3
(
J
3
-8
)
1
4
(
J
3
-1
6
)
(J1-8) 4
00
(J1-13)
400
400 I.D. JUMPER (Part of round plug and lead assembly.)
LOW I
DLE
COMM AND (0
V
@ LOW I
DLE)
TWISTED
PAI
R
TWISTED
PAI
R
ROTOR FL
ASHING
Located on back of
control panel.
P/
N G5507-1
Located on wiring behind
receptacles.
Control board com
mon is
at welder positive outp
ut
and shunt
Control board circuits
associated with J2 are
part
of engine
electrical syst
em and a
re comm
on to
frame g
round (
negative b
attery te
rminal).
Rotor Flashing: +12 volts
@ 0.5 amps
until gene
rator buil
ds up
then +160 volts @ 0 am
ps.
Swich closed for high idle.
W ELD AMM ETER
W ELD VOLTMETER
(J4-1 to
10)
(J5-1 to
10)
14
14 13
TWISTED
PAI
R
R4
50
OHM
100 W
R4 is located above
rectifier on upper left
interior panel behind
upper control panel.
5J
1
1
1
4
4
4
IDL
E
SOL.
HOLD COIL
247 (J31
-4)
IGBT'
S, FL
YBACK
DIODES
AND
FILTE
R CAPACIT
ORS
ARE I
NTEGRAL
TO
CHOPPER MODULES
AND NOT
INDI
VI
DUALLY
REPLACEABLE.
STATOR
W ELD
WINDINGS
ROTOR FI
ELD
SLI
P
RINGS
REMOTE
CONTROL
OIL
PRESS.
FUEL LVL.
SENSOR
Choke mounted behind
output terminal panel.
Power
Supply
to Control
Board
PWM Signal to Chopper
15 volt @ 20 kHz
Chopper module is located on right side of
interior panel behind upper control panel.
Rectifier is located on left side of interior
panel behind upper control panel.
Shunt on back of positive
output terminal
Located on back of
output panel
between terminals
60 TO 65 V
AC PHASE T
O PHASE
AT
HIGH IDL
E
REVOLVI
NG FI
ELD
RESI
STANCE
APPROX.
25 O
HMS
@ 75F
Field capacitor located on lower rear of
fan baffle on right side of machine.
Battery voltage:
12.6 volts
at rest
14 volts en
gine
running
Located on rear
of control panel
left side.
0.2 O
HM
11 O
HMS
Oil
Pressure
Switch
closes on low
oil pressur
e.
Temper
ature S
witch
closes on hi
gh
tempera
ture.
Engine protection
circuit. 1 mi
nute
delay on e
ngine
start.
3/4 Second
Timer
YELLOW
LAMP
230 O
HMS
EMPTY
30 O
HMS F
ULL
10 O
HMS
@ 0
PSI
100 O
HMS
@ 75
PS1
500-600
OHMS
COLD
50-100 OHM
S
HOT
(SEE
SHEET 2 F
OR
SIMPLIFI
ED
CONTROL
BOARD
SCHEMATI
C)
(SIM
PLIFI
ED BOARD
SCHEMATI
C)
(SIM
PLIFI
ED
BOARD
SCHEMATI
C)
250 (J3
-5)
250 (J3
-1)
Jumper
required
for outp
ut.
Low oil
pressure
or
high
tempera
ture
shutdown
4
6A
5H
Located in top of fuel tank
Located on front panel
Located in engine block
Right side, rear
Located in engine thermostat housing on
Left side of engine
Located on auxiliary
output panel
Located in injection pump
on right side of engine
J55-3
J55-4
J55-2
(J1-5) 4
00
(J1-12)
400
Weld Voltmeter and Ammeter
are standard on Vantage 400
HOUR
METER
+
_
(J31-10
) 263
Voltage
Regulator
+10
Volts
405 (J32
-2)
(J2-5)
405
J56
9 Ohms
at 75
v
F
SHUT
DOW N COIL
Located on right side of engine
inside engine access door
12 volt ground stud on rear of upper control panel.
Located on front
control panel.
Located on front
control panel.
Located on front
control panel.
Located on left
side of engine
block at flywheel
housing.
Battery is located in the
lower left front of
machine behind lower
control panel.
Ground stud on
generator cross
support.
J55 is located
near idle solenoid.
12 volt ground
stud on rear of
upper control
panel.
Located on front
control panel.
12 volt ground stud
on rear of upper
control panel.
Auxiliary power to front
panel receptacles via circuit
breakers on front panel.
P56
P55-4
P55-3
P55-2
244 (J33
-1)
YELLOW
LAMP
243 (J33
-6)
238
243
D
+
+
ENGINE
ALTERNATOR
Located on left side
of engine near
radiator fan.
208C
(J7-2)
215
(J7-10)
216
CONNECTOR
Located in engine
intake manifold
GLOW PLUGS
239
Located on front
control panel.
GLOW PLUG BUTTON SWITCH
238C
238B
3, 4 A
ND 6 - 240
VAC 3
PHASE
3 TO 6 - 240 V
AC 1
PHASE
6A T
O 5 -120
VAC 1
PHASE
3 TO 5 - 120 V
AC 1
PHASE
208B
206B
14C
13
13C
Located under VRD Control PCBd on the back of the control panel
Weld volts >32,
RED light on
Weld volts <32,
GREEN light on
+
-
VDR DISPLAY PC BOARD
Switching
Power
Supply
Voltage
Regulator
(J60-1)
13C
(J60-6)
14C
(J61-8)
206B
(J61-1)
208B
+15
DC
296A
296
GRN
RED
298 (J61
-10)
297 (J61
-9)
299 (J61
-4)
+
-
VRD
SWITCH
Diode Bridge located on upper control
panel, right rear.
Located on VRD control mounting
bracket. Shown in "ON" position
VRD "
OFF"
Tig
Pipe
CV
12
12
26
58
58
58
58
58
Min
Max
CC
Open
Circuit
Volts:
Open
Circuit
Volts:
CC
Max
Min
12
12
58
58
---
---
12
12
CV
Pipe
Tig
VRD "
ON"
*
*
NOTE:
Pipe Mode i
s not
active with
VRD On
Ferrite on Lead 208A
2 turns
Ferrite on meter leads
Ferrite onTwisted Pair
4 turns
Meters dis
play setpoin
t volts or a
mps when not welding.
Meters dis
play actual v
olts and a
mps when
welding.
Hold function displays act
ual volts an
d amps fo
r
approxim
ately 5 seco
nds after welding stop
s.
During this hold display t
he right
most deci
mal point will blink.
Ferrite on Leads 75A & 76A
3 turns
5P
262
CONTACTS
SHOW N I
N "+"
POSITI
ON
G-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.