Red-D-Arc Welderentals EXTREME 360 CC/CV Auto-Line Owner's Manual
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Red-D-Arc Welderentals EXTREME 360 CC/CV Auto-Line Owner's Manual

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OM-229409W
2016−05
Processes
Multiprocess Welding
Description
Arc Welding Power Source
EXTREME 360
CC/CV Auto-Line

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Summary of Contents for Red-D-Arc Welderentals EXTREME 360 CC/CV Auto-Line

  • Page 1 OM-229409W 2016−05 Processes Multiprocess Welding Description Arc Welding Power Source EXTREME 360 CC/CV Auto-Line...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − SMAW/CAC-A OPERATION ........... . . 9-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Placer les bouteilles debout en les fixant dans un support station- déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par naire ou dans un porte-bouteilles pour les empêcher de tomber ou induction.

  • Page 12: Proposition Californienne 65 Avertissements

    D N’utiliser que les pièces de rechange recommandées par le LE SOUDAGE À L’ARC risque de constructeur. provoquer des interférences. D Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de D L’énergie électromagnétique risque l’industrie, ainsi que les codes municipaux.

  • Page 13: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 3-2. Miscellaneous Symbols And Definitions Gas Tungsten Arc Voltage Sensing Remote Welding Feeder...

  • Page 14: Section 4 − Specifications

    A complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or rated output.

  • Page 15: Volt-Ampere Curves

    A complete Parts List is available at www.MillerWelds.com 4-4. Volt-Ampere Curves Volt-ampere curves show minimum A. CC Mode and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. SMAW GTAW SMAW GTAW...

  • Page 16: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Movement Do not move or operate unit where it could tip. Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 17: Selecting Cable Sizes

    A complete Parts List is available at www.MillerWelds.com 5-2. Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 18: Remote 14 Receptacle Information

    A complete Parts List is available at www.MillerWelds.com 5-4. Remote 14 Receptacle Information Socket* Socket Information 24 volts AC. Protected by supplementary protect- or CB2. 24 VOLTS AC Contact closure to A completes 24 volts AC C L N contactor control circuit. Output to remote control;...

  • Page 19: Optional Gas Valve Operation And Shielding Gas Connection

    A complete Parts List is available at www.MillerWelds.com 5-6. Optional Gas Valve Operation And Shielding Gas Connection Obtain gas cylinder and chain to running gear, wall, or other station- ary support so cylinder cannot fall and break off valve. Cylinder Regulator/Flowmeter Install so face is vertical.

  • Page 20: Electrical Service Guide

    A complete Parts List is available at www.MillerWelds.com 5-7. Electrical Service Guide Elec Serv 2015−05 NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available.
  • Page 21 A complete Parts List is available at www.MillerWelds.com Notes OM-229409 Page 17...

  • Page 22: Connecting 1-Phase Input Power

    A complete Parts List is available at www.MillerWelds.com 5-8. Connecting 1-Phase Input Power =GND/PE Earth Ground Tools Needed: input1 2012−05 − Ref. 803 766-C / Ref. 276 319-A OM-229409 Page 18...
  • Page 23 A complete Parts List is available at www.MillerWelds.com 5-8. Connecting 1-Phase Input Power (Continued) nected to any input power between 208 and Disconnect Device (switch shown in the Installation must meet all National and 575 VAC without removing cover to relink the OFF position) Local Codes −...

  • Page 24: Connecting 3-Phase Input Power

    A complete Parts List is available at www.MillerWelds.com 5-9. Connecting 3-Phase Input Power = GND/PE Earth Ground Tools Needed: input2 2012−05 − Ref. 803 766-C / Ref. 276 319-A OM-229409 Page 20...
  • Page 25 A complete Parts List is available at www.MillerWelds.com 5-9. Connecting 3-Phase Input Power (Continued) voltage available at site. This unit can be con- Input Conductors (L1, L2 And L3) Installation must meet all National and nected to any input power between 208 and Local Codes −...

  • Page 26: Section 6 − Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Front Panel Controls Power Switch sults, place Arc Control in the maximum posi- When set towards maximum, short-circuit tion. amperage is increased at low arc voltage to The fan motor is thermostatically assist with arc starts as well as reduce stick- Remote 14 Receptacle...

  • Page 27: Meter Functions

    A complete Parts List is available at www.MillerWelds.com 6-2. Meter Functions The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle Meter Reading While Welding Scratch 71.7 10.3 Start TIG Actual Volts (OCV) Preset Amps...

  • Page 28: Section 7 − Gtaw Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − GTAW OPERATION 7-1. Typical Connection For GTAW Process 264 339-A Remote 14 Receptacle Gas Out Connection (Optional) Turn off power before making con- nections. Connect desired remote control to Remote Negative (−) Weld Output Terminal 14 receptacle if required.

  • Page 29: Scratch Start Tig Welding Mode - Gtaw Process

    A complete Parts List is available at www.MillerWelds.com 7-2. Scratch Start TIG Welding Mode - GTAW Process 8 4.5 239 083-A Setup Operation Weld terminals are energized at all times in Scratch Start TIG welding For typical system connections refer to The Adjust Control is used to set desired mode.

  • Page 30: Lift-Arc Tig Welding Mode - Gtaw Process

    A complete Parts List is available at www.MillerWelds.com 7-3. Lift-Arc TIG Welding Mode - GTAW Process 1 3. 5 239 083-A 1 − 2 “Touch” Seconds Do NOT Strike Like A Match! Setup Operation Weld terminals are energized at all times in Lift Arc TIG welding mode.

  • Page 31: Tig Welding Mode - Gtaw Process

    A complete Parts List is available at www.MillerWelds.com 7-4. TIG Welding Mode - GTAW Process 239 083-A Setup Operation Weld terminals energized through the remote control in TIG For typical system connections refer to The Adjust Control is used to set desired welding mode.

  • Page 32: Section 8 − Gmaw/Fcaw Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − GMAW/FCAW OPERATION 8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process 264 343-A Workpiece Use of shielding gas is dependant on Wire Turn off power before making Type. connections. Remote 14-Receptacle The connection diagram illustrates Wire Feeder...

  • Page 33: Mig Welding Mode - Gmaw/Fcaw Process

    A complete Parts List is available at www.MillerWelds.com 8-2. MIG Welding Mode - GMAW/FCAW Process 25.0 239 083-A Rotate Mode Switch to MIG position as has a voltage control. This voltage con- Weld terminals energized shown. trol will override the Adjust Control of through the remote control in MIG preset voltage on the welding power welding mode.

  • Page 34: Typical Connection For Remote Control Feeder Gmaw-P Process

    A complete Parts List is available at www.MillerWelds.com 8-3. Typical Connection For Remote Control Feeder GMAW-P Process 264 347-A Workpiece Turn off power before making The connection diagram illustrates connections. DCEP (reverse polarity) suitable for all Optima - External Pulsing Device Wire Feeder wires except self-shielded FCAW.

  • Page 35: Pulsed Mig Welding Mode - Gmaw-P Process

    A complete Parts List is available at www.MillerWelds.com 8-4. Pulsed MIG Welding Mode - GMAW-P Process P P.P 239 083-A Adjust Control Left and Right Display will show PPP PPP. Weld terminals energized through the remote control in Setup Operation Pulsed MIG welding mode.

  • Page 36: Typical Connection For Voltage-Sensing Feeder Gmaw/Fcaw Process

    A complete Parts List is available at www.MillerWelds.com 8-5. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process 264 348-A Use of shielding gas is dependant on Wire Turn off power before making con- Type. nections. Gun Trigger Receptacle Positive (+) Weld Output Terminal The connection diagram illustrates Negative (−) Weld Output Terminal Wire Feeder...

  • Page 37: V-Sense Feeder Welding Mode - Gmaw/Fcaw Process

    A complete Parts List is available at www.MillerWelds.com 8-6. V-Sense Feeder Welding Mode - GMAW/FCAW Process 25.0 239 083-A to Section 8-5. Weld terminals are energized at all The Left Display toggling momentarily times in V-Sense Feeder welding pauses while the preset voltage is ad- Rotate Mode Switch to V-SENSE FEEDER mode.

  • Page 38: Section 9 − Smaw/Cac-A Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 9 − SMAW/CAC-A OPERATION 9-1. Typical Connection For SMAW And CAC-A Process 264 349-A cutting torch to to positive weld output ter- Connect desired remote control to remote Turn off power before making con- minal.

  • Page 39: Cc Welding Mode - Smaw/Cac-A Process

    A complete Parts List is available at www.MillerWelds.com 9-2. CC Welding Mode - SMAW/CAC-A Process 239 083-A Operation Arc Control (Dig) Weld terminals energized The Adjust Control is used to set desired through the remote control in CC Rotate Arc Control to select desired dig set- preset amperage.

  • Page 40: Stick Welding Mode - Smaw/Cac-A Process

    A complete Parts List is available at www.MillerWelds.com 9-3. Stick Welding Mode - SMAW/CAC-A Process 8 4.5 239 083-A The open circuit voltage is shown in the Left Arc Control (Dig) Weld terminals are energized at all Display and the preset amperage is shown times in Stick welding mode.

  • Page 41: Optional Low Open Circuit Voltage (Ocv) Welding Modes

    A complete Parts List is available at www.MillerWelds.com 9-4. Optional Low Open Circuit Voltage (OCV) Welding Modes Low OCV Operation The unit can be optionally configured for low open circuit voltage (OCV) operation in Stick and Scratch Start TIG modes. When the unit is config- ured for low OCV operation only a low sensing voltage (approximately 15 VDC) is present between the electrode and the workpiece prior to the electrode touching the workpiece.

  • Page 42: Section 10 − Maintenance & Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 10 − MAINTENANCE & TROUBLESHOOTING 10-1. Routine Maintenance Disconnect power Maintain more often during before maintaining. severe conditions. n = Check Z = Change ~ = Clean l = Replace Replace Damaged Replace Cracked Torch Body...

  • Page 43: Voltmeter/Ammeter Help Displays

    A complete Parts List is available at www.MillerWelds.com 10-3. Voltmeter/Ammeter Help Displays All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 1 Display HE.L P−1 Indicates a malfunction in the prima- ry power circuit.

  • Page 44: Troubleshooting

    A complete Parts List is available at www.MillerWelds.com 10-4. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position (see Sections 5-8 and 5-9). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Sections 5-8 and 5-9). Check for proper input power connections (see Sections 5-8 and 5-9).
  • Page 45 A complete Parts List is available at www.MillerWelds.com Notes OM-229409 Page 41...

  • Page 46: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM Figure 11-1. Circuit Diagram OM-229409 Page 42...
  • Page 47 271 733-A OM-229409 Page 43...
  • Page 48 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...
  • Page 49 Notes...
  • Page 50 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.

  • Page 51: Warranty

    Warranty Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 6 Months —...
  • Page 52 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 for: File a claim for loss or damage during shipment.

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