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THERMACUT EX-TRAFIRE 105HD Operating Instructions Manual

Plasma cutting system
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Plasma Cutting System
Operating Instructions – EX-5-902-004/N21609 – CE
st
Revision 4, 21
August, 2024

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Summary of Contents for THERMACUT EX-TRAFIRE 105HD

  • Page 1 Plasma Cutting System Operating Instructions – EX-5-902-004/N21609 – CE Revision 4, 21 August, 2024...
  • Page 2 ® EX-TRAFIRE 105HD 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 105HD Decommissioning ..........EN-31 Maintenance and cleaning ........EN-32 Maintenance and cleaning intervals ........EN-33 Faults and troubleshooting........EN-34 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 105HD 21.5.1 85 A cutting, shielded, with compressed air ......EN-60 21.6 100–105 A cutting, shielded, with compressed air....EN-61 21.6.1 100–105 A cutting, shielded, with compressed air....EN-62 21.7 40–45 A cutting, SmoothLine, shielded, with compressed air..............EN-63 21.7.1 40–45 A cutting, SmoothLine, shielded, with compressed air..............
  • Page 5 ® metals. The EX-TRAFIRE 105HD has to be operated only with original ® Thermacut consumables and maintenance parts. ® This documentation describes the EX-TRAFIRE 105HD cutting power supply system only.
  • Page 6 ® 1 Identification EX-TRAFIRE 105HD 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  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 ® 2 Safety EX-TRAFIRE 105HD 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 ® EX-TRAFIRE 105HD 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 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 ® EX-TRAFIRE 105HD 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 LCD Display Power cable POWER switch Work lead connection Optional BUS interface...
  • Page 12 ® 4 Product description EX-TRAFIRE 105HD Technical data Table 2 Power supply specifications Rated open circuit voltage (U 330 V DC Characteristic curve* Drooping * The curve is defined as output voltage versus output current Input voltage (U 400 V AC ± 15 % 3 PH/50 –...
  • Page 13 ® EX-TRAFIRE 105HD 4 Product description Table 5 Gas data Permissible gas Compressed air/nitrogen/argon* Gas inlet pressure, cutting 6.2 to10 bar Recommended compressed ISO 8573-1 class 1.2.2. air quality clean, and free from moisture and Recommended nitrogen/ Purity: ≥ 99.99 % argon quality Needed flow rate 205 l/min at 5 bar...
  • Page 14 ® 4 Product description EX-TRAFIRE 105HD ® ® Table 6 Technical data for FHT-EX 105TTH and FHT-EX 105TTM cutting torches ® ® FHT-EX 105TTH / FHT-EX 105TTM Gas post-flow period delay approx. 30 seconds Type of voltage Protection type for IP23 (EN 60529) ®...
  • Page 15 ® EX-TRAFIRE 105HD 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 ® 5 Transport and positioning EX-TRAFIRE 105HD 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 ® EX-TRAFIRE 105HD 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 ® 6 Setting up the power supply EX-TRAFIRE 105HD 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 ® EX-TRAFIRE 105HD 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 ® 6 Setting up the power supply EX-TRAFIRE 105HD 6.5.1 Installing the cutting torch's gear rack Fig. 7 Cutting torch Mounting sleeve with torch body Strain relief Reduction nut Cable Mounting tube 1 Disconnect the machine cutting torch from the cutting power supply. 2 Place on a flat surface.
  • Page 21 ® EX-TRAFIRE 105HD 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 105HD 1 Install nozzle into the retaining cap. 2 Insert electrode into the retaining cap and nozzle assembly. 3 Insert the swirl ring. 4 Screw the entire assembly onto the hand cutting torch. Do not overtighten.
  • Page 23 ® EX-TRAFIRE 105HD 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 1 Position the cutting torch perpendicular to the workpiece. 2 Use an angle gauge to align the machine cutting torch at 0°...
  • Page 24 ® 7 Operation EX-TRAFIRE 105HD 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 ® EX-TRAFIRE 105HD 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 ® 7 Operation EX-TRAFIRE 105HD 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. 1 Press the multi-function button for one second. The adjustable values as well as the word “Set”...
  • Page 27 ® EX-TRAFIRE 105HD 7 Operation 7.1.3 Connecting the work lead 1 Remove contamination from the workpiece. 2 Connect the work lead clamp to the workpiece in order to allow maximum electrical conduction. 3 Do not connect the work lead clamp to the material to be cut off. 4 Connect the work lead clamp as close as possible to the cutting area in order to minimize electromagnetic fields.
  • Page 28 ® 7 Operation EX-TRAFIRE 105HD Manual grid cutting and gouging process 1 Switch on the device. 2 Automatic gas test (five seconds). 3 Automatic system test (five seconds). 4 Select either grid cutting or gouging mode. 5 Press torch trigger. 6 Generate a pilot arc.
  • Page 29 ® EX-TRAFIRE 105HD 7 Operation If sparks escape upwards during cutting, the material has not yet been completely severed. Proceed as follows:  Reduce the speed at which the cutting torch is pulled.  Check the setting for the output current.
  • Page 30 ® 7 Operation EX-TRAFIRE 105HD 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. ...
  • Page 31 ® EX-TRAFIRE 105HD 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  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  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. Table 12 Parts inspection Consumable Check for Action  Replace the shield.
  • Page 34  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 35 Retaining cap is incorrectly start signal is on installed or has been tightened correctly installed, re-install too tightly. correctly and tighten, if needed. ®  Use only Thermacut Consumables used are not original ® Thermacut original parts. consumables.  Have the issue checked by a Missing phase.
  • Page 36 ® 10 Faults and troubleshooting EX-TRAFIRE 105HD Table 13 Fault messages in the display Error code Cause Troubleshooting  Check the inlet gas pressure. Gas inlet pressure is below 72.5 psi (5 bar).  Check the gas pressure and flow. Insufficient plasma gas flow.
  • Page 37 ® EX-TRAFIRE 105HD 10 Faults and troubleshooting Table 14 General faults Fault Description Cause Troubleshooting  Check the input power Switch is set to ON, No/low input Power supply is LCD does not power voltage. insufficient. voltage. illuminate.  Plug the input power plug Power cable is not connected.
  • Page 38 ® 10 Faults and troubleshooting EX-TRAFIRE 105HD 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 No contact between work lead clamp and and/or oxidation from the workpiece.
  • Page 39 ® EX-TRAFIRE 105HD 11 Disassembly Table 14 General faults Fault Description Cause Troubleshooting  Adjust the output current Incorrect setting Output current (amps) too low/material too for output strength to the thickness of current. thick. the workpiece.  Inspect consumables in the Consumables Consumables are are defective.
  • Page 40  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 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 ® 15 Accessories EX-TRAFIRE 105HD 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 43 Part number Description EX-5-801-003 Bevel cutting guide kit for FHT-EX®105RTXH/ FHT-EX®105TTH/ FHT-EX®45TTH ® EX-0-806-001 Thermacut cutting gloves EX-6-810-001 Hand gouging heat shield EX-0-805-001 Grease, 25 ml *Available on request For more information about accessories, visit our website: www.thermacut.com. EN - 43...
  • Page 44 ® ® 16 FHT-EX 105TTH hand cutting torch unit EX-TRAFIRE 105HD ® FHT-EX 105TTH hand cutting torch unit ® Table 16 FHT-EX 105TTH hand cutting torch Number Part number Description ® EX-5-133-002 FHT-EX 105TTH hand cutting torch without consumables with 5 m (16.5’) cable/TCS13 ®...
  • Page 45 ® ® EX-TRAFIRE 105HD 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 17 Consumables for hand cutting torch 45–85 A Item Part number Description...
  • Page 46 ® ® 17 FHT-EX 105TTH consumables for hand cutting torch EX-TRAFIRE 105HD ® 17.2 FHT-EX 105TTH consumables for hand cutting torch 100 105 A – Shielded Gouging Table 18 Consumables for hand cutting torch 100–105 A Item Part number Description EX-5-404-051 Swirl ring 45–105 A EX-5-401-051...
  • Page 47 ® ® EX-TRAFIRE 105HD 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 20 FHT-EX 105TTM machine cutting torch without gear rack Number Part number Description EX-5-202-031 FHT-EX ®...
  • Page 48 ® ® 18 FHT-EX 105TTM machine cutting torch unit EX-TRAFIRE 105HD ® 18.2 FHT-EX 105TTSM short machine cutting torch ® Table 21 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 ® ® EX-TRAFIRE 105HD 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 22 FHT-EX 105TTM consumables for standard machine cutting torch 45–85 A Item Part number...
  • Page 50 ® ® 19 FHT-EX 105TTM consumables for machine cutting torch EX-TRAFIRE 105HD ® 19.2 FHT-EX 105TTM consumables for standard machine cutting torch 100–105 A Shielded **Unshielded ® Table 23 FHT-EX 105TTM consumables for standard machine cutting torch 100–105A Item Part number Description EX-5-404-051 Swirl ring 45–105 A...
  • Page 51 ® ® EX-TRAFIRE 105HD 19 FHT-EX 105TTM consumables for machine cutting torch ® 19.3 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 52 ® ® 19 FHT-EX 105TTM consumables for machine cutting torch EX-TRAFIRE 105HD ® 19.4 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 53 ® EX-TRAFIRE 105HD 20 Ordering information on bulk packs and starter kits 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 54 ® 21 Cut charts for mechanized cutting EX-TRAFIRE 105HD 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 55 ® EX-TRAFIRE 105HD 21 Cut charts for mechanized cutting 21.1 45 A cutting, shielded, with compressed air Material Pierce Pierce Recommended speed Maximum speed Kerf thickness delay time width height height Settings for Standard quality settings (shield to (shield to highest quality work cut workpiece...
  • Page 56 ® 21 Cut charts for mechanized cutting EX-TRAFIRE 105HD 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 57 ® EX-TRAFIRE 105HD 21 Cut charts for mechanized cutting 21.3 65 A cutting, shielded, with compressed air Material Pierce Recommended speed Maximum speed Kerf Cut height Pierce thickness delay width (shield to height Settings for Standard quality work cut (shield to time highest quality settings...
  • Page 58 ® 21 Cut charts for mechanized cutting EX-TRAFIRE 105HD 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 59 ® EX-TRAFIRE 105HD 21 Cut charts for mechanized cutting 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 60 ® 21 Cut charts for mechanized cutting EX-TRAFIRE 105HD 21.5.1 85 A cutting, shielded, with compressed air Material Pierce Recommended speed Maximum speed Kerf Cut height Pierce height thickness delay width (shield to (shield to Settings for Standard quality work cut workpiece time highest quality...
  • Page 61 ® EX-TRAFIRE 105HD 21 Cut charts for mechanized cutting 21.6 100–105 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 62 ® 21 Cut charts for mechanized cutting EX-TRAFIRE 105HD 21.6.1 100–105 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 63 ® EX-TRAFIRE 105HD 21 Cut charts for mechanized cutting 21.7 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 64 ® 21 Cut charts for mechanized cutting EX-TRAFIRE 105HD 21.7.1 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 Cut height Pierce height Pierce Recommended speed Kerf Power thickness (shield to work (shield to work- delay time width supply...
  • Page 65 ® EX-TRAFIRE 105HD 21 Cut charts for mechanized cutting 21.8 Tables for marking 21.8.1 Marking, shielded, with compressed air or argon With compressed air Marking Power Cut height Initial Delay Marking Arc voltage Kerf Kerf supply (shield to marking speed width depth work cut...
  • Page 66 ® 22 Appendix EX-TRAFIRE 105HD 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-66. The control elements are located on the control panel.
  • Page 67 The voltage divider DIP switches must be set only by a certified electrician or trained personnel. 2 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...
  • Page 68 ® 22 Appendix EX-TRAFIRE 105HD 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 69 ® EX-TRAFIRE 105HD 22 Appendix EN - 69...
  • Page 70 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 71 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 72 Pedro do Rio, Petrópolis – Rio de Janeiro, CEP 25750-226 Tel.: +55 (24) 2222-9799 +55 (24) 2222-9789 +(24) 98134-2676 Fax: +55 (24) 2222-9789 E-mail: thermacut@thermacut.com.br www.thermacut.com.br ASIA CHINA TURKEY TMT (Shanghai) Cutting and Welding ABICOR BINZEL Kaynak Teknik Equipment Co., Ltd.
  • Page 73 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, Osaka RAKIA Freezone, Jazeera al Hamra 532-0003 Japan Ras al Kaimah, United Arab Emirates Mob.: +81 (0)80 4738 9752 Tel.: +971 (7) 2432355...
  • Page 74 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 27.1 kVA Revision R3/09_2023: — 4.2 „Technical data“ - Revised dimensions —...
  • Page 76 © Copyright 2022 Thermacut k.s, Subject to change without a notice. All Rights Reserved.