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Cougartron Power 30 User Manual

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Cougartron Power 30 / Power 30x/
Power 50x
User Guide
Original instructions
Read this guide before using the equipment
Retain this guide for future use

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Summary of Contents for Cougartron Power 30

  • Page 1 Cougartron Power 30 / Power 30x/ Power 50x User Guide Original instructions Read this guide before using the equipment Retain this guide for future use...
  • Page 2 Document ID: WELC6012 - 1.0 Purpose of manual This manual enables safe and efficient use of Cougartron Power Series devices. This manual is part of the device and must be stored where it is always accessible to operating personnel. The operating personnel must carefully read and understand this manual prior to beginning any work. The basic prerequisite for safe work is compliance with all safety instructions and operating instructions in this manual.

  • Page 3: Table Of Contents

    Contents 1 Safety information 1.1 Safety notices 1.2 Intended use 1.3 Safety symbols 1.4 PPE requirements 1.5 Safe operating area 1.6 Residual risks 1.6.1 Electrical 1.6.2 Heat 1.6.3 Fire 1.6.4 Corrosive 1.6.5 Tripping 1.6.6 Heavy 1.7 Responsibility of the owner 1.7.1 Owner responsibilities 2 Hardware description 2.1 Overview...
  • Page 4 Power 30/30x/50x - User Guide 4.4 Polishing surfaces 4.4.1 Selecting the polish function 4.4.2 Polishing the surface 4.5 Marking surfaces 4.5.1 Selecting the marking function 4.5.2 Marking and etching the surface 5 Service and maintenance 5.1 Cleaning the device 5.2 Inspecting the device 5.3 Replacing parts...

  • Page 5: Safety Information

    Safety information This section provides an overview of all safety aspects for the protection of people as well as safe and uninterrupted operation. Other task-related safety instructions are included in the specific sections. Safety notices The following safety notice formats are used in this manual. Safety notices are used at the start of sections or embedded in operating instructions.

  • Page 6: Intended Use

    Power 30/30x/50x- User Guide 1 Safety information Intended use Cougartron Power Series devices are electrochemical weld cleaning devices for stainless steel and aluminium welds and surfaces. The device is used to remove rust, oxidation, and other forms of contamination across a range of weld types and metal thicknesses.

  • Page 7: Ppe Requirements

    If you need to approach the device or work area, you must obtain permission from the operator to say that it is safe to do so. Cougartron recommends a safe area of at least 2 m (6'6") from the operator while they are working.

  • Page 8: Residual Risks

    Power 30/30x/50x- User Guide 1 Safety information Figure 1 - Safe operating area Residual risks The device incorporates the latest technology and complies with current safety requirements. Nevertheless, there are some residual risks that require your attention. The following section lists the residual risks and the measures that result from them.

  • Page 9: Heat

    Goggles must be worn when operating the device. Any fluid spilled on the skin must be washed off immediately. A Material Safety Data Sheet (MSDS) is available for all fluids and should be read before use. Contact Cougartron for more details. WELC6012 - 1.0 9 of 56...

  • Page 10: Tripping

    WARNING Care must be taken to use proper lifting techniques. The Power 30/30x device weights 6.5 kg (14.3 lbs), and the Power 50x device weights 7.1 kg (15.7 lbs). The device must be placed on a safe and stable area when being used.
  • Page 11 1 Safety information Power 30/30x/50x- User Guide The owner must be informed of the applicable occupational safety regulations and conduct a risk assessment to identify any additional risks that may arise due to the special working conditions at the device location.
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  • Page 13: Hardware Description

    Hardware description To operate the Cougartron Power Series devices, you should be familiar with the descriptions of the device parts and systems. Overview The Cougartron Power 30, Power 30x and Power 50x (device) are high-speed weld-cleaning systems designed for regular workshop usage and are very efficient in removing dis-coloration, heat tints, and oxides on metal surfaces after TIG welding.

  • Page 14: Main Parts

    Power 30/30x/50x- User Guide 2 Hardware description Main parts Figure 2 - Power 30/30x main parts 14 of 56 WELC6012 - 1.0...
  • Page 15 2 Hardware description Power 30/30x/50x- User Guide Table 3 - Power 30/Power 30x main parts Power 30/Power 30x Power 50x Part number Description Part number Description Power 30 /Power 30x device Power 50x device WELC3048 CGT-550 Weld Cleaning & WELC3048 CGT-550 Weld Cleaning &...

  • Page 16: Power Switch

    Power 30/30x/50x- User Guide 2 Hardware description Power switch The Power switch is located on the rear of the main device. WARNING Risk of serious injury or death! Ensure the power switch is set to OFF before setting up the device and fitting the brush and handle.

  • Page 17: Dimensions

    2 Hardware description Power 30/30x/50x- User Guide Dimensions Cougartron Power Series devices Height 378 mm (3.1") Width 220 mm (8.7") Depth 170 mm (6.7") Figure 4 - Main device dimensions WELC6012 - 1.0 17 of 56...

  • Page 18: Device Identification

    Power 30/30x/50x- User Guide 2 Hardware description Device identification Device identification label Location of device serial number Figure 5 - Location of the device identification label 18 of 56 WELC6012 - 1.0...

  • Page 19: Control Panel

    2 Hardware description Power 30/30x/50x- User Guide Control panel The control panel is located on the top of the device. Standby Used to power on and off the device. When the device is in standby there is no output to the work cables, but the device is turned on.
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  • Page 21: Getting Started

    Turning the device on 1. Inspect the device for damage before installing or operating it. If the device is damaged, do not use it. Contact your local Cougartron supplier to have the device inspected and repaired. 2. Use only single-phase AC power at 110 V/240 V.
  • Page 22 7. Screw the brush into the wand until they are in the correct position. Ensure they are fully tightened. To assist with removal of the brush after you have completed your work, Cougartron recommends applying a small amount of copper paste to the brush threads.
  • Page 23 3 Getting started Power 30/30x/50x- User Guide Caution Risk of injury! Ensure that your device type matches your power outlet. Mismatched power types can damage the device, work piece, and potentially harm the operator Damage caused by connecting to an incorrect power outlet could void your warranty.

  • Page 24: Shutting The Device Down

    Power 30/30x/50x- User Guide 3 Getting started Figure 11 - Power switch in the ON position 13. Select the correct operating function by pushing the clean button or polish button. ► For more information, see "Cleaning weld surfaces" on page 26 Shutting the device down 1.

  • Page 25: Operations

    The device has different modes that the user can select for different tasks. The following tables provide some guidelines on what device configuration should be used with which types of applications. Table 4 - Power 30 / 30x modes Mode Power...

  • Page 26: Selecting The Brush

    Remove rust Remove discolouration after welding Re-passivate the Heat Affected Zone (HAZ) after welding Use the mark function for the following task: Black mark stainless steel Table 7 - Clean function modes: Power 30/30x Mode Power Current Clean Mode 1 10.5 V AC...

  • Page 27: Selecting The Clean Function

    4 Operations Power 30/30x/50x- User Guide 4.3.1 Selecting the clean function To select the clean function, follow these steps: 1. Press the clean button on the control panel. The LCD display shows that the device is in clean function, 14 V.
  • Page 28 Power 30/30x/50x- User Guide 4 Operations Figure 13 - Device set up for cleaning 3. Apply the wetted brush to the weld area to be cleaned and proceed in a circular motion along the weld seam. Do not use excessive pressure. For the best results use light strokes.
  • Page 29 4 Operations Power 30/30x/50x- User Guide 4. When the surface has the desired finish, press the standby button to put the device in standby mode. 5. Place the brush on a clean, non-conductive and non-flammable surface. 6. After use, and when the brush is cool, fully wash the brush with clean water to remove all traces of the cleaning and polishing fluid.
  • Page 30 Power 30/30x/50x- User Guide 4 Operations 4.4.1 Selecting the polish function To select the polish function, follow these steps: 1. Press the polish button on the control panel. The LCD display shows that the device is in polish function. 2. Press the up-selection button...
  • Page 31 4 Operations Power 30/30x/50x- User Guide Caution Risk of injury! Do not touch the brush as it might be very hot. 7. When the surface has the desired finish, press the standby button to set the device to standby mode.
  • Page 32 Power 30/30x/50x- User Guide 4 Operations 4.5.2 Marking and etching the surface Caution Risk of injury! Avoid direct contact with all fluids used with the device. If fluids are spilled on the skin, wash them off with water immediately. ►...
  • Page 33 4 Operations Power 30/30x/50x- User Guide 4. Place the marking stencil on the work piece. Use tape to secure the stencil. 5. Apply the marking and etching fluid to the marking head. 6. Drag the marking head slowly over the stencil.
  • Page 34 Power 30/30x/50x- User Guide 4 Operations 7. Remove the stencil. 8. Apply a small amount of neutralizing fluid to the marked area of the work piece. 9. Wipe the marked area with a cloth. 10. Press the standby button to put the device in standby mode.
  • Page 35 Service and maintenance Caution Risk of injury! The device must only be repaired by a qualified and trained person. This section describes common tasks required for the service and maintenance of the device. Cleaning the device The following materials are required to clean the device: Clean water/running water installation Copper grease Small wire brush...
  • Page 36 Power 30/30x/50x- User Guide 5 Service and maintenance Figure 14 - Rinsing the brush 7. Flush the earth clamp on the black earth cable with clean water to remove the solution and prevent corrosion. 8. A small wire brush may be used on the threaded connections to remove any residue or dried acid.
  • Page 37 For more information, see "Replacing parts" on page 37 Replacing parts For optimal results, use only Cougartron brushes, shrouds and fluids. Consumable supplies are available from authorised Cougartron distributors. For more information, see "Spare parts and part numbers" on page 46 ►...
  • Page 38 5 Service and maintenance 5.3.3 Cougartron fluids A range of genuine Cougartron fluids is available. Please check with your local Cougartron distributor for details of fluids available in your region. Types of fluids available: Weld cleaning fluids - used for cleaning and, optionally, polishing...
  • Page 39 5 Service and maintenance Power 30/30x/50x- User Guide Spare parts diagram The following diagram shows the individual parts of the device with their part number. Figure 15 - Spare parts diagram Disposal The symbol on the device, the accessories, or packaging indicates that this device should not be treated as unsorted municipal waste but should be collected separately.
  • Page 40 Power 30/30x/50x- User Guide 5 Service and maintenance The packaging is made up of environmentally friendly materials that may be disposed of through your local recycling facilities. By disposing of the packaging and packaging waste in a proper manner, you help in avoiding possible environment and public health hazards.
  • Page 41 This section describes common troubleshooting solutions. If the device is not operating correctly, please refer to the error codes, troubleshooting, and repair sections before contacting your local Cougartron supplier. Error: LCD display illuminated, but no power at brush tip. Cause: Device malfunction.
  • Page 42 If an error occurs, the device goes into standby mode and displays an error code. Clear the error message by pressing the standby button. If the error message appears again, the problem has not been fixed and you should contact your local Cougartron supplier. Table 12 - Error codes...
  • Page 43 6 Troubleshooting Power 30/30x/50x- User Guide Error Cause Solution E023 Over Temperature Allow the machine to cool for 10 minutes Protection Over Current Restart the machine, and try working again. If the fault occurs Protection repeatedly, then the machine needs to be returned for service Over Current Restart the machine, and try working again.
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  • Page 45 This section details the specifications of the device. List of specifications Parameter Unit Part number WELC1055 WELC1056 WELC1058 Model Name Power 30 Power 30x Power 50x Application Applicable for TIG, MIG and other weld types on stainless steel and aluminum surfaces. Input power 110-240 V AC 110-240 V AC 110-240 V AC...
  • Page 46 WELC2120 Cougartron extension lead, black 4 m (13 ft), 50 A WELC3021 Copper grease 20 g (0.7oz) WELC2404 Cougartron transport Bag 40 x 20 x 26.5 cm (16 x 8 x 10 inch) WELC2064 Cougartron transport case WELC5006 Foam insert for WELC2064 7.2.2...
  • Page 47 Power / 30x Power 50x WELC2005 Acid pot 500 ml (1 Pt) with lid WELC2149 Cougartron microfibre cloth - 40x40 cm (16 x 16 inch) (black) Yes WELC2201 Cougartron spray bottle with sprayer 0.5 L (1 Pt) (empty) WELC2092 Cougartron sprayer for spray bottle - orange WELC2253 Tap for 5 L (1.3 Gal) weld cleaning fluids...
  • Page 48 Cougartron marking block without adaptor WELC4025 Cougartron carbon felt 75x40x4,6 mm (2.9x1.5 x 0.18") (10 pcs) WELC4033 Cougartron white felt 75x40x3 mm (2.9 x 1.5x0.1") (10 pcs) WELC4026 Cougartron yellow fabric 75x40 mm (2.9 x1.5") (10 pcs) WELC4002 Cougartron O-ring for std marking block (pack5) 7.2.7...
  • Page 49 PT-D600VP Brother Label Printer 18-24 mm (¾ - 1") tapes WELC4284 PT-E550WVP Brother Label Printer 18-24 mm (¾ - 1") tapes WELC4014 Cougartron Stencil tape, 18 mm x 3 m (¾ inch x 9 ft) WELC4015 Cougartron Stencil tape, 24 mm x 3m WELC4339 PT-800 W Brother Label Printer 18-36 mm (¾ - 1 ½ inch) tape Yes WELC4016 Cougartron Stencil tape, 36 mm x 3 m (1 7/ 16 inch x 9 ft)
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  • Page 51 Index acid 9 applications 25 brush cleaning 35 brushes 37 selection 26 buttons 19 care of device 37 clean brushes 35 clean function 19 cleaning the device 35 cleaning weld surfaces 26-27 consumables 37 Control panel 19 copper grease 35 device inspection 37 device not working 42 dimensions 17...
  • Page 52 Power 30/30x/50x- User Guide Index handle 37 hardware overview 14 identify device 18 inspection 37 LCD display illuminated, but no power at brush tip 41 lifting the device 10 main parts 14 maintenance 37 marking and etching surfaces 31-32 marking fluids 38...
  • Page 53 Index Power 30/30x/50x- User Guide powering on the device 21 PPE requirements 7 recycling parts 39 replacing parts 37 residual risk corrosive 9 electrical 8 heat 9 heavy 10 tripping 10 safe operating area 7 safety labels 6 safety notices 5...
  • Page 54 Power 30/30x/50x- User Guide Index twist shroud 37 unpacking the device 21 using the device 25 WEEE 39 weekly checks 37 weight 45 weld cleaning 26 54 of 56 WELC6012 - 1.0...
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This manual is also suitable for:

Power 30xPower 50x

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