Red-D-Arc EXTREME 360 Spécifications Page 1

TM-229 409A 2006−12Eff w/Serial Number LG250111AEXTREME 360 CC/CV Auto-LineArc Welding Power SourceProcessesDescriptionMultiprocess WeldingFile: MULTI

TM-229 409 Page 6 Extreme 3603-2. Connecting 1-Phase Input Power804 531-AY Installation must meet all Na-tional and Local Codes − haveonly qualified p

TM-229 409 Page 7Extreme 3603-3. Connecting 3-Phase Input Power804 531-AY Installation must meet all Nationaland Local Codes − have only quali-fied pe

TM-229 409 Page 8 Extreme 3603-4. Electrical Service GuideY CAUTION: INCORRECT INPUT POWER can damage this welding power source. Phase to groundvolt

TM-229 409 Page 9Extreme 3603-5. Weld Output Receptacles And Selecting Cable SizesTotal Cable (Copper) Length In Weld Circuit Not Exceeding100 ft (30

TM-229 409 Page 10 Extreme 360‘3-7. Optional Gas Valve Operation And Shielding Gas ConnectionRef. 803 705-A / Ref. 803 691-CObtain gas cylinder and ch

TM-229 409 Page 11Extreme 360SECTION 4 − OPERATIONV/A ADJUSTARC CONTROLARC CONTROLREMOTEELECTRODE HOT4-1. Front Panel Controls 1 Power Switch. The fan

TM-229 409 Page 12 Extreme 3604-2. Meter FunctionsThe meters display the actual weld output values for approximately three secondsafter the arc is bro

TM-229 409 Page 13Extreme 3604-4. Lift-Arc TIG ProcedureWith Process Switch in the Lift-ArcTIG position, start an arc as follows:1 TIG Electrode2 Work

TM-229 409 Page 14 Extreme 360SECTION 5 − THEORY OF OPERATIONPower Interconnect BoardPC2Remote 14-Pin ReceptacleRC50ArcControlVoltmeterVAmmeterA Front

TM-229 409 Page 15Extreme 360 Weld CircuitOptional♦StickBoostRectifierSR1StickBoostInductorL4StickBoostRelayCR1MainTransformerT1OutputDiodes D1 &

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-

TM-229 409 Page 16 Extreme 360Theory Of Operation Components1 Primary Input PowerSingle or Three-Phase AC primarypower supply.2 Power Switch S1Provide

TM-229 409 Page 17Extreme 360SECTION 6 − TROUBLESHOOTING6-1. Checking Unit Before Applying Power. See Section 6-24 for test points and values and Sect

PRE-POWER CHECKSTM-229 409 Page 18 Extreme 3606-2. Pre-Power FlowchartNOYESYESYESComplete Section 6-3, MeasuringInput Capacitor Voltage.Complete Secti

PRE-POWER CHECKSTM-229 409 Page 19Extreme 360Ref. 803 721-B / 907 1616-3. Measuring Input Capacitor VoltageY Turn Off welding powersource, and disconn

PRE-POWER CHECKSTM-229 409 Page 20 Extreme 3606-4. Input Pre-Regulator Module (MOD1)Ref. 907 161 / 225 065-AY Read and follow safetyinformation in Sec

PRE-POWER CHECKSTM-229 409 Page 21Extreme 3606-6. Inverter Module (MOD2)Ref. 907 161 / 225 065-AY Read and follow safetyinformation in Section 6-1befo

PRE-POWER CHECKSTM-229 409 Page 22 Extreme 3606-8. Power Switch (S1)Ref. 907 161 / Ref. 183 484Y Read and follow safetyinformation in Section 6-1befor

PRE-POWER CHECKSTM-229 409 Page 23Extreme 3606-9. Output Diodes D1, D2Ref. 907 161Diodes D1, D2− Weld OutputReceptacles+Y Read and follow safetyinform

PRE-POWER CHECKSTM-229 409 Page 24 Extreme 3606-11. Stick Boost Rectifier (SR1)Ref. 907 161Y Read and follow safetyinformation in Section 6-1before pr

PRE-POWER CHECKSTM-229 409 Page 25Extreme 360NotesOHM’S LAWVOLTAGE =CURRENT X RESISTANCECURRENT = VOLTAGERESISTANCERESISTANCE = VOLTAGECURRENT

TABLE OF CONTENTS6-27. Power Interconnect Board PC2 Testing Information (Use with Section 6-28) 44 . . . . . . . . . . . . . . . . . . . . 6-28. Power

PRE-POWER CHECKSTM-229 409 Page 26 Extreme 3606-13. Control/Auxiliary Power Board PC1 − Auxiliary Power CircuitRef. 217 184-F / 907 161Y Read and foll

PRE-POWER CHECKSTM-229 409 Page 27Extreme 3606-14. Control/Auxiliary Power Board PC1 − Auxiliary Power Circuit Test Point Values60Hz Auxiliary Power B

PRE-POWER CHECKSTM-229 409 Page 28 Extreme 3606-15. Control/Auxiliary Power Board PC1 − Pre-Regulator Control CircuitRef. 217 184-F / 907 161Y Read an

PRE-POWER CHECKSTM-229 409 Page 29Extreme 3606-16. Control/Auxiliary Power Board PC1 − Pre-Regulator Control Circuit Test Point ValuesPre-Regulator Co

PRE-POWER CHECKSTM-229 409 Page 30 Extreme 3606-17. Control/Auxiliary Power Board PC1 − Inverter Control CircuitRef. 217 184-F / 907 161Y Read and fol

PRE-POWER CHECKSTM-229 409 Page 31Extreme 3606-18. Control/Auxiliary Power Board PC1 − Inverter Control Circuit Test Point ValuesInverter Control DVM

PRE-POWER CHECKSTM-229 409 Page 32 Extreme 3606-19. Power Interconnect Board (PC2)Ref. 907 161 / 225 065-AY Read and follow safety informationin Secti

PRE-POWER CHECKSTM-229 409 Page 33Extreme 3606-20. Power Interconnect Board (PC2) Test Point ValuesPower Interconnect Board PC2 DVM Positive Lead DVM

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 34 Extreme 3606-21. Troubleshooting Table. See Section 6-24 for t

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 35Extreme 360Trouble RemedyErratic or improper weld output. Use p

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 36 Extreme 3606-22. Voltmeter/Ammeter Diagnostics. All directions

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 37Extreme 3606-23. Enabling Low Open Circuit Voltage Stick Mode (

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 38 Extreme 360Voltage Readingsa) Tolerance − ±10% unless specifie

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 39Extreme 360R5R9211 328-ER6R3See Section 6-25 forPC1 information

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 40 Extreme 3606-25. Control/Auxiliary Power Board PC1 Testing Inf

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 41Extreme 3606-26. Control/Auxiliary Power Board PC1 Test Point V

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 42 Extreme 360Section 6-26. Control/Auxiliary Power Board PC1 Tes

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 43Extreme 360Section 6-26. Control/Auxiliary Power Board PC1 Test

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 44 Extreme 3606-27. Power Interconnect Board PC2 Testing Informat

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 45Extreme 3606-28. Power Interconnect Board PC2 Test Point Values

TM-229 409 Page 1Extreme 360SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING1-1. Symbol UsageOM-229 409-B, safety_stm 8/03Means Warning! Watch Out! There

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 46 Extreme 360Section 6-28. Power Interconnect Board PC2 Test Poi

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 47Extreme 3606-29. Front Panel/Display Board PC3 Testing Informat

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 48 Extreme 3606-30. Front Panel/Display Board PC3 Test Point Valu

Always check unit before applying power (see Sections 6-1 thru 6-18).TM-229 409 Page 49Extreme 360Section 6-30. Front Panel/Display Board PC3 Test Poi

TM-229 409 Page 50 Extreme 360SECTION 7 − MAINTENANCE7-1. Routine MaintenanceY Disconnect power before maintaining.. Maintain more oftenduring severe

TM-229 409 Page 51Extreme 360SECTION 8 − ELECTRICAL DIAGRAMS. The circuits in this manual can be used for troubleshooting, but there might be minor ci

TM-229 409 Page 52 Extreme 360Figure 8-1. Circuit for EXTREME 360 (208 − 575 Volt) Eff. w/LG250111A And Following

TM-229 409 Page 53Extreme 360211 328-E

TM-229 409 Page 54 Extreme 360Figure 8-2. Wiring Diagram for EXTREME 360 (208 − 575 Volt) Eff. w/LG250111A And Following (1 of 2)

TM-229 409 Page 55Extreme 360220 922-B

TM-229 409 Page 2Extreme 360MOVING PARTS can cause injury.D Keep away from moving parts.D Keep away from pinch points such as driverolls.MAGNETIC FIEL

TM-229 409 Page 56 Extreme 360Figure 8-3. Wiring Diagram for EXTREME 360 (208 − 575 Volt) Eff. w/LG250111A And Following (2 of 2)

TM-229 409 Page 57Extreme 360220 922-B

TM-229 409 Page 58 Extreme 360NotesOver 80,000 trainedsince 1930!400 Trade Square East, Troy, Ohio 453731-800-332-9448 www.welding.orgStart Your Profe

Eff w/LG250111A And FollowingFor OM-229 409 Revisions A Thru BTM-229 409 2006−12Eff w/Serial Number LG250111AArc Welding Power SourceProcessesDescript

TM-229 409 Page 60Extreme 360SECTION 9 − PARTS LIST FOR LG250111A AND FOLLOWINGRef. 803 690-F123456789101213151617181920212223242526282930313234353637

Eff w/LG250111A And FollowingTM-229 409 Page 61Extreme 360DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Parts AssemblyQuantity1 229 541 Wrapper (Inclu

Eff w/LG250111A And FollowingTM-229 409 Page 62Extreme 360DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Parts Assembly (Continued)Quantity44 RT2 199 7

Notes16 Gauge (.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

PRINTED IN USA 2006−01Model Name Serial/Style NumberPurchase Date (Date which equipment was delivered to original customer.)DistributorAddressCityStat

TM-229 409 Page 3Extreme 360SECTION 2 − INTRODUCTION2-1. SpecificationsInputVoltage AmperageRange inMax.Open-CircuitRMS Amps Input at Rated Load Outpu

TM-229 409 Page 4 Extreme 3606 Minutes Welding 4 Minutes Resting2-3. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can w

TM-229 409 Page 5Extreme 360SECTION 3 − INSTALLATION3-1. Selecting a Locationloc_2 3/96 - Ref. ST-151 556 / Ref. 803 691-C1 Lifting HandlesUse handles