Theory Of Operation - Lincoln Electric VANTAGE 400 Service Manual

E-2
FIGURE E.2 — GENERAL DESCRIPTION, BATTERY, ENGINE, ROTOR, STATOR & ENGINE PROTECTION
GLOW PLUGS
ENGINE
STARTER
ALT
ALTERNATOR
SOL SOL
RUN/STOP
SWITCH (RUN)
S
H
U
I
T
D
D
L
O
+ E
W
R
N
BATTERY
-
Y
ENGINE
Y
TROUBLE
LIGHT
ALTERNATOR
LIGHT
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

THEORY OF OPERATION

STATOR
MECHANICAL
ROTATION
SLIP
RINGS
+
-
OIL PRESS
ENGINE
SENSORS
TEMP
AUX
CURRENT
TORROID
ROTOR
FLASH
ENGINE PROTECTION
IDLER CONTROL
P.C. BOARD
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
VANTAGE® 400
THREE-PHASE
RECTIFIER
+
80 VDC
W
I
D
N
L
30
D
VRD
E I
N
VOLTAGE REDUCTION
W
G
R G
VRD
LIGHTS
ROTOR
REMOTE
AMPHENOL
10 + 30 42 VAC TO 14 PIN AMPHENOL
FOR WIRE FEEDER
AUXILIARY WINDINGS
240 VAC
30
240VAC
RECEPTACLE
AUX. FEEDBACK
120VAC
RECEPTACLED (2)
LOW IDLE COMMAND
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.
WORK
TERMINAL
-
CHOPPER MODULE
ELECTRODE
TERMINAL
IGBT
+
CHOKE
SHUNT
F
C
E
U I
E
R D
VRD FEEDBACK
D
R L
B
E E
A
N
PWM
C
T
VRD
K
SIGNAL
SWITCH
(OFF)
WELD
CONTROL
BOARD
VOLTMETER
AMMETER
ARC OUTPUT PROCESS/RANGE
CONTROL SELECTOR
CONTROL
E-2