Thermal Dynamics COUGAR 125 Service Manual Download Page 1

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Manual No. 0-2717

July 30, 1999

Service Manual

Includes:
• 12 Amp Power Supply
• PCH-10 Torch with Leads
• Work Cable with Clamp
• Input Power Cable

For Models:
• 100 VAC 50Hz, 110 VAC 60Hz
• 120 VAC 50Hz
• 120 VAC 60Hz
• 220 VAC 50Hz
• 208/230 VAC 60Hz

Summary of Contents for COUGAR 125

Page 1: ...17 July 30 1999 Service Manual Includes 12 Amp Power Supply PCH 10 Torch with Leads Work Cable with Clamp Input Power Cable For Models 100 VAC 50Hz 110 VAC 60Hz 120 VAC 50Hz 120 VAC 60Hz 220 VAC 50Hz 208 230 VAC 60Hz ...

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Page 3: ...tion Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1998 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liabil ity to any party for any loss or damage caused by any error or omission in the COUGAR Plasm...

Page 4: ...ds Troubleshooting 14 4 0 REPAIRS REPLACEMENT PROCEDURES 14 4 1 General Information 14 4 2 Removing Cover Handle 15 4 3 Torch Head Assembly Replacement 15 4 4 Torch Switch Only Replacement 16 4 5 Capacitor Replacement 17 4 6 Control PC Board Replacement 17 4 7 Power Relay Replacement 17 4 8 ON OFF Power Switch Replacement 18 4 9 Fan Replacement 18 4 10 Diode Bridge Rectifier Replacement 18 4 11 Re...

Page 5: ...r head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any met als which may contain one or more of the follow ing Antimony Chromium Mercur...

Page 6: ...s always wear a welding hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or s...

Page 7: ...er davantage ou qui contribue à l efficacité de fonctionnement du système ATTENTION Toute procédure pouvant résulter l endommagement du matériel en cas de non respect de la procédure en question AVERTISSEMENT Toute procédure pouvant provoquer des blessures de l opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la procédure en question 1 5 Precautions De...

Page 8: ...réparation Lisez et respectez toutes les consignes du Manuel de consignes INCENDIE ET EXPLOSION Les incendies et les explosions peuvent résulter des scories chaudes des étincelles ou de l arc de plasma Le procédé à l arc de plasma produit du métal des étincelles des scories chaudes pouvant mettre le feu aux matières com bustibles ou provoquer l explosion de fumées inflammables Soyez certain qu auc...

Page 9: ...f Documents U S Government Printing Office Washington D C 20402 4 NormeANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l InstitutAméricain des Normes Nationales Ameri can National Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible auprès de l American National Stan...

Page 10: ...PRÉPARATIONÀLACOUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX disponible auprès de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTEC TION RESPIRATOIRE disponible auprès de l American National Standards Institute 1430 Broadway New York NY 10018 ...

Page 11: ...dardsAssociation standard C22 2 number 60 forArc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine design and...

Page 12: ...ucts shall be as follows with the exception of XL Plus Series CutMaster 80XL Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of sale by such distributor to the Purchaser and with the further limitations on such two 2 year period see chart below The limited warranty period for XL Plus Series and CutMaster 80XL shal...

Page 13: ...tter Information in this edition is particularly applicable to the Troubleshooting and Repair of the equipment and is intended for use by properly trained Service Technicians familiar with this equipment Read this manual and the COUGAR 125 Operating Manual 0 2716 thoroughly A complete understanding of the capabilities and functions of the equipment will assure obtaining the performance for which i...

Page 14: ...nit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot ing techniques 3 2 Periodic Inspection Maintenance The COUGAR 125 Operating Manual 0 2716 describes the inspection and maintenance procedures which should be performed at periodic intervals Routine Maintenance ensures optimum performance of equipment and can pre vent the user fro...

Page 15: ...resulting in a very smooth forgiving system This also means that the torch tip will wear fairly rapidly if you pilot for an extended time or cut with too great a standoff es sentially switching from a transferred cutting arc back to the constant DC pilot arc The best way to prevent this is to pilot for no more than 5 seconds at a time or start with the torch in contact with the material and drag c...

Page 16: ...he power switch is switched on go to next step If the circuit breaker or fuse is okay replace Fan 2 Faulty Transformer Assembly or Capacitor a With the Fan still disconnected disconnect two leads from the Transformer that are connected to the Capacitor C13 then apply power If the circuit breaker or fuse opens after power is applied the Capacitor is shorted Replace Capacitor C13 If the circuit brea...

Page 17: ...rrect torch parts a Check that all torch parts are in good condition and designed for use in the PCH 10 torch Re place worn parts as necessary 2 Parts not assembled correctly a Reassemble torch parts 3 Damaged torch or leads a Check per subsection 3 6 Torch and Leads Troubleshooting 4 Faulty Control PCB a Listen for a faint sharp clicking noise at about 3 4 clicks second from the Ferrite CoreAssem...

Page 18: ...head from the lead and check the torch head separately B Checking Torch Lead If the torch head assembly is okay check the torch lead by measuring the resistance between the positive pilot lead connector and the negative lead fitting If continu ity is found the insulation between the torch leads is breaking down and the torch and leads assembly should be replaced NOTE The lead cannot be replaced wi...

Page 19: ...le halves from the torch and leads assembly then complete the following a Disconnect positive pilot lead connection at torch head by removing pilot lead screw B b Cut tie wrap from torch hose C c Using X acto knife or other small cutting tool cut torch lead 1 25 4 mm from the end of black sleeve D to reveal butt splice 4 Pull torch head away from torch lead to expose 1 2 3 4 of cable 5 Clamp down ...

Page 20: ...4 2 Installing Torch Head Assembly 4 4 Torch Switch Only Replacement NOTE This procedure requires the following tools or equivalent screwdriver soldering iron flux WARNING Disconnect primary power to the system before dis assembling the torch leads or power supply 1 Remove consumable parts from front end of torch 2 Remove the six screws from the torch handle as sembly and remove torch and leads as...

Page 21: ...essary 5 Remove PC Board from unit by completing the fol lowing a Remove two 2 fastener plastic push ons from key slotted holes in corners of PC Board b Slide PC Board up or down to disengage then remove from unit 6 Install replacement key slotted PC Board by plac ing PC Board over standoffs and sliding Board down into position 7 Push a white fastener plastic push on into each keyhole just above s...

Page 22: ...12 24 25 Install switch with prongs posi tioned towards the top of the unit 5 To connect the input wiring to the ON OFF Switch refer to subsection 4 16 steps 6 7 6 Install cover handle by reversing step 1 keeping in mind the following NOTE Before replacing cover make sure all wires are care fully positioned to avoid pinching when the cover and handle are secured 4 9 Fan Replacement 1 Remove cover ...

Page 23: ...ting 3 Disconnect wire connections Pull L4 connector through loose tie wrap if available 4 Remove two Ferrite Core Assembly screws which hold the Transformer Ferrite Core Assembly in position Remove Transformer Ferrite Core As sembly from unit 5 Install replacement Transformer Ferrite Core As sembly by reversing steps 1 4 keeping in mind the following a Pull L4 through loose tie wrap if available ...

Page 24: ...o make all the connections inside the unit 8 Reconnect all connections by reversing step 2 9 Replace cover by reversing step 1 4 15 Work Cable Replacement 1 Remove cover handle from unit per subsection 4 2 2 Disconnect the Work Cable Faston from mount ing tab on bottom of Rectifier 3 LoosenStrainReliefandremoveWorkCablefrom unit 4 Install Strain Relief on replacement Work Cable 5 1 2 inches from F...

Page 25: ... Wire Black Wire 5 White Blue Wire 1 4 2 5 Black Wire 21 Black Wire 6 Black Wire 22 Black Brown Wire White Blue Wire Figure 4 6 Input Power Cable Replacement Strain Relief Primary Input Power Cable Ground A 02653 Green Wire from Primary Input Power Cable Green Wire with Tracer Connect to Compressor Frame Ground ON OFF Input Power Switch Figure 4 7 Ground Connections 8 Tighten Strain Relief 9 Repla...

Page 26: ...GAR 125 208 230 60Hz 9 7687 8 1 Regulator High Flow 8 4382 9 1 Pressure Gauge 9 0051 10 1 Solenoid SOL1 9 0050 11 1 Resistor 0 5ohm 55 watt 10 3 16 Faston R30 9 0011 12 1 Resistor 1Kohm 55 watt 5 3 16 Faston R31 9 0012 13 1 Work Cable 15 ft 4 6 m w Red Handles 9 0013 14 1 Input Power Cable 6 5 ft min 2 m COUGAR 125 100V 50Hz 110V 60Hz Power Cable 14 3 w molded plug 9 0052 COUGAR 125 120V 50Hz Powe...

Page 27: ...ve cover unfasten 4 side panel screws 2 handle screws 2 end panel screws A Screw 6 32 x 3 3 4 Lg Phil Pan Hd Zinc B 6 32 Regular Nylon Lock Nut Zinc Plated C 5 16 18 x 1 3 4 Unc Cap Socket Head Bolt D 10 32 x 5 Pph Swageform Stl Zn Parker Kalon E Screw Black 6 32 x 1 2 Pph Swageform Steel F 10 32 Kepnut w Star Washer Mild Steel HARDWARE QTY 2 2 2 4 2 2 NOTE Replacement hardware can be purchased lo...

Page 28: ...0 CE 1 2811 5 COUGAR 125 208 230 60Hz PCH 10 1 2111 2 B Power Supply Only Includes Power Supply Input Power Cord and Work Cable COUGAR 125 100V 50Hz 110V 60Hz 3 2112 COUGAR 125 120V 50Hz CE 3 2113 COUGAR 125 120V 60Hz 3 2111 COUGAR 125 220V 50Hz CE 3 2115 COUGAR 125 208 230 60Hz 3 2110 C Torch Leads Only Includes Torch Leads 90 Nylon Air Compressor Fitting Torch Leads alone are not replaceable PCH...

Page 29: ...g 1 1 PCH 10 70 Torch HeadAssembly 9 0016 2 1 Torch Handle Only 9 0019 3 1 Torch Switch 9 1058 4 1 Standard Electrode 9 6006 5 1 PCH 10 Tip 9 4476 6 1 Gas Distributor 9 6007 7 1 Shield Cup 9 6003 8 1 Torch Head Split Holders PCH 10 70 9 6259 9 1 PIP Parts In Place WireAssembly 9 6290 10 1 O Ring 8 0533 11 1 Torch Switch Button 8 4256 12 2 Torch Switch Button Springs 9 6292 1 1 4 NPT Hose Fitting N...

Page 30: ...COUGAR 125 Plasma Cutter 26 Service Manual 0 2717 APPENDIX I INTERCONNECTING DIAGRAM A 02250 ...

Page 31: ...Service Manual 0 2717 27 COUGAR 125 Plasma Cutter A 02250 1 1 ...

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