Red-D-Arc EXTREME 360 MAP Auto-Line Owner'S Manual Download Page 45

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OM-237 881 Page 41

SECTION 9 − MAINTENANCE & TROUBLESHOOTING

9-1.

Routine Maintenance

Maintain more often
during severe conditions.

Disconnect power
before maintaining.

3 Months

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 Inside

9-2.

Blowing Out Inside Of Unit

Do not remove case when
blowing out inside of unit.

To blow out unit, direct airflow
through front and back louvers as
shown.

Blowing Out Unit 2010−01

Summary of Contents for EXTREME 360 MAP Auto-Line

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

Page 2: ......

Page 3: ...able Sizes 14 4 5 Remote 14 Receptacle Information 15 4 6 Optional 115 Volts AC Duplex Receptacle And Supplementary Protectors 15 4 7 Optional Gas Valve Operation And Shielding Gas Connection 16 4 8 E...

Page 4: ...C A Process 38 8 3 Stick Welding Mode SMAW CAC A Process 39 8 4 Optional Low Open Circuit Voltage OCV Welding Modes 40 SECTION 9 MAINTENANCE TROUBLESHOOTING 41 9 1 Routine Maintenance 41 9 2 Blowing O...

Page 5: ...ds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following eq...

Page 6: ...ess they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to th...

Page 7: ...panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels cover...

Page 8: ...web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website ww...

Page 9: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivante...

Page 10: ...ou laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoque...

Page 11: ...eur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprim...

Page 12: ...stan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences D L nergie lectromagn tique risque de provoquer d...

Page 13: ...r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Ap...

Page 14: ...OM 237 881 Page 10...

Page 15: ...Overload Protection automatically shuts down the unit only when necessary to prevent damage to internal components if the duty cycle is exceeded or air flow and cooling are restricted see Section 3 4...

Page 16: ...and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or voltage or duty cycle before welding Single Phase Operation The unit is supplied with a 8 AWG power cord The rated output...

Page 17: ...A A D C B E G F A 11 3 4 in 298 mm B 1 11 16 in 42 mm C 15 3 4 in 400 mm D 19 3 32 in 485 mm E 8 11 16 in 221 mm F 1 17 32 in 39 mm G 1 4 20 UNC 2B thread Weight 80 lb 36 3 kg 93 5 lb 42 4 kg w optio...

Page 18: ...30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x2 0 2x70...

Page 19: ...10 volts DC out put signal from wire feeder M CC CV Select 0 to 10 volts DC N Wirefeed speed common A V AMPERAGE VOLTAGE F Current feedback 1 volt DC per 100 amperes H Voltage feedback 1 volt DC per...

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: ...30 Min Input Conductor Size In AWG Kcmil 4 8 8 10 12 12 Max Recommended Input Conductor Length In Feet Meters 72 22 89 27 176 54 140 43 219 67 Min Grounding Conductor Size In AWG Kcmil 4 8 8 10 12 12...

Page 22: ...k in put voltage available at site 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 is...

Page 23: ...the power source See rating label on unit and check input voltage available at site For Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Y...

Page 24: ...display the actual weld output values after arc initiation and remains dis played for approximately three seconds after the arc is broken 7 Amps Indicator 8 Setup Indicator 9 Adjust Control 10 Wire Ty...

Page 25: ...GTAW Electrode Hot Amps Panel Amps TIG GTAW Remote 14 Amps Panel Amps MIG GMAW Remote 14 Volts Volts Pulsed MIG GMAW P Remote 14 Arc Length 0 100 Arc Length 0 100 CC SMAW CAC A Remote 14 Amps Panel Am...

Page 26: ...ation Option Menu hold the Setup Button down during power up while the unit is displaying 8888 on the Left and Right Displays SET UP will be displayed momentarily Configurationoptions are displayed in...

Page 27: ...ed MIG process in units of Arc Length PULS ARC L or preset voltage PULS VOLT Wire Feed Speed And Wire Diameter Units WFS IPM WFS is displayed in inches per minute Diameter is displayed in inches WFS M...

Page 28: ...ng EXIT NO to return to the first configuration option Press the Setup Button while the unit is displaying EXIT YES to exit the Configuration Option Menu The Configuration Option Menu can be exited at...

Page 29: ...open circuit voltage is shown in the Left Display with the Volts Indicator lit Preset amperage is shown in the Right Display with the Amps Indicator lit Operation The Adjust Control is used to set de...

Page 30: ...before the electrode touches the work piece instead a low sensing voltage is present The sensing voltage allows the electrode to touch the workpiece without overheating sticking or getting contami nat...

Page 31: ...amperage is shown in the Right Display with the Amps Indicator lit Operation The Adjust Control is used to set desired preset amperage A remote control is required to turn on the weld output If the r...

Page 32: ...tacle 2 Positive Weld Output Terminal 3 Negative Weld Output Terminal 4 Ground Cable to Workpiece 5 Workpiece 6 Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder Use of shielding gas is dependant on Wire Ty...

Page 33: ...as Press the Setup Button repeatedly until the Wire Type indicator is lit The active Wire Type will appear in the Left and Right Dis play Rotate Adjust Control to select desired wire Press the Setup B...

Page 34: ...045 1 2 MCOR 052 1 4 MCOR 1 16 1 6 MCOR ARGN CO2 ARGON CARBON DIOXIDE 30 Stainless Steel 035 0 9 SSTL 045 1 2 SSTL TRI MIX TRI GAS MIXTURE ARGN OXY ARGON OXYGEN 70 Aluminum 035 0 9 AL4X 4000 Series 04...

Page 35: ...arpArc setting from 0 to 50 default is 25 Adjusting the SharpArc setting changes the welding arc cone Lower settings widen the arc cone increases puddle fluidity and flat tens the weld bead appearance...

Page 36: ...4000 Series ARGN ARGON 035 0 9 AL5X 5000 Series 040 1 0 AL5X 5000 Series 3 64 1 2 AL5X 5000 Series 1 16 1 6 AL5X 5000 Series ARGN ARGON HE AR25 HELIUM ARGON Nickel 035 0 9 NI 045 1 2 NI ARGN HE ARGON...

Page 37: ...t the wire feeder Power Source Display Wire Feeder with Remote Process Select Detected and Set for Pulsed MIG When the power source Right Display is PULS a Remote Process Select wire feeder is detecte...

Page 38: ...put Terminal 3 Ground Cable to Workpiece 4 Workpiece 5 Voltage Sensing Clamp 6 Gun 7 Gun Trigger Receptacle 8 Wire Feeder 9 Gas Hose 10 Gas Cylinder Use of shielding gas is dependant on Wire Type The...

Page 39: ...ss the Setup Button repeatedly until the Wire Type indicator is lit The active Wire Type will appear in the Left and Right Dis play Rotate Adjust Control to select desired wire Press the Setup Button...

Page 40: ...rily Arc Control SharpArc Press the Setup Button repeatedly until the Arc Control indicator is lit SHRP appears on the Left Display and the corresponding SharpArc setting appears on the Right Dis play...

Page 41: ...ak ing connections 1 Electrode Holder Carbon Arc For CAC A process connect car bon arc cutting torch to to positive weld output terminal 2 Electrode Holder 3 Positive Weld Output Terminal 4 Remote 14...

Page 42: ...otate Adjust Control to select desired dig setting from 0 to 100 Dig control allows the arc characteristics soft versus stiff to be changed for specific applications and electrodes Lower the dig setti...

Page 43: ...djust Control to select desired dig setting from 0 to 100 Dig control allows the arc characteristics soft versus stiff to be changed for specific applications and electrodes Lower the dig setting for...

Page 44: ...tion 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 workpiece prior to...

Page 45: ...ace 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 Inside 9 2...

Page 46: ...to allow the fan to cool it see Section 3 4 Operation will continue when the unit has cooled Help 6 Display Indicates operation at maximum input cur rent The unit has a maximum allowable input curren...

Page 47: ...On Input voltage outside acceptable range of variation see Section 4 8 Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 3 4 Erratic or improper weld o...

Page 48: ...OM 237 881 Page 44 SECTION 10 ELECTRICAL DIAGRAM Figure 10 1 Circuit Diagram...

Page 49: ...OM 237 881 Page 45 254 090 A...

Page 50: ...3 4 5 11 12 10 9 14 15 18 19 20 21 22 23 6 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 42 43 45 47 46 49 48 50 51 52 55 54 53 56 57 58 61 62 63 77 76 74 65 73 72 66 67 68 13 44 75 69 41 7 8 48 64...

Page 51: ...Inductor Input 1 25 083 147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 4 26 PC1 242 812 Circuit Card Assy Control W Program 1 26 PC1 242 341 Circuit Card Assy Control Aux Power W Program 1 216 113...

Page 52: ...lator And Inverter Module Includes 1 MOD 1 SKiip 83 HEC 1 MOD 2 SKiip 83 EC 1 PLG13 130 203 Housing Plug Pins Service Kit RC1 1 PLG14 201 665 Housing Plug Pins Service Kit RC2 1 PLG15 115 092 Housing...

Page 53: ...68 175 138 Box Louver 1 69 Label Order by Model and Serial Number 1 70 174 991 Knob Pointer 1 250 Dia X 250 Id W Spring Clip 21 2 71 231 468 Nut 375 32 56Hex 22H Brs Conical Knurl 1 72 231 469 Nut 50...

Page 54: ...mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8 mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 16 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in 3 4 in 13...

Page 55: ...RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work stat...

Page 56: ...iginal customer Distributor Address City State Zip Please complete and retain with your personal records Contact the Delivering Carrier for For assistance in filing or settling claims contact your dis...

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