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Red-D-Arc EXTREME 360 CC/CV Auto-Line, Owner'S Manual

The Red-D-Arc EXTREME 360 CC/CV Auto-Line is a powerful welding machine that offers exceptional performance. For detailed instructions on how to maximize its capabilities, download the free Owner's Manual from manualshive.com. This comprehensive manual will guide you through setup, operation, and maintenance of your welding equipment.

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OM-229 409 Page 25

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 8-1. Parts Assembly

Quantity

1

229 541

Wrapper (Includes Insulators and Safety Labels)

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . 

175 256

Insulator, Side Rh (Not Shown)

1

. . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

178 551

Insulator, Side (Not Shown)

1

. . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

2

134 327

Label, Warning General Precautionary Static & Wire Feed

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . 

3

138 442

Label, Caution Falling Equip Can Cause Injury

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . 

4

195 585

Handle, Rubberized Carrying

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5

135 483

Label, Important Remove These Two Handle Screws

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . 

6

R3/C4

196 518

Resistor/Capacitor

1

. . . 

. . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7

R4/C5

196 510

Resistor/Capacitor

1

. . . 

. . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8

SR1

201 530

Kit, Diode Fast Recovery Bridge

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

9

199 840

Bus Bar, Diode

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

10

196 355

Insulator, Screw

4

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

11

201 531

Kit, Diode Power Module

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

12

RT1

199 798

Thermistor, NTC 30K Ohm @ 25 Deg C 18In Lead

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . 

13

CR1

198 549

Relay, Encl 24VDC Spst 35a/300VAC 4pin Flange Mtg

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . 

14

227 127

Label, Warning Electric Shock/Exploding Parts

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . 

15

010 546

Bushing, Snap-In Nyl .375 Id X .500 Mtg Hole

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . 

16

L4

218 020

Inductor, Boost

1

. . . 

. . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17

179 276

Bushing, Snap-In Nyl 1.000 Id X 1.375 Mtg Hole Cent

3

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . 

18

170 647

Bushing, Snap-In Nyl 1.312 Id X 1.500 Mtg Hole

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . 

19

L3

212 150

Inductor, Output

1

. . . 

. . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20

T1

212 132

XFMR, HF Litz/Litz W/Boost

1

. . . 

. . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21

212 197

Heat Sink, Lh Rect

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22

L1

212 091

Inductor, Input

1

. . . 

. . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

23

083 147

Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High

4

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . 

24

PC1

218 007

Circuit Card Assy, Control/Aux Power W/Program

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . 

216 113

Stand-Off Support, PC Card .187 Dia W/P&l .375

2

. . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . 

PLG1

115 091

Housing Plug+Pins (Service Kit) RC1

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG2

201 665

Housing Plug+Pins (Service Kit) RC2

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG3

131 056

Housing Plug+Pins (Service Kit) RC3

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG5

131 204

Housing Plug+Pins (Service Kit) RC5

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG7

131 054

Housing Plug+Pins (Service Kit) RC7

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG8

131 054

Housing Plug+Pins (Service Kit) RC8

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG9

115 093

Housing Plug+Pins (Service Kit) RC9

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG10

115 094

Housing Plug+Pins (Service Kit) RC10

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG11

115 094

Housing Plug+Pins (Service Kit) RC11

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG12

115 092

Housing Plug+Pins (Service Kit) RC12

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

25

212 072

Bracket, Mtg Capacitor/Pc Board

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

26

C12,13

219 930

Kit, Capacitor Elctlt Replacement (Includes)

1

. . . 

. . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . 

193 738

Capacitor, Elctlt 1800 Uf 500 VDC Can 2.52 Dia

2

. . . . . . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . 

217 040

Nut, Nylon M12 Thread Capacitor Mounting

2

. . . . . . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . 

28

CB2

083 432

Circuit Breaker, Man Reset 1P 10A 250VAC Frict

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . 

29

CB1

089 807

Circuit Breaker, Man Reset 1P 2.5A 250VAC Frict

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . 

30

+212 071

Panel, Rear Standard

1

. . . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

31

126 026

Label, Warning Electric Shock Can Kill Significant

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . 

32

Nameplate, Rear (Order by Model and Serial Number)

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . 

34

217 480

Label, Warning Incorrect Connections

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

35

215 980

Bushing, Strain Relief .709/.984 Id X1.375 Mtg Hole

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . 

36

219 487

Cable, Power 12 Ft 8Ga 4C (Non-Stripped End)

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . 

37

182 445

Nut, Conduit 1.000 Npt Pld 1.730 Od X .200 Thk

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . 

38

T2

211 109

XFMR, Control 665V 336Va Syn Aux Pwr

1

. . . 

. . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . 

39

L2

218 018

Inductor, Pre-Regulator

1

. . . 

. . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

40

218 566

Gasket, Inductor Mounting

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

41

CT1

196 231

XMFR, Current Sensing 200/1

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

42

C15

196 143

Capacitor, Polyp Met Film 16. Uf 400 VAC 10%

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . 

43

216 117

Bracket, Mtg Capacitor Series

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

+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.

Summary of Contents for EXTREME 360 CC/CV Auto-Line

Page 1: ...Processes Description Multiprocess Welding Arc Welding Power Source OM 229 409B 2006 10 EXTREME 360 CC CV Auto Line...

Page 2: ......

Page 3: ...3 INTRODUCTION 9 3 1 Specifications 9 3 2 Volt Ampere Curves 9 3 3 Duty Cycle And Overheating 10 SECTION 4 INSTALLATION 11 4 1 Selecting a Location 11 4 2 Connecting 1 Phase Input Power 12 4 3 Connect...

Page 4: ......

Page 5: ...0 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that inpu...

Page 6: ...mbustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguishe...

Page 7: ...s computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt l...

Page 8: ...Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent...

Page 9: ...la norme OSHA 29 CFR 1910 147 voir normes de s curit D Installer le poste correctement et le mettre la terre convenablement selon les consignes du manuel de l op rateur et les normes nationales provin...

Page 10: ...es poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur p...

Page 11: ...ut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs D Demander seulement des personnes qualifi es familiaris es avec...

Page 12: ...bpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 31...

Page 13: ...40 4 36 1 20 6 17 8 14 1 14 2 13 6 1 Phase 300 A at 32 VDC 60 Duty Cycle 60 8 54 6 29 7 25 4 19 9 11 7 11 2 See Section 3 3 for Duty Cycle Rating 3 2 Volt Ampere Curves 217 836 A 217 837 B Volt amper...

Page 14: ...nd cooling fan runs Wait fifteen min utes for unit to cool Reduce amper age or voltage or duty cycle before welding Single Phase Operation The unit is supplied with a 8 AWG power cord The rated output...

Page 15: ...information on rear panel to determine input power needs 4 Line Disconnect Device Locate unit near correct input power supply Y Special installation may be required where gasoline or volatile liquids...

Page 16: ...nk the pow er source 1 Black And White Input Conductor L1 And L2 2 Red Input Conductor 3 Green Or Green Yellow Grounding Conductor 4 Insulation Sleeving 5 Electrical Tape Insulate and isolate red cond...

Page 17: ...een 208 and 575 VAC without removing cover to relink the power source For Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Groundin...

Page 18: ...hree Phase Input Voltage 208 230 400 460 575 Input Amperes At Rated Output 40 4 36 1 20 6 17 8 14 1 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 45 40 25 20 15 Normal Operating 3 60...

Page 19: ...or less drop or a current density of at least 300 circular mils per ampere S 0007 D 4 6 Remote 14 Receptacle Information Socket Socket Information 24 VOLTS AC A 24 volts ac Protected by circuit break...

Page 20: ...as In fitting Connect hose coupler to torch Connect one end of gas hose to hose coupler Connect remaining end of gas hose to Gas Out fitting Operation The gas solenoid controls gas flow during the TIG...

Page 21: ...cent of V A Adjust control setting value selected on V A Adjust is maximum available on remote In ELECTRODE HOT STICK mode the remote control is not used In the MIG mode remote control provides full r...

Page 22: ...l Volts OCV Preset Amps V A 71 7 85 Actual Volts Actual Amps V A 24 5 85 V Sense Feeder Flashes OCV And Preset Blank V A 71 7 Actual Volts Actual Amps V A 24 5 250 5 3 Mode Switch Settings The Stick a...

Page 23: ...g sticking or getting contaminated 1 1 2 Seconds Touch Do NOT Strike Like A Match 2 Ref S 156 279 5 5 Stick Start Procedure With Stick selected start arc as fol lows 1 Electrode 2 Workpiece 3 Arc Drag...

Page 24: ...s Replace Damaged Or Unreadable Labels Replace Cracked Torch Body Repair Or Replace Cracked Cables Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections 6 Months Blow Out Insid...

Page 25: ...e input current When this limit is reached the unit automatically reduces out put power to continue operation If this display is shown have a qualified electrician check the input voltage 6 Help 8 Dis...

Page 26: ...OM 229 409 Page 22 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram...

Page 27: ...OM 229 409 Page 23 211 328 E...

Page 28: ...5 6 7 8 9 10 12 13 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 31 32 34 35 36 37 38 39 42 43 45 47 46 48 49 50 51 52 53 54 55 56 57 58 59 60 61 63 64 66 68 67 69 70 71 72 73 11 44 65 74 41 76 75 49...

Page 29: ...LG2 201 665 Housing Plug Pins Service Kit RC2 1 PLG3 131 056 Housing Plug Pins Service Kit RC3 1 PLG5 131 204 Housing Plug Pins Service Kit RC5 1 PLG7 131 054 Housing Plug Pins Service Kit RC7 1 PLG8...

Page 30: ...756 Switch Tgl 3Pst 40A 600VAC Scr Term Wide Tgl 1 60 176 226 Insulator Switch Power 1 61 FM1 196 313 Fan Muffin 115V 50 60Hz 3000 Rpm 6 378 Mtg Holes 1 PLG16 131 054 Housing Plug Pins Service Kit 1 R...

Page 31: ...ch as contact tips cutting nozzles contactors relays brushes slip rings or parts that fail due to normal wear 2 Items furnished by manufacturer but manufactured by others such as engines or trade acce...

Page 32: ...tomer Distributor Address City State Zip Please complete and retain with your personal records Contact the Delivering Carrier to Owner s Record File a claim for loss or damage during shipment For assi...

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