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THERMACUT EX-TRAFIRE 125HD Operating Instructions Manual

Plasma cutting system for input voltage 3 x 480 v ac and for input voltage 3 x 575 v ac
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Plasma Cutting System
For input voltage 3 x 480 V AC
and
For input voltage 3 x 575 V AC
Operating Instructions – EX-6-902-003 – CSA
st
Revision 3, 31
January, 2024

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Summary of Contents for THERMACUT EX-TRAFIRE 125HD

  • Page 1 Plasma Cutting System For input voltage 3 x 480 V AC For input voltage 3 x 575 V AC Operating Instructions – EX-6-902-003 – CSA Revision 3, 31 January, 2024...

  • Page 2: Table Of Contents

    ® EX-TRAFIRE 125HD Table of contents Identification ................5 Labeling....................5 Identification plates................5 Signs and symbols used...............6 Classification of the warnings ..............6 Safety ..................7 Designated use..................7 Obligations of the operator ..............7 Warning and notice signs..............8 Product-specific safety instructions.............8 Safety instructions for the electrical power supply ......8 Safety instructions for plasma cutting..........9 Personal Protective Equipment............9 Emergency information ................9...
  • Page 3 ® EX-TRAFIRE 125HD Stopping the cutting process............32 Decommissioning ..............32 Maintenance and cleaning ............ 33 Maintenance and cleaning intervals ..........34 Faults and troubleshooting............ 35 Disassembly................40 Disposal ................. 41 12.1 Disposal of materials................41 12.2 Disposal of consumables ..............41 12.3 Packaging ....................
  • Page 4 ® EX-TRAFIRE 125HD 21.1 Connecting the optional CNC interface...........60 21.1.1 Setting the voltage divider DIP switches..........61 21.1.2 Enabling the external DC coil with an external power supply ..62 21.1.3 Enabling the external AC coil with an external power supply..62 21.1.4 Enabling the industrially insulated module with an external power supply ................63...

  • Page 5: Identification

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

  • Page 6: Signs And Symbols Used

    ® 1 Identification EX-TRAFIRE 125HD Signs and symbols used The following signs and symbols are used:  General instructions. Action(s) to be carried out in succession. Lists. 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.

  • Page 7: Safety

    ® EX-TRAFIRE 125HD 2 Safety Safety This chapter warns of potential hazards that should be kept in mind to operate the product safely. Non-observance of the safety instructions may result in risks to the life and health of personnel, environmental damage, or material damage.

  • 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: Safety Instructions For Plasma Cutting

    ® EX-TRAFIRE 125HD 2 Safety Safety instructions for plasma cutting  Plasma cutting may cause damage to the eyes, skin, and hearing. Note that other potential hazards may arise when the power supply is used with other cutting components. Therefore, always wear the prescribed personal protective equipment as defined by local regulations and laws.

  • Page 10: Scope Of Delivery

    ® 3 Scope of delivery EX-TRAFIRE 125HD Scope of delivery The following components are included in the scope of supply: ® — 1 × EX-TRAFIRE 125HD cutting power supply ® ® — 1 × FHT-EX 125TTH or FHT-EX 125TTM cutting torch —...

  • 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 power supply. 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 ® There are two EX-TRAFIRE 125HD systems: — System with 3 x 480 V AC and — System with 3 x 575 V AC The values of the maximum power input, the input voltage as well as the rated input current and the effective input current change accordingly.
  • Page 13 ® EX-TRAFIRE 125HD 4 Product description Table 3 Power supply specifications for the 3 x 575 V AC system Rated open circuit voltage (U 370 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Input voltage (U 575 V AC ±15 % 3 PH/50–60 Hz...

  • Page 14: Technical Data For Cutting Torches Fht-Ex

    ® 4 Product description EX-TRAFIRE 125HD Table 5 Ambient conditions for operation Ambient temperature 14 °F (-10 °C) to 104 °F (+40 °C) Relative humidity < 50 % at 104 °F (+40 °C) < 90 % at 68 °F (+20 °C) Installation above sea level Max.
  • Page 15 ® EX-TRAFIRE 125HD 4 Product description ® ® Table 7 Technical data for FHT-EX 125TTH, FHT-EX 125TTM and ® FHT-EX 125TTSMcutting torches ® ® FHT-EX 125TTH / FHT-EX 125TTM/ ® FHT-EX 125TTSM Sub-menu item Plasma cutting, gouging, optional marking Application type Manual and mechanized Rated current and duty cycle 125 A/100 %...

  • Page 16: Torch Dimensions Fht-Ex 125Tth

    ® 4 Product description EX-TRAFIRE 125HD ® 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...

  • Page 17: Transport And Positioning

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

  • Page 18: Setting Up The Power Supply

    ® 6 Setting up the power supply EX-TRAFIRE 125HD Setting up the power supply Connecting to the gas supply  Connect the gas hose with an inside diameter of at least 3/8” (10 mm) to the gas connection of the power supply.

  • Page 19: Connecting The Input Power Plug

    ® EX-TRAFIRE 125HD 6 Setting up the power supply Connecting the input power plug  Note the safety instructions.  2.5 Safety instructions for the electrical power supply on page 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 20: Connection To A Generator (Optional)

    ® 6 Setting up the power supply EX-TRAFIRE 125HD 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 generator rating as shown in the following table. Table 10 Minimum generator rating Generator rating Generator output current...

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

    ® EX-TRAFIRE 125HD 6 Setting up the power supply Installing consumables for the hand and machine cutting torches WARNING Electric shock due to live parts Fatal electric shock can occur if components are live during maintenance and cleaning work.  Set the POWER switch to OFF before maintenance and cleaning work. ...
  • Page 22 ® 6 Setting up the power supply EX-TRAFIRE 125HD 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 23: Aligning Fht-Ex ® 125Ttm Machine Cutting Torch

    ® EX-TRAFIRE 125HD 6 Setting up the power supply 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 18 Position the machine cutting torch perpendicular to the workpiece.

  • Page 24: Operation Of The Power Supply

    ® 7 Operation of the power supply EX-TRAFIRE 125HD Operation of the power supply WARNING Risk of injury due to unexpected ignition of the plasma arc Hand/Machine cutting torch: Unexpected ignition may occur.  Treat every torch as if it was ready to fire. WARNING Risk of injury when cutting Plasma cutting can cause serious injury.

  • Page 25: Lcd Description

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

  • Page 26: Setting The Parameters

    ® 7 Operation of the power supply EX-TRAFIRE 125HD 7.1.1 Setting the parameters The LCD menu is used to set the output current (amps), cutting modes, and pressure in bar, or psi. Press the multi-function button for one second. The adjustable values as well as the word “Set”...

  • Page 27: Connecting The Work Lead

    ® EX-TRAFIRE 125HD 7 Operation of the power supply Grid cutting The current is 30–125 A. The pressure of the cutting gas is 70 to 75 psi (4.8 to 5.2 bar). 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.

  • Page 28: Manual Cutting Process

    ® 7 Operation of the power supply EX-TRAFIRE 125HD Manual cutting process Switch on the power supply. Automatic gas test (five seconds). Automatic system test (five seconds). Press torch trigger. Generate a pilot arc. Once the workpiece is detected, the pilot arc switches to a cutting arc. The cutting process starts.

  • Page 29: Cutting - Edge Start

    ® EX-TRAFIRE 125HD 7 Operation of the power supply Cutting – Edge Start 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 30: 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 0.1 in (3 mm) from the nozzle to the workpiece. Press the torch trigger to ignite the arc.

  • Page 31: 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 32: Stopping The Cutting Process

    ® 8 Decommissioning EX-TRAFIRE 125HD ® 7.7.1 Table for FHT-EX 125TT material removal ® Table 11 Table for FHT-EX 125TT material removal Gouging parameters (Dynamic) air pressure 40 psi (2.7 bar) Distance between cutting torch and As close as possible workpiece Angle of cutting torch to workpiece 30°...

  • Page 33: Maintenance And Cleaning

    ® EX-TRAFIRE 125HD 9 Maintenance and cleaning Maintenance and cleaning Scheduled maintenance and cleaning are prerequisites for a long service life and trouble-free operation. The maintenance cycle is determined by ® the work environment and the EX-TRAFIRE 125HD’s maintenance intervals. If it is operated for more than eight hours a day, the maintenance intervals should be changed as needed.

  • Page 34: 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 by each time the ®...

  • Page 35: Faults And Troubleshooting

    125TTH consumables for hand cutting torch on page 45 ®  19 FHT-EX 125TTM consumables for machine cutting torch on page 49 ®  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 36 Consumables used are not ®  Use only Thermacut original ® Thermacut original parts. consumables. Missing phase.  Have the issue checked by a certified...
  • Page 37 ® EX-TRAFIRE 125HD 10 Faults and troubleshooting Table 14 Fault messages in the display Error code Cause Troubleshooting Incorrect cutting torch.  Verify the proper cutting torch is connected. No data communication at  Check the cable. the BUS.  Replace the CAN and BUS PCB. ...
  • Page 38 ® 10 Faults and troubleshooting EX-TRAFIRE 125HD Table 15 General faults Fault Description Cause Troubleshooting Power supply is  Check the input power insufficient. voltage. Power cable is not Switch is set to ON,  Plug the input power plug No/low input connected.
  • Page 39 ® EX-TRAFIRE 125HD 10 Faults and troubleshooting Table 15 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 40: Disassembly

    ® 11 Disassembly EX-TRAFIRE 125HD Table 15 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 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

    ® 13 Warranty EX-TRAFIRE 125HD Warranty The goods delivered to buyer under contract with seller may be subject to the terms, conditions, limitations, and restrictions of a warranty, if any, to the extent set forth in seller’s standard terms and conditions of sale as of the date of the contract between buyer and seller.

  • Page 43: Accessories

    ® EX-TRAFIRE 125HD 15 Accessories Accessories Table 16 Accessories Accessories Part number Description EX-0-802-001 DN 7.2 ES Quick-connect plug with male thread G 1/4" British standard straight thread EX-0-802-002 DN 7.2 ES Quick-connect socket with male thread G 1/4" British standard straight thread EX-0-803-001 CNC interface plug 14-pin kit, incl.

  • Page 44: 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 17 FHT-EX 125TTH hand cutting torch Number Part number Description ® EX-6-139-001 FHT-EX 125TTH hand cutting torch without consumables with 16.5 ft (5 m) cable/TCS13 ®...

  • Page 45: 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 18 Consumables for hand cutting torch 45–65 A Item Part number Description...

  • Page 46: Fht-Ex

    ® ® 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 47: 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 16.5 ft (5 m) cable/ TCS13 EX-6-270-002 FHT-EX...

  • Page 48: 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 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 16.5 ft (5 m) cable/ TCS13 EX-6-272-002 FHT-EX...

  • Page 49: Cutting Torch

    ® ® 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 50: Fht-Ex ® 125Ttm Consumables For Standard

    ® ® 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 51: Fht-Ex ® 125Ttm Consumables For Smoothline

    ® ® 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 52 ® ® 19 FHT-EX 125TTM consumables for machine cutting torch EX-TRAFIRE 125HD Page left intentionally blank...

  • Page 53: 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 54: Cutting, Shielded, With Compressed Air

    ® 20 Cut charts for mechanized cutting EX-TRAFIRE 125HD 20.1 45 A cutting, shielded, with compressed air EX-6-415-021 EX-6-401-021 EX-6-409-024 EX-6-404-021 EX-6-421-022 EX-6-415-022 Material Cut height Pierce height Pierce Recommended Maximum speed Kerf thickness (shield to (shield to delay time speed width work cut...

  • Page 55: Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 125HD 20 Cut charts for mechanized cutting 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 height Pierce Recommended speed Maximum speed Kerf thickness (shield to (shield to delay time width Settings for Standard quality...

  • Page 56: Cutting, Shielded, With Compressed Air

    ® 20 Cut charts for mechanized cutting EX-TRAFIRE 125HD 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 Cut height Pierce height Pierce Recommended speed Maximum speed Kerf thickness (shield to (shield to delay time width Settings for Standard quality...

  • Page 57: 105 A Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 125HD 20 Cut charts for mechanized cutting 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 height Pierce Recommended speed Maximum speed Kerf thickness (shield to (shield to delay time width Settings for Standard quality...

  • Page 58: 125 A Cutting, Shielded, With Compressed Air

    ® 20 Cut charts for mechanized cutting EX-TRAFIRE 125HD 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 Kerf (shield to thickness (shield to delay time width Settings for Standard quality...

  • Page 59: A Cutting, Smoothline, Shielded, With Compressed Air

    ® EX-TRAFIRE 125HD 20 Cut charts for mechanized cutting 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 Recommended speed Kerf Power thickness (shield to (shield to time width supply Settings for highest...

  • Page 60: Appendix

    ® 21 Appendix EX-TRAFIRE 125HD Appendix 21.1 Connecting the optional 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 27. Control elements are located on the control panel.

  • Page 61: Setting The Voltage Divider Dip Switches

    ® EX-TRAFIRE 125HD 21 Appendix Table 25 Signal and pin assignment for CNC interface Signal START Ground Voltage divider Start plasma Start machine cutting motion Type Input Output Ground Output Notice Open by Open by Reduced arc default. default. signal: Requires Potential-free 20:1...

  • Page 62: Enabling The External Dc Coil With An External Power Supply

    ® 21 Appendix EX-TRAFIRE 125HD 21.1.2 Enabling the external DC coil with an external power supply  For 24 V DC, use a 1N4007 diode. Fig. 11 Enable the external DC coil with an external power supply. 24 V DC Use diode 1N4007 if the voltage is...

  • Page 63: Enabling The Industrially Insulated Module With An External Power Supply

    ® EX-TRAFIRE 125HD 21 Appendix 21.1.4 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 64 ® 21 Appendix EX-TRAFIRE 125HD...
  • Page 65 ADDRESSES AND CONTACTS NORTH AND SOUTH AMERICA USA and Canada Mexico THERMACUT, Inc. BINZEL MEXICO S.A. de C.V. 153 Charlestown Road C. Municipio de Tepezalá No. 109 Claremont, NH 03743 de Arteaga No. 102 Tel.: +1 (800) 932-8312 Valle de Ags., C.P. 20358 +1 (603) 543-0585 San Fco.

  • Page 66: Revision History

    Revision history You can find the latest version of the operating manual on our website: WWW.EX-TRAFIRE.US Revision R1/07_2023 Revision R2/12_2023 — 4.3 “Technical data for cutting torches” – Torch dimensions added — 7.1.2 “Selecting the cutting mode” – Current for Optional marking corrected”...
  • Page 68 © Copyright 2023 Thermacut Inc., Subject to change without a notice. All Rights Reserved.

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