Red-D-Arc EXTREME 360 Technical Manual
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Red-D-Arc EXTREME 360 Technical Manual

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EXTREME 360
CC/CV Auto-Line
TM-229 409A
2006−12
Eff w/Serial Number LG250111A
Processes
Multiprocess Welding
Description
Arc Welding Power Source
File: MULTIPROCESS

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Summary of Contents for Red-D-Arc EXTREME 360

  • Page 1 TM-229 409A 2006−12 Eff w/Serial Number LG250111A Processes Multiprocess Welding Description Arc Welding Power Source EXTREME 360 CC/CV Auto-Line File: MULTIPROCESS...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING ......... . 1-1.
  • Page 3 TABLE OF CONTENTS 6-27. Power Interconnect Board PC2 Testing Information (Use with Section 6-28) ....6-28. Power Interconnect Board PC2 Test Point Values .

  • Page 5: Section 1 − Safety Precautions For Servicing

    D Do not place unit on, over, or near combustible D Keep away from moving parts such as fans. surfaces. D Keep all doors, panels, covers, and guards D Do not service unit near flammables. closed and securely in place. TM-229 409 Page 1 Extreme 360...

  • Page 6: California Proposition 65 Warnings

    About Pacemakers: welding or cutting. To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor, procedures: then following the above procedures is recommended. Extreme 360 TM-229 409 Page 2...

  • Page 7: Section 2 − Introduction

    Curves of other set- tings fall between curves shown. SMAW GTAW SMAW GTAW CONTROL 100% AMPERAGE B. CV Mode 5 00 AMPERAGE 217 836-A / 217 837-B TM-229 409 Page 3 Extreme 360...

  • Page 8: Duty Cycle And Overheating

    6 AWG. Y Exceeding duty cycle can damage unit void warranty. 60% Duty Cycle 6 Minutes Welding 4 Minutes Resting Overheating A or V Reduce Duty Cycle Minutes Ref. 216 568-A Notes TM-229 409 Page 4 Extreme 360...

  • Page 9: Section 3 − Installation

    − see NEC Article 511 or CEC Section 20. Location 18 in (460 mm) 18 in (460 mm) loc_2 3/96 - Ref. ST-151 556 / Ref. 803 691-C TM-229 409 Page 5 Extreme 360...

  • Page 10: Connecting 1-Phase Input Power

    Select type and size of overcurrent protection using Section 3-4 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout de- vice, and place switch in the On posi- tion. Tools Needed: 804 531-A TM-229 409 Page 6 Extreme 360...

  • Page 11: Connecting 3-Phase Input Power

    Select type and size of overcurrent protec- tion using Section 3-4 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. Tools Needed: 804 531-A TM-229 409 Page 7 Extreme 360...

  • Page 12: Electrical Service Guide

    4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. TM-229 409 Page 8 Extreme 360...

  • Page 13: Weld Output Receptacles And Selecting Cable Sizes

    Current feedback; +1 volt dc per 100 amperes. AMPERAGE Voltage feedback; +1 volt dc per 10 output recep- VOLTAGE tacle volts. Circuit common for 24 and 115 volts ac circuits. Chassis common. *The remaining sockets are not used. TM-229 409 Page 9 Extreme 360...

  • Page 14: Optional Gas Valve Operation And Shielding Gas Connection

    100 amps of weld cur- rent. The minimum post−flow time is 5 seconds. The maximum post− flow is 20 seconds (post flow set- tings are not adjustable by the end user). Ref. 803 705-A / Ref. 803 691-C TM-229 409 Page 10 Extreme 360...

  • Page 15: Section 4 − Operation

    For Air Carbon Arc (CAC-A) cutting and goug- selected on mode switch. When set towards selected, this control is not functional. V/A ADJUST ELECTRODE HOT ARC CONTROL REMOTE ARC CONTROL Ref. 803 692-B / Ref. 212 064 TM-229 409 Page 11 Extreme 360...

  • Page 16: Meter Functions

    Pulsed MIG GMAW-P (Requires an external pulsing device.) At Remote 14 Stick (SMAW) With Remote On/Off At Remote 14 Stick SMAW Electrode Hot V-Sense Feeder MIG (GMAW) With Voltage Sensing Wire Feeder Electrode Hot TM-229 409 Page 12 Extreme 360...

  • Page 17: Lift-Arc Tig Procedure

    15 VDC) is present between the electrode and the workpiece prior to the electrode touching the workpiece. Consult Factory Authorized Service Agent for infor- mation regarding how to configure the unit for low OCV stick welding operation. TM-229 409 Page 13 Extreme 360...

  • Page 18: Section 5 − Theory Of Operation

    Auxiliary Power 115 VAC 115 VAC Voltage/ Receptacle Amperage Control Adjust 24 VAC Remote 14-Pin Receptacle RC50 Ribbon Cable Positive (+) Output Voltage Feedback Weld Process Negative (−) Output Voltage Feedback Process Selector Control Switch TM-229 409 Page 14 Extreme 360...
  • Page 19 Secondary Primary Control/Auxiliary Power Heatsink Heatsink Thermistor Thermistor RT-1 RT-2 34 VAC Center Circuit Tapped 115 VAC Breaker Control Transformer Circuit 24 VAC 115 VAC Breaker Control Circuit Primary Circuit Weld Circuit ♦ Optional Extreme 360 TM-229 409 Page 15...
  • Page 20 Controls weld output by automati- Monitors temperature of primary condition by blocking the DC off- cally adjusting output current com- heatsink for fan motor control and set. mand signal to Inverter Control. overtemperature shutdown. TM-229 409 Page 16 Extreme 360...

  • Page 21: Section 6 − Troubleshooting

    C12 and C13, control board PC1, IGBT power modules MOD1 and MOD2, interconnecting board PC2, or input rectifier SR1; there is no output or limited output. Extreme 360 TM-229 409 Page 17...

  • Page 22: Pre-Power Flowchart

    All Measurements Pass? MOD2. (See Module Field Kit D1 & D2. Instructions.) Complete Sections 6-11 and 6-12, Stick Boost Rectifier SR1. Replace SR1. All Measurements Pass? Pre-power flowchart complete. Complete Section 6-31, Checking Unit After Servicing. TM-229 409 Page 18 Extreme 360...

  • Page 23: Measuring Input Capacitor Voltage

    Positive (+) lead to C13 (+) terminal, Negative (−) lead to C13 (−) terminal Test Equipment Needed: Positive (+) lead to C12 (+) terminal, Negative (−) lead to C12 (−) terminal Ref. 803 721-B / 907 161 Extreme 360 TM-229 409 Page 19...

  • Page 24: Input Pre-Regulator Module (Mod1)

    0.20 - 0.90 Input SCR 0.20 - 0.90 Input SCR 0.20 - 0.90 Input SCR 0.20 - 0.90 Input Diode −BUS 0.20 - 0.90 Input Diode −BUS 0.20 - 0.90 Input Diode −BUS 0.20 - 0.90 TM-229 409 Page 20 Extreme 360...

  • Page 25: Inverter Module (Mod2)

    100k Inverter IGBT Gate D4 Cathode −BUS 100k Snubber IGBT Gate D10 Cathode TP2 (D11 Cathode) 100k (w/Plug Removed From RC1) Snubber IGBT Gate D8 Cathode TP2 (D11 Cathode) 100k (w/Plug Removed From RC1) Extreme 360 TM-229 409 Page 21...

  • Page 26: Power Switch (S1)

    (see Section 6-2). Test Equipment Needed: Ref. 907 161 / Ref. 183 484 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. TM-229 409 Page 22 Extreme 360...

  • Page 27: Output Diodes

    6-10. Output Diodes D1, D2 Test Point Values Output Diodes D1 And D2 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms Terminal Anode Secondary Heatsink 0.10 - 0.90 Terminal Anode Secondary Heatsink 0.10 - 0.90 Extreme 360 TM-229 409 Page 23...

  • Page 28: Stick Boost Rectifier (Sr1)

    DVM Negative Lead DVM Diode DVM Ohms Terminal 2 Terminal 1 0.20 - 0.90 Terminal 4 Terminal 1 0.20 - 0.90 Terminal 3 Terminal 2 0.20 - 0.90 Terminal 3 Terminal 4 0.20 - 0.90 TM-229 409 Page 24 Extreme 360...
  • Page 29 PRE-POWER CHECKS Notes OHM’S LAW VOLTAGE = CURRENT X RESISTANCE CURRENT = VOLTAGE RESISTANCE RESISTANCE = VOLTAGE CURRENT Extreme 360 TM-229 409 Page 25...

  • Page 30: Control/Auxiliary Power Board Pc1 − Auxiliary Power Circuit

    (see 10 Diode D39 Remove all plugs from PC1 before Section 6-2). 11 Diode D42 testing. 12 Diode D43 Control Board PC1 If any measurements failed, replace Receptacle RC2 13 Diode D44 PC1. TM-229 409 Page 26 Extreme 360...

  • Page 31: Control/Auxiliary Power Board Pc1 − Auxiliary Power Circuit Test Point Values

    D43 Anode D43 Cathode 0.20 - 0.90 D44 Anode D44 Cathode 0.20 - 0.90 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. Extreme 360 TM-229 409 Page 27...

  • Page 32: Control/Auxiliary Power Board Pc1 − Pre-Regulator Control Circuit

    (see 10 Diode D49 Remove all plugs from PC1 before Section 6-2). 11 Diode D50 testing. 12 Diode D51 Control Board PC1 If any measurements failed, replace Receptacle RC2 13 Diode D52 PC1. TM-229 409 Page 28 Extreme 360...

  • Page 33: Control/Auxiliary Power Board Pc1 − Pre-Regulator Control Circuit Test Point Values

    Boost IGBT Gate Drive RC3 Pin 3 (PRE−12V) RC3 Pin 4 (BOOST−G) 0.20 - 0.90 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. Extreme 360 TM-229 409 Page 29...

  • Page 34: Control/Auxiliary Power Board Pc1 − Inverter Control Circuit

    (see dures with power applied to the ma- Diode D11 Section 6-2). chine. Diode D20 Remove all plugs from PC1 before If any measurements failed, replace testing. Unplug all connections to PC1. PC1. TM-229 409 Page 30 Extreme 360...

  • Page 35: Control/Auxiliary Power Board Pc1 − Inverter Control Circuit Test Point Values

    D11 Anode D11 Cathode 0.20 - 0.90 D20 Anode D20 Cathode 0.20 - 0.90 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. Extreme 360 TM-229 409 Page 31...

  • Page 36: Power Interconnect Board (Pc2)

    Y Pre-power checks are now com- 19 Diode D12 Resistor R14 plete. Remove earth grounded wrist 20 Diode D13 strap before performing any checks 21 Center Bus or procedures with power applied to 22 −BUS the machine. TM-229 409 Page 32 Extreme 360...

  • Page 37: Power Interconnect Board (Pc2) Test Point Values

    Bleeder Resistor R1 (Eff W/LF278161) Center Bus −BUS 37k - 41k Bleeder Resistor R8 +BUS Center Bus 28k - 32k (Prior to LF278160) Bleeder Resistor R8 (Eff W/LF278161) +BUS Center Bus 37k - 41k Notes Extreme 360 TM-229 409 Page 33...

  • Page 38: Troubleshooting Table

    Checks in Sections 6-13 thru 6-18, and also see Section 6-25). Check front panel/display board PC3 and connections, and replace if necessary (see Section 6-29). Check if Low Open Circuit Voltage Stick Mode is enabled (see Section 6-23). TM-229 409 Page 34 Extreme 360...
  • Page 39 Tungsten electrode oxidizing and not Shield weld zone from drafts. remaining bright after conclusion of remaining bright after conclusion of weld. Increase postflow time. Check and tighten all gas fittings. Water in torch. Refer to torch manual. Extreme 360 TM-229 409 Page 35...

  • Page 40: Voltmeter/Ammeter Diagnostics

    PC3 (see Section The unit has a maximum allowable input cur- Figure 8-2). Check operation of control relay 6-29). rent limit. As the line voltage decreases, the CR1 (see Section 6-24). TM-229 409 Page 36 Extreme 360...

  • Page 41: Enabling Low Open Circuit Voltage Stick Mode (Optional)

    Remove wrapper. Place switch position 1 in the Closed position by pressing actua- tor toward board. Reinstall wrapper. Follow the same arc starting proce- dures as described in Section 4-5. 907 161 / 217 181 Extreme 360 TM-229 409 Page 37...

  • Page 42: Troubleshooting Circuit Diagram

    See Section 6-29 for PC3 information Y HIGH VOLTAGE: Do not measure without Test Equipment Needed: proper instrumentation. V1 thru V5 and V8 − use only true RMS meter to obtain correct voltage reading. TM-229 409 Page 38 Extreme 360...
  • Page 43 Always check unit before applying power (see Sections 6-1 thru 6-18). See Section 6-27 for PC2 information Approx. 35K ohms at 705 F (215 C) See Section 6-25 for PC1 information 211 328-E Extreme 360 TM-229 409 Page 39...

  • Page 44: Control/Auxiliary Power Board Pc1 Testing Information (Use With Section 6-26)

    Receptacle RC1 Receptacle RC2 Receptacle RC3 Receptacle RC5 Receptacle RC6 Receptacle RC7 Receptacle RC8 Receptacle RC9 10 Receptacle RC10 11 Receptacle RC11 12 Receptacle RC12 Test Equipment Needed: Ref. 217 184-F / 907 161 TM-229 409 Page 40 Extreme 360...

  • Page 45: Control/Auxiliary Power Board Pc1 Test Point Values

    NOTE: All pins on this receptacle are referenced to the primary − Bus Output Control transformer primary; 665 volts ac rms with respect to RC5 pin 3 Not Used Output Control transformer primary; 665 volts ac rms with respect to RC5 pin 1 Extreme 360 TM-229 409 Page 41...
  • Page 46 Secondary side thermistor return; +2 volts dc at 25 C thermistor temperature Output +5 volts dc reference voltage for primary side thermistor ° Input Primary side thermistor return; +2 volts dc at 25 C thermistor temperature TM-229 409 Page 42 Extreme 360...
  • Page 47 Center tap of 34 volt ac connected to circuit common (GND) on board Not Used Input 115 volts ac rms Notes OHM’S LAW VOLTAGE = CURRENT X RESISTANCE CURRENT = VOLTAGE RESISTANCE RESISTANCE = VOLTAGE CURRENT Extreme 360 TM-229 409 Page 43...

  • Page 48: Power Interconnect Board Pc2 Testing Information (Use With Section 6-28)

    Be sure plugs are secure before applying power. See Section 6-28 for specific values during testing. Power Interconnect Board Receptacle RC1 Receptacle RC2 Receptacle RC3 Receptacle RC6 Receptacle RC7 Test Equipment Needed: Ref. 225 065-A / 907 161 TM-229 409 Page 44 Extreme 360...

  • Page 49: Power Interconnect Board Pc2 Test Point Values

    Snubber resistor2; inverter snubber, located in resistor module mounted to primary heat sink Snubber resistor1; input boost snubber, located in resistor module mounted to primary heat sink Not Used Snubber resistor2; inverter snubber, located in resistor module mounted to primary heat sink Extreme 360 TM-229 409 Page 45...
  • Page 50 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) TM-229 409 Page 46 Extreme 360...

  • Page 51: Front Panel/Display Board Pc3 Testing Information (Use With Section 6-30)

    Be sure plugs are secure before ap- plying power. See Section 6-30 for specific values during testing. Process Control Board PC3 Receptacle RC1 Receptacle RC2 Receptacle RC51 Test Equipment Needed: Ref. 217 181-B / 907 161 Extreme 360 TM-229 409 Page 47...

  • Page 52: Front Panel/Display Board Pc3 Test Point Values

    Output signal to remote command reference; 0 to 10 volts dc Remote command reference signal common Input Input signal from remote command; 0 to 10 volts dc Output Current feedback; 1 volt dc per 100 amperes of weld output TM-229 409 Page 48 Extreme 360...

  • Page 53: Checking Unit Output After Servicing

    Weld Output Terminals Check open-circuit voltage be- tween terminals according to Sec- tion 6-24 (voltage V-14) If correct voltage is not present, repeat troubleshooting procedures. Reinstall cover and side panels if removed. 803 691-C Extreme 360 TM-229 409 Page 49...

  • Page 54: Section 7 − Maintenance

    7-2. Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. Ref. 803 691-C / 803 692-C TM-229 409 Page 50 Extreme 360...

  • Page 55: Section 8 − Electrical Diagrams

    The following is a list of all diagrams for models covered by this manual. Model Serial Or Style Number Circuit Diagram Wiring Diagram EXTREME 360 LG250111A and following 211 328-E 220 922-B (208 − 575 Volt Models) Circuit Board PC1 LG250111A and following 217 185-F♦♦...
  • Page 56 Figure 8-1. Circuit for EXTREME 360 (208 − 575 Volt) Eff. w/LG250111A And Following TM-229 409 Page 52 Extreme 360...
  • Page 57 211 328-E Extreme 360 TM-229 409 Page 53...
  • Page 58 Figure 8-2. Wiring Diagram for EXTREME 360 (208 − 575 Volt) Eff. w/LG250111A And Following (1 of 2) TM-229 409 Page 54 Extreme 360...
  • Page 59 220 922-B Extreme 360 TM-229 409 Page 55...
  • Page 60 Figure 8-3. Wiring Diagram for EXTREME 360 (208 − 575 Volt) Eff. w/LG250111A And Following (2 of 2) TM-229 409 Page 56 Extreme 360...
  • Page 61 220 922-B Extreme 360 TM-229 409 Page 57...
  • Page 62 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org TM-229 409 Page 58 Extreme 360...
  • Page 63 TM-229 409 2006−12 Eff w/Serial Number LG250111A Processes Multiprocess Welding Description Arc Welding Power Source EXTREME 360 CC/CV Auto-Line Eff w/LG250111A And Following For OM-229 409 Revisions A Thru B...

  • Page 64: Section 9 − Parts List For Lg250111A And Following

    SECTION 9 − PARTS LIST FOR LG250111A AND FOLLOWING Ref. 803 690-F Figure 9-1. Parts Assembly Extreme 360 TM-229 409 Page 60...
  • Page 65 ........+When ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Extreme 360 TM-229 409 Page 61...
  • Page 66 ........+When ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Extreme 360 TM-229 409 Page 62...
  • Page 67 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in)
  • Page 68 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Contact the Delivering Carrier to: File a claim for loss or damage during shipment.

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