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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 3, 06
December, 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 3, 06 December, 2023...

  • Page 2: Table Of Contents

    ® EX-TRAFIRE 125HD Table of contents Identification.............. EN-5 Labeling................... EN-5 Identification plate ................. EN-5 Signs and symbols used..............EN-5 Classification of the warnings ............EN-6 Safety ................. EN-7 Designated use................EN-7 Obligations of the operator ............EN-7 Warning and notice signs.............. EN-8 Product-specific safety instructions..........
  • Page 3 ® EX-TRAFIRE 125HD Decommissioning............ EN-30 Maintenance and cleaning ........EN-30 Maintenance and cleaning intervals .......... EN-31 Faults and troubleshooting ........EN-33 Disassembly ............EN-38 Disposal..............EN-39 12.1 Disposal of materials..............EN-39 12.2 Disposal of consumables ............EN-39 12.3 Packaging ..................EN-39 Warranty..............
  • Page 4 ® EX-TRAFIRE 125HD 21.1.1 Setting the voltage divider DIP switches........EN-58 21.1.2 Enabling the external DC coil with an external power supply EN-58 21.1.3 Enabling the external AC coil with an external power supply EN-59 21.1.4 Enabling the industrially insulated module with an external power supply ..............

  • Page 5: Identification

    125HD uses compressed air or nitrogen to cut almost all ® electrically conductive metals. The EX-TRAFIRE 125HD has to be operated ® only with original Thermacut consumables and maintenance parts. This ® documentation describes the EX-TRAFIRE 125HD cutting power supply only.

  • Page 6: Classification Of The Warnings

    ® 1 Identification EX-TRAFIRE 125HD Cross-reference symbol refers to detailed, supplementary or further information. Caption, item description. 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.

  • Page 7: Safety

     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 IEC 60974 Part 4: “Periodic inspection and testing”. ® The EX-TRAFIRE...

  • Page 8: Warning And Notice Signs

    ® 2 Safety EX-TRAFIRE 125HD Warning and notice signs The following warning, notice, and mandatory signs can be found on top of the product: These markings must always be legible. They should not be covered, obscured, painted over, or removed. Product-specific safety instructions ®...

  • Page 9: Personal Protective Equipment

    ® EX-TRAFIRE 125HD 2 Safety  All metal vapors, especially lead, cadmium, copper, and beryllium, are harmful. Ensure sufficient ventilation or extraction. Do not exceed the current occupational exposure limits (OELs).  To prevent the formation of phosgene gas, rinse workpieces that have been degreased with chlorinated solvents using clean water.

  • Page 10: Scope Of Delivery

    The order data and ID numbers for the equipment parts and consumables can be found in this manual.  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 11: Product Description

    ® EX-TRAFIRE 125HD 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 EX-TRAFIRE 125HD. Fig. 2 Control elements and connections A LCD display F Power cable B POWER switch G Work lead connection...

  • Page 12: Technical Data

    ® 4 Product description EX-TRAFIRE 125HD Technical data Table 2 Power supply specifications Rated open circuit voltage (U 382.5 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Output arc current (I 30–125 A Nominal output arc voltage (U 180 V DC Output current at 100% Duty...

  • Page 13: 125Tth

    ® EX-TRAFIRE 125HD 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 184 l/min at 5.9 bar * Nitrogen may be used for cutting stainless steel and Aluminum;...
  • Page 14 ® 4 Product description EX-TRAFIRE 125HD ® ® Table 6 Technical data for FHT-EX 125TTH, FHT-EX 125TTM and ® FHT-EX 125TTSM cutting torches ® ® FHT-EX 125TTH / FHT-EX 125TTM/ ® FHT-EX 125TTSM Type of voltage Protection type for IP23 (EN 60529) ®...

  • Page 15: Torch Dimensions Fht-Ex 125Tth

    ® EX-TRAFIRE 125HD 4 Product description ® 4.3.1 Torch dimensions FHT-EX 125TTH ® Fig. 3 Torch dimensions FHT-EX 125TTH ® 4.3.2 Torch dimensions FHT-EX 125TTM ® Fig. 4 Torch dimensions FHT-EX 125TTM ® 4.3.3 Torch dimensions FHT-EX 125TTSM ® Fig. 5 Torch dimensions FHT-EX 125TTSM EN - 15...

  • Page 16: 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 17: 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 18 ® 6 Setting up the power supply EX-TRAFIRE 125HD 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. ®  If you want to operate the EX-TRAFIRE 125HD in a very humid environment or on conductive material, install ground fault circuit breakers (GFCI) in the power supply if according to electric code.

  • Page 19: Connection To A Generator (Optional

    ® EX-TRAFIRE 125HD 6 Setting up the power supply 6.4.1 Connection to a generator (optional)  Set the generator to 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 rating...

  • Page 20: Installing Consumables For The Hand And Machine Cutting Torches

    ® 6 Setting up the power supply EX-TRAFIRE 125HD 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 21 ® EX-TRAFIRE 125HD 6 Setting up the power supply Install nozzle into the retaining cap. Insert electrode into retaining cap and nozzle assembly. Assemble swirl ring holder onto swirl ring. Apply a small amount of O-ring lubricant onto O-ring. Take caution that the lubricant does not block or restrict any of the gas ports/holes.

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

    ® 6 Setting up the power supply EX-TRAFIRE 125HD Install retaining cap assembly with consumables onto torch. Do not over-tighten. Install shield. Do not over-tighten. ® Aligning FHT-EX 125TTM machine cutting torch For information on the cutting process see  6 Setting up the power supply on page EN-17 Position the cutting torch perpendicular to the workpiece.

  • 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: Setting The Parameters

    ® EX-TRAFIRE 125HD 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. The adjustable values as well as the word “Set”...

  • Page 26: Connecting The Work Lead

    ® 7 Operation of the power supply EX-TRAFIRE 125HD 7.1.3 Connecting the work lead Remove contamination from the workpiece. Connect the work lead clamp to the workpiece in order to allow maximum electrical conduction. Do not connect the work lead clamp to the material to be cut off. Connect the work lead clamp as close as possible to the cutting area in order to minimize electromagnetic fields.

  • Page 27: Cutting - Edge Start

    ® EX-TRAFIRE 125HD 7 Operation of the power supply Once the workpiece is detected, the pilot arc switches to a cutting arc. Grid cutting or gouging starts depending on the selected process. Extinguish the arc by releasing the torch trigger. Gas post-flow period is 10 to 105 seconds depending on the output current and is not adjustable.

  • 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: Stopping The Cutting Process

    ® EX-TRAFIRE 125HD 7 Operation of the power supply Use gouging consumables suitable to the cutting torch being used. Hold the cutting torch at an angle of 30° to 35° inclined to the workpiece. Hold the nozzle close enough to the workpiece so that it touches the workpiece.

  • Page 30: Decommissioning

     Verify the grounding has been established correctly.  Each time the cover plates are opened, have a safety inspection performed in accordance with IEC 60974 Part 4: “Periodic inspection ® and testing” by Thermacut or another authorized specialist. WARNING Electric shock due to live parts Fatal electric shock can occur if components are live during maintenance and cleaning work.

  • Page 31: Maintenance And Cleaning Intervals

    ®  Open the EX-TRAFIRE 125HD body and have the inside cleaned with a vacuum cleaner or dry, ® clean compressed air by Thermacut or trained personnel. Annually and after  Have a safety inspection performed in each time the accordance with IEC 60974 Part 4: “Periodic...
  • Page 32 ® 9 Maintenance and cleaning EX-TRAFIRE 125HD Table 12 Parts inspection Consumable Check for Action Outer surface is damaged or dirty. Electrode restriction due  Clean or replace the Swirl ring to dirt, debris, or damage swirl ring. on interior surfaces. Clogged or damaged gas holes.

  • Page 33: Faults And Troubleshooting

    ®  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. WARNING Electric shock due to live parts Fatal electric shock can occur if components are live during maintenance and cleaning work.
  • Page 34 CNC start has been tightened too re-install correctly and signal is on tightly. tighten, if needed. Consumables used are ®  Use only Thermacut ® not Thermacut original original consumables. parts. Missing phase.  Have the issue checked by a certified electrician or trained personnel.
  • Page 35 ® EX-TRAFIRE 125HD 10 Faults and troubleshooting Table 13 Fault messages in the display Error code Cause Troubleshooting No data communication  Check the cable. at the BUS.  Replace the CAN and BUS PCB.  Have the control PCB replaced by a certified electrician or trained personnel.
  • Page 36 ® 10 Faults and troubleshooting EX-TRAFIRE 125HD Table 14 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 voltage. insufficient. voltage. illuminate. Power cable is not ...
  • Page 37 ® EX-TRAFIRE 125HD 10 Faults and troubleshooting Table 14 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 and/or oxidation from the workpiece.

  • Page 38: Disassembly

    ® 11 Disassembly EX-TRAFIRE 125HD Table 14 General faults Fault Description Cause Troubleshooting Incorrect setting Output current (amps)  Adjust the output current for output too low/material too strength to the thickness of current. thick. the workpiece. Consumables Consumables are ...

  • 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: Accessories

    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 16 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 17 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 19 FHT-EX 125TTH consumables for hand cutting torch 85–125 A Item Part number Description Supplied with Swirl ring holder...

  • 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 20 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 ® ® 18 FHT-EX 125TTM machine cutting torch unit EX-TRAFIRE 125HD ® Table 21 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 22 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 23 FHT-EX 125TTM consumables for standard machine cutting torch 85–125 A Item Part number Description Supplied with...

  • 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 24 FHT-EX 125TTM consumables for SmoothLine machine cutting torch Item Part number Description Supplied with Swirl ring holder electrodes EX-6-440-021...
  • Page 50 ® ® 19 FHT-EX 125TTM consumables for machine cutting torch EX-TRAFIRE 125HD Page left intentionally blank EN - 50...

  • Page 51: Cut Charts For Mechanized Cutting

    ® EX-TRAFIRE 125HD 20 Cut charts for mechanized cutting Cut charts for mechanized cutting Cut charts serve as a guideline for mechanized 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 Cut charts for mechanized cutting EX-TRAFIRE 125HD 9145 11100 7470 9210 4675 7400 3700 5800 1740 2795 20.2 65 A cutting, shielded, with compressed air EX-6-415-021 EX-6-409-023 EX-6-401-021 EX-6-404-021 EX-6-421-022 EX-6-415-022 Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf (shield to...

  • Page 53: Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 125HD 20 Cut charts for mechanized cutting 7805 10265 6565 8790 5320 7320 2845 4375 2015 2750 1535 1980 1055 1600 Edge start 20.3 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 Pierce Recommended speed Maximum speed...

  • Page 54: 105 A Cutting, Shielded With Compressed Air

    ® 20 Cut charts for mechanized cutting EX-TRAFIRE 125HD Aluminum 8000 7900 6500 7500 3800 4900 2650 4050 1920 3000 1450 2300 1440 1050 Edge start 20.4 105 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 Cut height Pierce...

  • Page 55: 125 A Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 125HD 20 Cut charts for mechanized cutting 6340 6390 4330 4690 2660 3900 2020 3100 1350 1860 1220 Edge start 20.5 125 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 Cut height Pierce height Pierce Recommended speed Maximum speed...

  • Page 56: A Cutting, Smoothline, Shielded, With Compressed Air

    ® 20 Cut charts for mechanized cutting EX-TRAFIRE 125HD 7660 8560 5100 3100 2980 4400 2140 3620 1540 2500 1260 1950 1250 1075 Edge start 20.6 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 Cut height Pierce height Pierce delay...

  • Page 57: Appendix

    ® EX-TRAFIRE 125HD 21 Appendix Appendix 21.1 Connecting the CNC interface The optional CNC interface plug installs onto the rear panel of the ® EX-TRAFIRE 125HD. Control signals can be transmitted via the CNC interface. For signal types see Table 26 Signal and pin assignment for CNC interface on page EN-57.
  • Page 58 The voltage divider DIP switches must be set only by a certified electrician or trained personnel. Have a safety inspection performed in accordance with IEC 60974 Part 4: ® “Periodic inspection and testing” by Thermacut or another authorized specialist. Fig. 11 Voltage divider DIP switch settings 21.1.2 Enabling the external DC coil with an external power supply...
  • Page 59 ® EX-TRAFIRE 125HD 21 Appendix 21.1.3 Enabling the external AC coil with an external power supply Fig. 13 Enable the external AC coil with an external power supply 24 V AC 230 V AC 21.1.4 Enabling the industrially insulated module with an external power supply Fig.
  • Page 60 ® 21 Appendix EX-TRAFIRE 125HD EN - 60...

  • Page 61: Addresses And Contacts

    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 62 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 63 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 64 © Copyright 2022 Thermacut k.s, Subject to change without notice. All Rights Reserved.

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