Cougartron Power 30 User manual
Original instructions
Read this guide before using the equipment
Retain this guide for future use
Cougartron Power 30 / Power 30x/
Power 50x
User Guide
2 of 56 WELC6012 - 1.0
Published on: 01 February 2023
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.
The local occupational safety regulations and general safety regulations for the area of application of the device also apply.
Copyright
Copyright © 2023 Cougartron ApS. All Rights Reserved.
Contains information owned by Cougartron ApS. and/or its affiliates. Do not copy, store, transmit or disclose to any third party
without prior written permission from Cougartron ApS.
Other product and company names may be trademarks or registered trademarks of other companies and are the property of their
owners. They are used only for explanation, without intent to infringe.
Contact address
Cougartron ApS.
Brydehusvej 23
2750 Ballerup, Denmark
+45 4346 2010
Power 30/30x/50x - User Guide
Contents
1 Safety information 5
1.1 Safety notices 5
1.2 Intended use 6
1.3 Safety symbols 6
1.4 PPE requirements 7
1.5 Safe operating area 7
1.6 Residual risks 8
1.6.1 Electrical 8
1.6.2 Heat 9
1.6.3 Fire 9
1.6.4 Corrosive 9
1.6.5 Tripping 10
1.6.6 Heavy 10
1.7 Responsibility of the owner 10
1.7.1 Owner responsibilities 10
2 Hardware description 13
2.1 Overview 13
2.2 Main parts 14
2.3 Power switch 16
2.4 Dimensions 17
2.5 Device identification 18
2.6 Control panel 19
3 Getting started 21
3.1 Unpacking the device 21
3.2 Turning the device on 21
3.3 Shutting the device down 24
4 Operations 25
4.1 Overview of applications 25
4.2 Selecting the brush 26
4.3 Cleaning weld surfaces 26
4.3.1 Selecting the clean function 27
4.3.2 Cleaning the surface 27
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4.4 Polishing surfaces 29
4.4.1 Selecting the polish function 30
4.4.2 Polishing the surface 30
4.5 Marking surfaces 31
4.5.1 Selecting the marking function 31
4.5.2 Marking and etching the surface 32
5 Service and maintenance 35
5.1 Cleaning the device 35
5.2 Inspecting the device 37
5.3 Replacing parts 37
5.3.1 Cougartron brushes 37
5.3.2 Cougartron twist shrouds 37
5.3.3 Cougartron fluids 38
5.4 Spare parts diagram 39
5.5 Disposal 39
6 Troubleshooting 41
6.1 Error codes 42
7 Specifications 45
7.1 List of specifications 45
7.2 Spare parts and part numbers 46
7.2.1 Weld cleaning device accessories 46
7.2.2 Weld cleaning brush 46
7.2.3 Weld cleaning brush accessories 46
7.2.4 Weld cleaning fluids 47
7.2.5 Weld cleaning fluid accessories 47
7.2.6 Marking sets and accessories 48
7.2.7 Marking fluids 48
7.2.8 Marking stencils and printers 49
Index 51
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1 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.
1.1 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.
Ensure you fully understand and comply with the notices in this manual.
DANGER
Risk of death!
Indicates a hazardous situation which, if not avoided, will almost certainly result in
death or serious injury.
Caution
Risk of injury!
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
WARNING
Risk of serious injury or death!
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
Additional information relating to the current section.
Notice
Indicates an important situation which, if not avoided, may seriously impair
operations.
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1.2 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.
WARNING
Danger due to misuse!
Misuse of the device can result in hazardous situations.
lThe device is not designed for use on power generators or step down
transformers.
lOnly use the device in a well-ventilated space.
lOnly operate the device if it is in an undamaged and orderly condition.
lNever deviate from the prescribed maintenance intervals.
lOnly use parts that are specified in the technical data and approved for this
device.
lNever modify the device without consulting with the manufacturer.
lNever allow untrained personnel to operate the device.
lNever operate the device in potentially explosive atmospheres
1.3 Safety symbols
To draw attention to special hazards, the following symbols are used in this manual.
Table 1 - Safety symbols
Symbol Meaning
Electrical hazards and electrical shock hazards
General warning
Heavy objects or equipment
Fire hazard
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Symbol Meaning
Corrosive substance
Trip hazard
Hot surface
1.4 PPE requirements
Gloves and eye protection must also be worn during installation and usage of the device.
Table 2 - PPE requirements
Symbol Meaning
The device uses mild acids
Gloves must be worn to avoid prolonged skin contact with any of the fluids
Goggles must be worn to prevent fluid splashing in the eyes
Air extraction must always be used when working with the device
1.5 Safe operating area
A safe operating area around the device and work area should be maintained at all times. Non-
operators and other persons should not approach the device or work area.
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 2m (6'6") from the operator while they are
working.
You should also be aware of the main device location if it is located beyond this distance.
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Figure 1 - Safe operating area
1.6 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.
1.6.1 Electrical
WARNING
Danger of death due to electrical current!
There is an imminent risk of death by electrocution in the event of contact with live
parts. Damage to the cable insulation or individual components can pose a lethal
hazard.
lOnly qualified electricians are authorized to work on the device.
lIn case of damage to the cable insulation, immediately cut the power supply
and initiate repairs or replacement.
lKeep moisture away from live components as it can result in a short circuit.
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1.6.2 Heat
WARNING
Risk of hot surfaces!
The metal around the weld and the brushes can get hot during the cleaning process.
During use, the brush becomes extremely hot; +200°C (392°F).
lWhen operating the device, do not touch the brush.
lDo not place the brush near any flammable material.
1.6.3 Fire
WARNING
Risk of fire or flammable materials!
lHydrogen gas (an invisible but explosive gas) might be generated while
operating the device. Always use the device in a well-ventilated area with air
extraction.
lDo not use the device near flammable substances or in areas where dense
flammable gases, are likely to accumulate.
lThe device produces an electric current that can generate small sparks
between the brush and the work piece.
1.6.4 Corrosive
WARNING
Risk of corrosive substances!
A mild acid is used as part of the device cleaning process.
lWear appropriate protective clothing.
lGloves must be used to avoid prolonged contact with any of the fluids.
lGoggles must be worn when operating the device.
lAny fluid spilled on the skin must be washed off immediately.
lA Material Safety Data Sheet (MSDS) is available for all fluids and should be
read before use. Contact Cougartron for more details.
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1.6.5 Tripping
WARNING
Risk of injury from trips or falls!
There is a risk of tripping on the 4m earth or handle cables.
If the cables cross any access through a work area, then all necessary precautions
must be followed to warn and notify other users in the area.
Ensure that cables are routed safely away from heat sources or other potential
hazards.
Ensure the cables are not trapped or pinched during use.
1.6.6 Heavy
WARNING
Care must be taken to use proper lifting techniques.
The Power 30/30x device weights 6.5 kg (14.3lbs), and the Power 50x device
weights 7.1 kg (15.7lbs).
The device must be placed on a safe and stable area when being used.
Always use the machine handle to lift the device.
1.7 Responsibility of the owner
The owner is the person who operates the device for commercial or business purposes or
allows a third party to use the device and bears legal responsibility for the product during
operation for the protection of the user, personnel or third party. Note the device is not
designed for use on power generators or step down transformers.
1.7.1 Owner responsibilities
The device is used for commercial purposes. The owner of the device is therefore subject to
the legal responsibilities for occupational safety.
In addition to the safety instructions in this manual, the applicable safety regulations as well as
occupational safety and environmental regulations must be implemented for the area of
application of the device.
This applies to the following:
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lThe 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.
lThis information must be implemented in the form of operating instructions for the
operation of the device.
lDuring the entire period of device use, the owner must ensure that the operating
instructions created reflect the current state of policy and adjust them if necessary.
lThe owner must clearly regulate and define the responsibilities for operation,
troubleshooting, maintenance and cleaning.
lThe owner must ensure that all persons who work with the device have read and
understood this manual.
lThe owner must also train and inform personnel of hazards at regular intervals.
lThe owner must provide personnel with the required protective equipment and must
ensure that personnel wear the required protective equipment.
lThe owner must ensure adequate ventilation of the installation site around the device
and work area.
lThe owner is also responsible for ensuring that the device is always in good working
order. The following therefore applies:
lThe owner must ensure that the maintenance intervals described in this manual
are observed.
lThe owner must ensure that the required fire protection measures are always
compliant and functional.
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2 Hardware description
To operate the Cougartron Power Series devices, you should be familiar with the descriptions
of the device parts and systems.
2.1 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.
The lightweight and portable device provides excellent results when cleaning, passivating and
electropolishing. This is all done without any grinding, dust generation, or hazardous acids,
such as pickling paste.
This manual covers the following variants of the device:
lCougartron Power 30 WELC1055 (110-240 V ac 6.3Amps, 10.5-14 V ac/dc 30Amps,
50/60Hz)
lCougartron Power 30x WELC1056 (110-240 V ac 6.3Amps, 10.5-14 V ac/dc 30Amps,
50/60Hz)
lCougartron Power 50x WELC1058 (110-240 V ac 10Amps, 10.5-14 V ac/dc 50Amps,
50/60Hz)
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2.2 Main parts
Figure 2 - Power 30/30x main parts
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Table 3 - Power 30/Power 30x main parts
Power 30/Power 30x Power 50x
Part number Description Part number Description
1NA Power 30 /Power 30x device NA Power 50x device
2WELC3048 CGT-550 Weld Cleaning &
Polishing Fluid - 5L (1.3Gal)
WELC3048 CGT-550 Weld Cleaning &
Polishing Fluid - 5L (1.3Gal)
3WELC3158 CGT-N5 HyPerformance
Neutralising Fluid - 5L (1.3Gal)
WELC3158 CGT-N5 HyPerformance
Neutralising Fluid - 5L
(1.3Gal)
4WELC2149 CGT Microfibre Cloth 40cm x
40cm (16" x 16")
WELC2149 CGT Microfibre Cloth 40cm x
40cm (16" x 16")
5WELC2118 Cougartron lead with earth
clamp 4 m(13ft), 50A
(Xconnector)
WELC2118 Cougartron lead with earth
clamp 4 m(13ft), 50A
(Xconnector)
6WELC2047 Cougartron lead with handle 4 m
(13 ft), 50A (Xconnector)
WELC2047 Cougartron lead with handle 4
m (13 ft), 50A (Xconnector)
7WELC3101 Cougartron Powerbrush(M6, 30
A)- 10 pack
WELC3146 Cougartron Superbrush (M6,
50 A)- 10 pack
8WELC2226 Cougartron wand/twist shroud
set (for 1x M6 brush)
WELC2226 Cougartron wand/twist shroud
set (for 1x M6 brush)
9WELC2201 Cougartron spray bottle with
sprayer 0.5L (1pt) (empty)
WELC2201 Cougartron spray bottle with
sprayer 0.5L (1pt) (empty)
10 WELC5014 1L (2pt) Jerry Can with screw
cap
WELC5014 1L (2pt) Jerry Can with screw
cap
11 WELC2005 Acid pot 500ml (1pt) with lid WELC2005 Acid pot 500ml (1pt) with lid
12 WELC2064 Cougartron transport case -
Large
WELC2064 Cougartron transport case -
Large
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2.3 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.
1Power switch
Figure 3 - Location of the power switch
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2.4 Dimensions
Cougartron Power Series devices
1Height 378 mm (3.1")
2Width 220 mm (8.7")
3Depth 170 mm (6.7")
Figure 4 - Main device dimensions
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2.5 Device identification
1Device identification label
Location of device serial number
Figure 5 - Location of the device identification label
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2.6 Control panel
The control panel is located on the top of the device.
1Standby 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.
CAUTION:The device should always be returned to standby when
not in use to prevent accidental shorting of the work cables, and to
prevent potential electrical shock.
2Clean
function
Used to select different cleaning and marking modes.
3Polishing
function
Used to select polishing and etching modes.
4Marking
function
Used to add a dark, oxidised mark or print on the work piece, with no
change to the surface.
5Down
selection
Used to decrease the output amperage.
7Up
selection
Used to increase the output amperage.
6LCD display Used to display selected options and configure settings, for example
power and amp settings.
Figure 6 - Control panel and buttons
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