Cougartron ProPlus User manual

User Manual
ProPlus

Dear Customer
Thank you for purchasing a Cougartron ProPlus Weld Cleaning
Machine.
We would like to reward you with an exclusive extended 2 year
warranty!
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it to us by the below details;
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Alternatively you can register Online: www.cougartron.com/register
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have any questions.
Best Regards
The Cougartron Team
Congratulations!
a.
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Foreword
This User Manual is a very important tool!
Keep it with the machine at all times. The purpose of this manual is to
provide users with the necessary operating procedures and precau-
tions, essential for the safe and proper operation of the Cougartron
Machine.
Due to continuous improvements, BM Group I/S reserves the right to
make specication changes.
FOR:
• Accident reporting
• Product safety publications
• Current owner updates
• Questions regarding product safety
• Standards and regulations compliance information
• Questions regarding special product applications
• Questions regarding product modications
CONTACT
Your local Cougartron distributor. You can nd out your local
distributor by contacting;
[e-mail]
0045 4346 2010
BM Group I/S
Marielundvej 48D
2730, Herlev
Denmark
b.

Contents
Subject Page
1. Introduction 2
2. Safety Information 3 - 4
3. Description of Apparatus 5 - 6
3.1 Control Box 5
3.2 Leads 6
3.3 Handle and Wand 6
3.4 Earth Clamp 6
4. Cougartron Cleaning Method 7 - 8
4.1 Preparation 7
4.2 Assembly of the ProPlus 7
4.3 Cleaning Fluid 7
4.4 Operation 8
5. Power and Function Settings 9-10
5.1 ProPlus Power Settings 9
5.2 ProPlus Function Settings 10
6. Maintenance 11
7. Consumables 12
7.1 Cougartron Brushes 12
7.2 Cougartron Sliding Shrouds 12
7.3 Cougartron Fluids 12
8. Troubleshooting 13-14
9. Warranty Terms 15
10. Notes 16
1.

1. Introduction
The Cougartron ProPlus is a metal cleaner which uses the interaction
between an alternating electric current (ac) and a conductive uid to
remove weld marks from stainless steel.
The Cougartron ProPlus will also polish metal, by passing a negative dc
current through the same conductive uid.
This is called electro-polishing.
By using the Etching mode, and replacing the standard uid with an
etching solution, the Cougartron ProPlus, can Etch the pattern in an
overlay stencil onto the surface of the metal.
The Cougartron ProPlus comprises a machine unit and wand with a
soft bristle tip which, after wetting with a conductive uid, is applied
to the weld mark in a painting action. This unique cleaning system is
quick, eliminates the need for pickling paste, or abrasives, and
provides a superior nish.
The Cougartron ProPlus Cleaning uid is based on phosphoric acid
and supplies may be purchased from your supplier in quantities of one
litre or ve litre bottles. Refer to www.cougartron.com for your
nearest authorized supplier.
The Cougartron ProPlus is light and portable, and is powered by a 230
volts A.C. mains power source. The Cougartron ProPlus is provided
with a one year warranty on the control box, provided the unit is used
only for the purpose for which it was designed. Cougartron
accessories (brushes, insulating shrouds and leads) are not covered by
the warranty
1.
2.

2. Safety Information
Protect yourself and others by observing all safety information,
warnings and cautions. Failure to comply with instructions could result
in personal injury and/or damage to the product or property.
Read this documentation carefully before operating the equipment.
Please retain these instructions for future reference.
Before using the Cougartron ProPlus, make sure the work environment
is well ventilated and away from any combustible substances. Ensure
that all required equipment is available.
Do not use the Cougartron ProPlus for any purpose other than that
described in this manual. Failure to observe this warning may result in
permanent damage to the Cougartron ProPlus, cause damage to the
workpiece, cause injury to the operator and void the warranty.
The Cougartron ProPlus is amongst the safest appliances in its class.
However some precautions must be taken with the use of the
Cougartron ProPlus, as with any electro-cleaner.
• The Cougartron ProPlus uses mild acids; gloves should be used to
avoid prolonged contact with any of the uids.
• Goggles should be worn to prevent uid being splashed in the
eyes.
• Fluid spilled on the skin should be washed o as soon as practical.
• Material Safety Data Sheet is available for all uids ands hould be
read before use.
• The brush gets extremely hot, around 200°C degrees centigrade.
Be very careful touching the brush. Do not place the brush near
any ammable materials.
• The Cougartron ProPlus produces an electric current which may
generate small sparks between the brush and the metal being
cleaned.
3.

• Hydrogen gas may also be generated (which is an invisible but
explosive gas). Always use the apparatus in a well ventilated area.
Do not use near ammable substances, or in areas where dense
ammable gases (such as petrol vapour) may accumulate.
• The Cougartron ProPlus uses 240V AC only. Do not use with any
other voltage. If the power cord is damaged or if the Cougartron
ProPlus has been dropped from a height and damaged, do not use
the unit. Contact your Cougartron supplier to have the Cougartron
ProPlus inspected and repaired.
• Do not short out the terminals, or use the Cougartron ProPlus with
a damaged wand or cables. Doing so may permanently damage
the Cougartron ProPlus and cause damage to the workpiece being
cleaned. The high currents involved may also cause intense heat-
ing of the shorted or damaged part, which could result in burns to
the operator.
• Ensure that the Cougartron ProPlus is located where it cannot
easily fall and cause injury. Ensure that the cables do not present
a trip hazard.
4.

3. Description of Apparatus
3.1 ProPlus Control Box
The mains power ON/OFF switch is on the rear of the unit.
The Control Panel is the sloping panel on the top of the Cougartron
ProPlus containing the Power setting switches and the Function
selection switches. Each Function has a LED that lights up when that
function is active.
The Functions are selected using the buttons along the top of the
Conrol Panel. The dierent functions alter the way the Cougartron
ProPlus works to achieve dierent eects (i.e., cleaning, polishing,
etching)
The Power is adjusted by the 2 buttons either side of the small screen.
The power is adjustable in increments of 5 amps from 20 to 50. The
screen displays how many amps the machine is running on. The Power
setting switch is used to adjust the amount of voltage applied to the
brush, and therefore how fast the Cougartron ProPlus cleans.
The two sockets on the front of the machine towards the bottom right
hand side are the sockets into which the leads are connected. The
orange power lead connects into the socket with the “brush” icon and
the earth lead connects into the socket with the “clamp” icon.
The socket on the front of the machine towards the bottom left hand
side is the socket for the Etching Footswitch. This can be found in the
Cougartron ProPlus Etching Set. (Part Number WELC4035)
5.
LEDs
Power
On
Functions
Power
Display Power
Control

3.2 ProPlus Leads
The leads are 4 metres long, and connect the Cougartron ProPlus to
the Earth Clamp and the Handle/Wand. The Orange lead is the Power
lead, used for cleaning and the Black lead is the earth lead.
3.3 ProPlus Handle and Wand
The power cable extends in one piece from the cable end connector at
the Control Box, through to the end of the Wand. The Handle is
insulated from electricity and heat, and can be held safely. The Wand
screws into Handle. The brush tip screws into the Wand.
The brush tip bristles are conductive and can withstand high
temperatures. The brush tip has a teon sliding-shroud covering
the tip base to prevent direct shorting of the current to the work. The
shroud can be moved along the wand to change the prole of the
brush bristles. The shroud must be tted to the wand at all times when
the Cougartron ProPlus is in use. Extra shrouds can be purchased from
your supplier or from Cougarton at www.cougartron.com
The Cougartron ProPlus cleaner will survive the occasional, brief,
accidental short of the brush shell. A prolonged short of the shell may
cause damage to the Cougartron ProPlus cleaner, and will void the
warranty. Please ensure that the shroud always covers the shell.
The brush tip should be removed and cleaned after use and before
storage.
3.4 ProPlus Earth Clamp
The Earth Clamp is a spring loaded clamp for connecting one
terminal of the Cougartron ProPlus to the work piece.
The Earth Clamp can become dirty or coated in residue and should be
cleaned regularly.
6.

4. Cleaning Method
4.1 Preparation
1. Inspect unit and all cables for damage before use.
2. Ensure the unit is dry.
3.
Ensure the work environment is well ventilated and away from any
combustible substances.
4. Ensure that cables do not present a trip hazard.
5. If the items to be cleaned are small, place the parts in a plastic container
that can hold acidic uids safely.
6. Parts will need to be sprayed with the recommended
7. Cougartron neutraliser or washed down with water after cleaning.
Ensure there is ready access to water and a suitable place for washing.
8. Wear suitable personal protective equipment as recommended in the
MSDS. The minimum requirement is for gloves to protect hands from the
uid, and goggles to prevent  uid splashing into the eyes.
4.2 Assembly of the ProPlus
1. Attach connector of orange cable to top connector of Cougartron ProPlus
Unit.
2. Screw wand into handle.
3. Place shroud on brush and screw into wand.
4. Attach connector of black cable to bottom connector of the Cougartron
ProPlus Unit.
5. Set POWER switch to “OFF”.
6. Attach power cord to mains outlet and Cougartron ProPlus Unit.
7. Attach clamp to workpiece.
7.