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TM-229 409 Page 14

Extreme 360

SECTION 5

−

THEORY OF OPERATION

Power Interconnect Board

PC2

Remote 14-Pin Receptacle

RC50

Arc

Control

Voltmeter

Ammeter

Front Panel And Display Board PC3

Voltage/

Amperage

Adjust

Process

Selector

Switch

Weld

Process

Control

Positive (+) Output Voltage 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 Voltage

Current

Transformer

CT1

♦

Inverter

Module

Mod2

Bus

Capacitors

C12, C13

Boost

Snubber

Inductor

Snubber

Resistor

Module

RM1

Boost

Input

Inductor

Input

Pre-Regulator

Module

Mod1

Power

Switch

1 Phase

3 Phase

Input

Power

Содержание EXTREME 360

Страница 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...

Страница 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...

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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