THERMACUT EX-TRAFIRE 105HD Operating Instructions Manual
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THERMACUT EX-TRAFIRE 105HD Operating Instructions Manual

Plasma cutting power supply
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Plasma Cutting Power Supply
Operating Instructions – EX-5-902-004/N21609 – RCM
th
Revision 3, 6
April, 2023

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Summary of Contents for THERMACUT EX-TRAFIRE 105HD

  • Page 1 Plasma Cutting Power Supply Operating Instructions – EX-5-902-004/N21609 – RCM Revision 3, 6 April, 2023...

  • Page 2: Table Of Contents

    ® EX-TRAFIRE 105HD Table of contents Identification ............... EN-5 Marking....................EN-5 Identification plate ................EN-5 Signs and symbols used..............EN-5 Classification of the warnings ............EN-6 Safety................EN-6 Designated use................. EN-6 Obligations of the operator ............EN-7 Warning and notice signs..............EN-7 Product-specific safety instructions..........
  • Page 3 ® EX-TRAFIRE 105HD Gouging ..................EN-29 7.7.1 Table for FHT-EX®105TT material removal ......... EN-29 Stopping the cutting process ............EN-30 Disconnecting the unit..........EN-30 Maintenance and cleaning........EN-30 Maintenance and cleaning intervals ..........EN-31 Faults and troubleshooting........EN-32 Disassembly .............. EN-37 Disposal ..............
  • Page 4 ® EX-TRAFIRE 105HD 21.3 65 A cutting, shielded, with compressed air ......EN-54 21.4 75 A cutting, shielded, with compressed air ......EN-55 21.5 85 A cutting, shielded, with compressed air ......EN-56 21.5.185 A cutting, shielded, with compressed air ......EN-57 21.6 100 –...

  • Page 5: Identification

    The ® EX-TRAFIRE 105HD uses air or nitrogen to cut almost all conductive ® metals. The device may be operated only with original Thermacut parts. ® This documentation describes the EX-TRAFIRE 105HD cutting power supply only.

  • Page 6: Classification Of The Warnings

    ® 2 Safety EX-TRAFIRE 105HD 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 7: 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 8: Safety Instructions For The Electrical Power Supply

    ® 2 Safety EX-TRAFIRE 105HD 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 9: 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 10: Product Description

    ® 4 Product description EX-TRAFIRE 105HD 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 Display Power cable <POWER>...

  • Page 11: Technical Data

    ® EX-TRAFIRE 105HD 4 Product description Technical data Table 1 Power supply specifications Idle voltage (U 390 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Output current (I 20 –105 A Nominal voltage (U 180 V DC Output current at 100% duty 105 A...

  • Page 12: Technical Data For Cutting Torches Fht-Ex

    ® 4 Product description EX-TRAFIRE 105HD Table 4 Gas data Permissible gas Compressed air/nitrogen 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 205 l/min at 5 bar ®...
  • Page 13 ® EX-TRAFIRE 105HD 4 Product description ® ® Table 5 Technical data for FHT-EX 105TTH and FHT-EX 105TTM cutting torches ® ® FHT-EX 105TTH / FHT-EX 105TTM Type of voltage Protection type for device IP23S (EN 60529) Connection type TCS (torch connection system) – 13 pin Standard lengths 5 m/8 m/15 m/23 m (other lengths available upon...

  • Page 14: Transport And Positioning

    ® 5 Transport and positioning EX-TRAFIRE 105HD 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 15: Setting Up The Power Supply

    ® EX-TRAFIRE 105HD 6 Setting up the power supply Setting up the power supply Connecting to the gas supply  Connect the gas hose with an inside diameter of at least 6 mm to the gas connection of the device. Connecting the work lead ...

  • Page 16: Connecting The Input Power Plug

    ® 6 Setting up the power supply EX-TRAFIRE 105HD Connecting the input power plug  Note the safety instructions.  2.5 Safety instructions for the electrical power supply on page EN-8 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 17: Connecting The Cutting Torch

    ® EX-TRAFIRE 105HD 6 Setting up the power supply Connecting the cutting torch NOTICE Risk of material damage if used without TCS Latch with Key Assembly The TCS Latch with Key Assembly is important for the proper working of the machine. If used without, the device may be irreparably damaged. •...

  • Page 18: Setting The Dip Switches

     Fig. 4 DIP switch settings on page EN-18 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. 4...

  • Page 19: Enabling The External Dc Coil With An External Power Supply

    ® EX-TRAFIRE 105HD 6 Setting up the power supply 6.6.2 Enabling the external DC coil with an external power supply  For 24 V DC, use a 1N4007 diode. Fig. 5 Enable the external DC coil with an external power supply. Use diode 24 V DC 1N4007 if the...

  • Page 20: Enabling The Industrially Insulated Module With An External Power Supply

    ® 6 Setting up the power supply EX-TRAFIRE 105HD 6.6.4 Enabling the industrially insulated module with an external power supply Industrial insulated user module with 24 V DC power supply. Switch off the device. Remove the interface cover. Connect the interface cable with the cutting power supply.

  • Page 21: Installing Consumables For The Hand And Machine Cutting Torches

    ® EX-TRAFIRE 105HD 6 Setting up the power supply Screw the mounting tube with gear rack into the reduction nut. Hold the reduction nut and the torch mounting sleeve with torch body in order not to damage the cables. Tighten the mounting tube by hand. Screw in the strain relief.
  • Page 22 ® 6 Setting up the power supply EX-TRAFIRE 105HD Insert the nozzle into the retaining cap. Insert the electrode into retaining cap and nozzle. Insert the swirl ring. Screw the entire assembly onto the hand cutting torch.  Do not overtighten. ...

  • Page 23: Aligning Fht-Ex ® 105Ttm Machine Cutting Torch

    ® EX-TRAFIRE 105HD 7 Operation of the power supply ® Aligning FHT-EX 105TTM machine cutting torch Position the cutting torch perpendicular to the workpiece. Use an angle gauge to align the machine cutting torch at 0° and 90°. Operation of the power supply WARNING Risk of injury due to unexpected ignition of the plasma arc Hand cutting torch:...

  • Page 24: Lcd Description

    ® 7 Operation of the power supply EX-TRAFIRE 105HD NOTICE Material damage caused by unplugging the input power plug during operation If the input power plug is unplugged during operation, the device may be irreparably damaged. • Do not unplug the input power plug during operation and ensure a constant power supply.

  • Page 25: Setting The Parameters

    ® EX-TRAFIRE 105HD 7 Operation of the power supply 7.1.1 Setting the parameters The LCD menu is used to set the output current (amps), cutting modes, and pressure in bar, MPa, or psi. Press the multi-function button for one second. ...

  • Page 26: Connecting The Work Lead With The Work Lead Clamp

    ® 7 Operation of the power supply EX-TRAFIRE 105HD 7.1.3 Connecting the work lead with the work lead clamp Remove contamination from the workpiece. Clamp the work lead with the work lead clamp to the workpiece so that it conducts well. Do not clamp the work lead clamp to the material to be cut off.

  • Page 27: Manual Grid Cutting, Gouging, Marking Process

    ® EX-TRAFIRE 105HD 7 Operation of the power supply Manual grid cutting, gouging, marking process Switch on the power supply. Automatic gas test (5 seconds) Automatic system test (5 seconds) Press torch trigger. Generate a pilot arc. Once the workpiece is detected, the pilot arc switches to a cutting arc. Grid cutting, gouging, or marking starts depending on the selected process.

  • Page 28: Piercing

    ® 7 Operation of the power supply EX-TRAFIRE 105HD If sparks escape upwards during cutting, the material has not yet been completely severed. Proceed as follows:  Reduce the speed at which the cutting torch is pulled.  Check the setting for the output current.

  • Page 29: Gouging

    ® EX-TRAFIRE 105HD 7 Operation of the power supply Gouging Gouging can remove welding seams and achieve a controlled gouge profile. The gouge profile can be influenced by the actions in the following table: Gouge profile Actions Narrower and flatter  Reduce current or increase speed. ...

  • Page 30: Stopping The Cutting Process

    • 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 31: 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 or a different authorized specialist.  Have a safety inspection performed in...

  • Page 32: Faults And Troubleshooting

    105TTH consumables for hand cutting torch on page EN-42 ®  19 FHT-EX 105TTM consumables for machine cutting torch on page EN-46 ®  Contact your retailer or Thermacut in the event of questions or problems. Table 12 Fault messages in the display Error code Cause Troubleshooting ...
  • Page 33 CNC start has been tightened too re-install correctly and signal is tightly. tighten, if needed. switched on> ®  Consumables used are  Use only Thermacut ® not Thermacut original consumables. original parts. EN - 33...
  • Page 34 Table 12 Fault messages in the display Error code Cause Troubleshooting  Missing phase.  Have the issue checked by ® Thermacut or an authorized specialist.  Incorrect cutting torch.  Verify the proper cutting torch is connected.  No data  Check the cable.
  • Page 35 ® EX-TRAFIRE 105HD 10 Faults and troubleshooting Table 13 General faults Fault Description Cause Troubleshooting  No/low input  Power supply is  Check the input power Switch is set to on, LCD does not power insufficient. voltage. illuminate. voltage. ...
  • Page 36 ® 10 Faults and troubleshooting EX-TRAFIRE 105HD Table 13 General faults Fault Description Cause Troubleshooting  Poor contact  Connection fault in  Ensure that all cable between work work lead or cutting connections are correctly lead clamp torch cable. installed.

  • Page 37: Disassembly

    ® EX-TRAFIRE 105HD 11 Disassembly Table 13 General faults Fault Description Cause Troubleshooting  Incorrect  Output current  Adjust the output current setting for (amps) too strength to the thickness of output low/material too the workpiece. current. thick.  Consumables ...

  • Page 38: 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 39: 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 40: Block Diagram

    DN 7.2 ES Quick-connect socket with male thread 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 For more information about accessories, visit our website: www.thermacut.com. EN - 40...

  • Page 41: Fht-Ex 105Tth Hand Cutting Torch Unit

    ® ® EX-TRAFIRE 105HD 16 FHT-EX 105TTH hand cutting torch unit ® FHT-EX 105TTH hand cutting torch unit ® Table 15 FHT-EX 105TTH hand cutting torch Number Part number Description ® EX-5-133-002 FHT-EX 105TTH hand cutting torch without consumables with 5 m (16.5’) cable/TCS13 ®...

  • Page 42: Fht-Ex ® 105Tth Consumables For Hand Cutting Torch

    ® ® 17 FHT-EX 105TTH consumables for hand cutting torch EX-TRAFIRE 105HD ® FHT-EX 105TTH consumables for hand cutting torch ® 17.1 FHT-EX 105TTH consumables for hand cutting torch 45 – 85 A Table 16 Consumables for hand cutting torch 45 – 85 A Item Part number Description...

  • Page 43: Cutting Torch 100 - 105 A

    ® ® EX-TRAFIRE 105HD 17 FHT-EX 105TTH consumables for hand cutting torch ® 17.2 FHT-EX 105TTH consumables for hand cutting torch 100 105 A – Shielded Gouging Table 17 Consumables for hand cutting torch 100 – 105 A Item Part number Description EX-5-404-051 Swirl ring 45 –...

  • Page 44: Fht-Ex ® 105Ttm Machine Cutting Torch Unit

    ® ® 18 FHT-EX 105TTM machine cutting torch unit EX-TRAFIRE 105HD ® FHT-EX 105TTM machine cutting torch unit ® 18.1 FHT-EX 105TTM machine cutting torch without gear rack ® Table 19 FHT-EX 105TTM machine cutting torch without gear rack Number Part number Description EX-5-202-031 FHT-EX ®...

  • Page 45: Fht-Ex®105Ttsm Short Machine Cutting Torch

    ® ® EX-TRAFIRE 105HD 18 FHT-EX 105TTM machine cutting torch unit ® 18.2 FHT-EX 105TTSM short machine cutting torch ® Table 20 FHT-EX 105TTSM short machine cutting torch Number Part number Description EX-5-242-021 FHT-EX ® 105TTSM short machine cutting torch, without consumables, with 5 m (16.5') cable/ TCS13 EX-5-244-021 FHT-EX...

  • Page 46: Fht-Ex ® 105Ttm Consumables For Machine Cutting Torch

    ® ® 19 FHT-EX 105TTM consumables for machine cutting torch EX-TRAFIRE 105HD ® FHT-EX 105TTM consumables for machine cutting torch ® 19.1 FHT-EX 105TTM consumables for standard machine cutting torch 45 – 85 A Shielded **Unshielded ® Table 21 FHT-EX 105TTM consumables for standard machine cutting torch 45 –...

  • Page 47: Cutting Torch 100 - 105 A

    ® ® EX-TRAFIRE 105HD 19 FHT-EX 105TTM consumables for machine cutting torch ® 19.2 FHT-EX 105TTM consumables for standard machine cutting torch 100 – 105 A Shielded **Unshielded ® Table 22 FHT-EX 105TTM consumables for standard machine cutting torch 100 – 105A Item Part number Description...

  • Page 48: Fht-Ex ® 105Ttm Consumables For Smoothline Machine Cutting Torch

    ® ® 19 FHT-EX 105TTM consumables for machine cutting torch EX-TRAFIRE 105HD ® 19.3 FHT-EX 105TTM consumables for SmoothLine machine cutting torch Shielded **Unshielded ® Table 23 FHT-EX 105TTM consumables for SmoothLine machine cutting torch Item Part number Description EX-5-404-051 Swirl ring 45 –...

  • Page 49: Fht-Ex ® 105Ttm Consumables For Marking Machine Cutting Torch

    ® ® EX-TRAFIRE 105HD 19 FHT-EX 105TTM consumables for machine cutting torch ® 19.4 FHT-EX 105TTM consumables for marking machine cutting torch ® Table 24 FHT-EX 105TTM consumables for marking machine cutting torch Item Part number Description EX-5-404-051 Swirl ring 45 – 105 A EX-5-401-051 Electrode 45 –...

  • Page 50: Ordering Information On Bulk Packs And Starter Kits

    ® 20 Ordering information on bulk packs and starter kits EX-TRAFIRE 105HD Ordering information on bulk packs and starter kits ® ® Table 25 Bulk packs for EX-TRAFIRE 105TTH and EX-TRAFIRE 105TTM Part number Description EX-5-401-061 Bulk pack – electrode 45 – 105 A – 25 pcs. EX-5-410-060 Bulk pack –...

  • Page 51: Cutting Tables For Mechanical Cutting

    ® EX-TRAFIRE 105HD 21 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 52: Cutting, Shielded, With Compressed Air

    ® 21 Cutting tables for mechanical cutting EX-TRAFIRE 105HD 21.1 45 A cutting, shielded, with compressed air Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay time width Settings for Standard quality workpiece (shield) to highest quality settings distance...
  • Page 53 ® EX-TRAFIRE 105HD 21 Cutting tables for mechanical cutting 21.2 55 A cutting, shielded, with compressed air Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay time width Settings for Standard quality workpiece (shield) to highest quality settings distance...

  • Page 54: Cutting, Shielded, With Compressed Air

    ® 21 Cutting tables for mechanical cutting EX-TRAFIRE 105HD 21.3 65 A cutting, shielded, with compressed air Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay time width Settings for Standard quality workiece (shield) to highest quality settings distance...
  • Page 55 ® EX-TRAFIRE 105HD 21 Cutting tables for mechanical cutting 21.4 75 A cutting, shielded, with compressed air Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay time width Settings for Standard quality workiece (shield) to highest quality settings distance...

  • Page 56: Cutting, Shielded, With Compressed Air

    ® 21 Cutting tables for mechanical cutting EX-TRAFIRE 105HD 21.5 85 A cutting, shielded, with compressed air  Recommended speed: Speeds adjusted for cutting capacity do not necessarily represent maximum speeds. They are the speeds that must be achieved for the specified material thickness.
  • Page 57 ® EX-TRAFIRE 105HD 21 Cutting tables for mechanical cutting 21.5.1 85 A cutting, shielded, with compressed air Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay width Settings for Standard quality workpiece (shield) to time highest quality settings distance...

  • Page 58: 100 - 105 A Cutting, Shielded, With Compressed Air

    ® 21 Cutting tables for mechanical cutting EX-TRAFIRE 105HD 21.6 100 – 105 A cutting, shielded, with compressed air  Recommended speed: Speeds adjusted for cutting capacity do not necessarily represent maximum speeds. They are the speeds that must be achieved for the specified material thickness.

  • Page 59: 1100 - 105 A Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 105HD 21 Cutting tables for mechanical cutting 21.6.1 100 – 105 A cutting, shielded, with compressed air Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay width Settings for Standard quality workpiece (shield) to time highest quality settings...

  • Page 60: A Cutting, Smoothline, Shielded, With Compressed Air

    ® 21 Cutting tables for mechanical cutting EX-TRAFIRE 105HD 21.7 40 – 45 A cutting, SmoothLine, shielded, with compressed air  Recommended speed: Speeds adjusted for cutting capacity do not necessarily represent maximum speeds. They are the speeds that must be achieved for the specified material thickness.

  • Page 61: 140 - 45 A Cutting, Smoothline, Shielded, With Compressed Air

    ® EX-TRAFIRE 105HD 21 Cutting tables for mechanical cutting 21.7.1 40 – 45 A cutting, SmoothLine, shielded, with compressed air EX-5-415-050 EX-5-422-050 EX-5-410-050 EX-5-401-051 EX-5-404-051 EX-5-415-052 EX-5-423-001 Material Torch Pierce height Pierce delay Recommended speed Kerf Power thickness (shield) to (shield) to time width...

  • Page 62: Tables For Marking

    ® 21 Cutting tables for mechanical cutting EX-TRAFIRE 105HD 21.8 Tables for marking 21.8.1 Marking, shielded, with compressed air or argon With compressed air Marking Power Torch Initial Delay Marking Arc voltage Kerf Kerf supply (shield) to marking speed width depth workpiece height...
  • Page 63 Binzel PTY Ltd. 42 Hinkler Road Mordialloc Victoria 3195 Tel.: +61 (0)3 9587 8522 Fax: +61 (0)3 9580 8796 E-mail: sales@thermacut.com.au www.thermacut.net Revision history You can find the latest version of the operator manual on our website: www.thermacut.com.au Revision R1/06_2022 Revision R2/02_2023: —...
  • Page 64 © Copyright 2022 Thermacut k.s, Subject to change without a notice. All Rights Reserved.

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