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Red-D-Arc EXTREME 360 MAP Auto-Line Owner's Manual

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OM-237 881J
2011−09
Processes
Multiprocess Welding
Description
Arc Welding Power Source
EXTREME 360 MAP
™
Auto-Line
File: MULTIPROCESS

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Summary of Contents for Red-D-Arc EXTREME 360 MAP Auto-Line

  • Page 1 OM-237 881J 2011−09 Processes Multiprocess Welding Description Arc Welding Power Source EXTREME 360 MAP ™ Auto-Line File: MULTIPROCESS...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − SMAW/CAC-A OPERATION ........... . . 8-1.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • 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. 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 For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • 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- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-237 881 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

    3-4. 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 minutes for unit to cool.

  • 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

    4-4. 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 30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable size.

  • Page 19: Remote 14 Receptacle Information

    4-5. 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 contactor control circuit. 115 volts AC. Protected by supplementary pro- 115 VOLTS AC tector CB1.

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

    4-7. 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

    4-8. Electrical Service Guide 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

    4-9. 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

    4-10. 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 − General Operation

    SECTION 5 − GENERAL OPERATION 5-1. Front Panel 804 772-A / 226 611-A 12 Remote PC Interface Weld process operation sections de- The meters display the actual weld output 13 Setup Button scribe functionality of the identified items. values after arc initiation and remains dis- played for approximately three seconds 14 Gas Type Indicator Remote 14 Receptacle...

  • Page 25: Mode Switch Settings

    5-2. Mode Switch Settings Switch Position Process Output Control Panel Adjust Remote Adjust Scratch Start TIG GTAW Electrode Hot Amps % Panel Amps* Lift-Arc TIG GTAW Electrode Hot Amps % Panel Amps* GTAW Remote 14 Amps % Panel Amps GMAW Remote 14 Volts Volts...

  • Page 26: Configuration Option Menu

    5-3. Configuration Option Menu 226 611-A Mode Switch Setup Right Displays. SET−UP will be displayed momentarily. Remote 14 Receptacle The Configuration Option Menu provides a Configuration options are displayed in the Left Left Display means to customize some machine features Display.
  • Page 27 Configuration Option Menu (Continued) V-Sense Feeder Weld Process V.SEN This option enables MIG (V.SEN MIG) or Pulsed MIG (V.SEN PULS) when the Mode Switch is in the VSENSE FEEDER position. See Section 7-2 for MIG operation or Sec- tion 7-4 for Pulsed MIG operation. Pulsed MIG Manual/Auto Control AUTO PULS...

  • Page 28: Section 6 − Gtaw Operation

    Configuration Option Menu (Continued) Revision Information INFO This option identifies the unit’s weld library (INFO LIB) and firm- ware revision (INFO REV). Press the Setup Button while the unit is displaying INFO LIB to identify the unit’s weld library. Press the Setup Button while the unit is displaying INFO REV to identify the unit’s firmware revision.

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

    6-2. Scratch Start TIG Welding Mode - GTAW Process 7 2. 0 226 611-A Setup Operation Weld terminals are energized at all times in Scratch Start TIG welding The Adjust Control is used to set desired For typical system connections refer to mode.

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

    6-3. Lift-Arc TIG Welding Mode - GTAW Process 1 3. 5 226 611-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. For typical system connections refer to The Adjust Control is used to set desired Section 6-1.

  • Page 31: Tig Welding Mode - Gtaw Process

    6-4. TIG Welding Mode - GTAW Process 226 611-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. Section 6-1. preset amperage. Rotate Mode Switch to TIG position as A remote control is required to turn on the Mode Switch...

  • Page 32: Section 7 − Gmaw/Gmaw-P/Fcaw Operation

    SECTION 7 − GMAW/GMAW-P/FCAW OPERATION 7-1. Typical Connection For Remote Control Feeder GMAW/GMAW-P/FCAW Process 804 938-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 DCEP (reverse polarity) suitable for all Positive (+) Weld Output Terminal wires except self-shielded FCAW.

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

    7-2. MIG Welding Mode - GMAW/FCAW Process 226 611-A Press the Setup Button to confirm the Weld terminals energized The preset voltage can be adjusted re- selection. The unit will acknowledge a through the remote control in MIG motely at the wire feeder if the feeder change of wire and gas information by dis- welding mode.

  • Page 34: Mig - Wire And Gas Selection Table

    7-3. MIG - Wire and Gas Selection Table WIRE TYPES** GAS TYPES DEFAULT INDUCTANCE .035 (0.9) STL ARGN CO2 (ARGON / CARBON DIOXIDE) .045 (1.2) STL ARGN OXY (ARGON / OXYGEN) .052 (1.4) STL Steel .035 (0.9) STL CO2 (CARBON DIOXIDE) .045 (1.2) STL .035 (0.9) FCAW .045 (1.2) FCAW...

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

    7-4. Pulsed MIG Welding Mode - GMAW-P Process 25.0 226 611-A Pulsed MIG − Wire and Gas Selection Arc Length - Pulsed MIG Manual Control Weld terminals energized Table for available wires and gases (see Section 5-3) through the remote control in (see Section 7-5).

  • Page 36: Pulsed Mig - Wire And Gas Selection Table

    7-5. Pulsed MIG - Wire and Gas Selection Table WIRE TYPES* GAS TYPES .035 (0.9) STL ARGN CO2 (ARGON / CARBON DIOXIDE) Steel .045 (1.2) STL ARGN OXY (ARGON / OXYGEN) .045 (1.2) MCOR Metal Core ARGN CO2 (ARGON / CARBON DIOXIDE) .052 (1.4) MCOR TRI MIX (TRI-GAS MIXTURE) .035 (0.9) SSTL...

  • Page 37: Remote Process Select

    7-6. Remote Process Select This power source can be used with wire feeders that support Remote Process Se- lect. This feature allows the operator to switch the active welding process between MIG and Pulsed MIG at the wire feeder. To determine if the welding system is Remote Process Select capable, connect the wire feeder to the power source and review the...

  • Page 38: Typical Connection For Voltage-Sensing Feeder Gmaw/Gmaw-P/Fcaw Process

    7-7. Typical Connection For Voltage-Sensing Feeder GMAW/GMAW-P/FCAW Process Turn off power before mak- ing connections. Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal Ground Cable to Workpiece Workpiece Voltage Sensing Clamp Gun Trigger Receptacle Wire Feeder Gas Hose 10 Gas Cylinder Use of shielding gas is dependant on Wire Type.

  • Page 39: V-Sense Feeder Welding Mode - Gmaw/Fcaw Process

    7-8. V-Sense Feeder Welding Mode - GMAW/FCAW Process 226 611-A Operation Rotate Adjust Control to select desired gas. Weld terminals are energized at all times in V-Sense Feeder welding While the Volts Indicator is lit under the Left Press the Setup Button again to confirm the mode.

  • Page 40: V-Sense Feeder Welding Mode - Gmaw-P Process

    7-9. V-Sense Feeder Welding Mode - GMAW-P Process R200 226 611-A ment of Arc Control, Wire Type, Gas Type Higher settings narrow the arc cone, re- Weld terminals are energized at all and Arc Length. duces puddle fluidity and crowns the weld times in V-Sense Feeder welding bead appearance.

  • Page 41: Section 8 − Smaw/Cac-A Operation

    SECTION 8 − SMAW/CAC-A OPERATION 8-1. Typical Connection For SMAW And CAC-A Process Turn off power before mak- ing connections. Electrode Holder (Carbon Arc) For CAC-A process connect car- bon arc cutting torch to to positive weld output terminal. Electrode Holder Positive (+) Weld Output Terminal Remote 14 Receptacle...

  • Page 42: Cc Welding Mode - Smaw/Cac-A Process

    8-2. CC Welding Mode - SMAW/CAC-A Process 226 611-A Press the Setup Button repeatedly until the Weld terminals energized If the remote control has an amperage Arc Control light goes out to return to ad- through the remote control in CC adjustment, the adjustment will func- justment of preset amperage.

  • Page 43: Stick Welding Mode - Smaw/Cac-A Process

    8-3. Stick Welding Mode - SMAW/CAC-A Process 7 2. 0 226 611-A Right Display, the Adjust Control is used to Press the Setup Button repeatedly until the Weld terminals are energized at all set desired preset amperage. Arc Control light goes out to return to ad- times in Stick welding mode.

  • Page 44: Optional Low Open Circuit Voltage (Ocv) Welding Modes

    8-4. Optional Low Open Circuit Voltage (OCV) Welding Modes Low OCV Operation The unit can be optionally config- ured for low open circuit voltage (OCV) operation in Stick and Scratch Start TIG modes. When the unit is configured for low OCV op- eration only a low sensing voltage (approximately 15 VDC) is present between the electrode and the...

  • Page 45: Section 9 − Maintenance & Troubleshooting

    SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. 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 46: Help Displays

    9-3. Help Displays All directions are in reference to the front of the unit. All circuitry referred to is lo- cated inside the unit. Help 1 Display HELP Indicates a malfunction in the primary power circuit. If this display is shown, contact a Fac- tory Authorized Service Agent.

  • Page 47: Troubleshooting

    9-4. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position (see Sections 4-9 and 4-10). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Sections 4-9 and 4-10). Check for proper input power connections (see Sections 4-9 and 4-10). No weld output;...

  • Page 48: Section 10 − Electrical Diagram

    SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram OM-237 881 Page 44...
  • Page 49 254 090-A OM-237 881 Page 45...

  • Page 50: Section −11 − Parts List

    SECTION −11 − PARTS LIST Ref. 804 771-D Figure 11-1. Parts Assembly OM-237 881 Page 46...
  • Page 51 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Parts Assembly ....237 879 Wrapper (Includes Insulators and Safety Labels) ....
  • Page 52 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Parts Assembly (Continued) ......Nameplate, Rear (Order by Model and Serial Number) .
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Parts Assembly (Continued) ....218 183 Rcpt Assy, Tw Lk Insul Fem(Tweco Type) (Fac−Op) (Includes) .
  • Page 54 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 55: Warranty

    Warranty Effective January 1, 2011 (Equipment with a serial number preface of MB 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 56 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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