Schematic - Complete Machine (G5597 Page 1 - Lincoln Electric VANTAGE 400 Service Manual

G-3
SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 1)
G5597
ENGINEERING CONTROLLED CHANGE DETAIL: REVISED LEAD 208C ROUTING.
No
MANUFACTURER:
Shunt on back of positive
output terminal
SHUNT
POSITIVE
50MV=400 AMPS
OUTPUT
TERMINAL CURRENT L E VEL
204S
FEED BACK SI GNAL
206S
Located on back of 206B
206A
output panel
BY- PASS
between terminals WI REFEEDER
PC BOARD
VOLTMETER
21
POLARIT Y
208
208A
SWIT CH
CONTACTS
Ferrite on Lead 208A
SHOW N I N "+ "
2 turns 208C
POSITI ON
208B
206B
NEGATIVE
OUTPUT
TERMINAL
VRD " O FF"
Open Circuit Volts:
Max
Min
CC 58 58
58
CV 58
26
Pipe 58 Ferrite onTwisted Pair
Tig 12 12
4 turns
VRD " O N"
Open Circuit Volts:
Max Min
CC 12 12
CV 58 58
--- ---
* Pipe
Tig 12 12
* NOTE: Pipe Mode i s not
VRD On active with
ARC VOLTAGE F E EDBAC K SI GNAL
OUTPUT
R1
CONTROL 10 K
REMOTE
(TO AMPHENOL)
CONTROL 10 K
ARC
R2
CONTROL 10 K
TOROI D: Senses auxiliary power load to activat e idler.
Generator leads 3 and 6 pas s through torroid 3 times in
opposite di rections.
Located on wiring behind
receptacles.
Jumper required for outp
Control board circuits associated with J2 are
of engine electrical syst em and a re comm on to
frame g round ( negative b attery te rminal).
12 volt ground stud on rear of upper control panel.
Weld Voltmeter and Ammeter
are standard on Vantage 400
A 77B
REMOTE
B 76B
CONTROL
C 75B
D 2B
4B
E
GROUND F GND- B
CONNECTOR
® ®
Chopper module is located on right side of
interior panel behind upper control panel.
IG BT' S , FL YBACK DI ODES AND
FILTE R CAPACIT ORS ARE I NTEGRAL CHOPPPPER PC BOARD
TO CHOPPER M ODULES AND NOT
13C
INDI VI DUALL Y REPL ACEA BLE.
13
+COM
B2 B5
R4 is located above 7,200uF x6
rectifier on upper left R4
50 OHM +
interior panel behind
100 W
upper control panel. FILTE R
CAPACIT ORS (6) DC BUS VOLTAGE
FLY BACK 90+/-10V
Choke mounted behind
DI ODES (12)
output terminal panel.
B3
IG BT (16)
B1 B4
E
C
B6
CHOKE PWM Signal to Chopper
15 volt @ 20 kHz
B7 B8
GATE SI GNAL
14
14C
296 RED 299 (J61 -4)
Po wer Supply
to Control 296A GRN 297 (J61 -9)
Board
Weld volts >32,
14 13
298 (J61 -10) +15 DC Weld volts <32,
TWI STED TWI STED TWI STED
Switching
PAI R PAI R PAI R
Supply Voltage
Regulator
204S (J6-1) VDR DISPLAY PC BOARD
206S (J6-2)
Located under VRD Control PCBd on the back of the control panel
208C (J3-15) Control board com mon is
at welder positive outp ut
LOW I D LE COMM AND (0 V @ L OW I D LE)
10 V
(J2-5) 405
77 (J7- 1) and shunt
0-10 V
76 (J7- 4) Swich closed for high idle.
0 V
VRD WELD CONTROL
(J3-14) 257
IDL E R SWIT CH
0 V
75 (J7- 5) (J3-7) 256
PC BOARD
15 V
2A
10 V P/ N G5507-1 (TO AMPHENOL)
77A (J1-11) 15 V
(J1-4) 2
-15 V ( W/ O POT.)
Located on back of W EL D T ERM. SW.
76A (J1-14)
(J1-3) 4
control panel. 0 V
(TO AMPHENOL)
0 V 4A
75A (J1-10)
CV
(S EE SHEET 2 F OR
(J7-9) 214
279 -6) (J7
PI PE
SIM PLIFI ED
(J7-14) 218
MO DE
CONTROL BOARD CC
278 -7) (J7
SWIT CH
SCHEMATI C )
TIG
(J7-15) 220
277 (J7 -8)
(J7-16) 222
Located on VRD control mounting
(J7-2) 215
bracket. Shown in "ON" position
260 (J3 -4)
(J7-10) 216
261 (J3 -3)
VRD
(J1-5) 4 00
SWIT CH
250 -5) (J3
(J1-12) 400
400 I.D. JUMPER (Part of round plug and lead assembly.)
250 -1) (J3
(J1-8) 4 00
ut.
(J1-13) 400
5G (J2-3)
part (J4-1 to 10) (J5-1 to 10)
Ferrite on meter leads
Meters dis play setpoin t volts or a mps when not welding.
Meters dis play actual v olts and a mps when welding.
W EL D AMM ETER W ELD VOLTMETER
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.
J 31
115V A C
A 32
I 41A
42V AC
K
42A
H 21
W ORK
E 77A
REMOTE 77B
CONTROL F 76A
76B
G 75A
TO CONNECTOR J1
75B
CONTACTOR
D 4A
4B
C 2A
2B
GROUND B GND- A Ferrite on Leads 75A & 76A
3 turns
CONNECTOR
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS
Rectifier is located on left side of interior
panel behind upper control panel.
THREE PHASE
60 TO 65 V AC PHASE T O PHASE
RECTIFI ER
AT HI GH IDL E
W1 W6
W1 W6
W2 STAT OR
W2
W EL D
W3
DC @ HI I DLE WI NDI NGS
W3
FOUR POLE 1800 RPM ALT ERNATOR
W4 W5
W4 W5
41
Field capacitor located on lower rear of
ROTOR FI EL D
fan baffle on right side of machine.
42 V OLT AC
SLI P RI NGS
WI RE F E EDER
POWER 200
200A +
42
160 V DC
3
3200uf
Auxiliary power to front 300vdc
-
panel receptacles via circuit
6A 5H
(J61-1) 208B
breakers on front panel.
201
+ (J61-8) 206B 5
4
REVOLVI NG FI EL D
AC AUX. POWER
RESI STANCE APPROX.
3 TO 5 - 120 V AC 1 PHASE 5A
25 O HMS @ 75F
6A T O 5 -120 VAC 1 PHASE
RED light on
3 TO 6 - 240 V AC 1 PHASE 120 V OLT AC
GREEN light on
3, 4 A ND 6 - 240 VAC 3 PHASE
POWER F OR
6 ROTOR FI ELD CI RCUIT
Po wer
+ (J60-6) 14C
6A
-
(J60-1) 13C
5H
Located in engine
GLOW PLUG BUTT ON SWIT CH
GLOW PLUGS
intake manifold
Located on front
239 control panel.
+12 VOLTS RUN
238C
Located on front 238B
control panel.
RUN-STOP SWIT CH
SHOWN I N RUN POS.
Located on auxiliary
236B
output panel
232D
CB A 10
Located on front
236A
control panel.
232H START BUTT ON
SWIT CH
238A
231
238
ENGI NE
STARTER
SOLENOI D
Battery voltage:
12.6 volts at rest
14 volts en gine
Located on left
running ENGI NE
side of engine
STARTER
block at flywheel
+
238
housing.
Battery is located in the
12 V OLT
lower left front of
+
BATT ERY
machine behind lower
Ground stud on
control panel.
D
generator cross
support.
FRAME
ENGI NE
GROUND
ALT ERNATOR
Located on left side
of engine near
radiator fan.
+12 VOLTS RUN
OIL
FUEL PRESS. TEMP.
Located in top of fuel tank
4 1 4 1 4 1
FUEL LVL.
SENSOR
229
241
5J 230 O HMS EMPTY
228
30 O H MS F U LL
Oil Pressure Switch
closes on low
oil pressur
ENGINE PROTECTION/
OIL PRESSURE
Located on rear
IDLE CONTROL
of control panel
(J31-6) 234
PC BOARD
left side.
Low oil
SWIT CH
pressure or
high
247 (J31 -4)
tempera ture
Engine protection
shutdown
circuit. 1 mi nute
delay on e ngine
start. Temper ature S witch
SWIT CH
(SIM P LIFI ED closes on hi gh
EN G. YEL LOW BOARD tempera ture.
Located on front panel
PROT.
LAMP
SCHEMATI C )
Located in engine thermostat housing on
Left side of engine
+12 VOLTS RUN
Voltage
(J31-1) 232
Regulator
Diode Bridge located on upper control
panel, right rear.
+10 Volts
244 (J33 -1)
(J31-10 ) 263
(J31-9) 262
YEL LOW
ALT.
LAMP
(SIM P LIFI ED BOARD
SCHEMATI C )
J31-2 (2 32F)
Located on front
control panel.
0.2 O HM
IDL E SOL.
J55-4 PULL COIL
227 (B3)
P55-4
Located on right side of engine
inside engine access door
226 (J31 -8)
243 (J33 -6)
405 (J32 -2) 12 volt ground
stud on rear of
3/4 Second 5S ( B1)
upper control
Timer
panel.
ROTOR FL A SHI NG
200 (J33 -5)
Rotor Flashing: +12 volts
@ 0.5 amps
until gene rator buil ds up
then +160 volts @ 0 am ps.
Located in injection pump
on right side of engine
SHUT DOW N COIL
J56
262
9 Ohms
v
at 75 F
P56
5P
243
+
PROPRIETARY & CONFIDENTIAL: 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.
MANUFACTURING TOLERANCE PER E2056
DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: VANTAGE 400 (PERKINS)
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02
DRAWN BY: Maglietta G5388
ON 3 PLACE DECIMALS IS ± .002
SUBJECT: MACHINE SCHEMATIC
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER: BAM SCALE:
MATERIAL TOLERANCE (" ") TO AGREE t
WITH PUBLISHED STANDARDS. MATERIAL 10/26/2006
NA APPROVAL PROJECT
NONE
DO NOT SCALE THIS DRAWING APPROVED: DISPOSITION: DATE: NUMBER:
G-3
Located in engine block
Right side, rear
10 O H MS @ 0 PSI
e.
100 O HMS @ 75 PS1
SENDER
TEMPERATURE
SENDER
500-600 O HMS COLD
50-100 OHM S HOT
Located on front
control panel.
12 volt ground stud
HOUR
on rear of upper
METER
control panel.
+ _
J55-3
J55 is located
11 O H MS
near idle solenoid.
IDL E SOL.
J55-2
HOLD COIL
P55-3
P55-2
LE AD COLOR CODE: COM PONENT VAL UE UNIT S:
B- BL ACK OR GRAY CAPACIT OR: MF D/ VOLT S
G- GREEN
RESI STOR: OHMS/ W ATT S
O- ORANGE
R- RED OR PI NK
CONNECTOR PI N NUMBERS:
U- BL UE
W-W HIT E EX. 12 PIN CONNEC TOR
Y- YELL OW
1 2 6
LABELS:
COMM ON
7 12
FRAME GROUND LATCH
EARTH GROUND VIEW OF CONNEC TOR ON PC BOARD
1 2
PAGE ___ OF ___
DOCUMENT
DOCUMENT
NUMBER: REVISION:
G5597
C
CRM22115-GA
VANTAGE ® 400