Page 1
Service Manual
Includes:
• 12 Amp Power Supply
• PCH-10 Torch with Leads
• Work Cable with Clamp
• Input Power Cable
July 30, 1999
For Models:
• 100 VAC 50Hz, 110 VAC 60Hz
• 120 VAC 50Hz
• 120 VAC 60Hz
• 220 VAC 50Hz
• 208/230 VAC 60Hz
Manual No. 0-2717
Page 2
Page 3
WARNING
WARNING
Read and understand this entire manual and your employer’s
safety practices before installing, operating, or
servicing the equipment.
While the information contained in this manual represents our
best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
COUGAR 125 Plasma Cutter
Service Manual Number 0-2717
Published by:
Thermal Dynamics Corporation
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 Plasma Cutter Service Manual,
whether such error results from negligence, accident, or any
other cause.
Printed in the United States of America
July 30, 1999
Page 4
TABLE OF CONTENTS
1: GENERAL INFORMATION ...............................................................................................................1
1.1 Notes, Cautions and Warnings ........................................................................................1
1.2 Important Safety Precautions .......................................................................................... 1
1.3 Publications .............................................................................................................. ......2
1.4 Note, Attention et Avertissement .................................................................................... 3
1.5 Precautions De Securite Importantes ............................................................................. 3
1.6 Documents De Reference................................................................................................5
1.7 Declaration of Conformity ............................................................................................... 7
1.8 Statement of Warranty .................................................................................................... 8
2.0 INTRODUCTION...........................................................................................................................9
2.1 Scope Of Manual .............................................................................................................9
2.2 General Service Philosophy............................................................................................. 9
2.3 Service Responsibilities..................................................................................................9
2.4 Technical Specifications ................................................................................................. 9
2.5 Dimensions .................................................................................................................. 10
3.0: SERVICE TROUBLESHOOTING .................................................................................................. 10
3.1 Introduction ..................................................................................................................10
3.2 Periodic Inspection & Maintenance............................................................................... 10
3.3 Common Cutting Faults ................................................................................................ 10
3.4 Common Operating Problems ........................................................................................ 11
3.5 Troubleshooting Guide .................................................................................................. 11
3.6 Torch & Leads 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 Resistor Replacement ................................................................................................. 19
4.12 Transformer/Ferrite Core Assembly Replacement ...................................................... 19
4.13 Input Voltage Changeover (For 208/230 VAC Service Only) ......................................... 19
4.14 Torch & Leads Replacement ....................................................................................... 20
4.15 Work Cable Replacement............................................................................................. 20
4.16 Primary Input Power Cable Replacement ..................................................................... 21
5.0 PARTS LIST ............................................................................................................................... 21
5.1 Returns......................................................................................................................... 21
5.2 Power Supply Replacement Parts ................................................................................... 22
5.3 Parts Replacement ........................................................................................................ 24
5.4 Options & Accessories (not shown) ................................................................................ 24
5.5 Torch Replacement Parts .............................................................................................. 25
APPENDIX I: INTERCONNECTING DIAGRAM.................................................................................... 26
Page 5
1: GENERAL
INFORMATION
1.1 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A pr ocedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A pr ocedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.2 Important Safety Precautions
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your 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. Y ou must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always r ead the Material Safety Data Sheets (MSDS)
that should be supplied with the material you are
using. These MSDSs will give you the information
regarding the kind and amount of fumes and gases
that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection
1.3, Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-571 1 or your local distributor if you have any
questions.
6/22/99 1 GENERAL INFORMATION
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
• W ear dry gloves and clothing. Insulate yourself from
the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
Page 6
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.3, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have held
combustibles.
• Provide a fire watch when working in an area wher e
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. T rapped hydr ogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.3, Publications, in this manual.
PLASMA ARC RAYS
Plasma Ar c Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly pr otected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect 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 shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
1.3 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, W ashington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S.
Government Printing Office, W ashington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standar ds Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
GENERAL INFORMATION 2 6/22/99
Page 7
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFP A Standard 70, NA TIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply
Association, 1900 Ar ch Street, Philadelphia, PA 19103
14. American Welding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREP ARA TION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018
1.4 Note, Attention et
Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
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 Securite
Importantes
AVERTISSEMENT
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-571 1 ou votre distributeur
local si vous avez des questions.
FUMÉE et GAZ
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
6/22/99 3 GENERAL INFORMATION
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
Page 8
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 4.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
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 combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
P AS couper les alliages en aluminium sous l’eau ou
sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 4, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de plasma
produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur . Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
GENERAL INFORMATION 4 6/22/99
Page 9
• Use the shade of lens as suggested in the following
chart per ANSI/ASC Z49.1:
• Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.6 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superin-
tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (American 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 Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage (A WS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de
la American Welding Society, 550 N.W . LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFP A), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la Na-
tional Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de
la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ
DU SOUDAGE, disponible auprès de l’Association
Nationale de Fournitures de Soudage (National
Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
6/22/99 5 GENERAL INFORMATION
Page 10
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDA TIONS DE PRA TIQUES
SURES POUR LA PRÉPARATION À LA COUPE 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 PROTECTION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018
GENERAL INFORMATION 6 6/22/99
Page 11
1.7 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
W est Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standar ds and technical requirements among them ar e:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds 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
manufacturing process. This is to ensure the pr oduct is safe, when used according to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactur ed product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible r epresentative: Steve W ard
Director of Operations
Thermadyne UK
Chorley England
6/22/99 7 GENERAL INFORMATION
Page 12
1.8 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below , Thermal shall, upon notification ther eof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standar d industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
P ARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products 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 shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years fr om date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus Series & Parts Parts
PAK Units, Power Supplies CutMaster 80XL Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consolles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective May 6, 1999
GENERAL INFORMATION 8 6/22/99
Page 13
2.0 INTRODUCTION
2.1 Scope Of Manual
This manual provides service instructions for the Thermal Dynamics® COUGAR 125 Plasma Cutter.
Information in this edition is particularly applicable to
the T r oubleshooting 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 it was designed.
2.3 Service Responsibilities
The Service T echnician should be familiar with the equipment and its capabilities and should be prepared to recommend arrangements of components which will provide the most efficient layout, utilizing the equipment to
its best possible advantage.
Maintenance work should be accomplished in a timely
manner. If problems are encountered, or the equipment
does not function as specified, contact T echnical Services
Department in West Lebanon for assistance.
2.4 Technical Specifications
A. System Specifications
2.2 General Service Philosophy
Several key points are essential to properly support the
application and operation of this equipment.
A. Application
The equipment should satisfy the customer ’s requirements as supplied and as described in Section 3 of this
manual. Be sure to confirm that the equipment is capable
of the application desired.
B. Modifications
No physical or electrical modifications other than selection of standard options and accessories are to be made
to this equipment.
C. Customer/Operator Responsibilities
It is the customer/operator's responsibility to maintain
the equipment and peripheral accessories provided by
Thermal Dynamics in good operating order in accordance
with the procedures outlined in the Operating Manual,
and to protect the equipment from accidental or malicious damage.
D. Repair Restrictions
The electronics consists of a Printed Circuit Board Assembly which must be carefully handled, and must be replaced as a unit. No replacement of printed circuit solder-mounted components is allowed except as noted in
this manual. If PC Board is to be returned, the replaced
Printed Circuit Board Assembly must be properly packaged in protective material and returned intact per normal procedures.
System Specifications
Input/Out put
Specific a tions See subsecti on 2.4 B
Dut y Cycle See subs ection 2.4 B
Maximum OCV 280 VDC
Pilot Circuitry Capacitive Disc harge (CD), Constant DC
Weight with Leads 52 lbs (24 k g)
Power Supply L 16 in. (406 mm)
Dimensions W 9 in. (229 mm)
H 10 i n. (254 mm)
Work Cable 15 f t. (4.6 m)
Input Power Cable 6.6 f t. (2 m) minimum
Torch Style PCH-10 70°
Torch Dimensions L 8 in. (203 mm)
W 3 in. (75 mm)
Cutting Rating 12 Amps Max. Straight Polarit y
Duty Cycle 100% @ 12 amps on 1/8 in. (3.2 mm) metal
Cutting Range 28 ga. (.5mm) - 10 ga.(3 mm) carbon steel
Severance Most met als up to 3/16 in. (4.8 mm)
Pierce Rating 1/16 in. (1.6 m m)
Transfer Distance Approx. 1/8 in. (3.2 m m)
Gas Requirements Type: Compressed Air (External)
Operating Pressure: 25 psi (1.7 bar)
Flow: 60-80 sc fh @ 25 psi (see no te below)
(28.3-38 lpm @ 1.7 bar)
Leads Length 20 ft. (6.1 m)
NOTE
Customer-supplied Compressor should supply 150200 scfh @ 50 PSI (3.5 bar)
Service Manual 0-2717 9 COUGAR 125 Plasma Cutter
Page 14
B. Input/Output Specifications
Input
Model Hz
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
Amps
RMS
Output
Amps
(DC)
Output
Voltage
(DC)
Duty
Cycle %
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 troubleshooting techniques.
2.5 Dimensions
10.0 in.
(254 mm)
16.0 in
(406 mm)
Figure 2-1 Power Supply Dimensions
1.06 in (27 mm)
7.98 in (203 mm)
A-02235
9.0 in
(229 mm)
A-02006
2.95 in
(75 mm)
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 prevent the user from encountering problems with this equipment. 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
Figure 2-4 Torch Dimensions
3.0: SERVICE
TROUBLESHOOTING
3.1 Introduction
This section provides service diagnostics for the COUGAR 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 factory warranty.
COUGAR 125 Plasma Cutter 10 Service Manual 0-2717
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
Page 15
D. Short Torch Parts Life
1. Exceeding system capability (material too thick)
2. Excessive pilot arc time
3. Improperly assembled torch
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 cut”, that is, hold
the tip in direct contact with the material to be cut.
For some materials, holding a slight standoff (1/
16")(1.6 mm) may provide a better cut.
4. Incorrect gas pressure/flow
5. Ground or work lead not connected
3.4 Common Operating
Problems
Getting used to the way the system sounds and feels while
it is operating properly will help to determine the nature
of problems if they arise.
A. Power Source Related
If the available 120V service is saggy, pilot and cut performance will be degraded. In some cases, the service
circuit breaker may open during use. Some things that
will help:
• Use a service fused or circuit breaker for correct
amperage (Refer to Operator Manual 0-2716, subsection 4.0-D for service amperage.)
• Use heavy gauge extension cords (Refer to Operating Manual 0-2716 for sizes).
• Use as short an extension cord as possible.
• T ry dif ferent outlets on different branch cir cuits. Use
the one that gives the strongest pilot.
B. Power Supply/Torch Related
NOTE
Piloting is harder on parts life than actual cutting
because the pilot arc is directed from the electrode
to the tip rather than to a workpiece. Whenever
possible, avoid excessive pilot arc time to improve
parts life.
2. Torch Standoff
Improper standoff (the distance between the torch tip
and workpiece) can adversely affect tip life as well as
shield cup life. Reducing standoff will generally result in a more square cut.
NOTE
Although the COUGAR 125 will cut using standoff, this unit is primarily a drag-cutting machine.
3.5 Troubleshooting Guide
A. General
The troubleshooting covered in this Service Manual requires power supply disassembly and live measurements.
T roubleshooting and r epairing this unit is a process which
should be undertaken only by those familiar with high
voltage high power electronic equipment.
In some instances when the torch switch is pressed there
is no pilot. You may need to try several times before the
torch fires.
If the torch does not fire (no pilot arc) soon after the tor ch
switch is activated, try releasing the torch switch and letting the leads bleed down before trying again. This should
help because the torch fires best at a lower voltage with
lower air pressure at the torch.
C. Cutting Related
1. Piloting
One of the features of this plasma cutter is the constant DC pilot. This means the plasma arc is always
“on”- either as a pilot arc, or a cutting arc, 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 (essentially switching from a transferred cutting arc back
to the constant DC pilot arc).
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 troubleshooting techniques.
B. How To Use This Guide
The following information is a guide to help determine
the most likely causes for various symptoms. The guide
is set up in the following manner:
Service Manual 0-2717 11 COUGAR 125 Plasma Cutter
Page 16
X. Symptom (Bold Type)
1. Cause (Italic Type)
a. Check/Remedy (Test Type)
Locate your symptom, check causes (easiest is usually
first; sometimes the order is important, if noted), then
remedies. Repair as needed being sure to verify that the
unit is fully operational after any repairs.
C. No Power, AC switch on, red (amber for
220V) indicator dark, no fan.
1. No power from wall unit.
2. Faulty Transformer Assembly or Capacitor.
a. W ith 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 breaker or fuse is okay, replace
Transformer.
E. Power OK, fan runs, no air flow
operation or pilot when torch switch
pressed.
a. Test electrical outlet with voltmeter or some
other known good load (trouble light, hand
drill, etc).
If AC line voltage is present, go to next step.
If AC line voltage is not present, replace fuse
or reset circuit breaker.
2. Damaged power cord.
a. Confirm with voltmeter if AC line voltage is
present at input to power switch.
If AC voltage is present, proceed to next step.
If AC line voltage is not present, r eplace power
cord.
3. Power switch faulty.
a. Confirm with voltmeter if AC line voltage is
present at main capacitor (C13) terminals when
power switch is on.
If AC line voltage is not present, r eplace power
switch.
D. Power OK, service circuit breaker or
fuse opens after the power switch is
switched on.
NOTE
Proceed with troubleshooting for these components
in order:
1. Faulty Fan.
1. Air supply not connected or turned on.
a. Connect air supply or turn it on.
2. Shield cup loose, PIP not making contact.
a. Reseat the torch parts, tighten shield cup.
3. Unit overtemp.
a. Leave power on so fan can cool unit, test again
after 10 min.
4. Shorted torch parts.
a. Replace torch consumables.
5. Torch switch may have broken or shorted wires.
a. Refer to subsection 3.6, T orch and Leads Trouble-
shooting.
6. Shorted Bridge Rectifier (BR2)
a. If the Rectifier (upper) is hot and the T ransformer
is buzzing or heating up, the rectifier is shorted.
Replace Rectifier.
7 . Faulty Control PCB or Relay
CAUTION
Be sure torch is directed away fr om people or hazards. A pilot arc may start!
a. Push the test button on the side of the Relay. If
the Solenoid opens and the torch operates, the
PCB or Relay has most likely failed.
a. Disconnect the Fan and insulate each of the two
wires going to the Fan with tape, then reapply
power.
If the circuit breaker or fuse opens after the
power switch is switched on, go to next step.
If the circuit breaker or fuse is okay, replace
Fan.
COUGAR 125 Plasma Cutter 12 Service Manual 0-2717
The PCB can be isolated by removing the push
on connectors from the Relay coil and measuring the relay coil with an ohmmeter . If the coil
measures between 50 - 100ohms, the Relay is
good and the PCB should be replaced.
Page 17
If the Gas Solenoid energizes and gas flows
intermittently and arcing can be seen in the Relay Case while the torch switch is held on, the
Relay contacts are worn and the Relay should
be replaced.
3. Damaged torch or leads.
a. Check per subsection 3.6, Torch and Leads
Troubleshooting.
4. Faulty Control PCB.
7. Faulty Gas Solenoid
Check for 12 VDC (momentarily) between Solenoid wires #1 1 & 21. Replace Solenoid if voltage momentarily jumps to 12VDC with torch
switch pressed.
F. Power OK, Fan runs, Solenoid runs
intermittently, Relay Case shows
arcing when the torch switch is held
on.
1. Faulty Relay.
a. If the Solenoid opens intermittently and arcing
can be seen in the Relay Case while the torch
switch is held on, the Relay contacts are worn
and the Relay should be replaced.
G. Power OK, fan runs, Solenoid opens
then closes as soon as the torch switch
is pressed.
1. Shorted, damaged, or incorrect torch parts.
a. Check that all torch parts are in good condition
and designed for use in the PCH-10 torch.
2. Faulty (open) Voltage Divider Resistor.
a. The voltage divider is the top Resistor . Discon-
nect the push-on connectors and measure the
Resistor with an ohmmeter. It should read 1K
ohms. If measurement is not 1K ohms, replace
Resistor.
3. Shorted Bridge Rectifier (BR1).
a. Probable if a loud hum or buzz is heard from
the main Transformer after the Relay actuates.
If hum or buzzing noise exists, replace Bridge
Rectifier. (replace lower Bridge Rectifier, closest to Chassis).
a. Listen for a faint, sharp clicking noise, at about
3-4 clicks/second from the Ferrite Core Assembly. If nothing is heard, the PCB should be replaced.
5. Faulty (open) Pilot Resistor.
a. The Pilot Resistor is mounted closest to the chas-
sis. Disconnect the push on connectors and
measure the resistor with an ohmmeter. It
should read 0.5 ohms (essentially a short).
6. AC input too low.
a. If the AC line is below about 105vac, the torch
may not always start. Try an outlet on a different branch circuit.
7. Faulty Ferrite/Transformer Assembly.
a. The Ferrite Transformer Assembly is used to
generate a high voltage pulse to establish the
pilot arc. Troubleshooting is limited to visual
inspection. The two primary connections and
two secondary connections should be checked
for general integrity and snug fit onto the push
on connectors. The Transformer Assembly itself should be free of large ferrite chips and
cracks along the core.
I. Torch pilots but does not cut well.
1. AC input power too low.
a. Use shortest service from AC outlet to breaker
panel as possible or larger gauge extension cord.
2. Work cable not attached.
a. Check work cable connection.
3. Restricted air flow.
a. Check lead for kinks or pinching restricting air
flow.
H. Power OK, fan runs, air flows, no pilot
or cutting arc with the torch switch
pressed.
1. Worn, contaminated, or incorrect torch parts.
a. Check that all torch parts are in good condition
and designed for use in the PCH-10 torch. Replace worn parts as necessary.
2. Parts not assembled correctly.
a. Reassemble torch parts.
Service Manual 0-2717 13 COUGAR 125 Plasma Cutter
4. Loose shield cup.
a. Tighten shield cup.
5. One or more gas distributor holes blocked.
a. Replace Gas Distributor.
6. Excessive parts wear.
a. Inspect torch consumables and replace as nec-
essary.
Page 18
7. Air pressure set too low.
a. Adjust air pressure.
8. Damaged torch insulator.
a. Check insulator between anode and cathode for
charring per subsection 3.6, Torch and Leads
Troubleshooting.
3.6 Torch & Leads
Troubleshooting
tance (no continuity) should be found. If there is continuity between the two, remove the torch 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 continuity is found, the insulation between the torch leads is
breaking down and the torch and leads assembly should
be replaced.
NOTE
WARNINGS
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
DO NOT touch any internal torch parts while the
AC indicator light on the front panel of the power
supply is on.
Torch parts may get quite hot during normal operation. Always wear light cutting gloves when
changing torch parts just after operating the COUGAR 125 system.
A. Checking the Center Insulator
The Center Insulator separates the negative and positive
charged sections of the torch. If the center insulator does
not provide adequate resistance, current which is intended for the pilot arc may be dissipated into the torch
head, resulting in torch failure.
1. Remove the shield cup, tip, gas distributor, and elec-
trode from the torch.
The lead cannot be replaced without replacing the
torch assembly as well.
If no continuity is found, check the resistance between
the negative plasma lead fitting and the electrode seat in
torch head. If no continuity is found, replace the torch
and leads assembly.
C. Checking Pilot and Switch Control
Wires
Check the pilot and switch control wires for continuity
from one end of the torch lead to the other . If no continuity exists, replace torch and lead assembly.
D. Reassembling Torch and Leads
Replace parts as required, then recheck the torch head,
and lead connections to confirm proper measurements.
If each component is okay, reassemble torch and leads.
4.0 REPAIRS &
REPLACEMENT
PROCEDURES
PCH-10
Electrode
Torch Head Assembly
Gas
Distributor
Figure 3-1 PCH-10 Torch Head Parts Removal
2. Disconnect the torch lead from the power supply to
isolate the torch from power supply circuits. Refer to
Appendix I for Leads connections.
3. Using an ohmmeter (set to 10K or higher), check for
continuity between the electrode seat (negative) and
the brass threads of the torch assembly. Infinite resis-
COUGAR 125 Plasma Cutter 14 Service Manual 0-2717
Tip
Standard
Shield Cup
A-02007
4.1 General Information
• Failures identified on the Transformer/Inductor/
Chassis Assembly cannot be repaired - the entire
power supply must be replaced. Refer to the Parts
List for the catalog number for a replacement power
supply.
• The torch head, torch switch, and torch & leads assembly are replaceable parts. The torch leads alone
are not serviceable; problems encountered in the leads
will require the torch & leads assembly to be r eplaced.
• For instructions on replacing the torch & leads, work
cable & clamp, and input power cable, refer to Operating Manual 0-2716. (Refer to Appendix I, in this
manual, for leads connection diagram.)
• Most replacement hardware can be pur chased locally.
Page 19
WARNINGS
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
4.2 Removing Cover/Handle
1. Remove 2 screws in handle, 2 screws in end panels, and four screws near base to remove cover and
handle from unit.
NOTE
When replacing cover , make sure all wires ar e carefully positioned so that the wires are not pinched
when the cover and handle are secured.
4.3 Torch Head Assembly
Replacement
WARNINGS
6. Cut cable at end of butt splice and remove torch
head assembly (F).
7. Remove orange insulating sleeving from torch head
gas input (G). Note: Sleeving is optional. Some
torch assemblies may not have sleeving.
8. Remove torch O-ring from tor ch split holder (H).
9. Remove the two screws from the torch head split
holder and separate the halves (I).
10. Remove the torch head from the holder. Do not
disturb PIP connections.
Remove Six Screws
A
Disconnect primary power to the system before disassembling the torch or power supply.
Torch parts may get quite hot during normal operation. Always wear light cutting gloves when
changing torch parts just after operating the COUGAR 125 system.
To Remove Torch Head Assembly:
NOTE
Refer to Figure 4-1 for parts identification.
1. Remove consumable parts from front end of torch.
2. Remove six screws from torch handle assembly (A).
3. Remove both torch handle 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.
Switch
Cut Tie Wrap
C
Remove Screws
I
Washer
B
Remove Pilot
Lead Screw
H
O-Ring
Orange T orch
Sleeving
(Optional)
G
1.000
Cut Cable Here
Cut Black
Hose
D
Place Vise
Grips Here
E
F
A-02295
Figure 4-1 Removing Torch HeadAssembly
4. Pull torch head away from torch lead to expose 1/
2"-3/4" of cable.
5. Clamp down with vise grips on black sleeve of
lead so that cable cannot spring back into lead (E).
Service Manual 0-2717 15 COUGAR 125 Plasma Cutter
Page 20
To Install Replacement Torch Head Assembly:
NOTE
4.4 Torch Switch Only
Replacement
Refer to Figure 4-2 for parts identification.
1. Place replacement torch head in torch head split
holder halves and secure with 2 screws removed
in step 9 above (K). Do not disturb PIP connections.
2. Install O-ring removed in step 8 above (L).
3. Optional: Install orange sleeving on replacement
torch head gas input.
4. Place torch head in correct orientation, then insert
lead cable into torch butt slice and crimp (M).
5. Remove vise grips.
6. Lubricate torch head glands lightly with silicone
and push hose back onto barbs up to the point
where the teflon tubing and brass fitting meet (N).
7. Install tie wrap onto hose in correct position (C),
removing any excess.
8. Connect pilot lead to pilot lead terminal by placing
washer between terminal and connector and installing screw (O).
9. Push pilot lead under cable jacket until there is no
excess.
NOTE
This procedure requires the following tools (or
equivalent): screwdriver, soldering iron, flux.
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
1. Remove consumable parts from front end of torch.
2. Remove the six screws from the torch handle assembly and remove torch and leads assembly.
3. Using soldering iron, carefully remove solder wher e
orange wire connects to switch terminal.
NOTE
Be careful not to overheat the torch switch while
removing soldering from terminals.
4. Apply Flux to orange wir e and to switch post. Insert orange wire in switch post hole and solder,
keeping solder at a minimum required for good
joint.
New T orch Head
J
Install Screws
K
A-02296
Install
L
O-Ring
Washer
Install Pilot
Lead Screw
O
T eflon Tubing
Insert Cable Into
Butt Splice & Crimp
Butt Splice
N
4-2 Installing Torch Head Assembly
5. Repeat steps 3 and 4, this time for the white wire.
Torch Switch
To Control
Cable Wiring
Butt Splice
PIP Pin
Shield Cup
PIP Pin
A-00784
Figure 4-3 Torch Switch Schematic
6. Place the torch head in the torch handle bottom.
Carefully return the torch switch and button w/
springs to their proper position. Replace cover on
M
the handle assembly, and screw together with six
screws.
NOTE
Make sure torch switch wires are seated in their
guides so that the wires are not pinched when the
handle is secured.
7. Install consumables parts in front end of torch.
COUGAR 125 Plasma Cutter 16 Service Manual 0-2717
Page 21
4.5 Capacitor Replacement
WARNING
b. Slide PC Board up or down to disengage, then
remove from unit.
6. Install replacement key slotted PC Board by placing PC Board over standoffs and sliding Board
down into position.
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
1. Remove cover/handle from unit per subsection 4.2.
2. Make note of all wire connections and locations to
Capacitor.
3. Remove all wire connections to Capacitor.
4. The Capacitor is held in place by a tab located on
the Transformer frame. Using a screw driver or
similar tool, pry the tab back slightly to allow the
Capacitor to slide out of the bracket.
5. Install replacement Capacitor, by reversing steps
1-4, keeping in mind the following:
a. Make sure the Capacitor is securely positioned
behind tab. Tab may need to be bent.
b. Position wire connector L4 so that it runs along
side the Transformer, avoiding contact with
metal parts.
4.6 Control PC Board
Replacement
NOTES
It may be easier to remove the PC Board if the Capacitor is removed first.
7. Push a white fastener plastic push on into each
keyhole (just above standoffs) to secure the PC
Board into position.
8. Reverse steps 1-4, keeping in mind the following:
a. Make sure J2 is not offset by one or more pins.
b. Install new tie wraps on wires connected to the
PC Board, as necessary.
4.7 Power Relay Replacement
NOTE
The Control PC Board must be moved out of the
way before the Power Relay can be replaced. (It may
be easier to move the Contrl PC Board if the Capacitor is removed first.)
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
1. Remove cover/handle from unit per subsection 4.2.
2. (Optional) Remove Capacitor per instructions in
4.5.
3. Remove PCB from standoffs per subsection 4.6.
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
1. Remove cover/handle from unit per subsection 4.2.
2. (Optional) Remove Capacitor per subsection 4.6.
3. Note all wiring connections and locations to the
PC Board.
4. Disconnect all wire connections to the PC Board,
removing any tie wraps where necessary.
5. Remove PC Board from unit by completing the following:
a. Remove two (2) fastener plastic push ons from
key slotted holes in corners of PC Board.
Service Manual 0-2717 17 COUGAR 125 Plasma Cutter
4. Slide PC Board away from Relay.
5. Note all wiring connections and locations to the
Relay.
6. Remove wirings connected to Relay.
7. Slide Relay out from bracket, towards the center of
the unit.
8. Install replacement Relay, by reversing the above
steps, keeping in mind the following:
a. Position wire connector L4 so that it runs along
side the T ransformer , NOT acr oss the top of the
Transformer.
Page 22
4.8 ON/OFF Power Switch
Replacement
NOTE
NOTE
Before replacing cover, make sure all wires are car efully positioned to avoid pinching when the cover
and handle are secured.
When ordering a replacement ON/OFF Switch, order the same type as found in your unit. (Color is
not important.)
Model
A
B
Switch
Type
4 prong 1"x1-1/ 4" red 115 9-0021
4 prong 1"x1-1/ 4"
Dimensions
Neon
Color
amber
or red
Volta ge
220 9- 0029
Catalog
Number
W ARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
A. Model A:
1. Remove cover/handle from unit per subsection 4.2.
2. Note all wiring connections and locations to the
On/Off Switch.
3. Disconnect wires to ON/OFF Switch.
4. Push plastic clips down on top side of Switch and
slide Switch out by pulling it through front panel.
5. Install replacement ON/OFF Switch, by reversing
steps 1-4, keeping in mind the following:
a. Position wire connector L4 so that it runs along
side the T ransformer , NOT acr oss the top of the
Transformer.
B. Model B:
1. Remove cover/handle from unit per subsection 4.2.
2. Disconnect wires to ON/OFF Switch.
3. Push plastic clips down on top end of Switch and
slide Switch out through front panel.
4. Check the numbering sequence of the prongs on the
ON/OFF Switch and install the switch as follows:
a. 1,2,4,5 - Install switch with prongs positioned
towards the bottom of unit.
4.9 Fan Replacement
1. Remove cover/handle from unit per subsection 4.2.
2. Locate Fan on front panel of unit.
3. For reference, mark two wires connected to the right
side of the Fan with correct connection designation, then disconnect two wires.
4. Remove two (2) rivets* securing Fan to the front
panel and carefully remove Fan from unit. (Gauge
Assembly may have to be rotated slightly in order
to remove Fan).
NOTE
*Some models may use screws instead of rivets.
5. Install replacement Fan. Refer to Figure 5.1 for
proper Fan orientation (or refer to the arrows marked
on the Fan chassis).
NOTE
Proper Fan orientation is essential to ensure proper
cooling of power supply parts.
4.10 Diode Bridge Rectifier
Replacement
NOTE
Refer to subsection 4.1, General Information, for
information about wire harnesses.
1. Remove cover/handle from unit per subsection 4.2.
2. Note all wire connections and locations to the Diode Bridge Rectifier.
3. Disconnect wires to the Diode(s), and remove Diode from unit.
4. Install replacement Diode, by reversing steps 1-3
above, noting the following:
a. Diode should be oriented with plus sign (+)
down and to the right.
b. 11,12,24,25 - Install switch with prongs posi-
tioned towards the top of the unit.
5. T o 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:
COUGAR 125 Plasma Cutter 18 Service Manual 0-2717
Page 23
4.11 Resistor Replacement
NOTE
5. Install replacement Transformer/Ferrite Core Assembly by reversing steps 1-4, keeping in mind the
following:
The COUGAR 125 has two Resistors. The top Resistor is 1K ohm and the bottom Resistor is .5 ohm.
These parts are not interchangeable. Be sure to order the correct replacement part. To replace the bottom Resistor , the top Resistor must be removed first.
1. Remove cover/handle from unit per subsection 4.2.
2. Note all wire connections and locations to the
Resistor(s).
3. Disconnect al l wiring connections to the Resistor(s).
4. Remove two nuts and washers securing Resistor to
chassis.
5. Remove Resistor(s).
6. Install replacement Resistor(s) by reversing steps 15, noting the following:
a. The top Resistor is 1K ohm and the bottom Re-
sistor is .5 ohm.
b. Tighten scr ews securely.
4.12 Transformer/Ferrite Core
Assembly Replacement
a. Pull L4 through loose tie wrap if available.
b. Position wire connector L4 so that it runs along
side the T ransformer , NOT acr oss the top of the
Transformer or near any metal parts.
4.13 Input Voltage Changeover
(For 208/230 VAC Service
Only)
All 208/230 VAC units are factory set for 230 VAC. To
switch to 208VAC input power operation, complete the
following:
WARNINGS
Do not touch live electrical parts.
Disconnect primary power at source before assem-
bling or disassembling the power supply, torch
parts or torch and leads assemblies.
1. Remove cover/handle from unit per subsection 4.2.
2. Locate the wiring on the end of the Capacitor .
WARNINGS
Disconnect primary power at source before assembling or disassembling the power supply.
1. Remove cover/handle from unit per subsection 4.2.
2. Wire connections are as follows:
Connector Location
L1 E6 on P CB
L2 E1 on P CB
L3 E2 on P CB
Brass Torch
L4
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 Assembly from unit.
Lead Fit ting
3. Remove tie wrap and orange sleeving from wire
#208VAC.
4. Remove wire #230VAC from Capacitor and replace
with wire #208VAC.
5. Slide orange sleeving over wire #230VAC, fold over
and secure with a tie wrap.
W ARNING
Do not leave other input wire unprotected inside
unit.
6. Replace cover .
Service Manual 0-2717 19 COUGAR 125 Plasma Cutter
Page 24
Nylon Nut
Brass T orch
Lead Fitting
Faston Connector
to CD Coil
90˚White
Nylon Fitting
Torch
Lead
Strain
Relief
Torch Lead Faston Connector (Red)
(Connect to Bottom Resistor)
2-Pin Connectors
Figure 4-4 Torch & Leads Replacement
4.14 Torch & Leads
Replacement
1. Remove cover/handle from unit per subsection 4.2.
2. Disconnect the following (refer to Figure 4-4):
• Faston Connector (to CD Coil) from the Brass
T orch Lead Fitting
• Brass T or ch Lead Fitting from the 90 degree White
Nylon Fitting.
• 2-pin Connectors.
• Torch Lead Faston Connector (red) from bottom
Resistor.
Front Panel
Hole Location
Strain Relief
Torch Leads Assembly
Note: Do not remove strain relief from torch lead.
A-02009
Strain Relief Nut
1" Clearance
4.15 Work Cable Replacement
1. Remove cover/handle from unit per subsection
4.2.
2. Disconnect the Work Cable Faston from mounting tab on bottom of Rectifier .
3. Loosen Strain Relief and remove W ork Cable fro m
unit.
4. Install Strain Relief on replacement Work Cable 5
1/2 inches from Faston.
5. Install replacement W ork Cable by r eversing steps
1-3.
3. Loosen the Strain Relief Nut from the Strain Relief
and remove Torch Lead Assembly fr om unit.
4. Install Strain Relief on replacement torch.
5. Insert Torch leads through front hole on unit.
6. Slide Strain Relief Nut over the end of the torch lead.
7. Allow one inch clearance between the end of the
torch lead sheath and the hole in the front panel
then tighten the Strain Relief Nut. (This allows allow enough length in the torch lead to make all the
connections inside the unit.)
8. Reconnect all connections by reversing step 2.
9. Replace cover by reversing step 1.
COUGAR 125 Plasma Cutter 20 Service Manual 0-2717
A-02011
(Install 5 1/2" from Faston)
Work Cable
Strain Relief
Figure 4-5 Work Cable Replacement
Bridge
Rectifier
Work Cable Faston
(Connect to mounting
tab at bottom of Rectifier)
Page 25
4.16 Primary Input Power Cable
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
Replacement
1. Remove cover/handle from unit per subsection 4.2.
2. Disconnect Input Power Cable wiring to the ON/
OFF Switch and Ground.
3. Loosen Input Power Cable Strain Relief and remove
Input Cable from unit.
4. Install Strain Relief on replacement Input Power
Cable.
5. Install the Input Power Cable through rear panel.
6. Check the wire numbers on the Input Power Cable
and the prong numbers on the ON/OFF Switch.
Match that information to one of the configurations
in Figure 4-6 and connect the wires accordingly.
7. Connect the Ground W ir es as shown below.
Figure 4-7 Ground Connections
8. Tighten Strain Relief.
Black(Brown)
Wire
12
11
Black Wire
#5
Black Wire
#5
5
4
Black(Brown)
Wire
A
White(Blue)
Wire
Black Wire
#6
C
Black Wire
#6
White(Blue)
Wire
Black(Brown)
Wire
25
24
Black Wire
#21
Black Wire
#21
2
1
Black(Brown)
Wire
12
11
5
4
B
White(Blue)
Wire
25
24
Black Wire
#22
D
Black Wire
#22
2
1
White(Blue)
Wire
Figure 4-6 Input Power Cable Replacement
A-02652
9. Replace cover/handle by reversing step 1.
NOTE
When replacing cover, make sure all wires are
carefully positioned so that no wires are pinched.
5.0 PARTS LIST
Order replacement parts by catalog number and complete description of the part or assembly . Also include
the model and serial number of the torch. Address all
inquiries to your authorized distributor .
NOTE
Standard hardware has been used in this unit.
Replacement hardware can be purchased locally.
5.1 Returns
If a product must be returned for service, contact your
authorized distributor. Items return to the manufacturer without proper authorization will not be accepted.
Service Manual 0-2717 21 COUGAR 125 Plasma Cutter
Page 26
5.2 Power Supply Replacement Parts
Item # Qt y Description Ref. Catalog#
1 1 T ransformer/Inductor (Incl. Chassis): T1/L1
COUGAR 125 100V 50Hz, 110V 60Hz 9-0058
COUGAR 125 120V 50Hz 9-0057
COUGAR 125 120V 60Hz 9-0061
COUGAR 125 220V 50Hz 9-0060
COUGAR 125 208/230 60Hz 9-0059
2 1 Cover (incl. Labels) 9-0056
3 1 Control PCB Assembly 9-0003
4 1 Capacitor: C13
COUGAR 125 100V 50Hz, 110V 60Hz 9-0004
COUGAR 125 120V 50Hz 9-0004
COUGAR 125 120V 60Hz 9-0004
COUGAR 125 220V 50Hz 9-3924
COUGAR 125 208/230 60Hz 9-3924
5 1 W ire Harness (not shown) 9-0054
6 1 Relay, DPST , -NO, 25A @ 250V K1 9-7508
7 1 Fan:
COUGAR 125 100V 50Hz, 110V 60Hz 8-3209
COUGAR 125 120V 50Hz 8-3209
COUGAR 125 120V 60Hz 8-3209
COUGAR 125 220V 50Hz 9-7687
COUGAR 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, 1 10V 60Hz, Power Cable, 14/3 w/molded plug 9-0052
COUGAR 125 120V 50Hz, Power Cable "CE", ** 9-0044
COUGAR 125 120V 60Hz, Power Cable, 16/3 w/molded plug 9-0014
COUGAR 125 220V 50Hz, Power Cable, "CE" ** 9-0044
COUGAR 125 208/230 60Hz, Power Cable, 16/3** 9-0014
** Plug to be supplied by customer .
15 1 ON/OFF Switch: SW1
COUGAR 125 100V 50Hz, 110V 60Hz, RED NEON 9-0021
COUGAR 125 120V 50Hz, RED NEON 9-0021
COUGAR 125 120V 60Hz, RED NEON 9-0021
COUGAR 125 220V 50Hz, AMBER (or Red) NEON 9-0029
COUGAR 125 208/230 60Hz, AMBER (or Red) NEON 9-0029
16 1 CD T ransformer/Ferrite Core Assembly T2 9-0018
17 2 Bridge Rectifier BR1, BR2 7-3345
18 1 Handle, Molded 9-8115
COUGAR 125 Plasma Cutter 22 Service Manual 0-2717
Page 27
* For illustration purposes, the
Transformer/Inductor Assembly
is shown separated from the
Chassis. The Transformer/Inductor
/Chassis is actually one assembly
and should not be disassembled
for any field repairs.
To remove cover, unfasten:
• 4 side panel screws
• 2 handle screws
• 2 end panel screws
16
6
3
18
C
C
2
HARDWARE
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
NOTE: Replacement hardware can be purchased locally.
QTY
2
2
2
4
2
2
D
D
?????
22x661
D
B
B
1
17
9
A
A
15
Rotation
Direction
7
4
14
Air Flow
Direction
11
12
17
10
E
8
E
Torch & Leads
F
F
A-02371
13
Figure 6-1 Power Supply - Exploded View
Service Manual 0-2717 23 COUGAR 125 Plasma Cutter
Page 28
5.3 Parts Replacement
NOTE: Refer to Power Supply data tag to identify model of your unit.
Description Catalog #
A. Complete Systems
Includes Power Supply, PCH-10 70° T orch with Leads, Spar e Consumable Parts, Input Power Cord, and Work Cable.
COUGAR 125 100V 50Hz, 110V 60Hz, PCH-10 1-211 1-3
COUGAR 125 120V 50Hz, PCH-10, "CE" 1-2811-6
COUGAR 125 120V 60Hz, PCH-10 1-21 11-1
COUGAR 125 220V 50Hz, PCH-10, "CE" 1-281 1- 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 T or ch & Leads, 90° Nylon Air Compressor Fitting. Torch Leads alone are not replaceable.
PCH-10 (70°) w/20 ft. (6 m) Leads 2-1022
5.4 Options & Accessories (not shown)
Qty Description Catalog#
1 Single Stage In-Line Filter 7-0250
1 Replacement Cartridge 7-0252
1 Circle Cutting Guide Kit 7-8910
1 Leads Wrap - Installs Under Handle 9-7865
COUGAR 125 Plasma Cutter 24 Service Manual 0-2717
Page 29
5.5 Torch Replacement Parts
Item # Q ty Description Catalog#
1 1 PCH-10 (70°) Torch Head Assembly* 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 T ip 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) W ire Assembly 9-6290
10 1 O-Ring 8-0533
11 1 T orch Switch Button 8-4256
12 2 Torch Switch Button Springs 9-6292
1 1/4 NPT Hose Fitting (Not Shown) 8-4264
* To be replaced by Qualified T echnician only.
2
11
8
12
3
B
1
10
1
2
C
A
A
A
9
4
6
5
7
8
A-02360
A #2-56 x 5/16" LG Phillips Pan Head
B #6 Internal Star Washer
C #6-32 x 3/16" Phillips Pan Head M.S.,
A
A
HARDWARE QTY
Zinc Plated
A
6
1
1
Service Manual 0-2717 25 COUGAR 125 Plasma Cutter
Figure 6-2 Torch - Exploded View
Page 30
APPENDIX I: INTERCONNECTING DIAGRAM
A-02250
COUGAR 125 Plasma Cutter 26 Service Manual 0-2717
Page 31
1
1
Service Manual 0-2717 27 COUGAR 125 Plasma Cutter
A-02250
Page 32
Loading...