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THERMACUT ® EX-TRAFIRE ® 45SD PLASMA ARC CUTTING SYSTEM Operator Manual Revision: T-5 English 2020 BEFORE SWITCHING ON OR OPERATING THE SYSTEM, !IMPORTANT! READ THIS MANUAL, BECOME FAMILIAR WITH THE CONTENT. KEEP THE MANUAL LOCAL TO THE JOB SITE WITH EASY ACCESS TO ALL PERSONNEL. THE SYSTEM IS TO BE USED FOR METAL CUTTING ONLY.
EX-TRAFIRE 45SD ® INDEX SECTION 1: SAFETY ��������������������������������������������������������������������������������������5 !Caution! ��������������������������������������������������������������������������������������������������������������������������������������6 Plasma arc rays can burn eyes and skin �����������������������������������������������������������������������������������6 Noise can damage hearing ������������������������������������������������������������������������������������������������������6 Flying sparks (arc spray) can cause injury, fire or explosion ��������������������������������������������������6 Caution! Read operator’s manual ���������������������������������������������������������������������������������������������6 Cutting can cause fire or explosion �����������������������������������������������������������������������������������������7 Electric shock can kill������������������������������������������������������������������������������������������������������������������7 Plasma arc can injure ������������������������������������������������������������������������������������������������������������������7 Flying sparks (arc spray) can cause injury, fire or explosion ��������������������������������������������������7...
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EX-TRAFIRE 45SD ® Three-phase mains power lead ������������������������������������������������������������������������������������������ 3-22 Installation of three-phase mains power lead ������������������������������������������������������������������� 3-22 Torch installation step by step ��������������������������������������������������������������������������������������������� 3-23 Working (ground) cable installation step by step ������������������������������������������������������������� 3-26 Plasma gas supply ���������������������������������������������������������������������������������������������������������������� 3-27 Additional gas filtration �������������������������������������������������������������������������������������������������������� 3-27 Gas supply installation ���������������������������������������������������������������������������������������������������������...
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EX-TRAFIRE 45SD ® Purging/draining the built-in filter �������������������������������������������������������������������������������������� 5-55 SECTION 6: TORCHES AND TORCH PARTS ��������������������������������������������� 6-56 FHT-EX 45TTH Hand Torch Assembly �������������������������������������������������������������������������������� 6-57 ® FHT-EX 45TTH Hand Torch Components �������������������������������������������������������������������������� 6-58 ® FHT-EX 45TTH Hand Torch Consumables ������������������������������������������������������������������������� 6-59 ®...
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EX-TRAFIRE 45SD ® SECTION 1� SAFETY: !Caution! ��������������������������������������������������������������������������������������������������������������������������������������6 Plasma arc rays can burn eyes and skin �����������������������������������������������������������������������������������6 Noise can damage hearing ������������������������������������������������������������������������������������������������������6 Flying sparks (arc spray) can cause injury, fire or explosion ��������������������������������������������������6 Caution! Read operator’s manual ���������������������������������������������������������������������������������������������6 Cutting can cause fire or explosion �����������������������������������������������������������������������������������������7 Electric shock can kill������������������������������������������������������������������������������������������������������������������7 Plasma arc can injure ������������������������������������������������������������������������������������������������������������������7 Flying sparks (arc spray) can cause injury, fire or explosion ��������������������������������������������������7...
EX-TRAFIRE 45SD ® SAFETY !CAUTION! CAUTION! READ OPERATOR’S MANUAL The symbol shown in this section means: !Caution! !Beware! Follow the safety instructions to avoid danger� There are possible hazards with this procedure! Only qualified persons should install, operate, maintain and When you find this symbol in the manual or on the system, repair the system�...
EX-TRAFIRE 45SD ® CUTTING CAN CAUSE FIRE FLYING SPARKS (ARC SPRAY) CAN OR EXPLOSION CAUSE INJURY, FIRE OR EXPLOSION FIRE PREVENTION Flying sparks are created during the metal cutting/gouging • Keep flammable items away from the work area� processes; the area should be kept free from flammables� •...
EX-TRAFIRE 45SD ® SMOKE AND GASES CAN BE HAZARDOUS Induction heating of certain materials, adhesives, and fluxes may cause fumes or smoke� • Work in a confined space only if it is well ventilated, Breathing the fumes and smoke can be hazardous to your or while wearing an air-supplied respirator�...
EX-TRAFIRE 45HD ® EX-TRAFIRE 45SD Hand torch consumables installation ® WARNING Safety Sticker Plasma arc is generated immediately when the torch trigger is depressed Plasma arc is generated immediately when the torch trigger is depressed. The plasma arc will cut quickly through gloves and skin. EX-TRAFIRE 45HD ®...
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EX-TRAFIRE 45SD ® SECTION 2� SPECIFICATIONS: Dimensions and weight of the plasma arc power supply ����������������������������������������������� 2-11 Specifications: plasma arc power supply EX-TRAFIRE 45SD, 1-phase �������������������������� 2-12 ® Specifications: plasma arc power supply EX-TRAFIRE 45SD, 3-phase �������������������������� 2-13 ® Specifications: Torches FHT-EX 45TTH and FHT-EX 45TTM �������������������������������������������...
EX-TRAFIRE 45SD ® SPECIFICATIONS EX-TRAFIRE 45SD ® • I s a portable plasma arc cutting system� • Has been designed for Handheld Cutting, Mechanised Cutting and Gouging� • U ses compressed air or nitrogen for cutting Mild Steel, Stainless Steel, Aluminium and other electrically conductive metals�...
EX-TRAFIRE 45SD ® Specifications: plasma arc power supply EX-TRAFIRE 45SD, 1- phase ® Open circuit voltage (U 480 VDC Output characteristic* Drooping Curve is defined as the output voltage versus output current Input voltage (U ) *PFC 1x 120VAC ± 15% (CE) 1x 230VAC ±...
EX-TRAFIRE 45SD ® Specifications: plasma arc power supply EX-TRAFIRE 45SD, 3- phase ® Open circuit voltage (U 308 VDC Output characteristic* Drooping Curve is defined as the output voltage versus output current Input voltage (U 3x 400 VAC ± 15% Rated output current (I 20–45 A Standard rated output voltage (U...
EX-TRAFIRE 45SD ® Duty cycle Duty cycle is the percentage of time, during a period of 10 minutes, that the power supply can continuously cut� The following diagram represents a duty cycle of 80%� 8 minutes cutting 2 minutes resting Specifications: Torches FHT-EX 45TTH and FHT-EX 45TTM...
EX-TRAFIRE 45SD ® Symbols and marking S Mark; mark indicates that the power supply and torch are suitable for use in environments with danger of electrocution� The hand torches must have shielded consumable parts fitted to maintain mark compliance� CE Mark; This marking signifies the manufacturer’s declaration of conformity to applicable European directives and standards (EMC &...
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EX-TRAFIRE 45SD ® Symbol Description Symbol Description Indicates flow of the gas� Cutting mode Gas pressure fault� Direct Current (DC) power Gouging mode The power supply is working� Indicates pressing of torch trigger or connection of pins Indicates arc transfer 3, 4 in the CNC connector�...
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EX-TRAFIRE 45SD ® SECTION 3� INSTALLATION: Upon receipt of goods ��������������������������������������������������������������������������������������������������������� 3-19 Claims ������������������������������������������������������������������������������������������������������������������������������������� 3-19 Box contents �������������������������������������������������������������������������������������������������������������������������� 3-19 Power supply location ���������������������������������������������������������������������������������������������������������� 3-20 Mains power connection ����������������������������������������������������������������������������������������������������� 3-20 Connecting to an engine drive power generator ������������������������������������������������������������� 3-20 Grounding ����������������������������������������������������������������������������������������������������������������������������� 3-21 Mains power lead �����������������������������������������������������������������������������������������������������������������...
EX-TRAFIRE 45SD ® INSTALLATION Upon receipt of goods 1� Verify that all ordered items have been received, for short shipment or damage to equipment, contact the Authorized Supplier� 2� If there is evidence of damage, see Claims, below� 3� All communication relating to this plasma arc system should include the model and serial number located on the bottom of the plasma arc power supply�...
EX-TRAFIRE 45SD ® Power supply location Place the plasma arc power supply EX-TRAFIRE 45SD on a flat even surface with a minimum ® distance of 0�5 m of clear space all round to ensure good ventilation� Mains power connection The EX-TRAFIRE 45SD plasma arc power supply requires a 120 VAC ±...
EX-TRAFIRE 45SD ® Grounding To reduce electromagnetic interference (EMI) and to ensure personal safety and correct operation, the EX-TRAFIRE 45SD must be properly grounded through the mains power lead in accordance with ® local and national electrical codes of practice� The single-phase supply must be of the 3-wire type with a protective green-yellow wire for protective earth ground�...
EX-TRAFIRE 45SD ® Installation of single-phase mains power lead CE units Black (Brown) Blue Earth Green-Yellow Black (Brown) Blue Green-Yellow Three-phase mains power lead CE models are fitted with a 4 wire 1�5 mm mains power lead� To operate the EX-TRAFIRE 45SD, use ®...
EX-TRAFIRE 45SD ® Torch installation step by step 1� TURN “OFF” the power supply 45SD - Single phase 45SD - Three phase OFF (0) / Turn OFF OFF (0) / Turn OFF ON (I) / Turn ON ON (I) / Turn ON 2�...
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EX-TRAFIRE 45SD ® 3� Torch conenction – Torch TCS plug Latch with key position� TCS latch with key Torch TCS plug Latch with key position 4� Torch connection – 1st step – place the TCS latch with key into the TCS power supply socket� The TCS latch with key must be locked in the TCS socket properly with the latch nose�...
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EX-TRAFIRE 45SD ® 5� Torch connection – 2nd step – put TCS plug into the TCS socket� The torch TCS plug must be locked in the TCS socket properly with the key nose� TCS key nose 6� Torch connection – proper position of the TCS plug in the TCS socket� WARNING FHT-EX 45TTH, TTM torches are only for use with...
EX-TRAFIRE 45SD ® Working (ground) cable installation step by step 1� TURN “OFF” the power supply� 2� Push the connector of work clamp cable into the appropriate socket� 3� Turn the connector clockwise to lock the cable in the socket� 3-26 Operator Manual, Revision T-5...
45SD is equipped with a built-in filtration system� ® Additional gas filtration The Thermacut filtration system should be used when oil, moisture or other contaminants are found in the air supply� In more severe cases the 3-stage filtration system should be used� Water /...
EX-TRAFIRE 45SD ® Gas supply installation Connect the air-line hose as follows: 45SD - Single phase 45SD - Three phase 1� Air-line hose connection� Female G1/4” thread • adapter� 2� Air-line hose� Use an inert gas hose with a • minimum internal diameter of 6 mm, make a direct attachment or use a quick...
EX-TRAFIRE 45SD ® System CNC interface connection Each type of signal is available through the system CNC interface connector located on the rear control panel� Use the chart with details of each signal type below when connecting the system interface lead to the plasma arc power supply� START Arc transfer Signal:...
EX-TRAFIRE 45SD ® Activating an external DC coil with an external power supply Use a diode 1N4007 if the voltage is 24 VDC 24 VDC Activating an external AC coil with an external power supply 24 VAC 230 VAC 3-30 Operator Manual, Revision T-5...
EX-TRAFIRE 45SD ® Activating an industrial isolated module with an external power supply Notes: 1� Isolated input module, provided by the user� 2� 24 VDC power supply to be provided by the user� ISOLATED INPUT MODULE� Installation of the machine interface cable must be performed by a certified electrician or competent person�...
EX-TRAFIRE 45SD ® The circle cutting guide installation - for the FHT-EX 105RTXH/105TTH/45TTH ® 1� Disconnect the torch from the plasma power supply� 2� Insert the hand torch into the cutting guide� Hand torch Retaining cap Hand shield Cutting guide 3�...
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EX-TRAFIRE 45SD ® 5� The hand torch clamped in the cutting guide can be used alone or with a radius bar� If you don’t want use the radius bar, lock the cutting guide in a fixed position by using of the screw with hexagonal head so that the wheels of the cutting guide point in the same direction as the torch handle - see picture below�...
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EX-TRAFIRE 45SD ® 8� Use the following fasteners to anchor the radius bar to the center of the circle: Magnetic Free centering Straight base straight pin locking pin assembly 3-34 Operator Manual, Revision T-5...
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EX-TRAFIRE 45SD ® SECTION 4� OPERATION: Front view ������������������������������������������������������������������������������������������������������������������������������� 4-36 LCD detail ������������������������������������������������������������������������������������������������������������������������������ 4-36 Setting of power supply ������������������������������������������������������������������������������������������������������� 4-37 1� Cutting mode selection� �������������������������������������������������������������������������������������������������� 4-37 2� Cutting parameters� ���������������������������������������������������������������������������������������������������������� 4-38 3� Two variants of cutting torch� ������������������������������������������������������������������������������������������ 4-38 Rear view, Turn ON ��������������������������������������������������������������������������������������������������������������� 4-39 Rear control panel detail ������������������������������������������������������������������������������������������������������...
EX-TRAFIRE 45SD ® OPERATION Front view It displays machine status Multifunction knob (such as the cutting current, air It is used to cycle through pressure, cutting mode, etc)� two menu’s and to set the cutting parameters� Torch connector Work clamp connector LCD display details 1�...
EX-TRAFIRE 45SD ® Setting of power supply The LCD screen contains two menus� In the first menu, the cutting current (Amperage) and the operation modes can be adjusted� Turn the regulator knob left or right to set cutting current� Press the multifunction knob briefly to set operation modes�...
EX-TRAFIRE 45SD ® 2� Cutting parameters� Setting the gas pressure� Press the multifunction knob for 1 second, the cutting parametrs illuminate� Press on multifunction knob briefly to set bar, MPa or psi� Continue to press on multifunction knob briefly, the output voltage and detected length of the cutting torch is displayed�...
EX-TRAFIRE 45SD ® Rear view, Turn ON 45SD - Single phase 45SD - Three phase Rear panel Switch ON Switch ON Rear panel detail 45SD - Single phase 45SD - Three phase 1� Power supply switch 2� Mains power lead 3�...
EX-TRAFIRE 45SD ® Cutting preparation 1� Firmly connect the mains power lead to a suitable electrical socket, check the input supply voltage for compatibility� 2� Connect the air supply, connect the work clamp to the workpiece� 3� Switch on the power supply, the LCD illuminates, full system check� 4�...
EX-TRAFIRE 45SD ® Hand torch consumables installation WARNING Plasma arc is generated immediately when the torch trigger is depressed Plasma arc is generated immediately when the torch trigger is depressed� The plasma arc will cut quickly through gloves and skin� Make sure the power is switched off before changing consumables�...
EX-TRAFIRE 45SD ® Operating the hand torch WARNING Plasma arc is generated immediately when the torch trigger is depressed Plasma arc is generated immediately when the torch trigger is depressed� The plasma arc will cut quickly through gloves and skin� Make sure the power supply is switched off before changing consumables�...
EX-TRAFIRE 45SD ® WARNING SPARKS AND HOT METAL CAN BURN THE SKIN AND EYES When angling the torch for cutting or piercing, molten metal (Arc Spray) will occur in the direction that the torch is aimed� Aim the torch away from yourself and others� Fit the work clamp Secure the work clamp to the workpiece, ensure good contact, and remove surface contaminants�...
EX-TRAFIRE 45SD ® Hand torch cutting technique Avoid unnecessary firing of the torch, each firing of the torch reduces the lifetime of the electrode and nozzle� When cutting, ensure the arc spray exits the underside of the work piece� Direction of cut Incomplete severance is indicated by an upward arc spray�...
EX-TRAFIRE 45SD ® Piercing WARNING SPARKS AND HOT METAL CAN BURN THE SKIN AND EYES When angling the torch for cutting or piercing, molten metal (Arc Spray) will occur in the direction that the torch is aimed� Aim the torch away from yourself and others�...
EX-TRAFIRE 45SD ® Gouging WARNING SPARKS AND HOT METAL CAN BURN THE SKIN AND EYES When angling the torch for cutting, piercing or gouging, molten metal (Arc Spray) will occur in the direction that the torch is aimed� Aim the torch away from yourself and others�...
EX-TRAFIRE 45SD ® Machine torch consumables installation WARNING Plasma arc is generated immediately when the CNC start signal is ON Plasma arc is generated immediately when the CNC start signal is ON� The plasma arc will cut quickly through gloves and skin� Make sure the power supply is switched off before changing consumables�...
EX-TRAFIRE 45SD ® Mechanized Cutting Charts 30 A Cutting, Shielded Configuration Mild Steel Recommended Speed* Maximum Speed** Torch (Shield) Initial Pierce Pierce Material Best Quality Settings Standard Quality Settings Kerf to Workpiece Height Delay Thickness Width Distance (Shield) Time Voltage Voltage Speed Speed...
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EX-TRAFIRE 45SD ® Mechanized Cutting Charts 30 A Cutting, Shielded Configuration Notes: * Cut capacity speeds are not necessarily maximum speeds� They are the speeds that must be achieved to be rated at that thickness� ** Maximum cut speeds are the results of intensive laboratory testing�...
EX-TRAFIRE 45SD ® Mechanized Cutting Charts 45 A Cutting, Shielded Configuration Mild Steel Recommended Speed* Maximum Speed** Torch (Shield) Initial Pierce Pierce Material Best Quality Settings Standard Quality Settings Kerf to Workpiece Height Delay Thickness Width Distance (Shield) Time Voltage Voltage Speed Speed...
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EX-TRAFIRE 45SD ® Mechanized Cutting Charts 45 A Cutting, Shielded Configuration Notes: * Cut capacity speeds are not necessarily maximum speeds� They are the speeds that must be achieved to be rated at that thickness� ** Maximum cut speeds are the results of intensive laboratory testing�...
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EX-TRAFIRE 45SD ® SECTION 5� MAINTENANCE: Routine maintenance ����������������������������������������������������������������������������������������������������������� 5-53 Consumable parts inspection ��������������������������������������������������������������������������������������������� 5-54 Purging/draining of the built-in filter ���������������������������������������������������������������������������������� 5-55 5-52 Operator Manual, Revision T-5...
EX-TRAFIRE 45SD ® MAINTENANCE Routine maintenance WARNING ELECTRIC SHOCK CAN KILL Disconnect mains power lead before servicing; Qualified technicians only should perform any work that requires removal of the system cover� Allow a period (minimum 5 min�) for electrical discharge before handling internal parts� Check the gas pressure�...
EX-TRAFIRE 45SD ® Consumable parts inspection Part Inspect Operation Out of round orifice or worn cruciform Replace shield indicates worn condition Accumulated spatter in the gap between Clean away any material from the shield and the nozzle the shield and nozzle surface Heat damage, cracks / fractures, damaged Replace nozzle Retaining Cap threads, blocked gas holes...
EX-TRAFIRE 45SD ® Purging/draining the built-in filter This power supply is equipped with built-in float type auto drain filter� Do not cover outflow drain hole located on the bottom of the power supply (see the picture below)� Position of the outflow drain hole Operator Manual, Revision T-5 5-55...
INFORMATION EX-TRAFIRE 45SD ® SECTION 7� ADITIONAL ORDERING INFORMATION EX-TRAFIRE 45SD Plasma Power Supply Units ® Part No� DESCRIPTION EX-2-001-030 EX-TRAFIRE 45SD/CE/3x400V Power Supply Unit (fully-equipped) ® EX-2-001-024 EX-TRAFIRE 45SD/CE/1x110/230V Power Supply Unit (fully-equipped) ® EX-TRAFIRE 45SD Manual Plasma Cutting Systems ®...
EX-TRAFIRE 45SD ® SECTION 8� TROUBLESHOOTING: Fault This may mean Cause Solution Main switch is • No / Low mains • Insufficient mains • Check the mains input ON, the LCD voltage power power supply� voltage 120 VAC ± 20% (CE) screen does not supply�...
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EX-TRAFIRE 45SD ® Fault This may mean Cause Solution The error code • Consumables • Consumables are • Install the consumables and H08 appears� fault� loose, improperly fit the retaining cap� And icon installed or missing� • The retaining cap •...
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EX-TRAFIRE 45SD ® Fault This may mean Cause Solution No transfer • Work clamp • Fluctuating • Clean the surface of the between connection fault� connection clamp and material� pilot arc and between the clamp workpiece� and work piece� • No connection to •...
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EX-TRAFIRE 45SD ® Fault This may mean Cause Solution Cut quality • Incorrect current • Cutting current • Adjust the cutting current issues� setting� (Amperage) too low (Amperage) to suit the / material too thick� thickness of material to be cut�...
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EX-TRAFIRE 45SD ® ERROR CODES System operation failed No pilot arc established possibly due to a loss of current� Consumables in torch failed to separate during pilot arc� Over - temperature alarm Over - current alarm Torch inspection / cap sensor ( The cutting torch is missing or not connected�) Consumables in Place check Internal communication error remote control...
EX-TRAFIRE 45SD ® Filter-EX Quick Connect Couplings EX-0-802-000 EX-0-802-001 EX-0-802-002 DN 7�2 ES Quick Connect Plug DN 7�2 ES Quick Connect Plug DN 7�2 ES Quick Connect Coupling with female thread G 1/4“ with male thread G 1/4“ with male thread G 1/4“ CNC interface EX-0-803-001 EX-0-803-004...
EX-TRAFIRE 45SD ® Circle cutting guide kit for FHT-EX 105RTXH/105TTH/45TTH ® EX-5-801-002 This Circle cutting guide kit for hand-held cutting obtains: Circle cutting attachment • Cutting guide • Radius bar mm� 250 • Radius bar mm� 400 • Magnetic base assembly •...
Hereby Thermacut, k�s� confirms that to its knowledge all Plasma Power supply models EX-TRAFIRE H, SC, SD and HD (unless otherwise expressly stated) sold by Thermacut, k�s� fulfill the requirements of the EU directive 2011/65/EU� These products are compatible with the current RoHS requirements for the 7 substances (max 0�1% by weight in homogeneous materials for lead,...
This Warranty Certificate forms an integral part of General Business Conditions (“GBC”) of THERMACUT, k.s. (the “Seller”) and shall apply to supplies of Goods under Contract concluded between the Seller and the other contracting party as the recipient of the Goods (the “Buyer”); terms used herein have the same meaning as is ascribed to them in the GBC 1�...
EX-TRAFIRE 45SD ® Revision history: 1� Revision T-1/2020 - 02/2020 Official release 2� Revision T-2/2020 - 05/2020 New graphics of rear panel - rear panel without BUS connector Page 3-28 - New paragraph - Gas pressure adjustment Page 4-46 - new value of Voltage from: 7100 to: 115 (Mild Steel, Material Thickness =1�5 mm, Standard Quality Settings, Cut Speed=7100 mm/min)
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686 01, Uherské Hradiště Czech Republic www�thermacut�cz sales@thermacut�cz THERMACUT®, FHT-EX® and EX-TRAFIRE® are registered trademarks of THERMACUT, k�s� and may be registered in Czech Republic and/or other countries� All other trademarks are properties of their respective owners� 12-80 Operator Manual, Revision T-5...
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