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EX360 Service Manual - Red-D

Contents

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3. A Read and follow safety information in Section 6 1 before proceeding A Wear an earth grounded wrist strap when performing pre power checks Remove wrist strap before performing any checks or proce dures with power applied to the ma chine Remove all plugs from PC1 before testing 1 Control Board PC1 2 Receptacle RC2 ON DA Od P 0 9 10 11 12 13 Receptacle RC3 Receptacle RC5 IGBT Gate Drive IC U1 IGBT Gate Drive IC U4 IGBT Gate Drive IC U5 Diode D37 Diode D38 Diode D39 Diode D42 Diode D43 Diode D44 Rao A Dee pu AT 03 R155 E C Ri4 Rae j R4 J RIS R24 QiL el I DSL B R161 E zT
4. Nom Z D 0 PE 163 es G20 D4 C85 A141 O RCS o NH cie Roig a PGM zl sa FH O R110 E D FH R146 Q Ci n ct a RSS 4 PS jq D ize R142 R147 EL D12 i E jase 3 D29 ATTI 4 4 E 5 ic 98 Gre 42 co LI Ca RIB TA E E gi i CS UR3 pa Q a21 lo R148 E y C23 5 m El 1 pa FH E eee ABB Rh de L2 Cep I C21 031 R83 a D42 zy z C a csi J lo i ca2 LEDL c52 Roe 2 d a Ge VRIH d hs bang C O R153 AL3L J ke nG C HSL SA 924 154 L cus J L o vaz Ze z n 4 H C71 154 RAB Gi 1 C63 Re4Rt18 H n140 E 2 E ku AT 03 SN 3 L z RISS DI R14 me S 334 R117 q 1 pad R4 d las D25 D37 eg ce2 I R4 7 Ris R24 au Y E CH ALL c93 ES 1 F R167 H HA Desch e GK F Ras 5 R136 156 A E D4 A M Di4 E 1 IP Pe 7 R19 f
5. Zs KG 1 7 4 RCS o NM cio Pie a a GC Se SC a EY R146 O SCHER J Pom a O CF 4 QS O C O ti S c i 4 zal 4 7 o E E R147 10 3 H horum ES n kaz co CI CH iu H Eie 11 gii f C28 s UR C43 por 821 R148 E i 1 D13 q EE a Mr R88 Rh 12 D58 gt JR C31 si ucl R89 a gt Di l C32 LEDL C52 R98 de A 5 a ud VRIH d pro Se R153 SC EJ HSL s Zus I pou 1 e q ras D17 ces F poate m 2 KZ ku Los I 4 H R149 ie u R14 Rao 4 Et 022 f p s Hol 12 j Rt NG z eis B24 Gil m3 Er edi ps 7 H ie Em Ps o py D4 n LR pu CI GCNG d k gp E nes Bla ud 28 Q S SE 4 Eme Gs N RAS aa s EE R98 A118 Risa 8 CHOI 5 H R amp j Is Riz A25 C24 c34 z BZ nes gie E C a 5 will 8 RE cis 1 C25 a POETE RB c72 ge Y eor 4 ka p22 Sz PA D4 9 c de E ER Ben G 17 ES D43 C87 ps2 EM oy S Su Zeche o 4 m 14 SO C25 m C59 14 Md pP are p2 Jats c84 G2 J LJ R32 C35 css 1 La Ces s 13 cs J R26 DB ots RIO D38 E SER Exe OO 2 EI d Le 03 g 27 er R119 S lz Tafa ts I SG ara P m Rt R73 R192 j 122 L R47 we F E R123 ae cat a J H Z a DE E R74 o 8 Ca FH R48 R66 Pp Z5 a BI O gt pan coe ri
6. NOTE t The meters display the actual weld output values for approximately three seconds after the arc is broken Mode Meter Reading At Idle Meter Reading While Welding V A V A SC 71 7 85 10 3 85 Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A Lift Arc TIG 14 1 85 10 3 85 Actual Volts Preset Amps Actual Volts Actual Amps V A V A TIG 85 10 3 85 Blank Preset Amps Actual Volts Actual Amps V A V A MIG 24 5 24 5 250 Preset Volts Blank Actual Volts Actual Amps V A V A is PPP PPP 24 5 250 Pulse Display Pulse Display Actual Volts Actual Amps V A V A e 85 24 5 85 Blank Preset Amps Actual Volts Actual Amps V A V A Stick 71 7 85 24 5 85 Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A ve 71 7 24 5 250 Flashes OCV And Preset Blank Actual Volts Actual Amps 4 3 Mode Switch Settings NOTE 7 The Stick and CC modes provide the Adaptive Hot Start feature which automatically increases the output amperage at the start of a weld should the start require it This eliminates electrode sticking at arc start Mode Switch Setting Process Output On Off Control Scratch Start TI
7. 3 E OPTI 61 CB1 BITTOM Q UU U CB2 CB1 O cd oRC2O O0 Pa Pa A orror xor Mi AAAA o o o a KE St ai et sd d T T Pa E x S 1 EE B 8 3 H B 3 5 E z El a El a a 2 2 D u ei E Y a o e y 5 Y E OPTIDNAL GAS VALVE hlc ric 4 7 VIOLET GND nmnccicoo xd WHT PLES 3 ORANGE GB2 TOP YELLOW CB1 TOP AEVUM ES YELLOWCB1 TOP YELLOW PLG12 B rah TG D YELLOW PLG1 2 8 LR ERE BLUE PLG12 4 BLK PLGS 1 DE e E e BLEIZ BLU WHT PLG12 6 42F RO21 3 a SS BLU NHT PLE12 8 42G RCZ1 4 BLUE PLG12 42 FLGI E O BLUE PLG12 2 WHT PLBS 3 TOP Elo o o GROUND RCZ O Z O DEE 19A PLG14 4 18APLGT4 1 RCS 12A PLG15 5 PLCS 14A PLG15 6 TL BLK T2 EY 1T 4 E WHT T2 AE EI 1SAPLO15 7 Gab BIKOTI 21 BIO TWISTED PAIR de 13A PLG15 3 10A PLG15 8 11A PLE15 4 16A WHT PLC15 2 O aaa a J TWISTED PAR PC1 CONTROL AUX POWER O 26A WHT PLG13 10 D AH hc 27A BLKCPLO13 4YD J TWISTED PAR Gel f d 25A BLK PLGI 3 12 C ALU WHT T2 moa RCIZ Sd I Z4A WHKPLOT3 6XC J TWISTED PAR 12 BBH PLer2 E ZOA WHTPLGIJ 1XA SEH alle 2L 21A BLKCPLEI 3 7XA TWISTED PAR Z3A BLKCPLGT3 5B
8. MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 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 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Red D Arc Welderentals Www red d arc com Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2006 01
9. TM 229 409 Page 4 Extreme 360 SECTION 3 INSTALLATION 3 1 Selecting a Location JA Xx Dimensions And Weight 80 Ib 36 3 kg Movement 1 Lifting Handles Use handles to lift unit 2 Hand Cart A Do not move or operate unit M where it could tip Use cart or similar device to move unit 3 Rating Information Use rating information on rear panel to determine input power needs 4 Line Disconnect Device Locate unit near correct input power supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Location loc 2 3 96 Ref ST 151 556 Ref 803 691 C Extreme 360 TM 229 409 Page 5 3 2 Connecting 1 Phase Input Power 2 A Installation must meet all Na PN pasji tional and Local Codes have only qualified persons make this installation A Disconnect and lockout tag out input power before con necting input conductors from unit A Always connect green or green yellow conductor to GND PE supply grounding terminal Earth first and never to a line termi Ground nal 7 The Auto Line circuitry in this unit automatically adapts the power source to the primary voltage be ing applied Check input voltage available at site This unit can be connected to any input power be tween 208 and 575 VAC without removing cover to
10. 10 SECTION 4 OPERATION o sis sis REENEN EN RER e 11 dk Pront Panel Controls erre eR PE RUE AAA ea ROR Ea EAR Uns 11 4 2 Meter Functions ehh hh hn 12 4 3 Mode Switch Settings nn 12 4 4 Ef Arc TG Procedure s eii seca KANINA NE eer ERE OL EUER LE EL ES 13 4 5 Stick Start Proced re A A AA 13 SECTION 5 THEORY OF OPERATION 14 SECTION 6 TROUBLESHOOTING 00 e cece eee enn nne 17 6 1 Checking Unit Before Applying Power 17 6 2 Pre Power Flowchart aaa yi dasa veh das 18 6 3 Measuring Input Capacitor Voltage 19 6 4 Input Pre Regulator Module MOD1 20 6 5 Input Pre Regulator Module MOD1 Test Point Values 20 6 6 Inverter Module MOD2 eH n 21 6 7 Inverter Module MOD2 Test Point Values 21 6 8 Power Switch ST Sio eb A A ANG Gets PENES See UBER EEN 22 6 9 Output Diodes DT D2 1 rotten is 23 6 10 Output Diodes D1 D2 Test Point Values 23 6 11 Stick Boost Rectifier SR1 24 6 12 Stick Boost Rectifier SR1 Test Point Values 24 6 13 Con
11. Actual input voltage should not be 1096 less than minimum and or 1096 more than maximum input voltages listed in table If actual input voltage is outside this range output may not be available Single Phase Input Voltage 208 230 400 460 575 Input Amperes At Rated Output 60 8 54 6 29 7 25 4 19 9 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 70 60 35 30 25 Normal Operating 3 80 80 45 40 30 Min Input Conductor Size In AWG Kcmil 4 8 8 10 12 12 Max Recommended Input Conductor Length In Feet Meters ba en led id 67 Min Grounding Conductor Size In AWG Kcmil 4 8 8 10 12 12 Three 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 45 40 25 20 15 Normal Operating 60 50 30 25 20 Min Input Conductor Size In AWG Kcmil 4 8 10 12 14 14 Max Recommended Input Conductor Length In Feet Meters 36 ba Ka da Gn Min Grounding Conductor Size In AWG Kcmil 4 10 10 12 14 14 Reference 2005 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of af a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5
12. E ed 7 STA Z n 2 G EDI gt gt lt 9 224 ap con L A 08 gt s di g e0N PITT NZL E 44 ZEN Nee 151139 a lt lt Ni 1 203 G STOM Ex 1 994 pa PT Fus ZU NG ne en SES EECH lt lt r 5 e 3 7 298 ZA 7 lt re tere 1 208 gt gt AT ADOS a lt lt EN e x e 21 17 2 L5 S 19 5 KE kat TE Fu FONS 26 NG S x OI LOU v LOM Untog DY TONE 1G LA V 3343 io Qo tn L OM NENA ABEL CEL BN Eccc paa E rZrnn us 9 108 gt gt lt 6 104 56598 Ng RNS 2 EVA TX UM Pore en PESTE suma lt L 14 z b ot 7 LENS EZ NG SL gt gt Z i0N gt 2748 7NMS F8 LM lt mg L L9ON 8 8 2 p o SR JZMWW UZ NG m VEJO e E 1 108 SE BU D zm lt L LIM WHT BLK Extreme 360 ONAL 115VAC
13. e Keep away from moving parts e Keep away from pinch points such as drive rolls AA MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away from servicing areas until consulting your doctor TH OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle D lt e Reduce current or reduce duty cycle before D starting to weld again e Do not block or filter airflow to unit 1 3 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and 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 1 4 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency el
14. TM 229 409A 2006 1 2 Red AIC Eff w Serial Number LG250111A Welderentals Gees Multiprocess Weldin Description Fa Lu MEM Arc Welding Power Source EXTREME 360 CC CV Auto Line TECHNICAL MANUAL File MULTIPROCESS Pd TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS FOR SERVICING 0000 cece eee eee eee nn nnn 1 Tet Symbol Usage riser A cedars a ead A DREK ONE AA RY 1 1 2 Servicing Hazards ssec A ESCENA Eee eGR ON Cea AAA 1 1 3 California Proposition 65 Warnings 2 1 4 CEM Informations ae Se A LABS NU MR NEMESIS 2 SECTION 2 INTRODUCTION NENNEN eee dee RH ee ERR rh oe ee eee hm Rm Rem renee 3 2 Specifications 5s Lore RP RERO RS UO ERE eee NAWA ooh ted bis ROG er D EE 3 2 2 Volt Ampere CUrves csse re ER KAN NAN diia 3 2 3 Duty Cycle And Overheating sssssssssssssssseesss es hs 4 SECTION 3 2 INSTALLATION 08 cem n Rr t ede ei Rex Rm mmm Ram mm RR xe RU E RR 5 351 Selecting a Location ii A UR AA UE UC RR a e CREE EA FO S 5 3 2 Connecting 1 Phase Input Power 6 3 3 Connecting 3 Phase Input Power 7 3 4 Electrical Service GUIAS iii a dettes ducere eine Re pete hee wp eae da 8 3 5 Weld Output Receptacles And Selecting Cable Sizes 9 3 6 Remote 14 Receptacle Information 0 0 00 ccc Ie 9 3 7 Optional Gas Valve Operation And Shielding Gas Connection
15. V V V V OPTIONAL RCZ 115V RCPT 1 GAN HOT ag l OS NEUR lt NI GND K 42 00014 4 e a oo obal d T2 e FCSO A 23VAC amp Ng EB ees a ag B RCEO 415VAC 61 gt ES RCS50 G 23 115VAC NEUTRAL 47 S 2 42 S ROSO K CHASSIS GNO 47 x Na umm E RC50 J 115V RMT CONT em H IN DN ROSO B 24V RMT CONT 9 5 5 5 6 5 RCSO E REF IN RO51 V5 RESO C REF QUT d RCSO F 1V 100A V V RCSO D REF COM 4 1 ROSO H 1V 10V REA ug ROSO M CC AN SEL PCS FRONT PANEL amp DISPLAY RC2 PLG18 RG2Z 3 gt 1 RC2 1 gt V14 A HIGH VOLTAGE Do not measure without proper instrumentation 5 V1 thru V5 and V8 use only true RMS meter to obtain correct voltage reading TM 229 409 Page 38 Extreme 360 Always check unit before applying power see Sections 6 1 thru 6 18 See Section 6 27 for PC2 information R7 1 T O 8 use S daji n o 1 PCZ cin libo acz POWER O mo INTERCONNECT MODI indo Le Ac3 RC1 PLG13 il RIS ROZ 07 ii NEGATIVE HF XFMR nn 47 CHASSIS RC6 PLG20 mete ee m e Ii qp dog e mx Ti See ee li mz ne m mz e
16. amp ge o B au sj 5 L2 m E 3 d5 a i A a a S E py ZL i m SI skl miss if gaj sE EE p pr on A RC7 fren a la a HF XFMR deep N Ta a ARIS dr NN ie m a o a Tas s sej s RMI ise Jj VE x zz a Al ele mz m Pi A to YY d as d ala A i zl N amp NA S o o zB U SE NOTE RM1 IS CONNECTED TO THE ra L1 C0IL PRIMARY HEATSINK WHICH IS sj Q L1 12 LOCATED BENEATH PC2 L zi O o N z ENS E ST ZA BLK PLOS 5 DT TA 16A WHT F1G3 4 mun es SS SA PLCI I TIA PLE3 3 B 4 REZ RO Nici RISA Pics H2 3 Baas 4 aga IAS ge a EEN YEL END CHASSIS 18A PLG2 1 19MPLE2 4 gt ga 1A S1 LGAD1 gt o N3 2A 81 LOADP z 5 Loi ZA B1 LOADS 220 922 B Extreme 360 TM 229 409 Page 57 Notes HOBART INSTITUT OF WELDING TECHNOLOGY Start Your Professional A9 Trade Square East Troy Ohio 45373 OVer 80 000 trained Welding Career Now 1 800 332 9448 www weldina ora since 1930 TM 229 409 Page 58 Extreme 360 Red D Arc TM 229409 2006 1 2 E Serial Num ff wi ber LG250111A Welderentals A Kal pa Multiprocess Welding Description E Fa Gesi a Arc Welding Power Source EXTREME 360 CC CV Auto Line PARTS LIST Eff w LG250111A And Following For OM 2
17. up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements TM 229 409 Page 8 Extreme 360 3 5 Weld Output Receptacles And Selecting Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding M 100 0m Or Less 1301 200r 250m sf oso acom 10 60 60 100 eo palaso Du m 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 Output Receptacles 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 Weld cable size AWG is based on either a 4 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 Lal REMOTE 14 Socket Socket Information 24 VOLTS AC A 24 volts ac Protected by circuit breaker CB2 OUTPUT B Contact closure to A completes 24 volts ac
18. 031 078Thk 2 TEE PLG13 130203 Housing Plug Pins Service Kit RC1 Degli queer t edd TUS PLG14 201665 Housing Plug Pins Service Kit RC2 AA AN t PLG15 115092 Housing Plug Pins Service Kit RC3 E TENEO PLG20 115093 Housing Plug Pins Service Kit RC6 pd etm VERTES 153403 Bushing Snap In Nyl 750 Id X 1 000 Mtg Hole Cent 2 48 RM1 205 751 Module Power Resistor W Plug 1 m 217 625 Kit Input Pre Regulator And Inverter Module Includes 1 TEE MOD 1 SKip 83 HEC aia it E deene b d A E eo a em uet se ue ird MOD 2 SKiip 83 EC iraganari aa i a esee enn 1 eT ctas eno s 212206 Windtunnel Ph 1 Sub reuse vt ead EDS 196 330 Heat Sink Power Module 1 EE HA KN O el ato eon is LR en 1 DS sa eb sper 173 693 Foot Mtg Unrt AA a a a p E 4 SD aan Ka rye a 176 736 Screw Mtg Foot 4 OO IR 153 178 Label Warning Exploding Parts Can Serious Injury 1 E ota 212074 Bus Bar Output 2000 00 ia PARAAN 1 Sf sos HD1 182918 Transducer Current 400A Module Supply V 15V 1 58 PC3 218 008 Circuit Card Assy Front Panel 4 Display W Program 1 DEEN PLG18 131 204 Housing Plug Pins Service Kit RC2 USES quads e dene 1d diui RC50 210 239 Rept W Pins sss Lisa n uk pere d a PLG21 21
19. CONTACTOR contactor control circuit 115 VOLTS AC l 115 volts ac Protected by circuit breaker CB1 OUTPUT J Contact closure to completes 115 volts ac CONTACTOR contactor control circuit C Output to remote control O to 10 volts dc 10 volts dc in MIG mode REMOTE D Remote control circuit common OUTPUT CONTROL E 0 to 10 volts dc input command signal from remote control M CC CV select AN F Current feedback 1 volt dc per 100 amperes AMPERAGE H Voltage feedback 1 volt dc per 10 output recep VOLTAGE tacle volts G Circuit common for 24 and 115 volts ac circuits GND K Chassis common The remaining sockets are not used Extreme 360 TM 229 409 Page 9 3 7 Optional Gas Valve Operation And Shielding Gas Connection Obtain gas cylinder and chain to running gear wall or other station ary support so cylinder cannot fall and break off valve 1 Oylinder 2 Regulator Flowmeter Install so face is vertical 3 Gas Hose Connection Fitting has 5 8 18 right hand threads Obtain and install gas hose 4 GaslnFitting 5 Gas Out Fitting The Gas In and Gas Out fittings have 5 8 18 right hand threads Obtain proper size type and length hose and make connections as fol lows Connect hose from shielding gas supply regulator flowmeter 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 fi
20. Consult symbols and related instructions below for necessary actions to avoid the hazards FLYING METAL can injure eyes Bab e Wear safety glasses with side shields or face shield during servicing e Be careful not to short metal tools parts or wires together during testing and servicing HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on welding gun or torch EXPLODING PARTS can cause injury e Failed parts can explode or cause other parts to explode when power is applied to inverters e Always wear a face shield and long sleeves when servicing inverters SHOCK HAZARD from testing e Turn Off welding power source and wire feeder or stop engine before making or changing me ter lead connections e Use at least one meter lead that has a self retaining spring clip such as an alligator clip e Read instructions for test equipment FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place TM 229 409 Page 1 MOVING PARTS can cause injury
21. Eo om LORS mag ss 029 O Le mex H RE cke Riz R25 C24 C24 a dir cor kn 1 L sO LS TEZ RG nas CG C26 Wei H LB EN R31 q2 Q 4 L 4 R32 cas cs j L H26 De D2 E y Aza Ki LES 13 21 BM ix a le m0 si LE En 3 8 x 12 A m i 8 n e a 9 E 10 76 1h 2 Q ta F J p 1 o d R126 C93 N ka C84 J lo D d Fm L E g 24 G2 R135 1 F R127 DES dau x R145 2 Ke ssa PERA GAS O NE Test Equipment Needed 1 8 2 7 3 6 4 5 Pin sequence of IC chips Ref 217 184 F 907 161 Unplug all connections to PC1 Visually inspect PC1 for damage Check all measurements for PC1 Auxiliary Power Pre Regulator and Inverter Control see Sections 6 14 thru 6 18 If all measurements passed continue to the end of the pre power flowchart see Section 6 2 F7 If any measurements failed replace PCI TM 229 409 Page 26 Extreme 360 PRE POWER CHECKS 6 14 Control Auxiliary Power Board PC1 Auxiliary Power Circuit Test Point Values 60Hz Auxiliary Power Bridge DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms Auxiliary Bridge IGBT RC5 Pin 3 RC2 Pin 1 0 20 0 90 N A Auxiliary Bridge IGBT RC5 Pin 1 RC2 Pin 1 0 20 0 90 N A Auxiliary Bridge IGBT RC3 Pin 6 PRECOM RC5 Pin 3 0 20 0 90 N A Auxiliary Bridge IGBT RC3 Pin 6 PRECOM RC5 Pin 1 0 20 0 90 N A Auxiliary Bridge IGBT Gate Drive IC U1 RC3 Pin 6 PRECOM U1 Pin 5 0
22. Input Pre Regulator Module MOD1 Test Point Values Input Pre Regulator Module MOD1 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms Boost IGBT BUS L1 L2 0 20 0 90 N A Boost IGBT w Plug Removed From RC3 D12 Cathode BUS N A 100k Boost Snubber Diode L1 L2 TP1 C6 and C7 0 20 0 90 N A Input SCR AC1 L1 0 20 0 90 N A Input SCR AC2 L1 0 20 0 90 N A Input SCR AC3 L1 0 20 0 90 N A Input Diode BUS AC1 0 20 0 90 N A Input Diode BUS AC2 0 20 0 90 N A Input Diode BUS AC3 0 20 0 90 N A TM 229 409 Page 20 Extreme 360 6 6 PRE POWER CHECKS Inverter Module MOD2 Component Side Of Board Test Equipment Needed 14 13 12 CHRSSIS 9 T ASSEMBLY 11 10 A A Read and follow safety information in Section 6 1 before proceeding Wear an earth grounded wrist strap when performing pre power checks Remove wrist strap before perform ing any checks or proce dures with power applied to the machine Board layout may differ from that shown 1 MOD2 Visually inspect MOD2 for damage 2 BUS 3 TP2 4 TPI 5 L2 6 TP4 7
23. 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 U1 Pin 7 U1 Pin 6 0 20 0 90 N A Auxiliary Bridge IGBT Gate Drive IC U4 RC5 Pin 1 U5 Pin 7 0 20 0 90 N A Auxiliary Bridge IGBT Gate Drive IC U5 RC5 Pin 3 U4 Pin 7 0 20 0 90 N A D37 D37 Anode D37 Cathode 0 20 0 90 N A D38 D38 Anode D38 Cathode 0 20 0 90 N A D39 D39 Anode D39 Cathode 0 20 0 90 N A D42 D42 Anode D42 Cathode 0 20 0 90 N A D43 D43 Anode D43 Cathode 0 20 0 90 N A D44 D44 Anode D44 Cathode 0 20 0 90 N A Notes Extreme 360 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual TM 229 409 Page 27 PRE POWER CHECKS 6 15 Control Auxiliary Power Board PC1 Pre Regulator Control Circuit A bi ei A
24. 23 115VAC NEUTRAL 42 S u Y N Za 42 y Ni i al RCSO K CHASSIS CH Z 5 amp mS FS ATATNTATATATA gt RESO J 115V RMT CONT PLEZ1 Re21 Ta NG YO NONON SAL ON LL gt ROSO B 24V RMT CONT 0222828 gt RGSO E RF IN ROSI gt RC50 C REF GUT d gt RO50 F 1V 100A gt RC50 D REF COM gt ROSO H 1V 10V RCA Gee gt RCSO M CC CN SEL PCS FRONT PANEL DISPLAY RC2 PLG18 RD2 3 gt RC2 1 gt Figure 8 1 Circuit for EXTREME 360 208 575 Volt Eff w LG250111A And Following TM 229 409 Page 52 Extreme 360 NEGATIVE TE POSITIVE Jo O C7 I pi 211 328 E SUKI DE TM 229 409 Page 53 a EBD Bee N B 8 T gt gt d z 3 m i E gy e S 3 N H a N FT Cl ALE ER BE N E 0 su e IN SC t 5 DE pum ERUNT NS 2 29 neu B alate S e o D RCS PLGS sacl eu NU ER OPTIONAL CAS SOLENOID L RC16 PLG16 gt gt 2 JE JI T 44 45 Re10 2 gt RCI 1 7 gt RCIO 1X RCI 1 1 gt RCI1 X X RCI1 4X RCB PLGS RC7 PLG7 RC amp PLG amp RC9 PLG9 RC10 PLG10 RC11 PLG11 RC12 PLG12 te D OO OD p 9 92u RET EE G7 quem L 08 LUN SEROR gt gt AO 3 ETS p s3 SCH a l Pa
25. 8 We C47 R75 es 5 ria 6 5 45 106 24 A133 R2 4 m E 225 C40 577 107 67 a C89 Soe pena RR ro e Es H RIS mg s 1 P zi s T a tz 5 EY c e 76 Lat EL 8 TA E E ca d R2 14 Dit 1 H ijs n nes Ai25 H de z5 i Hz i 5 d gt R78 C62 R153 w s 83 T 4 L pee C81 R139 N min INO 113 J L g DE D 7 L A ha 3 T2 C17 4 Ge 1 fi E S E a2 pua H R144 o d Sg R135 Eso LE No R82 p p F R127 C91 R159 o Xm me I tte e nm 2 O R84 L Ve Res O O Ag S O A or BS zi 2 ki mx AC 3 D 8 Test Eguipment Needed 2 7 3 I 6 4 5 Pin sequence of IC chips Ref 217 184 F 907 161 A Read and follow safety information 3 Receptacle RC3 14 Diode D53 in Section 6 1 before proceeding 4 Receptacle RC5 Unplug all connections to PC1 A Wearan earth grounded wrist strap 5 IGBT Gate Drive IC U6 Visually inspect PC1 for damage when performing pre power 6 Diode D18 a checks Remove wrist strap before Check all measurements for PC1 Auxiliary performing any checks or proce 7 Diode D41 Power Pre Regulator and Inverter Control dures with power applied to the ma 8 Diode D46 see Sections 6 14 thru 6 18 chine 9 Diode D47 If all measurements passed continue to IF Remove all plugs from PC1 before 10 Diode D49 the end of the pre power flowchart see testing 11 Diode D50 Section 6 2 1 Control Board PC1 12 Diode D51 K7 If any measurements failed replace 2 Receptacle RC2 13 Diode D52 PC1 TM 229 409 Page 28
26. C6 7 214749 Capacitor Assy 1 EX Ep 216 112 Fastener Panel Receptacle Quick Access 2 S00 s bissl ia Nameplate Order by Model and Serial Number 1 e rS Nameplate Connection Order by Model and Serial Number 1 SUIS tle sanct Nameplate Power Order by Model and Serial Number 1 Bom 174991 Knob Pointer 1 250 Dia X 250 Id W Spring Clip 21 2 PO sess rut 174 992 Knob Pointer 840 Dia X 250 Id W Spring Clip 21 1 NA ees at Na 212949 Label Process 1 TA Bettie Megat ti ached 218041 Door W Quick Access Ball Fasteners 1 ia AC RE EI ua 1 75 138 BOX Leet isst e RA Ke al str D CAP X aa RET 1 kA Zeg Label Order by Model and Serial Number 1 PD Eta iii gi 212 207 Windtunnel LA LLL nn 1 MOS an Ela Ng 211 503 Insulator Heat Sink 1 MM AA 207 152 Nut 010 32 U Nut Multi Thread 4 Ul Bs bi A ratas 227 746 Gasket Inductor Mounting 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 TM 229 409 Page 62 Extreme 360 Notes
27. Extreme 360 PRE POWER CHECKS 6 16 Control Auxiliary Power Board PC1 Pre Regulator Control Circuit Test Point Values Pre Regulator Control DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms Buck IGBT U6 Pin 3 RC2 Pin 1 0 20 0 90 N A Buck Diode RC3 Pin 6 PRECOM U6 Pin 5 BUCK COM 0 20 0 90 N A Buck IGBT Gate Drive IC U6 U6 Pin 6 U6 Pin 7 BUCK 15V 0 20 0 90 N A D18 D18 Anode D18 Cathode 0 20 0 90 N A D41 D41 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 Anode D51 Cathode 0 20 0 90 N A D52 D52 Anode D52 Cathode 0 20 0 90 N A D53 D53 Anode D53 Cathode 0 20 0 90 N A Boost IGBT Gate Drive RC3 Pin 4 BOOST G RC3 Pin 2 PRE 15V 0 20 0 90 N A Boost IGBT Gate Drive RC3 Pin 4 BOOST G RC3 Pin 3 PRE 12V N A 1 9k 2 1k Boost IGBT Gate Drive RC3 Pin 3 PRE 12V RC3 Pin 4 BOOST G 0 20 0 90 N A Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual Extreme 360 TM 229 409 Page 29 PRE POWER CHECKS wer Board PC1 Inverter Control Circuit 6 17 Control Auxiliary Po
28. Primary side thermistor return 2 volts dc at 25 C thermistor temperature 18 GND Circuit common referenced to chassis 19 Input Foldback decreases weld output if input bus voltage drops O volts OK 15 volts dc 15Khz pwm squarewave foldback 20 GND Circuit common referenced to chassis 21 Input 24 volts dc unregulated dc voltage with respect to GND power feed to front panel pcb 22 Input 24 volts dc unregulated dc voltage with respect to GND power feed to front panel pcb 23 Input 24 volts dc unregulated dc voltage with respect to GND power feed to front panel pcb 24 Input 24 volts dc unregulated dc voltage with respect to GND power feed to front panel pcb RC2 1 Input Negative weld output terminal used for output voltage feedback 2 Not Used 3 Input Positive weld output terminal used for output voltage feedback RC50 A Output 23 volts ac RMS at 10 amps 14 pin remote accessory power B Input Remote output enable O volts ac weld output off 23 volts ac RMS weld output on C Output Output signal to remote command reference 0 to 10 volts dc D GND Remote command reference signal common E Input Input signal from remote command O to 10 volts dc F Output Current feedback 1 volt dc per 100 amperes of weld output TM 229 409 Page 48 Extreme 360 Always check unit before applying power see Sections 6 1 thru 6 18 Section 6 30 Front Panel Display Board PC3 Test Point Values Continued Receptacle P
29. ZE GHD ZA MENPLGTI 998 mwsren PAR RO3 PLGS 3IA PLG17 1 q zem Hete 7BA P1017 45 tH Gata Bellos Rd ROE E SE ail PLG6 PLG10 TWISTED 1 a JS ih NG o EH B E sd 8o aged gl g dd 1 3 a Q n fal bi tA i BB al a A 5 TOP Aram Si S 3 s A og FRONT laa I 3 i cr GROUND 9 ago E E RIBEON ra FC HS 3 5 5 z z Y z zl El E 8 9 SNS 4 a EE a E S 3 Figure 8 2 Wiring Diagram for EXTREME 360 208 575 Volt Eff w LG250111A And Following 1 of 2 TM 229 409 P age 54 Extreme 360 RC21 RLG21 42F TOP REAR SND 42G IQP REAR GND B1B CB1 BOT pt em Q O ER i RC50 I 59A RESDA A42ECRCbQ K 42DeRC50 G 81 WHT POS STUD RIBBON TO PCI NA PLETB BLK NEG STUD H B1A PLGZ1 1 4ZE PLGZI 3 SBA P1621 2 42 8ND STRAP TOP FRONT GROUND RC51 RCT D PCS FRONT PANEL de DISPLAY 51 pr 39 BUS BAR TO SECONDARY HEATSINK 420 PLG21 4 POSITIVE WHT PLE18 3 42 LEFT FRONT C7 BLK FLG1 amp 1 NEGATIVE STUD PLEIS FM1 IN
30. connections to Re mote 14 receptacle In TIG modes and the REMOTE STICK mode remote control is 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 full range of unit output regardless of V A Adjust control setting 7 Arc Control Control adjusts Dig when Stick or CC mode is selected on mode switch When set towards minimum short circuit amperage at low arc voltage is the same as normal welding amperage When set towards maximum short circuit amperage is increased at low arc voltage to assist with arc starts as well as reduce stick ing while welding Select setting best suited for application Control adjusts inductance when MIG or V Sense Feeder position is selected on the mode switch Inductance determines the wetness of the weld puddle When set to wards maximum wetness puddle fluidity increases When Pulsed MIG or one of the TIG modes is selected this control is not functional 2 3 4 O V A V A ADJUST 40 50 en Hans stick 70 80 scratch P GF V SENSE START FEEDER 90 TIG REMOTE Ref 803 692 B Ref 212 064 Extreme 360 TM 229 409 Page 11 4 2 Meter Functions
31. e 28 o cai C12 A h R30 ps st 1 M R9 ae L ncs Risa gt T R164 E C33 4 e D21 rss O Rigi H H nal m2 HS C24 T34 13 O sam 1 y R152 x Ri Ri nes q c t Bi E C25 R46 Dt sg Ri Cia 4 m RB C72 86 co a ek e x p22 c73 LS D47 z on Ase 4 k S de E Cl E Bes Da 43 C87 pc2 E sel a e ets 7 ls o q E D53 P L D5 cas za c59 l Ri C14 I 15 Lc H R18 06 R31 bomi y ple a5 d L a 4 kri Qas C54 q2 D 4 k 52 C35 Asa r tse A ces P C5 4 R26 De DLS E Rica D328 El D2 A 4 E H SH Qs E L R3 Cm ct ds Lt O SE pa km zum Lh La M lr 93 O a R27 REZ R72 Em R119 ST 2 N 1 prid T za H F R122 z RE lel Ed SI a o cst a 2 o P e 1 e R143 R138 RISI Mig ME Ja 5 de CS i o P R139 E BD 3 E s H R144 5 148 cso HE cat RISS R145 O ncs O A a as 2 7 3 6 4 5 Test Equipment Needed Pin sequence of IC chips Ref 217 184 F 907 161 A Read and follow safety information 1 Control Board PC1 Visually inspect PC1 for damage 4 We Secti n is E 2 Receptacle RC9 Check all measurements for PC1 Auxiliary ear an earth grounded wrist strap Power Pre Regulator and Inverter Control IGBT Gate D l 1 when performing pre power dE s e Ger see Sections 6 14 thru 6 18 checks Remove wrist strap before 4 IGBT Gate Drive IC U16 fta 4 i j performing any checks or proce E all measurements passed continue to dures with power applied to the ma Bt OBT Gate De ICU
32. primary line volts RC3 A High voltage present Voltages on this receptacle can exceed 900 volts DC from chassis GND NOTE All pins on this receptacle are referenced to the primary Bus 1 Input Do not measure Boost inductor current feedback 1 volt dc per 16 amps of boost inductor current 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 IGBT gate drive signal return 6 Precom Circuit common referenced to primary bus 7 Precom Circuit common referenced to primary bus 8 Precom Circuit common referenced to primary bus 9 Input Do not measure HF transformer current sense CT senses overcurrent in HF transformer primary 10 Do not measure HF transformer current sense CT return 11 Output Precharge relay coil return O volts dc relay contacts open 12 volts dc relay contacts closed 12 Not used 13 Input Do not measure Test point used to test board only 14 Input Do not measure Test point used to test board only RC5 A High voltage present Voltages on this receptacle can exceed 900 volts DC from chassis GND NOTE All pins on this receptacle are referenced to the primary Bus 1 Output Control transformer primary 665 volts ac rms with respect to RC5 pin 3 2 Not Used 3 Output Control transformer primary 665 volts ac rms with respect to RC5 pin 1 E
33. the end of the pre power flowchart see chine 6 Diode D11 Section 6 2 7 Diode D20 Remove all plugs from PC1 before testing x If any measurements failed replace Unplug all connections to PC1 PCI TM 229 409 Page 30 Extreme 360 PRE POWER CHECKS 6 18 Control Auxiliary Power Board PC1 Inverter Control Circuit Test Point Values Inverter Control DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms Inverter IGBT Gate Drive IC U16 U16 Pin 5 RC9 Pin 4 15V 0 20 0 90 N A Inverter IGBT Gate Drive IC U16 U16 Pin 7 RC9 Pin 4 15V 0 20 0 90 N A Inverter IGBT Gate Drive IC U16 RC9 Pin 6 GND U16 Pin 5 0 20 0 90 N A Inverter IGBT Gate Drive IC U16 RC9 Pin 6 GND U16 Pin 7 0 20 0 90 N A Inverter IGBT Gate Drive IC 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 Gate Drive IC U17 RC9 Pin 6 GND U17 Pin 7 0 20 0 90 N A Snubber IGBT Gate Drive IC U13 U13 Pin 5 RC9 Pin 4 15V 0 20 0 90 N A Snubber IGBT Gate Drive IC U13 U13 Pin 7 RC9 Pin 4 15V 0 20 0 90 N A Snubber IGBT Gate Drive IC U13 RC9 Pin 6 GND U13 Pin 5 0 20 0 90 N A Snubber IGBT Gate Drive IC U13 RC9 Pin 6 GND U13 Pin 7 0 20 0 90 N A D11 D11 Anode D11 Cathode 0 20 0 90 N A D20 D20 Anode D20 Cathode 0 20 0 90 N A Note
34. 0 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 Inverter Gate Protection Diode D3 D3 Anode D3 Cathode 0 20 0 90 N A Inverter Gate Protection Diode D4 D4 Anode D4 Cathode 0 20 0 90 N A Snubber Gate Protection Diode D8 D8 Anode D8 Cathode 0 20 0 90 N A Snubber Gate Protection Diode D9 D9 Anode D9 Cathode 0 20 0 90 N A Snubber Gate Protection Diode D10 D10 Anode D10 Cathode 0 20 0 90 N A Snubber Gate Protection Diode D11 D11 Anode D11 Cathode 0 20 0 90 N A Bleeder Resistor R1 Center Bus BUS N A 28k 32k Prior to LF278160 gt Bleeder resistor measurements may require several minutes to complete Bleeder Resistor R1 Eff W LF278161 Center Bus BUS N A 37k 41k Bleeder Resistor R8 BUS Center Bus N A 28k 32k Prior to LF278160 Bleeder Resistor R8 Eff W LF278161 BUS Center Bus N A 37k 41k Notes Extreme 360 TM 229 409 Page 33 Always check unit before applying power see Sections 6 1 thru 6 18 See Section 6 24 for test points and values and Section 9 for parts location Use MILLER Testing Booklet Part No 150 853 when servicing this unit Trouble Remedy No weld output unit completely inoperative Follow Pre Power Flowchart and replace any failed components see Section 6 2 Place line disconnect sw
35. 1 A PLI317 Y a O O 4207 LEFT FRONT GROUND 39 BUS BAR TQ PQS STUD Figure 8 3 Wiring Diagram for EXTREME 360 208 575 Volt Eff w LG250111A And Following 2 of 2 TM 229 409 Page 56 Extreme 360 POWER CORD 4 WARNING e Do not touch live electrical parts cl e Disconnect input power or stop kel NN engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit GND PE GRN YEL POWER CORD wre ST UNEJ SI LINEZ S1 UNE1 TQ T1 PRIMARY f S o NOTE RT2 IS CONNECTED TO THE PRIMARY HEATSINK WHICH IS LOCATED BENEATH PC2 PC2 POWER INTERCONNECT TO PC ROSA A Phi ei 12 C0lL KO
36. 2 Test Point Values 45 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 7Z MAINTENANCE iti iii iii ta da 50 7 1 Routine Maintenance eh hh nh nnn 50 7 2 Blowing Out Inside Of Unit RR hs 50 SECTION 8 ELECTRICAL DIAGRAMS resi si ki rl ln rura a 51 SECTION 9 PARTS LIST FOR LG250111A AND FOLLOWING 60 SECTION 1 SAFETY PRECAUTIONS FOR SERVICING 1 1 Symbol Usage ih A Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Servicing Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard A Only qualified persons should service test maintain and re pair this unit A During servicing keep everybody especially children away e ELECTRIC SHOCK can kill e Do not touch live electrical parts e Turn Off welding power source and wire f
37. 2088 Plug W Leads 1 ET RC21 167 640 Housing Plug Pins Service Kit 1 2x59 2 ti li xod 128 756 Switch Tgl 3Pst 40A 600VAC Scr Term Wide Tgl 1 ICI 176 226 Insulator Switch Power 1 61 FM1 196 313 Fan Muffin 115V 50 60Hz 3000 Rpm 6 378 Mtg Holes 1 Lex ERU PLG16 131 054 Housing Plug Pins Service Kit 1 noe s RC16 135 635 Housing Plug Pins Service Kit 1 E EE 218183 Rept Assy Tw Lk Insul Fem Tweco Type Fac op Includes 2 DRE etna de A eR da e gi ed 209 473 Receptacle Twist Lock Tweco Style Female Power 1 Leu Ah pter teda irat 185 712 Insulator Bulkhead Front 1 SUAM Rigel A UAE ak AUR 185 713 Insulator Bulkhead Rear 1 AA RU Sees dacs DON MENI 185 714 Washer Tooth 22Mmid X 31 5Mmod 1 310 1Mmt Intern 1 gid dag aides ats NAVE a Ea 185 717 Nut M20 1 5 1 00Hex 19H Brs Locking 1 D RAM 185718 O Ring 0 989 Id X 0 070 H 1 EE 186 228 O Ring 0 739 Id X 0 070 H 1 AUD is e 212070 Panel Front Standard 1 2045 uro
38. 215980 Bushing Strain Relief 709 984 Id X1 375 Mtg Hole E EE KEE 219 487 Cable Power 12 Ft 8Ga 4C Non Stripped End ur Od ris Ris 182 445 Nut Conduit 1 000 Npt Pld 1 730 Od X 200 Thk BB takes T2 211 109 XFMR Control 665V 336Va Syn Aux Pwr 39 E os 218018 Inductor Pre Regulator 1 opm 218566 Gasket Inductor Mounting 1 xd eee CT axis 196 231 XMFR Current Sensing 200 1 1 m TE C15 196 143 Capacitor Polyp Met Film 16 Uf 400 VAC 10 1 add as ED ERAI 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 Extreme 360 TM 229 409 Page 61 Eff w LG250111A And Following Item Dia Par No Mkgs No Description Quantity Figure 9 1 Parts Assembly Continued 44 RT2 199 798 Thermistor Ntc 30K Ohm 25 Deg C 18in Lead 1 45 PC2 225442 Circuit Card Assy Interconnect W Label amp Clips Includes 1 A 126026 Label Warning Electric Shock Can Kill Significant 1 BEE 223 343 Clip Wire Stdf 40 50 Bndl 156Hole
39. 29 409 Revisions A Thru B SECTION 9 PARTS LIST FOR LG250111A AND FOLLOWING Y 7 V Ref 803 690 F Figure 9 1 Parts Assembly TM 229 409 Page 60 Extreme 360 Eff w LG250111A And Following Item Dia Part No Mkgs No Description Quantity Figure 9 1 Parts Assembly e EE 229541 Wrapper Includes Insulators and Safety Labels as 175256 Insulator Side Rh Not Shown 178551 Insulator Side Not Shown NG hang paa Erie bo 134327 Label Warning General Precautionary Static 4 Wire Feed GT AT ERU hdd 138 442 Label Caution Falling Equip Can Cause Injury pa DEE 195 585 Handle Rubberized Carrying UD ugs ci SEI Peas 135 483 Label Important Remove These Two Handle Screws 20 4 R3 C4 196518 Resistor Capacitor d a R4 C5 196510 Resistor Capacitor Re quus SR1 201 530 Kit Diode Fast Recovery Bridge E id Andel aa 199840 Bus Bar Diode SMO ack al 196 355 Insulator Screw s va RE RAD Nka 201 531 Kit Diode Power Module S22 RT 1 4 199 798 Th
40. 3 Auxiliary Power a 115 VAC Voltage i 115 VAC h Arc Amperage Receptacle Control Adjust t 5 24 24 VAC ni fe Remote 14 Pin Receptacle RC50 Ribbon Cable 25 26 z ea Weld Positive Output Voltage Feedback Selector Process Negative Output Voltage Feedback Switch Control TM 229 409 Page 14 Extreme 360 15 19 Negative Output Weld Stabilizer Output L3 Receptacle Work 16 17 18 Stick Stick Stick Boost Boost Boost Relay Inductor Rectifier CR1 L4 SR1 15 pi ue 13 14 Positive Series Main Output Weld a Capacitor Transformer Samm Diodes P Output C15 T1 Di 4 D2 Output Receptacle Current Sensor s HD1 Main Transformer Output Current Feedback Current Feedback Elect Inverter Gating Signals 35 36 EON Optional Fan j Gas i Motor Solenoid FM1 GS1 l po s 29 30 Inverter Boost lay Control Control Medik DONE 37 38 Control Auxiliary Power oe e ME PC Thermistor Thermistor RT 1 RT 2 32 34 34 VAC Circuit Coney Breaker pu Ho NAG Tapped CB1 Control 33 Transformer Circuit s Breaker 24 VAC 115 VAC CB2 gt Control Circuit Pr
41. Control Auxiliary Power Board PC1 Auxiliary Power Circuit D13
42. Do not measure Test 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 O volts dc relay contacts closed 3 Output 24 volts output to gas valve coil 4 Gas valve coil return 24 volts dc valve closed no gas flow O volts dc valve open RC12 1 Not Used 2 Input 34 volts ac rms measure with respect to RC12 pin 4 power supply used to create 24 24 volts dc 3 Chassis Power source chassis circuit common GND on this pin bonded to chassis thru wire 4 Input 34 volts ac rms measure with respect to RC12 pin 2 power supply used to create 24 24 volts dc 5 Not Used 6 Input Center tap of 34 volt ac connected to circuit common GND on board 7 Not Used 8 Input 115 volts ac rms OHM S LAW VOLTAGE CURRENT X RESISTANCE CURRENT VOLTAGE RESISTANCE RESISTANCE VOLTAGE CURRENT Extreme 360 TM 229 409 Page 43 Always check unit before applying power see Sections 6 1 thru 6 18 6 27 Power Interconnect Board PC2 Testing Information Use with Section 6 28 A 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 6 28 for specific val
43. E Ces Es KS PAA E A ke O p 4 Test Eguipment Needed Ref 217 181 B 907 161 Extreme 360 TM 229 409 Page 47 Always check unit before applying power see Sections 6 1 thru 6 18 6 30 Front Panel Display Board PC3 Test Point Values a Tolerance 10 unless specified PC3 Voltage Readings ae i b Reference to circuit common lead 42 unless noted Receptacle Pin Type Value RC1 1 Output Output reference 1 volt dc per 425 amperes of weld output when machine is under load 2 Output Voltage feedback 1 volt dc per 10 volts dc of weld output 3 Input Current feedback 1 volt dc per 100 amperes of weld output 4 Not Used 5 Output Output enable O volts dc ON 15 volts dc OFF 6 Not Used 7 Boost relay coil return 24 volts dc relay contacts open 0 volts dc relay contacts closed 8 Gas valve coil return 24 volts dc valve closed no gas flow O volts dc valve open 9 Output Fan enable 5 volts dc fan on 15 volts dc fan off 10 Not Used 11 Input HF transformer over current detect O volts dc OK 5 volts dc OVERCURRENT 12 Not Used 13 Output 5 volts dc reference voltage for thermistors 14 GND Circuit common referenced to chassis 15 Input Secondary side thermistor return 2 volts dc at 25 C thermistor temperature 16 GND Circuit common referenced to chassis 17 Input
44. G GTAW Electrode Hot Lift Arc TIG GTAW See Section 4 4 Electrode Hot TIG GTAW With HF Unit Pulsing Device Or Remote Control At Remote 14 MIG GMAW At Remote 14 Pulsed MIG GMAW P Requires an external pulsing device At Remote 14 CC Stick SMAW With Remote On Off At Remote 14 Stick SMAW Electrode Hot V Sense Feeder MIG GMAW With Voltage Sensing Wire Feeder Electrode Hot TM 229 409 Page 12 Extreme 360 4 4 Lift Arc TIG Procedure kee N Y With Process Switch in the Lift Arc CR A Z Sm a TIG position start an arc as follows E r t MY 1 TIG Electrode 2 Workpiece Touch tungsten electrode to work piece at weld start point hold electrode to workpiece for 1 2 seconds and slowly lift electrode An arc will form when electrode is a lifted a Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between 1 2 electrode and workpiece The Touch Seconds solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece with out overheating sticking or getting contaminated Do NOT Strike Like A Match Ref S 156 279 4 5 Stick Start Procedure pe E CR y 9 DE With Stick selected start arc as fol Da MA ws e zu S T a Electrode 2 Workpiece 3 A
45. H FM1 4 WARNING 9 ei ELECTRIC SHOCK HAZARD Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit Extreme 360 RC2 ACS 1A PC2 AC1 O 51 2A PC2 AG2 OX O NI WII ELKPOWER CORD WHT ROWER GORD 220 922 B TM 229 409 Page 55 TO G1B REAR TERM EAN LH Bm p nr N87 O Y L4 IN ST cR 5 O O A n E O E amp E Ta E en sle E gu S O a E v WHT P167 1 RT1 WHT FL67 2 g Z Gi 9 oe E E TU SECONDARY BOOST f PA 3 bie Hans 4 cal hl dal IN L4 SISSE S a galet z aA SR
46. HF XFMR 8 D4 9 D2 10 TP3 11 D8 12 D10 13 D11 14 BUS 4 ds e gi Check all measurements for Invert ey s18 E Di Les SE MOD2 see Section 2D l al SITE 8 If all measurements passed MOD2 m lo pet aki 7 is OK lia tome a s an i Gg ue i s A Bone owchart see Sectio M gsi D m fi o ege 7 ul jo jo Vi o Ref 907 161 225 065 A 6 7 Inverter Module MOD2 Test Point Values Inverter Module MOD2 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms Boost Snubber Diode TP1 C6 and C7 TP4 C1 0 20 0 90 N A Boost Snubber Diode L2 TP4 C1 0 20 0 90 N A Main Boost Diode TP4 C1 BUS 0 20 0 90 N A Inverter IGBT HF XFMR BUS 0 20 0 90 N A Inverter IGBT BUS HF XFMR 0 20 0 90 N A Snubber IGBT TP2 D11 Cathode HF XFMR 0 20 0 90 N A Snubber IGBT TP2 D11 Cathode TP3 C2 0 20 0 90 N A Inverter IGBT Gate D2 Cathode HF XFMR N A 100k Inverter IGBT Gate D4 Cathode BUS N A 100k Snubber IGBT Gate D10 Cathode TP2 D11 Cathode N A 100k w Plug Removed From RC1 Snubber IGBT Gate D8 Cathode TP2 D11 Cathode N A 100k w Plug Removed From RC1 Extreme 360 TM 229 409 Page 21 PRE POWER CHECKS A Read and follow safety information in Section 6 1 before proceeding 1 Power Switch S1 Visually inspect S1 for damage Check switch mechanical opera tion by turning switch On and Off several times Switch should snap sharply between the On and Off pos
47. TM 229 409 Page 36 Extreme 360 Always check unit before applying power see Sections 6 1 thru 6 18 6 23 Enabling Low Open Circuit Voltage Stick Mode Optional A Disconnect and lockout tag out 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 PC3 2 Switch SW1 Remove wrapper Place switch position 1 in the Closed position by pressing actua tor toward board Reinstall wrapper Follow the same arc starting proce dures as described in Section 4 5 E z E zz AO on As cho o eat Je RSSEMBLY NO LA Kei j Pt E SA P TJ iF 907 161 217 181 Extreme 360 TM 229 409 Page 37 Always check unit before applying power see Sections 6 1 thru 6 18 6 24 Troubleshooting Circuit Diagram Voltage Readings 8 b Tolerance 10 unless specified Reference single arrow reference to circuit common lead 42 double arrow refer
48. and maximum voltage and amper age output capabilities of welding SMAW MAX SMAW GTAW 80A ARC 2596 CONTROL power source Curves of other set tings fall between curves shown GTAW MAX 200 300 400 AMPERAGE 100 B CV Mode 100 200 300 AMPERAGE 400 500 500 217 836 A 217 837 B Extreme 360 TM 229 409 Page 3 2 3 Duty Cycle And Overheating 500 425 400 350 300 250 THREE PHASE OPERATION 200 150 8AWG POWER CORD WELDING AMPERES 100 15 20 25 30 40 DUTY CYCLE Zo 6 Minutes Welding 50 60 70 80 90 100 60 Duty Cycle 20 5 4 Minutes Resting Overheating pem rk gt DEI Oo e Minutes Reduce Duty Cycle 6AWG POWER CORD SINGLE PHASE OPERATION Aor V Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats output stops a Help message is displayed 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 output with 8 AWG is 300 amps 32 volts at 4096 duty cycle To achieve 6096 duty cycle change cord to 6 AWG A Exceeding duty cycle can damage unit and void warranty gt S Ref 216 568 A Notes
49. art should be followed if any of the following conditions exist the symptoms are unknown the unit is completely inoperative visual damage is found on any of the following components capacitors C12 and C13 control board PC1 IGBT power modules MOD1 and MODA interconnecting board PC2 or input rectifier SR1 there is no output or limited output Extreme 360 TM 229 409 Page 17 6 2 Pre Power Flowchart PRE POWER CHECKS KA J e PN a ar Lo Complete Section 6 3 Measuring Input Capacitor Voltage Complete Sections 6 4 Thru 6 7 For Modules MOD1 And MOD2 NO Complete Sections 6 13 Thru All Measurements Pass 6 18 Control Auxiliary Board PC1 YES Complete Section 6 8 For Power All Measurements Pass Ech Replace PC1 Switch S1 Shape ps YES NO All Measurements Pass Replace S1 gui bara Rs AGAD Ste ke YES Complete Sections 6 9 and 6 10 NO Output Diodes D1 amp D2 e All Measurements Pass m Replace PC2 YES NO Replace Replace Modules MOD1 amp All Measurements Pass gt D1 amp D2 MOD2 See Module Field Kit uw o Instructions YES Complete Sections 6 11 and 6 12 Stick Boost Rectifier SR1 NO All Measurements Pass Re
50. cally live Significant DC 9 12 1 voltage can remain on capaci tors after unit is Off O ES em ACL x ES x mi o O Dar nag E Be sure plugs are secure before ap iss m e m i i E r o BC ERL Ei O ae y plying power See Section 6 26 for x I m E at d E x mb LE specific values during testing C OR GOD Hz Bc E P i 1 Inverter Control Board PC1 i em RI3B 117 lt gt esx de pus ud O cm 2 Receptacle DC WEE c oe x ocg c 9m eu Ti 3 Receptacle RC2 i med Fd AA mur Le a EEG pu E d m CE 71s AT p O LI a LET Ca 4 Receptacle RC3 2 a ns Jm a p18 Fz i
51. e Secondary Heatsink 0 10 0 90 N A Extreme 360 TM 229 409 Page 23 PRE POWER CHECKS 6 11 Stick Boost Rectifier SR1 A Read and follow safety information in Section 6 1 before proceeding 1 Stick Boost Rectifier SR1 Visually inspect SR1 for damage Check all measurements for stick boost 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 xm ZA p S Q mi A O bi a allel LO rra s Test Equipment Needed Ref 907 161 6 12 Stick Boost Rectifier SR1 Test Point Values Stick Boost Rectifier SR1 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms SR1 Terminal 2 Terminal 1 0 20 0 90 N A SR1 Terminal 4 Terminal 1 0 20 0 90 N A SR1 Terminal 3 Terminal 2 0 20 0 90 N A SR1 Terminal 3 Terminal 4 0 20 0 90 N A TM 229 409 Page 24 Extreme 360 PRE POWER CHECKS Notes OHM S LAW VOLTAGE CURRENT X RESISTANCE CURRENT VOLTAGE RESISTANCE RESISTANCE VOLTAGE CURRENT Extreme 360 TM 229 409 Page 25 PRE POWER CHECKS 6 13
52. ectric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures TM 229 409 Page 2 H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment install test and service H F producing units e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference READ INSTRUCTIONS e Use Testing Booklet Part No 150 853 when servicing this unit e Consult the Owner s Manual for welding safety precautions e Use only genuine replacement parts For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Die
53. eeder and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from re ceptacle or stop engine before servicing unless the procedure spe cifically requires an energized unit e Insulate yourself from ground by standing or working on dry insulat ing mats big enough to prevent contact with the ground e Do not leave live unit unattended e If this procedure requires an energized unit have only personnel familiar with and following standard safety practices do the job e When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free e Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts P STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling TIN boards or parts Ve e Use proper static proof bags and boxes to store move or ship PC boards FIRE OR EXPLOSION hazard e Do not place unit on over or near combustible surfaces e Do not service unit near flammables Extreme 360 OM 229 409 B safety stm 8 03 Die This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards
54. ence to points indicated c Wiring Diagram see Section 8 V1 665 volts ac RMS V2 V3 17 volts ac RMS V4 115 volts ac RMS V5 24 volts ac RMS V6 V7 470 volts dc V8 115 volts ac RMS when FM is running V9 24 volts dc when Relay is energized Relay energized in Stick mode with output current greater than 10 amps and preset current less than 225 amps V10 24 volts dc when gas is flowing see Section 3 7 for gas valve operation V11 15 volts dc V12 15 volts dc V13 1 volt dc per 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 EF 14 volts dc in Stick mode when low open circuit voltage Stick mode is enabled See Section 6 23 14 volts dc in Lift Arc TIG mode See Section 6 30 for RC50 information See Section 6 29 for PC3 information Test Equipment Needed Resistance Values a Tolerance 10 unless specified b Turn Off unit and disconnect input power before checking resistance Less than 1 ohm R1 thru R6 R9 R7 and R8 190 210 ohms A Discharge input capacitors according to Section 6 3 and be sure voltage is near zero before touching any parts No calibration available for voltmeter V or ammeter A Z han E a ANA uoc o o U 204754 oz 13042 o V V V
55. ermistor NTC 30K Ohm 25 Deg C 18In Lead Ld gera CR1 198 549 Relay Encl 24VDC Spst 35a 300VAC 4pin Flange Mig STA AE 227 127 Label Warning Electric Shock Exploding Parts LM AA ene 010546 Bushing Snap In Nyl 375 Id X 500 Mtg Hole LNB su L4 218 020 2 Ind ctor BOOST iii ear y an e v ener Dn ee s eA CI uu fats ens 179 276 Bushing Snap In Nyl 1 000 Id X 1 375 Mtg Hole Cent E Eh E 170 647 Bushing Snap In Nyl 1 312 Id X 1 500 Mtg Hole Mak EATE LO 212150 Inductor Output 0 n PO eon icity Innere 212132 XFMR HF Litz Litz W Boost ced se ENSEM 212197 Heat Sink Lh Rect 22 us ET sac 212 091 Inductor Input soe Ree ER Tq din maang Dd goa cen 083 147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 24 PC1 218 007 Circuit Card Assy Control Aux Power W Program Dade deti DRE 216 113 Stand Off Support PC Card 187 Dia W P amp I 375 DUET PLG1 115091 Housing Plug Pins Service Kit RC1 BEE PLG2 201 665 Housing Plug Pins Service Kit RC2 EE PLGS 131 056 Housing Plug Pins Service Kit RC3 iio eer ates PLG5 131 204 Housing Plug Pins Se
56. ge present RC2 A High voltage present Voltages on this receptacle can exceed 900 volts DC from chassis GND NOTE All pins on this receptacle are referenced to the primary Bus 1 Output Primary bus regulated to 940 volts dc with respect to primary bus 2 Not Used 3 Not Used 4 Output Primary rectifier rectified primary line volts RC3 A High voltage present Voltages on this receptacle can exceed 900 volts DC from chassis GND NOTE All pins on this receptacle are referenced to the primary Bus 1 Do not measure Boost IGBT gate drive signal return 2 Input Do not measure 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 Precom Circuit common referenced to primary bus 6 Precom Circuit common referenced to primary bus 7 Input Precharge relay coil return O volts dc relay contacts open 12 volts dc relay contacts closed 8 Input 15 volts dc regulated with respect to primary bus 15 volts dc power to boost inductor current sensor RC6 A ND E present Voltages on this receptacle can exceed 900 volts DC from chassis NOTE All pins on this receptacle are referenced to the primary Bus 1 Snubber resistor1 input boost snubber located in resistor module mounted to primary heat sink 2 Not Used 3 Snubber resistor2 inverter
57. imary Circuit e Weld Circuit Optional Extreme 360 TM 229 409 Page 15 Theory Of Operation Components 1 Primary Input Power Single or Three Phase AC primary power supply 2 Power Switch S1 Provides on off control of primary input power to welding power Source 3 Power Interconnect Board PC2 Provides electrical connections for L1 L2 MOD1 MOD2 RM1 C12 amp C13 Precharge and bleeder resis tors and snubber capacitors are mounted on PC2 4 Boost Input Inductor L1 Required to boost input rectifier voltage to bus voltage 5 Boost Snubber Inductor L2 Required to ensure soft switching of the boost IGBT located in MOD 6 Inverter Module MOD2 Contains the main inverter IGBTs snubber IGBTs main boost diode and two boost snubber diodes 7 Input Pre Regulator Module MOD1 Contains the input rectifier diodes boost IGBT and one boost snub ber diode 8 Snubber Resistor Module RM1 Contains one boost snubber resis tor and one inverter snubber resis tor 9 Bus Capacitors C12 amp C13 Stores energy and filters the DC bus voltage for input boost and in verter 10 Current Transformer CT1 Provides T1 current feedback to PC1 Used to protect inverter IGBTs in case of T1 primary over current 11 Series Capacitor C15 Provides protection against T1 sat uration Saturation occurs when the voltage across the transformer is not balanced The unba
58. in Type Value RC50 G GND 14 pin remote accessory power return Output Voltage feedback 1 volt dc per 10 volts dc of weld output l Output 115 volts ac at 2 amps 14 pin remote accessory power J Input Remote output enable O volts ac weld output off 115 volts ac weld output on K Chassis Power source chassis L Not used M Input Remote process select O volts dc CC 15 volts dc CV N Not used 6 31 Checking Unit Output After Servicing 1 Weld Output Terminals Check open circuit voltage be tween terminals according to Sec tion 6 24 voltage V 14 If correct voltage is not present repeat troubleshooting procedures Her Reinstall cover and side panels if removed 803 691 C Extreme 360 TM 229 409 Page 49 SECTION 7 MAINTENANCE 7T 1 Routine Maintenance ER TT A Disconnect power GF Maintain more often before maintaining during severe conditions 3 Months Damaged Or Unreadable Labels Cables Repair Or Replace Replace Cracked Cracked Torch Body Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections na VA Blow Out Inside 4 7 2 Blowing Out Inside Of Unit A Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back lou
59. itch in On position see Section 3 2 or 3 3 Check and replace line fuse s if necessary or reset circuit breaker see Sections 3 2 and 3 3 Check for proper input power connections and check condition of power cord see Section 3 2 or 3 3 Check continuity of Power switch S1 and replace if necessary see Section 6 8 Check control transformer T2 for signs of winding failure Check continuity across windings and check for proper connections Check secondary voltages Replace T2 if necessary Check control auxiliary power board PC1 and connections and replace if necessary see Pre Power Checks in Sections 6 13 thru 6 18 and also see Section 6 25 Check power interconnect board PC2 and connections and replace if necessary see Pre Power Checks in Sections 6 13 thru 6 18 and also see Section 6 27 Check front panel display board PC3 and connections and replace if necessary see Section 6 29 No weld output meter display On Follow Pre Power Flowchart and replace any failed components see Section 6 2 Unit overheated and HELP 3 or HELP 5 screen is displayed Allow unit to cool with fan On see Section 6 22 If a remote accessory is connected to remote 14 receptacle RC50 Check accessory contact closure continuity and replace accessory if necessary Check accessory amperage control potentiometer resistance and connections and replace accessory if necessary Check input and output
60. itions Check switch electrical operation by checking continuity across S1 contacts with switch in the On posi Electrical Schematic tion With switch in the Off position ohmmeter should read open Replace switch if necessary Continueto the end of the pre pow er flowchart see Section 6 2 Test Equipment Needed Ref 907 161 Ref 183 484 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual TM 229 409 Page 22 Extreme 360 PRE POWER CHECKS 6 9 Output Diodes D1 D2 A Read and follow safety information in Section 6 1 before proceeding 1 Diode D1 2 Diode D2 Visually inspect D1 and D2 for dam 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 Continue to the end of the pre pow Weld Output er flowchart see Section 6 2 A fu Receptacles el gt O ACER RI Test Eguipment Needed gt HAL Diodes D1 D2 Ref 907 161 6 10 Output Diodes D1 D2 Test Point Values Output Diodes D1 And D2 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms D1 Terminal Anode Secondary Heatsink 0 10 0 90 N A D2 Terminal Anod
61. lanced voltage appears as a DC offset voltage across the transformer and can cause a primary overcurrent The capacitor protects against this condition by blocking the DC off set 12 Main Transformer T1 Switching action of IGBTs in MOD2 creates the AC voltage source for T1 primary T1 secondary outputs supply power to the weld circuit 13 Output Diodes D1 D2 Rectifies the main secondary out put of T1 14 Output Current Sensor HD1 Provides weld output current feed back to PC1 15 Positive and Negative Weld Output Receptacles Provide weld output and allow changing of output polarity 16 Stick Boost Relay CR1 Provides on off control of Stick boost output circuit 17 Stick Boost Inductor L4 Limits current in the Stick boost output circuit 18 Stick Boost Rectifier SR1 Rectifies the Stick boost secon dary output of T1 19 Output Stabilizer L3 Filters or smooths the DC weld out put current 20 User Interface Board PC3 Consists of Voltmeter V Ammeter A Arc Control Voltage Amperage 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 Dig in Stick process or In ductance in MIG process See Section 4 1 Front Panel Controls 23 Voltage Amperage Adjust Selects weld output voltage or am perage level See Section 4 1 Front Panel Controls 24 Remote 14 Pi
62. m squarewave foldback 20 GND Circuit common referenced to chassis 21 Output 24 volts dc unregulated dc voltage with respect to GND 22 Output 24 volts dc unregulated dc voltage with respect to GND 23 Output 24 volts dc unregulated dc voltage with respect to GND 24 Output 24 volts dc unregulated dc voltage with respect to GND RC7 1 Output 5 volts dc reference voltage for secondary side thermistor 2 Input Secondary side thermistor return 2 volts dc at 25 C thermistor temperature RC8 1 Output 5 volts dc reference voltage for primary side thermistor 2 Input Primary side thermistor return 2 volts dc at 25 C thermistor temperature TM 229 409 Page 42 Extreme 360 Always check unit before applying power see Sections 6 1 thru 6 18 Section 6 26 Control Auxiliary Power Board PC1 Test Point Values Continued RC9 1 Output Do not measure Test point used to test board only 2 Output Do not measure Test point used to test board only 3 Input Do not measure Weld output current sensor signal 4 Output 15 volts dc power to current sensor 5 Output 15 volts dc power to current sensor 6 GND Weld output current sensor signal common RC10 1 Output 115 volts ac rms with respect to GND power feed to fan 2 Output Fan power return measure with respect to RC10 1 115 volts ac rms fan on 0 volts ac rms fan off 3 Output
63. n Receptacle RC50 Provides connection to auxiliary equipment See Sections 4 1 Front Panel Controls and 3 6 Re mote 14 Receptacle Information 25 Process Selector Switch Selects weld process See Sec tion 4 1 Front Panel Controls 26 Weld Process Control Controls weld output by automati cally adjusting output current com mand signal to Inverter Control 27 Optional Auxiliary Power 115 VAC Receptacle Provides connection for auxiliary equipment to welding power source 28 Control Auxiliary Power Board PC2 Contains the boost control auxilia ry power module and inverter con trol 29 Boost Control Controls switching of boost IGBT in MOD1 to regulate L1 current and the DC bus voltage 30 Auxiliary Power Module Contains power supply for boost control power and inverter IGBTs to create AC voltage source for T2 primary 31 Inverter Control Controls the main inverter and snubber IGBTs within MOD2 Regulates the weld output current to the value received from weld process controller Provides power to PC3 Drives fan motor and gas valve Provides interface between primary and secondary thermis tors and PC3 32 Circuit Breaker CB1 Provides overload protection for remote 14 pin 115 VAC power and optional 115 VAC receptacle 33 Circuit Breaker CB2 Provides overload protection for remote 14 pin 24 VAC power 34 Control Transformer T2 Provides power to inverter control on PC1 remote 14 pi
64. n motor does not run after approxi mately four minutes of operation at rated load Check and clear blocked fan blade Check receptacle wiring and connections Check thermistors RT 1 and RT 2 see Section 6 24 Fan motor FM1 starts and meters display HELP 2 when RT 1 or RT 2 is disconnected from PC1 When HT 1 or RT 2 is reconnected the meter displays change but the fan continues to run see Sec tion 6 22 Check fan motor FM see Section 6 24 and replace fan motor if necessary Wandering arc poor control of arc direction Use proper size tungsten Use properly prepared tungsten Reduce gas flow rate Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and tighten all gas fittings Water in torch Refer to torch manual Extreme 360 TM 229 409 Page 35 6 22 Voltmeter Ammeter Diagnostics Always check unit before applying power see Sections 6 1 thru 6 18 4 jedle weder EF All directions are in reference to the front of the unit All circuitry referred to is lo cated inside the unit 1 Help 1 Display Indicates a malfunction in the primary power circuit caused by an overcurrent condition in the primary IGBT switching circuit If this dis play is shown complete the Pre Power Flow chart in Section 6 2 2 Help 2 Display Indicates a malfunction in the thermal p
65. n receptacle and optional 115 VAC receptacle 35 Fan Motor FM1 Provides cooling of heatsinks and components mounted inside wind tunnel The fan motor is thermo statically controlled and only runs when cooling is needed Once unit is cooled to proper temperature fan will continue to run for ten min utes 36 Optional Gas Solenoid GS1 Provides on off flow of shielding gas to the arc while TIG welding 37 Secondary Heatsink Thermistor RT 1 Monitors temperature of secon dary heatsink for fan motor control and overtemperature shutdown 38 Primary Heatsink Thermistor RT 2 Monitors temperature of primary heatsink for fan motor control and overtemperature shutdown TM 229 409 Page 16 Extreme 360 SECTION 6 TROUBLESHOOTING 6 1 Checking Unit Before Applying Power Lay 4 pra we ei LF See Section 6 24 for test points and values and Section y Ze gt 9 for parts location A Discharge input capacitors according to Section 6 3 and be sure voltage is near zero before touching any parts A Before applying power to unit complete the pre power flowchart in Section 6 2 to avoid causing further damage A Although 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 to get a basic okay to power up unit N OTE tl The pre power flowch
66. nnections 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 connections and replace if necessary see Pre Power Checks in Sections 6 13 thru 6 18 and also see Section 6 25 Check front panel display board PC3 and connections and replace if necessary see Section 6 29 Check if Low Open Circuit Voltage Stick Mode is enabled see Section 6 23 TM 229 409 Page 34 Extreme 360 Always check unit before applying power see Sections 6 1 thru 6 16 Trouble Remedy Erratic or improper weld output Use proper size and type of weld cable see Section 3 4 Clean and tighten all weld connections Check for proper input and output connections Replace electrode If a remote accessory is connected to remote 14 receptacle RC50 Check all remote accessory connections proper pin socket alignment Check accessory amperage control potentiometer resistance and connections and replace 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 connections and replace if necessary see Pre Power Checks in Sections 6 13 thru 6 18 and also see Section 6 25 Check front panel display board PC3 and connections and replace if necessary see Section 6 29 Fa
67. place SR1 YES Pre power flowchart complete Complete Section 6 31 hit Checking Unit After Servicing TM 229 409 Page 18 Extreme 360 PRE POWER CHECKS 6 3 Measuring Input Capacitor Voltage Zeg Z Typical Bleeder Resistor 25 to 1000 ohm 5 watt resistor A Significant DC voltage can remain on capacitors after unit is Off Always check the voltage as shown to be sure the input capacitors have dis charged before working on unit 16 AWG 1000 volts dc insulation rating approx 3 in 76 mm leads Positive 4 lead to C12 4 terminal Test Equipment Needed Negative lead to C12 terminal Positive lead to C13 terminal Negative lead to C13 terminal A Turn Off welding power source and disconnect input power Remove cover 1 Power Interconnect Board PC2 2 Voltmeter 3 Capacitor C12 Measure the dc voltage across C12 Positive Terminal and C12 Negative Terminal on PC2 as shown until voltage drops to near 0 zero volts 4 Capacitor C13 Measure the dc voltage across C13 Positive Terminal and C13 Negative Terminal on PC2 as shown until voltage drops to near 0 zero volts EF If the capacitor voltage does not 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 discha
68. rc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc 1 goes out electrode was lifted to high a If electrode sticks to workpiece use LC 7 on a guick twist to free it wer n d Low OCV Stick The unit can be optionally config L 2 ured for low open circuit voltage LA 4 OCV operation When the unit is PES configured for low OCV operation poo 4M only a low sensing voltage approxi 3 mately 15 VDC is present between the electrode and the workpiece prior to the electrode touching the workpiece Consult a Factory Authorized Service Agent for infor mation regarding how to configure the unit for low OCV stick welding operation Extreme 360 TM 229 409 Page 13 SECTION 5 THEORY OF OPERATION 4 5 6 Boost Boost Input Snubber ie Inductor Inductor Mod2 L1 L2 7 8 9 nput Snubber Pre Regulator Resistor Bus Module Module Capacitors Mod1 RM1 C12 C13 1 2 1 Phase or Power 10 3 Phase Switch Power Interconnect Board Input 1 PC2 Current Power Transformer CT1 Bus Voltage Input Rectifier Voltage Input Boost Inductor Current Feedback Boost Gate Signal Front Panel And Display Board PC3 21 21 Voltmeter Ammeter V A Ze ION i Optional i 22 2
69. re NON NL wc m on o m 95 m il C7 Iso ds Hh 3 0n WEN a E AN TI ESEOEPVESPEENS g E E E Z p eee E i AA i HI n NG NG NG NG N ih al ag V14 gt T a n aul S You UE FISH Fg Fs T AUS dal alg NES Ge x sus n A w III gi REREREE SINS SRS HI amp 3 ecd ygs POSITIVE SIRRBEFEBRERE SS Y YI YS YS Ela Marara sla IS ESKE RIE KE N A A A A A R A A A A R A A NE RRA TA Tw Y RR T Er TI BE MGA HOT GREG 53665555 BI 3238093883308 S ZE E E E yr E E Y E ZS x SS SS SS Y Y SS Rm pes gt Z V11 Ros a sp dl RE7 1 gt gt V12 PCI 2 I SECONDARY HEATSINK V1 CONTROL AUX POWER Approx 35K ohms RC7 2 x e 3 RC1 PLG1 pp e o RGH 1 RT Z GC PLG2 at 70 F 21 C cg i E PRIMARY HEATSINK RC3 FLGI RCB 2 gt RC5 PLG5 RC16 PLG16 UE Rena gt gt FH RC8 PLC8 V8 Renz 3 39 gt RC9 PLGS RC10 PLO10 rem E C RC11 PLG11 v9 Ren 3 RE12 PLE12 CAT 45 ed VIO ae e ESCH EN D A WHT a BLK See Section 6 25 for PC1 information 4 WARNING e Do not touch live electrical parts TuS Disconnect input power or stop 3 engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 211 328 E Extreme 360 TM 229 409 Page 39 Always check unit before applying power see Sections 6 1 thru 6 18 6 25 Control Auxiliary Power Board PC1 Testing Information Use with Section 6 26 A Warning this procedure re quires the machine to be elec 5 tri
70. 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 conductor as shown 6 Input Power Cord 7 Disconnect Device switch shown in the OFF position 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 10 Overcurrent Protection Select type and size of overcurrent protection using Section 3 4 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout de vice and place switch in the On posi tion Tools Needed 804 531 A TM 229 409 Page 6 Extreme 360 3 3 Connecting 3 Phase Input Power Her P 7 WA D GND PE Earth Ground KY Tools Needed Esc H E EE A Installation must meet all National and Local Codes have only quali fied per
71. rge the capacitor s 5 Typical Bleeder Resistor An example of a typical bleeder re sistor is shown on this page Proceed with pre power flowchart Ref 803 721 B 907 161 Extreme 360 TM 229 409 Page 19 PRE POWER CHECKS Input Pre Regulator Module MOD1 6 4 Test Equipment Needed A Read and follow safety information in Section 6 1 before proceeding A Wear an earth grounded wrist strap when perform ing pre power checks Re move wrist strap before t le performing any checks or eg S procedures with power ap NI d plied to the machine SIN ae y E Board layout may differ from en that shown 1 MOD Visually inspect MOD1 for dam age S 2 BUS Jif 3 D12 Cathode A ACI M 5 AC 6 AC3 2 7 L1 Component Side Of Board 8 LI L2 9 TPI aag 1 0 1 0 BUS Check all measurements for Input Pre Regulator Module MOD1 see Section 6 5 If all measurements passed MOD is OK Continue to the end 9 of the pre power flowchart see Section 6 2 8 iO gs D gi s 7 0 E cus mi oe Ref 907 161 225 065 A 6 5
72. roce 13 Diode D3 Check all measurements for PC2 dures with power applied to the ma 14 Diode D4 If all measurements passed continue to chine 15 Diode D8 the end of the pre power flowchart see 1 Ge dee Board PC2 16 Diode D9 Section 6 2 2 ist 1 3 Pian R Ge 17 Diode D10 F If any measurements failed replace 4 Resistor R12 18 Diode D11 POS 5 Resistor R14 19 Diode D12 A Pre power checks are now com 20 Diode D13 plete Remove earth grounded wrist 6 AC strap before performing any checks 7 AC2 21 Center Bus or procedures with power applied to 8 AC3 22 BUS the machine TM 229 409 Page 32 Extreme 360 PRE POWER CHECKS 6 20 Power Interconnect Board PC2 Test Point Values Power Interconnect Board PC2 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms Pre Charge Resistor R14 R14 Bottom R14 Top N A 200 SCR Gate Resistor R10 R10 Left R10 Right N A 10 16 5 SCR Gate Resistor R11 R11 Left R11 Right N A 10 16 5 SCR Gate Resistor R12 R12 Left R12 Right N A 10 16 5 Pre Charge Diode D5 AC3 R14 Top 0 20 0 90 N A Pre Charge Diode D6 AC2 R14 Top 0 20 0 90 N A Pre Charge Diode D7 AC1 R14 Top 0 20 0 90 N A Boost Gate Protection Diode D12 D12 Anode D12 Cathode 0 20 0 90 N A Boost Gate Protection Diode D13 D13 Anode D13 Cathode 0 20 0 90 N A Inverter Gate MOSFET Q1 Q1 S Source Q1 D Drain 0 20 0 90 N A Inverter Gate MOSFET Q2 Q2 S Source Q2 D Drain 0 2
73. rotec tion circuit The unit has detected a shorted or open thermistor If this display is shown verify thermistors RT 1 and RT 2 are plugged into circuit board PC1 and check thermistor input values on circuit board PC3 see Section 6 29 3 Help 3 Display Indicates the left 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 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 when the unit has cooled 5 Help 6 Display Indicates operation at maximum input current The unit has a maximum allowable input cur rent limit As the line voltage decreases the required input current increases If the line voltage is too low the output power is limited by the 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 Display Indicates a malfunction in the secondary pow er circuit of the unit The unit has detected a high open circuit voltage condition If this dis play is shown complete the Pre Power Flow chart in Section 6 2 Check for proper connec tion of bypass capacitors C6 and C7 see Figure 8 2 Check operation of control relay CR1 see Section 6 24
74. rvice Kit RC5 mm PLG7 131 054 Housing Plug Pins Service Kit RC7 URS aede PLG8 131 054 Housing Plug Pins Service Kit RC8 exea env PLG9 115093 Housing Plug Pins Service Kit RC9 anni LG PLG10 115094 Housing Plug Pins Service Kit RC10 PLG11 115 094 Housing Plug Pins Service Kit RC11 nG Pur ed PLG12 115092 Housing Plug Pins Service Kit RC12 A 212072 Bracket Mtg Capacitor Pc Board 26 C12 13 219930 Kit Capacitor Elctlt Replacement Includes CERE 193 738 Capacitor Elctlt 1800 Uf 500 VDC Can 2 52 Dia ae dee 217040 Nut Nylon M12 Thread Capacitor Mounting 228 vx CB2 083 432 Circuit Breaker Man Reset 1P 10A 250VAC Frict issus CB1 089 807 Circuit Breaker Man Reset 1P 2 5A 250VAC Frict Joco 212 071 Panel Rear Standard SIGE NAN NAT freckles 126026 Label Warning Electric Shock Can Kill Significant UA vs en eppure Y os Nameplate Rear Order by Model and Serial Number e NA MA e eai 217 480 Label Warning Incorrect Connections Me OD olii da
75. s Extreme 360 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual TM 229 409 Page 31 PRE POWER CHECKS 6 19 Power Interconnect Board PC2 Mu nsa CENTER E h BUS RC3 Ri LT AB 5 Em FRCIS Z amo o ALI 013 ADD 012 rp R9 4 3 MOD1 Skiip 83 HEC XII E 6 Bs EE 9 dispo ET TA po a E a 13 ac O E EE E 2 8 ig 8 gt a O gt a mi zu O z zu O 14 8 E RC orc Bs O HF XFMR 8s 7 se E o GE ali x Or acz O 52 Elbe 52 bo 5 z S z 8 25 25 mi o O wn wo T E R18 I umor ea mu Q Q la C cig HDI I O lu es L2 O O Sp O Ref 907 161 225 065 A A Read and follow safety information 9 Q1 23 BUS In Section e I before proceedlng 10 Q2 CS Remove all plugs from PC2 before A Wear an earth grounded wrist strap 11 Diode D1 testing when performing pre power checks Remove wrist strap before 12 Diode D2 Visually inspect PC2 for damage performing any checks or p
76. s capacitors center point regulated to 470 volts dc with respect to bus Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 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 TM 229 409 Page 46 Extreme 360 Always check unit before applying power see Sections 6 1 thru 6 18 6 29 Front Panel Display Board PC3 Testing Information Use with Section 6 30 A 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 plying power See Section 6 30 for specific values during testing 1 Process Control Board PC3 Receptacle RC1 m 2 bai gt 3 3 Receptacle RC2 deo EE 4 Receptacle RC51 ir LE REG A ni mn D AR ca 3 c2 e ral T T S
77. sel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended Extreme 360 2 1 SECTION 2 INTRODUCTION Specifications Input Power Rated Output Max Open Circuit Voltage Amperage Range in CC Mode Voltage Range in CV Mode RMS Amps Input at Rated Load Output 60 Hz 3 Phase at NEMA Load Voltages and Class Rating 208 V 230V 400V 460V 575V KVA KW 3 Phase 350 A at 34 VDC 60 Duty Cycle 10 38 V 5 425 A 75 VDC 1 Phase 300 A at 32 VDC 60 Duty Cycle 40 4 36 1 20 6 17 8 14 1 14 2 13 6 60 8 54 6 29 7 25 4 19 9 See Section 2 3 for Duty Cycle Rating 2 2 Volt Ampere Curves 100 90 80 704 60 50 40 304 VOLTS 20 J MN 100 90 80 70 60 50 VOLTS 40 30 20 10 0 0 A CC Mode Volt ampere curves show minimum
78. snubber located in resistor module mounted to primary heat sink 4 Snubber resistor1 input boost snubber located in resistor module mounted to primary heat sink 5 Not Used 6 Snubber resistor2 inverter snubber located in resistor module mounted to primary heat sink Extreme 360 TM 229 409 Page 45 Always check unit before applying power see Sections 6 1 thru 6 18 Section 6 28 Power Interconnect Board PC2 Test Point Values Continued A High voltage present The following terminals are used to interconnect the main power circuit with the prima ry supply and with power circuit components not soldered in the pcb Voltages on this receptacle can exceed 900 volts DC from chassis GND Receptacle Pin Type Value AC1 Power Primary AC mains phase 1 line voltage measure with respect to AC2 or AC3 AC2 Power Primary AC mains phase 2 line voltage measure with respect to AC1 or AC3 AC3 Power Primary AC mains phase 3 line voltage measure with respect to AC or AC2 L1 Power Input boost inductor rectified line voltage measure with respect to bus L1 L2 Power Common point between input boost inductor and boost IGBT snubber inductor L2 Power Boost IGBT snubber inductor HF XFMR Power High frequency weld power transformer primary C13 Power Bus regulated to 940 volts dc with respect to bus C12 Power Bus power circuit common Center Bus Power Bu
79. sons make this installation A Disconnect and lockout tagout in put power before connecting input conductors from unit A Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal 5 The Auto Line circuitry in this unit au tomatically adapts the power source to the primary voltage being applied Check input voltage available at site This unit can be connected to any in put power 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 Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L1 L2 And L3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 7 Overcurrent Protection Select type and size of overcurrent protec tion using Section 3 4 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 804 531 A Extreme 360 TM 229 409 Page 7 3 4 Electrical Service Guide A CAUTION INCORRECT INPUT POWER can damage this welding power source Phase to ground voltage shall not exceed 10 of rated input voltage NOTE 7
80. t AT 288 ais HF K Risa gt KEE je Ja a gt re Que ES O D Jo 5 Receptacle RC5 H MI kis S Lb es 4 Looe me 072 e P pa a APO E de de u LF Qu or Fr CES 6 Receptacle RC6 6 cas H I i RI EE s Em 7 Receptacle RC7 E Raz Hu el TE 6 Hah O a C E 8 Receptacle RC8 pol ua C E H Da CT CI 5 4 kso HE E E e SH EJE 9 Receptacle RC9 NI C usur Mem d 10 Receptacle RC10 5 p g me Imm Cos ATM ve 2 P oie Op Ce Qua EL 11 Receptacle RC11 12 Receptacle RC12 8 aul C58 F H E ave ro a mI g 3 10 X ETT 4 D y ty Test Equipment Needed Ref 217 184 F 907 161 TM 229 409 Page 40 Extreme 360 Always check unit before applying power see Sections 6 1 thru 6 16 6 26 Control Auxiliary Power Board PC1 Test Point Values ei a Tolerance 10 unless specified pus 783 PC1 Voltage Readings ez b Reference to circuit common lead 42 unless noted Receptacle Pin Type Value RC1 A Do not measure high voltage present RC2 A High voltage present Voltages on this receptacle can exceed 900 volts DC from chassis GND NOTE All pins on this receptacle are referenced to the primary Bus 1 Input Primary bus regulated to 940 volts dc with respect to primary bus 2 Not used 3 Not used 4 Input Primary rectifier rectified
81. trol Auxiliary Power Board PC Auxiliary Power Circuit 26 6 14 Control Auxiliary Power Board PC1 Auxiliary Power Circuit Test Point Values 27 6 15 Control Auxiliary Power Board PC1 Pre Regulator Control Circuit 28 6 16 Control Auxiliary Power Board PC1 Pre Regulator Control Circuit Test Point Values 29 6 17 Control Auxiliary Power Board PC1 Inverter Control Circuit 30 6 18 Control Auxiliary Power Board PC1 Inverter Control Circuit Test Point Values 31 6 19 Power Interconnect Board PC2 32 6 20 Power Interconnect Board PC2 Test Point Values 33 6 21 Troubleshooting Table cessaci siiis hag RR EET LER LEA NE Rid 34 6 22 Voltmeter Ammeter Diagnostics 36 6 23 Enabling Low Open Circuit Voltage Stick Mode Optional 37 6 24 Troubleshooting Circuit Diagram RI n rs 38 6 25 Control Auxiliary Power Board PC1 Testing Information Use with Section 6 26 40 6 26 Control Auxiliary Power Board PC1 Test Point Values 41 TABLE OF CONTENTS 6 27 Power Interconnect Board PC2 Testing Information Use with Section 6 28 44 6 28 Power Interconnect Board PC
82. tting Operation The gas solenoid controls gas flow during the TIG process as follows Remote TIG Gas flow starts with remote contac tor on Gas flow stops at end of post flow if current was detected or with re mote contactor off if no current was detected Lift Arc TIG Gas flow starts when tungsten touches work touch sensed Gas flow stops at end of post flow Scratch Start TIG Gas flow starts when current is de tected Gas flow stops at end of post flow Post flow time is factory set to 5 seconds per 100 amps of weld cur rent The minimum post flow time is 5 seconds The maximum post flow is 20 seconds post flow set tings are not adjustable by the end user Ref 803 705 A Ref 803 691 C TM 229 409 Page 10 Extreme 360 SECTION 4 OPERATION 4 1 Front Panel Controls 1 Power Switch F7 The fan motor is thermostatically controlled and only runs when cooling is needed 2 Voltmeter 3 Ammeter 4 V A Voltage Amperage Adjustment Control 5 Mode Switch The Mode switch setting determines both the process and output On Off control see Sec tion 4 3 Source of control panel or remote for the amount of output is selected on the V A Control switch For Air Carbon Arc CAC A cutting and goug ing place switch in Stick position For best re sults place Arc Control in the maximum posi tion 6 Remote 14 Receptacle For remote control make
83. ues during testing 1 Power Interconnect Board PC2 2 Receptacle RC1 3 Receptacle RC2 4 Receptacle RC3 5 Receptacle RC6 6 Receptacle RC7 El LLL P a riti 1 ASSEMBLY CENTER Ran BUS O RCS8 CHRSSIS O 2 H mu e me Een E E me CL me T MOD1Skiip 83 HEC o 8 mua o 2 ac O 8 S a a 2 m 9 cs e 8 xa x 1 zu t WI gs l or RC or w HF XFMR w e 95 O 25 ai a Ze BE o Bs ms ua ua ue Bt Ora nez O g2 Ft g2 o Ly Ly 4 EN 5 zs E 28 28 ai Sc O E i E Test Equipment Needed 2 2 T z AL 4 L HL O O o cxi S o L1 L2 O L O a E O cig Hi Ref 225 065 A 907 161 TM 229 409 Page 44 Extreme 360 Always check unit before applying power see Sections 6 1 thru 6 18 6 28 Power Interconnect Board PC2 Test Point Values a Tolerance 10 unless specified b Reference to circuit common lead 42 unless noted PC2 Voltage Readings Receptacle Pin Type Value RC1 A Do not measure high volta
84. vers as shown Ref 803 691 C 803 692 C TM 229 409 Page 50 Extreme 360 SECTION 8 ELECTRICAL DIAGRAMS The following is a list of all diagrams for models covered by this manual E The circuits in this manual can be used for troubleshooting but there might be minor circuit differences from your machine Use circuit inside machine case or contact distributor for more information Front Panel Display Model Serial Or Style Number Circuit Diagram Wiring Diagram EXTREME 360 LG250111A and following 211 328 E 220 922 B 208 575 Volt Models Circuit Board PC1 LG250111A and following 217 185 F Control Auxiliary Power Circuit Board PC2 LG250111A and following 225 066 A Power Interconnect Circuit Board PC3 LG250111A and following 217 182 Be Not included in this manual Extreme 360 TM 229 409 Page 51 4 WARNING e Do not touch live electrical parts L Disconnect input power or stop s engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit GANE L10 AKNG Z I 120 WT AG Z ees a 13 04267797 OPTIONAL RCZ 115V RCPT si G A HAT gt a lt NEUTRI p lt GND L lt 42 E je Ao N 17V RCSO A ZZVAC 2 Ng RC56 115VAC BI gt EI x RCSO G
85. voltages of hall device HD1 see Section 6 24 Replace HD1 if necessary Check control auxiliary power board PC1 and connections and replace if necessary see Pre Power Checks in Sections 6 13 thru 6 18 and also see Section 6 25 Check front panel display board PC3 and connections and replace if necessary see Section 6 29 Low weld output with no control Check input and output voltages of hall device HD1 see Section 6 24 Replace HD1 if necessary Check control auxiliary power board PC1 and connections and replace if necessary see Pre Power Checks in Sections 6 13 thru 6 18 and also see Section 6 25 Check front panel display board PC3 and connections and replace if necessary see Section 6 29 Maximum weld output with no control Check input and output voltages of hall device HD1 see Section 6 24 Replace HD1 if necessary Check control auxiliary power board PC1 and connections and replace if necessary see Pre Power Checks in Sections 6 13 thru 6 18 and also see Section 6 25 Check front panel display board PC3 and connections and replace if necessary see Section 6 29 Limited output and low open circuit voltage OCV Check for proper input and output connections If a remote accessory is connected to remote 14 receptacle RC50 Check accessory contact closure continuity and replace accessory if necessary Check accessory amperage control potentiometer resistance and co
86. xtreme 360 TM 229 409 Page 41 Always check unit before applying power see Sections 6 1 thru 6 18 Section 6 26 Control Auxiliary Power Board PC1 Test Point Values Continued Receptacle Pin Type Value RC6 1 Input Output reference 1 volt dc per 425 amperes of weld output when machine is under load 2 Input Voltage feedback 1 volt dc per 10 volts dc of weld output 3 Output Current feedback 1 volt dc per 100 amperes of weld output 4 Not Used 5 Input Output enable O volts dc ON 15 volts dc OFF 6 Not Used 7 Boost relay coil return 24 volts dc relay contacts open 0 volts dc relay contacts closed 8 Gas valve coil return 24 volts dc valve closed no gas flow O volts dc valve open 9 Input Fan enable 5 volts dc fan on 15 volts dc fan off 10 Not Used 11 Output HF transformer over current detect O volts dc OK 5 volts dc OVERCURRENT 12 Not Used 13 Input 5 volts dc reference 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 chassis 17 Output Primary side thermistor return 2 volts dc at 25 C thermistor temperature 18 GND Circuit common referenced to chassis 19 Output Foldback decreases weld output if input bus voltage drops O volts OK 15 volts dc 15Khz pw

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