Lincoln Electric 400 Welder User Manual


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ELECTRICAL DIAGRAMS
G-4
VANTAGE
®
400
®®
SCHEMATIC - COMPLETE MACHINE - (G5597 PAGE 2)
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
2
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
SIMPLIFIED CONTROL BOARD SCHEMATIC
LE
AD C
OL
OR
C
OD
E:
B-
BL
AC
K
G-
GR
EE
N
O-
OR
AN
GE
R-
RED
U-
BLU
E
W-
WHI
TE
Y-
YE
LL
OW
COMPON
EN
T
V
ALU
E UN
IT
S:
CA
PA
CI
T
OR
: M
F
D/V
OLTS
RE
SI
ST
OR
:
OHMS
/W
ATTS
CO
NNEC
T
OR PIN
NUM
BE
RS:
VI
EW OF
CO
NNE
CTOR
ON
P
C
BO
ARD
1
2
6
7
12
LA
TCH
E
X.
12 PI
N
CO
NNE
CTOR
LABELS
:
CO
MM
ON
F
RA
ME
G
RO
UND
EA
RT
H
GROU
ND
J7-1
J7-4
J7-5
+10V
+10V
J1-10
J1-14
J1-11
TIG
MODE
ALL OT
HE
R
MODES
ARC
CONTR
OL
CI
RC
UI
T
RY
CO
NTROL
PO
INT
S
EL
ECT
VA
RI
A
BLE
PI
NCH
PI
P
E
AR
C
FO
RCE
VA
RI
A
BLE
AR
C
FO
RCE
FI
XE
D
AR
C
FO
RCE
LO
C
AL
REM
OT
E
TO
UC
H
ST
ART
OCV
J7-6
J7-7
J7-8
x80
G4109
(ONLY)
G4107
(ONLY)
47.5 ohms
J3-15
J6-2
J6-1
VOLTAG
E
F
EE
DBAC
K
CURRE
NT F
EE
DBAC
K
J5-10
J5-9
J5-8
J5-7
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-10
J4-9
J4-8
J4-7
J4-6
J4-5
J4-4
J4-3
J4-2
J4-1
MACHINE /
MODE
LOGIC
(CPU)
HO
LD
(
+5
V=
HO
LD
)
ON
/
OFF
(
+5
V=
ON
)
ON
/
OFF
(
+5
V=
ON
)
HO
LD
(
+5
V=
HO
LD
)
J7-16
J7-9
J7-10
J7-11
J7-12
J7-13
J7-14
J7-15
T
IG
M
OD
E
PI
PE
M
OD
E
(NO
T AV
AI
LABL
E ON
AU
STRAL
IAN
V
ANTAG
E
575)
N/A
N/A
N/A
VRD
EN
AB
LE
(
FOR AUSTRA
LI
AN
V
ANTAG
E
575)
CV
M
OD
E
+1
5V
J1-5
J1-6
J1-7
J1-8
J1-13
+1
5V
J1-12
MA
CH S
EL
4
MA
CH S
EL
3
MA
CH S
EL
2
MA
CH S
EL
1
PRESET
CURRE
NT F
EE
DBAC
K
VOLTAGE
F
EE
DBAC
K
AMMETER
DISPLAY
VOLTMETER
DISPLAY
SE
LEC
T
C
ON
T
RO
L P
OI
NT
FI
XE
D
H
OT S
TA
RT
J3-14
IDL
E
S
WI
T
CH S
EN
SE
+1
5V
J3-7
J1-3
J1-4
+1
5V
(4)
(2)
2-
4 S
EN
SE
J3-4
J3-3
R
EG
U
LATI
NG
AM
PLIFIE
R
PWM
CH
OP
PE
R
CONTROL
CIRCU
IT
CUR
RE
NT
LI
MI
TS,
AV
ERAGE
,
AB
SOLU
TE,
&
FOLDBACK
THERMAL SHUTDOWN
T
HER
MA
L S
HU
T
DO
WN
(
if
us
ed
)
CURRE
NT F
EE
DBAC
K
CO
NT
RO
L P
OI
NT
J3-12
J3-10
J3-11
J3-9
47.5 o
hm
T
RAN
SF
ORME
R
+1
5V
+3
.3V
-
15
V
+5
V
J3-16
J3-8
-
+
40-100VDC
INPUT
FRAME
+1
5V
IDL
E C
ON
T
RO
L
IDL
E C
ON
T
RO
L
+1
5V
CO
M
FRAME
J2-5
FRAME
+1
5V
CO
M
+12 V IS O L A T E D CIR C U ITR Y F OR E N GIN E F U N CTIO NS
- STUD
+ STUD
AU
XIL
LAR
Y
CURRE
NT
SE
NS
E
-
+
10
K
POT
10
K
POT
10
K
POT
AU
XIL
IAR
Y
SE
NS
E
T
OR
OI
D
MA
CHINE
IDE
NTIT
Y
T
AB
LE:
PIN
S
JU
MP
ER
ED
T
O
SE
LEC
T
M
ACHIN
E
1
2
3
4
A
T
IG
PI
PE
CC
CV
MODE
SELECTOR
SWITCH
(AUSTRAI
LI
AN
V
ANTAG
E
575 U
SE
S
A
3
PO
SITION TOGGL
E
SWITCH)
(
77
)
(
76
)
(
75
)
(
77
B)
(
76
B)
(
75
B)
(
277
)
(
278
)
(
279
)
OUTPUT
CONTROL
REMOTE
CONTROL
ARC CONTROL
+ ST
UD
(206S)
(204S)
+
-
(208B)
ME
T
ER
(+
)
INPU
T
(
0
-
2V
)
1V
=
100.0
ON
M
ET
ER
CHOPPER
BOARD
47.5 o
hm
47.5 o
hm
47.5 o
hm
50
mV
=
400
A
MP
S
SHUNT
+
-
CONTROL BOARD
POWER FROM
CHOPPER BOARD
F
EE
DBAC
K
CURRE
NT
LI
MI
TS
RE
GU
LA
T
IO
N M
OD
E
ME
T
ER
(-
)
INPU
T
ME
T
ER
(+
)
INPU
T
(
0
-
2V
)
1V
=
1000
ON
M
ET
ER
ME
T
ER
(-
)
INPU
T
BLI
NK
(
PULLED
L
O
W
AND H
IG
H
IN L
OO
KB
AC
K
T
O
F
LA
SH
DECI
MA
L P
OI
NT)
BLI
NK
(
PULLED
L
O
W
AND H
IG
H
IN L
OO
KB
AC
K
T
O
F
LA
SH
DECI
MA
L P
OI
NT)
PW
M
SI
GN
AL
(
+1
2V
ON
MU
LT
IM
ET
ER
)
PW
M C
O
MM
ON
+
ST
UD i
s C
O
MM
ON
F
OR
W
ELD
C
ON
T
RO
L
CIRCUI
TS
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN,
(
THERMAL OVERLOAD IF USED
),
VOLTAGE FEEDBACK
J4 AMMETER
(
NO CONNECTOR ON RANGER 250)
J5 VOLTMETER
(
NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
F
RA
ME
IS
CO
MM
ON
F
OR
EN
GI
NE C
ON
T
RO
L CIR
CUI
TS
PRESET
PRESET
DIS
PL
AY
W
ELD
A
MP
S
DIS
PL
AY
W
ELD
V
OLTS
DIS
PL
AY
PR
ES
ET
VA
LUE
+5
V
+5
V
+5
V
DIODE
ONLY
ON -E
V
ER
SION
AND
A
BO
VE
THE TOP
END OF THE R
EMOTE
POT IN
TIG MODE IS
THE S
ETTING OF THE LOCA
L
OUTPUT CONTROL POT.
IN E
V
ER
Y OTH
ER MODE,
THE REMOTE
POT WILL
S
ET MACHINE TO MA
X OUT
PUT.
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED
I
N EACH
APPLICATION
.
NOT ALL CIRCUITS ARE USED ALL THE TIME.
+1
5V
J7-2
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "A
LWA
YS
ON" PO
SITION
IDLER
CONTROL
SHOWN IN "HIGH" PO
SITION
J2-3
FRAME
0 V
olt
s
Low
Idl
e
(
AL
L CIR
CUI
T
S
ON
C
ON
NEC
T
OR
J
2)
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
+ ST
UD
TO IDLE
SO
LENO
ID CIRCUITS
ON ENG
INE
PROTECTION /
IDLER
PC
BO
ARD
J1-5
J1-6
J1-7
J1-8
MACHINE
RANGER 250 G&D
J1-13
RANGER 305 G&D
J1-13
VANTAGE 500
J1-13
VANTAGE 575
J1-13
AIR VANTAGE 500
J1-12 J1-13
VANTAGE 300
VRD
SWITCH
(215)
(216)
G-4
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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