THERMACUT EX-TRAFIRE 45HD Operating Instructions Manual
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THERMACUT EX-TRAFIRE 45HD Operating Instructions Manual

Plasma cutting system
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Plasma Cutting System
Operating Instructions – EX-2-902-002/N21603 – CE
th
Revision 2, 24
February, 2023

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Summary of Contents for THERMACUT EX-TRAFIRE 45HD

  • Page 1 Plasma Cutting System Operating Instructions – EX-2-902-002/N21603 – CE Revision 2, 24 February, 2023...

  • Page 2: Table Of Contents

    ® EX-TRAFIRE 45HD Table of contents Identification ............... EN-4 Marking....................EN-4 Identification plate ................EN-4 Signs and symbols used..............EN-4 Classification of the warnings ............EN-5 Safety................EN-5 Designated use................. EN-5 Obligations of the operator ............EN-6 Warning and notice signs..............EN-6 Product-specific safety instructions..........
  • Page 3 ® EX-TRAFIRE 45HD Manual grid cutting, gouging, marking process ......EN-29 Cutting ..................... EN-30 Piercing .................... EN-31 Gouging ..................EN-31 7.7.1 Table for FHT-EX®45TT material removal ........EN-32 Stopping the cutting process ............EN-33 Disconnecting the unit..........EN-33 Maintenance and cleaning........EN-34 Maintenance and cleaning intervals ..........

  • Page 4: Identification

    The EX-TRAFIRE 45HD uses gas, argon or nitrogen to cut almost all conductive metals. The device ® may be operated only with original Thermacut parts. This documentation ® describes the EX-TRAFIRE 45HD cutting power supply only.

  • Page 5: Classification Of The Warnings

    ® EX-TRAFIRE 45HD 2 Safety Classification of the warnings The warnings are divided into four different categories and are indicated prior to potentially dangerous work steps. The following signal words are used depending on the type of hazard: DANGER Describes an imminent threatening danger. If not avoided, it may cause severe injury or death.

  • Page 6: Obligations Of The Operator

     Keep untrained persons out of the work area. ®  Each time the device’s cover plates are opened, have Thermacut another authorized specialist perform a safety inspection in accordance with DIN IEC 60974 Part 4: “Periodic inspection and testing”.

  • Page 7: Safety Instructions For The Electrical Power Supply

    ® EX-TRAFIRE 45HD 2 Safety Safety instructions for the electrical power supply  Ensure that the input power cable is not damaged, for example by being driven over, crushed or torn.  Check the input power cable for damage and wear at regular intervals. ...

  • Page 8: Scope Of Delivery

     The order data and ID numbers for the equipment parts and consumables can be found in the product catalog.  For more information about points of contact, consultation, and orders, www.thermacut.com visit Although the items delivered are carefully checked and packaged, it is not possible to fully rule out the risk of transport damage.

  • Page 9: Product Description

    ® EX-TRAFIRE 45HD 4 Product description Product description Assembly and use The control elements are located on the control panel. The connections are on the front and rear of the device. Fig. 2 Control elements and connections, rear panel On/Off switch Optional BUS interface Optional CNC interface Input power cable...
  • Page 10 ® 4 Product description EX-TRAFIRE 45HD ON/OFF switch (A) Used to switch the device on and off. CNC interface This optional interface is used to connect the connection (B) device to an optional CNC cutting table or robot. Gas connection (C) This interface is used to connect a compressed air supply.

  • Page 11: Technical Data

    ® EX-TRAFIRE 45HD 4 Product description Technical data ® 4.2.1 EX-TRAFIRE 45HD, Single-phase Table 1 Power supply specifications, single-phase Idle voltage (U 292 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Output current (I 10 –...

  • Page 12: Ex-Trafire ® 45Hd, Three-Phase

    ® 4 Product description EX-TRAFIRE 45HD ® 4.2.2 EX-TRAFIRE 45HD, Three-phase Table 2 Power supply specifications, Three-phase Idle voltage (U 308 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Output current (I 10 –...

  • Page 13: Technical Data For Cutting Torches Fht-Ex

    ® EX-TRAFIRE 45HD 4 Product description Table 5 Gas data Permissible gas Compressed air/nitrogen/argon Max. gas inlet pressure 10 bar Recommended compressed air ISO 8573-1 Class 1.2.2. quality Purity: > 99,99% clean, and free from moisture and Max. flow rate 120 l/min at 10 bar ®...
  • Page 14 ® 4 Product description EX-TRAFIRE 45HD ® ® Table 6 Technical data for FHT-EX 45TTH and FHT-EX 45TTM cutting torches ® ® FHT-EX 45TTH / FHT-EX 45TTM Connection type TCS (Torch Connection System) - 13 Pin Standard lengths 5 m/8 m/15 m (other lengths available upon request) Table 7...

  • Page 15: Transport And Positioning

    ® EX-TRAFIRE 45HD 5 Transport and positioning Transport and positioning WARNING Risk of injury due to improper transport and installation Improper transport and installation can cause the device to tip or fall over. This may result in serious injury. • Wear your personal protective equipment. •...

  • Page 16: Setting Up The Power Supply

    ® 6 Setting up the power supply EX-TRAFIRE 45HD Setting up the power supply Connecting to the gas supply  Connect the gas hose with an inside Single-phase diameter of at least 6 mm to the gas connection of the device. Three-phase Connecting the work lead ...

  • Page 17: Connecting The Power Supply Cable

    ® EX-TRAFIRE 45HD 6 Setting up the power supply Connecting the power supply cable 6.3.1 Connecting the single-phase machine  The power supply should be Single -phase connected by a qualified electrician. L -> black (brown) N -> blue PE grounding -> green-yellow 6.3.2 Connecting the three-phase machine ...

  • Page 18: Connecting The Input Power Plug

    ® 6 Setting up the power supply EX-TRAFIRE 45HD Connecting the input power plug  Note the safety instructions.  2.5 Safety instructions for the electrical power supply on page EN-7 WARNING Electric shock due to improperly installed electrical power supply If the electrical power supply and grounding are improperly installed, fatal electric shock may occur.

  • Page 19: Connection To A Generator (Optional

    ® EX-TRAFIRE 45HD 6 Setting up the power supply 6.4.1 Connection to a generator (optional)  Set the generator to single-phase or three-phase alternating current.  Plug the input power plug into the socket.  Set the motor rating as shown in the following table. Table 9 Connection to a generator Generator motor rating...

  • Page 20: Connecting The Cnc Interface

    ® 6 Setting up the power supply EX-TRAFIRE 45HD Connecting the CNC interface The CNC interface is on the rear of the device. Control signals can be transmitted via the CNC interface. The signal types can be found in table 10. The control elements are located on the control panel. The connections are on the front and rear of the device.

  • Page 21: Setting The Dip Switches

     Fig. 5 DIP switch settings on page EN-21 The housing must be closed only by a qualified electrician. Have a safety inspection performed in accordance with DIN IEC 60974 ® Part 4: “Periodic inspection and testing” by Thermacut or another authorized specialist. Fig. 5 DIP switch settings 6.6.2 Enabling the external DC coil with an external power supply...

  • Page 22: Enabling The External Ac Coil With An External Power Supply

    ® 6 Setting up the power supply EX-TRAFIRE 45HD 6.6.3 Enabling the external AC coil with an external power supply Fig. 7 Enable the external AC coil with an external power supply. 24 V AC 230 V AC 6.6.4 Enabling the industrially insulated module with an external power supply Industrial insulated user module with 24 V DC power supply.

  • Page 23: Installing Consumables For The Hand And Machine Cutting Torches

    ® EX-TRAFIRE 45HD 6 Setting up the power supply Installing consumables for the hand and machine cutting torches WARNING Risk of injury due to unexpected ignition of the plasma arc Hand cutting torch: When the input power plug is plugged in, the plasma arc ignites immediately when the torch trigger is pressed.
  • Page 24 ® 6 Setting up the power supply EX-TRAFIRE 45HD Insert the nozzle into the retaining cap. Insert the swirl ring into retaining cap and nozzle. Insert the electrode. Screw the entire assembly onto the hand cutting torch.  Do not overtighten. ...

  • Page 25: Aligning Fht-Ex ® 45Ttm Machine Cutting Torch

    ® EX-TRAFIRE 45HD 7 Operation of the power supply ® Aligning FHT-EX 45TTM machine cutting torch For the setup of the torch and the cutting process see  6 Setting up the power supply on page 17 Position the cutting torch perpendicular to the workpiece.

  • Page 26: Lcd Description

    ® 7 Operation of the power supply EX-TRAFIRE 45HD Material damage due to exceeding the maximum duty cycle If the device is operated for longer than the maximum duty cycle, it may be overloaded and irreparably damaged. • Only operate the device up to the maximum permissible duty cycle. ...

  • Page 27: Setting The Parameters

    ® EX-TRAFIRE 45HD 7 Operation of the power supply 7.1.1 Setting the parameters The LCD display contains two menus: The output current (Amperage) and the cutting modes are set in the first menu. In the second menu, the pressure in Bar, Mpa or Psi can be set. In addition, the torch type, torch length, and operating voltage are displayed.

  • Page 28: Selecting The Cutting Mode

    ® 7 Operation of the power supply EX-TRAFIRE 45HD 7.1.2 Selecting the cutting mode Grid cutting  Briefly press the multifunction button to activate the cutting mode. The current is 20 – 45 A. The pressure of the cutting gas is 4.2 –...

  • Page 29: Powering On The Machine

    ® EX-TRAFIRE 45HD 7 Operation of the power supply Powering on the machine  Set switch to <ON>. Single-phase Three-phase Manual cutting process Switch on the power supply. Automatic gas test (5 seconds). Automatic system test (5 seconds). Press torch trigger. Generate a pilot arc.

  • Page 30: Cutting

    ® 7 Operation of the power supply EX-TRAFIRE 45HD Cutting Start the cutting process at the edge of the workpiece. Do not move the cutting torch until the material has been cut through completely. Place the cutting torch upright on the edge of the workpiece.

  • Page 31: Piercing

    ® EX-TRAFIRE 45HD 7 Operation of the power supply Piercing Hold the cutting torch at an angle to the workpiece with a max. distance of 3 mm from the nozzle to the workpiece. Press the torch trigger to ignite the arc.
  • Page 32 ® 7 Operation of the power supply EX-TRAFIRE 45HD Use gouging consumables suitable to the cutting torch being used. Hold the cutting torch at an angle of 35 – 45° inclined to the workpiece. Hold the nozzle close enough to the workpiece so that it touches the workpiece.

  • Page 33: Stopping The Cutting Process

    ® EX-TRAFIRE 45HD 8 Disconnecting the unit Stopping the cutting process CAUTION Risk of injury due to hot parts Parts may still be hot after the gas post-flow period ends. There is a risk of burns. • Wear your personal protective equipment. •...

  • Page 34: Maintenance And Cleaning

    • Each time the cover plates are opened, have a safety inspection performed in accordance with DIN IEC 60974 Part 4: “Periodic ® inspection and testing” by Thermacut or another authorized specialist. WARNING...

  • Page 35: Maintenance And Cleaning Intervals

    Every 3 months  Open the device body and have the inside of the device cleaned with a vacuum cleaner or ® dry, clean compressed air by Thermacut another authorized specialist.  Have a safety inspection performed in Annually and after...

  • Page 36: Faults And Troubleshooting

    EN-50 ®  17.3 FHT-EX 45TTM consumables for marking machine cutting torch on page EN-51 ®  Contact your retailer or Thermacut in the event of questions or problems. Table 13 Fault messages in the display Error code Cause Trouble shooting ...
  • Page 37 The following tightly. tighten, if needed. icon flashes: ®  Consumables used are  Use only Thermacut ® not Thermacut original consumables. original parts.  Dirt inside the torch.  Remove all consumables, clean the inside of the torch, and re-assemble in correct order.
  • Page 38 ® 10 Faults and troubleshooting EX-TRAFIRE 45HD Table 13 Fault messages in the display Error code Cause Trouble shooting  Watchdog fault.  Replace the control PCB.  Incorrect current  Verify the cutting power setting. settings.  Incorrect cutting mode.  Verify the cutting mode. ...
  • Page 39 ® EX-TRAFIRE 45HD 10 Faults and troubleshooting Table 14 General faults Error Description Cause Troubleshooting  Connection fault in  Ensure that all cable work lead or cutting connections are correctly torch cable. installed.  No contact between  Remove contamination and/ work lead clamp or oxidation from the and workpiece.

  • Page 40: Disassembly

    ® 11 Disassembly EX-TRAFIRE 45HD Table 14 General faults Error Description Cause Troubleshooting  Incorrect  Output current  Adjust the output current setting for (amps) too low/ strength to the thickness of output current. material too thick. the workpiece. ...

  • Page 41: Disposal

     Observe the relevant local regulations and disposal instructions in the safety data sheets specified by the manufacturer of the consumables. 12.3 Packaging ® Thermacut has reduced the packaging to the necessary minimum. The ability to recycle packaging materials is always considered during their selection.

  • Page 42: Warranty

    Warranty This warranty statement is an integral part of the Terms and Conditions ® (“T&C”) of Thermacut (hereinafter “Seller”) and applies to deliveries of goods under the contract concluded between the Seller and the other party to the contract as the recipient of the goods (hereinafter “Buyer”); the terms used herein have the same meaning as attributed to them in the T&C.

  • Page 43: Block Diagram

    ® EX-TRAFIRE 45HD 14 Block diagram Block diagram Fig. 8 Block diagram single-phase Fig. 9 Block diagram three-phase EN - 43...

  • Page 44: Accessories

    G 1/4" EX-0-803-001 CNC interface plug 14-pin kit, incl. 7 pins EX-0-803-004 CNC interface connection cable EX-0-805-001 Grease, 25 ml EX-5-801-002 Circle cutting guide kit for ® FHT-X 105RTXH/105TTH/45TTH For more information about accessories, visit our website: www.thermacut.com. EN - 44...

  • Page 45: Fht-Ex ® 45Tth Hand Cutting Torch Unit

    ® ® EX-TRAFIRE 45HD 16 FHT-EX 45TTH hand cutting torch unit ® FHT-EX 45TTH hand cutting torch unit ® Table 16 FHT-EX 45TTH hand cutting torch Part number Description ® EX-2-101-001 FHT-EX 45TTH hand cutting torch without consumables, with 5 m cable (16.5‘)/TCS13 ®...
  • Page 46 ® ® 16 FHT-EX 45TTH hand cutting torch unit EX-TRAFIRE 45HD Table 17 Components for hand cutting torch 45 A and gouging Hand cutting torch Item Part number Description EX-0-325-005 Male crimp pin for TCS plug EX-0-325-009 O-Ring (fitted in the TCS plug) EX-0-325-010 Retaining ring (outer circlip ring) EX-0-323-001...

  • Page 47: Fht-Ex ® 45Tth Consumables For Hand Cutting Torch

    ® ® EX-TRAFIRE 45HD 16 FHT-EX 45TTH hand cutting torch unit ® 16.2 FHT-EX 45TTH consumables for hand cutting torch Shielded Gouging ® Table 18 Consumables for hand cutting torch FHT-EX 45TTH Item Part number Description EX-2-401-201 Electrode EX-2-404-201 Swirl ring EX-2-409-201 Nozzle EX-2-415-201...

  • Page 48: Fht-Ex ® 45Ttm Machine Cutting Torch Unit

    ® ® 17 FHT-EX 45TTM machine cutting torch unit EX-TRAFIRE 45HD ® FHT-EX 45TTM machine cutting torch unit ® Table 19 FHT-EX 45TTM machine cutting torch Part number Description ® EX-2-233-001 FHT-EX 45TTM DEMO machine cutting torch with consumables/TCS13 ® EX-2-202-001 FHT-EX 45TTM machine cutting torch without consumables, with 5 m (16.5‘) lead/TCS13...
  • Page 49 ® ® EX-TRAFIRE 45HD 17 FHT-EX 45TTM machine cutting torch unit Table 20 Machine cutting torch components Item Part number Description EX-0-325-005 Male crimp pin for TCS plug EX-0-325-009 O-ring (fitted in the TCS plug) EX-0-325-010 Retaining ring (outer circlip ring) EX-0-323-001 TCS13 plug body EX-0-325-001 TCS clam shell lower EX-0-325-002 TCS clam shell upper...

  • Page 50: Fht-Ex 45Ttm Consumables For Standard

    ® ® 17 FHT-EX 45TTM machine cutting torch unit EX-TRAFIRE 45HD ® 17.2 FHT-EX 45TTM consumables for standard machine cutting torch Shielded Unshielded ® Table 21 FHT-EX 45TTM consumables for standard machine cutting torch Item Part number Description EX-2-401-201 Electrode EX-2-404-201 Swirl ring EX-2-409-201...

  • Page 51: Machine Cutting Torch

    ® ® EX-TRAFIRE 45HD 17 FHT-EX 45TTM machine cutting torch unit ® 17.3 FHT-EX 45TTM consumables for marking machine cutting torch ® Table 22 FHT-EX 45TTM consumables for marking machine cutting torch Item Part number Description EX-2-401-201 Electrode EX-2-404-201 Swirl ring EX-2-445-001 Nozzle, Marking EX-2-415-202...

  • Page 52: Ordering Information On Bulk Packs And Starter Kits

    ® 18 Ordering information on bulk packs and starter kits EX-TRAFIRE 45HD Ordering information on bulk packs and starter kits ® 18.1 EX-TRAFIRE 45HD plasma power supply ® Table 23 EX-TRAFIRE 45HD plasma power supply Part number Description ® EX-2-001-001 EX-TRAFIRE 45HD/CE/1x110/230 V power supply (fully equipped = CNC interface &...

  • Page 53: Ex-Trafire ® 45Hd Mechanized Plasma Cutting Systems

    ® EX-TRAFIRE 45HD 18 Ordering information on bulk packs and starter kits ® 18.3 EX-TRAFIRE 45HD mechanized plasma cutting systems ® Table 25 EX-TRAFIRE 45HD mechanized plasma cutting systems (fully equipped) Part number Description Length ® EX-2-011-041 EX-TRAFIRE 45HD/CE/1x110/230 V machine system (fully equipped = CNC &...

  • Page 54: Bulk Packs For Fht-Ex ® 45Tth And Fht-Ex ® 45Ttm

    ® 18 Ordering information on bulk packs and starter kits EX-TRAFIRE 45HD ® ® 18.4 Bulk packs for FHT-EX 45TTH and FHT-EX 45TTM ® ® Table 27 Bulk packs for FHT-EX 45TTH and FHT-EX 45TTM Part number Description Pck. EX-2-434-201 Bulk pack – Electrode – 25 pcs. EX-2-435-201 Bulk pack –...

  • Page 55: Cutting Tables For Mechanical Cutting

    ® EX-TRAFIRE 45HD 19 Cutting tables for mechanical cutting Cutting tables for mechanical cutting Cutting tables serve as a guideline for mechanical cutting. Individual systems can be “fine tuned” to achieve optimum cutting quality.  Recommended speed: Speeds adjusted for cutting capacity do not necessarily represent maximum speeds.

  • Page 56: Cutting, Shielded, With Compressed Air

    ® 19 Cutting tables for mechanical cutting EX-TRAFIRE 45HD 19.1 30 A cutting, shielded, with compressed air EX-2-421-201 EX-2-415-202 EX-2-409-201 EX-2-404-201 EX-2-401-201 EX-2-428-011 EX-2-415-201 EX-2-423-211 Material Torch Pierce Pierce delay Recommended Maximum speed Kerf thickness (shield) to height time speed width workpiece (shield) to...
  • Page 57 ® EX-TRAFIRE 45HD 19 Cutting tables for mechanical cutting 19.2 45 A cutting, shielded, with compressed air EX-2-409-201 EX-2-404-201 EX-2-401-201 EX-2-421-201 EX-2-415-202 EX-2-428-011 EX-2-415-201 EX-2-423-211 Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay time width Settings for Standard quality...

  • Page 58: Tables For Marking

    ® 19 Cutting tables for mechanical cutting EX-TRAFIRE 45HD 19.3 Tables for marking 19.3.1 Marking, shielded, with compressed air or Argon EX-2-415-202 EX-2-445-001 EX-2-404-201 EX-2-401-201 EX-2-445-002 EX-2-415-201 With compressed air Marking Power Torch (shield) Initial marking Delay Marking Kerf Kerf supply to workpiece height...
  • Page 59 Tel.: +385 53 882 622 Fax.: +49 (0)2736 29 49 11-77 E-mail: thermacut@gs.t-com.hr E-mail: info@thermacut.de www.thermacut.hr www.thermacut.de POLAND FRANCE THERMACUT-POLAND SP. Z O.O. THERMACUT FRANCE ul. Stawowa 20 6 Rue des Frères Lumière 43-400 Cieszyn 67201 Eckbolsheim POLAND Tel.:+33 3 88 76 58 75 Tel.: +48 33 852 13 34...
  • Page 60 E-mail: ac@binzel.se, E-mail: info@binzel.fi ket@binzel.se www.thermacut.net www.thermacut.net BELARUS SLOVAKIA IOOO „ABICOR BINZEL Technics“ THERMACUT SLOVAKIA, s.r.o. ul. Timirjazeva 97-10 Priemyselná ulica 1239 BY-220020 Minsk 931 01 Šamorín ?el.: +375 29 5 800 300 Tel.: +421 31 591 0121 E-mail: info@thermacut.by +421 903 644 954 www.thermacut.by...
  • Page 61 Pedro do Rio, Petrópolis – Rio de Janeiro, CEP 25750-226 Tel.: +55 (24) 2222-9799 +55 (24) 2222-9789 +(24) 98134-2676 Fax: +55 (24) 2222-9789 E-mail: thermacut@thermacut.com.br www.thermacut.com.br ASIA CHINA TURKEY TMT (Shanghai) Cutting and Welding ABICOR BINZEL Kaynak Teknik Equipment Co., Ltd.
  • Page 62 JAPAN UNITED ARAB EMIRATES Thermacut Japan Ltd. ABICOR BINZEL MIDDLE EAST FZE 3F Shin-Osaka Hankyu Building P.O Box: 86026, WFZ-04/27 1-1-1, Miyahara, Yodogawa-ku, Osaka RAKIA Freezone, Jazeera al Hamra 532-0003 Japan Ras al Kaimah, United Arab Emirates Mob.: +81 (0)80 4738 9752 Tel.: +971 (7) 2432355...
  • Page 63 Revision history You can find the latest version of the operator manual on our website: www.thermacut.com. Revision R1/10_2022 Revision R2/02_2023: — 4.2 „Technical data“: Maximum input power changed to 7.5 kVA (single-phase) and 11.4 kVA (three-phase)
  • Page 64 © Copyright 2022 Thermacut k.s, Subject to change without a notice. All Rights Reserved.

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