THERMACUT EX-TRAFIRE 100SD Operator'S Manual Download Page 1

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THERMACUT

EX-TRAFIRE

100SD

PLASMA CUTTING POWER SUPPLY

Operator Manual

Revision: T-5

English

2021

EX-5-907-001

N-22158

BEFORE SWITCHING ON OR OPERATING THE SYSTEM,

READ THIS MANUAL, BECOME FAMILIAR WITH THE

CONTENT. KEEP THE MANUAL LOCAL TO THE JOB SITE

WITH EASY ACCESS TO ALL PERSONNEL. THE SYSTEM IS TO BE USED FOR METAL

CUTTING ONLY.

PLEASE, CHECK THE LATEST VERSION OF THE OPERATOR MANUAL ON OUR WEBSITE:

www.ex-trafire.com

!IMPORTANT!

Summary of Contents for EX-TRAFIRE 100SD

Page 1: ...158 BEFORE SWITCHING ON OR OPERATING THE SYSTEM READ THIS MANUAL BECOME FAMILIAR WITH THE CONTENT KEEP THE MANUAL LOCAL TO THE JOB SITE WITH EASY ACCESS TO ALL PERSONNEL THE SYSTEM IS TO BE USED FOR METAL CUTTING ONLY PLEASE CHECK THE LATEST VERSION OF THE OPERATOR MANUAL ON OUR WEBSITE www ex trafire com IMPORTANT ...

Page 2: ... overheating and cause damage to the system 8 Magnetic field can affect pacemakers 8 Plasma cutting can cause interferenc 8 Safety Sticker 9 SECTION 2 SPECIFICATIONS 2 10 Dimensions and weight of the plasma arc power supply 2 11 Specifications plasma arc power supply 2 12 Hand torch setup 2 14 Machine torch setup 2 15 Symbols and marking 2 16 SECTION 3 INSTALLATION 3 17 Upon receipt of goods 3 18 ...

Page 3: ...ew 4 34 Rear control panel detail 4 34 Turn ON 4 35 Check the LED indicators 4 35 Operating the hand torch 4 36 Operating the torch safety trigger 4 36 Fit the work clamp 4 37 Edge start cutting 4 37 Hand torch cutting technique 4 38 Piercing 4 39 Gouging 4 40 Gouge profile 4 41 Modification of the gouge profile 4 41 Operating the machine torch 4 42 Alignment of the machine torch 4 42 SECTION 5 MA...

Page 4: ...for FHT EX 105RTXH 105TTH 45TTH 8 53 SECTION 9 SYSTEM CIRCUIT DIAGRAM 9 54 Power supply block diagram 9 54 SECTION 10 DISPOSAL OF PRODUCT 10 55 Use and disposal of waste 10 55 End of lifetime product disposal 10 55 SECTION 11 WARRANTY 11 56 Notes 11 57 Revision history 11 58 ...

Page 5: ...tting can cause fire or explosion 7 Electric shock can kill 7 Plasma arc can injure 7 Flying sparks arc spray can cause injury fire or explosion 7 Hot parts can cause severe burns 7 Smoke and gases can be hazardous 8 Caution when cutting around gas cylinders 8 Do not exceed the recommended duty cycle this can lead to overheating and cause damage to the system 8 Magnetic field can affect pacemakers...

Page 6: ...sses produce intense visible and invisible rays that can burn eyes and skin Use protective clothing made from durable flame resistant material appropriate footwear and hand protection Use face protection welding helmet or shield with the correct shade of filter lens fitted to protect your eyes and face see Table 1 1 Warn people of the dangers of looking at the arc use signs to warn inform PLASMA A...

Page 7: ...REVENTION Keep flammable items away from the work area Ensure that there is a fully charged fire extinguisher in the work area Ventilate the work area check for flammable combustible gases liquids and materials remove prior to cutting as they present a fire risk EXPLOSION PREVENTION Do not cut in areas containing explosives flammable gases or vapors Do not place the system on over or near combusti...

Page 8: ...SES CAN BE HAZARDOUS Work in a confined space only if it is well ventilated or while wearing an air supplied respirator The smoke and gases from the cutting gouging process can displace air and lower the oxygen level causing injury or death Monitor the breathable air quality as required MAGNETIC FIELD CAN AFFECT PACEMAKERS People with pacemakers hearing aids should avoid close contact with plasma ...

Page 9: ... 6 1 6 2 6 3 5 7 Safety instructions EX 0 904 008 N 21626 Torch consumables installation WARNING Plasma arc is generated immediately when the torch trigger is depressed The plasma arc will cut quickly through gloves and skin Make sure the power is switched off before changing consumables Hand torch Machine torch ...

Page 10: ...r Manual Revision T 5 2 10 Dimensions and weight of the plasma arc power supply 2 11 Specifications plasma arc power supply 2 12 Hand torch setup 2 14 Machine torch setup 2 15 Symbols and marking 2 16 SECTION 2 SPECIFICATIONS ...

Page 11: ...pply Weight of plasma arc power supply without torch 24 0 kg 265 mm 560 mm 400 mm EX TRAFIRE 100SD Is a portable plasma arc cutting system It can be used for machine and handheld cutting or handheld gouging too Uses air or nitrogen for cutting electrically conductive metals mild steel stainless steel and aluminium ...

Page 12: ...nd effective input current I1eff at rated output voltage U2 and rated output current I2 for cutting only I1eff I1 X used to determine rating of power cord eff effective rms root mean square U1rms I1rms I1eff 3 x 400 VAC 15 39 3 A 27 8 A This equipment conforms to IEC 61000 3 12 EN 60974 1 Isolation class H F IP Code Degree of protection provided by enclosure IP23S IP International Protection 2 No ...

Page 13: ... cutting capacity mm 50 Severance cutting capacity mm 50 Piercing capacity mm 20 Gouging capability Kg h up to 8 Protection level IP23S Isolation class H F Dimensions l x h x w mm 560 x 400 x 265 Weight kg 24 Gas pressure bar 5 5 Gas flow lpm 270 5 minutes cutting 5 minutes resting Duty cycle Duty cycle is the percentage of time during a period of 10 minutes that the power supply can continuously ...

Page 14: ...E 100SD Operator Manual Revision T 5 2 14 Hand torch setup Ground Work lead Power lead Gas supply Torch lead P view P Torch lead Work lead Workpiece Work table Gas hose min Ø8 mm min 270 LPM min 6 bar max 10 bar ...

Page 15: ...or Manual Revision T 5 2 15 Machine torch setup Ground Work lead Power lead Gas supply Torch lead Machine interface cable P view P Torch lead Work lead Workpiece Work table Gas hose min Ø8 mm min 270 LPM min 6 bar max 10 bar ...

Page 16: ...The terminal for the external protective earth conductor An inverter based power supply For compliance with the European Norm it is NOT permissible to use unshielded consumables in Hand Held applications S Mark This marking signifies the manufacturer s declaration of conformity to applicable European directives and standards EMC LVD The mark indicates that the power supply and torch are suitable f...

Page 17: ...ses mains power lead 3 20 The mains power lead connection 3 21 Torch installation step by step 3 21 Plasma gas supply 3 24 Additional gas filtration 3 24 Gas supply installation 3 25 Setting the gas pressure 3 25 System CNC interface connection 3 26 Activating an external DC coil with an external power supply 3 27 Activating an external AC coil with an external power supply 3 27 Activating an indu...

Page 18: ...ontact the carrier immediately take photographs of the packaging and areas of damage on the system Inform Authorized Supplier who will provide copies of relevant documentation For further assistance contact Customer Services details are listed at the back of this manual Claims for defective or missing goods All systems shipped from Authorized Supplier have been subjected to a rigorous quality cont...

Page 19: ... the EX TRAFIRE 100SD Engine drive operation 1 Set engine drive output to three phases AC 2 Plug the EX TRAFIRE 100SD mains power lead in to the power outlet 3 Hard wire connection No plug fitted should be performed by a certified electrician 4 Set the engine drive to maximum output see chart below 5 For optimum performance do not share the engine drive with other equipment such as welding plant l...

Page 20: ...nsion depending on length mm2 3 m 3 7 5 m 7 5 15 m 15 30 m 30 45 m Model CE Phase mm2 mm2 mm2 mm2 mm2 400 VAC 15 3 6 6 10 10 16 Note The system was tested with a 3 meter mains power lead for compliance with EMC standards Three phases mains power lead To operate the EX TRAFIRE 100SD use a plug that complies with national and local codes of practice A certified electrician or electrotechnically comp...

Page 21: ...nically competent person should connect the mains power lead to a plug or hard wire to a suitable supply according to national standards Torch installation step by step 1 TURN OFF the power supply OFF Turn OFF ON Turn ON Torch latch key position of TCS Torch Connection System plug 2 Torch connection power supply location ...

Page 22: ...CS plug Latch with key position TCS latch with key Torch TCS plug Latch with key position 4 Torch connection 1st step place the TCS latch with key into the TCS power supply socket The TCS latch with key must be locked in the TCS socket properly with the latch nose TCS latch nose ...

Page 23: ...vision T 5 3 23 5 Torch connection 2nd step put TCS plug into the TCS socket The torch TCS plug must be locked in the TCS socket properly with the key nose 6 Torch connection proper position of the TCS plug in the TCS socket TCS key nose ...

Page 24: ...ax dewpoint 3 C class 4 ref to ISO 8573 Purity 99 99 Gas quality Clean moisture free without oil Note A poor quality gas supply has a detrimental effect on cut speeds cut quality reduced thickness of material that can be cut and shorter consumable parts life WARNING Do not allow the input gas pressure to exceed 10 bar 145 psi The filter bowl could explode if the pressure is exceeded Note EX TRAFIR...

Page 25: ...to GOUGE by mode switch 2 Set the cutting gas pressure by pulling up and turning the regulator knob to it s recommended value 5 5 bar displayed on the manometer 3 Push down the regulator knob after setting up the gas pressure 4 Switch back from GOUGE to CUT by mode selector 5 Power supply is prepared to cut GOUGING 1 Switch from CUT to GOUGE by mode switch 2 Set the cutting gas pressure by pulling...

Page 26: ...Type Input Output Ground Output Note Normally open Open circuit voltage 12 VDC in the START terminals Requires a dry contact to close it Normally open Dry contact with maximum capacity of 125 VAC 10 A 250 VAC 5 A 30 VDC 5 A Divider arc voltage signal of 20 1 21 1 1 30 1 40 1 50 1 provides a maximum 18 V Rear socket connection 3 4 12 14 13 6 5 Internal wire colours white white yellow yellow green y...

Page 27: ...perator Manual Revision T 5 3 27 Activating an external DC coil with an external power supply Activating an external AC coil with an external power supply Use a diode 1N4007 if the voltage is 24 VDC 24 VDC 24 VAC 230 VAC ...

Page 28: ... isolated module with an external power supply Notes 1 Isolated input module provided by the user 2 24 VDC power supply to be provided by the user ISOLATED INPUT MODULE Installation of the machine interface cable must be performed by a certified electrician or competent person ...

Page 29: ...guide with help of the screw with hexagonal head Use the hexagonal wrench Tighten by hand The hand shield defines the required torch to workpiece distance Screw with hexagonal head Hexagonal wrench Workpiece machine shield 4 It s strictly recommended to use the machine shield in order to keep smooth cutting operation Unscrew the hand shield and replace with the machine shield The torch to workpiec...

Page 30: ...f the cutting guide point in the same direction as the torch handle see picture below Now the torch with the cutting guide is ready to cut Tighten the screw with hexagonal head with the hexagonal wrench 6 If you want use the radius bar make sure the screw with hexagonal head isn t tightened so that the cutting guide can rotate freely Screw with hexagonal head 7 Screw in the radius bar into the thr...

Page 31: ... TRAFIRE 100SD Operator Manual Revision T 5 3 31 8 Use the following fasteners to anchor the radius bar to the center of the circle Magnetic base assembly Straight locking pin Free centering straight pin ...

Page 32: ... 4 34 Turn ON 4 35 Check the LED indicators 4 35 Operating the hand torch 4 36 Operating the torch safety trigger 4 36 Fit the work clamp 4 37 Edge start cutting 4 37 Hand torch cutting technique 4 38 Piercing 4 39 Gouging 4 40 Gouge profile 4 41 Modification of the gouge profile 4 41 Operating the machine torch 4 42 Alignment of the machine torch 4 42 ...

Page 33: ...s error code will display 2 Torch control LED illuminates when consumables are loose improperly installed or missing 3 Gas indicator LED illuminates when the gas pressure is lower than 2 4 bar 4 Power ON OFF indicator LED1 illuminates when the power supply is turned ON 5 Pressure indicator 6 Cutting current regulator knob 7 CUT GOUGE mode switch 8 Over Temperature OT alarm indicator 2 1 3 4 5 7 6 ...

Page 34: ...E 100SD Operator Manual Revision T 5 4 34 Rear control panel detail Rear view Rear control panel 1 Power supply switch 2 Mains power lead 3 CNC interface connector 4 Gas supply input fitting G1 4 Female 4 3 1 2 ...

Page 35: ...D Operator Manual Revision T 5 4 35 Turn ON Check the LED indicators Check that LED1 is illuminated and LED2 LED3 and LED4 are not illuminated before cutting Switch ON I Note The cooling fan will only run when needed ...

Page 36: ... yourself or toward others Never use with the pendant control switch Important In case of operation of the power supply equipped with 23 m long hand torch you have to increase dynamic gas pressure to value 6 5 bar To refire the arc during post flow it s necessary to press the trigger button once to stop the flow of the air or wait until the post flow stops automatically Then wait approx 2 s until ...

Page 37: ...re good contact and remove surface contaminants DO NOT fit the work clamp to the material that will be severed scrap Fit the work clamp as close as possible to the cutting area to minimise exposure to electromagnetic fields EMF Do not hold the material that is to be severed scrap Edge start cutting Keep the nozzle of the torch upright at the edge of the workpiece Start cutting from the edge of the...

Page 38: ...e torch trigger is released the gas will continue to flow up to 100 seconds according to adjusted cutting current and used power supply to cool the torch and consumables Note The torch will be ready to restart by depressing the torch trigger during the post flow period To stop the post flow depress the torch trigger quickly and release DANGER Consumables can remain hot after the post flow period W...

Page 39: ... occur in the direction that the torch is aimed Aim the torch away from yourself and others Hold the torch so that the nozzle is within 3 mm of the workpiece before firing Hold the torch at an angle to the workpiece depress the torch trigger and slowly rotate the torch to a vertical position Arc spray exits the underside of the workpiece when the cut has achieved full thickness After the pierce pr...

Page 40: ...ction of the material to be removed Gouging mode is used for the weld removal or achievement a controlled gouge profile For gouging application must be set the gouging mode on the power supply Please use gouging consumables according to used plasma torch and according to set gouging amperage See the operator manual of the appropriate torch section Torches and Torch parts Hand Torch Consumables Hol...

Page 41: ... work distance Rotation of torch Angle of torch Width Depth Modification of the gouge profile The gouge profile The actions whitch affected the gouge profile With Depth Gouging amperage of the power supply Gouging speed of the torch Torch to workpiece distance Torch to workpiece angle decreasing decreasing decreasing decreasing decreasing increasing decreasing increasing decreasing decreasing incr...

Page 42: ... is generated immediately when the CNC start signal is ON The plasma arc will cut quickly through gloves and skin Make sure the power supply is switched off before changing consumables Keep away from the torch tip Do not hold the piece that is to be cut and keep your hands away from the cutting path Never point the torch toward yourself or toward others Never use with the pendant control switch Im...

Page 43: ...EX TRAFIRE 100SD Operator Manual Revision T 5 5 43 SECTION 5 MAINTENANCE Routine maintenance 5 44 Purging draining of the built in filter 5 45 ...

Page 44: ...pressed air Advisory note The dust can be harmful to health Full examination of the torch check the torch trigger safety mechanism check for signs of cracking in the torch body or exposed wires Immediately replace the mains power lead plug if damaged Immediately replace the torch lead if damaged Check air line hose filter elements and connections for leaks Routine maintenance WARNING ELECTRIC SHOC...

Page 45: ... 5 45 Purging draining the built in filter This power supply is equipped with built in float type auto drain filter Do not cover outflow drain hole located on the bottom of the power supply see the picture below Position of the outflow drain hole ...

Page 46: ... 100SD Mechanized Plasma Cutting Systems Part No DESCRIPTION Length EX 5 011 030 EX TRAFIRE 100SD CE 3x400V M System FHTEX 105RTXM NR Torch 8m M Starter Kit 8 m EX 5 011 031 EX TRAFIRE 100SD CE 3x400V M System FHTEX 105RTXM NR Torch 15m M Starter Kit 15 m Available Consumable Kits Part No DESCRIPTION Pcs EX 3 443 001 Hand Torch FHTEX 105RTXH Consumable Kit 55 65A 1 EX 3 444 001 Machine Torch FHTEX...

Page 47: ...tch Note The fan turns ON and OFF automatically The fan may not run when the plasma arc power supply is switched on The LED4 illuminates Over temperature OT Fan fault Ensure fan is free running correct condition Duty cycle over limit Allow the power supply to cool down and reset Do not exceed the rated duty cycle Over current OC Some of power supply inside component is over lifetime or burned out ...

Page 48: ...f the torch Reassemble in correct order The LED3 illuminates Torch connection fault Improperly installed torch or retaining cup is loose Install torch properly or tighten retaining cup Press the torch trigger or the CNC signal is ON but no gas output Gas valve or power supply fault Cable to the gas valve disconnected Contact your distributor Gas valve malfunction Contact your distributor Switch or...

Page 49: ...mp and workpiece Make sure that work lead has a good connection to a clean and dry area of workpiece Incorrect distance between the torch and the workpiece Maintain correct distance between the torch and the workpiece Voltage fault Incorrect input voltage Use the correct input voltage in accordance with specification The pilot arc is difficult to ignite and cuts out Consumables fault Check for wor...

Page 50: ...kness of material to be cut Consumables fault Consumables are worn Inspect consumables see section Consumable part inspection Incorrect cutting technique Poor cut quality Adjust the current to suite the cutting speed and torch to workpiece distance according to the thickness of material to be cut Poor connection Workpiece is dirty contaminated Clean the surface of the workpiece ...

Page 51: ...h H03 System operation failed e g no arc pressure H04 Missing nozzle or electrode H05 During the pilot arc the electrode is not separated from the nozzle check the electrode free movement H06 Over temperature alarm H07 Over current alarm H08 Torch inspection cap sensor H10 Air pressure alarm H11 Missing phase H14 Torch trigger is depressed or CNC start signal is ON during initial periode ...

Page 52: ...ot fall under the specification of pressure equipment and requires no revision Advantages of using the Filter EX Compressed Air Filter Removes solid particles aerosols and moisture from the compressed air Elimination of the negative effects caused by humidity during cutting Extends the service life time of the torch leads and consumables Reduces the risk of torch and power supply damage Positive e...

Page 53: ...face connection lead 6 m O Ring lubricant EX 0 805 001 Grease 25ml Circle cutting guide kit for FHT EX 105RTXH 105TTH 45TTH EX 5 801 002 This Circle cutting guide kit for hand held cutting obtains Circle cutting attachment Cutting guide Radius bar mm 250 Radius bar mm 400 Magnetic base assembly Free centering straight pin Straight locking pin ...

Page 54: ...on T 5 9 54 SECTION 9 POWER SUPPLY BLOCK DIAGRAM Power supply block diagram 50 60 HZ DC DC AC DC Rectifier Filter Inverter Transformer Rectifier Hall MCU DRIVE Initialization UC 3895 Calculation Comparison Panel Logic test 400 VAC 15 AC Hall ...

Page 55: ...formation on the recycling of this product refer to manufacturer who will be able to handle the disposal for you or refer to your local authority domestic waste processing organization or store where you purchased the product For local disposal the local regulations for the disposal of electrical and electronic scrap as well as materials must be observed This product complies with EU directive req...

Page 56: ...he purpose arising out of the Contract otherwise for usual purpose 2 The warranty period is valid from the date the goods are delivered to the buyer par 5 1 5 2 of the GBC 3 Par 3 4 and the following of the GBC shall apply to reporting claiming of Warranty defect asserting rights from defective performance and other rights and obligation of the Seller and Buyer 4 The warranty period is o Three 3 y...

Page 57: ...EX TRAFIRE 100SD Operator Manual Revision T 5 11 57 Notes ...

Page 58: ...l diameter of gas hose 8 mm 4 Revision T 4 2020 09 2020 a Page 2 13 new value of piercing capacity from 25 mm to 20 mm b Pages 3 29 31 new pages The circle cutting guide installation for the FHT EX 105RTXH 105TTH 45TTH added c Page 6 45 new items of additional ordering added d Pages 8 51 52 new items of accessories added EX 0 802 000 EX 0 803 001 EX 0 803 004 and EX 5 801 002 5 Revision T 5 2021 0...

Page 59: ...com hr THERMACUT HUNGÁRIA KFT Petőfi Sándor utca 37 atd 2500 Esztergom HUNGARY Tel 36 33 502 090 1 Fax 36 33 400 004 E mail info thermacut hu www thermacut hu THERMACUT SLOVAKIA S R O M R Štefánika 14 942 01 Šurany SLOVAKIA Tel 421 356 501516 8 Fax 421 356 501518 E mail obchod thermacut sk www thermacut sk THERMACUT FRANCE 6 Rue des Frères Lumiere 67201 Eckbolsheim FRANCE E mail thermacut thermacu...

Page 60: ...vská 574 Mařatice 686 01 Uherské Hradiště Czech Republic www thermacut cz sales thermacut cz THERMACUT FHT EX and EX TRAFIRE are registered trademarks of THERMACUT k s and may be registered in Czech Republic and or other countries All other trademarks are properties of their respective owners ...

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