Red-D-Arc Welderentals EXTREME 360 Owner's Manual
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Red-D-Arc Welderentals EXTREME 360 Owner's Manual

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OM-229 409N
2012−04
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

  • Page 1 OM-229 409N 2012−04 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 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 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 oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging 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_2011−10 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 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

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

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz D Fermer l’alimentation du gaz comprimé en cas sous haute pression. Si une bouteille est endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com).
  • Page 14 OM-229 409 Page 10...

  • Page 15: Section 3 − Introduction

    SECTION 3 − INTRODUCTION 3-1. Specifications RMS Amps Input at Rated Load Output, Max. 60 Hz 3-Phase at NEMA Load Voltages Amperage Open- and Class I Rating Input Voltage Range in Circuit Power Range in CV Mode 208 V 230 V 400 V 460 V 575 V...

  • Page 16: Duty Cycle And Overheating

    3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, output stops, a Help message is displayed and cooling fan runs. Wait fifteen min- utes for unit to cool. Reduce amper- age or voltage, or duty cycle before welding.

  • Page 17: Section 4 − Installation

    SECTION 4 − INSTALLATION 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. For future reference, write serial number in space provided on back cover of this manual. 4-2.

  • Page 18: Weld Output Receptacles And Selecting Cable Sizes

    4-3. Weld Output Receptacles And 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 19: Remote 14 Receptacle Information

    4-4. Remote 14 Receptacle Information Socket* Socket Information 24 volts AC. Protected by supplementary protect- 24 VOLTS AC or CB2. Contact closure to A completes 24 volts AC contactor control circuit. 115 volts AC. Protected by supplementary pro- C L N 115 VOLTS AC tector CB1.

  • Page 20: Optional Gas Valve Operation And Shielding Gas Connection

    4-6. 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. Gas Hose Connection GAS IN Fitting has 5/8-18...

  • Page 21: Electrical Service Guide

    4-7. Electrical Service Guide Elec Serv 2011− 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 22: Connecting 1-Phase Input Power

    4-8. Connecting 1-Phase Input Power Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. Disconnect and lockout/tag- out input power before con- necting input conductors from unit. Always connect green or green/yellow conductor =GND/PE supply grounding terminal Earth...

  • Page 23: Connecting 3-Phase Input Power

    4-9. Connecting 3-Phase Input Power Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Always connect green or green/ yellow conductor supply grounding terminal first, and never...

  • Page 24: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. 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 controlled and only runs when cooling is ing while welding.

  • Page 25: Meter Functions

    5-2. 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 Actual Volts Actual Amps 14.1 10.3...

  • Page 26: Lift-Arc Tig Procedure

    5-4. Lift-Arc TIG Procedure With Process Switch in the Lift-Arc TIG position, start an arc as follows: TIG Electrode Workpiece Touch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted.

  • Page 27: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Repair Or Replace Replace Cracked Replace Damaged Or Torch Body Cracked Unreadable Cables Labels Repair Or Replace Cracked Cables And Cords Clean Tighten Weld...

  • Page 28: Voltmeter/Ammeter Help Displays

    6-3. 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. If this display is shown, contact a Factory Authorized Service Agent.

  • Page 29: Troubleshooting

    6-4. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position (see Sections 4-8 and 4-9). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Sections 4-8 and 4-9). Check for proper input power connections (see Sections 4-8 and 4-9). No weld output;...

  • Page 30: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-229 409 Page 26...
  • Page 31 256 230-A OM-229 409 Page 27...

  • Page 32: Section 8 − Parts List

    SECTION 8 − PARTS LIST Ref. 803 690-J Figure 8-1. Parts Assembly OM-229 409 Page 28...
  • Page 33 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Parts Assembly ....229 541 Wrapper (Includes Insulators and Safety Labels) ....
  • Page 34 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Parts Assembly (Continued) ....234 126 Nut, Conduit 1.000 Npt Knurled ........
  • Page 35 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Parts Assembly (Continued) ....174 992 Knob, Pointer .840 Dia X .250 Id W/Spring Clip−.21 .
  • Page 36 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 37 Notes SOCKET/WRENCH SELECTION TABLE SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size U.S. Bolt Decimal Bolt Bolt Decimal Bolt Diameter Equivalent Diameter Equivalent 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm...
  • Page 38 Notes MATERIAL THICKNESS GAUGE...

  • Page 39: Warranty

    Warranty Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) This limited warranty supersedes all previous manufacturers 90 Days — Parts warranties and is exclusive with no other guarantees or Accessory (Kits) warranties expressed or implied. Canvas Covers Induction Heating Coils and Blankets, Cables, and LIMITED WARRANTY −...
  • Page 40 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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