Related Manuals for THERMACUT EX-TRAFIRE 85HD
Summary of Contents for THERMACUT EX-TRAFIRE 85HD
- Page 1 Plasma Cutting System Operating Instructions – EX-4-902-004/N-21607 – CE Revision 4, 26 July, 2024...
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Page 2: Table Of Contents
® EX-TRAFIRE 85HD Table of contents Identification ............EN-5 Labeling..................EN-5 Identification plate ............... EN-5 Signs and symbols used.............. EN-6 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 85HD Decommissioning ..........EN-31 Maintenance and cleaning ........EN-32 Maintenance and cleaning intervals ........EN-33 Faults and troubleshooting........EN-35 Disassembly............EN-39 Disposal ..............EN-40 12.1 Disposal of materials..............EN-40 12.2 Disposal of consumables ............EN-40 12.3 Packaging ..................EN-40 Warranty ..............
- Page 4 ® EX-TRAFIRE 85HD compressed air ................EN-61 21.7 Tables for marking..............EN-62 21.7.1 Marking, shielded, with compressed air or argon ....EN-62 Appendix..............EN-63 22.1 Connecting the CNC interface ..........EN-63 22.1.1 Setting the voltage divider DIP switches......... EN-64 22.1.2 Enabling the external DC coil with an external power supply ................
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Page 5: Identification
® metals. The EX-TRAFIRE 85HD has to be operated only with original ® Thermacut consumables and maintenance parts. ® This documentation describes the EX-TRAFIRE 85HD cutting power supply only. -
Page 6: Signs And Symbols Used
® 1 Identification EX-TRAFIRE 85HD 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
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 8: Warning And Notice Signs
® 2 Safety EX-TRAFIRE 85HD 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 85HD 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 device 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
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 85HD 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 device. 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 85HD Technical data Table 3 Power supply specifications Rated open circuit voltage (U 300 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Input voltage (U 3 x 400 V AC +15% 50/60 Hz Output arc current (I 20–85 A... -
Page 13: 105Tth
® EX-TRAFIRE 85HD 4 Product description 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 Recommended nitrogen/argon Purity: ≥ 99.99% quality Needed flow rate 170 l/min at 7 bar... - Page 14 ® 4 Product description EX-TRAFIRE 85HD ® ® Table 7 Technical data for FHT-EX 105TTH, FHT-EX 105TTM and FHT- ® 105TTSM cutting torches ® ® FHT-EX 105TTH / FHT-EX 105TTM/ ® FHT-EX 105TTSM Type of voltage Protection type for IP23 (EN 60529) ®...
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Page 15: Torch Dimensions Fht-Ex 105Tth
® EX-TRAFIRE 85HD 4 Product description ® 4.3.1 Torch dimensions FHT-EX 105TTH ® Fig. 3 Torch dimensions FHT-EX 105TTH ® 4.3.2 Torch dimensions FHT-EX 105TTM ® Fig. 4 Torch dimensions FHT-EX 105TTM ® 4.3.3 Torch dimensions FHT-EX 105TTSM ® Fig. 5 Torch dimensions FHT-EX 105TTSM EN - 15... -
Page 16: Transport And Positioning
® 5 Transport and positioning EX-TRAFIRE 85HD 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 17: Setting Up The Power Supply
® EX-TRAFIRE 85HD 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 18: Connecting The Input Power Plug
® 6 Setting up the power supply EX-TRAFIRE 85HD 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 19: Connection To A Generator (Optional
® EX-TRAFIRE 85HD 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 10 Connection to a generator Generator rating Generator output... -
Page 20: Installing The Cutting Torch's Gear Rack
® 6 Setting up the power supply EX-TRAFIRE 85HD 6.5.1 Installing the cutting torch's gear rack Fig. 7 Cutting torch A Mounting sleeve with torch body D Strain relief B Reduction nut E Cable C Mounting tube Disconnect the machine cutting torch from the cutting power supply. -
Page 21: Installing Consumables For The Hand And Machine Cutting Torches
® EX-TRAFIRE 85HD 6 Setting up the power supply 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 22 ® 6 Setting up the power supply EX-TRAFIRE 85HD Install nozzle into the retaining cap. Insert electrode into retaining cap and nozzle assembly. Insert the swirl ring. Screw the entire assembly onto the hand cutting torch. Do not overtighten. The nozzle must be firmly in place and must not move.
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Page 23: Aligning Fht-Ex ® 105Ttm Machine Cutting Torch
® EX-TRAFIRE 85HD 6 Setting up the power supply ® Aligning FHT-EX 105TTM 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. Use an angle gauge to align the machine cutting torch at 0°... -
Page 24: Operation
® 7 Operation EX-TRAFIRE 85HD 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 25: Lcd Description
® EX-TRAFIRE 85HD 7 Operation NOTICE 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 26: Setting The Parameters
® 7 Operation EX-TRAFIRE 85HD 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 27: Connecting The Work Lead
® EX-TRAFIRE 85HD 7 Operation 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 28: Cutting - Edge Start
® 7 Operation EX-TRAFIRE 85HD 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 approx. 30 seconds depending on the output current and is not adjustable. -
Page 29: Piercing
® EX-TRAFIRE 85HD 7 Operation 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. Turn the cutting torch slowly in a vertical direction. - Page 30 ® 7 Operation EX-TRAFIRE 85HD 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.
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Page 31: Stopping The Cutting Process
® EX-TRAFIRE 85HD 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. People are at a risk of burns. Wear your personal protective equipment. ... -
Page 32: 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 33: 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 - 33... - Page 34 ® 9 Maintenance and cleaning EX-TRAFIRE 85HD Table 14 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. ...
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Page 35: Faults And Troubleshooting
17 FHT-EX®105TTH consumables for hand cutting torch on page EN-45 19 FHT-EX®105TTM consumables for machine cutting torch on page EN-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 CNC start installed or has been tightened correctly installed, re-install correctly signal is on too tightly. and tighten, if needed. ® Use only Thermacut Consumables used are not original ® Thermacut original parts. consumables. Have the issue checked by a certified Missing phase.
- Page 37 ® EX-TRAFIRE 85HD 10 Faults and troubleshooting Table 15 Fault messages in the display Error code Cause Troubleshooting Have the control PCB replaced by a Watchdog fault. certified electrician or trained personnel. Verify the cutting power settings. Incorrect current setting. ...
- Page 38 ® 10 Faults and troubleshooting EX-TRAFIRE 85HD Table 16 General faults Fault Description Cause Troubleshooting Ensure that all cable Connection fault in work lead or cutting connections are correctly torch cable. installed. Remove contamination No contact between work lead clamp and and/or oxidation from the workpiece.
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Page 39: Disassembly
® EX-TRAFIRE 85HD 11 Disassembly Table 16 General faults Fault Description Cause Troubleshooting Adjust the output current Incorrect setting Output current (amps) for output too low/material too strength to the thickness of current. thick. the workpiece. Inspect consumables in the Consumables Consumables are are defective. -
Page 40: 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 41: 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 42: Accessories
® 15 Accessories EX-TRAFIRE 85HD Accessories Table 17 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" EX-0-803-001 CNC interface plug 14-pin kit, incl. - Page 43 ® EX-TRAFIRE 85HD 15 Accessories Table 17 Accessories Accessories Part number Description EX-0-805-001 Grease, 25 ml *Available on request For more information about accessories, visit our website: www.thermacut.com. EN - 43...
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Page 44: Fht-Ex 105Tth Hand Cutting Torch Unit
® ® 16 FHT-EX 105TTH hand cutting torch unit EX-TRAFIRE 85HD ® FHT-EX 105TTH hand cutting torch unit ® Table 18 FHT-EX 105TTH hand cutting torch Number Part number Description ® EX-5-139-001 FHT-EX 105TTH hand cutting torch without consumables with 5 m (16.5’) cable/TCS13 ®... -
Page 45: Fht-Ex
® ® EX-TRAFIRE 85HD 17 FHT-EX 105TTH consumables for hand cutting torch ® FHT-EX 105TTH consumables for hand cutting torch ® 17.1 FHT-EX 105TTH consumables for hand cutting torch 45–85 A Table 19 Consumables for hand cutting torch 45–85 A Item Part number Description... -
Page 46: 105Tth Consumables For Smoothline Hand
® ® 17 FHT-EX 105TTH consumables for hand cutting torch EX-TRAFIRE 85HD ® 17.2 FHT-EX 105TTH consumables for SmoothLine hand cutting torch Shielded ® Table 20 FHT-EX 105TTH consumables for SmoothLine hand cutting torch Item Part number Description EX-5-404-051 Swirl ring 45–105 A EX-5-401-051 Electrode 45–105 A EX-5-410-050... -
Page 47: Fht-Ex 105Ttm Machine Cutting Torch Unit
® ® EX-TRAFIRE 85HD 18 FHT-EX 105TTM machine cutting torch unit ® FHT-EX 105TTM machine cutting torch unit ® 18.1 FHT-EX 105TTM machine cutting torch without gear rack ® Table 21 FHT-EX 105TTM machine cutting torch without gear rack Number Part number Description EX-5-202-031 FHT-EX ®... -
Page 48: Fht-Ex 105Ttsm Short Machine Cutting Torch
® ® 18 FHT-EX 105TTM machine cutting torch unit EX-TRAFIRE 85HD ® 18.2 FHT-EX 105TTSM short machine cutting torch ® Table 22 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 49: Fht-Ex ® 105Ttm Consumables For Machine
® ® EX-TRAFIRE 85HD 19 FHT-EX 105TTM consumables for machine cutting torch ® 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 23 FHT-EX 105TTM consumables for standard machine cutting torch 45–85 A Item Part number... -
Page 50: Fht-Ex 105Ttm Consumables For Smoothline Machine Cutting Torch
® ® 19 FHT-EX 105TTM consumables for machine cutting torch EX-TRAFIRE 85HD ® 19.2 FHT-EX 105TTM consumables for SmoothLine machine cutting torch Shielded **Unshielded ® Table 24 FHT-EX 105TTM consumables for SmoothLine machine cutting torch Item Part number Description EX-5-404-051 Swirl ring 45–105 A EX-5-401-051 Electrode 45–105 A... -
Page 51: Fht-Ex 105Ttm Consumables For Marking Machine Cutting Torch
® ® EX-TRAFIRE 85HD 19 FHT-EX 105TTM consumables for machine cutting torch ® 19.3 FHT-EX 105TTM consumables for marking machine cutting torch ® Table 25 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 45–105 A EX-5-445-001... -
Page 52: Ordering Information On Bulk Packs And Starter Kits
® 20 Ordering information on bulk packs and starter kits EX-TRAFIRE 85HD Ordering information on bulk packs and starter kits ® ® Table 26 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 53: Cut Charts For Mechanized Cutting
® EX-TRAFIRE 85HD 21 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
® 21 Cut charts for mechanized cutting EX-TRAFIRE 85HD 21.1 45 A cutting, shielded, with compressed air Material Pierce delay Recommended Maximum speed Kerf Cut height Pierce thickness time speed width (shield to height work cut (shield to Settings for Standard quality height) workpiece... -
Page 55: Cutting, Shielded, With Compressed Air
® EX-TRAFIRE 85HD 21 Cut charts for mechanized cutting 21.2 55 A cutting, shielded, with compressed air Material Pierce Recommended speed Maximum speed Kerf Cut height Pierce thickness (shield to height delay time width Settings for Standard quality work cut (shield to highest quality settings... -
Page 56: Cutting, Shielded, With Compressed Air
® 21 Cut charts for mechanized cutting EX-TRAFIRE 85HD 21.3 65 A cutting, shielded, with compressed air Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf thickness delay width (shield to height Settings for Standard quality time work cut (shield to highest quality settings... -
Page 57: Cutting, Shielded, With Compressed Air
® EX-TRAFIRE 85HD 21 Cut charts for mechanized cutting 21.4 75 A cutting, shielded, with compressed air Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf thickness delay width (shield to height Settings for Standard quality time work cut (shield to highest quality settings... -
Page 58: Cutting, Shielded, With Compressed Air
® 21 Cut charts for mechanized cutting EX-TRAFIRE 85HD 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 59: Cutting, Shielded, With Compressed Air
® EX-TRAFIRE 85HD 21 Cut charts for mechanized cutting 21.5.1 85 A cutting, shielded, with compressed air Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf thickness delay width (shield to height Settings for Standard quality time work cut (shield to highest quality settings... - Page 60 ® 21 Cut charts for mechanized cutting EX-TRAFIRE 85HD 21.6 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.
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Page 61: A Cutting, Smoothline, Shielded, With Compressed Air
® EX-TRAFIRE 85HD 21 Cut charts for mechanized cutting 21.6.1 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 Pierce delay Recommended speed Kerf Power Cut height Pierce height thickness (shield to work (shield to work- time width... -
Page 62: Tables For Marking
® 21 Cut charts for mechanized cutting EX-TRAFIRE 85HD 21.7 Tables for marking 21.7.1 Marking, shielded, with compressed air or argon With compressed air Marking Power Cut height Initial Delay Marking Kerf Kerf supply (shield to marking height speed voltage width depth work cut... -
Page 63: Appendix
® EX-TRAFIRE 85HD 22 Appendix Appendix 22.1 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 28 Signal and pin assignment for CNC interface on page EN-63. The control elements are located on the control panel. -
Page 64: 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. 11 Voltage divider DIP switch settings 22.1.2 Enabling the external DC coil with an external... -
Page 65: Enabling The External Ac Coil With An External Power Supply
® EX-TRAFIRE 85HD 22 Appendix 22.1.3 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 22.1.4 Enabling the industrially insulated module with an external power supply Fig. - Page 66 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 67 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 68 E Blok No:72-6E PK:34852 Shanghai Maltepe Istanbul Türkiye Post: 201206 Tel.: +90 (216) 367 90 00 Tel.: 021-50390667 Fax: +90 (216) 367 90 14 Fax: 021-50390677 E-mail: E-mail: thermacut@weldstone.cn satisdestek@binzel-abicor.com.tr www.thermacut.cn www.thermacuttr.com INDIA KAZAKHSTAN ABICOR BINZEL TECHNOWELD ABICOR BINZEL CENTRAL ASIA АЛМАТЫ...
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Page 69: South Korea
6067 Fax: 0082 (31) 732 6064 www.thermacut.net E-mail: don.kim@binzel.kr www.thermacut.net JAPAN UNITED ARAB EMIRATES Thermacut Japan Ltd. ABICOR BINZEL MIDDLE EAST FZE 3F Shin-Osaka Hankyu Building P.O Box: 86026, WFZ-04/27 1-1-1, Miyahara, Yodogawa-ku, RAKIA Freezone, Jazeera al Hamra Osaka Ras al Kaimah, United Arab Emirates 532-0003 Japan Tel.: +971 (7) 2432355... - Page 72 © Copyright 2022 Thermacut k.s, Subject to change without a notice. All Rights Reserved.
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