Red-D-Arc EXTREME 360 Technical Manual Download Page 1

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TM-229 409A

2006

−

Eff w/Serial Number LG250111A

EXTREME 360

CC/CV Auto-Line

Arc Welding Power Source

Processes

Description

Multiprocess Welding

File: MULTIPROCESS

Summary of Contents for EXTREME 360

Page 1: ...TM 229 409A 2006 12 Eff w Serial Number LG250111A EXTREME 360 CC CV Auto Line Arc Welding Power Source Processes Description Multiprocess Welding File MULTIPROCESS...

Page 2: ...Pre Regulator Module MOD1 Test Point Values 20 6 6 Inverter Module MOD2 21 6 7 Inverter Module MOD2 Test Point Values 21 6 8 Power Switch S1 22 6 9 Output Diodes D1 D2 23 6 10 Output Diodes D1 D2 Test...

Page 3: ...6 29 Front Panel Display Board PC3 Testing Information Use with Section 6 30 47 6 30 Front Panel Display Board PC3 Test Point Values 48 6 31 Checking Unit Output After Servicing 49 SECTION 7 MAINTENAN...

Page 4: ......

Page 5: ...onductors from deenergized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters D Turn Off inverter disconnect input power and disch...

Page 6: ...related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling For Gasoline Engin...

Page 7: ...75 VDC 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 2 3 for Duty Cycle Rating 2 2 Volt Ampere Curves 217 836 A 217 837 B Volt...

Page 8: ...yed and 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 o...

Page 9: ...rating 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 l...

Page 10: ...relink 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...

Page 11: ...r between 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 Gr...

Page 12: ...60 575 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 50 30 25 20 Min Input Conductor Size I...

Page 13: ...volts or less drop or a current density of at least 300 circular mils per ampere S 0007 D 3 6 Remote 14 Receptacle Information Socket Socket Information 24 VOLTS AC A 24 volts ac Protected by circuit...

Page 14: ...r to Gas 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 t...

Page 15: ...a percent 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...

Page 16: ...Actual 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 4 3 Mode Switch Settings The S...

Page 17: ...heating sticking or getting contaminated 1 1 2 Seconds Touch Do NOT Strike Like A Match 2 Ref S 156 279 4 5 Stick Start Procedure With Stick selected start arc as fol lows 1 Electrode 2 Workpiece 3 Ar...

Page 18: ...Feedback Negative Output Voltage Feedback Ribbon Cable 24 VAC 115 VAC Boost Gate Signal Optional Auxiliary Power 115 VAC Receptacle Input Boost Inductor Current Feedback Input Rectifier Voltage Bus V...

Page 19: ...le Output Current Sensor HD1 14 15 Electrode Optional Gas Solenoid GS1 Fan Motor FM1 35 36 Output Current Feedback Primary Heatsink Thermistor RT 2 Secondary Heatsink Thermistor RT 1 37 38 Control Tra...

Page 20: ...erage Adjust Remote 14 pin receptacle Process Selector Switch and Weld Process Control 21 Voltmeter V Ammeter A See Sections 4 1 Front Panel Controls and 4 2 Meter Functions 22 Arc Control Controls Di...

Page 21: ...hough control auxiliary power board PC1 and power interconnect board PC2 are briefly checked in the pre power flowchart more complete tests may be needed later for these parts This procedure is simply...

Page 22: ...e PC1 Complete Sections 6 19 and 6 20 Power Interconnect PC2 NO All Measurements Pass Replace PC2 YES Replace Modules MOD1 MOD2 See Module Field Kit Instructions Complete Section 6 8 For Power Switch...

Page 23: ...ot drop to near zero after several minutes use a bleeder resistor of between 25 and 1000 ohms at least 5 watts 16 AWG 1000 volts dc insulating rating wire to discharge the capacitor s 5 Typical Bleede...

Page 24: ...nts for Input Pre Regulator Module MOD1 see Section 6 5 If all measurements passed MOD1 is OK Continue to the end of the pre power flowchart see Section 6 2 1 Component Side Of Board 2 8 3 9 4 7 5 6 T...

Page 25: ...end of the pre power flowchart see Section 6 2 1 Component Side Of Board 7 10 5 14 2 4 6 9 11 12 13 Test Equipment Needed 3 8 6 7 Inverter Module MOD2 Test Point Values Inverter Module MOD2 DVM Posit...

Page 26: ...several times Switch should snap sharply between the On and Off positions Check switch electrical operation by checking continuity across S1 contacts with switch in the On posi tion With switch in the...

Page 27: ...age Check all measurements for output diodes D1 and D2 see Section 6 10 If all measurements passed the output diodes D1 and D2 are OK Continueto the end of the pre pow er flowchart see Section 6 2 2...

Page 28: ...ost rectifier SR1 see Section 6 12 If all measurements passed SR1 is OK Continue to the end of the pre power flowchart see Section 6 2 1 3 4 2 1 Test Equipment Needed 6 12 Stick Boost Rectifier SR1 Te...

Page 29: ...PRE POWER CHECKS TM 229 409 Page 25 Extreme 360 Notes OHM S LAW VOLTAGE CURRENT X RESISTANCE CURRENT VOLTAGE RESISTANCE RESISTANCE VOLTAGE CURRENT...

Page 30: ...1 Control Board PC1 2 Receptacle RC2 3 Receptacle RC3 4 Receptacle RC5 5 IGBT Gate Drive IC U1 6 IGBT Gate Drive IC U4 7 IGBT Gate Drive IC U5 8 Diode D37 9 Diode D38 10 Diode D39 11 Diode D42 12 Diod...

Page 31: ...20 0 90 N A Auxiliary Bridge IGBT Gate Drive IC U1 U1 Pin 5 U1 Pin 6 0 20 0 90 N A Auxiliary Bridge IGBT Gate Drive IC U1 RC3 Pin 6 PRECOM U1 Pin 7 0 20 0 90 N A Auxiliary Bridge IGBT Gate Drive IC U1...

Page 32: ...esting 1 Control Board PC1 2 Receptacle RC2 3 Receptacle RC3 4 Receptacle RC5 5 IGBT Gate Drive IC U6 6 Diode D18 7 Diode D41 8 Diode D46 9 Diode D47 10 Diode D49 11 Diode D50 12 Diode D51 13 Diode D5...

Page 33: ...Anode D41 Cathode 0 20 0 90 N A D46 D46 Anode D46 Cathode 0 10 0 30 N A D47 D47 Anode D47 Cathode 0 10 0 30 N A D49 D49 Anode D49 Cathode 0 20 0 90 N A D50 D50 Anode D50 Cathode 0 20 0 90 N A D51 D51...

Page 34: ...ma chine Remove all plugs from PC1 before testing 1 Control Board PC1 2 Receptacle RC9 3 IGBT Gate Drive IC U13 4 IGBT Gate Drive IC U16 5 IGBT Gate Drive IC U17 6 Diode D11 7 Diode D20 Unplug all con...

Page 35: ...U17 U17 Pin 5 RC9 Pin 4 15V 0 20 0 90 N A Inverter IGBT Gate Drive IC U17 U17 Pin 7 RC9 Pin 4 15V 0 20 0 90 N A Inverter IGBT Gate Drive IC U17 RC9 Pin 6 GND U17 Pin 5 0 20 0 90 N A Inverter IGBT Gat...

Page 36: ...7 AC2 8 AC3 9 Q1 10 Q2 11 Diode D1 12 Diode D2 13 Diode D3 14 Diode D4 15 Diode D8 16 Diode D9 17 Diode D10 18 Diode D11 19 Diode D12 20 Diode D13 21 Center Bus 22 BUS 23 BUS Remove all plugs from PC...

Page 37: ...rter Gate MOSFET Q2 Q2 S Source Q2 D Drain 0 20 0 90 N A Inverter Gate Protection Diode D1 D1 Anode D1 Cathode 0 20 0 90 N A Inverter Gate Protection Diode D2 D2 Anode D2 Cathode 0 20 0 90 N A Inverte...

Page 38: ...resistance and connections and replace accessory if necessary Check input and output voltages of hall device HD1 see Section 6 24 Replace HD1 if necessary Check control auxiliary power board PC1 and c...

Page 39: ...lso see Section 6 25 Check front panel display board PC3 and connections and replace if necessary see Section 6 29 Fan motor does not run after approxi mately four minutes of operation at rated load C...

Page 40: ...will continue when the unit has cooled 4 Help 5 Display Indicates the right side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 2 3 Operation will continue...

Page 41: ...ut input power before re moving cover Follow this procedure to modify the unit for low open circuit voltage OCV when Stick welding OCV is reduced to about 15 volts dc 1 Front Panel And Display Board P...

Page 42: ...100 amperes of weld output V14 72 volts dc open circuit voltage in Scratch Start TIG TIG MIG Pulse MIG CC Stick and V Sense feeder modes 14 volts dc in Lift Arc TIG mode 6 24 Troubleshooting Circuit D...

Page 43: ...wer see Sections 6 1 thru 6 18 TM 229 409 Page 39 Extreme 360 R5 R9 211 328 E R6 R3 See Section 6 25 for PC1 information V6 R1 V8 See Section 6 27 for PC2 information R2 R7 R8 R4 V7 V9 V10 Approx 35K...

Page 44: ...lec trically live Significant DC voltage can remain on capaci tors after unit is Off Be sure plugs are secure before ap plying power See Section 6 26 for specific values during testing 1 Inverter Cont...

Page 45: ...rent 2 Output 15 volts dc regulated with respect to primary bus 3 Output 12 volts dc regulated with respect to primary bus 4 Output Do not measure Boost IGBT gate drive signal 5 Do not measure Boost I...

Page 46: ...ference voltage for thermistors 14 GND Circuit common referenced to chassis 15 Output Secondary side thermistor return 2 volts dc at 25 C thermistor temperature 16 GND Circuit common referenced to cha...

Page 47: ...st point used to test board only 4 Output Do not measure Test point used to test board only RC11 1 Output 24 volts output to boost relay coil 2 Boost relay coil return 24 volts dc relay contacts open...

Page 48: ...161 Y Warning this procedure requires the machine to be electrically live Signifi cant DC voltage can remain on capacitors after unit is Off Be sure plugs are secure before applying power See Section...

Page 49: ...sure Boost IGBT gate drive signal 3 Output Do not measure Boost inductor current feedback 4 Input 12 volts dc regulated with respect to primary bus 12 volts dc power to boost inductor current sensor 5...

Page 50: ...with respect to AC1 or AC3 AC3 Power Primary AC mains phase 3 line voltage measure with respect to AC1 or AC2 L1 Power Input boost inductor rectified line voltage measure with respect to bus L1 L2 Pow...

Page 51: ...30 Ref 217 181 B 907 161 Y Warning this procedure re quires the machine to be electrically live Significant DC voltage can remain on ca pacitors after unit is Off Be sure plugs are secure before ap pl...

Page 52: ...hermistor temperature 16 GND Circuit common referenced to chassis 17 Input Primary side thermistor return 2 volts dc at 25 C thermistor temperature 18 GND Circuit common referenced to chassis 19 Input...

Page 53: ...volts ac at 2 amps 14 pin remote accessory power J Input Remote output enable 0 volts ac weld output off 115 volts ac weld output on K Chassis Power source chassis L Not used M Input Remote process s...

Page 54: ...ce 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 7 2 B...

Page 55: ...n The following is a list of all diagrams for models covered by this manual Model Serial Or Style Number Circuit Diagram Wiring Diagram EXTREME 360 208 575 Volt Models LG250111A and following 211 328...

Page 56: ...TM 229 409 Page 52 Extreme 360 Figure 8 1 Circuit for EXTREME 360 208 575 Volt Eff w LG250111A And Following...

Page 57: ...TM 229 409 Page 53 Extreme 360 211 328 E...

Page 58: ...TM 229 409 Page 54 Extreme 360 Figure 8 2 Wiring Diagram for EXTREME 360 208 575 Volt Eff w LG250111A And Following 1 of 2...

Page 59: ...TM 229 409 Page 55 Extreme 360 220 922 B...

Page 60: ...TM 229 409 Page 56 Extreme 360 Figure 8 3 Wiring Diagram for EXTREME 360 208 575 Volt Eff w LG250111A And Following 2 of 2...

Page 61: ...TM 229 409 Page 57 Extreme 360 220 922 B...

Page 62: ...TM 229 409 Page 58 Extreme 360 Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now...

Page 63: ...w LG250111A And Following For OM 229 409 Revisions A Thru B TM 229 409 2006 12 Eff w Serial Number LG250111A Arc Welding Power Source Processes Description Multiprocess Welding EXTREME 360 CC CV Auto...

Page 64: ...ef 803 690 F 1 2 3 4 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 4...

Page 65: ...s 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 Se...

Page 66: ...vice Kit 1 59 S1 128 756 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...

Page 67: ...auge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERE...

Page 68: ...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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