Lincoln Electric 400 Welder User Manual


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ELECTRICAL DIAGRAMS
G-3
VANTAGE
®
400
®®
SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 1)
EN-170
S
O
L
ID
E
D
G
E
G5597
VA
NTA
GE 400
(PE
R
KINS
)
MAC
HI
N
E SC
HEM
ATIC
NONE
G5388
Ma
gli
e
tt
a
BA
M
DO NO
T
SC
AL
E
T
HIS DR
A
WING
D
RAWN
BY:
DESIG
N
I
NFO
RMATI
ON
ENG
I
NEER:
AP
PRO
VED
:
EQ
UIP
M
ENT
TYPE:
SUBJECT:
SCA
L
E:
NA
CRM22115
-GA
1
PAGE ___ OF
___
2
E
NGI
N
EE
RI
NG
CO
NT
RO
LLE
D
MA
NU
FA
CT
URE
R:
No
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBA
L, INC.
AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
TO O
THER PARTIES OR US
ED FOR
AN
Y
PURPOS
E WITHOU
T
THE EXPRES
S WRIT
TEN PERMISSION
OF LINCOLN GLOBAL, INC.
PRO
PRIETARY & C
ONFIDENTIAL:
C
10/26/2006
t
MAT
ERI
A
L TO
L
ER
ANC
E ("
"
) TO A
GR
EE
WITH
PU
B
LI
SH
ED
ST
ANDARD
S.
ON A
LL
AN
GL
E
S I
S ± .5 OF
A D
E
GR
EE
ON
3
PLACE
D
E
CIM
ALS
IS
± .
002
ON 2
PL
AC
E D
ECIM
AL
S I
S ± .02
UNLESS OTHERWISE SPECIFIED TOLERANCE:
M
ANUF
ACTURING TO
L
ER
ANC
E
P
ER
E
2056
R
EVISED LEA
D 208
C RO
UTI
NG.
CHAN
GE
D
ET
AIL:
REFER
ENCE:
MA
T
ERI
AL
DIS
PO
SI
T
ION:
AP
PRO
VA
L
DA
T
E:
PROJ
EC
T
NUMBER:
DOCUMEN
T
NUMBER:
DOCUMEN
T
REV
ISI
ON:
G5597
LE
A
D
C
OL
O
R
COD
E:
B-
BL
AC
K
O
R
GRAY
G-
GREEN
O-
ORANGE
R-
RE
D
O
R
PI
NK
U-
BL
UE
W-
W
HIT
E
Y-
Y
ELL
OW
C
OM
PONE
NT
V
AL
U
E
U
NIT
S:
CAPA
CIT
O
R: MF
D/
V
OLT
S
RE
SI
ST
O
R:
O
HM
S/
W
ATT
S
CONNE
CT
O
R
PI
N
N
UM
BER
S:
VIEW
OF
CONNEC
TO
R ON PC BOARD
1
2
6
7
12
LA
TCH
EX.
12
PIN CONNEC
TO
R
LABELS:
C
OMM
ON
FR
AM
E
GROUND
EA
RT
H
GROUND
TH
RE
E
PHASE
RE
CTIFI
ER
3200uf
300vdc
SHUNT
50
M
V=400
AM
PS
206S
204S
CURRE
NT L
EV
EL
FE
E
D
BAC
K
SI
GN
AL
POSITIVE
OUTPUT
TERMINAL
NEGATIVE
OUTPUT
TERMINAL
B
Y-
PASS
P
C
BOARD
206B
208
5A
A
C
AU
X.
POWER
42 V
OLT
AC
WI
R
E F
EEDER
POWER
41
42
FO
U
R
P
OL
E 1800
R
PM
ALT
ERN
AT
OR
120 V
OLT
AC
POWE
R F
OR
R
OT
O
R FI
EL
D CI
RC
UIT
12 V
OLT
B
ATT
ERY
EN
GI
NE
ST
A
RT
ER
S
OL
EN
OI
D
ST
A
RT
B
UTT
ON
S
WIT
CH
RU
N-STOP SWIT
CH
SHOWN I
N RUN
POS.
FR
AM
E
GROUND
W2
W2
W3
W3
W5
W4
W5W4
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
S
WIT
CH
TEM
PER
AT
URE
OIL
PRESSURE
S
WIT
CH
EN
G.
PRO
T.
FU
EL
TEM
P.
241
228
238
200 (J33
-5)
227 (B3)
IDL
E
S
OL.
P
ULL
C
OIL
226 (J31
-8)
5S (
B1)
J31-2 (2
32F)
ALT.
+12
V
OLT
S
RUN
EN
GI
NE
ST
A
RT
ER
+12
V
OLT
S
RUN
+12
V
OLT
S
RUN
201
200
200A
21
WI
R
EF
EEDER
V
OLTM
ET
ER
P
OL
A
RIT
Y
S
WIT
CH
206A
208A
231
238A
+
160 V
DC
6A
5H
+
236B
232H
232D
C
B 10
A
236A
C
E
CHOPPPPER PC BOARD
G
AT
E SI
GN
AL
IG
BT (16)
B7 B8
B6
B3
B5
B2
B4
B1
+CO
M
FLY
BACK
DI
ODE
S (12)
FILTE
R
CAPA
CIT
OR
S (6)
+
7,200uF
x6
C
HOKE
D
C
BU
S
V
OLT
AGE
90+/-10V
D
C
@
HI I
DL
E
AR
C
V
OLT
AG
E F
EEDBAC
K SI
GN
AL
R1
O
UT
P
UT
CO
NT
R
OL 10
K
77 (J7-
1)
76 (J7-
4)
75 (J7-
5)
R2
ARC
CO
NT
R
OL 10
K
279 (J7
-6)
278 (J7
-7)
277 (J7
-8)
(J3-14)
257
(J3-7)
256
IDL
E
R
S
WIT
CH
(J1-4)
2
(J1-3)
4
W
EL
D T
E
RM.
S
W.
MO
DE
S
WIT
CH
CC
CV
PI
PE
TIG
(J7-9)
214
(J7-14)
218
(J7-15)
220
(J7-16)
222
260 (J3
-4)
261 (J3
-3)
TO
R
OI
D:
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)
23 (J3-10)
25 (J3-9)
5G (J2-3)
R
EM
OT
E
CO
NT
R
OL 10
K
77A (J1-11)
76A (J1-14)
75A (J1-10)
10 V
0-10 V
0 V
10 V
-15 V (
W/
O
P
OT.)
0 V
0 V
15 V
15 V
0 V
(TO
AM
PHEN
OL)
(TO
AM
PHEN
OL)
2A
4A
(TO
AM
PHEN
OL)
31
32
41A
A
B
C
D
E
F
77A
21
42A
75A
GN
D-
A
4A
2A
76A
77B
76B
75B
GROU
ND
CONNE
CTO
R
TO
CONNE
CT
O
R J1
115V
AC
CO
NT
AC
T
OR
W
OR
K
RE
MOTE
CO
NT
RO
L
42V
AC
GROU
ND
J
A
D
C
H
B
K
E
F
G
I
77B
76B
75B
GN
D-
B
4B
2B
4B
2B
13 (J3-8)
14 (J3-16)
(J1-8) 4
00
(J1-13)
400
400 I.D. J
UM
PE
R (
Part of round plug a
nd lead as
sembly.)
LO
W I
DL
E
C
OMM
AN
D (0
V
@ L
O
W I
DL
E)
TWI
ST
ED
P
AI
R
TWI
ST
ED
P
AI
R
R
OT
O
R FL
AS
HI
NG
Located o
n back of
control pa
nel.
P/
N
G5507-1
Located o
n wiring behind
receptacle
s.
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.
S
wich closed for high idle.
W
EL
D
AMM
ET
ER
W
EL
D
V
OLTM
ET
ER
(J4-1 to
10)
(J5-1 to
10)
14
14
13
TWI
ST
ED
P
AI
R
R4
50
OH
M
100 W
R4 is located above
rectifier o
n upper l
eft
interior p
anel behin
d
upper control pan
el.
5J
1
1
1
4
4
4
IDL
E
S
OL.
H
OL
D
C
OIL
247 (J31
-4)
IG
BT'
S, FL
YBAC
K
DI
ODE
S
AND
FILTE
R
CAPA
CIT
OR
S
AR
E I
NT
EGR
AL
TO
CHOPPE
R M
OD
UL
E
S
AN
D
N
OT
INDI
VI
DU
ALL
Y
RE
PL
ACEA
BL
E.
STAT
OR
W
EL
D
WI
N
DI
NGS
R
OT
O
R FI
EL
D
SLI
P
RI
NGS
RE
MOTE
CO
NT
RO
L
OIL
PRES
S.
FU
EL LVL.
SENSOR
Choke mounted behi
nd
output te
rminal pa
nel.
Po
wer
Supply
to Control
Board
P
WM
S
ignal to Chopper
15 volt @ 20 kHz
Chopper module is loc
ated on
right side
of
interior p
anel behin
d upper control pa
nel.
Rectifier is located on lef
t side of int
erior
panel behi
nd uppe
r control
panel.
Shunt on back of positiv
e
output te
rminal
Located o
n back of
output pa
nel
between terminals
60 TO 65 V
A
C
PHAS
E T
O
PHASE
AT
HI
G
H IDL
E
REV
OL
VI
N
G FI
EL
D
RE
SI
ST
ANC
E
APPRO
X.
25 O
HM
S
@ 75F
Field capa
citor locate
d on lower rear of
fan baffle
on right si
de of mac
hine.
Battery voltage:
12.6 volts
at rest
14 volts en
gine
running
Located o
n rear
of control
panel
left side.
0.2 O
HM
11 O
HM
S
Oil
Pressure
S
witch
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
YEL
LO
W
LAM
P
230 O
HM
S
EM
PT
Y
30 O
HM
S F
ULL
10 O
HM
S
@ 0
P
SI
100 O
HM
S
@ 75
P
S1
500-600
O
HM
S
C
OL
D
50-100 OHM
S
H
OT
(S
E
E
SHE
ET 2 F
OR
SIM
PLIFI
ED
CO
NT
R
OL
BOARD
SCH
EM
ATI
C)
(SIM
PLIFI
E
D
BOARD
SCH
EM
ATI
C)
(SIM
PLIFI
ED
BOARD
SCH
EM
ATI
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 fu
el tank
Located o
n front p
anel
Located in
engine bl
ock
Right side, rear
Located in
engine th
ermostat
housing o
n
Left side o
f engine
Located o
n auxiliary
output pa
nel
Located in
injection pu
mp
on right si
de of engi
ne
J55-3
J55-4
J55-2
(J1-5) 4
00
(J1-12)
400
Weld
Voltmeter and Ammeter
are stand
ard on Vantage 400
HOUR
MET
ER
+
_
(J31-10
) 263
Voltage
Regulator
+10
Volts
405 (J32
-2)
(J2-5)
405
J56
9 Ohms
at 75
vF
SH
UT
DOW
N
C
OIL
Located o
n right sid
e of engin
e
inside engine access do
or
12 volt gr
ound stud
on rear
of uppe
r control
panel.
Located o
n front
control pa
nel.
Located o
n front
control pa
nel.
Located o
n front
control pa
nel.
Located o
n left
side of en
gine
block at flywheel
housing.
Battery is located in the
lower left front of
machine b
ehind lower
control pa
nel.
Ground stud on
generat
or cross
support.
J55 is locate
d
near idle s
olenoid.
12 volt gr
ound
stud on r
ear of
upper co
ntrol
panel.
Located o
n front
control pa
nel.
12 volt gr
ound stud
on rear
of upper
control pa
nel.
Auxiliary po
wer to front
panel rec
eptacles via
circuit
breakers
on front
panel.
P56
P55-4
P55-3
P55-2
244 (J33
-1)
YEL
LO
W
LAM
P
243 (J33
-6)
238 243
D+
+
EN
GI
NE
ALT
ERNATOR
Located o
n left side
of engine
near
radiator
fan.
208C
(J7-2)
215
(J7-10)
216
CONNE
CTO
R
Located in
engine
intake ma
nifold
GL
O
W
PL
UGS
239
Located o
n front
control pa
nel.
GL
O
W
PL
U
G
B
UTT
O
N
S
WIT
CH
238C
238B
3, 4 A
N
D 6 - 240
VA
C 3
PHASE
3 TO 6 - 240 V
A
C 1
PHASE
6A T
O 5 -120
VA
C 1
PHASE
3 TO 5 - 120 V
A
C 1
PHASE
208B
206B
14C
13
13C
Located u
nder V
R
D
Control
PC
Bd on the back of the
control pa
nel
Weld volts >32,
RE
D light on
Weld volts <32,
GREE
N light on
+
-
VDR DISPLAY PC BOARD
S
witching
Po
wer
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
S
WIT
CH
Diode
Bridge located on upp
er contr
ol
panel, rig
ht rear.
Located o
n V
R
D control mounting
bracket. Shown in "O
N" position
VR
D "
OFF"
Tig
P
ipe
CV
12
12
26
58
58
58
5858
Min
Max
CC
Open
Circuit
Volts:
Open
Circuit
Volts:
CC
Max
Min
12 12
58
58
--- ---
12 12
CV
P
ipe
Tig
VR
D "
O
N"
*
*
N
OT
E:
P
ipe Mode i
s not
active with
VR
D
On
Ferrite
on Lead
208A
2 turns
Ferrite
on mete
r 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 & 76
A
3 turns
5P
262
CO
NT
A
CT
S
SHOW
N I
N
"+
"
PO
SITI
ON
G-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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