THERMACUT EX-TRAFIRE 75SD Operator'S Manual Download

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EX-TRAFIRE

75SD

Operator Manual, Revision T-5

Plasma Arc Cutting

Current

Protection glass

shade number*

Up to 150A

ISO (DIN) 11

150A to 250A

ISO (DIN) 12

250A to 400A

ISO (DIN) 13

OVER 400A

ISO (DIN) 14

* According to ISO 4850:1979

Gas cylinders which contain gas under high pressure can
rupture and explode if damaged�

•

Handle and use compressed gas cylinders in accordance
with local or national codes�

•

Never allow electrical contact between the plasma arc
and a cylinder�

•

Never expose cylinders to excessive heat, sparks, slag or
flames�

CAUTION WHEN CUTTING

AROUND GAS CYLINDERS

Induction heating of certain materials, adhesives, and fluxes
may cause fumes or smoke�

•

Breathing the fumes and smoke can be hazardous to
your healthKeep your face out of the smoke, do not
breathe the fumes�

•

Use local exhaust ventilation for fume removal�

•

If ventilation is poor, wear an approved air-supplied
respirator�

SMOKE AND GASES 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 arc power supply�

•

People with pacemakers/hearing aids should consult
their doctor before operating plasma arc power
supply�

Do not exceed the recommended duty

cycle, this can lead to overheating

and cause damage to the system�

•

Allow a suitable cooling off period with high
demand usage�

•

Observe the duty cycle rating shown on the label
attached to the system�

PLASMA CUTTING CAN

CAUSE INTERFERENC

•

Electromagnetic energy can interfere with sensitive
electronic equipment such as computers, or
computer-driven equipment�

•

Ensure that all equipment in the cutting area is
electromagnetically compatible�

•

Ensure that the plasma arc cutting system is installed
and positioned in accordance with this manual�

Summary of Contents for EX-TRAFIRE 75SD

Page 1: ...59 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: ...se damage to the system 8 Magnetic field can affect pacemakers 8 Plasma cutting can cause interferenc 8 Safety Sticker 9 SECTION 2 SPECIFICATIONS 10 Dimensions and weight of the plasma arc power supply 2 11 Specifications plasma arc power supply 3 x 220 V 2 12 Specifications plasma arc power supply 3 x 400 V 2 13 Hand torch setup 2 15 Machine torch setup 2 16 Symbols and marking 2 17 SECTION 3 INS...

Page 3: ... 34 Rear view 4 35 Rear control panel detail 4 35 Turn ON 4 36 Check the LED indicators 4 36 Operating the hand torch 4 37 Operating the torch safety trigger 4 37 Fit the work clamp 4 38 Edge start cutting 4 38 Hand torch cutting technique 4 39 Piercing 4 40 Gouging 4 41 Gouge profile 4 42 Modification of the gouge profile 4 42 Operating the machine torch 4 43 Alignment of the machine torch 4 43 S...

Page 4: ...105TTH 45TTH 8 54 SECTION 9 SYSTEM CIRCUIT DIAGRAM 9 55 Power supply block diagram 9 55 SECTION 10 DISPOSAL OF PRODUCT 10 56 Use and disposal of waste 10 56 End of lifetime product disposal 10 56 SECTION 11 WARRANTY 11 57 Notes 11 58 Notes 11 59 Notes 11 60 Notes 11 61 Revision history 11 62 ...

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: ...EVENTION 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 combustib...

Page 8: ...ES 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 a...

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: ...N 2 SPECIFICATIONS Dimensions and weight of the plasma arc power supply 2 11 Specifications plasma arc power supply 3 x 220 V 2 12 Specifications plasma arc power supply 3 x 400 V 2 13 Hand torch setup 2 15 Machine torch setup 2 16 Symbols and marking 2 17 ...

Page 11: ...upply Weight of plasma arc power supply without torch 24 0 kg 265 mm 560 mm 400 mm EX TRAFIRE 75SD Is a portable plasma arc cutting system Has been designed for handheld cutting and handheld gouging Uses compressed air or nitrogen for cutting electrically conductive metals mild steel stainless steel and aluminium ...

Page 12: ...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 220 VAC 15 38 6 A 38 6 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 ingress forei...

Page 13: ...d 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 28 1 A 28 1 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 i...

Page 14: ...city mm 25 Maximum cutting capacity mm 35 Severance cutting capacity mm 35 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 It is recomended to unfold the cable because of bigger heat generation if it s longer than 8 m 10 minutes cutting Duty cycle Duty cycle...

Page 15: ...E 75SD Operator Manual Revision T 5 2 15 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 16: ...or Manual Revision T 5 2 16 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 17: ...on The hand torches must have shielded consumable parts fitted to mantain mark compliance CE Mark C Tick Mark This marking signifies compliance with appropriate Australian EMC standard IEC symbols The following symbols may be present on the plasma arc power supply data plate control labels and switches Symbol Description Symbol Description Alternating Current AC power Cutting Mode Over Temperature...

Page 18: ...es mains power lead 3 21 The mains power lead connection 3 22 Torch installation step by step 3 22 Plasma gas supply 3 25 Additional gas filtration 3 25 Gas supply installation 3 26 Setting the gas pressure 3 26 System CNC interface connection 3 27 Activating an external DC coil with an external power supply 3 28 Activating an external AC coil with an external power supply 3 28 Activating an indus...

Page 19: ...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 20: ...nerator to power the EX TRAFIRE 75SD Engine drive operation 1 Set engine drive output to three phases AC 2 Plug the EX TRAFIRE 75SD 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 w...

Page 21: ... the length requirements listed below Recommended mains power lead extension 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 16 220 VAC 15 3 10 10 16 16 25 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 75SD use a plug that com...

Page 22: ...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 23: ...S 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 24: ...ision T 5 3 24 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 25: ...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 26: ...g 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 up and turning the regulator knob to it...

Page 27: ...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 30V DC 5 A Divider arc voltage signal of 20 1 21 1 1 30 1 40 1 50 1 provides a maximum 18V Rear socket connection 3 4 12 14 13 6 5 Internal wire colours white white yellow yellow green ye...

Page 28: ...erator Manual Revision T 5 3 28 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 29: ...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 30: ...uide 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 workpiece...

Page 31: ...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 7 Screw in the radius bar into the threaded hole in the cutting ...

Page 32: ...X TRAFIRE 75SD Operator Manual Revision T 5 3 32 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 33: ...4 35 Turn ON 4 36 Check the LED indicators 4 36 Operating the hand torch 4 37 Operating the torch safety trigger 4 37 Fit the work clamp 4 38 Edge start cutting 4 38 Hand torch cutting technique 4 39 Piercing 4 40 Gouging 4 41 Gouge profile 4 42 Modification of the gouge profile 4 42 Operating the machine torch 4 43 Alignment of the machine torch 4 43 ...

Page 34: ...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 35: ...on T 5 4 35 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 EX TRAFIRE 75SD 3 x 220 V EX TRAFIRE 75SD 3 x 400 V 4 1 2 3 ...

Page 36: ...SD Operator Manual Revision T 5 4 36 Turn ON Check the LED indicators Check that LED1 is illuminated and LED2 LED3 and LED4 are not illuminated before cutting Switch ON Note The cooling fan will only run when needed ...

Page 37: ... 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 38: ...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 39: ...e torch trigger is released the gas will continue to flow up to 75 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 Wh...

Page 40: ...t 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 proceed with cutting Směr řez...

Page 41: ...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 42: ... torch Angle of torch Width Depth Torch to workpiece distance 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 in...

Page 43: ...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 Imp...

Page 44: ...EX TRAFIRE 75SD Operator Manual Revision T 5 5 44 SECTION 5 MAINTENANCE Routine maintenance 5 45 Purging draining of the built in filter 5 46 ...

Page 45: ...installed correctly and are not worn Every week Examine and check the torch retaining cap safety switch pins ensure that the LED3 safety indicator which indicates a loose retaining cap is fully functional Every 3 months Clean the dust from inside of the power supply using clean dry compressed air Advisory note The dust can be harmful to health Full examination of the torch check the torch trigger ...

Page 46: ... 5 46 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 47: ... 010 044 EX TRAFIRE 75SD CE 3x220V Hand System FHTEX 105RTXH Torch 15m H Starter Kit 15 m EX TRAFIRE 75SD Mechanized Plasma Cutting Systems Part No DESCRIPTION Length EX 4 011 030 EX TRAFIRE 75SD CE 3x400V M System FHTEX 105RTXM NR Torch 8m M Starter Kit 8 m EX 4 011 031 EX TRAFIRE 75SD CE 3x400V M System FHTEX 105RTXM NR Torch 15m M Starter Kit 15 m EX 4 011 032 EX TRAFIRE 75SD CE 3x220V M System...

Page 48: ...not plugged in to a live socket Plug the mains power lead in to a live socket Main power switch is defective Replace the main power switch 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 ...

Page 49: ...ning cap is not installed or tightened correctly Fit the retaining cap and correctly tighten Non original consumables Use original new consumables Short circuit inside the torch Consumables are incorrectly installed Install the consumables correctly Dirt inside the torch Remove all consumables clean the inside of the torch Reassemble in correct order The LED3 illuminates Torch connection fault Imp...

Page 50: ...ect distance between the torch and workpiece Maintain correct distance between the torch and workpiece Work cable is broken Replace the work cable The output is too low unstable or inadequate Connection fault Input and output connection leads Check all input and output connection leads Fluctuating connection between the clamp and workpiece Make sure that work lead has a good connection to a clean ...

Page 51: ...o a clean and dry area of workpiece Cut quality issues Incorrect current setting Low current or high material thickness Adjust the current to suit the thickness 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 dista...

Page 52: ...high 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 signal is ON during initial periode ...

Page 53: ...t 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 ef...

Page 54: ...ace 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 55: ...EX TRAFIRE 75SD Operator Manual Revision T 5 9 55 SECTION 9 POWER SUPPLY BLOCK DIAGRAM Power supply block diagram ...

Page 56: ...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 57: ...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 58: ...EX TRAFIRE 75SD Operator Manual Revision T 5 11 58 Notes ...

Page 59: ...EX TRAFIRE 75SD Operator Manual Revision T 5 11 59 Notes ...

Page 60: ...EX TRAFIRE 75SD Operator Manual Revision T 5 11 60 Notes ...

Page 61: ...EX TRAFIRE 75SD Operator Manual Revision T 5 11 61 Notes ...

Page 62: ...ion T 3 2020 07 2020 a Page 1 the latest version of manual link added b Page 3 26 new dimension of the minimum internal diameter of gas hose 8 mm 4 Revision T 4 2020 09 2020 a Page 2 14 new value of piercing capacity from 25 mm to 20 mm b Pages 3 30 32 new pages The circle cutting guide installation for the FHT EX 105RTXH 105TTH 45TTH added c Page 6 46 new items of additional ordering added d Page...

Page 63: ...om 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 thermacut...

Page 64: ...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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