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THERMACUT EX-TRAFIRE 65HD Operating Instructions Manual

Plasma cutting system
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Plasma Cutting System
Operating Instructions – EX-3-902-004/N21605 – RCM
th
Revision 4, 26
July, 2024

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Summary of Contents for THERMACUT EX-TRAFIRE 65HD

  • Page 1 Plasma Cutting System Operating Instructions – EX-3-902-004/N21605 – RCM Revision 4, 26 July, 2024...

  • Page 2: Table Of Contents

    ® EX-TRAFIRE 65HD 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 65HD Decommissioning ..........EN-31 Maintenance and cleaning ........EN-31 Maintenance and cleaning intervals ........EN-32 Faults and troubleshooting........EN-34 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 65HD 22.1 Connecting the CNC interface ..........EN-58 22.1.1 Setting the voltage divider DIP switches......... EN-59 22.1.2 Enabling the external DC coil with an external power supply ................EN-59 22.1.3 Enabling the external AC coil with an external power supply ................

  • Page 5: Identification

    65HD uses compressed air or nitrogen to cut almost all ® electrically conductive metals. The EX-TRAFIRE 65HD has to be operated ® only with original Thermacut consumables and maintenance parts. ® This documentation describes the EX-TRAFIRE 65HD cutting power supply only.

  • Page 6: Signs And Symbols Used

    ® 1 Identification EX-TRAFIRE 65HD 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 65HD Warning and notice signs The following warning, notice, and mandatory signs can be found on 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 65HD 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 65HD 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 65HD Technical data Table 2 Power supply specifications Rated open circuit voltage (U 311 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Input voltage (U 3 x 415 V AC + 15 % 50–60 Hz Output arc current (I 65 A...

  • Page 13: 105Tth

    ® EX-TRAFIRE 65HD 4 Product description Table 5 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 65HD ® ® Table 6 Technical data for FHT-EX 105TTH, FHT-EX 105TTM and ® FHT-EX 105TTSM cutting torches ® ® FHT-EX 105TTH / FHT-EX 105TTM/ ® FHT-EX 105TTSM Gas post-flow period delay ≤ 35 seconds Type of voltage Protection type for IP23 (EN 60529)

  • Page 15: Torch Dimensions Fht-Ex 105Tth

    ® EX-TRAFIRE 65HD 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 65HD 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 65HD 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 65HD 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 65HD 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 The Cutting Torch's Gear Rack

    ® 6 Setting up the power supply EX-TRAFIRE 65HD 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 65HD 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 65HD 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.

  • Page 23: Aligning Fht-Ex ® 105Ttm Machine Cutting Torch

    ® EX-TRAFIRE 65HD 6 Setting up the power supply ® Aligning FHT-EX 105TTM machine cutting torch For the setup of the torch and the cutting process see  6 Setting up the power supply on page EN-17 ff Position the machine cutting torch perpendicular to the workpiece.

  • Page 24: Operation

    ® 7 Operation EX-TRAFIRE 65HD 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 65HD 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 65HD 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 and the word “Set”...

  • Page 27: 7.1.3 Connecting The Work Lead

    ® EX-TRAFIRE 65HD 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 65HD 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 65HD 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 30: Stopping The Cutting Process

    ® 7 Operation EX-TRAFIRE 65HD 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 31: 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 32: Maintenance And Cleaning Intervals

    Thermacut or an authorized specialist.  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 - 32...
  • Page 33 ® EX-TRAFIRE 65HD 9 Maintenance and cleaning Table 12 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 34: Faults And Troubleshooting

     17 FHT-EX®105TTH consumables for hand cutting torch on page EN-44  19 FHT-EX®105TTM 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 35 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 36 ® 10 Faults and troubleshooting EX-TRAFIRE 65HD Table 13 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 37 ® EX-TRAFIRE 65HD 10 Faults and troubleshooting Table 14 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 and/or oxidation from the workpiece and the work Poor contact No contact between...

  • Page 38: Disassembly

    ® 11 Disassembly EX-TRAFIRE 65HD Table 14 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 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. EN - 39...

  • 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

    ® EX-TRAFIRE 65HD 15 Accessories Accessories Table 15 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 42 ® 15 Accessories EX-TRAFIRE 65HD Table 15 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 - 42...

  • Page 43: Fht-Ex 105Tth Hand Cutting Torch Unit

    ® ® EX-TRAFIRE 65HD 16 FHT-EX 105TTH hand cutting torch unit ® FHT-EX 105TTH hand cutting torch unit ® Table 16 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 44: Fht-Ex ® 105Tth Consumables For Hand Cutting Torch

    ® ® 17 FHT-EX 105TTH consumables for hand cutting torch EX-TRAFIRE 65HD ® FHT-EX 105TTH consumables for hand cutting torch ® 17.1 FHT-EX 105TTH 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 45: Fht-Ex 105Ttm Machine Cutting Torch Unit

    ® ® EX-TRAFIRE 65HD 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 19 FHT-EX 105TTM machine cutting torch without gear rack Number Part number Description EX-5-202-031 FHT-EX ®...

  • Page 46: Fht-Ex 105Ttsm Short Machine Cutting Torch

    ® ® 18 FHT-EX 105TTM machine cutting torch unit EX-TRAFIRE 65HD ® 18.2 FHT-EX 105TTSM short machine cutting torch ® Table 20 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 47: Fht-Ex ® 105Ttm Consumables For Machine Cutting Torch

    ® ® EX-TRAFIRE 65HD 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 45–65 A Shielded *Unshielded ® Table 21 FHT-EX 105TTM consumables for standard machine cutting torch 45–65 A Item Part number...

  • Page 48: Fht-Ex 105Ttm Consumables For Smoothline Machine Cutting Torch

    ® ® 19 FHT-EX 105TTM consumables for machine cutting torch EX-TRAFIRE 65HD ® 19.2 FHT-EX 105TTM consumables for SmoothLine machine cutting torch Shielded **Unshielded ® Table 22 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 49: Fht-Ex 105Ttm Consumables For Marking Machine Cutting Torch

    ® ® EX-TRAFIRE 65HD 19 FHT-EX 105TTM consumables for machine cutting torch ® 19.3 FHT-EX 105TTM consumables for marking machine cutting torch ® Table 23 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 50: Ordering Information On Bulk Packs And Starter Kits

    ® 20 Ordering information on bulk packs and starter kits EX-TRAFIRE 65HD Ordering information on bulk packs and starter kits ® ® Table 24 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 51: Cut Charts For Mechanized Cutting

    ® EX-TRAFIRE 65HD 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 52: Cutting, Shielded, With Compressed Air

    ® 21 Cut charts for mechanized cutting EX-TRAFIRE 65HD 21.1 45 A cutting, shielded, with compressed air Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf (shield to height thickness delay time width Settings for Standard quality work cut (shield to highest quality settings...

  • Page 53: 55 A Cutting, Shielded, With Compressed Air

    ® EX-TRAFIRE 65HD 21 Cut charts for mechanized cutting 21.2 55 A cutting, shielded, with compressed air Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf (shield to height thickness delay time width Settings for Standard quality work cut (shield to highest quality settings...
  • Page 54 ® 21 Cut charts for mechanized cutting EX-TRAFIRE 65HD 21.3 65 A cutting, shielded, with compressed air Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf thickness (shield to height delay time width Settings for Standard quality work cut (shield to highest quality settings...

  • Page 55: A Cutting, Smoothline, Shielded, With

    ® EX-TRAFIRE 65HD 21 Cut charts for mechanized cutting 21.4 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.

  • Page 56: 21.4.1 40-45 A Cutting, Smoothline, Shielded, With

    ® 21 Cut charts for mechanized cutting EX-TRAFIRE 65HD 21.4.1 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 Pierce Recommended speed Kerf Power thickness height height delay time width supply Settings for highest quality (shield to (shield to Cutting speed...

  • Page 57: Tables For Marking

    ® EX-TRAFIRE 65HD 21 Cut charts for mechanized cutting 21.5 Tables for marking 21.5.1 Marking, shielded, with compressed air or argon With compressed air Marking Power Cut height Initial Delay Marking Kerf Kerf supply (shield to marking speed voltage width depth work cut height...

  • Page 58: Appendix

    ® 22 Appendix EX-TRAFIRE 65HD 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 26 Signal and pin assignment for CNC interface on page EN-58. The control elements are located on the control panel.

  • Page 59: 22.1.1 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 60: Enabling The External Ac Coil With An External Power Supply

    ® 22 Appendix EX-TRAFIRE 65HD 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 61 ® EX-TRAFIRE 65HD 22 Appendix EN - 61...
  • Page 62 ADDRESSES AND CONTACTS AUSTRALIA Binzel PTY Ltd. 42 Hinkler Road Mordialloc Victoria 3195 Tel.: +61 (0)3 9587 8522 Fax: +61 (0)3 9580 8796 E-mail: sales@thermacut.com.au www.thermacut.net...

  • Page 63: Revision History

    Revision history You can find the latest version of the operator manual on our website: www.thermacut.com.au Revision R1/10_2022 Revision R2/08_2023 — 4.2 “Technical data“– Maximum input power changed to 17 kVA Revision 3/01_2024 — 4.2 „Technical data“ – Table 1 changed; torch dimensions added —...
  • Page 64 © Copyright 2022 Thermacut k.s, Subject to change without a notice. All Rights Reserved.

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