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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 4, 26
July, 2024

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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 4, 26 July, 2024...

  • Page 2: Table Of Contents

    ® EX-TRAFIRE 45HD Table of contents Identification.............. EN-4 Labeling................... EN-4 Identification plate ................. EN-4 Signs and symbols used..............EN-4 Classification of the warnings ............EN-5 Safety ................. EN-6 Designated use................EN-6 Obligations of the operator ............EN-6 Warning and notice signs.............. EN-7 Product-specific safety instructions..........
  • Page 3 ® EX-TRAFIRE 45HD Stopping the cutting process ............. EN-33 Decommissioning............ EN-33 Maintenance and cleaning ........EN-34 Maintenance and cleaning intervals .......... EN-35 Faults and troubleshooting ........EN-37 Disassembly ............EN-41 Disposal..............EN-42 12.1 Disposal of materials..............EN-42 12.2 Disposal of consumables ............EN-42 12.3 Packaging ..................

  • Page 4: Identification

    ® metals. The EX-TRAFIRE 45HD has to be operated only with original ® Thermacut consumables and maintenance parts. ® This documentation describes the EX-TRAFIRE 45HD cutting power supply only.

  • Page 5: Classification Of The Warnings

    ® EX-TRAFIRE 45HD 1 Identification 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: Safety

     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 IEC 60974 Part 4: “Periodic inspection and testing”.

  • Page 7: Warning And Notice Signs

    ® EX-TRAFIRE 45HD 2 Safety 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 8: Safety Instructions For Plasma Cutting

    ® 2 Safety EX-TRAFIRE 45HD 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 device is used with other cutting components. Therefore, always wear the prescribed personal protective equipment as defined by local regulations and laws.

  • Page 9: 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 10: Product Description

    ® 4 Product description EX-TRAFIRE 45HD 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 A POWER switch D Optional BUS interface B Optional CNC interface E Input power cable...
  • Page 11 ® EX-TRAFIRE 45HD 4 Product description POWER switch (A) Used to switch the device on and off. Optional 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 12: Technical Data

    ® 4 Product description EX-TRAFIRE 45HD Technical data ® 4.2.1 EX-TRAFIRE 45HD, Single-phase Table 2 Power supply specifications, single-phase Rated open circuit voltage (U 292 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Input voltage (U 240 V AC ±...

  • Page 13: 45Hd, Three-Phase

    ® EX-TRAFIRE 45HD 4 Product description ® 4.2.2 EX-TRAFIRE 45HD, Three-phase Table 3 Power supply specifications, Three-phase Rated open circuit voltage (U 308 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Input voltage (U 400 V AC ±...

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

    ® 4 Product description EX-TRAFIRE 45HD Table 6 Gas data Permissible gas Compressed air/nitrogen/argon* Gas inlet pressure, cutting 6.2 to 10 bar Recommended compressed air ISO 8573-1 Class 1.2.2. quality clean, and free from moisture and oil Recommended nitrogen/argon Purity: > 99,99% quality Needed flow rate 120 l/min at 10 bar...
  • Page 15 ® EX-TRAFIRE 45HD 4 Product description ® ® Table 7 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) * Nitrogen may be used for cutting stainless steel and aluminum;...
  • Page 16 ® 4 Product description EX-TRAFIRE 45HD ® 4.3.1 Torch dimensions FHT-EX 45TTH ® Fig. 4 Torch dimensions FHT-EX 45TTH ® 4.3.2 Torch dimensions FHT-EX 45TTM ® Fig. 5 Torch dimensions FHT-EX 45TTM Shielded with machine shield Unshielded with deflector EN - 16...

  • Page 17: 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 18: 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 19: Connecting The Three-Phase Machine

    ® EX-TRAFIRE 45HD 6 Setting up the power supply 6.3.2 Connecting the three-phase machine The power supply should be Three-phase connected by a certified electrician or trained personnel. L1 -> black (U) L2 -> brown (V) L3 -> gray (W) Gray PE grounding ->...

  • Page 20: Connection To A Generator (Optional

    ® 6 Setting up the power supply EX-TRAFIRE 45HD WARNING Risk of injury due to fire Improper use or connection can result in fire. This may result in serious injury.  Ensure that the operating voltage specified on the identification plate is suitable for the input voltage.

  • Page 21: Connecting The Cutting Torch

    ® EX-TRAFIRE 45HD 6 Setting up the power supply Connecting the cutting torch 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 device. If used without, the device will be damaged. ...

  • Page 22: Installing Consumables For The Hand And Machine Cutting Torches

    ® 6 Setting up the power supply EX-TRAFIRE 45HD 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 23 ® EX-TRAFIRE 45HD 6 Setting up the power supply Install nozzle into the retaining cap. Insert swirl ring into retaining cap and nozzle assembly. Insert electrode. Screw the entire assembly onto the hand cutting torch. Do not overtighten. The nozzle must be firmly in place and must not move.

  • Page 24: Aligning Fht-Ex 45Ttm Machine Cutting Torch

    ® 6 Setting up the power supply EX-TRAFIRE 45HD ® Aligning FHT-EX 45TTM machine cutting torch For information on the cutting process see  6 Setting up the power supply on page EN-18 Position the cutting torch perpendicular to the workpiece. Use an angle gauge to align the machine cutting torch at 0°...

  • Page 25: Operation

    ® EX-TRAFIRE 45HD 7 Operation Operation 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. Individuals can be seriously injured if the arc ignites unexpectedly.

  • Page 26: Lcd Description

    ® 7 Operation EX-TRAFIRE 45HD Material damage due to switching the output current strength during operation If the output current strength is switched during operation, the device may be damaged.  Set the output current strength before starting operation and do not switch it during the cutting process.

  • Page 27: Setting The Parameters

    ® EX-TRAFIRE 45HD 7 Operation 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 torch type, torch length, and operating voltage are displayed and the pressure in Bar, Mpa or Psi can be set.

  • Page 28: Selecting The Cutting Mode

    ® 7 Operation 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 to 5.6 bar.  Turn the multi-function button to increase or decrease the values.

  • Page 29: Powering On The Machine

    ® EX-TRAFIRE 45HD 7 Operation Powering on the machine  Set the POWER switch to ON. Single-phase Three-phase 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.

  • Page 30: Cutting - Edge Start

    ® 7 Operation EX-TRAFIRE 45HD 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. Pull the cutting torch in the cutting direction.

  • Page 31: Piercing

    ® EX-TRAFIRE 45HD 7 Operation Piercing Hold the cutting torch at an angle to the workpiece with a max. standoff of 3 mm from the nozzle to the workpiece. Press the torch trigger to ignite the arc. Turn the cutting torch slowly in a vertical direction.
  • Page 32 ® 7 Operation EX-TRAFIRE 45HD Use gouging consumables suitable to the cutting torch being used. Hold the cutting torch at an angle of 35° to 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 Decommissioning 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

     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 35: Maintenance And Cleaning Intervals

    Thermacut or trained personnel.  Have a safety inspection performed in Annually and after each time the accordance with IEC 60974 Part 4: “Periodic ® housing is opened inspection and testing” by Thermacut trained personnel. EN - 35...
  • Page 36 ® 9 Maintenance and cleaning EX-TRAFIRE 45HD Table 13 Parts inspection Consumable Check for Action  Replace the shield. Orifice is not round.  Clean the shield and Spatter in the gap Shield between the shield and nozzle surface. the nozzle. ...

  • Page 37: Faults And Troubleshooting

     17.2 FHT-EX®45TTM consumables for standard machine cutting torch on page EN-52  17.3 FHT-EX®45TTM consumables for marking machine cutting torch on page EN-53 ®  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 38 The following too tightly. and tighten, if needed. icon flashes: ®  Use only Thermacut Consumables used are not original ® Thermacut original parts. consumables.  Remove all consumables, clean the Dirt inside the torch.
  • Page 39 ® EX-TRAFIRE 45HD 10 Faults and troubleshooting Table 15 General faults Error Description Cause Troubleshooting  Check the input power Power supply is insufficient. voltage.  Plug the input power plug Switch is set to Power cable is not No/low input ON, LCD does connected.
  • Page 40 ® 10 Faults and troubleshooting EX-TRAFIRE 45HD Table 15 General faults Error Description Cause Troubleshooting  Ensure that all cable Connection fault in work lead or cutting connections are correctly torch cable. installed.  Remove contamination and/ or oxidation from the workpiece and the work lead Poor contact No contact between...

  • Page 41: Disassembly

    ® EX-TRAFIRE 45HD 11 Disassembly Table 15 General faults Error Description Cause Troubleshooting  Adjust the output current Incorrect setting Output current (amps) for output current. too low/material too strength to the thickness of thick. the workpiece.  Inspect consumables in the Consumables are Consumables are defective.

  • Page 42: 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 43: 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 44: Block Diagrams

    ® 14 Block diagrams EX-TRAFIRE 45HD Block diagrams 14.1 Block diagram single-phase 14.2 Block diagram three-phase EN - 44...

  • Page 45: Accessories

    ® EX-TRAFIRE 45HD 15 Accessories Accessories Table 16 Accessories Accessories Part number Description EX-0-804-001 Filter-EX compressed air filter (Standard package, 1 piece) EX-0-804-002 Filter-EX air filter cartridge (Standard package, 8 pieces) 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...
  • Page 46 Universal connection cable 5 m (16.4') EX-0-803-005 Plasma Arc START/STOP Remote Controller EX-0-805-001 Grease, 25 ml EX-5-801-002 Circle cutting guide kit for ® FHT-X 105RTXH/105TTH/45TTH *Available on request For more information about accessories, visit our website: www.thermacut.com. EN - 46...

  • Page 47: 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 17 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 48 ® ® 16 FHT-EX 45TTH hand cutting torch unit EX-TRAFIRE 45HD Table 18 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 49: 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 19 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 50: 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 20 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 51 ® ® EX-TRAFIRE 45HD 17 FHT-EX 45TTM machine cutting torch unit Table 21 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 52: 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 22 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 53 ® ® EX-TRAFIRE 45HD 17 FHT-EX 45TTM machine cutting torch unit ® 17.3 FHT-EX 45TTM consumables for marking machine cutting torch ® Table 23 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 54: Ex-Trafire 45Hd Plasma Power Supply

    ® 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 24 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 55: 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 26 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 56: 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 28 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 57: Cut Charts For Mechanized Cutting

    ® EX-TRAFIRE 45HD 19 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 58: Cutting, Shielded, With Compressed Air

    ® 19 Cut charts for mechanized cutting EX-TRAFIRE 45HD 19.1 30 A cutting, shielded, with compressed air EX-2-415-202 EX-2-409-201 EX-2-404-201 EX-2-401-201 EX-2-421-201 EX-2-428-011 EX-2-415-201 EX-2-423-211 Material Cut height Pierce Pierce delay Recommended Maximum speed Kerf thickness (shield to height time speed width work cut...

  • Page 59: Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 45HD 19 Cut charts for mechanized 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 Cut height Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield to height delay time width Settings for Standard quality...

  • Page 60: Tables For Marking

    ® 19 Cut charts for mechanized 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 Cut height Initial marking Delay Marking Kerf Kerf supply (shield to height...

  • Page 61: Appendix

    ® EX-TRAFIRE 45HD 20 Appendix Appendix 20.1 Connecting the CNC interface The optional CNC interface plug installs onto the rear panel of the device. Control signals can be transmitted via the CNC interface. For signal types see Table 29 Signal and pin assignment for CNC interface on page EN-61.

  • Page 62: Setting The Voltage Divider Dip Switches

    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. 10 Voltage divider DIP switch settings 20.1.2 Enabling the external DC coil with an external power supply...

  • Page 63: Enabling The External Ac Coil With An External Power Supply

    ® EX-TRAFIRE 45HD 20 Appendix 20.1.3 Enabling the external AC coil with an external power supply Fig. 12 Enable the external AC coil with an external power supply 24 V AC 230 V AC 20.1.4 Enabling the industrially insulated module with an external power supply Fig.
  • Page 64 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 65 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 Tel.: +375 29 5 800 300 Tel.: +421 31 591 0121 E-mail: info@thermacut.by +421 903 644 954 www.thermacut.by...
  • Page 66 E-mail: don.kim@binzel.kr www.thermacut.net www.thermacut.net JAPAN UNITED ARAB EMIRATES ABIRCOR BINZEL MIDDLE EAST FZE Thermacut Japan Ltd. 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...

  • Page 67: Revision History

    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) Revision R3/11_2023 — Revised phrasing —...
  • Page 68 © Copyright 2022 Thermacut k.s, Subject to change without a notice. All Rights Reserved.

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