Thermal Dynamics COUGAR 125, Service Manual

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COUGAR 125 Plasma Cutter 10 Service Manual 0-2717
B. Input/Output Specifications
Model Hz
Input
Amps
RMS
Output
Amps
(DC)
Output
Voltage
(DC)
Duty
Cycle %
100/110V 50/60 25/24 12 85 30
120V 50 22 12 95 30
120V 60 20 12 70 30
220V 50 13 12 85 30
208/230V 60 10 12 78 30
2.5 Dimensions
16.0 in
(406 mm)
9.0 in
(229 mm)
10.0 in.
(254 mm)
A-02235
Figure 2-1 Power Supply Dimensions
A-02006
7.98 in (203 mm)
1.06 in (27 mm)
2.95 in
(75 mm)
Figure 2-4 Torch Dimensions
3.0: SERVICE
TROUBLESHOOTING
3.1 Introduction
This section provides service diagnostics for the COU-
GAR 125 Plasma Cutter with PCH-10 Torch, aiding the
technician to isolate faulty subassemblies.
Under no circumstances are field repairs to be attempted
on Printed Circuit Boards or other subassemblies of this
unit. Evidence of unauthorized repairs will void the fac-
tory warranty.
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. 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 from encountering problems with this equip-
ment. Refer to that manual for instructions on power
supply and torch maintenance.
3.3 Common Cutting Faults
Poor or lackluster performance can often be improved
by slight modifications to technique or equipment. For
example:
A. Insufficient Penetration
1. Cutting speed too fast
2. Torch tilted too much
3. Metal too thick
4. Worn torch parts
5. Standoff too high
6. Line voltage too low
7. Extension cord with inadequate rating
B. Main Arc Extinguishes
1. Cutting speed too slow
2. Torch standoff too high from workpiece
3. Work cable disconnected
4. Worn torch parts
C. Excessive Dross Formation
1. Cutting speed too slow
2. Torch standoff too high from workpiece
3. Worn torch parts