Red-D-Arc EXTREME 360 User manual

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

TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. California Proposition 65 Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 −INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Volt-Ampere Curves 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Duty Cycle And Overheating 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 −INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Selecting a Location 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Connecting 1-Phase Input Power 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting 3-Phase Input Power 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Electrical Service Guide 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Weld Output Receptacles And Selecting Cable Sizes 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Remote 14 Receptacle Information 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Optional Gas Valve Operation And Shielding Gas Connection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 −OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Front Panel Controls 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Meter Functions 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Mode Switch Settings 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Lift-Arc TIG Procedure 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Stick Start Procedure 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 −THEORY OF OPERATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 −TROUBLESHOOTING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Checking Unit Before Applying Power 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Pre-Power Flowchart 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) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Inverter Module (MOD2) Test Point Values 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Power Switch (S1) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Output Diodes D1, D2 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Output Diodes D1, D2 Test Point Values 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Stick Boost Rectifier (SR1) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Stick Boost Rectifier (SR1) Test Point Values 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Control/Auxiliary Power Board PC1 −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 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-22. Voltmeter/Ammeter Diagnostics 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-23. Enabling Low Open Circuit Voltage Stick Mode (Optional) 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-24. Troubleshooting Circuit Diagram 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 PC2 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 7 −MAINTENANCE 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Blowing Out Inside Of Unit 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 −ELECTRICAL DIAGRAMS 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 −PARTS LIST FOR LG250111A AND FOLLOWING 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-229 409 Page 1
Extreme 360
SECTION 1 −SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-229 409-B, safety_stm 8/03
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
YMarks a special safety message.
.Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Servicing Hazards
YThe 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.
YOnly qualified persons should service, test, maintain, and re-
pair this unit.
YDuring servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
DDo not touch live electrical parts.
DTurn Off welding power source and wire feeder
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.
DInsulate yourself from ground by standing or working on dry insulat-
ing mats big enough to prevent contact with the ground.
DDo not leave live unit unattended.
DIf this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
DWhen testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
DDisconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
DTurn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any parts.
STATIC (ESD) can damage PC boards.
DPut on grounded wrist strap BEFORE handling
boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
FIRE OR EXPLOSION hazard.
DDo not place unit on, over, or near combustible
surfaces.
DDo not service unit near flammables.
FLYING METAL can injure eyes.
DWear safety glasses with side shields or face
shield during servicing.
DBe careful not to short metal tools, parts, or
wires together during testing and servicing.
HOT PARTS can cause severe burns.
DDo not touch hot parts bare handed.
DAllow cooling period before working on welding
gun or torch.
EXPLODING PARTS can cause injury.
DFailed parts can explode or cause other parts to
explode when power is applied to inverters.
DAlways wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
DTurn Off welding power source and wire feeder
or stop engine before making or changing me-
ter lead connections.
DUse at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
DRead instructions for test equipment.
FALLING UNIT can cause injury.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DUse equipment of adequate capacity to lift and
support unit.
DIf using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
MOVING PARTS can cause injury.
DKeep away from moving parts such as fans.
DKeep all doors, panels, covers, and guards
closed and securely in place.

TM-229 409 Page 2 Extreme 360
MOVING PARTS can cause injury.
DKeep away from moving parts.
DKeep away from pinch points such as drive
rolls.
MAGNETIC FIELDS can affect pacemakers.
DPacemaker wearers keep away from servicing
areas until consulting your doctor.
OVERUSE can cause OVERHEATING.
DAllow cooling period; follow rated duty cycle.
DReduce current or reduce duty cycle before
starting to weld again.
DDo not block or filter airflow to unit.
H.F. RADIATION can cause interference.
DHigh-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
DHave only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
DThe user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
DIf notified by the FCC about interference, stop using the
equipmentat once.
DHave the installation regularly checked and maintained.
DKeep 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.
DUse Testing Booklet (Part No. 150 853) when
servicing this unit.
DConsult the Owner’s Manual for welding safety
precautions.
DUse only genuine replacement parts.
1-3. California Proposition 65 Warnings
YWelding 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 &
Safety Code Section 25249.5 et seq.)
YBattery 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
reproductiveharm. Wash hands after handling.
For Gasoline Engines:
YEngine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
YDiesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
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
committee’s judgment, has not demonstrated that exposure to power-
frequency electric 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:
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.

TM-229 409 Page 3
Extreme 360
SECTION 2 −INTRODUCTION
2-1. Specifications
Input
Voltage
Amperage
Range in
Max.
Open-
Circuit
RMS Amps Input at Rated Load Output,
60 Hz 3-Phase at NEMA Load Voltages
and Class I Rating
Input
Power Rated Output
Voltage
Range in CV Mode
Range in
CC Mode
Circuit
Voltage 208 V 230 V 400 V 460 V 575 V KVA KW
3-Phase 350 A at 34
VDC, 60%
Duty Cycle
10−38 V 5−425 A 75 VDC 40.4 36.1 20.6 17.8 14.1 14.2 13.6
1-Phase 300 A at 32
VDC, 60%
Duty Cycle*
60.8 54.6 29.7 25.4 19.9 11.7 11.2
*See Section 2-3 for Duty Cycle Rating.
2-2. Volt-Ampere Curves
217 836-A / 217 837-B
Volt-amperecurves show minimum
and maximum voltage and amper-
age output capabilities of welding
power source. Curves of other set-
tings fall between curves shown.
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500
50%
75%
10 0 %
25%
0%
AMPERAGE
VOLTS
A. CC Mode
GTAW
MAX
SMAW
MAX
SMAW
80A
ARC
CONTROL
GTAW
MN
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500
VOLTS
B. CV Mode
AMPERAGE
MAX
MIN

TM-229 409 Page 4 Extreme 360
6 Minutes Welding 4 Minutes Resting
2-3. Duty Cycle And Overheating
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 40% duty cycle. To
achieve 60% duty cycle
change cord to 6 AWG.
YExceeding duty cycle can
damage unit and void
warranty.
60% Duty Cycle
Overheating 0
15
A or V
OR
Reduce Duty Cycle
Minutes
Ref. 216 568-A
Notes

TM-229 409 Page 5
Extreme 360
SECTION 3 −INSTALLATION
3-1. Selecting a Location
loc_2 3/96 - Ref. ST-151 556 / Ref. 803 691-C
1 Lifting Handles
Use handles to lift unit.
2 Hand Cart
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.
YSpecial installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
24 in
(610 mm)
17 in
(432 mm)
12-1/2 in
(318 mm)
Movement
1
2
YDo not move or operate unit
where it could tip.
Location 4
3
Dimensions And Weight
18 in
(460 mm)
18 in
(460 mm)
80 lb (36.3 kg)
1

TM-229 409 Page 6 Extreme 360
3-2. Connecting 1-Phase Input Power
804 531-A
YInstallation must meet all Na-
tional and Local Codes −have
only qualified persons make
this installation.
YDisconnect and lockout/tag-
out input power before con-
necting input conductors from
unit.
YAlways connect green or
green/yellow conductor to
supply grounding terminal
first, and never to a line termi-
nal.
.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
removingcover to 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.
7
6
L1
L2
1
=GND/PE
Earth
Ground
3
1
8
9
10
Tools Needed:
1
6
54
2
3

TM-229 409 Page 7
Extreme 360
3-3. Connecting 3-Phase Input Power
804 531-A
YInstallation must meet all National
and Local Codes −have only quali-
fied persons make this installation.
YDisconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
YAlways connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
.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.
= GND/PE Earth Ground
L1
2
1
L2
L3
3
3
4
5
6
7
Tools Needed:

TM-229 409 Page 8 Extreme 360
3-4. Electrical Service Guide
YCAUTION: INCORRECT INPUT POWER can damage this welding power source. Phase to ground
voltage shall not exceed +10% of rated input voltage.
Actual input voltage should not be 10% less than minimum and/or 10% more than
maximum input voltages listed in table. If actual input voltage is outside this range,
output may not be available.
NOTE
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 270 60 35 30 25
Normal Operating 380 80 45 40 30
Min Input Conductor Size In AWG/Kcmil 48 8 10 12 12
Max Recommended Input Conductor Length In Feet (Meters) 72
(22) 89 (27) 176 (54) 140 (43) 219 (67)
Min Grounding Conductor Size In AWG/Kcmil 48 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 245 40 25 20 15
Normal Operating 360 50 30 25 20
Min Input Conductor Size In AWG/Kcmil 48 10 12 14 14
Max Recommended Input Conductor Length In Feet (Meters) 119
(36) 96 (29) 175 (53) 150 (46) 234 (71)
Min Grounding Conductor Size In AWG/Kcmil 410 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” (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 9
Extreme 360
3-5. Weld Output Receptacles And Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less 150 ft
(45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m)
Weld Output
Terminals Welding Amperes
10 −60%
Duty
Cycle
60 −100%
Duty
Cycle 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
Socket* Socket Information
24 VOLTS AC A24 volts ac. Protected by circuit breaker CB2.
AJ
B
KI
24 VOLTS AC
BContact closure to A completes 24 volts ac
contactor control circuit.
B
KI
CLNH 115 VOLTS AC I115 volts ac. Protected by circuit breaker CB1.
CNH
DMG
EF
115 VOLTS AC
JContact closure to I completes 115 volts ac
contactor control circuit.
COutput to remote control; 0 to +10 volts dc, +10
volts dc in MIG mode.
REMOTE
OUTPUT
DRemote control circuit common.
OUTPUT
CONTROL E0 to +10 volts dc input command signal from
remote control.
MCC/CV select
A
/
VFCurrent feedback; +1 volt dc per 100 amperes.
A/V
AMPERAGE
VOLTAGE HVoltage feedback; +1 volt dc per 10 output recep-
tacle volts.
GND
GCircuit common for 24 and 115 volts ac circuits.
GND KChassis common.
*The remaining sockets are not used.

TM-229 409 Page 10 Extreme 360
‘
3-7. Optional Gas Valve Operation And Shielding Gas Connection
Ref. 803 705-A / Ref. 803 691-C
Obtain gas cylinder and chain to
running gear, wall, or other station-
ary support so cylinder cannot fall
and break off valve.
1 Cylinder
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 Gas In Fitting
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 fitting.
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).
4
3
1
2
GAS IN
GAS OUT
5

TM-229 409 Page 11
Extreme 360
SECTION 4 −OPERATION
V/A ADJUST
ARC CONTROL
ARC CONTROL
REMOTE ELECTRODE HOT
4-1. Front Panel Controls
1 Power Switch
.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 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.
23 4
57
6
Ref. 803 692-B / Ref. 212 064
1

TM-229 409 Page 12 Extreme 360
4-2. Meter Functions
The meters display the actual weld output values for approximately three seconds
after the arc is broken.
NOTE
Mode Meter Reading At Idle Meter Reading While Welding
Scratch
Start TIG
VA
Actual Volts (OCV) Preset Amps
71.7 85
Actual Volts Actual Amps
VA
10.3 85
Lift-Arc TIG
Actual Volts Preset Amps
VA
14.1 85
Actual Volts Actual Amps
VA
10.3 85
TIG
Blank Preset Amps
VA
85
Actual Volts Actual Amps
VA
10.3 85
MIG
Preset Volts Blank
VA
24.5
Actual Volts Actual Amps
VA
24.5 250
Pulsed
MIG
Pulse Display Pulse Display
VA
PPP PPP
Actual Volts Actual Amps
VA
24.5 250
CC
Blank Preset Amps
VA
85
Actual Volts Actual Amps
VA
24.5 85
Stick
Actual Volts (OCV) Preset Amps
VA
71.7 85
Actual Volts Actual Amps
VA
24.5 85
V-Sense
Feeder
Flashes OCV And Preset Blank
VA
71.7
Actual Volts Actual Amps
VA
24.5 250
4-3. Mode Switch Settings
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.
NOTE
Mode Switch Setting
Process
Output On/Off Control
M
o
d
e
S
w
i
tc
h S
ett
i
ng
P
rocess
O
utput
O
n
/Off C
ontro
l
Scratch Start TIG 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 13
Extreme 360
4-4. Lift-Arc TIG Procedure
With Process Switch in the Lift-Arc
TIG position, start an arc as follows:
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
lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
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.
1
1 −2
Seconds
“Touch”
Do NOT Strike Like A Match!
2
Ref. S-156 279
4-5. Stick Start Procedure
With Stick selected, start arc as fol-
lows:
1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to high.
If electrode sticks to workpiece, use
a quick twist to free it.
Low OCV Stick
The unit can be optionally config-
ured for low open circuit voltage
(OCV) operation. When the unit is
configured for low OCV operation
only a low sensing voltage (approxi-
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.
1
2
3

TM-229 409 Page 14 Extreme 360
SECTION 5 −THEORY OF OPERATION
Power Interconnect Board
PC2
Remote 14-Pin Receptacle
RC50
Arc
Control
Voltmeter
VAmmeter A
Front Panel And Display Board PC3
Voltage/
Amperage
Adjust
Process
Selector
Switch
Weld
Process
Control
Positive (+) Output Voltage Feedback
Negative (−) Output Voltage Feedback
Ribbon Cable
24 VAC
115 VAC
Boost Gate Signal
Optional
Auxiliary Power
115 VAC
Receptacle
Input Boost Inductor
Current Feedback
Input Rectifier Voltage
Bus Voltage
Current
Transformer
CT1
456
78
9
123
10
20
21 21
22 23
24
25 26
27 ♦
Inverter
Module
Mod2
Bus
Capacitors
C12, C13
Boost
Snubber
Inductor
L2
Snubber
Resistor
Module
RM1
Boost
Input
Inductor
L1
Input
Pre-Regulator
Module
Mod1
Power
Switch
S1
1 Phase
or
3 Phase
Input
Power

TM-229 409 Page 15Extreme 360
Weld Circuit
Optional
♦
Stick
Boost
Rectifier
SR1
Stick
Boost
Inductor
L4
Stick
Boost
Relay
CR1
Main
Transformer
T1
Output
Diodes
D1 & D2
181716
1312
Series
Capacitor
C15
11
Output
Stabilizer
L3
Negative (−)
Weld
Output
Receptacle
Work
15
19
Positive (+)
Weld
Output
Receptacle
Output
Current
Sensor
HD1
14 15
Electrode
Optional
Gas
Solenoid
GS1
Fan
Motor
FM1
35 36
Output Current Feedback
Primary
Heatsink
Thermistor
RT-2
Secondary
Heatsink
Thermistor
RT-1
37 38
Control
Transformer
T2
Circuit
Breaker
CB2
Circuit
Breaker
CB1
32
33
34
115 VAC
24 VAC
34 VAC
Center
Tapped
665
VAC
Inverter Gating Signals
Main Transformer
Current Feedback
Boost
Control
Auxiliary
Power
Module
Inverter
Control
31
3029
28
Control/Auxiliary Power
PC1
♦
Primary Circuit
Control Circuit
115 VAC

TM-229 409 Page 16 Extreme 360
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 &
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
MOD1.
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 & 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 unbalanced
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-Pin 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/AuxiliaryPower
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-pin 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
overtemperatureshutdown.