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