THERMACUT EX-TRAFIRE 125HD Operating Instructions Manual
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THERMACUT EX-TRAFIRE 125HD Operating Instructions Manual

Plasma cutting system
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Plasma Cutting System
Operating Instructions – EX-6-902-001/N-21611 – CE
th
Revision 1, 15
June, 2023

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Summary of Contents for THERMACUT EX-TRAFIRE 125HD

  • Page 1 Plasma Cutting System Operating Instructions – EX-6-902-001/N-21611 – CE Revision 1, 15 June, 2023...

  • Page 2: Table Of Contents

    ® EX-TRAFIRE 125HD 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 125HD 7.7.1 Table for FHT-EX®125TT 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-33 Disassembly ............EN-38 Disposal..............
  • Page 4 ® EX-TRAFIRE 125HD 20.5.1 125 A cutting, shielded, with compressed air ......EN-59 20.6 30–45 A cutting, SmoothLine, shielded, with compressed air ................EN-60 20.6.1 30–45 A cutting, SmoothLine, shielded, with compressed air ................EN-61 EN - 4...

  • Page 5: Identification

    125HD uses compressed air or nitrogen to cut almost all ® conductive metals. The EX-TRAFIRE 125HD may be operated only with ® original Thermacut parts. This documentation describes the ® EX-TRAFIRE 125HD cutting power supply only. When used in this documentation, the term “device” always refers to the ®...

  • Page 6: Classification Of The Warnings

    ® 2 Safety EX-TRAFIRE 125HD 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 EX-TRAFIRE 125HD’s cover plates are opened, have ® Thermacut or 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 125HD 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 125HD Product description Assembly and use The control elements are located on the control panel. The connections are ® on the front and rear of the EX-TRAFIRE 125HD. Fig. 2 Control elements and connections A Display F Power cable B <POWER>...

  • Page 11: Technical Data

    ® EX-TRAFIRE 125HD 4 Product description Technical data Table 1 Power supply specifications Idle voltage (U 400 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Output current (I 125 A Nominal output voltage (U 180 V DC Output current at 100% duty 125 A...

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

    ® 4 Product description EX-TRAFIRE 125HD 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 184 l/min at 5.9 bar ®...
  • Page 13 ® EX-TRAFIRE 125HD 4 Product description ® ® Table 5 Technical data for FHT-EX 125TTH and FHT-EX 125TTM cutting torches ® ® FHT-EX 125TTH / FHT-EX 125TTM Connection type TCS (torch connection system) – 13 pin Standard lengths 5 m/8 m/15 m/23 m (other lengths available upon request) Table 6...

  • Page 14: Transport And Positioning

    ® 5 Transport and positioning EX-TRAFIRE 125HD Transport and positioning WARNING Risk of injury due to improper transport and installation ® Improper transport and installation can cause the EX-TRAFIRE 125HD to tip or fall over. This may result in serious injury. •...

  • Page 15: Setting Up The Power Supply

    ® EX-TRAFIRE 125HD 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 ® EX-TRAFIRE 125HD.

  • Page 16: Connecting The Input Power Plug

    ® 6 Setting up the power supply EX-TRAFIRE 125HD 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 125HD 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.

  • 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 125HD 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. 24 V DC Use diode 1N4007 if the...

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

    ® 6 Setting up the power supply EX-TRAFIRE 125HD 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 EX-TRAFIRE 125HD. Remove the interface cover. Connect the interface cable with the cutting power supply.
  • Page 21 ® EX-TRAFIRE 125HD 6 Setting up the power supply A Shield D Electrode B Retaining cap E Swirl ring C Nozzle F Swirl ring holder G Hand cutting torch/Machine cutting torch Hand cutting torch Machine cutting torch Screw shield onto retaining cap and tighten by hand.

  • Page 22: Aligning Fht-Ex ® 125Ttm Machine Cutting Torch

    ® 6 Setting up the power supply EX-TRAFIRE 125HD Insert swirl ring into the entire assembly. Insert swirl ring holder.  Apply silicon to the O-ring of the swirl ring holder. Screw entire assembly onto the hand cutting torch.  Do not overtighten! ®...

  • Page 23: Operation Of The Power Supply

    ® EX-TRAFIRE 125HD 7 Operation of the power supply Operation of the power supply 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: Lcd Description

    ® 7 Operation of the power supply EX-TRAFIRE 125HD NOTICE Material damage due to switching the output current strength during operation If the output current strength is switched during operation, the unit may be damaged. • Set the output current strength before starting operation and do not switch it during the cutting process.

  • Page 25: Selecting The Cutting Mode

    ® EX-TRAFIRE 125HD 7 Operation of the power supply 7.1.2 Selecting the cutting mode Cutting The current is 30–125 A. The pressure of the cutting gas is 4.8 to 5.2 bar. Gouging The current is 30–125 A. The pressure of the cutting gas is 2.7 bar.

  • Page 26: Powering On The Machine

    ® 7 Operation of the power supply EX-TRAFIRE 125HD Powering on the machine  Set the <POWER> switch to <ON>.  The following is displayed immediately after switching on: — Type of power supply (85HD) — Length of torch cable (5, 8, 15, 23 m) —...

  • Page 27: Cutting

    ® EX-TRAFIRE 125HD 7 Operation of the power supply 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 28: Piercing

    ® 7 Operation of the power supply EX-TRAFIRE 125HD 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 29: Gouging

    ® EX-TRAFIRE 125HD 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. Narrower and ...

  • 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

    Annually and after  Have a safety inspection performed in each time the accordance with DIN IEC 60974 Part 4: housing is opened ® “Periodic inspection and testing” by Thermacut or another authorized specialist. EN - 31...
  • Page 32 ® 9 Maintenance and cleaning EX-TRAFIRE 125HD Table 11 Parts inspection Consumable Check for Action  Orifice is not round.  Replace the shield.  Spatter in the gap  Clean the shield and Shield between the shield nozzle surface. and the nozzle.

  • Page 33: Faults And Troubleshooting

    125TTH consumables for hand cutting torch on page EN-43 ®  19 FHT-EX 125TTM consumables for machine cutting torch on page EN-47 ®  Contact your retailer or Thermacut in the event of questions or problems. Table 12 Fault messages in the display Error code Cause Troubleshooting ...
  • Page 34 ®  Consumables used are  Use only Thermacut ® not Thermacut original consumables. original parts.  Missing phase.  Have the issue checked by ®...
  • Page 35 ® EX-TRAFIRE 125HD 10 Faults and troubleshooting Table 12 Fault messages in the display Error code Cause Troubleshooting  Incorrect current  Verify the cutting power setting. settings.  Incorrect cutting mode.  Verify the cutting mode.  Gas pressure fault. ...
  • Page 36 ® 10 Faults and troubleshooting EX-TRAFIRE 125HD Table 13 General faults Fault Description Cause Troubleshooting Switch is set to ON,  No/low input  Power supply is  Check the input power LCD does not power insufficient. voltage. illuminate. voltage. ...
  • Page 37 ® EX-TRAFIRE 125HD 10 Faults and troubleshooting Table 13 General faults Fault 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 work lead clamp and/or oxidation from the ...

  • Page 38: Disassembly

    ® 11 Disassembly EX-TRAFIRE 125HD 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 39: 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 40: 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 41: Block Diagram

    G 1/4" EX-0-803-001 CNC interface plug 14-pin kit, incl. 7 pins EX-0-803-003 CNC interface connection cable 3 m CNC interface connection EX-0-803-004 cable 6 m EX-0-805-001 Grease, 25 ml For more information about accessories, visit our website: www.thermacut.com. EN - 41...

  • Page 42: Fht-Ex 125Tth Hand Cutting Torch Unit

    ® ® 16 FHT-EX 125TTH hand cutting torch unit EX-TRAFIRE 125HD ® FHT-EX 125TTH hand cutting torch unit ® Table 15 FHT-EX 125TTH hand cutting torch Number Part number Description ® EX-6-139-001 FHT-EX 125TTH hand cutting torch without consumables with 5 m (16.5’) cable/TCS13 ®...

  • Page 43: Fht-Ex

    ® ® EX-TRAFIRE 125HD 17 FHT-EX 125TTH consumables for hand cutting torch ® FHT-EX 125TTH consumables for hand cutting torch ® 17.1 FHT-EX 125TTH consumables for hand cutting torch 45–65 A Shielded Gouging Table 16 Consumables for hand cutting torch 45–65 A Item Part number Description...

  • Page 44: 125Tth Consumables For Hand

    ® ® 17 FHT-EX 125TTH consumables for hand cutting torch EX-TRAFIRE 125HD ® 17.2 FHT-EX 125TTH consumables for hand cutting torch 85–125 A Shielded Gouging ® Table 18 FHT-EX 125TTH consumables for hand cutting torch 85–125 A Item Part number Description See item no.

  • Page 45: Fht-Ex 125Ttm Machine Cutting Torch Unit

    ® ® EX-TRAFIRE 125HD 18 FHT-EX 125TTM machine cutting torch unit ® FHT-EX 125TTM machine cutting torch unit ® 18.1 FHT-EX 125TTM machine cutting torch ® Table 19 FHT-EX 125TTM machine cutting torch Number Part number Description EX-6-270-001 FHT-EX ® 125TTM machine torch without consumables, with 5 m (16.5') cable/ TCS13 EX-6-270-002 FHT-EX...

  • Page 46: Fht-Ex®125Ttsm Short Machine Cutting Torch

    ® ® 18 FHT-EX 125TTM machine cutting torch unit EX-TRAFIRE 125HD ® 18.2 FHT-EX 125TTSM short machine cutting torch ® Table 20 FHT-EX 125TTSM short machine cutting torch Number Part number Description EX-6-272-001 FHT-EX ® 125TTSM short machine cutting torch, without consumables, with 5 m (16.5') cable/ TCS13 EX-6-272-002 FHT-EX...

  • Page 47: Fht-Ex ® 125Ttm Consumables For Machine

    ® ® EX-TRAFIRE 125HD 19 FHT-EX 125TTM consumables for machine cutting torch ® FHT-EX 125TTM consumables for machine cutting torch ® 19.1 FHT-EX 125TTM consumables for standard machine cutting torch 45–65 A Shielded Gouging ® Table 21 FHT-EX 125TTM consumables for standard machine cutting torch 45–65 A Item Part number...

  • Page 48: 125Ttm Consumables For Standard Machine Cutting Torch 85-125 A

    ® ® 19 FHT-EX 125TTM consumables for machine cutting torch EX-TRAFIRE 125HD ® 19.2 FHT-EX 125TTM consumables for standard machine cutting torch 85–125 A Shielded Gouging ® Table 22 FHT-EX 125TTM consumables for standard machine cutting torch 85–125 A Item Part number Description See item no.

  • Page 49: Fht-Ex 125Ttm Consumables For Smoothline Machine Cutting Torch

    ® ® EX-TRAFIRE 125HD 19 FHT-EX 125TTM consumables for machine cutting torch ® 19.3 FHT-EX 125TTM consumables for SmoothLine machine cutting torch Shielded ® Table 23 FHT-EX 125TTM consumables for SmoothLine machine cutting torch Item Part number Description See item no. 3 Swirl ring holder EX-6-440-021 Swirl ring, SmoothLine...
  • Page 50 ® ® 19 FHT-EX 125TTM consumables for machine cutting torch EX-TRAFIRE 125HD Page left intentionally blank EN - 50...

  • Page 51: Cutting Tables For Mechanical Cutting

    ® EX-TRAFIRE 125HD 20 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

    ® 20 Cutting tables for mechanical cutting EX-TRAFIRE 125HD 20.1 45 A cutting, shielded, with compressed air EX-6-415-021 EX-6-409-024 EX-6-401-021 EX-6-404-021 EX-6-421-022 EX-6-409-023 EX-6-415-022 Material Torch Pierce Pierce delay Recommended Maximum speed Kerf thickness (shield) to height time speed width workpiece (shield) to Settings for...

  • Page 53: Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 125HD 20 Cutting tables for mechanical cutting 20.2 65 A cutting, shielded, with compressed air EX-6-415-021 EX-6-409-024 EX-6-401-021 EX-6-404-021 EX-6-421-022 EX-6-409-023 EX-6-415-022 Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay width Settings for Standard quality workpiece (shield) to...

  • Page 54: Cutting, Shielded, With Compressed Air

    ® 20 Cutting tables for mechanical cutting EX-TRAFIRE 125HD 20.3 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 55: Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 125HD 20 Cutting tables for mechanical cutting 20.3.1 85 A cutting, shielded, with compressed air EX-6-415-021 EX-6-409-021 EX-6-401-021 EX-6-404-021 EX-6-421-021 EX-6-415-022 Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay width Settings for Standard quality workpiece (shield) to...
  • Page 56 ® 20 Cutting tables for mechanical cutting EX-TRAFIRE 125HD 20.4 105 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 57: 105 A Cutting, Shielded With Compressed Air

    ® EX-TRAFIRE 125HD 20 Cutting tables for mechanical cutting 20.4.1 105 A cutting, shielded with compressed air EX-6-415-021 EX-6-409-021 EX-6-401-021 EX-6-404-021 EX-6-421-021 EX-6-415-022 Material Torch Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield) to height delay width Settings for Standard quality workpiece (shield) to...
  • Page 58 ® 20 Cutting tables for mechanical cutting EX-TRAFIRE 125HD 20.5 125 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: 125 A Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 125HD 20 Cutting tables for mechanical cutting 20.5.1 125 A cutting, shielded, with compressed air EX-6-415-021 EX-6-409-021 EX-6-401-021 EX-6-404-021 EX-6-421-021 EX-6-415-022 Material Torch Pierce height Pierce Recommended speed Maximum speed Kerf thickness (shield) to (shield) to delay width Settings for Standard quality workpiece...
  • Page 60 ® 20 Cutting tables for mechanical cutting EX-TRAFIRE 125HD 20.6 30–45 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 ® EX-TRAFIRE 125HD 20 Cutting tables for mechanical cutting 20.6.1 30–45 A cutting, SmoothLine, shielded, with compressed air EX-6-414-022 EX-6-415-021 EX-6-414-021 EX-6-401-021 EX-6-440-021 Material Torch (shield) Pierce height Pierce delay Recommended speed Kerf Power thickness to workpiece (shield) to time width supply Settings for highest...
  • Page 62 ® 20 Cutting tables for mechanical cutting EX-TRAFIRE 125HD EN - 62...
  • Page 63 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 64 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 65 E-mail: ezio.minh@mnt.com.vn E-mail: info@thermacut.com.kz www.thermacut.net www.thermacut.kz SOUTH KOREA JAPAN Abicor Binzel Korea Ltd. Thermacut Japan Ltd. #A-101, 263, Gaejwa-ro 3F Shin-Osaka Hankyu Building Guemjeong-gu 1-1-1, Miyahara, Yodogawa-ku, Osaka Busan 532-0003 Japan Tel.: 0082 (31) 732 6065 / 6066 / 6067 Mob.: +81 (0)80 4738 9752...
  • Page 66 Revision history You can find the latest version of the operator manual on our website: www.thermacut.com. Revision R1/05_2023...
  • Page 68 © Copyright 2022 Thermacut k.s, Subject to change without a notice. All Rights Reserved.

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